Mercury 6, 8, 15, 9.9, 10 Service Manual

6/8/9.9/10/15

90-827242R02 February 2003

Starting Model Year 1986

6/8/9.9/10/15

Starting Model Year 1986

Serial Number 0A197112 and Up (USA)

09503295 and Up (Belgium)

Notice

Throughout this publication, Dangers, Warnings and Cautions (accompanied by the
International HAZARD Symbol

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.

) are used to alert the mechanic to special instructions

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.

90-827242R02 FEBRUARY 2003 Page i

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.

Page ii 90-827242R02 FEBRUARY 2003

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

General Information
& Specifications

Electrical and Ignition

Fuel System

Powerhead

Mid-Section

Lower Unit

Attachments/
Control Linkage

1
2
3
4
5
6
7

Manual Starter

8

90-827242R02 FEBRUARY 2003 Page iii

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 P ARTS 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

Revision No. 1

Month of Printing

Year of Printing

Page 2B-7

Section Number

Part of Section Letter

Page Number

Page iv 90-827242R02 FEBRUARY 2003

SPECIFICATIONS

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. . . . . . . . .

General Specifications

Model 6
Model 8
Model 8 Sailmate

PERFORMANCE

KW

(HP)

Model 9.9
Model 9.9 Sailpower
XR/MAG/Viking10
Model Sea Pro/Marathon 10
Model 15
Model Sea Pro/Marathon 15

1

A

Propeller Information Chart -9.9/10 HP 1A-7. . . . .

Propeller Information Chart -15 HP 1A-7. . . . . . . .

Mercury/Quicksilver Lubricants and Sealants 1A-8

Models 6/8/9.9/10/15

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

FUEL SYSTEM

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

Recommended Gasoline

Recommended Oil
Ratio

Fuel Tank Capacity
6/8/9.9/Sailpower, XR/MAG10
10 Sea Pro
Marathon/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)

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.

90-827242R02 FEBRUARY 2003 Page 1A-1

SPECIFICATIONS

CYLINDER

BLOCK

CYLINDER

BORE

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

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

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.)

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

CONNECTING

ROD

PISTON

Top Main Bearing Journal
Center Main Bearing Journal
Bottom Ball Bearing Journal
Connecting Rod Journal
Runout

Piston Pin End (I.D.)
Crankpin End (I.D.)

Piston Type
Ring End Gap

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.)

20.8 mm (0.8195 in.)

27.0 mm (1.0635 in.)
Aluminum

0.25 mm - 0.46 mm

(0.010 in. - 0.018 in.)

Reed Stand Open (Maximum)

REEDS

All Models

Reed Stop Opening (Maximum)

All Models

Page 1A-2 90-827242R02 FEBRUARY 2003

0.178 mm (0.007 in.)

7.54 mm (0.296 in.)

SPECIFICATIONS

GEAR

HOUSING

MID

SECTION

FUEL

SYSTEM

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)

Transom Height Short Shaft

Long Shaft

Extra Long Shaft
Steering Pivot Range
Tilt Pin Positions
Total Tilt Angle
Allowable Transom Thickness

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

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)

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.)

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

CHARGING

SYSTEM

Manual Start
Electric Start

Starter Draw (Under Load)
(No Load)

Alternator Output

BLACK Stator - 2 Magnet Flywheel

(8 Pole)(4 Pulses)

RED Stator - 4 Magnet Flywheel

(10 Pole)(5 Pulses)

Recoil

12 Volt
55 Amperes
15 Amperes

4 Amp. (48 Watt)

@ 6000 RPM

6 amp (72 Watt)

@ 6000 RPM

90-827242R02 FEBRUARY 2003 Page 1A-3

SPECIFICATIONS

BATTERY

IGNITION

SYSTEM

Battery Rating 465 Marine Cranking Amps (MCA)

or 350 Cold Cranking Amps (CCA)

Type

Capacitor Discharge

SPARK PLUG (1994)

6/8/9.9
10/15

NGK BP8H-N-10

NGK BP8HS-15

NGK BPZ8H-N-10*

SPARK PLUG GAP (1994)

6/8/9.9
10/15

1.0 mm (0.040 in.)

