1992-2000 Mercury Mariner 105-225HP Outboard motor Factory Service Manual
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- 1992 2000 Mercury Mariner Outboard 105 225 Service Manual
Original Mercury Service manual covers the following models:
MODELS: 105/140 JET, 135, 150, 175, 200, 225
1992 Through 2000: 105/140 Jet, 135, 150, 150 XR6, 150 Magnum III, 150 EFI, 175, 175 EFI, 200, 200 EFI with Serial Numbers: 0D082000 Through 0G960499
1992 Through 2000: 150/200/225 Pro Max, 150/200/225 Super Magnum with Serial Numbers: 0D082000 Through 0T105314
Manual covers detailed maintenance and repair procedures. It includes hi-resolution diagrams, wiring diagrams and detailed step-by-step instructions.
Manual chapters:
- Specifications
- Maintenance
- General Information
- Outboard Motor Installation
- Ignition System
- Battery Charging System and Starting System
- Timing, Synchronizing and Adjusting
- Wiring
- Fuel Pump
- Carburetors
- Fuel Injection S/N 0G303045 and Below
- Fuel Injection S/N 0G303046 and Above
- Oil Injection
- EMISSIONS
- POWERHEAD
- Cooling
- Clamp/Swivel Bracket and Driveshaft Housing
- Power Trim Square Motor and Round Motor Design
- E-Z Shift Gear Housing (Standard Rotation)
- Counter Rotating (Left Hand) Gear Case
- Mercury XR6/Mariner Magnum III Gear Housing
- E-Z Shift Gear Housing (Non-Ratcheting) (Standard Rotation) Starting S/N 0G438000
- E-Z Shift Counter Rotating Gear Housing (Non-Ratcheting) (Left-Hand Rotation) Starting S/N 0G438000
- Jet Outboards
- Attachments/Control Linkage
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Full list of manual chapters:
Models 105/140 Jet * 135 * 150 * 175 * 200 * 225
Notice
Notice to Users of This Manual
Cleanliness and Care of Outboard Motor
Page Numbering
Service Manual Outline
Specifications
Table of Contents
Master Specifications
Maintenance
Table of Contents
Specifications
Inspection and Maintenance Schedule
Before Each Use
After Each Use
Every 100 Hours of Use or Once yearly, Whichever occurs first
Before Periods of Storage
Lubrication Points
Checking Power Trim Fluid
Gear Case Lubrication
Gear Case Lubricant Capacity
Draining Gear Case
Checking Lubricant Level and Refilling Gear Case
Propeller Replacement
Removal
Installation
Corrosion Control Anode
Flushing Engine
Flushing Cooling System with Engine NOT Running ( Using Cowl Flush Plug)
Flushing Cooling System with Engine Running ( Using Flushing Attachment 44357A2)
Storage
General Information
Table of Contents
Serial Number Location
Conditions Affecting Performance
Weather
Boat
Engine
Following Complete Submersion
Salt Water Submersion (Special Instructions)
Submerged While Running (Special Instructions)
Submerged Engine (Fresh Water) ( Plus Special Instructions)
Propeller Selection Painting Procedures
Decal Application
Outboard Motor Installation
Table of Contents
Notice to Installer and Owner
Boat Horsepower Capacity
Outboard Remote Control
Selecting Accessories For The Outboard
Selecting Steering Cables and Remote Control Cables
Determining Recommended Outboard Mounting Height
Locating Centerline of Boat Transom
Drilling Outboard Mounting Holes
Applying Counter Rotation Decals
Lifting Outboard
Installing Outboard To Boat Transom
Single Steering Cable and Steering Link Rod Installation
Installing Ride Guide Cable to Outboard Tilt Tube
Steering Link Rod Installation
Routing Location for Wiring and Hoses thru Clamp in Bottom Cowl
Remote Control Installation
Required Side Mount Remote Control or Ignition Key Switch Assembly
Shift and Throttle Cable Installation to the Outboard
Shift Cable Installation
Throttle Cable Installation
Remote Wiring Connections Battery Connections
Fuel Connections
