Mercury 4 4-Stroke Manual
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Mercury 4 4-Stroke Manual

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Welcome Aboard!
Proper care and maintenance is an important part in keeping your Mercury Product operating at peak
efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key
to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty
coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose? Please check on www.marinepower.com. If
necessary, please contact your local dealer.
If the outboard motor's serial number plate contains the CE mark in the lower left-hand corner, the
following statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe
Inc. Park Industrel, de Petit-Rechain, Belgium complies with the requirements of the following directives
and standards, as amended:
Recreational Craft Directive: 94/25/EC; std. ISO 8665, ISO 11547
Machinery Directive:
EMC Directive:
Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Product Environmental Engineering Department, Mercury Marine, Fond du Lac, WI USA
98/37/EC,
89/336/EC; std. EN50081-1, SAE J551 (CISPR Pub. 12),
EN 50082-1, IEC 61000 PT4-2, IEC 61000 PT4-3
i

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Summary of Contents for Mercury 4 4-Stroke

  • Page 1 Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.

  • Page 2: Table Of Contents

    Warranty Registration Outside The United States And Canada................1 Mercury Marine Two Years Limited Warranty (Europe)..................2 Mercury Marine One Year Limited Warranty (Confederation of Independent States, Middle-East, Africa).... 3 3 Year Limited Warranty Against Corrosion......................5 Warranty Coverage And Exclusions........................6 GENERAL INFORMATION Boater's Responsibilities............................
  • Page 3 Protecting External Outboard Components......................43 Protecting Internal Engine Components....................... 43 Gearcase................................43 Positioning Outboard For Storage........................43 OWNER SERVICE ASSISTANCE Local Repair Service............................45 Service Away From Home............................ 45 Parts And Accessories Inquiries........................... 45 Service Assistance............................... 45 Mercury Marine Service Offices........................... 45...

  • Page 5: Warranty Information

    Warranty Registration United States And Canada You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 6: Mercury Marine Two Years Limited Warranty (Europe)

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 7: Mercury Marine One Year Limited Warranty (Confederation Of Independent States, Middle-East, Africa)

    No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine.
  • Page 8 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related laborand material, and any other expenses associated with that service.

  • Page 9: Year Limited Warranty Against Corrosion

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 10: Warranty Coverage And Exclusions

    Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti-fouling paints is also not covered by this limited warranty.
  • Page 11 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 12: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard.

  • Page 13: Lanyard Stop Switch

    GENERAL INFORMATION U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY ob00306 Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch.

  • Page 14: Protecting People In The Water

    GENERAL INFORMATION We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (e.g. if the operator is accidentally ejected). WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation.
  • Page 15 GENERAL INFORMATION WARNING Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness, brain damage, or death. GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. ob00316 Example of desired air flow through the boat.

  • Page 16: Selecting Accessories For Your Outboard

    Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.

  • Page 17: 4/5/6 4-Stroke Specifications - International

    GENERAL INFORMATION XXXXXXXX XXXX XXXX ob00444 Serial number Year manufactured Model year Certified Europe Insignia (As applicable) Model designation 4/5/6 4-stroke Specifications - International Models Horsepower Kilowatts 2.98 3.73 4.47 Full Throttle RPM Range 4500-5500 5000-6000 Idle Speed in Forward Gear 1100 RPM in Gear 1300 RPM in Neutral Number of Cylinders Piston Displacement...

  • Page 18: Installation

    INSTALLATION Installing Outboard BOAT TRANSOM HEIGHT REQUIREMENT Measure the transom height of your boat. The anti-ventilation plate should be 25 - 50 mm (1 - 2 in.) below the bottom of the boat. ob00445 Anti-ventilation plate INSTALLING OUTBOARD ON TRANSOM Place outboard on center line of transom.

