1986+ Mercury 6/8/9.9/10/15HP 2-stroke Factory Service Manual
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- 1986plus Mercury 6 8 9 9 15HP 2 Stroke Service Manual
Original 1986+ Mercury 6/8/9.9/10/15HP 2-stroke Factory Service Manual.
Starting Model Year 1986
Serial Number 0A197112 and Up (USA)
Serial Number 09503295 and Up (Belgium)
Manual is fully indexed and searchable with hi-resolution images and diagrams.
Mercury publication: 90-827242R02
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Reference and Info files
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Full list of manual chapters:
Cover and Table of Contents
6/8/9.9/10/15
Notice
Notice to Users of This Manual
Cleanliness and Care of Outboard Motor
Service Manual Outline
Propeller Information
How To Use This Manual
Page Numbering
Sec 1a - Specifications
Section 1A – Specifications
Table of Contents
General Specifications
Propeller Information Chart - 6 HP
Propeller Information Chart - 8 HP
Propeller Information Chart -9.9/10 HP
Propeller Information Chart -15 HP
Mercury/Quicksilver Lubricants and Sealants
Sec 1b - Maintenance
Section 1B – Maintenance
Table of Contents
Gearcase Lubricant Capacity
Special Tools
Inspection and Maintenance Schedule
Before Each Use
After Each Use
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
Every 300 Hours of Use or Three Years
Flushing The Cooling System
Fuel System
Fuel Line Inspection
Engine Fuel Filter
Corrosion Control Anode
Spark Plug Inspection
Battery Inspection
Fuse Replacement – Electric Start Remote Control Models
Lubrication Points
Gearcase Lubrication
Gearcase Lubricant Capacity
Draining Gearcase
Checking Lubricant Level and Refilling Gearcase
Storage Preparations
Fuel System
Protecting External Engine Components
Protecting Internal Engine Components
Gearcase
Positioning Outboard for Storage
Battery Storage
Sec 1c - General Information
Section 1C – General Information
Table of Contents
Serial Number Location
Conditions Affecting Performance
Weather
Boat
Engine
Following Complete Submersion
Submerged While Running
Fresh Water Submersion
Salt Water Submersion
Propeller Selection
Propeller Removal/Installation
Compression Check
Painting Procedures
Decal Application
Sec 1d - Outboard Installation
Section 1D – Outboard Installation
Table of Contents
Notice to Installer and Owner
Boat Horsepower Capacity
Outboard Remote Control
Selecting Accessories For The Outboard
Selecting Steering Cables and Remote Control Cables
Installing Outboard
Steering Cable and Steering Link Rod Installation
Installing Ride Guide Steering Cable to the Outboard
Steering Cable Seal
Steering Link Rod Installation
Remote Control Installation
Shift and Throttle Cable Installation to the Outboard
Remote Wiring Harness Connection to Engine
Battery Cable Connections
Tilt Pin Adjustment
Placing Tilt Pin in Lower Holes
Placing Tilt Pin in Upper Holes
Sec 2a - Ignition System
Section 2A – Ignition System
Table of Contents
Specifications
Special Tools Required
Electrical Components
Description
Test Procedures
Ignition Troubleshooting (BLACK Stator)
Ignition Troubleshooting (RED Stator)
Ignition Components Removal and Installation
