2000 Mercury Mariner 4hp, 5hp, 6hp Outboard Motor Service Manual

Comprehensive service and repair manual for 2000 Mercury Mariner 4hp, 5hp, and 6hp outboard motors. Covers all systems and components with detailed instructions. PN 90-857138R1

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Document Details

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Document Number / Seller:
27448 / Barbara Wright
File Size:
6.10 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
May 8, 2025

Models Covered & Key Technical Specifications

Mercury Mariner 4hp, 5hp, 6hp (2000) Outboard Motor Service Manual

Factory Grade Manual | Mercury Mariner Division

  • Engine Type: 4-Stroke Cycle – Over Head Valve
  • Displacement: 7.5 cu. in. (123 cc)
  • Standard Bore: 2.323 in. (59.00 mm)
  • Piston Type: Aluminum
  • Gear Ratio: 2.15:1
  • Ignition System: Capacitor Discharge Ignition

Professional Workshop Service Manual & Technical Specifications

Mercury Mariner 4hp, 5hp, 6hp (2000) Outboard Motor Service Manual: Factory Grade Manual

Serial-Range: 2000-2001 / Coverage-Scope: 4hp, 5hp, 6hp / Serial-Range: Factory Data

Assessment-Element Parameters Validation-Data
Engine Configuration 4-Stroke Cycle Over Head Valve
Displacement 7.5 cu. in. (123 cc) Standard Bore: 2.323 in. (59.00 mm)
Gear Ratio 2.15:1 Forward Gear: 28 Spiral/Bevel
Ignition Type Capacitor Discharge Ignition Spark Plug Gap: 0.035 in. (0.9 mm)
Lubricant Capacity Gearcase: 6.5 fl oz (195 mL) Oil Pan: 0.95 pt (450 ml)
Horsepower Ratings 4hp, 5hp, 6hp Engine Speed Limiter: 6300 ± 200 RPM

System Overview: Systematizing the service groups into logical sections, this manual details the complete maintenance and repair procedures for Mercury Mariner 4, 5, and 6 horsepower outboard motors from the 2000 model year. It provides comprehensive information on all engine systems, including ignition, fuel, electrical, and mechanical components. Specific attention is given to the powerhead, cylinder block, crankshaft, and gear housing, with detailed diagrams and specifications for each part.

Engine Tune-up & Maintenance: Fundamentally requiring meticulous attention to detail, this manual outlines procedures for engine tune-ups, carburetor adjustments, and lubrication of all critical components. It includes detailed specifications for valve clearance, ignition timing, and fluid capacities. Proper maintenance of the cooling system, fuel system, and lubrication points is thoroughly documented to ensure optimal engine performance and longevity.

Torque Statement: This manual documents torque specifications for fasteners to ensure proper fastener fatigue prevention.

FAQ

What **designated** adjustment procedures require specific tools? keyboard_arrow_down

Specific tools like a strap wrench (91-24937A1) and flywheel holder/puller (91-804552) are recommended for flywheel removal and installation procedures.

Identify the **critical** specifications for the ignition system. keyboard_arrow_down

Critical ignition system specifications include Spark Plug Gap: 0.035 in. (0.9 mm), Hex Size: 5/8 in. (16 mm), and Torque: 13 lb-ft (17.5 Nm) for the spark plug.

What **required** assembly sequence is documented for the piston and connecting rod? keyboard_arrow_down

The connecting rod (3H6 mark must face the oil pan) is assembled to the piston using the piston pin and new piston pin clips, with the direction arrow pointing towards the camshaft.

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Reviews (5)

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The download process was seamless. This manual has all the specs I needed for my Mariner motor. Thanks!
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The service manual was easy to download and packed with useful information. Highly recommend!
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I had a smooth experience downloading the manual. It covers everything you need for maintenance. Very satisfied!
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Professional service with a fast email response. The manual is comprehensive and easy to follow. Worth every penny!
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Quick response from support when I had a query. The manual is detailed and user-friendly. Great value!