1999-2004 Mercury M2 Jet Drive 210/240 HP Service Manual (P/N 90-877837)

• 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
• Includes detailed fuel-injection specifications for both the 210 HP and 240 HP configurations
• Provides the foundational technical data for the entire M2 Jet Drive model range produced during these years

Technical Documentation and System Walkthrough

This factory publication breaks down the 210 HP and 240 HP powerheads into five core areas: Important Information, Electrical, Fuel System, Powerhead, and Pump Unit. Whether you are prepping for a routine 100-hour service or roughing in hull cutout dimensions, the exact factory requirements are laid out clearly. The text covers step-by-step assembly and installation protocols specifically designed for inboard jet configurations.

Beyond basic maintenance, the manual details steering cable adjustments and bilge siphon installation. Electrical systems receive heavy focus. Mechanics can trace circuitry issues quickly using the complete wiring diagrams, which map out the ignition charging system, switch box circuitry, and CDM component flow charts.

Specification Highlights and Reference Data

Rebuilding or tuning these two-cycle V-6 engines requires exact numbers. This reference delivers them. Cylinder head bolt torque is strictly defined at 225 lb. in. (25.4 Nm) plus an additional 90-degree turn. Down at the pump unit, you need to hit exactly 150 lb. ft. (203 Nm) on the impeller nut. Dialing in the engine? Idle speed settings sit right at 1000–1100 RPM.

Other critical specs include ignition timing for the 210 HP model, listed at 24 degrees BTDC at cranking speed. Fuel pressure runs at 8 PSI during wide-open-throttle. Everything is based around the 153.0 cu. in. displacement block used across the 1999–2004 production run.

Marine service work involves high-pressure fuel systems and heavy rotating machinery. Always review standard safety precautions and wear appropriate protective gear before applying the specifications listed in this document. Please note that this page serves as a contents overview for the reference material and does not provide active repair or diagnostic instructions.