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Mercury 200 Sport-Jet Operation & Maintenance Manual

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  • Page 1 Operation Maintenance Warranty Manual...
  • Page 3 Declaration of Conformity ‑ For Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by Directive 2003/44/EC Name of engine manufacturer: Mercury Marine Address: W6250 Pioneer Road, P.O. Box 1939 Town: Fond du Lac, WI Post Code: 54936‑1939 Country: USA Name of Authorized Representative: Brunswick Marine in EMEA Inc.
  • Page 4 (they are) to be installed has been declared in conformity with the relevant provisions of the above mentioned Directives. Name / function: John Pfeifer, President, Mercury Marine Date and place of issue: September 10, 2014 Fond du Lac, Wisconsin, USA Welcome You have selected one of the finest jet drives available.
  • Page 5 Mercury Marine EPA Emissions Regulations Jet Drives manufactured 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 Jet Drive motors.
  • Page 6 Offers a clean, neat shop with well‑organized tools and service literature. Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves...

  • Page 7: Table Of Contents

    WARRANTY INFORMATION Warranty Registration United States and Canada..........1 Transfer of Warranty United States and Canada..........1 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada.................. 2 3 Year Limited Warranty Against Corrosion............2 Warranty Coverage and Exclusions..............4 U.S.
  • Page 8 Engine Break‑In Procedure................39 Starting the Engine................... 39 Shifting......................41 Stopping the Engine..................42 Maintenance Mercury Jet Drive Care..................43 Replacement Parts for Your Power Package........... 43 EPA Emissions Regulations................43 Inspection and Maintenance Schedule............. 44 Clearing A Clogged Water Intake..............46 Fuel System......................
  • Page 9 Service Away from Home................. 68 Stolen Power Package..................68 Attention Required After Submersion............... 68 Replacement Service Parts................68 Parts and Accessories Inquiries............... 68 Resolving a Problem..................69 Contact Information for Mercury Marine Customer Service......69 Ordering Literature.................... 70 Maintenance Log Maintenance Log....................72...
  • Page 10 viii...

  • Page 11: Warranty Information

    Federal Safety Act be required. You may change your registered 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 12: Transfer Of Mercury Product Protection (Extended Service Coverage) Plan United States And Canada

    Protection or an authorized dealer to receive a Request for Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee.
  • Page 13 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 predelivery inspection process is completed and documented.

  • Page 14: Warranty Coverage And Exclusions

    Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.
  • Page 15 8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. 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 16: U.s. Epa Emissions Limited Warranty

    U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of three years or 480 hours of engine use whichever occurs first to the retail purchaser, that the engine is...

  • Page 17: Warranty Policy-Australia And New Zealand

    NOTE: The emission‑related warranty does not cover components whose failure would not increase an engine's emissions on any regulated pollutant. Warranty Policy—Australia and New Zealand MERCURY/MARINER OUTBOARD LIMITED WARRANTY—AUSTRALIA AND NEW ZEALAND POLICY This limited warranty is given by Marine Power International Pty Ltd ACN 003 100 007 of 41–71 Bessemer Drive, Dandenong South, Victoria 3175 Australia...
  • Page 18 WARRANTY INFORMATION What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates.
  • Page 19 The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. A list of dealers and their contact details is available at www.mercurymarine.com.au.
  • Page 20 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. For additional information regarding events and circumstances covered by this...

  • Page 21: Global Warranty Charts Outboard And Jets

    You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department.
  • Page 22 WARRANTY INFORMATION CANADA WARRANTY CHARTS–OUTBOARD AND JET Standard Limited Standard Limited Product Corrosion Warranty Warranty 2‑Stroke carbureted (50 ‑ 90 hp) 1 year 3 years 2‑Stroke EFI (150 hp) 2 years 3 years 2‑Stroke carbureted (V6) 2 years 3 years FourStroke (2.5 ‑...
  • Page 23 WARRANTY INFORMATION SOUTH PACIFIC WARRANTY CHART–OUTBOARD AND JET Standard Standard Limited Products Limited Light Commercial Corrosion Warranty Warranty Contact the Marine All outboard 2 years 3 years Power Service Center closest to you Outside of South Pacific For product purchased outside of the South Pacific region, contact the distributor in your country, or the Marine Power Service Center closest to you.
  • Page 24 WARRANTY INFORMATION EUROPE AND THE CONFEDERATION OF INDEPENDENT STATES (CIS) WARRANTY CHARTS–OUTBOARD AND JET Standard Product Standard Limited Commercial (Recreational Limited Corrosion Application only) Warranty Warranty 2‑Stroke 2 years 3 years FourStroke 2 years 3 years Contact the Marine OptiMax Power Service Center (including Pro 3 years...
  • Page 25 WARRANTY INFORMATION Racing Product Standard Limited Standard Limited Corrosion (Recreational only) Warranty Warranty Verado 350 SCi 2 years 3 years Outside Middle‑East and Africa For products purchased outside of the Middle‑East and Africa regions, contact the distributor in your country, or the Marine Power Service Center closest to you.

