This comprehensive Mercury Outboard Service Manual covers a wide range of models from 1965 to 1989, encompassing horsepower ratings from 90 to 300. The manual caters specifically to Mercury's inline 6 and V6, 2-stroke outboard motors, including fuel injection and MR Drive models. It provides detailed information on servicing and repairing these motors, covering a wide range of model numbers: 90, 95, 100, 115, 125, 135, 140, 150, 150XR2/150 HP, 155 HP, 175 HP, 200 HP, 220XRi/200 HP, 225 HP, 275 HP, 300 HP, 850XS/90 HP, 4cyl 900/90hp, 6cyl 950/95hp, 6cyl 1000/100hp, 6cyl 1100/100hp, 6cyl 1150/115hp, 6cyl 1250/125hp, 6 cyl 1350/135hp, 6cyl 1400/140hp 1400/140hp, 6cyl 1500/150hp, 6cyl 1500XS/155hp, 6 cyl 1750/175hp, V6 2000/200hp, V6 models produced from 1965 to 1989. The manual delves deep into service procedures for the entire outboard engine, providing a step-by-step approach for removing and installing various components. Each chapter utilizes a combination of illustrations, diagrams, exploded parts views, pictures, and service information to facilitate understanding. You'll find detailed instructions for troubleshooting and maintenance, ensuring you have all the necessary information to keep your Mercury outboard running smoothly. The manual includes a comprehensive specifications section covering essential details like overall length, width, weight, transom height, operating range, idle speed, engine type, number of cylinders, total displacement, spark plug type, fuel supply system, exhaust system, cooling system, lubrication system, starting system, and more. The maintenance section provides a complete guide to scheduled maintenance, including intervals, recommendations, and step-by-step procedures for tasks such as spark plug replacement, fuel line replacement, breather hose replacement, engine oil and gear oil changes, lubrication, anode and bonding wire maintenance, battery maintenance, fuel mixture checks, engine oil filter changes, low and high-pressure fuel filter changes, ignition timing adjustments, idle speed adjustments, tappet clearance checks, water pump inspection and maintenance, propeller nut and pin maintenance, balancer chain inspection, timing belt inspection, and much more. The general information section offers essential insights including identification numbers, tightening torques, service data, specifications, cylinder numbering, propeller information, gasoline recommendations (87, 91, 92, 93, race gas), warm-up recommendations, and other crucial details. You'll find a dedicated section for the electrical systems, outlining the procedures for removing and installing electrical components. This section covers the inspection, removal, installation, and troubleshooting of monitor tachometers, starter motors, electric starter systems, battery charging systems, and their components. The ignition system section provides detailed information on specifications, special tools, ignition timing checks, charge coil resistance, crank position sensor resistance, ignition coil resistance, ECM engine speed limiter, spark cut-out reduction, ignition spark ECM, low oil pressure speed control, oil pressure switch, and more. If your outboard is equipped with a carburetor, the manual offers comprehensive guidance on adjusting, rebuilding, removing, inspecting, and cleaning the carburetor to factory specifications. This section includes information on specifications, special tools, intake carburetor adjustments, idle speed linkage adjustments, choke adjustments, carburetor removal, disassembly, cleaning, inspection, repair, and reassembly procedures, along with detailed instructions for measuring float height and installing electric choke models. For outboards equipped with electronic fuel injection (EFI), the manual provides thorough coverage of the system, outlining specifications, fuel injection nozzle information, fuel injection pump and fuel pump details, throttle body information, throttle control lever and linkage, high-pressure fuel line specifications, fuel cooler information, fuel hose details, fuel rail pressure regulator information, idle speed control assembly specifications, intake manifold information, throttle position sensor information, low-pressure fuel line/fuel pump information, fuel filter specifications, and more. The powerhead section covers everything needed to completely rebuild the engine block to factory specifications. This section delves into components like the cylinder head cover, intake manifold assembly, ring gear cover, air intake, power unit (powerhead), measuring pump components, oil pump, engine lubrication system, thermostat, cylinder, crankshaft, piston, counter balancer mechanism, and cylinder head assembly. It provides comprehensive instructions for removal, inspection, installation, and assembly procedures. The mid-section of the manual focuses on components like the engine side cover, driveshaft housing, oil pan, swivel bracket, steering bracket and clamp, water pressure valve, lower unit gear housing. You'll find detailed instructions for inspecting, removing, installing, cleaning, assembling, and reassembling these components. The lower unit section addresses the gear case, propeller, lower unit gears, shimming and adjustment procedures, trim tab, drive shaft, oil seal housing, water pump and related components, shift guide housing, propeller shaft components, gear bearing, propeller shaft gear housing, and more. The manual also contains additional chapters covering attachments and control linkage, throttle and shift linkage, tiller handle, manual starter, diagnostic troubleshooting, and wiring diagrams. This comprehensive resource provides everything you need to properly service and maintain your Mercury outboard motor, ensuring optimal performance for years to come.

This comprehensive service manual, aptly titled "MERCURY DOWNLOAD 1965-1989 Service Manual 90 to 300 HP Outboard," is an essential guide for anyone seeking to maintain, repair, or troubleshoot Mercury and Mariner outboard motors manufactured between 1965 and 1989. It covers a wide range of popular models, encompassing both inline six and V6 configurations, including fuel-injected and MR Drive systems. The manual features detailed information for motors ranging from 90 HP to 300 HP, ensuring that owners of these powerful outboard engines have access to a complete and accurate resource. This digital manual is a comprehensive solution, providing step-by-step instructions and illustrations for virtually every aspect of outboard maintenance and repair. The manual covers a wide range of topics, from basic maintenance procedures like oil changes and spark plug replacements to complex repairs involving engine components and electrical systems. It includes detailed specifications for each model, ensuring precise component selection and measurements. The manual also offers comprehensive troubleshooting guides, helping owners identify and rectify common issues. With its detailed instructions, diagrams, and exploded views, this manual empowers both amateur and professional mechanics to confidently tackle any repair task. Whether you're a seasoned marine enthusiast or a first-time owner, this digital service manual is an invaluable asset, offering comprehensive guidance, saving you time, money, and frustration.