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SERVIC. MANUA. MODELS Mercury/Mariner 4 5 V 6 (4-Stroke) Starting Serial Numbers 0R000001 and Above Printed in U.S.A. W2000, Mercury Marine 90-857138R1 MAY 2000 Notice Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning 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 injury 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 products, 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 includes the use of mechanics common hand tools and the special Mercury Marine or recommended 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 metric 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. Mismatched 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 whenever 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 manual, 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 described in this manual. Page Numbering Two number groups appear at the bottom of each page. The example below is self-explanatory. EXAMPLE: 90-826883 R1 JANUARY 1998 Page – 6A-7 Revision No. 1 Month of Printing Year of Printing Section Number Part of Section Letter Page Number Page ii 90-857138R1 MAY 2000 Service Manual Outline Section 1 – Important Information A – Specifications B – Maintenance C – General Information D – Outboard Installation Section 2 – Electrical A – Ignition B – Charging & Starting System C – Timing, Synchronizing & Adjusting D – Wiring Diagrams Section 3 – Fuel System A – Fuel Pump B – Carburetor C – Emissions Section 4 – Powerhead A – Cylinder Head B – Cylinder Block/Crankcase Section 5 – Mid-Section A – Clamp/Swivel Brackets & Drive Shaft Housing Section 6 – Lower Unit Section 7 – Attachments/Control Linkage A – Shift Linkage B – Tiller Handle Section 8 – Manual Starter Section 9 – Color Diagrams Important Information Electrical Fuel System Powerhead Mid-Section Lower Unit Attachment/Control Linkage Manual Starter 9Color Diagrams 90-857138R1 MAY 2000 Page iii SPECIFICATIONS IMPORTANT INFORMATION Section 1A – Specifications Table of Contents 1 A Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Propeller Information Charts . . . . . . . . . . . . . . 1A-8 Specifications Model 4/5/6 (4-Stroke) HORSEPOWER (kW) Model 4 Model 5 Model 6 4 hp (2.9 kW) 5 hp (3.7 kW) 6 hp (4.4 kW) OUTBOARD WEIGHT Short Shaft Long Shaft 55 lbs. (25.0 kg) 57 lbs. (26.0 kg) FUEL RECOMMENDED GASOLINE Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 OIL ENGINE OIL CAPACITY ENGINE OIL +20 +40 +60 +80 F C 0 +100 7 +4 +16 +27 18 +38 SAE 10W-30 SAE 25W-40 Either 15 fl oz. or 450 ml. SAE 10W-30 viscosity oil is recommended for use in all temperatures. SAE 25W-40 viscosity oil may be used at temperatures above 40 F (4 C). Use Quicksilver 4-Cycle Marine Oil with the proper viscosity for the expected temperature in your area (see range thermometer on left). If not available, use a premium quality 4-cycle engine oil, certified to meet or exceed anyone of the following American Petroleum Institute (API) service classifications SH, SG, SF, CF-4, CE, CD, CDll. CHARGING SYSTEM Readings taken @ 68F (20C). Alternator (Optional) Type: Lighting Coil Lighting Coil Resistance Battery Charging Rectifier (Optional) 12 Volt 60 Watt (Non Regulated Lighting Coil) 0.31 – 0.47 W (YEL/RED – YEL/RED) 2 Amperes (Rectified) STARTING SYSTEM Manual Start Recoil Starter 90-857138R1 MAY 2000 Page 1A-1 SPECIFICATIONS IGNITION SYSTEM Readings taken @ 68F (20C). Type Spark Plug: Type Gap Hex Size Torque Firing Order Ignition Timing: (Fixed) Capacitor Charge Coil Resistance Trigger Coil Resistance Ignition Coil Resistance: Primary Secondary (W/o Boots) Spark Plug Boot Engine Speed