Mercury 40 SeaPro Operation, Maintenance & Installation Manual
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Mercury 40 SeaPro Operation, Maintenance & 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: Table Of Contents

    Exhaust Emissions................... 10 Selecting Accessories for Your Outboard............12 Safe Boating Suggestions................12 Recording Serial Number................. 14 40 Sea Pro/Marathon Specifications..............14 40 SeaPro/Marathon Component Identification..........15 Transporting Trailering Boat/Outboard ................. 17 Transporting Portable Fuel Tanks..............17 Fuel and Oil Fuel Requirements...................
  • Page 8 Features and Controls Remote Control Features................. 23 Warning System ‑ Electric Start Models............24 Warning Horn System ‑ Manual Start Models..........25 Engine Over‑Speed Limiter................26 Manual Tilt System................... 27 Power Trim and Tilt (if equipped)..............34 Throttle Grip Friction Adjustment ‑ Tiller Handle Models........37 Steering Friction Adjustment ................
  • Page 9 Maintenance Cleaning Care Recommendations..............54 EPA Emissions....................56 Inspection and Maintenance Schedule ............56 Flushing the Cooling System................58 Top Cowl Removal and Installation..............59 Battery Inspection .................... 60 Fuel System...................... 60 Exterior Care..................... 63 Steering Link Rod Fasteners................64 Fuse Replacement ‑...
  • Page 10 Owner Service Assistance Service Assistance................... 90 Ordering Literature.................... 92 Maintenance Log Maintenance Log....................94 viii...

  • Page 11: 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 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 Remote Steering Notice WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.
  • Page 14 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 15 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 16: 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 17 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 18: 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 19: 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 20: 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 21 GENERAL INFORMATION WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide. Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway. STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmful carbon monoxide.

  • Page 22: 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 23 GENERAL INFORMATION Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). If in doubt, contact your dealer or the boat's manufacturer. Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs are properly made.

  • Page 24: 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. XXXXXXXXX XXXXXXXX XXXX 63746 Model year Serial number Certified Europe Insignia (as applicable) 40 Sea Pro/Marathon Specifications Models Horsepower Kilowatts...

  • Page 25: 40 Seapro/Marathon Component Identification

    GENERAL INFORMATION 40 SeaPro/Marathon Component Identification 3920 Trim tab Anti‑ventilation plate Driveshaft housing Bottom cowl Water pump indicator hole Top cowl Shift handle Throttle friction adjustment Tilt support pin Shallow water drive/trailering lever ‑ manual tilt system Transom bracket Primary cooling water intake...
  • Page 26 GENERAL INFORMATION Steering friction adjustment Tilt pin Stop switch...

  • Page 27: 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 28 TRANSPORTING AUTO-VENTING TYPE FUEL TANK 1. Disconnect the remote fuel line from tank. This will close 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 fuel or vapor to escape.

  • Page 29: Fuel And Oil

    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 30: 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 31: Mixing Fuel And Oil

    FUEL AND OIL MODELS WITHOUT OIL INJECTION Use a 25:1 (4%) gasoline/oil mixture in the first tank of fuel. After the break‑in fuel mixture is used up, use a 50:1 (2%) gasoline/oil mixture. Follow the table for mixing ratios. GASOLINE/OIL MIXING RATIO CHART Gas/Oil Ratio 3.8 liters (1 gal) gas 11.5 liters (3 gal) gas 23 liters (6 gal) gas 148 ml (5 fl oz) oil 473 ml (16 fl oz) oil...

  • Page 32: Filling Fuel Tank

    FUEL AND OIL Capacity Fluid Type Mercury or Quicksilver Premium TC‑W3 Oil tank 1.5 liters (50.5 fl oz) 2‑cycle oil Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks.

  • Page 33: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 26800 Control handle –...

  • Page 34: Warning System - Electric Start Models

    FEATURES AND CONTROLS Warning System ‑ Electric Start Models WARNING SYSTEM The outboard warning system incorporates a warning horn inside the boat. Remote control models will have the warning horn located inside the remote control or connected to the ignition key switch. Tiller handle models will have the warning horn located in the ignition key panel.

