1995-1997 Mercury Marine 90/95XR/120/120XR Sport Jet Service & Repair Manual

Printed in U.S.A. 90-831996R1 JUNE 1996 1996, Mercury Marine MODELS 1995 90/120 Sport Jet United States With Starting Serial Numbers Powerhead Pump Unit 90 HP 0E095088 0E080400 120 HP 0E093700 0E080400 1996 & 1997 95XR/120XR Sport Jet This Manual Supercedes 90-831996 95XR HP 0E141089 0E145580 120XR HP 0E141089 0E145580 1995 1996 1997 95XR HP 0E203000 0E151580 120XR HP 0E203000 0E151580

90-831996R1 JUNE 1996 Cleanliness and Care of Sport Jet A marine power product is a combination of many machined, honed, polished and lapped surfaces with tol- erances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is consid- ered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Before raising or removing an engine from a boat, the following precautions should be adhered to: 1. Check that flywheel is secured to end of crank- shaft with a locknut and lifting eye is threaded into flywheel a minimum of 5 turns. 2. Connect a hoist of suitable strength to the lifting eye. In addition, personnel should not work on or under an engine which is suspended. Engine should be at- tached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. Service Manual Outline Section 1 - General Information and Specifications Section 2 - Electrical and Ignition Part A - Ignition System Part B - CDM Ignition System Part C - Battery, Charging and Starting System Part D - Timing/Synchronizing/ Adjusting Section 3 - Fuel System and Carburetion Part A - Carburetor Part B - Fuel Pump Recirculation System Reed Valve Assembly Auto Enrichener Part C - Oil Injection System Section 4 - Powerhead Section 5 - Jet Pump Section 6 - Sport Jet Installation

90-831996R1 JUNE 1996 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incor- rectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident pre- vention measures. DANGER DANGER – Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING – Hazards or unsafe practices which COULD result in severe personal injury or death. Hazards or unsafe practices which could result in minor personal injury or product or property damage. CAUTION Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not under- taken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the product’s safety will be endangered by the service procedure selected. All information, illustrations and specifications con- tained in this manual are based on the latest product information available at the time of publication. As re- quired, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive inter- nal damage when the engine is started. It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Num- bers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mis- matched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a replacement that matches the original.

1995-1997 Mercury Marine 90/95XR/120/120XR Sport Jet Service & Repair Manual

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