Mercury Mariner Outboard motor 40/50/55/60 2-stroke Service Manual
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- Mercury Outboard 40 50 55 60 Service Manual
Original Mercury Service Manual for 40/50/55/60 2-stroke models.
Manual includes high resolution diagrams, images, detailed instruction and technical recommendations and more.
Manual is deeply indexed and searchable.
Part Number: 90-852572R1 JANUARY 1998
USA: 0G531301 and ABOVE
Belgium: 09974454 and ABOVE
Manual Chapters:
- SPECIFICATIONS
- MAINTENANCE
- GENERAL INFORMATION
- OUTBOARD MOTOR INSTALLATION
- IGNITION
- CHARGING AND STARTING SYSTEM
- TIMING/SYNCHRONIZING/ADJUSTING
- WIRING DIAGRAMS
- FUEL PUMP
- CARBURETOR
- OIL INJECTION
- EMISSIONS
- POWERHEAD
- 40/50 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING
- 55/60 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING
- 40/50 POWER TRIM
- 55/60 POWER TRIM
- 40/50 MANUAL TILT ASSIST
- 55/60 MANUAL TILT SYSTEM
- 40/50 LOWER UNIT
- 55/60 LOWER UNIT
- BIGFOOT GEAR HOUSING 4-1/4 IN. (108 MM) DIAMETER GEAR CASE
- JET DRIVE
- THROTTLE/SHIFT LINKAGE
- TILLER HANDLE
- MANUAL STARTER
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Full list of manual chapters:
COVER
Notice
WARNING
CAUTION
Notice to Users of This Manual
Cleanliness and Care of Outboard Motor
Page Numbering
Service Manual Outline
SPECIFICATIONS
Table of Contents
Specifications
Propeller Information Charts
MAINTENANCE
Table of Contents
Specifications
Special Tools
Quicksilver Lubricant/Sealant
Inspection and Maintenance Schedule
Before Each Use
After Each Use
Every 100 hours of Use or Once Yearly, Whichever Occurs First
Every 300 Hours of Use or Three Years
Before Periods of Storage
Flushing The Cooling System
Fuel System
Corrosion Control Anode
Lubrication Points
Checking Power Trim Fluid
60 HP
40/50 HP
Gear Case Lubrication
Draining Gear Case
Checking Lubricant Level and Filling
Gear Case
Storage Preparations
Protecting External Outboard Components
Protecting Internal Engine Components
Gear Case
Positioning Outboard for Storage
Battery Storage
GENERAL INFORMATION
Table of Contents
Serial Number Location
Conditions Affecting Performance
Weather
Boat
Engine
Following Complete Submersion
Salt Water Submersion (Special Instructions)
Submerged While Running (Special Instructions)
Submerged Engine (Fresh Water) (Plus Special Instructions)
Propeller Selection
Propeller Removal/Installation
Removal
Installation
OUTBOARD MOTOR INSTALLATION
Table of Contents
Lifting Outboard
Steering Link Rod
Installing Outboard 40-50 HP
40-50 Hp – Non-Thumb Screw Models
40-50 HP – Thumb Screw Models
Installing Outboard 55-60 HP
55-60 HP - Non-Thumb Screw Models
55-60 HP – Thumb Screw Models
Wiring Harness
Battery Cable Connections
Shift and Throttle Cable 40 and 50 Hp Models
40-50 Hp – Shift Cable Installation
40-50 Hp – Throttle Cable Installation
Shift and Throttle Cable 60 HP Models
60 HP – Shift Cable Installation
60 HP – Throttle Cable Installation
Trim Tab Adjustment
IGNITION
Table of Contents
Specifications
Special Tools
Flywheel And Stator (Electric)
Flywheel And Stator (Manual)
Electrical Components 40/50
Electrical Components 55/60
Theory of Operation
Capacitor Charging #1 CDM
Capacitor Charging #2 and #3 CDM
#1 CylinderTrigger Circuit
Ignition Coil Circuit
Stop Circuit
