Mercury 40 Jet Manual
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Mercury 40 Jet Manual

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See also: Operation, Maintenance and Installation Manual , User Manual
Welcome Aboard!
Proper care and maintenance is an important part in keeping
your Mercury Product operating at peak efficiency for
maximum performance and economy. The enclosed Owner's
Registration Card is your key to trouble‑free family fun. Refer
to your Operation and Maintenance Manual for full details
of your warranty coverage.
Details
of
your
www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose?
Please check on www.marinepower.com. If necessary,
please contact your local dealer.
Declaration of Conformity
Manufacturer:
Authorized Representative:
Recreational Craft Directive:
Applicable Requirement
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engines starting (A.5.1.4)
General steering system (A.5.4.1)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Module used for exhaust emission assessment: Module H;
Certification No. RCD‑H‑2
Module used for noise emission assessment: Module H;
Certification No. RCD‑H‑2
nearest
dealer
Mercury Marine
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54935-1939 USA,
Marine Power Europe, Inc.
Parc Industriel de Petit-Rechain
B-2800 Verviers - Belgium,
2003/44/EC amending 94/25/EC
i
can
be
found
Standards Applied
EN ISO 10240:2004
EN ISO 8665:1995
EN ISO 11547:1995
ABYC P‑17; EN ISO
10592:1995
EN ISO 8178‑1:1996
EN ISO 8665:1995
EN ISO 14509:2000
on

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  • Page 1 Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble‑free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.
  • Page 2 Name of Notified Body for exhaust emission assessment and noise emission assessment: Det Norske Veritas AS Veritasveien 1 1322 Hovik Norway Notified Body Number: 0575 Brands: Combustion cycle: 4 Engine type: Fuel type: Mercury, Outboard Gasoline stroke Mariner Module H Starting Engine Manufacturer Noise and Horsepower...
  • Page 3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe. Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA on May 1, 2006 European Regulations Contact: Regulations and Product Safety Department, Mercury Marine,...

  • Page 5: Table Of Contents

    Wave and Wake Jumping............25 Safety Instructions for Hand‑Tilled Outboards......26 Exhaust Emissions..............27 Selecting Accessories for Your Outboard........28 Safe Boating Suggestions............29 Recording Serial Number............31 40 Jet 4‑Stroke Specifications...........31 Component Identification............32 TRANSPORTING Trailering Boat/Outboard............33 Transporting Portable Fuel Tanks..........33...
  • Page 6 TABLE OF CONTENTS FUEL & OIL Fuel Recommendations.............35 Filling Fuel Tank................37 Engine Oil Recommendations...........37 Checking and Adding Engine Oil..........38 FEATURES & CONTROLS Remote Control Features............40 Warning System................41 Power Trim and Tilt..............43 Throttle Grip Friction Adjustment ‑ Tiller Handle Models...47 Steering Friction Adjustment............47 Replaceable Jet Drive Shear Key..........48 OPERATION Pre‑Starting Check List..............49...
  • Page 7 TABLE OF CONTENTS MAINTENANCE Outboard Care................65 EPA Emissions................65 Inspection and Maintenance Schedule........66 Flushing the Cooling System.............68 Top Cowl Removal and Installation...........69 Exterior Care................70 Battery Inspection ..............70 Fuel System................71 Steering Link Rod Fasteners.............72 Corrosion Control Anode............74 Spark Plug Inspection and Replacement........74 Steering Pull Adjustment............76 Worn/Dull Impeller..............76 Impeller Clearance Adjustment..........
  • Page 8 OWNER SERVICE ASSISTANCE Local Repair Service..............92 Service Away from Home............92 Parts and Accessories Inquiries..........92 Service Assistance..............92 Mercury Marine Service Offices..........93 OUTBOARD INSTALLATION Installation Information............... 95 Determining the Mounting Height of the Outboard ....96 Checking Boat Transom Construction........99 Fastening the Outboard............100 Steering Cable ‑...

  • Page 9: Warranty Information

    Warranty Registration United States and Canada 1. You may change your 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...

  • Page 10: Warranty Registration Outside The United States And Canada

    2. To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, E‑mail, or mail.

  • Page 11: Fourstroke Outboard Limited Warranty United States, Canada, Europe And Confederation Of Independent States

    Independent States Outside the United States, Canada, Europe and Confederation of Independent States ‑ check with local distributor. WHAT IS COVERED: Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below.
  • Page 12 WARRANTY 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 pre–delivery inspection process is completed and documented.
  • Page 13 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.

