Mercury FourStroke 4 User manual

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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.
© 2012 Mercury Marine 4/5/6 FourStroke 90-8M0055686 211

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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.
© 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 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.

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• 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

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Conformity assessment
module used for exhaust
emissions:
☐ B
+C
☐ B
+D
☐ B
+E
☐ 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

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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

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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

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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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