Mercury 40 TwoStroke Operation, Maintenance And Installation Manual
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Mercury 40 TwoStroke Operation, Maintenance And Installation Manual

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  • Page 1 Operation Maintenance Installation Manual...
  • Page 3 Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant! Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Name / function: John Pfeifer, President, Mercury Marine...
  • Page 4 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 Manual contains a description of what is...
  • Page 5 Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, GO BOLDLY., Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury...
  • Page 7 General Information Boater's Responsibilities..................1 Before Operating Your Outboard................ 1 Boat Horsepower Capacity................. 1 High‑Speed and High‑Performance Boat Operation.......... 2 Outboard Remote Control Models..............2 Remote Steering Notice..................3 Lanyard Stop Switch................... 4 Protecting People in the Water................6 Passenger Safety Message ‑ Pontoon Boats and Deck Boats......7 Wave and Wake Jumping...................
  • Page 8 Features and Controls Remote Control Features................. 43 Tilting Outboard....................43 Shallow Water Operation.................. 43 Trim Adjustment....................45 Steering Friction Adjustment................48 Throttle Grip Turning Friction Adjustment............49 Trim Tab Adjustment..................49 Operation Prestarting Check List..................51 Operating in Freezing Temperatures..............51 Operating in Saltwater or Polluted Water............
  • Page 9 Engine Runs Erratically..................90 Performance Loss..................... 91 Battery Will Not Hold Charge................91 Installation Mercury Marine Validated Engine Mounting Hardware........92 Accessories Mounted to the Transom Clamp Bracket........92 Boat Horsepower Capacity................96 Fastening the Outboard to the Transom............96 Installing Outboard..................
  • Page 10 Accessories Optional Accessories..................120 Owner Service Assistance Service Assistance..................124 Ordering Literature..................126 Maintenance Log Maintenance Log.................... 128 viii...

  • Page 11: Boater's Responsibilities

    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 12: 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. Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 13: Remote Steering Notice

    GENERAL INFORMATION WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. 37882 Remote Steering Notice WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod.

  • Page 14: Lanyard Stop Switch

    GENERAL INFORMATION 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 units are equipped with a lanyard stop switch.
  • Page 15 GENERAL INFORMATION Important Safety Information: The purpose of a lanyard 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.

  • Page 16: Protecting People In The Water

    GENERAL INFORMATION KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD OPERATING CONDITION Before each use, check to ensure the lanyard stop switch works properly. Start the engine and stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.

  • Page 17: Passenger Safety Message ‑ Pontoon Boats And Deck Boats

    GENERAL INFORMATION 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 for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.

  • Page 18: Wave And Wake Jumping

    GENERAL INFORMATION Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. 26783 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 19: Impact With Underwater Hazards

    GENERAL INFORMATION Impact with Underwater Hazards Your outboard may be equipped with a hydraulic trim and tilt system that also contains a shock absorbing feature. This feature helps the outboard withstand damage in the case of impact with an underwater object at low to moderate speeds.
  • Page 20 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 21: Exhaust Emissions

    GENERAL INFORMATION This product must be secured to the transom with the required mounting hardware. If the outboard strikes an underwater object, the required mounting hardware prevents the outboard from propelling off the transom. A decal on the swivel bracket reminds the installer of the potential hazard. WARNING Avoid serious injury or death.
  • Page 22 GENERAL INFORMATION 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, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing).

  • Page 23: 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 24 (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 25: Recording Serial Number

    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 26: Model Year Production Code

    GENERAL INFORMATION Serial number: Model year: Model designation: Year manufactured: Certified Europe Insignia (as applicable): Model Year Production Code The serial number decal lists the year of manufacture as an alpha code. This code can be deciphered into a corresponding number utilizing the following table.

