Mercury 40 4-Stroke Manual
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Mercury 40 4-Stroke Manual

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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 nearest dealer can be found on www.marinepower.com where country maps and
full contact information are displayed.
Is
your
engine
properly
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
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
Engine type: Outboard Fuel type: Gasoline Combustion cycle: 4 stroke
Manufacturer
Engine Family
Location
Verado 4
Belgium
Cylinder
registered
for
warranty
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
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
Horsepower
135,150
i
purpose?
Please
Brands: Mercury,
Mariner
Module H Noise
Starting Serial
and Exhaust
Number
Certificate
0P401000
RCD-H-2
check
on

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  • Page 1: Declaration Of Conformity

    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 CISPR 12; EN 55012:2002/A1:2005 Electrostatic discharge testing EN 61000-6-2; EN 61000-4-2; EN 61000-4-3 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...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Warranty Information Transfer Of Warranty..........................1 Warranty Registration United States And Canada................. 1 Warranty Registration Outside The United States And Canada............. 1 FourStroke Outboard Limited Warranty United States, Canada, Europe and Confederation of Independent States..........................2 FourStroke Outboard Limited Warranty (Middle‑East, and Africa)............3 3 Year Limited Warranty Against Corrosion...................
  • Page 4 TABLE OF CONTENTS FEATURES & CONTROLS Remote Control Features........................25 Warning System ‑ Manual Starting Models..................25 Warning System ‑ Electric Starting Models..................26 Power Trim and Tilt..........................28 Manual Tilt System ..........................30 Throttle Grip Friction Adjustment ‑ Tiller Handle Models..............33 Steering Friction Adjustment.........................
  • Page 5 Local Repair Service..........................67 Service Away From Home........................67 Parts And Accessories Inquiries......................67 Service Assistance..........................67 Mercury Marine Service Offices......................67 OUTBOARD INSTALLATION Installation Information.......................... 69 Fuel Hose Connection ‑ Remote Control Models................. 76 Electrical Connections and Control Cable Installation................76 Propeller Installation..........................

  • Page 7: Warranty Information

    Warranty Registration United States And Canada 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 department.

  • Page 8: Fourstroke Outboard Limited Warranty United States, Canada, Europe And Confederation Of Independent States

    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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 9: Fourstroke Outboard Limited Warranty (Middle-East, And Africa)

    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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 10: Year Limited Warranty Against Corrosion

    WHAT MERCURY WILL DO: Mercury’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified re–manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.
  • Page 11 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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 12: Warranty Coverage And Exclusions

    All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner's responsibility. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.
  • Page 13 WARRANTY INFORMATION 12. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard. 13. Water entering engine through the fuel intake, air intake or exhaust system or submersion. 14. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high or trimmed too far out.

  • Page 14: 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 on board 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 15: 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 16: Lanyard Stop Switch

    GENERAL INFORMATION 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 17: Protecting People In The Water

    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. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

  • Page 18: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat. 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.

  • Page 19: 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 re-enters the water.

  • Page 20: Safety Instructions For Hand Tilled Outboards

    WARNING 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.

  • Page 21: Selecting Accessories For Your Outboard

    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. IMPORTANT: Check with your dealer before installing accessories. The misuse of approved accessories...

  • Page 22: Safe Boating Suggestions

    GENERAL INFORMATION 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. Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions.

  • Page 23: Recording Serial Number

    It is important to record this number for future reference. The serial number is located on the outboard as shown. OTXXXXXX XXXX 24125 Serial number Year manufactured Model designation Certified Europe Insignia (as applicable) 40 4-Stroke Specifications - International Models Horsepower Kilowatts 29.8 Full Throttle RPM Range 5500-6000 RPM Idle Speed in Forward Gear Carburetor Models 800 ±...

  • Page 24: Component Identification

    GENERAL INFORMATION Models Gearcase Lubricant Capacity 440 ml (14.9 fl. oz.) Engine Oil Capacity 3.0 l (3 qt.) Battery Rating 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Operation Above 0 °C (32 °F) AMPS (CCA) 1000 Marine Cranking Amps (MCA) or 750 Cold Cranking Operation Below 0°...

