Mercury 40 JET FOURSTROKE Operation, Maintenance & Installation Manual
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Mercury 40 JET FOURSTROKE 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 Identification Records Please record the following applicable information: Outboard Engine Model and Horsepower Engine Serial Number Gear Ratio Propeller Number Pitch Diameter Hull Identification Number (HIN) Purchase Date Boat Manufacturer Boat Model Length Exhaust Gas Emissions Certification Number (Europe Only)

  • Page 7: Table Of Contents

    Low Permeation Fuel Hose Requirement ............18 EPA Pressurized Portable Fuel Tank Requirements........18 Fuel Demand Valve (FDV) Requirement............18 Mercury Marine's Pressurized Portable Fuel Tank........... 19 Filling Fuel Tank....................20 Engine Oil Recommendations................20 Checking and Adding Engine Oil..............21...
  • Page 8 Features and Controls Remote Control Features................. 23 Warning System....................24 Power Trim and Tilt................... 26 Throttle Grip Friction Adjustment ‑ Tiller Handle Models........29 Steering Friction Adjustment ‑ Tiller Handle Models......... 29 Replaceable Jet Drive Shear Key..............30 Operation Important Daily Inspection Before Each Use ........... 31 Prestarting Check List..................
  • Page 9 Maintenance Outboard Care....................46 EPA Emissions Regulations................46 Inspection and Maintenance Schedule............. 47 Flushing the Cooling System................48 Top Cowl Removal and Installation..............50 Exterior Care..................... 50 Battery Inspection .................... 50 Fuel System...................... 51 Steering Link Rod Fasteners................52 Corrosion Control Anode.................. 53 Spark Plug Inspection and Replacement............
  • Page 10 Parts and Accessories Inquiries............... 68 Service Assistance................... 68 Ordering Literature.................... 70 Outboard Installation Mercury Marine Validated Engine Mounting Hardware........72 Accessories Mounted to the Transom Clamp Bracket........72 Installation Information..................76 Determining the Mounting Height of the Outboard Jet ........78 Installing Outboard....................

  • 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: Boat Horsepower Capacity

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.

  • Page 13: Outboard Remote Control Models

    GENERAL INFORMATION Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral. WARNING Starting the engine with the drive in gear can cause serious injury or death.

  • Page 14: Lanyard Stop Switch

    GENERAL INFORMATION Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch.
  • Page 15 GENERAL INFORMATION Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position.

  • Page 16: Stopping The Boat In An Emergency

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

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

    GENERAL INFORMATION WHILE BOAT IS STATIONARY WARNING Avoid injury resulting from contacting the rotating impeller or having hair, clothing, or loose objects drawn into the water intake and wrapping around the impeller shaft. Stay away from the water intake and never insert an object into the water intake or water outlet nozzle when the engine is running.

  • Page 18: Wave And Wake Jumping

    GENERAL INFORMATION BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds. Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

  • Page 19: 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.
  • Page 20 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 21: 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. Read the installation, operation and maintenance manuals for all your selected accessories.
  • Page 22 GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways. • We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses.
  • Page 23 (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.

  • Page 24: Recording Serial Number

    Me rc ury Marine Brunswick Corp. Made in Japan 24125 Serial number Model designation Year manufactured Certified Europe Insignia (as applicable) 40 Jet FourStroke Specifications Models 40 Jet Horsepower Kilowatts 29.4 Full throttle RPM range 5000–5500 RPM Number of cylinders...

  • Page 25: Component Identification

    *Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.

  • Page 26: 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 27: 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 28: Low Permeation Fuel Hose Requirement

    IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause trouble;...

  • Page 29: Mercury Marine's Pressurized Portable Fuel Tank

    Vent/water drain holes 46273 Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks are available as an accessory or are provided with certain portable outboard models.

