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Mercury 90 Operation Maintenance Installation Warranty Manual
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American Wire Gauge (AWG)
Maximum Length
Meter (Feet)
2
12.2 m (40 ft)
1
15.2 m (50 ft)
1/0
19.6 m (64 ft)
2/0
24.4 m (80 ft)
Single Outboard
a -
Red sleeve ‑ positive
(+)
b -
Black sleeve ‑
negative (–)
c -
Cranking battery
(+)
(-)
b
a
c
15496
OUTBOARD INSTALLATION
eng
123
132
134
Table of Contents
Table of Contents
7
Warranty Registration United States and Canada
11
Transfer of Warranty United States and Canada
11
Warranty Information
11
Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada
12
Year Limited Warranty against Corrosion
12
Warranty Coverage and Exclusions
15
U.S. EPA Emissions Limited Warranty
16
Emission Control System Components
16
California Emissions Limited Warranty
17
California Air Resources Board Explanation of Your California Emission Control Warranty Statement
20
Emission Certification Star Label
20
Warranty Policy-Australia and New Zealand
21
Global Warranty Charts Outboard and Jets
26
Boater's Responsibilities
31
Before Operating Your Outboard
31
Boat Horsepower Capacity
31
General Information
31
High-Speed and High-Performance Boat Operation
32
Outboard Remote Control Models
32
Remote Steering Notice
33
Outboard Mounting Notice
33
Propeller Selection
34
Lanyard Stop Switch
35
Protecting People in the Water
37
Passenger Safety Message - Pontoon Boats and Deck Boats
38
Wave and Wake Jumping
39
Impact with Underwater Hazards
40
Exhaust Emissions
41
Selecting Accessories for Your Outboard
43
Safe Boating Recommendations
43
Recording Serial Number
45
Specifications 75-115
46
Specifications 115 Pro XS
47
Component Identification
49
Transporting
50
Trailering Boat/Outboard
50
Fuel Recommendations
51
Fuel and Oil
51
Fuel Additives
52
Avoiding Fuel Flow Restriction
52
Quick Disconnect Fuel Hose Fitting
52
Low Permeation Fuel Hose Requirement
53
EPA Pressurized Portable Fuel Tank Requirements
53
Fuel Demand Valve (FDV) Requirement
54
Mercury Marine's Pressurized Portable Fuel Tank
54
Filling Fuel Tank
55
Engine Oil Recommendations
56
Checking and Adding Engine Oil
56
Remote Control Features
59
Warning System
59
Features and Controls
59
Power Trim and Tilt
61
Important Information
65
Operation
65
Operating in Freezing Temperatures
66
Operating in Saltwater or Polluted Water
66
Operating at High Elevations
66
Effects of Elevation and Weather on Performance
66
Setting Trim Angle While Running Engine at Idle Speed
67
Operating in Shallow Water
67
Engine Break-In Procedure
68
Starting the Engine
68
Gear Shifting
71
Stopping the Engine
71
Outboard Care
72
EPA Emissions Regulations
72
Inspection and Maintenance Schedule
73
Maintenance Schedule Decal (75-115)
76
Flushing the Cooling System
77
Top Cowl Removal and Installation
78
Cleaning Care for Top and Bottom Cowls
79
Flywheel Cover Removal and Installation
80
Cleaning Care for the Powerhead (Saltwater Use)
80
Battery Inspection
81
Fuel System
81
Corrosion Control Anode
83
Propeller Replacement
84
Spark Plug Inspection and Replacement
87
Fuse Replacement
89
Lubrication Points
90
Checking Power Trim Fluid
93
Changing Engine Oil
93
Gearcase Lubrication
96
Storage Preparation
98
Protecting External Outboard Components
98
Storage
98
Protecting Internal Engine Components
99
Gearcase
99
Positioning Outboard for Storage
99
Battery Storage
99
Starter Motor will Not Crank the Engine
100
Engine will Not Start
100
Engine Runs Erratically
100
Troubleshooting
100
Performance Loss
101
Battery will Not Hold Charge
101
Service Assistance
102
Owner Service Assistance
102
Ordering Literature
104
Mercury Marine Validated Engine Mounting Hardware
106
Accessories Mounted to the Transom Clamp Bracket
106
Outboard Installation
106
Important Information
110
Boat Horsepower Capacity
110
Start in Gear Protection
111
Selecting Accessories for Your Outboard
111
Fuel System
111
Installation Specifications
116
Determining Recommended Outboard Mounting Height
117
Drilling Outboard Mounting Holes
118
Lifting Outboard
119
Shipping Bracket Removal
120
Steering Cable - Starboard Side Routed Cable
121
Fastening the Outboard to the Transom
122
Steering Link Rod Fasteners (if Equipped)
127
Electrical, Fuel Hose, and Control Cables
129
Trim in Pin
140
Maintenance Log
141
Other manuals for Mercury 90
Service Manual
574 pages
User Manual
62 pages
Manual
32 pages
Operation Maintenance Warranty Installation Manual
159 pages
Operation And Maintenance Manual
96 pages
4
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Mercury 90 Specifications
General
Brand
Mercury
Model
90
Category
Outboard Motor
Language
English
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