Mercury 40 jet fourstroke User manual

Operation
Maintenance
and
Installation
Manual
© 2017 Mercury Marine 40 Jet FourStroke
8M0118487 316 eng

eng

Welcome
You have selected one of the finest marine power packages 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 and Maintenance 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, Fond du Lac, Wisconsin, U.S.A.
Name / function:
John Pfeifer, President,
Mercury Marine
Read This Manual Thoroughly
IMPORTANT: If you do not understand any portion of this manual, contact your
dealer. Your dealer can also provide a demonstration of actual starting and
operating procedures.
Notice
Throughout this publication, and on your power package, warnings, cautions,
and notices, accompanied by the International Hazard Symbol !, may be
used to alert the installer and user to special instructions concerning a
particular service or operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully.
These safety alerts alone cannot eliminate the hazards that they signal. Strict
compliance with these special instructions while performing the service, plus
common sense operation, are major accident prevention measures.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
eng i

NOTICE
Indicates a situation which, if not avoided, could result in engine or major
component failure.
IMPORTANT: Identifies information essential to the successful completion of
the task.
NOTE: Indicates information that helps in the understanding of a particular step
or action.
IMPORTANT: The operator (driver) is responsible for the correct and safe
operation of the boat, the equipment aboard, and the safety of all occupants
aboard. We strongly recommend that the operator read this Operation and
Maintenance Manual and thoroughly understand the operational instructions for
the power package and all related accessories before the boat is used.
! WARNING
The engine exhaust from this product contains chemicals known to the state
of California to cause cancer, birth defects or other reproductive harm.
The serial numbers are the manufacturer’s keys to numerous engineering
details that apply to your Mercury Marine power package. When contacting
Mercury Marine about service, always specify model and serial numbers.
Descriptions and specifications contained herein were in effect at the time this
was approved for printing. Mercury Marine, whose policies are based on
continuous improvement, reserves the right to discontinue models at any time
or to change specifications or designs without notice and without incurring
obligation.
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 Manual included
with the product. The Warranty Manual 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 important information.
Copyright and Trademark Information
© MERCURY MARINE. All rights reserved. Reproduction in whole or in
part without permission is prohibited.
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, #1 On the Water and We're
Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a
trademark of Brunswick Corporation. Mercury Product Protection is a registered
service mark of Brunswick Corporation.
ii eng

Identification Records
Please record the following applicable information:
Outboard
Engine Model and Horsepower
Engine Serial Number
Gear Ratio
Propeller Number Pitch Diameter
Hull Identification Number (HIN) Purchase Date
Boat Manufacturer Boat Model Length
Exhaust Gas Emissions Certification Number (Europe Only)
eng iii

eng iv

General Information
Boater's Responsibilities..................................................................................... 1
Before Operating Your Outboard........................................................................ 1
Boat Horsepower Capacity................................................................................. 2
High‑Speed and High‑Performance Boat Operation.......................................... 2
Outboard Remote Control Models ..................................................................... 3
Remote Steering Notice......................................................................................3
Lanyard Stop Switch........................................................................................... 4
Stopping the Boat in an Emergency................................................................... 6
Protecting People In The Water..........................................................................6
Passenger Safety Message ‑ Pontoon Boats and Deck Boats...........................7
Wave and Wake Jumping................................................................................... 8
Safety Instructions for Hand‑Tilled Outboards.................................................... 9
Exhaust Emissions............................................................................................. 9
Selecting Accessories for Your Outboard......................................................... 11
Safe Boating Recommendations...................................................................... 11
Recording Serial Number................................................................................. 14
40 Jet FourStroke Specifications...................................................................... 14
Component Identification.................................................................................. 15
Transporting
Trailering Boat/Outboard.................................................................................. 16
Fuel and Oil
Fuel Requirements........................................................................................... 17
Low Permeation Fuel Hose Requirement ........................................................ 18
EPA Pressurized Portable Fuel Tank Requirements........................................ 18
Fuel Demand Valve (FDV) Requirement.......................................................... 18
Mercury Marine's Pressurized Portable Fuel Tank........................................... 19
Filling Fuel Tank............................................................................................... 20
Engine Oil Recommendations.......................................................................... 20
Checking and Adding Engine Oil...................................................................... 21
eng v

