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View and Download Mercury 9.9 operation and maintenance manual online. 9.9 Outboard Motor pdf manual download. Also for: 15. 3.3 Hp 1999 Mercury Outboard Manual.pdf - Free download Ebook, Handbook, Textbook, User Guide PDF files on the internet quickly and easily.
MERCURY MARINER SERVICE REPAIR MANUALS DOWNLOAD. Mercury Mariner 2HP-40HP Outboards Service Repair Manual (1965-1989). (323 cc), 9.9-15hp Bigfoot (4-Stroke) (323 cc) Outboards Factory Service Repair Manual. 40HP (4-Stroke) Outboards Factory Service Repair Manual (Starting Model Year 1999) Mercury Mariner 30HP, 40HP (4-Stroke) EFI.
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1998 Mercury 9.9 HP Outboard Service Manual 9.9HP Motor
1998 Mercury Outboard Service Manual 9.9 HP 2-Stroke
This 1998 Mercury 9.9 hp manual 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 1998 9.9 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 1998 Mercury 9.9 outboard 2-stroke 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.
Control Cables (Tiller Handle Shift) Removal/Installation Refer to Section 7C for removal and installation instructions. Control Platform Removal/Disassembly
1. Disconnect control cables from anchor bracket and pulley as outlined in Section 7C. 2. Disconnect throttle link rod from ball joint of primary throttle lever. 3. Disconnect shift link rod from ball joint of gear shift lever.
a - Cables b - Bracket c - Pulley d - Link rod e - Throttle lever f - Shift link rod g - Gear shift lever h - Shift lever 4. Remove 3 bolts and control platform. 5. Remove nuts and flat washers.
a - Bolts b - Control platform c - Nuts d - Flat washers
6. Disassemble control platform.
a - Nuts (2) [Torque to 6.8 Nm ( 60 lb. in.)] b - Flatwashers (2) c - Primary throttle lever d - Spacer (long) e - Secondary gear f - Spacer (short) g - Gear shift lever h - Control platform i - Bolts (2) j - Mount bolts [Torque to 6.8 Nm (60 lb. in.)]
4. Index primary throttle lever into secondary gear.
a - Primary throttle lever b - Secondary gear 5. Install bolts, washers and nuts. Torque nuts to 6.8 Nm (60 lb. in.).
a - Nuts [Torque to 6.8 Nm ( 60 lb. in.)] b - Washers c - Bolts 6. Secure assembled control platform onto cylinder block using 3 bolts. Torque bolts to 6.8 Nm (60 lb. in.).
7. Adjust shift link rod to a length of 13.0 cm (5-1/8 in.) as measured between ball joint centerlines. 8. Connect shift link rod between joints of gear shift lever and shift shaft lever.
a - Shift link rod [Adjust to length of 13.0 cm (5-1/8 in.)] b - Shift shaft lever c - Gear shift lever
9. Adjust throttle link rod to a length of 12.4 cm (4-7/8 in.) as measured between ball joint centerlines.
10. Connect throttle link rod between ball joints of primary throttle lever and throttle cam.
11. Connect control cables to pulley of secondary gears and anchor bracket as outlined in
a - Primary throttle lever b - Pulley c - Control cables d - Throttle cam e - Anchor bracket f - Throttle link rod [Adjust to length of 12.4cm (4-7/8 in. )]
Throttle Cam/Control Lever Removal 1. Refer to Section 7C for removal of throttle cables. 2. Remove bolt and flat washer securing cam/lever to powerhead.
a - Bolt b - Washer c - Cam/lever
Reassembly
1. Assemble inner spring and outer spring together. 2. Position spring assembly over hub of throttle cam.
a - Inner spring b - Outer spring c - Inner spring ends d - Outer spring ends e - Hub f - Tabs
3. Wind end of inner spring to position tab of cam between inner spring ends. Verify spring windings are firmly held around diameter of cam hub and that no windings are positioned on top of hub.
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4. Lubricate bushing with 2-4-C with Teflon and install bushing and wave washer.
a - Inner spring end b - Tab c - Cam hub d - Bushing e - Wave washer
5. Install control lever onto throttle cam assembly so that tab of control lever is positioned between ends of inner spring.
6. Hook longer spring end of outer spring behind peg of control lever.
a - Control lever b - Tab c - Ends of inner spring d - Longer spring end e - Peg
Installation
1. Secure throttle cam/control lever assembly onto mounting boss of crankcase cover with bolt. Torque bolt to 7.9 Nm (70 lb. in.).
2. Connect timing link between ball joints of control lever and trigger assembly.
a - Throttle cam b - Control lever c - Flat washer d - Bolt [Torque bolt to 7.9 Nm (70 lb. in.)] e - Timing link f - Control lever
3. Adjust throttle link rod to a length of 12.4 cm (4-7/8 in.) as measured between ball joint center lines.
4. Connect throttle link rod between ball joints of throttle cam and primary throttle lever.
a - Throttle link rod [Adjust to a length of 12.4 cm (4-7/8 in.)] b - Throttle cam c - Primary throttle lever
Neutral Interlock Control Lever
Reassembly/Installation
1. Lubricate bushing with 2-4-C with Teflon and install bushing and spring.
2. Secure interlock lever components with bolt onto mounting boss of crankcase cover.
a - Bushing b - Spring c - Interlock lever d - Spring ends e - Flat washer f - Bolt [Torque to 7.9 Nm (70 lb. in.)] g - Neutral interlock wire (install in top hole)