Mercury 55 Marathon Operation, Maintenance & Installation Manual Download Page 1

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Operation

Maintenance

and

Installation

Manual

60, 55/60 SeaPro/Marathon, Command Thrust

8M0133621

617

eng

Summary of Contents for 55 Marathon

Page 1: ...Operation Maintenance and Installation Manual 2017 Mercury Marine 60 55 60 SeaPro Marathon Command Thrust 8M0133621 617 eng ...

Page 2: ...eng ...

Page 3: ...anual Thoroughly IMPORTANT If you do not understand any portion of this manual contact your dealer Your dealer can also provide a demonstration of actual starting and operating procedures Notice Throughout this publication and on your power package warnings cautions and notices accompanied by the International Hazard Symbol may be used to alert the installer and user to special instructions concer...

Page 4: ...ased on continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation 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...

Page 5: ...Skyhook SmartCraft Sport Jet Verado VesselView Zero Effort Zeus 1 On the Water and We re Driven to Win are registered trademarks of Brunswick Corporation Pro XS is a trademark of Brunswick Corporation Mercury Product Protection is a registered service mark of Brunswick Corporation Identification Records Please record the following applicable information Outboard Engine Model and Horsepower Engine ...

Page 6: ...eng iv ...

Page 7: ...ts 6 Wave and Wake Jumping 8 Impact with Underwater Hazards 8 Exhaust Emissions 11 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 ...

Page 8: ...odels 34 Trim Tab Adjustment 35 Operation Important Daily Inspection Before Each Use 36 Prestarting Check List 36 Operating in Freezing Temperatures 37 Operating in Saltwater or Polluted Water 37 Effects of Elevation and Weather on Performance 37 Operating at High Elevations 38 Engine Break in Procedure 38 Starting the Engine 38 Gear Shifting 42 Stopping the Engine 43 Emergency Starting 43 Setting...

Page 9: ...1 Spark Plug Inspection and Replacement 64 Lubrication Points 65 Lubrication Points SeaPro Marathon Models 67 Checking Power Trim Fluid 69 Gearcase Lubrication 69 Submerged Outboard 71 Storage Storage Preparation 72 Protecting External Outboard Components 72 Protecting Internal Engine Components 73 Gearcase 73 Positioning Outboard for Storage 73 Battery Storage 73 Troubleshooting Starter Motor Wil...

Page 10: ...es 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 92 viii eng ...

Page 11: ...ng 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 WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which...

Page 12: ... 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...

Page 13: ...common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage a Self locking nuts 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 unit...

Page 14: ...rd 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 boat...

Page 15: ... 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 b...

Page 16: ... Stop the engine immediately whenever anyone in the water is near your boat Shift the outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat Passenger Safety Message Pontoon Boats and Deck Boats 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 f...

Page 17: ...njury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed Sit only in seats designated for traveling at faster speeds Any unexpected sudden reduction in boat speed could...

Page 18: ...r 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 Impact with Underwater...

Page 19: ...ng pipes bridge supports wing dams trees stumps and rocks Striking a floating or underwater object could result in any of an infinite number of situations Some of these situations could yield 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 A sharp change in direction can cause occupants to be thrown o...

Page 20: ... screws The use of clamp bracket screws alone is insufficient to properly and safely secure the outboard to the transom Proper installation of the outboard includes bolting the engine to the boat through the transom Refer to Engine Installation Installing Outboard for more complete installation information WARNING Failure to correctly fasten the outboard could result in the outboard propelling off...

Page 21: ...re to carbon monoxide Stay clear from exhaust areas when engine is running Keep the boat well ventilated while at rest or underway STAY CLEAR OF EXHAUST AREAS 41127 co co co co co co co co co co co co co co co co co co co co 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 ...

Page 22: ...ers 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 1 Examples of poor ventilation while the boat is stationary a Operating the engine when the boat is moored in a confined space b Mooring close to another boat that has its engine operating 2 Examples of poor ventilation while the boat is moving a Operating the b...

Page 23: ...lowing suggestions Know and obey all nautical rules and laws of the waterways We recommend that all powerboat operators complete a boating safety course In the U S the U S Coast Guard Auxiliary the Power Squadron the Red Cross and your state or provincial boating law enforcement agency provide courses For more information in the U S call the Boat U S Foundation at 1 800 336 BOAT 2628 Perform safet...

Page 24: ...overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities 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 Do not allow anyon...