Features and Controls
Remote Control Features................................................................................. 23
Warning System............................................................................................... 24
Power Trim and Tilt...........................................................................................26
Throttle Grip Friction Adjustment ‑ Tiller Handle Models.................................. 29
Steering Friction Adjustment ‑ Tiller Handle Models......................................... 29
Replaceable Jet Drive Shear Key..................................................................... 30
Operation
Important Daily Inspection Before Each Use ................................................... 31
Prestarting Check List.......................................................................................31
Operating in Freezing Temperatures................................................................ 32
Operating in Saltwater or Polluted Water......................................................... 32
Operating in Shallow Water.............................................................................. 32
How the Jet Drive Operates..............................................................................32
Stopping the Boat in an Emergency................................................................. 34
Steering the Boat.............................................................................................. 34
Mooring the Boat.............................................................................................. 35
Water Intake Blockage......................................................................................35
Clearing A Lodged Impeller.............................................................................. 35
Pre‑Starting Instructions................................................................................... 36
Engine Break‑in Procedure...............................................................................36
Starting the Engine ‑ Remote Control Models.................................................. 36
Starting the Engine ‑ Tiller Handle Models....................................................... 39
Gear Shifting .................................................................................................... 42
Stopping the Engine ........................................................................................ 43
Emergency Starting ......................................................................................... 43
vi eng

Maintenance
Outboard Care.................................................................................................. 46
EPA Emissions Regulations............................................................................. 46
Inspection and Maintenance Schedule............................................................. 47
Flushing the Cooling System............................................................................ 48
Top Cowl Removal and Installation.................................................................. 50
Exterior Care.....................................................................................................50
Battery Inspection ............................................................................................ 50
Fuel System...................................................................................................... 51
Steering Link Rod Fasteners............................................................................ 52
Corrosion Control Anode.................................................................................. 53
Spark Plug Inspection and Replacement..........................................................54
Steering Pull Adjustment.................................................................................. 55
Worn/Dull Impeller............................................................................................ 56
Impeller Clearance Adjustment.........................................................................56
Fuse Replacement............................................................................................57
Timing Belt Inspection...................................................................................... 58
Lubrication Points............................................................................................. 58
Checking Power Trim Fluid...............................................................................61
Changing Engine Oil ........................................................................................ 62
Submerged Outboard....................................................................................... 63
Storage
Storage Preparation..........................................................................................64
Protecting External Outboard Components...................................................... 64
Protecting Internal Engine Components........................................................... 65
Jet Drive............................................................................................................65
Positioning Outboard for Storage..................................................................... 65
Battery Storage................................................................................................. 65
Troubleshooting
Starter Motor Will Not Crank the Engine (Electric Start Models)...................... 66
Engine Will Not Start.........................................................................................66
Engine Runs Erratically.................................................................................... 66
Engine Overspeed (Excessive RPM)............................................................... 67
Performance Loss.............................................................................................67
Battery Will Not Hold Charge............................................................................ 67
eng vii

Owner Service Assistance
Local Repair Service.........................................................................................68
Service Away from Home................................................................................. 68
Parts and Accessories Inquiries....................................................................... 68
Service Assistance........................................................................................... 68
Ordering Literature............................................................................................70
Outboard Installation
Mercury Marine Validated Engine Mounting Hardware.................................... 72
Accessories Mounted to the Transom Clamp Bracket...................................... 72
Installation Information......................................................................................76
Determining the Mounting Height of the Outboard Jet .................................... 78
Installing Outboard............................................................................................80
Fastening the Outboard to the Transom........................................................... 81
Steering Cable ‑ Starboard Side Routed Cable................................................ 86
Steering Link Rod Fasteners............................................................................ 87
Steering Cable Seal.......................................................................................... 89
Fuel Hose Connection ‑ Remote Control Models............................................. 89
Electrical Connections and Control Cable Installation...................................... 90
Trim‑In Stop Adjustment ‑ Power Trim Models................................................. 95
Water Testing................................................................................................... 96
Maintenance Log
Maintenance Log.............................................................................................. 98
viii eng

