Mercury FourStroke 3.5 Manuals

Manuals and User Guides for Mercury FourStroke 3.5. We have 3 Mercury FourStroke 3.5 manuals available for free PDF download: Service Manual, Operation, Maintenance & Installation Manual, Brochure & Specs

Mercury FourStroke 3.5 Service Manual (205 pages)

Brand: Mercury | Category: Outboard Motor | Size: 19 MB

Important Information 1

6
- Table of Contents
  6
- Model Specifications
  7
- Ignition Specifications
  7
- Cooling System Specifications
  8
- Carburetor Specifications
  8
- Cylinder Block Specifications
  9
- Piston Specifications
  10
- Camshaft and Valve Specifications
  11
- Gear Housing Specifications
  11
- Propellers
  12
Important Information 1

14
- Before each Use
  15
- Emission Certification Label
  15
- EPA Emission Regulations
  15
- Inspection and Maintenance Schedule
  15
- Owner Responsibility
  15
- Selecting Accessories for Your Outboard
  15
- After each Use
  16
- Before Periods of Storage
  16
- Every 100 Hours of Use or Once Yearly, Whichever Occurs First
  16
- Exterior Care
  16
- Flushing the Cooling System
  16
- Submerged Outboard
  16
- Engine Oil Recommendations
  17
- Installation
  17
- Removal
  17
- Top Cowl Removal and Installation
  17
- Changing Engine Oil
  18
- Checking Engine Oil
  18
- Engine Oil Capacity
  18
- Oil Changing Procedure
  18
- Oil Filling
  18
- Corrosion Control Anode
  19
- Spark Plug Inspection and Replacement
  19
- Propeller Replacement
  20
- Draining Gearcase
  21
- Gearcase Lubrication
  21
- Checking Lubricant Level and Refilling Gearcase
  22
- Gearcase Lubricant Capacity
  22
- Lubrication Points
  22
- Fuel System
  23
- Storage Preparation
  23
- Gearcase
  24
- Positioning Outboard for Storage
  24
- Protecting External Outboard Components
  24
- Protecting Internal Engine Components
  24
Important Information 1

26
- 2/2.5/3.5 Fourstroke Front View
  27
- Component Identification
  27
- 2/2.5/3.5 Fourstroke Starboard View
  28
- 2/2.5/3.5 Fourstroke Aft View
  29
- 2/2.5/3.5 Fourstroke Port View
  30
- 2/2.5/3.5 Fourstroke Top View
  31
- Conditions Affecting Performance
  31
- Weather
  31
- Bottom of Boat
  32
- Cavitation
  32
- Detonation
  32
- Elevation and Climate
  32
- Water Absorption
  32
- Weight Distribution (Passengers and Gear) Inside the Boat
  32
- Engine Submerged While Running (Special Instructions)
  33
- Following Complete Submersion
  33
- Fresh Water Submersion (Special Instructions)
  33
- Propeller Selection
  33
- Saltwater Submersion (Special Instructions)
  33
- Compression Check
  34
- Cylinder Leakage Testing
  34
- Painting Procedures
  34
- Propellers
  34
- Application Temperature
  35
- Decal Removal
  35
- Gear Housing
  35
- Step One General Cleaning
  35
- Step Two Solvent Cleaning
  35
- Surface Preparation
  35
- Application Tips
  36
- Applying the Decal
  36
- Decal Application
  36
- Cleaning and Maintenance
  37
- Entrapped Air Removal
  37
- Final Decal Squeegee
  37
- General Cleaning Instruction
  37
Important Information 1

38
Electrical 2

42
- Ignition Specifications
  43
- Flywheel and Ignition Components
  45
- Flywheel Removal and Installation
  47
- Ignition System Description
  47
- Removal
  47
- Installation
  48
- Ignition Coil Replacement
  49
- Removal
  49
- Installation
  50
- Ignition Coil Testing
  52
- Secondary Resistance
  52
- Checking Ignition Timing
  53
Fuel System 3

54
- Carburetor Specifications
  55
- Carburetor Components
  57
- Fuel Tank Components
  59
- Carburetor Adjustments
  61
- Idle Speed
  61
- Pilot (Idle Mixture) Screw
  61
- Fuel Pump Removal and Installation
  62
- Removal
  62
- Fuel Pump Hoses
  63
- Installation
  63
- Carburetor Removal and Installation
  64
- Removal
  64
- Installation
  65
- Carburetor Disassembly
  69
- Inspection
  72
- Carburetor Assembly
  73
Powerhead

82
- Camshaft and Valve Specifications
  83
- Cooling System Specifications
  83
- Piston Specifications
  84
- Cylinder Block Specifications
  85
- Camshaft and Valve Components
  87
- Crankshaft, Piston, and Connecting Rod Components
  89
- Oil Pan Components
  91
- Cylinder Block Components
  93
- Removal
  95
- Thermostat
  95
- Inspection
  96
- Installation
  97
- Valve Clearance Adjustment
  99
- Powerhead Removal
  100
- Oil Pan Removal
  101
- Powerhead Disassembly
  101
- Cylinder Block Disassembly
  102
- Crankshaft/Piston Disassembly
  103
- Valve Lifter/Rocker Arm Disassembly
  104
- Cleaning/Inspection/Repair
  105
- Flywheel
  105
- Cylinder Bore Measurement
  106
- Piston
  106
- Piston Pin
  107
- Piston Rings
  108
- Connecting Rod
  109
- Crankshaft
  109
- Camshaft
  111
- Inspecting the Camshaft and Valves
  111
- Valves
  111
- Lifters and Push Rods
  112
- Valve Springs
  112
- Valve Guides
  113
- Valve Seat Reconditioning
  113
- Piston Assembly
  115
- Piston Ring Installation
  115
- Piston/Crankshaft Reassembly
  115
- Piston/Crankshaft Installation
  116
- Powerhead Assembly
  117
- Valve Train Assembly
  117
- Cylinder Block Assembly
  119
- Driveshaft Seal Replacement
  120
- Oil Pan Installation
  121
- Powerhead Installation
  123
Midsection