  • Page 14: Fourstroke Outboard Limited Warranty (Middle-East, And Africa)

    No individual or entity, including Mercury Marine authorized dealers, has been given authority by 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.
  • Page 15 WARRANTY 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 pre–delivery inspection process is completed and documented.
  • Page 16 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.

  • Page 17: Year Limited Warranty Against Corrosion

    No individual or entity, including Mercury Marine authorized dealers, has been given authority by 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.
  • Page 18 WARRANTY 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 pre‑delivery inspection process is completed and documented.
  • Page 19 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.
  • Page 20 Mercury Precision Parts or Quicksilver MerCathode system and/ or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti‑fouling paints is also not covered by this limited warranty.

  • Page 21: Warranty Coverage And Exclusions

    WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited...
  • Page 22 8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. Oils, lubricants or fluids changed as a matter of normal...
  • Page 23 WARRANTY INFORMATION 16. Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us. Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product.

  • Page 24: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard. Be sure at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.

  • Page 25: Boat Horsepower Capacity

    GENERAL INFORMATION DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

  • Page 26: 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 27: 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. 26779 Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts.

  • Page 28: 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 29 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 30: Stopping The Boat In An Emergency

    GENERAL INFORMATION Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations: • Occupants could be thrown forward due to unexpected loss of forward motion ‑ a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller.

  • Page 31: 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 when boating in an area where there might be people in the water.

  • Page 32: 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 33: 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 re‑enters the water.

  • Page 34: Safety Instructions For Hand-Tilled Outboards

    GENERAL INFORMATION There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward.

  • Page 35: Exhaust Emissions

    GENERAL INFORMATION Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines. This includes the outboards, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories.

  • Page 36: Selecting Accessories For Your Outboard

    The misuse of approved accessories or the use of non‑approved accessories can damage the product. 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...

  • Page 37: Safe Boating Suggestions

    GENERAL INFORMATION Safe Boating Suggestions In order to safely enjoy the waterways, the operator should be familiar with local and other governmental boating regulations and restrictions, and consider the following suggestions. Use flotation devices. Have an approved personal flotation device of suitable size for each person aboard (it is the law) and have it readily accessible.
  • Page 38 GENERAL INFORMATION Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operators view when operating the boat above idle speed.

  • Page 39: Recording Serial Number

    OTXXXXXX XXXX 24125 Serial number Year manufactured Model designation Certified Europe Insignia (as applicable) 40 Jet 4‑Stroke Specifications Models 40 Jet Horsepower Kilowatts 29.8 Full Throttle RPM Range 5000‑5500 RPM Number of Cylinders...

  • Page 40: Component Identification

    GENERAL INFORMATION Models 40 Jet Recommended Oil Refer to Fuel & Oil Engine Oil Capacity 3.0 Liter (3 Quarts) Battery Rating Operation Above 0 °C 465 Marine Cranking Amps (MCA) or 350 Cold (32 °F) Cranking AMPS (CCA) Operation Below 0 °C 1000 Marine Cranking Amps (MCA) or 750 Cold (32 °F)

  • Page 41: Transporting

    TRANSPORTING Trailering Boat/Outboard The boat should be trailered with the outboard tilted down in a vertical operating position. IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering. The outboard tilt support lever is not intended to support the outboard for trailering.
  • Page 42 TRANSPORTING 2. Install tether cap over the fuel line connector stem. This will protect the connector stem from being accidently pushed‑in, thus, allowing fuel or vapor to escape. 26794 Connector stem Tether cap...

  • Page 43: Fuel & 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 44 FUEL & OIL The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 45: Filling Fuel Tank

    Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions. Engine Oil Recommendations We recommend the use of Mercury or Quicksilver NMMA FC‑W certified synthetic blend 25W‑40 4‑Stroke Outboard Oil for general, all‑temperature use. If SAE 10W‑30 oil is preferred, use Mercury or Quicksilver NMMA FC‑W certified 10W‑30 4‑Stroke Outboard...

  • Page 46: Checking And Adding Engine Oil

    FUEL & OIL IMPORTANT: The use of non detergent 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 47 FUEL & OIL 3. Pull the dipstick back out again and observe the oil level. If the oil level is low, remove the oil filler cap and fill to (but not over) the upper oil level with the recommended oil. IMPORTANT: Inspect oil for signs of contamination.

  • Page 48: Features & Controls

    FEATURES & 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 49: Warning System

    FEATURES & CONTROLS Warning System WARNING HORN SIGNALS 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 50 Moving the throttle lever back to the idle position will reset the system. 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 51: Power Trim And Tilt

    FEATURES & CONTROLS Power Trim and Tilt Your outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down.
  • Page 52 FEATURES & CONTROLS The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface. WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of...
  • Page 53 FEATURES & CONTROLS • Generally increase top speed • Increase clearance over submerged objects or a shallow bottom • 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 •...
  • Page 54 FEATURES & CONTROLS 1. Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. 26809 NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.

