2000+ Mercury 75-90HP 4-Stroke Outboard Service & Repair Manual

1 A SPECIFICATIONS 90-858895R1 JANUARY 2001 Page 1A-1 IMPORTANT INFORMATION Section 1A - Specifications Table of Contents Specifications 1A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Information Charts 1A-10 . . . . . . . . . . . . . . . Specifications Models 75/90 (4-Stroke) PERFORMANCE Horsepower: Model 75 Model 90 Wide Open Throttle (WOT) RPM Range: Model 75 Model 90 75 hp (55.9 Kw) @ 5000 rpm 90 hp (67.1 Kw) @ 5500 rpm 4500 - 5500 5000 - 6000 OUTBOARD WEIGHT Electric 75/90 ELPT 386 lb (175.1 kg) FUEL Recommended Gasoline Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 OIL Oil Filter Oil Filter Wrench Engine Oil Capacity Engine Oil +20 +40 +60 +80 F° C° 0 +100 –7 +4 +16 +27 –18 +38 SAE 10W-30 SAE 25W-40 p/n 35-822626A2 p/n 91-802653 Either 5 Quarts or 5 Liters SAE 10W-30 viscosity oil is recommended for use in all temperatures. SAE 25W-40 viscosity oil may be used at temperatures above 40° F (4° C). Use Quicksilver 4-Cycle Marine Oil with the proper viscosity for the expected temperature in your area (see range thermometer on left). If not available, use a premium quality 4-cycle engine oil cer- tified to meet or exceed any one of the following American Petroleum Institute (API) service classifications SH, SG, SF, CF-4, CE, CD, CDll.

SPECIFICATIONS Page 1A-2 90-858895R1 JANUARY 2001 IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Torque Firing Order Ignition Timing: @ Idle (850 rpm) @ WOT (6000 rpm) Stator Output - Peak Voltage: @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Crank Position Sensor Output - Peak Voltage: (WHT/BLK - BLK) for Cylinders 1 & 4 (WHT/RED - BLK) for Cylinders 2 & 3 @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Crank Position Sensor Resistance (WHT/BLK - BLK) for Cylinders 1 & 4 (WHT/RED - BLK) for Cylinders 2 & 3 CDI Unit Output - Peak Voltage: (BLK/ORG - BLK) for Cylinders 1 & 4 (BLK/WHT - BLK) for Cylinders 2 & 3 @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Ignition Coil Resistance: Primary Secondary (Without Boots) High Tension Lead Resistance: Cylinder #1 Cylinder #2 Cylinder #3 Cylinder #4 Engine Protection Controls: Engine Speed Limiter Spark Cut-Out to Cylinders #1 or #4 #1 and #4 #1, #4, and #2 or #3 #1, #2, #3, and #4 Overheat/Low Oil Pressure Engine Speed Control (Spark Cut-Out to Cylinders #1 and #4) Water Temperature Sensor: 2000 Engine S/N OT178499 and Below Warning Horn/rpm Reduction Reset Temperature (Throttle Closed/Key off) 2001 Engine S/N OT178500 and Above Warning Horn/rpm Reduction Reset Temperature (Throttle Closed/Key Off) Microcomputer-Controlled CDI NGK LFR5A-11 0.043 in. (1.1 mm) 5/8 in. (16 mm) 18 lb-ft (25 Nm) 1-3-4-2 5° A.T.D.C 18° B.T.D.C 6 - 9 V (WHT – WHT) 12 - 18 V (WHT - WHT) 14 - 25 V (WHT - WHT) 0.32 - 0.48 Ω (WHT - WHT) 2.8 - 3.4 V 6.5 - 7.8 V 10.5 - 12.0 V 445 - 545 Ω 445 - 545 Ω 165 - 190 V 175 - 200 V 175 - 200 V 0.078 - 0.106 Ω (BLK - BLK/WHT) 3.5 - 4.7 kΩ (Between Towers) 4.5 - 10.7 kΩ 3.3 - 8.0 kΩ 3.7 - 8.9 kΩ 4.3 - 10.2 kΩ 6200 rpm 6250 rpm 6300 rpm 6350 rpm Gradually Lowers to 3000 rpm 140°F (60°C) 118°F (48°C) 194°F (90°F) 167°F (75°C)

