Mercury 20, 25 2-Stroke Carb Outboard Motor Service Manual

Covers: Mercury 20, 20 Jet, 25, 25 Marathon, 25 Sea Pro 2-stroke Outboard Motors

• United States – S/N 0G044027 and Above
• Belgium – S/N 09807909 and Above
• 1994 and up model years

Pages: 337
Format: PDF
File size: 11mb
Compatibility: Windows/Mac computers

Get the 1994+ Mercury 20 and 25 2-Stroke Carb Outboard Motor service manual in a convenient PDF format. It has instructions to service and repair the motor from top to bottom following the manufacturer’s specifications. This is the same manual professional marine technicians follow to diagnose and repair your outboard motor. It is ideal for owners, mechanics, and shops who need the most comprehensive OEM procedures and illustrations available. Whether it’s routine maintenance, such as tune-ups and fuel system service, or more extensive repairs such as engine overhaul, this manual has the information you need to safely and confidently work on the Mercury outboard.

Delivered as a collection of high-resolution PDFs, our automated system will email you a download link within minutes — no waiting for shipping. This manual is best viewed on a Windows or Mac laptop so that the links between sections work properly.

Topics:

Section 1 – Important Information

• Specifications
• Maintenance
• General Information
• Outboard Installation

Section 2 – Electrical

• Ignition
• Charging & Starting System
• Timing, Synchronizing & Adjusting
• Wiring Diagrams

Section 3 – Fuel System

• Carburetor/Fuel Pump
• Emissions

Section 4 – Powerhead

• Powerhead Removal/Installation
• Powerhead Disassembly/Assembly
• Cylinder Block and Crankcase Cover
• Exhaust Manifold and Exhaust Cover
• Cylinder Bore
• Crankshaft
• Seals
• Bearings
• Connecting Rod
• Pistons
• Reed Block
• Bleed System
• Thermostat
• Setup and Test Run Procedures
• Break-In Procedure

Section 5 – Mid-Section

• Clamp and Swivel Brackets
• Drive Shaft Housing

Section 6 – Lower Unit

• Gear Housing
• Jet Drive

Section 7 – Attachments/Control Linkage

• Throttle/Shift Linkage
• Tiller Handle
• Side Shift

Section 8 – Manual Starter