Mercury 200 OptiMax Jet Drive Manuals

Mercury 200 OptiMax Jet Drive Manuals

Manuals and User Guides for Mercury 200 OptiMax Jet Drive. We have 1 Mercury 200 OptiMax Jet Drive manual available for free PDF download: Service Manual

Mercury 200 OptiMax Jet Drive Service Manual

Mercury 200 OptiMax Jet Drive Service Manual (391 pages)

Brand: Mercury | Category: Outboard Motor | Size: 42 MB

Table of Contents

Important Information 1

6
Important Information 1

12
- After each Saltwater or Polluted Water Use
  13
- Every 10 Hours or Once a Month, Whichever Occurs First
  13
- Every 50 Hours or Once a Month, Whichever Occurs First
  13
- Inspection and Maintenance Schedule
  13
- Maintenance Specifications
  13
- Prior to Every Use
  13
- Before Periods of Storage
  14
- Clearing a Clogged Water Intake
  14
- Every 100 Hours or Once a Month, Whichever Occurs First
  14
- Manual Clearing
  14
- Fuel Line Filter
  15
- Fuel Line Inspection
  15
- Fuel System
  15
- Hydro-Surge Grate
  15
- Water Separating Fuel Filter
  15
- Fuses
  16
- Battery Information
  17
- Battery Inspection
  17
- Spark Plug Inspection and Replacement
  17
- Flywheel Cover Removal and Installation
  18
- Removal
  18
- Compressor Air Intake Filter
  19
- Installation
  19
- Flushing the Cooling System
  20
- Installation
  20
- Removal
  20
- Alternator Belt Inspection
  21
- Bilge Siphon Inspection
  21
- Corrosion Control Anodes
  21
- Belt Tensioner Idler Pulley Lubrication
  22
- Draining Lubricant
  22
- Drive Housing Lubricant
  22
- Adding Lubricant
  23
- Adding or Refilling Lubricant
  23
- Draining Lubricant
  23
- Stator Assembly Lubricant
  23
- Storage Preparation
  24
- Submerged Power Package
  24
- Battery Storage
  25
- Positioning Outboard for Storage
  25
- Protecting Internal Engine Components
  25
- Protecting Jet Pump Components
  25
Important Information 1

26
- General Specifications
  27
- Engine and Jet Pump
  28
- Serial Number Location
  28
- 200 Optimax Sportjet Powerhead Front View
  29
- Powerhead Views
  29
- 200 Optimax Sportjet Powerhead Port View
  31
- 200 Optimax Sportjet Powerhead Starboard View
  33
- 200 Optimax Sportjet Powerhead Aft View
  34
- 200 Optimax Sportjet Powerhead Top View
  35
- Mercury Jet Pump Port View
  36
- Mercury Jet Pump Starboard View
  36
- Bottom of Boat
  37
- Cavitation
  37
- Conditions Affecting Performance
  37
- Water Absorption
  37
- Weather
  37
- Weight Distribution (Passengers and Gear) Inside the Boat
  37
- Detonation
  38
- Following Complete Submersion
  38
- Saltwater Submersion
  38
- Submerged Engine (Freshwater)
  38
- Submerged While Running
  38
- Ventilation
  38
- Compression Check
  39
- Analysis
  40
- Cylinder Leakage Testing
  40
- Outboard Service Bulletin 2008-07
  40
- Overview of Regulations
  40
- Shipping of Hazardous Material (Hazmat) and Engine/Components Containing Hazardous Material
  40
- Application Instructions
  41
- Decal Application
  41
- Decal Removal
  41
- More Information on Hazardous Material
  41
- Overview of Training Requirements
  41
- Shipping of Complete Engines and Major Assemblies
  41
Important Information 1