  • Page 19: Transporting

    TRANSPORTING Carrying, Storing and Transporting Your Outboard When Removed From Boat Internal fuel tank models - With the outboard still in the water, close the fuel valve and run engine until it stops. This will drain fuel from the carburetor. Close the fuel tank vent after engine has stopped. ob00449 Fuel valve Fuel tank vent...

  • Page 20: Trailering Your Boat

    TRANSPORTING Trailering Your Boat IMPORTANT: The tilt lock mechanism is not intended to support the outboard in the tilted up position when trailering your boat. Use of the tilt lock mechanism could allow the outboard to bounce and drop down causing damage to the outboard.

  • Page 21: Fuel & Oil

    (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenates that is used in the gasoline, refer to Alcohol in Gasoline. These reformulated fuels are acceptable for use in the Mercury engine. ALCOHOL IN GASOLINE We do not recommend the use of gasoline which contains alcohol because of the possible adverse effect the alcohol may have on the fuel system.

  • Page 22: Engine Oil Recommendations

    FUEL & OIL Engine Oil Recommendations We recommend the use of Mercury or Quicksilver SAE 10W-30 multi-viscosity 4-Stroke Outboard Oil for general, all-temperature use. If SAE 25W-40 multi-viscosity oil is preferred, use Mercury MerCruiser 4-cycle engine oil or Quicksilver sterndrive & inboard 4-cycle engine oil. Never use 4-cycle engine oil that is not certified to meet or exceed any one or combination of the following American Petroleum Institute (API) Service Classification SH, SG, SF, CF-4, CE, CD, CDII.
  • Page 23 FUEL & OIL Reinstall the oil filler cap and tighten securely. ob00455 Full mark Add mark...

  • Page 24: Features & Controls

    FEATURES & CONTROLS Features & Controls Fuel Shut-Off Valve (4 Hp Models) - Turn valve up to close or down to open. If an optional remote fuel tank is used, turn valve up when using the remote fuel tank. Turn valve down when using the internal fuel tank. ob00456 Choke Knob - Pull completely out when starting a cold engine.
  • Page 25 FEATURES & CONTROLS Oil Pressure Indicator - If oil pressure drops too low, the oil pressure indicator light will turn on. If the oil pressure indicator light turns on while the engine is running, stop the engine as soon as possible. Check oil level and add oil as needed.

  • Page 26: Tilting Outboard

    FEATURES & CONTROLS ob00463 Tilting Outboard TILTING TO FULL UP POSITION Stop the engine. Shift the outboard into forward gear. Take hold of the top cowl grip and raise outboard to the full up position. ob00464 The spring loaded tilt lock lever will engage automatically and lock the outboard in full up position. LOWERING TO RUN POSITION Raise the outboard and pull up on the tilt release lever.

  • Page 27: Setting The Operating Angle Of Your Outboard

    FEATURES & CONTROLS ENGAGING SHALLOW WATER DRIVE Reduce engine speed to idle in forward gear. Take hold of the top cowl grip and raise outboard to the higher tilt position. The spring loaded tilt lock lever will engage automatically and lock the outboard in the shallow water drive position.

  • Page 28: Engine Over-Speed Protection System

    FEATURES & CONTROLS The tilt pin should be adjusted so the outboard is positioned to run perpendicular to the water when the boat is running at full speed. This allows the boat to be driven parallel to the water. Arrange passengers and load in the boat so the weight is distributed evenly. ob00468 Engine Over-Speed Protection System The engine over-speed protection system is activated if the engine speed should exceed the maximum allowable...

  • Page 29: Operation

    Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.
  • Page 30 OPERATION CAUTION Never start or operate your outboard (even momentarily) without water circulating through all the cooling water intake holes in the gearcase to prevent damage to the water pump (running dry) or overheating of the engine. Make sure the cooling water intake is submerged. ob00469 Check the engine oil level.
  • Page 31 OPERATION ob00473 Move the fuel shut-off valve to the lower position. ob00474 Starting models with remote fuel tank Connect the remote fuel line to the outboard. Make sure connector is snapped into place. ob00475 Open fuel tank vent on manual venting type tanks. ob00348 4 Hp Models with optional remote fuel tank - Move the fuel valve to the up position.
  • Page 32 OPERATION ob00477 If engine is cold, completely pull out the choke. Push in the choke halfway as the engine is warming up. Push in completely after engine is warmed up. ob00478 NOTE: Starting Flooded Engine - Push in the choke knob. Wait 30 seconds, then continue to crank engine for starting.

