Mercury 40, 45, 50 Bigfoot Service Manual
SERVICE
MANUAL
MODELS
Printed in U.S.A.
Mercury/Mariner
40·45·50·50 Bigfoot (4-Stroke)
With Starting Serial Numbers
United States 0G231123. . . . . .
1999, Mercury Marine
90-828631R3 MARCH 1999
Notice
Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol
cerning a particular service or operation that may be hazardous if performed incorrectly or
carelessly . OBSERVE THEM CAREFULLY!
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus “Common Sense” operation,
are major accident prevention measures.
) are used to alert the mechanic to special instructions con-
DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.
W ARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Notice to Users of This Manual
This service manual has been written and published by the Service Department of Mercury
Marine to aid our dealers’ mechanics and company service personnel when servicing the
products described herein.
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 products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the service trade of all conceivable procedures
by which a service might be performed and of the possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. Therefore, anyone who uses
a service procedure and/or tool, which is not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the products safety will be endangered by the
service procedure selected.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
It should be kept in mind, while working on the product, that the electrical system and ignition
system are capable of violent and damaging short circuits or severe electrical shocks. When
performing any work where electrical terminals could possibly be grounded or touched by
the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered
to protect against accidental entrance of foreign material which could enter the cylinders and
cause extensive internal damage when the engine is started.
90-828631R3 MARCH 1999 Page i
It is important to note, during any maintenance procedure replacement fasteners must have
the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial
lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal
injury . Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original.
Cleanliness and Care of Outboard Motor
A marine power product is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any
product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper 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 specifically stated.
Whenever components are removed for service, they should be retained in order. At the
time of installation, they should be installed in the same locations and with the same mating
surfaces as when removed.
Personnel should not work on or under an outboard which is suspended. Outboards should
be attached to work stands, or lowered to ground as soon as possible.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products de-
scribed in this manual.
90-826148 R1 JANUARY 1996
EXAMPLE:
LOWER UNIT - 6A-7
Revision No. 1
Month of Printing
Year of Printing
Page ii 90-828631R3 MARCH 1999
Section Description
Section Number
Part of Section Letter
Page Number
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
C - General Information
D - Outboard Motor Installation
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing,Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Carburetor
C - Emissions
Section 4 - Powerhead
A - Cylinder Head
B - Cylinder Block/Crankcase
C - Lubrication
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
B - Power Trim (1998 And Earlier Non-Bigfoot)
C - Power Trim (1999 And Later Non-Bigfoot/
All Big-Foot Model Years)
D - Manual Tilt Assist
Section 6 - Gear Housing
A - Non-Bigfoot Gear Housing
B - Bigfoot Gear Housing
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Important Information
Electrical
Fuel System
Powerhead
Mid-Section
Gear Housing
Attachments/
Control Linkage
1
2
3
4
5
6
7
9
90-828631R3 MARCH 1999 Page iii
SPECIFICATIONS
IMPORTANT INFORMATION
Section 1A - Specifications
Table of Contents
Specifications 1A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Design Identification 1A-7. . . . . . . . . . . . .
Propeller Information Charts 1A-8. . . . . . . . . . . . . . . .
Mercury/Mariner 50 (4-Stroke)
2.00:1 Non Bigfoot 1A-8. . . . . . . . . . . . . . . . . . . . . .
Specifications
Models 40/45/50/50 (4-Stroke)
HORSEPOWER
(kW)
OUTBOARD
WEIGHT
FUEL
OIL
Model 50
Model 45
Model 40
Electric
40/45/50 ELPT
RECOMMENDED GASOLINE Automotive Unleaded
ENGINE OIL CAPACITY
ENGINE OIL
SAE
25W-40
F°
+100
+80
+60
+40
+20
0
C°
+38
+27
+16
+4
–7
–18
SAE
10W-30
1
A
Mercury/Mariner 50 (4-Stroke)
1.83:1 Non Bigfoot 1A-9. . . . . . . . . . . . . . . . . . . . . .
Mercury/Mariner 50 (4-Stroke)
2.3:1 Bigfoot 1A-10. . . . . . . . . . . . . . . . . . . . . . . . . .
50 hp (37.3 Kw) @ 6000 rpm
45 hp (33.5 Kw) @ 6000 rpm
40 hp (29.8 Kw) @ 6000 rpm
224 lb (102 kg)
with a Minimum Pump Posted
Octane Rating of 87
Either 3 Quarts or 3 Liters
SAE 10W-30 viscosity oil is recom-
mended for use in all temperatures.
SAE 25W-40 viscosity oil may be used at
temperatures above 40° F (4° C).
Use Quicksilver 4-Cycle Marine Oil with
the proper viscosity for the expected
temperature in your area (see range
thermometer on left). If not available, use
a premium quality 4-cycle engine oil, cer-
tified to meet or exceed anyone of the
following American Petroleum Institute
(API) service classification SH, SG, SF,
CF-4, CE, CD, CDll.
