Mercury 90HP 3-Cylinder Outboard OEM Service & Repair Manual

1 A IMPORTANT INFORMATION SPECIFICATIONS

90-824052R3 JUNE 2002 1A-0 - IMPORTANT INFORMATION Table of Contents Page Master Specifications 1A-1 . . . . . . . . . . . . . . . . . . . . .

90-824052R3 JUNE 2002 IMPORTANT INFORMATION - 1A-1 Master Specifications Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI PRO MAX/SUPER MAGNUM 150/200/225 HORSEPOWER (KW) Model 135 Model 105 Jet/150/150XRI Model XR6/MAGIII Model 175/175XRI Model 140 Jet/200/200XRI Model Pro Max/Super Magnum 150 Model Pro Max/Super Magnum 200 Model Pro Max/Super Magnum 225 135 (100.6) 150 (111.8) 150 (111.8) 175(130.5) 200(149.1) 150 (111.8) 200(149.1) 225(167.9) OUTBOARD WEIGHT Model 135/150 Model Pro Max/Super Magnum 150/200/225 Model XR6/MAGIII/175/200 Model 150XRI/175XRI/200XRI Model 105 Jet Model 140 Jet 404.0 lbs. (184.0kg) 350.0 lbs. (159.0kg) 395.0 lbs. (180.0kg) 410.0 lbs. (186.0kg) 428.0 lbs. (195.0kg) 408.0 lbs. (185.5kg) CYLINDER BLOCK Model 105 Jet/135/150 Type Displacement Model 140 Jet/XR6/MAGIII/I75/200 150XRI/175XRI/200XRI/Pro Max/ Super Magnum 150/200/225 Type Displacement V–6 Cylinder, Two Cycle, Loop Charged 121.9 cu. in. (1998cc) V–6 Cylinder, Two Cycle, Loop Charged 153.0 cu. in. (2507cc) STROKE Length (All Models) 2.650 in. (67.31mm) CYLINDER BORE Diameter (Std) – Models 105 Jet/135/150 – Models XR6/MAGIII/175/200 150XRI/175XRI/200XRI/140 Jet Pro Max/Super Magnum 150/200/225 Taper/Out of Round/Maximum Wear Bore Type 3.125 in. (79.375mm) 3.501 in. (88.925mm) 0.003 in. (0.076mm) Cast Iron PISTON Piston Type Models 105 Jet/135/150 Standard 0.015 in. (0.381mm) Oversize 0.030 in. (0.762) Oversize Models XR6/MAGIII/175/200/140 Jet 150XRI/175XRI/200XRI/ProMax/ Super Magnum 150/200/225 Standard 0.015 in. (0.381mm) Oversize Aluminum 3.115 in. ± 0.002 in. (79.121mm ± 0.051mm) 3.130 in. ± 0.002 in. (79.502mm ± 0.051mm) 3.145 in. ± 0.002 in. (79.883mm ± 0.051mm) 3.494 in. ± 0.001 in. (88.748mm ± 0.025mm) 3.509 in. ± 0.001 in. (89.129mm ± 0.025mm)