  • Page 30: Filling Fuel Tank

    Mercury or Quicksilver NMMA FC‑W certified SAE 10W‑30 4‑Stroke Marine Engine Oil is recommended for general, all‑temperature use. If NMMA certified synthetic blend oil is preferred, use Mercury or Quicksilver SAE 25W‑40 Synthetic Blend Marine 4‑Stroke Engine Oil. If the recommended Mercury or Quicksilver NMMA FC‑W certified outboard oils are not available, a major...

  • Page 31: Checking And Adding Engine Oil

    FUEL AND OIL IMPORTANT: The use of nondetergent 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 32 FUEL AND OIL 4. 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. 28412 Full mark Add mark Dipstick Oil filler cap...

  • 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

    FEATURES AND 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 35 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 36: Power Trim And Tilt

    FEATURES AND 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 37 FEATURES AND CONTROLS WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. Maintain control of the boat if trimming beyond a neutral steering condition. Consider the following lists carefully.
  • Page 38 FEATURES AND CONTROLS 2. Lower outboard to rest on the tilt support lever. 3. Disengage the tilt support lever, by raising the outboard off the support lever and rotating the lever down. Lower the outboard. Tilt support lever Knob 28931 MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.

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

    FEATURES AND 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. Loosen friction Tighten friction 19807...

  • Page 40: Replaceable Jet Drive Shear Key

    FEATURES AND CONTROLS Replaceable Jet Drive Shear Key The jet drive is equipped with a shear key to protect it in the event of a lodged impeller. The shear key can be reached by removing the water intake housing and impeller. 29174...

  • Page 41: Operation

    OPERATION Important Daily Inspection Before Each Use Any outboard mounted on the boat must have the mounting hardware inspected and checked to ensure that the hardware has not become loose. A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use.

  • Page 42: Operating In Freezing Temperatures

    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 43 OPERATION The driveshaft driven impeller draws water up through the water intake and then directs 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. 29022 Water intake Water outlet nozzle...

  • Page 44: Stopping The Boat In An Emergency

    OPERATION Stopping the Boat in an Emergency A jet powered boat has emergency stopping capability unique to this form of propulsion. WARNING Using the emergency stopping capability of a jet drive unit will slow down the boat in an emergency. However, sudden stopping may cause the occupants of the boat to be thrown forward or out of the boat resulting in serious injury or death.

  • Page 45: Mooring The Boat

    OPERATION Mooring the Boat Be sure to tilt the jet drive out of the water when the boat is pulled onto a beach or tied to a dock in shallow water. Failure to do this may cause the water intake housing to fill with sand or debris and could prevent the outboard from cranking over for starting.

  • Page 46: Pre-Starting Instructions

    OPERATION Pre‑Starting Instructions 1. Check the engine oil level. 28525 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 47 OPERATION NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat. Never start or operate the engine without the intake housing in the water. 1. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 2.
  • Page 48 OPERATION 4. Shift outboard to neutral ("N") position. 26838 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 49: Starting The Engine - Tiller Handle Models

    OPERATION 8. After engine starts, 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 50 OPERATION 2. Connect the remote fuel line to the outboard. Make sure the connector is snapped into place. 28526 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.
  • Page 51 OPERATION 7. Starting a flooded engine ‑ Set the throttle grip to half‑way position. 0%100 0%100 START START START 19799 Start position Half‑way position 8. Turn the ignition key to the "START" position. If the engine fails to start in ten seconds, return the key to the "ON"...

  • Page 52: Gear Shifting

    OPERATION Gear Shifting IMPORTANT: Observe the following: • Never shift outboard into gear unless engine speed is at idle. • 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.

  • Page 53: Stopping The Engine

    OPERATION Stopping the Engine 1. Remote control models ‑ Reduce the engine speed and shift the outboard to neutral position. Turn the ignition key to "OFF" position. 26843 2. Tiller handle models ‑ Reduce the engine speed and shift the outboard to neutral position.
  • Page 54 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 55 OPERATION 5. Pull the starter rope to start the engine. 26848...

  • Page 56: Outboard Care

    Genuine Lubricants. EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments set to factory standards.

  • Page 57: Inspection And Maintenance Schedule

    MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in gear):...

