Mercury 45 Jet 50-55 - Oil Warning Module; Removal;Installation

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90-817643R1 DECEMBER 19963D-12 - FUEL SYSTEMS

Oil Warning Module

Removal/Installation

1. Disconnect battery cables.

51084

2. Disconnect warning module PURPLE, TAN and both

BLUE leads at bullet connectors. Remove warning

module from lower cowl.

50430

51204

a - Warning Module

b - Warning Module Leads

c - Screws

d - Ground Wire

3. Connect PURPLE, TAN and both BLUE leads at

respective bullet connectors. Secure warning module

BLACK lead to switch box mounting bolt and install

warning module.Tighten bolts securely.

51204

50430

a - Warning Module

b - Warning Module Leads

c - Screws

d - Ground Wire (BLACK)

4. Re-connect battery cables.

51084

Main Page

General Information 14
- Table of Contents4
- Propeller Information5
- How to Use this Manual5
- Page Numbering5
- Master Specifications6
- Powerhead8
- Lubrication Points18
- Painting Procedures27
- Decal Application28
Electrical and Ignition 230
- Description31
- Test Procedures31
- ADI Ignition Using a RED Stator with an Adapter Module35
- RED Stator with Adaptor and Ignition Coils36
- Ignition (Key) Switch Test37
- Ignition Components Removal and Installation37
Electrical 243
- Battery44
- Battery Charging System46
- Starting System55
- Starter Motor58
Electrical and Ignition 265
- Special Tools66
- Specifications66
- Timing Pointer Adjustment66
- Timing/Synchronizing/Adjusting66
- Carburetor Synchronization67
- Timing Adjustments68
  - Idle Timing Adjustment68
  - Maximum Timing69
- Idle Adjustment69
- Throttle Cable Installation69
Electrical and Ignition 271
- Model 45 Jet Electric Start Wiring Diagram72
- Model 50/60 Electric Start Wiring Diagram (Rectifier Models)73
- Model 50/60 Electric Start Wiring Diagram (Regulator Models)74
- Model 55 Manual Start Wiring Diagram76
- Wiring Diagram76
- Model 50/60 Power Trim Wiring Diagram79
- Wiring Diagram79
- (COMMANDER 2000 Side Mount Remote Control)80
- Key/Choke Switch Continuity Test80
- COMMANDER 2000 Side Mount Remote Control81
- Wiring Diagram81
- COMMANDER 2000 Side Mount Remote Control (Electric Start with Warning Horn) Wiring Diagram83
- COMMANDER Side Mount Remote Control83
- Wiring Diagram83
Fuel Systems85
- Special Tools86
- Specifications86
- Attenuator Plate87
- WME Carburetor Specifications89
  - Reed Valve Specifications89
- Notes90
- Carburetor91
- Carburetion93
- WME Carburetor Specifications97
Fuel Systems104
- Specifications105
- Fuel Pump (50/60)106
- Fuel Pump (55/60 Seapro/Marathon)108
- Fuel Pumps110
- Cleaning and Inspection112
- Fuel Pump Disassembly112
- Fuel Pump Removal112
- Fuel Pump Reassembly113
  - Check Valve Assembly113
  - Fuel Pump Assembly113
- Fuel Pump Exploded View114
- Fuel Tank115
  - Maintenance115
- Fuel Tank Components115
- Fuel Line and Primer Bulb Assembly116
  - Maintenance117
    - Enrichener System120
    - Enrichener Valve Test121
Fuel Systems123
- Operation of the Injection System124
- Set up Instructions for Oil Injection System131
- Outboard Operation132
  - Check Operation of the Oil Injection System (Engine Running)132
  - Required Side Mount Remote Control or Ignition Key Switch Assembly133
- Oil Injection System Troubleshooting Chart133
  - Troubleshooting the Oil Injection System133
- Installing Drive Gear (for Oil Injection Pump) Onto Crankshaft134
- Oil Warning Module135
  - Removal/Installation135
- Engine Mounted Oil Reservoir136
  - Removal136
  - Installation137
Powerhead139
- Quicksilver Lubricants and Service Aids140
- Special Tools140
- Specifications140
- Cylinder Block and Crankcase141
- Induction Manifold and Reed Block145
- Crankshaft, Pistons and Connecting Rods147
- Throttle Lever and Linkage149
- Powerhead Torque Sequence151
- General Information152
  - ELPTO Model152
- Powerhead Disassembly155
  - Removing Engine Components155
  - Crankshaft Disassembly157
- Cleaning and Inspection160
- Powerhead Reassembly and Installation165
- Important Information177
- Test Run Procedure177
MID-Section179
- MID-Section Components180
  - Swivel Bracket Components180
  - Transom Bracket Components (50/60 Models)182
- MID-Section Components182
  - Drive Shaft Housing Components183
- Disassembly184
- Reassembly184
  - Tilt Lock Lever/Transom Bracket184
- Drive Shaft Housing186
MID-Section188
- Power Trim General Information189
- Power Trim System Components191
  - Torque Specifications191
  - Quicksilver Lubricants and Service Aids191
- Power Trim Flow Diagrams Design192
- Electrical System Troubleshooting204
  - COMMANDER 2000 Side Mount Remote204
  - Power Trim System Wiring Diagram205
- Power Trim System Removal209
- Power Trim System Disassembly210
- Cleaning and Inspection of Trim Rod Components216
