Mercury Computer Diagnosic System Version 9.05 Update 06.2024
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Mercury Computer Diagnosic System Version 9.05 Update 06.2024
Size: 6.41 Gb
Interface Language: English Deutsch Espanol Franqais Italiano Nederlands Portugués Svensk
Type of machine: MARINER MERCRUISER RACE OUTBOARD M2 JET DRIVE 1 SPORT JE GENERIC RACE STERNDRIVE CUMMINS MERCRUISER
Working on Windows 10, Window 11 (Tested on Windows 10 64bit)
Software Supporter: Present
Function: Logged Faults Freeze Frame data Duty Cycle Monitor Engine Data Historic Faults Active Diagnostics Water Test System Information
Trim Limit Trailer Limit
Mercury Marine and Cummins MerCruiser Diesel are proud to now offer diagnostic support for the new QSD series diesel engines with SmartCraft capability. Simply select the Cummins MerCruiser Diesel Engine on the Engine Selection screen to access this new portion of the software. For more information on cables needed and basic functionality, please review the Mercury Computer Diagnostic System Help File.
What's New
Version 9.05 Mercury Computer Diagnostic Software (CDS) contains the following features.
Support for Windows XP and Windows 7 (32 and 64 bit) operating systems.
Support for reflash of Verado PCM08 processors.
Support for the use of a USB to Serial adapter for the SmartComms box, Multimeter and Pressure Tester. Com 1 port is no longer required on PC’s running MCDS.
Adobe reader version 10.0.1.
Version 8.28 Mercury Computer Diagnostic Software (CDS) contains the following features.
Enhancement to Active Test list for engines with 555 family processors.
Version 8.24 Mercury Computer Diagnostic Software (CDS) contains the following features.
Reflash enhancement and SmartComms update.
Version 8.22 Mercury Computer Diagnostic Software (CDS) contains the following features.
Cummins MerCruiser Diesel (CMD) engine support has been added for the QSD Series 2.0L, 2.8L and 4.2L engines. Support for these engines include:
Logged Faults
Freeze Frame data
Duty Cycle Monitor
Engine Data
Historic Faults
Active Diagnostics
Water Test
System Information
Cummins MerCruiser Diesel SIM Module Active Test support has been added for CMD engines. Support for this system includes:
Trim Limit
Trailer Limit
The Engine Select screen has been modified for the Model selection so that the engines are sorted by engine size or by alphabetic order to make selection easier.
Gauge Sweep functionality has been enabled for DTS systems. This selection is available by selecting DTS Command Module (MY07) on the System Info screen. Gauge Sweep requires the Gauge Sweep/Harness Test lead.
Service Manual support has been expanded to cover additional Mercury Marine engines for Outboard and MerCruiser engines.
Service Manual support has been added for the Cummins MerCruiser Diesel QSD series engines. These manuals can be located in the MerCruiser library of the Service Manual section.
1 – 90‑68648 1963–1973 Engines & Drives All
– – 90‑73033 1975 Jet Drive 400 All
2 – 90‑71707 1974–1977 Engines, Drives & Jet Drive 400 All
3 – 90‑95693 1978–1984 Engines: 4‑Cylinder, L6 & V8 All
4 – 90‑86137 1978–1982 Sterndrives: MC 120 to 260 All
5 – 90‑12935 1978–1993 Sterndrives: TR and TRS All
6 – 90‑12934‑2 1983–1990 Sterndrives: R, MR, Alpha One & Alpha
One SS All
7 – 90‑12410 1983–1993 Engines: GM V6 All
8 – 90‑44553 1985–1989 Engines: MM 4‑Cylinder All
9 – 90‑14499‑1 1985–1988 Engines: GM V8 All
10 – 90‑14693‑1 1985–1989 Engines: GM 4‑Cylinder All
11 – 90‑17431‑4 1988–1998 Sterndrives: Bravo All
12 – 90‑814099‑2 1989–1993 Engines: 5‑Cylinder & 6‑Cylinder Diesel All
13 – 90‑816462 1990–1997 Engines: GM 4‑Cylinder All
14 – 90‑818177‑3 1991– Sterndrives: Alpha One Gen II All
15 – 90‑816463 1989–1992 Engines: GM V8 All except High Performance
16 – 90‑823224‑2 1993–1997 Engines: GM V8 454cid & 502cid Gen V–Gen VI
17 – 90‑823225‑1
1993–1997 Engines: GM V8 305cid & 350cid
All
1993–1995 Engines: GM V8 5.0L
18 – 90‑823226‑1 1993–1997 Engines: GM V6 Gen II Balance Shaft All
19 – 90‑823227 1994–1996 Engines: V8 7.3L (IDI) Diesel All
20 – 90‑823228 1994–1998 Sterndrives: Blackhawk All
21 – 90‑806934 1994– Engines: 5‑Cylinder & 6‑Cylinder 3.0L,
3.6L, & 4.2L (IDI) Diesel All
22 – 90‑860074‑1 1997– Engines: D‑Tronic 2.8L & 4.2L (DI) Diesel Starting serial number 0K000001
22‑S 22 90‑860074020 2002– Engines: D4.2L 300 Diesel All
23 – 90‑861326‑1 1998–2001
Engines: GM V8 Gen VI
• Sterndrive 454 Mag MPI Starting serial number 0L010029
• Sterndrive 502 Mag MPI Starting serial number 0L017000
• Inboard 454 Mag MPI Horizon Starting serial number 0L002200
• Inboard 8.2L MPI Starting serial number 0L002450
Engines: GM V8 L‑29
• Sterndrive 7.4L MPI Starting serial number 0L010003
• Inboard 7.4L MPI Starting serial number 0L002006
1 – 90‑68648 1963–1973 Engines & Drives All
– – 90‑73033 1975 Jet Drive 400 All
2 – 90‑71707 1974–1977 Engines, Drives & Jet Drive 400 All
3 – 90‑95693 1978–1984 Engines: 4‑Cylinder, L6 & V8 All
4 – 90‑86137 1978–1982 Sterndrives: MC 120 to 260 All
5 – 90‑12935 1978–1993 Sterndrives: TR and TRS All
6 – 90‑12934‑2 1983–1990 Sterndrives: R, MR, Alpha One & Alpha
One SS All
7 – 90‑12410 1983–1993 Engines: GM V6 All
8 – 90‑44553 1985–1989 Engines: MM 4‑Cylinder All
9 – 90‑14499‑1 1985–1988 Engines: GM V8 All
10 – 90‑14693‑1 1985–1989 Engines: GM 4‑Cylinder All
11 – 90‑17431‑4 1988–1998 Sterndrives: Bravo All
12 – 90‑814099‑2 1989–1993 Engines: 5‑Cylinder & 6‑Cylinder Diesel All
13 – 90‑816462 1990–1997 Engines: GM 4‑Cylinder All
14 – 90‑818177‑3 1991– Sterndrives: Alpha One Gen II All
15 – 90‑816463 1989–1992 Engines: GM V8 All except High Performance
16 – 90‑823224‑2 1993–1997 Engines: GM V8 454cid & 502cid Gen V–Gen VI
17 – 90‑823225‑1
1993–1997 Engines: GM V8 305cid & 350cid
All
1993–1995 Engines: GM V8 5.0L
18 – 90‑823226‑1 1993–1997 Engines: GM V6 Gen II Balance Shaft All
19 – 90‑823227 1994–1996 Engines: V8 7.3L (IDI) Diesel All
20 – 90‑823228 1994–1998 Sterndrives: Blackhawk All
21 – 90‑806934 1994– Engines: 5‑Cylinder & 6‑Cylinder 3.0L,
