Mercury 4 FourStroke Manual
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Mercury 4 FourStroke Manual

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Thank You
for your purchase of one of the finest outboards available.
You have made a sound investment in boating pleasure.
Your outboard has been manufactured by Mercury Marine, a
world leader in marine technology and outboard
manufacturing since 1939. These years of experience have
been committed to the goal of producing the finest quality
products. This led to Mercury Marine's reputation for strict
quality control, excellence, durability, lasting performance,
and being the best at providing after the sale support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in
the operation, safe use, and care of your outboard.
All of us at Mercury Marine took pride in building your
outboard and wish you many years of happy and safe
boating.
Again, thank you for your confidence in Mercury Marine.
EPA Emissions Regulations
Outboards sold by Mercury Marine in the United States are
certified to the United States Environmental Protection
Agency as conforming to the requirements of the regulations
for the control of air pollution from new outboard motors.
This certification is contingent on certain adjustments being
set to factory standards. For this reason, the factory
procedure for servicing the product must be strictly followed
and, wherever practicable, returned to the original intent of
the design. Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any marine engine repair establishment or
individual.
Engines are labeled with an Emission Control Information
decal as permanent evidence of EPA certification.
The engine exhaust from this product contains chemicals
known to the state of California to cause cancer, birth
defects or other reproductive harm.
eng
WARNING
!
i

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  • Page 1 This manual has been prepared to assist you in the operation, safe use, and care of your outboard. All of us at Mercury Marine took pride in building your outboard and wish you many years of happy and safe boating.
  • Page 2 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 Information section of this manual. The warranty statement contains a description of what is covered, what is not...
  • Page 3 Declaration of Conformity ‑ For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC Name of engine manufacturer: Tohatsu Marine Corporation (TMC) Mercury Marine Joint Venture Address: Shimodaira 4495‑9 Town: Komagane‑City, Post Code: 399‑4101...
  • Page 4 Conformity assessment ☐ B ☐ B ☐ B ☐ B ☐ G ☒ H module used for exhaust emissions: ☐ Stage II of ☐ Directive or engine type approved according to: Directive 97/68/EC 88/77/EC Conformity assessment ☐ A ☐ Aa ☐...
  • Page 5 I declare on behalf of the engine manufacturer that the engines mentioned preceding complies with all applicable essential requirements in the way specified. Name / function: Mark D. Schwabero, President, Mercury Outboard Date and place of issue: July 24, 2008 Fond du Lac, Wisconsin, USA...

  • Page 7: Table Of Contents

    WARRANTY INFORMATION Warranty Registration..............1 Transfer of Warranty..............2 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada......... 2 FourStroke Outboard Limited Warranty........3 FourStroke Outboard Limited Warranty........7 FourStroke Outboard Limited Warranty........11 3 Year Limited Warranty Against Corrosion......15 Warranty Coverage and Exclusions..........
  • Page 8 Fuel Recommendations............. 43 Low Permeation Fuel Hose Requirement ......... 45 EPA Pressurized Portable Fuel Tank Requirements....45 Fuel Demand Valve (FDV) Requirement........45 Mercury Marine's Pressurized Portable Fuel Tank....46 Filling Fuel Tank................ 47 Engine Oil Recommendations........... 48 Checking Engine Oil..............49 FEATURES AND CONTROLS Features and Controls...............
  • Page 9 Protecting Internal Engine Components........84 Gearcase................... 84 Positioning Outboard for Storage..........84 OWNER SERVICE ASSISTANCE Local Repair Service..............86 Service Away from Home............86 Parts and Accessories Inquiries..........86 Service Assistance..............86 Mercury Marine Service Offices..........87 MAINTENANCE LOG Maintenance Log............... 89...

  • Page 11: Warranty Information

    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 12: Transfer Of Warranty

    To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address, and engine serial number to Mercury Marine’s warranty registration department. In the United States and...

  • Page 13: Fourstroke Outboard Limited Warranty

    Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee. Plan coverage is not transferable from one product to another product or for non‑eligible applications.
  • Page 14 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
  • Page 15 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.
  • Page 16 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...

