Mercury 60 FourStroke EFI Formula Race Manual
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Mercury 60 FourStroke EFI Formula Race Manual

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See also: Service Manual , Operation & Maintenance Manual
Thank You
for your purchase of one of the finest power packages
available. You have made a sound investment in boating
pleasure. Your power package has been manufactured by
Mercury Marine, a world leader in marine technology and
manufacturing since 1939. These years of experience have
been committed to the goal of producing the finest quality
products. This led to Mercury Marine's reputation for strict
quality control, excellence, durability, lasting performance and
being the best at providing after the sale support.
Please read this manual carefully before operating your power
package. This manual has been prepared to assist you in the
operation, safe use and care of your power package.
All of us at Mercury Marine took pride in building your power
package and wish you many years of happy and safe boating.
Again, thank you for your confidence in Mercury Marine.
Safety Alerts and Notices
The operator (driver) is responsible for the correct and safe
operation of the boat, the equipment aboard and the safety
of all occupants aboard. We strongly recommend that the
operator read this Operation, Maintenance and Warranty
Manual and thoroughly understand the operational
instructions for the power package and all related
accessories before the boat is used.
Mercury Racing,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585
WARNING
!
i
7406

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  • Page 1 This manual has been prepared to assist you in the operation, safe use and care of your power package. All of us at Mercury Marine took pride in building your power package and wish you many years of happy and safe boating.
  • Page 2 Throughout this publication, dangers, warnings, cautions, and notices, accompanied by the international HAZARD symbol are used to alert the technician to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.6‑2006 for product safety information in product manuals, instructions, and other collateral materials.
  • Page 3 Mariner, Verado, Vazer, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, SmartCraft, VesselView, Quicksilver, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.

  • Page 5: Table Of Contents

    Impact with Underwater Hazards..........11 Exhaust Emissions..............12 Selecting Accessories for Your Outboard........13 Safe Boating Suggestions............14 Recording Serial Number............16 60 FourStroke EFI Formula Race Engine Specifications..16 Component Identification............18 TRANSPORTING Trailering Boat/Outboard ............19 Transporting Portable Fuel Tanks..........20...
  • Page 6 TABLE OF CONTENTS FUEL AND OIL Fuel Recommendations.............21 Filling Fuel Tank................ 23 Engine Oil Recommendations...........23 Checking and Adding Engine Oil..........24 FEATURES AND CONTROLS Remote Control Features............26 Warning Light and Guardian............27 Overspeed Rev Limit..............29 Power Trim and Tilt..............30 Steering Friction Adjustment............34 Trim Tab Adjustment..............35 OPERATION Pre‑Starting Check List..............36...
  • Page 7 TABLE OF CONTENTS MAINTENANCE Outboard Care................45 EPA Emissions Regulations............45 Inspection and Maintenance Schedule........46 Flushing the Cooling System.............48 Top Cowl Removal and Installation...........49 Exterior Care................50 Battery Inspection ..............50 Fuel System................51 Corrosion Control Anode............52 Propeller Replacement ‑ 87.3 mm (3 ‑ 7/16 in.) Diameter Gearcase ....................53 Spark Plug Inspection and Replacement........
  • Page 8 OWNER SERVICE ASSISTANCE Local Repair Service..............72 Service Away from Home............72 Parts and Accessories Inquiries..........72 Service Assistance..............72 Mercury Marine Service Offices..........73 OUTBOARD INSTALLATION Installation Information............... 75 Installing Outboard..............77 Steering Arm Installation............81 Fuel Hose Connection ‑ Remote Control Models......83 Water Pressure Hose Connection..........84...

  • Page 9: Emissions Information

    EMISSIONS INFORMATION Star Label Outboards are labeled on the cowl with one of the following star labels. The Symbol for Cleaner Marine Engines Means: Cleaner Air and Water ‑ for a healthier lifestyle and environment. Better Fuel Economy ‑ burns up to 30‑40 percent less gas and oil than conventional carbureted two‑stroke engines, saving money and resources.