  • Page 33: Gear Shifting

    OPERATION Gear Shifting Your outboard has three gear shift positions to provide operation: Forward (F), Neutral (N), and Reverse (R). Reduce throttle speed to idle speed. Always shift outboard into gear with a quick motion. ob00461 Stopping The Engine Reduce engine speed and push in the stop switch or pull the lanyard. ob00480 Emergency Starting If the starter rope should break or the rewind starter fails, use the spare starter rope (provided) and follow this...
  • Page 34 OPERATION Disconnect linkage from rewind starter assembly. ob00481 Remove three bolts and rewind starter assembly. ob00482 WARNING To prevent getting an electrical shock, do not touch any ignition component, wiring, or spark plug wire when starting or running the engine. WARNING The exposed moving flywheel can cause serious injury.
  • Page 35 OPERATION Pull the starter rope to start the engine. ob00483...

  • Page 36: Maintenance

    SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 37: Inspection And Maintenance Schedule

    Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. NOTE: Do not run the engine while flushing the cooling system.

  • Page 38: Top Cowl Removal And Installation

    MAINTENANCE ob00484 Gasket Thread-in hose coupling Top Cowl Removal And Installation REMOVAL Unlock the rear latch by pushing lever down. ob00485 Lift rear of cowl and disengage front hook. ob00486 INSTALLATION Engage the front hook and push cowl back over the cowl seal. Push cowl down and move the rear latch lever up to lock.

  • Page 39: Exterior Care

    MAINTENANCE ob00487 Exterior Care Your outboard is protected with a durable baked enamel finish. Clean and wax often using marine cleaners and waxes. Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and do not smoke or allow open flames or sparks in the area while servicing any part of the fuel system.

  • Page 40: Propeller Replacement

    Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon.

  • Page 41: Spark Plug Inspection And Replacement

    MAINTENANCE Place a block of wood between gearcase and propeller to prevent rotation and tighten propeller nut. Secure propeller nut to the shaft with cotter pin. ob00489 Cotter pin Propeller Propeller nut Front thrust washer Rear thrust hub Spark Plug Inspection And Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots.

  • Page 42: Lubrication Points

    1/4 turn or torque to specifications. Description lb. in. lb. ft. Spark plug Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. • Co-Pilot - Lubricate threads. • Swivel Bracket - Lubricate through fittings.

  • Page 43: Changing Engine Oil

    Lubricate the following with Light Weight Oil. • Tilt Pivot. ob00495 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon. • Propeller Shaft - Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding to the shaft.

  • Page 44: Gearcase Lubrication

    MAINTENANCE IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil contaminated with fuel will have a stong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer.
  • Page 45 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 195 ml (6.6 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE Place outboard in a vertical operating position. Remove vent plug from vent hole.

  • Page 46: Submerged Outboard

    MAINTENANCE Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.

  • Page 47: Storage

    Lubricate all outboard components listed in Maintenance - Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch-up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Protecting Internal Engine Components •...
  • Page 48 STORAGE ob00499 Upright Tiller Side Down Never carry, store or transport the outboard in the positions shown below. Engine damage could result from oil draining out of the crankcase. ob00453...

  • Page 49: Owner Service Assistance

    Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your outboard product, contact your dealer or any authorized Mercury Marine dealership. If additional assistance is required, take these steps.
  • Page 50 Telephone (954) 744-3513 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744-3535 U.S.A. Japan Telephone 81-053-423-2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81-053-423-2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way...

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5 4-stroke6 4-stroke

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