MERCURY MARINE 115 125 135 150 175 200 225 OPTIMAX WORKSHOP SERVICE REPAIR MANUAL




THIS MANUAL IS COMPATIBLE WITH THE FOLLOWING COMPUTER OPERATING SYSTEMS:

# ALL WINDOWS VERSION
# ALL MAC VERSION

# YOU NEED THE ADOBE ACROBAT READER TO VIEW THE DOCUMENT AS THE MANUAL IS PDF FORMAT. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM ADOBE ACROBAT WEBSITE

# AS THIS MANUAL IS COMING TO YOU IN ZIP FORMAT, YOU NEED TO EXTRACT THE FILE BEFORE USE BY USING WINZIP OR WINRAR SOFTWARE. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM WINZIP WEBSITE



MODEL COVERED:
115 135 150 175 HP OPTIMAX, STARTING SERIAL NUMBER OG960500 (MODEL YEAR 2000+)
135 150 HP OPTIMAX, STARTING SERIAL NUMBER OG590000 (MODEL YEAR 1998-1999)
200 225 HP OPTIMAX, STARTING SERIAL NUMBER OG386496 (MODEL YEAR 1997-1999)
200 225 HP OPTIMAX, STARTING SERIAL NUMBER OG960500 (MODEL YEAR 2000+)
200 OPTIMAX JET DRIVE, POWERHEAD SERIAL 0E384500+ & PUMP UNIT SERIAL 0E379931+ (MODEL YEAR 2001+)


ENGINE COVERED:
2508 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 115/135/150/175 DFI)
3032 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 200/225 DFI)
3047 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 200/225 DFI)
2508 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 200 JET DRIVE)


CONTENTS:
GENERAL INFORMATION
SAFETY PRECAUTION
SPECIFICATIONS
TIGHTENING TORQUE
SPECIAL TOOLS
PAINTING PROCEDURES
DECAL APPLICATION
OUTBOARD MOTOR INSTALLATION
STEERING CABLE
ELECTRICAL, HOSES & CONTROL CABLES
REMOTE WIRING HARNESS
BATTERY CABLES
SHIFT CABLE INSTALLATION
THROTTLE CABLE SYSTEM
FILLING FUEL SYSTEM
INJECTION PUMP SYSTEM
IGNITION SYSTEM
ELECTRONIC CONTROL MODULE (ECM)
FLYWHEEL-COIL DRIVER
CRANK POSITION SENSOR
THROTTLE POSITION SENSOR (TPS)
CHARGING SYSTEM ALTERNATOR
FUEL INJECTORS SYSTEM
DDT FUNCTIONS - OPTIMAX MODELS SOFTWARE
STARTER SYSTEM
THROTTLE CAM ADJUSTMENT
IDLE SPEED SYSTEM
FUEL PUMP SYSTEM
DIRECT FUEL INJECTION
AIR COMPRESSOR SYSTEM
OILING SYSTEM
EMISSIONS SYSTEM
CRANKSHAFT-PISTONS-CONNECTING RODS
POWERHEAD DISASSEMBLY
BEARING BLEED SYSTEM
POWERHEAD REASSEMBLY
THROTTLE LEVER AND SHIFT SHAFT
COOLING SYSTEM
SWIVEL BRACKET AND STEERING ARM
TRANSOM BRACKETS
DRIVE SHAFT HOUSING
POWER TRIM MOTOR
HYDRAULIC REPAIR
TRAIL OVER SYSTEM
REVERSE OPERATION
ELECTRICAL SYSTEM
DRIVE SHAFT-PROPELLER SHAFT
WATER FLOW DIAGRAM
TROUBLESHOOTING
WIRING DIAGRAMS



THIS IS A VERY COMPREHENSIVE AND INTUITIVE ELECTRONIC PDF FORMAT WORKSHOP MANUAL WHICH HAS DETAILED ILLUSTRATIONS AS WELL AS STEP BY STEP INSTRUCTIONS WITH PICTURES & DIAGRAMS. ALL PAGES ARE PRINTABLE, SO RUN OFF WHAT YOU NEED AND TAKE IT WITH YOU INTO THE GARAGE OR WORKSHOP. THIS MANUAL ARE YOUR NUMBER ONE SOURCE FOR REPAIR AND SERVICE INFORMATION. THEY ARE SPECIFICALLY WRITTEN FOR THE DO-IT-YOURSELF AS WELL AS THE EXPERIENCED MECHANIC. USING THIS REPAIR MANUAL IS AN INEXPENSIVE WAY TO KEEP YOUR MACHINE/VEHICLE WORKING PROPERLY. EACH MANUAL PROVIDES STEP-BY-STEP INSTRUCTIONS BASED ON THE COMPLETE DIS-ASSEMBLY OF THE MACHINE. SO, IT ALLOWING YOU TO STOP WASTING MONEY ON ROUTINE MAINTENANCE, AND GIVE YOU ALL THE SOLID INFORMATION AND GUIDANCE NEEDED TO PERFORM LARGER REPAIRS AND MODIFICATIONS AT HOME.