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Mercury 40 FourStroke Tiller Handle Operation Maintenance Warranty Installation Manual

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Summary of Contents for Mercury 40 FourStroke Tiller Handle

  • Page 1 Outboard Operation Maintenance Warranty Installation Manual...
  • Page 3 Mercury Marine, a world leader in marine technology and outboard manufacturing since 1939. These years of experience have been committed to the goal of producing the finest quality products. This led to Mercury Marine's reputation for strict quality control, excellence, durability, lasting performance, and being the best at providing after the sale support.
  • Page 4 Mercury Premier Service Mercury evaluates the service performance of its dealers and assigns its highest rating of "Mercury Premier" to those demonstrating an exceptional commitment to service. Earning a Mercury Premier Service rating means a dealer: • Achieves a high 12 month customer satisfaction index (CSI) score for warranty service.

  • Page 5: Table Of Contents

    WARRANTY INFORMATION Warranty Registration United States and Canada..........1 Transfer of Warranty United States and Canada..........1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada.................. 2 3 Year Limited Warranty Against Corrosion............2 Warranty Coverage and Exclusions..............4 U.S.
  • Page 6 Low Permeation Fuel Hose Requirement ............38 EPA Pressurized Portable Fuel Tank Requirements........38 Fuel Demand Valve (FDV) Requirement............38 Mercury Marine's Pressurized Portable Fuel Tank........... 39 Filling Fuel Tank....................40 Engine Oil Recommendations................40 Checking and Adding Engine Oil..............41 Features and Controls Warning System ‑...
  • Page 7 Maintenance Outboard Care....................58 EPA Emissions Regulations................58 Inspection and Maintenance Schedule............. 59 Flushing the Cooling System................60 Top Cowl Removal and Installation..............62 Exterior Care..................... 62 Battery Inspection .................... 62 Fuel System...................... 63 Engine Fuel Filter ‑ Manual Starting Models............. 63 Corrosion Control Anode..................
  • Page 8 Installation Mercury Marine Validated Engine Mounting Hardware........84 Installation Information..................84 Fuel Hose Connection..................90 Flo‑Torq I Propeller Installation................. 90 Flo‑Torq Reflex Drive Hub Propeller Installation..........92 Trim Tab Adjustment..................98 Maintenance Log Maintenance Log....................99...

  • Page 9: Warranty Information

    Federal Safety Act be required. You may change your registered address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 10: Transfer Of Mercury Product Protection (Extended Service Coverage) Plan United States And Canada

    Protection or an authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee.
  • Page 11 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 predelivery inspection process is completed and documented.

  • Page 12: Warranty Coverage And Exclusions

    Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.
  • Page 13 9. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 10. Oils, lubricants, or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 14: U.s. Epa Emissions Limited Warranty

    U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides a five year or 175 hours of engine use warranty, whichever occurs first, to the retail customer, that the engine is designed, built,...

  • Page 15: California Emissions Limited Warranty

    Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below. The cost to diagnose a warranty failure is covered under the warranty (if the warranty claim is approved).
  • Page 16 Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.

  • Page 17: California Air Resources Board Explanation Of Your California Emission Control Warranty Statement

    California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.

  • Page 18: Emission Certification Star Label

    As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

  • Page 19: Warranty Policy-Australia And New Zealand

    What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates.
  • Page 20 Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage under this Limited Warranty 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 predelivery inspection process is completed and documented.
  • Page 21 The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. A list of dealers and their contact details is available at www.mercurymarine.com.au.
  • Page 22 Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional information regarding events and circumstances covered by this...

