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2000-2002 Mercury OptiMax 200 hp, 225 hp DFI outboard motor service manual Preview image 1
2000-2002 Mercury OptiMax 200 hp, 225 hp DFI outboard motor service manual Preview image 2
2000-2002 Mercury OptiMax 200 hp, 225 hp DFI outboard motor service manual Preview image 3
2000-2002 Mercury OptiMax 200 hp, 225 hp DFI outboard motor service manual Preview image 4
2000-2002 Mercury OptiMax 200 hp, 225 hp DFI outboard motor service manual Preview image 5
2000-2002 Mercury OptiMax 200 hp, 225 hp DFI outboard motor service manual Preview image 6

2000-2002 Mercury OptiMax 200 hp, 225 hp DFI outboard motor service manual

Includes the following models

  • 2000 Mercury OptiMax 200 hp DFI outboard
  • 2000 Mercury OptiMax 225 hp DFI outboard
  • 2001 Mercury OptiMax 200 hp DFI outboard
  • 2001 Mercury OptiMax 225 hp DFI outboard
  • 2002 Mercury OptiMax 200 hp DFI outboard
  • 2002 Mercury OptiMax 225 hp DFI outboard

Starting Model Year 2000, 2001, 2002
Starting Serial Number OG960500

File specifications

File size: 25.18 MB
File type: ZIP
Language: English (some of our manuals are multilingual)

Printable: Yes
Estimated download time: 0.52 Minutes
$14.99 Instant Download

Product Information

Table of Contents

1. General Information

  • Introduction
  • Engine Specifications
  • Maintenance Schedule
  • Safety Precautions
  • Tools and Equipment
  • Torque Specifications

2. Specifications

  • Master Specifications
  • Propeller Information Charts
  • Engine Specifications
  • Fuel System Specifications
  • Electrical System Specifications

3. Maintenance

  • Routine Maintenance Procedures
  • Lubrication Points
  • Fuel System Maintenance
  • Cooling System Maintenance
  • Electrical System Maintenance
  • Propeller Maintenance

4. Engine

  • Engine Removal and Installation
  • Powerhead Disassembly
  • Cylinder Head
  • Pistons and Connecting Rods
  • Crankshaft and Bearings
  • Engine Reassembly

5. Fuel System

  • Fuel System Overview
  • Fuel Tank and Lines
  • Fuel Pump
  • Fuel Injectors
  • Carburetor (if applicable)
  • Fuel System Troubleshooting

6. Cooling System

  • Cooling System Overview
  • Water Pump
  • Thermostat
  • Cooling Hoses and Lines
  • Cooling System Troubleshooting

7. Lubrication System

  • Oil Injection System
  • Oil Pump
  • Oil Tank and Lines
  • Lubrication System Troubleshooting

8. Ignition System

  • Ignition System Overview
  • Spark Plugs
  • Ignition Coils
  • Stator and Flywheel
  • Ignition Timing
  • Ignition System Troubleshooting

9. Electrical System

  • Electrical System Overview
  • Battery
  • Alternator
  • Starter Motor
  • Wiring Harness and Connectors
  • Electrical System Troubleshooting

10. Gearcase

  • Gearcase Removal and Installation
  • Gearcase Disassembly
  • Propeller Shaft and Bearings
  • Gears and Clutches
  • Gearcase Reassembly
  • Gearcase Troubleshooting

11. Power Trim and Tilt

  • Power Trim and Tilt Overview
  • Hydraulic Pump
  • Trim and Tilt Cylinders
  • Electrical Components
  • Power Trim and Tilt Troubleshooting

12. Steering System

  • Steering System Overview
  • Mechanical Steering
  • Hydraulic Steering
  • Steering Linkages
  • Steering System Troubleshooting

13. Controls and Cables

  • Control Box
  • Throttle and Shift Cables
  • Control Cable Adjustment
  • Control System Troubleshooting

14. Propeller

  • Propeller Selection
  • Propeller Removal and Installation
  • Propeller Inspection and Repair
  • Propeller Troubleshooting

15. Troubleshooting

  • General Troubleshooting Procedures
  • Engine Performance Issues
  • Fuel System Problems
  • Cooling System Problems
  • Electrical System Problems
  • Steering and Control Problems

16. Appendices

  • Special Tools
  • Conversion Tables
  • Service Specifications
  • Wiring Diagrams
  • Maintenance Log

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Manuals frequently bought together

1997-1999 Mercury OptiMax 200, OptiMax 225 DFI, 225 hp, 200 hp service manual

- Mercury OptiMax 200 - Mercury OptiMax 225 DFI - Mercury OptiMax 225 hp - Mercury OptiMax 200 hp Production/model years: 1997, 1998, 1999 Serial Numbers 0G386496 and Above

2000-2005 Mercury Optimax 200, Optimax 225 DFI outboard motor service manual

**Mercury Optimax Series 2000-2005** - 2000 > - Optimax 200 > - Optimax 225 DFI - 2001 > - Optimax 200 > - Optimax 225 DFI - 2002 > - Optimax 200 > - Optimax 225 DFI - 2003 > - Optimax 200 > - Optimax 225 DFI - 2004 > - Optimax 200 > - Optimax 225 DFI - 2005 > - Optimax 200 > - Optimax 225 DFI Starting Model Year 2000, 2001, 2002, 2003, 2004, 2005. Serial number or parts number: 0G960500 & Above - Mercury Optimax 200: starts with 0G386496 - Mercury Optimax 225: starts with 0G386496

2000-2004 Mercury 150hp, 175hp Optimax DFI outboard motor service manual

- Mercury 150XL Optimax DFI - Mercury 150CXL Optimax DFI - Mercury 175XL Optimax DFI - Mercury 175CXL Optimax DFI

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