Mercury Jet 20 Manual
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Mercury Jet 20 Manual

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If the outboard motor's serial number plate contains the CE mark in the low-
er left-hand corner, the following statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, Wis-
consin, USA or Marine Power Europe Inc. Park Industriel, de Petit-Re-
chain, Belgium complies with the requirements of the following directives
and standards, as amended:
Recreational Craft Directive:
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
94/25/EC; std. ISO 8665,
ISO 11547
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

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  • Page 1 If the outboard motor’s serial number plate contains the CE mark in the low- er left-hand corner, the following statement applies: This outboard motor manufactured by Mercury Marine, Fond du Lac, Wis- consin, USA or Marine Power Europe Inc. Park Industriel, de Petit-Re-...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Warranty Information Transfer of Warranty ..........Warranty Registration United States and Canada .
  • Page 4 TABLE OF CONTENTS Transporting Carrying Your Outboard ..........Trailering Your Boat .
  • Page 5 TABLE OF CONTENTS Operation Pre-Starting Check List ..........How the Jet Drive Operates .
  • Page 6 ..........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.

  • Page 7: Warranty Information

    Registration records will be changed on the factory computer registration file. There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the Mercury Marine Service Office closest to you.

  • Page 8: Warranty Registration

    WARRANTY INFORMATION Warranty Registration UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product. It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name and address.
  • Page 9 WARRANTY INFORMATION Warranty Registration OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.
  • Page 10 WARRANTY COVERAGE Warranty coverage is availble only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre–delivery inspection process is completed and documented.
  • Page 11 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.
  • Page 12 WARRANTY INFORMATION Mercury Marine Two Years Limited Warranty(Europe) ou24a WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommendedwide–open–throttle RPM range (see the Operation and Maintenance...
  • Page 13 WARRANTY INFORMATION Mercury Marine Two Years Limited Warranty(Europe) 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 14 WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre–delivery inspection process is completed and documented.
  • Page 15 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.

  • Page 16: Outside United States And Canada

    WARRANTY INFORMATION Mercury Marine ONE Year Limited Warranty(Confederation of Independent States, Middle– East, Africa) WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommendedwide–open–throttle RPM range (see the Operation and Maintenance...

  • Page 17: Outboard Limited Warranty

    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 makeany affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, andif made, shall not be enforceable against Mercury Marine.
  • Page 18 CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred,...

  • Page 19: Year Limited Warranty Against Corrosion

    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 transportationcharges and/or travel time.
  • Page 20 Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damagecaused by improper application of copper base anti–fouling paints is also not covered by this limited warranty.

  • Page 21: Warranty Coverage And Exclusions

    WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited Outboard Warranty.
  • Page 22 WARRANTY INFORMATION Warranty Coverage and Exclusions 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 23: General Information

    GENERAL INFORMATION oba2 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 24: Before Operating Your Outboard

    GENERAL INFORMATION obb2 Before Operating Your Outboard Read this manual carefully. Learn the difference in handling characteristics between a jet drive boat and a propeller driven boat including: • Steering at low speeds - unlike propeller driven boats, the jet drive boat tends to lose steering control as less water is drawn in and expelled.

  • Page 25: Boat Horsepower Capacity

    GENERAL INFORMATION gob1 U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY obc1 Boat Horsepower Capacity Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines.

  • Page 26: Outboard Remote Control (If Equipped)

    GENERAL INFORMATION gob31 obe2 Outboard Remote Control (If Equipped) 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 27: Lanyard Stop Switch

    GENERAL INFORMATION gob8 obg8 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. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch.
  • Page 28 GENERAL INFORMATION Lanyard Stop Switch (Continued) Read the following Safety Information before proceeding. Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator’s position to activate the switch.

  • Page 29: Stopping The Boat In An Emergency

    GENERAL INFORMATION Lanyard Stop Switch (Continued) 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: Occupants could be thrown forward due to unexpected loss of forward motion –...

