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90
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Mercury 90 - Special Tools
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Manual
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90-830234R3
DECEMBER 1997
ELECTRICAL
- 2A-1
Special T
ools
1.
Flywheel Holder 91-52344
2.
Flywheel Puller 91-73687A1
3.
V
olt/Ohm/DV
A Meter 91-99750
4.
Spark Gap T
ester 91-63998A1
5.
CDM T
est Harness 84-825207A2
38
40
Table of Contents
Main Page
Important 1 C
14
Propeller Information
3
How to Use this Manual
3
Table of Contents
14
Serial Number Location
15
Conditions Affecting Performance
15
Weather
15
Boat
16
Engine
16
Fresh Water Submersion
17
Following Complete Submersion
17
Salt Water Submersion
17
Submerged While Running
17
Propeller Selection
18
Propeller Installation
18
Power Trim System
19
General Information
19
Power Trim Operation
19
Trim "In" Angle Adjustment
20
Compression Check
20
Painting Procedures
21
Cleaning & Painting Aluminum Propellers & Gear Housings
21
Decal Application
22
Decal Removal
22
Instructions for "Wet" Application
22
Important 1 D
24
Boat Horsepower Capacity
25
Notice to Installer and Owner
25
Outboard Remote Control
25
Selecting Accessories for the Outboard
25
Selecting Steering Cables and Remote Control Cables
25
Drilling Outboard Mounting Holes
27
Locate Center Line of the Outboard
27
Lifting Outboard
28
Installing Ride Guide Steering Cable to the Outboard
29
Single Steering Cable and Steering Link Rod Installation
29
Steering Link Rod Installation
29
Co-Pilot Installation (Tiller Handle Models)
30
Boats Equipped with Panel or Console Mount Remote Control
31
Boats Equipped with Side Mount Remote Control
31
Remote Control Installation
31
Required Side Mount Remote Control or Ignition Key Switch Assembly
31
Shift and Throttle Cable Installation to the Outboard 1D-8
31
Shift Cable Installation
31
Throttle Cable Installation
32
Battery Connections
34
Set up Instructions for Oil Injection System
34
Bleeding Air from the Oil Injection System
35
Filling the Oil Injection System
35
Adjusting the Oil Injection Pump
36
Trim Tab Adjustment
36
Electrical 2
38
Special Tools
39
Cylinder Electrical Components (USA-0G127499/BEL-9836632 & BELOW)
40
Electrical Components (USA-0G127500 Thru 0G437999)(BEL-9836633 Thru 9926999)
42
Cylinder Electrical Components (USA-S/N-0G438000/BEL-9937000 & UP)
44
Cylinder Electrical Components (S/N-USA-437999/BEL-9926999 & BELOW)
46
Cylinder Electrical Components (USA-S/N-0G438000/BEL-9937000 & UP)
48
Description
50
Direct Voltage Adapter (DVA) Tests
50
Test Procedures
50
Test Sequence
51
Belgium-09793577 Thru 09879064
52
Cylinder Stators
52
Cylinder with 16 Ampere Stator 398-9710A31 USA-0D283222 Thru 0G301750 Belgium-09793577 Thru 09885527
52
Ignition System DVA Specifications Test Chart
52
Manual with 9 Ampere Stator 398-9873A20
52
Cylinder Stators
53
Cylinder with 16 Ampere Stator 398-9710A33 USA-0G301751 and above Belgium - 09885528 Thru 09916721
53
Manual with 9 Ampere Stator 398-9873A21
53
ADI Ignition Using a RED Stator with an Adapter Module
55
Electric Start Engines
56
Manual Start Engines
56
RED Stator DVA Test
56
RED Stator with Adaptor and Ignition Coils
56
Troubleshooting Procedures
56
Theory of Operation
57
Capacitor Charging #1 CDM
58
Capacitor Charging #2 & #3 CDM
59
Cylinder Trigger Circuit
60
Ignition Coil Circuit
61
Stop Circuit
62
Rev Limiter Circuit
63
Ignition Component Description
64
RED Stator with CDM
