Mercury 40 TwoStroke Operation, Maintenance & Installation Manual Download Page 85

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Mercury Marine Validated Engine Mounting Hardware

IMPORTANT: Mercury Marine provides validated fasteners and installation

instructions, including torque specifications, with all of our outboards so they

can be properly secured to boat transoms. Improper installation of the outboard

can cause performance and reliability issues that can lead to safety concerns.

Follow all of the instructions relating to the outboard installation. DO NOT

mount any other accessory onto the boat with the fasteners provided with the

outboard. For example, do not mount tow sport bars or boarding ladders onto

the boat using the mounting hardware included with the outboard. Installing

other products onto the boat that utilize the outboard mounting hardware will

compromise the ability of that hardware to properly and safely secure the

outboard to the transom.
Outboards that require validated mounting hardware will have the following

decal on the transom clamp.

51965

Accessories Mounted to the Transom Clamp Bracket

Mercury Marine has been made aware that certain aftermarket marine

accessories, such as emergency boarding ladders, shallow water anchors,

transom wedge kits, and tow sport attaching devices, have been mounted to

the boat by use of the same fasteners that secure the outboard to the transom

or jack plate. Using the same fastener to secure both an accessory and the

engine to the boat compromises the ability of the fasteners to maintain the

proper clamp load. A boat with loose engine mounting fasteners creates the

possibility of performance, durability, and safety issues.

ENGINE INSTALLATION

eng

Summary of Contents for 40 TwoStroke

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 75 90 TwoStroke 8M0133622 617 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: ...ine whose policies are based 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 Manua...

Page 5: ...ble information Outboard Engine Model and Horsepower Engine Serial Number Gear Ratio Propeller Number Pitch Diameter Hull Identification Number HIN Purchase Date Boat Manufacturer Boat Model Length Exhaust Gas Emissions Certification Number Europe Only eng iii ...

Page 6: ...eng iv ...

Page 7: ... Message Pontoon Boats and Deck Boats 6 Wave and Wake Jumping 8 Impact with Underwater Hazards 8 Exhaust Emissions 11 Selecting Accessories for Your Outboard 13 Safe Boating Recommendations 13 Recording Serial Number 15 75 90 Specifications 16 Component Identification 17 Transporting Trailering Boat Outboard 18 Fuel and Oil Fuel Requirements 19 Oil Recommendation 20 Fuel and Oil Ratio 20 Filling O...

Page 8: ...odels 34 Trim Tab Adjustment 35 Operation Important Daily Inspection Before Each Use 36 Prestarting Check List 36 Operating in Freezing Temperatures 37 Operating in Saltwater or Polluted Water 37 Effects of Elevation and Weather on Performance 37 Operating at High Elevations 38 Engine Break in Procedure 38 Starting the Engine 38 Gear Shifting 42 Stopping the Engine 43 Emergency Starting 43 Setting...

Page 9: ...on and Replacement 60 Lubrication Points 61 Checking Power Trim Fluid 63 Gearcase Lubrication 63 Submerged Outboard 65 Storage Storage Preparation 66 Protecting External Outboard Components 66 Protecting Internal Engine Components 67 Gearcase 67 Draining Hose Flush Attachment If Equipped 67 Positioning Outboard for Storage 67 Battery Storage 67 Troubleshooting Starter Motor Will Not Crank the Engi...

Page 10: ...e Validated Engine Mounting Hardware 75 Accessories Mounted to the Transom Clamp Bracket 75 Fastening the Outboard to the Transom 79 Installing Outboard 84 Maximum Outboard Mounting Height 85 Maintenance Log Maintenance Log 86 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: ...common 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 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 unit...

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: ...r 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 Underwater...

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: ...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 Engine Installation Installing Outboard for more complete installation information WARNING Failure to correctly fasten the outboard could result in the outboard propelling off ...

