Mercury FourStroke 4 Manual Download

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MAINTENANCE

eng

• Check that the idle relief muffler (if equipped) is in place.
• Check for loose hose clamps and rubber boots (if equipped)

on the air intake assembly.

BEFORE PERIODS OF STORAGE

• Refer to storage procedure. See Storage section.

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 will

help prevent a buildup of deposits from clogging the internal

water passages.
Use a Mercury Precision or Quicksilver accessory (or equivalent)

flushing attachment.

NOTE: Do not run the engine while flushing the cooling system.

1. Remove the plug and gasket.
2. Install the hose coupling into the plug opening.
3. Attach a water hose to the hose coupling. Turn on the water

gently and flush the cooling system for 3–5 minutes.

4. Remove the hose coupling and install the plug and gasket.

a -

Plug and gasket

b -

Hose coupling

Top Cowl Removal and Installation

REMOVAL

1. Release the rear latch.

45633

Summary of Contents for FourStroke 4

Page 1: ...u 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 conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments being set to factory standards For this reason...

Page 2: ...ation Mercury Marine Fond du Lac Wisconsin U S A Litho in U S A 2011 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers Mariner Quicksilver 1 On The Water Alpha Bravo Pro Max OptiMax Sport Jet K Planes MerCathode RideGuide SmartCraft Zero Effort M with Waves logo Mercury with Waves logo and SmartCraft logo are all registere...

Page 3: ... of engine manufacturer Tohatsu Marine Corporation TMC Mercury Marine Joint Venture Address Shimodaira 4495 9 Town Komagane City Nagano Post Code 399 4101 Country Japan Name of Authorized Representative Brunswick Marine in EMEA Inc Address Parc Industriel de Petit Rechain Town Verviers Post Code B 2800 Country Belgium Name of Notified Body for exhaust emission assessment Det Norske Veritas AS Addr...

Page 4: ...EC Electromagnetic Compatibility Directive 2004 108 EC Description of Engines and Essential Requirements Engine Type Fuel Type Combustion Cycle z or sterndrive without integral exhaust Diesel 2 stroke Outboard engine Petrol 4 stroke Identification of Engines Covered by This Declaration of Conformity Name of engine family Unique engine identification number starting serial number EC Module H certif...

Page 5: ...O 8665 1995 Annex 1 C Noise Emissions C 1 Noise emission levels EN ISO 14509 C 2 Owner s manual Owner s manual This declaration of conformity is issued under the sole responsibility of the manufacturer I declare on behalf of the engine manufacturer that the engines mentioned preceding complies with all applicable essential requirements in the way specified Name function Mark D Schwabero President ...

Page 6: ...vi eng ...

Page 7: ...ons Limited Warranty 20 Emission Control System Components 20 California Emissions Limited Warranty 21 California Air Resources Board Explanation of Your California Emission Control Warranty Statement 25 Emission Certification Star Label 26 GENERAL INFORMATION Boater s Responsibilities 28 Before Operating Your Outboard 28 Boat Horsepower Capacity 29 Lanyard Stop Switch 29 Protecting People in the ...

Page 8: ...zed Portable Fuel Tank 46 Filling Fuel Tank 47 Engine Oil Recommendations 48 Checking Engine Oil 49 FEATURES AND CONTROLS Features and Controls 51 Tilting Outboard 53 Shallow Water Operation 54 Setting the Operating Angle of Your Outboard 56 Engine Overspeed Protection System 56 OPERATION Prestarting Check List 57 Operating in Freezing Temperatures 57 Operating in Saltwater or Polluted Water 58 En...

Page 9: ...on and Replacement 75 Lubrication Points 76 Changing Engine Oil 79 Gearcase Lubrication 80 Submerged Outboard 82 STORAGE Storage Preparation 83 Protecting External Outboard Components 83 Protecting Internal Engine Components 84 Gearcase 84 Positioning Outboard for Storage 84 OWNER SERVICE ASSISTANCE Local Repair Service 86 Service Away from Home 86 Parts and Accessories Inquiries 86 Service Assist...

Page 10: ...x eng ...

Page 11: ...ealer on marine products sold in the United States should a safety recall notification under the Federal Safety Act be required You may change your address at any time including at time of warranty claim by calling Mercury Marine or sending a letter or fax with your name old address new address and engine serial number to Mercury Marine s warranty registration department Your dealer can also proce...

Page 12: ...d du Lac WI 54936 1939 920 929 5054 Fax 1 920 929 5893 Upon processing the transfer of warranty Mercury Marine will record the new owner s information There is no charge for this service OUTSIDE THE UNITED STATES AND CANADA For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Center closest to you Transfer of Mercury Produc...

