Mercury Mariner 4, 5, and 6HP 4-Stroke Factory Service Manual
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Original Mercury Mariner 4, 5, and 6HP 4-Stroke Factory Service Manual.
Manual is indexed and searchable with high-resolution diagrams and images.
MODELS COVERED:
Mercury/Mariner 4, 5, 6 HP (4-Stroke)
Starting Serial Numbers: 0R000001 and Above
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Full list of manual chapters:
COVER PAGE
Models Mercury/Mariner 4 - 5 - 6 (4-Stroke)
Notice
Notice to Users of This Manual
Cleanliness and Care of Outboard Motor
Page Numbering
Service Manual Outline
SPECIFICATIONS
Section 1A - Specifications
Table of Contents
Specifications
Propeller Information Charts
MAINTENANCE
Section 1B - Maintenance
Table of Contents
Specifications
Gear Case Lubricant Capacity
Special Tools
Quicksilver Lubricant/Sealant
Inspection and Maintenance Schedule
Before Each Use
After Each Use
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
Flushing The Cooling System
Fuel System
Fuel Line Inspection
Engine Fuel Filter
Corrosion Control Anode
Spark Plug Inspection
Lubrication Points
Changing Engine Oil
Gear Case Lubrication
Gear Case Lubricant Capacity
Draining Gear Case
Checking Lubricant Level and Refilling Gear case
Storage Preparations
Fuel System
Protecting External Engine Components
Protecting Internal Engine Components
Gear Case
Positioning Outboard for Storage
GENERAL INFORMATION
Section 1C - GENERAL INFORMATION
Table of Contents
Serial Number Location
Conditions Affecting Performance
Weather
Boat
Engine
Following Complete Submersion
Submerged While Running (Special Instructions)
Salt Water Submersion (Special Instructions)
Fresh Water Submersion (Special Instructions)
Propeller Selection
Propeller Removal/Installation
Compression Check
Cylinder Leakage Testing
Painting Procedures
Decal Application
OUTBOARD MOTOR INSTALLATION
Section 1D - Outboard Motor Installation
Table of Contents
Notice to Installer and Owner
Boat Horsepower Capacity
Selecting Accessories For The Outboard
Installing Outboard
Fastening Security Line
Tilt Pin Adjustment
Setting The Operating Angle Of Your Outboard
Engine Over-Speed Protection System
Installation Drawings
ELECTRICAL - IGNITION SYSTEM
Section 2A - Ignition System
Table of Contents
Specifications
Special Tools
Electrical Components
Description
Test Procedures
Direct Voltage Adaptor Specifications
Capacitor Charging Coil
Trigger Coil
Ignition Coil
CDI Unit
Ignition Components Removal and Installation
Flywheel
Capacitor Charging Coil
Trigger Coil
Ignition Coil
CDI Unit
ELECTRICAL - CHARGING SYSTEM
Section 2B - Charging System
Table of Contents
Specifications
Special Tools
Test Procedures
Lighting Coil
Rectifier Diode Test (Optional)
Lighting Coil Removal and Installation
Rectifier (Battery Charging)
Installation
Battery Connections
Special Operating Instructions
ELECTRICAL - TIMING AND SYNCHRONIZATION
Section 2C - Timing and Synchronization
Table of Contents
Specifications
Special Tools
Ignition Timing
TDC Timing Mark Alignment
Check Timing
ELECTRICAL - WIRING DIAGRAMS
Section 2D - Wiring Diagram
Table of Contents
Wiring Diagram
FUEL SYSTEM - FUEL PUMP and INTEGRAL FUEL TANK
Section 3A - Fuel Pump and Integral Fuel Tank
Table of Contents
Specifications
Quicksilver Lubricants and Service Aids
Fuel Pump
Fuel Pump Removal and Installation
Fuel Pump Disassembly
Fuel Pump Reassembly
Integral Fuel Tank (4 HP Models Only)
FUEL SYSTEM - CARBURATOR
Section 3B - Carburetor
Table of Contents
Specifications
Special Tools
Fuel System
Carburetor Adjustments
Carburetor Removal and Installation
Carburetor Disassembly
Inspection
Carburetor Reassembly
FUEL SYSTEM - EMISSIONS
Section 3C – Emissions
Table of Contents
Exhaust Emissions Standards
What Are Emissions?
