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MERCURY 60 65 75 80 100 125 135 140 200 225 250 HP JET OUTBOARD 1990-2000 SERVICE WORKSHOP MANUAL 1991 1992 1993 1994 1995 1996 1997 1998 1999

MERCURY 60 65 75 80 100 125 135 140 200 225 250 HP JET OUTBOARD 1990-2000 SERVICE WORKSHOP MANUAL Download!
This original MERCURY 60 65 75 80 100 125 135 140 200 225 250 HP JET OUTBOARD 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 manual is a detailed file and it is illustrated with clear step-by-step instructions.
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 https://www.tradebit.com. 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 200DFI449-452 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 52. 8 jetdrivemodels 661 jetpump unitmaintenanc.e..... 661-667 unitservice ..... 667-670 lowergearcase . 576 propeller .. 581-583 serviceprecaut https://www.tradebit.com.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 https://www.tradebit.com . 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 ams 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
The MERCURY 60 65 75 80 100 125 135 140 200 225 250 HP JET OUTBOARD 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 pdf contains help for troubleshooting and will support you how to fix your problems immediately.
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MERCURY 60 65 75 80 100 125 135 140 200 225 250 HP JET OUTBOARD 1990-2000 SERVICE WORKSHOP MANUAL for sale
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MERCURY 60 65 75 80 100 125 135 140 200 225 250 HP JET OUTBOARD 1990-2000 SERVICE WORKSHOP MANUAL
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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 https://www.tradebit.com. 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 200DFI449-452 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 52. 8 jetdrivemodels 661 jetpump unitmaintenanc.e..... 661-667 unitservice ..... 667-670 lowergearcase . 576 propeller .. 581-583 serviceprecaut https://www.tradebit.com.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 https://www.tradebit.com . 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 ams 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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