Description
This printed 1972-1989 Mercury 3.5hp – 40hp Outboard Boat Engine Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1972-1989 Mercury 3.5-40hp gas powered outboard boat engines including Mercury electric boat motors.
Boat engine models covered include Mercury Merc 3.5, Merc 3.6, Merc 4 (40), Merc 4.5 (45), Merc 5, Merc 6, Merc 7.5 (75), Merc 8, Merc 9.8 (110), Merc 9.9, Merc 15, Merc 18, Merc 20 (200), Merc 25, Merc 35, and Merc 40 (402).
Engines Manufactured from the following years are covered:
1972 1973 1974 1975 1976 1977 1978 1979
1980 1981 1982 1983 1984 1985 1986 1987 1988 1989
This Clymer Mercury Outboard Boat Engine manual includes general information about each model, tools and techniques, troubleshooting, lubrication, maintenance and tune-up, timing, synchronizing and adjusting, fuel system, ignition and electrical systems, power head, lower unit, automatic rewind starter, Merc Thruster electric outboards and complete wiring diagrams. Features 368 illustrated pages.
Table of 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
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, 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, AutoBlend oil injection, Winter storage, Anti-corrosion maintenance, Complete submersion, Engine flushing, Tune-up
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
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
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
CHAPTER EIGHT, POWER HEAD
Engine serial number, Gaskets and sealants, Power head
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
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
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, Lower unit, Control housing
INDEX
WIRING DIAGRAMS
