Mercury 5 HP FourStroke Propane Operation, Maintenance And Installation Manual
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Mercury 5 HP FourStroke Propane Operation, Maintenance And Installation Manual

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Operation, Maintenance,
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  • Page 1 Operation, Maintenance, and Installation Manual...
  • Page 3 Keep this manual with the product for ready reference whenever you are on the water. Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant. Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Name / function: John Pfeifer, President, Mercury Marine...
  • Page 4 The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers. Descriptions and specifications contained herein were in effect at the time this was approved for printing.
  • Page 5 In addition, certain Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations.
  • Page 6 Outboard Engine Model and Horsepower Engine Serial Number Gear Ratio Propeller Number Pitch Diameter Watercraft Identification Number (WIN) or Hull Purchase Date Identification Number (HIN) Boat Manufacturer Boat Model Length Exhaust Gas Emissions Certification Number (Europe Only)

  • Page 7: Table Of Contents

    General Information Boater's Responsibilities..................1 Boat Horsepower Capacity................. 1 Lanyard Stop Switch................... 1 Protecting People in the Water................3 Exhaust Emissions..................... 4 Selecting Accessories for Your Outboard............6 Safe Boating Recommendations................ 6 Recording Serial Number................... 9 Engine Specifications..................9 Installation Outboard Installation..................
  • Page 8 Operation Operating in Freezing Temperatures..............23 Operating in Saltwater or Polluted Water............23 Engine Break‑in Procedure................23 Starting the Engine................... 23 Gear Shifting ....................27 Stopping the Engine..................28 Emergency Starting..................29 Maintenance Outboard Care....................31 EPA Emissions Regulations................31 Inspection and Maintenance Schedule.............
  • Page 9 Maintenance Log Maintenance Log....................51...
  • Page 10 viii...

  • Page 11: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and the safety of its occupants and general public. It is strongly recommended that each operator read and understand this entire manual before operating the outboard.
  • Page 12 GENERAL INFORMATION One end of the lanyard cord has a clip that is meant to be inserted around the stop switch on the engine. It holds the switch closed, allowing the engine to operate. The other end of the lanyard cord has a clip to attach to the operator's personal flotation device (PFD) or wrist.

  • Page 13: Protecting People In The Water

    GENERAL INFORMATION • Releasing your grip on a steering wheel or tiller handle that is pulling in one direction • Operating the boat while under the influence of drugs or alcohol • Performing high speed boat maneuvers While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance, depending upon the velocity and degree of any turn at shutdown.

  • Page 14: Exhaust Emissions

    GENERAL INFORMATION Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. Whenever a boat is moving (coasting) and the outboard gear shift is in neutral position, there is sufficient force by the water on the propeller to cause the propeller to rotate.
  • Page 15 GENERAL INFORMATION Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing).

  • Page 16: Selecting Accessories For Your Outboard

    Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.
  • Page 17 (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.
  • Page 18 GENERAL INFORMATION • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown overboard or into the...

  • Page 19: Recording Serial Number

    GENERAL INFORMATION Recording Serial Number It is important to record the engine's serial number for future reference. The serial number is located on the outboard as shown. Serial number 68617 Engine Specifications Parameter Specification Power 3.7 kw (5 hp) Full throttle RPM range 5000–6000 Forward gear 1100 RPM...

  • Page 20: Installation

    INSTALLATION Outboard Installation BOAT TRANSOM HEIGHT REQUIREMENT Measure the transom height of your boat. The anti‑ventilation plate should be 25–50 mm (1–2 in.) below the bottom of the boat. Anti‑ventilation plate 27004 INSTALLING THE OUTBOARD ON THE TRANSOM 1. Place the outboard on the centerline of the transom. 68622 2.

  • Page 21: Transporting

    TRANSPORTING Aquatic Invasive Species (AIS) STOP AQUATIC HITCHHIKERS!™ Be A Good Steward. Clean. Drain. Dry. For additional information, visit StopAquaticHitchhikers.org. 68805 AIS and their spread can detrimentally impact the boating experience and the future of the boating lifestyle. Reducing the spread of AIS has led to significant national efforts to inspect boats moving between water bodies or across state and federal boundaries and could lead to delayed or denied access if AIS are suspected or found on board.

  • Page 22: Carrying, Storing, And Transporting Your Outboard When Removed From Boat

    TRANSPORTING Carrying, Storing, and Transporting Your Outboard When Removed from Boat 1. Disconnect the fuel line. Install the protective cap over the fuel connector. 68499 Fuel line connector Protective cap 2. Remove the outboard and hold it upright until the water is drained out. Keep the outboard in an upright position when carrying.

