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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
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Table of Contents
Related Manuals for Mercury 140
Summary of Contents for Mercury 140
- 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.
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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 Features and Controls Remote Control Features............................. 25 Warning System - Models with Carburetors......................25 Warning System - Models with Electronic Fuel Injection (EFI)................27 Power Trim and Tilt.............................. 29 Operation Pre-Starting Check List............................32 Operating In Freezing Temperatures........................32 Operating In Salt Water Or Polluted Water......................
- Page 4 Engine Will Not Start............................57 Engine Runs Erratically............................57 Performance Loss..............................57 Battery Will Not Hold Charge..........................58 Owner Service Assistance Local Repair Service............................59 Service Away From Home............................ 59 Parts And Accessories Inquiries........................... 59 Service Assistance............................... 59 Mercury Marine Service Offices........................... 59...
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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.
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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.
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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: 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 14: Lanyard Stop Switch
GENERAL INFORMATION WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. ob00655 Self-locking nuts 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. -
Page 15: Protecting People In The Water
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: Passenger Safety Message - Pontoon Boats And Deck Boats
GENERAL INFORMATION Passenger Safety Message - Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of boat. -
Page 17: 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 18: Exhaust Emissions
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 19: 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 20: 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) your state boating law enforcement agency. - Page 21 GENERAL INFORMATION Models Kilowatts Full Throttle RPM Range All Models except 200 EFI 5000-5600 RPM 200 EFI Models 5000-5800 RPM Idle Speed in Forward Gear 600-700 RPM Number of Cylinders Piston Displacement 2507 cc (153 cu. in.) Cylinder Bore 88.9 mm (3.500 in.) Stroke 67.3 mm (2.650 in.) Recommended Spark Plug...
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Page 22: Component Identification
GENERAL INFORMATION Component Identification 3403 Top cowl Auxiliary tilt switch Bottom cowl Transom brackets Water pump indicator hole Gearcase Driveshaft housing Cooling water intake holes Anti-ventilation plate... -
Page 23: 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 24: 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 25: 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 26: 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 27: Avoiding Fuel Flow Restriction
FUEL AND OIL After the break-in fuel mixture is used up, it is no longer necessary to add oil with the gasoline. NOTE: At the end of the break-in period, visually check to see if the oil level in the oil injection tank has dropped. Oil usage indicates the oil injection system is functioning correctly. -
Page 28: Filling Fuel Tank
FUEL AND OIL ob01076 Fill cap - EFI models Fill cap - Carburetor models 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. Fill fuel tanks outdoors away from heat, sparks, and open flames. -
Page 29: 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 30 FEATURES AND CONTROLS Warning System Function Sound Description Engine Over Temperature Continuous Engine Overheat Low Oil Level Intermittent Low Oil Level When the ignition key is initially turned on, the warning horn will sound for a moment as a test to show the system is working.
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Page 31: Warning System - Models With Electronic Fuel Injection (Efi)
FEATURES AND CONTROLS ob01077 Warning System - Models with Electronic Fuel Injection (EFI) 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 32 FEATURES AND CONTROLS Warning Horn Function Sound Description Cooling System Problem Continuous Engine Guardian System is activated. Power limit will vary with level of overheat. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.
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Page 33: Power Trim And Tilt
FEATURES AND CONTROLS 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, battery voltage, fuel consumption and engine operating hours. - Page 34 FEATURES AND CONTROLS Consider the following lists carefully. 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. •...
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Page 35: Auxiliary Tilt Switch
FEATURES AND CONTROLS NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. Turn out the manual tilt release valve 3 turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. -
Page 36: 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 37: Setting Trim Angle While Running Engine At Idle Speed
OPERATION Setting Trim Angle While Running Engine at Idle Speed The exhaust relief hole on the outboard may become submerged if the outboard is trimmed full-in while running at idle speed. This will cause exhaust restriction, rough idle, excessive smoke, and fouled spark plugs. If this condition exists, trim the outboard up until the exhaust relief hole is out of the water. - Page 38 OPERATION 3405 Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. ob00348 IMPORTANT: To prevent engine flooding, do not squeeze the primer bulb after engine has warmed up. Squeeze the fuel line primer bulb several times until it feels firm. ob00349 Set the lanyard stop switch to RUN position.
- Page 39 OPERATION ob00353 Fully closed position Maximum fast idle speed position • EFI Engines - Turn ignition key to the "START" position. If engine fails to start in ten seconds, return key to on position, wait 30 seconds and try again. ob00354 •...
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Page 40: Gear Shifting
OPERATION Gear Shifting IMPORTANT: Observe the following: • Never shift outboard into gear unless engine speed is at idle. • Do not shift outboard into reverse when the engine is not running. • Your outboard has three gear shift positions to provide operation. Forward (F), Neutral (N) and Reverse (R). •... - Page 41 OPERATION ob00351 Turn the ignition key to "ON" position. ob00364 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 OPERATION Pull the starter rope to start the engine.
