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Mercury Jet OptiMax 80, Manual, Page: 9 / 128

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Summary of Contents for Jet OptiMax 80

Page 1: ...for your confidence in Mercury Marine EPA Emissions Regulations Outboards sold by Mercury Marine in the United States are certified to the United States Environmental Protection Agency as conforming...

Page 2: ...on Mercury Marine Fond du Lac Wisconsin U S A Litho in U S A 2007 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers Mariner...

Page 3: ...f the following directives by meeting the associated standards as amended If the CE mark is accompanied by a notified body number the following Recreational Craft Directive applies Recreational Craft...

Page 4: ...IA 39 94 Vibration ICOMIA 38 94 Electromagnetic Compatibility Directive 89 336 EC Generic emission standard EN 50081 1 Generic immunity standard EN 50082 1 Vehicles boats and internal combustion engin...

Page 5: ...ponsibilities 19 Before Operating Your Outboard 19 Boat Horsepower Capacity 20 High Speed and High Performance Boat Operation 20 Outboard Remote Control Models 20 Remote Steering Notice 21 Lanyard Sto...

Page 6: ...s 42 Warning System 43 Power Trim and Tilt 46 Operation Pre Starting Check List 49 Operating In Freezing Temperatures 49 Operating in Saltwater or Polluted Water 50 Operating In Shallow Water 50 How t...

Page 7: ...8 Corrosion Control Anode 69 Battery Inspection 70 Battery Information 71 Spark Plug Inspection And Replacement 72 Steering Pull Adjustment 73 Worn Dull Impeller 73 Impeller Clearance Adjustment 74 Co...

Page 8: ...8 Mercury Marine Service Offices 89 Outboard Installation Important Information 91 Boat Horsepower Capacity 91 Start in Gear Protection 91 Selecting Accessories for Your Outboard 92 Fuel Tanks 92 Inst...

Page 9: ...TABLE OF CONTENTS ix Maintenance Log Maintenance Log 118...

Page 10: ...x...

Page 11: ...product by mail There is no charge for this service For products purchased outside the United States and Canada contact the distributor in your country or the Marine Power Service Center closest to yo...

Page 12: ...address new address and engine serial number to Mercury Marine s warranty registration department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Dep...

Page 13: ...service whichever occurs first Commercial users of these products receive warranty coverage of one 1 year from the date of first retail sale or one 1 year from the date on which the product was first...

Page 14: ...efunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured...

Page 15: ...ooling system by a foreign body running the engine out of water mounting the engine too high on the transom or running the boat with the engine trimmed out too far Use of the product for racing or oth...

Page 16: ...d has been designed and tested for your outboard but was not manufactured sold or factory installed by Mercury Marine The limited warranty on the outboard does not apply to the jet drive lower unit Th...

Page 17: ...ection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation...

Page 18: ...ser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to the dealer at the time warranty service is req...

Page 19: ...een the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for ad...

Page 20: ...is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have GENERAL EXCLUSIONS FROM WAR...

Page 21: ...ance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration 10 Participating in or preparing for racing or oth...

Page 22: ...icable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Health and Safety Code For information regarding the limited wa...

Page 23: ...provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury d...

Page 24: ...ower unit at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payme...

Page 25: ...onic ignition system c Spark advance retard system d Ignition coil and or control module e Ignition wires 4 Lubrication System 4 Stroke engines excluded a Oil pump and internal parts b Oil injectors c...

Page 26: ...5040 CALIFORNIA AIR RESOURCES BOARD EXPLANATION OF YOUR CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board is pleased to explain the...

Page 27: ...s or your failure to ensure the performance of all scheduled maintenance As the outboard engine owner you should however be aware that Mercury Marine may deny you warranty coverage if your outboard en...

Page 28: ...missions than One Star Low Emission engines A SS D 22533 Three Stars Ultra Low Emission The Three Star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard mar...

Page 29: ...oard properly If you have any questions contact your dealer Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage Th...

Page 30: ...M PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX 26777 High Speed and High Performance Boat Operation If your outboard is to be used on a high speed or high performance boat with which you are...

Page 31: ...e self locking nuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage WARNING Improper fasteners or improper installation pr...

