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Mercury 90 Operation Maintenance Warranty Installation Manual
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1.
The water pressure tube is coiled and attached on the side of the engine.
Cut the cable tie and route the water pressure tube out through the
grommet.
a -
Water pressure tube
2.
Remove the plug from the coupler and make the connection. A barb fitting
(22‑859731) can be installed for larger diameter hose connection.
a -
Plug
b -
Coupler
c -
Barb fitting (22‑859731)
a
23702
c
a
b
23708
OUTBOARD INSTALLATION
140
eng
149
151
Table of Contents
Table of Contents
7
Warranty Information
11
Warranty Registration United States and Canada
11
Transfer of Warranty United States and Canada
11
Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada
12
Mercury Jet Products Limited Warranty
12
Year Limited Warranty against Corrosion
15
Warranty Coverage and Exclusions
17
U.S. EPA Emissions Limited Warranty
19
Emission Control System Components
19
California Emissions Limited Warranty
20
California Air Resources Board Explanation of Your California Emission Control Warranty Statement
22
Emission Certification Star Label
23
Warranty Policy-Australia and New Zealand
24
Global Warranty Charts Outboard and Jets
28
General Information
33
Boater's Responsibilities
33
Before Operating Your Outboard
33
Boat Horsepower Capacity
33
High-Speed and High-Performance Boat Operation
34
Propeller Selection
34
Outboard Remote Control Models
36
Remote Steering Notice
37
Lanyard Stop Switch
37
Protecting People in the Water
40
Passenger Safety Message - Pontoon Boats and Deck Boats
40
Wave and Wake Jumping
42
Impact with Underwater Hazards
43
Exhaust Emissions
44
Selecting Accessories for Your Outboard
46
Safe Boating Recommendations
46
Recording Serial Number
48
Specifications
49
80 Jet Optimax Specifications
50
Component Identification
51
Component Identification
52
Transporting
53
Trailering Boat/Outboard
53
Fuel and Oil
54
Fuel Recommendations
54
Fuel Requirements
55
Fuel Additives
55
Avoiding Fuel Flow Restriction
55
Low Permeation Fuel Hose Requirement
55
EPA Pressurized Portable Fuel Tank Requirements
56
Fuel Demand Valve (FDV) Requirement
56
Mercury Marine's Pressurized Portable Fuel Tank
56
Oil Recommendation
57
Filling Oil Injection System
58
Filling Fuel Tank
60
Features and Controls
61
Remote Control Features
61
Warning System
61
Power Trim and Tilt
63
Trim Tab Adjustment
67
Operation
68
Important Information
68
Prestarting Check List
69
Operating in Freezing Temperatures
69
Operating in Saltwater or Polluted Water
69
Operating at High Elevations
70
Setting Trim Angle While Running Engine at Idle Speed
70
Engine Break-In
70
Starting the Engine
71
Gear Shifting
73
Stopping the Engine
74
Jet Drive Operation
74
Outboard Care
83
EPA Emissions Regulations
83
Inspection and Maintenance Schedule
84
Flushing the Cooling System
87
Top Cowl Removal and Installation
87
Cleaning Care for Top Cowl
88
Flywheel Cover Removal and Installation
88
Side Panel Removal and Installation
89
Oil Injection System
90
Fuel System
93
Steering Link Rod Fasteners
95
Fuse Replacement
96
Corrosion Control Anode
97
Battery Inspection
98
Battery Information (All Batteries Including DTS)
98
Propellers
99
Spark Plug Inspection and Replacement
102
Compressor Air Intake Filter
104
Alternator Belt Inspection
105
Lubrication Points
105
Lubrication Points
107
Checking Power Trim Fluid
109
Gearcase Lubrication
110
Storage
112
Storage Preparation
112
Fuel System
112
Protecting Internal Engine Components
114
Protecting External Outboard Components
114
Gearcase
114
Jet Drive
114
Positioning Outboard for Storage
114
Battery Storage
115
Owner Service Assistance
116
Local Repair Service
116
Service Away from Home
116
Parts and Accessories Inquiries
116
Service Assistance
116
Ordering Literature
119
Troubleshooting
121
Starter Motor will Not Crank the Engine
121
Engine will Not Start
121
Engine Runs Erratically
121
Performance Loss
122
Battery will Not Hold Charge
122
Jet Application Troubleshooting
122
Outboard Installation
124
Mercury Marine Validated Engine Mounting Hardware
124
Accessories Mounted to the Transom Clamp Bracket
124
Important Information
128
Boat Horsepower Capacity
128
Start in Gear Protection
129
Fuel System
129
Installation Specifications
131
Lifting the Outboard
131
Steering Cable - Starboard Side Routed Cable
132
Determining Recommended Outboard Mounting Height
134
Determining the Mounting Height of the Outboard Jet
135
Drilling Outboard Mounting Holes
137
Fastening the Outboard to the Transom
138
Electrical, Fuel Hose, Flush Hose, and Control Cables
143
Oil Injection Set-Up
156
Trim in Pin
157
Maintenance Log
159
Other manuals for Mercury 90
Service Manual
574 pages
User Manual
62 pages
Manual
32 pages
Operation And Maintenance Manual
96 pages
Operation Maintenance Installation Warranty Manual
141 pages
4
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Mercury 90 Specifications
General
Brand
Mercury
Model
90
Category
Outboard Motor
Language
English
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