Mercury 40 FourStroke Manuals

Manuals and User Guides for Mercury 40 FourStroke. We have 21 Mercury 40 FourStroke manuals available for free PDF download: Service Manual, Maintenance And Installation Manual, Operation And Maintenance Manual, Manual, User Manual, Operator's Manual, Service Bulletin

Mercury 40 FourStroke Service Manual

Mercury 40 FourStroke Service Manual (547 pages)

Brand: Mercury | Category: Outboard Motor | Size: 15 MB

Table of Contents

Important 1 a

6
Important 1 B

16
- Gear Case Lubricant Capacity
  17
- Quicksilver Lubricant/Sealant
  17
- Special Tools
  17
- Specifications
  17
- After each Use
  18
- Before each Use
  18
- Before Periods of Storage
  18
- Every 100 Hours of Use or Once Yearly, Whichever Occurs First
  18
- Every 300 Hours of Use or Three Years 1B-2
  18
- Inspection and Maintenance Schedule
  18
- Flushing the Cooling System
  19
- Fuel System
  19
- Corrosion Control Anode
  20
- Lubrication Points
  21
- 40/50 Hp
  23
- Checking Power Trim Fluid
  23
- Draining Gear Case
  24
- Gear Case Lubrication
  24
- Checking Lubricant Level and Filling Gear Case
  25
- Gear Case
  25
- Protecting External Outboard Components
  25
- Protecting Internal Engine Components 1B-9
  25
- Storage Preparations
  25
- Battery Storage
  26
- Positioning Outboard for Storage
  26
Important 1 C

28
- Conditions Affecting Performance
  29
- Serial Number Location
  29
- Weather
  29
- Boat
  30
- Engine
  31
- Following Complete Submersion
  31
- Salt Water Submersion (Special Instructions)
  31
- Submerged While Running (Special Instructions)
  31
- Propeller Selection
  32
- Submerged Engine (Fresh Water) (Plus Special Instructions)
  32
- Installation
  33
  - Lifting Outboard
    37
  - Steering Link Rod
    37
- Propeller Removal/Installation
  33
- Removal
  33
Electrical 2

49
- Special Tools
  50
- Specifications
  50
- Flywheel and Stator (Electric)
  51
- Flywheel and Stator (Manual)
  52
- Electrical Components 40/50
  53
- Electrical Components 40/50
  54
- Capacitor Charging #1 CDM
  57
- Theory of Operation
  57
- Capacitor Charging #2 & #3 CDM
  58
- Cylinder Trigger Circuit
  59
- Ignition Coil Circuit
  60
- Stop Circuit
  61
- Rev Limiter Circuit
  62
- Capacitor Discharge Module (CDM)
  63
- Flywheel
  63
- Ignition Component Description
  63
- Stator Assembly
  63
- Trigger Coil
  63
- CDM (P/N 827509)
  64
- CDM (P/N 827509) Trouble Shooting Flowchart
  64
- CDM Test Harness 84-825207A2
  64
- Spark Gap Tester P/N 91-850439
  64
- CDM Stop Diode Trouble Shooting
  65
- CDM Trouble Shooting Flowchart
  66
- CDM Trouble Shooting Flowchart
  67
- Direct Voltage Adaptor (DVA) Test
  69
- Ignition Test Procedures
  69
- Resistance Tests
  70
- Flywheel Removal and Installation
  71
- Stator Removal and Installation
  72
- Trigger
  72
- CDM
  73

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Mercury 40 FourStroke Service Manual

Mercury 40 FourStroke Service Manual (599 pages)

Brand: Mercury | Category: Outboard Motor | Size: 16 MB

Table of Contents

Important Information 1

15
- Cleanliness and Care of Outboard Motor
  3
- Page Numbering
  3
- Table of Contents
  15
- Quicksilver Lubricant/Sealant
  16
- Inspection and Maintenance Schedule
  18
- Before each Use
  18
- After each Use
  18
- Every 100 Hours of Use or Once Yearly, Whichever Occurs First
  19
- Every 300 Hours of Use or Three Years
  19
- Before Periods of Storage
  19
- Corrosion Control Anode
  20
- Spark Plug Inspection
  21
- Battery Inspection
  21
- Timing Belt Inspection
  22
- Fuse Replacement - Electric Start Models
  22
- Lubrication Points
  23
- Checking Power Trim Fluid
  24
- Changing Engine Oil
  25
- Oil Changing Procedure
  25
- Changing Oil Filter
  26
- Oil Filling
  26
- Gear Case Lubrication
  27
- 3-1/4 In. (83Mm) Diameter Gear Case
  27
- 4-1/4 In. (108Mm) Diameter Gear Case
  28
- Gear Case
  30
- Protecting Internal Engine Components
  30
- Protecting External Outboard Components
  30
- Storage Preparation
  30
- Fuel System
  30
- Positioning Outboard for Storage
  31
- Battery Storage
  31
Important Information 1

