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5 SERIES
Mercury 5 SERIES User Manual
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GEAR HOUSING
Page 6-12
90-857138R1 MA
Y 2000
Propeller Shaft
1.
Remove reverse gear and washer
.
2.
Remove cam follower and guide.
a
b
c
d
56400
56401
a
-
Reverse Gear
b
-
W
asher
c
-
Cam Follower
d
-
Guide
3.
Using a punch, tap cross pin from sliding clutch. Leave punch in hole to retain spring at
this time.
4.
Put end of shaft against solid object. Remove punch from sliding clutch, and slowly re-
lease spring compression.
a
b
c
d
56402
56403
a
-
Sliding Clutch
b
-
End of Shaft
c
-
Punch
d
-
Sliding Clutch
199
201
Table of Contents
Section 1
13
Cleanliness and Care of Outboard Motor
4
Page Numbering
4
Table of Contents
13
After each Use
15
Before each Use
15
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
15
Inspection and Maintenance Schedule
15
Flushing the Cooling System
16
Fuel System
16
Fuel Line Inspection
16
Engine Fuel Filter
16
Corrosion Control Anode
17
Spark Plug Inspection
17
Lubrication Points
18
Changing Engine Oil
20
Engine Oil Capacity
20
Oil Changing Procedure
20
Oil Filling
20
Gear Case Lubrication
21
Gear Case Lubricant Capacity
21
Draining Gear Case
21
Checking Lubricant Level and Refilling Gear Case
22
Storage Preparations
22
Fuel System
22
Protecting External Engine Components
22
Protecting Internal Engine Components
23
Gear Case
23
Positioning Outboard for Storage
23
Section 2
24
Conditions Affecting Performance
25
Weather
25
Boat
26
Engine
28
Serial Number Location
25
Following Complete Submersion
29
Submerged While Running
29
Salt Water Submersion
29
Fresh Water Submersion
29
Propeller Selection
30
Propeller Removal/Installation
31
Compression Check
33
Cylinder Leakage Testing
34
Analysis
34
Painting Procedures
35
Cleaning & Painting Aluminum Propellers & Gear Housings
35
Decal Application
36
Decal Removal
36
Instructions for "Wet" Application
36
Section 3
38
Notice to Installer and Owner
39
Boat Horsepower Capacity
39
Selecting Accessories for the Outboard
39
Installing Outboard
40
Fastening Security Line
41
Tilt Pin Adjustment
41
Setting the Operating Angle of Your Outboard 1D-4
41
Engine Over-Speed Protection System
42
Installation Drawings
43
Electrical Components
47
Battery Connections
70
Ignition Timing
74
Wiring Diagram
77
Fuel Pump
79
Carburetor Adjustments
94
Idle Speed
94
Carburetor Disassembly
96
Carburetor Reassembly
98
Fuel System
100
Exhaust Emissions Standards
101
What Are Emissions
101
Hydrocarbons
101
Carbon Monoxide - CO
101
Oxides of Nitrogen - Nox
101
Controlling Emissions
101
Stoichiometric (14.7:1) Air/Fuel Ratio
102
Outboard Hydrocarbon Emissions Reductions
102
1/3% # Per Year over 9 Model Years
102
Stratified Vs Homogenized Charge
103
Homogenized Charge
103
Stratified Charge
104
Emissions Information
105
Manufacturer's Responsibility
105
Dealer Responsibility
105
Owner Responsibility
105
EPA Emission Regulations
106
Manufacturer's Certification Label
107
Service Replacement Certification Label
108
Removal
108
Date Code Identification
108
Installation
108
Decal Location
108
Valve Clearance
116
Powerhead Disassembly
146
MID-Section
176
Driveshaft Housing
177
Clamp Brackets
179
Cowling
181
Clamp Bracket/Swivel Bracket
183
Disassembly
183
Reassembly
183
Drive Shaft Housing
186
Bottom Cowling
187
Water Tube
188
Gear Housing
189
Special Tools
190
Quicksilver Lubricants and Service Aids
191
Gear Housing (Drive Shaft)
192
Gear Housing (Prop Shaft)
194
Draining and Inspecting Gear Housing Lubricant
196
Propeller Removal
196
Gear Housing Removal
197
Gear Housing Disassembly
198
Bearing Carrier
198
Propeller Shaft
200
Water Pump Housing and Impeller
201
Water Pump Base and Shift Shaft
202
Drive Shaft
205
Forward Gear and Bearing
205
Lower Drive Shaft Needle Bearing
206
Zinc Anode
206
Water Pickup Screen
207
Cleaning and Inspection
207
Gear Housing/Bearing Carrier Castings
207
Bearings
207
Forward, Reverse and Pinion Gears
208
Propeller Shaft
209
Sliding Clutch
209
Cam Follower
209
Water Pump Components
209
Drive Shaft
210
Shift Shaft
210
Gear Housing Reassembly
210
Lower Drive Shaft Needle Bearing
210
Forward Gear Bearing
211
Forward Gear
212
Pinion Gear and Drive Shaft
212
Water Pump Base and Shift Shaft
213
Propeller Shaft
215
Bearing Carrier
217
Impeller and Water Pump Housing
218
Zinc Anode
221
Water Pickup Screen
221
Gear Housing Installation
221
Propeller Installation
223
Filling Gear Housing with Lubricant
224
Controls
231
Steering Handle
232
Steering Handle
233
Removal
234
Disassembly
235
Reassembly
237
Installation
239
Recoil Starter
243
5
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Mercury 5 SERIES Specifications
General
Brand
Mercury
Model
5 SERIES
Category
Outboard Motor
Language
English
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