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1998-2002 Mercury Bigfoot 25hp outboard engine repair manual

Models covered in this manual:

Bigfoot 25hp / Mercury (Brunswick Corporation)

  • Production/model years: 1998, 1999, 2000, 2001, 2002 onwards
  • Serial Numbers: 0G590000 through 0T408999

File specifications

File size: 11.09 MB
File type: ZIP
Language: English

Printable: Yes
Estimated download time: 0.23 Minutes
$14.99 Instant Download

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Product Information

Table of Contents

Section 1A - Specifications

  • Specifications
  • Propeller Information Chart
  • Mercury/Quicksilver Lubricants and Sealants
  • Torque Specifications

Section 1B - Maintenance

  • Maintenance Schedule
  • Pre-Operation Checks
  • Routine Maintenance
  • Lubrication Points
  • Inspection Procedures

Section 2 - Ignition System

  • Ignition System Components
  • Ignition Timing Adjustment
  • Spark Plug Service
  • Ignition Coil Testing
  • Troubleshooting

Section 3 - Fuel System

  • Fuel System Components
  • Carburetor Adjustment
  • Fuel Pump Service
  • Fuel Line Inspection
  • Troubleshooting

Section 4 - Powerhead

  • Powerhead Removal
  • Cylinder Head Service
  • Piston and Crankshaft Service
  • Valve Adjustment
  • Reassembly Procedures

Section 5 - Cooling System

  • Cooling System Components
  • Water Pump Service
  • Thermostat Replacement
  • Cooling System Flushing
  • Troubleshooting

Section 6 - Lower Unit

  • Lower Unit Removal
  • Gearcase Disassembly
  • Propeller Shaft Service
  • Lower Unit Reassembly
  • Troubleshooting

Section 7 - Electrical System

  • Electrical Components
  • Battery Service
  • Charging System Testing
  • Wiring Diagrams
  • Troubleshooting

Section 8 - Trim and Tilt

  • Trim and Tilt Components
  • Hydraulic System Service
  • Trim Adjustment
  • Troubleshooting

Section 9 - Manual Starter

  • Manual Starter Components
  • Starter Rope Replacement
  • Recoil Spring Service
  • Troubleshooting

Appendix

  • Special Tools
  • Service Tips
  • Technical Bulletins
  • Parts List

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