450r Information

Service Bulletin
Outboard No. 2019-04

OEM No. 2019-03
Circulate to: Sales Manager Accounting Service Manager Technician Parts Manager
Important New Model Information—450R

Models Covered
Model Serial Number
450R 1E083007 and above
Scope
Worldwide
Situation
The purpose of this bulletin is to highlight some key product information for the new V‑8 450R outboard model.
• 450R Specifications
• Engine Operation and Performance Specifications
• Gearcase Application and Warranty Chart
• Sport Master Gearcase Propeller Requirements
• 5.44 Heavy Duty (HD) Gearcase Propeller Requirements
• Trim Thrust Guide Wear Pad
• 450R Maintenance Schedule Decal
• Inspection and Maintenance Schedule
• Corrosion Control Anodes
• Lifting the Outboard
• 450R Steering System Requirements
• Multiple Steering Cylinders
• Rear‑Mounted Tie Bar Installation
• Engine Battery Specifications
• Battery Connections and Cables
• Battery Isolation
• Clean Power Harness
• Engine Oil Recommendations—450R
• 450R Required Gearcase Lubrication
• Fuel Requirements
• Fuel Line Primer Bulb
• Rigging the Engine
• Rigging Tube and Rigging Adapter
• Rigging Grommet
• Connections at the Engine
• Engine Rigging Center
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.
2019-04 JUNE 2019 © 2019 Mercury Marine Page 1 / 40

• Thrust Vector Module

• Mounting the Thrust Vector Module (TVM) to the Engine Rigging Center
• Digital Block Water Pressure Sensor
• Vessel Mounted Water‑Separating Fuel Filter Kit with WIF Sensor
• Fuel Supply Module Priming Procedure
• Propeller Hub Kit Selection
• Driveshaft/Housing Conversion Kits
• Gear Housing Removal and Installation
• Special Tools
• Diagnostic Tool Requirements
• Adaptive speed control propping with CDS G3
• Adaptive speed control propping without CDS G3
• Operational Note
450R Specifications
Attribute Specification
Horsepower 450
Kilowatts 336
Full throttle RPM range 5800–6400
Idle RPM in neutral gear* 600
Idle charge compensation** 600–725
Troll control RPM limit 600–1200
Number of cylinders 8
4.6 Liter
Displacement
4,576 cc (279.2 cid)
Cylinder bore 92 mm (3.62 in.)
Stroke 86 mm (3.38 in.)
Spark plug 8M0135348
Spark plug gap 0.9 mm (0.035 in.)
Spark plug hex size 14 mm
Spark plug torque 20 Nm (15 lb‑ft)
Sport Master gear ratio 1.60:1
137 mm (5.4 in. HD) gear ratio 1.60:1
Sport Master RH, LH 620 mL (21.0 fl oz)
Gearcase capacity 137 mm (5.4 in.) RH 720 mL (24.4 fl oz)
137 mm (5.4 in.) LH 680 mL (23.0 fl oz)
89 (R+M)/2 or 95 RON minimum, 10% maximum ethanol content
Recommended gasoline
Refer to Fuel Requirements for more information.
Mercury Racing 25W‑50 NMMA certified FC‑W® Marine Synthetic Blend
Recommended oil
Marine Engine Oil
Engine oil capacity with oil filter replacement 6.6 Liter (7.0 US qt)
Required battery type 12‑volt absorbed glass mat (AGM) battery
Series 31, 1370 minimum marine cranking amps (MCA) with a minimum
USA (SAE)
reserve capacity of 205 minutes RC25 rating
Battery type***
Series 31, 1150 minimum cold cranking amps (CCA) with a minimum of 100
International (EN)
amp hours (Ah)
Page 2 / 40 © 2019 Mercury Marine JUNE 2019 2019-04

*Engine at normal operation temperature.

**The idle charge compensation may automatically increase the engine speed up to 725 RPM to compensate for a low battery
charge condition. The increased idle RPM will charge the battery at a higher rate. Activating troll control (optional accessory) will
override the idle charge compensation feature.
***Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are
the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not
meet Mercury Marine battery requirements.
Engine Operation and Performance Specifications

Refer to the following tables for engine operation and performance specifications. This information will help set up a new boat
for maximum performance and reliability. It will also provide information about certain operating conditions that may reduce
performance.
Engine Performance
Wide‑open throttle (WOT) engine RPM
5800–6400 RPM
range
Peak power RPM range 6200–6400 RPM
Peak torque 4000 RPM
85% of peak torque 2000 RPM
Block Water Pressure at WOT (5800–6400 RPM)

Nominal 150–200 kPa (21.8–29.0 psi)
Marginal high pressure 200–250 kPa (29.0–36.3 psi)
Marginal low pressure (refer to IMPORTANT remark
125–150 kPa (18.1–21.8 psi)
following this table)
Critical low pressure (refer to IMPORTANT remark
Less than 125 kPa (18.1 psi)
following this table)
Critical high pressure More than 250 kPa (36.3 psi)
IMPORTANT: Marginal low water pressure may cause Engine Guardian to limit engine power during hot ambient temperature
conditions. Critical low water pressure may cause Engine Guardian to limit engine power during normal ambient temperature
conditions.
Block Water Temperature

Thermostat opening 65 °C (149 °F)
Nominal operating temperature 65–72 °C (149–161.6 °F)
Marginal operating temperature (hot) 73–78 °C (163.4–172.4 °F)
Oil Temperature
Nominal temperature at WOT 110–145 °C (230–293 °F)
Guardian power limit (hot) (refer to IMPORTANT
155 °C (311 °F)
remark following this table)
Guardian power limit (cold) (refer to IMPORTANT
Less than 55 °C (131 °F)
remark following this table)
IMPORTANT: Oil temperatures below 55 °C (131 °F) will cause Engine Guardian to limit the available power. Sufficient power
will be available to bring the boat on plane and run at a low cruise speed. Oil temperatures above 155 °C (311 °F) will cause
Engine Guardian to limit the available power, and an alarm will sound.

Gearcase Application and Warranty Chart

! WARNING
Installing a gearcase not designed for use with this model can result in serious injury or death. Install gearcases tested and
approved for use with this model.
IMPORTANT: Only the approved gearcases listed in the following table are allowed by Mercury Racing for use on the 450R.
The 450R outboard is equipped with a 1.60:1 gear ratio Sport Master or 5.44 HD gearcase as standard equipment. Any other
gearcase gear ratio installed will void the gearcase warranty. Use of an unapproved gearcase can result in serious injury or
death and will void the engine or gearcase warranty. Only the approved gearcases listed in the following table are allowed by
Mercury Racing for use on the 450R.
Gear Ratio
1.60:1 1.75:1 1.85:1
Voids gearcase
Sport Master Approved Not available
warranty
Voids gearcase
5.44 HD Approved Voids engine warranty
warranty
Torque Master Not available Voids engine warranty Not available
Sport Master Gearcase Propeller Requirements

! WARNING
Installing a propeller not rated for this application can cause serious injury or death from a broken propeller. Failure can
cause pieces of the propeller to strike occupants, the boat, or the engine. It can also lead to unexpected loss of control of the
vessel. Select a propeller that meets the drive’s propeller specification for horsepower and torque, as measured at the drive’s
propeller shaft.
Avoid damage to your engine caused by propellers not designed for surfacing applications. Damage to gearcase, midsection,
and powerhead can result by the failure of improper propellers.
Use only the following approved propellers:
• Mercury Racing Cleaver
• Mercury Racing Max5
• Mercury Racing Maximus
• Surfacing/HP rated equivalent competitor propeller
CAUTION
Avoid damage to your engine caused
by propellers not designed for surfacing
applications. Damage to gearcase,
midsection, and powerhead can result
by the failure of improper propellers.
Use only the following approved
propellers:
Racing Cleaver
Racing Max5
Racing Maximus
Surfacing / HP Rated Equivalent
Competitor
8M0155566
68600

