1998-2001 Mercury, Mariner 135HP, 150HP, 175HP, 200HP Outboard Service & Repair Manual

MODELS United States 0G960500 and Above . . . . . . With Serial Numbers SERVICE MANUAL 135 • 150 • 175 • 200 Printed in U.S.A. 2000, Mercury Marine 90-878079 JANUARY 2000

90-878079 JANUARY 2000 Page i Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In- ternational HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started.

Page ii 90-878079 JANUARY 2000 It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mis- matched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. Page Numbering Two number groups appear at the bottom of each page. The example below is self-explana- tory. EXAMPLE: 90-878079R1 OCTOBER 1999 LOWER UNIT - 6A-7 Revision No. 1 Month of Printing Year of Printing Section Description Section Number Part of Section Letter Page Number

1 2 3 4 5 6 7 General Information & Specifications Ignition System Fuel System Powerhead Mid-Section Gear Housing Attachment/Control Linkage 8 Color Diagrams 90-878079 JANUARY 2000 Page iii Service Manual Outline Section 1 - General Information & Specifications A - Specifications B - Maintenance C - General Information D - Outboard Installation Section 2 - Electrical A - Ignition B - Charging & Starting System C - Timing, Synchronizing & Adjusting D - Wiring Diagrams Section 3 - Fuel System A - Fuel Pump B - Carburetion C - Fuel Injection D - Oil Injection E - Emissions Section 4 - Powerhead A - Powerhead B - Cooling Section 5 - Mid-Section A - Clamp/Swivel Brackets & Drive Shaft Housing B - Power Trim Section 6 - Gear Housing A - Right Hand Non-Ratcheting B - Left Hand Non-Ratcheting Section 7 - Attachments/Control Linkage Section 8 - Color Diagrams

1 A SPECIFICATIONS 90-878079 JANUARY 2000 Page 1A-1 IMPORTANT INFORMATION Section 1A - Specifications Table of Contents Specifications 1A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications Model 135/XR6/MAGIII/200/150XRI/175XRI/200XRI HORSEPOWER (KW) Model 135 Model 150XRI Model XR6/MAGIII Model 175XRI Model 200/200XRI 135 (100.6) 150 (111.8) 150 (111.8) 175 (130.5) 200 (149.1) OUTBOARD WEIGHT Model 135 Model XR6/MAGIII/200 Model 150XRI/175XRI/200XRI 413.0 lbs. (188.0 kg) 406.0 lb (184.0 kg) 416.0 lb (189.0 kg) CYLINDER BLOCK Model 135 Type Displacement Thermostat Model XR6/MAGIII/200 150XRI/175XRI/200XRI Type Displacement Thermostat V–6 Cylinder, Two Cycle, Loop Charged 121.9 cu. in. (1998cc) 143°F (61.7°C) V–6 Cylinder, Two Cycle, Loop Charged 153.0 cu. in. (2507cc) 143°F (61.7°C) STROKE Length (All Models) 2.650 in. (67.31 mm) CYLINDER BORE Diameter (Std) – Models 135 – Models XR6/MAGIII/200 150XRI/175XRI/200XRI Taper/Out of Round/Maximum Wear Bore Type 3.125 in. (79.375 mm) 3.501 in. (88.925 mm) 0.003 in. (0.076 mm) Cast Iron CRANKSHAFT Maximum Runout 0.006 (0.152 mm)