Connecting Fuel Hose to Engine
Portable Fuel Tank
Permanent Fuel Tank
Fuel Line
Set Up Instructions for Oil Injection System
Installing Remote Oil Tank
Installing Oil Hoses To Engine Filling the Oil Injection System
Bleeding Air from Oil Injection Pump and Oil Injection Outlet Hose
Adjusting Oil Injection Pump
Propeller Selection
Propeller Installation
Power Trim System
General Information
Power Trim Operation
WARNING
Trim "In" Angle Adjustment
Checking Trim System Fluid Level
Trim Tab Adjustment
Ignition System
Table of Contents
Ignition Specifications
40 Ampere Stator
Trigger
Ignition Coil
DVA Specifications
Special Tools
Flywheel/Starter Motor
Ignition Coil/Voltage Regulator
Wiring Harness/Starter Solenoid
Theory of Operation
Ignition Test Procedures
Checking for Loss of Spark
Direct Voltage Adaptor (DVA)
Troubleshooting Tips
Ignition Troubleshooting
Multimeter/DVA Tester 91-99750A1
Test Sequence
Ignition System Test Chart
Ignition System
Idle Stabilizer Modules
Ignition Components Removal and Installation
Battery Charging System and Starting System
Table of Contents
Specifications
Special Tools
Battery Cable Size
Battery
Specific Gravity Readings
Specific Gravity Cell Comparison Test
Electrolyte Level
Charging a Discharged Battery
Winter Storage of Batteries
Battery Charging System Description
Battery Charging System Troubleshooting
General Troubleshooting
40 Ampere Alternator System
Troubleshooting 40 AMP Alternator System
System Wired for Split Output
System Wired for 40 Ampere Output to Isolator
Starter System
Starter Circuit Troubleshooting Flow Chart
Starter Removal and Installation
Starter Cleaning, Inspection and Testing
Timing, Synchronizing and Adjusting
Table of Contents
Timing/Synchronizing/ Adjusting
Specifications
Carburetor Models
Special Tools
Adjustments
Carburetor Models
Electronic Fuel Injection Models
Wiring
Table of Contents
Wiring Diagram 135/150
Wiring Diagram XR6/MAG III/175
Wiring Diagram 200
Wiring Diagram 200 Carb Serial # 0D077248 thru Serial # 0D122746
Wiring Diagram 150/175 EFI
Wiring Diagram 200 EFI
Wiring Diagram 200 Pro Max/Super Magnum ( Early Models with Detonation Module)
Wiring Diagram 150/200/225 Pro Max/Super Magnum
Wiring Diagram105/140 Jet
Power Trim Wiring Diagram with Solenoids
Power Trim Wiring Diagram with Relays
Instrument Wiring Connections
Commander 3000 Classic Panel Remote Control
Commander 3000 Panel Remote Control
Commander 3000/3000 Classic Components
Commander Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
Commander 2000 Side Mount Remote Control (Power Trim/ Tilt Electric Start with Warning Horn) Wiring Diagram
Oil Level Gauge Wiring Diagram
Visual Warning Wiring Diagram
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
Instrument/Lanyard Stop Switch Wiring Diagram
QSI Gauge Wiring Diagrams
Tachometer Wiring Diagram
Water Temperature Gauge
Oil Level Gauge Wiring
Engine Synchronizer Wiring Diagram
Maintenance
Multi-Function Guage
Dip Switch Setting/Testing
Outboard Multi-Function Gauge Setting
Panel Mount Remote Control Wiring Installation
Side Mount Remote Control Wiring Installation
Fuel Pump
Table of Contents
Specifications
Special Tools
Fuel Pump
General Information
Testing Fuel Pump
Checking Fuel Pump Lift ( Vacuum)
Vacuum Test Troubleshooting
Fuel Pump Removal/Disassembly
Cleaning/Inspection
Reassembly/lnstallation
Carburetors
Table of Contents
WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Assembly
WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Specifications
WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Front View
WMH 12,13,14,15,16,27 Carburetor Assembly
WMH 12,13,14,15,16,27 Carburetor Specifications
WMH 12,13,14,15,16,27 Carburetor Front View