  • Page 25: 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. Additional clearance may be required for railroad crossings, driveways and trailer bouncing.
  • Page 26 TRANSPORTING 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 27: 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 28: Filling Fuel Tank

    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 Oil. If the recommended Mercury or Quicksilver NMMA FC-W certified outboard oils are not available, a major brand of NMMA FC-W certified 4-stroke outboard oil of similar viscosity may be used.

  • Page 29: 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 30 FUEL & OIL Push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. Reinstall the oil filler cap and hand tighten securely. 28813 Full mark Dipstick Add mark Oil filler cap...

  • Page 31: 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...

  • Page 32: Warning System - Electric Starting Models

    FEATURES & CONTROLS Warning System Function Sound Description Engine Over Temperature Continuous Engine Over Heat Low Oil Pressure Intermittent Short Beeps Low Oil Pressure ENGINE OVERHEAT If the engine overheats, immediately reduce throttle speed to idle. Shift the outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.
  • Page 33 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 34: 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 35 FEATURES & CONTROLS WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner. •...

  • Page 36: Manual Tilt System

    FEATURES & CONTROLS NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system. 28534 Auxiliary tilt switch SHALLOW WATER OPERATION...

  • Page 37: Shallow Water Operation

    FEATURES & CONTROLS BASIC TILTING OPERATION Move tilt lock lever to the tilt position. Tilt outboard to desired position and lock in place by moving the tilt lock lever back to the lock/run position. 26802 Tilt position Lock/run position SHALLOW WATER OPERATION When operating your boat in shallow water, the outboard can be adjusted and locked at a higher tilt angle.
  • Page 38 FEATURES & CONTROLS Engage the tilt support lever by rotating the knob to bring the support lever upward. 28931 Tilt support lever Knob Lower the outboard to rest on the tilt support lever. Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down.

  • Page 39: Throttle Grip Friction Adjustment - Tiller Handle Models

    FEATURES & CONTROLS Adjusting the outboard close to the boat transom can: • 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 •...
  • Page 40 FEATURES & CONTROLS NOTE: To maintain proper adjustment, the locknut located on top of the steering friction lever pivot shaft can be tightened. 26811 Tighten friction Locknut Loosen friction 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 41: Trim Tab Adjustment

    FEATURES & CONTROLS Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal result from your outboard not trimmed with the propeller shaft parallel to the water surface. The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.

  • Page 42: 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 corrosion control anodes as this will reduce the effectiveness of the anodes.

  • Page 43: Engine Break-In Procedure

    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. 26837 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 44 OPERATION Set the lanyard stop switch to the "RUN" position. Refer to General Information - Lanyard Stop Switch. 19791 Shift the outboard to the neutral ("N") position. 26838 Models without power trim - Position the tilt lock lever to the lock position. 26839 Position the remote control or throttle-only lever as follows: •...

  • Page 45: Starting The Engine - Tiller Handle Models

    OPERATION • Starting flooded engine (EFI) - Advance the throttle-only lever or control handle to the maximum throttle-only position and continue to crank the engine for starting. Immediately reduce engine speed after engine starts. 26840 Fully closed position Maximum fast idle speed position Turn the ignition key to the "START"...
  • Page 46 OPERATION Open the fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 Connect the remote fuel line to the outboard. Make sure the connector is snapped into place. 28526 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 47 OPERATION Models without power trim - Position the lilt lock lever to the lock position. 26839 Position the throttle grip as follows: • Cold engine (carbureted) - Set the throttle grip to the start position. • Warm engine (carbureted) - Set the throttle grip to the half-way position. •...

  • Page 48: Gear Shifting

    OPERATION 10. Check for a steady stream of water flowing out of the water pump indicator hole. 28521 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.

  • Page 49: Stopping The Engine

    OPERATION • Always shift the outboard into gear with a quick motion. • After shifting the outboard into gear, advance the remote control lever or rotate the throttle grip (tiller handle) to increase speed. Stopping The Engine Remote Control Models - Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF"...
  • Page 50 OPERATION 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.
  • Page 51 OPERATION Pull the starter rope to start the engine. 26848...

  • Page 52: 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...

  • Page 53: Flushing The Cooling System

    MAINTENANCE AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the Cooling System. • Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in salt water.

  • Page 54: Top Cowl Removal And Installation

    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. Place a block of wood between the propeller blade and the anti-ventilation plate.

  • Page 55: Exterior Care

    MAINTENANCE 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. 28445 Exterior Care Your outboard is protected with a durable baked enamel finish.

