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15XD
Mercury 15XD User Manual
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92
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
Gear Case Lubricant Capacity
18
Draining Gear Case
18
Draining Gear Case
19
Checking Lubricant Level and Refilling Gear Case
19
Storage Preparations
20
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
Outboard Remote Control
35
Selecting Accessories for the Outboard
35
Selecting Steering Cables and Remote Control Cables
35
Installing Outboard
36
Steering Cable and Steering Link Rod Installation 1D-4
37
Installing Ride Guide Steering Cable to the Outboard
37
Steering Cable Seal
37
Steering Link Rod Installation
38
Remote Control Installation
39
Shift and Throttle Cable Installation to the Outboard
39
Shift Cable Installation
39
Throttle Cable Installation
40
Remote Wiring Harness Connection to Engine
41
Battery Cable Connections
43
Propeller Installation
43
Tilt Pin Adjustment
44
Placing Tilt Pin in Lower Holes
44
Placing Tilt Pin in Upper Holes
45
Trim Tab Adjustment
45
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
Electronic Spark Advance
60
Tool: Multimeter/Dva Tester 91-99750A1
60
Mechanical Spark Advance
61
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
Side Shift Models: Adjusting Tiller Handle
97
Tiller Shift Models: Adjusting Link Rod
98
Starting Procedure
99
Timing Checking and Adjustment
99
Adjusting Idle Speed
101
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
Manual Start Models (Electronic Advance)
112
Model 20 Jet (19941/2 THRU 1998)
112
Electric Start Models with Tiller Handle Start Button (Electronic Advance) Model 20/25 (19941/2 THRU 1997)
113
Electric Models Equipped with Remote Control (Electronic Advance) Model 20/25 (19941/2 THRU 1997)
114
Manual Start Models (Mechanical Advance) Model 20/25 (1998)
115
Electric Start Models with Tiller Handle Start Button (Mechanical Advance) Model 20/25 (1998)
116
Electric Models Equipped with Remote Control (Mechanical Advance) Model 20/25 (1998)
117
Manual Start Wiring Diagram (RED Stator) Model 20/25 (1999 and NEWER)(Work Model)
119
Electric Start Models with Tiller Handle Start Button
120
Electric Models Equipped with Remote Control (RED Stator) Model 20/25 (1999 and NEWER)
121
Optional Electrical Accessories Wiring Diagrams 2D-12
122
Commander Remote Control (Electric Start)
123
Commander 2000 Remote Control (Manual)
124
Commander 2000 Remote Control (Electric Start)
125
Commander 3000 Panel Mount Control
126
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
5
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Mercury 15XD Specifications
General
Brand
Mercury
Model
15XD
Category
Outboard Motor
Language
English
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