Page 25: ...operator should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is pers...

Page 26: ... 71 mm 2 796 in Recommended spark plug NGK BPZ8H N 10 Spark plug gap 1 0 mm 0 040 in Gear ratio Standard gearcase 1 64 1 Command Thrust gearcase 2 3 1 Gearcase lubricant Capacity Standard gearcase 340 ml 11 5 fl oz Command Thrust gearcase 666 ml 22 5 fl oz Recommended gasoline Refer to Fuel and Oil Recommended oil Refer to Fuel and Oil Battery rating 465 marine cranking amps MCA or 350 cold cranki...

Page 27: ... h Cooling water intake i Tilt pin j Auxiliary tilt switch power trim models k Shift handle l Stop switch m Throttle grip n Tiller handle o Throttle friction adjustment p Warning horn q Steering friction adjustment r Tilt lock lever models without power trim s Lanyard stop switch 3121 c a b d e f l m n s p o q r k j i h g GENERAL INFORMATION eng 17 ...

Page 28: ...ift handle i Tilt support lever j Anti ventilation plate k Tilt pin l Tilt lock lever m Primer n Starter handle o Throttle grip p Stop button q Tiller handle r Throttle grip friction adjustment s Transom mounting hardware bolts flat washers and locknuts t Driveshaft housing u Gearcase v Transom clamp handles f g a b c d e h i j m n o p q r v s u k t l GENERAL INFORMATION 18 eng ...

Page 29: ...cal dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 28419 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This prevents the propell...

Page 30: ...ently in use in the 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 fittin...

Page 31: ...IMPORTANT Oil must be NMMA certified TC W3 2 Cycle oil 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 Severe engine damage may ...

Page 32: ...ection 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 Oil tank 3 2 liters 96 fl oz Mercury or Quicksilver Premium 2 cycle TC W3 outboard oil 29163 3 Reinstall fill cap and tighten securely Filling Remote Oil Tank If Equipped 1 Remove fill cap and fill with the specified oil Capacity Fluid Type Oil tank 11 5 l...

Page 33: ...nks Fill the fuel tanks outdoors away from heat sparks and open flames Remove the portable fuel tanks from the boat to fill them Always stop the engine before filling the tanks Do not completely fill the fuel tanks Leave approximately 10 of the tank volume unfilled Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled PORTABLE FUEL TANK PL...

Page 34: ...if equipped Refer to Features and Controls Power Trim and Tilt d Lanyard stop switch Refer to General Information Lanyard Stop Switch e Lanyard Refer to General Information Lanyard Stop Switch f Throttle friction adjustment Console controls require cover removal for adjustment g Ignition key switch OFF ON START h Fast idle lever Refer to Operation Starting the Engine i Throttle only button Refer t...

Page 35: ...ning horn inside key switch Tiller handle models will have the warning horn located below the tiller handle 29165 WARNING SYSTEM OPERATION The warning horn will emit a continuous beep This will alert the operator and help identify the following listed situations Warning System Function Sound Description Engine Over Temperature Continuous Engine Over Heat Low Oil Level Oil Injected Models Continuou...

Page 36: ...allow some additional low speed idle running time before the engine starts to overheat again Operating an overheated engine will cause engine damage If a steady flow of water is coming out of the water pump indicator hole and the engine continues to overheat consult your dealer Operating an overheated engine will cause engine damage LOW OIL LEVEL The warning system will be activated if the oil lev...

Page 37: ...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 Moving the outboard further away from the boat transom is called trimming out or up The term trim generally refers to the adjustment of the outboard within the first 20 range of travel This is the range used while operating y...

Page 38: ...y with a heavy load or a stern heavy boat Generally improve the ride in choppy water Increase steering torque or pull to the right with the normal right hand rotation propeller In excess can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or oversteering if any t...

Page 39: ...es its maximum tilt position 1 Engage the tilt support lever by rotating knob to bring the support lever upward 2 Lower outboard to rest on the tilt support lever 3 Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down Lower the outboard a Tilt support lever b Knob MANUAL TILTING If the outboard cannot be tilted using the power trim tilt switch ...

Page 40: ...board will automatically return down to the maximum trim range Manual Tilt System Models without power trim are equipped with a tilt assist system that allows the operator to easily tilt and lock the outboard at any tilt position from full down to full up This tilt system is designed to be adjusted when the outboard is idling in neutral or with the engine turned off WARNING Operating the engine wi...

