Mercury 40 jet fourstroke User Manual

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Declaration of Conformity 30/40/50/60 4‑Stroke – For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC

Name of engine manufacturer: Mercury Marine Technology Suzhou Co., Ltd.

Address: No 200 Suhong Middle Road, Suzhou Industrial Park

Town: Suzhou Post Code: 215021 Country: CHINA

Name of Authorized Representative: Brunswick Marine in EMEA Inc.

Address: Parc Industriel de Petit‑Rechain

Town: Verviers Post Code: B‑4800 Country: Belgium

Name of Notified Body for exhaust emission assessment: Det

Norske Veritas AS

Address: Veritasveien 1

Town: Hovik

Post Code:

1322

Country:

Norway

ID Number: 0575

Name of Notified Body for noise emission assessment: Det Norske

Veritas AS

Address: Veritasveien 1

Town: Hovik

Post Code:

1322

Country:

Norway

ID Number: 0575

Conformity assessment module used for exhaust emissions:

☐ B +C

☐ B +D

☐ B +E

☐ B +F

☐ G ☒ H

Conformity assessment module used for noise emissions:

☐ A ☐ Aa ☐ G ☒ H

Other Community Directives applied: Safety of Machinery Directive 2006/42/EC; Electromagnetic Compatibility Directive 2004/108/EC

Description of Engines and Essential Requirements

Engine Type

Fuel Type Combustion Cycle

☐ z or sterndrive with integral exhaust

☐ Diesel ☐ 2 stroke

☒ Outboard engine ☒ Petrol ☒ 4 stroke

40 Jet FourStroke

90-8M0082964 513

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Identification of Engines Covered by This Declaration of Conformity

Name of engine family

Unique engine identification number: starting serial number

EC Module H certificate number

30, 40 hp 3 cylinder 1C010000 RCD‑H‑2 Rev 4

40, 50, 60 hp 4 cylinder 1C010000 RCD‑H‑2 Rev 4

60 hp Formula Race 4 cylinder

1C010000 RCD‑H‑2 Rev 4

Essential requirements

standards

other

normative

document/

method

technical

file

Please specify in more detail (* = mandatory standard)

Annex 1.B—Exhaust Emissions

B.1 engine identification

☐ ☐ ☒

B.2 exhaust emission requirements

☒* ☐ ☐

* EN ISO 8178‑1:1996

B.3 durability ☐ ☐ ☒

EN ISO 8178‑1:1996

B.4 owner's manual

☒ ☐ ☐

EN ISO 8665: 2006

Annex 1.C—Noise Emissions

C.1 Noise emission levels

☒* ☐ ☐ *EN ISO 14509

C.2 Owner's manual

☐ ☒ ☐ Owner's manual

This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of the engine manufacturer that the engines mentioned preceding complies with all applicable essential requirements in the way specified.

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Name / function:

Mark D. Schwabero, President, Mercury Outboard

Date and place of issue:

September 04, 2012 Fond du Lac, Wisconsin, USA

Welcome

You have selected one of the finest outboards available. It incorporates numerous design features to ensure operating ease and durability.

With proper care and maintenance, you will enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual.

The Operation, Maintenance, and Warranty Manual contains specific instructions for using and maintaining your product. We suggest that this manual remain with the product for ready reference whenever you are on the water.

Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant!

Mercury Marine

EPA Emissions Regulations

Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, wherever practicable, returned to the original intent of the design. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual.

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Engines are labeled with an emission control information decal as permanent evidence of EPA certification.

WARNING

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

Warranty Message

The product you have purchased comes with a limited warranty from Mercury Marine. The terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this information.

The description and specifications contained herein were in effect at the time this manual was approved for printing. Mercury Marine, whose policy is one of continued improvement, reserves the right to discontinue models at any time, and to change specifications, designs, methods, or procedures without notice and without incurring obligation.

Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, and #1 On the Water are registered trademarks of Brunswick Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.

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Mercury Premier Service

Mercury evaluates the service performance of its dealers and assigns its highest rating of "Mercury Premier" to those demonstrating an exceptional commitment to service.

Earning a Mercury Premier Service rating means a dealer:

• Achieves a high 12‑month service Customer Satisfaction Index (CSI) score for warranty service.

• Possesses all of the necessary service tools, test equipment, manuals, and parts books.

• Employs at least one certified or master technician.

• Provides timely service for all Mercury Marine customers.

• Offers extended service hours and mobile service, when appropriate.

• Uses, displays, and stocks an adequate inventory of genuine Mercury Precision Parts.

• Offers a clean, neat shop with well‑organized tools and service literature.

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WARRANTY INFORMATION

Warranty Registration United States and Canada....................... 1

Transfer of Warranty United States and Canada.........................1

Transfer of Mercury Product Protection (Extended Service

Coverage) Plan United States and Canada.................................2

3 Year Limited Warranty Against Corrosion................................ 3

Warranty Coverage and Exclusions............................................ 6

U.S. EPA Emissions Limited Warranty........................................ 8

Emission Control System Components....................................... 8

California Emissions Limited Warranty........................................ 9

California Air Resources Board Explanation of Your California

Emission Control Warranty Statement.......................................13

Emission Certification Star Label............................................... 14

Warranty Policy—Australia and New Zealand........................... 15

Global Warranty Charts Outboard and Jets...............................21

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General Information

Boater's Responsibilities............................................................ 27

Before Operating Your Outboard............................................... 27

Boat Horsepower Capacity........................................................ 28

High‑Speed and High‑Performance Boat Operation................. 29

Outboard Remote Control Models ............................................ 29

Remote Steering Notice.............................................................30

Lanyard Stop Switch.................................................................. 31

Stopping the Boat in an Emergency.......................................... 33

Protecting People In The Water.................................................34

Passenger Safety Message ‑ Pontoon Boats and Deck Boats

................................................................................................... 35

Wave and Wake Jumping.......................................................... 37

Safety Instructions for Hand‑Tilled Outboards........................... 37

Exhaust Emissions.................................................................... 38

Selecting Accessories for Your Outboard.................................. 41

Safe Boating Recommendations............................................... 41

Recording Serial Number.......................................................... 44

40 Jet FourStroke Specifications............................................... 45

Component Identification........................................................... 46

Transporting

Trailering Boat/Outboard........................................................... 47

Transporting Portable Fuel Tanks............................................. 47

Fuel and Oil

Fuel Recommendations............................................................. 49

Low Permeation Fuel Hose Requirement ................................. 50

EPA Pressurized Portable Fuel Tank Requirements................. 51

Fuel Demand Valve (FDV) Requirement................................... 51

Mercury Marine's Pressurized Portable Fuel Tank.................... 52

Filling Fuel Tank........................................................................ 53

Engine Oil Recommendations................................................... 54

Checking and Adding Engine Oil............................................... 54

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Features and Controls

Remote Control Features.......................................................... 56

Warning System........................................................................ 57

Power Trim and Tilt....................................................................59

Throttle Grip Friction Adjustment ‑ Tiller Handle Models........... 63

Steering Friction Adjustment ‑ Tiller Handle Models..................63

Replaceable Jet Drive Shear Key.............................................. 64

Operation

Important Daily Inspection Before Each Use ............................ 65

Prestarting Check List................................................................65

Operating in Freezing Temperatures......................................... 66

Operating in Saltwater or Polluted Water.................................. 66

Operating in Shallow Water....................................................... 67

How the Jet Drive Operates.......................................................67

Stopping the Boat in an Emergency.......................................... 69

Steering the Boat....................................................................... 69

Mooring the Boat....................................................................... 70

Water Intake Blockage...............................................................71

Clearing A Lodged Impeller....................................................... 71

Pre‑Starting Instructions............................................................ 72

Engine Break‑in Procedure........................................................72

Starting the Engine ‑ Remote Control Models........................... 73

Starting the Engine ‑ Tiller Handle Models................................ 75

Gear Shifting ............................................................................. 78

Stopping the Engine ................................................................. 79

Emergency Starting .................................................................. 80

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Maintenance

Outboard Care........................................................................... 83

EPA Emissions Regulations...................................................... 83

Inspection and Maintenance Schedule...................................... 84

Flushing the Cooling System..................................................... 86

Top Cowl Removal and Installation........................................... 88

Exterior Care..............................................................................88

Battery Inspection ..................................................................... 89

Fuel System............................................................................... 89

Steering Link Rod Fasteners..................................................... 91

Corrosion Control Anode........................................................... 92

Spark Plug Inspection and Replacement...................................93

Steering Pull Adjustment........................................................... 94

Worn/Dull Impeller..................................................................... 94

Impeller Clearance Adjustment..................................................95

Fuse Replacement.....................................................................96

Timing Belt Inspection............................................................... 97

Lubrication Points...................................................................... 97

Checking Power Trim Fluid......................................................101

Changing Engine Oil ............................................................... 102

Submerged Outboard.............................................................. 103

Storage

Storage Preparation.................................................................104

