Mercury 40 FourStroke Maintenance And Installation Manual Download Page 98

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INSTALLING OUTBOARD

Drilling Outboard Mounting Holes

1. Mark four mounting holes on the transom using 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

INSTALLATION

eng

Summary of Contents for 40 FourStroke

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 40 50 60 FourStroke 8M0134318 717 eng ...

Page 2: ...eng ...

Page 3: ...anual Thoroughly IMPORTANT If you do not understand any portion of this manual contact your dealer Your dealer can also provide a demonstration of actual starting and operating procedures Notice Throughout this publication and on your power package warnings cautions and notices accompanied by the International Hazard Symbol may be used to alert the installer and user to special instructions concer...

Page 4: ...ased on continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine the terms of the warranty are set forth in the Warranty Manual included with the product The Warranty Manual contains a description...

Page 5: ...Skyhook SmartCraft Sport Jet Verado VesselView Zero Effort Zeus 1 On the Water and We re Driven to Win are registered trademarks of Brunswick Corporation Pro XS is a trademark of Brunswick Corporation Mercury Product Protection is a registered service mark of Brunswick Corporation Identification Records Please record the following applicable information Outboard Engine Model and Horsepower Engine ...

Page 6: ...eng iv ...

Page 7: ...ards 8 Exhaust Emissions 10 Selecting Accessories for Your Outboard 12 Safe Boating Recommendations 12 Recording Serial Number 15 40 50 60 FourStroke Specifications 15 Component Identification 17 Transportation Trailering Boat Outboard 18 Transporting Portable Fuel Tanks 18 Fuel and Oil Fuel Requirements 20 Low Permeation Fuel Hose Requirement 21 EPA Pressurized Portable Fuel Tank Requirements 21 ...

Page 8: ... Trim Tab Adjustment 33 Operation Important Daily Inspection Before Each Use 35 Prestarting Check List 35 Operating in Freezing Temperatures 36 Operating in Saltwater or Polluted Water 36 Prestarting Instructions 36 Engine Break in Procedure 37 Starting the Engine Remote Control Models 37 Starting the Engine Tiller Handle Models 40 Gear Shifting 42 Stopping the Engine 43 Emergency Starting 44 vi e...

Page 9: ...meter Gearcase 58 Spark Plug Inspection and Replacement 62 Fuse Replacement 63 Timing Belt Inspection 63 Lubrication Points 64 Checking Power Trim Fluid 66 Changing Engine Oil 67 Gearcase Lubricant 69 Submerged Outboard 72 Storage Storage Preparation 73 Protecting External Outboard Components 73 Protecting Internal Engine Components 74 Gearcase 74 Positioning Outboard for Storage 74 Battery Storag...

Page 10: ...are 81 Accessories Mounted to the Transom Clamp Bracket 81 Installation Information 85 Fuel Hose Connection Remote Control Models 96 Electrical Connections and Control Cable Installation 97 Propeller Installation 104 Trim Tab Adjustment 109 Trim In Stop Adjustment Power Trim Models 109 Maintenance Log Maintenance Log 110 viii eng ...

Page 11: ...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 12: ... it at its high speed capability without first requesting an initial orientation and familiarization 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 Outboard Remote Control Models The remote control connected to your...

Page 13: ...or out of the boat Always use required components and follow instructions and torque procedures a Self locking nuts 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 accidental ejection from the operator s position to activate the switch Tiller handle outboards and some remote control units ...

Page 14: ...rd 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 boat...

Page 15: ... 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 b...

Page 16: ... 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 17: ...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 18: ...her 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 while airborne upon water contact it may penetrate under the water surface and submarine for an instant This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward The boat may also steer sharply to one side Impact with Underwat...

Page 19: ...ng pipes bridge supports wing dams trees stumps and rocks Striking a floating or underwater object could result in any of an infinite number of situations Some of these situations could yield the following Part of the outboard or the entire outboard could break loose and fly into the boat The boat could move suddenly in a new direction A sharp change in direction can cause occupants to be thrown o...

Page 20: ...includes bolting the engine to the boat through the transom Refer to Installation Installing Outboard for more complete installation information WARNING Failure to correctly fasten 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 hardwar...

