Mercury 40 Manual
  1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Outboard Motor
  5. 40 FourStroke
  6. Manual

Mercury 40 Manual

Hide thumbs Also See for 40:
Table of Contents

Advertisement

Quick Links

See also: Service Manual , Operation & Maintenance Manual
Thank You
for your purchase of one of the finest outboards available. You
have made a sound investment in boating pleasure. Your
outboard has been manufactured by Mercury Marine, a world
leader in marine technology and outboard manufacturing
since 1939. These years of experience have been committed
to the goal of producing the finest quality products. This led to
Mercury Marine's reputation for strict quality control,
excellence, durability, lasting performance and being the best
at providing after the sale support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in the
operation, safe use and care of your outboard.
All of us at Mercury Marine took pride in building your outboard
and wish you many years of happy and safe boating.
Again, thank you for your confidence in Mercury Marine.
EPA Emissions Regulations
Outboards sold by Mercury Marine in the United States 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 being set to
factory standards. For this reason, the factory procedure for
servicing the product must be strictly followed and, wherever
practicable, returned to the original intent of the design.
Maintenance, replacement, or repair of the emission
control devices and systems may be performed by any
marine engine repair establishment or individual.
Engines are labeled with an Emission Control Information
decal as permanent evidence of EPA certification.
The engine exhaust from this product contains chemicals
known to the state of California to cause cancer, birth defects
or other reproductive harm.
WARNING
!
i

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 40 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Mercury 40

Summary of Contents for Mercury 40

  • Page 1 This manual has been prepared to assist you in the operation, safe use and care of your outboard. All of us at Mercury Marine took pride in building your outboard and wish you many years of happy and safe boating.
  • Page 2 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 Information Section of this manual. The warranty statement contains a description of what is covered, what is not...
  • Page 3 • Provides timely service for all Mercury Marine customers. • Offers extended service hours and mobile service, when appropriate. • Uses, displays and stocks adequate inventory of genuine Mercury Precision Parts. • Offers a clean, neat shop with well organized tools and service...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Warranty Information Warranty Registration..............1 Transfer of Warranty..............1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada......... 2 Outboard Limited Warranty............3 3 Year Limited Warranty Against Corrosion........6 Warranty Coverage and Exclusions..........9 GENERAL INFORMATION Boater's Responsibilities............12 Before Operating Your Outboard..........12...
  • Page 6 Mixing Fuel and Oil..............37 Filling Oil Injection System............37 Filling Fuel Tank................38 FEATURES & CONTROLS Remote Control Features............39 Warning System ‑ Electric Start Models........40 Warning Horn System ‑ Manual Start Models......42 Engine Over‑Speed Limiter............43 Manual Tilt System..............43 Power Trim And Tilt (If Equipped)..........47 Throttle Grip Friction Adjustment ‑...
  • Page 7 TABLE OF CONTENTS OPERATION Pre‑Starting Check List..............54 Operating in Freezing Temperatures.........54 Operating in Saltwater or Polluted Water........55 Operating at High Elevations.............55 Engine Break‑in Procedure............55 Starting the Engine ‑ Electric Start Remote Control Models..56 Starting the Engine ‑ Tiller Handle Models........59 Gear Shifting................63 Stopping the Engine ..............64 Emergency Starting ‑...
  • Page 8 Engine Will Not Start..............93 Engine Runs Erratically.............93 Performance Loss..............94 Battery Will Not Hold Charge.............94 OWNER SERVICE ASSISTANCE Local Repair Service..............95 Service Away from Home............95 Parts and Accessories Inquiries..........95 Service Assistance..............95 Mercury Marine Service Offices..........96 MAINTENANCE LOG Maintenance Log...............98 viii...

  • Page 9: Warranty Information

    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 10: Transfer Of Mercury Product Protection (Extended Service Coverage) Plan United States And Canada

    Transfer form. Submit to Mercury Product Protection a receipt/ bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee. Plan coverage is not transferable from one product to another product or for non‑eligible applications.

  • Page 11: Outboard Limited Warranty

    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 predelivery inspection process is completed and documented.
  • Page 12 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 remanufactured 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 13 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 the limited warranty, and if made, shall not be enforceable against Mercury Marine.

  • Page 14: Year Limited Warranty Against Corrosion

    HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. 3 Year Limited Warranty Against Corrosion WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, Mercury MerCruiser Inboard or Sterndrive Engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
  • 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 predelivery inspection process is completed and documented.
  • Page 16 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 17: Warranty Coverage And Exclusions

    WARRANTY INFORMATION DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY.
  • Page 18 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 19 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 20: 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 21: Boat Horsepower Capacity

    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 22: 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 23: 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 24 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 25: Protecting People In The Water

    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 26: 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.

