© 2018 Mercury Marine Operation Maintenance and Installation Manual 4/5/6 FourStroke 8M0145516 418 eng
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Welcome You have selected one of the finest marine power packages available. It incorporates numerous design features to ensure operating ease and durability. With proper care and maintenance, you will enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual. The Operation and Maintenance Manual contains specific instructions for using and maintaining your product.
NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. IMPORTANT: The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard, and the safety of all occupants aboard.
Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, GO BOLDLY.
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General Information Boater's Responsibilities..................................................................................... 1 Before Operating Your Outboard........................................................................ 1 Boat Horsepower Capacity................................................................................. 1 Lanyard Stop Switch........................................................................................... 2 Protecting People in the Water.......................
Features and Controls Features and Controls...................................................................................... 21 Tilting Outboard................................................................................................ 23 Shallow Water Operation ................................................................................. 24 Setting the Operating Angle of Your Outboard ................................................ 25 Engine Overspeed Protection System.......................
Storage Storage Preparation.......................................................................................... 49 Protecting External Outboard Components...................................................... 49 Protecting Internal Engine Components........................................................... 49 Gearcase.......................................................................................................... 50 Positioning Outboard for Storage............................................
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GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public. It is strongly recommended that each operator read and understand this entire manual before operating the outboard. Be sure that at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.
GENERAL INFORMATION Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. U.S.
GENERAL INFORMATION The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.
GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.
GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
GENERAL INFORMATION ! WARNING Inhaling engine exhaust gases can 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‑ventilated while at rest or underway. STAY CLEAR OF EXHAUST AREAS co co co co co co co co co co co co co co co co co co co co 41127 Engine exhaust gases contain harmful carbon monoxide.
GENERAL INFORMATION 1. Examples of poor ventilation while the boat is stationary: a b 21626 a - Operating the engine when the boat is moored in a confined space b - Mooring close to another boat that has its engine operating 2.
GENERAL INFORMATION • We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628). Perform safety checks and required maintenance. • Follow a regular schedule and ensure that all repairs are properly made. Check safety equipment onboard.
GENERAL INFORMATION • Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard. Do not overload your boat. • Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water.
GENERAL INFORMATION • Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) 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 $500.00, or 4) there is complete loss of the boat.
GENERAL INFORMATION 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 4/5/6 Specifications Models Power Full throttle RPM range Idle speed 4 2.9 kw (4 hp) 5 6 3.7 kw (5 hp) 4.4 kw (6 hp) 4500–5500 5000–6000 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.
INSTALLATION Installing Outboard BOAT TRANSOM HEIGHT REQUIREMENT 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 a 27004 INSTALLING OUTBOARD ON TRANSOM 1. Place the outboard on the centerline of the transom. 27005 2. Tighten the transom clamp handles.
TRANSPORTING Carrying, Storing, and Transporting Your Outboard When Removed from Boat 1. Remote fuel tank models ‑ Disconnect the remote fuel line. Install the protector cap over the fuel connector. b a 45604 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 the engine until it stops. This will drain fuel from the carburetor. Close the fuel tank vent. a b 45605 a - Fuel valve "OFF" position b - Fuel tank vent 3.
TRANSPORTING 4. Carry, transport, or store the outboard only in the upright position or tiller handle down position. These positions will prevent oil from draining out of the crankcase. NOTICE 37-892904-010 a - Upright position b - Tiller handle down position THIS SIDE UP a b 45595 NOTE: Never carry, store, or transport the outboard in these positions. Engine damage could result from oil draining out of the crankcase.
FUEL AND OIL Fuel Requirements IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine and will not be covered under the limited warranty. FUEL RATINGS Mercury outboard engines will operate satisfactorily with any major brand of unleaded gasoline that meets the following specifications: USA and Canada ‑ A posted pump octane rating of 87 (R+M)/2, minimum, for most models.
FUEL AND OIL ! WARNING Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration requires replacement before further engine operation. IMPORTANT: If you use gasoline that contains or might contain methanol or ethanol, you must increase the frequency of inspection for leaks and abnormalities.
FUEL AND OIL The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case of a fuel blockage in the valve. b a c 46453 a - Fuel demand valve ‑ installed in the fuel hose between the fuel tank and primer bulb b - Manual release c - Vent/water drain holes Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements.
