Mercury / Mariner 2.5 - 60 HP Two-Stroke Outboards 1994 - 1997

Clymer Owners Marine Service & Repair Manual

1994, 1995, 1996, 1997

by Scott Johnson and Mark Jacobs

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Mercury / Mariner 2.5 - 60 HP Two-Stroke Outboards 1994 - 1997 - Front Cover

Front Cover

Front Cover

description

Mercury / Mariner 2.5 - 60 HP Two-Stroke Outboards (Includes Jet Drive Models) 1994 - 1997 Clymer Owners Marine Service & Repair Manual covers the following models:
● Mercury/Mariner 2.5 HP (1994-1997)
● Mercury/Mariner 3.3 HP (1994-1997)
● Mercury/Mariner 4 HP (1994-1997)
● Mercury/Mariner 5 HP (1994-1997)
● Mercury/Mariner 6 HP (1994-1997)
● Mercury/Mariner 8 HP (1994-1997)
● Mercury/Mariner 9.9 HP (1994-1997)
● Mercury/Mariner 15 HP (1994-1997)
● Mercury/Mariner 20 HP (1994-1997)
● Mercury/Mariner 20 Jet (1994-1997)
● Mercury/Mariner 25 HP (1994-1997)
● Mercury/Mariner 30 HP (1994-1997)
● Mercury/Mariner 30 Jet (1994-1997)
● Mercury/Mariner 40 HP (1994-1997)
● Mercury/Mariner 45 Jet (1994-1997)
● Mercury/Mariner 50 HP (1994-1997)
● Mercury/Mariner 60 HP (1994-1997)

Contents:
QUICK REFERENCE DATA

GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specificaitons

TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / MechanicĀfs techniques

TROUBLESHOOTING
Safety precautions / Operating requirements / Test and repair equipment / Starting system / AC alternating current lighting coil / Battery charging system / Electrical accessories / Ignition system / Capacitor discharge ignition (2.5, 3.3, 4 and 5 hp) / Alternator driven ignition (electronic advance [20-25 hp and 20 Jet]) / Alternator drive ignition (mechanical advance [6-60 ho and 30-45 Jet]) / Capacitor discharge module (CDM) ignition (30 and 40 hp [2-cylinder]) / Capacitor discharge module (CDM) ignition (40-60 hp [serial No. 0G531301-on]) / CDM module resistance tests (optional) / Fuel system / Fuel primer and enrichment systems / Engine temperature and overheating / Engine / Specifications

LUBRICATION, MAINTENANCE AND TUNE-UP
Hour meter / Fuels and lubrications / Fuel selection / Gasoline additives / Recommended fuel mixture ratio / Power head break-in procedure / Fuel mixing procedure / AutoBlend II injection system / Constant ratio oil injection / Variable ratio oil injection / Lower gearcase lubricant change / Jet pump maintenance / Propeller shaft service / Corrosion of the propeller shaft bearing carrier / Off-season storage / Anticorrosion maintenance / Engine submersion / Cooling system flushing / Tune-up / Removing combustion chamber carbon / Compression test / Cylinder head bolt torque tightening / Spark plug plugs / Lower gearcase and jet pump service / Fuel filter service / Air filter service / Fuel pump / Ignition system service / Battery and starter system / On-boat performance test / Specifications

SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
2.5 and 3.3 hp models / 4 and 5 hp models / 6, 8, 9.9 and 15 hp models / 20-25 hp and 20 Jet models / 30 and 40 hp (2-cylinder models) / 40 hp and 30 Jet models (4-cylinder models) / 50-60 hp and 45 Jet models (prior to serial No. 0G531301) / 40, 50 and 60 hp (serial No. 0G531301-on) / Specifications

FUEL SYSTEM
Fuel pump / Carburetors / 2.5 and 3.3 hp carburetor / 4 and 5 hp carburetor (with integral fuel pump) / WMC series carburetor (with integral fuel pump [6-25 hp and 20 Jet]) / WMA series carburetor (40 hp [4-cylinder] and 30 Jet models) / WME series carburetor (30 and 40 hp [2- and 3-cylinder], 50-60 hp and 45 Jet) / Fuel primer solenoid (6-25 hp and 20 Jet [remote control models]) / Fuel primer valve (30-60 hp and 30 and 45 Jet [remote control models]) / Antisiphon devices / Fuel filters / Fuel tanks / Fuel hose and primer bulb / Reed valve service / Fuel bleed (recirculation) system / Specifications

IGNITION AND ELECTRICAL SYSTEMS
Battery / Battery charging system / Fuses / Starting systems / Ignition systems / Capacitor discharge ignition (2.5, 3.3 4 and 5 hp) / Alternator driven capacitor discharge ignition (6-60 hp and 30 and 45 Jet) / Capacitor discharge module (CDM) ignition / Specifications

POWER HEAD
Power head break-in / Lubricants, sealant and adhesives / Sealing surfaces / Fasteners and torque / Removal installation / Disassembly / Cleaning and inspection / Assembly / Specifications

LOWER GEARCASE AND JET DRIVE UNIT
Lower gearcase / Gear case operation / Gear ratio / High-altitude operation / Service precautions / Corrosion control / Gearcase lubrication / Propeller / Trim tab adjustment / Gear housing / Water pump / Gearcase disassembly / assembly / Jet drive models / Jet pump unit maintenance / Jet pump unit service / Bearing housing / Water intake housing liner / Specifications

POWER TRIM AND TILT SYSTEMS AND POWER STEERING SYSTEM
Trim and tilt systems / Manual tilt systems / Power trim and tilt systems / Power trim and tilt system service / Specifications

OIL INJECTION SYSTEM
Autoblend II injection system / Constant-ratio oil injection--40 hp and 30 Jet (4-cylinder) / Variable-ratio oil injection / Specifications

MANUAL REWIND STARTER AND REMOTE CONTROL
Manual rewind starters / Remote controls / 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.

General information on Repair Manuals

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.

product details

  • Publisher: Clymer Publications
  • ISBN: 0892876980 (0-892-87698-0)
  • ISBN-13: 9780892876983 (978-0-892-87698-3)
  • Format: Softcover, 690 pages
  • Date Published: 06-01-1998

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