Mercury 40, 50, 55, 60 Service Manual
SERVICE
MANUAL
MODELS
Printed in U.S.A.
With Serial Numbers
United States 0G531301 and ABOVE. .
Belgium 09974454 and ABOVE. . . . . . .
1997, Mercury Marine
40·50·55·60
90-852572R1 JANUARY 1998
Notice
Throughout this publication, “Dangers”, “Warnings”
and “Cautions” (accompanied by the International
HAZARD Symbol
to special instructions concerning a particular service
or operation that may be hazardous if performed incorrectly or carelessly.
FULLY!
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.
DANGER - Immediate hazards which WILL result
in severe personal injury or death.
) are used to alert the mechanic
OBSERVE THEM CARE-
DANGER
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.
WARNING
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.
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.
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.
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
90-852572R1 JANUARY 1998 i
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.
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 crankshaft with a locknut and lifting eye is threaded into
flywheel a minimum of 5 turns.
In addition, 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 described in this
manual.
Page Numbering
Two number groups appear at the bottom of each
page. The example below is self-explanatory.
2. Connect a hoist of suitable strength to the lifting
eye.
EXAMPLE:
90-826148R1 JANUARY 1997
LOWER UNIT - 6A-7
Revision No. 1
Month of Printing
Year of Printing
Section Description
Section Number
Part of Section Letter
Page Number
ii 90-852572R1 JANUARY 1998
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
C - General Information
D - Outboard 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 - Oil Injection
D - Emissions
Section 4 - Powerhead
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
D - 55/60 Power Trim
E - 40/50 Manual Tilt
F - 55/60 Manual Tilt
Section 6 - Lower Unit
A - 40/50 Lower Unit
B - 55/60 Lower Unit
C - 60 Bigfoot
D - Jet Drive
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Section 8 - Manual Starter
Important
Information
1
Electrical
2
Fuel System
3
Powerhead
4
Mid-Section
5
Lower Unit
6
Attachments/
Control Linkage
7
Manual Starter
8
90-852572R1 JANUARY 1998
iii
IMPORTANT
INFORMATION
1
A
SPECIFICATIONS
Table of Contents
Specifications 1A-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Information Charts 1A-4. . . . . . . . . . . . .
Mercury/Mariner 40 HP (3 Cyl.) 1A-4. . . . . . . . .
Mercury/Mariner 50 HP (3 Cyl.) 1A-5. . . . . . . . .
Mercury/Mariner 55 HP (3 Cyl.) 1A-6. . . . . . . . .
Mercury/Mariner 60 HP (3 Cyl.) 1A-7. . . . . . . . .
Mercury/Mariner 60 HP (3 Cyl.) Bigfoot 1A-8. .
Page
1A-0 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Specifications
Models 40/50/55/60
HORSEPOWER
(kW)
OUTBOARD WEIGHT
CYLINDER BLOCK
STROKE Length 2.796 in. (71 mm)
CYLINDER BORE
PISTON
Model 40
Model 50
Model 55
Model 60
Manual
40/50 ML
55 ML
Electric
40/50 ELPTO
40/50 ELO
60 ELPTO
60 ELO
Type
Displacement
Diameter
Taper/Out of Round Maximum
Bore Type
Type
Standard Diameter
0.015 in. (0.381 mm) Oversize
0.030 in. (0.762 mm) Oversize
40 (29.8)
50 (37.3)
55 (41.0)
60 (44.7)
205 lbs. (93.0 kg)
220 lbs. (99.8 kg)
204 lbs. (92.5 kg)
200 lbs. (90.7 kg)
219 lbs. (99.3 kg)
215 lbs. (97.5 kg)
3 Cylinder-2 Cycle-Loop Charged
59 cu. in. (967 cc)
2.993 in. (76 mm)
0.003 in. (0.08 mm)
Cast Iron
Aluminum
2.988 in. (75.895 mm)
3.003 in. (76.276 mm)
3.018 in. (76.657 mm)
REEDS
FUEL SYSTEM
Reed Stand Open (Max.)
Reed Stop (Max.)
40
50/55/60
Reed Thickness
Recommended Gasoline
Recommended Oil
Break-in Gasoline/Oil Ratio
Manual Start Models
Electric Start Models
After Break-in Gasoline/Oil Ratio
Manual Start Models
Electric Start Models
Fuel Pressure
@ Idle
@ W.O.T.
