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Mercury 80hp Manual

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Mercury Thunderbolt 80 Hp Manual

View and Download Mercury 80 owner's manual online. Mercury Marine Outboard Motor Owner's manual. 80 Outboard Motor pdf manual download. Also for: 115, 100. Mercury Service Manual for 70-75-80-90-100-115 hp. Weights based on Owner’s Manual specifications. Testing performed by Mercury PD&E NVH staff at a Mercury Marine test location on a 2013 Bayliner 170.

Cause the boat to break apart, particularly around the transom area. Overpowering a boat can result in serious injury, death, or boat damage. 0 JANUARY 2003 Printed in U.S.A. - 2003, Mercury Marine Page 1 of 18. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Start in Gear Protection The remote control connected to the outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting in gear.

WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Lifting Outboard Use Flywheel Puller/Lifting Eye (91-83164M). Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate O-ring seal and entire cable end. Quicksilver 2-4-C Marine Lubricant with Teflon 2. Insert steering cable into tilt tube. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Steering Link Rod Installation Note NOTE: For ease of installation of special bolt (a) separate the front end of the bottom cowl.

Install steering link rod per illustration. Special Bolt (10-90041) Torque to 20 lb. Jaime 1000 S8 Manual. (27.1 Nm) Nylon Insert Locknut (11-34863) Torque to 20 lb.

• 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Installing Outboard Determining Recommended Outboard Mounting Height 26 in. (660mm) 25 in. (635mm) 24 in. (609mm) 23 in. Outboard (584mm) Mounting Height 22 in.

(See NOTE (560mm) Below) 21 in. (533mm) 20 in.

(508mm) 19 in. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Installing Outboard 1.

Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template (located in this manual) to boat transom. Mark and drill four 17/32 in. (13.5mm) mounting holes. Refer to “Determining Recommended Outboard Motor Mounting Height”, preceding, and install outboard to the nearest recommended mounting height.

• 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Electrical, Hoses, and Control Cables IMPORTANT: Warning Horn Requirement – The remote control or key switch assembly must be wired with a warning horn. This warning horn is used with the engine warning system. Front Cowl Grommet Pull up the cowl seal and remove the cover from the bottom cowl. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Battery Cable Connections SINGLE OUTBOARD (–) Red Sleeve (Positive) Black Sleeve (Negative) Starting Battery DUAL OUTBOARDS Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. (–) (–) Ground Cable (Same Wire Size As Engine Battery Cable) –.

• 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Fuel Hose PORTABLE FUEL TANK Select a suitable location in boat within engine fuel line length limitations and secure tank in place. PERMANENT FUEL TANK These should be installed in accordance with industry and federal safety standards which include recommendations applicable to grounding, anti-siphon protection, ventilation, etc. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 75 and 90 Hp Shift Cable Installation Install cables into the remote control following the instructions provided with the remote control. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral.

• 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 4. Position remote control into neutral. Align the shift cable end guide with the center point made in Step 2. Place shift cable on anchor pin. Adjust cable barrel so it slips freely into the barrel holder. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 75 and 90 Hp Throttle Cable Installation Install cables into the remote control following the instructions provided with the remote control.

Position remote control into neutral. Install throttle cable to the throttle arm with hairpin cotter. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 115 Hp Shift Cable Installation Install cables into the remote control following the instructions provided with the remote control. NOTE: Install the shift cable to the engine first.

The shift cable is the first cable to move when the remote control handle is moved out of neutral. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 4. Position remote control into neutral.

Align the shift cable end guide with the center point made in Step 2. Place shift cable on anchor pin. Adjust cable barrel so it slips freely into the barrel holder. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 115 Hp Throttle Cable Installation Install cables into the remote control following the instructions provided with the remote control. Position remote control into neutral. Install throttle cable to the throttle arm with hairpin cotter. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Propeller Installation WARNING If the propeller 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 start- ing and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Trim-In Stop Adjustment Some outboard boats, particularly some bass boats, are built with a greater than normal transom angle which will allow the outboard to be trimmed further “in” or “under”. This great- er trim “under”. • 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Trim Tab Adjustment The trim tab can be adjusted within limits to help compensate for steering torque. Adjust trim tab as follows: 1.

If boat tends to pull to the right, move the rear edge of the trim tab to the right.