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Jet 40 - Brunswick Marine in EMEA Center

1. AALS aa fatz a n 0b00317 a Running the engine when the boat is b Mooring close to another boat that has its moored in a confined space engine running WHILE BOAT IS MOVING 0b00318 a Running the boat with the trim angle of the b Running the boat with no forward hatches bow too high open GENERAL INFORMATION 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 Check with your dealer before installation of accessories The misuse of acceptable accessories or the use of unacceptable accessories can result in serious injury death or product failure 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 Suggestions In order to safely enjoy the waterways the operator should be familiar with local and other governmental boating regulations and restrictions and consider the following suggestions Use flotation devices Have an approved personal flotation device of suitable size for each person aboard it is the law and have it readily accessible Do not overload your boat Most boats are rated and certified for maximum load
2. AFTER EACH USE Flush out the outboard cooling system if operating in salt or polluted water See Flushing The Cooling System If operating in salt water wash off all salt deposits and flush out 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 freguently when used in salt water See Lubrication Points Inspect and clean spark plugs See Spark Plug Inspection and Replacement Check engine fuel filter for contaminants See Fuel System Check carburetor adjustments if reguired 1 1 Check engine timing setup Lubricate splines on the driveshaft 1 5 Check corrosion control anode Check more freguently when used in salt water See Corrosion Control Anode Check power trim fluid Inspect battery See Battery Inspection Remote control models Check control cable adjustments 1 3 Remove engine deposits with Quicksilver or Mercury Precision Power Tune Engine Cleaner Check tightness of bolts nuts and other fasteners EVERY 300 HOURS OF USE OR THREE YEARS Replace water pump impeller more often if overheating occurs or reduced water pressure is noted 1 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
3. in front of the boat in 5 seconds Watch fallen skiers When using the boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to assist the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water 14 GENERAL INFORMATION Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when the 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 Serial Number XXXXXXXX 1 0b01434 a Serial number d Year manufactured b Model year e Certified Europe Insignia as applicable c Model designation Jet 40 Specifications Engine Horsepower Full Throttle RPM Range 5000 5500 RPM Idle Speed in Forward Gear 650 700 RPM Number of Cylinders Piston Displacement 965 cc 58 9 cu in Recommended Gasoline Recommended Oi 465 Marine Cranking Amps MCA
4. 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 Outboard Limited Warranty Confederation of Independent States Middle East and Africa WHAT IS COVERED Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for one 1 year from the date the product is first sold to a recreational use retail purchaser or the date on which the product is first put into service whichever occurs first Commercial users of these products receive warranty coverage of one 1 years 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 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 wa
5. Using an outboard that exceeds the maximum horsepower limit of a boat can 1 cause loss of boat control 2 place too much weight at the transom altering the designed flotation characteristics of the boat or 3 cause the boat to break apart particularly around the transom area Overpowering a boat can result in serious injury death or boat damage GENERAL INFORMATION 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 CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 0b00306 Outboard Remote Control Models The remote control connected to your outboard must be eguipped 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 Avoid serious injury or death from a sudden unexpected acceleration when starting your engine The design of this outboard reguires that the remote control used with it must have a built in start in neutral only protection device 0b00308 Remote Steering Notice Disengagement of a steering link rod can result in the boat taking a full sudden sharp turn This potentially violent action can cause occupants to be thrown overboard ex
6. correspondence United States Telephone 920 929 5040 Mercury Marine W6250 W Pioneer Road See Kana P O Box 1939 www mercurymarine com Fond du Lac WI 54936 1939 Canada Telephone 905 567 6372 Mercury Marine Ltd 2395 Meadowpine Blvd Fax 905 567 8515 Mississauga Ontario LON 7W6 Canada 59 OWNER SERVICE ASSISTANCE Australia Pacific Telephone 61 3 9791 5822 Mercury Marine Australia 132 140 Frankston Road Fax 61 3 9793 5880 Dandenong Victoria 3164 Australia Europe Middle East Africa Telephone 32 87 32 32 11 Marine Power Europe Inc Parc Industriel de Petit Rechain Fax 32 87 31 19 65 B 4800 Verviers Belgium Mexico Central America South America Caribbean Telephone 954 744 3513 Mercury Marine 11650 Interchange Circle North 954 744 3535 Miramar FL 33025 U S A Japan Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Fax 81 053 423 2510 Shizuoka ken Japan 435 0005 Japan Asia Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way Fax 5467789 Singapore 508762 60 MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Maintenance Performed 61
7. 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 alerts to draw your attention to special safety instructions that should be followed A DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or property damage It may also be used to alert against unsafe practices Boat Horsepower Capacity
8. deliver product to an authorized dealer WARRANTY INFORMATION Additional service work requested by customer other than that necessary to satisfy the warranty obligation Labor performed by other than an authorized dealer may be covered only under 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 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 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs Oils lubricants or fluids changed as a matter of normal maintenance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit 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 Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard Wat
9. engine 38 MAINTENANCE 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 Neglected inspection and maintenance service of your outboard or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury death or product failure Record maintenance performed in 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 Using a replacement part that is inferior to the original part could result in personal injury death or product failure EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at time of manufacture EMISSION CONTROL LX ERCURY INFORMATION This engine conforms to model year EPA regulations for Marine SI engines Refer to Owner s Manual for reguired maintenance IDLE SPEED FAMILY CD hp cc FEL TIMING IN DEGREES Standard spark p
10. engine speed after engine starts Turn ignition key to START position and start the engine If engine is cold push in on key to prime the engine while cranking If engine fails to start in ten seconds wait 30 seconds and try again If engine begins to stall reprime until engine is running smoothly OFF 0b00354 After engine starts check for a steady stream of water flowing out of the water pump indicator hole 35 OPERATION 0b01438 IMPORTANT If no water is coming out of the water pump indicator hole stop engine and check cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by your dealer Operating the engine while overheated may cause serious engine damage Ge ar Shifting The outboard has three gear shift positions to provide operation Forward F Neutral N and Reverse R 0b00557 0b01447 Tiller handle models Reduce engine speed to idle before shifting A 0b01677 After shifting 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 engine speed and shift outboard to neutral position Turn ignition key to OFF position OFF ko 1eVLS 0b00360 Tiller Handle Models Reduce engine speed and shift outboard
