Mercury 4.9 TwoStroke Instruction Manual Download Page 81

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MAINTENANCE

eng

• Shift Handle Detent ‑ Lubricate detent.

27099

2. Lubricate the following with Light Weight Oil.

• Tilt Pivot.

28863

3. Lubricate the following with Quicksilver or Mercury Precision

Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE.

Tube

Ref No.

Description

Where Used

Part No.

Anti-Corrosion

Grease

Propeller shaft

92-802867Q 1

2-4-C with

PTFE

Propeller shaft

92-802859A 1

Summary of Contents for 4.9 TwoStroke

Page 1: ...k 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 confor...

Page 2: ...ecifications designs methods or procedures without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Litho in U S A 2012 Mercury Marine Mercury Mercury Marine MerCruis...

Page 3: ...Gasoline Combustion cycle 2 Stroke This declaration is issued under the sole responsibility of Mercury Marine and Brunswick Marine in EMEA Inc Name and function Mark D Schwabero President Mercury Mar...

Page 4: ...iv eng...

Page 5: ...tboard Limited Warranty Confederation of Independent States Middle East and Africa 12 3 Year Limited Warranty Against Corrosion 16 Warranty Coverage and Exclusions 19 General Information Boater s Resp...

Page 6: ...Filling Fuel Tank 44 Features and Controls Remote Control Features 45 Tilting Outboard 47 Shallow Water Operation 48 Trim Angle Adjustment 50 Operation Prestarting Check List 52 Operating in Freezing...

Page 7: ...8 Propeller Selection 70 Spark Plug Inspection And Replacement 70 Lubrication Points 71 Gearcase Lubrication 74 Submerged Outboard 76 Storage Storage Preparation 77 Protecting External Outboard Compon...

Page 8: ...viii eng Maintenance Log Maintenance Log 83 Accessories Propeller Recommendation 84 Tool Kit and Spare Parts 84 Optional Accessories 86 Wiring Diagram 88 Wire Color Code Abbreviations 89...

Page 9: ...7 6663 Upon processing the transfer of warranty Mercury Marine will send registration verification to the new owner of the product by mail There is no charge for this service For products purchased ou...

Page 10: ...rcury Marine s Warranty Registration Department Warranty Registration United States and Canada 1 You may change your address at any time including at the time of the warranty claim by calling Mercury...

Page 11: ...ranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area 2 The Warranty Reg...

Page 12: ...ealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be necessary to contact you Make sure your dealer distributor fills out the warranty regis...

Page 13: ...roduct Unexpired warranty coverage cannot be transferred either to or from a commercial use customer CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available onl...

Page 14: ...wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended wide open throttle RPM range see the Operation and Maintena...

Page 15: ...those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANT...

Page 16: ...WARRANTY PERIOD FOR RECREATIONAL USE This Limited Warranty provides coverage for three 3 years from the date the product is first sold to a recreational use retail purchaser or the date on which the...

Page 17: ...creational to commercial unless properly registered may void the warranty at the sole discretion of Mercury Marine Routine maintenance outlined in the Operation and Maintenance Manual must be timely p...

Page 18: ...inspection and any covered repair This Limited Warranty will not cover the purchaser for all related transportation charges and travel time If the service provided is not covered by this limited warr...

Page 19: ...for use with the product see the Operation and Maintenance Manual alteration or removal of parts water entering the engine through the fuel intake air intake or exhaust system or damage to the produc...

Page 20: ...cover any expenses you may incur claiming the warranty DISCLAIMERS AND LIMITATIONS EXCEPT FOR APPLICABLE GUARANTEES AND OTHER RIGHTS AND REMEDIES THAT A CONSUMER MAY HAVE UNDER THE AUSTRALIAN CONSUMER...

Page 21: ...e product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available...

Page 22: ...s limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engin...

Page 23: ...arding the product other than those contained in this limited warranty and if made shall not be enforceable against Mercury Marine For additional information regarding events and circumstances covered...

Page 24: ...quent noncommercial use purchaser upon proper reregistration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers tha...

Page 25: ...ated transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with tha...

Page 26: ...een the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for ad...

Page 27: ...on is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have GENERAL EXCLUSIONS FROM...

Page 28: ...ntenance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration 10 Participating in or preparing for racing or...

Page 29: ...ur products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered unde...

Page 30: ...tboard properly If you have any questions contact your dealer Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage...

Page 31: ...facturer following certain federal guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT...

Page 32: ...rmation The purpose of a lanyard 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 accident...

Page 33: ...g and operating procedures should they be required to operate the engine in an emergency e g if the operator is accidentally ejected WARNING Avoid serious injury or death from deceleration forces resu...

Page 34: ...a boat is moving coasting and the outboard gear shift is in neutral position there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation c...

Page 35: ...n 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...

Page 36: ...ient 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 and passengers in an open area of a...

Page 37: ...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 Safe Boating Su...

Page 38: ...he boat Never be under the influence of alcohol or drugs while boating it is the law Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly Prepare other boat oper...

