1986 Mercury 60 HP Outboard Manual

The 1986 Mercury 60 HP Outboard is a 3-cylinder, 2-stroke marine engine with 60 horsepower output, featuring CD ignition system, 60-degree V-block design, thermostatically controlled cooling, through-hub exhaust, and single-lever remote control operation. This manual covers operation, maintenance, troubleshooting, and specifications for proper use and care of your outboard motor.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Operation 6. Maintenance Schedule 7. Fuel System 8. Electrical System 9. Cooling System 10. Winter Storage 11. Troubleshooting

Features at a Glance

Key components: 3-cylinder 2-stroke engine, CD ignition, single-lever control, through-hub exhaust, water pump cooling.

FeatureDescription
Engine Type3-cylinder, 2-stroke, loop charged
Displacement49.8 cu in (816 cc)
Bore x Stroke2.95 x 2.44 in (75 x 62 mm)
Ignition SystemCD with alternator
Starting SystemElectric and manual rope start
Gear Ratio1.85:1
Full Throttle RPM5000-5600 RPM
WeightApprox. 195 lbs (88 kg)
Fuel Mix Ratio50:1 (gasoline to oil)
Recommended Fuel87 octane regular unleaded

Installation

Proper installation ensures optimal performance and safety.

  1. Select transom: Ensure transom height matches motor shaft length (20 inches standard).
  2. Mount motor: Use appropriate mounting bolts and brackets for secure attachment.
  3. Connect steering: Attach steering cable or tiller handle securely.
  4. Connect fuel system: Attach fuel line with quick-connect fitting.
  5. Connect electrical: Battery cables (red to positive, black to negative).

WARNING! Motor is heavy; use lifting eye and proper equipment. Ensure transom can support motor weight.

First-Time Setup

Initial setup for new installation or after storage.

  1. Fuel mixture: Prepare 50:1 fuel/oil mixture using TC-W3 certified oil.
  2. Priming: Squeeze fuel line bulb until firm.
  3. Battery: Connect fully charged 12V battery (minimum 450 CCA).
  4. Vent fuel tank: Open air vent on portable fuel tank.
  5. Test operation: Start motor and check for proper water pump operation.

CAUTION! Always operate in well-ventilated area. Check for fuel leaks before starting.

Specifications

Controls and Operation

Single-lever control combines throttle and shift functions.

Control Handle: Neutral (center), Forward (push forward), Reverse (pull back), Throttle (increase by rotating).

Starting Procedure: Ensure motor is in neutral, attach safety lanyard, prime fuel system, turn key to start. Warm-up: Allow 2-3 minutes at fast idle before operation. Shifting: Always shift at idle speed. Stopping: Return to neutral, turn key to off.

Maintenance Schedule

Regular maintenance ensures long engine life and reliability.

IntervalService Required
Every useCheck fuel system for leaks, inspect propeller
20 hours/30 daysCheck gearcase oil, inspect spark plugs
100 hoursChange gearcase oil, water pump impeller
SeasonalFuel system cleaning, corrosion inspection
300 hoursComplete tune-up, carburetor adjustment

Fuel System

Three single-barrel carburetors with fuel pump and primer system.

  1. Fuel mixture: Always use 50:1 ratio with TC-W3 certified oil.
  2. Carburetor adjustment: Idle mixture screws 1-1/4 turns out from lightly seated.
  3. Fuel filter: Replace annually or if contaminated.
  4. Fuel lines: Inspect regularly for cracks or deterioration.

Tip: Use fuel stabilizer if storing more than 30 days.

Electrical System

CD ignition with 9-amp alternator for battery charging.

  1. Battery: Minimum 450 CCA, maintain full charge.
  2. Spark plugs: Champion L77JC4, gap 0.030 inch.
  3. Ignition timing: 4° BTDC at idle, 21° BTDC at WOT.
  4. Charging system: Output 9 amps at 5000 RPM.

WARNING! Disconnect battery before servicing electrical components.

Cooling System

Water pump impeller cooling with thermostat control.

Thermostat: Opens at 143°F (62°C). Water pump: Replace impeller every 2 years or 300 hours. Tell-tale: Check for steady water stream indicating proper cooling. Overheat protection: Engine will reduce power if overheating detected.

Winter Storage

Proper storage prevents damage during off-season.

  1. Fuel system: Add stabilizer, run engine to distribute, drain carburetors.
  2. Fogging: Spray fogging oil into carburetors while running.
  3. Gearcase: Change gear oil, inspect for water contamination.
  4. Battery: Remove, clean, and store fully charged.
  5. External: Clean and wax exterior, store upright.

CAUTION! Never store with fuel in carburetors - causes varnish buildup.

Troubleshooting

SymptomPossible CauseCorrective Action
Engine won't startFuel, spark, or compressionCheck fuel supply, spark plugs, compression test
Poor performanceFuel restriction, fouled plugsClean fuel system, replace spark plugs
OverheatingWater pump, thermostatCheck tell-tale stream, replace impeller/thermostat
No chargingAlternator, rectifierTest alternator output, check rectifier diodes
VibrationPropeller damage, mountingInspect propeller, check motor mounting

Service: Contact authorized Mercury Marine dealer for major repairs.

Parts: Use genuine Mercury replacement parts for optimal performance.

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