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Mercury 4 Manual

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See also: Operation & Maintenance Manual , User Manual
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
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Summary of Contents for Mercury 4

  • 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......................42 Protecting Internal Engine Components....................... 42 Gearcase................................42 Positioning Outboard For Storage........................42 Owner Service Assistance Local Repair Service............................43 Service Away From Home............................ 43 Parts And Accessories Inquiries........................... 43 Service Assistance............................... 43 Mercury Marine Service Offices........................... 43...

  • 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

    - generally on the dashboard or side adjacent to the operator's position. The lanyard is a cord usually between 1220 and 1524 mm (4 and 5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.

  • 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

    1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00 or 4) there is complete loss of the boat.

  • Page 17: 4/5 Specifications

    XXXXXXXX XXXX XXXX ob00444 Serial number Year manufactured Model year Certified Europe Insignia (As applicable) Model designation 4/5 Specifications Models Horsepower Kilowatts 2.98 3.73 Full Throttle RPM Range 4500-5500 Idle Speed 850 RPM in Gear - 1000 RPM in Neutral...

  • 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 Outboard The outboard has a carrying handle located in front. ob01051 Transporting Outboard When Removed From Boat CAUTION Transport and store the outboard only as shown. Otherwise, engine damage or property damage could result from leaking oil. With the outboard still in the water, close the fuel shut-off valve or disconnect the remote fuel line (if equipped) and run engine until it stops.
  • Page 20 TRANSPORTING Set the gear shift into forward gear. This prevents the propeller from spinning freely. ob01053...

  • Page 21: Fuel And Oil

    IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil. Mercury or Quicksilver Premium TC-W3 2-Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC-W3 2-Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2-cycle outboard oil that is NMMA Certified TC-W3.

  • Page 22: Filling Fuel Tank

    GASOLINE/OIL MIXING RATIO CHART Gas/Oil Ratio 3.8 liters (1 gal.) gas 11.5 liters (3 gal.) gas 23 liters (6 gal.) gas 25:1 (4%) 148 ml (5 fl. oz.) oil 473 ml (16 fl. oz.) oil 946 ml (32 fl. oz.) oil 50:1 (2%) 89 ml (3 fl.

  • Page 23: Features And Controls

    FEATURES AND CONTROLS Features & Controls Throttle Grip Friction Knob - Turn friction knob to set and maintain the throttle at desired speed. Turn knob up to tighten friction and down to loosen friction. ob00458 Direction to tighten friction Direction to loosen friction Choke Knob - Pull completely out when starting a cold engine.
  • Page 24 FEATURES AND CONTROLS ob01271 Side Handle Gear Shift - Controls gear shift. ob01272 Engine Stop Switch/Lanyard Stop Switch - Push in or pull lanyard to stop engine. The engine will not start unless the lanyard is engaged with the stop switch. Lanyard - Read the Lanyard Stop Switch safety explanation and Warning in the General Information section.

  • Page 25: Tilting Outboard

    FEATURES AND CONTROLS ob01275 Yellow/red alternator leads IMPORTANT: If the battery charging alternator feature is not being used, disconnect the two yellow/red alternator leads located on the side of the engine. Any accessories such as lights, horns, etc., should be properly fused and installed with connections attached directly to the battery terminals.

  • Page 26: Shallow Water Operation

    FEATURES AND CONTROLS ob00465 Tilt release lever Tilt lock lever Shallow Water Operation This outboard has a shallow water drive position. This will allow you to tilt the outboard to a higher position to prevent hitting bottom. ENGAGING SHALLOW WATER DRIVE Reduce engine speed to idle in forward gear.

  • Page 27: Setting The Operating Angle Of Your Outboard

    FEATURES AND CONTROLS ob00465 Tilt release lever Tilt lock lever Setting The Operating Angle Of Your Outboard The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin in the adjustment holes provided. Proper adjustment allows the boat to achieve optimum performance, stability, and minimize steering effort.

  • Page 28: Pre-Starting Check List

    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 29: Starting The Engine

    OPERATION BREAK-IN PROCEDURE Vary the throttle setting during the first hour of operation. During the first hour of operation, avoid remaining at a constant speed for more than two minutes and avoid sustained wide open throttle. Starting the Engine Before starting, read the Pre-Starting Check List, Special Operating Instructions, and Engine Break-in Procedure in the Operation Section.
  • Page 30 OPERATION ob01277 Squeeze the fuel line primer bulb several times until it feels firm. ob00349 STARTING THE ENGINE Lower the outboard to the run position. Make sure the cooling water intake is submerged. 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.
  • Page 31 OPERATION ob01269 Move the throttle grip to the start position. ob01279 Move gear shift lever to neutral position. ob00461 Pull the starter rope slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow rope to return slowly. Repeat until engine starts. ob01274 NOTE: Starting Flooded Engine - Push in the choke knob.

  • Page 32: Gear Shifting

    OPERATION IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These conditions will cause the engine to overheat. Have the outboard checked by a dealer. Operating the engine while overheated may cause serious engine damage.
  • Page 33 OPERATION ob01278 NOTE: The engine will not start unless the lanyard is engaged with the stop switch. Disconnect linkage from rewind starter assembly. ob01282 Remove three bolts and rewind starter assembly. ob01283 WARNING To prevent getting an electrical shock, do not touch any ignition component, wiring, or spark plug wire when starting or running the engine.
  • Page 34 OPERATION Pull the starter rope to start the engine. ob01284...

  • Page 35: 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 36: 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 37: Top Cowl Removal And Installation

    MAINTENANCE ob01285 Plug and gasket 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 38: Exterior Care

    MAINTENANCE The anode requires periodic inspection especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. ob00487 Exterior Care Your outboard is protected with a durable baked enamel finish.

  • Page 39: Propeller Replacement

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

  • Page 40: 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 41: Carburetor Adjustments

    Spark Plug Spark plug gap 1.0 mm (0.040 in.) Before installing spark plug, clean off any dirt on the spark plug seat. Install plug finger tight, and then tighten 1/4 turn or torque to specifications. Description lb. in. lb. ft.

  • Page 42: Lubrication Points

    The carburetor is equipped with a standard size high speed fixed jet that is replaceable for operation at higher elevations. Lubrication Points Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. • Co-Pilot - Lubricate threads.

  • Page 43: Gearcase Lubrication

    Lubricate the following with Light Weight Oil. • Tilt Pivot. ob01291 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 LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 200 ml (6.8 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 45: Submerged Outboard

    MAINTENANCE IMPORTANT: Replace sealing washers if damaged. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 46: Storage

    • With engine running at fast idle, stop the fuel flow by closing the fuel shut-off valve. When engine begins to stall, quickly spray Quicksilver or Mercury Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel.

  • Page 47: 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 48 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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