Mariner Mercury 200 JET Manuals

Manuals and User Guides for Mariner Mercury 200 JET. We have 1 Mariner Mercury 200 JET manual available for free PDF download: Service Manual

Mariner Mercury 200 JET Service Manual

Mariner Mercury 200 JET Service Manual (797 pages)

Brand: Mariner Mercury | Category: Engine | Size: 19 MB

Table of Contents

Important 1 B

15
- Page Numbering
  3
- Important Information
  5
- Table of Contents
  15
- Specifications
  16
  - Gear Case Lubricant Capacity
    16
  - Special Tools
    16
  - Quicksilver Lubricant/Sealant
    16
- Inspection and Maintenance Schedule
  16
  - Before each Use
    16
  - After each Use
    16
- Lubrication Points
  17
- Checking Power Trim Fluid
  19
- Gear Case Lubrication
  20
- Propeller Replacement
  21
  - Removal
    21
  - Installation
    21
- Corrosion Control Anode
  22
- Flushing Engine
  23
  - Flushing Cooling System with Engine NOT Running (Using Cowl Flush Plug)
    23
  - Flushing Cooling System with Engine Running (Using Flushing Attachment 44357A2)
    23
- Storage
  24
Important 1 C

26
- Conditions Affecting Performance
  27
  - Weather
    27
  - Boat
    28
  - Engine
    29
- Serial Number Location
  27
- Following Complete Submersion
  30
- Painting Procedures
  31
  - Cleaning & Painting Aluminum Propellers & Gear Housings
    31
- Propeller Selection
  31
- Decal Application
  32
  - Decal Removal
    32
  - Instructions for "Wet" Application
    32
Important 1 D

35
Electrical 2

51
Electrical 2

81
- Battery Cable Size
  82
- Special Tools
  82
- Specifications
  82
- Battery
  83
  - Precautions
    83
- Specific Gravity Readings
  83
  - Specific Gravity Cell Comparison Test
    84
- Charging a Discharged Battery
  84
- Electrolyte Level
  84
- Battery Charging System Description
  85
- Winter Storage of Batteries
  85
- Battery Charging System Troubleshooting
  86
  - General Troubleshooting
    86
    
    40 Ampere Alternator System
    86
    
    Amp Stator Test (Alternator Coils Only)
    86
- Troubleshooting 40 Amp Alternator System
  86
- System Wired for Split Output
  90
  - 20 Amperes to Auxiliary Battery
    90
  - 20 Amperes to Cranking Battery
    90
- System Wired for 40 Ampere Output to Isolator
  91
- Starter System
  92
  - Starter System Components
    92
  - Description
    92
  - Troubleshooting the Starter Circuit
    92
- Starter Circuit Troubleshooting Flow Chart
  93
- Starter Removal and Installation
  94
  - Removal
    94
  - Installation
    95
  - Disassembly
    95
- Starter Cleaning, Inspection and Testing
  96
  - Cleaning and Inspection
    96
  - Testing
    96
  - Starter Reassembly
    98
  - Starter Solenoid Test
    100
Electrical 2

102
- Timing/Synchronizing/Adjusting
  103
  - Specifications
    103
    
    Carbureted Models
    103
    
    Electronic Fuel Injection Models
    104
- Special Tools
  104
- Adjustments
  105
  - Carburetor Models
    105
    
    Carburetor Synchronization
    105
    
    Timing Pointer Adjustment
    105
    
    Carburetor/Oil Pump Synchronization
    106
    
    Maximum Timing Adjustment
    107
    
    Timing Adjustments
    107
    
    Idle Speed Adjustment
    108
    
    Primary Pickup Timing Adjustment
    108
- Adjustments
  109
- Electronic Fuel Injection Models
  109
- Timing Pointer Adjustment
  109
- Throttle Cam Adjustment
  110
- Static Idle Timing Adjustment (Cranking Engine with Starter)
  111
- Maximum Throttle
  112
- Maximum Timing Adjustment for 225 Pro Max/Super Magnum
  112
- Static Maximum Timing Adjustment (Cranking Engine with Starter)
  112
- Throttle Position Sensor (TPS) Adjustment
  113
- Idle Adjustment
  114
- Idle Timing (Engine Running)
  114
- Throttle Cable Installation
  115
- Throttle Valve/Oil Pump Synchronization
  115
- Detonation Control (200 Model)
  116
- Maximum Timing Adjustment (Engine Running)
  116
Electrical 2

