PDF Service Manual Mercury Mariner 135HP 150HP 175HP 200HP Outboards - 2 MB
This service manual covers a range of Mercury Mariner outboard motors, from 135HP to 200HP.
It's an essential tool for boat owners and marine mechanics, providing step-by-step instructions for maintenance and repair.
The manual details everything from basic tune-ups to complete engine overhauls, ensuring your outboard runs reliably and efficiently.
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--- Page 1 ---
SERVICE
MANUAL
MODELS
135 • 150 • 175 • 200
With Serial Numbers
United States . . . . . . 0G960500 and Above
Printed in U.S.A. 2000, Mercury Marine 90-878079 JANUARY 2000
--- Page 3 ---
MAINTENANCE
Special Tools
1. Grease Gun 91-37299A1
2. Flushing Attachment 44357A2
Quicksilver Lubricant/Sealant
1. Gear Lubricant - Premium Blend 92-850737A1
2. Anti-Corrosion Grease 92-850735A1
Page 1B-2 90-878079 JANUARY 2000
--- Page 4 ---
MAINTENANCE
Gear Case Lubrication
When adding or changing gear case lubricant, visually check for the presence of water
in the lubricant. If water is present, it may have settled to the bottom and will drain out prior
to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
If water is noticed, have the gear case checked by your dealer.Water in the lubricant may
result in premature bearing failure or, in freezing temperatures, will turn to ice and damage
the gear case.
DRAINING GEAR CASE
NOTE: Some models may have the vent and fill/drain plugs on the opposite side.
1. Place outboard in a vertical operating position.
2. Place drain pan below outboard.
3. Remove vent plug and fill/drain plug and drain lubricant.
3
2 1
GEAR CASE LUBRICANT CAPACITY
Gear case lubricant capacity is approximately 22.5 fl. oz. (665 ml).
Page 1B-12 90-878079 JANUARY 2000
--- Page 5 ---
GENERAL INFORMATION
a. Remove remote oil hose (black without blue stripe) from pulse fitting on starboard
side of engine.
b. Drain any water from hose and reconnect.
c. If water was present in hose, check for water in the remote oil tank. Drain tank if
water is present.
15. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for
at least one hour to eliminate any water in engine.
16. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should
be run within 2 hours after recovery of outboard from water, or serious internal dam-
age may occur. If unable to start engine in this period, disassemble engine and clean
all parts. Apply oil as soon as possible.
90-878079 JANUARY 2000 Page 1C-7
--- Page 6 ---
GENERAL INFORMATION
Model 150 XRI/175 XRI/200 XRI Powerhead Aft View
13
17
12
1
14
2
11
3
10
4
12
9
5
15
8
16
6 7
58030
1 - Port Thermostat [143°F (61.7°C)] 10 - #3 CDM
2 - Temperature Sensor (Temperature Gauge) 11 - #1 CDM
3 - #2 CDM 12 - Water By-Pass Hose to Poppet Valve Cover
4 - #4 CDM 13 - Starboard Thermostat [143°F (61.7°C)]
5 - #6 CDM 14 - Temperature Sensor (Engine Overheat)
6 - Thermostat Outlet Hose to Adaptor Plate 15 - Water Pressure Gauge Hose
7 - Cylinder Block Flush Hose 16 - Trim Motor Bullet Connectors
8 - Tell–Tale Hose 17 - Detonation Sensor
9 - #5 CDM
90-878079 JANUARY 2000 Page 1C-17
--- Page 7 ---
OUTBOARD MOTOR INSTALLATION
Battery Cables
SINGLE OUTBOARD
a
(+)
b
c
(–)
a - RED Sleeve (Positive)
b - BLACK Sleeve (Negative)
c - Starting Battery
DUAL OUTBOARD
Connect a common ground cable (wire size same as engine battery cables) between
NEGATIVE (–) terminals on starting batteries.
(–)
d
(–)
d - Common Ground Cable
90-878079 JANUARY 2000 Page 1D-7
--- Page 8 ---
OUTBOARD MOTOR INSTALLATION
If adjustment is necessary, loosen trim tab bolt until trim tab moves freely (does not rub
against locking ridges). DO NOT strike tab to make adjustments. Make small adjustments
at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the
left. If the boat turns more easily to the right move the trailing edge of trim tab to the right.
