Download Complete Service Repair Manual for Mercury 3.5HP – 40HP Outboards.

This Factory Service Repair Manual offers all the service and repair information about Mercury 3.5HP – 40HP Outboards. The information on this manual covered everything you need to know when you want to repair or service Mercury 3.5HP – 40HP Outboards.

Models Covered:

Mercury Merc 3.5 (1972-1989)
Mercury Merc 3.6 (1972-1989)
Mercury Merc 4 (40) (1972-1989)
Mercury Merc 4.5 (45) (1972-1989)
Mercury Merc 5 (1972-1989)
Mercury Merc 6 (1972-1989)
Mercury Merc 7.5 (75) (1972-1989)
Mercury Merc 8 (1972-1989)
Mercury Merc 9.8 (110) (1972-1989)
Mercury Merc 9.9 (1972-1989)
Mercury Merc 15 (1972-1989)
Mercury Merc 18 (1972-1989)
Mercury Merc 20 (200) (1972-1989)
Mercury Merc 25 (1972-1989)
Mercury Merc 35 (1972-1989)
Mercury Merc 40 (402) (1972-1989)

Manual Contents:

QUICK REFERENCE DATA

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

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

CHAPTER THREE / TROUBLESHOOTING
Operating requirements / Starting system / Charging system / Ignition system / Phase-maker ignition troubleshooting / Thunderbolt flywheel CD ignition troubleshooting / Fuel system / Engine

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Model changes and redesignation / Lubrication / Fuel selection / Gasahol / Recommended fuel mixture / Fuel mixing procedures / AutoBlend oil injection / Lower drive unit lubrication / Salt water corrosion of gear housing bearing carrier and nut / Winter storage / Anti-corrosion maintenance / Complete submersion / Engine flushing / Tune-up / Compression test / Spark plugs / Lower unit and water pump check / Fuel system service / Fuel line service / Fuel filter service / Fuel pump / Ignition service / Maker-Point ignition / Battery, Starter and solenoid (electric start models only) / Timing, synchronization and adjustment / On-boat performance test / Specifications

CHAPTER FIVE / TIMING, SYNCHRONIZATION AND ADJUSTING
Engine timing / Synchronizing / Required equipment / Mercury 3.5 and 3.6 hp / Mercury 40 and 2-cylinder 4 hp with Thunderbolt breakerless ignition / Mercury 45, 4.5 and 4 (1986-1987) / Merc model 40, 75, and 110 with Phase-maker ignition / Merc 4 and 5 hp (1988-on) / Merc model 75 and 7.5 hp (through serial No. 5226934); Merc model 110 and 9.8 hp (through serial No. 5206549) / Mercury 7.5 hp (above serial No. 5226934); Mercury 9.8 hp (above serial No. 5206549) / Mercury 6, 8, 9.9 and 15 hp / Mercury 18 and 25 hp (1979-1984) / Mercury 18, 20 and 25 hp (with WMC carburetor) / Mercury 200 with Phase-maker ignition / Merc model 200 and 20 hp (1979-1980) with Thunderbolt breakerless ignition / Merc model 402, 35 and 40 hp / Specifications

CHAPTER SIX / FUEL SYSTEM
Fuel pump / Carburetors / Integral fuel pump carburetor (original design) / Integral fuel pump carburetor (1979-1985 Merc 18 and 25 hp) / Centerbowl carburetor (Merc 4 hp 2-cylinder model) / Sidebowl carburetor / 3.5 and 3.6 hp carburetor / Integral fuel pump carburetor (with primer system) / Integral fuel pump carburetor (1988-on Merc 4 and 5 hp) / Sight bowl fuel filter / Anti-siphon devices / Fuel tank / Fuel line and primer bulb / Specifications

CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS
Battery / Battery charging system / Electric starting system / Ignition system / Thunderbolt Phase-maker CD ignition system / Thunderbolt CD breakerless ignition system / Specifications

CHAPTER EIGHT / POWER HEAD
Engine serial number / Gaskets and sealants / Power head / Specifications

CHAPTER NINE / LOWER UNIT
Service precautions / Gear housing / Water pump / Bearing carrier and propeller shaft / Pinion gear, drive shaft and forward gear / Shift shaft, bushing and cam / Pinion depth/gear backlash / Propeller / Specifications

CHAPTER TEN / AUTOMATIC REWIND STARTERS
Merc 3.5 and 3.6 hp / Merc 4 and 5 hp (1988-on) / Merc 6, 8, 9.9, 15, 18, 20 (1986-on) and 25 hp / Merc 2-cylinder 4 hp / Merc 4.5, 45, 7.5, 75, 9.8, 110, 200, 20 (1979-1980), 402, 35 and 40 / Shift interlock adjustment / Specifications

CHAPTER ELEVEN / MERC THRUSTER ELECTRIC OUTBOARDS
Lubrication / Periodic maintenance / Battery / Propeller / Electrical troubleshooting / Electrical component testing (variable speed control models) / Electrical component testing rotary switch models / Lower unit / Control housing / Specifications

INDEX

WIRING DIAGRAMS

This manual can be used by anyone from a first time owner/amateur to a professional technician.Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings.Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

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File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English