SPECIFICATIONS 90-858895R1 JANUARY 2001 Page 1A-3 IGNITION SYSTEM Readings taken @ 68°F (20°C). 2000 Engine Oil Pressure Switch: S/N OT178499 and Below Warning Horn/rpm Reduction Reset Pressure ECM reset@ Closed Throttle/Key Off 2001 Engine Oil Pressure Switch: S/N OT178500 and Above Warning Horn/rpm Reduction Reset Pressure ECM reset@ Closed Throttle/Key Off Engine Water Temperature Sensor Resistance: @ -4°F (-20°C) @ 32°F (0°C) @ 68°F (20°C) @ 104°F (40°C) Throttle Position Sensor (TPS): Input Voltage @ Idle (850 rpm) Output Voltage@ Idle (850 rpm) Stamped P.15 Continuity Below 2.2 psi (15 kPa) No Continuity Above 2.2 psi (15 kPa) Stamped 1.5 Continuity Below 21.78 psi (150 kPa) No Continuity Above 21.78 psi (150 kPa) 15.5 kΩ 5.79 kΩ 2.45 kΩ 1.50 kΩ 5.0 ± 0.25 V (RED - ORG) 0.68 - 0.82 V (PNK - ORG) CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: Alternator Output Stator Coil Output - Peak Voltage: @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Rectifier/Regulator Output - Peak Voltage: @ 1000 rpm @ 1500 rpm @ 3500 rpm @ 6000 rpm Quicksilver Tachometer Setting Three Phase Stator Coil (12 Pole) 12.0 V; 20 Amps. (240 Watts) (Rectified/Regulated) 6 - 9 V (WHT – WHT) 12 - 18 V (WHT - WHT) 14 - 25 V (WHT - WHT) 0.32 - 0.48 Ω (WHT - WHT) 18 - 22 V (RED - BLK) 19 - 24 V (RED - BLK) 19 - 24 V (RED - BLK) 19 - 24 V (RED - BLK) “6P” or “4” STARTING SYSTEM Electric Start: Starter Type Model/Manufacturer Weight Output Rating Reduction Gear Ratio Brush: Length Minimum Length Commutator: Diameter Minimum Diameter Undercut Undercut Limit Ampere Draw Under: (Load) (No Load) Sliding Gear S114-828/Hitachi 7 lb, 11 oz (3.5 kg) 1.4 kW - 12 V 30 Seconds 7.85 (102:13) 0.610 in. (15.5 mm) 0.374 in. (9.5 mm) 1.113 in. (29.0 mm) 1.100 in. (28.0 mm) 0.020 in. (0.5 mm) 0.008 in. (0.2 mm) 165 Amps 80 Amps

SPECIFICATIONS Page 1A-4 90-858895R1 JANUARY 2001 BATTERY Battery Rating Minimum Requirement For operation below 32° F (0° C) Ampere-Hours (Ah) 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) 70 - 100 ENRICHMENT CONTROL SYSTEM Readings taken @ 68°F (20°C). Auto Enrichener Resistance 15 - 25 Ohms (BLU - BLK) FUEL SYSTEM Fuel Pump Type Fuel Pump: Discharge (@ 3000 rpm) Pressure (Maximum) Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 17 gph (65 L/h) 7 psi (49 kPa) 0.23 - 0.36 in. (5.85 - 9.05 mm) Accessory CARBURETOR Number of Carburetors ID Mark 75 90 Venturi Size 75 90 Idle rpm (Neutral) Warm Engine Idle rpm (Forward Gear) Warm Engine Wide Open Throttle rpm (WOT) Range: Model 75 Model 90 Main Jet 75 90 Main Air Jet 75 90 Pilot Jet 75 90 Pilot Air Jet 75 90 Mid Range Jet 75 90 Pilot Screw 75 90 Float Height 4 67G 67F 0.945 in. (24 mm) 1.181 in. (30 mm) 850 ± 25 rpm 775 - 800 rpm 4500-5500 5000–6000 #112 #128 #115 #75 #45 #42 #85 #85 None #40 2-1/2 ± 1/2 2 ± 1/2 0.51 - 0.59 in. (13.0-15.0 mm) CYLINDER BLOCK Type Displacement Number of Cylinders In–Line, 4 Stroke – DOHC, 16 Valves 97.4 cid (1,596 cc) 4

