Mercury Jet 40 Manual
  1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Outboard Motor
  5. 40 jet fourstroke
  6. Manual

Mercury Jet 40 Manual

Hide thumbs Also See for Jet 40:
Table of Contents

Advertisement

Quick Links

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 registered for warranty purpose? Please check on www.marinepower.com. If
necessary, please contact your local dealer.
If the outboard motor's serial number plate contains the CE mark in the lower left-hand corner, the
following statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe
Inc. Park Industrel, de Petit-Rechain, Belgium complies with the requirements of the following directives
and standards, as amended:
Recreational Craft Directive: 94/25/EC; std. ISO 8665, ISO 11547
Machinery Directive:
EMC Directive:
Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Product Environmental Engineering Department, Mercury Marine, Fond du Lac, WI USA
98/37/EC,
89/336/EC; std. EN50081-1, SAE J551 (CISPR Pub. 12),
EN 50082-1, IEC 61000 PT4-2, IEC 61000 PT4-3
i

Advertisement

Table of Contents
loading
Need help?

Need help?

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

Questions and answers

Related Manuals for Mercury Jet 40

Summary of Contents for Mercury Jet 40

  • Page 1 Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.

  • Page 2: Table Of Contents

    Warranty Registration Outside The United States And Canada................1 Mercury Marine Two Years Limited Warranty (Europe)..................2 Mercury Marine One Year Limited Warranty (Confederation of Independent States, Middle-East, Africa).... 3 3 Year Limited Warranty Against Corrosion......................5 Warranty Coverage And Exclusions........................6 General Information Boater's Responsibilities............................
  • Page 3 TABLE OF CONTENTS Engine Over-Speed Limiter..........................23 Power Trim And Tilt.............................. 23 Manual Tilt System............................... 25 Throttle Grip Friction Adjustment - Tiller Handle Models..................27 Steering Friction Adjustment - Tiller Handle Models.................... 27 Replaceable Jet Drive Shear Key......................... 28 Operation Pre-Starting Check List............................
  • Page 4 Engine Runs Erratically............................54 Engine Over-Speed (Excessive RPM)......................... 54 Performance Loss..............................55 Battery Will Not Hold Charge..........................55 Owner Service Assistance Local Repair Service............................56 Service Away From Home............................ 56 Parts And Accessories Inquiries........................... 56 Service Assistance............................... 56 Mercury Marine Service Offices........................... 56...

  • Page 5: 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 6: Mercury Marine Two Years Limited Warranty (Europe)

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 7: Mercury Marine One Year Limited Warranty (Confederation Of Independent States, Middle-East, Africa)

    No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine.
  • Page 8 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related laborand material, and any other expenses associated with that service.

  • Page 9: Year Limited Warranty Against Corrosion

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 10: Warranty Coverage And Exclusions

    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 11 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 12: 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.

  • Page 13: Outboard Remote Control Models

    GENERAL INFORMATION U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY ob00306 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 Avoid serious injury or death from a sudden unexpected acceleration when starting your engine.

  • 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: Stopping The Boat In An Emergency

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

  • Page 16: Exhaust Emissions

    GENERAL INFORMATION ob00314 The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.

  • Page 17: 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. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.

  • Page 18: Recording Serial Number

    GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by 1) The U.S. Coast Guard Auxiliary, 2) The Power Squadron, 3) The Red Cross and 4) any state boating law enforcement agency.

  • Page 19: Jet 40 Specifications

    R P M ob01434 Serial number Year manufactured Model year Certified Europe Insignia (as applicable) Model designation Jet 40 Specifications Models Jet Power Engine Horsepower Full Throttle RPM Range 5000 - 5500 RPM Idle Speed in Forward Gear 650 ± 700 RPM...

  • Page 20: Component Identification

    GENERAL INFORMATION Component Identification ob01435 Top Cowl Reverse gate Tilt lock lever Water outlet nozzle Transom bracket Driveshaft housing Jet drive housing Water pump indicator hole Water intake housing Bottom cowl...

  • Page 21: Installation

    INSTALLATION Installing Outboard WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance.

  • Page 22: 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. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device.

  • Page 23: Fuel And Oil

    IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil. Mercury or Quicksilver Premium TC-W3 2-Cycle oil is recommended for this engine. 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.

