Mercury 55 SeaPro Manuals

Manuals and User Guides for Mercury 55 SeaPro. We have 2 Mercury 55 SeaPro manuals available for free PDF download: Service Manual, Operation, Maintenance & Installation Manual

Mercury 55 SeaPro Service Manual

Mercury 55 SeaPro Service Manual (547 pages)

Brand: Mercury | Category: Outboard Motor | Size: 15.13 MB

Table of Contents

Important 1 a

6
Important 1 B

16
- Gear Case Lubricant Capacity
  17
- Quicksilver Lubricant/Sealant
  17
- Special Tools
  17
- Specifications
  17
- After each Use
  18
- Before each Use
  18
- Before Periods of Storage
  18
- Every 100 Hours of Use or Once Yearly, Whichever Occurs First
  18
- Every 300 Hours of Use or Three Years 1B-2
  18
- Inspection and Maintenance Schedule
  18
- Flushing the Cooling System
  19
- Fuel System
  19
- Corrosion Control Anode
  20
- Lubrication Points
  21
- 40/50 Hp
  23
- Checking Power Trim Fluid
  23
- Draining Gear Case
  24
- Gear Case Lubrication
  24
- Checking Lubricant Level and Filling Gear Case
  25
- Gear Case
  25
- Protecting External Outboard Components
  25
- Protecting Internal Engine Components 1B-9
  25
- Storage Preparations
  25
- Battery Storage
  26
- Positioning Outboard for Storage
  26
Important 1 C

28
- Conditions Affecting Performance
  29
- Serial Number Location
  29
- Weather
  29
- Boat
  30
- Engine
  31
- Following Complete Submersion
  31
- Salt Water Submersion (Special Instructions)
  31
- Submerged While Running (Special Instructions)
  31
- Propeller Selection
  32
- Submerged Engine (Fresh Water) (Plus Special Instructions)
  32
- Installation
  33
  - Lifting Outboard
    37
  - Steering Link Rod
    37
- Propeller Removal/Installation
  33
- Removal
  33
Electrical 2

49
- Special Tools
  50
- Specifications
  50
- Flywheel and Stator (Electric)
  51
- Flywheel and Stator (Manual)
  52
- Electrical Components 40/50
  53
- Electrical Components 40/50
  54
- Capacitor Charging #1 CDM
  57
- Theory of Operation
  57
- Capacitor Charging #2 & #3 CDM
  58
- Cylinder Trigger Circuit
  59
- Ignition Coil Circuit
  60
- Stop Circuit
  61
- Rev Limiter Circuit
  62
- Capacitor Discharge Module (CDM)
  63
- Flywheel
  63
- Ignition Component Description
  63
- Stator Assembly
  63
- Trigger Coil
  63
- CDM (P/N 827509)
  64
- CDM (P/N 827509) Trouble Shooting Flowchart
  64
- CDM Test Harness 84-825207A2
  64
- Spark Gap Tester P/N 91-850439
  64
- CDM Stop Diode Trouble Shooting
  65
- CDM Trouble Shooting Flowchart
  66
- CDM Trouble Shooting Flowchart
  67
- Direct Voltage Adaptor (DVA) Test
  69
- Ignition Test Procedures
  69
- Resistance Tests
  70
- Flywheel Removal and Installation
  71
- Stator Removal and Installation
  72
- Trigger
  72
- CDM
  73
Electrical 2

75
- Special Tools
  76
- Specifications
  76
- Starter Motor
  77
- Battery
  79
- Operating Engine Without Battery
  79
- Precautions
  79
- Specific Gravity Readings
  79
- Charging a Discharged Battery
  80
- Electrolyte Level
  80
- Specific Gravity Cell Comparison Test
  80
- Battery Charging System Troubleshooting Description
  81
- Winter Storage of Batteries
  81
- Description
  86
- Starting System
  86
- Starting System Components
  86
- Troubleshooting the Starting Circuit
  86
- Starting Circuit Wiring Diagram
  87
- Starting Circuit Troubleshooting Flow Chart 2B-13
  88
- Disassembly
  90
- Removal
  90
- Starter Motor
  90
- Cleaning and Inspection
  91
- Testing
  91
- Brush Replacement
  93
- Reassembly
  94
- Installation
  95
Electrical 2

