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1956-1989 90-300 HP Mercury Outboard motors repair manual Application: Covers all Mercury Motors from 1965 to 1989 90-300 hp Inline 6 and V6, 2 stroke models fuel injection and MR Drive: 90 95 100 115 125 135 140 150 150XR2/150 HP 155 HP 175 HP 200 HP 220XRi/200 HP 225 HP 275 HP 300 HP 850XS/90 HP, 4cyl 900/90hp, 6cyl 950/95hp, 6cyl 1000/100hp.
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- Mercury Mariner 40 HP 2-stroke Factory Service Repair Manual meets all your information needs to repair or make some adjustments to your Mercury Mariner 40 HP 2-stroke. This manual is intended as a handy, easy to read reference book for the mechanics and DIY persons.
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- 1965-1991 Mercury Mariner 2.2 to 40 Hp Outboard 2 Stroke Download Now 1965-1989 Mercury Mariner Download 45 to 115 Hp Outboard Ser Download Now 1990-2000 Mercury Mariner Outboard Motor Service Manual Repa Download Now.
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Free Download NowThis Mercury Mariner two stroke Workshop Manual/Repair manual covers the following years and model Outboard motors:
1965: 3.9 HP 6HP 9.8HP 20 HP 35 HP
1966: 3.9 HP 6HP 9.8HP 20 HP 35 HP
1967: 3.9 HP 6HP 9.8HP 20 HP 35 HP
1968: 3.9 HP 6HP 9.8HP 20 HP 35 HP
1969: 4 HP 7.5 HP 9.8HP 20 HP 35 HP
Mercury 40 Hp 2 Stroke
1970: 4 HP 7.5 HP 9.8HP 20 HP 40 HP1971: 4 HP 7.5 HP 9.8HP 20 HP 40HP
1972: 4 HP 7.5 HP 9.8HP 20 HP 40 HP
1973: 4 HP 7.5 HP 9.8HP 20 HP 40 HP
1974: 4 HP 7.5 HP 9.8HP 20 HP 40 HP
1975: 4.5 HP 7.5 HP 9.8HP 20 HP 40 HP
1976: 4 HP 4.5 HP 7.5 HP 9.8HP 20 HP 40 HP
1977: 4 HP 4.5 HP 7.5 HP 9.8HP 20 HP 40 HP
1978: 4 HP 4.5 HP 7.5 HP 9.8HP 20HP 40HP
1979: 4 HP 4.5 HP 7.5 HP 9.8HP 20HP 40HP
1980: 3.6 HP 4 HP 4.5 HP 7.5 HP 9.8HP 18HP 20 HP 25HP 40 HP
1981: 3.6 HP 4 HP 4.5 HP 7.5 HP 9.8HP 18 HP 20 HP 25 HP 40 HP
1982: 3.6 HP 4.5 HP 7.5 HP 9.8HP 18 HP 25 HP 40 HP
1983: 3.5 HP 4.5 HP 7.5 HP 9.8HP 18 HP 25HP 40 HP
1984: 2.2 HP 3.5 HP 4.5 HP 7.5 HP 9.8HP 18 HP 25 HP 35 HP
1985: 2.2 HP 3.5 HP 4.5 HP 7.5 HP 9.8HP 18 HP 25 HP 35HP
1986: 2.2 HP 4 HP 6 HP 8 HP 9.9 HP 20 HP 25 HP 35 HP
1987: 2.2 HP 4 HP 6 HP 8 HP 9.9 HP 20 HP 25 HP 35 HP
1988: 2.2 HP 4 HP 5 HP 8 HP 9.9 HP 15 HP 20 HP 25 HP 35 HP 1989: 2.2 HP 4 HP 5 HP 8 HP 9.9 HP 20 HP 25 HP 35 HP
1990: 3 HP 4HP 5 HP 8 HP 9.9 HP 15 HP 20 HP 25 HP
1991: 3 HP 4HP 5 HP 8 HP 9.9 HP 15 HP 20 HP 25 HP
The service manual download for the above listed Mercury/Mariner Outboard models describes the service procedures for the complete outboard. Follow the Maintenance Schedule recommendations to ensure that the engine is in peak operating condition. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the motor.
All chapters in the service manuals apply to the whole engine and illustrates procedures for removal & installation of components that are in detailed step-by-step fashion.
