Mercury 30/40 4-Stroke EFI Outboard Motor Service Manual


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Covers: Mercury 30/40 Four Stroke, EFI Outboard Motor

  • S/N 0T409000 and Above
  • 2002 and up model years

Pages: 583
Format: PDF
File size: 17mb
Compatibility: Windows/Mac/Tablet/Smartphone

This PDF service manual covers 2002 and up Mercury 30/40 4-Stroke EFI outboard motors and provides DIY and professional marine mechanics with the most accurate OEM technical information to maintain and service the motor. Service procedures, illustrations, torque specs and other important information are included.

High resolution digital PDF manual dated Feb. 2003.


Important Information

  • Specifications
  • Maintenance
  • General Information
  • Outboard Motor Installation


  • Ignition
  • Charging & Starting System
  • Timing, Synchronizing & Adjusting

Electronic Fuel Injection

  • Theory of Operation
  • Troubleshooting and Diagnostics
  • Service Procedures
  • Emissions


  • Cylinder Head
  • Cylinder Block/Crankcase
  • Lubrication


  • Clamp/Swivel Brackets & Drive Shaft Housing
  • Power Trim
  • Manual Tilt Assist

Lower Unit

  • Non-Bigfoot Gear Housing
  • Bigfoot Gear Housing

Attachments/Control Linkage

  • Throttle/Shift Linkage
  • Tiller Handle

Color Diagrams


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