Page 41: ...lt angle Operate the outboard at slow speed while tilted up for shallow water operation Keep the cooling water intake holes submerged in the water and continue to check for water discharge from the water pump indicator hole TILTING OUTBOARD Tilting To Full Up Position 1 Stop the engine Move the tilt lock lever to the tilt position Take hold of the top cowl grip and raise outboard to full tilt up p...

Page 42: ...gle of your outboard is adjusted by changing the position of the tilt pin in the five adjustment holes provided The outboard should be locked against this tilt pin by setting the tilt lock lever to the lock run position Proper adjustment allows the boat to achieve optimum performance stability and minimize steering effort NOTE Refer to the following lists when adjusting the operating angle of your...

Page 43: ...torque or pull to the right with the normal right hand rotation propeller In excess can lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered Adjusting the outboard away from the boat tra...

Page 44: ...els WARNING Insufficient friction adjustment can cause serious injury or death due to loss of boat control When setting the friction adjustment maintain sufficient steering friction to prevent the outboard from steering into a full turn if the tiller handle or steering wheel is released Adjust this lever to achieve the desired steering friction drag on the tiller handle a Tighten friction b Loosen...

Page 45: ...the desired tilt pin hole Turn your boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt and make small adjustments at a time If the boat turns more easily to the left move the trailing edge of trim tab to the left If the boat turns more easily to the right move the trailing edge of trim tab to the right Retighten bolt and retest MOD...

Page 46: ... aboard and readily accessible It is the law A ring type life buoy or buoyant cushion designed to be thrown to a person in the water Know the boat s maximum load capacity Look at the boat capacity plate Fuel supply OK Oil supply oil injection OK Arrange passengers and load in the boat so the weight is distributed evenly and everyone is seated in a proper seat Tell someone where you are going and w...

Page 47: ...s completely out of water except in freezing temperatures when not in use 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 Effects of Elevati...

Page 48: ...ly rich fuel mixture Engine Break in Procedure IMPORTANT Failure to follow the engine break in procedures can result in poor performance throughout the life of the engine and can cause engine damage Always follow break in procedures MODELS WITH OIL INJECTION Engine Break in Fuel Mixture Use a 50 1 2 gasoline oil mixture in the first tank of fuel Use of this fuel mixture combined with oil from the ...

Page 49: ...e outboard to the vertical operating position Make sure all cooling water intake holes are submerged 26837 2 Open fuel tank vent screw in filler cap on manual venting type fuel tanks 19748 3 Connect the fuel line to the outboard 29175 4 Squeeze the fuel line primer bulb several times until it feels firm 19779 NOTE The engine will not start unless the lanyard is set to the RUN position OPERATION en...

Page 50: ...1 6 Shift outboard to neutral N position N 26838 N 29176 7 Model without power trim Position tilt lock lever to the lock run position a Tilt position b Lock run position 8 Tiller handle models Align the throttle grip pointer to the START position 29598 9 Starting a cold engine a b 26802 OPERATION 40 eng ...

Page 51: ...10 Starting a flooded engine a Tiller handle models Advance the throttle grip to full throttle speed Without activating primer start engine following starting procedure Immediately start to reduce engine speed after engine starts b Remote control models Advance the fast idle speed lever or throttle only feature to the full maximum position Without activating the primer crank engine for 10 seconds ...

Page 52: ...checked by your dealer Operating the engine while overheated may cause serious engine damage Gear Shifting IMPORTANT Observe the following Never shift the outboard into or out of gear unless the engine speed is at idle Shifting at higher than engine idle speed could cause damage to the gearcase Do not shift the outboard into reverse when the forward motion of the boat is greater than a no wake spe...

Page 53: ...rol handle or rotate the throttle grip tiller handle to increase the engine speed Stopping the Engine 1 Remote control models Reduce the engine speed and shift the outboard to neutral position Turn the ignition key to OFF position 26843 OFF ON S T A R T 2 Tiller handle models Reduce the engine speed and shift the outboard to neutral position Push in the engine stop button or turn the ignition key ...

Page 54: ...tection 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 Shift outboard to neutral N position N 26838 N 29176 3 Turn the ignition key to ON position 26846 OPERATION 44 eng ...

Page 55: ...r metal test probes and stay clear of spark plug leads when performing live tests WARNING The exposed moving flywheel can cause serious injury Keep your hands hair clothing tools and other objects away from engine when starting or running the engine Do not attempt to reinstall the flywheel cover or top cowl when engine is running 5 Place starter rope knot into the flywheel notch and wind the rope ...