3.6L, & 4.2L (IDI) Diesel All
22 – 90‑860074‑1 1997– Engines: D‑Tronic 2.8L & 4.2L (DI) Diesel Starting serial number 0K000001
22‑S 22 90‑860074020 2002– Engines: D4.2L 300 Diesel All
23 – 90‑861326‑1 1998–2001
Engines: GM V8 Gen VI
• Sterndrive 454 Mag MPI Starting serial number 0L010029
• Sterndrive 502 Mag MPI Starting serial number 0L017000
• Inboard 454 Mag MPI Horizon Starting serial number 0L002200
• Inboard 8.2L MPI Starting serial number 0L002450
Engines: GM V8 L‑29
• Sterndrive 7.4L MPI Starting serial number 0L010003
• Inboard 7.4L MPI Starting serial number 0L002006
Supplement
To Part Number Years of
Publication Description Scope
39 – 90‑865612T00 2006–
Bravo Sterndrives
• Bravo Standard, Bravo X Starting serial number 0M198373
• Bravo XR Starting serial number 0W240000
• Transom Starting serial number 0W173658
• Transom (High Performance) Starting serial number 0W150260
40 30 & 31 90‑865376 2004–
Engines: Gen III Cool Fuel
• 5.0L MPI (Bravo)
Starting serial number 0W060000
• 350 MAG MPI (Bravo)
• 6.2L MPI (Bravo)
• Sterndrive 496 MAG
• Inboard 350 MAG MPI Starting serial number 0M398372
• Inboard 6.2L MPI Starting serial number 0M398395
• Inboard 8.1L (496cid) Starting serial number 0W090000
41 25, 26 &
31 90‑866202 2004–
Engines: Turn Key Start (TKS)
• 3.0L Starting serial number 0W30200
• 4.3L Starting serial number 0W300013
• 5.0L Starting serial number 0W300010
• 5.7L Starting serial number 0W300755
42 – 90‑866025 2006‑
Engines: 2.8L Diesel
• 2.8L ES & EI 170 Serial number 88005200–88010000
• 2.8L ES & EI 200 Serial number 88010001–88020000
N/A – 90‑895372 2004– SmartCraft Digital Throttle & Shift (DTS):
10‑Pin Engine Connection
USA version
N/A – 90‑896643 2004– International version
N/A – 90‑895072 2004–2005
SmartCraft Digital Throttle & Shift (DTS):
14‑Pin Engine Connection
USA version
N/A – 90‑896642 2004– International version
N/A – 90‑897790 2005– Version 06
N/A – 90‑814705R03 1998– Remote Controls All Mercury remote controls
Mercury Racing Sterndrives
# Supplement
To Part Number Manual
Type
Years of
Publication Description Scope
1 – 90‑817110 Service 1989–1992
Engines: Hi‑Performance
• Mark IV HP420/HP425/
HP465
• HP500 Bulldog
• HP575
All
2 – 90‑815526 Service 1982–
Sterndrives:
• III
• II, III, IV & V SSM
All
2‑S 2 90‑849776 Service Sterndrives: III A All
MERCRUISER AND MERCURY RACING (STERNDRIVE) SERVICE MANUAL INDEX
Products of Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts,
Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet,
K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo,
and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection
logo is a registered service mark of Brunswick Corporation.
W6250 Pioneer Road
Fond du Lac, WI 54936-1939
Page 4 / 4 90-862315019 JANUARY 2007
# Supplement
To Part Number Manual
Type
Years of
Publication Description Scope
3 – 90‑848294 Service 1992–1998
Engines: Hi‑Performance
• Gen V HP425/HP450/
HP465/HP500
• Mark IV
• Gen V HP525SC/HP600SC/
HP 800SC
All
4 – 90‑848656 Service Sterndrives: VI and VII (Non Dry
Sump) All
5 – 90‑840250 Service 1999– Sterndrives: VI (Dry Sump) All
6 – 90‑840283R01 Service 1999– Engines: HP500 EFI All
7 – 90‑840500 Service 1999– Engines: HP377 EFI All
8 –
90‑841053 Diagnostic 2001–
Engines: HP575 SCi Starting serial number 0L601000
90‑840542 Service 2001–
9 –
90‑843188 Diagnostic 2003–
Engines: HP525 EFI All
90‑843189 Service 2003–
10 –
90‑842770R02 Diagnostic 2005– Engines:
• HP850 SCi
• HP1075 SCi
• HP1200 SCi
90‑842771R01 Service 2004– All
11 –
90‑841965 Diagnostic 2006
Engines: HP600 SCi Serial number 0M950332–
90‑841966 Service 2006 0M954917
12 – 90‑840250R01 Service 1999– Sterndrives: VI (Dry Sump) All
13 –
90‑8M8000084 Diagnostic 2006M–
Engines HP525 EFI Model year 2006½, starting serial
90‑8M8021132 Service 2006M– number 0M953620
14 –
90‑8M8020286 Diagnostic 2006–
Engines:
• HP600 SCi
• HP700 SCi
Starting serial number 0M955081
90‑8M8020287 Service 2006– Starting serial number 0M954560
15 – 90‑8M8020285 Service 2006– Sterndrives: Dry Sump NXT¹ Starting serial Number 0M954570
N/
A – 90‑814705R03 Service 1998– Remote Controls Mercury remote controls
PART NUMBER/
REVISION DATE
MODEL (PREFIX) SERIAL
NUMBERS
90-25500 All models, 1965 and Prior All
90-68647 All Models, 1966 through 1974 All
90-75512 All Models, 1975 thru 1978, Except V-6 models. All
90-44477--1 /
1192
2.2/2.5/3.0/3.3 All
90-43183/483 3.5/3.6 All
90-17308R02
May 2003
4/5/102cc Sailpower (U) 0A809601 and
Above
(B) 09477830 and
Above
(C) 0A809601 and
Above
90-86136--1 /
1-393
4 Gnat/90cc Sailpower
4/4.5/7.5/9.8/20/40
All
90-13449--1 /
1187
6/8/8 Sailmate/9.9/9.9 Sailpower/
210 cc Sailpower/XR10/Magnum 10/10 Marathon/
10 Sea Pro/15
(U) 0A197112 thru
0D280999
(B) 09503295 thru
09792199
(C) 0A708341 and
Above
90-827242R02 /
February 2003
6/8/8 Sailmate/9.9/9.9 Sailpower/XR10/
Magnum 10/10 Marathon/ 10 Sea Pro/15
(U) 0A197112 and
Above
(B) 09503295 and
Above
90-825298940 /
993
15 Marathon/15 Sea Pro All
90-92235--1 /
1984
18/25 (U) 6416712 and
Below
(B) 9390290 and
Below
(C) 7207857 and
Below
90-43509--3 / 984 18/18XD/20/25/25XD
25 Marathon/25 Sea Pro
(U) 6416713 thru
0G044026
(B) 9390291 thru
09807908
(C) 7207858 and
Above
90-826883R03 /
November 2002
20 Jet/20/25/25 Marathon/25 Sea Pro (U) 0G44027 and
Above
(B) 09807909 and
Above
90-826148R03 /
July 2003
30/30 Marathon/30 Sea Pro/40
40 Marathon/40 Sea Pro (2 Cylinder)
(U) 0G053314 and
Above
(B) 09855139 and
Above
Service Manual Index
2 / 11 90-835450078 April 2007
PART NUMBER/
REVISION DATE
MODEL (PREFIX) SERIAL
NUMBERS
90-42794--1 / 690 35/40 (2 Cylinder) (U) 5823918 and
Above
(A) 9298956 and
Above
(B) 9298956 and
Above
(C) 7169338 and
Above
90-814676R1 /
December 1996
30 Jet/40/40 Magnum (4 Cylinder) (U) 0C159200 and
Above
(B) 9570305 and
Above
(C) 0A748269 and
above
90-86135--5 /
1-593
45 & 50 (4 Cylinder)
50 & 60 (3 Cylinder, 2 Carburetor)
AND
70 (3 Cylinder, 2 Carburetor)
(U) 4576237 and
Above
(A) 8042650 and
Above
(B) 9136250 and
Above
(C) 7088598 and
Above
(U) 4571652 thru
6428681
(A) 8042350 thru
8074512
(B) 913582 thru
9392276
