Mercury 140, Service Manual

Page 1: ...ct your local dealer If the outboard motor s serial number plate contains the CE mark in the lower left hand corner the following statement applies This outboard motor manufactured by Mercury Marine Fond du Lac WI USA or Marine Power Europe Inc Park Industrel de Petit Rechain Belgium complies with the requirements of the following directives and standards as amended Recreational Craft Directive 94...

Page 2: ...oat Operation 9 Outboard Remote Control Models 9 Remote Steering Notice 9 Lanyard Stop Switch 10 Protecting People In The Water 11 Passenger Safety Message Pontoon Boats And Deck Boats 12 Wave And Wake Jumping 12 Impact With Underwater Hazards 13 Exhaust Emissions 14 Selecting Accessories For Your Outboard 15 Safe Boating Suggestions 15 Recording Serial Number 16 Specifications 16 Component Identi...

Page 3: ...fting 36 Stopping The Engine 36 Emergency Starting 36 Maintenance Outboard Care 39 EPA Emissions 39 Inspection And Maintenance Schedule 40 Flushing The Cooling System 40 Top Cowl Removal And Installation 41 Fuel System 42 Steering Link Rod Fasteners 43 Fuse Replacement 44 Corrosion Control Anode 46 Battery Inspection 46 Propeller Replacement 47 Spark Plug Inspection and Replacement 49 Lubrication ...

Page 4: ...ne 57 Engine Will Not Start 57 Engine Runs Erratically 57 Performance Loss 57 Battery Will Not Hold Charge 58 Owner Service Assistance Local Repair Service 59 Service Away From Home 59 Parts And Accessories Inquiries 59 Service Assistance 59 Mercury Marine Service Offices 59 ...

Page 5: ...d 2 To be eligible for warranty coverage the product must be registered with Mercury Marine At the time of sale the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET E mail or mail Upon receipt of this warranty registration Mercury Marine will record the registration 3 Upon processing the warranty registration Mercury Marine will send registra...

Page 6: ...ustomer upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is availble only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified pre delivery inspection process is completed and docume...

Page 7: ... regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTI...

Page 8: ...unless requested by Mercury ship the product or parts of the product directly to Mercury The warranty registration card is the only valid registration identificationand must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear dama...

Page 9: ...rformed including without limitation the replacement of sacrificial anodes use of specified lubricants and touch up of nicks and scratches in order to maintain warranty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing...

Page 10: ...ATE TO STATE AND COUNTRY TO COUNTRY Warranty Coverage And Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The following information explains some of the types of services that are not covered by warranty The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Agains...

Page 11: ...r operating with a racing type lower unit 11 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty 12 Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard 13 Water entering e...

Page 12: ...structions that should be followed DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or proper...

Page 13: ...0 1 from your dealer distributor or Mercury Marine ob00307 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device This prevents the engine from starting when the shift is actuated in any position other than neutral WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engi...

Page 14: ...tal activation should the operator choose to move around in an area close to the normal operator s position If it is desired to have a shorter lanyard wrap the lanyard around the operator s wrist or leg or tie a knot in the lanyard ob00310 a b a Lanyard cord b Lanyard stop switch Read the following Safety Information before proceeding Important Safety Information The purpose of a lanyard stop swit...

Page 15: ...lso a possibility This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller Loss of power and directional control in heavy seas strong current or high winds Loss...

Page 16: ... or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water ob00312 WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over by the outboard Stay back from the front end of the deck and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Ele...

Page 17: ...boat may also steer sharply to one side Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is ...

Page 18: ...horoughly inspected and any necessary repairs made Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines This includes the outboards sterndrives and inboard engines that propel boats as well as the generators that power various boat accessories Carbon monoxide is a deadly gas that is odorless colorless and tastele...

Page 19: ... or product failure Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system Acquire and read the installation operation and maintenance manuals for all your selected accessories Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulati...

Page 20: ...w to maintain a proper lookout by sight and hearing The operator must have an unobstructed view particularly to the front No passengers load or fishing seats should block the operators view when operating the boat above idle speed Never drive your boat directly behind a water skier in case the skier falls As an example your boat traveling at 40 km h 25 MPH will overtake a fallen skier 61 m 200 ft ...

