Mercury 40 FourStroke Tiller Handle Operation Maintenance Warranty Installation Manual Download Page 104

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3. Install the aft washer onto the drive sleeve assembly and lightly tap the

drive sleeve assembly into the propeller. The aft washer will contact the

propeller when the drive sleeve assembly is properly seated.

a -

Aft washer

4. Install the thrust washer onto the propeller shaft.

IMPORTANT: The Flo‑Torq Reflex drive hub requires the use of the thrust

washer that is included with the drive hub kit.

43671

5. Install the propeller.
6. Install the aft washer, the tab washer, and secure with the propeller nut

included with the kit. Tighten the nut to the specified torque. Bend the

washer tabs onto the nut.

44725

INSTALLATION

eng

Summary of Contents for 40 FourStroke Tiller Handle

Page 1: ...Outboard Operation Maintenance Warranty Installation Manual 2015 Mercury Marine 40 FourStroke Tiller Handle 8M0104951 315 eng ...

Page 2: ...eng ...

Page 3: ...ng the product must be strictly followed and wherever practicable returned to the original intent of the design Maintenance replacement or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual Engines are labeled with an Emission Control Information decal as permanent evidence of EPA certification WARNING The engine exhaust from...

Page 4: ...s adequate inventory of genuine Mercury Precision Parts Offers a clean neat shop with well organized tools and service literature Copyright and Trademark Information MERCURY MARINE All rights reserved Reproduction in whole or in part without permission is prohibited Alpha Axius Bravo One Bravo Two Bravo Three Circle M with Waves Logo K planes Mariner MerCathode MerCruiser Mercury Mercury with Wave...

Page 5: ...ication Star Label 10 Warranty Policy Australia and New Zealand 11 Global Warranty Charts Outboard and Jets 15 General Information Boater s Responsibilities 20 Before Operating Your Outboard 20 Boat Horsepower Capacity 20 High Speed and High Performance Boat Operation 21 Lanyard Stop Switch 21 Protecting People in the Water 24 Passenger Safety Message Pontoon Boats and Deck Boats 24 Wave and Wake ...

Page 6: ... Manual Starting Models 43 SmartCraft Product 44 Manual Tilt System 44 Throttle Grip Friction Adjustment Tiller Handle Models 48 Steering Friction Adjustment Tiller Handle Models 48 Trim Tab Adjustment 49 Operation Important Daily Inspection Before Each Use 50 Prestarting Check List 50 Operating in Freezing Temperatures 51 Operating in Saltwater or Polluted Water 51 Prestarting Instructions 51 Eng...

Page 7: ...ng Belt Inspection 69 Lubrication Points 70 Changing Engine Oil 72 Gearcase Lubrication 73 Gearcase Lubricant Recommendation 75 Submerged Outboard 75 Storage Storage Preparation 76 Protecting External Outboard Components 76 Protecting Internal Engine Components 76 Gearcase 77 Positioning Outboard for Storage 77 Battery Storage 77 Troubleshooting Engine Will Not Start 78 Engine Runs Erratically 78 ...

Page 8: ...ed Engine Mounting Hardware 84 Installation Information 84 Fuel Hose Connection 90 Flo Torq I Propeller Installation 90 Flo Torq Reflex Drive Hub Propeller Installation 92 Trim Tab Adjustment 98 Maintenance Log Maintenance Log 99 vi eng ...

Page 9: ... s warranty registration department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 1 920 907 6663 OUTSIDE UNITED STATES AND CANADA For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Cent...

Page 10: ...0 00 per engine to cover the transfer fee Plan coverage is not transferable from one product to another product or for noneligible applications The certified preowned engine plans are not transferable For help or assistance contact Mercury Product Protection Department at 1 888 427 5373 from 7 30 a m to 4 30 p m CST Monday Friday or e mail mpp_support mercmarine com 3 Year Limited Warranty Against...

Page 11: ...with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product If the purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine Mercury Marine will then arrange for the inspection and any co...

Page 12: ...e Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SO...

Page 13: ...to the product for warranty service Customer must deliver product to an authorized dealer 6 Additional service work requested by customer other than that necessary to satisfy the warranty obligation 7 Labor performed by other than an authorized dealer may be covered only under the following circumstances when performed on emergency basis providing there are no authorized dealers in the area who ca...

