Mercury 40, 50, 60HP EFI 4 Stroke Service Kit

Daily checks

• Check for fuel leaks; inspect steering for binding; check gear-lube level (if equipped with remote reservoir); propeller/guards for damage; water intake for debris; warning horn self-test; battery secure/charged; engine-oil level.

• After each use: Flush cooling system; wash down and inspect for damage/corrosion; lubricate as listed; drain water from gearcase if freezing conditions are expected.
• Annually or 100 h: Inspect anodes; check/replace spark plugs; inspect fuel system & lines; change engine oil & filter; change gearcase lubricant; check timing belt; check battery and charging system; lubricate all points; check power-trim fluid; inspect fuses.
• 3 years or 300 h: Replace fuel lines/primer bulb if hardened, cracked, cut or swollen.

1. Attach an approved flushing device to the gearcase water intakes and connect a hose.
2. Turn water on fully before starting; idle for the specified period to flush salt/silt; verify steady tell-tale.
3. Shut the engine off first, then the water supply; remove the device.

1. Connect hose to the jet flush fitting; start engine at idle; flush for the specified period.
2. Shut down; disconnect hose; allow residual water to drain.

1. Inspect the link-rod, locknuts and retaining hardware for security and corrosion.
2. Verify full, free movement from lock-to-lock with no interference; tighten/torque per your control type.

1. Inspect external and internal (water-passage) anodes; replace if 50% depleted.
2. Do not paint anodes; ensure clean metal-to-metal contact.

1. Remove ignition coil/boot; blow debris from plug well; remove plug and inspect.
2. Set gap to 1.0 mm (0.040 in.); replace with Champion RA8HC if required.
3. Install and torque to 17 Nm (150 lb-in.); refit coil/boot securely.

• Clean and tighten terminals; apply corrosion inhibitor; ensure secure mounting; verify state of charge.

• Grease steering pivot points and tilt tube.
• Lubricate throttle/shift linkages and specified external pivots with marine grease.

1. With engine supported, remove the fill plug.
2. Top up to the bottom of the hole; reinstall plug; cycle trim UP/DOWN and recheck.

• Replace only with the specified fuse rating and type for each circuit/location shown in the product diagrams.

1. Inspect belt and pulleys; replace the belt if any of the following exist: cracks; missing teeth; oil-soaked; frayed edges; excessive wear; abnormal noise.

• Inspect primer bulb and lines for cuts, swelling, cracks, hardening or leaks; repair/replace as required.

1. Relieve fuel pressure; disconnect lines; remove the filter as illustrated for your model.
2. Install in correct flow direction; secure clamps; prime and check for leaks.

1. Warm the engine to operating temperature. Remove engine cowl.
2. Tilt the outboard so the drain hole faces downward; remove the drain screw and washers; drain completely.
3. Reinstall the drain screw with new washer(s).
4. Remove the oil filter; lightly oil the new filter gasket; install the new filter and tighten per instructions.
5. Fill through the oil fill to capacity; run briefly; shut down; recheck dipstick and leaks; top up if required.

1. Trim outboard to level operating position.
2. Remove dipstick; wipe; reinsert fully; remove and read. Add oil through fill as needed; do not overfill.

1. With engine vertical, remove the vent plug and drain/fill plug; drain completely.
2. Pump fresh gear lube from the drain until it exits the vent; install a new vent-plug washer and plug; then install the drain plug with a new washer.

1. Remove vent & drain plugs; drain completely with engine upright.
2. Fill from the drain until lubricant exits the vent; install a new vent-plug washer and plug; then install the drain plug with a new washer.

Steering pull adjustment

Adjust the steering-pull screw per the figure until steering effort is balanced.

Flushing the cooling system (jet)

Connect hose to the jet flush fitting; idle-flush; disconnect and drain.

Impeller clearance adjustment

1. Loosen fasteners; adjust wear-ring clearance per spec; retorque.

Impeller — removal & installation

1. Remove intake grate/fasteners; pull pump assembly.
2. Remove impeller per figure; note shims and orientation.
3. Reassemble with specified greases on splines and seals; torque nuts/bolts to values shown; verify clearance.
4. Reinstall pump and grate.

• Lubricate driveshaft bearing and other jet-specific points indicated for your model with the specified marine grease.

Inspect for rounded leading edges, chips or excessive clearance; service per jet section if performance drops.

Storage preparation

• Stabilise fuel; run engine to circulate; fog/protect per steps for your model.
• Change engine oil and gear lube; lubricate all points; clean and protect external surfaces.

Protecting external outboard components

• Wash, dry and apply corrosion-inhibiting protectant to metal parts; do not coat belts or anodes.

Protecting internal engine components

• Follow the manual’s internal protection steps (fogging/turning engine) for storage duration.

Gearcase

• Store with fresh lubricant; check for water intrusion (milky lube) and correct before lay-up.

Positioning outboard & battery

• Position unit to fully drain cooling passages; store battery clean, charged, cool/dry and disconnected.