Description
This Clymer Mariner 2-220 hp 1976-1989 Outboard Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1976-1989 Mariner 2-220hp outboard boat engines including electric motors. Covers 2, 3, 4 and 6 cylinder inline, and Mariner V6 motors. Includes general information on each model, tools and techniques, troubleshooting, lubrication, maintenance and tune-up, timing, synchronizing and adjusting, fuel system, electrical systems, power head, 2-48 hp (except 1986+ 45 hp) lower unit, 50-220 hp (including 1986+ 45 hp) lower unit, automatic rewind starter, electric motors, power trim and tilt systems and complete wiring diagrams. Features 720 illustrated pages.
1976 1977 1978 1979
1980 1981 1982 1983 1984 1985 1986 1987 1988 1989
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization, Notes, cautions and warnings, Torque specifications, Engine operation, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Propellers
CHAPTER TWO, TOOLS AND TECHNIQUES
Safety first, Basic hand tools, Test equipment, Service hints, Special tips, Mechanic’s techniques
CHAPTER THREE, TROUBLESHOOTING
Operating requirements, Starting system, Charging system, 2-48 hp Ignition system, 50-200 hp Ignition system, Cylinder firing order change (Mariner 70 hp), Fuel system, Engine
CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP
Model changes, Lubrication, Storage, Complete submersion, Anti-corrosion maintenance, Engine flushing, Tune-up, Compression check, Spark plugs, Lower unit and water pump check, Fuel system service, Magneto ignition system service, Battery and starter motor check, Solenoid check, Internal wiring harness check, Timing, synchronization and adjustment, Performance test (on boat)
CHAPTER FIVE, TIMING, SYNCHRONIZING AND ADJUSTING
Engine timing, Synchronizing, Required equipment, Mariner 2, Mariner 3.5, Mariner 4 and water-cooled 5, Mariner 5 (air-cooled) / Mariner 8A and 8B, Mariner 8 hp (1985-1987) / Mariner 9.9 and 15 (magneto ignition) / Mariner 9.9 and 15 (CDI) (except 1987-on 9.9 and 1989 15) / Mariner 8 (1988-on), 9.9 (1987-on) and 15 (1989) / Mariner 20, 25 and W25 (magneto ignition), Mariner 20, 25, W25, 30 and W30 (CDI) (except 1985-on 20) / Mariner 20 and 25 hp (1985-on with WMC carburetor) / Mariner 28, Mariner 40A, 40B and W40 (magneto ignition) / Mariner 40B and W40 (CDI, single carburetor), Mariner 40B and W40 (CDI, dual carburetors) / Mariner 48 (CDI) / Mariner 45 hp (1986-on) and 50 hp (through 1985) with alternator-driven CDI, Mariner 60 hp with CDI (1976-1983) / Mariner 70 hp, 1984-on 60 hp and 1986-on 40 hp with alternator-driven CDI, 1987-on Mariner 75 and 90, Mariner 90, 115 and 140 hp with distributor CDI, Mariner 1988-on 100 and 1989 115 with flywheel CD ignition, Mariner V135, V150, V150 Magnum, V150 Magnum II, V175 (serial no. 6618751 and above) and V200 (serial no. 6655032 and below) hp, Mariner V200 (serial no. 6655033 and above)
CHAPTER SIX, FUEL SYSTEM
Fuel pump, 2-48 hp carburetors, Throttle plunger carburetor (Mariner 2A and 2B) / Mikuni BV 18-14 carburetor (Mariner 3.5 hp), Throttle plunger carburetor (Mariner 15A, 15B, W15) / Downdraft carburetor (Mariner 8 and 8A) / Integral fuel pump carburetor, Center bowl carburetor (air cooled through W30) / Center bowl carburetor (Mariner 40 hp) / Center bowl carburetor (Mariner 48 hp), Integral fuel pump carburetor with primer system, Model 100 and model 115 Concept 2 + 2, Center bowl carburetor (50-200 hp except 1976-1983 Mariner 60 hp) / Center bowl carburetor (1976-1983 Mariner 60 hp) / Dual-float center bowl carburetor, Side bowl and back drag carburetor, WME carburetor, Electronic fuel injection (EFI) / Enrichener valve and choke solenoid systems, Anti-siphon devices, Water-separating fuel filter, Fuel tank, Fuel line and primer bulb
CHAPTER SEVEN, ELECTRICAL SYSTEM
Battery, Charging system, Electric starting system, Starting system, Magneto ignition system, Capacitor discharge ignition (CDI) / Distributor-type CDI system, Alternator drive CDI system, Small bore CDI system (1976-1983 Mariner 60 hp)
CHAPTER EIGHT, POWER HEAD
Engine serial number, Fasteners and torque, Gaskets and sealants, 2-48 hp (except 1986-on 45 hp) Power head removal/installation, Power head disassembly, 2-48 hp (except 1986-on 48 hp) Power head assembly, 50-220 hp (including 1986-on 45 hp) Power head
CHAPTER NINE, 2-48 HP (EXCEPT 1986-ON 45 HP) LOWER UNIT
Lower unit, Water pump, Bearing carrier and propeller shaft, Pinion gear and drive shaft, Shift shaft, Forward gear and bearing assembly, Lower unit housing, Pinion gear depth and gear backlash, Propeller, Trim tab and anode
CHAPTER TEN, 50-200 HP (INCLUDING 1986-ON 45 HP) LOWER UNIT AND DRIVE SHAFT HOUSING
Lower unit (except Model R drive) / Water pump, Bearing carrier and propeller shaft, Pinion gear, drive shaft and forward gear, Lower shift shaft, bushing and cam, Pinion gear depth and gear backlash, Model R drive lower unit, Water pump, Bearing carrier and propeller shaft, Drive shaft/pinion gear removal, Drive shat/pinion gear installation, Propeller shaft/forward gear removal/disassembly, Pinion gear height, Forward and reverse gear backlash, Propeller, Drive shaft housing, Trim tab adjustment
CHAPTER ELEVEN, AUTOMATIC REWIND STARTER
CHAPTER TWELVE, MARINER ELECTRIC MOTORS
Lubrication, Periodic maintenance, Battery, Propeller, Electrical troubleshooting, Electrical component testing (variable speed control models) / Electrical component testing (rotary switch models) / Lower unit, Control housing
CHAPTER THIRTEEN, POWER TRIM AND TILT SYSTEM
External power trim system, Hydraulic pump, Troubleshooting, Solenoid test, Trim limit adjustments, Trim cylinders, Design 2 power trim and tilt system, Hydraulic pump, Troubleshooting
INDEX
WIRING DIAGRAMS
