Mercury 75 MARATHON Manuals

Manuals and User Guides for Mercury 75 MARATHON. We have 1 Mercury 75 MARATHON manual available for free PDF download: Service Manual

Mercury 75 MARATHON Service Manual

Mercury 75 MARATHON Service Manual (574 pages)

Brand: Mercury | Category: Outboard Motor | Size: 15.05 MB

Table of Contents

Important 1 C

14
- Propeller Information
  3
- How to Use this Manual
  3
- Table of Contents
  14
- Serial Number Location
  15
- Conditions Affecting Performance
  15
- Weather
  15
- Boat
  16
- Engine
  16
- Fresh Water Submersion
  17
- Following Complete Submersion
  17
- Salt Water Submersion
  17
- Submerged While Running
  17
- Propeller Selection
  18
- Propeller Installation
  18
- Power Trim System
  19
- General Information
  19
- Power Trim Operation
  19
- Trim "In" Angle Adjustment
  20
- Compression Check
  20
- Painting Procedures
  21
- Cleaning & Painting Aluminum Propellers & Gear Housings
  21
- Decal Application
  22
- Decal Removal
  22
- Instructions for "Wet" Application
  22
Important 1 D

24
Electrical 2

38
Electrical 2

82
Electrical 2

109
- Special Tools
  110
- Specifications
  110
- Timing/Synchronizing/Adjusting (3 Cylinder Models)
  110
- Special Tools
  114
- Specifications
  114
- Throttle Cable Installation
  114
- Timing/Synchronizing/Adjusting (4 Cylinder Models)
  114
- Idle Adjustment
  118
- Throttle Cable Installation
  118
Electrical 2

120
Fuel System

147
- Notes
  148
- Jet 75-90 (3 Cyl.)
  149
- Jet-100-115-125 (4 Cyl.)
  150
- Fuel Pump (65 Jet/75/90)
  151
- Fuel Pump (80 Jet/100/115/125)
  155
- Testing
  157
- Theory of Operation
  157
- Troubleshooting Fuel Pump
  157
- Check Valve Reassembly
  158
- Fuel Pump - Cleaning/Inspection
  158
- Removal
  158
- Reassembly
  159
- Installation of Fuel Pump
  160
Fuel System

162
- Specifications
  163
- WME Carburetor Chart
  163
- Special Tools
  165
- Carburetor (WME-29/30/31/41/46/47/48/49)
  166
- Carburetor-WME-32/32A/33/34/40/40A
  172
- Carburetor-WME-50/51/52/79/80/81
  174
- Fuel System (Linkage)
  178
- Adjustments
  179
- Float Adjustment
  179
- Idle Mixture Screw Adjustment
  179
- Idle Speed Adjustment
  179
- Jet Orifice Size Chart
  180
- Main (High Speed) Jet Adjustment
  180
- High Altitude Jet Chart
  181
- Fuel System Troubleshooting
  182
- General Information
  182
- Problem: Engine Floods
  182
- Problem: Engine Runs too Rich
  182
- Problem: Fuel Blow Back out of Carburetor
  182
- Problem: Rough Idle
  182
- Problem: Engine Turns over but will Not Start or Starts Hard When Cold
  183
- Problem: Unable to Reduce Engine RPM to Slow Idle
  183
- Engine Idles Rough and Stalls -Engine Runs Uneven or Surges -Engine will Not Accelerate
  184
- Problem: Engine Runs too Lean
  184
- Problems
  184
- Inspection
  185
- Description for Four Cylinder Engines
  186
- Description for Three Cylinder Engines
  186
- Enrichener System
  186
- Enrichener Valve Hose Installation - Four Cylinder Engines
  186
- Enrichener Valve Hose Installation - Three Cylinder Engines
  186
- Acceleration Pump Circuit Operation - Four Cylinder Engines
  188
- Four Cylinder Engines
  188
Fuel System

