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Mercury Repair Manual for Outboard Engine DOWNLOAD
 
Submitted By Administrator on 2013-02-28( Views : 10758 ) ( Votes : 0 )
IN Service and Repair


Mercury Outboard Repair Manual


This Mercury outboard repair manual was written to guide the mechanic when servicing the engine and related parts. This manual assumes the mechanic is familiar with Mercury Marine engines and trained in the recommended repair procedures including the proper use of mechanics' tools commonly needed to aid in engine repair. 


Instant Download Manuals



YEARS

INSTANT DOWNLOAD LINK

1965-1991

Mercury/Mariner 2.2HP to 40HP Repair Manual

1965-1989

Mercury/Mariner 45HP to 115HP Repair Manual

1965-1989

Mercury/Mariner 90HP to 300HP Repair Manual

1986-2003

Mercury 6HP 8HP 9.9HP Repair Manual

1986-2003

Mercury 10HP 15HP Repair Manual

1990-2000

Mercury/Mariner 2.5HP to 275HP Repair Manual

1997-1998

Mercury 200/225 Optimax DFI 4-Stroke Manual

1998-1999

Mercury 135/150 Optimax DFI Repair Manual

1999-2003

Mercury 30/40 EFI 4-Stroke Repair Manual

2000-2001

Mercury 75/90 4-Stroke Repair Manual

2001

Mercury/Mariner 50/60 4-Stroke Repair Manual

2001-2002

Mercury/Mariner 115HP EFI 4-Stroke Manual

1992-1998

Mercury Optimax 115HP 135HP DFI Repair Manual

1992-1998

Mercury Optimax 150HP 175HP DFI Repair Manual

 


All information provided in these manuals such as specifications and illustrations are based on current knowledge available at the time of publishing. In some instances, revisions to the manual may occur of which are attainable from a supplemental manual.


It should be noted, the engines ignition and electrical system are capable of generating sever electrical shocks or causing damage to circuits. Ensure the cables to the battery are first disconnected as to prevent the possibility of terminals being touched or grounded. 


Moreover, the exhaust or intake openings must be covered anytime openings are exposed.  This prevents foreign material and other debris from entering the cylinders and causing extensive mechanical damage upon starting the motor. 


During any maintenance work, ensure that any fasteners that are replaced are done so with fasteners of the same strength and measurements as the ones removed and always use bolts and nuts with the same quality strength as the factory installed nuts and bolts.




Models and Years Covered in Repair Manuals 


1965-1989 Manual Covers: 2 HP thrugh 40HP 2 Stroke 1 & 2 cylinder engines.


1965-1989 Manual Covers: 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 Manual Covers: 90 through 300 HP models. 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


1990-2000 Manual Covers: Mercury and Mariner 2.5HP through 275 HP models. This pdf book is a workshop manual. 


1990-2000 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 Manual Covers: 6/8/9.9/15HP Motors 1986 and up With Serial Numbers OA1972112 and Above.


1995-2000 Manual Covers: Mercury and 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. 40HP (4-Stroke) 4 cylinder 1998, 1999 & 2000 Non-Bigfoot, 45 (4-Stroke) 4 cylinder 1998, 1999 & 2000 Non-Bigfoot and Big Foot, 50 (4-Stroke) 4 cylinder 1995, 1996, 1997 & 1998.


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


1997-1998 Manual Covers: 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 Manual Covers: Mercury/Mariner Outboard motors: 98-99 9.9hp (9.9 hp), 15hp (15 hp) Bigfoot and Non-Big Foot 4-Stroke Outboard Engine. Models Covered are 9.9/15 (4-Stroke) (323 cc) & 9.9/15 Bigfoot (4-Stroke) (323 cc) with Serial Numbers 0G590000 and Above.


1998-1999 Manual Covers: 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 Manual Covers: Mercury Outboard 30HP, 40HP (4-Stroke) - Non-Bigfoot & Bigfoot Engine-Motor (Four-Stroke) starting with serial number 0G760300 and above.


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


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


2000-2001 Manual Covers: Mercury OptiMax Outboard motors 2000-2001 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 Manual Covers 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 Manual Covers: Mercury 115 HP, Mercury 115 HP (115HP) EFI (Electronic Fuel Injection) outboard engine. 4 Cylinder InLine, 4 Stroke DOHC, 16 Valves. Starting Serial Number 0T178500.


2002-2004 Manual Covers: Mercury/Mariner Outboard motors, 2002-2004 40HP EFI 4-Stroke (Four-Stroke), 2002-2004, 60HP EFI 4-Stroke (Four-Stroke), 2002-2004, 50 HP EFI 4-Stroke (Four-Stroke), 2002-2004, 40 HP EFI 4-Stroke (FourStroke) Bigfoot, 2002-2004, 60 HP EFI 4-Stroke (FourStroke) Bigfoot.

 
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