  • Page 23: Global Warranty Charts Outboard And Jets

    You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department.
  • Page 24 WARRANTY INFORMATION Standard Limited Standard Limited Product Corrosion Warranty Warranty OptiMax jet drive (200 and 250 hp) 1 year 3 years Racing Product Standard Limited Standard Limited (Recreation use only) Warranty Corrosion Warranty OptiMax (250 XS) 2 years 3 years OptiMax (225 Sport XS) 2 years 3 years OptiMax (300 XS)
  • Page 25 WARRANTY INFORMATION Outside of South Pacific For product purchased outside of the South Pacific region, contact the distributor in your country, or the Marine Power Service Center closest to you. ASIA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion...
  • Page 26 WARRANTY INFORMATION Standard Racing Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty Contact the Marine Verado 400R 2 years 3 years Power Service Center closest to you Outside Europe and CIS For products purchased outside of Europe and CIS regions, contact the distributor in your country, or the Marine Power Service Center closest to you.
  • Page 27 WARRANTY INFORMATION SOUTH AFRICA WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 2 years 3 years FourStroke 2 years 3 years Contact the Marine OptiMax Power Service Center (including Pro 3 years 3 years closest to you Verado...

  • Page 28: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public. It is strongly recommended that each operator read and understand this entire manual before operating the outboard.

  • Page 29: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. 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.
  • Page 30 GENERAL INFORMATION The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.
  • Page 31 GENERAL INFORMATION 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.

  • Page 32: Protecting People In The Water

    GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
  • Page 33 GENERAL INFORMATION 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 at speeds above idle can cause serious injury or death.

  • Page 34: Wave And Wake Jumping

    GENERAL INFORMATION Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water.

  • Page 35: Impact With Underwater Hazards

    GENERAL INFORMATION Impact with Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 36: Safety Instructions For Hand-Tilled Outboards

    Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Safety Instructions for Hand‑Tilled Outboards No person or cargo should occupy the area directly in front of the outboard while the boat is in motion.
  • Page 37 GENERAL INFORMATION 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 enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.

  • Page 38: Selecting Accessories For Your Outboard

    Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.
  • Page 39 (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.
  • Page 40 GENERAL INFORMATION • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown overboard or into the...

  • Page 41: Recording Serial Number

    GENERAL INFORMATION Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard as shown. Model Number XXXXXXX Serial Number XXXXX XX XXXX XXX Me rc ury Marine Brunswick Corp. Made in Japan 24125 Serial number...
  • Page 42 GENERAL INFORMATION Models Recommended Gasoline Refer to Fuel and Oil Recommended Oil Refer to Fuel and Oil Gearcase Lubricant Capacity 440 ml (14.9 fl oz) Engine Oil Capacity 3.0 L (3 qt)

  • Page 43: Component Identification

    GENERAL INFORMATION Component Identification 58166 Tilt support knob Transom brackets Oil drain plug Primary cooling water intake Gearcase Trim tab Antiventilation plate Driveshaft housing Water pump indicator hole Bottom cowl Top cowl Shift handle Engine stop switch Throttle friction adjustment knob Lanyard stop switch Steering friction adjustment lever Tilt lock lever...

  • Page 44: Transporting

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations.

  • Page 45: Fuel And Oil

    FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump octane rating of 87 (R+M)/2 minimum.

  • Page 46: Low Permeation Fuel Hose Requirement

    IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided.

  • Page 47: Mercury Marine's Pressurized Portable Fuel Tank

    Vent/water drain holes 46273 Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks are available as an accessory or are provided with certain portable outboard models.

  • Page 48: Filling Fuel Tank

    Mercury or Quicksilver NMMA FC‑W certified SAE 10W‑30 4‑Stroke Marine Engine Oil is recommended for general, all‑temperature use. If NMMA certified synthetic blend oil is preferred, use Mercury or Quicksilver SAE 25W‑40 Synthetic Blend Marine 4‑Stroke Engine Oil. If the recommended Mercury or Quicksilver NMMA FC‑W certified outboard oils are not available, a major...

  • Page 49: Checking And Adding Engine Oil

    FUEL AND OIL IMPORTANT: The use of nondetergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality or oils that contain solid additives are not recommended.
  • Page 50 FUEL AND OIL 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. 28813 Full mark Add mark Dipstick Oil filler cap...

