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SPECIFICATIONS

IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Master Specifications . . . . . . . . . . . . . . . . . . . . 1A-2 Mercury/Quicksilver Lubricants and Sealants 1A-6

90-826883R03 NOVEMBER 2002 Page 1A-1


SPECIFICATIONS

Master Specifications

Model 15XD/20 Jet /20/25


HORSEPOWER Model 20 Jet 20 (14.9)
(KW) Model 20 20 (14.9
Model 25 25 (18.7)
OUTBOARD 15 in. (38 cm) 114 lbs - 52 kg
WEIGHT 20 in. (51 cm) 117 lbs - 53 kg
20 Jet 124 lbs - 56 kg
CYLINDER Type Two Cylinder - Two Cycle
BLOCK Displacement 24.4 cu. in. (400 cc)
STROKE Length 2.362 in. (60 mm)
CYLINDER Diameter (Standard) 2.562 in. (65.01 mm)
BORE Taper/Out of Round Maximum* 0.003 in. (0.08 mm)*
Bore Type:
S/N 0G202749 and Below Chrome
S/N 0G202750 and Above Mercosil
CRANK SHAFT Top Main Bearing Journal 1.251 in. (31.77 mm)
Center Main Bearing Journal 1.000 in. (25.40 mm)
Bottom Main Bearing Journal 1.125 in. (28.58 mm)
Connecting Rod Journal 0.883 in. (22.43 mm)
End Play 0.004-0.019 (0.10-0.64 mm)
CONNECTING Piston Pin End (I.D.) 0.897 in. (22.78 mm)
ROD Crankpin End (I.D.) 1.196 in. (30.38 mm)
PISTON Piston Type Aluminum
O.D. at Skirt (Standard) 2.5583 - 2.5593 in. (64.98 - 65.00)
Ring End Gap 0.011-0.025 in. (.28 mm - .64 mm)
PISTON DIA. 2.5583 in. ± .0005 in.
(64.98 mm ± .0127 mm) Using a
micrometer, measure dimension
“A” at location shown. Dimension
“A” should be 2.5583 in. ± .0005 for
Dimension “A” a STANDARD size piston (new) Di-
at Right Angle
mension “A” will be 0.001 – 0.0015
(90°) to Pis-
ton Pin less if coating is worn off piston
0.50 in. (used)
(12.7 mm)

*Models S/N 0G202749 and Below:


NOTE: The cylinder bores are chrome and cannot be be rebored or efficiently honed.
Check each cylinder bore for an out-of-round egg shaped cylinder. A maximum of 0.003
in. (0076mm) is allowable.
*Models S/N 0G202750 and Above:
NOTE: The cylinder block is Mercosil and the cylinders can be rebored to 0.030 in. over-
sized. Check each cylinder bore for an out-of-round egg shaped cylinder. A maximum of
0.003 in. (0.076mm) is allowed.

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SPECIFICATIONS

Master Specifications

GEAR Forward - Neutral - Reverse Full Shift


HOUSING Gear Ratio 2.25:1
Gearcase Capacity 8.8 fl. oz. (260 ml)
Lubricant Type Premium Gear Lubricant

Forward Gear - Number of Teeth-Type 27


Pinion Gear - Number of Teeth-Type 12
Pinion Not Adjustable
Foreword Gear Backlash Not Adjustable
Reverse Gear Backlash Not Adjustable
Water Pressure @ RPM 2-7 PSI @ 2000 RPM
Water Pressure With 120° Thermostat 0-6 PSI (SPORADIC) 2000 RPM
MID Transom Height - Short Shaft 15 in. (38 cm)
SECTION - Long Shaft 20 in. (51 cm)
FUEL Fuel Pump Type Integral
SYSTEM Recommended Gasoline Automotive Unleaded
with a Minimum Pump Posted
Octane Rating of 87
Fuel Tank Capacity 6.6 U.S. Gallons
Operating Fuel/Oil Ratio 50:1
OIL Recommended Oil (Pre-Mix @ 50:1) NMMA TC-W II or TC-W III
2-Cycle Outboard Oil
STARTING Manual Start Recoil
SYSTEM Rope Length 66 in. (1676 mm)
Electric Start 12 Volt
Ampere Draw (cranking) 55 amperes
CHARGING Alternator Output
SYSTEM BLACK Stator - 2 Magnet Flywheel 4 Amp. (48 Watt)
(8 Pole)(4 Pulses) @ 6000 RPM

