Mercury 60 FourStroke EFI Formula Race User manual

i
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.
Mercury Racing,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585
7406
Safety Alerts and Notices
! WARNING
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.
© 2008 Mercury Marine 60 FourStroke EFI Formula Race Engine 90-8M8022227 208

ii
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.
Observe these safety alerts carefully.
These safety alerts alone can not eliminate the hazards they
signal. Strict compliance to these special instructions when
performing the service, and common sense operation are major
accident prevention measures.
! DANGER
Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine
or major component failure.
IMPORTANT: Identifies information essential to the successful
completion of the task.
NOTE: Indicates information that helps in the understanding of a
particular step or action.

iii
! WARNING
The engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects or other
reproductive harm.
Copyright and Trademark Information
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Printed in U.S.A.
© 2008, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser,
Mercury Racing, Mercury Precision Parts, Mercury Propellers,
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.

iv

TABLE OF CONTENTS
v
EMISSIONS INFORMATION
Star Label....................................................................................1
EPA Emissions Regulations........................................................2
Warranty Coverage......................................................................3
GENERAL INFORMATION
Boater's Responsibilities..............................................................4
Before Operating Your Outboard.................................................4
Boat Horsepower Capacity..........................................................5
High‑Speed and High‑Performance Boat Operation...................5
Outboard Remote Control Models ..............................................5
Remote Steering Notice...............................................................6
Lanyard Stop Switch....................................................................6
Protecting People in the Water....................................................9
Passenger Safety Message.........................................................9
Wave and Wake Jumping..........................................................10
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

TABLE OF CONTENTS
vi
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
Operating in Freezing Temperatures.........................................36
Operating in Saltwater or Polluted Water..................................36
Pre‑Starting Instructions............................................................37
Engine Break‑in Procedure........................................................37
Starting the Engine....................................................................38
Gear Shifting .............................................................................41
Stopping The Engine ................................................................42
Emergency Starting ..................................................................42

TABLE OF CONTENTS
vii
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...................................56
Fuse Replacement.....................................................................57
Timing Belt Inspection...............................................................58
Lubrication Points......................................................................59
Checking Power Trim Fluid........................................................60
Changing Engine Oil .................................................................61
Gearcase Lubrication ‑ For 87.3 mm(3‑7/16 in.) Diameter
Gearcase...................................................................................63
Submerged Outboard................................................................65
STORAGE
Storage Preparation...................................................................66
Protecting External Outboard Components...............................67
Protecting Internal Engine Components....................................67
Gearcase...................................................................................67
Positioning Outboard for Storage..............................................67
Battery Storage..........................................................................67

TABLE OF CONTENTS
viii
TROUBLESHOOTING
Starter Motor Will Not Crank The Engine (Electric Start Models)
...................................................................................................69
Engine Will Not Start..................................................................69
Engine Runs Erratically.............................................................70
Performance Loss......................................................................70
Battery Will Not Hold Charge.....................................................70
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
Electrical Connections and Control Cable Installation...............86
Propeller Installation..................................................................94
Trim Tab Adjustment.................................................................95
Trim‑In Stop Adjustment ‑ Power Trim Models..........................96
MAINTENANCE LOG
Maintenance Log.......................................................................97

EMISSIONS INFORMATION
1
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.
Longer Emission Warranty ‑ Protects consumer for worry free
operation.
22531
One Star ‑ Low Emission
The One Star label identifies engines that meet the
Air Resources Board's 2001 exhaust emissions
standards. Engines meeting these standards have
75% lower emissions than conventional
carbureted two‑stroke engines. These engines are
equivalent to the U.S. EPA's 2006 standards for
marine engines.
FO
IDA
22532
Two Stars ‑ Very Low Emission
The Two Star label identifies engines that meet the
Air Resources Board's Personal Watercraft and
Outboard marine engine 2004 exhaust emissions
standards. Engines meeting these standards have
20% lower emissions than One Star ‑ Low
Emission engines.
A
SS
D
22533
Three Stars ‑ Ultra Low Emission
The Three Star label identifies engines that meet
the Air Resources Board's Personal Watercraft
and Outboard marine engine 2008 exhaust
emissions standards or the Sterndrive and Inboard
marine engine 2003‑2008 exhaust emission
standards. Engines meeting these standards have
65% lower emissions than One Star ‑ Low
Emission engines.

