1996+ Mercury Mariner 40HP 4-Cylinder Outboards OEM Service & Repair Manual

1 50332 IMPORTANT INFORMATION GENERAL INFORMATION and SPECIFICATIONS

1-0 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996 Table of Contents Page Propeller Information 1-1 . . . . . . . . . . . . . . . . . . . . . . How to Use this Manual 1-1 . . . . . . . . . . . . . . . . . . . . General Specifications 1-2 . . . . . . . . . . . . . . . . . . . . . Propeller Selection 1-3 . . . . . . . . . . . . . . . . . . . . . . . . Propeller Installation 1-3 . . . . . . . . . . . . . . . . . . . . . . . Trim “In” Angle Adjustment 1-4 . . . . . . . . . . . . . . . . . Power Trim System (Models with Power Trim) 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 1-4 . . . . . . . . . . . . . . . . . . . . . Checking Trim System Fluid Level 1-5 . . . . . . . . Trimming (Models with Power Trim) 1-5 . . . . . . . . . . Trimming Outboard “Out” (“Up”) Characteristics 1-5 . . . . . . . . . . . . . . . . . . . . . . . Trimming Outboard “In” (’Down”) Characteristics 1-5 . . . . . . . . . . . . . . . . . . . . . . . Trim Tab Adjustment 1-6 . . . . . . . . . . . . . . . . . . . . . . . Boat Performance 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . Test Instructions 1-6 . . . . . . . . . . . . . . . . . . . . . . . . Boat Test Chart (Example) 1-7 . . . . . . . . . . . . . . . Lubrication Points 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . Ride-Guide Steering Cable and Pivot Points Lubrication 1-9 . . . . . . . . . . . . . . . . . . . . Gear Housing Lubrication 1-10 . . . . . . . . . . . . . . . Salt Water Corrosion - Gear Housing Bearing Carrier and Cover Nut 1-10 . . . . . . . . Periodic Inspection 1-11 . . . . . . . . . . . . . . . . . . . . . . . Flushing Outboard Cooling System 1-11 . . . . . . . . . Following Complete Submersion 1-12 . . . . . . . . . . . Salt Water Submersion (Special Instructions) 1-12 . . . . . . . . . . . . . . . . . . . . . . . . . Submerged While Running (Special Instructions) 1-12 . . . . . . . . . . . . . . . . . . . . . . . . . Submerged Engine (Fresh Water) (Plus Special Instructions) 1-12 . . . . . . . . . . . . . . . . . Out-of-Season Outboard Storage 1-13 . . . . . . . . . . Out-of-Season Battery Storage 1-13 . . . . . . . . . . . . How Weather Affects Engine Performance 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . Conditions Affecting Operation 1-15 . . . . . . . . . . . . . Detonation: Causes and Prevention 1-15 . . . . . . . . Compression Check 1-16 . . . . . . . . . . . . . . . . . . . . . . Painting Procedure 1-17 . . . . . . . . . . . . . . . . . . . . . . . Decal Application 1-18 . . . . . . . . . . . . . . . . . . . . . . . . .

90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-1 Propeller Information For in-depth information on marine propellers and boat performance - written by marine engineers - see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers and Boat Performance Information” (Part No. 90-86144). How to Use this Manual The manual is divided into SECTIONS (shown, right) which represents major components and systems. Some SECTIONS are further divided into PARTS. Each PART has a title page. A “Table of Contents” for the particular PART is printed on the back of the title page. SECTIONS and PARTS are listed on the “Service Manual Outline” sheet which immediately follows the cover of this book. Section Section Heading 1 2 3 4 5 6 7 8 Important Information Electrical and Ignition Fuel System and Carburetion Powerhead Mid-Section Lower Unit Outboard Installation/Attachments Oil Injection System

