1. 2017 Mercury 15 Hp Outboard Owners Manual Free Download
2. Mercury 15 Hp Outboard Manual
3. 2017 Mercury 15 Hp Outboard Owners Manual Pdf

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. 6/8/9.9/10/15 Starting Model Year 1986 Serial Number 0A197112 and Up (USA) 09503295 and Up (Belgium). 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 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. Section 5 - Mid-Section Mid-Section A - Clamp/Swivel Brackets and Driveshaft Housing B - Power Trim Section 6 - Lower Unit Lower Unit Section 7 - Attachments/Control Linkage A - Throttle/Shift Linkage (Tiller Handle Shift Models) B - Throttle/Shift Linkage (Side Shift Models). 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.

Study guide for med surg. Medical-Surgical Nurse certification gives participants the chance to validate their knowledge and skills. How much does it cost to take the Medical-Surgical Nurse exam?

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. 2 Cycle Outboard Oil Ratio 25:1 (During break-in) FUEL SYSTEM 50:1 (After break-in) Fuel Tank Capacity 6/8/9.9/Sailpower, XR/MAG10 12.0 L, 2.7 Imp Gal., 3.2 U.S. 10 Sea Pro Marathon/15 25.0 L, 5.5 Imp Gal., 6.6 U.S.

2017 Mercury 15 Hp Outboard Owners Manual Free Download

90-827242R02 FEBRUARY 2003 Page 1A-1. Cast Iron STROKE Length 45.7 mm (1.800 in.) Top Main Bearing Journal 19.1 mm (0.7517 in.) Center Main Bearing Journal 20.6 mm (0.8108 in.) CRANKSHAFT Bottom Ball Bearing Journal 20.0 mm (0.7880 in.) Connecting Rod Journal 20.6 mm (0.8125 in.) Runout 0.076 mm (0.003 in.). SPECIFICATIONS GEAR Gear Ratio 2.0:1 HOUSING Gearcase Capacity 200 ml (6.8 fl. Oz.) Lubricant Type Quicksilver Gear Lube Premium Blend Forward Gear - Tooth count - Type 26 Spiral/Bevel Pinion Gear - Tooth count - Type 13 Spiral/Bevel Pinion Height.

SPECIFICATIONS Battery Rating 465 Marine Cranking Amps (MCA) BATTERY or 350 Cold Cranking Amps (CCA) Type Capacitor Discharge SPARK PLUG (1994) 6/8/9.9 NGK BP8H-N-10 10/15 NGK BP8HS-15 NGK BPZ8H-N-10. SPARK PLUG GAP (1994) 6/8/9.9 1.0 mm (0.040 in.) 10/15 1.5 mm (0.060 in.). SPECIFICATIONS Type Center Bowl, Integral Fuel Pump Idle RPM (In Gear) 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR/MAG/Viking 10 Wide Open Throttle RPM 4000 – 5000 4500 – 5500 9.9/9.9 Sailpower 5000 – 6000 10 Sea Pro/Marathon 5000 – 6000 XR/MAG/Viking 10 5000 –. SPECIFICATIONS Propeller Information Chart - 6 HP Wide Open Throttle RPM: 4000-5000 Recommended Transom Height: 15, 20, 25 Right Hand Rotation Standard Gear Reduction: 2:1 Diameter Pitch No.

Of Material Typical Gross Typical Boat Speed Propeller Part Blades Boat WGT. Up To 16 12-56A12 Alum.

1100 – 2000 14 - 17 12-54A12 9-1/4 Alum. 900 – 2400 14 - 18 8-52A12 9-3/4 6-1/2 Alum. 1400+ High Reverse 5-50A12 Thrust 9-3/4 5-1/2 Alum.

1700+ Workboat 1-48A12 Thrust Hub. SPECIFICATIONS Mercury/Quicksilver Lubricants and Sealants Mercury Part Num- Quicksilver Part Tube Description Ref. Number Needle Bearing As- 92-802868A1 sembly Lubricant Dielectric Grease 92-823506-1 92-823506-1 Loctite 271 – Thread 92-809819 Locker Loctite 567 PST Pipe 92-809822 Sealant Loctite Master Gasket. SPECIFICATIONS Mercury Part Num- Quicksilver Part Tube Description Ref.

# Number Premium Plus 2 Cycle TC-W3 Outboard Oil 92-802824A1 92-802824Q1 RTV 587 Silicone 92-809825 Sealer Loctite 7649 Primer N 92-809824 Storage Seal Rust In- 92-802878-78Q56 hibitor Corrosion Guard. SPECIFICATIONS Mercury Part Num- Quicksilver Part Tube Description Ref. # Number Cyanacrylate Adhe- Obtain Locally Obtain Locally sive 3M Permabond Obtain Locally Obtain Locally 1 1 42 #3M08155 Loctite 262 Obtain Locally Obtain Locally Loctite 290 Obtain Locally Obtain Locally.1B-12 Corrosion Control Anode.1B-6 Positioning Outboard for Storage.1B-13 Spark Plug Inspection. MAINTENANCE Gearcase Lubricant Capacity Gear Case Ratio Capacity 2.00:1 200.0 ml (6.8 fl. Oz.) Special Tools 1. Flushing attachment 12612Q2 2.

