INSTANT DOWNLOAD! Mercury 40 HP 50 HP 60 HP Service Repair Manual 2002-2004 OUTBOARD REPAIR / ENGINE MAINTENANCE / TROUBLESHOOTING

by admin on June 19, 2011


Instant Download

Mercury/Mariner Outboard motor service manual application:

1. 2002-2004 Mercury-Mariner 40HP EFI 4-Stroke (Four-Stroke).
2. 2002-2004 Mercury-Mariner 60HP EFI 4-Stroke (Four-Stroke).
3. 2002-2004 Mercury-Mariner 50 HP EFI 4-Stroke (Four-Stroke).
4. 2002-2004 Mercury-Mariner 40 HP EFI 4-Stroke (FourStroke) Bigfoot.
5. 2002-2004 Mercury-Mariner 60 HP EFI 4-Stroke (FourStroke) Bigfoot.

This expert text service repair manual gives complete step by step information on maintenance, tune-up, repair and overhaul. This manual is highly detailed with hundreds of photo illustrations to help guide you through every repair procedure. This ebook contains all you need to know to keep your Mercury-Mariner Outboard engine running right and is the only service repair manual you will need to repair and service your Outboard Motor. It will help you understand, care for, and lower the repair and maintenance cost for your boat motor for a overall improved satisfaction with your ownership.

Some of the Chapters Include:

Specifications
Maintenance
Electrical
Ignition
Starting
Wiring Diagrams
Fuel System and Carburetor
Powerhead
Mid-Section
Power Trim
Lower Unit
Jet Drive
Installation
Attachments

Below is just a small sample (1 Chapter) of topics covered in this Mercury/Mariner Service manual.

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4
Cylinder Block and Crankcase . . . . . . . . . . . . 4B-6
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4B-8
Power head Removal . . . . . . . . . . . . . . . . . . . . 4B-9
Removing Powerhead Components . . . . . . . 4B-12
Cylinder Block Disassembly . . . . . . . . . . . . . . 4B-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-17
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . 4B-17
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-18
Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-18
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20
Main Bearing Clearance . . . . . . . . . . . . . . . 4B-21
Connecting Rod Bearing Clearance . . . . . 4B-23
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-24
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 4B-24
Cylinder Block Reassembly . . . . . . . . . . . . . . . 4B-25
Selecting New Main Bearings . . . . . . . . . . 4B-25
Main Bearing Installation . . . . . . . . . . . . . . 4B-26
Selecting New Connecting Rod Bearings 4B-27
Installing Connecting Rod Bearings . . . . . 4B-27
Connecting Rod Installation . . . . . . . . . . . . 4B-28
Piston Ring Installation . . . . . . . . . . . . . . . . 4B-29
Piston Installation . . . . . . . . . . . . . . . . . . . . 4B-30
Crankshaft Installation . . . . . . . . . . . . . . . . 4B-30
Crankcase Cover Installation . . . . . . . . . . . 4B-32
Exhaust Cover Installation . . . . . . . . . . . . . 4B-33
Drive Gear Installation . . . . . . . . . . . . . . . . 4B-34
Installing Powerhead Components . . . . . . 4B-35
Engine Wiring Harness and
Ignition/Electrical Component Installation 4B-35
Ignition Components . . . . . . . . . . . . . . . . . . 4B-35
Charging/Starting System Components . 4B-35
Fuel Components . . . . . . . . . . . . . . . . . . . . 4B-35
Power head Installation . . . . . . . . . . . . . . . . . . . 4B-36
Tiller Handle Models . . . . . . . . . . . . . . . . . . 4B-3

1. ECM
2. Starboard ECM Connector
3. Manifold Air Temperature (MAT) Sensor
4. Manifold Absolute Pressure (MAP) Sensor
5. Throttle Position Sensor (TPS)
6. Engine Coolant Temperature (ECT) Sensor
7. Crank Position Sensor (CPS)
8. Oil Pressure Switch
9. Idle Air Control (IAC) Valve
10. Ignition Coil (EST) #1
11. Ignition Coil (EST) #2
12. Ignition Coil (EST) #3
13. Ignition Coil (EST) #4
14. Main Power Relay
15. SmartCraft Data Bus Circuit – 15 amp. fuse
16. Fuel Pump/IAC/Injector Circuit – 20 amp. fuse
17. Main Power Relay/Accessory Circuit – 20 amp. fuse
18. Ignition Coil Circuit – 2 amp. fuse
19. Voltage Regulator/Rectifier
20. Stator
21. Start Solenoid
22. Starter
23. To Trim Motor
24. Trim Down Relay
25. Trim Up Relay
26. To 12 Volt Battery
27. Cowl Mounted Trim Switch
28. To Trim Connections on Remote Control Harness
29. Suppression Diode
30. Vapor Separator Tank
31. Engine Harness Connection
32. Data Bus (10 pin) Control Area Network (CAN)
33. DDT Connection
34. Fuel Injector #1
35. Fuel Injector #2
36. Fuel Injector #3
37. Fuel Injector #4
38. Port ECM Connector
39. Neutral Start Switch
40. 12 Volt Switched Auxiliary Power Source
41. Key Switch
42. Warning Horn
43. Push Button Stop Switch
44. Lanyard Stop Switch
45. Tachometer Signal
46. Tiller Handle Harness

Manual Language: ENGLISH
Pages: 590
File Format: PDF
File Delivered In: PDF Format
Book Marked Indexed for easy navigation: YES
Zoom in/out: YES
Word Search: YES

Working on your outboard engine just go a whole lot easier!

Download this pdf to view it, save it on your computer and print pages when every you need to do repairs. To get this instant download manual now just click on the green download button at the top left corner of this page and pay through Paypal. No Paypal account needed and no registration required. Get your manual in just seconds.

Search Tags: Mercury-Mariner 2002, 2003, 2004 Parts, Aftermarket Parts, Used Parts, Boating, Egnine Problems, DIY, Handbook, Engine Repair Guide, Engine Will Not Start, Prop Install, Lower Unit

Searches:

* 50 mercury fourstroke 2004
* 2004 Mercury 50 hp 4 stroke owners manual

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