0.020 in. (0.50 mm)
0.090 in. (2.286 mm)
Not Adjustable
0.010 in. (0.254 mm)
Unleaded-87 Octane Minimum
Quicksilver TC-WII or TC-W3
2 Cycle Outboard Oil
Pre-mixed Gasoline and Oil 25:1
50:1 (In Fuel Tank)
Pre-mixed Gasoline and Oil 50:1
Straight Gasoline
3.5 PSI (24 kPa)
6.0 PSI (41 kPa)
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1A-1
GEAR HOUSING
40/50
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ Idle
@ W.O.T.
Pressure Test
55/60
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ Idle
@ W.O.T.
Pressure Test
60 Bigfoot
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ Idle
@ W.O.T.
Pressure Test
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
0.5-1.5 PSI (3-10 kPa)
5.0–7.0 PSI (35-48 kPa)
10-12 PSI (69-83 kPa)
for 5 Minutes
1.64:1
11.5 fl. oz. (340 mL)
Quicksilver Gear Lube-Premium Blend
23
14
0.025 in. (0.64 mm)
Pinion Gear Locating Tool
(91-817008A2)
0.013-0.019 in. (0.33-0.48 mm)
1–3 PSI (7-20 kPa)
7–12 PSI (48-83 kPa)
10-12 PSI (69-83 kPa)
for 5 Minutes
2.3:1
22.5 fl. oz. (655 mL)
Quicksilver Gear Lube-Premium Blend
30
13
0.025 in. (0.64 mm)
0.012 in.-0.019 in. (0.30 mm-0.48 mm)
10-15 PSI (69-103 kPa) @ 5250 RPM
2-7 PSI (14–48 kPa)
10-15 PSI (69-104 kPa)
10-12 PSI (69-83 kPa)
for 5 Minutes
1A-2 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
STARTING SYSTEM
IGNITION SYSTEM
CHARGING SYSTEM
Manual Start
Electric Start
Starter Draw (Under Load)
Battery Rating
Type
Spark Plug Type
Spark Plug Gap
Firing Order
Alternator Output
Electric Models
Manual Models (Not Regulated)
Recoil Starter
125 Amperes
Min. Reserve Cap. Rating of 100
Min. and CCA of 350 Amperes
Capacitor Discharge
NGK BP8H-N-10
*NGK BPZ8H-N-10
0.040 in. (1.0mm)
1-2-3
Single Phase (12 Pole)
16 Amperes @ 3000 RPM
9 Amperes @ 3000 RPM
7 Amperes @ 3000 RPM
CARBURETOR
OIL
INJECTION
TIMING
Idle RPM
Wide Open Throttle (W.O.T.) RPM
Idle Mixture Screw Adjustment
Preset (Turns Out)
Float Adjustment
Float Level
Main Jet
Model 40 (WME-53, 69)
Model 50 (WME-68)
Model 55 (WME-57)
Model 60 (WME-58)
Recommended Oil
Oil Tank Capacity/Approx. Time
Reserve Capacity/Approx. Time
Oil Output With Engine RPM of 1500
and Oil Pump @ W.O.T.
Model 40
Model 50/60
Idle
Maximum Timing
@ Cranking Speed
-Model 40/50/60
-Model 55/60 Seapro-Marathon
@ 5000 RPM
– Model 40/50/60
– Model 55/60 Seapro-Marathon
675 ± 25
5000-5500
1
/
±1/
1
4
4
9
/16 in. (14 mm)
0.044 in.
0.052 in.
0.058 in.
0.060 in.
Quicksilver TC-WII or TC-W3
2 Cycle Outboard Oil
3.0 qts. (2.8 L) 7 hours
14.5 fl. oz. (0.43 L)
1
/2 hour
15.0 ± 3.0 cc of oil in 10 minutes
22.0 ± 3.0 cc of oil in 10 minutes
T.D.C. ± 2°
24° B.T.D.C.
18° B.T.D.C.
22° B.T.D.C.
16° B.T.D.C.
Temperature
TEMPERATURE
SWITCH
Normal
190°F ± 8° (88°C ± 4°C)
170°F ± 8° (77°C ± 4°C)
*Suppressor (resistor) spark plug
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1A-3
Open - No Continuity
Closed - Full Continuity
Open - No Continuity
Propeller Information Charts
Mercury/Mariner 40 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”
Right Hand Rotation Standard
Gear Reduction : 1.83:1
Approx.
