Mercury OptiMax 250 Service Manual

1
D
INSTALLATION
90-888438 JUNE 2002 Page 1D-1
IMPORTANT INFORMATION
Section 1D - Mercury Jet Installation
Table of Contents
General Information 1D-2. . . . . . . . . . . . . . . . . . . . .
Notice to Installer 1D-2. . . . . . . . . . . . . . . . . . . . .
Torque Specifications 1D-3. . . . . . . . . . . . . . . . .
Installation Requirements 1D-3. . . . . . . . . . . . . . . .
Battery/Battery Cables 1D-3. . . . . . . . . . . . . . . .
Boat Construction 1D-4. . . . . . . . . . . . . . . . . . . .
Engine Compartment Ventilation 1D-4. . . . . . .
Exhaust System 1D-5. . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery System 1D-5. . . . . . . . . . . . . . . . .
Instrumentation 1D-6. . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams 1D-7. . . . . . . . . . . . . . . . . . . . .
Quicksilver Instrumentation, Typical
Analog Installation Shown 1D-7. . . . . . . . . . . . .
SmartCraft System Monitor –
Model Year 2001 and Newer 1D-8. . . . . . . . . . .
Remote Control and Cables 1D-9. . . . . . . . . . .
Mercury Jet Drive Hull Dimensions 1D-10. . . . . . . .
Steering Helm and Cable 1D-11. . . . . . . . . . . . . .
method for controlling location
and size 1D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Jet Pump 1D-12. . . . . . . . . . . . . . . . . . . . . .
Hull Cutout 1D-12. . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cable Adjustment 1D-16. . . . . . . . . . . .
Shift Cable Adjustment 1D-19. . . . . . . . . . . . . . . .
Bilge Siphon Feature 1D-22. . . . . . . . . . . . . . . . . . . .
Installing Bilge Siphon 1D-22. . . . . . . . . . . . . . . .
Water By-Pass System 1D-23. . . . . . . . . . . . . . . . . . .
Installation of Flushing Kit 1D-25. . . . . . . . . . . . .
Operation Instructions 1D-26. . . . . . . . . . . . . . . . .
Suggested Flushing Intervals 1D-27. . . . . . . . . .
Installing Powerhead 1D-28. . . . . . . . . . . . . . . . . . . .
Battery Connection 1D-30. . . . . . . . . . . . . . . . . . .
Throttle Cable 1D-31. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1D-31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Injection Set-Up 1D-32. . . . . . . . . . . . . . . . . . . . . .
Filling 1D-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming the Oil Injection Pump
(If Required) 1D-32. . . . . . . . . . . . . . . . . . . . . . . . .
Purging Air From the Engine Oil Tank 1D-32. . .
Trim Plate Adjustment 1D-33. . . . . . . . . . . . . . . . . . .
Exhaust System Installation 1D-34. . . . . . . . . . . . . .
General Exhaust System Notes 1D-34. . . . . . . .
Exhaust Outlet Measurement
Procedure 1D-34. . . . . . . . . . . . . . . . . . . . . . . . . . .
Top View 1D-35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aft View 1D-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side View 1D-37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Side View of Expansion Chamber
Outlet Pipe and Exhaust Pipe
Connection 1D-38. . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-delivery Inspection 1D-39. . . . . . . . . . . . . . . . . . .

Mercury OptiMax 250 Specifications

General

Engine Type	V6
Horsepower	250 hp
Gear Ratio	1.75:1
Starting System	Electric Start
Alternator	60 Amp
Shaft Length	20", 25"

Summary

General Information

Notice to Installer

Alerts the installer to special instructions concerning operations that may be hazardous if performed incorrectly.

Torque Specifications

Installation Requirements

Battery/Battery Cables

Details battery selection criteria, cable sizing, and proper connection procedures.

Boat Construction

Engine Compartment Ventilation

Exhaust System

Fuel Delivery System

Instrumentation

Wiring Diagrams

SmartCraft System Monitor – Model Year 2001 and Newer

Remote Control and Cables

Mercury Jet Drive Hull Dimensions

Steering Helm and Cable

Installing Jet Pump

Hull Cutout

Provides critical dimensions for the hull opening and procedures for installing the tunnel grommet.

Steering Cable Adjustment

Shift Cable Adjustment

Bilge Siphon Feature

Installing Bilge Siphon

Instructions for installing the bilge siphon hose, break, and pick-up screen.

Water By-Pass System

Installation of Flushing Kit

Operation Instructions

Suggested Flushing Intervals

Installing Powerhead

Battery Connection

Throttle Cable Installation

Oil Injection Set-Up

Filling

Procedures for filling the remote oil tank and the engine oil tank.

Priming the Oil Injection Pump (If Required)

Explains how to check and reprime the oil injection pump using the Digital Diagnostic Terminal.

Purging Air From the Engine Oil Tank

Steps for purging air from the engine oil tank after filling to ensure proper oil flow.

Trim Plate Adjustment

Exhaust System Installation

General Exhaust System Notes

Covers standards, cautions, and requirements for marine exhaust system components and installation.

Exhaust Outlet Measurement Procedure

Procedure for measuring exhaust outlet location and checking exhaust system slope.

Pre-delivery Inspection