Mercury 200 Sport-Jet Manual Download

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TROUBLESHOOTING

• Fouled impeller, inlet, or stator.
• Ride plate seal leak.

Battery Will Not Hold Charge

POSSIBLE CAUSES

• Battery connections are loose or corroded.
• Low electrolyte level in battery.
• Worn out or inefficient battery.
• Excessive use of electrical accessories.
• Defective rectifier, alternator, or voltage regulator.

Summary of Contents for 200 Sport-Jet

Page 1: ...product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm Warranty Message The product you have purchased comes with a limited warranty from...

Page 2: ...ng means a dealer Achieves a high 12 month service CSI Customer Satisfaction Index score for warranty service Possesses all necessary service tools test equipment manuals and parts books Employs at le...

Page 3: ...Hovik Post Code 1322 Country Norway ID Number 0575 Conformity assessment module used for exhaust emissions B C B D B E B F G H Conformity assessment module used for noise emissions A Aa G H Other Comm...

Page 4: ...3 durability B 4 owner s manual ISO 8665 1995 Annex 1 C Noise Emissions This declaration of conformity is issued under the sole responsibility of the manufacturer I declare on behalf of the engine man...

Page 5: ...l System Components 12 General Information Boater s Responsibilities 14 Before Operating Your Mercury Jet Drive 14 Boat Horsepower Capacity 15 High Speed and High Performance Boat Operation 16 Towing...

Page 6: ...30 Fuel Recommendations 31 Filling Remote Oil Tank 33 Filling Engine Mounted Oil Reservoir Tank 33 Features and Controls Bilge Siphon 34 Warning Horn Signals 34 Engine Guardian System 35 SmartCraft Pr...

Page 7: ...stallation 57 Alternator Belt Inspection 59 Compressor Air Intake Filter 60 Belt Tensioner Idler Pulley Lubrication 60 Flushing the Cooling System 61 Drive Housing Lubricant 63 Stator Assembly Lubrica...

Page 8: ...ONTENTS viii Owner Service Assistance Local Repair Service 73 Parts and Accessories Inquiries 73 Service Assistance 73 Mercury Marine Service Offices 74 Ordering Literature 75 Maintenance Log Maintena...

Page 9: ...d You may change your address at any time including at time of warranty claim by calling Mercury Marine or sending a letter or fax with your name old address new address and engine serial number to Me...

Page 10: ...ansfer of Mercury Product Protection Extended Service Coverage Plan United States and Canada The remaining coverage period of the Product Protection Plan is transferable to the subsequent purchaser of...

Page 11: ...ut into service whichever occurs first The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration dat...

Page 12: ...e of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured HOW TO OBTAIN WARRANTY COV...

Page 13: ...of parts water entering the engine through the fuel intake air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign b...

Page 14: ...GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY 3 Year Limited Warranty Against Corrosion WHAT IS COVERED We warrant each...

Page 15: ...tine maintenance outlined in the Operation and Maintenance Manual must be timely performed including without limitation the replacement of sacrificial anodes use of specified lubricants and touch up o...

Page 16: ...ested by Mercury ship the product or parts of the product directly to Mercury The warranty registration card is the only valid registration identification and must be presented to the dealer at the ti...

Page 17: ...ance Manual for additional details For additional information regarding events and circumstances covered by this warranty and those that are not refer to the Warranty Coverage section of the Operation...

Page 18: ...spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connection with normal services 2 Damage caused by neglect lack of maintenance accident abno...

Page 19: ...lure condition responsible for noise should be corrected under the warranty 11 Pump unit and or impeller damage caused by either striking a submerged object or rocks stones or foreign objects being dr...

Page 20: ...all the components listed in the Emission Control System Components Emission Control System Components The EPA and Califormia emission related warranty covers all the following list of components COMP...

Page 21: ...fittings tubing sealing gaskets or devices and mounting hardware b Pulleys belts and idlers c Vacuum temperature check and time sensitive valves and switches d Electronic controls The emission relate...

Page 22: ...efully Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage If you have any questions contact your dealer This manu...

Page 23: ...Drive is highly maneuverable at higher speeds more so than propeller driven boats Use caution when turning to prevent spinouts Steering in reverse unlike propeller driven boats turning the steering w...

Page 24: ...initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your Mercury Jet Drive For additional information obtain a copy of our Hi Performance Boat O...

Page 25: ...anyard is a cord usually 122 152 cm 4 5 feet in length when stretched out with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The l...

Page 26: ...operating at planing speeds in shallow or obstacle infested waters releasing your grip on a steering wheel that is pulling in one direction drinking alcohol or consuming drugs or daring high speed bo...

Page 27: ...of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller Loss of power and directional control in heavy seas strong current or high winds Loss of control when doc...

Page 28: ...the stern back of the boat and never insert an object into the water intake or water outlet nozzle when the engine is running WARNING Avoid injury resulting from contacting the rotating impeller or h...