Page 21: ...ediately behind the boat platform dragging teak body surfing This dangerous practice not only places a person in an area of high engine exhaust concentration but also subjects them to the possibility of injury from the boat propeller GOOD VENTILATION Ventilate the passenger area open side curtains or forward hatches to remove fumes Example of desired air flow through the boat 21622 POOR VENTILATIO...

Page 22: ...es are available from Mercury Marine dealers IMPORTANT Check with your dealer before installing accessories The misuse of approved accessories or the use of nonapproved accessories can damage the product Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system Acquire and read the installation operation and maint...

Page 23: ...r Radio Paddle or oar Spare propeller thrust hubs and an appropriate wrench First aid kit and instructions Waterproof storage containers Spare operating equipment batteries bulbs and fuses Compass and map or chart of the area Personal flotation device one per person onboard Watch for signs of weather change and avoid foul weather and rough sea boating Tell someone where you are going and when you ...

Page 24: ...that all passengers have a proper seat and are in it before any boat movement Never operate a boat while under the influence of alcohol or drugs It is the law Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly Know your boating area and avoid hazardous locations Be alert The operator of the boat is responsible by law to maintain a proper lookout by sight and...

Page 25: ...Number It is important to record this number for future reference The serial number is located on the outboard as shown a Serial number b Model designation c Certified Europe Insignia as applicable 40 50 60 FourStroke Specifications Models 40 50 60 Horsepower 40 50 60 Kilowatts 29 4 37 0 44 0 Full throttle RPM range 5500 6000 RPM Number of cylinders 4 Idle speed in forward gear Controlled by ECM P...

Page 26: ... cranking amps MCA 350 cold cranking amps CCA 70 amp hour Ah Operation below 0 C 32 F 1000 marine cranking amps MCA 750 cold cranking amps CCA 100 amp hour Ah Emission control system Electronic engine control EC Sound at drivers ear ICOMIA 39 94 dBA 81 1 Tiller handle vibration ICOMIA 38 94 m s 3 3 Battery manufacturers may rate and test their batteries to different standards MCA CCA Ah and reserv...

Page 27: ... Gearcase g Trim tab h Anti ventilation plate i Driveshaft housing j Water pump indicator hole k Bottom cowl l Top cowl m Shift handle n Engine stop switch o Throttle friction adjustment knob p Lanyard stop switch q Steering friction adjustment lever tiller handle models a b c e f g h i j k l m n o p q 28524 d GENERAL INFORMATION eng 17 ...

Page 28: ...er 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 Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion Follow the transporting instructions supplied with the portable fuel tank Transport the fuel tank in a well ventila...

Page 29: ...ose the air vent and prevent escape of fuel or vapors from tank 2 Install tether cap over the fuel line connector stem This will protect the connector stem from being accidentally pushed in allowing fuel or vapor to escape a Connector stem b Tether cap F a b 26794 TRANSPORTATION eng 19 ...

Page 30: ...ently in use in the USA is alcohol ethanol methanol or butanol GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16 1 butanol Bu16 that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline Contact your boat manufacturer for specific recommendations on your boat s fuel system components fuel tanks fuel lines and fittin...

Page 31: ...r 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 Type A1 15 defined as not exceeding 15 g m 24 h with CE 10 fuel at 23 C as specified in SAE J 1527 marine fuel hose ...

Page 32: ...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 33: ...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 34: ... 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 35: ...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 28412 FUEL AND OIL eng 25 ...

Page 36: ...if equipped Refer to Features and Controls Power Trim and Tilt d Lanyard stop switch Refer to General Information Lanyard Stop Switch e Lanyard Refer to General Information Lanyard Stop Switch f Throttle friction adjustment Console controls require cover removal for adjustment g Ignition key switch OFF ON START h Fast idle lever Refer to Operation Starting the Engine i Throttle only button Refer t...

Page 37: ... your boat however depending on the nature of the problem the engine s power may be limited by the Engine Guardian System see Engine Guardian System following to protect the engine You should contact your servicing dealer at your earliest convenience It is important to note that in either of the above scenarios the horn will only sound one time If you key the engine off and restart it the horn wil...

Page 38: ...lem will need to be identified and corrected if possible The system must be reset before the engine will operate at higher speeds Moving the throttle lever back to the idle position will reset the system SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard A few of the functions the instrument package will display are engine RPM coolant temperature o...

