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25 Hp Mercury Outboard Service Manual
Outboard Repair Manual
What Is a Mercury Outboard Repair Manual?
Benefits of Using an Outboard Repair Manual
- Product literature – The manual is your guide to knowing everything about the boat. Its year of manufacture, the maker, model number, safety features, technical specifications, service center contacts, warranty and service dates, and many other characteristics of the boat are clearly mentioned so you have all necessary information with you in one place.
- Safety booklet – Products with complex mechanical and electrical components should be handled with caution. Service manuals provide owners the exact procedure to follow when servicing their boats. Owners will, therefore, understand their knowledge and consult a professional when it goes beyond their scope.
- Economical – You can easily fix minor issues, if not major repairs, by using the outboard repair manual. The same fix at a professional service center will cost a lot more of your time and money.
Mercury Repair Manuals Available:
- Product literature – The manual is your guide to knowing everything about the boat. Its year of manufacture, the maker, model number, safety features, technical specifications, service center contacts, warranty and service dates, and many other characteristics of the boat are clearly mentioned so you have all necessary information with you in one place.
- Safety booklet – Products with complex mechanical and electrical components should be handled with caution. Service manuals provide owners the exact procedure to follow when servicing their boats. Owners will, therefore, understand their knowledge and consult a professional when it goes beyond their scope.
- Economical – You can easily fix minor issues, if not major repairs, by using the outboard repair manual. The same fix at a professional service center will cost a lot more of your time and money.
Mercury Repair Manuals Available:
Mercury Service Manuals Available:
Mercury Workshop Manuals Available:
Mercury Shop Manuals Available:
2002-2005 Mercury 50 hp Four-Stroke
Mercury 8 HP
Mercury 8 HP Sailmate
Mercury 75 HP
2002-2005 Mercury 60 hp 4-Stroke
Mercury 9.9 HP Sailpower, XR10/MAG 10/Viking 10
Mercury 6 HP
Mercury Sea Pro/Marathon 10
2002-2005 Mercury 40/50/60 ELPT Bigfoot 4-Stroke
Mercury 75 HP Jet
Mercury 90 HP M
Mercury 65 HP Jet
Mercury 75 HP Marathon
2002-2005 Mercury 40/50/60 ELPT 4-Stroke
2002-2005 Mercury 40 hp 4-Stroke
Mercury 100 HP
Mercury 80 HP Jet
Mercury 9.9 HP
Mercury 15 HP
Mercury 125 HP
Mercury 75 HP Sea Pro
Mercury 115 HP
Mercury Sea Pro/Marathon 15
Description
Don't miss another day of fishing on the water! This 1998-2006 Mercury-Mariner 25-60hp Outboard Boat Engine Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1998-2006 Mercury-Mariner 2.5-60hp two-Stroke outboard boat engines including 2.5 HP, 3.3 HP, 4 HP, 5 HP, 6 HP, 8 HP, 9.9 HP, 15 HP, 20 HP, 20 Jet, 25 HP, 30 HP, 30 Jet, 40 HP, 45 Jet, 50 HP, and 60 HP models.
1998 1999
2000 2001 2002 2003 2004 2005 2006
This 1998-2006 Mercury-Mariner 25-60hp Outboard Boat Engine Repair Manual includes general information on each model, tools and techniques, troubleshooting and testing, lubrication, maintenance and tune-up, synchronization and linkage adjustment, fuel system, electrical and ignition system, power head, gearcase, jet drive, trim and tilt system, oil injection system, manual rewind starters, and remote control systems. Complete wiring diagrams are included. Features 466 illustrated pages.
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization, Warnings, cautions and notes, Engine operation, Torque specifications, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Propellers
CHAPTER TWO, TOOLS AND TECHNIQUES
Safety, Basic hand tools, Test equipment, Service hints, Special tips, Mechanic's tips
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 (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, Engine, 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
CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP
Backgrounds for desktop for a mac. Hour meter, Fuels and lubrication, Off-season storage, Anticorrosion maintenance, Engine submersion, Cooling system flushing, Tune-up, Torque specifications, Maintenance schedule, Spark plug recommendations, Lubricant capacity
CHAPTER FIVE, SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Safety precautions, General information, Synchronization and linkage procedures, General 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, Torque specifications, Carburetor specifications, Reed valve 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, Torque specifications, Connecting rod service specifications, Crankshaft service specifications, Cylinder block service specifications, Piston service specifications, Model number codes
CHAPTER NINE, GEARCASE
1985 25 Hp Mercury Outboard Service Manual Free
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, Gearcase service specifications
1985 25 Hp Mercury Outboard Service Manual
CHAPTER TEN, JET DRIVE
Jet pump unit service, Torque specifications
CHAPTER ELEVEN, TRIM AND TILT SYSTEMS
Power trim and tilt systems, Power trim and tilt system service, Torque specifications
CHAPTER TWELVE, OIL INJECTION SYSTEMS
Oil injection system capacity, Oil pump output specifications, Torque specifications
25 Hp Mercury Outboard For Sale
CHAPTER THIRTEEN, MANUAL REWIND STARTERS
Torque specifications
CHAPTER FOURTEEN, REMOTE CONTROL
Commander 3000 control torque specifications
INDEX
WIRING DIAGRAMS