Mariner 80 Manuals

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Mariner 80 Service Manual

Mariner 80 Service Manual (391 pages)

Mariner Outboard Motor Service manual

Brand: Mariner | Category: Outboard Motor | Size: 9.3 MB

Table of Contents

General Information 1

5
Electrical and Ignition 2

19
- Description
  20
- Direct Voltage Adapter (DVA) Tests
  20
- Test Procedures
  20
- Troubleshooting Tips
  20
- Test Sequence
  21
- Ignition System Test Chart
  22
- 9/18/24 Ampere Stators
  23
- Stator Test
  23
- Commander 2000 Key Switch
  24
- Commander Key Switch
  24
- Ignition (Key) Switch Test
  24
- Ignition Coil Test
  24
- Trigger Test
  24
- Flywheel
  25
- Ignition Components Removal and Installation
  25
- Installation
  25
- Removal
  25
- Installation
  26
- Removal
  26
- Stator
  26
- Installation
  27
- Removal
  27
- Trigger
  27
- Ignition Coils (3 Cylinder Models)
  28
- Ignition Coils (4 Cylinder Models)
  28
- Switch Box
  29
Section 3

31
Section 4

59
- Special Tools
  60
- Specifications
  60
- Timing Pointer Adjustment
  60
- Timing/Synchronizing/Adjusting (3 Cylinder Models)
  60
- Carburetor Synchronization
  61
- Carburetor/Oil Pump Synchronization
  62
- Idle Timing Adjustment
  62
- Timing Adjustments
  62
- Idle Adjustment
  63
- Maximum Throttle
  63
- Maximum Timing
  63
- Throttle Cable Installation
  64
- Special Tools
  65
- Specifications
  65
- Timing Pointer Alignment
  65
- Timing/Synchronizing/Adjusting (4 Cylinder Models)
  65
- Carburetor Synchronization
  66
- Carburetor/Oil Pump Synchronization
  67
- Idle Timing Adjustment
  67
- Timing Adjustments
  67
- Maximum Timing
  68
- Carburetor Specifications
  69
- Initial Starting Adjustments
  69
- Low Speed Mixture Adjustments
  69
- Idle Adjustment
  70
- Throttle Cable Installation
  70
Section 5

72
Fuel System and Carburetion

87
- Caused by Anti-Siphon Valves
  88
- Checking for Restricted Fuel Flow
  88
- Fuel Pump Description/Operation
  88
- Fuel Pumps
  88
- General Information
  88
- Testing
  88
- Troubleshooting Fuel Pump
  88
- Fuel Pump Components (Design 1)
  89
- Fuel Pump - Cleaning/Inspection
  90
- Fuel Pump Cleaning, Inspection, Disassembly and Reassembly (Design 1 and 2)
  90
- Fuel Pump Removal/Installation (Design 1)
  90
- Check Valve Reassembly
  91
- Carburetion
  99
- Fuel System Troubleshooting
  99
- Caused by Anti-Siphon Valves
  100
- Checking for Restricted Fuel Flow
  100
- Fuel System (Carburetor)
  101
- Fuel System (Linkage)
  103
- Carburetor Adjustments
  104
- Carburetor Float Adjustment
  104
- Initial Starting Adjustment
  104
- Low Speed Mixture Adjustment
  104
- Carburetor Fastener Torques
  105
- Fuel Pump Pressure
  105
- Fuel Pump Specifications
  105
- Sealants
  105
- Settings
  105
- Specification Sheet - WME Carburetors
  105
- Idle Speed Adjustment
  106
- Main (High Speed) Jet Adjustment
  106
- Rejetting Carburetors for High Altitude Operation
  106
- Carburetor Removal and Disassembly
  107
- Jet Orifice Size/Part Number Chart
  107
- Carburetor Disassembly
  108
- Carburetor Reassembly
  109
- Cleaning and Inspection
  109
- Idle Air Screw
  110
- Description for Four Cylinder Engines
  111
- Description for Three Cylinder Engines
  111
- Enrichener System
  111
- Enrichener Valve Hose Installation - Four Cylinder Engines
  111
- Enrichener Valve Hose Installation - Three Cylinder Engines
  111
- Enrichener Valve Test
  112
- Acceleration Pump Circuit Operation - Four Cylinder Engines
  113
- Accelerator Pump Fuel Flow Circuit
  113
- Acceleration Pump Fuel Flow Circuit for Four Cylinder Engines
  114
- Fuel Tank
  115
- Fuel Tank Components
  115
- Maintenance
  115
- Fuel Line and Primer Bulb Assembly
  116
- Fuel Line Clamp Removal and Installation
  117
- Maintenance
  117
Oil Injection System