  • Page 35: Warning Horn System - Manual Start Models

    FEATURES AND CONTROLS If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine and check the cooling water intake holes for obstruction. If no obstruction is found, there may be a blockage in the cooling system or a water pump problem.

  • Page 36: Engine Over-Speed Limiter

    FEATURES AND CONTROLS ENGINE OVERHEAT If the engine overheats, the warning horn will sound and the warning system will automatically limit the engine speed to 2500 RPM. Immediately reduce throttle speed to idle. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.

  • Page 37: Manual Tilt System

    FEATURES AND CONTROLS Manual Tilt System TILT LOCK LEVER The tilt lock lever is used to engage the reverse lock mechanism, and prevent the outboard from lifting out of the water when operating in reverse gear due to reverse propeller thrust. The tilt lock lever can be placed in two positions as follows.
  • Page 38 FEATURES AND CONTROLS 4. Push in the tilt support pin. Lower the outboard to rest on the tilt support pin. 27460 Release position Lock position Tilt support pin Lowering To Run Position 1. Raise outboard slightly and pull out the tilt support pin. Lower the outboard.
  • Page 39 FEATURES AND CONTROLS 3. Rotate knob to engage the shallow water drive bracket. 27469 Release position Lock position Knob Shallow water drive bracket 4. Take hold of the top cowl grip and raise outboard to enable the shallow water drive bracket to swing down. 5.
  • Page 40 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 27399 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 41 FEATURES AND CONTROLS This tilt system is designed to be adjusted when the outboard is idling in neutral or with the engine turned off. Before operating, the outboard must be locked in its tilt position by moving the tilt lock lever to the lock/run position. WARNING Operating the engine without engaging the tilt lock lever can cause serious injury or death.
  • Page 42 FEATURES AND CONTROLS Tilting Outboard To Full Up Position 1. Stop the engine. Move the tilt lock lever to the tilt position. Take hold of the top cowl grip and raise outboard to full tilt up position. Lock the outboard in place by moving the tilt lock lever to the lock/run position. 27385 2.
  • Page 43 FEATURES AND CONTROLS Operating Angle Adjustment The transom brackets have five holes for adjusting the operating angle (forward stop movement) of the outboard. Tilt stops are installed for adjustment in the first hole. Use tilt pin provided for adjustments in the remaining four holes. Remove tilt pin when using the tilt stops.

  • Page 44: Power Trim And Tilt (If Equipped)

    FEATURES AND CONTROLS • Lower the 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 hand rotation propeller).
  • Page 45 FEATURES AND CONTROLS POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out.
  • Page 46 FEATURES AND CONTROLS • Increase steering torque or pull to the left at a normal installation height (with the normal right‑hand rotation propeller). • In excess, can cause boat porpoising (bouncing) or propeller ventilation. • Cause engine overheating if any cooling water intake holes are above the waterline.

  • Page 47: Throttle Grip Friction Adjustment - Tiller Handle Models

    FEATURES AND CONTROLS AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system. Auxiliary tilt switch 27779 SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.

  • Page 48: Trim Tab Adjustment

    FEATURES AND CONTROLS Steering Friction Adjustment ‑ Adjust this lever to achieve the desired steering friction (drag) on the tiller handle. Move lever to the left to tighten friction or move to the right to loosen friction. Tighten friction Loosen friction 3073 REMOTE STEERING MODELS Steering Friction Adjustment ‑...
  • Page 49 FEATURES AND CONTROLS 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. MODELS WITHOUT POWER TRIM Operate your boat at normal cruising speed trimmed to desired position by installing the tilt pin in the desired tilt pin hole.

