Mercury 40 Jet 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.................................................................................... 36 Low Permeation Fuel Hose Requirement ........................................................ 37 EPA Pressurized Portable Fuel Tank Requirements........................................ 37 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......................................................................................... 88 Service Away from Home................................................................................. 88 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 ! CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information[...]

GENERAL INFORMATION 22 eng Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral. ! WARNING Starting the engine with the drive in gear can cause serious injury o[...]

GENERAL INFORMATION eng 23 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. Tiller handle outboards and some remote control units are equipped with a lanyar[...]

GENERAL INFORMATION 24 eng Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's po[...]

GENERAL INFORMATION eng 25 KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD OPERATING CONDITION Before each use, check to ensure the lanyard stop switch works properly. Start the engine and stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat. Before each use, visually inspect the[...]

GENERAL INFORMATION 26 eng WHILE BOAT IS STATIONARY ! WARNING Avoid injury resulting from contacting the rotating impeller or having hair, clothing, or loose objects drawn into the water intake and wrapping around the impeller shaft. Stay away from the water intake and never insert an object into the water intake or water outlet nozzle when the eng[...]

GENERAL INFORMATION eng 27 BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds. Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling o[...]

GENERAL INFORMATION 28 eng There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat to a nearly instantaneous stop and can send [...]

GENERAL INFORMATION eng 29 ! 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 30 eng 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 eng 31 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 32 eng 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 eng 33 • 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 34 eng Models 40 Jet Valve clearance (cold) Intake valve 0.15–0.25 mm (0.006–0.010 in.) Exhaust valve 0.25–0.35 mm (0.010–0.014 in.) Recommended spark plug Champion RA8HC Spark plug gap 1.0 mm (0.040 in.) Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Engine oil capacity 3.0 L (3 US qt) [...]

TRANSPORTING eng 35 Trailering Boat/Outboard The boat should be trailered with the outboard tilted down in a vertical operating position. IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering. The outboard tilt support lever is not intended to support the outboard for trailerin[...]

FUEL AND OIL 36 eng 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 eng 37 ! 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 38 eng 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 eng 39 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 40 eng 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 eng 41 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 42 eng 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 eng 43 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 44 eng 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 eng 45 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 46 eng ! WARNING Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. Maintain control of the boat if trimming beyond a neutral steering condition. Consider the following lists carefully. Trimming in or down can: • Lower the bow • Re[...]

FEATURES AND CONTROLS eng 47 2. Lower outboard to rest on the tilt support lever. 3. Disengage the tilt support lever, by raising the outboard off the support lever and rotating 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 ma[...]

FEATURES AND CONTROLS 48 eng Throttle Grip Friction Adjustment ‑ Tiller Handle Models Throttle grip friction knob ‑ Turn friction knob to set and maintain the throttle at desired speed. Turn knob clockwise to tighten friction and turn knob counterclockwise to loosen friction. a - Loosen friction b - Tighten friction Steering Friction Adjustment[...]

FEATURES AND CONTROLS eng 49 Replaceable Jet Drive Shear Key The jet drive is equipped with a shear key to protect it in the event of a lodged impeller. The shear key can be reached by removing the water intake housing and impeller. 29174[...]

OPERATION 50 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 51 Check for debris around the rudder and reverse gate which may jam or hinder operation. Before launching, examine the jet drive water intake for obstructions which may prevent pumping of water. Ensure the driveshaft bearing on the jet drive is lubricated. Operating in Freezing Temperatures If there is a chance of ice forming on the [...]

OPERATION 52 eng The driveshaft driven impeller draws water up through the water intake and then directs it at a high pressure through the water outlet nozzle to create forward thrust. To obtain reverse, the reverse gate moves over the outlet nozzle to direct the water in the opposite direction. a - Water intake b - Water outlet nozzle c - Reverse [...]

OPERATION eng 53 Stopping the Boat in an Emergency A jet powered boat has emergency stopping capability unique to this form of propulsion. ! WARNING Using the emergency stopping capability of a jet drive unit will slow down the boat in an emergency. However, sudden stopping may cause the occupants of the boat to be thrown forward or out of the boat[...]

OPERATION 54 eng Mooring the Boat Be sure to tilt the jet drive out of the water when the boat is pulled onto a beach or tied to a dock in shallow water. Failure to do this may cause the water intake housing to fill with sand or debris and could prevent the outboard from cranking over for starting. Water Intake Blockage ! WARNING A rotating impelle[...]