No. of
Diameter
10” 19” 3 Alum Up to 900 Up to 14’ 41-49 48-73146A40
10” 17” 3 Alum Up to 900 Up to 14’ 35-43 48-73144A40
10” 16” 3 SS Up to 1200 Up to 15’ 32-40 48-91818A5
10” 16” 3 Alum Up to 1200 Up to 15’ 32-40 48-73142A40
10-1/8” 15” 3 SS 1000-1500 13-15’ 28-37 48-855862A5
10-1/8” 15” 3 Alum 1000-1500 13-15’ 28-37 48-73140A40
10-3/8” 14” 3 Alum 1100-1700 14-16’ 25-34 48-816706A40
10-1/4” 14” 3 SS 1100-1700 14-16’ 25-34 48-855860A5
10-1/4” 14” 3 Alum 1100-1700 14-16’ 25-34 48-73138A40
10-1/2” 13” 3 Alum 1300-2100 14-17’ 21-31 48-816704A40
10-3/8” 13” 3 SS 1300-2100 14-17’ 21-31 48-855858A5
10-3/8” 13” 3 Alum 1300-2100 14-17’ 21-31 48-73136A40
10-3/4” 12” 3 Alum 1500-2500 15-19’ 18-27 48-816702A40
10-5/8” 12” 3 SS 1500-2500 15-19’ 18-27 48-855856A5
10-5/8” 12” 3 Alum 1500-2500 15-19’ 18-27 48-73134A40
Pitch
Blades
Material
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
10-7/8” 11” 3 Alum 1800-3500 16-21’ 14-24 48-85632A40
11-1/4” 10” 3 Alum 2000+ 17’+ 11-21 48-73132A40
11-5/8” 11” 3 SS 1800-3500 16-21’ 14-24 48-823478A5
11-5/8” 10-1/2” 3 Alum 2000+ 17’+ 13-23 48-827312A10
12-1/4” 9” 3 Alum 2500+ 18’+ 8-17 48-87818A10
12-1/4” 9” 3 SS 2500+ 18’+ 8-17 48-97868A10
12-1/2” 8” 3 Alum 3000+ 20’+ 1-14 48-42738A10
1A-4 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Mercury/Mariner 50 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”, 22-1/2”
Right Hand Rotation Standard
Gear Reduction : 1.83:1
Diameter
Pitch
No. of
Blades
Material
Approx.
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
10” 19” 3 Alum Up to 1100 Up to 14’ 41-49 48-73146A40
10” 17” 3 Alum Up to 1400 Up to 14’ 35-43 48-73144A40
10” 16” 3 SS 1200-1500 Up to 15’ 32-40 48-91818A5
10” 16” 3 Alum 1200-1500 Up to 15’ 32-40 48-73142A40
10-1/8” 15” 3 SS 1300-1800 13-15’ 28-37 48-855862A5
10-1/8” 15” 3 Alum 1300-1800 13-15’ 28-37 48-73140A40
10-3/8” 14” 3 Alum 1400-2100 14-16’ 25-34 48-816706A40
10-1/4” 14” 3 SS 1400-2100 14-16’ 25-34 48-855860A5
10-1/4” 14” 3 Alum 1400-2100 14-16’ 25-34 48-73138A40
10-1/2” 13” 3 Alum 1600-2600 14-17’ 21-31 48-816704A40
10-3/8” 13” 3 SS 1600-2600 14-17’ 21-31 48-855858A5
10-3/8” 13” 3 Alum 1600-2600 14-17’ 21-31 48-73136A40
10-3/4” 12” 3 Alum 1900-3200 15-19’ 18-27 48-816702A40
10-5/8” 12” 3 SS 1900-3200 15-19’ 18-27 48-855856A5
10-5/8” 12” 3 Alum 1900-3200 15-19’ 18-27 48-73134A40
10-7/8” 11” 3 Alum 2200-4300 16-21’ 14-24 48-85632A40
11-1/4” 10” 3 Alum 2500+ 17’+ 11-21 48-73132A40
11-5/8” 11” 3 SS 2200-4300 16-21’ 14-24 48-823478A5
11-5/8” 10-1/2” 3 Alum 2200+ 17’+ 13-23 48-827312A10
12-1/4” 9” 3 Alum 3000+ 18’+ 8-17 48-87818A10
12-1/4” 9” 3 SS 3000+ 18’+ 8-17 48-97868A10
12-1/2” 8” 3 Alum 3500+ 20’+ 1-14 48-42738A10
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1A-5
Mercury/Mariner 55 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 16-1/2”, 21”, 23-1/2”
Right Hand Rotation Standard
Gear Reduction : 2.3:1
Diameter
Pitch
No. of
Blades
Material
Approx.
