Mercury 30 FourStroke Outboard Motor Manuals

Manuals and User Guides for Mercury 30 FourStroke Outboard Motor. We have 1 Mercury 30 FourStroke Outboard Motor manual available for free PDF download: Service Manual

Mercury 30 FourStroke Service Manual

Mercury 30 FourStroke Service Manual (584 pages)

Brand: Mercury | Category: Outboard Motor | Size: 18 MB

Table of Contents

Important Information 1

20
- Cleanliness and Care of Outboard Motor
  3
- Table of Contents
  20
- Special Tools
  21
- Mercury/Quicksilver Lubricants and Sealants 1B-2
  21
- Inspection and Maintenance Schedule
  22
  - Before each Use
    22
  - After each Use
    22
  - Every 300 Hours of Use or Three Years
    23
  - Before Periods of Storage
    23
- Flushing the Cooling System
  23
- Steering Link Rod Fasteners
  24
- Corrosion Control Anode
  25
- Spark Plug Inspection and Replacement
  26
- Battery Inspection
  26
- Fuse Replacement - Electric Start Models
  27
- Timing Belt Inspection
  27
- Lubrication Points
  28
- Checking Power Trim Fluid
  29
- Fuel System
  30
  - Fuel Filter
    30
  - Fuel Line Inspection
    30
- Changing Engine Oil
  31
  - Oil Changing Procedure
    31
  - Changing Oil Filter
    32
  - Checking and Adding Engine Oil
    32
- Changing Gear Case Lubricant
  33
  - 3-1/4 In. (83Mm) Diameter Gear Case
    33
  - 4-1/4 In. (108Mm) Diameter Gear Case
    34
- Storage Preparation
  36
  - Fuel System
    36
  - Protecting External Outboard Components
    36
  - Protecting Internal Engine Components
    36
  - Gear Case
    36
  - Positioning Outboard for Storage
    37
  - Battery Storage
    37
Important Information 1

38
- Conditions Affecting Performance
  39
  - Weather
    39
  - Boat
    40
  - Engine
    42
- Serial Number Location
  39
- Following Complete Submersion
  43
  - Submerged While Running
    43
  - Salt Water Submersion
    43
  - Fresh Water Submersion
    43
- Model 30/40 (4-Stroke) Powerhead Views Front View
  44
  - Starboard View
    45
  - Port View
    46
  - Top View
    47
  - Aft View
    48
- Propeller Selection
  49
- Propeller Removal/Installation
  50
  - 3-1/4 In. (83Mm) Diameter Gear Case
    50
  - 4-1/4 In. (108Mm) Diameter Gear Case
    51
- Power Trim System
  52
  - General Information
    52
  - Power Trim Operation
    52
  - Trim "In" Angle Adjustment
    53
- Trim Tab Adjustment
  54
- Compression Check
  55
- Cylinder Leakage Testing
  56
  - Analysis
    56
- Water Pressure Measurement
  57
- Painting Procedures
  58
  - Cleaning & Painting Aluminum Propellers & Gear Housings
    58
- Decal Removal/Application
  59
  - Removal
    59
  - Instructions for "Wet" Application
    59
Important Information 1

61
Electrical 2

76
- Specifications
  77
- Special Tools
  78
- Flywheel
  81
- Electrical Components
  83
- Ignition Component Description
  85
  - Electronic Control Module (ECM)
    85
  - Crank Position Sensor
    86
  - Stator Assembly
    86
  - Flywheel Assembly
    87
  - Ignition Coils
    87
- Ignition Description
  85
- Ignition Test Procedures
  87
  - Direct Voltage Adapter (DVA)
    87
- Ignition Troubleshooting
  88
- Ignition Diagnostic Procedures
  89
  - Recommended Test
    90
- Troubleshooting with the Digital Diagnostical Terminal
  92
  - Using the Digital Diagnostical Terminal (DDT)
    92
- Component Resistance Tests
  93
- Flywheel Removal/Installation
  97
  - Removal
    97
  - Installation
    99
- Stator Removal/Installation
  100
- Timing Belt
  101
  - Removal
    101
  - Installation
    102
- ECM Removal/Installation
  103
- Ignition Coil Removal/Installation
  104
- Voltage Regulator Removal/Installation
  105
- Engine Coolant Temperature (ECT) Sensor Removal/Installation
  107
  - Recommended Battery
    110
  - Operating Engine Without Battery
    110
  - Battery Charging System
    111
  - Stator Ohms Test
    115
  - Starting System Components
    118
  - Troubleshooting the Starting Circuit
    119
  - Brush Replacement
    128
Electrical 2