SPECIFICATIONS 90-858895R1 JANUARY 2001 Page 1A-5 STROKE Length 3.205 in. (81.4 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Taper/Out of Round Maximum Bore Type 3.110 - 3.111 in. (79.000 - 79.020 mm) 3.120 - 3.121 in. (79.250 - 79.270 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type Measure Point (H) O.D. at Skirt (H) Standard (D) Oversize-0.010 in. (0.25 mm) Pin Boss Inside Diameter H D Aluminum 0.51 in. (13 mm) 3.1073 - 3.1082 in. (78.928 - 78.949 mm) 3.1174 - 3.1182 in. (79.178 - 79.199 mm) 0.7090 - 0.7093 in. (18.008 - 18.015 mm) PISTON CLEARANCE Piston to Cylinder Clearance 0.0028 - .0031 in. (0.070 - 0.080 mm) RINGS Top Ring Dimension “B” Dimension “T” End Gap (Installed) Side Clearance Middle Ring Dimension “B” Dimension “T” End Gap (Installed) Side Clearance Bottom (Oil Ring) Dimension “B” Dimension “T” End Gap (Installed) Side Clearance T B T B T B 0.046 - 0.047 in. (1.17 - 1.19 mm) 0.114 - 0.115 in. (2.89 - 2.91 mm) 0.006 - 0.012 in. (0.15 - 0.30 mm) 0.001 - 0.003 in. (0.02 - 0.08 mm) 0.058 - 0.059 in. (1.47 - 1.49 mm) 0.118 - 0.126 in. (3.00 - 3.20 mm) 0.028 - 0.035 in. (0.70 - 0.90 mm) 0.001 - 0.003 in. (0.03 - 0.07 mm) 0.094 - 0.098 in. (2.38 - 2.48 mm) 0.094 in. (2.40 mm) 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.001 - 0.006 in. (0.03 - 0.15 mm) COMPRESSION RATIO Compression Ratio Cylinder Compression (Minimum) 9.6:1 138 psi (950 kPa) PISTON PIN Piston Pin Outside Diameter 0.7083 - 0.7087 in. (17.997 - 18.000 mm) CONNECTING ROD Small End Inside Diameter Big End Inside Diameter Oil Clearance (Big End) Big End Bearing Thickness Yellow Green Blue Red 0.7073 - 0.7081 in. (17.965 - 17.985 mm) 1.8514 - 1.8518 in. (47.025 - 47.035 mm) 0.0009 - 0.0014 in. (0.023 - 0.035 mm) 0.0590 - 0.0593 in. (1.499 -1.506 mm) 0.0593 - 0.0596 in. (1.506 - 1.513 mm) 0.0596 - 0.0598 in. (1.513 - 1.520 mm) 0.0598 - 0.0601 in. (1.520 - 1.527 mm)

