Mercury 40 FourStroke, 30 FourStroke Service Manual
30/40
FourStroke
Starting Model Year 1999
Starting Serial Number 0G760300
Starting Model Year 1999
90-857046R1 NOVEMBER 2001
30/40 FourStroke
Notice
Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol
cerning a particular service or operation that may be hazardous if performed incorrectly or
carelessly. OBSERVE THEM CAREFULLY!
These “Safe t y A l e rts” alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus “Common Sense” operation,
are major accident prevention measures.
) are used to alert the mechanic to special instructions con-
DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Notice to Users of This Manual
This service manual has been written and published by the Service Department of Mercury
Marine to aid our dealers’ mechanics and company service personnel when servicing the
products described herein.
It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they
have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the service trade of all conceivable procedures
by which a service might be performed and of the possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. Therefore, anyone who uses
a service procedure and/or tool, which is not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the products safety will be endangered by the
service procedure selected.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
It should be kept in mind, while working on the product, that the electrical system and ignition
system are capable of violent and damaging short circuits or severe electrical shocks. When
performing any work where electrical terminals could possibly be grounded or touched by
the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered
to protect against accidental entrance of foreign material which could enter the cylinders and
cause extensive internal damage when the engine is started.
90-857046R1 NOVEMBER 2001 Page i
It is important to note, during any maintenance procedure replacement fasteners must have
the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial
lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal
injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original.
Cleanliness and Care of Outboard Motor
A marine power product is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any
product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and
friction areas is a part of the repair procedure. This is considered standard shop practice
even if not specifically stated.
Whenever components are removed for service, they should be retained in order. At the
time of installation, they should be installed in the same locations and with the same mating
surfaces as when removed.
Personnel should not work on or under an outboard which is suspended. Outboards should
be attached to work stands, or lowered to ground as soon as possible.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products de-
scribed in this manual.
Page ii 90-857046R1 NOVEMBER 2001
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
C - General Information
D - Outboard Motor Installation
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing,Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Carburetor
C - Emissions
Section 4 - Powerhead
A - Cylinder Head
B - Cylinder Block/Crankcase
C - Lubrication
Section 5 - Mid-Section
A - Clamp/Swivel Bracket & Drive Shaft Housing
B - Power Trim
C - Manual Tilt Assist
Section 6 - Gear Housing
A - Non-Bigfoot Gear Housing
B - Bigfoot Gear Housing
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Section 8 - Manual Starter
Section 9 - Color Diagrams
Important Information
Electrical
Fuel System
Powerhead
Mid-Section
Gear Housing
Attachments/
Control Linkage
Manual Starter
Color Diagrams
1
2
3
4
5
6
7
8
9
90-857046R1 NOVEMBER 2001 Page iii
SPECIFICATIONS
IMPORTANT INFORMATION
Section 1A - Specifications
Table of Contents
Specifications 1A-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Information Charts 1A-8. . . . . . . . . . . . . .
Specifications
Models 30/40 EFI (4-Stroke)
HORSEPOWER
(kW)
OUTBOARD
WEIGHT
FUEL
Model 30
Model 40
Electric
30/40 MH
30/40 ELPT
40 ELPT BIGFOOT
RECOMMENDED GASOLINE Automotive Unleaded
OIL FILTER
OIL FILTER WRENCH
ENGINE OIL CAPACITY
ENGINE OIL
SAE
25W-40
F°
C°
SAE
10W-30
1
A
Mercury/Quicksilver Lubricants and Sealants 1A-11
Torque Chart 1A-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
30 hp (22.4 Kw) @ 5750 rpm
40 hp (29.8 Kw) @ 5750 rpm
204 lb (93 kg)
224 lb (112.7 kg)
235 lb (106.6 kg)
with a Minimum Pump Posted
Octane Rating of 87
p/n 35-822626A2
p/n 91-802653Q1
Either 3 Quarts or 3 Liters
SAE 10W-30 viscosity oil is recom-
mended for use in all temperatures.
SAE 25W-40 viscosity oil may be used at
temperatures above 40° F (4° C).
OIL
+100
+80
+60
+40
+20
+38
+27
+16
+4
–7
–18
0
Use 4-Stroke Outboard Oil with the proper
viscosity for the expected temperature in
your area (see range thermometer on
left). If not available, use a premium
quality 4-stroke engine oil, certified to
meet or exceed anyone of the following
American Petroleum Institute (API) ser-
vice classifications SH, SG, SF, CF-4,
CE, CD, CDll.
90-857046R1 NOVEMBER 2001 Page 1A-1
SPECIFICATIONS
IGNITION
SYSTEM
Readings taken @
68°F (20°C).
CHARGING
SYSTEM
Readings taken @
68°F (20°C).