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
12-3/4” 26” 5 SS Up to 800 Up to 15’ 48-54 48-815748A45
13-1/2” 26” 3 SS Up to 800 Up to 15’ 48-54 48-16996A30
12-3/4” 24” 5 SS Up to1000 Up to 15’ 46-52 48-815746A45
13-1/2” 24” 3 SS Up to 1000 Up to 15’ 46-52 48-16994A30
12-1/2” 23” 3 Alum 700-1100 Up to 15’ 45-51 48-77350A45
12-3/4” 22” 5 SS 700-1100 Up to 15’ 43-49 48-815744A45
13-1/2” 22” 3 SS 700-1100 Up to 15’ 43-59 48-16992A30
12-3/4” 21” 3 Alum 800-1200 13-16’ 40-47 48-77348A45
12-3/4” 20” 5 SS 800-1200 13-16’ 38-45 48-816612A45
13-1/2” 20” 3 SS 800-1200 13-17’ 38-45 48-16990A30
13” 19” 3 Alum 1000-1400 14-17’ 35-42 48-77346A45
13” 18” 3 SS 1000-1400 14-17’ 33-40 48-16988A30
13-1/4” 17” 3 Alum 1200-1700 15-18’ 31-38 48-77344A45
13-1/8” 16” 3 SS 1200-1700 15-18’ 29-36 48-16986A30
13-3/4” 15” 3 Alum 1500-2100 16-19’ 26-33 48-77342A45
13-3/8” 14” 3 SS 1500-2100 16-19’ 23-31 48-17314A30
14” 13” 3 Alum 1900-2500 17’+ 20-28 48-77340A45
14” 12” 3 SS 1900-2500 17’+ 17-26 48-17312A30
14” 11” 3 Alum 2200+ 18’+ 1-22 48-77338A45
14” 10” 3 SS 2400+ 19’+ 1-20 48-17310A30
1A-6 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Mercury/Mariner 60 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”
Right Hand Rotation Standard
Gear Reduction : 1.64:1
Diameter
Pitch
No. of
Blades
Material
Approx.
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
10” 19” 3 Alum Up to 800 Up to 14’ 48-55 48-73146A40
10” 17” 3 Alum Up to 1000 Up to 15’ 44-51 48-73144A40
10” 16” 3 SS 700-1100 Up to 15’ 41-48 48-91818A5
10” 16” 3 Alum 700-1100 Up to 15’ 41-48 48-73142A40
10-1/8” 15” 3 SS 800-1200 13-15’ 38-45 48-855862A5
10-1/8” 15” 3 Alum 800-1200 13-15’ 38-45 48-73140A40
10-1/4” 14” 3 SS 900-1500 14-16’ 35-41 48-816706A40
10-3/8” 14” 3 Alum 900-1500 14-16’ 35-41 48-855860A5
10-3/8” 13” 3 SS 1200-1800 15-17’ 32-38 48-73138A40
10-1/2” 13” 3 Alum 1200-1800 15-17’ 32-38 48-816704A40
10-5/8” 12” 3 SS 1500-2100 16-18’ 28-34 48-855858A5
10-3/4” 12” 3 Alum 1500-2100 16-18’ 28-34 48-73136A40
10-7/8” 11” 3 Alum 1800-2400 16-18’ 24-30 48-816702A40
11-5/8” 11” 3 SS Workboat 16’+ 24-30 48-855856A5
12” 10-1/2” 3 Alum 2000-2600 17’+ 22-28 48-73134A40
11-5/8” 10-1/2” 3 Alum 2000-2600 17’+ 22-28 48-85632A40
11-1/4” 10” 3 Alum 2100-2600 17’+ 20-26 48-73132A40
12-1/4” 9” 3 SS 2400+ 18’+ 14-22 48-823478A5
12-1/4” 9” 3 Alum 2400+ 18’+ 14-22 48-827312A10
12-1/2” 8” 3 Alum 2800+ 19’+ 1-18 48-87818A10
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1A-7
Mercury/Mariner 60 HP (3 Cyl.) Bigfoot
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”, 22-1/2”
Right Hand Rotation Standard
Gear Reduction : 2.31:1
Diameter
Pitch
No. of
Blades
Material
Approx.
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
13” 18” 3 SS Up to 1100 Up to 14’ 41-49 48-16988A45
13-1/4” 17” 3 Alum Up to 1400 Up to 14’ 35-43 48-77344A45
13-1/8” 16” 3 SS 1200-1500 Up to 15’ 32-40 48-16986A45
13-3/4” 15” 3 Alum 1200-1500 Up to 15’ 32-40 48-77342A45
13-3/8” 14” 3 SS 1300-1800 13-15’ 28-37 48-17314A45
14” 13” 3 Alum 1300-1800 13-15’ 28-37 48-77340A45
14” 12” 3 SS 1400-2100 14-16’ 25-34 48-17312A45
14” 11” 3 Alum 1400-2100 14-16’ 25-34 48-77338A45
14” 10” 3 Alum 1400-2100 14-16’ 25-34 48-854342A45
14” 9” 3 Alum 1600-2600 14-17’ 21-31 48-854340A45
1A-8 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
IMPORTANT
INFORMATION
1
B
MAINTENANCE
Table of Contents
Specifications 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubricant Capacity 1B-1. . . . . . . . .
