The Mercury Marine OptiMax Outboard, produced from 1997 through 2000 and beyond depending on the specific model, represents a line of V-6, 2-cycle direct injection engines. These outboards, available in various horsepower configurations including 115, 135, 150, 175, 200, and 225, are engineered for robust performance and reliability on the water. With displacements ranging from 2508 cc to 3047 cc, the OptiMax series is designed to meet the demands of diverse marine applications, offering advanced fuel injection technology for efficiency and power.
This workshop service repair manual provides comprehensive guidance for the maintenance and repair of your Mercury Marine OptiMax Outboard. It covers essential procedures such as disassembly, reassembly, installation, adjustment, and troubleshooting, supported by detailed illustrations, step-by-step instructions, and diagrams. The manual also delves into specific systems including electrical components like the ignition, charging, and starter systems, as well as fuel injection and cooling systems, and reverse operation. Furthermore, it includes information on DDT Functions for OptiMax models software, enabling detailed diagnostics for owners, mechanics, and technicians.
MERCURY MARINE 115 125 135 150 175 200 225 OPTIMAX WORKSHOP SERVICE REPAIR MANUAL
THIS MANUAL IS COMPATIBLE WITH THE FOLLOWING COMPUTER OPERATING SYSTEMS:
# ALL WINDOWS OPERATING SYSTEM
# ALL MAC OPERATING VERSION
YOU NEED THE ADOBE ACROBAT READER TO VIEW THE DOCUMENT AS THE MANUAL IS PDF FORMAT. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM: ADOBE WEBSITE
AS THIS MANUAL IS COMING TO YOU IN ZIP FORMAT, YOU NEED TO EXTRACT THE FILE BEFORE USE BY USING WINZIP OR WINRAR SOFTWARE. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM: ZIP WEBSITE
MODEL COVERED:
115 135 150 175 HP OPTIMAX, STARTING SERIAL NUMBER OG960500 (MODEL YEAR 2000+)
135 150 HP OPTIMAX, STARTING SERIAL NUMBER OG590000 (MODEL YEAR 1998-1999)
200 225 HP OPTIMAX, STARTING SERIAL NUMBER OG386496 (MODEL YEAR 1997-1999)
200 225 HP OPTIMAX, STARTING SERIAL NUMBER OG960500 (MODEL YEAR 2000+)
200 OPTIMAX JET DRIVE, POWERHEAD SERIAL 0E384500+ & PUMP UNIT SERIAL 0E379931+ (MODEL YEAR 2001+)
ENGINE COVERED:
2508 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 115/135/150/175 DFI)
3032 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 200/225 DFI)
3047 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 200/225 DFI)
2508 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 200 JET DRIVE)
CONTENTS:
GENERAL INFORMATION
SAFETY PRECAUTION
SPECIFICATIONS
TIGHTENING TORQUE
SPECIAL TOOLS
PAINTING PROCEDURES
DECAL APPLICATION
OUTBOARD MOTOR INSTALLATION
STEERING CABLE
ELECTRICAL, HOSES & CONTROL CABLES
REMOTE WIRING HARNESS
BATTERY CABLES
SHIFT CABLE INSTALLATION
THROTTLE CABLE SYSTEM
FILLING FUEL SYSTEM
INJECTION PUMP SYSTEM
IGNITION SYSTEM
ELECTRONIC CONTROL MODULE (ECM)
FLYWHEEL-COIL DRIVER
CRANK POSITION SENSOR
THROTTLE POSITION SENSOR (TPS)
CHARGING SYSTEM ALTERNATOR
FUEL INJECTORS SYSTEM
DDT FUNCTIONS - OPTIMAX MODELS SOFTWARE
STARTER SYSTEM
THROTTLE CAM ADJUSTMENT
IDLE SPEED SYSTEM
FUEL PUMP SYSTEM
DIRECT FUEL INJECTION
AIR COMPRESSOR SYSTEM
OILING SYSTEM
EMISSIONS SYSTEM
CRANKSHAFT-PISTONS-CONNECTING RODS
POWERHEAD DISASSEMBLY
BEARING BLEED SYSTEM
POWERHEAD REASSEMBLY
THROTTLE LEVER AND SHIFT SHAFT
COOLING SYSTEM
SWIVEL BRACKET AND STEERING ARM
TRANSOM BRACKETS
DRIVE SHAFT HOUSING
POWER TRIM MOTOR
HYDRAULIC REPAIR
TRAIL OVER SYSTEM
REVERSE OPERATION
ELECTRICAL SYSTEM
DRIVE SHAFT-PROPELLER SHAFT
WATER FLOW DIAGRAM
TROUBLESHOOTING
WIRING DIAGRAMS
THIS MANUAL PRESENTED FOR YOU IN ELECTRONIC FORMAT YOU CAN JUST PRINT OUT THE PAGE YOU NEED THEN DISPOSE OF IT WHEN YOU HAVE COMPLETED YOUR TASK. THIS MANUAL HAS DETAILED ILLUSTRATIONS AS WELL AS STEP BY STEP WRITTEN INSTRUCTIONS WITH THE NECESSARY DIAGRAMS OR PICTURES. THESE MANUAL ARE YOUR NUMBER ONE SOURCE FOR REPAIR AND SERVICE INFORMATION & SPECIFICALLY WRITTEN FOR THE DO-IT-YOURSELF AS WELL AS THE EXPERIENCED MECHANICS WORLDWIDE USED TO USE THIS FACTORY MANUAL TO FIX YOUR MACHINE. USING THIS REPAIR MANUAL IS AN INEXPENSIVE WAY TO KEEP YOUR VEHICLE WORKING PROPERLY. IT IS THIS LEVEL OF DETAIL, ALONG WITH ILLUSTRATED, THAT GUIDE THE READER THROUGH EACH SERVICE, REPAIR & MAINTENANCE PROCEDURE.
