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DIY ManualsDIY Manuals >> Service & Repair >> Outboard & Inboard >> Mercury Mariner Outboard Repair Manuals >> Mercury Mariner Repair Manual 75-250 HP 2-Stroke 1998-2002
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Mercury Mariner 75-250 HP 2-Stroke Repair Manual 1998-2002

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  • Item Description
  • Table of Contents
  • Specifications

This Clymer repair manual covers Mercury Mariner two-stroke outboard motors 1998 to 2002, including:

  • Mercury Mariner 65 Jet, 75 HP, 80 Jet, 90 HP
  • Mercury Mariner 100 HP
  • Mercury Mariner 105 Jet
  • Mercury Mariner 115 HP (4-cylinder), 115 HP Optimax (V6)
  • Mercury Mariner 125 HP
  • Mercury Mariner 135 HP, 135 HP Optimax
  • Mercury Mariner 140 Jet
  • Mercury Mariner 150 HP (carburetor equipped), 150 HP (EFI), 150 XR6, 150 Mag III, 150 HP Optimax
  • Mercury Mariner 175 HP (carburetor equipped), 175 HP (EFI), 175 HP Optimax
  • Mercury Mariner 200 HP (carburetor equipped), 200 HP (EFI), 200 HP Optimax
  • Mercury Mariner 225 HP (carburetor equipped), 225 HP (EFI), 225 HP Optimax
  • Mercury Mariner 250 HP (EFI)

Book Excerpt: 1998-2002 Mercury Mariner 75-250 HP 2-Stroke Repair Manual

GEARCASE

GEAR HOUSING: REMOVAL/INSTALLATION
(75- 125 hp, except 115 hp Optimax models)

REMOVAL

  1. Disconnect and ground the spark plug leads to the power head to prevent accidental starting.
  2. Remove the propeller as described in this chapter.
  3. Tilt the outboard to the fully up position and engage the tilt lock.
  4. Shift the gearcase into the forward position. Rotate the propeller shaft while shifting to assist full gear engagement.
  5. Mark the trim tab position with a white grease pencil or china marker. See Figure 11. Remove the retaining screw and trim tab.

  6. Remove the four screws (two on each side) and washers, and one locknut and washer in the trim tab cavity securing the gearcase to the drive shaft housing. See Figure 12.
  7. Pull the gearcase straight down and away from the drive shaft housig.
  8. Place the gearcase in a suitable holding fixture or on a clean workbench.

SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
THROTTLE POSITION SENSOR (TPS) ADJUSTMENT

The correct operation and setting of the TPS is critical to achieving the correct air/ fuel ratio, High TPS voltage provides a richer air/ fuel ratio.

Low TPS voltage provides a leaner air/ fuel ration. Adjustments to the TPS within the specification may be used to fine tune the idle air/ fuel mixture.

Never adjust the TPS out of the specified range. Only use a digital multimeter for the following test. A test harness is required for this procedure.

  • Use test harness part No. 91-816085 for 1998 and 1999 models.

  • Use test harness part No. 91-859199 for 2000-on models.
NOTE: Verify the correct idle speed before adjusting the TPS. If the idle speed is changed, readjust the TPS setting. It may be necessary to go back and forth between idle speed and TPS adjustment more than once to get both systems correctly adjusted.

TABLE of CONTENTS:
  • General information
  • Tools and techniques
  • Troubleshooting and testing
  • Lubrication, maintenance and tune-up
  • Engine synchronization and adjustment
  • Fuel system
  • Electrical and ignition systems
  • Power head
  • Gearcase
  • Jet Drive
  • Trim and tilt repair
  • Midsection and tiller control
  • Oil injection system
  • Remote control
  • Wiring diagrams

Subject: 1998, 1999, 2000, 2001, 2002 Mercury Mariner 75-250 HP 2-Stroke service, maintenance, repair. ISBN-10: 0892877960 | ISBN-13: 9780892877966

  • Publisher: Clymer Manuals
  • Pages: 620 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.25 x 10.75 inches
  • ISBN: 978-0-89287-796-6
  • Years: 1998 - 2002
  • Mercury Mariner Repair Manual 75-250 HP 2-Stroke 1998-2002
    $26.95
    5 Stars based on 1 Review(s)
    Lee
    Athens, Tx
    5 Stars
    I would recommend this item to a friend.

    Excellant Manual
    August 5, 2014
    I'm not a novice at mechanics, having worked in the auto industry for a long time. I have worked on older outboards, but I have had this one since it was new in 94. First real problem and I have narrowed it down to the fuel system, possibly pump. The manual has really helped in diagnostics and step by step teardown and repair. Worth every penny of the cost.