FUEL AND OIL 1. Open the manual vent screw on top of the fuel cap. 2. Turn the fuel cap until it contacts the tab lock. 3. Press down on the tab lock. Rotate the fuel cap 1/4 turn to relieve the pressure. 4. Press down on the tab lock again and remove the cap. DIRECTIONS FOR USING THE PRESSURIZED PORTABLE FUEL TANK 1. When installing 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.
FUEL AND OIL IMPORTANT: The use of nondetergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality or oils that contain solid additives are not recommended.
FUEL AND OIL NOTE: If oil level is at the add mark, add 100 ml (3 oz) of oil. a - Full mark b - Add mark a b 45609 NOTE: Under certain conditions, the operating temperature of four‑stroke outboard engines may not get hot enough to evaporate the normal fuel and moisture that accumulate in the crankcase. These conditions include operating at idle for long periods, repeated short trips, slow speed or quick stop‑and‑go operation, and operating in cooler climates.
FEATURES AND CONTROLS Features and Controls Fuel shut‑off valve for internal fuel tank ‑ Turn valve up to close or down to open. If an optional remote fuel tank is used, turn valve up when using the remote fuel tank. Turn valve down when using the internal fuel tank. • Using internal fuel tank ‑ Turning valve up to "OFF" (stops fuel flow). Turning valve down to "ON" (opens fuel flow). • Using optional remote fuel tank ‑ Turn valve up to the "OFF" position when using the remote fuel tank.
FEATURES AND CONTROLS Remote the fuel tank connector ‑ For optional remote fuel tank. b a c a - Choke knob b - Oil pressure indicator light c - Lanyard stop switch d - Remote fuel connector e - Lanyard d e 45613 Throttle grip friction knob ‑ Turn the friction knob to set and maintain the throttle at desired speed. Turn the knob clockwise to tighten friction or turn the knob counterclockwise to loosen friction.
FEATURES AND CONTROLS Shift handle ‑ Controls the gear shift. N F R a 45917 a - Shift handle Tilting Outboard TILTING TO FULL UP POSITION 1. 2. Stop the engine. Shift the outboard into forward gear. Take hold of the top cowl grip and raise the outboard to the full up position. 54600 3. The spring loaded tilt lock lever will engage automatically and lock the outboard in full up position. LOWERING TO RUN POSITION Raise the outboard and pull up on the tilt release lever.
FEATURES AND CONTROLS 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. ENGAGING SHALLOW WATER DRIVE 1. Reduce the engine speed to idle 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 drive position. 45599 2.
FEATURES AND CONTROLS 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. The tilt pin should be adjusted so the outboard is 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.
OPERATION Prestarting Check List • Operator knows safe navigation, boating, and operating procedures. • An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). • A ring type life buoy or buoyant cushion designed to be thrown to a person in the water. • Know your boats' maximum load capacity. Look at the boat capacity plate. • Fuel supply OK.
OPERATION 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 approximately half throttle. 2.
OPERATION 3. Shift the outboard to neutral (N) position. N F R 45602 NOTE: The engine will not start unless the lanyard is engaged with the stop switch. 4. Attach the lanyard to the stop switch. Refer to General Information ‑ Lanyard Stop Switch. a - Lanyard b - Stop switch b a 45619 5. Starting 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.
OPERATION a. Close the fuel cap vent on the internal fuel tank. b. Move the fuel valve to the "OFF" (closed) position. a b 45605 a - Fuel valve "OFF" (closed) position b - Fuel cap vent c. Connect the remote 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 b 45623 a - Remote fuel hose b - Primer blub e. Open the fuel tank vent on manual venting type tanks.
OPERATION • Warm engine ‑ Move to the RE‑START position. RE-START START a a - Warm engine start b - Cold engine start b 45624 8. If engine is cold, completely pull out the choke. Push in the choke halfway as the engine is warming up. Push in completely after engine is warmed up. a - Choke a 45625 NOTE: Starting flooded engine ‑ Push in the choke knob. Wait 30 seconds, then continue to crank engine for starting. 9.
OPERATION IMPORTANT: If no water is coming out of the water pump indicator 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 may cause serious engine damage.
OPERATION Stopping the Engine Reduce the engine speed and push in the stop switch or pull the lanyard. a - Lanyard b - Stop switch b a 45619 Emergency Starting If the starter rope should break or the rewind starter fails, use the spare starter rope (provided) and follow this procedure. 1. Shift the outboard to neutral position. N 45629 ! WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope.
