Mercury Mariner Outboard motor 45 Jet 50 55 60 HP Models Service Manual
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- Mariner Outboards 45 Jet 50 55 60 HP Models
Original Mercury Mariner Outboards Service and Repair Manual. It covers everything to fix/repair your Mercury Mariner Outboard. This is a complete manual with detailed instructions, diagrams and more.
Manual is deeply indexed and searchable. It includes very descriptive diagrams, detailed repair and diagnostic procedures with appropriate part numbers and all required references.
Mercury models covered by this manual:
- 45 Jet
- 50
- 55 Marathon
- 55 SeaPro
- 60
- 60 Big Foot
- 60 Marathon
- 60 SeaPro
With Serial Numbers
United States - 0D000750 and Above
Belgium - 09671687 and Above
Manual Chapters:
- GENERAL INFORMATION AND SPECIFICATIONS
- IGNITION SYSTEM
- BATTERY, CHARGING SYSTEM and STARTING SYSTEM
- TIMING/SYNCHRONIZING/ADJUSTING
- WIRING DIAGRAMS
- CARBURETION
- FUEL PUMP
- ENRICHMENT
- OIL INJECTION
- POWERHEAD
- CLAMP/SWIVEL BRACKETS and DRIVE SHAFT HOUSING
- POWER TRIM
- MANUAL TILT SYSTEM
- STANDARD GEAR HOUSING
- 60 BIG FOOT, 60 SEAPRO/MARATHON GEAR HOUSING (4-1/4 inch Torpedo, 2.3:1 Gear Ratio)
- JET DRIVE
- RIDE-GUIDE STEERING - THROTTLE/SHIFT CABLES & ELECTRICAL CONNECTIONS
- TILLER HANDLE and CO-PILOT
- REWIND STARTER
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Reference and Info files
Reviews - Write a Review
Rated: 5 by: Vicki Posted: Monday, June 19, 2023 at 3:10PM
Manual itself is very good and of a high quality
Full list of manual chapters:
Mariner Outboards 45 Jet 50 55 60 HP Models
Notice
Notice to Users of This Manual
Cleanliness and Care of Outboard Motor
Service Manual Outline
GENERAL INFORMATION AND SPECIFICATIONS
Table of Contents
Propeller Information
How To Use This Manual
Page Numbering
Master Specifications
Powerhead
Specifications
Special Tools
Cowl Removal
Filling Oil Injection System
Propeller Selection
Propeller Installation
Trim "In" Angle Adjustment
Propeller Information Chart
Power Trim System (Models with Power Trim)
Trimming (Models with Power Trim)
Trim Tab Adjustment
Boat Performance
Lubrication Points
Periodic Inspection
Flushing Outboard Cooling System
Following Complete Submersion
Out-of-Season Outboard Storage
Out-of-Season Battery Storage
How Weather Affects Engine Performance
Conditions Affecting Operation
Detonation: Causes and Prevention
Compression Check
Water Pressure Check
Serial Number Location
Painting Procedures
Decal Application
IGNITION SYSTEM
Table of Contents
Description
Test Procedures
Direct Voltage Adapter (DVA) Tests
Test Sequence
Ignition System Test Chart
ADI Ignition using a RED Stator with an Adapter Module
RED Stator with Adaptor and Ignition Coils
RED Stator DVA Test
Electric Start Engines
Manual Start Engines
Troubleshooting Procedures
Ignition (Key) Switch Test
Ignition Components Removal and Installation
Flywheel
BLACK and RED Stator
Trigger
Ignition Coils
Switch Box
BATTERY, CHARGING SYSTEM and STARTING SYSTEM
Table of Contents
Battery
Precautions
Recommended Battery
Operating Engine Without Battery
Specific Gravity Readings
Electrolyte Level
Charging A Discharged Battery
Winter Storage of Batteries
Battery Charging System
Description
Battery Charging System Troubleshooting
Stator Ohms Test (Alternator Coils Only)
Alternator System Test
9 Ampere Battery Charging Wiring Diagram (Rectifier Models)
9 Ampere Battery Charging Wiring Diagram (Regulator Models)
9 Ampere Battery Charging Diagram with Battery Isolator
15/16 Ampere Battery Charging Diagram with Battery Isolator
Rectifier Test
Starting System
Starting System Components
Description
Troubleshooting the Starting Circuit
Starting Circuit Troubleshooting Flow Chart
Starter Motor
Removal
Disassembly
Cleaning and Inspection
Testing
Brush Replacement
Reassembly
Installation
TIMING/SYNCHRONIZING/ADJUSTING
Table of Contents
Timing/Synchronizing/ Adjusting