191
- Notes
  192
- Oil Injection Components
  193
- Oil Injection Components (S/N-USA-0G301751/BEL-9885505
  193
- Description
  197
- Hose Connections
  197
- Oil Pump Drive System
  197
- And 4 Cylinder Oil Flow Diagram
  198
- Carburetor/Oil Pump Synchronization
  199
- Filling Oil Tank
  199
- Bleeding Air from Oil Injection System
  200
- Bleeding Air from Oil Pump Inlet Hose
  200
- Bleeding Air from Oil Pump Outlet Hose
  200
- Oil Pump Test
  200
- Low Oil Sensor Test
  201
- Warning Horn System
  201
- (Models with Warning Module)
  202
- Oil Injection System Troubleshooting Chart
  202
- Troubleshooting Chart
  202
- Troubleshooting the Oil Injection System
  202
Table of Contents

204
- Carbon Monoxide - CO
  205
- Controlling Emissions
  205
- Exhaust Emissions Standards
  205
- Hydrocarbons - HC
  205
- Oxides of Nitrogen - Nox
  205
- Stoichiometric (14.7:1) Air/Fuel Ratio
  205
- What Are Emissions
  205
- Outboard Hydrocarbon Emissions Reductions
  206
- Homogenized Charge
  207
- Stratified Charge
  207
- Stratified Vs Homogenized Charge
  207
- Dealer Responsibility
  208
- Emissions Information
  208
- EPA Emission Regulations
  208
- Manufacturer's Responsibility
  208
- Owner Responsibility
  208
- Decal Location for 1998 Models
  210
Powerhead

212
- Specifications
  213
- General Information
  214
- Tools for Powerhead Repair
  214
- Notes
  215
- Crankshaft, Pistons and Connecting Rods (3 Cyl.)
  216
- Cylinder Block (3 Cyl.) (USA-0G127499/BEL-9836632 & BELOW)
  218
- Cylinder Block (3 Cyl.) (USA-0G127500/BEL-9836633 & UP)
  222
- Induction Manifold and Reed Block (3 Cyl.)
  226
- Crankshaft, Pistons and Connecting Rods (4 Cyl.)
  228
- Cylinder Block and Crankcase (80 Jet/100/115/125)
  230
- Induction Manifold and Reed Block (80 Jet/100/115/125)
  234
- Throttle Lever and Linkage (65 Jet/75/90 Models)
  236
- Throttle Lever (Models 80Jet/100/115/125)
  238
- Powerhead Removal
  241
- Flywheel Removal
  246
- Powerhead Disassembly
  247
- Cleaning and Inspection
  252
- Cylinder Block and Crankcase Cover
  252
- Check Valves
  254
- Piston and Piston Rings
  254
- Connecting Rods
  256
- Crankshaft
  256
- Cylinder Cover, Exhaust Divider Plate and Exhaust Cover
  257
- Thermostat
  257
- Reed Blocks
  258
- Temperature Switch Test
  258
- General Information
  259
- Powerhead Reassembly and Installation
  259
- Assembling Rod to Piston
  260
- End Cap
  260
- Piston Ring Installation
  261
- Crankshaft Installation
  263
- Connecting Rod Cap Alignment
  266
- Crankcase Cover to Block
  267
- Cylinder Block Cover
  268
- Exhaust Plate Cover and Exhaust Divider Plate
  269
- Intake Manifold and Reed Block Installation
  271
- Accelerator Pump Installation (4 Cylinder Models)
  272
- Cylinder Bleed Hose Routing
  273
- Cylinder Bleed Hose Routing (1995 and Prior)
  274
- Cylinder Bleed Hose Routing (1996 and Newer)
  275
- Cylinder Fuel Enrichment/Accelerator Pump Hose Routing
  276
- And Newer 3 Cylinder Harness Routing (Without Oil Reservoir Installed)
  277
- And Newer 3 Cylinder Harness Routing (with Oil Reservoir Installed)
  278
- Cylinder Manual Start Harness Routing
  279
- And Newer 4 Cylinder Harness Routing
  281
- And Newer 4 Cylinder Harness Routing (with Oil Reservoir Installed)
  281
- Ignition Plate Installation
  282
- Trigger and Stator Installation
  283
- Stator Installation
  284
- Carburetor Installation
  286
- Temperature Sensor Installation
  286
- Flywheel Installation
  288
- Oil Reservoir Installation
  288
- Air Box Installation
  289
- Powerhead to Driveshaft Housing
  290
- Reinstall Bottom Cowl
  291
MID-Section