Page 39: ...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...

Page 40: ...GENERAL INFORMATION 32 eng Component Identification 4C 4 9 5BD 41059 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34...

Page 41: ...ntilation plate 11 Water inlet 12 Propeller 13 Starter handle 14 Shift lever 15 Throttle grip 16 Choke knob 17 Stop switch 18 Fuel connector 19 Clamp screw 20 Clamp bracket 21 Trim position pin 22 Oil...

Page 42: ...HP Max operating range 4500 5500 RPM Idle speed in forward gear 850 RPM Idle speed in neutral gear 1000 RPM Engine type Two Stroke Number of cylinders 1 Bore x stroke 55 x 43 mm 2 17 x 1 69 in Displac...

Page 43: ...10 Trim position 6 Gear oil Mercury Quicksilver gear oil or API GLS SAE 80 to 90 approximately 195 mL 6 6 fl oz Fuel tank capacity 2 5 L 0 66 US gal 2 5 L 0 66 US gal 2 5 L 0 66 US gal 12 L 3 17 US g...

Page 44: ...contact your dealer Do not operate the engine unit until it has been securely mounted on the boat in accordance with the instructions below 1 Position the outboard at the center of the transom Mount i...

Page 45: ...INSTALLATION eng 37 ATTACH THE ENGINE TO THE BOAT 1 Tighten the clamp screws by turning their handles Secure with a cable to prevent accidental loss overboard a Clamp screw 42041 a...

Page 46: ...you carry the motor 39485 NOTE If you carry the motor horizontal posture keep the power head higher than the propeller IMPORTANT Beware of explosion danger Spilled and vapored gasoline may easily cat...

Page 47: ...low the outboard to bounce and drop down causing damage to the outboard The boat should be trailered with the outboard tilted down normal operating position If trailering with the engine fully down is...

Page 48: ...ift into forward F gear This prevents the propeller from spinning freely 39486 NOTE The tilt support device supplied on your outboard is not intended for towing It is intended to support the engine wh...

Page 49: ...brand of leaded gasoline USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The 2 types of oxygenates used in these fuels are alcohol ethano...

Page 50: ...on particularly after storage Any sign of leakage or deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended tha...

Page 51: ...the break in fuel mixture is used up use a 1 50 oil gasoline mixture Refer to the table following for mixing ratios GASOLINE OIL MIXING RATIO CHART OIL GASOLINE MIXING RATIO CHART Oil Gas Ratio 3 8 l...

Page 52: ...er pressure if the tank is completely filled The oil and fuel mixture should always be thoroughly mixed in an approved container before pouring into motor fuel tank Do not pour separately into fuel ta...

Page 53: ...operations of the remote control a Remote control handle b Throttle only lever c Ignition key switch d Lanyard stop switch Throttle grip friction knob The throttle friction can be adjusted in accorda...

Page 54: ...with your preference by turning the adjustment screw a Steering adjustment screw b Turn counterclockwise to lighter steering c Turn clockwise to heavier steering WARNING Insufficient friction adjustm...

Page 55: ...gine is started 28851 After the engine has started push the choke knob back then return the grip to SLOW position and run the engine to warm up for several minutes Tilting Outboard TILTING TO FULL UP...

Page 56: ...gage 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 outboard down a Tilt lever b Tilt stopper...

Page 57: ...nd 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 27025 2 Ensure the cooling water int...

Page 58: ...d may damage the mounting bracket Care must be taken while running in this tilt position not come in contact with the bottom or submerged objects especially in reverse This may cause damage to the mot...

Page 59: ...l rise out of the water and the speed will decrease Furthermore the bow may sway or the bottom may slam the water while cruising In this case decrease the trim angle by setting the trim position pin i...

Page 60: ...ile under the influence of alcohol or drugs Know the waters and area you will be boating tides currents sand bars rocks and other hazards Make inspection checks listed in Maintenance Inspection and Ma...

Page 61: ...alt or polluted water This will prevent a buildup of deposits from clogging the water passages Refer to Maintenance Flushing the Cooling System If you keep your boat moored in the water always tilt th...

Page 62: ...d deliver oil to all the moving parts of an engine Operating the engine without warm up will reduce engine performance and shorten the life of the engine Be sure to check that cooling water is coming...

Page 63: ...sconnected from the engine NOTE The engine will not start unless the lanyard has been properly connected to the emergency stop switch 1 Lower the outboard to the run position Make sure the cooling wat...

Page 64: ...the primer bulb should be facing the engine separate fuel tank 5 Open the fuel valve internal fuel tank a Air vent screw b Fuel valve 6 Feed fuel to the carburetor by squeezing the primer bulb until...

Page 65: ...function that prevents starting in gear R F N 27020 NOTE If the motor somehow does start in gear do not operate it Contact your authorized dealer 8 Move the throttle grip to the start position 28847 9...

Page 66: ...IMPORTANT If no water is coming out of the water pump indicator hole stop the engine and check the cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage in...

