2000-2002 Mercury OptiMax 200 hp / 225 hp DFI Outboard Service Manual
This comprehensive Mercury OptiMax service manual covers 2000-2002 models, including the 200 hp and 225 hp DFI outboards. Essential for maintenance and repair. Part number 90-859769R1.
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Sample pages from the 2000-2002 Mercury OptiMax 200 hp / 225 hp DFI Outboard Service Manual manual
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Models Covered & Key Technical Specifications
Mercury OptiMax 200 / 225 DFI (90-859769R1) – 2000-2002
This comprehensive workshop manual provides detailed specifications and procedures for your Mercury OptiMax outboard. A functional repository of technical data and diagrams.
- General System Data: 516.0 lbs. (234.0 kg) is the base outboard weight for the 20 in. shaft configuration.
- Engine Cylinder Block: V-6 Cylinder, Two Cycle, Direct Injected displacement of 185.9 cu. in. (3047 cc) is designed for optimal performance.
- Critical Gear Ratio: 1.75:1 represents the standard gear reduction for all models.
- Advanced Ignition Timing: Digital Inductive 1-2-3-4-5-6 firing order ensures precise ignition control.
- Defined Air Pressure: 79 ± 2 psi (544.0 ± 13.8 kPa) indicates the specified high-pressure fuel line air pressure.
- General System Data: 27.0 fl. oz. (798.0 ml) is the standard gearcase capacity for ensuring proper lubrication.
Professional Workshop Service Manual & Technical Specifications
Mercury OptiMax 200 / 225 DFI Service Manual: Mercury Outboard Expert PDF manual: Mercury OptiMax 200/225 DFI, 2000, 2001, 2002 Repository
Model-Designation: 2000-2002 Mercury OptiMax 200 hp / 225 hp DFI Outboards // Series-Validation: Outboard Motor / DFI // Model-Designation: Service Manual
Specifications
| Metric | Value | Context |
|---|---|---|
| Full Throttle RPM | 5000 - 5750 | N/A |
| Idle RPM (In Gear) | 550 | N/A |
| Maximum Timing | Not Adjustable; Controlled by ECM | N/A |
| Idle Timing | Not Adjustable; Controlled by ECM | N/A |
| Firing Order | 1-2-3-4-5-6 | N/A |
| Throttle Position Sensor (@ Idle) | 4.0 - 4.7 VDC | N/A |
| Throttle Position Sensor (@ W.O.T) | 0.4 - 1.3 VDC | N/A |
Table of Contents
Maintenance hierarchies are structured into:
- Specifications
- Special Tools
- Fuel System
- Ignition System
- Charging & Starting System
Procedures
Fuel system procedures are documented for cleaning and inspecting fuel components. Adjustment procedures are detailed for throttle cam and roller alignment. Timing procedures are documented for crank position sensor setting. Technical notes are provided for air compressor pressure testing. Quality checks are addressed for battery and alternator systems.
...documents torque specifications for engine mounting bolts to ensure proper dynamic load distribution.
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