Mercury 4.5 Manuals

Manuals and User Guides for Mercury 4.5. We have 6 Mercury 4.5 manuals available for free PDF download: Service Manual, Operation And Maintenance Manual, Operation & Maintenance Manual

Mercury 4.5 Service Manual (599 pages)

Brand: Mercury | Category: Outboard Motor | Size: 16.48 MB

Important Information 1

15
- Cleanliness and Care of Outboard Motor
  3
- Page Numbering
  3
- Table of Contents
  15
- Quicksilver Lubricant/Sealant
  16
- Inspection and Maintenance Schedule
  18
- Before each Use
  18
- After each Use
  18
- Every 100 Hours of Use or Once Yearly, Whichever Occurs First
  19
- Every 300 Hours of Use or Three Years
  19
- Before Periods of Storage
  19
- Corrosion Control Anode
  20
- Spark Plug Inspection
  21
- Battery Inspection
  21
- Timing Belt Inspection
  22
- Fuse Replacement - Electric Start Models
  22
- Lubrication Points
  23
- Checking Power Trim Fluid
  24
- Changing Engine Oil
  25
- Oil Changing Procedure
  25
- Changing Oil Filter
  26
- Oil Filling
  26
- Gear Case Lubrication
  27
- 3-1/4 In. (83Mm) Diameter Gear Case
  27
- 4-1/4 In. (108Mm) Diameter Gear Case
  28
- Gear Case
  30
- Protecting Internal Engine Components
  30
- Protecting External Outboard Components
  30
- Storage Preparation
  30
- Fuel System
  30
- Positioning Outboard for Storage
  31
- Battery Storage
  31
Important Information 1

32
- Conditions Affecting Performance
  33
- Weather
  33
- Boat
  34
- Engine
  35
- Following Complete Submersion
  36
- Fresh Water Submersion (Special Instructions)
  36
- Salt Water Submersion (Special Instructions)
  36
- Submerged While Running (Special Instructions)
  36
- Propeller Selection
  37
- Propeller Removal/Installation
  38
- Standard Models
  38
- General Information
  40
- Power Trim Operation
  40
- Power Trim System
  40
- Trim "In" Angle Adjustment
  41
- Compression Check
  43
- Trim Tab Adjustment
  43
- Analysis
  44
- Cylinder Leakage Testing
  44
- Cleaning & Painting Aluminum Propellers & Gear Housings
  45
- Painting Procedures
  45
- Decal Application
  46
- Decal Removal
  46
- Instructions for "Wet" Application
  46
Important Information 1

48
- Installation Specifications
  49
- Selecting Accessories for the Outboard
  49
- Start in Gear Protection
  49
- Lifting Outboard
  50
- Steering Cable
  50
- Steering Cable Seal
  51
- Steering Link Rod
  51
- Installing Outboard - Thumb Screw Models
  52
- Installing Outboard - Non Thumb Screw Models
  53
- Wiring Harness
  54
- Battery Cable Connections
  55
- Dual Outboards
  55
- Single Outboards
  55
- 45-50 Hp - Shift Cable Installation
  56
- Shift and Throttle Cable 45 and 50 Hp Models
  56
- 45-50 Hp - Throttle Cable Installation
  58
- Trim Tab Adjustment
  60
- Trim-In Stop Adjustment - Power Trim Models
  60
Electrical 2

62
- Specifications
  63
- Special Tools
  64
- Flywheel
  65
- Flywheel
  66
- Electrical Components
  67
- Electrical Components
  68
- Capacitor Discharge Unit (CDI)
  69
- Ignition Component Description
  69
- Ignition Description
  69
- Stator Assembly
  70
- Trigger Coil
  70
- Flywheel Assembly
  71
- Ignition Coil
  71
- Direct Voltage Adapter (DVA)
  72
- Ignition Test Procedures
  72
- Ignition Troubleshooting
  73
- Ignition Diagnostic Procedures
  74
- Recommended Test
  74
- Suggested Testing Procedures
  74
- Resistance Tests
  76
- Testing Ignition Components
  76
- Trigger Coil Test
  76
- Lighting Coil
  77
- Stator Test (Ignition Charge Coil)
  77
- Ignition Coil (Primary)
  78
- Ignition Coil (Secondary)
  78
- Spark Plug Cap Removal
  78
- Spark Plug Cap Resistor Test
  79
- Thermo Switch
  79
- Flywheel Removal
  80
- Flywheel Removal and Installation
  80
- Flywheel Installation
  81
- Flywheel Without Load Ring & Spacer
  81
- Flywheel with Load Ring & Spacer
  82
- (CDI) Unit Removal and Installation
  83
- Ignition Coil Removal and Installation
  84
- Rectifier Removal and Installation
  85
- Stator Removal and Installation
  86
- Trigger Coil Removal and Installation
  87
Electrical 2