118
Fuel Systems

150
- Special Tools
  151
- Specifications
  151
  - Fuel Pump Pressure @ W.O.T
    151
  - Fuel Pump Pressure @ Idle
    151
- Fuel Pump
  152
  - General Information
    154
    
    Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
    154
    
    Fuel Pump Description/Operation
    154
  - Testing Fuel Pump
    155
- Checking Fuel Pump Lift (Vacuum)
  155
  - Vacuum Test Troubleshooting
    156
  - Fuel Pump Removal/Disassembly
    156
  - Cleaning/Inspection
    157
  - Reassembly/Lnstallation
    157
    
    Assembly
    157
Fuel Systems

160
- Notes
  161
- WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Assembly
  162
- WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Specifications
  164
- WMH 12,13,14,15,16,27 Carburetor Assembly
  166
- WMH 12,13,14,15,16,27 Carburetor Specifications
  168
- WMH 21,22,23,25,26,28 Carburetor Assembly
  170
- WMH 21,22,23,25,26,28 Carburetor Specifications
  172
- WMH 30,31,32,33,34,39 Carburetor Assembly
  174
- WMH 30,31,32,33,34,39 Carburetor Specifications
  176
- Wmv 1/1A, 2/2A, 3/3A, 4/4A, 5/5A
  178
- WMV 1,2,3,4,5 Carburetor Front View
  182
- WMV 1,2,3,4,5 Carburetor Specifications
  182
- Fuel System - Troubleshooting
  183
  - General Information
    183
- Reed Valve Leak Test
  185
  - Tools Needed for Test
    185
  - Thermal Air Valve Circuit Description
    186
- WMH Carburetor Fuel Circuit Description
  186
  - Idle Circuit Description
    186
    
    Idle Circuit Adjustments
    186
  - Off-Ldle Circuit Description
    187
  - Back Draft Circuit Description
    187
  - High Speed Fuel Circuit Description
    187
    
    High Speed Fuel Circuit Adjustments
    187
  - Carburetor Placement
    188
    
    Jet Location for each Cylinder
    188
- WMV Carburetor Fuel Circuit Description
  189
  - Float Bowl Circuit
    189
  - Idle Circuit
    189
  - Cold Start Circuit
    190
  - Off-Idle Circuit
    190
  - Main Circuit
    191
  - Back Draft Circuit
    191
  - Carburetor Placement and Jet Location for each Cylinder (WMV Carburetors)
    192
  - High Altitude Recommendations
    193
  - High Altitude Jet Chart
    194
  - Enrichener System Description
    195
    
    Enrichener Valve Replacement
    196
    
    Enrichener Valve Test
    196
- Carburetor Disassembly
  197
  - Carburetor Jet Removal
    197
  - Fuel Bowl Removal and Disassembly
    199
    
    Throttle Shaft Component Removal
    200
  - Carburetor Cleaning and Inspection
    200
  - Carburetor Reassembly
    200
  - Throttle Shaft Component Installation
    200
  - Fuel Bowl Reassembly
    201
  - Carburetor Jet Installation
    202
  - Installing Carburetor(S) to Engine
    203
- Removing Carburetor(S) from Engine
  197
- Fuel Line and Primer Bulb Assembly
  204
  - Fuel Line Clamp Removal and Installation
    205
Fuel Systems

