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User Agreement, Privacy, Cookies, and AdChoice Norton Secured - powered by Verisign. And by having access to our ebooks online or by storing it on your computer, you have convenient answers with 1986 2003 Mercury Mariner 6 8 9 9 10 15hp 2 Stroke Outboard Repair Manual. To get started finding 1986 2003 Mercury Mariner 6 8 9 9 10 15hp 2 Stroke Outboard Repair Manual, you are right to find our website which has a comprehensive collection of manuals listed. And by having access to our ebooks online or by storing it on your computer, you have convenient answers with Mercury Outboard Repair Manual. To get started finding Mercury Outboard Repair Manual, you are right to find our website which has a comprehensive collection of manuals listed. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem. Maintenance intervals should be judged by number of hours or months, whichever comes first. Tighten engine oil drain plug to specified torque. 7. Pour recommended engine oil into oil filler opening, then install oil filler cap. A short beep will be heard if cancellation is successfully finished. (4) Turn ignition key to “OFF” position, then set emergency stop switch plate 1 in original position. Refer to the MerCruiser Repair Manual as procedures can differ depending on model and year.Turn off engine and wait for approx.Always use a new gasket. Apply Water Resistant Grease to the following points.If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool. Adjust to within specified range if gap is out of specification.If it is extremely worn or burnt, replace spark plug. Also, be sure to replace spark plug if it has a broken insulator, damaged thread, etc. Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the threaded portion of the plug hole resulting in possible engine damage. Too small a tappet clearance may reduce engine power, too large a tappet clearance increases valve noise and hastens valve and seat wear. In this engine, the tappet clearance is increased or decreased by replacing the shim disc, made of a special wear resistant material, fitted to the top of the tappet. The shim discs are easy to remove and refit. Rotate crankshaft counterclockwise to prevent water pump impeller damage. Installation is reverse order of removal. At this time, caution buzzer will sound to notify that IAC duty is in fixed mode. Turning air screw clockwise: Engine speed will decrease. If engine speed does not return to specification, IAC passage (including the IAC hose) may be clogged or IAC system may not be operating correctly. Ignition timing: Approx.Inspect case and under panel. Replace If wear, cracks, distortion or corrosion is found. Inspect water pump impeller. Replace if vanes are cut, torn or worn. If level is low, add distilled water only. To perform fuel mixture check (O2 feedback) operation, use personal computer and Diagnostic System software. For fuel mixture check (O2 feedback) operation, refer to Diagnostic System Operation Manual”. If oil pressure is lower or higher than specification, following causes may be considered. Remove oil pressure switch. 4. Install oil pressure gauge in place of pressure switch hole. 5. Attach engine tachometer to ignition coil high tension cord. 6. Start engine and allow to warm up as follows: Disconnect the safety lanyard from the emergency stop switch prior to cranking the engine. This will prevent any residual fuel discharged from the cylinders being ignited by a spark discharge from the spark plug caps. 6. Disconnect remote control throttle cable from throttle lever. 7. Move and hold throttle lever in full-open position. 8. While cranking engine with starter motor, note maximum compression pressure reading on gauge for each cylinder. 9. Reinstall parts removed earlier. (spark plugs, side covers, etc.) V6 Cylinder, Two Cycle. V-6 Cylinder, Two Cycle, Direct Injected.Covers Bigfoot (Big Foot) and Non-Bigfoot models. Starting Serial Number 0T178500. Item Model Names: E48T, C55T, E48C, E48MH, E55C, 55BM, C55ER, 55BE, 55BEM, C55TR, 55BET. Item Model Names: E60, E60H, E60HM, E60HE, E60HEM, E60MH, E60EH. Covers USA, Canada and wold wide models. Item Model Names: E75V, E-75-V, E75-V, E-75V 75AM, 75AEM, 75AE, 75AET, 85AEM, 85AE, 85AET, E75B, E60J, E75MH. Covers USA, Canada and wold wide models. This manual covers all 15HP 4-Stroke models world wide including USA CANADA.This manual covers all 4HP 4-Stroke models world wide