97
- Idle Timing Adjustment
  99
- Maximum Timing Adjustment
  99
- Timing
  99
- Carburetor Synchronization
  100
- Adjustments
  101
- Idle
  101
Electrical 2

103
Fuel System

114
- Specifications
  115
- Fuel Pump (Electric) 40/50/55/60
  116
- Fuel Pump (Manual) 40/50
  118
- Fuel Pump (Manual) 40/50
  119
- Theory of Operation
  122
- Troubleshooting
  122
- Testing
  123
- Cleaning and Inspection
  124
- Fuel Pump Disassembly
  124
- Fuel Pump Removal
  124
- Check Valve Assembly
  125
- Fuel Pump Assembly
  125
- Reassembly
  125
Fuel System

127
- Special Tools
  128
- Specifications
  128
- WME Carburetor Chart
  128
- Carburetor 40/50
  129
- Carburetor 55/60
  132
- Attenuator Plate 40/50
  133
- Attenuator Plate 40/50
  134
- Adjustments
  137
- Float Adjustment
  137
- Idle Mixture Screw Adjustment
  137
- Idle Speed Adjustment
  137
- Jet Orifice Size Chart
  138
- Main (High Speed) Jet Adjustment
  138
- High Altitude Jet Chart
  139
- Fuel System Troubleshooting
  140
- General Information
  140
- Problem: Engine Floods
  140
- Problem: Engine Runs too Rich
  140
- Problem: Fuel Blow Back out of Carburetor
  140
- Problem: Rough Idle
  140
- Problem: Engine Turns over but will Not Start or Starts Hard When Cold
  141
- Problem: Unable to Reduce Engine RPM to Slow Idle
  141
- Engine Runs Uneven or Surges
  142
- Engine will Not Accelerate
  142
- Problem: Engine Runs too Lean
  142
- Problems: Engine Idles Rough and Stalls
  142
- Removal/Installation
  143
- Electric Enrichener Valve
  145
- Enrichment System
  145
- Manual Primer Button
  147
Fuel System

149
- Oil Injection Components 40/50
  151
- Oil Injection Components 40/50
  152
- Oil Flow Diagram
  155
- Theory of Operation
  155
- Adjustments
  156
- Bleeding Air from Oil Injection System
  156
- Bleeding Air from Oil Pump Inlet Hose
  156
- Bleeding Air from Oil Pump Outlet Hose
  156
- Carburetor/Oil Pump Synchronization
  156
- Check Operation of the Oil Injection System (Engine Running)
  157
- Oil Pump Volume (Flow) Test
  157
- Troubleshooting
  157
- Troubleshooting Chart
  158
- Engine Mounted Oil Reservoir
  159
- Installing Drive Gear (for Oil Injection Pump) Onto Crankshaft
  159
- Removal
  159
- Installation
  160
Table of Contents

163
- Carbon Monoxide - CO
  164
- Controlling Emissions
  164
- Exhaust Emissions Standards
  164
- Hydrocarbons - HC
  164
- Oxides of Nitrogen - Nox
  164
- Stoichiometric (14.7:1) Air/Fuel Ratio
  164
- What Are Emissions
  164
- Outboard Hydrocarbon Emissions Reductions
  165
- Homogenized Charge
  166
- Stratified Charge
  166
- Stratified Vs Homogenized Charge
  166
- Dealer Responsibility
  167
- Emissions Information
  167
- EPA Emission Regulations
  167
- Manufacturer's Responsibility
  167
- Owner Responsibility
  167
- Decal Location for 1998 Models
  168
Powerhead