RED Stator - 4 Magnet Flywheel 6 amp (72 Watt)


(10 Pole)(5 Pulses) @ 6000 RPM
BATTERY Battery Rating 465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)

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SPECIFICATIONS

Type Capacitor Discharge Ignition


Spark Plug Type (NGK) NGK BP8H-N-10
Spark Plug Gap 0.040 in. (1.0 mm)
Spark Plug Hex 18 mm
Firing Order 1-2

20 Jet 19941/2 through 1998


20/25 19941/2 through 1996
Electronic Spark Advance
Idle @ 750 ± 50 RPM (In Forward
Gear) 4° ± 2° B.T.D.C (Not Adjustable)
Fast Idle Speed 1400 RPM ± 250 RPM
Maximum BTDC (Running) 25° ± 1 @5500 RPM
Setup Timing 28° B.T.D.C. @ 3000 ± 200 R.P.M.
(Set-up timing of 28° B.T.D.C. will
be retarded to 25° B.T.D.C. @
5500 R.P.M.)
Stator High Speed Winding 100 – 180 Ω (RED – BLACK)
Stator Low Spending 2900 – 3500 Ω (BLUE – BLACK)
Diode Test 2800 – 3400 Ω (RED – BLUE)
IGNITION
Ignition Coil Resistance:
SYSTEM
Primary 0Ω
Readings taken @
Secondary (w/o Boots) 850 – 1200 Ω
68°F (20°C).
20 Jet 1999 and Newer
20/25 1997/98 Models
Mechanical Spark Advance
Idle @ 750 ± 50 RPM (In Forward
Gear) 6° ± 1° B.T.D.C
Fast Idle Speed 1500 RPM ± 200 RPM
Maximum BTDC (Running) 25° ± 1 @5500 RPM
Black Stator
Stator High Speed Winding 120 - 180 Ω (BLACK/WHITE -
GROUND)
Stator Low Speed Winding 3200 - 3800 Ω (BLACK/YELLOW -
GROUND)
Red Stator Charging Coil 370 - 445 Ω
Diode Test 3100 – 3700 Ω (BLACK/YELLOW
BLACK/WHITE)
Ignition Coil Resistance:
Primary 0.02 - 0.04 Ω
Secondary (w/o Boots) 8000 - 11000 Ω
Trigger 6500 - 8500 Ω
Rev Limit - Finish 6100 - 6300 RPM
JET DRIVE Impeller Liner Clearance 0.030 in. (0.8 mm)

* Use NGK BPZ8H-N-10 Where Radio Frequency Interference (RFI) Suppression is


Required.

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SPECIFICATIONS

Master Specifications
CARBURETOR Idle RPM (In Forward Gear) 750 ± 50
SPECIFI- Wide Open Throttle (WOT) RPM
CATIONS 20 4500 - 5500
25 5000 - 6000
Idle Mixture Screw
Adjustment (Preset-Turns Out)
20 1 ± 1/4 Turn
20 Jet 1-1/2 ± 1/2 Turn
25/25 Seapro/25 Marathon 1-1/4 ± 1/4 Turn
Float Level 1.0 in. (25.4 mm)
Main Jet Size
19941/2 through 1996
-20 (WMC-44) 0.044 in. (1.12 mm)
-25/20 Jet (WMC-45) 0.076 in. (1.93 mm)
-25 Seapro/Marathon (WMC-46) 0.076 in. (1.93 mm)
-25 Seapro/Marathon (WMC-46A) 0.080 in. (2.03 mm)
1997 and Newer
-20 Jet (WMC-45) 0.076 in. (1.93 mm)
-20 (WMC-52) 0.044 in. (1.12 mm)
-25 (WMC-53) 0.076 in. (1.93 mm)
-25 Seapro/Marathon (WMC-54) 0.080 in. (2.03 mm)
Electric Choke Gap 0.025 in. (0.635 mm)
TIMING 20 Jet 19941/2 through 1998
SPECIFI- 20/25 19941/2 through 1996
CATIONS Electronic Spark Advance
Idle @ 750 ± 50 RPM (In Forward
Gear) 4° ± 2° B.T.D.C (Not Adjustable)
Fast Idle Speed 1400 RPM ± 250 RPM
Maximum BTDC (Running) 25° ± 1 @ 5500 RPM
Setup Timing 28° B.T.D.C. @ 3000 ± 200 RPM
(Set-up timing of 28° B.T.D.C. will
be retarded to 25° B.T.D.C. @
5500 RPM)
20/25 1997 AND NEWER
20 Jet 1999 AND NEWER
Mechanical Spark Advance
Idle @ 750 ± 50 RPM (In Forward
Gear) 6° ± 1° B.T.D.C.
Fast Idle Speed 1500 RPM ± 200 RPM
Maximum BTDC (Running) 25° ± 1 @ 5500 RPM