Page 67: ...be in the slow running position before shifting is attempted NOTE Do not increase engine speed more than necessary in reverse a Reverse b Neutral c Forward d Shift lever Always shift outboard into gea...

Page 68: ...OPERATION 60 eng 3 Push the stop switch to stop the engine a Lanyard hook b Stop switch lock c Stop switch 41063 a b c...

Page 69: ...l Mercury Precision or Quicksilver replacement parts and Genuine Lubricants EPA Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection...

Page 70: ...OWNER RESPONSIBILITY The owner operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards The owner operator is not to modi...

Page 71: ...requently when used in saltwater See Lubrication Points Replace spark plug at first 100 hours or first year After that inspect spark plug every 100 hours or once yearly Replace spark plug as needed Se...

Page 72: ...ventilated Exhaust gas contains carbon monoxide a colorless and orderless gas which can be fatal if inhaled for any length of time Use a Mercury Precision or Quicksilver accessory or equivalent flushi...

Page 73: ...STALLATION 1 Engage the front hook and push cowl back over the cowl seal 2 Push cowl down and move the rear latch lever up to lock Corrosion Control Anode Your outboard has a corrosion control anode i...

Page 74: ...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 Keep the work area well ventilated and avoid prolonged ex...

Page 75: ...LTERS AND THE FUEL TANK The fuel filter is located between the fuel valve and the fuel pump 28857 Drain all fuel from the fuel tank Remove the fuel lines from the fuel filter Inspect the fuel filter I...

Page 76: ...e water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of woo...

Page 77: ...mended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 6 Apply Quicksilver or Mercury Precision Lubricants Anti Corrosion G...

Page 78: ...ngine to reach recommended RPM when cruising at wide open throttle Wide open throttle RPM range 4500 5500 Recommended propellers are listed under Propeller Recommendation in the Accessories section of...

Page 79: ...ed 26946 3 Set the spark plug gap to specification 26947 Spark Plug Spark plug gap 1 0 mm 0 040 in 4 Before installing spark plug clean off any dirt on the spark plug seat Install plug finger tight an...

Page 80: ...screws tiller handle bushing shift handle detent 92 802865Q02 Co Pilot Lubricate threads Swivel Bracket Lubricate through fittings a Co pilot b Swivel bracket Transom Clamp Screws Lubricate threads 2...

Page 81: ...ight Weight Oil Tilt Pivot 28863 3 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with PTFE Tube Ref No Description Where Used Part No 94 Anti...

Page 82: ...it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or i...

Page 83: ...CASE 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 a...

Page 84: ...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 Submerged Outboard A submerged outbo...

Page 85: ...fuel system If the gasoline being used contains alcohol it is advisable to drain as much of the remaining gasoline as possible from the fuel tank remote fuel line and engine fuel system Fill the fuel...

Page 86: ...rocedure for removing spark plug boots Place the outboard in water Start the engine and let it run in neutral to warm up With engine running at fast idle stop the fuel flow by closing the fuel shut of...

Page 87: ...ition to allow water to drain out of the outboard NOTICE Storing the outboard in a tilted position can damage the outboard Water trapped in the cooling passages or rain water collected in the propelle...

Page 88: ...ocal authorized dealer The dealer has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order...

Page 89: ...936 1939 Fax English 920 929 5893 Fran ais 905 636 1704 Website www mercurymarine com Australia Pacific Telephone 61 3 9791 5822 Brunswick Asia Pacific Group 41 71 Bessemer Drive Dandenong South Victo...

Page 90: ...OWNER SERVICE ASSISTANCE 82 eng Asia Singapore Telephone 65 65466160 Brunswick Asia Pacific Group T A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore 508944 Fax 65 65467789...

Page 91: ...MAINTENANCE LOG eng 83 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 92: ...x pitch in 200 x 229 7 9 x 9 0 198 x 203 7 8 x 8 0 198 x 178 7 8 x 7 0 Model Optional 4 9 5B D S L UL 4C S L Transom height S short L long UL extra long Tool Kit and Spare Parts A listed tools and spa...

Page 93: ...ACCESSORIES eng 85 Parts packaged with engine Fuel tank 12 L 1 5B D only Primer bulb 1set 5B D only...

Page 94: ...ACCESSORIES 86 eng Optional Accessories 41075 a b c d e f g h i j...

Page 95: ...2 V 60 W b Extension cord for light Lights are available on the market c Rectifier d Gear oil 500 mL e Flushing attachment f Grease 250 g g Vertical starter h Remote control box i Touch up paint 300 m...

Page 96: ...ACCESSORIES 88 eng Wiring Diagram 41076 a b c d f e g h i j k l...

Page 97: ...ghting unit optional f Pulser coil g CD unit h Ignition coil i Spark plug j Stop switch optional Wire Color Code Abbreviations Wire Color Abbreviations BLK Black BLU Blue BRN Brown GRY Gray GRN Green...

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Mercury 4.9 TwoStroke, Instruction Manual

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