The service manual downloads for the above listed Yamaha, Mercury, MerCrusier Mariner, Suzuki & Johnson/Evenrude models describes the service procedures for the complete inboard, outboard, jet drive or stern drive. Follow the Maintenance Schedule recommendations to ensure that the engine/jet drive/sterndrive is in peak operating condition. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the engine/jet drive/sterndrive.
All chapters in the service manuals apply to the whole engine (inboard/outboard), jet drive, or sterndrive and illustrates procedures for removal & installation of components that are in detailed step-by-step fashion.
Most all service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem.
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CHAPTER INDEX
GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE CONTROL SYSTEM ENGINE ELECTRICAL FUEL SYSTEM POWER UNIT MID UNIT POWER TRIM AND TILT LOWER UNIT WIRE / HOSE ROUTING
GENERAL INFORMATION
CONTENTS
WARNING / CAUTION / NOTE GENERAL PRECAUTIONS IDENTIFICATION NUMBER LOCATION FUEL AND OIL GASOLINE RECOMMENDATION ENGINE OIL ENGINE BREAK-IN PROPELLERS POWERHEAD DIRECTION OF ROTATION SPECIFICATIONS SERVICE DATA TIGHTENING TORQUE SPECIAL TOOLS MATERIALS REQUIRED
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE PERIODIC MAINTENANCE CHART MAINTENANCE AND TUNE-UP PROCEDURES ENGINE OIL / ENGINE OIL FILTER GEAR OIL LUBRICATION SPARK PLUG TAPPET CLEARANCE IDLE SPEED IGNITION TIMING BREATHER AND FUEL LINE LOW PRESSURE FUEL FILTER HIGH PRESSURE FUEL FILTER WATER PUMP / WATER PUMP IMPELLER PROPELLER / NUT / COTTER PIN ANODES AND BONDING WIRES BATTERY BOLT AND NUTS FUEL MIXTURE CHECK (O2 FEEDBACK) OIL PRESSURE CYLINDER COMPRESSION
ENGINE CONTROL SYSTEM
CONTENTS
ENGINE CONTROL SYSTEM STRUCTURE SYSTEM STRUCTURE 1 SYSTEM STRUCTURE 2 WIRING DIAGRAM FOR ENGINE CONTROL COMPONENTS FOR SYSTEM CONTROL ENGINE CONTROL MODULE (ECM) ECM CONNECTOR / TERMINALS LAYOUT ECM INTERNAL STRUCTURE SENSOR AND SWITCH IGNITION SYSTEM IGNITION CONTROL SYSTEM ELECTRONIC FUEL INJECTION SYSTEM FUEL INJECTION CONTROL SYSTEM FUEL DELIVERY SYSTEM COMPONENTS FUEL PUMP CONTROL SYSTEM AIR INTAKE COMPONENTS IDLE AIR CONTROL SYSTEM CAUTION SYSTEM OVER-REVOLUTION CAUTION SYSTEM LOW OIL PRESSURE CAUTION SYSTEM OVERHEAT CAUTION SYSTEM LOW BATTERY VOLTAGE CAUTION SYSTEM SELF-DIAGNOSTIC SYSTEM PRIORITY / CODE / PATTERN FOR SELF-DIAGNOSTIC SYSTEM OPERATION CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION FAIL-SAFE SYSTEM PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM OPERATING HOUR INDICATION SYSTEM OIL CHANGE REMINDER SYSTEM START-IN-GEAR PROTECTION SYSTEM O2 FEEDBACK SYSTEM INSPECTION PRECAUTION ON SYSTEM INSPECTION 44-PIN TEST CORD INSPECTION FOR ECM CIRCUIT VOLTAGE INSPECTION FOR RESISTANCE COMPONENT INSPECTIONS TROUBLESHOOTING REMOVAL / INSTALLATION FLYWHEEL CKP SENSOR / CMP SENSOR OIL PRESSURE SWITCH
ELECTRICAL
CONTENTS
BATTERY CHARGING SYSTEM OUTLINE INSPECTION REMOVAL / INSTALLATION ELECTRIC STARTER SYSTEM OUTLINE TROUBLESHOOTING INSPECTION STARTER MOTOR REMOVAL / INSTALLATION DISASSEMBLY INSPECTION & SERVICING ASSEMBLY PERFORMANCE TEST MONITOR-TACHOMETER INSPECTION ERECTRIC PARTS HOLDER REMOVAL / INSTALLATION |
FUEL SYSTEM
CONTENTS
PRECAUTION ON FUEL SYSTEM SERVICE GENERAL PRECAUTION FUEL PRESSURE RELIEF PROCEDURE FUEL LINE REMOVAL / INSTALLATION FUEL LEAKAGE CHECK PROCEDURE FUEL HOSE CONNECTION FUEL PRESSURE INSPECTION FUEL VAPOR SEPARATOR / HIGH PRESSURE FUEL PUMP REMOVAL / INSTALLATION DISASSEMBLY INSPECTION ASSEMBLY FUEL INJECTOR INSPECTION REMOVAL INSTALLATION LOW PRESSURE FUEL PUMP REMOVAL / INSTALLATION DISASSEMBLY / REASSEMBLY INSPECTION FUEL TANK DISASSEMBLY / REASSEMBLY INSPECTION
