Mercury 200 OptiMax Jet Drive Service Manual page 3

Notice to Users of This Manual
Throughout this publication, dangers, warnings, cautions, and notices (accompanied by the International HAZARD Symbol
are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if
performed incorrectly or carelessly. Observe them carefully!
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when
performing the service, plus common sense operation, are major accident prevention measures.
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.
NOTE: Indicates information that helps in the understanding of a particular step or action.
This manual has been written and published by the Service Department of Mercury Marine to aid our dealers' mechanics and
company service personnel when servicing the products described herein. We reserve the right to make changes to this manual
without prior notification.
© 2011, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Bravo Two, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode,
RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, VesselView, and SmartCraft logo are all
registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick
Corporation.
It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they
have been trained in the recommended service procedures of Mercury Marine Power Products, including the use of mechanics'
common hand tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or
results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the
manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered.
All information, illustrations, and specifications contained in this manual are based on the latest product information available at
the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these
products.
Refer to dealer service bulletins, operation maintenance and warranty manuals, and installation manuals for other pertinent
information concerning the products described in this manual.
Precautions
It should be kept in mind, while working on the product, that the electrical and ignition systems are capable of violent and damaging
short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or
touched by the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance
of foreign material into the cylinders which could cause extensive internal damage when the engine is started.
During any maintenance procedure, replacement fasteners must have the same measurements and strength as those removed.
Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial
lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in
damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations
whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a replacement that matches
the original.
DANGER
!
WARNING
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CAUTION
!
NOTICE
!
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