OPERATION 2. Disconnect the linkage from the rewind starter assembly. a b 45630 a - Rewind starter assembly b - Linkage 3. Remove the three 10 mm bolts and rewind starter assembly. a - 10 mm wrench ‑ provided with outboard a 45631 ! 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.
OPERATION 5. Pull the starter rope to start the engine.
MAINTENANCE Outboard Care To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers, and retain its dependability. Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts.
MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture. 2008 a JAN b MAR FEB APR c MAY d JUN EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2010 CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES. REFER TO OWNER’S MANUAL FOR REQUIRED MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.
MAINTENANCE • 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 OR 100 HOURS • Grease the engine, if applicable • Change the engine oil and filter, if equipped • Inspect the thermostat, saltwater or brackish water only • Add Quickleen to the fuel tank, once per year, per engine • Apply antiseize to the spark plug threads • Replace the gear lubr
MAINTENANCE 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. b a 45633 a - Plug and gasket b - Hose coupling Top Cowl Removal and Installation REMOVAL 1. Release the rear latch. 2. Lift up the rear of the cowl and push it towards the front of the engine to clear the front hook. 45638 INSTALLATION 1.
MAINTENANCE 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 protective coating on the anode as this will reduce effectiveness of the anode. 27092 Exterior Care Your outboard is protected with a durable baked enamel finish. Clean and wax often using marine cleaners and waxes. Fuel System ! WARNING Fuel is flammable and explosive.
MAINTENANCE FUEL LINE FILTER Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace. 45639 IMPORTANT: Visually inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line or primer bulb must be replaced.
MAINTENANCE 2. Move the gear shift lever into neutral. N 45629 3. Straighten and remove the cotter pin. 4. Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut. 5. Pull propeller straight off the shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer.
MAINTENANCE 8. Place a block of wood between the gearcase and the propeller and tighten the propeller nut. Secure the propeller nut to the shaft with a cotter pin. a b abcde- c e Cotter pin Propeller nut Rear thrust hub Propeller Front thrust washer 27094 d 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.
MAINTENANCE 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 4. 0.9 mm (0.035 in.) Before installing 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 2‑4‑C with PTFE or Extreme Grease. Tube Ref No. 95 Description Where Used Part No.
MAINTENANCE • Transom clamp screws ‑ lubricate threads. a - Transom clamp screws a 45641 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. • Tiller handle rubber bushing ‑ lubricate internal diameter. a a - Tiller handle rubber bushing 45642 • Shift detent ‑ lubricate detent shaft.
MAINTENANCE 2. Lubricate the tilt pivot points with lightweight oil. a - Tilt pivot points a 3. 45643 Lubricate the following with Extreme Grease or 2‑4‑C with PTFE. Tube Ref No. 95 Description Where Used Part No. Extreme Grease Propeller shaft 8M0071842 2-4-C with PTFE Propeller shaft 92-802859A 1 • Propeller shaft ‑ refer to Propeller Replacement for removal and installation of the propeller.
MAINTENANCE IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer. a - Drain plug a 45644 OIL FILLING IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil. Remove the oil fill cap and refill with 450 ml (15 fl oz) of oil. Install the oil fill cap.
MAINTENANCE 3. Remove the vent plug and fill/drain plug and drain lubricant. a a - Vent plug b - Fill/drain plug b 27146 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 the outboard in a vertical operating position. 2. Remove the vent plug from the vent hole. 3.
MAINTENANCE 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 minimize internal corrosion damage to the engine.
STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer). NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
STORAGE 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 outboard only in the following two positions.
OWNER SERVICE ASSISTANCE Service Assistance LOCAL REPAIR SERVICE If you need service for your Mercury‑outboard‑powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine. NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for your power package.
OWNER SERVICE ASSISTANCE RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury dealership. If you need additional assistance: 1. Talk with the dealership's sales manager or service manager. 2. If your question, concern, or problem cannot be resolved by your dealership, please contact the Mercury Marine Service Office for assistance.
OWNER SERVICE ASSISTANCE Mexico, Central America, South America, Caribbean Telephone +1 954 744 3500 Fax +1 954 744 3535 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 U.S.A. Japan Telephone +072 233 8888 Fax +072 233 8833 Kisaka Co., Ltd.
OWNER SERVICE ASSISTANCE 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 Price Total . . . . . . . . . . Total Due 54 .
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts.
