1997-2003 Mercury 75/90/100/115/125HP 2-Stroke Outboards OEM Service & Repair Manual

1 A 52485 IMPORTANT INFORMATION SPECIFICATIONS

1A-0 - IMPORTANT INFORMATION 90-830234R3 DECEMBER 1997 Table of Contents Page Master Specifications 1A-1 . . . . . . . . . . . . . . . . . . . . .

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1A-1 Master Specifications Model 65/80 Jet/75/90/100/115/125 HORSEPOWER (KW) Model 75 Model 65 Jet/90 Model 100 Model 80 Jet/115 Model 125 75 (55.9) 90 (67.1) 100 (74.6) 115 (85.8) 125 (93.2) OUTBOARD WEIGHT Model 65 Jet Model 75/90 Model 80 Jet Model 100/115/125 315 lbs. (143kg) 305 lbs. (139kg) 357 lbs. (162kg) 348 lbs. (158kg) CYLINDER BLOCK Model 65 Jet/75/90 Type Displacement Model 80 Jet/100/115/125 Type Displacement In-line 3 Cylinder, 2 Cycle, Loop Charged 84.6 cu. in. (1387cc) In-Line 4 Cylinder, 2 Cycle, Loop Charged 112.8 cu. in. (1848.8cc) STROKE Length 2.93 in. (74.42mm) CYLINDER BORE Diameter (Standard) Taper/Out of Round Maximum Bore Type 3.50 in. (88.9mm) 0.003 in. (0.076mm) Cast Iron PISTON Piston Type Standard 0.015 in. (0.381mm) Oversize 0.030 in. (0.762mm) Oversize Aluminum 3.495 in. (88.773mm) 3.510 in. (89.154mm) 3.525 in. (89.535mm) REEDS Reed Stand Open (Max.) Reed Stop (Max.) 0.020 in. (0.50mm) Not Adjustable TEMPERATURE SWITCH Temperature Normal 190°F ± 8° (88°C ± 4°C) 170°F ± 8° (77°C ± 4°C) Open – No Continuity Closed – Continuity Open – No Continuity GEAR HOUSING Model 75/90 Gear Ratio Gearcase Capacity Forward Gear - No. of Teeth-Type Pinion Gear - No. of Teeth-Type Pinion Height Forward Gear Backlash Water Pressure @ RPM Model 100/115/125 Gear Ratio Gearcase Capacity Forward Gear - No. of Teeth-Type Pinion Gear - No. of Teeth-Type Pinion Height Forward Gear Backlash Water Pressure @ RPM 2.3:1 22.5 fl. oz. (655ml) 30 13 0.025 in. (0.64mm) 0.012 in. to 0.019 in. (0.30mm to 0.48mm) 10 to 15 PSI (69 to 103 kPa) @ 5250 RPM 2.07:1 22.5 fl. oz. (655ml) 29 14 0.025 in. (0.64mm) 0.015 in. – 0.022 in. (0.38mm – 0.55mm) 10 – 15 PSI @ 5250 RPM FUEL SYSTEM Fuel Recommended Gasoline Recommended Oil Gasoline/Oil Ratio Fuel Pressure – @ Idle – @ WOT Gasoline and Oil Unleaded 87 Octane Minimum Quicksilver TC-W II or TC-W3 Outboard Oil 50:1 (25:1 Break-In) 3-1/2 PSI 6 PSI