293
MID-Section

318
- Special Tools
  319
- Power Trim Components (Black Fill Plug) (S/N-USA-0G360002/BEL-9934136 & BELOW)
  320
- Description
  322
- Power Trim - General Information
  322
- Trailering Outboard
  322
- Trimming Characteristics
  322
- Tilting Outboard up and down Manually
  323
- Trim "In" Angle Adjustment
  323
- Determining if Problem Is Electrical or Hydraulic 5B-6
  324
- Problem Chart
  324
- Troubleshooting
  324
- Date Code Location
  325
- Hydraulic System Troubleshooting
  325
- Leak down Check - Pump and Manifold Assembly
  326
- Preliminary Checks
  326
- Reassembly
  327
- Power Trim Partial Leak down at Maximum Trim
  328
- Leak down Check - Manual Release Valve
  329
- Leak down Check - Pilot Valve Assembly
  329
- Leaks Past Ball and Seat - Piston Assembly
  329
- Power Trim Rocker Arm
  330
- Troubleshooting Flow Diagram
  331
- Troubleshooting Flow Diagram
  332
- COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
  333
- Electrical System Troubleshooting
  333
- Power Trim System Wiring Diagram
  334
- Troubleshooting the "Down" Circuit
  335
- Troubleshooting the "Up" Circuit
  335
- Troubleshooting the "Down" and "Up" Circuits* (All Circuits Inoperative)
  336
- Power Trim System Removal
  337
- Power Trim System Disassembly
  342
- Trim Rod Removal
  342
- Trim Rod Disassembly
  343
- Trim Motor Removal
  344
- Reservoir Assembly Removal
  345
- Trim Motor Disassembly
  345
- Manifold Removal
  346
- Motor and Electrical Tests/Repair
  347
- Solenoid Test
  347
- Trim Pump Motor Test
  347
- Armature Tests
  348
- Motor Disassembly
  348
- Motor Repair
  349
- Manifold Installation
  351
- Power Trim System Reassembly
  351
- Reassembly
  351
- Reservoir Installation
  352
- Motor Installation
  353
- Trim Rod Reassembly
  354
- Trim Rod Installation
  355
- Power Trim Unit Installation
  356
- Purging Power Trim Unit
  356
MID-Section

360
- Special Tools
  361
- Power Trim Components (Yellow Fill Plug)
  362
- Description
  363
- Power Trim Flow Diagrams - Trim up Circuit
  366
- Tilt Circuit
  368
- Maximum Tilt
  370
- Down Circuit
  372
- Shock Function up
  374
- Shock Function Return
  376
- Manual Release
  378
- Adjustments
  380
- Trimming Characteristics
  380
- Tilting Outboard up and down Manually
  381
- Trailering Outboard
  381
- Preliminary Checks
  382
- Troubleshooting
  382
- Hydraulic System Troubleshooting Flow Chart
  383
- Troubleshooting the Power Trim Electrical System
  387
- Power Trim System Removal
  389
- Power Trim Disassembly
  390
- Pump and Components Removal
  391
- Trim Motor Removal
  391
- Manifold Removal
  392
- Shock Rod Removal
  392
- Shock Rod Disassembly
  393
- Memory Piston Removal
  395
- Cleaning/Inspection/Repair
  396
- Trim Motor Electrical Tests
  396
- O-Ring and Seal Placement
  397
- Reassembly
  397
- O-Ring Sizes
  398
- O-Ring Description and Sizes
  399
- Power Trim Reassembly
  400
- Shock Rod Reassembly
  400
- Shock Rod Installation
  401
- Manifold Installation
  402
- Manual Release Valve Installation
  402
- Trim Limit Assembly Installation
  402
- Oil Pump Installation
  403
- Pressure Operated Assembly Installation
  404
- Reservoir/Motor Installation
  404
- Bleeding Power Trim Unit
  405
- Installation of Power Trim System
  405
MID-Section

