Mercury 40 FourStroke User manual

Type
User manual

This manual is also suitable for

MODELS
United States 0G531301 and ABOVE. .
Belgium 09974454 and ABOVE. . . . . . .
With Serial Numbers
SERVICE
MANUAL
40·50·55·60
Printed in U.S.A.
1997, Mercury Marine
90-852572R1 JANUARY 1998
90-852572R1 JANUARY 1998 i
Notice
Throughout this publication, “Dangers”, “Warnings”
and “Cautions” (accompanied by the International
HAZARD Symbol
) are used to alert the mechanic
to special instructions concerning a particular service
or operation that may be hazardous if performed in-
correctly or carelessly.
OBSERVE THEM CARE-
FULLY!
These “Safety Alerts” alone cannot eliminate the haz-
ards that they signal. Strict compliance to these spe-
cial instructions when performing the service, plus
“Common Sense” operation, are major accident pre-
vention 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 minor 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 per-
sonnel when servicing the products described here-
in.
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 prod-
ucts which includes the use of mechanics’ common
hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service
trade of all conceivable procedures by which a ser-
vice might be performed and of the possible hazards
and/or results of each method. We have not under-
taken any such wide evaluation. Therefore, anyone
who uses a service procedure and/or tool, which is
not recommended by the manufacturer, 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 con-
tained in this manual are based on the latest product
information available at the time of publication. As re-
quired, revisions to this manual will be sent to all deal-
ers contracted by us to sell and/or service these prod-
ucts.
It should be kept in mind, while working on the prod-
uct, that the electrical system and ignition system are
capable of violent and damaging short circuits or se-
vere electrical shocks. When performing any work
where electrical terminals 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 accidental entrance of foreign material which
could enter the cylinders and cause extensive inter-
nal damage when the engine is started.
It is important to note, during any maintenance proce-
dure replacement fasteners must have the same
measurements and strength as those removed.
Numbers on the heads of the metric bolts and on the
surfaces of metric nuts indicate their strength. Ameri-
can bolts use radial lines for this purpose, while most
American nuts do not have strength markings. Mis-
matched or incorrect fasteners can result in damage
or malfunction, or possibly personal injury. There-
fore, fasteners removed should be saved for reuse 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.
ii 90-852572R1 JANUARY 1998
Cleanliness and Care of
Outboard Motor
A marine power product is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten thousands of
an inch./mm. When any product component is serv-
iced, 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 specif-
ically stated.
Whenever components are removed for service,
they should be retained in order. At the time of instal-
lation, they should be installed in the same locations
and with the same mating surfaces as when re-
moved.
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 crank-
shaft with a locknut and lifting eye is threaded into
flywheel a minimum 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
without prior notification.
Refer to dealer service bulletins for other pertinent in-
formation concerning the products described in this
manual.
Page Numbering
Two number groups appear at the bottom of each
page. The example below is self-explanatory.
EXAMPLE:
90-826148R1 JANUARY 1997
LOWER UNIT - 6A-7
Revision No. 1
Month of Printing
Year of Printing
Section Description
Section Number
Part of Section Letter
Page Number
Important
Information
Electrical
Fuel System
Powerhead
Mid-Section
Lower Unit
Attachments/
Control Linkage
Manual Starter
8
1
2
3
4
5
6
7
90-852572R1 JANUARY 1998
iii
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
C - General Information
D - Outboard 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 - Oil Injection
D - Emissions
Section 4 - Powerhead
Section 5 - Mid-Section
A - 40/50 Clamp/Swivel Brackets & Drive Shaft Housing
B - 55/60 Clamp/Swivel Brackets & Drive Shaft Housing
C - 40/50 Power Trim
D - 55/60 Power Trim
E - 40/50 Manual Tilt
F - 55/60 Manual Tilt
Section 6 - Lower Unit
A - 40/50 Lower Unit
B - 55/60 Lower Unit
C - 60 Bigfoot
D - Jet Drive
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Section 8 - Manual Starter
A
1
IMPORTANT
INFORMATION
SPECIFICATIONS
1A-0 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Table of Contents
Page
Specifications 1A-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Information Charts 1A-4. . . . . . . . . . . . .