EMISSIONS INFORMATION
2
RN
F
T
22534
Four Stars ‑ Super Ultra Low Emission
The Four Star label identifies engines that meet
the Air Resources Board's Sterndrive and Inboard
marine engine 2009 exhaust emission standards.
Personal Watercraft and Outboard marine
engines may also comply with these standards.
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. This certification is
contingent on certain adjustments set to factory standards. For this
reason, the factory procedure for servicing the product must be
strictly followed and, wherever practicable, returned to the original
intent of the design. Maintenance, replacement, or repair of the
emission control devices and systems may be performed by any
marine spark ignition (SI) engine repair establishment or individual.

EMISSIONS INFORMATION
3
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.
SPARK PLUG:
GAP:
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
CALIFORNIA AND U.S. EPA
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS
IDLE SPEED (in gear): FAMILY:
FEL:
TIMING (IN DEGREES):
COLD VALVE
CLEARANCE (mm)
INTAKE:
EXHAUST:
g/kWh
hp cc
21096
e
d
c
b
a
f
g
h
i
a - Idle speed
b - Engine horsepower
c - Piston displacement
d - Date of manufacture
e - Valve clearance (if
applicable)
f - Family number
g - Maximum emission
output for the engine
family
h - Timing specification
i - Recommended spark
plug and gap
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 emissions levels to exceed
their predetermined factory specifications.
Warranty Coverage
Mercury Racing does not offer a warranty with this power package.

GENERAL INFORMATION
4
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.
Before Operating Your Outboard
Read this manual carefully. Learn how to operate your outboard
properly. If you have any questions, contact your dealer.
Safety and operating information that is practiced, along with using
good common sense, can help prevent personal injury and product
damage.
This manual as well as safety labels posted on the outboard use
the following safety alerts to draw your attention to special safety
instructions that should be followed.
! DANGER
Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine
or major component failure.

GENERAL INFORMATION
5
Boat Horsepower Capacity
! WARNING
Exceeding the boat's maximum horsepower rating can cause
serious injury or death. Overpowering the boat can affect boat
control and flotation characteristics or break the transom. Do not
install an engine that exceeds the boat's maximum power rating.
Do not overpower or overload your boat. Most boats will carry a
required capacity plate indicating the maximum acceptable power
and load as determined by the manufacturer following certain
federal guidelines. If in doubt, contact your dealer or the boat
manufacturer.
U.S. COAST GUARD CAP ACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777
High‑Speed and High‑Performance Boat Operation
If your outboard is to be used on a high‑speed or high‑performance
boat with which you are unfamiliar, we recommend that you never
operate it at its high speed capability without first requesting an
initial orientation and familiarization demonstration ride with your
dealer or an operator experienced with your boat/outboard
combination. 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. This prevents the
engine from starting when the shift is actuated in any position other
than neutral.

GENERAL INFORMATION
6
! 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.
! 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.
Lanyard Stop Switch
The purpose of a lanyard stop switch is to turn off the engine when
the operator moves far enough away from the operator's position
(as in accidental ejection from the operator's position) to activate
the switch. Tiller handle outboards and some remote control units
are equipped with a lanyard stop switch. A lanyard stop switch can
be installed as an accessory ‑ generally on the dashboard or side
adjacent to the operator's position.

GENERAL INFORMATION
7
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. The lanyard is coiled to make its at‑rest condition
as short as possible to minimize the likelihood of lanyard
entanglement with nearby objects. Its stretched‑out length is made
to minimize the likelihood of accidental activation should the
operator choose to move around in an area close to the normal
operator's position. If it is desired to have a shorter lanyard, wrap
the lanyard around the operator's wrist or leg, or tie a knot in the
lanyard.
33580
a c
b
a - Lanyard cord
b - Lanyard stop switch cap
c - Lanyard stop switch
Read the following Safety Information before proceeding.
Important Safety Information: The purpose of a lanyard stop switch
is to stop the engine when the operator moves far enough away
from the operator's position to activate the switch. This would occur
if the operator accidentally falls overboard or moves within the boat
a sufficient distance from the operator's position. Falling overboard
and accidental ejections are more likely to occur in certain types
of boats such as low sided inflatables, bass boats, high
performance boats, and light, sensitive handling fishing boats
operated by a hand tiller. Falling overboard and accidental
ejections are also likely to occur as a result of poor operating
practices such as sitting on the back of the seat or gunwale at
planing speeds, standing at planing speeds, sitting on elevated
fishing boat decks, operating at planing speeds in shallow or
obstacle infested waters, releasing your grip on a steering wheel
that is pulling in one direction, drinking alcohol or consuming drugs,
or daring high speed boat maneuvers.

