Mercury Outboard Service and Repair Manual
This Clymer outboard shop manual covers Mercury 3-275 horsepower engines for the years 1990-1993.Models Included are:
MERCURY 100 HP
MERCURY 115 HP
MERCURY 135 HP
MERCURY 15 HP
MERCURY 150 HP
MERCURY 150XR4
MERCURY 150XR6
MERCURY 150XRi
MERCURY 175 HP
MERCURY 175XRi
MERCURY 20 HP
MERCURY 200 HP
MERCURY 200XRi
MERCURY 25 HP
MERCURY 250 HP
MERCURY 275 HP
MERCURY 3 HP
MERCURY 3.3 HP
MERCURY 4 HP
MERCURY 40 HP
MERCURY 5 HP
MERCURY 50 HP
MERCURY 60 HP
MERCURY 75 HP
MERCURY 8 HP
MERCURY 9.9 HP
MERCURY 90 HP
The Mercury outboard manual by Clymer is a great reference for repair and service information. This service manual is written for the do-it-yourselfer as well as the experienced mechanic. The repair manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the engine. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail. The shop manual will guide mechanics and owners through each service, troubleshooting and repair procedure possible.
The
Mercury outboard manual includes the following chapter information:
CHAPTER ONE | GENERAL INFORMATIONManual organization | Notes, cautions and warnings | Torque specifications | Engine operation | Fasteners | Lubricants | Gasket sealant | Galvanic corrosion | Protection from Galvanic corrosion | Propeller
CHAPTER TWO | TOOLS AND TECHNIQUESSafety first | Basic hand tools | Test equipment | Service hints | Special tips | Mechanic's techniques
CHAPTER THREE | TROUBLESHOOTINGOperating requirements | Starting system | Charging system | Ignition system | Breaker-point ignition troubleshooting (1990-1992 3 hp models) | Capacitor discharge ignition (CDI) | Direct voltage tests | Resistance test | Speed limiter | Spark advance|idle stabilizer module troubleshooting | Fuel system | Engine
CHAPTER FOUR | LUBRICATION, MAINTENANCE AND TUNE-UPLubrication | Storage | Anti-corrosion maintenance | Complete submersion | Flushing the cooling system | Tune-up
CHAPTER FIVE | TIMING, SYNCHRONIZING AND ADJUSTINGIgnition timing and synchronization | 3 hp models | 3 and 5 hp models | 8, 9.9 and 15 hp models | 20 and 25 hp models | 40 hp models | 50 and 60 hp models (prior to serial No. D000750) | 50 and 60 hp models (serial No. D000750-on) | 75 and 90 hp models | 100 and 115 hp models | 135-200 hp (except EFI) models | 250 and 275 hp models | 150Xri, 175Xri and 200Xri (EFI) models
CHAPTER SIX | FUEL SYSTEMFuel pump | Carburetors | Throttle plunger carburetor (3 and 3.3 hp models) | Integral fuel pump carburetor (4 and 5 hp models) | Integral fuel pump carburetor (8-25 hp models) | WMA carburetor (40 hp models) | MerCarb center bowl carburetor (50 and 50 hp models prior to serial No. D000750) | WME carburetor (50 and 60 hp serial No. D000750-on, 75, 90, 100 and 115 hp models) | WMH carburetor (135-200 hp models) | MerCarb center bowl carburetor (250 and 275 hp models) | Thermal air valve (135-200 hp models) | Enrichment valve and choke solenoid systems | Anti-siphon devices | Fuel filter | Fuel tank | Fuel hose and primer bulb | Electronic fuel injection (EFI) | Fuel management tests
CHAPTER SEVEN | IGNITION AND ELECTRICAL SYSTEMSBattery | Battery charging system | Starting system | Magneto breaker point ignition | Capacitor discharge ignition (CDI) (1993 3.3 hp models) | Capacitor discharge ignition (CDI) (4-275 hp models)
CHAPTER EIGHT | POWER HEADEngine serial number | Gaskets and sealants | Fasteners and torque | Power head
CHAPTER NINE | LOWER UNIT GEAR HOUSINGService precautions | Gear housing | Water pump | Bearing carrier and propeller shaft | Pinion gear, drive shaft and forward gear | Lower shift shaft, bushing and cam | Pinion depth|gear backlash | Propeller | Trim tab adjustment
CHAPTER TEN | POWER TRIM AND TILT SYSTEMManual tilt assist system | One-ram integral power trim system (40-60 hp models) | Three-ram integral power trim system (75-200 hp models) | One-ram oildyne power trim system (250-275 hp models) | Power trim assembly removal|installation | Power trim motor and pump assembly removal|installation
CHAPTER ELEVEN | OIL INJECTION SYSTEMAutoblend II (50 and 60 hp prior to serial No. D000750) | Constant ratio oil injection (40 hp and 50-60 [serial No. D000750-on] hp models) | Injection system service | Variable-ratio oil injection (75-115 hp models) | Warning horn system | Injection system service | Variable-ratio oil injection (V6 models) | Warning hose system | Injection system service
CHAPTER TWELVE | MANUAL REWIND STARTERS3 and 3.3 hp models | 4 and 5 hp models | 8, 9.9, 15, 20 and 25 hp models | 40 hp models
INDEXWIRING DIAGRAMS
Publisher: Clymer Manuals — 1993
Binding: Paperback — 8¼ x 10¾ inches
Pages: 620 — Hundreds of b&w photos and illustrations
ISBN: 9780892875689
The Mercury outboard service and repair manual applies to the following years:1990, 1991, 1992, 1993