OPERATION eng 55 Pre‑Starting Instructions 1. Check the engine oil level. 28525 2. Ensure that the driveshaft bearing on the jet drive is lubricated. Refer to Maintenance ‑ Lubrication Points . 28664 Engine Break‑in Procedure IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of th[...]

OPERATION 56 eng NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat. Never start or operate the engine without the intake housing in the water. 1. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 2. Position the fuel line primer bulb so the arrow on the si[...]

OPERATION eng 57 4. Shift outboard to neutral ("N") position. N 26838 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 throttl[...]

OPERATION 58 eng 8. After engine starts, 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 and check cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These c[...]

OPERATION eng 59 2. Connect the remote fuel line to the outboard. Make sure the connector is snapped into place. 28526 3. 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 4. Set the lanyard stop switch to "RUN" position. Refer[...]

OPERATION 60 eng 7. Starting a flooded engine ‑ Set the throttle grip to half‑way position. a - Start position b - Half‑way position 8. Turn the ignition key to the "START" position. If the engine fails to start in ten seconds, return the key to the "ON" position, wait 30 seconds and try again. 19804 ! WARNING Rapid accele[...]

OPERATION eng 61 Gear Shifting IMPORTANT: Observe the following: • Never shift outboard into gear unless engine speed is at idle. • Your outboard has three gear shift positions to provide operation: forward, neutral (out of gear), and reverse. F N R F N R 28523 • Remote control models ‑ When shifting, always stop at the neutral position and[...]

OPERATION 62 eng Stopping the Engine 1. Remote control models ‑ Reduce the engine speed and shift the outboard to neutral position. Turn the ignition key to "OFF" position. 26843 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 &quo[...]

OPERATION eng 63 2. Shift outboard to neutral ("N") position. N N 28528 ! WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear. 3. Electric start models ‑ Turn the i[...]

OPERATION 64 eng 5. Pull the starter rope to start the engine. 26848[...]

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 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, inspect spark plugs every 300 hours or three years. Replace spark [...]

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 Your outboard h[...]

MAINTENANCE 74 eng 1. Remove the spark plug boots. Twist the rubber boots slightly and pull off. 26899 2. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled. 26946 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 1.0 mm (0.040 in.) 4.[...]

MAINTENANCE eng 75 Steering Pull Adjustment The steering on some boats will have the tendency to pull towards starboard. This pulling condition can be corrected by using a pliers and bending the ends of the exhaust fins 1.5 mm (1/16 in.) toward the starboard side of the outboard. a - Exhaust fins Worn/Dull Impeller The intake of gravel through the [...]

MAINTENANCE 76 eng Impeller Clearance Adjustment The impeller should be adjusted so there is approximately 0.8 mm (0.03 in.) clearance between the impeller edge and liner. Operating the jet drive in waters that contain sand and gravel can cause wear to the impeller blades, and the clearance will start to exceed 0.8 mm (0.03 in.). As the blades wear[...]

MAINTENANCE eng 77 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 78 eng • Signs of wear on edges or outer surfaces of belt. 26958 Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision 2‑4‑C with PTFE. Tube Ref No. Description Where Used Part No. 95 2-4-C with PTFE Driveshaft bearing 92-802859A 1 IMPORTANT: It is important not to use a general all‑purpose grease f[...]

MAINTENANCE eng 79 iii. Connect the vent hose onto the grease fitting after greasing. a - Grease fitting b - Vent hose NOTE: After 30 hours of operation, pump in extra grease to purge out any moisture. Visually inspecting the purged grease at this time will give an indication of conditions inside the bearing housing. A gradual increase in moisture [...]

MAINTENANCE 80 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 81 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 82 eng Changing Engine Oil ENGINE OIL CAPACITY Capacity Fluid Type Engine oil 3.0 Liter (3 U.S. Quarts) Mercury Precision Parts or Quicksilver Synthetic Blend 25W‑40 4‑Stroke Outboard Oil Mercury Precision Parts or Quicksilver 10W‑30 4‑Stroke Outboard Oil OIL CHANGING PROCEDURE 1. Tilt the outboard up to the trailer position. 2.[...]

MAINTENANCE eng 83 4. 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. Stop the engine and check the oil level on the dipstick. Add oil if necessary. a - Oil fill cap[...]

STORAGE 84 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 85 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. Jet Drive [...]

TROUBLESHOOTING 86 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 87 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). Engine Overspeed (Excessive RPM) POSSIBLE CAUSES • Outboard mounted too high on the transom. • [...]

OWNER SERVICE ASSISTANCE 88 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 89 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 90 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 91 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 92 eng Quantity Item Stock Number Price Total . . Total Due .[...]

