Mercury 150 HP XR6 / MAG III Outboard 1999-2004 Service Repair Manual – PDF Download

🛠️ Mercury 150 HP XR6 / MAG III Outboard 1999-2004 Service Repair Manual – PDF Download

🧰 OEM Factory Workshop Manual – Covers Mercury 150 HP XR6 and MAG III V6 2-Stroke Outboard Engines (U.S. Serial No. 0G960500 and up)
📲 Instant PDF Download – Compatible with Windows, macOS, iOS, Android, and Linux
🔧 Trusted by boat owners, certified marine technicians, and Mercury service shops

🔍 Model Background

The Mercury 150 HP XR6 / MAG III outboards (1999–2004) were part of Mercury’s high-performance 2-stroke lineup based on the proven 2.5L V6 block. These engines were designed to deliver aggressive acceleration, high top-end speed, and rugged dependability for tournament anglers, bass boaters, and performance-minded recreational users.

The XR6 and MAG III were mechanically similar, featuring carbureted induction, oil injection (Precision Blend), and CDM ignition. Tuned exhaust, stiffer engine mounts, and performance-oriented gear ratios gave these engines a harder-hitting power curve than standard 150 models. The XR6 was commonly seen on high-performance bass boats, while the MAG III was favored by saltwater and multi-species anglers looking for reliable speed and simplicity.

Despite being carbureted in an era when EFI and DFI were gaining ground, the XR6/MAG III remained highly respected for their simplicity, throttle response, and ease of service. Many are still running strong today, thanks to solid parts availability and a large base of owner and mechanic knowledge.

📆 Model Years Covered:

• Mercury 150 HP XR6 / MAG III – 1999
• Mercury 150 HP XR6 / MAG III – 2000
• Mercury 150 HP XR6 / MAG III – 2001
• Mercury 150 HP XR6 / MAG III – 2002
• Mercury 150 HP XR6 / MAG III – 2003
• Mercury 150 HP XR6 / MAG III – 2004

📘 Manual Details:

• Model: 150 HP XR6 / MAG III V6 2-Stroke
• Serial Numbers: 0G960500 and above
• Document Type: OEM Service & Repair Manual (Factory Shop Manual)
• Language: English
• Publisher: Mercury Marine
• Pages: 900+ with detailed service procedures, diagnostics, and schematics

📚 Manual Sections Include:

• General Information & Specifications
• Ignition & Charging System
• Switch boxes, stators, timing adjustment
• Fuel System
• Carburetors, fuel pump, primer bulb, link & sync
• Powerhead
• Cylinder block, pistons, crankshaft, gaskets
• Cooling System
• Thermostat, impeller, water passages
• Midsection & Power Trim
• Tilt system, mounts, bushings
• Gearcase Assembly
• Propshaft, seals, shimming, water pickup
• Control Linkage & Adjustment
• Shift/throttle linkage, idle stop
• Wiring Diagrams
• Full schematics with color and component references

💾 Format & Compatibility:

• File Format: PDF
• Searchable & Bookmarked: ✅ Yes
• Printable: ✅ Yes – Entire manual or individual chapters
• Compatible With: Windows, macOS, iOS, Android, Linux
• Delivery: 📩 Instant Digital Download

🔍 Keywords:

Mercury 150 HP XR6 MAG III outboard service manual PDF, 1999-2004 repair guide, carburetor tuning, V6 2-stroke, powerhead, fuel system, gearcase, wiring diagrams, OEM Mercury PDF

❓ Mini FAQ:

Q: Is this the same manual used by Mercury-certified repair centers?
A: Yes – it’s the complete OEM shop manual trusted by professional marine technicians.

Q: Are full wiring and hydraulic diagrams included?
A: Yes – this manual includes complete color schematics and adjustment guides.

Q: Can I access this manual on my tablet or smartphone?
A: Absolutely – the PDF is fully searchable and mobile-friendly.

🧭 Helpful Resources for Mercury Outboard Owners

• Why Every Mercury Mariner Owner Needs a Service Manual for At-Home Repairs – Learn how a digital service manual can save you time and money on common DIY maintenance tasks.
• Outboard Engine Troubleshooter – Not sure what’s wrong with your engine? Our free troubleshooting guide covers common issues across Mercury Outboards and more.

🔧 Browse More Mercury Manuals

Note: While our manuals are designed for DIY use, they do not replace professional mechanical training. If you're unsure about a repair or your engine shows serious issues, we strongly recommend visiting a certified marine mechanic. These guides are best suited for owners with basic to moderate mechanical experience.