STARTING
SYSTEM
Type
Spark Plug:
Type
Gap
Hex Size
Torque
Hole Size
Firing Order
Ignition Timing:
@ Idle (800 rpm)
@ WOT (6000 rpm)
Charge Coil Resistance
Crank Position Sensor Resistance
Ignition Coil Resistance:
Primary
Secondary (W/o Boots)
ECM Engine Speed Limiter
Soft Reduction (Retards Timing)
Spark Cut-Out Reduction (Percent-
ages of ignition spark are Cut-Out)
ECM Overheat/Low Oil Pressure
Speed Control
Engine Temperature Sensor
Alternator Type:
6 Amp Manual Lighting Coil Output
Lighting Coil Resistance
15 Amp. Electric Alternator Output
Battery Charging Coil Resistance
Power Bobbin Resistance
(For Electrothermal Valve)
Quicksilver Tachometer Setting
Manual Start
Electric Start:
Starter Type
Output
Ampere Draw Under:
(Load)
(No Load)
Capacitor Discharge Ignition
NGK DPR6EA-9
0.035 in. (0.9 mm)
18 mm
150 lb-in. (17 Nm)
12mm
1-2-3
10° A.T.D.C
28° B.T.D.C
660 - 710 Ω (GRN/WHT - WHT/GRN)
300 - 350 Ω (RED - WHT)
0.08 - 0.7 Ω (BLK - BLK/WHT)
3.5 - 4.7 kΩ (BLK - High Tension)
6200 rpm
6250 rpm
Approximately 2000 rpm
See Graph Section 2A-Ignition
Single Phase (12 Pole)
6 Amps
0.9 - 1.1 Ohms (YEL-YEL)
12.6 V-15 Amps. (185 Watts)
(Rectified/Regulated)
0.22 - 0.24 Ohms (YEL-YEL)
6.7-7.1 Ohms (YEL/BLK-YEL/BLK)
“6P” or “4”
Recoil Start
Bendix
1.1 kW
174.0 Amps
23.7 Amps
Battery Rating
Minimum Requirement
For operation below 32° F (0° C)
BATTERY
Ampere-Hours (Ah) Minimum
For operation above 32° F (0° C)
For operation below 32° F (0° C)
IMPORTANT: Use resistive spark plugs only.
Page 1A-2 90-857046R1 NOVEMBER 2001
465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
1000 Marine Cranking Amps (MCA) or
775 Cold Cranking Amps (CCA)
70
105
SPECIFICATIONS
ENRICHMENT
CONTROL
SYSTEM
Readings taken @
68°F (20°C).
FUEL
SYSTEM
CARBURETOR
Auto Enrichener Resistance
Electrothermal Ram Projection
Fuel Pump Type
Fuel Pump:
Pressure
Fuel Tank Capacity
Idle rpm (Out Of Gear)
Idle rpm (In Forward Gear)
Wide Open Throttle rpm (WOT)
Range
Main Jet Size
Pilot Jet
Idle Jet
Float Height
15 - 25 Ohms (YEL/BLK - YEL/BLK)
0.3 in. (7mm) after 5 min. of power
Mechanical Water Cooled
(Plunger/Diaphragm)
3-6 psi
Accessory
900 ± 25 rpm
800 ± 25 rpm
5500–6000
#98
#38
#42
0.47-0.63 in. (12.0-16.0 mm)
CYLINDER
BLOCK
Type
Displacement
Number of Cylinders
4 Stroke – Over Head Camshaft
45.6 cu. in. (747 cc)
3
STROKE Length 2.953 in. (75 mm)
Diameter
2.5591 in. (65 mm)
2.5689 in. (65.25 mm)
2.5787 in. (65.5 mm)
0.003 in. (0.08 mm)
Cast Iron
Aluminum
CYLINDER
BORE
Standard
Oversize-0.010 in. (0.25 mm)
Oversize-0.020 in. (0.50 mm)
Taper/Out of Round Maximum
Bore Type
Piston Type
O.D. at Skirt
PISTON
PISTON
Standard
Oversize-0.010 in. (0.25 mm)
Oversize-0.020 in. (0.50 mm)
Piston to Cylinder Clearance 0.0014 - .0026 in. (0.035 - 0.065 mm)
2.5570 - 2.5578 in. (64.950 - 64.965 mm)
2.5669 - 2.5675 in. (65.2 - 65.215 mm)
2.5768 - 2.5774 in. (65.450 - 65.465 mm)
CLEARANCE
Ring End Gap (Installed)
0.006 - 0.012 in. (0.15 - 0.03 mm)
0.012 - 0.020 in. (0.30 - 0.50 mm)
0.008 - 0.028 in. (0.20 - 0.70 mm)
RINGS
Top
Middle
Bottom (Oil Ring)
Side Clearance:
Top
Middle
0.0008 - 0.0024 in. (0.02 - 0.06 mm)
0.0008 - 0.0024 in. (0.02 - 0.06 mm)
90-857046R1 NOVEMBER 2001 Page 1A-3
SPECIFICATIONS
Compression Ratio
COMPRESSION
RATIO
PISTON PIN Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm)
CONNECTING
ROD
CRANKSHAFT
CAMSHAFT
Cylinder Compression*
(Electric Models Only, Cold Engine @
W.O.T.)
Oil Clearance (Big End)
Small End Inside Diameter
Main Bearing Clearance
Crankshaft Run-out
Camshaft Dimensions
Intake “A”
Exhaust “A”
Intake “B”
Exhaust “B”
Run-out Limit
Camshaft Bearing Diameter “b”
B
0.0008 - 0.0020 in. (0.020 - 0.052 mm)
0.6293 - 0.6298 in. (15.985 - 15.998 mm)
0.0005 - 0.0017 in. (0.012 - 0.044 mm)
1.214 - 1.222 in. (30.83 - 31.03 mm)
1.214 - 1.222 in. (30.83 - 31.03 mm)
A
1.020 - 1.028 in. (25.90 - 26.10 mm)
1.020 - 1.028 in. (25.90 - 26.10 mm)
180 - 210 psi (Peak)
0.0018 in. (0.046 mm)
0.0039 in. (0.1 mm)
1.4541 - 1.4549 in.