Sec 2b - Charging and Starting System
Section 2B – Charging and Starting System
Table of Contents
Specifications
Recommended Battery
Battery
Operating Engine Without Battery
Battery Charging System Troubleshooting
Battery Charging System
Alternator Amperes Output 1998 And Prior (Stator - 8 Pole/4 Pulse)
Alternator Test (1998 And Prior)
Rectifier Test (1998 And Prior)
Alternator Amperes Output 1999 And Newer (Stator - 10 Pole/5 Pulse)
Tachometer Module Static Test
Tachometer Module Running or Cranking Test
Rectifier/Regulator (P/N 853358T1) Diode Test
Digital Meter (DMT 2000 or Equivalent)
Analog Meter
Starting System
Description
Troubleshooting the Starting Circuit
Starting Circuit Troubleshooting Flow Chart
Starting Circuit Troubleshooting Flow Chart
COMMANDER 2000 Key Switch Test
Emergency Stop Switch (Lanyard Type)
Push Button Stop Switch
Electrical Component Removal and Installation
Starter Motor
Disassembly
Cleaning and Inspection
Testing Motor Armature
Starter Motor Reassembly
Starter Solenoid Test
Flywheel Ring Gear
Neutral Start Switch ( Electric Start Tiller Handle Shift Models)
Tiller Handle Start Button
Choke Solenoid
Battery Cables/Engine Wiring Harness ( Remote Electric Start Models)
Battery Cables ( Tiller Handle Push Button Electric Start Models)
Plug Harness (Battery Charging Kit)
Emergency Stop Switch (Lanyard Type)
Sec 2c - Timing, Synchronizing, and Adjusting
Section 2C – Timing, Synchronizing and Adjusting
Table of Contents
Specifications
Special Tools
Adjustments
Side Shift Models
Tiller Handle Shift Models
Maximum Timing Adjustment
Idle Timing Adjustment
Fast Idle Adjustment
Sec 2d - Wiring Diagrams
Section 2D – Wiring Diagrams
Table of Contents
Manual Start Ignition Wiring Diagram (1998 And Prior)
Electric Start Models with Tiller Handle Start Button ( 1998 And Prior)
Electric Models Equipped with Remote Control ( 1998 And Prior)
Manual Start Ignition Wiring Diagram (1999 And Newer)
Manual Start Ignition Wiring Diagram (1999 And Newer) ( Marathon and Sea Pro Models)
Electric Start Models with Tiller Handle Start Button ( 1999 And Newer, Design I)
Electric Models Equipped with Remote Control (1999 And Newer, Design I)
Electric Start Models with Tiller Handle Start Button ( 1999 And Newer, Design II)
Electric Models Equipped with Remote Control (1999 And Newer, Design II)
Optional Electrical Accessories Wiring Diagrams
Commander 2000 Remote Control (Manual)
Commander 2000 Remote Control (Electric Start)
Commander 3000 Panel Mount Control
Sec 3a - Fuel Delivery System
Section 3A – Fuel Delivery System
Table of Contents
Specifications
WMC Carburetor Specifications
Special Tools
Carburetor Assembly
Carburetor Assembly (15) USA – S/N-0G112449/BEL – S/N-9831799 and Below
Carburetor Assembly USA – S/N-0G112450/BEL – S/N-9831800 and Up
Fuel System Troubleshooting
Carburetor Removal
Carburetor Installation
Carburetor Adjustments
Rejetting Carburetors for High Altitude
Fuel Pump
Removal and Disassembly
Cleaning and Inspection
Reassembly and Installation
Primer System
Servicing Sight Bowl Fuel Filter
Sec 3b - Emissions
Section 3B – Emissions
Table of Contents
Exhaust Emissions Standards
What Are Emissions?