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Page 43: 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 44: Inspection And Maintenance Schedule
MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. • Check outboard for tightness on transom. • Check steering system for binding or loose components. •... -
Page 45: Top Cowl Removal And Installation
MAINTENANCE ob01084 Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes. ob01085 Top Cowl Removal And Installation REMOVAL Pull out the front cowl latch. ob01086 Lift up the rear cowl latch. Remove the top cowl. ob01087 INSTALLATION Lower top cowl into position over engine. -
Page 46: Fuel System
MAINTENANCE Fuel System 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 47: Steering Link Rod Fasteners
MAINTENANCE ob01089 Remove and replace filter as follows: Turn ignition key switch to "OFF" position. Disconnect wire at bottom of filter. Remove filter by turning the filter clockwise. Tip the filter to drain fluid in a suitable container. Lubricate the sealing ring on the filter with oil. Thread on the filter and tighten securely by hand. Reconnect the wire to the filter. -
Page 48: Fuse Replacement
MAINTENANCE ob00676 Special washer head bolt (10-849838) Flat washer (2) Nylon insert locknut (11-826709113) Nylon insert locknut (11-826709113) Description lb. in. lb. ft. Special washer head bolt Nylon insert locknut "d" Nylon insert locknut "c" Tighten until seats, then back off 1/4 turn Assemble steering link rod to steering cable with two flat washers and self-locking nylon insert locknut. - Page 49 MAINTENANCE 3394 Good fuse Upper voltage regulator - 30 AMP fuse Blown fuse Accessories and starting circuit - 20 AMP fuse Lower voltage regulator - 30 AMP fuse MODELS WITH ELECTRONIC FUEL INJECTION (EFI) IMPORTANT: Always carry spare 5 and 20 AMP fuses. The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring.
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Page 50: Corrosion Control Anode
MAINTENANCE 3395 Good fuse Blown fuse SmartCraft data bus circuit - 5 AMP fuse Accessories - 20 AMP fuse Ignition coil circuit - 20 AMP fuse Electric fuel pump/ECM driver power/oil pump circuit - 20 AMP fuse Corrosion Control Anode Your outboard has corrosion control anodes at different locations. -
Page 51: Propeller Replacement
MAINTENANCE Turn off the engine before servicing the battery. Add water as necessary to keep the battery full. Make sure the battery is secure against movement. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. - Page 52 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.
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Page 53: Spark Plug Inspection And Replacement
MAINTENANCE ob00421 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Rear thrust hub Forward thrust hub Place a block of wood between gearcase and propeller and torque propeller nut to specifications. Description lb. in. lb. ft. Propeller nut 10. Secure propeller nut by bending three of the tabs into the thrust hub grooves. ob00422 Spark Plug Inspection and Replacement WARNING... -
Page 54: Lubrication Points
• Trim Ball Ends - Turn the ball ends to work the lubricant into the ball sockets. ob01093 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 55 MAINTENANCE Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. • Alternator Belt Tensioner Pivot Shaft (EFI Models) - Lubricate through fitting. ob01094 • Swivel Bracket - Lubricate through fitting. • Tilt Support Lever - Lubricate through fitting.
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Page 56: 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 57 MAINTENANCE Examine the drained gearcase lubricant for metal particles. A small amount of metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. DRAINING GEARCASE Place outboard in a vertical operating position.
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Page 58: Submerged Outboard
MAINTENANCE Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine. -
Page 59: Storage
With engine running at fast idle, stop the fuel flow by kinking the remote fuel line and run engine until it stops. This will drain the fuel system. When engine begins to stall, quickly spray Quicksilver or Mercury Precision Parts Storage Seal into carburetors until engine stops from lack of fuel. -
Page 60: Gearcase
STORAGE Gearcase • Drain and refill the gearcase lubricant (refer to Maintenance - Gearcase Lubrication). Positioning Outboard For Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. 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. -
Page 61: Starter Motor Will Not Crank The Engine
TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20 Amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •... -
Page 62: Battery Will Not Hold Charge
TROUBLESHOOTING • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES •... -
Page 63: Local Repair Service
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 64: Owner Service Assistance
OWNER SERVICE ASSISTANCE Australia, Pacific Telephone (61) (3) 9791-5822 Mercury Marine Australia 132-140 Frankston Road Dandenong, Victoria 3164 (61) (3) 9793-5880 Australia Europe, Middle East, Africa Telephone (32) (87) 32 • 32 • 11 Marine Power - Europe, Inc. Parc Industriel de Petit-Rechain B-4800 Verviers, (32) (87) 31 •...