207
- Special Tools
  208
- Specifications
  208
- Electronic Control Module (ECM) Assembly
  209
- Fuel Management System
  211
- Fuel Pump and Fuel Filter
  215
- Electronic Fuel Injection (Efl) System
  217
  - Introduction
    217
  - Using the Test Procedures
    217
  - EFI System Tests
    218
  - Safety Precautions
    218
  - Fuel Injection System Function
    218
- Outboard Powerhead View
  217
- Preliminary Steps
  219
  - Ignition Spark Check
    219
  - Electronic Fuel Injection Set up
    219
  - Fresh Quality Fuel
    220
  - Low Battery Voltage
    220
- Fuel Flow Diagram
  221
  - Fuel Flow Components
    222
- EFI Electrical Diagram
  223
  - EFI Electrical Components
    224
- EFI Fuel Management (Low Pressure Fuel Route)
  226
- EFI Fuel Management (High Pressure Fuel Route)
  227
- Fuel Rail Electrical/Fuel Determination
  228
- EFI System Test Procedures
  229
  - Fuel Gauge Connection/Pressure Test
    229
  - Vapor Separator Fuel Delivery Test
    230
  - Vapor Separator Float Test
    230
  - Water Separating Filter Flow Test
    231
  - Pulse Fuel Pump Delivery Test
    232
  - Final Filter Check and De-Pressurizing EFI System Procedures
    233
  - Pressure Regulator Test
    234
  - Electric Fuel Pump Test
    235
  - Voltage Test Chart
    237
  - Injector Electrical Harness Test
    238
  - Injector Fuel Delivery Test
    238
  - Injector Operation Test
    239
  - Induction Manifold Leak Check
    240
  - Air Temperature Sensor Test
    241
  - Engine Head Temperature Sensor Test
    242
  - Detonation Control System Test (200 Models Only)
    242
  - Detonation Sensor Check
    243
  - Detonation Control Module Check
    243
  - Throttle Position Sensor Test
    244
  - Map Sensor Test
    244
  - Problem Diagnosis
    244
- EFI Induction Manifold Removal
  247
  - Water Separating Filter Assembly Removal
    248
  - Throttle Position Sensor/Temperature Sensor
    248
    
    Fuel Injector Harness Disconnections
    248
  - Oil Reservoir Removal
    249
  - Final Filter Assembly Removal
    249
  - Electric Fuel Pump Removal
    250
  - Vapor Separator Removal
    250
  - Vapor Separator Disassembly
    251
    
    Pressure Regulator Removal and Disassembly
    251
    
    Vapor Separator Float Removal
    251
  - Vapor Separator Float Installation
    253
  - Manifold Removal
    254
- EFI Induction Manifold Disassembly
  255
  - Air Temperature Sensor Removal
    255
  - Throttle Position Sensor Removal
    256
  - Fuel Rail Removal
    256
  - Fuel Rail Disassembly
    257
  - Fuel Injector Removal and Disassembly
    258
  - Injector Harness Removal
    259
  - Throttle Linkage Removed
    259
- EFI System Cleaning and Inspection
  260
  - Cleaning
    260
  - Inspection
    260
- Induction Manifold Assembly
  261
  - Injector Harness Installation
    261
  - Fuel Injector Assembly and Installation
    262
  - Fuel Rail Assembly
    262
  - Fuel Rail Installation
    263
  - Throttle Position Sensor Installation
    264
  - Air Temperature Sensor Installation
    264
- EFI Induction Manifold Installation
  265
Fuel Systems

