Mercury 25 EFI FourStroke Manuals

Manuals and User Guides for Mercury 25 EFI FourStroke. We have 3 Mercury 25 EFI FourStroke manuals available for free PDF download: Service Manual, User Manual, Brochure & Specs

Mercury 25 EFI FourStroke Service Manual (540 pages)

Brand: Mercury | Category: Outboard Motor | Size: 73.92 MB

Important Information 1

7
Important Information 1

15
- EPA Regulations
  16
- Selecting Accessories for Your Outboard
  16
- EPA Emissions
  17
  - Emission Certification Label
    17
  - Owner Responsibility
    17
- Inspection and Maintenance Schedule
  17
  - Daily Checks
    17
  - After each Use
    17
  - Annually or 100 Hours
    17
  - Three Years or 300 Hours
    18
- Battery Inspection
  18
- Exterior Care
  18
- Flushing the Cooling System
  18
  - Flushing Jet Models
    19
- Submerged Outboard
  18
- Top Cowl Removal and Installation
  19
  - Removal
    19
  - Installation
    20
- Fuel System
  20
  - Fuel Line Inspection
    20
  - Fuel Filter (Low Pressure)
    20
  - Removal
    20
- Fuse Replacement - Electric Start Models
  20
- Spark Plug Inspection and Replacement
  21
- Changing Engine Oil
  22
  - Engine Oil Capacity
    22
  - Oil Changing Procedure
    22
  - Changing Oil Filter
    22
  - Oil Filling
    23
- Timing Belt Inspection
  22
- Checking Power Trim Fluid
  23
- Corrosion Control Anode
  23
- Propeller Replacement
  24
- Gearcase Lubrication
  26
- Lubrication Points
  27
- Jet Maintenance
  28
  - Worn/Dull Impeller
    28
  - Impeller Clearance Adjustment
    29
  - Impeller Removal and Installation
    29
  - Shift Link Rod Adjustment
    31
  - Corrosion Control Anode
    32
  - Lubrication Points
    33
- Storage Preparation
  35
  - Protecting External Outboard Components
    35
  - Protecting Internal Engine Components
    35
  - Gearcase
    35
  - Positioning Outboard for Storage
    35
  - Battery Storage
    36
  - Storage Lubrication Points
    36
Important Information 1

37
- Manual Start Component Identification
  39
- Electric Start Component Idenitication
  43
- Conditions Affecting Performance
  46
  - Weather
    46
  - Weight Distribution (Passengers and Gear) Inside the Boat
    47
  - Bottom of Boat
    47
  - Water Absorption
    47
  - Cavitation
    47
  - Elevation and Climate
    48
  - Detonation
    48
  - Propeller Selection
    48
- Following Complete Submersion
  48
- Fuel Requirements
  49
- Compression Check
  50
- Cylinder Leakage Testing
  50
  - Analysis
    51
- Painting Procedures
  51
  - Propellers
    51
  - Gear Housing
    51
- Decal Application
  52
  - Application Tips
    52
  - Applying the Decal
    52
  - Entrapped Air Removal
    53
  - Final Decal Squeegee
    53
- Decal Removal
  52
Important Information 1

55
Electrical 2

77
- Ignition Specifications
  78
- Theory of Operation
  79
- Accessing ECM Information with the CDS
  80
  - Fault Information
    81
- Troubleshooting with the Computer Diagnostic System (CDS)
  80
- Troubleshooting Without a Computer Diagnostic System (CDS)
  80
- Warning System
  82
  - Warning Horn
    82
  - Warning Light
    82
  - Warning System Operation
    82
  - Engine Overheat
    82
  - Low Oil Pressure
    83
  - Engine Overspeed Limiter
    83
- Warning Light and Warning Horn Wire Diagrams
  83
  - Warning Light Wire Diagram
    83
  - Warning Horn Wire Diagram-Tiller Handle Models
    84
- Ignition Components
  84
  - Flywheel/Timing Belt Cover
    84
  - Flywheel Assembly
    84
  - Stator
    84
  - Stator Testing
    85
  - Flywheel Removal and Installation
    87
- Stator Removal and Installation
  90
- Crank Position Sensor (CPS)
  91
- Crank Position Sensor Removal and Installation
  91
- Crank Position Sensor Testing
  94
- ECM Removal and Installation
  96
- Electronic Control Module (ECM)
  96
- Ignition Coil Removal and Installation
  97
- Ignition Coils
  97
- Ignition Coil Testing
  98
- Engine Temperature Coolant Sensor (ETC)
  100
- ETC Removal and Installation
  100
- ETC Sensor Test
  101
- Oil Pressure Sensor
  102
- Oil Pressure Switch Removal and Installation
  102
- Oil Pressure Switch Test
  104
- Manifold Air Temperature (MAT) Sensor
  105
- MAT Sensor Removal and Installation
  105
- Manifold Absolute Pressure (MAP) Sensor
  107
- MAP Sensor Removal and Installation
  107
- MAT Sensor Test
  107
- MAP Sensor Test
  109
- Throttle Position Sensor (TPS)
  109
- TPS Test
  110
- Tiller Handle Stop Button and Lanyard Stop Switch Test
  111
Electrical 2

