Mercury 4 SERIES Outboard Motors Manuals

Manuals and User Guides for Mercury 4 SERIES Outboard Motors. We have 1 Mercury 4 SERIES Outboard Motors manual available for free PDF download: Service Manual

Mercury 4 SERIES Service Manual

Mercury 4 SERIES Service Manual (260 pages)

4-STROKE

Brand: Mercury | Category: Outboard Motor | Size: 6 MB

Table of Contents

Section 1

13
- Cleanliness and Care of Outboard Motor
  4
- Page Numbering
  4
- Table of Contents
  13
- After each Use
  15
- Before each Use
  15
- Every 100 Hours of Use or Once Yearly, Whichever Occurs First
  15
- Inspection and Maintenance Schedule
  15
- Flushing the Cooling System
  16
- Fuel System
  16
  - Fuel Line Inspection
    16
  - Engine Fuel Filter
    16
- Corrosion Control Anode
  17
- Spark Plug Inspection
  17
- Lubrication Points
  18
- Changing Engine Oil
  20
  - Engine Oil Capacity
    20
  - Oil Changing Procedure
    20
  - Oil Filling
    20
- Gear Case Lubrication
  21
  - Gear Case Lubricant Capacity
    21
  - Draining Gear Case
    21
  - Checking Lubricant Level and Refilling Gear Case
    22
  - Storage Preparations
    22
    
    Fuel System
    22
    
    Protecting External Engine Components
    22
    
    Protecting Internal Engine Components
    23
    
    Gear Case
    23
    
    Positioning Outboard for Storage
    23
Section 2

24
- Conditions Affecting Performance
  25
  - Weather
    25
  - Boat
    26
  - Engine
    28
- Serial Number Location
  25
- Following Complete Submersion
  29
  - Submerged While Running
    29
  - Salt Water Submersion
    29
  - Fresh Water Submersion
    29
- Propeller Selection
  30
- Propeller Removal/Installation
  31
- Compression Check
  33
- Cylinder Leakage Testing
  34
  - Analysis
    34
- Painting Procedures
  35
  - Cleaning & Painting Aluminum Propellers & Gear Housings
    35
- Decal Application
  36
  - Decal Removal
    36
  - Instructions for "Wet" Application
    36
Section 3

38
- Notice to Installer and Owner
  39
  - Boat Horsepower Capacity
    39
  - Selecting Accessories for the Outboard
    39
- Installing Outboard
  40
  - Fastening Security Line
    41
- Tilt Pin Adjustment
  41
  - Setting the Operating Angle of Your Outboard 1D-4
    41
  - Engine Over-Speed Protection System
    42
- Installation Drawings
  43
  - Electrical Components
    47
  - Battery Connections
    70
  - Ignition Timing
    74
  - Wiring Diagram
    77
  - Fuel Pump
    79
  - Carburetor Adjustments
    94
  - Idle Speed
    94
  - Carburetor Disassembly
    96
  - Carburetor Reassembly
    98
Fuel System

100
- Exhaust Emissions Standards
  101
  - What Are Emissions
    101
  - Hydrocarbons
    101
  - Carbon Monoxide - CO
    101
  - Oxides of Nitrogen - Nox
    101
  - Controlling Emissions
    101
  - Stoichiometric (14.7:1) Air/Fuel Ratio
    102
- Outboard Hydrocarbon Emissions Reductions
  102
  - 1/3% # Per Year over 9 Model Years
    102
- Stratified Vs Homogenized Charge
  103
  - Homogenized Charge
    103
  - Stratified Charge
    104
- Emissions Information
  105
  - Manufacturer's Responsibility
    105
  - Dealer Responsibility
    105
  - Owner Responsibility
    105
  - EPA Emission Regulations
    106
- Manufacturer's Certification Label
  107
- Service Replacement Certification Label
  108
  - Removal
    108
  - Date Code Identification
    108
  - Installation
    108
  - Decal Location
    108
    
    Valve Clearance
    116
    
    Powerhead Disassembly
    146
MID-Section

176
- Driveshaft Housing
  177
- Clamp Brackets
  179
- Cowling
  181
- Clamp Bracket/Swivel Bracket
  183
- Disassembly
  183
- Reassembly
  183
- Drive Shaft Housing
  186
- Bottom Cowling
  187
- Water Tube
  188
Gear Housing

189
- Special Tools
  190
- Quicksilver Lubricants and Service Aids
  191
- Gear Housing (Drive Shaft)
  192
- Gear Housing (Prop Shaft)
  194
- Draining and Inspecting Gear Housing Lubricant
  196
- Propeller Removal
  196
- Gear Housing Removal
  197
- Gear Housing Disassembly
  198
  - Bearing Carrier
    198
  - Propeller Shaft
    200
  - Water Pump Housing and Impeller
    201
  - Water Pump Base and Shift Shaft
    202
  - Drive Shaft
    205
  - Forward Gear and Bearing
    205
  - Lower Drive Shaft Needle Bearing
    206
  - Zinc Anode
    206
  - Water Pickup Screen
    207
- Cleaning and Inspection
  207
  - Gear Housing/Bearing Carrier Castings
    207
  - Bearings
    207
  - Forward, Reverse and Pinion Gears
    208
  - Propeller Shaft
    209
  - Sliding Clutch
    209
  - Cam Follower
    209
  - Water Pump Components
    209
  - Drive Shaft
    210
  - Shift Shaft
    210
- Gear Housing Reassembly
  210
  - Lower Drive Shaft Needle Bearing
    210
  - Forward Gear Bearing
    211
  - Forward Gear
    212
  - Pinion Gear and Drive Shaft
    212
  - Water Pump Base and Shift Shaft
    213
  - Propeller Shaft
    215
  - Bearing Carrier
    217
  - Impeller and Water Pump Housing
    218
  - Zinc Anode
    221
  - Water Pickup Screen
    221
- Gear Housing Installation
  221
- Propeller Installation
  223
- Filling Gear Housing with Lubricant
  224
Controls

231
- Steering Handle
  232
- Steering Handle
  233
- Removal
  234
- Disassembly
  235
- Reassembly
  237
- Installation
  239
  - Recoil Starter
    243

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