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MODELS Mercury/Mariner 4 ⋅ 5 ⋅ 6 (4-Stroke)

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MODELS Mercury/Mariner 4 ⋅ 5 ⋅ 6 (4-Stroke) SERVICE MANUAL MODELS Mercury/Mariner 4 ⋅ 5 ⋅ 6 (4-Stroke) Starting Serial Numbers 0R000001 and Above Printed in U.S.A. 2000, Mercury Marine 90-857138R1 MAY 2000 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In- ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con- cerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal in- jury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these prod- ucts, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. 90-857138R1 MAY 2000 Page i It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mis- matched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations when- ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manu- al, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products de- scribed in this manual. Page Numbering Two number groups appear at the bottom of each page. The example below is self-explana- tory. EXAMPLE: 90-826883 R1 JANUARY 1998 Page - 6A-7 Revision No. 1 Section Number Month of Printing Part of Section Letter Year of Printing Page Number Page ii 90-857138R1 MAY 2000 Service Manual Outline Important Information Section 1 - Important Information 1 A - Specifications B - Maintenance C - General Information Electrical 2 D - Outboard Installation Section 2 - Electrical A - Ignition Fuel System B - Charging & Starting System 3 C - Timing, Synchronizing & Adjusting D - Wiring Diagrams Section 3 - Fuel System Powerhead A - Fuel Pump 4 B - Carburetor C - Emissions Mid-Section Section 4 - Powerhead 5 A - Cylinder Head B - Cylinder Block/Crankcase Section 5 - Mid-Section Lower Unit A - Clamp/Swivel Brackets & Drive Shaft Housing 6 Section 6 - Lower Unit Section 7 - Attachments/Control Linkage Attachment/Control Linkage A - Shift Linkage 7 B - Tiller Handle Section 8 - Manual Starter Manual Starter Section 9 - Color Diagrams 8 Color Diagrams 9 90-857138R1 MAY 2000 Page iii SPECIFICATIONS IMPORTANT INFORMATION 1 Section 1A - Specifications A Table of Contents Specifications. 1A-1 Propeller Information Charts. 1A-8 Specifications Model 4/5/6 (4-Stroke) Model 4 4 hp (2.9 kW) HORSEPOWER Model 5 5 hp (3.7 kW) (kW) Model 6 6 hp (4.4 kW) OUTBOARD Short Shaft 55 lbs. (25.0 kg) WEIGHT Long Shaft 57 lbs. (26.0 kg) RECOMMENDED GASOLINE Automotive Unleaded FUEL with a Minimum Pump Posted Octane Rating of 87 ENGINE OIL CAPACITY ENGINE OIL Either 15 fl oz. or 450 ml. SAE SAE SAE 10W-30 viscosity oil is recom- ° 25W-40 10W-30 mended for use in all temperatures. F° C SAE 25W-40 viscosity oil may be used at temperatures above 40° F (4° C). +100 +38 +80 +27 Use Quicksilver 4-Cycle Marine Oil with the proper viscosity for the expected +60 +16 OIL temperature in your area (see range +40 +4 thermometer on left). If not available, use +20 –7 a premium quality 4-cycle engine oil, cer- tified to meet or exceed anyone of the –18 0 following American Petroleum Institute (API) service classifications SH, SG, SF, CF-4, CE, CD, CDll. Alternator (Optional) Type: CHARGING Lighting Coil 12 Volt 60 Watt SYSTEM (Non Regulated Lighting Coil) Readings taken @ Ω ° ° Lighting Coil Resistance 0.31 - 0.47 (YEL/RED - YEL/RED) 68 F (20 C). Battery Charging Rectifier (Optional) 2 Amperes (Rectified) STARTING Manual Start Recoil Starter SYSTEM 90-857138R1 MAY 2000 Page 1A-1 SPECIFICATIONS Type Capacitor Discharge Ignition Spark Plug: Type NGK DCPR6E Gap 0.035 in. (0.9 mm) Hex Size 5/8 in. (16 mm) Torque 13 lb-ft. (17.5 Nm) Firing Order 1 IGNITION Ignition Timing: (Fixed) 25° ± 1° B.T.D.C. SYSTEM Capacitor Charge Coil Resistance 95 - 134 Ω (WHT - BLK/RED) Readings taken @ Trigger Coil Resistance 149 - 243 Ω (RED/WHT - BLK) 68°F (20°C). Ignition Coil Resistance: Primary 0.02 - 0.38 Ω Secondary (W/o Boots) 3000 - 4400 Ω Spark Plug Boot 3500 - 5200 Ω Engine Speed Limiter 6300 ± 200 RPM Oil Pressure Switch (Red Light) Continuity Below 3.5 psi ± 0.7 psi (24.5 ± 5 kPa) Idle rpm (Out Of Gear) 1300 ± 50 rpm Idle rpm (In Forward Gear) 1100 ± 50 rpm Wide Open Throttle rpm (WOT) 4/5 (1999 & 2000) 4500 -5500 4/5/6 (2001 & Newer) 5000 - 6000 Pilot (Idle Mixture) Screw 4/5/6 (1999 & 2000) 3 ± 1/2 Turns Out European Models Only 2001 & Newer 4 2-1/8 ± 1/2 Turns Out 5 1-1/2 ± 1/2 Turns Out 6 2-3/4 ± 1/2 Turns Out All Other Models Non-Adjustable Venturi Bore Diameter 4/5 13.5 mm 6 15 mm CARBURETOR Main Jet Size 4/5 (1999 & 2000) #70 4 (2001 & Newer) #58 5 (2001 & Newer) #65 6 (2000 & Newer) #75 4 (Bodensee) #55 5 (Bodensee) #62 6 (Bodensee) #68 Pilot Jet 4 (1999 & 2000) #40 5 (1999 & 2000) #42 4/5 (2001 & Newer) #38 6 (2000 & Newer) #45 4/5 (Bodensee) #38 6 (Bodensee) #42 Float Height 0.35 - 0.39 in. (9 - 10 mm) Page 1A-2 90-857138R1 MAY 2000 SPECIFICATIONS Fuel Pump Type External (Plunger/Diaphragm) Fuel Pump: FUEL Pressure 2.5 - 5.0 psi (17 - 35 kPa) SYSTEM Plunger Stroke 0.059 in. (1.5 mm) Diaphragm Stroke 0.059 in. (1.5 mm) Fuel Tank Capacity 3.2 US Gallons Type 4 Stroke Cycle – Over Head Valve CYLINDER Displacement 7.5 cu. in. (123 cc) BLOCK Number of Cylinders 1 STROKE Length 1.77 in. (45 mm) Diameter Standard 2.323 in. (59.00 mm) CYLINDER Oversize-0.020 in. (0.50 mm) 2.343 in. (59.50 mm) BORE Taper/Out of Round Maximum 0.003 in. (0.076 mm) Bore Type Steel Piston Type Aluminum O.D. at Skirt PISTON Standard 2.321 in. (58.960 mm) Oversize-0.020 in. (0.50 mm) 2.341 in. (59.460 mm) Piston to Cylinder Clearance 0.001 - 0.002 in. PISTON (0.020 - 0.055 mm) CLEARANCE Piston Clearance Limit 0.006 in.
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