Page 21: ...re to carbon monoxide Stay clear from exhaust areas when engine is running Keep the boat well ventilated while at rest or underway STAY CLEAR OF EXHAUST AREAS 41127 co co co co co co co co co co co co co co co co co co co co Engine exhaust gases contain harmful carbon monoxide Avoid areas of concentrated engine exhaust gases When engines are running keep swimmers away from the boat and do not sit ...

Page 22: ...ers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 1 Examples of poor ventilation while the boat is stationary a Operating the engine when the boat is moored in a confined space b Mooring close to another boat that has its engine operating 2 Examples of poor ventilation while the boat is moving a Operating the b...

Page 23: ...lowing suggestions Know and obey all nautical rules and laws of the waterways We recommend that all powerboat operators complete a boating safety course In the U S the U S Coast Guard Auxiliary the Power Squadron the Red Cross and your state or provincial boating law enforcement agency provide courses For more information in the U S call the Boat U S Foundation at 1 800 336 BOAT 2628 Perform safet...

Page 24: ...overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat s capacity plate Know your boat s operating and loading limitations Know if your boat will float if it is full of water When in doubt contact your authorized Mercury Marine dealer or the boat manufacturer Ensure that everyone in the boat is properly seated Do not allow anyon...

Page 25: ...operator should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is pers...

Page 26: ...85 8 cc 84 57 in Cylinder bore 88 9 mm 3 500 in Stroke 74 mm 2 930 in Recommended spark plug NGK BUZHW 2 Spark plug gap Surface Gap Gear ratio 2 3 1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Gearcase lubricant capacity 666 ml 22 5 fl oz Battery rating 500 marine cranking amps MCA or 450 cold cranking amps CCA Amp hour Ah 70 100 GENERAL INFORMATION 16 eng ...

Page 27: ...e Anti ventilation plate f Trim tab g Gearcase h Cooling water intake i Transom bracket j Auxiliary tilt switch k Hose flush attachment if equipped l Shift handle m Lanyard stop switch n Steering friction adjustment knob o Tilt lock lever 3125 a b c d e f g h i j k l m n o GENERAL INFORMATION eng 17 ...

Page 28: ...cal dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 28419 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This prevents the propell...

Page 29: ...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 30: ...IMPORTANT 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 Premium Plus TC W3 2 Cycle oil is recommended If Mercury or Quicksilver outboard oil is not available substitute another brand of 2 cycle outboard oil that is NMMA Certified TC W3 Severe engine damage may ...

Page 31: ...HART Gas Oil Ratio 3 8 liters 1 gal gas 11 5 liters 3 gal gas 23 liters 6 gal gas 25 1 4 148 ml 5 fl oz oil 473 ml 16 fl oz oil 946 ml 32 fl oz oil 50 1 2 89 ml 3 fl oz oil 237 ml 8 fl oz oil 473 ml 16 fl oz oil Filling Oil Injection System 1 Place the outboard in a vertical operating position Remove cowl cap 29462 2 Remove oil filler cap and pull out dipstick 2890 3 Use the dipstick to check oil ...

Page 32: ...il to bring the oil level up to the bottom of the fill neck 29465 Model Capacity Fluid Type 3 cylinder 3 liters 3 2 qt Mercury or Quicksilver Premium TC W3 2 Cycle 6 Install oil filler cap and retighten Reinstall the cowl cap 29466 Filling Remote Oil Tank If Equipped 1 Remove fill cap and fill with the specified oil FUEL AND OIL 22 eng ...

Page 33: ...caution when filling fuel tanks Always 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 unfille...

Page 34: ...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 35: ...ning horn inside key switch Tiller handle models will have the warning horn located below the tiller handle 29165 WARNING SYSTEM OPERATION The warning horn will emit a continuous beep This will alert the operator and help identify the following listed situations Warning System Function Sound Description Engine Over Temperature Continuous Engine Over Heat Low Oil Level Oil Injected Models Continuou...