POWER UNIT
CONTENTS
INTAKE MANIFOLD ASSEMBLY REMOVAL INSTALLATION POWER UNIT REMOVAL INSTALLATION OIL PUMP REMOVAL INSPECTION INSTALLATION TIMING CHAIN / TENSIONER REMOVAL INSPECTION INSTALLATION CYLINDER HEAD ASSEMBLY REMOVAL INSTALLATION DISASSEMBLY INSPECTION / SERVICING REASSEMBLY CYLINDER / CRANKSHAFT / PISTON DISASSEMBLY INSPECTION / SERVICING REASSEMBLY THERMOSTAT REMOVAL / INSPECTION / INSTALLATION OPERATION WATER COOLING SYSTEM ENGINE LUBRICATION SYSTEM
MID UNIT
CONTENTS
ENGINE SIDE COVER REMOVAL INSTALLATION DRIVESHAFT HOUSING AND OIL PAN REMOVAL INSPECTION ASSEMBLY SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET REMOVAL INSPECTION REASSEMBLY WATER PRESSURE VALVE REMOVAL / INSPECTION / INSTALLATION
POWER TRIM AND TILT
CONTENTS
SYSTEM WIRING DIAGRAM SERVICE PROCEDURE OIL LEVEL AIR BLEEDING POWER TRIM AND TILT UNIT REMOVAL DISASSEMBLY INSPECTION REASSEMBLY PTT MOTOR PTT MOTOR REMOVAL PTT MOTOR DISASSEMBLY PTT MOTOR INSPECTION PTT MOTOR ASSEMBLY PTT MOTOR INSTALLATION IPTT MOTOR RELAY PTT SWITCH OPERATION COMPONENTS PRINCIPLES OF OPERATION
LOWER UNIT
CONTENTS
REMOVAL & DISASSEMBLY PINION BEARING INSPECTION PROPELLER GEARCASE GEARS PROPELLER SHAFT COMPONENTS PROPELLER SHAFT BEARING HOUSING SHIFT ROD GUIDE HOUSING COMPONENTS WATER PUMP AND RELATED ITEMS DRIVESHAFT OIL SEAL HOUSING DRIVESHAFT ASSEMBLY & INSTALLATION TRIM TAB LOWER UNIT GEARS-SHIMMING AND ADJUSTMENT
WIRE / HOSE ROUTING
CONTENTS
WIRING DIAGRAM WIRE ROUTING FUEL / WATER HOSE ROUTING |
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy. Maintenance intervals should be judged by number of hours or months, whichever comes first.
NOTE: More frequent servicing should be performed on outboard motors that are used under severe conditions.
MAINTENANCE AND TUNE-UP PROCEDURES
1. Place mercury 40hp manual outboard motor upright on a level surface.
2. Remove motor cover. 3. Remove oil level dipstick and wipe it clean. 4. Insert it fully into dipstick hole, then remove it to check oil level. 5. Oil level should be between full level hole (Max.) and low level hole (Min.). If level is low, add recommended oil to full level hole (Max.).
Recommended oil :
• 4 stroke motor oil • API classification SE, SF, SG, SH, SJ. • Viscosity rating SAE 10 W-40.
This section describes servicing procedures for each of periodic maintenance requirements.
ENGINE OIL / ENGINE OIL FILTER ENGINE OIL LEVEL CHECK
Inspect oil level before every use.
ENGINE OIL CHANGE / ENGINE OIL FILTER REPLACEMENT ENGINE OIL
Change initially after 20 hours (1 month) and every 100 hours (6 months).
ENGINE OIL FILTER
Replace initially after 20 hours (1 month) and every 200 hours (12 months).
NOTE:
• Engine oil should be changed while engine is warm. • When replacing engine oil filter, change engine oil at the same time.
1. Place outboard motor upright on a level surface. 2. Remove oil filler cap. 3. Place a container under engine oil drain plug. 4. Remove engine oil drain plug and gasket to drain engine oil. 5. ENGINE OIL FILTER REPLACEMENT
NOTE: For engine oil change only, go to step 6.
To replace engine oil filter :
NOTE: Before fitting new oil filter, be sure to oil O-ring.
(1) Remove STBD side cover. (2) Using oil filter wrench to loosen the oil filter, then remove filter and O-ring. (3) Screw new filter on by hand until filter O-ring contacts the mounting surface. (4) Tighten filter 3/4 turn from point of contact with mounting surface using an oil filter wrench. (5) Install STBD side cover.
6. Install gasket and oil drain plug. Tighten engine oil drain plug to specified torque. 7. Pour recommended engine oil into oil filler opening, then install oil filler cap.
