Mercury 40 jet fourstroke Manual Download Page 47

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FUEL & OIL

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 to (but not over)

the upper oil level with the recommended oil.

IMPORTANT: Inspect oil for signs of contamination. Oil

contaminated with water will have a milky color to it; oil

contaminated with fuel will have a strong fuel smell. If

contaminated oil is noticed, have the engine checked by your

dealer.

4. Push the dipstick 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.

28412

a -

Full mark

b -

Add mark

c -

Dipstick

d -

Oil filler cap

Summary of Contents for 40 jet fourstroke

Page 1: ...ufacturer Mercury Marine W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54935 1939 USA Authorized Representative Marine Power Europe Inc Parc Industriel de Petit Rechain B 2800 Verviers Belgium Recreational Craft Directive 2003 44 EC amending 94 25 EC Applicable Requirement Standards Applied Owner s manual A 2 5 EN ISO 10240 2004 Handling characteristics A 4 EN ISO 8665 1995 Outboard engines start...

Page 2: ... Lac Wisconsin USA 135 150 1B227000 RCD H 2 Verado 6 Cylinder Belgium 200 225 250 275 0P401000 RCD H 2 Verado 6 Cylinder Fond du Lac Wisconsin USA 200 225 250 275 1B227000 RCD H 2 80 100 115 EFI Belgium 80 100 115 0P401000 RCD H 2 75 90 115 EFI Fond du Lac Wisconsin USA 75 90 115 1B366823 RCD H 2 40 3 Cylinder Belgium 40 0P401000 RCD H 2 40 50 60 4 Cylinder Belgium 40 50 60 0P401000 RCD H 2 4 5 6 ...

Page 3: ...o disturbance characteristics SAE J551 CISPR 12 CISPR 12 EN 55012 2002 A1 2005 Electrostatic discharge testing EN 61000 6 2 EN 61000 4 2 EN 61000 4 3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe Patrick C Mackey President Mercury Marine Fond du Lac WI USA on May 1 2006 European Regulations Contact Regulations and Product Safety Department Mercu...

Page 4: ...iv ...

Page 5: ...lities 16 Before Operating Your Outboard 16 Boat Horsepower Capacity 17 High Speed and High Performance Boat Operation 18 Outboard Remote Control Models 18 Remote Steering Notice 19 Lanyard Stop Switch 20 Stopping the Boat in an Emergency 22 Protecting People In The Water 23 Passenger Safety Message Pontoon Boats and Deck Boats 24 Wave and Wake Jumping 25 Safety Instructions for Hand Tilled Outboa...

Page 6: ...ve Shear Key 48 OPERATION Pre Starting Check List 49 Operating In Freezing Temperatures 49 Operating in Saltwater or Polluted Water 50 Operating In Shallow Water 50 How the Jet Drive Operates 50 Stopping the Boat in an Emergency 52 Steering the Boat 52 Mooring The Boat 53 Water Intake Blockage 53 Clearing A Lodged Impeller 54 Pre Starting Instructions 54 Engine Break in Procedure 55 Starting the E...

Page 7: ...on Control Anode 74 Spark Plug Inspection and Replacement 74 Steering Pull Adjustment 76 Worn Dull Impeller 76 Impeller Clearance Adjustment 77 Fuse Replacement 78 Timing Belt Inspection 79 Lubrication Points 80 Checking Power Trim Fluid 84 Changing Engine Oil 84 Submerged Outboard 86 STORAGE Storage Preparation 87 Protecting External Outboard Components 88 Protecting Internal Engine Components 88...

Page 8: ...s and Accessories Inquiries 92 Service Assistance 92 Mercury Marine Service Offices 93 OUTBOARD INSTALLATION Installation Information 95 Determining the Mounting Height of the Outboard 96 Checking Boat Transom Construction 99 Fastening the Outboard 100 Steering Cable Starboard Side Routed Cable 101 Steering Link Rod Fasteners 102 Steering Cable Seal 104 Fuel Hose Connection Remote Control Models 1...

Page 9: ...Fax 920 929 5893 Upon processing the transfer of warranty Mercury Marine will send registration verification to the new owner of the product by mail There is no charge for this service For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Center closest to you Warranty Registration United States and Canada 1 You may change y...

