Complete workshop & service manual with electrical wiring diagrams for Mercruiser/Mercury Racing Outboard Engines. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Mercruiser/Mercury Racing Outboard Engines service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

MAKE: Mercury
YEAR: 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2003 2004 2005 2006 2007 2008
MODEL: Mercruiser & Mercury Racing (Sterndrive) Marine Engine

MERCRUISER AND MERCURY RACING (STERNDRIVE) OUTBOARDS SERVICE MANUAL INDEX
1.7 GB PDF
├── 00 Index.pdf
├── 01. 1963-1973 Engines & Drives (#9068648).pdf
├── 02. 1974-1977 Engines, Drives & Jet Drive 400 (#9071707).pdf
├── 03. 1978-1984 Engines.. 4-Cylinder, L6 &V8 (#9095693R1).pdf
├── 04. 1978-1982 Sterndrives.. MC 120 to 260 (#9086137).pdf
├── 05. 1978-1993 Sterndrives.. TR & TRS (#9012935).pdf
├── 06. 1983-1990 Sterndrives.. R, MR, Alpha One & Alpha One SS (#90129342).pdf
├── 07. 1983-1993 Engines.. GM V6 (#9012410).pdf
├── 08. 1985-1999 Engines.. MM 4-Cylinder (#9044553R2).pdf
├── 09. 1985-1988 Engines.. GM V8 (#9014499R1).pdf
├── 10. 1985-1989 Engines.. GM 4-Cylinder (#90146931R1).pdf
├── 11. 1988-1998 Sterndrives.. Bravo (#90174314).pdf
├── 13. 1990-1997 Engines.. GM 4-Cylinder (#90816462R2).pdf
├── 14. 1991-2008 Sterndrives.. Alpha One Gen II (#908181773).pdf
├── 15. 1989-1992 Engines.. GM V8 (#90816463).pdf
├── 16. 1993-1997 Engines.. GM V8 454cid & 502cid (#908232242).pdf
├── 17. 1993-1997 Engines.. GM V8 5.0L, 454cid & 502cid (#908232251).pdf
├── 18. 1993-1997 Engines.. GM V6 Gen II Balance Shaft (#908232261).pdf
├── 22. 1997-2008 Engines.. D-Tronic 2.8L & 4.2L (DI) Diesel (#908600741).pdf
├── 23. 1998-2001 Engines.. GM V8 Gen VI & L29 (454cid & 502cid) (#908613261).pdf
├── 24. 1998-2001 Engines.. GM V8 305cid & 350cid (#908613271).pdf
├── 24-S. 2000-2001 Engines.. GM V8 377cid (6.2L) (Supplement to #24) (#90861327000).pdf
├── 25. 1998-2001 Engines.. GM V6 262cid (4.3L) (#908613281).pdf
├── 26. 1998-2001 Engines.. GM 4-Cylinder 181cid (3.0L) (#908613291).pdf
├── 27. 1998-2002 Engines.. V8 D7.3L D-Tronic (DI) Diesel (#90861784).pdf
├── 27-S. 1998-2002 Engines.. V8 D7.3L D-Tronic, D-Tronic LD (DI) Diesel (#90861784990).pdf
├── 28. 2000-2005 Sterndrives.. Bravo 1-2-3 & XZ-XR and Sport Master (#908631601).pdf
├── 29. 2000-2008 Engines.. Sterndrive D1.7L DTI In-Line Diesel (#90863016).pdf
├── 30. 2000-2008 Engines.. 496cid (8.1L) Gasoline Engine (#90863161).pdf
├── 31. 2001-2008 Engines.. 305cid (5.1L), 350cid (5.7L) & 377cid (6.2L) (#90864260001).pdf
├── 32. 2001-2008 Engines.. Sterndrive 4.3L MPI (#90864261).pdf
├── 33. 2001-2008 PCM 555 Diagnostics (#90863757002).pdf
├── 36. 2006-2008 ECM 555 Diagnostics (#90864573001).pdf
├── 37. 2002-2008 Engines.. Dry Joint Exhaust System (Supplement to #31) (#90864260020).pdf
├── 40. 2004-2008 Engines.. Gen III Cool Fuel (Supplement to #30, #31) (#90865376).pdf
└── 41. 2004-2008 Engines.. Turn Key Start (TKS) Carburetors (Supplement to #25, #26, & #31) (#90866202).pdf
90-8M0082470 - 200/225/250/275/300 250 & 300 Pro 300 CCT Verado FourStroke Service Manual (2005&up).pdf