Mercury/Mariner 40 HP (3 Cyl.) 1A-4. . . . . . . . .
Mercury/Mariner 50 HP (3 Cyl.) 1A-5. . . . . . . . .
Mercury/Mariner 55 HP (3 Cyl.) 1A-6. . . . . . . . .
Mercury/Mariner 60 HP (3 Cyl.) 1A-7. . . . . . . . .
Mercury/Mariner 60 HP (3 Cyl.) Bigfoot 1A-8. .
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1A-1
Specifications
Models 40/50/55/60
HORSEPOWER
(kW)
Model 40
Model 50
Model 55
Model 60
40 (29.8)
50 (37.3)
55 (41.0)
60 (44.7)
OUTBOARD WEIGHT
Manual
40/50 ML
55 ML
Electric
40/50 ELPTO
40/50 ELO
60 ELPTO
60 ELO
205 lbs. (93.0 kg)
220 lbs. (99.8 kg)
204 lbs. (92.5 kg)
200 lbs. (90.7 kg)
219 lbs. (99.3 kg)
215 lbs. (97.5 kg)
CYLINDER BLOCK
Type
Displacement
3 Cylinder-2 Cycle-Loop Charged
59 cu. in. (967 cc)
STROKE Length 2.796 in. (71 mm)
CYLINDER BORE
Diameter
Taper/Out of Round Maximum
Bore Type
2.993 in. (76 mm)
0.003 in. (0.08 mm)
Cast Iron
PISTON
Type
Standard Diameter
0.015 in. (0.381 mm) Oversize
0.030 in. (0.762 mm) Oversize
Aluminum
2.988 in. (75.895 mm)
3.003 in. (76.276 mm)
3.018 in. (76.657 mm)
REEDS
Reed Stand Open (Max.)
Reed Stop (Max.)
40
50/55/60
Reed Thickness
0.020 in. (0.50 mm)
0.090 in. (2.286 mm)
Not Adjustable
0.010 in. (0.254 mm)
FUEL SYSTEM
Recommended Gasoline
Recommended Oil
Break-in Gasoline/Oil Ratio
Manual Start Models
Electric Start Models
After Break-in Gasoline/Oil Ratio
Manual Start Models
Electric Start Models
Fuel Pressure
@ Idle
@ W.O.T.
Unleaded-87 Octane Minimum
Quicksilver TC-WII or TC-W3
2 Cycle Outboard Oil
Pre-mixed Gasoline and Oil 25:1
50:1 (In Fuel Tank)
Pre-mixed Gasoline and Oil 50:1
Straight Gasoline
3.5 PSI (24 kPa)
6.0 PSI (41 kPa)
1A-2 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
GEAR HOUSING
40/50
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ Idle
@ W.O.T.
Pressure Test
55/60
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ Idle
@ W.O.T.
Pressure Test
60 Bigfoot
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure
@ Idle
@ W.O.T.