170
- Specifications
  171
- Special Tools
  172
- Cylinder Block and Crankcase 40/50
  175
- Cylinder Block and Crankcase 55/60
  176
- Induction Manifold and Reed Block 40/50
  178
- Induction Manifold and Reed Block 40/50
  179
- Crankshaft, Pistons and Connection Rods
  182
- Water Circulation
  184
- Temperature Switch Test
  185
- Thermostat Test
  185
- General Information
  186
- Powerhead Removal
  186
- Powerhead Disassembly
  188
- Removing Engine Components
  188
- Crankshaft Disassembly
  190
- Cleaning and Inspection
  193
- Cylinder Block and Crankcase Cover
  193
- Check Valves
  194
- Piston and Piston Rings
  194
- Crankshaft
  195
- Connecting Rods
  196
- Reed Blocks
  197
- General Information
  198
- Reassembly and Installation
  198
- Assembling Rod to Piston
  199
- Piston Ring Installation
  201
- Crankshaft Installation
  202
- Connecting Rod Cap Alignment
  204
- Installing Rods to Crankshaft
  204
- Crankcase Cover to Block
  205
- Lower End Cap
  205
- Intake/Reed Block Manifold Installation
  206
- Thermostat Cover Installation
  207
- Install Remaining Engine Components
  208
- Powerhead Installation
  208
- Important Information
  211
- Test Run Procedure
  211
MID-Section

213
- Clamp Bracket
  215
- Swivel Tube Components
  217
- Swivel Bracket Components
  219
- Drive Shaft Housing/Exhaust Plate Components
  221
- Drive Shaft Housing Disassembly/Reassembly
  223
MID-Section

225
- Clamp Bracket Components (Manual)
  227
- Transom Bracket Components (Electric)
  229
- Swivel Bracket Components
  231
- Drive Shaft Housing
  233
- Drive Shaft Housing Disassembly/Reassembly
  235
MID Section

237
- Special Tools
  238
- Power Trim Components
  239
- Adjustments
  241
- Theory of Operation
  241
- Trimming Characteristics
  241
- Tilting Outboard up and down Manually
  242
- Trailering Outboard
  242
- Trim "In" Angle Adjustment
  242
- Power Trim Flow Diagrams
  243
- Trim up
  243
- Tilt up
  245
- Maximum Tilt
  247
- Down Mode
  250
- Shock Function
  253
- Shock Function Return
  253
- Manual Tilt
  255
- Preliminary Checks
  257
- Troubleshooting
  257
- Hydraulic System Troubleshooting Flow Chart
  258
- Hydraulic System Troubleshooting Flow Chart
  259
- Hydraulic System Troubleshooting Flow Chart
  260
- Hydraulic System Troubleshooting Flow Chart
  261
- Troubleshooting the Power Trim Electrical System
  262
- Troubleshooting the Power Trim Electrical System
  263
- Power Trim System Removal
  264
- Disassembly
  265
- Shock Rod Removal
  265
- Shock Rod Disassembly
  266
- Memory Piston Removal
  268
- Trim Motor Removal
  269
- Oil Pump Removal
  270
- Tilt Relief Valve Removal
  270
- Pilot Check Valve Assembly Removal
  271
- Suction Seat Removal
  271
- Cleaning/Inspection/Repair
  272
- O-Ring and Seal Placement
  273
- Reassembly
  273
- Power Trim Reassembly
  275
- Suction Seat Reassembly
  275
- Tilt Relief Valve Reassembly
  275
- Oil Pump Reassembly
  276
- Pilot Check Valve Reassembly
  276
- Shock Rod Reassembly
  277
- Trim Motor Reassembly
  277
- Bleeding Power Trim Unit
  279
- Manual Release Valve Installation
  279
- Shock Rod Installation
  279
- Power Trim System Installation
  280
MID-Section