  • Page 27: 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 28: Impact With Underwater Hazards

    Under these conditions, boat speed should be kept to a minimum planing speed of 24 to 40 km/h (15 to 25 MPH). 26785 Striking a floating or underwater object could result in an infinite number of situations.

  • Page 29: Safety Instructions For Hand-Tilled Outboards

    Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Safety Instructions for Hand‑Tilled Outboards No person or cargo should occupy the area directly in front of the outboard while the boat is in motion.

  • Page 30: Exhaust Emissions

    GENERAL INFORMATION MODELS WITH CLAMP SCREWS: Some outboards come with transom bracket clamp screws. The use of clamp bracket screws alone, is insufficient to properly and safely secure the outboard to the transom. Proper installation of the outboard includes bolting the engine to the boat through the transom.
  • Page 31 GENERAL INFORMATION GOOD VENTILATION Ventilate passenger area, open side curtains or forward hatches to remove fumes. 21622 Example of desired air flow through the boat POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.

  • Page 32: Selecting Accessories For Your Outboard

    The misuse of approved accessories or the use of nonapproved 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 33 Never drive your boat directly behind a water‑skier in case the skier falls. As an example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier 61 m (200 ft) in front of you in 5 seconds.

  • Page 34: Recording Serial Number

    XXXXXXXX XXXX XXXX 3098 Serial number Year manufactured Model year Certified Europe insignia (as applicable) Model designation 40/50 Specifications Models Horsepower Kilowatts 29.4 36.8 Full throttle RPM range 5000–5500 RPM Idle speed in forward gear 650–700 RPM Number of cylinders Piston displacement 965 cc (58.9 in³)
  • Page 35 GENERAL INFORMATION Models Recommended spark plug NGK BPZ8H‑N‑10 Spark plug gap 1.0 mm (0.040 in.) Gear ratio 1.83:1 Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Gearcase lubricant 440 ml (14.9 fl oz) capacity 465 marine cranking amps (MCA) or 350 cold Battery rating cranking amps (CCA)

  • Page 36: Component Identification

    GENERAL INFORMATION Component Identification 3099 Top cowl Secondary cooling water intake Water pump indicator hole Tilt lock lever (non power trim) Auxiliary tilt switch -Shift handle Driveshaft housing Throttle friction Anti‑ventilation plate adjustment knob Trim tab Engine stop switch Gearcase Tiller handle Transom bracket Lanyard stop switch...

  • Page 37: Installation

    INSTALLATION Installing Outboard WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly installed with the required mounting hardware. Do not accelerate above idle speed in water that may contain underwater obstacles if the outboard is not attached to the transom correctly.
  • Page 38 The outboard must be secured to the transom one of two ways: EITHER with clamp screws and the two mounting bolts and locknuts provided, OR with clamp screws and optional Quicksilver or Mercury Precision Parts Outboard Mounting Kit. Tighten retainer screws into the lower mounting holes when using outboard mounting kit.

  • Page 39: Propeller Selection

    INSTALLATION Propeller Selection For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to General Information ‑ Specifications).

  • Page 40: Trailering Boat/Outboard

    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 41: Transporting Portable Fuel Tanks

    TRANSPORTING Transporting Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion. Follow the transporting instructions supplied with the portable fuel tank. Transport the fuel tank in a well ventilated area away from open flame or sparks. MANUAL VENTING TYPE FUEL TANK Close fuel tank air vent when transporting tank.

  • Page 42: 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 43: Low Permeation Fuel Hose Requirement

    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 44: Oil Recommendation

    For added protection and lubrication, Mercury or Quicksilver Premium Plus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2‑cycle outboard oil that is NMMA Certified TC‑W3. Severe engine damage may result from use of an inferior oil.

  • Page 45: Mixing Fuel And Oil

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

  • Page 46: Filling Fuel Tank

    FUEL & OIL 2. Remove the fill cap and fill tank with oil. 3101 Capacity Fluid Type Mercury or Quicksilver Premium 2‑Cycle TC‑W3 Oil tank 3 liters (3.17 qt.) Outboard Oil Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion.

  • Page 47: 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 48: Warning System - Electric Start Models

    FEATURES & CONTROLS Warning System ‑ Electric Start Models WARNING SYSTEM The outboard warning system incorporates a warning horn inside the boat. Remote control models will have the warning horn located inside the remote control or connected to the ignition key switch. Tiller handle models will have the warning horn located in the ignition key panel.
  • Page 49 FEATURES & CONTROLS ENGINE OVERHEAT If the engine overheats, immediately reduce throttle speed to idle. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole. 19805 If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine and check the cooling water intake holes for obstruction.

  • Page 50: Warning Horn System - Manual Start Models

    FEATURES & CONTROLS Warning Horn System ‑ Manual Start Models The outboard warning system incorporates a warning horn beneath the bottom cowl. The warning horn will sound if the engine overheats. 3104 ENGINE OVERHEAT If the engine overheats, the warning horn will sound. Immediately reduce throttle speed to idle.

