Page 1: Table Of Contents
INSTALLATION IMPORTANT INFORMATION Section 1D - Mercury Jet Installation Table of Contents General Information ..... 1D-2 Water By-Pass System ....
Page 2: General Information
Mercury Marine. Also, that they have been trained in the recommended installation procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or rec- ommended tools from other suppliers.
Page 3: Torque Specifications
INSTALLATION Torque Specifications NOTE: Tighten all fasteners, not listed, securely. 10 mm Fasteners (Powerhead to Pump) 35 lb. ft. (47 Nm) Reverse Stop Screw 120 lb. in. (14 Nm) Forward Stop Screw 120 lb. in. (14 Nm) Ride Plate-to-Pump Screws 75 lb. in. (8.5 Nm) Pump Cover to Pump Housing Nuts...
Page 4: Boat Construction
Water that runs on or is splashed in the air intake may enter the engine and cause serious damage to internal engine parts. IMPORTANT: Mercury Marine will not honor any warranty claim for engine damage as a result of water entry. Engine Compartment Ventilation...
Page 5: Exhaust System
Improper installation may allow water to enter the expan- sion chamber and combustion chambers and severely damage the engine. Damage caused by water in the engine will not be covered by Mercury Marine Limited Warran- ty, unless this damage is the result of defective part(s).
Page 6: Instrumentation
INSTALLATION 3. On installations requiring long lines or numerous fittings, larger size lines should be used. 4. Fuel line should be installed free of stress and firmly secured to prevent vibration and/or chafing. 5. Sharp bends in fuel line should be avoided. 6.
Page 7: Wiring Diagrams
INSTALLATION Wiring Diagrams Quicksilver Instrumentation, Typical Analog Installation Shown NOTE: Refer to gauge manufacturer’s instructions for specific connections. a - Temperature Gauge b - Key Switch c - Tachometer Gauge d - Emergency Stop Switch e - Tachometer Harness (P/N 84-86396A8) (Not Included With Key/Choke Harness Kit) f - Connect Wires Together With Screw and Hex Nut (2 Places) Apply Quicksilver Liquid Neoprene to Connections...
Page 8: Smartcraft System Monitor - Model Year 2001 And Newer
INSTALLATION SmartCraft System Monitor – Model Year 2001 and Newer Monitor Accessory Horn (816492A9) Connection for Water Depth Warning System Link Engine Connection Optional Depth Transducer Ref. Part Number Description Qty. 879982T_ Wiring Harness SC1000-2RSL (20,30 ft) 879896K2 System Monitor – Front Mount (Outboard Only) 879896K1 System Monitor –...
Page 9: Remote Control And Cables
Follow shift cable adjustment procedure for proper adjustment. THROTTLE CABLE The throttle cable must have one end compatible with the control box. The other end must have Mercury style connectors. Follow throttle cable adjustment procedures for proper adjustment. 90-888438 JUNE 2002...
Page 10: Mercury Jet Drive Hull Dimensions
INSTALLATION Mercury Jet Drive Hull Dimensions HULL OPENING The pump to powerhead opening in the hull is the most important factor to consider in a Jet Drive installation. There are four areas of concern: 1. Location (a) of the pump to powerhead hull opening relative to the boat bottom for proper ride plate seal fit.
Page 11: Steering Helm And Cable
The steering cable should be able to withstand the steering loads imparted on it by the rudder. A locking tab is provided by Mercury to be used with the steering cable having threads and locknuts located 11.31 inches (287 mm) from cable end at pump with cable at center of travel.
Page 12: Installing Jet Pump
INSTALLATION Installing Jet Pump Hull Cutout CAUTION The hull opening dimensions are critical for proper sealing between Jet Pump and boat. Measure cutout thickness and overall dimensions before attempting a Jet Pump installation. 1. Install tunnel grommet in cut-out of boat by gluing front portion of grommet to tunnel with Loctite 454 or equivalent.
Page 13 INSTALLATION 3. Route steering cable through the through-hull fitting and bellows. Route steering cable through the port side hole in flange of pump housing. Install nut on shift cable before routing cable through wear ring. 58142 Steering Cable Wear Ring 4.
Page 14 INSTALLATION 5. Route shift cable through the through-hull fitting and bellows. Route shift cable through the starboard side hole in flange of pump housing. 58144 Shift Cable IMPORTANT: Ensure that the shift lever in the control box is set for three (3) inches of travel.