(36.935 - 36.955 mm)
9.7:1
VALVE SPRING
b
b
b
Free Length “a”
Tilt Limit “b”
b
b
Compressed Pressure (Installed)
Intake
Exhaust
Tilt Limit (Intake & Exhaust)
Dir. of Winding (Intake & Exhaust)
b
a
a
1.491-1.569 in. (37.85-39.85 mm)
Less than 0.060 in. (1.7 mm)
19.8 - 22.0 lbs. (9.0 - 10.0 kg)
19.8 - 22.0 lbs. (9.0 - 10.0 kg)
0.043 in. (1.1 mm)
Left Hand
Page 1A-4 90-857046R1 NOVEMBER 2001
SPECIFICATIONS
CYLINDER HEAD
VALVES
Warp Limit
* Lines indicate
straight edge
measurement
Camshaft Bore Inside Diameter “a”
a
a
a
a
56900
Valve/Valve Seat/Valve Guides:
Valve Clearance (cold)
Intake
Exhaust
Valve Dimensions:
“A” Head Diameter
Intake
Exhaust
“B” Face Width
Intake
Exhaust
“C” Seat Width
Intake
Exhaust
“D” Margin Thickness
Intake
Exhaust
Stem Outside Diameter
Intake
Exhaust
Guide Inside Diameter
Intake
Exhaust
Stem To Guide Clearance
Intake
Exhaust
Stem Run-out Limit (max.)
0.004 in. (0.1 mm)
56899
1.4567 - 1.4577 in.
(37.000 - 37.025 mm)
0.006 - 0.010 in. (0.15 - 0.25 mm)
0.010 - 0.014 in. (0.25 - 0.35 mm)
1.256 - 1.264 in. (31.9 - 32.1 mm)
1.020 - 1.028 in. (25.9 - 26.1 mm)
0.079 - 0.124 in. (2.00 - 3.14 mm)
0.079 - 0.124 in. (2.00 - 3.14 mm)
0.035 - 0.043 in. (0.9 - 1.1 mm)
0.035 - 0.043 in. (0.9 - 1.1 mm)
0.020 - 0.035 in. (0.5 - 0.9 mm)
0.020 - 0.035 in. (0.5 - 0.9 mm)
0.2156 - 0.2161 in. (5.475 - 5.490 mm)
0.2150 - 0.2156 in. (5.460 - 5.475 mm)
0.2165 - 0.2170 in. (5.500 - 5.512 mm)
0.2165 - 0.2170 in. (5.500 - 5.512 mm)
0.0004 - 0.0015 in. (0.010 - 0.037 mm)
0.0010 - 0.0020 in. (0.025 - 0.052 mm)
0.0006 in. (0.016 mm)
90-857046R1 NOVEMBER 2001 Page 1A-5
SPECIFICATIONS
Valve Dimensions
Head Diameter Face Width
ROCKER SHAFT
ROCKER ARM
THERMOSTAT
LUBRICATION
SYSTEM
“B”
“C”
“A”
Seat Width
Margin Thickness
Outside Diameter 0.6288 - 0.6296 in.
(15.971 - 15.991 mm)
Inside Diameter of Bore 0.6299 - 0.6306 in.
(16.000 - 16.018 mm)
Valve Opening Temperature
Full Open Temperature
Valve Lift (Minimum)
Pump Type
136° F - 143° F (58° C - 62° C)
158° F (70° C)
0.12 in. (3mm)
Trochoid
Engine Oil Pressure (Warm Engine)
@ 3000 rpm
Engine Oil Pan Capacity
30-40 psi (207-278 kPa)
Either 3 Qts. or 3 Liters
Oil Pump:
S/N OT427437 & Up (Electric)
S/N OT426439 & Up (Manual)
Outer Rotor to Housing “a”
Inner Rotor to Outer Rotor “b”
Rotor to Housing “c”
0.0045 - 0.009 in. (0.11 - 0.23 mm)
0.005 in. (0.12 mm)
0.0015 - 0.003 in. (0.04 - 0.08 mm)
Oil Pump:
S/N OT427436 & Below (Electric)
S/N OT426438 & Below (Manual)
Outer Rotor to Housing “a”
Inner Rotor to Outer Rotor “b”
Rotor to Housing “c”
0.0035 - 0.006 in. (0.09 - 0.15 mm)
0.005 in. (0.12 mm)
0.001 - 0.003 in. (0.03 - 0.08 mm)
“D”
Transom Height:
Short Shaft
Long Shaft
Steering Pivot Range:
MID-SECTION
Tiller
Remote
Tilt Pin Positions
Full Tilt Up Angle
Allowable Transom Thickness
Page 1A-6 90-857046R1 NOVEMBER 2001
a
b
c
15 in. (38 cm)
20 in. (51 cm)
90°
60°
5 + Shallow Water
69°
2-3/4 in. (69.8 mm)
SPECIFICATIONS
GEAR HOUSING
(2.00:1)
GEAR HOUSING
BIGFOOT
(2.3:1)
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure (Warm Engine)
@ 800 rpm
@ 6000 rpm (WOT)
Leak Test Pressure
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Pinion Gear Locating Tool
Flat Number
Disc Number
Forward Gear Backlash
Backlash Indicating Tool
Mark Number
Water Pressure
@ 800 rpm (Idle)
@ 6000 rpm (WOT)
Leak Test Pressure
2.00:1
14.9 fl oz (440 mL)
Premium Blend Gear Lube
26 Spiral/Bevel
13 Spiral/Bevel
0.025 in. (0.64 mm)
No Adjustment
2–4 psi (14-28 kPa)
12-17 psi (69-103 kPa)
10-12 psi (68-83 kPa)
for 5 Minutes
2.31:1
24 fl oz (710 mL)
Premium Blend Gear Lube
30 Spiral/Bevel
13 Spiral/Bevel
0.025 in. (0.64 mm)
91-12349A2
#8
#3
0.012-0.019 in. (0.30-0.48 mm)
91-78473
#4
2-7 psi (14-41 kPa)
12-17 psi (83-172 kPa)
10-12 psi (69-83 kPa)
for 5 Minutes
90-857046R1 NOVEMBER 2001 Page 1A-7
SPECIFICATIONS
Propeller Information Charts
Mercury/Mariner 30 (4-Stroke) 2.00:1 Non-Bigfoot
Wide Open Throttle RPM : 5500-6000
Recommended Transom Heights : 15”, 20”, 22.5”
Right Hand Rotation Standard
Gear Reduction : 2.00:1
Approx.