64
CDM (P/N 827509)
65
CDM Test Harness 84-825207A2
65
Spark Gap Tester P/N 91-850439
65
Direct Voltage Adaptor (DVA) Test
70
Resistance Tests
72
Flywheel Removal and Installation
73
Ignition (Key) Switch Test
73
Stator Removal and Installation
74
Trigger Removal and Installation
77
Ignition Coil Removal and Installation
79
Switch Box Removal and Installation
80
Electrical 2
82
Specifications
83
Battery
84
Operating Engine Without Battery
84
Precautions
84
Special Tools
84
Specific Gravity Readings
84
Charging a Discharged Battery
85
Electrolyte Level
85
BLACK Stator Battery Charging System Troubleshooting
86
Winter Storage of Batteries
86
Ampere (Manual Start) BLACK Stator Output Test
87
BLACK Stator 14 and 16 Ampere Alternator System Test
87
BLACK Stator Ohms Test (Alternator Coils Only)
87
RED Stator Battery Charging System Troubleshooting
88
Tachometer Terminal Block
88
Cylinder 14 and 16 Ampere BLACK Stator Battery Charging Wiring Diagram
91
Cylinder 14 and 16 Ampere BLACK Stator Battery Charging Wiring Diagram
92
Cylinder Battery Charging Diagram (with BLACK STATOR) with Battery Isolator
93
Cylinder Battery Charging Diagram (with RED STATOR) with Battery Isolator
94
Cylinder Battery Charging Diagram (with BLACK Stator) with Battery Isolator
95
Cylinder Battery Charging Diagram (with RED Stator) with Battery Isolator
96
Rectifier Test
97
Description
98
Starting System
98
Starting System Components
98
Troubleshooting the Starting Circuit
98
Starting Circuit Troubleshooting Flow Chart
99
Disassembly
101
Removal
101
Starter Motor
101
Starter Cleaning, Inspection and Testing
102
Testing
102
Brush Replacement
104
Electrical 2
109
Special Tools
110
Specifications
110
Timing/Synchronizing/Adjusting (3 Cylinder Models)
110
Special Tools
114
Specifications
114
Throttle Cable Installation
114
Timing/Synchronizing/Adjusting (4 Cylinder Models)
114
Idle Adjustment
118
Throttle Cable Installation
118
Electrical 2
120
1994/1995 65 Jet Wiring Diagram Electric (1-3-2 Firing Order)
121
65 Jet Wiring Diagram Electric (1-2-3 Firing Order)
122
1994/1995 75/90 Wiring Diagram (1-3-2 Firing Order)
123
75/90 Wiring Diagram (1-2-3 Firing Order)
124
75 Work Model Wiring Diagram Manual Start (1-2-3 Firing Order)
126
1994/1995/1996 80 Jet/100/115/125 Wiring Diagram
127
65 Jet Wiring Diagram (W/CDM) (1-2-3 Firing Order)
128
75/90 Wiring Diagram (W/CDM) (1-2-3 Firing Order)
130
80 Jet/100/115/125 Wiring Diagram (W/CDM)
131
1998 65 Jet Wiring Diagram
132
1998 75 Work Model Wiring Diagram
133
75 Electric Start Tiller Handle W/Power Trim Wiring Diagram
134
1998 75/90 Electric Start Wiring Diagram
135
1998 75/90 Electric Start W/Power Trim Wiring Diagram
136
1998 80 Jet/100/115/125 Wiring Diagram
137
Power Trim System Wiring Diagram (3 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control)
138
Power Trim System Wiring Diagram (3 Cylinder Models Using COMMANDER Side Mount Remote Control)
139
Power Trim System Wiring Diagram (4 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control)
139
Tachometer (with Adjustable Dial) and Trim Indicator Gauge Wiring Diagram
141
COMMANDER 2000 Side Mount Remote Control
142
Key/Choke Switch Continuity Test (COMMANDER 2000 Side Mount Remote Control)
142
Warning Horn) Wiring Diagram
143
COMMANDER 2000 Side Mount Remote Control
144
COMMANDER 2000 Side Mount Remote Control (Electric Start with Warning Horn) Wiring Diagram
144
Fuel System
147
Notes
148
Jet 75-90 (3 Cyl.)
149
Jet-100-115-125 (4 Cyl.)
