MerCruiser Stern Drives 502 Magnum (1998 - 2004)

This MerCruiser manual is 672 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specifications

CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques

CHAPTER THREE / TROUBLESHOOTING
Starting system / Charging system Drive unit identification / Starting system / Ignition system /Spark test / Knock control test / Shift interrupt switch test / Battery charging system / Fuses, circuit breaker and wiring harness / Fuel system / Oil pressure switch test / Carburetor / Electronic fuel injection (EFI) / Trouble codes / Idle air control motor test / Warning system / Engine mechanical / Cooling system / Drive unit / Trim system / Power steering / Mercathode system

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Before each use / After each use / Lubrication / Engine oi land filter change / Gearcase lubricant change / Propeller shaft lubrication / Engine coupler lubrication / Gimbal bearing lubrication / Universal joint lubrication and inspection / Steering system lubrication / Periodic inspection / Bellow inspection / Engine alignment / Winter inlet inspection / Gimbal ring fastener inspection / Anode and ground wire inspection / Engine coolant change (closed cooling system) / Heat exchanger cleaning / Pressure cap test / Coolant test / Clamps and fittings / Fuel requirements / Fuel filter service / Flame arrestor / PVC Valve / Carburetor and throttle body / Throttle and shift cable / Tune-up / Compression test / Spark plugs / Valve adjustment / Carburetor adjustment / Ignition timing / Test running engine / Specifications

CHAPTER FIVE / LAY-UP, WINTERIZING AND FITTING OUT
Lay-up / Winterizing / Testing the coolant / Fitting out / Specifications

CHAPTER SIX / ADJUSTMENTS
Drive belts / Trim position sender adjustment / Shift cable adjustment / Throttle cable / Ignition timing adjustment / Idle mixture and idle speed adjustment / Trim tab adjustment / Specifications

CHAPTER SEVEN / ENGINE
Removal installation / Engine alignment / Valve adjustment / Placing the No. 1 piston at TDC / Camshaft lobe lift / Cylinder head / Pushrod, rocker arm and rocker arm cover / Oil pan / Oil pump / Harmonic balancer / Timing gear cover / Timing chain and sprocket / Balance shaft / Camshaft and lifter / Piston and connecting rod / Crankshaft and rear main seal / Break-in / Specifications

CHAPTER EIGHT / FUEL SYSTEM
Carburetor / Cool fuel system / Boost pump removal installation (496 Mag and 496 Mag HO) / Throttle body TBI / Fuel rail and injectors / Air pressure sensor / Engine temperature sensor / Air temperature sensor / Fuel pressure sensor / Throttle position sensor / Knock sensor module / Idle air control motor / Manifold temperature sensor / Camshaft position sensor / Crankshaft position sensor / System relay and fuel pump relay / Engine control unit ECU / Manifold / Specifications

CHAPTER NINE / EXHAUST AND COOLING SYSTEM
Exhaust elbow / Exhaust flapper valve / Exhaust manifold / Water rail / Heat exchanger / Engine circulating pump / Thermostat and housing / Seawater pump / Coolant reservoir / Specifications

CHAPTER TEN / ELECTRICAL AND IGNITION SYSTEMS
Starting system / Ignition system / Warning system / Oil pressure sender / Oil pressure switch / Overheat switch / Engine temperature sensor / Engine temperature sender / Gearcase lubricant monitor / Water pressure sensor / Charging system / Specifications

CHAPTER ELEVEN / DRIVE UNIT AND PROPELLER
Alpha drive / Bravo drive / Drive ratio identification / Propeller / Drive unit removal installation / Water pump / Gearcase / Bravo I II III models / Drive shaft housing / Drive shaft unit inspection / Specifications

CHAPTER TWELVE / TRANSOM ASSEMBLY
Gimbal bearing / Shift cable / Trim limit switch and trim sender / Water hose / Bell housing / Gearcase lubricant hose and fitting / Exhaust bellows / Exhaust tube / Universal joint bellows / Speedometer hose and fitting / Gimbal ring, swivel shaft and steering lever / Inner transom plate / Transom assembly / Specifications

CHAPTER THIRTEEN / TRIM AND TILT SYSTEM
Relieving system pressure / Trim pump / Fluid reservoir / Trim motor / Hydraulic pump and pump adapter / Hydraulic trim cylinder and anchor pins / External hoses / Terminal block / Internal hose / Filling and bleeding the system / Specifications

CHAPTER FOURTEEN / STEERING SYSTEM
Safety precautions / Mechanical steering system / Power steering / Power steering pump / Specifications

CHAPTER FIFTEEN / CORROSION CONTROL SYSTEM
Anodes / Ground wires / Mercathode electrode / Specifications

CHAPTER SIXTEEN / SUPPLEMENT 2002-2013 MODELS

INDEX

WIRING DIAGRAMS

Stern Drives:
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 MerCruiser Alpha One
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 MerCruiser Bravo One
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 MerCruiser Bravo Two
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 MerCruiser Bravo Three
Engines:
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 3.0 L
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 4.3 L
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 5.0 L
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 5.7 L
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 350 Mag
1998 1999 2000 2001 2002 2003 2004 MX 6.2 L
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 454 Mag
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 502 Mag
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 496 Mag
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 496 Mag HO
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 7.4 L MPI

Clymer Manuals MerCruiser Alpha One Manual
Clymer Manuals MerCruiser Bravo One Manual
Clymer Manuals MerCruiser Bravo Two Manual
Clymer Manuals MerCruiser Bravo Three Manual
Clymer Manuals 3.0 L Manual
Clymer Manuals 4.3 L Manual
Clymer Manuals 5.0 L Manual
Clymer Manuals 5.7 L Manual
Clymer Manuals 350 Mag Manual
Clymer Manuals MX 6.2 L Manual
Clymer Manuals 454 Mag Manual
Clymer Manuals 502 Mag Manual
Clymer Manuals 496 Mag Manual
Clymer Manuals 496 Mag HO Manual
Clymer Manuals 7.4 L MPI Manual
Clymer Manuals MerCruiser Alpha One Online Manual
Clymer Manuals MerCruiser Bravo One Online Manual
Clymer Manuals MerCruiser Bravo Two Online Manual
Clymer Manuals MerCruiser Bravo Three Online Manual
Clymer Manuals 3.0 L Online Manual
Clymer Manuals 4.3 L Online Manual
Clymer Manuals 5.0 L Online Manual
Clymer Manuals 5.7 L Online Manual
Clymer Manuals 350 Mag Online Manual
Clymer Manuals MX 6.2 L Online Manual
Clymer Manuals 454 Mag Online Manual
Clymer Manuals 502 Mag Online Manual
Clymer Manuals 496 Mag Online Manual
Clymer Manuals 496 Mag HO Online Manual
Clymer Manuals 7.4 L MPI Online Manual

Stern Drives:
MerCruiser Alpha One (1998-2013)
MerCruiser Bravo One (1998-2013)
MerCruiser Bravo Two (1998-2013)
MerCruiser Bravo Three (1998-2013)

Engines: (1998-2013)
3.0 L (1998-2013)
4.3 L (1998-2013)
5.0 L (1998-2013)
5.7 L (1998-2013)
350 Mag (1998-2013)
MX 6.2 L (1998-2013)
454 Mag (1998-2013)
502 Mag (1998-2013)
496 Mag (1998-2013)
496 Mag HO (1998-2013)
7.4 L MPI (1998-2013)