WMH 21,22,23,25,26,28 Carburetor Assembly
WMH 21,22,23,25,26,28 Carburetor Specifications
WMH 21,22,23,25,26,28 Carburetor Front View
WMH 30,31,32,33,34,39 Carburetor Assembly
WMH 30,31,32,33,34,39 Carburetor Specifications
WMH 30,31,32,33,34,39 Carburetor Front View
WMV 1/1A, 2/2A, 3/3A, 4/4A, 5/5A
WMV 1,2,3,4,5 Carburetor Specifications
WMV 1,2,3,4,5 Carburetor Front View
Fuel System - Troubleshooting
Reed Valve Leak Test
Thermal Air Valve Circuit Description
WMH Carburetor Fuel Circuit Description
Idle Circuit Description
Off-ldle Circuit Description
Back Draft Circuit Description
High Speed Fuel Circuit Description
Carburetor Placement
WMV Carburetor Fuel Circuit Description
Float Bowl Circuit
Idle Circuit
Cold Start Circuit
Off-Idle Circuit
Main Circuit Back Draft Circuit
Carburetor Placement and Jet Location for Each Cylinder (WMV Carburetors)
High Altitude Recommendations
High Altitude Jet Chart
Enrichener System Description
Removing Carburetor(s) from Engine
Carburetor Disassembly
Carburetor Jet Removal
Fuel Bowl Removal and Disassembly
Carburetor Cleaning and Inspection
Carburetor Reassembly
Throttle Shaft Component Installation
Fuel Bowl Reassembly
Carburetor Jet Installation
Installing Carburetor(s) to Engine
Fuel Line and Primer Bulb Assembly
Fuel Injection S/N 0G303045 and Below
Table of Contents
Specifications
Special Tools
Electronic Control Module (ECM) ASSEMBLY
Fuel Management System
Fuel Pump and Fuel Filter
Outboard Powerhead View
Electronic Fuel Injection ( EFl) System
Introduction
Using the Test Procedures
EFI System Tests
Safety Precautions
Fuel Injection System Function
Preliminary Steps
Ignition Spark Check
Electronic Fuel Injection Set Up
Fresh Quality Fuel
Low Battery Voltage
Fuel Flow Diagram
EFI Electrical Diagram
EFI Fuel Management (Low Pressure Fuel Route)
EFI Fuel Management (High Pressure Fuel Route)
Fuel Rail Electrical/Fuel Determination
EFI System Test Procedures
Fuel Gauge Connection/Pressure Test
Vapor Separator Fuel Delivery Test
Vapor Separator Float Test
Water Separating Filter Flow Test
Pulse Fuel Pump Delivery Test
Final Filter Check and De-pressurizing EFI System Procedures
Pressure Regulator Test
Electric Fuel Pump Test
Injector Electrical Harness Test
Injector Fuel Delivery Test
Injector Operation Test (Manifold Cover Removed)
Induction Manifold Leak Check ( Manifold Cover Removed)
Air Temperature Sensor Test
Engine Head Temperature Sensor Test
Detonation Control System Test (200 Models Only)
Detonation Sensor Check
Detonation Control Module Check
Throttle Position Sensor Test
Map Sensor Test
Problem Diagnosis
Engine Head Temperature Sensor Removal
EFI Induction Manifold Removal
Water Separating Filter Assembly Removal
Throttle Position Sensor Temperature Sensor Fuel Injector Harness Disconnections
Oil Reservoir Removal
Final Filter Assembly Removal
Electric Fuel Pump Removal
Vapor Separator Removal
Vapor Separator Disassembly
Vapor Separator Component Reassembly
Vapor Separator Float Installation
Manifold Removal
EFI Induction Manifold Disassembly
Air Temperature Sensor Removal
Throttle Position Sensor Removal
Fuel Rail Removal
Fuel Rail Disassembly
Fuel Injector Removal and Disassembly
Injector Harness Removal
Throttle Linkage Removed
EFI System Cleaning and Inspection
Induction Manifold Assembly
Injector Harness Installation
Fuel Injector Assembly and Installation
Fuel Rail Assembly
Fuel Rail Installation
Throttle Position Sensor Installation
Air Temperature Sensor Installation
EFI Induction Manifold Installation
Vapor Separator Installation
Electric Fuel Pump Installation
Final Filter Assembly Installation
Oil Reservoir Installation
Throttle Position Sensor and Temperature Sensor Fuel Injector Harness Connections
