1995-2001 Mercury 40, 45, 50 4-Stroke Outboard Motor Service Manual

Covers: Mercury/Mariner 40, 45, 50, 50 Bigfoot Four Stroke, Carb Outboard Motor

• S/N 0G231123 and Above
• 1995-2001 model years

Pages: 599
Format: PDF
File size: 16mb
Compatibility: Windows/Mac/Tablet/Smartphone

Don’t let a stalled motor or a clogged carb ruin your weekend on the water. Skip the dealer wait times and get the official Mercury/Mariner 40hp, 45hp, and 50hp 4-stroke carbureted service manual in a clean, instant PDF download. This comprehensive shop guide covers standard and Bigfoot models from 1995 to 2001, giving you the exact technical guide professional marine mechanics use to diagnose, tune, and overhaul these legendary outboards.

Packed with high-resolution illustrations, step-by-step disassembly guidelines, and exact factory tolerances, this outboard manual takes the guesswork out of marine service:

• Powerhead Overhaul: Complete teardown and reassembly specs for the 4-stroke block, crankshaft, pistons, and valvetrain.
• Carburetor & Fuel System: Comprehensive cleaning, synchronization, float level adjustments, and fuel pump rebuilding instructions.
• Lower Unit & Gearcase: Detailed service steps for both standard and high-thrust Bigfoot gearcases, including shimming, propeller shaft seals, and water pump impeller replacement.
• Electrical & Ignition: Clear wiring diagrams and troubleshooting steps for the starter motor, charging coils, and CDI ignition modules.
• Midsection & Bracket: Servicing power trim and tilt assemblies, steering pivots, and swivel brackets.

Instant Email by Delivery: No waiting around for a bulky binder to ship. Your PDF download link lands in your inbox within minutes of checkout so you can fix it today. Save the file to your smartphone, tablet, or laptop. Pull up a wiring diagram or check a fluid capacity right at the boat ramp, on the trailer, or out on the water.

Topics:

Important Information

• Specifications
• Maintenance
• General Information
• Outboard Motor Installation

Electrical

• Ignition
• Charging & Starting System
• Timing, Synchronizing & Adjusting
• Wiring Diagrams

Fuel System

• Fuel Pump
• Carburetor
• Emissions

Powerhead

• Cylinder Head
• Cylinder Block/Crankcase
• Lubrication

Mid-Section

• Clamp/Swivel Brackets & Drive Shaft Housing
• Power Trim (1998 And Earlier Non-Bigfoot)
• Power Trim (1999 And Later Non-Bigfoot/All Big-Foot Model Years)
• Manual Tilt Assist

Gear Housing

• Non-Bigfoot Gear Housing
• Bigfoot Gear Housing

Attachments/Control Linkage

• Throttle/Shift Linkage
• Tiller Handle