Re: PDF-manual on Merc 90 Sportjet ?
Clymer man. is about $40.00us BUT it's pretty much just a guide. I have a 94sj90 and changing the wear ring and impeller is pretty straight forward. There are (2) different impellers though, early mod. and late mod. 93' probally has early threaded shaft aposed to the late mod. splined shaft. (1) take off the nozzel (unhook the steering and reverse gate (2)remove the stator, if you haven't allready, remove the reverse gate cable from the stator *Tip1: there are metal tabs bent up on the bolts to prevent them from backing out *Tip2: loosen the stator fill screw before removing the stator to avoid damage to the shaft seal, as soon as you get the stator off the shaft, tip it up as not to spill the gear lube all over. At this point the wear ring may have came off with the stator or maybe not, if it did just tap the wear ring with a rubber mallet adn maybe a screwdriver to seperate the two.(3) unless you have the special tool (offset wrench sort off)to remove the impeller you'll need to remove the rock grate and ride plate so you can get a open end wrench on the impeller nut and another wrench on the flats of the shaft.*Tip3: the impeller is reverse threaded "righty loosey in this case". Reassemble in backward order: remember to loosen the stator fill plug when putting back together (makes life easier) then refill stator with Mercury high performance gear lube($$) Tip4:fill it with a pump oil can as the fill hole is small and prone to "air locking" making a mess all over your shop floor.
Changing the gearcase oil is a little more frustrating at first sight, But with a little Tip you can change it pretty easily. First locate the drain plug and vent plug. Have your drip pan ready. Remove the drain plug first and drain out the gear lube. 2nd remove the vent plug and drain any fluid that might be in there. TIP have a big enough drain pan to catch both. To replace fluid I got a piece of rubber tubbing that would just fit into the drain plug hole and stay there and inserted my pump oil can into the other end. Start pumping until new Mercury high performance gear lube comes ou the vent tube. Stop pumping and reinstall vent plug. Quickly (have drain plug in hand) remove the rubber tube from the drain hole and insert the plug. Some lube may escape but thats ok. the vacume from having the vent plug in stops most of the lube from coming back out.
Hope this helps
