Mercury 40 Operator's Manual
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Mercury 40 Operator's Manual

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See also: Service Manual , Operation & Maintenance Manual
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.

Declaration of Conformity

This outboard motor's serial number plate contains in the lower corner left hand corner either the CE mark
alone or the CE mark accompanied by a notified body number. This outboard motor manufactured by Mercury
Marine, Fond du Lac, WI, USA or Marine Power Europe Inc. Park Industriel, de Petit‑Rechain, Belgium
complies with the requirements of the following directives by meeting the associated standards, as amended:
If the CE mark is accompanied by a notified body number, the following Recreational Craft Directive applies:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4)
Fuel tanks (A.5.2.2)
General steering system
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
The notified body responsible for surveillance of the quality system under Full Quality
Assurance Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
If the CE mark is not accompanied by a notified body number, the following Recreational Craft Directive
language applies:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4)
Fuel tanks (A.5.2.2)
2003/44/EC amending 94/25/EC
ISO 10240
ISO 8665
ISO 11547
ISO 13591; ISO 8469
ABYC P‑17
ISO 8178
ISO 8665
ISO 14509
ISO 10240
ISO 8665
ISO 11547
ISO 13591; ISO 8469
i
94/25/EC

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  • Page 1: Declaration Of Conformity

    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.
  • Page 2 EN 61000‑6‑2; EN 61000‑4‑2; EN Electrostatic discharge testing 61000‑4‑3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe. Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA European Regulations Contact: Regulations and Product Safety Department, Mercury Marine,...

  • Page 3: Table Of Contents

    Safety Instructions For Hand Tilled Outboards..................... 14 Exhaust Emissions............................... 14 Selecting Accessories For Your Outboard......................15 Safe Boating Suggestions............................ 16 Recording Serial Number............................. 16 40/50/60 4-Stroke Specifications - International....................17 Component Identification............................19 INSTALLATION Installing Outboard............................... 20 Propeller Selection............................... 20 TRANSPORTING Trailering Boat/Outboard .............................
  • Page 4 TABLE OF CONTENTS 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........................
  • Page 5 Starter Motor Will Not Crank The Engine (Electric Start Models).................66 Engine Will Not Start............................66 Engine Runs Erratically............................66 Performance Loss..............................67 Battery Will Not Hold Charge..........................67 OWNER SERVICE ASSISTANCE Local Repair Service............................68 Service Away From Home............................68 Parts And Accessories Inquiries...........................68 Service Assistance...............................68 Mercury Marine Service Offices........................... 68...

  • Page 7: Warranty Information

    You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department. Your dealer can also process this change of information.

  • Page 8: Fourstroke Outboard Limited Warranty United States, Canada And Europe

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 9: Fourstroke Outboard Limited Warranty

    FourStroke Outboard Limited Warranty (Confederation of Independent States, Middle‑East, and Africa WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE: This Limited Warranty provides coverage for one (1) year from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first.
  • Page 10 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related laborand material, and any other expenses associated with that service.

  • Page 11: Year Limited Warranty Against Corrosion

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 12: Warranty Coverage And Exclusions

    Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti‑fouling paints is also not covered by this limited warranty.
  • Page 13 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 14: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard.

  • Page 15: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. ob00307 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 16: Lanyard Stop Switch

    GENERAL INFORMATION WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. ob00309 Self‑locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch.

  • Page 17: Protecting People In The Water

    GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle.

  • Page 18: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat. Passenger Safety Message ‑ Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed.

  • Page 19: Impact With Underwater Hazards

    Under these conditions, boat speed should be kept to a minimum planing speed 24 to 40 km/h (15 to 25 MPH). ob00315...

  • Page 20: Safety Instructions For Hand Tilled Outboards

    GENERAL INFORMATION • The boat could move suddenly in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat. • A rapid reduction in speed. This will cause occupants to be thrown forward, or even out of the boat. •...

  • Page 21: Selecting Accessories For Your Outboard

    Running the boat with the trim angle of the Running the boat with no forward hatches bow too high. open. Selecting Accessories For Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers.

