This Factory Service Repair Manual offers all the service and repair information about Mercury Mariner 75-250 Hp 2-stroke Outboards. The information on this manual covered everything you need to know when you want to repair or service Mercury Mariner 75-250 Hp 2-stroke Outboards. I'm looking for a manual for a 4 HP 2-stroke Mercury outboard from 1981. It's Belgian made, two cylinder, serial # 9321742, although Mercury advised that I'd need to put a zero before the serial number (so, 09321742).
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Description
This Clymer Mercury-Mariner Two Stroke Outboard Repair Manual 75-250 hp 1998-2009 provides detailed service information, step-by-step repair instruction and maintenance specifications for 1998-2009 Mercury and Mariner 75-250 hp Outboard boat engines. This is the book you need to properly care and repair your outboard engine. Save a fortune by doing it yourself. Buy a copy to keep on the boat and another to study at home or work.
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization, Warnings, cautions and notes, Torque specifications, Engine operation, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Propellers
CHAPTER TWO, TOOLS AND TECHNIQUES
Safety first, Basic hand tools, Test equipment, Basic service methods
CHAPTER THREE, TROUBLESHOOTING
Safety precautions, Operating requirements, Terminology and test equipment, Starting system, Battery charging system, Electrical accessories, Ignition system, Capacitor discharge module (CDM) ignition (65 jet and 75-125 hp, except 105 jet and 115 Optimax) / Alternator driven ignition (1998 and 1999 105 jet and 135-200 hp [except Optimax models]) / Capacitor discharge module (CDM) ignition (200o-on 105 jet and 135-200 hp [except Optimax models]) / Capacitor discharge module (CDM) ignition (225 and 250 hp) / Digital inductive (DI [Optimax models]) / Fuel system, Fuel primer and enrichment systems, EFI fuel system troubleshooting, Optimax 115-225 hp air/fuel system troubleshooting, Engine temperature and overheating, Engine, Starting system troubleshooting, Ignition system troubleshooting, Fuel system troubleshooting, Starter motor current draw specifications, Charging system troubleshooting, Charging system amperage, Battery charging coil (stator) resistance specifications (except belt-driven) system, Ignition system voltage output specifications, Ignition stator resistance specification, Capacitor discharge module (CDM) resistance specifications, Ignition coil resistance specifications, Fuel pump pressure specifications, Engine coolant temperature (ECT) and compressor temperature sensor specifications, Air temperature (IAT) sensor specifications, Cooling system specifications
Screen prank. CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP
Hour meter, Fuels and lubrication, Off-season storage, Anticorrosion maintenance, Engine submersion, Cooling system flushing, Tune-up, Maintenance torque specifications, Maintenance schedule, Spark plug recommendations, Lubricant capacities
CHAPTER FIVE, SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Safety precautions, Test propeller, General information, 65 jet, 75 hp and 90 hp, 80 jet and 100-125 hp (except 115 Optimax) / 105 jet, 140 jet and 135-200 hp carbureted, 150-200 hp electronic fuel injection (EFI), 115-225 hp Optimax (direct fuel injection), 225 hp carbureted, 225 and 250 hp EFI, General specifications, Synchronization and linkage torque specifications
Synthesia key. CHAPTER SIX, FUEL SYSTEM
Fuel pump, Carburetors, Fuel primer valve (65 jet and 75-200 hp [remote control models]) / Thermal air valve (105 jet and 135-200 hp carbureted models) / Fuel enrichment valve (225 hp carbureted models), Accelerator pump circuit (100-125 hp and 80 jet models) / Antisiphon devices, Fuel filters, Fuel tanks, Fuel hose and primer bulb, Electronic fuel injection (EFI) and direction fuel injection (DFI) / Reed valve service, Fuel bleed (recirculation) system, Fuel system torque specifications, Carburetor specifications
CHAPTER SEVEN, ELECTRICAL SYSTEM
Battery, Charging system, Fuses, Starting systems, Ignition systems, Capacitor discharge module (CDM) ignition, Digital inductive ignition (115-225 hp Optimax models) / Electrical system torque specifications, Battery charge percentage, Battery capacity, Battery requirements (minimum), Battery cable requirements
CHAPTER EIGHT, POWER HEAD
Service consideration, Mercury/Mariner model identification, Power head break-in, Service recommendations, Lubricants, sealants and adhesives, Sealing surfaces, Fasteners and torque, Power head removal/installation, Power head disassembly, Power head cleaning and inspection, Power head assembly, Power head torque specifications, Cylinder bore specifications, Piston specifications, Engine characteristic codes
CHAPTER NINE, GEARCASE
Gearcase operation, Service precautions, Corrosion control, Gearcase lubrication, Propeller, Trim tab adjustment, Gear housing, Water pump, Gearcase disassembly/assembly, Gearcase cleaning and inspection, Gearcase pressure testing, Gearcase shimming, Gearcase torque specifications, Gear ratio and tooth counts, Pinion gear locating tool specifications, Gearcase backlash specifications
Mercury 75 Hp Two Stroke Outboard Manual
CHAPTER TEN, JET DRIVE
Jet pump unit maintenance, Jet pump unit repair, Jet drive torque specifications
CHAPTER ELEVEN, TRIM AND TILT SYSTEMS
Power trim and tilt system service, Trim and tilt system torque specifications
CHAPTER TWELVE, MIDSECTION AND TILLER CONTROL
Mid-section and tiller control torque specifications
CHAPTER THIRTEEN, OIL INJECTION SYSTEM
Variable ratio oil injection (75-125 hp [except 115 hp Optimax and 105 jet], 65 jet and 80 jet models), Variable-ratio oil injection (135-200 hp [except Optimax models], 105 jet and 140 jet models), Variable-ratio oil injectio (225 hp and 250 hp [except Optimax] models) / Variable-ratio electronically controlled oil injection (Optimax models) / Oil injection system torque specifications, Oil injection system specifications
CHAPTER FOURTEEN, REMOTE CONTROL
INDEX
WIRING DIAGRAMS