(C) 7087823 thru
7208333
90-817643R1 /
December 1996
45 Jet/50/55 Marathon/55 Sea Pro/
60/60 Bigfoot/60 Marathon/
60 Sea Pro
(U) 0D000750 and
Above
(B) 09671687 and
Above
90-852572R02 /
November 2002
40/50/55/60 (U) 0G531301 and
Above
(B) 09974454 and
Above
Service Manual Index
90-835450078 April 2007 3 / 11
PART NUMBER/
REVISION DATE
MODEL (PREFIX) SERIAL
NUMBERS
90-86134--4 /
1291
75, 80 & 85 (4 Cylinder)
AND
90, 115 &140 (In-line 6 Cylinder)
AND
150 (In-line 6 Cylinder)
(U) 4590512 and
Above
(A) 8043775 and
Above
(B) 9139350 and
Above
(C) 7091098 and
Above
(U) 4112635 and
Above
(A) 8027115 and
Above
(C) 7047258 and
Above
(U) 4121435 and
Above
(A) 8028040 and
Above
(C) 7048783 and
Above
90-13645--2 /
1095
70/75/75 Marathon/75XD/75 Sea Pro
80/90 (3 Cylinder)
1987 thru 1993 Models
AND
100 & 115 (4 Cylinder)
1988 thru 1993 Models
(U) 0A997142 thru
0D283221
(B) 09502135 thru
09793576
(C) 0A722297 and
Above
(U) 0B209468 thru
0D283221
(B) 09523034 thru
09793576
(C) 0A731673 and
Above
90-830234R04 /
May 2003
75/75 Marathon/75 Sea Pro
90/100/115/125/65 Jet/80 Jet
Model Year 1994 and Newer
(U) 0D283222 and
Above
(B) 09793577 and
Above
90-86133--3 /
1984
150/175/200
1976 thru 1979 V-6 Models
(U) 5464485 and
Below
(A) 8063934 and
Below
90-97658--3 / 1-
488
135/135 Marathon/150
150 Marathon/W 150/150 XR2
150 Magnum/150 XR4
150 Magnum II/175/200/220 EFI/225
1980 thru 1988 Models
(U) 5464486 thru
0C100860
(A) 8063935 and
Above
Service Manual Index
4 / 11 90-835450078 April 2007
PART NUMBER/
REVISION DATE
MODEL (PREFIX) SERIAL
NUMBERS
90-814098--1 /190 135/150/150 XR4/150 Magnum II
175/175 Ski
1989 Models
AND
200/200XRi
1989 & 1990 Models
(U) 0C100861 thru
0C221499
(U) 0C100861 thru
0C291519
90-816249--1 /491 135/150/150 XR4/150 Magnum II
175/175 Ski/175 XRi
175 Magnum EFI
1990 Models
AND
200/200XRi (2.5 Liter)
1991 Models
(U) 0C221500 thru
0D081999
(U) 0C291520 thru
0D081999
90-824052R3 /
June 2002
135/150/150 XR6/150 Magnum III
150 EFI/175/175 EFI/200/200 EFI
150/200/225 Pro Max
150/200/225 Super Magnum
1992 through 2000 Models
(U) 0D82000 and
Above
90-878079R01 –
August 2002
135/150XR6/150 Magnum III
150 EFI /175/175 EFI/200/200 EFI
Model Year 2000 and Newer
(U) 0G960500 and
Above
90-883728
May 2001
150/175/200 EFI
Model Year 2002 and Newer
(U) 0T409000 and
Above
90-885565 /
May 2001
150/175/200 EFI
Model Year 2002 and Newer
(U) 0T409000 and
Above
(I)
90-822900R3 /
December 1997
225/225 EFI/250 EFI
3.0 Liter Marathon/3.0 Liter Sea Pro
Model Year 1994 and Newer
(U) 0D280813 and
Above
90-884294R01 /
September 2003
200/225/250 3.0 Liter Work EFI
Model Year 2002 and Newer
(U) 0T409000 and
Above
90-885590R01 /
September 2003
200/225/250 3.0 Liter Work EFI
Model Year 2002 and Newer
(U) 0T409000 and
Above
(I)
90-813779 / 1-
1190
250/275 (3.4 Liter) All
90-43508 / 1184 300/3.4 Liter All
4-Stroke Outboards
2.5/3.5 FourStroke 0R131842 and Above
90-899925 /
February 2007 Service Manual
4/5/6 FourStroke - Model Year 1999 and Newer (U) 0R000001 and Above
(B) 0P073456 and Above
90-857138R02 /
December 2006 Service Manual
Service Manual Index
90-835450078 April 2007 5 / 11
8/9.9 FourStroke (U) 0H000058 - 0G589999
90-827857R1 /
November 1996 Service Manual
8/9.9 FourStroke
9.9 BigFoot FourStroke (U) 0R042475 and Above
90-892248R01 /
February 2004 Service Manual
9.9/15 FourStroke (323 cc)
9.9/15 BigFoot FourStroke (323 cc) (U) 0G590000 and Above
90-856159R02 /
September 2002 Service Manual
25 BigFoot FourStroke - Model Year 1998 and Newer (U) 0G590000 and Above
90-854785R2 /
November 2001 Service Manual
25/30 FourStroke EFI - Model Year 2006 and Newer (U) 0R106999 and Above
90-899182A01 Service Manual and Color Diagram Assembly
90-889182
June 2006 Service Manual
90-899696A01
June 2006 Color Diagram Assembly
30/40 FourStroke
40 BigFoot FourStroke (U) 0G760300 and Above
90-857046R1 /
November 2001 Service Manual
30/40 FourStroke EFI - Model Year 2002 and Newer (U) 0T409000 and Above
90-883064A01 Service Manual and Color Diagram Assembly
90-883064R02
July 2006 Service Manual
90-899697A01
July 2006 Color Diagram Assembly
40/45/50 FourStroke
50 BigFoot FourStroke ((U) 0G231123 and Above
90-828631R3 /
March 1999 Service Manual
40/50/60 4 Cyl. FourStroke EFI - Model Year 2002 and Newer (U) 0T409000 and Above
90-883065R01 /
September 2004 Service Manual
50/60 FourStroke - Model Year 2001 and Newer (U) 0T178500 and Above
90-858896 /
May 2000 Service Manual
Service Manual Index
6 / 11 90-835450078 April 2007
75/90 FourStroke - Model Year 2000 and Newer (U) 0G960500 and Above
90-858895R02 /
April 2003 Service Manual
75/90 FourStroke EFI - Model Year 2005 and 2006 (U) 1B172291 and Above
90-897725 /
March 2005 Service Manual
75/90/115 FourStroke EFI (U) 1B366823 and Above
90-899185A01 Service Manual & Color Diagram Assembly
90-899185
September 2006 Service Manual
90-899699A01
July 2006 Color Diagram Assembly
115 FourStroke EFI - Model Year 2001 through 2006 (U) 0T178500 and Above
90-881980R02 /
April 2003 Service Manual
225 FourStroke EFI - Model Year 2003 and Newer (U) 0T653945 and Above
90-888465 /
July 2002 Service Manual
Verado Outboards
135/150/175 Verado FourStroke - Model Year 2006 and
Newer (U) 1B227000 and Above
90-897928T00 /
July 2005 Service Manual
90-897928100 Verado Section 1 – Important Information
90-897928200 Verado Section 2 – Electrical System
90-897928300 Verado Section 3 – Fuel System
90-897928400 Verado Section 4 – Powerhead
90-897928500 Verado Section 5 – Mid-Section
90-897928600 Verado Section 6 – Lower Unit
90-897928700 Verado Section 7, 8 & 9 – Attachments, Power Steering and Color
Diagrams
200/225/250/275 Verado FourStroke - Model Year 2006 and
Newer (U) 0T980000 and Above
90-896579T00 /
July 2004 Service Manual
90-896580100 Section 1 – Important Information
90-896580200 Section 2 – Electrical System
90-896580300 Section 3 – Fuel System
90-896580400 Section 4 – Powerhead
90-896580500 Section 5 – Mid-Section
90-896580600 Section 6 – Lower Unit
90-896580700 Section 7, 8 & 9 – Attachments, Power Steering and Color Diagrams
Service Manual Index
