Mercury 15XD Manuals

Manuals and User Guides for Mercury 15XD. We have 1 Mercury 15XD manual available for free PDF download: Service Manual

Mercury 15XD Service Manual

Mercury 15XD Service Manual (336 pages)

Brand: Mercury | Category: Outboard Motor | Size: 12 MB

Table of Contents

Important Information 1

9
- Cleanliness and Care of Outboard Motor
  3
- Page Numbering
  3
- Table of Contents
  9
- After each Use
  11
- Before each Use
  11
- Every 100 Hours of Use or Once Yearly, Whichever Occurs First
  11
- Every 300 Hours of Use or Three Years
  11
- Inspection and Maintenance Schedule
  11
- Flushing the Cooling System
  12
  - Fuel System
    13
  - Fuel Line Inspection
    13
  - Engine Fuel Filter
    13
- Corrosion Control Anode
  14
- Battery Inspection
  15
- Spark Plug Inspection
  15
- Fuse Replacement -- Electric Start Remote Control Models
  16
- Lubrication Points
  16
- Gear Case Lubrication
  18
- Fuel System
  20
  - Protecting External Engine Components
    20
  - Protecting Internal Engine Components
    20
  - Gear Case
    21
  - Positioning Outboard for Storage
    21
  - Battery Storage
    21
  - Propeller Selection
    26
Important Information 1

34
Electrical 2

46
- Specifications
  47
- Special Tools
  48
- Ignition/Electrical Components
  49
- Ignition Description
  51
  - Electronic Spark Advance
    52
  - Mechanical Spark Advance
    52
- Ignition Component Description
  52
  - Trigger Coil
    52
  - Stator
    53
  - Flywheel
    53
  - Ignition Coil
    54
  - Ignition Switch Box
    54
- Electronic Spark Advance
  56
- Ignition Test Procedures
  57
  - Direct Voltage Adapter (DVA)
    57
- Ignition Diagnostic Procedures
  58
- Ignition Troubleshooting
  58
- Ignition Troubleshooting (RED Stator)
  62
Electrical 2

63
- Electric Start Components
  64
- Battery
  66
  - Precautions
    66
  - Recommended Battery
    66
  - Operating Engine Without Battery
    66
  - Specific Gravity Readings
    66
  - Electrolyte Level
    67
  - Charging a Discharged Battery
    68
  - Winter Storage of Batteries
    68
- Battery Charging System
  69
  - Description
    69
  - Alternator Amperes Output
    70
  - Battery Charging System Troubleshooting
    71
  - Alternator Test
    71
  - Rectifier Test
    72
- Voltage Regulator Test
  69
  - Lamps Burn out When Engine RPM Is Increased
    69
  - Lamps Burn DIM at Wide-Open-Throttle
    69
- Starting System
  73
  - Starter Motor Amperes Draw
    73
  - Starting System Components
    73
  - Description
    73
  - Troubleshooting the Starting Circuit
    73
- Commander 2000 Key Switch Test
  76
  - Emergency Stop Switch
    77
  - (Lanyard Type)
    77
  - Push Button Stop Switch
    77
- Starter Motor
  78
  - Disassembly
    78
  - Cleaning and Inspection
    79
  - Testing Motor Armature
    80
  - Starter Motor Reassembly
    81
  - Starter Solenoid Test
    83
- Flywheel Ring Gear
  84
  - Installation
    84
- Neutral Start Switch (Electric Start Tiller Handle Shift Models)
  85
- Tiller Handle Start Button
  86
- Choke Solenoid
  87
  - Installation
    87
- Battery Cables/Engine Wiring Harness (Remote Electric Start Models)
  88
- Battery Cables (Tiller Handle Push Button Electric Start Models)
  91
  - Installation
    91
- Emergency Stop Switch (Lanyard Type)
  93
- Plug Harness (Battery Charging Kit)
  93
  - Installation
    93
Electrical 2

