1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Outboard Motor
  5. 40 Sea Pro
  6. User manual

Mercury 40 Sea Pro User Manual

Mercury marine
Hide thumbs
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

Related Manuals for Mercury 40 Sea Pro

Summary of Contents for Mercury 40 Sea Pro

  • Page 1: Welcome Aboard

    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 3: 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 4 TABLE OF CONTENTS Filling Fuel Tank..............................26 FEATURES & CONTROLS Remote Control Features............................. 27 Warning System - Electric Start Models....................... 27 Warning Horn System - Manual Start Models...................... 28 Engine Over-Speed Limiter..........................29 Manual Tilt System............................... 30 Power Trim And Tilt (if equipped)......................... 36 Throttle Grip Friction Adjustment - Tiller Handle Models..................
  • Page 5 Engine Will Not Start............................73 Engine Runs Erratically............................73 Performance Loss..............................73 Battery Will Not Hold Charge..........................74 OWNER SERVICE ASSISTANCE Local Repair Service............................75 Service Away From Home............................ 75 Parts And Accessories Inquiries........................... 75 Service Assistance............................... 75 Mercury Marine Service Offices........................... 75...

  • Page 6: 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 7: 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 8: 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 9 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 10: 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 11: 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 12 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 13: 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 14: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi-Performance Boat Operation booklet (part number 90-849250--1) from your dealer, distributor, or Mercury Marine. ob00307 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 15: Lanyard Stop Switch

    GENERAL INFORMATION 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 (non-locking) as they will work loose and vibrate off, freeing the link rod to disengage. 3065 Self-locking nuts Lanyard Stop Switch...

  • Page 16: Protecting People In The Water

    GENERAL INFORMATION WARNING Should the operator fall out of the boat, the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately. Always properly connect both ends of the stop switch lanyard to the stop switch and the operator.

  • Page 17: Wave And Wake Jumping

    GENERAL INFORMATION BOATS HAVING AN OPEN FRONT DECK No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence or enclosure. 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.

  • Page 18: Impact With Underwater Hazards

    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 19: Safety Instructions For Hand Tilled Outboards

    GENERAL INFORMATION • A rapid reduction in speed. This will cause occupants to be thrown forward, or even out of the boat. • Impact damage to the outboard and/or boat. Keep in mind, the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed.

  • Page 20: Selecting Accessories For Your Outboard

    Running the boat with the trim angle of the bow too high. Running the boat with no forward hatches open. Selecting Accessories For Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers. WARNING Check with your dealer before installation of accessories.

  • Page 21: Safe Boating Suggestions

    GENERAL INFORMATION Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories. Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions.

  • Page 22: 40 Sea Pro/Marathon - 30/40 Hp Specifications

    XXXXXXXX XXXX XXXX 3066 Serial number Year manufactured Model year Certified Europe Insignia (as applicable) Model designation 40 Sea Pro/Marathon - 30/40 HP Specifications Models Horsepower Kilowatts 22.4 29.8 Full Throttle RPM Range - 4500-5500 RPM 5000-5500 RPM Pleasure Models...

  • Page 23: Component Identification

    GENERAL INFORMATION Component Identification 3067 Top cowl Secondary cooling water intake Water pump indicator hole Shallow water drive lever (non-power trim) Auxiliary tilt switch Shift handle Driveshaft housing Throttle friction adjustment knob Anti-ventilation plate Lanyard stop switch Trim tab Steering friction adjustment lever (tiller handle models) Gearcase Tilt support pin...

  • Page 24: 40 Seapro/Marathon Component Identification

    GENERAL INFORMATION 40 SeaPro/Marathon Component Identification 3920 Trim tab Transom bracket Anti-ventilation plate Primary cooling water intake Driveshaft housing Gearcase Bottom cowl Secondary cooling water intake Water pump indicator hole Tilt lever - gas assisted type tilt system Top cowl Primer Shift handle Starter rope...

  • Page 25: Installation

    MODELS WITH TRANSOM BRACKET CLAMP SCREWS The outboard must be secured to the transom one of two ways: either with clamp screws and the two mounting bolts, washers and locknuts provided, or with clamp screws and optional Quicksilver or Mercury Precision Parts Outboard Mounting Kit.

  • Page 26: 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 27: Transporting

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways and trailer bouncing.
  • Page 28 TRANSPORTING Install tether cap over the fuel line connector stem. This will protect the connector stem from being accidently pushed-in, thus, allowing fuel or vapor to escape. ob00326 Connector stem Tether cap...

  • Page 29: Fuel & 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 30: Mixing Fuel And Oil

    FUEL & OIL GASOLINE/OIL MIXING RATIO CHART Gas/Oil Ratio 3.8 liters (1 gal.) gas 11.5 liters (3 gal.) gas 23 liters (6 gal.) gas 50:1 (2%) 89 ml (3 fl. oz.) oil 237 ml (8 fl. oz.) oil 473 ml (16 fl. oz.) oil MODELS WITHOUT OIL INJECTION Use a 25:1 (4%) gasoline/oil mixture in the first tank of fuel.