  • Page 51: Features And Controls

    FEATURES AND CONTROLS Warning System ‑ Manual Starting Models The outboard warning system incorporates a warning horn below the tiller handle. Warning horn below tiller handle 28831 WARNING SYSTEM OPERATION The warning horn will emit either a continuous beep or intermittent short beeps, and engine speed will be limited to 2000 RPM.

  • Page 52: Smartcraft Product

    SmartCraft Product A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and engine operating hours.
  • Page 53 FEATURES AND CONTROLS SHALLOW WATER OPERATION When operating your boat in shallow water, the outboard can be adjusted and locked at a higher tilt angle. Operate your 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.
  • Page 54 FEATURES AND CONTROLS 2. Engage the tilt support lever by rotating the knob to bring the support lever upward. Tilt support lever Knob 28931 3. Lower the outboard to rest on the tilt support lever. 4. Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down.
  • Page 55 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 26806 Too much angle (stern down ‑ bow up) Not enough angle (stern up ‑ bow down) Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard.

  • Page 56: Throttle Grip Friction Adjustment - Tiller Handle Models

    FEATURES AND CONTROLS Throttle Grip Friction Adjustment ‑ Tiller Handle Models Throttle grip friction knob ‑ Turn friction knob to set and maintain the throttle at desired speed. Turn knob clockwise to tighten friction and turn knob counterclockwise to loosen friction. Loosen friction Tighten friction 19807...

  • Page 57: Trim Tab Adjustment

    FEATURES AND CONTROLS Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal result from your outboard not trimmed with the propeller shaft parallel to the water surface. The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.

  • Page 58: Operation

    OPERATION Important Daily Inspection Before Each Use Any outboard mounted on the boat must have the mounting hardware inspected and checked to ensure that the hardware has not become loose. A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use.

  • Page 59: Operating In Freezing Temperatures

    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.

  • Page 60: Engine Break-In Procedure

    OPERATION NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 26837 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.
  • Page 61 OPERATION 2. Connect the remote fuel line to the outboard. Verify the connector is snapped into place. 28526 3. Position 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.
  • Page 62 OPERATION 6. Models without power trim ‑ Position the tilt lock lever to the lock position. 26839 7. Position the throttle grip as follows: • Cold engine ‑ Set the throttle grip to the start position. • Warm engine ‑ Set the throttle grip to the half‑way position. •...

  • Page 63: Gear Shifting

    OPERATION 9. Check for a steady stream of water flowing out of the water pump indicator hole. 28521 IMPORTANT: If no water is coming out of the water pump indicator hole, stop the engine and check the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system.

  • Page 64: Stopping The Engine

    OPERATION • Reduce the engine speed to idle before shifting. 26842 • Always shift the outboard into gear with a quick motion. • After shifting the outboard into gear, advance the remote control lever or rotate the throttle grip (tiller handle) to increase speed. Stopping the Engine Reduce the engine speed and shift the outboard to neutral position and push the engine stop button in.
  • Page 65 OPERATION 2. Shift the outboard to the neutral (N) position. 58150 WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear. WARNING The exposed moving flywheel can cause serious injury.

  • Page 66: Outboard Care

    Genuine Lubricants. EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments set to factory standards.

  • Page 67: Inspection And Maintenance Schedule

    MAINTENANCE 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. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in gear):...

  • Page 68: Flushing The Cooling System

    MAINTENANCE AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water. Refer to Flushing the Cooling System. • Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in saltwater. EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS FIRST •...
  • Page 69 MAINTENANCE 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.

  • Page 70: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal and Installation REMOVAL Pull out the rear lock lever and remove the top cowl. 28439 INSTALLATION 1. Lower the top cowl over the engine. 2. Bring the front of the cowl down first and engage the front hook. Lower the cowl into its seated position and apply downward pressure to the back of the cowl to lock it in place.

  • Page 71: Fuel System

    MAINTENANCE 2. Ensure the battery is secure against movement. 3. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 4. Ensure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals. Fuel System WARNING Fuel is flammable and explosive.