94
- Special Tools
  95
- Timing/Synchronizing
  96
- Timing/Synchronizing/Adjusting - Remote Control Models
  103
- Shift and Throttle Cable Installation to the Outboard
  106
- Shift Cable Installation
  107
- Throttle Cable Installation
  108
- Starting Procedure
  109
- Adjusting Idle Speed
  110
Electrical 2

111
Fuel System

127
- Carburetor (20/25/JET 20)
  128
- Carburetor (Seapro/Marathon 15/25 & Super 15)
  130
- Carburetor Adjustments
  132
  - Low Speed Mixture Screw
    132
  - Main Jet
    132
  - High Altitude Jet Chart
    133
  - Carburetor Float Adjustment
    134
- Fuel System
  141
  - Fuel System Troubleshooting
    141
- Carburetor Removal
  144
- Carburetor Installation
  145
- Fuel Pump
  148
  - Removal and Disassembly
    148
  - Cleaning and Inspection
    148
  - Reassembly and Installation
    148
- Primer System
  149
  - Symptoms of a Defective Primer System
    149
- Servicing Sight Bowl Fuel Filter
  150
Fuel System

151
- Controlling Emissions
  152
- Oxides of Nitrogen - Nox
  152
- Stoichiometric (14.7:1) Air/Fuel Ratio
  152
- Outboard Hydrocarbon Emissions Reductions
  153
- Stratified VS Homogenized Charge
  154
  - Homogenized Charge
    154
- Emissions Information
  155
- Manufacturer's Responsibility
  155
- Stratified Charge
  155
- Dealer Responsibility
  156
- EPA Emission Regulations
  156
- Owner Responsibility
  156
- Decal Location
  157
  - Emission Control Information
    157
Section 4 - Powerhead

158
- Specifications
  159
- Special Tools
  160
- Cylinder Block and Covers
  162
- Crankshaft, Pistons and Flywheel
  164
- Torque Sequence
  166
- Powerhead Removal
  167
- Powerhead Disassembly
  169
  - Cylinder Block
    169
  - Crankshaft
    174
- Powerhead Cleaning and Inspection
  179
  - Cylinder Block and Crankcase Cover
    179
  - Exhaust Manifold and Exhaust Cover
    180
  - Cylinder Bore
    180
  - Crankshaft
    183
  - Seals
    184
  - Bearings
    184
  - Connecting Rod
    185
  - Pistons
    188
  - Reed Block
    189
  - Bleed System
    190
  - Thermostat
    191
- Powerhead Reassembly
  192
  - General Information
    192
  - Crankshaft
    192
  - Cylinder Block
    203
- Powerhead Installation
  208
- Break-In Procedure
  209
- Set-Up and Test-Run Procedures
  209
Midsection

210
- Clamp Bracket Assembly
  211
- Swivel Bracket Assembly
  213
- Drive Shaft Housing Assembly
  215
- Drive Shaft Housing Disassembly/Reassembly
  216
Specifications

217
- Quicksilver Lubricants and Service Aids
  218
- Special Tools
  218
- Gear Housing (Drive Shaft)
  222
- Gear Housing (Propeller Shaft)
  224
- General Service Recommendations
  226
- Draining and Inspecting Gear Lubricant
  227
- Gear Housing Removal
  228
  - Disassembly
    230
  - Bearing Carrier
    230
  - Propeller Shaft
    231
  - Water Pump
    232
  - Shift Shaft
    234
  - Drive Shaft and Pinion Gear
    234
  - Upper Drive Shaft and Bearing/Seals
    235
  - Lower Drive Shaft Bearing/Cup
    236
  - Forward Gear Race
    236
- Cleaning and Inspection
  237
  - Gear Housing/Bearing Carrier Castings
    237
  - Ball Bearings
    237
  - Needle Bearing
    237
  - Cam Follower
    238
  - Clutch
    238
  - Propeller Shaft
    238
  - Shift Shaft
    239
  - Reverse and Forward Gear
    239
  - Pinion Gear
    241
  - Driveshaft
    241
  - Bearing Carrier
    242
- Reassembly
  242
  - Drive Shaft Bearing and Seals
    242
  - Shift Shaft
    244
  - Forward Gear Installation
    245
  - Pinion and Driveshaft
    247
  - Propeller Shaft
    247
  - Bearing Carrier
    249
  - Bearing Carrier/Propeller Shaft Installation 6A-34
    250
  - Water Pump
    251
  - Gear Housing Installation
    252
  - Trim Tab Adjustment and Replacement
    257
- Filling Gear Housing with Lubricant
  258
Specifications

