Mercury 90 Service Manual

2B-0 - ELECTRICAL 90-830234R3 DECEMBER 1997
Table of Contents
Page
Specifications 2B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 2B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 2B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions 2B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Engine Without Battery 2B-2. . . . . . . . . . .
Specific Gravity Readings 2B-2. . . . . . . . . . . . . . . . . .
Electrolyte Level 2B-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Charging a Discharged Battery 2B-3. . . . . . . . . . . . . .
Winter Storage of Batteries 2B-4. . . . . . . . . . . . . . . . .
BLACK Stator Battery Charging System
Troubleshooting 2B-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Ampere (Manual Start) BLACK Stator Output
Test 2B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLACK Stator Ohms Test
(Alternator Coils Only) 2B-5. . . . . . . . . . . . . . . . . . . . .
BLACK Stator 14 and 16 Ampere Alternator
System Test 2B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer Terminal Block 2B-6. . . . . . . . . . . . . . . . .
Tachometer Terminal Block 2B-6. . . . . . . . . . . . . . . . .
RED Stator Battery Charging System
Troubleshooting 2B-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
3 Cylinder 14 and 16 Ampere BLACK Stator
Battery Charging Wiring Diagram 2B-9. . . . . . . . . . . .
4 Cylinder 14 and 16 Ampere BLACK Stator
Battery Charging Wiring Diagram) 2B-10. . . . . . . . . .
3 Cylinder Battery Charging Diagram
(with BLACK STATOR) with Battery Isolator 2B-11. .
3 Cylinder Battery Charging Diagram
(with RED STATOR) with Battery Isolator 2B-12. . . .
4 Cylinder Battery Charging Diagram
(with BLACK Stator) with Battery Isolator 2B-13. . . .
4 Cylinder Battery Charging Diagram
(with RED Stator) with Battery Isolator 2B-14. . . . . .
Rectifier Test 2B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System 2B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System Components 2B-16. . . . . . . . . . . . . .
Description 2B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting the Starting Circuit 2B-16. . . . . . . . .
Starting Circuit Troubleshooting Flow Chart 2B-17. .
Starter Motor 2B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 2B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 2B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Cleaning, Inspection and Testing 2B-20. . . . .
Testing 2B-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush Replacement 2B-22. . . . . . . . . . . . . . . . . . . . . . .

Mercury 90 Specifications

General

Brand	Mercury
Model	90
Category	Outboard Motor
Language	English