EXCERPT:
Manual Outline
1 - Important Information
A - Master Specifications
B - Maintenance
C - General Information
D - Outboard Motor Installation
E - Storage
2 - Electrical System
A - Ignition
B - Charging and Starting System
C - Timing, Synchronizing, and Adjusting
D - Digital Throttle and Shift
3 - Fuel System
A - Fuel System Operation
B - Troubleshooting and Diagnostics
C - Service Procedures
D - Emissions
4 - Powerhead
A - Cylinder Block/Crankcase
B - Cylinder Head
C - Lubrication
5 - Midsection
A - Pedestal/Mount Cradle and Driveshaft Housing
B - Adapter Plate
C - Power Trim
6 - Gear Housing
A - Right-Hand Rotation (4.8 in. Diameter)
B - Left-Hand Rotation (4.8 in. Diameter)
C - Right-Hand and Left-Hand Rotation (5.44 in.
Diameter)
7 - Attachments
A - Attachments
8 - Power Steering
A - Power Steering
9 - Color Diagrams
A - Color Diagrams
...
Alternator Description
The alternator employs a rotor that is supported in two end frames by ball bearings and is driven at 2.8 times engine speed.
The rotor contains a field winding enclosed between two multiple‑finger pole pieces. The ends of the field winding are connected to two brushes which make continuous sliding contact with the slip rings. The current flowing through the field winding creates a magnetic field that causes the adjacent fingers of the pole pieces to become alternate north and south magnetic poles.
The three phase stator is mounted directly over the rotor pole pieces and between the two end frames. It consists of three windings wound 120 degrees electrically out of phase on the inside of a laminated core.
The rectifier bridge contains six diodes which allows current to flow from the ground, through the stator, and to the output terminal, but not in the opposite direction.
When current is supplied to the rotor field winding and the rotor is turned, the movement of the magnetic fields created induces an alternating current into the stator windings. The rectifier bridge changes the alternating current to direct current which is present at the output terminal. The diode trio is connected to the stator windings to supply current to the regulator and the rotor field during operation.
Voltage output of the alternator is controlled by a transistorized voltage regulator that senses the voltage at the battery and regulates the field current to maintain alternator voltage for properly charging the battery. Current output of the alternator does not require regulation and is self‑limited by the design of the alternator. As long as the voltage is regulated within the prescribed limits, the alternator cannot produce excessive current. A cutout relay in the voltage regulator is not required. The rectifier diodes prevent the battery from discharging back through the stator.
A small amount of current is supplied by the excitation circuit in the regulator to the rotor field to initially start the alternator charging. Once the alternator begins to produce output, field current is supplied solely by the diode trio.
The alternator is equipped with two fans which induce air flow through the alternator to remove heat created by the rectifier and stator.
Diagnosis of Alternator System on Engine
1. If the problem is an undercharged battery, verify condition has not been caused by excessive accessory current draw or by accessories which have accidentally been left on.
2. Check physical condition and state of charge of battery. Battery must be at least 75% (1.230 specific gravity) of fully charged to obtain valid results in the following tests. If not, charge battery before testing system.
3. Inspect entire alternator system wiring for defects. Check all connections for tightness and cleanliness, particularly battery cable clamps and battery terminals.
IMPORTANT: Red output lead from alternator must be tight. A darkened red sleeve indicates lead was loose and becoming hot. Verify output lead attaching nut is torqued to specification.
...