2002+ Mercury 40HP/50HP/60HP 4-Stroke EFI Outboard Service & Repair Manual [Improved]

1 A SPECIFICATIONS 90-883065 APRIL 2001 Page 1A-1 IMPORTANT INFORMATION Section 1A - Specifications Table of Contents Specifications 1A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Information Charts 1A-8 . . . . . . . . . . . . . . Specifications Models 40/50/60 EFI (4-Stroke) HORSEPOWER (kW) Model 40 Model 50 Model 60 40 hp (29.8 Kw) @ 5750 rpm 50 hp (37.7 Kw) @ 5750 rpm 60 hp (44.7 Kw) @ 5750 rpm OUTBOARD WEIGHT Electric 40/50/60 ELPT 40/50/60 ELPT BIGFOOT 248 lb (112.7 kg) 264 lb (119.9 kg) FUEL RECOMMENDED GASOLINE Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 OIL OIL FILTER OIL FILTER WRENCH ENGINE OIL CAPACITY ENGINE OIL +20 +40 +60 +80 F° C° 0 +100 –7 +4 +16 +27 –18 +38 SAE 10W-30 SAE 25W-40 p/n 35-822626A2 p/n 91-802653Q1 Either 3 Quarts or 3 Liters SAE 10W-30 viscosity oil is recommended 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 classifications SH, SG, SF, CF-4, CE, CD, CDll.

SPECIFICATIONS Page 1A-2 90-883065 APRIL 2001 IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Torque Hole Size Firing Order Ignition Timing: @Idle @1500-1800 @ WOT (6000 rpm) Stator Resistance Crank Position Sensor (CPS) Resistance Ignition Coil Resistance: Internal Shielding Electronic Spark Trigger (EST) Secondary High Tension Lead/Boot Resistance ECM Engine Speed Limiter Fuel/Spark Cut-out on Cylinders #2 and #3 Fuel/Spark Cut-out on All Cylinders ECM Overheat Speed Control ECM Low Oil Pressure Speed Control MAT/ECT Temperature Sensor Manifold Absolute Pressure (MAP) Sensor Resistance Fuel Injector Resistance Main Power Relay Idle Air Control (IAC) Throttle Position Sensor Typical Range Output Voltage @Idle Output Voltage @WOT (6000) Capacitor Discharge Ignition Champion RA8HC 0.040 in. (1.0 mm) 5/8 in. (16 mm) 150 lb-in. (17 Nm) 12 mm 1-3-4-2 Controlled by ECM 14° B.T.D.C 28° B.T.D.C 0.20 - 0.30 Ω (YEL-YEL) 300 - 350 Ω (RED - WHT) 0 - 10.0 KΩ (Pin A - Mounting Bracket) 8.5 - 12KΩ (Pin B - Pin C) 3.0 - 7.0 kΩ (Pin A - Coil Tower) 0.600 - 1.100 KΩ 6225 rpm 6350 rpm Guardian System is activated. Power limit will vary with level of overheat. Guardian System is activated. Engine power is limited to 10% of maximum (Approximately 2000 RPM) See Graph Section 3B - EFI See Table Section 3B - EFI 10.0 - 13.5Ω 81-99 Ω (Pin 85 - Pin 86) 24-30 Ω (Between Pins) 0.39-1.00 Volts 3.66-4.80 Volts CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: 20 Amp. Electric Alternator Output Stator Resistance Quicksilver Tachometer Setting Single Phase (12 Pole) 12.6 V-20 Amps. (252 Watts) (Rectified/Regulated) 0.20 - 0.30 Ohms (YEL-YEL) “6P” or “4” STARTING SYSTEM Electric Start: Starter Type Output Ampere Draw Under: (Load) (No Load) Bendix 1.1 kW 174.0 Amps 23.7 Amps

SPECIFICATIONS 90-883065 APRIL 2001 Page 1A-3 BATTERY Battery Rating Minimum Requirement For operation below 32° F (0° C) Ampere-Hours (Ah) Minimum For operation above 32° F (0° C) For operation below 32° F (0° C) 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) 70 105 FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Fuel Tank Capacity Mechanical Water Cooled (Plunger/Diaphragm) 3-6 psi Accessory FUEL INJECTION Fuel Injector System Idle rpm (Out Of Gear) Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT) Range Fuel Pump Pressure - Electric Batch (1 & 4) - (2 & 3) 725 ± 25 rpm 725 ± 25 rpm 5500–6000 42-44 psi (290-303 kPa) CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 60.8 cu. in. (995 cc) 4 STROKE Length 2.953 in. (75 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Taper/Out of Round Maximum Bore Type 2.5591 in. (65 mm) 2.5689 in. (65.25 mm) 2.5787 in. (65.5 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type O.D. at Skirt Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Aluminum 2.5570 - 2.5578 in. (64.950 - 64.965 mm) 2.5669 - 2.5675 in. (65.2 - 65.215 mm) 2.5768 - 2.5774 in. (65.450 - 65.465 mm) PISTON CLEARANCE Piston to Cylinder Clearance 0.0014 - .0026 in. (0.035 - 0.065 mm) RINGS Ring End Gap (Installed) Top Middle Bottom (Oil Ring) Side Clearance: Top Middle 0.006 - 0.012 in. (0.15 - 0.03 mm) 0.012 - 0.020 in. (0.30 - 0.50 mm) 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.0008 - 0.0024 in. (0.02 - 0.06 mm) 0.0008 - 0.0024 in. (0.02 - 0.06 mm) COMPRESSION RATIO Compression Ratio Cylinder Compression* (Electric Models Only, Cold Engine @ W.O.T.) 9.7:1 180 - 210 psi (Peak) PISTON PIN Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm) CONNECTING ROD Oil Clearance (Big End) Small End Inside Diameter 0.0008 - 0.0020 in. (0.020 - 0.052 mm) 0.6293 - 0.6298 in. (15.985 - 15.998 mm)