Page 32: ...cm 4 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard is coiled to make its at r...

Page 33: ...ing in one direction drinking alcohol or consuming drugs or daring high speed boat maneuvers While activation of the lanyard stop switch will stop the engine immediately a boat will continue to coast...

Page 34: ...cking Stopping the Boat in an Emergency A jet powered boat has emergency stopping capability unique to this form of propulsion WARNING Using the emergency stopping capability of a jet drive unit will...

Page 35: ...pump as a high speed projectile WHILE BOAT IS STATIONARY WARNING Avoid injury resulting from contacting the rotating impeller or having hair clothing or loose objects drawn into the water intake and...

Page 36: ...No one should ever be on the deck in front of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could easily be thrown overboard o...

Page 37: ...y or completely out of the water certain hazards arise particularly when the boat re enters the water 26784 The primary concern is the boat changing direction while in the midst of the jump In such ca...

Page 38: ...by the outboard or the boat bottom The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed Under these con...

Page 39: ...so at greatly reduced speeds WARNING Operating a boat or engine with impact damage can result in product damage serious injury or death If the vessel experiences any form of impact have an authorized...

Page 40: ...with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an e...

Page 41: ...ely used with your outboard or outboard operating system Acquire and read the installation operation and maintenance manuals for all your selected accessories Safe Boating Suggestions In order to safe...

Page 42: ...d greatly reduces the ability to react quickly Prepare other boat operators Instruct at least one other person on board in the basics of starting and operating the jet drive and boat handling in case...

Page 43: ...h fallen skiers When using the boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to assist the skier The operator should...

Page 44: ...Certified Europe Insignia as applicable 80 Jet OptiMax Specifications Models 80 Horsepower 80 Kilowatts 59 7 Full throttle RPM range 5000 5750 RPM Idle speed in forward gear 625 675 RPM Number of cyl...

Page 45: ...nking amps CCA Charging system output 60 amps Component Identification a j i h b g f e d c 33496 a Top cowl b Auxiliary tilt switch c Transom brackets d Jet drive housing e Water intake housing f Reve...

Page 46: ...up using an accessory outboard support device Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing IMPORTANT Do not...

Page 47: ...and of leaded gasoline USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The 2 types of oxygenates used in these fuels are alcohol ethanol...

Page 48: ...particularly after storage Any sign of leakage or deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that...

Page 49: ...n IMPORTANT Adding components to the fuel supply system filters valves fittings etc may restrict the fuel flow This may cause engine stalling at low speed and or a lean fuel condition at high RPM that...

Page 50: ...rs 1 qt low The second ball marker indicates 1 89 liters 2 qt low a b 29464 a First ball marker b Second ball marker 4 Slowly fill the oil tank with the specified oil Do not overfill Add only enough o...

Page 51: ...o not smoke or allow open flames or sparks in the area while filling fuel tanks Fill fuel tanks outdoors away from heat sparks and open flames Remove portable fuel tanks from boat to refill them Alway...

Page 52: ...ndle forward neutral reverse b Neutral release lever c Lanyard stop switch Refer to General Information Lanyard Stop Switch d Trim tilt switch if equipped Refer to Features and Controls Power Trim and...

Page 53: ...will emit either a continuous beep or intermittent short beeps This will alert the operator and help identify the following listed situations For visual display of the specific engine functions and f...

Page 54: ...o lubricating oil is being supplied to the engine Engine overspeed Continuous The warning horn is activated any time engine speed exceeds the maximum allowable RPM The system will limit the engine spe...

Page 55: ...A Mercury SmartCraft System instrument package can be purchased for this outboard A few of the functions the instrument package will display are engine RPM coolant temperature battery voltage fuel con...

Page 56: ...ed while operating your boat on plane The term tilt is generally used when referring to adjusting the outboard further up out of the water With the engine turned off the outboard can be tilted out of...

Page 57: ...board will tilt up until the switch is released or it reaches its maximum tilt position 1 Engage the tilt support lever by rotating knob to bring the support lever upward 2 Lower outboard to rest on t...

Page 58: ...se This allows manual tilting of the outboard Tilt the outboard to the desired position and tighten the manual tilt release valve 22362 AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to t...

