Mercury 40 Marathon Operation, Maintenance & Installation Manual Download Page 9

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Maintenance

Cleaning Care Recommendations.................................................................... 54

EPA Emissions................................................................................................. 56

Inspection and Maintenance Schedule ............................................................ 56

Flushing the Cooling System............................................................................ 58

Top Cowl Removal and Installation.................................................................. 59

Battery Inspection ............................................................................................ 60

Fuel System...................................................................................................... 60

Exterior Care.....................................................................................................63

Steering Link Rod Fasteners............................................................................ 64

Fuse Replacement ‑ Electric Start Models....................................................... 65

Corrosion Control Anode.................................................................................. 65

Propeller Replacement..................................................................................... 66

Spark Plug Inspection and Replacement..........................................................69

Lubrication Points............................................................................................. 70

Checking Power Trim Fluid...............................................................................72

Gearcase Lubrication........................................................................................73

Submerged Outboard....................................................................................... 74

Storage

Storage Preparation..........................................................................................75

Protecting External Outboard Components...................................................... 75

Protecting Internal Engine Components........................................................... 76

Gearcase.......................................................................................................... 76

Positioning Outboard for Storage..................................................................... 76

Battery Storage................................................................................................. 76

Troubleshooting

Starter Motor Will Not Crank the Engine (Electric Start Models)...................... 77

Engine Will Not Start.........................................................................................77

Engine Runs Erratically.................................................................................... 77

Performance Loss.............................................................................................78

Battery Will Not Hold Charge............................................................................ 78

Installation

Installing Outboard............................................................................................79

Propeller Selection............................................................................................89

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Summary of Contents for 40 Marathon

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 40 SeaPro Marathon 8M0133626 617 eng...

Page 2: ...eng...

Page 3: ...nual 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 Throug...

Page 4: ...sed 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 y...

Page 5: ...kyhook 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...

Page 6: ...eng iv...

Page 7: ...ake Jumping 8 Impact with Underwater Hazards 9 Safety Instructions for Hand Tilled Outboards 10 Exhaust Emissions 10 Selecting Accessories for Your Outboard 12 Safe Boating Suggestions 12 Recording Se...

Page 8: ...Adjustment 37 Trim Tab Adjustment 38 Operation Prestarting Check List 40 Operating in Freezing Temperatures 40 Operating in Saltwater or Polluted Water 40 Operating at High Elevations 41 Engine Break...

Page 9: ...nspection and Replacement 69 Lubrication Points 70 Checking Power Trim Fluid 72 Gearcase Lubrication 73 Submerged Outboard 74 Storage Storage Preparation 75 Protecting External Outboard Components 75...

Page 10: ...Owner Service Assistance Service Assistance 90 Ordering Literature 92 Maintenance Log Maintenance Log 94 viii eng...

Page 11: ...g 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...

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 F...

Page 13: ...ommon nuts non locking as they will work loose and vibrate off freeing the link rod to disengage a Self locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine...

Page 14: ...d stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator accidentally falls overboard or moves w...

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...

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 Pass...

Page 17: ...jury 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...

Page 18: ...hange in direction can cause occupants to be thrown out of their seats or out of the boat WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of th...

Page 19: ...can cause occupants to be thrown out of their seats or out of the boat A rapid reduction in speed This will cause occupants to be thrown forward or even out of the boat Impact damage to the outboard a...

Page 20: ...board 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 inju...

Page 21: ...diately 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 o...

Page 22: ...PORTANT 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 b...

Page 23: ...ating the outboard and boat handling in case the driver becomes disabled or falls overboard Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back stern of...

Page 24: ...e speed in forward gear 700 750 RPM Number of cylinders 2 Piston displacement 644 cc 39 3 cu in Cylinder bore 76 mm 2 993 in Piston stroke 71 mm 2 796 in Recommended spark plug NGK BPZ8H N 10 Spark pl...

Page 25: ...g Shift handle h Throttle friction adjustment i Tilt support pin j Shallow water drive trailering lever manual tilt system k Transom bracket l Primary cooling water intake m Gearcase n Secondary cool...

Page 26: ...r Steering friction adjustment s Tilt pin t Stop switch GENERAL INFORMATION 16 eng...

Page 27: ...to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This prevents the propeller...

Page 28: ...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 f...

Page 29: ...ntly 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 ra...

Page 30: ...MPORTANT Oil must be NMMA certified TC W3 2 Cycle oil Mercury or Quicksilver Premium TC W3 2 Cycle oil is recommended for this engine For added protection and lubrication Mercury or Quicksilver Premiu...

