2002 Mercury 9.9 HP 2 Stroke Service & Repair Manual
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7
C
TILLER HANDLE
90-827242R1 MAY 1998 Page 7C-1
ATTACHMENTS/ CONTROL LINKAGE
Section 7C – Tiller Handle
Table of Contents
Swivel Head and Steering Handle 7C-2 . . . . . . . . . . .
Control Cables (Tiller Handle Shift Models) 7C-4 . . .
Removal 7C-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cables (Side Shift Models) 7C-5 . . . . . . . . . .
Removal 7C-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tiller Handle Removal/Disassembly 7C-6 . . . . . . . . .
Removal 7C-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7C-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Cables (Tiller Handle Shift Models) 7C-9 . . .
Installation 7C-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable (Side Shift Models) 7C-11 . . . . . . . . . .
Installation 7C-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TILLER HANDLE
Page 7C-2 90-827242R1 MAY 1998
Swivel Head and Steering Handle
1
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
2
6
95
95
95
95
95
4
95
2-4-C With Teflon (92-825407A12)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
2
6
TILLER HANDLE
90-827242R1 MAY 1998 Page 7C-3
Swivel Head and Steering Handle
REF.
TORQUE
REF .
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 SWIVEL HEAD (BLACK)
2 2 BUSHING
3 1 PLATE
4 1 GREASE FITTING
5 2 SCREW (M5 x 1 x 16) 70 7.9
6 2 WASHER
7 1 WAVE WASHER
8 1 WASHER
9 1 STEERING HANDLE ARM (BLACK)
10 1 RETAINER
11 1 SCREW (M5 x .8 x 16) 35 4.0
12 1 COVER KIT
13 1 PULLEY
14 1 PULLEY CASE
15 1 SCREW (10-16 x 1/2) 20 2.3
16 2 THROTTLE CABLE
17 1 SLEEVE
18 1 DECAL
19 1 GRIP
20 1 STOP SWITCH
21 1 THROTTLE FRICTION KNOB Finger Tight
22 1 THROTTLE FRICTION LOCK As Required
23 1 SCREW (M6 x 1 x 25)
24 1 THROTTLE HANDLE
25 1 TILLER TUBE
26 1 SPRING
27 1 START/STOP SWITCH
28 1
HOUSING ELECTRIC HANDLE
29 1 CLIP
TILLER HANDLE
Page 7C-4 90-827242R1 MAY 1998
Control Cables (Tiller Handle Shift Models)
Removal
1. Place tiller handle twist grip in NEUTRAL position
2. Remove throttle link rod from throttle cam and primary throttle lever.
53046
a
b
c
a
b
c
a- Link Rod
b- Throttle Cam
c- Primary Throttle Lever
3. Loosen jam nuts which secure control cables to anchor bracket.
4. Unwrap and remove control cables from pulley of secondary gear.
NOTE: If not replacing control cables, mark top cable with a piece of tape to aid in reassemb-
ly.
5. Disconnect stop button wires – BLACK/YELLOW and BLACK.
53157
c
53162
a
a
b
a
a
b
d
c
a- Jam Nuts
b- Secondary Gear
c- BLACK/YELLOW
d- BLACK
TILLER HANDLE
90-827242R1 MAY 1998 Page 7C-5
Throttle Cables (Side Shift Models)
Removal
1. Loosen jam nuts which secure throttle cables to anchor bracket and remove cables from
pulley of throttle cam.
NOTE: If not replacing throttle cables, mark top cable with a piece of tape to aid in reassemb-
ly.
53186
a
b
d
c
a
c
a
b
c
a
d
a- Jam Nuts
b- Throttle Cables
c- Anchor Bracket
d- Throttle Cam
2. Disconnect stop button wires – BLACK/YELLOW and BLACK.
53156
a
b
a
b
a- BLACK/YELLOW
b- BLACK
TILLER HANDLE
Page 7C-6 90-827242R1 MAY 1998
Tiller Handle Removal/Disassembly
Removal
1. Remove 2 bolts securing tiller handle to anchor bracket and remove tiller handle assem-
bly.
53155
a
a
a- Bolts
2. Remove bushing, flatwashers (2). wave washer and tiller handle washer. Remove re-
tainer and bolt.
