DOWNLOAD MERCURY-MARINER REPAIR MANUALS 


Download Manuals Below

 

 

1965-1991 Mercury/Mariner 2.2HP thru 40HP Repair Manual
1965-1989 Mercury/Mariner 45HP thru 115HP Repair Manual
1965-1989 Mercury/Mariner 90HP thru 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 thru 275HP Repair Manual
1992-1998 Mercury Optimax 150HP 175HP DFI Repair Manual
1992-1998 Mercury Optimax 115HP 135HP DFI 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
2001-2005 Mercury/Mariner 2.5HP thru 225HP Repair Manual
2001-2001 Mercury/Mariner 50/60 4-Stroke Repair Manual
2001-2002 Mercury/Mariner 115HP EFI 4-Stroke Manual
2002-2007 Mercury 40/50/60 HP 4-Stroke Repair Manual


 



LOWER UNIT
REMOVAL & DISASSEMBLY

Always disconnect the battery cable, before removing
lower unit.
1. Shift to “NEUTRAL” position.
2. Remove bolt and trim tab 1.
3. Remove seven (7) bolts 2 and separate gearcase 3 from
driveshaft housing.
4. Remove clutch rod from clutch shaft (if necessary).
5. Place a drain pan under oil drain plug.
Remove oil drain plug 6 first then oil level plug 5 and
allow gear oil to drain.
Inspect oil for water, contaminates or metal.
Clutch rod
NOTE:
Before gearcase is removed completely, disconnect speedometer
pick up tube 4 from gearcase.

6. Remove cotter pin 7 from propeller nut and remove pro
peller nut 8.
7. Remove washer 9, spacer 0, propeller A, stopper B and
spacer C from propeller shaft.
􀀣
To prevent injury from propeller blades, wear gloves
and place a block of wood between the anti-cavitation
plate and the propeller blade tips to lock the propeller
in place.
9. Keep impeller key 6 for reuse and discard plate gasket.
10. Remove three (3) bolts 1 and shift rod guide housing
assembly 2.

11. Remove two bolts 1 securing propeller shaft bearing
housing to gearcase.
12. Using special tools, draw out propeller shaft bearing
housing.
Remove propeller shaft and bearing housing assembly.
􀁜 09930-30104 : Sliding hammer A
09930-30161 : Propeller shaft remover B
13. Hold pinion nut securely, then fit special tool to the driveshaft
and loosen pinion nut.
􀁜 09921-29410 : Driveshaft holder
14. Remove four bolts 1 securing driveshaft oil seal housing
2, then remove oil seal housing and pinion shim 3.

15. Lift out driveshaft assembly 4.
Remove driveshaft collar 5, washer 6, wave washer 7,
washer (with tab) 8 and washer 9 from driveshaft.

Disassembly of propeller shaft components
1. Slide propeller shaft away from reverse gear 3 and bearing
housing assembly 1.
Account for reverse gear back-up shim 2 and reverse gear
thrust washer 4.

INSPECTION
NOTE:
If excessive ware, cracks, defective or other damage is found
on any component, replace component.
NOTE:
Thoroughly wash all metal components with cleaning solvent
and dry with compressed air.
􀀣
Wear safety grasses when using compressed air.
PROPELLER
• Inspect propeller for bent, chipped or broken blades.
Replace or repair if necessary.
• Inspect propeller bushing splines for wear or other damage.
Replace if necessary.
• Inspect propeller bushing for deterioration or slipping.
Replace if necessary.
GEARCASE
• Inspect gearcase for cracks or other damage.
Replace if necessary.
• Inspect pinion bearing for pitting, rough or other damage.
Replace if necessary.
NOTE:
If removal and replacement are required, see “PINION BEARING”
section on page 9-7.

LOWER UNIT
GEARS
• Inspect forward, reverse and pinion gear teeth and engaging
dogs for excessive wear or other damage.
Replace if necessary.
• Inspect forward gear bearing for pitting, rough or other damage.
Replace if necessary.
PROPELLER SHAFT COMPONENTS
• Inspect horizontal slider and connector pin for excessive wear
or other damage. Replace if necessary.
• Inspect clutch dog shifter for excessive wear, chip or other
damage. Replace if necessary.
• Inspect dog pin for bent or other damage. Replace if necessary.
• Inspect propeller shaft / splines for wear, twist or other damage.
Replace if necessary.
PROPELLER SHAFT BEARING HOUSING
• Inspect housing for cracks or other damage. Replace if necessary.
• Inspect propeller shaft bearings and reverse gear bearing
for pitting, rough or other damage. Replace if necessary.
• Inspect oil seals and O-ring for cuts, nicks or tears.