  • Page 17: Fourstroke Outboard Limited Warranty

    EUROPE AND CONFEDERATION OF INDEPENDENT STATES Outside Europe and Confederation of Independent States ‑ check with local distributor. WHAT IS COVERED: Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below.
  • Page 18 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
  • Page 19 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.
  • Page 20 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...

  • Page 21: Fourstroke Outboard Limited Warranty

    RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. FourStroke Outboard Limited Warranty MIDDLE-EAST AND AFRICA WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below.
  • Page 22 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
  • Page 23 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.
  • Page 24 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 25: Year Limited Warranty Against Corrosion

    WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
  • Page 26 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.
  • Page 27 Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.

  • Page 28: Warranty Coverage And Exclusions

    WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited...
  • Page 29 8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. Oils, lubricants, or fluids changed as a matter of normal...

  • Page 30: U.s. Epa Emissions Limited Warranty

    U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides a five year or 175 hours of engine use, whichever occurs first, to the retail customer, that the engine is designed, built, and equipped so as to conform at...

  • Page 31: California Emissions Limited Warranty

    California, and which were manufactured for the 2001 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the components listed in the Emission Control System...
  • Page 32 Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below.
  • Page 33 Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury. WHAT MERCURY WILL DO: Mercury Marine's sole and...
  • Page 34 California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.

  • Page 35: California Air Resources Board Explanation Of Your California Emission Control Warranty Statement

    Also included may be hoses, belts, connectors, and other emission‑related assemblies. Where a warrantable condition exists, Mercury Marine will repair your outboard engine at no cost to you, including diagnosis, parts, and labor.

  • Page 36: Emission Certification Star Label

    WARRANTY INFORMATION As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications. You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists.
  • Page 37 WARRANTY INFORMATION Three Stars ‑ Ultra Low Emission The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust 42538 emission standards.

  • Page 38: 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 39: Boat Horsepower Capacity

    GENERAL INFORMATION Boat Horsepower Capacity WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating.
  • Page 40 GENERAL INFORMATION 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 41 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. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

  • Page 42: 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 43 GENERAL INFORMATION Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness, and nausea. WARNING Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide.

  • Page 44: Selecting Accessories For Your Outboard

    The misuse of approved accessories or the use of nonapproved accessories can damage the product. 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 45: Safe Boating Suggestions

    GENERAL INFORMATION Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. Use flotation devices. Have an approved personal flotation device of suitable size for each person aboard (it is the law) and have it readily accessible.
  • Page 46 GENERAL INFORMATION Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when operating the boat above idle speed.

  • Page 47: Recording Serial Number

    GENERAL INFORMATION Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard as shown. XXXXXXXX XXXX 45646 Serial number Model designation Year manufactured Certified Europe Insignia (as applicable) 4/5/6 Specifications Models Power 2.94 kw (4 hp) 3.68 kw (5 hp)
  • Page 48 GENERAL INFORMATION Models Gear ratio 2.15:1 Recommended gasoline Refer to Fuel and Oil Emission control system Engine modification (EM) Sound at drivers ear 82.2 (ICOMIA 39‑94) bBA Tiller handle vibration (ICOMIA 38‑94) m/s²...

  • Page 49: 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. Anti‑ventilation plate 27004 INSTALLING OUTBOARD ON TRANSOM 1. Place outboard on centerline of transom. 27005 2.

  • Page 50: Carrying, Storing, And Transporting Your Outboard When Removed From Boat

    TRANSPORTING Carrying, Storing, and Transporting Your Outboard When Removed from Boat 1. Remote fuel tank models ‑ Disconnect the remote fuel line. Install the protector cap over the fuel connector. 45604 Remote fuel line Protector cap 2. With the outboard still in the water, move the fuel valve to the "OFF"...

  • Page 51: Trailering Your Boat

    TRANSPORTING 4. Carry, transport, or store the outboard only in the upright position or tiller handle down position. These positions will prevent oil from draining out of the crankcase. Upright position Tiller handle down position 45595 NOTE: Never carry, store, or transport the outboard in these positions.
  • Page 52 TRANSPORTING Set the gear shift into forward gear. This prevents the propeller from spinning freely. 45597...

  • Page 53: Fuel And Oil

    FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R+M)/2 minimum.
  • Page 54 FUEL AND OIL The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 55: Low Permeation Fuel Hose Requirement

    FUEL AND OIL Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale, sold, or offered for sale in the United States. • The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009 must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard.