Protecting External Outboard Components............................. 105

Protecting Internal Engine Components.................................. 105

Jet Drive...................................................................................105

Positioning Outboard for Storage............................................ 105

Battery Storage........................................................................ 105

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Troubleshooting

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

................................................................................................. 107

Engine Will Not Start................................................................107

Engine Runs Erratically........................................................... 108

Engine Overspeed (Excessive RPM)...................................... 108

Performance Loss....................................................................108

Battery Will Not Hold Charge................................................... 109

Owner Service Assistance

Local Repair Service................................................................110

Service Away from Home........................................................ 110

Parts and Accessories Inquiries.............................................. 110

Service Assistance.................................................................. 110

Ordering Literature...................................................................113

Outboard Installation

Mercury Marine Validated Engine Mounting Hardware........... 115

Installation Information.............................................................116

Determining the Mounting Height of the Outboard ................. 118

Checking Boat Transom Construction..................................... 121

Fastening the Outboard........................................................... 122

Steering Cable ‑ Starboard Side Routed Cable....................... 123

Steering Link Rod Fasteners................................................... 124

Steering Cable Seal................................................................. 126

Fuel Hose Connection ‑ Remote Control Models.................... 126

Electrical Connections and Control Cable Installation............. 127

Trim‑In Stop Adjustment ‑ Power Trim Models........................ 133

Water Testing.......................................................................... 133

Maintenance Log

Maintenance Log..................................................................... 135

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Warranty Registration United States and Canada

To be eligible for warranty coverage, the product must be registered with Mercury Marine.

At the time of sale, the selling dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, e‑mail, or mail. Upon receipt of this warranty registration, Mercury Marine will record the registration.

A copy of the warranty registration should be provided to you by your selling dealer.

NOTE: Registration lists must be maintained by Mercury Marine and any dealer of Mercury Marine products sold in the United States, should a safety recall notification under the Federal Safety Act be required.

You may change your registered 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. Mercury Marine Attn: Warranty Registration Department W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax +1 920 907 6663

OUTSIDE UNITED STATES AND CANADA

For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you.

Transfer of Warranty United States and Canada

The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications.

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To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address, and engine serial number to Mercury Marine’s warranty registration department. In the United States and Canada, mail to:

Mercury Marine Attn: Warranty Registration Department W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 920-929-5054 Fax +1 920 907 6663

Upon processing the transfer of warranty, Mercury Marine will record the new owner's information.

There is no charge for this service.

OUTSIDE THE UNITED STATES AND CANADA

For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you.

Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada

The remaining coverage period of the Product Protection Plan is transferable to the subsequent purchaser of the engine within thirty (30) days from the date of sale. Contracts not transferred within thirty (30) days of the subsequent purchase will no longer be valid and the product will no longer be eligible for coverage under the terms of the contract.

To transfer the plan to the subsequent owner, contact Mercury Product Protection or an authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee.

Plan coverage is not transferable from one product to another product or for noneligible applications.

The certified preowned engine plans are not transferable.

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For help or assistance, contact Mercury Product Protection Department at 1‑888‑427‑5373 from 7:30 a.m. to 4:30 p.m. CST, Monday–Friday or e‑mail mpp_support@mercmarine.com.

3 Year Limited Warranty Against Corrosion

WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport‑Jet, M2 Jet Drive,

Tracker by Mercury Marine Outboard, Mercury MerCruiser Inboard or Sterndrive Engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.

DURATION OF COVERAGE: This limited corrosion warranty provides coverage for three (3) years from either the date the product is first sold, or the date on which the product is first put into service, whichever occurs first. The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to subsequent (noncommercial use) purchaser upon proper reregistration of the product.

CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Corrosion prevention devices specified in the Operation and Maintenance Manual must be in use on the boat, and routine maintenance outlined in the Operation and Maintenance Manual must be timely performed (including, without limitation, the replacement of sacrificial anodes, use of specified lubricants, and touch‑up of nicks and scratches) in order to maintain warranty coverage. Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance.

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WHAT MERCURY WILL DO: Mercury's sole and exclusive obligation under this warranty is limited to, at our option, repairing a corroded part, replacing such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a 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. Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury. Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage.

WHAT IS NOT COVERED: This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse, or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty; replacement parts (parts purchased by customer); products used in a commercial application. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of the warranty period, even if the product is only occasionally used for such purposes.

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Corrosion damage caused by stray electrical currents (onshore power connections, nearby boats, submerged metal) is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system, such as the Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty. If antifouling protection is required, Tri‑Butyl‑Tin‑Adipate (TBTA) base antifouling paints are recommended on Outboard and MerCruiser boating applications. In areas where TBTA base paints are prohibited by law, copper base paints can be used on the hull and transom. Do not apply paint to the outboard or MerCruiser product. In addition, care must be taken to avoid an electrical interconnection between the warranted product and the paint. For MerCruiser product, an unpainted gap of at least 38 mm (1.5 in.) should be left around the transom assembly. Refer to the Operation and Maintenance Manual for additional details.

For additional information regarding events and circumstances covered by this warranty, and those that are not, see the Warranty Coverage section of the Operation and Maintenance Manual, incorporated by reference into this warranty.

DISCLAIMERS AND LIMITATIONS:

THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY.

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Warranty Coverage and Exclusions

The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited Outboard Warranty.

Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents, normal wear, and a variety of other causes that affect the product are not covered.

Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us.

Should you have any questions concerning warranty coverage, contact your authorized dealer. They will be pleased to answer any questions that you may have.

GENERAL EXCLUSIONS FROM WARRANTY

1. Minor adjustments and tune‑ups, including checking, cleaning, or adjusting spark plugs, ignition components, carburetor settings, filters, belts, controls, and checking lubrication made in connection with normal services.

2. Factory installed jet drive units ‑ Specific parts excluded from the warranty are: the jet drive impeller and jet drive liner damaged by impact or wear, and water damaged driveshaft bearings as a result of improper maintenance.

3. Damage caused by neglect, lack of maintenance, accident, abnormal operation, or improper installation or service.

4. Haul‑out, launch, towing charges, removal and/or replacement of boat partitions or material because of boat design for necessary access to the product, all related transportation charges and/or travel time, etc. Reasonable access must be provided to the product for warranty service. Customer must deliver product to an authorized dealer.

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5. Additional service work requested by customer other than that necessary to satisfy the warranty obligation.

6. Labor performed by other than an authorized dealer may be covered only under the following circumstances: when performed on emergency basis (providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul‑out, etc., and prior factory approval has been given to have the work performed at this facility).

7. All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner's responsibility.

8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs.

9. 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.

10.Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit.

11.Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty.

12.Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard.

13.Water entering engine through the fuel intake, air intake, or exhaust system or submersion.

14.Failure of any parts caused by lack of cooling water, which results from starting motor out of water, foreign material blocking inlet holes, motor being mounted too high, or trimmed too far out.

15.Use of fuels and lubricants which are not suitable for use with or on the product. Refer to the Maintenance section.

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16.Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us. Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product.

U.S. EPA Emissions Limited Warranty

Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides a five year or 175 hours of engine use, whichever occurs first, to the retail customer, that the engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, and that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations. This emission‑related warranty covers all the components listed in the Emission Control System Components.

Emission Control System Components

The EPA and California emission‑related warranty covers all the following list of components:

COMPONENTS OF THE EMISSIONS CONTROL SYSTEM:

1. Fuel metering system

a. Carburetor and internal parts (and/or pressure regulator

or fuel injection system) b. Cold start enrichment system c. Intake valves

2. Air induction system a. Intake manifold b. Turbocharger or supercharger systems (where

applicable)

3. Ignition system a. Spark plugs b. Magneto or electronic ignition system c. Spark advance/retard system

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d. Ignition coil and/or control module e. Ignition wires

4. Lubrication system (4‑Stroke engines excluded) a. Oil pump and internal parts b. Oil injectors c. Oil meter

5. Exhaust system a. Exhaust manifold b. Exhaust valves

6. Miscellaneous items used in above systems a. Hoses, clamps, fittings, tubing, sealing gaskets or

devices, and mounting hardware b. Pulleys, belts, and idlers c. Vacuum, temperature, check and time sensitive valves

and switches d. Electronic controls

The emission‑related warranty does not cover components whose failure would not increase an engine's emissions on any regulated pollutant.

California Emissions Limited Warranty

The California Air Resources Board has promulgated air emission regulations for outboard engines. The regulations apply to all outboard engines sold to retail consumers in California, and which were manufactured for the 2001 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the components listed in the Emission Control System Components), and further warrants that the outboard engine was designed, built, and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code. For information regarding the limited warranty for the nonemission‑related components of the outboard, please see the limited warranty statement for your outboard.

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WHAT IS COVERED: Mercury Marine warrants the components of the emissions control systems (see the components listed in the Emission Control System Components) of its new, 2001 model year and later outboards, sold by a California dealer to retail customers residing in California, to be free from defects in material or workmanship, that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below. The cost to diagnose a warranty failure is covered under the warranty (if the warranty claim is approved). Damage to other engine components caused by the failure of a warranted part will also be repaired under warranty.

