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Mercury Racing 500R Operation And Maintenance Manual

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  • Page 1 Operation Maintenance Manual Scan for service and support information...
  • Page 3 Keep this manual with the product for ready reference whenever you are on the water. 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 Buelow, President, Mercury Marine Read This Manual Thoroughly IMPORTANT: If you do not understand any portion of this manual, contact...
  • Page 4 Descriptions and specifications contained herein were in effect at the time this was approved for printing. Mercury Marine, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation.
  • Page 5 In addition, certain Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations.
  • Page 6   ...

  • Page 7: Table Of Contents

    General Information Boater's Responsibilities..................1 Before Operating Your Outboard................ 1 Boat Horsepower Capacity................. 1 High‑Speed and High‑Performance Boat Operation.......... 2 Propeller Selection....................2 Outboard Remote Control Models ..............4 Lanyard Stop Switch................... 4 Protecting People in the Water................7 Passenger Safety Message ‑ Pontoon Boats and Deck Boats......7 Wave and Wake Jumping...................
  • Page 8 Features and Controls Electronic Remote Control (ERC)..............35 Hot Foot......................45 Active Trim......................47 Adaptive Speed Control..................54 Advanced Sound Control.................. 54 Engine Synchronization (Multiple Engines)............54 Helm Transfer....................54 Quick Steer....................... 57 Throttle and Shift Operation with Three or Four Engines......... 57 Single‑Lever Mode (Multiple Engines)..............
  • Page 9 Maintenance Cleaning Care Recommendations..............83 EPA Emissions Regulations................85 Inspection and Maintenance Schedule............. 86 500R Maintenance Schedule Decal..............89 Flushing the Cooling System................89 Top Cowl Removal and Installation..............91 Battery Inspection .................... 94 Battery Connections and Cables..............94 Fuel System...................... 96 Corrosion Control Anodes................
  • Page 10 Owner Service Assistance Service Assistance..................135 Ordering Literature..................137 Maintenance Log Maintenance Log.................... 139    viii...

  • 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

    When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Racing. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercuryracing.com or see your local authorized Mercury dealer.
  • Page 13 GENERAL INFORMATION IMPORTANT: To ensure proper fit and performance, Mercury Marine recommends the use of Mercury or Quicksilver branded propellers and mounting hardware. Propellers are designated by the diameter, pitch, number of blades, and material. The diameter and pitch are stamped (cast) into the side or the end of the propeller hub.

  • Page 14: Outboard Remote Control Models

    3‑blade propeller. Outboard Remote Control Models The outboard must be equipped with a Mercury remote control designed for Digital Throttle and Shift (DTS). Start‑in‑gear protection is provided by the remote control system.
  • Page 15 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 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.

  • 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 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 19: 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 20 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 21: 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 22 GENERAL INFORMATION Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing).

  • 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 power package and may void warranty. Acquire and read the installation and operation manuals for each selected accessory.
  • Page 24 (refer to the boat's capacity plate). Know the boat's operating and loading limitations. Know if the boat will float if it is full of water. When in doubt, contact a Mercury Marine Authorized Dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.
  • Page 25 GENERAL INFORMATION • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown overboard or into the...

  • Page 26: Rear-Mounted Steering Tie Bar Requirements For Multiple Engine Applications Capable Of 161 Km/H(100 Mph) Top Speeds Or Higher

    GENERAL INFORMATION Rear‑Mounted Steering Tie Bar Requirements for Multiple Engine Applications Capable of 161 km/h (100 mph) Top Speeds or Higher Multiple engine applications capable of 161 km/h (100 mph) top speeds or higher are required to be equipped with a rear‑mounted steering tie bar (or tie bars, depending on the number of engines).

  • Page 27: Specifications-500R

    GENERAL INFORMATION Specifications—500R ENGINE OPERATION AND PERFORMANCE SPECIFICATIONS Refer to the following tables for engine operation and performance specifications. This information will help set up a new boat for maximum performance and reliability, and provide information about certain operating conditions that may reduce performance. Engine Performance Wide‑open throttle (WOT) engine RPM...
  • Page 28 GENERAL INFORMATION Oil Temperature Nominal temperature at WOT 110–145 °C (230–293 °F) Guardian power limit (hot) (refer to IMPORTANT remark following 155 °C (311 °F) this table) Guardian power limit (cold) (refer to IMPORTANT remark following Less than 50 °C (122 °F) this table) IMPORTANT: Oil temperatures below 55 °C (131 °F) will cause Engine Guardian to limit the available power.
  • Page 29 Oil (for best performance) Mercury Racing 25W‑50 NMMA certified Recommended oil FC‑W® Marine Synthetic Blend Marine Engine Oil (if Mercury Racing 10W‑30 MRX Full Synthetic Oil is not available) Engine oil capacity with oil 6.6 Liter (7.0 US qt) filter replacement Required battery type 12‑volt absorbed glass mat (AGM) battery...
  • Page 30 ***Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements. ENGINE BATTERY SPECIFICATIONS IMPORTANT: This engine requires a 12‑volt absorbed glass mat (AGM) marine...
  • Page 31 GENERAL INFORMATION WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose connections.

