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Mercury 40 Jet User Manual

Mercury 40 Jet
120 pages
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Welcome Aboard!
Proper care and maintenance is an important part in keeping
your Mercury Product operating at peak efficiency for
maximum performance and economy. The enclosed Owner's
Registration Card is your key to trouble‑free family fun. Refer
to your Operation and Maintenance Manual for full details
of your warranty coverage.
Details of your nearest dealer can be found on
www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose?
Please check on www.marinepower.com. If necessary,
please contact your local dealer.
Declaration of Conformity
Manufacturer:
Mercury Marine
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54935-1939 USA,
Authorized Representative:
Marine Power Europe, Inc.
Parc Industriel de Petit-Rechain
B-2800 Verviers - Belgium,
Recreational Craft Directive: 2003/44/EC amending 94/25/EC
Applicable Requirement Standards Applied
Owner's manual (A.2.5) EN ISO 10240:2004
Handling characteristics (A.4) EN ISO 8665:1995
Outboard engines starting (A.5.1.4) EN ISO 11547:1995
General steering system (A.5.4.1)
ABYC P‑17; EN ISO
10592:1995
Exhaust emission requirements (B.2) EN ISO 8178‑1:1996
Owner's manual (B.4) EN ISO 8665:1995
Noise emission levels (C.1) EN ISO 14509:2000
Module used for exhaust emission assessment: Module H;
Certification No. RCD‑H‑2
Module used for noise emission assessment: Module H;
Certification No. RCD‑H‑2
© 2008 Mercury Marine
40 Jet 4-Stroke 90-10258080 407

Table of Contents

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Mercury 40 Jet Specifications

General IconGeneral
Cylinders3
StartingElectric
SteeringRemote
Shaft Length20 in
Horsepower40 HP
Alternator Output226-watt
Warranty3 years

Summary

Warranty Information

Transfer of Warranty

Details process for transferring limited warranty to a subsequent owner.

Warranty Registration United States and Canada

Explains how to register product in US and Canada, including address changes.

Warranty Registration Outside the United States and Canada

Details warranty card process for buyers outside US and Canada.

FourStroke Outboard Limited Warranty United States, Canada, Europe and Confederation of Independent States

Covers warranty for new products against defects in material and workmanship.

3 Year Limited Warranty Against Corrosion

Warrants against rendering inoperative due to corrosion for three years.

Warranty Coverage and Exclusions

Explains services not covered by warranty, including common misunderstandings.

General Information

Boater's Responsibilities

Operator's responsibility for safe operation, safety of occupants, and public.

Before Operating Your Outboard

Read manual, understand handling differences between jet and propeller boats.

Boat Horsepower Capacity

Warning about exceeding boat's maximum horsepower rating and its consequences.

High-Speed and High-Performance Boat Operation

Advice on operating high-speed boats and obtaining orientation.

Remote Steering Notice

Importance of self-locking nuts for steering link rod to prevent disengagement.

Lanyard Stop Switch

Function of lanyard stop switch to turn off engine when operator moves away.

Stopping the Boat in an Emergency

Emergency stopping capability of jet drive units and associated risks.

Steering the Boat

How jet drive thrust affects steering and risks in tight turns.

Protecting People In The Water

Safety advice for people in water while cruising or boat is stationary.

Passenger Safety Message - Pontoon Boats and Deck Boats

Safety advice for passengers on pontoon and deck boats regarding seating and movement.

Wave and Wake Jumping

Hazards associated with jumping waves/wakes and potential for injury.

Safety Instructions for Hand-Tilled Outboards

Safety precautions for hand-tilled outboards, including mounting and operation.

Exhaust Emissions

Alert about carbon monoxide poisoning and need for good ventilation.

Selecting Accessories for Your Outboard

Advice on selecting and installing accessories.

Safe Boating Suggestions

Recommendations for safe boating, including flotation devices, rules, and avoiding alcohol/drugs.

Recording Serial Number

Importance of recording serial number for future reference.

40 Jet 4-Stroke Specifications

Technical specifications for the 40 Jet 4-Stroke engine model.

