Mercury Outboard Service and Repair Manual

This Clymer outboard shop manual covers Mercury 3.9-135 horsepower engines for the years 1964-1971.

Models Included are:
MERCURY 100 HP
MERCURY 110 HP
MERCURY 115 HP
MERCURY 125 HP
MERCURY 135 HP
MERCURY 20 HP
MERCURY 3.9 HP
MERCURY 35 HP
MERCURY 4 HP
MERCURY 40 HP
MERCURY 50 HP
MERCURY 6 HP
MERCURY 65 HP
MERCURY 7.5 HP
MERCURY 80 HP
MERCURY 85 HP
MERCURY 9.8
MERCURY 90 HP
MERCURY 95 HP

The Merucry outboard manual by Clymer is a great  reference for repair and service information. This service manual is written for the do-it-yourselfer as well as the experienced mechanic.  The repair manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the engine. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail.  The shop manual will guide mechanics and owners through each service, troubleshooting and repair procedure possible.

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The Mercury outboard manual includes the following chapter information:

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 | Fuel system | Engine temperature and overheating | Engine

CHAPTER FOUR | LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication | Storage | Anti-corrosion maintenance | Complete submersion | Engine flushing | Tune-up

CHAPTER FIVE | TIMING, SYNCHRONIZING AND ADJUSTING
Engine timing | Synchronizing | Required equipment | Merc model 39, 40, 60, 75 and 110 (1964-1969) | 1970 Merc model 40, 75 and 110 with Thunderbolt ignition | Merc model 110 with Phase-maker ignition | Merc model 200 (1967-1966) | Merc model 200 (1967-1969) | Merc model 200 with Thunderbolt ignition | Merc model 200 with Phase-maker ignition | Merc model 350 | Merc model 400 (1970-1971) | Merc model 500 (1964-1967) | Merc model 500 and 650 with lighting energizer ignition | Merc model 650 (1966-1967) | Merc model 650, 800 and 850 with Thunderbolt breakerless ignition | Merc model 950 and 1100 (Standard ignition) | Merc model 950SS and 1100SS (Thunderbolt breaker point ignition) | Merc model 500SS, 650SS, 950SS and 1100SS (1967 Thunderbolt breakerless ignition) | Merc model 1000SS and 1250SS (1968-1969 Thunderbolt breakerless ignition) | Merc model 1150 and 1350

CHAPTER SIX | FUEL SYSTEM
Fuel pump | Sidebowl carburetor | Integral fuel pump carburetor | Fuel tank | Fuel line and primer bulb

CHAPTER SEVEN | IGNITION AND ELECTRICAL SYSTEMS
Battery | Charging system | Starting system | Ignition systems | Phelon magneto braker point ignition | Kiekhaefer 4-cylinder | Kiekhaefer 6-cylinder | Thunderbolt breakerless battery ignition | Lighting energizer breakerless ignition | Thunderbolt Phase-maker CD ignition | Thunderbolt CD breakerless ignition | Ignition coil replacement | Switchbox replacement

CHAPTER EIGHT | POWER HEAD
Engine serial number | Fasteners and torque | Gaskets and sealant | Flywheel | Power head

CHAPTER NINE | GEARCASE AND DRIVE SHAFT HOUSING
Service precautions | Gearcase | Water pump | Bearing carrier and propeller shaft | Pinion gear, drive shaft and forward gear | Shift shaft, bushing and cam | Pinion depth|gear backlash | Propeller | Pressure and vacuum test | Drive shaft housing | Trim tab adjustment

CHAPTER TEN | AUTOMATIC REWIND STARTER

CHAPTER ELEVEN | POWER TRIM AND TILT SYSTEM
Power trim system | Hydraulic pump | Troubleshooting | Trim limit switch | Trim cylinders

INDEX

WIRING DIAGRAMS

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Publisher: Clymer Manuals — 1986
Binding: Paperback — 8¼ x 10¾ inches
Pages: 280 — Hundreds of b&w photos and illustrations
ISBN: 9780892874415

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The Merucry outboard service and repair manual applies to the following years:
1964, 1965, 1966, 1967, 1968, 1969, 1970, 1971

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