Mercury Outboard 1986-2003 6 to 15hp 2 stroke Repair Manual

6/8/9.9/10/15 Starting Model Year 1986 Serial Number 0A197112 and Up (USA) 09503295 and Up (Belgium) Starting Model Year 1986 90-827242R02 February 2003 6/8/9.9/10/15

90-827242R02 FEBRUARY 2003 Page i Notice Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus Common Sense operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started.

Page ii 90-827242R02 FEBRUARY 2003 It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual.

1 2 3 4 5 6 7 8 General Information & Specifications Electrical and Ignition Fuel System Powerhead Mid-Section Lower Unit Attachments/ Control Linkage Manual Starter 90-827242R02 FEBRUARY 2003 Page iii Service Manual Outline Section 1 - General Information & Specifications A - Specifications B - Maintenance C - General Information D - Outboard Installation Section 2 - Electrical and Ignition A - Ignition System B - Charging & Starting System C - Timing/Synchronizing & Adjusting D - Wiring Diagrams Section 3 - Fuel System A - Fuel Delivery System B - Emissions Section 4 - Powerhead Section 5 - Mid-Section A - Clamp/Swivel Brackets and Driveshaft Housing B - Power Trim Section 6 - Lower Unit Section 7 - Attachments/Control Linkage A - Throttle/Shift Linkage (Tiller Handle Shift Models) B - Throttle/Shift Linkage (Side Shift Models) C - Tiller Handle Section 8 - Manual Starter

Page iv 90-827242R02 FEBRUARY 2003 Propeller Information For in-depth information on marine propellers and boat performance – written by marine engineers – see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers... and Boat Performance Information” (Part No. 90-86144 92). How To Use This Manual The manual is divided into SECTIONS which represents major components and systems. Some SECTIONS are further divided into PARTS. Each PART has a title page. A Table of Contents for the particular PART is printed on the back of the title page. SECTIONS and PARTS are listed on the Service Manual Outline sheet which immediately follows the cover of this book. Page Numbering Two number groups appear at the bottom of each page. The example, below, is self-explanatory. EXAMPLE: 90-827242R1 MAY 1998 Page 2B-7 Revision No. 1 Month of Printing Year of Printing Section Number Part of Section Letter Page Number

1 A SPECIFICATIONS 90-827242R02 FEBRUARY 2003 Page 1A-1 GENERAL INFORMATION & SPECIFICATIONS Section 1A – Specifications Table of Contents General Specifications 1A-1 . . . . . . . . . . . . . . . . . . . Propeller Information Chart - 6 HP 1A-6 . . . . . . . . . Propeller Information Chart - 8 HP 1A-6 . . . . . . . . . Propeller Information Chart -9.9/10 HP 1A-7 . . . . . Propeller Information Chart -15 HP 1A-7 . . . . . . . . Mercury/Quicksilver Lubricants and Sealants 1A-8 General Specifications Models 6/8/9.9/10/15 PERFORMANCE KW (HP) Model 6 Model 8 Model 8 Sailmate Model 9.9 Model 9.9 Sailpower XR/MAG/Viking10 Model Sea Pro/Marathon 10 Model 15 Model Sea Pro/Marathon 15 4.5 (6) 5.9 (8) 5.9 (8) 7.4 (9.9) 7.4 (9.9) 7.5 (10) 7.5 (10) 11.2 (15) 11.2 (15) OUTBOARD WEIGHT Manual Start 6 8 8 Sailmate 9.9 9.9 Sailpower XR/MAG/Viking10 Sea Pro/Marathon 10 15 Sea Pro/Marathon 15 Electric Start 6 8 9.9 9.9 Sailpower 15 33.1 kg (73.0 lb) 33.1 kg (73.0 lb) 33.8 kg (74.5 lb) 33.8 kg (74.5 lb) 34.2 kg (76.5 lb) 33.8 kg (74.5 lb) 33.8 kg (74.5 lb) 34.0 kg (75.0 lb) 34.0 kg (75.0 lb) 36.1 kg (79.5 lb) 36.1 kg (79.5 lb) 36.7 kg (81.0 lb) 37.7 kg (83.0 lb) 37.0 kg (81.5 lb) FUEL SYSTEM Recommended Gasoline Recommended Oil Ratio Fuel Tank Capacity 6/8/9.9/Sailpower, XR/MAG10 10 Sea Pro Marathon/15 Automotive Unleaded with a Minimum Pump Posted Octane Rating of 86 2 Cycle Outboard Oil 25:1 (During break-in) 50:1 (After break-in) 12.0 L, 2.7 Imp Gal., 3.2 U.S. Gal. 25.0 L, 5.5 Imp Gal., 6.6 U.S. Gal.