150
Fuel Pump (65 Jet/75/90)
151
Fuel Pump (80 Jet/100/115/125)
155
Testing
157
Theory of Operation
157
Troubleshooting Fuel Pump
157
Check Valve Reassembly
158
Fuel Pump - Cleaning/Inspection
158
Removal
158
Reassembly
159
Installation of Fuel Pump
160
Fuel System
162
Specifications
163
WME Carburetor Chart
163
Special Tools
165
Carburetor (WME-29/30/31/41/46/47/48/49)
166
Carburetor-WME-32/32A/33/34/40/40A
172
Carburetor-WME-50/51/52/79/80/81
174
Fuel System (Linkage)
178
Adjustments
179
Float Adjustment
179
Idle Mixture Screw Adjustment
179
Idle Speed Adjustment
179
Jet Orifice Size Chart
180
Main (High Speed) Jet Adjustment
180
High Altitude Jet Chart
181
Fuel System Troubleshooting
182
General Information
182
Problem: Engine Floods
182
Problem: Engine Runs too Rich
182
Problem: Fuel Blow Back out of Carburetor
182
Problem: Rough Idle
182
Problem: Engine Turns over but will Not Start or Starts Hard When Cold
183
Problem: Unable to Reduce Engine RPM to Slow Idle
183
Engine Idles Rough and Stalls -Engine Runs Uneven or Surges -Engine will Not Accelerate
184
Problem: Engine Runs too Lean
184
Problems
184
Inspection
185
Description for Four Cylinder Engines
186
Description for Three Cylinder Engines
186
Enrichener System
186
Enrichener Valve Hose Installation - Four Cylinder Engines
186
Enrichener Valve Hose Installation - Three Cylinder Engines
186
Acceleration Pump Circuit Operation - Four Cylinder Engines
188
Four Cylinder Engines
188
Fuel System
191
Notes
192
Oil Injection Components
193
Oil Injection Components (S/N-USA-0G301751/BEL-9885505
193
Description
197
Hose Connections
197
Oil Pump Drive System
197
And 4 Cylinder Oil Flow Diagram
198
Carburetor/Oil Pump Synchronization
199
Filling Oil Tank
199
Bleeding Air from Oil Injection System
200
Bleeding Air from Oil Pump Inlet Hose
200
Bleeding Air from Oil Pump Outlet Hose
200
Oil Pump Test
200
Low Oil Sensor Test
201
Warning Horn System
201
(Models with Warning Module)
202
Oil Injection System Troubleshooting Chart
202
Troubleshooting Chart
202
Troubleshooting the Oil Injection System
202
Table of Contents
204
Carbon Monoxide - CO
205
Controlling Emissions
205
Exhaust Emissions Standards
205
Hydrocarbons - HC
205
Oxides of Nitrogen - Nox
205
Stoichiometric (14.7:1) Air/Fuel Ratio
205
What Are Emissions
205
Outboard Hydrocarbon Emissions Reductions
206
Homogenized Charge
207
Stratified Charge
207
Stratified Vs Homogenized Charge
207
Dealer Responsibility
208
Emissions Information
208
EPA Emission Regulations
208
Manufacturer's Responsibility
208
Owner Responsibility
208
Decal Location for 1998 Models
210
Powerhead
212
Specifications
213
General Information
214
Tools for Powerhead Repair
214
Notes
215
Crankshaft, Pistons and Connecting Rods (3 Cyl.)
216
Cylinder Block (3 Cyl.) (USA-0G127499/BEL-9836632 & BELOW)
218
Cylinder Block (3 Cyl.) (USA-0G127500/BEL-9836633 & UP)
222
Induction Manifold and Reed Block (3 Cyl.)
226
Crankshaft, Pistons and Connecting Rods (4 Cyl.)