  • Page 32: Component Identification

    GENERAL INFORMATION Component Identification g g g 74687 Service access door Top cowl Engine flush hose attachment point Auxiliary tilt switch Exhaust relief Rear tie bar bracket (optional) Cooling water intake holes Engine oil drain Manual tilt release Water pump indicator hole   ...

  • Page 33: Gearcase Identification

    GENERAL INFORMATION Gearcase Identification Diameter Identification Illustration or Type Features Interchangeable nose cap—up to 14 water pickup holes can be added 150 mm Four low water (5.9 in.) pickups R‑Drive 1.6 ratio gearset Skeg optimized for partial surfacing applications 74672 Interchangeable nose cap—...
  • Page 34 GENERAL INFORMATION Notes:   ...

  • Page 35: Transporting

    TRANSPORTING Trailering Boat/Outboard When transporting the boat on a trailer, the outboard should be positioned and supported in one of the following ways: 1. If the boat trailer provides sufficient ground clearance, the outboard may be tilted down to the vertical operating position with no additional support required.

  • Page 36: Aquatic Invasive Species (Ais)

    TRANSPORTING 3. For maximum ground clearance, the outboard can be tilted to the full tilt position and supported using the outboard tilt support bracket or an accessory transom support device. 63454 Additional clearance may be required for railroad crossings, driveways, and trailer bouncing.
  • Page 37 TRANSPORTING The impact of AIS has already resulted in the limiting of boating access to many waterways throughout North America, the closure of public boat ramps, and the reduction of availability for fishing and boating across the United States. Many federal, state, and local agencies have enacted laws and regulations for inspections, permits, launch availability, and water access for vessels entering public waterways.
  • Page 38 TRANSPORTING Notes:   ...

  • Page 39: 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 40: Fuel Additives

    Fuel Additives To minimize carbon deposit buildup in the engine, add Mercury or Quicksilver Quickleen Engine and Fuel System Cleaner to the engine's fuel at each tank throughout the boating season. Use the additive as directed on the container.

  • Page 41: Engine Oil Recommendations-500R

    Vent/water drain holes 46453 Engine Oil Recommendations—500R Mercury Racing 10W‑30 MRX Full Synthetic Oil is the preferred choice for best performance and general, all‑temperature use. Use Mercury Racing 25W‑50 NMMA certified FC‑W® Marine Synthetic Blend Marine Engine Oil if Mercury Racing 10W‑30 MRX Full Synthetic Oil is not available.
  • Page 42 FUEL AND OIL IMPORTANT: Do not overfill. Tilt the outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump. The outboard must be in a vertical (not tilted) position when checking the engine oil. For accurate readings, check the oil only when the engine is cold or after the engine has not run for at least an hour.
  • Page 43 FUEL AND OIL 4. Remove the dipstick and observe the area of the five beads. 63305 Service access door Oil fill cap Dipstick 5. The bead or crosshatch which shows oil furthest from the end is the oil level. 65509 Oil level example NOTE: With new oil in the engine, it may be difficult to view the oil level on the dipstick.
  • Page 44 1.8 Liter (2 US qt) of the specified outboard motor oil. Description Where Used Part No. Mercury Racing 10W-30 500R crankcase 8M0169264 MRX Full Synthetic Oil 7. Allow a few minutes for the oil to drain into the sump and insert the oil dipstick.

