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2000-2009 Mercury 75 hp, 90 hp outboard motor manual Preview image 1
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2000-2009 Mercury 75 hp, 90 hp outboard motor manual

Models covered in this manual:

  • 75 hp (3 cyl.) 2-stroke
  • 75 hp (4 cyl.) 2-stroke
  • 90 hp (3 cyl.) 2-stroke
  • 90 hp (4 cyl.) 2-stroke

Serial numbers:

  • 75 hp (3 cyl.) 2-stroke: 0G960500-1B226999
  • 75 hp (4 cyl.) 2-stroke: 0T178500-0T800999
  • 90 hp (3 cyl.) 2-stroke: 0G960500-1B226999
  • 90 hp (4 cyl.) 2-stroke: 0T178500-0T800999
    • Engines:
  • 75 hp (FourStroke)
  • 90 hp (FourStroke)

Serial numbers: Starting S/N 0G960500 and Above
Production/model years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009

File specifications

File size: 14.35 MB
File type: ZIP
Language: English

Printable: Yes
Estimated download time: 0.29 Minutes
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Product Information

Table of Contents

Section 1A: Specifications

  • Specifications
  • Propeller Information Charts
  • Mercury/Quicksilver Lubricants and Sealants
  • Torque Specifications

Section 1B: General Information

  • Introduction
  • Safety Precautions
  • Maintenance Schedule
  • Serial Number Locations
  • Tools and Equipment

Section 2: Ignition System

  • Spark Plug Specifications
  • Ignition Timing
  • Ignition Coil Resistance
  • Electronic Control Module (ECM)
  • Ignition System Troubleshooting

Section 3: Charging System

  • Battery Specifications
  • Alternator Output
  • Charging System Troubleshooting

Section 4: Fuel System

  • Fuel Pump Specifications
  • Carburetor Models
  • Fuel Injection Models
  • Fuel System Maintenance

Section 5: Cooling System

  • Water Pump
  • Thermostat
  • Cooling System Maintenance

Section 6: Power Unit

  • Cylinder Block
  • Cylinder Bore
  • Piston and Rings
  • Connecting Rod
  • Crankshaft

Section 7: Lubrication System

  • Oil Pump
  • Oil Filter
  • Oil Specifications and Capacities

Section 8: Starting System

  • Starter Motor Specifications
  • Starter Solenoid
  • Starting System Troubleshooting

Section 9: Gear Housing

  • Gear Ratios
  • Gear Housing Assembly
  • Propeller Shaft

Section 10: Trim and Tilt System

  • Hydraulic System
  • Trim and Tilt Motor
  • Trim and Tilt Troubleshooting

Section 11: Electrical System

  • Wiring Diagrams
  • Battery Maintenance
  • Electrical Component Locations
  • Electrical System Troubleshooting

Section 12: Maintenance

  • Periodic Maintenance Schedule
  • Maintenance Procedures
  • Service Intervals

Section 13: Troubleshooting

  • Engine Troubleshooting
  • Electrical System Troubleshooting
  • Cooling System Troubleshooting
  • Fuel System Troubleshooting
  • Ignition System Troubleshooting

Section 14: Special Tools

  • Required Tools
  • Tool Specifications
  • Tool Usage

Appendix

  • Technical Specifications
  • Conversion Tables
  • Glossary of Terms

Index


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