No. of
Diameter
10” 19” 3 Alum Up to 600 Up to 14’ 45-53 48-73146A40
10” 17” 3 Alum Up to 700 Up to 14’ 39-46 48-73144A40
10” 16” 3 Steel 600-800 Up to 14’ 36-42 48-91818A5
10” 16” 3 Alum 600-800 Up to 14’ 36-42 48-73142A40
10-1/8” 15” 3 Steel 700-900 13-14’ 33-39 48-76232A5
10-1/8” 15” 3 Alum 700-900 13-14’ 33-39 48-73140A40
10-1/4” 14” 3 Steel 800-1000 14-15’ 30-36 48-76230A5
10-1/4” 14” 3 Alum 800-1000 14-15’ 30-36 48-73138A40
10-3/8” 13” 3 Steel 900-1100 14-16’ 27-33 48-76228A5
10-3/8” 13” 3 Alum 900-1100 14-16’ 27-33 48-73136A40
10-5/8” 12” 3 Steel 1000-1200 15-17’ 24-29 48-79792A5
10-5/8” 12” 3 Alum 1000-1200 15-17’ 24-29 48-73134A40
11-5/8” 11” 3 Steel 1100-1400 15-17’ 21-26 48-823478A5
10-7/8” 11” 3 Alum 1100-1400 15-17’ 21-26 48-85632A40
11-5/8” 10-1/2” 3 Alum 1300-1700 15-18’ 19-24 48-827312A10
Pitch
Blades
Material
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
11-1/4” 10” 3 Alum 1400-1900 16’ + 18-22 48-73132A40
12-1/4” 9” 3 Steel 2000+ pontoon 15-19 48-97868A10
12-1/4” 9” 3 Alum 2000+ pontoon 15-19 48-87818A10
12-1/2” 8” 3 Alum 2400+ pontoon/
houseboat
12-1/2” 8” Cup 3 Alum pontoon 48-42738A12
Page 1A-8 90-857046R1 NOVEMBER 2001
1-17 48-42738A10
Mercury/Mariner 40 (4-Stroke) 2.00:1 Non-Bigfoot
Wide Open Throttle RPM : 5500-6000
Recommended Transom Heights : 15”, 20”, 22.5”
Right Hand Rotation Standard
Gear Reduction : 2.00:1
SPECIFICATIONS
Diameter Pitch
No. of
Blades
Material
Approx.
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
10” 19” 3 Alum Up to 800 Up to 14’ 45-53 48-73146A40
10” 17” 3 Alum Up to 1000 Up to 15’ 39-46 48-73144A40
10” 16” 3 Steel 900-1100 Up to 15’ 36-42 48-91818A5
10” 16” 3 Alum 900-1100 Up to 15’ 36-42 48-73142A40
10-1/8” 15” 3 Steel 1000-1200 13-15’ 33-39 48-76232A5
10-1/8” 15” 3 Alum 1000-1200 13-15’ 33-39 48-73140A40
10-1/4” 14” 3 Steel 1100-1300 14-16’ 30-36 48-76230A5
10-1/4” 14” 3 Alum 1100-1300 14-16’ 30-36 48-73138A40
10-3/8” 13” 3 Steel 1200-1500 14-17’ 27-33 48-76228A5
10-3/8” 13” 3 Alum 1200-1500 14-17’ 27-33 48-73136A40
10-5/8” 12” 3 Steel 1400-1700 15-17’ 24-29 48-79792A5
10-5/8” 12” 3 Alum 1400-1700 15-17’ 24-29 48-73134A40
11-5/8” 11” 3 Steel 1600-2000 16-18’ 21-26 48-823478A5
10-7/8” 11” 3 Alum 1600-2000 16-18’ 21-26 48-85632A40
11-5/8” 10-1/2” 3 Alum 1800-2400 16’ + 19-24 48-827312A10
11-1/4” 10” 3 Alum 2000-2600 17’ + 18-22 48-73132A40
12-1/4” 9” 3 Steel 2300+ pontoon 15-19 48-97868A10
12-1/4” 9” 3 Alum 2300+ pontoon 15-19 48-87818A10
12-1/2” 8” 3 Alum 2700+ Pontoon/
1-17 48-42738A10
houseboat
12-1/2” 8” Cup 3 Alum pontoon 48-42738A12
90-857046R1 NOVEMBER 2001 Page 1A-9
SPECIFICATIONS
Mercury/Mariner 40 (4-Stroke) 2.3:1 Bigfoot
Special soft rubber hub propellers designed to reduce clutch rattle
Wide Open Throttle rpm: 5500-6000
Recommended Transom Heights : 20”, 25”
Right Hand Rotation Standard
Gear Reduction : 2.31:1
IMPORT ANT: These specially designed rubber hub propellers are rated for 60 horsepower MAXIMUM.
Approx.
