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1977-1989 Mercury 45 hp-220 hp 2-stroke outboard motor service manual Preview image 1
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1977-1989 Mercury 45 hp-220 hp 2-stroke outboard motor service manual

Models covered in this manual:

  • 45hp, 4cyl, 1986 1987 1988 1989
  • 50hp, 3cyl, 1986 1987 1988 1989
  • 50hp, 4cyl, 1982 1983 1984 1985
  • 60hp, 3cyl, 1984 1985 1986 1987 1988 1989
  • 70hp, 3cyl, 1980 1981 1982 1983
  • 75hp, 3cyl, 1987 1988 1989
  • 75hp, 4cyl, 1984 1985 1986
  • 80hp, 4cyl, 1978 1979 1980 1981 1982 1983
  • 85hp, 4cyl, 1977
  • 90hp, 3cyl, 1987 1988 1989
  • 90hp, 6cyl, 1979 1980 1981 1982 1983 1984 1985 1986
  • 100hp, 4cyl, 1988 1989
  • 115hp, 4cyl, 1989
  • 115hp, 6cyl, 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988
  • 135hp, v6, 1986 1987 1988 1989
  • 140hp, 6cyl, 1978 1979 1980
  • 150hp, v6, 1979 1980
  • 175hp, v6, 1979 1980
  • 175hp, v6, 1985 1986 1987 1988 1989
  • 200hp, v6, 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989
  • 220EFI, v6,1987 1988

File specifications

File size: 34.75 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 0.71 Minutes
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Product Information

Table of Contents

Introduction and Safety Notice

  1. Introduction

    • Purpose of the Manual
    • How to Use This Manual
  2. Safety Notice

    • General Safety Precautions
    • Marine Safety Guidelines

General Troubleshooting Information

  1. Recommended Marine Shop Electrical Test Equipment and Tools

    • Tool List and Specifications
    • Usage Guidelines
  2. Troubleshooting Fundamentals

    • Basic Electrical Troubleshooting Techniques
    • Common Issues and Solutions
  3. Engine Performance Diagnostics

    • Compression Testing
    • Fuel System Diagnostics
  4. Ignition System Troubleshooting

    • Spark Test Procedures
    • Ignition Timing Adjustment
  5. Lubrication and Cooling System Maintenance

    • Oil Types and Usage
    • Cooling System Flushing

Chrysler Troubleshooting

  1. Ignition Systems

    • Capacitor Discharge Ignition (CDI) Systems
    • Ignition Coil Testing
  2. Charging Systems

    • Alternator Function and Testing
    • Battery Maintenance

Force Troubleshooting

  1. Ignition Systems

    • Coil and Spark Plug Inspection
    • Timing Adjustment
  2. Charging Systems

    • Stator and Regulator Testing
    • Battery Health Check

Johnson/Evinrude Troubleshooting

  1. Ignition Systems

    • Power Pack and Timer Base Testing
    • Coil Resistance Measurement
  2. Fuel Systems

    • Carburetor Cleaning and Adjustment
    • Fuel Pump Inspection
  3. Lower Unit Maintenance

    • Gear Oil Change
    • Propeller Shaft Inspection

Mercury Troubleshooting

  1. Ignition Systems

    • CDI and Distributor Systems
    • Trigger Coil Testing
  2. Fuel Systems

    • Fuel Line Inspection
    • Carburetor Tuning
  3. Lower Unit Maintenance

    • Water Pump Impeller Replacement
    • Gearcase Disassembly

Mercury/Force CDI Ignition Systems Troubleshooting

  1. CDI Ignition Overview

    • CDI Module Function
    • System Components
  2. Troubleshooting CDI Systems

    • Symptom Diagnosis
    • Test Equipment Usage
  3. Component Replacement Procedures

    • CDI Module Replacement
    • Coil and Trigger Replacement

Appendix

  1. Wiring Diagrams

    • Ignition and Charging Systems
    • Engine Control Systems
  2. Specifications and Charts

    • Electrical Specifications
    • Torque Specifications
  3. Service Bulletins and Updates

    • Recent Service Bulletins
    • Technical Updates
  4. Tool and Equipment Recommendations

    • Special Tools for Mercury Outboards
    • Recommended Test Equipment
  5. Glossary of Terms

    • Common Marine Terminology
    • Technical Definitions

Index

  1. Comprehensive Index
    • Quick Reference Guide
    • Page Numbering

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