EasyManua.ls Logo

Mercury 4 SERIES User Manual

Mercury 4 SERIES
260 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
To Previous Page IconTo Previous Page
To Previous Page IconTo Previous Page
Page #200 background image
GEAR HOUSING
Page 6-12 90-857138R1 MAY 2000
Propeller Shaft
1. Remove reverse gear and washer.
2. Remove cam follower and guide.
a
b
c
d
56400
56401
a - Reverse Gear
b - Washer
c - Cam Follower
d - Guide
3. Using a punch, tap cross pin from sliding clutch. Leave punch in hole to retain spring at
this time.
4. Put end of shaft against solid object. Remove punch from sliding clutch, and slowly re-
lease spring compression.
a
b
c
d
56402
56403
a - Sliding Clutch
b - End of Shaft
c - Punch
d - Sliding Clutch

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Mercury 4 SERIES and is the answer not in the manual?

Mercury 4 SERIES Specifications

General IconGeneral
StartingManual
Cylinders1
Fuel TypeGasoline
SteeringTiller
Recommended Fuel87 Octane
Warranty3 years
Horsepower4 HP
Full Throttle RPM5000 - 6000 RPM
Alternator OutputNot Available
Fuel SystemCarburetor
Cooling SystemWater Cooled
Shaft Length15 in
Gear ShiftForward, Neutral

Summary

IMPORTANT INFORMATION Section 1A - Specifications

IMPORTANT INFORMATION Section 1B - Maintenance

Inspection and Maintenance Schedule

Schedule outlining required inspections and maintenance tasks based on hours or time.

Fuel System

Information and procedures related to the fuel system, including inspection.

Changing Engine Oil

Step-by-step procedure for changing the engine oil, including capacity and filling.

Gear Case Lubrication

Procedure for draining, inspecting, and filling the gear case lubricant.

IMPORTANT INFORMATION Section 1C - General Information

DETONATION

Explanation of detonation in a 4-cycle engine, its causes, and prevention methods.

Propeller Selection

Guidelines for selecting the correct propeller for optimal engine performance and durability.

Propeller Removal/Installation

Step-by-step instructions for removing and installing the outboard propeller.

Compression Check

Procedure for checking cylinder compression to diagnose engine wear or performance issues.

IMPORTANT INFORMATION Section 1D - Outboard Motor Installation

Installing Outboard

Step-by-step instructions for mounting the outboard motor onto the boat transom.

ELECTRICAL Section 2A - Ignition System

Test Procedures

Procedures for testing the ignition system using ohmmeters and voltage testers.

Ignition Components Removal and Installation

Procedures for removing and installing ignition system components.

Ignition Coil

Procedures for removing and installing the ignition coil.

CDI Unit

Procedures for removing and installing the CDI unit.

ELECTRICAL Section 2B - Charging System

ELECTRICAL Section 2C - Timing and Synchronization

Ignition Timing

Information on ignition timing, noting it is fixed and cannot be adjusted.

Check Timing

Procedure for checking ignition timing at idle and wide-open throttle using a timing light.

ELECTRICAL Section 2D - Wiring Diagram

Wiring Diagram

Schematic diagram showing electrical connections for the outboard motor components.

FUEL SYSTEM Section 3A - Fuel Pump & Integral Fuel Tank

Fuel Pump Removal and Installation

Step-by-step procedures for removing and installing the fuel pump.

FUEL SYSTEM Section 3B - Carburetor

Carburetor Adjustments

Procedures for adjusting the carburetor's idle speed and pilot mixture screw.

Pilot (Idle Mixture) Screw

Procedure for adjusting the pilot mixture screw for optimal idle performance.

Idle Speed

Procedure for adjusting the engine's idle speed.

Carburetor Removal and Installation

Step-by-step instructions for removing and installing the carburetor.

POWERHEAD Section 4A - Cylinder Head

Cylinder Block

Exploded view and parts list for the cylinder block assembly.

Intake/Exhaust Valves

Exploded view of intake and exhaust valves, their components, and related service aids.

Valve Clearance

Procedure for checking and adjusting valve clearance while the engine is cool.

POWERHEAD Section 4B - Cylinder Block and Crankcase

Crankshaft

Exploded view and parts list for the crankshaft assembly.

Oil Pan

Exploded view and parts list for the oil pan assembly and its components.

Powerhead Removal

Procedure for removing the powerhead from the drive shaft housing.

Powerhead Installation

Steps for installing the reassembled powerhead onto the drive shaft housing, including component reassembly.

MID-SECTION Section 5

Driveshaft Housing

Exploded view and parts list for the driveshaft housing assembly.

Clamp Brackets

Exploded view and parts list for the clamp brackets and swivel bracket.

Clamp Bracket/Swivel Bracket

Procedures for reassembling the clamp bracket and swivel bracket components.

Drive Shaft Housing

Procedures for installing the drive shaft housing into the swivel bracket.

GEAR HOUSING Section 6

Specifications

Specifications for the gear housing, including ratio, capacity, and lubricant type.

Gear Housing (Drive Shaft)

Exploded view and parts list for the drive shaft portion of the gear housing.

Gear Housing (Prop Shaft)

Exploded view and parts list for the propeller shaft portion of the gear housing.

Draining and Inspecting Gear Housing Lubricant

Procedure for draining, inspecting, and checking the gear housing lubricant for contamination.

Propeller Removal

Safety precautions and steps for removing the propeller.

Gear Housing Removal

Procedure for removing the gear housing from the drive shaft housing.

Gear Housing Installation

Procedure for installing the gear housing, including safety precautions and shift shaft alignment.

Propeller Installation

Step-by-step instructions for installing the propeller onto the propeller shaft.

Filling Gear Housing with Lubricant

Procedure for filling the gear housing with Quicksilver Gear Lube, including plug removal and installation.

CONTROLS Section 7A - Shift Linkage

Shift Components

Exploded view and parts list for the shift linkage components.

Removal/Disassembly

Procedures for removing and disassembling the shift linkage components.

Reassembly/Installation

Procedures for lubricating and installing the shift linkage components.

CONTROLS Section 7B - Tiller Handle

Steering Handle

Exploded view and parts list for the steering handle assembly.

MANUAL STARTER Section 8

Recoil Starter

Exploded view and parts list for the recoil starter assembly.

Removal

Steps for removing the manual starter assembly from the engine.

Installation

Procedure for installing the rewind starter assembly onto the engine.

Disassembly

Detailed steps for disassembling the rewind starter, emphasizing spring tension safety.

Reassembly

Procedures for reassembling the rewind starter components, including lubrication.

Related product manuals