  • Page 10: Epa Emissions Regulations

    Engines meeting these standards have 90% lower emissions than One Star ‑ Low Emission engines. EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors.

  • Page 11: Warranty Coverage

    The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Warranty Coverage Mercury Racing does not offer a warranty with this power package.

  • Page 12: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard. Be sure at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.

  • Page 13: Boat Horsepower Capacity

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 14: Remote Steering Notice

    GENERAL INFORMATION WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. 26779 Remote Steering Notice Fasten the steering cables to the steering arms utilizing a secure method that will not work loose and vibrate off, enabling the steering cables to disengage.
  • Page 15 GENERAL INFORMATION The lanyard is a cord usually 122 ‑ 152 cm (4 ‑ 5 feet) in length when stretched out, with an element on one end made to be inserted onto the switch and a snap on the other end for attaching to the operator.
  • Page 16 GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

  • Page 17: Protecting People In The Water

    GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

  • Page 18: Wave And Wake Jumping

    GENERAL INFORMATION Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re‑enters the water.

  • Page 19: Impact With Underwater Hazards

    GENERAL INFORMATION Impact with Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 20: Exhaust Emissions

    Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Exhaust Emissions...

  • Page 21: Selecting Accessories For Your Outboard

    Running the boat with the trim angle of the bow too high Running the boat with no forward hatches open Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers.

  • Page 22: Safe Boating Suggestions

    The misuse of approved accessories or the use of non‑approved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.
  • Page 23 GENERAL INFORMATION Prepare other boat operators. Instruct at least one other person on board in the basics of starting and operating the outboard, and boat handling, in case the driver becomes disabled or falls overboard. Passenger boarding. Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat.

  • Page 24: Recording Serial Number

    Assembled in the USA from US and foreign components 30933 Serial number Model designation Month and year of Year manufactured manufacture 60 FourStroke EFI Formula Race Engine Specifications Model Horsepower Kilowatts 44.7 Full Throttle RPM Range 5500–6000 RPM Number of Cylinders...
  • Page 25 GENERAL INFORMATION Model Mercury or Quicksilver NMMA FC‑W certified synthetic blend 25W‑40‑4‑Stroke Outboard Recommended Engine Oil Refer to Fuel and Oil Engine Oil Capacity 3.0 Liter (3 Quarts) Recommended Gearcase Oil High Performance Gear Lube Gearcase Lubricant Capacity 87.3 mm (3‑7/16 in.) Diameter 340 ml (11.5 fl.

  • Page 26: Component Identification

    GENERAL INFORMATION Component Identification 33581 Auxiliary tilt switch Trim tab Tilt support knob Anti‑ventilation plate Transom brackets Driveshaft housing Oil drain plug Water pump indicator hole Primary cooling water intake Bottom cowl Gearcase Top cowl...

  • Page 27: Transporting

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways and trailer bouncing.

  • Page 28: Transporting Portable Fuel Tanks

    TRANSPORTING Transporting Portable Fuel Tanks WARNING Avoid serious injury or death from a gasoline fire or explosion. Follow the transporting instructions supplied with the portable fuel tank. Transport the fuel tank in a well ventilated area away from open flame or sparks. MANUAL VENTING TYPE FUEL TANK Close fuel tank air vent when transporting tank.

  • Page 29: Fuel And Oil

    FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R +M)/2 minimum.
  • Page 30 FUEL AND OIL The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 31: Filling Fuel Tank

    Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions. Engine Oil Recommendations We recommend the use of Mercury or Quicksilver NMMA FC‑W certified synthetic blend 25W‑40 4‑Stroke Outboard Oil for general, all‑temperature use. If SAE 10W‑30 oil is preferred, use Mercury or Quicksilver NMMA FC‑W certified 10W‑30 4‑Stroke Outboard...