including F4MSHX, F4MLHX, F4AMH, USA CANADA. Model Names: 25JMH, 25MH3, 30DMH, 25JMHO, 30DMHO, 30MH, 25JEHO, 25EH3, 30DWH, 25JEO, 25JETO, 25TR3, 30DEHO, 30EH, 30DMO, 30DE, 30DEO, 30ER, 30DET, 30DETO, 30TR Covers USA, Canada and wold wide models. Model Names: F100TR, F100-TR, F-100TR, F100AET, F-100AET, F100-AET Covers USA, Canada and woldwide models. Model name F40BMHD, F40BWHD, F40BED, F40BET, USA and Canada name F40MH, F40ER, F40TR. Model Name: F6AMH, F8CMH, F6MH, F8MH (F6-AMH, F6-MH, F8-AMH, F8-MH). Model name 70BETO, USA and Canada name 70TR 70C (70-C). Model name 90AETO, USA and Canada name 90TR 90C (90-C). Model Name: 115CETO (115-CETO), 130BETO (130-BETO) 115TR, 130TR. Model name F150TR, LF150TR (F-LF-150-TR) Model name F115AET LF115AET, USA and Canada name F115TR LF115TR. Model Name: 150FETO, 150GETO. Model name 60FETO USA and Canada name 60TR, 60C (60-C). Model Name F90TR. And by having access to our ebooks online or by storing it on your computer, you have convenient answers with Mercury Outboard Repair Manual 9 Hp. To get started finding Mercury Outboard Repair Manual 9 Hp, you are right to find our website which has a comprehensive collection of manuals listed. United States................. 0D281000. Belgium Produced............ 09792200. Printed in U.S.A. W1998, Mercury Marine 90-827242R1 MAY 1998 Throughout this publication, ?Dangers?, ?Warnings? and ?Cautions? (accompanied by the International. HAZARD Symbol These ?Safety Alerts? alone cannot eliminate the hazards that they signal. Strict compliance 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.It is assumed that these personnel are familiar with the servicing procedures of these products, We could not possibly know of and advise the service trade of all conceivable procedures Therefore, anyone who uses All information, illustrations and specifications contained in this manual are based on the As required, revisions to this. It should be kept in mind, while working on the product, that the electrical system and ignition Any time the intake or exhaust openings are exposed during service they should be covered Numbers on the heads of the metric American bolts use radial Mismatched Cleanliness and Care of Outboard Motor. A marine power product is a combination of many machined, honed, polished and lapped Throughout this manual, This is considered standard shop practice Whenever components are removed for service, they should be retained in order. At the Personnel should not work on or under an outboard which is suspended. Outboards should 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 Page ii 90-827242R1 MAY 1998 A - Specifications. B - Maintenance. C - General Information. D - Outboard Installation. Section 2 - Electrical and Ignition. A - Ignition System. D - Wiring Diagrams. Section 3 - Fuel System. A - Fuel Delivery System. B - Emissions. Section 4 - Powerhead. Section 5 - Mid-Section. Section 6 - Lower Unit. C - Tiller Handle. Section 8 - Manual Starter. General Information. Electrical and Ignition. Fuel System. Powerhead. Mid-Section. Lower Unit. Control Linkage. Manual Starter For in-depth information on marine propellers and boat performance.Quicksilver Propellers.How To Use This Manual. The manual is divided into SECTIONS (shown, right) which represents major components Some SECTIONS are further divided into PARTS. Each PART has a title page. A ?Table of. Contents? for the particular PART is printed on the back of the title page. SECTIONS and PARTS are listed on the ?Service Manual Outline.Page Numbering. Two number groups appear at the bottom of each page. The example, below, is self-explanatory. Revision No. 1. Month of Printing. Year of Printing. Section Number. Part of Section Letter. Page Number. Page iv 90-827242R1 MAY 1998 Table of Contents Propeller Information Chart - 8 HP......... 1A-6. General Specifications. HORSEPOWER Model 6 6 (4.5) Model 8 Sailmate 8 (5.9). Model 9.9 9.9 (7.4). Model 9.9 Sailpower 9.9 (7.4). Model 15 15 (11.2). STATIC THRUST Model 9.9 Sailpower W.O.T. in Forward ? 207 Lbs. (920.7 N). W.O.T. in Reverse ? 