Installing The Jet Pump - Mercury 200 OptiMax Jet Drive Service Manual

Jet Installation
• Allow for a minimum of 95.3 mm (3.75 in.) of travel
• Cable end at pump must allow for a 5/16 in. threaded adapter shouldered through bolt and locknut to connect the cable to
the steering arm
• A means of attaching and locking the cable to the steering cable bracket (provided)
• Protected against water intrusion and/or corrosion as the cable end (at the pump) is submersed in water with the boat at rest
• The steering cable should be able to withstand the steering loads imparted on it by the rudder
METHOD FOR CONTROLLING LOCATION AND SIZE
Mercury Marine recommends that the tunnel opening be done as a part of the manufacture of the tunnel. This will ensure
consistency of location as well as size.

Installing the Jet Pump

The location, dimensions, and thickness of the hull cut‑out opening is critical for preventing water and exhaust intrusion,
excessive engine or pump vibration, and power package assembly movement. Ensure the location, dimensions, and thickness
of the hull cut‑out opening are witin the recommended specifications prior to installing the jet pump assembly.
1. Ensure the location, dimensions, and thickness of the hull opening are within the recommended specifications.
4.07 ± 0.06 in.
a - Forward
b - Aft
c - Transom range
d - Hull opening thickness
2. Install the tunnel grommet in the cutout of the boat by gluing the front portion of the grommet to the tunnel with Loctite 454 or
equivalent.
Page 1D-10
!
16.23 ± 0.03 in.
a
0.75 ± 0.06 in. (4)
d
+0.05 in.
0.375
-0.03 in.
CAUTION
b
7.04 ± 0.03 in.
3.83 ± 0.06 in.
c
44388
90-8M0050731 MAY 2011