1989 Mercury 15HP 15 HP 2-Stroke Outboard Service Manual


 

1989 Mercury 15HP 15 HP Outboard Service Manual

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INTRODUCTION
 
This 1989 Mercury 15 hp Outboard 2-Stroke Engine service manual download describes the service procedures for the complete motor. Follow the Engine maintenance schedule recommendations to ensure that the motor is in peak operating condition and the emission levels are with in the standards set by states/county Resources Board. Performing the scheduled maintenance on your outboard engine is very important. It compensates for the initial wear that occurs during the life of the motor.
 
All chapters in this Mercury 1989 15 horsepower motor service manual applies to the whole engine and illustrates procedures for the removal and installation of components that are in a detailed step-by-step fashion.
 
Most all Mercury 15hp 1989 outboard engine service manual chapters start with an assembly or systems illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section. The subsequent pages give detailed service/repair procedures. If you don't know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem.
 
 
 
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Pinion Gear and Forward Gear

PINION GEAR

1. Inspect pinion gear teeth for breakage, rust, chipping or excessive wear.

2. If pinion gear teeth are damaged, inspect FORWARD and REVERSE gear for damage.

3. Replace gears as required.

FORWARD GEAR

1. Inspect forward gear teeth for breakage, rust, chipping and excessive wear.

2. Inspect forward gear clutch jaws for wear. Rounded jaws indicate the following:

a. Improper shift cable adjustment.
b. Engine idle speed too high.
c. Shifting too slowly.

a - Gear teeth
b - Clutch teeth

3. Inspect propeller shaft FORWARD gear bushing surface to determine condition of bushing. If surface is discolored from lack of lubricant, pitted or worn, propeller shaft and bushing should be replaced.

4. If necessary, press bushing from gear using Bushing Removal Tool.

a - Bushing
b - Bushing Removal Tool (91-824787)

IMPORTANT: If FORWARD gear tapered bearing or race requires replacement, replace bearing and race as a set.

NOTE: DO NOT remove tapered bearing from FORWARD gear unless replacement is necessary as removal process will damage bearing.

5. Inspect FORWARD gear tapered bearing and race for rust, roughness or excessive wear.

6. If bearing is in serviceable condition, DO NOT remove bearing from gear as removal process will damage bearing.

7. If bearing must be replaced, remove bearing from gear using Universal Puller Plate and a suitable mandrel.