Mariner 30 JET 40 (4 CYL) Manuals

Manuals and User Guides for Mariner 30 JET 40 (4 CYL). We have 1 Mariner 30 JET 40 (4 CYL) manual available for free PDF download: Service Manual

Mariner 30 JET 40 (4 CYL) Service Manual

Mariner 30 JET 40 (4 CYL) Service Manual (532 pages)

Brand: Mariner | Category: Outboard Motor | Size: 15.81 MB

Table of Contents

Important 1

6
Electrical and Ignition 2

26
- Ignition System
  27
  - Description
    27
  - Checking for Loss Spark
    28
  - Troubleshooting Test Equipment
    28
- Ignition Troubleshooting (Engines with Black Stator)
  29
- Ignition Troubleshooting (Engines with Red Stator)
  32
- Ignition Component Testing
  36
  - Trigger Test
    36
  - Ignition Coil Test
    36
  - Test for Spark
    38
  - Ignition (Key) Switch Test
    39
  - Mercury (Tilt) Stop Switch Test
    39
- Flywheel Removal and Installation
  40
  - Flywheel Removal
    40
    
    Electric Start Model
    40
    
    Manual Start Model
    40
  - Flywheel Installation
    41
- Ignition Components
  41
  - Stator Assembly Removal
    41
  - Black Stator Assembly Installation
    43
  - Red Stator Assembly Installation
    44
  - Trigger Plate Assembly Removal
    47
  - Trigger Plate Assembly Installation
    48
  - Ignition Coil Removal
    49
  - Ignition Coil Installation
    49
  - Switch Box Removal
    49
  - Switch Box Installation
    50
Electrical and Ignition 2

52
- Battery
  53
  - Precautions
    53
  - Operating Outboard Without Battery
    53
  - Specific Gravity Readings
    53
    
    Specific Gravity Cell Comparison Test
    54
  - Electrolyte Level
    54
  - Charging a Discharged Battery
    54
  - Winter Storage of Batteries
    55
- Battery Charging System
  55
- Starter System
  60
- Starter Removal and Installation
  62
  - Removal
    62
  - Installation
    62
- Bosch Starter
  63
  - Disassembly
    63
- Starter Cleaning, Inspection and Testing
  64
  - Cleaning and Inspection
    64
  - Testing
    64
    
    Armature Test for Ground
    64
    
    Armature Test for Shorts
    64
  - Checking Positive Brushes and Terminal
    65
  - Testing Negative Brushes for Ground (Bosch)
    65
  - Reassembly
    66
  - Starter Solenoid Test
    68
Electrical and Ignition 2

77
Fuel System and Carburetion

97
- Fuel System (Carburetor)
  99
- Fuel System (Fuel Pump)
  100
- Fuel Pump
  101
  - General Information
    101
    
    Caused by Anti-Siphon Valves
    101
    
    Checking for Restricted Fuel Flow
    101
    
    Fuel Pump Description/Operation
    101
  - Testing
    101
  - Troubleshooting Fuel Pump
    101
- Fuel Pump Removal (Electric Start Model)
  102
- Fuel Pump Disassembly
  103
- Fuel Pump Exploded View (Design 1)
  104
- Cleaning and Inspection
  105
  - Check Valve Reassembly (Design 1)
    105
- Fuel Pump Installation (Design 1)
  106
- Fuel Pump Exploded View (Design 2)
  107
- Cleaning and Inspection
  108
  - Check Valve Reassembly (Design 2)
    108
- Fuel Pump Installation (Design 2)
  108
- Carburetion System
  109
  - Fuel System - Troubleshooting
    109
  - Troubleshooting Charts
    109
  - Checking for Restricted Fuel Flow
    110
    
    Caused by Anti-Siphon Valves
    110
- Carburetor Adjustments
  110
  - Initial Starting Adjustment
    110
  - Idle Speed Adjustment
    110
  - Idle Mixture Screw Adjustment
    111
  - Float Adjustment
    111
    
