4/5/6 FourStroke - Brunswick Corporation

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! WARNINGThe engine exhaust from this product contains chemicalsknown to the state of California to cause cancer, birthdefects or other reproductive harm.engi90-8M0055686 2114/5/6 FourStrokeEPA Emissions RegulationsOutboards sold by Mercury Marine in the United States arecertified to the United States Environmental ProtectionAgency as conforming to the requirements of the regulationsfor the control of air pollution from new outboard motors.This certification is contingent on certain adjustments beingset to factory standards. For this reason, the factoryprocedure for servicing the product must be strictly followedand, wherever practicable, returned to the original intent ofthe design. Maintenance, replacement, or repair of theemission control devices and systems may beperformed by any marine engine repair establishment orindividual.Engines are labeled with an Emission Control Informationdecal as permanent evidence of EPA certification. 2012 Mercury MarineThank Youfor 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, aworld leader in marine technology and outboardmanufacturing since 1939. These years of experience havebeen committed to the goal of producing the finest qualityproducts. This led to Mercury Marine's reputation for strictquality control, excellence, durability, lasting performance,and being the best at providing after the sale support.Please read this manual carefully before operating youroutboard. This manual has been prepared to assist you inthe operation, safe use, and care of your outboard.All of us at Mercury Marine took pride in building youroutboard and wish you many years of happy and safeboating.Again, thank you for your confidence in Mercury Marine.

Warranty MessageThe product you have purchased comes with a limited warrantyfrom Mercury Marine, the terms of the warranty are set forth inthe Warranty Information section of this manual. The warrantystatement contains a description of what is covered, what is notcovered, the duration of coverage, how to best obtain warrantycoverage, important disclaimers and limitations of damages,and other related information. Please review this importantinformation.The description and specifications contained herein were ineffect at the time this manual was approved for printing. MercuryMarine, whose policy is one of continued improvement, reservesthe right to discontinue models at any time, to changespecifications, designs, methods, or procedures without noticeand without incurring obligation.Mercury Marine, Fond du Lac, Wisconsin U.S.A.Litho in U.S.A. 2011, Mercury MarineMercury, 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 Waveslogo, and SmartCraft logo are all registered trademarks ofBrunswick Corporation. Mercury Product Protection logo is aregistered service mark of Brunswick Corporation.Mercury Premier ServiceMercury evaluates the service performance of its dealers andassigns its highest rating of "Mercury Premier" to thosedemonstrating an exceptional commitment to service.Earning a Mercury Premier Service rating means a dealer: Achieves a high 12 month service CSI (CustomerSatisfaction Index) score for warranty service. Possesses all necessary service tools, test equipment,manuals, and parts books. Employs at least one Certified or Master technician.iieng

Provides timely service for all Mercury Marine customers.Offers extended service hours and mobile service, whenappropriate.Uses, displays, and stocks adequate inventory of genuineMercury Precision Parts.Offers a clean, neat shop with well organized tools andservice literature.Declaration of Conformity ‑ For Recreational Craft PropulsionEngines with the Requirements of Directive 94/25/EC asamended by 2003/44/ECName of engine manufacturer: Tohatsu Marine Corporation (TMC) MercuryMarine Joint VentureAddress: Shimodaira 4495‑9Town: Komagane‑City,NaganoPost Code: 399‑4101Country: JapanName of Authorized Representative: Brunswick Marine in EMEA Inc.Address: Parc Industriel de Petit‑RechainTown: VerviersPost Code: B‑2800Country: BelgiumName of Notified Body for exhaust emission assessment: Det NorskeVeritas ASAddress: Veritasveien 1Town: HovikPost Code:1322Country:NorwayID Number: 0575Name of Notified Body for noise emission assessment: Det NorskeVeritas ASAddress: Veritasveien 1Town: HovikengPost Code:1322Country:NorwayiiiID Number: 0575

Conformity assessmentmodule used for exhaustemissions: B C B E B F Stage II ofDirective 97/68/ECor engine type approvedaccording to:Conformity assessmentmodule used for noiseemissions: B D A Aa G G H Directive88/77/EC HOther Community Directives applied: Safety of Machinery Directive98/37/EC; Electromagnetic Compatibility Directive 2004/108/ECDescription of Engines and Essential RequirementsEngine TypeFuel TypeCombustion Cycle z or sterndrive without integral exhaust Diesel 2 stroke Outboard engine Petrol 4 strokeIdentification of Engines Covered by This Declaration ofConformityUnique engine identificationName of engine family number: starting serialnumberEC Module Hcertificate number4 hp, 5 hp, 6 hp0R332614RCD‑H‑28 hp, 9.9 hp0R334339RCD‑H‑29.9 hp BigFoot0R334339RCD‑H‑2iveng

nt/methodTechnicalfilePlease specify inmore detail(* mandatorystandard)Annex 1.B—Exhaust EmissionsB.1 engineidentification B.2 exhaustemissionrequirements * B.3 durability B.4 owner'smanual ISO 8665: 1995* EN ISO8178‑1:1996Annex 1.C—Noise EmissionsC.1 Noiseemission levels * EN ISO 14509C.2 Owner'smanual Owner's manualThis declaration of conformity is issued under the sole responsibility of themanufacturer. I declare on behalf of the engine manufacturer that the enginesmentioned preceding complies with all applicable essential requirements inthe way specified.Name / function:Mark D. Schwabero, President,Mercury OutboardDate and place of issue:July 24, 2008Fond du Lac, Wisconsin, USAengv