Pressure Test
1.83:1
14.9 fl. oz. (440 mL)
Quicksilver Gear Lube-Premium Blend
22 Spiral/Bevel
12 Spiral/Bevel
0.025 in. (0.64 mm)
No Adjustment
0.5-1.5 PSI (3-10 kPa)
5.0–7.0 PSI (35-48 kPa)
10-12 PSI (69-83 kPa)
for 5 Minutes
1.64:1
11.5 fl. oz. (340 mL)
Quicksilver Gear Lube-Premium Blend
23
14
0.025 in. (0.64 mm)
Pinion Gear Locating Tool
(91-817008A2)
0.013-0.019 in. (0.33-0.48 mm)
1–3 PSI (7-20 kPa)
7–12 PSI (48-83 kPa)
10-12 PSI (69-83 kPa)
for 5 Minutes
2.3:1
22.5 fl. oz. (655 mL)
Quicksilver Gear Lube-Premium Blend
30
13
0.025 in. (0.64 mm)
0.012 in.-0.019 in. (0.30 mm-0.48 mm)
10-15 PSI (69-103 kPa) @ 5250 RPM
2-7 PSI (14–48 kPa)
10-15 PSI (69-104 kPa)
10-12 PSI (69-83 kPa)
for 5 Minutes
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1A-3
STARTING SYSTEM
Manual Start
Electric Start
Starter Draw (Under Load)
Battery Rating
Recoil Starter
125 Amperes
Min. Reserve Cap. Rating of 100
Min. and CCA of 350 Amperes
IGNITION SYSTEM
Type
Spark Plug Type
Spark Plug Gap
Firing Order
Capacitor Discharge
NGK BP8H-N-10
*NGK BPZ8H-N-10
0.040 in. (1.0mm)
1-2-3
CHARGING SYSTEM
Alternator Output
Electric Models
Manual Models (Not Regulated)
Single Phase (12 Pole)
16 Amperes @ 3000 RPM
9 Amperes @ 3000 RPM
7 Amperes @ 3000 RPM
CARBURETOR
Idle RPM
Wide Open Throttle (W.O.T.) RPM
Idle Mixture Screw Adjustment
Preset (Turns Out)
Float Adjustment
Float Level
Main Jet
Model 40 (WME-53, 69)
Model 50 (WME-68)
Model 55 (WME-57)
Model 60 (WME-58)
675 ± 25
5000-5500
1
1
/
4
±
1
/
4
9
/
16
in. (14 mm)
0.044 in.
0.052 in.
0.058 in.
0.060 in.
OIL
INJECTION
Recommended Oil
Oil Tank Capacity/Approx. Time
Reserve Capacity/Approx. Time
Oil Output With Engine RPM of 1500
and Oil Pump @ W.O.T.
Model 40
Model 50/60
Quicksilver TC-WII or TC-W3
2 Cycle Outboard Oil
3.0 qts. (2.8 L) 7 hours
14.5 fl. oz. (0.43 L)
1
/
2
hour
15.0 ± 3.0 cc of oil in 10 minutes
22.0 ± 3.0 cc of oil in 10 minutes
TIMING
Idle
Maximum Timing
@ Cranking Speed
-Model 40/50/60
-Model 55/60 Seapro-Marathon
@ 5000 RPM
– Model 40/50/60
– Model 55/60 Seapro-Marathon
T.D.C. ± 2°
24° B.T.D.C.
18° B.T.D.C.
22° B.T.D.C.
16° B.T.D.C.
