Mercury Mariner Outboard 150HP Service Repair Manual SN:0G960500 and Above

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Transcript of Mercury Mariner Outboard 150HP Service Repair Manual SN:0G960500 and Above


    United States 0G960500 and Above. . . . . .

    With Serial Numbers



    135 • 150 • 175 • 200

    Printed in U.S.A.  2000, Mercury Marine 90-878079 JANUARY 2000

  • 90-878079 JANUARY 2000 Page i


    Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In- ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con- cerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY!

    These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures.

    DANGER DANGER - Imm ediate hazards which WILL result in severe personal injury or death.

    WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal in- jury or death.

    CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage.

    Notice to Users of This Manual

    This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein.

    It is assumed that these personnel are familiar with the servicing procedures of these prod- ucts, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers.

    We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected.

    All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products.

    It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery.

    Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started.

  • Page ii 90-878079 JANUARY 2000

    It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mis- matched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations when- ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original.

    Cleanliness and Care of Outboard Motor

    A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manu- al, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated.

    Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

    Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible.

    We reserve the right to make changes to this manual without prior notification.

    Refer to dealer service bulletins for other pertinent information concerning the products de- scribed in this manual.

    Page Numbering

    Two number groups appear at the bottom of each page. The example below is self-explana- tory.


    90-878079R1 OCTOBER 1999 LOWER UNIT - 6A-7

    Revision No. 1

    Month of Printing

    Year of Printing

    Section Description

    Section Number

    Part of Section Letter

    Page Number

  • 1







    General Information & Specifications

    Ignition System

    Fuel System



    Gear Housing

    Attachment/Control Linkage

    8Color Diagrams

    90-878079 JANUARY 2000 Page iii

    Service Manual Outline

    Section 1 - General Information & Specifications A - Specifications B - Maintenance C - General Information D - Outboard Installation

    Section 2 - Electrical A - Ignition B - Charging & Starting System C - Timing, Synchronizing & Adjusting D - Wiring Diagrams

    Section 3 - Fuel System A - Fuel Pump B - Carburetion C - Fuel Injection D - Oil Injection E - Emissions

    Section 4 - Powerhead A - Powerhead B - Cooling

    Section 5 - Mid-Section A - Clamp/Swivel Brackets & Drive Shaft Housing B - Power Trim

    Section 6 - Gear Housing A - Right Hand Non-Ratcheting B - Left Hand Non-Ratcheting

    Section 7 - Attachments/Control Linkage Section 8 - Color Diagrams

  • 1 A


    90-878079 JANUARY 2000 Page 1A-1

    IMPORTANT INFORMATION Section 1A - Specifications

    Table of Contents

    Specifications 1A-1. . . . . . . . . . . . . . . . . . . . . . . . . . .


    Model 135/XR6/MAGIII/200/150XRI/175XRI/200XRI HORSEPOWER

    (KW) Model 135 Model 150XRI Model XR6/MAGIII Model 175XRI Model 200/200XRI

    135 (100.6) 150 (111.8) 150 (111.8) 175 (130.5) 200 (149.1)


    Model 135 Model XR6/MAGIII/200 Model 150XRI/175XRI/200XRI

    413.0 lbs. (188.0 kg) 406.0 lb (184.0 kg) 416.0 lb (189.0 kg)


    Model 135 Type

    Displacement Thermostat

    Model XR6/MAGIII/200 150XRI/175XRI/200XRI Type

    Displacement Thermostat

    V–6 Cylinder, Two Cycle, Loop Charged

    121.9 cu. in. (1998cc) 143°F (61.7°C)

    V–6 Cylinder, Two Cycle, Loop Charged

    153.0 cu. in. (2507cc) 143°F (61.7°C)

    STROKE Length (All Models) 2.650 in. (67.31 mm)


    Diameter (Std) – Models 135 – Models XR6/MAGIII/200 150XRI/175XRI/200XRI

    Taper/Out of Round/Maximum Wear Bore Type

    3.125 in. (79.375 mm)

    3.501 in. (88.925 mm) 0.003 in. (0.076 mm)

    Cast Iron

    CRANKSHAFT Maximum Runout 0.006 (0.152 mm)


    Page 1A-2 90-878079 JANUARY 2000

    PISTON Piston Type Models 135


    0.015 in. (0.381 mm) Oversize

    0.030 in. (0.762 mm) Oversize

    Models XR6/MAGIII/200 150XRI/175XRI/200XRI Standard

    0.015 in. (0.381 mm) Oversize


    3.115 in. ± 0.002 in. (79.121 mm ± 0.051 mm)

    3.130 in. ± 0.002 in. (79.502 mm ± 0.051 mm)

    3.145 in. ± 0.002 in. (79.883 mm ± 0.051 mm)

    3.494 in. ± 0.001 in. (88.748 mm ± 0.025 mm)

    3.509 in. ± 0.001 in. (89.129 mm ± 0.025 mm)

    COMPRESSION All Models – Using a fully charged bat- tery, 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 135 Model XR6/MAGIII/200 Model 150XRI/175XRI/200XRI

    Reed Type Reed Stand 0pen (Max.) Reed Stop (Max.)

    Steel 0.020 in. (0.50 mm)

    Not Adjustable


    Power Trim ( Total Tilt Range) Power Trim ( Tilt Range) Maximum Allowable Leak down in 24 hrs. Tilt Pin Adjustment Positions Steering Pivot Range Allowable Transom Thickness

    75° 20°

    1 in. (25.4 mm) 5

    60° 2-3/8 in. (6.03 cm) Maximum


    Fuel Recommended Gasoline

    Model 135 Model XR6/MAGIII/200 Model 150XRI/175XRI/200XRI

    Recommended Oil Model 135 Model XR6/MAGIII/200 Model 150XRI/175XRI/200XRI

    Gasoline/Oil Ratio Fuel Pressure Pulse Driven Pump

    – @ Idle – @ WOT

    Gasoline w/Oil Injection

    Unleaded 87 Octane Minimum

    Quicksilver TC-W3 2 Cycle Outboard Oil Only

    50:1 (25:1 Break-In)

    1 – 3 psi (6.8 – 20.5 kPa) 12 psi (82.1 kPa) Minimum


    Manual Start – All Models Electric Start – All Models

    Starter Draw (Under Load) Starter Load (No Load)

    Battery Rating

    Emergency Start Rope