143
- 30/40 Elpt
  144
- 30/40 Ehpt
  145
- 30/40 Mh
  146
- Commander 2000 Remote Control (Electric Start)
  147
- Commander 3000 Panel Mount Control
  148
- Instrument/Lanyard Stop Switch Wiring Diagram
  149
- Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
  150
- Commander 2000 Key Switch Test
  152
- Instrument Wiring Connections
  153
  - Without Light Switch
    153
  - With Light Switch
    153
- Oil Pressure Wiring Diagram
  154
- QSI Gauge Wiring Diagrams
  155
  - Tachometer Wiring Diagram
    155
  - Water Temperature Gauge
    156
  - Engine Synchronizer Wiring Diagram
    157
- Remote Wiring Harness Connection to Engine
  160
  - Electric Start Remote Control Model
    160
- Remote Key
  161
- Power Trim Switch Wiring Diagram
  162
  - Carburetor Adjustments
    190
  - Idle Speed
    190
  - Carburetor Removal
    192
  - Carburetor Disassembly
    193
  - Carburetor Reassembly
    201
  - Carburetor Installation
    206
Fuel System

208
- Exhaust Emissions Standards
  209
  - What Are Emissions
    209
  - Hydrocarbons
    209
  - Carbon Monoxide - CO
    209
  - Oxides of Nitrogen - Nox
    209
  - Controlling Emissions
    209
  - Stoichiometric (14.7:1) Air/Fuel Ratio
    210
- Emissions Reductions
  210
  - 8 1/3% # Per Year over 9 Model Years
    210
- Outboard Hydrocarbon
  210
- Stratified Vs Homogenized Charge
  211
  - Homogenized Charge
    211
  - Stratified Charge
    212
- Emissions Information
  213
  - Manufacturer's Responsibility
    213
  - Dealer Responsibility
    213
  - Owner Responsibility
    213
  - EPA Emission Regulations
    214
  - Decal Location for 1999 Models
    215
  - Emission Control Information
    215
  - Decal Location for 2000 and Newer Models
    216
- Service Replacement Certification Label
  217
Powerhead

218
- Specifications
  219
- Special Tools
  222
- Cylinder Head
  223
- Camshaft/Oil Pump
  225
- Intake/Exhaust Valves
  227
- Torque Sequence
  229
- Valve Cover
  230
  - Removal
    230
  - Installation
    232
- Valve Clearance Adjustment
  235
  - Checking Valve Clearance
    235
  - Adjusting Valves
    236
- Timing Belt
  237
  - Removal
    237
  - Installation
    238
- Cylinder Head Removal
  239
- Cylinder Head Disassembly
  241
  - Rocker Arm Assembly Removal
    241
  - Oil Pump Removal
    241
  - Camshaft Removal
    242
  - Valve Removal
    243
  - Rocker Shaft and Rocker Arm
    244
- Cleaning/Inspection/Repair
  245
  - Camshaft
    245
  - Cylinder Head
    247
  - Valve Guide Inspection
    247
  - Valve Guide Replacement
    248
  - Valves
    249
  - Valve Springs
    250
  - Valve Seat Reconditioning
    252
  - Valve Refacing Steps
    253
- Cylinder Head Reassembly
  254
  - Valve Installation
    254
  - Camshaft Oil Seal Installation
    255
  - Camshaft Installation
    256
  - Oil Pump Installation
    257
  - Rocker Arm Shaft Assembly
    257
  - Rocker Arm Shaft Installation
    258
  - Cylinder Head Gasket
    259
- Cylinder Head Installation
  260
Powerhead

262
- Specifications
  263
- Special Tools
  264
- Crankshaft
  265
- Cylinder Block and Crankcase
  267
- Torque Sequence
  269
- Powerhead Removal
  270
- Removing Powerhead Components
  273
- Cylinder Block Disassembly
  274
  - Crankcase and Crankshaft Removal
    275
- Inspection
  278
  - Cylinder Bore
    278
  - Piston
    279
  - Piston Pin
    280
  - Piston Rings
    280
  - Crankshaft
    281
  - Checking Main Bearing Clearance
    282
  - Checking Connecting Rod Bearing Clearance
    284
  - Thermostat
    285
  - Oil Pressure Switch
    285
- Cylinder Block Reassembly
  286
  - Selecting New Main Bearings
    286
  - Main Bearing Installation
    287
  - Installing Connecting Rod Bearings
    288
  - Connecting Rod Installation
    289
  - Piston Ring Installation
    290
  - Piston Installation
    291
  - Crankshaft Installation
    291
  - Crankcase Cover Installation
    293
  - Thermostat and Exhaust Cover Installation
    294
  - Drive Gear Installation
    295
  - Installing Powerhead Components
    296
- Powerhead Installation
  297
  - Tiller Handle Models
    300
    
