DOWNLOAD 1965-2004 Mercury-Mariner Outboard Engine Service Manuals

1965-1989 Mercury Service Manual Application: 45 HP, 4 CYL, 1965 1966 1967 1968 1969 1970, 50 HP, 3 CYL, 1986 1987 1988 1989, 500/50 HP, 4 CYL, 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985, 60 HP, 3 CYL, 1984 1985 1986 1987 1988 1989, 650/65 HP, 3 CYL, 1972 1973 1974 1975 1976, 650/65 HP, 4 CYL, 1965 1966 1967 1968 1969 1970 1971, 650,700/70 HP, 3 CYL, 1976 1977 1978 1979 1980 1981 1982 1983, 70 HP, 3 CYL, 1986 1987 1988 1989, 75 HP, 4 CYL, 1984 1985 1986, 80 HP, 3 CYL, 1987 1988 1989, 800/80 HP, 4 CYL, 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983, 800/85 HP, 4 CYL, 1973 1974 1975 1976 1977, 90 HP, 3 CYL, 1987 1988 1989, 850XS/90 HP, 4 CYL, 1976, 100 HP, 4 CYL, 1988 1989, 115 HP, 4 CYL, 1988 1989.

1956-1989 90-300 HP Mercury Outboard motors repair manual Application: Covers all Mercury Motors from 1965 to 1989 90-300 hp Inline 6 and V6, 2 stroke models fuel injection and MR Drive: 90 95 100 115 125 135 140 150 150XR2/150 HP 155 HP 175 HP 200 HP 220XRi/200 HP 225 HP 275 HP 300 HP 850XS/90 HP, 4cyl 900/90hp, 6cyl 950/95hp, 6cyl 1000/100hp, 6cyl 1100/100hp, 6cyl 1150/115hp, 6cyl 1250/125hp, 6 cyl 1350/135hp, 6cyl 1400/140hp 1400/140hp, 6cyl 1500/150hp, 6cyl 1500XS/155hp, 6 cyl 1750/175hp, V6 2000/200hp, V6

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1990-2000 Mercury Mariner 2.5 / 275 HP Workshop Service Manual Repair

1990-2000 Mercury/Mariner Workshop Service Manual Repair Application: Manual covers 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 & 2000 Mercury Outboard 2-Stroke models, exact models listed: 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 00, 2.5hp, 3hp, 3.3hp, 4hp, 5hp, 6hp, 8hp, 9.9hp, 10hp, 15hp, 20hp, 25hp, 30hp, 40hp, 50hp, 60hp, 75hp, 90hp, 100hp, 115hp, 125hp, 135hp, 150hp, 175hp, 200hp, 225hp, 250hp, 275hp.

1986-1990 Service Manual Application: 6/8/9.9/15HP Motors 1986 and up With Serial Numbers OA1972112 and Above.

1995-2000 Mercury - Mariner 40hp · 45hp · 50hp Four Stroke (4-Stroke) Non-Big Foot and Bigfoot Engines With Starting Serial Numbers: 0G231123, 1995 & above with Serial Numbers 0G231123 & above. Mercury-Mainer 40 (4-Stroke) 4 cylinder 1998, 1999 & 2000 Non-Bigfoot, Mercury-Mainer 45 (4-Stroke) 4 cylinder 1998, 1999 & 2000 Non-Bigfoot and Big Foot, Mercury-Mainer 50 (4-Stroke) 4 cylinder 1995, 1996, 1997 & 1998.

1997-2000 Service Manual Model Application: 97-00 Mercury - Mariner 40-50-55-60 HP Two-Stroke Models with serial numbers OG531301 and above.

1997-1998 Service manual application: 1997-1998 Mercury 200HP ( 200 HP) & 225HP (225 HP) DFI (Direct Fuel Injection) outboard engine. V6 Cylinder, Two Cycle. Models covered are 200 & 225 OPTIMAX DIRECT FUEL INJECTION With Serial Numbers 0G386496 and Above.

1998-1999 Mercury/Mariner Outboard motor service manual application: 98-99 Mercury-Mariner 9.9hp (9.9 hp), 15hp (15 hp) Bigfoot and Non-Big Foot 4-Stroke Outboard Engine. Models Covered are Mercury - Mariner 9.9/15 (4-Stroke) (323 cc) & 9.9/15 Bigfoot (4-Stroke) (323 cc) with Serial Numbers 0G590000 and Above.

