1994-1997 Mercury Mariner 75HP-275HP Outboard Service & Repair Manual

Quick Reference Data RECOMMENDED SPARK PLUGS Model 75,90 hp and 65 Jet 100,115,125 hp and 80 Jet 135-200 hp, 105 and 140 Jet 200 DR (direct fuel Injected) 225 hp (carbureted 1994-1996) 225 hp (carbureted 1997) 225-250 hp EFI (electronic fuel injection) 275 hp *Use resistor or suppression NQK spark plug number (RFQ* BUHW-2 (BUZHW-2) BP8H-N-10(BPZ8H-N-10) BU8H(BUZ8H) Champion RC10ECC Use resistor (BPZ8H-N-10) Champion QL77CC Champion QL77CC BU8H (BUZ8H) spark plugs if radio frequency interference (RFI) Clap In. (min) NA .040(1.02) NA .040(1.02) .040(1.02) .035 (0.89) .035 (0.89) NA suppression is required. GEARCASE GEAR RATIO AND APPROXIMATE LUBRICANT CAPACITY Model 75 and 90 hp 100,115 and 125 hp 135 and 150 hp XR6 and Magnum III (smali gearcase) XR6 and Magnum III (large gearcase) 150-200 XRi, 175-200 hp 200 DFi (direct fuel injection) 225-250 hp (1994) 225-250 hp (1995-1997) 275 hp Gear ratio 2.3:1 2.07:1 2.00:1 1.78:1 1.87:1 1.87:1 1.75:1 1.64:1 1.75:1 1.64:1 Tooth count 13:30 14:29 14:28 14:25 15:28 15:28 12:21 17:28 12:21 17:28 Lubricant capacity 22.5 oz. (665 mi) 22.5 oz. (665 mi) 22.5 oz. (665 mi) 21.0oz.(621 ml) 22.5 oz. (665 ml) 22.5 oz. (665 ml) 28.0 oz. (828 mi) 28.0 oz. (828 mi) 28.0 oz. (828 ml) 29.0 oz. (858 ml) RECOMMENDED LUBRICANTS, SEALANTS AND ADHESIVES Lubricants Quicksilver 2-Cycie TC-W3 outboard oil Quicksilver Special Lubricant 101 Quicksilver 2-4-C Multi-Lube Quicksilver Anti-Corrosion Grease Quicksilver Needie Bearing Grease Quicksilver Power Trim and Steering Fluid Quicksilver Premium Biend Gear Lube Quicksilver High Performance Gear Lube Part No. (deaier stock Item) 92-13872A-1 (dealer stock item) 92-78376A-6 92-825265A-1 92-90100 A l 2 (dealer stock item) (dealer stock item) (continued) IX

RECOMMENDED LUBRICANTS, Seaiants Quicksilver Perfect Seal Loctite 5900 Ultra black RTV sealant Sealer (crankcase halves) Loctite Master Gasket Sealer Quicksliver Liquid Neoprene Loctite 567 PST pipe sealant Quicksiiver Bellows Adhesive Quicksilver Ignition Coil Insulation Compound Adhesives Locquic Primer Loctite 271 threadiocking seaiant (high strength) Loctite 242 threadiocking sealant (medium strength) Loctite RC680 high strength retaining compound Misceiianeous Quicksiiver Power Tune Engine Cleaner Quicksiiver Corrosion Guard Quicksilver Storage Seal Rust inhibitor Quicksilver Dieiectric silicone grease SEALANTS AND ADHESiVES (continued) Part No. 92-34227-1 92-809826 92-90113-2 92-12564-2 92-25711-2 92-809822 92-86166-1 92-41669-1 92-809824 92-809819 92-809821 92-809833 92-15104A12 92-815869A12 92-86145 Al 2 92-823506-1 Mercury outboard modeis 75 hp 90 hp 100 hp 115 hp 125 hp 135 hp 150 hp 175 hp 200 hp 200 DFI 225 hp 250 EFI 275 hp Mercury Jet models Jet65hp Jet 80 hp Jet 105 hp Jet 140 hp Mariner outboard models 75 hp 90 hp 100 hp 115 hp STARTING SERIAL NUMBER 1994 0D283222 0D283222 0D283222 0D283222 0D283222 0D284788 0D284788 0D284788 0D284788 0D280813 — 0D280900 0G052651 0G052652 0G052656 0G052657 0D283222 0D283222 0D283222 0D283222 1995 0G077367 0G077369 0G090125 0G127522 0G090127 0G127861 0G129272 0G129337 0G077376 0G077384 — - 0G077369 0G127529 0G129884 0G129601 0G127540 0G127561 0G127812 0G127500 (continued) LISTING 1996 0G301751 0G301751 0G301751 0G301751 0G301751 0G303046 0G303046 0G303046 0G303046 0G386496 0G303046 0G303046 - 0G301804 0G302040 0G304512 0G304134 0G301751 0G301751 0G302262 0G301751 1997 0G438000 OG438000 0G438000 0G438000 0G438000 0G438000 0G438OOO 0G438000 0G438000 0G438000 0G438000 OG438000 0G438000 0G438000 0G438000 0G438000 0G438000 0G438000 0G438000 0G438000