Grease gun 91-37299Q2 Page 1B-2 90-827242R20 FEBRUARY 2003. Check steering system for binding or loose components.

Visually check steering link rod fasteners for proper tightness. Check propeller blades for damage. After Each Use 1.

Flush out the outboard cooling system if operating in salt or polluted water. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at all times. Stop the engine, turn off the water, and remove the flushing attachment. Reinstall the propeller.

Place the O-ring seal into the sight bowl and screw the sight bowl hand tight into the cover. Filter cover Filter O-ring Sight bowl 6. Visually inspect for fuel leakage around the sight bowl by squeezing the primer bulb until firm, forcing fuel into the sight bowl.

90-827242R02 FEBRUARY 2003 Page 1B-5. Set the spark plug gap. See Specification Chart in General Information Section. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs finger tight, and tighten 1/4 turn or torque to 27 Nm (20 lb. Page 1B-6 90-827242R20 FEBRUARY 2003. MAINTENANCE Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability.

IMPORTANT: Read the safety and maintenance instructions which accompany your battery. Turn off the engine before servicing the battery. Add water as necessary to keep the battery full. MAINTENANCE Lubrication Points 1.

Lubricate the following with 2-4-C with Teflon or Special Lubricant 101. Transom clamp screws. Swivel bracket. Steering friction adjustment shaft (tiller handle models). Swivel bracket Steering friction adjustment shaft Page 1B-8 90-827242R20 FEBRUARY 2003.

MAINTENANCE Tilt lock pins (Make sure this pin is free to push in and out). Lubricate along the entire tilt pin track on both transom brackets. Tilt lock pins Tilt pin track Lubricate the throttle and shaft cables, moving components and pivot locations. WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Gear Case Ratio Capacity 2.00:1 200.0 ml (6.8 fl.

Oz.) Draining Gearcase When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. MAINTENANCE 1. Place outboard in a vertical operating position. Place drain pan below outboard. Remove fill/drain plug and vent plug and drain lubricant. Fill/Drain Plug Vent plug Checking Lubricant Level and Refilling Gearcase 1.

Place outboard in a vertical operating position. MAINTENANCE Storage Preparations Fuel System IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being used contains alcohol, It is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system. MAINTENANCE Positioning Outboard for Storage Store outboard in an upright position to allow water to drain out of outboard. CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard. Propeller Selection. 1C-6 Serial Number Location.

Mercury 15 Hp Outboard Manual

30% relative humidity, at 25 C (77 F) temperature and a barometric pressure of 29.61 inches of mercury. Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. GENERAL INFORMATION Due to the horsepower/RPM characteristics of an engine, this will result in further loss of horsepower at the propeller with another decrease in boat speed. This secondary loss, however, can be regained by switching to a smaller pitch propeller that allows the engine to again run at recommended RPM. GENERAL INFORMATION CAVITATION Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case or from an irregularity in the propeller blade itself. These vapor bubbles flow back and collapse when striking the surface of the propeller blade resulting in the erosion of the propeller blade surface. Pour alcohol into carburetor throats (alcohol will absorbed water).

Again rotate flywheel. Turn engine over and pour alcohol into spark plug openings and rotate flywheel. Turn engine over (place spark plug openings down) and pour engine oil into throat of carburetors while rotating flywheel to distribute oil throughout crankcase. (steering effort equal in both directions) without causing the propeller to break loose. Refer to Mercury Precision Parts/Quicksilver Accessory Guide for a complete list of available propellers. Select a propeller that will allow the engine to operate at or near the top of the recommended full throttle RPM range (refer to Section 1A - Specifications preceding) with a normal load.

GENERAL INFORMATION Propeller Removal/Installation WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. GENERAL INFORMATION 6. Install forward thrust hub, propeller, rear thrust hub and propeller nut onto the shaft. Forward thrust hub Propeller Rear thrust hub Propeller nut 7.

Place a block of wood between gear case and propeller and tighten propeller nut. 15% or compression for both cylinders is less than 685kPa (100psi), the powerhead should be disassembled and inspected. Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance. It is essential, therefore, that improper compression be corrected before proceeding with an engine tuneup.

Mix epoxy chromate primer (DP-90LF) with equal part catalyst (DP-402LF) per manufacturers instructions, allowing proper induction period for permeation of the epoxy primer and catalyst. GENERAL INFORMATION Decal Application Decal Removal 1. Mark decal location before removal to assure proper alignment of new decal. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water. Position pre-wetted decal on wetted surface and slide into position.

Starting at the center of the decal, lightly squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal. Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface. OUTBOARD INSTALLATION GENERAL INFORMATION & SPECIFICATIONS Section 1D – Outboard Installation Table of Contents Notice to Installer and Owner.

1D-1 Steering Cable Seal.1D-4 Boat Horsepower Capacity. Mercury Marine Quicksilver accessories are available from Mercury Marine dealers. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories. OUTBOARD INSTALLATION Installing Outboard 1. Measure the transom height of your boat.

