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FourStroke 3.5
Mercury FourStroke 3.5 User Manual
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2.5/3.5
F
ourStroke
Serial
Number
0R448033
and
Above
90-8M0065421
NOVEMBER 2012
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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
Boat Horsepower Capacity
39
Boat Transom Height Requirement
39
Installing the Outboard
39
Installing the Outboard on the Transom
39
Selecting Accessories for Your Outboard
39
Engine Overspeed Protection System
40
Tilt Pin Adjustment
40
Installation Drawings
41
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
4
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Mercury FourStroke 3.5 Specifications
General
Brand
Mercury
Model
FourStroke 3.5
Category
Outboard Motor
Language
English
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