2001 Mercury Mariner 50-60HP Factory Service Manual
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- Mercury Mariner 2001 50 60HP Service Manual
Original 2001 Mercury Mariner 50-60HP Factory Service Manual.
2001 (01) Mercury-Mariner models 50 HP (50HP) & 60 HP (60HP) 4-Stroke (Four Stroke) Outboard Engines With Serial Numbers 0T178500 and Above.
Covers Bigfoot (Big Foot) and Non-Bigfoot models. This is the original factory service manual 90-858896.
Manual is indexed and searchable with hi-resolution color diagrams and images.
Manual Chapters:
Section 1 - Important Information
A - Specifications
B - Maintenance
C - General Information
D - Outboard Motor 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 - Emissions
Section 4 - Powerhead
A - Cylinder Head
B - Cylinder Block/Crankcase
C - Lubrication
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
B - Power Trim
C - Manual Tilt Assist
Section 6 - Lower Unit
A - Non-Bigfoot Gear Housing
B - Bigfoot Gear Housing
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Section 8 - Color Diagrams
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"2001 Mercury Mariner 50-60HP Factory Service Manual" manual can be saved to any computer hard drive, flash storage, burned to a CD or DVD ROM or any other digital media.This Manual PDF file is:
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Reference and Info files
Reviews - Write a Review
Rated: 5 by: doug pearce Posted: Friday, April 15, 2011 at 11:04AM
thankyou very much .. well worth the money
Rated: 4 by: Dean Dobrilla Posted: Wednesday, May 25, 2011 at 05:39AM
Rated: 5 by: Gary Blandford Posted: Monday, October 3, 2011 at 07:36AM
Rated: 5 by: Dwight Posted: Thursday, August 31, 2023 at 1:23PM
Full list of manual chapters:
COVER
MODELS 50 - 60 (4-STROKE) 2001 AND NEWER
Notice
Notice to Users of This Manual
Cleanliness and Care of Outboard Motor
Service Manual Outline
SPECIFICATIONS
Section 1A - Specifications
Table of Contents
Specifications
Propeller Information Charts
Mercury/Mariner 50 (4-Stroke) 1.83:1 Non-Bigfoot
Mercury/Mariner 60 (4-Stroke) 1.83:1 Non-Bigfoot
Mercury/Mariner 50 (4-Stroke) 2.3:1 Bigfoot Special soft rubber hub propellers designed to reduce clutch rattle
Mercury/Mariner 60 (4-Stroke) 2.3:1 Bigfoot Special soft rubber hub propellers designed to reduce clutch rattle
MAINTENANCE
Section 1B - Maintenance
Table of Contents
Special Tools
Quicksilver Lubricant/Sealant
Inspection And Maintenance Schedule
Before Each Use
After Each Use
Every 100 Hours of Use or Once yearly, Whichever occurs first
Every 300 Hours of Use or Three Years
Before Periods of Storage
Flushing the Cooling System
Steering Link Rod Fasteners
Corrosion Control Anode
Spark Plug Inspection and Replacement
Battery Inspection
Fuse Replacement – Electric Start Models
Timing Belt Inspection
Lubrication Points
Checking Power Trim Fluid
Fuel System
Fuel Line Filter
Fuel Line Inspection
Changing Engine Oil
Oil Changing Procedure
Changing Oil Filter
Checking and Adding Engine Oil
Changing Gear Case Lubricant
3-1/4 In. (83mm) Diameter Gear Case
4-1/4 In. (108mm) Diameter Gear Case
Submerged Outboard
Storage Preparation
Fuel System
Protecting External Outboard Components
Protecting Internal Engine Components
Gear Case
Positioning Outboard for Storage
Battery Storage
GENERAL INFORMATION
Section 1C - GENERAL INFORMATION
Table of Contents
Serial Number Location
Conditions Affecting Performance
Weather
Boat
Engine
Following Complete Submersion
Submerged While Running (Special Instructions)
Salt Water Submersion (Special Instructions)
Fresh Water Submersion (Special Instructions)
Model 50/60 (4-Stroke) Powerhead Front View
Model 50/60 (4-Stroke) Powerhead Starboard View
Model 50/60 (4-Stroke) Powerhead Port View
Model 50/60 (4-Stroke) Powerhead Top View
Model 50/60 (4-Stroke) Powerhead Aft View
Propeller Selection