DURATION OF COVERAGE: This limited warranty provides coverage for the components of the emissions control systems of new, 2001 model year and later outboards, sold to retail customers in California for four (4) years from either the date the product is first sold, or first put into service, whichever occurs first, or the accumulation of 250 hours of engine operation (as determined by the engine's hour meter, if any). Emission‑related normal maintenance items such as spark plugs and filters, that are on the warranted parts list, are warranted up to their first required replacement interval only. Refer to Emission Control System Components and Maintenance Schedule. The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to a subsequent purchaser. (See instructions on transfer of warranty.)

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HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury 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. Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury.

WHAT MERCURY WILL DO: Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our expense and at our option, repairing or replacing defective parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

WHAT IS NOT COVERED: This limited warranty does not cover routine maintenance items, tune‑ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open throttle RPM range (see General Information ‑ Specifications), operation of the product in a manner inconsistent with the recommended operation procedures, neglect, accident, submersion, improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, jet pump impellers and liners, operation with fuels, oils, or lubricants which are not suitable for use with the product (see Fuel and Oil), alteration or removal of parts.

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Expenses related to haul‑out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.

Nonwarranty maintenance, replacement, or repair of emission control devices and systems may be performed by any marine engine repair establishment or individual. The use of non‑Mercury parts for nonwarranty maintenance or repairs will not be grounds for disallowing other warranty work. The use of add‑on (as defined at section 1900 (b)(1) and (b)(10) of Title 13 of the California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.

DISCLAIMERS AND LIMITATIONS

If you have any questions regarding your warranty rights and responsibilities, you should contact Mercury Marine at 1‑920‑929‑5040.

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California Air Resources Board Explanation of Your California Emission Control Warranty Statement

YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board is pleased to explain the emission control system warranty on your 2012–2013 model year outboard engine. In California, new outboard engines must be designed, built, and equipped to meet the State's stringent anti‑smog standards. Mercury Marine must warrant the emission control system on your outboard engine for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your outboard engine.

Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors, and other emission‑related assemblies.

Where a warrantable condition exists, Mercury Marine will repair your outboard engine at no cost to you, including diagnosis, parts, and labor.

MANUFACTURER'S WARRANTY COVERAGE: Select emission control parts from model year 2001 and later outboard engines are warranted for four (4) years, or for 250 hours of use, whichever first occurs. However, warranty coverage based on the hourly period is only permitted for outboard engines and personal watercraft equipped with hour meters as defined in s 2441(a)(13) or their equivalent. If any emission‑related part on your engine is defective under warranty, the part will be repaired or replaced by Mercury Marine.

OWNER'S WARRANTY RESPONSIBILITIES: As the outboard engine owner, you are responsible for the performance of the required maintenance listed in the Maintenance section. Mercury Marine recommends that you retain all receipts covering maintenance on your outboard engine, but Mercury Marine cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

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As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact Mercury Marine at 1‑920‑929‑5040.

Emission Certification Star Label

Outboards are labeled on the cowl with one of the following star labels.

The symbol for a cleaner marine engine means: Cleaner air and water ‑ for a healthier lifestyle and environment. Better fuel economy ‑ burns up to 30–40 percent less gas and oil

than conventional carbureted two‑stroke engines, saving money and resources.

Longer emission warranty ‑ protects consumer for worry‑free operation.

22531

One Star ‑ Low Emission

The One Star label identifies engines that meet the Air Resources Board's 2001 exhaust emissions standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

42537

Two Stars ‑ Very Low Emission

The Two Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emissions standards. Engines meeting these standards have 20% lower emissions than One Star ‑ Low Emission engines.

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42538

Three Stars ‑ Ultra Low Emission

The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star ‑ Low Emission engines.

42539

Four Stars ‑ Super Ultra Low Emission

The Four Star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than One Star ‑ Low Emission engines.

Warranty Policy—Australia and New Zealand

MERCURY/MARINER OUTBOARD LIMITED WARRANTY– AUSTRALIA AND NEW ZEALAND POLICY

This limited warranty is given by Marine Power International Pty Ltd ACN 003 100 007 of 41–71 Bessemer Drive, Dandenong South, Victoria 3175 Australia (telephone (61) (3) 9791 5822) e‑mail: merc_info@mercmarine.com.

What is Covered

Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates.

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Guarantees Under Australian Consumer Law

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Warranty Period for Recreational Use

This Limited Warranty provides coverage for three (3) years 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. Unexpired warranty coverage can be transferred to a subsequent recreational use customer upon proper registration of the product.

Warranty Period for Commercial Use

Commercial users of these products receive warranty coverage under this Limited Warranty of one (1) year from the date of first retail sale, or one (1) year from the date on which the product was first put into service, whichever occurs first. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of the warranty period, even if the product is only occasionally used for such purposes. Unexpired warranty coverage cannot be transferred either to or from a commercial use customer.

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Conditions That Must Be Met to Obtain Warranty Coverage

Warranty coverage under this Limited Warranty is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Inaccurate warranty registration information regarding recreational use, or subsequent change of use from recreational to commercial (unless properly registered) may void the warranty at the sole discretion of Mercury Marine. Routine maintenance outlined in the Operation and Maintenance Manual must be timely performed in order to maintain warranty coverage. Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance.

What Mercury Will Do

Mercury Marine's sole and exclusive obligation under this Limited Warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury Marine product. Mercury Marine reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

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How to Obtain Warranty Coverage Under This Limited Warranty

The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. A list of dealers and their contact details is available at www.mercurymarine.com.au

. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine at the address shown above. Mercury Marine will then arrange for the inspection and any covered repair. This Limited Warranty will not cover the purchaser for all related transportation charges and travel time. If the service provided is not covered by this limited warranty, the purchaser shall pay for all related labor and material and any other expenses associated with that service, provided that a consumer will not be obligated to pay where the service has been carried out to remedy a failure of an acceptable quality guarantee which is binding on Mercury Marine under the Australian Consumer Law. The purchaser shall not, unless requested by Mercury Marine, ship the product or parts of the product directly to Mercury Marine. Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage under this Limited Warranty.

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What is Not Covered

This limited warranty does not cover routine maintenance items, tune‑ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open throttle RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation and Maintenance Manual, neglect, accident, submersion, improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, use of an accessory or part not manufactured or sold by us, jet pump impellers and liners, operation with fuels, oils or lubricants which are not suitable for use with the product (see the Operation and Maintenance Manual), alteration or removal of parts, water entering the engine through the fuel intake, air intake or exhaust system, or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body, running the engine out of water, mounting the engine too high on the transom, or running the boat with the engine trimmed out too far. Use of the product for racing or other competitive activity, or operating with a racing type lower unit, at any point, even by a prior owner of the product, voids the warranty.

Expenses related to haul‑out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this Limited Warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.

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No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional information regarding events and circumstances covered by this warranty, and those that are not, see the Warranty Coverage section of the Operation and Maintenance Manual, incorporated by reference into this warranty.

Expense of Claiming This Limited Warranty

This Limited Warranty does not cover any expenses you may incur claiming the warranty.

DISCLAIMERS AND LIMITATIONS:

EXCEPT FOR APPLICABLE GUARANTEES AND OTHER RIGHTS AND REMEDIES THAT A CONSUMER MAY HAVE UNDER THE AUSTRALIAN CONSUMER LAW OR OTHER LAW IN RELATION TO WHICH THE PRODUCTS RELATE, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS LIMITED WARRANTY.

TRANSFER OF WARRANTY—AUSTRALIA AND NEW ZEALAND POLICY

To transfer the warranty to the subsequent owner, send or fax a copy of the Bill of Sale or Purchase Agreement, new owner’s name, address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department. In Australia and New Zealand, mail to:

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Mercury Marine

Attn: Warranty Registration Department

Brunswick Asia Pacific Group

Private Bag 1420

Dandenong South, Victoria 3164

Australia

Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail. There is no charge for this service.

You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department.

Global Warranty Charts Outboard and Jets

UNITED STATES WARRANTY CHARTS–OUTBOARD AND JET

Product

Standard Limited Warranty

Standard Limited Corrosion Warranty

FourStroke (2.5 ‑ 300 hp including Verado, Pro FourStroke and jet outboards)

3 years 3 years

OptiMax (75 ‑ 250 hp including Pro XS and jet outboards )

3 years 3 years

OptiMax jet drive (200 and 250 hp) 1 year 3 years

Racing Product (Recreation use only)

Standard Limited Warranty

Standard Limited Corrosion Warranty

OptiMax (250 XS) 2 years 3 years

OptiMax (225 Sport XS) 2 years 3 years

OptiMax (300 XS) 2 years 3 years

Verado (350 SCi) 2 years 3 years

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Outside the United States

For product purchased outside the Unites States, contact the distributor in your country, or the authorized Marine Power Service Center closest to you.