113
- Charging and Starting Specifications
  114
- Electrical Bracket and Cover
  116
- Flywheel, ECU, and Wiring Harness
  118
- Starter Motor and Rectifier
  120
- Starter Motor Components
  122
- Battery
  124
  - Battery Cable Test
    124
  - Original Battery Cable Length and Gauge Shipped with Engine
    124
  - Battery Cable Size for Outboard Models
    124
  - Replacement Parts
    125
  - Recommended Battery
    126
  - Battery Precautions
    126
  - Charging a Discharged Battery
    126
  - Winter Storage of Batteries
    126
- Battery Charging System
  127
- Engine Wire Harness (Remote Control)
  132
  - Engine Wire Harness Removal (Remote Control)
    132
  - Engine Wire Harness Installation (Remote Control)
    136
- Engine Wire Harness (Tiller Handle)
  142
  - Engine Wire Harness Removal (Tiller Handle)
    142
  - Engine Wire Harness Installation (Tiller Handle)
    145
- Starter Motor
  149
  - Starting System Description
    149
  - Troubleshooting the Starting Circuit
    149
  - Starter Solenoid Test
    149
  - Starting System Troubleshooting Chart
    150
  - Starter Motor Removal
    151
  - Starter Motor Disassembly
    152
  - Starter Motor Reassembly
    153
  - Starter Motor Installation
    156
Electrical 2

159
Fuel System 3

169
- Theory of Operation
  170
  - Air Induction System
    170
  - Fuel System
    170
  - Fuel Pump
    170
  - Vapor Separator
    170
  - Fuel Pressure Regulator
    171
  - Fuel Cooler
    171
  - Throttle Body
    171
- Sensors
  171
  - Function of Sensors
    171
  - Crank Position Sensor (CPS)
    172
- Engine Coolant Temperature (ECT) Sensor
  172
- Manifold Absolute Pressure (MAP) Sensor
  172
- Actuators
  173
- Engine Control Module
  173
- Function of Actuators
  173
- Manifold Air Temperature (MAT) Sensor
  173
- Oil Pressure Switch
  173
- Throttle Position Sensor (TPS)
  173
- Idle Air Control (IAC)
  174
- Fuel Injector
  175
Fuel System 3

177
Fuel System 3

185
- Fuel System Specifications
  186
- Fuel Pump Components
  188
- Fuel Rail and Vapor Separator Components
  190
- Fuel Cooler and Vapor Separator Components
  192
- Intake Manifold Components
  194
- Fuel Lift Pump
  196
  - Fuel Lift Pump Removal
    196
  - Fuel Lift Pump Disassembly and Reassembly
    197
  - Fuel Lift Pump Installation
    200
- High Pressure Fuel Filter
  202
  - High Pressure Fuel Filter Removal
    202
  - High Pressure Fuel Filter Installation
    203
- Vapor Separator Tank (VST)
  204
  - VST Removal
    204
  - VST Disassembly
    206
  - VST Reassembly
    208
  - VST Installation
    213
- Fuel Cooler
  215
  - Fuel Cooler Removal
    215
  - Fuel Cooler Disassembly and Reassembly
    217
  - Fuel Cooler Installation
    218
- Throttle Body
  219
  - Throttle Body Removal
    219
  - Throttle Body Disassembly and Reassembly
    220
  - Throttle Body Installation
    222
- Fuel Rail
  224
  - Fuel Rail Removal
    224
  - Fuel Rail Disassembly
    226
  - Fuel Rail Reassembly
    226
  - Fuel Rail Installation
    228
- Intake Manifold
  229
  - Intake Manifold Removal
    229
  - Intake Manifold Installation
    230
- Idle Air Control (IAC)
  232
  - IAC Removal
    232
  - IAC Installation
    234
  - Wire Color Code Abbreviations
    236
  - IAC Test
    237
Powerhead

