Mercury 40 Fourstroke (2014) manual

eng i Declaration of Conformity 30/40/50/60 FourStroke – For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC Name of engine manufacturer: Mercury Marine Technology Suzhou Co., Ltd. Address: No. 200 Suhong Middle Road, Suzhou Industrial Park Town: Suzhou Post Code: 215021 Country: CHINA Na[...]

ii eng Identification of Engines Covered by This Declaration of Conformity Name of engine family Unique engine identification number: starting serial number EC Module H certificate number 30, 40 hp 3 cylinder 1C010000 RCD ‑ H ‑ 2 Rev 4 40, 50, 60 hp 4 cylinder 1C010000 RCD ‑ H ‑ 2 Rev 4 60 hp Formula Race 4 cylinder 1C010000 RCD ‑ H ‑ 2[...]

eng iii Name / function: Mark D. Schwabero, President, Mercury Outboard Date and place of issue: September 04, 2012 Fond du Lac, Wisconsin, USA Welcome You have selected one of the finest outboards available. It incorporates numerous design features to ensure operating ease and durability. With proper care and maintenance, you will enjoy using this[...]

iv eng 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 Information section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, i[...]

eng v WARRANTY INFORMATION Warranty Registration United States and Canada.............................................. 1 Transfer of Warranty United States and Canada................................................ 1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada....................................[...]

vi eng Fuel and Oil Fuel Recommendations.................................................................................... 39 Low Permeation Fuel Hose Requirement ........................................................ 40 EPA Pressurized Portable Fuel Tank Requirements........................................ 40 Fuel Demand Valve (FDV) Requiremen[...]

eng vii Maintenance Outboard Care.................................................................................................. 65 EPA Emissions Regulations............................................................................. 65 Inspection and Maintenance Schedule............................................................. 66 Flushing [...]

viii eng Owner Service Assistance Local Repair Service......................................................................................... 96 Service Away from Home................................................................................. 96 Parts and Accessories Inquiries.................................................................[...]

WARRANTY INFORMATION eng 1 Warranty Registration United States and Canada To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the selling dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, e‑mail, or mail. Upon receipt of this warrant[...]

WARRANTY INFORMATION 2 eng Upon processing the transfer of warranty, Mercury Marine will record the new owner's information. There is no charge for this service. OUTSIDE THE UNITED STATES AND CANADA For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest t[...]

WARRANTY INFORMATION eng 3 CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection pro[...]

WARRANTY INFORMATION 4 eng Corrosion damage caused by stray electrical currents (onshore power connections, nearby boats, submerged metal) is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system, such as the Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolato[...]

WARRANTY INFORMATION eng 5 Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us. Should you have any questions concerning warranty coverage, contact your authorized dealer. They will be pleased to answer any questions that you may have. GENERAL EX[...]

WARRANTY INFORMATION 6 eng 13. Water entering engine through the fuel intake, air intake, or exhaust system or submersion. 14. Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high, or trimmed too far out. 15. Use of fuels and lubrica[...]

WARRANTY INFORMATION eng 7 a. Oil pump and internal parts b. Oil injectors c. Oil meter 5. Exhaust system a. Exhaust manifold b. Exhaust valves 6. Miscellaneous items used in above systems a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting hardware b. Pulleys, belts, and idlers c. Vacuum, temperature, check and time sensit[...]

WARRANTY INFORMATION 8 eng DURATION OF COVERAGE: This limited warranty provides coverage for the components of the emissions control systems of new, 2001 model year and later outboards, sold to retail customers in California for four (4) years from either the date the product is first sold, or first put into service, whichever occurs first, or the [...]

WARRANTY INFORMATION eng 9 Expenses related to haul‑out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of [...]

WARRANTY INFORMATION 10 eng Where a warrantable condition exists, Mercury Marine will repair your outboard engine at no cost to you, including diagnosis, parts, and labor. MANUFACTURER'S WARRANTY COVERAGE: Select emission control parts from model year 2001 and later outboard engines are warranted for four (4) years, or for 250 hours of use, wh[...]

WARRANTY INFORMATION eng 11 42537 Two Stars ‑ Very Low Emission The Two Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emissions standards. Engines meeting these standards have 20% lower emissions than One Star ‑ Low Emission engines. 42538 Three Stars ‑ Ultra[...]

WARRANTY INFORMATION 12 eng Guarantees Under Australian Consumer Law Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or repla[...]

WARRANTY INFORMATION eng 13 How to Obtain Warranty Coverage Under This Limited Warranty The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service th[...]