44
- General Information
  45
- Notice to Installer
  45
- Torque Specifications
  45
- Avoiding Fuel Flow Restriction
  46
- Before Starting the Engine
  46
- Boat Horsepower Capacity
  46
- Fuel Requirements
  46
- Important Information
  46
- Oil Recommendation
  46
- Fuel System
  47
- Fuel Tanks
  47
- Integrated Fuel Demand Valve (Ifdv) Requirement
  47
- Low Permeation Fuel Hose - Outboard
  47
- Selecting Accessories for Your Outboard
  47
- Start in Gear Protection
  47
- Fuel Requirements
  48
- Battery/Battery Cables
  49
- Installation
  49
- Installation Requirements
  49
- Boat Construction
  50
- Engine Compartment Ventilation
  50
- Exhaust and Engine Height
  51
- Fuel Delivery System
  51
- Instrumentation
  52
- Remote Control and Cables
  52
- Steering Helm and Cable
  52
- Installing the Jet Pump
  53
- Installing the Flush Kit
  57
- Installing the Powerhead
  58
- Flywheel Cover Removal and Installation
  59
- Removal
  59
- Installation
  60
- Installing the Throttle Cable
  60
- Fuel Hose and Vent Hose Connections
  61
- Battery Cable Connections
  62
- Battery Cable Installation Requirements
  62
- Remote Harness Connection
  63
- Oil Injection Hose Connections
  64
- Steering Cable Adjustment
  64
- Shift Cable Adjustment
  67
- Filling the Fuel System
  70
- Filling the Oil System
  70
- Filling the Oil Tanks
  70
- Priming the Oil Pump (if Required)
  71
- Trim Plate Adjustment
  72
- Bilge Siphon Feature
  73
- Features
  73
- Water Bypass System
  73
- General Exhaust System Notes
  75
- Installing the Exhaust System
  75
- Measuring the Exhaust Outlet
  75
- Top View
  76
- Aft View
  77
- Side View
  78
- Inner Sleeve Liner Fabrication
  79
- Recommended Predelivery Engine Break-In Procedure. 1D-36
  79
- Side View of Expansion Chamber Outlet Pipe and Exhaust Pipe Connection
  79
- Predelivery Inspection
  81
Electrical 2

82
Electrical 2

112
- Charging and Starting Specifications
  113
- Flywheel/Alternator
  115
- Starter Motor Components
  117
- Battery
  119
- Battery Cable Size for Outboard DTS Models
  119
- Battery Cable Test
  119
- Wire Color Code Abbreviations
  119
- Recommended Battery
  120
- Replacement Parts
  120
- Battery Precautions
  121
- Charging a Discharged Battery
  121
- Winter Storage of Batteries
  121
- Flywheel Removal and Installation
  122
- Removal
  122
- Alternator Description
  123
- Alternator System
  123
- Installation
  123
- Diagnosis of Alternator System on the Engine
  124
- Alternator System Circuitry Test
  125
- Current Output
  127
- Alternator Removal and Installation
  128
- Belt Tensioner Removal and Installation
  132
- Starter Removal and Installation
  134
- Starter System
  134
- Starter Circuit Troubleshooting
  136
- Start Solenoid Test
  140
- Starter Disassembly (Solenoid Driven Bendix)
  141
- Starter Assembly (Solenoid Driven Bendix)
  142
- Key Switch Test
  145
- Three Position Key Switch
  145
- Four Position Key Switch
  146
Electrical 2

148
- Maximum Throttle
  149
- Throttle Cam Adjustment
  149
- Crankshaft Position Sensor Air Gap
  151
- Throttle Plate Stop Screw
  151
- Throttle Position Sensor (TPS) Adjustment
  151
- Idle Speed Adjustment (All Models)
  152
Fuel System 3

154
- Fuel Lift Pump Specifications
  155
- Fuel Specifications
  155
- Fuel Pump System Components
  157
- Anti-Siphon Valves
  159
- Fuel Lift Pump Description/Operation
  159
- Testing the Fuel Lift Pump Vacuum
  159
- Fuel Lift Pump/System Troubleshooting
  160
- Pressure Test
  160
- Vacuum Test
  160
- Fuel Lift Pump Removal/Inspection/Installation
  161
- Removal
  161
- Filter Replacement
  162
- Fuel Lift Pump Installation
  162
Fuel System 3