  • Page 27: Specifications (Include English Units)

    Trim system Manual, 6 position Engine oil Mercury or Quicksilver oil or recommended oil (TC‑W3) Mercury or Quicksilver gear oil or API GL5, SAE #80 to Gear oil #90, approximately 500 mL Fuel tank capacity 25 L (6.6 US gal) Approximately 2.0 L...
  • Page 28 Power trim position Mercury or Quicksilver motor oil or recommended oil Engine oil (TC‑W3) Mercury or Quicksilver gear oil or API GL5, SAE #80 to Gear oil #90, approximately 500 mL Fuel tank capacity 25 L (6.6 US gal) Engine oil capacity Approximately 2.0 L (0.53 US gal)
  • Page 29 Manual, 6 position position Mercury or Quicksilver motor oil or recommended oil Engine oil (TC‑W3) Mercury or Quicksilver gear oil or API GL5, SAE #80 to Gear oil #90, approximately 700 mL Fuel tank capacity 25 L (6.6 US gal) Engine oil Approximately 2.0 L...
  • Page 30 GENERAL INFORMATION COMPONENT IDENTIFICATION 40MH/W50MH 38270 Tilt handle Top cowl Shift lever Cowl latch Water pump indicator hole Reverse lock lever Water plug Anti‑ventilation plate Trim tab Propeller Manual start handle Throttle grip Clamp screw Trim position pin Transom bracket Anode Oil drain plug (upper) Water intake...
  • Page 31 GENERAL INFORMATION Oil drain plug (lower) Stop switch Choke knob...
  • Page 32 GENERAL INFORMATION 40EH/50EH 38271 Tilt handle Top cowl Shift lever Cowl latch Water pump indicator hole Reverse lock lever Water plug Anti‑ventilation plate Trim tab Propeller Manual start handle Throttle grip Clamp screw Trim position pin Transom bracket Anode Oil drain plug (upper) Water intake Oil drain plug (lower)
  • Page 33 GENERAL INFORMATION Stop switch Choke knob Battery cables Start button...
  • Page 34 GENERAL INFORMATION 40EHO/50EHO 38272 Tilt handle Top cowl Shift lever Cowl latch Water pump indicator hole Reverse lock lever Water plug Anti‑ventilation plate Trim tab Propeller Manual start handle Throttle grip Clamp screw Trim position pin Transom bracket Anode Oil drain plug (upper) Water intake Oil drain plug (lower)
  • Page 35 GENERAL INFORMATION Stop switch Choke knob Battery cables Low oil light Start button...
  • Page 36 GENERAL INFORMATION 40EHPTO/50EHPTO 38273 Tilt handle Top cowl Shift lever Cowl latch Water pump indicator hole Tilt stopper Water plug Anti‑ventilation plate Trim tab Propeller Manual start handle Throttle grip Clamp screw Trim position pin Transom bracket Oil drain plug (upper) Water intake Oil drain plug (lower) Stop switch...
  • Page 37 GENERAL INFORMATION Choke knob Power trim and tilt Battery cables Low oil light Start button Anode...
  • Page 38 GENERAL INFORMATION 40EO/50EO 38274 Tilt handle Top cowl Cowl latch Water pump indicator hole Reverse lock lever Water plug Anti‑ventilation plate Trim tab Propeller Clamp screw Trim position pin Transom bracket Anode Oil drain plug (upper) Water intake Oil drain plug (lower) Choke knob Battery cables Oil fill door...
  • Page 39 GENERAL INFORMATION Fuel connector...
  • Page 40 GENERAL INFORMATION 40EPTO/50EPTO 38275 Tilt handle Top cowl Cowl latch Water pump indicaor hole Tilt stopper Water plug Anti‑ventilation plate Trim tab Propeller Clamp screw Trim position pin Transom bracket Oil drain plug (upper) Water intake Oil drain plug (lower) Choke knob Power trim and tilt Battery cables...
  • Page 41 GENERAL INFORMATION Power trim and tilt switch Fuel connector Anode...

  • Page 42: Removing The Motor

    TRANSPORTING Removing the Motor 1. Verify the engine has cooling water supplied. 2. Disconnect the fuel connector and run the engine out of fuel. Pull the choke out when the engine begins to stall. This will help evacuate the remaining fuel out of the carburetors. 3.