126
- Cowling Components
  129
- Clamp Bracket Components
  131
- Driveshaft Housing Components
  133
- Clamp Bracket Removal and Installation
  135
- Reassembly and Installation
  135
- Removal and Disassembly
  135
- Removal
  137
- Swivel Bracket Removal/Installation
  137
- Steering Co-Pilot Components
  138
- Installation
  139
- Steering Stop Components
  139
Lower Unit

142
- Gear Housing Specifications
  143
- Gear Housing (Driveshaft)
  145
- Gear Housing (Propeller Shaft)
  147
- Shift Linkage Components
  149
- Bearings
  151
- Draining and Inspecting the Gear Housing Lubricant
  151
- General Service Recommendations
  151
- Seals
  151
- Shims
  151
- Gear Housing Removal
  152
- Propeller Removal
  152
- Gear Housing Disassembly
  154
- Water Pump
  154
- Bearing Carrier and Propeller Shaft
  156
- Propeller Shaft Disassembly
  158
- Driveshaft, Pinion Gear, and Forward Gear
  159
- Upper Driveshaft Bearing
  160
- Lower Driveshaft Bearing/Forward Gear Bearing
  161
- Forward Gear Bearing
  162
- Gear Housing Assembly
  162
- Lower Driveshaft Bearing
  162
- Propeller Shaft Assembly
  162
- Forward Gear
  163
- Driveshaft
  164
- Bearing Carrier Assembly
  165
- Shift Shaft
  166
- Bearing Carrier
  167
- Forward Gear Backlash
  167
- Propeller Shaft
  167
- Water Pump
  168
- Filling the Gear Housing with Lubricant
  169
- Gear Housing
  169
- Gear Housing Installation
  170
- Propeller Installation
  172
Attachments

174
- Shift Linkage Components
  177
- Shift Linkage Removal
  179
- Shift Linkage Removal and Installation
  179
- Shift Linkage Installation
  180
Attachments

182
- Tiller Handle Components
  185
- Tiller Handle Removal
  187
- Tiller Handle Disassembly
  188
- Tiller Handle Reassembly
  188
- Tiller Handle Installation
  190
- Deceleration Cable
  192
- Throttle Cable Adjustment
  192
- Acceleration Cable
  193
- Recoil Starter Components
  197
- Recoil Starter Removal
  199
- Recoil Starter Spring Replacement
  200
- Removal
  200
- Reassembly
  201
- Recoil Starter Rope Replacement
  202
- Removal
  202
- Reassembly
  203
- Recoil Starter Installation
  204

Mercury FourStroke 3.5 Operation, Maintenance & Installation Manual (60 pages)

Brand: Mercury | Category: Outboard Motor | Size: 3 MB

Table of Contents
7
Boater's Responsibilities
11
Before Operating Your Outboard
11
Boat Horsepower Capacity
11
General Information
11
Lanyard Stop Switch
12
Protecting People in the Water
15
Exhaust Emissions
15
Selecting Accessories for Your Outboard
17
Safe Boating Recommendations
17
Recording Serial Number
20
Model Year Production Code
21
Specifications
21
Installing the Outboard
23
Installation
23
Carrying, Storing, and Transporting the Outboard When Removed from Boat
24
Transporting
24
Trailering the Boat
25
Fuel Requirements
27
Fuel and Oil
27
Special Features of the Fuel Tank
28
Filling the Fuel Tank
29
Engine Oil Recommendations
29
Checking Engine Oil
30
Features and Controls
32
Tilting Outboard
34
Setting the Operating Angle of the Outboard
35
Prestarting Check List
36
Operating in Freezing Temperatures
36
Operating in Saltwater or Polluted Water
36
Operation
36
Engine Break-In Procedure
37
Starting the Engine
37
Gear Shifting
40
Reversing Boat
41
Stopping the Engine
41
Outboard Care
42
EPA Emission Regulations
42
Maintenance
42
Inspection and Maintenance Schedule
43
Flushing the Cooling System
44
Top Cowl Removal and Installation
45
Corrosion Control Anode
46
Exterior Care
46
Propeller Replacement
47
Spark Plug Inspection and Replacement
49
Lubrication Points
50
Changing Engine Oil
51
Gearcase Lubrication
52
Submerged Outboard
53
Storage Preparation
54
Protecting External Outboard Components
54
Protecting Internal Engine Components
54
Storage
54
Gearcase
55
Positioning Outboard for Storage
55
Service Assistance
56
Owner Service Assistance
56
Ordering Literature
58

Mercury FourStroke 3.5 Brochure & Specs (2 pages)

Mercury Marine Outboard Motor User Manual

Brand: Mercury | Category: Outboard Motor | Size: 0 MB

Mercury Categories

Outboard Motor Automobile Engine Marine Equipment Boat

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Mercury FourStroke 3.5 Manuals

Mercury FourStroke 3.5 Service Manual (205 pages)

Table of Contents

Important Information 1

Important Information 1

Important Information 1

Important Information 1

Electrical 2

Fuel System 3

Powerhead

Midsection

Lower Unit

Attachments

Attachments

Mercury FourStroke 3.5 Operation, Maintenance & Installation Manual (60 pages)

Table of Contents

Mercury FourStroke 3.5 Brochure & Specs (2 pages)

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