3. Slide tiller tube out of pulley case.
53256
h
g
53248
a
b
c
b
d
e
f
g
h
a- Bushing
b- Flat Washer (2)
c- Wave Washer
d- Tiller Handle Washer
e- Retainer
f- Bolt
g- Tiller Tube
h- Pulley Case
TILLER HANDLE
90-827242R1 MAY 1998 Page 7C-7
4. Remove pulley case assembly from tiller handle and remove cover bolt.
5. Remove cover and lift pulley assembly from case. Replace cables as required.
53257
c
d
53262
a
b
a
b
c
d
a- Pulley Case Assembly
b- Cover Bolt
c- Cover
d- Pulley Assembly
Installation
1. Wrap cables around pulley. Top cable wraps and locks in top groove. Bottom cable
wraps and locks in bottom groove.
2. Place pulley and cable assembly into pulley case.
3. Install pulley cover and secure cover with bolt. Torque bolt to 20 lb. in. (2.3 N·m).
53262
d
e
53257
a
b
c
a
b
c
d
e
a- Pulley
b- Top Cable
c- Bottom Cable
d- Cover
e- Bolt [Torque to 20 lb. in. (2.3 N·m)]
4. Install pulley assembly into tiller handle and slide tiller tube into pulley.
53256
b
a a
b
a- Pulley Assembly
b- Tiller Tube
TILLER HANDLE
Page 7C-8 90-827242R1 MAY 1998
5. Secure tiller tube in handle with retainer and bolt. Torque bolt to 35 lb. in. (4.0 N·m).
6. Install tiller washer (tab aligns with slot in handle), plain washer, wave washer, plain
washer and flanged bushing over cable/harness assembly.
53248
d
e
d
e
h
f
g
f
c
a
b
a- Retainer
b- Bolt [Torque to 35 lb. in. (4.0 N·m)]
c- Tiller washer
d- Tab
e- Slot
f- Plain Washer
g- Wave Washer
h- Flanged Bushing
7. Slide tiller handle assembly into anchor bracket.
8. Route stop button harness through fuel connector opening in bottom cowl.
9. Route control cables through opening in bottom cowl.
10. Align tabs of inner and outer flanged bushings with slots in anchor bracket.
11. Pull on cable ends to remove slack and secure tiller handle to anchor bracket with plate
and 2 bolts. Torque bolts to 70 lb. in. (7.9 N·m).
53155
d
e
53169
c
a
b
a
b
c
d
e
a- Stop Button Harness
b- Control Cables
c- Tabs
d- Plate
e- Bolts [Torque to 70 lb. in. (7.9 N·m)]
TILLER HANDLE
90-827242R1 MAY 1998 Page 7C-9
Control Cables (Tiller Handle Shift Models)
Installation
1. Rotate tiller handle twist grip to REVERSE gear position.
2. Route extended cable over top of secondary gear pulley and secure cable into inner
groove of pulley. Place cable jacket into inner notch of cable anchor bracket.
53164
b
a
c
d
a
b
c
d
a- Extended Cable
b- Inner Groove
c- Cable Jacket
d- Inner Notch
3. Rotate tiller handle to FORWARD gear position.
4. Route remaining cable below secondary gear pulley and secure cable into outer groove
of pulley. Place cable jacket into lower notch of cable anchor bracket.
53165
c
d
a
b
a
b
c
d
a- Cable
b- Outer Groove
c- Cable Jacket
d- Lower Notch
TILLER HANDLE
Page 7C-10 90-827242R1 MAY 1998
5. Position tab washers to lock control cables to holes of cable anchor bracket.
a
b
b
a
a- Tab Washers
b- Hole
6. Rotate tiller handle twist grip to NEUTRAL.
7. Adjust jam nuts to remove slack from control cables while allowing full travel of throttle/
shift linkage.
53165
b
b a
a
a
a
b
b
a- Jam Nuts
b- Cables
8. After cables are adjusted, verify FORWARD, NEUTRAL and REVERSE gears can be
selected while smoothly advancing and retarding throttle. If throttle/shift operation is not
correct, inspect for pinched or kinked cables, misaligned linkage or loose attaching
bolts.
NOTE: It may be necessary to rotate propeller shaft in order to select REVERSE gear.
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Full Search Facility
Print one or all pages of your manual
$39.99
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