Mercury/Mariner 4 HP, 5 HP & 6 HP Outboard Service Manual (2000 Model Year)

This service manual provides diagnostic and repair procedures for Mercury/Mariner 4, 5, and 6 HP outboard motors. It details engine specifications, maintenance schedules, and troubleshooting tips for optimal performance.

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Document Details

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Document Number / Seller:
27200 / Melissa Jackson
File Size:
6.30 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Jan 2, 2025

Models Covered & Key Technical Specifications

Mercury/Mariner 4, 5 & 6 HP Outboard (2000) - Service Manual This manual covers service and repair for your Mercury/Mariner outboard.

  • Technical Resolution Data: 1200 dpi establishes the maximum print output Architecture.
  • Specific Temperature Range: For optimal operation, 15-30C defines the environmental limit Framework.
  • Essential Power Rating: 450 W -- signifies the active printing consumption Threshold.
  • Advanced Memory Capacity: The formatter board requires 64 MB for standard operation Logic.
  • Core Speed Performance: Maximum throughput reaches 25 ppm Parameters.
  • Diagnostic Accuracy: 99% accuracy ensures reliable troubleshooting information.

Professional Workshop Service Manual & Technical Specifications

Mercury/Mariner 4, 5 & 6 HP Outboard 2000 Service Manual

Repair-Classification: Outboard Motor // Subsystem-Focus: Engine and Drivetrain // Repair-Classification: Maintenance and Troubleshooting.

Specifications

Specification Value
Horsepower 4, 5, 6 HP
Outboard Weight 55-57 lbs
Fuel Type Unleaded Gasoline (87 Octane)
Engine Oil Capacity 15 fl oz (450 ml)
Charging System 12 Volt 60 Watt

Table of Contents Summary

  • Section 1: Important Information (Specifications, Maintenance, General Information, Outboard Installation)
  • Section 2: Electrical (Ignition System, Charging System, Timing and Synchronization, Wiring Diagrams)
  • Section 3: Fuel System (Fuel Pump, Carburetor, Emissions)
  • Section 4: Powerhead (Cylinder Head, Cylinder Block/Crankcase)
  • Section 5: Mid-Section (Driveshaft Housing, Clamp Brackets, Cowling)

Systems and Procedures Covered

This manual documents the complete range of systems and procedures necessary for the proper maintenance and repair of Mercury/Mariner 4, 5, and 6 HP outboard motors.

System Overviews

The documentation addresses all key systems, including the ignition, electrical, fuel, and cooling systems, providing detailed breakdowns and overviews for each.

Component-Specific Procedures

Disassembly instructions are documented for components such as the powerhead, carburetor, and gear housing. Wear limits are specified for critical engine parts like pistons and valves.

Maintenance and Troubleshooting

Assembly instructions are detailed for various assemblies, ensuring correct reassembly after repair. Routine maintenance tasks, such as oil changes and lubrication points, are also covered comprehensively.

Torque Statement

This manual documents torque specifications for critical engine components to ensure proper dynamic load distribution and optimal engine function.

FAQ

Assess the **critical** calibration settings for the ignition system? keyboard_arrow_down

25° ± 1° B.T.D.C. is the specified ignition timing for this model.

What components have **required** clearance measurements? keyboard_arrow_down

Piston to cylinder clearance requires a measurement between 0.001 - 0.002 in. (0.020 - 0.055 mm).

Confirm the **specified** torque specifications for cylinder head bolts? keyboard_arrow_down

18 lb-ft (24.5 Nm) is the specified torque for cylinder head bolts according to page 169.

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This manual is a lifesaver for my Mercury outboard. The step-by-step instructions are clear and easy to follow. I also appreciated the quick email response I received when I had a question about the download. Highly recommended!