CANADA WARRANTY CHARTS–OUTBOARD AND JET

Product

Standard Limited Warranty

Standard Limited Corrosion Warranty

2‑Stroke carbureted (50 ‑ 90 hp) 1 year 3 years

2‑Stroke EFI (150 hp) 2 years 3 years

2‑Stroke carbureted (V6) 2 years 3 years

FourStroke (2.5 ‑ 300 hp including Verado, Pro FourStroke and jet outboards)

3 years 3 years

OptiMax (75 ‑ 250 hp including Pro XS and jet outboards )

3 years 3 years

OptiMax jet drive (200 and 250 hp) 1 year 3 years

Racing Product (Recreation use only)

Standard Limited Warranty

Standard Limited Corrosion Warranty

OptiMax (250 XS) 2 years 3 years

OptiMax (225 Sport XS) 2 years 3 years

OptiMax (300 XS) 2 years 3 years

Verado (350 SCi) 2 years 3 years

Outside of Canada

For product purchased outside of Canada, contact the distributor in your country, or the authorized Marine Power Service Center or dealer closest to you.

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AUSTRALIA AND NEW ZEALAND WARRANTY CHARTS– OUTBOARD AND JET

Products

Standard Limited Warranty

Standard Limited Corrosion Warranty

Light Commercial

All outboard 3 years 3 years

Contact the Marine Power Service Center closest to you

Outside of Australia and New Zealand

For product purchased outside of Australia and New Zealand, contact the distributor in your country, or the Marine Power Service Center closest to you.

SOUTH PACIFIC WARRANTY CHART–OUTBOARD AND JET

Products

Standard Limited Warranty

Standard Limited Corrosion Warranty

Light Commercial

All outboard 2 years 3 years

Contact the Marine Power Service Center closest to you

Outside of South Pacific

For product purchased outside of the South Pacific region, contact the distributor in your country, or the Marine Power Service Center closest to you.

ASIA WARRANTY CHARTS–OUTBOARD AND JET

Product (Recreational only)

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

2‑Stroke 1 year 3 years

Contact the Marine Power Service Center closest to you

FourStroke 1 year 3 years

OptiMax 1 year 3 years

Verado 1 year 3 years

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Racing Product (Recreational only)

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

Verado 350 SCi 1 year 3 years None

Outside of Asia

For product purchased outside of the Asian region, contact the distributor in your country, or the Marine Power Service Center closest to you.

EUROPE AND THE CONFEDERATION OF INDEPENDENT STATES (CIS) WARRANTY CHARTS–OUTBOARD AND JET

Product (Recreational only)

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

2‑Stroke 2 years 3 years

Contact the Marine Power Service Center closest to you

FourStroke 2 years 3 years

OptiMax (including Pro XS)

3 years 3 years

Verado (including Pro)

3 years 3 years

Racing Product (Recreational only)

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

Verado 350 SCi 2 years 3 years

Contact the Marine Power Service Center closest to you

Outside Europe and CIS

For products purchased outside of Europe and CIS regions, contact the distributor in your country, or the Marine Power Service Center closest to you.

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MIDDLE-EAST AND AFRICA (EXCLUDING SOUTH AFRICA) WARRANTY CHARTS–OUTBOARD AND JET

Product (Recreational only)

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

2‑Stroke 1 year 3 years

Contact the Marine Power Service Center closest to you

FourStroke 2 years 3 years

OptiMax (including Pro XS)

3 years 3 years

Verado (including Pro)

3 years 3 years

Racing Product (Recreational only)

Standard Limited Warranty

Standard Limited Corrosion Warranty

Verado 350 SCi 2 years 3 years

Outside Middle‑East and Africa

For products purchased outside of the Middle‑East and Africa regions, contact the distributor in your country, or the Marine Power Service Center closest to you.

SOUTH AFRICA WARRANTY CHARTS–OUTBOARD AND JET

Product (Recreational only)

Standard Limited Warranty

Standard Limited Corrosion Warranty

Commercial Application

2‑Stroke 2 year 3 years

Contact the Marine Power Service Center closest to you

FourStroke 2 years 3 years

OptiMax (including Pro XS)

3 years 3 years

Verado (including Pro)

3 years 3 years

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Racing Product (Recreational only)

Standard Limited Warranty

Standard Limited Corrosion

Warranty

Verado 350 SCi 2 years 3 years

Outside South Africa

For products purchased outside of the South Africa region, contact the distributor in your country, or the Marine Power Service Center closest to you.

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Boater's Responsibilities

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

Be sure that at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.

Before Operating Your Outboard

Read this manual carefully. Learn the difference in handling characteristics between a jet drive boat and a propeller driven boat. If you have any questions, contact your dealer.

STEERING AT LOW SPEEDS

Unlike propeller driven boats, the jet drive boat tends to lose steering control as less water is drawn in and expelled. Increase speed slightly to regain steering.

MANEUVERABILITY

The jet drive is highly maneuverable at higher speeds, more so, than propeller driven boats. Use caution when turning to prevent spin‑outs.

IN NEUTRAL

The impeller will continue to rotate while the engine is in neutral. Although the approximate balancing of forward and reverse thrust will minimize boat movement, the boat may tend to move slowly forward or backward. This is normal for a direct‑drive jet driven boat. The operator should be aware of this and use caution whenever the engine is running.

Safety and operating information that is practiced, along with using good common sense, can help prevent personal injury and product damage.

This manual as well as safety labels posted on the outboard use the following safety alerts1. to draw your attention to special

safety instructions that should be followed.

1. These safety alerts follow ANSI standard Z535.6‑2006 for product safety information in product manuals, instructions, and other collateral materials.

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DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates a situation which, if not avoided, could result in engine or major component failure.

IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.

Boat Horsepower Capacity

WARNING

Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating.

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Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.

U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON CAPACITY (POUNDS) XXX

MAXIMUM WEIGHT CAPACITY XXX

26777

High‑Speed and High‑Performance Boat Operation

If your outboard is to be used on a high‑speed or high‑performance boat with which you are unfamiliar, we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat/outboard combination. For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.

Outboard Remote Control Models

The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral.

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WARNING

Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device.

26838

Remote Steering Notice

The steering link rod that connects the steering cable to the engine must be fastened utilizing self‑locking nuts. These self‑locking nuts must never be replaced with common nuts (non‑locking) as they will work loose and vibrate off, freeing the link rod to disengage.

WARNING

Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.

a - Self‑locking nuts

26780

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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. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed as an accessory ‑ generally on the dashboard or side adjacent to the operator's position.

The lanyard is a cord usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator's position. If it is desired to have a shorter lanyard, wrap the lanyard around the operator's wrist or leg, or tie a knot in the lanyard.

a - Lanyard cord b - Lanyard stop switch

Read the following Safety Information before proceeding.

21629

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Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position. Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables, bass boats, high performance boats, and light, sensitive handling fishing boats operated by a hand tiller. Falling overboard and accidental ejections are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or gunwale at planing speeds, standing at planing speeds, sitting on elevated fishing boat decks, operating at planing speeds in shallow or obstacle infested waters, releasing your grip on a steering wheel or tiller handle that is pulling in one direction, drinking alcohol or consuming drugs, or daring high speed boat maneuvers.

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. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (if the operator is accidentally ejected).

WARNING

If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat. Always properly connect the operator to the stop switch using a lanyard.

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WARNING

Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.

Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations:

• Occupants could be thrown forward due to unexpected loss of forward motion ‑ a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller.

• Loss of power and directional control in heavy seas, strong current, or high winds.

• Loss of control when docking.

KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD OPERATING CONDITION

Before each use, check to ensure the lanyard stop switch works properly. Start the engine and stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.

Before each use, visually inspect the lanyard cord to ensure it is in good working condition and that there are no breaks, cuts, or wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard cords.

Stopping the Boat in an Emergency

A jet powered boat has emergency stopping capability unique to this form of propulsion.

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WARNING

Using the emergency stopping capability of a jet drive unit will slow down the boat in an emergency. However, sudden stopping may cause the occupants of the boat to be thrown forward or out of the boat resulting in serious injury or death. Use caution when performing the emergency stopping procedure, and be sure to practice in a safe area.

In an emergency, putting the jet outboard into reverse and applying reverse throttle can rapidly slow down the boat and reduce stopping distance. However, such a maneuver may cause occupants in the boat to be thrown forward or possibly out of the boat.

Protecting People In The Water

WHILE YOU ARE CRUISING

It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed.

21604

Always slow down and exercise extreme caution when boating in an area where there might be people in the water.

Avoid shallow water or where any loose material such as sand, shells, seaweed, grass, tree branches, etc., can be pulled in and expelled from the pump as a high speed projectile.

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WHILE BOAT IS STATIONARY

WARNING

Avoid injury resulting from contacting the rotating impeller or having hair, clothing, or loose objects drawn into the water intake and wrapping around the impeller shaft. Stay away from the water intake and never insert an object into the water intake or water outlet nozzle when the engine is running.

