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MERCURY 100 TO 140 HP JET OUTBOARD SERVICE MANUAL WORKSHOP

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(ID 9017392)
If you own a Mercury outboard jet with HP 60 65 75 80 100 125 135 140 200 225 250 DFI then this is the massive service manual for you covers all you need to know aboput the service and repair of your jet outboard.

Sections are listed below;:
A
Accelerator pump circuit
l0O-125 hp and 80jet,
tuelsystem ......332-335
Altemator driven capacitor discharge
ignition 6O-275hpa nd6 5-140je t,
ignition and electrical
systems. 424_439
Alternator driven ignition 135-200 hp,
275hp,i 05 and1 40jetV6,
troubleshooting .....l.5-g}
Alternator driven ignition, mechanical
advance7, 5-125h p and6 5-80j et,
t roubleshoot ing. .......... . 64_j5
Anticorrosionm aintenancel,u brication
maintenanceandtun.e. .-.u. .p. 226
Antisiphon devices,
fuel system . 3f.S_337
B
Battery chargings ystem,ig nition and
electricalsystems ...4OT-415
Battery charging system,
troubleshooting...... . 51_62
Battery ignition and electrical
Index
systems ....399_407
Bearing housing, lower gearcase
andjet driveunits . . . . . . . . . . 670_6jI
c
Capacitor discharge module
(CDM) ignition
225 and25ohp,
troubleshooting. . . . . .... 97_Ll0
75-125 hp and 65-80 jet,
serial No. 0G438000-on.
houbleshooting.. . .. .... 90_97
ignition and electrical
systems. 439_441
Carburetors, fuel system. . . . . . . 30l.-30g
CDM ignition
225 and25ohp,
ignition and electrical
systems. 444_449
75-125 hp and 65-80 jet, serial No.
0G43 8000-on, ignition and
electrical systems 441-444
CDM module resistance tests
(optional), troubleshooting. . . 1 l0_lll
Cooling system flushing, lubrication
maintenance andtune-up . . . . 229_23I
Corrosionc ontrol,l owerg earcasaen d
jetdriveunits... ... 579-591
D
DFI airlfuel system
t r o u b l e s h o o t i n g . . ...... . . . 1 6 6 - 1 7 7
DI digiral inductive, 200 DFI
t r o u b l e s h o o t i n g . . ...... . . . l l l _ l 2 }
Digital inductive ignition, 200 DFI,
ignition and elecaical
systems M9_452
E
EFI fuel system,
t r o u b l e s h o o t i n g . . ...... . . . 1 2 9 _ 1 6 6
Electrical accessories,
t r o u b l e s h o o t i n g . . . . . . . . . 62
Electronic fuel injection (EFI) and
direct tuel injection (DFI),
fuelsysrem . . . . . 339-369
Engine submersion, lubrication
maintenance andtune-up . . . 226-229
Engine temperature and overheating,
troubleshooting .... lj7_Lg2
Engine, troubleshooting ..... . lg2-lg7
774 IiDEX
F
Fastenersa ndt orque,
powerhead .463-465
Fuel primer and enrichment systems,
ffoubleshooting.. . . . . . . . . . . 123-129
Fuelsystem. ..302-307
acceleratopr ump circuit,
100-125h p and8 0jet.. . . .332-335
antisiphondevices ..335-33i
carburetors .307-309
electronic fuel injection (EFI) and
direct fuel injection
(DFr) . .339_368
fuel bleed (recirculation)
system. . .381-392
fuel enrichment valve,225 hp
carburetedmode.l s. ....... 332
f u e l f i l t e r s . . . . . 3 3 j
fuel hose and primer bulb. . . . 338-339
fuel primer valve, 75 -2OOh p,
275h p and3 5-140je r, remote
controlmodels ..329-331
tuelpump . .302-307
fuel tanks, integral and portable,
remote. . . 337-338
reed valve service. . . 368-381
thermala ir valve,1 35-200h p
carburetedmodel.s . . . . .. 331-332
troubleshooting.. . . . . . . . . . . l2O-123
WME seriesc arburetor,7 5-L25h p,