SPECIFICATIONS Page 1A-2 90-878079 JANUARY 2000 PISTON Piston Type Models 135 Standard 0.015 in. (0.381 mm) Oversize 0.030 in. (0.762 mm) Oversize Models XR6/MAGIII/200 150XRI/175XRI/200XRI Standard 0.015 in. (0.381 mm) Oversize Aluminum 3.115 in. ± 0.002 in. (79.121 mm ± 0.051 mm) 3.130 in. ± 0.002 in. (79.502 mm ± 0.051 mm) 3.145 in. ± 0.002 in. (79.883 mm ± 0.051 mm) 3.494 in. ± 0.001 in. (88.748 mm ± 0.025 mm) 3.509 in. ± 0.001 in. (89.129 mm ± 0.025 mm) COMPRESSION All Models – Using a fully charged battery, throttle shutters wide open and cylinder block warm 110 – 135 psi (753.3 – 924.5 kPa) Variance between cylinders should not exceed 15 psi (102.7 kPa) REEDS Model 135 Model XR6/MAGIII/200 Model 150XRI/175XRI/200XRI Reed Type Reed Stand 0pen (Max.) Reed Stop (Max.) Steel 0.020 in. (0.50 mm) Not Adjustable MID SECTION Power Trim (Total Tilt Range) Power Trim (Tilt Range) Maximum Allowable Leak down in 24 hrs. Tilt Pin Adjustment Positions Steering Pivot Range Allowable Transom Thickness 75° 20° 1 in. (25.4 mm) 5 60° 2-3/8 in. (6.03 cm) Maximum FUEL SYSTEM Fuel Recommended Gasoline Model 135 Model XR6/MAGIII/200 Model 150XRI/175XRI/200XRI Recommended Oil Model 135 Model XR6/MAGIII/200 Model 150XRI/175XRI/200XRI Gasoline/Oil Ratio Fuel Pressure Pulse Driven Pump – @ Idle – @ WOT Gasoline w/Oil Injection Unleaded 87 Octane Minimum Quicksilver TC-W3 2 Cycle Outboard Oil Only 50:1 (25:1 Break-In) 1 – 3 psi (6.8 – 20.5 kPa) 12 psi (82.1 kPa) Minimum STARTING SYSTEM Manual Start – All Models Electric Start – All Models Starter Draw (Under Load) Starter Load (No Load) Battery Rating Emergency Start Rope 175 Amperes 40 Amperes Min. 630 Marine Cranking Amps (MCA) or 490 Cold Cranking Amps (CCA)

SPECIFICATIONS 90-878079 JANUARY 2000 Page 1A-3 IGNITION SYSTEM Type Spark Plug Type Spark Plug Gap Firing Order Capacitor Discharge NGK BPZ8HS-10 0.040 in. (1.0 mm) 1-2-3-4-5-6 CHARGING SYSTEM Alternator Output (Regulated) Voltage Regulator Draw with Ignition Key in the Off Position 40 Amperes @ 5000 rpm 0 – 4 Milliamperes Each (0 – 8 Milliamperes total system draw) TIMING Idle Speed/Pickup Timing – 135 Carb Models – XR6/MAG III – 200 Carb – 150XRI/175 XRI Models – 200 XRI Model Maximum BTDC – Model 135 @ Cranking Speed @ WOT RPM – XR6/MAG III Carb/175 XRI @ Cranking Speed @ WOT RPM – Model 150 XRI @ Cranking Speed @ WOT RPM – Model 200 Carb @ Cranking Speed @ WOT RPM – Model 200XRI @ Cranking Speed @ WOT RPM 0° – 9° ATDC 25° BTDC 19° BTDC 26° BTDC 20° BTDC 22° BTDC 16° BTDC 20° BTDC 18° BTDC 24° BTDC 18° BTDC *NOTE: Timing specifications listed are for 2000 model year engines. Refer to timing decal on engine for previous model year timing specifications.

SPECIFICATIONS Page 1A-4 90-878079 JANUARY 2000 GEAR HOUSING Gear Ratio – Models 135 – Models XR6/MAGIII/150XRI – Models 200/175XRI/200XRI Gear Ratio – High Altitude – Models 135 – Models XR6/MAGIII/175/200 150XRI/175XRI/200XRI Gearcase Capacity – 1.87:1/2.00:1/2.30:1 Pinion Height – All Models Forward Gear Backlash – 1.87:1 Ratio – 2.00:1 Ratio – 2.30:1 Ratio Water Pressure @ rpm 2.00:1 (14/28 teeth) 1.87:1 (15/28 teeth) 1.87:1 (15/28 teeth) 2.30:1 (13/30 teeth) 2.00:1 (14/28 teeth) 22.5 fl oz (665.4 ml) 0.025 in. (0.64 mm) 0.018 in. – 0.027 in. (0.460 mm – 0.686 mm) 0.015 in. – 0.022 in. (0.381 mm – 0.558 mm) 0.018 in. – 0.023 in. (0.460 mm – 0.584 mm) 12 psi Minimum @ 5500 rpm OIL INJECTION Recommended Oil Oil Tank Capacity Approx. Time – Model 135 – Model XR6/MAGIII/175/200 – Model 150XRI/175XRI/200XRI Reserve Capacity/Approx. Time Output @ 1000 RPM for 3 Minutes with Pump @ Full Open – Model 135 – Model XR6/MAG III/200 – Model 150XRI/175XRI/200XRI Quicksilver TC-W3 3 gal. (11.4 Liter) 8.7 hrs. Approx. 6.6 hrs. Approx. 6.6 hrs. Approx. .94 qt. (0.89 Liter) 30 – 35 min. 12cc @ 1000 rpm 15cc @ 1000 rpm 15cc @ 1000 rpm FUEL INJECTION Idle RPM – All Models Wide Open Throttle (WOT) RPM – Model 150XRI/175XRI – Model 200XRI Float Adjustment (Vapor Separator) Float Level Injectors – All Models (Quantity) – CDM # Controls: – #1 Primary Circuit – #3 Primary Circuit – #5 Primary Circuit Line Pressure @ Injectors 650 ± 50 5000 – 5600 5000 – 5800 Preset @ Factory 6 #3 and #4 Injectors #5 and #6 Injectors #1 and #2 Injectors 34 psi – 36 psi (234 kPa – 248 kPa)

