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A two-stroke outboard engine undergoes a full rebuild to address bearing failure caused by a degraded 40-year-old driveshaft seal.1:28 The process begins with a deep cleaning of all engine components, including the cylinder block and individual nuts and bolts, using an ultrasonic cleaner and manual scrubbing to remove carbon and grime.2:35 The team cleans the cylinder bores with CRC and fine sandpaper, verifying the absence of wear lips or burrs.7:34 Reassembly involves lubricating the rings and bearings, ensuring proper orientation of oil seals to maintain pressure, and using high-temperature RTV sealant on machined aluminum surfaces instead of paper gaskets to preserve precise clearances.14:05 The team also inspects the water pump impeller and tests the thermostat for proper wax-actuated valve operation.20:24 After torquing the power head bolts in a circular pattern to ensure even pressure, the engine is reattached to the outboard leg.16:38 The project concludes with the outboard mounted and ready for sea trials after departing Port Douglas.

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