MERCURY MARINER 30HP 40HP Service Manual

1 A SPECIFICATIONS 90-857046 AUGUST 1998 Page 1A-1 IMPORTANT INFORMATION Section 1A - Specifications Table of Contents Specifications 1A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Information Charts 1A-7 . . . . . . . . . . . . . . Specifications Models 30/40 (4-Stroke) HORSEPOWER (kW) Model 30 Model 40 30 hp (22.4 Kw) @ 5750 rpm 40 hp (29.8 Kw) @ 5750 rpm OUTBOARD WEIGHT Electric 30/40 ELPT 40 ELPT BIGFOOT 212 lb (96.2 kg) 235 lb (106.6 kg) FUEL RECOMMENDED GASOLINE Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 OIL OIL FILTER OIL FILTER WRENCH ENGINE OIL CAPACITY ENGINE OIL +20 +40 +60 +80 F° C° 0 +100 –7 +4 +16 +27 –18 +38 SAE 10W-30 SAE 25W-40 p/n 35-822626A2 p/n 91-802653 Either 3 Quarts or 3 Liters SAE 10W-30 viscosity oil is recommended for use in all temperatures. SAE 25W-40 viscosity oil may be used at temperatures above 40° F (4° C). Use Quicksilver 4-Cycle Marine Oil with the proper viscosity for the expected temperature in your area (see range thermometer on left). If not available, use a premium quality 4-cycle engine oil, cer- tified to meet or exceed anyone of the following American Petroleum Institute (API) service classifications SH, SG, SF, CF-4, CE, CD, CDll. IMPORTANT: Use resistive spark plugs only.

SPECIFICATIONS Page 1A-2 90-857046 AUGUST 1998 IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Firing Order Ignition Timing: @ Idle (800 rpm) @ WOT (6000 rpm) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Primary Secondary (W/o Boots) ECM Engine Speed Limiter Soft Reduction (Retards Timing) Spark Cut-Out Reduction (Percent ages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure Speed Control Engine Temperature Sensor Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 18 mm 1-2-3 10° A.T.D.C 28° B.T.D.C 660 - 710 Ω (GRN/WHT - WHT/GRN) 300 - 350 Ω (RED - WHT) 0.08 - 0.7 Ω (BLK - BLK/WHT) 3.5 - 4.7 kΩ (BLK - High Tension) 6200 rpm 6250 rpm Approximately 2000 rpm See Graph Section 2A-Ignition CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: 6 Amp. Manual Lighting Coil Output Lighting Coil Resistance 15 Amp. Electric Alternator Output Battery Charging Coil Resistance Power Bobbin Resistance (For Electrothermal Valve) Quicksilver Tachometer Setting Single Phase (12 Pole) 6 Amps. 0.9 - 1.1 Ohms (YEL-YEL) 12.6 V-15 Amps. (185 Watts) (Rectified/Regulated) 0.22 - 0.24 Ohms (YEL-YEL) 6.7-7.1 Ohms (YEL/BLK-YEL/BLK) “6P” or “4” STARTING SYSTEM Manual Start Electric Start: Starter Type Output Ampere Draw Under: (Load) (No Load) Recoil Starter Bendix 1.1 kW 106.0 Amps 21.1 Amps BATTERY Battery Rating Minimum Requirement For operation below 32° F (0° C) 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) ENRICHMENT CONTROL SYSTEM Readings taken @ 68°F (20°C). Auto Enrichener Resistance Electrothermal ram projection 15 - 25 Ohms (YEL/BLK - YEL/BLK) 0.3 in. (7 mm) after 5 min. of power FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 3-6 psi 0.23 - 0.38 in. (5.85 - 9.65 mm) Accessory

