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Mercury 40 FourStroke User Manual

Mercury 40 FourStroke
584 pages
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©2001, Mercury Marine. All rights reserved. Printed in U.S.A. 90-857046R1 NOVEMBER 2001
30/40
FourStroke
Starting Model Year 1999
Starting Serial Number 0G760300
Starting Model Year 1999
90-857046R1 NOVEMBER 2001
30/40 FourStroke
www.mercurymarine.com.au
Frankston Road
P.O. Box 80
Dandenong, Victoria 3175 Australia
www.mercurymarine.com
W6250 Pioneer Road
Fond du Lac, WI 54936-1939 USA
www.marinepower.com
(Parc Industriel de Petit-Rechain)
B-4822 Verviers/Belgium
Srvc Man - ME 30/40 FS 11/13/01 2:00 PM Page 1

Table of Contents

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Mercury 40 FourStroke Specifications

General IconGeneral
BrandMercury
Model40 FourStroke
CategoryOutboard Motor
LanguageEnglish

Summary

IMPORTANT INFORMATION

Section 1A - Specifications

Provides detailed technical specifications for the outboard motor, including engine details, weights, fuel, and oil requirements.

Section 1B - Maintenance

Outlines periodic inspections and maintenance schedules to keep the outboard in optimal operating condition and ensure safety.

Section 1C - GENERAL INFORMATION

Covers general information about the outboard, including serial number location, performance factors, and engine operation.

Section 1D - Outboard Motor Installation

Details the specifications and procedures for correctly installing the outboard motor onto the boat transom, including electrical connections.

ELECTRICAL

Section 2A - Ignition

Covers the ignition system components, specifications, tests, and troubleshooting procedures for reliable engine starting.

Section 2B - Charging & Starting System

Details the battery, charging system, starter motor, and related components for reliable engine operation and power supply.

Section 2C - Timing, Synchronizing, & Adjusting

Explains ignition timing, carburetor synchronization, and idle speed adjustments for optimal engine performance.

Section 2D - Wiring Diagrams

Provides essential color wiring diagrams for various engine models and systems, crucial for troubleshooting and installation.

FUEL SYSTEM

Section 3A - Fuel Pump

Details the fuel pump operation, specifications, removal, installation, disassembly, and reassembly for reliable fuel delivery.

Section 3B - Carburetor

Covers carburetor specifications, adjustments, removal, disassembly, inspection, reassembly, and installation for proper fuel-air mixture.

Section 3C – Emissions

Explains exhaust emissions standards, types of emissions, and methods for controlling them to meet EPA regulations.

POWERHEAD

Section 4A - Cylinder Head

Provides detailed specifications, procedures for removal, installation, disassembly, and reassembly of the cylinder head and its components.

Section 4B - Cylinder Block/Crankcase

Covers specifications, components, inspection, disassembly, and reassembly of the engine block, crankshaft, pistons, and related parts.

Section 4C - Lubrication

Details engine oil pressure, oil pump specifications, removal, disassembly, cleaning, reassembly, and installation for proper lubrication.

MID-SECTION

Section 5A - Clamp/Swivel Brackets & Drive Shaft Housing

Covers specifications and procedures for mid-section components like transom bracket, swivel bracket, and driveshaft housing.

Section 5B - Power Trim

Explains the power trim system theory, adjustments, troubleshooting, removal, disassembly, reassembly, and installation.

Section 5C - Manual Tilt Assist

Details manual tilt system components, flow diagrams, troubleshooting, removal, disassembly, cleaning, reassembly, and installation.

LOWER UNIT

Section 6A - Non-Bigfoot Gear Housing

Provides specifications and detailed procedures for the non-Bigfoot gear housing, including special tools, removal, disassembly, and reassembly.

Section 6B - Bigfoot Gear Housing

Details specifications and procedures for the Bigfoot gear housing, including special tools, removal, disassembly, and reassembly.

ATTACHMENTS/CONTROL LINKAGE

Section 7A - Throttle/Shift Linkage

Explains linkage components and procedures for non-Bigfoot and Bigfoot models, crucial for proper throttle and shift operation.

Section 7B - Tiller Handle

Details tiller handle components, disassembly, cleaning, reassembly, and installation procedures for proper steering and control.

MANUAL STARTER

Section 8

Covers manual starter components, adjustments, removal, disassembly, cleaning, reassembly, and installation for reliable engine starting.

Interlock Cable Adjustment

Explains the procedure for adjusting the interlock cable to ensure proper safety and starting interlock function.

COLOR DIAGRAMS

30/40 (4-STROKE) TILLER HANDLE ELECTRIC COLOR WIRING DIAGRAM

Provides a visual representation of the electrical system for tiller handle electric models, essential for troubleshooting and repair.

30/40 (4-STROKE) TILLER HANDLE MANUAL COLOR WIRING DIAGRAM

Offers a visual guide to the electrical system for tiller handle manual models, crucial for maintenance and diagnostics.

30/40 (4-STROKE) REMOTE CONTROL ELECTRIC COLOR WIRING DIAGRAM

Illustrates the electrical system for remote control electric models, vital for proper installation and troubleshooting.

30/40 (4-STROKE) OIL FLOW DIAGRAM

Depicts the engine's oil circulation path, aiding in understanding lubrication and identifying potential issues.

30/40 (4-STROKE) WATER FLOW DIAGRAM

Illustrates the engine's cooling water circulation path, important for understanding thermal management and troubleshooting.

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