Mercury 40 jet fourstroke

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MAINTENANCE

eng 99

• Swivel bracket ‑ Lubricate through fitting.

a - Tilt support lever

b - Swivel bracket

• 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

28466

Main Page

Table of Contents7
Warranty Registration United States and Canada13
Transfer of Warranty United States and Canada13
Warranty Information13
Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada14
Year Limited Warranty against Corrosion15
Warranty Coverage and Exclusions18
U.S. EPA Emissions Limited Warranty20
Emission Control System Components20
California Emissions Limited Warranty21
California Air Resources Board Explanation of Your California Emission Control Warranty Statement25
Emission Certification Star Label26
Warranty Policy-Australia and New Zealand27
Global Warranty Charts Outboard and Jets33
Boater's Responsibilities39
Before Operating Your Outboard39
General Information39
Boat Horsepower Capacity40
High-Speed and High-Performance Boat Operation41
Outboard Remote Control Models41
Remote Steering Notice42
Lanyard Stop Switch43
Stopping the Boat in an Emergency45
Protecting People in the Water46
Passenger Safety Message - Pontoon Boats and Deck Boats47
Wave and Wake Jumping49
Safety Instructions for Hand-Tilled Outboards49
Exhaust Emissions50
Selecting Accessories for Your Outboard53
Safe Boating Recommendations53
Recording Serial Number56
40 Jet Fourstroke Specifications57
Component Identification58
Trailering Boat/Outboard59
Transporting Portable Fuel Tanks59
Transporting59
Fuel Recommendations61
Fuel and Oil61
Low Permeation Fuel Hose Requirement62
EPA Pressurized Portable Fuel Tank Requirements63
Fuel Demand Valve (FDV) Requirement63
Mercury Marine's Pressurized Portable Fuel Tank64
Filling Fuel Tank65
Engine Oil Recommendations66
Checking and Adding Engine Oil66
Remote Control Features68
Features and Controls68
Warning System69
Power Trim and Tilt71
Throttle Grip Friction Adjustment - Tiller Handle Models75
Steering Friction Adjustment - Tiller Handle Models75
Replaceable Jet Drive Shear Key76
Important Daily Inspection before each Use77
Prestarting Check List77
Operation77
Operating in Freezing Temperatures78
Operating in Saltwater or Polluted Water78
Operating in Shallow Water79
How the Jet Drive Operates79
Stopping the Boat in an Emergency81
Steering the Boat81
Mooring the Boat82
Water Intake Blockage83
Clearing a Lodged Impeller83
Pre-Starting Instructions84
Engine Break-In Procedure84
Starting the Engine - Remote Control Models85
Starting the Engine - Tiller Handle Models87
Gear Shifting90
Stopping the Engine91
Emergency Starting92
Outboard Care95
EPA Emissions Regulations95
Inspection and Maintenance Schedule96
Flushing the Cooling System98
Top Cowl Removal and Installation100
Exterior Care100
Battery Inspection101
Fuel System101
Steering Link Rod Fasteners103
Corrosion Control Anode104
Spark Plug Inspection and Replacement105
Steering Pull Adjustment106
Worn/Dull Impeller106
Impeller Clearance Adjustment107
Fuse Replacement108
Timing Belt Inspection109
Lubrication Points109
Checking Power Trim Fluid113
Changing Engine Oil114
Submerged Outboard115
Storage Preparation116
Storage116
Protecting External Outboard Components117
Protecting Internal Engine Components117
Jet Drive117
Positioning Outboard for Storage117
Battery Storage117
Starter Motor will Not Crank the Engine (Electric Start Models)119
Engine will Not Start119
Troubleshooting119
Engine Runs Erratically120
Engine Overspeed (Excessive RPM)120
Performance Loss120
Battery will Not Hold Charge121
Local Repair Service122
Service Away from Home122
Parts and Accessories Inquiries122
Service Assistance122
Owner Service Assistance122
Ordering Literature125
Mercury Marine Validated Engine Mounting Hardware127
Outboard Installation127
Installation Information128
Determining the Mounting Height of the Outboard130
Checking Boat Transom Construction133
Fastening the Outboard134
Steering Cable - Starboard Side Routed Cable135
Steering Link Rod Fasteners136
Steering Cable Seal138
Fuel Hose Connection - Remote Control Models138
Electrical Connections and Control Cable Installation139
Trim-In Stop Adjustment - Power Trim Models145
Water Testing145
Maintenance Log147

Mercury 40 jet fourstroke - Page 111

Table of Contents

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