Page 14: ... 40 CFR Part 1045 Subpart B Mercury Marine provides a five year or 175 hours of engine use warranty whichever occurs first to the retail customer that the engine is designed built and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act and that the engine is free from defects in materials and workmanship that cause the engine to fail to ...

Page 15: ...that the outboard engine was designed built and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Health and Safety Code For information regarding the limited warranty for the nonemission related components of the outboard please see the limited warranty statement for your outboa...

Page 16: ...Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury WHAT MERCURY WILL DO Mercury Marine s...

Page 17: ...DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHT...

Page 18: ...er be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists The warranty repairs will be completed in a reasonable amount of time not to exceed 30 days...

Page 19: ...sources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 lower emissions than One Star Low Emission engines Warranty Policy Australia and New Zealand MERCURY MARINER OUTBOARD LIMITED WARRANTY AUSTRALIA AND NEW ZEALAND POLICY This limited warranty ...

Page 20: ...nexpired warranty coverage cannot be transferred either to or from a commercial use customer Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage under this Limited Warranty is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine spe...

Page 21: ... tear faded paint damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle RPM range see the Operation and Maintenance Manual operation of the product in a manner inconsistent with the recommended operation duty cycle section of the Operation and Maintenance Manual neglect accident submersion improper installat...

Page 22: ... A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS LIMITED WARRANTY TRANSFER OF WARRANTY AUSTRALIA AND NEW ZEALAND POLICY The limited warranty is transferable to a subsequent purchaser but only for the...

Page 23: ... and 250 hp 1 year 3 years Racing Product Recreation use only Standard Limited Warranty Standard Limited Corrosion Warranty OptiMax 250 XS 2 years 3 years OptiMax 300 XS 2 years 3 years Verado 400R 2 years 3 years Outside the United States For product purchased outside the United States contact the distributor in your country or the authorized Marine Power Service Center closest to you CANADA WARR...

Page 24: ...or dealer closest to you AUSTRALIA AND NEW ZEALAND WARRANTY CHARTS OUTBOARD AND JET Products Standard Limited Warranty Standard Limited Corrosion Warranty Light Commercial All outboard 3 years 3 years Contact the Marine Power Service Center closest to you Outside of Australia and New Zealand For product purchased outside of Australia and New Zealand contact the distributor in your country or the M...

Page 25: ...ional only Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application Verado 400R 1 year 3 years None Outside of Asia For product purchased outside of the Asian region contact the distributor in your country or the Marine Power Service Center closest to you EUROPE AND THE CONFEDERATION OF INDEPENDENT STATES CIS WARRANTY CHARTS OUTBOARD AND JET Product Recreational only St...

Page 26: ...AND JET Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application 2 Stroke 1 year 3 years Contact the Marine Power Service Center closest to you FourStroke 2 years 3 years OptiMax including Pro XS 3 years 3 years Verado including Pro 3 years 3 years Racing Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Ve...

Page 27: ...to you FourStroke 2 years 3 years OptiMax including Pro XS 3 years 3 years Verado including Pro 3 years 3 years Racing Product Recreational only Standard Limited Warranty Standard Limited Corrosion Warranty Verado 400R 2 years 3 years Outside South Africa For products purchased outside of the South Africa region contact the distributor in your country or the Marine Power Service Center closest to ...

Page 28: ...ng with using good common sense can help prevent personal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which...

Page 29: ...ization demonstration ride with your dealer or an operator experienced with your boat outboard combination For additional information obtain a copy of our Hi Performance Boat Operation booklet from your dealer distributor or Mercury Marine Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in ac...

Page 30: ...d stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator s position Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables bass boats...

Page 31: ...the operator s station without first disconnecting the stop switch lanyard from the operator Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the bo...

Page 32: ... Stop the engine immediately whenever anyone in the water is near your boat Shift the outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat Passenger Safety Message Pontoon Boats and Deck Boats Whenever the boat is in motion observe the location of all passengers Do not allow any passengers to stand or use seats other than those designated f...

Page 33: ...njury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed Sit only in seats designated for traveling at faster speeds Any unexpected sudden reduction in boat speed could...

Page 34: ...hange in direction can cause occupants to be thrown out of their seats or out of the boat WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible There is another less common hazardous result from allowing your boat to launch off a wave or wake If the bow of your boat pitches down far enough w...

