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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:

98/37/EC,

EMC Directive:

89/336/EC; std. EN50081-1, SAE J551 (CISPR Pub. 12),

EN 50082-1, IEC 61000 PT4-2, IEC 61000 PT4-3

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

© 2004 Mercury Marine

4/5/6 4-Stroke

90-10211050  204

Summary of Contents for 4 4-Stroke

Page 1: ...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 Fon...

Page 2: ...8 Boat Horsepower Capacity 8 Lanyard Stop Switch 9 Protecting People In The Water 10 Exhaust Emissions 10 Selecting Accessories For Your Outboard 12 Safe Boating Suggestions 12 Recording Serial Number...

Page 3: ...owl Removal And Installation 34 Corrosion Control Anode 34 Exterior Care 35 Fuel System 35 Propeller Replacement 36 Spark Plug Inspection And Replacement 37 Lubrication Points 38 Changing Engine Oil 3...

Page 4: ...iv...

Page 5: ...2 To be eligible for warranty coverage the product must be registered with Mercury Marine At the time of sale the dealer should complete the warranty registration and immediately submit it to Mercury...

Page 6: ...stomer upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is availble only to retail customers that purchase from a Dealer au...

Page 7: ...regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warrant...

Page 8: ...nless requested by Mercury ship the product or parts of the product directly to Mercury The warranty registration card is the only valid registration identificationand must be presented to the dealer...

Page 9: ...formed including without limitation the replacement of sacrificial anodes use of specified lubricants and touch up of nicks and scratches in order to maintain warranty coverage Mercury Marine reserves...

Page 10: ...TE TO STATE AND COUNTRY TO COUNTRY Warranty Coverage And Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The following...

Page 11: ...operating with a racing type lower unit 11 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failu...

Page 12: ...tructions that should be followed DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous...

Page 13: ...yard stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator accidentally falls overboard or move...

Page 14: ...d a boat heading in his her direction even at slow speed ob00311 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a b...

Page 15: ...osed cabins or cockpits with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers...

Page 16: ...eat or anywhere that an unexpected acceleration sudden stopping unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat Never be under the...

Page 17: ...4500 5500 5000 6000 Idle Speed in Forward Gear 1100 RPM in Gear 1300 RPM in Neutral Number of Cylinders 1 Piston Displacement 123 cc 7 51 cu in Cylinder Bore 59 mm 2 32 in Piston Stroke 45 mm 1 77 in...

Page 18: ...ure 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 a a Anti ventilation plate INSTALLING OUTBOARD ON TRANSOM 1 Place outboard...

Page 19: ...run engine until it stops This will drain fuel from the carburetor Install the protector cap over the fuel connector a ob00450 a Protector cap Remove outboard and hold it upright until the water is d...

Page 20: ...to bounce and drop down causing damage to the outboard Your boat should be trailered with the outboard tilted down normal operating position If additional ground clearance is required remove the outbo...

Page 21: ...is recommended If gasoline containing alcohol is used or if you suspect the presence of alcohol in your gasoline increase your inspection of the fuel system visually checking for fuel leaks or abnorm...

Page 22: ...oil may be used at temperatures above 4 C 40 F b SAE 10W 30 viscosity oil is recommended for use in all temperatures Checking Engine Oil IMPORTANT Do not overfill Be sure that the outboard is upright...

Page 23: ...FUEL OIL 19 3 Reinstall the oil filler cap and tighten securely a b ob00455 a Full mark b Add mark...

Page 24: ...Knob Turn friction knob to set and maintain the throttle at desired speed Turn knob up to tighten friction and down to loosen friction a b ob00458 a Direction to tighten friction b Direction to loose...

Page 25: ...oil as needed If the oil pressure indicator light should stay on when the oil level is correct consult your dealer ob00460 Side Handle Gear Shift Controls gear shift R F N ob00461 Engine Stop Switch L...

Page 26: ...pring loaded tilt lock lever will engage automatically and lock the outboard in full up position LOWERING TO RUN POSITION 1 Raise the outboard and pull up on the tilt release lever Gently lower outboa...

Page 27: ...ate outboard at slow speed for shallow water operation and keep the cooling water intake submerged 3 To release outboard back down to run position tilt outboard up slightly and pull up on the tilt rel...

Page 28: ...over speed protection system is activated if the engine speed should exceed the maximum allowable limit This will protect the engine from mechanical damage Anytime the engine over speed protection sys...

Page 29: ...will block water flow to the engine causing possible damage Operating In Salt Water Or Polluted Water We recommend that you flush the internal water passages of your outboard with fresh water after e...

Page 30: ...of the engine 1 Make sure the cooling water intake is submerged ob00469 2 Check the engine oil level ob00470 3 Shift outboard to neutral N position N ob00471 NOTE The engine will not start unless the...

Page 31: ...el line to the outboard Make sure connector is snapped into place ob00475 b Open fuel tank vent on manual venting type tanks ob00348 c 4 Hp Models with optional remote fuel tank Move the fuel valve to...

Page 32: ...pull rapidly to crank the engine Allow rope to return slowly Repeat until engine starts ob00463 10 Check for a steady stream of water flowing out of the water pump indicator hole IMPORTANT If no water...

Page 33: ...b00480 Emergency Starting If the starter rope should break or the rewind starter fails use the spare starter rope provided and follow this procedure 1 Shift outboard to neutral position N ob00471 WARN...

Page 34: ...g or spark plug wire when starting or running the engine WARNING The exposed moving flywheel can cause serious injury Keep your hands hair clothing tools and other objects away from engine when starti...

Page 35: ...OPERATION 31 5 Pull the starter rope to start the engine ob00483...

Page 36: ...ld result in personal injury death or product failure EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to e...

Page 37: ...yearly Replace spark plug as needed See Spark Plug Inspection and Replacement Drain and replace gearcase lubricant See Gearcase Lubrication Check fuel line filter for contaminants See Fuel System Chec...

Page 38: ...to lock Corrosion Control Anode Your outboard has a corrosion control anode installed on the gearcase An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slow...

Page 39: ...er to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved receptacle Any fuel system service must be performed in a well ventil...

Page 40: ...ve cotter pin 4 Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut 5 Pull propeller straight off shaft If propeller is seized to the shaft and cannot be re...

Page 41: ...ire or explosion caused by damaged spark plug boots Damaged spark plug boots can emit sparks Sparks can ignite fuel vapors under the engine cowl To avoid damaging spark plug boots do not use any sharp...

Page 42: ...ollowing with Quicksilver or Mercury Precision Lubricants 2 4 C with Teflon or Special Lubricant 101 Co Pilot Lubricate threads Swivel Bracket Lubricate through fittings a b a ob00491 a Swivel bracket...

Page 43: ...removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding to the shaft ob00490 Changing Engine Oil ENGINE OIL CAPACITY Engine...

Page 44: ...check for the presence of water in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milk...

Page 45: ...G GEARCASE 1 Place outboard in a vertical operating position 2 Remove vent plug from vent hole 3 Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole ob00498 a b...

Page 46: ...equire service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing dealer is necessary once the engine is exposed to the at...

Page 47: ...stalled Fuel Tank Pour the required amount of gasoline stabilizer follow instructions on container into a separate container and mix with approximately one quart one liter of gasoline Pour this mixtur...

Page 48: ...STORAGE 44 a b ob00499 a Upright b Tiller Side Down 2 Never carry store or transport the outboard in the positions shown below Engine damage could result from oil draining out of the crankcase ob00453...

Page 49: ...ery 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 assistan...

Page 50: ...triel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 954 744 3513 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U...

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