Position trim tab in one of the locating grooves BEFORE tightening bolt to prevent dam-
age to holding mechanism. Torque bolt to 40 lb-ft (54 Nm) and retest.
Models With Power Steering
Trim tab adjustment is not required. The trailing edge of the trim tab should be set straight
back.
90-878079 JANUARY 2000 Page 1D-17
--- Page 9 ---
IGNITION
CDM Mounting
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 POWER HARNESS
2 1 COVER
3 3 FUSE
4 3 STA STRAP
5 2 CLIP
6 1 CDM MOUNTING PLATE
7 4 SCREW (.312-18 x 1-1/4) 20 27
8 4 WASHER
9 4 GROMMET
10 4 BUSHING
11 15 SCREW (M6 x 16) 70 8
12 2 CABLE
13 6 CDM
14 6 SPARK PLUG (NGK#BPZ8HS10) 20 27
15 1 CDM HARNESS
16 1 CABLE
17 1 CLIP
18 1 ENGINE HARNESS
90-878079 JANUARY 2000 Page 2A-9
--- Page 10 ---
IGNITION
CDM Stop Diode Trouble Shooting (Con’t)
2.0/2.5 Litre 6 Cyl.:
CDM #1, #2 and #3 get their charging ground path through CDM #4, #5 or #6
CDM #4, #5 and #6 get their charging ground path through CDM #1, #2 or #3
A shorted Stop Diode in CDM #1, #2 or #3 would prevent CDMs #4, #5 and #6 from spark-
ing.
A shorted Stop Diode in CDM #4, #5 or #6 would prevent CDMs #1, #2 and #3 from spark-
ing.
1 2 3 4 5 6
3.0 Litre 6 Cyl.:
All CDMs get their charging ground path independently through the stator’s white leads.
A shorted Stop Diode in any one CDM will prevent at least 2 other CDMs from sparking.
1 3 5 2 4 6
90-878079 JANUARY 2000 Page 2A-19
--- Page 11 ---
IGNITION
ENGINE RUNNING AT 2500 RPM
It is not necessary to perform this test if the voltage output was tested in the previous step.
Stator Output Test 400 DVA Scale
Positive Meter Lead (+) Negative DVA
Meter Lead (–) Reading
Connect to Green Test Connect to Black Test Har-
Harness Lead ness Lead 160 - 320
If stator output is low, go to “Testing Stator Resistance”.
CDM Trigger Input Test 20 DVA Scale
Positive Meter Lead (+) Negative DVA
Meter Lead (–) Reading @ Idle to 2500
RPM
White Test Harness Lead Black Test Harness Lead 2 - 8 Volts
If reading is below specifications, go to “Testing Trigger Resistance”. If reading is above
specifications, check CDM and ground connections.
2.0/2.5L V-6 Models Only - Check control module bias circuit
Bias Circuit Test (All Models Except 200 EFI) 40 DVA Scale
@2500 RPM
Positive Meter Lead (+) Negative DVA
Meter Lead (–) Reading
Engine Ground Black/White Shift Switch
Wire 25 - 40 Volts
Bias Circuit Test (200 EFI) 40 DVA Scale
@2500 RPM
Positive Meter Lead (+) Negative DVA
Meter Lead (–) Reading
Engine Ground Disconnect 4 wire Detona-
tion Control Module con- 25 - 40 Volts
nector. Insert bent paper
clip into Black/White termi-
nal.
If reading is below specifications, replace control module.
90-878079 JANUARY 2000 Page 2A-29
--- Page 12 ---
IGNITION
Detonation Module Removal (200 XRI only)
1. Remove detonation sensor lead from sensor.
2. Disconnect detonation module harness connector.
3. Remove 3 bolts securing module and remove module.
a
d
b
c
e
58052
a - Sensor Lead d - Bolts (3)
b - Sensor e - Detonation Module
c - Harness Connector
Detonation Module Installation
1. Secure module with 3 bolts. Torque bolts to 30 lb. in. (3.4 Nm).
2. Reconnect 3 harness connectors.
3. Reconnect sensor lead to sensor.
90-878079 JANUARY 2000 Page 2A-39
--- Page 13 ---
CHARGING & STARTING SYSTEM
1. Remove battery from its installation as soon as possible and remove all grease, sul-
fate and dirt from top surface by running water over top of battery. Be sure, however,
that vent caps are tight beforehand, and blow off all excess water thoroughly with com-
pressed air. Check water level, making sure that plates are covered.
