Table of Contents
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Chapters
Table of Contents
Related Manuals for Mercury 4 SERIES
Summarization of Contents
Notice
DANGER
Immediate hazards resulting in severe personal injury or death.
WARNING
Hazards or unsafe practices that could result in severe personal injury or death.
CAUTION
Hazards or unsafe practices resulting in minor personal injury or product/property damage.
Notice to Users of This Manual
Information for mechanics and service personnel on manual usage and safety.
Cleanliness and Care of Outboard Motor
Page Numbering
Explanation of the two number groups appearing at the bottom of each page.
IMPORTANT INFORMATION
Section 1A - Specifications
Detailed specifications for engine models, weight, fuel, oil, charging, and starting systems.
Ignition System
Specifications for spark plug, timing, coil resistance, and engine speed limiter.
Carburetor
Specifications for idle RPM, jet sizes, bore diameter, and float height.
Fuel System
Specifications for fuel pump type, pressure, stroke, and tank capacity.
Specifications
Crankshaft
Specifications for crankshaft runout and bearing diameters.
Camshaft
Specifications for camshaft dimensions and bearing diameter.
Valve Spring
Specifications for free length, tilt limit, compressed pressure, and open height.
Valves
Specifications for valve clearance, dimensions, stem diameter, and run-out.
IMPORTANT INFORMATION
Section 1B - Maintenance
Outline of maintenance procedures, schedules, and specifications.
Quicksilver Lubricant/Sealant
Lists specific Quicksilver lubricants and sealants with part numbers.
Inspection and Maintenance Schedule
Details maintenance tasks based on usage intervals (before/after use, hours).
Changing Engine Oil
Procedure and capacity for changing engine oil.
MAINTENANCE
Flushing The Cooling System
Procedure for flushing cooling system with fresh water after use.
Fuel System
Information on fuel system service, inspection, and filter checks.
Corrosion Control Anode
Explanation of the anode's function and inspection requirements.
Spark Plug Inspection
Steps for inspecting and cleaning spark plugs.
Lubrication Points
Lubrication Points
Details lubrication points and recommended lubricants for various components.
Gear Case Lubrication
Gear Case Lubrication
Instructions for draining and filling gear case lubricant.
Storage Preparations
Storage Preparations
Steps for preparing the fuel system and engine components for storage.
Protecting Internal Engine Components
Procedures to protect internal engine parts during storage.
Positioning Outboard for Storage
Correct and incorrect positions for storing the outboard.
IMPORTANT INFORMATION
Section 1C - GENERAL INFORMATION
Overview of general information including serial numbers, weather, boat, engine, and submersion.
Serial Number Location
Location of the outboard serial number on the engine and swivel bracket.
Conditions Affecting Performance
Explanation of how weather conditions affect engine performance.
Boat
Information on weight distribution and bottom effects on boat performance.
CAVITATION
CAVITATION
Explanation of causes and effects of cavitation on propeller blades.
Engine DETONATION
Engine DETONATION
Description of detonation in 4-cycle engines and its causes.
Following Complete Submersion
Following Complete Submersion
Special instructions for engines submerged in water (running, salt, fresh).
Propeller Selection
Propeller Selection
Guidance on selecting the correct propeller for optimal performance and durability.
Propeller Removal/Installation
Propeller Removal/Installation
Step-by-step instructions for removing and installing the propeller.
Compression Check
Compression Check
Procedure for performing a cylinder compression test and interpreting results.
Cylinder Leakage Testing
Cylinder Leakage Testing
Method for testing cylinder leakage to pinpoint mechanical failures.
Analysis
Table and explanation for determining the cause of high percentage leaks.
Painting Procedures
Painting Procedures
Procedures for cleaning and painting aluminum propellers and gear housings.
Decal Application
Decal Application
Instructions for applying decals using the "Wet" application method.
Decal Removal
Steps for removing old decals to prepare for new ones.
IMPORTANT INFORMATION
Section 1D - Outboard Motor Installation
Information on installing the outboard motor.
Installing Outboard
Steps for measuring transom height and positioning the outboard.
Tilt Pin Adjustment
How to adjust the tilt pin for optimal performance and steering.
ELECTRICAL
Section 2A - Ignition System
Introduction to the ignition system components and specifications.
Special Tools
Lists specialized tools for ignition system testing and service.
Electrical Components
Illustrated diagram of electrical components.
Test Procedures
Important notes and procedures for testing the ignition system.
Ignition System
Ignition Components Removal and Installation
Procedures for removing and installing ignition components.
