by Randy Stephens and Sydnie A Wauson
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Mercury 3.5 - 40 HP Outboards (Includes Electric Motors) 1972 - 1989 Clymer Owners Marine Service & Repair Manual covers the following models, including electric motors.
● Mercury Merc 3.5 (1972-1989)
● Mercury Merc 3.6 (1972-1989)
● Mercury Merc 4 (40) (1972-1989)
● Mercury Merc 4.5 (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 9.8 (110) (1972-1989)
● Mercury Merc 9.9 (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)
● QUICK REFERENCE DATA
● GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Protection from galvanic corrosion / Propellers / Specifications
● TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques / Specifications
Operating requirements / Starting system / Charging system / Ignition system / Phase-maker ignition troubleshooting / Thunderbolt flywheel CD ignition troubleshooting / Fuel system / Engine
● 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
● 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 / Specifications
● 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 / Specifications
● 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
● POWER HEAD
Engine serial number / Gaskets and sealants / Power head / Specifications
● 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
● 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 / Specifications
● 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
● WIRING DIAGRAMS
Clymer marine manuals can save you money on maintenance and repair. Step-by-step procedures and detailed illustrations guide you through every job, from routine maintenance and troubleshooting, all the way to complete teardown & rebuild.
Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.
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