Rev Limiter Circuit
Ignition Component Description
Capacitor Discharge Module (CDM)
Trigger Coil
Stator Assembly
Flywheel
CDM (P/N 827509) Trouble Shooting Flowchart
CDM (P/N 827509)
Spark Gap Tester P/N 91-850439
CDM Test Harness 84-825207A2
CDM Stop Diode Trouble Shooting
CDM Trouble Shooting Flowchart
Ignition Test Procedures
Direct Voltage Adaptor (DVA) Test
Resistance Tests
Flywheel Removal and Installation
Stator Removal and Installation
Trigger
CDM
CHARGING AND STARTING SYSTEM
Table of Contents
Specifications
Special Tools
Starter Motor
Battery
Operating Engine Without Battery
Specific Gravity Readings
Specific Gravity Cell Comparison Test
Electrolyte Level
Charging A Discharged Battery
Winter Storage of Batteries
Battery Charging System Troubleshooting
Description
Starting System
Starting System Components
Description
Troubleshooting the Starting Circuit
Starting Circuit Wiring Diagram
Starting Circuit Troubleshooting Flow Chart
Starter Motor
Removal
Disassembly
Cleaning and Inspection Testing
Brush Replacement
Reassembly
Installation
TIMING/SYNCHRONIZING/ADJUSTING
Table of Contents
Specifications
Special Tools
Timing
Idle Timing Adjustment
Maximum Timing Adjustment
Carburetor Synchronization
Adjustments
Idle
WIRING DIAGRAMS
Table of Contents
40/55 MH Wiring Diagram
40/50/60 EO Wiring Diagram
40/50 EHPTO Wiring Diagram
40/50/60 EPTO Wiring Diagram
60 EHPTO Wiring Diagram
COMMANDER 2000 Side Mount Remote Control Wiring Diagrams
Power Trim/Tilt Electric Start with Warning Horn
Power Tilt Electric Start with Warning Horn
Electric Start with Warning Horn
FUEL PUMP
Table of Contents
Specifications
Fuel Pump (Electric) 40/50/55/60
Fuel Pump (Manual) 40/50
Fuel Pump (Manual) 55/60
Theory of Operation
Troubleshooting
Checking For Restricted Fuel Flow Caused by Anti-Siphon Valves
Testing
Fuel Pump Removal
Fuel Pump Disassembly
Cleaning and Inspection
Reassembly
Check Valve Assembly
Fuel Pump Assembly
CARBURETOR
Table of Contents
Specifications
WME Carburetor Chart
Special Tools
Carburetor 40/50
Carburetor 55/60
Attenuator Plate 40/50
Attenuator Plate 55/60
Adjustments
Idle Mixture Screw Adjustment
Idle Speed Adjustment
Float Adjustment
Main (High Speed) Jet Adjustment
Jet Orifice Size Chart
High Altitude Jet Chart
Fuel System Troubleshooting
General Information
Problem: Engine Floods
Problem: Engine Runs Too Rich
Problem: Fuel Blow Back Out Of Carburetor
Problem: Rough Idle
Problem: Engine Turns Over But Will Not Start Or Starts Hard When Cold
Problem: Unable to Reduce Engine RPM to Slow Idle
Problem: Engine Runs Too Lean
Problems: -Engine Idles Rough And Stalls -Engine Runs Uneven Or Surges -Engine Will Not Accelerate
Removal/Installation
40/50
55/60
Inspection
Enrichment System
Electric Enrichener Valve
Manual Primer Button
OIL INJECTION
Table of Contents
Specifications
Oil Injection Components 40/50
Oil Injection Components 55/60
Theory of Operation
Oil Flow Diagram
Adjustments
Carburetor/Oil Pump Synchronization
Bleeding Air From Oil Injection System
Check Operation of the Oil Injection
System (Engine Running)
Troubleshooting
Troubleshooting Chart
Installing Drive Gear (For Oil Injection Pump) Onto Crankshaft
Engine Mounted Oil Reservoir
Removal
Installation
EMISSIONS
Table of Contents
Exhaust Emissions Standards
What Are Emissions?