243
- Cylinder Block/Crankcase Specifications
  244
- Piston Specifications
  244
- Cylinder Block Components
  246
- Crankshaft, Piston, and Connecting Rod Components
  248
- Powerhead Removal
  250
- Powerhead Components Removal
  252
- Crankcase Disassembly
  253
- Cylinder Block Disassembly
  253
- Anode
  256
- Cleaning/Inspection/Repair
  256
  - Measuring Cylinder Bore
    256
  - Measuring Piston
    257
  - Crankcase Main Bearings
    259
  - Connecting Rod Oil Clearance
    261
- Crankshaft Drive Gear
  256
- Flywheel
  256
- Timing Belt
  256
- Cylinder Block Assembly
  262
  - Piston Installation
    262
  - Crankshaft Installation
    263
  - Thermostat and Anode Installation
    265
  - Powerhead Reassembly
    266
- Powerhead Installation
  269
Powerhead

273
- Cylinder Head Specifications
  274
- Cylinder Head Components
  276
- Camshaft and Timing Belt Tensioner Components
  278
- Intake and Exhaust Valve Components
  280
- Cylinder Head Removal
  282
  - Cylinder Head Disassembly
    283
- Cleaning and Inspection
  285
  - Valve Springs
    286
  - Cylinder Head Resurfacing
    286
  - Valve Guides
    287
  - Valve Seat Reconditioning
    287
- Cylinder Head Reassembly
  288
  - Valve Installation
    288
  - Cam and Rocker Installation
    289
- Cylinder Head Installation
  291
  - Valve Adjustments
    293
Powerhead

295
- Oil System Specifications
  296
- Oil Flow
  298
- Oil Pump Disassembly
  299
- Oil Pump Removal
  299
- Oil Pump Inspection
  300
- Oil Pump Reassembly
  300
- Oil Pump Installation
  302
MID-Section

307
- Driveshaft Housing Components
  310
- Swivel Bracket Components
  312
- Clamp Bracket Components - Power Trim and Gas Assist
  316
- Clamp Bracket Components - Manual Tilt
  318
- Driveshaft Housing Cover
  322
  - Removal
    322
  - Installation
    322
- Exhaust Covers
  322
  - Port Cover Removal
    322
  - Port Cover Installation
    322
  - Rear Cover Removal
    323
- Lower Motor Mount Replacement
  325
  - Removal
    325
  - Installation
    325
- Upper Motor Mount Replacement
  327
  - Removal - Power Trim Models
    327
  - Removal - All Models
    327
  - Installation - All Models
    330
  - Installation - Power Trim and Gas Assist Models
    333
- Clamp Bracket/Swivel Bracket - Power Trim and Gas Assist Models
  334
- Clamp Bracket/Swivel Bracket - Manual Tilt Models
  347
  - Clamp Bracket Removal
    347
  - Reverse Lock Hook
    348
  - Reverse Lock Lever
    351
  - Tilt Stop Bracket
    351
  - Clamp Bracket Installation
    353
  - Swivel Bracket/Clamp Bracket Removal
    355
  - Swivel Bracket - Disassembly and Reassembly
    356
  - Swivel Bracket/Clamp Bracket Installation
    359
- Gearcase/Reverse Hook Operation
  360
  - Operation
    360
  - Adjustments
    361
MID-Section

363
- Power Trim Specifications
  364
- Power Trim/Tilt Components
  366
- Power Trim General Information
  368
  - General Information
    368
  - Power Trim Operation
    368
  - Checking Power Trim Fluid
    369
  - Purging Power Trim System
    369
  - Manual Tilting
    369
  - Trailering Boat/Outboard
    369
- Wire Color Code Abbreviations
  370
- Theory of Operation
  371
  - Power Trim Hydraulic Diagram
    371
  - Operation
    372
- Troubleshooting the Power Trim System
  372
- Power Trim Removal
  380
- Power Trim Installation
  381
- Manual Release Valve Removal and Repair
  382
- Power Trim Motor
  383
- Power Trim Pump
  389
  - Power Trim Pump Disassembly
    389
  - Power Trim Pump Reassembly
    390
- Power Trim Cylinder
  393
  - Power Trim Cylinder Disassembly
    393
  - Power Trim Cylinder Reassembly
    396
MID-Section