1.5 mm (0.060 in.)

SPARK PLUG (1995 AND NEWER)

6/8

9.9/10/15

NGK BP8H-N-10

NGK BP8HS-15

NGK BPZ8H-N-10*

SPARK PLUG GAP (1995 AND
NEWER)

6/8

9.9/10/15
Firing Order
Stator High Speed Winding

1.0 mm (0.040 in.)

1.5 mm (0.060 in.)
1-2

120 - 180 Ω (BLACK/WHITE -

GROUND)

Stator Low Speed Winding
Diode Test

3200 - 3800 Ω (BLACK/YELLOW -

GROUND)

3100 – 3700 Ω (BLACK/YELLOW -

BLACK/WHITE)

Ignition Coil Resistance:

Primary
Secondary

Trigger

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.

Page 1A-4 90-827242R02 FEBRUARY 2003

SPECIFICATIONS

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

Idle

TIMING

SPECIFICATIONS

6
8/8 Sailmate

9.9/9.9 Sailpower
10 Sea Pro/Marathon
XR/MAG/Viking 10
15
15 Sea Pro/Marathon

8° BTDC ± 1°
8° BTDC ± 1°
8° BTDC ± 1°
8° BTDC ± 1°
8° BTDC ± 1°
8° BTDC ± 1°
8° BTDC ± 1°

Maximum BTDC @ 4500 RPM – All
Models

90-827242R02 FEBRUARY 2003 Page 1A-5

36° BTDC

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

9″ 9″ 3 Alum. Up To 1400 Up To 15′ 10-19 48-828156A12

9″ 8″ 3 Alum. 1000 – 2200 12′ - 16′ 8-15 48-828154A12
9-1/4″ 7″ 3 Alum. 1200 – 2600 13′ - 17′ 5-12 48-828152A12
9-3/4″ 6-1/2″ 3 Alum. 1500+ High Reverse

9-3/4″ 5-1/2″ 3 Alum. 1900+ Workboat 1-8 48-828148A12

Thrust Hub: 42630 1 (Forward)
Propeller Drive Hub: 827598T
Diffuser Ring: 42594 (Aluminum)

Pitch No. Of

Blades

Material Typical Gross

Boat WGT.

(LBS)

Typical Boat

Length

Thrust

Speed

Range

(MPH)

3-10 48-828150A12

Propeller Part

Number

Propeller Information Chart - 8 HP

Wide Open Throttle RPM: 4500-5500
Recommended Transom Height: 15″, 20″, 25″
Right Hand Rotation Standard
Gear Reduction: 2:1

Diameter

9″ 9″ 3 Alum. Up To 1200 Up To 16′ 12-22 48-82815612

9″ 8″ 3 Alum. 1100 – 2000 14′ - 17′ 10-20 48-828154A12
9-1/4″ 7″ 3 Alum. 900 – 2400 14′ - 18′ 7-15 48-828152A12
9-3/4″ 6-1/2″ 3 Alum. 1400+ High Reverse

9-3/4″ 5-1/2″ 3 Alum. 1700+ Workboat 1-10 48-828148A12

Thrust Hub: 42630 1 (Forward)
Propeller Drive Hub: 827598T
Diffuser Ring: 42594 (Aluminum)

Pitch No. Of

Blades

Material Typical Gross

Boat WGT.

