Mercury / Mariner 75 - 250 HP Two-Stroke Outboards 1998 - 2009

Clymer Owners Marine Service & Repair Manual

1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009

by Mark Rolling

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Mercury / Mariner 75 - 250 HP Two-Stroke Outboards 1998 - 2009 - Front Cover

Front Cover

Front Cover

Rear Cover

Rear Cover

description

Mercury / Mariner 75 - 250 HP Two-Stroke Outboards 1998 - 2009 Clymer Owners Marine Service & Repair Manual covers the following models:
● Mercury/Mariner 65 Jet (1998-2009)
● Mercury/Mariner 75 HP (1998-2009)
● Mercury/Mariner 80 Jet (1998-2009)
● Mercury/Mariner 90 Jet (1998-2009)
● Mercury/Mariner 100 HP (1998-2009)
● Mercury/Mariner 105 Jet (1998-2009)
● Mercury/Mariner 115 HP (4 Cyl.) (1998-2009)
● Mercury/Mariner 115 HP Optimax (V-6) (1998-2009)
● Mercury/Mariner 125 HP (1998-2009)
● Mercury/Mariner 135 HP (1998-2009)
● Mercury/Mariner 135 HP Optimax (1998-2009)
● Mercury/Mariner 140 Jet (1998-2009)
● Mercury/Mariner 150 HP (Carburetor Equipped) (1998-2009)
● Mercury/Mariner 150 HP (EFI) (1998-2009)
● Mercury/Mariner 150 XR6 (1998-2009)
● Mercury/Mariner 150 HP Optimax (1998-2009)
● Mercury/Mariner 150 Mag III (1998-2009)
● Mercury/Mariner 175 HP (Carburetor Equipped) (1998-2009)
● Mercury/Mariner 175 HP (EFI) (1998-2009)
● Mercury/Mariner 175 HP Optimax (1998-2009)
● Mercury/Mariner 200 HP (Carburetor Equipped) (1998-2009)
● Mercury/Mariner 200 HP (EFI) (1998-2009)
● Mercury/Mariner 200 HP Optimax (1998-2009)
● Mercury/Mariner 225 HP (Carburetor Equipped) (1998-2009)
● Mercury/Mariner 225 HP (EFI) (1998-2009)
● Mercury/Mariner 225 HP Optimax (1998-2009)

Contents:
QUICK REFERENCE DATA

GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Torque specification / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specifications

TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Basic service methods

TROUBLESHOOTING
Safety precautions / Operating requirements / Terminology and test equipment / Starting system / Battery charging system / Electrical accessories / Ignition system / Capacitor discharge module (CDM) ignition (65 jet and 75-125 hp, except 105 jet and 115 Optimax) / Alternator driven ignition (1998 and 1999 105 jet and 135-200 hp models [except Optimax models]) / Capacitor discharge module (CDM) ignition (2000-on 105 jet and 135-200 hp [except Optimax models]) / Capacitor discharge module (CDM) ignition (225 and 250 hp) / Digital inductive (DI [Optimax models]) / Fuel system / Fuel primer and enrichment system / EFI fuel system troubleshooting / Optimax 115-225 hp air/fuel system troubleshooting / Engine temperature and overheating / Engine / Starting system troubleshooting / Ignition system troubleshooting / Fuel system troubleshooting / Starter motor current draw specifications / Charging system troubleshooting / Charging system amperage / Battery charging coil (stator) resistance specifications (except belt-driven) system / Ignition system voltage output specifications / Ignition stator resistance specification / Capacitor discharge module (CDM) resistance specifications / Ignition coil resistance specifications / Fuel pump pressure specifications / Engine coolant temperature (ECT) and compressor temperature sensor specifications / Air temperature (IAT) sensor specifications / Cooling system specifications

LUBRICATION, MAINTENANCE AND TUNE-UP
Hour meter / Fuels and lubrication / Fuel selection / Recommended fuel/oil mixture ratio / Filling the oil tank reservoir / Power head break-in procedure / Fuel mixing procedure / Changing gfear case lubricant / Jet pump maintenance / Propeller shaft maintenance / Corrosion of the propeller shaft bearing carrier / Off-season storage / Anticorrosion maintenance / Engine submersion / Cooling system flushing / Tune-up / Remove carbon from combustion chamber / Compression test / Spark plug plugs / Lower gearcase and jet pump unit water pump / Fuel and oil injection systems / Fuel pump / Ignition system service / Sharging system service / Alternator belt (225 and 250 hp models except Optimax models) / Alternator belt (Optimax models) / Battery and starter system / On-water performance testing / Maintenance torque specifications / Maintenance schedule / Spark plug recommendations / Lubricant capacities

SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
65 jet, 75 hp and 90 hp models / 80 jet and 100-125 hp models (except 115 Optimax) / 105 jet, 140 jet and 135-200 hp carbureted models / 150-200 hp electronic fuel injection (EFI) models / 115-225 hp Optimax (direct fuel injection) models / 225 hp carbureted models / 225 and 250 hp EFI models

FUEL SYSTEM
Fuel pump / Carburetors / Fuel primer valve (65 jet and 75-200 hp [remote control models]) / Thermal air valve (105 jet and 135-200 hp carbureted models) / Fuel enrichment valve (225 hp carbureted models) / Accelerator pump circuit (100-125 hp and 80 jet models) / Antisiphon devices / Fuel filters / Fuel tanks / Fuel hose and primer bulb / Electronic fuel injection (EFI) and direction fuel injection (DFI) / Reed valve service / Fuel bleed (recirculation) system

ELECTRICAL SYSTEM
Battery / Charging system / Fuses / Starting systems / Ignition systems / Capacitor discharge module (CDM) ignition / Digital inductive ignition (115-225 hp Optimax models)

POWER HEAD
Power head break-in, disassembly, cleaning, inspection and assembly / Lubricants, sealants and adhesives / Sealing surfaces / Fasteners and torque

GEARCASE
Gear case operation, disassembly, assembly, pressure testing, shimming / Corrosion control / Gearcase lubrication / Propeller / Trim tab adjustment / Gear housing / Water pump / Gear ratio and tooth counts

JET DRIVE
Jet pump unit maintenance / Jet pump unit repair / Specifications

TRIM AND TILT SYSTEMS
Power trim and tilt system service / Specifications

MIDSECTION AND TILLER CONTROL
Specifications

OIL INJECTION SYSTEM
Variable ratio oil injection / Variable ratio electronically controlled oil injection / Specifications

REMOTE CONTROL
Specifications

WIRING DIAGRAMS

Clymer marine manuals can save you money on maintenance and repair. Step-by-step procedures and detailed illustrations guide you through every job, from routine maintenance and troubleshooting, all the way to complete teardown & rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 1620921359 (1-620-92135-9)
  • ISBN-13: 9781620921357 (978-1-620-92135-7)
  • Format: Softcover, 620 pages

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