    Float Level (WMA7B Carburetor)
    111
    
    Float Level and Float Drop Adjustment
    111
    
    Float Drop (WMA7B Carburetor Only)
    112
    
    Float Drop (WMA9 Carburetor Only)
    112
    
    Float Level (WMA9 Carburetor)
    112
  - Main (High Speed) Jet Adjustment
    112
  - Vent Jet
    113
  - High Altitude Jetting
    113
  - Carburetor Jet Orifice Sizes WMA7B
    113
  - Carburetor Jet Orifice Sizes WMA9
    113
- Enrichment System (Electric Start Models)
  114
  - Enrichener Hose Routed to Carburetor Flanges
    114
  - Enrichener Hose Routed to Balance Tube
    114
- Enrichener Valve (Manual Operation)
  115
- Primer System
  115
  - Hose Installation
    115
- Enrichener Valve Replacement
  116
- Enrichment Valve Test
  116
- Fuel Line and Primer Bulb Assembly
  117
  - Maintenance
    117
  - Fuel Line Clamp Removal and Installation
    117
- Carburetor Disassembly (Top Carburetor)
  118
- Carburetor Removal (Manual Start Model)
  118
- Cleaning and Inspection
  122
- Carburetor Reassembly
  123
- Carburetor Installation
  127
Powerhead

129
- General Information
  130
- Special Tools
  130
- Specifications
  130
- Throttle Control Linkage
  131
- Cylinder Block and Crankcase Assembly
  133
- End Caps and Exhaust Cover
  135
- Crankshaft, Pistons and Connecting Rods
  137
- Powerhead Torque Sequence and Torque Specifications
  139
- Powerhead Removal from Driveshaft Housing
  140
  - Electric Start Model
    140
  - Manual Start Model
    143
- Powerhead Disassembly
  145
- End Cap Disassembly
  150
- Crankshaft Disassembly
  151
- Cleaning and Inspection
  154
  - Cylinder Block and Crankcase Cover
    154
  - Cylinder Bore (Cleaning and Inspection)
    154
    
    Honing Procedure
    154
  - Cylinder Bore Size
    155
  - Pistons
    155
  - Measuring Piston Roundness
    156
  - Reed Blocks
    156
  - Connecting Rods
    157
  - Cleaning Connecting Rods
    159
  - Crankshaft
    159
  - Ball Bearing
    160
- Powerhead Reassembly
  160
  - General
    160
- Crankshaft Reassembly
  161
  - Piston Installation
    164
  - Crankshaft Seal Installation
    166
  - End Cap Reassembly
    167
    
    Lower End Cap
    167
    
    Upper End Cap
    168
- Cylinder Block Reassembly
  168
- Installing Powerhead on Driveshaft Housing
  177
  - MID-Section
    179
  - Swivel Bracket Components
    181
  - Transom Bracket
    182
MID-Section

189
- Power Trim General Information
  190
  - Description
    190
  - Trimming Characteristics
    190
    
    Trimming Outboard "Down
    190
    
    Trimming Outboard "Up" ("Out")
    190
  - Trailering Outboard
    191
  - Tilting Outboard up and down Manually
    191
  - Trim "In" Angle Adjustment
    191
- Power Trim System Components
  192
  - Torque Specifications
    192
  - Quicksilver Lubricants and Service Aids
    192
- Power Trim Flow Diagrams Design
  193
  - Determine if Problem Is Electrical or
    200
    
    Hydraulic
    200
  - Trouble Chart
    200
  - Hydraulic System Troubleshooting
    201
  - Preliminary Checks
    201
  - Leak down Check - Pump and Manifold Assembly
    201
  - Leak down Check - Pilot Valve Assembly
    202
  - Leak down Check - Manual Release
    202
    
    Valve
    202
  - Leakage Past Ball and Seat - Piston Assembly
    202
  - Troubleshooting Flow Diagram
    203
  - Troubleshooting Flow Diagram
    204
- Electrical System Troubleshooting
  205
  - COMMANDER 2000 Side Mount Remote
    205
  - Power Trim System Wiring Diagram
    206
    