(LBS)

Typical Boat

Length

Thrust

Speed

Range

(MPH)

4-12 48-828150A12

Propeller Part

Number

Page 1A-6 90-827242R02 FEBRUARY 2003

Propeller Information Chart -9.9/10 HP

Wide Open Throttle RPM: 5000-6000
Recommended Transom Height: 15″, 20″, 25″
Right Hand Rotation Standard
Gear Reduction: 2:1

SPECIFICATIONS

Diameter

9″ 9″ 3 Alum. Up To 1200 Up To 16′ 12-24 48-828156A12

9″ 8″ 3 Alum. 1100 – 2000 14′ - 17′ 12-22 48-828154A12
9-1/4″ 7″ 3 Alum. 900 – 2400 14′ - 18′ 8-18 48-828152A12
9-3/4″ 6-1/2″ 3 Alum. 1400+ High Reverse

9-3/4″ 5-1/2″ 3 Alum. 1700+ Workboat 1-13 48-828148A12

Thrust Hub: 42630 1 (Forward)
Propeller Drive Hub: 827598T
Diffuser Ring: 42594 (Aluminum)

Pitch No. Of

Blades

Material Typical Gross

Boat WGT.

(LBS)

Typical Boat

Length

Thrust

Speed
Range

(MPH)

5-15 48-828150A12

Propeller Part

Number

Propeller Information Chart -15 HP

Wide Open Throttle RPM: 5000-6000
Recommended Transom Height: 15″, 20″, 25″
Right Hand Rotation Standard
Gear Reduction: 2:1

Diameter

9″ 10-1/2″ 3 Alum. Up To 1000 Up To 16′ 18-28 48-828158A12

9″ 9″ 3 Alum. 600 – 1500 14′ - 18′ 14-24 48-828156A12

9″ 8″ 3 Alum. 800 – 2400 15′ - 20′ 15-25 48-828154A12
9-1/4″ 7″ 3 Alum. 1000 – 3400 16′ - 22′ 8-18 48-828152A12
9-3/4″ 6-1/2″ 3 Alum. 1800+ High Reverse

Thrust Hub: 42630 1 (Forward)
Propeller Drive Hub: 827598T
Diffuser Ring: 42594 (Aluminum)

Pitch No. Of

Blades

Material Typical Gross

Boat WGT.

(LBS)

Typical Boat

Length

Thrust

Speed
Range

(MPH)

1-15 48-828150A12

Propeller Part

Number

90-827242R02 FEBRUARY 2003 Page 1A-7

SPECIFICATIONS

Mercury/Quicksilver Lubricants and Sealants

Tube

Ref. No.