Page 31: ...il 50 1 2 89 ml 3 fl oz oil 237 ml 8 fl oz oil 473 ml 16 fl oz oil Mixing Fuel and Oil Portable Tank Pour 4 liters 1 gallon of gasoline into tank Add the correct amount of oil and mix thoroughly Add t...

Page 32: ...e 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 ta...

Page 33: ...f 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 Thrott...

Page 34: ...to ignition key switch c Horn in ignition key panel WARNING SYSTEM OPERATION The warning horn will emit a continuous beep This will alert the operator and help identify the following listed situation...

Page 35: ...erheat again Operating an overheated engine will cause engine damage If a steady flow of water is coming out of the water pump indicator hole and the engine continues to overheat consult your dealer O...

Page 36: ...ngine starts to overheat again Operating an overheated engine will cause engine damage If a steady flow of water is coming out of the water pump indicator hole and the engine continues to overheat con...

Page 37: ...ease position will allow you to tilt up the outboard Lock Position Place the tilt lock lever down in the lock position whenever operating the outboard a Release position b Lock position NOTE With the...

Page 38: ...ck lever down to the lock position SHALLOW WATER OPERATION The shallow water drive feature on the outboard allows you to position the outboard at a higher tilt angle to prevent hitting bottom IMPORTAN...

Page 39: ...wn 3 Move the tilt lock lever down to the lock position SETTING THE OPERATING ANGLE OF THE OUTBOARD The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin i...

Page 40: ...egin 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...

Page 41: ...outboard in its run position before operating Basic Tilting Operation Move tilt lock lever to the tilt position Tilt outboard to desired position and lock in place by moving the tilt lock lever back...

Page 42: ...place by moving the tilt lock lever to the lock run position 27385 2 Push in the tilt support pin 3 Lower outboard to rest on the tilt support pin Lowering Outboard to run position 1 Raise the outboa...

Page 43: ...outboard runs perpendicular to the water when the boat is at full speed Arrange passengers and load in the boat so the weight is distributed evenly a Too much angle bow up adjust in b Not enough angl...

Page 44: ...ropeller In excess can cause boat porpoising bouncing or propeller ventilation Power Trim and Tilt if equipped POWER TRIM AND TILT Your outboard has a trim tilt control called power trim This enables...

Page 45: ...bow Result in quicker planing off especially with a heavy load or a stern heavy boat Generally improve the ride in choppy water Increase steering torque or pull to the right with the normal right han...

Page 46: ...ush in the tilt support pin 27681 2 Lower outboard to rest on the tilt support pin 3 Disengage the tilt support pin by raising the outboard off the support pin and pulling out the support pin Lower th...

Page 47: ...automatically return down to the maximum trim range Throttle Grip Friction Adjustment Tiller Handle Models Throttle grip friction knob Turn friction knob to set and maintain the throttle at desired sp...

Page 48: ...steering wheel Turn screw clockwise to tighten friction or turn counterclockwise to loosen friction a Loosen friction b Tighten friction Trim Tab Adjustment Propeller steering torque will cause your...

Page 49: ...ime 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 trailing edge of trim tab to the right Retighten bolt a...

Page 50: ...at all times so the gearcase is submerged This prevents the trapped water in the gearcase from freezing and causing possible damage to the water pump and other components If there is a chance of ice...

Page 51: ...ed with oil from the oil injection system will supply adequate lubrication during engine break in Engine Break in Procedure Vary the throttle setting during the first hour of operation During the firs...

Page 52: ...iller cap on manual venting type fuel tanks 19748 3 Connect the fuel line to the outboard 3074 4 Squeeze the fuel line primer bulb several times until it feels firm 19779 5 Set the lanyard stop switch...

Page 53: ...en decelerating or operating in reverse causing loss of boat control Always lock the outboard in its run position before operating 8 Cold Engine Advance the fast idle lever or throttle only feature to...

Page 54: ...indicator hole 19805 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 o...

Page 55: ...iller cap on manual venting type fuel tanks 19748 3 Connect the fuel line to the outboard 3074 4 Squeeze the fuel line primer bulb several times until it feels firm 19779 5 Set the lanyard stop switch...

Page 56: ...on N 26838 N N 3107 7 Position the tilt lock lever to the lock position 27547 a b a Reverse tilt position b Lock run position 8 Tiller handle models Move throttle grip to START position 0 100 START ST...

Page 57: ...ld push in the primer bulb rapidly 4 to 6 times 3076 a Pull the starter rope slowly until starter engages then pull rapidly to crank the engine b Allow rope to return slowly Repeat until engine starts...

Page 58: ...er 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 th...

Page 59: ...43 OFF ON S T A R T 2 Tiller handle models Reduce the engine speed and shift the outboard to neutral position Push in the engine stop button or turn the ignition key to OFF position 26776 Emergency St...

