Mercury 40 FourStroke Maintenance And Installation Manual
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Mercury 40 FourStroke Maintenance And 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 Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, GO BOLDLY., Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury...

  • Page 7: Table Of Contents

    Low Permeation Fuel Hose Requirement ............21 EPA Pressurized Portable Fuel Tank Requirements........21 Fuel Demand Valve (FDV) Requirement............21 Mercury Marine's Pressurized Portable Fuel Tank........... 22 Filling Fuel Tank....................23 Engine Oil Recommendations................23 Checking and Adding Engine Oil..............24...
  • Page 8 Features and Controls Remote Control Features................. 26 Warning System....................27 Power Trim and Tilt................... 29 Throttle Grip Friction Adjustment ‑ Tiller Handle Models........32 Steering Friction Adjustment ‑ Tiller Handle Models......... 32 Trim Tab Adjustment..................33 Operation Important Daily Inspection Before Each Use ........... 35 Prestarting Check List..................
  • Page 9 Maintenance Cleaning Care Recommendations..............46 EPA Emissions Regulations................48 Inspection and Maintenance Schedule ............49 Flushing the Cooling System................50 Top Cowl Removal and Installation..............51 Exterior Care..................... 51 Battery Inspection .................... 51 Fuel System...................... 52 Steering Link Rod Fasteners................53 Corrosion Control Anode..................
  • Page 10 Owner Service Assistance Service Assistance................... 77 Ordering Literature.................... 79 Installation Mercury Marine Validated Engine Mounting Hardware........81 Accessories Mounted to the Transom Clamp Bracket........81 Installation Information..................85 Fuel Hose Connection ‑ Remote Control Models..........96 Electrical Connections and Control Cable Installation........97 Propeller Installation..................

  • 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: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 13: Remote Steering Notice

    GENERAL INFORMATION Remote Steering Notice The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.
  • Page 14 GENERAL INFORMATION The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.
  • Page 15 GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle.

  • Page 16: Protecting People In The Water

    GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
  • Page 17 GENERAL INFORMATION Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. 26782 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.

  • Page 18: Wave And Wake Jumping

    GENERAL INFORMATION Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water.
  • Page 19 GENERAL INFORMATION Reduce speed and proceed with caution whenever you drive a boat in shallow water areas or in areas where you suspect underwater obstacles may exist that could be struck by the outboard or the boat bottom. The most significant action you can take to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 20: Exhaust Emissions

    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 21 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 22: 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 23 GENERAL INFORMATION • 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. For more information in the U.S., call the Boat U.S.
  • Page 24 (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 25: Recording Serial Number

    GENERAL INFORMATION • Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00, or 4) there is...
  • Page 26 *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 27: Component Identification

    GENERAL INFORMATION Component Identification 28524 Auxiliary tilt switch Tilt support knob Transom brackets Oil drain plug Primary cooling water intake Gearcase Trim tab Anti‑ventilation plate Driveshaft housing Water pump indicator hole Bottom cowl Top cowl Shift handle Engine stop switch Throttle friction adjustment knob Lanyard stop switch Steering friction adjustment lever (tiller handle models)

  • Page 28: Transportation

    TRANSPORTATION 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.
  • Page 29 TRANSPORTATION AUTO-VENTING TYPE FUEL TANK 1. Disconnect the remote fuel line from tank. This will close the air vent and prevent escape of fuel or vapors from tank. 2. Install tether cap over the fuel line connector stem. This will protect the connector stem from being accidentally pushed‑in, allowing fuel or vapor to escape.

  • Page 30: 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 31: 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 32: 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 33: 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 34: 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 35 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 36: 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 37: 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 38 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 39: 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 40 FEATURES AND CONTROLS Trimming in or down can: • Lower the bow • Result in quicker planing off, especially with a heavy load or a stern heavy boat • Generally improve the ride in choppy water • Increase steering torque or pull to the right (with the normal right hand rotation propeller) •...
  • Page 41 FEATURES AND CONTROLS 3. To disengage the tilt support lever, raise the outboard off the support lever and rotate 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 42: Throttle Grip Friction Adjustment - Tiller Handle Models

    FEATURES AND CONTROLS SHALLOW WATER OPERATION When operating the boat in shallow water, the outboard can be tilted beyond the maximum trim range to prevent hitting bottom. 26803 1. Reduce engine speed below 2000 RPM. 2. Tilt outboard up, keeping the water intake holes submerged at all times. 3.