WARRANTY INFORMATION 14 eng 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. For additional info[...]

WARRANTY INFORMATION eng 15 You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department. Global Warranty Charts Outboard and Jets UNITED [...]

WARRANTY INFORMATION 16 eng Product Standard Limited Warranty Standard Limited Corrosion Warranty OptiMax Jet drive (200 and 250 hp) 1 year 3 years Racing Product (Recreation use only) Standard Limited Warranty Standard Limited Corrosion Warranty OptiMax (250 XS) 2 years 3 years OptiMax (300 XS) 2 years 3 years Verado (350 SCi) 2 years 3 years Outs[...]

WARRANTY INFORMATION eng 17 ASIA WARRANTY CHARTS–OUTBOARD AND JET Product (Recreational only) Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application 2‑Stroke 1 year 3 years Contact the Marine Power Service Center closest to you FourStroke 1 year 3 years OptiMax 1 year 3 years Verado 1 year 3 years Racing Product (R[...]

WARRANTY INFORMATION 18 eng Racing Product (Recreational only) Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application Verado 350 SCi 2 years 3 years Contact the Marine Power Service Center closest to you Outside Europe and CIS For products purchased outside of Europe and CIS regions, contact the distributor in your cou[...]

WARRANTY INFORMATION eng 19 SOUTH AFRICA WARRANTY CHARTS–OUTBOARD AND JET Product (Recreational only) Standard Limited Warranty Standard Limited Corrosion Warranty Commercial Application 2‑Stroke 2 years 3 years Contact the Marine Power Service Center closest to you FourStroke 2 years 3 years OptiMax (including Pro XS) 3 years 3 years Verado (i[...]

GENERAL INFORMATION 20 eng 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. Be sure that at least one additional per[...]

GENERAL INFORMATION eng 21 Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. U.S. COAST GUARD CAP ACITY MAXIMUM HORSEPOWER XXX MAXIM[...]

GENERAL INFORMATION 22 eng 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 (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage. ! WARNING Improper fasten[...]

GENERAL INFORMATION eng 23 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 likeli[...]

GENERAL INFORMATION 24 eng We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (if the operator is accidentally ejected). ! WARNING If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious inj[...]

GENERAL INFORMATION eng 25 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 peopl[...]

GENERAL INFORMATION 26 eng 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. Stay [...]

GENERAL INFORMATION eng 27 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. 26784 The primary concern is th[...]

GENERAL INFORMATION 28 eng Impact with Underwater Hazards 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 which could be struck by the outboard or the boat bottom. The most important thing you can do to help reduce injury or impact damage from strik[...]

GENERAL INFORMATION eng 29 ! WARNING 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 oc[...]

GENERAL INFORMATION 30 eng ! 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 41 127 [...]

GENERAL INFORMATION eng 31 1. Examples of poor ventilation while the boat is stationary: a - Operating the engine when the boat is moored in a confined space b - Mooring close to another boat that has its engine operating 2. Examples of poor ventilation while the boat is moving: a - Operating the boat with the trim angle of the bow too high b - Ope[...]

GENERAL INFORMATION 32 eng Know and obey all nautical rules and laws of the waterways. • 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 th[...]

GENERAL INFORMATION eng 33 Prepare other boat operators. • Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard. Do not overload your boat. • Most boats are rated and certified for maximum load (weight) capacities (refer to your boat&apos[...]

GENERAL INFORMATION 34 eng • 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 treatmen[...]

GENERAL INFORMATION eng 35 Models 40 50 60 Spark plug gap 1.0 mm (0.040 in.) Gear ratio 83 mm (3‑1/4 in.) diameter gearcase 1.83:1 108 mm (4‑1/4 in.) diameter gearcase 2.31:1 Gearcase lubricant capacity 83 mm (3‑1/4 in.) diameter gearcase 340 ml (11.5 fl oz) 108 mm (4‑1/4 in.) diameter gearcase 710 ml (24.0 fl oz) Recommended gasoline Refer[...]

GENERAL INFORMATION 36 eng Component Identification a - Auxiliary tilt switch b - Tilt support knob c - Transom brackets d - Oil drain plug e - Primary cooling water intake f - Gearcase g - Trim tab h - Anti‑ventilation plate i - Driveshaft housing j - Water pump indicator hole k - Bottom cowl l - Top cowl m - Shift handle n - Engine stop switch [...]

TRANSPORTATION eng 37 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 cr[...]

TRANSPORTATION 38 eng 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. a - Connector stem b - Tether cap F a b 26794[...]