Page 10: ... Outside the United States and Canada 1 It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area 2 The Warranty Registration Card identifies your name and address product model and serial numbers date of sale type of ...

Page 11: ...is our desire to have ALL products registered at the factory should it ever be necessary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area 5 For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing r...

Page 12: ... commercial use customer Warranty coverage may be terminated for used or repossessed product or product purchased at auction from a slvage yard or from an insurance company CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which...

Page 13: ...wear and tear 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 installation ...

Page 14: ...red by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance 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 O...

Page 15: ... product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage 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 specified pr...

Page 16: ...wear and tear 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 installation ...

Page 17: ...erage section of the Operation and Maintenance 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 ...

Page 18: ...spection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed including without limitation the replacement of sa...

Page 19: ...haser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover electrical system corrosion corrosion resulting from damage corrosion which causes purely cosmetic damage ...

Page 20: ...ween the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for additional details For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manua...

Page 21: ... is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have GENERAL EXCLUSIONS FROM WARRANTY 1 Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connection ...

Page 22: ...nance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration 10 Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit 11 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition wh...

Page 23: ...r products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product ...

Page 24: ... expelled Increase speed slightly to regain steering MANEUVERABILITY The jet drive is highly maneuverable at higher speeds more so than propeller driven boats Use caution when turning to prevent spin outs IN NEUTRAL The impeller will continue to rotate while the engine is in neutral Although the approximate balancing of forward and reverse thrust will minimize boat movement the boat may tend to mo...

Page 25: ...es a situation which if not avoided could result in engine or major component failure IMPORTANT Identifies information essential to the successful completion of the task NOTE Indicates information that helps in the understanding of a particular step or action Boat Horsepower Capacity WARNING Exceeding the boat s maximum horsepower rating can cause serious injury or death Overpowering the boat can ...

Page 26: ...d on a high speed or high performance boat with which you are unfamiliar we recommend that you never operate 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 y...

Page 27: ...se self locking nuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod This can cause a sudden unexpected loss of boat control resulting in serious injury or death due to occupants being thrown w...

Page 28: ... cm 4 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of accidental activation should t...

Page 29: ...ling in one direction drinking alcohol or consuming drugs or daring high speed boat maneuvers While activation of the lanyard stop switch will stop the engine immediately a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat...

Page 30: ...ocking Stopping the Boat in an Emergency A jet powered boat has emergency stopping capability unique to this form of propulsion WARNING Using the emergency stopping capability of a jet drive unit will slow down the boat in an emergency However sudden stopping may cause the occupants of the boat to be thrown forward or out of the boat resulting in serious injury or death Use caution when performing...

Page 31: ...e pump as a high speed projectile WHILE BOAT IS STATIONARY WARNING Avoid injury resulting from contacting the rotating impeller or having hair clothing or loose objects drawn into the water intake and wrapping around the impeller shaft Stay away from the water intake and never insert an object into the water intake or water outlet nozzle when the engine is running Stop the engine immediately whene...

Page 32: ... No one should ever be on the deck in front of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water 26782 WARNING Sitting or standing in an area of the boat not designed for passengers ...

Page 33: ...ly or completely out of the water certain hazards arise particularly when the boat re enters the water 26784 The primary concern is the boat changing direction while in the midst of the jump In such case the landing may cause the boat to veer violently in a new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat WARNING Wave or wake jum...

Page 34: ... outboards come with transom bracket clamp screws The use of clamp bracket screws alone is insufficient to properly and safely secure the outboard to the transom Proper installation of the outboard 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 re...

Page 35: ...soning can lead to unconsciousness brain damage or death Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide GOOD VENTILATION Ventilate passenger area open side curtains or forward hatches to remove fumes 21622 Example of desired air flow through the boat POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas...

Page 36: ...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 non approved accessories can damage the product Some accessories not manufactured or sold by Mercury Marine are not design...

Page 37: ...te boating law enforcement agency Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT Make sure everyone in the boat is properly seated Do not allow anyone to sit or ride on any part of the boat that was not intended for such use This includes the back of seats gunwales transom bow decks raised fishing seats any rotating fishing ...