Page 21: ...2507 cc 153 cu in Cylinder Bore 88 9 mm 3 500 in Stroke 67 3 mm 2 650 in Recommended Spark Plug NGK BPZ8HS 10 Spark Plug Gap 1 0mm 0 040 in Gear Ratio Standard Gearcase 1 87 1 High Altitude Gearcase 2 1 Recommended Gasoline Refer to Fuel Oil Recommended Oil Refer to Fuel Oil Gearcase Lubricant Capacity 710 ml 24 fl oz Battery Rating 630 Marine Cranking Amps MCA or 490 Cold Cranking Amps CCA or Amp...

Page 22: ...mponent Identification a b c d e f g h i 3403 a Top cowl b Bottom cowl c Water pump indicator hole d Driveshaft housing e Anti ventilation plate f Auxiliary tilt switch g Transom brackets h Gearcase i Cooling water intake holes ...

Page 23: ...ion and good performance If you install the outboard yourself follow instructions in the Outboard Installation Manual which is provided with the outboard The outboard must be secured to the transom with the four 12 7 mm 1 2 in diameter mounting bolts and locknuts provided Install two bolts through the upper set of holes and two bolts through the lower set of holes ob00658 MAXIMUM OUTBOARD MOUNTING...

Page 24: ...hile maintaining maximum boat speed ob00323 If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher elevations increased boat load or a dirty boat bottom gearcase a propeller change or cleaning may be required to maintain performance and ensure the outboards durability Check full throttle RPM using an accurate tachometer with t...

Page 25: ... Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing ob01074 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This p...

Page 26: ...stem visually checking for fuel leaks or abnormalities Gasoline containing alcohol may cause the following problems to your outboard and fuel system Corrosion of metal parts Deterioration of elastomers and plastic parts Wear and damage of internal engine parts Starting and operating difficulties Vapor lock or fuel starvation Some of these adverse effects are due to the tendency of gasoline contain...

Page 27: ...low Restriction IMPORTANT Adding components to the fuel supply system filters valves fittings etc may restrict the fuel flow This may cause engine stalling at low speed and or a lean fuel condition at high RPM that could cause engine damage Filling Remote Oil Tank Remove filler cap and fill with the specified oil Oil tank capacity is 11 5 liters 3 galllons Replace filler cap and tighten securely I...

Page 28: ... open flames or sparks in the area while filling fuel tanks Fill fuel tanks outdoors away from heat sparks and open flames Remove portable fuel tanks from boat to refill them Always stop engine before refilling tanks Do not completely fill the fuel tanks Leave approximately 10 of the tank volume unfilled Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is...

Page 29: ...nyard Refer to General Information Lanyard Stop Switch f Throttle friction adjustment Console controls require cover removal for adjustment g Ignition key switch off on start h Fast idle lever Refer to Operation Starting the Engine i Throttle only button Refer to Operation Starting the Engine Warning System Models with Carburetors The outboard warning system incorporates a warning horn inside the ...

Page 30: ...s found there may be a blockage in the cooling system or a water pump problem Have the outboard checked by your dealer Operating the engine while overheated will cause engine damage NOTE Should overheating occur and you are stranded stop the engine and allow it to cool down This will usually allow some additional low speed idle running time before the engine starts to overheat again Operating an o...

Page 31: ...w the horn is working The warning horn will emit either a continuous beep or intermittent short beeps This will alert the operator and help identify the following listed situations For visual display of the specific engine functions and for additional engine data refer to SmartCraft Product information following Warning Horn Function Sound Description Start Up One Beep Normal System Test Low Oil R...

Page 32: ...em is activated Power will be limited The warning horn is activated if the oil pump should ever stop functioning electrically No lubricating oil is being supplied to the engine Engine Overspeed Continuous The warning horn is activated any time engine speed exceeds the maximum allowable RPM The system will limit the engine speed to within the allowable range Engine overspeed indicates a condition t...

Page 33: ...he outboard can also be tilted up past the trim range to permit for example shallow water operation ob00663 a c b a Trim switch b Tilt range of travel c Trim range of travel POWER TRIM OPERATION With most boats operating around the middle of the trim range will give satisfactory results However to take full advantage of the trimming capability there may be times when you choose to trim your outboa...

