40-60 Horsepower FourStroke Rocker Shaft
Contents
1. engine Three cylinder engine a Rocker shaft b Rocker arms 110 i 4 Stroke 10W 30 Outboard Oil Rocker shaft and rocker arms 92 802833A1 8 Lubricate the rocker shaft screw threads with 4 Stroke 10W 30 Outboard Oil 9 Install the replacement rocker shaft to the cylinder head 10 Install the rocker shaft assembly with the rocker arm brackets rocker arm springs and the rocker arm overload springs onto the cylinder head as shown THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 6 11 2006 Mercury Marine JULY 2006 2006 09 40 60 Horsepower FourStroke Rocker Shaft Screw Torque NOTE Ensure all of the valve lash adjustment screws are loose at this time 11 Secure the rocker shaft assembly rocker arm brackets rocker arm springs and the rocker arm overload springs to the cylinder head with the rocker shaft screws Four cylinder engine a Rocker arm bracket 1 b Rocker arm spring 2 arrow must point towards driven gear c Rocker arm bracket 2 d Rocker shaft screw 5 M8 x 23 e Valve lash adjustment screw loose f Rocker arm overload spring 2 gL AOO hs oN Szy mA Oxo E a Oss Sai2. head a Rocker shaft screw M8 x 23 b Rocker arm shaft 2 Remove the rocker shaft assembly from the cylinder head 3 Remove the rocker arms rocker arm springs rocker arm brackets and rocker arm overload springs from the rocker shaft Retain the rocker arms rocker arm springs rocker arm brackets and rocker arm overload springs for installation on the new rocker shaft THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 4 11 2006 Mercury Marine JULY 2006 2006 09 40 60 Horsepower FourStroke Rocker Shaft Screw Torque 4 Loosen all of the valve lash adjustment screws several turns out Four Cylinder Engine a Rocker arm bracket 1 b Rocker arm spring 2 arrow must point towards driven gear c Rocker arm bracket 2 d Rocker shaft screw 5 M8 x 23 e Valve lash adjustment screw loose f Rocker arm overload spring 2 a Rocker arm spring 1 arrow must point toward driven gear b Rocker arm bracket 1 c Rocker arm overload spring 2 arrow must point toward driven gear d Rocker arm spring 1 e Rocker arm bracket 1 f Valve lash adjustment s
3. paint mark on the valve cover above the oil fill to identify rework was kta Fa complete 24234 16 Test run the engine to verify there are no leaks and that the engine functions properly Parts Required e Mercury 4 Stroke 10W 30 Outboard Oil e Rocker Shaft 834780T1 3 cylinder or Rocker Shaft 857085 1 4 cylinder THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 8 11 2006 Mercury Marine JULY 2006 2006 09 40 60 Horsepower FourStroke Rocker Shaft Screw Torque Owner Notification All registered owners within the affected serial range will receive a letter from Mercury Marine The letter will explain the situation and request that they contact their local dealer to set up a time to have this bulletin performed Repair Identification Engines reworked at the factory will contain an orange dot on the serial mat and or a white dot on the cylinder head as shown below Mercury 60 ELPT 4STR EFI 1 A60412FZ MUNUNIWII 10022557 TT IA 3 STAR RATING auan wean a 24244 Orange dot on the serial mat 24243 White dot on the cylinder head THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT A
4. ND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2006 09 JULY 2006 2006 Mercury Marine Page 9 11 40 60 Horsepower FourStroke Rocker Shaft Screw Torque Engines repaired by dealers will have a white paint mark on the valve cover Warranty WARRANTY CLAIM PROCEDURE FOR NEW ENGINE NOT YET RUN Mercury Marine will credit the dealer for the cost of parts and labor Complete warranty claim listing Outboard serial number 1 0 hour labor Warranty Flat Rate Code SB10 Part Code 425 Failure Code 00 WARRANTY CLAIM PROCEDURE FOR ENGINE THAT HAS BEEN RUN BUT DOES NOT NEED ROCKER SHAFT REPLACEMENT Mercury Marine will credit the dealer for the cost of parts and labor Complete warranty claim listing Outboard serial number 1 2 hour labor Warranty Flat Rate Codes SB10 and SB02 Part Code 425 Failure Code 00 WARRANTY CLAIM PROCEDURE FOR ENGINE THAT HAS BEEN RUN AND NEEDS ROCKER SHAFT REPLACEMENT Mercury Marine will credit the dealer for the cost of parts and labor Complete warranty claim listing Outboard serial number 1 5 hour labor Warranty Flat Rate Codes SB10 and SB05 Part Code 425 Failure Code 00 Rocker Shaft Part number 834780T1 3 cylinder or 857085 1 4 cylinder THE INFORMATION IN THIS D
5. OCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 10 11 2006 Mercury Marine JULY 2006 2006 09 40 60 Horsepower FourStroke Rocker Shaft Screw Torque US amp CANADA Complete process the claim via MercNET or return a warranty claim form INTERNATIONAL Follow the instructions issued by the Marine Power International office or by an authorized Marine Power Distributor THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2006 09 JULY 2006 2006 Mercury Marine Page 11 11 Dear Mercury Outboard Owner Thank you for your purchase of a Mercury FourStroke Outboard engine Mercury Marine is dedicated to providing superior reliability and customer satisfaction As part of our commitment to superior customer satisfaction we have determined that it is necessary to inspect the rocker shaft screws on your engine to insure the durability of your Mercury Outboard engine What is t
6. PFERCURY amarr Service Bulletin Bulletin No 2006 09 OEM No 2006 03 Circulate to O Sales Manager O Accounting IM service Manager Yf Technician MM Parts Manager 40 60 Horsepower FourStroke Rocker Shaft Screw Torque Models Affected Mercury Mariner THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2006 09 JULY 2006 2006 Mercury Marine Page 1 11 40 60 Horsepower FourStroke Rocker Shaft Screw Torque Situation Mercury Marine has identified engines listed above that may have incorrectly torqued rocker shaft screws Incorrectly torqued rocker shaft screws can lead to increased valve lash poor engine performance and excessive noise Correction NEW ENGINE NOT YET RUN 1 Remove the valve cover Refer to Section 4A of the service manual for the valve cover removal procedure 2 Remove the top rocker shaft screw Lubricate the rocker shaft screw threads with 4 Stroke 10W 30 Outboard Oil Reinstall the rocker shaft screw and tighten the rocker shaft screw to the specified torque Four cylinder engine Three cylinder engine a Rocker shaft screw M8
7. crew loose 5 Locate the end of the rocker shaft that must be oriented towards the top of the cylinder head Ensure all of the oil holes will line up with the oil holes in the cylinder head THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2006 09 JULY 2006 2006 Mercury Marine Page 5 11 40 60 Horsepower FourStroke Rocker Shaft Screw Torque IMPORTANT The rocker shaft must be installed correctly with all of the oil holes properly aligned with the oil holes in the cylinder head The three cylinder rocker shaft will have three oil holes that must be oriented towards the top of the cylinder head The four cylinder rocker shaft will have four oil holes that must be oriented towards the top of the cylinder head 24324 a Three cylinder rocker shaft b Four cylinder rocker shaft c Oil holes oriented towards the top of the cylinder head d One oil hole oriented towards the bottom of the cylinder head 6 Lubricate the rocker arms and the new rocker shaft with 4 Stroke 10W 30 Outboard Oil 7 Slide the rocker arms onto the rocker shaft as shown Four cylinder