    Troubleshooting the "Down" Circuit* (When "Up" Circuit Is OK)
    207
    
    Troubleshooting the "Up" Circuit* (When "Down" Circuit Is OK)
    208
    
    Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
    209
- Power Trim System Removal
  210
- Power Trim System Disassembly
  211
  - Trim Rod Removal
    211
  - Trim Rod Disassembly
    212
  - Trim "Motor" Removal
    214
  - Trim "Motor" Disassembly
    214
  - Reservoir Assembly Removal
    215
  - Oil Pump Removal
    216
  - Manifold Removal
    216
- Cleaning and Inspection of Trim Rod Components
  217
- Motor and Electrical Tests/Repair
  218
  - Trim Pump Motor Test
    218
  - Thermal Overload Switch Test
    218
    
    Motor Assembled
    218
    
    Motor Disassembled
    218
  - Armature Tests
    219
    
    Checking and Cleaning Commutator
    219
    
    Test for Ground
    219
    
    Test for Shorts
    219
- Power Trim System Reassembly
  219
  - Manifold Installation
    219
  - Oil Pump Installation
    220
  - Trim Motor Reassembly
    221
  - Reservoir Installation
    222
  - Trim Rod Reassembly
    224
  - Trim Rod Installation
    225
- Bleeding Power Trim Unit
  226
  - Power Trim Unit Installation
    226
MID-Section

229
- Power Trim General Information
  230
  - Trimming Characteristics
    230
    
    Trimming Outboard "Down" ("In")
    230
    
    Trimming Outboard "Up" ("Out")
    230
  - Trailering Outboard
    231
  - Tilting Outboard up and down Manually
    231
  - Trim "In" Angle Adjustment
    231
- Power Trim System Components
  232
  - Torque Specifications
    232
  - Quicksilver Lubricant/Sealant Application Points
    232
- Power Trim Flow Diagrams Design
  233
- Design II
  234
- Design II
  235
- Design II
  236
- Design II
  237
- Design II
  238
- Troubleshooting
  240
- Electrical System Troubleshooting
  245
  - COMMANDER 2000 Side Mount Remote
    245
  - Power Trim System Wiring Diagram
    246
    
    Troubleshooting the "Down" Circuit* (When "Up" Circuit Is OK)
    247
    
    Troubleshooting the "Up" Circuit* (When "Down" Circuit Is OK)
    248
    
    Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
    249
- Power Trim System Removal
  250
  - Power Trim System Disassembly
    251
    
    Trim Rod Removal
    251
    
    Trim Rod Disassembly
    252
    
    Trim "Motor" Removal
    254
    
    Trim Motor Disassembly
    254
    
    Reservoir Assembly Removal
    255
    
    Oil Pump/Manifold Removal
    256
- Cleaning and Inspection of Trim Rod Components
  257
  - Motor and Electrical Tests/Repair
    258
    
    Motor Assembled
    258
    
    Motor Disassembled
    258
    
    Thermal Overload Switch Test
    258
    
    Trim Pump Motor Test
    258
    
    Armature Tests
    259
    
    Checking and Cleaning Commutator
    259
    
    Test for Ground
    259
    
    Test for Shorts
    259
  - Power Trim System Reassembly
    259
    
    Manifold/Oil Pump Installation
    259
    
    Trim Motor Reassembly
    260
    
    Reservoir Installation
    262
    
    Trim Rod Reassembly
    263
    
    Trim Rod Installation
    264
  - Bleeding Power Trim Unit
    265
    
    Power Trim Unit Installation
    266
MID-Section

269
- Power Trim - General Information
  270
  - Description
    270
  - Trimming Characteristics
    270
    