65and80jet. . . . . 3 0 9 - 3 1 6
WMH andWMV series carburetors,
135-225h p and 105-140jet
models .316-325
WO series (Mercarb) carburetor,
275hp. . .325-329
Fuels and lubrication. lubrication
maintenancaen dtune-up. . . . 201-Z2O
Fuses,ig nition ande lecfical
systems ....415-416
G
Gear housing, lower gearcase and
j e t d r i v e u n i t s . . . . . . . . . 583
Gear ratio, lower gearcase andjet
drive units. . 577-579
Gearcase cleaning and inspection,
lower gearcase and jet driv
u n i t s . . . . . . . 6 5 1
Gearcase disassembly/assembly,
lower gearcase andjet drive
u n i t s. . . . . . . 6 0 3
Gearcase lubrication, lower gearcase
a n d j e t d r i v e u n i t s . . . . . . . . . . . .5. 8 1
Gearcase operation, lower gearcase
andjetdriveunits... 5i6-5'77
Gearcase pressure testing, lower
gearcaseandjetdriveunits . . . .. 652
Gearcases himming,l ower gearcase
andjetdriveunits.. .... 653
General information, synchronization
andlinkagea djustment.s . . . . 249-251
H
High-altitude operation, lower
gearcasaen djet driveu nits. . . . . . 578
Hour meter, lubrication maintenance
andtune-up .200-201
I
Ignitiona ndelectricasly stem.s . ... 399
alternator driven capacitor discharge
ignition, 60-275hp afi
65-140jet. .....424-438
battery. ....399-407
batteryc hargings ystem. . . .. 407-415
capacitord ischargem odule
(CDM) ignition. . .438-441
CDMignition
2 2 5a n d 2 5h0p . . . . . . . . . 4 4 4 - 4 4 9
75-125hp and 65-80jet, serial
No.0 G438000-o.n.. ... 441-444
digital inductive ignition
200DFI. .449-452
tuses.. . . . . 4 1 5 - 4 1 6
startingsystems. ....416-424
Ignition system,
troubleshootin.g .. . .. . . .. . . . . 62-64
Ignition systemsi,g nition and
electricalsystems ...... 424
J
Jet drive models,l ower gearcasea nd
jetdr i veuni t. s. . . . . . . . 661
Jetp ump unit maintenancel,o wer
gearcasaen djet driveu nits. . . 661-667
Jet pump unit service, lower gearcase
andjer drive units . . .667-670
L
Lowerg earcasaen djet driveu nits. . 576
bearinghousing ....670-671
corrosionc ontrol.. . . . . . . . . . 579-581
***
housing ..583-593
r a t i o . . . ..577-578
gearcase
cleaningandinspection.. . 651-652
disassembly/assemb. l.y .. . 603-651
l u b r i c a t i o n . . . . . . . . . . 581
operation. 576-577
pressuretestin. g. .. . ..... 652-653
shimming 653-661
high-al t ihrdeoperat ion. . . . . .5. .2. 8
jetdrivemodels. . . . . . . . 661
jetpump
unitmaintenanc.e.... ... 661-667
unitservice ..... 667-670
lowergearcase . . . . . . . . . 576
propeller .. 581-583
serviceprecaut i.o. .n.s. . . . 578-579
trimtabadjustment ..... 583
waterintakeh ousingli ner. . . . . . . 67I
water pump 593-603
Lubricantss, ealantsa nda dhesives,
powerhead 462-463
Lubrication maintenancea nd
tune-up . . . . . . . 200
anticorrosionmaintenan.c .e. . 226
coolings ystemfl ushing . . 228-231
enginesubmersi.o..n ... 226-228
fuelsa ndlubrication.. . .. 201-220
hourmeter. ..... 2OO-1OL
off-seasons torage 220-226
tune-up . 231-244
M
Mercury/I4arinemr odel
identificationp,o werhead... .... 460
o
Off-seasons toragel,u brication
maintenancaen dtune-up. . . 220-226
Oil injection system . . 732-733
variable-ratio electronically
controlledo il injection,200D FI
models 758-763
variable-ratio oil injection
135-20},275hpand -
105-l40jetmodel.s... . 739-750
225 and2 50h p models. . . 750-758
75-125hp and 65-80jet
models 733-739
Operathg requirements,
troubleshooting..... . 35-37
P
!