  • Page 56: Engine Fuel Filter - Manual Starting Models

    MAINTENANCE REMOVAL Read the preceeding fuel system servicing information and warning. Pull out the filter assembly from mount. Hold the cover to prevent it from turning and remove the sight bowl. Empty contents into an approved container. Inspect the filter element and replace the filter assembly if necessary. 28414 Cover O-ring seal...

  • Page 57: 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 ("e" - Part Number 10-856680) and self-locking nylon insert locknuts ("b" & "d" - Part Number 11-826709113). These locknuts must never be replaced with common nuts (non-locking) as they will work loose and vibrate off, freeing the link rod to disengage.

  • Page 58: Propeller Replacement

    MAINTENANCE This model has an anode installed on each side of the gearcase and one on the bottom of the transom bracket assembly. 32211 Anode on transom bracket assembly Gearcase anodes Propeller Replacement WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
  • Page 59 Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 26901 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon. 26902 Tube Ref No.

  • Page 60: Spark Plug Inspection And Replacement

    MAINTENANCE Flo-Torq I drive hub propellers - Install the forward thrust hub, propeller, propeller nut retainer, and propeller nut onto the shaft. 26903 Propeller nut Propeller Propeller nut retainer Forward thrust hub Place the propeller nut retainer over pins. Place a block of wood between the gearcase and propeller and tighten propeller nut to the specified torque.

  • Page 61: Fuse Replacement

    MAINTENANCE Remove the spark plug boots. Twist the rubber boots slightly and pull off. 26899 Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled. 26946 Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap...

  • Page 62: Timing Belt Inspection

    Excessive wear at the roots of the cogs. c. Rubber portion swollen by oil. d. Belt surfaces roughened. e. Signs of wear on edges or outer surfaces of belt. 26958 Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon.
  • Page 63 Anti-Corrosion Grease Propeller shaft 92-802867 Q1 2-4-C with Teflon Propeller shaft 92-802859Q1 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. Tube Ref No. Description Where Used Part No. Tilt support lever, swivel...
  • Page 64 MAINTENANCE • Co-pilot shaft (tiller handle models) - Lubricate through fitting. Move the steering friction lever back and forth while lubricating. 28823 • WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control.

  • Page 65: Checking Power Trim Fluid

    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 66 MAINTENANCE Turn the the outboard so the drain hole is facing downward. Remove the drain plug and drain the engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. 28531 Drain plug Drain hole CHANGING OIL FILTER Place a rag or towel below the oil filter to absorb any spilled oil.

  • Page 67: Gearcase Lubrication

    MAINTENANCE Gearcase Lubrication When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.

  • Page 68: Submerged Outboard

    MAINTENANCE Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. 26975 Vent hole Fill/drain plug Vent plug 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 69: Storage

    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 70: Gearcase

    STORAGE Gearcase • Drain and refill the gearcase lubricant (refer to Maintenance - Gearcase Lubrication). Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. NOTICE Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze.

  • Page 71: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) POSSIBLE CAUSES • Blown 20 Amp fuse in the starting circuit (carburetor Models) or main power relay/accessories circuit (EFI Models). Refer to Maintenance section. • Outboard is not shifted to neutral position. •...

  • Page 72: Performance Loss

    TROUBLESHOOTING Performance Loss POSSIBLE CAUSES • Engine Guardian System activated. Refer to Features & Controls - Warning System. • Throttle not fully open. • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. •...

  • Page 73: Owner Service Assistance

    Should you have a question, concern, or problem that cannot be resolved by your dealership, please contact Mercury Marine Service Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems.
  • Page 74 Telephone (954) 744-3500 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744-3535 U.S.A. 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...

  • Page 75: Outboard Installation

    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 76 OUTBOARD INSTALLATION INSTALLATION SPECIFICATIONS 2763 Minimum transom opening Engine centerline for dual engines Minimum Transom Opening Single engine (remote) 48.3 cm (19 in.) Single engine (tiller) 76.2 cm (30 in.) Dual engines 101.6 cm (40 in.) Engine Centerline Minimum 66 cm (26 in.) LIFTING OUTBOARD Use the lifting eye on the engine.

