Mercury 4C 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 4/4.9/5 90-8M0073872 812

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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.
© 2012, 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.
Declaration of Conformity ‑ Outboard, Conventional 2‑Stroke
Manufacturer:
Tohatsu Marine Corporation (TMC)
Mercury Marine Joint Venture
Shimodaira 4495‑9, Komagane‑City,
Nagano, Japan 399‑4101
Authorized Representative:
Brunswick Marine in EMEA Inc.
Parc Industriel De Petit‑Rechain,
B‑2800 Verviers, Belgium

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Safety of Machinery Directive 98/37/EC
Principles of safety integration (1.1.2) ISO 12100‑1; ISO 12100‑2;
EN 1050
Noise (1.5.8) ICOMIA 39/94
Vibration (1.5.9) ICOMIA 38/94
Engine type: Outboard
Fuel type: Gasoline
Combustion cycle: 2‑Stroke
This declaration is issued under the sole responsibility of
Mercury Marine and Brunswick Marine in EMEA Inc.
Name and function:
Mark D. Schwabero
President, Mercury Marine, Fond du Lac, WI USA
Date and place of issue:
November 20, 2008
Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Regulations and Product Safety Department,
Mercury Marine, Fond du Lac, WI USA

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Warranty Information
Transfer of Warranty.................................................................... 1
Transfer of Warranty–Australia and New Zealand Policy............ 1
Warranty Registration United States and Canada....................... 2
Warranty Registration Outside the United States and Canada... 3
Outboard Limited Warranty United States, Canada, and Europe
..................................................................................................... 4
Mercury/Mariner Outboard Limited Warranty–Australia and New
Zealand Policy............................................................................. 7
Outboard Limited Warranty (Confederation of Independent
States, Middle‑East, and Africa)................................................ 12
3 Year Limited Warranty Against Corrosion.............................. 16
Warranty Coverage and Exclusions.......................................... 19
General Information
Boater's Responsibilities............................................................ 22
Before Operating Your Outboard............................................... 22
Boat Horsepower Capacity........................................................ 23
Lanyard Stop Switch.................................................................. 23
Protecting People in the Water.................................................. 26
Exhaust Emissions.................................................................... 27
Selecting Accessories for Your Outboard.................................. 29
Safe Boating Suggestions......................................................... 29
Recording Serial Number.......................................................... 31
Component Identification—4C/4.9/5BD..................................... 32
4/4.9/5 Specifications.................................................................34
Installation
Installing Outboard.....................................................................36

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Transporting
Removing the Motor.................................................................. 38
Carrying the Motor..................................................................... 38
Storing the Motor....................................................................... 38
Trailering the Boat..................................................................... 39
Fuel and Oil
Fuel Recommendations............................................................. 41
Oil Recommendation................................................................. 43
Mixing Fuel and Oil.................................................................... 43
Engine Break‑In......................................................................... 43
Filling Fuel Tank........................................................................ 44
Features and Controls
Remote Control Features.......................................................... 45
Tilting Outboard......................................................................... 47
Shallow Water Operation........................................................... 48
Trim Angle Adjustment.............................................................. 50
Operation
Prestarting Check List................................................................52
Operating in Freezing Temperatures......................................... 52
Operating at High Elevations..................................................... 53
Operating in Saltwater or Polluted Water.................................. 53
Engine Break‑in Procedure........................................................53
Warming Up the Engine.............................................................54
Starting the Engine.................................................................... 55
Gear Shifting.............................................................................. 59
Stopping the Engine.................................................................. 59

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Maintenance
Outboard Care........................................................................... 61
EPA Regulations........................................................................61
EPA Emissions.......................................................................... 62
Inspection and Maintenance Schedule...................................... 63
Flushing The Cooling System.................................................... 64
Top Cowl Removal And Installation........................................... 65
Corrosion Control Anode........................................................... 65
Exterior Care..............................................................................66
Fuel System............................................................................... 66
Propeller Replacement.............................................................. 68
Propeller Selection.....................................................................70
Spark Plug Inspection And Replacement.................................. 70
Lubrication Points...................................................................... 71
Gearcase Lubrication.................................................................74
Submerged Outboard................................................................ 76
Storage
Storage Preparation...................................................................77
Protecting External Outboard Components............................... 77
Protecting Internal Engine Components.................................... 78
Gearcase................................................................................... 78
Positioning Outboard for Storage.............................................. 79
Owner Service Assistance
Local Repair Service..................................................................80
Service Away from Home.......................................................... 80
Parts and Accessories Inquiries................................................ 80
Service Assistance.................................................................... 80
Mercury Marine Service Offices.................................................81

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Maintenance Log
Maintenance Log....................................................................... 83
Accessories
Propeller Recommendation....................................................... 84
Tool Kit and Spare Parts............................................................84
Optional Accessories................................................................. 86
Wiring Diagram.......................................................................... 88
Wire Color Code Abbreviations................................................. 89

WARRANTY INFORMATION
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Transfer of Warranty
The limited warranty is transferable to a subsequent purchaser,
but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial
applications.
To transfer the warranty to the subsequent owner, send or fax a
copy of the Bill of Sale or Purchase Agreement, new owner’s
name, address, and engine serial number to Mercury Marine’s
Warranty Registration Department. In the United States and
Canada, mail to:
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax [phone]
Upon processing the transfer of warranty, Mercury Marine will
send registration verification to the new owner of the product by
mail.
There is no charge for this service.
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 Warranty–Australia and New Zealand
Policy
The limited warranty is transferable to a subsequent purchaser,
but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial
applications.
To transfer the warranty to the subsequent owner, send or fax a
copy of the Bill of Sale or Purchase Agreement, new owner’s
name, address, and hull identification number (HIN) to Mercury
Marine’s Warranty Registration Department. In Australia and
New Zealand, mail to:

WARRANTY INFORMATION
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Mercury Marine
Attn: Warranty Registration Department
Brunswick Asia Pacific Group
Private Bag 1420
Dandenong South, Victoria 3164
Australia
Upon processing the transfer of warranty, Mercury Marine will
send registration verification to the new owner of the product by
mail. There is no charge for this service.
You may change your address at any time, including at the time
of the warranty claim, by calling Mercury Marine or sending a
letter or fax with your name, old address, new address, and hull
identification number (HIN) to Mercury Marine’s Warranty
Registration Department.
Warranty Registration United States and Canada
1. You may change your address at any time, including at the
time of the 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
process this change of information.
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax [phone]
NOTE: Registration lists must be maintained by Mercury Marine
and any dealer on marine products sold in the United States,
should a safety recall notification under the Federal Safety Act
be required.