SPECIFICATIONS 90-878079 JANUARY 2000 Page 1A-5 CARBURETOR Idle RPM – Model 135/200 – Model XR6/MAGIII Wide Open Throttle (WOT) RPM – Model 135/200 – Model XR6/MAGIII Idle Mixture Screw Adjustment (Preset - Turns Out) – Carburetor Model 135 – Carburetor Models 150/200 – All EFI Models Float Adjustment Float Level 650 ± 50 675 ± 50 5000 – 5500 5000 – 5500 1-1/2 ± 1/8 1-1/4 ± 1/8 Not Adjustable Float Even with Bowl Edge w/Bowl Inverted CARBURETOR WMV Carburetor Jets – Model 135 (WMV 15) – Main Jet – Idle Air Jet – Vent Jet – Model XR6/MAGIII (WMV 16) – Main Jet – Idle Air Jet – Vent Jet – Model 200 (WMV 18) – Main Jet – Idle Air Jet – Vent Jet .072 (all cylinders) Cyl. 2,4 – .040 Cyl. 1 – .036 Cyl. 3 - .030 Cyl. 6 - .048 Cyl. 5 - .038 .086 (all cylinders) .074 (all cylinders) Cyl. 1,2,3,4,5 – .044 Cyl. 6 – .048 .082 (all cylinders) Cyl 2,3 – .082 Cyl. 1,4 – .080 Cyl. 5 – .084 Cyl. 6 – .078 Cyl. 2 – .038 Cyl. 1 – .042 Cyl. 3,4,5,6 – .028 .086 (all cylinders)

1 B MAINTENANCE 90-878079 JANUARY 2000 Page 1B-1 IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Specifications 1B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Case Lubricant Capacity 1B-1 . . . . . . . . . . . . . . Special Tools 1B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quicksilver Lubricant/Sealant 1B-2 . . . . . . . . . . . . . . . . . . Inspection and Maintenance Schedule 1B-4 . . . . . . . . . . Before Each Use 1B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . After Each Use 1B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 100 Hours of Use or Once Yearly, Whichever Occurs First 1B-4 . . . . . . . . . . . . . . . . . . . . Flushing Engine 1B-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flushing Cooling System – Using Cowl Flush Plug 1B-5 . . . . . . . . . . . . . . . . . . . . . Flushing Cooling System – Using Flushing Attachment 44357A2 1B-5 . . . . . . . . . . . . . . . . . . . . . . Fuel System 1B-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Line Inspection 1B-6 . . . . . . . . . . . . . . . . . . . . . . . Fuel Line Filter (Models With Carburetors) 1B-6 . . . . Water Separating Fuel Filter – EFI Models 1B-7 . . . . Corrosion Control Anode 1B-7 . . . . . . . . . . . . . . . . . . . . . . Spark Plug Inspection 1B-8 . . . . . . . . . . . . . . . . . . . . . . . . . Battery Inspection 1B-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse Replacement 1B-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Points 1B-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Power Trim Fluid 1B-11 . . . . . . . . . . . . . . . . . . . Gear Case Lubrication 1B-12 . . . . . . . . . . . . . . . . . . . . . . . Storage Preparation 1B-13 . . . . . . . . . . . . . . . . . . . . . . . . . Specifications Gear Case Lubricant Capacity Gear Case Ratio Capacity 1.87:1 22.5 fl. oz. (717 ml) 2.00:1 22.5 fl. oz. (717 ml) 2.30:1 22.5 fl. oz. (717 ml)

1998-2001 Mercury, Mariner 135HP, 150HP, 175HP, 200HP Outboard Service & Repair Manual

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