Service Manual Outline

Section 1 - Important Information

Important Information
1
A - Specification
B - Maintenance
C - General Information
D - Outboard Motor Installation
Electrical
2
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
Fuel System
3
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Carburetor
Powerhead
4
C - Emissions
Section 4 - Powerhead
A - Cylinder Head
B - Cylinder Block/Crankcase
Mid-Section
5
C - Oil Pump
Section 5 - Mid-Section
A - Clamp/Swivel Bracket & Driveshaft Housing
Lower Unit
6
B - Power Trim
Section 6 - Lower Unit
A - Gear Housing (Non-Bigfoot)
B - Gear Housing (Bigfoot)
Attachments/
Control Linkage 7
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Section 8 - Manual Starter
Manual Starter
8

90-856159R02 SEPTEMBER 2002 Page iii

Notice
Throughout this publication, Dangers, Warnings and Cautions (accompanied by the
International HAZARD Symbol ) are used to alert the mechanic to special instructions
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.

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 in-
jury 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.

90-856159R02 SEPTEMBER 2002 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 Numbering
Two number groups appear at the bottom of each page. The example below is
self-explanatory.
EXAMPLE:

90-826148 R1 JANUARY 1996 Page 6A-7

Revision No. 1 Section Number

Month of Printing Part of Section Letter

Year of Printing Page Number

Page ii 90-856159R02 SEPTEMBER 2002

 SPECIFICATIONS

IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Mariner 15 (4 - Stroke)
Propeller Information Charts . . . . . . . . . . . . . . 1A-8 Non-Bigfoot . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-9
Mercury/Mariner 9.9 (4 - Stroke) Mercury/Mariner 15 (4 - Stroke) Bigfoot . 1A-9
Non-Bigfoot . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-8 Mercury/Quicksilver Lubricants and Sealants 1A-10
Mercury/Mariner 9.9 (4 - Stroke) Bigfoot . 1A-8

Specifications

Models 9.9/15 (4-Stroke)

HORSEPOWER 9.9 7.4 kW (9.9 hp)
(kW) 15 11.2 kW (15 hp)
9.9/15 ML 50.8 kg (112 lb)
OUTBOARD
9.9/15 EL 2.6 kg (116 lb)
WEIGHT
9.9/15 EL Bigfoot 58.0 kg (128 lb)
RECOMMENDED GASOLINE Automotive Unleaded
FUEL with a Minimum Pump Posted
Octane Rating of 87
Fuel Pump Type External (Plunger/Diaphragm)
Fuel Pump:
FUEL
Pressure 21-41 kPa (3-6 psi)
SYSTEM
Plunger Stroke 3.52 - 6.58 mm (0.14 - 0.27 in.)
Fuel Tank Capacity 12 L (3.2 US Gal.)
OIL FILTER p/n 35-822626A1
OIL FILTER WRENCH p/n 91-802653
OIL PAN CAPACITY Either 1 Quart or 1 Liter
ENGINE OIL SAE 10W-30 viscosity oil is recom-
SAE SAE mended for use in all temperatures.
25W-40 10W-30 SAE 25W-40 viscosity oil may be used at
F° C°
temperatures above 4° C (40° F).
+100 +38
Use 4-Cycle Marine Oil with the proper
+80 +27 viscosity for the expected temperature in
+60 +16 your area (see range thermometer on
OIL left). If not available, use a premium
+40 +4 quality 4-cycle engine oil, certified to
+20 –7 meet or exceed anyone of the following
–18 American Petroleum Institute (API) ser-
0 vice classifications SH, SG, SF, CF-4,
CE, CD, CDll.

