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200 OptiMax Jet Drive
Mercury 200 OptiMax Jet Drive Service Manual
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Page iii
Manual Outline
1 - Important Information
A - Specifications
B - Maintenance
C - General Information
D - Jet Installation
2 - Electrical
A - Ignition
B - Charging and Starting System
C - Timing, Synchronizing, and Adjusting
3 - Fuel System
A - Fuel Pump
B - Direct Fuel Injection
C - Oil Injection
D - Emissions
4 - Powerhead
A - Powerhead
B - Cooling
5 - Pump Unit
A - Pump Unit
Important Information
1
Electrical
2
Fuel System
3
Powerhead
4
Pump Unit
5
2
Table of Contents
Important Information 1
6
Table of Contents
6
General Specifications
7
Maintenance Specifications
7
Charging and Starting Specifications
8
Ignition Specifications
8
Fuel Specifications
9
Fuel Lift Pump Specifications
9
Fuel Rail Specifications
9
Fuel System Specifications
9
Air Compressor Specifications
10
Powerhead Specifications
11
Cooling System Specifications
11
Wear Ring/Impeller Specifications
11
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
Ignition Specifications
83
Electrical Components
85
Electrical Plate Hardware
87
Electrical Plate Engine Harness
89
Troubleshooting with the Computer Diagnostic System (CDS)
91
Troubleshooting Without a Computer Diagnostic System (CDS)
91
Troubleshooting Guide
92
Wire Color Code Abbreviations
94
Fuses
95
Theory of Operation - Internal Ignition Coil Driver Models
95
Main Power Relay (MPR)
96
Main Power Relay Test
96
Flywheel
97
Flywheel Cover Removal and Installation
97
Propulsion Control Module (PCM)
98
Propulsion Control Module (PCM) Removal and Installation
98
Ignition Coil Test
99
Ignition Coils
99
Ignition Coil Removal and Installation
101
Crankshaft Position Sensor (CPS)
102
Crankshaft Position Sensor (CPS) Removal and Installation
103
Throttle Position Sensor (TPS)
103
Throttle Position Sensor (TPS) Removal and Installation
104
Throttle Position Sensor (TPS) Troubleshooting
104
Manifold Absolute Pressure (MAP) Sensor
106
Manifold Absolute Pressure Sensor Test
106
Cylinder Head Coolant Temperature Sensor
107
Temperature Sensors
107
Guardian Protection System
109
Manifold Intake Air Temperature (MAT) Sensor
109
Engine Overspeed Protection System
110
Guardian System Activation
110
Warning Horn Signals
110
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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Mercury 200 OptiMax Jet Drive Specifications
General
Brand
Mercury
Model
200 OptiMax Jet Drive
Category
Outboard Motor
Language
English
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