2002 & Later Mercury 30 & 40 HP EFI FourStroke Outboard Repair Manual PDF

A comprehensive service and repair manual for the Mercury 30 and 40 hp FourStroke outboards with electronic fuel injection. It covers the complete outboard: maintenance, ignition, charging and starting, electronic fuel injection, powerhead, mid-section, power trim, gear housings, throttle and shift linkage and tiller handle, with color wiring diagrams.

This manual applies to the Mercury 30 and 40 FourStroke EFI outboards starting with model year 2002 (starting serial number 0T409000). It is publication 90-883064, dated June 2001.

The manual covers many topics, including:

• Specifications, maintenance and outboard installation
• Ignition system
• Charging and starting system
• Timing, synchronizing and adjusting
• Electronic fuel injection: theory, troubleshooting, diagnostics and service
• Emissions
• Cylinder head, cylinder block, crankcase and lubrication
• Clamp and swivel brackets, drive shaft housing
• Power trim and manual tilt assist
• Non-Bigfoot and Bigfoot gear housings
• Throttle and shift linkage, tiller handle
• Color wiring diagrams

The manual is divided into the following sections:

1. Important Information
2. Electrical
3. Electronic Fuel Injection
4. Powerhead
5. Mid-Section
6. Lower Unit
7. Attachments / Control Linkage
8. Color Diagrams

The electronic manual is a 583-page PDF, available to download right after checkout. It is fully text-searchable and has detailed clickable bookmarks for every chapter and procedure. It works on Windows, Mac, tablets and phones, and you can print only the pages you need.

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