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 / Mechanics 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