Water Separating Filter Assembly Installation
ECM Installation
Engine Head Temperature Sensor Installation
Fuel Injection S/N 0G303046 and Above
Table of Contents
Specifications
Special Tools
Detonation Controller/Air Temperature Sensor/Throttle Position Sensor
Electronic Control Module (ECM) Assembly
Fuel Management System
Fuel Pump
Outboard Powerhead View
Electronic Fuel Injection ( EFl) System
Introduction
Using the Test Procedures
EFI System Tests
Safety Precautions
Fuel Injection System Function
Preliminary Checks
Ignition Spark Check
Electronic Fuel Injection Set Up
Fresh Quality Fuel Low Battery Voltage
Fuel Flow Diagram
Fuel Flow Component Description
Pulse Fuel Pump
Water Separating Filter
Vapor Separator
Bleed System
Final Filter
Electric Fuel Pump
Fuel Injectors
Induction Manifold
Fuel Pressure Regulator
Wiring Diagram 150 EFI/175 EFI/150 Pro Max/Super Magnum
Wiring Diagram 200 EFI/200 and 225 Pro Max/Super Magnum
EFI Electrical Components (from Electrical Component Diagram)
EFI Fuel Management (Low Pressure Fuel Route)
EFI Fuel Management (High Pressure Fuel Route)
Fuel Rail Electrical/Fuel Determination
EFI System Test Procedures
Fuel Gauge Connection/Pressure Test
Vapor Separator Fuel Delivery Test
Vapor Separator Float Test
Water Separating Filter Flow Test
Pulse Fuel Pump Delivery Test
Final Filter Check and De-pressurizing EFI System Procedures
Pressure Regulator Test
Electric Fuel Pump Voltage Test
Injector Electrical Harness Test
ECM Injector Driver Test
Injector Fuel Delivery Test
Injector Operation Test (Manifold Cover Removed)
Induction Manifold Leak Check ( Manifold Cover Removed)
Air Temperature Sensor Test
Engine Head Temperature Sensor Test
Detonation Control System Test (200 Models Only)
Detonation Sensor Check
Detonation Control Module Check
Throttle Position Sensor Test
Map Sensor Test
Problem Diagnosis
Engine Head Temperature Sensor Removal
EFI Induction Manifold Removal
Water Separating Filter Assembly Removal
Water Separating Filter Assembly Installation
Throttle Position Sensor and Temperature Sensor Fuel Injector Harness Disconnections
Oil Reservoir Removal
Fuel Pressure Regulator Removal
Fuel Pressure Regulator Disassembly
Fuel Pressure Regulator Reassembly
Vapor Separator Removal
Vapor Separator Disassembly
Vapor Separator Reassembly
Installing Vapor Separator Assembly to Induction Manifold
Manifold Removal
EFI Induction Manifold Disassembly
Air Temperature Sensor Removal
Throttle Position Sensor Removal
Fuel Rail Removal
Fuel Rail Disassembly
Fuel Injector Removal and Disassembly
Injector Harness Removal
Throttle Linkage Removal
EFI System Cleaning and Inspection
Induction Manifold Assembly
Injector Harness Installation
Fuel Injector Assembly and Installation
Fuel Rail Assembly
Fuel Rail Installation
Throttle Position Sensor Installation
Air Temperature Sensor Installation
EFI Induction Manifold Installation
Oil Reservoir Installation
Vapor Separator Installation
Throttle Position Sensor, Air Temperature Sensor and Fuel Injector Harness Connections
ECM Installation
Engine Head Temperature Sensor Installation
Oil Injection
Table of Contents
Operation of the Oil Injection System
Oil Injection Components ( See Page 3 for Location)
Oil Injection Flow System
Pump Drive Assembly
Pump Drive System
Set Up Instructions for Oil Injection System
Oil Injection Pump
Worm Bushing
Worm Bushing Removal
Worm Bushing Installation
Oil Injection Pump Installation
Installing Drive Gear (for Oil Injection Pump) Onto Crankshaft
Motion Sensor
Oil Injection System Trouble Shooting Chart
Oil Pump Volume (Flow) Test
EMISSIONS
Table of Contents
Exhaust Emissions Standards
What Are Emissions?
