Mercury 60 Operation, Maintenance & Installation Manual
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Mercury 60 Operation, Maintenance & Installation Manual

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  • Page 1 Operation Maintenance Installation Manual...
  • Page 3 Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant! Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Name / function: John Pfeifer, President, Mercury Marine...
  • Page 4 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Manual included with the product. The Warranty Manual contains a description of what is...
  • Page 5 Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, GO BOLDLY., Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury...

  • Page 7: Table Of Contents

    Selecting Accessories for Your Outboard............13 Safe Boating Recommendations..............13 Recording Serial Number................. 15 55/60 SeaPro/Marathon Specifications............16 60 Component Identification................17 55/60 SeaPro/Marathon Component Identification........... 18 Transporting Trailering Boat/Outboard ................. 19 Fuel and Oil Fuel Requirements................... 20 Oil Recommendation..................21 Fuel and Oil Ratio.....................
  • Page 8 Features and Controls Remote Control Features................. 24 Warning System....................25 Engine Overspeed Limiter................26 Power Trim and Tilt (If equipped)..............27 Manual Tilt System................... 30 Throttle Grip Friction Adjustment ‑ Tiller Handle Models........34 Steering Friction Adjustment ‑ Tiller Handle Models......... 34 Trim Tab Adjustment..................
  • Page 9 Maintenance Cleaning Care Recommendations..............47 Inspection and Maintenance Schedule ............49 Flushing the Cooling System................50 Top Cowl Removal and Installation..............51 Battery Inspection .................... 52 Fuel System...................... 52 Steering Link Rod Fasteners................55 Fuse Replacement.................... 57 Corrosion Control Anode.................. 57 Propeller Replacement–Standard Gearcase............
  • Page 10 Parts and Accessories Inquiries............... 76 Service Assistance................... 76 Ordering Literature.................... 78 Engine Installation Mercury Marine Validated Engine Mounting Hardware........80 Accessories Mounted to the Transom Clamp Bracket........80 Fastening the Outboard to the Transom............84 Installing Outboard.................... 89 Propeller Selection.................... 90 Maintenance Log Maintenance Log....................

  • Page 11: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public. It is strongly recommended that each operator read and understand this entire manual before operating the outboard.

  • Page 12: High-Speed And High-Performance Boat Operation

    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 13: Remote Steering Notice

    GENERAL INFORMATION Remote Steering Notice WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.
  • Page 14 GENERAL INFORMATION The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.
  • Page 15 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.

  • Page 16: 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 17 GENERAL INFORMATION Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. 26782 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.

  • 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 enters the water.
  • Page 19 GENERAL INFORMATION 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 that could be struck by the outboard or the boat bottom. The most significant action you can take to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.
  • Page 20 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. SAFETY INSTRUCTIONS FOR HAND-TILLED OUTBOARDS No person or cargo should occupy the area directly in front of the outboard while the boat is in motion.

  • Page 21: Exhaust Emissions

    GENERAL INFORMATION Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include headache, dizziness,...
  • Page 22 GENERAL INFORMATION Example of desired air flow through the boat: 21622 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains, or is near, a running engine may be exposed to a hazardous level of carbon monoxide.

  • Page 23: Selecting Accessories For Your Outboard

    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 24 (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.

  • Page 25: Recording Serial Number

    GENERAL INFORMATION • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed.

  • Page 26: 55/60 Seapro/Marathon Specifications

    GENERAL INFORMATION 55/60 SeaPro/Marathon Specifications Models Horsepower Kilowatts 40.5 Full throttle RPM range 5000–5500 RPM Idle speed in forward gear 650–700 RPM Number of cylinders Piston displacement 965 cc (58.9 cu. in.) Cylinder bore 76 mm (2.993 in.) Stroke 71 mm (2.796 in.) Recommended spark plug NGK BPZ8H‑N‑10...

  • Page 27: 60 Component Identification

    GENERAL INFORMATION 60 Component Identification 3121 Top cowl Bottom cowl Water pump indicator hole Driveshaft housing Anti‑ventilation plate Trim tab Gearcase Cooling water intake Tilt pin Auxiliary tilt switch (power trim models) Shift handle Stop switch Throttle grip Tiller handle...

