1992+ Mercury Mariner 200HP EFI 2-Stroke OEM Service & Repair Manual

6 F JET OUTBOARDS

6F-0 - JET OUTBOARDS 90-824052R3 JUNE 2002 Table of Contents Page 105/140 Jet 6F-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jet Components 6F-4 . . . . . . . . . . . . . . . . . . . . . . . . . Selecting a Boat that is best suited for Jet Power 6F-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Horsepower Selection 6F-5 . . . . . . . . . . . . . . Transom Height of the Boat 6F-6 . . . . . . . . . . . . . . . . Locate Centerline of the Outboard 6F-6 . . . . . . . . . . Outboard Mounting Height 6F-6 . . . . . . . . . . . . . . . . . Water Testing 6F-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking for Cavitation 6F-7 . . . . . . . . . . . . . . . . . Shift Cable Installation Jet 105 and 140 6F-8 . . . . . Lubricating the Driveshaft Bearing 6F-9 . . . . . . . . . . Impeller Removal and Installation 6F-9 . . . . . . . . . . Steering Pull Adjustment 6F-11 . . . . . . . . . . . . . . . . . Impeller Clearance Adjustment 6F-11 . . . . . . . . . . . . Worn (Dull) Impeller 6F-11 . . . . . . . . . . . . . . . . . . . . . Flushing the Cooling System 6F-11 . . . . . . . . . . . . . . Liner Replacement 6F-12 . . . . . . . . . . . . . . . . . . . . . . Jet Drive Removal and Installation 6F-12 . . . . . . . . . Bearing Carrier Disassembly 6F-14 . . . . . . . . . . . . . . Bearing Carrier Reassembly 6F-14 . . . . . . . . . . . . . . Installing Seals 6F-14 . . . . . . . . . . . . . . . . . . . . . . . Installing Upper Seals 6F-15 . . . . . . . . . . . . . . . . . Installing Driveshaft Bearing(s) 6F-15 . . . . . . . . . Installing Driveshaft 6F-16 . . . . . . . . . . . . . . . . . . . Installing Upper Seal Housing 6F-17 . . . . . . . . . .

90-824052R3 JUNE 2002 JET OUTBOARDS - 6F-1 Notes:

6F-2 - JET OUTBOARDS 90-824052R3 JUNE 2002 Jet Pump Assembly 1 2 3 4 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 7 21 95 2-4-C With Teflon (92-825407A12) 95 5 4 4 15 16

90-824052R3 JUNE 2002 JET OUTBOARDS - 6F-3 Jet Pump Assembly REF TORQUE REF . NO. QTY. DESCRIPTION lb. in. lb. ft. N·m – 1 JET PUMP (BLACK) S/N-0G605661 & BELOW – 1 JET PUMP (GRAY) – 1 JET PUMP (S/N-0G605662 & UP - W/ALUMINUM IMPELLER) – 1 JET PUMP (JET 105 - W/STAINLESS STEEL IMPELLER) – 1 JET PUMP (JET 140 - W/STAINLESS STEEL IMPELLER) 1 1 HOUSING–Pump (S/N-0G605662 & UP) 1 1 HOUSING–Pump (S/N-0G605661 & BELOW) 2 1 HOSE–Lube 1 IMPELLER (S/N-0G605662 & UP - ALUMINUM) 3 1 IMPELLER (JET 105 - STAINLESS STEEL) 3 1 IMPELLER (JET 140 - STAINLESS STEEL) 1 IMPELLER (S/N-0G605661 & BELOW) 4 1 HOUSING–Intake (S/N-0G605662 & UP) 4 1 HOUSING–Intake (S/N-0G605661 & BELOW) 5 1 LINER (S/N-0G605662 & UP) 6 1 LINER (S/N-0G605661 & BELOW) 7 1 SHAFT–Drive (S/N-0G605662 & UP) 7 1 SHAFT–Drive (S/N-0G605661 & BELOW) 8 1 SLEEVE 9 1 NUT Drive Tight 10 1 KEY–Impeller 11 8 SHIM 12 1 TAB WASHER 13 6 SCREW (.312-18 x 1) (S/N-0G605661 & BELOW) 144 12 16.5 14 4 SCREW (1/4-20 x .875) 70 8.0 14 4 SCREW (.312-18 x 1) 144 12 16.5 15 6 STUD (.312-18 x 1.81) (S/N-0G605662 & UP) 144 12 16.5 16 6 NUT 144 12 16.5 17 2 SCREW (1/4-20 x .625) 70 8.0 18 1 SCREW (.312-18 x 1.25) 160 13.5 18.0 19 1 BRACKET 20 1 NUT (.312-18) 160 13.5 18.0 21 2 PIN–Dowel 22 1 STUD (.438 x 3.12) 23 2 STUD (.44 x 2) 24 1 SCREW (.312-18 x 2-3/4) 25 2 STUD (1/4-20 x .875) 26 1 SCREW (3/8-16 x 3) 22.5 30.5 27 1 WASHER