Page 59: ...perate a boat while under the influence of alcohol or drugs Know the waters and area you will be boating tides currents sand bars rocks and other hazards Make inspection checks listed in Maintenance I...

Page 60: ...ving The engine can idle through areas of water less than 61 cm 2 ft deep but there should be more than 61 cm 2 ft of water under the boat when increasing speed to reach full plane Once the boat is on...

Page 61: ...erted to create reverse thrust This approximate balancing of forward and reverse thrust will minimize any boat movement Because the impeller is always rotating and creating thrust when the engine is r...

Page 62: ...ing in serious injury or death Use caution when performing the emergency stopping procedure and be sure to practice in a safe area In an emergency putting the jet outboard into reverse and applying re...

Page 63: ...le the boat will respond quickly but due to the relatively flat bottom hulls and lack of a gearcase in the water the boat will tend to skid on turns Turns must be started early and use sufficient powe...

Page 64: ...dge between the impeller and jet housing wall especially after the engine has been stopped This will lock the driveshaft and will prevent the engine from being able to crank over for starting Followin...

Page 65: ...d approximately every two minutes and avoid continuous operation at idle speed for more than ten minutes Short bursts of full throttle for periods up to ten seconds are acceptable c Avoid trimming the...

Page 66: ...ine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 1 Ensure that the driveshaft bearing on the jet drive...

Page 67: ...a Squeeze the fuel line primer bulb until it feels firm b Turn the ignition key switch to the ON position for three seconds This operates the electric fuel pump c Turn the ignition key switch back to...

Page 68: ...cator hole stop engine and check cooling water intake holes for obstruction No obstruction may indicate a water pump failure or blockage in the cooling system This condition will cause the engine to o...

Page 69: ...9 After shifting outboard into gear advance the lever further to increase speed N R F 27237 Stopping The Engine Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF posi...

Page 70: ...Mercury Precision or Quicksilver replacement parts and Genuine Lubricants EPA Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection A...

Page 71: ...c Timing specification d Recommended spark plug and gap e Valve clearance if applicable f Family number g Maximum emission output for the engine family h Piston placement i Date of manufacture OWNER...

Page 72: ...ystem for a minimum of 3 minutes IMPORTANT Do not run engine above idle speed when flushing 4 Turn off the water and remove the water hose from the hose adapter Reinstall the cover into the hose adapt...

Page 73: ...e the top cowl with clean water to remove dirt and dust that may scratch the surface 2 Wash the top cowl with clean water and a mild non abrasive soap Use a soft clean cloth when washing 3 Dry thoroug...

Page 74: ...ree mounting pins Insert the tabs into the slots in the side panel and push the cover down onto the mounting pins c a b 23754 a Flywheel cover b Mounting pins c Tabs Side Panel Removal and Installatio...

Page 75: ...lots c Mounting pins Fuel System WARNING Fuel is flammable and explosive Ensure the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spa...

Page 76: ...INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer bul...

Page 77: ...43 a Drain hose b Right side fitting c Drain screw 3 Retighten the drain screw and reattach the hose IMPORTANT Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until...

Page 78: ...at washer 2 c Nylon insert locknut 11 826709113 d Nylon insert locknut 11 826709113 Description Nm lb in lb ft Special washer head bolt 27 20 Nylon insert locknut d 27 20 Nylon insert locknut c Tighte...

Page 79: ...same rating a b 5 e 20 20 20 15 c d g h 2 23793 f a Good fuse b Blown fuse c 14 pin remote control harness cowl trim switch main power relay 15 amp fuse d Ignition coil circuit 20 amp fuse e SmartCra...

Page 80: ...ake housing a b 33505 a Anode on the water intake housing b Anode on the transom bracket assembly Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine start...

Page 81: ...box for future service reference One 5 16 in and one 3 8 in hex nut are supplied per battery for wing nut replacement Metric hex nuts are not supplied NOTICE DTS OptiMax Engines DO NOT USE DEEP CYCLE...

Page 82: ...id 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 leads Twist the rubber boots slightly and pull off 26899 2 Remove the...