    Trimming Outboard "Down" ("In")
    270
    
    Trimming Outboard "Up" ("Out")
    270
  - Trailering Outboard
    271
  - Tilting Outboard up and down Manually
    271
  - Trim "In" Angle Adjustment
    271
- Special Tools
  270
- Power Trim System Components
  272
- Troubleshooting
  273
- Power Trim System Removal
  283
- Power Trim System Disassembly
  284
  - Trim Rod Removal
    284
  - Trim Rod Disassembly
    285
  - Trim "Motor" Removal
    287
  - Trim "Motor" Disassembly
    287
  - Reservoir Assembly Removal
    287
  - Manifold Removal
    288
- Cleaning and Inspection of Trim Rod Components
  289
- Motor and Electrical Tests/Repair
  289
  - Trim Pump Motor Test
    289
  - Armature Tests
    289
    
    Test for Ground
    289
    
    Test for Shorts
    289
    
    Checking and Cleaning Commutator
    290
- Power Trim System Reassembly
  290
  - Manifold Installation
    290
  - Trim Motor Reassembly
    291
  - Reservoir Installation
    292
  - Trim Rod Reassembly
    293
  - Trim Rod Installation
    294
- Purging Power Trim Unit
  295
  - Power Trim Unit Installation
    295
MID-Section

299
- Special Tools
  300
- Adjustments
  303
  - Trimming Characteristics
    303
    
    Trimming Outboard "Down
    303
    
    Trimming Outboard "Up" ("Out")
    303
  - Trailering Outboard
    304
  - Tilting Outboard up and down Manually
    304
  - Trim up
    306
  - Tilt up
    308
  - Maximum Tilt
    309
  - Down Mode
    312
  - Shock Function up
    313
  - Shock Function Return
    315
  - Manual Tilt
    318
- Theory of Operation
  303
- Troubleshooting
  319
- Power Trim System Removal
  326
- Power Trim Disassembly
  327
  - Trim Motor Removal
    328
  - Pump and Components Removal
    328
  - Manifold Removal
    329
  - Shock Rod Removal
    329
- Shock Rod Disassembly
  330
  - Memory Piston Removal
    332
- Cleaning/Inspection/Repair
  333
  - Trim Motor Electrical Tests
    333
- Reassembly
  334
  - O-Ring and Seal Placement
    334
- O-Ring Sizes
  335
- O-Ring Description and Sizes
  336
- Power Trim Reassembly
  337
  - Shock Rod Reassembly
    337
  - Shock Rod Installation
    338
  - Trim Limit Assembly Installation
    339
  - Manual Release Valve Installation
    339
  - Manifold Installation
    339
  - Oil Pump Installation
    340
  - Pressure Operated Assembly Installation 5E-42
    341
  - Reservoir/Motor Installation
    341
  - Bleeding Power Trim Unit
    342
- Installation of Power Trim System
  342
MID-Section

346
- Torque Specification
  347
- Manual Tilt System Components (Design Three)
  348
  - Quicksilver Lubricant/Sealant Application Points
    348
  - Torque Specification
    348
- Manual Tilt Flow Diagrams Design 1
  349
- Manual Tilt Flow Diagrams Design 2
  354
- Manual Tilt Flow Diagrams Design 3
  359
- Hydraulic System Troubleshooting
  364
- Troubleshooting Flow Chart
  365
- Manual Tilt System Removal
  367
- Manual Tilt System Disassembly
  368
  - Accumulator Removal
    368
  - Shock Rod Removal
    369
- Shock Rod Disassembly
  370
  - Valve Block Removal
    372
- Valve Block Disassembly
  373
- Manual Tilt System Cleaning and Inspection
  374
- Manual Tilt System Reassembly
  374
  - Valve Block Reassembly
    374
  - Valve Block Installation
    376
  - Shock Rod Reassembly
    376
  - Shock Rod Installation
    378
- Instructions for Making Retaining Tool
  379
- Bleeding Manual Tilt System
  380
- Manual Tilt System Installation
  381
MID-Section

