Mercury 10/15 Sea Pro/Marathon - 6/8/9.9/10/15 HP Manuel de service

U.S. Version 90-827242R02©February 2003, Mercury Marine. All rights reserved. Printed in U.S.A. International Version 90-891600R026/8/9.9/10/15Startin

SPECIFICATIONS90-827242R02 FEBRUARY 2003 Page 1A-5CARBURETORSPECIFICATIONSTypeIdle RPM (In Gear)689.9/9.9 Sailpower10 Sea Pro/MarathonXR/MAG/Viking

TIMING, SYNCHRONIZING & ADJUSTING90-827242R02 FEBRUARY 2003 Page 2C-3Tiller Handle Shift Models1. Rotate tiller handle twist grip to NEUTRAL.2.

TIMING, SYNCHRONIZING & ADJUSTINGPage 2C-4 90-827242R02 FEBRUARY 2003Maximum Timing Adjustment1. Connect timing light to No. 1 (top) spark plug

TIMING, SYNCHRONIZING & ADJUSTING90-827242R02 FEBRUARY 2003 Page 2C-5Fast Idle Adjustment1. Push primer/fast idle knob completely in and rotate

2DWIRING DIAGRAMS90-827242R02 FEBRUARY 2003 Page 2D-1ELECTRICAL AND IGNITIONSection 2D – Wiring DiagramsTable of ContentsManual Start Ignition Wirin

WIRING DIAGRAMSPage 2D-2 90-827242R02 FEBRUARY 2003Manual Start Ignition Wiring Diagram (1998 And Prior)BLK = BLACKBRN = BROWNGRY = GRAYGRN = GREENR

WIRING DIAGRAMS90-827242R02 FEBRUARY 2003 Page 2D-3Electric Start Models with Tiller Handle Start Button(1998 And Prior)BLK = BlackBRN = BrownGRY =

WIRING DIAGRAMSPage 2D-4 90-827242R02 FEBRUARY 2003Electric Models Equipped with Remote Control(1998 And Prior)BLK = BLACKBRN = BROWNGRY = GRAYGRN =

WIRING DIAGRAMS90-827242R02 FEBRUARY 2003 Page 2D-5Manual Start Ignition Wiring Diagram (1999 And Newer)BLK = BLACKBRN = BROWNGRY = GRAYGRN = GREENR

WIRING DIAGRAMSPage 2D-6 90-827242R02 FEBRUARY 2003Manual Start Ignition Wiring Diagram (1999 And Newer) (Marathon and Sea Pro Models)BLK = BLACKBRN

WIRING DIAGRAMS90-827242R02 FEBRUARY 2003 Page 2D-7Electric Start Models with Tiller Handle Start Button (1999 And Newer, Design I)BLK = BLACKBRN =

SPECIFICATIONSPage 1A-6 90-827242R02 FEBRUARY 2003Propeller Information Chart - 6 HPWide Open Throttle RPM: 4000-5000Recommended Transom Height: 15″

WIRING DIAGRAMSPage 2D-8 90-827242R02 FEBRUARY 2003Electric Models Equipped with Remote Control (1999 AndNewer, Design I)BLK = BLACKBRN = BROWNGRY =

WIRING DIAGRAMS90-827242R02 FEBRUARY 2003 Page 2D-9Electric Start Models with Tiller Handle Start Button (1999 And Newer, Design II)BLK = BLACKBRN =

WIRING DIAGRAMSPage 2D-10 90-827242R02 FEBRUARY 2003Electric Models Equipped with Remote Control (1999 AndNewer, Design II)BLK = BLACKBRN = BROWNGRY

Manual Start Model with Lighting Coiland Unregulated AC VoltageManual Start Model with BatteryCharging KitManual Start Model with Voltage Regulato

WIRING DIAGRAMSPage 2D-12 90-827242R02 FEBRUARY 2003Commander 2000 Remote Control (Manual)BLK=BLACKYEL=YELLOW23893cbaabca-RUN – OFF switchb-Emergenc