Page 83: ...ed by using a pliers and bending the ends of the exhaust fins 1 5 mm 1 16 in toward the starboard side of the outboard a 29573 a Exhaust fins Worn Dull Impeller The intake of gravel through the pump c...

Page 84: ...so there is approximately 0 8 mm 0 03 in clearance between the impeller edge and liner Operating the jet drive in waters that contain sand and gravel can cause wear to the impeller blades and the cle...

Page 85: ...engine without the air filter REMOVAL 1 Remove three screws and filter cover from engine 2 Remove filter from the cover a b 29476 a Cover b Filter INSTALLATION 1 Install filter into cover 2 Fasten fil...

Page 86: ...cription Where Used Part No 95 2 4 C with Teflon Driveshaft bearing 92 802859A 1 IMPORTANT It is important not to use a general all purpose grease for this bearing The lubricant recommended is a water...

Page 87: ...dirty gray color the driveshaft bearing and seals should be inspected and replaced if necessary Some discoloration of the grease is normal during the break in period on a new set of seals 2 Lubricate...

Page 88: ...te steering wheel to fully retract the steering cable end into the outboard tilt tube Lubricate through fitting WARNING Incorrect cable lubrication can cause hydraulic lock leading to serious injury o...

Page 89: ...r 27877 2 Remove fill cap and check fluid level The fluid level should be even with the bottom of the fill hole Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid If not ava...

Page 90: ...equire 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 at...

Page 91: ...ine and engine fuel system The most effective method of storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen products as described...

Page 92: ...c Right side fitting 5 Retighten the drain screw and reattach the hose to the right side fitting 6 Pull the drain hose off the left side fitting Hold the open end of the hose over a container 7 Loose...

Page 93: ...fuel to fill the fuel system Protecting Internal Engine Components NOTE Make sure the fuel system has been prepared for storage Refer to Fuel System preceding IMPORTANT Refer to Spark Plug Inspection...

Page 94: ...utboard for Storage Store the outboard in an upright vertical position This will allow water to drain out of the outboard Battery Storage Follow the battery manufacturer s instructions for storage and...

Page 95: ...ch not in RUN position Battery not fully charged Incorrect starting procedure Refer to Operation section Old or contaminated fuel Fuel is not reaching the engine Fuel tank is empty Fuel tank vent not...

Page 96: ...connection of an air hose is loose Fuel pump failure Ignition system component failure Performance Loss POSSIBLE CAUSES Throttle not fully open Damaged impeller Boat overloaded or load improperly dist...

Page 97: ...AUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regul...

Page 98: ...e dealer has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service...

Page 99: ...bsite www mercurymarine com Canada Telephone 905 567 6372 Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario L5N 7W6 Canada Fax 905 567 8515 Australia Pacific Telephone 61 3 9791 5822 Mercury...

Page 100: ...an Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Shizuoka ken Japan 435 0005 Japan Fax 81 053 423 2510 Asia Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang W...

Page 101: ...ous injury or death Overpowering the boat can affect boat control and flotation characteristics or break the transom Do not install an engine that exceeds the boat s maximum power rating Do not overpo...

Page 102: ...or outboard operating system Acquire and read the installation operation and maintenance manuals for all selected accessories Fuel Tanks PORTABLE FUEL TANK Select a suitable location in the boat withi...

Page 103: ...eel for a minimum of five turns and that the hoist has the correct lifting capacity for the engine weight To lift the outboard 1 Remove the cowl from the outboard 2 Thread the lifting eye into the fly...

Page 104: ...Routed Cable 1 Lubricate O ring seal and entire cable end 3724 95 Tube Ref No Description Where Used Part No 95 2 4 C with Teflon O ring seal and entire cable end 92 802859A 1 2 Insert steering cable...

Page 105: ...f freeing the link rod to disengage WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod This can cause a sudden unexpected...

Page 106: ...most applications however because of different boat hull designs the setting should be rechecked by test running the boat Refer to Water Testing Installing the outboard too high on the transom will al...

Page 107: ...s position 3 Fasten the outboard to the transom at this height Refer to Fastening the Outboard 22403 BOATS WITH A FLAT BOTTOM HULL 1 Place center the outboard on the boat transom Set the height of the...

