1997+ Mercury Mariner 30/40HP 2-Stroke Outboard OEM Service & Repair Manual

A 1 IMPORTANT INFORMATION SPECIFICATIONS

1A-0 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997 Table of Contents Page General Specifications 1A-1 ....................... General Specifications 1A-2 ....................... General Specifications 1A-3 .......................

IIMPORTANT INFORMATION - 1A-1 90-826148R2 MARCH 1997 General Specifications Model 30/40 HORSEPOWER (KW) Model 30 Model 40 30 (22.4) 40 (29.8) OUTBOARD WEIGHT 15 in. (38 cm) 20 in. (51 cm) 22-1/2 in. (57 cm) 156 lbs. (70.7kg) 161 lbs. (73.0kg) 166 lbs. (75.3kg) CYLINDER BLOCK Type Displacement Two Cylinder - Two Cycle 39.3 cu. in. (644.4 cc) STROKE Length 2.796 in. (71 mm) CYLINDER BORE Diameter (Standard) Diameter [Oversize 0.015 (.381 mm)] Taper/Out of Round Maximum Bore Type Cylinder Finish Hone (I.D.) 2.993 in. (76 mm) 3.007 in. (76.38 mm) 0.003 in. (0.08 mm) Cast Iron 2.993 in. (76 mm) CRANKSHAFT Top Main Bearing Journal Center Main Bearing Journal Bottom Ball Bearing Journal Connecting Rod Journal Runout 1.375 in. (34.93 mm) 1.216 in. (30.89 mm) 1.385 in. (35.17 mm) 1.181 in. (29.99 mm) 0.003 in. (0.076 mm) CONNECTING ROD Piston Pin End (I.D.) Crankpin End (I.D.) 0.957 in. (24.31 mm) 1.499 in. (38.07 mm) PISTON Piston Type O.D. at Skirt (Standard) O.D. at Skirt [Oversize 0.015 (.381 mm)] Ring End Gap Aluminum 2.988 in. (75.90 mm) 3.003 in. (76.28 mm) 0.010 in. - 0.018 in. (0.25 mm - 0.46 mm) REEDS Reed Stand Open (Maximum) Reed Stop -- Model 30 -- Model 40 0.020 in. (0.508 mm) 0.090 in. (2.286 mm) Not Adjustable GEAR HOUSING Gear Ratio Gearcase Capacity Lubricant Type Forward Gear - No. of Teeth-Type Pinion Gear - No. of Teeth-Type Pinion Height Forward Gear Backlash Reverse Gear Backlash Water Pressure With Thermostat + Poppet -- @ W.O.T. -- @Idle All Models W/O Thermostat + Poppet -- @ W.O.T. -- @Idle Poppet Valve Opening 1994-1997 Poppet Valve Opening 1998 & Newer 2.0:1 14.9 oz. (440 mL) Quicksilver Gear Lube Premium Blend 26 Spiral/Bevel 13 Spiral/Bevel 0.025 in. (0.64 mm) No Adjustment No Adjustment 5 -- 7 PSI @ 5000 RPM 0.5 -- 1.5 PSI @ 750 RPM 5 -- 7 PSI @ 5000 RPM 0 -- 1 PSI @ 750 RPM 900-1000 RPM 3000-3500 RPM

1A-2 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997 General Specifications Model 30/40 MID SECTION Transom Height - Short Shaft - Long Shaft Steering Pivot Range Tilt Pin Positions Total Tilt Angle Allowable Transom Thickness 15 in. (38 cm) 20 in. (51 cm) 90 5 + Shallow Water 70 2-3/8 in. (60.3mm) FUEL SYSTEM Fuel Pump Pressure -- @ W.O.T. -- @Idle Recommended Gasoline Fuel Tank Capacity Break-in Gasoline Ratio Manual Outboard Electric Start Outboard 4-7 PSI (28-43 kPa) 2-1/2 -- 4 PSI (17-27 kPa) Automotive Regular or Unleaded with a Minimum Pump Posted Octane Rating of 87 6.6 U.S. Gallons (5 Imp. Gals.; 25 Liters) 25:1 50:1 (In Fuel Tank) OIL INJECTION Recommended Oil Oil Tank Capacity/Approx. Time Reserve Capacity/Approx. Time Output (cc/min.) w/Pump @ Full Open Quicksilver TC-W II or TC-W III 2-Cycle Outboard Oil 50.5 fl. oz. (1.5 liters) 4.7 Hours @ 5250 RPM 30 Minutes @ 5250 8.5 cc/10 Minutes @ 900 RPM STARTING SYSTEM Manual Start Electric Start Starter Draw (Under Load) (No Load) Recoil 12 Volt 95 Amperes 20 Amperes CHARGING SYSTEM Alternator Output -- Electric Start Red Stator Black Stator -- Manual Start Single Phase (12 Pole) 18 Amperes @ 3000 RPM 14 Amperes @ 5000 RPM 9 Amperes @ 3000 RPM BATTERY Battery Rating 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) IGNITION SYSTEM Type Spark Plug Type (NGK) Spark Plug Gap Optional Plug (NGK) Firing Order Capacitor Discharge BP8H-N-10 0.040 in. (1.0mm) BPZ8H-N-10* 0.040 in. (1.0mm) 1-2

IIMPORTANT INFORMATION - 1A-3 90-826148R2 MARCH 1997 General Specifications Model 30/40 CARBURETOR SPECIFICATIONS Idle RPM Full Throttle RPM Range -- Model 30/ 40 Sea Pro/Marathon -- Model 40 Idle Mixture Screw Adjustment (Preset - Turns Out) Float Level Main Jet -- 30 Manual (WME-36/36A)/(WME-63) -- 30 Electric (WME-37/37A)/(WME-64) -- 40 Manual (WME-38)/(WME-66) -- 40 Electric (WME-39/39A)/(WME-67) -- 30 EHO (WME-42/42A)/(WME-65) 700 - 800 RPM (In Forward Gear) 4500 - 5500 RPM 5000 - 5500 RPM 1-1/2 – 1/4 (All Models Except 40 MLL) 1-3/4 – 1/4 (WME-38 Carb on 40 MLL) 9/16 in. (14.29mm) 0.054 in. 0.054 in. 0.066 in. 0.066 in. 0.054 in. TIMING SPECIFICATIONS Models with (S/N-0G59999 & Below) Idle Maximum BTDC @ 2500-5500 RPM 3BTDC – 3 (Not Adjustable) 25– 3 (Not Adjustable) Models with (S/N-0G590000 & Above) Idle 8 BTDC 1 Models with (S/N-0G590000 & Above) Idle Maximum Spark Advance 8BTDC – 1 1 Turn Clockwise After Contacting Maximum Spark Advance 1 Turn Clockwise After Contacting Throttle Plate Throttle Plate

1997+ Mercury Mariner 30/40HP 2-Stroke Outboard OEM Service & Repair Manual

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