401
- Gas Assist Manual Trim/Tilt Components
  402
- Gas Assist Manual Trim/Tilt System
  402
  - Removal
    402
- Gas Assist Assembly Bushing Replacement
  404
- Installation
  405
Lower Unit

407
- Gearcase Specifications
  408
- Gear Housing (Driveshaft)
  412
- Gear Housing (Propeller Shaft)
  414
- Draining and Inspecting Gear Housing Lubricant
  416
- General Service Recommendations
  416
  - Shims
    416
  - Seals
    416
- Gear Housing Removal
  417
- Gear Housing Disassembly
  419
- Driveshaft Inspection
  433
- Forward Gear Bearing Installation
  434
- Gear Housing Reassembly
  434
- Pinion Bearing Installation
  434
- Bearing Carrier Reassembly
  435
- Propeller Shaft Reassembly
  437
- Water Pump Base Reassembly
  437
- Checking and Adjusting Pinion Gear Location
  438
- Checking and Adjusting Forward Gear Backlash
  441
- Shift Shaft Installation
  443
- Water Pump Cover Reassembly
  444
- Propeller Shaft and Bearing Carrier Installation
  446
- Anode Inspection and Installation
  447
- Gear Housing Installation
  448
- Checking Lubricant Level and Refilling Gearcase
  450
- Gearcase Lubricant Capacity
  450
- Gearcase Lubricant Recommendation
  450
- Propeller Installation
  451
Attachments

453
- Throttle and Steering Linkage Components
  456
- Shift and Cam Rod Components
  458
- Tiller Handle Models
  460
  - Throttle Only Operation
    460
  - Neutral Safety Start Switch
    460
- Throttle Only Removal and Disassembly
  461
- Throttle Only Reassembly and Installation
  463
- Remote Control Models
  467
- Shift Control Removal and Disassembly
  467
- Shift Control Assembly and Installation
  469
Attachments

473
- Tiller Handle Components
  476
- Throttle Cable/Linkage Adjustments
  478
  - Throttle Cables
    478
  - Linkage
    479
- Tiller Handle Operation
  478
- Power Trim Switch (Power Trim Models)
  479
  - Removal
    479
  - Installation
    481
- Tiller Handle Removal
  482
  - Throttle Cables
    482
  - Stop Wire Connections
    483
- Tiller Handle Disassembly
  483
- Throttle Cable Case
  486
  - Disassembly/Inspection
    486
  - Assembly
    486
- Tiller Handle Assembly
  487
- Shift/Throttle Cable Position Reference
  492
- Tiller Handle Installation
  493
  - Carry Handle/Tiller Handle
    493
  - Stop Wire Connections
    494
  - Throttle Cables
    494
  - Linkage and Grommet
    495
  - Recoil Starter Components
    502
  - Recoil Starter
    503
    
    Recoil Starter Removal
    504
    
    Recoil Starter Disassembly
    505
  - Recoil Starter Assembly
    506
  - Recoil Starter Installation
    510
  - Neutral Interlock Cable Adjustment
    511
Jet Drive Outboard

513
- Jet Unit Components
  516
- Jet Water Pump Components
  518
- Shift Linkage Components - Jet Tiller Handle
  520
- Shift Linkage Components - Jet Remote Control
  522
- Jet Drive Disassembly
  524
  - Jet Drive Removal
    524
  - Water Pump Disassembly
    526
  - Bearing Carrier Removal
    526
  - Liner Removal
    526
- Water Testing
  524
  - Checking for Cavitation
    524
- Jet Drive Reassembly
  527
  - Bearing Carrier Installation
    527
  - Water Pump Installation
    528
  - Liner Installation
    528
  - Jet Drive Installation
    529
- Shift Lever Removal and Installation (Tiller Models)
  532
  - Shift Lever Removal
    532
  - Shift Lever Installation
    533
- Shift Cam Adjustment (Tiller Models)
  534
- Shift Link Rod Removal and Installation (Tiller Models)
  534
- Shift Cam Adjustment (Remote Control Models)
  535
- Neutral Interlock Cable (Remote Models)
  536
  - Installation
    536

Mercury 25 EFI FourStroke User Manual (161 pages)