2. When adding distilled water to battery, be extremely careful not to fill more than 3/16
in. (4.8 mm) above perforated baffles inside battery. Battery solution or electrolyte ex-
pands from heat caused by charging. Overfilling battery will cause electrolyte to over-
flow (if filled beyond 3/16″ above baffles).
3. Grease terminal bolts well with 2-4-C Marine Lubricant and store battery in a COOL-
DRY place. Remove battery from storage every 30-45 days, check water level and
put on charge for 5 or 6 hours at 6 amperes. DO NOT FAST CHARGE.
4. If specific gravity drops below 1.240, check battery for reason and recharge. When
gravity reaches 1.260, discontinue charging. To check specific gravity, use a hydrom-
eter, which can be purchased locally.
5. Repeat preceding charging procedure every 30-45 days, as long as battery is in stor-
age, for best possible maintenance during inactive periods to ensure a good service-
able battery in spring. When ready to place battery back in service, remove excess
grease from terminals (a small amount is desirable on terminals at all times), recharge
again as necessary and reinstall battery.
Flywheel Removal and Installation
Removal
1. Remove flywheel cover from engine.
WARNING
Engine could possibly start when turning flywheel during removal and installa-
tion; therefore, disconnect (and isolate) spark plug leads from spark plugs to pre-
vent engine from starting.
2. Disconnect spark plug leads from spark plugs.
3. While holding flywheel with Flywheel Holder (91-52344), remove flywheel nut and
washer.
a
58035
a - Flywheel Holder (91-52344)
Page 2B-10 90-878079 JANUARY 2000
--- Page 14 ---
CHARGING & STARTING SYSTEM
Starter Circuit Troubleshooting Flow Chart
Starter Motor Does Not Turn
SAFETY WARNING: Disconnect YELLOW (starter motor)
cable from starter solenoid test point 1 BEFORE making
tests 1-thru-7 to prevent unexpected engine cranking.
TEST 1
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (-) battery post and common pow-
erhead ground.
No Continuity Indicated - There is an open circuit in the Continuity Indicated
BLACK NEGATIVE (-) battery cable between the NEGATIVE (-) Proceed to TEST 2
battery post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.
Test 2
a. Disconnect BLACK ground wire(s) from Test Point 2.
No voltage reading: b. Connect voltmeter between common engine ground and Test Point 2.
proceed to TEST 3. c. Turn ignition key to “Start” position.
TEST 3 12 Volt Reading*
a. Reconnect BLACK ground wire. Check BLACK ground wire for poor connection
b. Connect voltmeter between common engine ground and Test Point 3. or open circuit.
Reconnect ground wire to starter solenoid.
c. Turn ignition key to “Start” position. Proceed to TEST 7.
No voltage reading: 12 Volt Reading
Proceed to TEST 4 Defective starter solenoid
TEST 4
a. Connect voltmeter between common 12 Volt Reading*
No voltage reading: engine ground and Test Point 4. Neutral start switch is open or YELLOW/RED
Proceed to TEST 5 b. Turn ignition key to “Start” position. wire is open between Test Points 4 and 3.
TEST 5
No voltage reading: Connect voltmeter between common 12 Volt Reading*
Proceed to Test 6. engine ground and Test Point 5 Defective ignition switch.
TEST 6
Check for voltage between common engine ground and Test Point 6.
No voltage reading: 12 Volt Reading*
Check RED wire between battery (+) Check fuse in RED wire between Test Points
POSITIVE terminal and Test Point 6.
5 and 6.
Check for open RED wire between Test Points
5 and 6.
*Battery Voltage
Page 2B-20 90-878079 JANUARY 2000
--- Page 15 ---
CHARGING & STARTING SYSTEM
8. Place springs and brushes into brush holder and hold in place with brush retainer tool.
a
b
11661
a - Bushing Retainer Tool
b - Bushing (do not over lubricate)
9. Install armature into starter frame and align match marks (a). Install commutator end
cap onto starter frame and align match marks (b). Remove brush retainer tool. Install
through bolts (c) and torque to 70 lb. in. (8.0 N·m).
c c
a
b
11648
a - Alignment Marks
b - Alignment Marks
c - Bolts [Torque to 70 lb. in. (8 N m)]
Page 2B-30 90-878079 JANUARY 2000
--- Page 16 ---
TIMING, SYNCHRONIZING & ADJUSTING
IDLE SPEED ADJUSTMENT
1. With engine in water, connect fuel line to engine. Start engine and allow to warm up.
2. Place outboard in gear and monitor engine RPM. If RPM is above or below recom-
mended RPM (see specifications), readjust primary pickup screw to attain recom-
mended engine speed. Retighten jam nut.
a
58046
a - Primary Pickup Screw
CAUTION
Engine idle RPM must NEVER EXCEED 750 RPM in gear.