No. of
Diameter
13-3/4” 15” 3 Alum 1200-1500 14-16’ 27-32 48-77342A33
14” 13” 3 Alum 1500-2000 16-18’ 22-27 48-77340A33
14” 11” 3 Alum 2000-3000 pontoon 17-21 48-77338A33
14” 10” 3 Alum 2500+ pontoon/work 14-19 48-854342A33
14” 9” 3 Alum 3500+ houseboat/
Pitch
Blades
Material
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
work
Speed
Range
(mph)
1-15 48-854340A33
Propeller
Part Number
Page 1A-10 90-857046R1 NOVEMBER 2001
Mercury/Quicksilver Lubricants and Sealants
SPECIFICATIONS
Description
Needle Bearing Assy. Lubricant [8
oz. (226.8 grams)] tube
Dielectric Grease
[8 oz. (226.8 grams)] can
Loctite 271 – Thread Locker
(10 ml) tube
Loctite 567 PST Pipe Sealant
(50 ml) tube
Loctite Master Gasket Kit
2 Cycle Premium Outboard Oil
[1 Gallon (3.7 liter)]
Perfect Seal
[16 oz. (0.45 kg)] can
Mercury Part Number
92-802868A1
92-823506-1
92-809819
92-809822
92-12564-2
92-802815A1
92-34227-1
Quicksilver Part Number
N/A
92-823506-1
92-809819
92-809822
92-12564-2
92-802815Q1
92-34227-1
Liquid Neoprene
[8 oz. (226.8 grams)] can
Cyanacrylate Adhesive
Bellows Adhesive
Loctite 680 Retaining Compound
(10 ml) tube
Loctite 222 Thread Locker
(10 ml) tube
3M Permabond #3M08155
Loctite 242 Thread Locker
(10 ml) tube
Loctite 609
Loctite 405
92-25711-3
Obtain Locally
N/A
92-809833
92-809818
Obtain Locally
92-809821
Obtain Locally
Obtain Locally
92-25711-3
Obtain Locally
92-86166Q1
92-809833
92-809818
Obtain Locally
92-809821
Obtain Locally
Obtain Locally
90-857046R1 NOVEMBER 2001 Page 1A-11
SPECIFICATIONS
Description
RTV 587 Silicone Sealer
[3 oz. (85.05 grams)]
Loctite 262
Premium Gear Lubricant
[1 Quart (0.94 liter)]
Loctite 7649 Primer
[4.5 oz (127.57 grams)]
Anti-Corrosion Grease
[8 oz. (226.8 grams)] tube
2-4-C with Teflon
[8 oz. (226.8 grams)] tube
Loctite Quick Tite
Mercury Part Number
92-809825
Obtain Locally
92-802846A1
92-809824
92-802867A1
92-802859A1
Obtain Locally
Quicksilver Part Number
92-809825
Obtain Locally
92-802846Q1
92-809824
92-802867Q1
92-802859Q1
Obtain Locally
Isopropyl Alcohol
Hot Glue
Special Lubricant 101
[8 oz. (226.8 grams)] tube
4 Stroke 10W30 Outboard Oil
[1 Quart (0.94 liter)]
4 Cycle 25W40 Engine Oil
[1 Quart (0.94 liter)]
Power Trim & Steering Fluid
[8 oz. (226.8 grams)]
Engine Coupler Spline Grease
[14 oz. (0.39 kg)] cartridge
Power Tune Engine Cleaner
[13 oz. (384 ml)] spray can
Obtain Locally
Obtain Locally
92-802865A1
92-802833A1
92-802837A1
92-802880A1
92-802869A1
92-802878
Obtain Locally
Obtain Locally
92-802865Q1
92-802833Q1
92-802837Q1
92-802880Q1
92-802869Q1
92-802878Q57
Fuel System Treatment & Stabilizer
[12 oz. (355 ml)] plastic bottle
Page 1A-12 90-857046R1 NOVEMBER 2001
92-802875A1
92-802875Q1
Torque Chart
SPECIFICATIONS
Fastener Location
Diameter x
Length (mm)
Torque
lb-in. lb-ft..
Ignition
Coil Mounting Nuts M5 30 3.5
Coil Mount Plate Screw (Rear) M6 x 25 60 7
Coil Mount Plate Screw M6 x 30 75 8.5
Coil Plate Ground Screw M6 x 10 60 7
Spark Plug 12 mm 150 17
Charging & Starting System
Flywheel Cover Screws M6 x 25 75 8.5
Flywheel Nut N/A 116 157
Stator Screws (Electric) M5 x 30 85 9.5
Stator Screws (Manual) M5 x 25 85 9.5
Voltage Regulator Screws M6 x 40 75 8.5
Starter Motor Mount Bolts M8 x 45 21.5 29.5
Starter Cable Nut 1/4-20 60 7
Starter Motor Thru Bolts N/A 70 8
Battery Cable (+) Nut M6 60 7
Solenoid Plate Screw M6 x 14 45 5
Harness Retainer Screws M6 x 14 45 5
Wire Clamp Screw (Top of Block) M5 x 12 45 5
Cylinder Head
Cylinder Head Bolts (*) M9 x 95 34.5 47
Cylinder Head Bolts (*) M6 x 25 106 12
Baffle Plate Screws M4 x 10 Drive Tight
Valve Cover Screws M6 x 20 70 8
Valve Adjusting Nuts M6 120 13.5
Rocker Arm Shaft Screws M8 x 23 160 13 18
Driven Gear Screw M10 x 40 28 38
Cylinder Block/Crankcase
Crankcase Cover Bolts - Center (*) M8 x 82 22 30
Crankcase Cover Bolts - Outer (*) M6 x 35 106 12
Exhaust Cover Screws M6 x 35 106 12
Connecting Rod Bolts (*) Special 150 17
Oil Filter N/A 70 8
Oil Filter Nipple N/A 29.5 40
Powerhead Mounting Bolts (*) M8 x 110 33 44.5
Lifting Eye Screw M8 x 35 29 39.5
Oil Pressure Switch N/A 75 8.5
Oil Galley Plug 1/8-27 Pipe Plug 80 9
Oil Galley Plug 3/4-14 Pipe Plug 30 40.5
Oil Galley Plug 1/2-14 Pipe Plug 30 40.5
Nm
*NOTE:
90-857046R1 NOVEMBER 2001 Page 1A-13
Two Step Torque - See appropriate section of component for details.
