I burned up my engine this weekend. It was pumping perfectly when we went out, but coming in I noticed it was not pumping and dropped off plane, but it overheated and killed pretty much instantly with the dreaded smoking and sizzling sounds so I noticed too late. Although I have not had time to check compression etc, I am guessing that I am looking at a total rebuild or new engine. My problem is the lack of any new engines in the same power/weight class and I am not sure whether it is worth rebuilding the old one especially since some parts I need for the tiller are no longer made (I could have a machine shop make them for considerable expense). My old engine was a 1992 2-stroke Mercury 40 4-cylinder. It was used mostly in saltwater non-stop for 25 years, between runs to the camp, 70 mile fishing trips, hunting, wakeboarding, and kneeboarding. I even did search and rescue with it during Hurricane Katrina so I have gotten my money's worth out of it over 25 years of beating the tar out of it. My problem is that I cannot just go out and buy a new Mercury 40 because the weight of the new 4-stroke 40 would sink my boat the first time out. The new engines just weigh too damn much. I can't drop all the way down to a 30 hp engine because I needed more performance not less because I am always loaded down whether fishing or hunting. The old engine had a huge amount of torque for a 40 since it was 4 cylinder and based on the 50 or 60 block of the time, although on the top end they were never considered that speedy. The only company left that even makes a short (15") shaft 40 is Tohatsu and looking at Tohatsu's web site, they do not appear to offer it in a manual start or manual trim. I do not want to start carrying around 120 lbs of batteries just to start the engine (1 battery is fine if you have manual start as a backup), but it would be insane to trust your life to a single battery with no backup. I have been there, done that. The bugs will make you go insane if they don't kill you first when you get stuck out in the marsh during the summer. Can you guys think of any solutions to this? Thanks!