1987-1993 Mercury Mariner Outboard motor 70/75/80/90/100/115HP 3 and 4-cylinder Factory Service Manual
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- 1987 1993 Mercury Mariner Outboards 70 75 80 90 100 115HP 4 cylinder Service Repair Manual
Original 1987-1993 Mercury Mariner Outboards 70/75/80/90/100/115HP 4-cylinder Service Manual.
1987-1993 70 / 75 / 75 Marathon
75XD / 75 Seapro 80 / 90 (3 Cylinder) with Serial Numbers
UNITED STATES S/N 0A996142 thru 0D283221
BELGIUM S/N 09502135 thru 09793576
CANADA S/N 0A722297 and Above
1988-1993 100 /115 (4 Cylinder) with Serial Numbers
UNITED STATES S/N 0B209468 thru 0D283221
BELGIUM S/N 09523034 thru 09793576
CANADA S/N 0A731673 and Above
Section POWERHEAD 4 cylinder is MISSING!
Some Of The Chapters from the manual:
- Tools & Techniques
- Troubleshooting
- Maintenance And Tune-Up
- Timing And Adjustments
- Fuel System
- Electrical Ignition System
- Jet Drives / Sea Drives (if applicable)
- Base Repair
- Lower Unit
- Tilt & Trim
- Gear Case Repair
- Rewind Starter
- Parts Numbers
- Detailed Pictures And Diagrams
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"1987-1993 Mercury Mariner Outboard motor 70/75/80/90/100/115HP 3 and 4-cylinder Factory Service Manual" manual can be saved to any computer hard drive, flash storage, burned to a CD or DVD ROM or any other digital media.This Manual PDF file is:
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Full list of manual chapters:
COVER
MODELS 70*75*80*90*100*115
Notice
Notice to Users of This Manual
Cleanliness and Care of Outboard Motor
Service Manual Outline
GENERAL INFORMATION AND SPECIFICATION
GENERAL INFORMATION AND SPECIFICATIONS
Table Of Contents
General Specification
Cowl Removal
Filling Oil Injection System
Power Trim System
Trim "In" Angle Adjustment
Checking Trim System Fluid Level
Tilt Angle Adjustment
Connecting Engine Wiring Harness and Routing of Engine Battery Cables
Lubrication Points
Ride-Guide Steering Cable and Pivot Points Lubrication
Following Complete Submersion
Salt Water Submersion (Special Instructions)
Submerged While Running (Special Instructions)
Submerged Engine (Fresh Water) (Plus Special Instructions)
Out-of-Season Outboard Storage
Out-of-Season Battery Storage
How Weather Affects Engine Performance
Conditions Affecting Operation
Detonation: Causes and Prevention
Compression Check
IGNITION SYSTEM
IGNITION SYSTEM
Table Of Contents
Description
Test Procedures
Direct Voltage Adapter (DVA) Tests
Test Sequence
Ignition System Test Chart
Ignition Components Removal and Installation
Flywheel
Stator
Trigger
Ignition Coils (3 Cylinder Models)
Ignition Coils (4 Cylinder Models)
Switch Box
BATTERY, CHARGING SYSTEM AND STARTING SYSTEM
BATTERY, CHARGING SYSTEM, AND STARTING SYSTEM
Table of Contents
Battery
Precautions
Recommended Battery
Operating Engine Without Battery
Specific Gravity Readings
Electrolyte Level
Charging a Discharged Battery
Winter Storage of Batteries
Optional Voltage Regulator Test
Battery Charging System (9 Ampere Alternator)
Description
Battery Charging System Troubleshooting
Stator Ohms Test (Alternator Coils Only)
Standard Stator (Alternator Coils) 9 Amperes Output
16 Amp Alternator System Test
16 Ampere Alternator System Test
Optional 24 Amp Alternator System Test
Tachometer Terminal Block (Design 1)
Tachometer Terminal Block (Design 2)
Tachometer Terminal Block (Design 1 and 2)
3 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram
3 Cylinder 16 Ampere Battery Charging Wiring Diagram (with Small Voltage Regulator/Rectifier)
4 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram
4 Cylinder 16 Ampere Battery Charging Wiring Diagram (with Small Voltage Regulator/Rectifier)
3 Cylinder Battery Charging Diagram with Battery Isolator
3 Cylinder Battery Charging Diagram with Battery Isolator (Small Voltage Regulator)
4 Cylinder Battery Charging Diagram with Battery Isolator
4 Cylinder Battery Charging Diagram with Battery Isolator (Small Voltage Regulator)
Rectifier Test
Starting System
