Mercury FourStroke 4 Operation, Maintenance & Installation Manual Download

Page: 1 / 59

Operation

Maintenance

and

Installation

Manual

2.5, 3.3 TwoStroke

8M0133461

617

eng

Summary of Contents for FourStroke 4

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 2 5 3 3 TwoStroke 8M0133461 617 eng ...

Page 2: ...eng ...

Page 3: ...anual 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 Throughout this publication and on your power package warnings cautions and notices accompanied by the International Hazard Symbol may be used to alert the installer and user to special instructions concer...

Page 4: ...ased 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 you have purchased comes with a limited warranty from Mercury Marine the terms of the warranty are set forth in the Warranty Manual included with the product The Warranty Manual contains a description...

Page 5: ...ok 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 Mercury Product Protection is a registered service mark of Brunswick Corporation Identification Records Please record the following applicable information Outboard Engine Model and Horsepower Engine Seria...

Page 6: ...eng iv ...

Page 7: ...mendations 7 Recording Serial Number 10 Model Year Production Code 11 Specifications 11 Installation Installing Outboard 13 Transporting Carrying Outboard 14 Transporting Outboard When Removed From Boat 14 Trailering Boat 15 Fuel and Oil Fuel Requirements 16 Oil Recommendation 17 Mixing Fuel and Oil 17 Filling Fuel Tank 18 Features and Controls Features and Controls 19 Tilting Outboard 20 Setting ...

Page 8: ...owl Removal And Installation 31 Exterior Care 32 Flushing the Cooling System 32 Propeller Replacement 32 Corrosion Control Anode 34 Spark Plug Inspection And Replacement 35 Engine Idle Speed Adjustment 36 Lubrication Points 37 Gearcase Lubrication 39 Submerged Outboard 41 Storage Storage Preparation 42 Protecting External Outboard Components 42 Protecting Internal Engine Components 42 Gearcase 43 ...

Page 9: ...Owner Service Assistance Service Assistance 45 Ordering Literature 47 Maintenance Log Maintenance Log 49 eng vii ...

Page 10: ...eng viii ...

Page 11: ...ng 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 special safety instructions that should be followed WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which...

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 the switch Tiller handle outboards and some remote control units are equipped with a lanyard stop switch A lanyard stop switch can be installed as an accessory generally on the dashboard or side adjac...

Page 13: ...rd 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 within the boat a sufficient distance from the operator s position Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables bass boat...

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 cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the b...

Page 15: ...boat 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 and shut off the engine before allowing people to swim or be in the water near your boat Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide CO is a deadly gas that is present in th...

Page 16: ...mediately 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 of injury from the boat propeller GOOD VENTILATION Ventilate the passenger area open side curtains or forward hatches to remove fumes Example of desired air flow through the boat 21622 POOR VENTILATI...

Page 17: ...es 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 product Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system Acquire and read the installation operation and maint...

Page 18: ...er 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 map or chart of the area Personal flotation device one per person onboard Watch for signs of weather change and avoid foul weather and rough sea boating Tell someone where you are going and when you...

Page 19: ...that 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 and greatly reduce your ability to react quickly Know your boating area and avoid hazardous locations Be alert The operator of the boat is responsible by law to maintain a proper lookout by sight and...

Page 20: ...oats or other property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement Recording Serial Number It is important to record this number for future reference The serial number is located on the outboard as shown a Serial number b Model designation c Year manufactured d Certified Europe Insignia as applicable XXXXXXX XXXXX...

Page 21: ... F G H K X Corresponding Number 1 2 3 4 5 6 7 8 9 0 Examples XX 2000 HK 2089 AG 2017 Specifications Models 2 5 3 3 Horsepower 2 5 3 3 Kilowatts 1 8 2 4 Full Throttle RPM Range 4000 5000 4500 5500 Idle Speed in Forward Gear 900 1000 RPM Number of Cylinders 1 Piston Displacement 74 6 cc 4 6 cu in Cylinder Bore 47 mm 1 85 in Piston Stroke 43 mm 1 69 in Recommended Spark Plug NGK BPR6HS 10 or Champion...

Page 22: ...Models 2 5 3 3 Gear Ratio 2 18 1 1 85 1 Recommended Gasoline Refer to Fuel and Oil Recommended Oil Refer to Fuel and Oil GENERAL INFORMATION 12 eng ...

Page 23: ... height of your boat The anti ventilation plate should be 25 50 mm 1 2 in below the bottom of the boat a Anti ventilation plate INSTALLING OUTBOARD ON TRANSOM 1 Place outboard on centerline of transom 27005 2 Tighten transom clamp handles 28377 a 28376 INSTALLATION eng 13 ...

Page 24: ... valve and run engine until it stops The running engine will consume remaining fuel in the carburetor 58090 2 Close the fuel tank vent 58089 3 Remove the outboard from the boat and hold upright until all cooling water has drained out 4 Lay the outboard down on its back side so the tiller handle is facing up as shown Place a protective pad under the outboard 28380 TRANSPORTING 14 eng ...

