2001 Mercury 115/135/150/175HP OptiMax DFI Outboards OEM Service & Repair Manual

115/135/150/175 OptiMax Direct Fuel Injection Starting Model Year 2000 Starting Serial Number OG960500 Starting Model Year 2000 Starting S/N OG960500 115/135/150/175 OptiMax

90-859494R1 JUNE 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 90-859494R1 JUNE 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: 90-859494 R1 MAY 2000 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 90-859494R1 JUNE 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 - Direct Fuel Injection C - Oil Injection D - Emissions Section 4 - Powerhead A - Powerhead B - Cooling Section 5 - Mid-Section A - Clamp/Swivel Brackets & Drive Shaft Housing B - Power Trim – Design I (Showa) C - Power Trim – Design II (Oildyne) Section 6 - Gear Housing A - Right Hand (Standard) Rotation Non-Ratcheting B - Left Hand (Counter) Rotattion Non-Ratcheting Section 7 - Attachments/Control Linkage Section 8 - Color Diagrams

1 A SPECIFICATIONS 90-859494R1 JUNE 2000 Page 1A-1 IMPORTANT INFORMATION Section 1A - Specifications Table of Contents Master Specifications 1A-1 . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Information Charts 1A-7 . . . . . . . . . . . . . . . . . . . Master Specifications Model 115/135/150/175 DFI HORSEPOWER (KW) Model 115 Model 135 Model 150 Model 175 Full Throttle RPM (115/135) Full Throttle RPM (150/175) Idle RPM (In Gear) (115/135/150/175) RPM Limiter All Models 115 (85.8 kw) 135 (100.7 kw) 150 (111.8 kw) 175 (130.5 kw) 5000 - 5500 5250 - 5750 550 ± 25 Refer to System Information in the Digi- tal Diagnostic Terminal (DDT) for latest information OUTBOARD WEIGHT Model 115/135/150/175 – 20 in. (50.8cm) Shaft – 25 in. (63.5cm) Shaft 453 (205.5 kg) 462 (209.6 kg) CYLINDER BLOCK Type Displacement Thermostat V-6 Cylinder, Two Cycle, Direct Injected 153 cu. in. (2508 cc) 60° Vee 142° F (61° C) STROKE Length (All Models) 2.65 in. (67.3 mm) CYLINDER BORE Diameter (Std) Diameter 0.015 in. Oversize Taper/Out of Round/Wear Maximum Bore Type 3.501 in. (88.925 mm) 3.516 in. (89.306 mm) 0.003 in. (0.076 mm) Cast Iron CRANKSHAFT Maximum Runout 0.006 in. (0.152 mm) PISTON Piston Type Diameter Standard Diameter 0.015 in. Oversize Aluminum 3.4925 in. ± .0005 in. (88.7095 mm ± 0.0127 mm) 3.5075 in. ± 0.0005 in. (89.0905 mm ± 0.0127 mm)

SPECIFICATIONS Page 1A-2 90-859494R1 JUNE 2000 Model 115/135/150/175 DFI PISTON DIAMETER Dimension “A” at Right Angle (90°) to Piston Pin .700 17.78mm 3.4925 in. ± .0005 in. (88.7095 mm ± .0127 mm) Using a micrometer, measure dimension “A” at location shown. Dimension “A” should be 3.4925 in. ± .0005 for a STAN- DARD size piston (new) Dimension “A” will be 0.001 – 0.0015 less if coating is worn off piston (used) REEDS Reed Stand 0pen (Max.) 0.020 in. (0.50 mm) DIRECT INJECTION Injectors – Quantity – Injectors are Crank Angle Driven by ECM – #2 Cylinder – #4 Cylinder – #6 Cylinder – #1 Cylinder – #3 Cylinder – #5 Cylinder Fuel Line Pressure @ Injectors Air Pressure High Pressure Electric Fuel Pump Amperage Draw Low Pressure Electric Fuel Pump Amperage Draw Low Pressure Electric Fuel Pump Output Fuel Injector Ohm Resistance Direct Injector Ohm Resistance Fuel/Air Differential 6 WHT/RED + RED/WHT Leads WHT/YEL + YEL/WHT Leads WHT/PPL + PPL/WHT Leads WHT/BRN + BRN/WHT Leads WHT/ORG + ORG/WHT Leads WHT/DRK BLU + DRK BLU/WHT Leads 89 ± 2 psi (613.5 ± 13.8 kPa) 79 ± 2 psi (544.0 ± 13.8 kPa) 5 – 9 Amperes 1 – 2 Amperes 6 – 9 psi (41.37 – 62.04 kPa) 1.8 ± 0.1 Ω 1.3 ± 0.3 Ω 10 psi (68.5 kPa) FUEL SYSTEM Fuel Recommended Gasoline Recommended Oil Gasoline/Oil Ratio – @ Idle – @ WOT Gasoline w/Oil Injection Unleaded 87 Octane Minimum Quicksilver TC-W3 Premium Plus 2 Cycle Outboard Oil 300 – 400:1 60:1** **On some light boat applications after the break-in is completed and the engine is being run at cruising speed – between 4000 and 5000 RPM – the fuel to oil ratio may be as high as 28:1. This results from a re- duced throttle opening with a corresponding reduction in fuel consumption.