GENERAL INFORMATION
8
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.
We strongly recommend that other occupants be instructed on
proper starting and operating procedures should they be required
to operate the engine in an emergency (e.g. if the operator is
accidentally ejected).
! WARNING
If the operator falls out of the boat, stop the engine immediately
to reduce the possibility of serious injury or death from being
struck by the boat. Always properly connect the operator to the
stop switch using a lanyard.
! WARNING
Avoid serious injury or death from deceleration forces resulting
from accidental or unintended stop switch activation. The boat
operator should never leave the operator's station without first
disconnecting the stop switch lanyard from the operator.
Accidental or unintended activation of the switch during normal
operation is also a possibility. This could cause any, or all, of the
following potentially hazardous situations:
• Occupants could be thrown forward due to unexpected loss
of forward motion ‑ a particular concern for passengers in the
front of the boat who could be ejected over the bow and
possibly struck by the gearcase or propeller.
• Loss of power and directional control in heavy seas, strong
current or high winds.
• Loss of control when docking.

GENERAL INFORMATION
9
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.
Whenever a boat is moving (coasting) and the outboard gear shift
is in neutral position, there is sufficient force by the water on the
propeller to cause the propeller to rotate. This neutral propeller
rotation can cause serious injury.
WHILE BOAT IS STATIONARY
! WARNING
A spinning propeller, a moving boat, or any solid device attached
to the boat can cause serious injury or death to swimmers. Stop
the engine immediately whenever anyone in the water is near
your boat.
Shift outboard into neutral and shut off the engine before allowing
people to swim or be in the water near your boat.
Passenger Safety Message
Whenever the boat is in motion, observe the location of all
passengers. Do not allow any passengers to stand or use seats
other than those designated for traveling faster than idle speed. A
sudden reduction in boat speed, such as plunging into a large wave
or wake, a sudden throttle reduction, or a sharp change of boat
direction, could throw them within or out of the boat.

GENERAL INFORMATION
10
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.
26784
The primary concern is the boat changing direction while in the
midst of the jump. In such case the landing may cause the boat to
veer violently in a new direction. Such a sharp change in direction
can cause occupants to be thrown out of their seats, or out of the
boat.
! WARNING
Wave or wake jumping can cause serious injury or death from
occupants being thrown within or out of the boat. Avoid wave or
wake jumping whenever possible.
There is another less common hazardous result from allowing your
boat to launch off a wave or wake. If the bow of your boat pitches
down far enough while airborne, upon water contact it may
penetrate under the water surface and submarine for an instant.
This will bring the boat to a nearly instantaneous stop and can send
the occupants flying forward. The boat may also steer sharply to
one side.

GENERAL INFORMATION
11
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. Under these
conditions, boat speed should be kept to a minimum planing speed
of 24 to 40 km/h (15 to 25 MPH).
26785
Striking a floating or underwater object could result in an infinite
number of situations. Some of these situations could result in the
following:
• Part of the outboard or the entire outboard could break loose
and fly into the boat.
• The boat could move suddenly in a new direction. Such a
sharp change in direction can cause occupants to be thrown
out of their seats or out of the boat.
• A rapid reduction in speed. This will cause occupants to be
thrown forward, or even out of the boat.
• Impact damage to the outboard and/or boat.
Keep in mind, the most important thing you can do to help reduce
injury or impact damage during an impact is control the boat speed.
Boat speed should be kept to a minimum planing speed when
driving in waters known to have underwater obstacles.
After striking a submerged object, stop the engine as soon as
possible and inspect it for any broken or loose parts. If damage is
present or suspected, the outboard should be taken to an
authorized dealer for a thorough inspection and necessary repair.

GENERAL INFORMATION
12
The boat should also be checked for any hull fractures, transom
fractures, or water leaks.
Operating a damaged outboard could cause additional damage to
other parts of the outboard, or could affect control of the boat. If
continued running is necessary, do so at greatly reduced speeds.
! WARNING
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
BE ALERT TO CARBON MONOXIDE POISONING
Carbon monoxide is present in the exhaust fumes of all internal
combustion engines. This includes the outboards, sterndrives and
inboard engines that propel boats, as well as the generators that
power various boat accessories. Carbon monoxide is a deadly gas
that is odorless, colorless and tasteless.
Early symptoms of carbon monoxide poisoning which should not
be confused with seasickness or intoxication, include headache,
dizziness, drowsiness, and nausea.
! WARNING
Carbon monoxide poisoning can lead to unconsciousness, brain
damage, or death. Keep the boat well ventilated while at rest or
underway and avoid prolonged exposure to carbon monoxide.
GOOD VENTILATION
Ventilate passenger area, open side curtains, or forward hatches
to remove fumes.
21622
Example of desired air flow through the boat