164
- Air Compressor Specifications
  165
- Fuel System Specifications
  165
- Fuel Rail Specifications
  166
- Vapor Separator Components
  169
- Air Handler and Flywheel Cover
  171
- Air Handler Components
  173
- Fuel Rail Components (S/N 0T178500 and Above)
  175
- Fuel Hose Components
  177
- Air Hose Components
  179
- Air Compressor Components
  181
- Air Compressor System
  185
- Air Induction
  185
- DFI Operation
  185
- Electrical
  185
- Fuel
  185
- Oil
  185
- Operation
  186
- 200 Optimax Jet Drive Air/Fuel Schematic
  187
- Electric Fuel Pump Pressure Tests
  188
- High-Pressure Fuel Pump
  188
- Low-Pressure Boost Pump Test
  188
- Air Compressor Pressure Test
  189
- Fuel or Air Pressure Not to Specifications - Sportjet Models
  190
- Fuel Management Assembly Removal
  193
- Reed Block Assembly Removal
  196
- Throttle Body Assembly Removal
  196
- Air Management Assembly and Installation
  197
- Vapor Separator Tank
  201
- VST Removal
  201
- VST Disassembly
  203
- VST Assembly
  206
- VST Installation
  210
- Fuel Pressure Regulator
  212
- Fuel Rail
  212
- Fuel Pressure Regulator Cutaway
  213
- Air Pressure Regulator
  214
- Tracker Valve
  214
- Fuel Injectors
  216
- Fuel Rail Removal
  216
- Fuel Injector Removal
  220
- Direct Injector Removal
  222
- Direct Injectors
  222
- Direct Injector Tests
  223
- Fuel Pressure Regulator Removal
  226
- Air Pressure Regulator Removal (S/N 0T178500 and Above)
  227
- Tracker Valve Removal
  227
- Fuel Injector Installation
  228
- Fuel Rail Cleaning
  228
- Air Pressure Regulator Installation (S/N 0T178500 and Above)
  229
- Tracker Valve Installation
  229
- Fuel Pressure Regulator Installation
  230
- Fuel Rail Installation
  231
- Air Compressor
  234
- Air Compressor Flow Diagram
  234
- Air Compressor Removal
  235
- Air Compressor Disassembly
  237
- Air Compressor Assembly
  238
- Air Compressor Installation
  241
Fuel System 3

246
- Oil Injection Components
  249
- Oil Pump Output
  251
- Oil System Operation
  251
- Oil System Hose Installation (S/N 0T178500 and Above)
  252
- Engine Oil Reservoir Removal and Installation
  253
- Oil Pump Installation
  253
- Oil Pump Removal
  253
- Oil Pump Removal and Installation (S/N 1B490866 and Above)
  253
- Removal
  253
- Installation
  255
- Priming the Oil Injection Pump
  256
- Purging Air from the System
  256
- Method 1 - Computer Diagnostic System Break-In Clock Reset
  257
- Method 2 - Computer Diagnostic System Oil Pump Prime
  257
- Remote Oil Tank Hose Connections
  257
- Filling the Oil Tanks
  258
- Purging Air from the Engine Oil Reservoir and Remote Oil Hose
  258
- Warning Horn Signals
  259
- Low Oil Warning System Is Activated
  260
- Oil System Troubleshooting
  260
Fuel System 3

262
- Carbon Monoxide
  263
- Controlling Emissions
  263
- Emissions Information
  263
- Exhaust Emission Standards
  263
- Hydrocarbons
  263
- Models Affected
  263
- Oxides of Nitrogen - Nox
  263
- Stoichiometric (14.7:1) Air/Fuel Ratio
  263
- What Are Emissions
  263
- Dealer Responsibility
  264
- EPA Emission Regulations
  264
- Manufacturer's Responsibility
  264
- Owner Responsibility
  264
- Removal
  264
- Service Replacement EPA Decal
  264
- Emission Certification Label
  265
- Installation
  265
Powerhead