Specifications
Special Tools
Timing Pointer Adjustment
Carburetor Synchronization
Timing Adjustments
Idle Adjustment
Throttle Cable Installation
WIRING DIAGRAMS
Table of Contents
Model 45 Jet Electric Start Wiring Diagram
Model 50/60 Electric Start Wiring Diagram (Rectifier Models)
Model 50/60 Electric Start Wiring Diagram Regulator Models)
Model 50/60 Electric Start Tiller Handle Wiring Diagram
Model 55 Manual Start Wiring Diagram
Model 50/60 Power Trim Wiring Diagram
55/60 Manual Start with RED Stator Wiring Diagram
50/60 Electric Start with RED Stator Wiring Diagram
Key/Choke Switch Continuity Test (COMMANDER 2000 Side Mount Remote Control)
COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
COMMANDER Side Mount Remote Control (Power Tilt Electric Start with Warning Horn) Wiring Diagram
COMMANDER 2000 Side Mount Remote Control (Elec- tric Start with Warning Horn) Wiring Diagram
CARBURETION
Table of Contents
Specifications
Special Tools
Attenuator Plate
WME Carburetor Specifications
Carburetor
Carburetion
Fuel System Troubleshooting
Troubleshooting Charts
Carburetor Adjustments
WME Carburetor Specifications
Carburetor Removal
Carburetor Disassembly
Cleaning and Inspection
Carburetor Reassembly
Carburetor Installation
FUEL PUMP
Table of Contents
Specifications
Fuel Pump (50/60)
Fuel Pump (55/60 Seapro/Marathon)
Fuel Pumps
General Information
Testing
Troubleshooting Fuel Pump
Fuel Pump Removal
Fuel Pump Disassembly
Cleaning and Inspection
Fuel Pump Reassembly
Check Valve Assembly
Fuel Pump Assembly
Fuel Pump Exploded View
Fuel Tank
Fuel Tank Components
Fuel Line and Primer Bulb Assembly
Maintenance
ENRICHMENT
Table of Contents
Enrichener System
ENRICHENER VALVE TEST
OIL INJECTION
Table of Contents
Operation of the Injection System
Oil Injection System
Oil Injection Flow System (Fixed Ratio Oil Pump)
Pump Drive Assembly (Fixed Ratio Oil Pump)
Pump Drive System (Fixed Ratio Oil Pump)
Oil Pump to Powerhead Assembly (Fixed Ratio Oil Pump)
Oil Injection Flow System (Variable Ratio Oil Pump)
Pump Drive Assembly (Variable Ratio Oil Pump)
Pump Drive System (Variable Ratio Oil Pump)
Oil Pump to Powerhead Assembly (Variable Ratio Oil Pump)
Set Up Instructions for Oil Injection System
Carburetor/Oil Pump Synchronization (Variable Ratio Oil Pump)
Filling Oil Injection System with Oil
Bleeding Air From Oil Injection System
Outboard Operation
Check Operation of the Oil Injection System (Engine Running)
Required Side Mount Remote Control or Ignition Key Switch Assembly
Oil Injection System
Troubleshooting Chart
Installing Drive Gear (For Oil Injection Pump) Onto Crankshaft
Oil Warning Module
Engine Mounted Oil Reservoir
Removal
Installation
POWERHEAD
Table of Contents
Specifications
Special Tools
Quicksilver Lubricants and Service Aids
Cylinder Block and Crankcase
Induction Manifold and Reed Block
Crankshaft, Pistons and Connecting Rods
Throttle Lever and Linkage
Powerhead Torque Sequence
General Information
Powerhead Disassembly
Removing Engine Components
Crankshaft Disassembly
Cleaning and Inspection
Cylinder Block and Crankcase Cover
Check Valves
Piston and Piston Rings
Crankshaft
Connecting Rods
Thermostat
Reed Blocks
Powerhead Reassembly and Installation
General Information
End Cap
Assembling Rod to Piston
Piston Ring Installation
Crankshaft Installation
Installing Rods to Crankshaft
Connecting Rod Cap Alignment
Crankcase Cover to Block
Intake/Reed Block Manifold Installation
Thermostat Cover Installation
Install Remaining Engine Components
Powerhead Installation
Test Run Procedure
Important Information
CLAMP/SWIVEL BRACKETS and DRIVE SHAFT HOUSING
Table of Contents
Mid-Section Components
Swivel Bracket Components
Transom Bracket Components (55 Model)
Transom Bracket Components (50/60 Models)
Drive Shaft Housing Components
Disassembly Reassembly
Reassembly
Drive Shaft Housing
POWER TRIM (DESIGN 1)
Table of Contents
Power Trim General Information
Description
Trimming Characteristics
