Mercury 2 stroke service repair manual 135 150 175 200
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1
A
IMPORTANT
INFORMATION
SPECIFICATIONS
90-824052R3 JUNE 2002 1A-0 - IMPORTANT INFORMATION
Table of Contents
Page
Master Specifications 1A-1 . . . . . . . . . . . . . . . . . . . . .
90-824052R3 JUNE 2002 IMPORTANT INFORMATION - 1A-1
Master Specifications
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
HORSEPOWER
(KW)
Model 135
Model 105 Jet/150/150XRI
Model XR6/MAGIII
Model 175/175XRI
Model 140 Jet/200/200XRI
Model Pro Max/Super Magnum 150
Model Pro Max/Super Magnum 200
Model Pro Max/Super Magnum 225
135 (100.6)
150 (111.8)
150 (111.8)
175(130.5)
200(149.1)
150 (111.8)
200(149.1)
225(167.9)
OUTBOARD
WEIGHT
Model 135/150
Model Pro Max/Super Magnum
150/200/225
Model XR6/MAGIII/175/200
Model 150XRI/175XRI/200XRI
Model 105 Jet
Model 140 Jet
404.0 lbs. (184.0kg)
350.0 lbs. (159.0kg)
395.0 lbs. (180.0kg)
410.0 lbs. (186.0kg)
428.0 lbs. (195.0kg)
408.0 lbs. (185.5kg)
CYLINDER
BLOCK
Model 105 Jet/135/150
Type
Displacement
Model 140 Jet/XR6/MAGIII/I75/200
150XRI/175XRI/200XRI/Pro Max/
Super Magnum 150/200/225
Type
Displacement
V–6 Cylinder, Two Cycle, Loop Charged
121.9 cu. in. (1998cc)
V–6 Cylinder, Two Cycle, Loop Charged
153.0 cu. in. (2507cc)
STROKE Length (All Models) 2.650 in. (67.31mm)
CYLINDER
BORE
Diameter (Std)
– Models 105 Jet/135/150
– Models XR6/MAGIII/175/200
150XRI/175XRI/200XRI/140 Jet
Pro Max/Super Magnum
150/200/225
Taper/Out of Round/Maximum Wear
Bore Type
3.125 in. (79.375mm)
3.501 in. (88.925mm)
0.003 in. (0.076mm)
Cast Iron
PISTON Piston Type
Models 105 Jet/135/150
Standard
0.015 in. (0.381mm) Oversize
0.030 in. (0.762) Oversize
Models XR6/MAGIII/175/200/140 Jet
150XRI/175XRI/200XRI/ProMax/
Super Magnum 150/200/225
Standard
0.015 in. (0.381mm) Oversize
Aluminum
3.115 in. ± 0.002 in.
(79.121mm ± 0.051mm)
3.130 in. ± 0.002 in.
(79.502mm ± 0.051mm)
3.145 in. ± 0.002 in.
(79.883mm ± 0.051mm)
3.494 in. ± 0.001 in.
(88.748mm ± 0.025mm)
3.509 in. ± 0.001 in.
(89.129mm ± 0.025mm)
90-824052R3 JUNE 2002 1A-2 - IMPORTANT INFORMATION
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
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 105 Jet/135/150
Model XR6/MAGIII/175/200
Model 150XRI/175XRI/200XRI
Reed Type
Reed Stand 0pen (Max.)
Reed Stop (Max.)
Model Pro Max/Super Magnum
150/200/225
Reed Type
Reed Stop (Max.)
Steel
0.020 in. (0.50mm)
Not Adjustable
2 Stage Plastic
No Stop
MID
SECTION
Power Trim (Total Tilt Range)
Power Trim (Trim Range)
Steering Pivot Range
Tilt Pin Adjustment Positions
Allowable Transom Thickness
75°
20°
60°
5
2-3/8 in. (6.03cm) Maximum
GEAR
HOUSING
Gear Ratio
– Models 135/150
– Models XR6/MAGIII/150XRI
– Models XR6/MAGIII (4-1/4″ dia.)