119
- Description
  120
- Hose Connections
  120
- Oil Pump Drive System
  120
- Carburetor/Oil Pump Synchronization
  121
- Filling Oil Tank
  121
- Bleeding Air from Oil Injection System
  122
- Bleeding Air from Oil Pump Inlet Hose
  122
- Bleeding Air from Oil Pump Outlet Hose
  122
- Oil Pump Test
  122
- Description
  123
- Low Oil Sensor Test
  123
- Models Equipped with Test Button (3 Cylinder Only)
  123
- Warning Horn System
  123
- Warning Horn System Check
  123
- Description
  124
- Models Not Equipped with Test Button (3 and 4 Cylinder)
  124
- Warning Horn System Wiring Diagram
  125
- Oil Injection System Troubleshooting Chart (Models with Warning Module)
  126
- Troubleshooting Chart
  126
- Troubleshooting the Oil Injection System
  126
Powerhead 4 a

128
- Throttle Lever and Linkage Wave Washer
  129
- Crankshaft Assembly
  130
- Powerhead Block and Cover Assemblies
  132
- Torque Specifications, Torque Sequences
  134
- Disassembly and Reassembly
  137
- General Information
  137
- Powerhead Component Removal
  137
- Tools for Powerhead Repair
  137
- Flywheel Removal
  139
- Powerhead Disassembly
  141
- Cleaning and Inspection
  145
- Cylinder Block and Crankcase Cover
  145
- Honing Procedure
  146
- (Models with Check Valve Only)
  147
- Bleed Check Valve/Restrictor Kit (22-814204A1)
  147
- Check Valves
  147
- Design 2 (Models with Check Valve and Restrictor)
  147
- Design 3 (Models with Check Valve and Carrier)
  148
- Installation
  148
- Removal
  148
- Cleaning Piston Ring Grooves
  149
- Piston and Piston Rings
  149
- Crankshaft
  150
- Measuring Piston Skirt
  150
- And Exhaust Cover
  151
- Connecting Rods
  151
- Cylinder Cover, Exhaust Divider Plate
  151
- Backside - Reed Block Assembled
  152
- Reed Blocks
  152
- Thermostat
  152
- End Cap
  153
- General Information
  153
- Powerhead Reassembly and Installation
  153
- Design 1 - Bottom Guided
  154
- Design 2 - Top Guided
  154
- Assembling Rod to Piston
  155
- Piston Ring Installation
  156
- Crankshaft Installation
  157
- Installing Rods to Crankshaft
  159
- Connecting Rod Cap Alignment
  160
- Crankcase Cover to Block
  160
- Cylinder Block Cover
  161
- Reattach Crankcase Cover
  161
- Cylinder Head Cover Torque Sequence
  162
- Exhaust Plate Cover and Exhaust Divider Plate
  162
- Exhaust Plate Cover Torque Sequence
  162
- Powerhead to Driveshaft Housing
  163
- Electrical Components Installed
  164
- Reinstall Wiring Harness and Components as a Unit
  164
- Flywheel Installation
  165
- Intake Manifold - Torque Sequence
  165
- Attach Rear Cowl Mounting Bracket
  166
- Attach Front Cowl Mounting Bracket
  167
  - Lower Unit
    168
Gear Housing

169
- Notes
  170
- Drive Shaft and Water Pump Components
  171
- Propeller Shaft Components
  175
- Disassembly
  177
- Propeller Removal
  177
- Removal
  177
- Special Tools
  177
- Draining and Inspecting Gear Housing Lubricant
  178
- Water Pump (Design 1)
  179
- Water Pump (Design 2)
  180
- Bearing Carrier and Propeller Shaft
  181
- Pinion Gear, Drive Shaft, and Forward Gear
  184
- Upper Drive Shaft Bearing
  185
- Lower Drive Shaft Bearing Race
  186
- Oil Sleeve
  186
- Shift Shaft
  187
- Forward Gear Bearing Race
  188
- Reassembly
  188
- Shift Shaft
  188
- Trim Tab Adjustment and Replacement
  188
- Bearing Carrier Reassembly
  189
- Forward Gear Reassembly
  191
- Drive Shaft Wear Sleeve Installation
  192
- Propeller Shaft Reassembly
  192
- Lower Drive Shaft Bearing Race Installation
  193
- Oil Sleeve Installation
  194
- Upper Drive Shaft Bearing Installation
  194
- Determining Pinion Gear Depth
  195
- Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation
  195
- Pinion Gear Depth and Forward Gear Backlash
  195
- Bearing Carrier and Propeller Shaft Installation
  198
- Water Pump Reassembly and Installation
  199
- Filling Gear Housing with Lubricant
  201
- Gear Housing Pressure Test
  201
- Installation
  202
- Propeller Installation
  202
Lower Unit