90-835450078 April 2007 7 / 11
OptiMax Outboards
75/90/115 OptiMax - Model Year 2004 and Newer (U) 0T801000 and Above
90-889785 /
April 2003 Service Manual and Color Diagram Assembly
90-889785 /
April 2003 Service Manual
90-899862A01/
February 2007 Color Diagram Assembly
135/150 OptiMax DFI - 1998 through 1999 Models (U) 0G590000 thru
0G960499
90-855347R02 /
November 2002 Service Manual
115/135/150/175 OptiMax - Model Year 2000 and Newer (U) 0G960500 and Above
90-859494R1 /
June 2000 Service Manual
200/225 OptiMax DFI - 1997 through 1999 Models (U) 0G590000 thru
0G960499
90-855348R02 /
November 2002 Service Manual
200/225 OptiMax including DTS - Model Year 2000 and
Newer (U) 0G960500 and Above
90-859769R03 /
August 2003 Service Manual
200/225 OptiMax Diagnostic Guide - 2000 through 2003
Models (U) All
90-889525 /
June 2002 Service Manual
225 Pro XS OptiMax - Model Year 2005 and Newer
225 Sport XS OptiMax - Model Year 2006 and Newer
(U) 0T997974 and Above
(U) 1E000797 and Above
90-841916R01 Service Manual
Mercury Racing Outboards
#1
90-815595/1189 2.4 Carb & EFI/Mod VP/XR2 (U) 2.4: 0C175000 &
Above Mod VP: 0B290299
& Above
#2 90-815595-1/294
Replaced by
2.5 Carb & EFI (345 & 260
Horsepower)
(U) 0D030300 through
0D936999
Service Manual Index
8 / 11 90-835450078 April 2007
Manual
90-849240/996
#3
90-824052R3 /
June 2002
150/200/225 Pro Max 150/200/225
Super Magnum
1992 and Newer
135/150/150 XR6/150 Magnum III
150/EFI/175/175 EFI/200/200 EFI
(U) 0D082000 through
0T105314
#4 90-849240 / 996 2.5 Carb & EFI (245 & 260
Horsepower)
(U) 0D030300 & Above
#5 90-849372 / 797 300 Pro Max/Super Magnum
(3.0 Liter)
(U) 0D280813 & Above
#6 90-840151 /
October 1998
2.5 EFI/Short Shaft/Offshore
(280 Horsepower)
(U) 0G857020 & Above
#7 90-840421 /
January 2001
200 XS OptiMax Direct Fuel
Injection
(U) 0T235288 & Above
90-8M8020357 /
February 2006
200 XS OptiMax Supplement to
Service Manual 90-840421
(U) 1E000797 & Above
#8 90-840514 R01 /
June 2003
Pro Max 300X (3.0 Liter) (U) 0T235084 & Above
#9 90-840541 /
August 2002
Pro Max 225X (2.5 Liter) (U) 0T430254 & Above
#10 90-843128 R01 /
September 2003
250XS OptiMax Direct Fuel
Injection
(U) 0T651982 & Above
#11 90-891596 2.5XS OptiMax Direct Fuel
Injection
(U) 0T997974 & Above
#12 90-842009 /
March 2005
SportMaster, TorqueMaster, &
Fleet Master Gearcase
Starting Model Year 2005
Mercury Jet Drive
90 Sport Jet 0E021000 thru 0E080399
90-824724 Service Manual
90/120 Sport Jet - 1995 Models
90XR/120XR Sport Jet - 1996 and 1997 Models 0E080400 thru 0E344999
90-824724 Service Manual
120XR2 Sport Jet 0E345000 & Above
90-858804 Service Manual
175XR2 Sport Jet 0E151580 & Above
90-852396R1 /
November 1997 Service Manual
210/240M2 Jet Drive - Model Year 2000 and Newer 0E373939 & Above
90-877837R01 /
October 2002 Service Manual
Service Manual Index
90-835450078 April 2007 9 / 11
200 OptiMax Jet Drive - Model Year 2001 and Newer 0E384500 & Above
90-881986 /
January 2001 Service Manual
240 Jet Drive EFI - Model Year 2002 and Newer 0E406400 & Above
90-884822 /
December 2001 Service Manual
250 OptiMax Jet Drive - Model Year 2002 and Newer 0E407100 & Above
90-888438 /
June 2002 Service Manual
SmartCraft and DTS Publications
SmartCraft Digital Throttle and Shift (DTS) – 10 pin Engine
Connection - 2004 Model Year (U)
90-895372 /
July 2004 Service Manual
SmartCraft Digital Throttle and Shift (DTS) – 14 pin Engine
Connection - 2005 Model Year (U)
90-895072 /
August 2004 Service Manual
SmartCraft Digital Throttle and Shift (DTS) – 14 pin Engine
Connection (Version 06) - 2006 Model Year (U)
90-897790 /
November 2005 Service Manual
Electric Outboards
Electric Outboards Set
90-16777A-1 Service Manual
Electric Outboards - Mercury Models
Electric Outboards - Mariner Models
(U) 5523969 & Below
(U) 5516584 & Below
*90-84483-3 /
1984 Service Manual
Electric Outboards - Mercury Models (Except Thruster II)
Electric Outboards - Mariner Models (Except 222)
(U) 5523970 and Above
(U) 5516585 and Above
*90-90640-3 /
1984 Service Manual
Mercury Thruster II/Mariner 222 All
*90-99987-3 / Service Manual
Service Manual Index
10 / 11 90-835450078 April 2007
1984
Mercury Thruster T28-24/12, R28-24/12, RX28-24/12, T21,
R21, RL21
Mariner Stalker T28-24/12, T21, R21, RL21
All
*90-18141-1 / 688 Service Manual
Electric Thruster T33/R33/RX33/T45/R45/D45/RX45 All
*90-816427 /
1-1090 Service Manual
Miscellaneous Service Publications
Quicksilver Remote Controls All
90-814705R03 /
December 2006 Service Manual
Quicksilver Power Steering 70 to 200 2.5L and 3.0L - 1993
through 2000 Models
(U) 0C10000 thru
0T178499
90-852429R1 Service Manual
Mercury/Mariner Technicians Handbook All
90-816981921 /
1291 1992 Technicians Handbook
90-816981930 /
1-1093 1993 Technicians Handbook
90-816981940 /
893 1994 Technicians Handbook
90-816981950 /
894 1995 Technicians Handbook
90-816981960 /
1095 1996 Technicians Handbook
90-816981970 /
March 1997 1997 Technicians Handbook
Mercury Outboard Service Literature Aids
90-830571 /
1-696 Dealer Publications and Starting Serial Number Guide
90-898104A08 Current Service Manual & Color Diagram Assembly
(entire Service Manual set including all current manuals)
90-899755A01 Color Diagram Binder Assembly
Size: 6.41 Gb
Interface Language: English Deutsch Espanol Franqais Italiano Nederlands Portugués Svensk
Type of machine: MARINER MERCRUISER RACE OUTBOARD M2 JET DRIVE 1 SPORT JE GENERIC RACE STERNDRIVE CUMMINS MERCRUISER
Working on Windows 10, Window 11 (Tested on Windows 10 64bit)
Software Supporter: Present
Function: Logged Faults Freeze Frame data Duty Cycle Monitor Engine Data Historic Faults Active Diagnostics Water Test System Information
Trim Limit Trailer Limit
Mercury Marine and Cummins MerCruiser Diesel are proud to now offer diagnostic support for the new QSD series diesel engines with SmartCraft capability. Simply select the Cummins MerCruiser Diesel Engine on the Engine Selection screen to access this new portion of the software. For more information on cables needed and basic functionality, please review the Mercury Computer Diagnostic System Help File.
