Mercury 90 US 100 EU Four Stroke EFI Factory Service Repair Manual

Mercury 90 US 100 EU Four Stroke EFI Factory Service Repair Manual

Models Covered :
Mercury 90 US
Mercury 100 EU

Manual Covers :

• Master Specifications :
• Table of Contents
• General Specifications
• Fuel System Specifications
• Ignition Specifications
• Charging and Starting Specifications
• Cylinder Block/Crankcase Specifications
• Cylinder Head Specifications
• Oil System Specifications
• Mid-Section Specifications
• Power Trim Specifications
• Gear Housing Specifications
• Hydraulic Steering Specifications
• 75 80 EU EFI Four Stroke Propeller Information Chart
• 90 100 EU EFI Four Stroke Propeller Information Chart
• 115 EFI Four Stroke Propeller Information Chart
• Maintenance :
• EPA Emissions
• Inspection and Maintenance Schedule
• Corrosion Control Anode
• Battery Inspection
• Alternator Drive Belt Inspection
• Flushing the Cooling System
• Top Cowl Removal and Installation
• Flywheel Cover Removal and Installation
• Cleaning Care for Top and Bottom Cowls
• Cleaning Care for the Powerhead
• Air Filter
• Fuel System
• Checking Power Trim Fluid
• Checking Engine Oil Level
• Changing Engine Oil
• Spark Plug Inspection and Replacement
• Fuse Replacement
• Propeller Replacement
• Lubrication Points
• Gearcase Lubrication
• Storage
• General Information :
• Serial Number Location
• Powerhead Front View
• Powerhead Starboard View
• Powerhead Port View
• Powerhead Aft View
• Conditions Affecting Performance
• Following Complete Engine Submersion
• Fuel and Oil
• Warning System
• Power Trim and Tilt
• Compression Check
• Cylinder Leakage Testing
• Painting Procedures
• Decal Removal
• Decal Application
• Outboard Motor Installation :
• Important Information
• Boat Horsepower Capacity
• Start in Gear Protection
• Selecting Accessories for your Outboard
• Fuel Tanks
• Filling the Fuel System
• Installation Specifications
• Lifting Outboard
• Steering Cable- Starboard Side Routed Cable
• Steering Link Rod Fasteners
• Determining Recommended Outboard Mounting
• Height
• Drilling Outboard Mounting Holes
• Fastening the Outboard to the Transom
• Electrical, Fuel Hose, and Control Cables
• Trim in Pin
• Ignition :
• Ignition Specifications
• Electrical Components
• Electrical Plate Components
• Cylinder Head and Camshaft Components
• Integrated Air Fuel Module Components
• Troubleshooting without a Computer Diagnostic System
• Troubleshooting with a Computer Diagnostic System
• Troubleshooting Guide
• Flywheel
• Electronic Control Module
• Wire Color Code Abbreviations
• Main Power Rely
• Ignition Pencil Coil
• Crankshaft Position Sensor
• Camshaft Position Sensor
• Throttle Position Sensor
• Cylinder Block Coolant Temperature Sensor
• Manifold Absolute Pressure Sensor
• Manifold Intake Air Temperature Sensor
• Oil Pressure Sensor
• Charging and Starting System :
• Charging and Starting Specifications
• Alternator/Starboard Cylinder Block Components
• Electrical Components
• Electrical Plate Components
• Starter Motor
• Battery
• Wire Harness Replacement
• Alternator System
• Starter System
• Timing, Synchronizing and Adjusting :
• Ignition Specifications
• Idle Timing Adjustment
• Maximum Timing Adjustment
• Throttle Cable Adjustment
• Theory of Operation :
• Air Induction System
• Fuel Injection System
• Air Induction and Fuel Injection System
• Troubleshooting and Diagnostics :
• Fuel System Specifications
• Troubleshooting with the Computer Diagnostic System
• Troubleshooting without a Computer Diagnostic System
• Guardian Protection System
• Fuel System Component Troubleshooting and Diagnostics
• Fuel System :
• Fuel System Specifications
• Fuel System Module Components
• Integrated Air Fuel Module
• Integrated Air Fuel Module Components
• Fuel System Module Mount Components
• Fuel System Module Mount Components
• Fuel System Module Hoses
• Throttle Position Sensor Removal and Installation
• Idle Air Control Removal and Installation
• Vent Canister Purge Valve Removal and Installation
• Vent Canister Switch Removal and Installation
• Fuel Rail
• Intake Manifold
• Fuel System Module
• Emissions :
• Exhaust Emission Standards
• Outboard Hydrocarbon Emissions Reduction
• Manufacturers Certification Label
• Service Replacement EPA Decal
• Powerhead :
• Cylinder Block/Crankcase Specifications
• Cylinder Block Components
• Crankshaft, Piston and Connecting Rod Components
• Lower Cowl Removal
• Powerhead Removal
• Removing Powerhead Components
• Powerhead Disassembly
• Cleaning, Inspection and Repair
• Powerhead Reassembly
• Installing Powerhead Components
• Powerhead Installation
• Lower Cowl Installation
• Engine Break-in Procedure
• Cylinder Head :
• Cylinder Head Specifications
• Cylinder Head and Camshaft Components
• Cylinder Head Disassembly
• Cleaning/Inspection/Repair
• Cylinder Head Reassembly
• Valve Clearance and Adjustments
• Lubrication :
• Oil System Specifications
• Oil Pump Components
• Engine Guardian System
• Oil Pump
• Mid-Section :
• Mid-Section Specifications
• Swivel Bracket and Steering Arm Components
• Transom Bracket Components
• Adapter Plate Components
• Oil Pump Components
• Driveshaft Housing Components
• Bottom Cowl Components
• Bottom Cowl Removal and Installation
• Lower Mount
• Adapter Plate and Driveshaft Housing Removal
• Transom/Swivel Bracket
• Adapter Plate and Driveshaft Housing Reassembly
• Shift Shaft Installation
• Power Trim :
• Power Trim Specifications
• Power Trim Components
• Power Trim General Information
• Wire Color Code Abbreviations
• Power Trim Flow Diagrams
• Troubleshooting
• Testing the Power Trim System with Test Gauge Kit
• Power Trim System Removal
• Power Trim Disassembly
• Shock Rod Disassembly
• Memory Piston Removal
• Power Trim Cleaning, Inspection and Repair
• Power Trim Assembly
• Power Trim System Installation
• Lower Unit :
• Gear Housing Specifications
• Gear Housing EZ Shift Components
• Gear Housing EZ Shift Components
• General Service Recommendations
• Draining and Inspecting Gear Housing Lubricant
• Gear Housing Removal
• Gear Housing Disassembly
• Gear Housing Assembly
• Gearcase Installation
• Filling Gear Housing with Lubricant
• Trim Tab Adjustment and Replacement
• Attachments :
• Throttle Bracket Assembly Components
• Shift Assembly Components
• Throttle Lever Bracket Removal and Installation
• Shift Bracket Removal and Installation
• Tiller Handle :
• Tiller Handle Assembly
• Steering Handle Components
• Tiller Handle Bracket Components
• Tiller Handle Switch Replacement
• Tiller Handle Removal
• Tiller Handle Disassembly
• Tiller Handle Reassembly
• Tiller Handle Installation Instructions
• Hydraulic Steering :
• Hydraulic Steering Specifications
• Hydraulic Steering Helm Fill Plug Configuration
• Steering System Hydraulic Fittings Torque Specifications
• Steering Cylinder Components
• Hydraulic Steering Systems
• Steering Cylinder
• Steering Cylinder Removal
• Steering Cylinder Installation

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English
Format: PDF

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