- Motor and Electrical Tests/Repair217
- Power Trim System Reassembly218
- Bleeding Power Trim Unit225
  - Power Trim Unit Installation225
MID-Section228
- Power Trim General Information229
- Design II232
- Design II233
- Design II234
- Design II235
- Design II236
- Design II237
- Troubleshooting239
- Electrical System Troubleshooting244
  - COMMANDER 2000 Side Mount Remote244
  - Power Trim System Wiring Diagram245
- Power Trim System Removal249
- Power Trim System Disassembly250
- Cleaning and Inspection of Trim Rod Components256
- Motor and Electrical Tests/Repair257
- Power Trim System Reassembly258
- Bleeding Power Trim Unit264
  - Power Trim Unit Installation265
MID-Section268
- Power Trim - General Information269
- Special Tools269
- Troubleshooting272
- Power Trim System Removal282
- Power Trim System Disassembly283
- Cleaning and Inspection of Trim Rod Components288
- Motor and Electrical Tests/Repair288
  - Trim Pump Motor Test288
  - Armature Tests288
- Power Trim System Reassembly289
- Purging Power Trim Unit294
  - Power Trim Unit Installation294
MID-Section298
- Special Tools299
- Adjustments302
- Theory of Operation302
- Troubleshooting318
- Power Trim System Removal325
- Power Trim Disassembly326
- Shock Rod Disassembly329
  - Memory Piston Removal331
- Cleaning/Inspection/Repair332
  - Trim Motor Electrical Tests332
- Reassembly333
  - O-Ring and Seal Placement333
- O-Ring Sizes334
- O-Ring Description and Sizes335
- Power Trim Reassembly336
- Installation of Power Trim System341
MID-Section345
- Manual Tilt System Components345
- Manual Tilt Flow Diagrams Design348
- Manual Tilt Flow Diagrams Design353
- Manual Tilt Flow Diagrams Design358
- Hydraulic System Troubleshooting363
- Troubleshooting Flow Chart364
- Manual Tilt System Removal366
- Manual Tilt System Disassembly367
  - Accumulator Removal367
- Shock Rod Disassembly369
  - Valve Block Removal371
- Valve Block Disassembly372
- Manual Tilt System Cleaning and Inspection373
- Manual Tilt System Reassembly373
- Instructions for Making Retaining Tool378
- Bleeding Manual Tilt System379
MID-Section383
- Special Tools384
- Hydraulic System Troubleshooting399
- Manual Tilt System Removal400
- Manual Tilt System Disassembly401
  - Accumulator Removal401
  - Shock Rod Removal402
- Shock Rod Disassembly403
  - Valve Block Removal405
  - Memory Piston Removal405
- Valve Block Disassembly406
- Actual O-Ring Sizes408
- O-Ring Description and Sizes409
- Manual Tilt System Cleaning and Inspection410
- Manual Tilt System Reassembly410
- Instructions for Making415
- Retaining Tool415
- Bleeding Manual Tilt System416
- Manual Tilt System Installation418
- Manual Release Valve Adjustment419
Lower Unit421
- Lubrication/Sealant Application Points423
- Propeller Shaft Components423
- Torque Specifications423
- Draining and Inspecting Gear Lubricant426
- Gear Housing Removal427
- Propeller Removal427
- Gear Housing Disassembly428
- Gear Housing Reassembly434
- Gear Housing Installation445
- Gear Housing Pressure Test445
Lower Unit450
- Notes451
- Gear Housing (Drive Shaft)453
- Gear Housing (Propeller Shaft)455
- Removal458
- Special Tools458
- Reassembly468
- Filling Gear Housing with Lubricant481
- Propeller Installation482
- Gearcase Installation483
  - Trim Tab Adjustment484
Lower Unit486
- Notes487
- Jet Pump Assembly488
- Jet Components490
- Engine Horsepower Selection491
- Selecting a Boat Best Suited for Jet Power491
- Locate Center Line of the Outboard492
- Outboard Mounting Height492
- Transom Height of the Boat492
- Checking for Cavitation493
- Water Testing493
- Shift Cable Installation494
- Impeller Removal and Installation495
- Lubricating the Drive Shaft Bearing495
- Impeller Clearance Adjustment497
- Steering Pull Adjustment497
- Worn (Dull) Impeller497
- Flushing the Cooling System498
- Jet Drive Removal498
- Liner Replacement498
- Bearing Carrier Removal499
- Bearing Carrier Disassembly500
- Bearing Carrier Reassembly500
  - Installing Lower Seals500
  - Installing Upper Seals501
  - Installing Drive Shaft Ball Bearing501
  - Installing Drive Shaft501
- Installing Jet Drive to Drive Shaft Housing503
  - Reassembling Water Pump to Jet Drive . 6C-17503
  - Installing Jet Drive to Drive Shaft Housing 6C-18504
- Jet Drive Tiller Handle Adaptor Kit506
  - Installation Instructions506
  - Shift Cable Adjustment509
Outboard Installation/ Attachments511
- Installing Outboard Motor on Transom512
- Steering Cable Installation516
- Dual Steering Installation520
- Transom Mounted Ride-Guide Attaching Kit Installation524
  - Attaching Kit Installation524
- Clevis Attaching Kit Installation525
- Remote Control Installation527

Mercury 45 Jet 50-55 - Oil Warning Module; Removal;Installation

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