5.44 Heavy Duty (HD) Gearcase Propeller Requirements

! WARNING
Installing a propeller not rated for this application can cause serious injury or death from a broken propeller. Failure can
cause pieces of the propeller to strike occupants, the boat, or the engine. It can also lead to unexpected loss of control of the
vessel. Select a propeller that meets the drive’s propeller specification for horsepower and torque, as measured at the drive’s
propeller shaft.
Avoid damage to your engine caused by propellers not designed for high horsepower applications. Damage to gearcase,
midsection, and powerhead can result by the failure of improper propellers.
Use only the following approved propellers with 5.44 HD gearcases:
• Mercury Racing Bravo I FS
• Mercury Racing Bravo I LT
• Mercury Racing Cleavers
• Mercury Racing Enertia ECO XP
• Mercury Racing Revolution 4 XP
• Mercury Racing MAX5
• Mercury Racing Maximus
• Mercury Mirage Plus
• Mercury Enertia
Trim Thrust Guide Wear Pad

The 450R outboard utilizes thrust guide plates on either side of the driveshaft housing to improve stability of the engine. As the
engine is trimmed up or down, the thrust guide plates will rub against the trim thrust guide wear pads that are mounted on
either side of the trim manifold. Check the clearance between the trim thrust guide wear pad and the lower cradle on each side
to determine if replacement is necessary. Failure to replace the trim thrust guide wear pad may cause damage to the swivel
bracket. Damage to the swivel bracket caused by the trim thrust guide wear pad mounting hardware is not covered under
warranty. Refer to the Inspection and Maintenance Schedule for the proper maintenance interval.
Checking Trim Wear Pad Clearance
a - Trim manifold
b - Trim wear pads
a c - Clearance (refer to the following table)
b
68457
c
IMPORTANT: The trim thrust guide wear pads must be shimmed for a maximum clearance of 0.5 mm (0.02 in.) per side.
Trim thrust guide wear pad to lower cradle clearance (per side)
Minimum clearance 0.05 mm (0.002 in.)
Maximum clearance 0.5 mm (0.02 in.)

Replacing the Trim Thrust Guide Wear Pads

IMPORTANT: When replacing the trim thrust guide wear pads, replace both pads and install new retaining hardware.
c a - M6 x 20 screw with patch lock pad (8

quantity, 4 on each trim wear pad)
b - Trim thrust guide wear pad (2 quantity)
c - Trim manifold
a
b 36869
Description Nm lb‑in. lb‑ft

M6 x 20 screw (8) 6 53 –
450R Maintenance Schedule Decal

The maintenance schedule decal is located under the engine cowling.
68229
Inspection and Maintenance Schedule

Before Each Use
• Check the engine oil level. Refer to Checking Engine Oil Level.
• Check that the lanyard stop switch stops the engine.

• Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, tighten
the outboard mounting fasteners to the specified torque. When looking for signs of looseness, look for loss of outboard
transom bracket material or paint caused by movement between the outboard mounting fasteners and the outboard
transom brackets. Also look for signs of movement between the outboard transom brackets and the boat transom (lift plate/
setback bracket).

Outboard mounting locknuts and bolts ‑ standard boat transom 75 – 55.3
Outboard mounting locknuts and bolts ‑ metal lift plates and setback brackets 122 – 90
• Visually inspect the fuel system for deterioration or leaks.
• Check the steering system for binding or loose components.
• Check the propeller blades for damage.
• Inspect the hydraulic steering fittings and hoses for leaks or damage, if equipped.
• Inspect the hydraulic steering fluid level, if equipped.
After Each Use

• Flush out the outboard cooling system if operating in salt, polluted, or muddy water. Refer to Flushing the Cooling
System.
• Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in
saltwater.
• If operating in saltwater, inspect the powerhead and powerhead components for salt buildup. Refer to Cleaning Care for
the Powerhead (Saltwater Use).
After 10 Hours of Use

• Change the engine oil and replace the oil filter. Refer to Changing Engine Oil and Filter.
• Drain and replace the gearcase lubricant. Refer to Gearcase Lubrication.
Every 100 Hours of Use or Once Yearly, Whichever Occurs First

• Change the engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under
adverse conditions, such as extended trolling. Refer to Changing Engine Oil and Filter.
• Check the vessel mounted water‑separating low‑pressure fuel filter for water or contaminants. Replace the filter if required.
Refer to Fuel System.
• Check the boat mounted water‑separating fuel filter for the presence of water or contaminants. Drain the water or replace
the filter if required.
• Remove the propeller and lubricate the propeller shaft. Refer to Propeller Replacement.
• Inspect the thermostat visually for corrosion or a broken spring. Ensure that the thermostat closes completely at room
temperature—dealer service.
• Check the outboard mounting fasteners that fasten the outboard to the boat transom. Tighten the fasteners to the specified
torque—dealer service.

Outboard mounting locknuts and bolts ‑ standard boat transom 75 – 55.3
Outboard mounting locknuts and bolts ‑ metal lift plates and setback brackets 122 – 90
• Check the corrosion control anodes. Check more frequently when used in saltwater. Refer to Corrosion Control Anode.
• Drain and replace the gearcase lubricant. Refer to Gearcase Lubrication.
• Replace the supercharger belt—dealer service.
• Inspect the battery. Refer to Battery Inspection.
• Saltwater usage: Remove and inspect the spark plugs for corrosion and replace as necessary. Apply Anti‑Seize
Compound only on the threads of the spark plug prior to installation. Refer to Spark Plug Inspection and Replacement.
Tube Ref No. Description Where Used Part No.

81 Anti-Seize Compound Spark plug threads 92-898101389

• Check the tightness of bolts, nuts, and other fasteners—dealer service.

• Add Quickleen Engine and Fuel System Cleaner to the fuel tank.

Quickleen Engine & Fuel
Fuel tank 8M0047931
System Cleaner
• Check the cowl seals to ensure seals are intact and not damaged.
• Check that the intake silencer is in place, if equipped.
• Check that the idle relief muffler is in place, if equipped.
• Check for loose hose clamps and rubber boots on the air intake assembly, if equipped.
Every 300 Hours of Use or Three Years

• Check the power trim fluid. Refer to Checking Power Trim Fluid.
• Lubricate all lubrication points. Lubricate more frequently when used in saltwater. Refer to Lubrication Points.
• Replace the water pump impeller—dealer service.1.
• Lubricate the splines on the upper driveshaft—dealer service.
• Check all wiring and connectors—dealer service.
• Replace the alternator drive belt. Refer to Alternator Drive Belt—dealer service.
• Replace the spark plugs.
• Replace the vessel mounted water‑separating low‑pressure fuel filter.
• Inspect the trim thrust guide wear pads.
Before Periods of Storage

• Refer to the Storage section.
Corrosion Control Anode

The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic
corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.
Each anode requires periodic inspection, especially in saltwater which will accelerate the erosion. To maintain this corrosion
protection, always replace the anode before it is 50% eroded. Never paint or apply a protective coating on the anode as this will
reduce effectiveness of the anode.
Two anodes are located on the engine; one is on the bottom of the transom bracket assembly and the other is on the gear
housing.
a - Transom bracket anode

a b - Gear housing anode
68245
Lifting the Outboard

! CAUTION
Improper lifting during removal or installation of the engine can cause injury or damage to engine components. Use a hoist,
lifting arm, or other approved lifting device. Do not allow the lifting device to hook or compress any engine components.
1. Replace the water pump impeller more often if overheating occurs or reduced water pressure is noted.

IMPORTANT: All engine lifting devices (straps, slings, chains, or hoists) must have a minimum capacity of 450 kg (1000 lb).
Single‑Point Lifting Procedure

This method has less control when lifting the outboard from horizontal to vertical, but the outboard will hang vertical when it is
lifted.
1. Remove the top cowl from the engine.
2. Remove the flywheel cover:
a. Remove the engine oil dipstick from the dipstick tube.
b. Lift the flywheel cover up to remove.
a - Engine oil dipstick

b - Flywheel cover
68612
3. Install the flywheel lifting ring onto the flywheel with the lifting ring perpendicular to the engine centerline. Install the six
supplied screws and tighten them to the specified torque.
a - Flywheel lifting ring

b - Threaded holes in flywheel
b
b
a
68610

Flywheel lifting ring screws (6) 22.5 – 16.6
450R Flywheel Lifting Ring 8M0156840
Attaches to the flywheel to allow lifting of the powerhead or installation/

removal of the engine.
68661

4. Lift the engine and shipping crate to a vertical position with an overhead hoist.
IMPORTANT: Ensure that the lifting hoist chain or straps do not compress or damage the alternator or other engine
components while lifting.
5. Lower the engine and shipping crate to the ground in the vertical position. Keep the overhead hoist attached to the flywheel
lifting ring.
IMPORTANT: Never allow the outboard to stand upright in the shipping crate unsupported.
6. While supporting the weight of the outboard with the overhead hoist, remove the shipping crate from the engine and lower
the shipping crate to the ground, leaving the outboard suspended from the overhead hoist.
7. After the outboard has been secured to the vessel or a suitable engine stand, remove the lifting chain or straps.
8. Remove the flywheel lifting ring.
9. Install the flywheel cover and the engine oil dipstick.
Dual‑Point Lifting Procedure