1998-1999 Service manual application: 98-99 Mercury 135HP (135 HP) & 150HP (150 HP) DFI (Direct Fuel Injection) outboard engine. V-6 Cylinder, Two Cycle, Direct Injected. Models covered are 135 & 150 OPTIMAX DIRECT FUEL INJECTION With Serial Numbers OG590000 and Above.

1999-2002 Service manual application: Mercury Outboard 30HP, 40HP (4-Stroke) - Non-Bigfoot & Bigfoot Engine-Motor (Four-Stroke) starting with serial number 0G760300 and above.

1999-2000 Mercury Service Manual Application: 99-00 Mercury 4 HP - 5 HP & 6 HP Four Stroke Engines.

2000-2001 Service Repair Manual Year Application: 2000 & 2001 Mercury 75hp (75 hp) 90hp (90 hp) 4-Stroke (Four-Stroke-FourStroke) Outboard boat motor engine. Starting model year 2000 & starting Serial Number 0G960500 and above.

2000-2001 Mercury OptiMax Outboard motor service manual application: 2000-2001 Mercury 115hp (115 hp) 135hp (135 hp) 150hp (150 hp) 175hp (175 hp) DFI (Direct Fuel Injection) outboard motor. Starting Model Year 2000 & Starting Serial Number OG960500 & above.

2001 Service Repair Manual Application: 2001 (01) Mercury-Mariner models 50 HP (50HP) & 60 HP (60HP) 4-Stroke (Four Stroke) Outboard Engines With Serial Numbers 0T178500 and Above. Covers Bigfoot (Big Foot) and Non-Bigfoot models.

2001-2002 Mercury 115 HP Service manual application: Mercury Outboard motor 01-02 Mercury 115 HP (115HP) EFI (Electronic Fuel Injection) outboard engine. 4 Cylinder InLine, 4 Stroke DOHC, 16 Valves. Starting Serial Number 0T178500.

2002-2004 Mercury/Mariner Outboard motor service manual application: 2002-2004 Mercury-Mariner 40HP EFI 4-Stroke (Four-Stroke), 2002-2004 Mercury-Mariner 60HP EFI 4-Stroke (Four-Stroke), 2002-2004 Mercury-Mariner 50 HP EFI 4-Stroke (Four-Stroke), 2002-2004 Mercury-Mariner 40 HP EFI 4-Stroke (FourStroke) Bigfoot, 2002-2004 Mercury-Mariner 60 HP EFI 4-Stroke (FourStroke) Bigfoot.

A Typical Mercury-Mariner Service Manual Contains The Following Chapters:

Subjects may differ depending on year/model.

Section 1 - Important Information

A - Specifications
B - Maintenance
C - General Information
D - Outboard Motor Installation

Section 2 - Electrical

A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting

Section 3 - Electronic Fuel Injection

A - Theory of Operation
B - Diagnostics & Troubleshooting
C - Service Procedures
D - Emissions

Section 4 - Powerhead

A - Cylinder Head
B - Cylinder Block/Crankcase
C - Lubrication

Section 5 - Mid-Section

A - Clamp/Swivel Brackets & Drive Shaft Housing
B - Power Trim

Section 6 - Lower Unit

A - Gear Housing

Section 7 - Attachments/Control Linkage

A - Throttle/Shift Linkage

Section 8 - Wiring Diagrams

RELATED MERCURY - MARINER OUTBOARD SEARCHES:

Carburetor Models:

CARBURETOR

Theory of Operations

Prime Start System

This carburetor assembly uses the PrimeStart system for precise fuel delivery during start-up, at all temperatures. Two electrothermal valves are installed on the carburetor assembly. The upper electrothermal valve controls fuel flow for carburetors #1 and #2, and the lower valve controls fuel flow for carburetors #3 and #4. Before start-up, the electrothermal ram (needle) is retracted (the fuel enrichment valve is opened) according to the temperature, allowing a high percentage of fuel to flow form the flat chamber into the venturi during start-up.

During start-up, the electrothermal ram (needle) is still retracted (the fuel enrichment valve is opened) according to the temperature, allowing a rich air/fuel mixture to be fed to the cylinders. After start-up, the current supplied form the electric power source and then flows to the electrothermal valves causing the wax in the valves to heat up.

