1995–2002 Yamaha 9.9S / 15S Outboard Motor Service Manual (P/N LIT-18616-00-99)

This first-edition Yamaha Service Manual (P/N LIT-18616-00-99) covers the 1993–2002 9.9S and 15S outboards in the 6E7 and 6E8 model series. Coverage includes 9.9MH/9.9D, 9.9EH/9.9DE, 15MH/15D, and 15EH/15DE variants with manual and electric starting.

Navigation and wiring detail: Chapter and section bookmarks are available, but PDF text search is not. Small wire-color labels are readable when enlarged. The “Return to main index” bookmark points to a separate file outside this PDF.

• Power unit repair: Powerhead removal and reinstallation, cylinder and crankcase disassembly, piston and crankshaft inspection, reed-valve service, and recoil-starter rebuilding.

• Fuel system: Carburetor overhaul, diaphragm fuel-pump disassembly, fuel-joint pressure testing, float inspection and adjustment, and fuel-enrichment valve service.

• Lower unit and cooling: Water-pump and impeller replacement, dog-clutch and gear inspection, shim selection, backlash adjustment, gearcase pressure testing, and thermostat checks.

• Electrical diagnosis: C.D.I., charge-coil, and pulser-coil tests, starter-motor overhaul, charging-circuit checks, and wiring diagrams for different starting configurations.

• Controls and bracket unit: Throttle-link and start-in-gear protection adjustments, steering-handle repair, and clamp-bracket, swivel-bracket, and tilt-mechanism service.

• Service references: Periodic maintenance schedules, dimensional drawings, general and component-specific torque tables, fluid capacities, inspection limits, and electrical test specifications.

Written primarily for Yamaha dealers and their trained mechanics, this manual assumes an understanding of mechanical and electrical service procedures.

Carburetor Service and Control Adjustments

Carburetor exploded views identify the jets, needle valve, float, and fuel-pump diaphragms. The specification tables distinguish 9.9 and 15 HP carburetor calibrations and European variants. Fuel-enrichment solenoid testing applies to European electric-start models.

Illustrated ignition-timing adjustments accompany idle-speed and throttle-link procedures for tiller and remote controls. Neutral and reverse throttle-opening limits are covered separately.

Engine Inspection and Repair

The power-unit chapter covers internal inspection of the 246 cc two-stroke twin, including cylinder wear, piston clearance, ring gaps, crankshaft runout, and small-end bearings. Reed-valve stopper specifications and assembly details distinguish the 9.9 HP regional versions from the 15 HP engine.

Flywheel-removal notes explain how uneven puller loading can damage the engine or tools. The timing section warns that reverse flywheel rotation can distort the impeller blades and reduce water-pump performance.

Lower Unit and Bracket Repairs

Separate shim-selection sections cover U.S./Canadian and other-market procedures, with forward/reverse gear backlash measurement charts and pinion-height checks. Tool references include the YB-34232 pinion height gauge and YB-6265 backlash indicator.

The backlash guidance relates combined forward- and reverse-gear readings to pinion height, helping identify which adjustment needs attention after gear or housing replacement.

Bracket-unit procedures extend to the upper casing, bottom cowling, rubber mounts, pivot shaft, and steering-handle knee gears, with alignment references for reassembly.

Wiring, C.D.I. Testing, and Fault Tracing

Separate wiring diagrams cover manual-start models, electric-start models with regional differences, and the European 703 remote control box. Wire-color keys identify the connections for each configuration.

C.D.I. coverage consists of resistance and output tests with replacement criteria. The resistance-test instructions specify an analog meter. Starter-motor procedures cover brushes, armature, commutator, and pinion clutch.

Troubleshooting flowcharts address starting and rough-running complaints, power loss, misfires, gear shifting, and battery charging. The shifting charts distinguish tiller-operated and remote-control models.

Follow the manual’s fuel-handling and electrical-test precautions, including its warnings about fuel vapor and ignition sparks.

Printable PDF and Included Pages

One printable English-language PDF contains 170 pages total: 153 numbered chapter pages, 10 chapter contents pages, and seven preliminary pages comprising the cover, publication notice, four pages of reading instructions and symbols, and main index. These pages are all included in the total; no separate supplements are included.