This method has more control when lifting the outboard from horizontal to vertical, but the outboard will lean backwards slightly
(as if trimmed out) while hanging vertical.
1. Remove the top cowl from the engine.
2. Attach the two equal length (longer) straps of the lifting strap to the port and starboard lifting eyes on the engine. Secure
the third (red) strap out of the way to avoid damaging engine components.
68540
Port and starboard lifting eyes
Lifting strap 883705T01
Use with an overhead hoist to lift an engine.
67021
3. Lift the engine and shipping crate to a vertical position with an overhead hoist.
IMPORTANT: Ensure that the lifting hoist chain or straps do not compress or damage the alternator or other engine
components while lifting.
4. Lower the engine and shipping crate to the ground in the vertical position. Keep the overhead hoist attached to the port and
starboard lifting eyes.
IMPORTANT: Never allow the outboard to stand upright in the shipping crate unsupported.

5. While supporting the weight of the outboard with the overhead hoist, remove the shipping crate from the engine and lower
the shipping crate to the ground, leaving the outboard suspended from the overhead hoist.
6. If necessary, temporarily attach the battery cables to the engine starting battery to activate the power trim to get the
transom bracket flush with the vessel or engine stand. Refer to Connections at the Engine and Connecting Battery
Cables and Clean Power Harness for more information.
7. After the outboard has been secured to the vessel or a suitable engine stand, remove the lifting straps.
450R Steering System Requirements

Important Steering Installation Guidelines
IMPORTANT: Joystick piloting has its own special requirements and is not part of this steering installation.
IMPORTANT: Do not use more than two cylinders with non‑joystick multiple engine installations. The power steering pump is
designed to support the displacement of two steering cylinders. Address concerns to your Mercury product application
engineer.
There are a few important installation guidelines that must be considered when installing the steering components on
multiengine installations. Installing the wrong steering helm and cylinder configuration may result in a less than acceptable
steering wheel lock‑to‑lock ratio.
• A 40 cc displacement helm should be used on single cylinder and liquid tie bar installations. This will yield four full turns,
lock‑to‑lock.
• A 50 cc displacement helm should be used on all dual cylinder installations rigged in parallel. This will yield 6.4 turns,
lock‑to‑lock.

AMS Models—Power Steering
c
b
d e
a
L PORT
R STAR
T
P
29204
a- Thin wrench
b- Helm hex fitting wrench size (P and T) ‑ 19 mm (3/4 in.)
c- Helm hex fitting wrench size (R and L) ‑ 16 mm (5/8 in.)
d- Hydraulic hose hex fitting wrench size (P and T) ‑ 21 mm (13/16 in.)
e- Hydraulic hose hex fitting wrench size (R STAR and L PORT) ‑ 18 mm (11/16 in.)
Helm Fitting ID Mark Hose ID Mark Description

P P Pressure from pump to helm
T T Tank low pressure return to pump
R R STAR Hose connects to starboard side of steering cylinder
L L PORT Hose connects to port side of steering cylinder
Multiple Engine Steering Requirements

Front-Mounted Steering Tie Bar
To install the front‑mounted steering tie bars, follow the instructions included with the steering tie bar kit and observe the
following guidelines:
• Dual Engine Application—Dual Outboard Tie Bar kit
• Triple Engine Application—Dual Outboard Tie Bar kit with a Plus One Tie Bar Kit (two steering cylinders—starboard and
port engines)

• Quad Engine Application—Dual Outboard Tie Bar kit with two Plus One Tie Bar Kits (two steering cylinders—starboard and
port engines)
Rear-Mounted Steering Tie Bar

450R models are available with rear‑mounted steering tie bar brackets, or the bracket can be retrofitted to the engine if the
lower chaps are changed to accommodate the brackets. Refer to Rear‑Mounted Steering Tie Bar Installation for more
information.
a - Rear‑mounted steering tie bar attachment point

b - Tie bar bracket
a
b
68539
Multiple Steering Cylinders

On some large/heavy dual‑outboard boats, the steering forces generated in extreme maneuvers may create loads that exceed
the pump's pressure capacity, where the operator may feel intermittent periods of load feedback at the steering wheel. The
steering wheel may feel hard to turn for brief periods during these extreme maneuvers. If this happens and steering
performance is deemed unacceptable for the application, a second (accessory) steering cylinder can be installed. When using
a second steering cylinder, the 40 cc helm should be replaced with a 50 cc helm.
Applications with multiple engines of 350 hp or higher require two of the engines to be equipped with a power steering cylinder
along with the use of a 50 cc or greater displacement helm. Address concerns to your Mercury product application engineer.

! CAUTION
Avoid momentary loss of steering control caused by high steering forces. Installations with multiple engines of 350 hp or
higher must have two steering cylinders.
a
a- 50 cc helm
b- T‑fitting
b c- Starboard cylinder
d- Port cylinder
6333
Rear‑Mounted Steering Tie Bar Installation

! WARNING
Incorrect steering system installation can result in serious injury or death. After completing installation and before operating
the outboard, check steering operation. The outboard must turn left and right in conjunction with the steering wheel. Check
the steering through the full range and at all tilt angles.
NOTICE
Incorrect tie bar installation can damage the drive and steering system. Do not let the tie bar contact other components during
severe turning conditions. Always calculate sufficient turning clearances, observe recommended tie bar arrangements, and
check for proper installation before operating the boat.

450R models are available with rear‑mounted steering tie bar brackets, or the bracket can be retrofitted to the engine if the
lower chaps are changed to accommodate the brackets.
a - Rear‑mounted steering tie bar attachment point

b - Tie bar bracket
a
b
68539

Refer to the following diagram for dimensions to help select the correct steering tie bar for your application.
d
a f
e
g
c j m
h n
k
o
i l
68598
a- 0.5 mm (0.02 in.) minimum clearance required

b- 42.11 mm (1.658 in.)
c- 2.39 mm (0.094 in.)
d- 32.89 mm (5.232 in.)
e- 40°
f- 30°
g- 26.28 mm (1.035 in.)
h- 47.9 mm (1.89 in.)
i- 40.42 mm (1.591 in.)
j- 22.17–22.22 mm (0.873–0.875 in.)
k- 15.82–15.87 mm (0.623–0.625 in.)
l- 5/8‑18 UNF threads
m- 62.6 mm (2.47 in.)
n- 108.0 mm (4.25 in.)
o- 20.0 mm (0.79 in.)

Retaining nut 150 – 110.6
Engine Battery Specifications

IMPORTANT: This engine requires a 12‑volt absorbed glass mat (AGM) marine starting battery that meets the minimum
ratings.
Do not use flooded (wet cell), gel cell type lead acid batteries or lithium ion batteries for starting marine engines.
Each engine must be equipped with its own starting battery.
If the boat application requires additional battery loads for boat accessories or marine electronics, install an auxiliary battery, or
batteries.
Required 12‑Volt Absorbed Glass Mat (AGM) Battery Ratings

Series 31, 1370 minimum marine cranking amps (MCA) with a minimum reserve
USA (SAE) starting battery rating:
capacity of 205 minutes RC25 rating

Required 12‑Volt Absorbed Glass Mat (AGM) Battery Ratings

Series 31, 1150 minimum cold cranking amps (CCA) with a minimum of 100 amp
International (EN) starting battery rating:
hours (Ah)
NOTE: Do not use an engine starting battery that does not meet the specified ratings. If a battery that does not meet the ratings
is used, the electrical system may perform poorly.
IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards, and Coast Guard regulations must be adhered
to when installing the battery. Ensure that the battery cable installation meets the pull test requirements and that the positive
battery terminal is properly insulated in accordance with regulations.
It is recommended (required in some states) that the battery be installed in an enclosed case. Refer to regulations for your
area.
! WARNING
Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system,
leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to
avoid loose connections.