  • Page 55: Throttle Grip Friction Adjustment - Tiller Handle Models

    FEATURES & 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. 19807 Loosen friction Tighten friction...

  • Page 56: Replaceable Jet Drive Shear Key

    FEATURES & CONTROLS REMOTE STEERING MODELS WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control. When setting the friction adjustment, maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released.

  • Page 57: Operation

    OPERATION Pre‑Starting Check List • Operator knows safe navigation, boating, and operating procedures. • An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). • A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.

  • Page 58: Operating In Saltwater Or Polluted Water

    Wash down the outboard exterior and flush out the exhaust outlet of the jet drive with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. NOTE: Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.
  • Page 59 OPERATION The driveshaft driven impeller draws water up through the water intake and then redirects it at a high pressure through the water outlet nozzle to create forward thrust. To obtain reverse, the reverse gate moves over the outlet nozzle to direct the water in the opposite direction.

  • Page 60: Stopping The Boat In An Emergency

    OPERATION The jet drive is always drawing water into the housing when the engine is running. Do not operate the jet drive with the grate removed from the water intake. Keep hands, feet, hair, loose clothing, life jackets, etc., away from the water intake. Never insert an object into the water intake or water outlet nozzle when the engine is running.

  • Page 61: Mooring The Boat

    OPERATION WARNING A loss or reduction in water jet thrust will directly affect boat directional control, and may result in property damage, personal injury, or death. Boat directional control can also be substantially reduced or lost altogether by a sudden loss of power such as running out of gas, quickly backing off the throttle, turning off the ignition switch, activating the lanyard stop switch, or plugging the water intake to the jet pump.

  • Page 62: Clearing A Lodged Impeller

    OPERATION A large amount of debris being drawn into the water intake may result in a loss of power. Intake suction holding debris against the grate will result in restricted water flow. Shutting the engine off may allow the debris to fall off the intake grate allowing full power to be restored.

  • Page 63: Engine Break-In Procedure

    OPERATION 2. Ensure that the driveshaft bearing on the jet drive is lubricated. Refer to Maintenance - Lubrication Points. 28664 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 64 OPERATION 1. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 2. 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 65 OPERATION 5. Move the throttle‑only lever to the fully closed position or press the throttle‑only button. 26840 Fully closed position Maximum fast idle speed position 6. Starting a flooded engine ‑ Advance the throttle‑only lever or control handle to the maximum throttle‑only position and continue to crank the engine for starting.

  • Page 66: Starting The Engine - Tiller Handle Models

    OPERATION IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat.
  • Page 67 OPERATION 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. 27348 4. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑...

  • Page 68: Gear Shifting

    OPERATION 8. Turn the ignition key to the "START" position. If the engine fails to start in ten seconds, return the key to the "ON" position, wait 30 seconds and try again. 19804 WARNING Rapid acceleration can result in serious injury or death from being thrown within or out of the boat.
  • Page 69 OPERATION • Your outboard has three gear shift positions to provide operation: forward, neutral (out of gear), and reverse. 28523 • Remote control models ‑ When shifting, always stop at the neutral position and allow the engine speed to return to idle. 26779 •...

  • Page 70: Stopping The Engine

    OPERATION Stopping The Engine 1. Remote Control Models ‑ Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position. 26843 2. Tiller Handle Models ‑ Reduce engine speed and shift outboard to neutral position. Push in the engine stop button or turn ignition key to "OFF"...
  • Page 71 OPERATION 2. Shift outboard to neutral ("N") position. 28528 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. 3.
  • Page 72 OPERATION 5. Pull the starter rope to start the engine. 26848...

  • Page 73: Maintenance

    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. EPA Emissions EMISSION CERTIFICATION LABEL...

  • Page 74: Inspection And Maintenance Schedule

    MAINTENANCE OWNER RESPONSIBILITY The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.
  • Page 75 MAINTENANCE • Check the engine water separating fuel filter for contaminants. Clean or replace the filter. See Fuel System. • Check the corrosion control anode. Check more frequently when used in saltwater. See Corrosion Control Anode. • Drain and replace the gearcase lubricant. See Gearcase Lubrication.

  • Page 76: Flushing The Cooling System

    MAINTENANCE • Replace the accessory drive belt. See Accessory Drive Belt Inspection. BEFORE PERIODS OF STORAGE • Refer to Storage Preparation. 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.