Trailering Outboard
Tilting Outboard Up and Down Manually
Trim "In" Angle Adjustment
Power Trim System Components
Power Trim Flow Diagrams Design 1
Troubleshooting
Determine if Problem is Electrical or Hydraulic
Trouble Chart
Hydraulic System Troubleshooting
Preliminary Checks
Leak Down Check - Pump and Manifold Assembly
Leak Down Check - Pilot Valve Assembly
Leak Down Check – Manual Release Valve
Leakage Past Ball and Seat - Piston Assembly
Troubleshooting Flow Diagram
Electrical System Troubleshooting
COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
Power Trim System Wiring Diagram
Troubleshooting the "Down" Circuit (When "Up" Circuit is OK)
Troubleshooting the "Up" Circuit (When "Down" Circuit Is OK)
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
Power Trim System Removal
Power Trim System Disassembly
Trim Rod Removal
Trim Rod Disassembly
Trim "Motor" Removal
Trim "Motor" Disassembly
Reservoir Assembly Removal
Oil Pump Removal
Manifold Removal
Cleaning and Inspection of Trim Rod Components
Motor and Electrical Tests/Repair
Trim Pump Motor Test
Thermal Overload Switch Test
Armature Tests
Power Trim System Reassembly
Manifold Installation
Oil Pump Installation
Trim Motor Reassembly
Reservoir Installation
Trim Rod Reassembly
Trim Rod Installation
Bleeding Power Trim Unit
Power Trim Unit Installation
POWER TRIM (DESIGN II)
Table of Contents
Power Trim General Information
Description
Trimming Characteristics
Trailering Outboard
Tilting Outboard Up and Down Manually
Trim "In" Angle Adjustment
Power Trim System Components
Power Trim Flow Diagrams Design II
Troubleshooting
Determining if Problem is Electrical or Hydraulic
Trouble Chart
Hydraulic System Troubleshooting
Preliminary Checks
Leak Down Check - Pump and Manifold Assembly
Leak Down Check - Pilot Valve Assembly
Leak Down Check – Manual Release Valve
Leakage Past Ball and Seat - Piston Assembly
Troubleshooting Flow Diagram
Electrical System Troubleshooting
COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
Power Trim System Wiring Diagram
Troubleshooting the "Down" Circuit (When "Up" Circuit is OK)
Troubleshooting the "Up" Circuit (When "Down" Circuit Is OK)
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
Power Trim System Removal
Power Trim System Disassembly
Trim Rod Removal
Trim Rod Disassembly
Trim "Motor" Removal
Trim Motor Disassembly
Reservoir Assembly Removal
Oil Pump/Manifold Removal
Cleaning and Inspection of Trim Rod Components
Motor and Electrical Tests/Repair
Trim Pump Motor Test
Thermal Overload Switch Test
Armature Tests
Power Trim System Reassembly
Manifold/Oil Pump Installation
Trim Motor Reassembly
Reservoir Installation
Trim Rod Reassembly
Trim Rod Installation
Bleeding Power Trim Unit
Power Trim Unit Installation
POWER TRIM (DESIGN 3)
Table of Contents
Special Tools
Quicksilver Lubricants and Service Aids
Power Trim - General Information
Description
Trimming Characteristics
Trailering Outboard
Tilting Outboard Up and Down Manually
Trim "In" Angle Adjustment
Power Trim System Components
Troubleshooting
Determining if Problem is Electrical or Hydraulic
Hydraulic System Troubleshooting
Preliminary Checks
Leak Down Check - Pump and Manifold Assembly
Leak Down Check - Pilot Valve Assembly
Leak Down Check - Manual Release Valve
Leaks Past Ball and Seat - Piston Assembly
Troubleshooting Flow Diagram
Electrical System Troubleshooting
COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
Power Trim System Wiring Diagram
Troubleshooting the "Down" Circuit (When "Up" Circuit is OK)
Troubleshooting the "Up" Circuit (When "Down" Circuit Is OK)
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
Power Trim System Removal
Power Trim System Disassembly
Trim Rod Removal
Trim Rod Disassembly
Trim "Motor" Removal
Trim "Motor" Disassembly
Reservoir Assembly Removal
Manifold Removal
Cleaning and Inspection of Trim Rod Components
Motor and Electrical Tests/Repair