Page 34: ...r and inserting it in whatever adjustment hole in the transom brackets is desired The non stainless steel shipping bolt should not be used in this application other than on a temporary basis 2 Trimming Out or Up can Lift the bow higher out of the water Generally increase top speed Increase clearance over submerged objects or a shallow bottom Increase steering torque or pull to the left at a normal...

Page 35: ...0665 AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system a ob00666 a Auxiliary tilt switch SHALLOW WATER OPERATION When operating your boat in shallow water you can tilt the outboard beyond the maximum trim range to prevent hitting bottom 1 Reduce engine speed below 2000 RPM 2 Tilt outboard up Make sure all the water intake holes ...

Page 36: ...ting In Salt Water Or Polluted Water We recommend that you flush the internal water passages of your outboard with fresh water after each use in salt or polluted water This will prevent a buildup of deposits from clogging the water passages Refer to Maintenance Flushing The Cooling System If you keep your boat moored in the water always tilt the outboard so the gearcase is completely out of water ...

Page 37: ... the time between 3000 and 4500 RPM or three quarter throttle b Change engine speed approximately every two minutes and avoid continuous operation at idle speed for more than ten minutes Short bursts of full throttle for periods up to ten seconds are acceptable c Avoid trimming the outboard out up beyond a vertical trim position during operation NOTE It is the driver s responsibility to always dri...

Page 38: ...al times until it feels firm ob00349 4 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch ob00350 5 Shift outboard to neutral N position N ob00351 6 Starting procedure NOTE Models with Electronic Fuel Injection EFI Do not advance the fast idle lever or throttle only feature for starting The electronic starting system will automatically prime choke the engi...

Page 39: ...art the engine If engine fails to start in ten seconds wait 30 seconds and try again If engine begins to stall re prime push key in After starting keep engine sped below 2500 RPM to prevent engine over speed Starting Flooded Engine Carbureted Advance the fast idle speed lever or throttle only feature to the full maximum position Without activating primer crank engine for 10 seconds Wait 30 seconds...

Page 40: ... further to increase speed N R F ob00557 Stopping The Engine Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF position ob00360 Emergency Starting NOTE Models with Electronic Fuel Injection cannot be started manually If the starter system fails use the spare starter rope provided and follow procedure 1 Remove flywheel cover ob01081 WARNING When using emergency sta...

Page 41: ...d moving flywheel can cause serious injury Keep your hands hair clothing tools and other objects away from engine when starting or running the engine Do not attempt to reinstall the flywheel cover or top cowl when engine is running 4 If engine is cold push in the fuel primer button for 6 seconds to prime the engine ob01082 5 Place the starter rope knot into the flywheel notch and wind the rope clo...

Page 42: ...OPERATION 38 6 Pull the starter rope to start the engine ...

Page 43: ...uld result in personal injury death or product failure EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at time of manufacture EMISSION CONTROL INFORMATION TIMING IN DEGREES FAMILY FEL cc IDLE SPEED hp GAP g kW h Standard spark plug Suppressor spark plug This engine con...

Page 44: ... or once yearly Replace spark plugs as needed See Spark Plug Inspection and Replacement Replace water separating fuel filter EFI models See Fuel System Check corrosion control anode Check more frequently when used in salt water See Corrosion Control Anodes Drain and replace gearcase lubricant See Gearcase Lubrication Lubricate splines on the drive shaft and shift shaft 1 Check power trim fluid See...

Page 45: ...01085 Top Cowl Removal And Installation REMOVAL 1 Pull out the front cowl latch ob01086 2 Lift up the rear cowl latch Remove the top cowl ob01087 INSTALLATION 1 Lower top cowl into position over engine 2 Push down the rear cowl latch to lock down the rear and push in the front cowl latch to lock down the front ...

Page 46: ...ually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer bulb must be replaced FUEL LINE FILTER MODELS WITH CARBURETORS Inspect the fuel line filter If the filter appears to be contaminated remove and replace IMPORTANT Visually inspect for fuel leakage from the filter connec...