Page 38: ...e slowly forward or backward This is normal for a direct drive jet driven boat The operator should be aware of this and use caution whenever the engine is running Never drive the boat directly behind a water skier in case the skier falls As an example a boat traveling at 40 km hr 25 MPH will overtake a fallen skier 61 m 200 ft in front of the boat in 5 seconds Watch fallen skiers When using the bo...

Page 39: ...cable 40 Jet 4 Stroke Specifications Models 40 Jet Horsepower 40 Kilowatts 29 8 Full Throttle RPM Range 5000 5500 RPM Number of Cylinders 4 Idle Speed in Forward Gear Controlled by ECM Piston Displacement 995 cc 60 8 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...

Page 40: ...ranking AMPS CCA Operation Below 0 C 32 F 1000 Marine Cranking Amps MCA or 750 Cold Cranking AMPS CCA Ampere Hours Ah 70 100 Component Identification a b c d e f g h i j k 28684 a Auxiliary tilt switch b Tilt support knob c Transom brackets d Jet drive housing e Water intake housing f Reverse gate g Water outlet nozzle h Driveshaft housing i Water pump indicator hole j Bottom cowl k Top cowl ...

Page 41: ... your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 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 ventilated area away from open flame or sparks MANUAL VEN...

Page 42: ...ING 34 2 Install tether cap over the fuel line connector stem This will protect the connector stem from being accidently pushed in thus allowing fuel or vapor to escape F a b 26794 a Connector stem b Tether cap ...

Page 43: ...nd of leaded gasoline USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The 2 types of oxygenates used in these fuels are alcohol ethanol or ether MTBE or ETBE If ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol These reformulated gasolines are acceptable for use in your Mercury Mar...

Page 44: ...particularly after storage Any sign of leakage or deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is req...

Page 45: ... tank is completely filled PORTABLE FUEL TANK PLACEMENT IN THE BOAT Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions Engine Oil Recommendations We recommend the use of Mercury or Quicksilver NMMA FC W certified synthetic blend 25W 40 4 Stroke Outboard Oil for general all temperature use If SAE 10W 30 oil is preferred use Mercury or Qu...

Page 46: ...scosity for Engine Oil a NMMA FC W certified 10W 30 outboard oil may be used at temperatures below 4 C 40 F b NMMA FC W certified synthetic blend 25W 40 outboard oil may be used in all temperatures Checking and Adding Engine Oil IMPORTANT Do not 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 th...

Page 47: ...igns of contamination Oil contaminated with water will have a milky color to it oil contaminated with fuel will have a strong fuel smell If contaminated oil is noticed have the engine checked by your dealer 4 Push the dipstick 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 b c d 28412 a Full mark b Add mark c Dip...

Page 48: ...dle forward neutral reverse b Neutral release lever c Lanyard stop switch Refer to General Information Lanyard Stop Switch d Trim tilt switch if equipped Refer to Features and Controls Power Trim and Tilt 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 leve...

Page 49: ...System may engage and protect the engine by limiting it s power You should return to port immediately and contact your servicing dealer 2 Intermittent short beeps for six seconds Indicates a non critical engine condition This condition does not require immediate attention You may continue using your boat however depending on the nature of the problem the engine s power may be limited by the Engine...

Page 50: ...r have to be concerned about whether or not you are protected The system will respond to a problem by sounding the warning horn for six seconds and or reducing engine power in order to provide engine protection If the Guardian System has been activated reduce throttle speed The problem will need to be identified and corrected if possible The system must be reset before the engine will operate at h...

Page 51: ...to adjusting the outboard further up out of the water With the engine turned off the outboard can be tilted out of the water At low idle speed the outboard can also be tilted up past the trim range to permit for example shallow water operation d a b c 28710 a Remote control trim switch b Panel mount trim switch c Tilt range of travel d Trim range of travel POWER TRIM OPERATION With most boats oper...

Page 52: ... Increase steering torque or pull to the right with the 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 over steering if any turn is attempted or if a significant wave is encountered WARNING Operating the boat...

Page 53: ... outboard shut off the engine and press the trim tilt switch or auxiliary tilt switch to the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position 1 Engage the tilt support lever by rotating knob to bring the support lever upward 2 Lower outboard to rest on the tilt support lever 3 Disengage the tilt support lever by raising the outboard off the...

