SOURCE: 1994 40 hp mercury force outboard with no spark
If the fuel was not treated with a fuel stabilizer than you probably have a varnish build up in the carburetor. This varnish will clog fuel needle valves and jets. You need to disassemble the carb to clean the jets and needle valves. Sometimes cleaner is not enough you need to us compressed air to blow out the jets. Good luck.
SOURCE: impeller replacing on 1999 merc. 25hp 2 stroke
Should not be that hard. Tape up the ends so you can hold it with out getting cut, (if its ragged or sharp from damage). should be one nut holding the impeller on. If its to tight to hold try air or electric Impact wrench. If its bad you can tap with a hammer to help in removing the old one. If it turned on the shaft you will need to rent a puller. Repost if you need more help.
SOURCE: Re-assembling lower unit of 40HP Mercury 4 stroke
I found a lower gear case assembly diagram at http://www.crowleymarine.com/mercury_parts/6995/240.cfm which helped me understand how the shift mechanism works. This clued me in to the fact that I was missing the cam follower rod which I then found I had inadvertently mopped up in a shop towel when cleaning up spilled gear oil. After that discovery, assembly and operation was quick and successful.
SOURCE: I have a 2008 25
I have one of these tilters and it's on a 2009 25Merc. I had to modify it because the pull handle is located lower on the back of motor.
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