2002 Mercury OptiMax 250 Jet Drive Service Manual

2002 Mercury OptiMax 250HP Jet Drive Service Manual.

Part Number: 90-888438

Starting Model Year 2002

Starting Serial Number 0E407100

Manual chapters:
250 OptiMax Jet Drive
  - Notice
  - Notice to Users of This Manual
  - Cleanliness and Care of Mercury Jet Unit
  - Page Numbering
  - Service Manual Outline
Section 1A - Specifications
  - Table of Contents
  - Master Specifications
  - Mercury/Quicksilver Lubricants and Sealants
Section 1B - Maintenance
  - Table of Contents
  - Specifications
  - Special Tools
  - Mercury/Quicksilver Lubricants and Sealants
  - Maintenance
  - Fuel System
  - Spark Plug Inspection
  - Battery Inspection
  - Fuse Replacement
  - Compressor Air intake Filter
  - Flushing Cooling System
  - Out-of-Season Storage
Section 1C - General Information
  - Table of Contents
  - Serial Number Location
  - Conditions Affecting Performance
  - Following Complete Submersion
  - Model 250 Optimax Jet Front View
  - Model 250 Optimax Jet Starboard View
  - Model 250 Optimax Jet Port View
  - Model 250 Optimax Jet Aft View
  - Model 250 Optimax Jet Top View
  - Mercury Jet Pump Starboard View
  - Mercury Jet Pump Port View
Section 1D - Mercury Jet Installation
  - Table of Contents
  - General Information
  - Installation Requirements
  - Mercury Jet Drive Hull Dimensions
  - Installing Jet Pump
  - Bilge Siphon Feature
  - Water By-Pass System
  - Installing Powerhead
  - Throttle Cable
  - Oil Injection Set-Up
  - Trim Plate Adjustment
  - Exhaust System Installation
  - Pre-delivery Inspection
Section 2A – Ignition
  - Table of Contents
  - Specifications
  - Special Tools
  - Coil Plate
  - Solenoid Plate Model
  - Theory of Operation
  - Ignition Component Description
  - Troubleshooting Without Digital Diagnostic Terminal
  - Troubleshooting With the Digital Diagnostic Terminal
  - DDT Functions – Optimax Models Software Version 1.0 ( P/ N 880118)
  - Ignition Components Removal and Installation
Section 2B – Charging & Starting System
  - Table of Contents
  - Specifications
  - Special Tools
  - Battery Cable Size
  - Replacement Parts
  - Recommended Battery
  - Battery
  - Charging a Discharged Battery
  - Winter Storage of Batteries
  - Flywheel Removal and Installation
  - Flywheel/Alternator
  - System Components
  - Alternator Description
  - Diagnosis of Alternator System on Engine
  - Alternator System Circuitry Test
  - Repair
  - Installation
  - Alternator Belt Tension Adjustment
  - Starter System
  - Starter Motor
  - Troubleshooting the Starter Circuit
  - Starter Circuit Troubleshooting Flow Chart
  - Starter Removal and Installation
  - Disassembly
  - Cleaning and Inspection
  - Reassembly
  - Starter Cleaning, Inspection and Testing
  - Commander 2000 Key Switch Test
Section 2C – Timing, Synchronizing & Adjusting
  - Table of Contents
  - Specifications
  - Special Tools
  - Crank Position Sensor
  - Throttle Cam Adjustment
  - Throttle Position Sensor (TPS) Adjustment
  - Idle Speed
Section 3A – Electric Fuel Pump
  - Table of Contents
  - Specifications
  - Fuel Pump Assembly
  - Special Tools
  - Fuel Lift Pump Description/Operation
  - Checking for Restricted Fuel Flow Caused by Anti-siphon Valves
  - Checking Fuel Pump Lift (Vacuum)
  - Fuel Lift Pump Disassembly/Assembly
Section 3B – Direct Fuel Injection
  - Table of Contents
  - Specifications
  - Special Tools
  - Air Handler
  - Air Handler Components
  - Vapor Separator Components
  - Fuel Rails
  - Air Compressor Components
  - DFI Operation
  - Testing Electric Fuel Pump Pressure Output
  - Fuel Management Assembly Removal
Section 3C – Oil Injection
  - Table of Contents
  - Oil System Operation
  - Oiling System
  - Oil System Troubleshooting
Section 3D – Emissions
  - Table of Contents
  - Exhaust Emissions Standards
  - Stratified vs Homogenized Charge
  - Emissions Information
  - Service Replacement Certification Label
Section 4A - Powerhead
  - Table of Contents
  - Powerhead Specifications
  - Special Tools
  - Cylinder Block Assembly
  - Crankshaft, Pistons and Connecting Rods
  - Expansion Chamber and Adaptor Plates
  - Torque Sequence
  - General Information
  - Powerhead Removal from Pump Unit
  - Exhaust Chamber Removal
  - Powerhead Disassembly
  - Cleaning and Inspection
  - Powerhead Reassembly and Installation
  - Reinstalling Engine Components
  - Throttle Lever and Shift Shaft
  - Powerhead Installation on Pump Unit
  - Break-ln Procedure
Section 4B - Cooling
  - Table of Contents
  - Specifications
  - Special Tools
  - Model 250 Optimax Jet Water Flow
  - Water Pressure Check
Section 5 - Jet Pump
  - Table of Contents
  - General Information
  - Master Specifications Jet Pump
  - Drive Housing Components
  - Pinion & Impeller Shaft
  - Nozzle/Rudder Components
  - Servicing Stator, Impeller and Wear Ring
  - Removing Jet Drive From Boat
  - Drive Housing Disassembly and Reassembly
Section 6 - Color Diagrams
  - 250 Optimax Jet Drive Engine Wiring
  - 250 Optimax Jet Drive Typical Key Switch Wiring
  - 250 Optimax Jet Drive Typical Remote Control and Dash Wiring Non-SmartCraft
  - 250 Optimax Jet Drive Typical Remote Control and Dash Wiring with SmartCraft
  - 250 Optimax Jet Drive Fuel & Air Flow Diagram
  - 250 Optimax Jet Drive Water Flow

Manual is indexed with searchable text.