Mercury 40 Jet - Top Cowl Removal and Installation

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MAINTENANCE

5. Stop the engine. Turn off the water and remove the hose.

Reinstall the propeller.

28518

Top Cowl Removal and Installation

REMOVAL

1. Pull out the rear lock lever and remove the top cowl.

28439

INSTALLATION

1. Lower the top cowl over the engine.

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Table of Contents5
Transfer of Warranty9
Warranty Registration United States and Canada9
Warranty Information9
Warranty Registration Outside the United States and Canada10
Fourstroke Outboard Limited Warranty United States, Canada, Europe and Confederation of Independent States11
Fourstroke Outboard Limited Warranty (Middle-East, and Africa)14
Year Limited Warranty against Corrosion17
Warranty Coverage and Exclusions21
Boater's Responsibilities24
Before Operating Your Outboard24
General Information24
Boat Horsepower Capacity25
High-Speed and High-Performance Boat Operation26
Outboard Remote Control Models26
Remote Steering Notice27
Lanyard Stop Switch28
Stopping the Boat in an Emergency30
Protecting People in the Water31
Passenger Safety Message - Pontoon Boats and Deck Boats32
Wave and Wake Jumping33
Safety Instructions for Hand-Tilled Outboards34
Exhaust Emissions35
Selecting Accessories for Your Outboard36
Safe Boating Suggestions37
Recording Serial Number39
40 Jet 4-Stroke Specifications39
Component Identification40
Transporting Portable Fuel Tanks41
Trailering Boat/Outboard41
Transporting41
Fuel Recommendations43
Fuel & Oil43
Filling Fuel Tank45
Engine Oil Recommendations45
Checking and Adding Engine Oil46
Remote Control Features48
Features & Controls48
Warning System49
Power Trim and Tilt51
Throttle Grip Friction Adjustment - Tiller Handle Models55
Steering Friction Adjustment55
Replaceable Jet Drive Shear Key56
Pre-Starting Check List57
Operating in Freezing Temperatures57
Operation57
Operating in Saltwater or Polluted Water58
Operating in Shallow Water58
How the Jet Drive Operates58
Stopping the Boat in an Emergency60
Steering the Boat60
Mooring the Boat61
Water Intake Blockage61
Clearing a Lodged Impeller62
Pre-Starting Instructions62
Engine Break-In Procedure63
Starting the Engine - Remote Control Models63
Starting the Engine - Tiller Handle Models66
Gear Shifting68
Stopping the Engine70
Emergency Starting70
Outboard Care73
EPA Emissions73
Maintenance73
Inspection and Maintenance Schedule74
Flushing the Cooling System76
Top Cowl Removal and Installation77
Exterior Care78
Battery Inspection78
Fuel System79
Steering Link Rod Fasteners80
Corrosion Control Anode82
Spark Plug Inspection and Replacement82
Steering Pull Adjustment84
Worn/Dull Impeller84
Impeller Clearance Adjustment85
Fuse Replacement86
Timing Belt Inspection87
Lubrication Points88
Checking Power Trim Fluid92
Changing Engine Oil92
Submerged Outboard94
Storage Preparation95
Storage95
Protecting External Outboard Components96
Protecting Internal Engine Components96
Jet Drive96
Positioning Outboard for Storage96
Battery Storage96
Starter Motor will Not Crank the Engine (Electric Start Models)97
Engine will Not Start97
Troubleshooting97
Engine Runs Erratically98
Engine Over-Speed (Excessive RPM)98
Performance Loss98
Battery will Not Hold Charge99
Local Repair Service100
Service Away from Home100
Parts and Accessories Inquiries100
Service Assistance100
Owner Service Assistance100
Mercury Marine Service Offices101
Installation Information103
Outboard Installation103
Determining the Mounting Height of the Outboard104
Checking Boat Transom Construction107
Fastening the Outboard108
Steering Cable - Starboard Side Routed Cable109
Steering Link Rod Fasteners110
Steering Cable Seal112
Fuel Hose Connection - Remote Control Models112
Electrical Connections and Control Cable Installation113
Trim-In Stop Adjustment - Power Trim Models119
Water Testing119

Mercury 40 Jet - Top Cowl Removal and Installation

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