1998 Mercury 9.9/15HP 4-stroke Outboard motor factory service manual
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- 1998 Mercury 9 9 15 4 stroke outboards
Models covered:
Mercury/Mariner
9.9/15 (4-Stroke) (323 cc)
9.9/15 Bigfoot (4-Stroke) (323 cc)
With Serial Numbers
United States . . . . . . 0G590000 and Above
Service Manual Outline
Section 1 - Important Information
A - Specification
B - Maintenance
C - General Information
D - Outboard Motor Installation
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Carburetor
C - Emissions
Section 4 - Powerhead
A - Cylinder Head
B - Cylinder Block/Crankcase
C - Oil Pump
Section 5 - Mid-Section
Section 6 - Lower Unit
A - Gear Housing (Non-Bigfoot)
B - Gear Housing (Bigfoot)
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Section 8 - Manual Starter
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Full list of manual chapters:
MODELS Mercury/ Mariner 9.9/ 15 (4- Stroke) (323 cc) 9.9/ 15 Bigfoot (4- Stroke) (323 cc)
Notice
Notice to Users of This Manual
Cleanliness and Care of Outboard Motor
Page Numbering
Service Manual Outline
Section 1A - Specifications
Table of Contents
Specifications
Propeller Information Charts
Mercury/Mariner 9.9 (4 - Stroke) Non-Bigfoot
Mercury/Mariner 9.9 (4 - Stroke) Bigfoot
Mercury/Mariner 15 (4 - Stroke) Non-Bigfoot
Mercury/Mariner 15 (4 - Stroke) Bigfoot
Section 1B - Maintenance
Table of Contents
Special Tools
Quicksilver Lubricant/Sealant
Inspection And Maintenance Schedule
Before Each Use
After Each Use
Every 100 Hours Of Use Or Once Yearly, Whichever Occurs First
Every 300 Hours of Use or Three Years
Before Periods of Storage
Flushing The Cooling System
Standard Models
Bigfoot Models
Fuel System
Fuel Line Filter
Fuel Line Inspection
Corrosion Control Anode
Spark Plug Inspection
Battery Inspection
Fuse Replacement - Electric Start Models
Timing Belt Inspection
Lubrication Points
Changing Engine Oil
Oil Draining Procedure
Changing Oil Filter
Oil Filling
Gear Case Lubrication
Draining Gear Case
Gear Case Lubricant Capacity
Checking Gear Case Lubricant Level and Refilling Gear Case
Storage Preparation
Fuel System
Protecting External Outboard Components
Protecting Internal Engine Components
Gear Case
Positioning Outboard for Storage
Battery Storage
Section 1C - General Information
Table of Contents
Serial Number Location
Conditions Affecting Performance
Weather
Boat
Engine
Following Complete Submersion
Submerged While Running (Special Instructions)
Salt Water Submersion (Special Instructions)
Fresh Water Submersion (Special Instructions)
Propeller Selection
Propeller Removal/Installation
Standard Models
Bigfoot Models
Trim Tab Adjustment
Compression Check
Cylinder Leakage Testing
Analysis
Painting Procedures
Decal Application
Section 1D - Outboard Motor Installation
Table of Contents
Boat Horsepower Capacity
Start in Gear Protection
Selecting Accessories For The Outboard
Installing Outboard
Steering Cable
Steering Cable Seal
Steering Link Rod
Wiring Harness
Battery Cable Connections
Shift and Throttle Cable
Shift Cable Installation
Throttle Cable Installation
Section 2A - Ignition
Table of Contents
Specifications
Special Tools
Flywheel
Electrical Components
Ignition Description
Ignition Component Description
Electronic Control Module (ECM)
Crank Position Sensor
Ignition and Battery Charging Coils
Flywheel Assembly
Ignition Coil
Ignition Test Procedures
Ignition Troubleshooting
Ignition Diagnostic Procedures
Testing Ignition Components
Flywheel Removal and Installation
Flywheel Removal
Flywheel Installation