Page 36: ... This will usually allow some additional low speed idle running time before the engine 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 consult your dealer Operating an overheated engine will cause engine damage LOW OIL LEVEL The warning system will be activ...

Page 37: ...enables the operator to easily adjust the position of the outboard by pressing the trim switch Moving the outboard in closer to the boat transom is called trimming in or down Moving the outboard further away from the boat transom is called trimming out or up The term trim generally refers to the adjustment of the outboard within the first 20 range of travel This is the range used while operating y...

Page 38: ...y 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 hand rotation propeller In excess can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or oversteering if any t...

Page 39: ...es 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 support lever and rotating the lever down Lower the outboard a Tilt support lever b Knob MANUAL TILTING If the outboard cannot be tilted using the power trim tilt switch ...

Page 40: ...board will automatically return down to the maximum trim range Manual Tilt System Models without power trim are equipped with a tilt assist system that allows the operator to easily tilt and lock the outboard at any tilt position from full down to full up This tilt system is designed to be adjusted when the outboard is idling in neutral or with the engine turned off WARNING Operating the engine wi...

Page 41: ...lt angle Operate the outboard at slow speed while tilted up for shallow water operation Keep the cooling water intake holes submerged in the water and continue to check for water discharge from the water pump indicator hole TILTING OUTBOARD Tilting To Full Up Position 1 Stop the engine Move the tilt lock lever to the tilt position Take hold of the top cowl grip and raise outboard to full tilt up p...

Page 42: ...gle of your outboard is adjusted by changing the position of the tilt pin in the five adjustment holes provided The outboard should be locked against this tilt pin by setting the tilt lock lever to the lock run position Proper adjustment allows the boat to achieve optimum performance stability and minimize steering effort NOTE Refer to the following lists when adjusting the operating angle of your...

Page 43: ...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 Adjusting the outboard away from the boat tra...

Page 44: ...els WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control When setting the friction adjustment maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released Adjust this lever to achieve the desired steering friction drag on the tiller handle a Tighten friction b Loosen...

Page 45: ...the desired tilt pin hole Turn your boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen 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 trailing edge of trim tab to the right Retighten bolt and retest MOD...

Page 46: ... 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 the boat s maximum load capacity Look at the boat capacity plate Fuel supply OK Oil supply oil injection 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 w...

Page 47: ...s completely out of water except in freezing temperatures when not in use Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use Each month spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes Effects of Elevati...

Page 48: ...ly rich fuel mixture Engine Break in Procedure IMPORTANT Failure to follow the engine break in procedures can result in poor performance throughout the life of the engine and can cause engine damage Always follow break in procedures MODELS WITH OIL INJECTION Engine Break in Fuel Mixture Use a 50 1 2 gasoline oil mixture in the first tank of fuel Use of this fuel mixture combined with oil from the ...

Page 49: ...e outboard to the vertical operating position Make sure all cooling water intake holes are submerged 26837 2 Open fuel tank vent screw in filler cap on manual venting type fuel tanks 19748 3 Connect the fuel line to the outboard 29175 4 Squeeze the fuel line primer bulb several times until it feels firm 19779 NOTE The engine will not start unless the lanyard is set to the RUN position OPERATION en...

Page 50: ...1 6 Shift outboard to neutral N position N 26838 N 29176 7 Model without power trim Position tilt lock lever to the lock run position a Tilt position b Lock run position 8 Tiller handle models Align the throttle grip pointer to the START position 29598 9 Starting a cold engine a b 26802 OPERATION 40 eng ...

Page 51: ...10 Starting a flooded engine a Tiller handle models Advance the throttle grip to full throttle speed Without activating primer start engine following starting procedure Immediately start to reduce engine speed after engine starts b Remote control models Advance the fast idle speed lever or throttle only feature to the full maximum position Without activating the primer crank engine for 10 seconds ...

Page 52: ...checked by your dealer Operating the engine while overheated may cause serious engine damage 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 the forward motion of the boat is greater than a no wake spe...

