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10. Install the spark plug leads.

Spark Plug Inspection and Replacement

WARNING

Damaged spark plug boots may emit sparks that can ignite fuel vapors under

the engine cowl, resulting in serious injury or death from a fire or explosion.

To avoid damaging the spark plug boots, do not use any sharp object or

metal tool to remove 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 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.

MAINTENANCE

eng

Содержание 40 Marathon

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

Страница 2: ...eng...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ...eng iv...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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