90-856159R02 SEPTEMBER 2002 Page 1A-1

SPECIFICATIONS

Type Capacitor Discharge Ignition

Spark Plug
Type NGK DPR6EA-9
Gap 1.0 mm (0.035 in.)
Hex 18 mm
Firing Order 1-2
Ignition Timing:
Below 800 rpm 5° B.T.D.C.
IGNITION
@ 2800-3300 rpm 30° B.T.D.C.
SYSTEM
Charge Coil Resistance 270 - 410 Ω (Bown - Blue)
Readings taken @
Crank Position Sensor Resistance 230 - 350 Ω (Green/White - Black)
20°C (68°F).
Ignition Coil Resistance:
Primary 0.16 - 0.24 Ω
Secondary (W/o Boots) 3.9 - 5.9 k Ω
ECM Engine Speed Limiter
Spark Cut-Out Reduction (Percent
ages of ignition spark are Cut-Out) 5850 rpm
ECM Low Oil Pressure Speed Control Approximately 2000 rpm
Oil Pressure Switch Below 17 kPa (2.5 psi) Continuity
Alternator Type Single Phase (6 Pole)
6 AMP Manual (Standard) Alternator:
CHARGING Output 12 Volts-6 Amps. (Rectified)
SYSTEM Battery Charging Resistance 0.48 - 0.72 Ohms (Green-Green)
Readings taken @ 10 AMP Electric (Standard) Alternator:
20°C (68°F). Output 12V-10 Amps. (Rectified/Regulated)
Battery Charging Coil Resistance 0.24 - 0.36 Ohms (Green-Green)
Quicksilver Tachometer Setting “6C” or “2”
Manual Start Recoil Starter
Electric Start:
Starter Type Bendix
STARTING
Output 0.8 kW
SYSTEM
Ampere Draw Under:
(Load) 106.0 Amps
(No Load) 21.1 Amps
Battery Rating
Minimum Requirement 465 Marine Cranking Amps (MCA)
BATTERY or 350 Cold Cranking Amps (CCA)
For operation below 0° C (32° F) 1000 Marine Cranking Amps (MCA) or
775 Cold Cranking Amps (CCA)
Idle rpm (Out Of Gear) 950 ± 50 rpm
Idle rpm (In Forward Gear) 850 ± 50 rpm
Wide Open Throttle rpm (WOT)
Standard Model Range 4500-5500
Bodensee Model Range 5200-5700
Standard Model
Main Jet Size
CARBURETOR 9.9 hp #68
15 hp #104
Pilot Jet #45
Bodensee Model
Main Jet Size
9.9 hp #68
15 hp #103
Pilot Jet #45
Float Height 15.5 ± 1.0 mm (0.61 ± 0.04 in.)

Page 1A-2 90-856159R02 SEPTEMBER 2002

 SPECIFICATIONS

Type 4 Stroke Cycle – Over Head Camshaft

CYLINDER
Displacement 323 cc (19.7 cu. in.)
BLOCK
Number of Cylinders 2
STROKE Length 59 mm (2.323 in.)
Diameter
Standard 59.00-59.02 mm (2.3228-2.3236 in.)
CYLINDER Oversize-0.25 mm (0.010 in.) 59.25-59.27 mm (2.3327-2.3335 in.)
BORE Oversize-0.50 mm (0.020 in.) 59.50-59.52 mm (2.3425-2.3433 in.)
Taper/Out of Round Maximum 0.08 mm (0.003 in.)
Bore Type Cast Iron
Piston Type Aluminum
O.D. at Skirt
PISTON Standard 58.950 - 58.965 mm (2.3209 - 2.3214 in.)
Oversize-0.25mm (0.010 in.) 59.200 - 59.215 mm (2.3307 - 2.3313 in.)
Oversize-0.50mm (0.020 in.) 59.450 - 59.465 mm (2.3406 - 2.3411 in.)
PISTON Piston to Cylinder Clearance 0.035 - 0.065 mm (0.0014 - 0.0026 in.)
CLEARANCE
Ring End Gap (Installed)
Top 0.15 - 0.30 mm (0.006 - 0.012 in.)
Middle 0.30 - 0.50 mm (0.012 - 0.020 in.)
RINGS Bottom (Oil Ring) 0.20 - 0.70 mm (0.008 - 0.028 in.)
Side Clearance:
Top 0.04 - 0.08 mm (0.0016 - 0.0032 in.)
Middle 0.03 - 0.07 mm (0.0012 - 0.0028 in.)
Compression Ratio
Cylinder Compression 9.3:1
COMPRESSION
(cold engine @ W.O.T.) 185 - 190 psi (Peak)
RATIO
Manual Models With Compression
Release, S/N OT178500 and Above 40 lbs. - 60 lbs.
PISTON PIN Piston Pin Diameter 13.996 - 14.000 mm (0.5510 - 0.5512 in.)
CONNECTING Oil Clearance (Big End) 0.021 - 0.045 mm (0.0008 - 0.0018 in.)
ROD Small End Inside Diameter 14.015 - 14.029 mm (0.5518 - 0.5523 in.)
Main Bearing Clearance 0.011 - 0.039 mm (0.0004 - 0.0015 in.)
CRANKSHAFT
Crankshaft Run-out 0.02 mm (0.0008 in.)
TIMING BELT Deflection 10 mm (0.39 in.)
Warp Limit 0.1 mm (0.004 in.)

