Mercury Two stroke 105 140 JET 135 150 175 200 225 250 Mariner Factory Service Repair Manual + Wirings

Mercury Two stroke 105 140 JET 135 150 175 200 225 250 Mariner Factory Service Repair Manual + Wirings

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Mercury. 

Thousands of Pages

Models Covered :  

• 105/140 JET
• 135
• 150
• 150 XR6
• 150 MAGNUM III
• 150 EFI
• 175
• 175 EFI
• 200
• 200 EFI
• 150/200/225 PRO MAX
• 150/200/225 SUPER MAGNUM
• 225/250 EFI  3.0 Liter Work

With Serial Numbers:

0D082000  Through  0G960499

0D082000  Through  0T105314

0D082000  and  Above

0G960500  and  Above

0T409000  and  Above – Starting 2002

Year:

1992-2000

Manual Covers :

Information:

• Specifications
• Maintenance
• General Information
• Outboard Installation

Electrical:

• Ignition
• Charging and Starting System
• Timing, Synchronizing and Adjusting
• Wiring Diagrams

Fuel System:

• Fuel Pump
• Carburetor
• Fuel Injection1995-Prior
• Fuel Injection 1996 and Up
• Oil Injection
• Emissions

Powerhead:

• Powerhead
• Cooling

Mid-Section:

• Clamp/Swivel Brackets and Drive Shaft Housing
• Power Trim

Lower Unit:

• Right Hand Rotation
• Left Hand Rotation
• 78:1 Ratio (4-1/4” Dia)
• Right Hand Non-Ratcheting
• Left Hand Non-Ratcheting
• Jet Outboards

Attachments/Control Linkage

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly

• Performance: They offer high maneuverability in situations where a propeller would be damaged.
• Characteristics: The jet drive results in a slight horsepower loss compared to a prop-driven counterpart but provides specialized performance for rivers and other shallow areas. 

• Early models (pre-mid-1990s): Most were carbureted and came in displacements like 2.0L, 2.4L, and 2.5L. Performance models included the Black Max series and XR-series with enhanced features.
• EFI and Optimax (mid-1990s and later): In the mid-1990s, Mercury introduced Electronic Fuel Injection (EFI) for better fuel efficiency and throttle response. This was followed by the Optimax line, which used Direct Fuel Injection (DFI) to improve fuel economy and lower emissions significantly

  .

• High-performance versions: The Pro Max, Super Magnum, and later XS models (Optimax) offered high-performance features like revised porting, special pistons, and different engine control module (PCM) calibration for competitive use. 

• 135, 150, 175 HP: These typically used the 2.5L V6 block, with the different horsepower ratings achieved through carburetor size or EFI programming. For example, a 150 HP XR6 had different tuning than a standard 150 HP.
• 200, 225, 250 HP: These used both 2.5L and 3.0L blocks over time. The larger displacement allowed for more power, especially at lower RPMs. In the Optimax line, the 250 HP might have different pistons, heads, and a higher air/fuel pressure than the 200 or 225

  .

• Mariner vs. Mercury: A Mariner 225 EFI from 1996 would be mechanically identical to a Mercury 225 EFI from the same year, with parts often being interchangeable. 

• Optimax fuel system: Owners of Optimax models must be diligent with fuel filter changes and fuel system checks. The DFI system is more complex and requires clean fuel to function correctly.
• Powerhead issues: While generally reliable, older engines can experience wear on pistons, rings, and crank seals. Any decrease in performance or unusual engine noise warrants an inspection.
• Trim motor

  : Aftermarket trim motors are commonly available for these models.

• Water pump impeller: Given the age of these engines, the water pump impeller should be inspected and replaced regularly to prevent overheating.