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Mercury Jet 65 Manual

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Welcome Aboard!
Proper care and maintenance is an important part in keeping your Mercury Product operating at peak
efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key
to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty
coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose? Please check on www.marinepower.com. If
necessary, please contact your local dealer.
If the outboard motor's serial number plate contains the CE mark in the lower left-hand corner, the
following statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe
Inc. Park Industrel, de Petit-Rechain, Belgium complies with the requirements of the following directives
and standards, as amended:
Recreational Craft Directive: 94/25/EC; std. ISO 8665, ISO 11547
Machinery Directive:
EMC Directive:
Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Product Environmental Engineering Department, Mercury Marine, Fond du Lac, WI USA
98/37/EC,
89/336/EC; std. EN50081-1, SAE J551 (CISPR Pub. 12),
EN 50082-1, IEC 61000 PT4-2, IEC 61000 PT4-3
i

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Summary of Contents for Mercury Jet 65

  • Page 1 Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.

  • Page 2: Table Of Contents

    Warranty Registration Outside The United States And Canada................1 Mercury Marine Two Years Limited Warranty (Europe)..................2 Mercury Marine One Year Limited Warranty (Confederation of Independent States, Middle-East, Africa).... 3 3 Year Limited Warranty Against Corrosion......................5 Warranty Coverage And Exclusions........................6 General Information Boater's Responsibilities............................
  • Page 3 TABLE OF CONTENTS Power Trim And Tilt..............................25 Replaceable Jet Drive Shear Key......................... 27 Operations Pre-Starting Check List............................28 Operating In Freezing Temperatures........................28 Operating In Salt Water Or Polluted Water......................28 Operating at High Elevations..........................28 Operating In Shallow Water..........................28 How the Jet Drive Operates..........................
  • Page 4 Engine Runs Erratically............................53 Engine Over-Speed (Excessive RPM)......................... 53 Performance Loss..............................54 Battery Will Not Hold Charge..........................54 Owner Service Assistance Local Repair Service............................55 Service Away From Home............................ 55 Parts And Accessories Inquiries........................... 55 Service Assistance............................... 55 Mercury Marine Service Offices........................... 55...

  • Page 5: Warranty Information

    Warranty Registration United States And Canada You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 6: Mercury Marine Two Years Limited Warranty (Europe)

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 7: Mercury Marine One Year Limited Warranty (Confederation Of Independent States, Middle-East, Africa)

    No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine.
  • Page 8 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related laborand material, and any other expenses associated with that service.

  • Page 9: Year Limited Warranty Against Corrosion

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 10: Warranty Coverage And Exclusions

    Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti-fouling paints is also not covered by this limited warranty.
  • Page 11 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 12: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard.

  • Page 13: Outboard Remote Control Models

    GENERAL INFORMATION U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY ob00306 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine.

  • Page 14: Lanyard Stop Switch

    GENERAL INFORMATION WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch.

  • Page 15: Stopping The Boat In An Emergency

    GENERAL INFORMATION WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations: •...

  • Page 16: Wave And Wake Jumping

    GENERAL INFORMATION Wave And Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re-enters the water.

  • Page 17: Selecting Accessories For Your Outboard

    Running the boat with the trim angle of the bow too high. Running the boat with no forward hatches open. Selecting Accessories For Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers. WARNING Check with your dealer before installation of accessories.

  • Page 18: Safe Boating Suggestions

    GENERAL INFORMATION Some accessories not manufactured or sold by Mercury Marine are not designed to be safely 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 safely enjoy the waterways, the operator should be familiar with local and other governmental boating regulations and restrictions, and consider the following suggestions.

  • Page 19: Jet 65/80 Specifications

    XXXX XXXX RP M ob00656 Serial number Year manufactured Model year Certified Europe Insignia (as applicable) Model designation Jet 65/80 Specifications Models Jet Power Engine Horsepower Full Throttle RPM Range 5000-5500 4750-5250 Idle Speed in Forward Gear 650-700 RPM Number of Cylinders Piston Displacement 1385.8 cc (84.57 cu.

  • Page 20: Component Identification

    GENERAL INFORMATION Component Identification 2889 Top cowl Reverse gate Auxiliary tilt switch Water outlet nozzle Transom brackets Driveshaft housing Jet drive housing Water pump indicator hole Water intake housing Bottom cowl...

  • Page 21: Installation

    INSTALLATION Installing Outboard WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance.

  • Page 22: Transporting

    TRANSPORTING Trailering Boat/Outboard The boat should be trailered with the outboard tilted down in a vertical operating position. IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering. The outboard tilt support lever is not intended to support the outboard for trailering. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device.

  • Page 23: Fuel And Oil

    IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil. Mercury or Quicksilver Premium TC-W3 2-Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC-W3 2-Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2-cycle outboard oil that is NMMA Certified TC-W3.

