DOWNLOAD Mercury Outboard Repair Manual 1963-2009 Models

Mercury Outboard Repair Manual

A downloadable Mercury outboard repair manual, also known as a service manual, is a book of instructions consisting of product specifications, maintenance procedures, troubleshooting guide, and step-by-step directions to fix the outboard motor back to working order. The handbook is often used by do-it-yourself mechanics and dealership technicians to overhaul, restore or perform maintenance based on the boat motor’s manufacture specifications.

It is possible to download a Mercury outboard repair manual straight to your computer, tablet or smart phone in just seconds. However, it’s probably best to download a manual to a tablet or computer for more efficient viewing. Keep reading to lean how a Mercury repair manual download can help you.

How can a download mercury repair manual be of service to you?

Download-Online-Factory-Service-Repair-manual-PDF-free

Most importantly, a downloadable Mercury repair manual covers every aspect of repair—from basic maintenance to complete engine overhaul. Once a copy of the manual has been downloaded to your electronic device, such as a computer. It can be saved to the downloads folder or desktop forever.

Traditional paperback repair manuals often get dirty or greasy when being used to perform repairs. But with a download Mercury repair manual, you can print out only the page(s) you need to complete the repair work—and throw them in the trash when you’re done. You can even print out the entire Mercury manual if need be.

Traditional paperback Mercury repair books are often hard to find and usually need to be special ordered online. Aside from being very expensive, it can take weeks to finally receive it in the mail box. However, with a download Mercury repair manual, you can literally get one transferred  to your electronic device in under 3 minutes.

What type of content is in a download Mercury repair manual?

Table of contents

Every Mercury outboard repair manual begins with a table of contents, which is a list of titles or chapters of the book. And organized in the order of importance. In many cases the digitally delivered book contains clickable chapters and subchapters, allowing the user to navigate to parts of the book with the click of the mouse.

Product specifications

Every download repair manual contains a section which list the motor’s complete specifications; e.g. powerhead specs, lower unit specs, mid-unit specs and electrical specifications. It also contains torque specifications and other data.

Maintenance information

A wealth of information can be found in the maintenance section. Maintenance is important for keeping the boat engine in good condition. Performing routine maintenance also helps to extend the life of the motor. Maintenance schedules are included in every manual, detailing when and how each part should be maintained. Because outboard maintenance is so incredibly important, every boat owner should own a download repair manual for this reason.

Troubleshooting

Troubleshooting is a systematic process of tracing and solving faults in the Mercury outboard’s mechanical or electronic system. And at some point, every outboard will experience some type of fault. Sometimes the malfunction will be obvious, but at other times it can be difficult to understand what is wrong with the outboard motor. Having a troubleshooting guide handy is a simple way to easily trace and fix the motor’s problem. It’s important to print out the troubleshooting guide and keep a copy on the boat at all times.

Step-by-step servicing procedures

Don’t know how to fix your boat motor? No problem, download a repair manual now! A download repair manual is the same manual dealership mechanics use to fix the motor. It covers complete part inspection, removal, disassembly, cleaning, assembly and installation procedures. It also covers detailed testing procedures when applicable. Pictures, diagrams and illustrations are included when necessary to aid the mechanic through the repair process.

Wring and hose diagrams

Sometimes when fixing the motor the mechanic will remove hoses and wires from their position, then completely forget where they go. Reinstalling a wire or hose in the wrong spot can cause the motor to run terribly. This is another reason to always have a Mercury repair manual handy. Moreover, wiring diagrams are absolutely critical when performing electrical repairs, testing or when a wire color code chart is needed.

In summary, these are a few reasons why you should download a Mercury outboard repair manual. You never know when or if you might need one. And you don’t want to be 50 miles from shore with a dead motor and not knowing what to do get it started again. Trust me, I been there before! It’s not a good experience.

