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45 Jet 50-55
Mercury 45 Jet 50-55 Manuals
Manuals and User Guides for Mercury 45 Jet 50-55. We have
1
Mercury 45 Jet 50-55 manual available for free PDF download: Service Manual
Mercury 45 Jet 50-55 Service Manual (564 pages)
Brand:
Mercury
| Category:
Outboard Motor
| Size: 15.81 MB
Table of Contents
General Information 1
4
Table of Contents
4
Propeller Information
5
How to Use this Manual
5
Page Numbering
5
Master Specifications
6
Powerhead
8
Specifications
8
Special Tools
8
Cowl Removal
9
Filling Oil Injection System
9
Propeller Selection
10
Propeller Installation
10
Trim "In" Angle Adjustment
11
Propeller Information Chart
12
50/55 Models
12
Propeller Information Chart
13
50-60 Models
13
Stainless Steel Race Propellers - Available from Mercury Performance Products
13
General Information
13
Power Trim System (Models with Power Trim)
14
General Information
14
Checking Trim System Fluid Level
15
Trimming (Models with Power Trim)
15
Trimming Outboard "Out" ("Up")
15
Trimming Outboard "In" ("Down")
15
Trim Tab Adjustment
16
Boat Performance
16
Test Instructions
16
Lubrication Points
18
Ride Guide Steering Cable and Pivot Point Lubrication
19
Gear Housing Lubrication
20
Salt Water Corrosion - Gear Housing Bearing Carrier and Cover Nut
20
Periodic Inspection
21
Flushing Outboard Cooling System
21
Following Complete Submersion
22
Salt Water Submersion (Special Instructions)
22
Submerged While Running (Special Instructions)
22
Submerged Engine (Fresh Water) (Plus Special Instructions)
22
Out-Of-Season Outboard Storage
23
Out-Of-Season Battery Storage
23
How Weather Affects Engine Performance
24
Conditions Affecting Operation
25
Detonation: Causes and Prevention
25
Compression Check
25
Water Pressure Check
26
Serial Number Location
26
Painting Procedures
27
Decal Application
28
Electrical and Ignition 2
30
Description
31
Test Procedures
31
Direct Voltage Adapter (DVA) Tests
31
Test Sequence
32
Ignition System Test Chart
33
Stator Test
34
Ignition Coil Test
35
Trigger Test
35
ADI Ignition Using a RED Stator with an Adapter Module
35
RED Stator with Adaptor and Ignition Coils
36
RED Stator DVA Test
36
Electric Start Engines
36
Manual Start Engines
36
Troubleshooting Procedures
36
Ignition (Key) Switch Test
37
Ignition Components Removal and Installation
37
Flywheel
37
Removal
37
Installation
38
BLACK and RED Stator
38
Removal
38
BLACK Stator Installation
39
RED Stator Installation
39
Trigger
40
Removal
40
Installation
40
Ignition Coils
41
Switch Box
41
Electrical 2
43
Battery
44
Precautions
44
Recommended Battery
44
Operating Engine Without Battery
44
Specific Gravity Readings
44
Specific Gravity Cell Comparison Test
45
Electrolyte Level
45
Charging a Discharged Battery
45
Winter Storage of Batteries
46
Battery Charging System
46
Description
46
Battery Charging System Troubleshooting
47
Stator Ohms Test (Alternator Coils Only)
47
Alternator System Test
48
Unregulated Systems
48
Regulated Systems
48
Ampere Battery Charging Wiring Diagram (Rectifier Models)
50
Ampere Battery Charging Wiring Diagram (Regulator Models)
51
Ampere Battery Charging Diagram with Battery Isolator (Rectifier Models)
52
15/16 Ampere Battery Charging Diagram with Battery Isolator
53
Rectifier Test
54
Starting System
55
Starting System Components
55
Description
55
Troubleshooting the Starting Circuit
55
Starter Motor
58
Removal
58
Disassembly
58
Cleaning and Inspection
59
Testing
59
Armature Test for Shorts
59
Armature Test for Ground
60
Checking Positive Brushes and Terminals
60
Testing Negative Brushes for Ground
60
Starter Solenoid Test
61
Brush Replacement
61
Reassembly
61
Installation
63
Electrical and Ignition 2
65
Special Tools
66
Specifications