SPECIFICATIONS 90-857046 AUGUST 1998 Page 1A-3 CARBURETOR Idle rpm (Out Of Gear) Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT) Range Main Jet Size Pilot Jet Idle Jet Float Height 900 ± 25 rpm 800 ± 25 rpm 5500–6000 #98 #38 #42 0.47-0.63 in. (12.0-16.0 mm) CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 45.6 cu. in. (747cc) 3 STROKE Length 2.953 in. (75 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Taper/Out of Round Maximum Bore Type 2.5591 in. (65 mm) 2.5689 in. (65.25 mm) 2.5787 in. (65.5 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type O.D. at Skirt Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Aluminum 2.5570 - 2.5578 in. (64.950 - 64.965 mm) 2.5669 - 2.5675 in. (65.2 - 65.215 mm) 2.5768 - 2.5774 in. (65.450 - 65.465 mm) PISTON CLEARANCE Piston to Cylinder Clearance 0.0014 - .0026 in. (0.035 - 0.065 mm) RINGS Ring End Gap (Installed) Top Middle Bottom (Oil Ring) Side Clearance: Top Middle 0.006 - 0.012 in. (0.15 - 0.03 mm) 0.012 - 0.020 in. (0.30 - 0.50 mm) 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.0008 - 0.0024 in. (0.02 - 0.06 mm) 0.0008 - 0.0024 in. (0.02 - 0.06 mm) COMPRESSION RATIO Compression Ratio Cylinder Compression* (Electric Models Only, Cold Engine @ W.O.T.) 9.8:1 180 -210 psi (Peak) PISTON PIN Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm) CONNECTING ROD Oil Clearance (Big End) Small End Inside Diameter 0.0008 - 0.0020 in. (0.020 - 0.052 mm) 0.6293 - 0.6298 in. (15.985 - 15.998 mm) CRANKSHAFT Main Bearing Clearance Crankshaft Run-out 0.0005 - 0.0017 in. (0.012 - 0.044 mm) 0.0018 in. (0.046 mm) *NOTE: Manual start models are equipped with compression relief mechanism which will not allow compression testing.

SPECIFICATIONS Page 1A-4 90-857046 AUGUST 1998 CAMSHAFT Camshaft Dimensions Intake “A” Exhaust “A” Intake “B” Exhaust “B” Run-out Limit Camshaft Bearing Diameter “b” A B b b b b 1.216 - 1.220 in. (30.89 - 30.99 mm) 1.216 - 1.220 in. (30.89 - 30.99 mm) 1.022 - 1.025 in. (25.95 - 26.05 mm) 1.022 - 1.025 in. (25.95 - 26.05 mm) 0.0039 in. (0.1 mm) 1.4541 - 1.4549 in. (36.935 - 36.955 mm) VALVE SPRING Free Length “a” Tilt Limit “b” Compressed Pressure (Installed) Intake Exhaust Tilt Limit (Intake & Exhaust) Dir. of Winding (Intake & Exhaust) a b 1.491-1.569 in. (37.85-39.85 mm) Less than 0.060 in. (1.7 mm) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 0.043 in. (1.1 mm) Left Hand CYLINDER HEAD Warp Limit * Lines indicate straight edge measurement Camshaft Bore Inside Diameter “a” 56900 a a a a 56899 0.004 in. (0.1 mm) 1.4567 - 1.4577 in. (37.000 - 37.025 mm)

SPECIFICATIONS 90-857046 AUGUST 1998 Page 1A-5 VALVES Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake Exhaust Valve Dimensions: “A” Head Diameter Intake Exhaust “B” Face Width Intake Exhaust “C” Seat Width Intake Exhaust “D” Margin Thickness Intake Exhaust Stem Outside Diameter Intake Exhaust Guide Inside Diameter Intake Exhaust Stem To Guide Clearance Intake Exhaust Stem Run-out Limit (max.) 0.006 - 0.010 in. (0.15 - 0.25 mm) 0.010 - 0.014 in. (0.25 - 0.35 mm) 1.256 - 1.264 in. (31.9 - 32.1 mm) 1.020 - 1.028 in. (25.9 - 26.1 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.035 - 0.043 in. (0.9 - 1.1 mm) 0.035 - 0.043 in. (0.9 - 1.1 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.2156 - 0.2161 in. (5.475 - 5.490 mm) 0.2150 - 0.2156 in. (5.460 - 5.475 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.0004 - 0.0015 in. (0.010 - 0.037 mm) 0.0010 - 0.0020 in. (0.025 - 0.052 mm) 0.0006 in. (0.016 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness ROCKER SHAFT Outside Diameter 0.6288 - 0.6296 in. (15.971 - 15.991 mm) ROCKER ARM Inside Diameter of Bore 0.6299 - 0.6306 (16.000 - 16.018 mm) THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 136° F - 143° F (58° C - 62° C) 158° F (70° C) 0.12 in. (3 mm)

MERCURY MARINER 30HP 40HP Service Manual

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