90-828631R3 MARCH 1999 Page 1A-1
SPECIFICATIONS
IGNITION SYSTEM*
*Readings taken @ 68°F
(20°C).
CHARGING
SYSTEM
STARTING
SYSTEM
BATTERY
ENRICHMENT
CONTROL SYSTEM
FUEL SYSTEM
Type
Spark Plug Type (NGK)
Spark Plug Gap
Firing Order
Ignition Timing:
40/45 HP
Fully Retarded
Fully Advanced (2500-3000 rpm)
50 HP
Fully Retarded
Fully Advanced (2500-3000 rpm)
Charge Coil Resistance
Trigger Coil Resistance
Ignition Coil Resistance:
Primary
Secondary
cdi Engine Speed Limiter
cdi Overheat Speed Control
Engine Temperature Switch
Above 131° F (55° C)
Below 104° F (40° C)
Alternator Type
Alternator Output:
Electric Start
Lighting Coil Resistance (Grn - Grn)
Lighting Coil Output Peak Voltage
P/N 50-825095 Top Mounted
Electric Start:
Starter Type
Output
Ampere Draw Under:
(Load)
(No Load)
P/N 50-834749 Side Mounted
Starter Type
Output
Ampere Draw Under:
(Load)
(No Load)
Battery Rating
Minimum Requirement
For operation below 32° F (0° C)
Choke Solenoid
Electro-thermal ram projection
Fuel Pump Type
Fuel Pump:
Pressure
Diaphragm Stroke
Plunger Stroke
Fuel Tank Capacity
Capacitor Discharge Ignition
NGK DPR6EA-9
0.035 in. (1.0 mm)
1-3-4-2
5° B.T.D.C
25° B.T.D.C
5° B.T.D.C
35° B.T.D.C
272 - 408 Ω (BRN-BLU)
396 - 594 Ω (WHT/BLK-WHT/RED)
0.1 - 0.7 Ω
3.5 - 4.7 kΩ
6120 - 6280 rpm
1600 - 2400 rpm
No Continuity
Continuity
Three Phase
12 Volts - 10 Amps. (Regulated)
1.2 - 3.2 Ohms @ 68°F (20°C)
8.9 Volts @ 1500 rpm
Bendix
1.1 kW
106.0 Amps
21.1 Amps
Bendix
1.1 kW
95.0 Amps
20.0 Amps
465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA).
1000 Marine Cranking Amps (MCA) or
775 Cold Cranking Amps (CCA)
3.2 - 4.8 Ω @ 68°F (20 °C)
0.3 in. (7 mm) after 5 min. of power
External (Plunger/Diaphragm)
3-6 psi (21-41 kPa)
0.14 - 0.20 in. (3.5 - 5.1 mm)
0.23 - 0.38 in. (5.85 - 9.65 mm)
Accessory
Page 1A-2 90-828631R3 MARCH 1999
CARBURETOR
Idle rpm (Out Of Gear)
45 hp
40/50 hp
Idle rpm (In Forward Gear)
45 hp
40/50 hp
Wide Open Throttle rpm (WOT)
Range
Main Jet Size
40/45 hp
Carburetors 1 and 2
Carburetors 3 and 4
50 hp
Pilot Jet
Float Height
SPECIFICATIONS
950 ± 25 rpm
825 ± 25 rpm
850 ± 25 rpm
725 ± 25 rpm
5500–6000 rpm
#104
#103
#112
#42
0.39 ± 0.02 in. (10.0 ± 0.5 mm)
CYLINDER BLOCK
Type
Displacement
4 Stroke Cycle – Over Head Camshaft
57 cu. in. (935cc)
Number of Cylinders
STROKE Length 2.953 in. (75 mm)
Diameter
2.4803 in. (63.0 mm)
2.5003 in. (63.5 mm)
0.003 in. (0.08 mm)
CYLINDER BORE
Standard
Oversize-0.020 in. (0.050 mm)
Taper/Out of Round Maximum
Bore Type
PISTON
PISTON
Piston Type
O.D. at Skirt
Standard
Oversize-0.020 in. (0.50mm)
2.4783-2.4789 in. (62.950-62.965 mm)
2.4983-2.4989 in. (63.450-63.465 mm)
Piston to Cylinder Clearance 0.0014 - .0026 in. (0.035 - 0.065 mm)
Aluminum
CLEARANCE
Ring End Gap (Installed)
0.006 - 0.012 in. (0.15 - 0.30 mm)
0.012 - 0.020 in. (0.30 - 0.50 mm)
0.008 - 0.028 in. (0.20 - 0.70 mm)
RINGS
Top
Middle
Bottom (Oil Ring)
Side Clearance:
Top
Middle
0.002 - 0.003 in. (0.04 - 0.08 mm)
0.001 - 0.003 in. (0.03 - 0.08 mm)
4
Steel
COMPRESSION
RATIO
Compression Ratio
Cylinder Compression (cold engine
@ W.O.T.)