6F-4 - JET OUTBOARDS 90-824052R3 JUNE 2002 Jet Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 21 95 95 95 2-4-C With Teflon (92-825407A12) REF TORQUE REF . NO. QTY. DESCRIPTION lb. in. lb. ft. N·m 1 3 SCREW (.190-32 x 1.62) 30 3.5 2 3 WASHER 3 3 BUSHING 4 1 PLATE 5 1 REV LIMITER 6 1 HARNESS–Adaptor-rev limiter 7 1 GREASE KIT 8 1 WATER PUMP BASE 9 1 GASKET 10 1 OIL SEAL 11 1 OIL SEAL 12 1 GASKET–lower 13 1 GASKET–upper 14 1 FACE PLATE 15 1 WATER PUMP BODY ASSEMBLY 16 1 INSERT 17 1 SEAL–rubber 18 1 lMPELLER 19 1 KEY 20 1 SCREW (2-1/4 IN.) 50 5.5 21 2 WASHER 22 2 NUT 50 5.5 23 1 WASHER 24 1 SLEEVE

90-824052R3 JUNE 2002 JET OUTBOARDS - 6F-5 Selecting A Boat That Is Best Suited For Jet Power To obtain the best performance from the jet drive, the boat should have the following features: 1. The boat should be as light as possible. 2. The boat should have hull and transom that is designed for use with a jet drive. 3. The boat should be at least 13 feet in length. Engine Horsepower Selection A boat operating at slow speed requires considerably more depth than one which is planing on the surface of the water. It is important therefore to use sufficient horsepower and not to overload your boat beyond its ability to plane. See the following table. The following table is based on experience ob- tained with sled-type boats using outboard jets. The gross weights shown includes the outboard, boat people and all the gear carried. For a given horsepower, loading beyond these weights will give less than satisfactory performance. Engine Horsepower Selection 0 20 40 60 80 100 120 140 160 180 200 220 500 6 8 1000 12 14 16 2000 22 24 26 28 18 3000 32 34 36 HP Gross Weight - Lbs.

6F-6 - JET OUTBOARDS 90-824052R3 JUNE 2002 Transom Height of the Boat Outboards with jet drives will be mounted approxi- mately 7 inches higher on the transom than propeller driven outboards. This requires outboards that have a 15 in. shaft length to be installed on boats having a 22 in. transom height and outboards that have a 20 in. shaft length to be installed on boats having a 27 in. transom height. If the boat transom is of insufficient height, and the outboard cannot be installed to the recommended height, contact the boat manufacturer for recommended procedure to build up the boat transom. Locate Centerline of the Outboard Locate (and mark with pencil) the vertical centerline (a) of boat transom. B A D C a a - Centerline of Transom Outboard Mounting Height The initial outboard mounting height setting will work good for most applications, however, because of different boat/hulls designs, the setting should be rechecked by test-running the boat. Refer to Water Testing. • Installing the outboard too high on the transom will allow the water intake to suck in air and cause cavitation (cavitation will cause the engine to overspeed in spurts and reduce thrust). This condition should be avoided by proper height setting. • Installing the outboard too low on the transom will allow excessive drag. SETTING OUTBOARD MOUNTING HEIGHT ON BOATS WITH “V” BOTTOM HULLS 1. Measure the width of the leading edge on the water intake housing. Make a horizontal line (a) on the transom up from the “V” bottom the same length as the width of the water intake housing (b). a b 2. Place (center) the outboard on the boat transom so that the transom brackets are resting on top of the transom. Temporally fasten the outboard to the transom using two C-clamps. 3. Position the outboard in a vertical position. 4. Line-up a straight edge (c) along the bottom of the boat with the horizontal line made in Step 1 and measure the distance between the horizontal line and top front edge of the water intake housing (d). c d 5. Raise the outboard up on the transom the distance measured in Step 4. Use a straight edge and recheck the mounting height. The top edge of the water intake housing should be lined-up with the horizontal line made in Step 1. 6. Fasten outboard to the transom at this height.

