Our Mercury Outboard Engines workshop manuals contain in-depth maintenance, service and repair information. Get your eManual now! 1996 Mercury Marine Outboard Models pdf Factory Service & Work Shop Manual Download. VIEW DETAILS. Mercury 40 / 50 / 60 Hp EFI 4 Stroke Outboard Repair Manual Improved. This 1996 Mercury 9.9 hp manual describes the service procedures for the complete motor. Follow the Engine maintenance schedule recommendations to ensure that the motor is in peak operating condition and the emission levels are with in the standards set by states/county Resources Board.
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1996 Mercury 15 HP 15HP Outboard 2-Stroke Service Manual
1996 Mercury 15 HP Outboard 2-Stroke Service Manual
This 1996 Mercury 15 hp Outboard 2-Stroke Engine service manual download describes the service procedures for the complete motor. Follow the Engine maintenance schedule recommendations to ensure that the motor is in peak operating condition and the emission levels are with in the standards set by states/county Resources Board. Performing the scheduled maintenance on your outboard engine is very important. It compensates for the initial wear that occurs during the life of the motor.
All chapters in this Mercury 1996 15 horsepower motor service manual applies to the whole engine and illustrates procedures for the removal and installation of components that are in a detailed step-by-step fashion.
Most all Mercury 1996 15hp outboard engine service manual chapters start with an assembly or systems illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section. The subsequent pages give detailed service/repair procedures. If you don't know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem.
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IDLE SCREW
Problem: Unable to Reduce Engine RPM to Slow Idle Chipped or broken reeds on reed block. Problem: Rough Idle Excessive preload on reeds. Problem: Engine Runs Too Lean
Carburetor is loose. Air leaks past mixing chamber cover. Tighten bolts securely. Tighten cover or replace gasket.
Guide does not substitute the user manual. To ensure that Philips Lumea Precision Plus hair removal system is suitable for you and safe for you to use, read the user manual carefully before first use. Before you use Philips Lumea Precision Plus, perform a skin test: Choose a hair-free area close to the area to be treated.
Fuel level is too low. Reset float level.
Clogged high speed jet. Inspect jet for varnish or debris and clean.
Restricted fuel flow to carburetor. Check fuel lines and filters for restricted flow.
Incorrect high speed jet. Refer to main jet chart and replace with proper jet.
Idle mixture set too lean. Adjust to run richer. Turn idle mix screw counterclockwise.
Air leakage into fuel system. Inspect fuel line connections, hose clamps, fuel pump and fuel outlet tube (located in fuel tank) for loose fittings.
Anti-siphon valve restricting fuel flow. Inspect valve and/or test engine without valve in fuel system.
Carburetor Removal
1. Loosen primer cam retaining screw.
2. Remove retaining clip.
a - Screw b - Retaining clip
3. Push down on primer arm and pull primer knob, bezel and slide block out of bottom cowl. ' 4. Remove link wire from fast idle lever.
5. Disconnect fuel line from carburetor.
6. Remove carburetor mounting nuts.
7. Lift carburetor from engine. Remove bleed line from fitting in bottom of carburetor.
8 Hp Mercury Outboard Specifications
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Hp User Guides And Manuals
1996 Mercury 9.9 HP Outboard Service Manual 9.9HP Marine Engine
This 1996 Mercury 9.9 hp manual describes the service procedures for the complete motor. Follow the Engine maintenance schedule recommendations to ensure that the motor is in peak operating condition and the emission levels are with in the standards set by states/county Resources Board. Performing the scheduled maintenance on your outboard engine is very important. It compensates for the initial wear that occurs during the life of the motor.
All chapters in this Mercury 1996 9.9 service manual applies to the whole engine and illustrates procedures for the removal and installation of components that are in a detailed step-by-step fashion.
Most all 1996 Mercury 9.9 outboard 2-stroke manual chapters start with an assembly or systems illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section. The subsequent pages give detailed service/repair procedures. If you don't know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem.
