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Mercury FourStroke 3.5 User Manual

Mercury FourStroke 3.5
205 pages
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2.5/3.5
FourStroke
Serial Number 0R448033 and Above
90-8M0065421 NOVEMBER 2012
2.5/3.5 FourStroke
©2012, Mercury Marine. All rights reserved. Printed in U.S.A. 90-8M0065421 NOVEMBER 2012
www.mercurymarine.com.au
41-71 Bessemer Drive
Dandenong South, Victoria 3175 Australia
www.mercurymarine.com
P.O. Box 1939
Fond du Lac, WI 54936-1939 USA
www.marinepower.com
Parc Industriel de Petit-Rechain
B-4800 Verviers, Belgium

Table of Contents

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Mercury FourStroke 3.5 Specifications

General IconGeneral
BrandMercury
ModelFourStroke 3.5
CategoryOutboard Motor
LanguageEnglish

Summary

Important Information

Section 1A - Master Specifications

Provides detailed technical specifications for the engine's components and systems.

Model Specifications

Key performance and dimensional data for the 2.5/3.5 HP FourStroke models.

Section 1B - Maintenance

Procedures for routine checks, adjustments, and replacement of wear items.

Inspection and Maintenance Schedule

A schedule outlining maintenance tasks based on usage hours or time.

Section 1D - Outboard Installation

Guidance on installing the outboard motor onto a boat's transom.

Electrical

Section 2A - Ignition

Details on the ignition system, including specifications and component servicing.

Ignition Specifications

Key parameters for the ignition system such as timing and coil resistance.

Fuel System

Section 3A - Carburetor and Fuel Pump

Information on carburetor and fuel pump components and servicing.

Carburetor Specifications

Detailed specifications for carburetor adjustments and settings.

Carburetor Removal and Installation

Steps for removing and installing the carburetor on the engine.

Powerhead

Section 4A - Powerhead

Detailed procedures for servicing the engine's powerhead components.

Camshaft and Valve Specifications

Technical data for camshaft, valves, and related components.

Piston Specifications

Measurements and clearances for pistons, piston pins, and rings.

Crankshaft, Piston, and Connecting Rod Components

Diagram and specifications for crankshaft, connecting rod, and piston assembly.

Powerhead Removal

Step-by-step guide for safely removing the powerhead from the engine.

Midsection

Section 5A - Clamp/Swivel Bracket and Driveshaft Housing

Service procedures for the midsection components.

Lower Unit

Section 6A - Gear Housing

Comprehensive guide to servicing the gear housing assembly.

Gear Housing Disassembly

Detailed instructions for disassembling the gear housing.

Manual Starter

Section 8A - Recoil Starter

Information on the recoil starter system and its components.

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