Mercury 90 Service Manual

5B-0 - MID-SECTION 90-830234R3 DECEMBER 1997
Table of Contents
Page
Special Tools 5B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim Components (Black Fill Plug)
(S/N-USA-0G360002/BEL-9934136 & BELOW) 5B-2. .
Power Trim - General Information 5B-4. . . . . . . . . . . . . .
Description 5B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trimming Characteristics 5B-4. . . . . . . . . . . . . . . . . . .
Trailering Outboard 5B-4. . . . . . . . . . . . . . . . . . . . . . . .
Tilting Outboard Up and Down Manually 5B-5. . . . . .
Trim “In” Angle Adjustment 5B-5. . . . . . . . . . . . . . . . .
Troubleshooting 5B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining if Problem is Electrical or Hydraulic 5B-6
Problem Chart 5B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System Troubleshooting 5B-7. . . . . . . . . . .
Date Code Location 5B-7. . . . . . . . . . . . . . . . . . . . . . .
Preliminary Checks 5B-8. . . . . . . . . . . . . . . . . . . . . . . .
Leak Down Check - Pump and Manifold
Assembly 5B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 5B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim Partial Leak Down at Maximum
Trim 5B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Down Check - Pilot Valve Assembly 5B-11. . . .
Leak Down Check - Manual Release Valve 5B-11. .
Leaks Past Ball and Seat - Piston Assembly 5B-11.
Power Trim Rocker Arm 5B-12. . . . . . . . . . . . . . . . . . .
Troubleshooting Flow Diagram 5B-13. . . . . . . . . . . . .
Troubleshooting Flow Diagram 5B-14. . . . . . . . . . . . .
Electrical System Troubleshooting 5B-15. . . . . . . . . .
COMMANDER 2000 Side Mount
Remote Control (Power Trim/Tilt
Electric Start with Warning Horn)
Wiring Diagram 5B-15. . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim System Wiring Diagram 5B-16. . . . . . . .
Troubleshooting the “Down” Circuit*
(When “Up” Circuit is OK) 5B-17. . . . . . . . . . . . . . . . .
Troubleshooting the “Up” Circuit*
(When “Down” Circuit Is OK) 5B-17. . . . . . . . . . . . . . .
Troubleshooting the “Down” and “Up” Circuits*
(All Circuits Inoperative) 5B-18. . . . . . . . . . . . . . . . . . .
Page
Power Trim System Removal 5B-19. . . . . . . . . . . . . . . . .
Power Trim System Disassembly 5B-24. . . . . . . . . . . . . .
Trim Rod Removal 5B-24. . . . . . . . . . . . . . . . . . . . . . .
Trim Rod Disassembly 5B-25. . . . . . . . . . . . . . . . . . . .
Trim Motor Removal 5B-26. . . . . . . . . . . . . . . . . . . . . .
Trim Motor Disassembly 5B-27. . . . . . . . . . . . . . . . . . .
Reservoir Assembly Removal 5B-27. . . . . . . . . . . . . .
Manifold Removal 5B-28. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection of Trim Rod Components 5B-29
Motor and Electrical Tests/Repair 5B-29. . . . . . . . . . . . . .
Trim Pump Motor Test 5B-29. . . . . . . . . . . . . . . . . . . .
Solenoid Test 5B-29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Disassembly 5B-30. . . . . . . . . . . . . . . . . . . . . . .
Armature Tests 5B-30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Repair 5B-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 5B-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim System Reassembly 5B-33. . . . . . . . . . . . . .
Manifold Installation 5B-33. . . . . . . . . . . . . . . . . . . . . .
Reservoir Installation 5B-34. . . . . . . . . . . . . . . . . . . . .
Motor Installation 5B-35. . . . . . . . . . . . . . . . . . . . . . . . .
Trim Rod Reassembly 5B-36. . . . . . . . . . . . . . . . . . . .
Trim Rod Installation 5B-37. . . . . . . . . . . . . . . . . . . . . .
Purging Power Trim Unit 5B-38. . . . . . . . . . . . . . . . . . . . .
Power Trim Unit Installation 5B-38. . . . . . . . . . . . . . . . . . .

Mercury 90 Specifications

General

Brand	Mercury
Model	90
Category	Outboard Motor
Language	English