Timing Belt Removal and Installation
Ignition Charge Coil Removal and Installation
Ignition Coil Removal and Installation
Crank Position Sensor Removal and Installation
Rectifier/Regulator and ECM Removal and Installation
Section 2B - Charging and Starting System
Table of Contents
Specifications
Special Tools
Battery
Battery Charging System – Manual Start Models
Battery Charging System – Electric Start Models
Battery Charging System Tests
Testing The Battery Charging Coil
Testing The Battery Charging System
Testing The Rectifier/Regulator (Diode Test)
Starting System
Starter Motor Amperes Draw
Starting System Components
Description
Troubleshooting the Starting Circuit
Starter Solenoid Test
Starting System Troubleshooting Flow Chart
Starter Motor Components
Starter Motor
Removal
Disassembly
Cleaning and Inspection
Testing
Brush Replacement
Reassembly
Installation
Section 2C - Timing, Synchronizing and Adjusting
Table of Contents
Specifications
Special Tools
Checking Ignition Timing
Section 2D - Wiring Diagrams
Table of Contents
Electric Start Tiller Handle Models Wiring Diagram
Electric Start Remote Control Models Wiring Diagram
Manual Start Models Wiring Diagram
Electric Start Tiller Handle Models Wiring Locations
Electric Start Remote Control Models Wiring Locations
Manual Start Models Wiring Locations
Section 3A – Fuel Pump
Table of Contents
Specifications
Fuel Pump
Fuel Pump Removal
Fuel Pump Disassembly
Cleaning/Inspection/Repair
Fuel Pump Reassembly
Fuel Pump Installation
Section 3B – Carburetor
Table of Contents
Specifications
Special Tools
Carburetor
Intake
Carburetor Adjustments
Idle Speed
Linkage
Choke
Carburetor Removal
Carburetor Disassembly
Cleaning/Inspection/Repair
Carburetor Reassembly
Float Height Measurement
Carburetor Installation
Section 3C - Emissions
Table of Contents
Exhaust Emissions Standards
What Are Emissions?
Hydrocarbons - HC
Carbon Monoxide - CO
Oxides of Nitrogen - NOx
Controlling Emissions
Stoichiometric (14.7:1) Air/Fuel Ratio
STRATIFIED VS HOMOGENIZED CHARGE
Homogenized Charge
Stratified Charge
Emissions Information
Manufacturer's Responsibility:
Dealer Responsibility:
Owner Responsibility:
EPA Emission Regulations:
Decal Location for 1998 Models:
Section 4A – Cylinder Head
Table of Contents
Specifications
Special Tools
Cylinder Head
Intake/Exhaust Valves
Oil Pump/Camshaft
Adjustments
Preparing Cylinder Head for Removal
Cylinder Head Removal
Oil Pump Removal
Cylinder Head Disassembly
Cleaning/Inspection/Repair
Cylinder Head
Cylinder Head Resurfacing
Rocker Arm and Rocker Arm Shaft Inspection
Camshaft
Valve Guide inspection
Valve Guide Replacement
Valve Seat Reconditioning
Valves
Valve Springs
Cylinder Head Reassembly
Oil Pump Installation
Cylinder Head Installation
Following Cylinder Head Installation
Section 4B – Cylinder Block/Crankcase
Table of Contents
Specifications
Special Tools
Crankshaft
Cylinder Block And Covers
Preparing Powerhead for Removal
Remote Control Models
Tiller Handle Models
Electric Start Models
Manual Start Models
All Models (If So Equipped)
Powerhead Removal
Preparing Powerhead for Disassembly
Powerhead Disassembly
Thermostat, Exhaust, and Breather Cover Removal
Anode Removal
Crankcase and Crankshaft Removal
Piston Disassembly
Cleaning/Inspection/Repair
Flywheel
Drive Gear
Timing Belt
Anode
Oil Pressure Switch
Thermostat
Cylinder
Piston
Piston Pin
Piston Rings
Crankshaft
Crankcase and Bearing
Connecting Rod Oil Clearance
Powerhead Reassembly
Piston Ring Installation
Piston Installation
Crankcase and Crankshaft Installation
Anode Installation
