Mercury 40

TABLE OF CONTENTS
iv
FEATURES & CONTROLS
Remote Control Features..................................................................................................................................... 28
Warning System................................................................................................................................................... 28
Power Trim and Tilt (If Equipped).........................................................................................................................30
Throttle Grip Friction Adjustment - Tiller Handle Models...................................................................................... 33
Steering Friction Adjustment................................................................................................................................ 33
Trim Tab Adjustment............................................................................................................................................ 34
OPERATION
Pre-Starting Check List......................................................................................................................................... 36
Operating In Freezing Temperatures................................................................................................................... 36
Operating In Salt Water Or Polluted Water.......................................................................................................... 36
Pre-Starting Instructions....................................................................................................................................... 36
Engine Break-in Procedure.................................................................................................................................. 37
Starting The Engine - Remote Control Models..................................................................................................... 37
Starting The Engine - Tiller Handle Models..........................................................................................................39
Gear Shifting ........................................................................................................................................................41
Stopping The Engine ...........................................................................................................................................42
Emergency Starting .............................................................................................................................................42
MAINTENANCE
Outboard Care......................................................................................................................................................44
EPA Emissions.....................................................................................................................................................44
Inspection And Maintenance Schedule................................................................................................................ 45
Flushing The Cooling System...............................................................................................................................45
Top Cowl Removal And Installation......................................................................................................................46
Exterior Care........................................................................................................................................................ 46
Battery Inspection ................................................................................................................................................46
Fuel System..........................................................................................................................................................47
Steering Link Rod Fasteners................................................................................................................................48
Corrosion Control Anode...................................................................................................................................... 49
Propeller Replacement - 87.3 mm (3 - 7/16 in.) Diameter Gearcase................................................................... 49
Propeller Replacement - 108 mm (4 - 1/4 in.) Diameter Gearcase...................................................................... 52
Spark Plug Inspection And Replacement.............................................................................................................55
Fuse Replacement............................................................................................................................................... 55
Timing Belt Inspection.......................................................................................................................................... 56
Lubrication Points.................................................................................................................................................56
Checking Power Trim Fluid.................................................................................................................................. 58
Changing Engine Oil ............................................................................................................................................ 59
Gearcase Lubrication - For 87.3 mm(3-7/16 in.) Diameter Gearcase.................................................................. 60
Gearcase Lubrication - For 108 mm(4 - 1/4 in.) Diameter Gearcase................................................................... 61
Submerged Outboard...........................................................................................................................................63
STORAGE
Storage Preparation............................................................................................................................................. 64
Protecting External Outboard Components..........................................................................................................64
Protecting Internal Engine Components............................................................................................................... 64
Gearcase..............................................................................................................................................................64