  • Page 22: Safe Boating Suggestions

    Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier 61 m (200 ft.) in front of you in 5 seconds.

  • Page 23: 40/50/60 4-Stroke Specifications - International

    GENERAL INFORMATION OTXXXXXX 20XX XXXX ob00319 Serial number Year manufactured Model year Certified Europe Insignia (as applicable) Model designation 40/50/60 4‑Stroke Specifications ‑ International Models Horsepower Kilowatts 29.8 37.7 44.7 Full Throttle RPM Range 5500‑6000 RPM Number of Cylinders Idle Speed in Forward Gear...
  • Page 24 GENERAL INFORMATION Models Recommended Oil Refer to Fuel & Oil Gearcase Lubricant Capacity 83mm (3‑1/4 in.) Diameter 340 ml (11.5 fl. oz.) Gearcase 108mm (4‑1/4 in.) Diameter 710 ml (24.0 fl. oz.) Gearcase Engine Oil Capacity 3.0 Liter (3 Quarts) Battery Rating Operation Above 0 °C 465 Marine Cranking Amps (MCA) or 350 Cold Cranking...

  • Page 25: Component Identification

    GENERAL INFORMATION Component Identification ob00647 Auxiliary tilt switch Water pump indicator hole Tilt support knob Bottom cowl Transom brackets Top cowl Primary cooling water intake Shift handle Gearcase Engine stop switch Trim tab Throttle friction adjustment knob Anti‑ventilation plate Lanyard stop switch Driveshaft housing Steering friction adjustment lever (tiller handle models)

  • Page 26: Installation

    INSTALLATION Installing Outboard WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance.
  • Page 27 INSTALLATION ob00323 If changing conditions cause the RPM to drop below the recommended range (such as warmer, more humid weather, operation at higher elevations, increased boat load, or a dirty boat bottom/gearcase), a propeller change or cleaning may be required to maintain performance and ensure the outboards durability. Check full‑throttle RPM, using an accurate tachometer, with the engine trimmed out to a balanced‑steering condition (steering effort equal in both directions) without causing the propeller to break loose.

  • Page 28: Transporting

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways and trailer bouncing.
  • Page 29 TRANSPORTING ob00326 Connector stem Tether cap...

  • Page 30: Fuel & Oil

    The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 31: Filling Fuel Tank

    NMMA FC‑W certified 4‑stroke outboard oil of similar viscosity may be used. When operating in temperatures above 4 °C (40° F), we encourage the use of NMMA FC‑W certified synthetic blend 25W‑40 4‑Stroke Outboard Oil.

  • Page 32: Checking And Adding Engine Oil

    Recommended SAE Viscosity for Engine Oil NMMA FC‑ W certified 10W‑30 outboard oil NMMA FC‑W certified synthetic blend may be used at temperatures below 4 °C 25W‑40 outboard oil may be used in all (40 °F) temperatures. Checking And Adding Engine Oil IMPORTANT: Do not overfill.
  • Page 33 FUEL & OIL Push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. Reinstall the oil filler cap and hand tighten securely. ob00648 Dipstick Oil filler cap...

  • Page 34: Features & Controls

    FEATURES & CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. ob00329 Control handle ‑...
  • Page 35 FEATURES & CONTROLS Warning Horn Function Sound Description Start Up One Beep Normal System Test Engine Fault Six Beeps at Start Up or The horn sounds when there While Driving may be a problem with one of the engine functions. Have your dealer check the engine soon.

  • Page 36: Power Trim And Tilt (If Equipped)

    Consult your dealer for assistance. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption and engine operating hours.

  • Page 37: Power Trim Operation

    FEATURES & CONTROLS ob00338 Remote control trim switch Tilt range of travel Panel mount trim switch Trim range of travel POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out.

  • Page 38: Auxiliary Tilt Switch

    FEATURES & CONTROLS • In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets are desired. Trimming Out or Up can: •...