PISTON PIN Piston Pin Diameter 0.6285-0.6287 in. (15.965 - 15.970 mm)
CONNECTING
ROD
90-828631R3 MARCH 1999 Page 1A-3
Oil Clearance (Big End)
Small End Inside Diameter
9.8:1
2
170 -190 lb/in
(Peak)
0.0008 - 0.0020 in. (0.020 - 0.052 mm)
0.6293 - 0.6298 in. (15.985-15.998 mm)
SPECIFICATIONS
CRANKSHAFT
CAMSHAFT
VALVE SPRING
Main Bearing Clearance
Crankshaft Run-out
Camshaft Dimensions
Intake “A”
Exhaust “A”
Intake “B”
Exhaust “B”
Run-out Limit
B
Free Length “a”
Tilt Limit “b”
b
a
Compressed Pressure (Installed)
Intake
Exhaust
Tilt Limit (Intake & Exhaust)
Dir. of Winding (Intake & Exhaust)
Warp Limit
0.0005 - 0.0017 in. (0.012 - 0.044 mm)
0.0012 in. (0.03 mm)
1.216 - 1.220 in. (30.89 - 30.99 mm)
1.213 - 1.217 in. (30.82 - 30.92 mm)
A
1.022 - 1.025 in. (25.95 - 26.05 mm)
1.022 - 1.025 in. (25.95 - 26.05 mm)
0.0039 in. (0.1 mm)
1.491-1.569 in. (37.85-39.85 mm)
Less than 0.060 in. (1.7 mm)
19.8 - 22.0 lb (9.0 - 10.0 kg)
19.8 - 22.0 lb (9.0 - 10.0 kg)
0.043 in. (1.1 mm)
Left Hand
0.004 in. (0.1 mm)
CYLINDER HEAD
* Lines indicate
straight edge
measurement
Page 1A-4 90-828631R3 MARCH 1999
VALVES
Valve/Valve Seat/Valve Guides:
Valve Clearance (cold)
Intake
Exhaust
Valve Dimensions:
“A” Head Diameter
Intake
Exhaust
“B” Face Width
Intake
Exhaust
“C” Seat Width
Intake
Exhaust
“D” Margin Thickness
Intake
Exhaust
Stem Outside Diameter
Intake
Exhaust
Guide Inside Diameter
Intake
Exhaust
Stem To Guide Clearance
Intake
Exhaust
Stem Run-out Limit (max.)
SPECIFICATIONS
0.006 - 0.010 in. (0.15 - 0.25 mm)
0.010 - 0.014 in. (0.25 - 0.35 mm)
1.177 - 1.185 in. (29.9 - 30.1 mm)
1.020 - 1.028 in. (25.9 - 26.1 mm)
0.079 - 0.124 in. (2.00 - 3.14 mm)
0.079 - 0.124 in. (2.00 - 3.14 mm)
0.035 - 0.043 in. (0.9 - 1.1 mm)
0.035 - 0.043 in. (0.9 - 1.1 mm)
0.020 - 0.035 in. (0.5 - 0.9 mm)
0.020 - 0.035 in. (0.5 - 0.9 mm)
0.2156 - 0.2161 in. (5.475 - 5.490 mm)
0.2150 - 0.2156 in. (5.460 - 5.475 mm)
0.2165 - 0.2170 in. (5.500 - 5.512 mm)
0.2165 - 0.2170 in. (5.500 - 5.512 mm)
0.0004 - 0.0015 in. (0.010 - 0.037 mm)
0.0010 - 0.0020 in. (0.025 - 0.052 mm)
0.0006 in. (0.016 mm)
Valve Dimensions
“A”
Head Diameter Face Width
“B”
Seat Width
“C”
“D”
Margin Thickness
90-828631R3 MARCH 1999 Page 1A-5
SPECIFICATIONS
THERMOSTAT
LUBRICATION
SYSTEM
MID-SECTION
1995/1996
GEAR HOUSING
(2.00:1)
Valve Opening Temperature
Full Open Temperature
Valve Lift
Pump Type
Engine Oil Pressure
Engine Oil Pan Capacity
Oil Pump:
Outer Rotor to Housing “a”
Inner Rotor to Outer Rotor “b”
Rotor to Housing “c”
a
b
c
Transom Height:
Long Shaft
Steering Pivot Range
Tilt Pin Positions
Full Tilt Up Angle
Allowable Transom Thickness
45/50 1995/1996 models
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ Idle
@ WOT
136° F - 143° F (58° C - 62° C)
158° F (70° C)
0.12 in. (3 mm)
Trochoid
30-40 psi at 3000 rpm (Warm Engine)
Either 3 Qts. or 3 Liters
0.001 - 0.006 in. (0.03 - 0.15 mm)
0.005 in. (0.12 mm)
0.001 - 0.003 in. (0.03 - 0.08 mm)
20 in. (51 cm)
90°
5 + Shallow Water
70°
2-3/8 in. (60.3 mm)
2.00:1
14.9 fl oz (440 mL)
Quicksilver Gear Lube-Premium Blend
26 Spiral/Bevel
13 Spiral/Bevel
0.025 in. (0.64 mm)
No Adjustment
2-4 psi (14-28 kPa) @ 750 rpm