3. With end of throttle cable connected to throttle lever, hold throttle lever against idle
stop. Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket
with a very light preload of throttle lever against idle stop. Lock barrel in place.
4. Check preload on throttle cable by placing a thin piece of paper between idle stop
screw and idle stop. Preload is correct when paper can be removed without tearing
but has some drag on it. Readjust cable barrel, if necessary.
IMPORTANT: Excessive preload on throttle cable will cause difficulty when shifting
from forward to neutral. (Readjust throttle cable barrel, if necessary.)
NOTE: Carburetors are equipped with idle mixture adjustment screws. See carburetor
specifications for mixture screw adjustment.
NOTE: If sufficient throttle cable barrel adjustment is not available, check for correct in-
stallation of link rod between the throttle lever and throttle cam. The throttle end of this
link rod must be threaded into its plastic barrel until it bottoms against the throttle lever
casting, then turned out only far enough to obtain correct orientation of link rod (less than
one turn). All timing adjustments must be reset after this procedure.
90-878079 JANUARY 2000 Page 2C-9
--- Page 17 ---
TIMING, SYNCHRONIZING & ADJUSTING
THROTTLE CABLE INSTALLATION
1. With end of throttle cable connected to throttle lever, hold throttle lever (a) against idle
stop (b). Adjust throttle cable barrel to slip into barrel recess of control cable anchor
bracket, with a light preload of throttle lever against idle stop. Lock barrel in place.
IMPORTANT: Excessive preload on throttle cable will cause difficulty when shifting
from “FORWARD” to “NEUTRAL” (readjust throttle cable barrel, if necessary).
a
c d b
57838
a - Throttle Lever
b - Idle Stop
c - Cable Barrel – Adjust To Hold Idle Stop Screw Against Stop
d - Idle Stop Screw
2. Check preload on throttle cable by placing a thin piece of paper between idle stop
screw (a) and idle stop (b). Preload is correct when paper can be removed without
tearing, but has some drag on it (readjust throttle barrel, if necessary).
b
a
57839
a - Idle Stop Screw
b - Idle Stop
DETONATION CONTROL (200 MODEL)
1. With outboard running in “FORWARD” gear, advance throttle to 3500 RPM and check
that spark timing has electronically advanced timing to 24° BTDC. This indicates
knock control circuit is functioning.
90-878079 JANUARY 2000 Page 2C-19
--- Page 18 ---
WIRING DIAGRAMS
IMPORTANT: On installations where gauge options will not be used, tape back and
isolate unused wiring harness leads
gg
BATT GND
i
SENDER
aa
ee
jj
ff
oo
m
STARBOARD INSTALLATION 52206
i - Synchronizer Gauge
j - Synchronizer Module
k - Lanyard Switch (Isolation) Diode
l - Y Harness
m - Power Trim Harness Connector
n - Connect Wires together with Screw and Nut (4 Places); Apply Liquid Neo-
prene to Connections and slide Rubber Sleeve over each Connection.
o - Lead to Visual Warning Kit
90-878079 JANUARY 2000 Page 2D-9
--- Page 19 ---
WIRING DIAGRAMS
2.5 Litre V-6 Carburetor Wiring Diagram 2000 Models
1 - Control Module
2 - Control Module Mounting Bolt
3 - Stator 9
4 - Trigger 8 10 11
5 - Low Oil Switch 3
6 - Shift Switch 4 6 7 12 BLK = Black
7 - Fuel Enrichment Solenoid N
5 BLU = Blue
8 - Upper Voltage Regulator #8 #7 BRN = Brown
9 - Lower Voltage Regulator #9
#6
GRY = Gray
2 5
10 - Regulator Mounting Bolt 18WHT
6
2 GRN = Green
18YEL #5
11 - Solenoid Plate #10 ORN = Orange
16BLK
16BLK
4
18BLU