Special Tools 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricant/Sealant 1B-1. . . . . . . . . . . .
Inspection and Maintenance Schedule 1B-2. . . .
Before Each Use 1B-2. . . . . . . . . . . . . . . . . . . .
After Each Use 1B-2. . . . . . . . . . . . . . . . . . . . . .
Every 100 Hours of Use or Once Yearly,
Whichever Occurs First 1B-2. . . . . . . . . . . . . . .
Every 300 Hours of Use or Three Years 1B-2
Before Periods of Storage 1B-2. . . . . . . . . . . .
Flushing The Cooling System 1B-3. . . . . . . . . . . .
Fuel System 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrosion Control Anode 1B-4. . . . . . . . . . . . . . . .
Lubrication Points 1B-5. . . . . . . . . . . . . . . . . . . . . .
Checking Power Trim Fluid 1B-7. . . . . . . . . . . . . .
60 HP 1B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40/50 HP 1B-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubrication 1B-8. . . . . . . . . . . . . . . . . .
Draining Gear Case 1B-8. . . . . . . . . . . . . . . . . .
Checking Lubricant Level and Filling
Gear Case 1B-9. . . . . . . . . . . . . . . . . . . . . . . . . .
Storage Preparations 1B-9. . . . . . . . . . . . . . . . . . .
Protecting External Outboard
Components 1B-9. . . . . . . . . . . . . . . . . . . . . . . .
Protecting Internal Engine Components 1B-9
Gear Case 1B-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning Outboard for Storage 1B-10. . . . . .
Battery Storage 1B-10. . . . . . . . . . . . . . . . . . . . .
Page
1B-0- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Specifications
Gear Case Lubricant Capacity
Gear Case Ratio Capacity
2. Quicksilver Anti-Corrosion Grease
P/N 92-78376A6
1.83:1
1.64 :1
2.3:1
14.9 fl. oz. (440 mL)
11.5 fl. oz. (340 mL)
22.5 fl. oz. (655 mL)
Special Tools
1. Quicksilver Flushing Attachment (44357A2)
3. 2-4-C Marine Lubricant with Teflon
P/N 92-825407A12
4. SAE 30W Motor Oil - Obtain Locally
50551
Quicksilver
Lubricant/Sealant
1. Gear Lube-Premium Blend P/N 92-19007A24
30W
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-1
Inspection and Maintenance
Schedule
Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration
or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Remote Control Models – Visually check steering
link rod fasteners for proper tightness.
6. Check propeller blades for damage.
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. Inspect and clean spark plugs.
3. Check engine fuel filter for contaminants.
4. Adjust carburetor(s) (if required).
5. Check engine timing setup.∗
6. Check corrosion control anodes. Check more frequently when used in salt water.
7. Drain and replace gear case lubricant.
8. Lubricate splines on the drive shaft.
9. Check power trim fluid.
10. Inspect battery.
∗
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.
11. Check control cable adjustments.
12. Remove engine deposits with Quicksilver Power
Tune Engine Cleaner.
13. Check tightness of bolts, nuts, and other fasteners.
These items should be serviced by an authorized
*
dealer.
∗
Every 300 Hours of Use or Three
Years
1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is
noted).
Before Periods of Storage
Refer to Storage Procedure.
1B-2- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Flushing The Cooling
System
Flush the internal water passages of the outboard
with fresh water after each use in salt, polluted, or
muddy water. This will help prevent a buildup of deposits from clogging the internal water passages.
Use a Quicksilver accessory (or equivalent) flushing
attachment.
W ARNING
To avoid possible injury when flushing, remove
the propeller. Refer to Propeller Replacement.
1. Remove propeller (refer to Propeller Replacement). Install the flushing attachment so the rubber cups fit tightly over the cooling water intake
holes.
3. Start the engine and run it at idle speed in neutral
shift position.
4. Adjust water flow (if necessary) so excess water
continues leaking out from around the rubber
cups to ensure the engine is receiving an adequate supply of cooling water.
5. Check for a steady stream of water flowing out of
the water pump indicator hole. Continue flushing
the outboard for 3 to 5 minutes, carefully monitoring water supply at all times.
2. Attach a water hose to the flushing attachment.
Turn on the water and adjust the flow so water is
leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water.
6. Stop the engine, turn off the water, and remove
the flushing attachment. Reinstall the propeller.