WIRING DIAGRAMS90-827242R02 FEBRUARY 2003 Page 2D-13Commander 2000 Remote Control (Electric Start)BLK = BLACKBRN = BROWNGRY = GRAYGRN = GREENRED = R

WIRING DIAGRAMSPage 2D-14 90-827242R02 FEBRUARY 2003Commander 3000 Panel Mount ControlNeutral InterlockSwitchYEL=YELLOWRED=REDababa-Neutral interloc

3AFUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-1FUEL SYSTEMSection 3A – Fuel Delivery SystemTable of ContentsSpecifications 3A-2. . . . .

FUEL DELIVERY SYSTEMPage 3A-2 90827242R02 FEBRUARY 2003SpecificationsModels 6/8/9.9/10/15CARBURETORSPECIFICATIONSTypeIdle RPM (In Gear) –689.9/9.9 S

MODEL CARB0 – 5000 ft 5000 – 7500 ft 7500 – 10000 ftFLOATLEVELIDLEMIX(0 – 1524m)(1524 – 2286m) (1524 – 3048m)1994689.915MAIN JETWMC-18B .046.044.042 1

SPECIFICATIONS90-827242R02 FEBRUARY 2003 Page 1A-7Propeller Information Chart -9.9/10 HPWide Open Throttle RPM: 5000-6000Recommended Transom Height:

MODEL CARB0 – 5000 ft 5000 – 7500 ft 7500 – 10000 ftFLOATLEVELIDLEMIX(0 – 1524m)(1524 – 2286m) (1524 – 3048m)1997689.915MAIN JETWMC-41 .046.044.0421-1

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-5WMC Carburetor SpecificationsMODEL CARB0 – 5000 ft 5000 – 7500 ft 7500 – 10000 ftFLOATLEVELI

FUEL DELIVERY SYSTEMPage 3A-6 90827242R02 FEBRUARY 2003Carburetor Assembly (6 - 8) (9.9 - USA–S/N-0G112449/BEL–S/N-9831799 & Below)1234567891011

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-7Carburetor Assembly (6 - 8)(9.9 - USA–S/N-0G112449/BEL–S/N-9831799 & Below) (continued)R

FUEL DELIVERY SYSTEMPage 3A-8 90827242R02 FEBRUARY 2003Carburetor Assembly (15) USA–S/N-0G112449/BEL–S/N-9831799 & Below123456789101112131415161

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-9Carburetor Assembly (15) USA–S/N-0G112449/BEL–S/N-9831799 & Below (continued)REFTORQUERE

FUEL DELIVERY SYSTEMPage 3A-10 90827242R02 FEBRUARY 2003CARBURETOR ASSEMBLYUSA–S/N-0G112450/BEL–S/N-9831800 & Up12345678910111213141516171819202

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-11Carburetor AssemblyUSA–S/N-0G112450/BEL–S/N-9831800 & Up (continued)REFTORQUEREF.NO.QTY

FUEL DELIVERY SYSTEMPage 3A-12 90827242R02 FEBRUARY 2003Fuel System TroubleshootingGeneral InformationProblems thought to be caused by the fuel syst

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-13Possible Cause Corrective ActionImproperly mixed fuel. Contaminants (water, dirt,etc.) in f

SPECIFICATIONSPage 1A-8 90-827242R02 FEBRUARY 2003Mercury/Quicksilver Lubricants and SealantsTubeRef. No.DescriptionMercury Part Num-berQuicksilver

FUEL DELIVERY SYSTEMPage 3A-14 90827242R02 FEBRUARY 2003Problem: Fuel Blowback Out of CarburetorProblem: Unable to Reduce Engine RPM to Slow IdlePos

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-153. Push down on primer arm and pull primer knob, bezel and slide block out of bottom cowl.4