32
- Conditions Affecting Performance
  33
- Weather
  33
- Boat
  34
- Engine
  35
- Following Complete Submersion
  36
- Fresh Water Submersion (Special Instructions)
  36
- Salt Water Submersion (Special Instructions)
  36
- Submerged While Running (Special Instructions)
  36
- Propeller Selection
  37
- Propeller Removal/Installation
  38
- Standard Models
  38
- General Information
  40
- Power Trim Operation
  40
- Power Trim System
  40
- Trim "In" Angle Adjustment
  41
- Compression Check
  43
- Trim Tab Adjustment
  43
- Analysis
  44
- Cylinder Leakage Testing
  44
- Cleaning & Painting Aluminum Propellers & Gear Housings
  45
- Painting Procedures
  45
- Decal Application
  46
- Decal Removal
  46
- Instructions for "Wet" Application
  46
Important Information 1

48
- Installation Specifications
  49
- Selecting Accessories for the Outboard
  49
- Start in Gear Protection
  49
- Lifting Outboard
  50
- Steering Cable
  50
- Steering Cable Seal
  51
- Steering Link Rod
  51
- Installing Outboard - Thumb Screw Models
  52
- Installing Outboard - Non Thumb Screw Models
  53
- Wiring Harness
  54
- Battery Cable Connections
  55
- Dual Outboards
  55
- Single Outboards
  55
- 45-50 Hp - Shift Cable Installation
  56
- Shift and Throttle Cable 45 and 50 Hp Models
  56
- 45-50 Hp - Throttle Cable Installation
  58
- Trim Tab Adjustment
  60
- Trim-In Stop Adjustment - Power Trim Models
  60

Mercury 40 FourStroke Service Manual

Mercury 40 FourStroke Service Manual (584 pages)

Brand: Mercury | Category: Outboard Motor | Size: 18 MB

Table of Contents

Important Information 1

20
- Cleanliness and Care of Outboard Motor
  3
- Table of Contents
  20
- Special Tools
  21
- Mercury/Quicksilver Lubricants and Sealants 1B-2
  21
- Inspection and Maintenance Schedule
  22
  - Before each Use
    22
  - After each Use
    22
  - Every 300 Hours of Use or Three Years
    23
  - Before Periods of Storage
    23
- Flushing the Cooling System
  23
- Steering Link Rod Fasteners
  24
- Corrosion Control Anode
  25
- Spark Plug Inspection and Replacement
  26
- Battery Inspection
  26
- Fuse Replacement - Electric Start Models
  27
- Timing Belt Inspection
  27
- Lubrication Points
  28
- Checking Power Trim Fluid
  29
- Fuel System
  30
  - Fuel Filter
    30
  - Fuel Line Inspection
    30
- Changing Engine Oil
  31
  - Oil Changing Procedure
    31
  - Changing Oil Filter
    32
  - Checking and Adding Engine Oil
    32
- Changing Gear Case Lubricant
  33
  - 3-1/4 In. (83Mm) Diameter Gear Case
    33
  - 4-1/4 In. (108Mm) Diameter Gear Case
    34
- Storage Preparation
  36
  - Fuel System
    36
  - Protecting External Outboard Components
    36
  - Protecting Internal Engine Components
    36
  - Gear Case
    36
  - Positioning Outboard for Storage
    37
  - Battery Storage
    37
Important Information 1

38
- Conditions Affecting Performance
  39
  - Weather
    39
  - Boat
    40
  - Engine
    42
- Serial Number Location
  39
- Following Complete Submersion
  43
  - Submerged While Running
    43
  - Salt Water Submersion
    43
  - Fresh Water Submersion
    43
- Model 30/40 (4-Stroke) Powerhead Views Front View
  44
  - Starboard View
    45
  - Port View
    46
  - Top View
    47
  - Aft View
    48
- Propeller Selection
  49
- Propeller Removal/Installation
  50
  - 3-1/4 In. (83Mm) Diameter Gear Case
    50
  - 4-1/4 In. (108Mm) Diameter Gear Case
    51
- Power Trim System
  52
  - General Information
    52
  - Power Trim Operation
    52
  - Trim "In" Angle Adjustment
    53
- Trim Tab Adjustment
  54
- Compression Check
  55
- Cylinder Leakage Testing
  56
  - Analysis
    56
- Water Pressure Measurement
  57
- Painting Procedures
  58
  - Cleaning & Painting Aluminum Propellers & Gear Housings
    58
- Decal Removal/Application
  59
  - Removal
    59
  - Instructions for "Wet" Application
    59

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Mercury 40 FourStroke Service Manual