Page 25: ...damage to the outboard The boat should be trailered with the outboard tilted down normal operating position If additional ground clearance is required remove the outboard from the boat and store securely Additional clearance may be needed for railroad crossings driveways and trailer bouncing Side shift models Set the gear shift into forward gear This prevents the propeller from spinning freely 283...

Page 26: ...ently 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 rating requirements are an acceptable substitute for unleaded gasoline Contact your boat manufacturer for specific recommendations on your boat s fuel system components fuel tanks fuel lines and fittin...

Page 27: ...oard 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 Quicksilver Premium Plus TC W3 2 Cycle oil is recommended If Mercury or Quicksilver outboard oil is not available substitute another brand of 2 cycle outboard oil that is NMMA Certified TC W3 Severe engine da...

Page 28: ...at sparks and open flames Always stop engine before refilling tanks Do not overfill 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 approved container before pouring into motor fuel tank Do not pour separately into fuel tank Pour fuel into tank through a f...

Page 29: ...ter engine is warmed up Engine stop switch Lanyard stop switch Push in or pull lanyard to stop engine The engine will not start unless the lanyard is engaged with the stop switch Lanyard Refer to General Information Lanyard Stop Switch a Engine stop switch lanyard stop switch b Throttle lever c Lanyard d Choke lever Fuel shut off valve Turn clockwise to open fuel line and turn counterclockwise to ...

Page 30: ...eve the desired steering friction drag on the tiller handle Move knob clockwise to tighten friction and move knob counterclockwise to loosen friction a Tighten friction b Loosen friction Side handle gear shift if equipped controls gear shift 28385 Tilting Outboard TILTING TO FULL UP POSITION 1 Close the fuel shut off valve and run the engine out of fuel This will prevent fuel spilling out of the c...

Page 31: ...ull out the tilt support pin Lower the outboard 28387 2 Open the fuel tank vent and open the fuel shut off valve Setting The Operating Angle Of Your Outboard The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin in the adjustment holes provided Proper adjustment allows the boat to achieve optimum performance stability and minimize steering effort FEATUR...

Page 32: ... positioned to run perpendicular to the water when the boat is running at full speed This allows the boat to be driven parallel to the water 28388 Arrange passengers and load in the boat so the weight is distributed evenly FEATURES AND CONTROLS 22 eng ...

Page 33: ...o the gearcase is submerged This prevents 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 and drained completely of water If ice should form at the water level inside the outboard driveshaft housing it will block water flow to the engine causing possibl...

Page 34: ...ion avoid remaining at a constant speed for more than two minutes and avoid sustained wide open throttle Starting The Engine Before starting read the Prestarting Check List special operating instructions and Engine Break in Procedure in the Operation section NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient s...

Page 35: ... Information Lanyard Stop Switch NOTE The engine will not start unless the lanyard is engaged with the stop switch STOP 28397 5 If engine is cold move choke lever to closed up position Move halfway down as engine warms up Move down to the open position after engine is warmed up OPERATION eng 25 ...

Page 36: ...d is a direct drive model meaning the lower unit is in gear at all times Do not start the engine with the throttle lever past the start position and remain seated when starting 8 Always remain seated when attempting to start the engine Pull the starter rope slowly until the starter engages then pull rapidly to crank the engine Allow rope to return slowly Repeat until engine starts 28399 STOP a b 2...

Page 37: ...ator hole stop engine and check cooling water intake for obstruction No obstruction 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 your dealer Operating the engine while overheated will cause engine damage 28400 Gear Shifting Models with Gear Shift The outboard has two gear shift positions to provi...

Page 38: ...ve when starting the engine with the emergency starter rope Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear 1 Side shift models Shift outboard to neutral position 2 Remove three bolts and rewind starter assembly 28402 3 Reinstall the rear rewind starter mounting bolt into the fuel tank IMPORTANT The black lead from the engine stop switch wil...

Page 39: ...the key is turned on especially when starting or operating the engine Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests WARNING The exposed moving flywheel can cause serious injury Keep your hands hair clothing tools and other objects away from engine when starting or running the engine Do not attempt to reinstall the rewind starter...

Page 40: ...s 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 equipped Check the hydraulic steering fluid level if equipped AFTER EACH USE Wash the power package exterior with fresh water Flush the outboard cooling system saltwater or brackish water only ANNUALLY O...

Page 41: ...ctors dealer item Check the remote control cable adjustment if equipped dealer item Replace the high pressure fuel filter if equipped dealer item Replace the accessory drive belt if equipped dealer item Check the power trim fluid level if equipped dealer item Inspect the engine motor mounts dealer item Top Cowl Removal And Installation REMOVAL 1 Open cowl latches on both sides of cowl 28406 2 Lift...