Hydrocarbons – HC
Carbon Monoxide – CO
Oxides of Nitrogen - NOx
Controlling Emissions
Stoichiometric (14.7:1) Air/Fuel Ratio
Outboard Hydrocarbon Emissions Reductions
Stratified Vs Homogenized Change
Homogenized Charge
Stratified Charge
Emissions Information
Manufacturer s Responsibility
Dealer Responsibility
Owner Responsibility
EPA Emission Regulations
Manufacturers Certification Label
Service Replacement Certification Label
Removal
Date Code Identification
Installation
Decal Location
POWERHEAD - CYLINDER HEAD
Section 4A - Cylinder Head
Table of Contents
Specifications
Special Tools
Quicksilver Lubricants and Service Aids
Cylinder Block
Intake/Exhaust Valves
Adjustments
Cylinder Head Removal
Cylinder Head Disassembly
Cleaning and Inspection
Cylinder Head
Cylinder Head Resurfacing
Valves
Valve Springs
Cylinder Head Reassembly
Cylinder Head Installation
Cylinder Head Identification Mark
POWERHEAD - CYLINDER BLOCK and CRANKCASE
Section 4B - Cylinder Block and Crankcase
Table of Contents
Specifications
Special Tools
Quicksilver Lubricants and Service Aids
Powerhead - General Information
Cylinder Block
Crankshaft
Oil Pan
Torque Sequence
Cylinder Block Identification Mark
Powerhead Removal
Removing Powerhead Components
Powerhead Disassembly
Inspection
Measuring Cylinder Bore
Measuring Diameter of the Piston Skirt
Measuring Piston Clearance (Clearance Between Piston and Cylinder)
Measuring Outer Diameter of Piston Pin
Measuring Diameter of the Piston Pin Hole
Clearance Between Piston Pin and Piston Pin Hole
Measuring Piston Ring Side Clearance
Measuring Piston Ring End Gap
Measuring Diameter of the Small End of Connecting Rod
Measuring Side Clearance of the Big End of Connecting Rod
Measuring Diameter of Crank Pin "A"
Measuring Outer Diameter of Crankshaft in the Oil Pan Bearing "B"
Measuring Oil Clearance at Big End of Connecting Rod Using Plastigauge
Measuring Camshaft Lobe Height "A" Intake/Exhaust
Measuring Camshaft Bearing Diameter "B"
Measuring Inside Diameter of Oil Pan Bearing - Crankshaft
Clearance Between the Oil Pan Bearing and Crankshaft
Measuring Inside Diameter of Oil Pan Bearing - Camshaft
Clearance Between the Oil Pan Bearing and Camshaft
Inspecting Push Rod
Inspecting Valve Lifter
Measuring Depth of Oil Pump Body
Measuring Inside Diameter of Oil Pump Body
Measuring Clearance Between Inner and Outer Rotors "A"
Measure Clearance Between Outer Rotor and Body "B"
Measuring Height of Oil Pump Outer Rotor
Measuring Side Clearance Between Oil Pump Outer Rotor and Body
Measuring/Testing Thermostat
Powerhead Reassembly
Powerhead Installation
MID-SECTION
Section 5
Table of Contents
Quicksilver Lubricants and Service Aids
Driveshaft Housing
Clamp Brackets
Cowling
Disassembly
Reassembly
Clamp Bracket/Swivel Bracket
Drive Shaft Housing
Bottom Cowling
Water Tube
GEAR HOUSING
Section 6
Table of Contents
Specifications
Special Tools
Quicksilver Lubricants and Service Aids
Gear Housing (Drive Shaft)
Gear Housing (Prop Shaft)
Draining and Inspecting Gear Housing Lubricant
Propeller Removal
Gear Housing Removal
Gear Housing Disassembly
Bearing Carrier
Propeller Shaft
Water Pump Housing and Impeller
Water Pump Base and Shift Shaft
Drive Shaft
Forward Gear and Bearing
Lower Drive Shaft Needle Bearing
Zinc Anode
Water Pickup Screen
Cleaning and Inspection
Gear Housing/Bearing Carrier Castings
Bearings
Forward, Reverse and Pinion Gears
Propeller Shaft
Sliding Clutch
Cam Follower
Water Pump Components
Drive Shaft
Shift Shaft
Gear Housing Reassembly
Lower Drive Shaft Needle Bearing
Forward Gear Bearing
Forward Gear
Pinion Gear and Drive Shaft
Water Pump Base and Shift Shaft
Propeller Shaft
Bearing Carrier
Impeller and Water Pump Housing
Zinc Anode
Water Pickup Screen
Gear Housing Installation
Propeller Installation
Filling Gear Housing with Lubricant
CONTROLS - SHIFT LINKAGE
Section 7A - Shift Linkage
Table of Contents
Quicksilver Lubricants and Service Aids
Shift Components
Removal/Disassembly
Reassembly/Installation
CONTROLS - TILLER HANDLE
Section 7B - Tiller Handle
Table of Contents
Quicksilver Lubricants and Service Aids
Steering Handle
Removal
Disassembly
Reassembly
Installation
MANUAL STARTER
Section 8
Table of Contents
Quicksilver Lubricants and Service Aids
Recoil Starter
Removal
Installation
Disassembly
Cleaning and Inspection
Reassembly
COLOR DIAGRAMS
COLOR DIAGRAMS
Table of Contents
4/5/6 (4-Stroke) Wiring Diagram
4/5/6 (4-Stroke) Water Flow Diagram
4/5/6 (4-Stroke) Oil Flow Diagram