Page 53: ...rol handle or rotate the throttle grip tiller handle to increase the engine speed Stopping the Engine 1 Remote control models Reduce the engine speed and shift the outboard to neutral position Turn the ignition key to OFF position 26843 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 ...

Page 54: ...tection 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 outboard from starting in gear 2 Shift outboard to neutral N position N 26838 N 29176 3 Turn the ignition key to ON position 26846 OPERATION 44 eng ...

Page 55: ...r 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 reinstall the flywheel cover or top cowl when engine is running 5 Place starter rope knot into the flywheel notch and wind the rope ...

Page 56: ...e exhaust relief hole on the outboard may become submerged if the outboard is trimmed full in while running at idle speed This will cause exhaust restriction rough idle excessive smoke and fouled spark plugs If this condition exists trim the outboard up until the exhaust relief hole is out of the water The outboard should be lowered for accelerating from a standing start or from idle speed 28423 O...

Page 57: ...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 58: ...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 59: ...ng system saltwater or brackish water only 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 anti seize to the spark plug threads Replace the gear lubricant Inspect the corrosion control anodes Lubricate the propeller shaft splines R...

Page 60: ... equivalent flushing attachment 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 1 Remove prop...

Page 61: ...imes 6 Stop the engine turn off the water and remove the flushing attachment Reinstall the propeller Flushing the Cooling System Models with Accessory Hose Flush Attachment Flush the internal water passages of the outboard with fresh water after each use in salt polluted or muddy water This will help prevent a build up of deposits from clogging the internal water passages 1 Thread a water hose int...

Page 62: ...er FREEZING TEMPERATURE The water should be drained out of the engine flush hose if there is a chance of freezing temperature Drain water as follows 1 Remove water hose from the hose adapter 2 Insert the adapter only into the flush connector 3 Tilt the outboard up until all the water has drained out of the hose Top Cowl Removal and Installation REMOVAL 1 Unlock the rear latch by pushing lever down...

Page 63: ...servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always 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 system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material...

Page 64: ...e sight bowl for water accumulation The sight bowl is equipped with a float that floats on water Also inspect the filter element for sediment Clean filter as follows Removal 1 Turn the engine off 2 Turn off cap and remove the sight bowl 3 Remove the filter element and wash with cleaning solvent a Filter element b Spring c Float d O ring seal e Sight bowl f Cap 3128 a b c d e f MAINTENANCE 54 eng ...

Page 65: ... locknuts must never be replaced with common nuts nonlocking 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 within or out...

Page 66: ...ting circuit is protected from overload by an ATC 20 amp fuse If the fuse is blown the electric starter motor will not operate Try to locate and correct the cause of the overload If the cause is not found the fuse may blow again Replace fuse with a fuse of the same rating Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse with a new fuse wit...

Page 67: ... 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 Shift outboard to neutral N position N 26838 N 29176 IMPORTANT Refer to Spark Plug Inspection and Replacement for removing...

Page 68: ...eller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 6 Coat the propeller shaft with Quicksilver or Mercury 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 MAINTENANCE 58 eng ...

Page 69: ...r nut retainer c Rear thrust hub d Continuity washer e Propeller f Forward thrust hub 8 Flo Torq II drive hub propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut 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 9 Place a block of wood between...

Page 70: ...wist 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 28438 3 Set the spark plug gap to specifications if applicable 26947 Spark Plug Gap NGK BPZ8H N 10 1 0 mm 0 040 in NGK BUZHW 2 Surface gap 4 Before installing spark plugs clean off any dirt on the spark plug seats...

Page 71: ...er Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft 26902 2 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C with PTFE Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Swivel bracket tilt support lever tilt tube tiller handle steering cable grease fitting 92 802859A 1 Swivel Bracket Lubric...

Page 72: ...tboard tilt tube Lubricate through fitting 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 Fitting b Steering cable end 3 Lubricate the following with light weight oil Steering Link Rod Pivot Points Lubricate pivot points 2901 2900 a b MAINTENANCE 6...