*Line s
indicate
straight edge
measurement
CYLINDER HEAD
Camshaft Bore Diameter A = 18.000 - 18.018 mm
(0.7087 - 0.7094 in.)

90-856159R02 SEPTEMBER 2002 Page 1A-3

SPECIFICATIONS

Free Length A A = 34.4 mm (1.354 in.)

Tilt Limit B B = Less than 1.1 mm (0.043 in.)
B

A
VALVE SPRING

Compressed Pressure (Installed)

Intake 10.5 - 11.5 kg (23.1 - 25.4 lb)
Exhaust 10.5 - 11.5 kg (23.1 - 25.4 lb)
Dir. of Winding (Intake & Exhaust) Right Hand

VALVE GUIDES Valve Guide Inside Diameter 5.500 - 5.512 mm (0.2165 - 0.2170 in.)

Page 1A-4 90-856159R02 SEPTEMBER 2002

 SPECIFICATIONS

Camshaft Dimensions 1999 Model Year and Newer

(Manual/Electric)
Intake & Exhaust “a” 23.90 - 24.00 mm (0.941 - 0.945 in.)
Intake & Exhaust “b” 19.95 - 20.05 mm (0.785 - 0.789 in.)

2001 Model Year and Newer

a (Manual only)
Intake & Exhaust “a” 27.66 - 27.69 mm (1.089 - 1.090 in.)
Intake & Exhaust “b” 23.96 - 24.02 mm (0.943 - 0.946 in.)
b

Run-out Limit 0.03 mm (0.001 in.)

Camshaft Bearing Diameter
CAMSHAFT
Cylinder Head Upper “b” 15.97 -15.98 mm (0.628 - 0.629 in.)
Oil Pump Housing Lower “a” 17.97 - 17.99 mm (0.707 - 0.708 in.)

a b 1999 Model Year and Newer

(Manual/Electric)

a b 2001 Model Year and Newer

(Manual Only)
00185
B 1999 and Newer
Manual/Electric
C A = 23.8 mm (0.937 in.)
B = 32.0 mm (1.26 in)
A
C = 16.000 - 16.0188 mm
1999 and Newer (0.6299 - 0.63066 in.)

Oil Pump B 2001 and Newer

C Manual only
A = 21.39 mm (0.842 in.)
A B = 34.98 mm (1.378 in.)
C = 16.000 - 16.0188 mm
2001 and Newer (0.6299 - 0.63066 in.)

90-856159R02 SEPTEMBER 2002 Page 1A-5

SPECIFICATIONS

Valve/Valve Seat/Valve Guides:

Valve Clearance (cold)
Intake 0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust 0.20 - 0.30 mm (0.008 - 0.012 in.)
Valve Dimensions:
“A” Head Diameter
Intake 27.9 - 28.1 mm (1.098 - 1.106 in.)
Exhaust 21.9 - 22.1 mm (0.862 - 0.870 in.)
“B” Face Width
Intake 2.00 - 3.14 mm (0.079 - 0.124 in.)
Exhaust 2.00 - 3.14 mm (0.079 - 0.124 in. ()
“C” Seat Width
Intake 0.6 - 0.8 mm (0.024 - 0.031 in.)
VALVES Exhaust 0.6 - 0.8 mm (0.024 - 0.031 in.)
“D” Margin Thickness
Intake 0.5 - 0.9 mm (0.020 - 0.035 in.)
Exhaust 0.5 - 0.9 mm (0.020 - 0.035 in.)
Stem Outside Diameter
Intake 5.475 - 5.490 mm (0.2156 - 0.2161 in.)
Exhaust 5.460 - 5.475 mm (0.2150 - 0.2156 in.)
Guide Inside Diameter
Intake 5.500 - 5.512 mm (0.2165 - 0.2170 in.)
Exhaust 5.500 - 5.512 mm (0.2165 - 0.2170 in.)
Stem To Guide Clearance
Intake 0.010 - 0.037 mm (0.0004 - 0.0015 in.)
Exhaust 0.025 - 0.052 mm (0.0010 - 0.0020 in.
Stem Run-out Limit (max.) 0.016 mm (0.0006 in.)