273
- Special Tools
  274
- Specifications
  274
- Detonation Controller/Air Temperature Sensor/Throttle Position Sensor
  276
- Electronic Control Module (ECM) Assembly
  277
- Fuel Management System
  279
- Fuel Pump
  283
- Electronic Fuel Injection (Efl) System
  285
  - Introduction
    285
  - Using the Test Procedures
    285
  - EFI System Tests
    286
  - Safety Precautions
    286
  - Fuel Injection System Function
    286
- Outboard Powerhead View
  285
- Preliminary Checks
  287
- Fuel Flow Diagram
  289
- Fuel Flow Component Description
  290
  - Fuel Injectors
    290
  - EFI Electrical Components (from Electrical Component Diagram)
    294
- EFI Fuel Management (Low Pressure Fuel Route)
  296
- EFI Fuel Management (High Pressure Fuel Route)
  297
- Fuel Rail Electrical/Fuel Determination
  298
- EFI System Test Procedures
  299
  - Fuel Gauge Connection/Pressure Test
    299
  - Vapor Separator Fuel Delivery Test
    300
  - Vapor Separator Float Test
    301
  - Water Separating Filter Flow Test
    301
  - Pulse Fuel Pump Delivery Test
    302
  - Final Filter Check and De-Pressurizing EFI System Procedures
    302
  - Pressure Regulator Test
    304
  - Electric Fuel Pump Voltage Test
    305
  - Voltage Test Chart
    306
  - Injector Electrical Harness Test
    307
  - ECM Injector Driver Test
    307
  - Injector Fuel Delivery Test
    307
  - Injector Operation Test
    308
  - Induction Manifold Leak Check
    309
  - Air Temperature Sensor Test
    310
  - Engine Head Temperature Sensor Test
    310
  - Detonation Control System Test (200 Models Only)
    311
  - Detonation Sensor Check
    311
  - Detonation Control Module Check
    312
  - Throttle Position Sensor Test
    312
  - Map Sensor Test
    313
  - Problem Diagnosis
    314
- EFI Induction Manifold Removal
  317
- EFI Induction Manifold Disassembly
  328
  - Air Temperature Sensor Removal
    328
  - Throttle Position Sensor Removal
    329
  - Fuel Rail Removal
    329
  - Fuel Rail Disassembly
    330
  - Fuel Injector Removal and Disassembly
    331
  - Injector Harness Removal
    332
  - Throttle Linkage Removed
    332
- EFI System Cleaning and Inspection
  333
  - Cleaning
    333
  - Inspection
    333
- Induction Manifold Assembly
  334
  - Injector Harness Installation
    334
  - Fuel Injector Assembly and Installation
    335
  - Fuel Rail Assembly
    335
  - Fuel Rail Installation
    336
  - Throttle Position Sensor Installation
    337
  - Air Temperature Sensor Installation
    337
- EFI Induction Manifold Installation
  338
Fuel Systems

345
- Operation of the Oil Injection System
  346
- Oil Injection Components
  347
- Oil Injection Flow System
  348
- Pump Drive Assembly
  349
- Pump Drive System
  349
  - Set up Instructions for Oil Injection System
    350
- Oil Injection Pump
  353
  - Oil Pump Removal
    353
- Worm Bushing
  354
- Motion Sensor
  355
  - Oil Injection System Troubleshooting Chart
    356
- Oil Pump Volume (Flow) Test
  360
  - Oil Warning Module
    360
  - Engine Mounted Oil Reservoir
    360
  - Emission Control Information
    362
Table of Contents

363
- Exhaust Emissions Standards
  364
  - What Are Emissions
    364
  - Hydrocarbons - HC
    364
  - Carbon Monoxide - CO
    364
  - Oxides of Nitrogen - Nox
    364
  - Controlling Emissions
    364
  - Stoichiometric (14.7:1) Air/Fuel Ratio
    364
- Outboard Hydrocarbon Emissions Reductions
  365
- Stratified Vs Homogenized Charge
  366
  - Homogenized Charge
    366
  - Stratified Charge
    366
- Emissions Information
  367
  - Manufacturer's Responsibility
    367
  - Dealer Responsibility
    367
  - Owner Responsibility
    367
  - EPA Emission Regulations
    367
  - Service Replacement Certification Label
    368
  - Decal Location for 1998 Models
    369
Powerhead

371
- Powerhead Specifications
  372
- Special Tools
  373
  - Powerhead Repair Stand
    374
- Cylinder Block and End Caps
  375
- Exhaust Manifold and Exhaust Plate
  377
- Reed Block and Cylinder Head
  379
- Crankshaft, Pistons and Connecting Rods
  381
- Torque Sequence
  383
- General Information
  384
- Powerhead Removal from Driveshaft Housing
  384
  - Removing Engine Components
    388
- Powerhead Disassembly
  389
  - Water Pressure Relief Valve Components
    395
  - Torque Specifications
    395
- Cleaning and Inspection
  396
  - Cylinder Block and Crankcase Cover
    396
  - Special Service Information
    396
  - Cylinder Bores
    396
    