Hydrocarbons - HC
Carbon Monoxide - CO
Oxides of Nitrogen - NOx
Controlling Emissions
Stoichiometric (14.7:1) Air/Fuel Ratio
Stratified vs Homogenized Charge
Emissions Information
Service Replacement Certification Label
Removal
Date Code Identification
Installation
Decal Location for 1998 Models:
POWERHEAD
Table of Contents
Powerhead Specifications
Special Tools
Powerhead Repair Stand
Cylinder Block and End Caps
Exhaust Manifold and Exhaust Plate
Reed Block and Cylinder Head
Crankshaft, Pistons and Connecting Rods
Torque Sequence
General Information
Powerhead Removal from Driveshaft Housing
Powerhead Disassembly
Water Pressure Relief Valve Components
Cleaning and Inspection
Cylinder Block and Crankcase Cover
Special Service Information
Cylinder Bores
Pistons and Piston Rings
Cylinder Heads and Exhaust Divider Plate
Crankshaft
Crankshaft (and End Cap) Bearings
Reed Block Assembly
Reed Block Housing
Connecting Rods
Thermostats
Powerhead Reassembly and Installation
General
Crankshaft Installation
Piston and Connecting Rod Reassembly
Piston and Piston Ring Combinations
Piston Installation (Standard and High Performance Models)
Crankcase Cover Installation ( Standard and High Performance Models)
Assembly of Reed Blocks to Intake Manifold ( Standard and High Performance Models)
Assembly of Exhaust Divider Plate to Block ( Standard and High Performance Models)
Bleed Line Routing ( Carbureted Models)
Bleed Line Routing (Fuel Injected Models)
Reinstalling Engine Components
Throttle Lever and Shift Shaft
Powerhead Installation on Driveshaft Housing
Break-ln Procedure
Cooling
Table of Contents
Specifications
Special Tools
Water Flow
Troubleshooting
Thermostat Test
Water Pressure Check
Water Pump Cleaning and Inspection
Problem Diagnosis
Clamp/Swivel Bracket adn Driveshaft Housing
Table of Contents
Swivel Bracket and Steering Arm
Transom Brackets (S/N-0G589999 and BELOW)
Transom Brackets (S/N-0G590000 and UP)
Drive Shaft Housing and Exhaust Tube
Drive Shaft Housing and Dyna-Float Suspension
Removal and Disassembly
Reassembly and Installation
Power Trim Square Motor and Round Motor Design
Table of Contents
Power Trim Specifications
Special Tools
Power Trim Components
Power Trim Motor
Power Trim - General Information
Description
Trimming Characteristics
Trailering Outboard
Tilting Outboard Manually
Trim "In" Angle Adjustment
Striker Plate Replacement
Anode Plate
Trim Indicator Gauge
Check, Fill and Purge - Power Trim System
Troubleshooting
Power Trim System with Relays and 2 Wire Trim Motor
Electrical System Troubleshooting
Troubleshooting the "Down Circuit"
Troubleshooting the "Up" Circuit
Troubleshooting the "Down" and "Up" Circuits ( All Circuits Inoperative)
Power Trim Assembly Removal and Installation
Removal
Installation
Testing Power Trim System With Test Gauge Kit ( 91- 52915A6)
"UP" Pressure Check
"DOWN" Pressure Check
Hydraulic Repair
Trim Rod End Cap Seal
Tilt Ram
Disassembly
Scraper Seal Replacement
Motor and Electrical Tests/ Repair
Trim Pump Motor Test
Motor Disassembly
Armature Tests
Motor Repair
Reassembly
Reassembly - Motor and Pump
Priming Power Trim System
Trim Sender Test
Trim Indicator Gauge Needle Adjustment
Trim Indicator Wiring Diagrams
E-Z Shift Gear Housing (Standard Rotation)
Table of Contents
Gear Housing Specifications ( Standard Rotation)
Special Tools
Gear Housing (Drive Shaft) (Standard Rotation) ( S/ N- 0G437999 and BELOW)
Gear Housing (Prop Shaft) (Standard Rotation) ( S/ N- 0G437999 and BELOW)
Gear Housing (Drive Shaft) (CLE) (Standard Rotation) ( Pro Max/ Super Magnum Models)
Gear Housing (Prop Shaft) (CLE) (Standard Rotation) ( Pro Max/ Super Magnum Models)