66
Timing Pointer Adjustment
66
Timing/Synchronizing/Adjusting
66
Carburetor Synchronization
67
(Models with One Piece Throttle Link Rod)
67
(Models with Adjustable Length Throttle Link Rod)
67
(Both One Piece and Adjustable Link Rod)
67
Timing Adjustments
68
Idle Timing Adjustment
68
Maximum Timing
69
Idle Adjustment
69
Throttle Cable Installation
69
Electrical and Ignition 2
71
Model 45 Jet Electric Start Wiring Diagram
72
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 Diagram
76
Wiring Diagram
76
Model 50/60 Power Trim Wiring Diagram
79
Wiring Diagram
79
(COMMANDER 2000 Side Mount Remote Control)
80
Key/Choke Switch Continuity Test
80
COMMANDER 2000 Side Mount Remote Control
81
Wiring Diagram
81
COMMANDER 2000 Side Mount Remote Control (Electric Start with Warning Horn) Wiring Diagram
83
COMMANDER Side Mount Remote Control
83
Wiring Diagram
83
Fuel Systems
85
Special Tools
86
Specifications
86
Attenuator Plate
87
WME Carburetor Specifications
89
Reed Valve Specifications
89
Notes
90
Carburetor
91
Carburetion
93
Fuel System Troubleshooting
93
Troubleshooting Charts
93
Carburetor Adjustments
96
Initial Starting Adjustment
96
Idle Speed Adjustment
96
Idle Mixture Screw Adjustment
96
Carburetor Float Adjustment
96
Main (High Speed) Jet Adjustment
96
WME Carburetor Specifications
97
Rejetting Carburetors for High Altitude Operation
97
Jet Orifice Size/Part Number Chart
97
Carburetor Removal
98
Carburetor Disassembly
98
Cleaning and Inspection
100
Carburetor Reassembly
100
Carburetor Installation
102
Fuel Systems
104
Specifications
105
Fuel Pump (50/60)
106
Fuel Pump (55/60 Seapro/Marathon)
108
Fuel Pumps
110
General Information
110
Fuel Pump Description/Operation
110
Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
110
Testing
110
Troubleshooting Fuel Pump
111
Cleaning and Inspection
112
Fuel Pump Disassembly
112
Fuel Pump Removal
112
Fuel Pump Reassembly
113
Check Valve Assembly
113
Fuel Pump Assembly
113
Fuel Pump Exploded View
114
Fuel Tank
115
Maintenance
115
Fuel Tank Components
115
Fuel Line and Primer Bulb Assembly
116
Maintenance
117
Enrichener System
120
Enrichener Valve Test
121
Fuel Systems
123
Operation of the Injection System
124
Oil Injection System
124
Oil Injection Flow System (Fixed Ratio Oil Pump)
125
Pump Drive Assembly (Fixed Ratio Oil Pump)
126
Pump Drive System (Fixed Ratio Oil Pump)
126
Oil Pump to Powerhead Assembly (Fixed Ratio Oil Pump)
127
Oil Injection Flow System (Variable Ratio Oil Pump)
128
Pump Drive Assembly (Variable Ratio Oil Pump)
129
Pump Drive System (Variable Ratio Oil Pump)
129
Oil Pump to Powerhead Assembly (Variable Ratio Oil Pump)
130
Set up Instructions for Oil Injection System
131
Carburetor/Oil Pump Synchronization (Variable Ratio Oil Pump)
131
Filling Oil Injection System with Oil
131
Bleeding Air from Oil Injection System
132
Bleeding Air from Oil Pump Inlet Hose
132
Bleeding Air from Oil Pump Outlet Hose
132
Outboard Operation
132
Check Operation of the Oil Injection System (Engine Running)
132
Required Side Mount Remote Control or Ignition Key Switch Assembly
133
Oil Injection System Troubleshooting Chart
133
Troubleshooting the Oil Injection System
133
Installing Drive Gear (for Oil Injection Pump) Onto Crankshaft
134
Oil Warning Module
135
Removal/Installation
135
Engine Mounted Oil Reservoir
136
Removal
136
Installation
137
Powerhead
139
Quicksilver Lubricants and Service Aids
140
Special Tools
140
Specifications
140
Cylinder Block and Crankcase
141
Induction Manifold and Reed Block
145
Crankshaft, Pistons and Connecting Rods
147
Throttle Lever and Linkage
149
Powerhead Torque Sequence
151
General Information
152
ELPTO Model
152
Powerhead Disassembly
155
Removing Engine Components
155
Crankshaft Disassembly
