Mercury FourStroke 4 User manual

eng i

Thank You

for your purchase of one of the finest outboards available.

You have made a sound investment in boating pleasure.

Your outboard has been manufactured by Mercury Marine, a

world leader in marine technology and outboard

manufacturing since 1939. These years of experience have

been committed to the goal of producing the finest quality

products. This led to Mercury Marine's reputation for strict

quality control, excellence, durability, lasting performance,

and being the best at providing after the sale support.

Please read this manual carefully before operating your

outboard. This manual has been prepared to assist you in

the operation, safe use, and care of your outboard.

All of us at Mercury Marine took pride in building your

outboard and wish you many years of happy and safe

boating.

Again, thank you for your confidence in Mercury Marine.

EPA Emissions Regulations

Outboards sold by Mercury Marine in the United States are

certified to the United States Environmental Protection

Agency as 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, the factory

procedure for servicing the product must be strictly followed

and, wherever practicable, returned to the original intent of

the design. Maintenance, replacement, or repair of the

emission control devices and systems may be

performed by any marine engine repair establishment or

individual.

Engines are labeled with an Emission Control Information

decal as permanent evidence of EPA certification.

! WARNING

The engine exhaust from this product contains chemicals

known to the state of California to cause cancer, birth

defects or other reproductive harm.

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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 Information section of this manual. The warranty

statement contains a description of what is covered, what is not

covered, the duration of coverage, how to best obtain warranty

coverage, important disclaimers and limitations of damages,

and other related information. Please review this important

information.

The description and specifications contained herein were in

effect at the time this manual was approved for printing. Mercury

Marine, whose policy is one of continued improvement, reserves

the right to discontinue models at any time, to change

specifications, designs, methods, or procedures without notice

and without incurring obligation.

Mercury Marine, Fond du Lac, Wisconsin U.S.A.

Litho in U.S.A.

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 registered trademarks of

Brunswick Corporation. Mercury Product Protection logo is a

registered service mark of Brunswick Corporation.

Mercury Premier Service

Mercury evaluates the service performance of its dealers and

assigns its highest rating of "Mercury Premier" to those

demonstrating an exceptional commitment to service.

Earning a Mercury Premier Service rating means a dealer:

• Achieves a high 12 month service CSI (Customer

Satisfaction Index) score for warranty service.

• Possesses all necessary service tools, test equipment,

manuals, and parts books.

• Employs at least one Certified or Master technician.

eng iii

• Provides timely service for all Mercury Marine customers.

• Offers extended service hours and mobile service, when

appropriate.

• Uses, displays, and stocks adequate inventory of genuine

Mercury Precision Parts.

• Offers a clean, neat shop with well organized tools and

service literature.

Declaration of Conformity ‑ For Recreational Craft Propulsion

Engines with the Requirements of Directive 94/25/EC as

amended by 2003/44/EC

Name 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

Address: Veritasveien 1

Town: Hovik Post Code:

1322

Country:

Norway ID Number: 0575

Name of Notified Body for noise emission assessment: Det Norske

Veritas AS

Address: Veritasveien 1

Town: Hovik Post Code:

1322

Country:

Norway ID Number: 0575

iv eng

Conformity assessment

module used for exhaust

emissions:

☐ B

+F ☐ G☒ H

or engine type approved

according to:

☐ Stage II of

Directive 97/68/EC

☐ Directive

88/77/EC

Conformity assessment

module used for noise

emissions:

☐ A☐ Aa ☐ G☒ H

Other Community Directives applied: Safety of Machinery Directive

98/37/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

certificate number

4 hp, 5 hp, 6 hp 0R332614 RCD‑H‑2

8 hp, 9.9 hp 0R334339 RCD‑H‑2

9.9 hp BigFoot 0R334339 RCD‑H‑2

eng v

Essential

requirements Standards

Other

normative

document/

method

Technical

file

Please specify in

more detail

(* = mandatory

standard)

Annex 1.B—Exhaust Emissions

B.1 engine

identification ☐ ☐ ☒

B.2 exhaust

emission

requirements

☒* ☐ ☐ * EN ISO

8178‑1:1996

B.3 durability ☐ ☐ ☒

B.4 owner's

manual ☒ ☐ ☐ ISO 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,

Mercury Outboard

Date and place of issue:

July 24, 2008

Fond du Lac, Wisconsin, USA

vi eng

eng vii

WARRANTY INFORMATION

Warranty Registration.................................................................. 1

Transfer of Warranty.................................................................... 2

Transfer of Mercury Product Protection (Extended Service

Coverage) Plan United States and Canada.................................2

FourStroke Outboard Limited Warranty....................................... 3

FourStroke Outboard Limited Warranty....................................... 7

FourStroke Outboard Limited Warranty..................................... 11

3 Year Limited Warranty Against Corrosion.............................. 15

Warranty Coverage and Exclusions.......................................... 18

U.S. EPA Emissions 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 Water.................................................. 32

Exhaust Emissions.................................................................... 32

Selecting Accessories for Your Outboard.................................. 34

Safe Boating Suggestions......................................................... 35

Recording Serial Number.......................................................... 37

4/5/6 Specifications....................................................................37

INSTALLATION

Installing Outboard.....................................................................39

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TRANSPORTING

Carrying, Storing, and Transporting Your Outboard When

Removed from Boat................................................................... 40

Trailering Your Boat................................................................... 41

FUEL AND OIL

Fuel Recommendations............................................................. 43

Low Permeation Fuel Hose Requirement ................................. 45

EPA Pressurized Portable Fuel Tank Requirements................. 45

Fuel Demand Valve (FDV) Requirement................................... 45

Mercury Marine's Pressurized 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

Engine Break‑in Procedure........................................................58

Starting the Engine.................................................................... 58

Gear Shifting ............................................................................. 63

Stopping the Engine ................................................................. 64

Emergency Starting................................................................... 64

eng ix

MAINTENANCE

Outboard Care........................................................................... 67

EPA Emission Regulations........................................................ 67

Inspection and Maintenance Schedule...................................... 68

Flushing the Cooling System..................................................... 70

Top Cowl Removal and Installation........................................... 70

Corrosion Control Anode........................................................... 71

Exterior Care..............................................................................72

Fuel System............................................................................... 72

Propeller Replacement.............................................................. 73

Spark Plug Inspection 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 Assistance.................................................................... 86

Mercury Marine Service Offices.................................................87

MAINTENANCE LOG

Maintenance Log....................................................................... 89

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