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SPECIFICATIONS

Mercury/Quicksilver Lubricants and Sealants


Tube Mercury Part Num- Quicksilver Part
Description
Ref. No. ber Number
Needle Bearing Assy.
4 92-802868A1 N/A
Lubricant
Dielectric Grease
6 92-823506-1 92-823506-1

Loctite 271 – Thread


7 92-809819 92-809819
Locker
Loctite 567 PST Pipe
9 92-809822 92-809822
Sealant
Loctite Master Gasket
12 92-12564-2 92-12564-2
Kit
2 Cycle Premium Out-
14 92-802813A1 92-802813Q1
board Oil
19 Perfect Seal 92-34227-1 92-34227-1

25 Liquid Neoprene 92-25711-3 92-25711-3

27 Bellows Adhesive N/A 92-86166Q1


Loctite 680 Retaining
33 92-809833 92-809833
Compound
34 Special Lubricant 101 92-802865A1 92-802865Q1
U-Joint and Gimbal 92-802870A1 92-802870Q1
42
Bearing Grease
Loctite 222 Thread
51 92-809818 92-809818
Locker
Loctite 242 Thread
66 92-809821 92-809821
Locker
4 Cycle 25W40 En-
79 92-802837A1 92-802837Q1
gine Oil
Premium Gear Lubri-
82 92-802846A1 92-802846Q1
cant
High Performance 92-802854A1 92-802854Q1
87
Gear Lube
Engine Coupler
91 92-802869A1 92-802869Q1
Spline Grease
Anti-Corrosion
94 92-802867A1 92-802867Q1
Grease
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30 Out-
110 92-802833A1 92-802833Q1
board Oil
Power Trim & Steer-
114 92-802880A1 92-802880Q1
ing Fluid

Page 1A-6 90-826883R03 NOVEMBER 2002


SPECIFICATIONS

Tube Mercury Part Num- Quicksilver Part


Description
Ref. # ber Number
Premium Plus 2
115 Cycle TC-W3 Out- 92-802824A1 92-802824Q1
board Oil
RTV 587 Silicone
116 92-809825 92-809825
Sealer
117 Loctite 7649 Primer N 92-809824 92-809824
Storage Seal Rust In- 92-802878-56 92-802878Q56
119
hibitor
120 Corrosion Guard 92-802878 55 92-802878Q55

121
15W40 4-cycle Diesel 92-877695K1 92-877695Q1
Engine Oil
Extended Life Anti- 92-877770K1 92-877770K1
122
freeze/Coolant
Marine Engine Cool- NA 92-813054A2
123
ant
Fuel System Treat-
124 ment and Stabilizer 92-802876A1 92-802876Q1
Concentrate
Heat Transfer Com- 92-805701 1
125
pound
126 Liquid Gasket 92-808137 NA

127 T442 Sealant 92-862258 NA


Loctite 5900 Ultra 92-809826 NA
128 Black RTV Silicone
Sealant
Loctite Gasket Re- 92-809828 1 NA
129
mover
Sealer Kit, Two Part NA 92-65150 1
130
Epoxy
131 Anti-seize Compound 92-881091K1
132 Torco MTF Gear Oil 92–849864–1
Optimol Longtime PD 92–848767
133
2
Dexron III Automatic Obtain Locally Obtain Locally
134
Transmission Fluid
135 Loctite 592 Obtain Locally Obtain Locally
136 Loctite Quick Tite Obtain Locally Obtain Locally
137 Isopropyl Alcohol Obtain Locally Obtain Locally
138 Hot Glue Obtain Locally Obtain Locally
139 Loctite 609 Obtain Locally Obtain Locally
1
140 Loctite 405 Obtain Locally Obtain Locally

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SPECIFICATIONS

Tube Mercury Part Num- Quicksilver Part


Description
Ref. # ber Number
Cyanacrylate Adhe-
1
141 Obtain Locally Obtain Locally
sive
3M Permabond
142 Obtain Locally Obtain Locally
#3M08155
143 Loctite 262 Obtain Locally Obtain Locally
144 Loctite 290 Obtain Locally Obtain Locally

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