by Robert Mills and Randy Stephens
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Mariner 2.5 - 275 HP Outboards 1990 - 1993 Clymer Owners Marine Service & Repair Manual covers the following models:
● Mariner 2.5 HP, 3.3 HP, 4.0 HP, 5.0 HP, 8.0 HP, 9.9 HP
● Mariner 15 HP, 20 HP, 25 HP, 40 HP, 50 HP, 60 HP, 75 HP, 90 HP
● Mariner 100 HP, 115 HP, 135 HP
● Mariner 150 HP, 150 Magnum II, 150 Magnum III, 150 Magnum EFI
● Mariner 175 HP, 175 Magnum EFI
● Mariner 200 HP, 200 Magnum EFI, 250 HP, 275 HP
● QUICK REFERENCE DATA
● GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Protection from galvanic corrosion / Propellers / Specifications
● TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques / Specifications
Operating requirements / Starting system / Charging system / Ignition system / Breaker-point ignition troubleshooting (1990-1992 2.5 hp models) / Capacitor discharge ignition (CDI) / Direct voltage test / Resistance test / Speed limiter / Spark advance/idle stabilizer module troubleshooting / Fuel system / Engine / Specifications
● LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Proper fuel selection / Recommended fuel mixture / Autoblend oil injection / oil injection systems / Fuel mixing procedure / AutoBlend 2 injection system / Constant ratio oil injection / Variable ratio oil injection / Checking lower drive unit lubrication / Lower drive unit lubricant change / Propeller shaft lubrication / Saltwater corrosion of gear housing bearing carrier and nut / Storage / Anti-corrosion maintenance / Complete submersion / Flushing the cooling system / Tune-up / Compression test / Spark plugs / Lower unit and water pump check / Fuel system service / Fuel line and hoses inspection / Fuel filter service / inline fuel filter / Sight bowl filter / Water separating filter (EFI models) / Final fuel filter (EFI models) / Fuel pump (except EFI models) / Fuel pump pressure test / Ignition system service / Breaker point and condenser service / Battery and starter check / Starter solenoid check / Alternator and rectifier check / Ignition timing and synchronization / On-boat performance test / Specifications
● TIMING, SYNCHRONIZING AND ADJUSTING
Ignition timing and synchronization / 2.5 hp models (prior to serial No. D90217) / 4 and 5 hp models / 8, 9.9 and 15 hp models / 20 and 25 hp models / 40 hp models / 50 and 60 hp models (prior to serial No. D000750) / 50 and 60 hp models (serial No. D000750-on) / 75 and 90 hp models / 100 and 115 hp models / 135-200 hp (except EFI) models / 250 and 275 hp models / 150, 175 and 200 EFI models / Specifications
● FUEL SYSTEM
Fuel pump / Carburetor / Throttle plunger carburetor (2.5 and 3.3 hp models) / Integral fuel pump carburetor (4 and 5 hp models) / Integral fuel pump carburetor with primer system (8-25 hp models) / WMA carburetor (40 hp models) / MerCarb center bowl carburetor (50 and 60 hp models prior to serial No. D000750) / WME carburetor (50 and 60 hp serial No. D000750-on, 75, 90, 100 and 115 hp models) / WMH carburetor (135-200 hp models) / MerCarb center bowl carburetor (250 and 275 models) / Thermal air valve (135-200 hp models) / Enrichment valve and choke solenoid systems / Anti-siphon devices / Fuel filter / Fuel tank / Fuel hose and primer bulb / Electronic fuel injection (EFI) / Fuel management tests / Specifications
● IGNITION AND ELECTRICAL SYSTEMS
Battery / Battery charging system / Starting system / Magneto breaker point ignition / Capacitor discharge ignition (CDI) (1993 [serial No. D901217-on] 2.5 and 3.3 hp models) / Capacitor discharge ignition (CDI) (4-275 hp models) / Specifications
● POWER HEAD
Engine serial number / Gaskets and sealants / Fasteners and torque / Power head / Specifications
● LOWER UNIT GEAR HOUSING
Service precautions / Gear housing / Water pump / Bearing carrier and propeller shaft / Pinion gear, drive shaft and forward gear / Lower shift shaft, bushing and cam / Propeller / Trim tab adjustment / Specifications
● POWER TRIM AND TILT SYSTEM
Manual tilt assist system / One-ram integral power trim system (40-60 hp models) / Three-ram integral power trim system (75-200 hp models) / One-ram Oildyne power trim system (250-275 hp models) / Power trim assembly removal/installation / Power trim motor and pump assembly removal/installation / Specifications
● OIL INJECTION SYSTEM
AutoBlend II (50 and 60 hp prior to serial No. D000750) / Constant-ratio oil injection (40 hp and 50-60 hp models [serial No. D000750-on]) / Injection system service / Variable-ratio oil injection (75-115 hp models) / Warning horn system / Injection system service / Variable-ratio oil injection (V6 models) / Warning horn system / Injection system service / Specifications
● MANUAL REWIND STARTERS
2.5 and 3.3 hp models / 4 and 5 hp models / 8, 9.9, 15, 20 and 25 hp models / 40 hp models / Specifications
● WIRING DIAGRAMS
Clymer marine manuals can save you money on maintenance and repair. Step-by-step procedures and detailed illustrations guide you through every job, from routine maintenance and troubleshooting, all the way to complete teardown & rebuild.
Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.
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