SPECIFICATIONS Page 1A-6 90-858895R1 JANUARY 2001 CRANKSHAFT Crankshaft Journal Diameter Minimum Diameter Crankshaft Pin Diameter Minimum Diameter Crankshaft Run-out 1.8892 - 1.8898 in. (47.985 - 48.000 mm) 1.8887 in. (47.972 mm) 1.7316 - 1.7323 in. (43.982 - 44.000 mm) 1.7311 in. (43.971 mm) 0.001 in. (0.03 mm) CRANKCASE Crankcase Main Journal Inside Diameter Crankshaft Journal Oil Clearance Upper Crankcase Main Journal Bearing Thickness Green Blue Red Lower Crankcase Main Journal Bearing Thickness Yellow Green Blue Red No. 3 Main Journal Bearing Thickness Green Blue Red 2.1269 - 2.1276 in. (54.023 - 54.042 mm) 0.0009 - 0.0017 in. (0.024 - 0.044 mm) 0.1178 - 0.1181 in. (2.992 - 2.999 mm) 0.1181 - 0.1183 in. (2.999 - 3.006 mm) 0.1183 - 0.1186 in. (3.006 - 3.013 mm) 0.1185 -0.1188 in. (3.010 - 3.017 mm) 0.1188 - 0.1191 in. (3.017- 3.024 mm) 0.1191 - 0.1193 in. (3.024 - 3.031 mm) 0.1193 - 0.1196 in. (3.031 - 3.038 mm) 0.1178 - 0.1181 in. (2.992 - 2.999 mm) 0.1181 - 0.1183 in. (2.999 - 3.006 mm) 0.1183 - 0.1186 in. (3.006 - 3.013 mm)

SPECIFICATIONS 90-858895R1 JANUARY 2001 Page 1A-7 CAMSHAFT Camshaft Dimensions Intake “A” Exhaust “A” Intake “B” Exhaust “B” Valve Lift Intake Exhaust Run-out Limit Camshaft Bearing Diameter “a” Camshaft Bearing Oil Clearance A B A 1.465 - 1.472 in. (37.22 - 37.38 mm) 1.453 - 1.459 in. (36.90 - 37.06 mm) 1.178 - 1.184 in. (29.92 - 30.08 mm) 1.178 - 1.184 in. (29.92 - 30.08 mm) 0.273 in. (6.94 mm) 0.259 in. (6.58 mm) 0.0039 in. (0.1 mm) 0.9827 - 0.9835 in. (24.96 - 24.98 mm) 0.0008-0.0024 in.(0.020-0.061 mm) VALVE SPRING Free Length “a” Minimum Free Length Tilt Limit “b” a b 2.094 in. (53.20 mm) 2.057 in. (52.25 mm) Less than 0.10 in. (2.6 mm) CYLINDER HEAD Warp Limit Camshaft Bearing Inside Diameter a Valve Lifter Bore Inside Diameter 0.004 in. (0.1 mm) 0.984 - 0.985 in. (25.000 - 25.021 mm) 1.102 - 1.103 in. (28.000 - 28.021 mm)

SPECIFICATIONS Page 1A-8 90-858895R1 JANUARY 2001 VALVES Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake Exhaust Valve Face Angle Intake Exhaust Valve Dimensions: “A” Head Diameter Intake Exhaust “B” Face Width Intake Exhaust “C” Seat Width Intake Exhaust “D” Margin Thickness Intake Exhaust Stem Outside Diameter Intake Exhaust Guide Inside Diameter Intake Exhaust Stem To Guide Clearance Intake Exhaust Stem Run-out Limit (max.) 0.007 - 0.009 in. (0.17 - 0.23 mm) 0.011 - 0.014 in. (0.31 - 0.34 mm) 120°, 91°, 110° 140°, 91°, 110° 1.142 - 1.150 in. (29.0 - 29.2 mm) 0.945 - 0.953 in. (24.0 - 24.20 mm) 0.079 - 0.096 in. (2.00 - 2.43 mm) 0.090 - 0.107 in. (2.28 - 2.71 mm) 0.014 - 0.022 in. (0.35 - 0.55 mm) 0.014 - 0.022 in. (0.35 - 0.55 mm) 0.018 - 0.026 in. (0.45 - 0.65 mm) 0.026 - 0.033 in. (0.65 - 0.85 mm) 0.2352 - 0.2358 in. (5.975 - 5.990 mm) 0.2346 - 0.2352 in. (5.960 - 5.975 mm) 0.2364 - 0.2369 in. (6.005 - 6.018 mm) 0.2364 - 0.2369 in. (6.005 - 6.018 mm) 0.0006 - 0.0017 in. (0.015 - 0.043 mm) 0.0012 - 0.0023 in. (0.030 - 0.058 mm) 0.001 in. (0.03 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness VALVE LIFTERS Valve Lifter Outside diameter Valve Lifter to Lifter Bore Clearance 1.1010 - 1.1016 in. (27.965 - 27.980 mm) 0.0008 - 0.0022 in. (0.020 -0.056 mm) VALVE SHIM Valve shim Thickness (in 0.025 mm increments) 0.0787 - 0.1299 in. (2.000 - 3.300 mm) THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 140° F (60° C) 158° F (70° C) 0.12 in. (3 mm)