Page 108: ...nting Height and install outboard to the nearest recommended mounting height 1 Mark four mounting holes on the transom using the transom drilling fixture 2757 a a b c a Drill guide holes b Transom dri...

Page 109: ...28421 Washer Inner 0 516 in ID x 1 50 in OD 12 54012 Washer Outer 0 53 in ID x 0 87 in OD Available Transom Mounting Bolts Part Number Part Name Description 10 67755005 Transom bolt 1 2 20 x 2 50 in l...

Page 110: ...e the construction of the transom may not be adequate The boat transom must be strengthened or the load carrying area increased 18961 a b a Transom yielding under bolt torque b Transom cracking under...

Page 111: ...for the upper transom bolts a b 33962 a Large transom washer b Transom reinforcement plate Description Part Number Large transom washer 67 896392 Transom reinforcement plate 67 896305 1 Apply marine...

Page 112: ...ter bolt 4 c Shank of bolt d Flat washer 4 e Locknut 4 Description Nm lb in lb ft Outboard mounting locknuts and bolts 75 55 Electrical Fuel Hose Flush Hose and Control Cables FRONT COWL GROMMET NOTE...

Page 113: ...om the bottom cowl a b 23714 a Access cover b Screws 2 Insert the lower alignment pin on the grommet into the hole in the lower cover Ensure the lettered side of the grommet is facing out 3 Route the...

Page 114: ...h hose b Grommet c Remote boat harness d Not used e Throttle cable f Fuel hose g Upper alignment pin h SmartCraft harness or additional harness opening i Water pressure tube j Battery cables k Lower a...

Page 115: ...E ROUTING If desired the flush hose can be routed outside the cowling as follows 1 Using a needle nose pliers break out the semi circular knockouts in the access cover and lower cover Smooth the edges...

Page 116: ...in a loss of power to the Digital Throttle and Shift DTS system leading to serious injury or death due to loss of boat control Secure the battery leads to the battery posts with hex nuts to avoid loo...

Page 117: ...BATTERIES DTS Digital Throttle and Shift applications and OptiMax engines must use a marine starting battery with 1000 MCA 800 CCA or 180 Ah rating IMPORTANT Battery cable size and length is critical...

Page 118: ...Outboards Connect a common ground cable wire size same as engine battery cables between negative terminals on starting batteries a a b b c d d 15497 a Red sleeve Positive b Black sleeve Negative c Gr...

Page 119: ...tboard route the SmartCraft wiring harness through the grommet and connect it to the SmartCraft harness connector on the engine a 23700 a SmartCraft harness connector WATER PRESSURE TUBE CONNECTION If...

Page 120: ...e Cut the cable tie and route the water pressure tube out through the grommet a 23702 a Water pressure tube 2 Remove the plug from the coupler and make the connection A barb fitting 22 859731 can be i...

Page 121: ...ff the rudder suddenly and unexpectedly slowing the boat This can cause serious injury or death from occupants being thrown within or out of the boat Adjust the shift cable to prevent the reverse gate...

Page 122: ...e adjustment barrel 5 Recheck the shift cable adjustment in forward shift position The correct shift adjustment will position the cam far enough on the roller to lock the reverse gate into forward pos...

Page 123: ...en the locknut then back off the locknut 1 4 turn 3 Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop 4 Place the cable barrel into the barr...

Page 124: ...il tank 4 72 liters 5 qt Optimax DFI 2 Cycle Engine Oil PRIMING THE OIL INJECTION PUMP Before starting engine for the first time prime the oil injection pump Priming will remove any air that may be in...

Page 125: ...imer bulb so that the arrow on the side of the bulb is pointing up Squeeze the fuel hose primer bulb until it feels firm 27348 3 Turn the ignition key switch to the ON position 26846 4 Within the firs...

Page 126: ...ty is desirable to improve acceleration reduce the angle and time spent in a bow high boat during planing off and in some cases may be necessary to plane off a boat with aft live wells given the varie...

Page 127: ...This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in whatever adjustment hole in the transom brackets is desired A non stainless steel shipping bolt sho...

Page 128: ...MAINTENANCE LOG 118 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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