FUEL DELIVERY SYSTEMPage 3A-16 90827242R02 FEBRUARY 20032. Reconnect bleed hose to fitting on carburetor and install carburetor and securecarburetor

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-17Carburetor Adjustments1. Place outboard in water.2. Check tiller handle cable adjustment fo

FUEL DELIVERY SYSTEMPage 3A-18 90827242R02 FEBRUARY 2003NOTE: For Models NOT equipped with an idle speed screw:1. Loosen cam locking screw.2. Press

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-19IDLE WIRE ADJUSTMENT1. Push primer/fast idle knob completely in and rotate fully counterclo

FUEL DELIVERY SYSTEMPage 3A-20 90827242R02 FEBRUARY 20035. Continue turning mixture screw clockwise until too lean a mixture is obtained and engines

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-21CARBURETOR FLOAT ADJUSTMENTCheck float level by removing fuel bowl and checking level of fl

FUEL DELIVERY SYSTEMPage 3A-22 90827242R02 FEBRUARY 2003Rejetting Carburetors for High AltitudeFactory installed main fuel jets are normally adequat

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-23Fuel PumpRemoval and DisassemblyIMPORTANT: Fuel pump check valve diaphragm and gasket shoul

SPECIFICATIONS90-827242R02 FEBRUARY 2003 Page 1A-9TubeRef. #DescriptionMercury Part Num-berQuicksilver PartNumber115 Premium Plus 2 CycleTC-W3 Outbo

FUEL DELIVERY SYSTEMPage 3A-24 90827242R02 FEBRUARY 2003Primer SystemThe primer system provides extra fuel to the outboard whenever the primer knob

FUEL DELIVERY SYSTEM90-827242R02 FEBRUARY 2003 Page 3A-25Servicing Sight Bowl Fuel FilterWARNINGExercise extreme caution when cleaning fuel filter e

3BEMISSIONS90-827242R02 FEBRUARY 2003 Page 3B-1FUEL SYSTEMSection 3B – EmissionsTable of ContentsExhaust Emissions Standards 3B-1. . . . . . . . . .

EMISSIONSPage 3B-2 90-827242R02 FEBRUARY 2003Oxides of Nitrogen - NOxNOx is a slightly different byproduct of combustion. Nitrogen is one of the ele

EMISSIONS90-827242R02 FEBRUARY 2003 Page 3B-3Stratified vs. Homogenized ChargeDFI engines use a stratified charge inside the combustion chamber to a

EMISSIONSPage 3B-4 90-827242R02 FEBRUARY 2003Stratified ChargeA stratified charge engine only pulls air through the transfer system. The fuel requir

EMISSIONS90-827242R02 FEBRUARY 2003 Page 3B-5Dealer Responsibility:When performing service on all 1998 and later outboards that carry a certificatio

EMISSIONSPage 3B-6 90-827242R02 FEBRUARY 2003CERTIFICATION LABEL:The certification label must be placed on each engine at the time of manufacture an

EMISSIONS90-827242R02 FEBRUARY 2003 Page 3B-7Service Replacement Certification LabelIMPORTANT: By federal law, it is required that all 1998 and newe

EMISSIONSPage 3B-8 90-827242R02 FEBRUARY 2003InstallationInstall the label on a clean surface in the original factory location.Decal Location:Model

SPECIFICATIONSPage 1A-10 90-827242R02 FEBRUARY 2003TubeRef. #DescriptionMercury Part Num-berQuicksilver PartNumber1411Cyanacrylate Adhe-siveObtain L

1BMAINTENANCE90-827242R02 FEBRUARY 2003 Page 1B-1GENERAL INFORMATION & SPECIFICATIONSSection 1B – MaintenanceTable of ContentsTable of Contents

MAINTENANCEPage 1B-2 90-827242R20 FEBRUARY 2003Gearcase Lubricant CapacityGear Case Ratio Capacity2.00:1 200.0 ml (6.8 fl. oz.)Special Tools1. Flush

MAINTENANCE90-827242R02 FEBRUARY 2003 Page 1B-3Inspection and Maintenance ScheduleBefore Each Use1. Check that lanyard stop switch stops the engine.