228
Cylinder Block and Crankcase (80 Jet/100/115/125)
230
Induction Manifold and Reed Block (80 Jet/100/115/125)
234
Throttle Lever and Linkage (65 Jet/75/90 Models)
236
Throttle Lever (Models 80Jet/100/115/125)
238
Powerhead Removal
241
Flywheel Removal
246
Powerhead Disassembly
247
Cleaning and Inspection
252
Cylinder Block and Crankcase Cover
252
Check Valves
254
Piston and Piston Rings
254
Connecting Rods
256
Crankshaft
256
Cylinder Cover, Exhaust Divider Plate and Exhaust Cover
257
Thermostat
257
Reed Blocks
258
Temperature Switch Test
258
General Information
259
Powerhead Reassembly and Installation
259
Assembling Rod to Piston
260
End Cap
260
Piston Ring Installation
261
Crankshaft Installation
263
Connecting Rod Cap Alignment
266
Crankcase Cover to Block
267
Cylinder Block Cover
268
Exhaust Plate Cover and Exhaust Divider Plate
269
Intake Manifold and Reed Block Installation
271
Accelerator Pump Installation (4 Cylinder Models)
272
Cylinder Bleed Hose Routing
273
Cylinder Bleed Hose Routing (1995 and Prior)
274
Cylinder Bleed Hose Routing (1996 and Newer)
275
Cylinder Fuel Enrichment/Accelerator Pump Hose Routing
276
And Newer 3 Cylinder Harness Routing (Without Oil Reservoir Installed)
277
And Newer 3 Cylinder Harness Routing (with Oil Reservoir Installed)
278
Cylinder Manual Start Harness Routing
279
And Newer 4 Cylinder Harness Routing
281
And Newer 4 Cylinder Harness Routing (with Oil Reservoir Installed)
281
Ignition Plate Installation
282
Trigger and Stator Installation
283
Stator Installation
284
Carburetor Installation
286
Temperature Sensor Installation
286
Flywheel Installation
288
Oil Reservoir Installation
288
Air Box Installation
289
Powerhead to Driveshaft Housing
290
Reinstall Bottom Cowl
291
MID-Section
293
Swivel Bracket and Steering Arm (65 Jet/75/90)
295
Transom Bracket(Non Power Trim & Power Trim) (65 Jet/75/90)
297
Transom Bracket (Manual Tilt Assist) (65 Jet/75/90)
299
Swivel Bracket and Steering Arm (80 Jet/100/115/125)
301
Transom Bracket (S/N-USA-0G589999/BEL-9973099 & BELOW)
303
Transom Bracket (S/N-USA-0G590000/ BEL-9973100 & UP)
303
Exhaust Plate (65 Jet/75/90)
307
Exhaust Plate (80 Jet/100/115/125)
309
Drive Shaft Housing (65 Jet/75/90)
311
Drive Shaft Housing (80 Jet/100/115/125)
313
Reference Views
315
MID-Section
318
Special Tools
319
Power Trim Components (Black Fill Plug) (S/N-USA-0G360002/BEL-9934136 & BELOW)
320
Description
322
Power Trim - General Information
322
Trailering Outboard
322
Trimming Characteristics
322
Tilting Outboard up and down Manually
323
Trim "In" Angle Adjustment
323
Determining if Problem Is Electrical or Hydraulic 5B-6
324
Problem Chart
324
Troubleshooting
324
Date Code Location
325
Hydraulic System Troubleshooting
325
Leak down Check - Pump and Manifold Assembly
326
Preliminary Checks
326
Reassembly
327
Power Trim Partial Leak down at Maximum Trim
328
Leak down Check - Manual Release Valve
329
Leak down Check - Pilot Valve Assembly
329
Leaks Past Ball and Seat - Piston Assembly
329
Power Trim Rocker Arm
330
Troubleshooting Flow Diagram
331
Troubleshooting Flow Diagram
332
COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
333
Electrical System Troubleshooting
333
Power Trim System Wiring Diagram
334
Troubleshooting the "Down" Circuit
335
Troubleshooting the "Up" Circuit
335
Troubleshooting the "Down" and "Up" Circuits* (All Circuits Inoperative)
336
Power Trim System Removal
337
Power Trim System Disassembly
342
Trim Rod Removal
342
Trim Rod Disassembly
343
Trim Motor Removal
344
Reservoir Assembly Removal
345
Trim Motor Disassembly
345
Manifold Removal
346
Motor and Electrical Tests/Repair
347
Solenoid Test
347
Trim Pump Motor Test
