Mercury 9.9-15HP 4-Stroke Outboards OEM Service & Repair Manual
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7
B
TILLER HANDLE
90-856159R1 AUGUST 1998 Page 7B-1
ATTACHMENTS/CONTROL LINKAGE
Section 7B – Tiller Handle
Table of Contents
Tiller Handle 7B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable/Linkage Installation and
Adjustment 7B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cables 7B-4 . . . . . . . . . . . . . . . . . . . . . . . . .
Side Shift Models 7B-4 . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cables 7B-6 . . . . . . . . . . . . . . . . . . . . . . . . .
Front Shift Models 7B-6 . . . . . . . . . . . . . . . . . . . . . .
Linkage 7B-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing Tiller Handle Assembly for
Removal 7B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tiller Handle Assembly Removal 7B-11 . . . . . . . . . . .
Tiller Handle Disassembly 7B-11 . . . . . . . . . . . . . . . . .
Cleaning/Inspection/Repair 7B-15 . . . . . . . . . . . . . . . .
Tiller Handle Reassembly 7B-16 . . . . . . . . . . . . . . . . .
Tiller Handle Installation 7B-20 . . . . . . . . . . . . . . . . . . .
Following Tiller Handle Installation 7B-20 . . . . . . . . . .
TILLER HANDLE
Page 7B-2 90-856159R1 AUGUST 1998
Tiller Handle
1
2
3
4
5 7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25 26
27
28 29
5
6
20
21
30
95
2-4-C w/Teflon (92-850736A1)
95
95
95
TILLER HANDLE
90-856159R1 AUGUST 1998 Page 7B-3
Tiller Handle
REF
TORQUE
REF .
NO.
QTY. DESCRIPTION lb-in. lb-ft Nm
– 1 TILLER HANDLE ASSEMBLY (BLACK)
– 1 TILLER HANDLE ASSEMBLY (GRAY)
1 1 COVER
2 1 PULLEY
3 1 CASE
4 1 SCREW (10-16 x 1/2) Drive Tight
5 2 THROTTLE CABLE
6 1 SLEEVE
7 1 STEERING HANDLE ARM
8 2 BOLT (M5 x 16) 70 8
9 1 BOLT (M5 x 16) 50 5.6
10 1 KNOB-Throttle Friction
11 1 SPRING
12 1 LOCK-Throttle Friction
13 1 BOLT (M6 x 25) Hand Tight
14 1 TILLER TUBE
15 1 DECAL
16 1 THROTTLE HANDLE
17 1 GRIP
18 1 STOP SWITCH
19 1 RETAINER
20 2 BUSHING
21 2 WASHER
22 1 WAVE WASHER
23 1 WASHER
24 1 BRACKET-Steering Arm
25 2 BOLT (M10 X 80) 32.5 44
26 1 PLATE
27 1 SWITCH HOUSING
28 1
CLIP ELECTRIC HANDLE
29 1 SWITCH
30 1 DECAL-Start
TILLER HANDLE
Page 7B-4 90-856159R1 AUGUST 1998
Throttle Cable/Linkage Installation and Adjustment
Throttle Cables
SIDE SHIFT MODELS
1. Rotate the tiller twist grip to full counterclockwise position.
a
a- Wide Open Throttle Position
2. Rotate pulley to align the pointer with the match mark on the bracket as shown below.
b
a
a- Pulley Pointer
b- Match Mark
TILLER HANDLE
90-856159R1 AUGUST 1998 Page 7B-5
3. Install longest cable barrel into anchor “a”.
4. Wrap longest cable into inner groove around top side of pulley. Place cable jacket into
upper anchor bracket.
a
c
b
a- Anchor “a”
b- Cable Jacket
c- Upper Anchor Bracket
5. Rotate tiller twist grip to full clockwise (idle) position.
6. Install remaining barrel into anchor “b”.
7. Place remaining cable into outer groove, wrap around to bottom side of pulley. Place
cable jacket into lower anchor bracket.
a
b
c
d
a- Remaining Cable
b- Anchor “b”
c- Cable Jacket
d- Lower Anchor Bracket
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This manual covers the four-stroke models from 1998 to 2002, including 9.9/15 HP and big foot 323 cc. It includes comprehensive coverage of overhauls and maintenance for all systems such as fuel, electrical, cooling, controls, powerhead power trim and tilt, upper and lower units, specs, full-color wiring diagrams, and more. The manual is fully illustrated with photos and exploded views, making it an invaluable resource for professional mechanics and DIY enthusiasts. It is fully indexed and bookmarked for easy navigation, and users have the option to print any or all of the pages.
