Mercury Marathon-Seapro 60-60 Manuals

Manuals and User Guides for Mercury Marathon-Seapro 60-60. We have 1 Mercury Marathon-Seapro 60-60 manual available for free PDF download: Service Manual

Mercury Marathon-Seapro 60-60 Service Manual

Mercury Marathon-Seapro 60-60 Service Manual (564 pages)

Brand: Mercury | Category: Outboard Motor | Size: 15.81 MB

Table of Contents

General Information 1

4
Electrical and Ignition 2

30
- Description
  31
- Test Procedures
  31
  - Direct Voltage Adapter (DVA) Tests
    31
  - Test Sequence
    32
  - Ignition System Test Chart
    33
    
    Stator Test
    34
    
    Ignition Coil Test
    35
    
    Trigger Test
    35
- ADI Ignition Using a RED Stator with an Adapter Module
  35
- RED Stator with Adaptor and Ignition Coils
  36
  - RED Stator DVA Test
    36
  - Electric Start Engines
    36
  - Manual Start Engines
    36
  - Troubleshooting Procedures
    36
- Ignition (Key) Switch Test
  37
- Ignition Components Removal and Installation
  37
  - Flywheel
    37
    
    Removal
    37
    
    Installation
    38
  - BLACK and RED Stator
    38
    
    Removal
    38
    
    BLACK Stator Installation
    39
    
    RED Stator Installation
    39
  - Trigger
    40
    
    Removal
    40
    
    Installation
    40
  - Ignition Coils
    41
  - Switch Box
    41
Electrical 2

43
- Battery
  44
  - Precautions
    44
  - Recommended Battery
    44
  - Operating Engine Without Battery
    44
  - Specific Gravity Readings
    44
    
    Specific Gravity Cell Comparison Test
    45
  - Electrolyte Level
    45
  - Charging a Discharged Battery
    45
  - Winter Storage of Batteries
    46
- Battery Charging System
  46
- Starting System
  55
  - Starting System Components
    55
  - Description
    55
  - Troubleshooting the Starting Circuit
    55
- Starter Motor
  58
  - Removal
    58
  - Disassembly
    58
  - Cleaning and Inspection
    59
  - Testing
    59
    
    Armature Test for Shorts
    59
    
    Armature Test for Ground
    60
    
    Checking Positive Brushes and Terminals
    60
    
    Testing Negative Brushes for Ground
    60
    
    Starter Solenoid Test
    61
  - Brush Replacement
    61
  - Reassembly
    61
  - Installation
    63
Electrical and Ignition 2

65
- Special Tools
  66
- Specifications
  66
- Timing Pointer Adjustment
  66
- Timing/Synchronizing/Adjusting
  66
- Carburetor Synchronization
  67
- Timing Adjustments
  68
  - Idle Timing Adjustment
    68
  - Maximum Timing
    69
- Idle Adjustment
  69
- Throttle Cable Installation
  69
Electrical and Ignition 2

71
Fuel Systems

85
- Special Tools
  86
- Specifications
  86
- Attenuator Plate
  87
- WME Carburetor Specifications
  89
  - Reed Valve Specifications
    89
- Notes
  90
- Carburetor
  91
- Carburetion
  93
  - Fuel System Troubleshooting
    93
  - Troubleshooting Charts
    93
  - Carburetor Adjustments
    96
    
    Initial Starting Adjustment
    96
    
    Idle Speed Adjustment
    96
    
    Idle Mixture Screw Adjustment
    96
    
    Carburetor Float Adjustment
    96
    
    Main (High Speed) Jet Adjustment
    96
- WME Carburetor Specifications
  97
  - Rejetting Carburetors for High Altitude Operation
    97
  - Jet Orifice Size/Part Number Chart
    97
  - Carburetor Removal
    98
  - Carburetor Disassembly
    98
  - Cleaning and Inspection
    100
  - Carburetor Reassembly
    100
  - Carburetor Installation
    102
Fuel Systems

104
- Specifications
  105
- Fuel Pump (50/60)
  106
- Fuel Pump (55/60 Seapro/Marathon)
  108
- Fuel Pumps
  110
  - General Information
    110
    
    Fuel Pump Description/Operation
    110
    
    Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
    110
  - Testing
    110
  - Troubleshooting Fuel Pump
    111
- Cleaning and Inspection
  112
- Fuel Pump Disassembly
  112
- Fuel Pump Removal
  112
- Fuel Pump Reassembly
  113
  - Check Valve Assembly
    113
  - Fuel Pump Assembly
    113
- Fuel Pump Exploded View
  114
- Fuel Tank
  115
  - Maintenance
    115
- Fuel Tank Components
  115
- Fuel Line and Primer Bulb Assembly
  116
  - Maintenance
    117
    