Battery hex nuts 13.5 120 –
IMPORTANT: Battery cable size and length is critical. Refer to the Battery Cable Sizing table for size requirements.
A decal advising against using deep cycle batteries and wing nuts should be placed on or near the battery box for future service
reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not
supplied.
NOTICE
DO NOT USE DEEP CYCLE BATTERIES!
13.5Nm (120 lb-in.)
DO NOT
USE
WINGNUTS
IMPORTANT:
Refer to the outboard owner’s manual for
battery requirements.
Battery cable size and length is critical.
Refer to engine installation manual for
size requirements.
8M0085862
Place decal on or near battery box for future

service reference. Included with the engine
rigging components are 5/16" and 3/8” hex
nuts to be used for battery terminal wing nut
replacement. Metric hex nuts must be obtained
locally.
54395
Battery Connections and Cables

Battery
IMPORTANT: Adhere to Boating industry standards (BIA, ABYC, etc.), federal standards, and Coast Guard regulations for
proper battery installation. Install the battery cable to meet the pull test requirements and insulate the positive battery terminal
in accordance with regulations.
• Use tapered post connectors or stud connections. Do not use a battery with wing nut connectors.
• Refer to NMMA, ABYC, and U.S. Coast Guard boating standards and regulations for complete guidelines.
Battery Cable Recommendations

Refer to NMMA, ABYC, and U.S. Coast Guard boating standards and regulations for complete guidelines.
IMPORTANT: Solder the terminals to the cable ends to ensure good electrical contact. Use electrical grade (resin flux) solder
only. Acid flux solder may cause corrosion and a subsequent failure.

1. Measure the length of the positive (+) battery cable.

2. Measure the length of the negative (–) battery cable.
3. Using the total cable length and the chart below, determine what gauge of wire to use for both cables.
NOTE: Place the battery as close to the engine as possible.
Total Cable Length (a + b)

Minimum Cable Size
Minimum Maximum
– 7.4 m (24.3 ft) 21.2 mm² (2 AWG)
7.4 m (24.3 ft) 12.2 m (40.0 ft) 33.6 mm² (2 AWG)
12.2 m (40.0 ft) 15.2 m (49.9 ft) 42.4 mm² (1 AWG)
15.2 m (49.9 ft) 19.6 m (64.3 ft) 53.5 mm² (0 AWG)
19.6 m (64.3 ft) 24.4 m (80.0 ft) 67.7 mm² (00 AWG)
Preferred Charging Circuit

Modify the charging circuit so that both engines charge the auxiliary battery but also isolate the auxiliary battery from the port
and starboard engine start batteries. This configuration provides enough current to operate the boat's accessories and still have
current available to start the engines.
Positive battery terminals: Boats with multiengine EFI power packages require that each engine has its positive battery cable
connected to its own battery. This ensures that the engine's propulsion control module (PCM) has a stable voltage source.
Negative battery terminals: Connect all negative battery cables at one source.
Auxiliary batteries: To ensure proper charging, properly switch or isolate single engine applications. In multiengine
applications, do not consider the auxiliary battery as another engine's battery. Use proper switching or isolation of the auxiliary
battery to ensure proper charging and separation of engine's positive battery cables.
Battery switches: Position battery switches so that each engine operates off its own battery. Do not use switches that have
OFF, 1, 2, or both positions. Battery switches should be on, off or maybe an emergency only position. In an emergency,
another engine's battery can be used to start an engine with a dead battery. Label all switches for proper operation.
Battery isolators: Use isolators to charge an auxiliary battery used for powering accessories in the boat. Do not use isolators
to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose.
Battery Isolation
Control, Isolation, and Charging Components
Diode/semiconductor isolation is the isolation method supported and recommended by Mercury Marine. Other (nonsupported)
isolation methods include low‑voltage disconnects (LVDs), voltage sensing relays (VSRs), and automatic closing/charging
relays (ACRs). Consult with the device manufacturer for proper use and installation.
NOTE: Mechanical devices can have unintended operation due to mechanical shock. This is the primary reason solid‑state
isolation techniques should be chosen over mechanical devices.
1. The shore power AC‑to‑DC converter connection to the battery bank must be on an unswitched battery circuit with
appropriate circuit protection.
2. When using cranking battery DC chargers (AC‑DC or DC‑DC) that require specific settings for different battery types, the
vessel manufacturer must convey initial charger settings for the cranking batteries in an easily identifiable format. Ensure
that the battery charger matches the battery type.
3. Engines that are connected to multiple battery sources must use a control/isolation device capable of charging both
batteries automatically from the engine alternator regardless of the battery switch state.
NOTE: This requirement does not apply to the emergency parallel circuit, only to the battery selector circuit.
Isolation Cable Sizing

Observe the following specifications for alternator‑to‑isolator and isolator‑to‑battery wiring:
1. Cables for isolator wiring must have a rating of 105 °C (221 °F).
NOTE: Refer to ABYC E‑11 for all cable insulation requirements.
2. If the specification in the battery isolator connection chart differs from the specification shown in the battery cable sizing
chart, then the ground lead must match the larger of the two specifications.

Use the following charts when selecting cables for battery isolator installations.
Cable Size from Auxiliary Hot Stud to Battery Isolator (10% Allowable Voltage Drop)
Maximum
3m 4.5 m 6m 7.6 m 9.1 m 12.2 m 15.2 m
Alternator
(10 ft) (15 ft) (20 ft) (25 ft) (30 ft) (40 ft) (50 ft)
Output
115 A 21.2 mm2 33.6 mm2 33.6 mm2 33.6 mm2 33.6 mm2 33.6 mm2 42.4 mm2
(4 AWG) (2 AWG) (2 AWG) (2 AWG) (2 AWG) (2 AWG) (1 AWG)
Auxiliary Loads and Power Source

1. The MerCathode controller must be connected to the nonswitched side of the respective engine cranking battery or the
house battery pack. It must be protected by a 5‑amp fuse or circuit breaker. If switching of the MerCathode power is
desired, then a switchable circuit breaker can be used.
2. Trim pumps must be connected to the switched side of the battery if a battery switch is used.
Isolated Battery Architecture

The isolated Mercury battery architecture specification is designed for powering the cranking system and specified critical
vessel loads only. If any auxiliary vessel components (loads or other power sources) are connected to the engine power
source, they must be connected in a way such that they are not allowed to degrade the propulsion power source to less than
11.5 VDC. The battery system architecture must protect the primary propulsion system voltage from nonessential power drains.
Final verification of appropriate cable size for the entire system load is the responsibility of the vessel manufacturer.
Battery connections for noncritical auxiliary loads are as follows:
1. Standard connection: Noncritical loads must be connected to an independent battery bank, not to a propulsion cranking
battery.
2. Optional connection:
a. Noncritical vessel loads cannot derive power or ground from the cranking circuit. Both the positive and negative
cables associated with noncritical vessel loads must have independent connections to the power source.
b. The cranking battery can only be used as the reserve capacity power source to the house battery bank if the
minimum voltage requirement of 11.5 VDC is maintained.
Battery connections for critical vessel and propulsion loads are as follows:
IMPORTANT: The following table identifies components that may source power from the cranking battery. The 11.5 VDC
requirement mentioned above does not apply to these components. The components may be connected directly to the battery
or anywhere along the cranking circuit.
Components that can be connected to the cranking battery

Propulsion Vessel Charging
Propulsion cranking motor Navigation lights AC/DC converter
Trim pump Bilge blower Diode isolator
Steering pump Bilge pumps ACR/VSR
Clean power Wipers Other load shedding device
Helm/steering engine MPR Emergency radio –
MerCathode Depth sounder –
Propulsion gauges/sensors Generator cranking motor –
IMPORTANT: The generator cranking motor must be connected directly to the battery.
Clean Power Harness

! WARNING
Avoid serious injury or death from the loss of DTS electrical power. The DTS power harness must be securely fastened with
cable ties to one of the battery cables near the battery. If not properly secured, the DTS power harness could be pulled off the
battery, resulting in the loss of electrical power and a loss of throttle and shift control.

NOTE: Do not extend the lead length of the clean power harness. Harnesses are available in different lengths ranging from
0.91 m (3 ft) to 7.62 m (25 ft).
Description Part Number

4‑pin clean power harness—3 feet 8M0150521
4‑pin clean power harness—10 feet 899887T13
4‑pin clean power harness—20 feet 899887T14
1. Install the clean power harness directly to the starting battery.