MAINTENANCEPage 1B-4 90-827242R20 FEBRUARY 2003Flushing The Cooling SystemFlush the internal water passages of the outboard with fresh water after e

90-827242R02 FEBRUARY 2003 Page iNoticeThroughout this publication, Dangers, Warnings and Cautions (accompanied by theInternational HAZARD Symbol )

MAINTENANCE90-827242R02 FEBRUARY 2003 Page 1B-5Fuel SystemWARNINGAvoid serious injury or death from gasoline fire or explosion. Carefully follow all

MAINTENANCEPage 1B-6 90-827242R20 FEBRUARY 2003Corrosion Control AnodeThe outboard has a corrosion control anode installed to the gear case. An anod

MAINTENANCE90-827242R02 FEBRUARY 2003 Page 1B-7Battery InspectionThe battery should be inspected at periodic intervals to ensure proper engine start

MAINTENANCEPage 1B-8 90-827242R20 FEBRUARY 2003Lubrication Points1. Lubricate the following with 2-4-C with Teflon or Special Lubricant 101.• Tilt

MAINTENANCE90-827242R02 FEBRUARY 2003 Page 1B-9• Tilt lock pins (Make sure this pin is free to push in and out).• Lubricate along the entire tilt pi

MAINTENANCEPage 1B-10 90-827242R20 FEBRUARY 20032. Lubricate the following with light weight oil.• Steering Link Rod Pivot Points.3. Lubricate the f

MAINTENANCE90-827242R02 FEBRUARY 2003 Page 1B-111. Place outboard in a vertical operating position.2. Place drain pan below outboard.3. Remove fill/

MAINTENANCEPage 1B-12 90-827242R20 FEBRUARY 2003Storage PreparationsFuel SystemIMPORTANT: Gasoline containing alcohol (ethanol or methanol) can caus

MAINTENANCE90-827242R02 FEBRUARY 2003 Page 1B-13Positioning Outboard for StorageStore outboard in an upright position to allow water to drain out of

Page ii 90-827242R02 FEBRUARY 2003It is important to note, during any maintenance procedure replacement fasteners must havethe same measurements and

1CGENERAL INFORMATION90-827242R02 FEBRUARY 2003 Page 1C-1GENERAL INFORMATION & SPECIFICATIONSSection 1C – General InformationTable of ContentsTa

GENERAL INFORMATIONPage 1C-2 90-827242R02 FEBRUARY 2003Conditions Affecting PerformanceWeatherENGINE RPMRated hpSummer hpHorsepower LossDue to Atmos

GENERAL INFORMATION90-827242R02 FEBRUARY 2003 Page 1C-3Due to the horsepower/RPM characteristics of an engine, this will result in further loss ofho

GENERAL INFORMATIONPage 1C-4 90-827242R02 FEBRUARY 2003CAVITATIONCavitation is caused by water vapor bubbles forming either from a sharp edge or ang

GENERAL INFORMATION90-827242R02 FEBRUARY 2003 Page 1C-5Following Complete SubmersionSubmerged While RunningWhen an engine is submerged while running

GENERAL INFORMATIONPage 1C-6 90-827242R02 FEBRUARY 2003Propeller SelectionFor in-depth information on marine propellers and boat performance see you

GENERAL INFORMATION90-827242R02 FEBRUARY 2003 Page 1C-7Propeller Removal/InstallationWARNINGIf the propeller shaft is rotated while the engine is in

GENERAL INFORMATIONPage 1C-8 90-827242R02 FEBRUARY 20036. Install forward thrust hub, propeller, rear thrust hub and propeller nut onto the shaft.ab

GENERAL INFORMATION90-827242R02 FEBRUARY 2003 Page 1C-9Compression CheckNormal Compression (All Models) 787 – 856 kPa (115 – 125 psi)1. Remove spark