  • Page 31: Filling Fuel Tank

    Fluid Type Oil tank 1.5 liters (50.5 fl. oz.) Mercury or Quicksilver Premium TC-W3 2-cycle oil Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks.

  • Page 32: 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. ob00329 Control handle - forward, neutral, reverse.

  • Page 33: Warning Horn System - Manual Start Models

    FEATURES & CONTROLS 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 34: Engine Over-Speed Limiter

    FEATURES & CONTROLS 3104 ENGINE OVERHEAT If the engine overheats, the warning horn will sound and the warning system will automatically limit the engine speed to 2500 RPM. 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.

  • Page 35: Manual Tilt System

    FEATURES & CONTROLS Manual Tilt System TILT LOCK LEVER The tilt lock lever is used to engage the reverse lock mechanism, and prevent the outboard from lifting out of the water when operating in reverse gear due to reverse propeller thrust. The tilt lock lever can be placed in two positions as follows.

  • Page 36: Shallow Water Operation

    FEATURES & CONTROLS ob00615 Release position Lock position Tilt support pin Lowering To Run Position Raise outboard slightly and pull out the tilt support pin. Lower the outboard. Move the tilt lock lever down to the lock position. SHALLOW WATER OPERATION The shallow water drive feature on the outboard allows you to position the outboard at a higher tilt angle to prevent hitting bottom.
  • Page 37 FEATURES & CONTROLS ob00616 Release position Knob Lock position Shallow water drive bracket Take hold of the top cowl grip and raise outboard to enable the shallow water drive bracket to swing down. Lower the outboard to rest on the shallow water drive bracket. Move the tilt lock lever down to the lock position.
  • Page 38 FEATURES & CONTROLS ob00613 Too much angle (stern down - bow up) Not enough angle (stern up - bow down) Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard. Adjusting the outboard close to the boat transom can: •...
  • Page 39 FEATURES & CONTROLS WARNING Before operating, the outboard must be locked in its lock/run position. Failure to lock the outboard in its lock/ run position could result in the outboard tilting up out of the water during deceleration or while operating in reverse, resulting in possible loss of boat control.
  • Page 40 FEATURES & CONTROLS ob00611 Tilt support pin Operating Angle Adjustment The transom brackets have five holes for adjusting the operating angle (forward stop movement) of the outboard. Tilt stops are installed for adjustment in the first hole. Use tilt pin provided for adjustments in the remaining four holes.

  • Page 41: Power Trim And Tilt (If Equipped)

    FEATURES & CONTROLS ob00613 Too much angle (bow up) - adjust in. Angle adjusted properly (bow slightly up). Not enough angle (bow down) - adjust out. 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 42: Power Trim Operation

    FEATURES & CONTROLS ob00663 Trim switch Trim range of travel Tilt range of travel 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.
  • Page 43 FEATURES & CONTROLS WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle.

  • Page 44: Throttle Grip Friction Adjustment - Tiller Handle Models

    FEATURES & CONTROLS ob00666 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. Reduce engine speed below 2000 RPM. Tilt outboard up. Make sure all the water intake holes stay submerged at all times. Operate the engine at slow speed only.

  • Page 45: Trim Tab Adjustment

    FEATURES & CONTROLS 3073 Tighten friction Loosen friction REMOTE STEERING MODELS Steering Friction Adjustment - Adjust this screw to achieve the desired steering friction (drag) on the steering wheel. Turn screw clockwise to tighten friction or turn counterclockwise to loosen friction. ob00623 Loosen friction Tighten friction...
  • Page 46 FEATURES & CONTROLS MODELS WITH POWER TRIM Operate your boat at normal cruising speed, trimmed to desired position. Turn your boat left and right and note the direction the boat turns more easily. 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.

  • Page 47: Operation

    Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

  • Page 48: 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 49 OPERATION ob00350 Shift outboard to neutral (N) position. ob00351 Models without power trim - Position the tilt lock lever down to the lock position. ob00625 WARNING Models without power trim - Before operating, the outboard must be locked in its tilt position. Failure to lock the outboard in its tilt position could result in the outboard lifting out of the water when operating in reverse, resulting in possible loss of boat control.

  • Page 50: Starting The Engine - Tiller Handle Models And Manual Start Remote Control Models

    OPERATION ob00354 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. 11.
  • Page 51 OPERATION ob00348 Connect the fuel line to the outboard. 3074 Squeeze the fuel line primer bulb several times until it feels firm. ob00349 Set the lanyard stop switch to "RUN" position. Refer to General Information - Lanyard Stop Switch. ob00350 Shift outboard to neutral (N) position.
  • Page 52 OPERATION ob00625 ob00333 Reverse/tilt position Lock/run position Tiller handle models - Move throttle grip to "START" position. 0%100 START START 3075 Remote control models - Move on/off switch to the on position. 3026 NOTE: Manual starting models - For initial start of a new engine or first start after a prolonged storage, primer lines may have air in them.
  • Page 53 OPERATION 3076 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, re-prime until engine is running. 3072 11. Electric starting models - Turn ignition key to the "START" position and start the engine. If engine is cold, push in on key to choke engine.

