Diagram based mercruiser 502 engine diagram completed

Quick Links. Table of Contents. Direct Fuel Injection. Starting Model Year Starting Serial Number OG Outboard Motor Mercury 60 Manual 32 pages.

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Page 3: Page Numbering It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength.

diagram based mercruiser 502 engine diagram completed

American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Grease Gun A1 2. Anti-Corrosion Grease A6 3. Check that lanyard stop switch stops the engine. Visually inspect the fuel system for deterioration or leaks. Check outboard for tightness on transom.

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Check steering system for binding or loose components. This will help prevent a buildup of deposits from clogging the internal water passages. Carefully follow all fuel system service instructions. Another anode b is installed on the bottom of the transom bracket assembly. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.

diagram based mercruiser 502 engine diagram completed

Turn off the engine before servicing the battery. Add water as necessary to keep the battery full. Never run the engine without the air filter. Removal 1. Remove flywheel cover from the engine. Snap out the retainer a and remove filter b. 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. Steering Cable Grease Fitting If Equipped — Rotate steering wheel to fully retract the steering cable end a into the outboard tilt tube.

Lubricate through fitting b.

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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 gear case 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 gear case.

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Table of Contents. Starting Model Year Starting Serial Number 0T Engine Mercury 8. Page 3 It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings.

Page 5 Table of Contents Specifications Page 7 0. Lubricant A1 [8 oz. Page Table Of Contents Grease Gun A1 2. Check that lanyard stop switch stops the engine. Visually inspect the fuel system for deterioration or leaks. Check outboard for tightness on transom. Check steering system for binding or loose components. This will help prevent a buildup of deposits from clogging the internal water passages.

Carefully follow all fuel system service instructions. Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel sys- tem.

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Another anode b is installed on the bottom of the transom bracket assembly. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. Turn off the engine before servicing the battery.

Add water as necessary to keep the battery full. Trim Rod Ball Ends — Turn the ball ends to work the lubricant into the ball sockets. Steering Cable Grease Fitting If Equipped — Rotate steering wheel to fully retract the steering cable end a into the outboard tilt tube. Lubricate through fitting b. 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.

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If water is noticed, have the gear case 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 gear case. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage two months or longer. CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gear case could freeze and cause damage to the outboard.

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Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce engine power. Shifting weight to the rear stern 1.We have not undertaken any such wide evaluation.

All information, illustrations and specifications contained in this manual are based on the latest product information available at time of publication.

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It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started.

It is important to note that, during any maintenance procedure, replacement fasteners must have the same measurements and strength as those removed, whether metric or customary. Numbers on the heads of the metric bolts and on surfaces of metric nuts indicate their strength. Customary bolts use radial lines for this purpose, while most customary nuts do not have strength markings.

Mismatched or incorrect fasteners can result in damage or malfunction, or possible personal injury. Therefore, fasteners removed should be saved for re-use in the same locations whenever possible.

Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that meets the same specifications as the original. Notice Throughout this publication, Dangers, Warnings and Cautions are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully! These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures.

Notice to Users of This Manual This service manual has been written and published by the service department of Mercury Marine to aid our dealers, mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, of like or similar products manufactured and marketed by Mercury Marine, and that they have been trained in the recommended servicing procedures for these products which include the use of mechanics common hand tools and the special Mercury Marine or recommended tools from other suppliers.

Many of the engine mechanical components are designed for marine applications.

diagram based mercruiser 502 engine diagram completed

Unlike automotive engines, marine engines are subjected to extended periods of heavy load and wide-open-throttle operation and, therefore, require heavy-duty components. Special marine engine parts have design and manufacturing specifications which are required to provide long life and dependable performance.

Marine engine parts also must be able to resist the corrosive action of salt or brackish water that will rust or corrode standard automotive parts within a short period of time. Use of parts other than recommended service replacement parts, will void the warranty on those parts which are damaged as a result of the use of other than recommended replacement parts.Notice Throughout this publication, Dangers, Warnings and Cautions accompanied by the International HAZARD Symbol are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.

These Safety Alerts alone cannot eliminate the hazards that they signal.

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Strict compliance to these special instructions when performing the service, plus Common Sense operation, are major accident prevention measures. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers mechanics and company service personnel when servicing the products described herein.

It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics common hand tools and the special Mercury Marine or recommended tools from other suppliers.

We have not undertaken any such wide evaluation. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks.

When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started.

It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings.

Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible.

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Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. Engine Mechanical Components Many of the engine mechanical components are designed for marine applications.

diagram based mercruiser 502 engine diagram completed

Unlike automotive engines, marine engines are subjected to extended periods of heavy load and wide-open-throttle operation and, therefore, require heavy-duty components. Special marine engine parts have design and manufacturing specifications which are required to provide long life and dependable performance. Marine engine parts also must be able to resist the corrosive action of salt or brackish water that will rust or corrode standard automotive parts within a short period of time.

Use of parts other than recommended service replacement parts, will void the warranty on those parts which are damaged as a result of the use of other than recommended replacement parts. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided.

When servicing the electrical, ignition and fuel systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed. Table of Contents Table of Contents.This test should remind you that it is not the existence of a privacy policy that should be tested, but the actual copy of the privacy policy.

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