  • Page 30: Protecting People In The Water

    GENERAL INFORMATION gob3 obh3 Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in their direction even at slow speed. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

  • Page 31: Wave And Wake Jumping

    GENERAL INFORMATION gob4 obu1 Wave And Wake Jumping Operating recreational boats over waves and wakes 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 32: Exhaust Emissions

    GENERAL INFORMATION gob4 Courtesy of ABYC obi2 Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, stern drives and inboard engines that propel boats, as well as the generators that power various boat accessories.
  • Page 33 GENERAL INFORMATION gob39 Courtesy of ABYC obi3 Exhaust Emissions (Continued) POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits 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 unclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.

  • Page 34: Selecting Accessories For Your Outboard

    These accessories are available from Mercury Marine dealers. 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.
  • Page 35 GENERAL INFORMATION Safe Boating Suggestions (Continued) Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary, (2) The Power Squadron, (3) The Red Cross and (4) your state boating law enforcement agency.
  • Page 36 GENERAL INFORMATION Safe Boating Suggestions (Continued) Watch for boat creeping in neutral. When the jet drive is in neutral, the drive impeller continues to rotate. Although the approximate balancing of forward and reverse thrust will minimize boat movement, the boat may tend to creep slowly forward or backward.

  • Page 37: Specifications

    GENERAL INFORMATION obm13 Specifications Models Jet Power Engine Horsepower Full Throttle RPM Range 5000-6000 RPM 750 ± 50 RPM Idle Speed in Forward Gear Number of Cylinders Piston Displacement 24.4 cu. in. (400cc) Cylinder Bore 2.560 in. (65mm) Piston Stroke 2.360 in.

  • Page 38: Installation

    INSTALLATION goc18 ocj1 Installing Outboard On The Transom NOTE: Determine the recommended mounting height of your outboard by following instructions in the outboard jet installation supplement(provided with the outboard). Place outboard on center line of transom. Tighten transom clamp handles. To prevent loss of outboard overboard, fasten outboard by drilling two 5/16 in.

  • Page 39: Fastening Security Line

    INSTALLATION goc19 occ1 Fastening Security Line The primary purpose for installing a security line is to prevent loss of the outboard if the outboard becomes detached from the boat transom. An effective security line should be of a working strength of at least five times the weight of the outboard.

  • Page 40: Battery Installation - Electric Start Models

    INSTALLATION goc20 ock1 Battery Installation – Electric Start Models MOUNTING BATTERY Follow battery manufacturer’s instructions carefully. Mount battery in the boat so it is secured against movement, preferably in a battery box. Make sure battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals.

  • Page 41: Carrying Your Outboard

    TRANSPORTING god12 oda5 Carrying Your Outboard Your outboard has a carrying handle located in front and a rear hand grip in the bottom cowl. Trailering Your Boat Your boat should be trailered with the outboard tilted down (normal operating position). IMPORTANT: The tilt lock and shallow water drive feature (tiller handle models) on the outboard are not intended to support the outboard in the tilted position when trailering your boat.

  • Page 42: Transporting Your Outboard When Removed From Boat

    TRANSPORTING god19 odb2 Transporting Your Outboard When Removed From Boat With the outboard still in the water, disconnect the fuel line from the outboard and run engine until it stops, draining carburetor. Remove outboard from the boat and hold upright until all cooling water is drained out. Lay the outboard down horizontally on it’s (tiller handle) side.

  • Page 43: Fuel & Oil

    FUEL & OIL oeb6 Gasoline Recommendations UNITED STATES AND CANADA Use a major brand of automotive unleaded gasoline with a minimum posted octane rating of 87. Mid-grade automotive gasolines that contain fuel injector cleaner are preferred for added internal engine cleanliness. Leaded gasoline is not recommended.

