Mercury 3-275 HP Outboards 1990-93 Clymer Marine Manual

Mercury 3 - 275 HP Outboards 1990 - 1993 Covers the following Mercury outboard motors: 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 hp.
Table of Contents:

•Quick Reference Data

•General Information
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Protection from Galvanic corrosion / Propeller

•Tools and Techniques
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques

•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

•Lubrication, Maintenance and Tune-Up
Lubrication / Storage / Anti-corrosion maintenance / Complete submersion / Flushing the cooling system / Tune-up

•Timing Synchronization and Adjusting
Ignition timing and synchronization / 3 hp models / 3 and 5 hp models / 8, 9.9 and 15 hp models / 20 and 25 hp models / 40 hp models / 50 and 60 hp models (prior to serial No. D000750) / 50 and 60 hp models (serial No. D000750-on) / 75 and 90 hp models / 100 and 115 hp models / 135-200 hp (except EFI) models / 250 and 275 hp models / 150Xri, 175Xri and 200Xri (EFI) models

•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 models 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

•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)

•Power Head
Engine serial number / Gaskets and sealants / Fasteners and torque / Power head

•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

•Power Trim and Power 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

•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

•Manual Rewind Starters
3 and 3.3 hp models / 4 and 5 hp models / 8, 9.9, 15, 20 and 25 hp models / 40 hp models

•Wiring Diagrams

Clymer marine manuals can save you money on maintenance and repair. Step-by-step procedures and detailed illustrations guide you through every job, from routine maintenance and troubleshooting, all the way to complete teardown & rebuild.