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Mercury Marathon 40 HP User Manual

Mercury Marathon 40 HP
81 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 40 Sea Pro/Marathon - 30/40 HP 90-10148050 304

Table of Contents

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Mercury Marathon 40 HP Specifications

General IconGeneral
Horsepower40 HP
Engine Type3-cylinder
Full Throttle RPM Range5000-6000 RPM
Starting SystemElectric
SteeringRemote
Alternator Output18 Amp
Shaft Length20 inches

Summary

WARRANTY INFORMATION

Transfer Of Warranty

Details on transferring the limited warranty to a subsequent purchaser.

Warranty Registration

Procedures for registering the product for warranty coverage in the US and abroad.

Mercury Marine Two Years Limited Warranty (Europe)

Details of Mercury Marine's two-year limited warranty coverage for products sold in Europe.

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

Details of Mercury Marine's one-year limited warranty for specific regions.

3 Year Limited Warranty Against Corrosion

Information on Mercury Marine's three-year limited warranty against corrosion damage.

Warranty Coverage And Exclusions

Explanation of what is covered and not covered by Mercury Marine warranties.

GENERAL INFORMATION

Boater's Responsibilities

Outlines the operator's duties for safe boat operation and occupant safety.

Before Operating Your Outboard

Guidance on pre-operation checks and understanding the manual for safe use.

Boat Horsepower Capacity

Warnings and advice regarding matching outboard horsepower to boat capacity.

Safety Alerts and Warnings

Explanation of DANGER, WARNING, and CAUTION alerts for safe boating practices.

High-Speed And High-Performance Boat Operation

Recommendations for operating high-speed or high-performance boats safely.

Lanyard Stop Switch

Description and importance of the lanyard stop switch for operator safety.

Protecting People In The Water

Safety advice for preventing injury to people in the water around the boat.

Wave And Wake Jumping

Hazards associated with operating a boat over waves and wakes.

Impact With Underwater Hazards

Precautions and speed recommendations when encountering underwater obstacles.

Exhaust Emissions

Information on carbon monoxide poisoning risks and ventilation.

Safe Boating Suggestions

General recommendations for safe and responsible boating practices.

40 Sea Pro/Marathon - 30/40 HP Specifications

Technical specifications for the 30/40 HP Sea Pro/Marathon outboard models.

Component Identification

Diagrams identifying various parts of the outboard motor.

INSTALLATION

Installing Outboard

Instructions and warnings for correctly mounting the outboard motor to the transom.

Propeller Selection

Guidance on choosing the appropriate propeller for optimal performance.

TRANSPORTING

Trailering Boat/Outboard

Proper procedures for trailering a boat with the outboard motor.

Transporting Portable Fuel Tanks

Safety instructions for transporting portable fuel tanks.

FUEL & OIL

Gasoline Recommendations

Advice on the type and octane rating of gasoline suitable for the outboard.

Oil Recommendation

Guidance on the recommended type of 2-cycle oil for the outboard engine.

Fuel and Oil Ratio

Mixing ratios for gasoline and oil for models without oil injection.

Filling Oil Injection System

Instructions for filling the outboard's oil injection system.

Filling Fuel Tank

Instructions and warnings for safely filling the outboard's fuel tank.

FEATURES & CONTROLS

Remote Control Features

Description of functions and operation of Mercury/Quicksilver remote controls.

Warning System Operation

Explanation of the outboard's warning horn and system alerts.

Engine Overheat and Over-Speed

Procedures for addressing engine overheating and the function of the over-speed limiter.

Manual Tilt System

Details on the manual tilt lock lever and tilting operations.

Shallow Water Operation

How to use the shallow water drive feature for operating in shallow water.

Power Trim Operation

Instructions for adjusting the outboard's trim and tilt position using power trim.

Steering Friction Adjustment

How to adjust steering friction on tiller handle and remote steering models.

Trim Tab Adjustment

Using trim tabs to compensate for steering torque and improve boat handling.

OPERATION

Pre-Starting Check List

Essential checks to perform before starting the outboard engine.

Operating Procedures

Guidance for operating in freezing temps, salt water, and at high elevations.

Engine Break-in Procedure

Critical steps for breaking in a new outboard engine to ensure longevity.

Starting The Engine

Step-by-step instructions for starting electric and manual start models.

Gear Shifting and Stopping

Procedures for shifting gears and safely stopping the engine.

Emergency Starting

Instructions for starting the engine using the emergency starter rope.

MAINTENANCE

Outboard Care and Parts

Basic care, selecting replacement parts, and EPA emission information.

Inspection and Maintenance Schedule

Recommended schedule for periodic inspections and maintenance tasks.

Flushing The Cooling System

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

Fuel System Maintenance

Includes fuel line inspection, fuel filter, and fuel pump maintenance.

Carburetor Adjustments

Instructions for adjusting slow and high speed mixture and idle speed.

Propeller Replacement

Step-by-step guide for removing and installing the outboard propeller.

Spark Plug Inspection and Replacement

Procedure for inspecting, gapping, and replacing spark plugs.

Lubrication Points

Locations and types of lubricants for various outboard components.

Gearcase Lubrication

Instructions for draining, refilling, and checking gearcase lubricant levels.

STORAGE

Storage Preparation

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

Fuel System Preparation

Steps to prepare the fuel system for storage, including stabilizer use.

Protecting External and Internal Components

Methods to protect outboard components from rust and corrosion during storage.

Battery Storage

Guidelines for safely storing the boat battery.

TROUBLESHOOTING

Engine Crankshaft and Starting Issues

Troubleshooting guide for starter motor and engine start failures.

Engine Running and Performance Issues

Diagnosing and resolving erratic engine running and performance loss.

Battery Charge Issues

Identifying causes and solutions for batteries that won't hold a charge.

OWNER SERVICE ASSISTANCE

Local Repair Service

Advice on returning the outboard to a local authorized dealer for service.

Service Away From Home

Guidance for obtaining service when away from the local dealer.

Parts and Accessories Inquiries

How to inquire about and order genuine Mercury parts and accessories.

Service Assistance

Steps to follow when seeking assistance or resolving dealership issues.

Mercury Marine Service Offices

Contact information for Mercury Marine service offices worldwide.

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