Gear Housing (Driveshaft) (Standard Rotation) ( Torque Master) ( Pro Max/ Super Magnum Models)
Gear Housing (Prop Shaft) (Standard Rotation) ( Torque Master) ( Pro Max/ Super Magnum Models)
Gear Housing (Driveshaft) (Standard Rotation) ( Sportmaster)
Gear Housing (Driveshaft) (Standard Rotation) ( Sportmaster)
Gear Housing (Prop Shaft) (Standard Rotation) ( Sportmaster)
General Service Recommendations
Removal, Disassembly, Cleaning and Inspection - Standard Rotation
Water Pump
Bearing Carrier and Propeller Shaft Removal
Shift Shaft
Propeller Shaft
Clutch Actuator Rod
Pinion Gear and Drive Shaft
Forward Gear
Gear Housing
Reassembly and Installation Standard Rotation
Driveshaft Needle Bearing
Bearing Carrier
Forward Gear
Forward Gear Bearing Race
Driveshaft and Pinion Gear
Pinion Gear Depth/Drive Shaft End Play (Sport Master)/Forward Gear Backlash/Reverse Gear Backlash
Clutch Actuator Rod
Shift Shaft Bushing
Propeller Shaft
Water Pump
Gear Lubricant Filling Instructions
Installing Gear Housing to Drive Shaft Housing
Propeller Installation
Counter Rotating (Left Hand) Gear Case
Table of Contents
Gear Housing Specifications ( Counter Rotation)
Special Tools
Gear Housing (Driveshaft) (Counter Rotation) ( S/ N- 0G437999 and BELOW)
Gear Housing (Prop Shaft) (Counter Rotation) ( S/ N- 0G437999 and BELOW)
Gear Housing (Driveshaft) (Counter Rotation) ( Sportmaster)
Gear Housing (Prop Shaft) (Counter Rotation) ( Sportmaster)
General Service Recommendations
Removal, Disassembly, Cleaning and Inspection of Counter Rotation ( Left Hand) Gear Housing
Water Pump
Bearing Carrier and Propeller Shaft Removal
Shift Shaft
Propeller Shaft
Clutch Actuator Rod
Forward Gear and Bearing Adapter
Pinion Gear and Driveshaft
Reverse Gear
Gear Housing
Reassembly and Installation of Counter Rotation Gear Housing
Driveshaft Needle Bearing
Bearing Carrier, Forward Gear and Bearing Adaptor
Driveshaft and Pinion Gear
Pinion Gear Depth
Reverse Gear
Forward Gear
Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier
Clutch Actuator Rod
Shift Shaft Bushing
Propeller Shaft
Water Pump
Gear Lubricant Filling Instructions
Installing Gear Housing to Driveshaft Housing
Propeller Installation
Mercury XR6/Mariner Magnum III Gear Housing
Table of Contents
Gear Housing Specifications ( 1.78: 1 Ratio)
Special Tools
Gear Housing (Driveshaft) - XR6/Magnum III - 1.78:1 Ratio
Gear Housing (Prop Shaft) - XR6/Magnum III - 1.78:1 Ratio
General Service Recommendations
Removal, Disassembly, Cleaning and Inspection
Draining Lubricant from Gear Housing
Water Pump
Cleaning and Inspection
Bearing Carrier and Propeller Shaft Removal
Pinion Gear and Driveshaft
Forward Gear and Bearings
Shift Shaft, Bushing and Cam
Gear Housing
Driveshaft Needle Bearing
Reassembly and Installation
Driveshaft Needle Bearing
Lower Shift Shaft and Bushing
Bearing Carrier
Forward Gear and Race
Driveshaft and Pinion Gear
Determining Pinion Gear Depth
Propeller Shaft
Determining Forward Gear Backlash
Water Pump
Filling Gear Housing With Lubricant
Installing Gear Housing to Driveshaft Housing
Propeller Installation
E-Z Shift Gear Housing (Non-Ratcheting)(Standard Rotation) Starting S/N 0G438000
Table of Contents
Gear Housing Specifications ( Standard Rotation)
Special Tools
Gear Housing (Driveshaft) (Standard Rotation) ( S/ N- 0G438000 and UP)
Gear Housing (Prop Shaft) (Standard Rotation) ( S/ N- 0G438000 and UP)
General Service Recommendations
Removal, Disassembly, Cleaning and Inspection – Standard Rotation
Water Pump
Bearing Carrier and Propeller Shaft Removal
Shift Shaft
Propeller Shaft
Clutch Actuator Rod
Pinion Gear and Driveshaft
Forward Gear