90-824052R3 JUNE 2002 1A-2 - IMPORTANT INFORMATION Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI PRO MAX/SUPER MAGNUM 150/200/225 COMPRESSION All Models – Using a fully charged battery, throttle shutters wide open and cylinder block warm 110 – 135 psi (753.3 – 924.5 kPa) Variance between cylinders should not exceed 15 psi (102.7 kPa) REEDS Model 105 Jet/135/150 Model XR6/MAGIII/175/200 Model 150XRI/175XRI/200XRI Reed Type Reed Stand 0pen (Max.) Reed Stop (Max.) Model Pro Max/Super Magnum 150/200/225 Reed Type Reed Stop (Max.) Steel 0.020 in. (0.50mm) Not Adjustable 2 Stage Plastic No Stop MID SECTION Power Trim (Total Tilt Range) Power Trim (Trim Range) Steering Pivot Range Tilt Pin Adjustment Positions Allowable Transom Thickness 75° 20° 60° 5 2-3/8 in. (6.03cm) Maximum GEAR HOUSING Gear Ratio – Models 135/150 – Models XR6/MAGIII/150XRI – Models XR6/MAGIII (4-1/4″ dia.) – Models 175/200/175XRI/200XRI – Model Pro Max/Super Magnum 200/225 Gear Ratio – High Altitude – Models 135/150 – Models XR6/MAGIII/175/200 150XRI/175XRI/200XRI – Model Pro Max/Super Magnum 150 Gearcase Capacity – 1.87:1/2.00:1/2.30:1 – 1.78:1 Pinion Height – All Models Forward Gear Backlash – 1.78:1 Ratio – 1.87:1 Ratio – 2.00:1 Ratio – 2.30:1 Ratio Water Pressure @ RPM 2.00:1 (14/28 teeth) 1.87:1 (15/28 teeth) 1.78:1 (14/25 teeth) 1.87:1 (15/28 teeth) 1.87:1 (15/28 teeth) 2.30:1 (13/30 teeth) 2.00:1 (14/28 teeth) 2.00:1 (14/28 teeth) 22.5 fl. oz. (665.4ml) 21.0 fl. oz. (621.0ml) 0.025 in. (0.64mm) 0.016 in – 0.019 in. (0.406mm – 0.482mm) 0.018 in. – 0.027 in. (0.460mm – 0.686mm) 0.015 in. – 0.022 in. (0.381mm – 0.558mm) 0.018 in. – 0.023 in. (0.460mm – 0.584mm) 12 PSI Minimum @ 5500 RPM

90-824052R3 JUNE 2002 IMPORTANT INFORMATION - 1A-3 Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI PRO MAX/SUPER MAGNUM 150/200/225 FUEL SYSTEM Fuel Recommended Gasoline Model 105/140 Jet/135/150 Model XR6/MAGIII/175/200 Model 150XRI/175XRI/200XRI Model Pro Max/Super Magnum 150/200/225 Recommended Oil All Models Gasoline/Oil Ratio Fuel Pressure – @ Idle – @ WOT Gasoline w/Oil Injection Unleaded 87 Octane Minimum Unleaded 92 Octane Minimum Quicksilver TC-W3 2 Cycle Outboard Oil Only 50:1 (25:1 Break-In) Normal – 2-3 psi (14-21 kPa) Minimum – 1 psi (7 kPa) Maximum – 10 psi (69 kPa) Normal – 8-10 psi (55–69 kPa) Minimum – 3 psi (21 kPa) STARTING SYSTEM Manual Start – All Models Electric Start – All Models Starter Draw (Under Load) Starter Load (No Load) Battery Rating Emergency Start Rope 175 Amperes 40 Amperes Min. Reserve Cap. Rating of 100 Min. and CCA of 490 (MCA of 630 Amperes) IGNITION SYSTEM Type Spark Plug Type (Except 225 ProMax and 225 Super Magnum Spark Plug Type (225 ProMax and 225 Super Magnum only) Spark Plug Gap Capacitor Discharge NGK BU8H Surface Gap NGK BUZHW Surface Gap CHARGING SYSTEM Alternator Output (Regulated) 40 Amperes @ 5000 RPM F U E L I N J E C T I O N Idle RPM – All Models Wide Open Throttle (WOT) RPM – Model 150XRI/175XRI – Model 200XRI – Pro Max/Super Magnum Float Adjustment (Vapor Separator) Float Level Injectors – All Models (Quantity) – Inner Switch Box Controls: – #1 Primary Circuit – #3 Primary Circuit – #5 Primary Circuit Line Pressure @ Injectors – 150XRI/175XRI/200XRI – Pro Max/Super Magnum – (S/N 0G303045 and below) – (S/N 0G303046 and above) 650 ± 50 5000 – 5600 5000 – 5800 6200 – 6500 Preset @ Factory 6 #3 and #4 Injectors #5 and #6 Injectors #1 and #2 Injectors 34 PSI - 36 PSI (234 kPa - 248 kPa) 36 PSI - 39 PSI (248 kPa - 269 kPa) 34 PSI - 36 PSI (234 kPa - 248 kPa)

Mercury 90HP 3-Cylinder Outboard OEM Service & Repair Manual

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