  • Page 43: Trailering Boat/Outboard

    TRANSPORTING Trailering Boat/Outboard The boat should be trailered with the outboard in the vertical (normal running), fully down position. NOTE: Trailering in the tilted position may cause damage to the motor, boat, etc. If trailering with the engine fully down is not acceptable (the gearcase skeg is too close to the road in a vertical position), fix the motor securely using a device (like a transom saver bar) in the tilted position.
  • Page 44 TRANSPORTING 1. Disconnect the fuel connector from the engine. 38345 2. Set the reverse lock lever on the starboard side to release by turning it downward. 38366 IMPORTANT: When tilting up or down, be sure your finger, or hand, is not placed in‑between the swivel bracket and transom bracket.
  • Page 45 TRANSPORTING 4. To tilt the outboard down. Turn the reverse lock lever upward (toward release). Tilt the engine up slightly and then tilt the engine down. The reverse lock will release automatically. 39890 EHPTO, EPTO 1. Disconnect the fuel connector from the engine. 38345 2.
  • Page 46 TRANSPORTING 3. The engine can also be tilted up using the switch provided under the bottom cowl. 38379 Power trim and tilt switch 4. Lock the tilt with the tilt stopper after the engine has been tilted up. 38381 Tilt stopper...

  • Page 47: Storing The Motor

    TRANSPORTING 5. Manual tilting: If the engine cannot be trimmed up electrically, turn the manual valve a few turns counterclockwise. This will allow manual tilting of the engine. 38382 Storing the Motor Keep the motor in a vertical position when you store it. NOTE: If you store the motor in a horizontal position, lay the motor as shown in the figure.

  • Page 48: Transporting Portable Fuel Tanks

    TRANSPORTING 2. Pay attention to the tilting direction so as not to be injured by the transom bracket. Reverse lock lever Lock Transom bracket Tilting direction Rope 39894 Transporting Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion. Follow the transporting instructions supplied with the portable fuel tank.

  • Page 49: Fuel Requirements

    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 fittings).

  • Page 50: Oil Recommendation

    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.

  • Page 51: Oil Injected Models: Eho, Ehpto, Eo, Epto

    FUEL AND OIL Engine Break‑in Procedure Refer to Operation ‑ Engine Break‑In Procedure for correct break‑in procedure. Oil Injected Models: EHO, EHPTO, EO, EPTO The required amount of engine oil is automatically supplied from the oil pump according to the engine running conditions. IMPORTANT: During engine break‑in, engine oil must be added to the gasoline in addition to the oil, which is automatically supplied from the oil tank.

  • Page 52: Fuel And Oil

    FUEL AND OIL 2. Turn off the ignition switch, and fill up the oil tank with recommended engine oil. 3. Start the engine, and shift into gear carefully. 4. Confirm that the indicator lamp goes out and the buzzer does not sound. Replenishing the oil in the engine oil tank: 1.

  • Page 53: Remote Control Features

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with the remote control shown. If not, consult your dealer for a description of the functions and operations of the remote control. 39924 Remote control box Remote control handle Power trim and tilt switch Neutral warm‑up lever Ignition key switch...
  • Page 54 FEATURES AND CONTROLS NOTE: Please follow the instructions below: • When running in shallow water, take care the water in take is submerged at all times and that water is continuously running out of the water pump indicator hole. • Be sure to run slowly when using the shallow water drive.

  • Page 55: Trim Adjustment

    FEATURES AND CONTROLS 3. Releasing the shallow water setting: a. Turn the reverse lock lever upward to set them in the lock position. b. Tilt up the engine slightly and let it go down. The shallow water setting is released. c.
  • Page 56 FEATURES AND CONTROLS • Trim down: If the trim angle is excessive, the bow will rise out of the water and the speed will decrease. 38372 Select a lower hole • Trim up: If the trim angle is low, the bow will dip into the water, the speed will decrease, and water may enter the boat.
  • Page 57 FEATURES AND CONTROLS How to use the trim gauge: When the trim angle is set as desired, take a reading off the trim gauge, and record it for future reference. Trim angle adjustable range 74° 8° 28° 38375 • Correct trim: The trim angle is optimum when the boat is parallel to the water surface while running.

