This service manual covers the 1999-2002 Mercury Outboard models including 30HP, 40HP, EFI (4-Stroke), 30/40 MH, 30/40 ELPT, and 40 ELPT BIGFOOT. It provides detailed service procedures for the complete outboard, with maintenance schedule recommendations to keep the engine in peak operating condition.
All chapters in the manual illustrate step-by-step procedures for the removal and installation of components, starting with assembly or system illustrations, diagrams, exploded parts views, pictures, service information, and troubleshooting for each section.
The manual is available in PDF format and does not require special software to access. It is suitable for use on all computers.
Specifications: The manual includes detailed specifications such as overall length, overall width, weight, transom height, recommended operating range, engine type, fuel supply system, cooling system, lubrication system, and more.
Maintenance: Complete maintenance specs, charts, intervals, and step-by-step procedures for spark plugs, fuel lines, engine oil, gear oil, lubrication, anodes, bonding wires, battery, water pump, propeller, and more are covered in this section.
General Information: This section covers identification numbers, tightening torque, service data, cylinder number, propellers, and gasoline recommendations.
Electrical: The manual includes information on electrical parts, inspection, removal, installation, and troubleshooting of electrical components such as the starter motor, battery charging system, and more.
Ignition: Information on ignition timing, spark plug, ignition coil, engine speed limiter, and other related topics is provided in this section.
Carburetor: For motors with a carburetor, the manual includes specifications, adjustments, removal, cleaning, inspection, and rebuilding procedures to factory specs.
EFI System: This section covers specifications, fuel injection components, throttle control, fuel hoses, pressure regulator, intake manifold, and more related to the electronic fuel injection system.
Powerhead (Power Head): Information on rebuilding the engine block to factory specs, including cylinder head, intake manifold, oil pump, lubrication system, and more, is provided in this section.
Mid-Section: This section includes procedures for inspection, removal, installation, cleaning, and assembly of components such as engine side cover, driveshaft housing, swivel bracket, and more.
Lower Unit: Detailed information on gear case, propeller, lower unit gears, water pump, shift guide housing, and related components is covered in this section.
Additional chapters in the manual include Attachments/Control Linkage, Throttle/Shift Linkage, Tiller Handle, Manual Starter, Diagnostic Troubleshooting, and Wiring Diagrams.
Whether you are a professional mechanic or a DIY enthusiast, this comprehensive manual provides everything you need to service your entire motor.