The boat bottom should be aligned or be within 25 mm (1 in.) above the anti-ventilation plate of the outboard. Place outboard on center line of transom. 0 - 25 mm (0 - 1 in) Anti-Ventilation Plate. Steering Cable Attaching Nut Torque 47.5 Nm (35 lb-ft) Steering Cable Seal 1. Place a mark on tilt tube 6.4 mm (.250 in.) from port end of tube. Slide plastic spacer, O-ring and cap over steering cable end, to tilt tube on engine.

6.4mm (.250 in.). OUTBOARD INSTALLATION Steering Link Rod Installation IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special self locking nuts. These locknuts must never be replaced with common nuts (non-locking) as they will work loose and vibrate off freeing the link rod to disengage. Ball joint (flat end facing up) Steering bracket Spacer - 9.5 mm (3/8 in.) Rubber spacer Flat washer 20.6 mm (13/16 in.) Locknut. Tighten to specified torque. Flat washer 15.9 mm (5/8 in.) (2) Spacer Locknut. Tighten until nut seats, then back off 1/4-turn.

NOTE: Attach shift cable to outboard first. Shift cable is the first cable to move when remote control handle is advanced from NEUTRAL position toward in-gear position. Refer to the Mercury Precision Parts/Quicksilver Accessory Guide to determine correct length of remote control cables. OUTBOARD INSTALLATION 4. Install cable ties on control cables. NOTE: Cable ties will prevent retainers from slipping off cables whenever cables are removed from engine. Place end of control cables on anchor pins and lock in place with retainers.

Cable tie SHIFT CABLE INSTALLATION 1. Slip barrel into barrel recess. Place end of shift cable on shift lever pin and lock in place with cable retainer. Secure barrel after throttle cable is installed. Slide barrel of throttle cable into barrel recess of control cable anchor bracket. Place end of cable on throttle lever pin.

With remote control in the wide open throttle position, a 1.6 mm (1/16 in.) gap must exist between guide of anchor bracket and control cable end. Adjust throttle barrel as required. Push grommet with control cables into opening in starboard bottom cowl.

Place remote control in neutral position. Manually shift outboard into neutral position. Slide control cable barrels into barrel recess of anchor bracket. Place ends of control cables onto pins of shift/throttle levers and lock in place with cable retainers. OUTBOARD INSTALLATION SECURING CABLES TO ANCHOR BRACKET 1. Position barrel retainer over barrels of control cables.

53254 Retainer Barrels 2. Secure barrel retainer with latch.

Latch must snap onto barrel retainer. Align hole in latch with hooks of barrel retainer and secure with latch pin. 53251 Retainer Latch. OUTBOARD INSTALLATION THROTTLE LINK ROD INSTALLATION 1. Adjust throttle link rod to a length of 21.6 cm (8.5 in.) as measured between ball joint centerlines. Install throttle link rod between ball joint of throttle control lever and ball joint of actuating lever.

OUTBOARD INSTALLATION Battery Cable Connections SINGLE OUTBOARD (–) Red sleeve (positive) Black sleeve (negative) Starting battery DUAL OUTBOARD 1. Connect a common ground cable (wire size same as engine battery cables) between negative terminals on starting batteries. (–) (–) Ground cable (same wire size as engine battery cable) - connect between negative Terminals Page 1D-42R02 FEBRUARY 2003. OUTBOARD INSTALLATION Tilt Pin Adjustment Placing Tilt Pin in Lower Holes 1. Lower the bow.

Result in quicker planing off, especially with a heavy load or a stern heavy boat. Generally improve the ride in choppy water. Increase steering torque or pull to the right (with the normal right hand rotation propeller). 2A-9 Description. 2A-6 Ignition Components Removal and Test Procedures. IGNITION SYSTEM Special Tools Required 1.

2017 Mercury 15 Hp Outboard Owners Manual Pdf

Flywheel Holder 91-5234 54964 2. Flywheel Holder 91-24937A1 3. DMT 2000 Digital Multimeter 91-854009A1 4. Spark Gap Board 91-87 5. Flywheel Puller 91-83164M Page 2A-2 90-827242R02 FEBRUARY 2003. IGNITION SYSTEM Notes: 90-827242R02 FEBRUARY 2003 Page 2A-3. IGNITION SYSTEM Electrical Components A – RED Stator B – BLACK Stator Page 2A-4 90-827242R02 FEBRUARY 2003.

IGNITION SYSTEM Electrical Components (continued) TORQUE REF. DESCRIPTION lb. Nm STATOR ASSEMBLY SCREW (M5 x 30) STATOR AUXILIARY (ELECTRIC/ALTERNATOR MODELS) SCREW (M5 x 30) SCREW (M5 x 10) (MANUAL) TRIGGER ASSEMBLY CLIP–trigger lead SWITCH BOX SCREW–switch box to block (M5 x 35) Drive Tight SCREW–ground wire (10-16 x 1/2) Drive Tight. Verify that wire connections are tight and free of corrosion. Inspect all electrical components that are grounded directly to the engine and all ground wires that they are properly grounded to engine. Inspect for disconnected wires and short and open circuits.

