Mercury 40/50/60 FourStroke EFI Service & Repair Manual (2002 and Later)
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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 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 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
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This service repair manual is an essential resource for anyone working with the Mercury Mariner 40 50 60 Bigfoot EFI 4-Stroke 4 Cyl Outboards. It contains high-quality diagrams and detailed instructions for servicing and repairing your outboard motor, making it invaluable for both professional mechanics and DIY enthusiasts.
The manual covers a wide range of topics, including important information, electrical systems, electronic fuel injection, powerhead, mid-section, lower unit, attachments/control linkage, and jet drive outboard. It provides in-depth specifications, maintenance guidelines, general information, and installation instructions for the outboard motor.
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