283
- Special Tools
  284
- Power Trim Components
  285
- Adjustments
  287
- Theory of Operation
  287
- Trimming Characteristics
  287
- Tilting Outboard up and down Manually
  288
- Trailering Outboard
  288
- Trim up
  290
- Tilt up
  292
- Maximum Tilt
  293
- Down Mode
  296
- Shock Function up
  297
- Shock Function Return
  299
- Manual Tilt
  302
- Preliminary Checks
  303
- Troubleshooting
  303
- Hydraulic System Troubleshooting Flow Chart
  304
- Hydraulic System Troubleshooting Flow Chart
  305
- Hydraulic System Troubleshooting Flow Chart
  306
- Hydraulic System Troubleshooting Flow Chart
  307
- Troubleshooting the Power Trim Electrical System
  308
- Troubleshooting the Power Trim Electrical System
  309
- Power Trim System Removal
  310
- Power Trim Disassembly
  311
- Pump and Components Removal
  312
- Trim Motor Removal
  312
- Manifold Removal
  313
- Shock Rod Removal
  313
- Shock Rod Disassembly
  314
- Memory Piston Removal
  316
- Cleaning/Inspection/Repair
  317
- Trim Motor Electrical Tests
  317
- O-Ring and Seal Placement
  318
- Reassembly
  318
- O-Ring Sizes
  319
- O-Ring Description and Sizes
  320
- Power Trim Reassembly
  321
- Shock Rod Reassembly
  321
- Shock Rod Installation
  322
- Manifold Installation
  323
- Manual Release Valve Installation
  323
- Trim Limit Assembly Installation
  323
- Oil Pump Installation
  324
- Reservoir/Motor Installation
  325
- Bleeding Power Trim Unit
  326
- Installation of Power Trim System
  326
MID-Section

330
- Clamp Bracket
  332
- Hydraulic Assist Adjustments
  334
- Manual Trim System Removal
  334
- Manual Trim System Installation
  335
MID-Section

338
- Special Tools
  339
- Manual Tilt Components
  340
- Manual Tilt Components
  341
- Tilt up
  343
- Tilt down
  345
- Slow Tilt down under High Thrust
  346
- Under Water Strike with Valves Open
  349
- Shock Function with Valves Closed
  351
- Shock Function Return
  353
- Hydraulic System Troubleshooting
  354
- Manual Tilt System Removal
  355
- Accumulator Removal
  356
- Manual Tilt System Disassembly
  356
- Shock Rod Removal
  357
- Shock Rod Disassembly
  358
- Memory Piston Removal
  360
- Valve Block Removal
  360
- Valve Block Disassembly
  361
- Actual O-Ring Sizes
  363
- O-Ring Description and Sizes
  364
- Manual Tilt System Reassembly
  365
- Valve Block Installation
  366
- Shock Rod Reassembly
  367
- Shock Rod Installation and Fluid Filling Procedure
  368
- Filling Procedure Option Two Instructions for Making Retaining Tool
  370
- Bleeding Manual Tilt System
  371
- Manual Tilt System Installation
  373
- Manual Release Valve Adjustment
  374
Lower Unit

376
- Specifications
  377
- Special Tools
  378
- Gear Housing (Drive Shaft)(40/50
  380
- Gear Housing (Propeller Shaft)(40/50
  382
- Bearings
  384
- General Service Recommendations
  384
- Seals
  384
- Draining and Inspecting Gear Lubricant
  385
- Propeller Removal
  385
- Gear Housing Removal
  386
- Disassembly
  387
- Water Pump
  387
- Water Pump Seals
  390
- Inspection
  391
- Pinion Gear
  391
- Pinion Gear Bearing
  391
- Upper Drive Shaft Bearing
  391
- Forward Gear
  392
- Shift Shaft
  393
- Cam Follower
  394
- Clutch
  394
- Propeller Shaft and Carrier Inspection
  394
- Propeller Shaft Disassembly
  394
- Reverse Gear
  395
- Reverse Gear Bearing
  395
- Bearing Carrier
  396
- Gear Housing Reassembly
  397
- Pinion Bearing Race
  398
- Shift Shaft Assembly
  398
- Forward Gear
  399
- Pinion Gear/Drive Shaft Assembly
  399
- Propeller Shaft
  400
- Bearing Carrier
  401
- Water Pump
  402
- Filling Gear Housing with Lubricant
  403
- Gear Housing Installation
  403
- Gear Housing Pressure Test
  403
- Installing Gear Housing to Drive Shaft Housing
  404
- Trim Tab Adjustment and Replacement
  405
- Propeller Installation
  406
Lower Unit