  • Page 32: Checking And Adding Engine Oil

    FUEL AND OIL IMPORTANT: The use of non detergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality or oils that contain solid additives are not recommended.
  • Page 33 FUEL AND OIL 3. Pull the dipstick back out again and observe the oil level. If the oil level is low, remove the oil filler cap and fill to (but not over) the upper oil level with the recommended oil. IMPORTANT: Inspect oil for signs of contamination.

  • Page 34: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 26800 Control handle ‑...

  • Page 35: Warning Light And Guardian

    FEATURES AND CONTROLS Warning Light and Guardian START rob7 Ignition module Ignition switch Lanyard stop switch cap Start switch and stop switch Ignition/warning light When the ignition switch is toggled to the "ON" position, the warning light will turn on for a moment as a test to ensure it is working.
  • Page 36 FEATURES AND CONTROLS Light Mode Problem Guardian Monitor Display Air Compressor Temperature Sensor Failure Block Water Pressure Sensor Power Limit 10 Blinks Every 4 Failure Minutes Head Temperature Power Limit Sensor Failure Throttle Position Power Limit Sensor Failure Low Oil in Engine 4 Blinks Every 2 Oil Tank Minutes...

  • Page 37: Overspeed Rev Limit

    FEATURES AND CONTROLS SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this power package. A few functions some of the instrument packages will display are engine RPM, coolant temp, water pressure, battery voltage, fuel consumption and engine operating hours.

  • Page 38: Power Trim And Tilt

    FEATURES AND CONTROLS Power Trim and Tilt Your outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down.
  • Page 39 FEATURES AND CONTROLS The most significant control hazard is a pull or torque that is felt on the steering wheel or tiller handle. This steering torque results from the outboard trimmed so that the propeller shaft is not parallel to the water surface.
  • Page 40 FEATURES AND CONTROLS • Generally increase top speed • Increase clearance over submerged objects or a shallow bottom • Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller) • In excess can cause boat porpoising (bouncing) or propeller ventilation •...
  • Page 41 FEATURES AND CONTROLS 1. Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to the desired position and tighten the manual tilt release valve. 26809 NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.

  • Page 42: Steering Friction Adjustment

    FEATURES AND CONTROLS 1. Reduce engine speed below 2000 RPM. 2. Tilt outboard up, keeping the water intake holes submerged at all times. 3. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range.

  • Page 43: Trim Tab Adjustment

    FEATURES AND CONTROLS Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal result from your outboard not trimmed with the propeller shaft parallel to the water surface. The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.

  • Page 44: Operation

    OPERATION Pre‑Starting Check List • Operator knows safe navigation, boating, and operating procedures. • An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). • A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.

  • Page 45: Pre-Starting Instructions

    Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

  • Page 46: Starting The Engine

    OPERATION 1. For the first hour of operation, run the engine at varied throttle settings up to 3500 RPM or at approximately half throttle. 2. For the second hour of operation, run the engine at varied throttle settings up to 4500 RPM or at three‑quarter throttle, and during this period of time, run it at full throttle for approximately one minute every ten minutes.
  • Page 47 OPERATION 3. Install the lanyard stop switch cap onto the stop switch. See General Information ‑ Lanyard Stop Switch. START rob7 Ignition module Ignition switch Lanyard stop switch Start switch cap and stop switch Ignition/warning light 4. Shift outboard to neutral ("N") position. 26838 5.
  • Page 48 OPERATION 6. Move the throttle‑only lever to the fully closed position or press the throttle‑only button. 26840 Fully closed position Maximum fast idle speed position 7. Starting a flooded engine ‑ Advance the throttle‑only lever or control handle to the maximum throttle‑only position and continue to crank the engine for starting.

  • Page 49: Gear Shifting

    OPERATION Gear Shifting IMPORTANT: Observe the following: • Never shift outboard into gear unless engine speed is at idle. • Do not shift outboard into reverse when the engine is not running. • Your outboard has three gear shift positions to provide operation: forward, neutral (out of gear), and reverse.

