Mercury 90 - Page 2

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Table of Contents7
Warranty Information11
Warranty Registration United States and Canada11
Transfer of Warranty United States and Canada11
Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada12
Mercury Jet Products Limited Warranty12
Year Limited Warranty against Corrosion15
Warranty Coverage and Exclusions17
U.S. EPA Emissions Limited Warranty19
Emission Control System Components19
California Emissions Limited Warranty20
California Air Resources Board Explanation of Your California Emission Control Warranty Statement22
Emission Certification Star Label23
Warranty Policy-Australia and New Zealand24
Global Warranty Charts Outboard and Jets28
General Information33
Boater's Responsibilities33
Before Operating Your Outboard33
Boat Horsepower Capacity33
High-Speed and High-Performance Boat Operation34
Propeller Selection34
Outboard Remote Control Models36
Remote Steering Notice37
Lanyard Stop Switch37
Protecting People in the Water40
Passenger Safety Message - Pontoon Boats and Deck Boats40
Wave and Wake Jumping42
Impact with Underwater Hazards43
Exhaust Emissions44
Selecting Accessories for Your Outboard46
Safe Boating Recommendations46
Recording Serial Number48
Specifications49
80 Jet Optimax Specifications50
Component Identification51
Component Identification52
Transporting53
Trailering Boat/Outboard53
Fuel and Oil54
Fuel Recommendations54
Fuel Requirements55
Fuel Additives55
Avoiding Fuel Flow Restriction55
Low Permeation Fuel Hose Requirement55
EPA Pressurized Portable Fuel Tank Requirements56
Fuel Demand Valve (FDV) Requirement56
Mercury Marine's Pressurized Portable Fuel Tank56
Oil Recommendation57
Filling Oil Injection System58
Filling Fuel Tank60
Features and Controls61
Remote Control Features61
Warning System61
Power Trim and Tilt63
Trim Tab Adjustment67
Operation68
Important Information68
Prestarting Check List69
Operating in Freezing Temperatures69
Operating in Saltwater or Polluted Water69
Operating at High Elevations70
Setting Trim Angle While Running Engine at Idle Speed70
Engine Break-In70
Starting the Engine71
Gear Shifting73
Stopping the Engine74
Jet Drive Operation74
Outboard Care83
EPA Emissions Regulations83
Inspection and Maintenance Schedule84
Flushing the Cooling System87
Top Cowl Removal and Installation87
Cleaning Care for Top Cowl88
Flywheel Cover Removal and Installation88
Side Panel Removal and Installation89
Oil Injection System90
Fuel System93
Steering Link Rod Fasteners95
Fuse Replacement96
Corrosion Control Anode97
Battery Inspection98
Battery Information (All Batteries Including DTS)98
Propellers99
Spark Plug Inspection and Replacement102
Compressor Air Intake Filter104
Alternator Belt Inspection105
Lubrication Points105
Lubrication Points107
Checking Power Trim Fluid109
Gearcase Lubrication110
Storage112
Storage Preparation112
Fuel System112
Protecting Internal Engine Components114
Protecting External Outboard Components114
Gearcase114
Jet Drive114
Positioning Outboard for Storage114
Battery Storage115
Owner Service Assistance116
Local Repair Service116
Service Away from Home116
Parts and Accessories Inquiries116
Service Assistance116
Ordering Literature119
Troubleshooting121
Starter Motor will Not Crank the Engine121
Engine will Not Start121
Engine Runs Erratically121
Performance Loss122
Battery will Not Hold Charge122
Jet Application Troubleshooting122
Outboard Installation124
Mercury Marine Validated Engine Mounting Hardware124
Accessories Mounted to the Transom Clamp Bracket124
Important Information128
Boat Horsepower Capacity128
Start in Gear Protection129
Fuel System129
Installation Specifications131
Lifting the Outboard131
Steering Cable - Starboard Side Routed Cable132
Determining Recommended Outboard Mounting Height134
Determining the Mounting Height of the Outboard Jet135
Drilling Outboard Mounting Holes137
Fastening the Outboard to the Transom138
Electrical, Fuel Hose, Flush Hose, and Control Cables143
Oil Injection Set-Up156
Trim in Pin157
Maintenance Log159

Mercury 90 - Page 2

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