This service manual covers the 1998-2001 Mercury/Mariner 4-Stroke Outboard models, including 9.9/15 (4-Stroke) (323 cc), 9.9/15 Bigfoot (4-Stroke) (323 cc), 9.9HP, and 15HP. It provides detailed service procedures for the complete outboard, with maintenance schedule recommendations to keep the engine in peak operating condition.
All chapters in the manual illustrate step-by-step procedures for the removal and installation of components, starting with assembly or system illustrations, diagrams, exploded parts views, pictures, service information, and troubleshooting for each section.
The service manual is delivered in PDF format and includes comprehensive information on specifications, maintenance, general information, electrical systems, ignition, carburetor, EFI system, powerhead, mid-section, lower unit, attachments/control linkage, throttle/shift linkage, tiller handle, manual starter, diagnostic troubleshooting, and wiring diagrams.
Specifications section covers overall length, width, weight, transom height, recommended operating range, idle speed, engine type, DOHC, number of cylinders, total displacement, spark plug, fuel supply system, exhaust system, cooling system, lubrication system, starting system, lower unit, fuel recommendations, gearcase oil capacity, maximum tilt angle, transmission, propeller shaft rotation, cylinder compression, engine oil pressure, viscosity rating, engine oil amounts, oil filter change, thermostat operating temperature, and more.
The maintenance section includes complete maintenance specifications, charts, intervals, and step-by-step procedures for spark plugs, fuel line, engine oil, gear oil, lubrication, anodes & bonding wires, battery, fuel mixture check, ignition timing, tappet clearance, water pump, propeller nut & pin, balancer chain, bolt & nuts, timing belt inspection, changing engine oil, oil filter, and more.
The general information section covers identification numbers, tightening torque, service data, specifications, cylinder number, propellers, gas recommendations, and warm-up recommendations.
The electrical section includes information on electrical parts holder removal and installation, inspection, removal, installation, and troubleshooting of monitor tachometer, starter motor, electric starter system, battery charging system, disassembly, cleaning, testing, brush replacement, and battery charging system tests.
The ignition section covers specifications, special tools, checking ignition timing, spark plug, ignition timing, charge coil resistance, ignition coil resistance, ECM, engine speed limiter, ignition spark, ECM low oil pressure, and speed control oil pressure switch.
The carburetor section provides information on specifications, special tools, intake, carburetor adjustments, idle speed linkage, choke, carburetor removal, disassembly, cleaning, inspection, repair, reassembly, float height measurement, installation, and idle rpm.
The EFI system section includes specifications, fuel injection nozzle, fuel injection pump, throttle body, throttle control lever and linkage, high-pressure fuel line, fuel cooler, fuel hoses, fuel rail pressure regulator, idle speed control assembly, intake manifold, throttle position sensor, low-pressure fuel line/fuel pump, fuel filter, and more.
The powerhead section contains information on cylinder head cover, intake manifold assembly, ring gear cover, air intake, power unit (powerhead), measuring pump components, oil pump, engine lubrication system, thermostat, cylinder, crankshaft, piston, counter balancer mechanism, cylinder head assembly, removal, inspection, and installation.
The mid-section section covers engine side cover, driveshaft housing and oil pan, swivel bracket, steering bracket and clamp, water pressure valve, lower unit gear housing, and all related inspection, removal, installation, cleaning, assembly, and reassembly procedures.
The lower unit section includes information on gear case, propeller, lower unit gears, shimming and adjustment, trim tab, drive shaft and oil seal housing, water pump, and related items, shift guide housing, propeller shaft components, gear bearing, propeller shaft, gear housing, and more.
Other chapters in the manual include attachments/control linkage, throttle/shift linkage, tiller handle, manual starter, diagnostic troubleshooting, and wiring diagrams.