Page 35: ... can cause occupants to be thrown out of their seats or out of the boat A rapid reduction in speed This will cause occupants to be thrown forward or even out of the boat Impact damage to the outboard and or boat Keep in mind the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed Boat speed should be kept to a minimum planing speed when...

Page 36: ...the outboard could result in the outboard propelling off the boat transom resulting in property damage serious injury or death Before operation the outboard must be correctly installed with the required mounting hardware If an obstacle is struck at planing speed and the outboard is not securely fastened to the transom it is possible the outboard could lift off the transom and land in the boat Exha...

Page 37: ...lation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide WHILE BOAT IS STATIONARY a Running the engine when the boat is moored in a confined space b M...

Page 38: ...oating Recommendations To safely enjoy the waterways familiarize yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions Know and obey all nautical rules and laws of the waterways We recommend that all powerboat operators complete a boating safety course In the U S the U S Coast Guard Auxiliary the Power Squadron the Red Cross and ...

Page 39: ...flotation devices Federal law requires that there be a U S Coast Guard approved life jacket personal flotation device correctly sized and readily accessible for every person onboard plus a throwable cushion or ring We strongly advise that everyone wear a life jacket at all times while in the boat Prepare other boat operators Instruct at least one person onboard in the basics of starting and operat...

Page 40: ... block the operator s view when the boat is above idle or planing transition speed Watch out for others the water and your wake Never drive your boat directly behind a water skier Your boat traveling at 40 km h 25 mph will overtake a fallen skier who is 61 m 200 ft in front of you in five seconds Watch fallen skiers When using your boat for waterskiing or similar activities always keep a fallen or...

Page 41: ...RPM Idle Speed in Forward Gear 800 25 RPM Number of Cylinders 3 Piston Displacement 747 cc 45 6 cu in Cylinder Bore 65 mm 2 559 in Stroke 75 mm 2 953 in Valve Clearance Cold Intake Valve 0 15 0 25 mm 0 006 0 010 in Exhaust Valve 0 25 0 35 mm 0 010 0 014 in Recommended Spark Plug Carburetor Models NGK DPR6EA 9 Spark Plug Gap 0 9 mm 0 035 in Gear Ratio 2 00 1 24125 H P L B XXXXXXX XXXXX XX XL Mercur...

Page 42: ...Models 40 Recommended Gasoline Refer to Fuel and Oil Recommended Oil Refer to Fuel and Oil Gearcase Lubricant Capacity 440 ml 14 9 fl oz Engine Oil Capacity 3 0 L 3 qt GENERAL INFORMATION 34 eng ...

Page 43: ...f Trim tab g Antiventilation plate h Driveshaft housing i Water pump indicator hole j Bottom cowl k Top cowl l Shift handle m Engine stop switch n Throttle friction adjustment knob o Lanyard stop switch p Steering friction adjustment lever q Tilt lock lever a b c d e f g h i j k l m n o p q 58166 GENERAL INFORMATION eng 35 ...

Page 44: ...y outboard support device Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 28517 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering TRANSPORTING 36 en...

Page 45: ...e in your area refer to Gasolines Containing Alcohol These reformulated gasolines are acceptable for use in your Mercury Marine engine GASOLINES CONTAINING ALCOHOL If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of...

Page 46: ...from internal components Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale sold or offered for sale in the United States The Environmental Protection Agency EPA requires that any outboard manufactured after January 1 2009 must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard Low permeation hose is USCG Type B1 15 or Typ...

Page 47: ...e tank exceeds 34 4 kPa 5 0 psi A hissing noise may be heard as the tank vents to the atmosphere This is normal The fuel tank includes a fuel demand valve that prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage When installing the fuel tank cap turn the cap to the right until you hear a click This signals that the fuel cap is fully seate...

Page 48: ...ays stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks Fill the fuel tanks outdoors away from heat sparks and open flames Remove the portable fuel tanks from the boat to fill them Always stop the engine before filling the tanks Do not completely fill the fuel tanks Leave approximately 10 of the tank volume unfilled Fuel will expand in volume as its...

Page 49: ... overfill Be sure that the outboard is upright not tilted when checking oil 1 Turn the engine off Have the outboard in a level operating position Remove the top cowl 2 Flip the handle up and pull out the dipstick Wipe it with a clean rag or towel and push it back in all the way 3 Pull the dipstick back out again and observe the oil level If the oil level is low remove the oil filler cap and fill t...