  • Page 72: Corrosion Control Anode

    MAINTENANCE IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter. 28830 Fuel filter Corrosion Control Anode The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals.

  • Page 73: Propeller Replacement

    MAINTENANCE Propeller Replacement 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.
  • Page 74 MAINTENANCE 5. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 26901 6. Apply 2‑4‑C with PTFE to the propeller shaft. 26902 Tube Ref Description Where Used...
  • Page 75 MAINTENANCE 7. Flo‑Torq I drive hub propellers ‑ Install the forward thrust hub, propeller, propeller nut retainer, and propeller nut onto the shaft. Propeller nut Propeller nut retainer Propeller Forward thrust hub 26903 8. Place the propeller nut retainer over the pins. Place a block of wood between the gearcase and propeller.

  • Page 76: Spark Plug Inspection And Replacement

    MAINTENANCE IMPORTANT: The Flo‑Torq Reflex drive hub requires the use of the propeller nut included with the drive hub kit. The use of a propeller nut that was not included with the Flo‑Torq Reflex drive hub kit will result with the nylon portion of the locknut not fully engaging the propeller shaft threads.

  • Page 77: Timing Belt Inspection

    MAINTENANCE 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 0.9 mm (0.035 in.) 4.

  • Page 78: Lubrication Points

    MAINTENANCE • Signs of wear on edges or outer surfaces of belt. 26958 Lubrication Points 1. Apply a liberal amount of oil to the clamp bracket screw threads. 58153 2. Lubricate the following with 2‑4‑C with PTFE: Tube Ref Description Where Used Part No.
  • Page 79 MAINTENANCE • Swivel bracket ‑ Lubricate through fitting. Tilt support lever Swivel bracket 28466 • Copilot shaft (tiller handle models) ‑ Lubricate through fitting. Move the steering friction lever back and forth while lubricating. 28823 • Propeller shaft ‑ Apply a liberal amount on the splines of the propeller shaft.

  • Page 80: Changing Engine Oil

    MAINTENANCE Changing Engine Oil ENGINE OIL CAPACITY Capacity Fluid Type Mercury or Quicksilver SAE 25W‑40 Synthetic Blend Marine 4‑Stroke Engine Oil 3 Liter Engine oil (3 US qt) Mercury or Quicksilver SAE 10W‑30 4‑Stroke Marine Engine Oil OIL CHANGING PROCEDURE 1.

  • Page 81: Gearcase Lubrication

    MAINTENANCE 2. Remove the filter by turning the filter counterclockwise. 58164 3. Clean the mounting base. Lubricate the new oil filter gasket with engine oil. Do not use grease. Thread the filter on until the gasket contacts the base, then tighten 3/4 to 1 turn. OIL FILLING 1.
  • Page 82 MAINTENANCE DRAINING GEARCASE 1. Place outboard in a vertical operating position. 2. Place a drain pan below outboard. 3. Remove vent plug and fill/drain plug and drain lubricant. Vent plug Fill/drain plug 26973 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 440 ml (14.9 fl. oz.). CHECKING GEARCASE LUBRICANT LEVEL AND REFILLING GEARCASE 1.

  • Page 83: Gearcase Lubricant Recommendation

    Vent plug Fill/drain plug Gearcase Lubricant Recommendation Mercury or Quicksilver Premium or High Performance Gear Lubricant. 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 84: Storage

    Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref Description Where Used Part No.

  • Page 85: Gearcase

    STORAGE • Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall spark plugs. • Change the engine oil. Gearcase • Drain and refill the gearcase lubricant (refer to Gearcase Lubrication). Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of the outboard.

  • Page 86: Troubleshooting

    TROUBLESHOOTING Engine Will Not Start POSSIBLE CAUSES • 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.

  • Page 87: Battery Will Not Hold Charge

    TROUBLESHOOTING • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES •...

  • Page 88: Owner Service Assistance

    STOLEN POWER PACKAGE If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packages.
  • Page 89 RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury dealership. If you need additional assistance: 1.