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid
during storage and can damage the fuel system.
If the gasoline being used 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 carburetors) 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.
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.
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-3
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 carburetors.
Corrosion Control Anode
1. Y our outboard has two corrosion control anodes.
One of the anodes is the trim tab installed on the
gear case and the other is installed on the bottom
of the transom bracket assembly . An anode helps
protect the outboard against galvanic corrosion
by sacrificing its metal to be slowly eroded instead of the outboard metals.
a
b
a - Trim Tab Anode
b - Transom Bracket Anode
NOTE: Each anode requires periodic inspection especially in salt water which will accelerate the erosion. T o 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.
1B-4- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Lubrication Points
ITEM
NO.
1
2
DESCRIPTION
Throttle/Shift linkage
Pivot Points
Shift Handle (Tiller
Handle Models)
3 Swivel Pin
4
Ride Guide Steering
Cable
5 Tilt Tube/Co-Pilot
6
Steering Link Rod
Pivot Points
7 Propellor Shaft
8
9
*
10
◊
Starter Motor Pinion
Gear
Gear Housing Bear-
ing Carrier
Gear Housing
Engine Crankshaft
∆
Splines to Drive Shaft
Splines
TYPE OF
LUBRICANT
Quicksilver 2-4-C
Marine Lubricant
100 Hours of Use or
Once Per Season
SAE 30W Motor Oil
Quicksilver Anti-Cor-
rosion Grease or
2-4-C W/Teflon
SAE 30W Motor Oil
Quicksilver Special
Lubricant 101
Quicksilver Gear
Lube
Quicksilver 2-4-C
Marine Lubricant
FRESH WATER
FREQUENCY
SALT WATER
FREQUENCY
100 Hours of Use or Once Per Season
Once Per Season
* Refer to lubrication instructions outlined in “Salt Water Cor-
rosion - Gear Housing Bearing Carrier and Cover Nut”
of this section (see “Table of Contents”).
◊ Refer to “Gear Housing Lubrication” of this section (see
“T able of Contents”).
∆ Refer to “Gear Housing Removal and Installation”.
1
1
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-5
1 - Throttle/Shift Linkage Pivot Points
2
2 - Shift Handle (Tiller Handle Models)
3
2
5
5
5 - Tilt Tube/Co-Pilot
5
3 - Swivel Pin
4
4 - Ride Guide Steering Cable
6
6 - Steering Link Rod Pivot Points
4
7
7 - Propellor Shaft
1B-6- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
8
a
50157
8 - Starter Motor Pinion Gear
9
9 - Gear Housing Bearing Carrier
10-Gear Housing
51118
10
50558
a - Tilt Lock Lever
2. Remove fill screw and check fluid level. Fluid level should be to bottom of threads in fill hole.
3. If necessary, add Quicksilver Power Trim &
Steering Fluid or; Automatic Transmission Fluid
(A TF) Type F, F A or Dexron II fluid to trim system.
4. Reinstall fill screw.
40/50 HP
1. Tilt outboard to the full up position and engage
the 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 (A TF) automatic transmission fluid.
Checking Power Trim Fluid
IMPORT ANT : This trim system is pressurized. Remove
fill screw when outboard is trimmed to the full “up” position. Retighten fill screw securely.
60 HP
1. Trim outboard to full “up” position. Engage tilt lock
lever. Trim system fluid can only be checked
when outboard is in this position.
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-7
a
b
a - Tilt Support Lock
b - Fill Cap
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.W ater 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.
a
b
WARNING
If gear housing is installed on outboard, to avoid
accidental starting, disconnect (and isolate)
spark plug leads from spark plugs before working near the propeller.
CAUTION
Do not use automotive grease in the gear housing. Use only Quicksilver Gear Lube or Quicksilver Super-Duty Lower Unit Lubricant.
Draining Gear Case
1. Tilt outboard so that lubricant in gear housing will
drain toward front of housing, out fill hole and into
clean container.
IMPORTANT:
for damage. Use new washers as needed.
2. Remove lubricant Fill plug and washer. Note
amount of metal particles on magnetic Fill plug.
Remove all magnetic particles from Fill plug.
Inspect FILL and VENT plug washers
a - Lubricant Vent Plug/Washer
b - Lubricant Fill Plug/Washer
4. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Presence of fine metal particles (resembling powder)
on the magnetic fill plug indicates normal wear.
The presence of metal chips on the magnetic fill
plug indicates the need for gear housing disassembly and components inspection.
5. Note color of gear lubricant. White or cream color
indicates presence of water in lubricant. Gear lubricant which has been drained from a gear housing recently in operation, will have a yellowish color due to lubricant agitation/aeration. This is
normal and should not be confused with the presence of water.