Component Identification

Identifies various parts of the outboard engine with labels.

Transporting

Trailering Boat/Outboard

Instructions for trailering a boat with an outboard, including tilt support.

Transporting Portable Fuel Tanks

Safety warnings and instructions for transporting portable fuel tanks.

Fuel & Oil

Fuel Recommendations

Guidelines on acceptable gasoline types, octane ratings, and leaded/unleaded fuels.

Filling Fuel Tank

Safety warnings and procedures for filling fuel tanks, including tank placement.

Engine Oil Recommendations

Recommended oil types and viscosity for 4-stroke outboard engines.

Checking and Adding Engine Oil

Step-by-step guide for checking and adding engine oil, including contamination inspection.

Features & Controls

Remote Control Features

Overview of Mercury/Quicksilver remote control features and functions.

Warning System

Explains warning horn signals (continuous/intermittent beeps) and their meanings.

Engine Guardian System

Monitors engine sensors to detect problems and protect the engine.

SmartCraft Product

Details Mercury SmartCraft System for monitoring engine data and diagnostics.

Power Trim and Tilt

Explains how power trim/tilt adjusts outboard position and its operation.

Tilting Operation

Steps for tilting the outboard using power trim or manual tilt.

Manual Tilting

Procedure for manually tilting the outboard if power trim is unavailable.

Auxiliary Tilt Switch

Using the auxiliary tilt switch to operate power trim.

Throttle Grip Friction Adjustment - Tiller Handle Models

Adjusting throttle grip friction for desired speed control on tiller models.

Steering Friction Adjustment (Tiller Handle Models)

Adjusting steering friction (drag) on tiller handle models.

Steering Friction Adjustment (Remote Steering Models)

Adjusting steering friction (drag) on steering wheel for remote steering.

Replaceable Jet Drive Shear Key

Function of shear key for protecting the jet drive impeller.

Operation

Pre-Starting Check List

Comprehensive checklist for pre-starting the outboard and boat.

Operating In Freezing Temperatures

Precautions and procedures for operating the outboard in freezing conditions.

Operating in Saltwater or Polluted Water

Procedures for flushing and protecting outboard after use in saltwater.

Operating In Shallow Water

Advice for operating in shallow water to protect impeller and avoid damage.

How the Jet Drive Operates

Explanation of jet drive handling characteristics and operator adjustment.

Mooring The Boat

Importance of tilting jet drive out of water when mooring in shallow areas.

Water Intake Blockage

Warning about rotating impeller and avoiding contact with water intake.

Clearing A Lodged Impeller

Steps to free a lodged impeller and potential hazards.

Pre-Starting Instructions

Initial pre-start check for engine oil level.

Engine Break-in Procedure

Recommended procedure for breaking in the engine during the first hours of operation.

Starting the Engine - Remote Control Models

Procedures for starting the engine using remote control.

Starting the Engine - Tiller Handle Models

Procedures for starting the engine using tiller handle controls.

Stopping The Engine

Procedures for stopping the engine on remote control and tiller handle models.

Emergency Starting

Instructions for starting the engine using a spare starter rope.

Gear Shifting

Explanation of gear shift positions and procedures for remote/tiller models.

Maintenance

Outboard Care

Importance of periodic inspections and maintenance for optimal condition and safety.

Selecting Replacement Parts for Your Outboard

Recommendation to use genuine Mercury/Quicksilver parts and lubricants.

EPA Emissions

Information about the emission certification label on the engine.

Owner Responsibility

Owner's duty to perform routine maintenance for emission standards.

Inspection and Maintenance Schedule

Schedule of checks required before and after each use, and at intervals.

Flushing the Cooling System

Procedure for flushing cooling system with fresh water after use in dirty water.

Top Cowl Removal and Installation

Steps for removing and reinstalling the top cowl of the outboard.

Exterior Care

Advice on cleaning and waxing the outboard's exterior finish.

Battery Inspection

Periodic inspection of the battery to ensure starting capability.

Fuel System

Safety warnings and procedures for servicing the fuel system.

