MERCURY SPORT JET 120 120XR SERVICE MANUAL

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Service Manual Outline
Section 1 - General Information & Specifications Section 2 - Electrical and Ignition A - CDM Ignition B - Batery, Charging and Starting Systems C - Timing/Synchronizing/Adjusting Section 3 - Fuel System and Carburetion A - Carburetor B - Fuel Pump, Recirculation System, Reed Valve Assembly and Auto Enrichner C - Oil Injection System Section 4 - Powerhead Section 5 - Jet Pump Section 6 - Sport Jet Installation

General Information & Specifications

1 2 3 4 5 6

Electrical and Ignition

Fuel System and Carburetion

Powerhead

Jet Pump

Sport Jet Installation

90-858804 AUGUST 1998

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GENERAL INFORMATION AND SPECIFICATIONS

SECTION 1A ­ GENERAL INFORMATION AND SPECIFICATIONS
Table of Contents
How To Use This Manual . . . . . . . . . . . . . . . . . . . Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . Master Specifications . . . . . . . . . . . . . . . . . . . . . . Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Hardware . . . . . . . . . . . . . . . . . . . . . Metric Hardware . . . . . . . . . . . . . . . . . . . . . . . Flushing Cooling System . . . . . . . . . . . . . . . . Following Complete Submersion . . . . . . . . . 1A-1 1A-2 1A-2 1A-6 1A-6 1A-7 1A-7 1A-8 Out-of-Season Storage . . . . . . . . . . . . . . . . . . 1A-9 Out-of-Season Battery Storage . . . . . . . . . . 1A-10 How Weather Affects Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . 1A-11 Detonation: Causes and Prevention . . . . . 1A-11 Compression Check . . . . . . . . . . . . . . . . . . . 1A-12 Water Pressure Check . . . . . . . . . . . . . . . . . 1A-12

1
A

How To Use This Manual
The manual is divided into SECTIONS (shown right) which represents major components and systems. Some SECTIONS are further divided into PARTS. Each PART has a title page. A Table of Contents for the particular PART is printed on the back of the title page. SECTIONS and PARTS are listed on the Service Manual Outline sheet which immediately follows the cover of this book.
Section 1 2 3 4 5 6 Section Heading General Information/Specifications Electrical and Ignition Fuel System and Carburetion Powerhead Jet Pump Sport Jet Installation

90-858804 AUGUST 1998

Page 1A-1

GENERAL INFORMATION AND SPECIFICATIONS

Page Numbering
Two number groups appear at the bottom of each page. The example below is self-explanatory.
EXAMPLE:

90-826148R1 MAY 1994

Page 4A-7

Revision No. 1 Month of Printing Year of Printing

Section Number Part of Section Letter Page Number

Master Specifications
120
HORSEPOWER (KW) PH / PUMP WEIGHT CYLINDER BLOCK STROKE CYLINDER BORE PISTON

Model 120

120 (89.5) 260 lbs.

Type Displacement Length Diameter (Standard) Taper/Out of Round Max. Bore Type Piston Type Standard 0.015 in. (0.378 mm) Oversize 0.030 in. (0.752 mm) Oversize Reed Stand Open (Max.)

4 Cylinder In-Line 102.9 cu. in. (1687 cc) 2.876 in. (73.05 mm) 3.375 in. (85.7 mm) 0.0015 Cast Iron Aluminum Diameter 3.3700 (85.598 mm) Diameter 3.3850 (85.979 mm) Diameter 3.4000 (86.360 mm) 0.010 (0.254 mm)

REEDS

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90-858804 AUGUST 1998