4

6

7

9

12

14

19

25

27

33

Description

Needle Bearing As-

sembly Lubricant

Dielectric Grease

Loctite 271 – Thread

Locker

Loctite 567 PST Pipe

Sealant

Loctite Master Gasket

Kit

2 Cycle Premium Out-

board Oil

Mercury Part Num-

ber

92-802868A1 N/A

92-823506-1 92-823506-1

92-809819 92-809819

92-809822 92-809822

92-12564-2 92-12564-2

92-802813A1 92-802813Q1

Quicksilver Part

Number

Perfect Seal 92-34227-1 92-34227-1

Liquid Neoprene 92-25711-3 92-25711-3

Bellows Adhesive N/A 92-86166Q1

Loctite 680 Retaining

Compound

92-809833 92-809833

94

51

66

95

110

34

79

82

91

42

87

Special Lubricant 101 92-802865A1 92-802865Q1

U-Joint and Gimbal

92-802870A1 92-802870Q1

Bearing Grease

Loctite 222 Thread

Locker

Loctite 242 Thread

Locker

4 Cycle 25W40 Engine

Oil

Premium Gear Lubri-

cant

High Performance

92-809818 92-809818

92-809821 92-809821

92-802837A1 92-802837Q1

92-802846A1 92-802846Q1
92-802854A1 92-802854Q1

Gear Lube

Engine Coupler Spline

Grease

92-802869A1 92-802869Q1

Anti-Corrosion Grease 92-802867A1 92-802867Q1

2-4-C with Teflon 92-802859A1 92-802859Q1

4 Stroke 10W30 Out-

board Oil

92-802833A1 92-802833Q1

114

Page 1A-8 90-827242R02 FEBRUARY 2003

Power Trim & Steering

Fluid

92-802880A1 92-802880Q1

SPECIFICATIONS

Tube

Ref. #

115

116

117

119

120

121

122

123

124

125

Description

Mercury Part Num-

ber

Quicksilver Part

Number

Premium Plus 2 Cycle

TC-W3 Outboard Oil

RTV 587 Silicone

Sealer

92-802824A1 92-802824Q1

92-809825 92-809825

Loctite 7649 Primer N 92-809824 92-809824
Storage Seal Rust In-

92-802878-56 92-802878Q56

hibitor

Corrosion Guard 92-802878 55 92-802878Q55

15W40 4-cycle Diesel

92-877695K1 92-877695Q1

Engine Oil

Extended Life Anti-

92-877770K1 92-877770K1

freeze/Coolant

Marine Engine Coolant NA 92-813054A2

Fuel System Treat­ment and Stabilizer

92-802876A1 92-802876Q1

Concentrate

Heat Transfer Com-

92-805701 1

pound

126

127

128

129

130

131

132

133

134

135

136

137

Liquid Gasket 92-808137 NA
T442 Sealant 92-862258 NA

Loctite 5900 Ultra

92-809826 NA

Black RTV Silicone

Sealant

Loctite Gasket Remov-

92-809828 1 NA

er

Sealer Kit, Two Part

NA 92-65150 1

Epoxy

Anti-seize Compound 92-881091K1

Torco MTF Gear Oil 92–849864–1

Optimol Longtime PD

92–848767

2

Dexron III Automatic

Obtain Locally Obtain Locally

Transmission Fluid

Loctite 592 Obtain Locally Obtain Locally

Loctite Quick Tite Obtain Locally Obtain Locally
Isopropyl Alcohol Obtain Locally Obtain Locally

138

139

1401

90-827242R02 FEBRUARY 2003 Page 1A-9

Hot Glue Obtain Locally Obtain Locally
Loctite 609 Obtain Locally Obtain Locally
Loctite 405 Obtain Locally Obtain Locally

SPECIFICATIONS

Tube

Ref. #

1411

1142

143

144

145

146

Description

Cyanacrylate Adhe-

sive

3M Permabond

#3M08155

Mercury Part Num-

ber

Obtain Locally Obtain Locally

Obtain Locally Obtain Locally

Quicksilver Part

Loctite 262 Obtain Locally Obtain Locally
Loctite 290 Obtain Locally Obtain Locally

Loctite 598 RTV Seal-

Obtain Locally Obtain Locally

ant

Insulating Compound 92–41669–1

Number

Page 1A-10 90-827242R02 FEBRUARY 2003

MAINTENANCE

GENERAL INFORMATION & SPECIFICATIONS

Section 1B – Maintenance

Table of Contents

Table of Contents 1B-1. . . . . . . . . . . . . . . . . . . . . . .

Gearcase Lubricant Capacity 1B-2. . . . . . . . . . . . .

Special Tools 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and Maintenance Schedule 1B-3. . . . .

Before Each Use 1B-3. . . . . . . . . . . . . . . . . . . . .

After Each Use 1B-3. . . . . . . . . . . . . . . . . . . . . . .

Every 100 Hours of Use or Once Yearly,

Whichever Occurs First 1B-3. . . . . . . . . . . . . . .

Every 300 Hours of Use or Three Years 1B-3.

Flushing The Cooling System 1B-4. . . . . . . . . . . . .

Fuel System 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Line Inspection 1B-5. . . . . . . . . . . . . . . . . .

Engine Fuel Filter 1B-5. . . . . . . . . . . . . . . . . . . .

Corrosion Control Anode 1B-6. . . . . . . . . . . . . . . . .

Spark Plug Inspection 1B-6. . . . . . . . . . . . . . . . . . . .

Battery Inspection 1B-7. . . . . . . . . . . . . . . . . . . . . . .

1

B

Fuse Replacement – Electric Start Remote

Control Models 1B-7. . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Points 1B-8. . . . . . . . . . . . . . . . . . . . . . .

