Mercury OptiMax 250 Service Manual

1
D
INSTALLATION
90-888438 JUNE 2002 Page 1D-1
IMPORTANT INFORMATION
Section 1D - Mercury Jet Installation
Table of Contents
General Information 1D-2. . . . . . . . . . . . . . . . . . . . .
Notice to Installer 1D-2. . . . . . . . . . . . . . . . . . . . .
Torque Specifications 1D-3. . . . . . . . . . . . . . . . .
Installation Requirements 1D-3. . . . . . . . . . . . . . . .
Battery/Battery Cables 1D-3. . . . . . . . . . . . . . . .
Boat Construction 1D-4. . . . . . . . . . . . . . . . . . . .
Engine Compartment Ventilation 1D-4. . . . . . .
Exhaust System 1D-5. . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery System 1D-5. . . . . . . . . . . . . . . . .
Instrumentation 1D-6. . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams 1D-7. . . . . . . . . . . . . . . . . . . . .
Quicksilver Instrumentation, Typical
Analog Installation Shown 1D-7. . . . . . . . . . . . .
SmartCraft System Monitor –
Model Year 2001 and Newer 1D-8. . . . . . . . . . .
Remote Control and Cables 1D-9. . . . . . . . . . .
Mercury Jet Drive Hull Dimensions 1D-10. . . . . . . .
Steering Helm and Cable 1D-11. . . . . . . . . . . . . .
method for controlling location
and size 1D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Jet Pump 1D-12. . . . . . . . . . . . . . . . . . . . . .
Hull Cutout 1D-12. . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cable Adjustment 1D-16. . . . . . . . . . . .
Shift Cable Adjustment 1D-19. . . . . . . . . . . . . . . .
Bilge Siphon Feature 1D-22. . . . . . . . . . . . . . . . . . . .
Installing Bilge Siphon 1D-22. . . . . . . . . . . . . . . .
Water By-Pass System 1D-23. . . . . . . . . . . . . . . . . . .
Installation of Flushing Kit 1D-25. . . . . . . . . . . . .
Operation Instructions 1D-26. . . . . . . . . . . . . . . . .
Suggested Flushing Intervals 1D-27. . . . . . . . . .
Installing Powerhead 1D-28. . . . . . . . . . . . . . . . . . . .
Battery Connection 1D-30. . . . . . . . . . . . . . . . . . .
Throttle Cable 1D-31. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1D-31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Injection Set-Up 1D-32. . . . . . . . . . . . . . . . . . . . . .
Filling 1D-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming the Oil Injection Pump
(If Required) 1D-32. . . . . . . . . . . . . . . . . . . . . . . . .
Purging Air From the Engine Oil Tank 1D-32. . .
Trim Plate Adjustment 1D-33. . . . . . . . . . . . . . . . . . .
Exhaust System Installation 1D-34. . . . . . . . . . . . . .
General Exhaust System Notes 1D-34. . . . . . . .
Exhaust Outlet Measurement
Procedure 1D-34. . . . . . . . . . . . . . . . . . . . . . . . . . .
Top View 1D-35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aft View 1D-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side View 1D-37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Side View of Expansion Chamber
Outlet Pipe and Exhaust Pipe
Connection 1D-38. . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-delivery Inspection 1D-39. . . . . . . . . . . . . . . . . . .

Mercury OptiMax 250 Specifications

General

Brand	Mercury
Model	OptiMax 250
Category	Outboard Motor
Language	English