  • Page 44: Oil Recommendations

    Mercury or Quicksilver Premium TC-W3 2-cycle oil is recommended for your 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 45: Filling Fuel Tank

    FUEL & OIL oee6 Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Always stop the engine and DO 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.

  • Page 46: Features & Controls

    FEATURES & CONTROLS gog79 ogd8 Tiller Handle Models ° Tiller handle – Handle can be tilted 100 for convenient handling during transportation and storage. Starter Rope – Pulling the starter rope cranks the engine over for starting. Primer/Idle Speed Knob – Pulling the knob out supplies a small amount of fuel to the engine for cold starting.
  • Page 47 FEATURES & CONTROLS gog80 ogd12 Tiller Handle Models Lanyard Stop Switch – Read the Lanyard Stop Switch safety explanation and Warning in the General Information Section. Lanyard – Read the Lanyard Stop Switch safety explanation and Warning in the General Information Section. Engine Stop Switch –...
  • Page 48 FEATURES & CONTROLS gog81 ogd10 Tiller Handle Models Throttle Grip Friction Knob – Turn friction knob to set and maintain the throttle at desired speed. Turn knob towards (a) to tighten friction and move knob towards (b) to loosen friction. Side Handle Gear Shift –...
  • Page 49 FEATURES & CONTROLS gog28 ogd11 Tiller Handle Models Throttle Grip – Controls engine speed. Move to the start (slow speed) position for starting the engine. NOTE: The outboard is equipped with a rewind starter “lock-out” mechanism. The throttle grip will have to be in the start (slow speed) position in order to start engine. Electric Start Button (Electric Start Models) –...

  • Page 50: Tilting Outboard To Full Up Position

    FEATURES & CONTROLS gog82 ogf4 Tilting Outboard To Full Up Position Stop the engine. Shift the outboard into forward gear position. Take hold of the top cowl grip and raise outboard to the full up position. Move the tilt lock to the lock position. Lowering Outboard Down To Run Position Lift outboard and release tilt lock lever.

  • Page 51: Shallow Water Operation

    FEATURES & CONTROLS gog83 1–2 ogm1 Shallow Water Operation – Tiller Handle Models Tiller handle model outboards are equipped with a shallow water tilt feature that allows you to tilt the outboard to a higher tilt angle to prevent hitting bottom. ENGAGING SHALLOW WATER DRIVE Reduce engine speed to idle.

  • Page 52: Setting The Operating Angle Of Your Outboard

    FEATURES & CONTROLS gog84 ogg3 Setting The Operating Angle Of Your Outboard The vertical operating angle of your outboard is adjusted by changing the position of the tilt pin (a) in the five adjustment holes provided. Proper adjustment allows the boat to run stable, achieve optimum performance.

  • Page 53: Pre-Starting Check List

    OPERATION ofa4 Pre-Starting Check List j Operator knows safe navigation, boating, and operating procedures. j An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). j A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.

  • Page 54: How The Jet Drive Operates

    OPERATION gof86 onm1 How The Jet Drive Operates A jet-driven boat has substantially different handling characteristics compared to a propeller-driven boat. It is suggested that you adjust yourself to these characteristics by experimentation in open water at both high and low speeds. The drive shaft driven impeller draws water up through the water intake (a) and then redirects it at a high pressure through the water outlet nozzle (b) to create forward thrust.

  • Page 55: Stopping The Boat In An Emergency

    OPERATION How The Jet Drive Operates (Continued) The jet drive is always drawing water into the housing when the engine is running. DO NOT operate the jet drive with the grate removed from the water intake. Keep your hands, feet, hair, loose clothing, life jackets, etc. away from the water intake. Never insert an object into the water intake or water outlet nozzle when the engine is running.

  • Page 56: Steering Your Boat

    OPERATION onl1 Steering Your Boat The jet drive is dependent on water jet thrust for steering the boat. The jet drive has a steerable outlet nozzle that directs this water jet thrust to the right or left. If the water jet thrust should ever stop, (water blockage, the engine stops, or, etc.) will cause the boat to slow to a stop.