GENERAL INFORMATIONPage 1C-10 90-827242R02 FEBRUARY 2003GEAR HOUSINGSThe following procedures should be used in refinishing gear housings. This proc

12345678General Information& SpecificationsElectrical and IgnitionFuel SystemPowerheadMid-SectionLower UnitAttachments/Control LinkageManual Start

GENERAL INFORMATION90-827242R02 FEBRUARY 2003 Page 1C-11Decal ApplicationDecal Removal1. Mark decal location before removal to assure proper alignme

GENERAL INFORMATIONPage 1C-12 90-827242R02 FEBRUARY 2003DECAL APPLICATION1. Mix 16 ml (1/2 ounce) of dish washing liquid in 4 literes (1 gallon) of

1DOUTBOARD INSTALLATION90-827242R02 FEBRUARY 2003 Page 1D-1GENERAL INFORMATION & SPECIFICATIONSSection 1D – Outboard InstallationTable of Conten

OUTBOARD INSTALLATIONPage 1D-2 90-827242R02 FEBRUARY 2003WARNINGUsing an outboard that exceeds the maximum horsepower limit of a boat can: 1)cause l

OUTBOARD INSTALLATION90-827242R02 FEBRUARY 2003 Page 1D-3Installing Outboard1. Measure the transom height of your boat. The boat bottom should be al

OUTBOARD INSTALLATIONPage 1D-4 90-827242R02 FEBRUARY 20032. Insert steering cable end through outboard tilt tube and secure steering cable to tilt t

OUTBOARD INSTALLATION90-827242R02 FEBRUARY 2003 Page 1D-5Steering Link Rod InstallationIMPORTANT: The steering link rod that connects the steering c

OUTBOARD INSTALLATIONPage 1D-6 90-827242R02 FEBRUARY 20032. Secure steering link rod between engine steering bracket and steering cable end.959595ab

OUTBOARD INSTALLATION90-827242R02 FEBRUARY 2003 Page 1D-7Remote Control InstallationRefer to Mercury Precision Parts/Quicksilver Accessory Guide for

OUTBOARD INSTALLATIONPage 1D-8 90-827242R02 FEBRUARY 20034. Install cable ties on control cables.NOTE: Cable ties will prevent retainers from slippi

Page iv 90-827242R02 FEBRUARY 2003Propeller InformationFor in-depth information on marine propellers and boat performance – written by marineenginee

OUTBOARD INSTALLATION90-827242R02 FEBRUARY 2003 Page 1D-92. Wrap rubber control cable grommet around shift cable.53212aba-Grommetb-Cable3. Push grom

OUTBOARD INSTALLATIONPage 1D-10 90-827242R02 FEBRUARY 20037. Check shift cable adjustment as follows:a. Shift remote control into forward gear. The

OUTBOARD INSTALLATION90-827242R02 FEBRUARY 2003 Page 1D-11SPECIAL INSTRUCTIONSOn installations where control cables will frequently be removed and r

OUTBOARD INSTALLATIONPage 1D-12 90-827242R02 FEBRUARY 2003SECURING CABLES TO ANCHOR BRACKET1. Position barrel retainer over barrels of control cable

OUTBOARD INSTALLATION90-827242R02 FEBRUARY 2003 Page 1D-13THROTTLE LINK ROD INSTALLATION1. Adjust throttle link rod to a length of 21.6 cm (8.5 in.)

OUTBOARD INSTALLATIONPage 1D-14 90-827242R02 FEBRUARY 2003Battery Cable ConnectionsSINGLE OUTBOARD(+)(–)baca-Red sleeve (positive)b-Black sleeve (ne

OUTBOARD INSTALLATION90-827242R02 FEBRUARY 2003 Page 1D-15Tilt Pin AdjustmentPlacing Tilt Pin in Lower Holes1. Lower the bow.2. Result in quicker pl

2AIGNITION SYSTEM90-827242R02 FEBRUARY 2003 Page 2A-1ELECTRICAL AND IGNITIONSection 2A – Ignition SystemTable of ContentsSpecifications 2A-1. . . .