SPECIFICATIONS 90-858895R1 JANUARY 2001 Page 1A-9 LUBRICATION SYSTEM Pump Type Oil Pump Drive Discharge at 212°F (100°C) with 10W-30 Oil at 1000 rpm Engine Oil Pressure (Warm Engine) @ 850 rpm Engine Oil Pan Capacity Relief Valve Opening Pressure Oil Pump: Non-Serviceable Trochoid with Relief Valve Drive shaft Spline 1.56 gph (5.9 L/h) 46.5 psi (320 kPa) Either 5 Qts. or 5 Liters 71 psi (490 kPa) MID-SECTION Recommended Transom Height: Short Shaft Long Shaft Steering Pivot Range Full Tilt Up Angle Allowable Transom Thickness (Max) 20 in. (51 cm) 25 in. (64 cm) 60° 71° 3 in. (76.2 mm) GEAR HOUSING BIGFOOT (2.07:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Pinion Gear Locating Tool Flat Number Disc Number Forward Gear Backlash Backlash Indicating Tool Mark Number Water Pressure @ 1000 rpm @ 6000 rpm (WOT) 2.07:1 22.5 fl oz (665 mL) Quicksilver Gear Lube-Premium Blend 29 Spiral/Bevel 14 Spiral/Bevel 0.025 in. (0.64 mm) 91-12349A2 #2 #3 0.015-0.022 in. (0.38-0.55 mm) 91-19660--1 #1 5 psi (34.5 kPa) 20.5 psi (141.5 kPa)

SPECIFICATIONS Page 1A-10 90-858895R1 JANUARY 2001 Propeller Information Charts Mercury/Mariner 75 (4-Stroke) 2.07:1 Wide Open Throttle RPM : 4500-5500 Recommended Transom Heights : 20” Right Hand Rotation Standard Gear Reduction : 2.07:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 13-1/2” 26” 3 Steel Up to 1400 Up to 16’ 47-64 48-16996A45 13-1/2” 24” 3 Steel Up to 1600 Up to 16’ 42-58 48-16994A45 12-1/2” 23” 3 Alum 1200-1700 15-17’ 40-55 48-77350A45 13-1/2” 22” 3 Steel 1300-1900 15-17’ 38-52 48-16992A45 12-3/4” 21” 3 Alum 1400-2000 15-17’ 35-49 48-77348A45 13-1/4” 20” 3 Steel 1500-2200 16-18’ 33-46 48-16990A45 13” 19” 3 Alum 1600-2400 16-18’ 31-43 48-77346A45 13” 18” 3 Steel 1800-2600 16-18’ 29-40 48-16988A45 13-1/4” 17” 3 Alum 1900-2900 17-19’ 27-37 48-77344A45 13-1/8” 16” 3 Steel 2100-3200 17-19’ 24-34 48-16986A45 13-1/4” 16” 3 Alum 2100-3200 17-19’ 24-34 48-854360A45 13-3/4” 15” 3 Alum 2300-3600 17-20’ 22-32 48-77342A45 13-3/8” 14” 3 Steel 2600-4100 19-21’ 20-29 48-17314A45 14” 13” 3 Alum 2900-4600 19-22’ 18-26 48-77340A45 14” 12” 3 Steel 3700+ pontoon 16-23 48-17312A45 14” 11” 3 Alum 4500+ pontoon/work 15-21 48-77338A45 14” 10” 3 Steel 5500+ houseboat/ work 1-18 48-17310A45 14” 10” 3 Alum 5500+ houseboat/ work 1-18 48-854342A45

2000+ Mercury 75-90HP 4-Stroke Outboard Service & Repair Manual

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