  • Page 90: Ordering Literature

    Ordering Literature 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:...
  • Page 91 (USA only) P.O. Box 1939 Fond du Lac, WI 54936-1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package. Mercury Marine Submit the following...

  • Page 92: Installation

    INSTALLATION 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.
  • Page 93 Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.
  • Page 94 INSTALLATION INSTALLATION SPECIFICATIONS 58167 Minimum Transom Opening Single engine (tiller) 76.2 cm (30 in.) LIFTING OUTBOARD Use the lifting eye on the engine. 58176...

  • Page 95: Installing Outboard

    INSTALLATION INSTALLING OUTBOARD Drilling Outboard Mounting Holes 1. Mark four mounting holes on the transom using the transom drill fixture. Drill guide holes Transom drilling fixture Transom centerline 2757 Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes.
  • Page 96 INSTALLATION Checking Boat Transom Construction IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.
  • Page 97 INSTALLATION Fastening the Outboard to the Transom 1. Install the outboard so that the antiventilation plate is in‑line or within 25 mm (1 in.) below the bottom of the boat. Antiventilation plate 25 mm (1 in.) 8045 2. Apply marine sealer to the shanks of the bolts, not the threads. 3.

  • Page 98: Fuel Hose Connection

    INSTALLATION Fuel Hose Connection FUEL HOSE CONNECTION The minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.). The fuel hose connection on this engine model is a snap lock design. Fasten the remote fuel hose to the fitting with a metal hose clamp or the plastic type hose clamp that is provided with the outboard.
  • Page 99 INSTALLATION Tube Ref Description Where Used Part No. 2-4-C with PTFE Propeller shaft 92-802859A 1 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed.

  • Page 100: Flo-Torq Reflex Drive Hub Propeller Installation

    INSTALLATION 5. Align the flat sides of the propeller nut with the tabs on the propeller nut retainer. Secure the propeller nut by bending the tabs up and against the flats on the propeller nut. Pins Tabs 26906 6. Install the spark plug leads. Flo‑Torq Reflex Drive Hub Propeller Installation WARNING Performing service or maintenance without first disconnecting the battery can...
  • Page 101 INSTALLATION Tube Ref Description Where Used Part No. 2-4-C with PTFE Propeller shaft splines 92-802859A 1 DRIVE SLEEVE ALIGNMENT Alignment Method 1 1. Align the identification number on the aft drive sleeve with the rectangular mark on the front drive sleeve. 2.
  • Page 102 INSTALLATION 2. Insert the aft drive sleeve into the front drive sleeve. 58186 Wide spacer on front drive sleeve Wide gap between fingers on the aft drive sleeve O‑ring...
  • Page 103 INSTALLATION INSTALLING THE DRIVE SLEEVE INTO THE PROPELLER 1. Ensure that there is no gap between the front drive sleeve and the aft drive sleeve. 44714 2. Insert the drive sleeve assembly onto the propeller and push the drive sleeve assembly onto the propeller. 56279 NOTE: Ensure that the O‑ring is seated in the counterbore of the aft drive sleeve.
  • Page 104 INSTALLATION 3. Install the aft washer onto the drive sleeve assembly and lightly tap the drive sleeve assembly into the propeller. The aft washer will contact the propeller when the drive sleeve assembly is properly seated. 44725 Aft washer 4. Install the thrust washer onto the propeller shaft. IMPORTANT: The Flo‑Torq Reflex drive hub requires the use of the thrust washer that is included with the drive hub kit.
  • Page 105 INSTALLATION IMPORTANT: The Flo‑Torq Reflex drive hub requires the use of the propeller nut included with the drive hub kit. The use of a propeller nut that was not included with the Flo‑Torq Reflex drive hub kit will result with the nylon portion of the locknut not fully engaging the propeller shaft threads.

  • Page 106: Trim Tab Adjustment

    INSTALLATION Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.

  • Page 107: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

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