- 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
1997-1999 Mercury OptiMax 200, OptiMax 225 DFI, 225 hp, 200 hp service manual
Models covered in this manual:
File specifications
File type: PDF
Language: English
Printable: Yes
Estimated download time: 0.99 Minutes
$14.99
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Product Information
Table of Contents
- General Information
- Manual Organization
- Notes, Cautions, and Warnings
- Safety First
- Cleaning Parts
- Handling Gasoline Safely
- Service Hints
- Torque Specifications
- Fasteners
- Lubricants
- Threadlocking Compound
- RTV Gasket Sealant
- Expendable Supplies
- Serial Numbers
- Warning and Information Labels
- Basic Hand Tools
- Precision Measuring Tools
- Special Tools
- Fabricating Tools
- Mechanic’s Tips
- Bearing Replacement
- Seals
- Storage
- Troubleshooting
- Operating Requirements
- Troubleshooting Instruments
- Starting the Engine
- Starting Difficulties
- Engine is Difficult to Start
- Engine Starting System
- Charging System
- Ignition System
- Electronic Throttle Control
- Fuel System
- Engine Overheating
- Engine
- Engine Noises
- Cylinder Leak Down Test
- Power Train
- Steering
- Frame Noise
- Brakes
- Lubrication, Maintenance and Tune-Up
- Pre-Ride Checklist
- Tires and Wheels
- Battery
- Battery Electrical Cable Connectors
- Periodic Lubrication
- Periodic Maintenance
- Unscheduled Inspection and Maintenance
- Engine Tune-Up
- Engine Top End
- Engine Principles
- Engine Cooling
- Engine Lubrication
- Servicing the Engine in the Frame
- Exhaust System
- Cylinder Head Cover
- Rocker Arm Assembly
- Camshaft
- Cylinder Head
- Valves and Valve Components
- Cylinder Block
- Piston and Piston Rings
- Camshaft Chain and Sprockets
- Break-In Procedure
- Engine Lower End
- Engine
- Flywheel and Stator Plate
- Recoil Starter
- Crankcase
- Crankshaft Inspection
- Balancer Shaft Inspection
- Shaft End Float Measurement and Shim Selection
- Oil Pump
- Oil System One-Way Check Valve
- Break-In Procedure
- Fuel System
- Carburetor Operation
- Carburetor
- Carburetor Cleaning and Inspection
- Carburetor Tests and Adjustments
- Throttle Cable Replacement
- Starting Enrichment (Choke) Cable
- Fuel Tank
- Fuel Shutoff Valve
- Air Filter Air Box
- Fuel Pump
- Cooling Systems
- Polaris Variable Transmission (PVT) Air Cooling System
- Engine Cooling System
- Safety Precautions
- Hoses and Hose Clamps
- Engine Gaskets/Seals
- Cooling System Inspection
- Radiator
- Cooling Fan
- Coolant Pump
- Thermostat
- Temperature Sensors
- Clutch/Drive Belt System
- Drive Unit
- Drive Pulley
- Special Tools
- Driven Pulley
- Drive Belt
- Drive Pulley
- Driven Pulley
- Clutch Outer and Inner Cover (All Models)
- Transmission
- Transmission
- Transmission Inspection
- Shift Shafts
- Front Output Shaft
- Transmission Gearcase Oil Seal Inspection and Replacement
- Shift Selector Linkage
- Front Drive System
- Front Hub and Hillard Clutch
- Front Drive Axle, Boots and CV (Constant Velocity) Joints
- Front Drive Shaft
- Front Drive Unit
- Electrical System
- Basic Information
- Negative Battery Terminal
- Charging System
- Alternator Stator
- Voltage Regulator/Rectifier
- Capacitor Discharge Ignition
- Ignition Coil
- Ignition Stator Coils
- Electric Starting System
- Starter Drive Gears
- Starter Solenoid
- Lighting System
- Electrical Components
- Switches
- Wiring Diagrams
- Front Suspension and Steering
- Front Wheel
- Front Hub
- Front Strut Cartridge and Spring
- Front Strut/Spindle
- Control Arm
- Handlebar
- Tie Rods
- Steering Shaft
- Tires and Wheels
- Rear Suspension
- Rear Wheels
- Tire Changing and Tire Repairs
- Shock Absorber
- Rear Hub and Bearing Carrier
- Rear Axles
- Upper Control Arm
- Lower Control Arm
- Upper and Lower Control Arm Inspection
- Stabilizer Linkage
- Stabilizer Support
- Brakes
- Disc Brakes
- Front Brake Pad Replacement
- Front Caliper
- Output Shaft Brake Pad Replacement (1996-1997 Models)
- Output Shaft Brake Caliper (1996-1997 Models)
- Output Shaft Brake Pad Replacement (1998-On Models)
- Output Shaft Brake Caliper (1998-On Models)
- Front Master Cylinder
- Rear Master Cylinder
- Brake Hose Replacement
- Rear Brake Pedal
- Rear Brake Lever (1996-1997 Sweden Models)
- Foot Brake (1998-On Sweden Models)
- Brake Disc
- Bleeding the System
- Body
- Seat
- Front Rack and Grille
- Side Panels
- Front Fender
- Front Bumper (Models So Equipped)
- Radiator Guard
- Rear Rack
- Rear Fender
- Footwells
- Rear Bumper (Models So Equipped)
- Supplement
- 2001-2003 Service Information
- Starting the Engine
- Ignition System
- Periodic Maintenance
- Engine Tune-Up
- Cylinder Block
- Piston and Piston Rings
- Engine
- Flywheel and Stator Plate
- Carburetor (Sportsman 500 H.O. Models)
- Cleaning and Inspection
- Carburetor Tests and Adjustments
- Drive Belt
- Driven Pulley (2003 Models Built After 07/08/02)
- Transmission
- Lighting System
- Electrical Components
- Steering Shaft (2002-On Models)
- Rear Hub and Bearing Carrier (2003 Models)
- Rear Brake Pad Replacement (2003 Models)
- Rear Calipers (2003 Models)
- Front Master Cylinder
- Rear Master Cylinder
- Rear Brake Disc (2003 Models)
- Brake Hose Replacement (2003 Models)
- Index
- Wiring Diagrams
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