Mercury 40

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MAINTENANCE

Submerged Outboard

A submerged outboard will require service within a few hours by an authorized dealer once the outboard is

recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed

to the atmosphere to minimize internal corrosion damage to the engine.

Main Page

Declaration of Conformity1
Table of Contents3
Warranty Information7
Transfer of Warranty7
Warranty Registration United States and Canada7
Warranty Registration Outside the United States and Canada7
Fourstroke Outboard Limited Warranty United States, Canada and Europe8
Fourstroke Outboard Limited Warranty9
Year Limited Warranty against Corrosion11
Warranty Coverage and Exclusions12
General Information14
Boater's Responsibilities14
Before Operating Your Outboard14
Boat Horsepower Capacity14
High-Speed and High-Performance Boat Operation15
Outboard Remote Control Models15
Remote Steering Notice15
Lanyard Stop Switch16
Protecting People in the Water17
Passenger Safety Message - Pontoon Boats and Deck Boats18
Wave and Wake Jumping18
Impact with Underwater Hazards19
Safety Instructions for Hand Tilled Outboards20
Exhaust Emissions20
Selecting Accessories for Your Outboard21
Safe Boating Suggestions22
Recording Serial Number22
40/50/60 4-Stroke Specifications - International23
Component Identification25
Installation26
Installing Outboard26
Propeller Selection26
Transporting28
Trailering Boat/Outboard28
Transporting Portable Fuel Tanks28
Fuel & Oil30
Fuel Recommendations30
Filling Fuel Tank31
Engine Oil Recommendations31
Checking and Adding Engine Oil32
Features & Controls34
Remote Control Features34
Warning System34
Power Trim and Tilt (if Equipped)36
Power Trim Operation37
Auxiliary Tilt Switch38
Throttle Grip Friction Adjustment - Tiller Handle Models39
Steering Friction Adjustment39
Trim Tab Adjustment40
Operation42
Pre-Starting Check List42
Operating in Freezing Temperatures42
Operating in Salt Water or Polluted Water42
Pre-Starting Instructions42
Engine Break-In Procedure43
Starting the Engine - Remote Control Models43
Starting the Engine - Tiller Handle Models45
Gear Shifting47
Stopping the Engine48
Emergency Starting48
Maintenance50
Outboard Care50
EPA Emissions50
Inspection and Maintenance Schedule51
Flushing the Cooling System51
Top Cowl Removal and Installation52
Exterior Care52
Battery Inspection52
Fuel System53
Steering Link Rod Fasteners54
Corrosion Control Anode55
Propeller Replacement - 87.3 MM (3 - 7/16 In.) Diameter Gearcase55
Propeller Replacement - 108 MM (4 - 1/4 In.) Diameter Gearcase58
Spark Plug Inspection and Replacement61
Fuse Replacement61
Timing Belt Inspection62
Lubrication Points62
Checking Power Trim Fluid64
Changing Engine Oil65
Gearcase Lubrication - for 87.3 MM(3-7/16 In.) Diameter Gearcase66
Gearcase Lubrication - for 108 MM(4 - 1/4 In.) Diameter Gearcase67
Submerged Outboard69
Storage70
Storage Preparation70
Protecting External Outboard Components70
Protecting Internal Engine Components70
Gearcase70
Positioning Outboard for Storage70
Battery Storage71
Troubleshooting72
Starter Motor will Not Crank the Engine (Electric Start Models)72
Engine will Not Start72
Engine Runs Erratically72
Performance Loss73
Battery will Not Hold Charge73
Owner Service Assistance74
Local Repair Service74
Service Away from Home74
Parts and Accessories Inquiries74
Service Assistance74
Mercury Marine Service Offices74

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