Mercury 90HP 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)

Mercury 90HP Outboard Service & Repair Manual

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