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Mercury Manuals
Outboard Motor
40 FourStroke
Service manual
Mercury 40 FourStroke Service Manual
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Also See for 40 FourStroke
:
Service manual
(599 pages)
,
Maintenance and installation manual
(120 pages)
,
Manual
(106 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Important Information 1
Cleanliness and Care of Outboard Motor
Table of Contents
Special Tools
Mercury/Quicksilver Lubricants and Sealants 1B-2
Inspection and Maintenance Schedule
Before each Use
After each Use
Every 300 Hours of Use or Three Years
Before Periods of Storage
Flushing the Cooling System
Steering Link Rod Fasteners
Corrosion Control Anode
Spark Plug Inspection and Replacement
Battery Inspection
Fuse Replacement - Electric Start Models
Timing Belt Inspection
Lubrication Points
Checking Power Trim Fluid
Fuel System
Fuel Filter
Fuel Line Inspection
Changing Engine Oil
Oil Changing Procedure
Changing Oil Filter
Checking and Adding Engine Oil
Changing Gear Case Lubricant
3-1/4 In. (83Mm) Diameter Gear Case
4-1/4 In. (108Mm) Diameter Gear Case
Storage Preparation
Fuel System
Protecting External Outboard Components
Protecting Internal Engine Components
Gear Case
Positioning Outboard for Storage
Battery Storage
Important Information 1
Conditions Affecting Performance
Weather
Boat
Engine
Serial Number Location
Following Complete Submersion
Submerged While Running
Salt Water Submersion
Fresh Water Submersion
Model 30/40 (4-Stroke) Powerhead Views Front View
Starboard View
Port View
Top View
Aft View
Propeller Selection
Propeller Removal/Installation
3-1/4 In. (83Mm) Diameter Gear Case
4-1/4 In. (108Mm) Diameter Gear Case
Power Trim System
General Information
Power Trim Operation
Trim "In" Angle Adjustment
Trim Tab Adjustment
Compression Check
Cylinder Leakage Testing
Analysis
Water Pressure Measurement
Painting Procedures
Cleaning & Painting Aluminum Propellers & Gear Housings
Decal Removal/Application
Removal
Instructions for "Wet" Application
Important Information 1
Installation Specifications
Selecting Accessories for the Outboard
Start in Gear Protection
Lifting Outboard
Steering Cable
Steering Cable Seal
Steering Link Rod
Installing Outboard Thumb Screw Models
Wiring Harness
Battery Cable Connections
Shift and Throttle Cable Installation
Throttle Cable Installation
Trim Tab Adjustment
Trim-In Stop Adjustment Power Trim Models 1D-13
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
Electrical 2
Specifications
Special Tools
Flywheel
Electrical Components
Ignition Component Description
Electronic Control Module (ECM)
Crank Position Sensor
Stator Assembly
Flywheel Assembly
Ignition Coils
Ignition Description
Ignition Test Procedures
Direct Voltage Adapter (DVA)
Ignition Troubleshooting
Ignition Diagnostic Procedures
Recommended Test
Troubleshooting with the Digital Diagnostical Terminal
Using the Digital Diagnostical Terminal (DDT)
Component Resistance Tests
Spark Plug Cap Removal
Spark Plug Cap Resistor Test-P/N VDFP 2A-20
Spark Plug Cap Resistor Test P/N VDO5FP
Engine Coolant Temperature (ECT) Sensor
Flywheel Removal/Installation
Removal
Installation
Stator Removal/Installation
Timing Belt
Removal
Installation
ECM Removal/Installation
Ignition Coil Removal/Installation
Voltage Regulator Removal/Installation
Engine Coolant Temperature (ECT) Sensor Removal/Installation
Recommended Battery
Operating Engine Without Battery
Battery Charging System
Stator Ohms Test
Starting System Components
Troubleshooting the Starting Circuit
Brush Replacement
Electrical 2
30/40 Elpt
30/40 Ehpt
30/40 Mh
Commander 2000 Remote Control (Electric Start)
Commander 3000 Panel Mount Control
Instrument/Lanyard Stop Switch Wiring Diagram
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
Commander 2000 Key Switch Test
Instrument Wiring Connections
Without Light Switch
With Light Switch
Oil Pressure Wiring Diagram
QSI Gauge Wiring Diagrams
Tachometer Wiring Diagram
Water Temperature Gauge
Engine Synchronizer Wiring Diagram
Remote Wiring Harness Connection to Engine
Electric Start Remote Control Model
Remote Key
Power Trim Switch Wiring Diagram
Carburetor Adjustments
Idle Speed
Carburetor Removal
Carburetor Disassembly
Carburetor Reassembly
Carburetor Installation
Fuel System
Exhaust Emissions Standards
What Are Emissions
Hydrocarbons
Carbon Monoxide - CO
Oxides of Nitrogen - Nox
Controlling Emissions
Stoichiometric (14.7:1) Air/Fuel Ratio
Emissions Reductions
8 1/3% # Per Year over 9 Model Years
Outboard Hydrocarbon
Stratified Vs Homogenized Charge
Homogenized Charge
Stratified Charge
Emissions Information
Manufacturer's Responsibility
Dealer Responsibility
Owner Responsibility
EPA Emission Regulations
Decal Location for 1999 Models
Emission Control Information
Decal Location for 2000 and Newer Models
Service Replacement Certification Label
Powerhead
Specifications
Special Tools
Cylinder Head