12-17 psi (83-117 kPa) @ 6000 rpm
Page 1A-6 90-828631R3 MARCH 1999
1997 AND NEWER
GEAR HOUSING
(1.83:1)
1998 AND NEWER
BIGFOOT GEAR
HOUSING
(2.3:1)
40/45/50 1997 and Newer models
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ Idle
@ WOT
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ 750 rpm (Idle)
@ 6000 rpm (WOT)
SPECIFICATIONS
1.83:1
14.9 fl oz (440 mL)
Quicksilver Gear Lube-Premium Blend
22 Spiral/Bevel
12 Spiral/Bevel
0.025 in. (0.64 mm)
No Adjustment
2-4 psi (14-28 kPa) @ 750 rpm
12-17 psi (83-117 kPa) @ 6000 rpm
2.3:1
22.5 fl oz (655 mL)
Quicksilver Gear Lube-Premium Blend
30 Spiral/Bevel
13 Spiral/Bevel
0.025 in. (0.64 mm)
0.012-0.019 in. (0.30-0.48 mm)
2-4 psi (14-28 kPa)
10-15 psi (69-103 kPa)
Gear Case Design Identification
a
“3 Jaw Reverse Clutch” “6 Jaw Reverse Clutch”
a-Design I - “3 Jaw Reverse Clutch” Gear Case Identifier
b-Design II - “6 Jaw Reverse Clutch” Gear Case Identifier
Identify gear case design to ensure correct components are being installed. Design I “3 Jaw Reverse Clutch” (a) gear case identified with straight machined edge for trim tab
screw mounting surface. Design II - “6 Jaw Reverse Clutch” (b) gear case identified with
angled machined edge for trim tab screw mounting surface.
b
90-828631R3 MARCH 1999 Page 1A-7
SPECIFICATIONS
Propeller Information Charts
Mercury/Mariner 50 (4-Stroke) 2.00:1 Non Bigfoot
Wide Open Throttle rpm : 5500-6000
Recommended Transom Heights : 15”, 20”, 22.5”
Right Hand Rotation Standard
Gear Reduction : 2.00:1
Approx.
No. of
Diameter
10” 19” 3 Alum Up to 800 Up to 14’ 43-51 48-73146A40
10” 17” 3 Alum Up to 900 Up to 15’ 40-46 48-73144A40
10” 16” 3 Steel 800-1000 Up to 15’ 37-43 48-91818A5
10” 16” 3 Alum 800-1000 Up to 15’ 37-43 48-73142A40
10-1/8” 15” 3 Steel 900-1300 13-15’ 34-41 48-76232A5
10-1/8” 15” 3 Alum 900-1300 13-15’ 34-41 48-73140A40
10-3/8” 14” 3 Alum 1000-1500 14-16’ 32-37 48-816706A40
10-1/4” 14” 3 Steel 1000-1500 14-16’ 32-37 48-76230A5
10-1/4” 14” 3 Alum 1000-1500 14-16’ 32-37 48-73138A40
10-1/2” 13” 3 Alum 1100-1700 14-17’ 29-34 48-816704A40
10-3/8” 13” 3 Steel 1100-1700 14-17’ 29-34 48-76228A5
10-3/8” 13” 3 Alum 1100-1700 14-17’ 29-34 48-73136A40
10-3/4” 12” 3 Alum 1200-1900 15-17’ 25-31 48-816702A40
10-5/8” 12” 3 Steel 1200-1900 15-17’ 25-31 48-79792A5
10-5/8” 12” 3 Alum 1200-1900 15-17’ 25-31 48-73134A40
Pitch
Blades
Material
Gross Boat
Wgt. (lb)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
10-7/8” 11” 3 Alum 1400-2100 16-18’ 22-27 48-85632A45
11-5/8” 11” 3 Steel 1400-2100 16’ + 22-27 48-823478A5
11-5/8” 10-1/2” 3 Alum 1500-2300 16’ + 20-25 48-827312A10
11-1/4” 10” 3 Alum 1700-2500 17’ + 18-23 48-73132A40
12-1/4” 9” 3 Steel 1900+ 18’ + 13-20 48-97868A10
12-1/4” 9” 3 Alum 1900+ 18’ + 13-20 48-87818A10
12-1/2” 8” 3 Alum 2100+ 18’ + 1-16 48-42738A10
12-1/2” 8” Cup 3 Alum pontoon 48-42738A12
Page 1A-8 90-828631R3 MARCH 1999
Mercury/Mariner 50 (4-Stroke) 1.83:1 Non Bigfoot
Wide Open Throttle rpm : 5500-6000
Recommended Transom Heights : 15”, 20”, 22.5”
Right Hand Rotation Standard
Gear Reduction : 1.83:1
SPECIFICATIONS
Diameter
Pitch
No. of
Blades
Material
Approx.