2. Connect the clean power harness to the clean power harness connector at the engine rigging center. Refer to Engine
Rigging Center for details.
a a- Engine rigging center

b- Clean power harness connector
c- Clean power harness
d
b d- Negative engine battery cable
e- Battery
f- Clean power 30‑amp fuse
f g- Positive engine battery cable
c e h- Battery cables to the engine
h
g 68509
3. Fasten the clean power harness to one of the battery cables with a cable tie.
3711
Engine Oil Recommendations—450R

Mercury Racing 25W‑50 NMMA certified FC‑W® Marine Synthetic Blend Marine Engine Oil is the preferred choice for general,
all‑temperature use in the 450R. If the recommended Mercury Racing FC‑W certified oils are not available, a major outboard
manufacturer's brand of NMMA FC‑W certified 4‑Stroke outboard oil of the same viscosity may be used.

IMPORTANT: The use of nondetergent oils, multiviscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a
major brand NMMA FC‑W certified oil), full synthetic oils, low quality oils, or oils that contain solid additives are not
recommended.
68235
450R Required Gearcase Lubrication

All 1.60:1 ratio Sport Master and 5.44 HD gearcases are factory filled with SAE 85W‑90 Extreme Performance Gear Lube. This
lubricant conforms to Enlube MGO‑4‑653‑HP specifications and should not be mixed with other types of gear lubricant.

SAE 85W-90 Extreme
All 450R gearcases 8M0111677
Performance Gear Lube
Fuel Requirements
IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper
gasoline is considered misuse of the engine and will not be covered under the limited warranty.
Fuel Ratings
Mercury outboard engines will operate satisfactorily with any major brand of unleaded gasoline that meets the following
specifications:
USA and Canada ‑ A posted pump octane rating of 89 (R+M)/2, minimum, for most models. Premium gasoline 91 (R+M)/2
octane is also acceptable. Do not use leaded gasoline.
Outside USA and Canada ‑ A posted pump octane rating of 95 RON, minimum, for most models. Premium gasoline (98 RON)
is also acceptable. Do not use leaded gasoline.
Using Reformulated (Oxygenated) Gasoline (USA Only)

Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The
only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).
Gasoline Containing Alcohol

Bu16 Butanol Fuel Blends
Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable
substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system
components (fuel tanks, fuel lines, and fittings).

Methanol and Ethanol Fuel Blends

IMPORTANT: The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol (methanol or
ethanol) content in the gasoline. Your boat's fuel system may not be capable of withstanding the same percentage of alcohol.
Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines,
and fittings).
Be aware that gasoline containing methanol or ethanol may cause increased:
• Corrosion of metal parts
• Deterioration of rubber or plastic parts
• Fuel permeation through the rubber fuel lines
• Likelihood of phase separation (water and alcohol separating from the gasoline in the fuel tank)
! WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system
components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or
deterioration requires replacement before further engine operation.
IMPORTANT: If you use gasoline that contains or might contain methanol or ethanol, you must increase the frequency of
inspection for leaks and abnormalities.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline
in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause
trouble; boats often sit idle long enough for phase separation to take place. Internal corrosion may occur during storage if
alcohol has washed protective oil films from internal components.
Fuel Line Primer Bulb

IMPORTANT: Do not install a fuel line primer bulb into the fuel system of this outboard.
IMPORTANT: All fuel system hoses, lines, pickups, and fittings must be 12.7 mm (0.5 in.) inside diameter. Each engine
requires a separate 12.7 mm (0.5 in.) pickup.
The 450R outboard does not use a fuel primer bulb to prime the fuel system.
Rigging the Engine

IMPORTANT: Leave sufficient slack in wiring harnesses, battery cables, and hoses that are routed between the rigging
grommet and engine attachment points, to relieve stress and prevent hoses from being kinked or pinched.
Rigging Tube and Rigging Adapter

IMPORTANT: A rigging tube is required on the 450R to prevent water from entering the cowl. The use of the rigging adapter
and rigging grommet is mandatory.
1. Thread the rigging adapter onto the end of the rigging tube.
2. Ensure that all applicable items are routed through the rigging tube and the rigging adapter, allowing enough slack to make
the connections on the engine:
• Battery cables
• Engine data harness—requires 81.3 cm (32 in.) from the end of the rigging tube
• 12.7 mm (0.5 in.) inside diameter fuel line

Rigging Grommet
IMPORTANT: A rigging tube is required on the 450R to prevent water from entering the cowl.
The use of the rigging adapter and rigging grommet is mandatory.
68517
Ref Marking Opening used for

a. F Not used on 450R
1. Engine data harness from engine rigging center
2. Positive (+) battery cable
b. –
3. Negative (–) battery cable
4. Fuel line—12.7 mm (0.5 in.) inside diameter
1. Arrange the harnesses and fuel hose in the approximate positions they will occupy in the rigging grommet.
2. Work the grommet around the battery cables, engine data harness, and fuel hose. Start with the inboard and innermost
items, and work outward.
3. Press the rigging grommet into the opening.
NOTICE
Inspect the position of the hose clamp located on the fuel hose to ensure that it will not chafe or cut into the adjacent wiring
harnesses.
4. Slide the rigging adapter and rigging tube into place over the grommet.
5. Fasten the rigging grommet and rigging adapter with three screws. Tighten the screws to the specified torque.
c a - Rigging tube
b - Rigging adapter
c - Screws (3)
c
b
64395

Screws for attaching the rigging adapter 6.0 53.1 –
Connections at the Engine

The space available for rigging is limited. Follow these guidelines to ensure a trouble‑free rigging process.
1. Connect the battery cables to the engine:

a. Remove the propulsion control module (PCM) cover by pulling outward.
68514
PCM cover
b. Route the battery cables through the rigging tube and rigging grommet. Refer to Rigging Grommet for details.
c. Connect the battery cables to the engine. Tighten the nuts on the battery connections to the specified torque and
apply Liquid Neoprene to the connections.
a - Positive (+) battery cable connection

a b - Negative (–) battery cable connection
68516

Battery connection nuts 17 150 –

25 Liquid Neoprene Battery connections at the engine 92- 25711 3
2. Route the engine data harness:

a. Route the 14‑pin connector end of the engine data harness (marked "ENGINE" on the harness decal) through the
rigging grommet. Refer to Rigging Grommet for details. Ensure that the engine data harness extends 81.3 cm
(32 in.) from the end of the rigging tube.
a - Engine data harness

b - Harness decal (marked "ENGINE")
c - 14‑pin connector 81.3 cm (32 in.) from the end of the rigging tube
b
c
68790
b. Remove the 14‑pin connector on the engine harness end from the retainer.
a - 14‑pin connector
b - Retainer
68791
c. Connect the 14‑pin connectors and push the connectors into the retainer.
a - Harness retainer
b - 14‑pin engine data harness connector
c - 14‑pin connector on the engine harness end
b
a
68792

d. Route the engine data harness around the PCM as shown. Ensure that the harness is retained by the harness
brackets. Secure the harness with a cable tie.
c a- Engine data harness

b b- Harness brackets
b c- Cable tie
d- PCM
68518
3. Install the PCM cover.
68514
PCM cover
4. Connect the remote fuel line to the fitting at the ingress. Press the fuel hose onto the quick connect fitting until it clicks.
IMPORTANT: The minimum fuel hose inside diameter (ID) is 12.7 mm (0.5 in.), with a separate fuel hose/fuel tank pickup
for each engine.
IMPORTANT: Install the fuel hose onto the quick connect fitting with the temporary in‑line fuel filter in place. The in‑line fuel
filter will catch initial fuel system debris before it reaches the engine. This filter must be removed before customer delivery,
and the engine should never be run at wide‑open throttle (WOT) with this filter installed or severe engine damage may
result.
a - Quick connect fitting

b - Temporary in‑line fuel filter
b
68521

Engine Rigging Center

The 450R outboard utilizes an engine rigging center located inside the boat. This is used to make electrical connections
between the engine and the vessel. Refer to the following information for making connections to the rigging center.