157
Cleaning and Inspection
160
Cylinder Block and Crankcase Cover
160
Honing Procedure
160
Check Valves
161
Piston and Piston Rings
161
Cleaning Piston Ring Grooves
162
Measuring Piston Skirt
162
Crankshaft
162
Connecting Rods
163
Thermostat
163
Reed Blocks
164
Powerhead Reassembly and Installation
165
General Information
165
End Cap
165
Assembling Rod to Piston
165
Piston Ring Installation
167
Crankshaft Installation
169
Connecting Rod Cap Alignment
171
Crankcase Cover to Block
171
Intake/Reed Block Manifold Installation
173
Thermostat Cover Installation
174
Install Remaining Engine Components
174
Important Information
177
Test Run Procedure
177
MID-Section
179
MID-Section Components
180
Swivel Bracket Components
180
Transom Bracket Components (50/60 Models)
182
MID-Section Components
182
Drive Shaft Housing Components
183
Disassembly
184
Reassembly
184
Tilt Lock Lever/Transom Bracket
184
Drive Shaft Housing
186
MID-Section
188
Power Trim General Information
189
Description
189
Trimming Characteristics
189
Trimming Outboard "Up" ("Out")
189
Trimming Outboard "Down
189
Trailering Outboard
190
Tilting Outboard up and down Manually
190
Trim "In" Angle Adjustment
190
Power Trim System Components
191
Torque Specifications
191
Quicksilver Lubricants and Service Aids
191
Power Trim Flow Diagrams Design
192
Determine if Problem Is Electrical or
199
Hydraulic
199
Trouble Chart
199
Hydraulic System Troubleshooting
200
Preliminary Checks
200
Leak down Check - Pump and Manifold
200
Assembly
201
Leak down Check - Pilot Valve Assembly
201
Leak down Check - Manual Release
201
Valve
201
Leakage Past Ball and Seat - Piston Assembly
201
Troubleshooting Flow Diagram
202
Troubleshooting Flow Diagram
203
Electrical System Troubleshooting
204
COMMANDER 2000 Side Mount Remote
204
Power Trim System Wiring Diagram
205
Troubleshooting the "Down" Circuit* (When "Up" Circuit Is OK)
206
Troubleshooting the "Up" Circuit* (When "Down" Circuit Is OK)
207
Troubleshooting the "Down" and "Up" Circuits
208
Power Trim System Removal
209
Power Trim System Disassembly
210
Trim Rod Removal
210
Trim Rod Disassembly
211
Trim "Motor" Removal
213
Trim "Motor" Disassembly
213
Reservoir Assembly Removal
214
Oil Pump Removal
215
Manifold Removal
215
Cleaning and Inspection of Trim Rod Components
216
Motor and Electrical Tests/Repair
217
Trim Pump Motor Test
217
Thermal Overload Switch Test
217
Motor Assembled
217
Motor Disassembled
217
Armature Tests
218
Test for Shorts
218
Test for Ground
218
Checking and Cleaning Commutator
218
Power Trim System Reassembly
218
Manifold Installation
218
Oil Pump Installation
219
Trim Motor Reassembly
220
Reservoir Installation
221
Trim Rod Reassembly
223
Trim Rod Installation
224
Bleeding Power Trim Unit
225
Power Trim Unit Installation
225
MID-Section
228
Power Trim General Information
229
Trimming Characteristics
229
Trimming Outboard "Up" ("Out")
229
Trimming Outboard "Down" ("In")
229
Trailering Outboard
230
Tilting Outboard up and down Manually
230
Trim "In" Angle Adjustment
230
Design II
232
Design II
233
Design II
234
Design II
235
Design II
236
Design II
237
Troubleshooting
239
Determining if Problem Is Electrical or Hydraulic
239
Trouble Chart
239
Hydraulic System Troubleshooting
240
Preliminary Checks
240
Leak down Check - Pump and Manifold
240
Assembly
241
Leak down Check - Pilot Valve Assembly
241
Leak down Check - Manual Release Valve
241
Leakage Past Ball and Seat - Piston Assembly
241
Troubleshooting Flow Diagram
242
Troubleshooting Flow Diagram
243
Electrical System Troubleshooting
244
COMMANDER 2000 Side Mount Remote
244
Power Trim System Wiring Diagram
245
Troubleshooting the "Down" Circuit* (When "Up" Circuit Is OK)
246
Troubleshooting the "Up" Circuit* (When "Down" Circuit Is OK)