Valve Dimensions

B C

D
A
Head Diameter Face Width Seat Width Margin Thickness

Outside Diameter 12.941 - 12.951 mm

ROCKER SHAFT
(0.5095 - 0.5099 in.)
Inside Diameter of Bore 13.000 - 13.018 mm
ROCKER ARM
(0.5118 - 0.5125)
Valve Opening Temperature 58° C - 62° C (136° F - 143° F)
THERMOSTAT Full Open Temperature 70° C (158° F)
Valve Lift (Minimum) 3 mm (0.12 in.)

Page 1A-6 90-856159R02 SEPTEMBER 2002

 SPECIFICATIONS

Pump Type Trochoid

Engine Oil Pressure 207 - 279kPa (30-40 psi) at 3000 rpm
(Warm Engine)
Oil Pressure Switch Below 17 kPa (2.5 psi) Continuity
Oil Pump:
Outer Rotor to Housing “a” 0.06 - 0.11 mm (0.0024 - 0.0043 in.)
Inner Rotor to Outer Rotor “b” 0.02 - 0.15 mm (0.0008 - 0.0059 in.)
Rotor to Housing “c” 0.02 - 0.07 mm (0.008 - 0.003 in.)
LUBRICATION Relief Valve Opening Pressure 3.88-4.50 Kg/cm2 (55-64 psi)
SYSTEM 388-450 kPa
a

b
Test Fitting
c p/n 22-883147
1/8 x 28 B/S

Transom Height:
Short Shaft 38 cm (15 in.)
Long Shaft 51 cm (20 in.)
MID-SECTION Steering Pivot Range 70°
Tilt Pin Positions 5 + Shallow Water
Full Tilt Up Angle 66°
Allowable Transom Thickness 60.3 mm (2-3/8 in.)
Gear Ratio 2.0:1
Gearcase Capacity 200 mL (6.8 fl oz)
Lubricant Type Gear Lube-Premium Blend
Forward Gear
Number of Teeth 26 Spiral/Bevel
Pinion Gear
GEAR HOUSING
Number of Teeth 13 Spiral/Bevel
NON-BIGFOOT
Pinion Height Floating
(2.0:1)
Forward Gear Backlash No Adjustment
Reverse Gear Backlash No Adjustment
Water Pressure
@ Idle 3.44 - 10.34 kPa (0.5 – 1.5 psi)
@ 950 rpm
@ WOT 34.4 - 48.2 kPa (5-7 psi) @ 5000 rpm
Gear Ratio 2.42:1
Gearcase Capacity 230 mL (7.8 fl oz)
Lubricant Type Gear Lube-Premium Blend
Forward Gear
Number of Teeth 29 Spiral/Bevel
GEAR HOUSING
Pinion Gear
BIGFOOT
Number of Teeth 12 Spiral/Bevel
(2.42:1)
Pinion Height 0.64 mm (0.025 in.)
Forward Gear Backlash No Adjustment
Water Pressure (With Thermostat)
@ Idle 6.8 - 27.5 kPa (1 - 4 psi) @ 950 rpm
@ WOT 41.3 - 62 kPa (6 - 9 psi) @ 5000 rpm

