MERCURY DOWNLOAD 1986 2003 6 8 9.9 10 15 HP Service Manual 2 STROKE


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Mercury/Mariner Outboard Motor Service Manual Application: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 6 HP (6HP), 8 HP (8HP), 9.9 HP (9.9HP), 10 HP (10HP), 15 HP (15HP) 2 Stroke, Two Stroke, 2Stroke 2-Cycle Outboard Engine Motor.

Starting Model Year 1986
Serial Number 0A197112 and Up (USA)
09503295 and Up (Belgium)

This expert text service repair manual gives complete step by step information on maintenance, tune-up, repair and overhaul. This manual is highly detailed with hundreds of photo illustrations to help guide you through every repair procedure. This ebook contains all you need to know to keep your 1986-2003 Mercury 2-Stroke Outboard motor running right and is the only service repair manual you will need to repair and service your 1986-2003 6 8 9.9 10 15 HP Outboard engine. It will help you understand, care for, and lower the repair and maintenance cost for your boat motor for a overall improved satisfaction with your ownership.

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BELOW ARE TYPICAL CHAPTERS AND TOPICS FOUND
IN A MERCURY OUTBOARD SERVICE MANUAL, SUBJECTS
MAY DIFFER DEPENDING ON EXACT YEAR AND MODEL.
============================================

Chapters Include:

Section 1 – Important Information

A – Specification
B – Maintenance
C – General Information
D – Outboard Motor Installation

Section 2 – Electrical

A – Ignition
B – Charging & Starting System
C – Timing, Synchronizing & Adjusting
D – Wiring Diagrams

Section 3 – Fuel System

A – Fuel Pump
B – Carburetor
C – Emissions

Section 4 – Powerhead

A – Cylinder Head
B – Cylinder Block/Crankcase
C – Oil Pump

Section 5 – Mid-Section

Section 6 – Lower Unit

A – Gear Housing
B – Gear Housing

Section 7 – Attachments/Control Linkage

A – Throttle/Shift Linkage
B – Tiller Handle
Section 8 – Manual Starter

So much more in this manual!

Below is just a SMALL sample of some of the topics tipically found in a Mercury Service Manual.