206
- Swivel Bracket Components
  208
- Transom Bracket Components
  210
- Exhaust Plate Components
  212
- Drive Shaft Housing Components
  214
- Reference Views
  216
Design I 6 a

224
- Description
  225
- Power Trim - General Information
  225
- Trailering Outboard
  225
- Trimming Characteristics
  225
- Trimming Outboard "DOWN" (In)
  225
- Trimming Outboard "UP" (Out)
  225
- Tilting Outboard Manually
  226
- Trim "In" Angle Adjustment
  226
- Anode Plate
  227
- Fill, Check, and Purge - Power Trim System
  227
- Striker Plate Replacement
  227
- To Fill
  227
- Trim Indicator Gauge
  227
- Bleeding Air from Power Trim System
  228
- Determining if Problem Is Electrical or Hydraulic
  229
- Trouble Chart
  229
- Troubleshooting
  229
- Hydraulic System Troubleshooting
  230
- Trim Indicator Gauge and Trim Sender Wiring Diagrams
  231
- Wiring Diagram
  231
- Side Mount Remote Control Wiring Diagram
  232
- Down" Circuit Is
  235
- Electrical System Troubleshooting
  235
- General Checks
  235
- Troubleshooting the "Trailer" Circuit
  235
- Troubleshooting the "Up" and "Trailer
  235
- (All Circuits Inoperative)
  236
- Troubleshooting the "Down," "Up" and
  236
- Troubleshooting the "Up" Circuit* (When "Trailer" Circuit Is OK)
  236
- (All Circuits Inoperative)
  237
- Troubleshooting the "Down," "Up" and
  237
- Troubleshooting the "Down" Circuit (When "Up" Circuit Is OK)
  238
- Troubleshooting the "Up" Circuit* (When "Down" Circuit Is OK)
  239
- Troubleshooting the "Down" and "Up" Circuits* (All Circuits Inoperative)
  240
- Power Trim Assembly Removal and Installation
  241
- Removal
  241
- Support Tool
  241
- Installation
  243
- Testing Power Trim System with Test Gauge Kit (91-52915A3)
  244
- UP" Pressure Check
  245
- DOWN" Pressure Check
  246
- Power Trim Components
  248
- Cleaning and Inspection - Trim Rods and Caps
  250
- Hydraulic Repair
  250
- Trim Rod Removal and Repair
  250
- Trim Rod End Cap Seal
  251
- Trim Rod Installation
  251
- Tilt Ram Components
  252
- Disassembly
  253
- Removal
  253
- Tilt Ram
  253
- Cleaning and Inspection
  255
- Scraper Replacement
  255
- Reassembly
  256
- Installation
  257
- Inoperative Trim Motor
  258
- Operative Trim Motor
  258
- Pump Replacement
  258
- Motor and Electrical Tests/Repair
  259
- Motor Assembled
  259
- Thermal Overload Switch Test
  259
- Motor Disassembled
  260
- Motor Disassembly
  260
- Solenoid Test
  260
- Trim Pump Motor Test
  260
- Armature Tests
  261
- Checking and Cleaning Commutator
  261
- Field Tests
  261
- Test for Ground
  261
- Test for Shorts
  261
- Cleaning and Inspection
  262
- Disassembly
  262
- Motor Repair
  262
- Removal
  262
- Trim Indicator Gauge (Optional Accessory) Needle Adjustment
  262
- Trim Sender (Optional Accessory) Test
  262
- Square" Motor Components
  263
- Reassembly
  264
- Brush Replacement
  266
Design II (Aft Fill Reservoir) 6