259
- Jet Pump Assembly (S/N 0G157845 & Below)
  260
- Jet Linkage (S/N 0G157845 & Below)
  262
- Jet Water Pump Components
  263
- Jet Pump Assembly (S/N 0G157846 & Up)
  264
- Jet Linkage (S/N 0G157846 & Up)
  266
- Engine Horsepower Selection
  268
- Selecting a Boat that Is Best Suited for Jet Power 6B-10
  268
- Locate Centerline of the Outboard
  269
- Outboard Mounting Height
  269
- Transom Height of the Boat
  269
- Water Testing
  271
  - Checking for Cavitation
    271
- Shift Link Rod Adjustment
  273
  - Checking Shift Link Rod Adjustment
    273
  - Adjusting Shift Link Rod
    273
- Lubricating the Drive Shaft Bearing
  274
- Impeller Removal and Installation
  275
- Impeller Clearance Adjustment
  278
- Steering Pull Adjustment
  278
- Worn (Dull) Impeller
  279
- Liner Replacement
  280
- Jet Drive Removal and Installation
  281
  - Removal
    281
  - Installation
    281
- Water Pump Removal and Installation
  282
  - Removal
    282
  - Installation
    282
- Bearing Carrier Removal and Installation
  283
  - Removal
    283
  - Installation
    283
- Installing Drive Shaft Bearing
  283
  - Single Bearing System (Small Diameter Bearing)
    283
  - Single Bearing System (Large Diameter Bearing)
    284
- Installing Drive Shaft
  285
- Installing Upper Seal Housing
  286
  - Single Bearing System
    286
Controls

287
- Throttle and Shift Linkage (Tiller Handle Shift)
  288
- Control Cables (Tiller Handle Shift)
  290
  - Removal/Installation
    290
- Control Platform
  290
  - Removal/Disassembly
    290
  - Reassembly/Installation
    293
- Throttle Cam/Control Lever
  296
  - Reassembly
    296
  - Installation
    298
- Neutral Interlock Control Lever
  299
  - Reassembly/Installation
    299
- Horizontal Shift Shaft
  300
  - Removal
    300
  - Installation
    301
  - Tiller Handle Assembly
    304
  - Control Cables
    306
  - Removal
    306
  - Tiller Handle Removal/Disassembly
    308
  - Removal
    308
  - Installation
    310
  - Control Cables
    312
  - Installation
    312
  - Throttle and Shift Linkage (Side Shift)
    315
  - Throttle Cables (Side Shift Models)
    317
    
    Removal/Installation
    317
  - Throttle Cam/Control Lever
    317
    
    Removal
    317
  - Throttle Cam/Control Lever
    318
    
    Reassembly
    318
    
    Installation
    319
  - Neutral Interlock Control Lever
    321
    
    Reassembly/Installation
    321
  - Horizontal Shift Shaft
    322
    
    Reassembly/Installation
    322
  - Starter Assembly (Manual)
    325
  - Rewind Starter Assembly
    327
  - Removal
    327
  - Section 8 - Manual Starter
    327
  - Starter Rope Replacement
    330
  - Disassembly
    334
  - Cleaning and Inspection
    335
  - Reassembly
    335

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