Page 15 INSTALLATION 7. Install jet pump by pushing unit through opening in tunnel grommet. Ride plate seal should fit snug in boat tunnel without any gaps along perimeter. 58180 Jet Pump Tunnel Grommet NOTE: Before torquing fasteners, check ride plate seal for proper fit in tunnel. 8.
Page 16: Steering Cable Adjustment
INSTALLATION Steering Cable Adjustment 1. Slide bellows assembly over cable and thread on cable completely. Do not tighten. 2. Route cable thru-hull fitting after routing through bellows 54456 3. Thread cable end adaptor on steering cable 14 turns (to allow for adjustment). WARNING Cable end adaptor must be installed a minimum of nine (9) turns.
Page 17 INSTALLATION 6. Adjust cable end adaptor until thru-hole in adaptor lines up with threaded hole in steering arm. This is the steering cable fine adjustment. Cable end adaptor MUST be installed on steering cable a minimum of nine (9) turns. 7.
Page 18 INSTALLATION 11. Apply perfect seal to end threads and cable conduit end. Perfect Seal 12. Turn bellows nut out and tighten against cable end adaptor. 54908 Bellows Clamp Bellows Nut Tight Against Jam Nut 13. Turn rudder to port to compress bellows as much as possible. Pull bellows over cable conduit and secure with bellows clamp.
Page 19: Shift Cable Adjustment
INSTALLATION Shift Cable Adjustment IMPORTANT: The shift cable MUST BE properly adjusted. The shift cable is adjusted so that the reverse gate is not pre-loaded against either the forward or reverse stop. Pre-load in either position may cause failure of the stop and/or premature wear of the shift cable or control box components.
Page 20 INSTALLATION 4. Loosen the locknuts and unfasten the top end of the shift cable retainer. NOTE: Locknuts do not have to be removed to open retainer. Shift Cable Retainer Plastic Barrel Holder 5. Install shift cable end in slot of the reverse gate and secure with clevis pin, flat washer, and cotter pin.
Page 21 INSTALLATION 6. Adjust shift cable as follows: a. Position the control box into forward position. b. Position the reverse gate against the forward stop. With the reverse gate at this posi- tion, adjust the cable barrel to fit into the barrel holder with slight tension of the re- verse gate against the stop.
Page 22: Bilge Siphon Feature
INSTALLATION 9. Seal the thru-hull fitting to prevent any water leaks. Steering Cable Thru-Hull Fitting Bilge Siphon Feature The Sport Jet incorporates an automatic bilge siphoning feature. The bilge siphon is working whenever the engine is running above idle speeds. Maximum performance of the bilge si- phon is realized above 3,000 rpm.
Page 23: Water By-Pass System
INSTALLATION Water By-Pass System The water by-pass system is designed to improve powerhead cooling at idle speed. 1. Locate the water by-pass components (provided). Thru-Hull Fitting Hose Clamp Brass Nut IMPORTANT: The thru-hull fitting must be correctly positioned in the boat transom as instructed in Step 3.
Page 24 INSTALLATION 4. After the location has been selected for the thru-hull fitting, drill a 9/16 in. (14.3 mm) di- ameter hole. 5. Apply Marine Sealer to entire length of threads and under the head of the thru-hull fitting. Fasten the fitting into the transom with the brass nut (provided). Through-Hull Fitting Brass Nut Marine Sealer...
Page 25: Installation Of Flushing Kit
INSTALLATION Installation of Flushing Kit 1. Attach flush hose to fitting and secure with hose clamp. Failure to secure hose will allow water to fill boat. 59290 58202 M10x1.5 Nuts (10) Cover and Gasket Attach Flush Hose to Fitting with Hose Clamp 2.
Page 26: Operation Instructions
INSTALLATION 4. Snap flush adapter into bracket as shown. Bracket Flush Adapter Operation Instructions WARNING DO NOT run engine on flushing kit above idle speeds. Damage to engine from over- heating, due to lack of water supply may occur. 1. With engine off, remove flush adapter plug and attach water hose. 52121 Flush Adapter Water Hose...
Page 27: Suggested Flushing Intervals
INSTALLATION 4. Flush outer surfaces of water outlet nozzle. Suggested Flushing Intervals After running jet in salt water environment Where boat was operated in shallow water or run aground. Overheat warning horn sounds (May be caused from accumulation of particles/debris in jet powerhead) CAUTION If any of the above conditions are not corrected with normal flushing of engine, it...
