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

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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