  • Page 28: 55/60 Seapro/Marathon Component Identification

    GENERAL INFORMATION 55/60 SeaPro/Marathon Component Identification Water intake Transom bracket Lanyard cord Steering friction adjustment Warning horn Lanyard stop switch Top cowl Shift handle Tilt support lever Anti‑ventilation plate Tilt pin Tilt lock lever Primer Starter handle Throttle grip Stop button...

  • Page 29: 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.

  • Page 30: Fuel And Oil

    USA is alcohol (ethanol, methanol, or butanol). GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 31: Oil Recommendation

    Mercury or Quicksilver Premium TC‑W3 2‑Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2‑cycle outboard oil that is NMMA Certified TC‑W3.

  • Page 32: Filling Oil Injection System

    1. Check oil level using the sight gauge in front of the outboard. 2. Remove the fill cap and fill tank with oil. Capacity Fluid Type Mercury or Quicksilver Premium 2‑cycle Oil tank 3.2 liters (96 fl oz) TC‑W3 outboard oil 29163 3.

  • Page 33: Filling Fuel Tank

    FUEL AND OIL IMPORTANT: Always make sure the oil tank caps are threaded on tight. An air leak will prevent oil flow to the engine. 2723 Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks.

  • 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 System

    FEATURES AND CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat. Remote control models will have the warning horn located inside the remote control or connected to the ignition key switch. 27755 Warning horn inside remote control Warning horn inside key switch Tiller handle models will have the warning horn located below the tiller handle.

  • Page 36: Engine Overspeed Limiter

    FEATURES AND CONTROLS ENGINE OVERHEAT If the engine overheats, immediately reduce throttle speed to idle. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole. 19805 If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine and check the cooling water intake holes for obstruction.

  • Page 37: Power Trim And Tilt (If Equipped)

    FEATURES AND CONTROLS • Propeller ventilation. • A propeller which has an incorrect pitch or diameter. • Propeller hub slippage. • Outboard mounted too high on the transom. • Tilting the outboard out beyond a vertical position. • Cavitation of the propeller due to rough water or obstruction in the boat hull.
  • Page 38 FEATURES AND CONTROLS POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out.
  • Page 39 FEATURES AND CONTROLS • 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 40: Manual Tilt System

    FEATURES AND CONTROLS 2. Tilt the outboard to the desired position and tighten the manual tilt release valve. AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system. Auxiliary tilt switch 27779 SHALLOW WATER OPERATION...
  • Page 41 FEATURES AND CONTROLS BASIC TILTING OPERATION Move tilt lock lever to the tilt position. Tilt outboard to desired position and lock in place by moving the tilt lock lever back to the lock/run position. Tilt position Lock/run position 26802 SHALLOW WATER OPERATION When operating the boat in shallow water, the outboard can be adjusted and locked at a higher tilt angle.
  • Page 42 FEATURES AND CONTROLS 2. Engage the tilt support lever by rotating knob to bring the tilt support lever upward. Tilt support lever Knob 26805 3. Lower outboard to rest on the tilt support lever. Lowering To Run Position 1. Disengage the tilt support lever by raising the outboard off the tilt support lever and rotating the lever down.
  • Page 43 FEATURES AND CONTROLS Arrange passengers and load in the boat so the weight is distributed evenly. 3123 Too much angle (stern down ‑ bow up) Not enough angle (stern up ‑ bow down) Angle adjusted properly (bow slightly up) Consider the following lists carefully when adjusting the operating angle of your outboard.

  • Page 44: Throttle Grip Friction Adjustment - Tiller Handle Models

    FEATURES AND CONTROLS • In excess can cause boat porpoising (bouncing) or propeller ventilation. Throttle Grip Friction Adjustment ‑ Tiller Handle Models Turn the wing nut to set and maintain the throttle at desired speed. 29172 Steering Friction Adjustment ‑ Tiller Handle Models WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control.

  • Page 45: 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 46: Operation

    OPERATION Important Daily Inspection Before Each Use Any outboard mounted on the boat must have the mounting hardware inspected and checked to ensure that the hardware has not become loose. A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use.