90-856159R02 SEPTEMBER 2002 Page 1A-7

SPECIFICATIONS

Propeller Information Charts

Mercury/Mariner 9.9 (4 - Stroke) Non-Bigfoot
Wide Open Throttle rpm: 4500-5500
Recommended Transom Heights : 15”, 20”
Right Hand Rotation Standard
Gear Reduction : 2:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
9” 10.5” 3 Alum Up to 800 Up to 16’ 17-24 48-828158A12
9” 9” 3 Alum 600-1000 15’-17’ 13-19 48-828156A12
*
9” 8” 3 Alum 700-1200 16’-19’ 10-16 48-828154A12
9.25” 7” 3 Alum 900-1600 16’-20’ 8-14 48-828152A12
9.75” 6.5” 3 Alum 1000-1800 sailboat/work 7-12 48-828150A12
9.75” 6” 4 Alum 1400 + pontoon/work 6-11 48-850204A12
9.75” 5.5” 3 Alum 1700 + work 1-10 48-828148A12

Mercury/Mariner 9.9 (4 - Stroke) Bigfoot

Wide Open Throttle rpm: 4500-5500
Recommended Transom Heights : 20”, 25”
Right Hand Rotation Standard
Gear Reduction : 2.42:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
10.25” 14.5” 3 Alum Up to 700 Up to 15’ 19-28 48-19642A40
10.38” 13” 3 Steel 500-900 13’-16’ 17-25 48-19644A5
10.38” 13” 3 Alum 500-900 13’-16’ 17-25 48-19640A40
10.38” 12” 3 Alum 600-1000 14’-17’ 15-23 48-19639A40
10.38” 11” 3 Alum 700-1100 15’-18’ 14-20 48-19638A40
10.38” 9.5” 3 Alum 1000 + pontoon/work 1-16 48-19636A10
*

* Indicates standard with engine

Page 1A-8 90-856159R02 SEPTEMBER 2002

 SPECIFICATIONS

Mercury/Mariner 15 (4 - Stroke) Non-Bigfoot

Wide Open Throttle rpm: 4500-5500
Recommended Transom Heights : 15”, 20”
Right Hand Rotation Standard
Gear Reduction : 2:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
9” 10.5” 3 Alum Up to 900 Up to 15’ 19-26 48-828158A12
9” 9” 3 Alum 800-1200 14’-16’ 15-22 48-828156A12
*
9” 8” 3 Alum 900-1500 15’-17’ 12-18 48-828154A12
9.25” 7” 3 Alum 1200-2000 15’-18’ 10-15 48-828152A12
9.75” 6.5” 3 Alum 1300-2300 sailboat/work 9-14 48-828150A12
9.75” 6” 4 Alum 1500 + pontoon/work 8-12 48-850204A12
9.75” 5.5” 3 Alum 1700 + work 1-11 48-828148A12

Mercury/Mariner 15 (4 - Stroke) Bigfoot

Wide Open Throttle rpm: 4500-5500
Recommended Transom Heights : 20”, 25”
Right Hand Rotation Standard
Gear Reduction : 2.42:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
10.25” 14.5” 3 Alum Up to 900 Up to 16’ 19-28 48-19642A40
10.38” 13” 3 Steel 600-1000 14’-17’ 17-25 48-19644A5
10.38” 13” 3 Alum 600-1000 14’-17’ 17-25 48-19640A40
10.38” 12” 3 Alum 700-1100 15’-18’ 15-23 48-19639A40
10.38” 11” 3 Alum 800-1300 15’-19’ 14-20 48-19638A40
10.38” 9.5” 3 Alum 1100 + pontoon/work 1-16 48-19636A10
*

* Indicates standard with engine.

90-856159R02 SEPTEMBER 2002 Page 1A-9

SPECIFICATIONS

Mercury/Quicksilver Lubricants and Sealants

Tube Mercury Part Num- Quicksilver Part
Description Container Size
Ref. # ber Number
Needle Bearing Assy.
4 8 oz (226.8 g) tube 92-802868A1 N/A
Lubricant
Dielectric Grease
6 8 oz (226.8 g) can 92-823506-1 92-823506-1

Loctite 271 – Thread

7 10 ml tube 92-809819 92-809819
Locker
Loctite 567 PST Pipe
9 50 ml tube 92-809822 92-809822
Sealant
Loctite Master Gasket
12 92-12564-2 92-12564-2
Kit
2 Cycle Premium Out-
14 1 US qt (0.94 L) 92-802813A1 92-802813Q1
board Oil
19 Perfect Seal 16 oz (0.45 kg) can 92-34227-1 92-34227-1

