2004 MERCURY 4-STROKE Model 9.9 OUTBOARD Factory Service & Work Shop Manual

A 1 IMPORTANT INFORMATION SPECIFICATIONS

1A-0 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 Table of Contents Page General Specifications 1A-1 . . . . . . . . . . . . . . . . . .

90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1A-1 General Specifications Model 8/9.9 HORSEPOWER (KW) Model 8.0 (BODENSEE) Model 9.9 (BODENSEE) Model 9.9 8.0 (6.0) 9.9 (7.4) 9.9 (7.4) OUTBOARD WEIGHT Manual Start Electric Start 102 lbs. (46.3kg) 107 lbs. (48.5kg) FUEL Recommended Gasoline Automotive Unleaded with a minimum pump posted octane rating of 87 OIL Engine Oil Capacity +20 +40 +60 +80 F° C° 0 +100 –7 +4 +16 +27 –18 +38 SAE 25W-40 SAE 10W-30 Either 1.0 quart (1.0 Liter) SAE 10W-30 viscosity oil is recommended for use in all temperatures. SAE 25W-40 viscosity oil may be used at temperatures above 40 °F (4°C). Use Quicksilver 4-Cycle Marine Oil with the proper viscosity for the expected tem- perature in your area (see chart above). If not available, use a premium quality 4 cycle engine oil, certified to meet or ex- ceed anyone or combination of the fol- lowing American Petroleum Institute (API) Service Classification SH, SG, SF, CF-4, CE, CD, CDII. IGNITION SYSTEM Type Spark Plug Type (NGK) Spark Plug Gap Firing Order Capacitor Discharge Ignition CR6HS 0.024 - 0.028 in. (0.6 - 0.7 mm) 1 - 2 BATTERY Battery Rating 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) STARTING SYSTEM Manual Start Electric Start Ampere Draw Under: (Load) (No Load) Recoil Start 12 Volt 41.5 Amperes 14.2 Amperes CHARGING SYSTEM Alternator Output Manual Start Model Electric Start Model 6 Amperes (Non Regulated Lighting Coil) 10 Amperes (Regulated) FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Diaphragm Stroke Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 3-6 PSI (20-41 kPa) 0.0945 in. (2.4 mm) 0.2283 in. (5.8 mm) 6.6 U.S. Gallons

1A-2 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 Model 8/9.9 CARBURETOR SPECIFICATIONS Idle RPM Trolling RPM Wide Open Throttle (WOT) RPM 8.0/9.9 (BODENSEE) 9.9 Pilot Screw (Turns Out) 8.0/9.9 (BODENSEE) 9.9 Main Jet Size 8.0/9.9 (BODENSEE) 9.9 Pilot Jet Enrichener Jet Float Height* 950 ± 50 RPM (Out Of Gear) 850 ± 50 5000 - 5500 4500 - 5500 Not Adjustable 3 ± 1 #82 #86 #48 .024 (0.61 mm) 1 ± 0.04 in. (25.5 ± 1 mm) TIMING SPECIFICATIONS Ignition Timing (Full Retarded) 850 ± 50 RPM (Full Advanced) 2500-3000 RPM 5° ± 1° B.T.D.C. 35°± 1° B.T.D.C. CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 14.16 cu. in. (232cc) 2 STROKE Length 1.67 in. (42.4mm) CYLINDER BORE Diameter (Std) Taper/Out of Round Maximum Bore Type Bore Wear Limit 2.323 in. (59.0mm) 0.003 in. (0.076mm) Steel 2.326 in. (59.1mm) PISTON Piston Type O.D. at Skirt (Standard) (Oversize) 0.010 (0.254mm) (Oversize) 0.020 (0.508mm) Aluminum 2.3209 - 2.3216 in. (58.950 - 58.965 mm) 2.333 in. (59.25 mm) 2.343 in. (59.50 mm) COMPRESSION/ RATIO Compression Ratio Cylinder Compression (cold engine) 9.3:1 Highest reading and lowest reading should not differ by more than 10% CRANKSHAFT Top Main Bearing Journal Bottom Main Bearing Journal Connecting Rod Journal Crankshaft Width (Width of Thrust Sur- faces) “A” Runout Limit “B” Main Bearing Clearance B B A 1.181 in. ± 0.0001 in. (30.0 mm ± 0.003 mm) 1.181 in. ± 0.0001 in. (30.0 mm ± 0.003 mm) 1.102 in. ± 0.0001 in. (28.0 mm ± 0.003 mm) 4.87 - 4.88 in. (123.7 - 123.9 mm) 0.0008 in. (0.02 mm) 0.0002 - 0.0017 in. (0.005 - 0.0043 mm)

90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1A-3 Model 8/9.9 CONNECTING ROD Rod Clearance (Big End) 0.0008 - 0.0018 in. (0.021 - 0.045 mm) CYLINDER HEAD Warp Limit * * Lines indicate straight edge measurement 0.004 in. (0.1 mm) RINGS Ring End Gap (Installed) Top Middle Bottom (Oil Ring) Wear Limit Side Clearance: Top Middle Wear Limit 0.006 - 0.012 in. (0.15 - 0.03 mm) 0.006 - 0.012 in. (0.15 - 0.03 mm) 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.020 in. (0.50 mm) 0.002 - 0.003 in. (0.04 - 0.08 mm) 0.001 - 0.003 in. (0.03 - 0.07 mm) 0.020 in. (0.50 mm) VALVES Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake Exhaust Valve Dimensions: “A” Head Diameter Intake Exhaust “B” Face Width Intake Exhaust “C” Seat Width Intake Exhaust “D” Margin Thickness Intake Exhaust Stem Outside Diameter Intake Exhaust Guide Inside Diameter Intake Exhaust Stem To Guide Clearance Intake Exhaust Stem Runout Limit (max.) 0.0059 - 0.0079 in. (0.15 - 0.20 mm) 0.0079 - 0.0098 in. (0.20 - 0.25 mm) 1.020 - 1.028 in. (25.9 - 26.1 mm) 0.862 - 0.870 in. (21.9 - 22.1 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.024 - 0.031 in. (0.6 - 0.8 mm) 0.024 - 0.031 in. (0.6 - 0.8 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.2156 - 0.2161 in. (5.475 - 5.490 mm) 0.2150 - 0.2156 in. (5.460 - 5.475 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.0004 - 0.0015 in. (0.010 - 0.037 mm) 0.0010 - 0.0020 in. (0.025 - 0.052 mm) 0.0006 in. (0.016 mm)

2004 MERCURY 4-STROKE Model 9.9 OUTBOARD Factory Service & Work Shop Manual

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