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Mercury Mariner 135HP 150HP 175HP 200HP Outboards Service Manual – PDF DOWNLOAD
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Description
Mercury Mariner 135HP 150HP 175HP 200HP Outboards Service Manual
FILE DETAILS:
Mercury Mariner 135HP 150HP 175HP 200HP Outboards Service Manual
Language : English
Pages : 638
Downloadable : YES
Format : PDF
Size : 15.9 MB
DESCRIPTION:
Mercury Mariner 135HP 150HP 175HP 200HP Outboards Service Manual
Users of This Manual:
This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers.
- We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected.
- All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks.
- When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started.
TABLE OF CONTENTS:
Mercury Mariner 135HP 150HP 175HP 200HP Outboards Service Manual
cover................................................................................................. 1 MODELS 135 * 150 * 175 * 200...................................................................... 1 Notice........................................................................................ 2 Notice to Users of This Manual................................................................ 2 Cleanliness and Care of Outboard Motor........................................................ 3 Page Numbering................................................................................ 3 Service Manual Outline........................................................................ 4 1a.................................................................................................... 5 Section 1A - Specifications....................................................................... 5 Table of Contents............................................................................. 5 Specifications................................................................................ 5 1b.................................................................................................... 10 Section 1B - Maintenance.......................................................................... 10 Table of Contents............................................................................. 10 Specifications................................................................................ 10 Special Tools................................................................................. 11 Quicksilver Lubricant/Sealant................................................................. 11 Inspection and Maintenance Schedule........................................................... 13 Before Each Use........................................................................... 13 After Each Use............................................................................ 13 Every 100 Hours of Use or Once Yearly, Whichever Occurs First............................. 13 Flushing Engine............................................................................... 14 Flushing Cooling System – Using Cowl Flush Plug........................................... 14 Flushing Cooling System – Using Flushing Attachment 44357A2............................... 14 Fuel System................................................................................... 15 Fuel Line Inspection...................................................................... 15 Fuel Line Filter (Models With Carburetors)................................................ 15 Water Separating Fuel Filter – EFI Models................................................. 16 Corrosion Control Anode....................................................................... 16 Spark Plug Inspection......................................................................... 17 Battery Inspection............................................................................ 17 Fuse Replacement.............................................................................. 18 Lubrication Points............................................................................ 18 Checking Power Trim Fluid..................................................................... 20 Gear Case Lubrication......................................................................... 21 Storage Preparation........................................................................... 22 1c.................................................................................................... 25 Section 1C - General Information.................................................................. 25 Table of Contents............................................................................. 25 Serial Number Location........................................................................ 25 Conditions Affecting Performance.............................................................. 26 Weather................................................................................... 26 Boat...................................................................................... 27 Trim...................................................................................... 28 Engine.................................................................................... 29 Engine Compression........................................................................ 29 Following Complete Submersion................................................................. 30 Model 135/150/200 Powerhead Front View........................................................ 32 Model 135/150/200 Powerhead Starboard View.................................................... 33 Model 135/150/200 Powerhead Port View......................................................... 34 Model 135/150/200 Powerhead Top View.......................................................... 35 Model 135/150/200 Powerhead Aft View.......................................................... 36 Model 150 XRI/175 XRI/200 XRI Powerhead Front View............................................ 37 Model 150 XRI/175 XRI/200 XRI Powerhead Starboard View........................................ 38 Model 150 XRI/175 XRI/200 XRI Powerhead Port View............................................. 39 Model 150 XRI/175 XRI/200 XRI Powerhead Top View.............................................. 40 Model 150 XRI/175 XRI/200 XRI Powerhead Aft View.............................................. 41 Painting Procedures........................................................................... 42 Decal Application............................................................................. 43 1d.................................................................................................... 45 Section 1D - Outboard Motor Installation.......................................................... 45 Table of Contents............................................................................. 45 Installation Specifications................................................................... 45 Lifting Outboard.............................................................................. 45 Installing Outboard to Boat Transom........................................................... 46 Installing Outboard........................................................................... 47 Drilling Outboard Mounting Holes.......................................................... 47 Securing Outboard To Boat Transom......................................................... 48 Steering Cable................................................................................ 48 Steering Link Rod............................................................................. 49 Electrical, Hoses and Control Cables.......................................................... 50 Installation Note......................................................................... 50 Remote Wiring Harness..................................................................... 50 Battery Cables............................................................................ 51 Fuel Hose Connection...................................................................... 52 Oil Hose Connections...................................................................... 52 Speedometer Tubing Connection............................................................. 52 Water Pressure Tubing Connection.......................................................... 