DOWNLOAD SERVICE MANUALS - Mercury Suzuki Yamaha Johnson Mariner Evinrude. PERIODIC MAINTENANCEPERIODIC MAINTENANCE SCHEDULEThe chart below lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy. Maintenance intervals should be judged by number of hours or months, whichever comes first. NOTE: More frequent servicing should be performed on outboard motors that are used under severe conditions. MAINTENANCE AND TUNE- UP PROCEDURES1. Place mercury 4. 0hp manual outboard motor upright on a level surface. Remove motor cover. Important manual information EMU31285 To the owner Thank you for selecting a Yamaha outboard motor. This Owner’s Manual contains infor-mation needed for proper. Remove oil level dipstick and wipe it clean. Insert it fully into dipstick hole, then remove it to check oil level. Oil level should be between full level hole (Max.) and low level hole (Min.). If level is low, add recommended oil to full level hole (Max.).
Recommended oil . Place outboard motor upright on a level surface. Remove oil filler cap. Place a container under engine oil drain plug. Remove engine oil drain plug and gasket to drain engine oil. ENGINE OIL FILTER REPLACEMENTNOTE: For engine oil change only, go to step 6. To replace engine oil filter : NOTE: Before fitting new oil filter, be sure to oil O- ring.(1) Remove STBD side cover. Install gasket and oil drain plug. Tighten engine oil drain plug to specified torque. Pour recommended engine oil into oil filler opening, then install oil filler cap. Engine oil amounts: Oil change only : 5. L (5. 8 / 4. 8 US / Imp. To reset oil change reminder system’s operation time to zero (cancellation) ; (1) Turn ignition key to “ON” position.(2) Pull out emergency stop switch plate 1.(3) Pull up emergency stop switch knob 2 three times in seven seconds. A short beep will be heard if cancellation is successfully finished.(4) Turn ignition key to “OFF” position, then set emergency stop switch plate 1 in original position. Start engine and allow it to run for several minutes at idle speed. Refer to the Mer. Cruiser Repair Manual as procedures can differ depending on model and year. Turn off engine and wait for approx. Place outboard motor upright on a level surface. Place a container under lower unit. Remove lower gear oil drain plug before gear oil level plug and drain gear oil. Fill with recommended gear oil through oil drain hole until oil just starts to flow out from oil level hole. Gear oil amounts : 1. US / Imp. Install oil level plug before removing oil filler tube from drain hole. Install oil drain plug. Go here for johnson manuals http: //www. Do not re- use gaskets once removed. Always use a new gasket. NOTE: To avoid insufficient injection of gear oil, check gear oil level 1. If oil level is low, slowly inject gear oil up to the correct level. LUBRICATIONInspect every 5. Apply Water Resistant Grease to the following points. Throttle / shift linkage. Propeller shaft. Swivel bracket. Swivel bracket. SPARK PLUG. If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool. SPARK PLUG GAPUsing thickness gauge, measure for spark plug gap. Adjust to within specified range if gap is out of specification. Spark plug gap : 0. CONDITION OF ELECTRODEInspect electrode for a worn or burnt condition. If it is extremely worn or burnt, replace spark plug. Also, be sure to replace spark plug if it has a broken insulator, damaged thread, etc. Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the threaded portion of the plug hole resulting in possible engine damage. TAPPET CLEARANCEInspect initially after 2. The tappet clearance specification is the same for both intake and exhaust valves. Too small a tappet clearance may reduce engine power, too large a tappet clearance increases valve noise and hastens valve and seat wear. When the tappets are set to the specified clearance, the engine will run without excessive noise from the valve mechanism and will deliver full power. In this engine, the tappet clearance is increased or decreased by replacing the shim disc, made of a special wear resistant material, fitted to the top of the tappet. The shim discs are easy to remove and refit. Tappet clearance adjustment should be checked and adjusted . Remove following parts . Remove breather hose 1 and evaporation hose 2 from cylinder head cover. Remove fuel hose 3 and 4 from low pressure fuel pump. Remove fifteen (1. Rotate crankshaft counterclockwise to bring cam nose vertical to shim surface. Measure tappet clearances by inserting thickness gauge between cam and shim surface. Tappet clearance (cold engine condition) : IN. Rotate crankshaft counterclockwise to prevent water pump impeller damage. NOTE. If out of specification, adjust tappet clearance by changing shim. ADJUSTMENTTappet clearances are adjusted by replacing tappet shim. Close valve and turn tappet cut- away toward inside as shown in figure. Rotate crankshaft to open (lift up) valve and then remove camshaft housing bolts where shim is to be replaced. Install special tool with camshaft housing bolts as shown in figure. Rotate top of cam 9. After removing shim, measure thickness of original shim and determine correct thickness of shim for proper tappet clearance as calculated by following formula. A = B + (C – 0. 