Limiter Oil Pressure Switch (Red Light) Capacitor Discharge Ignition NGK DCPR6E 0.035 in. (0.9 mm) 5/8 in. (16 mm) 13 lb-ft. (17.5 Nm) 1 251 B.T.D.C. 95 – 134 W (WHT – BLK/RED) 149 – 243 W (RED/WHT – BLK) 0.02 – 0.38 W 3000 – 4400 W 3500 – 5200 W 6300 200 RPM Continuity Below 3.5 psi 0.7 psi (24.5 5 kPa) CARBURETOR Idle rpm (Out Of Gear) Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT) 4/5 (1999 & 2000) 4/5/6 (2001 & Newer) Pilot (Idle Mixture) Screw 4/5/6 (1999 & 2000) European Models Only 2001 & Newer 4 5 6 All Other Models Non-Adjustable Venturi Bore Diameter 4/5 6 Main Jet Size 4/5 (1999 & 2000) 4 (2001 & Newer) 5 (2001 & Newer) 6 (2000 & Newer) 4 (Bodensee) 5 (Bodensee) 6 (Bodensee) Pilot Jet 4 (1999 & 2000) 5 (1999 & 2000) 4/5 (2001 & Newer) 6 (2000 & Newer) 4/5 (Bodensee) 6 (Bodensee) Float Height 1300 50 rpm 1100 50 rpm 4500 -5500 5000 – 6000 3 1/2 Turns Out 2-1/8 1/2 Turns Out 1-1/2 1/2 Turns Out 2-3/4 1/2 Turns Out 13.5 mm 15 mm 70 58 65 75 55 62 68 40 42 38 45 38 42 0.35 – 0.39 in. (9 – 10 mm) Page 1A-2 90-857138R1 MAY 2000 SPECIFICATIONS FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Plunger Stroke Diaphragm Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 2.5 – 5.0 psi (17 – 35 kPa) 0.059 in. (1.5 mm) 0.059 in. (1.5 mm) 3.2 US Gallons CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle Over Head Valve 7.5 cu. in. (123 cc) 1 STROKE Length 1.77 in. (45 mm) CYLINDER BORE Diameter Standard Oversize-0.020 in. (0.50 mm) Taper/Out of Round Maximum Bore Type 2.323 in. (59.00 mm) 2.343 in. (59.50 mm) 0.003 in. (0.076 mm) Steel PISTON Piston Type O.D. at Skirt Standard Oversize-0.020 in. (0.50 mm) Aluminum 2.321 in. (58.960 mm) 2.341 in. (59.460 mm) PISTON CLEARANCE Piston to Cylinder Clearance Piston Clearance Limit 0.001 – 0.002 in. (0.020 – 0.055 mm) 0.006 in. (0.15 mm) Ring End Gap (Installed) Top 0.006 – 0.014 in. (0.15 – 0.35 mm) Middle 0.012 – 0.020 in. (0.30 – 0.50 mm) RINGS Bottom (Oil Ring) Side Clearance: 0.008 – 0.016 in. (0.20 – 0.40 mm) Top 0.0015 – 0.003 in. (0.04 – 0.08 mm) Middle 0.0012 – 0.003 in. (0.03 – 0.07 mm) Bottom (Oil Ring) 0.0004 – 0.007 in. (0.01 – 0.18 mm) Compression Ratio With Decompression 8.5:1 COMPRESSION RATIO 4/5 (1999 & 2000) 42 psi 14 psi (0.29 0.1 MPa) 4/5 (2001 & Newer) 9.5:1 6 (2000 & Newer) 42 psi 14 psi (0.29 0.1 MPa) Outer Diameter 0.6299 in. (16.00 mm) PISTON PIN Diameter of Piston Pin Hole Clearance between Piston Pin and 0.6300 in. (16.002 mm) Piston Pin Hole 0.0001 – 0.0005 in. (0.002 mm – 0.012 mm) Oil Clearance (Big End) 0.002 – 0.003 in. (0.053 – 0.079 mm) CONNECTING Side Clearance (Big End) 0.008 – 0.016 in. ROD (0.20 – 0.40 mm) Small End Inside Diameter 0.6303 in. (16.01 mm) 90-857138R1 MAY 2000 Page 1A-3 SPECIFICATIONS Crankshaft Runout Diameter of Crank Pin (A) Less than 0.002 in. (0.05 mm) 1.179 – 1.177 in. Outer Diameter of Crankshaft in Oil (29.94 – 29.91 mm) Pan Bearing (B) 0.983 – 0.982 in. CRANKSHAFT A B (24.98 – 24.96 mm) Camshaft Dimensions Intake/Exhaust A 4 (1999 & 2000) 5 (1999 & 2000) A 0.993 in. (25.24 mm) 1.047 in. (26.59 mm) 6 (2000) 1.115 in. (28.33 mm) 4/5/6 (2001 & Newer) 1.115 in. (28.33 mm) CAMSHAFT Bearing Diameter B B 0.550 in. (13.98 mm) Inside Diameter of Oil Pan Bearing: Crankshaft A 0.985 in. (25.01 mm) Camshaft B AB 0.5515 in. (14.01 mm) OIL PAN Crankshaft to Oil Pan Bearing Clearance Camshaft to Oil Pan Bearing 0.0006 – 0.0015 in. (0.015 – 0.040 mm) Clearance 0.0008 – 0.002 in. (0.02 – 0.05 mm) Page 1A-4 90-857138R1 MAY 2000 SPECIFICATIONS Free Length (Intake/Exhaust) a Tilt Limit b (Intake/Exhaust) 4/5 (1999) 4/5/6 (2000 & Newer) b a = 1.260 in. (32.0 mm) b = 0.044 in. (1.12 