52 Shift Cable................................................................................... 53 Installation.............................................................................. 54 Throttle Cable................................................................................ 56 Front Clamp Reassembly.................................................................... 57 Filling the Oil Injection System.............................................................. 58 Bleeding Air from Oil Injection Pump and Oil Injection Outlet Hose............................ 59 Adjusting the Oil Injection Pump.............................................................. 59 Trim In Stop Adjustment....................................................................... 60 Trim Tab Adjustment........................................................................... 60 Models Without Power Steering............................................................. 60 Models With Power Steering................................................................ 61 2a.................................................................................................... 63 Section 2A - Ignition............................................................................. 63 Table of Contents............................................................................. 63 Specifications................................................................................ 64 Special Tools................................................................................. 66 Flywheel/Starter Motor........................................................................ 68 CDM Mounting.................................................................................. 70 Solenoid Mounting............................................................................. 72 Theory of Operation........................................................................... 74 V-6 2.0/2.5L CDM Ignition..................................................................... 75 Capacitor Charging #1, #2, & #3 CDMs...................................................... 76 Capacitor Charging #4, #5 & #6 CDMs....................................................... 76 #1 CylinderTrigger Circuit................................................................ 76 Ignition Coil Circuit..................................................................... 76 Stop Circuit.............................................................................. 76 Ignition Component Description................................................................ 77 Capacitor Discharge Module (CDM).......................................................... 77 Trigger Coil.............................................................................. 77 Control Module............................................................................ 77 Stator Assembly........................................................................... 78 Flywheel.................................................................................. 78 CDM (P/N 827509) Trouble Shooting Flowchart................................................... 79 CDM (P/N 827509).......................................................................... 79 CDM Stop Diode Trouble Shooting........................................................... 80 CDM Trouble Shooting Flowchart............................................................ 82 Direct Voltage Adaptor (DVA).............................................................. 87 Troubleshooting Tips...................................................................... 87 Ignition Test Procedures...................................................................... 88 Direct Voltage Adaptor (DVA) Test......................................................... 88 Resistance Tests.......................................................................... 92 Bias Circuit.................................................................................. 92 Shift Stabilizer Circuit...................................................................... 93 Idle Stabilizer............................................................................... 93 Rev-Limit Circuit............................................................................. 93 EFI Injector Timing Signal Test............................................................... 94 EFI Detonation Control System................................................................. 94 Ignition Component Removal.................................................................... 95 Flywheel Removal.......................................................................... 95 Flywheel Installation..................................................................... 95 Stator Removal............................................................................ 96 Stator Installation....................................................................... 97 Trigger Removal........................................................................... 98 Trigger Installation...................................................................... 99 CDM Removal...............................................................................100 CDM Installation..........................................................................100 Control Module Removal....................................................................100 Control Module Installation...............................................................100 Detonation Module Removal (200 XRI only)..................................................101 Detonation Module Installation............................................................101 2b....................................................................................................102 Section 2B - Charging and Starting System.........................................................102 Table of Contents.............................................................................102 Specifications................................................................................102 Electrical Plate..............................................................................103 Flywheel/Starter Motor........................................................................105 Starter Motor.................................................................................107 Battery Cable Size............................................................................108 Replacement Parts.............................................................................108 Recommended Battery...........................................................................108 Special Tools.................................................................................109 Battery.......................................................................................109 Charging a Discharged Battery.................................................................110 Winter Storage of Batteries...................................................................110 Flywheel Removal and Installation.............................................................111 Removal...................................................................................111 Installation..............................................................................112 Battery Charging System Description...........................................................113 Precautions...............................................................................113 Battery Charging System Troubleshooting.......................................................114 General Troubleshooting...................................................................114 40 Ampere Alternator System...............................................................114 Troubleshooting 40 Amp Alternator System..................................................115 Removal of Voltage Regulators.............................................................117 Installation of Voltage Regulators........................................................118 Incorporating a Battery Isolator with a 40 Ampere Charging System.........................118 System Wired for 40 Ampere Output to Isolator.............................................118 System Wired for Split Output.............................................................119 Starter System................................................................................119 