This workshop manual/repair manual covers the following years and model Outboard motors:
1965-1970: 45 HP (45HP), 4 cylinder outboard engine
1986-1989: 50 HP (50HP), 3 cylinder outboard engine
1965-1985: 50 HP, 4 cylinder outboard engine
1985-1989: 60 HP (60HP), 3 cylinder outboard engine
1972-1976: 65 HP (65HP), 3 cylinder outboard engine
1965-1971: 65 HP, 4 cylinder outboard engine
1976-1983: 70 HP (70HP), 3 cylinder outboard engine
1986-1989: 70 HP, 3 cylinder outboard engine
1984-1986: 75 HP (75HP), 4 cylinder outboard engine
1987-1989: 80 HP (80HP), 3 cylinder outboard engine
1969-1983: 80 HP, 4 cylinder outboard engine
1973-1977: 85 HP (85HP), 4 cylinder outboard engine
1987-1989: 90 HP (90HP), 3 cylinder outboard motor
1988-1989: 100 HP (100HP), 4 cylinder outboard motor
1988-1989: 115 HP (115HP), 4 cylinder outboard motor
The service manual for the above listed Mercury/Mariner Outboard models provides detailed service procedures for the complete outboard. It is essential for both professional mechanics and DIY enthusiasts to follow the Maintenance Schedule recommendations to ensure peak operating condition of the engine. Performing scheduled maintenance compensates for initial wear that occurs during the motor's lifespan.
All chapters in the service manuals apply to the entire engine and illustrate detailed step-by-step procedures for removal & installation of components. Most chapters start with an assembly or system illustration, diagrams, exploded parts view, pictures, service information, and troubleshooting for the section. The subsequent pages provide detailed procedures. This manual is available in .PDF format and does not require special software as it works on all computers.
Below is a small sample of information you might find in a typical service manual, covering everything needed to service the entire motor. Information will differ depending on the year and model:
Specifications: Overall length, overall width, weight, transom height, recommended operating range, idle speed, engine type, DOHC, number of cylinders, total displacement, spark plug, fuel supply system, multi-point sequential electronic fuel injection, exhaust system, cooling system, water cooled, lubrication system, wet sump, starting system, electric lower unit, fuel recommendations, outboard motor gear oil, gearcase oil capacity, maximum tilt angle, transmission, forward-neutral-reverse, propeller shaft rotation, propeller, cylinder compression, engine oil pressure, viscosity rating, engine oil amounts, oil filter change, piston, piston rings, thermostat operating temperature, and more.
Maintenance: Complete maintenance specs, maintenance charts, intervals, and recommendations including step by step procedures for spark plug, fuel line, engine oil, gear oil, lubrication, anodes & bonding wires, battery, fuel mixture check, engine oil filter, low pressure fuel filter, high pressure fuel filter, ignition timing, idle speed, tappet clearance, water pump, propeller nut & pin, balancer chain, bolt & nuts, timing belt inspection, lubrication points, changing engine oil, oil draining procedure, changing oil filter, oil filling, and more.
General Information: Identification numbers, tightening torque, service data, specifications, cylinder number, propellers, gasoline recommendations, warm-up recommendations, and more.
Electrical: Electrical parts holder removal and installation, inspection, removal, installation, troubleshooting outline of monitor, tachometer, starter motor, electric starter system, battery charging system, disassembly, cleaning, testing, brush replacement, reassembly, battery charging system manual start, battery charging system tests, testing the battery charging coil, testing the battery charging system, testing the rectifier/regulator, and more.
Carburetor: Specifications, special tools, intake, carburetor adjustments, idle speed linkage, choke, carburetor removal, disassembly, cleaning, inspection, repair, reassembly, float height measurement, installation, idle rpm, wide open throttle rpm, main jet size, float height, and more.
EFI System: Specifications, fuel injection nozzle, fuel injection pump, throttle body, throttle control lever and linkage, high pressure fuel line, fuel cooler, fuel hoses, fuel rail pressure regulator, idle speed control assembly, intake manifold, throttle position sensor, low pressure fuel line/fuel pump, fuel filter, fuel pump, and more.
Powerhead (Power Head): Cylinder head cover, intake manifold assembly, ring gear cover, air intake, power unit (powerhead), measuring pump components, oil pump, engine lubrication system, thermostat, cylinder, crankshaft, piston, counter balancer mechanism, cylinder head assembly, removal, inspection, installation, and more.
Mid-Section: Engine side cover, driveshaft housing and oil pan, swivel bracket, steering bracket and clamp, water pressure valve, lower unit gear housing, inspection, removal, installation, cleaning, assembly, and reassembly procedures.
Lower Unit: Gear case, propeller, lower unit gears, shimming and adjustment, trim tab, drive shaft and oil seal housing, water pump, shift guide housing, propeller shaft components, gear bearing, propeller shaft, gear housing, and more.