Engine oil amounts:
Oil change only : 5.5 L (5.8 / 4.8 US / Imp. qt) Oil filter change : 5.7 L (6.0 / 5.0 US / Imp. qt)
8. To reset oil change reminder system’s operation time to zero (cancellation) ;
(1) Turn ignition key to “ON” position. (2) Pull out emergency stop switch plate 1. (3) Pull up emergency stop switch knob 2 three times in seven seconds. A short beep will be heard if cancellation is successfully finished. (4) Turn ignition key to “OFF” position, then set emergency stop switch plate 1 in original position.
9. Start engine and allow it to run for several minutes at idle speed. Refer to the MerCruiser Repair Manual as procedures can differ depending on model and year. to Check oil filter for oil leakage. Turn off engine and wait for approx. two minutes, then recheck engine oil level.
GEAR OIL
Change initially after 20 hours (1 month) and every 100 hours (6 months).
1. Place outboard motor upright on a level surface. 2. Place a container under lower unit. 3. Remove lower gear oil drain plug before gear oil level plug and drain gear oil. 4. Fill with recommended gear oil through oil drain hole until oil just starts to flow out from oil level hole. Gear oil amounts : 1050 ml (35.5 / 37.0 US / Imp. oz) Recommended oil : Outboard Motor Gear Oil or SAE #90 Hypoid gear oil. 5. Install oil level plug before removing oil filler tube from drain hole. 6. Install oil drain plug.
Do not re-use gaskets once removed. Always use a new gasket.
NOTE: To avoid insufficient injection of gear oil, check gear oil level 10 minutes after doing procedure in step 6. If oil level is low, slowly inject gear oil up to the correct level.
LUBRICATION
Inspect every 50 hours (3 months). Apply Water Resistant Grease to the following points. Throttle / shift linkage Propeller shaft Swivel bracket Swivel bracket
SPARK PLUG
• Inspect every 100 hours (6 months). • Replace every 200 hours (12 months).
Standard spark plug : NGK BKR6E
CARBON DEPOSIT
Inspect for a carbon deposit on spark plug bases. If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool.
SPARK PLUG GAP
Using thickness gauge, measure for spark plug gap. Adjust to within specified range if gap is out of specification. Spark plug gap : 0.7 – 0.8 mm (0.028 – 0.031 in.)
CONDITION OF ELECTRODE
Inspect electrode for a worn or burnt condition. If it is extremely worn or burnt, replace spark plug. Also, be sure to replace spark plug if it has a broken insulator, damaged thread, etc. Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the threaded portion of the plug hole resulting in possible engine damage.
TAPPET CLEARANCE
Inspect initially after 20 hours (1 month) and every 200 hours (12 months).
The tappet clearance specification is the same for both intake and exhaust valves. Too small a tappet clearance may reduce engine power, too large a tappet clearance increases valve noise and hastens valve and seat wear.
When the tappets are set to the specified clearance, the engine will run without excessive noise from the valve mechanism and will deliver full power. In this engine, the tappet clearance is increased or decreased by replacing the shim disc, made of a special wear resistant material, fitted to the top of the tappet. The shim discs are easy to remove and refit.
Tappet clearance adjustment should be checked and adjusted :
• at time of periodic inspection • when valve mechanism is serviced • when camshafts are disturbed by removing them for inspection
CHECKING AND ADJUSTING TAPPET CLEARANCE
1. Remove following parts :
• Engine side covers • Flywheel cover • Spark plugs
2. Remove breather hose 1 and evaporation hose 2 from cylinder head cover. 3. Remove fuel hose 3 and 4 from low pressure fuel pump. 4. Remove fifteen (15) bolts securing cylinder head cover 5 to cylinder head and remove cylinder head cover.
5. Rotate crankshaft counterclockwise to bring cam nose vertical to shim surface. 6. Measure tappet clearances by inserting thickness gauge between cam and shim surface.
Tappet clearance (cold engine condition) : IN. : 0.23 – 0.27 mm (0.009 – 0.011 in.) EX. : 0.23 – 0.27 mm (0.009 – 0.011 in.)
This is a left hand (LH) rotation powerhead. Rotate crankshaft counterclockwise to prevent water pump impeller damage.
NOTE:
• Rotate crankshaft and measure clearance for each tappet respectively by bringing cam nose vertical to shim surface. • All tappet clearances can be measured during two turns of crankshaft.
7. If out of specification, adjust tappet clearance by changing shim.
ADJUSTMENT
Tappet clearances are adjusted by replacing tappet shim.
1. Close valve and turn tappet cut-away toward inside as shown in figure. 2. Rotate crankshaft to open (lift up) valve and then remove camshaft housing bolts where shim is to be replaced. 3. Install special tool with camshaft housing bolts as shown in figure. 4. Rotate top of cam 90 degree clockwise and remove shim from cut-away at tappet. (Two tappets can be adjusted at the same time) 5. After removing shim, measure thickness of original shim and determine correct thickness of shim for proper tappet clearance as calculated by following formula.
A = B + (C – 0.25 mm)
A : Correct thickness of shim for proper tappet clearance (mm) B : Thickness of original shim (mm) C : Original tappet clearance (mm)
6. Install shim. Identification number should face towards tappet. 7. Rotate crankshaft to be open (lift up) valve. 8. Remove tappet holder 1 and tighten camshaft housing bolts to specified torque.