  • Page 43: Trim Tab Adjustment

    FEATURES AND CONTROLS NOTE: To maintain proper adjustment, the locknut located on top of the steering friction lever pivot shaft can be tightened. Tighten friction Loosen friction Locknut 26811 WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control.
  • Page 44 FEATURES AND CONTROLS If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right, move the trailing edge of trim tab to the right.

  • Page 45: 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 46: Operating In Freezing Temperatures

    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 47: Engine Break-In Procedure

    OPERATION NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 26837 Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage.
  • Page 48 OPERATION 2. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm. 27348 3. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑...
  • Page 49 OPERATION 5. Move the throttle‑only lever to the fully closed position or press the throttle‑only button. 26840 Fully closed position Maximum fast idle speed position 6. Starting a flooded engine ‑ Advance the throttle‑only lever or control handle to the maximum throttle‑only position and continue to crank the engine for starting.

  • Page 50: Starting The Engine - Tiller Handle Models

    OPERATION WARMING UP ENGINE Before beginning operation, allow the engine to warm up at idling speed for three minutes. Starting the Engine ‑ Tiller Handle Models Before starting, read the Prestarting Check List, special operating instructions, and Engine Break‑in Procedure in the Operation section. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
  • Page 51 OPERATION 4. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 5. Shift outboard to neutral ("N") position. 28522 6. Set the throttle grip to start position. 7. Starting a flooded engine ‑ Set the throttle grip to half‑way position. 0%100 0%100 START...

  • Page 52: Gear Shifting

    OPERATION WARNING Rapid acceleration can result in serious injury or death from being thrown within or out of the boat. Decrease engine speed before shifting into gear. 9. Check for a steady stream of water flowing out of the water pump indicator hole.

  • Page 53: Stopping The Engine

    OPERATION • Your outboard has three gear shift positions to provide operation: forward, neutral (out of gear), and reverse. 28523 • Remote control models ‑ When shifting, always stop at the neutral position and allow the engine speed to return to idle. 26779 •...

  • Page 54: Emergency Starting

    OPERATION 2. Tiller handle models ‑ Reduce the engine speed and shift the outboard to neutral position. Push in the engine stop button or turn the ignition key to "OFF" position. 26776 Emergency Starting If the starter system fails, use the spare starter rope (provided) and follow procedure.
  • Page 55 OPERATION 3. Electric start models ‑ Turn the ignition key to "ON" position. 26846 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.

  • Page 56: Cleaning Care Recommendations

    Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. Selecting Replacement Parts For Your Outboard We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. DO NOT USE CAUSTIC CLEANING CHEMICALS IMPORTANT: Do not use caustic cleaning chemicals on the outboard power package.
  • Page 57 Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys.

  • Page 58: Epa Emissions Regulations

    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 59: Inspection And Maintenance Schedule

    MAINTENANCE The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Inspection and Maintenance Schedule DAILY CHECKS • Check the engine oil level • Check the lanyard stop switch •...

  • Page 60: Flushing The Cooling System

    MAINTENANCE • Check the remote control cable adjustment, if equipped—dealer item • Replace the high‑pressure fuel filter, if equipped—dealer item • Replace the accessory drive belt, if equipped—dealer item • Check the power trim fluid level, if equipped—dealer item • Inspect the engine motor mounts—dealer item Flushing the Cooling System Flush the internal water passages of the outboard with fresh water after each...

  • Page 61: 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 62: 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 63: 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 64: 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 65: Propeller Replacement - 87.3 Mm (3-7/16 In.) Diameter Gearcase

    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. This model has an anode installed on each side of the gearcase and one on the bottom of the transom bracket assembly.
  • Page 66 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 the gearcase and propeller to keep the propeller from turning. Remove the propeller nut. 5.
  • Page 67 MAINTENANCE 6. Apply to the propeller shaft Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE. 26902 Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 IMPORTANT: To prevent the propeller hub from corroding and seizing to the...