  • Page 50: Operation

    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 51: 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 52 OPERATION 1. Make sure the cooling water intake is submerged. 26837 2. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 3. Connect the fuel line to the outboard. 3074 4. Squeeze the fuel line primer bulb several times until it feels firm. 19779 5.
  • Page 53 OPERATION 6. Shift outboard to neutral (N) position. 26838 7. Models without power trim ‑ Position the tilt lock lever down to the lock position. 27547 WARNING Operating the engine without engaging the tilt lock lever can cause serious injury or death. The outboard can tilt upwards when decelerating or operating in reverse, causing loss of boat control.

  • Page 54: Starting The Engine - Tiller Handle Models And Manual Start Remote Control Models

    OPERATION 9. Turn ignition key to the START position and start the engine. If engine is cold, push in on key to choke engine. If engine fails to start in 10 seconds, wait 30 seconds and try again. If engine begins to stall, re‑prime (push key in) until engine is running.
  • Page 55 OPERATION 1. Make sure the cooling water intake is submerged. 26837 2. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 3. Connect the fuel line to the outboard. 3074 4. Squeeze the fuel line primer bulb several times until it feels firm. 19779 5.
  • Page 56 OPERATION 6. Shift outboard to neutral (N) position. 3107 26838 7. Position the tilt lock lever to the lock position. 27547 Reverse/tilt position Lock/run position 26802 8. Tiller handle models ‑ Move throttle grip to START position. 0%100 START START 3075...
  • Page 57 OPERATION 9. Remote control models ‑ Move on/off switch to the on position. 3026 NOTE: Manual starting models ‑ For initial start of a new engine or first start after a prolonged storage, primer lines may have air in them. In this case, push in the primer bulb several times until fluid can be felt and then the normal 4 to 6 rapid primes.

  • Page 58: Gear Shifting

    OPERATION WARNING Rapid acceleration can result in serious injury or death from being thrown within or out of the boat. Decrease engine speed before shifting into gear. 19804 12. Check for a steady stream of water flowing out of the water pump indicator hole.

  • Page 59: Stopping The Engine

    OPERATION • Always shift the outboard into gear with a quick motion. • After shifting the outboard into gear, advance the remote control handle or rotate the throttle grip (tiller handle) to increase the engine speed. Stopping the Engine 1. Remote control models ‑ Reduce the engine speed and shift the outboard to neutral position.
  • Page 60 OPERATION 1. Shift outboard to neutral (N) position. 3107 26838 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. 3097...
  • Page 61 OPERATION WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine. Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests. WARNING The exposed moving flywheel can cause serious injury.

  • Page 62: Emergency Starting - Manual Start Models

    OPERATION Emergency Starting ‑ Manual Start Models If the starter system fails, use the spare starter rope (provided) and follow procedure. 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.
  • Page 63 OPERATION 4. Remove rewind starter. 3085 WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine. Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests. WARNING The exposed moving flywheel can cause serious injury.

  • Page 64: 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 65 Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys.

  • Page 66: Epa Emissions

    MAINTENANCE Tube Ref Description Where Used Part No. External metal surfaces of the powerhead Corrosion Guard 92-802878 55 and powerhead components. EPA Emissions 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.
  • Page 67 MAINTENANCE • Inspect the fuel system for leaks • Inspect the engine tightness on the transom • Check the steering system for binding • Check the propeller for damage • Inspect the hydraulic steering fittings and hoses for leaks or signs of damage, if equipped •...

  • Page 68: Flushing The Cooling System

    Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. WARNING Rotating propellers can cause serious injury or death.

  • Page 69: Top Cowl Removal And Installation

    MAINTENANCE 4. Adjust 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 70: Battery Inspection

    MAINTENANCE 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. Turn off the engine before servicing the battery. 2. Ensure the battery is secure against movement. 3.
  • Page 71 MAINTENANCE 3. Pull out the filter element and wash it with cleaning solvent. 3933 Cover Filter element O‑ring Sight bowl 29055 Installation 1. Push 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.
  • Page 72 MAINTENANCE CARBURETOR ADJUSTMENTS Slow Speed Mixture Adjustment 1. Before starting engine, turn the slow speed mixture screw in until it is lightly seated then back it out 1‑1/4 turns. 3951 2. With boat tied securely to dock, start engine and allow it to warm up. 3.