  • Page 24: Filling Oil Injection System

    Check oil level using the sight gauge in front of the outboard. Remove the fill cap and fill tank with oil. Capacity Fluid Type Oil tank 3.2 liters (96 fl. oz.) Mercury or Quicksilver Premium 2-cycle TC-W3 outboard oil ob01436 Reinstall fill cap and tighten securely. Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion.

  • Page 25: 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. ob00329 Control handle - forward, neutral, reverse.
  • Page 26 FEATURES AND CONTROLS ob01437 WARNING SYSTEM OPERATION The warning horn will emit a continuous beep. This will alert the operator and help identify the following listed situations. Warning System Function Sound Description Engine Over Temperature Continuous Engine Over Heat Low Oil Level Continuous Low Oil Level ENGINE OVERHEAT...

  • Page 27: Engine Over-Speed Limiter

    FEATURES AND CONTROLS 3103 Engine Over-Speed Limiter The outboard is equipped with an engine over-speed limiter which limits the engine maximum RPM. This will protect the engine from mechanical damage. Some causes of engine over-speed are as follows: • Outboard mounted too high on the transom. •...
  • Page 28 FEATURES AND CONTROLS POWER TRIM OPERATION The power trim and tilt feature of the outboard is convenient for drifting and when operating at low throttle speed in very shallow water. When under power, do not trim out the outboard in an effort to gain speed as is done with a conventional propeller driven boat.

  • Page 29: Manual Tilt System

    FEATURES AND CONTROLS ob00666 Auxiliary tilt switch Manual Tilt System Models without power trim are equipped with a tilt assist system that allows the operator to easily tilt and lock the outboard at any tilt position from full down to full up. This tilt system is designed to be adjusted when the outboard is idling in neutral or with the engine turned off.
  • Page 30 FEATURES AND CONTROLS ob01440 The tilt pin should be adjusted so the outboard is positioned to run perpendicular to the water when the boat is running at full speed. This allows the boat to be driven parallel to the water. Arrange passengers and load in the boat so the weight is distributed evenly.

  • Page 31: Throttle Grip Friction Adjustment - Tiller Handle Models

    FEATURES AND CONTROLS Throttle Grip Friction Adjustment - Tiller Handle Models Turn the wing nut to set and maintain the throttle at desired speed. ob01441 Steering Friction Adjustment - Tiller Handle Models WARNING Avoid possible serious injury or death from loss of boat control. Maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released.

  • Page 32: 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. Refer to Maintenance - Impeller Removal and Installation.

  • Page 33: Operation

    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 34: How The Jet Drive Operates

    OPERATION When boating through shallow water areas, choose a course of travel that avoids sharp rocks and other underwater obstacles that could damage the boat. Running the boat through these areas on full plane may be helpful as the boat will be riding higher in the water. If the boat gets stuck on the bottom, immediately stop the engine and move the boat to deeper water.

  • Page 35: Steering The Boat

    OPERATION WARNING Using the emergency stopping capability of the jet drive will slow down the boat in an emergency. However, sudden stopping may cause the occupants in the boat to be thrown forward or even out of the boat. This action may result in serious injury or death.

  • Page 36: Clearing A Lodged Impeller

    OPERATION Clearing A Lodged Impeller WARNING If the flywheel is rotated to free a lodged impeller, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury, always turn the ignition key or lanyard stop switch to the "OFF"...
  • Page 37 OPERATION ob00348 Connect the fuel line to the outboard. ob01445 Squeeze the fuel line primer bulb several times until it feels firm. ob00349 NOTE: The engine will not start unless the lanyard is set to the "RUN" position. Set the lanyard stop switch to the "RUN" position. Refer to General Information - Lanyard Stop Switch. ob00350 Shift outboard to neutral (N) position.
  • Page 38 OPERATION ob00352 Tiller handle models - Align the throttle grip pointer to the "START" position. ob01677 Remote control models - If engine is cold, advance the fast idle speed lever of throttle only feature to an approximate halfway setting. After engine start up, immediately adjust neutral fast idle setting so engine speed drops below 2000 RPM.

  • Page 39: 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. Have the outboard checked by your dealer. Operating the engine while overheated may cause serious engine damage.

