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Mercury Outboard Service Manuals. 200 HP + 150-199 HP 100-149 HP 50-99 HP 2004 Models 2003 Models 2002 Models 2001 Models 2000 Models 1999 Models 1998 Models. 2002-2004 Mercury 225, 250 & 3.0L Work EFI Repair Manual; 2004-2006 Mercury 75hp 90hp 115hp OptiMax Repair Manual; 2005-2007 Mercury Verado 200 225 250 275 Repair Manual; 2005-2011 Mercury 2.5 to 350hp Repair Manual 4-Stroke; 2008-2012 Mercury 15 20 HP Repair Manual 4-Stroke; 2008-2012 Mercury 40 50 60 EFI 4-Cylinder (Bigfoot & Non Bigfoot) 4.

This Mercury Mariner two stroke Workshop Manual/Repair manual covers the following years and model Outboard motors:
1965: 3.9 HP 6HP 9.8HP 20 HP 35 HP
1966: 3.9 HP 6HP 9.8HP 20 HP 35 HP
1967: 3.9 HP 6HP 9.8HP 20 HP 35 HP
1968: 3.9 HP 6HP 9.8HP 20 HP 35 HP
1969: 4 HP 7.5 HP 9.8HP 20 HP 35 HP
1970: 4 HP 7.5 HP 9.8HP 20 HP 40 HP
1971: 4 HP 7.5 HP 9.8HP 20 HP 40HP
1972: 4 HP 7.5 HP 9.8HP 20 HP 40 HP
1973: 4 HP 7.5 HP 9.8HP 20 HP 40 HP
1974: 4 HP 7.5 HP 9.8HP 20 HP 40 HP
1975: 4.5 HP 7.5 HP 9.8HP 20 HP 40 HP
1976: 4 HP 4.5 HP 7.5 HP 9.8HP 20 HP 40 HP
1977: 4 HP 4.5 HP 7.5 HP 9.8HP 20 HP 40 HP
1978: 4 HP 4.5 HP 7.5 HP 9.8HP 20HP 40HP
1979: 4 HP 4.5 HP 7.5 HP 9.8HP 20HP 40HP
1980: 3.6 HP 4 HP 4.5 HP 7.5 HP 9.8HP 18HP 20 HP 25HP 40 HP

