Mercury 25 EFI Jet Manuals

Manuals and User Guides for Mercury 25 EFI Jet. We have 1 Mercury 25 EFI Jet manual available for free PDF download: Service Manual

Mercury 25 EFI Jet Service Manual

Mercury 25 EFI Jet Service Manual (540 pages)

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

Table of Contents

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

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