Mercury 200 OptiMax Jet Drive Service Manual page 44

Table of Contents
General Information...........................................................1D-2
Notice to Installer........................................................1D-2
Torque Specifications.................................................1D-2
Before Starting the Engine.........................................1D-3
Important Information.........................................................1D-3
Fuel Requirements.....................................................1D-3
Oil Recommendation..................................................1D-3
Avoiding Fuel Flow Restriction..........................................1D-3
Boat Horsepower Capacity................................................1D-3
Start in Gear Protection.....................................................1D-4
Selecting Accessories for Your Outboard..........................1D-4
Fuel System.......................................................................1D-4
Fuel Tanks..................................................................1D-4
Integrated Fuel Demand Valve (iFDV) Requirement
................................................................................1D-4
Low Permeation Fuel Hose - Outboard......................1D-4
Fuel Requirements.....................................................1D-5
Installation Requirements..................................................1D-6
Installation..................................................................1D-6
Battery/Battery Cables................................................1D-6
Boat Construction.......................................................1D-7
Engine Compartment Ventilation................................1D-7
Exhaust and Engine Height........................................1D-8
Fuel Delivery System..................................................1D-8
Instrumentation...........................................................1D-9
Remote Control and Cables.......................................1D-9
Steering Helm and Cable...........................................1D-9
Installing the Jet Pump....................................................1D-10
Installing the Flush Kit......................................................1D-14
Installing the Powerhead.................................................1D-15
Flywheel Cover Removal and Installation........................1D-16
90-8M0050731 MAY 2011
Important Information
Section 1D - Jet Installation
Installing the Throttle Cable ............................................1D-17
Fuel Hose and Vent Hose Connections...........................1D-18
Battery Cable Connections..............................................1D-19
Remote Harness Connection...........................................1D-20
Oil Injection Hose Connections........................................1D-21
Steering Cable Adjustment..............................................1D-21
Shift Cable Adjustment....................................................1D-24
Filling the Fuel System....................................................1D-27
Filling the Oil System.......................................................1D-27
Trim Plate Adjustment.....................................................1D-29
Features...........................................................................1D-30
Installing the Exhaust System..........................................1D-32
Recommended Predelivery Engine Break-in Procedure. 1D-36
Predelivery Inspection.....................................................1D-38
Removal...................................................................1D-16
Installation................................................................1D-17
Battery Cable Installation Requirements..................1D-19
Battery Cable Connections.......................................1D-19
Filling the Oil Tanks..................................................1D-27
Priming the Oil Pump (if required)............................1D-28
Bilge Siphon Feature................................................1D-30
Water Bypass System..............................................1D-30
General Exhaust System Notes...............................1D-32
Measuring the Exhaust Outlet..................................1D-32
Top View...................................................................1D-33
Aft View....................................................................1D-34
Side View..................................................................1D-35
Side View of Expansion Chamber Outlet Pipe and
Exhaust Pipe Connection......................................1D-36
Inner Sleeve Liner Fabrication..................................1D-36
Jet Installation
1
D
Page 1D-1