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Mercury 200 SportJet User Manual

Mercury 200 SportJet
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EPA Emissions Regulations
Jet Drives manufactured by Mercury Marine in the United
States are certified to the United States Environmental
Protection Agency as conforming to the requirements of the
regulations for the control of air pollution from new Jet Drive
motors. This certification is contingent on certain adjustments
being set to factory standards. For this reason, the factory
procedure for servicing the product must be strictly followed
and, wherever practicable, returned to the original intent of the
design. Maintenance, replacement, or repair of the emission
control devices and systems may be performed by any marine
engine repair establishment or individual.
Engines are labeled with an Emission Control Information
decal as permanent evidence of EPA certification.
!
WARNING
The engine exhaust from this 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 Mercury Marine, the terms of the warranty are
set forth in the Warranty Information section of this manual.
The warranty statement contains a description of what is
covered, what is not covered, the duration of coverage, how
to best obtain warranty coverage, important disclaimers and
limitations of damages, and other related information.
Please review this important information.
The description and specifications contained herein were in
effect at the time this manual was approved for printing.
Mercury Marine, whose policy is one of continued
improvement, reserves the right to discontinue models at any
time, to change specifications, designs, methods, or
procedures without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Litho in U.S.A.
© 2010 Mercury Marine
200 SportJet 90-10271090 710

Table of Contents

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Mercury 200 SportJet Specifications

General IconGeneral
Model200
Horsepower200
Kilowatts149.1
Full throttle RPM range5150–5650
Idle speed RPM range900–1000
Number of cylinders6
Piston displacement2508 cc (153 in³)
Cylinder bore88.4 mm (3.500 in.)
Stroke67.3 mm (2.650 in.)
Spark plugNGK IZFR6J‑11
Spark plug gap1.1 mm (.043 in.)
Recommended gasolineRefer to Fuel and Oil
Recommended oilRefer to Fuel and Oil
Emission control systemElectronic engine control (EC)
Battery rating (minimum)1000 marine cranking amps (MCA) or 800 cold cranking amps (CCA)
Charging system output60 A

Summary

EPA Emissions Regulations

Mercury Premier Service

Declaration of Conformity for Recreational Craft Propulsion Engines

WARRANTY INFORMATION

Warranty Registration

Process for registering the product for warranty coverage.

Transfer of Warranty

Procedures for transferring limited warranty to a new owner.

Mercury Jet Products Limited Warranty

Details of the limited warranty for new Jet products.

3 Year Limited Warranty Against Corrosion

Warranty coverage for corrosion damage over three years.

Warranty Coverage and Exclusions

Explanation of what is and is not covered by warranty.

U.S. EPA Emissions Limited Warranty

Warranty for emission control system components.

GENERAL INFORMATION

Boater's Responsibilities

Operator's duties for safe operation and understanding the manual.

Before Operating Your Mercury Jet Drive

Important pre-operation checks and reading guidelines.

Boat Horsepower Capacity

Guidelines on adhering to the boat's maximum horsepower rating.

High-Speed and High-Performance Boat Operation

Advice for operating in high-speed or high-performance situations.

Towing the Watercraft in Water

Instructions and precautions for towing the watercraft.

Mercury Jet Drive Remote Control

Information about the remote control system and its safety features.

Lanyard Stop Switch

Explanation and importance of the lanyard stop switch for safety.

Protecting People in the Water

Safety guidelines for preventing injury to people in the water.

Exhaust Emissions

Information and warnings about carbon monoxide from exhaust fumes.

Poor Ventilation

Risks and prevention of carbon monoxide buildup due to poor ventilation.

Wave and Wake Jumping

Hazards associated with operating over waves and wakes.

Stopping the Boat in an Emergency

Procedures for emergency stopping of the jet drive boat.

Selecting Accessories for Your Mercury Jet Drive

Guidance on selecting and installing compatible accessories.

Safe Boating Suggestions

General advice for safe and enjoyable boating practices.

FUEL AND OIL

Fuel Requirements

Guidelines for using appropriate gasoline for the engine.

Fuel Additives

Recommendation for using additives to minimize carbon buildup.

Avoiding Fuel Flow Restriction

Importance of maintaining an unrestricted fuel supply.

Low Permeation Fuel Hose Requirement

EPA requirement for fuel hose type for US sales.

Oil Recommendation

Recommended engine oil and alternatives.