8. he condition It is possible that the rocker shaft screws on your engine may be incorrectly torqued resulting in the loss of engine performance over time To eliminate the possibility of this occurring Mercury Marine will inspect the rocker shaft screws valve lash and rocker shaft at no charge to you What will Mercury Marine do Any authorized Mercury Marine dealer will perform the required inspection and if necessary replace your rocker shaft at no charge to you What should you do Please contact your Mercury Outboard dealer regarding Mercury Service Bulletin 2006 09 to schedule an appointment to have the rocker shaft screws inspected Your dealer will be able to determine how long the repair will take on your engine Please present this notice to your dealer when you bring your boat in for your service appointment What if you have other questions or if you no longer own this engine Please contact your Mercury Outboard dealer or call Mercury Outboard Customer Service at 1 920 929 5040 between 7 30 AM and 5 30 PM CST We have sent this notice in the interest of your continued satisfaction with our product and we sincerely regret any inconvenience this may cause you Thank you for boating with Mercury Marine Mercury Marine Service
9. lues recorded to the following THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2006 09 JULY 2006 2006 Mercury Marine Page 3 11 40 60 Horsepower FourStroke Rocker Shaft Screw Torque a Ifthe intake valve lash is 0 25 0 50 mm 0 010 0 020 in and the exhaust valve lash is 0 35 0 71 mm 0 014 0 028 in follow the previous procedure on torquing the rocker shaft screws When the rocker shaft screws are retorqued to specifications verify the valve lash is within the specifications as noted in Section 4A of the service manual If the valve lash is not within the specification readjustment is required b Ifthe intake valve lash is greater than 0 50 mm 0 020 in or exhaust valve lash is greater than 0 71 mm 0 028 in a replacement rocker shaft is required Follow the procedures for the rocker shaft replacement ROCKER SHAFT REPLACEMENT 1 Remove the rocker shaft screws securing the rocker shaft to the cylinder head NOTE The four cylinder engine has 5 rocker shaft screws The three cylinder head has 4 rocker shaft screws Four cylinder head Three cylinder
10. s ORS HO 5 s D7 ETIA O ZS nae Es a ys J ERE lt ca i gt 24228 Three cylinder engine a Rocker shaft screw 4 M8 x 23 e Rocker arm bracket 1 b Rocker arm bracket 1 f Rocker arm spring 1 arrow must c Rocker arm overload spring 2 point toward driven gear arrow must point toward driven g Valve lash adjustment screw loose gear d Rocker arm spring 1 THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2006 09 JULY 2006 2006 Mercury Marine Page 7 11 40 60 Horsepower FourStroke Rocker Shaft Screw Torque 110 om 4 Stroke 10W 30 Outboard Oil Rocker shaft screw 92 802833A1 12 Following the sequence shown tighten the rocker shaft screws in 2 steps to the specified torque LL ak 24321 Four cylinder engine Three cylinder engine Rocker shaft screw wooo 13 Adjust the valve lash Refer to Section 4A of the service manual for the correct valve lash adjustment procedures 14 Reassemble the valve cover Refer to Section 4A of the service manual 15 Place a white
11. x 23 b Rocker arm shaft H 110 4 Stroke 10W 30 Outboard Oil Top rocker shaft screw 92 802833A1 pesn a o 3 Remove the remaining rocker shaft screws one at a time beginning with the bottom screw and working towards the top rocker shaft screw Lubricate the rocker shaft screw threads with 4 Stroke 10W 30 Outboard Oil THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 2 11 2006 Mercury Marine JULY 2006 2006 09 40 60 Horsepower FourStroke Rocker Shaft Screw Torque 4 Reinstall the rocker shaft screws Tighten the rocker shaft screws in the sequence shown to the specified torque Ona Rocker shaft screw 5 Reinstall the valve cover Refer to Section 4A of the service manual 6 Place a white paint mark on the valve cover above the oil fill to identify rework was completed 24234 7 Test run the engine to verify no leaks are present and the engine functions properly ENGINE THAT HAS BEEN RUN 1 Measure and record the cold valve lash for each valve Refer to Section 4A of the service manual for proper valve lash measurement procedures 2 Compare the va
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