Mercury Marine Parts Accessories and Manuals. Copyright 2018 Mercury Marine. All Rights Reserved. Ecommerce Software by Volusion. View our SSL. This manual has been prepared to assist you in the operation, safe use, and care of your outboard. All of us at Mercury. Provides timely service for all Mercury Marine customers. 40, 50, 60 hp 4 cylinder OP401000, or 1C010000.

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1965-1989 Service Manual Application: 2 hp To 40hp 2 Stroke 1 & 2 cylinder engines. We estimate that 75% of engine repair work can be directly or indirectly attributed to lack of proper care for the engine. This is especially true of care during the off-season period. There is no way on this green earth for a mechanical engine, particularly an outboard motor, to be left sitting idle for an extended period of time, say for six months, and then be ready for instant satisfactory service. Imagine, if you will, leaving your car or truck for six months, and then expecting to turn the key, having it roar to life, and being able to drive off in the same manner as a daily occurrence. Therefore it is critical for an outboard engine to either be run (at least once a month), preferably, in the water and properly maintained between uses or for it to be specifically prepared for storage and serviced again immediately before the start of the season.

Only through a regular maintenance program can the owner expect to receive long life and satisfactory performance at minimum cost. Many times, if an outboard is not performino properly, the owner will 'nurseU'it through the season with good intentions of working on the unit once it is no lonaer beina used, As with manv New Year's resolutions. The good intentions i r e not completed and the ohboard may lie for manimonths before the work is begun or the unit is taken to the marine shop for repair. Imagine, if you will, the cause of the problem being a blown head gasket. And let us assume water has found its way into a cylinder. This water, allowed to remain over a long period of time, will do considerably more damage than it would have if the unit had been disassembled and the repair work performed immediately. Therefore, if an outboard is not functioning properly, do not stow it away with promises to get at it when you get time, because the work and expense will only get worse, the longer corrective action is postponed.

In the example of the blown head gasket, a relatively simple and inexpensive repair job could very well develop into major overhaul and rebuild work. OK, perhaps no one thing that we do as boaters will protect us from risks involved with enjoying the wind and the water on a powerboat. But, each time we perform maintenance on our boat or motor, we increase the likelihood that we will find a potential hazard before it becomes a problem.

Each time we inspect our boat and motor, we decrease the possibility that it could leave us stranded on the water. In this way, performing boat and engine service is one of the most important ways that we, as boaters, can help protect ourselves, our boats, and the friends and family that we bring aboard. Owners of sailboats pride themselves in their ability to use the wind to clear a harbor or for movement from Port A to Port B, or maybe just for a day sail on a lake. For some, the outboard is carried only as a last resort - in case the wind fails completely, or in an emergency situation or for ease of docking. Therefore, in some cases, the outboard is stowed below, usually in a very poorly ventilated area, and subjected to moisture and stale air - in short, an excellent environment for 'sweating' and corrosion. If the owner could just take the time at least once every month, to pull out the outboard, clean it up, and give it a short run, not only would heishe have 'peace of mind knowing it will start in an emergency, but also maintenance costs will be drastically reduced. We strongly feel that every boat owner should pay close attention to this section.

We also know that it is one of the most frequently used portions of our manuals. The material in this section is divided into sections to help simplify the process of maintenance. Be sure to read and thoroughly understand the various tasks that are necessary to keep your outboard in tip-top shape. Topics covered in this section include: 1.

General Information (What Everyone Should Know About Maintenance) - an introduction to the benefits and need for proper maintenance. A guide to tasks that should be performed before and after. Maintenance you will conduct will be the Lubrication Service.

This section takes you through each of the various steps you must take to keep corrosion from slowly destroying your motor before your very eyes. Engine Maintenance -the various procedures that must be performed on a regular basis in order to keep the motor and all of its various systems operating properly. Boat Maintenance -the various procedures that must be performed on a regular basis in order to keep the boat hull and its accessories looking and working like new. Tune-up - also known as the pre-season tune-up, but don't let the name fool you. A complete tune-up is the best way to determine the condition of your outboard while also preparing it for hours and hours of hopefully trouble-free enjoyment.

Winter Storage and Spring Commissioning Checklists - use these sections to guide you through the various parts of boat and motor maintenance that protect your valued boat through periods of storage and return it to operating condition when it is time to use it again. Specification Charts - located at the end of the section are quickreference, easy to read charts that provide you with critical information such as General Engine Specifications, Maintenance Intervals, Lubrication Service (intervals and lubricant types) and Capacities.

From 1965 to 2004 Mercury produced a large number of models with regards to horsepower ratings, as well a large number of trim and option variances on each of those models. In this manual, we've included all of the 1-4 cylinder inline models (of both 2 and 4-stroke designs). We chose to do this because of the many similarities these motors have to each other. But, enough differences exist that many procedures will apply only to a sub-set of these motors. When this occurs, we'll either refer to the differences within a procedure or, if the differences are significant, we'll break the motors out and give separate procedures.

In order to prevent confusion, we try to sort and name the models in a way that is most easily understood. In many cases, it is simply not enough to refer to a motor as a 9.9 hp model, since in these years Mercury produced four different 2- cylinder motors with that rating (the 211cc Cstroke, the 216cc 2-stroke, the 255cc 2-stroke, and the 305cc 4-stroke). Across that same year span, Mercury produced and sold no fewer than 4 different 2-stroke motors rated at 25hp (the 2-cylinder, 521cc, the 2-cylinder 737cc, the 3- cylinder 913cc and the 3-cylinder 933cc). This makes proper engine identification important for everything from ordering parts to even just using the procedures in this manual. Throughout this manual we will make reference to motors the easiest way possible. In some cases procedures will apply to all 2-strokes or all 4- strokes, in other cases, they will apply to all I-cylinder or all 2-cylinder motor (or all 3 or 4-cylinder motors, as applicable).

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When it is necessary to distinguish beiween different types of moto'rs with the same number of cvlinders. We'll differentiate usina the Ho ratina or, since different motors may iave the'same rating, we'll use?he Hp;ahg blus the size. In most cases, ' mechanical procedures will be similar or the same across different Hp ratings of the same engine family (of the same size).

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So it won't be uncommon to see a title or a procedure refer to 9.911 5 hp (255cc) motors or 9.911 5 hp (305cc) motors. In both cases, we would be referring to the 9.9 or 15 hp motors of a particular family, including all Rope Start, Tiller Electric or Remote Electric Models. In the case of the 9.9115 hp (255cc) motors, we would be referring to the 2-strokes, of that size, including any Sail, Commercial or other special models. To help with proper engine identfication, all of the engines covered by this manual are listed in the General Engine and General Engine System Specifications charts at the end of this section. In these charts, the engines are listed with their respective engine families, by horsepower rating, number of cylinders, engine type (2- or 4-stroke), years of production and displacement (cubic inches and cubic centimeters or CCs). But, whether you are trying to tell which version of a particular horsepower rated motor you have in order to follow the correct procedure or are trying to order replacement parts, the absolute best method is to start by referring to the engine serial number tag. For all models covered by this manual.