Stop the engine immediately whenever a person is in the water near the boat. The jet drive is always drawing water through the water intake when the engine is running. Stay away from the water intake located under the jet drive and never insert an object into the water intake or outlet nozzle when the engine is running.

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. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat. Falling over the front of the boat between the two pontoons will position them to be run over by the outboard.

BOATS HAVING AN OPEN FRONT DECK

No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence or enclosure.

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Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water.

26782

WARNING

Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.

BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS

Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds.

Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

26783

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Wave and Wake Jumping

Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water.

26784

The primary concern is the boat changing direction while in the midst of the jump. In such case, the landing may cause the boat to veer violently 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.

WARNING

Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat to a nearly instantaneous stop and can send the occupants flying forward. The boat may also steer sharply to one side.

Safety Instructions for Hand‑Tilled Outboards

No person or cargo should occupy the area directly in front of the outboard while the boat is in motion. If an underwater obstacle is struck, the outboard will tilt up and could seriously injure anyone occupying this area.

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MODELS WITH CLAMP SCREWS:

Some outboards come with transom bracket clamp screws. The use of clamp bracket screws alone, is insufficient to properly and safely secure the outboard to the transom. Proper installation of the outboard includes bolting the engine to the boat through the transom. Refer to Installation ‑ Installing Outboard for more complete installation information.

WARNING

Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death. Before operation, the outboard must be correctly installed with the required mounting hardware.

If an obstacle is struck at planing speed and the outboard is not securely fastened to the transom, it is possible the outboard could lift off the transom and land in the boat.

Exhaust Emissions

BE ALERT TO CARBON MONOXIDE POISONING

Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling CO.

Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include headache, dizziness, drowsiness, and nausea.

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WARNING

Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide.

Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.

STAY CLEAR OF EXHAUST AREAS

Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing). This dangerous practice not only places a person in an area of high engine exhaust concentration, but also subjects them to the possibility of injury from the boat propeller.

GOOD VENTILATION

Ventilate the passenger area, open side curtains or forward hatches to remove fumes.

Example of desired air flow through the boat:

21622

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POOR VENTILATION

Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.

Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains, or is near, a running engine may be exposed to a hazardous level of carbon monoxide.

1. Examples of poor ventilation while the boat is stationary:

a - Operating the engine when the boat is moored in a

confined space

b - Mooring close to another boat that has its engine

operating

2. Examples of poor ventilation while the boat is moving:

a - Operating the boat with the trim angle of the bow too high b - Operating the boat with no forward hatches open (station

wagon effect)

21626

21628

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eng 41

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.

IMPORTANT: Check with your dealer before installing accessories. The misuse of approved accessories or the use of nonapproved accessories can damage the product.

Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.

Safe Boating Recommendations

To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions.

Know and obey all nautical rules and laws of the waterways.

• We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).

Perform safety checks and required maintenance.

• Follow a regular schedule and ensure that all repairs are properly made.

Check safety equipment onboard.

• Here are some suggestions of the types of safety equipment to carry when boating:

Approved fire extinguishers Signal devices: flashlight, rockets or flares, flag, and

whistle or horn Tools necessary for minor repairs Anchor and extra anchor line

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Manual bilge pump and extra drain plugs Drinking water Radio Paddle or oar Spare propeller, thrust hubs, and an appropriate wrench First aid kit and instructions Waterproof storage containers Spare operating equipment, batteries, bulbs, and fuses Compass and map or chart of the area Personal flotation device (one per person onboard)

Watch for signs of weather change and avoid foul weather and rough‑sea boating.

Tell someone where you are going and when you expect to return.

Passenger boarding.

• Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive unit into neutral is not sufficient.

Use personal flotation devices.

• Federal law requires that there be a U.S. Coast Guard‑approved life jacket (personal flotation device), correctly sized and readily accessible for every person onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat.

Prepare other boat operators.

• Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard.

Do not overload your boat.

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• Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer.

Ensure that everyone in the boat is properly seated.

• Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat movement.

Never operate a boat while under the influence of alcohol or drugs. It is the law.

• Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly.

Know your boating area and avoid hazardous locations.

Be alert.

• The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed. Watch out for others, the water, and your wake.

Never drive your boat directly behind a water skier.

• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is 61 m (200 ft) in front of you in five seconds.

Watch fallen skiers.

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• When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.

Report accidents.

• Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00, or 4) there is complete loss of the boat. Seek further assistance from local law enforcement.

Recording Serial Number

It is important to record this number for future reference. The serial number is located on the outboard as shown.

a - Serial number b - Model designation c - Year manufactured d - Certified Europe Insignia (as applicable)

24125

H P L B

- - - . -

- -

XXXXXXX

XXXXX XX

Mercury

Marine

Serial Number

Brunswick Corp. Made in Japan

XXXX XXX

HP XXX LB XXX

KG XXX

KW XXX

Model Number

Page 57

GENERAL INFORMATION

eng 45

40 Jet FourStroke Specifications

Models 40 Jet

Horsepower 40

Kilowatts 29.4

Full throttle RPM range 5000–5500 RPM

Number of cylinders 4

Idle speed in forward gear

Controlled by ECM

Piston displacement 995 cc (60.8 in³)

Cylinder bore 65 mm (2.559 in.)

Stroke 75 mm (2.953 in.)

Valve clearance (cold)

Intake valve 0.15–0.25 mm (0.006–0.010 in.)

Exhaust valve 0.25–0.35 mm (0.010–0.014 in.)

Recommended spark plug

Champion RA8HC

Spark plug gap 1.0 mm (0.040 in.)

Recommended gasoline Refer to Fuel and Oil

Recommended oil Refer to Fuel and Oil

Engine oil capacity 3.0 L (3 US qt)

Emission control system Electronic engine control (EC)

Battery rating*

Operation above 0 °C (32 °F)

465 marine cranking amps (MCA) or 350 cold

cranking amps (CCA)

Operation below 0 °C (32 °F)

1000 marine cranking amps (MCA) or 750 cold

cranking amps (CCA)

Ampere hours (Ah) 70–100

*Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.

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Component Identification

a - Auxiliary tilt switch b - Tilt support knob c - Transom brackets d - Jet drive housing e - Water intake housing f - Reverse gate g - Water outlet nozzle h - Driveshaft housing i - Water pump indicator

hole

j - Bottom cowl k - Top cowl

28684

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TRANSPORTING

eng 47

Trailering Boat/Outboard

The boat should be trailered with the outboard tilted down in a vertical operating position.

IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering. The outboard tilt support lever is not intended to support the outboard for trailering.

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.

Transporting Portable Fuel Tanks

WARNING

Avoid serious injury or death from a gasoline fire or explosion. Follow the transporting instructions supplied with the portable fuel tank. Transport the fuel tank in a well ventilated area away from open flame or sparks.

MANUAL VENTING TYPE FUEL TANK

Close the fuel tank air vent when transporting tank. This will prevent escape of fuel or vapors from tank.

26793

AUTO-VENTING TYPE FUEL TANK

1. Disconnect the remote fuel line from tank. This will close the air vent and prevent escape of fuel or vapors from tank.

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TRANSPORTING

48 eng

2. Install tether cap over the fuel line connector stem. This will protect the connector stem from being accidentally pushed‑in, allowing fuel or vapor to escape.

a - Connector stem b - Tether cap

26794

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eng 49

Fuel Recommendations

IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty.

FUEL RATINGS

Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications:

USA and Canada ‑ having a posted pump octane rating of 87 (R +M)/2 minimum. Premium gasoline (92 [R+M]/2 octane) is also acceptable. Do not use leaded gasoline.

Outside USA and Canada ‑ having a posted pump octane rating of 90 RON minimum. Premium gasoline (98 RON) is also acceptable. If unleaded gasoline is not available, use a major brand of leaded gasoline.

USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY)

This type of gasoline is required in certain areas of the USA. The two types of oxygenates used in these fuels are alcohol (ethanol) or ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasolines Containing Alcohol.

These reformulated gasolines are acceptable for use in your Mercury Marine engine.

GASOLINES CONTAINING ALCOHOL

If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain adverse effects that can occur. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in the fuel can also worsen these adverse effects.

Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air, resulting in a separation of the water/alcohol from the gasoline in the fuel tank.

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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). Be aware that gasolines containing alcohol may cause increased:

• Corrosion of metal parts

• Deterioration of rubber or plastic parts

• Fuel permeation through rubber fuel lines

• Starting and operating difficulties

WARNING

Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration requires replacement before further engine operation.

Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol‑free gasoline be used where possible. If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnormalities is required.

IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars, alcohol‑blend fuels normally are consumed before they can absorb enough moisture to cause trouble, but boats often sit idle long enough for phase separation to take place. In addition, internal corrosion may take place during storage if alcohol has washed protective oil films from internal components.

Low Permeation Fuel Hose Requirement

Required for outboards manufactured for sale, sold, or offered for sale in the United States.