Page 47: ...nk Rod Fasteners IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt a Part Number 10 849838 and self locking nylon insert locknuts c d Part Number 11 826709113 These locknuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage WARNING Disengagement o...

Page 48: ...back nut off 1 4 turn Assemble steering link rod to engine with special washer head bolt and self locking nylon insert locknut First torque bolt then torque locknut to specifications Fuse Replacement MODELS WITH CARBURETORS IMPORTANT Always carry spare 20 and 30 AMP fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring If a fuse is blown try to loc...

Page 49: ...I IMPORTANT Always carry spare 5 and 20 AMP fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow again 1 Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse Replace fuse with a n...

Page 50: ...inspection especially in salt water which will accelerate the erosion To maintain this corrosion protection always replace the anode before it is completely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode The gearcase has two corrosion control anodes one on each side A third anode is installed on the bottom of the transom bracket assembl...

Page 51: ...ne is in gear there is the possibility that the engine will crank over and start To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller 1 Shift outboard to neutral N position N ob00351 IMPORTANT Refer to Spark Plug Inspe...

Page 52: ... apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 7 Flo Torq I Drive Hub Propellers Install forward thrust hub propeller continuity washer rear thrust hub propeller nut retainer and propeller nut onto the shaft ob00382 a b c d e f a Propeller nut b Propeller nut retainer c Rear thrust hub d ...

Page 53: ...422 Spark Plug Inspection and Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots Damaged spark plug boots can emit sparks Sparks can ignite fuel vapors under the engine cowl To avoid damaging spark plug boots do not use any sharp object or metal tool such as pliers screwdriver etc to remove spark plug boots 1 Remove the spark plug leads Twis...

Page 54: ...Spark plug 27 20 Lubrication Points 1 Lubricate the following with Quicksilver or Mercury Precision Lubricants Special Lubricant 101 Trim Ball Ends Turn the ball ends to work the lubricant into the ball sockets ob01093 2 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon Propeller Shaft Refer to Propeller Replacement for removal and ...

Page 55: ...er Tilt Tube Lubricate through fitting ob00684 WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked A hydraulically locked steering cable will cause loss of steering control possibly resulting in serious injury or death Steeri...

Page 56: ...y Precision Lubricants Power Trim Steering Fluid If not available use automotive ATF automatic transmission fluid ob01095 Gearcase Lubrication When adding or changing gearcase lubricant visually check for the presence of water in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colo...

Page 57: ... b 3399 a Vent plug b Fill drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 710 ml 24 fl oz CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1 Place outboard in a vertical operating position 2 Remove vent plug 3 Remove fill drain plug Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole a b c 3400 a Vent plug b Vent hole c Fi...

Page 58: ...require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine ...

Page 59: ... Internal Engine Components CARBURETOR MODELS 1 Remove carburetor cover NOTE Before performing the following steps make sure the fuel system has been prepared for storage Refer to Fuel System preceeding 2 Place the outboard in water or connect flushing attachment for circulating cooling water Start the engine and let it run in neutral to warm up 3 With engine running at fast idle stop the fuel flo...

Page 60: ...ed up in freezing temperature trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard Battery Storage Follow the battery manufacturer s instructions for storage and recharging Remove the battery from the boat and check water level Recharge if necessary Store the battery in a cool dry place Periodically che...

Page 61: ...ne is disconnected or kinked d Primer bulb not squeezed e Primer bulb check valve is faulty f Fuel filter is obstructed Refer to Maintenance section g Fuel pump failure h Fuel tank filter obstructed Blown 20 Amp fuse EFI Models Refer to Maintenance section Ignition system component failure Wiring or electrical connection faulty Spark plugs fouled or defective Refer to Maintenance section Engine Ru...

Page 62: ... water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator EFI models Open circuit in the alternator output wire fused link ...

Page 63: ...very important to your dealer and to us If you ever have a problem question or concern about your outboard product contact your dealer or any authorized Mercury Marine dealership If additional assistance is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question conce...

Page 64: ...striel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 954 744 3513 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 954 744 3535 Japan Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Shizuoka ken Japan 435 0005 Japan Fax 81 053 423 2510 Asia Singapore Telephone 5466160 Mercury Ma...