150 Lbs. (667.2 N). OUTBOARD Manual Start 6 73.0 lbs. (31.1kg). WEIGHT 8 73.0 lbs. (31.1kg) Electric Start 6 79.5 lbs. (36.1kg) Displacement (1994 Model) STROKE Length 1.800 in. (45.7mm) Cast Iron. CRANKSHAFT Top Main Bearing Journal 0.7517. Center Main Bearing Journal 0.8108. Bottom Ball Bearing Journal 0.7880. Connecting Rod Journal 0.8125. Runout 0.003 in. (0.076mm) Crankpin End (I.D.) Ring End Gap. Aluminum REEDS Reed Stand Open (Maximum). All Models. Reed Stop Opening (Maximum) All Models 0.296 in. (7.54mm). Page 1A-2 90-827242R1 MAY 1998 Gearcase Capacity. Lubricant Type. Forward Gear - No. of Teeth-Type. Pinion Gear - No. of Teeth-Type. Pinion Height. Forward Gear Backlash. Reverse Gear Backlash. Water Pressure. With Thermostat Quicksilver Gear Lube Premium Blend. Floating. No Adjustment. MID Transom Height - Short Shaft 15 in. (38 cm). SECTION - Long Shaft 20 in. (51 cm) Steering Pivot Range 78. Total Tilt Angle 78? Recommended Gasoline. Recommended Oil. Fuel Tank Capacity Automotive Lead-Free. Quicksilver TC-W II or TC-W3 Electric Start. Starter Draw (Under Load) Recoil CHARGING Alternator Output. SYSTEM BLACK Stator - 2 Magnet Flywheel 4 Amp. (48 Watt). RED Stator - 4 Magnet Flywheel 6 amp (72 Watt) Stator High Speed Winding. Stator Low Speed Winding. Diode Test. Ignition Coil Resistance. Primary. Secondary. Trigger. Capacitor Discharge Idle RPM (In Gear) ? Float Setting (All Models). Main Jet ? 6 TIMING Idle ? 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. Length Range Number Propeller Drive Hub: 42630--1. Diffuser Ring: 42594 (Aluminum). Propeller Information Chart - 8 HP. Wide Open Throttle RPM: 4500-5500. Page 1A-6 90-827242R1 MAY 1998 Recommended Transom Height: 15,, 20,, 25. Propeller Information Chart -15 HP. Wide Open Throttle RPM: 5000-6000. Diffuser Ring: 42594 (Aluminum) Table of Contents SpecialTools. 1B-1. Inspection and Maintenance Schedule........ 1B-2. BeforeEachUse. 1B-2. AfterEachUse. 1B-2. Every 100 Hours of Use or Once yearly. Whicheveroccursfirst. 1B-2. Every 300 Hours of Use or Three Years.... 1B-3. FlushingTheCoolingSystem. 1B-3. FuelSystem. 1B-5. FuelLineInspection. 1B-5. EngineFuelFilter. 1B-5. CorrosionControlAnode. 1B-6. SparkPlugInspection. 1B-6. BatteryInspection. 1B-7. Fuse Replacement -ControlModels. 1B-7. LubricationPoints. 1B-7. GearCaseLubrication. 1B-9. GearCaseLubricantCapacity. 1B-9. DrainingGearCase. 1B-9. Checking Lubricant Level and Refilling. Gearcase. 1B-10. StoragePreparations. 1B-10. Fuelsystem. 1B-10. Protecting External Engine Components.. 1B-11. Protecting Internal Engine Components... 1B-11. GearCase. 1B-11. Positioning Outboard for Storage........ 1B-11. BatteryStorage. 1B-11. Gear Case Lubricant Capacity. Gear Case Ratio Capacity Special Tools Before Each Use After Each Use Every 100 Hours of Use or Once Yearly, Whichever Occurs First Lubricate more frequently when used in salt water. Check more frequently when used in salt water. Page 1B-2 Flushing The Cooling System. Flush the internal water passages of the outboard with fresh water after each use in salt, This will help prevent a buildup of deposits from clogging the internal Use a Quicksilver accessory (or equivalent) flushing attachment. Refer to Propeller Replacement. Install the flushing attachment so Turn on the water and adjust the flow Reinstall the Carefully follow all Always stop the engine and DO NOT smoke or allow Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain Use an approved container to collect and store fuel. Wipe up Material used to contain spillage must be disposed of in an approved Fuel Line Inspection. Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness or other If any of these conditions is found, the fuel line or primer Engine Fuel Filter. Inspect the sight bowl for water accumulation and inspect the filter element for sediment. Clean filter as follows. Page 1B-4 The outboard has a corrosion control anode installed to the gear case. An anode helps protect Spark Plug Inspection. Inspect spark plugs at the recommended intervals. Replace spark plug if electrode is worn See Specification Chart in General Information Section. Install plugs finger The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your Positive to positive Fuse Replacement -The electric starting circuit is protected from overload by a SFE 20 AMP fuse. If the fuse is Try to locate and correct the cause of the Replace the fuse with a fuse Lubrication Points. Lubricate Points 1 thru 8 with Quicksilver 2-4-C with Teflon Marine Lubricant or Special. Lubricant 101. Pin (a) is spring loaded. Make sure this pin is free An hydraulically locked steering Lubricate through fitting (b). Lubricate points 9 With Light Weight Oil Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding Gear Case Lubricant Capacity. Gear Case Ratio Capacity Draining