Mercury 4 TwoStroke Operation, Maintenance And Installation Manual
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Mercury 4 TwoStroke Operation, Maintenance And Installation Manual

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  • Page 1 Operation Maintenance Installation Manual...
  • Page 3 Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant! Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Name / function: John Pfeifer, President, Mercury Marine...
  • Page 4 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Manual included with the product. The Warranty Manual contains a description of what is...
  • Page 5 Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, GO BOLDLY., Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury...
  • Page 7 General Information Boater's Responsibilities..................1 Before Operating Your Outboard................ 1 Boat Horsepower Capacity................. 1 Lanyard Stop Switch................... 2 Protecting People in the Water................5 Exhaust Emissions..................... 5 Selecting Accessories for Your Outboard............7 Safe Boating Recommendations................ 7 Recording Serial Number................. 10 Model Year Production Code................
  • Page 8 Operation Prestarting Check List..................30 Operating in Freezing Temperatures..............30 Operating at High Elevations................30 Operating in Saltwater or Polluted Water............30 Engine Break‑in Procedure................31 Warming Up the Engine..................31 Starting the Engine................... 32 Gear Shifting..................... 36 Stopping the Engine..................36 Maintenance Outboard Care....................
  • Page 9 Owner Service Assistance Local Repair Service..................51 Service Away from Home................. 51 Parts and Accessories Inquiries............... 51 Service Assistance................... 51 Mercury Marine Service Offices................ 51 Maintenance Log Maintenance Log....................53 Accessories Optional Accessories..................54 Wiring Diagram....................56 Wire Color Code Abbreviations................ 57 Tool Kit and Spare Parts...................
  • Page 10 viii...

  • Page 11: Boater's Responsibilities

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

  • Page 12: Lanyard Stop Switch

    GENERAL INFORMATION Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. U.S.
  • Page 13 GENERAL INFORMATION The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.
  • Page 14 GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle.

  • Page 15: Protecting People In The Water

    GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
  • Page 16 GENERAL INFORMATION WARNING Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide. Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway. STAY CLEAR OF EXHAUST AREAS 41127 Engine exhaust gases contain harmful carbon monoxide.

  • Page 17: 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 18 GENERAL INFORMATION • We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For more information in the U.S., call the Boat U.S.
  • Page 19 (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.

  • Page 20: Recording Serial Number

    GENERAL INFORMATION • Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 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...
  • Page 21 GENERAL INFORMATION Model Year Manufactured Code Alpha Production Code Corresponding Number Examples: • XX = 2000 • HK = 2089 • AG = 2017...

  • Page 22: Component Identification—4C/4.9/5Bd

    GENERAL INFORMATION Component Identification—4C/4.9/5BD 41059...

  • Page 23: Specifications

    GENERAL INFORMATION Air vent screw Fuel tank cap Tilt handle Upper motor cover Lower motor cover Water pump indicator port Tilt lever Steering friction adjustment screw Anode 10 - Anti‑ventilation plate 11 - Water inlet 12 - Propeller 13 - Starter handle 14 - Shift lever...
  • Page 24 Engine oil 1:50 (Engine oil:fuel) mixing ratio Starting Manual starter system Ignition Flywheel magneto CDI system Spark plug NGK BPR7HS‑10 Trim position Mercury/Quicksilver gear oil or API GLS, SAE #80 to #90, Gear oil approximately 195 mL (6.6 fl oz)
  • Page 25 GENERAL INFORMATION Models 5B‑D Fuel tank 2.5 L 2.5 L 2.5 L (0.66 US gal), capacity (0.66 US gal) (0.66 US gal) 12 L (3.17 US gal)* Gear 2.15 (13:28) reduction ratio * In case of dual fuel tank system, use together with 12 L separate tank.

  • Page 26: Installing Outboard

    INSTALLATION Installing Outboard INSTALLING OUTBOARD ON TRANSOM IMPORTANT: Most boats are rated and certified in terms of their maximum horsepower, and this is shown on the boat's certification plate. Do not equip your boat with an outboard that exceeds this limit. If in doubt, contact your dealer.
  • Page 27 INSTALLATION ATTACH THE ENGINE TO THE BOAT 1. Tighten the clamp screws by turning the handles. Secure with a cable to prevent accidental loss overboard. Clamp screw 42041...

  • Page 28: Removing The Motor

    TRANSPORTING Removing the Motor IMPORTANT: Ensure the proper procedures are followed for transportation and storage of the outboard to avoid the possibility of oil leaks. 1. Stop the engine and close the air vent screw. 2. Close the fuel valve knob. Disconnect the fuel connector. 3.