What's New
Version 9.05 Mercury Computer Diagnostic Software (CDS) contains the following features.
Support for Windows XP and Windows 7 (32 and 64 bit) operating systems.
Support for reflash of Verado PCM08 processors.
Support for the use of a USB to Serial adapter for the SmartComms box, Multimeter and Pressure Tester. Com 1 port is no longer required on PC’s running MCDS.
Adobe reader version 10.0.1.
Version 8.28 Mercury Computer Diagnostic Software (CDS) contains the following features.
Enhancement to Active Test list for engines with 555 family processors.
Version 8.24 Mercury Computer Diagnostic Software (CDS) contains the following features.
Reflash enhancement and SmartComms update.
Version 8.22 Mercury Computer Diagnostic Software (CDS) contains the following features.
Cummins MerCruiser Diesel (CMD) engine support has been added for the QSD Series 2.0L, 2.8L and 4.2L engines. Support for these engines include:
Logged Faults
Freeze Frame data
Duty Cycle Monitor
Engine Data
Historic Faults
Active Diagnostics
Water Test
System Information
Cummins MerCruiser Diesel SIM Module Active Test support has been added for CMD engines. Support for this system includes:
Trim Limit
Trailer Limit
The Engine Select screen has been modified for the Model selection so that the engines are sorted by engine size or by alphabetic order to make selection easier.
Gauge Sweep functionality has been enabled for DTS systems. This selection is available by selecting DTS Command Module (MY07) on the System Info screen. Gauge Sweep requires the Gauge Sweep/Harness Test lead.
Service Manual support has been expanded to cover additional Mercury Marine engines for Outboard and MerCruiser engines.
Service Manual support has been added for the Cummins MerCruiser Diesel QSD series engines. These manuals can be located in the MerCruiser library of the Service Manual section.
1 – 90‑68648 1963–1973 Engines & Drives All
– – 90‑73033 1975 Jet Drive 400 All
2 – 90‑71707 1974–1977 Engines, Drives & Jet Drive 400 All
3 – 90‑95693 1978–1984 Engines: 4‑Cylinder, L6 & V8 All
4 – 90‑86137 1978–1982 Sterndrives: MC 120 to 260 All
5 – 90‑12935 1978–1993 Sterndrives: TR and TRS All
6 – 90‑12934‑2 1983–1990 Sterndrives: R, MR, Alpha One & Alpha
One SS All
7 – 90‑12410 1983–1993 Engines: GM V6 All
8 – 90‑44553 1985–1989 Engines: MM 4‑Cylinder All
9 – 90‑14499‑1 1985–1988 Engines: GM V8 All
10 – 90‑14693‑1 1985–1989 Engines: GM 4‑Cylinder All
11 – 90‑17431‑4 1988–1998 Sterndrives: Bravo All
12 – 90‑814099‑2 1989–1993 Engines: 5‑Cylinder & 6‑Cylinder Diesel All
13 – 90‑816462 1990–1997 Engines: GM 4‑Cylinder All
14 – 90‑818177‑3 1991– Sterndrives: Alpha One Gen II All
15 – 90‑816463 1989–1992 Engines: GM V8 All except High Performance
16 – 90‑823224‑2 1993–1997 Engines: GM V8 454cid & 502cid Gen V–Gen VI
17 – 90‑823225‑1
1993–1997 Engines: GM V8 305cid & 350cid
All
1993–1995 Engines: GM V8 5.0L
18 – 90‑823226‑1 1993–1997 Engines: GM V6 Gen II Balance Shaft All
19 – 90‑823227 1994–1996 Engines: V8 7.3L (IDI) Diesel All
20 – 90‑823228 1994–1998 Sterndrives: Blackhawk All
21 – 90‑806934 1994– Engines: 5‑Cylinder & 6‑Cylinder 3.0L,
3.6L, & 4.2L (IDI) Diesel All
22 – 90‑860074‑1 1997– Engines: D‑Tronic 2.8L & 4.2L (DI) Diesel Starting serial number 0K000001
22‑S 22 90‑860074020 2002– Engines: D4.2L 300 Diesel All
23 – 90‑861326‑1 1998–2001
Engines: GM V8 Gen VI
• Sterndrive 454 Mag MPI Starting serial number 0L010029
• Sterndrive 502 Mag MPI Starting serial number 0L017000
• Inboard 454 Mag MPI Horizon Starting serial number 0L002200
• Inboard 8.2L MPI Starting serial number 0L002450
Engines: GM V8 L‑29
• Sterndrive 7.4L MPI Starting serial number 0L010003
• Inboard 7.4L MPI Starting serial number 0L002006
1 – 90‑68648 1963–1973 Engines & Drives All
– – 90‑73033 1975 Jet Drive 400 All
2 – 90‑71707 1974–1977 Engines, Drives & Jet Drive 400 All
3 – 90‑95693 1978–1984 Engines: 4‑Cylinder, L6 & V8 All
4 – 90‑86137 1978–1982 Sterndrives: MC 120 to 260 All
5 – 90‑12935 1978–1993 Sterndrives: TR and TRS All
6 – 90‑12934‑2 1983–1990 Sterndrives: R, MR, Alpha One & Alpha
One SS All
7 – 90‑12410 1983–1993 Engines: GM V6 All
8 – 90‑44553 1985–1989 Engines: MM 4‑Cylinder All
9 – 90‑14499‑1 1985–1988 Engines: GM V8 All
10 – 90‑14693‑1 1985–1989 Engines: GM 4‑Cylinder All
11 – 90‑17431‑4 1988–1998 Sterndrives: Bravo All
12 – 90‑814099‑2 1989–1993 Engines: 5‑Cylinder & 6‑Cylinder Diesel All
13 – 90‑816462 1990–1997 Engines: GM 4‑Cylinder All
14 – 90‑818177‑3 1991– Sterndrives: Alpha One Gen II All
15 – 90‑816463 1989–1992 Engines: GM V8 All except High Performance
16 – 90‑823224‑2 1993–1997 Engines: GM V8 454cid & 502cid Gen V–Gen VI
17 – 90‑823225‑1
1993–1997 Engines: GM V8 305cid & 350cid
All
1993–1995 Engines: GM V8 5.0L
18 – 90‑823226‑1 1993–1997 Engines: GM V6 Gen II Balance Shaft All
19 – 90‑823227 1994–1996 Engines: V8 7.3L (IDI) Diesel All
20 – 90‑823228 1994–1998 Sterndrives: Blackhawk All
21 – 90‑806934 1994– Engines: 5‑Cylinder & 6‑Cylinder 3.0L,
3.6L, & 4.2L (IDI) Diesel All
22 – 90‑860074‑1 1997– Engines: D‑Tronic 2.8L & 4.2L (DI) Diesel Starting serial number 0K000001
22‑S 22 90‑860074020 2002– Engines: D4.2L 300 Diesel All
23 – 90‑861326‑1 1998–2001
Engines: GM V8 Gen VI
• Sterndrive 454 Mag MPI Starting serial number 0L010029
• Sterndrive 502 Mag MPI Starting serial number 0L017000
• Inboard 454 Mag MPI Horizon Starting serial number 0L002200
• Inboard 8.2L MPI Starting serial number 0L002450
Engines: GM V8 L‑29
• Sterndrive 7.4L MPI Starting serial number 0L010003
• Inboard 7.4L MPI Starting serial number 0L002006
Supplement