  • Page 73: Exterior Care

    MAINTENANCE Engine Idle Speed Adjustment 1. With boat tied securely to dock, start engine and allow it to warm up. 2. Shift the outboard into forward gear while maintaining idle speed. 3108 0%100 START START 3075 3. Adjust the idle speed screw to obtain the recommended engine idle speed.

  • Page 74: Steering Link Rod Fasteners

    MAINTENANCE Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("a" ‑ Part Number 10‑856680) and self‑locking nylon insert locknuts ("b" & "e" ‑ Part Number 11‑826709113).

  • Page 75: Fuse Replacement - Electric Start Models

    MAINTENANCE Description lb‑in. lb‑ft Nylon insert locknut "e" Tighten until seats, then back off 1/4 turn Fuse Replacement ‑ Electric Start Models IMPORTANT: An ATC fuse has the fuse element enclosed or sealed inside the plastic housing. This type of fuse must be used for marine applications. Marine applications are exposed to environments that may have the potential to accumulate explosive vapors.

  • Page 76: Propeller Replacement

    MAINTENANCE The trim tab on the gearcase is a corrosion control anode. Models that have a longer transom bracket will have another anode installed on the bottom of the transom bracket assembly. 3088 Trim tab anode Transom bracket anode Propeller Replacement WARNING Rotating propellers can cause serious injury or death.
  • Page 77 MAINTENANCE 2. Remove the spark plug leads to prevent engine from starting. 26899 3. Straighten the bent tabs on the propeller nut retainer. 26900 4. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut. 26901 5.
  • Page 78 MAINTENANCE 6. Coat the propeller shaft with Quicksilver or Mercury Extreme Grease or 2‑4‑C with PTFE. 26902 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 79: Spark Plug Inspection And Replacement

    MAINTENANCE 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.

  • Page 80: Lubrication Points

    MAINTENANCE Description lb‑in. lb‑ft Spark plug – Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Extreme Grease or 2‑4‑C with PTFE. Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 •...
  • Page 81 MAINTENANCE • Co‑Pilot Shaft (Tiller Handle Models) ‑ Lubricate through fitting. Move the steering friction lever back and forth while lubricating. Tilt Tube Co‑pilot shaft 3089 • Lubricate threads of transom clamp screws (if equipped). 27661 • Shift Handle (Tiller Handle Models) ‑ Lubricate through fittings. 3091 •...

  • Page 82: Checking Power Trim Fluid

    MAINTENANCE WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. Fitting Steering cable end 3092 3. Lubricate the following with lightweight oil. •...

  • Page 83: Gearcase Lubrication

    MAINTENANCE 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.

  • Page 84: Submerged Outboard

    MAINTENANCE GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. 2. Remove vent plug. 26975 Vent hole Vent plug Fill/drain plug 3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.

  • Page 85: Storage

    STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer). NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.

  • Page 86: Protecting Internal Engine Components

    STORAGE • 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. Corrosion Guard External metal surfaces...

  • Page 87: Troubleshooting

    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 88: 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 89: Installation

    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 90 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 91 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 92 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 93 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 94 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 95 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 96 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 97 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 98 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 WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death.

  • Page 99: Propeller Selection

    INSTALLATION MODELS WITH TRANSOM BRACKET CLAMP SCREWS The outboard must be secured to the transom with the clamp screws and the two mounting bolts, washers and locknuts provided with the engine. Transom bracket clamp screws Mounting bolts, washers and locknuts 61365 Propeller Selection For best all around performance from your outboard/boat combination, select a...
  • Page 100 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 101 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 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 Marine power package, contact your nearest Mercury Marine dealer or contact: Mercury Marine Telephone Mail Mercury Marine (920) 929‑5110 (920) 929‑4894...
  • Page 103 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 104 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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