11. of season storage or prolonged storage two months or longer FUEL SYSTEM IMPORTANT Gasoline containing alcohol ethanol or methanol can cause a formation of acid during storage and can damage the fuel system If the gasoline being used contains alcohol it is advisable to drain as much of the remaining gasoline as possible from the fuel tank remote fuel line and engine fuel system Fill the fuel tank and engine fuel system with treated stabilized fuel to help prevent formation of varnish and gum Proceed with following instructions Portable Fuel Tank Pour the reguired amount of gasoline stabilizer follow instructions on container into fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel Permanently Installed Fuel Tank Pour the required amount of gasoline stabilizer follow instructions on container into a separate container and mix with approximately one quart one liter of gasoline Pour this mixture into fuel tank Place the outboard in water or connect flushing attachment for circulating cooling water Run the engine for ten minutes to fill the engine fuel system Protecting External Outboard Components Lubricate all outboard components listed in Maintenance Inspection and Maintenance Schedule Touch up any paint nicks See your dealer for touch up paint Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces except corrosion control anodes Ext
12. the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim forms WARRANTY INFORMATION 4 In some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor dealer If you receive a plastic Warranty Registration Card you may discard the Purchaser s Copy that you received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you IMPORTANT Registration lists must be maintained by the factory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be necessary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area 5 For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing refer to the International Warranty Outboard Limited Warranty United States Canada and Europe Outside the United States Canada and Europe check with local distributor WHAT IS COVERED Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below
13. to neutral position Push in the engine stop button or turn ignition key to OFF position 36 OPERATION Emergency Starting If the starter system fails use the spare starter rope provided and follow procedure 1 Remove flywheel cover 0b01448 When using emergency starter rope to start engine the start in gear protection device is inoperative Make sure to set the outboard gear shift into neutral to prevent outboard from starting in gear Sudden unexpected acceleration could result in serious injury or death 2 Shift outboard to neutral N position 0b01446 3 Turn the ignition key to ON position o0b00364 37 OPERATION 4 Set the lanyard stop switch to the RUN position Refer to General Information Lanyard Stop Switch 0b00350 To prevent getting an electrical shock do not touch any ignition component wiring or spark plug wire when starting or running the engine 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 5 Place starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel 6 If engine is cold hold the fuel primer button in and pump up the fuel pressure with the fuel primer bulb o0b01649 7 Pull the starter rope to start the
14. warranty registration department In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 920 929 5893 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 For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Center closest to you Warranty Registration United States And Canada 1 You may change your address at any time including at time of warranty claim by calling Mercury Marine or sending a letter or fax with your name old address new address and engine serial number to Mercury Marine s warranty registration department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 920 929 5893 NOTE Registration lists must be maintained by Mercury Marine and any dealer on marine products sold in the United States should a safety recall notification under the Federal Safety Act be required 2 To be eligible for warranty coverage the product must be registered with Mercury Marine At the time of sale the dealer should complete the warranty registration and immediately submit it to Mercu
15. 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 laborand 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 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 i
16. ANT Always carry spare SFE 20 AMP fuses The electric starting circuit is protected from overload by an SFE 20 AMP fuse If the fuse is blown the electric starter motor will not operate Try to locate and correct the cause of the overload If the cause is not found the fuse may blow again Replace fuse with a fuse of the same rating 1 Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse with a new fuse with the same rating 0b01655 a Good fuse b Broken band Corrosion Control Anode The outboard has corrosion control anode installed on the bottom of the transom bracket assembly An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals 0b01656 The anode reguires periodic inspection especially in salt water which will accelerate the erosion To maintain this corrosion protection always replace the anode before it is completely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode 44 MAINTENANCE Spark Plug Inspection and Replacement Avoid serious injury or death from fire or explosion caused by damaged spark plug boots Damaged spark plug boots can emit sparks Sparks can ignite fuel vapors under the engine cowl To avoid damaging spark plug boots do not use any sharp object or metal tool such as pliers screwdriver e
17. DURATION OF COVERAGE This Limited Warranty provides coverage for two 2 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 Commercial users of these products receive warranty coverage of one 1 year from the date of first retail sale or one 1 year from the date in 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 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 from one recreational use customer to a subsequent recreational use customer upon proper re registration of the product Unexpired warrant coverage cannot be transferred either to or from a commercial use customer 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 pre delivery inspection process is completed and documented War
18. LESHOOTING Starter Motor Will Not Crank The Engine Electric Start Models POSSIBLE CAUSES Remote control models Blown 20 Amp fuse in the starting circuit Refer to Maintenance section Outboard is not shifted to neutral position Weak battery or battery connections are loose or corroded Ignition key switch failure Wiring or electrical connection faulty Starter motor or starter solenoid failure Engine Will Not Start POSSIBLE CAUSES Lanyard stop switch not in RUN position Incorrect starting procedure Refer to Operation section Old or contaminated gasoline Engine flooded Refer to Operation section Fuel is not reaching the engine a Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Primer bulb not squeezed Primer bulb check valve is faulty Fuel filter is obstructed Refer to Maintenance section Oo mp a00 Fuel pump failure h Fuel tank filter obstructed Ignition system component failure Spark plugs fouled or defective Refer to Maintenance section Engine Runs Erratically POSSIBLE CAUSES Spark plugs fouled or defective Refer to Maintenance section Incorrect setup and adjustments Fuel is being restricted to the engine Engine fuel filter is obstructed Refer to Maintenance section e Fuel tank filter obstructed e Stuck anti siphon valve on built in fuel tank e Fuel line is kinked or pinched Fuel pump failure I