To Part Number Years of
Publication Description Scope
39 – 90‑865612T00 2006–
Bravo Sterndrives
• Bravo Standard, Bravo X Starting serial number 0M198373
• Bravo XR Starting serial number 0W240000
• Transom Starting serial number 0W173658
• Transom (High Performance) Starting serial number 0W150260
40 30 & 31 90‑865376 2004–
Engines: Gen III Cool Fuel
• 5.0L MPI (Bravo)
Starting serial number 0W060000
• 350 MAG MPI (Bravo)
• 6.2L MPI (Bravo)
• Sterndrive 496 MAG
• Inboard 350 MAG MPI Starting serial number 0M398372
• Inboard 6.2L MPI Starting serial number 0M398395
• Inboard 8.1L (496cid) Starting serial number 0W090000
41 25, 26 &
31 90‑866202 2004–
Engines: Turn Key Start (TKS)
• 3.0L Starting serial number 0W30200
• 4.3L Starting serial number 0W300013
• 5.0L Starting serial number 0W300010
• 5.7L Starting serial number 0W300755
42 – 90‑866025 2006‑
Engines: 2.8L Diesel
• 2.8L ES & EI 170 Serial number 88005200–88010000
• 2.8L ES & EI 200 Serial number 88010001–88020000
N/A – 90‑895372 2004– SmartCraft Digital Throttle & Shift (DTS):
10‑Pin Engine Connection
USA version
N/A – 90‑896643 2004– International version
N/A – 90‑895072 2004–2005
SmartCraft Digital Throttle & Shift (DTS):
14‑Pin Engine Connection
USA version
N/A – 90‑896642 2004– International version
N/A – 90‑897790 2005– Version 06
N/A – 90‑814705R03 1998– Remote Controls All Mercury remote controls
Mercury Racing Sterndrives
# Supplement
To Part Number Manual
Type
Years of
Publication Description Scope
1 – 90‑817110 Service 1989–1992
Engines: Hi‑Performance
• Mark IV HP420/HP425/
HP465
• HP500 Bulldog
• HP575
All
2 – 90‑815526 Service 1982–
Sterndrives:
• III
• II, III, IV & V SSM
All
2‑S 2 90‑849776 Service Sterndrives: III A All
MERCRUISER AND MERCURY RACING (STERNDRIVE) SERVICE MANUAL INDEX
Products of Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts,
Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet,
K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo,
and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection
logo is a registered service mark of Brunswick Corporation.
W6250 Pioneer Road
Fond du Lac, WI 54936-1939
Page 4 / 4 90-862315019 JANUARY 2007
# Supplement
To Part Number Manual
Type
Years of
Publication Description Scope
3 – 90‑848294 Service 1992–1998
Engines: Hi‑Performance
• Gen V HP425/HP450/
HP465/HP500
• Mark IV
• Gen V HP525SC/HP600SC/
HP 800SC
All
4 – 90‑848656 Service Sterndrives: VI and VII (Non Dry
Sump) All
5 – 90‑840250 Service 1999– Sterndrives: VI (Dry Sump) All
6 – 90‑840283R01 Service 1999– Engines: HP500 EFI All
7 – 90‑840500 Service 1999– Engines: HP377 EFI All
8 –
90‑841053 Diagnostic 2001–
Engines: HP575 SCi Starting serial number 0L601000
90‑840542 Service 2001–
9 –
90‑843188 Diagnostic 2003–
Engines: HP525 EFI All
90‑843189 Service 2003–
10 –
90‑842770R02 Diagnostic 2005– Engines:
• HP850 SCi
• HP1075 SCi
• HP1200 SCi
90‑842771R01 Service 2004– All
11 –
90‑841965 Diagnostic 2006
Engines: HP600 SCi Serial number 0M950332–
90‑841966 Service 2006 0M954917
12 – 90‑840250R01 Service 1999– Sterndrives: VI (Dry Sump) All
13 –
90‑8M8000084 Diagnostic 2006M–
Engines HP525 EFI Model year 2006½, starting serial
90‑8M8021132 Service 2006M– number 0M953620
14 –
90‑8M8020286 Diagnostic 2006–
Engines:
• HP600 SCi
• HP700 SCi
Starting serial number 0M955081
90‑8M8020287 Service 2006– Starting serial number 0M954560
15 – 90‑8M8020285 Service 2006– Sterndrives: Dry Sump NXT¹ Starting serial Number 0M954570
N/
A – 90‑814705R03 Service 1998– Remote Controls Mercury remote controls
PART NUMBER/
REVISION DATE
MODEL (PREFIX) SERIAL
NUMBERS
90-25500 All models, 1965 and Prior All
90-68647 All Models, 1966 through 1974 All
90-75512 All Models, 1975 thru 1978, Except V-6 models. All
90-44477--1 /
1192
2.2/2.5/3.0/3.3 All
90-43183/483 3.5/3.6 All
90-17308R02
May 2003
4/5/102cc Sailpower (U) 0A809601 and
Above
(B) 09477830 and
Above
(C) 0A809601 and
Above
90-86136--1 /
1-393
4 Gnat/90cc Sailpower
4/4.5/7.5/9.8/20/40
All
90-13449--1 /
1187
6/8/8 Sailmate/9.9/9.9 Sailpower/
210 cc Sailpower/XR10/Magnum 10/10 Marathon/
10 Sea Pro/15
(U) 0A197112 thru
0D280999
(B) 09503295 thru
09792199
(C) 0A708341 and
Above
90-827242R02 /
February 2003
6/8/8 Sailmate/9.9/9.9 Sailpower/XR10/
Magnum 10/10 Marathon/ 10 Sea Pro/15
(U) 0A197112 and
Above
(B) 09503295 and
Above
90-825298940 /
993
15 Marathon/15 Sea Pro All
90-92235--1 /
1984
18/25 (U) 6416712 and
Below
(B) 9390290 and
Below
(C) 7207857 and
Below
90-43509--3 / 984 18/18XD/20/25/25XD
25 Marathon/25 Sea Pro
(U) 6416713 thru
0G044026
(B) 9390291 thru
09807908
(C) 7207858 and
Above
90-826883R03 /
November 2002
20 Jet/20/25/25 Marathon/25 Sea Pro (U) 0G44027 and
Above
(B) 09807909 and
Above
90-826148R03 /
July 2003
30/30 Marathon/30 Sea Pro/40
40 Marathon/40 Sea Pro (2 Cylinder)
(U) 0G053314 and
Above
(B) 09855139 and
Above
Service Manual Index
2 / 11 90-835450078 April 2007
PART NUMBER/
REVISION DATE
MODEL (PREFIX) SERIAL
NUMBERS
90-42794--1 / 690 35/40 (2 Cylinder) (U) 5823918 and
Above
(A) 9298956 and
Above
(B) 9298956 and
Above
(C) 7169338 and
Above
90-814676R1 /
December 1996
30 Jet/40/40 Magnum (4 Cylinder) (U) 0C159200 and
Above
(B) 9570305 and
Above
(C) 0A748269 and
above
90-86135--5 /
1-593
45 & 50 (4 Cylinder)
50 & 60 (3 Cylinder, 2 Carburetor)
AND
70 (3 Cylinder, 2 Carburetor)
(U) 4576237 and
Above
(A) 8042650 and
Above
(B) 9136250 and
Above
(C) 7088598 and
Above
(U) 4571652 thru
6428681
(A) 8042350 thru
8074512
(B) 913582 thru
9392276
(C) 7087823 thru
7208333
90-817643R1 /
December 1996
45 Jet/50/55 Marathon/55 Sea Pro/
60/60 Bigfoot/60 Marathon/
60 Sea Pro
