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Mercury FourStroke 2.5 User Manual

Mercury FourStroke 2.5
205 pages
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2.5/3.5
FourStroke
Serial Number 0R448033 and Above
90-8M0065421 NOVEMBER 2012
2.5/3.5 FourStroke
©2012, Mercury Marine. All rights reserved. Printed in U.S.A. 90-8M0065421 NOVEMBER 2012
www.mercurymarine.com.au
41-71 Bessemer Drive
Dandenong South, Victoria 3175 Australia
www.mercurymarine.com
P.O. Box 1939
Fond du Lac, WI 54936-1939 USA
www.marinepower.com
Parc Industriel de Petit-Rechain
B-4800 Verviers, Belgium

Table of Contents

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Mercury FourStroke 2.5 Specifications

General IconGeneral
Horsepower2.5 HP
Starting SystemManual
Gear Ratio2.15:1
Cooling SystemWater-cooled
SteeringTiller
Full Throttle RPM Range5000-6000 RPM
Fuel Induction SystemCarbureted
Weight17 kg (37.5 lbs)
Fuel TypeGasoline
Shaft Length15 inches
Fuel Tank Capacity1.0 L
Oil Capacity0.6 L
Engine TypeSingle-cylinder

Summary

Master Specifications

Model Specifications

Provides detailed specifications for the 2.5/3.5 FourStroke outboard models.

Ignition Specifications

Details ignition system parameters like spark plug type, gap, and timing.

Carburetor Specifications

Lists specifications for the carburetor, including venturi size and jet sizes.

Cooling System Specifications

Outlines cooling system parameters like thermostat temperatures and water pressure.

Piston Specifications

Provides dimensions and clearances for pistons and piston rings.

Maintenance Procedures

Inspection and Maintenance Schedule

Outlines routine checks and maintenance tasks based on usage intervals.

Flushing the Cooling System

Instructions for flushing the outboard's cooling system with fresh water.

Engine Oil Recommendations

Specifies the recommended engine oil viscosity and type for optimal performance.

Spark Plug Inspection and Replacement

Guidance on inspecting, gapping, and replacing spark plugs.

Gearcase Lubrication

Details on draining, inspecting, and refilling gearcase lubricant.

Storage Preparation

Procedures for preparing the outboard for long-term storage.

General Information

Component Identification

Diagrams identifying key components of the outboard motor.

Conditions Affecting Performance

Discusses factors like weather, weight, and cavitation impacting engine performance.

Propeller Selection

Guidance on choosing the correct propeller for optimal engine RPM and performance.

Compression Check

Procedure for performing a compression test on the engine cylinders.

Painting Procedures

Steps for properly painting external components like the gear housing.

Ignition System

Ignition Specifications

Lists critical ignition system parameters and values.

Flywheel Removal and Installation

Detailed steps for removing and reinstalling the engine flywheel.

Ignition Coil Replacement

Procedures for removing and installing the ignition coil.

Checking Ignition Timing

Instructions for verifying ignition timing using a timing light.

Carburetor and Fuel Pump

Carburetor Specifications

Provides specific settings and dimensions for the carburetor.

Carburetor Components

Illustrated breakdown of carburetor parts with reference numbers.

Fuel Pump Removal and Installation

Steps for safely removing and reinstalling the fuel pump.

Carburetor Removal and Installation

Procedure for removing and reinstalling the carburetor assembly.

Carburetor Disassembly

Detailed steps for taking the carburetor apart for service.

Powerhead Service

Camshaft and Valve Specifications

Technical data for camshaft lobes, valve guides, and valve clearances.

Piston Specifications

Details piston and piston ring dimensions and clearances.

Cylinder Block Specifications

Specifications for cylinder bore, stroke, and crankshaft dimensions.

Powerhead Removal

Step-by-step instructions for safely removing the powerhead.

Cylinder Block Assembly

Procedures for assembling the cylinder block halves.

Powerhead Installation

Steps for reinstalling the powerhead onto the driveshaft housing.

Midsection Components

Cowling Components

Illustrated breakdown of the outboard motor's cowling parts.

Clamp Bracket Components

Diagram and list of parts for the clamp bracket assembly.

Driveshaft Housing Components

Illustrated parts list for the driveshaft housing.

Swivel Bracket Removal/Installation

Instructions for removing and installing the swivel bracket.

Steering Stop Components

Details on the steering stop mechanism components.

Gear Housing Service

Gear Housing Specifications

Key specifications for the gear housing, including gear ratio and capacity.

Draining and Inspecting the Gear Housing Lubricant

Procedure for checking and draining the gear housing lubricant.

Water Pump

Steps for disassembly, inspection, and replacement of water pump components.

Gear Housing Installation

Instructions for properly installing the gear housing onto the driveshaft.

Propeller Installation

Guidance on installing the propeller onto the propeller shaft.

Shift Linkage

Shift Linkage Components

Illustrated breakdown of the shift linkage parts.

Shift Linkage Removal and Installation

Procedures for removing and reinstalling the shift linkage assembly.

Tiller Handle Operation

Tiller Handle Components

Illustrated parts list for the tiller handle assembly.

Tiller Handle Removal

Step-by-step instructions for removing the tiller handle.

Tiller Handle Installation

Procedures for installing the tiller handle assembly.

Throttle Cable Adjustment

Guidance on adjusting the deceleration and acceleration throttle cables.

Recoil Starter Service

Recoil Starter Components

Illustrated breakdown of recoil starter assembly parts.

Recoil Starter Removal

Steps for removing the recoil starter assembly from the outboard.

Recoil Starter Spring Replacement

Instructions for safely replacing the rewind spring in the starter.

Recoil Starter Rope Replacement

Procedure for replacing the starter rope and handle.

Recoil Starter Installation

Steps for reinstalling the recoil starter assembly.

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