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• The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009, must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard.

• Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not exceeding 15/gm²/24 h with CE 10 fuel at 23 °C as specified in SAE J 1527 ‑ marine fuel hose.

EPA Pressurized Portable Fuel Tank Requirements

The Environmental Protection Agency (EPA) requires portable fuel systems that are produced after January 1, 2011, for use with outboard engines to remain fully sealed (pressurized) up to

34.4 kPa (5.0 psi). These tanks may contain the following:

• An air inlet that opens to allow air to enter as the fuel is drawn out of the tank.

• An air outlet that opens (vents) to the atmosphere if pressure exceeds 34.4 kPa (5.0 psi).

Fuel Demand Valve (FDV) Requirement

Whenever a pressurized fuel tank is used, a fuel demand valve is required to be installed in the fuel hose between the fuel tank and primer bulb. The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage.

The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case of a fuel blockage in the valve.

a - Fuel demand valve ‑ installed

in the fuel hose between the

fuel tank and primer bulb

b - Manual release c - Vent/water drain holes

46273

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FUEL AND OIL

52 eng

Mercury Marine's Pressurized Portable Fuel Tank

Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks are available as an accessory or are provided with certain portable outboard models.

SPECIAL FEATURES OF THE PORTABLE FUEL TANK

• The fuel tank has a two‑way valve which allows air to enter the tank as the fuel is drawn to the engine, and also opens to vent to the atmosphere if internal pressure in the tank exceeds 34.4 kPa (5.0 psi). A hissing noise may be heard as the tank vents to the atmosphere. This is normal.

• The fuel tank includes a fuel demand valve that prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage.

• When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated. A built‑in device prevents overtightening.

• The fuel tank has a manual vent screw which should be closed for transportation and open for operation and cap removal.

Since sealed fuel tanks are not vented, they will expand and contract as the fuel expands and contracts during heating and cooling cycles of the outside air. This is normal.

REMOVING THE FUEL CAP

a - Fuel cap b - Manual vent screw c - Tab lock

IMPORTANT: Contents may be under pressure. Rotate the fuel cap 1/4 turn to relieve pressure before opening.

1. Open the manual vent screw on top of the fuel cap.

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2. Turn the fuel cap until it contacts the tab lock.

3. Press down on the tab lock. Rotate the fuel cap 1/4 turn to relieve the pressure.

4. Press down on the tab lock again and remove the cap.

DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK

1. When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated. A built‑in device prevents overtightening.

2. Open the manual vent screw on top of the cap for operation and cap removal. Close the manual vent screw for transportation.

3. For fuel hoses that have quick disconnects, disconnect the fuel line from the engine or fuel tank when not in use.

Follow Filling Fuel Tank instructions for fueling.

Filling Fuel Tank

WARNING

Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks.

Fill the fuel tanks outdoors away from heat, sparks, and open flames.

Remove the portable fuel tanks from the boat to fill them. Always stop the engine before filling the tanks. Do not completely fill the fuel tanks. Leave approximately 10% of

the tank volume unfilled. Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled.

PORTABLE FUEL TANK PLACEMENT IN THE BOAT

Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions.

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54 eng

Engine Oil Recommendations

We recommend the use of Mercury or Quicksilver NMMA FC‑W certified synthetic blend 25W‑40 4‑Stroke Outboard Oil for general, all‑temperature use. If SAE 10W‑30 oil is preferred, use Mercury or Quicksilver NMMA FC‑W certified 10W‑30 4‑Stroke Outboard Oil. If the recommended Mercury or Quicksilver NMMA FC‑W certified outboard oils are not available, a major brand of 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.

IMPORTANT: The use of nondetergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality oils, or oils that contain solid additives are not recommended.

Recommended SAE viscosity for engine oil

a - NMMA FC‑ W certified

10W‑30 outboard oil may be used at temperatures below 4 °C (40 °F)

b - NMMA FC‑W certified

synthetic blend 25W‑40 outboard oil may be used in all temperatures

Checking and Adding Engine Oil

IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil.

+20

+40

+60

+80

F° C°

+100

-7

+16

+27

-18

+38

11583

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FUEL AND OIL

eng 55

1. Turn the engine off. Have the outboard in a level operating position. Remove the top cowl.

2. Flip the handle up and pull out the dipstick. Wipe it with a clean rag or towel and push it back in all the way.

3. Pull the dipstick back out again and observe the oil level. If the oil level is low, remove the oil filler cap and fill to (but not over) the upper oil level with the recommended oil.

IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer.

4. 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.

a - Full mark b - Add mark c - Dipstick d - Oil filler cap

28412

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FEATURES AND CONTROLS

56 eng

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.

a - Control handle – forward, neutral, reverse b - Neutral release lever c - Trim/tilt switch (if equipped) – Refer to Features and

Controls – Power Trim and Tilt

d - Lanyard stop switch – Refer to General Information –

Lanyard Stop Switch

e - Lanyard – Refer to General Information – Lanyard Stop

Switch

f - Throttle friction adjustment – Console controls require

cover removal for adjustment

g - Ignition key switch – "OFF," "ON," START" h - Fast idle lever – Refer to Operation – Starting the Engine i - Throttle only button – Refer to Operation – Starting the

Engine

26800

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FEATURES AND CONTROLS

eng 57

Warning System

WARNING HORN SIGNALS

The outboard warning system incorporates a warning horn inside the boat. Remote control models will have the warning horn located inside the remote control or connected to the ignition key switch. Tiller handle models will have the warning horn located in the ignition key panel.

a - Horn inside remote control b - Horn connected to ignition key switch c - Horn in ignition key panel

There are two types of warning horns to alert the operator of an active problem within the engine's operating system.

Continuous six second beep: Indicates a critical engine condition. Depending on the condition, the Engine Guardian System may engage and protect the engine by limiting its power. You should return to port immediately and contact your servicing dealer.

Intermittent short beeps for six seconds: Indicates a noncritical engine condition. This condition does not require immediate attention. You may continue using your boat, however, depending on the nature of the problem, the engine’s power may be limited by the Engine Guardian System (see Engine Guardian System following) to protect the engine. You should contact your servicing dealer at your earliest convenience.

26801

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FEATURES AND CONTROLS

58 eng

It is important to note that in either of the above scenarios, the horn will only sound one time. If you key the engine off and restart it, the horn will sound again, one time, if the fault is still present. For visual display of the specific engine functions and additional engine data, refer to SmartCraft Product information, following.

The operator is able to correct a couple engine problems indicated by the warning horn. These conditions are as follows:

• Cooling system (water pressure or engine temperature) problem. The warning horn will sound Intermittent short beeps for six seconds. Stop the engine and check the water intake holes in the gearcase for obstruction.

• Low oil pressure problem. The warning horn will sound a continuous six second beep. Stop the engine and check for low engine oil level. Refer to Fuel and Oil – Checking and Adding Engine Oil.

ENGINE GUARDIAN SYSTEM

The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems. Engine Guardian is functional whenever your engine is operating, so you never have to be concerned about whether or not you are protected. The system will respond to a problem by sounding the warning horn for six seconds and/or reducing engine power in order to provide engine protection.

If the Guardian System has been activated, reduce throttle speed. The problem will need to be identified and corrected, if possible. The system must be reset before the engine will operate at higher speeds. Moving the throttle lever back to the idle position will reset the system.

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, oil pressure, water pressure, battery voltage, fuel consumption, and engine operating hours.

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The SmartCraft Instrument package will also aid in Engine Guardian diagnostics. The SmartCraft Instrument package will display critical engine alarm data and potential problems.

Power Trim and Tilt

Your outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down. Moving the outboard further away from the boat transom is called trimming out or up. The term trim generally refers to the adjustment of the outboard within the first 20° range of travel. This is the range used while operating your boat on plane. The term tilt is generally used when referring to adjusting the outboard further up out of the water. With the engine turned off, the outboard can be tilted out of the water. At low idle speed, the outboard can also be tilted up past the trim range to permit, for example, shallow water operation.

a - Remote control trim switch b - Panel mount trim switch c - Tilt range of travel d - Trim range of travel

28710

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FEATURES AND CONTROLS

60 eng

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. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards.

The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface.

WARNING

Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of boat control. Maintain control of the boat if trimming beyond a neutral steering condition.

Consider the following lists carefully. Trimming in or down can:

• Lower the bow

• Result in quicker planing off, especially with a heavy load or a stern heavy boat

• Generally improve the ride in choppy water

• Increase steering torque or pull to the right (with the normal right hand rotation propeller)

• In excess, can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction (called bow steering or oversteering) if any turn is attempted, or if a significant wave is encountered.

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WARNING

Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.

• In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by repositioning the tilt stop pins into the desired transom bracket adjustment holes.