  • Page 45: Features And Controls

    Digital Throttle and Shift (DTS) Features. There are several DTS ERCs that can be used with electric steering, depending on the number of engines and the desired features. The following images show the current Mercury ERCs that will function with electric steering. 71712 71715...
  • Page 46 FEATURES AND CONTROLS 71718 71719 Dual-engine console ERC - Triple-engine console ERC - premier standard 71720 71721 Triple-engine console ERC - Quad-engine console ERC - premier standard 71722 71723 Quad-engine console ERC - Five or six-engine console ERC premier The basic styles of ERC are panel mount (single‑engine only), single‑handle console (single‑engine only), and dual‑handle console (two or more engines).
  • Page 47 Increases and decreases the brightness settings for the lights Brightness (+ and –) on the ERC and Mercury helm components. Allows the boat operator to increase engine RPM without shifting into THROTTLE ONLY gear.
  • Page 48 FEATURES AND CONTROLS Control/LED Function The ACTIVE TRIM button turns the ACTIVE TRIM (if Active Trim feature ON or OFF. Refer equipped) to Active Trim. Changes the selected Active Trim Profile ▲ and ▼ profile. Indicates the currently selected Active Trim profile. Active Trim LEDs (1, NOTE: If the LED indicators are 2, 3, 4, 5)
  • Page 49 The light flashes when the engine is in throttle‑only mode. Increases and decreases the brightness settings Brightness (+ and for the lights on the ERC and Mercury helm –) components. Allows boat control to be transferred to a different helm.
  • Page 50 FEATURES AND CONTROLS Ref Control/LED Function Raises and lowers the engine/drive for best UP ▲ and DN ▼— efficiency, or for conditions such as shallow water or trailering. Some boats are equipped with trim control separately‑mounted trim controls. Pressing the mechanical lock bar allows the engine to shift.
  • Page 51 Increases and decreases the brightness settings Brightness (+ and –) for the lights and display (if equipped) on the ERC and Mercury helm components. Enables the throttle and shift functions of all engines to be controlled by the port lever. Refer 1 LEVER to Single‑Lever Mode.
  • Page 52 FEATURES AND CONTROLS Ref Control/LED Function Press to start or stop the indicated engine, as START/STOP equipped: P (port), PC (port center), C (center), SC individual engines (starboard center), S (starboard) Display and display buttons (premier Refer to ERC Supplemental Display for details. ERCs only) Starts or stops all engines.
  • Page 53 FEATURES AND CONTROLS ELECTRONIC REMOTE CONTROL (ERC) OPERATION Operation of the shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle from the forward position to the neutral position to decrease speed and eventually stop.
  • Page 54 FEATURES AND CONTROLS Remove the access cover from the front of the ERC to expose the adjustment screws. Using a hex wrench turn the desired screw clockwise to increase tension, or counterclockwise to decrease tension. Install the access cover after the desired tension is achieved.

  • Page 55: Hot Foot

    FEATURES AND CONTROLS 71978 Dual-handle console ERC Access cover Detent adjustment screws Handle friction adjustment screws ZERO EFFORT CONTROLS Zero Effort controls allow the operator to control the shifting and throttle with separate control handles. Zero Effort controls are available in single, and multiple engine applications including shadow mode operation.
  • Page 56 FEATURES AND CONTROLS DTS HOT FOOT OPERATION DTS Hot Foot DTS hot foot operation use is unique and is generally used on boats that can reach significant speeds. The use of a hot foot allows the operator to keep both hands on the steering wheel at all speeds, which allows the operator a greater control of the boat.

  • Page 57: Active Trim

    21084 Active Trim INTRODUCTION TO ACTIVE TRIM Active Trim is Mercury Marine’s patented GPS‑based automatic trim system. This intuitive, hands‑free system continually adjusts engine or drive trim for changes in operating conditions to improve performance, fuel economy, and ease of operation. It responds to boat maneuvers with precision and delivers a better overall driving experience.
  • Page 58 Active Trim system is immediately overridden, returning full control to the operator. 61899 Setup and Configuration Refer to your authorized Mercury dealer for setup and configuration instructions. ACTIVE TRIM ERC CONTROLS IMPORTANT: Authorized Mercury dealers have the ability to disable the Active Trim feature.
  • Page 59 FEATURES AND CONTROLS Use the buttons and lights on the ERC to control the Active Trim feature. 71956 Active Trim controls on the ERC Control/LED Function ACTIVE TRIM Turns the Active Trim feature on or off. button Provides Active Trim status information: •...
  • Page 60 FEATURES AND CONTROLS • Active Trim will maintain the last known trim position when operating at speeds in excess of 80 km/h (50 mph). • Operation above 80 km/h (50 mph) may require trim adjustments using the panel mounted or control handle trim position switch. •...
  • Page 61 FEATURES AND CONTROLS What Trim Is The trim angle of an outboard or sterndrive is the angle between the boat bottom and the propeller shaft formed by moving the engine or sterndrive closer to the boat transom. This movement is called trimming in or down. Moving the engine or sterndrive further away from the transom is called trimming out or up.
  • Page 62 FEATURES AND CONTROLS If the engine or drive is trimmed out too far, the propeller may lose its hold on the water, fast V‑bottom boats may start to walk from side to side (chine walking), steering torque will increase in the opposite direction to that when trimmed in, and getting on plane may be difficult or labored.
  • Page 63 FEATURES AND CONTROLS Single Flashing Red 61841 Light (on or off) Interval Fault Condition Description Notes GPS signal has achieved GPS signal Indicates loss of GPS fix, but is dropping out intermittent signal. intermittently. Indicates obstructed GPS signal GPS has not achieved fix since GPS antenna or weak unavailable key on.