Starter System Components.................................................................119 Description...............................................................................119 Troubleshooting the Starter Circuit.......................................................120 Starter Circuit Troubleshooting Flow Chart................................................121 Starter Removal...........................................................................122 Installation..............................................................................123 Disassembly...............................................................................123 Starter Cleaning, Inspection and Testing..................................................125 Starter Reassembly........................................................................128 2c....................................................................................................133 Section 2C - Timing, Synchronizing & Adjusting....................................................133 Table of Contents.............................................................................133 Specifications................................................................................133 Special Tools.................................................................................135 Adjustments...................................................................................136 Carburetor Models.........................................................................136 Electronic Fuel Injection Models..........................................................142 2d....................................................................................................153 Section 2D - Wiring Diagrams......................................................................153 Table of Contents.............................................................................153 Power Trim Wiring Diagram.....................................................................154 Instrument Wiring Connections.................................................................155 Commander 3000 Classic Panel Remote Control...................................................156 Commander 3000 Panel Remote Control...........................................................157 Instrument/Lanyard Stop Switch Wiring Diagram.................................................158 Oil Level Gauge Wiring Diagram................................................................159 Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard).................................160 Panel Mount Remote Control Wiring Installation................................................162 QSI Gauge Wiring Diagrams.....................................................................163 Tachometer Wiring Diagram.................................................................163 Water Temperature Gauge...................................................................164 Oil Level Gauge Wiring....................................................................165 Engine Synchronizer Wiring Diagram........................................................167 Maintenance...................................................................................168 Multi-Function Gauge..........................................................................169 Dip Switch Setting/Testing................................................................169 Outboard Multi-Function Gauge Setting.....................................................170 2.5 Litre V-6 Carburetor Wiring Diagram 2000 Models...........................................171 2.5 Litre V-6 150/175 EFI Wiring Diagram 2000 Models..........................................172 2.5 Litre V-6 200 EFI Wiring Diagram 2000 Models..............................................173 3a....................................................................................................174 Section 3A - Fuel Pump............................................................................174 Table of Contents.............................................................................174 Specifications................................................................................175 Special Tools.................................................................................175 Fuel Pump Assembly............................................................................177 Fuel Pump Description/Operation...............................................................179 Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves................................179 Checking Fuel Pump Lift (Vacuum)..............................................................180 Vacuum Test Troubleshooting...............................................................180 Testing Fuel Pump.........................................................................181 Fuel Pump Removal/Disassembly.............................................................182 Cleaning/Inspection.......................................................................183 Reassembly/lnstallation...................................................................183 3b....................................................................................................186 Section 3B - Carburetors..........................................................................186 Table of Contents.............................................................................186 Attenuator And Carb Throttle Levers...........................................................187 Fuel Lines....................................................................................189 Carburetor....................................................................................191 Fuel System - Troubleshooting.................................................................195 Reed Valve Leak Test..........................................................................197 Thermal Air Valve Circuit Description.........................................................198 Enrichener System Description.................................................................199 Manual Operation of Enrichener Valve......................................................199 Enrichener Valve Test.....................................................................200 Carburetor....................................................................................201 Carburetor Fuel Circuits......................................................................202 Float Bowl Circuit........................................................................202 Idle Circuit..............................................................................203 Cold Start Circuit........................................................................204 Off-Idle Circuit..........................................................................204 Main Circuit..............................................................................205 Back Draft Circuit........................................................................206 Carburetor Specifications.................................................................207 Carburetor Placement and Jet Location for Each Cylinder...................................208 Carburetor Jet Placement..................................................................209 High Altitude Recommendations.............................................................210 Jet Part Number Chart.....................................................................210 High Altitude Jet Chart...................................................................211 Removing Carburetor(s) from Engine............................................................212 Throttle Shaft Screws.....................................................................213 Float Adjustment..........................................................................213 Installing Carburetor(s) to Engine........................................................214 3c....................................................................................................215 Section 3C - Fuel Injection.......................................................................215 Table of Contents.............................................................................215 