19. TAINING 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 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 FIRE AND EXPLOSION HAZARD Fuel leakage from any part of the fuel system can be a fire and explosion hazard which can cause serious bodily injury or death Careful periodic inspection of entire fuel system is mandatory particularly after storage All fuel components should be inspected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before furthe
20. Welcome Aboard Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy The enclosed Owner s Registration Card is your key to trouble free family fun Refer to your Operation and Maintenance Manual for full details of your warranty coverage Details of your nearest dealer can be found on www marinepower com where country maps and full contact information are displayed Is your engine properly registered for warranty purpose Please check on www marinepower com If necessary please contact your local dealer Declaration of Conformity If the outboard motor s serial number plate contains the CE mark in the lower left hand corner the following statement applies This outboard motor manufactured by Mercury Marine Fond du Lac WI USA or Marine Power Europe Inc Park Industriel de Petit Rechain Belgium complies with the requirements of the following directives and standards as amended Recreational Craft Directive 94 25 EC Owner s manual A 2 5 ISO 10240 Handling characteristics A 4 ISO 8665 Outboard engine starting A 5 1 4 ISO 11547 Fuel tanks A 5 2 2 ISO 13591 ISO 8469 General steering system ABYC P 17 Safety of Machinery Directive 98 37 EC Principles of safety integration 1 1 2 EN 292 1 EN 292 2 EN 1050 Noise 1 5 8 ICOMIA 39 94 Electromagnetic Compatibility Directive 89 336 EC Generic emission standard EN 61000 6 3 Ge
21. ard 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 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 to slow to a stop However while slowing there will be a reduced ability to steer the boat Avoid serious injury or death Do not attempt to steer the boat into a tight turn At high speeds the boat could spin out or even roll over resulting in occupants being thrown within the boat or out of the boat Avoid injury death or property damage resulting from collision due to loss of directional control Directional control is derived from the water jet thrust Caution should be exercised when maneuvering at higher speeds in areas where debris weeds logs gravel etc could be picked up into the jet drive This can cut off or reduce the water jet thrust thereby directly affecting boat directional control 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 throttle turning off ignition switch or activating lanyard stop switch Remember you ability to take evasive action is dependent on sufficient water jet thrust to control the boat While steering the boat at
22. ater 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 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 re enters the water 0b00314 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 Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake Avoid wave or wake jumping whenever possible Instruct all occupants that if a wake or wave jump occurs get low and hang on to a boat hand hold 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 ma
23. aterial from bottom side only 0b01409 a Leading edge b Top side lifting angle Impeller Clearance Adjustment The impeller should be adjusted so there is approximately 0 8 mm 0 03 in clearance between the impeller edge and liner Operating the jet drive in waters that contain sand and gravel can cause wear to the impeller blades and the clearance will start to exceed 0 8 mm 0 03 in 46 MAINTENANCE As the blades wear shims located in the stack outside of the impeller can be transferred behind the impeller This will move the impeller further down into the tapered liner to reduce the clearance 0b01410 a Shims b Clearance between impeller edge and liner Check the impeller clearance by sliding a feeler gauge through the intake grate and measure the clearance between the impeller edge and liner If adjustment is required refer to Impeller Removal and Installation Impeller Removal and Installation If the driveshaft is rotated while the engine is in gear there is the possibility that the engine will crank over and start To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating impeller always shift outboard to neutral position and remove spark plug leads when servicing the propeller REMOVAL 1 Shift outboard to neutral N position 0b00351 2 Remove spark plug leads to prevent engine from starting 47 MAINTENANCE 3 3 R
24. bulb must be replaced Exterior Care Your outboard is protected with a durable baked enamel finish Clean and wax often using marine cleaners and waxes Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt d Part Number 10 856680 and self locking nylon insert locknuts a amp c Part Number 11 8267091 13 These locknuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage Disengagement of a steering link rod can result in the boat taking a full sudden sharp turn This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death PAI OA 5 4 4 0b01654 a Nylon insert locknut 11 8267091 13 d Special washer head bolt 10 856680 b Flat washers e Spacer c Nylon insert locknut 11 8267091 13 Special washer head bolt 27 Nylon insert locknut a Nylon insert locknut c Tighten until seats then back off 1 4 turn Assemble steering link rod to steering cable with two flat washers and nylon insert locknut Tighten locknut until it seats then back nut off 1 4 turn 43 MAINTENANCE Assemble steering link rod to engine with special washer head bolt locknut and spacer First torque special washer head bolt then torque locknut to specifications Fuse Replacement IMPORT
25. d 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 non commercial use purchaser upon proper re registration 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 pre delivery 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 WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing a corroded part replacing
26. e boat Remote control models will have the warning horn located inside the remote control or connected to the ignition key switch le ob00662 a Warning horn inside remote control b Warning horn inside key switch Tiller handle models will have the warning horn located below the tiller handle 22 FEATURES AND CONTROLS 0b01437 WARNING SYSTEM OPERATION The warning horn will emit a continuous beep This will alert the operator and help identify the following listed situations Warning System Engine Over Temperature Engine Over Heat Low Oil Level Low Oil Level ENGINE OVERHEAT If the engine overheats immediately reduce throttle speed to idle Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole 0b00331 If no water is coming out of the water pump indicator hole or flow is intermittent stop engine and check the cooling water intake holes for obstruction If no obstruction is found there may be a blockage in the cooling system or a water pump problem Have the outboard checked by your dealer Operating the engine while overheated will cause engine damage NOTE Should overheating occur and you are stranded stop the engine and allow it to cool down This will usually allow some additional low speed idle running time before the engine starts to overheat again Operating an overheated engine will cause engine damage If a steady flow of water is coming out
27. e 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 30 OPERATION 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 The driveshaft driven impeller draws water up through the water intake and then redirects 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 0b01392 a Water intake c Reverse gate b Water outlet nozzle 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 crea
