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Mercury 40 hp, 50 hp, 60 hp EFI outboard motor service manual Preview image 1
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Mercury 40 hp, 50 hp, 60 hp EFI outboard motor service manual

Models covered in this manual:

Mercury (Brunswick Corporation)

  • Mercury 40 HP EFI FourStroke
  • Mercury 50 HP EFI FourStroke
  • Mercury 60 HP EFI FourStroke

Serial numbers: 0T409000
Production/model years: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

File specifications

File size: 17.34 MB
File type: ZIP
Language: English

Printable: Yes
Estimated download time: 0.36 Minutes
$13.99 Instant Download

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Product Information

Table of Contents

Section 1A: Specifications

  • Specifications
  • Mercury/Quicksilver Lubricants and Sealants
  • Propeller Information Charts
  • Torque Chart

Section 1B: General Information

  • General Description
  • Engine Serial Number Location
  • Model Identification
  • Fuel and Oil Recommendations
  • Maintenance Schedules

Section 2: Ignition System

  • Spark Plug
  • Ignition Timing
  • Ignition Coil Resistance
  • Starter Motor
  • Capacitor Discharge Ignition (CDI)

Section 3: Fuel System

  • Fuel Pump Type
  • Fuel Injection System
  • Fuel Pressure
  • Carburetor

Section 4: Cooling System

  • Water Pump
  • Thermostat
  • Cooling System Maintenance

Section 5: Power Unit

  • Cylinder Block
  • Cylinder Bore
  • Piston and Rings
  • Connecting Rod
  • Crankshaft

Section 6: Lubrication System

  • Oil Pump
  • Oil Filter
  • Oil Capacity and Specifications

Section 7: Electrical System

  • Battery Specifications
  • Charging System
  • Alternator Output

Section 8: Starting System

  • Starter Motor Specifications
  • Starter Solenoid
  • Starting System Troubleshooting

Section 9: Gear Housing

  • Gear Ratio
  • Gear Housing Assembly
  • Propeller Shaft

Section 10: Trim and Tilt System

  • Hydraulic System
  • Trim and Tilt Motor
  • Trim and Tilt Troubleshooting

Section 11: Maintenance

  • Periodic Maintenance Schedule
  • Maintenance Procedures
  • Service Intervals

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