90-824052R3 JUNE 2002 JET OUTBOARDS - 6F-7 SETTING OUTBOARD MOUNTING HEIGHT ON BOATS WITH FLAT BOTTOM HULLS 1. Place (center) the outboard on the boat transom so that the transom brackets are resting on top of the transom. Temporally fasten the outboard to the transom using two C-clamps. 2. Position the outboard in a vertical position. 3. Place a straight edge (a) along the bottom of the boat as shown and measure the distance between the bottom of the boat and top front edge of the water intake housing (b). b a a - Straight Edge b - Top Edge of Water Intake Housing 4. Raise the outboard up on the transom the distance measured in Step 3. Use a straight edge and recheck the mounting height. The top edge of the water intake housing should be in line with the bottom of the boat as shown. 5. Fasten outboard to the transom at this height. Water Testing Checking for Cavitation Making the initial outboard height setting should be close to the optimum setting for the outboard. However because of the hull design of some boats, obstructions or imperfections in the hull ahead of the water intake may require this setting to change in order to prevent cavitation at running speeds. When operating the boat, the outboard driveshaft should be vertical when planing or tilted toward the boat in order to provide a scooping angle on the water intake. Tilting the outboard out beyond a vertical position reduces the scoop angle and can cause impeller slippage and cavitation. If the angle of the boat transom does not allow the driveshaft to be positioned vertical a Wedge kit should be installed behind the transom brackets to increase the tilt-in angle. NOTE: Slight cavitation in sharp turns and rough water is acceptable but excessive cavitation is harmful to the outboard and should be avoided. Test run the boat. If cavitation occurs (air enters the pump causing loss of thrust, engine over-speeds erratically), the first thing to try is lowering the outboard height 1/4 in. This can be accomplished by elongating the drilled mounting holes in the boat transom by 1/4 in. If cavitation still exists after lowering the outboard 1/4 in., it maybe helpful to seek advice from the boat manufacturer. A number of other options are available to further reduce cavitation. 1. Water intake fin kit (a) – Available from Quicksilver Accessories for the Jet 20 and the Specialty Mfg. Co. for jet models 30 thru 140. The purpose of these fins is to ram more water into the intake and shield the forward sides of the intake from the entrance of air. This kit will help reduce cavitation when running with the wind in a chop. a a - Intake Fin Kit Jet 105 and 140 – Water Intake Fin Kit Part No.1186 for jet models 105 and 140 is available from: Specialty Mfg. Co. 2035 Edison Ave. San Leandro, CA 94577

6F-8 - JET OUTBOARDS 90-824052R3 JUNE 2002 Water Testing Checking for Cavitation (Continued) 2. Rough Water Plate (b) – Using this type of plate may be helpful in reducing cavitation when running in windy rough water conditions where air is sucked-in the water intake when jumping waves. Install a 1/32 in. metal plate that extends from the hull bottom to the top of the water intake housing. This plate tends to reduce air intake as well as reduce spray. b b - Rough Water Plate Shift Cable Installation Jet 105 and 140 WARNING The shift cable must be adjusted to lock the reverse gate against unexpected engagement (caused by water pressure hitting the gate) while operating the boat in forward. Activation of the reverse gate will cause sudden unexpected stopping of the boat. Sudden stopping may cause occupants to be thrown within the boat or even out of the boat. This action may result in serious injury or death. 1. Attach shift cable (a) to the shift cam (b) with flat washer and locknut as shown. Tighten locknut against the flat washer, then back-off the locknut 1/4 turn. 2. Place remote control handle into full forward position. 3. Adjust the brass barrel (c) on the shift cable so that roller (d) is at the full end of travel (bottom) in the shift cam when the remote control is in full forward. 4. Attach the brass barrel (c) to the bracket with bolt and locknut. Tighten the bolt until it seats against the barrel, then back-off the bolt 1/4 turn. Hold bolt from turning, and tighten locknut on bolt. The barrel must be free to pivot. c b a d a - Shift Cable b - Shift Cam c - Barrel d - Roller 5. Recheck the shift cable adjustment in forward shift position. The correct shift adjustment will position the cam far enough on the roller in order to lock the the reverse gate into forward position. You should not be able to forcibly push up the reverse gate toward neutral. Pull on the reverse gate by hand to verify this. IMPORTANT: The forward locking of the reverse gate must be met. If not, readjust the shift cable.

1992+ Mercury Mariner 200HP EFI 2-Stroke OEM Service & Repair Manual

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