FUEL AND OIL eng 39 Fuel Recommendations IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty. FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a majo[...]

FUEL AND OIL 40 eng ! WARNING Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration requires replacement before further engine operation. Because of [...]

FUEL AND OIL eng 41 The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case of a fuel blockage in the valve. a - Fuel demand valve ‑ installed in the fuel hose between the fuel tank and primer bulb b - Manual release c - Vent/water drain holes Mercury Marine's Pressurized Port[...]

FUEL AND OIL 42 eng 1. Open the manual vent screw on top of the fuel cap. 2. Turn the fuel cap until it contacts the tab lock. 3. Press down on the tab lock. Rotate the fuel cap 1/4 turn to relieve the pressure. 4. Press down on the tab lock again and remove the cap. DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK 1. When installing the fue[...]

FUEL AND OIL eng 43 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. Recommended SAE viscosity for engine oil a - Mercury or Quicksilver SAE 25[...]

FUEL AND OIL 44 eng 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. a - Full mark b - Add mark c - Dipstick d - Oil filler cap a b c d 28412[...]

FEATURES AND CONTROLS eng 45 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. a - Control handle – forward, neutral, reverse b - Neutral release lever c - Trim/tilt switch (i[...]

FEATURES AND CONTROLS 46 eng 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. a - H[...]

FEATURES AND CONTROLS eng 47 ENGINE GUARDIAN SYSTEM The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems. Engine Guardian is functional whenever your engine is operating, so you never have to be concerned about whether or not you are protected. The system will respond to a problem by sounding [...]

FEATURES AND CONTROLS 48 eng 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. Moving the outboard further away from the boat transom is call[...]

FEATURES AND CONTROLS eng 49 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) • In excess, can lower the bow of some boats [...]

FEATURES AND CONTROLS 50 eng 3. To disengage the tilt support lever, raise the outboard off the support lever and rotate the lever down. Lower the outboard. a - Tilt support lever b - Knob MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. Turn out the manual tilt release valve thr[...]

FEATURES AND CONTROLS eng 51 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. Operate the engine at slow speed only. If engin[...]

FEATURES AND CONTROLS 52 eng NOTE: To maintain proper adjustment, the locknut located on top of the steering friction lever pivot shaft can be tightened. a - Tighten friction b - Loosen friction c - Locknut ! WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control. When setting the friction adjustment,[...]

FEATURES AND CONTROLS eng 53 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. Retighten bolt and retest. MODELS WITH POWER TRIM [...]

OPERATION 54 eng 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. 51985 Decal on the transom [...]

OPERATION eng 55 Operating in Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures, keep the outboard tilted down at all times so the gearcase is submerged. This prevents the trapped water in the gearcase from freezing and causing possible damage to the water pump and other componen[...]

OPERATION 56 eng 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 througho[...]

OPERATION eng 57 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 ‑ Lanyard Stop Switch . 19791 4. Shift outboard to neutral ("N") p[...]

OPERATION 58 eng 5. Move the throttle‑only lever to the fully closed position or press the throttle‑only button. a - Fully closed position b - 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[...]

OPERATION eng 59 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 Pre ‑ Starting Check List , special operating instructions, and Engine Break ‑ in Procedure in the Operation section. NOTICE Without sufficient cooli[...]

OPERATION 60 eng 4. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch . 19791 5. Shift outboard to neutral ("N") position. N 28522 6. Set the throttle grip to start position. 7. Starting a flooded engine ‑ Set the throttle grip to half‑way position. a - Start position b - Hal[...]

OPERATION eng 61 ! 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. 28521 IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine[...]

OPERATION 62 eng • Remote control models ‑ When shifting, always stop at the neutral position and allow the engine speed to return to idle. 26779 • Tiller handle models ‑ Reduce the engine speed to idle before shifting. 26842 • Always shift the outboard into gear with a quick motion. • After shifting the outboard into gear, advance the [...]

OPERATION eng 63 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. NOTE: EFI models ‑ Engine must have [...]

OPERATION 64 eng 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. ! WARNING The ex[...]

MAINTENANCE eng 65 Outboard Care To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule . We urge you to keep it maintained properly to ensure the safety of you and your passengers, and retain its dependability. Reco[...]

MAINTENANCE 66 eng EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. a - Idle speed b - Engine horsepower c - Piston displacement d - Engine power ‑ kilowatts e - Date of manufacture f - Family number g [...]