Page 50: ...ck back in all the way then flip the handle down to lock the dipstick in place Reinstall the oil filler cap and hand tighten securely a Full mark b Add mark c Dipstick d Oil filler cap a b c d 28813 FUEL AND OIL 42 eng ...

Page 51: ...gine overheats immediately reduce throttle speed to idle Shift the outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole 28521 If no water is coming out of the water pump indicator hole or flow is intermittent stop engine and check cooling water intake holes for obstruction If no obstruction is found this may indicate a blockage in the cooling sys...

Page 52: ...aid in Engine Guardian diagnostics The SmartCraft Instrument package will display critical engine alarm data and potential problems Manual Tilt System Models without power trim are equipped with a tilt assist system that allows the operator to easily tilt and lock the outboard at any tilt position from full down to full up This tilt system is designed to be adjusted when the outboard is idling in ...

Page 53: ...ling water intake holes submerged in the water and continue to check for water discharge from the water pump indicator hole 26803 TILTING OUTBOARD TO FULL UP POSITION 1 Stop the engine Move the tilt lock lever to the tilt position Take hold of the top cowl grip and raise outboard to full tilt up position Lock the outboard in place by moving the tilt lock lever to the lock run position 28916 FEATUR...

Page 54: ...rd is adjusted by changing the position of the tilt pin in the five adjustment holes provided The outboard should be locked against this tilt pin by setting the tilt lock lever to the lock run position Proper adjustment allows the boat to run stably achieve optimum performance and minimize steering effort NOTE Refer to the following lists when adjusting the operating angle of your outboard The til...

Page 55: ...e normal right hand rotation propeller In excess can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or oversteering if any turn is attempted or if a significant wave is encountered Adjusting the outboard away from the boat transom can Lift the bow out of the wat...

Page 56: ...achieve the desired steering friction drag on the tiller handle Move lever to the left to tighten friction or move to the right to loosen friction NOTE To maintain proper adjustment the locknut located on top of the steering friction lever pivot shaft can be tightened a Tighten friction b Loosen friction c Locknut WARNING Insufficient friction adjustment can cause serious injury or death due to lo...

Page 57: ...rd is installed with the antiventilation plate approximately 50 mm 2 in or more above the boat bottom TRIM TAB ADJUSTMENT Operate your boat at normal cruising speed trimmed to desired position by installing the tilt pin in the desired tilt pin hole Turn your boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen the trim tab bolt and make small adju...

Page 58: ... for each person aboard and readily accessible it is the law A ring type life buoy or buoyant cushion designed to be thrown to a person in the water Know your boats maximum load capacity Look at the boat capacity plate Fuel supply OK Arrange passengers and load in the boat so the weight is distributed evenly and everyone is seated in a proper seat Tell someone where you are going and when you expe...

Page 59: ... the internal water passages of your outboard with fresh water after each use in salt or polluted water This will prevent a buildup of deposits from clogging the water passages Refer to Maintenance Flushing the Cooling System If you keep your boat moored in the water always tilt the outboard so the gearcase is completely out of water except in freezing temperatures when not in use Wash the outboar...

Page 60: ...un the engine at varied throttle settings up to 4500 RPM or at three quarter throttle and during this period of time run it at full throttle for approximately one minute every ten minutes 3 For the next eight hours of operation avoid continuous operation at full throttle for more than five minutes at a time Starting the Engine Tiller Handle Models Before starting read the Prestarting Check List sp...

Page 61: ...ine primer bulb so the arrow on the side of the bulb is pointing up Squeeze the fuel line primer bulb several times until it feels firm 27348 4 Set the lanyard stop switch to the RUN position Refer to General Information Lanyard Stop Switch 19791 5 Shift the outboard to the neutral N position N 28522 OPERATION eng 53 ...

Page 62: ...e throttle grip to the half way position NOTE After starting a cold engine air temperature below 4 C 40 F slowly advance the throttle speed until the engine is warmed up a Start position b Half way position 8 Manual start models Pull the starter rope slowly until you feel the starter engage then pull rapidly to crank the engine Allow the rope to return slowly Repeat until the engine starts 28917 A...