    Honing Procedure
    396
  - Pistons and Piston Rings
    398
    
    Cleaning Piston Ring Grooves
    398
    
    Measuring Piston Roundness
    399
  - Cylinder Heads and Exhaust Divider Plate
    399
  - Crankshaft
    400
  - Crankshaft (and End Cap) Bearings
    400
  - Reed Block Assembly
    401
  - Reed Block Housing
    401
  - Connecting Rods
    401
- Powerhead Reassembly and Installation
  404
- Bleed Line Routing (Carbureted Models)
  416
  - Front View
    416
  - Port Side View
    416
  - Starboard Side View
    416
- Bleed Line Routing (Fuel Injected Models)
  416
  - Port Side View
    417
  - Starboard Side View
    417
- Reinstalling Engine Components
  417
- Notes
  418
- Throttle Lever and Shift Shaft
  419
- Powerhead Installation on Driveshaft Housing
  423
- Break-Ln Procedure
  428
  - Break-In Fuel Mixture
    428
    
    Engine Break-In Procedure (All Models)
    428
    
    Gasoline/Oil Mixing Ratio Chart
    428
Powerhead

430
- Special Tools
  431
- Specifications
  431
  - Thermostat
    431
  - Water Pressure
    431
- Water Flow
  433
  - Description
    433
  - Troubleshooting
    437
  - Thermostat Test
    437
  - Water Pressure Check
    438
  - Water Pump Cleaning and Inspection
    439
  - Problem Diagnosis
    440
MID-Section

442
- Notes
  443
- Swivel Bracket and Steering Arm
  444
- Transom Brackets (S/N-0G590000
  446
- Drive Shaft Housing and Exhaust Tube
  450
- Drive Shaft Housing and Dyna-Float Suspension
  452
  - Removal and Disassembly
    452
  - Shift Linkage Assembly
    452
  - Reassembly and Installation
    454
MID-Section

458
- Power Trim Specifications
  459
- Special Tools
  459
- Power Trim Components
  460
- Power Trim Motor
  462
- Power Trim - General Information
  463
  - Description
    463
  - Trimming Characteristics
    463
  - Trailering Outboard
    463
  - Tilting Outboard Manually
    464
  - Trim "In" Angle Adjustment
    464
  - Striker Plate Replacement
    464
  - Anode Plate
    465
  - Trim Indicator Gauge
    465
  - Check, Fill and Purge - Power Trim System
    465
  - Troubleshooting
    466
  - Power Trim System with Relays and 2 Wire Trim Motor
    468
- Electrical System Troubleshooting
  469
  - General Checks
    469
- Troubleshooting the "Down Circuit
  469
- Troubleshooting the "Up" Circuit
  470
- Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
  471
- Power Trim Assembly Removal and Installation
  472
  - Removal
    472
  - Installation
    474
  - Testing Power Trim System with Test Gauge Kit (91-52915A6)
    475
  - UP" Pressure Check
    475
  - DOWN" Pressure Check
    477
  - Hydraulic Repair
    479
  - Trim Rod End Cap Seal
    480
  - Tilt Ram
    480
  - Disassembly
    481
  - Scraper Seal Replacement
    483
- Motor and Electrical Tests/Repair
  485
  - Trim Pump Motor Test
    485
  - Motor Disassembly
    486
  - Armature Tests
    486
  - Motor Repair
    487
  - Reassembly
    490
  - Reassembly - Motor and Pump
    491
  - Priming Power Trim System
    492
  - Trim Sender Test
    493
- Trim Indicator Wiring Diagrams
  494
  - Lower Unit
    495
Lower Unit