Page 13: ...not transferable from one product to another product or for non eligible applications The Certified Pre Owned engine plans are not transferable For help or assistance contact Mercury Product Protection Department at 1 888 427 5373 from 7 30 a m to 4 30 p m CST Monday Friday or email mpp_support mercmarine com FourStroke Outboard Limited Warranty UNITED STATES AND CANADA Outside the United States a...

Page 14: ...on proper reregistration of the product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer Warranty coverage may be terminated for used repossessed product or product purchased at auction from a salvage yard or from an insurance company CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers...

Page 15: ...or warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer written notice must be given to Mercury We will then arrange for the inspection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If t...

Page 16: ...ake air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body running the engine out of water mounting the engine too high on the transom or running the boat with the engine trimmed out too far Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point eve...

Page 17: ...OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY FourStroke Out...

Page 18: ...coverage can be transferred from one recreational use customer to a subsequent recreational use customer upon proper reregistration of the product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer Warranty coverage may be terminated for used or repossessed product or product purchased at auction from a salvage yard or from an insurance company CONDITIONS...

Page 19: ...or warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer written notice must be given to Mercury We will then arrange for the inspection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If t...

Page 20: ...ntake air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body running the engine out of water mounting the engine too high on the transom or running the boat with the engine trimmed out too far Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point e...

Page 21: ...ARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE ...

Page 22: ...the 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 only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified...

Page 23: ...is 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 engine to run in its recommended wide open throttle RPM range see the Operation and Maintenance Manual operation of the product in a manner inconsistent with the recommended operation duty cycle section o...

Page 24: ...garding 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 by this warranty and 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...

Page 25: ...equent 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 that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified predelivery inspection proce...

Page 26: ...lated 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 that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warran...

Page 27: ...ween 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 additional details For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manua...

Page 28: ...ion 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 WARRANTY 1 Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connecti...

Page 29: ...intenance 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 other competitive activity or 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 conditio...

Page 30: ...the time of sale with applicable regulations under section 213 of the Clean Air Act and that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations This emission related warranty covers all the components listed in the Emission Control System Components Emission Control System Components The EPA and Califormia emission rel...

Page 31: ...ty The California Air Resources Board has promulgated air emission regulations for outboard engines The regulations apply to all outboard engines sold to retail consumers in California and which were manufactured for the 2001 model year and later Mercury Marine in compliance with those regulations provides this limited warranty for the emission control systems see the components listed in the Emis...

Page 32: ... a warranted part will also be repaired under warranty DURATION OF COVERAGE This limited warranty provides coverage for the components of the emissions control systems of new 2001 model year and later outboards sold to retail customers in California for four 4 years from either the date the product is first sold or first put into service whichever occurs first or the accumulation of 250 hours of e...

Page 33: ...is warranty is limited to at our expense and at our option repairing or replacing defective parts with new or Mercury Marine certified remanufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured WHAT IS NOT COVERED This limited warrant...

Page 34: ... Regulations or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim at the discretion of Mercury Marine Failures of warranted parts caused by the use of a nonexempted add on or modified part will not be covered DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLA...

Page 35: ...ssemblies Where a warrantable condition exists Mercury Marine will repair your outboard engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Select emission control parts from model year 2001 and later outboard engines are warranted for four 4 years or for 250 hours of use whichever occurs first However warranty coverage based on the hourly period is only p...

Page 36: ...The symbol for a cleaner marine engine means Cleaner air and water for a healthier lifestyle and environment Better fuel economy burns up to 30 40 percent less gas and oil than conventional carbureted two stroke engines saving money and resources Longer emission warranty protects consumer for worry free operation 22531 One Star Low Emission The One Star label identifies engines that meet the Air R...

Page 37: ...xhaust emission standards Engines meeting these standards have 65 lower emissions than One Star Low Emission engines 42539 Four Stars Super Ultra Low Emission The Four Star label identifies engines that meet the Air Resources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meet...

Page 38: ...utboard 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 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 DANGER Indicates a hazardous ...

Page 39: ...ufacturer 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 CAPACITY XXX 26777 Lanyard Stop Switch 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 f...

Page 40: ...ormation 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 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 ...

Page 41: ...ng 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 resulting from accidental or unintended stop switch activation The boat operator should never leave the operator s station without first disconnecting the stop switch lanyard from the operator Accidental...

Page 42: ...tral propeller rotation can cause serious injury WHILE BOAT IS STATIONARY WARNING A spinning propeller a moving 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 outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat Exha...