Page 63: ...o overheat Have the outboard checked by your dealer Operating the engine while overheated may cause serious engine damage WARMING UP ENGINE Before beginning operation allow the engine to warm up at idling speed for three minutes Gear Shifting IMPORTANT Observe the following Never shift the outboard into gear unless the engine speed is at idle Do not shift the outboard into reverse when the engine ...

Page 64: ...ol lever or rotate the throttle grip tiller handle to increase speed Stopping the Engine Reduce the engine speed and shift the outboard to neutral position and push the engine stop button in 26776 Emergency Starting If the starter system fails use the spare starter rope provided and follow procedure 1 Remove flywheel cover or manual starter assembly 26844 OPERATION 56 eng ...

Page 65: ... outboard from starting in gear WARNING The exposed moving flywheel can cause serious injury Keep your hands hair clothing tools and other objects away from engine when starting or running the engine Do not attempt to reinstall the flywheel cover or top cowl when engine is running 3 Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel 4 Pull the start...

Page 66: ...or Quicksilver replacement parts and Genuine Lubricants EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments set to factory standards For this r...

Page 67: ...er that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications Inspection and Maintenance Schedule BEFORE EACH USE Check engine oil level Refer to Fuel and Oil Checking and Adding Engine Oil Check that lanyard stop switch stops the engine Visually inspect the fuel system for deterioration or leaks Check outboard for tightness on transom Check stee...

Page 68: ...ode Drain and replace gearcase lubricant Refer to Gearcase Lubrication Lubricate splines on the driveshaft 1 Inspect battery Refer to Battery Inspection Inspect timing belt Refer to Timing Belt Inspection Check tightness of bolts nuts and other fasteners EVERY 300 HOURS OF USE OR THREE YEARS Replace spark plugs at first 300 hours or third year After that inspect spark plugs every 300 hours or thre...

Page 69: ... either the operating position vertical or in a tilted position 2 Remove the propeller Refer to Propeller Replacement 3 Thread a water hose into the rear fitting Partially open the water tap 1 2 maximum Do not open the water tap all the way as this allows a high pressure flow of water IMPORTANT Do not run engine above idle when flushing 4 Shift the outboard into neutral Start the engine and flush ...

Page 70: ...he cowl to lock it in place Gently pull up on the back of cowl to make sure it is securely fastened 28445 Exterior Care Your outboard is protected with a durable baked enamel finish Clean and wax often using marine cleaners and waxes Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability IMPORTANT Read the safety and maintenance instruc...

Page 71: ...d fuel immediately Before servicing any part of the fuel system stop engine and disconnect the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved receptacle Any fuel system service must be performed in a well ventilated area Inspect any completed service w...

Page 72: ...roded instead of the outboard metals Each anode requires periodic inspection especially in saltwater which will accelerate the erosion To maintain this corrosion protection always replace the anode before it is completely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode This model has an anode installed on each side of the gearcase and on...

Page 73: ...the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate 1 Shift the outboard to the neutral N position F N R 58150 2 Remove the spark plug leads to prevent the engine from starting 26899 3 Straighten the bent tabs on the propeller nut retainer 26900 4 Place a block of wood between the gearcase and propeller Remove...

Page 74: ...ropeller shaft 26902 Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Propeller shaft 92 802859A 1 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in saltwater always apply the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed MAINTENANCE 66 eng ...

Page 75: ...cription Nm lb in lb ft Propeller nut 75 55 9 Align the flat sides of the propeller nut with the tabs on the propeller nut retainer Secure the propeller nut by bending the tabs up and against the flats on the propeller nut a Pins b Tabs 10 Reflex hub Install the thrust washer onto the propeller shaft 43671 11 Install the propeller 12 Install the aft washer the tab washer and secure with the propel...

Page 76: ...inding does not exist between the gear housing and the propeller Description Nm lb in lb ft Nut 75 55 NOTE A small amount of rotation play is normal 14 Install the spark plug leads Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl resulting in serious injury or death from a fire or explosion To avoid damaging th...

Page 77: ...y dirt on the spark plug seats Install plugs finger tight and then tighten 1 4 turn or tighten to the specified torque Description Nm lb in lb ft Spark plug 27 20 Timing Belt Inspection Inspect the timing belt and have it replaced by an authorized dealer if any of the following conditions are found Cracks in the back of the belt or in the base of the belt teeth Excessive wear at the roots of the c...

