1996-2002 Mercury Mariner 50, 55, 60, 45 Jet Outboard Motor Service Manual

Wiring diagrams, specifications, and repair sequences for Mercury Mariner 50, 55, 60, and 45 Jet outboard motors. Part number 90-817643R1.

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Document Details

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Document Number / Seller:
27447 / Edward Grant
File Size:
13.08 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Feb 27, 2025

Models Covered & Key Technical Specifications

Mercury Mariner 50, 55, 60, 45 Jet Outboard Motor (90-817643R1) - 1996-2002 Covers wiring diagrams, specifications, and repair sequences for Mercury Mariner 50, 55, 60, and 45 Jet outboard motors.

  • Technical Data: 51.8 cu. in. (849cc) displacement provides standard power output.
  • Engine Specifications: 2.520 in. (64.008mm) stroke defines the operational range.
  • Cylinder Bore: 2.955 in. (75.057mm) establishes the maximum print output architecture.
  • Piston Details: Aluminum construction signifies the component material.
  • Gear Housing: 1.64:1 gear ratio ensures optimal torque transfer.
  • Fuel System: Pre-mixed gasoline and oil provides the recommended fuel mixture.

Professional Workshop Service Manual & Technical Specifications

Mercury Mariner 50, 55, 60, 45 Jet Outboard Motor Manual: Mercury Mariner 50/55/60/45 Jet Manual (90-817643R1)

General Information: 1996-2002 Outboard Motor Logic // System Type: Outboard Motor / Carbureted Power System // Specifications: 51.8 cu. in. (849cc)

Performance-Element Operational-Logic Calibration-Spec
Engine Type Two-Stroke Cycle 3 Cylinder
Horsepower 50-60 HP N/A
Displacement 51.8 cu. in. (849cc) N/A
Stroke 2.520 in. (64.008mm) N/A
Bore 2.955 in. (75.057mm) N/A

Technical units are distributed across the following chapters:

  • General Information and Specifications
  • Electrical & Ignition
  • Fuel Systems
  • Powerhead
  • Mid-Section
  • Lower Unit

This manual thoroughly documents the internal combustion engine's power output and operational characteristics, providing comprehensive coverage for maintenance and repair. Safely requiring proper procedures, it details components like the ignition system, fuel delivery, and powerhead assembly, including specific torque values and alignment guidelines. The document covers carburetor synchronization, timing adjustments, and fuel pump servicing, ensuring a complete overview of the engine's systems. It also addresses oil injection system operation and troubleshooting, alongside mid-section and drive shaft housing components.

FAQ

Check the **standard** piston diameter for the 50/55/60 models. keyboard_arrow_down

2.950 in. (74.93 mm) is the standard piston diameter for the 50/55/60 models.

What does the **necessary** idle speed adjustment entail for these engines? keyboard_arrow_down

1-1/4 turns off seat is the initial setting for the idle mixture screw adjustment, ensuring a baseline for smooth idling.

Reference the **recommended** flywheel torque for installation. keyboard_arrow_down

100 lb. ft. (136 N·m) is the recommended torque for the flywheel locknut, ensuring secure installation.

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Reviews (5)

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As a first-time boat owner, this manual was a lifesaver. The download was smooth and customer support was very accommodating. Highly satisfied!
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This manual has every detail I need for my Mariner. The download process was seamless and support was quick to respond to my questions. Highly recommend!
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Rated 5 out of 5 stars
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I love how detailed this manual is! The support team was very professional and helped me with my queries swiftly. Great experience overall!
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I found this manual incredibly helpful for servicing my outboard motor. The email with the download link arrived promptly. Excellent service!