496
- Forward Gear Backlash
  497
- Lubricant Capacity
  497
- Pinion Depth
  497
- Reverse Gear Backlash
  497
- (S/N-0G437999 & Below)
  504
- Gear Housing (Prop Shaft)(Standard Rotation) (S/N-0G437999 & BELOW)
  504
- Gear Housing (Drive Shaft) (CLE) (Standard Rotation) (Pro Max/Super Magnum Models)
  506
- Gear Housing (Prop Shaft) (CLE) (Standard Rotation) (Pro Max/Super Magnum Models)
  508
- Gear Housing (Drive Shaft) (Standard Rotation) (Torque Master)(Pro Max/Super Magnum Models)
  510
- Gear Housing (Prop Shaft) (Standard Rotation) (Torque Master) (Pro Max/Super Magnum Models)
  512
- Gear Housing (Driveshaft) (Standard Rotation) (Sportmaster)
  514
- Gear Housing (Prop Shaft) (Standard Rotation) (Sportmaster)
  518
- General Service Recommendations
  520
- Removal, Disassembly, Cleaning and Inspection - Standard Rotation
  521
  - Removal
    521
  - Draining and Inspecting Gear Housing Lubricant
    522
  - Water Pump
    523
    
    Cleaning and Inspection
    523
    
    Removal and Disassembly
    523
  - Bearing Carrier and Propeller Shaft Removal
    524
  - Shift Shaft
    526
    
    Cleaning and Inspection
    526
    
    Disassembly
    526
    
    Disassembly- Bearing Carrier
    527
  - Propeller Shaft
    528
    
    Inspection
    528
  - Disassembly (Std. Gear Cases)
    530
- Pinion Gear and Drive Shaft
  531
  - Removal
    531
- Forward Gear
  533
  - Removal and Disassembly
    533
- Gear Housing
  534
- Bearing Carrier
  535
  - Reassembly
    535
- Driveshaft Needle Bearing
  535
  - Reassembly/Installation
    535
- Reassembly and Installation Standard Rotation
  535
- Forward Gear
  537
  - Reassembly
    537
- Forward Gear Bearing Race
  537
  - Installation
    537
- Driveshaft and Pinion Gear
  538
  - Reassembly/Installation
    538
  - Play (Sport Master)
    543
  - Drive Shaft End Play
    543
- Clutch Actuator Rod
  545
  - (Std. Gear Case)
    545
  - Reassembly/Shimming (High-Performance Gear Cases)
    546
- Propeller Shaft
  546
- Shift Shaft Bushing
  546
  - Reassembly
    546
- Water Pump
  549
- Gear Lubricant Filling Instructions
  551
- Installing Gear Housing to Drive Shaft Housing
  552
- Propeller Installation
  553
Lower Unit

556
- Gear Housing (Prop Shaft)(Counter Rotation) (S/N-0G437999 & BELOW)
  564
- Gear Housing (Driveshaft)(Counter Rotation) (Sportmaster)
  568
- Gear Housing (Prop Shaft)(Counter Rotation) (Sportmaster)
  572
- General Service Recommendations
  576
- Removal, Disassembly, Cleaning and Inspection of Counter Rotation (Left Hand) Gear Housing
  577
  - Removal
    577
  - Draining and Inspecting Gear Housing Lubricant
    578
  - Water Pump
    579
    
    Cleaning and Inspection
    579
    
    Removal and Disassembly
    579
  - Bearing Carrier and Propeller Shaft Removal
    580
  - Shift Shaft
    583
    
