Market Position:
Mid-range four-stroke outboards for recreational and light commercial use.
Competitive Advantage:
Lightweight design, fuel efficiency, and reliable starting.
Key Features:
Electronic fuel injection (EFI), CD ignition, through-prop exhaust, and corrosion-resistant construction.
Publication Specifications
Coverage Areas:
Complete engine, fuel, ignition, lubrication, cooling, lower unit, and electrical systems.
Page Count:
Approximately 500 pages
Manual Type:
Service Repair Manual
Delivery Method:
Instant download
Engine Mechanical:
Cylinder head, cylinder block, pistons, connecting rods, crankshaft, and bearings.
Fuel System:
Electronic fuel injection (EFI) components, fuel pump, fuel injectors, and fuel lines.
Ignition System:
CD ignition module, ignition coils, spark plugs, and stator.
Lubrication System:
Oil pump, oil filter, and oil passages.
Cooling System:
Water pump, thermostat, and cooling passages.
Lower Unit:
Gearcase, propeller shaft, gears, and seals.
Electrical System:
Battery, starting system, charging system, and wiring.
Power Trim and Tilt:
Hydraulic system and electrical controls.
Mid-Section:
Mount brackets, swivel bracket, and exhaust housing.
Powerhead:
Complete disassembly and assembly procedures.
Tiller Handle:
Throttle and shift controls.
Remote Control:
Cables and connections.
Diagnostic Procedures:
Troubleshooting charts and fault codes.
Disassembly and Assembly:
Step-by-step with torque specifications.
Maintenance Schedules:
Periodic service and inspection intervals.
Adjustments:
Throttle, shift, and idle adjustments.
Testing:
Component testing and electrical tests.
Specifications:
Torque values, clearances, and wear limits.
Illustrations:
Detailed diagrams and exploded views.
Special Tools:
List of required tools and part numbers.
Part Diagrams:
Exploded views with part numbers.
Part Numbers:
OEM part numbers for replacement.
Ordering:
N/A - not included in this manual
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Engine Type:
Four-stroke, in-line 3-cylinder
Displacement:
526 cc (32.1 cu in)
Bore x Stroke:
61.0 x 60.0 mm (2.40 x 2.36 in)
Horsepower:
30 HP (22.4 kW) and 40 HP (29.8 kW) models
Full Throttle RPM:
5000-6000 RPM
Fuel System:
Electronic Fuel Injection (EFI)
Fuel Type:
87 octane minimum
Fuel Tank Capacity:
N/A - external tank dependent
Oil Capacity:
Engine oil capacity 2.5 L (2.6 US qt) with filter
Oil Type:
NMMA FC-W certified 10W-30 or 10W-40
Cooling System:
Water-cooled, thermostatically controlled
Spark Plug:
NGK DPR6EA-9 or equivalent, gap 0.9 mm (0.035 in)
Alternator Output:
18 amp (226 watt)
Transmission Specifications
Standard Transmission:
Forward, Neutral, Reverse with dog clutch
Optional Transmission:
N/A - not offered for this model
Gear Ratio:
2.00:1 (30 HP) / 1.83:1 (40 HP)
Lubrication:
Gearcase lubricant, capacity 430 ml (14.5 fl oz)
Lubricant Type:
Mercury High Performance Gear Lube or equivalent
Shift Mechanism:
Mechanical cable control
Wheelbase:
N/A - not applicable for outboard
Length:
N/A - varies with shaft length and mounting
Shaft Length:
20 in (508 mm) or 25 in (635 mm)
Transom Height:
20 in or 25 in models
Weight (Curb):
30 HP: 73 kg (161 lb); 40 HP: 79 kg (174 lb) for 20 in shaft
Propeller:
N/A - depends on application
Crash Test Ratings:
N/A - not applicable for outboard motors
Active Features:
Emergency stop switch (lanyard), over-rev limiter, low oil pressure warning, overheat warning
Passive Features:
Corrosion protection with sacrificial anodes, cowling latch
First Service:
After first 20 hours or 3 months
Regular Service Interval:
Every 100 hours or annually
Engine Oil Change:
Every 100 hours or annually
Gearcase Lubricant:
Every 100 hours or annually
Spark Plugs:
Every 100 hours or annually
Water Pump Impeller:
Every 300 hours or 3 years
Fuel Filter:
Every 100 hours or annually
Valve Clearance:
Inspect every 500 hours
Engine Oil:
10W-30 or 10W-40 NMMA FC-W certified
Gearcase Lubricant:
Mercury High Performance Gear Lube
Fuel:
87 octane minimum, up to 10% ethanol
Coolant:
Raw water cooled, no coolant required
Common Wear Items:
Water pump impeller, spark plugs, fuel filter, anodes, propeller
Known Issues:
Early models may experience fuel injector clogging; regular maintenance recommended.
Manufacturer:
Mercury Marine, a division of Brunswick Corporation
Founded:
1939 in Cedarburg, Wisconsin, USA
Headquarters:
Fond du Lac, Wisconsin, USA
Introduction:
30/40 HP four-stroke introduced in 2006
Updates:
Minor updates through 2015
Successor:
Replaced by newer models after 2015
Manufactured In:
Fond du Lac, Wisconsin, USA
Production Years:
2006-2015