As the wax heats up the electrothermal ram (needle) begins to extend, partially closing the fuel enrichment valve, and reducing the flow of fuel from the float chamber into the venturi. After a few minutes, the electrothermal ram (needle) is fully extended, the fuel enrichment valve is fully closed, and enrichment ceases.

a - Electrothermal Valve
b - Fuel Enrichment Valve
c - Electrothermal Ram (needle)
d - Carburetor #1 and #3
e - Carburetor #2 and #4

Acceleration

This carburetor assembly uses an accelerator pump to ensure that the proper amount of fuel reaches all of the carburetors during rapid throttle openings (preventing temporary lean
conditions). As the throttle is opened, the throttle lever rotates and pushes the throttle lever link rod. The throttle lever link rod then pushes the diaphragm in the dashpot, forcing out the air. The air
flows through the in-line, one-way valve, and then to all of the carburetors. This additional air flows into the carburetors and mixes with the fuel from the main jets. This air/fuel mixture is then injected into the venturi, ensuring that enough fuel reaches the engine.

As the throttle is closed, the throttle lever rotates back and the throttle lever link rod returns, causing the diaphragm in the dashpot to move back, As the diaphragm moves back, suction causes the air from the venturi of carburetor #4 to flow through a one-way valve in the carburetors and back to the dashpot. The in-line, one-way valve prevents the air in the hoses from flowing back to the dashpot. Also, the diaphragm functions as a coasting enrichener during quick deceleration, preventing the engine form stalling.

a - Throttle Lever
b - Throttle Lever Link Rod
c - Diaphragm
d - Dashpot
e - In-Line, One-Way Valve
f - To Carburetor #1
g - To Carburetor #2
h - To Carburetor #3
i - Main Jet
j - One-Way Valve

Carburetor Adjustments

Float Level

1. With carburetor turned upside down, and carb scale seated on inner edge, check float level from top of float to float bowl flange as shown. Adjust tab if out of specification.

NOTE: Measure float level without gasket.
NOTE: Bend tab to adjust float height.

Idle Speed

NOTE: Outboard should be completely warmed up for the idle speed adjustment.

1. With the outboard in forward gear, adjust idle speed screw to obtain the specified idle speed.

NOTE: Turning idle speed adjustment screw;

-clockwise will increase engine idling speed.
-counterclockwise will decrease engine idling speed.

CYLINDER HEAD

Adjustments

Valve Clearance

NOTE: Valve clearance adjustment should be made on a cold engine at room temperature.

1. Remove flywheel cover and spark plug cover.
2. Disconnect spark plug leads and fuel hoses.

a - Screw (2) M6 x 20
b - Flywheel Cover
c - Screw (5) M6 x 16
d - Spark Plug Cover
e - Fuel Hoses

3. Align timing marks on driven cams.

NOTE: Use flywheel holder (91-83163M) to rotate flywheel and align timing marks.

4. Loosen timing belt tensioner bolt and remove tensioner spring.

a - Timing Marks
b - Timing Belt Tensioner Screw M10 x 45
c - Tensioner Spring

5. Remove timing belt and driven sprockets.
6. Remove cylinder head cover and spark plugs.

a - Driven Sprocket Screw (2) M10 x 35
b - Washer (2)
c - Driven Sprocket (2)
d - Pin (2)
e - Breather Hose
f - Screw (14) M6 x 30
g - Cylinder Head Cover
h - Rubber Gasket

7. Re-install driven sprockets and timing belt.

NOTE: Make sure timing marks are still aligned.

a - Pin (2)
b - Washer (2)
c - Driven Sprocket (2)
d - Driven Sprocket Screw (2) M10 x 35
e - Timing Marks Aligned

Driven Sprocket Screw Torque - 44 lb-ft (60 Nm)

8. Install tensioner spring and tighten timing belt tensioner.

a - Timing Belt Tensioner Screw M10 x 45
b - Tensioner Spring

Timing Belt Tensioner Screw Torque - 29 lb-ft (40 Nm)

9. Measure intake and exhaust valve clearance using the Valve Clearance Measurement Steps below.

VALVE CLEARANCE MEASUREMENT STEPS:

a. Turn flywheel clockwise until cylinder #1’s piston is at TDC.
b. Measure and record the intake valve clearance for cylinders #1 and #2.
c. Measure and record the exhaust valve clearance for cylinders #1 and #3.
d. Turn the flywheel 360° clockwise.
e. Measure and record the intake valve clearance for cylinders #3 and #4.
f. Measure and record the exhaust valve clearance for cylinders #2 and #4.

10. If adjustment of intake or exhaust valve clearance is necessary (out of specification) follow Changing Pad Thickness below. If no adjustment is necessary skip to step #11 on.