SPECIFICATIONS 90-859494R1 JUNE 2000 Page 1A-3 Model 115/135/150/175 DFI FUEL PUMP Fuel Pressure Crankcase Pump – @ Idle – @ WOT Normal – 2-3 psi (13.7 – 20.5 kPa) Minimum – 1 psi (6.8 kPa) Maximum – 10 psi (68.5 kPa) Normal – 8-10 psi (41.0 – 54.8 kPa) Minimum – 3 psi (20.5 kPa) STARTING SYSTEM Electric Start – All Models Model Year 2000 Starter Draw (Under Load) Starter Draw (No Load) Minimum Brush Length Model Year 2001 Starter Draw (Under Load) Starter Draw (No Load) Minimum Brush Length Battery Rating 165 Amperes 30 Amperes 0.25 in. (65.4 mm) 170 Amperes 60 Amperes 0.25 in. (65.4 mm) 1000 (Minimum) Marine Cranking Amps 750 (Minimum) Cold Cranking Amps 105 (Minimum) Ampere Hours IGNITION SYSTEM Type Spark Plug Type Model Year 2000 Spark Plug Gap Model Year 2001 Spark Plug Gap Maximum Timing Idle Timing Throttle Position Sensor @ Idle @ WOT Crank Position Sensor Air Gap Digital Inductive Champion QC12GMC 0.040 in. (1.0 mm) NGK PZFR5F-11 0.040 in. (1.0 mm) Not Adjustable; Controlled by ECM Not Adjustable; Controlled by ECM 4.0 – 4.7 VDC 0.4 – 1.3 VDC 0.025 in. – 0.040 in. (0.635 mm – 1.01 mm) CHARGING SYSTEM Alternator Output (Regulated) Brush Length Voltage Output Regulator Current Draw 32 - 38 Amperes @ 2000 RPM @ Battery* 52 - 60 Amperes @ 2000 RPM @ Alternator Std Exposed Length: 0.413 in. (10.5 mm) Min. Exposed Length: 0.059 in. (1.5 mm) 13.5 to 15.1 Volts 0.15 mA (Ign. Switch Off) 30.0 mA (Ign. Switch On) *Amperage listed is when battery is in a discharged state. If battery is fully charged, amperage readings will be less.

SPECIFICATIONS Page 1A-4 90-859494R1 JUNE 2000 Model 115/135/150/175 DFI TIMING Full Throttle RPM Range (115/135) (150/175 Idle RPM (In Forward Gear) Maximum Timing: @ Wide OPEN Idle Timing Throttle Position Sensor @ Idle @ W.O.T. Firing Order 5000 - 5500 5250 - 5750 550 ± 25 Not Adjustable Controlled by ECM Not Adjustable Controlled by ECM 3.20 - 4.90 VDC 0.10 - 1.50 VDC 1-2-3-4-5-6 AIR COMPRESSOR Type Compressor Output Reciprocating Piston (1 to 1 ratio with engine RPM) @ Idle – 80 psi @ W.O.T. – 110 psi Cylinder Block Displacement 7.07 cu. in. (116 cc) Cylinder Bore Diameter (Standard) Taper/Out-of-Round/ Wear Maximum Bore Type 2.5591 in. (65.0 mm) 0.001 in. (0.025 mm) Cast Iron Stroke Length 1.374 in. (34.9 mm) Piston Type Aluminum Piston Diameter 2.5578 ± .0004 in. (64.97 ± 0.010 mm) Dimension “A” at Right Angle (90°) to Piston Pin 0.500 in. Piston Ring End Gap Top Ring Middle Ring Bottom Ring 0.0059 – 0.0098 in. (0.15 – 0.25 mm) 0.0059 – 0.0098 in. (0.15 – 0.25 mm) 0.0039 – 0.014 in. (0.10 – 0.35 mm) Reeds Stand Open 0.010 in. (0.25 mm)

