Mercury 40 Service Manual

1
D
OUTBOARD MOTOR INSTALLATION
90-828631R3 MARCH 1999 Page 1D-1
IMPORTANT INFORMATION
Section 1D - Outboard Motor Installation
Table of Contents
Electric Fuel Pump 1D-1. . . . . . . . . . . . . . . . . . . . . . . .
Boat Horsepower Capacity 1D-1. . . . . . . . . . . . . . . . .
Start in Gear Protection 1D-2. . . . . . . . . . . . . . . . . . . .
Selecting Accessories For The Outboard 1D-2. . . . .
Installation Specifications 1D-2. . . . . . . . . . . . . . . . . . .
Lifting Outboard 1D-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cable 1D-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cable Seal 1D-4. . . . . . . . . . . . . . . . . . . . . . .
Steering Link Rod 1D-4. . . . . . . . . . . . . . . . . . . . . . . . .
Installing Outboard – Thumb Screw Models 1D-5. . .
Installing Outboard – Non Thumb
Screw Models 1D-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Harness 1D-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cable Connections 1D-8. . . . . . . . . . . . . . . . .
Single Outboards 1D-8. . . . . . . . . . . . . . . . . . . . . . .
Dual outboards 1D-8. . . . . . . . . . . . . . . . . . . . . . . . .
Shift and Throttle Cable 45 and 50 hp Models 1D-9.
45-50 hp - Shift Cable Installation 1D-9. . . . . . . .
45-50 hp - Throttle Cable Installation 1D-11. . . . .
Trim-In Stop Adjustment – Power
Trim Models 1D-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment 1D-13. . . . . . . . . . . . . . . . . . . . . .
Electric Fuel Pump
If an electric fuel pump is used, the fuel pressure must not exceed 4 psi at the engine. If nec-
essary, install a pressure regulator to regulate the pressure.
Boat Horsepower Capacity
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
U.S. COAST GUARD CAPACITY
Do not overpower or overload the boat. Most boats will carry a required capacity plate indi-
cating the maximum acceptable power and load as determined by the manufacturer follow-
ing certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.
WARNING
Using an outboard that exceeds the maximum horsepower limit of a boat can: 1.
cause loss of boat control 2. place too much weight at the transom, altering the de-
signed flotation characteristics of the boat or 3. cause the boat to break apart, par-
ticularly around the transom area. Overpowering a boat can result in serious injury,
death, or boat damage.

Mercury 40 Specifications

General

Brand	Mercury
Model	40
Category	Outboard Motor
Language	English