1A-2 - IMPORTANT INFORMATION 90-830234R3 DECEMBER 1997 Model 65/80 Jet/75/90/100/115/125 OIL INJECTION Model 65 Jet/75/90 Oil Tank Capacity/Approx. Time Max. Run Time Per Tank @ WOT Oil Remaining When Alarm Sounds Max. Run Time @ W.O.T. After Alarm Sounds Gasoline/Oil Ratio @ Idle Gasoline/Oil Ratio @ W.O.T Output @ 700 RPM for 15 Minutes with Pump @ Full Open Model 80 Jet/100/115/125 Oil Tank Capacity/Approx. Time Max. Run Time Per Tank @ WOT Oil Remaining When Alarm Sounds Max. Run Time @ W.O.T. After Alarm Sounds Gasoline/Oil Ratio @ Idle Gasoline/Oil Ratio @ W.O.T Output @ 700 RPM for 15 Minutes with Pump @ Full Open 1 gallon (3.78 liters) 6 Hours 1 qt. (.95 liters) 1 Hour Approx. 80:1 50:1 22cc Min. 1.4 gal. (5.3Liter) 5 hrs. 1 qt. (0.95Liter) 50 min. 80:1 50:1 29cc Minimum STARTING SYSTEM Manual Start - Commercial 75 Manual Start - All Electric Models Electric Start - Model 65 Jet/75/90 Starter Draw (Under Load) Starter Draw (No Load) Electric Start - Model 80Jet/100/115/125 Starter Draw (Under Load) Starter Draw (No Load) Battery Rating Recoil Starter Emergency Starter Rope 120 Amperes 75 Amperes 150 Amperes 75 Amperes Min. Reserve Cap. Rating of 100 Min. and CCA of 350 Amperes

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1A-3 Model 65/80 Jet/75/90/100/115/125 CHARGING SYSTEM Alternator Model 3 Cyl. Manual – Black & Red Stator 3 Cyl. Electric – Black Stator Stamped 398-9710A3 Serial Number USA 0D283222 – 0G280043 Belgium 09793577 – 09879064 3 Cyl. Electric – Black Stator Stamped 398-9873A24 Serial Number USA 0G280044 – 0G404505 Belgium 09879065 – 09916672 3 Cyl. Electric – Red Stator Stamped 398-832075A3 Serial Number USA 0G404506 and Above Belgium 09916673 and Above 4 Cyl. Electric – Black Stator Stamped 398-9710A31 Serial Number USA 0D283222 – 0G301750 Belgium 09793577 – NA 4 Cyl. Electric – Black Stator Stamped 398-9710A33 Serial Number USA 0G301751 – 0G404616 Belgium NA – 09916721 4 Cyl. Electric – Red Stator Stamped 398-832075A3 Serial Number USA 0G404617 and Above Belgium 09916722 and Above Alternator Output @ 5250 RPM 10 Amperes 16 Amperes 14 Amperes 16 Amperes 16 Amperes 16 Amperes 16 Amperes IGNITION SYSTEM Model 65 Jet/75/90 Type Spark Plug Type (NGK) Spark Plug Gap Optional (Inductor Plug) Model 80 Jet/100/115/125 Type Spark Plug Type Spark Plug Gap Optional (Inductor Plug) Capacitor Discharge NGK BUHW-2 Surface Gap NGK BUZHW-2 Capacitor Discharge NGK BP8H-N-10 0.040 in. (1.0mm) BPZ8H-N-10 C A R B U R E T O R Idle RPM Wide Open Throttle (WOT) RPM – Model 75/80 Jet/100/115/125 – Model 65 Jet/90 Idle Mixture Screw Adjustment (Preset - Turns Out) Model 75Work/75 Model 65 Jet/90 Model 80 Jet/100/115/125 Float Setting Float Weight 675 ± 25 RPM 4750 – 5250 5000 – 5500 1-1/8 ± 1/4 TURN 1-1/4 ± 1/4 TURN 1 – 1-1/2 TURNS 9/16 in. (± 0.015 in.) 12.29mm (± 0.38 mm) 7 Grams (± 0.4 Grams)