88
- Specifications
  89
- Special Tools
  90
- Starter Motor (S/N-0G472132 & Below)
  91
- Starter Motor (S/N-0G472133 & UP)
  93
- Battery
  95
- Battery Charging System Troubleshooting
  95
- Operating Engine Without Battery
  95
- Recommended Battery
  95
- Battery Charging System
  96
- Description (10 Ampere)
  96
- Wiring Diagram (10 Ampere)
  96
- Alternator System Test (10 Ampere Stator)
  97
- Stator Ohms Test (Alternator Lighting/Charging Coil)
  98
- Description
  100
- Starting System Components
  100
- Troubleshooting the Starting Circuit
  100
- Starter Solenoid Test
  101
- Removal
  104
- Starter Motor P/N 50-825095 (Top Mounted) . 2B-17
  104
- Cleaning and Inspection
  105
- Disassembly
  105
- Reassembly
  109
- Installation
  112
- Removal
  113
- Starter Motor P/N 50-834749 (Side Mounted) . 2B-26
  113
- Disassembly
  114
- Cleaning and Inspection
  115
- Testing
  116
- Brush Replacement
  118
- Reassembly
  119
- Installation
  122
Electrical 2

134
Fuel System

142
- Fuel Pump
  143
- Fuel Pump Operation
  145
- Fuel Pump Removal
  146
- Fuel Pump
  147
- Fuel Pump Disassembly
  147
- Cleaning/Inspection/Repair
  148
- Fuel Pump Reassembly
  149
- Fuel Pump
  151
- Fuel Pump Installation
  151
Fuel System

152
- Specifications
  153
- Special Tools
  154
- Carburetor Linkage
  155
- Carburetor (40/45)
  157
- Carburetor (50)
  158
- Intake
  161
- Carburetor Adjustments
  163
- Carburetor Synchronization-Static Adjustment
  163
- Idle Mixture Screw Adjustment-Static Adjustment
  164
- Choke Cam Angle Adjustment
  165
- Fast Idle Adjustment
  166
- Unloader Adjustment
  167
- Choke Shutter Closing Adjustment
  168
- Carburetor Unit Removal
  169
- Carburetor Link Removal
  172
- Electrothermal Plunger Removal
  173
- Solenoid Coil
  173
- Acceleration Pump
  174
- Disassembly
  174
- Removal
  174
- Fuel Piping Removal
  175
- Inspection
  175
- Carburetor
  176
- Disassembly
  176
- Silencer Removal
  176
- Inspection
  178
- Carburetor Assembly
  179
- Acceleration Pump
  182
- Assembly
  182
- Silencer Installation
  182
- Installation
  183
- Fuel Piping Installation
  184
- Electrothermal Plunger Installation
  185
- Solenoid Coil Installation
  185
- Carburetor Link Installation
  186
- Carburetor Unit Installation
  187
Fuel System

189
- Carbon Monoxide - CO
  190
- Controlling Emissions
  190
- Exhaust Emissions Standards
  190
- Hydrocarbons
  190
- Oxides of Nitrogen - Nox
  190
- What Are Emissions
  190
- 1/3% # Per Year over 9 Model Years
  191
- Outboard Hydrocarbon Emissions Reductions
  191
- Stoichiometric (14.7:1) Air/Fuel Ratio
  191
- Homogenized Charge
  192
- Stratified Vs Homogenized Charge
  192
- Stratified Charge
  193
- Dealer Responsibility
  194
- Emissions Information
  194
- Manufacturer's Responsibility
  194
- Owner Responsibility
  194
- EPA Emission Regulations
  195
- Decal Location for 1999 Models
  196
  - Emission Control Information
    196

Mercury 4.5 Operation And Maintenance Manual (98 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1.42 MB

Mercury 4.5 Operation And Maintenance Manual (98 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1.63 MB

Mercury 4.5 Operation And Maintenance Manual (95 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1.36 MB

Mercury 4.5 Operation And Maintenance Manual (69 pages)

Brand: Mercury | Category: Outboard Motor | Size: 0.82 MB

Mercury 4.5 Operation & Maintenance Manual (22 pages)

Brand: Mercury | Category: Outboard Motor | Size: 3.19 MB

Important Owner Identification and Registration Information
2
Dealer's Responsibilities
3
Operator's Responsibilities
3
Replacement Parts
4
Service Parts Inquiries
4
Table of Contents
5
Specifications
6
General Information
7
Marine Operating Symbols
7
Periodic Checkup
7
Motor Installation
8
Transom Height
8
Mounting Motor on Transom
8
Tilt Lock Pin
8
Adjusting Co-Pilot
9
Battery Cable Routing
9
Electrical Accessories Connections
9
Trailering Boat/Motor
9
Removing Motor from Boat
10
Installing Propeller
10
Ventilation/Prop Slip
10
Installing Fuel Tank
10
Gasoline Recommendations
11
Oil Recommendations
11
Fuel Mixture
11
Correct Fuel Mixing Procedure
11
Motor Operation
12
Twist Grip Throttle
12
Shifting Gears
12
Water Pump Operation
12
Break-In Procedure
13
Starting Procedure-Manual
13
Twist Connector and Manual Choke
13
Priming Fuel System
13
Starting Procedure-Electric
14
Operation Without Battery (Electric Starting Models)
14
Stopping Procedure
15
Shallow Water Troll
15
Operation in Salt Water
15
Attention Required Following Operation in Salt Water or Silt-Flushing
15
Adjustments and Maintenance
16
Periodic Inspection
16
Removing Top Cowl
16
Carburetor
16
Low Speed Mixture Adjustment
17
Idle Speed Adjustment
17
Servicing Fuel Tank Filter
17
Servicing Carburetor Fuel Filter/Screen
17
Gear Housing Lubrication
18
Lubrication Chart
18

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