  • Page 64: Adaptive Speed Control

    FEATURES AND CONTROLS Adaptive Speed Control This outboard package utilizes adaptive speed control which automatically adjusts the engine load (throttle) to maintain engine speed (RPM). For example, when the boat operator steers into a hard turn, which results in increased load on the engine and a loss of RPM, the propulsion control module (PCM) will open the throttle to maintain RPM through the turn, without the need for the operator to increase the remote control throttle handle.

  • Page 65: Helm Transfer

    Some fault codes may appear on the Mercury‑approved multifunction display if other control or navigation functions are attempted after the helm transfer procedure is started.
  • Page 66 FEATURES AND CONTROLS REQUESTING HELM TRANSFER NOTE: Any movement of the joystick (if equipped) or ERC levers TRANSFER after pressing the transfer button terminates the helm transfer request. A single beep sounds and the transfer button light turns off signaling the end of the transfer request. 72258 To request the transfer of vessel control from one helm to another: 1.

  • Page 67: Quick Steer

    FEATURES AND CONTROLS • Route mode (waypoint sequencing) control of the route and display of route data on your chartplotter does not automatically transfer to the chartplotter at the active helm. You must turn on the chartplotter at the selected active helm, input the waypoint route to be tracked, and engage route mode.
  • Page 68 FEATURES AND CONTROLS Port Center Starboard Control Handle Function Engine Engine Engine Port and center engine throttle and Running Running shift = controlled by port control handle Starboard and center engine throttle Running Running and shift = controlled by starboard control handle Port engine throttle and shift = controlled by port control handle...
  • Page 69 FEATURES AND CONTROLS Port Starboard Port Outer Starboard Inner Inner Control Handle Function Engine Outer Engine Engine Engine Port inner and outer engines throttle and shift = controlled by port control handle Running Running Running Running Starboard inner and outer engines throttle and shift = controlled by starboard control handle Port inner and outer...

  • Page 70: Single-Lever Mode (Multiple Engines)

    FEATURES AND CONTROLS Port Starboard Port Outer Starboard Inner Inner Control Handle Function Engine Outer Engine Engine Engine Port inner engine throttle and shift = controlled by port control handle Off (ignition Off (ignition key switch key switch Running Running Starboard inner engine turned ON) turned ON)

  • Page 71: Start/Stop All Engines

    FEATURES AND CONTROLS 3. Place the port ERC lever into gear. 4. The RPM on all engines will increase and decrease in sync, while all drives remain in gear. To disengage single‑lever mode: 1. Place both ERC levers in neutral. 2.

  • Page 72: Throttle-Only Mode

    FEATURES AND CONTROLS ALL ENGINES RUNNING - STOP ENGINES When all engines are running (and all engine status LEDs are lit), press the START/STOP ALL ENGINES button to stop all engines. All engine status LEDs (individual and the ALL ENGINES LED) will turn off. SOME (NOT ALL) ENGINES RUNNING - STOP ENGINES When some but not all engines are running (and the corresponding engine status LEDs are lit), press the START/STOP ALL ENGINES button to stop...

  • Page 73: Warning System

    FEATURES AND CONTROLS Warning System WARNING HORN SIGNALS When the key switch is turned to the ON position, the horn will turn on for a moment as a test to indicate the horn is working. There are two types of warning horns to alert the operator of an active problem within the engine’s operating system.
  • Page 74 There is no audible warning while Engine Guardian overspeed limit is active. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and engine operating hours.

  • Page 75: Power Trim And Tilt

    FEATURES AND CONTROLS 3. If there is no blockage and the condition persists, return to port immediately. Power Trim and Tilt The 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 76 FEATURES AND CONTROLS NOTE: Exceeding 4250 RPMs the engine PCM will begin Engine Guardian protection. 63456 Trim switch Tilt range Trim range 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 the outboard all the way in or out.
  • Page 77 FEATURES AND CONTROLS WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.
  • Page 78 FEATURES AND CONTROLS MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. 75747 NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation. Turn out the manual tilt release valve three turns counterclockwise.
  • Page 79 FEATURES AND CONTROLS OPERATING IN SHALLOW WATER When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom. 1. Reduce the engine speed below 2000 RPM. 2. Tilt the outboard up. Make sure all the cooling water intake holes stay submerged at all times.
  • Page 80 FEATURES AND CONTROLS Notes:   ...