Brand: Mercury | Category: Outboard Motor | Size: 8.41 MB

Table of Contents
7
Warranty Registration
11
Warranty Information
11
Transfer of Warranty
12
Fourstroke Outboard Limited Warranty
12
Fourstroke Outboard Limited Warranty
16
Fourstroke Outboard Limited Warranty
20
Year Limited Warranty against Corrosion
24
Warranty Coverage and Exclusions
27
Boater's Responsibilities
30
Before Operating Your Outboard
30
General Information
30
Boat Horsepower Capacity
31
High-Speed and High-Performance Boat Operation
31
Propeller Selection
32
Outboard Remote Control Models
35
Remote Steering Notice
35
Lanyard Stop Switch
36
Protecting People in the Water
40
Passenger Safety Message - Pontoon Boats and Deck Boats
41
Wave and Wake Jumping
42
Impact with Underwater Hazards
43
Safety Instructions for Hand-Tilled Outboards
44
Exhaust Emissions
45
Selecting Accessories for Your Outboard
47
Safe Boating Suggestions
48
Recording Serial Number
50
Specifications
50
Component Identification
52
Trailering Boat/Outboard
58
Transporting Your Outboard When Removed from Boat
58
Transporting Portable Fuel Tanks
59
Fuel Recommendations
61
FUEL and OIL
61
Low Permeation Fuel Hose Requirement
63
Filling Fuel Tank
63
Engine Oil Recommendations
64
Checking and Adding Engine Oil
64
Remote Control Features
67
FEATURES and CONTROLS
67
Tiller Handle Model Features
68
Warning System
69
Warning System
72
Tiller Handle Models with Manual Gas Assist Tilt
74
Tiller Handle Models with Manual Tilt
79
Power Trim and Tilt (if Equipped)
84
Trim Tab Adjustment
89
Prestarting Check List
91
Operating in Freezing Temperatures
91
Operation
91
Operating in Saltwater or Polluted Water
92
Pre-Starting Instructions
92
Engine Break-In Procedure
93
Starting the Engine - Remote Control Models
93
Starting the Engine - Tiller Handle Models
96
Gear Shifting
99
Stopping the Engine
100
Emergency Starting
100
Outboard Care
103
Owner Responsibility
104
EPA Emissions
104
Inspection and Maintenance Schedule
105
Flushing the Cooling System
106
Top Cowl Removal and Installation
109
Exterior Care
109
Battery Inspection
110
Fuel System
110
Steering Link Rod Fasteners
112
Corrosion Control Anode
113
Propeller Replacement
115
Spark Plug Inspection and Replacement
118
Fuse Replacement - Electric Start Models
119
Timing Belt Inspection
120
Lubrication Points
121
Checking Power Trim Fluid
124
Changing Engine Oil
124
Gearcase Lubrication
126
Submerged Outboard
128
Storage Preparation
129
Storage
129
Protecting External Outboard Components
130
Protecting Internal Engine Components
130
Gearcase
130
Positioning Outboard for Storage
130
Battery Storage
131
Starter Motor will Not Crank the Engine (Electric Start Models)
132
Engine will Not Start
132
Troubleshooting
132
Engine Runs Erratically
133
Performance Loss
133
Battery will Not Hold Charge
133
Local Repair Service
135
Service Away from Home
135
Parts and Accessories Inquiries
135
Service Assistance
135
Owner Service Assistance
135
Mercury Marine Service Offices
136
Installation Information
138
Installation
138
Installation Specifications
140
Installing Outboard
140
Lifting Outboard
141
Electrical Harness, Battery Connection, Fuel Tanks
150
Control Cable Installation
155
Installing Propeller
159

Mercury 25 EFI FourStroke Brochure & Specs (2 pages)

Mercury Marine Outboard Motor User Manual

Brand: Mercury | Category: Outboard Motor | Size: 0.77 MB

Mercury Categories

Outboard Motor Automobile Engine Marine Equipment Motherboard

More Mercury Manuals

Mercury 25 EFI FourStroke Manuals

Mercury 25 EFI FourStroke Service Manual (540 pages)

Table of Contents

Important Information 1

Important Information 1

Important Information 1

Important Information 1

Electrical 2

Electrical 2

Electrical 2

Fuel System 3

Fuel System 3

Fuel System 3

Powerhead

Powerhead

Powerhead

MID-Section

MID-Section

MID-Section

Lower Unit

Attachments

Attachments

Jet Drive Outboard

Mercury 25 EFI FourStroke User Manual (161 pages)

Table of Contents

Mercury 25 EFI FourStroke Brochure & Specs (2 pages)

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