Hydrocarbons - HC
Carbon Monoxide - CO
Oxides of Nitrogen - NOx
Controlling Emissions
Stoichiometric (14.7:1) Air/Fuel Ratio
OUTBOARD HYDROCARBON EMISSIONS REDUCTIONS
STRATIFIED VS HOMOGENIZED CHARGE
Homogenized Charge
Stratified Charge
Emissions Information
Manufacturer's Responsibility
Dealer Responsibility
Owner Responsibility
EPA Emission Regulations
Decal Location for 1998 Models:
POWERHEAD
Table of Contents
Specifications
Special Tools
Cylinder Block And Crankcase 40/50
Cylinder Block And Crankcase 55/60
Induction Manifold And Reed Block 40/50
Induction Manifold And Reed Block 55/60
Crankshaft, Pistons And Connection Rods
Water Circulation
Thermostat Test
Temperature Switch Test
General Information
Powerhead Removal
Powerhead Disassembly
Removing Engine Components
Crankshaft Disassembly
Cleaning and Inspection
Cylinder Block and Crankcase Cover
Check Valves
Piston and Piston Rings
Crankshaft
Connecting Rods
Reed Blocks
Reassembly and Installation
General Information
Assembling Rod to Piston
Piston Ring Installation
Crankshaft Installation
Installing Rods to Crankshaft
Connecting Rod Cap Alignment
Crankcase Cover to Block
Lower End Cap
Intake/Reed Block Manifold Installation
Thermostat Cover Installation
Install Remaining Engine Components
Powerhead Installation
Test Run Procedure
Important Information
40/50 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING
Table of Contents
Clamp Bracket
Swivel Tube Components
Swivel Bracket Components
Drive Shaft Housing/Exhaust Plate Components
Drive Shaft Housing Disassembly/Reassembly
55/60 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING
Table of Contents
Clamp Bracket Components (Manual)
Transom Bracket Components (Electric)
Swivel Bracket Components
Drive Shaft Housing
Drive Shaft Housing Disassembly/Reassembly
40/50 POWER TRIM
Table of Contents
Special Tools
Power Trim Components
Theory Of Operation
Adjustments
Trimming Characteristics
Trailering Outboard
Tilting Outboard Up and Down Manually
Trim "In" Angle Adjustment
Power Trim Flow Diagrams
Trim Up
Tilt Up
Maximum Tilt
Down Mode
Shock Function Up
Shock Function Return
Manual Tilt
Troubleshooting
Preliminary Checks
Hydraulic System Troubleshooting Flow Chart
Troubleshooting the Power Trim Electrical System
Power Trim System Removal
Disassembly
Shock Rod Disassembly
Memory Piston Removal
Trim Motor Removal
Oil Pump Removal
Tilt Relief Valve Removal
Suction Seat Removal
Pilot Check Valve Assembly Removal
Cleaning/Inspection/Repair
Trim Motor Electrical Tests
Reassembly
Power Trim Reassembly
Tilt Relief Valve Reassembly
Suction Seat Reassembly
Pilot Check Valve Reassembly
Oil Pump Reassembly
Trim Motor Reassembly
Shock Rod Reassembly
Shock Rod Installation
Manual Release Valve Installation
Bleeding Power Trim Unit
Power Trim System Installation
55/60 POWER TRIM
Table of Contents
Special Tools
Power Trim Components
Theory Of Operation
Adjustments
Trimming Characteristics
Trailering Outboard
Tilting Outboard Up and Down Manually
Trim Up
Tilt Up
Maximum Tilt
Down Mode
Shock Function Up
Shock Function Return
Manual Tilt
Troubleshooting
Preliminary Checks
Hydraulic System Troubleshooting Flow Chart
Troubleshooting the Power Trim Electrical System
Power Trim System Removal