40 Comments

    • See download link at top of page. There is a repair manual that covers the following models and years:

      1984-1989 2.2HP Mercury 1-Cylinder
      1990-1991 2.2 HP (Model 3.0) 1-Cylinder
      1983-1985 3.5 HP Mercury 1-Cylinder
      1980-1982 3.6 HP Mercury 1-Cylinder
      1965-1968 3.9 HP Mercury (Model 39) 1-Cylinder
      1969-1974 4 HP Mercury (Model 40) 1-Cylinder
      1976-1980 4HP Mercury 2-Cylinder
      1986-1987 4HP Mercury 1-Cylinder
      1975-1978, 1979-1985 4.5HP Mercury 1-Cylinder
      1968-1987 6 HP Mercury 2-Cylinder
      1969-1978, 1979-1985 7.5HP Mercury 2-Cylinder
      1986-1990 8HP Mercury 2-Cylinder
      1965-1978 9.8 HP Mercury 2-Cylinder (Model 110)
      1979-1985 9.8HP Mercury 2-Cylinder (Model 9.8)
      1986-1991 9.9 HP Mercury 2-Cylinder
      1988-1990 15 HP Mercury 2-Cylinder
      1981-1983 18 HP Mercury 2-Cylinder
      1984-1985 18HP Mercury 2-Cyl. (Model 18XD)
      1968-1972, 1973-1990 20 HP Mercury 2-Cyl. (Model 200)
      1980-1983 25 HP Mercury 2-Cyl.
      1986-1989 25HP Mercury 2-Cyl.
      1984-1985 25HP Mercury 2-Cyl. (Model 25XD)
      1965-1969 35HP Mercury 2-Cyl. (Model 350)
      1984-1989 35 HP Mercury 2-Cyl. (Model 35)
      1970-1971 40HP Mercury 2-Cyl. (Model 400)
      1971-1974 40 HP Mercury 2-Cyl. (Model 402)
      1979-1983 40 HP Mercury 2-Cyl. (Model 40)

  1. I have a 2002 mercury 40hp with engine problems and need the service manual to fix it. I also have a 2003 50 hp mercury. Do you have manuals for these motors?

    • There’s a manual you can download that covers both models, as well as many others. It covers the following models:

      2.5 HP Mercury 1-Cylinder 2001-2005
      3.3 HP Mercury 1-Cylinder 2001-2005
      4 HP Mercury 1-Cylinder 2001-2005
      5 HP Mercury 1-Cylinder 2001-2005
      6 HP Mercury 2-Cyl. 2001-2003
      8 HP Mercury 2-Cyl. 2001-2005
      9.9 HP Mercury 2-Cyl. 2001-2005
      10 HP Mercury 2-Cyl. 2001
      15 HP Mercury 2-Cyl. 2001-2005
      20 HP Mercury 2-Cyl. 2001-2003
      20 (25) Jet Mercury 2-Cyl. 2001-2003
      25 HP Mercury 2-Cyl. 2001-2005
      30 HP Mercury 2-Cyl. 2001-2002
      40 HP Mercury 2-Cyl. 2001-2003
      40HP Mercury 3-Cyl. 2001-2005
      40 Jet (60) Mercury 3-Cyl. 2001-2005
      50 HP Mercury 3-Cyl. 2001-2005
      55 HP Mercury 3 Cyl. 2001
      60 HP Mercury 3 Cyl. 2001-2005
      75 HP Mercury 3 Cyl. 2001-2005
      75HP Mercury Optimax 3-Cyl. 2004-2005
      65 Jet (90) Mercury 3-Cyl. 2001-2005
      90 HP Mercury 3-Cyl. 2001-2005
      90HP Mercury Optimax 3-Cyl. 2004-2005
      115 HP Mercury Optimax 3-Cyl. 2004-2005
      80 Jet (115) Mercury 4-Cyl. 2001-2005
      115HP Mercury 4-Cyl. 2001-2005
      125 HP Mercury 4-Cyl. 2001-2005
      135 HP Mercury Optimax V-6 2001-2005
      150 HP (XR6, Classic) Mercury V-6 2001-2005
      150HP EFI Mercury 6-Cylinder 2001-2005
      150HP Mercury Optimax V-6 2001-2005
      175 HP EFI Mercury V6 2001-2002
      175HP Mercury Optimax V6 2001-2005
      200 HP Mercury V6 2001-2005
      200HP EFI (3.0L) Mercury 2004-2005
      200HP Mercury Optimax V-6 2001-2005
      225 HP EFI Mercury V6 2001-2005
      225HP Mercury Optimax V6 2001-2005
      250 HP EFI Mercury V-6 2001-2005