  • Page 57: Operating In Shallow Water

    OPERATION onk1 Operating In Shallow Water The life of the impeller and water intake can be greatly increased by avoiding the intake of sand and gravel. The intake suction, acting on the bottom, will act like a dredge when the water intake comes within 2 to 3 inches of the bottom. It is better to stop the engine and drift up to shore when landing, and to shove off with an oar when leaving.

  • Page 58: Clearing A Jammed Impeller

    OPERATION ona1 Clearing A Jammed Impeller It is possible, for a stone or other debris inside the jet housing to lodge between the impeller and wall, especially after the engine has been stopped. This will lock the drive shaft and will prevent the engine from being able to crank over for starting. In this case follow these steps for freeing the jam.

  • Page 59: Operating At High Elevations

    (except in freezing temperature) when not in use. Wash down the outboard exterior and flush out the exhaust outlet of the jet drive with fresh water after each use. Each month, spray Quicksilver or Mercury Precision Corrosion Guard on external metal surfaces.

  • Page 60: Pre-Starting Instructions

    OPERATION gof87 ofc3 Pre-Starting Instructions Connect the remote fuel line to the outboard. Make sure connector is snapped into place. Make sure the drive shaft bearing on the jet drive is lubricated. Refer to Maintenance Section. CAUTION Never start or run your outboard (even momentarily) without the water intake in the water to prevent damage to the water pump (running dry) or overheat- ing of the engine.

  • Page 61: Starting The Engine

    OPERATION gof108 off6 Starting The Engine – Tiller Handle Models Before starting, read the Pre-Starting Check List, Special Operating Instructions, Pre-Starting Instructions, and Engine Break-in Procedure on the first three pages in the Operation Section. Open fuel tank vent on manual venting type tanks. Squeeze the fuel line primer bulb several times until it feels firm.
  • Page 62 OPERATION gof89 off1 Starting The Engine – Tiller Handle Models Side Handle Gear Shift Models – Set the gear shift to NEUTRAL position. Turn Primer/idle speed knob full clockwise (direction of arrow) to increase engine idle speed for starting. When engine is cold, pull out and push in the primer/idle speed knob one to three times to prime the engine.
  • Page 63 OPERATION gof31 off17 Starting The Engine – Tiller Handle Models Push in the primer/idle speed knob after engine starts. If engine begins to stall, re-prime until engine is running smoothly. NOTE: Starting Flooded Engine – push in the primer/idle speed knob and turn full clockwise.

  • Page 64: Gear Shifting

    OPERATION gof90 ofj6 Gear Shifting Your outboard has three gear shift positions to provide operation: Forward (F), Neutral (out of gear), and Reverse (R) NOTE: In neutral, the impeller continues to rotate. Although the approximate balancing of forward and reverse thrust will minimize boat movement, the boat may tend to creep slowly forward or backward.

  • Page 65: Emergency Starting

    OPERATION gof91 ofp4 Emergency Starting If the starter rope should break or the rewind starter fails, use the spare starter rope (provided) and follow this procedure. Shift outboard to neutral position. WARNING When using emergency starter rope to start engine, the start at idle speed protection is inoperative.
  • Page 66 OPERATION gof34 ofp5 Emergency Starting (Continued) Electric Start Remote Control Models – Turn the ignition key to ON position. Tie one end of the spare starter rope around screwdriver tool (provided) and tie a knot in other end. WARNING To prevent getting an electrical shock, DO NOT touch any ignition component, wiring, or spark plug wire when starting or running the engine.

  • Page 67: Maintenance

    Record maintenance performed in Maintenance Log at the back of this book. Save all maintenance work orders and receipts. 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...

  • Page 68: Epa Emissions Regulations

    EPA Emissions Regulations All new outboards manufactured by Mercury Marine 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.