247
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
248
Power Trim System Removal
249
Power Trim System Disassembly
250
Trim Rod Removal
250
Trim Rod Disassembly
251
Trim "Motor" Removal
253
Reservoir Assembly Removal
254
Oil Pump/Manifold Removal
255
Cleaning and Inspection of Trim Rod Components
256
Motor and Electrical Tests/Repair
257
Trim Pump Motor Test
257
Thermal Overload Switch Test
257
Motor Assembled
257
Motor Disassembled
257
Armature Tests
258
Test for Shorts
258
Test for Ground
258
Checking and Cleaning Commutator
258
Power Trim System Reassembly
258
Manifold/Oil Pump Installation
258
Trim Motor Reassembly
259
Reservoir Installation
261
Trim Rod Reassembly
262
Trim Rod Installation
263
Bleeding Power Trim Unit
264
Power Trim Unit Installation
265
MID-Section
268
Power Trim - General Information
269
Description
269
Trimming Characteristics
269
Trimming Outboard "Up" ("Out")
269
Trimming Outboard "Down" ("In")
269
Trailering Outboard
270
Tilting Outboard up and down Manually
270
Trim "In" Angle Adjustment
270
Special Tools
269
Troubleshooting
272
Determining if Problem Is Electrical or Hydraulic
272
Problem Chart
272
Hydraulic System Troubleshooting
273
Preliminary Checks
273
Leak down Check - Pump and Manifold Assembly
273
Leak down Check - Pilot Valve Assembly
274
Leak down Check - Manual Release
274
Valve
274
Leaks Past Ball and Seat - Piston Assembly
274
Troubleshooting Flow Diagram
275
Troubleshooting Flow Diagram
276
Electrical System Troubleshooting
277
Commander 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
277
Power Trim System Wiring Diagram
278
Troubleshooting the "Down" Circuit* (When "Up" Circuit Is
279
Troubleshooting the "Up" Circuit* (When "Down" Circuit Is
280
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
281
Power Trim System Removal
282
Power Trim System Disassembly
283
Trim Rod Removal
283
Trim Rod Disassembly
284
Trim "Motor" Removal
286
Trim "Motor" Disassembly
286
Reservoir Assembly Removal
286
Manifold Removal
287
Cleaning and Inspection of Trim Rod Components
288
Motor and Electrical Tests/Repair
288
Trim Pump Motor Test
288
Armature Tests
288
Test for Shorts
288
Test for Ground
288
Checking and Cleaning Commutator
289
Power Trim System Reassembly
289
Manifold Installation
289
Trim Motor Reassembly
290
Reservoir Installation
291
Trim Rod Reassembly
292
Purging Power Trim Unit
294
Power Trim Unit Installation
294
MID-Section
298
Special Tools
299
Adjustments
302
Trimming Characteristics
302
Trimming Outboard "Up" ("Out")
302
Trimming Outboard "Down
302
Trailering Outboard
303
Tilting Outboard up and down Manually
303
Trim up
305
Tilt up
307
Maximum Tilt
308
Down Mode
311
Shock Function up
312
Shock Function Return
314
Manual Tilt
317
Theory of Operation
302
Troubleshooting
318
Preliminary Checks
318
Hydraulic System Troubleshooting Flow Chart
319
Hydraulic System Troubleshooting Flow Chart
320
Hydraulic System Troubleshooting Flow Chart
321
Hydraulic System Troubleshooting Flow Chart
322
Troubleshooting the Power Trim Electrical System (Wiring Diagram)
323
Troubleshooting the Power Trim Electrical System
324
Power Trim System Removal
325
Power Trim Disassembly
326
Trim Motor Removal
327
Pump and Components Removal
327
Manifold Removal
328
Shock Rod Removal
328
Shock Rod Disassembly
329
Memory Piston Removal
331
Cleaning/Inspection/Repair
332
Trim Motor Electrical Tests
332
Reassembly
333
O-Ring and Seal Placement
333
O-Ring Sizes
334
O-Ring Description and Sizes
335
Power Trim Reassembly
336
Shock Rod Reassembly
336
Shock Rod Installation
337
Trim Limit Assembly Installation
338
Manual Release Valve Installation
338
Manifold Installation
338
Oil Pump Installation
339
Pressure Operated Assembly Installation 5E-42