Page 54: ...sired 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 or down using the power trim system a 28534 a Auxiliary tilt switch ...

Page 55: ...9807 a Loosen friction b Tighten friction Steering Friction Adjustment TILLER HANDLE MODELS Steering Friction Adjustment Adjust this lever to 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...

Page 56: ... released Steering Friction Adjustment Adjust this screw to achieve the desired steering friction drag on the steering wheel Turn screw clockwise to tighten friction or turn counterclockwise to loosen friction a b 28519 a Loosen friction b Tighten friction Replaceable Jet Drive Shear Key The jet drive is equipped with a shear key to protect it in the event of a lodged impeller The shear key can be...

Page 57: ...operate a boat while under the influence of alcohol or drugs Know the waters and area you will be boating tides currents sand bars rocks and other hazards Make inspection checks listed in Maintenance Inspection and Maintenance Schedule Check steering for free operation Check for debris around the rudder and reverse gate which may jam or hinder operation Before launching examine the jet drive water...

Page 58: ...aving The engine can idle through areas of water less than 61 cm 2 ft deep but there should be more than 61 cm 2 ft of water under the boat when increasing speed to reach full plane Once the boat is on plane the boat speed will prevent the ingestion of gravel and other debris from the bottom The suction is still present but the water intake passes too quickly over the bottom to allow debris to be ...

Page 59: ...verted to create reverse thrust This approximate balancing of forward and reverse thrust will minimize any boat movement Because the impeller is always rotating and creating thrust when the engine is running the boat may tend to move slowly forward or backward This is normal for a direct drive jet driven boat The operator should be aware of this and use caution whenever the engine is running WARNI...

Page 60: ...ting in serious injury or death Use caution when performing the emergency stopping procedure and be sure to practice in a safe area In an emergency putting the jet outboard into reverse and applying reverse throttle can rapidly slow down the boat and reduce stopping distance However such a maneuver may cause occupants in the boat to be thrown forward or possibly out of the boat Steering the Boat T...

Page 61: ...dle the boat will respond quickly but due to the relatively flat bottom hulls and lack of a gearcase in the water the boat will tend to skid on turns Turns must be started early and use sufficient power to maintain steering control Mooring The Boat Be sure to tilt the jet drive out of the water when the boat is pulled onto a beach or tied to a dock in shallow water Failure to do this may cause the...

Page 62: ...ways turn the ignition key or lanyard stop switch to the OFF position and remove all spark plug leads from the spark plugs It is possible for debris to lodge between the impeller and jet housing wall especially after the engine has been stopped This will lock the driveshaft and will prevent the engine from being able to crank over for starting Following are steps for dislodging the impeller 1 Posi...

Page 63: ...r of operation run 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 pre star...

Page 64: ...ion the fuel line 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 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 ...

Page 65: ... only lever or control handle to the maximum throttle only position and continue to crank the engine for starting Immediately reduce engine speed after engine starts 7 Turn 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 8 After engine starts check for a steady stream of water flowing out of the wa...

Page 66: ... operation allow the engine to warm up at idling speed for three minutes Starting the Engine Tiller Handle Models Before starting read the pre starting check list special operating instructions and engine break in procedure in the Operation section NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat Never start or operate the engine withou...

Page 67: ...feels firm 27348 4 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch 19791 5 Shift outboard to neutral N position N 28522 6 Set the throttle grip to start position 7 Starting a flooded engine Set the throttle grip to half way position ART 0 100 START ST 0 100 START START a b 19799 a Start position b Half way position ...

Page 68: ...ator 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 blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated may cause serious engine damage WARMING UP ...

Page 69: ...hen shifting always stop at the neutral position and allow the engine speed to return to idle 26779 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 ...

Page 70: ...dels Reduce engine speed and shift outboard to neutral position Push in the engine stop button or turn ignition key to OFF position 26776 Emergency Starting If the starter system fails use the spare starter rope provided 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 ...

Page 71: ...voltage is present any time the key is turned on especially when starting or operating the engine Do not touch ignition components or metal test probes and stay clear of spark 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 ...

Page 72: ...OPERATION 64 5 Pull the starter rope to start the engine 26848 ...