Trimming out or up can:

• Lift the bow higher out of the water

• Generally increase top speed

• Increase clearance over submerged objects or a shallow bottom

• Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller)

• In excess, can cause boat porpoising (bouncing) or propeller ventilation

• Cause engine overheating if any cooling water intake holes are above the waterline

TILTING OPERATION

To tilt outboard, shut off the engine and press the trim/tilt switch or auxiliary tilt switch to the up position. The outboard will tilt up until the switch is released or it reaches its maximum tilt position.

1. Engage the tilt support lever, by rotating knob to bring the support lever upward.

2. Lower outboard to rest on the tilt support lever.

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FEATURES AND CONTROLS

62 eng

3. Disengage the tilt support lever, by raising the outboard off the support lever and rotating the lever down. Lower the outboard.

a - Tilt support lever b - Knob

MANUAL TILTING

If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.

1. Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve.

26809

NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.

28931

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AUXILIARY TILT SWITCH

The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system.

a - Auxiliary tilt switch

Throttle Grip Friction Adjustment ‑ Tiller Handle Models

Throttle grip friction knob ‑ Turn friction knob to set and maintain the throttle at desired speed. Turn knob clockwise to tighten friction and turn knob counterclockwise to loosen friction.

a - Loosen friction b - Tighten friction

Steering Friction Adjustment ‑ Tiller Handle Models

NOTE: Steering friction adjustment is only provided on models with tiller handles.

Adjust this lever to achieve the desired steering friction (drag) on the tiller handle. Move lever to the left to tighten friction or move to the right to loosen friction.

28534

19807

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FEATURES AND CONTROLS

64 eng

NOTE: To maintain proper adjustment, the locknut located on top of the steering friction lever pivot shaft can be tightened.

a - Tighten friction b - Loosen friction c - Locknut

WARNING

Insufficient friction adjustment can cause serious injury or death due to loss of boat control. When setting the friction adjustment, maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle is released.

Replaceable Jet Drive Shear Key

The jet drive is equipped with a shear key to protect it in the event of a lodged impeller. The shear key can be reached by removing the water intake housing and impeller.

29174

26811

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OPERATION

eng 65

Important Daily Inspection Before Each Use

Any outboard mounted on the boat must have the mounting hardware inspected and checked to ensure that the hardware has not become loose. A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use.

51985

Decal on the transom bracket

Prestarting Check List

Operator knows safe navigation, boating, and operating procedures.

An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law).

A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.

Know your boats maximum load capacity. Look at the boat capacity plate.

Fuel supply OK. Oil supply (oil injection) OK. Ensure the boat drain plug is installed. Arrange passengers and load in the boat so the weight is

distributed evenly and everyone is seated in a proper seat. Tell someone where you are going and when you expect to

return.

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OPERATION

66 eng

It is illegal to operate a boat while under the influence of alcohol or drugs.

Know the waters and area you will be boating; tides, currents, sand bars, rocks, and other hazards.

Make inspection checks listed in Maintenance ‑ Inspection and Maintenance Schedule.

Check steering for free operation. Check for debris around the rudder and reverse gate which

may jam or hinder operation. Before launching, examine the jet drive water intake for

obstructions which may prevent pumping of water. Ensure the driveshaft bearing on the jet drive is lubricated.

Operating in Freezing Temperatures

If there is a chance of ice forming on the water, the jet drive should be removed and drained completely of water. If ice should form at the water level inside the outboard driveshaft housing, it will block water flow to the engine causing possible damage. Do not start the engine until the ice is clear.

Operating in Saltwater or Polluted Water

If the boat is kept moored in the water, always tilt the outboard so the water intake is completely out of the water (except in freezing temperatures) when not in use.

Wash down the outboard exterior and flush out the exhaust outlet of the jet drive with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces.

NOTE: Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

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OPERATION

eng 67

Operating in Shallow Water

The life of the impeller and water intake can be greatly increased by avoiding the intake of sand and gravel. The intake suction will act like a dredge when the water intake comes close to the bottom. It is better to stop the engine and drift up to shore when landing, and to shove off with an oar when leaving. The engine can idle through areas of water less than 61 cm (2 ft) deep, but there should be more than 61 cm (2 ft) of water under the boat when increasing speed to reach full plane.

Once the boat is on plane, the boat speed will prevent the ingestion of gravel and other debris from the bottom. The suction is still present, but the water intake passes too quickly over the bottom to allow debris to be drawn into the water intake.

When boating through shallow water areas, choose a course of travel that avoids sharp rocks and other underwater obstacles that could damage the boat. Running the boat through these areas on full plane may be helpful as the boat will be riding higher in the water. If the boat gets stuck on the bottom, immediately stop the engine and move the boat to deeper water.

How the Jet Drive Operates

A jet driven boat has substantially different handling characteristics compared to a propeller driven boat. It is recommended that the operator adjusts to these characteristics by experimenting in open water at both high and low speeds.

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OPERATION

68 eng

The driveshaft driven impeller draws water up through the water intake and then directs it at a high pressure through the water outlet nozzle to create forward thrust. To obtain reverse, the reverse gate moves over the outlet nozzle to direct the water in the opposite direction.

a - Water intake b - Water outlet nozzle c - Reverse gate

When the jet drive is in neutral, the impeller continues to rotate. However, the reverse gate is positioned so that some of the forward thrust is diverted to create reverse thrust. This approximate balancing of forward and reverse thrust will minimize any boat movement. Because the impeller is always rotating and creating thrust when the engine is running, the boat may tend to move slowly forward or backward. This is normal for a direct‑drive jet driven boat. The operator should be aware of this and use caution whenever the engine is running.

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eng 69

WARNING

The jet drive is always drawing water into the housing when the engine is running. Do not operate the jet drive with the grate removed from the water intake. Keep hands, feet, hair, loose clothing, life jackets, etc., away from the water intake. Never insert an object into the water intake or water outlet nozzle when the engine is running.

Stopping the Boat in an Emergency

A jet powered boat has emergency stopping capability unique to this form of propulsion.

WARNING

Steering the Boat

The jet drive is dependent on water jet thrust for steering the boat. If the water jet thrust should ever stop (water blockage, engine stops, etc.), the boat will slow to a stop. However, while slowing there will be a reduced ability to steer the boat.

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OPERATION

70 eng

WARNING

Steering the vessel in a tight turn can result in loss of boat control. In some cases, the boat can spin out or roll over, causing serious injury or death. Avoid steering beyond the capabilities of the vessel, especially at high speeds.

WARNING

A loss or reduction in water jet thrust will directly affect boat directional control, and may result in property damage, personal injury, or death. Boat directional control can also be substantially reduced or lost altogether by a sudden loss of power such as running out of gas, quickly backing off the throttle, turning off the ignition switch, activating the lanyard stop switch, or plugging the water intake to the jet pump. Use caution when maneuvering at high speeds in areas where debris (weeds, logs, gravel, etc.) could be picked up into the jet drive. The ability to take evasive action is dependent on sufficient water jet thrust to control the boat.

While steering the boat at engine speeds above idle, the boat will respond quickly; but, due to the relatively flat‑bottom hulls and lack of a gearcase in the water, the boat will tend to skid on turns. Turns must be started early and use sufficient power to maintain steering control.

Mooring the Boat

Be sure to tilt the jet drive out of the water when the boat is pulled onto a beach or tied to a dock in shallow water. Failure to do this may cause the water intake housing to fill with sand or debris and could prevent the outboard from cranking over for starting.

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OPERATION

eng 71

Water Intake Blockage

WARNING

A rotating impeller could cause injury if contact is made with hands, clothing, or tools. To avoid injury, keep hands and clothing away from the inlet or outlet of the jetdrive, regardless of whether the boat is in the water. Secure tools and loose items to avoid being struck by projectiles as a result of contact with the rotating impeller, and to prevent damage to the impeller.

A large amount of debris being drawn into the water intake may result in a loss of power. Intake suction holding debris against the grate will result in restricted water flow. Shutting the engine off may allow the debris to fall off the intake grate allowing full power to be restored. If debris does not fall off the intake grate, the engine must be shut off and debris physically removed from the grate.

Clearing A Lodged Impeller

WARNING

Rotating the flywheel to free a lodged impeller can accidentally start the engine, resulting in serious injury or death. Always turn the ignition key or lanyard stop switch to the "OFF" position and remove all spark plug leads from the spark plugs.

It is possible for debris to lodge between the impeller and jet housing wall, especially after the engine has been stopped. This will lock the driveshaft and will prevent the engine from being able to crank over for starting. Following are steps for dislodging the impeller.

1. Position the lanyard stop switch to the "OFF" position.

2. Remove the spark plug leads to prevent the engine from accidentally starting.

3. Remove the flywheel or rewind cover and rotate the engine flywheel counterclockwise.

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OPERATION

72 eng

If this does not dislodge the impeller, it will be necessary to remove the six screws and water intake housing.

Pre‑Starting Instructions

1. Check the engine oil level.

28525

2. Ensure that the driveshaft bearing on the jet drive is lubricated. Refer to Maintenance ‑ Lubrication Points.

28664

Engine Break‑in Procedure

IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures.