    Enrichener System
    120
    
    Enrichener Valve Test
    121
Fuel Systems

123
Powerhead

139
- Quicksilver Lubricants and Service Aids
  140
- Special Tools
  140
- Specifications
  140
- Cylinder Block and Crankcase
  141
- Induction Manifold and Reed Block
  145
- Crankshaft, Pistons and Connecting Rods
  147
- Throttle Lever and Linkage
  149
- Powerhead Torque Sequence
  151
- General Information
  152
  - ELPTO Model
    152
- Powerhead Disassembly
  155
  - Removing Engine Components
    155
  - Crankshaft Disassembly
    157
- Cleaning and Inspection
  160
  - Cylinder Block and Crankcase Cover
    160
    
    Honing Procedure
    160
  - Check Valves
    161
  - Piston and Piston Rings
    161
    
    Cleaning Piston Ring Grooves
    162
    
    Measuring Piston Skirt
    162
  - Crankshaft
    162
  - Connecting Rods
    163
  - Thermostat
    163
  - Reed Blocks
    164
- Powerhead Reassembly and Installation
  165
  - General Information
    165
  - End Cap
    165
  - Assembling Rod to Piston
    165
  - Piston Ring Installation
    167
  - Crankshaft Installation
    169
  - Connecting Rod Cap Alignment
    171
  - Crankcase Cover to Block
    171
  - Intake/Reed Block Manifold Installation
    173
  - Thermostat Cover Installation
    174
  - Install Remaining Engine Components
    174
- Important Information
  177
- Test Run Procedure
  177
MID-Section

179
- MID-Section Components
  180
  - Swivel Bracket Components
    180
  - Transom Bracket Components (50/60 Models)
    182
- MID-Section Components
  182
  - Drive Shaft Housing Components
    183
- Disassembly
  184
- Reassembly
  184
  - Tilt Lock Lever/Transom Bracket
    184
- Drive Shaft Housing
  186
MID-Section

188
- Power Trim General Information
  189
  - Description
    189
  - Trimming Characteristics
    189
    
    Trimming Outboard "Up" ("Out")
    189
    
    Trimming Outboard "Down
    189
  - Trailering Outboard
    190
  - Tilting Outboard up and down Manually
    190
  - Trim "In" Angle Adjustment
    190
- Power Trim System Components
  191
  - Torque Specifications
    191
  - Quicksilver Lubricants and Service Aids
    191
- Power Trim Flow Diagrams Design
  192
  - Determine if Problem Is Electrical or
    199
    
    Hydraulic
    199
  - Trouble Chart
    199
  - Hydraulic System Troubleshooting
    200
  - Preliminary Checks
    200
  - Leak down Check - Pump and Manifold
    200
    
    Assembly
    201
  - Leak down Check - Pilot Valve Assembly
    201
  - Leak down Check - Manual Release
    201
    
    Valve
    201
  - Leakage Past Ball and Seat - Piston Assembly
    201
  - Troubleshooting Flow Diagram
    202
  - Troubleshooting Flow Diagram
    203
- Electrical System Troubleshooting
  204
  - COMMANDER 2000 Side Mount Remote
    204
  - Power Trim System Wiring Diagram
    205
    
    Troubleshooting the "Down" Circuit* (When "Up" Circuit Is OK)
    206
    
    Troubleshooting the "Up" Circuit* (When "Down" Circuit Is OK)
    207
    
    Troubleshooting the "Down" and "Up" Circuits
    208
- Power Trim System Removal
  209
- Power Trim System Disassembly
  210
  - Trim Rod Removal
    210
  - Trim Rod Disassembly
    211
  - Trim "Motor" Removal
    213
  - Trim "Motor" Disassembly
    213
  - Reservoir Assembly Removal
    214
  - Oil Pump Removal
    215
  - Manifold Removal
    215
- Cleaning and Inspection of Trim Rod Components
  216
- Motor and Electrical Tests/Repair
  217
  - Trim Pump Motor Test
    217
  - Thermal Overload Switch Test
    217
    
    Motor Assembled
    217
    
    Motor Disassembled
    217
  - Armature Tests
    218
    
    Test for Shorts
    218
    
    Test for Ground
    218
    
    Checking and Cleaning Commutator
    218
- Power Trim System Reassembly
  218
  - Manifold Installation
    218
  - Oil Pump Installation
    219
  - Trim Motor Reassembly
    220
  - Reservoir Installation
    221
  - Trim Rod Reassembly
    223
  - Trim Rod Installation
    224
- Bleeding Power Trim Unit
  225
  - Power Trim Unit Installation
    225
MID-Section