      New manuals added for…

      2008+ Mercury 40hp 50hp 60hp manual
      2008-2009 Mercury 15hp 20hp manual
      2010-2011 Mercury 15 hp 20 hp manual
      2012 Mercury 15hp 20hp manual
      2012 thru 2014 and 2015 Mercury 30hp 40hp Bigfoot and non Bigfoot

    • There is a couple different manuals for the 135hp. These models are covered:

      1998-2000 Mercury 135 hp Optimax DFI Direct Fuel Injection
      1999-2000 Mercury 150 hp Optimax DFI Direct Fuel Injection

      1992-1998 Mercury 135
      1992-1998 Mercury 150
      1992-1998 Mercury 150 XR6
      1992-1997 Mercury 150 Magnum III
      1992-1997 Mercury 150 EFI
      1992-1997 Mercury 175 HP
      1992-1998 Mercury 175 EFI
      1992-1998 Mercury 200 & 200 EFI
      1992-1996 Mercury 150 HP Pro Max
      1992-1998 Mercury 200/225 Pro Max
      2001-2002 200 hp OptiMax Jet Drive
      1992-1998 Mercury 150, 200, 225 Horsepower Super Magnum

      Both carburetor and fuel injection models covered.

    • There’s a download repair manual for the following models…yours is included. Just see download link at top of page.

      Models It Includes

      2002-2005 Mercury 40 hp 4-Stroke
      2002-2005 Mercury 50 hp Four-Stroke
      2002-2005 Mercury 60 hp 4-Stroke
      2002-2005 Mercury 40/50/60 ELPT 4-Stroke
      2002-2005 Mercury 40/50/60 ELPT Bigfoot 4-Stroke

      Hope that helps.

      • Have a 1983 Mercury 200 had the stator and Trigger replaced now the idle is at 3000 anything in the manual that would give me information on that issue

    • Yes, it’s a good repair manual! Covers every aspect of repair. It also covers a few other models in the same manual. Here’s a list of what’s covered. 1986-2003 Mercury outboard 6 thru 15 horsepower models:

      Mercury 6 HP
      Mercury 8 HP
      Mercury 8 HP Sailmate
      Mercury 9.9 HP
      Mercury 9.9 HP Sailpower, XR10/MAG 10/Viking 10
      Mercury Sea Pro/Marathon 10
      Mercury 15 HP
      Mercury Sea Pro/Marathon 15

    • You didn’t mention what model you have. Going to assume you have a 115 or 125 hp? But yes, the book details how to check for voltage issues, just see the download link. It covers the following models:

      Mercury 75 HP
      Mercury 75 HP Marathon
      Mercury 75 HP Sea Pro
      Mercury 90 HP M
      Mercury 100 HP
      Mercury 115 HP
      Mercury 125 HP
      Mercury 65 HP Jet
      Mercury 75 HP Jet
      Mercury 80 HP Jet
      Mercury 90 HP Jet

  2. Mercury Outboard, 2 Stroke, 85HP, Blue Line, 1979?m Thunderbolt Ignition. Couldn’t find a manual for my motor. Can you help ??

  3. I need a repair/workshop manual for a 2007 Mercury 200hp Optimax. I found one on your site that covers 2001-2005 models but not one for a 2007 model.

  4. Need service manual for 1999 200 EFI
    0G824030 Serial number

    Everything I read says it is an Optimax but cowl cover says EFI

  5. I have a Mercury 3.3 HP 2-stroke, Serial # 0D927536, Model #(?) 3G9.

    What year is that so I can purchase the appropriate maintenance and repair manual?

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