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1972-1989 Mercury 45-225hp Outboard Service Workshop Manual

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This manual can be used by anyone from a first time owner/amateur to a professional https://www.tradebit.comy to read type,And give you all the information needed to do the procedure https://www.tradebit.comp this parts manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

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MODELS COVERED:

Mercury Merc inline 3 (1972-1989)
Mercury Merc inline 4 (1972-1989)
Mercury Merc inline 6 (1972-1989)
Mercury Merc V6 (1972-1989)

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MANUAL CONTENTS:

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Protection from galvanic corrosion / Propellers / Specifications

CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques / Specifications

CHAPTER THREE / TROUBLESHOOTING
Operating requirements / Starting system / Charging system / Ignition system / Troubleshooting lightning energizer ignition system / Distributor-type CD ignition system troubleshooting / Flywheel CD ignition system troubleshooting / Spark advance/idle stabilizer module troubleshooting / Fuel system / Engine / Specifications

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Model designation / Lubrication / Proper fuel selection / Recommended fuel mixture / Correct fuel mixing / Oil injection / OilBlend injection / 879 oil injection system / Lower drive unit lubrication / Salt water corrosion of gear housing bearing carrier and nut / Storage / Complete submersion / Engine flushing / Tune-up / Compression test / Spark plug plugs / Lower unit and water pump check / Fuel line service / Fuel pump filter service / Inline canister fuel filter service / Fuel pump pressure test / Battery and starter check / Solenoid check / Alternator and rectifier check / Timing, synchronization and adjustments / On-boat performance test / Specifications

CHAPTER FIVE / TIMING, SYNCHRONIZING AND ADJUSTING
Mercury 500 with lightning energizer ignition / Mercury 500 with distributor-less ignition (to serial No. 4576236) / Mercury 500, 40 and 50 (4-cyl) with distributor-less ignition (serial No. 4576236 and above) / Mercury 650 distributor-less ignition / Mercury 650 with distributor CD ignition / Mercury 700, 70 (prior to 1984), 60 and 50 (3-cyl) with flywheel CD ignition / 1987-on Mercury 70, 80 and 90 / Mercury 850 with distributor CD ignition / Mercury 75, 80 (prior to 1984), 800 and 850 with distributor-less ignition / Mercury 900, 1150, 1400, 1500 and 1500XS with distributor CD ignition / Mercury 90, 115 and 140 hp (6-cly) with distributor-less ignition / Mercury 100 (1988-on) and 115 (1989) with flywheel CD ignition / Mercury 1750 V6 (1976-1977) / Mercury 1750 and 175 (1978-on) / Mercury 135, 1500, 150, V150 XR2, 2000 and 200 V6 (below serial No. 6073192) / Mercury 150 XR4, 200 V6 (above serial No. 6073191) and 225 V6 / Specifications

CHAPTER SIX / FUEL SYSTEM
Fuel pump / Integral fuel pump carburetor (except 45 and 50 [4-cyl] hp models) / Integral fuel pump carburetor (45 an d50 [4-cyl] hp models) / Model 100 and 115 concept 2+2 / Center bowl carburetor / Dual-float center bowl carburetor / Sidebowl and back drag carburetor / WME carburetor / Electronic fuel injection (EFI) / Enrichener valve and choke solenoid systems / Anti-siphon devices / Fuel tank / Fuel line and primer bulb / Specifications

CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS
Battery / Battery charging system / Starting system / Starter motor / Ignition system / Lightning energizer ignition (model 500 through 1975) / Thunderbolt CD ignition system with distributor / Thunderbolt CD ignition system (without distributor) / Specifications

CHAPTER EIGHT / POWER HEAD
Engine serial numbers / Gasket and sealant / Power head / Specifications

CHAPTER NINE / LOWER UNIT AND DRIVE SHAFT HOUSING
Service precautions / Standard 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 / Model R drive gear housing / Drive shaft housing / Trim tab adjustment / Specifications

CHAPTER TEN / POWER TRIM AND TILT SYSTEM
External power trim system / Hydraulic pump / Troubleshooting / Solenoid test / Trim limit adjustment / Trim cylinders / Integral power trim system / Hydraulic pump / Troubleshooting / Specifications

INDEX

WIRING DIAGRAMS

Models covered:
1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 Mercury Merc inline 3
1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 Mercury Merc inline 4
1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 Mercury Merc inline 6
1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 Mercury Merc V6



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Mercury Merc inline 3 (1972-1989)
Mercury Merc inline 4 (1972-1989)
Mercury Merc inline 6 (1972-1989)
Mercury Merc V6 (1972-1989)



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Language: English
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