Mercury Mariner 3.5HP – 40HP Outboards (INCLUDES ELECTRIC MOTORS) Service Repair Manual (1972-1989)

Download Complete Service Repair Manual for Mercury 35HP – 40HP Outboards

This Factory Service Repair Manual offers all the service and repair information about Mercury 35HP – 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 35 (1972-1989)
Mercury Merc 36 (1972-1989)
Mercury Merc 4 (40) (1972-1989)
Mercury Merc 45 (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 98 (110) (1972-1989)
Mercury Merc 99 (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 36 hp / Mercury 40 and 2-cylinder 4 hp with Thunderbolt breakerless ignition / Mercury 45 45 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 98 hp (through serial No 5206549) / Mercury 75 hp (above serial No 5226934); Mercury 98 hp (above serial No 5206549) / Mercury 6 8 99 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 36 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 36 hp / Merc 4 and 5 hp (1988-on) / Merc 6 8 99 15 18 20 (1986-on) and 25 hp / Merc 2-cylinder 4 hp / Merc 45 45 75 75 98 110 200 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 drawingsKeep 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