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1998 Mercury 9.9/15HP 4-stroke Outboard motor factory service manual

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Number of pages: 369
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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

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