(U) 0D000750 and
Above
(B) 09671687 and
Above
90-852572R02 /
November 2002
40/50/55/60 (U) 0G531301 and
Above
(B) 09974454 and
Above
Service Manual Index
90-835450078 April 2007 3 / 11
PART NUMBER/
REVISION DATE
MODEL (PREFIX) SERIAL
NUMBERS
90-86134--4 /
1291
75, 80 & 85 (4 Cylinder)
AND
90, 115 &140 (In-line 6 Cylinder)
AND
150 (In-line 6 Cylinder)
(U) 4590512 and
Above
(A) 8043775 and
Above
(B) 9139350 and
Above
(C) 7091098 and
Above
(U) 4112635 and
Above
(A) 8027115 and
Above
(C) 7047258 and
Above
(U) 4121435 and
Above
(A) 8028040 and
Above
(C) 7048783 and
Above
90-13645--2 /
1095
70/75/75 Marathon/75XD/75 Sea Pro
80/90 (3 Cylinder)
1987 thru 1993 Models
AND
100 & 115 (4 Cylinder)
1988 thru 1993 Models
(U) 0A997142 thru
0D283221
(B) 09502135 thru
09793576
(C) 0A722297 and
Above
(U) 0B209468 thru
0D283221
(B) 09523034 thru
09793576
(C) 0A731673 and
Above
90-830234R04 /
May 2003
75/75 Marathon/75 Sea Pro
90/100/115/125/65 Jet/80 Jet
Model Year 1994 and Newer
(U) 0D283222 and
Above
(B) 09793577 and
Above
90-86133--3 /
1984
150/175/200
1976 thru 1979 V-6 Models
(U) 5464485 and
Below
(A) 8063934 and
Below
90-97658--3 / 1-
488
135/135 Marathon/150
150 Marathon/W 150/150 XR2
150 Magnum/150 XR4
150 Magnum II/175/200/220 EFI/225
1980 thru 1988 Models
(U) 5464486 thru
0C100860
(A) 8063935 and
Above
Service Manual Index
4 / 11 90-835450078 April 2007
PART NUMBER/
REVISION DATE
MODEL (PREFIX) SERIAL
NUMBERS
90-814098--1 /190 135/150/150 XR4/150 Magnum II
175/175 Ski
1989 Models
AND
200/200XRi
1989 & 1990 Models
(U) 0C100861 thru
0C221499
(U) 0C100861 thru
0C291519
90-816249--1 /491 135/150/150 XR4/150 Magnum II
175/175 Ski/175 XRi
175 Magnum EFI
1990 Models
AND
200/200XRi (2.5 Liter)
1991 Models
(U) 0C221500 thru
0D081999
(U) 0C291520 thru
0D081999
90-824052R3 /
June 2002
135/150/150 XR6/150 Magnum III
150 EFI/175/175 EFI/200/200 EFI
150/200/225 Pro Max
150/200/225 Super Magnum
1992 through 2000 Models
(U) 0D82000 and
Above
90-878079R01 –
August 2002
135/150XR6/150 Magnum III
150 EFI /175/175 EFI/200/200 EFI
Model Year 2000 and Newer
(U) 0G960500 and
Above
90-883728
May 2001
150/175/200 EFI
Model Year 2002 and Newer
(U) 0T409000 and
Above
90-885565 /
May 2001
150/175/200 EFI
Model Year 2002 and Newer
(U) 0T409000 and
Above
(I)
90-822900R3 /
December 1997
225/225 EFI/250 EFI
3.0 Liter Marathon/3.0 Liter Sea Pro
Model Year 1994 and Newer
(U) 0D280813 and
Above
90-884294R01 /
September 2003
200/225/250 3.0 Liter Work EFI
Model Year 2002 and Newer
(U) 0T409000 and
Above
90-885590R01 /
September 2003
200/225/250 3.0 Liter Work EFI
Model Year 2002 and Newer
(U) 0T409000 and
Above
(I)
90-813779 / 1-
1190
250/275 (3.4 Liter) All
90-43508 / 1184 300/3.4 Liter All
4-Stroke Outboards
2.5/3.5 FourStroke 0R131842 and Above
90-899925 /
February 2007 Service Manual
4/5/6 FourStroke - Model Year 1999 and Newer (U) 0R000001 and Above
(B) 0P073456 and Above
90-857138R02 /
December 2006 Service Manual
Service Manual Index
90-835450078 April 2007 5 / 11
8/9.9 FourStroke (U) 0H000058 - 0G589999
90-827857R1 /
November 1996 Service Manual
8/9.9 FourStroke
9.9 BigFoot FourStroke (U) 0R042475 and Above
90-892248R01 /
February 2004 Service Manual
9.9/15 FourStroke (323 cc)
9.9/15 BigFoot FourStroke (323 cc) (U) 0G590000 and Above
90-856159R02 /
September 2002 Service Manual
25 BigFoot FourStroke - Model Year 1998 and Newer (U) 0G590000 and Above
90-854785R2 /
November 2001 Service Manual
25/30 FourStroke EFI - Model Year 2006 and Newer (U) 0R106999 and Above
90-899182A01 Service Manual and Color Diagram Assembly
90-889182
June 2006 Service Manual
90-899696A01
June 2006 Color Diagram Assembly
30/40 FourStroke
40 BigFoot FourStroke (U) 0G760300 and Above
90-857046R1 /
November 2001 Service Manual
30/40 FourStroke EFI - Model Year 2002 and Newer (U) 0T409000 and Above
90-883064A01 Service Manual and Color Diagram Assembly
90-883064R02
July 2006 Service Manual
90-899697A01
July 2006 Color Diagram Assembly
40/45/50 FourStroke
50 BigFoot FourStroke ((U) 0G231123 and Above
90-828631R3 /
March 1999 Service Manual
40/50/60 4 Cyl. FourStroke EFI - Model Year 2002 and Newer (U) 0T409000 and Above
90-883065R01 /
September 2004 Service Manual
50/60 FourStroke - Model Year 2001 and Newer (U) 0T178500 and Above
90-858896 /
May 2000 Service Manual
Service Manual Index
6 / 11 90-835450078 April 2007
75/90 FourStroke - Model Year 2000 and Newer (U) 0G960500 and Above
90-858895R02 /
April 2003 Service Manual
75/90 FourStroke EFI - Model Year 2005 and 2006 (U) 1B172291 and Above
90-897725 /
March 2005 Service Manual
75/90/115 FourStroke EFI (U) 1B366823 and Above
90-899185A01 Service Manual & Color Diagram Assembly
90-899185
September 2006 Service Manual
90-899699A01
July 2006 Color Diagram Assembly
115 FourStroke EFI - Model Year 2001 through 2006 (U) 0T178500 and Above
90-881980R02 /
April 2003 Service Manual
225 FourStroke EFI - Model Year 2003 and Newer (U) 0T653945 and Above
90-888465 /
July 2002 Service Manual
Verado Outboards
135/150/175 Verado FourStroke - Model Year 2006 and
Newer (U) 1B227000 and Above
90-897928T00 /
July 2005 Service Manual
90-897928100 Verado Section 1 – Important Information
90-897928200 Verado Section 2 – Electrical System
90-897928300 Verado Section 3 – Fuel System
90-897928400 Verado Section 4 – Powerhead
90-897928500 Verado Section 5 – Mid-Section
90-897928600 Verado Section 6 – Lower Unit
90-897928700 Verado Section 7, 8 & 9 – Attachments, Power Steering and Color
Diagrams
200/225/250/275 Verado FourStroke - Model Year 2006 and
Newer (U) 0T980000 and Above
90-896579T00 /
July 2004 Service Manual
