Clean Used 1985 Mariner 40 HP 2 Cylinder Carbureted 2 Stroke 15' (Short Shaft) Tiller Outboard Motor. Model number: 40M. Serial number: 6E9-S-006187. Weight - 143 lbs. 140-143 psi compression on both cylinders. Comes with Aluminum Propeller. Non Oil Injected. Motor has been inspected and ready to mount. 2001-2002 Mercury/Mariner 115HP EFI 4-Stroke Manual. 2002-2007 Mercury 40/50/60 HP 4-Stroke Repair Manual. REMOVAL & DISASSEMBLY. Always disconnect the battery cable, before removing. Shift to “NEUTRAL” position.
LOWER UNIT
REMOVAL & DISASSEMBLY
Always disconnect the battery cable, before removing
lower unit.
1. Shift to “NEUTRAL” position.
2. Remove bolt and trim tab 1.
3. Remove seven (7) bolts 2 and separate gearcase 3 from
driveshaft housing.
4. Remove clutch rod from clutch shaft (if necessary).
5. Place a drain pan under oil drain plug.
Remove oil drain plug 6 first then oil level plug 5 and
allow gear oil to drain.
Inspect oil for water, contaminates or metal.
Clutch rod
NOTE:
Before gearcase is removed completely, disconnect speedometer
pick up tube 4 from gearcase.
6. Remove cotter pin 7 from propeller nut and remove pro
peller nut 8.
7. Remove washer 9, spacer 0, propeller A, stopper B and
spacer C from propeller shaft.
To prevent injury from propeller blades, wear gloves
and place a block of wood between the anti-cavitation
plate and the propeller blade tips to lock the propeller
in place.
9. Keep impeller key 6 for reuse and discard plate gasket.
10. Remove three (3) bolts 1 and shift rod guide housing
assembly 2.
11. Remove two bolts 1 securing propeller shaft bearing
housing to gearcase.
12. Using special tools, draw out propeller shaft bearing
housing.
Remove propeller shaft and bearing housing assembly.
09930-30104 : Sliding hammer A
09930-30161 : Propeller shaft remover B
13. Hold pinion nut securely, then fit special tool to the driveshaft
and loosen pinion nut.
09921-29410 : Driveshaft holder
14. Remove four bolts 1 securing driveshaft oil seal housing
2, then remove oil seal housing and pinion shim 3.
15. Lift out driveshaft assembly 4.
Remove driveshaft collar 5, washer 6, wave washer 7,
washer (with tab) 8 and washer 9 from driveshaft.
Disassembly of propeller shaft components
1. Slide propeller shaft away from reverse gear 3 and bearing
housing assembly 1.
Account for reverse gear back-up shim 2 and reverse gear
thrust washer 4.
INSPECTION
NOTE:
If excessive ware, cracks, defective or other damage is found
on any component, replace component.
NOTE:
Thoroughly wash all metal components with cleaning solvent
and dry with compressed air.
Wear safety grasses when using compressed air.
PROPELLER
• Inspect propeller for bent, chipped or broken blades.
Replace or repair if necessary.
• Inspect propeller bushing splines for wear or other damage.
Replace if necessary.
• Inspect propeller bushing for deterioration or slipping.
Replace if necessary.
GEARCASE
• Inspect gearcase for cracks or other damage.
Replace if necessary.
• Inspect pinion bearing for pitting, rough or other damage.
Replace if necessary.
NOTE:
If removal and replacement are required, see “PINION BEARING”
section on page 9-7.
LOWER UNIT
GEARS
• Inspect forward, reverse and pinion gear teeth and engaging
dogs for excessive wear or other damage.
Replace if necessary.
• Inspect forward gear bearing for pitting, rough or other damage.
Replace if necessary.
PROPELLER SHAFT COMPONENTS
• Inspect horizontal slider and connector pin for excessive wear
or other damage. Replace if necessary.
• Inspect clutch dog shifter for excessive wear, chip or other
damage. Replace if necessary.
• Inspect dog pin for bent or other damage. Replace if necessary.
• Inspect propeller shaft / splines for wear, twist or other damage.
Replace if necessary.
PROPELLER SHAFT BEARING HOUSING
• Inspect housing for cracks or other damage. Replace if necessary.
• Inspect propeller shaft bearings and reverse gear bearing
for pitting, rough or other damage. Replace if necessary.
• Inspect oil seals and O-ring for cuts, nicks or tears.
Replacing propeller shaft oil seal
1. Remove retaining ring 1 and washer 2.
2. Extract oil seals 3 using oil seal remover.
09913-50121 : Oil seal remover
Do not re-use oil seal once removed.
Always use a new oil seal.
3. Apply Water Resistant Grease to inner circumference of
housing.
4. Using an oil seal installer, drive two oil seals (one at a time)
into housing.
The lipped portion of seal should face towards propeller.
Apply Water Resistant Grease to seal lips.
99000-25161 : Water Resistant Grease
5. Install washer and retaining ring.
Service Bulletins
MERCURY FLO-TORQ REFLEX HUB SYSTEM SOB-10-0620-MAY-2010
FUEL STARVATION (REPLACED BY SB2001-17) SOB-99-0525-FEB-2003
POWER TRIM MANUAL RELEASE VALVE TIP BREAKAGE - 35 THRU 125 SOB-95-1614-APR-2000
FUEL STARVATION SOB-01-1707-MAY-1999
EXCESSIVE EXHAUST SMOKE/SPARK PLUG FOULING-MAR 40 MAG/MERC 40 E (4 CYL) SOB-90-0627-JAN-1999
OBSTRUCTED FUEL LINE C0ONNECTOR-M/M 8-200 MODELS SOB-90-0826-JAN-1999
SERVICE/REPAIR-ELECTRICAL TEST EQUIPMENT SOB-90-0526-JAN-1999
USA & CANADA GASOLINE RECOMMENDATIONS-M/M SOB-90-1126-JAN-1999
LOWER END CAP SEAL INPROVEMENT-40 (4 CYL) SOB-90-1526-JAN-1999
Mariner 40 Elo 6e9 L Manual
GEARHOUSING MODIFICATIONS SOB-97-0721-JAN-1998
WARR & REGISTRATION OF UNSOLD NON CURRENT OUTBOARDS SOB-97-0626-JUN-1997
REFORMULATED GASOLINE (USA) SOB-95-0515-NOV-1995
FLYWHEEL PULLER-91-73687A2-35 THRU 275 SOB-91-2104-APR-1995
QUICKSILVER PROPELLER FAILURES AND GUIDELINES SOB-92-1817-MAR-1995
OUTBOARD WIRING COLOR CHART SOB-92-2117-MAR-1995
FUEL RECOMMENDATION - 2 THRU 275 SOB-93-0320-DEC-1994
SHIFT CABLE LOST MOTION AND ATTACHMENT SOB-93-0920-DEC-1994
Mariner 40 6e9 Manual Download
SERVICE/REPAIR OF ELECTRICAL TEST EQUIPMENT SOB-93-1413-OCT-1994
Mariner 40 6e9 Manual Transmission
IMPROVED MAN TILT ASSIST-SPEED/EFFORT 1991-93 40 THRU 60HP SOB-93-1110-OCT-1994