347
Armature Tests
348
Motor Disassembly
348
Motor Repair
349
Manifold Installation
351
Power Trim System Reassembly
351
Reassembly
351
Reservoir Installation
352
Motor Installation
353
Trim Rod Reassembly
354
Trim Rod Installation
355
Power Trim Unit Installation
356
Purging Power Trim Unit
356
MID-Section
360
Special Tools
361
Power Trim Components (Yellow Fill Plug)
362
Description
363
Power Trim Flow Diagrams - Trim up Circuit
366
Tilt Circuit
368
Maximum Tilt
370
Down Circuit
372
Shock Function up
374
Shock Function Return
376
Manual Release
378
Adjustments
380
Trimming Characteristics
380
Tilting Outboard up and down Manually
381
Trailering Outboard
381
Preliminary Checks
382
Troubleshooting
382
Hydraulic System Troubleshooting Flow Chart
383
Troubleshooting the Power Trim Electrical System
387
Power Trim System Removal
389
Power Trim Disassembly
390
Pump and Components Removal
391
Trim Motor Removal
391
Manifold Removal
392
Shock Rod Removal
392
Shock Rod Disassembly
393
Memory Piston Removal
395
Cleaning/Inspection/Repair
396
Trim Motor Electrical Tests
396
O-Ring and Seal Placement
397
Reassembly
397
O-Ring Sizes
398
O-Ring Description and Sizes
399
Power Trim Reassembly
400
Shock Rod Reassembly
400
Shock Rod Installation
401
Manifold Installation
402
Manual Release Valve Installation
402
Trim Limit Assembly Installation
402
Oil Pump Installation
403
Pressure Operated Assembly Installation
404
Reservoir/Motor Installation
404
Bleeding Power Trim Unit
405
Installation of Power Trim System
405
MID-Section
414
Special Tools
415
Manual Tilt Assist Components
416
Manual Trim Flow Diagrams - up Circuit
418
Tilt up
419
Down Circuit
420
Tilt down
421
Slow Tilt down under High Thrust
422
Slow Tilt down under High Thrust
423
Under Water Strike (Valves Open)
424
Under Water Strike with Valves Open
425
Shock Function (Valve Closed)
426
Shock Function with Valves Closed
427
Shock Function Return
428
Shock Function Return
429
Hydraulic System Troubleshooting
430
Manual Tilt System Removal
431
Accumulator Removal
432
Manual Tilt System Disassembly
432
Shock Rod Removal
433
Shock Rod Disassembly
434
Memory Piston Removal
436
Valve Block Removal
436
Valve Block Disassembly
437
Reassembly - O-Ring and Seal Placement
438
Actual O-Ring Sizes
439
O-Ring Description and Sizes
440
Manual Tilt System Cleaning and Inspection
441
Manual Tilt System Reassembly
441
Valve Block Installation
442
Shock Rod Reassembly
443
Shock Rod Installation and Fluid Filling Procedure
444
Filling Procedure Option Two Instructions for Making Retaining Tool
446
Bleeding Manual Tilt System
447
Manual Tilt System Installation
449
Manual Release Valve Adjustment
450
Lower Unit
452
Specifications
453
Lower Unit - 6A
453
Special Tools
454
Gear Housing (Drive Shaft)
456
Gear Housing (Propeller Shaft)
458
Disassembly
460
Draining and Inspecting Gear Housing
460
Gear Case Identification
460
Removal
460
Water Pump
461
Bearing Carrier and Propeller Shaft
463
Pinion Gear, Drive Shaft, and Forward Gear
465
Oil Sleeve
467
Upper Drive Shaft Bearing
467
Lower Drive Shaft Bearing Race
468
Shift Shaft
468
Forward Gear Bearing Race
469
Trim Tab Adjustment and Replacement
469
Forward Gear Bearing Race
470
Reassembly
470
Shift Shaft
470
Bearing Carrier Reassembly
471
Forward Gear Reassembly
473
Propeller Shaft Reassembly
474
Drive Shaft Wear Sleeve Installation
475
Lower Drive Shaft Bearing Race Installation
476
Oil Sleeve Installation
476
Upper Drive Shaft Bearing Installation
476
Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation
477
Pinion Gear Depth and Forward Gear Backlash
478
Bearing Carrier and Propeller Shaft Installation
482