  • Page 81: 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 82: 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 83: Effects Of Elevation And Weather On Performance

    OPERATION Effects of Elevation and Weather on Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems: • Above sea level elevations • High temperature • Low barometric pressure • High humidity These conditions above reduce air density to the engine, which in turn lowers the following: •...

  • Page 84: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION Setting Trim Angle while Running Engine at Idle Speed The exhaust relief hole on the outboard can become submerged on some boats if the engine is trimmed full in while running at idle speed. This may result in exhaust restriction, rough idle, excessive smoke, and fouled spark plugs. If this condition exists, trim outboard up until exhaust relief hole is out of the water.

  • Page 85: Fuel Supply Module Priming Procedure

    OPERATION Fuel Supply Module Priming Procedure The fuel supply module (FSM) is not vented to the ambient air. The air trapped in the FSM, fuel lines, and fuel rail will be slightly compressed during the initial ignition key on with a dry or drained fuel system. Additional key on events under these conditions will not compress the air further to finish the priming of the FSM.

  • Page 86: Starting The Engine

    OPERATION PRIMING THE FSM (RAN OUT OF FUEL CONDITION) The use of a purge tool for priming the FSM is the preferred method, but is not always practical. When the vessel fuel system is void of fuel volume, it can be primed without the use of a purge tool.
  • Page 87 OPERATION 1. Check the engine oil level. Refer to Fuel and Oil ‑ Checking and Adding Engine Oil. 63305 Service access door Oil fill cap Dipstick 2. Verify that the cooling water intake and antiventilation plate is submerged. IMPORTANT: The antiventilation plate must be submerged or the water pump will not prime.
  • Page 88 OPERATION 3. Set the lanyard stop switch to the RUN position. Refer to General Information ‑ Lanyard Stop Switch. 19791 4. Shift the outboard to the neutral (N) position. 51902 Forward Neutral Reverse NOTE: For initial start of a new engine or for an engine that ran out of fuel, refer to Fuel Supply Module Priming Procedure .

  • Page 89: Gear Shifting

    OPERATION 6. After the engine starts, check for a steady stream of water flowing out of the water pump indicator hole. IMPORTANT: If no water is coming out of the water pump indicator hole, stop the engine and check the cooling water intake for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system.
  • Page 90 OPERATION • When shifting, always stop at the neutral position and allow the engine speed to return to idle. • Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position. 3428 •...

  • Page 91: Stopping The Engine

    OPERATION • Advance the control lever to further increase speed. ZERO EFFORT CONTROL GEAR SHIFTING 1. Verify the throttle lever is at the idle position. 2. Move the shift lever forward or reverse. 3. Advance the throttle lever to apply power. 58267 Shift levers in neutral position Trim switch...
  • Page 92 OPERATION Notes:   ...

  • Page 93: 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...
  • Page 94 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.

  • Page 95: Epa Emissions Regulations

    UV damage. 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. This certification is contingent on certain adjustments set to factory standards.

  • Page 96: Inspection And Maintenance Schedule

    MAINTENANCE OWNER RESPONSIBILITY The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications.
  • Page 97 MAINTENANCE AFTER 10 HOURS OF USE • Change the engine oil and replace the oil filter. Refer to Changing Engine Oil and Filter. • Drain and replace the gearcase lubricant. Refer to Gearcase Lubrication. • Remove the in‑line fuel filter from the fuel inlet hose on the outboard. Refer to Fuel System.
  • Page 98 MAINTENANCE • Inspect the battery. Refer to Battery Inspection. • Saltwater usage: Remove and inspect the spark plugs for corrosion and replace as necessary. Apply Anti‑Seize Compound only on the threads of the spark plug prior to installation. Refer to Spark Plug Inspection and Replacement.

  • Page 99: 500R Maintenance Schedule Decal

    MAINTENANCE 500R Maintenance Schedule Decal The maintenance schedule decal is located under the engine cowling. 75850 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.
  • Page 100 MAINTENANCE 3. Remove the cover from the flush connector and thread a water hose into the flush connector. Flush connector Water hose 68590 4. Turn on the water tap (1/2 maximum) and let the water flush through the cooling system for about 15 minutes. 5.

  • Page 101: Top Cowl Removal And Installation

    MAINTENANCE 3. Locate the engine flush port on the boat transom and insert the quick‑connect fitting. Flush quick connector Engine flush port on transom 72593 4. Turn on the water tap. 5. Press the start button on the boat‑mounted automatic outboard flushing system, or the remote‑mounted button if equipped.
  • Page 102 MAINTENANCE 2. Push down on the port side of the service access door to unlock and open the door. 64230 Push here to unlock 3. Press on the red lock button and lift the handle. Service access door Red lock button Handle 63306   ...
  • Page 103 MAINTENANCE 4. Push the handle towards the aft to lock the handle into the cowl lift position. 63308 Handle locked in the lift position 5. With a firm grip on the handle, carefully lift the cowl off the engine. INSTALLATION 1.

