Mercury 40 Service Manual

SPECIFICATIONS
90-828631R3 MARCH 1999 Page 1A-7
1997 AND NEWER
GEAR HOUSING
(1.83:1)
40/45/50 1997 and Newer models
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ Idle
@ WOT
1.83:1
14.9 fl oz (440 mL)
Quicksilver Gear Lube-Premium Blend
22 Spiral/Bevel
12 Spiral/Bevel
0.025 in. (0.64 mm)
No Adjustment
2-4 psi (14-28 kPa) @ 750 rpm
12-17 psi (83-117 kPa) @ 6000 rpm
1998 AND NEWER
BIGFOOT GEAR
HOUSING
(2.3:1)
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ 750 rpm (Idle)
@ 6000 rpm (WOT)
2.3:1
22.5 fl oz (655 mL)
Quicksilver Gear Lube-Premium Blend
30 Spiral/Bevel
13 Spiral/Bevel
0.025 in. (0.64 mm)
0.012-0.019 in. (0.30-0.48 mm)
2-4 psi (14-28 kPa)
10-15 psi (69-103 kPa)
Gear Case Design Identification
a
b
“3 Jaw Reverse Clutch” “6 Jaw Reverse Clutch”
a-Design I - “3 Jaw Reverse Clutch” Gear Case Identifier
b-Design II - “6 Jaw Reverse Clutch” Gear Case Identifier
Identify gear case design to ensure correct components are being installed. Design I -
“3 Jaw Reverse Clutch” (a) gear case identified with straight machined edge for trim tab
screw mounting surface. Design II - “6 Jaw Reverse Clutch” (b) gear case identified with
angled machined edge for trim tab screw mounting surface.

Mercury 40 Specifications

General

Horsepower	40 hp
Starting System	Electric
Steering	Remote
Fuel Induction System	EFI (Electronic Fuel Injection)
Shaft Length	20"
Full Throttle RPM Range	6000