408
- Gear Housing (Drive Shaft) (55/60
  414
- Gear Housing (Propeller Shaft)(55/60
  416
- Bearings
  418
- General Service Recommendations
  418
- Seals
  418
- Draining and Inspecting Gear Lubricant
  419
- Propeller Removal
  419
- Gear Housing Disassembly
  420
- Gear Housing Removal
  420
- Water Pump
  420
- Bearing Carrier and Propeller Shaft
  422
- Propeller Shaft Disassembly
  423
- Pinion Gear, Driveshaft and Forward Gear
  424
- Forward Gear Bearing Race
  425
- Lower Driveshaft Bearing
  425
- Upper Driveshaft Bearing
  425
- Shift Shaft
  426
- Gear Housing Reassembly
  427
- Shift Shaft
  427
- Forward Gear Bearing Race
  428
- Propeller Shaft
  428
- Bearing Carrier
  429
- Forward Gear
  430
- Reverse Gear
  430
- Lower Driveshaft Bearing Installation
  431
- Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer and Driveshaft Installation
  432
- Upper Driveshaft Bearing Installation
  432
- Pinion Gear Location and Forward Gear Backlash
  433
- Determining Forward Gear Backlash
  434
- Bearing Carrier and Propeller Shaft Installation
  435
- Bearing Carrier
  436
- Water Pump Re-Assembly and Installation
  437
- Gear Housing Pressure Test
  439
- Filling Gear Housing with Lubricant
  440
- Gear Housing Installation
  440
- Gear Housing Installation
  441
- Propeller Installation
  442
- Trim Tab Adjustment and Replacement
  442
Lower Unit

444
- Special Tools
  445
- Specifications
  445
- Special Tools
  446
- Gear Housing (Drive Shaft)(60 Bigfoot)
  448
- Gear Housing (Prop Shaft)(60 Bigfoot)
  450
- Disassembly
  452
- Draining and Inspecting Gear Housing Lubricant
  452
- Gear Case Identification
  452
- Removal
  452
- Water Pump
  453
- Bearing Carrier and Propeller Shaft
  455
- Pinion Gear, Drive Shaft, and Forward Gear
  457
- Oil Sleeve
  459
- Upper Drive Shaft Bearing
  459
- Lower Drive Shaft Bearing Race
  460
- Shift Shaft
  460
- Forward Gear Bearing Race
  461
- Trim Tab Adjustment and Replacement
  461
- Forward Gear Bearing Race
  462
- Reassembly
  462
- Shift Shaft
  462
- Bearing Carrier Reassembly
  463
- Forward Gear Reassembly
  465
- Propeller Shaft Reassembly
  466
- Drive Shaft Wear Sleeve Installation
  467
- Lower Drive Shaft Bearing Race Installation
  468
- Oil Sleeve Installation
  468
- Upper Drive Shaft Bearing Installation
  468
- Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation
  469
- Pinion Gear Depth and Forward Gear Backlash
  470
- Determining Forward Gear Backlash
  472
- Bearing Carrier and Propeller Shaft Installation
  474
- Water Pump Reassembly and Installation
  475
- Filling Gear Housing with Lubricant
  477
- Gear Housing Pressure Test
  477
- Gearcase Installation
  478
- Trim Tab Adjustment
  480
Lower Unit

482
- Jet 30 Pump Assembly
  484
- Jet 30 Water Pump Components
  486
- Notes
  487
- Jet 45 Pump Assembly
  488
- Jet 45 Water Pump Components
  490
- Engine Horsepower Selection
  491
- Selecting a Boat that Is 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
- Setting Outboard Mounting Height on Boats with Flat Bottom Hulls
  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
- Removal
  500
- Water Pump Removal and Installation
  500
- Bearing Carrier Disassembly
  501
- Bearing Carrier Reassembly
  501
- Bearing Carrier Removal
  501
- Installing Lower Seals
  501
- Installing Drive Shaft
  502
- Installing Drive Shaft Ball Bearing
  502
- Installing Upper Seals
  502
- Installing Jet Drive to Drive Shaft Housing
  504
Attachments/Control Linkage

