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.