1-2 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996 General Specifications Model 40 Horsepower 40 Engine Type 4 Cylinder, In-Line, Two-Stroke Full Throttle RPM Range 5000-5500 Idle RPM Range (in Forward Gear) 600-700 Piston Displacement 44 cu. in. (721cc) Cylinder Bore Standard 2.565 in. (65.151mm) Stroke 2.125 in. (53.975mm) Ignition Type Thunderbolt Capacitor Discharge Firing Order 1-3-2-4 Recommended Spark Plug NGK BUHW-2 Gear Selection Forward - Neutral - Reverse Gear Ratio 2:1 Gear Housing Lubricant Capacity 12.5 fl. oz. (370ml) Outboard Weight (ELPTO) 192 lbs. (87kg) Carburetion 2 Carburetors, Center Bowl Recommended Gasoline Any leaded or unleaded (lead-free) gasoline, with a minimum posted octane rating of 86 (research octane number 90) Remote Fuel Tank Capacity: - U.S. Gallons - Imperial Gallons - Liters 6.6 5.5 25 Recommended Oil Quicksilver 2-Cycle Outboard Oil Gasoline/Oil Ratio 50:1 Oil Tank Capacity* 0.935 gal. (3.54 Liters) Maximum Operation at Full Throttle* 7 Hours Oil Remaining when Warning Buzzer Sounds* 7.5 fl. oz. Approximate Running Time Remaining at Wide Open Throttle when Buzzer Sounds* 30 Minutes Recommended Battery Rating Minimum Reserve Capacity rating of 100 Minutes and Cold Cranking Amperage of 350 Amperes *Specification for Oil Injected Model

90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-3 Propeller Selection 1. Select a propeller that will allow the engine to op- erate at or near the top of the recommended full throttle RPM range (listed in “Specifications,” preceding) with a normal load. Maximum engine speed (RPM) for propeller selection exists when boat speed is maximum and trim is minimum for that speed. (High RPM, caused by an excessive trim angle, should not be used in determining cor- rect propeller.) Normally, there is a 150-350 RPM change between propeller pitches. 2. If full throttle operation is below the recommended range, the propeller MUST BE changed to a lower pitch to prevent loss of performance and possible engine damage. 3. For better acceleration, such as is needed in water skiing, propping up to 500 RPM above the recommended range is advised. Continuous operation above the recommended maximum RPM, however, is not permissible. 4. After initial propeller installation, the following common conditions may require that the propeller be changed to a lower pitch: a. Warmer weather and great humidity will cause an RPM loss. b. Operating in a higher elevation causes an RPM loss. c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an RPM loss. d. Operation with an increased load (additional passengers, equipment, pulling skiers, etc.). Propeller Installation WARNING If the propeller shaft 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 propeller, always shift outboard to neutral position and remove spark plug leads when you are serv- icing the propeller. Coat the propeller shaft with Quicksilver Anti-Corro- sion Grease or 2-4-C Marine Lubricant with Teflon. IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, es- pecially in salt water, always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. Flo-Torq I Drive Hub Propellers a c b a - Forward Thrust Hub b - Propeller Nut Retainer c - Propeller Nut Flo-Torq II Drive Hub Propellers a c b d e a - Forward Thrust Hub b - Replaceable Drive Sleeve c - Rear Thrust Hub d - Propeller Nut Retainer e - Propeller Nut 1. Tighten propeller nut to 55 lb.ft. (75 N·m). Bend tabs against nut. a b b a - Propeller Nut - Torque To 55 lb. ft. (75 N·m) b - Bend Tabs Against Nut

1996+ Mercury Mariner 40HP 4-Cylinder Outboards OEM Service & Repair Manual

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1996+ Mercury Mariner 40HP 4-Cylinder Outboards OEM Service & Repair Manual

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What’s Inside the Mercury Mariner 40HP Service & Repair Manual

Important Information

Electrical & Ignition System

Fuel System & Carburetion

Powerhead

Mid-Section Assembly

Lower Unit

Outboard Motor Installation & Attachments

Oil Injection System

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