  • Page 77: Top Cowl Removal And Installation

    MAINTENANCE 5. Stop the engine. Turn off the water and remove the hose. Reinstall the propeller. 28518 Top Cowl Removal and Installation REMOVAL 1. Pull out the rear lock lever and remove the top cowl. 28439 INSTALLATION 1. Lower the top cowl over the engine.

  • Page 78: Exterior Care

    MAINTENANCE 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. Gently pull up on the back of cowl to make sure it is securely fastened.

  • Page 79: Fuel System

    MAINTENANCE Fuel System WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.

  • Page 80: Steering Link Rod Fasteners

    MAINTENANCE 3. Inspect the filter element. If replacement is necessary, replace the filter assembly. 28414 Cover O‑ring seal Filter element Sight bowl INSTALLATION IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter. 1.
  • Page 81 MAINTENANCE 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.

  • Page 82: Corrosion Control Anode

    MAINTENANCE Corrosion Control Anode Your 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. Each anode requires periodic inspection, especially in salt water which will accelerate the erosion.
  • Page 83 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 84: Steering Pull Adjustment

    MAINTENANCE Steering Pull Adjustment The steering on some boats will have the tendency to pull towards starboard. This pulling condition can be corrected by using a pliers and bending the ends of the exhaust fins 1.5 mm (1/16 in.) toward the starboard side of the outboard.

  • Page 85: Impeller Clearance Adjustment

    MAINTENANCE Check the impeller blades occasionally for damage. Use a flat file to resharpen the leading edges. Sharpen to a 0.8 mm (1/32 in.) radius by removing material from bottom side only. 29079 Leading edge Top side lifting angle Impeller Clearance Adjustment The impeller should be adjusted so there is approximately 0.8 mm (0.03 in.) clearance between the impeller edge and liner.

  • Page 86: Fuse Replacement

    MAINTENANCE Check the impeller clearance by sliding a feeler gauge through the intake grate and measure the clearance between the impeller edge and liner. If adjustment is required, refer to Impeller Removal and Installation. Fuse Replacement IMPORTANT: Always carry spare 20 amp fuses. The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring.

  • Page 87: Timing Belt Inspection

    MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. 28900 Spare fuse slot Diagnostic circuit 4 pin connector ‑ 2 amp fuse SmartCraft data bus circuit ‑...

  • Page 88: Lubrication Points

    MAINTENANCE e. Signs of wear on edges or outer surfaces of belt. 26958 Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision 2‑4‑C with Teflon. Tube Ref No. Description Where Used Part No. 92-802859A 2-4-C with Teflon Driveshaft bearing IMPORTANT: It is important not to use a general all purpose grease for this bearing.
  • Page 89 Some discoloration of the grease is normal during the break‑in period on a new set of seals. 2. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with Teflon or Special Lubricant 101. Tube Ref No.
  • Page 90 MAINTENANCE • Swivel bracket ‑ Lubricate through fitting. 28466 Tilt support lever Swivel bracket • Tilt tube ‑ Lubricate through fitting. 28461 • Co‑pilot shaft (tiller handle models) ‑ Lubricate through fitting. Move the steering friction lever back and forth while lubricating.
  • Page 91 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. • Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube.

  • Page 92: Checking Power Trim Fluid

    2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
  • Page 93 MAINTENANCE 2. Turn the steering on the outboard so that the drain hole is facing downward. Remove drain plug and drain engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. 28633 Drain plug CHANGING OIL FILTER 1.

  • Page 94: Submerged Outboard

    MAINTENANCE 2. Idle the engine for five minutes and check for leaks. Stop the engine and check the oil level on the dipstick. Add oil if necessary. 28418 Oil fill cap Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 95: 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).

  • Page 96: Protecting External Outboard Components

    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 No. Description Where Used Part No.

  • Page 97: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) POSSIBLE CAUSES • Blown 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 98: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Guardian System activated. Refer to Features & Controls - Warning System. • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a.

  • Page 99: Battery Will Not Hold Charge

    TROUBLESHOOTING • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES • Battery connections are loose or corroded. • Low electrolyte level in battery. • Worn out or inefficient battery. • Excessive use of electrical accessories. •...

  • Page 100: Owner Service Assistance

    Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Parts and Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer.

  • Page 101: Mercury Marine Service Offices

    Model and serial number of your outboard • The name and address of your dealership • Nature of problem Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States Telephone (920) 929‑5040...
  • Page 102 OWNER SERVICE ASSISTANCE Japan Telephone 81‑053‑423‑2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81‑053‑423‑2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way 5467789 Singapore, 508762...

