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MERCURY 100 TO 140 HP JET OUTBOARD SERVICE MANUAL WORKSHOP
Sections are listed below;:
A
Accelerator pump circuit
l0O-125 hp and 80jet,
tuelsystem ......332-335
Altemator driven capacitor discharge
ignition 6O-275hpa nd6 5-140je t,
ignition and electrical
systems. 424_439
Alternator driven ignition 135-200 hp,
275hp,i 05 and1 40jetV6,
troubleshooting .....l.5-g}
Alternator driven ignition, mechanical
advance7, 5-125h p and6 5-80j et,
t roubleshoot ing. .......... . 64_j5
Anticorrosionm aintenancel,u brication
maintenanceandtun.e. .-.u. .p. 226
Antisiphon devices,
fuel system . 3f.S_337
B
Battery chargings ystem,ig nition and
electricalsystems ...4OT-415
Battery charging system,
troubleshooting...... . 51_62
Battery ignition and electrical
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 65-80 jet,
serial No. 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 65-80 jet, serial No.
0G43 8000-on, ignition and
electrical systems 441-444
CDM module resistance tests
(optional), troubleshooting. . . 1 l0_lll
Cooling system flushing, lubrication
maintenance andtune-up . . . . 229_23I
Corrosionc ontrol,l owerg earcasaen d
jetdriveunits... ... 579-591
D
DFI airlfuel system
t r o u b l e s h o o t i n g . . ...... . . . 1 6 6 - 1 7 7
DI digiral inductive, 200 DFI
t r o u b l e s h o o t i n g . . ...... . . . l l l _ l 2 }
Digital inductive ignition, 200 DFI,
ignition and elecaical
systems M9_452
E
EFI fuel system,
t r o u b l e s h o o t i n g . . ...... . . . 1 2 9 _ 1 6 6
Electrical accessories,
t r o u b l e s h o o t i n g . . . . . . . . . 62
Electronic fuel injection (EFI) and
direct tuel injection (DFI),
fuelsysrem . . . . . 339-369
Engine submersion, lubrication
maintenance andtune-up . . . 226-229
Engine temperature and overheating,
troubleshooting .... lj7_Lg2
Engine, troubleshooting ..... . lg2-lg7
774 IiDEX
F
Fastenersa ndt orque,
powerhead .463-465
Fuel primer and enrichment systems,
ffoubleshooting.. . . . . . . . . . . 123-129
Fuelsystem. ..302-307
acceleratopr ump circuit,
100-125h p and8 0jet.. . . .332-335
antisiphondevices ..335-33i
carburetors .307-309
electronic fuel injection (EFI) and
direct fuel injection
(DFr) . .339_368
fuel bleed (recirculation)
system. . .381-392
fuel enrichment valve,225 hp
carburetedmode.l s. ....... 332
f u e l f i l t e r s . . . . . 3 3 j
fuel hose and primer bulb. . . . 338-339
fuel primer valve, 75 -2OOh p,
275h p and3 5-140je r, remote
controlmodels ..329-331
tuelpump . .302-307
fuel tanks, integral and portable,
remote. . . 337-338
reed valve service. . . 368-381
thermala ir valve,1 35-200h p
carburetedmodel.s . . . . .. 331-332
troubleshooting.. . . . . . . . . . . l2O-123
WME seriesc arburetor,7 5-L25h p,
65and80jet. . . . . 3 0 9 - 3 1 6
WMH andWMV series carburetors,
135-225h p and 105-140jet
models .316-325
WO series (Mercarb) carburetor,
275hp. . .325-329
Fuels and lubrication. lubrication
maintenancaen dtune-up. . . . 201-Z2O
Fuses,ig nition ande lecfical
systems ....415-416
G
Gear housing, lower gearcase and
j e t d r i v e u n i t s . . . . . . . . . 583
Gear ratio, lower gearcase andjet
drive units. . 577-579
Gearcase cleaning and inspection,
lower gearcase and jet driv
u n i t s . . . . . . . 6 5 1
Gearcase disassembly/assembly,
lower gearcase andjet drive
u n i t s. . . . . . . 6 0 3
Gearcase lubrication, lower gearcase
a n d j e t d r i v e u n i t s . . . . . . . . . . . .5. 8 1
Gearcase operation, lower gearcase
andjetdriveunits... 5i6-5'77
Gearcase pressure testing, lower
gearcaseandjetdriveunits . . . .. 652
Gearcases himming,l ower gearcase
andjetdriveunits.. .... 653
General information, synchronization
andlinkagea djustment.s . . . . 249-251
H
High-altitude operation, lower
gearcasaen djet driveu nits. . . . . . 578
Hour meter, lubrication maintenance
andtune-up .200-201
I
Ignitiona ndelectricasly stem.s . ... 399
alternator driven capacitor discharge
ignition, 60-275hp afi
65-140jet. .....424-438
battery. ....399-407
batteryc hargings ystem. . . .. 407-415
capacitord ischargem odule
(CDM) ignition. . .438-441
CDMignition
2 2 5a n d 2 5h0p . . . . . . . . . 4 4 4 - 4 4 9
75-125hp and 65-80jet, serial
No.0 G438000-o.n.. ... 441-444
digital inductive ignition
200DFI. .449-452
tuses.. . . . . 4 1 5 - 4 1 6
startingsystems. ....416-424
Ignition system,
troubleshootin.g .. . .. . . .. . . . . 62-64
Ignition systemsi,g nition and
electricalsystems ...... 424
J
Jet drive models,l ower gearcasea nd
jetdr i veuni t. s. . . . . . . . 661
Jetp ump unit maintenancel,o wer