  • Page 23: Trailering Your Boat

    TRANSPORTING Trailering Your Boat IMPORTANT: The tilt lock mechanism is not intended to support the outboard in the tilted up position when trailering your boat. Use of the tilt lock mechanism could allow the outboard to bounce and drop down causing damage to the outboard.

  • Page 24: Fuel And Oil

    FUEL AND OIL Fuel Recommendations This engine has been specifically designed to operate only on propane (liquified petroleum gas). LPG (Propane) Safety Precautions Use propane only in containers or remote tanks specifically designed and approved for propane. Propane is a combustible gas. It is colorless and thus invisible to the naked eye.
  • Page 25 FUEL AND OIL HANDLING AND STORAGE OF PROPANE CYLINDERS IMPORTANT: Be certain to observe the following precautions for storing cylinders: • Keep valves on empty cylinders closed and disconnected. Keep protective covers, caps, or plugs in place. • Store reserve cylinders in ventilated housings on open decks or in gastight lockers that are vented overboard and intended for that purpose.

  • Page 26: Engine Oil Recommendations

    FC‑W certified 4‑stroke outboard oil may be used. IMPORTANT: The use of nondetergent oils, multi‑viscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a major brand NMMA FC‑W certified oil), synthetic oils, low quality or oils that contain solid additives are not recommended.
  • Page 27 FUEL AND OIL NOTE: If the oil level is at the add mark, add 100 ml (3 oz) of oil. Full mark Add mark 45609 NOTE: Under certain conditions, the engine operating temperature may not get high enough to evaporate the normal moisture that accumulates in the crankcase.

  • Page 28: Features And Controls

    Check the oil level and add oil as needed. If the oil pressure indicator light stays on when the oil level is correct, consult an authorized Mercury dealer. Engine stop switch/lanyard stop switch ‑ Push in or pull the lanyard to stop the engine.

  • Page 29: Tilting Outboard

    FEATURES AND CONTROLS Steering friction adjustment ‑ Adjust this knob to achieve the desired steering friction (drag) on the tiller handle. Turn the knob clockwise to increase friction and counterclockwise to decrease friction. Decrease friction (counterclockwise) Increase friction (clockwise) Steering friction knob 45615 Shift handle ‑...

  • Page 30: Shallow Water Operation

    FEATURES AND CONTROLS LOWERING TO RUN POSITION Raise the outboard and pull up on the tilt release lever. Gently lower the outboard down. Tilt release lever Tilt lock lever 45616 Shallow Water Operation This outboard has a shallow water drive position. This will allow you to tilt the outboard to a higher position to prevent hitting bottom.

  • Page 31: Setting The Operating Angle Of Your Outboard

    FEATURES AND CONTROLS IMPORTANT: Operate outboard at slow speed for shallow water operation and keep the cooling water intake submerged. 3. To release outboard back down to run position, tilt outboard up slightly and pull up on the tilt release lever. Gently lower the outboard down. Tilt release lever Tilt lock lever 45616...
  • Page 32 FEATURES AND CONTROLS NOTE: Your engine speed should never reach the maximum limit to activate the system unless the propeller is ventilating, an incorrect propeller is being used, or the propeller is faulty.

  • Page 33: Operation

    Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.
  • Page 34 OPERATION 1. Ensure that the cooling water intake is submerged. 27029 2. Check the engine oil level. 27030 3. Shift the outboard to the neutral (N) position. 68555 NOTE: The engine will not start unless the lanyard is engaged with the stop switch.
  • Page 35 OPERATION 4. Attach the lanyard to the stop switch. Refer to General Information ‑ Lanyard Stop Switch. Stop switch Lanyard 68624 IMPORTANT: Use only a non‑leaching fuel hose. A non‑leaching fuel hose is imprinted with the designation RPF, whereas a standard hose is designated RHA.
  • Page 36 OPERATION 6. Open the fuel tank valve. RPF fuel hose (to engine) Open fuel tank valve 68641 7. Position the throttle grip to the START position. 68626 8. If the engine is cold, completely pull out the choke. Push the choke in halfway as the engine is warming up.

  • Page 37: Gear Shifting

    These conditions will cause the engine to overheat. Have the outboard checked by an authorized Mercury dealer. Operating the engine while it is overheated can cause serious engine damage.

  • Page 38: Stopping The Engine

    OPERATION Always shift the outboard into gear with a quick motion. 68555 Stopping the Engine Reduce the engine speed and push in the stop switch or pull the lanyard. Stop switch Lanyard 68624...