  • Page 51: Engine Over-Speed Limiter

    FEATURES & CONTROLS If a steady flow of water is coming out of the water pump indicator hole and the engine continues to overheat, consult your dealer. Operating an overheated engine will cause engine damage. Engine Over‑Speed Limiter The outboard is equipped with an engine over‑speed limiter which limits the engine maximum RPM.
  • Page 52 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 the boat in shallow water, the outboard can be adjusted and locked at a higher tilt angle.
  • Page 53 FEATURES & CONTROLS 2. Push in the tilt support pin. 27386 Tilt support pin 3. Lower outboard to rest on the tilt support pin. Lowering To Run Position 1. Raise the outboard off the support pin to disengage tilt support. Pulling out the support pin and lower the outboard. 2.
  • Page 54 FEATURES & CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 27399 Too much angle (bow up) ‑ adjust in Not enough angle (bow down) ‑ adjust out Angle adjusted properly (bow slightly up) NOTE: The outboard should be locked against the tilt stops or tilt pin during operation by setting the tilt lock lever to the lock/run position.

  • Page 55: Power Trim And Tilt (If Equipped)

    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 56 FEATURES & CONTROLS POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards.
  • Page 57 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 58 FEATURES & CONTROLS 3. Disengage the tilt support pin, by raising the outboard off the support pin and pulling out the support pin. Lower the outboard. 27475 MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.

  • Page 59: Throttle Grip Friction Adjustment - Tiller Handle Models

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

  • Page 60: Steering Friction Adjustment

    FEATURES & CONTROLS Steering Friction Adjustment 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 61: 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 62: Pre-Starting Check List

    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 63: Operating In Saltwater Or Polluted Water

    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 64: Starting The Engine - Electric Start Remote Control Models

    OPERATION Engine Break-in Procedure - Vary the throttle setting during the first hour of operation. During the first hour of operation, avoid remaining at constant speed for more than two minutes and avoid sustained wide open throttle. MODELS WITHOUT OIL INJECTION Engine Break-in Fuel Mixture - Use a 25:1 (4%) gasoline/oil mixture in the first tank of fuel.
  • Page 65 OPERATION 2. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 3. Connect the fuel line to the outboard. 3106 4. Squeeze the fuel line primer bulb several times until it feels firm. 19779 5.
  • Page 66 OPERATION 7. Models without power trim ‑ Position the tilt lock lever down to the lock position. 26802 Tilt position Lock/run position WARNING Operating the engine without engaging the tilt lock lever can cause serious injury or death. The outboard can tilt upwards when decelerating or operating in reverse, causing loss of boat control.

  • Page 67: Starting The Engine - Tiller Handle Models

    OPERATION 10. Starting flooded engine ‑ Advance the fast idle lever or throttle only feature to the maximum position. Without activating primer, crank engine for 10 seconds. Wait 30 seconds and repeat until engine starts. Immediately start to reduce engine speed after engine starts.
  • Page 68 OPERATION 2. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 3. Connect the fuel line to the outboard. 3106 4. Squeeze the fuel line primer bulb several times until it feels firm. 19779 5.
  • Page 69 OPERATION 7. Move throttle grip to start position. 27239 8. Models without power trim ‑ Position the tilt lock lever to the lock/run position. 26802 Tilt position Lock/run position WARNING Rapid acceleration can result in serious injury or death from being thrown within or out of the boat.
  • Page 70 OPERATION b. Pull the starter rope slowly until starter engages, then pull rapidly to crank the engine. Allow rope to return slowly. Repeat until engine starts. If engine begins to stall, reprime until engine is running. 3072 10. Electric starting models ‑ Turn ignition key to the "START" position and start the engine.

  • Page 71: Gear Shifting

    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 72: Stopping The Engine

    OPERATION • After shifting outboard into gear, advance the remote control lever or rotate the throttle grip (tiller handle) to increase speed. Stopping the Engine 1. Remote control models ‑ Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position.
  • Page 73 OPERATION 1. Shift outboard to neutral (N) position. 3107 26838 2. Turn ignition key to "ON" position. 26846 3. Set the lanyard stop switch to "RUN" position. Refer to General Information - Lanyard Stop Switch. 19791 4. Remove flywheel cover. 3097...
  • Page 74 OPERATION WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine. Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests. WARNING The exposed moving flywheel can cause serious injury.

  • Page 75: Emergency Starting - Manual Start Models

    OPERATION Emergency Starting ‑ Manual Start Models If the starter system fails, use the spare starter rope (provided) and follow procedure. WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear.
  • Page 76 OPERATION 3. If starter rope is intact, pull rope out of the rewind housing and tie a knot in the rope. Remove retainer from end of rope and untie the retainer knot. 3084 4. Remove the rewind starter. 3085 WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine.
  • Page 77 OPERATION 5. Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel. 3079 6. If engine is cold, push in the fuel primer button 4 to 6 times. 7. Pull the starter rope to start the engine.