Boater's Responsibilities
The operator (driver) is responsible for the correct and safe operation of the
boat and the safety of its occupants and general public. It is strongly
recommended that each operator read and understand this entire manual
before operating the outboard.
Be sure that at least one additional person onboard is instructed in the basics
of starting and operating the outboard and boat handling in case the driver is
unable to operate the boat.
Before Operating Your Outboard
Read this manual carefully. Learn the difference in handling characteristics
between a jet drive boat and a propeller driven boat. If you have any questions,
contact your dealer.
STEERING AT LOW SPEEDS
Unlike propeller driven boats, the jet drive boat tends to lose steering control as
less water is drawn in and expelled. Increase speed slightly to regain steering.
MANEUVERABILITY
The jet drive is highly maneuverable at higher speeds, more so, than propeller
driven boats. Use caution when turning to prevent spin‑outs.
IN NEUTRAL
The impeller will continue to rotate while the engine is in neutral. Although the
approximate balancing of forward and reverse thrust will minimize boat
movement, the boat may tend to move slowly forward or backward. This is
normal for a direct‑drive jet driven boat. The operator should be aware of this
and use caution whenever the engine is running.
Safety and operating information that is practiced, along with using good
common sense, can help prevent personal injury and product damage.
This manual as well as safety labels posted on the outboard use the following
safety alerts1. to draw your attention to special safety instructions that should be
followed.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
1. These safety alerts follow ANSI standard Z535.6‑2006 for product safety information in product manuals,
instructions, and other collateral materials.
GENERAL INFORMATION
eng 1

! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major
component failure.
IMPORTANT: Identifies information essential to the successful completion of
the task.
NOTE: Indicates information that helps in the understanding of a particular step
or action.
Boat Horsepower Capacity
! WARNING
Exceeding the boat's maximum horsepower rating can cause serious injury
or death. Overpowering the boat can affect boat control and flotation
characteristics or break the transom. Do not install an engine that exceeds
the boat's maximum power rating.
Do not overpower or overload your boat. Most boats will carry a required
capacity plate indicating the maximum acceptable power and load as
determined by the manufacturer following certain federal guidelines. If in doubt,
contact your dealer or the boat manufacturer.
U.S. COAST GUARD CAP ACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777
High‑Speed and High‑Performance Boat Operation
If your outboard is to be used on a high‑speed or high‑performance boat with
which you are unfamiliar, we recommend that you do not operate it at its high
speed capability without first requesting an initial orientation and familiarization
demonstration ride with your dealer or an operator experienced with your boat/
outboard combination. For additional information, obtain a copy of our
Hi‑Performance Boat Operation booklet from your dealer, distributor, or
Mercury Marine.
GENERAL INFORMATION
2 eng

Outboard Remote Control Models
The remote control connected to your outboard must be equipped with a start
in neutral only protection device. This prevents the engine from starting when
the shift is actuated in any position other than neutral.
! WARNING
Starting the engine with the drive in gear can cause serious injury or death.
Never operate a boat that does not have a neutral‑safety‑protection device.
N
26838
Remote Steering Notice
The steering link rod that connects the steering cable to the engine must be
fastened utilizing self‑locking nuts. These self‑locking nuts must never be
replaced with common nuts (non‑locking) as they will work loose and vibrate
off, freeing the link rod to disengage.
! WARNING
Improper fasteners or improper installation procedures can result in
loosening or disengagement of the steering link rod. This can cause a
sudden, unexpected loss of boat control, resulting in serious injury or death
due to occupants being thrown within or out of the boat. Always use required
components and follow instructions and torque procedures.
a - Self‑locking nuts
a
a26780
GENERAL INFORMATION
eng 3

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.
A decal near the lanyard stop switch is a visual reminder for the operator to
attach the lanyard to their personal flotation device (PFD) or wrist.
The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out,
with an element on one end made to be inserted into the switch and a clip on
the other end for attaching to the operator's PFD or wrist. The lanyard is coiled
to make its at‑rest condition as short as possible to minimize the likelihood of
lanyard entanglement with nearby objects. Its stretched‑out length is made to
minimize the likelihood of accidental activation should the operator choose to
move around in an area close to the normal operator's position. If it is desired
to have a shorter lanyard, wrap the lanyard around the operator's wrist or leg,
or tie a knot in the lanyard.
a - Lanyard cord clip
b - Lanyard decal
c - Lanyard stop switch
Read the following Safety Information before proceeding.
c
a
b
53910
OFF
RUN
ATTACH LANYARD
GENERAL INFORMATION
4 eng

