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1 Version 90-827242R02 February 2003, Mercury Marine. All rights reserved. Printed in Version 90-891600R026/8 Model Year 1986 Serial Number 0A197112 and Up (USA)09503295 and Up (Belgium)Starting Model Year 1986 90-827242R02 February 20036/8 Box 80 Dandenong, Victoria 3175 Box 1939 Fond du Lac, WI 54936-1939 (Parc Industriel de Petit-Rechain)B-4822 Verviers/Belgium6/8 2/20/03 7:58 AM Page 190-827242R02 FEBRUARY 2003 Page iNoticeThroughout this publication, Dangers, Warnings and Cautions (accompanied by theInternational HAZARD Symbol ) are used to alert the mechanic to special instructionsconcerning a particular service or operation that may be hazardous if performed incorrectlyor carelessly.

2 OBSERVE THEM CAREFULLY!These Safety Alerts alone cannot eliminate the hazards that they signal. Strict complianceto these special instructions when performing the service, plus Common Sense operation,are major accident prevention - Immediate hazards which WILL result in severe personal injury or - Hazards or unsafe practices which COULD result in severe personalinjury or or unsafe practices which could result in minor personal injury or productor property to Users of This ManualThis service manual has been written and published by the Service Department of MercuryMarine to aid our dealers mechanics and company service personnel when servicing theproducts described is assumed that these personnel are familiar with the servicing procedures of theseproducts, or like or similar products manufactured and marketed by Mercury Marine.

3 Thatthey have been trained in the recommended servicing procedures of these products whichincludes the use of mechanics common hand tools and the special Mercury Marine orrecommended tools from other could not possibly know of and advise the service trade of all conceivable proceduresby which a service might be performed and of the possible hazards and/or results of eachmethod. We have not undertaken any such wide evaluation. Therefore, anyone who usesa service procedure and/or tool, which is not recommended by the manufacturer, first mustcompletely satisfy himself that neither his nor the products safety will be endangered by theservice procedure information, illustrations and specifications contained in this manual are based on thelatest product information available at the time of publication.

4 As required, revisions to thismanual will be sent to all dealers contracted by us to sell and/or service these should be kept in mind, while working on the product, that the electrical system and ignitionsystem are capable of violent and damaging short circuits or severe electrical shocks. Whenperforming any work where electrical terminals could possibly be grounded or touched bythe mechanic, the battery cables should be disconnected at the time the intake or exhaust openings are exposed during service they should be coveredto protect against accidental entrance of foreign material which could enter the cylinders andcause extensive internal damage when the engine is ii90-827242R02 FEBRUARY 2003It is important to note, during any maintenance procedure replacement fasteners must havethe same measurements and strength as those removed.

5 Numbers on the heads of themetric bolts and on the surfaces of metric nuts indicate their strength. American bolts useradial lines for this purpose, while most American nuts do not have strength or incorrect fasteners can result in damage or malfunction, or possibly personalinjury. Therefore, fasteners removed should be saved for reuse in the same locationswhenever possible. Where the fasteners are not satisfactory for re-use, care should betaken to select a replacement that matches the and Care of Outboard MotorA marine power product is a combination of many machined, honed, polished and lappedsurfaces with tolerances that are measured in the ten thousands of an inch/mm.

6 When anyproduct component is serviced, care and cleanliness are important. Throughout thismanual, it should be understood that proper cleaning, and protection of machined surfacesand friction areas is a part of the repair procedure. This is considered standard shop practiceeven if not specifically components are removed for service, they should be retained in order. At thetime of installation, they should be installed in the same locations and with the same matingsurfaces as when should not work on or under an outboard which is suspended. Outboards shouldbe attached to work stands, or lowered to ground as soon as reserve the right to make changes to this manual without prior to dealer service bulletins for other pertinent information concerning the productsdescribed in this Information& SpecificationsElectrical and IgnitionFuel SystemPowerheadMid-SectionLower UnitAttachments/Control LinkageManual Starter90-827242R02 FEBRUARY 2003 Page iiiService Manual OutlineSection 1 - General Information & SpecificationsA - SpecificationsB - MaintenanceC - General InformationD - Outboard InstallationSection 2 - Electrical and IgnitionA - Ignition SystemB - Charging & Starting SystemC - Timing/Synchronizing & AdjustingD - Wiring