  • Page 24: Filling Oil Injection System

    FUEL AND OIL GASOLINE/OIL MIXING RATIO CHART Gas/Oil Ratio 3.8 liters (1 gal.) gas 11.5 liters (3 gal.) gas 23 liters (6 gal.) gas 50:1 (2%) 89 ml (3 fl. oz.) oil 237 ml (8 fl. oz.) oil 473 ml (16 fl. oz.) oil MIXING GASOLINE AND OIL Portable Tank - Pour 4 liters (1 gallon) of gasoline into tank.

  • Page 25: Filling Fuel Tank

    Model Capacity Fluid Type 3 cylinder 3 liters (3.2 qt.) Mercury or Quicksilver Premium TC-W3 2-Cycle 4 cylinder 4.9 liters (5.13 qt.) Mercury or Quicksilver Premium TC-W3 2-Cycle Install oil filler cap and retighten. Reinstall the cowl cap. ob01603...
  • Page 26 FUEL AND OIL Remove portable fuel tanks from boat to refill them. Always stop engine before refilling tanks. Do not completely fill the fuel tanks. Leave approximately 10% of the tank volume unfilled. Fuel will expand in volume as its temperature rises and can leak under pressure if the tank is completely filled. PORTABLE FUEL TANK PLACEMENT IN THE BOAT Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions.

  • Page 27: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. ob00329 Control handle - forward, neutral, reverse.
  • Page 28 FEATURES AND CONTROLS ob01437 WARNING SYSTEM OPERATION The warning horn will emit a continuous beep. This will alert the operator and help identify the following listed situations. Warning System Function Sound Description Engine Over Temperature Continuous Engine Over Heat Low Oil Level Continuous Low Oil Level ENGINE OVERHEAT...

  • Page 29: Power Trim And Tilt

    FEATURES AND CONTROLS 2891 Power Trim And Tilt The outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down.

  • Page 30: Auxiliary Tilt Switch

    FEATURES AND CONTROLS Disengage the tilt support lever, by raising the outboard off the support lever and rotating the lever down. Lower the outboard. ob00664 Tilt support lever Knob MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted. NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during reverse operation.

  • Page 31: Replaceable Jet Drive Shear Key

    FEATURES AND CONTROLS Replaceable Jet Drive Shear Key The jet drive is equipped with a shear key to protect it in the event of a lodged impeller. The shear key can be reached by removing the water intake housing and impeller. Refer to Maintenance - Impeller Removal and Installation.

  • Page 32: Operations

    Wash down the outboard exterior and flush out the exhaust outlet of the jet drive with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. NOTE: Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

  • Page 33: How The Jet Drive Operates

    OPERATIONS When boating through shallow water areas, choose a course of travel that avoids sharp rocks and other underwater obstacles that could damage the boat. Running the boat through these areas on full plane may be helpful as the boat will be riding higher in the water. If the boat gets stuck on the bottom, immediately stop the engine and move the boat to deeper water.

  • Page 34: Steering The Boat

    OPERATIONS WARNING Using the emergency stopping capability of the jet drive will slow down the boat in an emergency. However, sudden stopping may cause the occupants in the boat to be thrown forward or even out of the boat. This action may result in serious injury or death.

  • Page 35: Clearing A Lodged Impeller

    OPERATIONS Clearing A Lodged Impeller WARNING If the flywheel is rotated to free a lodged impeller, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury, always turn the ignition key or lanyard stop switch to the "OFF"...
  • Page 36 OPERATIONS ob00348 Squeeze the fuel line primer bulb several times until it feels firm. ob00349 NOTE: The engine will not start unless the lanyard is set to the "RUN" position. Set the lanyard stop switch to the "RUN" position. Refer to General Information - Lanyard Stop Switch. ob00350 Shift outboard to neutral (N) position.

  • Page 37: Gear Shifting

    OPERATIONS Remote control models - If engine is cold, advance the fast idle speed lever of throttle only feature to an approximate halfway setting. After engine start up, immediately adjust neutral fast idle setting so engine speed drops below 2000 RPM. Return back to normal idle speed after engine is warmed up. 3030 Fast idle speed lever Throttle only feature...

  • Page 38: Stopping The Engine

    OPERATIONS ob00557 ob01447 • Tiller handle models - Reduce engine speed to idle before shifting. ob01677 • After shifting outboard into gear, advance the remote control lever or rotate the throttle grip (tiller handle) to increase speed. Stopping The Engine Remote Control Models - Reduce engine speed and shift outboard to neutral position.
  • Page 39 OPERATIONS ob01448 WARNING When using emergency starter rope to start engine, the start in gear protection device is inoperative. Make sure to set the outboard gear shift into neutral to prevent outboard from starting in gear. Sudden unexpected acceleration could result in serious injury or death. Shift outboard to neutral (N) position.
  • Page 40 OPERATIONS WARNING The exposed moving flywheel can cause serious injury. Keep your hands, hair, clothing, tools, and other objects away from engine when starting or running the engine. Do not attempt to reinstall the flywheel cover or top cowl when engine is running. Place starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel.