Page 2A-6 90-827242R02 FEBRUARY 2003. BLACK/YELLOW R x 100 31 - 37 BLACK/WHITE BLACK BROWN/YELLOW Trigger (BROWN/ YELLOW and BROWN/WHITE R x 100 6.5 - 8.5 wires disconnected from switch box) BLACK BROWN/WHITE Resistance Tested Part Connected To Multimeter Scale (ohms) + Terminal R x 1 0.02 - 0.04. WHITE/GREEN R x 1 370 - 445 wires disconnected WHITE/GREEN BLACK from switch boxes) BROWN/YELLOW Trigger (BROWN/ YELLOW and R x 100 6.5 - 8.5 BROWN/WHITE wires disconnected BROWN/WHITE BLACK from switch boxes) Resistance Tested Part Connected To Multimeter Scale.

IGNITION SYSTEM Ignition Components Removal and Installation CAUTION Do not strike flywheel with a hard object as flywheel damage could occur. Inspect flywheel magnets for clinging debris before installation. WARNING Engine could possibly start when turning flywheel during removal and installation. Disconnect (and isolate) spark plug leads. IGNITION SYSTEM Ignition Components Removal and Installation (continued) Torque Specifications 4.0 Nm (35 lb-in.) 2.3 Nm (20 lb-in.) No Torque; Drive Tight Liquid Neoprene 53047 Bolt (2) Retainer (2) Washer (2) Nut (4) Sta-strap (2) Spark plug lead Ignition coil Switch box Screw (3) 10.

SYSTEM 2 Magnet Flywheel 4 Amp. (48 Watt) (8 Pole)(4 Pulses) @ 6000 RPM 4 Magnet Flywheel 6 amp (72 Watt) (10 Pole)(5 Pulses) @ 6000 RPM BATTERY Battery Rating 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA). CHARGING AND STARTING SYSTEM Recommended Battery A 12 volt battery with a Marine Cranking Amperage rating minimum of 465 amperes or a Cold Cranking Amperage of 400. Battery Precautions When charging batteries, an explosive gas mixture forms in each cell. A portion of this gas escapes through holes in vent plugs and may form an explosive atmosphere around battery if ventilation is poor.

CHARGING AND STARTING SYSTEM Battery Charging System Troubleshooting A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See Electrolyte Level, and Charging a Discharged Battery. If battery will NOT accept a satisfactory charge, replace battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows. CHARGING AND STARTING SYSTEM Alternator Amperes Output 1998 And Prior (Stator - 8 Pole/4 Pulse) Amperage output can be measured by installing a amp meter a (10 amp minimum) in series between the rectifier and the battery or by clamping an inductive type amp meter (10 amp minimum) over the RED output lead from the rectifier to the battery.

CHARGING AND STARTING SYSTEM Connect red meter lead to ground (d), black lead alternately to terminals (a) and (c). Continuity Indicated No Continuity Indicated Connect black meter lead to ground (d), red Connect black meter lead to ground (d), red lead alternately to terminals (a) and (c). RED to YELLOW, BLACK to YELLOW R x 1000 RED to either YELLOW, BLACK to GROUND NO CONTINUITY.DC resistance of these windings generally is less than 1 ohm. A reading that resembles a short is acceptable.

Page 2B-6 90-827242R02 FEBRUARY 2003. GRAY BLACK OR GROUND 5.

Connect the multi-meter RED lead to engine ground or BLACK harness wire. Connect the BLACK multi-meter lead to the GRAY tachometer module bullet connector.

Measure voltage. METER TEST LEADS METER SCALE READING (V) BLACK 0 5 0 9 V lt 0.5 - 0.9 Volts. CHARGING AND STARTING SYSTEM 9. Connect GRAY, YELLOW, and YELLOW/BLACK tachometer module leads to engine harness. Measure resistance. METER TEST LEADS METER SCALE READING (W) BLACK 1 3 M 1 - 3 Mega Ohms TACHOMETER MODULE LEADS BLACK OR GROUND GRAY 11.

CHARGING AND STARTING SYSTEM Tachometer Module Running or Cranking Test OUTPUT VOLTAGE TEST 91-854009A1 91-89045-1 59093 Alternator, stator Voltage regulator/rectifier Tachometer module Engine ground leads Gray tachometer lead 1. Disconnect the GRAY tachometer lead.

Set meter to Voltage scale. CHARGING AND STARTING SYSTEM Rectifier/Regulator (P/N 853358T1) Diode Test WARNING Disconnect battery leads from battery before testing rectifier. Digital Meter (DMT 2000 or Equivalent) NOTE:Voltage regulator/rectifier specifications are given for informational purposes only. Use the appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system.

CHARGING AND STARTING SYSTEM VOLTAGE SPIKE SUPRESSER 1. Set meter to 2. Connect RED (+) meter lead to regulator case.