  • Page 58: Steering Friction Adjustment

    FEATURES AND CONTROLS • Trim up: If the trim angle is low, the bow will dip into the water and the speed will decrease. Water may also enter the boat. In this case, the trim angle should be increased by pressing the switch on the remote control lever to UP.

  • Page 59: Throttle Grip Turning Friction Adjustment

    FEATURES AND CONTROLS EHPTO, EPTO Tight Loose Copilot 38387 Throttle Grip Turning Friction Adjustment Turn the screw clockwise to tighten friction and turn the screw counterclockwise to loosen friction. Loosen friction Tighten friction 38388 Trim Tab Adjustment Propeller steering torque will cause the boat to pull in one direction. This steering torque is a normal result from the outboard not trimmed with the propeller shaft parallel to the water surface.
  • Page 60 FEATURES AND CONTROLS IMPORTANT: The trim tab also acts as an anode to prevent galvanic corrosion. Do not apply any paint, grease, or other material to the surface of the trim tab. NOTE: Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti‑ventilation plate approximately 50 mm (2 in.) or more above the boat bottom.

  • Page 61: Prestarting Check List

    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...

  • Page 62: Operating At High Elevations

    OPERATION Operating at High Elevations IMPORTANT: To prevent serious damage to the engine caused by a lean fuel mixture, do not operate your outboard (if the jets were changed for high elevation) at a lower elevation unless the jets are changed again to correspond to the new elevation.
  • Page 63 OPERATION PREPARATIONS 1. Loosen the air vent screw on the fuel tank cap. For tanks with a fuel tank auto air vent (optional): There is no need to loosen the air vent screw. An air vent opens automatically when the connector is attached to the tank. Air vent screw 38342 2.
  • Page 64 OPERATION 4. Install the lanyard cord. 38346 Lanyard cord Lanyard switch Lanyard switch Lanyard cord Hook IMPORTANT: Be sure to connect the lanyard stop switch to your body. The engine is shut down if the stop switch is disconnected. STARTING (MANUAL START) IMPORTANT: Before starting, read the Prestarting Check List, special operating instructions, and Engine Break‑in Procedure in the Operation section.
  • Page 65 OPERATION NOTE: If the engine starts in gear, do not use the engine. Contact your dealer. 2. Turn the throttle grip so the indicator line meets the START mark. 38348 3. Pull the choke knob out. 38349 NOTE: Operation of the choke knob is not required if the engine is warm. 4.
  • Page 66 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. EH, EHO, EHPTO: Tiller Handle Model 1. Set the shift lever to Neutral (N). 38347 NOTE: If the engine starts in gear, do not use the engine.
  • Page 67 OPERATION 4. Turn the key switch to ON. Continue turning the key switch clockwise to start the motor. Start 38350 5. Release the key switch as soon as the engine starts. The key will return to the ON position automatically. 6.
  • Page 68 OPERATION STARTING (REMOTE CONTROL MODEL) IMPORTANT: Before starting, read the Prestarting Check List, special operating instructions, and Engine Break‑in Procedure in the Operation section. EO, EPTO 1. Insert the key into the ignition. 2. Set the remote control lever to Neutral (N), and move the neutral warm‑up lever up.
  • Page 69 OPERATION 4. While keeping the key pressed in, turn it to START. Start Push to choke 38354 NOTE: If the engine is warm, there is no need to press the key for choking when turning it to START. 5. When the engine starts, release the key and allow it to return to ON. Push to choke 37466 IMPORTANT: Please follow the instructions below:...