Page 78: ...t of oil to the clamp bracket screw threads 58153 2 Lubricate the following with 2 4 C with PTFE Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Tilt support lever swivel bracket copilot shaft propeller shaft 92 802859A 1 Tilt support lever Lubricate through fitting MAINTENANCE 70 eng ...

Page 79: ...r b Swivel bracket Copilot shaft tiller handle models Lubricate through fitting Move the steering friction lever back and forth while lubricating 28823 Propeller shaft Apply a liberal amount on the splines of the propeller shaft 58155 a b 28466 MAINTENANCE eng 71 ...

Page 80: ...the outboard up to the trailer position 2 Turn the outboard so the drain hole is facing down Remove the drain plug and drain the engine oil into an appropriate container Allow several minutes for the engine oil to drain 3 Lubricate the seal on the drain plug with oil and install Tighten the drain plug securely a Drain plug b Drain hole CHANGING OIL FILTER 1 Place a rag or towel below the oil filte...

Page 81: ... lubricant visually check for the presence of water in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will tur...

Page 82: ...t capacity is approximately 440 ml 14 9 fl oz CHECKING GEARCASE LUBRICANT LEVEL AND REFILLING GEARCASE 1 Place outboard in a vertical operating position 2 Remove vent plug 3 Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole IMPORTANT Replace sealing washers if damaged 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubr...

Page 83: ... Premium or High Performance Gear Lubricant Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine 26975 a b c MAINTENANCE eng 75 ...

Page 84: ...Portable fuel tank Pour the required amount of gasoline stabilizer follow instructions on container into the fuel tank Tip the fuel tank back and forth to mix the stabilizer with the fuel Permanently installed fuel tank Pour the required amount of gasoline stabilizer follow instructions on container into a separate container and mix with approximately one quart one liter of gasoline Pour this mixt...

Page 85: ...d NOTICE Storing the outboard in a tilted position can damage the outboard Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze Store the outboard in the full down position Battery Storage Follow the battery manufacturer s instructions for storage and charging Remove the battery from the boat and check water level Charge if necess...

Page 86: ...faulty Spark plugs fouled or defective Refer to Maintenance section Engine Runs Erratically POSSIBLE CAUSES Guardian System activated Refer to Features and Controls Warning System Manually Starting Models Spark plugs fouled or defective Refer to Maintenance section Incorrect setup and adjustments Fuel is being restricted to the engine a Engine fuel filter is obstructed Refer to Maintenance section...

Page 87: ...ed Excessive water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator TROUBLESHOOTING eng 79 ...

Page 88: ...ct the nearest Marine Power International Service Center STOLEN POWER PACKAGE If your power package is stolen immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packages ATTENTION REQUIRED A...

Page 89: ...rvice manager Contact the owner of the dealership if the sales manager and service manager have been unable to resolve the problem 2 If your question concern or problem cannot be resolved by your dealership please contact the Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the Cus...

Page 90: ...r FL 33025 U S A Fax 1 954 744 3535 Japan Telephone 072 233 8888 Kisaka Co Ltd 4 130 Kannabecho Sakai ku Sakai shi Osaka 590 0984 Japan Fax 072 233 8833 Asia Singapore Telephone 65 65466160 Brunswick Asia Pacific Group T A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore 508944 Fax 65 65467789 Ordering Literature Before ordering literature have the following information about your power ...

Page 91: ...ce center to order additional literature that is available for your particular power package Submit the following order form with payment to Mercury Marine Attn Publications Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Copy this form and print or type This is your shipping label Name Address City State Province ZIP or postal code Country Quantity Item Stock Number P...

Page 92: ...not mount a tow sport bars or boarding ladders onto the boat using the mounting hardware included with the outboard Installing other products onto the boat that utilize the outboard mounting hardware will compromise the ability of that hardware to properly and safely secure the outboard to the transom Outboards that require validated mounting hardware will have the following decal on the transom c...

Page 93: ...vice This prevents the engine from starting in gear SELECTING ACCESSORIES FOR YOUR OUTBOARD Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard These accessories are available from Mercury Marine dealers IMPORTANT Check with your dealer before installing accessories The misuse of approved accessories or the use of nonapproved accessorie...