WARRANTY INFORMATIONWarranty Registration. 1Transfer of Warranty. 2Transfer of Mercury Product Protection (Extended ServiceCoverage) Plan United States and Canada. 2FourStroke Outboard Limited Warranty. 3FourStroke Outboard Limited Warranty. 7FourStroke Outboard Limited Warranty. 113 Year Limited Warranty Against Corrosion. 15Warranty Coverage and Exclusions. 18U.S. EPA Emissions Limited Warranty. 20Emission Control System Components. 20California Emissions Limited Warranty. 21California Air Resources Board Explanation of Your CaliforniaEmission Control Warranty Statement. 25Emission Certification Star Label. 26GENERAL INFORMATIONBoater's Responsibilities. 28Before Operating Your Outboard. 28Boat Horsepower Capacity. 29Lanyard Stop Switch. 29Protecting People in the Water. 32Exhaust Emissions. 32Selecting Accessories for Your Outboard. 34Safe Boating Suggestions. 35Recording Serial Number. 374/5/6 Specifications. 37INSTALLATIONInstalling Outboard. 39engvii

TRANSPORTINGCarrying, Storing, and Transporting Your Outboard WhenRemoved from Boat. 40Trailering Your Boat. 41FUEL AND OILFuel Recommendations. 43Low Permeation Fuel Hose Requirement . 45EPA Pressurized Portable Fuel Tank Requirements. 45Fuel Demand Valve (FDV) Requirement. 45Mercury Marine's Pressurized Portable Fuel Tank. 46Filling Fuel Tank. 47Engine Oil Recommendations. 48Checking Engine Oil. 49FEATURES AND CONTROLSFeatures and Controls. 51Tilting Outboard. 53Shallow Water Operation . 54Setting the Operating Angle of Your Outboard . 56Engine Overspeed Protection System. 56OPERATIONPrestarting Check List. 57Operating in Freezing Temperatures. 57Operating in Saltwater or Polluted Water. 58Engine Break‑in Procedure. 58Starting the Engine. 58Gear Shifting . 63Stopping the Engine . 64Emergency Starting. 64viiieng

MAINTENANCEOutboard Care. 67EPA Emission Regulations. 67Inspection and Maintenance Schedule. 68Flushing the Cooling System. 70Top Cowl Removal and Installation. 70Corrosion Control Anode. 71Exterior Care. 72Fuel System. 72Propeller Replacement. 73Spark Plug Inspection and Replacement. 75Lubrication Points. 76Changing Engine Oil . 79Gearcase Lubrication. 80Submerged Outboard. 82STORAGEStorage Preparation. 83Protecting External Outboard Components. 83Protecting Internal Engine Components. 84Gearcase. 84Positioning Outboard for Storage. 84OWNER SERVICE ASSISTANCELocal Repair Service. 86Service Away from Home. 86Parts and Accessories Inquiries. 86Service Assistance. 86Mercury Marine Service Offices. 87MAINTENANCE LOGMaintenance Log. 89engix


WARRANTY INFORMATIONWarranty RegistrationUNITED STATES AND CANADATo be eligible for warranty coverage, the product must beregistered with Mercury Marine.At the time of sale, the selling dealer should complete thewarranty registration and immediately submit it to MercuryMarine via MercNET, e‑mail, or mail. Upon receipt of thiswarranty registration, Mercury Marine will record the registration.A copy of the warranty registration should be provided to you byyour selling dealer.NOTE: Registration lists must be maintained by Mercury Marineand any dealer on marine products sold in the United States,should a safety recall notification under the Federal Safety Actbe required.You may change your address at any time, including at time ofwarranty claim, by calling Mercury Marine or sending a letter orfax with your name, old address, new address, and engine serialnumber to Mercury Marine’s warranty registration department.Your dealer can also process this change of information.Mercury MarineAttn: Warranty Registration DepartmentW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939920-929-5054Fax 1 920 929 5893OUTSIDE UNITED STATES AND CANADAFor products purchased outside the United States and Canada,contact the distributor in your country, or the Marine PowerService Center closest to you.eng1