  • Page 26: General Information

    If you have any questions, contact your dealer. This manual as well as safety labels posted on the Mercury Jet Drive use safety alerts to draw your attention to special safety instructions that must be followed.

  • Page 27: Boat Horsepower Capacity

    26777 High‑Speed and High‑Performance Boat Operation If your Mercury Jet Drive is to be used in a high‑speed or high‑performance boat with which you are unfamiliar, we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your Mercury Jet Drive.

  • Page 28: Mercury Jet Drive Remote Control

    GENERAL INFORMATION Mercury Jet Drive Remote Control The remote control connected to your Mercury Jet Drive must be equipped with a start‑in‑gear protection device. This prevents the engine from starting when the Mercury Jet Drive is in forward or reverse.
  • Page 29 GENERAL INFORMATION 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. This would occur if the operator accidentally falls overboard or otherwise moves away from the operator's position.

  • Page 30: Protecting People In The Water

    Stop the Mercury Jet Drive engine immediately whenever anyone in the water is near your boat. The Mercury Jet Drive is always drawing water through the water intake grate when the engine is running. Stay away from the water intake located under the stern (back) of the boat and never insert an object into the water intake or water outlet nozzle while the engine is running.

  • Page 31: Exhaust Emissions

    GENERAL INFORMATION Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include headache, dizziness,...
  • Page 32 GENERAL INFORMATION Example of desired air flow through the boat: 5448 POOR VENTILATION Under certain running or wind conditions, permanently enclosed cabins, 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 calm day, swimmers and passengers in an open area of a stationary boat that contains, or is near, a running engine may be exposed to a hazardous level of carbon monoxide.

  • Page 33: 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 enters the water.

  • Page 34: Selecting Accessories For Your Mercury Jet Drive

    Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your Mercury Jet Drive. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.
  • Page 35 Prepare other boat operators. Instruct at least one other person onboard in the basics of starting and operating your Mercury Jet Drive, and boat handling, in case the driver becomes disabled or falls overboard. Passenger boarding. Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat.

  • Page 36: Recording Serial Numbers

    Model Number XXXXXXX Model # XXXXXXX XXXXXXX Serial # Serial Number XXXXXXX XXXXXX Mercury Marine Brunswick Corp. Fond du Lac, WI 54935 Assembled in the USA from US and foreign components 44931 Engine serial number Model designation Year of manufacture...

  • Page 37: Specifications

    *Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.

  • Page 38: Component Identification

    GENERAL INFORMATION Component Identification 44935 Reverse gate Rudder Stator Wear ring Bilge siphon hose ‑ from engine Bilge siphon pickup screen Water intake...

  • Page 39: Fuel And Oil

    Fuel Additives To minimize carbon deposit buildup in the engine, add Mercury or Quicksilver Quickare Fuel Treatment to the engine's fuel at each tank fill throughout the boating season. Use the additive as directed on the container.

  • Page 40: Fuel Recommendations

    FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump octane rating of 87 (R+M)/2 minimum.

  • Page 41: Filling Remote Oil Tank

    IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided.
  • Page 42 FUEL AND OIL 2. Tighten the fill cap. 29394...

  • Page 43: Features And Controls

    FEATURES AND CONTROLS Bilge Siphon The Mercury Jet Drive incorporates an automatic bilge siphoning feature. The bilge siphon is working whenever the engine is running above idle speeds. Maximum performance of the bilge siphon is realized above 3000 RPM. 44938...
  • Page 44 FEATURES AND CONTROLS 1. Continuous six second beep: Indicates a critical engine condition. Depending on the condition, the Engine Guardian system may engage and protect the engine by limiting power. You should return to port immediately and contact your servicing dealer. 2.
  • Page 45 2. Engage the throttle. If the engine does not respond, repeat step 1. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and engine operating hours.

  • Page 46: Operation

    OPERATION Before Starting the Engine NOTICE Lack of oil pressure in the system can cause severe internal engine damage during start‑up. Prime the oil injection pump on new or rebuilt engines or after performing maintenance on the oiling system. Refer to Priming the Oil Injection Pump for instructions. Prestarting Checklist Ensure that you are familiar with safe navigation, boating, and operating procedures.

  • Page 47: Special Operating Instructions

    The jet drive works by drawing water up through the bottom water intake and directs it to the rear for forward thrust. The Mercury Jet Drive has a steerable rudder that can direct the jet thrust to the right or left. If the engine stops or the water flow is blocked, this will stop the jet thrust causing the boat to slow to a stop.
  • Page 48 OPERATION • If the jet intake becomes fouled such that the boat cannot reach planing speeds, it may be possible to clear the obstruction as follows (perform this maneuver only in an area clear of obstacles and hazards as steering control will momentarily be lost): a.

