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The original Haynes Repair Manual - Based on a complete stripdown and rebuild of a vehicle

Mercury/Mariner Outboard 200 DFI (1994 - 1997) Clymer

  • Print edition only!
  • What's Included

    Print on demand books shipped within a week
    Fault Finder - Diagnose 400+ problems
    Take on bigger jobs with Haynes’ help
    Wiring diagrams for key vehicle systems
    700+ pictures & diagrams of your vehicle
    Suitable for novice and pro mechanics
  • Online edition only!
  • What's Included

    Use the online manual straight away
    Includes ALL content of a printed manual
    Fault Finder - Diagnose 400+ problems
    Take on bigger jobs with Haynes’ help
    Wiring diagrams for key vehicle systems
    Extra videos in online manual
    Print any page at home
    700+ pictures & diagrams of your vehicle

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Online Manual Only
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Online editions are online only digital products.

What's Covered

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This Mercury/Mariner manual is 824 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specifications

CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanicâ??s techniques

CHAPTER THREE / TROUBLESHOOTING
Safety precautions / Operating requirements / Test and repair equipment / Starting system / Battery charging system / Electrical accessories / Ignition system / Alternator driven ignition (mechanical advance [75-125 hp and 65-80 Jet]) / Alternator driven ignition (135-200 hp, 275 hp, 105 and 140 Jet [V6]) / Capacitor discharge module (CDM) ignition (75-125 hp and 65-80 Jet [serial No. 0G438000-on]) / Capacitor discharge module (CDM) Ignition (225 and 250 hp) / CVD module resistance tests / DI (digital inductive (200 DFI) / Fuel system / Fuel primer and enrichment system / Electronic fuel injection (EFI) fuel system troubleshooting / DFI air/fuel system troubleshooting / Engine temperature and overheating / Specifications

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Hour meter / Fuels and lubrication / Recommended fuel/oil mixture ratio / Fuel mixing procedure / Variable ratio oil injection / Variable ratio electronically controlled oil injection (200 DFI models) / Lower gearcase lubricant change / Jet pump maintenance / Propeller shaft maintenance / Corrosion of the propeller shaft carrier bearing / Off-season storage / Anticorrosion maintenance / Engine submersion / Cooling system flushing / Tune-up /Removing carbon build-up from the combustion chamber / Compression check / Cylinder head bolt torque / Spark plug plugs / Lower gearcase and Jet Pump water pump service / Fuel and oil injection system / Fuel filter service / Fuel pump service / Ignition system service / Charging system service / Alternator belt (200 DFI) / Battery and electric starter service / On-water performance testing / Specifications

CHAPTER FIVE / SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
75, 90 hp and 60 Jet models / 100-125 hp and 80 Jet models / 135-200 hp carbureted models / 150-200 hp EFI (electronic fuel injection) models / 200 DFI (direct fuel injection) models / 225 hp carbureted models / 225 and 250 hp EFI models / 275 hp models / Specifications

CHAPTER SIX / FUEL SYSTEM
Fuel pump / Carburetors / WME series carburetor / WMH and WMV series carburetors / WO series Mercarb carburetor / Fuel primer valve / Thermal air valve / Fuel enrichment valve / Accelerator pump circuit / Antisiphon devices / Fuel filters / Fuel tanks / Fuel hose and primer bulb / Electronic fuel injection EFI and direct fuel injection DFI / Reed valve / Fuel bleed (recirculation) system / Specifications

CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS
Battery charging system / Fuses / Starting systems / Ignition systems / Alternator driven capacitor discharge ignition (60-275 hp and 65-140 Jet) / Capacitor discharge module (CDM) ignition / Digital inductive ignition (200 DFI) / Specifications

CHAPTER EIGHT / POWER HEAD
Break-in / Lubricants, sealants and adhesives / Seal surfaces / Fasteners and torque / Removal installation / Disassembly / Cleaning and inspection / Assembly / Specifications

CHAPTER NINE / LOWER GEARCASE AND JET DRIVE UNITS
Lower gearcase / Gear case operation / Gear ratio / High-altitude operation / Service precautions / Corrosion control / Gearcase lubrication / Propeller / Trim tab adjustment / Gear housing / Water pump / Gearcase disassembly assembly / Gearcase cleaning and inspection / Gearcase pressure testing / Gearcase shimming / Jet drive models / Jet pump unit maintenance / Jet pump unit service / Bearing housing / Water intake housing liner / Specifications

CHAPTER TEN / POWER TRIM AND TILT SYSTEMS AND POWER STEERING SYSTEM
Trim and tilt systems / Power trim and tilt systems / Power trim and tilt system service / Power steering system / Specifications

CHAPTER ELEVEN / OIL INJECTION SYSTEM
Variable ratio oil injection / Variable-ratio electronically controlled oil injection / Specifications

CHAPTER TWELVE / REMOTE CONTROL

INDEX

WIRING DIAGRAMS

Models covered: 1994 1995 1996 1997 Mercury/Mariner 75 HP
1994 1995 1996 1997 Mercury/Mariner 90 HP
1994 1995 1996 1997 Mercury/Mariner 100 HP
1994 1995 1996 1997 Mercury/Mariner 115 HP
1994 1995 1996 1997 Mercury/Mariner 125 HP
1994 1995 1996 1997 Mercury/Mariner 135 HP
1994 1995 1996 1997 Mercury/Mariner 150 HP
1994 1995 1996 1997 Mercury/Mariner 150 XR6
1994 1995 1996 1997 Mercury/Mariner 150 Magnum III
1994 1995 1996 1997 Mercury/Mariner 175 HP
1994 1995 1996 1997 Mercury/Mariner 200 DFI
1994 1995 1996 1997 Mercury/Mariner 200 HP
1994 1995 1996 1997 Mercury/Mariner 225 HP
1994 1995 1996 1997 Mercury/Mariner 250 HP
1994 1995 1996 1997 Mercury/Mariner 275 HP
1994 1995 1996 1997 Mercury/Mariner 65 Jet
1994 1995 1996 1997 Mercury/Mariner 80 JET
1994 1995 1996 1997 Mercury/Mariner 105 Jet
1994 1995 1996 1997 Mercury/Mariner 140 JET

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Clymer Manuals Mercury/Mariner 65 Jet Online Manual
Clymer Manuals Mercury/Mariner 80 JET Online Manual
Clymer Manuals Mercury/Mariner 105 Jet Online Manual
Clymer Manuals Mercury/Mariner 140 JET Online Manual

Mercury/Mariner 75 HP (1994-1997)
Mercury/Mariner 90 HP (1994-1997)
Mercury/Mariner 100 HP (1994-1997)
Mercury/Mariner 115 HP (1994-1997)
Mercury/Mariner 125 HP (1994-1997)
Mercury/Mariner 135 HP (1994-1997)
Mercury/Mariner 150 HP (1994-1997)
Mercury/Mariner 150 XR6 (1994-1997)
Mercury/Mariner 150 Magnum III (1994-1997)
Mercury/Mariner 175 HP (1994-1997)
Mercury/Mariner 200 DFI (1994-1997)
Mercury/Mariner 200 HP (1994-1997)
Mercury/Mariner 225 HP (1994-1997)
Mercury/Mariner 250 HP (1994-1997)
Mercury/Mariner 275 HP (1994-1997)
Mercury/Mariner 65 Jet (1994-1997)
Mercury/Mariner 80 JET (1994-1997)
Mercury/Mariner 105 Jet (1994-1997)
Mercury/Mariner 140 JET (1994-1997)

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