414
- Special Tools
  415
- Manual Tilt Assist Components
  416
- Manual Trim Flow Diagrams - up Circuit
  418
- Tilt up
  419
- Down Circuit
  420
- Tilt down
  421
- Slow Tilt down under High Thrust
  422
- Slow Tilt down under High Thrust
  423
- Under Water Strike (Valves Open)
  424
- Under Water Strike with Valves Open
  425
- Shock Function (Valve Closed)
  426
- Shock Function with Valves Closed
  427
- Shock Function Return
  428
- Shock Function Return
  429
- Hydraulic System Troubleshooting
  430
- Manual Tilt System Removal
  431
- Accumulator Removal
  432
- Manual Tilt System Disassembly
  432
- Shock Rod Removal
  433
- Shock Rod Disassembly
  434
- Memory Piston Removal
  436
- Valve Block Removal
  436
- Valve Block Disassembly
  437
- Reassembly - O-Ring and Seal Placement
  438
- Actual O-Ring Sizes
  439
- O-Ring Description and Sizes
  440
- Manual Tilt System Cleaning and Inspection
  441
- Manual Tilt System Reassembly
  441
- Valve Block Installation
  442
- Shock Rod Reassembly
  443
- Shock Rod Installation and Fluid Filling Procedure
  444
- Filling Procedure Option Two Instructions for Making Retaining Tool
  446
- Bleeding Manual Tilt System
  447
- Manual Tilt System Installation
  449
- Manual Release Valve Adjustment
  450
Lower Unit

452
- Specifications
  453
  - Lower Unit - 6A
    453
- Special Tools
  454
- Gear Housing (Drive Shaft)
  456
- Gear Housing (Propeller Shaft)
  458
- Disassembly
  460
- Draining and Inspecting Gear Housing
  460
- Gear Case Identification
  460
- Removal
  460
- Water Pump
  461
- Bearing Carrier and Propeller Shaft
  463
- Pinion Gear, Drive Shaft, and Forward Gear
  465
- Oil Sleeve
  467
- Upper Drive Shaft Bearing
  467
- Lower Drive Shaft Bearing Race
  468
- Shift Shaft
  468
- Forward Gear Bearing Race
  469
- Trim Tab Adjustment and Replacement
  469
- Forward Gear Bearing Race
  470
- Reassembly
  470
- Shift Shaft
  470
- Bearing Carrier Reassembly
  471
- Forward Gear Reassembly
  473
- Propeller Shaft Reassembly
  474
- Drive Shaft Wear Sleeve Installation
  475
- Lower Drive Shaft Bearing Race Installation
  476
- Oil Sleeve Installation
  476
- Upper Drive Shaft Bearing Installation
  476
- Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation
  477
- Pinion Gear Depth and Forward Gear Backlash
  478
- Bearing Carrier and Propeller Shaft Installation
  482
- Water Pump Reassembly and Installation
  483
- Filling Gear Housing with Lubricant
  485
- Gear Housing Pressure Test
  485
- Gearcase Installation
  486
- Trim Tab Adjustment
  488
Lower Unit

490
- Jet Drive (3 Cylinder)
  492
- Jet Pump Assembly
  493
- Jet Drive (4 Cylinder)
  494
- Jet Water Pump Components
  496
- Engine Horsepower Selection
  497
- Selecting a Boat that Is Best Suited for Jet Power
  497
- Locate Centerline of the Outboard
  498
- Outboard Mounting Height
  498
- Transom Height of the Boat
  498
- Checking for Cavitation
  499
- Water Testing
  499
- Shift Cable Installation
  500
- Impeller Removal and Installation
  501
- Lubricating the Drive Shaft Bearing
  501
- Flushing the Cooling System
  503
- Impeller Clearance Adjustment
  503
- Steering Pull Adjustment
  503
- Worn (Dull) Impeller
  503
- Jet Drive Removal
  504
- Liner Replacement
  504
- Bearing Carrier Removal
  505
- Bearing Carrier Disassembly
  506
- Bearing Carrier Reassembly
  507
- Installing Lower Seals
  507
- Installing Upper Seals
  507
- Installing Drive Shaft
  508
- Installing Drive Shaft Ball Bearings
  508
- Bearing Carrier Installation
  509
- Installing Upper Seal Housing
  509
- Jet Drive Installation
  510
- Reassembling Water Pump to Jet Drive
  510
- Installing Jet Drive to Drive Shaft Housing
  511
Attachments/ Control Linkage

514

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