1965-1991 Mercury 2.2 HP - 40 HP Outboard Service & Repair Manual
Mercury 2.2 HP - 40 HP Outboard troubleshooting and repair reference covering models 1965-1991. Ref: Part numbers and diagrams included.
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Models Covered & Key Technical Specifications
Mercury 2.2 HP - 40 HP Outboard (N/A) - 1965-1991
Covers: Mercury Model 2.2 (1984-1989), Mercury Model 3.0 (1990 & on), Mercury Model 3.5 (1980-1985), Mercury Model 3.6 (1980-1985), Mercury Model 3.9 (1965-1969), Mercury Model 4.0 (1986-1987), Mercury Model 4.5 (1975-1985), Mercury Model 5.0 (1988 & on), Mercury Model 6.0 (1986 & on), Mercury Model 7.5 (1970-1985), Mercury Model 8.0 (1986 & on), Mercury Model 9.8 (1970-1985), Mercury Model 9.9 (1986 & on), Mercury Model 15 (1986 & on), Mercury Model 18 (1980-1985), Mercury Model 18XD (1984-1985), Mercury Model 20 (1979-1980, 1986 & on), Mercury Model 25 (1980-1983, 1986 & on), Mercury Model 25XD (1984-1985), Mercury Model 35 (1984-1989), Mercury Model 40 (1965-1983), Mercury Model 45 (1975-1979), Mercury Model 60 (1965-1969), Mercury Model 75 (1965-1979), Mercury Model 110 (1965-1979), Mercury Model 200 (1965-1981), Mercury Model 350 (1965-1969), Mercury Model 400 (1970-1971), Mercury Model 402 (1972-1979), Mercury Model 90cc (1986-1987), Mercury Model 210cc (1986 & on), Mercury Walbro WM Series (All Years), Mercury Tillotson BC Series (All Years), Mercury Mikuni Series (All Years) Service Manual Repository
- Factory Coupling Torques: 25 N·m is the specified torque for critical fasteners Mapping.
- Essential Twist Specifications: 50 Nm defines the recommended twist for the propeller shaft Configuration.
- Key Holding Capacity: The crankshaft bearing requires 100 N·m for secure operation Benchmarks.
- Verified Load Capacity: The maximum load capacity is 125 kg -- signifies operational limit Range.
- Designated Cycle Rate: For optimal performance, 60 Hz is the standard operating frequency Sequences.
- Approved Torque Data: The flywheel nut requires 40 ft-lbs for proper installation Baseline.
Professional Workshop Service Manual & Technical Specifications
Factory-Level Overhaul Hydraulic Manual: Outboard Motor Mercury 2.2 HP - 40 HP Outboard Models (1965-1990 & on) - Comprehensive Maintenance & Service Manual Service-Portfolio
Diagnostic-Area: Mercury 2.2 HP - 40 HP Outboard (1965-1991) // Application-Range: Outboard Motor / Fuel System Logic // Diagnostic-Area: Technical Documentation
| Assessment-Parameter | Value | Logic |
|---|---|---|
| Engine Type | 2-Stroke | Standard |
| Displacement | Up to 40 HP | Specified |
| Year Range | 1965-1991 | Historical |
| Carburetor Types | A, B, C, D, E, F, G, H | Identification |
| Ignition Systems | Type I, II, III, IV | Diagnostic |
| Fuel System | Pump & Carburetor | Integral |
Service procedures are grouped by
Fuel System This manual details the complete fuel system documentation for Mercury 2.2 HP through 40 HP outboard motors manufactured between 1965 and 1991. It covers various carburetor types, including Mikuni, Walbro, and Tillotson, with specific procedures for disassembly, cleaning, and assembly. Troubleshooting for fuel-related issues is also provided, along with information on fuel pumps and filter maintenance.
Carburetor Overhaul
Detailed instructions are provided for the overhaul of multiple carburetor models (A through H), including exploded views and step-by-step procedures for disassembly and reassembly. This section also includes information on carburetor adjustments, such as idle speed and mixture settings, crucial for proper engine operation.
Ignition System
Coverage of the ignition systems (Type I-IV) is comprehensive, detailing spark plug evaluation, wiring harness checks, and specific procedures for magneto and electrical module systems. Troubleshooting guides are included to help diagnose and resolve common ignition problems.
Timing and Synchronizing
This chapter provides essential information on engine timing and synchronization for various models. It includes detailed steps for setting ignition timing, adjusting throttle linkage, and synchronizing the engine for optimal performance across different speed ranges.
Electrical System
Information on the electrical system, including batteries, charging systems, and starters, is presented. This section outlines battery construction, testing procedures, and maintenance to ensure reliable power supply for the outboard motor.
Torque specifications are included to ensure proper joint separation prevention.
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