Page 39: ...b Panel mount trim switch c Tilt range of travel d Trim range of travel POWER TRIM OPERATION With most boats operating around the middle of the trim range will give satisfactory results However to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out Along with an improvement in some performance aspects comes a greater respons...

Page 40: ...t in a safe manner In rare circumstances the owner may decide to limit the trim in This is accomplished by repositioning the tilt stop pins into the desired adjustment holes in the transom brackets Trimming out or up can Lift the bow higher out of the water Generally increase top speed Increase clearance over submerged objects or a shallow bottom Increase steering torque or pull to the left at a n...

Page 41: ...alve three turns counterclockwise This allows manual tilting of the outboard Tilt the outboard to the desired position and tighten the manual tilt release valve 26809 NOTE The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up o...

Page 42: ...ttle Grip Friction Adjustment Tiller Handle Models Throttle grip friction knob Turn friction knob to set and maintain the throttle at desired speed Turn knob clockwise to tighten friction and turn knob counterclockwise to loosen friction a Loosen friction b Tighten friction Steering Friction Adjustment Tiller Handle Models NOTE Steering friction adjustment is only provided on models with tiller ha...

Page 43: ...eering torque is a normal result from your outboard not trimmed with the propeller shaft parallel to the water surface The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort 26816 NOTE Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti ventilation...

Page 44: ...MODELS WITH POWER TRIM Operate your boat at normal cruising speed trimmed to 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 If the boat turns more easily to the left move the trailing edge of trim tab to the left If the boat turns more easily to the right move the ...

Page 45: ... 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 46: ...mend that you flush 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 u...

Page 47: ...n 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 Remote Control Models Before starting read the Prestarting Check List sp...

Page 48: ...f the bulb is pointing up Squeeze the fuel line primer bulb several times until it feels firm 27348 3 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch 19791 4 Shift outboard to neutral N position N 26838 OPERATION 38 eng ...

Page 49: ...he engine fails to start in ten seconds return the key to the ON position wait 30 seconds and try again 19804 8 After engine starts check for a steady stream of water flowing out of the water pump indicator hole 28521 IMPORTANT If no water is coming out of the water pump indicator hole stop engine and check cooling water intake for obstruction No obstruction may indicate a water pump failure or bl...

Page 50: ...ater the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 1 Open fuel tank vent screw in filler cap on manual venting type fuel tanks 19748 2 Connect the remote fuel line to the outboard Make sure the connector is snapped into place 28526 3 Position the fuel line primer bulb so the arrow on the side...

Page 51: ...rottle grip to start position 7 Starting a flooded engine Set the throttle grip to half way position a Start position b Half way position 8 Turn the ignition key to the START position If the engine fails to start in ten seconds return the key to the ON position wait 30 seconds and try again 19804 ART 0 100 START ST 0 100 START START a b 19799 OPERATION eng 41 ...

Page 52: ...e 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 or out of gear unless the engine speed is at idle Shifting at higher than engine idle speed could cause damage to the gearcase Do not shift the outboard into reverse when t...

Page 53: ...Tiller handle models Reduce the engine speed to idle before shifting 26842 Always shift the outboard into gear with a quick motion After shifting the outboard into gear advance the remote control lever or rotate the throttle grip tiller handle to increase speed Stopping the Engine 1 Remote control models Reduce the engine speed and shift the outboard to neutral position Turn the ignition key to OF...

Page 54: ...vided and follow procedure NOTE EFI models Engine must have a fully charged battery to start the engine 1 Remove flywheel cover or manual starter assembly 26844 2 Shift outboard to neutral N position N N 28528 WARNING The neutral speed protection device is inoperative when starting the engine with the emergency starter rope Set the engine speed at idle and the gear shift in neutral to prevent the ...

Page 55: ... plug leads when performing live tests 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 4 Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel 5 Pull th...

Page 56: ...ilure Some caustic cleaning chemicals may cause or accelerate corrosion Exercise caution when using cleaning chemicals around the engine and follow the recommendations on the packaging of the cleaning product CLEANING GAUGES IMPORTANT Never use high pressure water to clean gauges Routine cleaning of the gauges is recommended to prevent a buildup of salt and other environmental debris Crystalized s...