    Transom Bracket
    310
    
    Swivel Bracket
    312
    
    Steering Arm
    318
MID-Section

322
- Special Tools
  323
- Power Trim
  325
- Adjustments
  327
  - Trimming Characteristics
    327
  - Trailering Outboard
    328
  - Tilting Outboard up and down Manually
    328
- Theory of Operation
  327
- Power Trim Flow Diagrams
  329
  - Trim up Circuit
    329
  - Tilt Circuit
    331
  - Maximum Tilt
    333
  - Down Circuit
    335
  - Shock Function
    337
  - Shock Function Return
    339
  - Manual Release
    341
- Troubleshooting
  343
- Power Trim System Removal
  350
- Power Trim Disassembly
  351
  - Trim Motor Removal
    352
  - Pump and Components Removal
    352
  - Manifold Removal
    353
  - Shock Rod Removal
    354
- Shock Rod Disassembly
  354
  - Memory Piston Removal
    357
- Cleaning/Inspection/Repair
  358
  - Trim Motor Electrical Tests
    358
- Reassembly
  359
  - O-Ring and Seal Placement
    359
- O-Ring Sizes
  360
- Power Trim Reassembly
  362
  - Shock Rod Reassembly
    362
  - Shock Rod Installation
    364
  - Trim Limit Assembly Installation
    365
  - Manual Release Valve Installation
    365
  - Manifold Installation
    366
  - Oil Pump Installation
    367
  - Reservoir/Motor Installation
    369
  - Bleeding Power Trim Unit
    370
- Installation of Power Trim System
  370
MID-Section

374
- Manual Tilt Components
  375
- Manual Trim Flow Diagrams
  377
  - Up Circuit
    377
  - Down Circuit
    379
  - Slow Tilt down under High Thrust
    381
  - Under Water Strike (Valves Open)
    383
  - Shock Function (Valve Closed)
    385
  - Shock Function Return
    387
- Hydraulic System Troubleshooting
  389
- Manual Tilt System Removal
  391
- Manual Tilt System Disassembly
  393
  - Accumulator Removal
    393
  - Shock Rod Removal
    394
- Shock Rod Disassembly
  394
  - Valve Block Removal
    397
  - Memory Piston Removal
    398
- Valve Block Disassembly
  399
- Reassembly - O-Ring and Seal Placement
  400
- Actual O-Ring Sizes
  401
- Manual Tilt System Reassembly
  402
- O-Ring Description and Sizes
  402
- Manual Tilt System Installation
  413
  - Manual Release Valve Adjustment
    416
    
    Upper Drive Shaft Bearing
    490
    
    Oil Sleeve
    491
    
    Lower Drive Shaft Bearing Race
    492
    
    Forward Gear Bearing Race
    495
    
    Bearing Carrier Reassembly
    499
    
    Forward Gear Reassembly
    503
    
    Propeller Shaft Reassembly
    505
    
    Drive Shaft Wear Sleeve Installation
    506
    
    Oil Sleeve Installation
    509
  - Tiller Handle
    537
  - Tiller Handle Assembly Removal
    539
  - Tiller Handle Disassembly
    541
  - Cleaning/Inspection/Repair
    543
  - Tiller Handle Reassembly
    544
  - Tiller Handle Installation
    549
  - Manual Starter
    555
  - Interlock Cable Adjustment
    557
  - Manual Starter Removal
    558
  - Manual Starter Disassembly
    559
  - Cleaning and Inspection
    561
  - Rewind Starter Reassembly
    562
  - Adjusting Rewind Spring Tension
    563
  - Manual Starter Installation
    567
  - 30/40 (4-Stroke) Tiller Handle Electric
    570
  - Wiring Diagram
    570
  - 30/40 (4-Stroke) Tiller Handle Manual
    573
  - Wiring Diagram
    573
  - 30/40 (4-Stroke) Remote Control Electric
    576
  - Wiring Diagram
    576
  - 30/40 (4 Stroke) Oil Flow Diagram
    579
  - 30/40 (4 Stroke) Water Flow Diagram
    582

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