Page 94: ...INSTALLATION SPECIFICATIONS 58167 Minimum Transom Opening Single engine tiller 76 2 cm 30 in LIFTING OUTBOARD Use the lifting eye on the engine 58176 INSTALLATION 86 eng ...

Page 95: ...ing the transom drill fixture a Drill guide holes b Transom drilling fixture c Transom centerline Transom Drilling Fixture 91 98234A2 5489 Aids in engine installation by acting as a template for engine mounting holes 2 Drill four 13 5 mm 17 32 in mounting holes 3973 2757 a a b c INSTALLATION eng 87 ...

Page 96: ...som cracking under bolt torque When first determining transom strength use a dial torque wrench If the bolt or nut continues to turn without the torque reading on the dial increasing it is an indication that the transom is yielding The load area can be increased by using a larger washer or a transom reinforcement plate NOTE The inside holes on the transom reinforcement plate are for the lower tran...

Page 97: ...bolts not the threads 3 Fasten the outboard with the provided mounting hardware Tighten the locknuts to the specified torque NOTE For a more accurate torque tighten the locknuts rather than turning the mounting bolts a Clamp bracket screw b 1 2 in diameter bolt 4 c Flat washer 4 d Locknut 4 Description Nm lb in lb ft Outboard mounting hardware 75 55 4 Tighten the clamp bracket screws securely a b ...

Page 98: ...onal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing installing or removing engine or drive components WARNING Rotating the propeller shaft may cause the engine to crank over and start To prevent this type of accidental engine starting and possible serious injury caused from bein...

Page 99: ...tainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Propeller d Forward thrust hub 3 Flo Torq II drive hub propellers Install forward thrust hub propeller replaceable drive sleeve rear thrust hub propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Rear thrust hub d Replaceable drive sleeve e Propeller f Forward thrust hu...

Page 100: ...electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing installing or removing engine or drive components WARNING Rotating the propeller shaft may cause the engine to crank over and start To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller always tur...

Page 101: ...aft drive sleeve with the rectangular mark on the front drive sleeve 2 Insert the aft drive sleeve into the front drive sleeve a Rectangular mark on the front drive sleeve b Identification number on the aft drive sleeve 1 or 2 c O ring Alignment Method 2 1 Align the fingers of the aft drive sleeve with the pockets of the front drive sleeve as shown 2 a b c 56277 INSTALLATION eng 93 ...

Page 102: ...2 Insert the aft drive sleeve into the front drive sleeve a Wide spacer on front drive sleeve b Wide gap between fingers on the aft drive sleeve c O ring 2 a b a b c 58186 INSTALLATION 94 eng ...

Page 103: ... between the front drive sleeve and the aft drive sleeve 44714 2 Insert the drive sleeve assembly onto the propeller and push the drive sleeve assembly onto the propeller 56279 NOTE Ensure that the O ring is seated in the counterbore of the aft drive sleeve INSTALLATION eng 95 ...

Page 104: ...a Aft washer 4 Install the thrust washer onto the propeller shaft IMPORTANT The Flo Torq Reflex drive hub requires the use of the thrust washer that is included with the drive hub kit 43671 5 Install the propeller 6 Install the aft washer the tab washer and secure with the propeller nut included with the kit Tighten the nut to the specified torque Bend the washer tabs onto the nut a 44725 INSTALLA...

Page 105: ... of the locknut not fully engaging the propeller shaft threads a Forward thrust washer b Propeller c Front drive sleeve d Aft drive sleeve e O ring f Drive sleeve adapter g Tab washer h Locknut 7 Rotate the propeller to verify interference or binding does not exist between the gear housing and the propeller Description Nm lb in lb ft Nut 75 55 NOTE A small amount of rotation play is normal a b c d...

Page 106: ... little effect reducing steering torque if the outboard is installed with the anti ventilation plate approximately 50 mm 2 inches or more above the boat bottom Operate your boat at normal cruising speed trimmed to the desired position Turn your boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt and make small adjustments at a time ...

Page 107: ...Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours MAINTENANCE LOG eng 99 ...

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Summary of Contents for 40 FourStroke Tiller Handle

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Mercury 40 FourStroke Tiller Handle, Operation Maintenance Warranty Installation Manual, Page: 104 / 107

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Summary of Contents for 40 FourStroke Tiller Handle

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