266
- Powerhead Specifications
  267
- Cylinder Block and End Caps
  271
- Exhaust Manifold and Exhaust Plate
  275
- Cylinder Head
  277
- Crankshaft, Pistons, and Connecting Rods
  279
- Expansion Chamber and Adapter Plate Components
  281
- Powerhead Removal from the Pump Unit
  285
- Individual Components
  286
- Removing Powerhead Components
  286
- Vapor Separator Tank Removal
  287
- Electrical Plate and Harness Removal
  289
- Fuel Rail Removal
  291
- Air Compressor Removal
  294
- Oil Hoses and Reservoir Removal
  296
- Throttle Body and Air Plenum Removal
  297
- Powerhead Disassembly
  298
- Lower Crankshaft Ball Bearing Removal
  303
- Cleaning and Inspection
  304
- Cylinder Block and Crankcase Cover
  304
- Cylinder Bores
  304
- Special Service Information
  304
- Pistons and Piston Rings
  305
- Crankshaft
  306
- Cylinder Heads and Exhaust Divider Plate
  306
- Crankshaft and End Cap Bearings
  307
- Connecting Rods
  308
- End Bearing Bleed System
  310
- Reed Block Assembly
  310
- Crankshaft Bearings Installation
  311
- Powerhead Assembly
  311
- Powerhead Preassembly Cleaning Recommendations
  311
- Crankshaft Installation
  314
- Piston and Connecting Rod Assembly
  315
- Piston and Piston Ring Combinations
  317
- Piston Installation
  317
- Crankcase Cover Installation
  320
- Reed Block Assembly
  322
- Exhaust Divider Assembly
  323
- Reed Block Adapter Plate Assembly
  323
- Cylinder Head Installation
  324
- Starboard Side Oil Hose Routing
  326
- Port Side Oil Hose Routing
  327
- Installing Individual Engine Components
  328
- Installing Powerhead Components
  328
- Water Bypass Hose Routing
  328
- Oil Hoses and Reservoir Installation
  329
- Air Compressor Installation
  330
- Electrical Plate and Harness Installation
  333
- Powerhead Installation on the Pump Unit
  335
- Engine Break-In Procedure after Powerhead Assembly. 4A-72
  337
- Engine Break-In Procedure (All Models)
  338
- Fuel Requirements
  338
- Initiating Engine Break-In Sequence (Priming Oil Pump)
  338
- Recommended Break-In Procedure
  338
Powerhead

340
- Cooling System Specifications
  341
- Temperature Sensor Location and Function
  341
- And 2 Wire Temperature Sensor
  342
- Temperature Sensors
  342
- Pin Connector Cylinder Head Temperature Sensor
  343
- Water Pressure Check
  344
- Description
  345
- Model 200 Water Flow
  345
- Problem Diagnosis
  345
- Water Flow Diagram
  347
Pump Unit

350
- Wear Ring/Impeller Specifications
  351
- Components Contained in Kit
  354
- XR2 Sport Jet Special Tool Kit 91-809957A1
  354
- Pinion and Impeller Shaft Components
  355
- Nozzle and Rudder Components
  357
- Jet Drive Housing Components
  361
- Expansion Chamber and Adapter Plate Components
  365
- Bearings
  369
- General Service Recommendations
  369
- Principles of Operation
  369
- Seals
  369
- Shims
  369
- Disassembly
  370
- Servicing the Stator, Impeller, and Wear Ring
  370
- Inspecting the Wear Ring and Impeller
  373
- Wear Ring
  373
- Impeller
  374
- Impeller and Stator Installation
  374
- Removing Jet Drive from Boat
  377
- Draining and Inspecting Drive Housing Lubricant
  378
- Drive Housing Disassembly and Assembly
  378
- Pinion Shaft Removal
  379
- Impeller Shaft Removal
  382
- Shimming Procedures and Assembly
  386

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