mm) a = 1.378 in. (35.0 mm) b = 0.044 in. (1.12 mm) a VALVE SPRING Compressed Pressure (Installed) Intake/Exhaust: Closed Height 0.965 in. (24.4 mm) 4/5 (1999 & 2000) 6 (2000) 4/5/6 (2001 & Newer) Open Height 0.709 in. (17.4 mm) 4/5 (1999 & 2000) 6 (2000) 4/5/6 (2001 & Newer) Direction of Winding (Intake/Exhaust) 17 lbf. (7.7 kgf) 24 lbf. (10.8 kgf) 24 lbf. (10.8 kgf) 31 lbf. (14.0 kgf) 39.4 lbf. (17.9 kgf) 39.4 lbf. (17.9 kgf) Right Hand CYLINDER HEAD Warp Limit * * Lines indicate straight edge measurement 0.0012 in. (0.03 mm) A B Valve Dimensions Head Diameter Face Width Seat Width C D Margin Thickness 90-857138R1 MAY 2000 Page 1A-5 SPECIFICATIONS Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.002 – 0.005 in. (0.06 – 0.14 mm) Exhaust Valve Dimensions: A Head Diameter 0.004 – 0.007 in. (0.11 – 0.19 mm) Intake 0.980 – 0.988 in. (24.9 – 25.1 mm) Exhaust B Face Width 0.941 – 0.949 in. (23.9 – 24.1 mm) Intake 0.102 in. (2.6 mm) Exhaust C Seat Width 0.102 in. (2.6 mm) Intake 0.031 in. (0.8 mm) Exhaust D Margin Thickness 0.031 in. (0.8 mm) VALVES Intake 0.028 in. (0.7 mm) Exhaust Stem Outside Diameter 0.047 in. (1.2 mm) Intake 0.216 in. (5.48 mm) Exhaust Guide Inside Diameter 0.214 in. (5.44 mm) Intake 0.2165 in. (5.5 mm) Exhaust Stem To Guide Clearance 0.2165 in. (5.5 mm) Intake 0.0008 – 0.0017 in. (0.020 – 0.044 mm) Exhaust 0.0018 – 0.0028 in. (0.045 – 0.072 mm) Stem Run-out Limit (max.) 0.0006 in. (0.016 mm) THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 122F – 129F (50C – 54C) 145F – 153F (63C – 67C) 0.12 in. (3 mm) Page 1A-6 90-857138R1 MAY 2000 SPECIFICATIONS LUBRICATION SYSTEM Pump Type Engine Oil Pressure* (Warm Engine): @ 1300 rpm @ 5000 rpm Engine Oil Pan Capacity Oil Pump Clearance: Inner Rotor to Outer Rotor A Outer Rotor to Body B Rotor to Body (Side) C Height of Outer Rotor D Relief Valve Operating Pressure* D Trochoid 4.0 psi (0.03 MPa) Minimum 21.0 psi (0.15 MPa) Minimum 0.95 pt (450 ml) 0.006 in. (0.15 mm) or Less 0.005 – 0.008 in. (0.12 – 0.20 mm) 0.0008 – 0.0028 in. (0.02 – 0.07 mm) 0.236 in. (5.99 mm) 31 – 40 psi (2.2 – 2.8 kg/cm2) 216 – 275 kPa A B C Transom Height – Short Shaft17 in. (38 cm) – Long Shaft 22 in. (51 cm) Steering Pivot Range 78 MID-SECTION Tilt Pin Positions Total Tilt Angle 6 75 Tilt Angle 4 – 24 Shallow Water Tilt Angle 32.5 Allowable Transom Thickness 2.2 in. (55 mm) GEAR HOUSING (2.15:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Water Pressure: @ 1300 rpm (Idle) Neutral @ 5000 rpm 2.15:1 6.5 fl oz (195 mL) Quicksilver Gear Lube-Premium Blend 28 Spiral/Bevel 13 Spiral/Bevel Floating No Adjustment 2.3 – 3.6 psi (16 – 25 kPa) 8 – 15 psi (55 – 103.5 kPa) * Oil pressure specifications listed were obtained with oil at 165F (75C) Water pressure readings will vary with thermostat operation. 90-857138R1 MAY 2000 Page 1A-7 SPECIFICATIONS Propeller Information Charts Mercury/Mariner 4 (4-Stroke) Wide Open Throttle RPM : 5000-6000 Recommended Transom Heights : 15, 20 Right Hand Rotation Standard Gear Reduction : 2.15:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 8-3/8 9 3 Alum Up to 400 Up to 14 12-18 48-812950T1 8-3/8 8 3 Alum 300-500 13-15 10-16 48-812950 8-3/8 7 3 Alum 400-700 14-16 8-13 48-812949* 8-3/8 6 3 Alum 600+ 15+ 1-11 48-16144 8-3/8 6 3 Alum Sailboat 1-8 48-812951A1 Mercury/Mariner 5 (4-Stroke) Wide Open Throttle RPM : 5000-6000 Recommended Transom Heights : 15, 20 Right Hand Rotation Standard Gear Reduction : 2.15:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 8-3/8 9 3 Alum Up to 500 Up to 14 12-18 48-812950T1 8-3/8 8 3 Alum 400-700 13-15 10-16 48-812950* 8-3/8 7 3 Alum 500-900 14-16 8-13 48-812949 8-3/8 6 3 Alum 