  • Page 50: Stopping The Engine

    OPERATION Stopping The Engine 1. Reduce engine speed and shift outboard to neutral position. Toggle ignition switch to the "OFF" position. START 33690 Emergency Starting If the starter system fails, use the spare starter rope (provided) and follow procedure. NOTE: EFI models ‑ Engine must have a fully charged battery to start the engine.
  • Page 51 OPERATION WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear. 3. Toggle the ignition switch to the "ON" position. START 33685 WARNING...
  • Page 52 OPERATION 5. Pull the starter rope to start the engine. 26848...

  • Page 53: Outboard Care

    We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors.

  • Page 54: Inspection And Maintenance Schedule

    MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in gear):...
  • Page 55 MAINTENANCE • Check steering arm and cable fasteners for proper tightness. See Steering Arm Installation. • Check propeller blades for damage. AFTER EACH USE • Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the Cooling System. •...

  • Page 56: Flushing The Cooling System

    MAINTENANCE EVERY 300 HOURS OF USE OR THREE YEARS • Replace spark plugs at first 300 hours or third year. After that, inspect spark plugs every 300 hours or three years. Replace spark plugs as needed. See Spark Plug Inspection and Replacement.

  • Page 57: Top Cowl Removal And Installation

    MAINTENANCE 4. Shift the outboard into neutral. Start the engine and flush the cooling system for at least five minutes. Keep the engine speed at idle. 5. Stop the engine. Turn off the water and remove the hose. Reinstall the propeller. 28518 Top Cowl Removal and Installation REMOVAL...

  • Page 58: Exterior Care

    MAINTENANCE 2. Bring the front of the cowl down first and engage the front hook. Lower the cowl into its seated position and apply downward pressure to the back of the cowl to lock it in place. Gently pull up on the back of cowl to make sure it is securely fastened.

  • Page 59: Fuel System

    MAINTENANCE Fuel System WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.

  • Page 60: Corrosion Control Anode

    MAINTENANCE 3. Inspect the filter element. If replacement is necessary, replace the filter assembly. 28414 Cover O‑ring seal Filter element Sight bowl INSTALLATION IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter. 1.

  • Page 61: Propeller Replacement - 87.3 Mm (3 - 7/16 In.) Diameter Gearcase

    MAINTENANCE ANODE LOCATION - MODELS WITH 87.3 MM (3-7/16 IN.) GEARCASES One of the anodes is the trim tab installed on the gearcase. Another anode is installed on the bottom of the transom bracket assembly. 28884 Anode on the transom bracket assembly Trim tab Propeller Replacement ‑...
  • Page 62 4. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 26901 5. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C Marine Lubricant with Teflon. 26902 Tube Ref No.
  • Page 63 MAINTENANCE Tube Ref No. Description Where Used Part No. 2-4-C Marine 92-802859A Propeller shaft Lubricant with Teflon IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in salt water), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and each time the propeller is removed.

  • Page 64: Spark Plug Inspection And Replacement

    MAINTENANCE 8. Place the propeller nut retainer over the pins. Place a block of wood between the gearcase and the propeller and tighten the propeller nut to the specified torque. Description lb. in. lb. ft. Propeller nut 9. Align the flat sides of the propeller nut with the tabs on the propeller nut retainer.

  • Page 65: Fuse Replacement

    MAINTENANCE 2. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered, or fouled. 26946 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 1.0 mm (0.040 in.) 4.

  • Page 66: Timing Belt Inspection

    MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. 28900 Spare fuse slot Diagnostic circuit 4 pin connector ‑ 2 amp fuse SmartCraft data bus circuit ‑...

  • Page 67: Lubrication Points

    MAINTENANCE e. Signs of wear on edges or outer surfaces of belt. 26958 Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. Tube Ref No. Description Where Used Part No. Anti-Corrosion...

  • Page 68: Checking Power Trim Fluid

    MAINTENANCE • Swivel bracket ‑ Lubricate through fitting. 28466 Tilt support lever Swivel bracket • Tilt tube ‑ Lubricate through fitting. 28461 Checking Power Trim Fluid 1. Tilt the outboard to the full up position and engage the tilt support lock. 28474...