  • Page 69: Inspection And Maintenance Schedule

    MAINTENANCE ohd34 Inspection And Maintenance Schedule BEFORE EACH USE Check that lanyard stop switch stops the engine. Visually inspect the fuel system for deterioration or leaks. Check outboard for tightness on transom. Check steering system for binding or loose components. Remote Control models –...
  • Page 70 Electric start models – Inspect battery. (page 62) ∗ Remote control models – Check control cable adjustments. Remove engine deposits with Quicksilver or Mercury Precision Power Tune Engine Cleaner. Clean fuel tank pick up filter. 10. Salt water use - remove and grease the jet drive mounting hardware, and reassemble.

  • Page 71: Top Cowl Removal And Installation

    MAINTENANCE goh43 ohf2 Top Cowl Removal And Installation REMOVAL Unlock the rear latch by pushing lever down. Lift rear of cowl and disengage front hook. 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. ohn1 Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine...

  • Page 72: Fuel System

    MAINTENANCE goh44 ohh2 Fuel System WARNING Avoid serious injury, or death from gasoline fire, or explosion. Carefully follow all fuel system service instructions. Always stop the engine, and DO NOT smoke or allow open flames, or sparks in the area while servicing any part of the fuel system.

  • Page 73: Exterior Care

    MAINTENANCE goh127 ohz1 ENGINE FUEL FILTER Inspect the sight bowl for water accumulation and inspect the filter element for sediment. Clean filter as follows. REMOVAL Read Fuel System servicing information and Warning on the previous page. Hold onto the cover to prevent it from turning. Turn off the sight bowl.

  • Page 74: Steering Link Rod Fasteners

    MAINTENANCE goh46 ohi1 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” – Part Number 10-14000) and self locking nylon insert locknuts (“b” & “c” – Part Number 11-34863).

  • Page 75: Fuse Replacement (Electric Start Remote Control Model)

    MAINTENANCE goh47 oma1 Fuse Replacement – Electric Start Remote Control Models IMPORTANT: Always carry spare SFE 20 AMP fuses. The electric starting circuit is protected from overload by a SFE 20 AMP fuse. If the fuse is blown, the electric starter motor will not operate.Try to locate and correct the cause of the overload.

  • Page 76: Worn (Dull) Impeller

    MAINTENANCE goh128 Do Not sharpen or alter the top side lift- ing angle Enlarged View leading edge Sharpen to a 1/32 in. (.8mm) radius by removing material from bottom side only omm1 Worn (Dull) Impeller The intake of gravel through the pump can round off and wear the leading edges on the impeller.

  • Page 77: Impeller Clearance Adjustment

    MAINTENANCE goh129 .03 in. (.8mm) omn1 Impeller Clearance Adjustment The impeller should be adjusted so there is approximately .03 in. (.8mm) clearance between the impeller edge and liner. Operating your jet drive in waters that contain sand and gravel can cause wear to the impeller blades, and the clearance will start to exceed .03 in.

  • Page 78: Impeller Removal And Installation

    MAINTENANCE goh130 omo1 Impeller Removal And Installation WARNING If the drive shaft 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 you are servicing the propeller.
  • Page 79 MAINTENANCE goh131 .03 in. (.8mm) omo2 Impeller Removal And Installation INSTALLATION Grease the drive shaft, shear key, and impeller bore. Place the plastic sleeve (a) inside the impeller (b) and install impeller, shear key (c), shims (d) nut retainer (e), and impeller nut (f). Turn the nut tight on the shaft to remove any play between the impeller and shaft.
  • Page 80 After setting the impeller height, tighten the impeller nut snug with a wrench. Secure impeller nut by bending tabs (a) against the flats on the 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.

