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Mercury 40 Service Manual

Mercury 40
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BIGFOOT GEAR HOUSING
Page 6B-60 90-828631R3 MARCH 1999
CAUTION
Do not use lubricant on top of driveshaft. Excess lubricant, that is trapped in clear-
ance space, will not allow driveshaft to fully engage with crankshaft. Subsequently,
tightening the gear housing fasteners (while lubricant is on top of driveshaft) will
load the driveshaft/crankshaft and damage either or both the power head and gear
housing. Top of driveshaft is to be wiped free of lubricant.
6. Apply a light coat of Quicksilver 2-4-C w/Teflon onto driveshaft splines.
7. Apply a light coat of Quicksilver 2-4-C w/Teflon on gear case shift shaft splines and upper
shift shaft splines. Do not use lubricant on ends of shift shafts.
8. Install components as shown in appropriate photo.
ALL EXCEPT 75 W/MECHANICAL REVERSE LOCK
53968
a
b
c
a-Nylon Spacer
b-Shift Shaft Coupler
c-Bushing 40/45/50 Bigfoot (4-Stroke) Only
75 W/MECHANICAL REVERSE LOCK
53925
a
b
c
a-Nylon Spacer
b-Shift Shaft Coupler
c-Flat; MUST BE Positioned Toward Front of Gear Housing

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Mercury 40 Specifications

General IconGeneral
Horsepower40 hp
Starting SystemElectric
SteeringRemote
Fuel Induction SystemEFI (Electronic Fuel Injection)
Shaft Length20"
Full Throttle RPM Range6000

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