TEMPERATURE
SWITCH
Temperature
Normal
190°F ± 8° (88°C ± 4°C)
170°F ± 8° (77°C ± 4°C)
Open - No Continuity
Closed - Full Continuity
Open - No Continuity
*Suppressor (resistor) spark plug
1A-4 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Propeller Information Charts
Mercury/Mariner 40 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”
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 900 Up to 14’ 41-49 48-73146A40
10” 17” 3 Alum Up to 900 Up to 14’ 35-43 48-73144A40
10” 16” 3 SS Up to 1200 Up to 15’ 32-40 48-91818A5
10” 16” 3 Alum Up to 1200 Up to 15’ 32-40 48-73142A40
10-1/8” 15” 3 SS 1000-1500 13-15’ 28-37 48-855862A5
10-1/8” 15” 3 Alum 1000-1500 13-15’ 28-37 48-73140A40
10-3/8” 14” 3 Alum 1100-1700 14-16’ 25-34 48-816706A40
10-1/4” 14” 3 SS 1100-1700 14-16’ 25-34 48-855860A5
10-1/4” 14” 3 Alum 1100-1700 14-16’ 25-34 48-73138A40
10-1/2” 13” 3 Alum 1300-2100 14-17’ 21-31 48-816704A40
10-3/8” 13” 3 SS 1300-2100 14-17’ 21-31 48-855858A5
10-3/8” 13” 3 Alum 1300-2100 14-17’ 21-31 48-73136A40
10-3/4” 12” 3 Alum 1500-2500 15-19’ 18-27 48-816702A40
10-5/8” 12” 3 SS 1500-2500 15-19’ 18-27 48-855856A5
10-5/8” 12” 3 Alum 1500-2500 15-19’ 18-27 48-73134A40
10-7/8” 11 3 Alum 1800-3500 16-21’ 14-24 48-85632A40
11-1/4” 10” 3 Alum 2000+ 17’+ 11-21 48-73132A40
11-5/8” 11 3 SS 1800-3500 16-21’ 14-24 48-823478A5
11-5/8” 10-1/2” 3 Alum 2000+ 17’+ 13-23 48-827312A10
12-1/4” 9” 3 Alum 2500+ 18’+ 8-17 48-87818A10
12-1/4” 9” 3 SS 2500+ 18’+ 8-17 48-97868A10
12-1/2” 8” 3 Alum 3000+ 20’+ 1-14 48-42738A10
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1A-5
Mercury/Mariner 50 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”, 22-1/2”
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 1100 Up to 14’ 41-49 48-73146A40
10” 17” 3 Alum Up to 1400 Up to 14’ 35-43 48-73144A40
10” 16” 3 SS 1200-1500 Up to 15’ 32-40 48-91818A5
10” 16” 3 Alum 1200-1500 Up to 15’ 32-40 48-73142A40
10-1/8” 15” 3 SS 1300-1800 13-15’ 28-37 48-855862A5
10-1/8” 15” 3 Alum 1300-1800 13-15’ 28-37 48-73140A40
10-3/8” 14” 3 Alum 1400-2100 14-16’ 25-34 48-816706A40
10-1/4” 14” 3 SS 1400-2100 14-16’ 25-34 48-855860A5
10-1/4” 14” 3 Alum 1400-2100 14-16’ 25-34 48-73138A40
10-1/2” 13” 3 Alum 1600-2600 14-17’ 21-31 48-816704A40
10-3/8” 13” 3 SS 1600-2600 14-17’ 21-31 48-855858A5
10-3/8” 13” 3 Alum 1600-2600 14-17’ 21-31 48-73136A40
10-3/4” 12” 3 Alum 1900-3200 15-19’ 18-27 48-816702A40
10-5/8” 12” 3 SS 1900-3200 15-19’ 18-27 48-855856A5
10-5/8” 12” 3 Alum 1900-3200 15-19’ 18-27 48-73134A40
10-7/8” 11 3 Alum 2200-4300 16-21’ 14-24 48-85632A40
11-1/4” 10” 3 Alum 2500+ 17’+ 11-21 48-73132A40
11-5/8” 11 3 SS 2200-4300 16-21’ 14-24 48-823478A5
11-5/8” 10-1/2” 3 Alum 2200+ 17’+ 13-23 48-827312A10
12-1/4” 9” 3 Alum 3000+ 18’+ 8-17 48-87818A10
12-1/4” 9” 3 SS 3000+ 18’+ 8-17 48-97868A10
12-1/2” 8” 3 Alum 3500+ 20’+ 1-14 48-42738A10
1A-6 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Mercury/Mariner 55 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 16-1/2”, 21”, 23-1/2”
Right Hand Rotation Standard
Gear Reduction : 2.3:1
Diameter
Pitch
No. of
Blades
Material
Approx.