Page 57: ...a mild nonabrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a nonabrasive automotive polish polish designed for clear coat finishes Remove the applied wax by hand using a clean soft cloth 5 To remove minor scratches use Mercury Marine Cowl Finishing Compound 92 859026K 1 CLEANING CARE FOR THE POWERHEAD SALTWATER USE If the outboard i...

Page 58: ...IFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at the time of manufacture a Idle speed b Engine horsepower c Piston displacement d Engine power kilowatts e Date of manufacture f US EPA engine family name g Regulated emission limit for the engine family h Regulated emission limit for the engine ...

Page 59: ... ANNUALLY OR 100 HOURS Grease the engine if applicable Change the engine oil and filter if equipped Inspect the thermostat saltwater or brackish water only Add Quickleen to the fuel tank once per year per engine Apply antiseize to the spark plug threads Replace the gear lubricant Inspect the corrosion control anodes Lubricate the propeller shaft splines Replace all filters on the suction side of t...

Page 60: ...death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage 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 Place the outboard in either the operating position vertical or in a tilted position 2 Remove the p...

Page 61: ...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 62: ...m completely Use an approved container to collect and store the 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 work for sign of fuel leakage FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling le...

Page 63: ...proper position on the sight bowl and screw the sight bowl hand tight into the cover 3 Push the filter assembly back into the mount Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt e Part Number 10 856680 and self locking nylon insert locknuts b and d Part Number 11 826709113 These locknuts mu...

Page 64: ...scription Nm lb in lb ft Nylon insert locknut b 27 20 Nylon insert locknut d Tighten until it seats then back off 1 4 turn Special washer head bolt 27 20 Assemble steering link rod to steering cable with two flat washers and nylon insert locknut Tighten locknut until it seats then back nut off 1 4 turn Assemble steering link rod to engine with special washer head bolt locknut and spacer First torq...

Page 65: ...of the transom bracket assembly a Anode on transom bracket assembly b Gearcase anodes Propeller Replacement 87 3 mm 3 7 16 in Diameter Gearcase 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 turn the ignition key or lanyard stop s...

Page 66: ... retainer 26900 4 Place a block of wood between the gearcase and propeller to keep the propeller from turning Remove the propeller nut 5 Pull the propeller straight off the shaft If the propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 26901 MAINTENANCE 56 eng ...

Page 67: ... shaft at the recommended maintenance intervals and each time the propeller is removed 7 Flo Torq I drive hub propellers Install the forward thrust hub propeller propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Propeller d Forward thrust hub 8 Flo Torq II drive hub propellers Install the forward thrust hub propeller replaceable drive sleeve rear th...

Page 68: ...ats on the propeller nut a Pins b Tabs 11 Install the spark plug leads Propeller Replacement 108 mm 4 1 4 in Diameter Gearcase 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 turn the ignition key or lanyard stop switch to the OFF ...

Page 69: ... nut retainer 26900 4 Place a block of wood between gearcase and propeller to keep the propeller from turning Remove the propeller nut 5 Pull the propeller straight off the shaft If the propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 26901 MAINTENANCE eng 59 ...

Page 70: ...ed maintenance intervals and each time the propeller is removed 7 Flo Torq I drive hub propellers Install the thrust washer propeller continuity washer thrust hub propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Thrust hub d Continuity washer e Propeller f Thrust washer 8 Flo Torq II drive hub propellers Install the forward thrust hub replaceable d...

Page 71: ...iner and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Rear thrust hub d Propeller e Replaceable drive sleeve f Forward thrust hub 10 Place a block of wood between the gearcase and propeller and torque the propeller nut to the specified torque Description Nm lb in lb ft Propeller nut 75 55 11 Secure the propeller nut by bending three of the tabs into the thrust hub groove...

Page 72: ...he spark plug boots Twist the rubber boots slightly and pull off 26899 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blistered or fouled 26946 3 Set the spark plug gap to specification 26947 Spark Plug Spark plug gap 1 0 mm 0 040 in 4 Before installing spark plugs clean off any dirt on the spark plug seats Install plugs finger ...

Page 73: ...se If the band is broken replace the fuse Replace the fuse with a new fuse of the same rating a Ignition coil circuit 20 amp b Fuel pump idle air control fuel injector circuits 20 amp c Voltage regulator 25 amp d Main power relay accessories remote control 15 amp e Spare 20 amp f Good fuse g Blown fuse Timing Belt Inspection Inspect the timing belt and have it replaced by an authorized dealer if a...