Propeller Removal/Installation
3-1/4 In. (83mm) Diameter Gear Case
4-1/4 In. (108mm) Diameter Gear Case
Power Trim System
General Information
Power Trim Operation
Trim "In" Angle Adjustment
Trim Tab Adjustment
Compression Check
Cylinder Leakage Testing
Analysis
Water Pressure Measurement
Painting Procedures
Decal Application
Decal Removal
Instructions for ïWet" Application
OUTBOARD MOTOR INSTALLATION
Section 1D - Outboard Motor Installation
Table of Contents
Electric Fuel Pump
Boat Horsepower Capacity
Start in Gear Protection
Selecting Accessories For The Outboard
Installation Specifications
Lifting Outboard
Steering Cable
Steering Cable Seal
Steering Link Rod
Installing Outboard – Thumb Screw Models
Installing Outboard – Non Thumb Screw Models
Wiring Harness
Battery Cable Connections
Shift and Throttle Cable Installation
Shift Cable Installation
Throttle Cable Installation
Trim-In Stop Adjustment - Power Trim Models
Trim Tab Adjustment
IGNITION
Section 2A - Ignition
Table of Contents
Specifications
Special Tools
Flywheel
Electrical Components
Ignition Description
Ignition Component Description
Electronic Control Module (ECM)
Crank Position Sensor
Stator Assembly
Flywheel Assembly
Ignition Coils
Ignition Test Procedures
Ignition Troubleshooting
Ignition Diagnostic Procedures
Recommended Test
Troubleshooting with the Digital Diagnostical Terminal
Testing Ignition Components
Resistance Tests
Spark Plug Cap Removal
Spark Plug Cap Resistor Test-P/N VDO5FP
Flywheel Removal and Installation
Removal
Installation
Stator Removal and Installation
Timing Belt Removal and Installation
ECM Removal and Installation
Ignition Coil Removal and Installation
Voltage Regulator Removal and Installation
Crank Position Sensor Removal and Installation
Temperature Sensor Removal and Installation
CHARGING and STARTING SYSTEM
Section 2B - Charging and Starting System
Table of Contents
Specifications
Special Tools
Starter Motor
Battery
Recommended Battery
Operating Engine Without Battery
Battery Charging System Troubleshooting
Battery Charging System
Description (15 Ampere)
Wiring Diagram (15 Ampere)
Alternator System Test
6 Ampere Stator
15 Ampere Stator
Stator Ohms Test
Regulator/Rectifier (P/N 854514-1) Diode Test
Analog Meter
Digital Meter
Starting System Components
Troubleshooting the Starting Circuit
Starter Solenoid Test
Starting Circuit Troubleshooting Flow Chart
Starter Motor
Removal
Disassembly
Cleaning and Inspection
Testing
Brush Replacement
Reassembly
Installation
TIMING, SYNCHRONIZING and ADJUSTING
Section 2C - Timing, Synchronizing, and Adjusting
Table of Contents
Specifications
Special Tools
Timing
Carburetor Synchronization
Idle Speed Adjustment
Dashpot Adjustment
WIRING DIAGRAMS
Section 2D - Wiring Diagrams
Table of Contents
50/60 ELPT
50/60 EHPT
Commander Series Remote Control (Electric Start)
MPC 4000 Series Mechanical Panel Control
Key Switch Test
Instrument/Lanyard Stop Switch Wiring Diagram
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
Instrument Wiring Connections
Oil Pressure Wiring Diagram
QSI Gauge Wiring Diagrams
Tachometer Wiring Diagram
Water Temperature Gauge
Engine Synchronizer Wiring Diagram
2 Function Gauge
Remote Wiring Harness Connection to Engine
Remote Key
Power Trim Switch Wiring Diagram
FUEL PUMP
Section 3A - Fuel Pump
Table of Contents
Specifications
Fuel Pump
Fuel Pump Operation
Fuel Pump Removal
Fuel Pump Disassembly
Cleaning/Inspection/Repair
Fuel Pump Reassembly
Fuel Pump Installation
CARBURETOR
Section 3B - Carburetor
Table of Contents
Specifications
Special Tools
Fuel Lines
Carburetor
Intake
Carburetor Adjustments
Float Level
Idle Speed
Idle Mixture Screw Adjustment
Carburetor Removal
Carburetor Disassembly
Inspection
Carburetor Reassembly
Carburetor Installation
EMISSIONS
Section 3C – Emissions
Table of Contents
Exhaust Emissions Standards
What Are Emissions?