  • Page 47: Operating In Freezing Temperatures

    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 48: Operating At High Elevations

    OPERATION • Change gear ratio. Some boat performance can be improved by dropping to a lower pitch propeller, but engine performance will still remain lower. In some cases, a gear ratio reduction may be more beneficial. To optimize engine performance, prop the engine to allow it to operate at or near the top end of the recommended maximum RPM range at wide‑open throttle with a normal boat load.
  • Page 49 OPERATION NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 1. Lower the outboard to the vertical operating position. Make sure all cooling water intake holes are submerged.
  • Page 50 OPERATION 5. Set the lanyard stop switch to the RUN position. Refer to General Information ‑ Lanyard Stop Switch. 19791 6. Shift outboard to neutral (N) position. 29176 26838 7. Model without power trim ‑ Position tilt lock lever to the lock/run position. Tilt position Lock/run position 26802...
  • Page 51 OPERATION a. Remote control models ‑ Advance the fast idle speed lever of throttle only feature to an approximate halfway setting. After engine start up, immediately adjust neutral fast idle setting so engine speed drops below 2000 RPM. Return back to normal idle speed after engine is warmed up.

  • Page 52: Gear Shifting

    OPERATION WARNING Rapid acceleration can result in serious injury or death from being thrown within or out of the boat. Decrease engine speed before shifting into gear. 12. Manual start models ‑ Pull starter rope. 3072 13. After engine starts, check for a steady stream of water flowing out of the water pump indicator hole.

  • Page 53: Stopping The Engine

    OPERATION • Remote control models—always stop at the neutral position to allow the engine idle speed to stabilize before shifting into another gear. • Tiller handle models—reduce the engine speed to idle before shifting into another gear. • Always shift the outboard into gear with a quick motion. •...
  • Page 54 OPERATION 1. Remove flywheel cover. 3954 29192 Electric start models Manual start models 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. 2.
  • Page 55 OPERATION 4. Set the lanyard stop switch to the "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. 19791 WARNING High voltage is present any time the key is turned on, especially when starting or operating the engine. Do not touch ignition components or metal test probes and stay clear of spark plug leads when performing live tests.

  • Page 56: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION 6. If engine is cold, hold the fuel primer button in and pump up the fuel pressure with the fuel primer bulb. 29544 7. Pull the starter rope to start the engine. Setting Trim Angle While Running Engine at Idle Speed The exhaust relief hole on the outboard may become submerged if the outboard is trimmed full‑in while running at idle speed.

  • Page 57: Cleaning Care Recommendations

    Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts. Selecting Replacement Parts For Your Outboard We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. DO NOT USE CAUSTIC CLEANING CHEMICALS IMPORTANT: Do not use caustic cleaning chemicals on the outboard power package.
  • Page 58 Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys.

  • Page 59: Inspection And Maintenance Schedule

    MAINTENANCE Tube Ref Description Where Used Part No. External metal surfaces of the powerhead Corrosion Guard 92-802878 55 and powerhead components. Inspection and Maintenance Schedule DAILY CHECKS • Check the engine oil level • Check the lanyard stop switch • Inspect the fuel system for leaks •...

  • Page 60: Flushing The Cooling System

    Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. WARNING Rotating propellers can cause serious injury or death.

  • Page 61: Top Cowl Removal And Installation

    MAINTENANCE IMPORTANT: Do not run engine above idle when flushing. 4. Adjust water flow (if necessary) so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water. 27260 5.

  • Page 62: Battery Inspection

    MAINTENANCE Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Ensure the battery is secure against movement. 3.
  • Page 63 MAINTENANCE SEAPRO/MARATHON MODELS Fuel Pump Filter WARNING Fuel is flammable and explosive. Ensure that 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. Keep the work area well ventilated and avoid prolonged exposure to vapors.
  • Page 64 MAINTENANCE 1. Loosen main jet plugs with 1 turn on side of carburetors to drain fuel. 3807 2. Dispose of fuel properly. FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line or primer bulb must be replaced.

  • Page 65: Steering Link Rod Fasteners

    MAINTENANCE 5. Turn the slow speed mixture screw slowly out until the engine starts to load up or fire unevenly due to a rich mixture. Note the position of the screw slot. 6. Set the slow speed mixture screw midway between the rich and lean setting.
  • Page 66 MAINTENANCE WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat. Always use required components and follow instructions and torque procedures.