Gearcase Lubrication 1B-10. . . . . . . . . . . . . . . . . . . .

Gearcase Lubricant Capacity 1B-10. . . . . . . . . .

Draining Gearcase 1B-10. . . . . . . . . . . . . . . . . . .

Checking Lubricant Level and Refilling

Gearcase 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage Preparations 1B-12. . . . . . . . . . . . . . . . . . . .

Fuel System 1B-12. . . . . . . . . . . . . . . . . . . . . . . . .

Protecting External Engine Components 1B-12
Protecting Internal Engine Components 1B-12.

Gearcase 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning Outboard for Storage 1B-13. . . . . . .

Battery Storage 1B-13. . . . . . . . . . . . . . . . . . . . . .

90-827242R02 FEBRUARY 2003 Page 1B-1

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

Inspection and Maintenance Schedule

Before Each Use

1. Check that lanyard stop switch stops the engine.

2. Visually inspect the fuel system for deterioration or leaks.

3. Check outboard for tightness on transom.

4. Check steering system for binding or loose components.

5. Visually check steering link rod fasteners for proper tightness.

6. Check propeller blades for damage.

After Each Use

1. Flush out the outboard cooling system if operating in salt or polluted water.

2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase
with fresh water if operating in salt water.

Every 100 Hours of Use or Once Yearly, Whichever Occurs First

1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.

MAINTENANCE

2. Inspect and clean spark plugs.

3. Check fuel line filter for contaminants.

4. Check carburetor adjustments, if required.

5. Check corrosion control anodes. Check more frequently when used in salt water.

6. Drain and replace gearcase lubricant.

7. Lubricate splines on the drive shaft.

8. Electric start models – Inspect battery.

9. Remote control models – Check control cable adjustments.

10. Remove engine deposits with Power Tune Engine Cleaner.

11. Check tightness of bolts, nuts, and other fasteners.

12. Clean fuel tank pick up filter.

Every 300 Hours of Use or Three Years

1. Replace water pump impeller (more often if overheating occurs or reduced water
pressure is noted).*

∗

These items should be serviced by an authorized dealer.

∗

∗

90-827242R02 FEBRUARY 2003 Page 1B-3

MAINTENANCE

Flushing The Cooling System

Flush the internal water passages of the outboard with fresh water after each use in salt,
polluted, or muddy water. This will help prevent a buildup of deposits from clogging the
internal water passages.

Use a Quicksilver accessory or equivalent flushing attachment.

To avoid possible injury when flushing, remove the propeller. Refer to Propeller
Replacement.

1. Remove propeller (refer to Propeller Replacement). Install the flushing attachment so
the rubber cups fit tightly over the cooling water intake holes.

WARNING

CAUTION

Never start or run your outboard (even momentarily) without water circulating
through the cooling water intake in the gearcase to prevent damage to the water
pump (running dry) or overheating of the engine.

2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow
so water is leaking around the rubber cups to ensure the engine receives an adequate
supply of cooling water.

3. Start the engine and run it at idle speed in neutral shift position.

4. Adjust water flow if necessary so excess water continues leaking out from around the
rubber cups to ensure the engine is receiving an adequate supply of cooling water.

5. 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.

6. Stop the engine, turn off the water, and remove the flushing attachment. Reinstall the
propeller.

Page 1B-4 90-827242R20 FEBRUARY 2003

Fuel System

Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or
allow open flames or sparks in the area while servicing any part of the fuel system.

Before servicing any part of the fuel system, stop engine and disconnect the battery . Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an
approved receptacle. Any fuel system service must be performed in a well ventilated area.
Inspect any completed service work for sign of fuel leakage.

Fuel Line Inspection

Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness or other
signs of det e r i o r a t i o n o r damage. If any of these conditions are found, the fuel line or primer
bulb must be replaced.

Engine Fuel Filter

Inspect the sight bowl for water accumulation and inspect the filter element for sediment.
Clean filter as follows.

