Mercury 45 Jet 50-55 - Design II

Mercury 45 Jet 50-55

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51645

MID-SECTION - 5C-590-817643R1 DECEMBER 1996

Design II

Table of Contents

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

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