  • Page 58: Flushing The Cooling System

    MAINTENANCE • Check the hydraulic steering fluid level, if equipped AFTER EACH USE • Wash the power package exterior with fresh water • Flush the outboard cooling system, saltwater or brackish water only ANNUALLY OR 100 HOURS • Grease the engine, if applicable •...
  • Page 59 MAINTENANCE WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 60: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal and Installation REMOVAL Pull out the rear lock lever and remove the top cowl. 28439 INSTALLATION 1. Lower the top cowl over the engine. 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.

  • Page 61: Fuel System

    MAINTENANCE 2. Ensure the battery is secure against movement. 3. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 4. Ensure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals. Fuel System WARNING Fuel is flammable and explosive.

  • Page 62: Steering Link Rod Fasteners

    MAINTENANCE 3. Inspect the filter element. If replacement is necessary, replace the filter assembly. 28414 Cover Filter element O‑ring seal 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 63: Corrosion Control Anode

    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. Always use required components and follow instructions and torque procedures.

  • Page 64: Spark Plug Inspection And Replacement

    MAINTENANCE Each anode requires periodic inspection, especially in saltwater which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. One anode is installed on the bottom of the transom bracket assembly and the other anode is located on the water intake housing.

  • Page 65: Steering Pull Adjustment

    MAINTENANCE 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. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 1.0 mm (0.040 in.) 4.

  • Page 66: Worn/Dull Impeller

    MAINTENANCE Worn/Dull Impeller The intake of gravel through the pump can round off and wear the leading edges of the impeller. Some conditions that could be experienced from a worn/ dull impeller are as follows: • Noticeable performance loss, especially on acceleration •...

  • Page 67: 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. Fuse Replacement IMPORTANT: Always carry spare fuses. The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring.

  • Page 68: Timing Belt Inspection

    • Belt surfaces roughened. • 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 PTFE. Tube Ref Description Where Used Part No. 2-4-C with PTFE...
  • Page 69 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 PTFE. Tube Ref...
  • Page 70 MAINTENANCE • 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. 28823 WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control.

  • Page 71: Checking Power Trim Fluid

    28474 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 and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).

  • Page 72: Changing Engine Oil

    MAINTENANCE Changing Engine Oil ENGINE OIL CAPACITY Capacity Fluid Type Mercury Precision Parts or Quicksilver Synthetic Blend 25W‑40 4‑Stroke Outboard Oil 3.0 Liter Engine oil (3 U.S. Quarts) Mercury Precision Parts or Quicksilver 10W‑30 4‑Stroke Outboard Oil OIL CHANGING PROCEDURE 1.

  • Page 73: Submerged Outboard

    MAINTENANCE 4. Screw the new filter on until the gasket contacts the base, then tighten 3/4 to 1 turn. 28417 OIL FILLING 1. Remove the oil fill cap and add oil to the proper operating level. 2. Idle the engine for five minutes and check for leaks. Stop the engine and check the oil level on the dipstick.

  • Page 74: 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).

  • Page 75: Protecting Internal Engine Components

    STORAGE Tube Ref Description Where Used Part No. Corrosion Guard External metal surfaces 92-802878 55 Protecting Internal Engine Components • Remove the spark plugs and add approximately 30 ml (1 oz.) of engine oil or inject a five second spray of storage seal into each spark plug hole. •...

  • Page 76: 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 77: Engine Overspeed (Excessive Rpm)

    TROUBLESHOOTING c. Stuck anti‑siphon valve located on permanently built‑in type fuel tanks. d. Fuel line is kinked or pinched. • Fuel pump failure. • Ignition system component failure. • Fuel injection component failure (EFI Models). Engine Overspeed (Excessive RPM) POSSIBLE CAUSES •...

  • Page 78: Owner Service Assistance

    STOLEN POWER PACKAGE If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packages.
  • Page 79 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 80: Ordering Literature

    OWNER SERVICE ASSISTANCE CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance, call, fax, or write to the geographic office in your area. Please include your daytime telephone number with mail and fax correspondence. United States, Canada English +1 920 929 5040...
  • Page 81 OWNER SERVICE ASSISTANCE 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 Attn: Publications Department...