OUTBOARD INSTALLATION eng 93 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 94 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 MOUNTING[...]

OUTBOARD INSTALLATION eng 95 • 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 fa[...]

OUTBOARD INSTALLATION 96 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 97 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 c[...]

OUTBOARD INSTALLATION 98 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 99 LIFTING OUTBOARD Use the lifting eye on the engine. 28510 Determining the Mounting Height of the Outboard Jet The following outboard mounting height settings will work good for most applications, however, because of different boat/hull designs, the setting should be checked by test running the boat. Refer to Water Testi[...]

OUTBOARD INSTALLATION 100 eng BOATS WITH A "V" BOTTOM HULL 1. Measure the width of the leading edge on the water intake housing. Make a horizontal line on the transom up from the "V" bottom the same length as the width of the water intake housing. a - Horizontal line b - Width of the leading edge on the water intake housing 2. P[...]

OUTBOARD INSTALLATION eng 101 2. Fasten outboard to the transom at this height. Refer to Fastening the Outboard . 22403 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. [...]

OUTBOARD INSTALLATION 102 eng NOTE: The inside holes on the transom reinforcement plate are for the lower transom bolts and the outside holes are for the upper transom bolts. a - Large transom washer b - Transom reinforcement plate Description Part Number Large transom washer 67‑896392 Transom reinforcement plate 67‑896305 Fastening the Outboar[...]

OUTBOARD INSTALLATION eng 103 The outboard must be secured to the transom with the four 13 mm (1/2 in.) diameter mounting bolts and locknuts provided. Install two bolts through the upper set of mounting holes and two bolts through the lower set of mounting holes. a - 1/2 in. diameter bolt (4) b - Flat washer (4) c - Locknut (4) Description Nm lb‑[...]

OUTBOARD INSTALLATION 104 eng 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. Nut 47.5 35 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" ?[...]

OUTBOARD INSTALLATION eng 105 ! 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 106 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. Steering Cable Seal 1[...]

OUTBOARD INSTALLATION eng 107 Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover. a - Access cover a 28696[...]

OUTBOARD INSTALLATION 108 eng Route the remote wiring harness through the rubber grommet. Connect the 14 pin connector to the engine harness. Fasten the harness with the retainer. a - Remote wiring harness b - Retainer c - 14 pin connector THROTTLE CABLE INSTALLATION Install the cables into the remote control following the instructions provided wit[...]

OUTBOARD INSTALLATION eng 109 2. Center the roller with the alignment mark on the cam. Adjust the cable barrel so that it fits into the anchor pocket. N 26838 3. Fit the throttle cable through the rubber grommet. a - Rubber grommet b - Throttle cable 4. Place the throttle cable on the throttle lever pin. Lock in place with the retainer. a b 28701[...]

OUTBOARD INSTALLATION 110 eng 5. Adjust the cable barrel so the center of the roller is lined up with the alignment mark on the cam when the cable barrel is placed in the barrel receptacle. a - Cable barrel b - Alignment mark c - Roller d - Retainer 6. Place the cable barrel into the barrel receptacle. 7. Lock in barrel in place with the barrel lat[...]

OUTBOARD INSTALLATION eng 111 8. 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 6 53 SHIFT CABLE INSTALLATION—OUTBOARD JET ! WARNING If not properly installed, the reverse gate can interfere with water coming off the rudder, suddenly and unexpe[...]

OUTBOARD INSTALLATION 112 eng 4. Attach the shift cable adjustment barrel to the bracket with a bolt and locknut. Tighten the bolt until it seats against the adjustment barrel, then back‑off the bolt 1/4 turn. Hold the bolt from turning, and tighten the locknut on the bolt. The adjustment barrel must be free to pivot. a - Roller b - Shift cam c -[...]

OUTBOARD INSTALLATION eng 113 Description Nm lb‑in. lb‑ft Tilt stop pins 24.4 18 Water Testing CHECKING FOR CAVITATION The initial outboard height setting should be close to the optimum setting for the outboard. However, because of the hull design of some boats, obstructions, or imperfections in the hull ahead of the water intake, adjustments m[...]

OUTBOARD INSTALLATION 114 eng A rough water plate may be helpful in reducing cavitation when running in windy, rough water conditions where air is sucked into the water intake when jumping waves. Install a 0.8 mm (1/32 in.) metal plate that extends from the hull bottom to the top of the water intake housing. This plate tends to reduce air intake as[...]

MAINTENANCE LOG eng 115 Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours[...]