Gross Boat
Wgt. (lb)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
10” 19” 3 Alum Up to 800 Up to 14’ 49-58 48-73146A40
10” 17” 3 Alum Up to 900 Up to 15’ 43-50 48-73144A40
10” 16” 3 Steel 900-1300 Up to 15’ 39-46 48-91818A5
10” 16” 3 Alum 900-1300 Up to 15’ 39-46 48-73142A40
10-1/8” 15” 3 Steel 1000-1400 13-15’ 36-43 48-76232A5
10-1/8” 15” 3 Alum 1000-1400 13-15’ 36-43 48-73140A40
10-1/4” 14” 3 Steel 1100-1600 14-16’ 33-39 48-76230A5
10-1/4” 14” 3 Alum 1100-1600 14-16’ 33-39 48-73138A40
10-3/8” 13” 3 Steel 1300-1800 14-17’ 30-35 48-76228A5
10-3/8” 13” 3 Alum 1300-1800 14-17’ 30-35 48-73136A40
10-5/8” 12” 3 Steel 1400-2000 15-17’ 27-32 48-79792A5
10-5/8” 12” 3 Alum 1400-2000 15-17’ 27-32 48-73134A40
11-5/8” 11” 3 Steel 1700-2400 16-18’ 24-29 48-823478A5
10-7/8” 11” 3 Alum 1700-2400 16-18’ 24-29 48-85632A45
11-5/8” 10-1/2” 3 Alum 1900-2700 16’ + 21-25 48-827312A10
11-1/4” 10” 3 Alum 2100-3000 17’ + 19-24 48-73132A40
12-1/4” 9” 3 Steel 2500+ pontoon 17-21 48-97868A10
12-1/4” 9” 3 Alum 2500+ pontoon 17-21 48-87818A10
12-1/2” 8” 3 Alum 3000+ pontoon/
1-18 48-42738A10
houseboat
12-1/2” 8” Cup 3 Alum pontoon 48-42738A12
90-828631R3 MARCH 1999 Page 1A-9
SPECIFICATIONS
Mercury/Mariner 50 (4-Stroke) 2.3:1 Bigfoot
Wide Open Throttle rpm : 5500-6000
Recommended Transom Heights : 20”, 25”
Right Hand Rotation Standard
Gear Reduction : 2.31:1
Approx.
No. of
Diameter
13” 18” 3 Steel Up to 1400 Up to 14’ 34-40 48-16988A45
13-1/4” 17” 3 Alum 1300-1600 Up to 14’ 32-38 48-77344A45
13-1/8” 16” 3 Steel 1400-1700 14-16’ 29-35 48-16986A45
13-3/4” 15” 3 Alum 1500-1900 14-16’ 27-32 48-77342A45
13-3/8” 14” 3 Steel 1700-2200 15-17’ 24-30 48-17314A45
14” 13” 3 Alum 1900-2400 16-18’ 22-27 48-77340A45
14” 12” 3 Steel 2500-3200 17’+ 18-24 48-17312A45
14” 11” 3 Alum 2800-4000 pontoon 17-21 48-77338A45
14” 10” 3 Alum 3000+ pontoon/work 14-19 48-854342A45
14” 9” 3 Alum 5000+ houseboat/
Pitch
Blades
Material
Gross Boat
Wgt. (lb)
Approx.
Boat
Length
work
Speed
Range
(mph)
1-15 48-854340A45
Propeller
Part Number
Mercury/Mariner 50 (4-Stroke) 2.3:1 Bigfoot
Special soft rubber hub propellers designed to reduce clutch rattle
Wide Open Throttle rpm : 5500-6000
Recommended Transom Heights : 20”, 25”
Right Hand Rotation Standard
Gear Reduction : 2.31:1
IMPORT ANT: These specially designed rubber hub propellers are rated for 50 horsepower MAXIMUM.
No. of
Diameter
14” 13” 3 Alum 1900-2400 16-18’ 22-27 48-77340A33
14” 11” 3 Alum 2800-4000 pontoon 17-21 48-77338A33
14” 10” 3 Alum 3000+ pontoon/work 14-19 48-854342A33
14” 9” 3 Alum 5000+ houseboat/
Page 1A-10 90-828631R3 MARCH 1999
Pitch
Blades
Material
Approx.