Thermostat, Exhaust, and Breather Cover Installation
Following Powerhead Assembly
Timing Belt Installation
Electrical Component Installation
Carburetor Installation
Powerhead Installation
Following Powerhead Installation
Electric Start Models
Manual Start Models
All Models (If Equipped)
Driveshaft Housings Covers
Section 4C - Oil Pump
Table of Contents
Specifications
Oil Pump Removal
Oil Pump Disassembly
Cleaning/Inspection/Repair
Oil Pump Reassembly
Oil Pump Installation
Section 5 – Clamp/Swivel Brackets and Drive Shaft Housing
Table of Contents
Specifications
Clamp Bracket Assembly
Swivel Bracket Assembly
Drive Shaft Housing Assembly
Driveshaft Housing Cover Removal/Installation
Upper Motor Mount Replacement
Removal/Installation of Clamp Bracket Assembly
Reverse Lock Link Rod Installation (2 Piece Design)
Reverse Lock Link Rod Up-Grade (Refer to Mercury/Mariner Service Bulletin No. 98-13)
Pre-Assembly
Section 6A – Non-Bigfoot Gear Housing
Table of Contents
Specifications
Special Tools
Gear Housing (Drive Shaft)
Gear Housing (Propeller Shaft)
General Service Recommendations
Draining and Inspecting Gear Lubricant
Gear Housing Removal
Disassembly
Bearing Carrier
Propeller Shaft
Water Pump, Drive Shaft and Shift Shaft
Pinion Gear and Forward Gear
Drive Shaft Bushing, Bearing and Lubrication Sleeve
Aluminum Anode and Water Inlet
Reassembly
Drive Shaft Needle Bearing, Bushing and Lubrication Sleeve Installation
Forward Gear Bearing Race Installation
Forward Gear Reassembly
Bearing Carrier Reassembly
Water Pump Base and Shift Shaft Reassembly
Propeller Shaft Reassembly
Forward Gear, Pinion Gear and Drive Shaft Installation
Shift Shaft and Water Pump Base Installation
Water Pump Cover Reassembly
Impeller and Pump Cover Installation
Propeller Shaft and Bearing Carrier Installation
Aluminum Anode and Water Inlet Installation
Filling Gear Housing with Lubricant
Installation
Section 6B – Big Foot
Table of Contents
Specifications
Quicksilver Lubricants and Service Aids
Special Tools
Gear Housing (Drive Shaft)
Gear Housing (Propeller Shaft)
General Service Recommendations
Draining and Inspecting Gear Lubricant
Gear Housing Removal
Disassembly
Bearing Carrier
Propeller Shaft
Water Pump
Shift Shaft
Drive Shaft and Pinion Gear
Upper Drive Shaft and Bearing/Seals
Lower Drive Shaft Bearing/Cup
Forward Gear Race
Cleaning and Inspection
Gear Housing/Bearing Carrier Castings
Ball Bearings
Needle Bearing
Cam Follower
Clutch
Propeller shaft
Shift Shaft
Reverse And Forward Gear
Pinion Gear
Driveshaft
Bearing Carrier
Reassembly
Drive Shaft Bearing and Seals
Shift Shaft
Forward Gear Installation
Pinion and Driveshaft
Propeller Shaft
Bearing Carrier
Bearing Carrier/Propeller Shaft Installation
Water Pump
Gear Housing Installation
Trim Tab Adjustment and Replacement
Filling Gear Housing with Lubricant
Section 7A – Throttle/Shift Linkage
Table of Contents
Throttle/Shift Linkage (Handle Models) (Side Shift)
Throttle/Shift Linkage (Handle Models) (Front Shift)
Throttle/Shift Linkage (Non-Handle Models)
Section 7B - Tiller Handle
Table of Contents
Tiller Handle
Throttle Cable/Linkage Installation and Adjustment
Throttle Cables
Linkage
Preparing Tiller Handle Assembly for Removal
Tiller Handle Assembly Removal
Tiller Handle Disassembly
Cleaning/Inspection/Repair
Tiller Handle Reassembly
Tiller Handle Installation
Following Tiller Handle Installation
Section 8
Table of Contents
Starter Assembly
Manual Starter Removal
Manual Starter Installation
Neutral Interlock Adjustment
Manual Rewind Disassembly
Manual Rewind Reassembly