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Mercury 4 TwoStroke, Operation, Maintenance And Installation Manual

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Mercury 4 TwoStroke Operation, Maintenance And Installation Manual Download Page 9

Owner Service Assistance

Local Repair Service.........................................................................................51

Service Away from Home................................................................................. 51

Parts and Accessories Inquiries....................................................................... 51

Service Assistance........................................................................................... 51

Mercury Marine Service Offices........................................................................51

Maintenance Log

Maintenance Log.............................................................................................. 53

Accessories

Optional Accessories........................................................................................ 54

Wiring Diagram................................................................................................. 56

Wire Color Code Abbreviations........................................................................ 57

Tool Kit and Spare Parts...................................................................................57

Propeller Recommendation.............................................................................. 58

eng

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Summary of Contents for 4 TwoStroke

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 4 4 9 5 TwoStroke 8M0133462 617 eng...

Page 2: ...eng...

Page 3: ...nual Thoroughly IMPORTANT If you do not understand any portion of this manual contact your dealer Your dealer can also provide a demonstration of actual starting and operating procedures Notice Throug...

Page 4: ...sed on continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Warranty Message The product y...

Page 5: ...kyhook SmartCraft Sport Jet Verado VesselView Zero Effort Zeus 1 On the Water and We re Driven to Win are registered trademarks of Brunswick Corporation Pro XS is a trademark of Brunswick Corporation...

Page 6: ...eng iv...

Page 7: ...10 Model Year Production Code 10 Component Identification 4C 4 9 5BD 12 4 4 9 5 Specifications 13 Installation Installing Outboard 16 Transporting Removing the Motor 18 Carrying the Motor 18 Storing t...

Page 8: ...7 Inspection and Maintenance Schedule 37 Flushing the Cooling System 38 Top Cowl Removal And Installation 39 Corrosion Control Anode 39 Exterior Care 40 Fuel System 40 Propeller Replacement 41 Propell...

Page 9: ...arts and Accessories Inquiries 51 Service Assistance 51 Mercury Marine Service Offices 51 Maintenance Log Maintenance Log 53 Accessories Optional Accessories 54 Wiring Diagram 56 Wire Color Code Abbre...

Page 10: ...eng viii...

Page 11: ...g with using good common sense can help prevent personal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to...

Page 12: ...The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate t...

Page 13: ...d 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 moves w...

Page 14: ...the operator s station without first disconnecting the stop switch lanyard from the operator Accidental or unintended activation of the switch during normal operation is also a possibility This could...

Page 15: ...oat or any solid device attached to the boat can cause serious injury or death to swimmers Stop the engine immediately whenever anyone in the water is near your boat Shift the outboard into neutral an...

Page 16: ...ediately behind the boat platform dragging teak body surfing This dangerous practice not only places a person in an area of high engine exhaust concentration but also subjects them to the possibility...

Page 17: ...s are available from Mercury Marine dealers IMPORTANT Check with your dealer before installing accessories The misuse of approved accessories or the use of nonapproved accessories can damage the produ...

Page 18: ...r Radio Paddle or oar Spare propeller thrust hubs and an appropriate wrench First aid kit and instructions Waterproof storage containers Spare operating equipment batteries bulbs and fuses Compass and...

Page 19: ...hat all passengers have a proper seat and are in it before any boat movement Never operate a boat while under the influence of alcohol or drugs It is the law Alcohol or drugs can impair your judgment...

Page 20: ...rial Number It is important to record the serial number and other important information for future reference Please record the serial number of the engine as indicated on the lower engine cover and th...

Page 21: ...Model Year Manufactured Code Alpha Production Code A B C D E F G H K X Corresponding Number 1 2 3 4 5 6 7 8 9 0 Examples XX 2000 HK 2089 AG 2017 GENERAL INFORMATION eng 11...

Page 22: ...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 GENERAL INFORMATION 12 eng...

Page 23: ...5 Throttle grip 16 Choke knob 17 Stop switch 18 Fuel connector 19 Clamp screw 20 Clamp bracket 21 Trim position pin 22 Oil plug upper 23 Oil plug lower 24 Fuel tank 25 Fuel pickup elbow 26 Primer bulb...

Page 24: ...ore x stroke 55 x 43 mm 2 17 x 1 69 in Displacement 102 mL 6 22 in Exhaust system Through hub exhaust Cooling system Thermostat controlled Lubrication system Engine oil mixed gasoline Fuel Unleaded re...

Page 25: ...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 gal Gear reduction ratio 2 15 13 28 In case of dual fuel tank system use together with 12 L separate tank GENERAL...

Page 26: ...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 it using a cushioning...

Page 27: ...ATTACH THE ENGINE TO THE BOAT 1 Tighten the clamp screws by turning the handles Secure with a cable to prevent accidental loss overboard a Clamp screw 42041 a INSTALLATION eng 17...

Page 28: ...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 catch fire and explode...

Page 29: ...oard The boat should be trailered with the outboard tilted down normal operating position If trailering with the engine fully down is not possible the gearcase skeg is too close to the road in a verti...

Page 30: ...NOTE The tilt support device supplied on your outboard is not intended for towing It is intended to support the engine while the boat is docked beached etc TRANSPORTING 20 eng...

