This comprehensive Mercury 2-Stroke Outboard Service Manual/Repair Manual covers a wide range of models and years, specifically Mercury 6HP, 8HP, 9.9HP, 10HP, and 15HP outboards manufactured between 1986 and 2003. This manual serves as your ultimate guide for servicing and repairing your Mercury outboard engine. It provides detailed step-by-step instructions for all aspects of maintenance and repair, ensuring that your engine remains in peak operating condition. The manual includes detailed information on various engine systems, including specifications, maintenance procedures, general information, electrical systems, ignition systems, carburetor systems, EFI systems, powerhead components, mid-section components, lower unit components, attachments and control linkage, throttle and shift linkage, tiller handle, manual starter, diagnostic troubleshooting, and wiring diagrams. Within these sections, you'll find detailed instructions for tasks like: * **Specifications:** Discover crucial engine specifications such as length, weight, transom height, engine type, cylinder count, displacement, spark plug type, fuel system, cooling system, oil system, starting system, gear oil capacity, and more. * **Maintenance:** Learn about recommended maintenance intervals, along with step-by-step procedures for tasks like spark plug replacement, fuel line replacement, breather hose replacement, engine oil changes, gear oil changes, lubrication, anode and bonding wire maintenance, fuel mixture checks, oil filter changes, fuel filter changes, ignition timing adjustments, idle speed adjustments, tappet clearance adjustments, water pump inspection and replacement, propeller inspection and maintenance, and more. * **General Information:** Access important engine identification numbers, tightening torque values, service data, cylinder numbering, propeller recommendations, gasoline recommendations, warm-up procedures, and other essential general information. * **Electrical Systems:** Gain comprehensive knowledge on the electrical system, including component identification, removal, installation, inspection, and troubleshooting procedures for parts like the monitor tachometer, starter motor, electric starter system, battery charging system, battery charging coil, rectifier/regulator, and more. * **Ignition Systems:** Understand the ignition system with detailed instructions on specifications, special tools, ignition timing checks, spark plug firing order, ignition coil resistance checks, crank position sensor resistance checks, ECM engine speed limiter, spark cut-out reduction, ignition spark ECM, low oil pressure speed control, and oil pressure switch testing. * **Carburetor Systems:** If your engine utilizes a carburetor, this manual provides everything you need to adjust, rebuild, remove, inspect, and clean the carburetor to factory specifications. This includes information on carburetor adjustments, idle speed linkage, choke adjustment, carburetor removal, disassembly, cleaning, inspection, repair, reassembly, float height measurement, and more. * **EFI Systems:** If your engine is equipped with an electronic fuel injection system, you'll find information on fuel injection nozzle, fuel injection pump, fuel pump, throttle body, throttle control lever and linkage, high-pressure fuel line, fuel cooler, fuel hoses, fuel rail pressure regulator, idle speed control assembly, intake manifold, throttle position sensor, low-pressure fuel line, fuel pump, and fuel filter. * **Powerhead Components:** Learn about the powerhead components, including cylinder head cover, intake manifold assembly, ring gear cover, air intake power unit (powerhead), measuring pump components, oil pump, engine lubrication system, thermostat, cylinder, crankshaft, piston, counter balancer mechanism, and cylinder head assembly. The manual provides detailed procedures for removal, inspection, and installation of these components. * **Mid-Section Components:** Focus on the mid-section components such as the engine side cover, driveshaft housing, oil pan, swivel bracket, steering bracket and clamp, water pressure valve, lower unit gear housing, and more. Detailed information on inspection, removal, installation, cleaning, assembly, and reassembly is included. * **Lower Unit Components:** Explore the lower unit components including the gear case, propeller, lower unit gears, shimming and adjustment, trim tabs, drive shaft, oil seal housing, water pump, shift guide housing, propeller shaft components, gear bearing, propeller shaft gear housing, and more. This manual also includes dedicated sections for attachments and control linkage, throttle and shift linkage, tiller handle, manual starter, diagnostic troubleshooting, and wiring diagrams. These sections provide comprehensive information on these key aspects of your engine, ensuring that you have everything you need to diagnose and fix any issues that may arise.

This comprehensive service manual is your essential guide to maintaining and repairing Mercury 2-stroke outboard engines from 1986 to 2003, spanning models with 6, 8, 9.9, 10, and 15 horsepower. This digital manual, available in convenient PDF format, offers a wealth of information in a user-friendly layout, making it accessible to both experienced mechanics and DIY enthusiasts. It covers every aspect of these engines, from basic maintenance procedures to intricate powerhead rebuilds, ensuring you have the knowledge and tools to keep your outboard running smoothly. The manual is meticulously organized, with chapters dedicated to specific systems and components, such as the electrical system, ignition system, carburetor, fuel injection, powerhead, mid-section, and lower unit. Each chapter provides detailed step-by-step instructions, accompanied by clear diagrams, exploded views, and photographs, for easy comprehension. It goes beyond simple repair guides, encompassing troubleshooting tips, maintenance charts, specifications, and even recommended tools, empowering you to diagnose issues, perform routine maintenance, and tackle complex repairs with confidence. This manual is an invaluable resource for anyone who owns a Mercury 2-stroke outboard engine, offering the knowledge to ensure its optimal performance and longevity.