Page 43: ...ION Ventilate passenger area open side curtains or forward hatches to remove fumes 21622 Example of desired air flow through the boat POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas enclosed 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 r...

Page 44: ... or Quicksilver Accessories have been specifically designed and tested for your outboard These accessories 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 us...

Page 45: ...oating law enforcement agency Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT Make sure everyone in the boat is properly seated Do not allow anyone to sit or ride on any part of the boat that was not intended for such use This includes the back of seats gunwales transom bow decks raised fishing seats any rotating fishing seat...

Page 46: ...ing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to assist the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is invol...

Page 47: ...68 kw 5 hp 4 41 kw 6 hp Full throttle RPM range 4500 5500 5000 6000 Idle speed 1100 RPM in Forward Gear 1300 RPM in Neutral Number of cylinders 1 Piston displacement 123 cc 7 51 cid Cylinder bore 59 mm 2 32 in Piston stroke 45 mm 1 77 in Valve clearance cold Intake valve 0 06 0 14 mm 0 002 0 005 in Exhaust valve 0 11 0 19 mm 0 004 0 007 in Engine oil capacity 450 ml 15 fl oz Recommended spark plug...

Page 48: ...ON 38 eng Models 4 5 6 Gear ratio 2 15 1 Recommended gasoline Refer to Fuel and Oil Emission control system Engine modification EM Sound at drivers ear ICOMIA 39 94 bBA 82 2 Tiller handle vibration ICOMIA 38 94 m s 7 3 ...

Page 49: ... Measure the transom 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 45603 a 27004 ...

Page 50: ... a Remote fuel line b Protector cap 2 With the outboard still in the water move the fuel valve to the OFF closed position Run engine until it stops This will drain fuel from the carburetor Close the fuel tank vent a Fuel valve OFF position b Fuel tank vent 3 Remove outboard and hold it upright until the water is drained out Keep the outboard in an upright position when carrying a b 45604 a b 45605...

Page 51: ...e crankcase 45596 Trailering Your Boat IMPORTANT The tilt lock mechanism is not intended to support the outboard in the tilted up position when trailering your boat Use of the tilt lock mechanism could allow the outboard 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 requ...

Page 52: ...TRANSPORTING 42 eng Set the gear shift into forward gear This prevents the propeller from spinning freely 45597 ...

Page 53: ... 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 ethanol or ether MTBE or ETBE If ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol These reformulated gasolines are acceptable for use in your Mercury...

Page 54: ...ion 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 that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is...

Page 55: ...Tank Requirements The Environmental Protection Agency EPA will require portable fuel systems that are produced after January 1 2011 for use with outboard engines to remain fully sealed pressurized up to 34 4 kPa 5 0 psi These tanks may contain the following An air inlet that opens to allow air to enter as the fuel is drawn out of the tank An air outlet that opens vents to the atmosphere if pressur...

Page 56: ...tank as the fuel is drawn to the engine and also opens to vent to the atmosphere if internal pressure in the tank exceeds 34 4 kPa 5 0 psi A hissing noise may be heard as the tank vents to the atmosphere This is normal The fuel tank includes a fuel demand valve that prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage When installing the f...

Page 57: ...ling the fuel tank cap turn the cap to the right until you hear a click This signals that the fuel cap is fully seated A built in device prevents overtightening 2 Open the manual vent screw on top of the cap for operation and cap removal Close the manual vent screw for transportation 3 For fuel hoses that have quick disconnects disconnect the fuel line from the engine or fuel tank when not in use ...

Page 58: ...UEL TANK PLACEMENT IN THE BOAT Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions Engine Oil Recommendations We recommend the use of Mercury or Quicksilver NMMA FC W certified 10W 30 4 Stroke Outboard Oil for general all temperature use If NMMA certified synthetic blend 25W 40 4 Stroke outboard oil is preferred use Mercury or Quicksilve...

Page 59: ...MA FC W certified 10W 30 4 stroke outboard oil is recommended for use in all temperatures Checking Engine Oil IMPORTANT Do not overfill Be sure that the outboard is upright not tilted when checking oil 1 Position the outboard vertical and remove the top cowl 2 Remove the oil filler cap Wipe oil off the dipstick and screw the oil filler cap back into the oil fill hole completely Remove the oil fill...

Page 60: ...ects in the crankcase eventually ends up in the oil sump and will add to the total volume of oil that appears on the dipstick reading This increase in oil volume is known as oil dilution Outboard engines can typically handle large amounts of oil dilution without causing durability problems However to ensure extended life of the outboard engine Mercury recommends that the oil be changed regularly f...

