Mercury 40 Sea Pro

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Welcome Aboard1
Table of Contents3
Transfer of Warranty6
Warranty Registration United States and Canada6
Warranty Registration Outside the United States and Canada6
Warranty Information6
Mercury Marine Two Years Limited Warranty (Europe)7
Mercury Marine One Year Limited Warranty (Confederation of Independent States, Middle-East, Africa)8
Year Limited Warranty against Corrosion10
Warranty Coverage and Exclusions11
Boater's Responsibilities13
Before Operating Your Outboard13
Boat Horsepower Capacity13
General Information13
High-Speed and High-Performance Boat Operation14
Outboard Remote Control Models14
Remote Steering Notice14
Lanyard Stop Switch15
Protecting People in the Water16
Passenger Safety Message - Pontoon Boats and Deck Boats16
Wave and Wake Jumping17
Impact with Underwater Hazards18
Safety Instructions for Hand Tilled Outboards19
Exhaust Emissions19
Selecting Accessories for Your Outboard20
Safe Boating Suggestions21
Recording Serial Number21
40 Sea Pro/Marathon - 30/40 HP Specifications22
Component Identification23
40 Seapro/Marathon Component Identification24
Installing Outboard25
Installation25
Propeller Selection26
Trailering Boat/Outboard27
Transporting Portable Fuel Tanks27
Transporting27
Gasoline Recommendations29
Oil Recommendation29
Fuel and Oil Ratio29
Fuel & Oil29
Mixing Fuel and Oil30
Filling Oil Injection System30
Filling Fuel Tank31
Remote Control Features32
Warning System - Electric Start Models32
Features & Controls32
Low Oil Level33
Warning Horn System - Manual Start Models33
Engine Over-Speed Limiter34
Manual Tilt System35
Shallow Water Operation36
Power Trim and Tilt (if Equipped)41
Power Trim Operation42
Throttle Grip Friction Adjustment - Tiller Handle Models44
Steering Friction Adjustment44
Trim Tab Adjustment45
Pre-Starting Check List47
Operating in Freezing Temperatures47
Operating in Salt Water or Polluted Water47
Operating at High Elevations47
Engine Break-In Procedure47
Operation47
Starting the Engine - Electric Start Remote Control Models48
Starting the Engine - Tiller Handle Models and Manual Start Remote Control Models50
Gear Shifting54
Stopping the Engine54
Emergency Starting - Electric Start Models55
Emergency Starting - Manual Start Models57
Outboard Care59
EPA Emissions59
Maintenance59
Inspection and Maintenance Schedule60
Flushing the Cooling System60
Top Cowl Removal and Installation61
Battery Inspection62
Fuel System62
Carburetor Adjustments65
Exterior Care66
Steering Link Rod Fasteners66
Fuse Replacement - Electric Start Models67
Corrosion Control Anode68
Propeller Replacement68
Spark Plug Inspection and Replacement70
Lubrication Points71
Checking Power Trim Fluid73
Gearcase Lubrication74
Submerged Outboard75
Protecting Internal Engine Components76
Gearcase76
Positioning Outboard for Storage76
Storage Preparation76
Protecting External Outboard Components76
Storage76
Battery Storage77
Starter Motor will Not Crank the Engine (Electric Start Models)78
Engine will Not Start78
Engine Runs Erratically78
Performance Loss78
Troubleshooting78
Battery will Not Hold Charge79
Local Repair Service80
Service Away from Home80
Parts and Accessories Inquiries80
Service Assistance80
Mercury Marine Service Offices80
Owner Service Assistance80

Mercury 40 Sea Pro - Page 2

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