  • Page 68: Propeller Replacement - 108 Mm (4-1/4 In.) Diameter Gearcase

    MAINTENANCE 9. Place the propeller nut retainer over the pins. Place a block of wood between the gearcase and the propeller and tighten the propeller nut to the specified torque. Description lb‑in. lb‑ft Propeller nut – 10. Align the flat sides of the propeller nut with the tabs on the propeller nut retainer.
  • Page 69 MAINTENANCE 2. Remove the spark plug leads to prevent the 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 keep the propeller from turning. Remove the propeller nut. 5.
  • Page 70 MAINTENANCE 6. Apply to the propeller shaft Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE. 26902 Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 IMPORTANT: To prevent the propeller hub from corroding and seizing to the...
  • Page 71 MAINTENANCE NOTE: We recommend the installation of a Flo‑Torq III drive hub propeller for stainless steel applications. 9. Flo‑Torq III drive hub propellers ‑ Install the forward thrust hub, replaceable drive sleeve, propeller, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. 3223 Propeller nut Propeller nut retainer...

  • Page 72: Spark Plug Inspection And Replacement

    MAINTENANCE Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that 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 73: Fuse Replacement

    MAINTENANCE Fuse Replacement IMPORTANT: Always carry spare fuses. The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. Open the fuse holder and look at the silver colored band inside the fuse.

  • Page 74: Lubrication Points

    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 Lubricants Extreme Grease or 2‑4‑C with PTFE. Tube Ref Description Where Used Part No.
  • Page 75 MAINTENANCE • Swivel bracket ‑ Lubricate through fitting. Tilt support lever Swivel bracket 28466 • 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...

  • Page 76: Checking Power Trim Fluid

    MAINTENANCE • Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. 28468 Fitting Steering cable end 3. Lubricate the following with lightweight oil. • Steering link rod pivot points ‑ Lubricate points. 28471 Checking Power Trim Fluid 1.

  • Page 77: Changing Engine Oil

    MAINTENANCE 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 78 MAINTENANCE 2. Turn the outboard so the drain hole is facing downward. Remove the drain plug and drain the engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. 28531 Drain plug Drain hole CHANGING OIL FILTER 1.

  • Page 79: Gearcase Lubricant

    MAINTENANCE 2. Idle the engine for five minutes and check for leaks. Stop the engine and check the oil level on the dipstick. Add oil if necessary. Oil fill cap 28418 Gearcase Lubricant GEARCASE LUBRICATION - FOR 87.3 MM (3-7/16 IN.) DIAMETER GEARCASE When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant.
  • Page 80 MAINTENANCE Gearcase Lubricant Capacity Gearcase lubricant capacity is approximately 340 ml (11.5 fl oz). Checking Gearcase Lubricant Level and Refilling Gearcase 1. Place the outboard in a vertical operating position. 2. Remove the vent plug. 3. Place the lubricant tube into the fill hole and add lubricant until it appears at the vent hole.
  • Page 81 MAINTENANCE 2. Place a drain pan below the outboard. 3. Remove the vent plugs and fill/drain plug and drain the lubricant. Vent plugs Fill/drain plug 26977 Gearcase Lubricant Capacity Gearcase lubricant capacity is approximately 710 ml (24 fl oz). Checking Lubricant Level and Filling Gearcase 1.

  • Page 82: Submerged Outboard

    MAINTENANCE 6. Remove the lubricant tube and install a cleaned fill/drain plug and sealing washer. 27001 Front vent plug Front vent hole Rear vent hole Rear vent plug Fill/drain plug and sealing washer Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 83: 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 84: 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 85: 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 86: Performance Loss

    TROUBLESHOOTING c. Stuck antisiphon 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). Performance Loss POSSIBLE CAUSES • Engine Guardian System activated.

  • Page 87: 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 88 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 89: Ordering Literature

    Ordering Literature Before ordering literature, have the following information about your power package available: 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:...
  • Page 90 (USA only) P.O. Box 1939 Fond du Lac, WI 54936-1939 OUTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package. Mercury Marine Submit the following...

