service repair manual

1. A
Acceleratorpumpcircuit
l0O-125hpand80jet,
tuelsystem ......332-335
Altematordrivencapacitordischarge
ignition6O-275hpand65-140jet,
ignition andelectrical
systems. 424_439
Alternatordrivenignition 135-200hp,
275hp,i05 and140jetV6,
troubleshooting .....l.5-g}
Alternatordrivenignition, mechanical
advance,75-125hpand65-80jet,
troubleshooting............ 64_j5
Anticorrosionmaintenance,lubrication
maintenanceandtune-up....... 226
Antisiphondevices,
fuelsystem . 3f.S_337
B
Batterychargingsystem,ignition and
electricalsystems ...4OT-415
Batterychargingsystem,
troubleshooting...... . 51_62
Batteryignition andelectrical
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 65-80jet,
serialNo. 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 65-80jet, serialNo.
0G438000-on, ignition and
electrical systems 441-444
CDM module resistance tests
(optional), troubleshooting. . . 1l0_lll
Cooling system flushing, lubrication
maintenanceandtune-up . . . . 229_23I
Corrosioncontrol,lowergearcaseand
jetdriveunits... ... 579-591
D
DFI airlfuel system
tro u b le sh o o tin g ........... 166-177
DI digiral inductive, 200 DFI
tro u b le sh o o tin g ........... lll_l2}
Digital inductive ignition, 200 DFI,
ignition and elecaical
systems M9_452
E
EFI fuel system,
tro u b le sh o o tin g ........... 129_166
Electrical accessories,
tro u b le sh o o tin g ..... .... 62
Electronic fuel injection (EFI) and
direct tuel injection (DFI),
fu e lsysre m ..... 339-369
Engine submersion, lubrication
maintenance andtune-up . . . 226-229
Engine temperature and overheating,
troubleshooting .... lj7_Lg2
Engine,troubleshooting..... . lg2-lg7

2. 774 IiDEX
F
Fastenersandtorque,
powerhead .463-465
Fuelprimerandenrichmentsystems,
ffoubleshooting.. . . . . . . . . . . 123-129
Fuelsystem. ..302-307
acceleratorpumpcircuit,
100-125hpand80jet.. . . .332-335
antisiphondevices ..335-33i
carburetors .307-309
electronicfuel injection(EFI) and
directfuel injection
(DFr). .339_368
fuelbleed(recirculation)
system. . .381-392
fuel enrichmentvalve,225hp
carburetedmodels......... 332
f u e l f i l t e r s . . . . . 3 3 j
fuelhoseandprimerbulb.. . . 338-339
fuelprimervalve,75-2OOhp,
275hp and35-140jer,remote
controlmodels ..329-331
tuelpump . .302-307
fuel tanks,integralandportable,
remote. . . 337-338
reedvalveservice. . . 368-381
thermalairvalve,135-200hp
carburetedmodels. . . . . .. 331-332
troubleshooting.. . . . . . . . . . . l2O-123
WME seriescarburetor,75-L25hp,
6 5 a n d 8 0 j e t . . . . . 3 0 9 - 3 1 6
WMH andWMV seriescarburetors,
135-225hpand105-140jet
models .316-325
WO series(Mercarb)carburetor,
275hp. . .325-329
Fuelsandlubrication.lubrication
maintenanceandtune-up. . . . 201-Z2O
Fuses,ignition andelecfical
systems ....415-416
G
Gear housing, lower gearcaseand
j e t d r i v e u n i t s . . . . . . . . . 5 8 3
Gear ratio, lower gearcaseandjet
drive units. . 577-579
Gearcasecleaning and inspection,
lower gearcaseandjet driv
u n i t s . . . . . . . 6 5 1
Gearcasedisassembly/assembly,
lower gearcaseandjet drive
u n i t s. . . . . . . 6 0 3
Gearcaselubrication, lower gearcase
a n d j e t d r i v e u n i t s . . . . . . . . . . . . .5 8 1
Gearcaseoperation, lower gearcase
andjetdriveunits... 5i6-5'77
Gearcasepressuretesting, lower
gearcaseandjetdriveunits . . . .. 652
Gearcaseshimming,lowergearcase
andjetdriveunits.. .... 653
Generalinformation,synchronization
andlinkageadjustments. . . . . 249-251
H
High-altitudeoperation,lower
gearcaseandjetdriveunits.. . . . . 578
Hour meter,lubricationmaintenance
andtune-up .200-201
I
Ignitionandelectricalsystems. .... 399
alternatordrivencapacitordischarge
ignition,60-275hpafi
65-140jet. .....424-438
battery. ....399-407
batterychargingsystem. . . .. 407-415
capacitordischargemodule
(CDM)ignition. . .438-441
CDMignition
2 2 5a n d 2 5 0h p . . . . . . . . . 4 4 4 - 4 4 9
75-125hpand65-80jet,serial
No.0G438000-on... ... 441-444
digital inductiveignition
200DFI. .449-452
t u s e s . . . . . . 4 1 5 - 4 1 6
startingsystems. ....416-424
Ignition system,
troubleshooting.. . . .. . . .. . . . . 62-64
Ignition systems,ignition and
electricalsystems ...... 424
J
Jetdrivemodels,lowergearcaseand
jetdriveunits.. ....... 661
Jetpumpunit maintenance,lower
gearcaseandjetdriveunits.. . 661-667
Jetpumpunit service,lowergearcase
andjerdriveunits. . .667-670
L
Lowergearcaseandjetdriveunits. . 576
bearinghousing ....670-671
corrosioncontrol.. . . . . . . . . . 579-581
geil
housing ..583-593
ratio... ..577-578
gearcase
cleaningandinspection.. . 651-652
disassembly/assembly.. . . . 603-651
l u b r i c a t i o n . . . . . . . . . . 5 8 1
operation. 576-577
pressuretesting.. . . . ..... 652-653
shimming 653-661
high-altihrdeoperation.........528
jetdrivemodels. ....... 661
jetpump
unitmaintenance..... ... 661-667
unitservice ..... 667-670
l o w e r g e a r c a s e . . . . . . . . . 5 7 6
propeller .. 581-583
serviceprecautions.. ...... 578-579
trimtabadjustment ..... 583
waterintakehousingliner.. . . . . . 67I
waterpump 593-603
Lubricants,sealantsandadhesives,
powerhead 462-463
Lubricationmaintenanceand
t u n e - u p . . . . . . . 2 0 0
anticorrosionmaintenance. .. . 226
coolingsystemflushing. . 228-231
enginesubmersion... ... 226-228
fuelsandlubrication.. ... 201-220
hourmeter. ..... 2OO-1OL
off-seasonstorage 220-226
tune-up . 231-244
M
Mercury/I4arinermodel
identification,powerhead... .... 460
o
Off-seasonstorage,lubrication
maintenanceandtune-up. . . 220-226
Oil injectionsystem. . 732-733
variable-ratioelectronically
controlledoil injection,200DFI
models 758-763
variable-ratiooil injection
135-20},275hpand -
105-l40jetmodels.... . 739-750
225and250hpmodels. . . 750-758
75-125hpand65-80jet
models 733-739
Operathg requirements,
troubleshooting..... . 35-37
P
!
Po we rh e a d ...... 458
assembly . . 524-570
b r e a k - i n . . . . . . . 4 6 1
cleaning andinspection. . . . . 508-524
disassembly. ...... 480-508
fastenersandtorque 463-465
lubricants,sealantsand
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
serviceconsiderations.. . . . . 459-460
servicerecommendations.. . 461-462