  • Page 70: Gear Shifting

    OPERATION 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 speed.
  • Page 71 OPERATION 2. Before moving the shift lever to Reverse (R), ensure the reverse lock is engaged in the UP position. 39890 MH, EH, EHO, EHPTO 3. The shift lever cannot be moved from Neutral (N) to Reverse (R) unless the throttle grip is placed in the SLOW position. EO, EPTO 1.
  • Page 72 OPERATION 2. If the shift/throttle handle is moved pass the gear detent position, the throttle will begin to open. 37531 Full throttle position Idle position Throttle range Shift range (32°) Neutral (N) Forward (F) Reverse (R) Neutral warm‑up lever 3. The engine must be at idle speed when the shift lever is moved from Forward (F) to Reverse (R).

  • Page 73: Emergency Starting

    OPERATION Emergency Starting If the starter system fails, use the spare starter rope (provided) and follow the procedure. IMPORTANT: To prevent getting an electrical shock, do not touch any ignition component, wiring, or spark plug wire when starting or running the engine. 1.
  • Page 74 OPERATION 4. Pull the choke knob. 38349 5. MH, EH, EHO, EHPTO: Turn the throttle grip so the indicator line meets the "START" mark. 38348 6. EO, EPTO: Lift up the neutral warm‑up lever 1/3 to 1/2 of its stroke. 38356...
  • Page 75 OPERATION 7. EO, EPTO: Turn the key switch to ON. Key switch 37881 8. EH, EHO, EHPTO: Turn the key switch to ON. 38359 9. Wind the starter rope around the flywheel a few turns clockwise. Give it a sharp tug to start the engine. Use a socket wrench to get a firm grip on the end of the rope.
  • Page 76 OPERATION WARM-UP Before driving the boat, let the engine run at low speed for approximately three minutes to let it warm‑up. If the engine is not warmed up beforehand, the engine life will shorten greatly. During the warm‑up operation, confirm that cooling water is discharged from the water pump indicator hole and idle port.

  • Page 77: Stopping The Engine

    OPERATION NOTE: Check for a steady stream flowing out of the water pump indicator hole. If no water is coming out of the water pump indicator hole or flow is intermittent, stop the engine and check cooling water intake holes for obstruction. If no obstruction is found, this may indicate a blockage in the cooling system or a water pump problem.
  • Page 78 OPERATION 2. Turn the main switch to OFF, press the stop switch or pull the lanyard. The engine will then stop. 38369 Lanyard/stop switch EO, EPTO 1. Move the remote control lever to Neutral (N) and let the engine idle for two or three minutes to allow it to cool down.
  • Page 79 OPERATION 2. Turn the key switch counterclockwise to the OFF position or pull the lanyard. The engine will then stop. The engine can also be stopped by pressing on the lanyard switch. Stop switch lock plate 39943 NOTE: Please follow the instructions below: •...

  • Page 80: Cleaning Care Recommendations

    Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. Selecting Replacement Parts For Your Outboard We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. DO NOT USE CAUSTIC CLEANING CHEMICALS IMPORTANT: Do not use caustic cleaning chemicals on the outboard power package.

  • Page 81: Inspection And Maintenance Schedule

    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). Inspection and Maintenance Schedule DAILY CHECKS •...

  • Page 82: Flushing The Cooling System

    This will help prevent a buildup of deposits from clogging the internal water passages. Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. IMPORTANT: The engine must be run during flushing in order to open the...
  • Page 83 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 84: Top Cowl Removal And Installation

    MAINTENANCE 4. Adjust the water flow (if necessary) so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water. 27260 5. Check for a steady stream of water flowing out of the water pump indicator hole.

  • Page 85: Battery Inspection

    MAINTENANCE 2. Push cowl down and move the rear latch lever up to lock. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1.
  • Page 86 NOTE: Do not fully unscrew the oil plug with the engine tilted down. Pressurized oil in the oil tank may spurt out. 3. Recommended oil: Add Mercury or Quicksilver Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).

  • Page 87: Fuse Replacement ‑ Electric Start Remote Control Models

    MAINTENANCE 1. Loosen a fuel pickup elbow and remove it. Then clean the fuel filter. 39900 Fuel pickup elbow Filter 2. Clean the fuel filter on the engine after removing the fuel filter cases. Oil filter Fuel filter 38393 3. Oil filter and oil tank: Check the oil tank and/or filter for entrapped water and dust.