2. A : Correct thickness of shim for proper tappet clearance (mm)B : Thickness of original shim (mm)C : Original tappet clearance (mm)6. Install shim. Identification number should face towards tappet. Rotate crankshaft to be open (lift up) valve. Remove tappet holder 1 and tighten camshaft housing bolts to specified torque. Camshaft housing bolt : 1. N. m (1. 1 kg- m, 8. Recheck tappet clearance. NOTE: After completing tappet clearance adjustment and securing camshaft housing bolts, inspect tappet clearance again. INSTALLATIONAfter checking and adjusting all tappet clearances, install cylinder head cover. Installation is reverse order of removal. IDLE SPEEDInspect initially after 2. NOTE. Start engine and allow to warm up. Attach engine tachometer to the ignition high- tension cord. Check engine speed. Idle speed (in neutral gear) : 6. ADJUSTMENT: If idle speed is out of specification, perform following adjustment procedure. Check that CTP switch is in ON position. To set the IAC valve duty to constant 1. At this time, caution buzzer will sound to notify that IAC duty is in fixed mode. Turning air screw counterclockwise : Engine speed will increase. Turning air screw clockwise : Engine speed will decrease. NOTE. During fixed mode of IAC valve duty, adjust engine speed to 6. Open warm- up lever to turn CTP switch off. NOTE: The fixed mode of IAC valve duty can be manually cancelled by turning CTP switch off. Close warm- up lever and then recheck engine speed. It should now be stable at 6. NOTE: Idling / trolling speed of 6. If engine speed does not return to specification, IAC passage (including the IAC hose) may be clogged or IAC system may not be operating correctly. NOTE: Trolling speed (in- gear idle speed) is same as idle speed. IGNITION TIMINGInspect every 2. NOTE: Before checking ignition timing, make sure idle speed is adjusted within specification. Start engine and allow to warm up. Attach timing light cord to No. Check ignition timing while operating engine in neutral gear at 1. Ignition timing : Approx. If leakage, cracks, swelling or other damage is found, replace breather line and/or fuel line. LOW PRESSURE FUEL FILTER. Inspect case and under panel. Replace If wear, cracks, distortion or corrosion is found. WATER PUMP IMPELLERReplace every 2. Inspect water pump impeller. Replace if vanes are cut, torn or worn. PROPELLER / NUT / COTTER PINInspect initially after 2. Replace propeller if damage noticeably affects operation. Replace propeller if splines are worn, damaged or twisted. Replace if necessary. The anode should be periodically cleaned with a wire brush to ensure maximum effectiveness. NOTE: The anode securing bolt should be covered with Suzuki Silicone Seal. BONDING WIRES. Connect positive (+) terminal first. Connect negative (–) terminal second. How to disconnect: 1. Disconnect negative (–) terminal first. Disconnect positive (+) terminal second. BATTERY SOLUTION LEVEL CHECKBattery solution level should be between UPPER level and LOWER level. If level is low, add distilled water only. BATTERY SOLUTION GRAVITY CHECKMeasure gravity of battery solution using hydrometer. Battery solution gravity : 1. To perform fuel mixture check (O2 feedback) operation, use personal computer and Diagnostic System software. For fuel mixture check (O2 feedback) operation, refer to Diagnostic System Operation Manual”. OIL PRESSUREOil pressure (at normal operating temp.): 5. Pa (5. 5 – 6. 0 kg/cm. NOTE: The figure shown above is a guideline only, not an absolute service limit. If oil pressure is lower or higher than specification, following causes may be considered. Low oil pressure. Check engine oil level. Remove bolts and air duct 3. Loosen screw and disconnect blue lead wire from oil pressure switch. Remove oil pressure switch. Install oil pressure gauge in place of pressure switch hole. Attach engine tachometer to ignition coil high tension cord. Start engine and allow to warm up as follows : Summer : 5 min. After warming up, shift into forward gear and increase engine speed to 3. After testing, reinstall oil pressure switch. Reinstall air duct. CYLINDER COMPRESSIONCylinder compression : Standard : 1. Pa (1. 3 – 1. 7 kg/cm. Max. Low compression pressure can indicate one or more of following. Start engine and allow to warm up, then shut engine off. Remove STBD / PORT side covers.(See page 7- 2)3. Remove all spark plugs. Install compression gauge hose attachment into plug hole, then connect compression gauge hose to gauge hose attachment and compression gauge. Compression gauge. Compression gauge hose. Compression gauge hose attachment. Disconnect safety lanyard (switch plate) from emergency stop switch. Disconnect the safety lanyard from the emergency stop switch prior to cranking the engine.
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