Connect BLACK (–) meter lead to RED regulator lead. Voltage Specification 0.4 - 0.7 VOLTS VOLTAGE SPIKE SUPRESSER DIODE TEST 1. CHARGING AND STARTING SYSTEM Analog Meter NOTE:Voltage regulator/rectifier specifications are given for informational purposes only.

Use the appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. BLK = Black RED = Red YEL = Yellow DIODE TEST 1.

CHARGING AND STARTING SYSTEM Starting System STARTER MOTOR AMPERES DRAW STARTER MOTOR NO LOAD NORMAL PART NO. DRAW 50-90983A1 15 AMPS 55 AMPS Starter Motor Teeth STARTING SYSTEM COMPONENTS The starting system consists of the following components. CHARGING AND STARTING SYSTEM Starting Circuit Troubleshooting Flow Chart To Rectifier/Regualtor 53056 Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (with YELLOW sleeve) cable from starter solenoid test point 1 BEFORE making tests to prevent unexpected engine cranking.

TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads between NEGATIVE battery post and common powerhead. 12 Volt Reading.

No voltage reading; check RED wire between battery positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6. CHARGING AND STARTING SYSTEM COMMANDER 2000 Key Switch Test 1. Disconnect remote control wiring harness and instrument panel connector 2. Set ohmmeter on R x 1 scale for the following tests: CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS: POSITION BLK/YEL YEL/RED YEL/BLK.

CHARGING AND STARTING SYSTEM Emergency Stop Switch (Lanyard Type) IMPORTANT: Refer to Section 2D-Wiring Diagrams for wiring connections. Disconnect emergency stop switch leads from engine wiring. Use an ohmmeter and perform the following tests. “RUN” “OFF” NO CONTINUITY CONTINUITY (1 Ohm or Less) 23421.

CHARGING AND STARTING SYSTEM Electrical Component Removal and Installation Voltage Regulator Rectifier Starter Solenoid 53261 Torque Specifications Tighten Securely 70 lb. (7.9 Nm) 15 lb. (1.7 Nm) 30 lb. (3.4 Nm) Liquid Neoprene 25 lb. (2.8 Nm) Page 2B-42R02 FEBRUARY 2003.

CHARGING AND STARTING SYSTEM Starter Motor Disassembly 1. Remove 2 thru-bolts from starter. Lightly tap on end of shaft and lower end cap with rubber mallet. Do not lose brush springs. 53235 Bolts Lower end cap Washers Bolts 3. Tap on drive end cap to loosen. Remove end cap and armature from starter housing.

CHARGING AND STARTING SYSTEM Cleaning and Inspection 1. If brushes are pitted, chipped or worn to less than 4.8mm (3/16 in.), replace brushes. IMPORTANT: DO NOT clean the starter drive assembly or armature shaft while starter motor is installed on outboard. The cleaning solution will drain dirt into motor housing. CHARGING AND STARTING SYSTEM TESTING ARMATURE FOR GROUND 1. Use an ohmmeter (R x 100) to check for no continuity between commutator and armature core or commutator and shaft.

If continuity exists, armature is grounded and must be replaced. 01441 Commutator Core.

CHARGING AND STARTING SYSTEM 2. Apply a drop of SAE 10W oil to to helix threads on armature shaft. DO NOT over lubricate. Apply a drop of SAE 10W oil to bushings in drive end cap and lower end cap. DO NOT over lubricate.

CHARGING AND STARTING SYSTEM 6. Install springs and brushes into brush holders. Spread brushes and hold in place with a strip of spring steel. Push in on drive end of shaft so that commutator will extend out of starter frame.

Screws Torque to 11.3 Nm (100 lb. In.) Neutral Start Switch (Electric Start Tiller Handle Shift Models) 1. Mount neutral start switch onto control platform with 2 bolts and plate. Torque mounting bolts to 0.6 Nm (5 lb.

53077 Neutral start switch Plate Bolts Torque to 0.6 Nm (5 lb. CHARGING AND STARTING SYSTEM 3. Route switch harness over block. Secure harness to stator harness with cable-tie. Route harness behind rectifier.

Attach BLACK lead to solenoid mount bolt. Attach BLACK lead with YELLOW sleeve to terminal 1 of starter solenoid.

53076 Switch harness BLACK lead. CHARGING AND STARTING SYSTEM 3. The starter button harness is routed down the PORT side of lower engine to cowl. The RED harness lead is connected to the POSITIVE terminal of the rectifier. Torque attaching nut to 2.8 Nm (25 lb. CHARGING AND STARTING SYSTEM Battery Cables/Engine Wiring Harness (Remote Electric Start Models) 1.

Slide battery cables through sleeve. Thread battery cable/sleeve through wire retainer of engine wiring harness. Verify 25.4mm (1 in.) of sleeve remains to the outside of wire retainer. 25.4mm (1 in.) 6. CHARGING AND STARTING SYSTEM 5.

Route engine wiring harness and battery cable/sleeve (under carburetor location) around to PORT side of cylinder block. Push wire retainer into opening of bottom cowl and secure with clip. 53068 Clip 7. Secure harness and battery cable/sleeve with cable-tie just inside bottom cowl.