Replacing propeller shaft oil seal
1. Remove retaining ring 1 and washer 2.
2. Extract oil seals 3 using oil seal remover.
􀁜 09913-50121 : Oil seal remover
􀀃
Do not re-use oil seal once removed.
Always use a new oil seal.
3. Apply Water Resistant Grease to inner circumference of
housing.
4. Using an oil seal installer, drive two oil seals (one at a time)
into housing.
The lipped portion of seal should face towards propeller.
Apply Water Resistant Grease to seal lips.
􀁎 99000-25161 : Water Resistant Grease
5. Install washer and retaining ring.

SHIFT ROD GUIDE HOUSING COMPONENTS
• Inspect shift rod guide housing for cracks or other damage.
Replace if necessary.
• Inspect shifter yoke for excessive wear or other damage.
Replace if necessary.
• Inspect oil seal and O-ring for wear, cuts, nicks or tears.
• Inspect shift rod / splines for excessive wear, twist or other
damage. Replace if necessary.
• Inspect detent ball for wear, rough or other damage. Replace
if necessary.
WATER PUMP AND RELATED ITEMS
• Inspect impeller vanes for cuts, cracks, tears or excessive
wear. Replace if necessary.
• Inspect pump case and under panel for cracks, distortion or
corrosion. Replace if necessary.

DRIVESHAFT OIL SEAL HOUSING
• Inspect housing for cracks or other damage. Replace if necessary.
• Inspect oil seals and O-ring for wear, cuts, nicks or tears.
Replacing driveshaft oil seal
1. Extract oil seals using oil seal remover.
􀁜 09913-50121 : Oil seal remover
2. Apply Water Resistant Grease to inner circumference of
housing.
􀁎 99000-25161 : Water Resistant Grease
3. Using an oil seal installer, drive two oil seals (one at a time)
into housing.
The lipped portion of seal should face towards water pump
case.
Grease inner lips of seal.

1 Dust seal
2 Shift rod guide housing
3 Bolt
4 Ball
5 Spring
6
7 O-ring
8 Washer
9 Circlip
0 E-ring
A Shift rod
B Shifter yoke
C Pin
D Horizontal slider
E Magneto
F Grommet
G Water pump case
H Pin
I Bolt
J Key
K Water pump impeller
L Pump case under panel
M Gasket
N Exhaust seal
O Exhaust seal plate
P Union
Q Hose
R Nipple
S Gearcase
T Bolt
U Bolt
V Pin
W Anode
X Washer
Y Bolt
Z Trim tab
[ Bolt
\ Screw
] Water filter PORT
^ Water filter STBD

WATER PUMP
1. Place dowel pins 1, under panel gasket 2 and under panel
3 into position.
2. Insert key 4 in driveshaft and slide impeller 5 onto
driveshaft, ensuring that key and keyway are aligned.
3. Install pump case 6 while rotating driveshaft clockwise to
flex impeller vanes in correct direction.
4. Tighten four pump case bolts to specified torque.
􀀢 Pump case bolt : 20 N.m (2.0 kg-m, 14.5 lb.-ft.)
PROPELLER INSTALLATION
1. Install spacer 1 and propeller stopper 2 onto propeller
shaft, then slide on propeller 3.
2. Fit spacer 4, washer 5 and nut 6, then tighten nut to
specified torque.
􀀢 Propeller nut : 55 N.m (5.5 kg-m, 40.0 lb.-ft.)
3. Push cotter pin 7 through nut and shaft, then bend to
secure.
LOWER UNIT INSTALLATION
1. Apply clutch rod splines with Water Resistant Grease,
then install clutch rod 1 by aligning clutch rod splines
with splines in clutch shaft.
2. Ensure that shift rod 2 is at neutral position.
NOTE:
Before install lower unit assembly, bring shift to neutral position
by turning shift rod.