IGNITION SYSTEMPage 2A-2 90-827242R02 FEBRUARY 2003Special Tools Required1. Flywheel Holder 91-5234491–52344549642. Flywheel Holder 91-24937A13. DMT

1ASPECIFICATIONS90-827242R02 FEBRUARY 2003 Page 1A-1GENERAL INFORMATION & SPECIFICATIONSSection 1A – SpecificationsTable of ContentsGeneral Spec

IGNITION SYSTEM90-827242R02 FEBRUARY 2003 Page 2A-3Notes:

IGNITION SYSTEMPage 2A-4 90-827242R02 FEBRUARY 2003Electrical ComponentsAB123456789101112131415161718192021222324252627282912531323334353630A – RED

IGNITION SYSTEM90-827242R02 FEBRUARY 2003 Page 2A-5Electrical Components (continued)REFTORQUEREF.NO.QTY. DESCRIPTION lb. in. lb. ft. N·m1 1 STATOR A

IGNITION SYSTEMPage 2A-6 90-827242R02 FEBRUARY 2003DescriptionThe ignition system is an alternator driven capacitor discharge system. Major componen

TOOL : MULTIMETER/DVATested PartMultimeterWiresConnected ToResistance(ohms)ScaleStator (BLACK/YELLOW andBLACK/WHITEwires disconnectedfrom switch box)R

TOOL : MULTIMETER/DVATested PartMultimeterWiresConnected ToResistance(ohms)ScaleStator (GREEN/WHITE andWHITE/GREENwires disconnectedfrom switch boxes)

IGNITION SYSTEM90-827242R02 FEBRUARY 2003 Page 2A-9Ignition Components Removal and InstallationCAUTIONDo not strike flywheel with a hard object as f

IGNITION SYSTEMPage 2A-10 90-827242R02 FEBRUARY 2003Ignition Components Removal and Installation (continued)4.0 Nm (35 lb-in.)2.3 Nm (20 lb-in.)Torq

2BCHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-1ELECTRICAL AND IGNITIONSection 2B – Charging and Starting SystemTable of ContentsS

CHARGING AND STARTING SYSTEMPage 2B-2 90-827242R02 FEBRUARY 2003Recommended BatteryA 12 volt battery with a Marine Cranking Amperage rating minimum

SPECIFICATIONSPage 1A-2 90-827242R02 FEBRUARY 2003CYLINDERBLOCKTypeDisplacement (1994 Model) 6 8 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 1

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-3Battery Charging System TroubleshootingA fault in the battery charging system usuall

CHARGING AND STARTING SYSTEMPage 2B-4 90-827242R02 FEBRUARY 2003Alternator Amperes Output 1998 And Prior (Stator - 8 Pole/4 Pulse)Amperage output ca

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-5Connect red meter lead to ground (d), black leadalternately to terminals (a) and (c)

CHARGING AND STARTING SYSTEMPage 2B-6 90-827242R02 FEBRUARY 2003(1999 And Newer)The battery charging system components are the alternator, rectifier

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-7Tachometer Module Static Test1. Disconnect GRAY, YELLOW, and YELLOW/BLACK tachometer

CHARGING AND STARTING SYSTEMPage 2B-8 90-827242R02 FEBRUARY 20039. Connect GRAY, YELLOW, and YELLOW/BLACK tachometer module leads to engineharness.1

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-9Tachometer Module Running or Cranking TestOUTPUT VOLTAGE TEST59093bcad91-854009A191-

CHARGING AND STARTING SYSTEMPage 2B-10 90-827242R02 FEBRUARY 2003Rectifier/Regulator (P/N 853358T1) Diode TestWARNINGDisconnect battery leads from b

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-11VOLTAGE SPIKE SUPRESSER1. Set meter to .2. Connect RED (+) meter lead to regulator

CHARGING AND STARTING SYSTEMPage 2B-12 90-827242R02 FEBRUARY 2003Analog MeterNOTE:Voltage regulator/rectifier specifications are given for informati

SPECIFICATIONS90-827242R02 FEBRUARY 2003 Page 1A-3GEARHOUSINGGear RatioGearcase CapacityLubricant TypeForward Gear - Tooth count - TypePinion Gear -

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-13Starting SystemSTARTER MOTOR AMPERES DRAWStarter Motor Teeth10STARTER MOTORPART NO.