MAINTENANCE eng 67 • Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, retighten the outboard mounting fasteners. When looking for signs of looseness, look for loss of outboard transom bracket material or paint caused by movement between the outboard mounting fasteners and the ou[...]

MAINTENANCE 68 eng • Check that the intake silencer (if equipped) is in place. • Check that the idle relief muffler (if equipped) is in place. • Check for loose hose clamps and rubber boots (if equipped) on the air intake assembly. EVERY 300 HOURS OF USE OR THREE YEARS • Replace spark plugs at first 300 hours or third year. After that, insp[...]

MAINTENANCE eng 69 5. Stop the engine. Turn off the water and remove the hose. Reinstall the propeller. 28518 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.[...]

MAINTENANCE 70 eng 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. Gently pull up on the back of cowl to make sure it is securely fastened. 28445 Exterior Care Your outboard is protected with a durable baked enamel f[...]

MAINTENANCE eng 71 Before servicing any part of the fuel system, stop the engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store the fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be per[...]

MAINTENANCE 72 eng 2. Place the O‑ring seal into its proper position on the sight bowl and screw the sight bowl hand‑tight into the cover. 3. Push the filter assembly back into the mount. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt (&[...]

MAINTENANCE eng 73 Assemble steering link rod to steering cable with two flat washers and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn. Assemble steering link rod to engine with special washer head bolt, locknut, and spacer. First torque bolt, then locknut to specification. Corrosion Control Anode The outboard ha[...]

MAINTENANCE 74 eng 1. Shift the outboard to the neutral ("N") position. N N 28528 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.[...]

MAINTENANCE eng 75 5. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 26901 6. Apply to the propeller shaft Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE. 26902 Tube Ref No. Description Where Used Part No[...]

MAINTENANCE 76 eng 7. Flo‑Torq I drive hub propellers ‑ Install the forward thrust hub, propeller, propeller nut retainer, and propeller nut onto the shaft. a - Propeller nut b - Propeller nut retainer c - Propeller d - Forward thrust hub 8. Flo‑Torq II drive hub propellers ‑ Install the forward thrust hub, propeller, replaceable drive slee[...]

MAINTENANCE eng 77 Propeller Replacement ‑ 108 mm (4‑1/4 in.) Diameter Gearcase ! WARNING Rotating the propeller shaft may cause the engine to crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always turn the ignition key or lanyard stop switch [...]

MAINTENANCE 78 eng 5. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 26901 6. Apply to the propeller shaft Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE. 26902 Tube Ref No. Description Where Used Part No[...]

MAINTENANCE eng 79 7. Flo‑Torq I drive hub propellers ‑ Install the thrust washer, propeller, continuity washer, thrust hub, propeller nut retainer, and propeller nut onto the shaft. a - Propeller nut b - Propeller nut retainer c - Thrust hub d - Continuity washer e - Propeller f - Thrust washer 8. Flo‑Torq II drive hub propellers ‑ Install[...]

MAINTENANCE 80 eng 10. Place a block of wood between the gearcase and propeller and torque the propeller nut to the specified torque. Description Nm lb‑in. lb‑ft Propeller nut 75 55 11. Secure the propeller nut by bending three of the tabs into the thrust hub grooves. 26945 Spark Plug Inspection and Replacement ! WARNING Damaged spark plug boot[...]

MAINTENANCE eng 81 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 1.0 mm (0.040 in.) 4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight, and then tighten 1/4 turn or torque to specifications. Description Nm lb‑in. lb‑ft Spark plug 27 20 Fuse Replacement IMPORTA[...]

MAINTENANCE 82 eng Open the fuse holder and look at the silver colored band inside the fuse. If the band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. a - Spare fuse slot b - Diagnostic circuit 4 pin connector ‑ 2 amp fuse c - SmartCraft data bus circuit ‑ 5 amp fuse d - Main circuit ‑ 25 amp fuse e - Spare 2[...]

MAINTENANCE eng 83 • 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 No. Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 95 2-4-C with PTFE Propeller shaft 92-802859A 1 2. [...]

MAINTENANCE 84 eng • 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 injury or death from loss of boat control. Comple[...]

MAINTENANCE eng 85 3. Lubricate the following with lightweight oil. • Steering link rod pivot points ‑ Lubricate points. 28471 Checking Power Trim Fluid 1. Tilt the outboard to the full up position and engage the tilt support lock. 28474 2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill[...]

