Mercury 60HP BigFoot Outboard OEM Service & Repair Manual
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7
C
OUTBOARD
INSTALLATION/
ATTACHMENTS
REWIND STARTER
7C-0 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996
Table of Contents
Page
Notes 7C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rewind Starter Components 7C-2 . . . . . . . . . . . . . . . . . . . .
Rewind Starter Disassembly 7C-4 . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection 7C-4 . . . . . . . . . . . . . . . . . . . . .
Rewind Starter Reassembly 7C-5 . . . . . . . . . . . . . . . . . . . .
Adjusting Rewind Spring Tension 7C-6 . . . . . . . . . . . . .
Starter Interlock Cable Adjustment 7C-7 . . . . . . . . . . . .
OUTBOARD INSTALLATION/ATTACHMENTS - 7C-1 90-817643R1 DECEMBER 1996
Notes:
7C-2 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996
Starter Assembly (MANUAL – 55)
95
2-4-C With Teflon (92-825407A12)
14
2 Cycle Outboard Oil (92-13249A24)
OUTBOARD INSTALLATION/ATTACHMENTS - 7C-3 90-817643R1 DECEMBER 1996
Starter Assembly (MANUAL – 55)
REF.
TORQUE
REF .
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 HANDLE ASSEMBLY
2 1 REST
3 1 SEAL
4 2 SCREW 55 6.0
5 2 SPACER
6 4 BUSHING
7 8 GROMMET
8 8 WASHER
9 4 NUT 75 8.5
10 1 INTERLOCK CABLE
11 1 SCREW Drive Tight
12 1 WASHER
13 1 COTTER PIN
14 1 SCREW Drive Tight
15 1 COTTER PIN
16 1 WASHER
– 1 RECOIL STARTER
17 1 STARTER HOUSING
18 1 SPRING
19 1 INTERLOCK LEVER
20 1 CAM
21 1 RETAINER
22 3 SCREW
23 1 WASHER - SPRING
24 1 SPRING
25 1 STARTER SHEAVE
26 2 SPRING
27 2 CAM
28 2 RETAINING RING
29 1 STARTER ROPE
30 1 SPRING
31 1 CAM
32 1 SCREW
33 1 BUSHING
34 1 RETAINING RING
7C-4 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996
Rewind Starter Disassembly
! WARNING
When disassembling and reassembling rewind start-
er, SAFETY GLASSES must be worn in case rewind
spring uncoils out of the housing.
1. Remove retaining clip and attaching screw which se-
cures shift interlock cable to starter housing.
2. Remove bolts (4) securing rewind starter to engine.
51606
b
c
a
c
c c
a - Retaining Clip
b - Screw
c - Bolts (4)
3. Slowly pull the starter rope out from the handle rest
approximately 2 feet (60 cm) and tie an overhand knot
between the rewind housing and the handle rest.
4. Remove retainer from rope handle and untie the rope
handle knot.
5. Remove the rewind starter.
a
b
a - Overhand Knot
b - Retainer
6. Remove cam retainer.
28374
a
b
a - Screws (3)
b - Cam Retainer
7. Remove cam lever, cam lever spring, and interlock le-
ver.
28375
a
b
c
a - Cam Lever
b - Cam Lever Spring
c - Interlock Lever
OUTBOARD INSTALLATION/ATTACHMENTS - 7C-5 90-817643R1 DECEMBER 1996
8. Remove starter sheave.
51605
b
a
a - Starter Sheave
b - Screw
9. Spring is replaced as a spring/cover assembly.
51607
a
a - Spring/Cover Assembly
Cleaning and Inspection
1. Clean components in solvent and dry with compressed
air.
2. Inspect rewind spring for kinks, burrs, corrosion of
breakage.
3. Inspect starter sheave, rope guide and starter housing
for nicks, grooves, cracks, wear or distortion, especial-
ly area of rope travel.
4. Inspect bushing, starter drive pawl and spring for wear
or damage.
5. Inspect starter rope for wear.
6. Replace components as necessary.
Rewind Starter Reassembly
! WARNING
When reassembling rewind starter, SAFETY GLASSES
must be worn in case rewind spring uncoils out of the
housing.
1. Install spring/cover assembly into sheave.
51607
a
a - Spring/Cover Assembly
7C-6 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996
2. Install starter sheave to housing and secure in place
with screw. Torque to 135 lb. in. (15.3 N·m).
51605
b
a
a - Starter Sheave
b - Screw
3. Install interlock lever, position cam spring into recess
of starter housing and reinstall cam lever.
28375
a
b
c
a - Cam Lever
b - Cam Lever Spring
c - Interlock Lever
4. Reinstall cam retainer and secure with screws (3).
28374
a
b
a - Screws (3)
b - Cam Retainer
Adjusting Rewind Spring Tension
1. Rotate sheave counterclockwise until it stops (coil is
bound). Then back off one full turn, plus what is needed
to align rope end with hole in housing. Never back off
sheave less than one full turn.
2. Route starter rope thru rope guide in housing. Tie a
overhand knot in rope approximately 12 in. (305 mm)
from end of rope.
b
a - Rotate Counterclockwise and Back Off at Laest One Full Turn
b - Tie Off Starter Rope 12 Inches (305 mm) from End with Overhand
Knot
OUTBOARD INSTALLATION/ATTACHMENTS - 7C-7 90-817643R1 DECEMBER 1996
NOTE: Check operation of rewind and rewind tension be-
fore outboard installation.
3. Place rewind starter on engine.
4. Pull starter rope thru bracket, handle, and starter rope
retainer. Secure starter rope to starter rope retainer
with knot.
a
b
c
d
a - Starter Rope
b - Bracket
c - Handle
d - Starter Rope Retainer
5. Secure rewind starter to engine bolts (4), torque to
90 lb. in. (10 N·m). Secure interlock lock cable with
retaining clip and screw.
51606
b
c
a
c
c c
d
a - Retaining Clip
b - Screw
c - Bolts (4) Torque to 90 lb. in. (10 N·m)
d - Bracket
Starter Interlock Cable Adjustment
IMPORTANT: Lubricate core wire of interlock cable
with light oil prior to making adjustments.
1. While rotating the propeller shaft, place the gear shift
lever into REVERSE.
2. Return the gear shift lever to NEUTRAL without going
past neutral detent.
3. Place end of interlock cable over pin of cam lever and
secure with retaining pin.
4. Secure interlock cable to starter housing using adjust-
ing screw. Do not tighted screw at this time.
5. Adjust interlock cable to align raised mark of cam lever
with pointer of rewind housing.
28376
a
b
c
d
e
a - Interlock Cable
b - Retaining Pin
c - Adjustment Screw
d - Raised Mark of Cam Lever
e - Pointer of Rewind Housing
6. Tighten cable adjustment screw and check adjustment
after 4 or 5 shift cycles.
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Full Search Facility
Print one or all pages of your manual
$45.99
Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your Mercury 60 Big Foot Outboard.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every nut and bolt. With hundreds of pages, it offers instructions on diagnosing and fixing any issue, from simple tasks like an oil change to more complex procedures like a transmission swap. The manual includes numerous illustrations to assist you and features easy-to-understand text throughout.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual is designed to walk you through the fundamentals of maintenance and repair, providing a step-by-step approach to equip you with the knowledge that factory-trained technicians possess. By utilizing the information in this service repair manual, both professional mechanics and DIY enthusiasts can confidently make informed decisions regarding the maintenance and repair of their machine.
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