Page 73: ... Genuine Lubricants EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at time of manufacture SPARK PLUG GAP EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES CALIFORNIA AND U S EPA REFER TO OWNERS MANUAL FOR REQUI...

Page 74: ...ing fittings and hoses for leaks or signs of damage Check tie bar fasteners on multiple outboard installations for proper tightness Check propeller blades for damage AFTER EACH USE Flush out the outboard cooling system if operating in salt or polluted water See Flushing the Cooling System Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if ...

Page 75: ...on the threads of the spark plugs prior to installation See Spark Plug Inspection and Replacement Tube Ref No Description Where Used Part No 81 Anti Seize Compound Spark plug threads 92 881091K 1 EVERY 300 HOURS OF USE OR THREE YEARS IMPORTANT The engine oil must be drained before removing the gearcase to avoid oil spillage Perform the scheduled water pump replacement in combination with an engine...

Page 76: ...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 propeller Refer to Pr...

Page 77: ...engine Turn off the water and remove the hose Reinstall the propeller 28518 Top Cowl Removal and Installation REMOVAL 1 Pull out the rear lock lever and remove the top cowl 28439 INSTALLATION 1 Lower the top cowl over the engine ...

Page 78: ... waxes Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability IMPORTANT Read the safety and maintenance instructions which accompany your battery 1 Turn off the engine before servicing the battery 2 Add water as necessary to keep the battery full 3 Make sure the battery is secure against movement 4 Battery cable terminals should be clea...

Page 79: ...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 leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer bulb must b...

Page 80: ... Place the O ring seal into its 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 d Part Number 11...

Page 81: ...95 a Spacer 12 71970 b Nylon insert locknut 11 826709113 c Flat washer 2 d Nylon insert locknut 11 826709113 e Special washer head bolt 10 856680 Description 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 Tighte...

Page 82: ...pletely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode One anode is installed on the bottom of the transom bracket assembly and the other anode is located on the water intake housing a 24838 b 28703 a Water intake housing anode b Transom bracket anode Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks...

Page 83: ... 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 tight and then tighten 1 4 turn or torque to specifications Description Nm lb in lb ft Spark plug 27 20 ...

Page 84: ...board side of the outboard a 29573 a Exhaust fins Worn Dull Impeller The intake of gravel through the pump can round off and wear the leading edges of the impeller Some conditions that could be experienced from a worn dull impeller are as follows Noticeable performance loss especially on acceleration Difficulty getting the boat on plane An increase in engine RPM at wide open throttle IMPORTANT Do ...

Page 85: ...d so there is approximately 0 8 mm 0 03 in clearance between the impeller edge and liner Operating the jet drive in waters that contain sand and gravel can cause wear to the impeller blades and the clearance will start to exceed 0 8 mm 0 03 in As the blades wear shims located in the stack outside of the impeller can be transferred behind the impeller This will move the impeller further down into t...

Page 86: ...liner If adjustment is required refer to Impeller Removal and Installation Fuse Replacement IMPORTANT Always carry spare 20 amp fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow again ...

Page 87: ...p fuse d Main circuit 25 amp fuse e Spare 20 amp fuse f Main relay accessories 15 amp fuse g Ignition coil circuit 25 amp fuse h Fuel pump idle air control fuel injector circuits 20 amp fuse i Blown fuse j Good fuse Timing Belt Inspection 1 Inspect the timing belt and have it replaced by an authorized dealer if any of the following conditions are found a Cracks in the back of the belt or in the ba...

Page 88: ...bearing 92 802859A 1 IMPORTANT It is important not to use a general all purpose grease for this bearing The lubricant recommended is a water resistant grease of the proper consistency for this application If a substitute is used be sure that it is water resistant Driveshaft bearing i Pull vent hose off of the grease fitting ii Pump in grease through the grease fitting using the grease gun provided...

Page 89: ... color the driveshaft bearing and seals should be inspected and replaced if necessary Some discoloration of the grease is normal during the break in period on a new set of seals 2 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with Teflon or Special Lubricant 101 Tube Ref No Description Where Used Part No 95 2 4 C with Teflon Tilt support lever swivel bracket tilt t...

Page 90: ... through fitting a b 28466 a Tilt support lever b Swivel bracket Tilt tube Lubricate through fitting 28461 Co pilot shaft tiller handle models Lubricate through fitting Move the steering friction lever back and forth while lubricating 28823 ...