Specifications................................................................................216 Special Tools.................................................................................217 Ignition Controller and Detonation Module.....................................................220 ECM Assembly..................................................................................222 Fuel Management System........................................................................224 Fuel Pump.....................................................................................228 Electronic Fuel Injection (EFl) System........................................................230 Introduction..............................................................................230 Using the Test Procedures.................................................................230 EFI System Tests..........................................................................230 Safety Precautions........................................................................230 Fuel Injection System Function............................................................231 Preliminary Checks............................................................................231 Ignition Spark Check......................................................................231 Electronic Fuel Injection Set Up..........................................................232 Fresh Quality Fuel........................................................................232 Low Battery Voltage.......................................................................232 Fuel Flow Diagram.............................................................................233 Fuel Flow Component Description...............................................................234 Pulse Fuel Pump (k).......................................................................234 Water Separating Filter (i)...............................................................234 Vapor Separator (n).......................................................................234 Bleed System (f,g)........................................................................234 Final Filter (t)..........................................................................234 Electric Fuel Pump (Inside Vapor Separator) (q)...........................................234 Fuel Injectors (a)........................................................................235 Induction Manifold (r)....................................................................235 Fuel Pressure Regulator (e)...............................................................235 EFI Electrical Components.................................................................235 EFI Fuel Management (Low Pressure Fuel Route).................................................238 EFI Fuel Management (High Pressure Fuel Route)................................................239 Fuel Rail Electrical/Fuel Determination.......................................................240 EFI System Test Procedures....................................................................241 Fuel Gauge Connection/Pressure Test.......................................................241 Vapor Separator Fuel Delivery Test........................................................242 Vapor Separator Float Test................................................................243 Water Separating Filter Flow Test.........................................................244 Pulse Fuel Pump Delivery Test.............................................................245 Final Filter Check and De-Pressurizing EFI System Procedures..............................246 Pressure Regulator Test...................................................................248 Electric Fuel Pump Voltage Test...........................................................250 Injector Electrical Harness Test..........................................................253 ECM Injector Driver Test..................................................................254 Injector Fuel Delivery Test...............................................................254 Injector Operation Test (Manifold Cover Removed)..........................................254 Induction Manifold Leak Check (Manifold Cover Removed)....................................257 Air Temperature Sensor Test...............................................................259 Engine Head Temperature Sensor Test.......................................................260 Detonation Control System Test (200 Models Only)..........................................260 Detonation Sensor Check...................................................................261 Detonation Control Module Check...........................................................262 Throttle Position Sensor Test.............................................................263 Map Sensor Test...........................................................................264 Problem Diagnosis.........................................................................265 Engine Head Temperature Sensor Removal........................................................268 EFI Induction Manifold Removal................................................................269 Water Separating Filter Assembly Removal..................................................270 Water Separating Filter Assembly Installation.............................................271 Throttle Position Sensor and Temperature Sensor Fuel Injector Harness Disconnections......271 Oil Reservoir Removal.....................................................................273 Fuel Pressure Regulator Removal...........................................................274 Fuel Pressure Regulator Disassembly.......................................................275 Fuel Pressure Regulator Reassembly........................................................275 Vapor Separator Removal...................................................................276 Vapor Separator Disassembly...............................................................278 Installing Vapor Separator Assembly to Induction Manifold.................................284 Manifold Removal..........................................................................287 EFI Induction Manifold Disassembly............................................................289 Air Temperature Sensor Removal............................................................289 Throttle Position Sensor Removal..........................................................290 Fuel Rail Removal.........................................................................291 Fuel Rail Disassembly.....................................................................293 Fuel Injector Removal and Disassembly.....................................................293 Injector Harness Removal..................................................................295 Throttle Linkage Removed..................................................................296 EFI System Cleaning and Inspection............................................................297 Induction Manifold Assembly...................................................................298 Injector Harness Installation.............................................................298 Fuel Injector Assembly and Installation...................................................299 Fuel Rail Assembly........................................................................301 Fuel Rail Installation....................................................................301 Throttle Position Sensor Installation.....................................................303 Air Temperature Sensor Installation.......................................................304 EFI Induction Manifold Installation...........................................................306 Oil Reservoir Installation................................................................308 Vapor Separator Installation..............................................................309 Throttle Position Sensor, Air Temperature Sensor and Fuel Injector Harness Connections....311 ECM Installation..........................................................................313 Engine Head Temperature Sensor Installation...............................................314 3d....................................................................................................315 