Page 73: ...d to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gearcase Examine the drained gearcase lubricant for metal particles A small amount ...

Page 74: ...LLING GEARCASE 1 Place the outboard in a vertical operating position 2 Remove the front vent plug and rear vent plug 3 Remove the fill drain plug Place the lubricant tube into the fill drain plug hole and add lubricant until it appears at the front vent hole At this time install the front vent plug and sealing washer a Front vent plug b Front vent hole c Rear vent hole d Rear vent plug e Fill drai...

Page 75: ...l drain 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 MAINTENANCE eng 65 ...

Page 76: ...ystem 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 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 fuel tank Pour the required amount of ga...

Page 77: ...rage 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 the flywheel manually several times to distribute the storage seal in the cylinder Reinstall spark plug Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubricant Draining Hose Flush Attachment If Equipped If...

Page 78: ... Remove the battery from the boat and check water level Charge if necessary Store the battery in a cool dry place Periodically check the water level and charge the battery during storage STORAGE 68 eng ...

Page 79: ...hing 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 Ignition system component failure Spark plugs fouled or defective Refer to Maintenance section Engine Runs Erratica...

Page 80: ...p 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 electrical accessories Defective rectifier alternator or voltage regulator TROUBLESHOOTING 70 eng ...

Page 81: ...rs 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 possibility of serious engine damage REPLACEMENT SERVICE PARTS WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine produ...

Page 82: ...erial 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 geographic office in your area Please include your daytime telephone number with mail and fax correspondence United States Canada Telephone English 1 920 929 5040 Français 1 905 636 4751 Mercury Marine ...

Page 83: ...e 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 Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Department P O ...

Page 84: ...s 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 Price Total Total Due OWNER SERVICE ASSISTANCE 74 eng ...

Page 85: ...t 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 bo...

Page 86: ...CESSORY 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 The...

Page 87: ...lamp 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 ENGINE INSTALLATION eng 77 ...

Page 88: ...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 ENGINE INSTALLATION 78 eng ...

Page 89: ...25 in thread 826711 17 Nylon insert locknut 20 28421 Flat washer 1 50 in diameter 54012 Flat washer 0 875 in diameter Available Outboard Mounting Bolts Part Number Description 67755005 20 x 2 50 in long 1 25 in thread 67755006 20 x 3 50 in long 1 25 in thread 814259 20 x 4 00 in long 2 25 in thread 67755 1 20 x 4 50 in long 2 25 in thread 8M0071543 20 x 5 00 in long 3 25 in thread 8M0038370 20 x 5...

Page 90: ...e The boat transom must be strengthened or the load carrying area increased a Transom yielding under bolt torque b Transom cracking under bolt torque Use a dial torque wrench to determine transom strength If the bolt or nut continues to turn without the torque reading on the dial increasing it is an indication that the transom is yielding The load area can be increased by using a larger washer or ...

Page 91: ...t 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 transom not allowed a b 51817 ENGINE INSTALLATION eng 81 ...

Page 92: ...o 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 drawn ...

Page 93: ... 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 a c d c a d 40952 b e ENGINE INSTALLATION eng 83 ...

Page 94: ...lling off the boat transom resulting in property damage serious injury or death Before operation the outboard must be correctly installed with the required mounting hardware We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance If you install the outboard yourself follow instructions in the outboard installation manu...

Page 95: ...lts through the upper set of holes and two bolts through the lower set of holes 26789 Maximum Outboard Mounting Height The mounting height of the outboard must not exceed 635 mm 25 in for EL models and 762 mm 30 in for EXL models Mounting the outboard higher may cause damage to the gearcase components 27747 ENGINE INSTALLATION eng 85 ...

Page 96: ...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 86 eng ...

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Mercury 40 TwoStroke, Operation, Maintenance & Installation Manual

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