Camshaft housing bolt : 11 N.m (1.1 kg-m, 8.0 lb.-ft.)
9. Recheck tappet clearance.
NOTE: After completing tappet clearance adjustment and securing camshaft housing bolts, inspect tappet clearance again.
INSTALLATION
After checking and adjusting all tappet clearances, install cylinder head cover. Installation is reverse order of removal.
IDLE SPEED
Inspect initially after 20 hours (1 month) and every 200 hours (12 months).
NOTE:
• Before checking idle speed, engine should be allowed to warm up. • Check and/or adjust idle speed after engine speed has stabilized. • Before checking idle speed, check throttle link mechanism and throttle valve for smooth operation.
1. Start engine and allow to warm up. 2. Attach engine tachometer to the ignition high-tension cord. 3. Check engine speed. Idle speed (in neutral gear) : 600 – 650 r/min.
ADJUSTMENT:
If idle speed is out of specification, perform following adjustment procedure.
4. Check that CTP switch is in ON position. 5. To set the IAC valve duty to constant 15%, raise engine speed to 1000 r/min. or higher by turning the by-pass air screw and hold that speed for 10 seconds. At this time, caution buzzer will sound to notify that IAC duty is in fixed mode.
Turning air screw counterclockwise :
Engine speed will increase. Turning air screw clockwise : Engine speed will decrease.
NOTE:
• While IAC valve duty is at fixed 15%, caution buzzer will sound for repeated 0.5 second with an interval of 3 seconds. • The 15% fixed mode of IAC valve duty will continue for 5 minutes and then it will be automatically cancelled.
6. During fixed mode of IAC valve duty, adjust engine speed to 625 ± 25 r/min. by turning by-pass air screw. 7. Open warm-up lever to turn CTP switch off.
NOTE: The fixed mode of IAC valve duty can be manually cancelled by turning CTP switch off.
8. Close warm-up lever and then recheck engine speed. It should now be stable at 600 – 650 r/min.
NOTE: Idling / trolling speed of 600 – 650 r/min. is controlled by IAC (idle air control) system. If engine speed does not return to specification, IAC passage (including the IAC hose) may be clogged or IAC system may not be operating correctly.
NOTE: Trolling speed (in-gear idle speed) is same as idle speed.
IGNITION TIMING
Inspect every 200 hours (12 months).
NOTE: Before checking ignition timing, make sure idle speed is adjusted within specification.
1. Start engine and allow to warm up. 2. Attach timing light cord to No.1 ignition high-tension cord. 3. Check ignition timing while operating engine in neutral gear at 1000 r/min. Ignition timing : Approx. BTDC 8° at 1000 r/min.
BREATHER AND FUEL LINE
• Inspect initially after 20 hours (1 month) and every 50 hours (3 months). • Replace every 2 years. If leakage, cracks, swelling or other damage is found, replace breather line and/or fuel line.
LOW PRESSURE FUEL FILTER
• Inspect every 50 hours (3 months). • Replace every 400 hours or 2 years.
If water accumulation, sediment, leakage, cracks, or other damage is found, replace fuel filter.
WATER PUMP / WATER PUMP IMPELLER WATER PUMP
Inspect every 200 hours (12 months). Inspect case and under panel. Replace If wear, cracks, distortion or corrosion is found.
WATER PUMP IMPELLER
Replace every 200 hours (12 months). Inspect water pump impeller. Replace if vanes are cut, torn or worn.
PROPELLER / NUT / COTTER PIN
Inspect initially after 20 hours (1 month) and every 100 hours (6 months).
• Inspect propeller for bent, chipped or broken blades. Replace propeller if damage noticeably affects operation. • Inspect propeller splines. Replace propeller if splines are worn, damaged or twisted. • Inspect propeller bush for slippage. Replace if necessary. • Make sure that propeller nut is torqued to specification and cotter pin is installed securely.
ANODES AND BONDING WIRES
Inspect every 50 hours (3 months).
ANODES
If 2/3 of zinc anode has corroded away, replace anode. The anode should be periodically cleaned with a wire brush to ensure maximum effectiveness.
NOTE: The anode securing bolt should be covered with Suzuki Silicone Seal.
BONDING WIRES
• If breakage or other damage is found on bonding wire, replace wire. • If rust, corrosion or other damage is found on terminal, clean with cleaning solvent or replace wire.
BATTERY
Inspect every 50 hours (3 months)
CONNECTING BATTERY
Upon completion of connection, lightly apply grease to battery terminals.
How to connect:
1. Connect positive (+) terminal first. 2. Connect negative (–) terminal second.
How to disconnect:
1. Disconnect negative (–) terminal first. 2. Disconnect positive (+) terminal second.
BATTERY SOLUTION LEVEL CHECK
Battery solution level should be between UPPER level and LOWER level. If level is low, add distilled water only.