  • Page 88: Corrosion Control Anode

    MAINTENANCE Corrosion Control Anode Your outboard has a corrosion control anode installed on the gearcase and in the cylinder. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals. The anode requires periodic inspection, especially in saltwater which will accelerate the erosion.
  • Page 89 MAINTENANCE 2. Tiller handle model: Move shift lever to Neutral (N) position. 38347 3. Remove the spark plug leads to prevent the engine from starting. 26899 4. Place a block of wood between the gearcase and propeller to hold the propeller.
  • Page 90 6. Pull propeller straight off the propeller shaft. If the propeller is seized to the propeller shaft and cannot be removed, have the propeller removed by an authorized dealer. 7. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE. Tube Ref...

  • Page 91: Spark Plug Inspection And Replacement

    MAINTENANCE 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. INSTALLING PROPELLER 1.
  • Page 92 MAINTENANCE 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.

  • Page 93: Lubrication Points

    It is important to inspect and maintain your outboard motor regularly. Maintenance intervals should be determined according to the number of hours or number of months, whichever comes first. For periodic servicing and maintenance guidelines, please contact your local Mercury dealer. Every 50 hours or 3 Every 100 hours or...
  • Page 94 MAINTENANCE Vent plug Fill plug 39897 4. Place the lubricant tube nozzle into the fill/drain hole and add the lubricant until it appears at the upper oil plug hole. 40/50 Vent plug Fill plug Lubricant tube nozzle 38392 Vent plug Fill plug 39898...

  • Page 95: Submerged Outboard

    Approximation 700 mL 24 fl oz 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 96 MAINTENANCE 1. Immediately take it out of the water and wash it with fresh water to remove salt or dirt. 2. Remove the spark plugs and completely drain the water from the engine by pulling the rewind starter several times. 3.

  • Page 97: Storage Preparation

    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).

  • Page 98: Protecting Internal Engine Components

    With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel line. When engine begins to stall, quickly spray Quicksilver or Mercury Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel. •...
  • Page 99 STORAGE • Check the electrolyte level, and measure the voltage and specific gravity of the battery. Specific Gravity at 20 °C Terminal Voltage (V) Charge Condition 1.120 10.5 Fully discharged 1.160 11.1 1/4 charged 1.210 11.7 1/2 charged 1.250 12.0 3/4 charged 1.280 13.2...

  • Page 100: Starter Motor Will Not Crank The Engine (Electric Start Models)

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • Remote control models ‑ Blown 20 amp fuse in the starting circuit. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 101: Performance Loss

    TROUBLESHOOTING • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. • Excessive water in bilge. •...

  • Page 102: Mercury Marine Validated Engine Mounting Hardware

    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.
  • Page 103 INSTALLATION WARNING Avoid serious injury or death resulting from a loss of boat control. Loose engine fasteners could cause the transom bracket to fail, resulting in a loss of the driver's ability to control the boat. Always ensure that the engine fasteners are tightened to the specified torque.
  • Page 104 INSTALLATION • The installation must not create interference issues, as would an accessory mounting plate resting in the radius of the transom clamp bracket. Refer to Figure 1. 54624 Figure 1 Minimum clearance 3.175 mm (0.125 in.) Edge of accessory bracket Transom clamp bracket wall Radius Engine supplied mounting fasteners...
  • Page 105 INSTALLATION UNACCEPTABLE ACCESSORY MOUNTING IMPORTANT: Do not use the fasteners that secure the engine to the boat (either the transom or the jack plate) for any purpose other than securing the engine to the boat. 1. Do not mount an accessory to the transom clamp bracket in an unsupported condition.