CHARGING AND STARTING SYSTEMPage 2B-14 90-827242R02 FEBRUARY 2003Starting Circuit Troubleshooting Flow ChartStarter Motor Does Not TurnSAFETY WARNIN

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-15a. Connect voltmeter between common engine ground and Test Point 2.b. Push start sw

CHARGING AND STARTING SYSTEMPage 2B-16 90-827242R02 FEBRUARY 2003COMMANDER 2000 Key Switch Test1. Disconnect remote control wiring harness and instr

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-17Emergency Stop Switch (Lanyard Type)IMPORTANT: Refer to Section 2D-Wiring Diagrams

CHARGING AND STARTING SYSTEMPage 2B-18 90-827242R02 FEBRUARY 2003Electrical Component Removal and Installation70 lb. in. (7.9 N·m)15 lb. in. (1.7 N·

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-19Starter MotorDisassembly1. Remove 2 thru-bolts from starter.2. Lightly tap on end o

CHARGING AND STARTING SYSTEMPage 2B-20 90-827242R02 FEBRUARY 2003Cleaning and Inspection1. If brushes are pitted, chipped or worn to less than 4.8mm

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-21TESTING ARMATURE FOR GROUND1. Use an ohmmeter (R x 100) to check for no continuity

CHARGING AND STARTING SYSTEMPage 2B-22 90-827242R02 FEBRUARY 20032. Apply a drop of SAE 10W oil to to helix threads on armature shaft. DO NOT overlu

SPECIFICATIONSPage 1A-4 90-827242R02 FEBRUARY 2003BATTERYBattery Rating 465 Marine Cranking Amps (MCA)or 350 Cold Cranking Amps (CCA)IGNITIONSYSTEMT

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-236. Install springs and brushes into brush holders. Spread brushes and hold in place

CHARGING AND STARTING SYSTEMPage 2B-24 90-827242R02 FEBRUARY 2003Flywheel Ring GearInstallationIMPORTANT: Before installing ring gear on flywheel, i

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-253. Route switch harness over block. Secure harness to stator harness with cable-tie

CHARGING AND STARTING SYSTEMPage 2B-26 90-827242R02 FEBRUARY 20033. The starter button harness is routed down the PORT side of lower engine to cowl.

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-27Battery Cables/Engine Wiring Harness (Remote Electric Start Models)1. Slide battery

CHARGING AND STARTING SYSTEMPage 2B-28 90-827242R02 FEBRUARY 20035. Route engine wiring harness and battery cable/sleeve (under carburetor location)

CHARGING AND STARTING SYSTEM90-827242R02 FEBRUARY 2003 Page 2B-29Battery Cables (Tiller Handle Push Button Electric Start Models)Installation1. Fast

CHARGING AND STARTING SYSTEMPage 2B-30 90-827242R02 FEBRUARY 2003Plug Harness (Battery Charging Kit)Installation1. Install plug harness through fuel

2CTIMING, SYNCHRONIZING & ADJUSTING90-827242R02 FEBRUARY 2003 Page 2C-1ELECTRICAL AND IGNITIONSection 2C – Timing, Synchronizing & Adjusting

TIMING, SYNCHRONIZING & ADJUSTINGPage 2C-2 90-827242R02 FEBRUARY 2003Special Tools1. DMT 2000 Service Tachometer 91-854009A12. Timing Light 91-9