  • Page 40: Emergency Starting

    OPERATION Emergency Starting If the starter system fails, use the spare starter rope (provided) and follow procedure. Remove flywheel cover. ob01448 WARNING When using emergency starter rope to start engine, the start in gear protection device is inoperative. Make sure to set the outboard gear shift into neutral to prevent outboard from starting in gear.
  • Page 41 OPERATION WARNING To prevent getting an electrical shock, do not touch any ignition component, wiring, or spark plug wire when starting or running the engine. WARNING The exposed moving flywheel can cause serious injury. Keep your hands, hair, clothing, tools, and other objects away from engine when starting or running the engine.

  • Page 42: Maintenance

    SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 43: Inspection And Maintenance Schedule

    Inspect battery. See Battery Inspection. • Remote control models - Check control cable adjustments. • Remove engine deposits with Quicksilver or Mercury Precision Power Tune Engine Cleaner. • Check tightness of bolts, nuts, and other fasteners. EVERY 300 HOURS OF USE OR THREE YEARS •...

  • Page 44: Top Cowl Removal And Installation

    MAINTENANCE ob01650 Plug and gasket Hose coupling Attach a water hose to the hose coupling. Slowly turn on water. Start the engine and run it at idle speed only. IMPORTANT: Do not run engine above idle when flushing. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at all times.

  • Page 45: Battery Inspection

    MAINTENANCE ob01652 INSTALLATION Engage the front hook and push cowl back over the cowl seal. Push cowl down and move the rear latch lever up to lock. 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 46: Exterior Care

    MAINTENANCE IMPORTANT: Visually inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage.

  • Page 47: Fuse Replacement

    MAINTENANCE 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. First torque special washer head bolt, then torque locknut to specifications.

  • Page 48: Spark Plug Inspection And Replacement

    MAINTENANCE Spark Plug Inspection and Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors under the engine cowl. To avoid damaging spark plug boots, do not use any sharp object or metal tool such as pliers, screwdriver, etc.

  • Page 49: Worn/Dull Impeller

    MAINTENANCE ob01657 Exhaust fins 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 50: Impeller Removal And Installation

    MAINTENANCE As the blades wear, shims located in the stack outside of the impeller can be transferred behind the impeller. This will move the impeller further down into the tapered liner to reduce the clearance. ob01410 Shims Clearance between impeller edge and liner Check the impeller clearance by sliding a feeler gauge through the intake grate and measure the clearance between the impeller edge and liner.
  • Page 51 MAINTENANCE ob00375 Remove the water intake housing that is fastened with six screws. ob01411 Straighten the bent tabs on the impeller nut retainer and remove the impeller nut. ob01412 Tabs Impeller nut Pull impeller straight off the shaft. If the impeller is tight, use a hammer and block of wood to rotate the impeller clockwise on the shaft until the keyway is directly above the flat on the shaft.
  • Page 52 MAINTENANCE ob01413 Plastic sleeve Shims Impeller Nut retainer Shear key Impeller nut Turn the nut tight on the shaft to remove any play between the impeller and shaft. If the tabs on the retainer do not line up with the flats on the nut, remove the nut and turn the retainer over and re-tighten the nut again. Temporarily reinstall the water intake housing in order to check for impeller clearance.
  • Page 53 Tabs Impeller nut NOTE: If the outboard is used in salt water, apply Quicksilver or Mercury Precision Anti-Corrosion Grease around the entire mounting flange on the water intake housing and also to the threads on the six mounting bolts. Reinstall the water intake housing with six bolts. Check clearance around the impeller to ensure the water intake housing is centered and not rubbing against the liner.

  • Page 54: Lubrication Points

    Some discoloration of the grease is normal during the break-in period on a new set of seals. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C Marine Lubricant with Teflon or Special Lubricant 101.

  • Page 55: Checking Power Trim Fluid

    MAINTENANCE ob01659 • Tiller handle - Lubricate through fitting. ob01660 • Steering Cable - Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked.

  • Page 56: Submerged Outboard

    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 57: Storage

    • With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel line. When engine begins to stall, quickly spray Quicksilver or Mercury Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel.

  • Page 58: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) POSSIBLE CAUSES • Remote control models - Blown 20 Amp 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 59: Performance Loss

    TROUBLESHOOTING • Cavitation of the impeller due to rough water or obstruction in the boat hull. • Blockage of the water intake. Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged impeller. • Incorrect engine timing, adjustments, or setup. •...

  • Page 60: Owner Service Assistance

    Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your outboard product, contact your dealer or any authorized Mercury Marine dealership. If additional assistance is required, take these steps.
  • Page 61 Telephone (954) 744-3513 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...

Table of Contents