Product Description
Overview
Clymer Marine and PWC manuals are the #1 source for DIY maintenance, troubleshooting and repair. With step-by-step procedures combined with detailed photography and extensive use of exploded parts views, Clymer manuals are a must-have tool for the do-it-yourselfer.
QUICK REFERENCE DATA
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 / Specifications
CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques / Specifications
CHAPTER THREE / TROUBLESHOOTING
Operating requirements / Starting system / Charging system / Ignition system / Fuel system / Engine temperature and overheating / Engine / Specifications
CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Fuel selection / Recommended fuel mixture / Correct fuel mixing / Gearcase lubrication / Salt water corrosion of gearcase bearing carrier and nut / Storage / Anti-corrosion maintenance / Complete submersion / Engine flushing / Tune-up Compression check / Spark plugs / Gearcase and water pump check / Fuel system service / Fuel filter service/ Fuel lines / Fuel pump service / Breaker point ignition service / Breaker point replacement / Breaker point adjustment / Battery, starter and solenoid (electric start models only) / Choke solenoid resistance check / On-boat performance test / Specifications
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 / Specifications
CHAPTER SIX / FUEL SYSTEM
Fuel pump / Sidebowl carburetor / Integral fuel pump carburetor / Fuel tank / Fuel line and primer bulb / Specifications
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 / Specifications
CHAPTER EIGHT / POWER HEAD
Engine serial number / Fasteners and torque / Gaskets and sealant / Flywheel / Power head / Specifications
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 / Specifications
CHAPTER TEN / AUTOMATIC REWIND STARTER
CHAPTER ELEVEN / POWER TRIM AND TILT SYSTEM
Power trim system / Hydraulic pump / Troubleshooting / Trim limit switch / Trim cylinders / Specifications
INDEX
WIRING DIAGRAMS
This manual covers nearly 60 Mercury 2-Stroke Outboard Motors ranging from 3.9-135 HP.
Models covered:
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 3.9 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 4 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 6 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 7.5 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 9.8
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 20 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 35 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 40 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 50 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 65 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 80 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 85 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 90 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 95 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 100 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 110 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 115 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 125 HP
1964 1965 1966 1967 1968 1969 1970 1971 Mercury 135 HP
Clymer Manuals Mercury 3.9 HP Manual
Clymer Manuals Mercury 4 HP Manual
Clymer Manuals Mercury 6 HP Manual
Clymer Manuals Mercury 7.5 HP Manual
Clymer Manuals Mercury 9.8 Manual
Clymer Manuals Mercury 20 HP Manual
Clymer Manuals Mercury 35 HP Manual
Clymer Manuals Mercury 40 HP Manual
Clymer Manuals Mercury 50 HP Manual
Clymer Manuals Mercury 65 HP Manual
Clymer Manuals Mercury 80 HP Manual
Clymer Manuals Mercury 85 HP Manual
Clymer Manuals Mercury 90 HP Manual
Clymer Manuals Mercury 95 HP Manual
Clymer Manuals Mercury 100 HP Manual
Clymer Manuals Mercury 110 HP Manual
Clymer Manuals Mercury 115 HP Manual
Clymer Manuals Mercury 125 HP Manual
Clymer Manuals Mercury 135 HP Manual
Mercury 3.9 HP (1964-1971)
Mercury 4 HP (1964-1971)
Mercury 6 HP (1964-1971)
Mercury 7.5 HP (1964-1971)
Mercury 9.8 (1964-1971)
Mercury 20 HP (1964-1971)
Mercury 35 HP (1964-1971)
Mercury 40 HP (1964-1971)
Mercury 50 HP (1964-1971)
Mercury 65 HP (1964-1971)
Mercury 80 HP (1964-1971)
Mercury 85 HP (1964-1971)
Mercury 90 HP (1964-1971)
Mercury 95 HP (1964-1971)
Mercury 100 HP (1964-1971)
Mercury 110 HP (1964-1971)
Mercury 115 HP (1964-1971)
Mercury 125 HP (1964-1971)
Mercury 135 HP (1964-1971)