Mariner outboard modeis (continued) 125 hp 135 hp 150 hp 175 hp 200 hp 200 DFi 225 hp 250 EFI 275 hp Mariner Jet modeis Jet 65 HP Jet 80 HP Jet 105 HP Jet 140 HP STARTING SERIAL 1994 0D283222 0D284788 0D284788 0D284788 0D284788 - 0D280813 - 0D280900 0G052651 0G052652 0G052656 0G052657 NUMBER LISTING 1995 0G127766 0G129222 0G129477 0G129394 0G129303 - 0G106786 - 0G127642 0G127629 0G129872 0G129675 (continued) 1996 0G301751 0G303046 0G303046 0G303046 0G303046 0G386496 0G303046 0G303046 — 0G302037 0G301751 0G325593 0G303046 1997 0G438000 0G438000 OG438000 0G438000 0G438000 0G438000 0G438000 0G438000 0G438000 0G438000 0G438000 0G438000 XI

Chapter One General Information This detailed, comprehensive manual contains complete information covering maintenance, repair and overhaul. Hundreds of photos and drawings guide you throughout every procedure. Troubleshooting, tune-up, maintenance and repair are not difficult if you know what tools and equipment to use and what to do. Anyone not afraid to get their hands dirty, of average in- telligence and with some mechanical ability can perform most ofthe procedures in this manual. See Chapter Two for more information on tools and techniques. A shop manual is a reference. You want to be able to find information quickly. Clymer books are designed with you in mind. All chapters are thumb tabbed and important items are indexed at the end ofthe manual. All procedures, tables, photos and instructions in this manual assume the reader may be working on the machine or using the manual for the first time. Keep the manual in a handy place in your tool- box or boat. It will help you to better understand how your boat runs, lower repair and maintenance costs and generally increase your enjoyment of your boat. MANUAL ORGANIZATION This chapter provides general information useful to boat owners and marine mechanics. Chapter Two discusses the tools and techniques for preventative maintenance, troubleshooting and repair. Chapter Three provides troubleshooting and testing procedures for all systems and individual components. Following chapters describe specific systems, providing disassembly, inspection, assembly and adjustment procedures in simple step-by- step form. Specifications concerning a specific system are included at the end ofthe appropriate chapter.

CHAPTER ONE NOTES, CAUTIONS AND WARNINGS The terms NOTE, CAUTION and WARNING have specific meanings in this manual. A NOTE provides additional information to make a step or procedure easier or more clear. Disregarding a NOTE could cause inconvenience, but would not cause damage or personal injury. A CAUTION emphasizes areas where equipment damage could cause permanent mechanical damage; however, personal injury is unlikely. A WARNING emphasizes areas where personal injury or even death could result from neg- ligence. Mechanical damage may also occur. WARNINGS must be taken seriously. In some cases, serious injury or death has resulted from disregarding similar warnings. TORQUE SPECIFICATIONS Torque specifications throughout this manual are given in foot-pounds (ft.-lb.), inch-pounds (in.-lb.) and newton meters (N»m.). Newton meters are being adopted in place of me- ter-kilograms (mkg) in accordance with the International Modernized Metric System. Ex- isting torque wrenches calibrated in me- ter-kilograms can be used by performing a simple conversion: move the decimal point one place to the right. For example, 4.7 mkg = 47 N»m. This conversion is accurate enough for most mechanical operations even though the ex- act mathematical conversion is 3.5 mkg = 34.3 N*m. ENGINE OPERATION All marine engines, whether two or four-stroke, gasoline or diesel, operate on the Otto cycle of intake, compression, power and exhaust phases. Two-Stroke Cycle A two-stroke engine requires one crankshaft revolution (two strokes of the piston) to complete the Otto cycle. All engines covered in this manual are a two-stroke design. Figure 1 shows gasoline two-stroke engine operation. Four-Stroke Cycle A four-stroke engine requires two crankshaft revolutions (four strokes of the piston) to complete the Otto cycle. Figure 2 shows gasoline four-stroke engine operation. FASTENERS The material and design of the various fasteners used on marine equipment are carefully thought out and designed. Fastener design deter- mines the type of tool required to work with the fastener. Fastener material is carefully selected to decrease the possibility of physical failure or corrosion. See Galvanic Corrosion in this chapter for information on marine materials. Nuts, bolts and screws are manufactured in a wide range of thread patterns. To join a nut and bolt, the diameter of the bolt and the diameter of the hole in the nut must be the same. It is just as important that the threads are compatible. The easiest way to determine if fastener threads are compatible is to tum the nut on the bolt, or bolt into its threaded opening, using fin- gers only. Be sure both pieces are clean. If much force is required, check the thread condition on each fastener. If the thread condition is good but the fasteners jam, the threads are not compatible. Four important specifications describe the thread: 1. Diameter. 2. Threads per inch. 3. Thread pattern.