  • Page 41: Maintenance

    SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 42: Inspection And Maintenance Schedule

    Inspect battery. See Battery Inspection. • Remote control models - Check control cable adjustments. • Remove engine deposits with Quicksilver or Mercury Precision Power Tune Engine Cleaner. • Check tightness of bolts, nuts, and other fasteners. EVERY 300 HOURS OF USE OR THREE YEARS •...

  • Page 43: Top Cowl Removal And Installation

    MAINTENANCE ob01650 Plug and gasket Hose coupling Attach a water hose to the hose coupling. Slowly turn on water. Start the engine and run it at idle speed only. IMPORTANT: Do not run engine above idle when flushing. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at all times.

  • Page 44: Battery Inspection

    MAINTENANCE 2895 INSTALLATION Engage the front hook and push cowl back over the cowl seal. Push cowl down and move the rear latch lever up to lock. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery.

  • Page 45: Steering Link Rod Fasteners

    MAINTENANCE 2896 FUEL LINE 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 bulb must be replaced. Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("a"...

  • Page 46: Fuse Replacement

    MAINTENANCE Description lb. in. lb. ft. Nylon insert locknut "c" Tighten until seats, then back off 1/4 turn Assemble steering link rod to steering cable with two flat washers and nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn. Assemble steering link rod to engine with special washer head bolt and locknut.

  • Page 47: Spark Plug Inspection And Replacement

    MAINTENANCE 3176 The anode requires periodic inspection, especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. Spark Plug Inspection and Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots.

  • Page 48: Steering Pull Adjustment

    MAINTENANCE ob00424 Spark Plug Gap NGK BPZ8H-N-10 1.0 mm (0.040 in.) NGK BUZHW-2 Surface gap Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger tight, and then tighten 1/4 turn or torque to specifications. Description lb.

  • Page 49: Impeller Clearance Adjustment

    MAINTENANCE Check the impeller blades occasionally for damage. Use a flat file to resharpen the leading edges. Sharpen to a 0.8 mm (1/32 in.) radius by removing material from bottom side only. ob01409 Leading edge Top side lifting angle Impeller Clearance Adjustment The impeller should be adjusted so there is approximately 0.8 mm (0.03 in.) clearance between the impeller edge and liner.

  • Page 50: Impeller Removal And Installation

    MAINTENANCE Impeller Removal and Installation WARNING If the driveshaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating impeller, always shift outboard to neutral position and remove spark plug leads when servicing the propeller.
  • Page 51 MAINTENANCE ob01412 Tabs Impeller nut Pull impeller straight off the shaft. If the impeller is tight, use a hammer and block of wood to rotate the impeller clockwise on the shaft until the keyway is directly above the flat on the shaft. This will free the jammed key and allow removal.
  • Page 52 Tabs Impeller nut NOTE: If the outboard is used in salt water, apply Quicksilver or Mercury Precision Anti-Corrosion Grease around the entire mounting flange on the water intake housing and also to the threads on the six mounting bolts. Reinstall the water intake housing with six bolts. Check clearance around the impeller to ensure the water...

  • Page 53: Lubrication Points

    Some discoloration of the grease is normal during the break-in period on a new set of seals. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C Marine Lubricant with Teflon or Special Lubricant 101.
  • Page 54 MAINTENANCE ob00683 Swivel bracket Tilt support lever • Tilt Tube - Lubricate through fitting. 2899 • Tiller handle - Lubricate through fitting. ob01660 • Steering Cable - Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting.

  • Page 55: Checking Power Trim Fluid

    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 & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.

  • Page 56: Storage

    • With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel line. When engine begins to stall, quickly spray Quicksilver or Mercury Precision Lubricants Storage Seal into carburetor until engine stops from lack of fuel.

  • Page 57: Starter Motor Will Not Crank The Engine (Electric Start Models)

    TROUBLESHOOTING Starter Motor Will Not Crank The Engine (Electric Start Models) POSSIBLE CAUSES • Remote control models - Blown 20 Amp fuse in the starting circuit. Refer to Maintenance section. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 58: Performance Loss

    TROUBLESHOOTING • Cavitation of the impeller due to rough water or obstruction in the boat hull. • Blockage of the water intake. Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged impeller. • Incorrect engine timing, adjustments, or setup. •...

  • Page 59: Local Repair Service

    Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your outboard product, contact your dealer or any authorized Mercury Marine dealership. If additional assistance is required, take these steps.

  • Page 60: Owner Service Assistance

    Telephone (954) 744-3513 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744-3535 U.S.A. Japan Telephone 81-053-423-2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81-053-423-2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way...

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