Fuel Line Inspection

Inspecting fuel lines and primer bulb for signs of deterioration or damage.

Engine Fuel Filter

Checking the fuel filter for water or sediment and filter replacement.

Steering Link Rod Fasteners

Importance of using specific bolts and self-locking nuts for steering link rod.

Corrosion Control Anode

Function and inspection of corrosion control anodes to prevent galvanic corrosion.

Spark Plug Inspection and Replacement

Procedure for inspecting, gapping, and replacing spark plugs.

Steering Pull Adjustment

Correcting tendency of the outboard to pull towards starboard.

Worn/Dull Impeller

Symptoms and effects of a worn or dull impeller on engine performance.

Impeller Clearance Adjustment

Adjusting impeller clearance to the liner for optimal performance.

Fuse Replacement

Procedure for replacing blown fuses and identifying their locations.

Timing Belt Inspection

Conditions requiring replacement of the timing belt.

Lubrication Points

Locations and procedures for lubricating outboard components with specific lubricants.

Storage

Storage Preparation

Procedures to protect outboard from rust, corrosion, and freezing during storage.

Protecting External Outboard Components

Lubricating components and touching up paint for external protection.

Protecting Internal Engine Components

Steps to protect internal engine parts with oil or storage seal.

Jet Drive

Procedure to pump extra grease into jet drive bearing to purge moisture.

Positioning Outboard for Storage

Storing the outboard in an upright position to allow water drainage.

Battery Storage

Instructions for storing the battery, including checking water level and recharging.

Troubleshooting

Starter Motor Will Not Crank The Engine (Electric Start Models)

Lists possible causes for the starter motor not cranking the engine.

Engine Will Not Start

Lists possible causes for the engine failing to start.

Engine Runs Erratically

Lists possible causes for the engine running erratically.

Engine Over-Speed (Excessive RPM)

Lists possible causes for the engine exceeding its normal RPM range.

Performance Loss

Lists possible causes for a general loss of engine performance.

Battery Will Not Hold Charge

Lists possible causes for the battery failing to hold its charge.

Owner Service Assistance

Local Repair Service

Recommends returning outboard to authorized dealer for factory-trained service.

Service Away from Home

How to contact nearest dealer or Mercury Marine Service Office when away from home.

Parts and Accessories Inquiries

Directs inquiries for parts and accessories to the authorized dealer.

Service Assistance

Steps to follow for resolving problems with dealer or Mercury Marine.

Outboard Installation

Installation Information

General information regarding outboard installation.

Boat Horsepower Capacity

Warning about exceeding boat's maximum horsepower rating.

Start in Gear Protection

Warning and explanation of neutral-start protection devices.

Selecting Accessories for Your Outboard

Advice on selecting and installing accessories.

Electric Fuel Pump

Fuel pressure considerations for electric fuel pumps.

Lifting Outboard

Guidance on using the lifting eye for outboard installation.

Determining the Mounting Height of the Outboard

How to set initial outboard mounting height, referencing water testing.

Boats with a "V" Bottom Hull

Procedure for determining mounting height for V-bottom hulls.

Boats with a Flat Bottom Hull

Procedure for determining mounting height for flat-bottom hulls.

Checking Boat Transom Construction

Method to determine transom strength and adequacy for outboard mounting.

Fastening the Outboard

Steps for drilling mounting holes and fastening the outboard to the transom.

Steering Cable - Starboard Side Routed Cable

Lubrication instructions for the steering cable end.

Steering Link Rod Fasteners

Importance of using specific hardware and locknuts for steering link rod.

Trim-In Stop Adjustment - Power Trim Models

Adjusting trim-in stop by repositioning tilt stop pins.

Water Testing

General guidance on water testing procedures and checks.

Fuel Hose Connection - Remote Control Models

Fastening remote fuel hose with hose clamps.

Electrical Connections and Control Cable Installation

Installing remote wiring harness and access cover.

Throttle Cable Installation

Installing throttle cables into the remote control unit.

Shift Cable Installation

Procedures for installing and adjusting the shift cable.

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