MERCURY MARINE OPTIMAX 75 90 115 125 & PRO XS 115 WORKSHOP SERVICE REPAIR MANUAL





THIS MANUAL IS COMPATIBLE WITH THE FOLLOWING COMPUTER OPERATING SYSTEMS:

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# ALL MAC VERSION

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APPLICABLE MODEL: 2010 ONWARD
SERIAL NUMBER: 0T801000 & ABOVE
75 OPTIMAX (LASER II, HIGH FIVE, BLACK MAX ALUMINUM, TROPHY, VENGEANCE)
90 OPTIMAX (LASER II, HIGH FIVE, BLACK MAX ALUMINUM, TROPHY, VENGEANCE)
115 OPTIMAX (LASER II, HIGH FIVE, BLACK MAX ALUMINUM, TROPHY, VENGEANCE)
115 PRO XS (LASER II, TROPHY, VENGEANCE)
125 OPTIMAX (LASER II, HIGH FIVE, BLACK MAX ALUMINUM, TROPHY, VENGEANCE)


ENGINE COVERED:
1.5L 3-CYLINDER, WATER-COOLED


CONTENTS:
IMPORTANT INFORMATION
PRECAUTIONS
GENERAL SPECIFICATIONS
PROPELLER INFORMATION CHARTS
MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUE
SPECIAL TOOLS
OUTBOARD INSTALLATION
STEERING CABLE
DRILLING OUTBOARD MOUNTING HOLES
FRONT COWL GROMMET
FLUSH HOSE ROUTING
REMOTE BOAT HARNESS
BATTERY CABLE CONNECTIONS
SMARTCRAFT HARNESS CONNECTION
SHIFT CABLE INSTALLATION
THROTTLE CABLE INSTALLATION
FUEL SYSTEM
INJECTION SYSTEM
PADDLE WHEEL SPEED SENSOR
IGNITION SYSTEM
PROPULSION CONTROL MODULE (PCM)
COMPUTER DIAGNOSTIC SYSTEM (CDS)
MAIN POWER RELAY (MPR)
FLYWHEEL SYSTEM
THROTTLE POSITION SENSOR (TPS)
MANIFOLD SYSTEM
GUARDIAN PROTECTION SYSTEM
CHARGING AND STARTING SYSTEM
STARTER MOTOR-ALTERNATOR
TIMING-SYNCHRONIZING-ADJUSTING
IDLE SPEED ADJUSTMENT
DFI OPERATION SYSTEM
AIR INDUCTION SYSTEM
VAPOR SEPARATOR SYSTEM
FUEL RAIL SYSTEM
CONTROLLING EMISSIONS SYSTEM
POWERHEAD SYSTEM
CRANKSHAFT-PISTONS-CONNECTING RODS
CYLINDER BLOCK AND CRANKCASE
AIR COMPRESSOR ASSEMBLY
COOLING SYSTEM
CLAMP/SWIVEL BRACKETS
DRIVESHAFT HOUSING
POWER TRIM OPERATION
SHOCK FUNCTION SYSTEM
GEAR HOUSING SYSTEM
BEARING CARRIER & PROPELLER SHAFT
THROTTLE LEVER & LINKAGE
EXHAUST PLATE SYSTEM
SHIFT BRACKET SYSTEM
TROUBLESHOOTING
CIRCUIT 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.