  • Page 29: Trailering The Boat

    TRANSPORTING 2. Lay the outboard down on its back side so the tiller handle is facing up as shown. Place a protective pad under the outboard. 40803 3. Close the fuel tank vent. Trailering the Boat IMPORTANT: The tilt lock mechanism is not intended to support the outboard in the tilted up position when trailering.
  • Page 30 TRANSPORTING NOTE: The tilt support device supplied on your outboard is not intended for towing. It is intended to support the engine while the boat is docked, beached, etc.

  • Page 31: Fuel Requirements

    USA is alcohol (ethanol, methanol, or butanol). GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 32: Oil Recommendation

    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 33: Engine Break‑In

    FUEL AND OIL Engine Break‑In Engine Break‑In Fuel Mixture Use a 1:25 oil/gasoline mixture in the first tank of fuel. Engine Break‑In Procedure Refer to Operation ‑ Engine Break‑In Procedure for correct break‑in procedure. Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks.

  • Page 34: Remote Control Features

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with the remote control shown. If not, consult your dealer for a description of the functions and operations of the remote control. 37982 Remote control handle Throttle only lever Ignition key switch Lanyard stop switch Throttle grip friction knob: The throttle friction can be adjusted in accordance...
  • Page 35 FEATURES AND CONTROLS Choke knob: Pull completely out when starting a cold engine. Push halfway in as engine is warming up. Push in completely after engine is warmed up. 38349 Steering friction adjustment: The steering friction can be adjusted in accordance with your preference by turning the adjustment screw.

  • Page 36: Tilting Outboard

    FEATURES AND CONTROLS Tilting Outboard TILTING TO FULL UP POSITION 1. Stop the engine. Shift the outboard into Forward (F) gear. 2. Take hold of the top cowl grip and raise outboard to the full up position. 27023 3. Then slightly lower the motor for locking at tilt‑up position. Tilt up position Tilt stopper Tilt lever...

  • Page 37: Shallow Water Operation

    FEATURES AND CONTROLS 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 1. Reduce engine speed to idle in forward gear. Take hold of the top cowl grip and raise outboard to the higher tilt position.

  • Page 38: Trim Angle Adjustment

    FEATURES AND CONTROLS 3. To release outboard back down to run position, tilt outboard up slightly (approximately 15°), then pull up on the tilt release lever. Gently lower outboard down to the normal running position. Tilt lever Tilt stopper 41066 Please follow the instructions below.
  • Page 39 FEATURES AND CONTROLS • Trim up: If the trim angle is too small, the bow will enter the water, the speed will decrease, and water may enter the boat. In this case, the trim angle should be increased by setting the trim position pin in a higher position.

  • Page 40: Prestarting Check List

    OPERATION Prestarting Check List • Operator knows safe navigation, boating, and operating procedures. • An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). • A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.

  • Page 41: Engine Break‑In Procedure

    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 42: Starting The Engine

    OPERATION Engine speed: Idling speed after warming up. In Gear In Neutral 850 RPM 1000 RPM Starting the Engine Before starting, read the Prestarting Check List, special operating instructions, and Engine Break‑In Procedure in this section. IMPORTANT: Be sure to connect the emergency lanyard to your waist or clothing.
  • Page 43 OPERATION 19748 3. Attach the fuel connector to the engine connector. 42043 4. The arrow mark on the primer bulb should be facing the engine (separate fuel tank). 5. Open the fuel valve (internal fuel tank). Air vent screw Fuel valve 41834 6.
  • Page 44 OPERATION 7. Move gear shift lever to neutral (N) position. Be sure that the shift lever is in neutral (N) when starting the engine. This model is provided with a function that prevents starting in gear. 27020 NOTE: If the motor somehow does start in gear, do not operate it. Contact your authorized dealer.
  • Page 45 OPERATION 10. Pull the starter rope slowly until you feel the starter engage, then pull rapidly to crank the engine. Allow the rope to return slowly. Repeat until the engine starts. 28840 NOTE: Starting flooded engine ‑ push in the choke knob. Wait 30 seconds, then continue to crank engine for starting.

  • Page 46: 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. NOTE: Personal injury and/or equipment damage may occur if shifting at high speed. Engine must be in the slow running position before shifting is attempted. NOTE: Do not increase engine speed more than necessary in reverse.

  • Page 47: Outboard Care

    Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. Inspection and Maintenance Schedule DAILY CHECKS •...

  • Page 48: Flushing The Cooling System

    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. 1. Remove the water plug from the motor, and install in the flushing attachment (hose adapter).

