1996 Mercury Outboard Motors Service Manual - 45 Jet, 50, 55, 60 HP

Complete service manual for Mercury 45 Jet, 50, 55 Marathon, 55 SeaPro, 60, 60 Big Foot, 60 Marathon, and 60 SeaPro outboard motors. Includes diagrams and specifications. Part No. 90-817643R1.

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Document Details

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Document Number / Seller:
25504 / Jennifer Owens
File Size:
15.96 MB
File Type:
PDF
Language:
English
Printable:
Yes
Estimated Download Time:
0.33 Minutes
Delivery Format:
Digital (PDF) - Instant Access
Category:
Outboard Motor
Brand:
Mercury
Reviewed and Approved:
Sep 1, 2025
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Models Covered & Key Technical Specifications

Mercury Outboard Motors (90-817643R1) - 1996

Precision Service & Repair for Classic Outboards

Covers 45 Jet, 50, 55 Marathon, 55 SeaPro, 60, 60 Big Foot, 60 Marathon, 60 SeaPro models. Comprehensive diagrams and specifications. Package: Resource

  • Engineered Specifications: 51.8 cu. in. (849cc) displacement defines the total volume for engine operation.
  • Defined Performance Metrics: 675 25 RPM establishes the standard idle operation Threshold.
  • Standard Electrical Specs: 400 VDC testing capacity determines the voltage parameters for diagnostic measurements.
  • Principal System Data: 70 lb. in. (7.9 N m) torque signifies the tightening requirement for the manifold assembly.
  • Advanced Power Output: 16 Amperes @ 3000 RPM sets the alternator output for electric models.
  • Verified Cooling Capacity: 10.5 hours of running time at wide open throttle is the core operating capacity.

Professional Workshop Service Manual & Technical Specifications

Strategic Engineering Diagnostic Manual: Mercury 45 Jet, 50, 55 Marathon, 55 SeaPro, 60, 60 Big Foot, 60 Marathon, 60 SeaPro - Precision Service & Repair for Classic Outboards Workshop-Compendium

Repair-Classification: Marine Outboard Motor // Design-Core: 1996 Mercury 45 Jet, 50, 55 Marathon, 55 SeaPro, 60, 60 Big Foot, 60 Marathon, 60 SeaPro // Repair-Classification: Outboard Motor

Service-Nexus System-Path Logic
Electrical & Ignition Powerhead Components
Fuel Systems Carburetion Operation
Powerhead Crankshaft Specifications
Mid-Section Swivel Bracket Components
Power Trim System Hydraulic Diagrams
Oil Injection System Pump Operation

Repair procedures are structured around detailed system overviews, including electrical, fuel, powerhead, and mid-section components. Specific sections cover troubleshooting, maintenance, and component replacement for each system.

This manual documents torque specifications for various components to ensure proper fastener fatigue prevention.

Thorough documentation of all systems ensures complete understanding of engine operation and maintenance.

FAQ

Calculate the **precise** pressure specifications for the fuel pump? keyboard_arrow_down

4-7 PSI (28-43 kPa) is the specified fuel pump pressure at Wide Open Throttle (W.O.T.) according to the manual.

What values indicate **proper** assembly sequence for the flywheel? keyboard_arrow_down

Torquing the flywheel nut to 100 lb. ft. (136 N·m) is required to ensure the proper assembly sequence, as detailed in the flywheel installation section.

Assess the **standard** service interval parameters for lubrication? keyboard_arrow_down

Every 60 days is the standard service interval for lubrication points such as the throttle/shift linkage pivot points and upper shift shaft, when operating in fresh water conditions.

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Reviews (3)

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Rated 5 out of 5 stars
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This manual has been a lifesaver for my Mercury outboard. The step-by-step instructions are clear and easy to follow. Highly recommend!
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The diagrams and troubleshooting charts are incredibly helpful. I had a smooth download experience, and the support team responded quickly to my questions.