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Author Topic:   Mercury 90, 4-Stroke Outboard Service Manual Pays for Itself
Barney posted 12-03-2005 04:35 PM ET (US)   Profile for Barney   Send Email to Barney  
2Manyboats knows I've been having some trouble with the outboard and gave me some good advice on fuel additives. But the trouble lingered. Soumething else was happening too. My 2004 90 HP 4-Stroke Mercury has been really hard to start and impossible to start this morning. Went to the "Owners" manual, trouble shooting section, nothing really helpful except that it led me to the ignition of the Service manual.

Opened the Service manual to the Recommended Tests listed in the ignition section. Number one on the list for "Engine Hard To Start Cold" was Debris in the carburetor enrichener circuit. Easy to work on with the manual. I blew out the upper enrichener and a wad of grit came out. Check the lower and put it back together. Fired right up. Probably need a better fuel filter. Jim

sosmerc posted 12-03-2005 09:20 PM ET (US)     Profile for sosmerc  Send Email to sosmerc     
Mercury has always done an excellent job with their factory service manuals. I have always tried to make it a practice to have the factory service manual for whatever I am working on. It gets expensive, especially after you work on these things for over 25 years. But there really is no substitute for having the factory manual if you intend to do your own work.
I'm glad you were able to figure out your problem. I'd sugguest that you run Stabil...or Startron fuel treatment ALL the time...and maybe you won't ever have another fuel issue such as you just had. Change your fuel filters every year, no matter what condition your gas appears to be in.
Thanks for posting this's way overlooked.
Barney posted 12-04-2005 10:01 AM ET (US)     Profile for Barney  Send Email to Barney     
Thanks. Took a boat ride this morning. The fuel treatment recommended by 2Manyboats, Seafoam, seems to have corrected the hesitation. Started better than new with the carb enrichener circuits cleaned.

The little fuel filter on the outboard is fragile and hard to get off and on, I checked it in September and it was full of junk after one tank of bad fuel. So a bigger spin-on remote filter would be best and like you said changed frequently. Jim

TRAFFICLAWYER posted 12-04-2005 10:07 AM ET (US)     Profile for TRAFFICLAWYER    
For these smaller outboards [my sons 60 bigfoot]I have
installed a Racor PN#S3240. This is a smaller unit perfect for these motors.
Barney posted 12-04-2005 10:09 AM ET (US)     Profile for Barney  Send Email to Barney     
Hey thanks that is good info. Jim
LHG posted 12-04-2005 01:42 PM ET (US)     Profile for LHG    
My Merc mechanic tells me similar things to what SosMecc has said, and also recommend to me to use StaBil on a regular basis in my carbureted Merc 150 2-stroke.

He also indicated that carbs on 4-stroke outboards are an even bigger problem than on the old 2-strokes, as they have miniscule passages in them that easily get fouled up. This is why the EFI 4-strokes are what you want to have today.

Regarding Stabil, I have a source in my area, Menards, a Home Depot style operation, that sells the 80 gallon treatment big bottle for $8.00., or a dime per gallon of gas. Theft Marine sells the same thing for $17.00!

swist posted 12-05-2005 09:02 AM ET (US)     Profile for swist  Send Email to swist     
I always used to get Clymer manuals for my ourboards because the factory manuals were so expensive, and I have a fair amount of experience fixing 2-stroke engines, but My Merc 90 is my first four-stroke and I thought I should bite the bullet with the factory book ($80!!!). So far I got what I paid for - it's much clearer, and so nice not to have to sift through the instructions for 19 other motors that you don't have.
2manyboats posted 12-05-2005 10:22 PM ET (US)     Profile for 2manyboats  Send Email to 2manyboats     
glad your running good jim, for years I didn't know mercs were black as I had never seen one with the cowling on.
kingfish posted 12-06-2005 10:18 AM ET (US)     Profile for kingfish  Send Email to kingfish     
Barney posted 12-06-2005 11:21 AM ET (US)     Profile for Barney  Send Email to Barney     
Yeah, I've got Beth back there with a screw driver tweaking the carbs as we go. The cowl stays at home. :0
2manyboats posted 12-15-2005 01:41 PM ET (US)     Profile for 2manyboats  Send Email to 2manyboats     
for some reason I just don't believe you
Barney posted 12-16-2005 08:48 PM ET (US)     Profile for Barney  Send Email to Barney     
Why she changed the truck's orle this morning?
swist posted 12-17-2005 09:03 AM ET (US)     Profile for swist  Send Email to swist     
As the want-ad says

"Woman wanted as fisherman's wife, must be able to cook, clean, repair nets, boats, and engines. Must have own boat and motor. Send picture of boat and motor to PO box 4251 Gloucester MA"

2manyboats posted 12-18-2005 07:15 PM ET (US)     Profile for 2manyboats  Send Email to 2manyboats     
If Beth has time could she come over and finish cleaning up our back yard. I just can't get Kathy to get the yard done

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