1. 2004 Mercury 50 Hp Manual

This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service per- sonnel when servicing the products described here- in. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these prod- ucts which includes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers.

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We could not possibly know of and advise the service trade of all conceivable procedures by which a ser- vice might be performed and of the possible hazards and/or results of each method. We have not under- taken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected.

All information, illustrations and specifications con- tained in this manual are based on the latest product informa tion available at the time of publication. As re- quired, revisions to this manual will be sent to all deal- ers contracted by us to sell and/or service these prod- ucts. It should be kept in mind, while working on the prod- uct, that the electrical system and ignition system are capable of violent and damaging short circuits or se- vere electrical shocks.

When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive inter- nal damage when the engine is started. It is important to note, during any maintenance proce- dure replacement fasteners must have the same measurements and strength as those removed.

Numbers on the heads of the metric bolts and on the surface s of metric nuts indicate their strength. Ameri- can bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mis- matched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. There- fore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original.

2004 Mercury 50 Hp Manual

A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch./mm. When any product component is serv- iced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure.

This is conside red standard shop practice even if not specif- ically stated. Whenever components are removed for service, they should be retained in order.

At the time of instal- lation, they should be installed in the same locations and with the same mating surfaces as when re- moved. Before raising or removing and outboard engine from a boat, the following precautions should be adhered to: 1. Check that flywh eel is secur ed to end o f cra nk- shaft with a locknut and lifting eye is threaded into flywheel a minimum of 5 turns. Conne ct a hoist of s uitabl e st rength to t he lif ting eye.

In addition, personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent in- formation concerning the products described in this manual.