BATTERY SOLUTION GRAVITY CHECK
Measure gravity of battery solution using hydrometer. Battery solution gravity : 1.28 at 20°C
BOLT AND NUTS
Check that all bolts and nuts listed below are tightened to their specified torque.
ITEM TIGHTENING TORQUE
Cylinder head cover bolt Flywheel bolt Power unit mounting bolt Clamp bracket shaft nut Gearcase bolt Propeller nut
FUEL MIXTURE CHECK (O2 FEEDBACK)
Perform every 2 years. To perform fuel mixture check (O2 feedback) operation, use personal computer and Diagnostic System software. For fuel mixture check (O2 feedback) operation, refer to Diagnostic System Operation Manual”.
OIL PRESSURE
Oil pressure (at normal operating temp.):
550 – 600 kPa (5.5 – 6.0 kg/cm2, 78 – 85 psi.) at 3000 r/min.
NOTE: The figure shown above is a guideline only, not an absolute service limit. If oil pressure is lower or higher than specification, following causes may be considered.
Low oil pressure:
• Clogged oil filter • Leakage from oil passages • Defective oil pump • Defective oil pressure regulator • Damage O-ring • Combination of above items
High oil pressure:
• Using an engine oil of too high viscosity • Clogged oil passage • Clogged oil pressure regulator • Combination of above items
TEST PROCEDURE
1. Check engine oil level. 2. Remove bolts and air duct 3. Loosen screw and disconnect blue lead wire from oil pressure switch. Remove oil pressure switch. 4. Install oil pressure gauge in place of pressure switch hole. 5. Attach engine tachometer to ignition coil high tension cord. 6. Start engine and allow to warm up as follows :
Summer : 5 min. at 2000 r/min. Winter : 10 min. at 2000 r/min.
7. After warming up, shift into forward gear and increase engine speed to 3000 r/min. then compare pressure indicate on gauge to specifications. 8. After testing, reinstall oil pressure switch. 9. Reinstall air duct.
CYLINDER COMPRESSION
Cylinder compression :
Standard : 1300 – 1700 kPa (13 – 17 kg/cm2, 185 – 242 psi.)
Max. difference between any other cylinders : 100kPa (1.0 kg/cm2, 14 psi.)
NOTE: Figures shown are guidelines only, not absolute service limits. Low compression pressure can indicate one or more of following : • Excessively worn cylinder wall • Worn piston or piston rings • Stuck piston rings • Poor seating of valves • Ruptured or otherwise damaged cylinder head gasket
TEST PROCEDURE
1. Start engine and allow to warm up, then shut engine off. 2. Remove STBD / PORT side covers.(See page 7-2) 3. Remove all spark plugs. 4. Install compression gauge hose attachment into plug hole, then connect compression gauge hose to gauge hose attachment and compression gauge.
Compression gauge Compression gauge hose Compression gauge hose attachment
5. Disconnect safety lanyard (switch plate) from emergency stop switch. Disconnect the safety lanyard from the emergency stop switch prior to cranking the engine. This will prevent any residual fuel discharged from the cylinders being ignited by a spark discharge from the spark plug caps. 6. Disconnect remote control throttle cable from throttle lever. 7. Move and hold throttle lever in full-open position. 8. While cranking engine with starter motor, note maximum compression pressure reading on gauge for each cylinder. 9. Reinstall parts removed earlier. (spark plugs, side covers, etc.) |
Service Manual, Repair Manuals, Owner's Manuals, Textbook, Handbook, Book, Repair Guide, PDF Download, Factory Manual, Shop Manual, Workshop Manual, Diagrams Manual, Cutaway, Parts Book, Parts Manual |
Suzuki Outboard Service Manuals Available:
2000-2003 Service Manual Application: 2000 2001 2002 2003 Suzuki Outboard 4-Stroke DF25 (25HP, 25 HP) & DF30 (30HP, 30 HP) Models.
1999-2008 Suzuki DF40 DF50 Service Manual DF 40/50
1999-2008 Service Manual Application: Suzuki DF40QH, DF50QH, DF40 (DF-40HP, DF-40 HP) & DF50 (DF-50HP, DF-50 HP) 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 & 2008 Outboard boat 4-stroke (four stroke) engine (motor).
2001-2009 Suzuki DF90 DF100 DF115 DF140 Service Manual Outboard 1988 2003 Suzuki DT Outboard Service Manual 2 thru 225
2001-2009 Models Covered: Suzuki DF90 (DF-90) DF100 (DF-100), DF115 (DF-115), DF140 (DF-140) 4-Stroke Outboard boat engine.