Page 74: ...ase or 2 4 C with PTFE Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 95 2 4 C with PTFE Propeller shaft 92 802859A 1 2 Lubricate the following with Quicksilver or Mercury Precision Lubricant 2 4 C with PTFE Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Tilt support lever swivel bracket tilt tube steering cable grease fitting 92 802859A 1 Tilt s...

Page 75: ...ler handle models Lubricate through fitting Move the steering friction lever back and forth while lubricating 28823 WARNING Incorrect cable lubrication can cause hydraulic lock leading to serious injury or death from loss of boat control Completely retract the end of the steering cable before applying lubricant a b 28466 MAINTENANCE eng 65 ...

Page 76: ... outboard tilt tube Lubricate through fitting a Fitting b Steering cable end 3 Lubricate the following with lightweight oil Steering link rod pivot points Lubricate points 28471 Checking Power Trim Fluid 1 Tilt the outboard to the full up position and engage the tilt support lock 28474 b a 28468 MAINTENANCE 66 eng ...

Page 77: ...fluid ATF 28476 Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim reservoir 92 858074K01 Changing Engine Oil ENGINE OIL CAPACITY Capacity Fluid Type Engine oil 3 0 Liter 3 U S Quarts Mercury or Quicksilver SAE 25W 40 Synthetic Blend Marine 4 Stroke Engine Oil Mercury or Quicksilver SAE 10W 30 4 Stroke Marine Engine Oil OIL CHANGING PROCEDURE 1 Tilt the outboar...

Page 78: ...OIL FILTER 1 Place a rag or towel below the oil filter to absorb any spilled oil 2 Unscrew the old filter by turning the filter to the left 3 Clean the mounting base Apply a film of clean oil to the filter gasket Do not use grease Screw the new filter on until the gasket contacts the base then tighten 3 4 to 1 turn 28417 OIL FILLING 1 Remove the oil fill cap and add oil to the proper operating lev...

Page 79: ...f 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 turn to ice and damage the gearcase Examine the drained gearcase lubricant for metal particles A small amount of fine metal particles indicates normal gear wear An excessive amount of metal filings or larger particles chips may indicate abnorma...

Page 80: ...R GEARCASE When adding or changing gearcase 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 f...

Page 81: ...ase 1 Place the outboard in a vertical operating position 2 Remove the front vent plug and rear vent plug 3 Place the lubricant tube into the fill hole and add lubricant until it appears at the front vent hole At this time install the front vent plug and sealing washer 4 Continue adding lubricant until it appears at the rear vent hole 5 Stop adding lubricant Install the rear vent plug and sealing ...

Page 82: ...n plug and sealing washer 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 27001 b a c d e MAINTENANCE 72 eng ...

Page 83: ...tructions Portable fuel tank Pour the required amount of gasoline stabilizer follow instructions on container into the fuel tank Tip fuel tank back and forth to mix 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 liter one quart of gasoline Pour this mi...

Page 84: ...arcase Lubricant Positioning Outboard for Storage Store outboard in an upright vertical position to allow water to drain out of the outboard 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 Foll...

Page 85: ...ng the engine a Fuel tank is empty b Fuel tank vent not open or restricted c Fuel line is disconnected or kinked d Primer bulb not squeezed e Primer bulb check valve is faulty f Fuel filter is obstructed Refer to Maintenance section g Fuel pump failure h Fuel tank filter obstructed Blown fuse Refer to Maintenance section Ignition system component failure Spark plugs fouled or defective Refer to Ma...

Page 86: ...trols Warning System Throttle not fully open Damaged or improper size propeller Incorrect engine timing adjustments or setup Boat overloaded or load improperly distributed 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 el...

Page 87: ...he 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 AFTER SUBMERSION 1 Before recovery contact an authorized Mercury dealer 2 After recovery immediate service by an authorized Mercury dealer is required to reduce the possibilit...

Page 88: ...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 89: ...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 90: ...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 91: ...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 clamp 51965 Accessories Mounted to the Transom Clamp Bracket Mercury Marine has been made aware that certain aftermarket marine accessories such as emergency...

