Mercury / Mariner 2.5-60 HP Two-Stroke Outboards 1998 - 2006

Clymer Owners Marine Service & Repair Manual

1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

by Clymer Staff

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Mercury / Mariner 2.5-60 HP Two-Stroke Outboards 1998 - 2006 - Front Cover

Front Cover

Front Cover

Rear Cover

Rear Cover

description

Mercury / Mariner 2.5-60 HP Two-Stroke Outboards 1998 - 2006 Clymer Owners Marine Service & Repair Manual covers the following models:
● 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)

Contents:
QUICK REFERENCE DATA

GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Engine operation / Torque specifications / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specifications

TOOLS AND TECHNIQUES
Safety / Basic hand tools / Test equipment / Service hints / Special tips / Mechanics techniques

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

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

SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Safety precautions / General information / Synchronization and linkage procedures / Specifications

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

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

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

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

JET DRIVE
Jet pump unit service

TRIM AND TILT SYSTEMS
Power trim and tilt systems / Power trim and tilt system service

OIL INJECTION SYSTEMS
Oil injection system capacity / Oil pump output specifications / Specifications

MANUAL REWIND STARTERS
Specifications

REMOTE CONTROL
Commander 3000 control / 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: 1620921332 (1-620-92133-2)
  • ISBN-13: 9781620921333 (978-1-620-92133-3)
  • Format: Softcover, 466 pages

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