Page 56: ...e exhaust relief hole on the outboard may become submerged if the outboard is trimmed full in while running at idle speed This will cause exhaust restriction rough idle excessive smoke and fouled spark plugs If this condition exists trim the outboard up until the exhaust relief hole is out of the water The outboard should be lowered for accelerating from a standing start or from idle speed 28423 O...

Page 57: ...ilure Some caustic cleaning chemicals may cause or accelerate corrosion Exercise caution when using cleaning chemicals around the engine and follow the recommendations on the packaging of the cleaning product CLEANING GAUGES IMPORTANT Never use high pressure water to clean gauges Routine cleaning of the gauges is recommended to prevent a buildup of salt and other environmental debris Crystalized s...

Page 58: ...a mild nonabrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a nonabrasive automotive polish polish designed for clear coat finishes Remove the applied wax by hand using a clean soft cloth 5 To remove minor scratches use Mercury Marine Cowl Finishing Compound 92 859026K 1 CLEANING CARE FOR THE POWERHEAD SALTWATER USE If the outboard i...

Page 59: ...stem saltwater or brackish water only ANNUALLY OR 100 HOURS Grease the engine if applicable Change the engine oil and filter if equipped Inspect the thermostat saltwater or brackish water only Add Quickleen to the fuel tank once per year per engine Apply antiseize to the spark plug threads Replace the gear lubricant Inspect the corrosion control anodes Lubricate the propeller shaft splines Replace...

Page 60: ...uicksilver accessory or equivalent flushing attachment WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilat...

Page 61: ...cator hole Continue flushing the outboard for 3 to 5 minutes carefully monitoring water supply at all times 6 Stop the engine turn off the water and remove the flushing attachment Reinstall the propeller Top Cowl Removal and Installation REMOVAL 1 Unlock the rear latch by pushing lever down 29549 2 Lift rear of cowl and disengage front hook 29551 INSTALLATION 1 Engage the front hook and push cowl ...

Page 62: ...f spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately Before servicing any part of the fuel system stop the engine and disconnect the battery Drain the fuel system completely Use an approved container to collect and store fuel W...

Page 63: ...and wipe up any spilled fuel immediately 1 Remove the filter a Filter b O ring seal c Sight bowl 2 Wash sight bowl and filter in cleaning solvent 3806 Carburetor Fuel Bowl 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 wo...

Page 64: ...ulb must be replaced CARBURETOR ADJUSTMENTS Slow Speed Mixture Adjustment 1 Before starting engine turn the slow speed mixture screw in until it is lightly seated then back it out 1 1 4 turns 3912 2 With boat tied securely to dock start engine and allow it to warm up 3 Shift the outboard into forward gear while maintaining idle speed F R N 29191 4 Turn the slow speed mixture screw slowly in until ...

Page 65: ...eed screw to obtain the recommended engine idle speed Refer to General Information Specifications 3914 High Speed Mixture Adjustment The carburetor is equipped with a standard size high speed fixed jet that is replaceable for operation at higher elevations See an authorized dealer Steering Link Rod Fasteners IMPORTANT The steering link rod that connects the steering cable to the engine must be fas...

Page 66: ... Flat washers c Nylon insert locknut 11 826709113 d Special washer head bolt 10 856680 e Spacer Description Nm lb in lb ft Special washer head bolt 27 20 Nylon insert locknut a 27 20 Nylon insert locknut c Tighten until seats then back off 1 4 turn Assemble steering link rod to steering cable with two flat washers and nylon insert locknut Tighten locknut until it seats then back nut off 1 4 turn A...

Page 67: ... is not found the fuse may blow again Replace fuse with a fuse of the same rating Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse with a new fuse with the same rating a Good fuse b Broken band Corrosion Control Anode The outboard has corrosion control anodes at different locations An anode helps protect the outboard against galvanic corro...

Page 68: ...b Trim tab c Anode on each side of gearcase Propeller Replacement Standard Gearcase WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propelle...

Page 69: ... propeller to hold the propeller and remove the propeller nut 26901 5 Pull propeller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 6 Coat the propeller shaft with Extreme Grease or 2 4 C with PTFE Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 MAINTENANCE eng 59 ...

