The 1997-1998 Mercury/Mariner Outboard Marine Service Manual/Repair Manual covers the following models: 200HP (200 HP) Optimax DFI & 225HP (225 HP) Optimax DFI Engine.
The service manual for the above listed Mercury Outboard models describes the service procedures for the complete outboard. It is useful for both professional mechanics and DIY enthusiasts. Following the Maintenance Schedule recommendations is crucial to ensure the engine is in peak operating condition. Performing the scheduled maintenance compensates for the initial wear that occurs during the life of the motor.
All chapters in the service manuals apply to the whole engine and illustrate procedures for removal & installation of components in a detailed step-by-step fashion.
Most service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, pictures, service information, and troubleshooting for the section. The subsequent pages give detailed procedures. This is a simple to book, just like any book you would buy in a store except this book is delivered to you instantly upon purchase. No special software required as this manual works on all computers. The manual is in PDF format and delivered in PDF format.
SPECIFICATIONS
Overall length
Overall width
Weight
Transom height
Recommended operating range
Idle speed
Engine type
DOHC
Number of cylinders
Total displacement
Spark plug
Fuel supply system
Multi-point sequential electronic fuel injection
Exhaust system
Cooling system
Water cooled
Lubrication system
Wet sump
Starting system
Electric Lower Unit
Fuel recommendations
Outboard Motor Gear Oil
Gearcase oil capacity ml
Maximum tilt angle degree
Transmission Forward-Neutral-Reverse
Propeller shaft rotation
Propeller Right-hand rotation
Propeller Counter rotation
Cylinder compression
Engine oil pressure
Viscosity rating
Engine oil amounts
Oil filter change
Piston
Piston Rings
Thermostat operating temperature and much more.
MAINTENANCE
Complete maintenance specs
Maintenance charts
Intervals and recommendations
Step by step procedures for the following:
Spark plug
Fuel line
Replace fuel hose
Breather hose
Engine oil
Gear oil
Lubrication
Anodes & Bonding wires
Battery
Fuel mixture check
Engine oil filter
Low pressure fuel filter
High pressure fuel filter
Ignition timing
Idle speed
Tappet clearance
Water pump
Propeller nut & pin
Balancer chain
Bolt & Nuts
Timing Belt Inspection
Lubrication Points
Changing Engine Oil
Oil Draining Procedure
Changing Oil Filter
Oil Filling and much more.
GENERAL INFORMATION
Identification Numbers
Tightening Torque
Service Data
Specifications
Cylinder Number
Propellers
Gas (gasoline Recommendations)
87 91 92 93 Race Gas
Warm-Up Recommendations
ELECTRICAL
Electrical parts holder removal and installation
Inspection, removal, installation, troubleshooting outline of monitor tachometer starter motor
Electric starter system
Battery charging system
Disassembly Cleaning Testing
Brush Replacement
Reassembly
Battery Charging System Manual Start
Battery Charging System Tests
Testing The Battery Charging Coil
Testing The Battery Charging System
Testing The Rectifier/Regulator
IGNITION
Specifications
Special Tools
Checking Ignition Timing
Type Spark Plug
Firing Order
Ignition Timing
Charge Coil Resistance
Crank Position Sensor Resistance
Ignition Coil Resistance
ECM Engine Speed Limiter
Spark Cut-Out Reduction ignition spark
ECM Low Oil Pressure Speed Control
Oil Pressure Switch and more.
CARBURETOR
Specifications
Special Tools
Intake Carburetor Adjustments
Idle Speed Linkage Choke
Carburetor Removal
Carburetor Disassembly
Cleaning/Inspection/Repair
Carburetor Reassembly
Float Height Measurement
Carburetor Installation
Electric Choke Models Installation
Idle rpm (Out Of Gear)
Idle rpm (In Forward Gear)
Wide Open Throttle rpm (WOT)
Main Jet Size
Pilot Jet Main Jet Size
Float Height 950 ± 50 rpm
850 ± 50 rpm
4500-5500
5200-5700
500-1000 rpm
1200-1500 rpm
1500-2000 rpm
2200 2500 rpm
3000-3500 rpm and much more.
EFI SYSTEM
Specifications
Fuel Injection Nozzle
Fuel Injection Pump
Throttle Body
Throttle Control Lever and Linkage
High Pressure Fuel Line
High-Pressure Fuel Line
Fuel Cooler
Fuel Hoses
Fuel Rail Pressure Regulator
Idle Speed Control Assembly
Intake Manifold
Throttle Position Sensor
Low Pressure Fuel Line/Fuel Pump
Fuel Filter
Fuel Pump and more.
POWERHEAD (POWER HEAD)
Cylinder head cover
Intake manifold assembly
Ring gear cover and air intake
Power unit (powerhead)
Measuring pump components
Oil pump
Engine lubrication system
Thermostat
Cylinder crankshaft
Piston counter balancer mechanism
Cylinder head assembly removal inspection installation
MID-SECTION
Engine side cover
Driveshaft housing and oil pan
Swivel bracket
Steering bracket and clamp
Water pressure valve
Lower unit gear housing and all inspection removal installation cleaning assembly and reassembly procedures.
LOWER UNIT
Gear case
Propeller lower unit gears shimming and adjustment
Trim tab drive shaft and oil seal housing
Water pump and related items
Shift guide housing propeller shaft components gear bearing propeller shaft gear housing and more.
Other Chapters
Attachments/Control Linkage
Throttle/Shift Linkage
Tiller Handle
Manual Starter
Diagnostic Troubleshooting
Wiring Diagrams
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