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
work
Speed
Range
(mph)
1-15 48-854340A33
Propeller
Part Number
MAINTENANCE
IMPORTANT INFORMATION
Section 1B - Maintenance
Table of Contents
Special Tools 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricant/Sealant 1B-2. . . . . . . . . . . . . . .
Inspection And Maintenance Schedule 1B-4. . . . . . .
Before Each Use 1B-4. . . . . . . . . . . . . . . . . . . . . . .
After Each Use 1B-4. . . . . . . . . . . . . . . . . . . . . . . . .
Every 100 Hours of Use or Once yearly,
Whichever occurs first 1B-5. . . . . . . . . . . . . . . . . .
Every 300 Hours of Use or Three Years 1B-5. . .
Before Periods of Storage 1B-5. . . . . . . . . . . . . . .
Corrosion Control Anode 1B-6. . . . . . . . . . . . . . . . . . .
Spark Plug Inspection 1B-7. . . . . . . . . . . . . . . . . . . . . .
Battery Inspection 1B-7. . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Replacement – Electric Start Models 1B-8. . . .
Timing Belt Inspection 1B-8. . . . . . . . . . . . . . . . . . . . .
Lubrication Points 1B-9. . . . . . . . . . . . . . . . . . . . . . . . .
Checking Power Trim Fluid 1B-10. . . . . . . . . . . . . . . .
1
B
Changing Engine Oil 1B-11. . . . . . . . . . . . . . . . . . . . . .
Oil Changing Procedure 1B-11. . . . . . . . . . . . . . . .
Changing Oil Filter 1B-12. . . . . . . . . . . . . . . . . . . . .
Oil Filling 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubrication 1B-13. . . . . . . . . . . . . . . . . . . .
3-1/4 In. (83mm) Diameter Gear Case 1B-13. . .
4-1/4 In. (108mm) Diameter Gear Case 1B-14. .
Storage Preparation 1B-16. . . . . . . . . . . . . . . . . . . . . .
Fuel System 1B-16. . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting External Outboard
Components 1B-16. . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting Internal Engine Components 1B-16. .
Gear Case 1B-16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning Outboard for Storage 1B-17. . . . . . . .
Battery Storage 1B-17. . . . . . . . . . . . . . . . . . . . . . .
Special Tools
1. Flushing Attachment P/N 44357A2
2. Crankcase Oil Pump P/N 90265A2
3. Oil Filter Wrench P/N 91-802653
90-828631R3 MARCH 1999 Page 1B-1
MAINTENANCE
Quicksilver Lubricant/Sealant
1. Quicksilver Anti-Corrosion Grease P/N 92-78376A6
2. 2-4-C Marine Lubricant with Teflon P/N 92-825407A12
3. Special Lubricant 101 P/N 92-13872A1
4. Quicksilver Power Trim and Steering Fluid P/N 92-190100A12
Page 1B-2 90-828631R3 MARCH 1999
5. Quicksilver 4-Stroke Outboard Oil P/N 92-828000A12
6. Gear Lube-Premium Blend P/N 92-19007A24
MAINTENANCE
7. Quicksilver 4-Cycle Marine Engine Oil P/N 92-832111A1
4-CYCLE
MARINE
ENGINE OIL
Premium Blend
SAE 25W-40
NET 32 OZ (1 QT) 946 ml
90-828631R3 MARCH 1999 Page 1B-3
MAINTENANCE
Inspection And Maintenance Schedule
To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance
Schedule. We urge you to keep it maintained properly to ensure the safety of you and your
passengers and retain its dependability.
WARNING
Neglected inspection and maintenance service of your outboard or attempting to
perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury, death, or product
failure.
Before Each Use
1. Check engine oil level.
2. Check that lanyard stop switch stops the engine.
3. Visually inspect the fuel system for deterioration or leaks.
4. Check outboard for tightness on transom.
5. Check steering system for binding or loose components.
6. Visually check steering link rod fasteners for proper tightness.
7. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case
with fresh water if operating in salt water.
Page 1B-4 90-828631R3 MARCH 1999
Every 100 Hours of Use or Once yearly, Whichever occurs first
1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Change engine oil and replace the oil filter. The oil should be changed more often when
the engine is operated under adverse conditions such as extended trolling.
3. Inspect thermostat visually for corrosion, broken spring, and to determine that the valve
is completely closed at room temperature. If questionable, inspect thermostat as outlined in Section 4B “Thermostat”.