Mercury 40 FourStroke Service Manual (332 pages)

Brand: Mercury | Category: Outboard Motor | Size: 8 MB

Table of Contents

Important Information 1 B

10
- Important Information
  4
- General Specifications
  6
- Table of Contents
  10
- Specifications
  11
- Gear Case Lubricant Capacity
  11
- Special Tools
  11
- Quicksilver Lubricant/Sealant
  11
- Every 100 Hours of Use or Once Yearly, Whichever Occurs First
  12
- Every 300 Hours of Use or Three Years 1B-2
  12
- Before Periods of Storage
  12
- After each Use
  12
- Before each Use
  12
- Inspection and Maintenance Schedule
  12
- Lubrication Points
  13
- (S/N-0G589999 & Below)
  13
- (S/N-0G590000 & Above)
  13
- Checking Power Trim Fluid
  15
- Gear Case Lubrication
  16
- Draining Gear Case
  16
- Checking Lubricant Level and Filling Gear Case
  16
- Propeller Replacement
  17
- Removal
  17
- Installation
  17
- Corrosion Control Anode
  18
- Fuel Line and Primer Bulb
  19
- Fuel Tank Filter
  19
- Maintenance
  19
- Fuel Tank
  19
- Flushing the Cooling System
  20
- Storage
  20
- Fuel System
  20
- Protecting External Outboard Components
  21
- Protecting Internal Outboard Components
  21
- Gear Case
  21
- Positioning Outboard for Storage
  21
- Battery Storage
  21
Important Information 1 C

23
- Conditions Affecting Performance
  24
- Serial Number Location
  24
- Weather
  24
- Boat
  25
- Bottom
  25
- Trim
  25
- Trimming Outboard "In" ("Down")
  25
- Trimming Outboard "Out" ("Up")
  25
- Water Absorption
  25
- Weight Distribution
  25
- Cavitation
  26
- Detonation
  26
- Engine
  26
- Following Complete Submersion
  26
- Salt Water Submersion (Special Instructions)
  26
- Submerged While Running (Special Instructions)
  26
- Propeller Selection
  27
- Submerged Engine (Fresh Water) (Plus Special Instructions)
  27
- Propeller Information Chart - 30 HP
  29
- Propeller Information Chart - 40 HP
  30
Important Information 1 D

32

Mercury 40 FourStroke Operation And Maintenance Manual

Mercury 40 FourStroke Operation And Maintenance Manual (100 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 40 FourStroke Operation And Maintenance Manual

Mercury 40 FourStroke Operation And Maintenance Manual (104 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 40 FourStroke Operation And Maintenance Manual

Mercury 40 FourStroke Operation And Maintenance Manual (110 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 40 FourStroke Operation And Maintenance Manual

Mercury 40 FourStroke Operation And Maintenance Manual (97 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

English

3

Mercury 40 FourStroke Operation And Maintenance Manual

Mercury 40 FourStroke Operation And Maintenance Manual (98 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 40 FourStroke Operation And Maintenance Manual

Mercury 40 FourStroke Operation And Maintenance Manual (103 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 40 FourStroke Operation And Maintenance Manual

Mercury 40 FourStroke Operation And Maintenance Manual (99 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 40 FourStroke Operation And Maintenance Manual

Mercury 40 FourStroke Operation And Maintenance Manual (96 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 40 FourStroke Operation And Maintenance Manual

Mercury 40 FourStroke Operation And Maintenance Manual (93 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 40 FourStroke Maintenance And Installation Manual

Mercury 40 FourStroke Maintenance And Installation Manual (120 pages)

Brand: Mercury | Category: Outboard Motor | Size: 5 MB

Table of Contents

Mercury 40 FourStroke Manual

Mercury 40 FourStroke Manual (106 pages)

Brand: Mercury | Category: Outboard Motor | Size: 3 MB

Table of Contents

Mercury 40 FourStroke User Manual

Mercury 40 FourStroke User Manual (81 pages)

Mercury Marine

Brand: Mercury | Category: Outboard Motor | Size: 5 MB

Table of Contents

Mercury 40 FourStroke Operator's Manual

Mercury 40 FourStroke Operator's Manual (75 pages)

Brand: Mercury | Category: Outboard Motor | Size: 4 MB

Table of Contents

Mercury 40 FourStroke Manual

Mercury 40 FourStroke Manual (34 pages)

Brand: Mercury | Category: Outboard Motor | Size: 0 MB

Table of Contents

Mercury 40 FourStroke Manual

Mercury 40 FourStroke Manual (36 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 40 FourStroke Manual

Mercury 40 FourStroke Manual (33 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 40 FourStroke Service Bulletin

Mercury 40 FourStroke Service Bulletin (3 pages)

Brand: Mercury | Category: Water Pump | Size: 0 MB

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