Fuel Recommendations

Specific octane ratings and types of gasoline to use.

Gasolines Containing Alcohol

Adverse effects of alcohol in gasoline and storage recommendations.

Fuel System

Warning about fuel system compatibility with alcohol and leak inspection.

Filling Remote Oil Tank

Procedure for filling the remote oil tank.

Filling Engine-Mounted Oil Reservoir Tank

Procedure for filling the engine-mounted oil reservoir.

FEATURES AND CONTROLS

Bilge Siphon

Description of the automatic bilge siphoning feature.

Warning Horn Signals

Explanation of warning horn sounds and their meanings.

Engine Guardian System

System that monitors sensors and protects the engine.

SmartCraft Product

Information about the SmartCraft instrument package for diagnostics.

OPERATION

Pre-Starting Check List

A comprehensive list of checks before starting the engine.

Special Operating Instructions

Specific procedures and precautions for operating the jet drive.

Operating on the Water

Handling characteristics and safety for jet drive boats.

Operating in Freezing Temperatures

Precautions for operating in freezing water conditions.

Operating in Saltwater or Polluted Water

Recommended flushing procedures for saltwater use.

Engine Break-In Procedure

Step-by-step guide for breaking in the engine for optimal life.

Starting the Engine

Step-by-step guide to starting the engine safely.

Shifting

How to operate the forward, neutral, and reverse gears.

Stopping the Engine

Procedures for stopping the boat normally and in emergencies.

MAINTENANCE

Mercury Jet Drive Care

General advice for maintaining the jet drive for optimal performance.

Replacement Parts for Your Power Package

Recommendation to use genuine Mercury replacement parts.

EPA Emissions Regulations

Information on EPA certification and servicing emission control systems.

Emission Certification Label

Explanation of the emission certification label on the engine.

Owner Responsibility

The owner's role in maintaining emission levels.

Inspection and Maintenance Schedule

Periodic checks and maintenance tasks required.

Clearing A Clogged Water Intake

Steps to clear weeds or debris from the water intake.

Fuel System

Maintenance procedures for the fuel system, including filters.

Fuses

Information about engine fuses and their replacement.

Corrosion Control Anodes

Inspection and replacement of corrosion control anodes.

Battery Inspection

How to inspect the battery for proper starting capability.

Spark Plug Inspection and Replacement

Procedures for inspecting and replacing spark plugs.

Flywheel Cover Removal and Installation

Steps for removing and reinstalling the flywheel cover.

Alternator Belt Inspection

How to inspect the alternator belt for wear or damage.

Compressor Air Intake Filter

Procedures for replacing the compressor air intake filter.

Belt Tensioner Idler Pulley Lubrication

Lubrication instructions for the belt tensioner idler pulley.

Flushing the Cooling System

Essential procedure for cleaning the cooling system after use.

Drive Housing Lubricant

Procedures for draining and adding lubricant to the drive housing.

Stator Assembly Lubricant

Procedures for draining and adding lubricant to the stator assembly.

Bilge Siphon Inspection

Periodic inspection of the bilge siphon system for performance.

Submerged Power Package

Immediate service required for a submerged engine.

STORAGE

Storage Preparation

Procedures for preparing the jet drive for long-term storage.

Fuel System

Fuel system preparation for storage, including stabilizers.

Protecting Internal Engine Components

Steps to protect internal engine parts during storage.

TROUBLESHOOTING

Starter Motor Will Not Crank the Engine

Possible causes and solutions for the starter not cranking.

Engine Will Not Start

Possible causes and solutions for the engine failing to start.

Engine Runs Erratically

Potential causes for the engine running unevenly.

Performance Loss at Normal RPM

Factors that can cause performance loss at normal operating speeds.

Performance Loss at Wide-Open Throttle

Causes for performance loss at full throttle, engine or pump related.

Battery Will Not Hold Charge

Potential causes for the battery not retaining its charge.

OWNER SERVICE ASSISTANCE

Local Repair Service

Recommendation to use authorized dealers for service.

Parts and Accessories Inquiries

How to inquire about and order replacement parts and accessories.

Service Assistance

Steps to follow when seeking assistance from Mercury Marine.

Mercury Marine Service Offices

Contact information for Mercury Marine service offices worldwide.

Ordering Literature

Information required to order additional documentation.

MAINTENANCE LOG