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Mercury/Mariner 25 MARATHON User Manual

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337 pages
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MODELS
United States 0G044027 and Above. . . . . . .
Belgium 09807909 and Above. . . . . . . . . . .
With Serial Numbers
SERVICE
MANUAL
20 JET 20 25
Mercury/Mariner
25 MARATHON 25 SEAPRO
Printed in U.S.A.
1998, Mercury Marine
90-826883R2 JUNE 1998

Table of Contents

Questions and Answers:

Mercury/Mariner 25 MARATHON Specifications

General IconGeneral
BrandMercury/Mariner
Model25 MARATHON
CategoryOutboard Motor
LanguageEnglish

Summary

Important Information

Specifications

Details specific technical data and parameters for the outboard motor models.

Maintenance

Outlines routine inspection and maintenance tasks for the outboard motor.

Outboard Motor Installation

Covers the procedures and safety for installing the outboard motor onto a boat.

Electrical

Ignition

Details the ignition system components, specifications, and troubleshooting for engine starting.

Battery Charging and Starting Systems

Explains the battery, charging system, and starting system components and maintenance.

Wiring Diagrams

Presents various wiring diagrams for different models and systems of the outboard.

Fuel System

Carburetor/Fuel Pump

Details specifications, adjustments, and components of the carburetor and fuel pump system.

Emissions

Explains exhaust emissions, standards, and control methods for marine engines.

Powerhead

Specifications

Lists specifications for engine components like bore, stroke, pistons, and crankshaft.

Powerhead Removal

Outlines the steps for safely removing the powerhead from the engine assembly.

Powerhead Reassembly

Provides instructions for reassembling the powerhead after disassembly or repair.

CLAMP and SWIVEL BRACKET

Clamp Bracket Assembly

Details the components and assembly of the clamp bracket used for mounting the outboard.

Swivel Bracket Assembly

Explains the assembly and components of the swivel bracket, critical for steering.

Gear Housing

Specifications

Lists specifications for the gear housing, including ratio, capacity, and lubricant.

Gear Housing Removal

Outlines the steps for safely removing the gear housing from the outboard.

Reassembly

Provides instructions for reassembling the gear housing after disassembly or repair.

Jet Drive

Specifications

Lists specifications for the jet drive system, including impeller clearance.

Outboard Mounting Height

Explains how to set the correct outboard mounting height to prevent cavitation or drag.

Shift Link Rod Adjustment

Details the procedure for adjusting the shift link rod to ensure proper gear engagement and safety.

Throttle/Shift Linkage

Throttle and Shift Linkage (Tiller Handle Shift)

Details the components and assembly of the throttle and shift linkage for tiller handle models.

Control Platform

Covers the removal, disassembly, reassembly, and installation of the control platform.

Horizontal Shift Shaft

Covers the removal, installation, and securing of the horizontal shift shaft.

Tiller Handle

Tiller Handle Assembly

Details the components and assembly of the tiller handle, including various models and colors.

Tiller Handle Removal/Disassembly

Outlines the steps for removing and disassembling the tiller handle assembly.

Side Shift

Throttle And Shift Linkage (Side Shift)

Details the components and linkage for throttle and shift operations on side shift models.

Throttle Cam/Control Lever

Covers the reassembly and installation of the throttle cam and control lever for side shift models.

Manual Starter

Specifications

Provides specifications for the manual starting system, including rope length.

Starter Assembly (Manual)

Details the components and assembly of the manual starter system.

Rewind Starter Assembly

Outlines the removal and installation procedures for the rewind starter assembly.

Starter Rope Replacement

Provides instructions for replacing the starter rope on the rewind starter assembly.