340
Reservoir/Motor Installation
340
Bleeding Power Trim Unit
341
Installation of Power Trim System
341
MID-Section
345
Manual Tilt System Components
345
Quicksilver Lubricant/Sealant Application
345
Torque Specification
347
Three)
347
Points
347
Manual Tilt Flow Diagrams Design
348
Manual Tilt Flow Diagrams Design
353
Manual Tilt Flow Diagrams Design
358
Hydraulic System Troubleshooting
363
Troubleshooting Flow Chart
364
Manual Tilt System Removal
366
Manual Tilt System Disassembly
367
Accumulator Removal
367
Shock Rod Disassembly
369
Valve Block Removal
371
Valve Block Disassembly
372
Manual Tilt System Cleaning and Inspection
373
Manual Tilt System Reassembly
373
Valve Block Reassembly
373
Valve Block Installation
375
Shock Rod Reassembly
375
Shock Rod Installation
377
Instructions for Making Retaining Tool
378
Bleeding Manual Tilt System
379
MID-Section
383
Special Tools
384
Tilt up
388
Tilt down
390
Slow Tilt down under High Thrust
391
Under Water Strike
393
Shock Function
395
With Valves Closed
396
Shock Function Return
397
Hydraulic System Troubleshooting
399
Manual Tilt System Removal
400
Manual Tilt System Disassembly
401
Accumulator Removal
401
Shock Rod Removal
402
Shock Rod Disassembly
403
Valve Block Removal
405
Memory Piston Removal
405
Valve Block Disassembly
406
Actual O-Ring Sizes
408
O-Ring Description and Sizes
409
Manual Tilt System Cleaning and Inspection
410
Manual Tilt System Reassembly
410
Cam Shaft Reassembly
410
Valve Body Check Reassembly
410
Velocity Valve Reassembly
410
Check Retainer Reassembly
411
Valve Plug Reassembly
411
Valve Block Installation
411
Shock Rod Reassembly
412
Shock Rod Installation and Fluid Filling Procedure
413
Instructions for Making
415
Retaining Tool
415
Bleeding Manual Tilt System
416
Manual Tilt System Installation
418
Manual Release Valve Adjustment
419
Lower Unit
421
Lubrication/Sealant Application Points
423
Propeller Shaft Components
423
Torque Specifications
423
Draining and Inspecting Gear Lubricant
426
Gear Housing Removal
427
Propeller Removal
427
Gear Housing Disassembly
428
Water Pump
428
Bearing Carrier and Propeller Shaft
429
Propeller Shaft Disassembly
431
Pinion Gear, Driveshaft and Forward Gear
432
Upper Driveshaft Bearing
432
Lower Driveshaft Bearing
433
Forward Gear Bearing Race
433
Shift Shaft
433
Gear Housing Reassembly
434
Shift Shaft
434
Propeller Shaft
435
Forward Gear Bearing Race
436
Bearing Carrier
436
Reverse Gear
437
Forward Gear
438
Lower Driveshaft Bearing Installation
438
Upper Driveshaft Bearing Installation
439
Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer and Driveshaft Installation
439
Pinion Gear Location and Forward Gear Backlash
440
Determining Pinion Gear Location
440
Determining Forward Gear Backlash
441
Bearing Carrier and Propeller Shaft Installation
442
Water Pump Re-Assembly and Installation
443
Gear Housing Installation
445
Filling Gear Housing with Lubricant
445
Gear Housing Installation
446
Propeller Installation
447
Trim Tab Adjustment and Replacement
448
Gear Housing Pressure Test
445
Lower Unit
450
Notes
451
Gear Housing (Drive Shaft)
453
Gear Housing (Propeller Shaft)
455
Removal
458
Propeller Removal
458
Draining and Inspecting Gear Housing Lubricant
459
Water Pump
460
Bearing Carrier and Propeller Shaft
461
Pinion Gear, Drive Shaft, and Forward Gear
464
Upper Drive Shaft Bearing
465
Oil Sleeve
466
Lower Drive Shaft Bearing Race
466
Shift Shaft
467
Forward Gear Bearing Race
468
Trim Tab Adjustment and Replacement
468
Special Tools
458
Reassembly
468
Shift Shaft
468
Bearing Carrier Reassembly
469
Forward Gear Reassembly
471
Propeller Shaft Reassembly
472
Drive Shaft Wear Sleeve Installation
472
Lower Drive Shaft Bearing Race Installation
