This manual covers Mercury 90 HP and 120 HP Sport Jet models manufactured between 1993 and 1995. These engines are engineered for reliable performance, offering a robust solution for various watercraft applications. Their design prioritizes durability and user-friendliness, making them a dependable choice for recreational and professional use.
This comprehensive guide provides essential information for owners and technicians alike. It details routine maintenance, troubleshooting procedures, and technical specifications necessary for optimal operation and longevity. By following the instructions within this manual, users can ensure their Mercury Sport Jet engines are maintained to the highest standards, preventing premature failures and costly repairs.
Manual Covers Models:
Mercury 90 HP Sport Jet (1993 1994 1995)
Mercury 120 HP Sport Jet (1993 1994 1995)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type, And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Fasteners / Lubricants / Gasket sealant / Threadlocking compound / Serial numbers / Special tools / Mechanics tips / Bearing replacement / Oil Seals / Specifications
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting system / Choke circuit and solenoid test / key (ignition) switch test / Charging system / Ignition system / Fuel system / Power head
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Fuel selection / Alcohol extended gasoline / Oil selection / Oil mixture / Jet drive lubrication / Storage / Anticorrosion maintenance / Engine flushing and auxiliary cooling water connection / Tune-up / Compression check test / Spark plugs / Starter solenoid check / Wiring harness check / Performance test / Specifications
CHAPTER FOUR / ENGINE SYNCHRONIZATION AND ADJUSTMENT
Engine timing and synchronization / Carburetor linkage adjustment / Ignition timing / Choke valve synchronization / Throttle and oil pump synchronization / Specifications
CHAPTER FIVE / FUEL SYSTEM
Fuel pump / Carburetors / Carburetor disassembly, reassembly and adjustment / Carburetor cleaning and inspection / Core plugs and lead shot / Reed valve assembly / Choke solenoid / Fuel recirculation system / Specifications
CHAPTER SIX / IGNITION AND ELECTRICAL SYSTEMS
Battery / Component wiring / Alternator charging system / Electric starting system / Starter motor system / Ignition system / Specifications
CHAPTER SEVEN / POWER HEAD
Serial numbers / Fasteners and torque specifications / Flywheel removal/installation / Power head disassembly / Piston and connecting rod assembly / Connecting rod and crankshaft / Specifications
CHAPTER EIGHT / DRIVE SYSTEM
Serial numbers / Impeller selection / Shift cable adjustment / Steering cable adjustment / Main drive housing / Shim selection / Jet drive pump / Specifications
CHAPTER NINE / OIL INJECTION SYSTEM
Oil injection / Specifications
INDEX
WIRING DIAGRAMS
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader & WinZip
Manual Covers Models:
Mercury 90 HP Sport Jet (1993 1994 1995)
Mercury 120 HP Sport Jet (1993 1994 1995)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type, And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Fasteners / Lubricants / Gasket sealant / Threadlocking compound / Serial numbers / Special tools / Mechanics tips / Bearing replacement / Oil Seals / Specifications
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting system / Choke circuit and solenoid test / key (ignition) switch test / Charging system / Ignition system / Fuel system / Power head
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Fuel selection / Alcohol extended gasoline / Oil selection / Oil mixture / Jet drive lubrication / Storage / Anticorrosion maintenance / Engine flushing and auxiliary cooling water connection / Tune-up / Compression check test / Spark plugs / Starter solenoid check / Wiring harness check / Performance test / Specifications
CHAPTER FOUR / ENGINE SYNCHRONIZATION AND ADJUSTMENT
Engine timing and synchronization / Carburetor linkage adjustment / Ignition timing / Choke valve synchronization / Throttle and oil pump synchronization / Specifications
CHAPTER FIVE / FUEL SYSTEM
Fuel pump / Carburetors / Carburetor disassembly, reassembly and adjustment / Carburetor cleaning and inspection / Core plugs and lead shot / Reed valve assembly / Choke solenoid / Fuel recirculation system / Specifications
CHAPTER SIX / IGNITION AND ELECTRICAL SYSTEMS
Battery / Component wiring / Alternator charging system / Electric starting system / Starter motor system / Ignition system / Specifications
CHAPTER SEVEN / POWER HEAD
Serial numbers / Fasteners and torque specifications / Flywheel removal/installation / Power head disassembly / Piston and connecting rod assembly / Connecting rod and crankshaft / Specifications
CHAPTER EIGHT / DRIVE SYSTEM
Serial numbers / Impeller selection / Shift cable adjustment / Steering cable adjustment / Main drive housing / Shim selection / Jet drive pump / Specifications
CHAPTER NINE / OIL INJECTION SYSTEM
Oil injection / Specifications
INDEX
WIRING DIAGRAMS
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader & WinZip