Power Trim Disassembly
Trim Motor Removal
Pump and Components Removal
Manifold Removal
Shock Rod Removal
Shock Rod Disassembly
Memory Piston Removal
Cleaning/Inspection/Repair
Trim Motor Electrical Tests
Reassembly
O-ring Sizes
Power Trim Reassembly
Shock Rod Reassembly
Shock Rod Installation
Trim Limit Assembly Installation
Manual Release Valve Installation
Manifold Installation
Oil Pump Installation
Pressure Operated Assembly Installation
Reservoir/Motor Installation
Bleeding Power Trim Unit
Installation of Power Trim System
40/50 MANUAL TILT ASSIST
Table of Contents
Clamp Bracket
Hydraulic Assist Adjustments
Manual Trim System Removal
Manual Trim System Installation
55/60 MANUAL TILT SYSTEM
Table of Contents
Special Tools
Manual Tilt Components
Manual Trim Flow Diagrams
Up Circuit
Tilt Up
Down Circuit
Tilt Down
Slow Tilt Down Under High Thrust
Slow Tilt Down Under High Thrust
Under Water Strike (Valves Open)
Under Water Strike with Valves Open
Shock Function (Valve Closed)
Shock Function with Valves Closed
Shock Function Return
Shock Function Return
Hydraulic System Troubleshooting
Manual Tilt System Removal
Manual Tilt System Disassembly
Accumulator Removal
Shock Rod Removal
Shock Rod Disassembly
Valve Block Removal
Memory Piston Removal
Valve Block Disassembly
Reassembly - O-Ring and Seal Placement
Actual O-Ring Sizes
O-ring Description and Sizes
Manual Tilt System Cleaning and Inspection
Manual Tilt System Reassembly
Valve Block Installation
Shock Rod Reassembly
Shock Rod Installation and Fluid Filling Procedure
Filling Procedure Option Two Instructions for Making Retaining Tool
Bleeding Manual Tilt System
Manual Tilt System Installation
Manual Release Valve Adjustment
40/50 LOWER UNIT
Table of Contents
Specifications
Special Tools
Gear Housing (Drive Shaft)(40/50)
Gear Housing (Propeller Shaft)(40/50)
General Service Recommendations
Seals
Bearings
Draining and Inspecting Gear Lubricant
Propeller Removal
Gear Housing Removal
Disassembly
Water Pump
Water Pump Seals
Inspection
Upper Drive Shaft Bearing
Pinion Gear Bearing
Pinion Gear
Forward Gear
Shift Shaft
Propeller Shaft Disassembly
Propeller Shaft and Carrier Inspection
Clutch
Cam Follower
Reverse Gear
Reverse Gear Bearing
Bearing Carrier
Gear Housing Reassembly
Shift Shaft Assembly
Pinion Bearing Race
Forward Gear
Pinion Gear/Drive Shaft Assembly
Propeller Shaft
Bearing Carrier
Water Pump
Gear Housing Pressure Test
Gear Housing Installation
Filling Gear Housing with Lubricant
Installing Gear Housing to Drive Shaft Housing
Trim Tab Adjustment and Replacement
Propeller Installation
55/60 LOWER UNIT
Table of Contents
Specifications
Special Tools
Gear Housing (Drive Shaft)(55/60)
Gear Housing (Propeller Shaft)(55/60)
General Service Recommendations
Bearings
Seals
Draining and Inspecting Gear Lubricant
Propeller Removal
Gear Housing Removal
Gear Housing Disassembly
Water Pump
Bearing Carrier and Propeller Shaft
Propeller Shaft Disassembly
Pinion Gear, Driveshaft and Forward Gear
Upper Driveshaft Bearing
Lower Driveshaft Bearing
Forward Gear Bearing Race
Shift Shaft
Gear Housing Reassembly
Shift Shaft
Propeller Shaft
Forward Gear Bearing Race
Bearing Carrier
Reverse Gear
Forward Gear
Lower Driveshaft Bearing Installation
Upper Driveshaft Bearing Installation
Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer and Driveshaft Installation
Pinion Gear Location and Forward Gear Backlash
Determining Forward Gear Backlash
Bearing Carrier and Propeller Shaft Installation
Bearing Carrier
Water Pump Reassembly and Installation
Gear Housing Pressure Test
Gear Housing Installation
Filling Gear Housing with Lubricant
Gear Housing Installation
Propeller Installation
Trim Tab Adjustment and Replacement
BIGFOOT GEAR HOUSING 4-1/4 IN. (108 MM) DIAMETER GEAR CASE
Table of Contents
Specifications
Special Tools
Gear Housing (Drive Shaft)(60 Bigfoot)
Gear Housing (Prop Shaft)(60 Bigfoot)
Gear Case Identification
Removal
Disassembly
Draining and Inspecting Gear Housing Lubricant
Water Pump
Bearing Carrier and Propeller Shaft
Pinion Gear, Drive Shaft, and Forward Gear
Upper Drive Shaft Bearing
Oil Sleeve
Lower Drive Shaft Bearing Race
Shift Shaft
Forward Gear Bearing Race
Trim Tab Adjustment and Replacement
Reassembly
Forward Gear Bearing Race
Shift Shaft
Bearing Carrier Reassembly
Forward Gear Reassembly
Propeller Shaft Reassembly
Drive Shaft Wear Sleeve Installation
Lower Drive Shaft Bearing Race Installation
Oil Sleeve Installation
Upper Drive Shaft Bearing Installation
Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation
Pinion Gear Depth and Forward Gear Backlash
Determining Forward Gear Backlash
Bearing Carrier and Propeller Shaft Installation
Water Pump Reassembly and Installation
Gear Housing Pressure Test
Filling Gear Housing With Lubricant
Gearcase Installation
Trim Tab Adjustment
JET DRIVE
Table of Contents
Jet 30 Pump Assembly
Jet 30 Water Pump Components
Jet 45 Pump Assembly
Jet 45 Water Pump Components
Selecting A Boat That Is Best Suited For Jet Power
Engine Horsepower Selection
Transom Height of the Boat
Locate Center Line of the Outboard
Outboard Mounting Height
Setting Outboard Mounting Height on Boats with Flat Bottom Hulls
Water Testing
Shift Cable Installation
Lubricating The Drive Shaft Bearing
Impeller Removal and Installation
Steering Pull Adjustment
Impeller Clearance Adjustment
Worn (Dull) Impeller
Flushing The Cooling System
Liner Replacement
Jet Drive Removal
Water Pump Removal and Installation
Removal
Reassembling Water Pump to Jet Drive
Bearing Carrier Removal
Bearing Carrier Reassembly
Bearing Carrier Disassembly
Installing Lower Seals
Installing Upper Seals
Installing Drive Shaft Ball Bearing
Installing Drive Shaft
Bearing Carrier Installation
Installing Jet Drive to Drive Shaft Housing
THROTTLE/SHIFT LINKAGE
Table of Contents
Throttle Lever And Linkage 40/50
Throttle Lever And Linkage 55/60
TILLER HANDLE
Table of Contents
Tiller Handle 40/50
Steering Handle Kit 55/60
Steering Handle Kit 55/60
Tiller Arm/Shift Lever Removal
Tiller Handle Disassembly
Tiller Arm Reassembly
Tiller Arm/Shift Lever Installation
Shift Link Rod Installation and Adjustment to Engine
Throttle Cable Installation and Adjustment
Co-Pilot Installation
Tiller Handle Installation
Wiring Harness Connection
MANUAL STARTER
Table of Contents
Starter Assembly (Manual) 40/50
Starter Assembly (Manual) 55/60
Rewind Starter Disassembly
Cleaning and Inspection
Rewind Starter Reassembly
Adjusting Rewind Spring Tension
Starter Interlock Cable Adjustment