Control Cables (Tiller Handle Shift) Removal/Installation Refer to Section 7C for removal and installation instructions. Control Platform Removal/Disassembly
1. Disconnect control cables from anchor bracket and pulley as outlined in Section 7C. 2. Disconnect throttle link rod from ball joint of primary throttle lever. 3. Disconnect shift link rod from ball joint of gear shift lever.
a - Cables b - Bracket c - Pulley d - Link rod e - Throttle lever f - Shift link rod g - Gear shift lever h - Shift lever 4. Remove 3 bolts and control platform. 5. Remove nuts and flat washers.
a - Bolts b - Control platform c - Nuts d - Flat washers
6. Disassemble control platform.
a - Nuts (2) [Torque to 6.8 Nm ( 60 lb. in.)] b - Flatwashers (2) c - Primary throttle lever d - Spacer (long) e - Secondary gear f - Spacer (short) g - Gear shift lever h - Control platform i - Bolts (2) j - Mount bolts [Torque to 6.8 Nm (60 lb. in.)]
4. Index primary throttle lever into secondary gear.
a - Primary throttle lever b - Secondary gear 5. Install bolts, washers and nuts. Torque nuts to 6.8 Nm (60 lb. in.).
a - Nuts [Torque to 6.8 Nm ( 60 lb. in.)] b - Washers c - Bolts 6. Secure assembled control platform onto cylinder block using 3 bolts. Torque bolts to 6.8 Nm (60 lb. in.).
7. Adjust shift link rod to a length of 13.0 cm (5-1/8 in.) as measured between ball joint centerlines. 8. Connect shift link rod between joints of gear shift lever and shift shaft lever.
a - Shift link rod [Adjust to length of 13.0 cm (5-1/8 in.)] b - Shift shaft lever c - Gear shift lever
9. Adjust throttle link rod to a length of 12.4 cm (4-7/8 in.) as measured between ball joint centerlines.
10. Connect throttle link rod between ball joints of primary throttle lever and throttle cam.
11. Connect control cables to pulley of secondary gears and anchor bracket as outlined in
a - Primary throttle lever b - Pulley c - Control cables d - Throttle cam e - Anchor bracket f - Throttle link rod [Adjust to length of 12.4cm (4-7/8 in. )]
Throttle Cam/Control Lever Removal 1. Refer to Section 7C for removal of throttle cables. 2. Remove bolt and flat washer securing cam/lever to powerhead.
a - Bolt b - Washer c - Cam/lever
Reassembly
1. Assemble inner spring and outer spring together. 2. Position spring assembly over hub of throttle cam.
a - Inner spring b - Outer spring c - Inner spring ends d - Outer spring ends e - Hub f - Tabs
3. Wind end of inner spring to position tab of cam between inner spring ends. Verify spring windings are firmly held around diameter of cam hub and that no windings are positioned on top of hub.
4. Lubricate bushing with 2-4-C with Teflon and install bushing and wave washer.
a - Inner spring end b - Tab c - Cam hub d - Bushing e - Wave washer
5. Install control lever onto throttle cam assembly so that tab of control lever is positioned between ends of inner spring.
6. Hook longer spring end of outer spring behind peg of control lever.
a - Control lever b - Tab c - Ends of inner spring d - Longer spring end e - Peg
Installation
1. Secure throttle cam/control lever assembly onto mounting boss of crankcase cover with bolt. Torque bolt to 7.9 Nm (70 lb. in.).
2. Connect timing link between ball joints of control lever and trigger assembly.
a - Throttle cam b - Control lever c - Flat washer d - Bolt [Torque bolt to 7.9 Nm (70 lb. in.)] e - Timing link f - Control lever
3. Adjust throttle link rod to a length of 12.4 cm (4-7/8 in.) as measured between ball joint center lines.
4. Connect throttle link rod between ball joints of throttle cam and primary throttle lever.
a - Throttle link rod [Adjust to a length of 12.4 cm (4-7/8 in.)] b - Throttle cam c - Primary throttle lever
Neutral Interlock Control Lever
Reassembly/Installation
1. Lubricate bushing with 2-4-C with Teflon and install bushing and spring.
2. Secure interlock lever components with bolt onto mounting boss of crankcase cover.
a - Bushing b - Spring c - Interlock lever d - Spring ends e - Flat washer f - Bolt [Torque to 7.9 Nm (70 lb. in.)] g - Neutral interlock wire (install in top hole)