Starting System Components
Description
Troubleshooting the Starting Circuit
Starting Circuit Troubleshooting Flow Chart
Starter Motor
Removal
Disassembly
Starter Cleaning, Inspection and Testing
Testing
Brush Replacement
Installation
TIMING/SYNCHRONIZING/ADJUSTING
TIMING/SYNCHRONIZING/ADJUSTING
Table Of Contents
Timing/Synchronizing/ Adjusting (3 Cylinder Models)
Specifications
Special Tools
Timing Pointer Adjustment
Throttle Cable Installation
Timing/Synchronizing/ Adjusting (4 Cylinder Models)
Specifications
Special Tools
Timing Pointer Alignment
Carburetor Specifications
Idle Adjustment
Throttle Cable Installation
WIRING DIAGRAMS
WIRING DIAGRAMS
Table Of Contents
Engine Wiring Diagram (3 Cylinder Models With Low Oil Warning Module)
Engine Wiring Diagram (3 Cylinder Models Without Low Oil Warning Module)
Engine Wiring Diagram (3 Cylinder Models With Small Voltage Regulator/Rectifier)
Engine Wiring Diagram (4 Cylinder Models)
Engine Wiring Diagram (4 Cylinder Models With Small Voltage Regulator/Rectifier)
Power Trim System Wiring Diagram (3 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control)
Power Trim System Wiring Diagram (3 Cylinder Models Using COMMANDER Side Mount Remote Control)
Power Trim System Wiring Diagram (4 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control)
Tachometer (With Adjustable Dial) and Trim Indicator Gauge Wiring Diagram
Key/Choke Switch Continuity Test (COMMANDER 2000 Side Mount Remote Control)
COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start With Warning Horn) Wiring Diagram
COMMANDER 2000 Side Mount Remote Control (Electric Start With Warning Horn) Wiring Diagram
COMMANDER Side Mount Remote Control (Power Trim/Tilt Electric Start With Warning Horn) Wiring Diagram
FUEL SYSTEM AND CARBURATION
FUEL SYSTEM AND CARBURETION
Table Of Contents
Fuel Pumps
General Information
Testing
Troubleshooting Fuel Pump
Fuel Pump Components (Design 1)
Fuel Pump Removal/Installation (Design 1)
Reinstall Fuel Pump (Design 1)
Fuel Pump Cleaning, Inspection, Disassembly and Reassembly (Design 1 and 2)
Fuel Pump – Cleaning/Inspection
Check Valve Reassembly
Step-by-Step Reassembly
70-75-80-90 (3 cyl.) (Design 1)
100-115 (4 cyl.) (Design 1)
70-75-80-90 (3 cyl.) (Design 2)
100-115 (4 cyl.) (Design 2)
Installation of Design 2 Fuel Pump
Carburetion
Fuel System Troubleshooting
Troubleshooting Charts
Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
Fuel System (Carburetor)
Fuel System (Linkage)
Carburetor Adjustments
Specification Sheet - WME Carburetors
Carburetor Disassembly
Carburetor Reassembly
Enrichener System
Description for Three Cylinder Engines
Enrichener Valve Hose Installation - Four Cylinder Engines
Description for Four Cylinder Engines
Enrichener Valve Hose Installation - Three Cylinder Engines
Acceleration Pump Circuit Operation - Four Cylinder Engines
Acceleration Pump Fuel Flow Circuit for Four Cylinder Engines
Fuel Tank
Fuel Tank Components
Fuel Line and Primer Bulb Assembly
Maintenance
OIL INJECTION SYSTEM
OIL INJECTION SYSTEM
Table Of Contents
Description
Hose Connections
Oil Pump Drive System
Filling Oil Tank
Carburetor/Oil Pump Synchronization
Bleeding Air from Oil Injection System
Bleeding Air from Oil Pump Inlet Hose
Bleeding Air from Oil Pump Outlet Hose
Oil Pump Test
Low Oil Sensor Test
Warning Horn System
Models Equipped with Test Button (3 Cylinder Only)
Models Not Equipped With Test Button (3 and 4 Cylinder)
Oil Injection System Troubleshooting Chart (Models with Warning Module)
Troubleshooting the Oil Injection System
Troubleshooting Chart
POWERHEAD
3-CYLINDER ENGINES
Table Of Contents
Crankshaft Assembly
Powerhead Block and Cover Assemblies
Torque Specifications, Torque Sequences
Tools for Powerhead Repair
General Information
Powerhead Component Removal
Flywheel Removal
Powerhead Disassembly
Cleaning and Inspection
Cylinder Block and Crankcase Cover
Check Valves
Piston and Piston Rings
Crankshaft
Connecting Rods
Cylinder Cover, Exhaust Divider Plate and Exhaust Cover