25 Liquid Neoprene 8 oz (226.8 g) can 92-25711-3 92-25711-3

27 Bellows Adhesive 1.5 oz (42.5 g) tube N/A 92-86166Q1

Loctite 680 Retaining
33 10 ml tube 92-809833 92-809833
Compound
34 Special Lubricant 101 8 oz (226.8 g) tube 92-802865A1 92-802865Q1
U-Joint and Gimbal 92-802870A1 92-802870Q1
42
Bearing Grease
Loctite 222 Thread
51 10 ml tube 92-809818 92-809818
Locker
Loctite 242 Thread
66 10 ml tube 92-809821 92-809821
Locker
4 Cycle 25W40 En-
79 92-802837A1 92-802837Q1
gine Oil
Premium Gear Lubri-
82 1 US qt (0.94 L) 92-802846A1 92-802846Q1
cant
High Performance 1 US qt (0.94 L) 92-802854A1 92-802854Q1
87
Gear Lube
Engine Coupler 14 oz (0.39 kg) car-
91 92-802869A1 92-802869Q1
Spline Grease tridge
Anti-Corrosion
94 8 oz (226.8 g) tube 92-802867A1 92-802867Q1
Grease
95 2-4-C with Teflon 8 oz (226.8 g) tube 92-802859A1 92-802859Q1
4 Stroke 10W30 Out-
110 1 US qt (0.94 L) 92-802833A1 92-802833Q1
board Oil
Power Trim & Steer-
114 8 oz (226.8 g) 92-802880A1 92-802880Q1
ing Fluid

Page 1A-10 90-856159R02 SEPTEMBER 2002

 SPECIFICATIONS

Tube Mercury Part Num- Quicksilver Part

Description Container Size
Ref. # ber Number
Premium Plus 2
115 Cycle TC-W3 Out- 1 US qt (0.94 L) 92-802824A1 92-802824Q1
board Oil
RTV 587 Silicone
116 3 oz (85.05 g) 92-809825 92-809825
Sealer
117 Loctite 7649 Primer N 4.5 oz (127.57 g) 92-809824 92-809824
Storage Seal Rust In- 12 oz (325 ml) spray 92-802878-56 92-802878Q56
119
hibitor can
Corrosion Guard 12 oz (325 ml) spray 92-802878 55 92-802878Q55
120
can
121
15W40 4-cycle Diesel 1.06 US gal.(4 L) 92-877695K1 92-877695Q1
Engine Oil
Extended Life Anti- 1 US gal. (3.78 L) 92-877770K1 92-877770K1
122
freeze/Coolant
Marine Engine Cool- 1.33 US gal. (5 L) NA 92-813054A2
123
ant
Fuel System Treat-
124 ment and Stabilizer 16 oz (437 ml) 92-802876A1 92-802876Q1
Concentrate
Heat Transfer Com- 1.5 oz (42.5 g) tube 92-805701 1
125
pound
126 Liquid Gasket 92-808137 NA

127 T442 Sealant 92-862258 NA

Loctite 5900 Ultra 13 oz (371 g) tube 92-809826 NA
128 Black RTV Silicone
Sealant
Loctite Gasket Re- 18 oz (532 ml) spray 92-809828 1 NA
129
mover can
Sealer Kit, Two Part NA 92-65150 1
130
Epoxy
131 Anti-seize Compound 8 fl oz (237 ml) 92-881091K1
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
Hot Glue Obtain Locally Obtain Locally
Loctite 609 Obtain Locally Obtain Locally
Loctite 405 Obtain Locally Obtain Locally

90-856159R02 SEPTEMBER 2002 Page 1A-11

SPECIFICATIONS

Tube Mercury Part Num- Quicksilver Part

Description Container Size
Ref. # ber Number
Cyanacrylate
Obtain Locally Obtain Locally
Adhesive
3M Permabond
Obtain Locally Obtain Locally
#3M08155
Loctite 262 Obtain Locally Obtain Locally
Loctite 290 Obtain Locally Obtain Locally

Page 1A-12 90-856159R02 SEPTEMBER 2002