228
- Power Trim General Information
  229
  - Trimming Characteristics
    229
    
    Trimming Outboard "Up" ("Out")
    229
    
    Trimming Outboard "Down" ("In")
    229
  - Trailering Outboard
    230
  - Tilting Outboard up and down Manually
    230
  - Trim "In" Angle Adjustment
    230
- Design II
  232
- Design II
  233
- Design II
  234
- Design II
  235
- Design II
  236
- Design II
  237
- Troubleshooting
  239
  - Determining if Problem Is Electrical or Hydraulic
    239
  - Trouble Chart
    239
  - Hydraulic System Troubleshooting
    240
  - Preliminary Checks
    240
  - Leak down Check - Pump and Manifold
    240
    
    Assembly
    241
  - Leak down Check - Pilot Valve Assembly
    241
  - Leak down Check - Manual Release Valve
    241
  - Leakage Past Ball and Seat - Piston Assembly
    241
  - Troubleshooting Flow Diagram
    242
  - Troubleshooting Flow Diagram
    243
- Electrical System Troubleshooting
  244
  - COMMANDER 2000 Side Mount Remote
    244
  - Power Trim System Wiring Diagram
    245
    
    Troubleshooting the "Down" Circuit* (When "Up" Circuit Is OK)
    246
    
    Troubleshooting the "Up" Circuit* (When "Down" Circuit Is OK)
    247
    
    Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
    248
- Power Trim System Removal
  249
- Power Trim System Disassembly
  250
  - Trim Rod Removal
    250
  - Trim Rod Disassembly
    251
  - Trim "Motor" Removal
    253
  - Reservoir Assembly Removal
    254
  - Oil Pump/Manifold Removal
    255
- Cleaning and Inspection of Trim Rod Components
  256
- Motor and Electrical Tests/Repair
  257
  - Trim Pump Motor Test
    257
  - Thermal Overload Switch Test
    257
    
    Motor Assembled
    257
    
    Motor Disassembled
    257
  - Armature Tests
    258
    
    Test for Shorts
    258
    
    Test for Ground
    258
    
    Checking and Cleaning Commutator
    258
- Power Trim System Reassembly
  258
  - Manifold/Oil Pump Installation
    258
  - Trim Motor Reassembly
    259
  - Reservoir Installation
    261
  - Trim Rod Reassembly
    262
  - Trim Rod Installation
    263
- Bleeding Power Trim Unit
  264
  - Power Trim Unit Installation
    265
MID-Section

268
- Power Trim - General Information
  269
  - Description
    269
  - Trimming Characteristics
    269
    
    Trimming Outboard "Up" ("Out")
    269
    
    Trimming Outboard "Down" ("In")
    269
  - Trailering Outboard
    270
  - Tilting Outboard up and down Manually
    270
  - Trim "In" Angle Adjustment
    270
- Special Tools
  269
- Troubleshooting
  272
- Power Trim System Removal
  282
- Power Trim System Disassembly
  283
  - Trim Rod Removal
    283
  - Trim Rod Disassembly
    284
  - Trim "Motor" Removal
    286
  - Trim "Motor" Disassembly
    286
  - Reservoir Assembly Removal
    286
  - Manifold Removal
    287
- Cleaning and Inspection of Trim Rod Components
  288
- Motor and Electrical Tests/Repair
  288
  - Trim Pump Motor Test
    288
  - Armature Tests
    288
    
    Test for Shorts
    288
    
    Test for Ground
    288
    
    Checking and Cleaning Commutator
    289
- Power Trim System Reassembly
  289
  - Manifold Installation
    289
  - Trim Motor Reassembly
    290
  - Reservoir Installation
    291
  - Trim Rod Reassembly
    292
- Purging Power Trim Unit
  294
  - Power Trim Unit Installation
    294
MID-Section

298
- Special Tools
  299
- Adjustments
  302
  - Trimming Characteristics
    302
    
