Installation manual

ManualsBrandsMercury ManualsBoatXR2

90-10164040 1203

- 1 -

Printed in U.S.A.

175XR

Jet Drive

Installation Manual

NOTICE to INSTALLER

After Completing Installation, These Instruc-

tions Should Be Placed with the Product for the

Owner’s Future Use.

NOTICE to COMMISSIONING DEALER

Pre-delivery Preparation Instructions Must Be

Performed Before Delivering Boat to the Prod-

uct Owner.

NOTICE to INSTALLER

The United States Coast Guard does not have

a method to determine the maximum recom-

mended horsepower for Inboard Jet Boats.

Therefore, it is the responsibility of the boat

manufacturer to install the Mercury

Jet Drive, as

well as any other Jet Drive model, in a boat which

has been determined to be of suitable size,

weight, construction, and hull configuration for

the power chosen. The Mercury

Jet Drive, in par-

ticular, brings a new level of performance to the

jet boat category and is capable of propelling

many hulls at speeds exceeding 50 miles per

hour.

In selecting the proper Jet Drive package for a

particular application, please consider the over-

all performance capability of the craft. Your boat

may react to and handle differently with each Jet

Drive model.

PLEASE carefully test and evaluate the over-

all handling characteristics of the boat pack-

age before distribution for sale.

If you have application or installation questions,

please contact your Mercury Marine OEM Sales

Coordinator. The Sales Coordinator will arrange

to provide the necessary assistance.

Please assess your boat’s performance com-

pletely before making the Jet Drive model selec-

tion.

Safe boating is good for everyone.

 2003 Mercury Marine

The following are registered trademarks of Brunswick Corpora-

tion: AutoBlend, Force, Jet-Prop, Mariner, Merc, MerCathode,

MerCruiser, Mercury, Mercury Marine, Quicksilver, RideGuide,

Sport Jet, and Thruster.

Table of Contents

Page

General Information 2. . . . . . . . . . . . . . . . . . . . . . . . .

Notice to Installer 2. . . . . . . . . . . . . . . . . . . . . . . . .

Installation Products 2. . . . . . . . . . . . . . . . . . . . .

Torque Specifications 2. . . . . . . . . . . . . . . . . . . . .

Serial Number Decal Location 3. . . . . . . . . . . . . .

Corrosion Protection 3. . . . . . . . . . . . . . . . . . . . . .

Installation Requirements 3. . . . . . . . . . . . . . . . . . . .

Battery/Battery Cables 3. . . . . . . . . . . . . . . . . . . .

Boat Construction 4. . . . . . . . . . . . . . . . . . . . . . . .

Engine Compartment Ventilation 4. . . . . . . . . . . .

Exhaust System 4. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Delivery System 5. . . . . . . . . . . . . . . . . . . . .

Instrumentation 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagrams 6. . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Selection 7. . . . . . . . . . . . . . . . . . . . . . . .

Remote Control and Cables 7. . . . . . . . . . . . . . . .

Steering Helm and Cable 7. . . . . . . . . . . . . . . . . .

Mercury Jet Drive Hull Dimensions 175XR

8. . . . .

Installing Jet Pump 10. . . . . . . . . . . . . . . . . . . . . . . . .

Steering Cable Adjustment 12. . . . . . . . . . . . . . . .

Shift Cable Adjustment 13. . . . . . . . . . . . . . . . . . .

Bilge Siphon Feature 15. . . . . . . . . . . . . . . . . . . . . . .

Installing Bilge Siphon 15. . . . . . . . . . . . . . . . . . . .

Water By-Pass System 15. . . . . . . . . . . . . . . . . . . . .

Installing Powerhead 16. . . . . . . . . . . . . . . . . . . . . . .

Battery Connection 17. . . . . . . . . . . . . . . . . . . . . .

Throttle Cable Adjustment 18. . . . . . . . . . . . . . . .

Oil Injection System 18. . . . . . . . . . . . . . . . . . . . . .

Bleeding Air from Oil Injection Pump 19. . . . . . .

Adjusting Oil Injection Pump 19. . . . . . . . . . . . . .

Turn-Key Start Feature 20. . . . . . . . . . . . . . . . . . . . . .

Trim Plate Adjustment 20. . . . . . . . . . . . . . . . . . . . . .

Pre-delivery Inspection 21. . . . . . . . . . . . . . . . . . . . . .