Page 91: ... the end of the steering cable before applying lubricant Steering cable grease fitting if equipped Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through fitting b a 28468 a Fitting b Steering cable end 3 Lubricate the following with lightweight oil Steering link rod pivot points Lubricate points 28471 ...

Page 92: ... Fluid If not available use automotive ATF automatic transmission fluid 28476 Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim reservoir 92 858074K0 1 Changing Engine Oil ENGINE OIL CAPACITY Capacity Fluid Type Engine oil 3 0 Liter 3 U S Quarts Mercury Precision Parts or Quicksilver Synthetic Blend 25W 40 4 Stroke Outboard Oil Mercury Precision Parts or Quick...

Page 93: ...33 a Drain plug CHANGING 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 4 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 ...

Page 94: ...necessary a 28418 a Oil fill cap 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 ...

Page 95: ...l tank remote fuel line and engine fuel system Fill the fuel tank and engine fuel system with treated stabilized fuel to help prevent formation of varnish and gum Proceed with following instructions Portable Fuel Tank Pour the required amount of gasoline stabilizer follow instructions on container into fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel Permanently Installed Fue...

Page 96: ...0 ml 1 oz of engine oil or inject a five second spray of storage seal into each spark plug hole Rotate the flywheel manually several times to distribute the oil in the cylinders Reinstall spark plugs Change the engine oil Jet Drive Pump extra grease into the jet drive bearing to purge out moisture Positioning Outboard for Storage Store the outboard in an upright vertical position This will allow w...

Page 97: ...USES Lanyard stop switch not in RUN position Incorrect starting procedure Refer to Operation section Old or contaminated gasoline Engine flooded Refer to Operation section Fuel is not reaching 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 ...

Page 98: ...e is kinked or pinched Fuel pump failure Ignition system component failure Fuel injection component failure EFI Models Engine Over Speed Excessive RPM POSSIBLE CAUSES Outboard mounted too high on the transom Worn jet pump impeller or liner Incorrect jet pump impeller clearance adjustment Tilting the outboard out beyond a vertical position Cavitation of the impeller due to rough water or obstructio...

Page 99: ...aged 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 ...

Page 100: ...he dealer has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistance Your satisfaction with your outboard product is very important to your dealer and to us If you ever have a problem question or concern about your outboard product contact your dealer or a...

Page 101: ...ebsite www mercurymarine com Canada Telephone 905 567 6372 Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario L5N 7W6 Canada Fax 905 567 8515 Australia Pacific Telephone 61 3 9791 5822 Mercury Marine Australia 132 140 Frankston Road Dandenong Victoria 3164 Australia Fax 61 3 9793 5880 Europe Middle East Africa Telephone 32 87 32 32 11 Marine Power Europe Inc Parc Industriel de Petit Recha...

Page 102: ...pan Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Shizuoka ken Japan 435 0005 Japan Fax 81 053 423 2510 Asia Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way Singapore 508762 Fax 5467789 ...

Page 103: ...lines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 26777 START IN GEAR PROTECTION WARNING Starting the engine with the drive in gear can cause serious injury or death Never operate a boat that does not have a neutral safety protection device The remote control connected to the...

Page 104: ...eration and maintenance manuals for all your selected accessories ELECTRIC FUEL PUMP If an electric fuel pump is used the fuel pressure must not exceed 27 58 kPa 4 psi at the engine If necessary install a pressure regulator to regulate the pressure LIFTING OUTBOARD Use the lifting eye on the engine 28510 Determining the Mounting Height of the Outboard The following outboard mounting height setting...

Page 105: ...ITH A V BOTTOM HULL 1 Measure the width of the leading edge on the water intake housing Make a horizontal line on the transom up from the V bottom the same length as the width of the water intake housing a b 22401 a Horizontal line b Width of the leading edge on the water intake housing 2 Place center the outboard on the boat transom Set the height of the outboard on the boat transom so that the f...

Page 106: ...1 Place center the outboard on the boat transom Set the height of the outboard on the boat transom so that the front edge of the water intake housing is in line with the bottom of the boat as shown Temporarily clamp the outboard to the transom at this position 2 Fasten outboard to the transom at this height Refer to Fastening the Outboard 22403 ...