Page 70: ...peller nut onto the shaft a Propeller nut b Propeller nut retainer c Propeller d Forward thrust hub 8 Flo Torq II drive hub propellers Install forward thrust hub propeller replaceable drive sleeve rear thrust hub propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Rear thrust hub d Replaceable drive sleeve e Propeller f Forward thrust hub 9 Place the ...

Page 71: ...Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate 1 Shift outboard to neutral N position N 26838 N 2917...

Page 72: ... propeller to hold the propeller and remove the propeller nut 26901 5 Pull propeller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer 6 Coat the propeller shaft with Extreme Grease or 2 4 C with PTFE Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 MAINTENANCE 62 eng ...

Page 73: ...propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Rear thrust hub d Continuity washer e Propeller f Forward thrust hub 8 Flo Torq II drive hub propellers Install forward thrust hub replaceable drive sleeve propeller rear thrust hub propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Rear thrust hub d Pr...

Page 74: ... under the engine cowl resulting in serious injury or death from a fire or explosion To avoid damaging the spark plug boots do not use any sharp object or metal tool to remove the spark plug boots 1 Remove the spark plug boots Twist the rubber boots slightly and pull off 26899 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blist...

Page 75: ...e following with Extreme Grease or 2 4 C with PTFE Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft 8M0071842 95 2 4 C with PTFE Propeller shaft 92 802859A 1 Propeller shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft 26902 2 ...

Page 76: ...iller handle steering cable grease fitting 8M0071842 Swivel bracket Lubricate through fitting Tilt support lever Lubricate through fitting a Tilt support lever b Swivel bracket Tilt tube Lubricate through fitting 29575 Tiller handle Lubricate through fitting 29576 Steering cable Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through fitting a b ...

Page 77: ...h Extreme Grease or 2 4 C with PTFE Tube Ref No Description Where Used Part No Extreme Grease Propeller shaft swivel bracket tilt support lever tilt tube tiller handle clamp screw threads 8M0071842 95 2 4 C with PTFE Propeller shaft swivel bracket tilt support lever tilt tube tiller handle clamp screw threads 92 802859A 1 Propeller shaft Refer to Propeller Replacement for removal and installation ...

Page 78: ...t lever Lubricate through fitting a Tilt support lever b Swivel bracket Tilt tube Lubricate through fitting 29575 Tiller handle Lubricate through fitting 29576 Clamp screw threads 3906 a b 29574 MAINTENANCE 68 eng ...

Page 79: ...t If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gearcase Remove the fill drain plug and exa...

Page 80: ...er Premium or High Performance Gear Lubricant CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1 Place the outboard in a vertical operating position 2 Remove the front vent plug and rear vent plug 3 Remove the fill drain plug Place the lubricant tube into the fill drain plug hole and add lubricant until it appears at the front vent hole At this time install the front vent plug and sealing washer a Fr...

Page 81: ...bricant tube and install cleaned fill drain plug and sealing washer Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine MAINTENANCE eng 71 ...

Page 82: ...ystem Fill the fuel tank and engine fuel system with treated stabilized fuel to help prevent formation of varnish and gum Proceed with the following instructions Portable fuel tank Pour the required amount of gasoline stabilizer follow instructions on container into fuel tank Tip fuel tank back and forth to mix stabilizer with the fuel Permanently installed fuel tank Pour the required amount of ga...

Page 83: ...ry Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel Remove the spark plugs and inject a five second spray of storage seal around the inside of the cylinder Rotate the flywheel manually several times to distribute the storage seal in the cylinder Reinstall spark plug Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubricant Positioning Outboa...

Page 84: ...ection Fuel is not reaching the engine a Fuel tank is empty b Fuel tank vent not open or restricted c Fuel line is disconnected or kinked d Primer bulb not squeezed e Primer bulb check valve is faulty f Fuel filter is obstructed Refer to Maintenance section g Fuel pump failure h Fuel tank filter obstructed Ignition system component failure Spark plugs fouled or defective Refer to Maintenance secti...

Page 85: ...p Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator TROUBLESHOOTING eng 75 ...

Page 86: ...it to your authorized dealer Only authorized dealers specialize in Mercury products and have factory trained mechanics special tools and equipment and genuine Quicksilver parts and accessories to properly service your engine NOTE Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for your power package SERVICE AWAY FROM HOME If you are away from your local de...

Page 87: ...ssories from the factory Mercury Marine does not sell to unauthorized dealers or retail customers When inquiring about parts and accessories the dealer requires the engine model and serial numbers to order the correct parts 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...