CHANGING PAD THICKNESS

1. Align timing marks on driven cams.
2. Loosen timing belt tensioner and remove tensioner spring.

NOTE: Do not mix valve train parts (valve pads, camshaft caps, camshafts). Keep individual cylinder parts together.

a - Timing Marks
b - Timing Belt Tensioner Screw M10 x 45
c - Tensioner Spring

3. Remove timing belt and driven sprockets.
4. Remove camshaft caps and camshafts.

IMPORTANT: Remove camshaft cap bolts in reverse sequence (ex. #20 #1).

a - Driven Sprocket Screw (2) M10 x 35
b - Washer (2)
c - Driven Sprocket (2)
d - Pin (2)
e - Screw (4) M7 x 48
f - Screw (16) M7 x 37
g - Camshaft Cap - Top (2)
h - Camshaft Cap (8)
i - Oil Seal (2)
j - Camshaft (2)

5. Carefully pry up the valve pad and remove it.
6. Measure and record (in the Measurement Table) the thickness of the removed valve pad with a micrometer.

a - Valve Pad
b - Screwdriver
c - Measure Valve Pad Thickness With a Micrometer
a. Select a proper replacement valve pad by calculating its thickness with the following formula.

Removed Pad Thickness
+
Measured Valve Clearance
–
Specified Valve Clearance

= New Pad Thickness

NOTE: Measure the thickness of the new valve pads with a micrometer (thickness is not indicated on the pad).
NOTE: Lubricate the valve pads with molybdenum disulfide before installing.

b. Insert the proper valve pad into the valve lifter.

7. Install camshafts and camshaft caps

IMPORTANT: Install camshaft cap bolts in the proper sequence and torque.

a - Screw (4) M7 x 48
b - Camshaft Cap Top (2)
c - Screw (16) M7 x 37
d - Camshaft Cap (8)
e - Oil Seal (2)
f - Camshaft - Intake
g - Camshaft - Exhaust
h - Pink Identification
i - Exhaust Cam Tang

8. Install driven sprockets and timing belt.
9. Tighten timing belt tensioner and install tensioner spring.
10. Re-check valve clearance using Valve Clearance Measurement Steps.

NOTE: If any valve clearance is still out of specification, repeat all the valve clearance adjustment steps until the specified clearance is obtained.

11. Loosen timing belt tensioner screw and remove tensioner spring.
12. Remove driven sprockets and timing belt.
13. Install cylinder head cover and driven sprockets.

a - Rubber Gasket
b - Cylinder Head Cover
c - Screw (14) M6 x 30
d - Breather Hose
e - Pin (2)
f - Driven Sprocket (2)
g - Washer (2)
h - Driven Sprocket Screw (2) M10 x 35

Cylinder Head Cover Screw Torque - 70 lb-in. (8 Nm)
Driven Sprocket Screw Torque - 44 lb-ft (60 Nm)

14. Install timing belt and spark plugs.
15. Install tensioner spring and tighten timing belt tensioner bolt.
16. Connect fuel hoses and spark plug leads.
17. Install spark plug cover and flywheel cover.

a - Fuel Hoses
b - Spark Plug Cover
c - Screw (5) M6 x 16
d - Flywheel Cover
e - Screw (2) M6 x 20

Mercury Marine Outboard Service Manual, Mariner Outboard Repair Manual, Owner's Shop Manual, Workshop Manual, Handbook, Book, 2004, 2003, 2002, 2001, 2000, 1999, 1998, 1997, 1996, 1995, 1994, 1993, 1992, 1991, 1990, 1989, 1988, 1987, 1986, 1985, 1984, 1983, 1982,1981, 1980, 1979, 1978, 1977, 1976, 1975, 1974, 1973, 1972, 1971, 1970, 1969, 1968, 1967, 1966, 1965 Exploded Views, Exploded Diagrams, Repair Guide, Engine Repair Guide, How To Fix, How Do you Repair and Fix, Parts Locations Diagrams, 13.9 HP (3.9HP), 6HP (6-HP), 9.8HP (9.8 HP), 20 HP (20-HP), 35 HP (35HP), 4.0 HP (4.0HP), 7.5 HP (7.5HP), 40 HP (40HP) 4.5 HP (4.5HP) 3.6 HP 18HP, (18 HP), 20 HP, 25HP, 2.2 HP (2.2HP) 6.0 (6.0HP), 8.0 (8.0HP), 9.9 (9.9HP), 20 HP (20HP), 25 HP,35 (35-HP), 15 HP (15HP), 45 HP, 50 HP, 3 CYL (50HP 3 Cylinder Engine), 60 HP, 65 HP, 3 CYL (65HP 3 Cylinder Engine), Outboard, 70 HP, 75 HP4 CYL (75HP 4 Cylinder Motor), 80 HP, 85, 90 HP, 100 HP, 4 CYL, 100HP, 1988-1989 - 115 HP