FREE Shipping!*
exclusions apply

Product Category

Contact Us
Mon-Fri 10:30 A.M. to 4:30 P.M. Central Standard Time 888-659-2953 Email us: Sales@TheManualStore.com
 

  Home > Boat Manual > Outboard Manual > Mercury >

  Mercury Outboard Manual 1972-1989 3.5-40 HP
Mercury Outboard Repair Manual 1972-1989
Learn How to Winterize your Boat Motor
With Winterization Instructions



 
Buy this shop manual online today and get FREE SHIPPING.

Our Price: $34.95
Sale Price: $31.99
You save $2.96!

Availability:: Usually Ships in 24 Hours
Product Code: B721

Description
 

Mercury Outboard Service and Repair Manual

This Clymer outboard shop manual covers Mercury 3.5-40 horsepower engines for the years 1972-1989.
Includes Electric Motors

Models Included are:
MERCURY Merc 15
MERCURY Merc 18
MERCURY Merc 20 (200)
MERCURY Merc 25
MERCURY Merc 3.5
MERCURY Merc 3.6
MERCURY Merc 35
MERCURY Merc 4 (40)
MERCURY Merc 4.5 (45)
MERCURY Merc 40 (402)
MERCURY Merc 5
MERCURY Merc 6
MERCURY Merc 7.5 (75)
MERCURY Merc 8
MERCURY Merc 9.8 (110)
MERCURY Merc 9.9


The Mercury 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.

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 | 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 models | Lower unit | Control housing

INDEX

WIRING DIAGRAMS

Publisher: Clymer Manuals 1989
Binding: Paperback 8 x 10 inches
Pages: 352 Hundreds of b&w photos and illustrations
ISBN: 0892873957

The Mercury outboard service and repair manual applies to the following years:
1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989


Share your knowledge of this product with other customers... Be the first to write a review

Browse for more products in the same category as this item:

Boat Manual > Outboard Manual > Mercury
Clymer Manuals
Boat Manual > Outboard Manual
Boat Manual