  • Page 106: Boat Horsepower Capacity

    INSTALLATION 3. Do not install wedges or plates between the transom clamp brackets and the transom (or jack plate). Refer to Figure 4. Figure 4 Boat transom or jack plate Transom clamp bracket Wedge/plate 54058 Boat Horsepower Capacity WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death.
  • Page 107 INSTALLATION Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description 826711‑17 Nylon insert locknut ½‑20 28421 Flat washer 1.50 in. diameter 54012 Flat washer 0.875 in. diameter Available Outboard Mounting Bolts Part Number Description 67755005 ½‑20 x 2.50 in. long (1.25 in. thread) 67755006 ½‑20 x 3.50 in.
  • Page 108 INSTALLATION 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 a transom reinforcement plate.
  • Page 109 Failure to maintain clearance may damage the transom bracket and cause the transom bracket to fail. Adjustments to the position of the Mercury Marine transom drilling fixture may be required to ensure proper clearance of the transom bracket relief radius area.
  • Page 110 INSTALLATION NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts. 40952 0.500 in. diameter outboard mounting bolt (4) 0.875 in. flat washer (4) Nylon insert locknut (4) 1.500 in. flat washer (4) Marine sealer –...

  • Page 111: Installing Outboard

    INSTALLATION A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Installing Outboard We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance.
  • Page 112 INSTALLATION INSTALLATION 1. Single engine installation: Position the outboard motor at the center of the transom. Mount it using a cushioning pad or plate. Outboard on the centerline of the transom 38301 2. Twin engine installation: Position the outboard engines 470–660 mm (18.5–26.0 in.) apart, measured from the centerline of each engine, and equal distance (a) from the center of the transom.
  • Page 113 INSTALLATION 3. Transom height: Clearance between the anti‑ventilation plate of the motor and the bottom of the boat must be 10–30 mm (0.4–1.2 in.). If the height difference exceeds 30 mm (1.2 in.), engine power performance is likely to be reduced as a result of increased water resistance to the gearcase assembly.
  • Page 114 INSTALLATION TRANSOM BRACKET DIMENSIONAL DRAWING Manual tilting model: MH, EH, EHO, EO 234(9.21) 117(4.61) 117(4.61) 39(1.54) 64(2.52) 25(0.98) 89(3.5) 25(0.98) 204(8.03) 102(4.02) 102(4.02) 222(8.74) 248(9.76) 38305 Washer (smaller diameter) Bolt (M12 x 105 mm) Top of transom Washer (larger diameter)
  • Page 115 INSTALLATION Power trim and tilt model: EHPTO, EPTO 327(12.87) 163.5(6.44) 163.5(6.44) (6.81) 51(2) 69(2.72) 18(0.7) 18(0.7) 87(3.43) 18(0.7) 105(4.13) 316(12.44) 158(6.22) 158(6.22) (1.18) 251(9.87) 125.5 125.5 254(10) (4.24) (4.24) 310(12.2) (0.51) 38306 Washer (smaller diameter) Bolt (M12 x 105 mm) Top of transom Washer (larger diameter) NOTE: We recommend the bolt head of the upper bolts face inward while the...

  • Page 116: Installing The Remote Control Box

    INSTALLATION Installing the Remote Control Box 1. Position the remote control box in a place that will not interfere with the handling of the controls, levers, and switches. Confirm that there are no obstacles in the passage of the remote control cables. 41202 2.

  • Page 117: Connecting The Remote Control Cable To The Engine

    INSTALLATION Connecting the Remote Control Cable to the Engine 1. Detach the top cowl by rotating the cowl latch. 38308 2. Detach the bracket and set cable harness B and remote control cables. Having secured the remote control cables to the bracket, attach them to the bottom cowl.
  • Page 118 INSTALLATION 3. Detach the throttle and shift cable joints by removing the cotter pins. Throttle cable joint Cotter pin Washer Shift cable joint Washer Cotter pin 38310 4. Thread at least 15 mm (0.59 in.) of the remote control cables through the terminal eyes.
  • Page 119 INSTALLATION • Double‑check that the remote control cables, the throttle cable, and the shift cable have been connected correctly. Move the remote control lever Forward (F) until the first engaging point (approximately 32°). The cable which is moved first when the lever is turned, is a shift cable.