SPECIFICATIONS 90-859494R1 JUNE 2000 Page 1A-5 Model 115/135/150/175 DFI MID SECTION Steering Pivot Range Tilt Pin Adjustment Positions Allowable Transom Thickness 60° 4 2-3/8 in. (6.03 cm) POWER TRIM Design I (Showa) Trim “UP” Trim “DOWN” Design II (Oildyne) Trim ”UP” Trim “DOWN” Leak Down Design I & II Total Tilt Range Design I & II Tilt Range Design I & II 1300 PSI (91kg/cm 2 ) Maximum Pressure 500 PSI (35kg/cm 2 ) Minimum Pressure 2000 PSI (91kg/cm 2 ) Maximum Pressure 600 PSI (35kg/cm 2 ) Minimum Pressure Maximum Acceptable Amount of Leak Down in 24 hours is 1 in. (25.4 mm) 75° 20° GEAR HOUSING Gear Ratio – 115 – 135 – 150 – 175 Optional High Altitude Ratio – 115 (Standard Only) – 135 (Standard Only) – 150 – 175 Gearcase Capacity Pinion Height Forward Gear Backlash – 1.87:1 – 2.00:1 – 2.30:1 (Standard Only) Reverse Gear Backlash Water Pressure @ RPM 2.00:1 14/28 Teeth 2.00:1 14/28 Teeth 1.87:1 15/28 Teeth 1.87:1 15/28 Teeth 2.30:1 13/30 Teeth 2.30:1 13/30 Teeth 2.00:1 14/28 Teeth 2.00:1 14/28 Teeth 22.5 fl. oz. (665.4 ml) 0.025 in. (0.635 mm) 0.017 in. – 0.028 in. (0.431 mm – 0.711 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) 0.030 in. to 0.050 in. (0.076 mm to 0.127 mm) 12 psi minimum @ 5500 RPM

SPECIFICATIONS Page 1A-6 90-859494R1 JUNE 2000 Propeller Information Charts Optimax 115 • Wide Open Throttle RPM: 5000-5500 • Gear Reduction: 2.00:1 Diameter Pitch No. of Blades Model Gross Boat Wgt. (lbs) Boat Length Speed (mph) Propeller Part Number 13.75″ 26 4 Trophy+ Up to 1600 Up to 18′ 56-63 48-825944A47 13.75″ 25 3 Laser II 1500 – 1700 16 – 18′ 54-60 48-16550A46 13.75″ 25 4 Trophy+ 1500 – 1700 16 – 18′ 54-60 48-825942A47 13.25″ 25 5 Hi-Five 1500 – 1700 16 – 18′ 54-60 48-816374A46 13.38″ 25 3 Vengeance 1500 – 1700 16 – 18′ 54-60 48-16322A45 13.38″ 25 3 Aluminum 1500 – 1700 16 – 18′ 54-60 48-78126A45 13.75″ 24 4 Trophy+ 1600 – 1800 16 – 18′ 51-58 48-825940A47 13.75″ 23 3 Laser II 1700 – 2000 17 – 19′ 49-55 48-16548A46 13.75″ 23 4 Trophy+ 1700 – 2000 17 – 19′ 49-55 48-825938A47 13.25″ 23 5 Hi-Five 1700 – 2000 17 – 19′ 49-55 48-815762A46 13.5″ 23 3 Vengeance 1700 – 2000 17 – 19′ 49-55 48-16320A45 14″ 23 3 Aluminum 1700 – 2000 17 – 19′ 49-55 48-832834A45 13.88″ 21 3 Laser II 1900 – 2300 18 – 20′ 43-50 48-16546A46 13.75″ 21 4 Trophy+ 1900 – 2300 18 – 20′ 43-50 48-825936A47 13.25″ 21 5 Hi-Five 1900 – 2300 18 – 20′ 43-50 48-815760A46 13.75″ 21 3 Vengeance 1900 – 2300 18 – 20′ 43-50 48-16318A45 14.25″ 21 3 Aluminum 1900 – 2300 18 – 20′ 43-50 48-832832A45 14″ 19 3 Laser II 2100 – 2500 18 – 21′ 38-45 48-16544A46 13.75″ 19 4 Trophy+ 2100 – 2500 18 – 21′ 38-45 48-825932A46 13.25″ 19 5 Hi-Five 2100 – 2500 18 – 21′ 38-45 48-815758A46 14″ 19 3 Vengeance 2100 – 2500 18 – 21′ 38-45 48-16316A45 14.5″ 19 3 Aluminum 2100 – 2500 18 – 21′ 38-45 48-832830A45 13.75″ 17 4 Trophy+ 2300 – 3100 19 – 22′ 32-40 48-825930A46 13.5″ 17 5 Hi-Five 2300 – 3100 19 – 22′ 32-40 48-821154A46 14.5″ 17 3 Vengeance 2300 – 3100 19 – 22′ 32-40 48-16314A45 15″ 17 3 Aluminum 2300 – 3100 19 – 22′ 32-40 48-832828A45 14.5″ 15 3 Vengeance 2900 – 4100 20 – 24′ 25-34 48-16312A45 15.5″ 15 3 Aluminum 2900 – 4100 20 – 24′ 25-34 48-78116A45 16″ 13 3 Aluminum 4000+ Pontoon 19-28 48-78114A45 16″ 12 3 Aluminum 4500+ Pontoon/Work 16-25 48-16436A45 16″ 11 3 Aluminum 5500+ House/Work 1-20 48-78112A45

2001 Mercury 115/135/150/175HP OptiMax DFI Outboards OEM Service & Repair Manual

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