384
- Special Tools
  385
  - Tilt up
    389
  - Tilt down
    391
  - Slow Tilt down under High Thrust
    392
  - Under Water Strike with Valves Open
    395
  - Shock Function with Valves Closed
    397
  - Shock Function Return
    398
- Hydraulic System Troubleshooting
  400
- Manual Tilt System Removal
  401
- Manual Tilt System Disassembly
  402
  - Accumulator Removal
    402
  - Shock Rod Removal
    403
- Shock Rod Disassembly
  404
  - Valve Block Removal
    406
  - Memory Piston Removal
    406
- Valve Block Disassembly
  407
- Actual O-Ring Sizes
  409
- O-Ring Description and Sizes
  410
- Manual Tilt System Cleaning and Inspection
  411
- Manual Tilt System Reassembly
  411
  - Cam Shaft Reassembly
    411
  - Valve Body Check Reassembly
    411
  - Velocity Valve Reassembly
    411
  - Check Retainer Reassembly
    412
  - Valve Plug Reassembly
    412
  - Valve Block Installation
    412
  - Shock Rod Reassembly
    413
  - Shock Rod Installation and Fluid Filling Procedure
    414
- Instructions for Making Retaining Tool
  415
- Bleeding Manual Tilt System
  416
- Manual Tilt System Installation
  418
- Manual Release Valve Adjustment
  419
  - Lower Unit
    420
Lower Unit

421
- Quicksilver Lubricants and Service Aids
  422
- Special Tools
  422
- Gear Housing Assembly - Drive Shaft Components
  423
  - Torque Specifications
    423
  - Lubrication/Sealant Application Points
    423
- Gear Housing Assembly - Propeller Shaft Components
  424
  - Torque Specifications
    424
  - Lubrication/Sealant Application Points
    424
- Draining and Inspecting Gear Housing Lubricant
  425
- Trim Tab/Propeller Removal
  425
- Gear Housing Disassembly
  426
  - Water Pump Removal
    427
  - Bearing Carrier and Propeller Shaft Removal
    429
  - Drive Shaft and Pinion Gear Removal
    431
  - Lubrication Sleeve Removal
    432
  - Forward Gear and Bearing Removal
    433
  - Shift Shaft Removal
    433
  - Drive Shaft Needle Bearing Removal
    434
- Gear Housing Removal
  426
- Cleaning and Inspection
  434
  - Gear Housing/Bearing Carrier Castings
    434
  - Bearings
    434
    
    Ball/Roller Bearings
    434
    
    Needle Bearing
    435
  - Propeller Shaft
    435
  - Forward, Reverse an Pinion Gears
    435
  - Sliding Clutch
    436
  - Cam Follower
    436
  - Water Pump Components
    436
  - Drive Shaft
    436
  - Shift Shaft
    437
- Gear Housing Reassembly
  437
- Gear Housing Installation
  446
- Filling Gear Housing with Lubricant
  448
- Propeller/Trim Tab Installation
  448
Lower Unit

451
- Notes
  452
- Jet Pump Assembly
  453
- Engine Horsepower Selection
  455
- Selecting a Boat Best Suited for Jet Power
  455
- Locate Centerline of the Outboard
  456
- Outboard Mounting Height
  456
- Transom Height of the Boat
  456
- Checking for Cavitation
  457
- Water Testing
  457
- Shift Cable Installation
  458
- Impeller Removal and Installation
  459
- Lubricating the Drive Shaft Bearing
  459
- Impeller Clearance Adjustment
  461
- Steering Pull Adjustment
  461
- Worn (Dull) Impeller
  461
- Jet Drive Removal and Installation
  462
- Liner Replacement
  462
- Bearing Carrier Removal and Installation
  463
- Water Pump Removal and Installation
  463
- Bearing Carrier Disassembly
  464
- Bearing Carrier Reassembly
  464
  - Installing Lower Seals
    464
  - Installing Upper Seals
    465
  - Installing Drive Shaft Ball Bearing
    465
  - Installing Drive Shaft
    465
- Jet Drive Tiller Handle Adaptor Kit
  467
  - Installation Instructions
    467
  - Shift Cable Adjustment
    470
Outboard Motor Installation/ Attachments

472
Oil Injection System

521

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