Flywheel
Steps for removing the flywheel using a strap wrench.
Flywheel
Removal of flywheel using a holder/puller method.
Flywheel
Steps for installing the flywheel, washer, and nut.
Capacitor Charging Coil
Capacitor Charging Coil
Procedures for removing and installing the capacitor charging coil.
Trigger Coil
Trigger Coil
Procedures for removing and installing the trigger coil.
Ignition Coil
Ignition Coil
Procedures for removing and installing the ignition coil.
ELECTRICAL
Section 2B - Charging System
Introduction to the charging system and its specifications.
Special Tools
Lists specialized tools for charging system testing.
Lighting Coil
Test procedure for checking lighting coil resistance.
Rectifier Diode Test (Optional)
Continuity test for the rectifier diode.
Lighting Coil Removal and Installation
Lighting Coil Removal and Installation
Procedures for removing and installing the lighting coil.
Rectifier (Battery Charging) Installation
Rectifier (Battery Charging) Installation
Installation procedure for the rectifier kit for battery charging.
ELECTRICAL
Section 2C - Timing and Synchronization
Introduction to ignition timing and synchronization procedures.
Special Tools
Lists specialized tools for timing and synchronization.
Ignition Timing
Procedure for aligning TDC timing marks on the flywheel and crankcase.
Ignition Timing
Procedure for checking ignition timing at idle and wide-open throttle.
ELECTRICAL
Section 2D - Wiring Diagram
Introduction to the wiring diagram.
Wiring Diagram
Schematic showing electrical connections and component identification.
FUEL SYSTEM
Section 3A - Fuel Pump & Integral Fuel Tank
Introduction to fuel pump and integral fuel tank components.
Fuel Pump
Exploded view diagram of the fuel pump components.
Fuel Pump Removal and Installation
Procedures for removing and installing the fuel pump.
Fuel Pump Reassembly
Steps for reassembling the fuel pump.
Integral Fuel Tank (4 HP Models Only)
Integral Fuel Tank (4 HP Models Only)
Procedures for disassembly, assembly, cleaning, and inspection of the integral fuel tank.
FUEL SYSTEM
Section 3B - Carburetor
Introduction to carburetor specifications and adjustments.
Special Tools
Lists specialized tools for carburetor service.
Fuel System
Exploded view diagram of fuel system components related to the carburetor.
Carburetor Adjustments
Procedures for adjusting idle speed and pilot mixture screw.
Carburetor Removal and Installation
Carburetor Removal and Installation
Steps for removing and installing the carburetor.
Carburetor Disassembly
Carburetor Disassembly
Steps for disassembling the carburetor.
Inspection
How to inspect carburetor jets, needle valve, and float.
Carburetor Reassembly
Carburetor Reassembly
Steps for reassembling the carburetor, including float level check.
FUEL SYSTEM
Section 3C – Emissions
Introduction to exhaust emissions standards and pollutants.
Exhaust Emissions Standards
EPA established standards for marine engine emissions.
What Are Emissions?
Explanation of what exhaust emissions are and how they are formed.
Controlling Emissions
Methods for reducing emissions through air/fuel ratio and timing.
Stoichiometric (14.7:1) Air/Fuel Ratio
Stoichiometric (14.7:1) Air/Fuel Ratio
Importance of the stoichiometric air/fuel ratio for controlling emissions.
STRATIFIED VS HOMOGENIZED CHARGE
STRATIFIED VS HOMOGENIZED CHARGE
Explanation of stratified and homogenized charges in engines.
Emissions Information
Emissions Information
Information on manufacturer, dealer, and owner responsibilities for emissions compliance.
EPA Emission Regulations
Information on EPA certification and contact locations for emission regulations.
Manufacturer’s Certification Label
Description and example of the engine emission certification label.
Service Replacement Certification Label
Instructions for obtaining and installing replacement emission certification labels.
POWERHEAD
Section 4A - Cylinder Head
Introduction to cylinder head specifications.
Valve Dimensions
Specifications for valve dimensions like head diameter and face width.
VALVES
Specifications for valve clearance, stem diameter, and run-out.
Special Tools
Lists specialized tools for cylinder head service.
Cylinder Block
Cylinder Block
Exploded view diagram of the cylinder block components.
Intake/Exhaust Valves
Intake/Exhaust Valves
Exploded view diagram of intake and exhaust valves.
Adjustments
Valve Clearance
Procedure for checking and adjusting valve clearance.