  • Page 104: Battery Inspection

    MAINTENANCE NOTE: It may be necessary to slightly lift the larger gap side of the cowl to correctly position the alignment guides. 68495 Port side shown, starboard side similar Cowl alignment guide Bottom cowl 3. Gently push down on the cowl. 4.
  • Page 105 MAINTENANCE • Refer to NMMA, ABYC, and U.S. Coast Guard boating standards and regulations for complete guidelines. BATTERY CABLE RECOMMENDATIONS Refer to NMMA, ABYC, and U.S. Coast Guard boating standards and regulations for complete guidelines. IMPORTANT: Solder the terminals to the cable ends to ensure good electrical contact.

  • Page 106: Fuel System

    MAINTENANCE Battery switches: Position battery switches so that each engine operates off its own battery. Do not use switches that have OFF, 1, 2, or both positions. Battery switches should be on, off or maybe an emergency only position. In an emergency, another engine's battery can be used to start an engine with a dead battery.
  • Page 107 MAINTENANCE Install the fuel hose onto the quick‑connect fitting with the in‑line fuel filter in place. The in‑line fuel filter will catch fuel system debris before it reaches the engine. This filter must remain in place for the first ten hours of engine run time. 68521 Quick‑connect fitting In‑line fuel filter...
  • Page 108 MAINTENANCE 4. Disconnect the water‑in‑fuel (WIF) sensor harness. Fuel filter base Fuel filter assembly WIF sensor connection 72232 5. Remove the filter assembly from the base by turning counterclockwise. 6. Empty the fuel filter contents into an approved container and dispose according to local regulations.
  • Page 109 MAINTENANCE 2. Verify that the O‑ring is installed on the water‑in‑fuel (WIF) sensor. Lubricate the O‑ring with clean engine oil. Plug removed WIF sensor O‑ring 72234 3. Thread the WIF sensor clockwise into the fuel filter and tighten to the specified torque.

  • Page 110: Corrosion Control Anodes

    MAINTENANCE 5. Lightly lubricate the fuel filter O‑ring with clean engine oil. Thread the fuel filter clockwise onto the fuel filter base until the O‑ring makes contact with the base. Then tighten the filter another 2/3–1 turn. Fuel filter base Lubricate fuel filter O‑ring Fuel filter assembly WIF sensor connection...

  • Page 111: Propeller Replacement-38.1 Mm (1.5 In.) Diameter Propeller Shaft

    MAINTENANCE Each anode requires periodic inspection, especially in saltwater, which will accelerate the corrosion. To maintain corrosion protection, always replace the anode before it is completely corroded. Never paint or apply a protective coating on the anode, as this will reduce the effectiveness of the anode. Bottom of transom bracket Bottom of each power trim ram (2)
  • Page 112 4. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Mercury/Quicksilver products: Description Where Used Part No.
  • Page 113 MAINTENANCE 1. Apply a light layer of 2‑4‑C with PTFE to the outer diameter of the entire propeller hub prior to installation into the propeller. Outer diameter of the entire propeller hub 76534 Description Where Used Part No. 2-4-C with PTFE Outer diameter of the entire propeller hub 92-802859A 1 2.

  • Page 114: Spark Plug Inspection And Replacement

    MAINTENANCE Description lb‑in. lb‑ft Locknut 115.2 – 76533 Locknut 0.75‑16 brass hex nut Washer Propeller HD propeller hub Labyrinth propeller seal Propeller shaft Spark Plug Inspection and Replacement 1. Remove the top cowl. Refer to Top Cowl Removal and Installation.   ...
  • Page 115 MAINTENANCE 2. Grasp the spark plug boot and use a twisting motion to assist removing the spark plug boot from the spark plugs. 63312 Spark plug boot 3. Remove the spark plug with a 14 mm deep socket. NOTE: Replace the spark plug if the electrode is worn; the insulator is rough, cracked, broken, or blistered;...
  • Page 116 MAINTENANCE 4. Check the spark plug gap. Refer to General Information ‑ Specification. 27848 a. All of the spark plugs should have the gap checked and corrected as necessary before installation. b. Measure the gap with a feeler gauge or pin gauge. Never use a wedge‑type gap checking tool to inspect or to adjust the gap.