Camshaft/Oil Pump
Intake/Exhaust Valves
Torque Sequence
Valve Cover
Removal
Installation
Valve Clearance Adjustment
Checking Valve Clearance
Adjusting Valves
Timing Belt
Removal
Installation
Cylinder Head Removal
Cylinder Head Disassembly
Rocker Arm Assembly Removal
Oil Pump Removal
Camshaft Removal
Valve Removal
Rocker Shaft and Rocker Arm
Cleaning/Inspection/Repair
Camshaft
Cylinder Head
Valve Guide Inspection
Valve Guide Replacement
Valves
Valve Springs
Valve Seat Reconditioning
Valve Refacing Steps
Cylinder Head Reassembly
Valve Installation
Camshaft Oil Seal Installation
Camshaft Installation
Oil Pump Installation
Rocker Arm Shaft Assembly
Rocker Arm Shaft Installation
Cylinder Head Gasket
Cylinder Head Installation
Powerhead
Specifications
Special Tools
Crankshaft
Cylinder Block and Crankcase
Torque Sequence
Powerhead Removal
Removing Powerhead Components
Cylinder Block Disassembly
Crankcase and Crankshaft Removal
Inspection
Cylinder Bore
Piston
Piston Pin
Piston Rings
Crankshaft
Checking Main Bearing Clearance
Checking Connecting Rod Bearing Clearance
Thermostat
Oil Pressure Switch
Cylinder Block Reassembly
Selecting New Main Bearings
Main Bearing Installation
Installing Connecting Rod Bearings
Connecting Rod Installation
Piston Ring Installation
Piston Installation
Crankshaft Installation
Crankcase Cover Installation
Thermostat and Exhaust Cover Installation
Drive Gear Installation
Installing Powerhead Components
Powerhead Installation
Tiller Handle Models
Transom Bracket
Swivel Bracket
Steering Arm
MID-Section
Special Tools
Power Trim
Adjustments
Trimming Characteristics
Trailering Outboard
Tilting Outboard up and down Manually
Theory of Operation
Power Trim Flow Diagrams
Trim up Circuit
Tilt Circuit
Maximum Tilt
Down Circuit
Shock Function
Shock Function Return
Manual Release
Troubleshooting
Preliminary Checks
Hydraulic System Troubleshooting Flow Chart
Troubleshooting the Power Trim Electrical System
Power Trim System Removal
Power Trim Disassembly
Trim Motor Removal
Pump and Components Removal
Manifold Removal
Shock Rod Removal
Shock Rod Disassembly
Memory Piston Removal
Cleaning/Inspection/Repair
Trim Motor Electrical Tests
Reassembly
O-Ring and Seal Placement
O-Ring Sizes
Power Trim Reassembly
Shock Rod Reassembly
Shock Rod Installation
Trim Limit Assembly Installation
Manual Release Valve Installation
Manifold Installation
Oil Pump Installation
Reservoir/Motor Installation
Bleeding Power Trim Unit
Installation of Power Trim System
MID-Section
Manual Tilt Components
Manual Trim Flow Diagrams
Up Circuit
Down Circuit
Slow Tilt down under High Thrust
Under Water Strike (Valves Open)
Shock Function (Valve Closed)
Shock Function Return
Hydraulic System Troubleshooting
Manual Tilt System Removal
Manual Tilt System Disassembly
Accumulator Removal
Shock Rod Removal
Shock Rod Disassembly
Valve Block Removal
Memory Piston Removal
Valve Block Disassembly
Reassembly - O-Ring and Seal Placement
Actual O-Ring Sizes
Manual Tilt System Reassembly
Valve Block Installation
Shock Rod Reassembly
Shock Rod Installation and Fluid Filling Procedure Option One
Fluid Filling Procedure Option Two
O-Ring Description and Sizes
Manual Tilt System Installation
Manual Release Valve Adjustment
Upper Drive Shaft Bearing
Oil Sleeve
Lower Drive Shaft Bearing Race
Forward Gear Bearing Race
Bearing Carrier Reassembly
Forward Gear Reassembly
Propeller Shaft Reassembly
Drive Shaft Wear Sleeve Installation
Oil Sleeve Installation
Tiller Handle
Tiller Handle Assembly Removal
Tiller Handle Disassembly
Cleaning/Inspection/Repair
Tiller Handle Reassembly
Tiller Handle Installation
Manual Starter
Interlock Cable Adjustment
Manual Starter Removal
Manual Starter Disassembly
Cleaning and Inspection
Rewind Starter Reassembly
Adjusting Rewind Spring Tension
Manual Starter Installation
30/40 (4-Stroke) Tiller Handle Electric
Wiring Diagram
30/40 (4-Stroke) Tiller Handle Manual
Wiring Diagram
30/40 (4-Stroke) Remote Control Electric
Wiring Diagram
30/40 (4 Stroke) Oil Flow Diagram
30/40 (4 Stroke) Water Flow Diagram
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See also:
Service Manual
,
Operation & Maintenance Manual
30/40
FourStroke
Starting Model Year 1999
Starting Serial Number 0G760300
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
Advertisement
Chapters
Important Information 1
20
Important Information 1
38
Important Information 1
61
Electrical 2
76
Electrical 2
143
Fuel System
208
Powerhead
218
Powerhead
262
MID-Section
322
MID-Section
374
Table of Contents
Troubleshooting
Ignition Troubleshooting
88
Troubleshooting with the Digital Diagnostical Terminal
92
troubleshooting the starting circuit
119
Troubleshooting
343
Hydraulic System Troubleshooting Flow Chart
344
Troubleshooting the Power Trim Electrical System
348
Hydraulic System Troubleshooting
389
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30 fourstroke
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