CHARGING AND STARTING SYSTEM Battery Cables (Tiller Handle Push Button Electric Start Models) Installation 1. Fasten harness clamp to bottom cowl with nut, washer and bolt. 53069 Clamp Washer Bolt 2. Slide battery cables through sleeve.

Slide harness clamp over battery cable sleeve and position cables into bottom cowl. CHARGING AND STARTING SYSTEM Plug Harness (Battery Charging Kit) Installation 1. Install plug harness through fuel fitting opening in bottom cowl.

Route harness along PORT side of engine to rectifier. 53063 Harness 3. Refer to Section 2D for wiring connections. Emergency Stop Switch (Lanyard Type) Installation 1.2C-5 Specifications MAXIMUM TIMING 36 BTDC IDLE TIMING 8 BTDC 6/8/9.9/10/15 IDLE RPM IN FORWARD GEAR – 8/9.9/15 10 SEA PRO MARATHON XR/MAG/VIKING 10 15 SEA PRO. TIMING, SYNCHRONIZING & ADJUSTING Special Tools 1. DMT 2000 Service Tachometer 91-854009A1 2.

Timing Light 91-99379 Adjustments 1. Place engine in water. Side Shift Models 1. Check tiller handle cable adjustment for full throttle movement in both Forward and Reverse gears. TIMING, SYNCHRONIZING & ADJUSTING Tiller Handle Shift Models 1. Rotate tiller handle twist grip to NEUTRAL.

Adjust jam nuts to remove slack from control cables while allowing full travel of throttle/ shift linkage. 53046 Jam nuts TIMING POINTER LOCATION 40 30 20 10 Timing pointer. TIMING, SYNCHRONIZING & ADJUSTING Maximum Timing Adjustment 1. Connect timing light to No. 1 (top) spark plug lead. With engine in Forward gear, fully advance throttle to WOT (Wide Open Throttle) position. Adjust maximum spark advance screw to align the 36 BTDC (Before Top Dead Center) timing mark on flywheel with timing pointer.

TIMING, SYNCHRONIZING & ADJUSTING Fast Idle Adjustment 1. Push primer/fast idle knob completely in and rotate knob fully COUNTERCLOCKWISE. Shift outboard to NEUTRAL. Adjust screw to remove all clearance between idle wire and trigger. 23970 Fast idle screw Idle wire 4. Sea Pro Models).2D-6 Start).

WIRING DIAGRAMS Manual Start Ignition Wiring Diagram (1998 And Prior) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW Stator Trigger Switch box Ignition coil top cylinder Ignition coil bottom cylinder Stop switch Emergency stop switch Page 2D-2. WIRING DIAGRAMS Electric Start Models with Tiller Handle Start Button (1998 And Prior) BLK = Black BRN = Brown GRY = Gray GRN = Green RED = Red WHT = White YEL = Yellow Stator Trigger Switch box Ignition coil top cylinder Ignition coil bottom cylinder Alternator stator Rectifier. WIRING DIAGRAMS Electric Models Equipped with Remote Control (1998 And Prior) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW Stator Trigger Switch box Ignition coil top cylinder Ignition coil bottom cylinder Alternator stator Rectifier. WIRING DIAGRAMS Manual Start Ignition Wiring Diagram (1999 And Newer) GRN/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW Stator Trigger Switch box Ignition coil bottom cylinder Ignition coil top cylinder Emergency stop switch.

BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW Stator Trigger Switch box Ignition coil bottom cylinder Ignition coil top cylinder Stop switch Emergency stop switch Alternator stator Page 2D-6 90-827242R02 FEBRUARY 2003. WIRING DIAGRAMS Electric Start Models with Tiller Handle Start Button (1999 And Newer, Design I) GRN/YEL BLK/YEL BLK/YEL J7 J6 BLK/YEL BLK/YEL – YEL/RED BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW Stator Trigger. WIRING DIAGRAMS Electric Models Equipped with Remote Control (1999 And Newer, Design I) GRN/YEL BLK/YEL BLK/YEL YEL/BLK – YEL/RED BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW Stator Trigger Switch box.

WIRING DIAGRAMS Electric Start Models with Tiller Handle Start Button (1999 And Newer, Design II) GRN/YEL BLK/YEL BLK/YEL J7 J6 BLK/YEL BLK/YEL – BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW Stator Trigger. WIRING DIAGRAMS Electric Models Equipped with Remote Control (1999 And Newer, Design II) GRN/YEL BLK/YEL BLK/YEL YEL/BLK – YEL/RED BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW Stator Trigger Switch box.

WIRING DIAGRAMS Optional Electrical Accessories Wiring Diagrams Rectifier Terminal Block Manual Start Model with Lighting Coil Manual Start Model with Battery and Unregulated AC Voltage Charging Kit Late Model Voltage Regulator Tachometer Module Early Model Voltage Regulator Late Model Voltage Regulator with Manual Start Model with Tachometer Module Voltage Regulator. WIRING DIAGRAMS Commander 2000 Remote Control (Manual) BLK=BLACK YEL=YELLOW 23893 RUN – OFF switch Emergency stop switch Stop switch harness Page 2D-42R02 FEBRUARY 2003.