Summary of content (21 pages)

PAGE 1
Table of Contents 175XR2 Jet Drive Installation Manual Page General Information . . . . . . . . . . . . . . . . . . . . . . . . . 2 Notice to Installer . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation Products . . . . . . . . . . . . . . . . . . . . . 2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . 2 Serial Number Decal Location . . . . . . . . . . . . . . 3 Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . 3 Installation Requirements . . . . . . . . . . .
PAGE 2
We could not possibly know of and advise the marine trade of all conceivable procedures by which an installation might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses an installation procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the product’s safety will be endangered by the installation procedure selected.
PAGE 3
Serial Number Decal Location Corrosion Protection A serial number decal is located on the side of the flywheel cover and on top of the cylinder block. This power package is equipped with anodes to help protect it from galvanic corrosion under moderate conditions. See the Operator’s Manual for location of anodes. a OGXXXXXX 19XX Installation Requirements b OGXXXXXX d XX IMPORTANT: The Jet Drive is considered an INBOARD engine.
PAGE 4
Boat Construction Exhaust System IMPORTANT: All applicable U.S. Coast Guard regulations for INBOARD engines must be complied with, when constructing engine compartment. IMPORTANT: It is the responsibility of the boat manufacturer, or installing dealer, to properly locate the engine. Improper installation may allow water to enter the exhaust manifold and combustion chambers and severely damage the engine.
PAGE 5
Fuel Delivery System Instrumentation ! CAUTION ! WARNING Boating standards (NMMA, ABYC, etc.), federal standards and U. S. Coast Guard regulations for INBOARD engines must be adhered to when installing fuel delivery system. Failure to comply could result in severe personal injury or death. If a fused accessory panel is to be used, it is recommended that a separate circuit (properly fused) be used from the battery to the fuse panel with sufficient wire size to handle the intended current load.
PAGE 6
Wiring Diagrams INSTRUMENTATION, TYPICAL INSTALLATION SHOWN REFER TO GAUGE MANUFACTURER’S INSTRUCTIONS FOR SPECIFIC CONNECTIONS. a b h c f e g i Temperature Sender (Included With Gauge) a - Temperature Gauge b - Key Switch c - Tachometer Gauge d - Emergency Stop Switch e - Tachometer Harness (P/N 84-86396A8) (Not Included With Key/Choke Harness Kit) f - Connect Wires Together With Screw and Hex Nut (2 Places) Apply Liquid Neoprene to Connections and Slide Rubber Sleeve Over Each Connection.
PAGE 7
• Impeller Selection IMPORTANT: Installed impeller must allow engine to run in its specified maximum wide open throttle RPM range. Protected against water intrusion and/or corrosion as the cable end (at the pump) is submersed in water with the boat at rest. A cable bellows is provided with the cable (P/N 64-858342A_). Follow installation procedures for proper sealing of cable.
PAGE 8
• The steering cable should be able to withstand the steering loads imparted on it by the rudder. Mercury Jet Drive Hull Dimensions 175XR2 A cable bellows is provided with the cable (P/N 64-835457A_). Follow installation procedures for proper sealing of cable. HULL OPENING CUT OUT The pump to powerhead opening in the hull is the most important factor to consider in a Jet Drive installation.
PAGE 9
METHODS OF CONTROLLING LOCATION AND SIZE If the tunnel area in the plug is correct, the boat bottom mold should repeat and reproduce the tunnel area which will aid the cut out process. CHECKING MOUNTING FLANGE THICKNESS AND FLATNESS Use a flat plate that will contact the flange at the reference points (b) and a .030 in. feeler gauge to check flatness. A reference area for the cut out can be produced on the plug and bottom mold as a raised area or a cutting guide.
PAGE 10
3. Install tab washer and nut on cable after guiding through wear ring. Locate tab washer in tab hole. Coarse cable adjustment is made using these nuts. Do not tighten until after final steering adjustment is made. Installing Jet Pump Hull Cutout ! CAUTION c The hull cutout dimensions are critical for proper sealing between Jet Pump and boat. Measure cutout thickness and overall dimensions before attempting a Jet Pump installation. 1. Install tunnel grommet (a) in cut-out of boat.
PAGE 11