  • Page 81: Shift Link Rod Adjustment

    MAINTENANCE goh155 omp1 Shift Link Rod Adjustment WARNING The shift link rod must be adjusted to lock the reverse gate against unexpected engagement (caused by water pressure hitting the gate) while operating the boat in forward. Activation of the reverse gate will cause sudden unexpected stopping of the boat.

  • Page 82: Lubrication Points

    Lubrication Points Lubricating the drive shaft bearing. Recommended Lubrication - Use Quicksilver or Mercury Precision Lubricants 2-4-C w/Teflon, or Lubriplate 630-AA Grease. IMPORTANT: It is important that you do not use a general-all-purpose grease for this bearing. The lubricant we recommend is a water resistant grease of the proper consistency for this application.
  • Page 83 MAINTENANCE goh134 oho34 Lubrication Points Lubricate Points 2 thru 7 with Quicksilver or Mercury Precision Lubricants 2-4-C Marine Lubricant with Teflon or Special Lubricate 101. Steering Friction Adjustment Shaft (Tiller Handle Models) – Lubricate fitting. Swivel Bracket – Lubricate fitting.
  • Page 84 MAINTENANCE goh135 oho17 Lubrication Points (Continued) WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. An hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death.

  • Page 85: Spark Plug Inspection And Replacement

    MAINTENANCE goh14 ohm16 Spark Plug Inspection and Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots (a). Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors under the engine cowl. To avoid damaging spark plug boots, do not use any sharp object or metal tool such as pliers, screwdriver, etc.

  • Page 86: Carburetor Adjustments

    MAINTENANCE goh50 ohx2 Carburetor Adjustments SLOW SPEED MIXTURE ADJUSTMENT Remove access plug from cover. Before starting engine, turn the slow speed mixture screw in until it is lightly seated then back it out 1-1/2 turns. With the boat tied securely to dock, start engine and allow it to warm up. Shift the outboard to forward gear and reduce engine speed to idle.

  • Page 87: Submerged Outboard

    MAINTENANCE goh136 8-10 ohu3 ENGINE IDLE SPEED ADJUSTMENT With boat tied securely to dock, start engine and allow it to warm up. Shift outboard to forward gear and reduce engine speed to idle. Make sure the Primer/Fast Idle Knob is pushed all the way in and turned to the slowest idle speed.

  • Page 88: Storage Preparation

    STORAGE oia2 Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer).
  • Page 89 Place the outboard in water. Start the engine and let it run in neutral to warm up. 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 90 STORAGE oif3 POSITIONING OUTBOARD FOR STORAGE Store outboard in an upright (vertical) position to allow water to drain out of outboard. oig1 BATTERY STORAGE Follow the battery manufacturers instructions for storage and recharging. Remove the battery from the boat and check water level. Recharge if necessary. Store the battery in a cool, dry place.

  • Page 91: Troubleshooting

    TROUBLESHOOTING ojc1 1 – 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. •...
  • Page 92 TROUBLESHOOTING 3 – ENGINE RUNS ERRATICALLY POSSIBLE CAUSES • Spark plugs fouled or defective. Refer to Maintenance Section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. Engine Fuel filter is obstructed. Refer to Maintenance Section. Fuel tank filter obstructed.

  • Page 93: Owner Service Assistance

    If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office.

  • Page 94: Service Assistance

    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 95: Mercury Marine Service Offices

    (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 Parc Industriel de Petit-Rechain B-4800 Verviers Belgium Mexico, Central America, South America, Caribbean Mercury Marine - Latin America (305) 385-9585 (305) 385-5507 & Caribbean 9010 S.W. 137th Ave. Suite 226 Miami, FL 33186 U.S.A.

  • Page 96: Maintenance Log

    MAINTENANCE LOG oka1 Maintenance Log Record here all maintenance performed on your outboard. Be sure to save all work orders and receipts. Engine Maintenance Performed Date Hours...
  • Page 97 MAINTENANCE LOG Engine Maintenance Performed Date Hours...

This manual is also suitable for:

Jet 65Jet 80

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