Service Manuals/Factory Repair Guides/Owner's manuals for the Do-It-Yourself Mechanic
Free Service Manual Sample Download!
1.HERE IS A SAMPLE OF MERCURY/MARINER FACTORY SERVICE MANUAL
2. HERE IS THE FULL MERCURY/MARINER FACTORY SERVICE MANUAL BOOK
Mercury-Mariner Outboard Service Manuals
Download Manuals Below
1965-1989 Mercury Mariner Workshop Manual 2 To 40 Hp 2 Stroke
1965-1989 Mercury Repair Manual 45 Thru 115hp 2 Stroke
1986-2003 Mercury Factory Service Manual 6/8/9.9/10/15HP 2 Stroke
1995-2000 Mercury Mariner 40 45 50 HP Service Manual
1997-2000 Mercury Mariner 40 50 55 60hp Service Manual 2 Stroke
1997 1998 Mercury Optimax 200 & 225 HP Service Manual
1998-1999 Mercury Mariner 9.9 & 15 HP Service Repair Manual
1998-1999 Mercury 135HP (135 HP) & 150HP (150 HP) Service Manual
1999-2002 Mercury - Mariner 30 HP 40 HP Service Manual 4-Stroke Outboard
1999-2000 Mercury - Mariner Service Manual 4HP 5HP 6HP (4 Stroke)
2000 2001 Mercury 75/90 HP (75hp & 90hp) Outboard Service Manual
2000-2001 Mercury Optimax 115 135 150 175 Service Repair Manual DFI
2001 Mercury Mariner 50 HP & 2001 60 HP Service Manual
2001 2002 Mercury 115 HP (115HP) Service Manual 4-Stroke
2002-2004 Mercury 40 HP 50 HP 60 HP Service Manual
POWERHEAD Cylinder Head
POWERHEAD
Cylinder Head
CYLINDER HEAD Warp Limit * Lines indicate straight edge measurement 0.004 in. (0.1 mm) VALVES Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake Exhaust Valve Dimensions: “A” Head Diameter Intake Exhaust “B” Face Width Intake Exhaust “C” Seat Width Intake Exhaust “D” Margin Thickness Intake Exhaust Stem Outside Diameter Intake Exhaust Guide Inside Diameter Intake Exhaust Stem To Guide Clearance Intake Exhaust Stem Run-out Limit (max.)
CYLINDER HEAD
Warp Limit
* Lines indicate
straight edge
measurement
0.004 in. (0.1 mm)
VALVES
Valve/Valve Seat/Valve Guides:
Valve Clearance (cold)
Intake
Exhaust
Valve Dimensions:
“A” Head Diameter
“B” Face Width
“C” Seat Width
“D” Margin Thickness
Stem Outside Diameter
Guide Inside Diameter
Stem To Guide Clearance
Stem Run-out Limit (max.)
Cylinder Head Cover Removal 1. Disconnect the breather hose and vent hose. 2. Remove fuel pump assembly.
Cylinder Head Cover Removal
1. Disconnect the breather hose and vent hose.
2. Remove fuel pump assembly.
Adjusting Valves NO. 1 AND NO. 2 INTAKE VALVES NO. 1 AND NO. 3 EXHAUST VALVES 1. Disconnect spark plug leads. 2. Turn the driven gear and align the “1” mark on the gear with the cylinder head mark “ ”. Adjusting Valves 2. Reinstall the fuel pump. Tighten bolts to the specified torque. 3. Reconnect the breather hose and vent hose. Use sta-straps to fasten all hose connections. C ylinder Head Cover Installation 1. Reinstall the cylinder head cover. Tighten bolts to the specified torque.
Adjusting Valves
NO. 1 AND NO. 2 INTAKE VALVES
NO. 1 AND NO. 3 EXHAUST VALVES
1. Disconnect spark plug leads.
2. Turn the driven gear and align the “1” mark on the gear with the cylinder head mark “
”. Adjusting Valves
2. Reinstall the fuel pump. Tighten bolts to the specified torque. 3. Reconnect the breather hose and vent hose. Use sta-straps to fasten all hose connections. C ylinder Head Cover Installation 1. Reinstall the cylinder head cover. Tighten bolts to the specified torque.
2. Reinstall the fuel pump. Tighten bolts to the specified torque.
3. Reconnect the breather hose and vent hose. Use sta-straps to fasten all hose connections.
C ylinder Head Cover Installation
1. Reinstall the cylinder head cover. Tighten bolts to the specified torque.
3. Adjust the valve clearance for No. 1 and No. 2 intake valves and No. 1 and No. 3 exhaust
valves .