SPECIFICATIONS
Fastener Location
Diameter x
Length (mm)
Torque
lb-in. lb-ft.
Lubrication
Oil Pump Mounting Screws M6 x 40 70 8
Oil Pump Cover Screws M6 x 16 70 8
Mid-Section
Top Cowl Latch Screw/Nut M4 x 14 Drive Tight
Top Rear Cowl Latch Screw/Nut M6 x 16 90 10
Bottom Cowl Screws M6 x 30 60 7
Bottom Cowl Screws M6 x 60 60 7
Rear Cowl Latch Screw (Bottom) M6 x 16 60 7
Oil Drain Plug N/A 17.5 23.5
Gear Housing Mounting Stud M10 144 12 16
Adaptor Plate Mounting Screw M8 x 45 33 44.5
Co-Pilot Plate Bolt (Shoulder) 1/4-20 x 0.68 70 8
Steering Bracket Bolts M10 x 30 32.5 44
Steering Link Rod Bolt Special 20 27
Steering Link Rod Nut 3/8-24 Torque to 120 lb-in. then
back off 1/4 turn.
Upper Mount Bolts M6 x 20 130 14.5
Upper Mount Bolts M12 x 154 24 32.5
Upper Mount Nuts M12 24 32.5
Lower Mount Bolts M10 x 105 32.5 44
Lower Mount Nuts M12 32.5 44
Ground Screws 10-16 x 0.38 Drive Tight
Tilt Lever Bolt (Shoulder) 3/8-16 x 0.62 18 25
Tilt Stop Bolt M10 x 40
Tilt Tube Nut 3/414 Torque to 32 lb-ft., then back
off 1/4 turn.
Anchor Bracket Screws M8 x 30 25 34
Anchor Bracket Screws M8 x 35 25 34
Anode Screws M6 x 25 60 7
Adaptor Plate (Socket Head) Screw M6 x 55 150 17
Oil Pressure Relief Valve N/A 34 46
Oil Pickup/Gasket Screw M6 x 20 75 8.5
Oil Gallery Plug 1/214 Pipe Plug 24 33
Power Trim
Shock Rod Piston N/A 90 122
Piston Spring Plate Screws N/A 35 4
Cylinder End Cap N/A 45 61
Trim Cylinder/Reservoir Screws N/A 100 11
Pump to Manifold Screws N/A 70 8
Check Valve Plug N/A 120 13
Reservoir Screws N/A 80 9
Nm
Page 1A-14 90-857046R1 NOVEMBER 2001
SPECIFICATIONS
Fastener Location
Diameter x
Length (mm)
Torque
lb-in. lb-ft.
Manual Tilt Assist
Plug, Velocity Valve N/A 75 8.5
Plug, Plunger (2) N/A 75 8.5
Shock Rod Piston N/A 90 122
Piston Spring Plate Screws N/A 35 4
Cylinder End Cap N/A 45 61
Tilt Cylinder/Reservoir Screws N/A 100 11
Accumulator N/A 35 47
Non-Bigfoot Gear Housing
Pinion Nut N/A 50 68
Bearing Carrier Screws M8 x 25 19 25.5
Vent, Fill/Drain Screw NA 60 7
Water Pump Cover Screws M6 x 16 60 7
Gear Housing Mounting Screws M10 x 45 40 54
Gear Housing Mounting Nut M10 40 54
Trim Tab Screw M8 x 20 23 31.5
Propeller Nut N/A 55 74.5
Bigfoot Gear Housing
Bearing Carrier Nut M8 25 34
Water Pump Base Screws M6 x 25 60 7
Water Pump Cover Screws M6 x 30 60 7
Vent, Fill/Drain, Oil Level Screw N/A 60 7
Gear Housing Mounting Bolts M10 x 45 40 54
Gear Housing Mounting Nut M10 40 54
Trim Tab Screw 7/16 x 1-1/4 in 22 30
Anode Screw M6 x 40 60 7
Propeller Nut
Throttle/Shift Linkage
Throttle/Shift Lever Screw M8 x 70 100 11.5
Throttle Cam Mounting Screw M6 x 40 75 8.5
Throttle Cam Screw 10-16 x 5/8 in. Drive Tight
Remote Control Cable Anchor Bracket Screws M6 x 16 75 8.5
Shift Spring Screw M5 x 16 45 5
Neutral Start Switch Screws M3 x 20 20 2.5
Shift Link Nut (Bigfoot) M6
Tiller Handle
Tiller Mounting Bracket Screws M10 x 90 35 47.5
Shift Handle Screw M8 x 150 100 11
Tiller Tube Retainer Screw M5 x 16 35 4
Tiller Mount Cover Screws M8 x 25 135 15
Pulley Case Screws Self Tapping 10-16 x 1/2 20 2.5
Nm
90-857046R1 NOVEMBER 2001 Page 1A-15
MAINTENANCE
IMPORTANT INFORMATION
Section 1B - Maintenance
Table of Contents
Table of Contents 1B-1. . . . . . . . . . . . . . . . . . . . . . .
Special Tools 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercury/Quicksilver Lubricants and Sealants 1B-2
Inspection And Maintenance Schedule 1B-3. . . . .
Before Each Use 1B-3. . . . . . . . . . . . . . . . . . . . .
After Each Use 1B-3. . . . . . . . . . . . . . . . . . . . . . .
Every 100 Hours of Use or Once yearly 1B-3.
Every 300 Hours of Use or Three Years 1B-4.
Before Periods of Storage 1B-4. . . . . . . . . . . . .
