Mercury Jet OptiMax 80 User manual

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Thank You
for your purchase of one of the finest outboards available. You
have made a sound investment in boating pleasure. Your
outboard has been manufactured by Mercury Marine, a world
leader in marine technology and outboard manufacturing
since 1939. These years of experience have been committed
to the goal of producing the finest quality products. This led to
Mercury Marine's reputation for strict quality control,
excellence, durability, lasting performance and being the best
at providing after the sale support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in the
operation, safe use and care of your outboard.
All of us at Mercury Marine took pride in building your outboard
and wish you many years of happy and safe boating.
Again, thank you 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 to the requirements of the regulations
for the control of air pollution from new outboard motors. This
certification is contingent on certain adjustments being set to
factory standards. For this reason, the factory procedure for
servicing the product must be strictly followed and, wherever
practicable, returned to the original intent of the design.
Maintenance, replacement, or repair of the emission
control devices and systems may be performed by any
marine engine repair establishment or individual.
Engines are labeled with an Emission Control Information
decal as permanent evidence of EPA certification.
! WARNING
The engine exhaust from this product contains chemicals
known to the state of California to cause cancer, birth defects
or other reproductive harm.
© 2008 Mercury Marine 80 Jet OptiMax 90-10259080 108

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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 Information Section of this manual. The warranty
statement 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. Please review this important
information.
The description and specifications contained herein were in effect
at the time this manual was approved for printing. Mercury Marine,
whose policy is one of continued improvement, reserves the right
to discontinue models at any time, to change specifications,
designs, methods, or procedures without notice and without
incurring obligation.
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, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max,
OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide,
SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves
logo, and SmartCraft logo are all registered trademarks of
Brunswick Corporation. Mercury Product Protection logo is a
registered service mark of Brunswick Corporation.
Mercury Premier Service
Mercury evaluates the service performance of its dealers and
assigns its highest rating of "Mercury Premier" to those
demonstrating an exceptional commitment to service.
Earning a Mercury Premier Service rating means a dealer:
• Achieves a high 12 month service CSI (Customer Satisfaction
Index) score for warranty service.
• Possesses all necessary service tools, test equipment,
manuals and parts books.
• Employs at least one Certified or Master technician.

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• Provides timely service for all Mercury Marine customers.
• Offers extended service hours and mobile service, when
appropriate.
• Uses, displays and stocks adequate inventory of genuine
Mercury Precision Parts.
• Offers a clean, neat shop with well organized tools and service
literature.
Declaration of Conformity
This outboard motor’s serial number plate, in the lower left hand
corner, contains either the CE mark alone or the CE mark
accompanied by a notified body number. This outboard motor
manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine
Power Europe Inc. Park Industriel, de Petit‑Rechain, Belgium
complies with the requirements of 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 Directive: 2003/44/EC amending 94/25/EC
Owner's manual (A.2.5) ISO 10240
Handling characteristics (A.4) ISO 8665
Outboard engine starting (A.5.1.4) ISO 11547
Fuel tanks (A.5.2.2) ISO 13591; ISO 8469
General steering system ABYC P‑17
Exhaust emission requirements (B.
2) ISO 8178
Owner's manual (B.4) ISO 8665
Noise emission levels (C.1) ISO 14509
The notified body responsible for surveillance of the quality system under Full
Quality Assurance Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
If the CE mark is not accompanied by a notified body number, the
following Recreational Craft Directive language applies:

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Recreational Craft Directive: 94/25/EC
Owner's manual (A.2.5) ISO 10240
Handling characteristics (A.4) ISO 8665
Outboard engine starting (A.5.1.4) ISO 11547
Fuel tanks (A.5.2.2) ISO 13591; ISO 8469
General steering system ABYC P‑17
The following applies to all product covered by this manual:
Safety of Machinery Directive 98/37/EC
Principles of safety integration
(1.1.2) EN 292‑1; EN 292‑2; EN 1050
Noise (1.5.8) ICOMIA 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 engine driven devices ‑
radio disturbance characteristics
SAE J551 (CISPR 12)
Electrostatic discharge testing EN 61000‑6‑2; EN 61000‑4‑2; EN
61000‑4‑3
This declaration is issued under the sole responsibility of Mercury
Marine and Marine Power Europe.
Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Regulations and Product Safety Department, Mercury Marine,
Fond du Lac, WI USA