  • Page 69: Changing Engine Oil

    2. Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
  • Page 70 MAINTENANCE 2. Turn the outboard so the drain hole is facing downward. Remove the drain plug and drain the engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. 28531 Drain plug Drain hole CHANGING OIL FILTER 1.

  • Page 71: Gearcase Lubrication - For 87.3 Mm(3-7/16 In.) Diameter Gearcase

    MAINTENANCE 2. Idle the engine for five minutes and check for leaks. Stop the engine and check the oil level on the dipstick. Add oil if necessary. 28418 Oil fill cap Gearcase Lubrication ‑ For 87.3 mm (3‑7/16 in.) Diameter Gearcase When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant.
  • Page 72 MAINTENANCE 3. Remove vent plug and fill/drain plug and drain lubricant. 26973 Vent plug Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity approximately 340 (11.5 fl. oz.). CHECKING GEARCASE LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. 2.

  • Page 73: Submerged Outboard

    MAINTENANCE 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. 26975 Vent hole Fill/drain plug Vent plug Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 74: Storage

    STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer).

  • Page 75: Protecting External Outboard Components

    Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No. Description Where Used Part No.
  • Page 76 STORAGE • Remove the battery from the boat and check water level. Recharge if necessary. • Store the battery in a cool, dry place. • Periodically check the water level and recharge the battery during storage.

  • Page 77: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) POSSIBLE CAUSES • Blown fuse in the starting circuit. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 78: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Guardian System activated. Refer to Features & Controls - Warning System. • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a.
  • Page 79 TROUBLESHOOTING • Excessive use of electrical accessories. • Defective rectifier, alternator, or voltage regulator.

  • Page 80: Owner Service Assistance

    Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Parts and Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer.

  • Page 81: Mercury Marine Service Offices

    Model and serial number of your outboard • The name and address of your dealership • Nature of problem Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States Telephone Mercury Marine W6250 W.
  • Page 82 Mexico, Central America, South America, Caribbean Telephone Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744‑3500 (954) 744‑3535 U.S.A. Japan Telephone Mercury Marine - Japan 283-1 Anshin-cho Hamamatsu Shizuoka, 435-0005 81‑53‑423‑2500 81‑53‑423‑2510 Japan Asia, Singapore Telephone Mercury Marine Singapore 72 Loyang Way...

  • Page 83: Outboard Installation

    This prevents the engine from starting in gear. SELECTING ACCESSORIES FOR YOUR OUTBOARD Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers.

  • Page 84: Installation Specifications

    The misuse of approved accessories or the use of non‑approved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.
  • Page 85 OUTBOARD INSTALLATION LIFTING OUTBOARD Use the lifting eye on the engine. 28510...

  • Page 86: Installing Outboard

    OUTBOARD INSTALLATION Installing Outboard DRILLING OUTBOARD MOUNTING HOLES 1. Mark four mounting holes on the transom using the transom drill fixture. 2757 Drill guide holes Transom drilling fixture Transom center line Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes.
  • Page 87 OUTBOARD INSTALLATION 2. Drill four 13.5 mm (17/32 in.) mounting holes. 3973 CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb. ft.) of torque without the boat transom yielding or cracking.
  • Page 88 OUTBOARD INSTALLATION NOTE: The inside holes on the transom reinforcement plate are for the lower transom bolts and the outside holes are for the upper transom bolts. 20860 Large transom washer Transom reinforcement plate Description Part Number Large transom washer 67‑896392 Transom reinforcement plate 67‑896305...