Flushing the Cooling System 1B-4. . . . . . . . . . . . . .
Steering Link Rod Fasteners 1B-5. . . . . . . . . . . . . .
Corrosion Control Anode 1B-6. . . . . . . . . . . . . . . . .
Spark Plug Inspection and Replacement 1B-7. . .
Battery Inspection 1B-7. . . . . . . . . . . . . . . . . . . . . . .
Fuse Replacement - Electric Start Models 1B-8. .
Timing Belt Inspection 1B-8. . . . . . . . . . . . . . . . . . .
Lubrication Points 1B-9. . . . . . . . . . . . . . . . . . . . . . .
Checking Power Trim Fluid 1B-10. . . . . . . . . . . . . . .
1
B
Fuel System 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Line Inspection 1B-11. . . . . . . . . . . . . . . . . .
Changing Engine Oil 1B-12. . . . . . . . . . . . . . . . . . . . .
Oil Changing Procedure 1B-12. . . . . . . . . . . . . . .
Changing Oil Filter 1B-13. . . . . . . . . . . . . . . . . . . .
Checking and Adding Engine Oil 1B-13. . . . . . .
Changing Gear Case Lubricant 1B-14. . . . . . . . . . .
3-1/4 In. (83mm) Diameter Gear Case 1B-14. .
4-1/4 In. (108mm) Diameter Gear Case 1B-15.
Storage Preparation 1B-17. . . . . . . . . . . . . . . . . . . . .
Fuel System 1B-17. . . . . . . . . . . . . . . . . . . . . . . . .
Protecting External Outboard
Components 1B-17. . . . . . . . . . . . . . . . . . . . . . . . .
Protecting Internal Engine Components 1B-17.
Gear Case 1B-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning Outboard for Storage 1B-18. . . . . . .
Battery Storage 1B-18. . . . . . . . . . . . . . . . . . . . . .
90-857046R1 NOVEMBER 2001 Page 1B-1
MAINTENANCE
Special Tools
1. Crankcase Oil Pump P/N 90265A5
2. Oil Filter Wrench P/N 91-802653Q1
3. Flushing Attachment P/N 44357A2
Mercury/Quicksilver Lubricants and Sealants
NOTE: See section 1A for lubricants and sealants chart.
Page 1B-2 90-857046R1 NOVEMBER 2001
Inspection And Maintenance Schedule
To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance
Schedule. We urge you to keep it maintained properly to ensure the safety of you and your
passengers and retain its dependability.
WARNING
Neglected inspection and maintenance service of your outboard or attempting to
perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury, death, or product
failure.
Before Each Use
1. Check engine oil level.
2. Check that lanyard stop switch stops the engine.
3. Visually inspect the fuel system for deterioration or leaks.
4. Check outboard for tightness on transom.
5. Check steering system for binding or loose components.
MAINTENANCE
6. Visually check steering link rod fasteners for proper tightness.
7. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. If operating in salt water, wash off all salt deposits and flush out the exhaust outlet of the
propeller and gear case with fresh water.
Every 100 Hours of Use or Once yearly, Whichever occurs first
1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Change engine oil and replace the oil filter . The oil should be changed more often when
the engine is operated under adverse conditions such as extended trolling.
3. Inspect thermostat visually for corrosion, broken spring, and to determine that the valve
is completely closed at r oom t emperature. I f q uestionable, i nspect t hermostat a s o utlined
in Section 4B “Thermostat”.
4. Inspect and clean spark plugs.
5. Check engine fuel filter for contaminants.
6. Check engine timing setup.
7. Check corrosion control anodes. Check more frequently when used in salt water.
8. Drain and replace gear case lubricant.
9. Lubricate splines on the drive shaft.
10. Check and adjust valve clearance, if necessary.
11. Check power trim fluid.
12. Inspect battery.
13. Check control cable adjustments.
14. Inspect timing belt.
90-857046R1 NOVEMBER 2001 Page 1B-3
MAINTENANCE
15. Remove engine deposits with Power Tune Engine Cleaner.
16. Check tightness of bolts, nuts, and other fasteners.
Every 300 Hours of Use or Three Years, Whichever Occurs First
1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).
Before Periods of Storage
1. Refer to Storage procedure (this section).
Flushing the Cooling System
Flush the internal water passages of the outboard with fresh water after each use in salt,
polluted or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages.
IMPORTANT: The engine must be run during flushing in order to open the thermostat
and circulate water through the water passages.
NOTE: You can have the outboard tilted or in the vertical operating position during flushing.
WARNING
To avoid possible injury when flushing, remove the propeller. Refer to Propeller Replacement.
1. Place the outboard in either the operating position (vertical) or in a tilted position.
2. Remove propeller (refer to Propeller Replacement).
3. 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.
a
a-Water Hose Threaded into Rear Fitting
IMPORTANT: Do not run engine above idle when flushing.
4. Shift outboard into neutral. Start the engine and flush the cooling system for at least 5
minutes. Keep engine speed at idle.
5. Stop the engine. Turn off the water and remove hose. Reinstall the propeller.
Page 1B-4 90-857046R1 NOVEMBER 2001
Steering Link Rod Fasteners
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.
IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special washer head bolt (“a” – Part Number 10-823919) and
self locking nylon insert locknuts (“b” & “c” – Part Number 11-826709113). These
locknuts must never be replaced with common nuts (non locking) as they will work
loose and vibrate off, freeing the link rod to disengage.
f
e
MAINTENANCE
WARNING
b
d
c
a
a-Special Washer Head Bolt (10-823919)
b-Nylon Insert Locknut (11-826709113)
c-Nylon Insert Locknut (11-826709113)
d-Flat Washers
e-Spacer (12-71970)
f-Link Rod Mount Hole
1. Assemble steering link rod to steering cable with two flat washers (d) and nylon insert
locknut (“c” – Part Number 11-826709113). Tighten locknut (c) until it seats, then back
nut off 1/4 turn.