Page 92: ...E ACCESSORY MOUNTING TO THE TRANSOM CLAMP BRACKET After the engine is mounted to the transom or jack plate in accordance with the engine installation instructions it is acceptable to attach an accessory to the boat by use of the unused bolt holes in the transom clamp bracket as shown in Figure 1 The following list provides additional guidelines for mounting accessories to the transom clamp bracket...

Page 93: ...m clamp bracket Refer to Figure 1 Figure 1 a Minimum clearance 3 175 mm 0 125 in b Edge of accessory bracket c Transom clamp bracket wall d Radius e Engine supplied mounting fasteners f Fasteners supplied by the accessory manufacturer installed through unused engine mounting bracket holes b c d a f 54624 e INSTALLATION eng 83 ...

Page 94: ...an securing the engine to the boat 1 Do not mount an accessory to the transom clamp bracket in an unsupported condition Refer to Figure 2 54625 Figure 2 2 Do not attach an accessory to the boat by use of the engine mounting hardware Refer to Figure 3 Figure 3 a Engine supplied mounting fasteners b Transom clamp bracket c Accessory 53523 a b c INSTALLATION 84 eng ...

Page 95: ...an affect boat control and flotation characteristics or break the transom Do not install an engine that exceeds the boat s maximum power rating Do not overpower or overload your boat Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines If in doubt contact your dealer or the boat manuf...

Page 96: ...ires 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 Type A1 15 defined as not exceeding 15 g m 24 h with CE 10 fuel at 23 C as specified in SAE J 1527 marine fuel hose ELECTRIC FUEL PUMP If an electric fuel pump is used the fuel pressure must not excee...

Page 97: ...Minimum Transom Opening Dual engines 101 6 cm 40 in Engine Centerline Minimum 66 cm 26 in LIFTING OUTBOARD Use the lifting eye on the engine 28510 INSTALLATION eng 87 ...

Page 98: ...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 88 eng ...

Page 99: ...in thread 8M0071543 20 x 5 00 in long 3 25 in thread 8M0038370 20 x 5 50 in long 3 25 in thread 67755 2 20 x 6 50 in long 2 75 in thread 8M0028080 20 x 7 50 in long 2 75 in thread 8M0032860 20 x 8 00 in long 2 75 in thread Checking Boat Transom Construction IMPORTANT Determine the strength of the boat transom The outboard mounting locknuts and bolts should be able to hold 75 Nm 55 lb ft of torque ...

Page 100: ...her or a transom reinforcement plate a Large transom washer b Transom reinforcement plate Fastening the Outboard to the Transom IMPORTANT The transom mounting surface must be flat within 3 17 mm 0 125 in No step in the transom mounting surface is allowed The inside transom mounting bolt washer surface must be flat within 3 17 mm 0 125 in a Step not allowed b Gap between transom clamp and boat tran...

Page 101: ...d to ensure proper clearance of the transom bracket relief radius area 51867 Installation 1 Apply marine sealer to the shanks of the bolts not to the threads 2 Fasten the outboard with the correct mounting hardware Tighten the locknuts to the specified torque IMPORTANT Ensure that a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening The locknut must be dra...

Page 102: ...ting bolt 4 b 0 875 in flat washer 4 c Nylon insert locknut 4 d 1 500 in flat washer 4 e Marine sealer apply to the shank of the bolts not the threads Description Nm lb in lb ft Outboard mounting locknuts and bolts standard boat transom 75 55 Outboard mounting locknuts and bolts metal lift plates and setback brackets 122 90 INSTALLATION 92 eng ...

Page 103: ...ansom before each use 51985 Decal on the transom bracket STEERING CABLE STARBOARD SIDE ROUTED CABLE 1 Lubricate the entire cable end 10261 Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Steering cable end 92 802859A 1 2 Insert the steering cable into the tilt tube 28507 INSTALLATION eng 93 ...

Page 104: ...ing seal d Cap STEERING LINK ROD FASTENERS IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt a Part Number 10 856680 and self locking nylon insert locknuts b e Part Number 11 826709113 These locknuts must never be replaced with common nuts nonlocking as they will work loose and vibrate off freeing the link rod to disengag...

Page 105: ... Always use required components and follow instructions and torque procedures a Special washer head bolt 10 856680 b Nylon insert locknut 11 826709113 c Spacer 12 71970 d Flat washer 2 e Nylon insert locknut 11 826709113 f Use middle hole steer outboard to the side to gain hole access Description Nm lb in lb ft Special washer head bolt 27 20 Nylon insert locknut b 27 20 Nylon insert locknut e Tigh...

