New 4-stroke

alphaboat

Cadet
Joined
Jun 25, 2007
Messages
8
Just took my new 60-HP Mercury EFI 4-stroke out for first two hours of break-in today.
All-in-all, the experience left me wondering about my $6,100 purchase.

One question for someone in the group who knows more about the Mercury 4-strokes than I do....
On the starboard side of the intake manifold, there is a solenoid with two barb fittings coming out of it. The lower one had a hose running from the front of the intake manifold connected to it. The other fitting was left open. I put my finger over the open fitting and there is vacuum.
Wouldn't this be a vaccum leak, and therefore, something to plug?
If this is an oversite, and the open fitting should be plugged (or worse yet...connected to somehing that it is not), it just adds a little more frustration regarding the less than perfect job of rigging I received when I purchased this new motor for my boat.
When I first fired it up the idle was up around 3000.
Then I took the Cowling off and looked around and couldn't see anything out of order. However, when I remounted the Cowling, the idle was down at a normal under 1000 level. I went ahead and ventured out into the river. When I tried to idle again, the RPM's were way too high.
Another look "under the hood" revealed that a wire had somehow gotten behind some throttle linkage and was the reason for the intermittant elevated idle speed.
Once I got that under control, the two hour break-in cruise was as expected.
That first hour keeping her reigned in to no more than 3500 RPM was a drag. Second hour running up to 4500 RPM with 1-minute jaunts at WOT was more fun! These 4-strokes do have quite a punch out of the hole!
I will need to go up a inch in pitch as I need to hold her back a bit to keep under 6,000 RPM at WOT. Came with a 10-3/4 X 12 and pretty sure I will be happy with 10-1/2 X 13.

Anyway...anyone with info about the open vacuum fitting??? I apreciate the help!
 

achris

More fish than mountain goat
Joined
May 19, 2004
Messages
27,468
Re: New 4-stroke

I don't know what area you're in, but if you have more than one Merc dealer handy, I'd be looking at another dealer. If there is something not right with the engine as it is from the factory, any Merc dealer can do warranty work. If it really is a problem caused by the installing dealer, then another dealer should advise you as such. Then you can opt to return to the installing dealer and have him rectify his work, or be prepared to pay another dealer to do it. Either way I would give the installing dealer a chance to explain himself. If you are not satisfied with that, then please write to Mercury with your grievances. You'll find them very helpful and if they have a dealer out there not doing the right thing, they need to know. I was a Merc dealer years ago and they are very focused on customer satisfaction.

Chris...........
 

Silvertip

Supreme Mariner
Joined
Sep 22, 2003
Messages
28,771
Re: New 4-stroke

A vacuum leak on a four stroke is not a good thing and may also account for the increased idle speed. Stop at a dealer and ask about it or just check an engine as suggested. You can also go to the Mercury Parts Express web site and key in the serial number to view the parts list. The parts list would show if there was a hose connected to that fitting.
 

alphaboat

Cadet
Joined
Jun 25, 2007
Messages
8
Re: New 4-stroke

After another look at things this morning (digging through the documentation that came with the replacement engine) it looks to me like what happened here is the dealer used what appears to be an adapter to connect the new Merc 60 HP 4-stroke engine with the existing remote wiring harness from the old '95 Merc 50 HP 2-stroke. This adapter has four additional wires that were not gathered up with a nylon tie and it is one of those wires that worked itself behind a nearby throttle linkage and caused the "run away" high idle.
Low and behold, when I got in there with a good light for a close look, I saw a broken nylon tie strap laying in the bottom of the engine compartment. My guess is the technician tried to secure things but things didn't go as planned.
Oh well, I have "sanitized it now and don't think I'll have any more trouble.

As far as the vacuum connection, I have found documentation that clearly shows that barb fitting being open....so I guess that is O.K....still seems odd that you can put your finger over that fitting when the engine is running and feel vacuum and also (don't know if I mentioned this earlier) the running characteristics of the motor change slightly when I plugged the open fitting momentarily. Still a little "up in the air" regarding that issue but the picture in the manual shows it open.

One last thing......mounting height.
The anti-ventilation plate, with the motor trimmed to the point where the anti-ventilation plate is parallel to the bottom of the boat, is about 3/8" above the bottom of the boat.
The mounting instructions that came with the boat suggest in line with to 1" below the bottom of the boat.
One thing I noticed on the run yesterday was what seemed to be a very narrow band of trim available before I could hear the prop start cavitating.
Ideas?...Suggestions??

Thanks for the support!
 

achris

More fish than mountain goat
Joined
May 19, 2004
Messages
27,468
Re: New 4-stroke

One last thing......mounting height.
The anti-ventilation plate, with the motor trimmed to the point where the anti-ventilation plate is parallel to the bottom of the boat, is about 3/8" above the bottom of the boat.
The mounting instructions that came with the boat suggest in line with to 1" below the bottom of the boat.
One thing I noticed on the run yesterday was what seemed to be a very narrow band of trim available before I could hear the prop start cavitating.
Ideas?...Suggestions??

Thanks for the support!

That is one I'd take back to the dealer. It's not a big job to move the engine down a hole and shouldn't take too long.

Cheers,

Chris..........
 

gss036

Commander
Joined
Jan 18, 2003
Messages
2,914
Re: New 4-stroke

I think I would definately take back to the installing dealer and ask that they have a "MASTER TECH" take a look at the motor and the installation. Tell then that you have found too many things wrong and have a lack of confidence in the installation and rigging.
I would think they would understand your position. Most shops just have labor employees do this type of work.
 
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