Mercury 200 OptiMax Jet Drive, Service Manual, Page: 310 / 391

Powerhead
90-8M0050731 MAY 2011 Page 4A-45
8. If necessary, clean the connecting rod bearing surfaces, as follows:
a. Ensure that etched marks on the connecting rod (crankshaft end) are perfectly aligned with etched marks on the
connecting rod cap. Tighten the connecting rod cap attaching bolts securely.
b. Clean the crankshaft end of the connecting rod by using crocus cloth placed in a slotted, 9.5 mm (3/8 in.) diameter shaft,
as shown. Secure the shaft in a drill press and operate the press at high speed, keeping the connecting rod at a 90°
angle to the slotted shaft.
IMPORTANT: Use only crocus cloth to clean the bearing surface at the crankshaft end of the connecting rod. Do not
use other types of abrasive materials to clean the bearing surface.
c. Clean the connecting rod just enough to clean up the bearing surfaces. Do not continue to clean after marks are removed
from the bearing surfaces.
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d. Using a 320 grit carborundum cloth (instead of crocus cloth), clean the wrist pin end of the connecting rod using the
same method as in step "b."
e. Thoroughly wash the connecting rods to remove abrasive grit. Recheck the bearing surfaces. Replace any connecting
rod that cannot be properly cleaned up. Lubricate the bearing surfaces of the connecting rods being reused with light
oil to prevent rust.
Reed Block Assembly
IMPORTANT: Do not remove the reeds from reed blocks unless replacement is necessary. Do not turn used reeds over for reuse.
Replace reeds in sets.
1. Thoroughly clean the gasket surfaces of the reed blocks and reed block housing. Check for deep grooves, cracks, or distortion
that could cause leakage. Replace parts as necessary.
2. Inspect the reed block neoprene surface for wear, cuts, or abrasions. Replace the reed blocks as necessary.
3. Check for chipped and broken reeds.
a - 0.51 mm (0.020 in.) opening
NOTE: Allowable reed opening is 0.51 mm (0.020 in.) or less. Replace reeds if either reed is standing open more than 0.51 mm
(0.20 in.).
End Bearing Bleed System
1. Check the rubber bleed hoses. Replace any cracked, cut, or deteriorating hoses.
2. Check operation of the lower end cap check valve. If the valve is working properly, air can be drawn through the check valve
one way only. If air can pass through a check valve both ways, replace the valve.
a
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