Download Complete Service Repair Manual for Mercury Mariner 2.5-60 HP 2-STROKE Outboards.
This Factory Service Repair Manual offers all the service and repair information about Mercury Mariner 2.5-60 HP 2-STROKE Outboards. The information on this manual covered everything you need to know when you want to repair or service Mercury Mariner 2.5-60 HP 2-STROKE Outboards.
Models Covered:
Mercury/Mariner 2.5 HP (1998-2006)
Mercury/Mariner 3.3 HP (1998-2006)
Mercury/Mariner 4 HP (1998-2006)
Mercury/Mariner 5 HP (1998-2006)
Mercury/Mariner 6 HP (1998-2006)
Mercury/Mariner 8 HP (1998-2006)
Mercury/Mariner 9.9 HP (1998-2006)
Mercury/Mariner 15 HP (1998-2006)
Mercury/Mariner 20 HP (1998-2006)
Mercury/Mariner 25 HP (1998-2006)
Mercury/Mariner 30 HP (1998-2006)
Mercury/Mariner 40 HP (1998-2006)
Mercury/Mariner 50 HP (1998-2006)
Mercury/Mariner 60 HP (1998-2006)
Mercury/Mariner 20 Jet (1998-2006)
Mercury/Mariner 30 Jet (1998-2006)
Mercury/Mariner 45 Jet (1998-2006)
Manual Contents:
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Engine operation / Torque specifications / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specifications
CHAPTER TWO / TOOLS AND TECHNIQUES
Safety / Basic hand tools / Test equipment / Service hints / Special tips / Mechanics techniques
CHAPTER THREE / TROUBLESHOOTING
Safety precautions / Terminology and test equipment / Operating requirements / Starting system / Lighting coil / Battery charging system / Electrical accessories / Ignition system / Capacitor discharge ignition (CDI) (2.5, 3.3, 4 and 5 hp) / Alternator-driven ignition (6-25 hp except 1998 20 jet) / Alternator-driven ignition (1998 20 jet) / Capacitor discharge module (CDM) ignition (30 and 40 hp two-cylinder models) / Capacitor discharge module (CDM) ignition (40-60 hp three-cylinder models) / Fuel system Fuel primer and enrichment systems / Engine temperature and overheating / Boat wiring harness standard wire colors / Battery cable recommendations / Starting system troubleshooting / Charging system troubleshooting / Ignition system troubleshooting / Fuel system troubleshooting / Electric starter specifications / Charging system specifications / Stator resistance specifications (battery charging/lighting circuit) / CDI ignition system specifications / Ignition stator resistance specifications / Ignition system identification / Specifications
CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Hour meter / Fuels and lubrication / Fuel mixing ratio / Gearcase lubricant change Off-season storage / Anticorrosion maintenance / Engine submersion / Cooling system flushing / Tune-up / Compression test / Spark plugs / Ignition timing / Torque specifications / Maintenance schedule / Spark plug recommendations / Lubricant capacity / Specifications
CHAPTER FIVE / SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Safety precautions / General information / Synchronization and linkage procedures / Specifications
CHAPTER SIX / FUEL SYSTEM
Fuel pump / Carburetors / Fuel primer solenoid (6-25 hp and 20 jet remote control models) / Fuel primer valve (30-60 hp remote control models) / Engine mounted primer bulb (30-55 hp manual start models) / Antisiphon devices / Fuel filters / Fuel tanks / Fuel hose and primer bulb / Reed valve service / Fuel bleed (recirculation) system / Specifications
CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS
Battery / Charging system / Fuses / Starting systems / Capacitor discharge ignition (2.5-5 hp models) / Alternator driven capacitor discharge ignition system (6-25 hp models) / Capacitor discharge module (CDM) ignition (30-60 hp models) / Torque specifications / Battery capacity (hours) / Battery cable recommendations / Battery state of charge / Boat wiring harness standard wire colors
CHAPTER EIGHT / POWER HEAD
Service considerations / Model identifications / Power head break-in / Service recommendations / Lubricants, sealants and adhesives / Sealing surfaces / Fasteners and torque / Power head removal/installation / Power head disassembly / Cleaning and inspection / Power head assembly / Specifications
CHAPTER NINE / GEARCASE
Gearcase operation / Gear ratio / High-altitude operation / Service precautions / Corrosion control / Gearcase lubrication / Propeller / Trim tab adjustment / Gear housing / Water pump / Gearcase disassembly/assembly / Torque specifications / Gear ratio and approximate lubricant capacity / Specifications
CHAPTER TEN / JET DRIVE
Jet pump unit service
CHAPTER ELEVEN / TRIM AND TILT SYSTEMS
Power trim and tilt systems / Power trim and tilt system service
CHAPTER TWELVE / OIL INJECTION SYSTEMS
Oil injection system capacity / Oil pump output specifications / Specifications
CHAPTER THIRTEEN / MANUAL REWIND STARTERS
Specifications
CHAPTER FOURTEEN / REMOTE CONTROL
Commander 3000 control / Specifications INDEX
WIRING DIAGRAMS
This manual can be used by anyone from a first time owner/amateur to a professional technician.Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings.Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
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File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English