Page 28: Installing Powerhead
INSTALLATION Installing Powerhead 1. Install gasket on drive housing cover. Ensure sealing bead is facing up towards drive housing cover. 2. Install two (2) O-rings. 3. Check that slinger is on drive shaft. 4. Lubricate drive shaft splines with Special Lubricant 101. 59291 Gasket, with Sealing Bead Facing Up Drive Housing Cover O-Ring...
Page 29 INSTALLATION 7. Connect fuel line to fuel inlet fitting, secure with U.S. Coast Guard approved hose clamp (183.532). 8. Vapor separator tank (VST) must be vented to fuel tank (250 hp). Vent hose must comply with U.S. Coast Guard/ABYC regulations. 59414 VST Vent Hose Fitting Fuel Inlet Fitting...
Page 30: Battery Connection
INSTALLATION Battery Connection NOTE: Engine electrical system is negative (–) ground. 1. Connect positive (+) battery cable (usually red) to slave solenoid using protective boot (provided). 2. Connect negative (–) battery cable (usually black) to engine ground under starter bracket. 3.
Page 31: Throttle Cable
INSTALLATION Throttle Cable Installation 1. Position remote control into neutral. 2. Attach throttle cable to the throttle lever. Secure with washer and locknut. 57837 Washer and Locknut – Tighten locknut and back off 1/4 turn 3. Adjust the cable barrel so that the installed throttle cable will hold the idle stop screw against the stop.
Page 32: Oil Injection Set-Up
Fill Cap Priming the Oil Injection Pump (If Required) All Mercury Jet Drive powerheads have the oil systems primed. To determine if repriming is necessary, check the clear oil line between the engine oil reservoir and the oil pump. If there are no air bubbles in the line, it is not necessary to reprime the oil system.
Page 33: Trim Plate Adjustment
INSTALLATION Trim Plate Adjustment The Jet Drive unit trim plate is factory set for general applications. Should a particular boat experience porpoising problems, the trim plate can be adjusted as follows: 1. Loosen both jam nuts on trim plate (one starboard and one port). Jam Nut with Washer (Two: One On Each Side) Jam Nut Small Diameter Washer...
Page 34: Exhaust System Installation
5. Rubber hose should be connected to pipes with flares or beads or barbs to prevent the hose from sliding off the pipe under pressure. 6. For additional exhaust system recommendations, see MERCURY publication 90–884386 which covers all jet drive exhaust applications not covered under these guidelines.
Page 35: Top View
INSTALLATION Top View 200/240/250 hp – 878147–A1 Muffler Assy, Port [9.0 in (22.8 cm)] with 3.0 in (7.6 cm) Outlet 210 hp – 859388A1 Muffler Assy, Port [9.0 in (22.8 cm)] with 2.5 in (6.4 cm) Outlet Connection Piping between Expansion Chamber and Muffler must be made of 3.0 in (7.6 cm) O.D.
Page 36: Aft View
Final system installation shall be reviewed by a MERCURY Field Representa- tive using a modified expansion chamber to ensure back pressure does not ex- ceed 1.8 psi (10.3 kg) at 1000 ft (304.8 m) above sea level or less. This test needs to be performed with the boat in the water and under way.
Page 37: Side View
INSTALLATION Side View This line represents the bottom edge of the muffler outlet tube. Measure to en- sure that the lowest possible location of the bottom edge of the muffler tubes never gets within 2.0 in (5.1 cm) of the maximum depth waterline. 2.0 in (5.1 cm).
Page 38: Side View Of Expansion Chamber Outlet Pipe And Exhaust Pipe Connection
INSTALLATION Side View of Expansion Chamber Outlet Pipe and Exhaust Pipe Connection A spacer must be used with all 3.0 in (7.6 cm) tube applications. A spacer hav- ing a 2.65 in (6.73 cm) I.D. and a 3.0 in (7.6 cm) O.D. needs to be installed over the expansion chamber outlets.
Page 39: Pre-Delivery Inspection
INSTALLATION Pre-delivery Inspection Check/ CHECK BEFORE RUNNING Applicable Adjust Water hose connection/torqued Idle:____________RPM Cover plate & adaptor plate Idle mixture adjusted fasteners torqued Forward-Neutral-Reverse Battery meets engine operational specification Steering operational throughout Battery charged & secure entire range All electrical connections tight Acceleration test All fuel connections tight WOT:___________RPM...

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