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Mercury Jet 40 - User Manual

Mercury Jet 40
61 pages
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Welcome Aboard!
Proper care and maintenance is an important part in keeping your Mercury Product operating at peak
efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key
to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty
coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose? Please check on www.marinepower.com. If
necessary, please contact your local dealer.
If the outboard motor’s serial number plate contains the CE mark in the lower left-hand corner, the
following statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe
Inc. Park Industrel, de Petit-Rechain, Belgium complies with the requirements of the following directives
and standards, as amended:
Recreational Craft Directive: 94/25/EC; std. ISO 8665, ISO 11547
Machinery Directive: 98/37/EC,
EMC Directive: 89/336/EC; std. EN50081-1, SAE J551 (CISPR Pub. 12),
EN 50082-1, IEC 61000 PT4-2, IEC 61000 PT4-3
Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Product Environmental Engineering Department, Mercury Marine, Fond du Lac, WI USA
© 2004 Mercury Marine Jet 40 90-10136050 204

Table of Contents

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Mercury Jet 40 Specifications

General IconGeneral
Horsepower40 HP
Cylinders3
Weight240 lbs (109 kg)
SteeringRemote
Displacement45.6 cu in (747 cc)
StartingElectric
Full Throttle RPM Range5000 - 6000 RPM
Fuel Induction SystemCarburetor
Alternator Output18 Amp
Shaft Length20 in

Summary

Warranty Information

Transfer Of Warranty

How to transfer the limited warranty to a subsequent purchaser.

Warranty Registration United States And Canada

Process for registering warranty for products sold in the US and Canada.

Warranty Registration Outside The United States And Canada

Process for registering warranty for products sold outside North America.

Mercury Marine Two Years Limited Warranty (Europe)

Details of the two-year limited warranty for Mercury Marine products in Europe.

Mercury Marine One Year Limited Warranty (Confederation of Independent States, Middle-East, Africa)

Details of the one-year limited warranty for specific regions outside North America.

3 Year Limited Warranty Against Corrosion

Specifics of the three-year limited warranty covering corrosion damage.

Warranty Coverage And Exclusions

Clarification of what is covered and excluded under the warranty.

General Information

Boaters Responsibilities

Operator's duties for safe boat operation and occupant safety.

Before Operating Your Outboard

Essential checks and information required before operating the outboard.

Boat Horsepower Capacity

Importance of matching the outboard to the boat's maximum horsepower rating.

Outboard Remote Control Models

Requirements for remote control systems used with the outboard.

Remote Steering Notice

Safety warning regarding the proper fastening of steering link rod components.

Lanyard Stop Switch

Function, operation, and safety precautions for the lanyard stop switch.

Stopping the Boat in an Emergency

Procedures for emergency stopping of the jet drive boat.

Protecting People In The Water

Safety measures to prevent injury to persons in the water near the boat.

Wave And Wake Jumping

Hazards and precautions associated with jumping waves or wakes.

Exhaust Emissions

Information on carbon monoxide poisoning and necessary ventilation.

Selecting Accessories For Your Outboard

Guidelines for choosing and installing compatible accessories for the outboard.

Safe Boating Suggestions

General advice and suggestions for safe boating practices.

Recording Serial Number

Importance of recording and referencing the outboard's serial number.

Component Identification

Diagram identifying the main external components of the outboard.

Jet 40 Specifications

Installation

Installing Outboard

Instructions and safety warnings for properly mounting the outboard.

Transporting

Trailering Boat;Outboard

Recommendations for safely trailering a boat with the outboard.

Fuel and Oil

Gasoline Recommendations

Guidelines for selecting the correct type and octane of gasoline.

Oil Recommendation

Specifies the required type of 2-cycle oil for the engine.

New Engine Gasoline;Oil Break-in Mixture

Procedure for breaking in a new engine using a specific fuel/oil mixture.

Features and Controls

Remote Control Features

Overview of different remote control types and their functions.

Warning System

Description of the audible warning system for engine conditions.

Engine Over-Speed Limiter

How the engine's over-speed protection mechanism functions.

Power Trim And Tilt

Operation and benefits of the power trim and tilt system.

Manual Tilting

Procedure for manually tilting the outboard.

Auxiliary Tilt Switch

Using an auxiliary switch to tilt the outboard.

Manual Tilt System

Operation of manual tilt systems on models without power trim.