4. Inspect and clean spark plugs.
5. Check engine fuel filter for contaminants.
6. Adjust carburetor(s) (if required).
7. Check engine timing setup.
8. Check corrosion control anodes. Check more frequently when used in salt water.
9. Drain and replace gear case lubricant.
10. Lubricate splines on the drive shaft.
11. Check and adjust valve clearance, if necessary.
12. Check power trim fluid.
MAINTENANCE
13. Inspect battery.
14. Check control cable adjustments.
15. Inspect timing belt.
16. Remove engine deposits with Quicksilver Power Tune Engine Cleaner.
17. Check tightness of bolts, nuts, and other fasteners.
Every 300 Hours of Use or Three Years
1. Replace water pump impeller (more often if overheating occurs or reduced water pres-
sure is noted).
Before Periods of Storage
1. Refer to Storage procedure (this section).
90-828631R3 MARCH 1999 Page 1B-5
MAINTENANCE
Corrosion Control Anode
Your outboard has control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the
outboard metals.
Each anode requires periodic inspection especially in salt water which will accelerate the
erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce
effectiveness of the anode.
1. An anode is installed on the bottom of the transom bracket assembly. Trim tab is also
an anode on the 3-1/4 in. (83 mm) diameter gear case. The 4-1/4 in. (108 mm) diameter
gear case has three anodes. One of the anodes is the trim tab and two anodes are located on the side.
c
b
a
a-Bottom Anode
b-Trim Tab
c-Side Anodes
2. Four anodes are installed in the engine block. Remove anodes at locations shown.
Install each anode with rubber seal and cover. Torque bolts to specified torque.
c
a
b
a-Anodes-Engine Block
b-Rubber Seal
c-Cover
Page 1B-6 90-828631R3 MARCH 1999
Bolt Torque
70 lb-in. (8 Nm)
Spark Plug Inspection
Inspect spark plugs at the recommended intervals.
1. Remove the spark plug leads by twisting the rubber boots slightly and pull off.
2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.
3. Set the spark plug gap. See Specification Chart.
MAINTENANCE
4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs fin-
ger tight, and tighten 1/4 turn or torque to specified torque.
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting capability .
IMPORT ANT: Read the safety and maintenance instructions which accompany your
battery .
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive
and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.
Spark Plug Torque
20 lb-in. (27 Nm)
90-828631R3 MARCH 1999 Page 1B-7
MAINTENANCE
Fuse Replacement – Electric Start Models
The electric starting circuit is protected from overload by an SFE 20 AMP fuse. If the fuse
is blown, the electric starter motor will not operate. Try to locate and correct the cause of
the overload. If the cause is not found, the fuse may blow again. Replace the fuse with a
fuse of the same rating.
1. Open the fuse holder and look at the silver colored band inside the fuse. If band is broken
replace the fuse. Replace fuse with a new fuse with the same rating.
a
a-Blown Fuse
Timing Belt Inspection
1. Inspect the timing belt and replace if any of the following conditions are found.
a. Cracks in the back of the belt or in the base of the belt teeth.
b. Excessive wear at the roots of the cogs.
c. Rubber portion swollen by oil.
d. Belt surfaces roughened.
e. Signs of wear on edges or outer surfaces of belt.
a-Timing Belt
a
Page 1B-8 90-828631R3 MARCH 1999
Lubrication Points
Lubricate Point 1 with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant
with Teflon
1. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the pro-
peller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.
Lubricate Points 2 thru 4 with Quicksilver 2-4-C Marine Lubricant with T eflon or Special Lubricant 101.
MAINTENANCE
1
2. Swivel Bracket – Lubricate through fitting.
3. Tilt Support Lever – Lubricate through fitting.
2
3
90-828631R3 MARCH 1999 Page 1B-9
MAINTENANCE
Lubricate Point 4 with light weight oil.
4. Steering Cable Grease Fitting – Rotate steering wheel to fully retract the steering cable
end into the outboard tilt tube. Lubricate through fitting. Lubricate steering link rod pivot
points with light weight oil.
b
a
4
a-Steering Cable End
b-Fitting
WARNING
The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could
cause steering cable to become hydraulically locked. An hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or
death.
Checking Power Trim Fluid
1. Tilt outboard to the full up position and engage the tilt support lock.
a-Tilt Support Lock
2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of
the fill hole. Add Quicksilver Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
a
a-Fill Cap
Page 1B-10 90-828631R3 MARCH 1999
a
Changing Engine Oil
Oil Changing Procedure
Pump Method
1. Place the outboard in an vertical upright position.
2. Remove dipstick and thread a Quicksilver Crankcase Oil Pump onto the dipstick tube.
Pump out the engine oil into an appropriate container.