  • Page 39: Throttle Grip Friction Adjustment - Tiller Handle Models

    FEATURES & CONTROLS ob00340 Auxiliary tilt switch SHALLOW WATER OPERATION When operating the boat in shallow water, the outboard can be tilted beyond the maximum trim range to prevent hitting bottom. ob00334 Reduce engine speed below 2000 RPM. Tilt outboard up. Make sure all the water intake holes stay submerged at all times. Operate the engine at slow speed only.

  • Page 40: Trim Tab Adjustment

    FEATURES & CONTROLS NOTE: To maintain proper adjustment, the locknut located on top of the steering friction lever pivot shaft can be tightened. ob00342 Tighten friction Locknut Loosen friction REMOTE STEERING MODELS WARNING Avoid possible serious injury or death from loss of boat control. Maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released.
  • Page 41 FEATURES & CONTROLS ob00344 NOTE: Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti‑ventilation plate approximately 50 mm (2 in.) or more above the boat bottom. MODELS WITHOUT POWER TRIM Operate your boat at normal cruising speed trimmed to desired position by installing the tilt pin in the desired tilt pin hole.

  • Page 42: Operation

    Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

  • Page 43: Engine Break-In Procedure

    OPERATION ob00346 Make sure the cooling water intake is submerged. CAUTION Never start or operate your outboard (even momentarily) without water circulating through all the cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or overheating of the engine. ob00347 Engine Break‑in Procedure CAUTION...
  • Page 44 OPERATION Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. ob00348 Squeeze the fuel line primer bulb several times until it feels firm. ob00349 Set the lanyard stop switch to RUN position. Refer to General Information ‑ Lanyard Stop Switch. ob00350 Shift outboard to neutral (N) position.

  • Page 45: Starting The Engine - Tiller Handle Models

    OPERATION Turn ignition key to the "start" position. If engine fails to start in ten seconds, return key to "on" position, wait 30 seconds and try again. ob00354 After engine starts, check for a steady stream of water flowing out of the water pump indicator hole. ob00331 IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake for obstruction.
  • Page 46 OPERATION Set the lanyard stop switch to RUN position. Refer to General Information ‑ Lanyard Stop Switch. ob00350 Shift outboard to neutral (N) position. ob00355 Set the throttle grip to start position. 0%100 0%100 START START START ob00356 Start position Half‑way position Starting Flooded Engine ‑...

  • Page 47: Gear Shifting

    OPERATION ob00331 IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat. Have the outboard checked by your dealer. Operating the engine while overheated may cause serious engine damage.

  • Page 48: Stopping The Engine

    OPERATION • After shifting outboard into gear, advance the remote control lever or rotate the throttle grip (tiller handle) to increase speed. Stopping The Engine Remote Control Models ‑ Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF"...
  • Page 49 OPERATION WARNING When using emergency starter rope to start engine, the start in gear protection device is inoperative. Make sure to set the outboard gear shift into neutral to prevent outboard from starting in gear. Sudden unexpected acceleration could result in serious injury or death. Electric Start Models ‑...

  • Page 50: Maintenance

    SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 51: Inspection And Maintenance Schedule

    MAINTENANCE The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Inspection And Maintenance Schedule BEFORE EACH USE • Check engine oil level. See Fuel & Oil ‑ Checking and Adding Engine Oil. •...

  • Page 52: Top Cowl Removal And Installation

    MAINTENANCE Place the outboard in either the operating position (vertical) or in a tilted position. Remove propeller. Refer to Propeller Replacement. Thread a water hose into the rear fitting. Partially open the water tap (1/2 maximum). Do not open the water tap all the way, as this allows a high pressure flow of water.

  • Page 53: Fuel System

    MAINTENANCE IMPORTANT: Read the safety and maintenance instructions which accompany your battery. Turn off the engine before servicing the battery. Add water as necessary to keep the battery full. Make sure the battery is secure against movement. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative.

  • Page 54: Steering Link Rod Fasteners

    MAINTENANCE INSTALLATION IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter. Push the filter element into the cover. Place the O‑ring seal into its proper position on the sight bowl, and screw the sight bowl hand tight into the cover.