269
- Power Trim System
  270
- Quicksilver Lubricants and Service Aids
  270
- Special Tools
  270
- Specifications
  270
- Power Trim Components
  271
- Description
  273
- Power Trim - General Information
  273
- Trailering Outboard
  273
- Trimming Characteristics
  273
- Trimming Outboard "DOWN" (In)
  273
- Trimming Outboard "UP" (Out)
  273
- Tilting Outboard Manually
  274
- Trim "In" Angle Adjustment
  274
- Anode Plate
  275
- Fill, Check, and Purge - Power Trim System
  275
- Striker Plate Replacement
  275
- Trim Indicator Gauge
  275
- Hydraulic System Troubleshooting
  276
- To Check
  276
- To Purge
  276
- Troubleshooting
  276
- Electrical System Troubleshooting
  278
- Power Trim System Wiring Diagram
  278
- Side Mount Remote Control Wiring Diagram (Test Points for Electrical Troubleshooting)
  279
- Electrical System
  280
- General Checks
  280
- Troubleshooting
  280
- Troubleshooting the "Down" Circuit
  280
- Troubleshooting the "Up" Circuit (When "Down" Circuit Is OK)
  281
- Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
  282
- Power Trim Assembly Removal and Installation
  283
- Removal
  283
- Support Tool
  283
- Installation
  285
- UP" Pressure Check
  287
- DOWN" Pressure Check
  288
- Cleaning and Inspection - Trim Rods and Caps
  289
- Hydraulic Repair
  289
- Trim Rod Removal and Repair
  289
- Trim Rod End Cap Seal
  290
- Trim Rod Installation
  290
- Removal - Tilt Rod Assembly Only
  291
- Tilt Ram
  291
- Tilt Ram Components
  291
- Disassembly
  292
- Tilt Ram Removal - Power Trim System Removed from Outboard
  292
- Cleaning and Inspection
  294
- Scraper Seal Replacement
  294
- Reassembly
  295
- Tilt Ram Assembly Installation
  296
- Motor and Pump Replacement
  297
- Motor and Electrical Tests/Repair
  298
- Motor Disassembly
  298
- Solenoid Test
  298
- Trim Pump Motor Test
  298
- Armature Tests
  299
- Checking and Cleaning Commutator
  299
- Field Tests
  299
- Test for Ground
  299
- Test for Shorts
  299
- Cleaning and Inspection
  300
- Disassembly
  300
- Motor Repair
  300
- Removal
  300
- Brush Replacement
  301
- Reassembly
  302
- Priming Power Trim System
  303
- Reassembly - Motor and Pump
  303
- Trim Sender (Optional Accessory) Test
  303
- Trim Indicator Gauge Needle Adjustment
  304
- Trim Indicator Wiring Diagrams
  304
Power Trim 6 C

306
- Description
  307
- Power Trim - General Information
  307
- Quicksilver Lubricants and Service Aids
  307
- Special Tools
  307
- Trimming Characteristics
  307
- Trimming Outboard "Down" ("In")
  307
- Trimming Outboard "Up" ("Out")
  307
- Tilting Outboard up and down Manually
  308
- Trailering Outboard
  308
- Trim "In" Angle Adjustment
  308
- Power Trim System Components
  310
- Determining if Problem Is Electrical or Hydraulic
  312
- Problem Chart
  312
- Troubleshooting
  312
- Date Code Location
  313
- Hydraulic System Troubleshooting
  313
- Preliminary Checks
  313
- Leak down Check - Pump and Manifold Assembly
  314
- Reassembly
  315
- Power Trim Partial Leak down at Maximum Trim
  316
- Leak down Check - Manual Release Valve
  317
- Leak down Check - Pilot Valve Assembly
  317
- Leaks Past Ball and Seat - Piston Assembly
  317
- Power Trim Rocker Arm
  318
- Troubleshooting Flow Diagram
  319
- COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
  321
- Electrical System Troubleshooting
  321
- Power Trim System Wiring Diagram
  322
- Troubleshooting the "Down" Circuit* (When "Up" Circuit Is OK)
  323
- Troubleshooting the "Up" Circuit* (When "Down" Circuit Is OK)
  323
- Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
  324
- Power Trim System Removal
  325
- Power Trim System Disassembly
  326
- Trim Rod Removal
  326
- Trim Rod Disassembly
  327
- Reservoir Assembly Removal
  329
- Trim "Motor" Disassembly
  329
- Trim "Motor" Removal
  329
- Manifold Removal
  330
- Armature Tests
  331
- Cleaning and Inspection of Trim Rod Components
  331
- Motor and Electrical Tests/Repair
  331
- Test for Ground
  331
- Test for Shorts
  331
- Trim Pump Motor Test
  331
- Checking and Cleaning Commutator
  332
- Manifold Installation
  332
- Power Trim System Reassembly
  332
- Trim Motor Reassembly
  333
- Reservoir Installation
  334
- Trim Rod Reassembly
  335
- Trim Rod Installation
  336
- Power Trim Unit Installation
  337
- Purging Power Trim Unit
  337
Engine Attachments/ Engine Installation 7

341

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