I ALSO HAVE LOTS OF MANUAL WHICH ARE NOT ADVERTISED IN MY STORE, IF YOU NOT FOUND YOUR DESIRED MANUAL IN MY STORE, PLEASE MASSAGE ME AND I WILL TRY MY BEST TO PROVIDE YOU THAT MANUAL.
MERCURY MARINE 115 125 135 150 175 200 225 OPTIMAX WORKSHOP SERVICE REPAIR MANUAL
THIS MANUAL IS COMPATIBLE WITH THE FOLLOWING COMPUTER OPERATING SYSTEMS:
# ALL WINDOWS OPERATING SYSTEM
# ALL MAC OPERATING VERSION
YOU NEED THE ADOBE ACROBAT READER TO VIEW THE DOCUMENT AS THE MANUAL IS PDF FORMAT. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM: ADOBE WEBSITE
AS THIS MANUAL IS COMING TO YOU IN ZIP FORMAT, YOU NEED TO EXTRACT THE FILE BEFORE USE BY USING WINZIP OR WINRAR SOFTWARE. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM: ZIP WEBSITE
MODEL COVERED:
115 135 150 175 HP OPTIMAX, STARTING SERIAL NUMBER OG960500 (MODEL YEAR 2000+)
135 150 HP OPTIMAX, STARTING SERIAL NUMBER OG590000 (MODEL YEAR 1998-1999)
200 225 HP OPTIMAX, STARTING SERIAL NUMBER OG386496 (MODEL YEAR 1997-1999)
200 225 HP OPTIMAX, STARTING SERIAL NUMBER OG960500 (MODEL YEAR 2000+)
200 OPTIMAX JET DRIVE, POWERHEAD SERIAL 0E384500+ & PUMP UNIT SERIAL 0E379931+ (MODEL YEAR 2001+)
ENGINE COVERED:
2508 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 115/135/150/175 DFI)
3032 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 200/225 DFI)
3047 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 200/225 DFI)
2508 cc 6-CYLINDER V-6, 2-CYCLE, DIRECT INJECTED FUEL(MODEL 200 JET DRIVE)
CONTENTS:
GENERAL INFORMATION
SAFETY PRECAUTION
SPECIFICATIONS
TIGHTENING TORQUE
SPECIAL TOOLS
PAINTING PROCEDURES
DECAL APPLICATION
OUTBOARD MOTOR INSTALLATION
STEERING CABLE
ELECTRICAL, HOSES & CONTROL CABLES
REMOTE WIRING HARNESS
BATTERY CABLES
SHIFT CABLE INSTALLATION
THROTTLE CABLE SYSTEM
FILLING FUEL SYSTEM
INJECTION PUMP SYSTEM
IGNITION SYSTEM
ELECTRONIC CONTROL MODULE (ECM)
FLYWHEEL-COIL DRIVER
CRANK POSITION SENSOR
THROTTLE POSITION SENSOR (TPS)
CHARGING SYSTEM ALTERNATOR
FUEL INJECTORS SYSTEM
DDT FUNCTIONS - OPTIMAX MODELS SOFTWARE
STARTER SYSTEM
THROTTLE CAM ADJUSTMENT
IDLE SPEED SYSTEM
FUEL PUMP SYSTEM
DIRECT FUEL INJECTION
AIR COMPRESSOR SYSTEM
OILING SYSTEM
EMISSIONS SYSTEM
CRANKSHAFT-PISTONS-CONNECTING RODS
POWERHEAD DISASSEMBLY
BEARING BLEED SYSTEM
POWERHEAD REASSEMBLY
THROTTLE LEVER AND SHIFT SHAFT
COOLING SYSTEM
SWIVEL BRACKET AND STEERING ARM
TRANSOM BRACKETS
DRIVE SHAFT HOUSING
POWER TRIM MOTOR
HYDRAULIC REPAIR
TRAIL OVER SYSTEM
REVERSE OPERATION
ELECTRICAL SYSTEM
DRIVE SHAFT-PROPELLER SHAFT
WATER FLOW DIAGRAM
TROUBLESHOOTING
WIRING DIAGRAMS
THIS MANUAL PRESENTED FOR YOU IN ELECTRONIC FORMAT YOU CAN JUST PRINT OUT THE PAGE YOU NEED THEN DISPOSE OF IT WHEN YOU HAVE COMPLETED YOUR TASK. THIS MANUAL HAS DETAILED ILLUSTRATIONS AS WELL AS STEP BY STEP WRITTEN INSTRUCTIONS WITH THE NECESSARY DIAGRAMS OR PICTURES. THESE MANUAL ARE YOUR NUMBER ONE SOURCE FOR REPAIR AND SERVICE INFORMATION & SPECIFICALLY WRITTEN FOR THE DO-IT-YOURSELF AS WELL AS THE EXPERIENCED MECHANICS WORLDWIDE USED TO USE THIS FACTORY MANUAL TO FIX YOUR MACHINE. USING THIS REPAIR MANUAL IS AN INEXPENSIVE WAY TO KEEP YOUR VEHICLE WORKING PROPERLY. IT IS THIS LEVEL OF DETAIL, ALONG WITH ILLUSTRATED, THAT GUIDE THE READER THROUGH EACH SERVICE, REPAIR & MAINTENANCE PROCEDURE.
I ALSO HAVE LOTS OF MANUAL WHICH ARE NOT ADVERTISED IN MY STORE, IF YOU NOT FOUND YOUR DESIRED MANUAL IN MY STORE, PLEASE MASSAGE ME AND I WILL TRY MY BEST TO PROVIDE YOU THAT MANUAL.
