Mercury Two stroke 20 25 30 40 45 50 55 60 Mariner Factory Service Repair Manual + Wirings
Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Mercury.
Thousands of Pages
Models Covered :
- 20
- 20 JET
- 25
- 25 MARATHON
- 25 SEAPRO
- 30
- 30 MARATHON
- 30 SEAPRO
- 30 JET
- 40
- 40 MARATHON
- 40 SEAPRO
- 40 4 CYL
- 45 JET
- 50
- 55
- 55 MARATHON
- 55 SEAPRO
- 60
- 60 MARATHON
- 60 SEAPRO
- 60 BIG FOOT
With Serial Numbers:
United States 0G044027 and Above
United States 0G044027 and Above
United States 0C159200 and Above
United States 0G531301 and Above
United States 0D000750 and Above
Belgium 09807909 and Above
Belgium 09855139 and Above
Belgium 9570305 and Above
Belgium 09974454 and Above
Belgium 09671687 and Above
Canada 0A748269 and Above
Manual Covers :
Information:
- Specifications
- Maintenance
- General Information
- Outboard Installation
Electrical:
- Ignition
- Charging and Starting System
- Timing, Synchronizing and Adjusting
- Wiring Diagrams
Fuel System:
- Fuel Pump
- Carburetor
- Oil Injection
- Emissions
Powerhead:
Mid-Section:
- Clamp/Swivel Brackets and Drive Shaft Housing
- Power Trim
Lower Unit:
- Lower Unit
- Jet Drive
Attachments/Control Linkage
Manual Starter
This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.
Language: English
Format: PDF – Indexed and Searchable
COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.)
Windows/Mac/Tablet/Phone Friendly
- Design: Many were compact and lightweight, making them popular for smaller boats, jon boats, and as auxiliary power.
- Fueling: Earlier models had carburetors, while later two-strokes (before the line was discontinued) featured Electronic Fuel Injection (EFI) for better performance and fuel economy.
- Maintenance
: Common issues can include carburetor flooding or clogged jets, especially after prolonged storage. Fuel filters and spark plugs require regular maintenance.
- Design: Models like the 40 HP Classic Fifty were a popular choice during their time and can still be found on used boats.
- Variations: The horsepower was sometimes shared across different models. For example, some two-cylinder 55 HP models shared the same block as 60 HP twins, making many parts interchangeable.
- Controls
: Many were tiller models, but remote steering options were also common.
- Troubleshooting: Common problems can include fuel pump issues, especially for older engines. Weak or dirty carburetors can cause rough idling, stalling, or loss of power.
- Fuel system: For hard-starting issues, check the fuel pump, lines, filters, and carburetor jets for clogs or leaks. Replacing old fuel and using a stabilizer is critical for engines that are stored.
- Ignition system: Faulty or worn-out spark plugs are a frequent cause of poor performance. Issues with the stator, trigger, and ignition coil can cause starting problems.
- Cooling system
: Overheating can be caused by a worn-out water pump impeller or a blocked cooling system. Impellers should be replaced regularly to prevent failure.
- Parts interchangeability: For Mariner models, many original parts will be stamped with both Mercury and Mariner branding, or can be cross-referenced to a Mercury equivalent.
- Fuel pumps: A replacement fuel pump is available on eBay for a wide range of two-stroke Mercury and Mariner models, including 30, 40, 45, 50, 55, and 60 HP.
- Engine oil: Mercury Precision Lubricants Premium 2-Cycle Outboard Oil is sold by various online marine supply stores.