Water Pump Reassembly and Installation
483
Filling Gear Housing with Lubricant
485
Gear Housing Pressure Test
485
Gearcase Installation
486
Trim Tab Adjustment
488
Lower Unit
490
Jet Drive (3 Cylinder)
492
Jet Pump Assembly
493
Jet Drive (4 Cylinder)
494
Jet Water Pump Components
496
Engine Horsepower Selection
497
Selecting a Boat that Is Best Suited for Jet Power
497
Locate Centerline of the Outboard
498
Outboard Mounting Height
498
Transom Height of the Boat
498
Checking for Cavitation
499
Water Testing
499
Shift Cable Installation
500
Impeller Removal and Installation
501
Lubricating the Drive Shaft Bearing
501
Flushing the Cooling System
503
Impeller Clearance Adjustment
503
Steering Pull Adjustment
503
Worn (Dull) Impeller
503
Jet Drive Removal
504
Liner Replacement
504
Bearing Carrier Removal
505
Bearing Carrier Disassembly
506
Bearing Carrier Reassembly
507
Installing Lower Seals
507
Installing Upper Seals
507
Installing Drive Shaft
508
Installing Drive Shaft Ball Bearings
508
Bearing Carrier Installation
509
Installing Upper Seal Housing
509
Jet Drive Installation
510
Reassembling Water Pump to Jet Drive
510
Installing Jet Drive to Drive Shaft Housing
511
Attachments/ Control Linkage
514
Steering Cable and Steering Link Rod Installation
515
Cable Routing Types
516
Installation and Maintenance
516
Ride-Guide Attachment - Dual Front Installation (92876A2)
516
Installing Steering Cables and Steering Link Rods to Engines
517
Parallel Routed Steering Cables and Attaching Kit Installation
517
Super Ride-Guide Steering Kit Installation
517
Steering Eyes and Coupler Installation
519
Steering System Tension Adjustment (Parallel Routed Steering Cables)
520
Installing Steering Cables and Steering Link Rods to Engines
522
Opposite Side Routed Steering Cables and Attaching Kit Installation
522
Super Ride-Guide Steering Kit Installation
522
Steering Eyes and Coupler Installation
524
Steering System Tension Adjustment
526
Maintenance Instructions
527
Trim Tab Installation
527
Attaching Kit Installation
528
Extension Couplers
528
Ride Guide Steering Attachment
528
Transom Mounted Ride-Guide Attaching Kit Installation (73770A1)
528
Maintenance Instructions
530
Dual Cable - Single Outboard
531
Ride-Guide Steering Cable/Attaching Kit Installation (92876A3)
531
Super Ride-Guide Steering Kit Installation
531
Mounting Bracket Installation
532
Steering Cable Mounting Tube Installation
532
Installing Steering Cables
533
Coupler Installation
534
Installing Link Rod
534
Maintenance Instructions
536
Remote Control Installation
536
Boats Equipped with Panel or Console Mount Remote Control
537
Boats Equipped with Side Mount Remote Control
537
Connecting Remote Wiring Harness to the Engine
537
Required Side Mount Remote Control or Ignition Key Switch Assembly
537
Shift and Throttle Cable Installation to the Outboard
538
Shift Cable Installation
538
Throttle Cable Installation
539
Determining Recommended Outboard Mounting Height
540
Installing Outboard Motor on Transom
540
Locate Centerline of Boat Transom
540
Drilling Outboard Mounting Holes
541
Installing Engine to Transom
541
Lifting Engine
541
Steering Handle Components
546
Co-Pilot
550
Tiller Arm/Shift Lever Removal
551
Tiller Handle Disassembly
554
Tiller Arm Reassembly
557
Tiller Handle/Shaft Bracket Installation
560
Shift Link Rod Installation and Adjustment to Engine
564
Co-Pilot Installation
565
Manual Starter
567
Throttle Cable Installation and Adjustment to Engine
565
Notes
569
Starter Assembly (Manual)
570
Rewind Starter Disassembly
572
Cleaning and Inspection
573
Rewind Starter Reassembly
573
Adjusting Rewind Spring Tension
574
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