© 2019 Mercury Marine 5 HP FourStroke Propane Operation, Maintenance, and Installation Manual 8M0153256 219 eng
eng
Welcome You have selected one of the finest marine power packages available. It incorporates numerous design features to ensure operating ease and durability. With proper care and maintenance, you will enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual. The Operation and Maintenance Manual contains specific instructions for using and maintaining your product.
Additional alerts provide information that requires special attention: NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. IMPORTANT: The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard, and the safety of all occupants aboard.
Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Manual, which can be accessed any time on the Mercury Marine website, at http:// www.mercurymarine.com/warranty‑manual. The Warranty Manual contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.
Outboard Engine Model and Horsepower Engine Serial Number Gear Ratio Propeller Number Pitch Diameter Watercraft Identification Number (WIN) or Hull Identification Number (HIN) Purchase Date Boat Manufacturer Length Boat Model Exhaust Gas Emissions Certification Number (Europe Only) iv eng
General Information Boater's Responsibilities..................................................................................... 1 Boat Horsepower Capacity................................................................................. 1 Lanyard Stop Switch........................................................................................... 1 Protecting People in the Water........................................................................... 3 Exhaust Emissions.................................
Operation Operating in Freezing Temperatures................................................................ 23 Operating in Saltwater or Polluted Water......................................................... 23 Engine Break‑in Procedure............................................................................... 23 Starting the Engine........................................................................................... 23 Gear Shifting ...............................................................
Maintenance Log Maintenance Log..............................................................................................
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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. Be sure that at least one additional person onboard is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.
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. The lanyard cord is coiled to make its at‑rest condition as short as possible, to minimize the likelihood of lanyard entanglement with nearby objects.
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.
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. This neutral propeller rotation can cause serious injury.
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).
GENERAL INFORMATION 2. Examples of poor ventilation while the boat is moving: a b 21628 a - Operating the boat with the trim angle of the bow too high b - Operating the boat with no forward hatches open (station wagon effect) Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers. IMPORTANT: Check with your dealer before installing accessories.
GENERAL INFORMATION Anchor and extra anchor line Manual bilge pump and extra drain plugs Drinking water Radio Paddle or oar Spare propeller, thrust hubs, and an appropriate wrench First aid kit and instructions Waterproof storage containers Spare operating equipment, batteries, bulbs, and fuses Compass and map or chart of the area Personal flotation device (one per person onboard) Watch for signs of weather change and avoid foul weather and rough‑sea boating.
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 boat.
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. a a - Serial number 68617 Engine Specifications Parameter Specification Power 3.7 kw (5 hp) Full throttle RPM range Idle speed 5000–6000 Forward gear Neutral 1100 RPM 1100–1300 RPM Number of cylinders 1 Piston displacement 123 cc (7.51 cid) Cylinder bore 59 mm (2.32 in.) Piston stroke 45 mm (1.77 in.
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. a - Anti‑ventilation plate a 27004 INSTALLING THE OUTBOARD ON THE TRANSOM 1. Place the outboard on the centerline of the transom. 68622 2. Tighten the transom clamp handles.
TRANSPORTING Aquatic Invasive Species (AIS) STOP AQUATIC HITCHHIKERS!™ Be A Good Steward. Clean. Drain. Dry. 68805 For additional information, visit StopAquaticHitchhikers.org. AIS and their spread can detrimentally impact the boating experience and the future of the boating lifestyle.
TRANSPORTING Carrying, Storing, and Transporting Your Outboard When Removed from Boat 1. Disconnect the fuel line. Install the protective cap over the fuel connector. a b 68499 a - Fuel line connector b - 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. 3. Carry, transport, or store the outboard only in the upright position or tiller handle down position.
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. Your boat should be trailered with the outboard tilted down (normal operating position). If additional ground clearance is required, remove the outboard from the boat and store securely.
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. To ensure safe operation, always adhere to the following safety precautions.
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. • Never store in enclosed spaces.
FUEL AND OIL Engine Oil Recommendations Mercury or Quicksilver NMMA FC‑W certified SAE 10W‑30 4‑Stroke Marine Engine Oil is recommended for general, all‑temperature use. If NMMA certified synthetic blend oil is preferred, use Mercury or Quicksilver SAE 25W‑40 Synthetic Blend Marine 4‑Stroke Engine Oil. If the recommended Mercury or Quicksilver NMMA FC‑W certified outboard oils are not available, a major FC‑W certified 4‑stroke outboard oil may be used.
FUEL AND OIL NOTE: If the oil level is at the add mark, add 100 ml (3 oz) of oil. a - Full mark b - Add mark a b 45609 NOTE: Under certain conditions, the engine operating temperature may not get high enough to evaporate the normal moisture that accumulates in the crankcase. These conditions include operating at idle for long periods, repeated short trips, slow speed or quick stop‑and‑go operation, and operating in cooler climates.
FEATURES AND CONTROLS Features and Controls Choke knob ‑ Pull completely out when starting a cold engine. Push halfway in as the engine is warming up. Push in completely after the engine is warmed up. Oil pressure indicator ‑ If the oil pressure drops too low, the oil pressure indicator light will turn on. If the oil pressure indicator light turns on while the engine is running, stop the engine as soon as possible. Check the oil level and add oil as needed.