    Cleaning and Inspection
    583
    
    Disassembly
    583
    
    Disassembly- Bearing Carrier
    583
  - Propeller Shaft
    584
    
    Disassembly
    584
    
    Inspection
    584
  - Clutch Actuator Rod
    586
    
    Cleaning and Inspection
    586
    
    Disassembly
    586
  - Forward Gear and Bearing Adapter
    587
    
    Disassembly/Cleaning/Inspection
    587
  - Pinion Gear and Driveshaft
    588
    
    Removal
    588
  - Reverse Gear
    591
    
    Cleaning and Inspection
    591
    
    Removal and Disassembly
    591
  - Gear Housing
    592
    
    Cleaning and Inspection
    592
- Driveshaft Needle Bearing
  592
  - Reassembly/Installation
    592
- Reassembly and Installation of Counter Rotation Gear Housing
  592
- Bearing Carrier, Forward Gear and Bearing Adaptor
  593
- Driveshaft and Pinion Gear
  595
  - Reassembly/Installation
    595
- Pinion Gear Depth
  597
  - Determining Pinion Gear Depth
    597
  - Setting/Checking Driveshaft End Play (Sport Master Only)
    598
- Reverse Gear
  600
  - Determining Reverse Gear Backlash
    600
- Forward Gear
  601
- Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier
  603
  - Reassembly
    603
- Clutch Actuator Rod
  606
  - Reassembly/Shimming
    606
- Propeller Shaft
  607
- Shift Shaft Bushing
  607
  - Reassembly
    607
- Water Pump
  611
- Gear Lubricant Filling Instructions
  613
- Installing Gear Housing to Driveshaft Housing
  613
- Propeller Installation
  614
Lower Unit

617
- Gear Housing Specifications (1.78:1 Ratio)
  618
- Special Tools
  618
  - 1.78:1 Ratio
    618
- Gear Housing (Prop Shaft) - Xr6/Magnum III - 1.78:1 Ratio
  623
- General Service Recommendations
  625
- Removal, Disassembly, Cleaning and Inspection
  626
  - Removing Gear Housing from Driveshaft Housing
    626
  - Draining Lubricant from Gear Housing
    627
  - Water Pump
    628
    
    Removal and Disassembly
    628
  - Cleaning and Inspection
    629
  - Bearing Carrier and Propeller Shaft Removal
    629
    
    Bearing Carrier Cleaning and Inspection
    630
    
    Bearing Carrier Disassembly
    630
    
    Propeller Shaft Cleaning and Inspection
    631
    
    Propeller Shaft Disassembly
    632
  - Pinion Gear and Driveshaft
    632
    
    Cleaning and Inspection
    633
  - Forward Gear and Bearings
    634
    
    Cleaning and Inspection
    634
    
    Removal and Disassembly
    634
  - Shift Shaft, Bushing and Cam
    635
    
    Shift Shaft Removal
    635
  - Gear Housing
    635
    
    Cleaning and Inspection
    635
  - Driveshaft Needle Bearing
    636
    
    Removal of Driveshaft Needle Bearing - Early Model
    636
    
    Removal of Driveshaft Needle Bearing - Late Model
    637
- Driveshaft Needle Bearing
  637
- Reassembly and Installation
  637
- Driveshaft Needle Bearing
  638
  - Installation - Late Model
    638
  - Late Model
    638
- Lower Shift Shaft and Bushing
  639
  - Reassembly and Installation
    639
- Bearing Carrier
  640
  - Reassembly
    640
- Forward Gear and Race
  640
- Driveshaft and Pinion Gear
  642
  - Reassembly/Installation
    642
- Determining Pinion Gear Depth
  643
- Propeller Shaft
  644
  - Reassembly
    644
- Determining Forward Gear Backlash
  645
- Water Pump
  647
  - Reassembly/Installation
    647
- Filling Gear Housing with Lubricant
  648
- Installing Gear Housing to Driveshaft Housing
  648
- Propeller Installation
  650
Lower Unit

652
- Gear Housing Specifications (Standard Rotation)
  653
- Special Tools
  653
  - (S/N-0G438000
    658
  - (S/N-0G438000
    660
- General Service Recommendations
  662
- Removal, Disassembly, Cleaning and Inspection - Standard Rotation
  663
  - Draining and Inspecting Gear Housing Lubricant
    664
    