– Models 175/200/175XRI/200XRI
– Model Pro Max/Super Magnum
200/225
Gear Ratio – High Altitude
– Models 135/150
– Models XR6/MAGIII/175/200
150XRI/175XRI/200XRI
– Model Pro Max/Super Magnum
150
Gearcase Capacity
– 1.87:1/2.00:1/2.30:1
– 1.78:1
Pinion Height
– All Models
Forward Gear Backlash
– 1.78:1 Ratio
– 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)
1.78:1 (14/25 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)
2.00:1 (14/28 teeth)
22.5 fl. oz. (665.4ml)
21.0 fl. oz. (621.0ml)
0.025 in. (0.64mm)
0.016 in – 0.019 in. (0.406mm –
0.482mm)
0.018 in. – 0.027 in. (0.460mm –
0.686mm)
0.015 in. – 0.022 in. (0.381mm –
0.558mm)
0.018 in. – 0.023 in. (0.460mm –
0.584mm)
12 PSI Minimum @ 5500 RPM
90-824052R3 JUNE 2002 IMPORTANT INFORMATION - 1A-3
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
FUEL
SYSTEM
Fuel
Recommended Gasoline
Model 105/140 Jet/135/150
Model XR6/MAGIII/175/200
Model 150XRI/175XRI/200XRI
Model Pro Max/Super Magnum
150/200/225
Recommended Oil
All Models
Gasoline/Oil Ratio
Fuel Pressure – @ Idle
– @ WOT
Gasoline w/Oil Injection
Unleaded 87 Octane Minimum
Unleaded 92 Octane Minimum
Quicksilver TC-W3 2 Cycle Outboard Oil
Only
50:1 (25:1 Break-In)
Normal – 2-3 psi (14-21 kPa)
Minimum – 1 psi (7 kPa)
Maximum – 10 psi (69 kPa)
Normal – 8-10 psi (55–69 kPa)
Minimum – 3 psi (21 kPa)
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. Reserve Cap. Rating of 100 Min.
and CCA of 490
(MCA of 630 Amperes)
IGNITION
SYSTEM
Type
Spark Plug Type (Except 225 ProMax
and 225 Super Magnum
Spark Plug Type (225 ProMax
and 225 Super Magnum only)
Spark Plug Gap
Capacitor Discharge
NGK BU8H
Surface Gap
NGK BUZHW
Surface Gap
CHARGING
SYSTEM
Alternator Output (Regulated) 40 Amperes @ 5000 RPM
F
U
E
L
I
N
J
E
C
T
I
O
N
Idle RPM
– All Models
Wide Open Throttle (WOT) RPM
– Model 150XRI/175XRI
– Model 200XRI
– Pro Max/Super Magnum
Float Adjustment (Vapor Separator)
Float Level
Injectors
– All Models (Quantity)
– Inner Switch Box Controls:
– #1 Primary Circuit
– #3 Primary Circuit
– #5 Primary Circuit
Line Pressure @ Injectors
– 150XRI/175XRI/200XRI
– Pro Max/Super Magnum
– (S/N 0G303045 and below)
– (S/N 0G303046 and above)
650 ± 50
5000 – 5600
5000 – 5800
6200 – 6500
Preset @ Factory
6
#3 and #4 Injectors
#5 and #6 Injectors
#1 and #2 Injectors
34 PSI - 36 PSI (234 kPa - 248 kPa)
36 PSI - 39 PSI (248 kPa - 269 kPa)
34 PSI - 36 PSI (234 kPa - 248 kPa)
90-824052R3 JUNE 2002 1A-4 - IMPORTANT INFORMATION
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
C
A
R
B
U
R
E
T
O
R
Idle RPM
– Model 105/140 Jet
135/150/175/200
– Model Pro Max/Super Magnum
150/200/225
– Model XR6/MAGIII
Wide Open Throttle (WOT) RPM
– Model 105/140 Jet
135/150/175/200
– Model XR6/MAGIII
– Model Pro Max/Super Magnum
150/200/225
Idle Mixture Screw Adjustment
(Preset - Turns Out)
– All Carburetor Models
– All EFI Models
Float Adjustment
Float Level
WMH Carburetor Jets
– Model 135 (WMH 30)
– Main Jet
– Off-Idle Jet
– Idle Air Jet
– Vent Jet
– Model 105 Jet/150 (WMH 31)
– Main Jet
– Off-Idle Jet
– Idle Air Jet
– Vent Jet
– Model XR6/MAGIII (WMH 32)
– Main Jet
– Off-Idle Jet
– Idle Air Jet
– Vent Jet
– Model 175 (WMH 33)
– Main Jet
– Off-Idle Jet
– Idle Air Jet
– Vent Jet
– Model 140 Jet/200 (WMH 34/39)
– Main Jet
– Off-Idle Jet
– Idle Air Jet
– Vent Jet
650 ± 50
650 ± 50
650 ± 50
675 ± 50
5000 – 5600
5000 – 5500
5000 – 5500
6200 – 6500
1-1/2 ±1/8
Not Adjustable
Float Even with Bowl Edge w/Bowl
Inverted
.066
.050
.054
.084
.062
.050
.052
.086
.062
.040
.058
.090
.064
.050
.048
.084
Cyl. 1,2 – .066