SPECIFICATIONS Page 1A-2 90-827242R02 FEBRUARY 2003 CYLINDER BLOCK Type Displacement (1994 Model) 6 8 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 Displacement (1995 and Newer) 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR/MAG/Viking 10 15 15 Sea Pro/Marathon Two-Stoke Cycle – Cross Flow 209 cc (12.8 cu. in.) 209 cc (12.8 cu. in.) 209 cc (12.8 cu. in.) 209 cc (12.8 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in. 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) CYLINDER BORE Diameter (Standard)(1994 Model) 6 8 8 Sailmate 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR/Mag 10 15 Diameter (Standard)(1995 Model) 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR/Mag/Viking 10 15 15 Sea Pro/Marathon Taper/Out of Round Maximum Bore Type 53.975 mm (2.125 in.) 53.975 mm (2.125 in.) 53.975 mm (2.125 in.) 53.975 mm (2.125 in.) 53.975 mm (2.125 in.) 60.325 mm (2.375 in.) 60.325 mm (2.375 in.) 60.325 mm (2.375 in.) 60.325 mm (2.375 in.) 60.325 mm (2.375 in.) 60.325 mm (2.375 in.) 60.325 mm (2.375 in.) 60.325 mm (2.375 in.) 60.325 mm (2.375 in.) 0.1016 mm (0.004 in.) Cast Iron STROKE Length 45.7 mm (1.800 in.) CRANKSHAFT Top Main Bearing Journal Center Main Bearing Journal Bottom Ball Bearing Journal Connecting Rod Journal Runout 19.1 mm (0.7517 in.) 20.6 mm (0.8108 in.) 20.0 mm (0.7880 in.) 20.6 mm (0.8125 in.) 0.076 mm (0.003 in.) CONNECTING ROD Piston Pin End (I.D.) Crankpin End (I.D.) 20.8 mm (0.8195 in.) 27.0 mm (1.0635 in.) PISTON Piston Type Ring End Gap Aluminum 0.25 mm - 0.46 mm (0.010 in. - 0.018 in.) REEDS Reed Stand Open (Maximum) All Models Reed Stop Opening (Maximum) All Models 0.178 mm (0.007 in.) 7.54 mm (0.296 in.)

SPECIFICATIONS 90-827242R02 FEBRUARY 2003 Page 1A-3 GEAR HOUSING Gear Ratio Gearcase Capacity Lubricant Type Forward Gear - Tooth count - Type Pinion Gear - Tooth count - Type Pinion Height Forward Gear Backlash Reverse Gear Backlash Water Pressure With Thermostat – @ W.O.T (5000 RPM) – @ Idle (750 RPM) W/O Thermostat – @ W.O.T (5000 RPM) – @ Idle (750 RPM) 2.0:1 200 ml (6.8 fl. oz.) Quicksilver Gear Lube Premium Blend 26 Spiral/Bevel 13 Spiral/Bevel Floating No Adjustment No Adjustment 34.5 - 48.3 kPa (5 - 7 PSI) 3.4 - 10.3 kPa (.5 – 1.5 PSI) 34.5 - 48.3 kPa (5 – 7 PSI) 0 - 7 kPa (0 – 1 PSI) MID SECTION Transom Height Short Shaft Long Shaft Extra Long Shaft Steering Pivot Range Tilt Pin Positions Total Tilt Angle Allowable Transom Thickness 38 cm (15 in.) 51 cm (20 in.) 63.5 cm (25 in.) 78° 3 + 3 Shallow Water 78° 60.3 mm (2-3/8 in.) FUEL SYSTEM Fuel Recommended Gasoline Recommended Oil Gasoline/Oil Ratio Fuel Tank Capacity 6/8/9.9/9.9 Sailpower XR/MAG/10 Sea Pro/ Marathon/15 Pre-Mixed Gasoline and Oil Automotive Lead-Free 2 Cycle Outboard Oil 25:1 (During Break-In) 50:1 (After Break-In) 12.0 L, 3.2 U.S. Gal. 25.0 L, 6.6 U.S. Gal. STARTING SYSTEM Manual Start Electric Start Starter Draw (Under Load) (No Load) Recoil 12 Volt 55 Amperes 15 Amperes CHARGING SYSTEM Alternator Output BLACK Stator - 2 Magnet Flywheel (8 Pole)(4 Pulses) RED Stator - 4 Magnet Flywheel (10 Pole)(5 Pulses) 4 Amp. (48 Watt) @ 6000 RPM 6 amp (72 Watt) @ 6000 RPM