90-896580100 Section 1 – Important Information
90-896580200 Section 2 – Electrical System
90-896580300 Section 3 – Fuel System
90-896580400 Section 4 – Powerhead
90-896580500 Section 5 – Mid-Section
90-896580600 Section 6 – Lower Unit
90-896580700 Section 7, 8 & 9 – Attachments, Power Steering and Color Diagrams
Service Manual Index
90-835450078 April 2007 7 / 11
OptiMax Outboards
75/90/115 OptiMax - Model Year 2004 and Newer (U) 0T801000 and Above
90-889785 /
April 2003 Service Manual and Color Diagram Assembly
90-889785 /
April 2003 Service Manual
90-899862A01/
February 2007 Color Diagram Assembly
135/150 OptiMax DFI - 1998 through 1999 Models (U) 0G590000 thru
0G960499
90-855347R02 /
November 2002 Service Manual
115/135/150/175 OptiMax - Model Year 2000 and Newer (U) 0G960500 and Above
90-859494R1 /
June 2000 Service Manual
200/225 OptiMax DFI - 1997 through 1999 Models (U) 0G590000 thru
0G960499
90-855348R02 /
November 2002 Service Manual
200/225 OptiMax including DTS - Model Year 2000 and
Newer (U) 0G960500 and Above
90-859769R03 /
August 2003 Service Manual
200/225 OptiMax Diagnostic Guide - 2000 through 2003
Models (U) All
90-889525 /
June 2002 Service Manual
225 Pro XS OptiMax - Model Year 2005 and Newer
225 Sport XS OptiMax - Model Year 2006 and Newer
(U) 0T997974 and Above
(U) 1E000797 and Above
90-841916R01 Service Manual
Mercury Racing Outboards
#1
90-815595/1189 2.4 Carb & EFI/Mod VP/XR2 (U) 2.4: 0C175000 &
Above Mod VP: 0B290299
& Above
#2 90-815595-1/294
Replaced by
2.5 Carb & EFI (345 & 260
Horsepower)
(U) 0D030300 through
0D936999
Service Manual Index
8 / 11 90-835450078 April 2007
Manual
90-849240/996
#3
90-824052R3 /
June 2002
150/200/225 Pro Max 150/200/225
Super Magnum
1992 and Newer
135/150/150 XR6/150 Magnum III
150/EFI/175/175 EFI/200/200 EFI
(U) 0D082000 through
0T105314
#4 90-849240 / 996 2.5 Carb & EFI (245 & 260
Horsepower)
(U) 0D030300 & Above
#5 90-849372 / 797 300 Pro Max/Super Magnum
(3.0 Liter)
(U) 0D280813 & Above
#6 90-840151 /
October 1998
2.5 EFI/Short Shaft/Offshore
(280 Horsepower)
(U) 0G857020 & Above
#7 90-840421 /
January 2001
200 XS OptiMax Direct Fuel
Injection
(U) 0T235288 & Above
90-8M8020357 /
February 2006
200 XS OptiMax Supplement to
Service Manual 90-840421
(U) 1E000797 & Above
#8 90-840514 R01 /
June 2003
Pro Max 300X (3.0 Liter) (U) 0T235084 & Above
#9 90-840541 /
August 2002
Pro Max 225X (2.5 Liter) (U) 0T430254 & Above
#10 90-843128 R01 /
September 2003
250XS OptiMax Direct Fuel
Injection
(U) 0T651982 & Above
#11 90-891596 2.5XS OptiMax Direct Fuel
Injection
(U) 0T997974 & Above
#12 90-842009 /
March 2005
SportMaster, TorqueMaster, &
Fleet Master Gearcase
Starting Model Year 2005
Mercury Jet Drive
90 Sport Jet 0E021000 thru 0E080399
90-824724 Service Manual
90/120 Sport Jet - 1995 Models
90XR/120XR Sport Jet - 1996 and 1997 Models 0E080400 thru 0E344999
90-824724 Service Manual
120XR2 Sport Jet 0E345000 & Above
90-858804 Service Manual
175XR2 Sport Jet 0E151580 & Above
90-852396R1 /
November 1997 Service Manual
210/240M2 Jet Drive - Model Year 2000 and Newer 0E373939 & Above
90-877837R01 /
October 2002 Service Manual
Service Manual Index
90-835450078 April 2007 9 / 11
200 OptiMax Jet Drive - Model Year 2001 and Newer 0E384500 & Above
90-881986 /
January 2001 Service Manual
240 Jet Drive EFI - Model Year 2002 and Newer 0E406400 & Above
90-884822 /
December 2001 Service Manual
250 OptiMax Jet Drive - Model Year 2002 and Newer 0E407100 & Above
90-888438 /
June 2002 Service Manual
SmartCraft and DTS Publications
SmartCraft Digital Throttle and Shift (DTS) – 10 pin Engine
Connection - 2004 Model Year (U)
90-895372 /
July 2004 Service Manual
SmartCraft Digital Throttle and Shift (DTS) – 14 pin Engine
Connection - 2005 Model Year (U)
90-895072 /
August 2004 Service Manual
SmartCraft Digital Throttle and Shift (DTS) – 14 pin Engine
Connection (Version 06) - 2006 Model Year (U)
90-897790 /
November 2005 Service Manual
Electric Outboards
Electric Outboards Set
90-16777A-1 Service Manual
Electric Outboards - Mercury Models
Electric Outboards - Mariner Models
(U) 5523969 & Below
(U) 5516584 & Below
*90-84483-3 /
1984 Service Manual
Electric Outboards - Mercury Models (Except Thruster II)
Electric Outboards - Mariner Models (Except 222)
(U) 5523970 and Above
(U) 5516585 and Above
*90-90640-3 /
1984 Service Manual
Mercury Thruster II/Mariner 222 All
*90-99987-3 / Service Manual
Service Manual Index
10 / 11 90-835450078 April 2007
1984
Mercury Thruster T28-24/12, R28-24/12, RX28-24/12, T21,
R21, RL21
Mariner Stalker T28-24/12, T21, R21, RL21
All
*90-18141-1 / 688 Service Manual
Electric Thruster T33/R33/RX33/T45/R45/D45/RX45 All
*90-816427 /
1-1090 Service Manual
Miscellaneous Service Publications
Quicksilver Remote Controls All
90-814705R03 /
December 2006 Service Manual
Quicksilver Power Steering 70 to 200 2.5L and 3.0L - 1993
through 2000 Models
(U) 0C10000 thru
0T178499
90-852429R1 Service Manual
Mercury/Mariner Technicians Handbook All
90-816981921 /
1291 1992 Technicians Handbook
90-816981930 /
1-1093 1993 Technicians Handbook
90-816981940 /
893 1994 Technicians Handbook
90-816981950 /
894 1995 Technicians Handbook
90-816981960 /
1095 1996 Technicians Handbook
90-816981970 /
March 1997 1997 Technicians Handbook
Mercury Outboard Service Literature Aids
90-830571 /
1-696 Dealer Publications and Starting Serial Number Guide
90-898104A08 Current Service Manual & Color Diagram Assembly
(entire Service Manual set including all current manuals)
90-899755A01 Color Diagram Binder Assembly
Last edited by a moderator:
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