28. e fully retracted into the outboard tilt tube before adding lubricant Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked A hydraulically locked steering cable will cause loss of steering control possibly resulting in serious injury or death o0b01661 a Fitting b Steering cable end 3 Lubricate the following with light weight oil Steering Link Rod Pivot Points Lubricate pivot points o0b01662 Checking Power Trim Fluid 1 Tilt outboard to the full up position and engage the tilt support lock 0b00434 2 Remove fill cap and check fluid level The fluid level should be even with the bottom of the fill hole Add Quicksilver or Mercury Precision Lubricants Power Trim amp Steering Fluid If not available use automotive ATF automatic transmission fluid o0b01663 53 MAINTENANCE Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine 54 STORAGE Storage Preparation The major consideration in preparing the outboard for storage is to protect it from rust corrosion and damage caused by freezing of trapped water The following storage procedures should be followed to prepare outboard for out
29. eep 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 drive shaft 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
30. eft 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 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 K
31. emove the water intake housing that is fastened with six screws 4 0b01412 a Tabs b Impeller nut 5 Pull impeller straight off the shaft If the impeller is tight use a hammer and block of wood to rotate the impeller clockwise on the shaft until the keyway is directly above the flat on the shaft This will free the jammed key and allow removal INSTALLATION 1 Grease the driveshaft shear key and impeller bore 2 Place the plastic sleeve inside the impeller 3 Install impeller shear key shims nut retainer and impeller nut 48 MAINTENANCE S4 i ia C O s O O SN 0b01413 a Plastic sleeve d Shims b Impeller e Nut retainer c Shear key f Impeller nut 4 Turnthe nut tight on the shaft to remove any play between the impeller and shaft If the tabs on the retainer do not line up with the flats on the nut remove the nut and turn the retainer over and re tighten the nut again 5 Temporarily reinstall the water intake housing in order to check for impeller clearance The clearance between the impeller and liner should be 0 08 mm 0 03 in Shim washers can be transferred to either side of the impeller to raise or lower the impeller to the correct clearance setting The water intake housing can be shifted sideways a small amount in order to center the liner 49 MAINTENANCE 0b01410 a Shims b Clearance between impeller edge and liner 6 After setting the impeller height tighte
32. 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 Water Intake Blockage Avoid injury resulting from contacting the rotating impeller Always shut off the engine before attempting to remove a blockage from the water intake 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 32 OPERATION Clearing A Lodged Impeller If the flywheel is rotated to free a lodged impeller there is the possibility that the engine will crank over and start To prevent this type of accidental engine starting and possible serious injury always turn the ignition key or lanyard stop switch to the OFF position and remove all spark plug
33. er entering engine through the fuel intake air intake or exhaust system or submersion 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 Use of fuels and lubricants which are not suitable for use with or on the product Refer to the Maintenance section 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 GENERAL INFORMATION Boater s Responsibilities The operator driver is responsible for the correct and safe operation of the boat and safety of its occupants and general public It is strongly recommended that each operator driver read and understand this entire manual before operating the outboard Be sure at least one additional person on board 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
34. ering 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 WARRANTY INFORMATION Corrosion damage caused by stray electrical currents on shore 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 anti fouling paints is also not covered by this limited warranty If anti fouling protection is required Tri Butyl Tin Adipate TBTA base anti fouling 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 l
35. ernal metal surfaces 92 802878Q55 Protecting Internal Engine Components NOTE Make sure the fuel system has been prepared for storage Refer to Fuel System preceeding IMPORTANT Refer to Maintenance Spark Plug Inspection and Replacement for correct procedure for removing spark plug boots Place the outboard in water or connect flushing attachment for circulating cooling water Start the engine and let it run in neutral to warm up With engine running at fast idle stop the fuel flow by disconnecting the remote fuel line When engine begins to stall quickly spray Quicksilver or Mercury Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel Remove the spark plugs and inject a five second spray of storage seal around the inside of the cylinder Rotate the flywheel manually several times to distribute the storage seal in the cylinder Reinstall spark plug Jet Drive Pump extra grease into the jet drive bearing to purge out moisture Positioning Outboard for Storage Store the outboard in an upright vertical position This will allow water to drain out of the outboard 55 STORAGE Battery Storage Follow the battery manufacturer s instructions for storage and recharging Remove the battery from the boat and check water level Recharge if necessary Store the battery in a cool dry place Periodically check the water level and recharge the battery during storage 56 TROUB
36. gnition system component failure Engine Over Speed Excessive RPM POSSIBLE CAUSES Outboard mounted too high on the transom Worn jet pump impeller or liner Incorrect jet pump impeller clearance adjustment 57 TROUBLESHOOTING Tilting the outboard out beyond a vertical position Cavitation of the impeller due to rough water or obstruction in the boat hull Blockage of the water intake Performance Loss POSSIBLE CAUSES Throttle not fully open Damaged impeller Incorrect engine timing adjustments or setup Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator 58 OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise Only he has the factory trained mechanics knowledge special tools equipment and genuine parts and accessories to properly service your engine should the need occur He knows your engine best Service Away From Home If you are away from your local dealer and the need arises for service contact the nearest authorized dealer Refer to the Yellow Pages of the telephone directory If for any reason
37. hat 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 WARRANTY INFORMATION 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 or 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 runni
38. he battery is secure against movement 4 Battery cable terminals should be clean tight and correctly installed Positive to positive and negative to negative 5 Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals Fuel System Avoid serious injury or death from gasoline fire or explosion Carefully follow all fuel system service instructions Always stop the engine and do not smoke or allow open flames or sparks in the area while servicing any part of the fuel system Before servicing any part of the fuel system stop engine and disconnect the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved receptacle Any fuel system service must be performed in a well ventilated area Inspect any completed service work for sign of fuel leakage FUEL LINE FILTER Inspect the fuel line filter If the filter appears to be contaminated remove and replace 0b01653 42 MAINTENANCE IMPORTANT Visually inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm forcing fuel into the filter FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer
39. ifications Component Identification Installing Outboard Trailering R aUOUtbG Att ARBANI Na aa 18 Fuel Recommendations Oil Recommendation New Engine Gasoline Oil Break in Mixtu Filling Oil Injection System Filling Fuel Tank re Features and Controls Remote Control Features Warning System TABLE OF CONTENTS Engine Over Speed Limiter Power Trim And Tilt Manual Tilt System Throttle Grip Friction Adjustment Tiller Handle Models Steering Friction Adjustment Tiller Handle Models Replaceable Jet Drive Shear Key Operation Pre Starting Check List Operating In Freezing Temperatures Operating In Salt Water Or Polluted Water Operating at High Elevations Operating In Shallow Water How the Jet Drive Operates Stopping the Boat inan Emergency 4 5 in entin ca cent ccce cece ceesanceubenesbeasei caseeedecececesseceenansebsenanat entecdeedeectiess Steering The Boat Mooring The Boat Water Intake Blockage Clearing A Lodged Impelle Engine Break in Procedure Starting The Engine Gear Shifting Stopping The Engine Emergency Starting s cttessecseecsuesesuceassaeevereue Maan naa resi an aga Ea AMAN na RS aa Outboard Care EPA Emissions Inspection And Maintenance Schedule Flushing The Cooling System Top Cowl Removal And Installation Battery Inspection Fuel System Exterior Care Steering Link Rod Fasteners Fuse Replacement Corro
40. 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 WARRANTY INFORMATION 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 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 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 sol
41. ine oil mixture in the first tank of fuel Refer to the following table for mixing ratios Use of this fuel mixture combined with oil from the oil injection system will supply adequate lubrication during engine break in After the break in fuel mixture is used up it is no longer necessary to add oil with the gasoline NOTE At the end of the break in period visually check to see if the oil level in the oil injection tank has dropped Oil usage indicates the oil injection system is functioning correctly GASOLINE OIL MIXING RATIO CHART Gas Oil Ratio 3 8 liters 1 gal gas 11 5 liters 3 gal gas 23 liters 6 gal gas 50 1 2 89 ml 3 fl oz oil 237 ml 8 fl oz oil 473 ml 16 fl oz oil MIXING GASOLINE AND OIL Portable Tank Pour 4 liters 1 gallon of gasoline into tank Add the correct amount of oil and mix thoroughly Add the remainder of gasoline Build in Tank Using a funnel pour the correct amount of oil slowly with the gasoline as tank is filled Filling Oil Injection System 1 Check oil level using the sight gauge in front of the outboard 2 Remove the fill cap and fill tank with oil Oil tank 3 2 liters 96 fl oz Mercury or sa aki TA 0b01436 3 Reinstall fill cap and tighten securely 20 FUEL AND OIL Filling Fuel Tank Avoid serious injury or death from a gasoline fire or explosion Always stop the engine and do not smoke or allow open flames or sparks in the area while fill
42. ing 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 FUEL AND OIL 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 2 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 CON
43. ing fuel tanks Fill fuel tanks outdoors away from heat sparks and open flames Remove portable fuel tanks from boat to refill them Always stop engine before refilling 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 21 FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown If not consult your dealer for a description of the functions and operations of the remote control 0b00329 a Control handle forward neutral reverse f Throttle friction adjustment Console b Neutral release lever controls require cover removal for c Trim tilt switch if equipped Refer to adjustment Features amp Controls Power Trim and Tilt g Ignition key switch OFF ON START d Lanyard stop switch Refer to General h Fast idle lever Refer to Operation Starting Information Lanyard Stop Switch the Engine e Lanyard Refer to General Information i Throttle only button Refer to Operation Lanyard Stop Switch Starting the Engine Warning System The outboard warning system incorporates a warning horn inside th
44. k the outboard in its lock run position could result in the outboard tilting up out of the water during deceleration or while operating in reverse resulting in possible loss of boat control Loss of boat control can result in serious injury death or boat damage Before operating the outboard must be locked in its tilt position by moving the tilt lock lever to the lock run position BASIC TILTING OPERATION Move tilt lock lever to the tilt position Tilt outboard to desired position and lock in place by moving the tilt lock lever back to the lock run position 0b00333 a Tilt position b Lock run position SETTING THE OPERATING ANGLE OF THE OUTBOARD The vertical operating angle of the outboard is adjusted by changing the position of the tilt pin in the adjustment holes provided Proper adjustment allows the boat to achieve optimum performance stability and minimize steering effort 26 FEATURES AND CONTROLS 0b01440 The tilt pin should be adjusted so the outboard is positioned to run perpendicular to the water when the boat is running at full speed This allows the boat to be driven parallel to the water Arrange passengers and load in the boat so the weight is distributed evenly TILTING OUTBOARD Tilting To Full Up Position 1 Stop the engine Move the tilt lock lever to the tilt position Take hold of the top cowl grip and raise outboard to full tilt up position Lock the outboard in place by mo
45. 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 lanyard stop switch to the OFF position 2 Remove spark plug leads to prevent the engine from accidentally starting 3 Remove flywheel or rewind cover and rotate the engine flywheel counterclockwise If this does not dislodge the impeller it will be necessary to remove the six screws and water intake housing Engine Break in Procedure Severe damage to the engine can result by not complying with the Engine Break in Procedure ENGINE BREAK IN FUEL MIXTURE Use a50 1 2 gasoline oil mixture in the first tank of fuel Refer to the following table for mixing ratios Use of this fuel mixture combined with oil from the oil injection system will supply adeguate lubrication during engine break in BREAK IN PROCEDURE Vary the throttle setting during the first hour of operation During the first hour of operation avoid remaining at a constant speed for more than two minutes and avoid sustained wide open throttle Starting The Engine Before starting read the Pre Starting Check List Special Operating Instructions and Engine Break in Procedure in the Operation section 0b01394 33 OPERATION 2 Open fuel
46. lug Suppressor spark plug GAP Valve Clearance Cold mm 0b01071 a Idle speed f Family number b Engine horsepower g Maximum emission output for the engine c Timing specification family d Recommended spark plug and gap h Piston placement e Valve clearance if applicable i Date of manufacture OWNER RESPONSIBILITY The owner operator is reguired 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 emissions levels to exceed their predetermined factory specifications 39 MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE Check that lanyard stop switch stops the engine Visually inspect the fuel system for deterioration or leaks Check outboard for tightness on transom Check throttle shift steering system for binding or loose components Remote control models 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 AND AFTER EVERY 10 HOURS OF OPERATION Lubricate the driveshaft bearing on the jet drive See Lubrication Points
47. ly 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 Itis 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 Salt Water Or Polluted Water If the boat is kept moored in
48. m 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 speed the outboard can also be tilted part the trim range to permit for example shallow water operation 0b01439 a Trim switch remote control c Tilt range of travel b Trim switch tiller handle d Trim range of travel 24 FEATURES AND CONTROLS POWER TRIM OPERATION The power trim and tilt feature of the outboard is convenient for drifting and when operating at low throttle speed in very shallow water When under power do not trim out the outboard in an effort to gain speed as is done with a conventional propeller driven boat When planing the outboard should be positioned vertical or tilted in toward the boat to provide a scooping angle on the water intake grate Tilting the outboard out beyond a vertical position reduces the scoop angle and can cause impeller slippage and cavitation burns on the impeller blades 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
