This comprehensive workshop service repair manual provides detailed instructions and specifications for the Mercury Mariner 40 4-Stroke outboard motor, covering model years 1999 through 2003. The manual is designed to be an essential resource for mechanics and technicians who need to perform maintenance, repairs, and troubleshooting on these engines. It includes a wide range of technical information, such as: * **Detailed Engine Disassembly and Assembly Procedures:** The manual guides you step-by-step through the process of taking apart and reassembling the engine, covering everything from removing the engine cover to rebuilding the powerhead. * **Complete Electrical System Diagrams:** Understand the intricate wiring and electrical components of the engine with clear and comprehensive diagrams, simplifying troubleshooting and repair. * **Troubleshooting Charts and Diagnostic Tables:** Quickly and effectively identify potential problems by using the detailed troubleshooting charts and tables that provide specific solutions for common issues. * **Extensive Parts Lists and Diagrams:** Locate and identify specific parts easily with the comprehensive parts lists and detailed diagrams that show the exact location of each component. * **Torque Specifications and Technical Data:** Ensure proper assembly and prevent damage with accurate torque specifications and essential technical data for all engine components. This manual is your go-to reference for maintaining and repairing your Mercury Mariner 40 4-Stroke outboard motor, empowering you to perform professional-level service and ensure optimal performance.

The Mercury Mariner 40, a 40-horsepower outboard motor manufactured by Mercury Marine from 1999 to 2003, was a popular choice for small to medium-sized boats. This lightweight and relatively compact motor boasted a two-cylinder, four-stroke engine, offering a balance of power and fuel efficiency. It featured a single-cylinder design with a displacement of 675cc, capable of reaching a maximum speed of 4,500 RPM. The Mariner 40 was known for its smooth and quiet operation, making it suitable for a variety of recreational boating activities, such as fishing, waterskiing, and cruising. Notably, it was praised for its reliability and ease of maintenance. The Mercury Mariner 40 came equipped with various features that enhanced its performance and usability. These included a pull-start system for easy ignition, a single-lever throttle and shift control for intuitive operation, and a remote steering option for greater maneuverability. It also boasted a built-in tilt mechanism for convenient storage and transport. The Mariner 40 was available with both short and long shaft options, catering to different hull configurations and boat sizes. Furthermore, its robust construction and durable components made it suitable for both freshwater and saltwater environments. While discontinued, the Mercury Mariner 40 remains a sought-after motor, thanks to its reliable performance and robust design, offering a perfect balance of power and efficiency for recreational boating enthusiasts.