6. Presence of water in gear lubricant indicates the
need for disassembly and inspection of oil seals,
seal surfaces, o-rings, water pump gaskets, as
well as, gear housing components for damage.
3. Remove Vent plug and washer and allow all lubricant to drain.
1B-8- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Checking Lubricant Level and Filling
Gear Case
IMPORTANT: Never add lubricant to gear housing
without first removing VENT plug, as trapped air
will prevent housing from being filled. Fill gear
housing only when outboard is in operating position.
NOTE:
lubricant capacity.
Refer to “Specifications,” for gear housing
Storage Preparations
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-of-season storage
or prolonged storage (two months or longer).
CAUTION
1. With outboard in operating position, insert lubricant tube into fill hole.
2. Fill gear housing until excess lubricant flows from
VENT hole.
b
a
a - Lubricant/Fill Hole
b - Vent Hole
Never start or run your outboard (even momentarily) without water circulating through all the
cooling water intake holes in the gear case to prevent damage to the water pump (running dry) or
overheating of the engine.
Protecting External Outboard
Components
1. Lubricate all outboard components listed in the
Inspection and Maintenance Schedule.
2. Touch up any paint nicks. See your dealer for
touch-up paint.
3. Spray Quicksilver Corrosion Guard on engine exterior, electrical components, and other metal
surfaces (except corrosion control anodes).
Protecting Internal Engine
Components
3. Install VENT plug and washer.
4. Install FILL plug and washer.
a - Vent Plug/Washer
b - Fill Plug/Washer
NOTE: Before performing the following steps, make
sure the fuel system has been prepared for storage.
Refer to Fuel System.
1. Place the outboard in water or connect flushing
attachment for circulating cooling water. Start the
engine and let it run in neutral to warm up.
2. With engine running at fast idle, stop the fuel flow
by disconnecting the remote fuel line. When engine begins to stall, quickly spray Quicksilver
Storage Seal into carburetor until engine stops
from lack of fuel.
3. Remove the spark plugs and inject a five second
spray of Quicksilver Storage Seal around the inside of each cylinder.
4. Rotate the flywheel manually several times to
distribute the storage seal in the cylinders. Reinstall spark plugs.
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-9
Gear Case
1. Drain and refill the gear case lubricant (refer to
maintenance procedure).
Positioning Outboard for Storage
1. Store outboard in an upright (vertical) position to
allow water to drain out of outboard.
CAUTION
If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may
have entered the propeller exhaust outlet in the
gear case could freeze and cause damage to the
outboard.
Battery Storage
1. Follow the battery manufacturers instructions for
storage and recharging.
2. Remove the battery from the boat and check water level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge
the battery during storage.
1B-10- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
IMPORTANT
INFORMATION
1
C
GENERAL INFORMATION
Table of Contents
Serial Number Location 1C-1. . . . . . . . . . . . . . . . .
Conditions Affecting Performance 1C-1. . . . . . . .
Weather 1C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boat 1C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 1C-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Following Complete Submersion 1C-3. . . . . . . . .
Salt Water Submersion
(Special Instructions) 1C-3. . . . . . . . . . . . . . . . . .
Submerged While Running
(Special Instructions) 1C-3. . . . . . . . . . . . . . . . . .
Submerged Engine (Fresh Water)
(Plus Special Instructions) 1C-4. . . . . . . . . . . . .
Propeller Selection 1C-4. . . . . . . . . . . . . . . . . . . . .
Propeller Removal/Installation 1C-5. . . . . . . . . . .
Removal 1C-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1C-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
1C-0 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Serial Number Location
The Outboard serial number is located on the lower
starboard side of the engine block. A serial number
is also located on the starboard side of the swivel
bracket.
a
OGXXXXXX
19XX
XXXX
b
c
e
XX
a - Serial Number
b - Model Year
c - Model Description
d - Year Manufactured
e - Certified Europe Insignia
d
Conditions Affecting
Performance
Corporations internationally have settled on adoption of I.S.O. (International Standards Organization)
engine test standards, as set forth in I.S.O. 3046
standardizing the computation of horsepower from
data obtained on the dynamometer, correcting all values to the power that the engine will produce at sea
level, at 30% relative humidity at 77° F (25° C) temperature and a barometric pressure of 29.61 inches
of mercury.
Summer Conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. This, in turn, is reflected in
decreased boat speeds, as much as 2 or 3 miles-perhour (3 or 5 km per-hour) in some cases. (Refer to
previous chart.) Nothing will regain this speed for the
boater, but the coming of cool, dry weather.