49. n the impeller nut snug with a wrench Secure impeller nut by bending tabs against the flat on the impeller nut 0b01412 a Tabs b Impeller nut NOTE If the outboard is used in salt water apply Quicksilver or Mercury Precision Anti Corrosion Grease around the entire mounting flange on the water intake housing and also to the threads on the six mounting bolts Tube Ref No Where Used Water intake housing Anti Corrosion Grease mounting flange and 92 802867Q1 mounting bolts 7 Reinstall the water intake housing with six bolts Check clearance around the impeller to ensure the water intake housing is centered and not rubbing against the liner Torque mounting bolts to specifications 50 MAINTENANCE Description Water intake housing mounting bolts Lubrication Points 1 Lubricate the following with Quicksilver or Mercury Precision 2 4 C with Teflon 95 Cp 2 4 C with Teflon Driveshaft bearing 92 802859Q1 IMPORTANT It is important not to use a general all purpose grease for this bearing The lubricant recommended is a water resistant grease of the proper consistency for this application If a substitute is used be sure that it is water resistant and of the same consistency Driveshaft Bearing i Pull vent hose off of the grease fitting ii Pump in grease through the great fitting using the grease gun provided until excess grease starts to exit the vent hose iii Reconnect the vent hose onto the grea
50. n 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 or 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 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 coveredby 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 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
51. neric immunity standard EN 61000 6 1 Vehicles boats and internal combustion engine driven devices radio disturbance SAE J551 CISPR 12 characteristics Electrostatic discharge testing aaa Na ENG IOOU ereaeN This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe 90 10136060 505 Jet 40 2005 Mercury Marine Fe Patrick C Mackey President Mercury Marine Fond du Lac WI USA European Regulations Contact Regulations and Product Safety Department Mercury Marine Fond du Lac WI USA TABLE OF CONTENTS Warranty Information Transfer Of Warranty Warranty Registration United States And Canada Warranty Registration Outside The United States And Canada Outboard Limited Warranty United States Canada and Europe Outboard Limited Warranty Confederation of Independent States Middle East and Africa 3 Year Limited Warranty Against Corrosion Warranty Coverage And Exclusions Dnw Boater s Responsibilities nimue d onian AN EN ee ad Before Operating Your Outboard Boat Horsepower Capacity Outboard Remote Control Models Remote Steering Notice Lanyard Stop Switch Stopping the Boat in an Emergency Protecting People In The Water Wave And Wake Jumping Exhaust Emissions sig 12 Selecting Accessories For Your Outboard Safe Boating Suggestions Recording Serial Number Jet 40 Spec
52. ng 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 e g if the operator is accidentally ejected GENERAL INFORMATION Should the operator fall out of the boat the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately Always properly connect both ends of the stop switch lanyard to the stop switch and the operator 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 jet drive Loss of power and directional control in heavy seas strong current or high winds Loss of control when docking Stopping the Boat in an Emergency A jet powered boat has emergency stopping capability unique t
53. ng 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 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 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 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
54. o this form of propulsion Using the emergency stopping capability of the jet drive will slow down the boat in an emergency However sudden stopping may cause the occupants in the boat to be thrown forward or even out of the boat This action may result in serious injury or death 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 0b00311 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 GENERAL INFORMATION WHILE BOAT IS STATIONARY 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 w
55. of the water pump indicator hole and the engine continues to overheat consult your dealer Operating an overheated engine will cause engine damage LOW OIL LEVEL The warning system will be activated if the oil level drops below the sight gauge in the cowl when the outboard is in a vertical position There is still oil reserve remaining for 30 minutes of full speed operation Refer to Fuel amp Oil Filling Oil Injection System FEATURES AND CONTROLS 3103 Engine Over Speed Limiter The outboard is equipped with an engine over speed limiter which limits the engine maximum RPM This will protect the engine from mechanical damage Some causes of engine over speed are as follows Outboard mounted too high on the transom Worn jet pump impeller or liner Incorrect jet pump impeller clearance adjustment Tilting the outboard out beyond a vertical position Cavitation of the impeller due to rough water or obstruction in the boat hull Blockage of the water intake When the engine over speed limiter is activated it will reduce ignition voltage to momentarily decrease the engine speed Excessive over speed above 5700 RPM will result in cutout of the cylinders to prevent operation above this limit Power Trim And Tilt The 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 transo
56. or 350 Cold Cranking AMPS CCA Ampere Hours Ah 70 100 Battery Rating Component Identification GENERAL INFORMATION Top Cowl Tilt lock lever Transom bracket Jet drive housing Water intake housing 0b01435 f Reverse gate g Water outlet nozzle h Driveshaft housing i Water pump indicator hole j Bottom cowl INSTALLATION Installing Outboard Before operation the outboard must be correctly installed with the required mounting hardware as shown Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury death or property damage We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance If you install the outboard yourself follow instructions in the outboard installation manual which is provided with the outboard The outboard must be secured to the transom with the four 12 7 mm 1 2 in diameter mounting bolts and locknuts provided Install two bolts through the upper set of holes and two bolts through the lower set of holes 0b00321 TRANSPORTING 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 trailer
57. ot in the lanyard a Oo RUN 1 NN NN D 0b00310 a Lanyard cord b Lanyard stop switch Read the following Safety Information before proceeding 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 coasti
58. p the engine whenever passengers are boarding unloading or are near the back stern of the boat Just shifting the outboard into neutral is not sufficient 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 operators view when operating the boat above idle speed Avoid shallow water conditions Never operate the jet drive in very shallow water or where there is a noticeable amount of floating debris or weeks Always be in at least 61 to 91 cm 2 to 3 ft of water Any loose material such as sand shells seaweed grass tree branches etc can be pulled in by the pump This may not only block the water flow and cause lost of steering control but can be expelled from the rear of the pump as a high speed projectile Watch for boat movement in neutral When the jet drive is in neutral the drive impeller continues to rotate 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 Never drive the boat directly behind a water skier in case the skier falls As an example a boat traveling at 40 km hr 25 MPH will overtake a fallen skier 61 m 200 ft
59. posing them to serious injury or death 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 GENERAL INFORMATION a Self locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch 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 between 122 and 152 cm 4 and 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 kn
60. r 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 FUEL AND OIL Oil Recommendation Recommended Oil Mercury or Quicksilver Premium 2 Cycle TC W3 Outboard Oil IMPORTANT Oil must be NMMA certified TC W3 2 Cycle oil Mercury or Quicksilver Premium TC W3 2 Cycle oil is recommended for this engine For added protection and lubrication Mercury or Quicksilver Premium Plus TC W3 2 Cycle oil is recommended If Mercury or Quicksilver outboard oil is not available substitute another brand of 2 cycle outboard oil that is NMMA Certified TC W3 Severe engine damage may result from use of an inferior oil New Engine Gasoline Oil Break in Mixture Use a 50 1 2 gasol
61. ranty coverage becomes available upon proper registration of the product by the authorized dealer 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 future warranty coverage contingent on proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this 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 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 t
62. rranty coverage can be transferred from one recreational use customer to a subsequent recreational use customer upon proper re registration of the product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer WARRANTY INFORMATION 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 pre delivery inspection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer 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 on proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing a defective part replacing such part or parts with new or Mercury Marine certified re manufactured 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
63. ry Marine via MercNET E mail or mail Upon receipt of this warranty registration Mercury Marine will record the registration 3 Upon processing the warranty registration Mercury Marine will send registration verification by mail to the purchaser of the product If this registration verification is not received within 30 days please contact your selling dealer immediately Warranty coverage is not effective until your product is registered with Mercury Marine Warranty Registration Outside The United States And Canada 1 Itis important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area 2 The Warranty Registration Card identifies your name and address product model and serial numbers date of sale type of use and the selling distributor s dealer s code number name and address The distributor dealer also certifies that you are the original purchaser and user of the product 3 A copy of the Warranty Registration Card designated as the Purchaser s Copy MUST be given to you immediately after the card has been completely filled out by the selling distributor dealer This card represents your factory registration identification and should be retained by you for future use when required Should you ever require warranty service on this product your dealer may ask you for
64. se fitting after greasing 0b01416 a Grease fitting b Vent hose NOTE After 30 hours of operation pump in extra grease to purge out any moisture Visually inspecting the purged grease at this time will give an indication of conditions inside the bearing housing A gradual increase in moisture content indicates seal wear If the grease begins to turn dark dirty gray the driveshaft bearing and seals should be inspected and replaced if necessary Some discoloration of the grease is normal during the break in period on a new set of seals 51 MAINTENANCE 2 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2 4 C Marine Lubricant with Teflon or Special Lubricant 101 Tube Ref No Where Used Swivel bracket tilt support lever tilt tube tiller handle steering 92 80286501 cable grease fitting Special Lubricant 101 Swivel bracket tilt support lever tilt tube tiller handle steering 92 80285901 cable grease fitting 2 4 C with Teflon e Swivel Bracket Lubricate through fitting e Tilt Support Lever Lubricate through fitting a Tilt support lever e Tilt Tube Lubricate through fitting WY wy N ob01659 e Tiller handle Lubricate through fitting 0b01660 Steering Cable Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through fitting 52 MAINTENANCE The end of the steering cable must b
65. sion Control Anode Spark Plug Inspection and Replacement Steering Pull Adjustment Worn Dull Impeller Impeller Clearance Adjustment Impeller Removal and Installation Lubrication Points Checking Power Trim Flui ia Submerged Outboard ie ang wwe cpa aan Secu ze AN aa aman nanas Storage Preparation ee KA ANE NN EN Protecting External Outboard Components Protecting Internal Engine Components Jet Drive TABLE OF CONTENTS Positioning Outboard for Storage Battery Storage Troubleshooting Starter Motor Will Not Crank The Engine Electric Start Models Engine Will Not Start Engine Runs Erratically Engine Over Speed Excessive RPM Performance Loss Battery Will Not Hold Charge Local Repair Service Service Away From Home Parts And Accessories Inquiries Service Assistance Mercury Marine Service Offices Maintenance Log MaintenanGe LOG ae halim mual RN Kn an RE Mg an eee ee Sa aa 61 vi WARRANTY INFORMATION Transfer Of Warranty 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 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
66. such part or parts with new or Mercury Marine certified re manufactured 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 ste
67. tank vent screw in filler cap on manual venting type fuel tanks 0b00348 3 Connect the fuel line to the outboard 0b01445 4 Squeeze the fuel line primer bulb several times until it feels firm 0b00349 NOTE The engine will not start unless the lanyard is set to the RUN position 5 Set the lanyard stop switch to the RUN position Refer to General Information Lanyard Stop Switch 6 Shift outboard to neutral N position PN ob00351 0b01446 7 Models without power trim Position tilt lock lever to the lock position 34 OPERATION 0b00352 0b01677 Remote control models If engine is cold advance the fast idle speed lever of throttle only feature to an approximate halfway setting After engine start up immediately adjust neutral fast idle setting so engine speed drops below 2000 RPM Return back to normal idle speed after engine is warmed up 3030 a Fast idle speed lever b Throttle only feature Starting a flooded engine a Tiller handle models Advance the throttle grip to full throttle speed Without activating primer start engine following starting procedure Immediately start to reduce engine speed after engine starts b Remote control models Advance the fast idle speed lever or throttle only feature to the full maximum position Without activating the primer crank engine for 10 seconds Wait 30 seconds and repeat until engine starts Immediately start to reduce
68. tc to remove spark plug boots 1 Remove the spark plug leads Twist the rubber boots slightly and pull off P3 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blistered or fouled o0b01092 3 Set the spark plug gap to specifications H i 0b00424 Spark Plug Spark plug gap 1 0 mm 0 040 in 4 Before installing spark plugs clean off any dirt on the spark plug seats Install plugs finger tight and then tighten 1 4 turn or torque to specifications Daron O CO Steering Pull Adjustment The steering on some boats will have the tendency to pull towards starboard This pulling condition can be corrected by using a pliers and bending the ends of the exhaust fins 1 5 mm 1 16 in toward the starboard side of the outboard 45 MAINTENANCE 0b01657 a Exhaust fins Worn Dull Impeller The intake of gravel through the pump can round off and wear the leading edges of the impeller Some conditions that could be experienced from a worn dull impeller are as follows Noticeable performance loss especially on acceleration Difficulty getting the boat on plane An increase in engine RPM at wide open throttle IMPORTANT Do not sharpen or alter the top side lifting angle Check the impeller blades occasionally for damage Use a flat file to resharpen the leading edges Sharpen to a 0 8 mm 1 32 in radius by removing m
69. te 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 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 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 31 OPERATION Using the emergency stopping capability of the jet drive will slow down the boat in an emergency However sudden stopping may cause the occupants in the boat to be thrown forward or even out of the boat This action may result in serious injury or death In an emergency putting the jet outbo
70. 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 3 Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down Lower the outboard 0b00336 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 3 turns counterclockwise This allows manual tilting of the outboard 0b00339 NOTE The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation 2 Tilt the outboard to the desired position and tighten the manual tilt release valve AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system 25 FEATURES AND CONTROLS ob00666 a Auxiliary tilt switch Manual Tilt System Models without power trim are equipped with a tilt assist system that allows the operator to easily tilt and lock the outboard at any tilt position from full down to full up This tilt system is designed to be adjusted when the outboard is idling in neutral or with the engine turned off Before operating the outboard must be locked in its lock run position Failure to loc
71. the water always tilt the outboard so the water intake is completely out of 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 Operating at High Elevations IMPORTANT To prevent serious damage to the engine caused by a lean fuel mixture do not operate the outboard if the jets were changed for high elevation at a lower elevation unless the jets are changed again to correspond to the new elevation Operating the outboard at an elevation higher than 762 m 2500 ft above sea level may require a carburetor jet change Consult your dealer This will reduce the normal performance loss experienced as a result of reduced oxygen in the air causing an overly rich fuel mixture 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 th
72. ving the tilt lock lever to the lock run position 2 0b00336 a Tilt support lever b Knob 3 Lower outboard to rest on the tilt support lever Lowering To Run Position 1 Disengage the tilt support lever by raising the outboard off the tilt support lever and rotating the lever down Lower the outboard 2 Move tilt lock lever to lock run position 27 FEATURES AND CONTROLS Throttle Grip Friction Adjustment Tiller Handle Models Turn the wing nut to set and maintain the throttle at desired speed 0b01441 Steering Friction Adjustment Tiller Handle Models Avoid possible serious injury or death from loss of boat control Maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released Adjust this lever to achieve the desired steering friction drag on the tiller handle de 0b01442 a Tighten friction b Loosen friction 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 Refer to Maintenance Impeller Removal and Installation 28 FEATURES AND CONTROLS fl 0b01443 29 OPERATION Pre Starting Check List Operator knows safe navigation boating and operating procedures An approved personal flotation device of suitable size for each person aboard and readi
73. weight capacities refer to your boat capacity plate If in doubt contact your dealer or the boats manufacturer Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made Know and obey all nautical rules and laws of the waterways Boat operators should complete a boating safety course Courses are offered in the U S A by 1 The U S Coast Guard Auxiliary 2 The Power Squadron 3 The Red Cross and 4 any state boating law enforcement agency Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT Make sure 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 back of seats gunwales transom bow decks raised fishing seats any rotating fishing seat or anywhere that an 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 Never be under the influence of alcohol or drugs while boating it is the law Alcohol or drug use impairs judgment and greatly reduces the ability to react quickly Prepare other boat operators Instruct at least one other person on board in the basics of starting and operating the jet drive and boat handling in case the driver becomes disabled or falls overboard Passenger boarding Sto
74. will help prevent a buildup of deposits from clogging the internal water passages Use a Mercury Precision Parts or Quicksilver accessory hose coupling 1 Remove plug and gasket 1 These items should be serviced by an authorized dealer 40 MAINTENANCE 2 Thread in hose coupling 0b01650 a Plug and gasket b Hose coupling 3 Attach a water hose to the hose coupling Slowly turn on water Start the engine and run it at idle speed only IMPORTANT Do not run engine above idle when flushing 4 Check for a steady stream of water flowing out of the water pump indicator hole Continue flushing the outboard for 3 to 5 minutes carefully monitoring water supply at all times 0b01438 5 Stop the engine turn off the water and remove the hose coupling Reinstall plug and gasket Top Cowl Removal And Installation REMOVAL 1 Unlock the rear latch by pushing lever down 0b01651 2 Lift rear of cowl and disengage front hook 41 MAINTENANCE 0b01652 INSTALLATION 1 Engage the front hook and push cowl back over the cowl seal 2 Push cowl down and move the rear latch lever up to lock Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability IMPORTANT Read the safety and maintenance instructions which accompany your battery Turn off the engine before servicing the battery 2 Add water as necessary to keep the battery full 3 Make sure t
75. y also steer sharply to one side Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines This includes the outboards sterndrives and inboard engines that propel boats as well as the generators that power various boat accessories Carbon monoxide is a deadly gas that is odorless colorless and tasteless Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication include headache dizziness drowsiness and nausea GENERAL INFORMATION Avoid the combination of a running engine and poor ventilation Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness brain damage or death GOOD VENTILATION Ventilate passenger area open side curtains or forward hatches to remove fumes eee ee 0b00316 Example of desired air flow through the boat 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 enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide WHILE BOAT IS STATIONARY
76. you cannot obtain service contact the nearest Mercury Marine Service Office Parts And Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer The dealer has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistance Your satisfaction with your outboard product is very important to your dealer and to us If you ever have a problem question or concern about your outboard product contact your dealer or any authorized Mercury Marine dealership If additional assistance is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question concern or problem that cannot be resolved by your dealership please contact Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the service office Your name and address Daytime telephone number Model and serial number of your outboard The name and address of your dealership Nature of problem Mercury Marine Service Offices For assistance call fax or write Please include your daytime telephone number with mail and fax

Jet 40 - Brunswick Marine in EMEA Center

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