5. Spray soapy water on tunnel grommet, both side foam exhaust seals, ride plate seal and sides of boat tunnel. 7. Install gasket and cover (d) on jet pump. Align holes in cover with locating pins in housing and secure with four (4) M10 x 1.5 nuts . NOTE: Before torquing fasteners, check side exhaust seals and ride plate seal for proper fit in tunnel. 8. Torque nuts to 47 Nm (35 lb ft). a b b a a - Gasket and Cover b - M10 x 1.
PAGE 12
6. Attach steering cable to steering arm with bolt, washer and locknut. Torque nut to 20.3 Nm (180 lb in.). Steering Cable Adjustment 1. Slide bellows assembly over cable and thread on cable completely. Do Not tighten. c e 54456 d 2. Thread cable end adaptor on steering cable 14 turns (to allow for adjustment). a ! WARNING Cable end adaptor must be installed a minimum of nine (9) turns.
PAGE 13
NOTE: Removing the oil film from the shift cable is necessary to prevent the bellows from sliding on the cable. 11. Turn bellows nut out and tighten against cable end adaptor. b a 3. Apply Perfect Seal to cable conduit ahead of the threads. Perfect Seal 19 19 54908 a - Bellows Clamp b - Bellows Nut Tight Against Jam Nut a a - Remove Oil Film From This Area 12. Turn rudder to port to compress bellows as much as possible. Pull bellows over cable conduit and secure with bellows clamp. 4.
PAGE 14
6. Install shift cable end in slot of the reverse gate and secure with clevis pin, flat washer, and cotter pin. Bend over ends of cotter pin. ! 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 overboard. Serious injury or death could result. c b a 9.5 – 12.7 mm (3/8 in. – 1/2 in.
PAGE 15
10. Seal the thru-hull fitting to prevent any water leaks. Water By-Pass System The water by-pass system is designed to improve powerhead cooling at idle speed. a 1. Locate the water by-pass components (provided). a - Steering Cable Thru-Hull Fitting a Bilge Siphon Feature a - Thru-Hull Fitting b - Brass Nut c - Hose Clamp The Jet Drive incorporates an automatic bilge siphoning feature. The bilge siphon is working whenever the engine is running above idle speeds.
PAGE 16
4. After the location has been selected for the thruhull fitting, drill a 14.3 mm (9/16 in.) diameter hole. Installing Powerhead 1. Install gasket on drive housing cover. 5. Apply Marine Sealer to entire length of threads and under the head of the thru-hull fitting. Fasten the fitting into the transom with the brass nut (provided). b a b c a b c d a - d 28242 Gasket Drive Housing Cover O-Ring Slinger “TOP” Facing Up c 2. Install drive housing cover O-ring.
PAGE 17
6. Secure powerhead to drive housing cover with eight (8) M10 x1.5 nuts. Torque fasteners to 47 Nm (35 lb ft) following the torque sequence given. Repeat torque sequence to ensure all fasteners retain their torque. Battery Connection NOTE: Engine electrical system is negative (–) ground. 1. Connect positive (+) battery cable (usually red) to starter solenoid using protective boot (provided). 2. Connect negative (–) battery cable (usually black) to engine ground at forward starter motor bolt. ! WARNING U.
PAGE 18
4. Attach remote control harness plug to engine harness plug. Reinstall harness plug in clip. Oil Injection System 1. Mount the oil reservoir in a suitable location. Use the oil tank hold down kit provided. 28243 2. Oil hoses must be arranged so they cannot become pinched, kinked, sharply bent or stretched during operation of the engine. 3. Remove (and discard) the shipping cap from hose fitting. a 4. Connect oil hose from remote oil tank (hose with blue stripe) to fitting. Secure with cable tie.
PAGE 19
BLEEDING AIR FROM OIL INJECTION PUMP OUTLET HOSE Any air bubbles in outlet hose in most cases will be purged out of the system during operation of the engine. NOTE: If air bubbles persist, they can be purged out of the hose by removing link rod and rotating the pump arm full clockwise while operating engine at 1000 to 1500 RPM: If necessary, gently pinch the fuel line between the fuel tank and the fuel pump T fitting.
PAGE 20
Turn-Key Start Feature The Jet Drive utilizes an automatic enrichner to start a cold engine. The enrichner is controlled by the ECM (Electronic Control Module). There are no adjustments for the Turn Key Start Feature. IMPORTANT: The Turn Key Start relies on closed throttle plates at idle. Ensure throttle plates are fully closed at idle. Trim Plate Adjustment The Jet Drive trim plate is factory set for general applications.
PAGE 21
Pre-delivery Inspection On the water test (continued) Not Check/ Applicable Adjust Not Check/ Applicable Adjust CHECK BEFORE RUNNING Water hose connection/torqued Cover plate & adaptor plate fasteners torqued Battery charged & secure All electrical connections tight All fuel connections tight Throttle, shift, & steering adjusted correctly and fasteners torqued Steering operational t