gearcasaen djet driveu nits. . . 661-667
Jet pump unit service, lower gearcase
andjer drive units . . .667-670
L
Lowerg earcasaen djet driveu nits. . 576
bearinghousing ....670-671
corrosionc ontrol.. . . . . . . . . . 579-581
***
housing ..583-593
r a t i o . . . ..577-578
gearcase
cleaningandinspection.. . 651-652
disassembly/assemb. l.y .. . 603-651
l u b r i c a t i o n . . . . . . . . . . 581
operation. 576-577
pressuretestin. g. .. . ..... 652-653
shimming 653-661
high-al t ihrdeoperat ion. . . . . .5. .2. 8
jetdrivemodels. . . . . . . . 661
jetpump
unitmaintenanc.e.... ... 661-667
unitservice ..... 667-670
lowergearcase . . . . . . . . . 576
propeller .. 581-583
serviceprecaut i.o. .n.s. . . . 578-579
trimtabadjustment ..... 583
waterintakeh ousingli ner. . . . . . . 67I
water pump 593-603
Lubricantss, ealantsa nda dhesives,
powerhead 462-463
Lubrication maintenancea nd
tune-up . . . . . . . 200
anticorrosionmaintenan.c .e. . 226
coolings ystemfl ushing . . 228-231
enginesubmersi.o..n ... 226-228
fuelsa ndlubrication.. . .. 201-220
hourmeter. ..... 2OO-1OL
off-seasons torage 220-226
tune-up . 231-244
M
Mercury/I4arinemr odel
identificationp,o werhead... .... 460
o
Off-seasons toragel,u brication
maintenancaen dtune-up. . . 220-226
Oil injection system . . 732-733
variable-ratio electronically
controlledo il injection,200D FI
models 758-763
variable-ratio oil injection
135-20},275hpand -
105-l40jetmodel.s... . 739-750
225 and2 50h p models. . . 750-758
75-125hp and 65-80jet
models 733-739
Operathg requirements,
troubleshooting..... . 35-37
P
!
Powerhead . . . . . . 458
assembly . . 524-570
b r e a k - i n . . . . . . . 461
cleaning andinspection. . . . . 508-524
disassembly. . . . . . . 480-508
fasteners andtorque 463-465
lubricants, sealants and
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
service considerations. . . . . . 459-460
servicerecommendations .. . 461-462
II[DEX 775
Power trim and tilt systems and
power steering system
power trim and tilt system
service. 702-723
power steering system . ... 723-729
power trim and tilt
systems. 678-702
Propeller, lower gearcase andjet
driveunits .. 581-583
R
Reed valve service,
fuel system . 368-381
Remotecontrol. . . . . . . 7 6 5 - 7 7 1
S
Safety precautions,
synchronization and linkage
adjustments. .....248-'249
troubleshooting...... .34-35
Sealings urfacesp, owerhead. . .. .. 463
Service considerations,
powerhead .459-460
Service precautions, lower gearcase
andjet drive units. . . 578-579
Service recommendations,
powerhead .46I-462
Starting system,
troubleshooting.. ... . 42-51
Starting systems, ignition and
electricalsystems ...416-424
Synchronization and linkage
adjustments. ...248
100-125 hp and 80jet
models . .256-261
135-200 hp carbureted
models . .261-270
150-200 hp EFI (electronic fuel
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, 90 hp and 65 jet
models. ..251-256
generailn formation .249-251
safetyprecautio.n .s .. . ... .. 248-249
T
Test and repair
equipment,
troubleshooting. . . . . . . . . . .37-42
Thermal air valve,
135-200 hp
carburetedm odels,
fuelsystem. ....331.332
Trim and tilt systems,
power trim and tilt
systems and power
steeringsystem. .... 678
Trim tab adjustment,
lower gearcase
a n d j e t d r i v e u n i t s . . . . . . . . . . . 583
Tr o u b l e s h o o t i.n. .g. . . . . . . 3 3
alternator driven
ignition,
135-200 hp, 275 hp,
105 and 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
system. . . . . 5 1 - 6 2
capacitord ischargem odule
(CDM) ignition, 7 5 -I25 hp
and 65-80 jet, serial No.
0G438000-on ...90-97
capacitor discharge module (CDM):
ignition, 225 and 250 hp. . . . 97 -110
CDM module resistance tests,
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
operatingrequiremen.t.s. .... 35-37
s a f e t y p r e c a u t i o n s ........ . . . 3 4 - 3 5
startings ystem. ..... 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
105-140j et models,
oilinjection system. . . . . .'739-750
225 and250 hp models, oil
injection system . 750-758
75-125 hp and 65-80 jet models,
oilinjection system. ..... 733-739
w
Water intake housing liner, lower
gearcase andjet drive units. . . . . . 671
Water pump, lower gearcase and
jetdriveunits. . . . . . 593-603
Wi r i n g d i a g r am. .s. . . . . . . . . . 7 7 6 - 8 0 7
WME series carburetor, 75-l25hp,
65 and 80 jet, tuel system. . . 309-316
WMH and WMV series carburetor
135-225 hp and 105-140jet
models,fuelsystem... ... 316-325
WO series (Mercarb) carburetor,
275 hp, tuel system. 325-329
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