TABLE OF CONTENTS
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Warranty Information
Transfer of Warranty....................................................................1
Transfer of Mercury Product Protection (Extended Service
Coverage) Plan............................................................................1
Warranty Registration United States And Canada......................2
OptiMax Outboard Limited Warranty...........................................3
Jet Drive Lower Unit Warranty.....................................................6
3 Year Limited Warranty Against Corrosion................................6
Warranty Coverage and Exclusions.......................................... 10
California Emissions Limited Warranty......................................12
Star Label.................................................................................. 17
General Information
Boater's Responsibilities............................................................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 Stop Switch..................................................................22
Stopping the Boat in an Emergency..........................................24
Protecting People In The Water.................................................25
Passenger Safety Message ‑ Pontoon Boats and Deck Boats..26
Wave and Wake Jumping..........................................................27
Impact with Underwater Hazards...............................................28
Exhaust Emissions.................................................................... 29
Selecting Accessories for Your Outboard..................................31
Safe Boating Suggestions......................................................... 31
Recording Serial Number.......................................................... 34
80 Jet OptiMax Specifications................................................... 34
Component Identification...........................................................35
Transporting
Trailering Boat/Outboard .......................................................... 36

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Fuel and Oil
Fuel Recommendations.............................................................37
Fuel Requirements....................................................................39
Fuel Additives............................................................................39
Avoiding Fuel Flow Restriction..................................................39
Oil Recommendation.................................................................39
Filling Oil Injection System.........................................................39
Filling Fuel Tank........................................................................41
Features and Controls
Remote Control Features..........................................................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 the Jet Drive Operates.......................................................50
Stopping the Boat in an Emergency..........................................52
Steering the Boat.......................................................................52
Mooring The Boat......................................................................53
Water Intake Blockage...............................................................53
Clearing A Lodged Impeller.......................................................54
Engine Break‑in Procedure........................................................54
Starting the Engine....................................................................55
Gear Shifting..............................................................................58
Stopping The Engine.................................................................59

TABLE OF CONTENTS
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Maintenance
Outboard Care...........................................................................60
EPA Regulations........................................................................60
EPA Emissions..........................................................................61
Flushing the Cooling System ....................................................61
Top Cowl Removal and Installation...........................................62
Cleaning Care for Top Cowl......................................................63
Flywheel Cover Removal and Installation..................................63
Side Panel Removal and Installation.........................................64
Fuel System...............................................................................65
Steering Link Rod Fasteners.....................................................67
Fuse Replacement.....................................................................68
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
Compressor Air Intake Filter......................................................75
Alternator Belt Inspection...........................................................75
Lubrication Points......................................................................76
Checking Power Trim Fluid........................................................79
Submerged Outboard................................................................80
Storage
Storage Preparation...................................................................81
Fuel System...............................................................................81
Protecting Internal Engine Components....................................83
Protecting External Outboard Components...............................83
Jet Drive.....................................................................................84
Positioning Outboard for Storage..............................................84
Battery Storage..........................................................................84

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Troubleshooting
Starter Motor Will Not Crank the Engine....................................85
Engine Will Not Start..................................................................85
Engine Runs Erratically.............................................................86
Performance Loss......................................................................86
Engine Over‑Speed (Excessive RPM).......................................86
Battery Will Not Hold Charge.....................................................87
Owner Service Assistance
Local Repair Service..................................................................88
Service Away from Home..........................................................88
Parts and Accessories Inquiries................................................88
Service Assistance....................................................................88
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
Installation Specifications..........................................................92
Lifting the Outboard...................................................................93
Steering Cable ‑ Starboard Side Routed Cable.........................94
Steering Link Rod Fasteners.....................................................95
Determining the Mounting Height of the Outboard ...................96
Drilling Outboard Mounting Holes..............................................98
Fastening the Outboard to the Transom....................................99
Electrical, Fuel Hose, Flush Hose, and Control Cables...........102
Oil Injection Set‑Up..................................................................114
Trim In Pin...............................................................................116

TABLE OF CONTENTS
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Maintenance Log
Maintenance Log.....................................................................118

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