Mercury 40/50 Series User manual

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Thank You
for your purchase of one of the finest outboards available. You
have made a sound investment in boating pleasure. Your
outboard has been manufactured by Mercury Marine, a world
leader in marine technology and outboard manufacturing
since 1939. These years of experience have been committed
to the goal of producing the finest quality products. This led to
Mercury Marine's reputation for strict quality control,
excellence, durability, lasting performance and being the best
at providing after the sale support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in the
operation, safe use and care of your outboard.
All of us at Mercury Marine took pride in building your outboard
and wish you many years of happy and safe boating.
Again, thank you for your confidence in 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.
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.
© 2010 Mercury Marine 40/50 90-10262081 110

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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 important
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, to change specifications,
designs, methods, or procedures without notice and without
incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Litho in U.S.A.
© 2009, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser,
Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max,
OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide,
SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves
logo, and SmartCraft logo are all registered trademarks of
Brunswick Corporation. Mercury Product Protection logo is a
registered service mark of Brunswick Corporation.
Declaration of Conformity ‑ Outboard, Conventional 2‑Stroke
Manufacturer:
Tohatsu Marine Corporation (TMC)
Mercury Marine Joint Venture
Shimodaira 4495‑9, Komagane‑City,
Nagano, Japan 399‑4101
Authorized Representative:
Brunswick Marine in EMEA Inc.
Parc Industriel De Petit‑Rechain,
B‑2800 Verviers, Belgium

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Safety of Machinery Directive 98/37/EC
Principles of safety integration (1.1.2) ISO 12100‑1; ISO 12100‑2;
EN 1050
Noise (1.5.8) ICOMIA 39/94
Vibration (1.5.9) ICOMIA 38/94
Engine type: Outboard
Fuel type: Gasoline
Combustion cycle: 2‑Stroke
This declaration is issued under the sole responsibility of Mercury
Marine and Brunswick Marine in EMEA Inc.
Name and function:
Mark D. Schwabero
President, Mercury Marine, Fond du Lac, WI USA
Date and place of issue:
November 20, 2008
Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Regulations and Product Safety Department,
Mercury Marine, Fond du Lac, WI USA

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TABLE OF CONTENTS
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Warranty Information
Transfer of Warranty....................................................................1
Transfer of Mercury Product Protection (Extended Service
Coverage) Plan............................................................................1
Warranty Registration United States and Canada.......................2
Outboard Limited Warranty..........................................................3
3 Year Limited Warranty Against Corrosion................................6
Warranty Coverage and Exclusions............................................9
GENERAL INFORMATION
Boater's Responsibilities............................................................12
Before Operating Your Outboard...............................................12
Boat Horsepower Capacity........................................................13
High‑Speed and High‑Performance Boat Operation................. 13
Outboard Remote Control Models.............................................13
Remote Steering Notice.............................................................14
Lanyard Stop Switch..................................................................15
Protecting People in the Water..................................................17
Passenger Safety Message ‑ Pontoon Boats and Deck Boats..18
Wave and Wake Jumping..........................................................19
Impact with Underwater Hazards...............................................20
Exhaust Emissions.................................................................... 21
Selecting Accessories for Your Outboard..................................23
Safe Boating Suggestions......................................................... 24
Recording Serial Number.......................................................... 25
40/50 Specifications (Include English Units)..............................26

TABLE OF CONTENTS
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INSTALLATION
Boat Horsepower Capacity........................................................41
Installing Outboard.....................................................................41
Installing the Remote Control Box.............................................46
Installation of the Remote Control Cables (Box Side)............... 46
Installation of the Remote Control Box on your Boat.................46
Connecting the Remote Control Cable to the Engine................47
Connecting Electrical Harnesses...............................................51
Attaching the Steering Link Rod................................................55
Battery Installation ....................................................................56
Propeller Selection.....................................................................57
TRANSPORTING
Removing the Motor..................................................................59
Carrying the Motor.....................................................................59
Trailering Boat/Outboard...........................................................60
Mooring with the Engine Tilted Up.............................................61
Storing the Motor.......................................................................65
Transporting Portable Fuel Tanks.............................................66
FUEL AND OIL
Fuel Recommendations.............................................................68
Oil Recommendation.................................................................70
Non‑Oil Injected Models: MH, EH..............................................70
Oil Injected Models: EHO, EHPTO, EO, EPTO.........................70

TABLE OF CONTENTS
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FEATURES & CONTROLS
Remote Control Features..........................................................74
Tilting Outboard.........................................................................74
Shallow Water Operation...........................................................75
Trim Adjustment.........................................................................76
Steering Friction Adjustment......................................................80
Throttle Grip Turning Friction Adjustment..................................81
Trim Tab Adjustment.................................................................81
OPERATION
Pre‑Starting Check List..............................................................84
Operating in Freezing Temperatures.........................................84
Operating in Saltwater or Polluted Water..................................84
Operating at High Elevations.....................................................85
Engine Break‑in Procedure........................................................85
Starting the Engine....................................................................86
Gear Shifting..............................................................................94
Emergency Starting...................................................................98
Stopping the Engine................................................................ 103

TABLE OF CONTENTS
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MAINTENANCE
Outboard Care......................................................................... 106
EPA Regulations......................................................................106
EPA Emissions........................................................................ 107
Inspection and Maintenance Schedule....................................107
Flushing the Cooling System................................................... 109
Top Cowl Removal and Installation......................................... 110
Battery Inspection ................................................................... 111
Fuel System.............................................................................111
Fuse Replacement ‑ Electric Start Remote Control Models.... 114
Corrosion Control Anode......................................................... 114
Propeller Replacement............................................................ 115
Spark Plug Inspection and Replacement.................................120
Lubrication Points.................................................................... 121
Gearcase Lubrication...............................................................121
Submerged Outboard.............................................................. 124
STORAGE
Storage Preparation.................................................................125
Protecting External Outboard Components.............................126
Protecting Internal Engine Components..................................126
Gearcase.................................................................................127
Positioning Outboard for Storage............................................127
Battery Storage........................................................................127
Pre‑Season Check...................................................................127
TROUBLESHOOTING
Starter Motor Will Not Crank the Engine (Electric Start Models)
.................................................................................................129
Engine Will Not Start................................................................129
Engine Runs Erratically...........................................................129
Performance Loss....................................................................130
Battery Will Not Hold Charge...................................................130

TABLE OF CONTENTS
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ASSOCIATED PARTS
Associated Parts......................................................................131
Propeller Selection...................................................................132
NOTE:......................................................................................133
ACCESSORIES
Optional Accessories...............................................................134
OWNER SERVICE ASSISTANCE
Local Repair Service................................................................138
Service Away from Home........................................................138
Parts and Accessories Inquiries..............................................138
Service Assistance..................................................................138
Mercury Marine Service Offices...............................................139
WIRING DIAGRAMS
Wiring Diagrams......................................................................141
Wire Color Code Abbreviations...............................................142

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