  • Page 49: Engine Break-In Procedure

    OPERATION Wash the exterior and interior of the jet drive with fresh water after each use. Each month, spray Quicksilver or Mercury Precision Corrosion Guard on external metal surfaces. Do not spray Corrosion Guard on the corrosion control anodes. Coating the anodes with Corrosion Guard will reduce the effectiveness of the anodes.
  • Page 50 OPERATION 1. Before starting, operate the bilge blower for at least five minutes to remove explosive fumes from the engine compartment. 4640 NOTICE Avoid damaging the engine and drive from overheating. Never start or run the power package without water circulating through the cooling system. 2.

  • Page 51: Shifting

    OPERATION 4. Shift the jet drive into neutral. Do not advance the throttle speed past idle for starting. Dual handle Single handle 44355 5. For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel, fill the fuel system as follows: a.

  • Page 52: Stopping The Engine

    OPERATION b. Neutral (N) ‑ has the reverse gate covering half the water outlet nozzle to distribute thrust both forward and backward. The drive impeller continues to rotate and the boat may tend to creep in one direction. This is normal for a direct‑drive jet‑driven boat. Use caution whenever the engine is running.

  • Page 53: Maintenance

    Mercury recommends using original Mercury Precision replacement parts and lubricants. EPA Emissions Regulations All new Mercury Jet Drives 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 Mercury Jet Drive motors.

  • Page 54: Inspection And Maintenance Schedule

    MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in gear):...
  • Page 55 Drain and replace the stator housing lubricant. Refer to Stator Assembly Lubricant. • Remove the impeller and lubricate the impeller shaft with Quicksilver or Mercury Precision 2‑4‑C with PTFE to prevent the impeller from seizing to the shaft. • Inspect the alternator belt. Refer to Alternator Belt Inspection.

  • Page 56: Clearing A Clogged Water Intake

    MAINTENANCE Clearing A Clogged Water Intake The hydro surge (weed) grate and cast aluminum grate are intended for general use. The rock grate is intended for use if operating the jet drive in rocky, shallow conditions. 5465 Hydro surge grate Cast aluminum grate Rock grate MANUAL CLEARING...

  • Page 57: Fuel System

    MAINTENANCE c. Apply Loctite 242 Threadlocker to the threads of the screws. d. Tighten the screws to the specified torque. Tube Ref Description Where Used Part No. Loctite 242 Water intake grate screw threads 92-809821 Threadlocker Description lb‑in. lb‑ft Front screws –...
  • Page 58 MAINTENANCE FUEL LINE INSPECTION Inspect the fuel line for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line must be replaced. FUEL LINE FILTER Replace the fuel filter once a season or every 100 hours of use. 44568 Fuel filter IMPORTANT: Visually inspect for fuel leakage from the filter connections.

  • Page 59: Fuses

    MAINTENANCE 2. Disconnect the wire from the bottom of the filter. Remove the filter (a) by turning the filter in the direction of the arrow (clockwise). Tip the filter to drain the fluid into a suitable container. 44939 Water separating fuel filter 3.
  • Page 60 MAINTENANCE The fuses and circuits are identified as follows: 44940 Good fuse Open (blown) fuse SmartCraft data bus circuit ‑ 5‑amp fuse Ignition system circuit ‑ 20‑amp fuse Spare fuse Electric fuel pump (VST), ECM driver power, and oil pump circuit ‑ 20‑amp fuse Main power relay ‑...

  • Page 61: Corrosion Control Anodes

    Anodes help protect the Mercury Jet Drive against galvanic corrosion by sacrificing their metal to be slowly eroded instead of the Mercury Jet Drive metals. Anodes a a a 5467 All anodes require periodic inspection, especially in saltwater.

  • Page 62: Spark Plug Inspection And Replacement

    MAINTENANCE Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks that can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the spark plug boots.
  • Page 63 MAINTENANCE IMPORTANT: The color of the plug may not accurately reflect its condition. To accurately diagnose a faulty plug, inspect the precious metal on the plug's electrode. If no precious metal is visible, replace the plug. 9381 Precious metal 5. Set the spark plug gap. Refer to General Information ‑ Specifications. 27848 •...

  • Page 64: Flywheel Cover Removal And Installation

    MAINTENANCE Description lb‑in. lb‑ft Spark plug – 7. Inspect the expansion chamber gasket on the adapter plate. Do not remove the gasket from the adapter plate. Replace if damaged. 8. Install the expansion chamber. Tighten the mounting nuts to the specified torque.
  • Page 65 MAINTENANCE 2. Push the cover down onto the alignment pins and onto the air intake tube for the air compressor. 44545 Air plenum intake flange Air intake tube for the air compressor 3. Attach the retaining strap to the cover. 44528 Retaining strap...

