2018 Mercury 90hp Outboard Service 2 Stroke Manual


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Rules within the EU mean you can no longer buy a new, small 2-stroke outboard motor in Europe, but their light weight, compact size and longevity means tens of thousands of used examples are still to be found on boats from Caithness to Crete. The start of the season is when any unreliability issues are most likely to rear their ugly head, and there’s a good reason for that.

‘Most people assume they can just take their outboard off their boat and put it straight into their shed for the winter,’ technician Steve Dawkins told me in his workshop at the Cabin Boatyard on the Hamble River. ‘Then, come the spring, they’re surprised when it doesn’t work.’ I kept quiet. My outboard had been sitting forlornly in the garage among a pile of ropes, fenders and sails since it came ashore at the end of last summer.

Do it yourself! This step-by-step guide takes you through a service of a small 2-stroke outboard. The pictures show Mariner 3.3hp and Suzuki 2hp outboards, and while other makes of engine are subtly different, the main components should be recognisable. Anyone with a reasonable level of technical ability should be able to breeze through the service, but if you’re in any doubt, take yours along to a dealer. If you are going to do it yourself – and this mostly applies to late-model motors – check first that what you’re doing won’t invalidate any warranties. 1: Drain the old fuel ‘The most common complaint we get is from people saying it worked fine last year but now it won’t start,’ said Steve. This is because petrol evaporates over time, leaving behind an oily, paraffin-type residue which gums up the carburettor.

So the first step is to drain the old fuel. 8: Now reattach the gearbox to the lower leg.

2018 Mercury 90hp Outboard Service 2 Stroke Manual

Carefully slide in the gearbox, making sure the water pickup pipe (small spigot just above the gearbox linkage in this photo) is unblocked and lined up correctly inside its socket. On smaller engines with only one gear Remove the propeller and then the plate behind it. The water pump impeller can be found behind this plate. Check and replace the gearbox oil The professionals perform a pressure test to check the seals are still doing their job. Without the right equipment you’ll struggle to do this, so you’ll have to make do with a visual inspection.

One way to see if you have a major problem is to leave the engine standing on a piece of clean cardboard overnight and check for telltale leaks in the morning.


2004 Mercury 90 Hp Outboard Manual

2018 Mercury 90hp Outboard Service 2 Stroke Manual

You are ready to get your boat out on the water, but something is wrong — and it appears to be the outboard. You figure you can save yourself a few bucks and try to repair it yourself, but you cannot find your Mercury outboard manual anywhere.

Looks like you will be heading to a professional. On the other hand, you could buy a replacement from the vast inventory on eBay.

All you need to know is what model of Mercury or Mariner outboard you own, as well as the year it was made. After all, the company has been around since 1939. You can even find books that date back several decades. All manuals are written so that a do-it-yourself mechanic can troubleshoot his or her own boat, but they provide the exact same guidance that professional mechanics use. In fact, the U.S. Navy and Coast Guard use a Mercury outboard manual when necessary, as do numerous trade schools and higher education institutions.

Mercury 90 Hp Outboard

Save yourself some grief, and go ahead and pick up a manual for your boat before the need for it arises. Shop the large inventory of boats, and!

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