Throttle Grip Friction Adjustment

Adjusting the throttle friction for tiller handle models.

Steering Friction Adjustment

Adjusting steering friction for tiller handle models.

Replaceable Jet Drive Shear Key

Function and location of the jet drive shear key.

Operation

Pre-Starting Check List

Essential checks and procedures to perform before starting the engine.

Operating In Freezing Temperatures

Precautions and procedures for operating in freezing conditions.

Operating In Salt Water Or Polluted Water

Care and maintenance guidelines for operating in salt or polluted water.

Operating at High Elevations

Considerations for operating the outboard at high altitudes.

Operating In Shallow Water

Safe operating practices in shallow water to protect the jet drive.

How the Jet Drive Operates

Explanation of the jet drive propulsion system's functionality.

Stopping the Boat in an Emergency

Procedures for emergency stopping of the boat using the jet drive.

Steering The Boat

How to effectively steer the boat using jet thrust.

Mooring The Boat

Proper procedures for mooring the boat safely.

Water Intake Blockage

Causes, symptoms, and solutions for water intake blockages.

Clearing A Lodged Impeller

Steps to free a lodged impeller in the jet drive.

Engine Break-in Procedure

Instructions for the initial break-in period of a new engine.

Starting The Engine

Step-by-step guide for starting the outboard engine.

Gear Shifting

Explanation of the outboard's gear shifting positions (Forward, Neutral, Reverse).

Stopping The Engine

Procedures for safely stopping the outboard engine.

Emergency Starting

How to start the engine using the emergency starter rope.

Maintenance

Outboard Care

General advice for maintaining the outboard's optimal operating condition.

EPA Emissions

Information regarding the emission certification label on the engine.

Inspection And Maintenance Schedule

Schedule of required inspections and maintenance tasks for the outboard.

Flushing The Cooling System

Procedure for flushing the outboard's cooling system with fresh water.

Top Cowl Removal And Installation

Steps for safely removing and reinstalling the engine's top cowl.

Battery Inspection

How to inspect and maintain the boat's battery for starting capability.

Fuel System

Safety precautions and maintenance procedures for the fuel system.

Exterior Care

Instructions for cleaning and waxing the outboard's exterior finish.

Steering Link Rod Fasteners

Importance of using correct fasteners for steering link rod connections.

Fuse Replacement

Procedure for replacing a blown fuse in the electric starting circuit.

Corrosion Control Anode

Function and maintenance of the corrosion control anode.

Spark Plug Inspection and Replacement

Procedures for inspecting and replacing spark plugs.

Steering Pull Adjustment

How to adjust steering to correct a pulling condition.

Worn;Dull Impeller

Symptoms and causes of a worn or dull impeller.

Impeller Clearance Adjustment

How to adjust the clearance between the impeller and the liner.

Impeller Removal and Installation

Step-by-step guide for servicing the jet drive impeller.

Lubrication Points

Locations and types of lubricants for various outboard components.

Checking Power Trim Fluid

Procedure for checking the fluid level in the power trim system.

Submerged Outboard

Immediate service requirements for an outboard that has been submerged.

Storage

Storage Preparation

Procedures for preparing the outboard for out-of-season or prolonged storage.

Protecting External Outboard Components

Methods to protect external outboard parts from corrosion and damage during storage.

Protecting Internal Engine Components

Methods to protect internal engine components during storage.

Positioning Outboard for Storage

Correct orientation for storing the outboard to allow water drainage.

Battery Storage

Guidelines for storing the boat battery safely.

Troubleshooting

Starter Motor Will Not Crank The Engine (Electric Start Models)

Diagnosing issues when the electric starter motor does not engage.

Engine Will Not Start

Common causes and solutions for an engine that fails to start.

Engine Runs Erratically

Troubleshooting common causes for erratic engine performance.

Engine Over-Speed (Excessive RPM)

Diagnosing and addressing conditions that cause excessive engine RPM.

Performance Loss

Identifying potential causes for reduced engine performance.

Battery Will Not Hold Charge

Troubleshooting issues related to the battery not retaining charge.

Owner Service Assistance

Local Repair Service

Recommendation to use authorized local dealers for servicing.

Service Away From Home

Guidance on finding service when traveling away from the local dealer.

Parts And Accessories Inquiries

Information on where to direct inquiries for parts and accessories.

Service Assistance

Steps to follow for obtaining assistance with unresolved service issues.

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