Section 3D - Oil Injection........................................................................315 Table of Contents.............................................................................315 Operation of the Oil Injection System.........................................................316 Final Checks Before Operation of Engine...................................................316 Checking Operation of the Oil Injection System (Engine Running)...........................317 Oil Injection Components......................................................................318 Oil Injection Flow System.....................................................................321 Pump Drive Assembly...........................................................................322 Pump Drive System.............................................................................322 Set Up Instructions for Oil Injection System..............................................323 Bleeding Air from Oil Injection Pump and Oil Injection Outlet Hose........................325 Adjusting Oil Injection Pump..............................................................326 Oil Injection Pump............................................................................327 Worm Bushing..................................................................................328 Worm Bushing Removal......................................................................328 Worm Bushing Installation.................................................................328 Oil Injection Pump Installation...........................................................329 Installing Drive Gear (for Oil Injection Pump) onto Crankshaft............................329 Oil Injection System Trouble Shooting Chart...............................................330 Oil Pump Volume (Flow) Test...................................................................332 Engine Mounted Oil Reservoir..............................................................333 3e....................................................................................................334 Section 3E – Emissions............................................................................334 Table of Contents.............................................................................334 Exhaust Emissions Standards...................................................................334 What Are Emissions?.......................................................................334 Hydrocarbons – HC.........................................................................334 Carbon Monoxide – CO......................................................................334 Oxides of Nitrogen - NOx..................................................................335 Controlling Emissions.....................................................................335 Stoichiometric (14.7:1) Air/Fuel Ratio....................................................335 Outboard Hydrocarbon Emissions Reductions.....................................................335 Stratified vs Homogenized Charge..............................................................336 Homogenized Charge........................................................................336 Stratified Charge.........................................................................337 Emissions Information.........................................................................337 Manufacturer s Responsibility:............................................................337 Dealer Responsibility:....................................................................338 Owner Responsibility:.....................................................................338 EPA Emission Regulations:.................................................................338 Manufacturer s Certification Label:...........................................................339 Service Replacement Certification Label.......................................................340 Removal...................................................................................340 Date Code Identification..................................................................340 Installation..............................................................................340 Decal Location:...........................................................................340 4a....................................................................................................341 Section 4A - Powerhead............................................................................341 Table of Contents.............................................................................341 Powerhead Specifications (2 Liter Model 135)..................................................342 Powerhead Specifications (2.5 Liter Model 150/175/200)........................................343 Special Tools.................................................................................344 Powerhead Repair Stand....................................................................345 Cylinder Block Assembly.......................................................................346 Exhaust Manifold and Exhaust Plate............................................................348 Crankshaft, Pistons and Connecting Rods.......................................................350 Reed Block and Cylinder Head..................................................................352 Bleed System Routing (Carburetor Models)......................................................354 Bleed System Routing (EFI Models).............................................................355 Torque Sequence...............................................................................356 General Information...........................................................................357 Powerhead Removal from Driveshaft Housing.....................................................358 Removing Engine Components................................................................362 Powerhead Disassembly.........................................................................363 Cleaning and Inspection.......................................................................374 Cylinder Block and Crankcase Cover........................................................374 Special Service Information...............................................................374 Cylinder Bores............................................................................375 Pistons and Piston Rings..................................................................376 Cylinder Heads and Exhaust Divider Plate..................................................378 Crankshaft................................................................................378 Crankshaft (and End Cap) Bearings.........................................................379 Reed Block Assembly.......................................................................379 Reed Block Housing........................................................................380 Connecting Rods...........................................................................380 Powerhead Reassembly and Installation.........................................................383 General...................................................................................383 Crankshaft Installation...................................................................388 Piston and Connecting Rod Reassembly......................................................390 Piston and Piston Ring Combinations.......................................................393 Piston Installation.......................................................................393 Crankcase Cover Installation..............................................................397 Assembly of Reed Blocks to Intake Manifold................................................399 Assembly of Exhaust Manifold to Block.....................................................399 Cleaning and Inspection.......................................................................401 Cylinder Block and Crankcase Cover........................................................401 Reinstalling Engine Components............................................................403 Throttle Lever and Shift Shaft................................................................404 Powerhead Installation