7 DiagramsSection 3 - Fuel SystemA - Fuel Delivery SystemB - EmissionsSection 4 - PowerheadSection 5 - Mid-SectionA - Clamp/Swivel Brackets and Driveshaft HousingB - Power TrimSection 6 - Lower UnitSection 7 - Attachments/Control LinkageA - Throttle/Shift Linkage (Tiller Handle Shift Models)B - Throttle/Shift Linkage (Side Shift Models)C - Tiller HandleSection 8 - Manual StarterPage iv90-827242R02 FEBRUARY 2003 Propeller InformationFor in-depth information on marine propellers and boat performance written by marineengineers see your Authorized Dealer for the illustrated What You Should Know AboutQuicksilver and Boat Performance Information (Part No. 90-86144 92).

8 How To Use This ManualThe manual is divided into SECTIONS which represents major components and SECTIONS are further divided into PARTS. Each PART has a title page. A Table ofContents for the particular PART is printed on the back of the title and PARTS are listed on the Service Manual Outline sheet which immediatelyfollows the cover of this NumberingTwo number groups appear at the bottom of each page. The example, below, :90-827242R1 MAY 1998 Page 2B-7 Revision No. 1 Month of PrintingYear of PrintingSection NumberPart of Section LetterPage Number1 ASPECIFICATIONS90-827242R02 FEBRUARY 2003 Page 1A-1 GENERAL INFORMATION & SPECIFICATIONSS ection 1A SpecificationsTable of ContentsGeneral Specifications1A-1.

9 Propeller Information Chart - 6 HP1A-6.. Propeller Information Chart - 8 HP1A-6.. Propeller Information Chart HP1A-7.. Propeller Information Chart -15 HP1A-7.. Mercury/Quicksilver Lubricants and Sealants1A-8 General SpecificationsModels 6/8 KW(HP)Model 6 Model 8 Model 8 SailmateModel SailpowerXR/MAG/Viking10 Model Sea Pro/Marathon 10 Model 15 Model Sea Pro/Marathon (6) (8) (8) ( ) ( ) (10) (10) (15) (15)OUTBOARDWEIGHTM anual Start688 SailpowerXR/MAG/Viking10 Sea Pro/Marathon 1015 Sea Pro/Marathon 15 Electric kg ( lb) kg ( lb) kg ( lb) kg ( lb) kg ( lb) kg ( lb) kg ( lb) kg ( lb) kg ( lb) kg ( lb) kg ( lb) kg ( lb) kg ( lb) kg ( lb)

10 FUEL SYSTEMR ecommended GasolineRecommended OilRatioFuel Tank Capacity6/8 , XR/MAG1010 Sea ProMarathon/15 Automotive Unleadedwith a Minimum Pump PostedOctane Rating of 862 Cycle Outboard Oil25:1 (During break-in)50:1 (After break-in) L, Imp Gal., L, Imp Gal., 1A-290-827242R02 FEBRUARY 2003 CYLINDERBLOCKTypeDisplacement (1994 Model) 6 8 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 Displacement (1995 and Newer) Sailpower 10 Sea Pro/Marathon XR/MAG/Viking 10 1515 Sea Pro/MarathonTwo-Stoke Cycle Cross Flow209 cc ( cu. in.)209 cc ( cu. in.)209 cc ( cu. in.)209 cc ( cu. in.)262 cc ( cu. in.)262 cc ( cu. in.)262 cc ( cu. in.)262 cc ( cu.)