Hydrocarbons – HC
Carbon Monoxide – CO
Oxides of Nitrogen - NOx
Controlling Emissions
Stoichiometric (14.7:1) Air/Fuel Ratio
Outboard Hydrocarbon Emissions Reductions
Stratified vs. Homogenized Charge
Homogenized Charge
Stratified Charge
Emissions Information
Manufacturer's Responsibility:
Dealer Responsibility:
Owner Responsibility:
EPA Emission Regulations:
Service Replacement Certification Label
Removal
Date Code Identification
Installation
Decal Location:
Sec 4 - Powerhead
Section 4
Table of Contents
Specifications
Special Tools
Powerhead Torque Sequence
Cylinder Block and Covers
Crankshaft, Pistons and Flywheel
Powerhead Removal
Powerhead Disassembly
Cylinder Block
Crankshaft
Powerhead Cleaning and Inspection
Cylinder Block and Crankcase Cover
Exhaust Manifold and Exhaust Cover
Cylinder Bore
Crankshaft
Seals
Bearings
Connecting Rod
Pistons
Reed Block
Bleed System
Thermostat (If Equipped)
Powerhead Reassembly
General Information
Crankshaft
Cylinder Block
Powerhead Installation
Set-Up and Test-Run Procedures
Break-In Procedure
Sec 5a - Clamp, Swivel Bracket and Driveshaft Housing
Section 5A – Clamp/Swivel Brackets and Drive Shaft Housing
Table of Contents
Clamp Bracket
Swivel Bracket
Drive Shaft Housing
Drive Shaft Housing Disassembly/Reassembly
Sec 5b - Power Trim
Section 5B – Power Trim
Table of Contents
Specifications
Special Tools
Power Trim Components
Power Trim – General Information
Troubleshooting
Hydraulic Troubleshooting
Electrical Troubleshooting
Power Trim Relay Test Procedure
Remote Control
Tiller Handle
General Checks
Troubleshooting the Down Circuit
Troubleshooting the Up Circuit
Troubleshooting the Down and Up Circuits ( All Circuits Inoperative)
Power Trim
Cylinder Removal
Cylinder Assembly/Installation
Hydraulic Pump
Removal
Installation
Filling Hydraulic Reservoir
Sec 6 - Gear Housing
Section 6 – Gear Housing
Table of Contents
Specifications
Special Tools
Gear Housing (Drive Shaft) (2.00:1 Gear Ratio)
Gear Housing (Propeller Shaft) (2.00:1 Gear Ratio)
Gearcase Removal
Gearcase Disassembly
Propeller Removal
Draining and Inspecting Gear Lubricant
Bearing Carrier
Propeller Shaft
Water Pump, Drive Shaft and Shift Shaft
Pinion Gear and Forward Gear
Drive Shaft Bushing, Bearing and Lubrication Sleeve
Aluminum Anode and Water Inlet
Reassembly
Drive Shaft Needle Bearing, Bushing and Lubrication Sleeve Installation
Forward Gear Bearing Race Installation
Forward Gear Reassembly
Bearing Carrier Reassembly
Water Pump Base and Shift Shaft Reassembly
Propeller Shaft Reassembly
Forward Gear, Pinion Gear and Drive Shaft Installation
Shift Shaft and Water Pump Base Installation
Water Pump Cover Reassembly
Impeller and Pump Cover Installation
Propeller Shaft and Bearing Carrier Installation
Installation
Propeller Installation
Filling Gear Housing with Lubricant
Sec 7a - Throttle Shift Linkage Tiller Handle Models
Section 7A – Throttle/Shift Linkage (Tiller Handle Shift Models)
Table of Contents
Throttle and Shift Linkage (Tiller Handle Shift)
Control Cables (Tiller Handle Shift)
Control Platform
Removal/Disassembly
Reassembly/Installation
Throttle Cam/Control Lever
Removal
Reassembly
Installation
Neutral Interlock Control Lever
Horizontal Shift Shaft
Sec 7b - Throttle Shift Linkage Side Shift Models
Section 7B – Throttle Shift Linkage (Side Shift Models)
Table of Contents
Throttle and Shift Linkage (Side Shift)
Throttle Cables (Side Shift Models)
Throttle Cam/Control Lever
Removal
Reassembly
Installation
Neutral Interlock Control Lever
Horizontal Shift Shaft
Sec 7c - Tiller Handle
Section 7C – Tiller Handle
Table of Contents
Swivel Head and Steering Handle
Control Cables (Tiller Handle Shift Models)
Throttle Cables (Side Shift Models)
Tiller Handle Removal/Disassembly
Removal
Installation
Control Cables (Tiller Handle Shift Models)
Throttle Cable (Side Shift Models)
Sec 8 - Manual Starter
Section 8
Table of Contents
Manual Starter
Rewind Starter Assembly
Removal
Installation
Starter Rope Replacement
Disassembly
Cleaning and Inspection
Reassembly