GENERAL INFORMATION © TWO-STROKE OPERATING PRINCIPLES As the piston travels downward, it uncovers the exhaust port (A) allowing the exhaust gases to leave the cylinder. A fresh air-fuei charge, which has been compressed slightly in the crankcase, enters the cylinder through the transfer port (B). Since this charge enters under pressure, it also helps to push out the exhaust gases. r While the cranicshaft continues to rotate, the piston moves upward, covering the transfer (B) and exhaust (A) ports. The piston compresses the new air-fuel mixture and creates a low-pressure area in the crankcase at the same time. As the piston continues to travel, it uncovers the intake port (C). A fresh air-fuel charge from the carburetor (D) is drawn into the crankcase through the intake port. As the piston aimost reaches the top of the travel, the spark plug fires, igniting the compressed air-fuel mixture. The piston continues to top dead center (TDC) and is pushed downward by the expanding gases. r As the piston traveis down, the exhaust gases leave the cylinder and the complete cy< cie starts all over again.

CHAPTER ONE FOUR-STROKE GASOLINE OPERATING PRINCIPLES intake valve As the piston travels downward, the exhaust valve Is closed and the intake vaive opens, allowing the new air-fuel mixture from the carburetor to be drawn Into the cyiinder. When the piston reaches the bottom dead center (BDC), the intake valve closes and remains closed for the next 11/2 revoiu- tions of the crankshaft. Spark plug As the piston aimost reaches the top of its travel, the spark plug fires, igniting the compressed alr-fuei mixture. The piston continues to top dead center (TDC) and is pushed downward by expanding gases. Whiie the crankshaft continues to rotate, the piston moves upward, compressing the air-fuei mixture. Exhaust vaive When the piston aimost reaches BDC, the exhaust valve opens and remains open until the piston Is near TDC. The upward travel of the piston forces the exhaust gases out of the cyiinder. After the piston has reached TDC, the exhaust vaive cioses and the cycie starts aii over again.

GENERAL INFORMATION Hex Flat MACHINE SCREWS Oval Fllister Round 4. Thread direction Figure 3 shows the first two specifications. Thread pattern is more subtle. Italian and British standards exist, but the most commonly used by marine equipment manufactures are American standard and metric standard. The root and top of the thread are cut differently as shown in Fig- ure 4. Most threads are cut so the fastener must be turned clockwise to tighten it. These are called right-hand threads. Some fasteners have left-hand threads; they must be turned counterclockwise to tighten. Left-hand threads are used in locations where normal rotation of the equipment would tend to loosen a right-hand threaded fastener. As- sume all fasteners use right-hand threads unless the instructions specify otherwise. Machine Screws There are many different types of machine screws (Figure 5). Most are designed to pro- trude above the secured surface (rounded head) or be slightly recessed below the surface (flat head). In some applications the screw head is recessed well below the fastened sur-

CHAPTER ONE © OPENINGS FOR TURNING TOOLS Slotted Phillips Allen Internai torx External torx face. Figure 6 shows a number of screw heads requiring different types of turning tools. Bolts Commonly called bolts, the technical name for this fastener is cap screw. They are normally described by diameter, threads per inch and length. For example, 1/4-20 x 1 indicates a bolt 1/4 in. in diameter with 20 threads per inch, 1 in. long. The measurement across two flats of the bolt head indicates the proper wrench size required to tum the bolt. Nuts Nuts are manufactured in a variety of types and sizes. Most are hexagonal (six-sides) and fit on bolts, screws and studs with the same diameter and threads per inch. Figure 7 shows several types of nuts. The common nut is usually used with some type of lockwasher. Self-locking nuts have a nylon insert that helps prevent the nut from loosening; no lockwasher is required. Wing nuts are designed for fast removal by hand. Wing nuts are used for convenience in non-critical locations. To indicate the size of a nut, manufactures specify the diameter of the opening and the threads per inch. This is similar to a bolt specifi- © Common nut Self-iocking nut Wing nut cation, but without the length dimension. The measurement across two flats of the nut indicates the wrench size required to tum the nut. Washers There are two basic types of washers: flat washers and lockwashers. A flat washer is a simple disc with a hole that fits the screw or bolt. Lockwashers are designed to prevent a fastener from working loose due to vibration, expansion and contraction. Figure 8 shows several types of lockwashers. Note that flat washers are often