  • Page 78: Maintenance

    We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. EPA 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.

  • Page 79: Epa Emissions

    MAINTENANCE EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture. EMISSION CONTROL INFORMATION This engine conforms to model year EPA regulations for Marine SI engines. Refer to Owner's Manual for required maintenance.
  • Page 80 Inspect battery. See Battery Inspection. • Check control cable adjustments. • Remove engine deposits with Mercury Precision or Quicksilver Power Tune Engine Cleaner. • Check tightness of bolts, nuts, and other fasteners. EVERY 300 HOURS OF USE OR THREE YEARS •...

  • Page 81: Flushing The Cooling System

    This will help prevent a buildup of deposits from clogging the internal water passages. Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.

  • Page 82: Exterior Care

    MAINTENANCE 3. Start the engine and run it at idle speed in neutral shift position. IMPORTANT: Do not run engine above idle when flushing. 4. Adjust water flow (if necessary) so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water.

  • Page 83: Battery Inspection

    MAINTENANCE 2. Make sure the bottom rubber seal fits properly and lock the front and rear latches. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery.

  • Page 84: Steering Link Rod Fasteners

    MAINTENANCE IMPORTANT: Visually inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. 3111 FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line or primer bulb must be replaced.

  • Page 85: Fuse Replacement - Electric Start Models

    MAINTENANCE Assemble steering link rod to engine with special washer head bolt, locknut and spacer. First torque bolt to specifications, then torque locknut to specifications. 3086 Special washer head bolt (10‑856680) Nylon insert locknut (11‑826709113) Spacer Flat washers Nylon insert locknut (11‑826709113) Description lb.

  • Page 86: Corrosion Control Anode

    MAINTENANCE 1. 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. 3112 Good fuse Fuse holder Blown fuse Corrosion Control Anode The outboard has corrosion control anodes at different locations.

  • Page 87: Propeller Replacement

    MAINTENANCE One of the anodes is the trim tab installed on the gearcase. Another anode is installed on the bottom of the transom bracket assembly. 27577 Trim tab Transom bracket anode Propeller Replacement WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
  • Page 88 MAINTENANCE 2. Remove the spark plug leads to prevent engine from starting. 26899 3. Straighten the bent tabs on the propeller nut retainer. 26900 4. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut. 26901 5.
  • Page 89 MAINTENANCE 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. 26902 Tube Ref Description Where Used Part No. Anti-Corrosion Propeller shaft 92-802867Q 1 Grease 2-4-C with Teflon Propeller shaft 92-802859A 1 IMPORTANT: To prevent the propeller hub from corroding and...
  • Page 90 MAINTENANCE 8. 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 9.

  • Page 91: Spark Plug Inspection And Replacement

    MAINTENANCE Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks which can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots.

  • Page 92: Lubrication Points

    Install plugs finger‑tight, and then tighten 1/4 turn or torque to specifications. Description lb. in. lb. ft. Spark plug Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. Tube Ref Description Where Used Part No. Anti-Corrosion...
  • Page 93 MAINTENANCE Tube Ref Description Where Used Part No. Swivel bracket, tilt tube, co-pilot shaft, transom clamp 2-4-C with Teflon 92-802859A 1 screws, shift handle, steering cable grease fitting • Swivel Bracket ‑ Lubricate through fitting. 27580 • Tilt Tube ‑ Lubricate through fitting. •...
  • Page 94 MAINTENANCE • Shift Handle (Tiller Handle Models) ‑ Lubricate through fittings. 3091 • Steering Cable Grease Fitting (If equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control.

  • Page 95: Checking Power Trim Fluid

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

  • Page 96: 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 97: Submerged Outboard

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

  • Page 98: Storage Preparation

    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 99: 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 Description Where Used Part No.

  • Page 100: Gearcase

    STORAGE • Rotate the flywheel manually several times to distribute the storage seal in the cylinder. Reinstall spark plug. 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.

  • Page 101: 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 102: Performance Loss

    TROUBLESHOOTING • Incorrect setup and adjustments. • Fuel is being restricted to the engine. • Engine fuel filter is obstructed. Refer to Maintenance section. • Fuel tank filter obstructed. • Stuck anti‑siphon valve on built in fuel tank. • Fuel line is kinked or pinched. •...

  • Page 103: 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 104: Mercury Marine Service Offices

    • 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, Canada English ‑ (920) 929‑5040...
  • Page 105 OWNER SERVICE ASSISTANCE Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way 5467789 Singapore, 508762...

  • Page 106: 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...

This manual is also suitable for:

50

Table of Contents

Save PDF