2. Assemble steering link rod to engine with special washer head bolt (“a” – Part Number
10-823919), locknut (“b” – Part Number 11-826709113) and spacer (“e” – 12-71970).
First torque bolt (a) to 20 lb. ft. (27 Nm), then torque locknut (b) to 20 lb. ft. (27 Nm).
90-857046R1 NOVEMBER 2001 Page 1B-5
MAINTENANCE
Corrosion Control Anode
Your outboard has control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded 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. Never paint or apply a protective coating on the anode as this will reduce
effectiveness of the anode.
1. An anode is installed on the bottom of the transom bracket assembly. On the 3-1/4 in.
(83 mm) diameter gear case the trim tab is also an anode. The 4-1/4 in. (108 mm) diameter (Bigfoot) gear case has three anodes. One of the anodes is the trim tab and two
anodes (one on each side) are located on the side of the housing.
c
b
a
a-Bottom Anode
b-Trim Tab
c-Side Anodes (Big Foot Models Only)
MANUAL START MODELS S/N OT426439 AND BELOW
ELECTRIC START MODELS S/N OT427437 AND BELOW
2. Three anodes are installed in the engine block. Remove the three ignition coils for clearance. Remove anodes at locations shown. Install each anode with rubber seal and
cover. Tighten screws to 70 lb-in. (8 Nm) torque. Reinstall the ignition coils. Tighten coil
screws to 70 lb-in. (8 Nm) torque
b
d
a
c
a-Anodes-Engine Block
b-Ignition Coils
Page 1B-6 90-857046R1 NOVEMBER 2001
c-Rubber Seal
d-Cover
Spark Plug Inspection and Replacement
Inspect spark plugs at the recommended intervals.
WARNING
Avoid ser i ous 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. T o avoid damaging spark plug boots, do not use any sharp
object or metal tool such as pliers, screwdriver, etc. to remove spark plug boots.
1. Remove the spark plug leads by twisting the rubber boots slightly and pulling off.
2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.
IMPORTANT: Use resistive spark plugs only.
MAINTENANCE
3. Set the spark plug gap. See Specification Chart.
4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs fin-
ger tight, and tighten 1/4 turn or torque to 12.5 lb-ft (17 Nm).
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting capability.
IMPORTANT: Read the safety and maintenance instructions which accompany your
battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive
and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.
90-857046R1 NOVEMBER 2001 Page 1B-7
MAINTENANCE
Fuse Replacement – Electric Start Models
IMPORTANT: Always carry spare 20 AMP Fuses.
The electric starting circuit is protected from overload by a 20 Amp. fuse. If the fuse is blown,
the electric starter motor will not operate. Try to locate and correct the cause of the overload.
If the cause is not found, the fuse may blow again. Replace the fuse with a fuse of the same
amperage rating.
1. Disconnect fuse holder , and remove fuse. Look at the silver colored band inside the fuse.
If band is broken replace the fuse. Replace fuse with a new fuse with the same amperage rating.
a
a-Fuse Holder and 20 Amp. Fuse
b-Blown Fuse
Timing Belt Inspection
1. Inspect the timing belt and replace if any of the following conditions are found.
a. Cracks in the back of the belt or in the base of the belt teeth.
b. 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.
b
a
a-Timing Belt
Page 1B-8 90-857046R1 NOVEMBER 2001
Lubrication Points
Lubricate Point 1 with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.
1. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the pro-
peller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.
Lubricate Points 2 thru 6 with 2 -4-C Marine Lubricant with Teflon or Special Lubricant 101.
2. Swivel Bracket – Lubricate through fitting.
MAINTENANCE
1
3. Tilt Support Lever – Lubricate through fitting.
4. Tilt Tube – Lubricate through fitting.
3
2
4
90-857046R1 NOVEMBER 2001 Page 1B-9
MAINTENANCE
WARNING
The end o f t he s teering c able must be fully r etracted i nto the outboard t ilt t ube b efore
adding lubricant. Adding lubricant t o steering cable w hen f ully e xtended c ould c ause
steering cable to become hydraulically l ocked. A h ydraulically l ocked s teering c able
will cause loss of steering control, possibly resulting in serious injury or death.
5. Steering Cable Grease Fitting (5) (If equipped) - Rotate steering wheel to fully retract
the steering cable end into the outboard tilt tube. Lubricate through fitting.
Lubricate Pivot Points with light weight oil.
6. This grease fitting (6) is for lubricating the threaded rod for the co-pilot.
6
a
5
b
a-Steering Cable End
b-Pivot Points
Checking Power Trim Fluid
1. Tilt outboard to the full up position and engage the tilt support lock.
a-Tilt Support Lock
2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of
the fill hole. Add Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
a
a-Fill Cap
Page 1B-10 90-857046R1 NOVEMBER 2001
a
Fuel System
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or
allow open flames or sparks in the area while servicing any part of the fuel system.
Before servicing any part of the fuel system, stop engine and disconnect the battery . Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. Inspect any completed service work for signs of fuel leakage.
Fuel Filter
IMPORT ANT: Visually inspect for fuel leakage from the filter by squeezing the primer
bulb until firm, forcing fuel into the filter.
Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace.
MAINTENANCE
WARNING
a
a-Filter
Fuel Line Inspection
Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other
signs of det e r i o r a t i o n o r damage. If any of these conditions are found, the fuel line or primer
bulb must be replaced.
90-857046R1 NOVEMBER 2001 Page 1B-11
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