Mercury 90 Service Manual

2A-0 - ELECTRICAL 90-830234R3 DECEMBER 1997
Table of Contents
Page
Special Tools 2A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Cylinder Electrical Components
(USA-0G127499/BEL-9836632 & BELOW) 2A-2. . . . . .
Electrical Components
(USA-0G127500 thru 0G437999)(BEL-9836633 thru
9926999) 2A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Cylinder Electrical Components
(USA-S/N-0G438000/BEL-9937000 & UP) 2A-6. . . . . . .
4 Cylinder Electrical Components
(S/N-USA-437999/BEL-9926999 & BELOW) 2A-8. . . . .
4 Cylinder Electrical Components
(USA-S/N-0G438000/BEL-9937000 & UP) 2A-10. . . . . .
Description 2A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedures 2A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Voltage Adapter (DVA) Tests 2A-12. . . . . . . . .
Test Sequence 2A-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System DVA Specifications Test Chart 2A-14. .
3 Cylinder Stators
75 Manual with 9 Ampere Stator 398-9873A20,
USA-0D283222 thru 0G227199
75/90 Electric with 16 Ampere Stator
398-9710A3, USA-0D283222 thru 0G280043
Belgium-09793577 thru 09879064 2A-14. . . . . . . . . .
4 Cylinder with 16 Ampere Stator 398-9710A31
USA-0D283222 thru 0G301750
Belgium-09793577 thru 09885527 2A-14. . . . . . . . . .
3 Cylinder Stators
75 Manual with 9 Ampere Stator 398-9873A21,
USA-0D227200 and Above
75/90 Electric with 14 Ampere Stator
398-9873A24, USA-0G280044 thru 0G404505
Belgium-09879065 thru 09916672 2A-15. . . . . . . . . .
Page
4 Cylinder with 16 Ampere Stator 398-9710A33
USA-0G301751 and Above
Belgium - 09885528 thru 09916721 2A-15. . . . . . . . .
ADI Ignition using a RED Stator with an
Adapter Module 2A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RED Stator with Adaptor and Ignition Coils 2A-18. . . . .
RED Stator DVA Test 2A-18. . . . . . . . . . . . . . . . . . . . .
Electric Start Engines 2A-18. . . . . . . . . . . . . . . . . . . . .
Manual Start Engines 2A-18. . . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedures 2A-18. . . . . . . . . . . . . . .
Theory of Operation 2A-19. . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor Charging #1 CDM 2A-20. . . . . . . . . . . . . . .
Capacitor Charging #2 & #3 CDM 2A-21. . . . . . . . . .
#1 Cylinder Trigger Circuit 2A-22. . . . . . . . . . . . . . . . .
Ignition Coil Circuit 2A-23. . . . . . . . . . . . . . . . . . . . . . .
Stop Circuit 2A-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rev Limiter Circuit 2A-25. . . . . . . . . . . . . . . . . . . . . . . .
RED Stator with CDM 2A-26. . . . . . . . . . . . . . . . . . . . . . . .
Ignition Component Description 2A-26. . . . . . . . . . . .
CDM (P/N 827509) 2A-27. . . . . . . . . . . . . . . . . . . . . . .
Spark Gap Tester P/N 91-850439 2A-27. . . . . . . . . .
CDM Test Harness 84-825207A2 2A-27. . . . . . . . . . .
Direct Voltage Adaptor (DVA) Test 2A-32. . . . . . . . . .
Resistance Tests 2A-34. . . . . . . . . . . . . . . . . . . . . . . . .
Ignition (Key) Switch Test 2A-35. . . . . . . . . . . . . . . . . .
Flywheel Removal and Installation 2A-35. . . . . . . . . . . . .
Stator Removal and Installation 2A-36. . . . . . . . . . . . . . .
Trigger Removal and Installation 2A-39. . . . . . . . . . . . . .
Ignition Coil Removal and Installation 2A-41. . . . . . . . . .
Switch Box Removal and Installation 2A-42. . . . . . . . . . .

Mercury 90 Specifications

General

Brand	Mercury
Model	90
Category	Outboard Motor
Language	English