Gear Case. When adding or changing gear case lubricant, visually check for the presence of water in If water is noticed, have the gear case checked by your dealer. Water in the lubricant may An excessive Page 1B-8 90-827242R1 MAY 1998 Install the vent plug and sealing washer before removing the lubricant Storage Preparations. Fuel system. IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation If the gasoline being Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with treated (stabilized) Proceed with following instructions. Tip fuel tank back and forth to mix stabilizer with Stabilizer (follow instructions on container) into a separate container and mix with approximately Pour this mixture into fuel tank. Run the engine for ten minutes to allow treated fuel to fill the fuel system. Protecting Internal Engine Components. NOTE: Before performing Steps 1 and 2, make sure the fuel system has been prepared for Start the engine and let it run in neutral to warm up. When engine begins to stall, quickly spray Quicksilver Storage Seal into carburetor until Reinstall spark plugs. Gear Case. Drain and refill the gear case lubricant (refer to maintenance procedure). Positioning Outboard for Storage. Store outboard in an upright position to allow water to drain out of outboard. Battery Storage Recharge if necessary. Page 1B-10 Table of Contents SerialNumberLocation. 1C-1. Conditions Affecting Performance............ 1C-2. Weather. 1C-2. Boat. 1C-3. Engine. 1C-4. Following Complete Submersion............. 1C-5. Submerged While Running (Special. Instructions). 1C-5. Salt Water Submersion (Special. Fresh Water Submersion (Special. PropellerSelection. 1C-6. CompressionCheck. 1C-9. PaintingProcedures. 1C-9. GearHousings. 1C-9. DecalApplication. 1C-11. DecalRemoval. 1C-11. Instructions for ?Wet?Application......... 1C-11. Serial Number Location. The Outboard serial number is located on the lower starboard side of the engine block. A Weather Summer hp. Horsepower Loss. Due to Atmosphere. Conditions. Secondary Loss Due to. Propeller Becoming To Large RPM Drop. Due to Weather. Rated RPM. It is a known fact that weather conditions exert a profound effect on power output of internal Corporations internationally have settled on adoption of I.S.O. (International Standards Organization) Summer Conditions of high temperature, low barometric pressure and high humidity all This, in turn, is reflected in decreased boat speeds--as Nothing will regain this speed for the boater, but the coming of cool, dry weather. In pointing out the practical consequences of weather effects, an engine--running on a hot, The horsepower, that any internal combustion engine Accompanying this weather-inspired loss of power is a second but more subtle loss. At rigging With the coming of the summer Page 1C-2 90-827242R1 MAY 1998 This secondary loss, however, For boaters to realize optimum engine performance under changing weather conditions, it Not only does this allow the engine to develop full power, but equally important is the fact This, of course, enhances overall reliability and durability of the engine. Boat Shifting weight to the rear (stern) Shifting weight to the front (bow) Clean surfaces when necessary. These vapor bubbles flow If allowed to continue, eventual blade failure (breakage) will Engine A few of the most common causes of detonation in a marine 2-cycle application are as follows: Detonation usually can be prevented if: Page 1C-4 90-827242R1 MAY 1998 Submerged While Running (Special Instructions). When an engine is submerged while running, the possibility of internal engine damage is If this is the case, the powerhead must be disassembled. Salt Water Submersion (Special Instructions). Due to the corrosive effect of salt water on internal engine components, complete disassembly Fresh Water Submersion (Special Instructions) DO NOT attempt Disassemble powerhead if necessary to clean components. Most water Again rotate flywheel. If engine starts, it should be run for Engine should For in-depth information on marine propellers and boat performance -written by marine engineers Quicksilver Propellers.This RPM range allows for better If changing conditions cause the RPM to drop below the recommended range (such as Check full-throttle RPM using an accurate tachometer with the engine trimmed out to a balanced-Refer to ?Quicksilver Accessory Guide?for a complete list of available propellers. RPM change between propeller pitches.