SPECIFICATIONS Page 1A-4 90-827242R02 FEBRUARY 2003 BATTERY Battery Rating 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) IGNITION SYSTEM Type SPARK PLUG (1994) 6/8/9.9 10/15 SPARK PLUG GAP (1994) 6/8/9.9 10/15 SPARK PLUG (1995 AND NEWER) 6/8 9.9/10/15 SPARK PLUG GAP (1995 AND NEWER) 6/8 9.9/10/15 Firing Order Stator High Speed Winding Stator Low Speed Winding Diode Test Ignition Coil Resistance: Primary Secondary Trigger Capacitor Discharge NGK BP8H-N-10 NGK BP8HS-15 NGK BPZ8H-N-10* 1.0 mm (0.040 in.) 1.5 mm (0.060 in.) NGK BP8H-N-10 NGK BP8HS-15 NGK BPZ8H-N-10* 1.0 mm (0.040 in.) 1.5 mm (0.060 in.) 1-2 120 - 180 Ω (BLACK/WHITE - GROUND) 3200 - 3800 Ω (BLACK/YELLOW - GROUND) 3100 – 3700 Ω (BLACK/YELLOW - BLACK/WHITE) 0.02 - 0.04 Ω 8000 - 11000 Ω 6500 - 8500 Ω NOTE: *Use NGK-BPZ8H-N-10 where radio frequency interference (RFI) suppression is required.

SPECIFICATIONS 90-827242R02 FEBRUARY 2003 Page 1A-5 CARBURETOR SPECIFICATIONS Type Idle RPM (In Gear) 6 8 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR/MAG/Viking 10 15 Wide Open Throttle RPM 6 8 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR/MAG/Viking 10 15 15 Sea Pro/Marathon Idle Mixture Screw (Initial Setting) Float Setting (All Models) Main Jet – Thread size 6 8 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR/MAG 10 15 6 8 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR/MAG 10 15/Viking 10 15 Sea Pro/Marathon Center Bowl, Integral Fuel Pump 650 ± 75 725 ± 50 725 ± 50 850 ± 50 725 ± 50 725 ± 50 4000 – 5000 4500 – 5500 5000 – 6000 5000 – 6000 5000 – 6000 5000 – 6000 5000 – 6000 Refer to Section 3 for Specifics 25.4 mm (1 in.) 10–32 1994 Model Year .042 .046 .052 .064 .052 .066 1995 and Newer .042 .046 .048 .052 .052 .072 .072 TIMING SPECIFICATIONS Idle 6 8/8 Sailmate 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR/MAG/Viking 10 15 15 Sea Pro/Marathon Maximum BTDC @ 4500 RPM – All Models 8° BTDC ± 1° 8° BTDC ± 1° 8° BTDC ± 1° 8° BTDC ± 1° 8° BTDC ± 1° 8° BTDC ± 1° 8° BTDC ± 1° 36° BTDC

Mercury Outboard 1986-2003 6 to 15hp 2 stroke Repair Manual

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