1999 Mercury 30/40 FourStroke Outboard Motor Service Manual
Complete 1999 Mercury 30/40 FourStroke outboard motor service manual for troubleshooting, removal, and installation procedures. Includes diagrams and specifications.
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Sample pages from the 1999 Mercury 30/40 FourStroke Outboard Motor Service Manual manual
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Models Covered & Key Technical Specifications
Mercury 30/40 FourStroke (90-857046R1 NOVEMBER 2001) - 1999 FourStroke 4-Stroke Over Head Camshaft | Outboard Motor Marine Engine Logic.
- Engine Type: 4-Stroke Over Head Camshaft
- Displacement: 45.6 cu. in. (747 cc)
- Horsepower: Model 30: 30 hp (22.4 Kw) @ 5750 rpm Model 40: 40 hp (29.8 Kw) @ 5750 rpm
- Outboard Weight: Electric: 204 lb (93 kg) 30/40 MH: 224 lb (112.7 kg) 30/40 ELPT: 235 lb (106.6 kg)
- Recommended Fuel: Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87
- Recommended Oil: SAE 10W-30 viscosity oil for all temperatures.
Professional Workshop Service Manual & Technical Specifications
Mercury 30/40 FourStroke Outboard Motor Service Manual: Mercury Outboard Motor Repair Manual (1999) Data-Compendium
Service-Level: 1999 Mercury 30/40 FourStroke Models // Conceptual-Layout: Outboard Motor / Marine Engine Logic // Service-Level: Technical Specifications and Repair Procedures.
Mercury/Quicksilver Lubricants and Sealants
NOTE: See section 1A for lubricants and sealants chart.
Torque Chart
| Fastener Location | Diameter x Length (mm) | Torque lb-in. | lb-ft. | Nm |
|---|---|---|---|---|
| Ignition | ||||
| Coil Mounting Nuts | M5 | 30 | 3.5 | |
| Coil Mount Plate Screw (Rear) | M6 x 25 | 60 | 7 | |
| Coil Mount Plate Screw | M6 x 30 | 75 | 8.5 | |
| Coil Plate Ground Screw | M6 x 10 | 60 | 7 | |
| Spark Plug | 12 mm | 150 | 17 | |
| Charging & Starting System | ||||
| Flywheel Cover Screws | M6 x 25 | 75 | 8.5 | |
| Flywheel Nut | N/A | 116 | 157 | |
| Stator Screws (Electric) | M5 x 30 | 85 | 9.5 | |
| Stator Screws (Manual) | M5 x 25 | 85 | 9.5 | |
| Voltage Regulator Screws | M6 x 40 | 75 | 8.5 | |
| Starter Motor Mount Bolts | M8 x 45 | 21.5 | 29.5 | |
| Starter Cable Nut | 1/4-20 | 60 | 7 | |
| Starter Motor Thru Bolts | N/A | 70 | 8 | |
| Battery Cable (+) Nut | M6 | 60 | 7 | |
| Solenoid Plate Screw | M6 x 14 | 45 | 5 | |
| Harness Retainer Screws | M6 x 14 | 45 | 5 | |
| Wire Clamp Screw (Top of Block) | M5 x 12 | 45 | 5 | |
| Cylinder Head | ||||
| Cylinder Head Bolts (*) | M9 x 95 | 34.5 | 47 | |
| Cylinder Head Bolts (*) | M6 x 25 | 106 | 12 | |
| Baffle Plate Screws | M4 x 10 | Drive Tight | ||
| Valve Cover Screws | M6 x 20 | 70 | 8 | |
| Valve Adjusting Nuts | M6 | 120 | 13.5 | |
| Rocker Arm Shaft Screws | M8 x 23 | 160 | 13 | |
| Driven Gear Screw | M10 x 40 | 28 | 38 | |
| Cylinder Block/Crankcase | ||||
| Crankcase Cover Bolts - Center (*) | M8 x 82 | 22 | 30 | |
| Crankcase Cover Bolts - Outer (*) | M6 x 35 | 106 | 12 | |
| Exhaust Cover Screws | M6 x 35 | 106 | 12 | |
| Connecting Rod Bolts (*) | Special | 150 | 17 | |
| Oil Filter | N/A | 70 | 8 | |
| Oil Filter Nipple | N/A | 29.5 | 40 | |
| Powerhead Mounting Bolts (*) | M8 x 110 | 33 | 44.5 | |
| Lifting Eye Screw | M8 x 35 | 29 | 39.5 | |
| Oil Pressure Switch | N/A | 75 | 8.5 | |
| Oil Galley Plug | 1/8-27 Pipe Plug | 80 | 9 | |
| Oil Galley Plug | 3/4-14 Pipe Plug | 30 | 40.5 | |
| Oil Galley Plug | 1/2-14 Pipe Plug | 30 | 40.5 |
*NOTE: Two Step Torque - See appropriate section of component for details.
Reference chapters include Section 1B - Maintenance, Section 1C - General Information, Section 2A - Ignition, Section 2B - Charging & Starting System, Section 2C - Timing, Synchronizing, & Adjusting, Section 2D - Wiring Diagrams, and Section 3A - Fuel Pump.
This professional Mercury outboard motor service manual provides comprehensive procedural information for the 30/40 FourStroke models. Coverage includes detailed specifications, ignition system diagnostics, charging and starting system troubleshooting, carburetor adjustments, and wiring diagrams. Procedures are outlined for fuel pump maintenance, electrical system checks, and engine timing. This manual is intended for mechanics and service personnel familiar with outboard motor servicing.
This service manual provides specific technical data and procedures for servicing Mercury outboard motors, ensuring proper operation and longevity. It includes information on maintaining the ignition, charging, and fuel systems, as well as guidance on carburetor synchronization and idle speed adjustments. Torque specifications are provided for various components to ensure correct assembly and performance.
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