2001 Mercury 75hp 2 Stroke Specs

1981: 3.6 HP 4 HP 4.5 HP 7.5 HP 9.8HP 18 HP 20 HP 25 HP 40 HP
1982: 3.6 HP 4.5 HP 7.5 HP 9.8HP 18 HP 25 HP 40 HP
1983: 3.5 HP 4.5 HP 7.5 HP 9.8HP 18 HP 25HP 40 HP
1984: 2.2 HP 3.5 HP 4.5 HP 7.5 HP 9.8HP 18 HP 25 HP 35 HP
1985: 2.2 HP 3.5 HP 4.5 HP 7.5 HP 9.8HP 18 HP 25 HP 35HP
1986: 2.2 HP 4 HP 6 HP 8 HP 9.9 HP 20 HP 25 HP 35 HP
1987: 2.2 HP 4 HP 6 HP 8 HP 9.9 HP 20 HP 25 HP 35 HP
1988: 2.2 HP 4 HP 5 HP 8 HP 9.9 HP 15 HP 20 HP 25 HP 35 HP
1989: 2.2 HP 4 HP 5 HP 8 HP 9.9 HP 20 HP 25 HP 35 HP
1990: 3 HP 4HP 5 HP 8 HP 9.9 HP 15 HP 20 HP 25 HP
1991: 3 HP 4HP 5 HP 8 HP 9.9 HP 15 HP 20 HP 25 HP
The service manual download for the above listed Mercury/Mariner Outboard models describes the service procedures for the complete outboard. Follow the Maintenance Schedule recommendations to ensure that the engine is in peak operating condition. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the motor.
All chapters in the service manuals apply to the whole engine and illustrates procedures for removal & installation of components that are in detailed step-by-step fashion.
Most all service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures. This is a simple to download book, just like any book you would buy in a store except this book is delivered to you instantly upon purchase. No special software required as this manual works on all computers. Manual is in pdf format and delivered in pdf format.
BELOW IS JUST A SMALL SAMPLE OF INFORMATION YOU MIGHT FIND IN A TYPICAL SERVICE MANUAL BUT IT COVERS EVERYTHING YOU WILL EVER NEED TO SERVICE YOUR ENTIRE MOTOR. TO MUCH INFORMATION TO LIST. INFORMATION WILL DIFFER DEPENDING ON YEAR AND MODEL
SPECIFICATIONS
Some of the topics you might find in a specifications sections are Overall length Overall width Weight Transom height Recommended operating range Idle speed Engine type DOHC Number of cylinders Total displacement Spark plug Fuel supply system Multi-point sequential electronic fuel injection Exhaust system Cooling system Water cooled Lubrication system Wet sump Starting system Electric Lower Unit Fuel recommendatons Outboard Motor Gear Oil Gearcase oil capacity ml Maximum tilt angle degree Transmission Forward-Neutral-Reverse Propeller shaft rotation Propeller Right-hand rotation Propeller Counter rotation Cylinder compression Engine oil pressure Viscosity rating Engine oil amounts Oil filter change Pistion Pistion Rings Thermostat operating temperature and much more.
MAINTENANCE
In the maintenance section you will find complete maintenance specs, maintenance charts, intervals and recomendations including step by step procedures for the following: Spark plug Fuel line Replace fuel hose Breather hose Engine oil Gear oil Lubrication Anodes & Bonding wires Battery Fuel mixture check Engine oil filter Low pressure fuel filter High pressure fuel filter Ignition timing Idle speed Tappet clearance Water pump Water pump impeller Propeller nut & pin Balancer chain Bolt & Nuts Timing Belt Inspection Lubrication Points Changing Engine Oil Oil Draining Procedure Changing Oil Filter Oil Filling and much more.
GENERAL INFORMATION
The gerneral information sections will usually identify the following topics and much more: Identification Numbers Tightening Torque Service Data Specfications Cylinder Number Propellers Gas (gasoline Recomendations) 87 91 92 93 Race Gas Warm-Up Recommendations.
ELECTRICAL
The electrial sections you will find in a service manual include electrical parts holder removal and installation, and the inspection, removal, installation, troubleshooting outline of monitor tachometer starter motor, electric starter system battery charging system Disassembly Cleaning Testing Brush Replacement Reassembly Battery Charging System Manual Start Battery Charging System Tests Testing The Battery Charging Coil Testing The Battery Charging System Testing The Rectifier/Regulator.
IGNITION
A short list of some information you will find in this ignition system section include Specifications Special Tools Checking Ignition Timing Type Spark Plug Firing Order Ignition Timing Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance ECM Engine Speed Limiter Spark Cut-Out Reduction ignition spark ECM Low Oil Pressure Speed Control Oil Pressure Switch and more.
CARBURETOR
If your motor carb (carburetor) than you will find everthing you need to fully adjust the carb, rebuild, remove, inspect, and clean to factory specs. Here are just a small sample you will find in service manuals where carb models apply: Specifications Special Tools Intake Carburetor Adjustments Idle Speed Linkage Choke Carburetor Removal Carburetor Disassembly Cleaning/Inspection/Repair Carburetor Reassembly Float Height Measurement Carburetor Installation Electric Choke Models InstallationIdle rpm (Out Of Gear) Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT) Main Jet Size Pilot Jet Main Jet Size Float Height 950 ± 50 rpm 850 ± 50 rpm 45005500 5200-5700 500-1000 rpm 1200-1500 rpm 1500-2000 rpm 2200 2500 rpm 3000-3500 rpm and much more.
EFI SYSTEM
A short list of some topics found in the electronic fuel injection system include Specifications Fuel Injection Nozzle Fuel Injection Pump Fuel Pump Throttle Body Throttle Control Lever and Linkage High Pressure Fuel Line High-Pressure Fuel Line Fuel Cooler Fuel Hoses Fuel Rail Pressure Regulator Idle Speed Control Assembly Intake Manifold Throttle Position Sensor Low Pressure Fuel Line/Fuel Pump Fuel Filter Fuel Pump and more.
POWERHEAD (POWER HEAD)
The powerhead section contains everthing you will need to completly rebuild your engine block back to factory specs, some information inculdes: cylinder head cover intake manifold assembly ring gear cover and air intake power unit (powerhead) measuring pump components oil pump engine lubrication system thermostat cylinder crankshaft pistion counter balancer mechanism cylinder head assembly removal inspection installation.
MID-SECTION
A quick run down of main topics in this section are engine side cover driveshaft housing and oil pan swivel bracket steering bracket and clamp wather pressure valve lower unit gear housing and all inspection removal installation cleaning assembly and reassembly procedures.