Gear Housing
Reassembly and Installation Standard Rotation
Driveshaft Needle Bearing
Bearing Carrier
Forward Gear
Forward Gear Bearing Race
Driveshaft and Pinion Gear
Pinion Gear Depth/Forward Gear Backlash/Reverse Gear Backlash
Clutch Actuator Rod
Shift Shaft Bushing
Propeller Shaft
Water Pump
Gear Lubricant Filling Instructions
Installing Gear Housing to Driveshaft Housing
Propeller Installation
E-Z Shift Counter Rotating Gear Housing (Non-Ratcheting)(Left-Hand Rotation) Starting S/N 0G438000
Table of Contents
Gear Housing Specifications (Counter Rotation)
Special Tools
Gear Housing (Driveshaft) (Counter Rotation) ( S/ N- 0G438000 and UP)
Gear Housing (Prop Shaft) (Counter Rotation) ( S/ N- 0G438000 and UP)
General Service Recommendations
Removal, Disassembly, Cleaning and Inspection of Counter Rotation ( Left Hand) Gear Housing
Water Pump
Bearing Carrier and Propeller Shaft
Shift Shaft
Propeller Shaft
Clutch Actuator Rod
Forward Gear and Bearing Adapter
Pinion Gear and Driveshaft
Reverse Gear
Gear Housing
Reassembly and Installation of Counter Rotation Gear Housing
Driveshaft Needle Bearing
Bearing Carrier, Forward Gear and Bearing Adaptor
Reverse Gear Bearing Adaptor Assembly
Driveshaft and Pinion Gear
Pinion Gear Depth
Reverse Gear
Forward Gear
Propeller Shaft/Forward Gear Bearing Adapter/ Bearing Carrier
Water Pump
Gear Lubricant Filling Instructions
Installing Gear Housing to Driveshaft Housing
Propeller Installation
Jet Outboards
Table of Contents
Jet Pump Assembly
Jet Components
Selecting A Boat That Is Best Suited For Jet Power
Engine Horsepower Selection
Transom Height of the Boat
Locate Centerline of the Outboard
Outboard Mounting Height
Water Testing
Shift Cable Installation Jet 105 and 140
Lubricating the Driveshaft Bearing
Impeller Removal and Installation
Steering Pull Adjustment
Impeller Clearance Adjustment
Worn (Dull) Impeller
Flushing the Cooling System
Liner Replacement
Jet Drive Removal and Installation
Bearing Carrier Disassembly
Bearing Carrier Reassembly
Installing Seals
Installing Upper Seals
Installing Driveshaft Bearing(s)
Installing Driveshaft
Installing Upper Seal Housing
Attachments/Control Linkage
Table of Contents
Installing Production Outboards
Installing High Performance Outboards - Pro Max/ Super Magnum Models
Lifting Outboard
RideGuide Steering Cable/Attaching Kit Installation (92876A1)
Single Cable - Single High Performance Outboard
Single Cable - Single Production Outboard
Maintenance Instructions
RideGuide Steering Cable/Attaching Kit Installation (92876A3)
Dual Cable - Single Outboard
Super RideGuide Steering Kit Installation
Steering Cable Mounting Tube Installation
Installing Steering Cables
Coupler Installation
Installing Link Rod
Maintenance Instructions
RideGuide Steering Cable/Attaching Kit Installation (92876A6)
Dual Cable - Dual Outboard
Installation Requirements
Parallel Routed Steering Cables and Attaching Kit Installation
Opposite Side Routed Steering Cables and Attaching Kit Installation
Trim Tab Adjustment RideGuide Steering Attachment Extension Couplers
Maintenance Instructions
Transom Mounted RideGuide Attaching Kit Installation (73770A1)
Attaching Kit Installation
Maintenance Instructions
Clevis Attaching Kit Installation ( A-70599A2)
Installation Instructions
Maintenance Instructions
Remote Control Installation
Required Side Mount Remote Control or Ignition Key Switch Assembly
Routing Location for Wiring and Hoses thru Clamp in Bottom Cowl
Remote Control Installation
Shift Cable Adjustment and Installation to the Engine
Throttle Cable Adjustment and Installation to the Engine
Battery Connections
Fuel Connections
