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1999-2010 Mercury 30hp, 40hp outboard motor manual Preview image 1
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1999-2010 Mercury 30hp, 40hp outboard motor manual

Models covered in this manual:

Mercury (Brunswick Corporation)

  • 30 hp (FourStroke)
  • 40 hp (FourStroke)
    • Mercury 30hp:
  • 30hp Standard: 2010-2020
  • 30hp BigFoot: 2012-2020
    • Mercury 40hp:
  • 40hp Standard: 2010-2020
  • 40hp BigFoot: 2011-2020
    • Strating S/N 0G760300 and Above

Starting Model Year 1999

Production Years: 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

File specifications

File size: 16.07 MB
File type: ZIP

Printable: Yes
Estimated download time: 0.33 Minutes
$13.99 Instant Download

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Product Information

Table of Contents

Section 1A: Specifications

  • Specifications
  • Propeller Information Chart
  • Mercury/Quicksilver Lubricants and Sealants
  • Torque Specifications

Section 1B: General Information

  • Introduction
  • Safety Precautions
  • Maintenance Intervals
  • Serial Number Locations
  • Tools

Section 2: Ignition System

  • Spark Plug
  • Ignition Timing
  • Ignition Coil Resistance
  • Starter Motor
  • Capacitor Discharge Ignition (CDI)

Section 3: Fuel System

  • Fuel Pump
  • Carburetor
  • Fuel Filter
  • Throttle Body
  • Fuel Line Inspection

Section 4: Cooling System

  • Water Pump
  • Thermostat
  • Cooling System Maintenance

Section 5: Power Unit

  • Cylinder Block
  • Cylinder Bore
  • Piston and Rings
  • Connecting Rod
  • Crankshaft

Section 6: Lubrication System

  • Oil Pump
  • Oil Filter
  • Oil Capacity and Specifications

Section 7: Electrical System

  • Battery Specifications
  • Charging System
  • Alternator Output
  • Wiring Diagrams

Section 8: Starting System

  • Starter Motor Specifications
  • Starter Solenoid
  • Starting System Troubleshooting

Section 9: Gear Housing

  • Gear Ratio
  • Gear Housing Assembly
  • Propeller Shaft

Section 10: Trim and Tilt System

  • Hydraulic System
  • Trim and Tilt Motor
  • Trim and Tilt Troubleshooting

Section 11: Maintenance

  • Periodic Maintenance Schedule
  • Maintenance Procedures
  • Service Intervals

Section 12: Troubleshooting

  • Drive System Troubleshooting
  • Hydraulic System Troubleshooting
  • Electrical System Troubleshooting
  • Cooling System Troubleshooting
  • Fuel System Troubleshooting

Section 13: Special Tools

  • Required Tools
  • Tool Specifications
  • Tool Usage


  • Technical Specifications
  • Torque Specifications
  • Conversion Tables
  • Glossary of Terms


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