Powerhead Reassembly and Installation
General Information
End Cap
Assembling Rod to Piston
Piston Ring Installation
Crankshaft Installation
Connecting Rod Cap Alignment
Crankcase Cover to Block
Cylinder Block Cover
Exhaust Plate Cover and Exhaust Divider Plate
Powerhead to Driveshaft Housing
Flywheel Installation
LOWER UNIT - GEAR HOUSING
GEAR HOUSING
Table of Contents
Drive Shaft and Water Pump Components
Propeller Shaft Components
Special Tools
Removal
Disassembly
Propeller Removal
Draining and Inspecting Gear Housing Lubricant
Water Pump (Design 1)
Water Pump (Design 2)
Bearing Carrier and Propeller Shaft
Pinion Gear, Drive Shaft, and Forward Gear
Upper Drive Shaft Bearing
Oil Sleeve
Lower Drive Shaft Bearing Race
Shift Shaft
Forward Gear Bearing Race
Trim Tab Adjustment and Replacement
Reassembly
Forward Gear Bearing Race
Shift Shaft
Bearing Carrier Reassembly
Forward Gear Reassembly
Propeller Shaft Reassembly
Drive Shaft Wear Sleeve Installation
Lower Drive Shaft Bearing Race Installation
Oil Sleeve Installation
Upper Drive Shaft Bearing Installation
Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation
Pinion Gear Depth and Forward Gear Backlash
Bearing Carrier and Propeller Shaft Installation
Water Pump Reassembly and Installation
Gear Housing Pressure Test
Filling Gear Housing With Lubricant
Propeller Installation
Installation
LOWER UNIT - MID-SECTION
MID-SECTION
Table of Contents
Swivel Bracket Components
Transom Bracket Components
Exhaust Plate Components
Drive Shaft Housing Components
Reference Views
LOWER UNIT - SHOCK ABSORBER
SHOCK ABSORBER
Table Of Contents
Engines Equipped with a Single Shock Absorber
Removal
Inspection and Repair
Installation
POWER TRIM - SIIDE FILL RESERVOIR
DESIGN I (SIDE FILL RESERVOIR)
Table Of Contents
Power Trim - General Information
Description
Trimming Characteristics
Trailering Outboard
Tilting Outboard Manually
Trim "In" Angle Adjustment
Striker Plate Replacement
Anode Plate
Trim Indicator Gauge
Fill, Check, and Purge - Power Trim System
Bleeding Air From Power Trim System
Troubleshooting
Hydraulic System Troubleshooting
Wiring Diagram
Trim Indicator Gauge and Trim Sender Wiring Diagrams
Side Mount Remote Control Wiring Diagram
Electrical System Troubleshooting
General Checks
Troubleshooting the "Trailer" Circuit (When "Up" Circuit Is OK)
Troubleshooting the "Up" and "Trailer" Circuits (Both Circuits Inoperative: "Down" Circuit Is OK)
Troubleshooting the "Up" Circuit (When "Trailer" Circuit Is OK)
Troubleshooting the "Down," "Up" and "Trailer" Circuits (All Circuits Inoperative)
Troubleshooting the "Down" Circuit (When "Up" Circuit Is OK)
Troubleshooting the "Up" Circuit (When "Down" Circuit Is OK)
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
Power Trim Assembly Removal and Installation
Installation
Removal
Testing Power Trim System With Test Gauge Kit (91-52915A3)
"UP" Pressure Check
"DOWN" Pressure Check
Power Trim Components
Hydraulic Repair
Trim Rod End Cap Seal
Tilt Ram Components
Tilt Ram
Pump Replacement
Motor and Electrical Tests/Repair
Thermal Overload Switch Test
Trim Pump Motor Test
Solenoid Test
Motor Disassembly
Armature Tests
Field Tests
Trim Sender (Optional Accessory) Test
Trim Indicator Gauge (Optional Accessory) Needle Adjustment
Motor Repair
"Square" Motor Components
Reassembly
Brush Replacement ("Square" Motor)
POWER TRIM - AFT FILL RESERVOIR
DESIGN II (AFT FILL RESERVOIR)
Table Of Contents
Power Trim System
Power Trim Components
Power Trim - General Information
Description
Trimming Characteristics
Trailering Outboard
Tilting Outboard Manually
Trim "In" Angle Adjustment
Striker Plate Replacement
Anode Plate
Trim Indicator Gauge
Fill, Check, and Purge - Power Trim System
Hydraulic System Troubleshooting
Troubleshooting
Side Mount Remote Control Wiring Diagram (Test Points for Electrical Troubleshooting)
Electrical System Troubleshooting
Troubleshooting the "Down" Circuit (When "Up" Circuit is OK)
Troubleshooting the "Up" Circuit (When "Down" Circuit is OK)