1988-2003 Models Covered: DT2 (DT-2) DT2.2 (DT-2.2) / DT4 (DT-4) / DT5Y (DT-5-Y) / DT6 ( DT-6) / DT8 (DT-8) / DT9.9 ( DT-9.9) / DT15 (DT-15) / DT20 (DT-20) / DT25 (DT-25) / DT30 (DT-30) / DT35 (DT-35) / DT40 (DT-40) / DT55 (DT-55) / DT65 (DT-65) / DT75 (DT-75) / DT85 (DT-85) / DT90 (DT-90) / DT100 (DT-100) 1989-1996 & 1996-2001 EFI / DT140 (DT-140) EFI / DT150 (150) EFI / DT175 (175) / DT200 (200) EFI / DT225 (225) / DT4/DT5Y / DT5 DT6 & DT8 / DT25C DT30C (DT25-C, DT30-C) / DT75 & DT85 / DT100TC / DT115STC & DT140TC EFI (DT115-STC, DT140-TC) / DT150 / 175 / 200 / DT225 "M"
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Mercury - Mariner Service Manuals Available For Download:
1965-1989 Mercury Mariner 2 To 40 Hp 2 Stroke 1965-1989 Mercury Repair Manual 40 115hp 2 Stroke 1986-1990 Mercury Service Manual 6/8/9.9/15HP 2 Stroke 1995-2000 Mercury Mariner 40 45 50 HP Service Manual 1997-2000 Mercury Mariner 40 50 55 60hp Service Manual 2 Stroke 1997 1998 Mercury Optimax 200 & 225 HP Service Manual 1998-1999 Mercury Mariner 9.9 & 15 HP Service Repair Manual 1998-1999 Mercury 135HP (135 HP) & 150HP (150 HP) Service Manual 1999-2002 Mercury - Mariner 30 HP 40 HP Service Repair Manual 4-Stroke Outboard 1999-2000 Mercury/mariner Service Manual 4HP 5HP 6HP (4 Stroke) 2000 2001 Mercury 75/90 HP (75hp & 90hp) Outboard Service Manual 2000-2001 Mercury Optimax 115 135 150 175 Service Repair Manual DFI 2001 Mercury Mariner 50 HP & 2001 60 HP Service Manual 2001 2002 Mercury 115 HP (115HP) Service Manual 4-Stroke 2002-2004 Mercury 40 HP 50 HP 60 HP Service Manual
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.
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. |
YAMAHA OUTBOARD ENGINE SERVICE MANUALS AVAILABLE
1995 Yamaha Outboard 9.9HP (9.9-HP) Service Manual 4-STROKE LIT-18616-01-24 1995 1997 Yamaha E48T C55T Service Manual 48 55 HP 2-STROKE LIT-18616-01-28 1996 1997 Yamaha 8HP & 9.9HP Service Manual 4-STROKE LIT-18616-01-35 1996 1997 Yamaha 60HP E60 E60H Service Manual 2 STROKE LIT-18616-01-29 1997 Yamaha 75HP 75-HP Service Manual E75V 2-STROKE LIT-18616-01-73 1997 1998 Yamaha 20HP 25HP Service Manual 2-STROKE LIT-18616-01-66 1998 1999 Yamaha Service Manual 40 50 HP 2-STROKE LIT-18616-01-81 1998 2005 Yamaha Outboard 15HP 15 HP Service Manual 4-STROKE 1998-2006 Yamaha 8HP & 9.9HP Service Manual 4-STROKE LIT-18616-01-83 1999 2005 Yamaha Outboard 4HP 4 HP Service Manual 4-STROKE LIT-18616-01-79 1999 2000 25HP 30HP Yamaha Service Manual 2-STROKE LIT-18616-01-94 1999 2002 100HP 100 HP Yamaha Service Manual 4-STROKE LIT-18616-01-96 2000 2003 Yamaha 40HP 40 HP Service Manual 4-STROKE LIT-18616-02-16 2001 2003 Yamaha F6Z & F8Z Service Manual 6HP-8HP 4-STROKE LIT-18616-02-19 2003 2006 Yamaha 250HP Service Manual 2-STROKE & 4-STROKE ALL 250 MODELS 2004 2005 Yamaha 2.5HP 2.5 HP Service Manual 4-STROKE LIT-18616-02-54 2004 2005 Yamaha 9.9C 15C Service Manual 9.9HP-15HP 2-STROKE LIT-1816-02-59 2004 2005 Yamaha Outboard 25HP 25 HP Service Manual 4-STROKE LIT-18616-02-61 2004-2005 Yamaha 40HP 50HP Service Manual 4-STROKE LIT-18616-02-65 2004-2005 Yamaha Outboard 70HP 70-HP Service Manual 2-STROKE 2004-2005 Yamaha Outboard 90HP 90-HP Service Manual 2-STROKE LIT-18616-02-66 2004 2005 Yamaha 130HP-115HP Service Manual 115C-130C 2-STROKE LIT-18616-02-72 2004 2005 Yamaha Outboard 150HP 150 HP Service Manual 4-STROKE LIT-18616-02-51 2004 2005 Yamaha Outboard 115HP 115 HP Service Manual 4-STROKE LIT-18616-02-71 2004 2005 Yamaha 150C V150C Service Manual 150HP 2-STROKE LIT-18616-02-73 2004-2005 Yamaha Outboard 60HP 60-HP Service Manual 2-STROKE LIT-18616-02-66 2004 2005 Yamaha 200 & 225 HP Service Manual 4-STORKE LIT-18616-02-76 2005 Yamaha 50 & 60 HP Service Manual 4-STROKE LIT-18616-02-85 2005 2006 Yamaha F90D Service Manual 90 HP 4-STROKE LIT-18616-02-86 |
LIT-18616-01-24 Service Manual Application: Yamaha Ouboard 9.9HP (9.9-HP) 4-stroke engines. Model Names: T9.9T (T9.9-T), F9.9T (F9.9T), T9.9MH (T9.9-MH), F9.9AM (F9.9-AM), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), F9.9AE (F9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), T9.9EH (T9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE).