On Driveshaft Housing..................................................408 Gasoline/Oil Break-in Mixture.................................................................413 Break-ln Procedure............................................................................413 4b....................................................................................................414 Section 4B - Cooling..............................................................................414 Table of Contents.............................................................................414 Specifications................................................................................414 Special Tools.................................................................................415 Temperature Sensor........................................................................416 Water Flow....................................................................................417 2.5 Litre V-6 Water Flow Diagram 2000 Models..................................................418 Troubleshooting...............................................................................420 Thermostat Test...........................................................................420 Water Pressure Check......................................................................421 Water Pump Cleaning and Inspection........................................................422 Problem Diagnosis.........................................................................423 5a....................................................................................................424 Section 5A – Clamp/Swivel Brackets & Driveshaft Housing...........................................424 Table of Contents.............................................................................424 Swivel Bracket and Steering Arm...............................................................425 Transom Brackets..............................................................................427 Drive Shaft Housing and Exhaust Tube..........................................................429 Drive Shaft Housing and Dyna-Float Suspension.................................................431 Removal and Disassembly...................................................................431 Reassembly and Installation...............................................................434 5b....................................................................................................438 Section 5B - Power Trim...........................................................................438 Table of Contents.............................................................................438 Power Trim Specifications.....................................................................438 Special Tools.................................................................................439 Power Trim Components.........................................................................441 Power Trim Motor..............................................................................443 Power Trim - General Information..............................................................444 Description...............................................................................444 Trimming Characteristics..................................................................444 Trailering Outboard.......................................................................445 Tilting Outboard Manually.................................................................445 Trim “In” Angle Adjustment................................................................446 Striker Plate Replacement.................................................................446 Anode Plate...............................................................................447 Trim Indicator Gauge......................................................................447 Check, Fill and Purge - Power Trim System.................................................447 Troubleshooting...........................................................................449 Power Trim System with Relays and 2 Wire Trim Motor.......................................451 Electrical System Troubleshooting.............................................................452 Troubleshooting the “Down Circuit”............................................................452 Troubleshooting the “Up” Circuit..............................................................453 Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative).......................454 Power Trim Assembly Removal and Installation..................................................455 Removal...................................................................................455 Installation..............................................................................458 Testing Power Trim System With Test Gauge Kit (91-52915A6)................................460 “UP” Pressure Check.......................................................................460 “DOWN” Pressure Check.....................................................................463 Hydraulic Repair..........................................................................465 Trim Rod End Cap Seal.....................................................................466 Tilt Ram..................................................................................467 Disassembly...............................................................................468 Scraper Seal Replacement..................................................................471 Motor and Electrical Tests/Repair.............................................................475 Trim Pump Motor Test......................................................................475 Motor Disassembly.........................................................................475 Armature Tests............................................................................476 Motor Repair..............................................................................477 Reassembly................................................................................481 Reassembly - Motor and Pump...............................................................483 Priming Power Trim System.................................................................484 Trim Sender Test..........................................................................484 Trim Indicator Gauge Needle Adjustment....................................................485 Trim Indicator Wiring Diagrams................................................................486 6a....................................................................................................487 Section 6A – Right Hand Non-Ratcheting............................................................487 Table of Contents.............................................................................487 Gear Housing Specifications (Standard Rotation)...............................................487 Special Tools.................................................................................488 Gear Housing (Drive Shaft)(Standard Rotation).................................................492 Gear Housing (Prop Shaft)(Standard Rotation)..................................................494 General Service Recommendations...............................................................496 Removal, Disassembly, Cleaning and Inspection – Standard Rotation.............................497 Removal...................................................................................497 Draining and Inspecting Gear Housing Lubricant............................................498 Water Pump................................................................................499 Bearing Carrier and Propeller Shaft Removal...............................................502 Shift Shaft...............................................................................504 Propeller Shaft...........................................................................506 Clutch Actuator Rod.......................................................................508 Pinion Gear and Driveshaft................................................................508 Forward Gear..............................................................................511 Gear