Important Safety Information: The purpose of a lanyard stop switch is to stop
the engine when the operator moves far enough away from the operator's
position to activate the switch. This would occur if the operator accidentally falls
overboard or moves within the boat a sufficient distance from the operator's
position. Falling overboard and accidental ejections are more likely to occur in
certain types of boats such as low sided inflatables, bass boats, high
performance boats, and light, sensitive handling fishing boats operated by a
hand tiller. Falling overboard and accidental ejections are also likely to occur as
a result of poor operating practices such as sitting on the back of the seat or
gunwale at planing speeds, standing at planing speeds, sitting on elevated
fishing boat decks, operating at planing speeds in shallow or obstacle infested
waters, releasing your grip on a steering wheel or tiller handle that is pulling in
one direction, drinking alcohol or consuming drugs, or daring high speed boat
maneuvers.
While activation of the lanyard stop switch will stop the engine immediately, a
boat will continue to coast for some distance depending upon the velocity and
degree of any turn at shut down. However, the boat will not complete a full
circle. While the boat is coasting, it can cause injury to anyone in the boat's
path as seriously as the boat would when under power.
We strongly recommend that other occupants be instructed on proper starting
and operating procedures should they be required to operate the engine in an
emergency (if the operator is accidentally ejected).
! WARNING
If the operator falls out of the boat, stop the engine immediately to reduce the
possibility of serious injury or death from being struck by the boat. Always
properly connect the operator to the stop switch using a lanyard.
! WARNING
Avoid serious injury or death from deceleration forces resulting from
accidental or unintended stop switch activation. The boat operator should
never leave the operator's station without first disconnecting the stop switch
lanyard from the operator.
Accidental or unintended activation of the switch during normal operation is
also a possibility. This could cause any, or all, of the following potentially
hazardous situations:
• Occupants could be thrown forward due to unexpected loss of forward
motion ‑ a particular concern for passengers in the front of the boat who
could be ejected over the bow and possibly struck by the gearcase or
propeller.
• Loss of power and directional control in heavy seas, strong current, or
high winds.
• Loss of control when docking.
GENERAL INFORMATION
eng 5

KEEP THE LANYARD STOP SWITCH AND LANYARD CORD IN GOOD
OPERATING CONDITION
Before each use, check to ensure the lanyard stop switch works properly. Start
the engine and stop it by pulling the lanyard cord. If the engine does not stop,
have the switch repaired before operating the boat.
Before each use, visually inspect the lanyard cord to ensure it is in good
working condition and that there are no breaks, cuts, or wear to the cord.
Check that the clips on the ends of the cord are in good condition. Replace any
damaged or worn lanyard cords.
Stopping the Boat in an Emergency
A jet powered boat has emergency stopping capability unique to this form of
propulsion.
! WARNING
Using the emergency stopping capability of a jet drive unit will slow down the
boat in an emergency. However, sudden stopping may cause the occupants
of the boat to be thrown forward or out of the boat resulting in serious injury
or death. Use caution when performing the emergency stopping procedure,
and be sure to practice in a safe area.
In an emergency, putting the jet outboard into reverse and applying reverse
throttle can rapidly slow down the boat and reduce stopping distance. However,
such a maneuver may cause occupants in the boat to be thrown forward or
possibly out of the boat.
Protecting People In The Water
WHILE YOU ARE CRUISING
It is very difficult for a person standing or floating in the water to take quick
action to avoid a boat heading in his/her direction, even at slow speed.
21604
Always slow down and exercise extreme caution when boating in an area
where there might be people in the water.
Avoid shallow water or where any loose material such as sand, shells,
seaweed, grass, tree branches, etc., can be pulled in and expelled from the
pump as a high speed projectile.
GENERAL INFORMATION
6 eng

WHILE BOAT IS STATIONARY
! WARNING
Avoid injury resulting from contacting the rotating impeller or having hair,
clothing, or loose objects drawn into the water intake and wrapping around
the impeller shaft. Stay away from the water intake and never insert an object
into the water intake or water outlet nozzle when the engine is running.
Stop the engine immediately whenever a person is in the water near the boat.
The jet drive is always drawing water through the water intake when the engine
is running. Stay away from the water intake located under the jet drive and
never insert an object into the water intake or outlet nozzle when the engine is
running.
Passenger Safety Message ‑ Pontoon Boats and Deck Boats
Whenever the boat is in motion, observe the location of all passengers. Do not
allow any passengers to stand or use seats other than those designated for
traveling faster than idle speed. A sudden reduction in boat speed, such as
plunging into a large wave or wake, a sudden throttle reduction, or a sharp
change of boat direction, could throw them over the front of the boat. Falling
over the front of the boat between the two pontoons will position them to be run
over by the outboard.
BOATS HAVING AN OPEN FRONT DECK
No one should ever be on the deck in front of the fence while the boat is in
motion. Keep all passengers behind the front fence or enclosure.
Persons on the front deck could easily be thrown overboard or persons
dangling their feet over the front edge could get their legs caught by a wave
and pulled into the water.
26782
! WARNING
Sitting or standing in an area of the boat not designed for passengers at
speeds above idle can cause serious injury or death. Stay back from the front
end of deck boats or raised platforms and remain seated while the boat is in
motion.
GENERAL INFORMATION
eng 7

BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS
Elevated fishing seats are not intended for use when the boat is traveling faster
than idle or trolling speed. Sit only in seats designated for traveling at faster
speeds.
Any unexpected, sudden reduction in boat speed could result in the elevated
passenger falling over the front of the boat.
26783
Wave and Wake Jumping
Operating recreational boats over waves and wake is a natural part of boating.
However, when this activity is done with sufficient speed to force the boat hull
partially or completely out of the water, certain hazards arise, particularly when
the boat enters the water.
26784
The primary concern is the boat changing direction while in the midst of the
jump. In such case, the landing may cause the boat to veer violently in a new
direction. Such a sharp change in direction can cause occupants to be thrown
out of their seats, or out of the boat.
! WARNING
Wave or wake jumping can cause serious injury or death from occupants
being thrown within or out of the boat. Avoid wave or wake jumping whenever
possible.
GENERAL INFORMATION
8 eng

There is another less common hazardous result from allowing your boat to
launch off a wave or wake. If the bow of your boat pitches down far enough
while airborne, upon water contact it may penetrate under the water surface
and submarine for an instant. This will bring the boat to a nearly instantaneous
stop and can send the occupants flying forward. The boat may also steer
sharply to one side.
Safety Instructions for Hand‑Tilled Outboards
No person or cargo should occupy the area directly in front of the outboard
while the boat is in motion. If an underwater obstacle is struck, the outboard will
tilt up and could seriously injure anyone occupying this area.
MODELS WITH CLAMP SCREWS:
Some outboards come with transom bracket clamp screws. The use of clamp
bracket screws alone, is insufficient to properly and safely secure the outboard
to the transom. Proper installation of the outboard includes bolting the engine to
the boat through the transom. Refer to Installation ‑ Installing Outboard for
more complete installation information.
! WARNING
Failure to correctly fasten the outboard could result in the outboard propelling
off the boat transom resulting in property damage, serious injury, or death.
Before operation, the outboard must be correctly installed with the required
mounting hardware.
If an obstacle is struck at planing speed and the outboard is not securely
fastened to the transom, it is possible the outboard could lift off the transom
and land in the boat.
Exhaust Emissions
BE ALERT TO CARBON MONOXIDE POISONING
Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of
all internal combustion engines, including the engines that propel boats, and
the generators that power boat accessories. By itself, CO is odorless, colorless,
and tasteless, but if you can smell or taste engine exhaust, you are inhaling
CO.
Early symptoms of carbon monoxide poisoning, which are similar to the
symptoms of seasickness and intoxication, include headache, dizziness,
drowsiness, and nausea.
GENERAL INFORMATION
eng 9

! WARNING
Inhaling engine exhaust gases can result in carbon monoxide poisoning,
which can lead to unconsciousness, brain damage, or death. Avoid exposure
to carbon monoxide.
Stay clear from exhaust areas when engine is running. Keep the boat
well‑ventilated while at rest or underway.
STAY CLEAR OF EXHAUST AREAS
41127
Engine exhaust gases contain harmful carbon monoxide. Avoid areas of
concentrated engine exhaust gases. When engines are running, keep
swimmers away from the boat, and do not sit, lie, or stand on swim platforms or
boarding ladders. While underway, do not allow passengers to be positioned
immediately behind the boat (platform dragging, teak/body surfing). This
dangerous practice not only places a person in an area of high engine exhaust
concentration, but also subjects them to the possibility of injury from the boat
propeller.
GOOD VENTILATION
Ventilate the passenger area, open side curtains or forward hatches to remove
fumes.
Example of desired air flow through the boat:
21622
POOR VENTILATION
Under certain running and/or wind conditions, permanently enclosed or canvas
enclosed cabins or cockpits with insufficient ventilation may draw in carbon
monoxide. Install one or more carbon monoxide detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and
passengers in an open area of a stationary boat that contains, or is near, a
running engine may be exposed to a hazardous level of carbon monoxide.
GENERAL INFORMATION
10 eng