3. II[DEX 775
Power trim and tilt systemsand
power steering system
power trim and tilt system
service. 702-723
powersteeringsystem. ... 723-729
power trim and tilt
systems. 678-702
Propeller,lower gearcaseandjet
driveunits .. 581-583
R
Reedvalve service,
fuel system . 368-381
Remotecontrol . . . . . . . 765- 771
S
Safetyprecautions,
synchronization and linkage
adjustments. .....248-'249
troubleshooting...... .34-35
Sealingsurfaces,powerhead. . .. .. 463
Serviceconsiderations,
powerhead .459-460
Serviceprecautions,lower gearcase
andjet driveunits. . . 578-579
Servicerecommendations,
powerhead .46I-462
Starting system,
troubleshooting... ... . 42-51
Starting systems,ignition and
electricalsystems ...416-424
Synchronization and linkage
adjustments. ...248
100-125hp and80jet
models . .256-261
135-200hp carbureted
models . .261-270
150-200hp EFI (electronicfuel
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
75,90hpand65jet
models. ..251-256
generalinformation .249-251
safetyprecautions.. . . .... .. 248-249
T
Test and repair
equipment,
troubleshooting.. . . . . . . . . . .37-42
Thermal air valve,
135-200hp
carburetedmodels,
fuelsystem. ....331.332
Trim and tilt systems,
power trim and tilt
systemsand power
steeringsystem. .... 678
Trim tab adjustment,
lower gearcase
a n d j e t d r i v e u n i t s . . . . . . . . . . .5 8 3
Tr oubl e sh o o tin g..... ..... 3 3
alternator driven
ignition,
135-200hp, 275 hp,
105and 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
syste m. ....5 1 -6 2
capacitordischargemodule
(CDM) ignition, 75-I25 hp
and65-80jet, serialNo.
0G438000-on ...90-97
capacitor discharge module (CDM):
ignition, 225 and 250 hp. . . . 97-110
CDM module resistancetests,
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
operatingrequirements... .... 35-37
sa fe typ re ca u tio n s........... 34-35
startingsystem. ..... 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
105-140jet models,
oilinjection system.. . . . .'739-750
225 and250 hp models,oil
injection system . 750-758
75-125 hp and 65-80jet models,
oilinjectionsystem...... 733-739
w
Water intake housing liner, lower
gearcaseandjet drive units. . . . . . 671
Water pump, lower gearcaseand
jetdriveunits. ..... 593-603
Wirin g d ia g ra ms...... ...... 776-807
WME seriescarburetor,75-l25hp,
65 and 80jet, tuel system. . . 309-316
WMH and WMV seriescarburetor
135-225hp and 105-140jet
models,fuelsystem...... 316-325
WO series (Mercarb) carburetor,
275 hp, tuel system. 325-329
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