Mercury Mariner 8/9.9HP 4-Stroke Factory Service Manual
- Home
- Outboard motors
- Mercury
- Mercury Mariner 8 9 9 4 stroke Service Manual
Original Mercury Mariner 8/9.9 4-Stroke Factory Service Manual in PDF format for immediate download.
MODELS COVERED:
Mercury/Mariner 8/9.9HP (4-Stroke)
With Starting Serial Numbers: United States 0H000058
Manual P/N: 90-827857R1 NOVEMBER 1996
Manual is indexed and fully searchable for easy access. It has only hi-resolution images and color diagrams.
To find information in PDF file please use "Ctrl+F" or "Command+F" for Mac and enter keywords you need to find in a manual.
File will be available for download in minutes!
This Manual PDF file is:
- + Printable: Yes
- + Viewable on: MS Windows, Mac, Android, iOS, Linux
- + Requires: Adobe Acrobat/Preview
Once manual is downloaded any number of pages could be printed or it could be printed in whole.
Manual could be opened in Adobe Acrobat on any mobile device (like iPad, iPhone or Android device etc.) any computer capable of viewing a PDF files including IBM compatible computers running Windows, Linux (or any other flavor of UNIX). Apple Computers have native support for PDF files.
Reference and Info files
Reviews - Write a Review
Rated: 5 by: 2 speed Posted: Tuesday, May 22, 2012 at 8:38PM
Rated: 5 by: Bill Posted: Saturday, December 22, 2012 at 4:33PM
Rated: 5 by: Rob Posted: Wednesday, August 21, 2013 at 08:57AM
Rated: 5 by: Geoff X. Martin Posted: Wednesday, March 5, 2014 at 00:09AM
Rated: 5 by: Valentin Posted: Saturday, July 8, 2023 at 6:09PM
Rated: 5 by: Brent Posted: Wednesday, July 26, 2023 at 12:09PM
Full list of manual chapters:
COVER
MODELS Mercury/ Mariner 8/ 9.9 (4-Stroke)
Notice
Notice to Users of This Manual
Cleanliness and Care of Outboard Motor
Page Numbering
Service Manual Outline
SPECIFICATIONS
SPECIFICATIONS
Table of Contents
General Specifications
MAINTENANCE
MAINTENANCE
Table of Contents
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
Fuse Replacement-Electric Start Models
Spark Plug Inspection
Timing Belt Inspection
Checking Engine Oil
Changing Engine Oil
Oil Filter Change Intervals
Engine Oil Capacity
Oil Changing Procedure
Fuel System
Fuel Line Filter
Fuel Line Inspection
Lubrication Points
Gear Case Lubrication
Draining Gear Case
Gear Case Lubricant Capacity
Checking Lubricant Level And Refilling Gear Case
Propeller Replacement
Removal
Installation
Corrosion Control Anode
Flushing The Cooling System
Out-of-Season Outboard Storage
Fuel System
Protecting External Outboard Components
Protecting Internal Engine Components
Gear Case
Positioning outboard for storage
Out-of-Season Battery Storage
GENERAL INFORMATION
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
Compression Check
Cylinder Leakage Testing
Analysis
OUTBOARD MOTOR INSTALLATION
OUTBOARD MOTOR INSTALLATION
Table of Contents
Mounting Outboard Motor on Transom
Boat Transom Height Requirement
Installation
Fastening Security Line
Ride-Guide Steering Cable Installation To the Outboard
Shift and Throttle Cable Installation To The Outboard
Shift Cable Installation
Throttle Cable Installation
Remote Wiring Harness Connection to Engine
IGNITION
IGNITION
Table of Contents
Theory of Operation
Ignition Component Description
Capacitor Discharge Unit (CDI)
Trigger Coil
Stator Assembly
Flywheel Assembly
Ignition Coil
Ignition Test Procedures
Ignition Troubleshooting
Ignition Diagnostic Procedures
Recommended Test
Testing Ignition Components
Flywheel Removal and Installation
Flywheel Removal
Flywheel Installation
Ignition Cover Removal and Installation
Wire Holder
(CDI) Unit Removal and Installation
Ignition Coil Removal and Installation
Rectifier Removal and Installation
Stator Removal and Installation
Trigger Coil Removal and Installation
CHARGING and STARTING SYSTEM
CHARGING and STARTING SYSTEM
Table of Contents
Battery
Precautions
Recommended Battery
Operating Engine Without Battery
Specific Gravity Readings
Electrolyte Level
Charging A Discharged Battery
Winter Storage of Batteries
Charging System Troubleshooting
Battery Charging System
6 Ampere Charging System Manual Start Models
10 Ampere Charging System Electric Start Models
Optional Electrical Accessories Wiring Diagrams
Stator Ohms Test (Alternator Lighting/Charging Coil)
Alternator System Test (6 Amphere Stator)
Alternator System Test (10 Ampere Stator)
Rectifier/Regulator Diode Test
Starting System
Starter Motor Amperes Draw
Description
Troubleshooting the Starting Circuit
Starting Circuit Troubleshooting Flow Chart
Starter Motor Assembly
Starter Motor Removal
Starter Motor Disassembly
Cleaning and Inspection
Starter Motor Reassembly
Starter Motor Installation
TIMING, SYNCHRONIZING and ADJUSTING
TIMING, SYNCHRONIZING and ADJUSTING
Table of Contents
Specifications
Tiller Handle Cable Adjustment
Full Throttle Link Rod Adjustment
