Mercury Marine MerCruiser Service Manual #41 Turn Key Start (TKS) Carburetors

Supplement to #25, 26, & 31
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This Workshop Service Repair manual PDF download for the Turn Key Start (TKS) Mercury Marine MerCruiser has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

This supplement is intended to be used in conjunction with the appropriate Mercury MerCruiser Service Manual for your engine, and not in place of the manual. The scope of this supplement is to highlight new or different specifications, components, and procedural information as they pertain to Turn Key Start (TKS) Systems


APPLICABLE MODELS :

Model - Serial Number
3.0L Alpha - 0W302000
4.3L Alpha - 0W300013
5.0L Alpha and Bravo - 0W300010
5.7L Bravo - 0W300755


TABLE OF CONTENTS :

1 - Important Information
A - General Information
B - Maintenance
C - Troubleshooting
2 - Engine
A - Oil Pressure Switch
3 - Electrical Systems
A - Wiring Diagrams
4 - Fuel System
A - TKS Carburetor
B - Diagnostics
5 - Cooling Systems
A - Cooling System


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 90-866202
Total Pages : 106


All Official Mercury Marine Manuals for MerCruiser Sterndrives and Inboards include easy to follow, step-by-step illustrated procedures based on the complete dismantling, repair, and assembling of boat motors, from the simplest repair to complex procedures, this manuals give you everything you need to do the job with confidence.

This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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90-866202
Front matter
Notice to Users of This Manual
Precautions
Replacement Parts
Cleanliness and Care of Product
Manual Outline
Section 1A - General Information
Table of Contents
Important Information
General Information
How To Use This Manual
Page Identification
Directional References
Section 1B - Maintenance
Table of Contents
Maintenance
Torque Specifications
Special Tools
Section 1C - Troubleshooting
Table of Contents
Turn Key Start: Theory of Operation
TKS Starting Characteristics
TKS Special Information
Troubleshooting
TKS Troubleshooting
Normal Starting Procedure
Hard Start - Cold
Hard Start - Hot
Engine Does Not Start
Engine Does Not Idle Correctly
Hissing Noise
Section 3A - Oil Pressure Switch
Table of Contents
Oil Pressure Switch
Oil Pressure Switch Test and Inspection
Inspect the TKS Oil Pressure Switch
Testing the 3.0L Oil Pressure Switch
Testing the V-6 and V-8 Oil Pressure Switch
Oil Pressure Switch Replacement
Section 4E - Wiring Diagrams
Table of Contents
TKS Wiring Diagrams
Wire Color Code Abbreviations
3.0L TKS Wiring Diagram
3.0L TKS Retrofit Wiring Diagram
4.3L and 5.0L TKS Alpha Wiring Diagram
5.0L and 5.7L TKS Bravo Wiring Diagram
4.3L, 5.0L, and 5.7L TKS Retrofit Wiring Diagram
Section 5B - TKS Carburetor
Table of Contents
Maintenance
Identification
TKS Carburetor Part Number and Date Code
Venturi Cluster Identification
Replacement Parts Warning
Identification of TKS Carburetors
The 3.0L TKS Carburetor
Generation 2
The 4.3L TKS Carburetor
Generation 1
Generation 2
The 5.0/5.7L TKS Carburetor
Generation 1
Generation 2
Specifications
Important Service Information
8 Point Carburetor Check List
Flooding At Idle RPM
Needle / Seat Change
Adjustable Accelerator Pump Lever
Description
Flame Arrestor with Carburetor Cover
REMOVAL
CLEANING AND INSPECTION
INSTALLATION
Fuel Inlet Filter
REMOVAL
CLEANING
INSTALLATION
Adjustments
Replacing Carburetor
Repair
Exploded View Generation 1
Exploded View Generation 2
Disassembly
TKS Module
Air Horn
Float Bowl
Cleaning and Inspection

Reassembly
Carburetor Body
Float Bowl
Air Horn
Float Level
Float Drop
TKS Module
Carburetor Installation
Section 5G - Diagnostics
Table of Contents
3.0L TKS General Diagnostics
V6-V8 TKS General Diagnostics
TKS Fuel System Diagnostics
Troubleshoot the Fuel System
Test Power to the Fuel Pump
Test TKS Enrichment Circuit
Clean Carburetor Enrichment Circuit
Replacement Parts Warning
TKS Electrical System Diagnostics
Electrical System Diagnostics
TKS Coolant Temperature Switch
TKS Oil Pressure Switch
TKS Module
Electrical Supply
Heater Function
TKS Module Resistance Check
TKS Module Bench Test
Section 6A - Cooling System
Table of Contents
Raw Water Cooled
3.0L TKS Thermostat Housing Removal
Replace the 3.0L TKS Temperature Switch
Test the TKS Coolant Temperature Switch
On-engine Test
Bench Test
Install the TKS Thermostat Housing
Replace the V-6 and V-8 TKS Temperature Switch
Close Cooled
Replace the Close Cooled 3.0L TKS Temperature Switch Unit
Test the TKS Coolant Temperature Switch
Replace the Close Cooled V-6 and V-8 TKS Temperature Switch

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