Page 61: ...fuel tank a Fuel shut off valve b ON open position c OFF closed position Choke knob Pull completely out when starting a cold engine Push halfway in as engine is warming up Push in completely after engine is warmed up Oil pressure indicator If oil pressure drops too low the oil pressure indicator light will turn on If the oil pressure indicator light turns on while the engine is running stop the en...

Page 62: ...knob clockwise to tighten friction or turn knob counterclockwise to loosen friction a Throttle grip friction knob b Loosen friction counterclockwise c Tighten friction clockwise WARNING 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 steering into a...

Page 63: ... Turn knob clockwise to tighten friction and counterclockwise to loosen friction a Loosen friction counterclockwise b Tighten friction clockwise c Steering friction knob Shift handle Controls gear shift a Shift handle Tilting Outboard TILTING TO FULL UP POSITION 1 Stop the engine Shift the outboard into forward gear 45615 a b c R F N a 45917 ...

Page 64: ...ically and lock the outboard in full up position LOWERING TO RUN POSITION Raise the outboard and pull up on the tilt release lever Gently lower outboard down a Tilt release lever b Tilt lock lever Shallow Water Operation This outboard has a shallow water drive position This will allow you to tilt the outboard to a higher position to prevent hitting bottom a b 45616 ...

Page 65: ...utomatically and lock the outboard in the shallow water drive position 45599 2 Ensure the cooling water intake is submerged 27029 IMPORTANT Operate 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 release lever Gently lower outboard down a Tilt release lev...

Page 66: ...d load in the boat so the weight is distributed evenly a Tilt pin IMPORTANT Do not operate the outboard with the tilt pin removed Engine Overspeed Protection System The engine overspeed 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 overspeed protection system is activated the engin...

Page 67: ...hile 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 Maintenance Schedule Operating in Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures keep the outboard tilted down at all times so t...

Page 68: ...t spray on corrosion control anodes as this will reduce the effectiveness of the anodes Engine Break in Procedure IMPORTANT Failure to follow the engine break in procedures can result in poor performance throughout the life of the engine and can cause engine damage Always follow break in procedures 1 For the first hour of operation run the engine at varied throttle settings up to 2000 RPM or at ap...

Page 69: ...eat and suffer damage Provide a sufficient supply of water to the water inlets during operation 1 Ensure the cooling water intake is submerged 27029 2 Check the engine oil level 27030 3 Shift outboard to neutral N position R F N 45602 NOTE The engine will not start unless the lanyard is engaged with the stop switch ...

Page 70: ...tarting procedure when using the internal fuel tank for fuel a Open the fuel cap vent on the internal fuel tank b Move the fuel valve to the ON open position a Fuel valve ON open position b Fuel tank vent 6 Starting procedure when using optional remote fuel tank a Close the fuel cap vent on the internal fuel tank b a 45619 b a 45621 ...

Page 71: ... fuel line to the outboard d Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up Squeeze the fuel line primer bulb several times until it feels firm a Remote fuel hose b Primer blub e Open the fuel tank vent on manual venting type tanks 19748 7 Position the throttle grip as follows a b 45605 a b 45623 ...

Page 72: ...fway as the engine is warming up Push in completely after engine is warmed up a Choke NOTE Starting flooded engine Push in the choke knob Wait 30 seconds then continue to crank engine for starting 9 Pull the starter rope slowly until you feel the starter engage then pull rapidly to crank the engine Allow rope to return slowly Repeat until engine starts a Starter rope START RE START a b 45624 a 456...

Page 73: ...y 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 may cause serious engine damage 45601 Gear Shifting Your outboard has three gear shift positions to provide operation Forward F Neutral N and Reverse R Reduce throttle speed to idle speed Always shift out...

Page 74: ...ld break or the rewind starter fails use the spare starter rope provided and follow this procedure 1 Shift outboard to neutral position N 45629 WARNING The neutral speed protection device is inoperative 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 b a 45619 ...

Page 75: ...ed with outboard 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 assembly or top cowl when engine is running 4 Place the starter rope knot into the starter cup notch and wind the rope clockwise around the cup a b 45630 a 45631 ...

Page 76: ...OPERATION 66 eng 5 Pull the starter rope to start the engine a Starter rope provided with outboard a 45632 ...

Page 77: ...l Mercury Precision or Quicksilver replacement parts and Genuine Lubricants EPA Emission Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments set to factory s...

Page 78: ...perator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications Inspection and Maintenance Schedule BEFORE EACH USE Check engine oil level See Fuel and Oil Checking and Adding Engine Oil Visually inspect the fuel system for deterioration or leaks 2008 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC THIS...