Power Trim System Reassembly
Manifold Installation
Trim Motor Reassembly
Reservoir Installation
Trim Rod Reassembly
Trim Rod Installation
Power Trim Unit Installation
Purging Power Trim Unit
POWER TRIM (DESIGN 4)
Table of Contents
Special Tools
POWER TRIM COMPONENTS
Theory Of Operation
Adjustments
Trimming Characteristics
Trailering Outboard
TIlting Outboard Up and Down Manually
Trim Up
Tilt Up
Maximum Tilt
Down Mode
Shock Function Up
Shock Function Return
Manual Tilt
Troubleshooting
Preliminary Checks
Hydraulic System Troubleshooting Flow Chart
Troubleshooting the Power Trim Electrical System
Power Trim System Removal
Power Trim Disassembly
Trim Motor Removal
Pump and Components Remvoal
Manifold Removal
Shock Rod Removal
Shock Rod Disassembly
Memory Piston Removal
Cleaning/Inspection/Repair
Trim Motor Electrical Tests
Reassembly
O-Ring and Seal Placement
O-ring Sizes
O-ring Description and Sizes
Power Trim Reassembly
Shock Rod Reassembly
Shock Rod Installation
Trim Limit Assembly Installation
Manual Release Valve Installation
Manifold Installation
Oil Pump Installation
Pressure Operated Assembly Installation
Reservior/Motor Installation
Bleeding Power Trim Unit
Installation of Power Trim System
MANUAL TILT SYSTEM (DESIGN I, II, III)
Table of Contents
Manual Tilt System Components (Design One and Two)
Manual Tilt System Components (Design Three)
Manual Tilt Flow Diagrams Design 1
Manual Tilt Flow Diagrams Design 2
Manual Tilt Flow Diagrams Design 3
Hydraulic System Troubleshooting
Troubleshooting Flow Chart
Manual Tilt System Removal
Manual Tilt System Disassembly
Accumulator Removal
Shock Rod Removal
Shock Rod Disassembly
Valve Block Removal
Valve Block Disassembly
Manual Tilt System Cleaning and Inspection
Manual Tilt System Reassembly
Valve Block Reassembly
Valve Block Installation
Shock Rod Reassembly
Shock Rod Installation
Instructions for Making Retaining Tool
Bleeding Manual Tilt System
Manual Tilt System Installation
MANUAL TILT SYSTEM (DESIGN 4)
Table of Contents
Special Tools
Manual Tilt Components
Manual Trim Flow Diagrams
Up Circuit
Down Circuit
Slow Tilt Down Under High Thrust
Under Water Strike (Valves Open)
Shock Function (Valve Closed)
Shock Function Return
Hydraulic System Troubleshooting
Manual Tilt System Removal
Manual Tilt System Disassembly
Accumulator Removal
Shock Rod Removal
Shock Rod Disassembly
Valve Block Removal
Memory Piston Removal
Valve Block Disassembly
REASSEMBLY - O-RING AND SEAL PLACEMENT
Actual O-ring Sizes
O-ring Description and Sizes
Manual Tilt System Cleaning and Inspection
Manual Tilt System Reassembly
Valve Block Installation
Shock Rod Reassembly
Shock Rod Installation and Fluid Filling Procedure
Filling Procedure Option Two Instructions for Making Retaining Tool
Bleeding Manual Tilt System
Manual Tilt System Installation
Manual Release Valve Adjustment
STANDARD GEAR HOUSING
Table of Contents
Drive Shaft and Water Pump Components
Propeller Shaft Components
Special Tools
Quicksilver Lubricants and Service Aids
New Tools Required for 50-60 Gear Housing
Draining and Inspecting Gear Lubricant
Propeller Removal
Gear Housing Removal
Gear Housing Disassembly
Water Pump
Bearing Carrier and Propeller Shaft
Propeller Shaft Disassembly
Pinion Gear, Driveshaft and Forward Gear
Upper Driveshaft Bearing
Lower Driveshaft Bearing
Forward Gear Bearing Race
Shift Shaft
Gear Housing Reassembly
Shift Shaft
Propeller Shaft
Forward Gear Bearing Race
Bearing Carrier
Reverse Gear
Forward Gear
Lower Driveshaft Bearing Installaton
Upper Driveshaft Bearing Installation
Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer and Driveshaft Installation
Pinion Gear Location and Forward Gear Backlash
Bearing Carrier and Propeller Shaft Installation
Water Pump Reassembly and Installation
Gear Housing Pressure Test
Gear Housing Installation
Filling Gear Housing with Lubricant
Gear Housing Installation
Propeller Installation
Trim Tab Adjustment and Replacement