  • Page 67: Fuse Replacement

    MAINTENANCE Fuse Replacement IMPORTANT: An ATC fuse has the fuse element enclosed or sealed inside the plastic housing. This type of fuse must be used for marine applications. Marine applications are exposed to environments that may have the potential to accumulate explosive vapors.

  • Page 68: Propeller Replacement-Standard Gearcase

    MAINTENANCE One anode is installed on the bottom of the transom bracket assembly. The trim tab is also an anode on the 87.3 mm (3‑7/16 in.) diameter gearcase. The 108 mm (4‑1/4 in.) diameter gearcase has three anodes. One of the anodes is the trim tab, and the other two anodes are located on each side of the gearcase.
  • Page 69 MAINTENANCE 2. Remove the spark plug leads to prevent engine from starting. 26899 3. Straighten the bent tabs on the propeller nut retainer. 26900 4. Place a block of wood between the gearcase and propeller to hold the propeller and remove the propeller nut. 26901 5.
  • Page 70 MAINTENANCE Tube Ref Description Where Used Part No. 2-4-C with PTFE Propeller shaft 92-802859A 1 26902 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed.

  • Page 71: Propeller Replacement-Command Thrust Gearcase

    MAINTENANCE Description lb‑in. lb‑ft Propeller nut – 10. Secure propeller nut by bending tabs up and against the flats on the propeller nut. Pins Tabs 26906 11. Install the spark plug leads. Propeller Replacement–Command Thrust Gearcase WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
  • Page 72 MAINTENANCE 2. Remove the spark plug leads to prevent engine from starting. 26899 3. Straighten the bent tabs on the propeller nut retainer. 26900 4. Place a block of wood between the gearcase and propeller to hold the propeller and remove the propeller nut. 26901 5.
  • Page 73 MAINTENANCE Tube Ref Description Where Used Part No. 2-4-C with PTFE Propeller shaft 92-802859A 1 26902 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals, and also each time the propeller is removed.

  • Page 74: Spark Plug Inspection And Replacement

    MAINTENANCE 10. Secure propeller nut by bending tabs up and against the flats on the propeller nut. 26945 11. Install the spark plug leads. Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion.

  • Page 75: Lubrication Points

    Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 26902 2. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE or Extreme Grease.
  • Page 76 MAINTENANCE Tube Ref Description Where Used Part No. Swivel bracket, tilt support lever, tilt 2-4-C with PTFE tube, tiller handle, steering cable grease 92-802859A 1 fitting Swivel bracket, tilt support lever, tilt Extreme Grease tube, tiller handle, steering cable grease 8M0071842 fitting •...

  • Page 77: Lubrication Points-Seapro/Marathon Models

    MAINTENANCE WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. Fitting Steering cable end 29577 3. Lubricate the following with lightweight oil. •...
  • Page 78 MAINTENANCE • Tilt support lever ‑ Lubricate through fitting. Tilt support lever Swivel bracket 29574 • Tilt tube ‑ Lubricate through fitting. 29575 • Tiller handle ‑ Lubricate through fitting. 29576 • Clamp screw threads. 3906...

  • Page 79: Checking Power Trim Fluid

    26967 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).
  • Page 80 Standard gearcase–approximately 340 ml (11.5 fl oz). Command Thrust gearcase–approximately 666 ml (22.5 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1. Place the outboard in a vertical operating position.

  • Page 81: Submerged Outboard

    MAINTENANCE 4. Continue adding the lubricant until it appears at the rear vent hole. 5. Stop adding the lubricant. Install the rear vent plug and sealing washer before removing lubricant tube. 6. Remove the lubricant tube and install cleaned fill/drain plug and sealing washer.

  • Page 82: 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). NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.

  • Page 83: Protecting Internal Engine Components

    STORAGE • 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 Description Where Used Part No. Corrosion Guard External metal surfaces...

  • Page 84: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine (Electric Start Models) POSSIBLE CAUSES • Remote control models ‑ Blown 20 amp 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 85: Performance Loss

    TROUBLESHOOTING • Ignition system component failure. Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. • Excessive water in bilge. •...

  • Page 86: Owner Service Assistance

    STOLEN POWER PACKAGE If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packages.
  • Page 87 RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury dealership. If you need additional assistance: 1.