    Trimming Outboard "Up" ("Out")
    302
    
    Trimming Outboard "Down
    302
  - Trailering Outboard
    303
  - Tilting Outboard up and down Manually
    303
  - Trim up
    305
  - Tilt up
    307
  - Maximum Tilt
    308
  - Down Mode
    311
  - Shock Function up
    312
  - Shock Function Return
    314
  - Manual Tilt
    317
- Theory of Operation
  302
- Troubleshooting
  318
- Power Trim System Removal
  325
- Power Trim Disassembly
  326
  - Trim Motor Removal
    327
  - Pump and Components Removal
    327
  - Manifold Removal
    328
  - Shock Rod Removal
    328
- Shock Rod Disassembly
  329
  - Memory Piston Removal
    331
- Cleaning/Inspection/Repair
  332
  - Trim Motor Electrical Tests
    332
- Reassembly
  333
  - O-Ring and Seal Placement
    333
- O-Ring Sizes
  334
- O-Ring Description and Sizes
  335
- Power Trim Reassembly
  336
  - Shock Rod Reassembly
    336
  - Shock Rod Installation
    337
  - Trim Limit Assembly Installation
    338
  - Manual Release Valve Installation
    338
  - Manifold Installation
    338
  - Oil Pump Installation
    339
  - Pressure Operated Assembly Installation 5E-42
    340
  - Reservoir/Motor Installation
    340
  - Bleeding Power Trim Unit
    341
- Installation of Power Trim System
  341
MID-Section

345
- Manual Tilt System Components
  345
  - Quicksilver Lubricant/Sealant Application
    345
  - Torque Specification
    347
  - Three)
    347
  - Points
    347
- Manual Tilt Flow Diagrams Design
  348
- Manual Tilt Flow Diagrams Design
  353
- Manual Tilt Flow Diagrams Design
  358
- Hydraulic System Troubleshooting
  363
- Troubleshooting Flow Chart
  364
- Manual Tilt System Removal
  366
- Manual Tilt System Disassembly
  367
  - Accumulator Removal
    367
- Shock Rod Disassembly
  369
  - Valve Block Removal
    371
- Valve Block Disassembly
  372
- Manual Tilt System Cleaning and Inspection
  373
- Manual Tilt System Reassembly
  373
  - Valve Block Reassembly
    373
  - Valve Block Installation
    375
  - Shock Rod Reassembly
    375
  - Shock Rod Installation
    377
- Instructions for Making Retaining Tool
  378
- Bleeding Manual Tilt System
  379
MID-Section

383
- Special Tools
  384
  - Tilt up
    388
  - Tilt down
    390
  - Slow Tilt down under High Thrust
    391
  - Under Water Strike
    393
  - Shock Function
    395
  - With Valves Closed
    396
  - Shock Function Return
    397
- Hydraulic System Troubleshooting
  399
- Manual Tilt System Removal
  400
- Manual Tilt System Disassembly
  401
  - Accumulator Removal
    401
  - Shock Rod Removal
    402
- Shock Rod Disassembly
  403
  - Valve Block Removal
    405
  - Memory Piston Removal
    405
- Valve Block Disassembly
  406
- Actual O-Ring Sizes
  408
- O-Ring Description and Sizes
  409
- Manual Tilt System Cleaning and Inspection
  410
- Manual Tilt System Reassembly
  410
  - Cam Shaft Reassembly
    410
  - Valve Body Check Reassembly
    410
  - Velocity Valve Reassembly
    410
  - Check Retainer Reassembly
    411
  - Valve Plug Reassembly
    411
  - Valve Block Installation
    411
  - Shock Rod Reassembly
    412
  - Shock Rod Installation and Fluid Filling Procedure
    413
- Instructions for Making
  415
- Retaining Tool
  415
- Bleeding Manual Tilt System
  416
- Manual Tilt System Installation
  418
- Manual Release Valve Adjustment
  419
Lower Unit

421
- Lubrication/Sealant Application Points
  423
- Propeller Shaft Components
  423
- Torque Specifications
  423
- Draining and Inspecting Gear Lubricant
  426
- Gear Housing Removal
  427
- Propeller Removal
  427
- Gear Housing Disassembly
  428
  - Water Pump
    428
  - Bearing Carrier and Propeller Shaft
    429
  - Propeller Shaft Disassembly
    431
  - Pinion Gear, Driveshaft and Forward Gear
    432
  - Upper Driveshaft Bearing
    432
  - Lower Driveshaft Bearing
    433
  - Forward Gear Bearing Race
    433
  - Shift Shaft
    433
- Gear Housing Reassembly
  434
  - Shift Shaft
    434
  - Propeller Shaft
    435
  - Forward Gear Bearing Race
    436
  - Bearing Carrier
    436
  - Reverse Gear
    437
  - Forward Gear
    438
  - Lower Driveshaft Bearing Installation
    438
  - Upper Driveshaft Bearing Installation
    439
  - Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer and Driveshaft Installation
    439
  - Pinion Gear Location and Forward Gear Backlash
    440
    