MAINTENANCE 86 eng Changing Engine Oil ENGINE OIL CAPACITY Capacity Fluid Type Engine oil 3.0 Liter (3 U.S. Quarts) Mercury or Quicksilver SAE 25W‑40 Synthetic Blend Marine 4‑Stroke Engine Oil Mercury or Quicksilver SAE 10W‑30 4‑Stroke Marine Engine Oil OIL CHANGING PROCEDURE 1. Tilt the outboard up to the trailer position. 2. Turn the outb[...]

MAINTENANCE eng 87 3. Clean the mounting base. Apply a film of clean oil to the filter gasket. Do not use grease. Screw the new filter on until the gasket contacts the base, then tighten 3/4 to 1 turn. 28417 OIL FILLING 1. Remove the oil fill cap and add oil to the proper operating level. 2. Idle the engine for five minutes and check for leaks. Sto[...]

MAINTENANCE 88 eng 2. Place a drain pan below the outboard. 3. Remove the vent plug and fill/drain plug and drain the lubricant. a - Vent plug b - Fill/drain plug 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 [...]

MAINTENANCE eng 89 5. Remove the lubricant tube and install a cleaned fill/drain plug and sealing washer. a - Vent hole b - Vent plug c - Fill/drain plug Gearcase Lubrication ‑ For 108 mm (4‑1/4 in.) Diameter Gearcase When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it m[...]

MAINTENANCE 90 eng 3. Remove the vent plugs and fill/drain plug and drain the lubricant. a - Vent plugs b - Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 710 ml (24 fl oz). CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1. Place the outboard in a vertical operating position. 2. Remove the front vent plug an[...]

MAINTENANCE eng 91 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.[...]

STORAGE 92 eng Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer). NOTICE Without su[...]

STORAGE eng 93 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. • Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall spark plugs. • Change the engine oil. Gearcase ?[...]

TROUBLESHOOTING 94 eng 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. • Ignition key switch failure. • Wiring or electrical connect[...]

TROUBLESHOOTING eng 95 c. Stuck anti‑siphon 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. Refer to Features & Cont[...]

OWNER SERVICE ASSISTANCE 96 eng Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and accessories to properly service your engine should the need occur. He knows your engine best. Servic[...]

OWNER SERVICE ASSISTANCE eng 97 REPLACEMENT SERVICE PARTS ! WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with the[...]

OWNER SERVICE ASSISTANCE 98 eng CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance, call, fax, or write to the geographic office in your area. Please include your daytime telephone number with mail and fax correspondence. United States, Canada Telephone English +1 920 929 5040 Français +1 905 636 4751 Mercury Marine W6250 Pione[...]

OWNER SERVICE ASSISTANCE eng 99 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: Mercury Marine Telepho[...]

OWNER SERVICE ASSISTANCE 100 eng Quantity Item Stock Number Price Total . . Total Due .[...]

OUTBOARD INSTALLATION eng 101 Mercury Marine Validated Engine Mounting Hardware IMPORTANT: Mercury Marine provides validated fasteners and installation instructions, including torque specifications, with all of our outboards so they can be properly secured to boat transoms. Improper installation of the outboard can cause performance and reliability[...]

OUTBOARD INSTALLATION 102 eng ! 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. ACCEPTABLE ACCESSORY MOUNTIN[...]

OUTBOARD INSTALLATION eng 103 • 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. Figure 1 a - Minimum clearance 3.175 mm (0.125 in.) b - Edge of accessory bracket c - Transom clamp bracket wall d - Radius e - Engine supplied mounting f[...]

OUTBOARD INSTALLATION 104 eng 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. Refer to Figure 2. 54625 Figure[...]

OUTBOARD INSTALLATION eng 105 3. Do not install wedges or plates between the transom clamp brackets and the transom (or jack plate). Refer to Figure 4. Figure 4 a - Boat transom or jack plate b - Transom clamp bracket c - Wedge/plate Installation Information BOAT HORSEPOWER CAPACITY ! WARNING Exceeding the boat's maximum horsepower rating can [...]

OUTBOARD INSTALLATION 106 eng 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. This prevents the[...]

OUTBOARD INSTALLATION eng 107 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[...]

OUTBOARD INSTALLATION 108 eng INSTALLING OUTBOARD Drilling Outboard Mounting Holes 1. Mark four mounting holes on the transom using the transom drill fixture. a - Drill guide holes b - Transom drilling fixture c - Transom centerline Transom Drilling Fixture 91‑98234A2 5489 Aids in engine installation by acting as a template for engine mounting ho[...]

OUTBOARD INSTALLATION eng 109 Checking Boat Transom Construction IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom ma[...]