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. a - Decrease friction (counterclockwise) b - Increase friction (clockwise) c - Steering friction knob a b c 45615 Shift handle ‑ Controls the gear shift. R N F 68555 Tilting Outboard TILTING TO FULL UP POSITION 1. Stop the engine. Shift the outboard into forward gear. 2.
FEATURES AND CONTROLS LOWERING TO RUN POSITION Raise the outboard and pull up on the tilt release lever. Gently lower the outboard down. a - Tilt release lever b - Tilt lock lever b a 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. ENGAGING SHALLOW WATER DRIVE 1. Reduce the engine speed to idle in forward gear.
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.
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.
OPERATION Operating in Freezing Temperatures When using your outboard or having your outboard moored in freezing or near freezing temperatures, keep the outboard tilted down at all times so the gearcase is submerged. This prevents the trapped water in the gearcase from freezing and causing possible damage to the water pump and other components. If there is a chance of ice forming on the water, the outboard should be removed and drained completely of water.
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. R N F 68555 NOTE: The engine will not start unless the lanyard is engaged with the stop switch.
OPERATION 4. Attach the lanyard to the stop switch. Refer to General Information ‑ Lanyard Stop Switch. a - Stop switch b - Lanyard a b 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. a d abcd5. b c 68672 RHA Standard hose RPF Non‑leaching hose Connect the fuel hose to the outboard.
OPERATION 6. Open the fuel tank valve. a a - RPF fuel hose (to engine) b - Open fuel tank valve b 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. Push in completely after the engine is warmed up. a - Choke a 45625 NOTE: Starting a flooded engine ‑ Push in the choke knob. Wait 30 seconds. Then continue to crank the engine for starting.
OPERATION 9. Pull the starter rope slowly until the starter engages. Then pull rapidly to crank the engine. Allow the rope to return slowly. Repeat until the engine starts. 68627 10. Check for a steady stream of water flowing out of the water pump indicator hole. IMPORTANT: If no water is coming out of the water pump indicator hole, stop the engine and check the cooling water intake for obstructions. No obstructions may indicate a water pump failure or blockage in the cooling system.
OPERATION Always shift the outboard into gear with a quick motion. R N F 68555 Stopping the Engine Reduce the engine speed and push in the stop switch or pull the lanyard.
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. 1. Shift the outboard to the neutral (N) position. R N F 68555 2. Disconnect the linkage from the rewind starter assembly.
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. Place the starter rope knot into the starter cup notch and wind the rope clockwise around the cup. 5. Pull the starter rope to start the engine.
MAINTENANCE Outboard Care To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers, and retain its dependability. Record maintenance performed in the Maintenance Log at the back of this book. Save all maintenance work orders and receipts.
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 a CALIFORNIA AND U.S.
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. See Lubrication Points. • Change the engine oil. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. See Changing Engine Oil.
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. 4. Remove the hose coupling and install the plug and gasket.
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. To maintain this corrosion protection, always replace the anode before it is completely eroded.
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. • Inspect all valves and connectors for corrosion, damage, or leaks. Replace or repair as necessary.
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. 6.
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. 1. Remove the spark plug boot. Twist the rubber boot slightly and pull off. 26899 2. Remove the spark plug to inspect.
MAINTENANCE Lubrication Points 1. Lubricate the following with 2‑4‑C with PTFE or Extreme Grease. Tube Ref No. 95 Description Where Used Part No. 2-4-C with PTFE Copilot, swivel bracket, transom clamp screws, tiller handle bushing, shift handle detent 92-802859A 1 Extreme Grease Copilot, swivel bracket, transom clamp screws, tiller handle bushing, shift handle detent 8M0071842 • Copilot ‑ lubricate threads. • Swivel bracket ‑ lubricate through fittings.
MAINTENANCE • Tiller handle rubber bushing ‑ lubricate internal diameter. a - Tiller handle rubber bushing a 68633 • Shift detent ‑ lubricate detent shaft. a - Shift detent a 45648 2. Lubricate the tilt pivot points with lightweight 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 No. 95 Description Where Used Part No.
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. a - Drain plug a 68635 OIL FILLING IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil. Remove the oil filler cap and fill with 450 ml (15 fl oz) of oil. Install the oil filler cap. Operate the engine at idle for five minutes and check for leaks.
MAINTENANCE 3. Remove the vent plug and fill/drain plug, and drain the lubricant. a a - Vent plug (remove) b - Fill/drain plug (remove) c - Drain pan b c 68637 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. 2. Remove the vent plug from the vent hole.
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.
STORAGE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer). Protecting External Outboard Components • Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • Touch up any paint nicks.
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. 1. Carry, transport, or store the outboard only in the following two positions. These positions will prevent oil from draining out of the crankcase.
OWNER SERVICE ASSISTANCE Service Assistance LOCAL REPAIR SERVICE If you need service for your Mercury‑outboard‑powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine. NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for your power package.
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. Talk with the dealership's sales manager or service manager. 2. If your question, concern, or problem cannot be resolved by your dealership, please contact the Mercury Marine Service Office for assistance.
OWNER SERVICE ASSISTANCE Mexico, Central America, South America, Caribbean Telephone +1 954 744 3500 Fax +1 954 744 3535 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 U.S.A.
OWNER SERVICE ASSISTANCE Quantity Item Stock Number Price Total . . . . . . . . . Total Due 50 . .
MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts.