Page 29: ...concentrated engine exhaust gases When engines are running keep swimmers away from the boat and do not sit lie or stand on swim platforms or boarding ladders While underway do not allow passengers to...

Page 30: ...ers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 1 Examples of poor ventilation while the boat is stationary a...

Page 31: ...s to be thrown out of their seats or out of the boat WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whe...

Page 32: ...reverse until bow is just above the waterline Selecting Accessories for Your Mercury Jet Drive Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your...

Page 33: ...expected acceleration sudden stopping unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat Never be under the influence of alcohol or dr...

Page 34: ...loss of life or probable loss of life 2 there is personal injury requiring medical treatment beyond first aid 3 there is damage to boats or other property where the damage value exceeds 500 00 or 4 t...

Page 35: ...nce a decal listing both the powerhead and pump serial number is located on the engine a Engine serial number b Model designation c Year of manufacture d Pump serial number a c a d 44931 XXXXXXX XL Me...

Page 36: ...6 Piston displacement 2508 cc 153 in Cylinder bore 88 4 mm 3 500 in Stroke 67 3 mm 2 650 in Spark plug NGK IZFR6J 11 Spark plug gap 1 1 mm 043 in Recommended gasoline Refer to Fuel and Oil Recommended...

Page 37: ...GENERAL INFORMATION 29 Component Identification 1 Reverse gate 2 Rudder 3 Stator 4 Wear ring 5 Bilge siphon hose from engine 6 Bilge siphon pickup screen 7 Water intake 5 7 6 4 3 2 1 44935...

Page 38: ...gh RPM that could cause engine damage Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale sold or offered for sale in the United States The Environmental Protection Agenc...

Page 39: ...and of leaded gasoline USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The 2 types of oxygenates used in these fuels are alcohol ethanol...

Page 40: ...particularly after storage Any sign of leakage or deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that...

Page 41: ...t An air leak will prevent oil flow to the engine 2723 Filling Engine Mounted Oil Reservoir Tank NOTE Filling this tank is only necessary if the oil level should ever drop and the low oil warning syst...

Page 42: ...ose is routed to and positioned in the bilge on the side of the jet tunnel The bilge siphon system incorporates a siphon break which prevents water from siphoning back into the boat when the engine is...

Page 43: ...ine Guardian System is activated Power limit will vary with level of overheat Stop engine and check water intake for obstruction Oil level is critically low Continuous Engine Guardian System is activa...

Page 44: ...sed for this Mercury Jet Drive A few functions the instrument package will display are engine RPM coolant temperature battery voltage fuel consumption and engine operating hours The SmartCraft instrum...

Page 45: ...a boat while under the influence of alcohol or drugs Know the waters you will be using tides currents sand bars rock and other hazards Make inspection checks listed in the Inspection and Maintenance...

Page 46: ...ou adjust yourself to these characteristics by experimentation in open water at both high and low speeds Although jet drive applications do not pose some of the risks associated with exposed propeller...

Page 47: ...ay be possible to clear the obstruction as follows perform this maneuver only in an area clear of obstacles and hazards as steering control will momentarily be lost a Run the boat forward at maximum a...

Page 48: ...from the water If ice should form at the water level inside the jet drive it will block water flow to the engine causing possible damage OPERATING IN SALTWATER OR POLLUTED WATER We recommend that you...

Page 49: ...us operation at idle speed for more than 10 minutes Run the engine the majority of time between 3000 4500 RPM approximately three quarter throttle Vary engine speed change engine speed approximately e...

Page 50: ...the unit 2 Do not start the jet drive unless water is supplied to the engine Make sure the water intake is submerged If using the flushing attachment ensure that water is flowing through the engine at...

Page 51: ...sition for three seconds and then back to the OFF position for five seconds b Continue this procedure five times to allow the electric fuel pump to fill the fuel system 6 Turn ignition key to the STAR...

Page 52: ...se R has the reverse gate covering the entire water outlet nozzle to divert the exiting water stream forward to reverse boat motion 2 After shifting into forward or reverse advance the throttle lever...

Page 53: ...maintenance work orders and receipts Replacement Parts for Your Power Package Mercury recommends using original Mercury Precision replacement parts and lubricants EPA Emissions Regulations All new Mer...

Page 54: ...performed to maintain emission levels within prescribed certification standards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels t...

Page 55: ...s and other fasteners Check exhaust hoses for holes or distortion due to overheating EVERY 50 HOURS OR ONCE A MONTH WHICHEVER OCCURS FIRST Check level and condition of drive housing and stator lubrica...

Page 56: ...Replace engine fuel line filter See Fuel System Replace water separating fuel filter See Fuel System Replace compressor air intake filter See Compressor Air Intake Filter BEFORE PERIODS OF STORAGE Re...

Page 57: ...ing even when in neutral 2 Clean debris from the entire jet drive unit water intake impeller and nozzle If the jet drive cannot be easily cleaned return the boat to the trailer or to a boat lift befor...