Powerhead . . . . . . 458
assembly . . 524-570
b r e a k - i n . . . . . . . 461
cleaning andinspection. . . . . 508-524
disassembly. . . . . . . 480-508
fasteners andtorque 463-465
lubricants, sealants and
adhesives 462-463 ;
Mercury/I4ariner model
identification . . . . . . . . 460
removaVinstallation. . . . . . . . 465-480
s e a l i n g s u r f a c e s . . ........ . . . . . 4 6 3
service considerations. . . . . . 459-460
servicerecommendations .. . 461-462
II[DEX 775
Power trim and tilt systems and
power steering system
power trim and tilt system
service. 702-723
power steering system . ... 723-729
power trim and tilt
systems. 678-702
Propeller, lower gearcase andjet
driveunits .. 581-583
R
Reed valve service,
fuel system . 368-381
Remotecontrol. . . . . . . 7 6 5 - 7 7 1
S
Safety precautions,
synchronization and linkage
adjustments. .....248-'249
troubleshooting...... .34-35
Sealings urfacesp, owerhead. . .. .. 463
Service considerations,
powerhead .459-460
Service precautions, lower gearcase
andjet drive units. . . 578-579
Service recommendations,
powerhead .46I-462
Starting system,
troubleshooting.. ... . 42-51
Starting systems, ignition and
electricalsystems ...416-424
Synchronization and linkage
adjustments. ...248
100-125 hp and 80jet
models . .256-261
135-200 hp carbureted
models . .261-270
150-200 hp EFI (electronic fuel
injection) models . 270-276
200 DFI (direct tuel injection)
models . .276-279
225 and 250 hp EFI
models . .287-292
225 hp carbveted models . . . 279-287
275hpmodels ......292-297
75, 90 hp and 65 jet
models. ..251-256
generailn formation .249-251
safetyprecautio.n .s .. . ... .. 248-249
T
Test and repair
equipment,
troubleshooting. . . . . . . . . . .37-42
Thermal air valve,
135-200 hp
carburetedm odels,
fuelsystem. ....331.332
Trim and tilt systems,
power trim and tilt
systems and power
steeringsystem. .... 678
Trim tab adjustment,
lower gearcase
a n d j e t d r i v e u n i t s . . . . . . . . . . . 583
Tr o u b l e s h o o t i.n. .g. . . . . . . 3 3
alternator driven
ignition,
135-200 hp, 275 hp,
105 and 140 iet, V6. . . . . .75-90
alternator driven ignition,
mechanical advance,
75-125hp and
6 5 - 8 0 j e t . . . . . . . 6 4 - 7 5
battery charging
system. . . . . 5 1 - 6 2
capacitord ischargem odule
(CDM) ignition, 7 5 -I25 hp
and 65-80 jet, serial No.
0G438000-on ...90-97
capacitor discharge module (CDM):
ignition, 225 and 250 hp. . . . 97 -110
CDM module resistance tests,
optional. . 110-111
DFI airituel system. . 166-177
DI, digital inductive,
200DFr llt-r2O
EFItuelsystem. ....129-166
electricalaccessories. .... 62
engine temperature and
overheating ..... 177-182
engine . ... 182-187
fuel primer and enrichment
systems . 123-129
tuel system l2O-I23
ignitionsystem. . . . . . 62-64
operatingrequiremen.t.s. .... 35-37
s a f e t y p r e c a u t i o n s ........ . . . 3 4 - 3 5
startings ystem. ..... 42-5I
test and repair
e q u i p m e n t . . . . . . . . 3 7
Tune-up, lubrication maintenance
andtune-up 231-244
V
Variable-ratio electronically
controlled oil injection,
200 DFI models, oil injection
system. 758-763
Variable-ratio oil injection,
135-200,275hp and
105-140j et models,
oilinjection system. . . . . .'739-750
225 and250 hp models, oil
injection system . 750-758
75-125 hp and 65-80 jet models,
oilinjection system. ..... 733-739
w
Water intake housing liner, lower
gearcase andjet drive units. . . . . . 671
Water pump, lower gearcase and
jetdriveunits. . . . . . 593-603
Wi r i n g d i a g r am. .s. . . . . . . . . . 7 7 6 - 8 0 7
WME series carburetor, 75-l25hp,
65 and 80 jet, tuel system. . . 309-316
WMH and WMV series carburetor
135-225 hp and 105-140jet
models,fuelsystem... ... 316-325
WO series (Mercarb) carburetor,
275 hp, tuel system. 325-329


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