1. For the first hour of operation, run the engine at varied throttle settings up to 3500 RPM or at approximately half throttle.

2. For the second hour of operation, run the engine at varied throttle settings up to 4500 RPM or at three‑quarter throttle, and during this period of time, run it at full throttle for approximately one minute every ten minutes.

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3. For the next eight hours of operation, avoid continuous operation at full throttle for more than five minutes at a time.

Starting the Engine ‑ Remote Control Models

Before starting, read the pre‑starting check list, special operating instructions, and engine break‑in procedure in the Operation section.

NOTICE

Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat. Never start or operate the engine without the intake housing in the water.

1. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks.

19748

2. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm.

27348

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OPERATION

74 eng

3. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch.

19791

4. Shift outboard to neutral ("N") position.

26838

5. Move the throttle‑only lever to the fully closed position or press the throttle‑only button.

a - Fully closed position b - Maximum fast idle speed position

6. Starting a flooded engine ‑ Advance the throttle‑only lever or control handle to the maximum throttle‑only position and continue to crank the engine for starting. Immediately reduce engine speed after engine starts.

26840

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OPERATION

eng 75

7. Turn ignition key to the "START" position. If the engine fails to start in ten seconds, return the key to the "ON" position, wait 30 seconds and try again.

19804

8. After engine starts, check for a steady stream of water flowing out of the water pump indicator hole.

28521

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 will cause engine damage.

WARMING UP ENGINE

Before beginning operation, allow the engine to warm up at idling speed for three minutes.

Starting the Engine ‑ Tiller Handle Models

Before starting, read the pre‑starting check list, special operating instructions, and engine break‑in procedure in the Operation section.

NOTICE

Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat. Never start or operate the engine without the intake housing in the water.

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OPERATION

76 eng

1. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks.

19748

2. Connect the remote fuel line to the outboard. Make sure the connector is snapped into place.

28526

3. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel line primer bulb several times until it feels firm.

27348

4. Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch.

19791

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OPERATION

eng 77

5. Shift outboard to neutral ("N") position.

28522

6. Set the throttle grip to start position.

7. Starting a flooded engine ‑ Set the throttle grip to half‑way position.

a - Start position b - Half‑way position

8. Turn the ignition key to the "START" position. If the engine fails to start in ten seconds, return the key to the "ON" position, wait 30 seconds and try again.

19804

WARNING

Rapid acceleration can result in serious injury or death from being thrown within or out of the boat. Decrease engine speed before shifting into gear.

ART

0%100

START

0%100

START

19799

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OPERATION

78 eng

9. Check for a steady stream of water flowing out of the water pump indicator hole.

28521

WARMING UP ENGINE

Before beginning operation, allow the engine to warm up at idling speed for three minutes.

Gear Shifting

IMPORTANT: Observe the following:

• Never shift outboard into gear unless engine speed is at idle.

• Your outboard has three gear shift positions to provide operation: forward, neutral (out of gear), and reverse.

28523

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OPERATION

eng 79

• Remote control models ‑ When shifting, always stop at the neutral position and allow the engine speed to return to idle.

26779

• Tiller handle models ‑ Reduce the engine speed to idle before shifting.

26842

• Always shift the outboard into gear with a quick motion.

• After shifting the outboard into gear, advance the remote control lever or rotate the throttle grip (tiller handle) to increase speed.

Stopping the Engine

1. Remote control models ‑ Reduce the engine speed and shift the outboard to neutral position. Turn the ignition key to "OFF" position.

26843

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OPERATION

80 eng

2. Tiller handle models ‑ Reduce the engine speed and shift the outboard to neutral position. Push in the engine stop button or turn the ignition key to "OFF" position.

26776

Emergency Starting

If the starter system fails, use the spare starter rope (provided) and follow procedure.

NOTE: EFI models ‑ Engine must have a fully charged battery to start the engine.

1. Remove flywheel cover or manual starter assembly.

26844

2. Shift outboard to neutral ("N") position.

28528

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OPERATION

eng 81

WARNING

The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear.

3. Electric start models ‑ Turn the ignition key to "ON" position.

26846

WARNING

High voltage is present any time the key is turned on, especially when starting or operating the engine. Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests.

WARNING

The exposed moving flywheel can cause serious injury. Keep your hands, hair, clothing, tools, and other objects away from engine when starting or running the engine. Do not attempt to reinstall the flywheel cover or top cowl when engine is running.

4. Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel.

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OPERATION

82 eng

5. Pull the starter rope to start the engine.

26848

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MAINTENANCE

eng 83

Outboard Care

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.

Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts.

SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD

We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants.

EPA Emissions Regulations

All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, wherever practicable, returned to the original intent of the design. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine spark ignition (SI) engine repair establishment or individual.

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MAINTENANCE

84 eng

EMISSION CERTIFICATION LABEL

An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture.

a - Idle speed b - Engine horsepower c - Piston displacement d - Engine power ‑ kilowatts e - Date of manufacture f - Family number g - Regulated emission limit for the engine family h - Regulated emission limit for the engine family i - Recommended spark plug and gap j - Percent of fuel line permeation

OWNER RESPONSIBILITY

The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards.

The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission 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.

SPARK PLUG:

GAP:

EMISSION CONTROL INFORMATION

THIS ENGINE CONFORMS TO EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES

CALIFORNIA AND U.S. EPA

REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS

IDLE SPEED (in gear):

FAMILY:

HC+NOx:FEL:

LOW PERM/HIGH PERM:

g/kWh

HC+NOx:FEL:

g/kWh

CO FEL:

g/kWh

43210

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MAINTENANCE

eng 85

• Check that lanyard stop switch stops the engine.

• Visually inspect the fuel system for deterioration or leaks.

• Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, retighten the outboard mounting fasteners. When looking for signs of looseness, look for loss of outboard transom bracket material or paint caused by movement between the outboard mounting fasteners and the outboard transom brackets. Also look for signs of movement between the outboard transom brackets and the boat transom.

• Check steering system for binding or loose components.

• Visually check steering link rod fasteners for proper tightness. See Steering Link Rod Fasteners.

• Make sure the driveshaft bearing on the jet drive is lubricated. See Lubrication Points.

AFTER EACH USE

• Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the Cooling System.

• If operating in saltwater, wash off all salt deposits and flush out the exhaust outlet on the jet drive with fresh water.

EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS FIRST

• Lubricate all lubrication points. Lubricate more frequently when used in saltwater. See Lubrication Points.

• 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. See Changing Engine Oil.

• Inspect thermostat visually for corrosion and broken spring. Make sure thermostat closes completely at room

temperature.

• Check engine fuel filter for contaminants. See Fuel System.

•

Check engine timing setup.

1. These items should be serviced by an authorized dealer.

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MAINTENANCE

86 eng

• Check corrosion control anodes. Check more frequently when used in saltwater. See Corrosion Control Anodes.

•

Lubricate splines on the driveshaft.

• Check power trim fluid. See Checking Power Trim Fluid.

• Inspect battery. See Battery Inspection.

•

Check control cable adjustments.

• Inspect timing belt. See Timing Belt Inspection.

• Check tightness of bolts, nuts, and other fasteners.

• Check cowl seals to make sure seals are intact and not damaged.

• Check internal cowl sound reduction foam (if equipped) to make sure foam is intact and not damaged.

• Check that the intake silencer (if equipped) is in place.

• Check that the idle relief muffler (if equipped) is in place.

• Check for loose hose clamps and rubber boots (if equipped) on the air intake assembly.

EVERY 300 HOURS OF USE OR THREE YEARS

• Replace spark plugs at first 300 hours or third year. After that, inspect spark plugs every 300 hours or three years. Replace spark plugs as needed. See Spark Plug Inspection and Replacement.

• Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).

•

Check and adjust valve clearance, if necessary.

BEFORE PERIODS OF STORAGE

• Refer to storage procedure. See Storage 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.

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MAINTENANCE

eng 87

IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages.

WARNING

Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

1. Place the outboard in either the operating position (vertical) or in a tilted position.

2. Remove the 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.

IMPORTANT: Do not run engine above idle when flushing.

4. Shift the outboard into neutral. Start the engine and flush the cooling system for at least five minutes. Keep the engine speed at idle.

5. Stop the engine. Turn off the water and remove the hose. Reinstall the propeller.

28518

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MAINTENANCE

88 eng

Top Cowl Removal and Installation

REMOVAL

1. Pull out the rear lock lever and remove the top cowl.

28439

INSTALLATION

1. Lower the top cowl over the engine.

2. Bring the front of the cowl down first and engage the front hook. Lower the cowl into its seated position and apply downward pressure to the back of the cowl to lock it in place. Gently pull up on the back of cowl to make sure it is securely fastened.

28445

Exterior Care

Your outboard is protected with a durable baked enamel finish. Clean and wax often using marine cleaners and waxes.

Mercury 40 jet fourstroke User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual