Mercury 40 jet fourstroke User manual

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Declaration of Conformity 30/40/50/60 4‑Stroke – For
Recreational Craft Propulsion Engines with the
Requirements of Directive 94/25/EC as amended by
2003/44/EC
Name of engine manufacturer: Mercury Marine Technology Suzhou
Co., Ltd.
Address: No 200 Suhong Middle Road, Suzhou Industrial Park
Town: Suzhou Post Code: 215021 Country: CHINA
Name of Authorized Representative: Brunswick Marine in EMEA Inc.
Address: Parc Industriel de Petit‑Rechain
Town: Verviers Post Code: B‑4800 Country: Belgium
Name of Notified Body for exhaust emission assessment: Det
Norske Veritas AS
Address: Veritasveien 1
Town: Hovik Post Code:
1322
Country:
Norway ID Number: 0575
Name of Notified Body for noise emission assessment: Det Norske
Veritas AS
Address: Veritasveien 1
Town: Hovik Post Code:
1322
Country:
Norway ID Number: 0575
Conformity assessment
module used for exhaust
emissions:
☐ B
+C
☐ B
+D
☐ B
+E
☐ B
+F ☐ G☒ H
Conformity assessment
module used for noise
emissions:
☐ A☐ Aa ☐ G☒ H
Other Community Directives applied: Safety of Machinery Directive
2006/42/EC; Electromagnetic Compatibility Directive 2004/108/EC
Description of Engines and Essential Requirements
Engine Type Fuel Type Combustion Cycle
☐ z or sterndrive with
integral exhaust ☐ Diesel ☐ 2 stroke
☒ Outboard engine ☒ Petrol ☒ 4 stroke
© 2013 Mercury Marine 40 Jet FourStroke 90-8M0082964 513

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Identification of Engines Covered by This Declaration of
Conformity
Name of engine family
Unique engine
identification number:
starting serial number
EC Module H
certificate number
30, 40 hp 3 cylinder 1C010000 RCD‑H‑2 Rev 4
40, 50, 60 hp 4 cylinder 1C010000 RCD‑H‑2 Rev 4
60 hp Formula Race 4
cylinder 1C010000 RCD‑H‑2 Rev 4
Essential
requirements standards
other
normative
document/
method
technical
file
Please specify in
more detail
(* = mandatory
standard)
Annex 1.B—Exhaust Emissions
B.1 engine
identification ☐ ☐ ☒
B.2 exhaust
emission
requirements
☒* ☐ ☐ * EN ISO
8178‑1:1996
B.3 durability ☐ ☐ ☒ EN ISO
8178‑1:1996
B.4 owner's
manual ☒ ☐ ☐ EN ISO 8665: 2006
Annex 1.C—Noise Emissions
C.1 Noise
emission levels ☒* ☐ ☐ *EN ISO 14509
C.2 Owner's
manual ☐ ☒ ☐ Owner's manual
This declaration of conformity is issued under the sole responsibility of the
manufacturer. I declare on behalf of the engine manufacturer that the engines
mentioned preceding complies with all applicable essential requirements in
the way specified.

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Name / function:
Mark D. Schwabero, President, Mercury
Outboard
Date and place of issue:
September 04, 2012
Fond du Lac, Wisconsin, USA
Welcome
You have selected one of the finest outboards available. It
incorporates numerous design features to ensure operating ease
and durability.
With proper care and maintenance, you will enjoy using this
product for many boating seasons. To ensure maximum
performance and carefree use, we ask that you thoroughly read
this manual.
The Operation, Maintenance, and Warranty Manual contains
specific instructions for using and maintaining your product. We
suggest that this manual remain with the product for ready
reference whenever you are on the water.
Thank you for purchasing one of our products. We sincerely
hope your boating will be pleasant!
Mercury Marine
EPA Emissions Regulations
Outboards sold by Mercury Marine in the United States are
certified to the United States Environmental Protection Agency
as conforming to the requirements of the regulations for the
control of air pollution from new outboard motors. This
certification is contingent on certain adjustments being set to
factory standards. For this reason, the factory procedure for
servicing the product must be strictly followed and, wherever
practicable, returned to the original intent of the design.
Maintenance, replacement, or repair of the emission control
devices and systems may be performed by any marine engine
repair establishment or individual.

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Engines are labeled with an emission control information decal
as permanent evidence of EPA certification.
! WARNING
The engine exhaust from this product contains chemicals
known to the state of California to cause cancer, birth defects
or other reproductive harm.
Warranty Message
The product you have purchased comes with a limited warranty
from Mercury Marine. The terms of the warranty are set forth in
the Warranty Information section of this manual. The warranty
statement contains a description of what is covered, what is not
covered, the duration of coverage, how to best obtain warranty
coverage, important disclaimers and limitations of damages, and
other related information. Please review this information.
The description and specifications contained herein were in
effect at the time this manual was approved for printing. Mercury
Marine, whose policy is one of continued improvement, reserves
the right to discontinue models at any time, and to change
specifications, designs, methods, or procedures without notice
and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Printed in the U.S.A.
© 2013, Mercury Marine
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with
Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser,
Mercury, Mercury with Waves Logo, Mercury Marine, Mercury
Precision Parts, Mercury Propellers, Mercury Racing,
MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook,
SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus,
and #1 On the Water are registered trademarks of Brunswick
Corporation. Mercury Product Protection is a registered service
mark of Brunswick Corporation.

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Mercury Premier Service
Mercury evaluates the service performance of its dealers and
assigns its highest rating of "Mercury Premier" to those
demonstrating an exceptional commitment to service.
Earning a Mercury Premier Service rating means a dealer:
• Achieves a high 12‑month service Customer Satisfaction
Index (CSI) score for warranty service.
• Possesses all of the necessary service tools, test
equipment, manuals, and parts books.
• Employs at least one certified or master technician.
• Provides timely service for all Mercury Marine customers.
• Offers extended service hours and mobile service, when
appropriate.
• Uses, displays, and stocks an adequate inventory of
genuine Mercury Precision Parts.
• Offers a clean, neat shop with well‑organized tools and
service literature.

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WARRANTY INFORMATION
Warranty Registration United States and Canada....................... 1
Transfer of Warranty United States and Canada.........................1
Transfer of Mercury Product Protection (Extended Service
Coverage) Plan United States and Canada.................................2
3 Year Limited Warranty Against Corrosion................................ 3
Warranty Coverage and Exclusions............................................ 6
U.S. EPA Emissions Limited Warranty........................................ 8
Emission Control System Components....................................... 8
California Emissions Limited Warranty........................................ 9
California Air Resources Board Explanation of Your California
Emission Control Warranty Statement.......................................13
Emission Certification Star Label............................................... 14
Warranty Policy—Australia and New Zealand........................... 15
Global Warranty Charts Outboard and Jets...............................21

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General Information
Boater's Responsibilities............................................................ 27
Before Operating Your Outboard............................................... 27
Boat Horsepower Capacity........................................................ 28
High‑Speed and High‑Performance Boat Operation................. 29
Outboard Remote Control Models ............................................ 29
Remote Steering Notice.............................................................30
Lanyard Stop Switch.................................................................. 31
Stopping the Boat in an Emergency.......................................... 33
Protecting People In The Water.................................................34
Passenger Safety Message ‑ Pontoon Boats and Deck Boats
................................................................................................... 35
Wave and Wake Jumping.......................................................... 37
Safety Instructions for Hand‑Tilled Outboards........................... 37
Exhaust Emissions.................................................................... 38
Selecting Accessories for Your Outboard.................................. 41
Safe Boating Recommendations............................................... 41
Recording Serial Number.......................................................... 44
40 Jet FourStroke Specifications............................................... 45
Component Identification........................................................... 46
Transporting
Trailering Boat/Outboard........................................................... 47
Transporting Portable Fuel Tanks............................................. 47
Fuel and Oil
Fuel Recommendations............................................................. 49
Low Permeation Fuel Hose Requirement ................................. 50
EPA Pressurized Portable Fuel Tank Requirements................. 51
Fuel Demand Valve (FDV) Requirement................................... 51
Mercury Marine's Pressurized Portable Fuel Tank.................... 52
Filling Fuel Tank........................................................................ 53
Engine Oil Recommendations................................................... 54
Checking and Adding Engine Oil............................................... 54

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Features and Controls
Remote Control Features.......................................................... 56
Warning System........................................................................ 57
Power Trim and Tilt....................................................................59
Throttle Grip Friction Adjustment ‑ Tiller Handle Models........... 63
Steering Friction Adjustment ‑ Tiller Handle Models..................63
Replaceable Jet Drive Shear Key.............................................. 64
Operation
Important Daily Inspection Before Each Use ............................ 65
Prestarting Check List................................................................65
Operating in Freezing Temperatures......................................... 66
Operating in Saltwater or Polluted Water.................................. 66
Operating in Shallow Water....................................................... 67
How the Jet Drive Operates.......................................................67
Stopping the Boat in an Emergency.......................................... 69
Steering the Boat....................................................................... 69
Mooring the Boat....................................................................... 70
Water Intake Blockage...............................................................71
Clearing A Lodged Impeller....................................................... 71
Pre‑Starting Instructions............................................................ 72
Engine Break‑in Procedure........................................................72
Starting the Engine ‑ Remote Control Models........................... 73
Starting the Engine ‑ Tiller Handle Models................................ 75
Gear Shifting ............................................................................. 78
Stopping the Engine ................................................................. 79
Emergency Starting .................................................................. 80

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Maintenance
Outboard Care........................................................................... 83
EPA Emissions Regulations...................................................... 83
Inspection and Maintenance Schedule...................................... 84
Flushing the Cooling System..................................................... 86
Top Cowl Removal and Installation........................................... 88
Exterior Care..............................................................................88
Battery Inspection ..................................................................... 89
Fuel System............................................................................... 89
Steering Link Rod Fasteners..................................................... 91
Corrosion Control Anode........................................................... 92
Spark Plug Inspection and Replacement...................................93
Steering Pull Adjustment........................................................... 94
Worn/Dull Impeller..................................................................... 94
Impeller Clearance Adjustment..................................................95
Fuse Replacement.....................................................................96
Timing Belt Inspection............................................................... 97
Lubrication Points...................................................................... 97
Checking Power Trim Fluid......................................................101
Changing Engine Oil ............................................................... 102
Submerged Outboard.............................................................. 103
Storage
Storage Preparation.................................................................104
Protecting External Outboard Components............................. 105
Protecting Internal Engine Components.................................. 105
Jet Drive...................................................................................105
Positioning Outboard for Storage............................................ 105
Battery Storage........................................................................ 105