  • Page 89: Steering Arm Installation

    OUTBOARD INSTALLATION NOTE: For a more accurate torque, turn/tighten the mounting locknuts rather than turning the mounting bolts. 28481 1/2 in. diameter bolt (4) Flat washer (4) Locknut (4) Description lb. in. lb. ft. Outboard mounting locknuts and bolts Steering Arm Installation IMPORTANT: Fasten the steering arms using the provided hardware.
  • Page 90 OUTBOARD INSTALLATION WARNING Damaged or loose steering components can lead to loss of steering control, which can cause serious injury or death. Properly secure all steering components to prevent them from becoming loose or disengaged. All steering hardware and fastening components must be appropriate for the application. 33550 Port Side Shown Flanged hexhead bolt (6) (10‑824459‑40)

  • Page 91: Fuel Hose Connection - Remote Control Models

    OUTBOARD INSTALLATION Description lb. in. lb. ft. Nylon insert locknut (6) (11‑826365) 27–34 20–25 Nylon insert locknut (f) (factory 27–34 20–25 installed) 1. Assemble the steering arm to the steering adapter plate (as shown) with three flanged hexhead bolts, six hardened flat washers, and three nylon insert locknuts.

  • Page 92: Water Pressure Hose Connection

    OUTBOARD INSTALLATION Water Pressure Hose Connection 1. Remove the water pressure access plug. 20708 Water pressure access plug 2. Apply pipe sealant to the threads of the water pressure gauge hose fitting. 3. Install the hose fitting into the water pressure access port (where the plug resided).
  • Page 93 OUTBOARD INSTALLATION 4. Thread the water pressure gauge hose through the bottom cowl along side the main engine harness. 33672 Hole in bottom cowl Approximate location of where main engine water pressure access harness is routed. port. 5. Install the water pressure gauge hose to the hose fitting. 6.

  • Page 94: Electrical Connections And Control Cable Installation

    OUTBOARD INSTALLATION Electrical Connections and Control Cable Installation REMOTE WIRING HARNESS Remove the access cover. 28505 Access cover Route the remote wiring harness through the rubber grommet.
  • Page 95 OUTBOARD INSTALLATION Connect the 14 pin connector to the engine harness and fasten the harness with the retainer. 28482 Remote wiring harness Retainer 14 pin connector...
  • Page 96 OUTBOARD INSTALLATION BATTERY CABLE CONNECTIONS Single Outboard 15496 Red sleeve ‑ Positive (+) Cranking battery Black sleeve ‑ Negative (–)
  • Page 97 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ Positive (+) Ground cable Black sleeve ‑ Negative Cranking battery (–) SHIFT CABLE INSTALLATION Install the cables into the remote control following the instructions provided with the remote control.
  • Page 98 OUTBOARD INSTALLATION c. Make a center mark ("c"), midway between marks ("a" and "b"). Align the cable end guide with this center mark when installing cable to the engine. 6098 2. Manually shift the outboard into neutral. The propeller will rotate freely.
  • Page 99 OUTBOARD INSTALLATION 5. Attach the shift cable to the shift lever with a cotter pin retainer. 6. Adjust the cable barrel so the center mark on the cable is aligned with the end guide when the cable barrel is placed in the barrel receptacle.
  • Page 100 OUTBOARD INSTALLATION a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end guide. b. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the barrel away from the cable end guide.
  • Page 101 OUTBOARD INSTALLATION 5. Fasten the throttle cable to the mounting stud with a flat washer and locknut. Tighten the locknut to the specified torque. 28494 Throttle cable Locknut Cotter pin retainer Cable barrel Flat washer Description lb. in. lb. ft. Throttle cable locknut...

  • Page 102: Propeller Installation

    OUTBOARD INSTALLATION 6. Reinstall the access cover with two bolts. Tighten the bolts to the specified torque. 28500 Access cover Description lb. in. lb. ft. Access cover bolt Propeller Installation See Maintenance - Propeller Replacement.

  • Page 103: Trim Tab Adjustment

    OUTBOARD INSTALLATION Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.

  • Page 104: Trim-In Stop Adjustment - Power Trim Models

    OUTBOARD INSTALLATION Trim‑In Stop Adjustment ‑ Power Trim Models If an adjustment is required to the trim‑in stop, reposition the tilt stop pins in the desired holes. Tighten the tilt stop pins to the specified torque. 28538 Tilt stop pins Description lb.

  • Page 105: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

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