Mercury 40-50-55-60 Service Repair Manual

SERVICE
MANUAL
MODELS
40·50·55·60
With Serial Numbers

United States . . 0G531301 and ABOVE
Belgium . . . . . . . 09974454 and ABOVE
Printed in U.S.A. 1997, Mercury Marine 90-852572R1 JANUARY 1998

Notice who uses a service procedure and/or tool, which is
not recommended by the manufacturer, first must
Throughout this publication, “Dangers”, “Warnings” completely satisfy himself that neither his nor the
and “Cautions” (accompanied by the International products safety will be endangered by the service
HAZARD Symbol ) are used to alert the mechanic procedure selected.
to special instructions concerning a particular service
All information, illustrations and specifications con-
or operation that may be hazardous if performed in-
tained in this manual are based on the latest product
correctly or carelessly. OBSERVE THEM CARE-
FULLY! information available at the time of publication. As re-
quired, revisions to this manual will be sent to all deal-
These “Safety Alerts” alone cannot eliminate the haz- ers contracted by us to sell and/or service these prod-
ards that they signal. Strict compliance to these spe- ucts.
cial instructions when performing the service, plus
It should be kept in mind, while working on the prod-
“Common Sense” operation, are major accident pre-
vention measures. uct, that the electrical system and ignition system are
capable of violent and damaging short circuits or se-
vere electrical shocks. When performing any work
DANGER where electrical terminals could possibly be
DANGER - Immediate hazards which WILL result grounded or touched by the mechanic, the battery
in severe personal injury or death. cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed
WARNING during service they should be covered to protect
WARNING - Hazards or unsafe practices which against accidental entrance of foreign material which
COULD result in severe personal injury or death. could enter the cylinders and cause extensive inter-
nal damage when the engine is started.
CAUTION It is important to note, during any maintenance proce-
Hazards or unsafe practices which could result dure replacement fasteners must have the same
in minor personal injury or product or property measurements and strength as those removed.
damage. Numbers on the heads of the metric bolts and on the
surfaces of metric nuts indicate their strength. Ameri-
can bolts use radial lines for this purpose, while most
American nuts do not have strength markings. Mis-
Notice to Users of This matched or incorrect fasteners can result in damage
or malfunction, or possibly personal injury. There-
Manual fore, fasteners removed should be saved for reuse in
This service manual has been written and published the same locations whenever possible. Where the
by the Service Department of Mercury Marine to aid fasteners are not satisfactory for re-use, care should
our dealers’ mechanics and company service per- be taken to select a replacement that matches the
sonnel when servicing the products described here- original.
in.
It is assumed that these personnel are familiar with
the servicing procedures of these products, or like or
similar products manufactured and marketed by
Mercury Marine, that they have been trained in the
recommended servicing procedures of these prod-
ucts which includes the use of mechanics’ common
hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service
trade of all conceivable procedures by which a ser-
vice might be performed and of the possible hazards
and/or results of each method. We have not under-
taken any such wide evaluation. Therefore, anyone
90-852572R1 JANUARY 1998 i

Cleanliness and Care of In addition, personnel should not work on or under an
outboard which is suspended. Outboards should be
Outboard Motor attached to work stands, or lowered to ground as
soon as possible.
A marine power product is a combination of many
machined, honed, polished and lapped surfaces with We reserve the right to make changes to this manual
tolerances that are measured in the ten thousands of without prior notification.
an inch./mm. When any product component is serv- Refer to dealer service bulletins for other pertinent in-
iced, care and cleanliness are important. Throughout formation concerning the products described in this
this manual, it should be understood that proper manual.
cleaning, and protection of machined surfaces and
friction areas is a part of the repair procedure. This is
considered standard shop practice even if not specif-
ically stated.
Whenever components are removed for service,
Page Numbering
they should be retained in order. At the time of instal- Two number groups appear at the bottom of each
lation, they should be installed in the same locations page. The example below is self-explanatory.
and with the same mating surfaces as when re-
moved.
Before raising or removing and outboard engine from
a boat, the following precautions should be adhered
to:
1. Check that flywheel is secured to end of crank-
shaft with a locknut and lifting eye is threaded into
flywheel a minimum of 5 turns.
2. Connect a hoist of suitable strength to the lifting
eye.
EXAMPLE:
90-826148R1 JANUARY 1997 LOWER UNIT - 6A-7
Revision No. 1 Section Description
Month of Printing Section Number
Year of Printing Part of Section Letter
Page Number
ii 90-852572R1 JANUARY 1998
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
Important
Information
1
C - General Information
D - Outboard Installation
Section 2 - Electrical
A - Ignition
Electrical
2
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
Fuel System
3
B - Carburetor
C - Oil Injection
D - Emissions
Section 4 - Powerhead
Powerhead
4
Section 5 - Mid-Section
A - 40/50 Clamp/Swivel Brackets & Drive Shaft Housing
B - 55/60 Clamp/Swivel Brackets & Drive Shaft Housing
C - 40/50 Power Trim
Mid-Section
5
D - 55/60 Power Trim
E - 40/50 Manual Tilt
F - 55/60 Manual Tilt
Section 6 - Lower Unit
Lower Unit
6
A - 40/50 Lower Unit
B - 55/60 Lower Unit
C - 60 Bigfoot
D - Jet Drive
Attachments/
Control Linkage
7
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Section 8 - Manual Starter
Manual Starter
8
90-852572R1 JANUARY 1998 iii

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SERVICE

With Serial Numbers

Printed in U.S.A. 1997, Mercury Marine 90-852572R1 JANUARY 1998

90-852572R1 JANUARY 1998 i

90-826148R1 JANUARY 1997 LOWER UNIT - 6A-7

Revision No. 1 Section Description

Month of Printing Section Number

Year of Printing Part of Section Letter

90-852572R1 JANUARY 1998 iii

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