Mercury FourStroke F3.5 MLH Manuals

Manuals and User Guides for Mercury FourStroke F3.5 MLH. We have 1 Mercury FourStroke F3.5 MLH manual available for free PDF download: Service Manual

Mercury FourStroke F3.5 MLH Service Manual

Mercury FourStroke F3.5 MLH Service Manual (205 pages)

Brand: Mercury | Category: Outboard Motor | Size: 19.62 MB

Table of Contents

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

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