General Information; Powerhead Removal - Mercury 40 Service Manual

General Information

Powerhead "Disassembly" and "Reassembly" in-
structions are printed in a sequence that should be
followed to assure best results when removing or re-
placing powerhead components. If complete disas-
sembly is not necessary, start reassembly at point
disassembly was stopped. Refer to "Table of Con-
tents" preceding.
If major powerhead repairs are to be performed, re-
move powerhead from drive shaft housing as an as-
sembly. Remove external engine components refer-
ring to appropriate section of service manual.

Powerhead Removal

1. Disconnect battery leads from battery (if applica-
ble).
2. Remove spark plug leads from spark plugs.
3. Disconnect remote control harness from engine
(if applicable) - or lanyard and stop button/horn
wiring on manual models.
4. Disconnect trim switch and trim relay wires.
5. Disconnect fuel connector from engine. Fuel line
must also be removed at either engine tray or fuel
filter.
6. Remove throttle and shift cables.
4-16 - POWERHEAD
7. Disconnect blue oil warning module wires.
8. Remove BLACK ground lead between power-
head and engine tray.
9. Remove tell-tale hose from powerhead.
10. Remove anti-start in gear cable on manual start
models and disconnect neutral switch bullet con-
nectors on all models.
11. Remove primer hoses from carb and manifold on
manual start models and remove recoil starter.
12. Remove bolt, nut and flat washer securing upper
drive shaft housing cover and remove cover.
b
a - Nut
b - Drive Shaft Housing Cover
90-852572R1 JANUARY 1998
a