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
12-3/4” 26” 5 SS Up to 800 Up to 15’ 48-54 48-815748A45
13-1/2” 26” 3 SS Up to 800 Up to 15’ 48-54 48-16996A30
12-3/4” 24” 5 SS Up to1000 Up to 15’ 46-52 48-815746A45
13-1/2” 24” 3 SS Up to 1000 Up to 15’ 46-52 48-16994A30
12-1/2” 23” 3 Alum 700-1100 Up to 15’ 45-51 48-77350A45
12-3/4” 22” 5 SS 700-1100 Up to 15’ 43-49 48-815744A45
13-1/2” 22” 3 SS 700-1100 Up to 15’ 43-59 48-16992A30
12-3/4” 21” 3 Alum 800-1200 13-16’ 40-47 48-77348A45
12-3/4” 20” 5 SS 800-1200 13-16’ 38-45 48-816612A45
13-1/2” 20” 3 SS 800-1200 13-17’ 38-45 48-16990A30
13” 19” 3 Alum 1000-1400 14-17’ 35-42 48-77346A45
13” 18” 3 SS 1000-1400 14-17’ 33-40 48-16988A30
13-1/4” 17” 3 Alum 1200-1700 15-18’ 31-38 48-77344A45
13-1/8” 16” 3 SS 1200-1700 15-18’ 29-36 48-16986A30
13-3/4” 15” 3 Alum 1500-2100 16-19’ 26-33 48-77342A45
13-3/8” 14” 3 SS 1500-2100 16-19’ 23-31 48-17314A30
14” 13” 3 Alum 1900-2500 17’+ 20-28 48-77340A45
14” 12” 3 SS 1900-2500 17’+ 17-26 48-17312A30
14” 11 3 Alum 2200+ 18’+ 1-22 48-77338A45
14” 10” 3 SS 2400+ 19’+ 1-20 48-17310A30
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1A-7
Mercury/Mariner 60 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”
Right Hand Rotation Standard
Gear Reduction : 1.64:1
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’ 48-55 48-73146A40
10” 17” 3 Alum Up to 1000 Up to 15’ 44-51 48-73144A40
10” 16” 3 SS 700-1100 Up to 15’ 41-48 48-91818A5
10” 16” 3 Alum 700-1100 Up to 15’ 41-48 48-73142A40
10-1/8” 15” 3 SS 800-1200 13-15’ 38-45 48-855862A5
10-1/8” 15” 3 Alum 800-1200 13-15’ 38-45 48-73140A40
10-1/4” 14” 3 SS 900-1500 14-16’ 35-41 48-816706A40
10-3/8” 14” 3 Alum 900-1500 14-16’ 35-41 48-855860A5
10-3/8” 13” 3 SS 1200-1800 15-17’ 32-38 48-73138A40
10-1/2” 13” 3 Alum 1200-1800 15-17’ 32-38 48-816704A40
10-5/8” 12” 3 SS 1500-2100 16-18’ 28-34 48-855858A5
10-3/4” 12” 3 Alum 1500-2100 16-18’ 28-34 48-73136A40
10-7/8” 11 3 Alum 1800-2400 16-18’ 24-30 48-816702A40
11-5/8” 11 3 SS Workboat 16’+ 24-30 48-855856A5
12” 10-1/2” 3 Alum 2000-2600 17’+ 22-28 48-73134A40
11-5/8” 10-1/2” 3 Alum 2000-2600 17’+ 22-28 48-85632A40
11-1/4” 10” 3 Alum 2100-2600 17’+ 20-26 48-73132A40
12-1/4” 9” 3 SS 2400+ 18’+ 14-22 48-823478A5
12-1/4” 9” 3 Alum 2400+ 18’+ 14-22 48-827312A10
12-1/2” 8” 3 Alum 2800+ 19’+ 1-18 48-87818A10
1A-8 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Mercury/Mariner 60 HP (3 Cyl.) Bigfoot
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”, 22-1/2”
Right Hand Rotation Standard
Gear Reduction : 2.31:1
Diameter
Pitch
No. of
Blades
Material
Approx.