Hydrocarbons – HC
Carbon Monoxide – CO
Oxides of Nitrogen - NOx
Controlling Emissions
Stoichiometric (14.7:1) Air/Fuel Ratio
Outboard Hydrocarbon Emissions Reductions
Stratified Vs. Homogenized Charge
Homogenized Charge
Stratified Charge
Emissions Information
Manufacturer s Responsibility
Dealer Responsibility
Owner Responsibility
EPA Emission Regulations
Decal Location for 2001 Models
Service Replacement Certification Label
Removal
Date Code Identification
Installation
Decal Location
CYLINDER HEAD
Section 4A - Cylinder Head
Table of Contents
Specifications
Special Tools
Cylinder Head
Camshaft
Intake/Exhaust Valve
Torque Sequence
Valve Clearance Adjustment
Valve Cover Removal
Adjusting Valves
Valve Cover Installation
Cylinder Head Disassembly
Valve Cover Removal
Cylinder Head Removal
Rocker Arm Assembly Removal
Oil Pump Removal
Camshaft Removal
Valve Removal
Rocker Shaft and Rocker Arm
Camshaft
Cylinder Head
Valve Guides
Valve Guide Replacement
Valves
Valve Springs
Valve Seat Reconditioning
Valve Refacing Steps
Cylinder Head Reassembly
Valve Installation
Camshaft Oil Seal Installation
Camshaft Installation
Oil Pump Installation
Rocker Arm Shaft Assembly
Rocker Arm Shaft Installation
Cylinder Head Gasket
Cylinder Head Installation
Timing Belt Installation
Valve Cover Installation
CYLINDER BLOCK/CRANKCASE
Section 4B - Cylinder Block/Crankcase
Table of Contents
Specifications
Special Tools
Crankshaft
Cylinder Block and Crankcase
Torque Sequence
Powerhead Removal
Remote Control Model
Tiller Handle Model
Removing Powerhead Components
Cylinder Block Disassembly
Inspection
Cylinder Bore
Piston
Piston Pin
Piston Rings
Crankshaft
Checking Main Bearing Clearance
Checking Connecting Rod Bearing Clearance
Thermostat
Oil Pressure Switch
Cylinder Block Reassembly
Selecting New Main Bearings
Main Bearing Installation
Selecting New Connecting Rod Bearings
Installing Connecting Rod Bearings
Connecting Rod Installation
Piston Ring Installation
Piston Installation
Crankshaft Installation
Crankcase Cover Installation
Exhaust Cover Installation
Drive Gear Installation
Installing Powerhead Components
Engine Wiring Harness and Ignition/Electrical Component Installation
Ignition Components
Charging and Starting System Components
Fuel Components
Powerhead Installation
Remote Control Model
Tiller Handle Model
Tiller Handle Models
LUBRICATION
Section 4C - Lubrication
Table of Contents
Specifications
Oil Pump Removal
Oil Pump Disassembly
Cleaning and Inspection
Oil Pump Reassembly
Oil Pump Installation
CLAMP/SWIVEL BRACKETS and DRIVE SHAFT HOUSING
Section 5A - Clamp/Swivel Brackets and Drive Shaft Housing
Table of Contents
Specifications
Swivel Bracket
Steering Arm
Transom Bracket
Adaptor Plate
Driveshaft Housing
Bottom Cowl
Bottom Cowl Removal/Installation
Adaptor Plate Removal
Cleaning Oil Sump
Adaptor Plate Inspection/Cleaning
Adaptor Plate Reassembly
Driveshaft Housing Reassembly
POWER TRIM
Section 5B - Power Trim
Table of Contents
Special Tools
Quicksilver Lubricants and Service Aids
Power Trim
Theory Of Operation
Adjustments
Trimming Characteristics
Trailering Outboard
Tilting Outboard Up and Down Manually
Power Trim Flow Diagrams
Trim Up Circuit
Tilt Circuit
Maximum Tilt
Down Circuit
Shock Function Up
Shock Function Return
Manual Release
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 Removal
Manifold Removal
Shock Rod Removal
Shock Rod Disassembly
Memory Piston Removal
Cleaning/Inspection/Repair
Reassembly
O-ring 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
Reservoir/Motor Installation
Bleeding Power Trim Unit
Installation of Power Trim System
MANUAL TILT ASSIST
Section 5C - Manual Tilt Assist
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
NON-BIGFOOT GEAR HOUSING
Section 6A - Non-Bigfoot Gear Housing
Table of Contents
Specifications
Special Tools
Quicksilver Lubricants and Service Aids
Gear Housing (Drive Shaft)(1.83:1 Gear Ratio)
Gear Housing (Prop Shaft)(1.83:1 Gear Ratio)
General Service Recommendations
Bearings
Seals
Draining and Inspecting Gear Lubricant
Removal
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 Installation
Upper Driveshaft Bearing Installation
Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer and Driveshaft Installation
Pinion Gear Location and Forward Gear Backlash
Determining Forward Gear Backlash
Bearing Carrier and Propeller Shaft Installation
Water Pump Re-assembly and Installation
Gear Housing Pressure Test
Gear Housing Installation
Gear Housing Installation
Filling Gear Housing with Lubricant
Trim Tab Adjustment and Replacement
BIGFOOT GEAR HOUSING
Section 6B - Bigfoot Gear Housing
Table of Contents
Specifications
Special Tools
Quicksilver Lubricants and Service Aids
Gear Housing (Drive Shaft)(2.31:1 Gear Ratio)
Gear Housing (Prop Shaft)(2.31:1 Gear Ratio)
General Service Recommendations
Draining and Inspecting Gear Lubricant
Removal
Disassembly
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
Gearcase Installation
Trim Tab Adjustment
THROTTLE/SHIFT LINKAGE
Section 7A - Throttle/Shift Linkage
Table of Contents
Linkage (Remote)
Linkage (Handle)
TILLER HANDLE
Section 7B - Tiller Handle
Table of Contents
Tiller Handle
Tiller Handle Assembly Removal
Tiller Handle Disassembly
Cleaning/Inspection/Repair
Tiller Handle Reassembly
Tiller Handle Installation
COLOR DIAGRAMS
COLOR DIAGRAMS
Table of Contents
50/60 (4-Stroke) Tiller Handle Electric Color Wiring Diagram 2001 Models
50/60 (4-Stroke) Remote Control Electric Color Wiring Diagram 2001 Models
MPC 4000 Mechanical Panel Control Color Wiring Diagram
