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Mercury 250 Jet Installation Manual Download Page 44

250 HP JET DRIVE INSTALLATION MANUAL

Page 44 

90-10240040   DECEMBER   2003

Side View of Expansion Chamber Outlet Pipe and Exhaust Pipe Connection

a

a -

A spacer must be used with all 7.6 cm (3.0 in.) tube applications. A spacer
having a 6.73 cm (2.65 in.) I.D. and a 7.6 cm (3.0 in.) O.D. needs to be installed
over the expansion chamber outlets.

Summary of Contents for 250 Jet

Page 1: ...provide the necessary assistance Please assess your boat s performance completely before making the Jet Drive model selection Safe boat ing is good for everyone Table of Contents General Information 2...

Page 2: ...rtment of Mercury Marine to aid installers when installing the products described herein It is assumed that these personnel are familiar with the installation procedures of these products or like or s...

Page 3: ...deral standards and Coast Guard regulations must be adhered to when installing battery Be sure battery cable installation meets the pull test requirements and that positive battery terminal is properl...

Page 4: ...ir for engine breathing and also must vent off any fumes in engine compartment in accordance with industry standards ABYC NMMA etc federal standards and U S Coast Guard regulations for inboard engines...

Page 5: ...fitting with U S Coast Guard approved hose clamp Inspect for fuel leaks 1 Fuel pickup should be at least 25 mm 1 in from the bottom of the fuel tank to prevent picking up impurities 2 Fuel lines used...

Page 6: ...lanyard stop switch etc A typical jet boat of this nature will see water splashed on these components Therefore precautions must be taken to avoid ignition failure due to shorting out of ignition comp...

Page 7: ...0 Series Cable 40 Series bulkhead fitting at output end Allow for a minimum of 76 mm 3 iin of travel A means of attaching and locking the cable to the shift cable bracket provided Cable end at pump mu...

Page 8: ...ow for a 5 16 in threaded adaptor shouldered thru bolt and locknut to connect the cable to the steering arm A means of attaching and locking the cable to the steering cable bracket provided Protected...

Page 9: ...Neoprene to Connections and Slide Rubber Sleeve Over Each Connection g To Neutral Start Safety Switch In Remote Control Box Liquid Neoprene Dielectric Grease T h Speedometer Gauge i Overheat low oil...

Page 10: ...T2 859223 Oil Tank Sender 816190A1 IMPORTANT DO NOT connect the Black Orange wire to the fuel tank sensor when there is a engine battery ground strap connected to the fuel tank or sender assembly If n...

Page 11: ...d on 2002 Model Year and newer V 6 models that are equipped for SmartCraft System Monitor CAN System Link Gauges System Monitor SC1000 2RSL System Monitor Harness System Link Connector NOTE System Mon...

Page 12: ...boxes This as sures a robust mechanical implementation as well as proper connection of all signals The ideal installation uses a single trunk line with short drops to individual modules Two terminati...

Page 13: ...with Terminator Resistor on One End 10 Ft 15 Ft 20 Ft 30 Ft 10 Ft 15 Ft 30 Ft 3 Ft 10 Ft 30 Ft Junction Box Weather Cap For correct placement on these terminator resistors refer to Wiring Installatio...

Page 14: ...ard Only 1 b 879896K4 System Monitor 2 Front Mount All Models 1 b 879896K3 System Monitor 2 Rear Mount All Models 1 c 881931A1 Depth Transducer Transom Mount 1 c 881932A1 Depth Transducer In Hull 1 c...

Page 15: ...ing corner radii b straightness c and size d for proper grommet installation and corner radii e for ride plate seal fit 3 Flatness and thickness of the area around the hull opening for proper grommet...

Page 16: ...t in cut out of boat by gluing front portion of grommet to tunnel with Loctite 454 or equivalent Avoid gluing flexible sealing lips to tunnel NOTE The procedure for gluing the grommet is not required...

Page 17: ...Route steering cable through the thru hull fitting and bellows Route cable through the port side flange of pump housing Install nut on cable before routing cable through wear ring 58142 a b a Shift Ca...

Page 18: ...NT Ensure that the shift lever in the control box is set for 76 mm 3 in of travel NOTE It is easier to adjust the shift and steering cables before installing pump unit in boat 6 Spray soapy water on i...

Page 19: ...ring seal on jet pump a b a Gasket b O Ring Seal 9 Install cover on jet pump and secure with ten locknuts Torque to 47 Nm 35 lb ft NOTE Before torquing nuts check ride plate seal for proper fit in tun...

Page 20: ...40040 DECEMBER 2003 Steering Cable Adjustment 1 Slide bellows assembly over cable and thread on cable completely Do not tighten 54456 a a Bellows 2 Thread cable end adaptor on steering cable 14 turns...

Page 21: ...NG Cable end adaptor must be installed a minimum of nine 9 turns Failure to install cable end adaptor on steering cable a minimum of nine 9 turns could result in loss of steering control of boat perso...

Page 22: ...port to compress bellows as much as possible Push bellows over cable conduit and secure with bellows clamp 13 Secure bellows to thru hull fitting with clamp Slide slit adaptor over cable and push int...

