Every 100 Hours Or Once A Month, Whichever Occurs First; Before Periods Of Storage; Clearing A Clogged Water Intake; Manual Clearing - Mercury 200 OptiMax Jet Drive Service Manual

Every 100 Hours or Once A Month, Whichever Occurs First

• Replace spark plugs at first 100 hours or first year. After that, inspect spark plugs every 100 hours or once yearly. Replace
spark plugs as needed. See Spark Plug Inspection and Replacement.
• Drain and replace drive housing lubricant. See Drive Housing Lubricant.
• Drain and replace stator housing lubricant. See Stator Assembly Lubricant.
• Remove impeller and lubricate impeller shaft with Quicksilver or Mercury Precision 2‑4‑C w/Teflon to prevent impeller from
seizing to the shaft.
• Inspect alternator belt. See Alternator Belt Inspection.
• Lubricate the belt tensioned pivot shaft. See Belt Tensioner Idler Pulley Lubrication.
• Replace engine fuel line filter. See Fuel System.
• Replace water separating fuel filter. See Fuel System.
• Replace compressor air intake filter. See Compressor Air Intake Filter.

Before Periods of Storage

• Refer to the Storage section.

Clearing A Clogged Water Intake

The hydro‑surge (weed) grate and casted aluminum grate are intended for general use. The rock grate is intended for use if
operating the jet drive in rocky, shallow conditions.
a

Manual Clearing

Avoid injury resulting from contacting the rotating impeller or having hair, clothing, or loose objects drawn into the water intake
and wrapping around the impeller shaft. Stay away from the water intake and never insert an object into the water intake or
water outlet nozzle when the engine is running.
If weeds or debris clog the water intake, turn the engine off and completely clean out the blockage to return the unit to proper
running order.
1. Turn off the engine and remove the key from the ignition switch. The pump impeller still spins and pumps water when the
engine is running, even when in neutral.
2. Clean debris from the entire jet drive unit (water intake, impeller, and nozzle). If the jet drive cannot be easily cleaned, return
the boat to the trailer or to a boat lift before performing any further work.
3. It may be necessary to remove the water intake grate from the bottom of the jet drive to clean debris from the water intake.
Remove the water intake grate by removing the four screws. Reinstall the water intake grate with the same four screws. Apply
Loctite 242 to the threads of the screws. Tighten the screws to the specified torque.
Tube Ref No.
Loctite 242 Threadlocker
66
90-8M0050731 MAY 2011
c
!
Description
b
a - Hydro‑surge grate
b - Casted aluminum grate
c - Rock grate
5465
WARNING
Where Used
Water intake grate screws
Maintenance
Part No.
92-809821
Page 1B-3