60 BIG FOOT, 60 SEAPRO/MARATHON GEAR HOUSING (4-1/4 inch Torpedo, 2.3:1 Gear Ratio)
Table of Contents
Gear Hsg. (Drive Shaft)(60 Seapro/Marathon/Big Foot)
Gear Hsg. (Prop Shaft)(60 Seapro/Marathon/Big Foot)
Special Tools
Removal
Propeller Removal
Draining and Inspecting Gear Housing Lubricant
Water Pump
Bearing Carrier and Propeller Shaft
Pinion Gear, Drive Shaft, and Forward Gear
Upper Drive Shaft Bearing
Oil Sleeve
Lower Drive Shaft Bearing Race
Shift Shaft
Forward Gear Bearing Race
Trim Tab Adjustment and Replacement
Reassembly
Forward Gear Bearing Race
Shift Shaft
Bearing Carrier Reassembly
Forward Gear Reassembly
Propeller Shaft Reassembly
Drive Shaft Wear Sleeve Installation
Lower Drive Shaft Bearing Race Installation
Oil Sleeve Installation
Upper Drive Shaft Bearing Installation
Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation
Pinion Gear Depth and Forward Gear Backlash
Bearing Carrier and Propeller Shaft Installation
Water Pump Reassembly and Installation
Gear Housing Pressure Test
Filling Gear Housing With Lubricant
Propeller Installation
Gearcase Installation
Trim Tab Adjustment
JET DRIVE
Table of Contents
Jet Pump Assembly
Jet Components
Selecting A Boat That Is Best Suited For Jet Power
Engine Horsepower Selection
Transom Height of the boat
Locate Center line Of The Outboard
Outboard Mounting Height
Water testing
Shift Cable Installation
Lubricating The Drive Shaft Bearing
Impeller Removal and Installation
Steering Pull Adjustment
Impeller Clearance Adjustment
Worn (Dull) Impeller
Flushing The Cooling System
Liner Replacement
Jet Drive Removal
Bearing Carrier Removal
Bearing Carrier Disassembly
Bearing Carrier Reassembly
Installing Lower Seals
Installing Upper Seals
Installing Drive Shaft Ball Bearing
Installing Drive Shaft
Bearing Carrier Installation
Installing Jet Drive to Drive Shaft Housing
Reassembling Water Pump to Jet Drive
Installing Jet Drive to Drive Shaft Housing
Jet Drive Tiller Handle Adaptor Kit
Installation Instructions
Shift Cable Adjustment
RIDE-GUIDE STEERING - THROTTLE/SHIFT CABLES and ELECTRICAL CONNECTIONS
Table of Contents
Installing Outboard Motor on Transom
Determining Recommended Outboard Mounting Height
Locate Centerline of Boat Transom
Lifting Outboard (Electric Start Models)
Lifting Outboard (Manual Start Models)
Drilling Outboard Mounting Holes (Electric Start Models)
Fastening Outboard on Boat Transom (Manual Start Models)
Securing Outboard to Boat Transom (Electric Start Models)
Steering Cable Installation
Dual Outboard
Cable Installation to Tilt Tube - Cable Routed on Starboard Side of Boat
Cable Installation to Tilt Tube - Cable Routed on Port Side of Boat
Installing Steering Link Rod
Maintenance Instructions
Dual Steering Installation
Steering Coupler Assembly
Installation
Ride-Guide Steering Attachment Extension Couplers
Trim Tab Adjustment
Maintenance Instructions
Transom Mounted Ride-Guide Attaching Kit Installation
Clevis Attaching Kit Installation
Installation Instructions
Steering Cable Installation
Maintenance Instructions
Remote Control Installation
Shift Cable Installation and Adjustment to Engine
Throttle Cable Installation and Adjustment to Engine
Connecting Remote Control Wiring Harness to Engine Wiring Harness (Electric Start Models)
Power Trim Wiring Connections (Models So Equipped)
Battery Connections
TILLER HANDLE and CO-PILOT
Table of Contents
Steering Handle Kit
Tiller Handle Adaptor Kit (JET 45)
Tiller Arm/Shift Lever Removal
Tiller Handle Disassembly
Tiller Arm Reassembly
Tiller Arm/Shift Lever Installation
Shift Link Rod Installation and Adjustment to Engine
Throttle Cable Installation and Adjustment
Co-Pilot Installation
Tiller Handle Installation
Wiring Harness Connection
REWIND STARTER
Table of Contents
Starter Assembly (MANUAL – 55)
Rewind Starter Disassembly
Cleaning and Inspection
Rewind Starter Reassembly
Adjusting Rewind Spring Tension
Starter Interlock Cable Adjustment