  • Page 56: Mercury Marine's Pressurized Portable Fuel Tank

    46273 Vent/water drain holes Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks are available as an accessory or are provided with certain portable outboard models.

  • Page 57: Filling Fuel Tank

    FUEL AND OIL REMOVING THE FUEL CAP Fuel cap Manual vent screw Tab lock 46290 IMPORTANT: Contents may be under pressure. Rotate the fuel cap 1/4 turn to relieve pressure before opening. 1. Open the manual vent screw on top of the fuel cap. 2.

  • Page 58: Engine Oil Recommendations

    Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions. Engine Oil Recommendations We recommend the use of Mercury or Quicksilver NMMA FC‑W certified 10W‑30 4‑Stroke Outboard Oil for general, all‑temperature use. If NMMA certified synthetic blend 25W‑40 4‑Stroke outboard oil is preferred, use Mercury or Quicksilver...

  • Page 59: Checking Engine Oil

    FUEL AND OIL IMPORTANT: The use of detergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality or oils that contain solid additives are not recommended.
  • Page 60 However, to ensure extended life of the outboard engine, Mercury recommends that the oil be changed regularly following the oil change interval and using the recommended oil quality. It is further recommended that if your outboard is operated frequently in the conditions described above, that more frequent oil change intervals be considered.

  • Page 61: Features And Controls

    FEATURES AND CONTROLS Features and Controls Fuel shut‑off valve for internal fuel tank ‑ 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.
  • Page 62 FEATURES AND CONTROLS Remote fuel tank connector ‑ For optional remote fuel tank. Choke knob Oil pressure indicator light Lanyard stop switch Remote fuel connector Lanyard 45613 Throttle grip friction knob ‑ Turn friction knob to set and maintain the throttle at desired speed. Turn knob clockwise to tighten friction or turn knob counterclockwise to loosen friction.

  • Page 63: Tilting Outboard

    FEATURES AND CONTROLS Steering friction adjustment ‑ Adjust this knob to achieve the desired steering friction (drag) on the tiller handle. Turn knob clockwise to tighten friction and counterclockwise to loosen friction. Loosen friction (counterclockwise) Tighten friction (clockwise) Steering friction knob 45615 Shift handle ‑...

  • Page 64: Shallow Water Operation

    FEATURES AND CONTROLS 2. Take hold of the top cowl grip and raise outboard to the full up position. 54600 3. 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 65 FEATURES AND CONTROLS 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. The spring loaded tilt lock lever will engage automatically and lock the outboard in the shallow water drive position.

  • Page 66: Setting The Operating Angle Of Your Outboard

    FEATURES AND CONTROLS 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 67: Operation

    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 68: Operating In Saltwater Or Polluted Water

    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 69 OPERATION NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 1. Ensure the cooling water intake is submerged. 27029 2.
  • Page 70 OPERATION 4. Attach the lanyard to the stop switch. Refer to General Information ‑ Lanyard Stop Switch. Lanyard Stop switch 45619 5. Starting procedure when using the internal fuel tank for fuel: a. Open the fuel cap vent on the internal fuel tank. b.
  • Page 71 OPERATION b. Move the fuel valve to the "OFF" (closed) position. 45605 Fuel valve "OFF" (closed) position Fuel cap vent c. Connect the remote fuel line to the outboard. d. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up.
  • Page 72 OPERATION • Cold engine ‑ Move to the START position. • Warm engine ‑ Move to the RE‑START position. RE-START Warm engine start START Cold engine start 45624 8. If engine is cold, completely pull out the choke. Push in the choke halfway as the engine is warming up.

  • Page 73: Gear Shifting

    OPERATION 10. Check for a steady stream of water flowing out of the water pump indicator hole. 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.

  • Page 74: Stopping The Engine

    OPERATION Stopping the Engine Reduce engine speed and push in the stop switch or pull the lanyard. Lanyard Stop switch 45619 Emergency Starting If the starter rope should break or the rewind starter fails, use the spare starter rope (provided) and follow this procedure. 1.
  • Page 75 OPERATION 2. Disconnect the linkage from the rewind starter assembly. 45630 Rewind starter assembly Linkage 3. Remove the three 10 mm bolts and rewind starter assembly. 10 mm wrench ‑ provided with outboard 45631 WARNING The exposed moving flywheel can cause serious injury. Keep your hands, hair, clothing, tools, and other objects away from engine when starting or running the engine.
  • Page 76 OPERATION 5. Pull the starter rope to start the engine. Starter rope ‑ provided with outboard 45632...