MAINTENANCE
Engine Oil Capacity
3 U.S. Quarts (3.0 Liters)
a
a-Crankcase Oil Pump
Drain Plug Method
1. Tilt the outboard up to the trailer position.
2. Turn the steering on the outboard so that the drain hole is facing downward. Remove
drain plug and drain engine oil into an appropriate container. Lubricate the seal on the
drain plug with oil and reinstall.
a
a-Drain Hole
90-828631R3 MARCH 1999 Page 1B-1 1
MAINTENANCE
Changing Oil Filter
1. Place a rag or towel below the oil filter to absorb any spilled oil.
2. Unscrew old filter by turning the filter counterclockwise.
3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease.
Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn.
a-Oil Filter
Oil Filling
1. Remove the oil fill cap and add oil to the proper operating level.
a
91-802653
2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Add oil if necessary.
a
a-Oil Fill Cap
Page 1B-12 90-828631R3 MARCH 1999
Gear Case Lubrication
When adding or changing gear case lubricant, visually check for the presence of water in
the lubricant. If water is present, it may have settled to the bottom and will drain out prior
to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
If water is noticed, have the gear case checked by your dealer.Water in the lubricant may
result in premature bearing failure or, in freezing temperatures, will turn to ice and damage
the gear case.
Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A
small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and
should be checked by an authorized dealer.
3-1/4 In. (83mm) Diameter Gear Case
DRAINING GEAR CASE
1. Place outboard in a vertical operating position.
2. Place a drain pan below outboard.
3. Remove vent plug and fill/drain plug and drain lubricant.
MAINTENANCE
a-Vent Plug and Fill/Drain Plug
GEAR CASE LUBRICANT CAPACITY
Gear case lubricant capacity is approximately 14.9 fl oz (440 ml).
a
90-828631R3 MARCH 1999 Page 1B-13
MAINTENANCE
CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE
1. Place outboard in a vertical operating position.
2. Remove vent plug.
3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.
IMPORTANT: Replace sealing washers if damaged.
4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube.
5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
c
a
b
a-Vent Plug/Sealing Washer
b-Lubricant Tube
c-Vent Hole
d-Fill/Drain Plug and Sealing Washer
4-1/4 In. (108mm) Diameter Gear Case
When adding or changing gear case lubricant, visually check for the presence of water in
the lubricant. If water is present, it may have settled to the bottom and will drain out prior
to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
If water is noticed, have the gear case checked by your dealer. Water in the lubricant may
result in premature bearing failure or, in freezing temperatures, will turn to ice and damage
the gear case.
Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A
small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and
should be checked by an authorized dealer.
d
Page 1B-14 90-828631R3 MARCH 1999
DRAINING GEAR CASE
1. Place outboard in a vertical operating position.
2. Place a drain pan below outboard.
3. Remove vent plugs and fill/drain plug and drain lubricant.
a-Vent Plugs and Fill/Drain Plug
MAINTENANCE
a
GEAR CASE LUBRICANT CAPACITY
Gear case lubricant capacity is approximately 22.5 fl oz (655 ml).
CHECKING LUBRICANT LEVEL AND FILLING GEAR CASE
1. Place outboard in a vertical operating position.
2. Remove the front vent plug and rear vent plug.
3. Place lubricant tube into the fill hole and add lubricant until it appears at the front vent
hole. At this time install the front vent plug and sealing washer.
4. Continue adding lubricant until it appears at the rear vent hole.
5. Stop adding lubricant. Install the rear vent plug and sealing washer before removing
lubricant tube.
6. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
d
a
a-Front Vent Plug
b-Rear Vent Plug
c-Front Vent Hole
d-Rear Vent Hole
e-Fill/Drain Plug and Sealing Washer
90-828631R3 MARCH 1999 Page 1B-15
c
b
e
MAINTENANCE
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for out-ofseason storage or prolonged storage (two months or longer).
Never start or run your outboard (even momentarily) without water circulating
through the cooling water intake in the gear case to prevent damage to the water
pump (running dry) or overheating of the engine.
Fuel System
IMPORT ANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being use
contains alcohol, it is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pump, and carburetor) with treated (stabilized) fuel to
help prevent formation of varnish and gum. Proceed with following instructions.
1. Portable Fuel T ank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow
instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with
the fuel.
CAUTION
2. Permanently Installed Fuel Tank – Pour the required amount of Quicksilver Gasoline
Stabilizer (follow instructions on container) into a separate container and mix with
approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank.
3. Place the outboard in water or connect flushing attachment for circulating cooling water.
Run the engine for ten minutes to allow treated fuel to reach the carburetor.
Protecting External Outboard Components
1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule.
2. Touch up any paint nicks.
3. Spray Quicksilver Corrosion Guard on external metal surfaces (except corrosion control
anodes).
Protecting Internal Engine Components
1. Remove the spark plugs and inject a small amount of engine oil inside of each cylinder.
2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall
spark plugs.
3. Change the engine oil.
Gear Case
1. Drain and refill the gear case lubricant (refer to maintenance procedure).
Page 1B-16 90-828631R3 MARCH 1999
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