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Re: Mercury 4 hp hard start
The Merc 4 uses a Tohatsu 'power head'.
The problem as you describe most likely is the *interlock* between the recoil starter and 'gear shift' is out of adjustment. This interlock prevents pull starting in either forward or reverse gear position but not neutral.
Id recommend that you jiggle the *gear shift* lever positions back and forth and in small increments, while slow pulling the recoil starter to possibly locate where the interlock does not engage
There is a Tohatsu SERVICE MANUAL "4 Stroke MFS - 4/5/6B,C Models" that should contain the adjustment procedure ... the manual is available from most 'brick & mortar' and also online/internet Tohatsu dealers. Should also be available (Mercury 4 Service Manual) from most Merc online dealers.
Purchase your service manual based on the Model, serial number, and YEAR purchased.
If you are an experienced DIYer, you can probably, remove the engine top cover ... examine the shifting mechanism and linkage, find the problem and fix it yourself without the need for a manual. Just remember that the interlock 'set point' is: 'Center' of the neutral (shift lever) position allows easy/full movement of the recoil starter mechanism.
Without seeing this OB, my first guess would be that the recoil starter assembly has come slightly loose on top of the power head. I would also guess that this OB has been fully disassembled or possibly 'rebuilt' and the mechanic forgot to put BLUE LOCKTITE thread sealer on the screws threads that mount the recoil starter - just a guess.
Last edited by RichH; 1 Week Ago at 02:40 PM.