  • Page 66: Alternator Belt Inspection

    MAINTENANCE Alternator Belt Inspection Inspect the alternator belt and have it replaced by an authorized dealer if any of the following conditions are found. • Cracks or deterioration in the rubber portion of the belt • Belt surfaces rough or uneven •...

  • Page 67: Belt Tensioner Idler Pulley Lubrication

    MAINTENANCE 2. Secure the filter with the retainer. Belt Tensioner Idler Pulley Lubrication Lubricate through the fitting with 2‑4‑C with PTFE. 29399 Tube Ref Description Where Used Part No. 2-4-C with PTFE Tensioner pulley grease fitting 92-802859A 1 Flushing the Cooling System Flushing the cooling system is essential after each use in saltwater, after the boat has run aground, or if the warning horn sounds due to an overheated engine.
  • Page 68 MAINTENANCE 3. Remove the cap from the boat's flush adapter. The adapter may be mounted to the hull or in the engine compartment. Flushing attachment (hull mount) Flushing attachment (engine compartment mount) 5469 IMPORTANT: Do not run the engine above idle when flushing. 4.

  • Page 69: Drive Housing Lubricant

    In either case, have the drive housing checked by your authorized Mercury Marine dealer. Water in the lubricant can cause premature gear or bearing failure or, in freezing weather, damage to the drive housing.

  • Page 70: Stator Assembly Lubricant

    In either case, have the stator checked by your authorized Mercury Marine dealer. Water in the lubricant can cause premature bearing failure or, in freezing weather, damage to the stator.
  • Page 71 MAINTENANCE Tube Ref Description Where Used Part No. Loctite 242 Stator bolts and ride plate screws 92-809821 Threadlocker Description lb‑in. lb‑ft Stator bolts – Ride plate screws – ADDING OR REFILLING LUBRICANT 5474 Fill hole Reverse gate (bottom edge) Rudder (outside diameter) Fluid Type Capacity High Performance Gear Lube...

  • Page 72: Bilge Siphon Inspection

    8. Check that the bottom edge of the reverse gate is above the outside diameter of the rudder. If the reverse gate is below the outer diameter of the rudder, do not operate the boat. See an authorized Mercury Marine dealer for proper adjustment.

  • Page 73: Submerged Power Package

    MAINTENANCE 2. Inspect the hole in the siphon break for blockage. Clean with a small wire if necessary. 3. Ensure that the siphon break is secured above the waterline. Submerged Power Package A submerged power package requires prompt service by an authorized dealer after recovery.

  • Page 74: Storage

    STORAGE Storage Preparation The major consideration in preparing your Mercury Jet Drive 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 Mercury Jet Drive for out of season storage or prolonged storage (two months or longer).

  • Page 75: Protecting Internal Engine Components

    STORAGE 7. Using the flushing adapter, start the engine and allow the engine to run at idle speed for 10 minutes to allow the treated fuel to fill the fuel system. Protecting Internal Engine Components NOTE: Make sure that the fuel system has been prepared for storage. Refer to , preceding.

  • Page 76: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • 20‑amp fuse in the starting circuit is open. Refer to Maintenance. • Jet drive is not shifted into the neutral position. • Battery is weak or the battery connections are loose or corroded. •...

  • Page 77: Performance Loss At Normal Rpm

    TROUBLESHOOTING • Threaded connection of an air hose is loose. • Fuel pump failed. • Ignition system component failed. Performance Loss at Normal RPM POSSIBLE CAUSES • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Performance Loss at Wide‑Open Throttle POSSIBLE CAUSES OF LOW RPM (USUALLY ENGINE RELATED) •...

  • Page 78: Owner Service Assistance

    Stolen Power Package If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in the recovery of stolen power packages.

  • Page 79: Resolving A Problem

    OWNER SERVICE ASSISTANCE Resolving a Problem Satisfaction with your Mercury product is important to your dealer and to us. If you ever have a problem, question, or concern about your power package, contact your dealer or any authorized Mercury dealership. If you need additional assistance: 1.

  • Page 80: Ordering Literature

    Before ordering literature, have the following information about your power package available: Model Serial Number Horsepower Year UNITED STATES AND CANADA For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact: Mercury Marine Telephone Mail Mercury Marine (920) 929‑5110 (920) 929‑4894...
  • Page 81 OWNER SERVICE ASSISTANCE Mercury Marine Submit the following Attn: Publications Department order form with payment W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Ship To: (Copy this form and print or type–This is your shipping label) Name...

  • Page 82: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your Mercury Jet Drive here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

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