WIRING DIAGRAMS Commander 2000 Remote Control (Electric Start) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW 23890 Ignition/Choke switch Emergency stop switch Neutral start switch Tachometer/Accessories harness connector Wiring harness connector 90-827242R02 FEBRUARY 2003 Page 2D-13. WIRING DIAGRAMS Commander 3000 Panel Mount Control Neutral Interlock Switch RED=RED YEL=YELLOW Neutral interlock switch Emergency stop switch Page 2D-42R02 FEBRUARY 2003. 3A-14 Carburetor Assembly (6 - 8) Carburetor Installation.

FUEL DELIVERY SYSTEM Specifications Models 6/8/9.9/10/15 Type Center Bowl, Integral Fuel Pump Idle RPM (In Gear) – 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR/MAG/Viking10 Wide Open Throttle RPM 4000 – 5000 4500 – 5500 9.9/9.9 Sailpower 5000 – 6000 10 Sea Pro/Marathon 5000 –. FUEL DELIVERY SYSTEM WMC Carburetor Specifications 1994 MAIN JET 0 – 5000 ft 5000 – 7500 ft 7500 – 10000 ft FLOAT IDLE MODEL CARB (0 – 1524m) (1524 – 2286m) (1524 – 3048m) LEVEL 25.4mm.038 WMC-20B.040.042 1-3/8 (1 in.) 25.4mm. FUEL DELIVERY SYSTEM WMC Carburetor Specifications 1997 MAIN JET 0 – 5000 ft 5000 – 7500 ft 7500 – 10000 ft FLOAT IDLE MODEL CARB (0 – 1524m) (1524 – 2286m) (1524 – 3048m) LEVEL 25.4mm.038 WMC-20B.040.042 1-3/8 (1 in.) 25.4mm. FUEL DELIVERY SYSTEM WMC Carburetor Specifications 2002 and UP MAIN JET 0 – 5000 ft 5000 – 7500 ft 7500 – 10000 ft FLOAT IDLE MODEL CARB (0 – 1524m) (1524 – 2286m) (1524 – 3048m) LEVEL 25.4mm WMC-66.042.040.038 1-1/4. FUEL DELIVERY SYSTEM Carburetor Assembly (6 - 8) (9.9 - USA–S/N-0G112449/BEL–S/N-9831799 & Below) Page 3A-6 90827242R02 FEBRUARY 2003. FUEL DELIVERY SYSTEM Carburetor Assembly (6 - 8) (9.9 - USA–S/N-0G112449/BEL–S/N-9831799 & Below) (continued) TORQUE REF.

DESCRIPTION lb. Nm CARBURETOR THROTTLE VALVE SHAFT FUEL BOWL FLOAT FLOAT PIN SCREW INLET NEEDLE VALVE MAIN FUEL JET PLUG–jet retainer COVER–diaphragm. FUEL DELIVERY SYSTEM Carburetor Assembly (15) USA–S/N-0G112449/BEL–S/N-9831799 & Below Page 3A-8 90827242R02 FEBRUARY 2003. FUEL DELIVERY SYSTEM Carburetor Assembly (15) USA–S/N-0G112449/BEL–S/N-9831799 & Below (continued) TORQUE REF. DESCRIPTION lb.

Nm CARBURETOR (WMC-73) THROTTLE VALVE THROTTLE SHAFT (INCLS. SCREW & SPRING) FUEL BOWL FLOAT INLET NEEDLE VALVE MAIN FUEL JET (.066) PLUG–jet retainer COVER–diaphragm SCREW–diaphragm cover FUEL PUMP KIT. FUEL DELIVERY SYSTEM CARBURETOR ASSEMBLY USA–S/N-0G112450/BEL–S/N-9831800 & Up Page 3A-2R02 FEBRUARY 2003. GASKET–carburetor DIAPHRAGM GASKET/DIAPHRAGM KIT REPAIR PARTS KIT IDLE WIRE FAST IDLE LEVER PRIMER BRACKET PUSHNUT SCREW (6-32 x 3/4) SPRING SCREW (M5 x 8 x 12) SCREW (8-32 x 1/2) Tighten Securely PRIMER LEVER CAM BLOCK RETAINING CLIP CHOKE BEZEL. Ignition Timing 4. Ignition Spark Voltage 5.

Cylinder Compression 6. Reed Valves Typical symptoms and solutions in troubleshooting a fuel system are shown below: Problem: Engine Turns Over but Will Not Start or Starts Hard When Cold Problem: Engine Idles Rough and Stalls. FUEL DELIVERY SYSTEM Possible Cause Corrective Action Improperly mixed fuel. Contaminants (water, dirt, Check fuel in tank and replace if necessary.

Etc.) in fuel. Carburetor loose on intake manifold. Check tightness of carburetor nuts. Reed block loose or gasket defective. Using a pressure oil can, apply 2-cycle oil around reed block housing/crankcase housing matching surfaces and carburetor base.