  • Page 117: Fuses

    MAINTENANCE 8. Push on the end of the spark plug boot to ensure the boot is completely engaged and seated onto the spark plug. 63315 Push the spark plug boot 9. Install the top cowl. Fuses CAUTION Always use the appropriate size wire and fuse to protect the wiring or components from starting a fire due to high current draw.
  • Page 118 MAINTENANCE IMPORTANT: Spare fuses are located on the back of the PCM cover. 68326 Air inlet Fuse holder cover PCM cover (spare fuses located on the back) 2. Remove the suspected open fuse and look at the silver band inside the fuse.
  • Page 119 MAINTENANCE IMPORTANT: Replace the fuse with a new fuse with the same amp rating. 68333 Fuel injectors ‑ 20‑amp Advanced sound control driver ‑ 5‑amp Propulsion control module (PCM) power ‑ 20‑amp Diagnostics/moving propeller (MP) alert ‑ 5‑amp Ignition coils ‑ 20‑amp Thrust vector module (TVM) power ‑15‑amp Oxygen sensor ‑...

  • Page 120: Accessory Drive Belts

    The alternator drive belt and supercharger drive belts are located under the flywheel cover. The alternator and supercharger drive belt inspection must be completed by an authorized Mercury dealer at the recommended interval. Refer to Inspection and Maintenance Schedule. Trim Thrust Guide Wear Pad The 500R outboard utilizes thrust guide plates on either side of the driveshaft housing to improve stability of the engine.
  • Page 121 MAINTENANCE CHECKING TRIM WEAR PAD CLEARANCE 68457 Trim manifold Trim wear pads Clearance (refer to the following table) IMPORTANT: The trim thrust guide wear pads must be shimmed for a maximum clearance of 0.5 mm (0.02 in.) per side. Trim thrust guide wear pad to lower cradle clearance (per side) Minimum clearance 0.05 mm (0.002 in.) Maximum clearance...

  • Page 122: Cooling System Strainers

    MAINTENANCE REPLACING THE TRIM THRUST GUIDE WEAR PADS IMPORTANT: When replacing the trim thrust guide wear pads, replace both pads and install new retaining hardware. 74679 M6 x 20 screw with patch lock pad (8 quantity, 4 on each trim wear pad) Trim thrust guide wear pad (2 quantity) Trim manifold...
  • Page 123 MAINTENANCE 2. Remove the M6 x 20 screw securing the elbow to the exhaust tube and remove the elbow. Starboard side of exhaust tube Starboard idle relief muffler Strainer housing (with two hose connections, hidden) M6 x 16 screws (2) Elbow M6 x 20 screw 76814...
  • Page 124 MAINTENANCE CHARGE AIR COOLER (CAC) STRAINER 1. Remove the two M6 x 16 screws securing the strainer to the exhaust tube. 76816 Cowl support bracket not shown for visual clarity Strainer with poppet valve (not equipped on all models) Port side of exhaust tube Strainer M6 x 16 screws (2) 2.

  • Page 125: Checking Power Trim Fluid

    MAINTENANCE FUEL SUPPLY MODULE (FSM) STRAINER 1. Remove the M6 x 20 screw securing the strainer fitting to the exhaust tube. Starboard lower cowl support bracket Starboard idle relief muffler Strainer fitting M6 x 20 screw 76817 2. Remove any debris from the strainer fitting. 3.

  • Page 126: Checking Power Steering Fluid

    Pedestal 29312 5. The fluid level should be approximately 25 mm (1 in.) from the top of the fill neck. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).
  • Page 127 MAINTENANCE 1. Remove the power steering pump cover from the enclosure by releasing the straps and lifting the cover. Straps (2) Power steering pump cover 68422 2. Observe the power steering fluid level inside the reservoir. The fluid level should be between the "MIN" and "MAX" lines on the reservoir. 3.

  • Page 128: Changing Engine Oil And Filter

    MAINTENANCE Changing Engine Oil and Filter ENGINE OIL CAPACITY Engine oil capacity is approximately 6.6 Liter (7.0 US qt). IMPORTANT: Tilt the outboard out/up past vertical for approximately one minute to allow any trapped oil to drain back to the oil sump. OIL CHANGE ON LAND PROCEDURE 1.
  • Page 129 MAINTENANCE Description lb‑in. lb‑ft Oil drain valve 132.7 – IMPORTANT: Overtightening the oil drain valve can damage the oil sump. 8. Add the appropriate amount of engine oil. OIL CHANGE ON WATER PROCEDURE 1. Tilt the outboard out/up past vertical for approximately one minute to allow any trapped oil to drain back to the oil sump.
  • Page 130 MAINTENANCE 5. Install the oil drain hose onto the crankcase oil pump. Verify the hose is securely attached. 63845 Crankcase oil pump Oil drain hose Crankcase Oil Pump 802889A1 Aids in the removal of engine oil without draining the crankcase. 11591 Oil Drain Hose 8M0129230...
  • Page 131 MAINTENANCE 6. Install the crankcase oil pump assembly onto the dipstick tube. Verify the pump is securely attached to the tube by pulling it up lightly. Oil drain hose Lock button 63843 7. Place the drain tube of the crankcase oil pump into an appropriate container.
  • Page 132 MAINTENANCE 2. Remove the old filter by turning the filter counterclockwise. 68321 Oil filter Oil filter mounting base 3. Allow the oil in the oil filter mounting base to drain. 4. Clean the remaining oil from the oil filter mounting base area. 5.