Gross Boat
Wgt. (lbs)
Approx.
Boat
Length
Speed
Range
(mph)
Propeller
Part Number
13” 18” 3 SS Up to 1100 Up to 14’ 41-49 48-16988A45
13-1/4” 17” 3 Alum Up to 1400 Up to 14’ 35-43 48-77344A45
13-1/8” 16” 3 SS 1200-1500 Up to 15’ 32-40 48-16986A45
13-3/4” 15” 3 Alum 1200-1500 Up to 15’ 32-40 48-77342A45
13-3/8” 14” 3 SS 1300-1800 13-15’ 28-37 48-17314A45
14” 13” 3 Alum 1300-1800 13-15’ 28-37 48-77340A45
14” 12” 3 SS 1400-2100 14-16’ 25-34 48-17312A45
14” 11 3 Alum 1400-2100 14-16’ 25-34 48-77338A45
14” 10” 3 Alum 1400-2100 14-16’ 25-34 48-854342A45
14” 9” 3 Alum 1600-2600 14-17’ 21-31 48-854340A45
B
1
IMPORTANT
INFORMATION
MAINTENANCE
1B-0- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Table of Contents
Page
Specifications 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubricant Capacity 1B-1. . . . . . . . .
Special Tools 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricant/Sealant 1B-1. . . . . . . . . . . .
Inspection and Maintenance Schedule 1B-2. . . .
Before Each Use 1B-2. . . . . . . . . . . . . . . . . . . .
After Each Use 1B-2. . . . . . . . . . . . . . . . . . . . . .
Every 100 Hours of Use or Once Yearly,
Whichever Occurs First 1B-2. . . . . . . . . . . . . . .
Every 300 Hours of Use or Three Years 1B-2
Before Periods of Storage 1B-2. . . . . . . . . . . .
Flushing The Cooling System 1B-3. . . . . . . . . . . .
Fuel System 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrosion Control Anode 1B-4. . . . . . . . . . . . . . . .
Lubrication Points 1B-5. . . . . . . . . . . . . . . . . . . . . .
Checking Power Trim Fluid 1B-7. . . . . . . . . . . . . .
60 HP 1B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40/50 HP 1B-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubrication 1B-8. . . . . . . . . . . . . . . . . .
Draining Gear Case 1B-8. . . . . . . . . . . . . . . . . .
Checking Lubricant Level and Filling
Gear Case 1B-9. . . . . . . . . . . . . . . . . . . . . . . . . .
Storage Preparations 1B-9. . . . . . . . . . . . . . . . . . .
Protecting External Outboard
Components 1B-9. . . . . . . . . . . . . . . . . . . . . . . .
Protecting Internal Engine Components 1B-9
Gear Case 1B-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning Outboard for Storage 1B-10. . . . . .
Battery Storage 1B-10. . . . . . . . . . . . . . . . . . . . .
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-1
Specifications
Gear Case Lubricant Capacity
Gear Case Ratio Capacity
1.83:1
1.64 :1
2.3:1
14.9 fl. oz. (440 mL)
11.5 fl. oz. (340 mL)
22.5 fl. oz. (655 mL)
Special Tools
1. Quicksilver Flushing Attachment (44357A2)
50551
Quicksilver
Lubricant/Sealant
1. Gear Lube-Premium Blend P/N 92-19007A24
2. Quicksilver Anti-Corrosion Grease
P/N 92-78376A6
3. 2-4-C Marine Lubricant with Teflon
P/N 92-825407A12
4. SAE 30W Motor Oil - Obtain Locally
30W
1B-2- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
Inspection and Maintenance
Schedule
Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration
or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose com-
ponents.
5. Remote Control Models – Visually check steering
link rod fasteners for proper tightness.
6. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operat-
ing in salt or polluted water.
2. Wash off all salt deposits and flush out the ex-
haust outlet of the propeller and gear case with
fresh water if operating in salt water.