  • Page 91: 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 92 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 93 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 94 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 95: Installation Information

    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 96 INSTALLATION START IN GEAR PROTECTION 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. The remote control connected to the outboard must be equipped with a start in neutral only protection device.
  • Page 97 INSTALLATION Minimum Transom Opening Dual engines 101.6 cm (40 in.) Engine Centerline Minimum 66 cm (26 in.) LIFTING OUTBOARD Use the lifting eye on the engine. 28510...
  • Page 98 INSTALLATION 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 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes.
  • Page 99 INSTALLATION 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 28421 Flat washer 1.50 in.
  • Page 100 INSTALLATION Use a dial torque wrench to determine transom strength. If the bolt or nut continues to turn without the torque reading on the dial increasing, it is an indication that the transom is yielding. The load area can be increased by using a larger washer or a transom reinforcement plate.
  • Page 101 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 102 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 – apply to the shank of the bolts, not the threads Description lb‑in.
  • Page 103 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 104 INSTALLATION 3. Tighten the nut to the specified torque. 29506 Description lb‑in. lb‑ft 47.5 – STEERING CABLE SEAL 1. Mark tilt tube 6.4 mm (0.25 in.) from end. Install seal components. 2. Thread cap to the mark. 8041 6.4 mm (1/4 in.) Plastic spacer O‑ring seal STEERING LINK ROD FASTENERS...
  • Page 105 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 106: Fuel Hose Connection - Remote Control Models

    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 107: Electrical Connections And Control Cable Installation

    INSTALLATION Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover. 28505 Access cover Route the remote wiring harness through the rubber grommet.
  • Page 108 INSTALLATION Connect the 14‑pin connector to the engine harness and fasten the harness with the retainer. 41014 Remote wiring harness Retainer 14‑pin connector BATTERY CABLE CONNECTIONS Single Outboard Red sleeve ‑ Positive Black sleeve ‑ Negative (–) Cranking battery 15496...
  • Page 109 INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ Positive (+) Black sleeve ‑ Negative (–) Ground cable Cranking battery SHIFT CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control.
  • Page 110 INSTALLATION c. Make a center mark ("c"), midway between marks ("a" and "b"). Align the cable end guide with this center mark when installing cable to the engine. 6098 2. Manually shift the outboard into neutral. The propeller will rotate freely. 3.
  • Page 111 INSTALLATION 6. Adjust the cable barrel so the center mark on the cable is aligned with the end guide when the cable barrel is placed in the barrel receptacle. 28487 Cable end guide Bow tie clip retainer Center mark Cable barrel Barrel latch 7.
  • Page 112 INSTALLATION c. Shift remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer to the cable end guide. Repeat steps a through c. THROTTLE CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control.
  • Page 113 INSTALLATION 5. Fasten the throttle cable to the mounting stud with a flat washer and locknut. Tighten the locknut to the specified torque. 28494 Cable end guide Bow tie clip retainer Flat washer Locknut Cable barrel Description lb‑in. lb‑ft Throttle cable locknut –...

  • Page 114: Propeller Installation

    INSTALLATION 6. Install the access cover with two bolts. Tighten the bolts to the specified torque. 28500 Access cover Description lb‑in. lb‑ft Access cover bolt – Propeller Installation PROPELLER INSTALLATION - 108 MM (4-1/4 IN.) DIAMETER GEARCASE WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
  • Page 115 INSTALLATION 1. Apply to the propeller shaft Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE. 26902 Tube Ref Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 IMPORTANT: To prevent the propeller hub from corroding and seizing to the...
  • Page 116 INSTALLATION NOTE: Stainless steel applications ‑ Installation of a Flo‑Torq III drive hub propeller is recommended. 4. Flo‑Torq III drive hub propellers ‑ Install forward thrust hub, replaceable drive sleeve, propeller, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft. 3223 Propeller nut Propeller nut retainer...
  • Page 117 Place a block of wood between the propeller blade and the anti‑ventilation plate. 1. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE. 26902...
  • Page 118 INSTALLATION 3. 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. Propeller nut Propeller nut retainer Rear thrust hub Replaceable drive sleeve Propeller Forward thrust hub 26904 4.

  • Page 119: Trim Tab Adjustment

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

  • Page 120: 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 fourstroke60 fourstroke

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