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)
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1990-2002 Mercury Outboard Motors Service & Repair Manual
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Description
The 1990-2002 Mercury Outboard Motors Service & Repair Manual covers all 1990 to 2002 Mercury 2 and 4 stroke engines up to 300 horsepower, including Optimax and Jet models. This comprehensive manual is designed for both professional mechanics and DIY enthusiasts.
The manual includes detailed service instructions for:
- 15 service manuals for 2 stroke engines ranging from 2.2 hp to 250 hp, including models such as the 150, 175, 200, 225, 250, and the 3.0 Litre EFI engines.
- 13 service manuals for 4 stroke engines ranging from 4 hp to 225 hp.
- 4 service manuals for Optimax engines ranging from 115 to 225 hp.
- 7 service manuals for Jet engines covering 90 to 250 hp.
This CD Rom edition contains over 39 complete Mercury manuals. It is packed with exploded views, schematic diagrams, assembly/disassembly instructions, scheduled maintenance guidelines, diagnostic procedures, and thousands of pages of high-quality diagrams and repair instructions for thorough servicing of your outboard motor.