Page 79: ...nging Engine Oil 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 See Spark Plug Inspection and Replacement Drain and replace gearcase lubricant See Gearcase Lubrication Check fuel line filter for contaminants See Fuel System Check corrosion control anode Check more frequently when used in saltwater See Co...

Page 80: ...ll help prevent a buildup of deposits from clogging the internal water passages Use a Mercury Precision or Quicksilver accessory or equivalent flushing attachment NOTE Do not run the engine while flushing the cooling system 1 Remove the plug and gasket 2 Install the hose coupling into the plug opening 3 Attach a water hose to the hose coupling Turn on the water gently and flush the cooling system ...

Page 81: ...ontrol 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 The anode requires periodic inspection especially in saltwater which will accelerate the erosion To maintain this corrosion protection always replace the anode before it is completely eroded Never paint or apply a protec...

Page 82: ...d wipe up any spilled fuel immediately Before servicing any part of the fuel system stop the engine and disconnect the battery Drain the fuel system completely Use an approved container to collect and store the fuel Wipe up any spillage immediately Material used to contain the spillage must be disposed of in an approved receptacle Any fuel system service must be performed in a well ventilated area...

Page 83: ...ver 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 lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate 1 Remove the spark plug lead to prevent engine from starting 26899 2 Move gear shift lever into neutral N 456...

Page 84: ... of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 6 Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with PTFE 27095 Tube Ref No Description Where Used Part No 94 Anti Corrosion Grease Propeller shaft 92 802867Q 1 95 2 4 C with PTFE Propeller shaft ...

Page 85: ...t thrust washer Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks which 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 Remove the spark plug boot Twist the rubber boot slightly and pull off...

Page 86: ...spark plug clean off any 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 with Quicksilver or Mercury Precision Lubricants 2 4 C with PTFE or Special Lubricant 101 Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Co pilot swivel bracket tr...

Page 87: ...5Q02 Co pilot lubricate threads Swivel bracket lubricate through fittings a Swivel bracket lubrication fittings b Co pilot Transom clamp screws lubricate threads a Transom clamp screws NOTE Lubricating the tiller handle bushing and shift detent shaft requires disassembly of the product These points should be lubricated at least once a year by an authorized dealer a b 45640 a 45641 ...

Page 88: ...nt shaft a Shift detent 2 Lubricate the tilt pivot points with lightweight oil a Tilt pivot points 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 Corrosion Grease Propeller shaft 92 802867Q 1 a 45642 a 45648 a 45643 ...

Page 89: ...haft with lubricant to prevent the propeller hub from corroding to the shaft 27095 Changing Engine Oil ENGINE OIL CAPACITY Engine oil capacity is approximately 450 ml 15 fl oz OIL CHANGING PROCEDURE 1 Place outboard in an upright not tilted position 2 Turn the outboard to gain access to the drain plug Remove drain plug and drain engine oil into an appropriate container Lubricate the seal on the dr...

Page 90: ... necessary Gearcase Lubrication When adding or changing gearcase 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 lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result i...

Page 91: ...d drain lubricant a Vent plug b Fill drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 195 ml 6 6 fl oz GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1 Place outboard in a vertical operating position 2 Remove vent plug from vent hole a b 27146 ...

Page 92: ...lug and sealing washer before removing the lubricant tube 5 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer Submerged Outboard A submerged outboard will require 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 atmosphere to min...

Page 93: ...ng 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 tank and engine fuel system with treated stabilized fuel to help prevent formation of varnish and gum Proceed with the following instructions Pour the required amount of gasoline stabilizer follow instructions on container into the...

Page 94: ... engine oil Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubrication Positioning Outboard for Storage NOTICE Storing the outboard in a tilted position can damage the outboard Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze Store the outboard in the full down position 1 Carry transport or store the outboa...

Page 95: ...STORAGE eng 85 2 Never carry store or transport the outboard in the positions shown below Engine damage could result from oil draining out of the crankcase 27012 ...

Page 96: ...local 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 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 about your outboard product...

Page 97: ...4936 1939 Fax English 920 929 5893 Français 905 636 1704 Website www mercurymarine com Australia Pacific Telephone 61 3 9791 5822 Brunswick Asia Pacific Group 41 71 Bessemer Drive Dandenong South Victoria 3175 Australia Fax 61 3 9706 7228 Europe Middle 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 Cen...

Page 98: ...OWNER SERVICE ASSISTANCE 88 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 99: ...MAINTENANCE LOG eng 89 Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours ...

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