1A-4 - IMPORTANT INFORMATION 90-830234R3 DECEMBER 1997 Model 65/80 Jet/75/90/100/115/125 Main Jet – Model 75 WME-29 – Carb #1 – Carb #2 – Carb #3 WME-41/46 – Carb #1 – Carb #2 – Carb #3 WME-59 – Carb #1 – Carb #2 – Carb #3 WME-59 – Carb #3A WME-75 – Carb #1 – Carb #2 – Carb #3 WME-77 – Carb #1 – Carb #2 – Carb #3 – Model 75 Work WME-30 – Carb #1 – Carb #2 _ Carb #3 WME-47/48/76 – Carb #1 – Carb #2 – Carb #3 WME-60/61 – Carb #1 – Carb #2 – Carb #3 – Model 65 Jet/90 WME-31 – Carb #1 – Carb #2 – Carb #3 WME-49/62 – Carb #1 – Carb #2 – Carb #3 WME-62-3A – Carb #3 WME-78 – Carb #1 – Carb #2 – Carb #3 .050 .052 .050 .052 .052 .052 .052 .054 .052 .054 .052 .054 .054 .054 .054 .054 .050 .052 .050 .054 .054 .054 .054 .054 .054 .062 .064 .062 .062 .064 .062 .064 .062 .064 .064

90-830234R3 DECEMBER 1997 IMPORTANT INFORMATION - 1A-5 Model 65/80 Jet/75/90/100/115/125 C A R B U R E T O R – Model 100 WME-32 – Carb #1 – Carb #2 – Carb #3 – Carb #4 WME-50 – Carb #1 – Carb #2 – Carb #3 – Carb #4 WME-50-3A – Carb #3 WME-79 – Carb #1 – Carb #2 – Carb #3 – Carb #4 Model 115 WME-33 – Carb #1 – Carb #2 – Carb #3 – Carb #4 Model 80Jet/115 WME-40 – Carb #1 – Carb #2 – Carb #3 – Carb #4 WME-40 – Carb #1A – Carb #2A – Carb #3A – Carb #4A WME-51 – Carb #1 – Carb #2 – Carb #3 – Carb #4 WME-51-3A – Carb #3 WME-80 – Carb #1 – Carb #2 – Carb #3 – Carb #4 .046 .048 .052 .052 .048 .050 .048 .052 .050 .048 .050 .050 .052 .052 .056 .056 .060 .066 .068 .068 .070 .060 .070 .070 .074 .062 .062 .060 .064 .062 .060 .064 .062 .064

1A-6 - IMPORTANT INFORMATION 90-830234R3 DECEMBER 1997 Model 65/80 Jet/75/90/100/115/125 C A R B U R E T O R Model 125 WME-34 – Carb #1 – Carb #2 – Carb #3 – Carb #4 WME-52 – Carb #1 – Carb #2 – Carb #3 – Carb #4 WME-52-3A – Carb #3 WME-81 – Carb #1 – Carb #2 – Carb #3 – Carb #4 Vent Jet WME-46/47/48/49 WME-32/33/34/40/50/51/52/59/60/61/62/ 75/76/77/78/79/80/81 . .066 .068 .070 .072 .070 .080 .078 .082 .080 .070 .080 .080 .082 .094 None T I M I N G Idle (All Models 1994/1995/1996/1997) Model 65 Jet/75/90 Model 80 Jet/100/115/125 Maximum BTDC (1994/1995) @ Cranking Speed – Model 75 – Model 65/80 Jet/90/100/115/125 @ 3000 RPM – Model 75 – Model 65/80 Jet/90/100/115/125 Maximum BTDC (1996/1997) @ Cranking Speed – Model 75 – Model 65/Jet/90 – Model 80 Jet/100/115/125 @ 3000 RPM – Model 75 – Model 65/Jet/90 – Model 80 Jet/100/115/125 Firing Order 1994/1995 Model 65 Jet/75/90 Model 80 Jet/100/115/125 1996/1997/1998 Model 65 Jet/75/90 Model 80 Jet/100/115/125 2° ATDC – 6° BTDC 4° ATDC – 2° BTDC 20° BTDC 22° BTDC 18° BTDC 20° BTDC 20° BTDC 22° BTDC 25° BTDC 18° BTDC 20° BTDC 23° BTDC 1-3-2 1-3-2-4 1-2-3 1-3-2-4

1997-2003 Mercury 75/90/100/115/125HP 2-Stroke Outboards OEM Service & Repair Manual

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