1999-2004 Mercury M2 Jet Drive 210/240 HP Service Manual

Complete service and repair procedures for Mercury M2 Jet Drive with 210 and 240 horsepower gasoline engines. Technical reference for precision maintenance and component overhaul specifications. Document 90-877837.

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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

Mercury Models Covered & Key Technical Specifications

Models: Mercury M2 Jet Drive 210 HP, Mercury M2 Jet Drive 240 HP
Sub-models / Variants: 210 HP model, 240 HP model, Powerhead unit, Pump unit
Build Years: 1999–2004
Serial Numbers: Powerhead 0E373939 and higher, Pump unit 0E370718 and higher
Technical Data:

  • Engine type: V-6 Cylinder, 2-cycle, loop-charged
  • Engine displacement: 153.0 cu. in. (2507 cc)
  • Horsepower: 210 HP (156.6 kW), 240 HP (178.9 kW)
  • Fuel system: Oil Injection, 50:1 fuel-to-oil ratio (25:1 break-in)
  • Fuel pressure: 2 PSI @ idle, 8 PSI @ wide-open-throttle
  • Idle RPM: 1000–1100 RPM
  • Ignition system: Capacitor Discharge (CDM for 240 HP, Switch Box for 210 HP)
  • Charging system: 15 Amperes @ 3000 RPM (210 HP), 40 Amperes @ 5000 RPM (240 HP)
Technical Specifications
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Document Number / Seller:
25408 / Richard Miller
File Size:
12.99 MB
File Type:
PDF
Language:
English
Pages:
409
Printable:
Yes
Category:
Inboard-Engines-Sterndrives
Last updated / verified
Mar 27, 2025

Mercury Manual Features & Content Preview

Mercury M2 Jet Drive 210/240 HP Service Manual Coverage

  • Built for owners and technicians servicing the 1999–2004 Mercury M2 Jet Drive 210 HP and 240 HP inboard jet drive power packages
  • Official Mercury Marine publication P/N 90-877837, November 1999 edition
  • Contains 409 pages of technical specifications, exploded-view diagrams, wiring schematics, and ignition system troubleshooting flow charts
  • Accessible from your device as soon as the order is placed
  • Suitable for printing individual sections for shop-floor use
  • Indexed PDF search covers every chapter and appendix
  • Re-download the file any time, no expiration
  • This 1999 factory manual provides the foundational technical data for the entire M2 Jet Drive 210/240 HP model range produced during these years

Technical Documentation and System Walkthrough

This factory service publication provides technical data for the M2 Jet Drive 210 HP and 240 HP powerheads. The document segments information into five core technical areas: Important Information, Electrical, Fuel System, Powerhead, and Pump Unit. The manual covers assembly, installation requirements for inboard jet configurations, and maintenance schedules for 10, 50, and 100-hour service intervals.

The document details specific procedures for hull cutout dimensions, steering cable adjustment, and bilge siphon installation. It includes comprehensive electrical wiring diagrams for the M2 Jet Drive, encompassing the ignition charging system, switch box circuitry, and CDM component troubleshooting flow charts for both the 210 HP and 240 HP configurations.

Specification Highlights and Reference Data

The technical sections contain precise data for rebuilding and tuning these two-cycle V-6 engines. Cylinder head bolt torque is documented at 225 lb. in. (25.4 Nm) plus an additional 90° turn. Impeller nut torque for the pump unit is specified at 150 lb. ft. (203 Nm). Idle speed settings for the 210/240 HP M2 Jet Drive are defined at 1000–1100 RPM.

Ignition timing for the 210 HP model is listed at 24° BTDC at cranking speed. Fuel pressure for the system is documented at 8 PSI at wide-open-throttle. This official factory reference guide covers engine displacement of 153.0 cu. in. for the complete 1999–2004 Mercury M2 Jet Drive line.

Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions.

An official 409-page Mercury Marine OEM workshop manual covering the 1999–2004 Mercury M2 Jet Drive, documenting engine, jet pump, electrical, and fuel-injection specifications for the 210 and 240 HP power packages.

Manual FAQ, Purchase & Download Details

Is there a reference for tightening specifications and torque charts within the manual? keyboard_arrow_down

Manual includes dedicated specification tables that list torque requirements for various assemblies like the powerhead and pump unit. These sections provide reference ranges for fasteners to assist with identification and proper hardware application.

Can I find information about the electrical system or wiring diagrams in this document? keyboard_arrow_down

Section 2 contains electrical content including ignition, charging, and starting system details along with comprehensive wiring diagrams.

Does the manual provide exploded views of the engine or pump unit components? keyboard_arrow_down

Document contains various component views and diagrams, such as those illustrating the starboard and port sides of the 210 and 240 HP models. These figures help visualize the location of assemblies like the flywheel cover, expansion chamber, and pump housing. You can use these references to understand the layout and arrangement of parts throughout the M2 Jet Drive system.

Are the PDF manuals provided as instant downloads for immediate access? keyboard_arrow_down

Publication is provided as a digital PDF document available for immediate download upon purchase, compatible with standard viewing devices.

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