Page 31: ...ntly in use in the USA is alcohol ethanol methanol or butanol GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16 1 butanol Bu16 that meet the published Mercury Marine fuel ra...

Page 32: ...utboard Oil IMPORTANT Oil must be NMMA certified TC W3 2 Cycle oil Mercury or Quicksilver Premium TC W3 2 Cycle oil is recommended for this engine For added protection and lubrication Mercury or Quick...

Page 33: ...the fuel tank Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled The oil and fuel mixture should always be thoroughly mixed in an approve...

Page 34: ...trol 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 accordance with your preference by t...

Page 35: ...Insufficient friction adjustment can cause serious injury or death due to loss of boat control When setting the friction adjustment maintain sufficient steering friction to prevent the outboard from...

Page 36: ...ghtly lower the motor for locking at tilt up position a Tilt up position b Tilt stopper c Tilt lever 4 The spring loaded tilt lock lever will engage automatically and lock the outboard in full up posi...

Page 37: ...dle 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...

Page 38: ...position of the tilt pin in the adjustment holes provided Proper adjustment allows the boat to achieve optimum performance stability and minimize steering effort The following instructions explain ho...

Page 39: ...and water may enter the boat In this case the trim angle should be increased by setting the trim position pin in a higher position a Correct trim b Trim down c Trim up d Move pin to raise bow up e Mo...

Page 40: ...ts the trapped water in the gearcase from freezing and causing possible damage to the water pump and other components If there is a chance of ice forming on the water the outboard should be removed an...

Page 41: ...URE Use a 1 25 oil gasoline mixture in the first tank of fuel BREAK IN PROCEDURE Vary the throttle setting during the first hour of operation During the first hour of operation avoid remaining at a co...

Page 42: ...the lanyard becomes disconnected 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 Mak...

Page 43: ...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 it is firm separa...

Page 44: ...vents 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 If the engine is...

Page 45: ...tion may indicate a water pump failure or blockage in the cooling system These conditions will cause the engine to overheat Have the outboard checked by a dealer Operating the engine while overheated...

Page 46: ...ear with a quick motion Forward Turn the throttle grip to reduce engine speed When the engine reaches trolling or idling speed quickly pull the shift lever to the Forward F position Reverse Reduce eng...

Page 47: ...Inspect the engine tightness on the transom Check the steering system for binding Check the propeller for damage Inspect the hydraulic steering fittings and hoses for leaks or signs of damage if equi...

Page 48: ...item Inspect the engine motor mounts dealer item Flushing the Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt polluted or muddy water This wil...

Page 49: ...has a corrosion control anode installed on the gearcase An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals Th...

Page 50: ...ct the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approve...

Page 51: ...time or after the motor has been stored for a long period of time over three months Propeller Replacement WARNING Rotating propellers can cause serious injury or death Never operate the boat out of th...

Page 52: ...om corroding and seizing to the propeller shaft especially in saltwater always apply the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time...

Page 53: ...throttle Wide open throttle RPM range 4500 5500 Recommended propellers are listed under Propeller Recommendation in the Accessories section of this manual Spark Plug Inspection And Replacement WARNING...

Page 54: ...dirt on the spark plug seat Install plug finger tight and then tighten 1 4 turn or torque to specifications Description Nm lb in lb ft Spark plug 27 20 Lubrication Points 1 Lubricate the following wit...

Page 55: ...ler handle bushing and shift handle detent requires disassembly of the product These points should be lubricated at least once a year by an authorized dealer Tiller Handle Rubber Bushing Lubricate int...

Page 56: ...e lubricant visually 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 lubric...

Page 57: ...capacity is approximately 195 cc 6 6 fl oz GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant CHANGING GEAR OIL 1 Place outboard in a vertical operati...

Page 58: ...tall 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 outboard will require se...

Page 59: ...tion of varnish and gum Proceed with the following instructions Pour the required amount of gasoline stabilizer follow instructions on container into the fuel tank Tip fuel tank back and forth to mix...

Page 60: ...d the inside of the cylinder Rotate the flywheel manually several times to distribute the storage seal in the cylinder Reinstall spark plug Gearcase Drain and refill the gearcase lubricant Refer to Ge...

Page 61: ...nd serial number to order the correct parts Service Assistance Your satisfaction with your outboard product is very important to your dealer and to us If you ever have a problem question or concern ab...

Page 62: ...East Africa Telephone 32 87 32 32 11 Brunswick Marine Europe Parc Industriel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 954 74...

Page 63: ...Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours MAINTENANCE LOG eng 53...

Page 64: ...Optional Accessories 41075 a b c d e f g h i j ACCESSORIES 54 eng...

Page 65: ...n 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 mL j Engine oil 0 4...

Page 66: ...Wiring Diagram 41076 a b c d f e g h i j k l ACCESSORIES 56 eng...

Page 67: ...ions BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN or ORG Orange PNK Pink PPL or PUR Purple RED Red TAN Tan WHT White YEL Yellow LT or LIT Light DK or DRK Dark Tool Kit and Spare Parts A listed...

Page 68: ...r A propeller must be selected so that the engine RPM measured at wide open throttle while cruising is within the recommended range 4500 5500 RPM Light boats Heavy boats Size as indicated on propeller...

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