MERCURY OUTBOARD Service Manual Workshop Fix Repair

MODELS 45 Jet • 50 • 55 • 60 With Serial Numbers United States 0D000750 and Above . . . . . . . Belgium 09671687 and Above . . . . . . . . . . . SERVICE MANUAL 45 Jet • 50 • 55 Marathon • 55 SeaPro • 60 60 Big Foot • 60 Marathon • 60 SeaPro 90-817643R1 DECEMBER 1996 Printed in U.S.A. 1996, Mercury Marine

! 90-817643R1 DECEMBER 1996 i Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special in- structions concerning 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 instruc- tions when performing the service, plus “Common Sense” operation, are major accident prevention measures. ! DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. ! WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death. ! CAUTION Hazards or unsafe practices which could result in mi- nor 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 eval- uation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufactur- er, 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 vi- olent and damaging short circuits or severe electrical shocks. When performing any work where electrical termi- nals 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 acci- dental 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 measure- ments 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 re- use 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.

90-817643R1 DECEMBER 1996 ii Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with toler- ances 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 mini- mum of 5 turns. (2) Connect a hoist of suitable strength to the lifting eye. 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 with- out prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. Service Manual Outline Section 1 - General Information & Specifications Section 2 - Electrical & Ignition Part A - Ignition System Part B - Battery, Charging System & Starting System Part C - Timing/Synchronizing & Adjusting Part D - Wiring Diagrams Section 3 - Fuel Systems Part A - Carburetion Part B - Fuel Pump Part C - Fuel Enrichment Part D - Oil Injection Section 4 - Powerhead Section 5 - Mid-Section Part A - Clamp/Swivel Brackets and Driveshaft Housing Part B - Power Trim (Design I) Part C - Power Trim (Design II) Part D - Power Trim (Design III) Part E - Power Trim (Design IV) Part F - Manual Tilt (Design I, II, III) Part G - Manual Tilt (Design IV) Section 6 - Lower Unit Part A - Standard Gear Housing Part B - 60 Big Foot, 60 SeaPro & Marathon Gear Housing Part C - Jet Drive Section 7 - Outboard Installation/ Attachments Part A - Ride-Guide Steering - Throttle/Shift Cables & Electrical Connections Part B - Tiller Handle and Co-Pilot Part C - Rewind Starter

MERCURY OUTBOARD Service Manual Workshop Fix Repair

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