  • Page 133: Checking And Adding Engine Oil

    MAINTENANCE Checking and Adding Engine Oil IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer.
  • Page 134 MAINTENANCE 4. Remove the dipstick and observe the area of the five beads. 63305 Service access door Oil fill cap Dipstick 5. The bead or crosshatch which shows oil furthest from the end is the oil level. 65509 Oil level example NOTE: With new oil in the engine, it may be difficult to view the oil level on the dipstick.

  • Page 135: Adaptive Speed Control Propping With Cds G3

    1.8 Liter (2 US qt) of the specified outboard motor oil. Description Where Used Part No. Mercury Racing 10W-30 500R crankcase 8M0169264 MRX Full Synthetic Oil 7. Allow a few minutes for the oil to drain into the sump and insert the oil dipstick.
  • Page 136 MAINTENANCE • Demand ‑ the final demand value requested by the software. If the engine is propped correctly, with engine speed at wide‑open throttle falling within the operating range at optimum trim, this value should be at 100%. 68724 3. Run the engine with the handle at wide‑open throttle (100% DemandLinear) at optimum trim.

  • Page 137: Adaptive Speed Control Propping Without Cds G3

    Adaptive Speed Control Propping without CDS G3 IMPORTANT: Boat propping can be performed using the normal method used for Mercury Outboards. To achieve optimum propeller selection, however, follow the Adaptive Speed Control Propping with CDS G3 procedure. IMPORTANT: To operate the engine at full throttle before the break‑in period is complete, follow this procedure.

  • Page 138: Gearcase Lubricant

    MAINTENANCE 6. To test if the correct propeller has been installed, operate the boat with a normal load on board at WOT and check the RPM with an accurate tachometer. The engine RPM should be near the top of the specified range so that, under a heavy load, the engine speed will not fall below the specified RPM range.
  • Page 139 MAINTENANCE GEARCASE LUBRICANT CAPACITY NOTE: The specified gear lubricant quantity will put the lubricant level at the bottom of the lubricant level plug hole when full. Gearcase Lubricant Capacity Right‑hand rotation 940 mL (31.8 fl oz) R‑Drive Sport Left‑hand rotation 940 mL (31.8 fl oz) Right‑hand rotation 940 mL (31.8 fl oz) R‑Drive...
  • Page 140 MAINTENANCE 4. Remove the tube and install the fill/drain plug. 5. Tighten the plugs to the specified torque. Description lb‑in. lb‑ft Plugs 11.3 – Checking Lubricant Level 1. Place the outboard in a vertical operating position. Allow up to 30 minutes for the lubricant level to stabilize in the gear housing.

  • Page 141: Storage

    92-8M0047932 Protecting External Outboard Components • 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). Description Where Used Part No. Corrosion Guard...

  • Page 142: Gearcase

    STORAGE • Spray approximately 30 ml (1 fl oz) of Storage Seal Rust Inhibitor into each spark plug hole. Description Where Used Part No. Storage Seal Rust Spark plug holes 92-858081K03 Inhibitor • Actuate key/push button start switch to crank the engine through one start cycle, which will distribute the storage seal throughout the cylinders.

  • Page 143: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in RUN position. • Open clean power harness circuit fuse. Refer to Maintenance section. • Remote control is not shifted to the neutral position. • Shift actuator failure.

  • Page 144: Performance Loss

    TROUBLESHOOTING a. Engine fuel filter is obstructed. Refer to Maintenance section. b. Fuel tank filter obstructed. c. Stuck anti‑siphon valve located on permanently built‑in type fuel tanks. d. Fuel line is kinked or pinched. • Fuel system is not primed. •...
  • Page 145 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 146 OWNER SERVICE ASSISTANCE 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 147 Before ordering literature, have the following information about your power package available: 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 Attn: Publications Department (920) 929‑5110...
  • Page 148 OWNER SERVICE ASSISTANCE Quantity Item Stock Number Price Total Total Due       ...
  • Page 149 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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