    Determining Pinion Gear Location
    440
    
    Determining Forward Gear Backlash
    441
  - Bearing Carrier and Propeller Shaft Installation
    442
  - Water Pump Re-Assembly and Installation
    443
- Gear Housing Installation
  445
  - Filling Gear Housing with Lubricant
    445
  - Gear Housing Installation
    446
  - Propeller Installation
    447
  - Trim Tab Adjustment and Replacement
    448
- Gear Housing Pressure Test
  445
Lower Unit

450
- Notes
  451
- Gear Housing (Drive Shaft)
  453
- Gear Housing (Propeller Shaft)
  455
- Removal
  458
  - Propeller Removal
    458
  - Draining and Inspecting Gear Housing Lubricant
    459
  - Water Pump
    460
  - Bearing Carrier and Propeller Shaft
    461
  - Pinion Gear, Drive Shaft, and Forward Gear
    464
  - Upper Drive Shaft Bearing
    465
  - Oil Sleeve
    466
  - Lower Drive Shaft Bearing Race
    466
  - Shift Shaft
    467
  - Forward Gear Bearing Race
    468
  - Trim Tab Adjustment and Replacement
    468
- Special Tools
  458
- Reassembly
  468
- Filling Gear Housing with Lubricant
  481
- Propeller Installation
  482
- Gearcase Installation
  483
  - Trim Tab Adjustment
    484
Lower Unit

486
- Notes
  487
- Jet Pump Assembly
  488
- Jet Components
  490
- Engine Horsepower Selection
  491
- Selecting a Boat Best Suited for Jet Power
  491
- Locate Center Line of the Outboard
  492
- Outboard Mounting Height
  492
- Transom Height of the Boat
  492
- Checking for Cavitation
  493
- Water Testing
  493
- Shift Cable Installation
  494
- Impeller Removal and Installation
  495
- Lubricating the Drive Shaft Bearing
  495
- Impeller Clearance Adjustment
  497
- Steering Pull Adjustment
  497
- Worn (Dull) Impeller
  497
- Flushing the Cooling System
  498
- Jet Drive Removal
  498
- Liner Replacement
  498
- Bearing Carrier Removal
  499
- Bearing Carrier Disassembly
  500
- Bearing Carrier Reassembly
  500
  - Installing Lower Seals
    500
  - Installing Upper Seals
    501
  - Installing Drive Shaft Ball Bearing
    501
  - Installing Drive Shaft
    501
- Installing Jet Drive to Drive Shaft Housing
  503
  - Reassembling Water Pump to Jet Drive . 6C-17
    503
  - Installing Jet Drive to Drive Shaft Housing 6C-18
    504
- Jet Drive Tiller Handle Adaptor Kit
  506
  - Installation Instructions
    506
  - Shift Cable Adjustment
    509
Outboard Installation/ Attachments

511
- Installing Outboard Motor on Transom
  512
- Steering Cable Installation
  516
- Dual Steering Installation
  520
  - Steering Coupler Assembly
    520
  - Installation
    521
    
    Models with Forged Two Hole Steering
    521
    
    Arm and One Piece Top Cowl
    521
    
    Models with Two Hole Two Piece Steering Arm/Bracket and One Piece Top Cowl
    522
  - Ride-Guide Steering Attachment
    523
  - Extension Couplers
    523
  - Trim Tab Adjustment
    523
    
    Dual Outboard
    523
  - Maintenance Instructions
    523
- Transom Mounted Ride-Guide Attaching Kit Installation
  524
  - Attaching Kit Installation
    524
- Clevis Attaching Kit Installation
  525
  - Installation Instructions
    525
  - Steering Cable Installation
    526
  - Maintenance Instructions
    526
- Remote Control Installation
  527
  - Shift Cable Installation and Adjustment to Engine
    527
  - Throttle Cable Installation and Adjustment to Engine
    528
  - Connecting Remote Control Wiring Harness to Engine Wiring Harness (Electric Start Models)
    528
  - Power Trim Wiring Connections (Models Equipped)
    529
  - Battery Connections
    529
  - Notes
    532
  - Steering Handle Kit
    533
  - Tiller Handle Adaptor Kit (JET 45)
    539
    
    Tiller Arm/Shift Lever Removal
    540
    
    Tiller Handle Disassembly
    542
    
    Tiller Arm Reassembly
    545
    
    Tiller Arm/Shift Lever Installation
    548
    
    Shift Link Rod Installation and Adjustment to Engine
    550
    
    Throttle Cable Installation and Adjustment
    551
    
    Co-Pilot Installation
    552
    
    Wiring Harness Connection
    554
  - Notes
    558
  - Rewind Starter Disassembly
    561
    
    Cleaning and Inspection
    562
  - Rewind Starter Reassembly
    562
    
    Adjusting Rewind Spring Tension
    563
    
    Starter Interlock Cable Adjustment
    564

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