Mercury Mariner Outboard 75 / 75 MARATHON / 75 SEA PRO 90 / 100 / 115 / 125 / 65/80 JET Service Repair Manual
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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
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What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$30.99
This service repair manual is a comprehensive guide for the Mercury Mariner Outboard 75 / 75 MARATHON / 75 SEA PRO 90 / 100 / 115 / 125 / 65/80 JET models with serial numbers above 0D283222 (United States) and 09793577 (Belgium).
It includes detailed service and repair procedures, assembly and disassembly instructions, as well as essential wiring diagrams for maintenance and repair.
The manual covers the following sections:
- Section 1 - Important Information
- Specifications
- Maintenance
- General Information
- Outboard Installation
- Section 2 - Electrical
- Ignition
- Charging & Starting System
- Timing, Synchronizing & Adjusting
- Wiring Diagrams
- Section 3 - Fuel System
- Fuel Pump
- Carburetor
- Oil Injection
- Emissions
- Section 4 - Powerhead
- Section 5 - Mid-Section
- Clamp/Swivel Brackets & Drive Shaft Housing
- Power Trim (S/N-USA 0G360002/BEL-9934136 and Below)
- Power Trim (S/N-USA 0G360003/BEL-9934137 and Above)
- Shock Absorber
- Manual Tilt
- Section 6 - Lower Unit
- Lower Unit
- Jet Drive
- Section 7 - Attachments/Control Linkage
- Throttle/Shift Linkage
- Tiller Handle
- Section 8 - Manual Starter
This high-quality manual is available in English and is compatible with all versions of Windows, Mac, and Linux. It is provided in PDF format, allowing for easy printing of all pages without any shipping costs or the need to wait for a CD-ROM.