  • Page 77: Installing Outboard

    OUTBOARD INSTALLATION INSTALLING OUTBOARD Drilling Outboard Mounting Holes Mark four mounting holes on the transom using the transom drill fixture. 2757 Drill guide holes Transom center line Transom drilling fixture Transom Drilling Fixture 91-98234A2 Aids in engine installation by acting as a template for engine mounting holes.
  • Page 78 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 79 OUTBOARD INSTALLATION Fastening the Outboard to the Transom Install the outboard so that the anti-ventilation plate is in-line or within 25 mm (1 in.) below the bottom of the boat. 8045 Anti-ventilation plate 25 mm (1 in.) Apply marine sealer to the shanks of bolts, not the threads. Fasten the outboard with the provided mounting hardware.
  • Page 80 OUTBOARD INSTALLATION Tube Ref No. Description Where Used Part No. 2-4-C Marine Lubricant with Steering cable end 92-802859Q1 Teflon Insert the steering cable into the tilt tube. 28507 Tighten the nut to the specified torque. 29506 Description lb. in. lb. ft. 47.5 STEERING CABLE SEAL Mark tilt tube 6.4 mm (0.25 in.) from end.
  • Page 81 OUTBOARD INSTALLATION 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" - Part Number 10-856680) and self-locking nylon insert locknuts ("b" & "d" - Part Number 11-826709113).

  • Page 82: Fuel Hose Connection - Remote Control Models

    OUTBOARD INSTALLATION Fuel Hose Connection - Remote Control Models REMOTE FUEL HOSE SIZE Minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.). Use a separate fuel hose/fuel tank pickup for each engine. 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.
  • Page 83 OUTBOARD INSTALLATION Connect the 14 pin connector to the engine harness and fasten the harness with the retainer. 28482 Remote wiring harness 14 pin connector Retainer BATTERY CABLE CONNECTIONS Single Outboard 15496 Red sleeve - Positive (+) Cranking battery Black sleeve - Negative (–)
  • Page 84 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve - Positive (+) Ground cable Black sleeve - Negative (–) Cranking battery SHIFT CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control.
  • Page 85 OUTBOARD INSTALLATION c. Make a center mark ("c"), midway between marks ("a" and "b"). Align the cable end guide with this center mark when installing cable to the engine. 6098 Manually shift the outboard into neutral. The propeller will rotate freely. Position the remote control handle into neutral.

  • Page 86: Throttle Cable Installation

    OUTBOARD INSTALLATION Adjust the cable barrel so the center mark on the cable is aligned with the end guide when the cable barrel is placed in the barrel receptacle. 28487 Cable end guide Cable barrel Cotter pin retainer Barrel latch Center mark Place the cable barrel into the barrel receptacle.
  • Page 87 OUTBOARD INSTALLATION Position the remote control into neutral. 26838 Fit the throttle cable through the rubber grommet. 28491 Rubber grommet Throttle cable Attach the throttle cable to the throttle lever with a cotter pin retainer. Adjust cable barrel until the barrel slips onto the mounting stud.
  • Page 88 OUTBOARD INSTALLATION Fasten the throttle cable to the mounting stud with a flat washer and locknut. Tighten the locknut to the specified torque. 28494 Throttle cable Locknut Cotter pin retainer Cable barrel Flat washer Description lb. in. lb. ft. Throttle cable locknut Reinstall the access cover with two bolts.

  • Page 89: Propeller Installation

    Place a block of wood between the propeller blade and the anti-ventilation plate. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.
  • Page 90 OUTBOARD INSTALLATION Flo-Torq II Drive Hub Propellers - Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft. 26941 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Thrust hub Forward thrust hub NOTE: Stainless Steel Applications - Installation of a Flo-Torq III drive hub propeller is recommended.
  • Page 91 Place a block of wood between the propeller blade and the anti-ventilation plate. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.

  • Page 92: Trim Tab Adjustment

    OUTBOARD INSTALLATION Flo-Torq II Drive Hub Propellers - Install forward thrust hub, propeller, replaceable drive sleeve, rear thrust hub, propeller nut retainer and propeller nut onto the shaft. 26904 Propeller nut Replaceable drive sleeve Propeller nut retainer Propeller Rear thrust hub Forward thrust hub Place propeller nut retainer over pins.

  • Page 93: Trim-In Stop Adjustment - Power Trim Models

    OUTBOARD INSTALLATION 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 inches) or more above the boat bottom. Operate your boat at normal cruising speed, trimmed to the desired position. Turn your boat left and right and note the direction the boat turns more easily.

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