In pointing out the practical consequences of weather effects, an engine running on a hot, humid summer
day--may encounter a loss of as much as 14% of the
horsepower it would produce on a dry , brisk spring or
fall day. The horsepower that any internal combustion engine produces, depends upon the density of
the air that it consumes and, in turn, this density is dependent upon the temperature of the air , its barometric pressure and water vapor (or humidity) content.
Weather
It is a known fact that weather conditions exert a profound effect on power output of internal combustion
engines. Therefore, established horsepower ratings
refer to the power that the engine will produce at its
rated RPM under a specific combination of weather
conditions.
Accompanying this weather-inspired loss of power is
a second but more subtle loss. At rigging time in early
spring, the engine was equipped with a propeller that
allowed the engine to turn within its recommended
RPM range at full throttle. With the coming of the
summer weather and the consequent drop in available horsepower, this propeller will, in ef fect, become
too large. Consequently , the engine operates at less
than its recommended RPM.
Due to the horsepower/RPM characteristics of an engine, this will result in further loss of horsepower at
the propeller with another decrease in boat speed.
This secondary loss, however, can be regained by
switching to a smaller pitch propeller that allows the
engine to again run at recommended RPM.
For boaters to realize optimum engine performance
under changing weather conditions, it is essential
that the engine have the proper propeller to allow it
to operate at or near the top end of the recommended
maximum RPM range at wide-open-throttle with a
normal boat load.
Not only does this allow the engine to develop full
power, but equally important is the fact that the engine also will be operating in an RPM range that discourages damaging detonation. This, of course, enhances overall reliability and durability of the engine.
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-1
Boat
TRIM
WEIGHT DISTRIBUTION
1. Proper positioning of the weight inside the boat
(persons and gear) has a significant effect on the
boat’s performance, for example:
a. Shifting weight to the rear (stern)
(1.)Generally increases top speed.
(2.) If in excess, can cause the boat to por-
poise.
(3.) Can make the bow bounce excessively in
choppy water.
(4.) Will increase the danger of waves splash-
ing into the boat when coming off plane.
b. Shifting weight to the front (bow)
(1.) Improves ease of planing off.
(2.) Generally improves rough water ride.
(3.) If excessive, can make the boat veer left
and right (bow steer).
BOTTOM
For maximum speed, a boat bottom should be
nearly a flat plane where it contacts the water and
particularly straight and smooth in fore-and-aft direction.
1. Hook: Exists when bottom is concave in fore-
and-aft direction when viewed from the side.
When boat is planing, “hook” causes more lift on
bottom near transom and allows bow to drop,
thus greatly increasing wetted surface and reducing boat speed. “Hook” frequently is caused
by supporting boat too far ahead of transom while
hauling on a trailer or during storage.
2. Rocker: The reverse of hook and much less
common. “Rocker” exists if bottom is convex in
fore-and-aft direction when viewed from the side,
and boat has strong tendency to porpoise.
TRIMMING OUTBOARD “OUT” (“UP”)
WARNING
Excessive trim “out” also may reduce the stability of some high speed hulls. T o correct instability at high speed, reduce the power GRADUALLY
and trim the outboard “in” slightly before resuming high speed operation. (Rapid reduction in
power will cause a sudden change of steering
torque and may cause additional momentary
boat instability.)
1. Will lift bow of boat, generally increasing top
speed.
2. Transfers steering torque harder to left on single
outboard installations below 23 in. (584mm) transom height.
3. Increases clearance over submerged objects.
4. In excess, can cause porpoising and/or ventilation.
5. If trimmed out beyond the water pickup, reduced
water supply can cause overheating resulting in
engine damage.
TRIMMING OUTBOARD “IN” (“DOWN”)
WARNING
Excessive speed at minimum trim “in” may
cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling
characteristics after any adjustment is made to
the angle (trim adjustment bolt relocation.)
1. Will help planing off, particularly with a heavy
load.
2. Usually improves ride in choppy water.
3. In excess, can cause boat to veer to the left or
right (bow steer).
3. Surface Roughness: Moss, barnacles, etc., on
boat or corrosion of outboard’s gear housing increase skin friction and causes speed loss. Clean
surfaces when necessary.
4. Transfers steering torque harder to right (or less
to the left) on single outboard installations.
5. Improves planing speed acceleration (by moving
trim adjustment bolt one hole closer to transom).
WATER ABSORPTION
It is imperative that all through hull fasteners be
coated with a quality marine sealer at time of installation. Water intrusion into the transom core and/or inner hull will result in additional boat weight (reduced
boat performance), hull decay and eventual structural failure.
1C-2 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
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