Most all service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures. This is a simple to download book, just like any book you would buy in a store except this book is delivered to you instantly upon purchase. No special software required as this manual works on all computers. Manual is in pdf format and delivered in pdf format. BELOW IS JUST A SMALL SAMPLE OF INFORMATION YOU MIGHT FIND IN A TYPICAL SERVICE MANUAL BUT IT COVERS EVERYTHING YOU WILL EVER NEED TO SERVICE YOUR ENTIRE MOTOR. TO MUCH INFORMATION TO LIST. INFORMATION WILL DIFFER DEPENDING ON YEAR AND MODEL
SPECIFICATIONS
Mercury 40 Hp 4 Cylinder 2 Stroke Manual
Some of the topics you might find in a specifications sections are Overall length Overall width Weight Transom height Recommended operating range Idle speed Engine type DOHC Number of cylinders Total displacement Spark plug Fuel supply system Multi-point sequential electronic fuel injection Exhaust system Cooling system Water cooled Lubrication system Wet sump Starting system Electric Lower Unit Fuel recommendatons Outboard Motor Gear Oil Gearcase oil capacity ml Maximum tilt angle degree Transmission Forward-Neutral-Reverse Propeller shaft rotation Propeller Right-hand rotation Propeller Counter rotation Cylinder compression Engine oil pressure Viscosity rating Engine oil amounts Oil filter change Pistion Pistion Rings Thermostat operating temperature and much more.
MAINTENANCE
In the maintenance section you will find complete maintenance specs, maintenance charts, intervals and recomendations including step by step procedures for the following: Spark plug Fuel line Replace fuel hose Breather hose Engine oil Gear oil Lubrication Anodes & Bonding wires Battery Fuel mixture check Engine oil filter Low pressure fuel filter High pressure fuel filter Ignition timing Idle speed Tappet clearance Water pump Water pump impeller Propeller nut & pin Balancer chain Bolt & Nuts Timing Belt Inspection Lubrication Points Changing Engine Oil Oil Draining Procedure Changing Oil Filter Oil Filling and much more.
GENERAL INFORMATION
The gerneral information sections will usually identify the following topics and much more: Identification Numbers Tightening Torque Service Data Specfications Cylinder Number Propellers Gas (gasoline Recomendations) 87 91 92 93 Race Gas Warm-Up Recommendations.
ELECTRICAL
The electrial sections you will find in a service manual include electrical parts holder removal and installation, and the inspection, removal, installation, troubleshooting outline of monitor tachometer starter motor, electric starter system battery charging system Disassembly Cleaning Testing Brush Replacement Reassembly Battery Charging System Manual Start Battery Charging System Tests Testing The Battery Charging Coil Testing The Battery Charging System Testing The Rectifier/Regulator.
IGNITION
A short list of some information you will find in this ignition system section include Specifications Special Tools Checking Ignition Timing Type Spark Plug Firing Order Ignition Timing Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance ECM Engine Speed Limiter Spark Cut-Out Reduction ignition spark ECM Low Oil Pressure Speed Control Oil Pressure Switch and more.
CARBURETOR
If your motor carb (carburetor) than you will find everthing you need to fully adjust the carb, rebuild, remove, inspect, and clean to factory specs. Here are just a small sample you will find in service manuals where carb models apply: Specifications Special Tools Intake Carburetor Adjustments Idle Speed Linkage Choke Carburetor Removal Carburetor Disassembly Cleaning/Inspection/Repair Carburetor Reassembly Float Height Measurement Carburetor Installation Electric Choke Models InstallationIdle rpm (Out Of Gear) Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT) Main Jet Size Pilot Jet Main Jet Size Float Height 950 ± 50 rpm 850 ± 50 rpm 45005500 5200-5700 500-1000 rpm 1200-1500 rpm 1500-2000 rpm 2200 2500 rpm 3000-3500 rpm and much more.
EFI SYSTEM
Mercury 40 Outboard 2 Stroke
A short list of some topics found in the electronic fuel injection system include Specifications Fuel Injection Nozzle Fuel Injection Pump Fuel Pump Throttle Body Throttle Control Lever and Linkage High Pressure Fuel Line High-Pressure Fuel Line Fuel Cooler Fuel Hoses Fuel Rail Pressure Regulator Idle Speed Control Assembly Intake Manifold Throttle Position Sensor Low Pressure Fuel Line/Fuel Pump Fuel Filter Fuel Pump and more.
POWERHEAD (POWER HEAD)
The powerhead section contains everthing you will need to completly rebuild your engine block back to factory specs, some information inculdes: cylinder head cover intake manifold assembly ring gear cover and air intake power unit (powerhead) measuring pump components oil pump engine lubrication system thermostat cylinder crankshaft pistion counter balancer mechanism cylinder head assembly removal inspection installation.
MID-SECTION
A quick run down of main topics in this section are engine side cover driveshaft housing and oil pan swivel bracket steering bracket and clamp wather pressure valve lower unit gear housing and all inspection removal installation cleaning assembly and reassembly procedures.
LOWER UNIT
Some of the main topics discussed in the lower unit section include gear case, propeller lower unit gears shimming and adjustment trim tab drive shaft and oil seal housing, water pump and related items, shift guide housing propeller shaft components gear bearing propeller shaft gear housing and more.
Other Chaptrs you might find in a service manual/ repair manual for your outboard motor include:
ATTACHMENTS/CONTROL LINKAGE
THROTTLE/SHIFT LINKAGE
TILLER HANDLE
MANUAL STARTER
DIAGNOSTIC TROUBLESHOOTING