LIT-18616-01-28 Service Repair Manual Application: 1995, 1996, 1997 (95, 96, 97) Yamaha Marine Outboard E48T (E48-T) C55T (C55-T) 48HP & 55HP 2-Stroke. Item Model Names: E48T, C55T, E48C, E48MH, E55C, 55BM, C55ER, 55BE, 55BEM, C55TR, 55BET.
LIT-18616-01-35 Service Manual Application: 1996-1997 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines. Exact Models Covered (Covers All 1996-1997 Models World Wide): F8B (F8-B), F9.9A (F9.9-A), F9.9B (F9.9-B), T9.9U (T9.9-U), F9.9U (F9.9-U), F8BM (F8-BM), F8BEM (F8-BEM), F8BE (F8-BE), T9.9MH (T9.9-MH), T9.9AM (T9.9-AM), FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), F9.9EH (F9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE).
LIT-18616-01-29 Service Repair Manual Application: 1996, 1997 (96, 97) E60, E60H 60HP (60-HP) Yamaha Marine Outboard 2-Stroke. Item Model Names: E60, E60H, E60HM, E60HE, E60HEM, E60MH, E60EH. Covers USA, Canada and wold wide models.
LIT-18616-01-73 Service Repair Manual Application: 1997 97' Yamaha Marine Outboard 75HP (75HP) 2-Stroke. Item Model Names: E75V, E-75-V, E75-V, E-75V 75AM, 75AEM, 75AE, 75AET, 85AEM, 85AE, 85AET, E75B, E60J, E75MH. Covers USA, Canada and wold wide models.
LIT-18616-01-66 Service Repair Manual Application: 1997-1998 Yamaha Marine Outboard 20HP (20-HP) & 25HP 25-HP) 10V, 25V, 25V2 2-Stroke Engines. Model Names 20DM (20-DM), 20DMO (20-DMO), 20DEM (20-DEM), 20DEMO (20-DEMO), 20DERO (20-DERO), 20MH (20-MH), 20MH2 (20-MH2), 20EH (20-EH), 20EH2 (20-EH2), 25DM (25-DM), 25NMO (25-NMO), 25NEMO (25-NEMO), 25NE (25-NE), 25NEO (25-NEO), 25NERO (25-NERO), 25MH (25-MH), 25MH2 (25-MH2), 25EH (25-EH), 25ER (25-ER).
LIT-18616-01-81 Service Repair Manual Application: 1998-1999 98-99 40HP (40-HP) & 50HP (50-HP) 40W 50W Yamaha Marine Outboard 2-Stroke Item Model Names: 40-W, 50-W, 40VMH, 40VMHD, 40VMHO, 40VMO, 40VWH, 40VE, 40VEO, 40VEHTO, 40VET, C40MH, 40MH, C40ER, 40ER, P40TH, C40TR, 40VETO, 50HMHO, 50HMHD, 50HMO, 50HMDO, 50HWHD, 50HEDO, 50HET, 50HETO, 40TR, 50ER, C50TR, 50TR Covers USA, Canada and wold wide models.
LIT-18616-F1-50 & LIT-18616-02-12 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 15HP (15-HP) 4-Stroke Engines F15W (F15-W), F15Z (F15-Z) 1998, 1999, 2000, 2001, 2002, 2003, 2004 & 2005. This manual covers all 15HP 4-Stroke models world wide including USA CANADA. USA & CANADA MODELS: F15MHW (F15-MHW), F15EHW (F15-EHW), F15AMH (F15-AMH), F15AEH (F15-AEH), F15AEP (F15-AEP), F15AEHP (F15-AEHP), F15PR (F15-PR), F15PH (F15-PH), F15AEP (F15-AEP), F15AEHP (F15-AEHP). WOLD WIDE MODELS: F15AMH (F15-AMH), F15AEH (F15-AEH), F15AE (F15-AE).
LIT-18616-01-83 Service Manual Application: 1998-2006 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines for 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 & 2006. Model Name: T9.9W (T9.9-W), F9.9W (F9.9-W), F8BMH (F8-BMH), F8BEH (F8-BEH), F8BE (F8-BE), T9.9MH (T9.9-MH) FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), FT9.9AEH (FT9.9-AEH), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BMH (F9.9-BMH), F9.9EH (F9.9-EH), F9.9BEH (F9.9-BEH), F9.9BE (F9.9-BE).
LIT-18616-01-79 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 4HP (4-HP) 4-Stroke Engines F4X (F4-X, F-4X) 1999, 2000, 2001, 2002, 2003, 2004 & 2005. This manual covers all 4HP 4-Stroke models world wide including F4MSHX, F4MLHX, F4AMH, USA CANADA.