GENERAL INFORMATION Piain Foiding Internal tooth External tooth © Correct installation of cotter pin used between a lockwasher and a fastener to provide a smooth bearing surface. This allows the fastener to be tumed easily with a tool. Cotter Pins In certain applications, a fastener must be secured so it cannot possibly loosen. The propeller nut on some marine drive systems is one such ap- oo Internal snap ring Plain circlip External snap ring Plain circlip plication. For this purpose, a cotter pin (Figure 9) and slotted or castellated nut is often used. To use a cotter pin, first make sure the pin fits snugly, but not too tight. Then, align a slot in the fastener with the hole in the bolt or axle. Insert the cotter pin through the nut and bolt or propeller shaft and bend the ends over to secure the cotter pin tightly. If the holes do not align, tighten the nut just enough to obtain the proper alignment. Unless specifically instructed to do so, never loosen the fastener to align the slot and hole. Because the cotter pin is weakened after installation and removal, never reuse a cotter pin. Cotter pins are available in several styles, lengths and diameters. Measure cotter pin length from the bottom of its head to the tip of its shortest prong. Snap Rings Snap rings (Figure 10) can be an intemal or extemal design. They are used to retain components on shafts (extemal type) or inside openings (intemal type). Snap rings can be reused if they are not distorted during removal. In some applications, snap rings of varying thickness

1994-1997 Mercury Mariner 75HP-275HP Outboard Service & Repair Manual

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Model	Starting Serial Numbers
Model	1994	1995	1996	1997
Mercury 75 hp	0D283222	0G073767	0G301751	0G438000
Mercury 90 hp	0D283222	0G073769	0G301751	0G438000
Mercury 100 hp	0D283222	0G127522	0G301751	0G438000
Mercury 115 hp	0D283222	0G090167	0G301751	0G438000
Mercury 125 hp	0D283222	0G127661	0G301751	0G438000
Mercury 135 hp	0D284788	0G129272	0G303046	0G438000
Mercury 150 hp	0D284788	0G129377	0G303046	0G438000
Mercury 175 hp	0D284788	0G129337	0G303046	0G438000
Mercury 200 hp	0D284788	0G129302	0G303046	0G438000
Mercury 200 DFI	–	0G077376	0G386496	0G438000
Mercury 225 hp	0D280813	0G077384	0G303046	0G438000
Mercury 250 EFI	–	–	0G303046	0G438000
Mercury 275 hp	0D280900	–	–	0G438000
Mercury Jet 65 hp	0G52651	0G07369	0G301804	0G438000
Mercury Jet 80 hp	0G127529	0G127529	0G301751	0G438000
Mercury Jet 105 hp	0G052565	0G129884	0G304512	0G438000
Mercury Jet 140 hp	0G052567	0G129601	0G325593	0G438000
Mariner 75 hp	0D283222	0G127540	0G301751	0G438000
Mariner 90 hp	0D283222	0G127561	0G301751	0G438000
Mariner 100 hp	0D283222	0G127812	0G302262	0G438000
Mariner 115 hp	0D283222	0G127500	0G301751	0G438000
Mariner 125 hp	0D283222	0G127766	0G301751	0G438000
Mariner 135 hp	0D284788	0G129222	0G303046	0G438000
Mariner 150 hp	0D284788	0G129477	0G303046	0G438000
Mariner 175 hp	0D284788	0G129934	0G303046	0G438000
Mariner 200 hp	0D284788	0G129303	0G303046	0G438000
Mariner 200 DFI	–	–	0G386496	0G438000
Mariner 225 hp	0D280813	0G106786	0G303046	0G438000
Mariner 250 EFI	–	–	0G303046	0G438000
Mariner 275 hp	0D280900	–	–	0G438000
Mariner Jet 65 hp	0G052651	0G127642	0G302037	0G438000
Mariner Jet 80 hp	0G052652	0G127629	0G301751	0G438000
Mariner Jet 105 hp	0G052656	0G129872	0G325593	0G438000
Mariner Jet 140 hp	0G052657	0G129675	0G303046	0G438000