Housing..............................................................................512 Reassembly and Installation Standard Rotation.................................................512 Driveshaft Needle Bearing.................................................................512 Bearing Carrier...........................................................................513 Forward Gear..............................................................................516 Forward Gear Bearing Race.................................................................517 Driveshaft and Pinion Gear................................................................518 Pinion Gear Depth/Forward Gear Backlash/Reverse Gear Backlash.............................520 Clutch Actuator Rod.......................................................................524 Shift Shaft Bushing.......................................................................524 Propeller Shaft...........................................................................525 Water Pump................................................................................528 Gear Lubricant Filling Instructions.......................................................531 Installing Gear Housing to Driveshaft Housing.............................................531 Right Hand Rotation Outboard..............................................................531 Propeller Installation....................................................................533 Speedometer Tube Installation.............................................................534 6b....................................................................................................535 Section 6B – Left Hand Non-Ratcheting.............................................................535 Table of Contents.............................................................................535 Gear Housing Specifications (Counter Rotation)................................................535 Special Tools.................................................................................536 Gear Housing (Drive Shaft)(Counter Rotation)..................................................540 Gear Housing (Prop Shaft)(Counter Rotation)...................................................542 General Service Recommendations...............................................................545 Removal, Disassembly, Cleaning and Inspection of Counter Rotation (Left Hand) Gear Housing....546 Water Pump................................................................................549 Bearing Carrier and Propeller Shaft.......................................................551 Shift Shaft...............................................................................553 Propeller Shaft...........................................................................555 Clutch Actuator Rod.......................................................................558 Forward Gear and Bearing Adapter..........................................................558 Pinion Gear and Driveshaft................................................................560 Reverse Gear..............................................................................562 Gear Housing..............................................................................564 Reassembly and Installation of Counter Rotation Gear Housing..................................565 Driveshaft Needle Bearing.................................................................565 Bearing Carrier, Forward Gear and Bearing Adaptor.........................................566 Reverse Gear Bearing Adaptor Assembly.....................................................569 Driveshaft and Pinion Gear................................................................571 Pinion Gear Depth.........................................................................573 Reverse Gear..............................................................................575 Forward Gear..............................................................................576 Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier..............................579 Water Pump................................................................................586 Gear Lubricant Filling Instructions.......................................................589 Installing Gear Housing to Driveshaft Housing.............................................589 Propeller Installation....................................................................591 Speedometer Tube Installation.............................................................592 7.....................................................................................................593 Section 7.........................................................................................593 Table of Contents.............................................................................593 Ride Guide Steering Cable/Attaching Kit Installation (92876A1)................................593 Single Cable..............................................................................593 Maintenance Instructions..................................................................594 Ride Guide Steering Cable/Attaching Kit Installation (92876A3)................................595 Dual Cable - Single Outboard..............................................................595 Super Ride-Guide Steering Kit Installation................................................596 Steering Cable Mounting Tube Installation.................................................597 Installing Steering Cables................................................................598 Coupler Installation......................................................................599 Installing Link Rod.......................................................................599 Maintenance Instructions..................................................................601 Ride Guide Steering Cable/Attaching Kit Installation (92876A6)................................602 Dual Cable - Dual Outboard................................................................602 Installation Requirements.................................................................602 Parallel Routed Steering Cables and Attaching Kit Installation............................603 Opposite Side Routed Steering Cables and Attaching Kit Installation.......................610 Trim Tab Adjustment.......................................................................617 Ride Guide Steering Attachment Extension Couplers.........................................617 Maintenance Instructions..................................................................618 Transom Mounted Ride Guide Attaching Kit Installation (73770A1)...............................620 Attaching Kit Installation................................................................620 Maintenance Instructions..................................................................623 Clevis Attaching Kit Installation (A-70599A5).................................................624 Installation Instructions.................................................................624 Maintenance Instructions..................................................................624 8.....................................................................................................625 COLOR DIAGRAMS....................................................................................625 Table of Contents.............................................................................625 2.5 Liter V-6 Carburetor Color Wiring Diagram 2000 Models.....................................627 2.5 Litre V-6 Carburetor 2000 Models......................................................629 2.5 Liter V-6 150/175 EFI Color Wiring Diagram 2000 Models....................................630 2.5 Litre V-6 150/175 EFI 2000 Models.....................................................632 2.5 Liter V-6 200 EFI Color Wiring Diagram 2000 Models........................................633 2.5 Litre V-6 200 EFI 2000 Models.........................................................635 2.5 Liter V-6 Color Water Flow Diagram 2000 Models............................................636 2.5 Litre V-6 Water Flow Diagram 2000 Models..............................................638
MERCURY MARINER 135HP 150HP 175HP 200HP OUTBOARDS SERVICE MANUAL – PDF DOWNLOAD:
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