SPECIFICATIONS Page 1A-4 90-883065 APRIL 2001 CRANKSHAFT Main Bearing Clearance Crankshaft Run-out 0.0005 - 0.0017 in. (0.012 - 0.044 mm) 0.0018 in. (0.046 mm) CAMSHAFT Camshaft Dimensions Intake “A” Exhaust “A” Intake “B” Exhaust “B” Run-out Limit Camshaft Bearing Diameter “b” A B b b b b b 1.214 - 1.222 in. (30.83 - 31.03 mm) 1.214 - 1.222 in. (30.83 - 31.03 mm) 1.020 - 1.028 in. (25.90 - 26.10 mm) 1.020 - 1.028 in. (25.90 - 26.10 mm) 0.0039 in. (0.1 mm) 1.4541 - 1.4549 in. (36.935 - 36.955 mm) VALVE SPRING Free Length “a” Tilt Limit “b” Compressed Pressure (Installed) Intake Exhaust Tilt Limit (Intake & Exhaust) Dir. of Winding (Intake & Exhaust) a b a b 1.491-1.569 in. (37.85-39.85 mm) Less than 0.060 in. (1.7 mm) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 0.043 in. (1.1 mm) Left Hand

SPECIFICATIONS 90-883065 APRIL 2001 Page 1A-5 CYLINDER HEAD Warp Limit * Lines indicate straight edge measurement Camshaft Bore Inside Diameter “a” a a a a a 0.004 in. (0.1 mm) 1.4567 - 1.4577 in. (37.000 - 37.025 mm) 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.) 0.006 - 0.010 in. (0.15 - 0.25 mm) 0.010 - 0.014 in. (0.25 - 0.35 mm) 1.256 - 1.264 in. (31.9 - 32.1 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)

SPECIFICATIONS Page 1A-6 90-883065 APRIL 2001 “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness ROCKER SHAFT Outside Diameter 0.6288 - 0.6296 in. (15.971 - 15.991 mm) ROCKER ARM Inside Diameter of Bore 0.6299 - 0.6306 in. (16.000 - 16.018 mm) THERMOSTAT Valve Opening Temperature Full Open Temperature 118° F - 123° F (48° C - 51° C) 145° F (63° C) LUBRICATION SYSTEM Pump Type Engine Oil Pressure (Warm Engine) @ 3000 rpm Engine Oil Pan Capacity Oil Pump: Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c” a b c a b c Trochoid 30-40 psi (207-278 kPa) Either 3 Qts. or 3 Liters 0.0045 - 0.009 in. (0.11 - 0.23 mm) 0.005 in. (0.12 mm) 0.0015 - 0.003 in. (0.04 - 0.08 mm) MID-SECTION Transom Height: Long Shaft Steering Pivot Range: Tiller Remote Full Tilt Up Angle Allowable Transom Thickness 20 in. (51 cm) 90° 60° 71° 2-3/4 in. (69.8 mm)

SPECIFICATIONS 90-883065 APRIL 2001 Page 1A-7 GEAR HOUSING (1.83:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Water Pressure (Warm Engine) @ 800 rpm @ 6000 rpm (WOT) Leak Test Pressure 1.83:1 11.5 fl oz (340 mL) Quicksilver Gear Lube-Premium Blend 22 Spiral/Bevel 12 Spiral/Bevel 0.025 in. (0.64 mm) Pinion Gear Locating Tool (91-817008A2) 0.011-0.017 in. (0.28-0.43 mm) Backlash Indicator Tool (91-19660--1) MARK #4 or 0.366 in. (9.3 mm) 1–3 psi (7-21 kPa) 12–25 psi (83-172 kPa) 10-12 psi (68-83 kPa) for 5 Minutes GEAR HOUSING BIGFOOT (2.3:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Pinion Gear Locating Tool Flat Number Disc Number Forward Gear Backlash Backlash Indicating Tool Mark Number Water Pressure @ 800 rpm (Idle) @ 6000 rpm (WOT) Leak Test Pressure 2.31:1 24 fl oz (710 mL) Quicksilver Gear Lube-Premium Blend 30 Spiral/Bevel 13 Spiral/Bevel 0.025 in. (0.64 mm) 91-12349A2 #8 #3 0.012-0.019 in. (0.30-0.48 mm) 91-78473 #4 2-6 psi (14-41 kPa) 12-25 psi (83-172 kPa) 10-12 psi (69-83 kPa) for 5 Minutes

