Hydro-Surge Grate; Fuel System; Fuel Line Inspection; Fuel Line Filter - Mercury 200 OptiMax Jet Drive Service Manual

Maintenance
Description
Front screws
Rear screws
IMPORTANT: Do not operate the jet drive without the water intake grate installed.
Hydro‑Surge Grate
The hydro‑surge grate is spring‑loaded. If the intake gets plugged, the pump suction will pull open the grate, and the water will
push the blockage pass the grate and clear the intake.
If operating the boat at slow speeds in weedy areas, the water intake grate can become plugged with weeds. A plugged grate
causes the pump to cavitate during acceleration (over‑revving without thrusting the boat).
If the grate becomes plugged:
1. Slowly advance the throttle to get the boat up on plane, making sure not to cavitate the pump.
2. Continue to advance the throttle until the boat is running at top speed. The force of the water should clear the pump of any
remaining weeds.

Fuel System

Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start.
Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid
prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any spilled fuel
immediately.
Before servicing any part of the fuel system, stop the engine and disconnect the battery. Drain the fuel system completely. Use
an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be
disposed of in an approved receptacle. Any fuel system service must be performed in a well‑ventilated area. Inspect any completed
service work for signs of fuel leakage.

Fuel Line Inspection

Visually 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.
a
IMPORTANT: Visually inspect for fuel leakage from the filter connections.

Water Separating Fuel Filter

This filter removes moisture and debris from the fuel. If the filter becomes filled with water, the water can be removed. If the filter
becomes plugged with debris, replace the filter. The warning system engages when water in the fuel filter reaches the full level.
Refer to Section 2A - Warning Horn Signals.
Refer to the Inspection and Maintenance Schedule for the proper maintenance interval.
Remove and replace filter as follows:
1. Turn ignition key switch to the "OFF" position.
Page 1B-4
WARNING
!
a - Fuel filter
44568
Nm lb‑in.
23 200
8.5 75
90-8M0050731 MAY 2011
lb‑ft