600+ 15+ 1-11 48-16144 8-3/8 6 3 Alum Sailboat 1-8 48-812951A1 Mercury/Mariner 6 (4-Stroke) Wide Open Throttle RPM : 5000-6000 Recommended Transom Heights : 15, 20 Right Hand Rotation Standard Gear Reduction : 2.15:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 8-3/8 9 3 Alum Up to 500 Up to 14 14-21 48-812950T1 8-3/8 8 3 Alum 500-800 13-15 12-18 48-812950* 8-3/8 7 3 Alum 600-1100 14-16 10-14 48-812949 8-3/8 6 3 Alum 800+ 15+ 1-12 48-16144 8-3/8 6 3 Alum Sailboat 1-9 48-812951A1 *Standard propeller shipped with outboard. Page 1A-8 90-857138R1 MAY 2000 MAINTENANCE IMPORTANT INFORMATION Section 1B – Maintenance Table of Contents 1 B Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Gear Case Lubricant Capacity . . . . . . . . . . . . . . . 1B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Quicksilver Lubricant/Sealant . . . . . . . . . . . . . . . . 1B-2 Inspection and Maintenance Schedule . . . . . . . . . . . 1B-3 Before Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 After Each Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Every 100 Hours of Use or Once Yearly, Whichever Occurs First . . . . . . . . . . . . . . . . . . . . . 1B-3 Flushing The Cooling System . . . . . . . . . . . . . . . . . . . 1B-4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Fuel Line Inspection . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Engine Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Corrosion Control Anode . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Spark Plug Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Specifications Gear Case Lubricant Capacity Special Tools 1. Grease Gun 91-37299A1 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6 Changing Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Engine Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Oil Changing Procedure . . . . . . . . . . . . . . . . . . . . . 1B-8 Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Gear Case Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Gear Case Lubricant Capacity . . . . . . . . . . . . . . . 1B-9 Draining Gear Case . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Checking Lubricant Level and Refilling Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Storage Preparations . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Protecting External Engine Components . . . . . 1B-10 Protecting Internal Engine Components . . . . . . 1B-11 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11 Positioning Outboard for Storage . . . . . . . . . . . . 1B-11 Gear Case Ratio Capacity 2.15:1 6.6 fl oz. (195.0 ml) 90-857138R1 MAY 2000 Page 1B-1 MAINTENANCE Quicksilver Lubricant/Sealant 1. Quicksilver Anti-Corrosion Grease P/N 92-850735A1 2. 2-4-C Marine Lubricant with Teflon P/N 92-850736A1 3. SAE 10-30W Motor Oil P/N 92-802833A1 4. Quicksilver Gear Lubricant P/N 92-19007A24 Page 1B-2 90-857138R1 MAY 2000 MAINTENANCE Inspection and Maintenance Schedule Before Each Use 1. Check engine oil level. 2. Visually inspect the fuel system for deterioration or leaks. 3. Check outboard for tightness on transom. 4. Check propeller blades for damage. After Each Use 1. Flush out the outboard cooling system if operating in salt or polluted water. 2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case with fresh water if operating in salt water. Every 100 Hours of Use or Once Yearly, Whichever Occurs First 1. Lubricate all lubrication points. Lubricate more frequently when used in salt water. 2. Change engine oil. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. 3. Inspect and clean spark plugs. 4. Check fuel line filter for contaminants. 