SPECIFICATIONS Page 1A-8 90-883065 APRIL 2001 Propeller Information Charts Mercury/Mariner 40 EFI (4-Stroke) 1.83:1 Non-Bigfoot Wide Open Throttle RPM : 5500-6000 Recommended Transom Heights : 20”, 22.5” 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” 17” 3 Alum Up to 800 Up to 15’ 43-50 48-73144A40 10” 16” 3 Steel 800-1000 Up to 15’ 39-46 48-91818A5 10” 16” 3 Alum 800-1000 Up to 15’ 39-46 48-73142A40 10-1/8” 15” 3 Steel 900-1200 13-15’ 36-43 48-855862A5 10-1/8” 15” 3 Alum 900-1200 13-15’ 36-43 48-73140A40 10-1/4” 14” 3 Steel 1000-1200 14-16’ 33-39 48-855860A5 10-1/4” 14” 3 Alum 1000-1200 14-16’ 33-39 48-73138A40 10-3/8” 13” 3 Steel 1100-1400 14-17’ 30-35 48-855858A5 10-3/8” 13” 3 Alum 1100-1400 14-17’ 30-35 48-73136A40 10-5/8” 12” 3 Steel 1300-1600 15-17’ 27-32 48-855856A5 10-5/8” 12” 3 Alum 1300-1600 15-17’ 27-32 48-73134A40 11-5/8” 10.5” 3 Steel 1500-1900 16-18’ 24-29 48-823478A5 10-7/8” 11” 3 Alum 1500-1900 16-18’ 24-29 48-85632A40 11-5/8” 10-1/2” 3 Alum 1600-2000 16’ + 21-25 48-827312A10 11-1/4” 10” 3 Alum 1700-2200 17’ + 19-24 48-73132A40 12-1/4” 9” 3 Steel 2000+ pontoon 17-21 48-97868A10 12-1/4” 9” 3 Alum 2000+ pontoon 17-21 48-87818A10 12-1/2” 8” 3 Alum 2500+ Pontoon/ houseboat 1-18 48-42738A10 12-1/2” 8” Cup 3 Alum pontoon 48-42738A12

SPECIFICATIONS 90-883065 APRIL 2001 Page 1A-9 Mercury/Mariner 50 EFI (4-Stroke) 1.83:1 Non-Bigfoot Wide Open Throttle RPM : 5500-6000 Recommended Transom Heights : 20”, 22.5” 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 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 48-855862A5 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 48-855860A5 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 48-855858A5 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 48-855856A5 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 48-85632A40 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/ houseboat 1-18 48-42738A10 12-1/2” 8” Cup 3 Alum pontoon 48-42738A12

SPECIFICATIONS Page 1A-10 90-883065 APRIL 2001 Mercury/Mariner 60 EFI (4-Stroke) 1.83:1 Non-Bigfoot Wide Open Throttle RPM : 5500-6000 Recommended Transom Heights : 20”, 22.5” 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 1000 Up to 14’ 49-58 48-73146A40 10” 17” 3 Alum Up to 1200 Up to 15’ 43-50 48-73144A40 10” 16” 3 Steel 1200-1600 Up to 16’ 39-46 48-91818A5 10” 16” 3 Alum 1200-1600 Up to 16’ 39-42 48-73142A40 10-1/8” 15” 3 Steel 1300-1700 14-16’ 36-43 48-855862A5 10-1/8” 15” 3 Alum 1300-1700 14-16’ 36-43 48-73140A40 10-1/4” 14” 3 Steel 1400-2000 15-17’ 33-39 48-855860A5 10-1/4” 14” 3 Alum 1400-2000 15-17’ 33-39 48-73138A40 10-3/8” 13” 3 Steel 1600-2200 15-18’ 30-35 48-855858A5 10-3/8” 13” 3 Alum 1600-2200 15-18’ 30-35 48-73136A40 10-5/8” 12” 3 Steel 1800-2500 16-18’ 27-32 48-855856A5 10-5/8” 12” 3 Alum 1800-2500 16-18’ 27-32 48-73134A40 11-5/8” 11” 3 Steel 2300-3000 17-19’ 24-29 48-823478A5 10-7/8” 11” 3 Alum 2300-3000 17-19’ 24-29 48-85632A40 11-5/8” 10-1/2” 3 Alum 2500-3300 17’ + 21-25 48-827312A10 11-1/4” 10” 3 Alum 2800-3600 18’ + 19-24 48-73132A40 12-1/4” 9” 3 Steel 3300+ pontoon 17-21 48-97868A10 12-1/4” 9” 3 Alum 3300+ pontoon 17-21 48-87818A10 12-1/2” 8” 3 Alum 4000+ Pontoon/ houseboat 1-18 48-42738A10 12-1/2” 8” Cup 3 Alum pontoon 48-42738A12

2002+ Mercury 40HP/50HP/60HP 4-Stroke EFI Outboard Service & Repair Manual [Improved]

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