Page 23: ...ontrol box components It may also cause stiffness of the throttle control 1 Thread the cable barrel onto the shift cable a a Cable Barrel 2 Use a de greaser and clean off all oil film from the area on...

Page 24: ...lat washer and cotter pin Bend over ends of cotter pin a b c a Clevis Pin b Flat Washer c Cotter Pin WARNING The shift cable must be adjusted correctly so that the reverse gate does not inter fere wit...

Page 25: ...ngage WARNING Disengagement of the shift cable can result in the boat suddenly shifting into reverse This unexpected action could cause occupants to be thrown forward in the boat or to be ejected over...

Page 26: ...clamp Slide slit adaptor over cable and push into bellows Secure with clamp b c c d e a a Shift Cable Thru Hull Fitting and Bellows Assembly b Thru Hull Fitting and Nut c Clamp d Bellows e Slit Adapto...

Page 27: ...al Lubricant 101 a b c d a Gasket b Water Inlet O Ring c Drive Shaft Opening O Ring d Lubricate driveshaft splines with Special Lubricant 101 4 Lower powerhead on drive housing cover Align driveshaft...

Page 28: ...nect fuel line to fuel inlet fitting secure with U S Coast Guard approved hose clamp 183 532 2 Vapor separator tank VST must be vented to fuel tank Vent hose must comply with U S Coast Guard ABYC regu...

Page 29: ...solenoid terminal Seal connection with Liquid Neoprene Push the protector boot over the connection 3 Fasten the negative battery cable to engine grounding bolt located on the engine block below the st...

Page 30: ...the stop a b a Cable Barrel Adjust To Hold Idle Stop Screw Against Stop b Idle Stop Screw 4 Check throttle cable adjustment as follows a Move throttle from idle to wide open several times to activate...

Page 31: ...must be arranged so they cannot become pinched kinked sharply bent or stretched during operation of the engine 3 Remove shipping cap from oil filter and connect oil hose with blue stripe to filter wi...

Page 32: ...l pump If there are no air bubbles in the line it is not necessary to reprime the oil system If air bubbles are present it will be necessary to reprime the system using the Digital Diagnostic Terminal...

Page 33: ...siphon drawing water out of the boat Installing Bilge Siphon The siphon break must be located above the water line at the highest point The siphon break has a 0 020 in hole which must be kept open 1...

Page 34: ...itting must be mounted in either side of the transom within the zones marked A The thru hull fitting must be located a Minimum of 50 mm 2 in above the water line when boat is at its maximum load capac...

Page 35: ...03 5 Connect a water by pass hose between engine fitting and thru hull fitting Secure con nections with hose clamps NOTE Make sure the hose slopes at a minimum rate of 25 mm 1 in drop per 300 mm 12 in...

Page 36: ...1 Attach flush hose to fitting in drive housing cover Secure with hose clamp IMPORTANT Failure to secure flush hose to fittings will allow water to fill boat b a a Flush Hose b Hose Clamp 2 Attach flu...

Page 37: ...RE with throttle and or con trol linkage NOTE Mount flush adapter bracket in an area of the motor compartment that has a mount ing surface that is thicker than the depth of the mounting screws 3 Locat...

Page 38: ...ient flow of water to the engine may cause the engine to overheat If the warning horn sounds immediately stop engine and allow to cool 3 Stop the engine Turn off the water and remove water hose from f...

Page 39: ...ottom of boss should be equal on both sides a b c d e f a Jam Nut with Washer Two One On Each Side b Jam Nut c Small Diameter Washer d Large Diameter Washer e Plate f Screw WARNING Adjusting the trim...

Page 40: ...requirements will vary with exhaust system design and the amount of G forces to be encountered 5 Rubber hose should be connected to pipes with flares or beads or barbs to prevent the hose from sliding...

Page 41: ...g must be either 5052 or 6061 14 ga alumi num or type 304 14 ga stainless steel to protect against corrosion c 57885 A1 Flange Assembly 2 required or equivalent through transom fittings may extend 12...

Page 42: ...l g 25 maximum from horizontal h Optional exhaust outlet cover i 5 1 cm 2 0 in minimum j 10 2 cm 4 0 in k To minimize the back flow of exhaust gases into the cockpit or interior of boat the exhaust te...

Page 43: ...maximum depth waterline b 5 1 cm 2 0 in When installing muffler assemblies a 5 1 cm 2 0 in minimum distance between bottom of muffler and water line must be kept This minimum distance must be calcula...

Page 44: ...R 2003 Side View of Expansion Chamber Outlet Pipe and Exhaust Pipe Connection a a A spacer must be used with all 7 6 cm 3 0 in tube applications A spacer having a 6 73 cm 2 65 in I D and a 7 6 cm 3 0...

Page 45: ...ve rudder in forward w slack pulled out of cable and against the stop Pump housing oil level full See Owner s Manual Oil injection reservoir full and bled Warning system operational ON THE WATER CHECK...

Page 46: ......

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