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Mercury Mariner 8/9.9HP 4-Stroke Factory Service Manual

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Number of pages: 251
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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

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Reviews   -   Write a Review

Rated: 5 by: 2 speed Posted: Tuesday, May 22, 2012 at 8:38PM

just what the doctor ordered

Rated: 5 by: Bill Posted: Saturday, December 22, 2012 at 4:33PM

Exelent service very easy to download good value

Rated: 5 by: Rob Posted: Wednesday, August 21, 2013 at 08:57AM

Excellent manual for the money. Cannot be beat. Will use this company again

Rated: 5 by: Geoff X. Martin Posted: Wednesday, March 5, 2014 at 00:09AM

Excellent service. Fast download. No problems.

Rated: 5 by: Valentin Posted: Saturday, July 8, 2023 at 6:09PM

Great manual and service. Thank you!

Rated: 5 by: Brent Posted: Wednesday, July 26, 2023 at 12:09PM

I was under impression this manual is old. Yet, it's a high quality manual with wealth of information for people who needs technical data to fix and maintain motor.

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

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