  • Page 77: Outboard Care

    We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. EPA Emission Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors.

  • Page 78: Inspection And Maintenance Schedule

    FAMILY : FEL : HC+NOx= HP : MAXIMUM POWER : LOW-PERM/HIGH-PERM : TIMING : IDLE SPEED (IN GEAR) : MERCURY MARINE 43058 Piston displacement Maximum emission output for the engine family Percent of fuel line permeation Timing specification Family number Engine family description Engine power ‑...
  • Page 79 MAINTENANCE • Check outboard for tightness on transom. • Check propeller blades for damage. AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the Cooling System. • Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in saltwater.

  • Page 80: 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. NOTE: Do not run the engine while flushing the cooling system.

  • Page 81: Corrosion Control Anode

    MAINTENANCE 2. Lift up the rear of the cowl and push it towards the front of the engine to clear the front hook. 45638 INSTALLATION 1. Engage the front hook and position the cowl over the engine. 2. Lock the rear latch. Corrosion Control Anode Your outboard has a corrosion control anode installed on the gearcase.

  • Page 82: 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.

  • Page 83: Propeller Replacement

    MAINTENANCE FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line or primer bulb must be replaced. Propeller Replacement WARNING Rotating propellers can cause serious injury or death.
  • Page 84 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE.

  • Page 85: Spark Plug Inspection And Replacement

    MAINTENANCE 8. Place a block of wood between gearcase and propeller and tighten the propeller nut. Secure propeller nut to the shaft with a cotter pin. Cotter pin Propeller nut Rear thrust hub Propeller Front thrust washer 27094 Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks which can ignite fuel vapors under the engine cowl, resulting in serious injury or...

  • Page 86: 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 or Special Lubricant 101. Tube Description Where Used Part No. Ref No.
  • Page 87 MAINTENANCE Tube Description Where Used Part No. Ref No. Co-pilot, swivel bracket, Special transom clamp screws, tiller 92-802865Q02 Lubricant 101 handle bushing, shift handle detent • Co‑pilot ‑ lubricate threads. • Swivel bracket ‑ lubricate through fittings. Swivel bracket lubrication fittings Co‑pilot 45640...
  • Page 88 • Shift detent ‑ lubricate detent shaft. Shift detent 45648 2. Lubricate the tilt pivot points with lightweight oil. Tilt pivot points 45643 3. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE. Tube Description Where Used Part No.

  • Page 89: Changing Engine Oil

    MAINTENANCE Tube Description Where Used Part No. Ref No. 2-4-C with Propeller shaft 92-802859A 1 PTFE • 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 90: 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 strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer.
  • Page 91 27146 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 1. Place outboard in a vertical operating position.

  • Page 92: Submerged Outboard

    MAINTENANCE 3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. Vent plug Lubricant at vent hole Fill/drain plug 27148 IMPORTANT: Replace sealing washers if damaged. 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube.

  • Page 93: 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).

  • Page 94: Protecting Internal Engine Components

    STORAGE Tube Description Where Used Part No. Ref No. Corrosion External metal surfaces 92-802878 55 Guard Protecting Internal Engine Components • Remove the spark plug and inject a small amount of engine oil inside the cylinder. • Rotate the flywheel manually several times to distribute the oil in the cylinder.
  • Page 95 STORAGE 2. Never carry, store, or transport the outboard in the positions shown below. Engine damage could result from oil draining out of the crankcase. 27012...

  • Page 96: Owner Service Assistance

    If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Parts and Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer.

  • Page 97: Mercury Marine Service Offices

    • The name and address of your dealership • Nature of problem Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States, Canada English ‑ (920) 929‑5040...
  • Page 98 OWNER SERVICE ASSISTANCE Asia, Singapore Telephone (65) 65466160 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive (65) 65467789 Singapore, 508944...

  • Page 99: 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...

This manual is also suitable for:

5 fourstroke6 fourstroke

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