  • Page 39: Emergency Starting

    OPERATION Emergency Starting If the starter rope breaks or the rewind starter fails, use the spare starter rope (provided) and follow this procedure. WARNING The neutral‑speed‑protection device is inoperative when starting the engine with the emergency starter rope. Set the engine speed at idle and the gear shift in neutral to prevent the outboard from starting in gear.
  • Page 40 OPERATION WARNING The exposed moving flywheel can cause serious injury. Keep your hands, hair, clothing, tools, and other objects away from engine when starting or running the engine. Do not attempt to reinstall the rewind starter assembly or top cowl when engine is running. 4.

  • Page 41: Maintenance

    Genuine Lubricants. EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments set to factory standards.

  • Page 42: Inspection And Maintenance Schedule

    MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in gear):...

  • Page 43: Flushing The Cooling System

    MAINTENANCE • Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in saltwater. EVERY 100 HOURS OF USE OR ONCE YEARLY, WHICHEVER OCCURS FIRST • Lubricate all lubrication points. Lubricate more frequently when used in saltwater.

  • Page 44: Top Cowl Removal And Installation

    MAINTENANCE Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. NOTE: Do not run the engine while flushing the cooling system. 1. Remove the plug and gasket. 2. Install the hose coupling into the plug opening. 3. Attach a water hose to the hose coupling. Turn on the water gently and flush the cooling system for 3–5 minutes.

  • Page 45: Corrosion Control Anode

    MAINTENANCE Corrosion Control Anode This outboard has a corrosion control anode installed on the gearcase. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly corroded instead of the outboard metals. The anode requires periodic inspection, especially in saltwater, which will accelerate the erosion.

  • Page 46: Propeller Replacement

    MAINTENANCE FUEL SYSTEM INSPECTION • Regularly check all fuel system connections for leakage. • Do not use solutions containing ammonia. • Never use a flame to check for leaks. • Inspect hoses in the LPG system regularly (at least annually) and replace with hoses of the same type approval, if any deterioration is found.
  • Page 47 MAINTENANCE 5. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed.

  • Page 48: Spark Plug Inspection And Replacement

    MAINTENANCE Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots.

  • Page 49: Lubrication Points

    MAINTENANCE Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease. Tube Ref Description Where Used Part No. Copilot, swivel bracket, transom clamp 2-4-C with PTFE screws, tiller handle bushing, shift 92-802859A 1 handle detent Copilot, swivel bracket, transom clamp Extreme Grease screws, tiller handle bushing, shift 8M0071842...
  • Page 50 MAINTENANCE • Tiller handle rubber bushing ‑ lubricate internal diameter. Tiller handle rubber bushing 68633 • Shift detent ‑ lubricate detent shaft. Shift detent 45648 2. Lubricate the tilt pivot points with lightweight oil. Tilt pivot points 68634...

  • Page 51: Changing Engine Oil

    MAINTENANCE 3. Lubricate the propeller shaft with Extreme Grease or 2‑4‑C with PTFE. (Refer to Propeller Replacement for removal and installation of the propeller.) Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding to the shaft. 68645 Tube Ref Description...

  • Page 52: Gearcase Lubrication

    MAINTENANCE IMPORTANT: Inspect the oil for signs of contamination. Oil contaminated with water will have a milky color. If contaminated oil is observed, have the engine checked by an authorized dealer. Drain plug 68635 OIL FILLING IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil.
  • Page 53 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 195 ml (6.6 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND FILLING GEARCASE 1. Place the outboard in a vertical operating position.

  • Page 54: Submerged Outboard

    MAINTENANCE Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.

  • Page 55: Storage

    Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref Description Where Used Part No.

  • Page 56: Positioning Outboard For Storage

    STORAGE Positioning Outboard for Storage NOTICE Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water collected in the propeller exhaust outlet in the gearcase can freeze. Store the outboard in the full down position.

  • Page 57: Owner Service Assistance

    STOLEN POWER PACKAGE If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packages.
  • Page 58 OWNER SERVICE ASSISTANCE RESOLVING A PROBLEM Satisfaction with your Mercury product is important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury dealership. If you need additional assistance: 1.

  • Page 59: Ordering Literature

    Before ordering literature, have the following information about your power package available: Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact: Mercury Marine Telephone Mail Mercury Marine (920) 929‑5110 (920) 929‑4894...
  • Page 60 OWNER SERVICE ASSISTANCE Quantity Item Stock Number Price Total Total Due...
  • Page 61 MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

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