5. Check corrosion control anode. Check more frequently when used in salt water. 6. Drain and replace gear case lubricant. 7. Lubricate splines on the drive shaft.* 8. Check tightness of bolts, nuts, and other fasteners. 9. Replace water pump impeller.* * These items should be serviced by an authorized dealer. 90-857138R1 MAY 2000 Page 1B-3 MAINTENANCE Flushing The Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. NOTE:Do not run the engine while flushing the cooling system. 1. Remove plug and gasket and thread-in hose coupling. 2. Attach a water hose to the hose coupling. Turn on the water gently and flush the cooling system for 3 to 5 minutes. 3. Remove the thread-in hose coupling and reinstall plug and gasket. b a a-Plug and Gasket b-Hose Coupling Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system. Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. Inspect any completed service work for sign of fuel leakage. Fuel Line Inspection Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness or other signs of deterioration or damage. If any of these conditions is found, the fuel line or primer bulb must be replaced. Engine Fuel Filter Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace. Page 1B-4 90-857138R1 MAY 2000 MAINTENANCE Corrosion Control Anode Your outboard has a corrosion control anode installed to the gear case. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. The anode requires periodic inspection especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. a a-Anode Spark Plug Inspection Inspect spark plugs at the recommended intervals. 1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. 2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 3. Set the spark plug gap. See Specification Chart in General Information Section. 4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs finger tight, and tighten 1/4 turn or torque to 13 lb-ft (17.5 Nm). 90-857138R1 MAY 2000 Page 1B-5 MAINTENANCE Lubrication Points Lubricate Points 1 thru 5 with Quicksilver 2-4-C with Teflon Marine Lubricant or Special Lubricant 101. 1. Co-Pilot Lubricate threads. 2. Swivel Bracket Lubricate fitting. 2 2 12 3. Transom Clamp Screws Lubricate threads. 32 NOTE:Lubricating points 4 and 5 require disassembly of the product. These points should be lubricated at least once a year by an authorized dealer. 4. Tiller Handle Rubber Bushing Lubricate internal diameter. 42 5. Shift Handle Detent Lubricate detent. 52 Page 1B-6 90-857138R1 MAY 2000 MAINTENANCE Lubricate Point 6 with Light Weight Oil 6. Tilt Pivot. 6 6 Lubricate Point 7 with Quicksilver Anti-Corrosion Grease or 2-4-C with Teflon Marine Lubricant. 7. Propeller Shaft Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding to the shaft. 7 90-857138R1 MAY 2000 Page 1B-7 MAINTENANCE Changing Engine Oil ENGINE OIL CAPACITY 15 fl oz. (450 mL) OIL CHANGING PROCEDURE 1. Place outboard in an upright slightly tilted position. 2. Turn the steering on the outboard to gain access to the drain plug. Remove drain plug and drain engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. a a-Drain Plug IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil contaminated with fuel will smell strongly of fuel. If contaminated oil is noticed, have the engine checked by your dealer. OIL FILLING IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil. Remove the oil fill cap and refill with 15 fl oz. (450 mL) of oil. Reinstall the oil fill cap. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Add oil if necessary. Page 1B-8 90-857138R1 MAY 2000 MAINTENANCE Gear Case Lubrication Gear Case Lubricant Capacity Gear Case Ratio Capacity 2.15:1 6.6 fl oz. (195 mL) When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer. Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case. Also examine the gear case lubricant for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. Draining Gear Case 1. Place outboard in a vertical operating position. 2. Place drain pan below outboard. 3. Remove fill/drain plug and vent plug and drain lubricant. b a a-Fill/Drain Plug b-Vent Plug 90-857138R1 MAY 2000 Page 1B-9 MAINTENANCE Checking Lubricant Level and Refilling Gear case 1. Place outboard in a vertical operating position. 2. Remove vent plug. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. a c db a-Vent Plug/Sealing Washer b-Lubricant Tube c-Vent Hole d-Fill/Drain Plug and Sealing Washer Storage Preparations Fuel System IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being used contains alcohol, it is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system. Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with following instructions. 1. Portable Fuel Tank Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel. 2. Permanently Installed Fuel Tank Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank. 3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine for ten minutes to allow treated fuel to fill the fuel system. Protecting External Engine Components 1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule. 2. Touch up any paint nicks. 3. Spray Quicksilver Corrosion Guard on external metal surfaces (except corrosion control anodes). Page 1B-10 90-857138R1 MAY 2000 MAINTENANCE 90-857138R1 MAY 2000 Page 1B-11 Protecting Internal Engine Components NOTE: Before performing Steps 1 and 2, make sure the fuel system has been prepared for storage. 1. Change the engine oil. 2. Place the outboard in water or connect flushing attachment for circulating cooling water. Start the engine and let it run in neutral to warm up. 3. With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel line. When engine begins to stall, quickly spray Quicksilver Storage Seal into carburetor until engine stops from lack of fuel. 4. Remove the spark plugs and inject a five second spray of Quicksilver Storage Seal around the inside of each cylinder. 5. Rotate the flywheel manually several times to distribute the storage seal in the cylinders. Reinstall spark plugs. Gear Case Drain and refill the gear case lubricant (refer to maintenance procedure). Positioning Outboard for Storage 1. Carry, transport or store the outboard only in these two positions. These positions will prevent oil from draining out of the crankcase. a. Upright b. Tiller Side Down a b 2. Never carry, store or transport the outboard in these positions. Engine damage could result from oil draining out of the crankcase. CAUTION If outboard is on a boat and is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gear case could freeze and cause damage to the outboard. GENERAL INFORMATION IMPORTANT INFORMATION Section 1C – GENERAL INFORMATION Table of Contents 1 C Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Conditions Affecting Performance . . . . . . . . . . . . . . . 1C-2 Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Following Complete Submersion . . . . . . . . . . . . . . . . 1C-6 Submerged While Running . . . . . . . . . . . . . . . . . . 1C-6 Salt Water Submersion . . . . . . . . . . . . . . . . . . . . . . 1C-6 Fresh Water Submersion . . . . . . . . . . . . . . . . . . . . 1C-6 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-7 Propeller Removal/Installation . . . . . . . . . . . . . . . . . . 1C-8 Compression Check . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10