Mercury 40 4-Stroke - Maintenance

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Declaration of Conformity1
Table of Contents3
Transfer of Warranty7
Warranty Registration United States and Canada7
Warranty Registration Outside the United States and Canada7
Warranty Information7
Fourstroke Outboard Limited Warranty United States, Canada, Europe and Confederation of Independent States8
Fourstroke Outboard Limited Warranty (Middle-East, and Africa)9
Year Limited Warranty against Corrosion10
Warranty Coverage and Exclusions12
Boater's Responsibilities14
Before Operating Your Outboard14
Boat Horsepower Capacity14
General Information14
High-Speed and High-Performance Boat Operation15
Outboard Remote Control Models15
Remote Steering Notice15
Lanyard Stop Switch16
Protecting People in the Water17
Passenger Safety Message - Pontoon Boats and Deck Boats18
Wave and Wake Jumping19
Impact with Underwater Hazards19
Safety Instructions for Hand Tilled Outboards20
Exhaust Emissions20
Selecting Accessories for Your Outboard21
Safe Boating Suggestions22
Recording Serial Number23
40 4-Stroke Specifications - International23
Component Identification24
Trailering Boat/Outboard25
Transporting Portable Fuel Tanks25
Transporting25
Fuel Recommendations27
Fuel & Oil27
Filling Fuel Tank28
Engine Oil Recommendations28
Checking and Adding Engine Oil29
Remote Control Features31
Warning System - Manual Starting Models31
Features & Controls31
Warning System - Electric Starting Models32
Power Trim and Tilt34
Manual Tilt System36
- Shallow Water Operation37
- Tilting Outboard to Full up Position37
Throttle Grip Friction Adjustment - Tiller Handle Models39
Steering Friction Adjustment39
Trim Tab Adjustment41
Pre-Starting Check List42
Operating in Freezing Temperatures42
Operating in Salt Water or Polluted Water42
Pre-Starting Instructions42
Operation42
Engine Break-In Procedure43
Starting the Engine - Remote Control Models43
Starting the Engine - Tiller Handle Models45
Gear Shifting48
Stopping the Engine49
Emergency Starting49
Outboard Care52
EPA Emissions52
Inspection and Maintenance Schedule52
Maintenance52
Flushing the Cooling System53
Top Cowl Removal and Installation54
Exterior Care55
Battery Inspection55
Fuel System55
Engine Fuel Filter - Electric Starting Models55
Engine Fuel Filter - Manual Starting Models56
Steering Link Rod Fasteners57
Corrosion Control Anode57
Propeller Replacement58
Spark Plug Inspection and Replacement60
Fuse Replacement61
Timing Belt Inspection62
Lubrication Points62
Checking Power Trim Fluid65
Changing Engine Oil65
Gearcase Lubrication67
Submerged Outboard68
Storage Preparation69
Protecting External Outboard Components69
Protecting Internal Engine Components69
Storage69
Gearcase70
Positioning Outboard for Storage70
Battery Storage70
Starter Motor will Not Crank the Engine (Electric Start Models)71
Engine will Not Start71
Engine Runs Erratically71
Troubleshooting71
Performance Loss72
Battery will Not Hold Charge72
Local Repair Service73
Service Away from Home73
Parts and Accessories Inquiries73
Service Assistance73
Mercury Marine Service Offices73
Owner Service Assistance73
Installation Information75
Outboard Installation75
Installing Outboard77
Fuel Hose Connection - Remote Control Models82
Electrical Connections and Control Cable Installation82
Throttle Cable Installation86
Propeller Installation89
Trim Tab Adjustment92
Trim-In Stop Adjustment - Power Trim Models93

Mercury 40 4-Stroke - Maintenance

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