    Cleaning and Inspection
    665
    
    Removal and Disassembly
    665
    
    Water Pump
    665
    
    Bearing Carrier and Propeller Shaft Removal
    666
    
    Cleaning and Inspection
    668
    
    Shift Shaft
    668
    
    Disassembly- Bearing Carrier
    669
    
    Balance Wheels
    670
    
    Propeller Shaft
    670
    
    Cleaning and Inspection
    672
    
    Clutch Actuator Rod
    672
    
    Pinion Gear and Driveshaft
    672
    
    Cleaning and Inspection
    673
    
    Cleaning and Inspection
    674
    
    Forward Gear
    674
    
    Removal and Disassembly
    674
    
    Cleaning and Inspection
    675
    
    Gear Housing
    675
- Reassembly and Installation Standard Rotation
  675
  - Reassembly/Installation
    675
- Bearing Carrier
  676
- Forward Gear
  677
- Forward Gear Bearing Race
  678
- Driveshaft and Pinion Gear
  679
  - Reassembly/Installation
    679
- Pinion Gear Depth/Forward Gear Backlash/Reverse Gear Backlash
  680
  - Determining Pinion Gear Depth
    680
  - Determining Forward Gear Backlash
    681
- Clutch Actuator Rod
  683
- Shift Shaft Bushing
  683
- Propeller Shaft
  684
- Water Pump
  686
- Gear Lubricant Filling Instructions
  688
- Installing Gear Housing to Driveshaft Housing
  688
- Propeller Installation
  689
Lower Unit

692
- Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G438000 & UP)
  700
- General Service Recommendations
  704
- Removal, Disassembly, Cleaning and Inspection of Counter Rotation (Left Hand) Gear Housing
  705
  - Draining and Inspecting Gear Housing Lubricant
    706
  - Water Pump
    707
    
    Cleaning and Inspection
    707
    
    Removal and Disassembly
    707
  - Bearing Carrier and Propeller Shaft
    708
  - Shift Shaft
    711
    
    Cleaning and Inspection
    711
    
    Disassembly- Bearing Carrier
    711
  - Propeller Shaft
    712
  - Clutch Actuator Rod
    714
    
    Cleaning and Inspection
    714
  - Forward Gear and Bearing Adapter
    714
    
    Disassembly/Cleaning/Inspection
    714
  - Pinion Gear and Driveshaft
    715
    
    Cleaning and Inspection
    717
  - Reverse Gear
    717
    
    Removal and Disassembly
    717
    
    Cleaning and Inspection
    718
  - Gear Housing
    719
    
    Cleaning and Inspection
    719
- Driveshaft Needle Bearing
  719
  - Reassembly/Installation
    719
- Reassembly and Installation of Counter Rotation Gear Housing
  719
- Bearing Carrier, Forward Gear and Bearing Adaptor
  720
  - Propeller Shaft Needle Roller Bearing and Oil Seal Installation
    720
  - Reverse Gear and Bearing Cup Adaptor Reassembly
    721
- Driveshaft and Pinion Gear
  723
  - Reassembly/Installation
    723
- Pinion Gear Depth
  724
  - Determining Pinion Gear Depth
    724
- Forward Gear
  726
- Reverse Gear
  726
  - Determining Reverse Gear Backlash
    726
- Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier
  729
- Water Pump
  735
  - Reassembly/Installation
    735
- Gear Lubricant Filling Instructions
  737
- Installing Gear Housing to Driveshaft Housing
  737
- Propeller Installation
  738
Jet Outboards

741
- Jet Components
  745
- Engine Horsepower Selection
  746
- Selecting a Boat that Is Best Suited for Jet Power
  746
- Locate Centerline of the Outboard
  747
- Outboard Mounting Height
  747
- Transom Height of the Boat
  747
- Water Testing
  748
  - Checking for Cavitation
    748
- Shift Cable Installation Jet 105 and
  749
- Impeller Removal and Installation
  750
- Lubricating the Driveshaft Bearing
  750
- Flushing the Cooling System
  752
- Impeller Clearance Adjustment
  752
- Steering Pull Adjustment
  752
- Worn (Dull) Impeller
  752
- Jet Drive Removal and Installation
  753
- Liner Replacement
  753
- Bearing Carrier Disassembly
  755
- Bearing Carrier Reassembly
  755
  - Installing Seals
    755
  - Installing Upper Seals
    756
  - Installing Driveshaft Bearing(S)
    756
  - Installing Driveshaft
    757
  - Installing Upper Seal Housing
    758
Attachments/Control Linkage

760

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