Page 60: ...utral N position N 26838 N N 3107 2 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch 19791 3 Turn ignition key to ON position 26846 4 Remove flywheel cover...

Page 61: ...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 5 I...

Page 62: ...ngine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear 1 Shift outboard to neutral N position N 26838 N N 3107 2 If starter rope is intact pull rope out of the...

Page 63: ...ious 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 rewind starter assembly or top cowl when engine i...

Page 64: ...lure 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...

Page 65: ...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 Remo...

Page 66: ...ture OWNER RESPONSIBILITY The owner operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards The owner operator is not to...

Page 67: ...nspect the corrosion control anodes Lubricate the propeller shaft splines Replace all filters on the suction side of the fuel system dealer item Lubricate the driveshaft splines dealer item Check the...

Page 68: ...er 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 Remove prop...

Page 69: ...g the outboard for 3 to 5 minutes carefully monitoring water supply at all times 6 Stop the engine turn off the water and remove the flushing attachment Reinstall the propeller Top Cowl Removal and In...

Page 70: ...check for leaks before attempting to start the engine and wipe up any spilled fuel immediately Before servicing any part of the fuel system stop the engine and disconnect the battery Drain the fuel s...

Page 71: ...the filter element with open end toward cover into the cover 2 Place the O ring seal into the sight bowl and screw the sight bowl hand tight into the cover IMPORTANT Visually inspect for fuel leakage...

Page 72: ...speed N N 3108 F R 0 100 START START 3075 4 Turn the slow speed mixture screw slowly in until the engine starts to misfire or stall due to a lean mixture Note the position of the screw slot 5 Turn th...

Page 73: ...eed screw to obtain the recommended engine idle speed Refer to General Information Specifications High Speed Mixture Adjustment The carburetor is equipped with a standard size high speed fixed jet tha...

Page 74: ...oss of boat control resulting in serious injury or death due to occupants being thrown within or out of the boat Always use required components and follow instructions and torque procedures Assemble s...

Page 75: ...to locate and correct the cause of the overload If the cause is not found the fuse may blow again Open the fuse holder and look at the silver colored band inside the fuse If the band is broken replac...

Page 76: ...t 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 neu...

Page 77: ...he propeller nut retainer 26900 4 Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut 26901 5 Pull propeller straight off shaft If propeller is seized to th...

Page 78: ...ub Propellers Install 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 Place propeller n...

Page 79: ...emove the spark plug boots 1 Remove the 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...

Page 80: ...ement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft 26902 2 Lubricate the following...

Page 81: ...Tube b Co pilot shaft Lubricate threads of transom clamp screws if equipped 27661 Shift Handle Tiller Handle Models Lubricate through fittings 3091 Steering Cable Grease Fitting If equipped Rotate ste...

Page 82: ...ly retract the end of the steering cable before applying lubricant a Fitting b Steering cable end 3 Lubricate the following with lightweight oil Steering Link Rod Pivot Points Lubricate points 3093 Ch...

Page 83: ...s 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 drain...

Page 84: ...TANT Replace sealing washers if damaged 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove lubricant tube and reinstall cleaned fill drain plu...

Page 85: ...stem Fill the fuel tank and engine fuel system with treated stabilized fuel to help prevent formation of varnish and gum Proceed with the following instructions Portable fuel tank Pour the required am...

Page 86: ...y Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel Remove the spark plugs and inject a five second spray of storage seal around the inside of the cylinder Rotate...

Page 87: ...ction 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...

Page 88: ...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 elec...

Page 89: ...the boat that utilize the outboard mounting hardware will compromise the ability of that hardware to properly and safely secure the outboard to the transom Outboards that require validated mounting ha...

Page 90: ...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 accessor...

Page 91: ...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 suppl...

Page 92: ...n 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...

Page 93: ...t 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 follo...

Page 94: ...70 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 IM...

Page 95: ...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...

Page 96: ...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 moun...

Page 97: ...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 bol...

Page 98: ...ith the required mounting hardware We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance If you install the outboard y...

Page 99: ...lly loaded refer to General Information Specifications This RPM range allows for better acceleration while maintaining maximum boat speed 22551 If changing conditions cause the RPM to drop below the r...

Page 100: ...s 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...

Page 101: ...rial numbers of your power package The name and address of your dealership The nature of the problem CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance call fax or write to the geo...

Page 102: ...Before ordering literature have the following information about your power package available Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Ma...

Page 103: ...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 Q...

Page 104: ...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 94 eng...

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Summary of Contents for 40 Marathon

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Mercury 40 Marathon, Operation, Maintenance & Installation Manual, Page: 9 / 104

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Summary of Contents for 40 Marathon

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