Engine rigging center 8M0153448
Installation Requirements
The following guidelines must be followed when mounting the rigging center inside the boat:
1. One rigging center is required per engine.
2. The rigging center must be installed in an accessible and dry location.
3. Keep the included sealed weather caps on any rigging center connections not being utilized.
4. At least 12.7 cm (5.0 in.) of clearance is required for the 14‑pin helm and engine harness connections.
5. At least 5.08 cm (2.0 in.) of clearance is required on the other sides of the engine rigging center for vessel connections and
cable routing.
b a - Engine rigging center

b - At least 5.08 cm (2.0 in.) of
a clearance required
c - At least 12.7 cm (5.0 in.) of
clearance required
b
c
b
68694
6. Secure the rigging center to the vessel with four screws (not supplied).
7. Engine rigging centers can be stacked. Do not stack more than two rigging centers together. To install the rigging centers
in a stacked configuration:
a. Install the spacers between the two rigging centers.
b. Install the washers and screws into the threaded inserts to secure the two rigging centers.

c. Tighten the screws to the specified torque.
b a a - Threaded inserts (4)

b - Rigging center mounting holes (4)
b
a
b
68850
a b

0.250‑20 x 3.50 in. stainless steel hex head screws 4.5 40 –
8. For Joystick Piloting for Outboard (JPO) applications, the thrust vector module (TVM) can be stacked on top of the engine
rigging center. Only one TVM and one engine rigging center are allowed per stack. Be sure to pair the TVM with the rigging
center for the appropriate engine. Refer to Mounting the Thrust Vector Module (TVM) to the Engine Rigging Center.
9. A rigging center fuse decal is included in the rigging center kit. Place the fuse decal in a visible location near the rigging
center.
Engine Rigging Center Connections

a b a - Fuel demand relay connector
b - Thrust vector module (TVM)
connector
m c c - Fuse holder
d - Engine data harness connector
l e - 14‑pin connector to helm
f - Fuel level connector
g - Water‑in‑fuel (WIF) sensor
k connector
d h - Power steering connector
j i - Power
j - Remote joystick vessel module
connector
e k - Termination resistor
l - Gauge relay
68693 m - Mounting hole for optional fuel
i h g f demand relay

Engine Rigging Center Fuses

f g
a- Gauge power ‑ 7.5 amp
a 7.5 b b- Clean power ‑ 5 amp
c- Fuel relay disconnect ‑ 2 amp
7.5
d- Spare fuse ‑ 7.5 amp
e 7.5 c
e- Remote joystick vessel module ‑ 7.5 amp
68472 f- Good fuse
d
g- Open (blown) fuse
A rigging center fuse decal is included in the rigging center kit. Place the fuse decal in a visible location near the rigging center.
Engine Data Harness

The engine data harness connects the engine rigging center to the engine. The 21‑pin connector connects to the engine rigging
center, and the 14‑pin connector connects to the engine.

Engine data harness—10 feet 8M0153451
Thrust Vector Module

One thrust vector module (TVM) is required for each engine. The TVM must be installed so that it is electronically connected
between the helm harness and the engine rigging center. However, the mounting location does not need to be at the stern,
provided that the power steering actuator harness can reach the TVM using one extension harness.

TVM for twin‑ and triple‑engine JPO applications 8M0157205
TVM for quad‑engine JPO applications 8M0157207
Installation
The TVM, as supplied, is mounted to a panel for easy installation. It can be mounted separately, or to the engine rigging center.
Removal of the TVM from the panel should not be necessary under most circumstances.
a b TVM panel components

a - Main power relay
b - Power steering actuator
connector
g c - Current sensor connector
d - Power steering signal driver
connector
e - 120 ohm termination resistor
f - TVM connector (connects to
engine rigging center)
f g - Spacers (4) for option
mounting onto the engine
e rigging center
d
c 68868

1. Use the guidelines in the TVM instruction sheet to identify a location to mount the TVM panel. Ensure that all connections
to other components can be made without exceeding maximum harness length specifications. If mounting the TVM to the
engine rigging center, refer to Mounting the Thrust Vector Module (TVM) to the Engine Rigging Center.
2. Mount the TVM panel (or TVM) according to the instruction sheet that accompanies the TVM.
3. Remove the weather cap from the power steering actuator connector.
4. Connect the power steering actuator harness to the TVM.
NOTE: Extension harnesses are available in 1.5 m (5.0 ft) and 3.0 m (10.0 ft) lengths. Only one extension harness may be
used, for a maximum total power steering actuator harness length of 6.7 m (22 ft).
TVM Connection Diagram

NOTE: The TVM power 15‑amp fuse is located in the outboard's fuse panel.
4
-
10
8 11
7
3
1
2
+
12
5 6 68757
1- Engine rigging center

2- Steering cylinder/actuator assembly
3- Power steering actuator harness (shown without optional extension harness)
4- Thrust vector module (TVM)
5- 14‑pin engine data harness
6- 14‑pin helm data harness
7- Signal driver extension harness
8- Power steering signal driver
9- Power steering pump
10 - Power steering pump fuse
11 - Current sensor
12 - TVM connector
Mounting the Thrust Vector Module (TVM) to the Engine Rigging Center
For dual‑ and triple‑engine JPO boats, one TVM is required per engine. Quad‑engine JPO boats require two TVM's; one for the
port outer and inner engines, and one for the starboard outer and inner engines. Each TVM must be mounted in a location
where the steering actuator can be reached with a maximum of one extension harness.

The TVM is supplied with its own panel. Even though it can be removed from the panel, Mercury Marine recommends mounting
the TVM and panel as a unit. TVM panels can be stacked using appropriate standoffs. Alternatively, the TVM can be mounted
to the engine rigging center. If mounting the TVM to an engine rigging center, ensure that each TVM is mounted to the engine
rigging center for the corresponding engine.
Refer to the instruction sheet supplied with the TVM for additional mounting considerations.
b TVM panel mounted to the engine

rigging center
a c a - TVM panel
b - 0.250‑20 x 5.0 in. stainless steel hex
d head screw (4)
c - Washer (4)
d - Spacer (4)
e e - Engine rigging center
68801

0.250‑20 x 5.0 in. stainless steel hex head screws 4.5 40 –
Digital Block Water Pressure Sensor

450R engines are equipped with a digital block water pressure sensor.
Vessel Mounted Water‑Separating Fuel Filter Kit with WIF Sensor

NOTE: Filter element is rated at 10 micron.
a - Fuel filter bracket

c b - Water‑separating fuel filter service
replacement
b c - Quick‑connect fitting—5/8 in. to 1/2 in.
d hose connection (2)
a d - Water‑in‑fuel sensor extension
harness
e - Water drain knob with harness
connection
f - O‑ring
f e
68253

Water‑separating fuel filter kit with WIF sensor—vessel mounted 8M0150504

If the boat uses a generator, a metal filter will be need and there is no current Mercury‑supplied option for a WIF sensor. The
QC4v style metal fuel filter is the best option for generator‑equipped boats. Customer‑supplied fittings will be required to adapt
to 12.7 mm (0.5 in.) fuel lines.

QC4v style metal fuel filter for generator‑equipped boats 8M0000493
Fuel Supply Module Priming Procedure

The fuel supply module (FSM) is not vented to the ambient air. The air trapped in the FSM, fuel lines, and fuel rail, will be
slightly compressed during the initial ignition key ON with a dry or drained fuel system. Additional key ON events under these
conditions, will not compress the air further to finish the priming of the FSM. An excessive number of key ON events may
eventually damage the fuel pumps. The volume of air trapped in the FSM must be purged to prime the fuel system. This can be
achieved by connecting a tool to the fuel rail Schrader valve fitting to quickly purge the system into an approved container, or by
cranking the engine.
Priming the FSM with a Purge Tool

The use of a purge tool for priming the FSM is the preferred method, but is not always practical. The objective is to purge the
air entrained in the fuel system through a purge tool connected to the fuel rail Schrader valve fitting. During key ON, opening
the dump valve will allow the air to be purged from the FSM and fuel rail. This method should be used on vessels where the
fuel inlet system to the outboard is restrictive; contains an anti‑siphon valve or holds a relatively large volume of fuel because of
a long fuel supply line or water‑separating fuel filter.
1. Verify the engine is in a level vertical position.
2. Verify the vessel fuel supply line is connected to the outboard fuel system inlet fitting.
3. Connect a fuel pressure gauge to the fuel rail Schrader valve.
4. Secure the fuel pressure gauge purge hose into an appropriate fuel container to collect excess fuel.
5. Open the fuel pressure gauge purge valve and turn the ignition key ON. The fuel pumps will run for approximately five
seconds.
6. Turn the ignition key OFF and then back ON. The fuel pumps will run for approximately five seconds. Continue this ignition
key cycle until the purged fuel is relatively clear of air bubbles.
NOTE: If the outboard fuel system does not prime within 15 key ON events, check for leaks in the fuel supply line to the
outboard. Repair as needed. If no leak is found, the fuel supply system to the outboard may be too restrictive. Correct the
condition and try again.
7. Remove the fuel pressure gauge.
8. Turn the ignition key ON. When the fuel pumps stop running, start the engine. The engine may not start on the first
attempt. The engine will run rough at idle for up to two minutes while the residual air is purged from the fuel system.
Priming the FSM (Ran out of Fuel Condition)