  • Page 49: Top Cowl Removal And Installation

    MAINTENANCE Top Cowl Removal And Installation REMOVAL 1. Unlock the rear latch by pushing lever down. 27084 2. Lift rear of cowl and disengage front hook. 27091 INSTALLATION 1. Engage the front hook and push cowl back over the cowl seal. 2.

  • Page 50: Exterior Care

    MAINTENANCE Exterior Care Your outboard is protected with a durable baked enamel finish. Clean and wax often using marine cleaners and waxes. Fuel System WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.

  • Page 51: Propeller Replacement

    MAINTENANCE • If there is water or dirt inside, replace the filter. Install the filter in the same orientation as it was removed. Fuel filter 41074 • For external tanks, loosen the fuel pickup elbow, remove it and clean the fuel filter.
  • Page 52 6. Apply Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE to the entire propeller shaft and splines. 27095...

  • Page 53: Propeller Selection

    MAINTENANCE 8. Place a block of wood between the gearcase and the propeller to prevent rotation and tighten the propeller nut. Secure the propeller nut to the shaft with a cotter pin. Cotter pin Propeller nut Rear thrust hub Propeller Front thrust washer 27094 Propeller Selection...

  • Page 54: Lubrication Points

    Install plug finger tight, and then tighten 1/4 turn or torque to specifications. Description lb‑in. lb‑ft Spark plug – Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE. Tube Ref Description Where Used Part No. Co-pilot threads, swivel bracket, 2-4-C with PTFE...
  • Page 55 MAINTENANCE • Swivel Bracket ‑ Lubricate through fittings. Co‑pilot Swivel bracket 28862 • Transom Clamp Screws ‑ Lubricate threads. 27097 NOTE: Lubricating the tiller handle bushing and shift handle detent requires disassembly of the product. These points should be lubricated at least once a year by an authorized dealer.

  • Page 56: Gearcase Lubrication

    MAINTENANCE • Tilt Pivot. 28863 3. Lubricate the following with Quicksilver or Mercury Precision Lubricants Extreme Grease or 2‑4‑C with PTFE. Tube Ref Description Where Used Part No. 2-4-C with PTFE Propeller shaft 92-802859A 1 Extreme Grease Propeller shaft 8M0071842 •...
  • Page 57 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 195 cc (6.6 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHANGING GEAR OIL 1. Place outboard in a vertical operating position. 2. Remove the oil drain plugs (upper and lower), and completely drain the gear oil into a pan.

  • Page 58: Submerged Outboard

    4. Replace the oil plug gasket with a new one. Install the upper oil plug, and then remove oil tube nozzle and install the lower oil plug. NOTE: Use Mercury or Quicksilver gear oil or the recommended gear oil (API GL‑5:SAE #80 to #90). Required volume: approx. 195 mL...

  • Page 59: Storage Preparation

    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). Tube Ref Description Where Used Part No.

  • Page 60: Gearcase

    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 61: Local Repair Service

    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 62: Owner Service Assistance

    Miramar, FL 33025 (954) 744‑3535 U.S.A. Japan Telephone 072‑233‑8888 Kisaka Co., Ltd. 4-130 Kannabecho Sakai-shi Sakai-ku 5900984 Osaka, 072‑233‑8833 Japan Asia, Singapore Telephone (65) 65466160 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive (65) 65467789 Singapore, 508944...

  • Page 63: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

  • Page 64: Optional Accessories

    ACCESSORIES Optional Accessories 41075...
  • Page 65 ACCESSORIES Alternator (12 V, 60 W) Extension cord for light (Lights are available on the market.) Rectifier Gear oil (500 mL) Flushing attachment Grease (250 g) Vertical starter Remote control box Touch up paint (300 mL) Engine oil (0.4 L, 1 L, 4 L, 20 L)

  • Page 66: Wiring Diagram

    ACCESSORIES Wiring Diagram 41076...

  • Page 67: Wire Color Code Abbreviations

    ACCESSORIES Battery Extension cord (optional) Rectifier (optional) Light extension cord (optional) Lighting unit (optional) Pulser coil CD unit Ignition coil Spark plug Stop switch (optional) Grommet Secondary stop switch Wire Color Code Abbreviations Wire Color Abbreviations Black Blue Brown Gray Green ORN or ORG Orange...

  • Page 68: Propeller Recommendation

    Primer bulb 1set 5B‑D only Propeller Recommendation Use Mercury/Quicksilver propeller. A propeller must be selected so that the engine RPM measured at wide‑open throttle while cruising is within the recommended range: 4500–5500 RPM. Light boats ‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑ Heavy boats Size as indicated on propeller...

This manual is also suitable for:

4.9 twostroke5 twostroke

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