Page 42: ... test tank containing fresh water IMPORTANT Do not run engine above idle when flushing 2 Start the outboard and operate at idle RPM in neutral for five minutes Propeller Replacement WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the ...

Page 43: ...t be removed have the propeller removed by an authorized dealer 28706 IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft especially in saltwater always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed MAINTENANCE eng 33 ...

Page 44: ...n propeller engages with the drive pin 8 Install the cotter pin through hole in propeller and bend cotter pins to secure the propeller in place a Cotter pin b Propeller c Drive pin 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 slowly corroded instead of the ...

Page 45: ...eness of the anode 28709 Spark Plug Inspection And Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl resulting in serious injury or death from a fire or explosion To avoid damaging the spark plug boots do not use any sharp object or metal tool to remove the spark plug boots 1 Open the spark plug access door 287111 2 Remove the spark plug...

Page 46: ...k plug gap 1 0 mm 0 040 in 5 Before installing spark plug clean off any dirt on the spark plug seats Install plugs finger tight and then tighten 1 4 turn or torque to specifications Description Nm lb in lb ft Spark plug 27 20 Engine Idle Speed Adjustment 1 With boat tied securely to dock start engine and allow it to warm up 2 With outboard in forward gear reduce engine speed to idle MAINTENANCE 36...

Page 47: ...ecifications 28712 Lubrication Points 1 Lubricate the following with 2 4 C with PTFE Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Copilot threads swivel bracket tilt support pin transom clamp screw threads propeller shaft 92 802859A 1 Copilot Lubricate threads 28713 MAINTENANCE eng 37 ...

Page 48: ... 28714 Tilt support pin 28387 Transom clamp screw threads 28715 Propeller shaft Refer to Propeller Replacement for removal and installation of the propeller Apply 2 4 C with PTFE to the entire propeller shaft to prevent the propeller hub from corroding to the shaft 28707 MAINTENANCE 38 eng ...

Page 49: ...red appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gearcase Examine the drained gearcase lubricant for metal particles A small amount of metal particles indicates normal gear wear An excessive amount of metal filings or larger particles chips may indic...

Page 50: ...erating position 2 Remove vent plug 3 Remove fill drain plug Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole a Vent plug b Vent hole c Fill drain plug IMPORTANT Replace sealing washers if damaged 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove lubricant tube and reinstall cleaned fill drain plu...

Page 51: ...ithin 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 atmosphere to minimize internal corrosion damage to the engine MAINTENANCE eng 41 ...

Page 52: ...ation 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 stabilizer with the fuel Place the outboard in water or connect flushing attachment for circulating cooling water Start the outboard and operate at idle RPM in neutral for five minutes to allow stabi...

Page 53: ...nd 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 Gearcase Lubrication Positioning Outboard for Storage Store outboard in an upright vertical position to allow water to drain out of the outboard NOTICE Storing the outboard in a tilted position can dam...

Page 54: ...park plug fouled or defective Refer to Maintenance section Carburetor inlet needle stuck from contaminated gasoline Engine Runs Erratically POSSIBLE CAUSES Spark plug fouled or defective Refer to Maintenance section Fuel is being restricted to the engine a Fuel tank vent not open or restricted b Fuel tank filter obstructed Ignition system component failure Performance Loss POSSIBLE CAUSES Damaged ...

Page 55: ...he model and serial numbers and to whom the recovery is to be reported This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packages ATTENTION REQUIRED AFTER SUBMERSION 1 Before recovery contact an authorized Mercury dealer 2 After recovery immediate service by an authorized Mercury dealer is required to reduce the possibilit...

Page 56: ...rvice manager Contact the owner of the dealership if the sales manager and service manager have been unable to resolve the problem 2 If your question concern or problem cannot be resolved by your dealership please contact the Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the Cus...

Page 57: ...r FL 33025 U S A Fax 1 954 744 3535 Japan Telephone 072 233 8888 Kisaka Co Ltd 4 130 Kannabecho Sakai ku Sakai shi Osaka 590 0984 Japan Fax 072 233 8833 Asia Singapore Telephone 65 65466160 Brunswick Asia Pacific Group T A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore 508944 Fax 65 65467789 Ordering Literature Before ordering literature have the following information about your power ...

Page 58: ...ce center to order additional literature that is available for your particular power package Submit the following order form with payment to Mercury Marine Attn Publications Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Copy this form and print or type This is your shipping label Name Address City State Province ZIP or postal code Country Quantity Item Stock Number P...

Page 59: ...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 49 ...

Search results

Summary of Contents for FourStroke 4

Reviews:

Related manuals for FourStroke 4

Brands by name

Popular brands

Mercury FourStroke 4, Operation, Maintenance & Installation Manual

Search results

Summary of Contents for FourStroke 4

Reviews:

Related manuals for FourStroke 4

Brands by name

Popular brands