The use of a purge tool for priming the FSM is the preferred method, but is not always practical. When the vessel fuel system is
void of fuel volume, it can be primed without the use of a purge tool. The objective is to purge the air entrained in the fuel
system through the fuel injectors during engine cranking to allow fuel to enter the fuel module. This method can be used on
vessels where the fuel inlet system to the outboard is less restrictive and holds a relatively small volume of fuel; a short fuel
supply line, no water‑separating fuel filter, or water‑separating fuel filter is already primed. A full fuel tank can make the priming
process quicker.
1. Verify the engine is in a level vertical position.
2. Verify the vessel fuel supply line is connected to the outboard fuel system inlet fitting.
3. Turn the ignition key ON. The fuel pumps will run for approximately five seconds.
4. Turn the ignition key to the START position and release the key. The ECM controls the activation of the starter. The starter
may continue cranking for up to eight seconds.
NOTE: When priming a drained fuel system, residual fuel may cause the engine to flare and stall which shortens the
engine cranking event.
5. Continue with the ignition key ON and START sequence until the engine continues to run.
IMPORTANT: Allow the starter motor to cool for 20 to 30 seconds between full eight second crank events. Limit the
number of events to a maximum of 10 full eight second cranking events.
6. Once the engine starts, it may run rough at idle for up to two minutes while the residual air is purged from the fuel system.

7. If the fuel system will not prime within 10 full eight second cranking events, use the previous procedure Priming the FSM
with a Purge Tool to prime the fuel system.
Propeller Hub Kit Selection

IMPORTANT: All 450R gearcases are equipped with a 1.25 in. diameter propeller shaft.
Joystick Piloting for Outboard (JPO) Applications

For JPO applications, two propeller hub options are available:
• The Flo‑Torq II HD solid hub kit offers the most durability for high‑horsepower outboards such as the 450R, and is the
preferred choice when using propellers designed for surfacing operation.
• The Flo‑Torq SSR HD hub kit is optional for JPO applications when reduced shift noise is desired.
Propeller Shaft Optional Hub Kit Best Hub Kit

1.25 inch Flo‑Torq SSR HD Hub Kit Flo‑Torq II HD Solid Hub Kit
JPO applications only 8M0101601 840389K06
Non‑JPO Applications
For non‑JPO applications, the Flo‑Torq solid hub kit is required. This hub kit provides the most durability for high‑horsepower
outboards such as the 450R.
Propeller Shaft Required Hub Kit

1.25 inch Flo‑Torq II HD Solid Hub Kit
Non‑JPO applications 840389K06
Driveshaft/Housing Conversion Kits

Order both a driveshaft housing conversion (spacer) kit and a matching driveshaft conversion kit for each installation. The
maximum driveshaft housing conversion (spacer) kit available is 25.5 cm (10 in.), which will convert a long (L) shaft to an extra,
extra long (XXL) shaft, which is 76.2 cm (30 in.) long.
Driveshaft Housing Conversion (Spacer) Kits

Driveshaft housing spacer kit ‑ 12.7 cm (5 in.) Gray 8M0146973
Driveshaft housing spacer kit ‑ 12.7 cm (5 in.) White 8M0146623
Driveshaft housing spacer kit ‑ 25.5 cm (10 in.) Gray 8M0146974
Driveshaft housing spacer kit ‑ 25.5 cm (10 in.) White 8M0146624
67884

Driveshaft Conversion Kits

5.4 in. gearcase long shaft ‑ 50.8 cm (20 in.) 8M0146065
5.4 in. gearcase extra long shaft ‑ 63.5 cm (25 in.) 8M0146066
5.4 in. gearcase extra, extra long shaft ‑ 76.2 cm (30 in.) 8M0146067
67885
Gear Housing Removal and Installation

NOTE: It is not necessary to drain the oil sump when removing the gear housing.
IMPORTANT: The XL and XXL models use a driveshaft housing spacer which will come off with the gear housing. Be careful
not to drop or lose the driveshaft housing spacer on these models.
Gear Housing Installation

1. On right‑hand rotation gearcases, use the shift shaft tool to rotate the shift shaft counterclockwise into the front (forward)
gear. For left‑hand rotation gearcases, use the shift shaft tool to rotate the shift shaft clockwise into the front (reverse) gear.
NOTE: It may be necessary to rotate the propeller shaft to ensure that the clutch is engaged.
a - Shift shaft in neutral position
66729
Shift shaft handle tool 8M0127025

2. Ensure that the notch on the shift shaft coupler aligns with the notch on the shift actuator output shaft.
a - Notch on shift actuator coupler

b - Notch on shift actuator output shaft
b
a
65132
3. On right‑hand rotation gearcases, use a 15 mm wrench to rotate the shift actuator coupler so the notch on the coupler is
aligned with the "F" marking on the shift actuator. For left‑hand rotation gearcases, use a 15 mm wrench to rotate the shift
actuator coupler so the notch on the coupler is aligned with the "R" marking on the shift actuator.
a- Shift actuator coupler

b- Tab on shift actuator coupler
c- "F" marking on shift actuator
d- Wrench
F
d
c
b
a
65127
a- Shift actuator coupler

b- Tab on shift actuator coupler
c- "R" marking on shift actuator
d- Wrench
c
R
a
d
65128

4. Position the gear housing and spacer if equipped, so the driveshaft is protruding into the driveshaft housing.
5. Move the gear housing up toward the driveshaft housing while aligning the water pump coupler to the water tube and the
shift shaft into the shift shaft actuator coupler.
NOTE: If the driveshaft splines will not align with the crankshaft splines, rotate the propeller shaft slightly to reposition the
splines.
6. Secure the gear housing assembly to the driveshaft housing.
Special Tools
Rigging
Lifting Strap 883705T01
Use with an overhead hoist to lift an engine.
67021
450R Flywheel Lifting Ring 8M0156840
Attaches to the flywheel to allow lifting of the powerhead or installation/removal

of the engine.
68661
Data Cable Puller 888462A 1
Attaches to the end of the DTS data harness to aid in pulling the harness
4618 through the boat. Prevents damage to the DTS data harness.
Transom Drilling Fixture 8M0125231
Aids in engine installation by acting as a template for the engine mounting holes.
64191

Fuel Pressure Gauge Kit 91‑881833A03
Tests the fuel pump pressure; can be used to relieve fuel pressure.
2807
Maintenance
Crankcase Oil Pump 802889A1
Aids in the removal of engine oil without draining the crankcase.
11591
Oil Drain Hose 8M0129230
Aids in the removal of engine oil without draining the crankcase. Connect to
the crankcase oil pump.
64627
Oil Filter Wrench 91‑889277
Aids in the removal of the oil filter. Cup size: 76mm x 14 flute.
5221
Alternator Belt Shoe 8M0146862
Aids in the installation and removal of the alternator belt on V‑8 and V‑6
FourStroke outboards. Tool ID number 8M0140323.
66881

Flywheel Rotation Tool 8M0146861
Aids in the manual rotation of the flywheel, especially for alternator belt
removal and installation. Tool ID number 8M0144583.
66882
Diagnostic Tool Requirements

a
d 65112
a- Mercury Marine G3 license key

b- G3 SmartCraft diagnostic interface
c- CAN‑P/CAN‑H adapter harness
d- G3 engine harness adapter with resistor

G3 interface kit 91‑8M0138392
Mercury Marine G3 2018 license key 90‑8M0138391
The 450R outboard requires G3 2018 update 3 or greater. Along with the standard data fault support in this version/update, the
following active diagnostics are also supported for this outboard:
• Injector pulse test
• Ignition spark gap test
• Tachometer output test
• Fuel pump output test
• IAC output test
• Horn output test
• Cylinder misfire test
• Smart start test