3. Insert two dowel pins 3.
4. Apply driveshaft splines and shift rod splines with Water
Resistant Grease.
5. Apply Mercury Silicone Seal lightly to mating surfaces of
gearcase and driveshaft housing.
6. Set clutch control lever 4 at neutral position, then slide
lower unit 5 into place, ensuring that top of driveshaft engages
properly with countershaft and that water tube locates
in water pump case outlet.
NOTE:
In order for shift rod splines and clutch rod splines to be aligned
correctly, clutch rod may need to be turned slightly right or left.
7. Apply Silicone Seal to seven gearcase bolts 6 and tighten
them to specified torque.
􀀢 Gearcase bolt : 55 N . m (5.5 kg-m, 40.0 lb.-ft.)
􀁎 99000-25161 : Water Resistant Grease
􀁍 99000-31120 : Mercury-Mariner Silicone Seal
8. Move clutch control lever 4 to forward and reverse positions
from neutral position to check proper gear engagement.
GEAR OIL
Fill gearcase with specified gear oil.
(See “PERIODIC MAINTENANCE / GEAR OIL” section on page
2-6)
􀁌 99000-22540 : Mercury-Mariner Outboard Motor Gear Oil.


1965-1989 Service Manual Application: 2 hp To 40hp 2 Stroke 1 & 2 cylinder engines.

1965-1989 Mercury Service Manual Application: 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 90-300 HP Mercury Outboard motors repair manual Application: Covers all Mercury Motors from 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 Mercury Mariner 2.5 / 275 HP Workshop Service Manual Repair

1990-2000 Mercury/Mariner Workshop Service Manual Repair Application: 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 Service Manual Application: 6/8/9.9/15HP Motors 1986 and up With Serial Numbers OA1972112 and Above.

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

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

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

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

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

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

2000-2001 Mercury OptiMax Outboard motor service manual application: 2000-2001 Mercury 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 Service Repair Manual Application: 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 Mercury 115 HP Service manual application: Mercury Outboard motor 01-02 Mercury 115 HP (115HP) EFI (Electronic Fuel Injection) outboard engine. 4 Cylinder InLine, 4 Stroke DOHC, 16 Valves. Starting Serial Number 0T178500.

2002-2004 Mercury/Mariner Outboard motor service manual application: 2002-2004 Mercury-Mariner 40HP EFI 4-Stroke (Four-Stroke), 2002-2004 Mercury-Mariner 60HP EFI 4-Stroke (Four-Stroke), 2002-2004 Mercury-Mariner 50 HP EFI 4-Stroke (Four-Stroke), 2002-2004 Mercury-Mariner 40 HP EFI 4-Stroke (FourStroke) Bigfoot, 2002-2004 Mercury-Mariner 60 HP EFI 4-Stroke (FourStroke) Bigfoot.



Mercury Marine Outboard Service Manual, Mariner Outboard Repair Manual, Owner's Shop Manual, Workshop Manual, Handbook, Book, 2004, 2003, 2002, 2001, 2000, 1999, 1998, 1997, 1996, 1995, 1994, 1993, 1992, 1991, 1990, 1989, 1988, 1987, 1986, 1985, 1984, 1983, 1982,1981, 1980, 1979, 1978, 1977, 1976, 1975, 1974, 1973, 1972, 1971, 1970, 1969, 1968, 1967, 1966, 1965 Exploded Views, Exploded Diagrams, Repair Guide, Engine Repair Guide, How To Fix, How Do you Repair and Fix, Parts Locations Diagrams, 13.9 HP (3.9HP), 6HP (6-HP), 9.8HP (9.8 HP), 20 HP (20-HP), 35 HP (35HP), 4.0 HP (4.0HP), 7.5 HP (7.5HP), 40 HP (40HP)  4.5 HP (4.5HP) 3.6 HP 18HP, (18 HP), 20 HP, 25HP, 2.2 HP (2.2HP) 6.0 (6.0HP), 8.0 (8.0HP), 9.9 (9.9HP), 20 HP (20HP), 25 HP,35 (35-HP), 15 HP (15HP, 45, 50, 55, 60, 65, 70, 90 Horsepower Engines