Page 88: ...175 Australia Fax 61 3 9706 7228 Europe Middle East Africa Telephone 32 87 32 32 11 Brunswick Marine Europe Parc Industriel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 1 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 1 954 744 3535 Japan Telephone 072 233 8888 Kisaka Co Ltd 4 130 Kannabe...

Page 89: ...OUTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package Submit the following order form with payment to Mercury Marine Attn Publications Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Copy this form and print or type This is your shipping label...

Page 90: ...t utilize the outboard mounting hardware will compromise the ability of that hardware to properly and safely secure the outboard to the transom Outboards that require validated mounting hardware will have the following decal on the transom clamp 51965 Accessories Mounted to the Transom Clamp Bracket Mercury Marine has been made aware that certain aftermarket marine accessories such as emergency bo...

Page 91: ...CESSORY MOUNTING TO THE TRANSOM CLAMP BRACKET After the engine is mounted to the transom or jack plate in accordance with the engine installation instructions it is acceptable to attach an accessory to the boat by use of the unused bolt holes in the transom clamp bracket as shown in Figure 1 The following list provides additional guidelines for mounting accessories to the transom clamp bracket The...

Page 92: ...lamp bracket Refer to Figure 1 Figure 1 a Minimum clearance 3 175 mm 0 125 in b Edge of accessory bracket c Transom clamp bracket wall d Radius e Engine supplied mounting fasteners f Fasteners supplied by the accessory manufacturer installed through unused engine mounting bracket holes b c d a f 54624 e ENGINE INSTALLATION 82 eng ...

Page 93: ...securing the engine to the boat 1 Do not mount an accessory to the transom clamp bracket in an unsupported condition Refer to Figure 2 54625 Figure 2 2 Do not attach an accessory to the boat by use of the engine mounting hardware Refer to Figure 3 Figure 3 a Engine supplied mounting fasteners b Transom clamp bracket c Accessory 53523 a b c ENGINE INSTALLATION eng 83 ...

Page 94: ...25 in thread 826711 17 Nylon insert locknut 20 28421 Flat washer 1 50 in diameter 54012 Flat washer 0 875 in diameter Available Outboard Mounting Bolts Part Number Description 67755005 20 x 2 50 in long 1 25 in thread 67755006 20 x 3 50 in long 1 25 in thread 814259 20 x 4 00 in long 2 25 in thread 67755 1 20 x 4 50 in long 2 25 in thread 8M0071543 20 x 5 00 in long 3 25 in thread 8M0038370 20 x 5...

Page 95: ...e The boat transom must be strengthened or the load carrying area increased a Transom yielding under bolt torque b Transom cracking under bolt torque Use a dial torque wrench to determine transom strength If the bolt or nut continues to turn without the torque reading on the dial increasing it is an indication that the transom is yielding The load area can be increased by using a larger washer or ...

Page 96: ...t 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 a Step not allowed b Gap between transom clamp and boat transom not allowed a b 51817 ENGINE INSTALLATION 86 eng ...

Page 97: ...o ensure proper clearance of the transom bracket relief radius area 51867 Installation 1 Apply marine sealer to the shanks of the bolts not to the threads 2 Fasten the outboard with the correct mounting hardware Tighten the locknuts to the specified torque IMPORTANT Ensure that a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening The locknut must be drawn ...

Page 98: ... 875 in flat washer 4 c Nylon insert locknut 4 d 1 500 in flat washer 4 e Marine sealer apply to the shank of the bolts not the threads Description Nm lb in lb ft Outboard mounting locknuts and bolts standard boat transom 75 55 Outboard mounting locknuts and bolts metal lift plates and setback brackets 122 90 a c d c a d 40952 b e ENGINE INSTALLATION 88 eng ...

Page 99: ...lling off the boat transom resulting in property damage serious injury or death Before operation the outboard must be correctly installed with the required mounting hardware We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance If you install the outboard yourself follow instructions in the outboard installation manu...

Page 100: ...fer to General Information Specifications This RPM range allows for better acceleration while maintaining maximum boat speed 22551 If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher elevations increased boat load or a dirty boat bottom gearcase a propeller change or cleaning may be required to maintain performance and ensu...

Page 101: ...quire 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 ENGINE INSTALLATION eng 91 ...

Page 102: ...Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours MAINTENANCE LOG 92 eng ...

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Mercury 55 Marathon, Operation, Maintenance & Installation Manual

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Summary of Contents for 55 Marathon

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