OUTBOARD INSTALLATION 110 eng Fastening the Outboard to the Transom 1. Install the outboard so that the anti‑ventilation plate is in‑line or within 25 mm (1 in.) below the bottom of the boat. a - Anti‑ventilation plate b - 25 mm (1 in.) 2. Apply marine sealer to the shanks of bolts, not the threads. 3. Fasten the outboard with the provided mo[...]

OUTBOARD INSTALLATION eng 111 STEERING CABLE - STARBOARD SIDE ROUTED CABLE 1. Lubricate the entire cable end. 10261 Tube Ref No. Description Where Used Part No. 95 2-4-C with PTFE Steering cable end 92-802859A 1 2. Insert the steering cable into the tilt tube. 28507 3. Tighten the nut to the specified torque. 29506 Description Nm lb. in. lb. ft. Nu[...]

OUTBOARD INSTALLATION 112 eng 2. Thread cap to the mark. a - 6.4 mm (1/4 in.) b - Plastic spacer c - O‑ring seal d - Cap STEERING LINK ROD FASTENERS IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("a" ‑ Part Number 10‑856680) and self‑locking nylon in[...]

OUTBOARD INSTALLATION eng 113 ! 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 f[...]

OUTBOARD INSTALLATION 114 eng Assemble steering link rod to steering cable with two flat washers and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn. Assemble steering link rod to engine with special washer head bolt, locknut and spacer. First torque bolt, then torque locknut to specifications. Fuel Hose Connection [...]

OUTBOARD INSTALLATION eng 115 Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover. a - Access cover Route the remote wiring harness through the rubber grommet. a 28505[...]

OUTBOARD INSTALLATION 116 eng Connect the 14 pin connector to the engine harness and fasten the harness with the retainer. a - Remote wiring harness b - Retainer c - 14 pin connector BATTERY CABLE CONNECTIONS Single Outboard a - Red sleeve ‑ Positive (+) b - Black sleeve ‑ Negative (–) c - Cranking battery a b c 41014 (+) (-) b a c 15496[...]

OUTBOARD INSTALLATION eng 117 Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. a - Red sleeve ‑ Positive (+) b - Black sleeve ‑ Negative (–) c - Ground cable d - Cranking battery SHIFT CABLE INSTALLATION Install the cables into the remote control fol[...]

OUTBOARD INSTALLATION 118 eng 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 b c a 2. Manually shift the outboard into neutral. The propeller will rotate freely. 3. Position the remote control handle into neutral[...]

OUTBOARD INSTALLATION eng 119 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. a - Cable end guide b - Bow tie clip retainer c - Center mark d - Cable barrel e - Barrel latch 7. Place the cable barrel into the barrel receptacle. 8. Lock barrel in place[...]

OUTBOARD INSTALLATION 120 eng 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. 1. Position[...]

OUTBOARD INSTALLATION eng 121 5. Fasten the throttle cable to the mounting stud with a flat washer and locknut. Tighten the locknut to the specified torque. a - Cable end guide b - Bow tie clip retainer c - Flat washer d - Locknut e - Cable barrel Description Nm lb‑in. lb‑ft Throttle cable locknut 6 53 28494 b a c d e[...]

OUTBOARD INSTALLATION 122 eng 6. Install the access cover with two bolts. Tighten the bolts to the specified torque. a - Access cover Description Nm lb‑in. lb‑ft Access cover bolt 10 89 Propeller Installation PROPELLER INSTALLATION - 108 MM (4-1/4 IN.) DIAMETER GEARCASE ! WARNING Rotating propellers can cause serious injury or death. Never oper[...]

OUTBOARD INSTALLATION eng 123 1. Apply to the propeller shaft Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE. 26902 Tube Ref No. Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 95 2-4-C with PTFE Propeller shaft 92-802859A 1 IMPORTANT: To prevent the propeller hub from corroding and seizin[...]

OUTBOARD INSTALLATION 124 eng 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. a - Propeller nut b - Propell[...]

OUTBOARD INSTALLATION eng 125 PROPELLER INSTALLATION - 87.3 MM (3-7/16 IN.) DIAMETER GEARCASE ! WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent th[...]

OUTBOARD INSTALLATION 126 eng 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. a - Propeller nut b - Propeller nut retainer c - Rear thrust hub d - Replaceable drive sleeve e - Propeller f - Forward thrust hub 4. Plac[...]

OUTBOARD INSTALLATION eng 127 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 b[...]

MAINTENANCE LOG 128 eng Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours[...]