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Propeller Information Charts . . . . . . . . . . . . . . . . 1A-7
Mercury 8 (2 – Stroke)
Mercury 9.9 (2 – Stroke) . . . 1A-7
Mercury 15 (2 – Stroke)
Mercury 10 (2 – Stroke)
Mercury 6 (2-Stroke)
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Fuel Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Fuel Line Inspection . . . . . . . . . . . . . . . . . . . . 1B-7
Corrosion Control Anode . . . . . . . . . . . . . . . . . . . 1B-8
Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . 1B-8
Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Fuse Replacement Electric Start Models . . . . 1B-9
Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . . 1B-9
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . 1B-12
Oil Draining Procedure . . . . . . . . . . . . . . . . . 1B-12
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . 1B-12
Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Gear Case Lubrication . . . . . . . . . . . . . . . . . . . . 1B-13
Draining Gear Case . . . . . . . . . . . . . . . . . . . 1B-13
Gear Case Lubricant Capacity . . . . . . . . . . 1B-13
Checking Gear Case Lubricant Level and
Refilling Gear Case . . . . . . . . . . . . . . . . . . . . 1B-14
Storage Preparation . . . . . . . . . . . . . . . . . . . . . . 1B-15
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Protecting External Outboard
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Protecting Internal Engine Components . . 1B-15
Propeller Removal/Installation . . . . . . . . . . . . . . 1C-7
Standard Models . . . . . . . . . . . . . . . . . . . . . . . 1C-7
Bigfoot Models . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9
Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . 1C-12
Compression Check . . . . . . . . . . . . . . . . . . . . . . 1C-12
Cylinder Leakage Testing . . . . . . . . . . . . . . . . . . 1C-13
Ignition Diagnostic Procedures . . . . . . . . . . . . . 2A-13
Recommended Test . . . . . . . . . . . . . . . . . . . 2A-13
Testing Ignition Components . . . . . . . . . . . . . . . 2A-15
Resistance Tests . . . . . . . . . . . . . . . . . . . . . . 2A-15
Flywheel Removal and Installation . . . . . . . . . . 2A-18
Flywheel Removal . . . . . . . . . . . . . . . . . . . . . 2A-18
Flywheel Installation . . . . . . . . . . . . . . . . . . . 2A-19
Timing Belt Removal and Installation . . . . . . . . 2A-20
Ignition Charge Coil Removal and Installation 2A-21
Ignition Coil Removal and Installation . . . . . . . 2A-22
Crank Position Sensor Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-23
Rectifier/Regulator and ECM Removal
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-
Starter Motor Components . . . . . . . . . . . . . . . . 2B-13
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B
Electric Start Tiller Handle Models
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2
Electric Start Remote Control Models
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3
Manual Start Models Wiring Diagram . . . . . . . . 2D-4
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2
Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . . . 3A-4
Fuel Pump Disassembly . . . . . . . . . . . . . . . . . . . 3A-5
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-3
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-4
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-5
Carburetor Adjustments . . . . . . . . . . . . . . . . . . . . 3B-6
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6
Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6
Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . . . 4A-8
Oil Pump/Camshaft . . . . . . . . . . . . . . . . . . . . . . . 4A-10
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-12
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . 4A-12
Preparing Cylinder Head for Removal . . . . . . . 4A-14
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . 4A-15
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . 4A-16
Cylinder Head Disassembly . . . . . . . . . . . . . . . 4A-16
Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 4A-19
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 4A-19
Cylinder Head Resurfacing . . . . . . . . . . . . . 4A-20
Rocker Arm and Rocker Arm Shaft
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-21
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-22
Valve Guide inspection . . . . . . . . . . . . . . . . . 4A-23
Valve Guide Replacement . . . . . . . . . . . . . . 4A-23
Valve Seat Reconditioning . . . . . . . . . . . . . . 4A-24
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-27
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29
Cylinder Head Reassembly . . . . . . . . . . . . . . . . 4A-30
Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-21
Crankcase and Bearing . . . . . . . . . . . . . . . . 4B-22
Connecting Rod Oil Clearance . . . . . . . . . . 4B-25
Powerhead Reassembly . . . . . . . . . . . . . . . . . . 4B-27
Piston Ring Installation . . . . . . . . . . . . . . . . . 4B-27
Piston Installation . . . . . . . . . . . . . . . . . . . . . 4B-28
Crankcase and Crankshaft Installation . . . 4B-29
Anode Installation . . . . . . . . . . . . . . . . . . . . . 4B-32
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . 4C-2
Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . . . 4C-2
Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . . 4C-3
Oil Pump Reassembly . . . . . . . . . . . . . . . . . . . . . 4C-4
Gear Housing (Drive Shaft) . . . . . . . . . . . . . . . . . 6A-4
Gear Housing (Propeller Shaft) . . . . . . . . . . . . . . 6A-6
General Service Recommendations . . . . . . . . . 6A-8
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-8
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-8
Draining and Inspecting Gear Lubricant . . . . . . 6A-9
Gear Housing Removal . . . . . . . . . . . . . . . . . . . 6A-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-11
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . 6A-11
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 6A-13
Water Pump, Drive Shaft and Shift Shaft . 6A-15
Pinion Gear and Forward Gear . . . . . . . . . . 6A-20
Drive Shaft Bushing, Bearing and
Lubrication Sleeve . . . . . . . . . . . . . . . . . . . . . 6A-23
Aluminum Anode and Water Inlet . . . . . . . . 6A-25
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26
Drive Shaft Needle Bearing, Bushing
and Lubrication Sleeve Installation . . . . . . . 6A-26
Forward Gear Bearing Race Installation . . 6A-28
Forward Gear Reassembly . . . . . . . . . . . . . 6A-28
Bearing Carrier Reassembly . . . . . . . . . . . . 6A-29
Water Pump Base and Shift Shaft
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31
Propeller Shaft Reassembly . . . . . . . . . . . . 6A-33
Forward Gear, Pinion Gear and Drive
Shaft Installation . . . . . . . . . . . . . . . . . . . . . . 6A-34
Shift Shaft and Water Pump Base
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35
Water Pump Cover Reassembly . . . . . . . . . 6A-37
Impeller and Pump Cover Installation . . . . 6A-38
Propeller Shaft and Bearing Carrier
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-39
Aluminum Anode and Water Inlet
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40
Filling Gear Housing with Lubricant . . . . . . . . . 6A-40

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AND SO MUCH MORE YOU WILL FIND IN A
MERCURY/MARINER SERVICE MANUAL, JUST
TO MUCH INFORMATION TO LIST!
====================================

Manual Language: ENGLISH
Pages: 300
File Format: PDF
File Delieverd In: PDF Format
Indexed for easy navigation: YES
Zoom in/out: YES
Work Search: YES

1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 6 HP (6HP), 8 HP (8HP), 9.9 HP (9.9HP), 10 HP (10HP), 15 HP (15HP) 2 Stroke 2-Cycle Outboard Engine Motor, Service Manual, Sailmate, XR/MAG/Viking, Sea Pro/MarathoN, Repair Manual, Owner’s Repair Guide, Shop Manual, Workshop Manual, Specifications, Specs, Spark Plug, Spark Plug Gap, Spark Plug Heat Range 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 00, 01, 02, 03,

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