Every 100 Hours of Use or Once
Yearly, Whichever Occurs First
1. Lubricate all lubrication points. Lubricate more
frequently when used in salt water.
2. Inspect and clean spark plugs.
3. Check engine fuel filter for contaminants.
4. Adjust carburetor(s) (if required).
5. Check engine timing setup.
6. Check corrosion control anodes. Check more fre-
quently when used in salt water.
7. Drain and replace gear case lubricant.
8. Lubricate splines on the drive shaft.
9. Check power trim fluid.
10. Inspect battery.
11. Check control cable adjustments.
12. Remove engine deposits with Quicksilver Power
Tune Engine Cleaner.
13. Check tightness of bolts, nuts, and other fasten-
ers.
*
These items should be serviced by an authorized
dealer.
Every 300 Hours of Use or Three
Years
1. Replace water pump impeller (more often if over-
heating occurs or reduced water pressure is
noted).
Before Periods of Storage
Refer to Storage Procedure.
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-3
Flushing The Cooling
System
Flush the internal water passages of the outboard
with fresh water after each use in salt, polluted, or
muddy water. This will help prevent a buildup of de-
posits from clogging the internal water passages.
Use a Quicksilver accessory (or equivalent) flushing
attachment.
WARNING
To avoid possible injury when flushing, remove
the propeller. Refer to Propeller Replacement.
1. Remove propeller (refer to Propeller Replace-
ment). Install the flushing attachment so the rub-
ber cups fit tightly over the cooling water intake
holes.
2. Attach a water hose to the flushing attachment.
Turn on the water and adjust the flow so water is
leaking around the rubber cups to ensure the en-
gine receives an adequate supply of cooling wa-
ter.
3. Start the engine and run it at idle speed in neutral
shift position.
4. Adjust water flow (if necessary) so excess water
continues leaking out from around the rubber
cups to ensure the engine is receiving an ade-
quate supply of cooling water.
5. Check for a steady stream of water flowing out of
the water pump indicator hole. Continue flushing
the outboard for 3 to 5 minutes, carefully monitor-
ing water supply at all times.
6. Stop the engine, turn off the water, and remove
the flushing attachment. Reinstall the propeller.
Fuel System
IMPORTANT: Gasoline containing alcohol (etha-
nol or methanol) can cause a formation of acid
during storage and can damage the fuel system.
If the gasoline being used contains alcohol, it is
advisable to drain as much of the remaining gas-
oline as possible from the fuel tank, remote fuel
line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pump, and car-
buretors) with treated (stabilized) fuel to help prevent
formation of varnish and gum. Proceed with following
instructions.
1. Portable Fuel Tank – Pour the required amount of
Quicksilver Gasoline Stabilizer (follow instruc-
tions on container) into fuel tank. Tip fuel tank
back and forth to mix stabilizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the re-
quired amount of Quicksilver Gasoline Stabilizer
(follow instructions on container) into a separate
container and mix with approximately one quart
(one liter) of gasoline. Pour this mixture into fuel
tank.
1B-4- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998
3. Place the outboard in water or connect flushing
attachment for circulating cooling water. Run the
engine for ten minutes to allow treated fuel to
reach the carburetors.
Corrosion Control Anode
1. Your outboard has two corrosion control anodes.
One of the anodes is the trim tab installed on the
gear case and the other is installed on the bottom
of the transom bracket assembly. An anode helps
protect the outboard against galvanic corrosion
by sacrificing its metal to be slowly eroded in-
stead of the outboard metals.
a
b
a - Trim Tab Anode
b - Transom Bracket Anode
NOTE: Each anode requires periodic inspection es-
pecially in salt water which will accelerate the ero-
sion. To maintain this corrosion protection, always re-
place the anode before it is completely eroded. Never
paint or apply a protective coating on the anode as
this will reduce effectiveness of the anode.
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