Page 107: ...ue the construction of the transom may not be adequate The boat transom must be strengthened or the load carrying area increased 18961 a b a Transom yielding under bolt torque b Transom 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 transo...

Page 108: ...ge transom washer 67 896392 Transom reinforcement plate 67 896305 Fastening the Outboard 1 Drill four 13 5 mm 17 32 in mounting holes 2 Install the outboard so that the water intake housing is set at the correct height Refer to Determining Outboard Mounting Height 3 Apply marine sealer to shanks of bolts Do not apply marine sealer to the threads of the bolts 4 Fasten the outboard with provided mou...

Page 109: ...ing holes and two bolts through the lower set of mounting holes 28481 b c a a 1 2 in diameter bolt 4 b Flat washer 4 c Locknut 4 Description Nm lb in lb ft Outboard mounting locknuts and bolts 75 55 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 Marine Lubricant with Teflon Steering cable end 92 802859A 1 ...

Page 110: ...ink 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 d Part Number 11 826709113 These locknuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage ...

Page 111: ... injury or death due to occupants being thrown within or out of the boat Always use required components and follow instructions and torque procedures a c b 28479 f d e 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 ...

Page 112: ...urn Assemble steering link rod to engine with special washer head bolt locknut and spacer First torque bolt then torque locknut to specifications Steering Cable Seal 1 Mark tilt tube 6 4 mm 0 25 in from end Install seal components 2 Thread cap to the mark a b c d 8041 a a 6 4 mm 1 4 in b Plastic spacer c O ring seal d Cap Fuel Hose Connection Remote Control Models REMOTE FUEL HOSE SIZE Minimum fue...

Page 113: ...ose to the fitting with a metal hose clamp or the plastic type hose clamp that is provided with the outboard a b 28511 a Hose clamp b Remote fuel hose Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover a 28696 a Access cover ...

Page 114: ...harness Fasten the harness with the retainer a b c 28697 a Remote wiring harness b Retainer c 14 pin connector THROTTLE CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control 1 Place the throttle cable on the throttle lever pin and lock in place with the retainer ...

Page 115: ...mark on the cam Adjust the cable barrel so that it fits into the anchor pocket N 26838 3 Fit the throttle cable through the rubber grommet a b 28701 a Rubber grommet b Throttle cable 4 Place the throttle cable on the throttle lever pin Lock in place with the retainer ...

Page 116: ...ned up with the alignment mark on the cam when the cable barrel is placed in the barrel receptacle a b c d 28699 a Cable barrel b Alignment mark c Roller d Retainer 6 Place the cable barrel into the barrel receptacle 7 Lock in barrel in place with the barrel latch 28700 a a Barrel latch ...

Page 117: ...his can cause serious injury or death from occupants being thrown within or out of the boat Adjust the shift cable to prevent the reverse gate from interfering with water flow off the rudder 1 Attach the shift cable to the shift cam with a flat washer and a self locking nylon insert locknut as shown Tighten the locknut against the flatwasher then back off the locknut 1 4 turn 2 Place the remote co...

Page 118: ...vot a b c d 28716 a Roller b Shift cam c Shift cable d Shift cable adjustment barrel 5 Recheck the shift cable adjustment in forward shift position The correct shift adjustment will position the cam far enough on the roller to lock the reverse gate into forward position Push on the reverse gate by hand to verify it is locked into position The reverse gate should not move when pushed toward the neu...

Page 119: ...ahead of the water intake adjustments may be required to prevent cavitation at running speeds When operating the boat the outboard driveshaft housing should be vertical or tilted toward the boat when planing to provide a scooping angle on the water intake Tilting the outboard out beyond a vertical position reduces the scoop angle and can cause impeller slippage and cavitation IMPORTANT If the angl...

Page 120: ...boat manufacturer Another option to further reduce cavitation is a rough water plate A rough water plate may be helpful in reducing cavitation when running in windy rough water conditions where air is sucked into the water intake when jumping waves Install a 0 8 mm 1 32 in metal plate that extends from the hull bottom to the top of the water intake housing This plate tends to reduce air intake as ...

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Mercury 40 jet fourstroke, Manual

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