1994-1997 Mercury-Mariner 75-275 hp Outboard Boat Engine Repair Manual

Description

This 1994 1995 1996 1997 Mercury-Mariner 75-275 hp Outboard Boat Engine Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1994-1997 Mercury-Mariner 75-275hp two-stroke outboard boat engines including 75 HP, 90 HP, 100 HP, 115 HP, 125 HP, 135 HP, 150 HP, 150 XR6, 150 Magnum III, 175 HP, 200 HP, 200 DFI, 225 HP, 250 HP, 275 HP, 65 Jet, 80 Jet, 105 Jet, 140 Jet motors.

Includes general information on each model, tools and techniques, troubleshooting and testing, lubrication, maintenance and tune-up, synchronization and linkage adjustments, fuel system, electrical and ignition systems, power head, lower gearcase, Jet drive units, power trim and tilt systems, power steering system, oil injection system, remote control and complete wiring diagrams. Features 700 illustrated pages.

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION

Manual organization, Notes, cautions and warnings, Torque specifications, Engine operation, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Protection from galvanic corrosion, Propellers

CHAPTER TWO, TOOLS AND TECHNIQUES

Safety first, Basic hand tool, Test equipment, Service hints, Special tips, Mechanic’s techniques

CHAPTER THREE, TROUBLESHOOTING

Safety precautions, Operating requirements, Test and repair equipment, Starting system, Battery charging system, Electrical accessories, Ignition system, Alternator driven ignition (mechanical advance [75-125 hp and 65-80 Jet]) , Alternator driven ignition (135-200 hp, 275 hp, 105 and 140 Jet [V6]), Capacitor discharge module (CDM) ignition (75-125 hp and 65-80 Jet [serial No. 0G438000-on]) , Capacitor discharge module (CDM) ignition (225 and 250 hp) , CDM module resistance tests (optional) , DI (digital inductive [200 DFI]) , Fuel system, Fuel primer and enrichment system, EFI fuel system troubleshooting, DFI air/fuel system troubleshooting, Engine temperature and overheating, Engine

CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP

Hour meter, Fuels and lubrication, Off-season storage, Anticorrosion maintenance, Engine submersion, Cooling system flushing, Tune-up

CHAPTER FIVE, SYNCHRONIZATION AND LINKAGE ADJUSTMENTS

Safety precautions, General information, 75, 90 hp and 60 Jet models, 100-125 hp and 80 Jet models, 135-200 hp carbureted models, 150-200 hp EFI (electronic fuel injection) models, 200 DFI (direct fuel injection) models, 225 hp carbureted models, 225 and 250 hp EFI models, 275 hp models

CHAPTER SIX, FUEL SYSTEM

Fuel pump, Carburetors, WME series carburetor (75-125 hp, 65 and 80 Jet) , WMH and WMV series carburetors (135-225 hp and 105-140 Jet models) , WO series (Mercarb) carburetor (275 hp) ,  Fuel primer valve (75-200 hp, 275 hp and 65-140 Jet [remote control model[), Thermal air valve (135-200 hp carbureted models) , Fuel enrichment valve (225 hp carbureted models) , Accelerator pump circuit (100-125 hp and 80 Jet) , Antisiphon devices, Fuel filters, Fuel tanks (integral and portable [remote]) , Fuel hose and primer bulb, Electronic fuel injection (EFI) and direct fuel injection (DFI) , Reed valve service, Fuel bleed (recirculation) system

CHAPTER SEVEN, IGNITION AND ELECTRICAL SYSTEMS

Battery, Battery charging system, Fuses, Starting systems, Ignition systems, Alternator driven capacitor discharge ignition (60-275 hp and 65-140 Jet) , Capacitor discharge module (CDM) ignition, CDM ignition (75-125 hp and 65-80 Jet [serial No. 0G438000-on) , CDM ignition (225 and 250 hp) , Digital inductive ignition (200 DFI)

CHAPTER EIGHT, POWER HEAD

Service considerations, Mercury/Mariner model identification, Power head break-in, Service recommendations, Lubricants, sealants and adhesives, Seal surfaces, Fasteners and torque, Power head removal/installation, Power head disassembly, Power head cleaning and inspection, Power head assembly

CHAPTER NINE, LOWER GEARCASE AND JET DRIVEUNITS

Lower gearcase, Gearcase operation, Gear ratio, High-altitude operation, Service precautions, Corrosion control, Gearcase lubrication, Propeller, Trim tab adjustment, Gear housing, Water pump, Gearcase disassembly/assembly, Gearcase cleaning and inspection, Gearcase pressure testing, Gearcase shimming, Jet drive models, Jet pump unit maintenance, Jet pump unit service, Bearing housing, Water intake housing liner

CHAPTER TEN, POWER TRIM AND TILT SYSTEMS AND POWER STEERING SYSTEM

Trim and tilt systems, Power trim and tilt systems, Power trim and tilt system service, Power steering system

CHAPTER ELEVEN, OIL INJECTION SYSTEM

Variable ratio oil injection (75-125 hp and 65-80 Jet models) , Variable-ratio oil injection (135-200, 275 hp and 105-140 Jet models) , Variable-ratio oil injection (225 and 250 hp models) , Variable-ratio electronically controlled oil injection (200 DFI models)

CHAPTER TWELVE, REMOTE CONTROL

INDEX

WIRING DIAGRAMS