3.5 Hp Mercury Outboard Manual

LOWER UNIT
Some of the main topics discussed in the lower unit section include gear case, propeller lower unit gears shimming and adjustment trim tab drive shaft and oil seal housing, water pump and related items, shift guide housing propeller shaft components gear bearing propeller shaft gear housing and more.
Other Chaptrs you might find in a service manual/ repair manual for your outboard motor include:
ATTACHMENTS/CONTROL LINKAGE
THROTTLE/SHIFT LINKAGE
TILLER HANDLE
MANUAL STARTER
DIAGNOSTIC TROUBLESHOOTING
WIRING DIAGRAMS

Description

This Clymer Mercury-Mariner Two Stroke Outboard Repair Manual 75-250 hp 1998-2009 provides detailed service information, step-by-step repair instruction and maintenance specifications for 1998-2009 Mercury and Mariner 75-250 hp Outboard boat engines. This is the book you need to properly care and repair your outboard engine. Save a fortune by doing it yourself. Buy a copy to keep on the boat and another to study at home or work.

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

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION

Manual organization, Warnings, cautions and notes, Torque specifications, Engine operation, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Propellers

CHAPTER TWO, TOOLS AND TECHNIQUES

Safety first, Basic hand tools, Test equipment, Basic service methods

CHAPTER THREE, 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 [except Optimax models]) / Capacitor discharge module (CDM) ignition (200o-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 systems, 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

CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP

Hour meter, Fuels and lubrication, Off-season storage, Anticorrosion maintenance, Engine submersion, Cooling system flushing, Tune-up, Maintenance torque specifications, Maintenance schedule, Spark plug recommendations, Lubricant capacities

CHAPTER FIVE, SYNCHRONIZATION AND LINKAGE ADJUSTMENTS

Safety precautions, Test propeller, General information, 65 jet, 75 hp and 90 hp, 80 jet and 100-125 hp (except 115 Optimax) / 105 jet, 140 jet and 135-200 hp carbureted, 150-200 hp electronic fuel injection (EFI), 115-225 hp Optimax (direct fuel injection), 225 hp carbureted, 225 and 250 hp EFI, General specifications, Synchronization and linkage torque specifications

CHAPTER SIX, 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, Fuel system torque specifications, Carburetor specifications

CHAPTER SEVEN, ELECTRICAL SYSTEM

Battery, Charging system, Fuses, Starting systems, Ignition systems, Capacitor discharge module (CDM) ignition, Digital inductive ignition (115-225 hp Optimax models) / Electrical system torque specifications, Battery charge percentage, Battery capacity, Battery requirements (minimum), Battery cable requirements

CHAPTER EIGHT, POWER HEAD

Service consideration, Mercury/Mariner model identification, Power head break-in, Service recommendations, Lubricants, sealants and adhesives, Sealing surfaces, Fasteners and torque, Power head removal/installation, Power head disassembly, Power head cleaning and inspection, Power head assembly, Power head torque specifications, Cylinder bore specifications, Piston specifications, Engine characteristic codes

CHAPTER NINE, GEARCASE

Gearcase operation, Service precautions, Corrosion control, Gearcase lubrication, Propeller, Trim tab adjustment, Gear housing, Water pump, Gearcase disassembly/assembly, Gearcase cleaning and inspection, Gearcase pressure testing, Gearcase shimming, Gearcase torque specifications, Gear ratio and tooth counts, Pinion gear locating tool specifications, Gearcase backlash specifications

CHAPTER TEN, JET DRIVE

Jet pump unit maintenance, Jet pump unit repair, Jet drive torque specifications

CHAPTER ELEVEN, TRIM AND TILT SYSTEMS

Power trim and tilt system service, Trim and tilt system torque specifications

2000 Mercury 75hp 2 Stroke Specs

CHAPTER TWELVE, MIDSECTION AND TILLER CONTROL

Mid-section and tiller control torque specifications

CHAPTER THIRTEEN, OIL INJECTION SYSTEM

2001 Mercury 75hp 2 Stroke Manual

Variable ratio oil injection (75-125 hp [except 115 hp Optimax and 105 jet], 65 jet and 80 jet models), Variable-ratio oil injection (135-200 hp [except Optimax models], 105 jet and 140 jet models), Variable-ratio oil injectio (225 hp and 250 hp [except Optimax] models) / Variable-ratio electronically controlled oil injection (Optimax models) / Oil injection system torque specifications, Oil injection system specifications

Mercury 75hp 2 Stroke Manual

CHAPTER FOURTEEN, REMOTE CONTROL

INDEX

WIRING DIAGRAMS