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This printed and bound paper 1990 1991 1992 1993 Mercury 3-275hp Outboard Boat Engine Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1990-1993 Mercury 3-275hp outboard boat engines including 3 hp, 3.3 hp, 4 hp, 5 hp, 8 hp, 9.9 hp, 15 hp, 20 hp, 25 hp, 40 hp, 50 hp, 60 hp, 75 hp, 90 hp, 100 hp, 115 hp, 135 hp, 150 hp, 150XR4, 150XR6, 150XRi, 175 hp, 175XRi, 200 hp, 200XRi, 250 hp, and 275 horesepower motors.
This repair manual includes general information for each Mercury outboard engine, tools and techniques, troubleshooting, lubrication, maintenance and tune-up, timing, synchronizing and adjusting, fuel system, ignition and electrical systems, power head, lower unit gear housing, power trim and tilt systems, oil injection system, manual rewind starter and complete wiring diagrams. Features 640 illustrated pages.
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization, Notes, cautions and warnings, Torque specifications, Engine operation, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Protection from Galvanic corrosion, Propeller
CHAPTER TWO, TOOLS AND TECHNIQUES
Safety first, Basic hand tools, Test equipment, Service hints, Special tips, Mechanic’s techniques
CHAPTER THREE, TROUBLESHOOTING
Operating 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-UP
Lubrication, Storage, Anti-corrosion maintenance, Complete submersion, Flushing the cooling system, Tune-up
CHAPTER FIVE, TIMING, SYNCHRONIZING AND ADJUSTING
Ignition timing and synchronization, 3 hp, 3 and 5 hp, 8, 9.9 and 15 hp, 20 and 25 hp, 40 hp, 50 and 60 hp (prior to serial No. D000750), 50 and 60 hp (serial No. D000750-on), 75 and 90 hp, 100 and 115 hp, 135-200 hp (except EFI), 250 and 275 hp, 150Xri, 175Xri and 200Xri (EFI) models
CHAPTER SIX, FUEL SYSTEM
Fuel 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 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 SYSTEMS
Battery, 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 HEAD
Engine serial number, Gaskets and sealants, Fasteners and torque, Power head
CHAPTER NINE, LOWER UNIT GEAR HOUSING
Service 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 SYSTEM
Manual 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 SYSTEM
Autoblend 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 STARTERS
3 and 3.3 hp, 4 and 5 hp, 8, 9.9, 15, 20 and 25 hp, 40 hp models
INDEX
WIRING DIAGRAMS
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