  • Page 88: Ordering Literature

    OWNER SERVICE ASSISTANCE CONTACT INFORMATION FOR MERCURY MARINE CUSTOMER SERVICE For assistance, call, fax, or write to the geographic office in your area. Please include your daytime telephone number with mail and fax correspondence. United States, Canada English +1 920 929 5040...
  • Page 89 OWNER SERVICE ASSISTANCE Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact: Mercury Marine Telephone Mail Mercury Marine (920) 929‑5110 (920) 929‑4894 Attn: Publications Department...

  • Page 90: Engine Installation

    51965 Accessories Mounted to the Transom Clamp Bracket Mercury Marine has been made aware that certain aftermarket marine accessories, such as emergency boarding ladders, shallow water anchors, transom wedge kits, and tow sport attaching devices, have been mounted to the boat by use of the same fasteners that secure the outboard to the transom or jack plate.
  • Page 91 ENGINE INSTALLATION WARNING Avoid serious injury or death resulting from a loss of boat control. Loose engine fasteners could cause the transom bracket to fail, resulting in a loss of the driver's ability to control the boat. Always ensure that the engine fasteners are tightened to the specified torque.
  • Page 92 ENGINE INSTALLATION • The installation must not create interference issues, as would an accessory mounting plate resting in the radius of the transom clamp bracket. Refer to Figure 1. 54624 Figure 1 Minimum clearance 3.175 mm (0.125 in.) Edge of accessory bracket Transom clamp bracket wall Radius Engine supplied mounting fasteners...
  • Page 93 ENGINE INSTALLATION UNACCEPTABLE ACCESSORY MOUNTING IMPORTANT: Do not use the fasteners that secure the engine to the boat (either the transom or the jack plate) for any purpose other than securing the engine to the boat. 1. Do not mount an accessory to the transom clamp bracket in an unsupported condition.

  • Page 94: Fastening The Outboard To The Transom

    ENGINE INSTALLATION 3. Do not install wedges or plates between the transom clamp brackets and the transom (or jack plate). Refer to Figure 4. Figure 4 Boat transom or jack plate Transom clamp bracket Wedge/plate 54058 Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑...
  • Page 95 ENGINE INSTALLATION 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. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.
  • Page 96 ENGINE INSTALLATION FASTENING THE OUTBOARD TO THE TRANSOM IMPORTANT: The transom mounting surface must be flat within 3.17 mm (0.125 in.). No step in the transom mounting surface is allowed. The inside transom mounting bolt washer surface must be flat within 3.17 mm (0.125 in.). 51817 Step (not allowed) Gap between transom clamp and boat transom (not allowed)
  • Page 97 Failure to maintain clearance may damage the transom bracket and cause the transom bracket to fail. Adjustments to the position of the Mercury Marine transom drilling fixture may be required to ensure proper clearance of the transom bracket relief radius area.
  • Page 98 ENGINE INSTALLATION NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts. 40952 0.500 in. diameter outboard mounting bolt (4) 0.875 in. flat washer (4) Nylon insert locknut (4) 1.500 in. flat washer (4) Marine sealer –...

  • Page 99: Installing Outboard

    ENGINE INSTALLATION A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each use. 51985 Decal on the transom bracket Installing Outboard WARNING Failure to correctly fasten the outboard could result in the outboard propelling off the boat transom resulting in property damage, serious injury, or death.

  • Page 100: Propeller Selection

    ENGINE INSTALLATION The outboard must be secured to the transom with the four 12.7 mm (1/2 in.) diameter mounting bolts and locknuts provided. Install two bolts through the upper set of holes and two bolts through the lower set of holes. 26789 Propeller Selection For best all around performance from your outboard/boat combination, select a...
  • Page 101 ENGINE INSTALLATION PROPELLER REQUIREMENTS–COMMAND THRUST MODELS Command Thrust models require the use of specially designed rubber hub propellers to reduce both instances and severity of gearcase clutch rattle. The use of the other propellers, although not detrimental to either performance or durability, could result in clutch rattle.

  • Page 102: 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...

This manual is also suitable for:

55 seapro60 seapro55 marathon60 marathonCommand thrust

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