1998-2002 Mercury Mariner OUTBOARD 2.5 60 HP 2-STROKE SERVICE MANUAL

1998-2002 Mercury Mariner OUTBOARD 2.5 60 HP 2-STROKE SERVICE MANUAL

Mercury Mariner OUTBOARD 25-60 HP 2-STROKE SERVICE REPAIR MANUAL 1998 1999 2000 2001 2002
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this service 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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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)

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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

Models covered:
1998 1999 2000 2001 2002 2003 2004 2005 2006 Mercury/Mariner 2.5 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 Mercury/Mariner 3.3 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 Mercury/Mariner 4 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 Mercury/Mariner 5 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 Mercury/Mariner 6 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 Mercury/Mariner 8 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 Mercury/Mariner 9.9 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 Mercury/Mariner 15 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 Mercury/Mariner 20 HP
1998 1999 2000 2001 2002 2003 2004 2005 2006 Mercury/Mariner 25 HP
1998 1999 2000 2001 2002 Mercury/Mariner 30 HP
1998 1999 2000 2001 2002 Mercury/Mariner 40 HP
1998 1999 2000 2001 2002 Mercury/Mariner 50 HP
1998 1999 2000 2001 2002 Mercury/Mariner 60 HP
1998 1999 2000 2001 2002 Mercury/Mariner 20 Jet
1998 1999 2000 2001 2002 Mercury/Mariner 30 Jet
1998 1999 2000 2001 2002 Mercury/Mariner 45 Jet



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Clymer Manuals Mercury/Mariner 60 HP Online Manual
Clymer Manuals Mercury/Mariner 20 Jet Online Manual
Clymer Manuals Mercury/Mariner 30 Jet Online Manual
Clymer Manuals Mercury/Mariner 45 Jet Online Manual



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)

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File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader & WinZip
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