Serwisowka-Mercury-Mariner-30-40.pdf

MODELS

30/40 (2 CYLINDER)

30 ¯ 30 Marathon ¯ 30 Sea Pro

40 ¯ 40 Marathon ¯ 40 Sea Pro

With Serial Numbers

United States

. .

0G044027 and ABOVE

Belgium

. . . . . . .

09855139 and ABOVE

Printed in U.S.A.

ª 1997, Mercury Marine

90-826148R2 MARCH 1997

Notice

Throughout this publication, “Dangers”, “Warnings”

and “Cautions” (accompanied by the International

HAZARD Symbol ) are used to alert the mechanic

to special instructions concerning a particular service

or operation that may be hazardous if performed in-

correctly or carelessly. OBSERVE THEM CARE-

FULLY!

These “Safety Alerts” alone cannot eliminate the haz-

ards that they signal. Strict compliance to these spe-

cial instructions when performing the service, plus

“Common Sense” operation, are major accident pre-

vention measures.

who uses a service procedure and/or tool, which is

not recommended by the manufacturer, first must

completely satisfy himself that neither his nor the

products safety will be endangered by the service

procedure selected.

All information, illustrations and specifications con-

tained in this manual are based on the latest product

information available at the time of publication. As re-

quired, revisions to this manual will be sent to all deal-

ers contracted by us to sell and/or service these prod-

ucts.

It should be kept in mind, while working on the prod-

uct, that the electrical system and ignition system are

capable of violent and damaging short circuits or se-

vere electrical shocks. When performing any work

where electrical terminals could possibly be

grounded or touched by the mechanic, the battery

cables should be disconnected at the battery.

Any time the intake or exhaust openings are exposed

during service they should be covered to protect

against accidental entrance of foreign material which

could enter the cylinders and cause extensive inter-

nal damage when the engine is started.

It is important to note, during any maintenance proce-

dure replacement fasteners must have the same

measurements and strength as those removed.

Numbers on the heads of the metric bolts and on the

surfaces of metric nuts indicate their strength. Ameri-

can bolts use radial lines for this purpose, while most

American nuts do not have strength markings. Mis-

matched or incorrect fasteners can result in damage

or malfunction, or possibly personal injury. There-

fore, fasteners removed should be saved for reuse in

the same locations whenever possible. Where the

fasteners are not satisfactory for re-use, care should

be taken to select a replacement that matches the

original.

DANGER

DANGER - Immediate hazards which WILL result

in severe personal injury or death.

WARNING

WARNING - Hazards or unsafe practices which

COULD result in severe personal injury or death.

CAUTION

Hazards or unsafe practices which could result

in minor personal injury or product or property

damage.

Notice to Users of This

Manual

This service manual has been written and published

by the Service Department of Mercury Marine to aid

our dealer’s mechanics and company service per-

sonnel when servicing the products described here-

in.

It is assumed that these personnel are familiar with

the servicing procedures of these products, or like or

similar products manufactured and marketed by

Mercury Marine, that they have been trained in the

recommended servicing procedures of these prod-

ucts which includes the use of mechanics’ common

hand tools and the special Mercury Marine or recom-

mended tools from other suppliers.

We could not possibly know of and advise the service

trade of all conceivable procedures by which a ser-

vice might be performed and of the possible hazards

and/or results of each method. We have not under-

taken any such wide evaluation. Therefore, anyone

90-826148R2 MARCH 1997

Cleanliness and Care of

Outboard Motor

A marine power product is a combination of many

machined, honed, polished and lapped surfaces with

tolerances that are measured in the ten thousands of

an inch./mm. When any product component is serv-

iced, care and cleanliness are important. Throughout

this manual, it should be understood that proper

cleaning, and protection of machined surfaces and

friction areas is a part of the repair procedure. This is

considered standard shop practice even if not specif-

ically stated.

Whenever components are removed for service,

they should be retained in order. At the time of instal-

lation, they should be installed in the same locations

and with the same mating surfaces as when re-

moved.

Before raising or removing an outboard engine from

a boat, the following precautions should be adhered

to:

1. Check that flywheel is secured to end of crank-

shaft with a locknut and the lifting eye is threaded

into flywheel a minimum of 5 turns.

2. Connect a hoist of suitable strength to the lifting

eye.

In addition, personnel should not work on or under an

outboard which is suspended. Outboards should be

attached to work stands, or lowered to ground as

soon as possible.

We reserve the right to make changes to this manual

without prior notification.

Refer to dealer service bulletins for other pertinent in-

formation concerning the products described in this

manual.

Page Numbering

Two number groups appear at the bottom of each

page. The example below is self-explanatory.

EXAMPLE:

90-826148 R2 MARCH 1997

LOWER UNIT - 6A-7

Revision No. 1

Section Description

Month of Printing

Section Number

Year of Printing

Part of Section Letter

Page Number

90-826148R2 MARCH 1997

Service Manual Outline

Section 1 - Important Information

A - Specifications

B - Maintenance

C - General Information

D - Outboard Installation

Section 2 - Electrical

A - Ignition

B - Charging & Starting System

C - Timing, Synchronizing & Adjusting

D - Wiring Diagrams

Section 3 - Fuel System

A - Fuel Pump

B - Carburetor

C - Oil Injection

Section 4 - Powerhead

Section 5 - Mid-Section

A - Clamp/Swivel Brackets & Drive Shaft Housing

B - Power Trim

C - Manual Tilt

Section 6 - Lower Unit

Section 7 - Attachments/Control Linkage

A - Throttle/Shift Linkage

B - Tiller Handle

Section 8 - Manual Starter

Important

Information

Electrical

Fuel System

Powerhead

Mid-Section

Lower Unit

Attachments/

Control Linkage

Manual Starter

90-826148R2 MARCH 1997

iii

IMPORTANT INFORMATION

SPECIFICATIONS

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