  • Page 82: Outboard 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 83 OUTBOARD 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 84 OUTBOARD 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 85 OUTBOARD 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 86: Installation Information

    OUTBOARD 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 Installation Information BOAT HORSEPOWER CAPACITY WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death.
  • Page 87 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 88: Determining The Mounting Height Of The Outboard Jet

    OUTBOARD INSTALLATION LIFTING OUTBOARD Use the lifting eye on the engine. 28510 Determining the Mounting Height of the Outboard Jet The following outboard mounting height settings will work good for most applications, however, because of different boat/hull designs, the setting should be checked by test running the boat.
  • Page 89 OUTBOARD INSTALLATION BOATS WITH A "V" BOTTOM HULL 1. Measure the width of the leading edge on the water intake housing. Make a horizontal line on the transom up from the "V" bottom the same length as the width of the water intake housing. 22401 Horizontal line Width of the leading edge on the water intake housing...

  • Page 90: Installing Outboard

    OUTBOARD INSTALLATION 2. Fasten outboard to the transom at this height. Refer to Fastening the Outboard. 22403 Installing Outboard DRILLING OUTBOARD MOUNTING HOLES 1. Mark four mounting holes on the transom using the transom drill fixture. Drill guide holes Transom drilling fixture Transom centerline 2757 Transom Drilling Fixture...

  • Page 91: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION 2. Drill four 13.5 mm (17/32 in.) mounting holes. 3973 Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description 8M0071543 Outboard mounting bolt ½‑20 x 5.00 in. long (3.25 in. thread) 826711‑17 Nylon insert locknut ½‑20...
  • Page 92 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 93 OUTBOARD INSTALLATION FASTENING THE OUTBOARD TO THE TRANSOM IMPORTANT: The transom mounting surface must be flat within 3.17 mm (0.125 in.). No step in the transom mounting surface is allowed. The inside transom mounting bolt washer surface must be flat within 3.17 mm (0.125 in.). Step (not allowed) Gap between transom clamp and boat transom (not allowed)
  • Page 94 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 95 OUTBOARD INSTALLATION NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts. 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 96: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Steering Cable ‑ Starboard Side Routed Cable 1. Lubricate the entire cable end. 10261 Tube Ref Description...

  • Page 97: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION 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 ("a" ‑ Part Number 10‑856680) and self‑locking nylon insert locknuts ("b"...
  • Page 98 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. Always use required components and follow instructions and torque procedures.

  • Page 99: Steering Cable Seal

    OUTBOARD INSTALLATION 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. Assemble steering link rod to engine with special washer head bolt, locknut and spacer.

  • Page 100: Electrical Connections And Control Cable Installation

    OUTBOARD INSTALLATION Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover. 28696 Access cover...
  • Page 101 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. 41029 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 102 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. Rubber grommet Throttle cable 28701 4.
  • Page 103 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 Alignment mark Roller Retainer 6.
  • Page 104 OUTBOARD INSTALLATION 8. Install 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—OUTBOARD JET WARNING If not properly installed, the reverse gate can interfere with water coming off the rudder, suddenly and unexpectedly slowing the boat.

  • Page 105: Trim-In Stop Adjustment - Power Trim Models

    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.

  • Page 106: Water Testing

    OUTBOARD INSTALLATION Description lb‑in. lb‑ft Tilt stop pins 24.4 Water Testing CHECKING FOR CAVITATION The initial outboard height setting should be close to the optimum setting for the outboard. However, because of the hull design of some boats, obstructions, or imperfections in the hull ahead of the water intake, adjustments may be required to prevent cavitation at running speeds.
  • Page 107 OUTBOARD INSTALLATION A rough water plate may be helpful in reducing cavitation when running in windy, rough water conditions where air is sucked into the water intake when jumping waves. Install a 0.8 mm (1/32 in.) metal plate that extends from the hull bottom to the top of the water intake housing.

  • Page 108: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

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