2000-2001 OptiMax DFI Factory Service Manual

Mercury-Mariner Outboard Service Manuals 

Download Manuals Below

1965-1989 Mercury Mariner Workshop Workshop Manual 2 To 40 Hp 2 Stroke

1965-1989 Mercury Workshop Repair Manual 45 Thru 115hp 2 Stroke

1965-1989 Mercury Outboard 90-300 HP Repair Manual

1990-2000 Mercury Mariner Workshop Repair Manual 2.5 to 275 2-Stroke Motors

1986-2003 Mercury Factory Service Manual 6/8/9.9/10/15HP 2 Stroke

1995-2000 Mercury Mariner Factory 40 45 50 HP Service Manual

1997-2000 Mercury Mariner Factory 40 50 55 60hp Service Manual 2 Stroke

1997 1998 Mercury Factory Optimax 200 & 225 HP Service Manual

1998-1999 Mercury Mariner Factory 9.9 & 15 HP Service Repair Manual

1998-1999 Mercury Factory 135HP (135 HP) & 150HP (150 HP) Service Manual

1999-2002 Mercury - Mariner Factory 30 HP 40 HP Service Manual 4-Stroke Outboard

1999-2000 Mercury - Mariner Factory Service Manual 4HP 5HP 6HP (4 Stroke)

2000 2001 Mercury Factory 75/90 HP (75hp & 90hp) Outboard Service Manual

2000-2001 Mercury Factory Optimax 115 135 150 175 Service Repair Manual DFI

2001 Mercury Mariner Factory 50 HP & 2001 60 HP Service Manual

2001 2002 Mercury Factory 115 HP (115HP) Service Manual 4-Stroke

2002-2004 Mercury Factory 40 HP 50 HP 60 HP Service Manual 4-Stroke

Factory Service Manual Application: Mercury OptiMax Outboard motor service manual application: 2000-2001 Mercury 115hp (115 hp) 135hp (135 hp) 150hp (150 hp) 175hp (175 hp) DFI (Direct Fuel Injection) outboard motor.

Starting Model Year 2000
Starting Serial Number OG960500.


Service Manual Information

It is assumed that these personnel are familiar with the servicing procedures of these products,

or like or similar products manufactured and marketed by Mercury Marine, that they

have been trained in the recommended servicing procedures of these products which includes

the use of mechanics’ common hand tools and the special Mercury Marine or recommended

tools from other suppliers.

We could not possibly know of and advise the service trade of all conceivable procedures

by which a service might be performed and of the possible hazards and/or results of each

method. We have not undertaken any such wide evaluation. Therefore, anyone who uses

a service procedure and/or tool, which is not recommended by the manufacturer, first must

completely satisfy himself that neither his nor the products safety will be endangered by the

service procedure selected.

All information, illustrations and specifications contained in this manual are based on the

latest product information available at the time of publication. As required, revisions to this

manual will be sent to all dealers contracted by us to sell and/or service these products.

It should be kept in mind, while working on the product, that the electrical system and ignition

system are capable of violent and damaging short circuits or severe electrical shocks. When

performing any work where electrical terminals could possibly be grounded or touched by

the mechanic, the battery cables should be disconnected at the battery.

Any time the intake or exhaust openings are exposed during service they should be covered

to protect against accidental entrance of foreign material which could enter the cylinders and

cause extensive internal damage when the engine is started.

A marine power product is a combination of many machined, honed, polished and lapped

surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any

product component is serviced, care and cleanliness are important. Throughout this manual,

it should be understood that proper cleaning, and protection of machined surfaces and

friction areas is a part of the repair procedure. This is considered standard shop practice

even if not specifically stated.

Whenever components are removed for service, they should be retained in order. At the

time of installation, they should be installed in the same locations and with the same mating

surfaces as when removed.

Personnel should not work on or under an outboard which is suspended. Outboards should

be attached to work stands, or lowered to ground as soon as possible.

We reserve the right to make changes to this manual without prior notification.

Refer to dealer service bulletins for other pertinent information concerning the products described

in this manual.


Service Manual Outline


Section 1 - General Information & Specifications


A - Specifications

B - Maintenance

C - General Information

D - Outboard Installation


Section 2 - Electrical


A - Ignition

B - Charging & Starting System

C - Timing, Synchronizing & Adjusting

D - Wiring Diagrams


Section 3 - Fuel System


A - Fuel Pump

B - Direct Fuel Injection

C - Oil Injection

D - Emissions


Section 4 - Powerhead


A - Powerhead

B - Cooling


Section 5 - Mid-Section


A - Clamp/Swivel Brackets & Drive Shaft Housing

B - Power Trim – Design I (Showa)

C - Power Trim – Design II (Oildyne)


Section 6 - Gear Housing


A - Right Hand (Standard) Rotation Non-Ratcheting

B - Left Hand (Counter) Rotattion Non-Ratcheting


Section 7 - Attachments/Control Linkage

Section 8 - Color Diagrams