  • Page 103: Outboard Installation

    This prevents the engine from starting in gear. SELECTING ACCESSORIES FOR YOUR OUTBOARD Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers.

  • Page 104: Determining The Mounting Height Of The Outboard

    The misuse of approved accessories or the use of non‑approved accessories can damage the product. 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 105 OUTBOARD INSTALLATION • Installing the outboard too high on the transom will allow the water intake to suck in air and cause cavitation. (Cavitation will cause the engine to overspeed in spurts and reduce thrust.) This condition should be avoided by proper height setting.
  • Page 106 OUTBOARD INSTALLATION 3. Fasten the outboard to the transom at this height. Refer to Fastening the Outboard. 22403 BOATS WITH A FLAT BOTTOM HULL 1. Place (center) the outboard on the boat transom. Set the height of the outboard on the boat transom so that the front edge of the water intake housing is in line with the bottom of the boat as shown.

  • Page 107: Checking Boat Transom Construction

    OUTBOARD 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 108: Fastening The Outboard

    OUTBOARD INSTALLATION NOTE: The inside holes on the transom reinforcement plate are for the lower transom bolts and the outside holes are for the upper transom bolts. 20860 Large transom washer Transom reinforcement plate Description Part Number Large transom washer 67‑896392 Transom reinforcement plate 67‑896305...

  • Page 109: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION The outboard must be secured to the transom with the four 13 mm (1/2 in.) diameter mounting bolts and locknuts provided. Install two bolts through the upper set of mounting holes and two bolts through the lower set of mounting holes. 28481 1/2 in.

  • Page 110: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION 2. Insert the steering cable into the tilt tube. 28507 3. Tighten the nut to the specified torque. 29506 Description lb. in. lb. ft. 47.5 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 ("e"...
  • Page 111 OUTBOARD INSTALLATION 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.

  • Page 112: Steering Cable Seal

    OUTBOARD INSTALLATION Description lb. in. lb. ft. Nylon insert locknut "b" Tighten until it seats, then back off 1/4 Nylon insert locknut "e" turn Assemble steering link rod to steering cable with two flat washers and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn.

  • Page 113: Electrical Connections And Control Cable Installation

    OUTBOARD INSTALLATION FUEL HOSE CONNECTION 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. 28511 Hose clamp Remote fuel hose Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover.
  • Page 114 OUTBOARD INSTALLATION Route the remote wiring harness through the rubber grommet. Connect the 14 pin connector to the engine harness. Fasten the harness with the retainer. 28697 Remote wiring harness Retainer 14 pin connector THROTTLE CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control.
  • Page 115 OUTBOARD INSTALLATION 2. Center the roller with the alignment mark on the cam. Adjust the cable barrel so that it fits into the anchor pocket. 26838 3. Fit the throttle cable through the rubber grommet. 28701 Rubber grommet Throttle cable 4.
  • Page 116 OUTBOARD INSTALLATION 5. Adjust the cable barrel so the center of the roller is lined up with the alignment mark on the cam when the cable barrel is placed in the barrel receptacle. 28699 Cable barrel Roller Alignment mark Retainer 6.
  • Page 117 OUTBOARD INSTALLATION 8. Reinstall the access cover with two bolts. Tighten the bolts to the specified torque. 28702 Access cover Description lb. in. lb. ft. Access cover bolt SHIFT CABLE INSTALLATION WARNING If not properly installed, the reverse gate can interfere with water coming off the rudder, suddenly and unexpectedly slowing the boat.
  • Page 118 OUTBOARD INSTALLATION 4. Attach the shift cable adjustment barrel to the bracket with a bolt and locknut. Tighten the bolt until it seats against the adjustment barrel, then back‑off the bolt 1/4 turn. Hold the bolt from turning, and tighten the locknut on the bolt. The adjustment barrel must be free to pivot.

  • Page 119: Trim-In Stop Adjustment - Power Trim Models

    OUTBOARD INSTALLATION Trim‑In Stop Adjustment ‑ Power Trim Models If an adjustment is required to the trim‑in stop, reposition the tilt stop pins in the desired holes. Tighten the tilt stop pins to the specified torque. 28538 Tilt stop pins Description lb.
  • Page 120 OUTBOARD INSTALLATION Test run the boat. If cavitation occurs (air enters the pump), the first thing to try is lowering the outboard mounting height. If cavitation still exists after lowering the outboard, it may be helpful to seek advice from the boat manufacturer. Another option to further reduce cavitation is a rough water plate.

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