1998-2006 Mercury-Mariner 2.5hp – 60hp 2-Stroke Outboard Boat Engine Repair Manual

Description

Don’t miss another day of fishing on the water! This 1998-2006 Mercury-Mariner 2.5-60hp 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

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

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

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

CHAPTER THIRTEEN, MANUAL REWIND STARTERS

Torque specifications

CHAPTER FOURTEEN, REMOTE CONTROL

Commander 3000 control torque specifications

INDEX

WIRING DIAGRAMS