Cylinder Head Disassembly
Cylinder Head Disassembly
Steps for disassembling the cylinder head, noting valve train component locations.
Cleaning and Inspection
Cleaning and Inspection
How to clean and inspect the cylinder head for deposits and warpage.
Cylinder Head Resurfacing
Cylinder Head Resurfacing
Procedure for resurfacing the cylinder head if warped.
VALVE GUIDE INSPECTION
VALVE GUIDE INSPECTION
How to measure valve guide bore and check for wear.
VALVE SEAT RECONDITIONING
VALVE SEAT RECONDITIONING
Cleaning and reseating valve seats, measuring valve seat width.
VALVE SEAT POSITIONS AND CORRECTIONS
VALVE SEAT POSITIONS AND CORRECTIONS
Correcting valve seat position based on width and angle specifications.
Valve Springs
Valve Springs
How to check valve springs for compressed pressure, free length, and tilt.
Cylinder Head Reassembly
Cylinder Head Reassembly
Procedures for reassembling the cylinder head components.
Cylinder Head Installation
Cylinder Head Installation
Steps for installing the cylinder head and cover.
POWERHEAD
Section 4B - Cylinder Block and Crankcase
Introduction to cylinder block and crankcase specifications.
Special Tools
Lists specialized tools for cylinder block and crankcase service.
Powerhead - General Information
General guidelines regarding powerhead disassembly and reassembly.
Cylinder Block
Exploded view diagram of cylinder block components.
Crankshaft
Crankshaft
Exploded view diagram of crankshaft components.
Oil Pan
Oil Pan
Exploded view diagram of oil pan components.
Torque Sequence Oil Pan
Diagram showing the torque sequence for oil pan bolts.
Powerhead Removal
Powerhead Removal
Steps for draining oil and removing components before powerhead removal.
Removing Powerhead Components
List of components to remove before powerhead separation.
Powerhead Disassembly
Powerhead Disassembly
Steps for disassembling the oil seal housing and removing seals.
Inspection
Measuring Cylinder Bore
How to measure cylinder bore diameter and check for wear.
Measuring Diameter of the Piston Skirt
How to measure piston skirt diameter.
Measuring Piston Clearance (Clearance Between Piston and Cylinder)
How to measure piston to cylinder clearance.
Measuring Piston Ring Side Clearance
How to measure piston ring side clearance.
Measuring Piston Ring End Gap
Measuring Piston Ring End Gap
How to measure piston ring end gap.
Measuring Diameter of the Small End of Connecting Rod
How to measure the small end diameter of the connecting rod.
Measuring Side Clearance of the Big End of Connecting Rod
How to measure side clearance of the connecting rod's big end.
Measuring Oil Clearance at Big End of Connecting Rod Using Plastigauge
Measuring Oil Clearance at Big End of Connecting Rod Using Plastigauge
Procedure for measuring connecting rod oil clearance with plastigauge.
Measuring Camshaft Lobe Height “A” Intake/Exhaust
Measuring Camshaft Lobe Height “A” Intake/Exhaust
How to measure camshaft lobe height.
Measuring Camshaft Bearing Diameter “B”
How to measure camshaft bearing diameter.
Inspecting Push Rod
Inspecting Push Rod
How to inspect push rods for straightness and wear.
Inspecting Valve Lifter
How to inspect valve lifters for wear or corrosion.
Measuring Depth of Oil Pump Body
Measuring Depth of Oil Pump Body
How to measure the depth of the oil pump body.
Measuring Inside Diameter of Oil Pump Body
Measuring Inside Diameter of Oil Pump Body
How to measure the inside diameter of the oil pump body.
Measuring Clearance Between Inner and Outer Rotors “A”
Measuring Clearance Between Inner and Outer Rotors “A”
How to measure clearance between inner and outer oil pump rotors.
Measure Clearance Between Outer Rotor and Body “B”
How to measure clearance between outer rotor and oil pump body.
Measuring/Testing Thermostat
Measuring/Testing Thermostat
Procedure for testing thermostat valve opening temperature and lift.
Powerhead Reassembly
Powerhead Reassembly
General guidelines for powerhead reassembly, including lubrication and torque.
Powerhead Installation
Powerhead Installation
Steps for securing the powerhead onto the drive shaft housing and installing components.
MID-SECTION
Section 5
Introduction to mid-section components and procedures.
Driveshaft Housing
Exploded view diagram of the driveshaft housing components.
Clamp Brackets
Exploded view diagram of clamp bracket components.
Cowling
Exploded view diagram of the cowling components.