473
Oil Sleeve Installation
474
Upper Drive Shaft Bearing Installation
474
Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation
475
Pinion Gear Depth and Forward Gear Backlash
475
Determining Pinion Gear Depth
475
Determining Forward Gear Backlash . 6B-27
477
Bearing Carrier and Propeller Shaft Installation
478
Water Pump Reassembly and Installation
479
Gear Housing Pressure Test
481
Filling Gear Housing with Lubricant
481
Propeller Installation
482
Gearcase Installation
483
Trim Tab Adjustment
484
Lower Unit
486
Notes
487
Jet Pump Assembly
488
Jet Components
490
Engine Horsepower Selection
491
Selecting a Boat Best Suited for Jet Power
491
Locate Center Line of the Outboard
492
Outboard Mounting Height
492
Transom Height of the Boat
492
Checking for Cavitation
493
Water Testing
493
Shift Cable Installation
494
Impeller Removal and Installation
495
Lubricating the Drive Shaft Bearing
495
Impeller Clearance Adjustment
497
Steering Pull Adjustment
497
Worn (Dull) Impeller
497
Flushing the Cooling System
498
Jet Drive Removal
498
Liner Replacement
498
Bearing Carrier Removal
499
Bearing Carrier Disassembly
500
Bearing Carrier Reassembly
500
Installing Lower Seals
500
Installing Upper Seals
501
Installing Drive Shaft Ball Bearing
501
Installing Drive Shaft
501
Installing Jet Drive to Drive Shaft Housing
503
Reassembling Water Pump to Jet Drive . 6C-17
503
Installing Jet Drive to Drive Shaft Housing 6C-18
504
Jet Drive Tiller Handle Adaptor Kit
506
Installation Instructions
506
Shift Cable Adjustment
509
Outboard Installation/ Attachments
511
Installing Outboard Motor on Transom
512
Determining Recommended Outboard Mounting Height
512
Locate Centerline of Boat Transom
512
Lifting Outboard (Electric Start Models)
512
Lifting Outboard (Manual Start Models)
512
Drilling Outboard Mounting Holes (Electric Start Models)
513
Fastening Outboard on Boat Transom (Manual Start Models)
513
(Electric Start Models)
513
Steering Cable Installation
516
Securing Outboard to Boat Transom
516
Dual Outboard
516
Cable Installation to Tilt Tube - Cable Routed on Starboard Side of Boat
517
Cable Installation to Tilt Tube - Cable Routed on Port Side of Boat
518
Installing Steering Link Rod
518
Arm/Bracket
519
Maintenance Instructions
520
Dual Steering Installation
520
Steering Coupler Assembly
520
Installation
521
Models with Forged Two Hole Steering
521
Arm and One Piece Top Cowl
521
Models with Two Hole Two Piece Steering Arm/Bracket and One Piece Top Cowl
522
Ride-Guide Steering Attachment
523
Extension Couplers
523
Trim Tab Adjustment
523
Dual Outboard
523
Maintenance Instructions
523
Transom Mounted Ride-Guide Attaching Kit Installation
524
Attaching Kit Installation
524
Clevis Attaching Kit Installation
525
Installation Instructions
525
Steering Cable Installation
526
Maintenance Instructions
526
Remote Control Installation
527
Shift Cable Installation and Adjustment to Engine
527
Throttle Cable Installation and Adjustment to Engine
528
Connecting Remote Control Wiring Harness to Engine Wiring Harness (Electric Start Models)
528
Power Trim Wiring Connections (Models Equipped)
529
Battery Connections
529
Notes
532
Steering Handle Kit
533
Tiller Handle Adaptor Kit (JET 45)
539
Tiller Arm/Shift Lever Removal
540
Tiller Handle Disassembly
542
Tiller Arm Reassembly
545
Tiller Arm/Shift Lever Installation
548
Shift Link Rod Installation and Adjustment to Engine
550
Throttle Cable Installation and Adjustment
551
Co-Pilot Installation
552
Wiring Harness Connection
554
Notes
558
Rewind Starter Disassembly
561
Cleaning and Inspection
562
Rewind Starter Reassembly
562
Adjusting Rewind Spring Tension
563
Starter Interlock Cable Adjustment
564
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