  • Page 120: Connecting Electrical Harnesses

    INSTALLATION 7. Adjust the cable joint until the hole meets with the throttle arm pin. After adjustment, lock a cable joint with a nut and secure with a cotter pin. Cotter pin Cable joint Throttle cable 38314 Connecting Electrical Harnesses 1.
  • Page 121 INSTALLATION INSTALLING THE METERS 1. Install the meters securely in the dashboard where they can be easily read and are not exposed to water splashes. The recommended dashboard thickness is 2–11 mm (0.08–0.4 in.). For dashboards thicker than 11 mm (0.4 in.), the fitting plate should be cut accordingly. Be sure to tighten the nuts on the bracket evenly.
  • Page 122 INSTALLATION 4. Cut holes with 85 mm (3.346 in.) diameter for the tachometer and 52.5 mm (2.067 in.) for the trim gauge. Tachometer Trim gauge 5. Connection of leads: • Tachometer: EO, EPTO • Trim gauge: EPTO • Trim sender: EPTO...
  • Page 123 INSTALLATION Meter wiring diagram 38319 Meter lamp switch (optional) Trim gauge Tachometer Analog gauge harness Key switch harness Trim sender NOTE: The parts of * mark is to be wired when a meter lamp switch (optional) is connected.

  • Page 124: Wire Color Code Abbreviations

    INSTALLATION Wire Color Code Abbreviations Wire Color Abbreviations Black Blue Brown Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark Attaching the Steering Link Rod WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod.

  • Page 125: Battery Installation

    INSTALLATION NOTE: Apply grease in the required places (refer to the illustration below). Apply grease inside the tilt tube. Grease (apply grease inside the tilt tube) Apply grease on tip of steering cable Seal ring Grease Lock nut Washer Collar Bolt Steering link rod Cotter pin...

  • Page 126: Propeller Selection

    INSTALLATION • Battery must be fully charged before running the motor. Red cable Black cable 37712 IMPORTANT: Please follow the instructions below: • Hydrogen gas is generated when charging a battery. Keep the battery in a well‑ventilated area during charging. Remove the battery from the boat; this will protect your hull and interior from damage.
  • Page 127 INSTALLATION Check full‑throttle RPM, using an accurate tachometer, with the engine trimmed out to a balanced‑steering condition (steering effort equal in both directions) without causing the propeller to break loose.

  • Page 128: Associated Parts

    ASSOCIATED PARTS Associated Parts We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. Name Quantity Dimensions Tool bag Pliers Socket wrench 10 x 13 mm Socket wrench 21 mm Service Socket wrench tools handle Screwdriver (phillips and flat...
  • Page 129 ASSOCIATED PARTS 5000–5700 RPM 5150–5850 RPM Lower numbers indicates heavier load and higher numbers indicates lighter load Mark XL transom C 12.5 SL transom XL transom C 13.5 SL transom C 14.5 C 16 NOTE: * Shows propeller with four blades. Mark L transom 16.5...

  • Page 130: Optional Accessories

    ACCESSORIES Optional Accessories 38397...
  • Page 131 ACCESSORIES Tie bar kit B (for twin ‑ engine operation) Twin ‑ control kit (for twin ‑ engine operation) Propeller Grease Gear oil (500 ml) Touch‑up spray...
  • Page 132 ACCESSORIES 38396 Speedometer (50 mph) Speedometer (75 mph) Water pressure gauge Water temperature gauge...
  • Page 133 ACCESSORIES Voltmeter Hour meter (engine operation hour counter) Fuel gauge Tachometer Flushing attachment Drive cleaner...

  • Page 134: 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 135 OWNER SERVICE ASSISTANCE 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 136: 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: Mercury Marine Telephone Mail Mercury Marine (920) 929‑5110 (920) 929‑4894...
  • Page 137 OWNER SERVICE ASSISTANCE Mercury Marine Submit the following Attn: Publications Department order form with payment 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...

  • Page 138: 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...

This manual is also suitable for:

50 twostroke

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