by Kal Lahue
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Mercury 45 - 225 HP Outboards 1972 - 1989 Clymer Owners Marine Service & Repair Manual Covers the following models:
● Mercury Merc inline 3 (1972-1989)
● Mercury Merc inline 4 (1972-1989)
● Mercury Merc inline 6 (1972-1989)
● Mercury Merc V6 (1972-1989)
● 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 / Propellers / Specifications
● TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques / Specifications
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
● 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
● 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
● 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
● 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
● POWER HEAD
Engine serial numbers / Gasket and sealant / Power head / Specifications
● 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
● 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
● 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.
Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.
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