Cyl. 3,4,5,6 – .064
.050
.046
.084
90-824052R3 JUNE 2002 IMPORTANT INFORMATION - 1A-5
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
C
A
R
B
U
R
E
T
O
R
WMV Carburetor Jets
– Model 135 (WMV 1/1A)
– Main Jet
– Idle Air Jet
– Vent Jet
– Model 105 Jet/150 (WMV 2/2A)
– Main Jet
– Idle Air Jet
– Vent Jet
– Model XR6/MAGIII (WMV 3/3A)
– Main Jet
– Idle Air Jet
– Vent Jet
– Model 175 (WMV 4/4A)
– Main Jet
– Idle Air Jet
– Vent Jet
– Model 140 Jet/200 (WMV 5/5A)
– Main Jet
– Idle Air Jet
– Vent Jet
.072
Cyl. 1,2,3,4,6 – .036; Cyl. 5 – .040
.086
.074
Cyl. 1,2,3,4,6 – .034; Cyl.5 – .038
.086
.074
Cyl. 1,2,3,4,6 – .044; Cyl.5 – .048
.082
.078
Cyl. 1,2,3,4,6 – .030; Cyl.5 – .034
.086
Cyl 1,2 – .082
Cyl. 3,4,5,6 – .080
Cyl 1,2 – .052
Cyl. 3,4,6 – .028
Cyl. 5 – .032
.096
90-824052R3 JUNE 2002 1A-6 - IMPORTANT INFORMATION
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
T
I
M
I
N
G
Idle Speed/Pickup Timing
– 105 JET/135/150 Carb Models
– XR6/MAG III/175 Carb
– 140 Jet/200 Carb
– All Pro Max/Super Magnum
– 150XRI/175 XRI Models
– 200 XRI Model
Maximum BTDC
– Model 105 Jet/135/150
@ Cranking Speed
@ WOT RPM
– XR6/MAG III/175 Carb
– 175 XRI
– Pro Max/Super Magnum 150
@ Cranking Speed
@ WOT RPM
– 150 XRI
@ Cranking Speed
@ WOT RPM
– 140 Jet/200 Carb
Models with Spark Advance
Module
@ Cranking Speed
@ WOT RPM
Models with Idle Stabilizer
Module
@ Cranking Speed
@ WOT RPM
– Model 200XRI
@ Cranking Speed
@ 5800 RPM
– Pro Max/Super Magnum 200
@ Cranking Speed
– Pro Max/Super Magnum 225
@ 3000 RPM
2° – 9° ATDC
0° – 9° ATDC
21° BTDC
19° BTDC
20° BTDC
19° BTDC
15° BTDC
16° BTDC
21° BTDC
25° BTDC
22° BTDC
20° BTDC
16° BTDC
22° BTDC
With Spark Advance Box – 20° BTDC
Without Spark Advance Box – 25° BTDC
23° BTDC
NOTE: Timing specifications listed are for 1998 model year engines. Refer to timing decal on engine for previous
model year timing specifications.
90-824052R3 JUNE 2002 IMPORTANT INFORMATION - 1A-7
Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI
PRO MAX/SUPER MAGNUM 150/200/225
OIL
INJECTION
Recommended Oil (All Models)
Hi-Perf. Pro Max/Super Magnum
Oil Tank Capacity
Approx. Time
– Model 105 Jet/135/150
– Model 140 Jet/XR6/MAGIII/175/200
– Model 150XRI/175XRI/200XRI/Pro
Max/Super Magnum 150/200/225
Reserve Capacity/Approx. Time
Output @ 1000 RPM for 3 Minutes
with Pump @ Full Open
– Model 105 Jet/135/150
– Model 140 Jet/XR6/MAG III/175/200
– Model 150XRI/175XRI/200XRI/Pro
Max/Super Magnum 150/200/225
Quicksilver TC-W3
Quicksilver TC-W3
3 gal. (11.4Liter)
8.7 hrs. Approx.
6.6 hrs. Approx.
6.6 hrs. Approx.
.94 qt. (0.89Liter) 30 – 35 min.
12cc @ 1000 RPM
15cc @ 1000 RPM
15cc @ 1000 RPM
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What's Included?
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Fast Download Speeds
Offline Viewing
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Full Search Facility
Print one or all pages of your manual
$39.99
This manual is a comprehensive guide covering the 135 150 175 200 2-stroke models manufactured between 2000 and 2002. It includes detailed information on overhauls and maintenance for all systems including fuel, electrical, cooling, controls, powerhead power trim and tilt, upper and lower units, specifications, full-color wiring diagrams, and more. The manual is fully illustrated with photos and exploded views, making it an invaluable resource for both professional mechanics and DIY enthusiasts. Additionally, it is fully indexed and bookmarked for easy navigation, and allows for the convenient printing of any or all pages.