Page 106: ... torque bolt then torque locknut to specifications Fuel Hose Connection Remote Control Models REMOTE FUEL HOSE SIZE Minimum fuel hose inside diameter ID is 8 mm 5 16 in Use a separate fuel hose fuel tank pickup for each engine FUEL HOSE CONNECTION Fasten the remote fuel hose to the fitting with a metal hose clamp or the plastic type hose clamp that is provided with the outboard a Hose clamp b Remo...

Page 107: ...Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover a Access cover Route the remote wiring harness through the rubber grommet a 28505 INSTALLATION eng 97 ...

Page 108: ...ess and fasten the harness with the retainer a Remote wiring harness b Retainer c 14 pin connector BATTERY CABLE CONNECTIONS Single Outboard a Red sleeve Positive b Black sleeve Negative c Cranking battery a b c 41014 b a c 15496 INSTALLATION 98 eng ...

Page 109: ...l 1 Locate the center point of the slack or lost motion that exists in the shift cable as follows a Move the remote control handle from neutral into forward and advance the handle to full speed position Slowly return the handle back to neutral Place a mark a on the cable next to the cable end guide b Move the remote control handle from neutral into reverse and advance the handle to full speed posi...

Page 110: ...gine 6098 b c a 2 Manually shift the outboard into neutral The propeller will rotate freely 3 Position the remote control handle into neutral N 26838 4 Fit the shift cable through the rubber grommet a Rubber grommet b Shift cable 5 Attach the shift cable to the shift lever with a bow tie clip retainer a b 28489 INSTALLATION 100 eng ...

Page 111: ...ptacle 8 Lock barrel in place with the barrel latch a Barrel latch 9 Check shift cable adjustments as follows a Shift remote control into forward The propeller shaft should be locked in gear If not adjust the barrel closer to the cable end guide b Shift remote control into reverse while turning propeller The propeller shaft should be locked in gear If not adjust the barrel away from the cable end ...

Page 112: ...the cables into the remote control following the instructions provided with the remote control 1 Position the remote control into neutral N 26838 2 Fit the throttle cable through the rubber grommet a Rubber grommet b Throttle cable 3 Attach the throttle cable to the throttle lever with a bow tie clip retainer 4 Adjust cable barrel until the barrel slips onto the mounting stud a b 28491 INSTALLATIO...

Page 113: ...d with a flat washer and locknut Tighten the locknut to the specified torque a Cable end guide b Bow tie clip retainer c Flat washer d Locknut e Cable barrel Description Nm lb in lb ft Throttle cable locknut 6 53 28494 b a c d e INSTALLATION eng 103 ...

Page 114: ... 4 IN DIAMETER GEARCASE WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate 28500 a INSTALLATION ...

Page 115: ...ed maintenance intervals and also each time the propeller is removed 2 Flo Torq I drive hub propellers Install thrust washer propeller continuity washer thrust hub propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Thrust hub d Continuity washer e Propeller f Thrust washer 3 Flo Torq II drive hub propellers Install forward thrust hub replaceable driv...

Page 116: ...retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Rear thrust hub d Propeller e Replaceable drive sleeve f Forward thrust hub 5 Place a block of wood between gearcase and propeller and torque propeller nut to specifications Description Nm lb in lb ft Propeller nut 75 55 6 Secure propeller nut by bending three of the tabs into the thrust hub grooves 26945 3223 a b...

Page 117: ...nts Extreme Grease or 2 4 C with PTFE 26902 Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 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 a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance i...

Page 118: ...er f Forward thrust hub 4 Place propeller nut retainer over pins Place a block of wood between gearcase and propeller and tighten propeller nut to specifications Description Nm lb in lb ft Propeller nut 75 55 5 Align flat sides of the propeller nut with tabs on the propeller nut retainer Secure propeller nut by bending tabs up and against the flats on the propeller nut a Pins b Tabs 6 Install spar...

Page 119: ...re 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 If the boat turns more easily to the left move the trailing edge of trim tab to the left If the boat turns more easily to the right mov...

Page 120: ...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 110 eng ...

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Mercury 40 FourStroke, Maintenance And Installation Manual

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