LIT-18616-01-94 Service Repair Manual Application: 1999-2000 99-00 25HP (25-HP) & 30HP (30-HP) 25X, 25-X, 30X, 30-X, 25J, 25-J, 30D, 30-D Yamaha Marine Outboard 2-Stroke. Model Names: 25JMH, 25MH3, 30DMH, 25JMHO, 30DMHO, 30MH, 25JEHO, 25EH3, 30DWH, 25JEO, 25JETO, 25TR3, 30DEHO, 30EH, 30DMO, 30DE, 30DEO, 30ER, 30DET, 30DETO, 30TR Covers USA, Canada and wold wide models.
LIT-18616-01-96 Service Repair Manual Application: 1999, 2000, 2001, 2002 99, 00, 01, 02 100HP (100-HP) F100X, F100-X, F-100X Yamaha Marine Outboard 4-Stroke. Model Names: F100TR, F100-TR, F-100TR, F100AET, F-100AET, F100-AET Covers USA, Canada and woldwide models.
LIT-18616-02-16 Service Repair Manual Application: 2000, 2001, 2002, 2003 Yamaha Marine Outboard 40HP (40-HP) F40B (F-40B-F40-B) 4-Stroke Engines. Model name F40BMHD, F40BWHD, F40BED, F40BET, USA and Canada name F40MH, F40ER, F40TR.
LIT-18616-02-19 Service Repair Manual Application: 2001, 2002, 2003, 01, 02, 03, Yamaha Marine Outboard 6HP & 8HP (F6Z F8Z) 4-Stroke Engines. Model Name: F6AMH, F8CMH, F6MH, F8MH (F6-AMH, F6-MH, F8-AMH, F8-MH).
ALL 250HP 2003-2006 MODELS ervice Repair Manual Application: 2003, 2004, 2005, 2006 Yamaha Marine Outboard 250HP (250-HP) 2-Stroke & 4-Stroke Engines. LIT-18616-02-78 - 2004-2005 Z250C & LZ250C LZ250TR 2-STROKE ENGINE. LIT-18616-02-43 - 2003-2005 Z250B & LZ250B MODEL NAME Z250TR/LZ250TR 2-STROKE ENGINE. LIT-18616-02-97 - 2005-2006 F250 & LF250 F250TR/LF250TR 4-STROKE ENGINE.
LIT-18616-02-54 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 2.5HP (2.5-HP) F2.5C (F2.5-C, F 2.5C) F2.5MH 4-Stroke Engines.
LIT-1816-02-59 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 9.9HP & 15HP (9.9-HP 15-HP) 2-Stroke Engines. Model name 9.9CMH & 15CMH ( 9.9 & 15 CMH).
LIT-18616-02-61 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 25HP (25-HP) 4-Stroke Engines F25C, T25C (F-25C F25-C T25-C T-25C) F25MH, F25EH, F25ER, F25TR, T25TR.
LIT-18616-02-65 Service Repair Manual Application: 2004 04' & 2005 05' Yamaha Marine Outboard 40HP (40-HP) & 50HP (50-HP) 4-Stroke Engines. Exact model name 40VETO 50HETO, Both USA and CANADA models covered 40TR 50TR / 40C-50C.
LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 70HP (70-HP) 2-Stroke Engines. Model name 70BETO, USA and Canada name 70TR 70C (70-C).
LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 90HP (90-HP) 2-Stroke Engines. Model name 90AETO, USA and Canada name 90TR 90C (90-C).
LIT-18616-02-72 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 130HP & 115HP (115C 130C) 2-Stroke Engines. Model Name: 115CETO (115-CETO), 130BETO (130-BETO) 115TR, 130TR.
LIT-18616-02-51 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 150HP (150-HP) F150C & LF150C (LF-F-150C-F150-C) 4-Stroke Engines. Model name F150TR, LF150TR (F-LF-150-TR)
LIT-18616-02-71 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 115HP (115-HP) 4-Stroke Engines. Model name F115AET LF115AET, USA and Canada name F115TR LF115TR.
LIT-18616-02-73 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 150 HP (150HP) 150C & V150C 2-Stroke Engines. Model Name: 150FETO, 150GETO.
LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 60HP (60-HP) 2-Stroke Engines. Model name 60FETO USA and Canada name 60TR, 60C (60-C).
LIT-18616-02-76 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard F200C, LF200C, F225C, LF225C 200HP (200-HP) & 225HP (225-HP) V6 4-Stroke Engines.
LIT-18616-02-85 Service Repair Manual Application: 2005 Yamaha Marine Outboard 50HP & 60HP (50-HP, 60-HP) 4-Stroke Engines F50D T50D F60D T60D (F-50-D, T-50-D, F60-D, T60-D).
LIT-18616-02-86 Service Repair Manual Application: 2005-2006 05-06' Yamaha Marine Outboard F90D 90HP 4-Stroke Engines. Model Name F90TR |
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) |
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