  • Page 54: Gear Shifting

    OPERATION Gear Shifting IMPORTANT: Never shift outboard into gear unless engine speed is at idle. Do not shift outboard into reverse when the engine is not running. • The outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R). 3108 ob00557 •...

  • Page 55: Emergency Starting - Electric Start Models

    OPERATION ob00361 Emergency Starting - Electric Start Models If the starter system fails, use the spare starter rope (provided) and follow procedure. 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 56 OPERATION 3097 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 57: 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 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 58 OPERATION 3085 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 59: 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 60: Inspection And Maintenance Schedule

    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 61: Top Cowl Removal And Installation

    MAINTENANCE ob01604 Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water. ob00570 Start the engine and run it at idle speed in neutral shift position. IMPORTANT: Do not run engine above idle when flushing.

  • Page 62: Battery Inspection

    MAINTENANCE ob00369 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 63 MAINTENANCE 3933 ob01406 Cover O-ring Filter element Sight bowl Installation Push the filter element (with open end toward cover) into the cover. Place the O-ring seal into the sight bowl and screw the sight bowl hand tight into the cover. IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter.
  • Page 64 MAINTENANCE 3933 Cover O-ring seal Filter Sight bowl Wash sight bow and filter in cleaning solvent. 3806 Carburetor Fuel Bowl WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and do not smoke or allow open flames or sparks in the area while servicing any part of the fuel system.

  • Page 65: Carburetor Adjustments

    MAINTENANCE CARBURETOR ADJUSTMENTS Slow Speed Mixture Adjustment Before starting engine, turn the slow speed mixture screw in until it is lightly seated then back it out 1-1/4 turns. 3951 With boat tied securely to dock, start engine and allow it to warm up. Shift the outboard into forward gear while maintaining idle speed.

  • Page 66: Exterior Care

    MAINTENANCE High Speed Mixture Adjustment The carburetor is equipped with a standard size high speed fixed jet that is replaceable for operation at higher elevations. See an authorized dealer. Exterior Care Your outboard is protected with a durable baked enamel finish. Clean and wax often using marine cleaners and waxes.

  • Page 67: Fuse Replacement - Electric Start Models

    MAINTENANCE 3086 Special washer head bolt (10-856680) Nylon insert locknut (11-826709113) Spacer Flat washers Nylon insert locknut (11-826709113) Description lb. in. lb. ft. Special washer head bolt Nylon insert locknut "b" Nylon insert locknut "e" Tighten until seats, then back off 1/4 turn Fuse Replacement - Electric Start Models IMPORTANT: Always carry spare SFE 20 AMP fuses.

  • Page 68: Corrosion Control Anode

    MAINTENANCE 3087 Good band Fuse holder Broken band Corrosion Control Anode The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. Each anode requires periodic inspection, especially in salt water which will accelerate the erosion.
  • Page 69 Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon.

  • Page 70: Spark Plug Inspection And Replacement

    MAINTENANCE IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in salt water), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed. Flo-Torq I Drive Hub Propellers - Install forward thrust hub, propeller, propeller nut retainer, and propeller nut onto the shaft.

  • Page 71: Lubrication Points

    Spark plug Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon. • Propeller Shaft - Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.
  • Page 72 MAINTENANCE Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. • Swivel Bracket - Lubricate through fitting. ob00635 • Tilt Tube - Lubricate through fitting. • Co-Pilot Shaft (Tiller Handle Models) - Lubricate through fitting. Move the steering friction lever back and forth while lubricating.

  • Page 73: Checking Power Trim Fluid

    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 74: Gearcase Lubrication

    GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 440 ml (14.9 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE Place outboard in a vertical operating position. Remove vent plug.

  • Page 75: Submerged Outboard

    MAINTENANCE ob00440 Vent hole Fill/drain plug Vent plug Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. IMPORTANT: Replace sealing washers if damaged. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.

  • Page 76: 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 77: Battery Storage

    STORAGE CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard. Battery Storage • Follow the battery manufacturer's instructions for storage and recharging. •...

  • Page 78: 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 79: Battery Will Not Hold Charge

    TROUBLESHOOTING • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES • Battery connections are loose or corroded. • Low electrolyte level in battery. • Worn out or inefficient battery. • Excessive use of electrical accessories.

  • Page 80: 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 81 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...

This manual is also suitable for:

Marathon - 3040 hp504040 seapro40 marathon ... Show all

Table of Contents