514
- Tiller Handle 40/50
  516
- Tiller Handle 40/50
  517
- Steering Handle Kit 55/60
  518
- Steering Handle Kit 55/60
  519
- Steering Handle Kit 55/60
  520
- Tiller Arm/Shift Lever Removal
  524
- Tiller Handle Disassembly
  526
- Tiller Arm Reassembly
  528
- Tiller Arm/Shift Lever Installation
  531
- Shift Link Rod Installation and Adjustment to Engine
  532
- Throttle Cable Installation and Adjustment
  533
- Co-Pilot Installation
  534
- Tiller Handle Installation
  535
- Wiring Harness Connection
  536
- Starter Assembly (Manual) 40/50
  540
- Starter Assembly (Manual) 40/50
  541
- Rewind Starter Disassembly
  544
- Cleaning and Inspection
  545
- Rewind Starter Reassembly
  545
- Adjusting Rewind Spring Tension
  546
- Starter Interlock Cable Adjustment
  547

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Mercury 55 SeaPro Operation, Maintenance & Installation Manual

Mercury 55 SeaPro Operation, Maintenance & Installation Manual (102 pages)

Brand: Mercury | Category: Outboard Motor | Size: 5.86 MB

Table of Contents

Table of Contents
7
General Information
11
Boater's Responsibilities
11
Before Operating Your Outboard
11
Boat Horsepower Capacity
11
High-Speed and High-Performance Boat Operation
12
Outboard Remote Control Models
12
Remote Steering Notice
13
Lanyard Stop Switch
13
Protecting People in the Water
16
Passenger Safety Message - Pontoon Boats and Deck Boats
16
Wave and Wake Jumping
18
Impact with Underwater Hazards
18
Exhaust Emissions
21
Selecting Accessories for Your Outboard
23
Safe Boating Recommendations
23
Recording Serial Number
25
55/60 Seapro/Marathon Specifications
26
60 Component Identification
27
55/60 Seapro/Marathon Component Identification
28
Transporting
29
Trailering Boat/Outboard
29
Fuel and Oil
30
Fuel Requirements
30
Oil Recommendation
31
Fuel and Oil Ratio
31
Filling Oil Injection System
32
Filling Remote Oil Tank (if Equipped)
32
Filling Fuel Tank
33
Features and Controls
34
Remote Control Features
34
Warning System
35
Engine Overspeed Limiter
36
Power Trim and Tilt (if Equipped)
37
Manual Tilt System
40
Throttle Grip Friction Adjustment - Tiller Handle Models
44
Steering Friction Adjustment - Tiller Handle Models
44
Trim Tab Adjustment
45
Operation
46
Important Daily Inspection before each Use
46
Prestarting Check List
46
Operating in Freezing Temperatures
47
Operating in Saltwater or Polluted Water
47
Effects of Elevation and Weather on Performance
47
Operating at High Elevations
48
Engine Break-In Procedure
48
Starting the Engine
48
Gear Shifting
52
Stopping the Engine
53
Emergency Starting
53
Setting Trim Angle While Running Engine at Idle Speed
56
Cleaning Care Recommendations
57
Inspection and Maintenance Schedule
59
Flushing the Cooling System
60
Top Cowl Removal and Installation
61
Battery Inspection
62
Fuel System
62
Steering Link Rod Fasteners
65
Fuse Replacement
67
Corrosion Control Anode
67
Propeller Replacement-Standard Gearcase
68
Propeller Replacement-Command Thrust Gearcase
71
Spark Plug Inspection and Replacement
74
Lubrication Points
75
Lubrication Points-Seapro/Marathon Models
77
Checking Power Trim Fluid
79
Gearcase Lubrication
79
Submerged Outboard
81
Storage
82
Storage Preparation
82
Protecting External Outboard Components
82
Protecting Internal Engine Components
83
Gearcase
83
Positioning Outboard for Storage
83
Battery Storage
83
Troubleshooting
84
Starter Motor will Not Crank the Engine (Electric Start Models)
84
Engine will Not Start
84
Engine Runs Erratically
84
Performance Loss
85
Battery will Not Hold Charge
85
Owner Service Assistance
86
Local Repair Service
86
Service Away from Home
86
Parts and Accessories Inquiries
86
Service Assistance
86
Ordering Literature
88
Engine Installation
90
Mercury Marine Validated Engine Mounting Hardware
90
Accessories Mounted to the Transom Clamp Bracket
90
Fastening the Outboard to the Transom
94
Installing Outboard
99
Propeller Selection
100
Maintenance Log
102

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