To connect the G3 SmartCraft interface cable to the engine, you must remove the yellow resistor cap from below the propulsion
control module (PCM) cover and replace it with the SmartCraft interface adapter harness P/N 8M0046081. The adapter
harness contains the proper termination for the CAN bus circuit. Proper termination is required to ensure reliable
communication. The adapter allows the SmartCraft diagnostic interface to connect directly to the 10‑pin connector on the
engine.
b Shown with bottom cowl removed

a - Starboard side charge air cooler
a b - PCM cover
c c - Termination resistor
68594
Adaptive Speed Control Propping with CDS G3

A special propping procedure using CDS G3 should be used for optimum propping.
1. Install the best guess propeller.
2. Connect CDS G3 to the engine, and monitor the following values:
• RPM ‑ engine speed. In this example, for a new boat with a new engine, the ideal RPM is at the upper end of the
RPM range.
• DemandLinear ‑ requested handle position. This should be at 100% at wide‑open throttle. If this value is not at 100%
when the handle is in the full forward position, DTS helm configuration needs to be performed.
• DemandLinear_with_Guardian ‑ software controlled limit with any engine protection/Guardian limits applied. This
value should also be at 100% when underway and with the handle in the full forward position. If this value is less than
the DemandLinear value, check faults for Guardian cause and correct the issue.
• Demand ‑ the final demand value requested by the software. If the engine is propped correctly, with engine speed at
wide‑open throttle falling within the operating range at optimum trim, this value should be at 100%.
68724
3. Run the engine with the handle at wide‑open throttle (100% DemandLinear) at optimum trim. Use the following chart to aid
in final propeller selection.
Scenario Engine Speed

At or Just Above Within Operating At or Just Below
# Description <5,800 RPM >6,400 RPM
5,800 RPM Range 6,400 RPM
Decrease
DemandLinear = 100% Consider a slightly Consider a slightly
propeller pitch
DemandLinear with lower pitch No change higher pitch
1 until engine speed N/A
Guardian = 100% propeller. (See needed. propeller. (See
falls within
Demand = 100% NOTE 1.) NOTE 2 and 3.)
operating range.
DemandLinear = 100% Increase propeller
DemandLinear with pitch until engine
2 N/A N/A N/A N/A
Guardian = 100% speed falls within
Demand < 100% operating range.
DemandLinear < 100%
3 Adjust throttle cable or reconfigure DTS handle so that 100% DemandLinear can be reached.
with throttle lever at max

Scenario Engine Speed

At or Just Above Within Operating At or Just Below
# Description <5,800 RPM >6,400 RPM
5,800 RPM Range 6,400 RPM
DemandLinear = 100%
4 DemandLinear with Check faults for cause of Guardian condition.
Guardian < 100%
NOTE: Refer to the following notes:

1. Lowering the pitch of the propeller will increase the engine speed above the 5,800 RPM lower threshold, to account for
variations in loading and ambient conditions.
2. Increasing the pitch of the propeller will decrease the engine speed below the 6,400 RPM upper threshold, to account for
variations in loading and ambient conditions.
3. Demand may be slightly less than 100%.
Adaptive Speed Control Propping without CDS G3

IMPORTANT: Boat propping can be performed using the normal method used for Mercury Outboards. To achieve optimum
propeller selection, however, follow the Adaptive Speed Control Propping with CDS G3 procedure.
IMPORTANT: To operate the engine at full throttle before the break‑in period is complete, follow this procedure.
1. Place the remote control in neutral, idle speed and start the engine.
2. Slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
3. Watch all gauges for normal readings.
4. When the engine reaches normal operating temperature, run the boat up on plane.
5. Advance the engine RPM (in 200 RPM increments) until the engine reaches its maximum rated RPM. Refer to the
following table for the wide‑open throttle RPM range.
Engine Performance
Wide‑open throttle (WOT) engine RPM
5800–6400 RPM
range
Peak power RPM range 6200–6400 RPM
6. To test if the correct propeller has been installed, operate the boat with a normal load on board at WOT and check the
RPM with an accurate tachometer. The engine RPM should be near the top of the specified range so that, under a heavy
load, the engine speed will not fall below the specified RPM range. If the engine speed is too low, replace the propeller with
a lower pitch propeller. Normally a 25 mm (1 in.) propeller pitch change causes an RPM change of 150 RPM.
IMPORTANT: Adaptive Speed Control will not allow the engine to exceed 6400 RPM even if the boat is under propped.
Adaptive Speed Control does not operate like a rev limiter. The operator may not notice that engine power is being limited
because the engine will still reach, but not exceed 6400 RPM. If a heavy load on board the boat does not cause the engine
RPM to drop at WOT, consider switching to a larger pitch propeller.
IMPORTANT: Using a target of 6350 RPM at WOT will provide the best results when propping the boat without using CDS
G3. This ensures that Adaptive Speed Control is not limiting the available engine power.
7. Return to idle speed.
8. Shut off the engine.
Operational Note
A noticeable noise may be emitted from the outboard’s electronic actuators during a key OFF, tilt switch actuation. To allow the
outboard to be tilted with the key in the OFF position, the PCM is momentarily turned on with the tilt switch. When the PCM
turns on, the actuators will cycle and create a clicking or a buzzing sound. The noise created by this actuator cycling is
considered normal operation.

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Service Bulletin

Outboard No. 2019-04

Important New Model Information—450R

2019-04 JUNE 2019 © 2019 Mercury Marine Page 1 / 40

• Thrust Vector Module

Page 2 / 40 © 2019 Mercury Marine JUNE 2019 2019-04

*Engine at normal operation temperature.

Engine Operation and Performance Specifications

Block Water Pressure at WOT (5800–6400 RPM)

Block Water Temperature

2019-04 JUNE 2019 © 2019 Mercury Marine Page 3 / 40

Gearcase Application and Warranty Chart

Sport Master Gearcase Propeller Requirements

Page 4 / 40 © 2019 Mercury Marine JUNE 2019 2019-04

5.44 Heavy Duty (HD) Gearcase Propeller Requirements

Trim Thrust Guide Wear Pad

Checking Trim Wear Pad Clearance

2019-04 JUNE 2019 © 2019 Mercury Marine Page 5 / 40

Replacing the Trim Thrust Guide Wear Pads

c a - M6 x 20 screw with patch lock pad (8

Description Nm lb‑in. lb‑ft

450R Maintenance Schedule Decal

Inspection and Maintenance Schedule

Page 6 / 40 © 2019 Mercury Marine JUNE 2019 2019-04

Description Nm lb‑in. lb‑ft

After Each Use

After 10 Hours of Use

Every 100 Hours of Use or Once Yearly, Whichever Occurs First

Description Nm lb‑in. lb‑ft

Tube Ref No. Description Where Used Part No.

2019-04 JUNE 2019 © 2019 Mercury Marine Page 7 / 40

• Check the tightness of bolts, nuts, and other fasteners—dealer service.

Tube Ref No. Description Where Used Part No.

Every 300 Hours of Use or Three Years

Before Periods of Storage

Corrosion Control Anode

a - Transom bracket anode

Lifting the Outboard

Page 8 / 40 © 2019 Mercury Marine JUNE 2019 2019-04

Single‑Point Lifting Procedure

a - Engine oil dipstick

a - Flywheel lifting ring

Description Nm lb‑in. lb‑ft

450R Flywheel Lifting Ring 8M0156840

Attaches to the flywheel to allow lifting of the powerhead or installation/

2019-04 JUNE 2019 © 2019 Mercury Marine Page 9 / 40

Dual‑Point Lifting Procedure

Port and starboard lifting eyes

Lifting strap 883705T01

Use with an overhead hoist to lift an engine.

Page 10 / 40 © 2019 Mercury Marine JUNE 2019 2019-04

450R Steering System Requirements

2019-04 JUNE 2019 © 2019 Mercury Marine Page 11 / 40

AMS Models—Power Steering

Helm Fitting ID Mark Hose ID Mark Description

Multiple Engine Steering Requirements

Page 12 / 40 © 2019 Mercury Marine JUNE 2019 2019-04

Rear-Mounted Steering Tie Bar

a - Rear‑mounted steering tie bar attachment point