2000–2001 Mercury/Mariner 4 HP, 5 HP & 6 HP 4-Stroke Outboard Service Manual (P/N 90-857138R1)

Mercury Marine service publication 90-857138R1, dated May 2000, covers 2000–2001 Mercury/Mariner 4 HP, 5 HP, and 6 HP 4-stroke outboards, including short- and long-shaft versions, from serial number 0R000001 and above.

Text search and diagram navigation: Service text and tables are searchable, with embedded PDF bookmarks for sections and individual procedures. Some lettering within illustrations is not searchable. Small labels on the wide-format wiring diagram are best viewed enlarged.

• Powerhead repair: Removal, teardown, cylinder-head inspection, valve-seat reconditioning, valve-clearance adjustment, camshaft timing, and powerhead reassembly.

• Ignition and charging: DVA testing, ignition-coil checks, timing verification, lighting-coil testing, and optional rectifier diagnosis and installation.

• Fuel system: Fuel pump repair, carburetor disassembly, float and idle adjustments, and integral fuel-tank service for 4 HP models.

• Lower unit and cooling: Gearcase overhaul, lower unit resealing, shaft and gear inspection, water pump impeller replacement, and thermostat testing.

• Mid-section and controls: Clamp and swivel bracket service, driveshaft housing assembly, shift linkage repairs, and tiller-handle throttle-cable adjustment.

• Manual starter: Recoil starter rebuilds, rope and rewind-spring inspection, ratchet-pawl checks, and start-in-gear interlock service.

• Diagrams and assembly views: Color wiring schematics, water and oil flow diagrams, exploded assembly views, and component-specific torque tables and drawings.

Written for Mercury Marine dealer mechanics and service personnel already familiar with outboard servicing and the specified shop tools.

Powerhead Diagnosis and Internal Repair

Compression checks distinguish readings with the decompression mechanism active or disabled. The cylinder-leakage chart connects escaping air with likely valve, piston/ring, or head-gasket faults, helping narrow a low-compression diagnosis before teardown.

Cylinder-head procedures cover resurfacing, valve-guide inspection, valve-seat correction, and intake/exhaust valve checks. Internal repair extends to piston and ring measurements, connecting-rod oil-clearance checks with Plastigauge, and oil-pump rotor inspection.

Head, camshaft, and piston identification charts distinguish component versions. Factory specifications include crankshaft runout, connecting-rod clearances, wear limits, lubricant capacities, and valve settings; oil-pan torque-sequence drawings support reassembly.

Ignition Tests and Optional Charging Equipment

The electrical sections cover the flywheel/magneto, capacitor charging coil, trigger coil, ignition coil, and CDI unit. DVA tables provide test connections and readings alongside primary and secondary coil-resistance tests. Multi-Meter/DVA Tester 91-99750 and Flywheel Holder/Puller 91-804552 are among the specified tools.

Timing coverage includes TDC-mark alignment and fixed-ignition checks. A separate identification table distinguishes CU2526, CU2564, and CU2568 CDI units by their markings, outer-tube colors, speed limits, and timing characteristics.

The charging section includes lighting-coil replacement, rectifier diode tests, and the Rectifier Kit Installation wiring diagram. It warns that reversed battery polarity can damage the charging system.

Carburetor Variants and Fuel Pump Repair

Carburetor tables distinguish model-specific venturis, main jets, pilot jets, and Bodensee calibrations. European pilot-screw settings are separated from nonadjustable applications.

Fuel-pump inspection covers the plunger, diaphragm, check valves, and seals. The 4 HP integral-tank section adds fuel-cock and filter-screen inspection. Follow the manual's fuel-system fire precautions and electrical-isolation instructions during service.

Gear Housing, Controls and Recoil Starter

Gear-housing repair covers the bearing carrier, propeller shaft, sliding clutch, cam follower, and forward, reverse, and pinion gears. The manual warns that removing the propeller-shaft or forward-gear bearing damages that bearing, an important parts-planning detail for lower-unit work.

Short- and long-shaft driveshaft housings, water tubes, and shift rods are identified separately. Tiller-handle procedures show cable routing; the manual-starter section includes final checks of pawl operation, rope travel, and rewind.

Wiring, Flow Diagrams and Installation References

The color section contains the 4/5/6 (4-Stroke) Wiring Diagram, Water Flow Diagram, and Oil Flow Diagram. Propeller Information Charts and installation drawings support propeller selection and mounting checks; the installation drawing also lists ultra-long-shaft dimensions.

PDF Contents and Page Breakdown

One printable, English-language 260-page PDF: 1 cover page, 3 preliminary pages, 248 pages in Sections 1–8, and 8 pages in the Color Diagrams section. The total includes one notes page within Sections 1–8 and the color section's contents page, blank page, three diagram title pages, and three diagram sheets; there are no separate supplements.