  • Page 55: Corrosion Control Anode

    MAINTENANCE Corrosion Control Anode Your outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals. Each anode requires periodic inspection, especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded.
  • Page 56 Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. ob00377 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. ob00378 Tube Ref No.
  • Page 57 MAINTENANCE Flo‑Torq I Drive Hub Propellers ‑ Install forward thrust hub, propeller, propeller nut retainer and propeller nut onto the shaft. ob00379 Propeller nut Propeller Propeller nut retainer Forward thrust hub Flo‑Torq II Drive Hub Propellers ‑ Install forward thrust hub, propeller, replaceable drive sleeve, rear thrust hub, propeller nut retainer and propeller nut onto the shaft.

  • Page 58: Propeller Replacement - 108 Mm (4 - 1/4 In.) Diameter Gearcase

    MAINTENANCE Propeller Replacement ‑ 108 mm (4 ‑ 1/4 in.) Diameter Gearcase WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller.
  • Page 59 MAINTENANCE Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. ob00378 Tube Ref No. Description Where Used Part No. Anti-Corrosion Grease Propeller shaft 92-802867Q1 2-4-C with Teflon Propeller shaft 92-802859Q1 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in salt water), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed.
  • Page 60 MAINTENANCE ob00421 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Thrust hub Forward thrust hub NOTE: Stainless Steel Applications ‑ Installation of a Flo‑Torq III drive hup propeller is recommended. Flo‑Torq III Drive Hub Propellers ‑ Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft.

  • Page 61: Spark Plug Inspection And Replacement

    MAINTENANCE Spark Plug Inspection And Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors under the engine cowl. To avoid damaging spark plug boots, do not use any sharp object or metal tool such as pliers, screwdriver, etc.

  • Page 62: Timing Belt Inspection

    Excessive wear at the roots of the cogs. c. Rubber portion swollen by oil. d. Belt surfaces roughened. e. Signs of wear on edges or outer surfaces of belt. ob00427 Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon.
  • Page 63 Propeller Shaft ‑ Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. ob00378 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with Teflon or Special Lubricant 101. Tube Ref No.

  • Page 64: Checking Power Trim Fluid

    MAINTENANCE ob00428 WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. A hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death.

  • Page 65: Changing Engine Oil

    Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.

  • Page 66: Gearcase Lubrication - For 87.3 Mm(3-7/16 In.) Diameter Gearcase

    MAINTENANCE ob00437 OIL FILLING Remove the oil fill cap and add oil to proper operating level. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Add oil if necessary. ob00651 Oil fill cap Gearcase Lubrication ‑...

  • Page 67: Gearcase Lubrication - For 108 Mm(4 - 1/4 In.) Diameter Gearcase

    MAINTENANCE ob00439 Vent plug Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 340 ml (11.5 fl. oz.). CHECKING GEARCASE LUBRICANT LEVEL AND REFILLING GEARCASE Place outboard in a vertical operating position. Remove vent plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. IMPORTANT: Replace sealing washers if damaged.
  • Page 68 MAINTENANCE DRAINING GEARCASE Place outboard in a vertical operating position. Place a drain pan below outboard. Remove vent plugs and fill/drain plug and drain lubricant. ob00441 Vent plugs Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 710 ml (24 fl. oz.). CHECKING LUBRICANT LEVEL AND FILLING GEARCASE Place outboard in a vertical operating position.

  • Page 69: Submerged Outboard

    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.

  • Page 70: Storage

    Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No. Description Where Used Part No.

  • Page 71: Battery Storage

    STORAGE CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard. Battery Storage • Follow the battery manufacturer's instructions for storage and recharging. •...

  • Page 72: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) POSSIBLE CAUSES • Blown fuse in the starting circuit. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 73: Performance Loss

    TROUBLESHOOTING Performance Loss POSSIBLE CAUSES • Engine Guardian System activated. Refer to Features & Controls ‑ Warning System. • Throttle not fully open. • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. •...

  • Page 74: Owner Service Assistance

    Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your outboard product, contact your dealer or any authorized Mercury Marine dealership. If additional assistance is required, take these steps.
  • Page 75 Telephone (954) 744‑3513 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744‑3535 U.S.A. Japan Telephone 81‑053‑423‑2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81‑053‑423‑2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way...

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