A Nor-Tech 400 Sport commemorates Mercury Racing’s 50-year milestone.
Mercury Racing introduced a new 500-hp beast in honor of its 50th anniversary.
By Gregg Mansfield
As it continues to mark its 50th anniversary, Mercury Racing unveiled the 500R outboard and two V8 package drives during a gala in Charleston, South Carolina, in June.
The supercharged 500-hp outboard is the second significant product introduction this year, succeeding the 400R V10 outboard that premiered at the 2023 Miami International Boat Show.
A Midnight Express 43 Open equipped with quint Mercury Racing 500R outboards.
Developed over more than three years, the 500R incorporates a range of innovations, including a new crankshaft, enhanced midsection, and humidity compensation technology.
“We take great pride in this flagship. We have two excellent normally aspirated engines (the 300R and 400R), and now with the 500R, you get that supercharged performance,” stated Stuart Halley, former general manager of Mercury Racing, after the introduction of the new outboard. “We required a new gearcase, and our team accepted the challenge and created the R-Drive.”
On-water evaluations showed that the 500R offered increased midrange power and superior top-end speed with an extra 50 horsepower.
The event drew key figures from the high-performance industry to the Mercury Racing gathering in Charleston’s historical district.
Notable attendees included industry giants like Peter Hledin from Skater Powerboats, John Cosker of Mystic Powerboats, Randy Scism from Marine Technology, and John Tomlinson from TNT Custom Marine.
500R Specifications
Mercury Racing claims the 500R exceeds 500 horsepower, boasting an additional 50 horsepower and 10% higher torque compared to the 450R. Its 4.6-liter 64-degree V8 FourStroke powerhead is enhanced by a Mercury Racing supercharger, requiring a minimum of 89-octane fuel.
The Mercury Racing 500R outboard was the highlight at the 50th anniversary gala in Charleston, S.C.
To accommodate the enhanced power, Mercury Racing upgraded the powerhead, cooling system, midsection, and steering system. Engineers devised a new gearcase specifically for the 500R outboard, named the R-Drive.
The R-Drive, available in either a base or sport variant, features a crescent-shaped leading edge and long aspect torpedo, optimized for high speeds, as per Mercury Racing. The updated 5.9-inch gearcase can support propellers up to 17 inches in diameter, which is an inch larger than the 450R gearcase. Both drives are intended for semi-surfacing or full-surfacing applications, with a 1.60:1 gear ratio.
“This is a completely new gearcase designed specifically for this product,” explained Chris Jenks, Mercury Racing’s technical development manager for the 500R. “It features a larger input shaft, a larger prop shaft, and bigger internal components with enhanced bearings. We concentrated on the water pickups and hydrodynamic characteristics.”
Humidity Compensation Technology
The 500R introduces the first humidity compensation technology in a marine engine. A new sensor in the intake attenuator gauges the humidity of incoming air. This data allows the engine ECM to adjust spark timing based on the current humidity, air pressure, and temperature.
According to Mercury Racing, boaters should experience a notable boost in power during high humidity conditions. This technology reportedly enhances power by an additional 30 horsepower, which would not be accessible under high humidity alone.
The 500R is designed for catamarans, center consoles, and pontoon boats and comes with a three-year warranty. Though the industry anticipated the debut of a 500-hp outboard at the Mercury Racing gala in Charleston, many were surprised that it was built on a V8 platform rather than the V10 framework of the 400R launched in Miami.
Halley noted that planning for the 500R began following the 400R’s release in 2019, which is based on a V8 platform. Mercury Racing currently offers six outboards ranging from 60 to 500 horsepower. The 500R is available in the colors phantom black or cold fusion white, but buyers also have the option for a ready-to-paint version.
“We considered various elements during the 450R’s design, but were unable to incorporate them fully,” Halley mentioned. “We always envisioned a follow-up.”
Experiencing On Water
The day after unveiling the new 500R outboard, Mercury Racing provided invited guests and marine media a chance to experience the engines firsthand at its 50th anniversary celebration in Charleston, S.C.
Mercury Racing showcased catamarans, center consoles, and stepped-bottom boats to highlight the new 500R unveiled on June 15. Builders from the West Coast to South Carolina were on hand for the on-water demonstrations.
Among the boats featured in Charleston were the Cigarette 42 Artemis, DCB Racing M37R Wide Body, Fountain 43NX, Fountain 38 CCF, Freeman 47, Midnight Express 43 Open, MTI 44 Cat, MTI V50, Mystic C4000, Nor-Tech 46 Flyer, Nor-Tech 400 Sport, and Performance Boats’ new PBC P360.
The Safe Harbor Bristol Marina provided real-world conditions for testing the new Mercury Racing 500R outboards, with a strong Ashley River current and steady winds creating small white caps. Our first testing vessel was the Mystic C4000, piloted by the company’s general manager, Ryan Zivitski, utilizing twin 15 1/4” x 34” propellers.
The Mystic catamaran quickly got on plane, reaching a stable 70 mph within seconds while carrying five passengers. The engines’ quietness allowed everyone onboard to converse easily.
Pushing forward on the controls, Zivitski accelerated the catamaran to 108 mph, still having more speed potential on the top-end. Most manufacturers taking part in the on-water experience received their new Mercury Racing 500R outboards only days before the event, leaving them little time for fine-tuning.
“The performance from the bottom end to the top has improved,” Zivitski noted. “The new lower units, having a larger design, provide better stern lift and we altered prop rotation. The boat lifts its stern when planning, minimizing the prop buzz we experienced with the 450R outboards.
“There’s a notable improvement in midrange torque and acceleration, plus enhanced top-end performance, currently at least 5 mph faster. I believe this will improve even further with more optimization.”
Dr. John Mehalik from Fort Myers, Fla., noted similar improvements in midrange and top-end speed on his Nor-Tech 46 Flyer, which also participated in the Mercury Racing on-water experience. He upgraded his quad-engine boat from Mercury Racing 450R outboards to the 500R, realizing a significant 200 horsepower boost.
“I loved the boat as it was; I experienced no issues with my 450Rs—they were excellent for our time with the boat,” Mehalik commented. “The 500Rs are undeniably impressive. They are incredibly enjoyable, especially in midrange acceleration.”
Mehalik described the new engines as providing considerably more torque and power in the midrange on the 46 Flyer. He noted at least a 1 mph increase in top-end speed, achieving 84 mph in less-than-ideal weather conditions.
With a new total of 2,000 horsepower, the 46 Flyer now cruises between 60 and 70 mph (up from 50 to 60 mph) and offers improved range.
“Range is crucial since we travel extensively on this boat,” said Mehalik. “We often take 10 or 12 passengers when heading to the Bahamas. Having sufficient range and efficiency is essential for me.”
The Mercury Racing 500R outboards are in production, starting at a retail price of $72,000. The 500R includes a limited three-year warranty, with the option for up to five additional years of Mercury Product Protection available.