MAINTENANCE

WARNING

REMOVAL

INSTALLATION

1. Hold onto the filter cover cover to prevent it from turning.

2. Turn off the sight bowl.

3. Pull out the filter element and wash it with cleaning solvent.

4. Push the open end of the filter element, into cover.

5. Place the O-ring seal into the sight bowl and screw the sight bowl hand tight into the

cover.

a

b

c

d

a-Filter cover
b-Filter
c-O-ring
d-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

MAINTENANCE

Corrosion Control Anode

The outboard has a corrosion control anode installed to the gear case. An anode helps
protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded
instead of the outboard metals.

1. The anode requires periodic inspection especially in salt water which will accelerate the
erosion. To maintain this corrosion protection, always replace the anode before it is
completely eroded. Never paint or apply a protective coating on the anode as this will
reduce effectiveness of the anode.

a

a-Anode

Spark Plug Inspection

Inspect spark plugs at the recommended intervals.

1. Remove the spark plug leads by twisting the rubber boots slightly and pull off.

2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.

3. Set the spark plug gap. See Specification Chart in General Information Section.

4. 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 N·m (20 lb. ft.).

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.

1. Turn off the engine before servicing the battery.

2. Add water as necessary to keep the battery full.

3. Make sure the battery is secure against movement.

4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive

and negative to negative.

5. Make sure the battery is equipped with a nonconductive shield to prevent accidental

shorting of battery terminals.

Fuse Replacement – Electric Start Remote Control Models

The electric starting circuit is protected from overload by a SFE 20 AMP fuse. If the fuse is
blown, the electric starter motor will not operate. Locate and correct the cause of the
overload. If the cause is not found, the fuse may blow again. Replace the fuse with a fuse
of the same rating.

1. Replace with a new SFE 20 AMP fuse.

a

a-SFE 20 amp fuse

90-827242R02 FEBRUARY 2003 Page 1B-7

MAINTENANCE

Lubrication Points

1. Lubricate the following with 2-4-C with Teflon or Special Lubricant 101.

• Tilt tube.

• Transom clamp screws.

• Swivel bracket.

• Steering friction adjustment shaft (tiller handle models).

b

a

a-Swivel bracket

b-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.

a

a

b

a-Tilt lock pins
b-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. Adding lubricant to steering cable when fully extended
could cause steering cable to become hydraulically locked. An hydraulically locked
steering cable will cause loss of steering control, possibly resulting in serious
injury or death.

• Rotate steering wheel (if so equipped) to fully retract the steering cable end into
the outboard tilt tube. Lubricate steering cable through grease fitting and cable
end.

a

a-Grease fitting
b-Steering cable end

b

90-827242R02 FEBRUARY 2003 Page 1B-9

MAINTENANCE

2. Lubricate the following with light weight oil.

• Steering Link Rod Pivot Points.

3. Lubricate the following with anti-corrosion grease or 2-4-C with Teflon.

• Coat the entire propeller shaft with lubricant to prevent the propeller hub from
corroding to the shaft.

Gearcase Lubrication

Gearcase Lubricant Capacity

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.
If water is noticed, have the gearcase checked by your dealer. Water in the lubricant may
result in premature bearing failure or, in freezing temperatures, will turn to ice and damage
the gearcase.

Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A
small amount of metal filings or fine metal particles indicates normal gear wear. An
excessive amount of metal filings or larger particles (chips) may indicate abnormal gear
wear and should be checked by an authorized dealer.

Page 1B-10 90-827242R20 FEBRUARY 2003

1. Place outboard in a vertical operating position.

2. Place drain pan below outboard.

3. Remove fill/drain plug and vent plug and drain lubricant.

a-Fill/Drain Plug
b-Vent plug

Checking Lubricant Level and Refilling Gearcase

1. Place outboard in a vertical operating position.

MAINTENANCE

bab

2. Remove vent plug from vent hole.

3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.

4. Stop adding lubricant. Install the vent plug and sealing washer before removing the
lubricant tube.

b

a

a-Fill/Drain plug
b-Vent plug

5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.