WARRANTY INFORMATIONTransfer of WarrantyUNITED STATES AND CANADAThe limited warranty is transferable to a subsequent purchaser,but only for the remainder of the unused portion of the limitedwarranty. This will not apply to products used for commercialapplications.To transfer the warranty to the subsequent owner, send or fax acopy of the bill of sale or purchase agreement, new owner’sname, address, and engine serial number to Mercury Marine’swarranty registration department. In the United States andCanada, mail to:Mercury MarineAttn: Warranty Registration DepartmentW6250 W. Pioneer RoadP.O. Box 1939Fond du Lac, WI 54936-1939920-929-5054Fax 1 920 929 5893Upon processing the transfer of warranty, Mercury Marine willrecord the new owner's information.There is no charge for this service.OUTSIDE THE UNITED STATES AND CANADAFor products purchased outside the United States and Canada,contact the distributor in your country, or the Marine PowerService Center closest to you.Transfer of Mercury Product Protection (ExtendedService Coverage) Plan United States and CanadaThe remaining coverage period of the Product Protection Plan istransferable to the subsequent purchaser of the engine withinthirty (30) days from the date of sale. Contracts not transferredwithin thirty (30) days of the subsequent purchase will no longerbe valid and the product will no longer be eligible for coverageunder the terms of the contract.2eng

WARRANTY INFORMATIONTo transfer the plan to the subsequent owner, contact MercuryProduct Protection or an authorized dealer to receive a Requestfor Transfer form. Submit to Mercury Product Protection areceipt/bill of sale, a completed Request of Transfer form, and acheck payable to Mercury Marine in the amount of 50.00 (perengine) to cover the transfer fee.Plan coverage is not transferable from one product to anotherproduct or for non‑eligible applications.The Certified Pre‑Owned engine plans are not transferable.For help or assistance, contact Mercury Product ProtectionDepartment at 1‑888‑427‑5373 from 7:30 a.m. to 4:30 p.m. CST,Monday–Friday or email mpp [email protected] Outboard Limited WarrantyUNITED STATES AND CANADAOutside the United States and Canada ‑ Check with your localdistributor.WHAT IS COVERED: Mercury Marine warrants its new productsto be free of defects in material and workmanship during theperiod described below.eng3

WARRANTY INFORMATIONDURATION OF COVERAGE: This Limited Warranty providescoverage for three (3) years from the date the product is first soldto a recreational use retail purchaser, or the date on which theproduct is first put into service, whichever occurs first.Commercial users of these products receive warranty coverageof one (1) year from the date of first retail sale, or one (1) yearfrom the date on which the product was first put into service,whichever occurs first. Commercial use is defined as any work oremployment related use of the product, or any use of the productwhich generates income, for any part of the warranty period,even if the product is only occasionally used for such purposes.The repair or replacement of parts, or the performance of serviceunder this warranty, does not extend the life of this warrantybeyond its original expiration date. Unexpired warranty coveragecan be transferred from one recreational use customer to asubsequent recreational use customer upon proper reregistrationof the product. Unexpired warranty coverage cannot betransferred either to or from a commercial use customer.Warranty coverage may be terminated for used repossessedproduct; or product purchased at auction, from a salvage yard, orfrom an insurance company.CONDITIONS THAT MUST BE MET IN ORDER TO OBTAINWARRANTY COVERAGE: Warranty coverage is available onlyto retail customers that purchase from a Dealer authorized byMercury Marine to distribute the product in the country in whichthe sale occurred, and then only after the Mercury Marinespecified predelivery inspection process is completed anddocumented. Warranty coverage becomes available upon properregistration of the product by the authorized dealer. Inaccuratewarranty registration information regarding recreational use, orsubsequent change of use from recreational to commercial(unless properly reregistered) may void the warranty at the solediscretion of Mercury Marine. Routine maintenance outlined inthe Operation and Maintenance Manual must be timelyperformed in order to maintain warranty coverage. MercuryMarine reserves the right to make warranty coverage contingentupon proof of proper maintenance.4eng

WARRANTY INFORMATIONWHAT MERCURY WILL DO: Mercury's sole and exclusiveobligation under this warranty is limited to, at our option,repairing a defective part, replacing such part or parts with newor Mercury Marine certified remanufactured parts, or refundingthe purchase price of the Mercury product. Mercury reserves theright to improve or modify products from time to time withoutassuming an obligation to modify products previouslymanufactured.HOW TO OBTAIN WARRANTY COVERAGE: The customermust provide Mercury with a reasonable opportunity to repair,and reasonable access to the product for warranty service.Warranty claims shall be made by delivering the product forinspection to a Mercury dealer authorized to service the product.If purchaser cannot deliver the product to such a dealer, writtennotice must be given to Mercury. We will then arrange for theinspection and any covered repair. Purchaser, in that case, shallpay for all related transportation charges and/or travel time. If theservice provided is not covered by this warranty, purchaser shallpay for all related labor and material, and any other expensesassociated with that service. Purchaser shall not, unlessrequested by Mercury, ship the product or parts of the productdirectly to Mercury. Proof of registered ownership must bepresented to the dealer at the time warranty service is requestedin order to obtain coverage.eng5


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.

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