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
Power Trim Assembly Removal and Installation
Removal
Installation
"UP" Pressure Check
"DOWN" Pressure Check
Hydraulic Repair
Trim Rod End Cap Seal
Tilt Ram
Disassembly
Scraper Seal Replacement
Motor and Electrical Tests/Repair
Trim Pump Motor Test
Solenoid Test
Armature Tests
Motor Repair
Reassembly
Reassembly - Motor and Pump
Priming Power Trim System
Trim Sender (Optional Accessory) Test
Trim Indicator Gauge Needle Adjustment
Trim Indicator Wiring Diagrams
POWER TRIM - SINGLE RAM
SINGLE RAM
Table Of Contents
Special Tools
Quicksilver Lubricants and Service Aids
Power Trim - General Information
Description
Trimming Characteristics
Trailering Outboard
Tilting Outboard Up and Down Manually
Trim "In" Angle Adjustment
Power Trim System Components
Troubleshooting
Determining if Problem is Electrical or Hydraulic
Problem Chart
Hydraulic System Troubleshooting Preliminary Checks
Date Code Location
Leak Down Check - Pump and Manifold Assembly
Reassembly
Power Trim Partial Leak Down at Maximum Trim
Leak Down Check - Pilot Valve Assembly
Leak Down Check - Manual Release Valve
Leaks Past Ball and Seat - Piston Assembly
Power Trim Rocker Arm
Troubleshooting Flow Diagram
Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
Power Trim System Wiring Diagram
Troubleshooting the "Down" Circuit (When "Up" Circuit is OK)
Troubleshooting the "Up" Circuit (When "Down" Circuit Is OK)
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)*
Power Trim System Removal
Power Trim System Disassembly
Trim Rod Removal
Trim Rod Disassembly
Trim "Motor" Removal
Trim "Motor" Disassembly
Reservoir Assembly Removal
Manifold Removal
Cleaning and Inspection of Trim Rod Components
Motor and Electrical Tests/Repair
Power Trim System Reassembly
Manifold Installation
Trim Motor Reassembly
Reservoir Installation
Trim Rod Reassembly
Trim Rod Installation
Purging Power Trim Unit
Power Trim Unit Installation
ENGINE ATTACHEMENTS/INSTALLATION
ENGINE ATTACHMENTS/ ENGINE INSTALLATION
Table Of Contents
Steering Cable and Steering Link Rod Installation
Ride-Guide Attachment – Dual Front Installation (92876A2)
Installation and Maintenance
Cable Routing Types
Parallel Routed Steering Cables and Attacking Kit Installation
Super Ride-Guide Steering Kit Installation
Installing Steering Cables and Steering Link Rods to Engines
Steering Eyes and Coupler Installation
Steering System Tension Adjustment (Parallel Routed Steering Cables)
Opposite Side Routed Steering Cables and Attaching Kit Installation
Super Ride-Guide Steering Kit Installation
Installing Steering Cables and Steering Link Rods to Engines
Steering Eyes and Coupler Installation
Steering System Tension Adjustment
Trim Tab Installation
Trim Tab Adjustment
Maintenance Instructions
Ride Guide Steering Attachment Extension Couplers
Transom Mounted Ride-Guide Attaching Kit Installation (73770A1)
Maintenance Instructions
Ride-Guide Steering Cable/Attaching Kit Installation (92876A3)
Dual Cable - Single Outboard
Super Ride-Guide Steering Kit Installation
Mounting Bracket Installation
Steering Cable Mounting Tube Installation
Installing Steering Cables
Coupler Installation
Installing Link Rod
Maintenance Instructions
Remote Control Installation
Shift Cable Installation and Adjustment to Engine
Throttle Cable Installation and Adjustment to Engine
Connecting Engine Wiring Harness and Routing of Engine Cables
Installing Outboard Motor on Transom
Determining Recommended Outboard Mounting Height
Locate Centerline of Boat Transom
Drilling Outboard Mounting Holes Lifting Engine
Lifting Engine
Installing Engine to Transom
OUTBOARD MOTOR INSTALLATION
TILLER HANDLE AND CO-PILOT
Table Of Contents
Tiller Arm Components
Tiller Arm Bracket Assembly
Co-Pilot Components
Tiller Arm/Shift Lever Removal
Tiller Handle Disassembly
Tiller Arm Reassembly
Tiller Handle/Shaft Bracket Installation
Shift Link Rod Installation Adjustment to Engine
Throttle Cable Installation and Adjustment to Engine
Co-Pilot Installation