90-827242R02 FEBRUARY 2003 Page 1B-11

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.

Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with treated
(stabilized) fuel to help prevent formation of varnish and gum. Proceed with following
instructions.

1. Portable fuel tank – Pour the required amount of fuel system/stabilizer concentrate
(follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix
stabilizer with the fuel.

2. Permanently Installed Fuel Tank – Pour the required amount of fuel system/stabilizer
concentrate (follow instructions on container) into a separate container and mix with
approximately one liter (one quart) of gasoline. Pour mixture into fuel tank.

3. Place the outboard in water or connect flushing attachment. Run the engine for ten
minutes to allow treated fuel to fill the fuel system.

Protecting External Engine Components

1. Lubricate all outboard c omponents l isted i n t he Inspection a nd M aintenance Schedule.

2. Touch up any paint nicks.

3. Spray Corrosion Guard on external metal surfaces (except corrosion control anodes).

Protecting Internal Engine Components

NOTE: Before performing Steps 1 and 2, make sure the fuel system has been prepared for

storage.

1. Place the outboard in water or connect flushing attachment. Start the engine and let it
run in neutral to warm up.

2. With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel line.
When engine begins to stall, quickly spray Storage Seal Rust Inhibitor into carburetor
until engine stops from lack of fuel.

3. Remove the spark plugs and inject a five second spray of Storage Seal Rust Inhibitor
around the inside of each cylinder.

4. Rotate the flywheel manually several times to distribute the Storage Seal in the
cylinders. Reinstall spark plugs.

Gearcase

Drain and refill the gearcase lubricant. Refer to Refilling Gearcase

Page 1B-12 90-827242R20 FEBRUARY 2003

Positioning Outboard for Storage

Store outboard in an upright position to allow water to drain out of outboard.

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.

Battery Storage

1. Follow the battery manufacturers instructions for storage and recharging.

2. Remove the battery from the boat and check water level. Recharge if necessary.

3. Store the battery in a cool, dry place.

4. Periodically check the water level and recharge the battery during storage.

MAINTENANCE

CAUTION

90-827242R02 FEBRUARY 2003 Page 1B-13

GENERAL INFORMATION

GENERAL INFORMATION & SPECIFICATIONS

Section 1C – General Information

Table of Contents

Table of Contents 1C-1. . . . . . . . . . . . . . . . . . . . . . .

Serial Number Location 1C-1. . . . . . . . . . . . . . . . . .

Conditions Affecting Performance 1C-2. . . . . . . . .

Weather 1C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boat 1C-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine 1C-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Following Complete Submersion 1C-5. . . . . . . . . .

Submerged While Running 1C-5. . . . . . . . . . . .

Fresh Water Submersion 1C-5. . . . . . . . . . . . . .

Salt Water Submersion 1C-5. . . . . . . . . . . . . . . .

Serial Number Location

The Outboard serial number is located on the lower starboard side of the engine block. A
serial number is also located on the starboard side of the swivel bracket.

1

C

Propeller Selection 1C-6. . . . . . . . . . . . . . . . . . . . . .

Propeller Removal/Installation 1C-7. . . . . . . . . . . .

Compression Check 1C-9. . . . . . . . . . . . . . . . . . . . .

Painting Procedures 1C-9. . . . . . . . . . . . . . . . . . . . .

Cleaning & Painting Aluminum Propellers

& Gear Housings 1C-9. . . . . . . . . . . . . . . . . . . .

Decal Application 1C-11. . . . . . . . . . . . . . . . . . . . . . . .

Decal Removal 1C-11. . . . . . . . . . . . . . . . . . . . . . .

Instructions for Wet Application 1C-11. . . . . . . . .

a

OGXXXXXX

19XX

XXXX

b
c

e

a-Serial number
b-Model year
c-Model description
d-Year manufactured
e-Certified Europe insignia

XX

d

90-827242R02 FEBRUARY 2003 Page 1C-1