Idle Speed - Initial Setting
Pilot Mixture Screw
Float Level Adjustment
WIRING DIAGRAMS
WIRING DIAGRAMS
Table of Contents
Manual Start Wiring Diagram
Electric Start Wiring Diagram
Battery Charging System
6 Ampere Charging System Manual Start Models
10 Ampere Charging System Electric Start Models
Commander Remote Control (Electric Start)
Commander 2000 Remote Control (Manual)
Commander 2000 Remote Control (Electric Start)
Commander 3000 Panel Mount Control
Remote Wiring Harness Connection to Engine
FUEL PUMP
FUEL PUMP
Table of Contents
Fuel Pump
Fuel Pump Removal
Fuel Pump Disassembly
Fuel Pump Reassembly
Bodensee
Fuel Pump Installation
CARBURATOR
CARBURETOR
Table of Contents
Specifications
Special Tools
Carburetor
Carburetor Adjustments
Pilot Mixture Screw
Float Level Adjustment
Carburetor Removal
Carburetor Disassembly
Inspection
Electrothermal Valve
Assembly
CYLINDER HEAD
CYLINDER HEAD
Table of Contents
Specifications
Special Tools
Camshaft/Oil Pump
Intake/Exhaust Valve
Valve Clearance Adjustment
Checking Valve Clearance
Adjusting Valves
Timing Belt inspection
Timing Belt Removal
Timing Belt Installation
Cylinder Head Disassembly
Cylinder Head Cover Removal
Cylinder Head Removal
Oil Pump Removal
Rocker Arm Removal
Camshaft Removal
Anode Removal
Exhaust Valve Removal
Intake Valve Removal
Cleaning and Inspection
Oil Pump
Rocker Shaft and Rocker Arm
Camshaft
Cylinder Head
Valve Guides
Valves
Valve Springs
Valves Seat Reconditioning
Valve Refacing Steps
Oil Separator
Cylinder Head Reassembly
Exhaust Valve Installation
Intake Valve Installation
Anode Assembly
Camshaft Oil Seal Installation
Camshaft and Driven Gear Assembly
Rocker Arm Assembly
Oil Pump Assembly
Oil Pump Installation
Cylinder Head Gasket
Cylinder Head Installation
Cylinder Head Cover Installation
Intake Manifold Assembly
Oil Filter Assembly
Oil Separator Installation
CYLINDER BLOCK/CRANKCASE
CYLINDER BLOCK/CRANKCASE
Table of Contents
Specifications
Cylinder Block And Crankcase
Crankshaft, Pistons And Connecting Rods
Crankcase and Main Bearing Selection
Powerhead Removal
Handle Rest Removal
Neutral Interlock Cable (Manual Start Models)
Battery Lead (Electric Start Models)
Throttle Linkage Removal (Remote Control Models)
Throttle Linkage Removal (Tiller Handle Models)
Powerhead Disassembly
Crankshaft
Cleaning/Inspection/Repair
Cylinder Bore
Piston
Piston Pin
Piston Rings
Crankshaft
Checking Main Bearing Clearance
Checking Connecting Rod Oil Clearance
Thermostat
Powerhead Reassembly
Main Bearing Selection
Main Bearing Installation
Piston Rings and Connecting Rod
Piston Installation
Crankshaft Assembly
Crankshaft Cover
Exhaust Cover
Thermostat Housing
Oil Pressure Switch
Drive Gear
Cylinder Head Gasket
Cylinder Head Installation
Electrical Mounting Plates
Cylinder Head Cover Installation
Water Hose Routing
Powerhead Installation
Throttle Linkage Installation (Electric Start Models)
Throttle Linkage Installation (Manual Start Models)
Neutral Interlock Cable (Manual Start Models)
Handle Rest Installation
Battery Lead (Electric Start Models)
MID-SECTION
MID-SECTION
Table of Contents
Driveshaft Housing
Swivel Bracket
Swivel Head and Steering Handle
Clamp Bracket
Drive Shaft Housing Disassembly/Reassembly
LOWER UNIT
LOWER UNIT
Table of Contents
Gear Housing Specifications
Special Tools Required For Disassembly And Reassembly
Forward/Reverse Gear Backlash and Pinion Depth
Gear Housing (Drive Shaft)
Gear Housing (Propeller Shaft)
Gearcase Removal
Gearcase Disassembly
Propeller Removal
Draining and Inspecting Gear Lubricant
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
Propeller Installation
Filling Gear Housing with Lubricant
Installation
THROTTLE/SHIFT LINKAGE - TILLER HANDLE SHIFT and SIDE SHIFT MODELS
THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT and SIDE SHIFT MODELS)
Table of Contents
Throttle Linkage (Manual)
Tiller Handle Shift Models
Control Cables
Control Platform
Side Shift Models
Throttle Cables
Control Platform
THROTTLE/SHIFT LINKAGE - REMOTE CONTROL MODELS
THROTTLE/SHIFT LINKAGE (REMOTE CONTROL MODELS)
Table of Contents
Throttle Linkage (Electric-Remote Control)
Remote Platform
Removal/Disassembly
Reassembly/Installation
TILLER HANDLE
TILLER HANDLE
Table of Contents
Swivel Head and Tiller Handle
Cable Removal
Tiller Shift Models-Control Cables
Side Shift Models-Throttle Cables
Tiller Handle
Removal
Disassembly
Reassembly
Installation
Cable Installation
Tiller Shift Models-Control Cables
Side Shift Models-Throttle Cables
MANUAL STARTER
MANUAL STARTER
Table of Contents
Starter Assembly (Manual)
Removal
Disassembly
Pinion Gear
Drum Removal
Spiral Spring
Reassembly
Spiral Spring
Stopper Assembly
Stopper Arm Assembly
Installing Starter Rope
Drum Installation
Pinion Installation
Adjusting Spring Tension
Plate Assembly
Rewind Starter Installation