Reassembly
Clamp Bracket/Swivel Bracket
Procedures for reassembling the clamp and swivel brackets.
Drive Shaft Housing
Drive Shaft Housing
Procedures for installing the drive shaft housing and related components.
Bottom Cowling
Bottom Cowling
Attaching components to and securing the bottom cowl.
Water Tube
Installing the water tube and related components.
GEAR HOUSING
Section 6
Introduction to gear housing specifications and procedures.
Special Tools
Lists specialized tools for gear housing service.
Quicksilver Lubricants and Service Aids
Lists Quicksilver lubricants and sealants for gear housing.
Gear Housing (Drive Shaft)
Exploded view diagram of drive shaft housing components.
Gear Housing (Prop Shaft)
Gear Housing (Prop Shaft)
Exploded view diagram of propeller shaft housing components.
Draining and Inspecting Gear Housing Lubricant
Draining and Inspecting Gear Housing Lubricant
Procedures for draining, inspecting, and noting lubricant condition.
Propeller Removal
Steps for safely removing the propeller.
Gear Housing Removal
Gear Housing Removal
Steps for removing the gear housing from the driveshaft housing.
Gear Housing Disassembly
Bearing Carrier
Steps for removing the bearing carrier.
Propeller Shaft
Propeller Shaft
How to check propeller shaft for twists, grooves, or worn threads.
Sliding Clutch
Replacing the sliding clutch if jaws or splines are worn.
Cam Follower
Replacing the cam follower if it shows signs of wear.
Water Pump Components
Replacing water pump components if worn or damaged.
Drive Shaft
Drive Shaft
How to remove shims and the drive shaft assembly.
Forward Gear and Bearing
How to remove the forward gear and its bearing.
Lower Drive Shaft Needle Bearing
Lower Drive Shaft Needle Bearing
How to drive out the lower drive shaft needle bearing.
Water Pickup Screen
Water Pickup Screen
How to remove the water pickup screen.
Cleaning and Inspection
How to clean and inspect gear housing castings and bearings.
Forward, Reverse and Pinion Gears
Forward, Reverse and Pinion Gears
How to replace gears if teeth are chipped or worn.
Bearing Carrier
Bearing Carrier
Installing propeller shaft oil seal, bearing, and O-ring into the carrier.
Impeller and Water Pump Housing
Impeller and Water Pump Housing
Installing gaskets, plate, and water pump components.
Gear Housing Installation
Gear Housing Installation
Safety warning and initial steps for installing the gear housing.
Propeller Installation
Propeller Installation
Procedures for coating the propeller shaft and installing the propeller.
Filling Gear Housing with Lubricant
Filling Gear Housing with Lubricant
Instructions for filling the gear housing with Quicksilver Gear Lube.
CONTROLS
Section 7A - Shift Linkage
Introduction to shift linkage components and procedures.
Removal/Disassembly
Steps for removing the powerhead, gear housing, and shift lever assembly.
Reassembly/Installation
Procedures for lubricating and installing the detent ball, spring, and shift lever.
CONTROLS
Section 7B - Tiller Handle
Introduction to tiller handle specifications and procedures.
Steering Handle
Exploded view diagram of steering handle components.
Removal
Steps for removing throttle cables and retaining plate from the steering handle.
Disassembly
Steps for disassembling the tiller handle, sliding bushings and washers.
Reassembly
Reassembly
Procedures for reassembling the friction block, throttle shaft, and handle grip.
Installation
Installation
Installing the inner bushing and throttle cables.
MANUAL STARTER
Section 8
Introduction to recoil starter components and procedures.
Recoil Starter
Exploded view diagram of recoil starter assembly.
Removal
Steps for removing the top cowl and manual starter assembly.
Installation
Steps for installing the rewind assembly and reconnecting the link rod.
Disassembly
Disassembly
Steps for disassembling the starter sheave, rope, and components.
Cleaning and Inspection
Cleaning and Inspection
How to clean and inspect starter components for wear or damage.
Reassembly
Reassembly
Procedures for applying lubricant and installing the spring/housing assembly.
COLOR DIAGRAMS
Table of Contents
Lists available color diagrams: wiring, water flow, and oil flow.
4/5/6 (4-STROKE) WIRING DIAGRAM
Title page for the wiring diagram.
4/5/6 (4-STROKE) WATER FLOW DIAGRAM
Title page for the water flow diagram.
4/5/6 (4-STROKE) OIL FLOW DIAGRAM
Title page for the oil flow diagram.
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