FUEL DELIVERY SYSTEM Problem: Fuel Blowback Out of Carburetor Problem: Unable to Reduce Engine RPM to Slow Idle Possible Cause Corrective Action Chipped or broken reeds on reed block. Replace reeds. Problem: Rough Idle Possible Cause Corrective Action Excessive preload on reeds. Replace reeds. Push down on primer arm and pull primer knob, bezel and slide block out of bottom cowl.

Remove link wire from fast idle lever. Disconnect fuel line from carburetor. Remove carburetor mounting nuts. Lift carburetor from engine. Remove bleed line from fitting in bottom of carburetor.

Push down on primer arm and insert primer knob, bezel and slide block into primer assembly. Tighten screw to secure slide block in place. Align notch in back side of bezel with tab on bottom cowl and secure bezel in place with retaining clip. FUEL DELIVERY SYSTEM Carburetor Adjustments 1. Place outboard in water. Check tiller handle cable adjustment for full throttle movement in both Forward and Reverse gears. Adjust jam nuts for proper travel and to eliminate any slack.

Adjustment jam nuts INITIAL CARBURETOR ADJUSTMENTS Idle Speed Screw (Models So Equipped) 1. FUEL DELIVERY SYSTEM NOTE: For Models NOT equipped with an idle speed screw: 1. Loosen cam locking screw. Press cam follower down until it contacts throttle cam. Retighten cam locking screw.

Cam locking screw Cam follower Throttle cam LOW SPEED MIXTURE SCREW 1. FUEL DELIVERY SYSTEM IDLE WIRE ADJUSTMENT 1. Push primer/fast idle knob completely in and rotate fully counterclockwise.

Shift engine to Neutral. Adjust screw to remove all clearance between idle wire and trigger. Check fast idle speed by turning primer knob to full clockwise position.

Fast idle speed should be 1500 - 2000 RPM. Continue turning mixture screw clockwise until too lean a mixture is obtained and engine slows down and misfires.

Set low speed mixture screw halfway between rich and lean. DO NOT adjust leaner than necessary to attain reasonably smooth idling. When in doubt, set mixture slightly richer rather than too lean. FUEL DELIVERY SYSTEM CARBURETOR FLOAT ADJUSTMENT Check float level by removing fuel bowl and checking level of float as shown. If necessary, adjust float level by bending float hinge. 25.4mm (1 in.) Measure From Bottom of Float JET ORIFICE SIZE/PART NUMBER CHART NOTE: Thread size for jets is 10-32.

Carburetor jet changes must be reversed to avoid a lean fuel condition when used at low elevation. Feet 1000 2000 3000 4000 5000 6000 7000 8000 9000 033 12000 Meter 304.8 609.6 914.4 1219.2 1524 1828.8 2133.6 2438.4 2743.2 3048 52.8 3657.6 Jet Size 0.034 0.034 0.034 0.032 0.032 0.032.

FUEL DELIVERY SYSTEM Fuel Pump Removal and Disassembly IMPORTANT: Fuel pump check valve diaphragm and gasket should NOT be re-used once the fuel pump is disassembled. Remove 5 screws securing fuel pump assembly to carburetor. Separate fuel pump components. Cleaning and Inspection 1. Primer passage is plugged with debris or varnish.

Outboard smokes excessively at idle. Primer check ball is not seated due to debris, varnish or damaged check ball spring. Seal Screw (4) Torque to 1.6 Nm (14 lb-in.) Cover Diaphragm Gasket. FUEL DELIVERY SYSTEM Servicing Sight Bowl Fuel Filter WARNING Exercise extreme caution when cleaning fuel filter elements. Gasoline is extremely flammable and highly explosive under certain conditions.

Always stop the engine and DO NOT smoke or allow open flames in the area while cleaning fuel filter elements. EMISSIONS FUEL SYSTEM Section 3B – Emissions Table of Contents Exhaust Emissions Standards.

3B-1 Emissions Information.3B-4 What Are Emissions?. EMISSIONS Oxides of Nitrogen - NOx NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine.

Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion chambers when temperatures are too high. EMISSIONS Stratified vs.

Homogenized Charge DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models use a homogenized charge. The difference between the two Homogenized Charge A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This mixing occurs inside the carburetor venturi, reed blocks and crankcase.

EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system. The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder (head). The injector sprays a fuel/air mixture in the form of a bubble into the cylinder. Surrounding this bubble is air supplied by the transfer system.

EPA Emission Regulations: All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. Recommended oil/fuel ratio for best engine performance and minimal emissions Month of production (boxing month will be punched) FEL: represents (Mercury Marine) statement of the maximum emissions output for the engine family W M9X M 0016 2 1 0 Family example. EMISSIONS Service Replacement Certification Label IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible emission certification label.

If this label is missing or damaged, contact Mercury Marine Service for replacement if appropriate. Install the label on a clean surface in the original factory location. Decal Location: Model Service Part No.

Location on Engine 1998 Merc/Mar 262cc (6-8 hp) 37-855577 3 Inside Rear Top Cowl 1998 Merc/Mar 262cc (9.9-15 hp) 37-855577 4 Inside Rear Top Cowl.