- 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
Pay with Bitcoin
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
How to Download Your Manual - Delivery Policy
Within a minute after completing the payment process, you will receive two emails from us. One for the completed payment and another with the download link. The download link is valid for 3 days.
Lifetime Guarantee
Manuals frequently bought together
Add Comment
Insert Bullet List
Please enter at least one item.
Item:
Item:
Item:
Item:
Item:
Insert Numeric List
Please enter at least one item.
Item:
Item:
Item:
Item:
Item:
Insert Link
Please enter the link of the website
Optionally you can add display text
Insert Email
Please enter the email address
Optionally add any display text
Insert Image
Please enter the link of the image
Insert YouTube Video
Please enter the link of the video
Privacy Policy
This policy contains information about your privacy. By posting, you are declaring that you understand this policy:
- Your name, rating, website address, town, country, state and comment will be publicly displayed if entered.
- Aside from the data entered into these form fields, other stored data about your comment will include:
- Your IP address (not displayed)
- The time/date of your submission (displayed)
- Your email address will not be shared. It is collected for only two reasons:
- Administrative purposes, should a need to contact you arise.
- To inform you of new comments, should you subscribe to receive notifications.
- A cookie may be set on your computer. This is used to remember your inputs. It will expire by itself.
This policy is subject to change at any time and without notice.
Terms and Conditions
These terms and conditions contain rules about posting comments. By submitting a comment, you are declaring that you agree with these rules:
- Although the administrator will attempt to moderate comments, it is impossible for every comment to have been moderated at any given time.
- You acknowledge that all comments express the views and opinions of the original author and not those of the administrator.
- You agree not to post any material which is knowingly false, obscene, hateful, threatening, harassing or invasive of a person's privacy.
- The administrator has the right to edit, move or remove any comment for any reason and without notice.
Failure to comply with these rules may result in being banned from submitting further comments.
These terms and conditions are subject to change at any time and without notice.
{"commentics_url":"\/\/www.repairloader.com\/comments\/","page_id":149627,"enabled_country":false,"country_id":0,"enabled_state":false,"state_id":0,"enabled_upload":false,"maximum_upload_amount":3,"maximum_upload_size":5,"maximum_upload_total":5,"captcha":true,"captcha_url":"https:\/\/www.repairloader.com\/comments\/frontend\/index.php?route=main\/form\/captcha&page_id=149627","cmtx_wait_for_comment":"cmtx_wait_for_comment","lang_error_file_num":"A maximum of %d files are allowed to be uploaded","lang_error_file_size":"Please upload files no bigger than %.1f MB in size","lang_error_file_total":"The total size of all files must be less than %.1f MB","lang_error_file_type":"Only image file types are allowed to be uploaded","lang_text_loading":"Loading ..","lang_placeholder_country":"Country","lang_placeholder_state":"State","lang_text_country_first":"Please select a country first","lang_button_submit":"Add Comment","lang_button_preview":"Preview","lang_button_remove":"Remove","lang_button_processing":"Please Wait.."}
{"commentics_url":"\/\/www.repairloader.com\/comments\/","language":"english"}
Comments