Page 58: ...the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated...

Page 59: ...from the fuel If the filter becomes filled with water the water can be removed If the filter becomes plugged with debris replace the filter The warning system engages when water in the fuel filter rea...

Page 60: ...r and tighten securely by hand Reconnect the wire to the filter Fuses IMPORTANT Always carry spare 5 and 20 amp fuses The electrical wiring circuits on the engine are protected from overload by fuses...

Page 61: ...llows a Good fuse b Blown fuse c SmartCraft data bus circuit 5 amp fuse d Ignition system circuit 20 amp fuse e Spare fuse f Electric fuel pump VST ECM driver power oil pump circuit 20 amp fuse g Main...

Page 62: ...sion Parts only Anodes help protect the power package against galvanic corrosion by sacrificing its metal to be slowly eroded instead of other metals This model has three corrosion control anodes One...

Page 63: ...ing the battery 2 Ensure the battery is secure against movement 3 Battery cable terminals should be clean tight and correctly installed Positive to positive and negative to negative 4 Ensure the batte...

Page 64: ...plug boots by twisting the rubber boots slightly and pull off 26899 4 Remove the spark plugs to inspect Replace the spark plug if the electrode is worn or the insulator is rough cracked broken blister...

Page 65: ...ove the gasket from the adapter plate Replace if damaged 8 Install the expansion chamber Tighten the mounting nuts to the specified torque Install the hoses to the expansion chamber and secure with cl...

Page 66: ...um intake flange Tilt the cover side to side until the cover slides down onto the intake flange 2 Push the cover down onto the alignment pins and onto the air intake tube for the air compressor a Air...

Page 67: ...Belt Inspection Inspect the alternator belt and have it replaced by an authorized dealer if any of the following conditions are found Cracks or deterioration in the rubber portion of the belt Belt su...

Page 68: ...run the engine without the air filter REMOVAL 1 Remove flywheel cover from engine 2 Snap out the retainer and remove filter a Retainer b Filter INSTALLATION 1 Install filter into cover 2 Secure filter...

Page 69: ...ing the flushing attachment do not run the engine above idle CAUTION Never start or run the jet drive without water circulating through the cooling system to prevent damage to the unit a Flushing atta...

Page 70: ...o overheat If the warning horn sounds stop the engine immediately and allow to cool 4 Stop the engine turn off the water and remove the water hose from the flush adapter Install the cap and tighten se...

Page 71: ...ng checked by your authorized Mercury Marine dealer Water in the lubricant can cause premature gear or bearing failure or in freezing weather damage to the drive housing a Drive housing bottom view b...

Page 72: ...lky color In either case have the stator checked by your authorized Mercury Marine dealer Water in the lubricant can cause premature bearing failure or in freezing weather damage to the stator a Screw...

Page 73: ...tside diameter Fluid Type Capacity High Performance Gear Lube 562 ml 19 fl oz 1 Install the stator to the pump Be careful when sliding the shaft past the seals to prevent damage to the seals Apply Loc...

Page 74: ...or stiffness Correct adjustments as necessary 8 Shift to forward position and check that the reverse gate is not preloaded You should be able to slightly rock the reverse gate up and down Excessive p...

Page 75: ...lean if necessary 2 Inspect the hole in the siphon break for blockage Clean with a small wire if necessary 3 Ensure that the siphon break is secured above the waterline Submerged Power Package A subme...

Page 76: ...d engine fuel system The most effective method for storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and Mercury Precision Quickleen products as described on th...

Page 77: ...tric fuel pump to fill the fuel system 7 Using the flushing adapter start the engine and allow the engine to run at idle speeds for 10 minutes to allow the treated fuel to fill the fuel system Protect...

Page 78: ...POSSIBLE CAUSES Lanyard stop switch not in RUN position Battery not fully charged Incorrect starting procedure Refer to Operation section Old or contaminated fuel Fuel is not reaching the engine Fuel...

Page 79: ...nched e Injector plugged Threaded connection of an air hose is loose Fuel pump failure Ignition system component failure Performance Loss at Normal RPM POSSIBLE CAUSES Boat overloaded or load improper...

Page 80: ...ate seal leak Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical access...

Page 81: ...rvice Assistance Your satisfaction with your Mercury Jet Drive product is very important to your dealer and to us If you ever have a problem question or concern about your Mercury Jet Drive product co...

Page 82: ...ic Group 132 140 Frankston Road Dandenong Victoria 3164 Australia Fax 61 3 9706 7228 Europe Middle East Africa Telephone 32 87 32 32 11 Brunswick Marine Europe Parc Industriel de Petit Rechain B 4800...

Page 83: ...cular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact MERCURY MARINE Telephone Fax Mail 920 929 5110 920 929 4894 Mercury Marine Attn Publicati...

Page 84: ...MAINTENANCE LOG 76 Maintenance Log Record all maintenance performed on your Mercury Jet Drive here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours...

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