Checking and Adding Jetdrive Lubricant................................................................1B-16Changing Jetdrive Lubricant...................1B-17
General Maintenance.....................................1B-22Power Package Exterior Surfaces..........1B-22Steering Nozzle and Reverse Bucket ....1B-22Jetdrive Anodes......................................1B-22Boat Bottom Care...................................1B-23Jetdrive Corrosion Protection.................1B-23Gear Box Breather..................................1B-24Cleaning and Inspecting the Impeller.....1B-25
Power Package Extended Storage andRecommissioning...........................................1B-29
Power Package Extended Storage.........1B-29Power Package Recommissioning.........1B-30
Maintenance
Page 1B-2 90-866211 FEBRUARY 2005
Lubricant, Sealant, AdhesivesTube Ref No. Description Where Used Part No.
82 Premium Gear LubricantStator
Gear lube monitorGear case cavity
92-802846A1
91 Engine Coupler Spline Grease Jetdrive unit coupler 92-802869A1
95 2-4-C Marine Lubricant with Teflon Cable shafts and eyes 92-802859A1
120 Corrosion Guard Painted surfaces 92-802878-55
Jetdrive Special Tool IdentificationPart Number Description Image
91‑887532 Tool Kit All of the tools indicated below
91‑887499 Carrier assembly seal installation tool
ST-DJ10P-004
10636
91‑887500 Bearing race driver
ST-DJ10P-003
10635
91‑887501 Bearing race driver
ST-DJ10P-004
10636
91‑887502 Bearing race driver
ST-DJ10P-005
10637
91‑887503 Bearing race driver
ST-DJ10P-006
10638
91‑887504 Bearing race driver
ST-DJ10P-007
10639
91‑887505 Bearing race driver
ST-DJ10P-008
10640
91‑887506 Bronze bush driver
ST-DJ10P-009
10641
Maintenance
90-866211 FEBRUARY 2005 Page 1B-3
Part Number Description Image
91‑890036 Shaft support toolST-DJ10P-001
10633
91‑887508 Lock nut removal toolST-DJ10P-010
10642
91‑887509 Locking nut wrench12480
Tools Not In Kit
Obtain Locally Installation plate Image not available. (Round metal disk)
91‑37241 Bearing Puller
12219
Torque SpecificationsDescription Nm lb. in. lb. ft.
Operating tiller bolt 44 33
Steering tiller bolt 44 33
Steering rod anchor bolt 35 26
Tie rod bolt 85 63
Inspection cover bolts 27 20
Reverse gate bolts 75 55
Reverse bucket bolts 85 63
Reverse shaft and tiller ball joint nut 85 63
Reverse power cylinder bolts 35 25
Maintenance
Page 1B-4 90-866211 FEBRUARY 2005
Jetdrive SpecificationsDescription Type
PUMP TYPE Axial Flow / High Volume
IMPELLER DIAMETER 25 cm (10 inches)
NOZZLE DIAMETER 155mm (6 inches)
INTEGRAL GEARBOX Interchangeable Ratio Options
IMPELLER MATERIAL Stainless Steel / Five Blade
TRIM SYSTEM Adjustable Trim Plate
TRIMMABLE NOZZLE Optional
CASTING MATERIAL Aluminium Alloy
REAR BEARING Oil Lubricated Bearing
THRUST BEARING Oil Lubricated Bearing
SHAFT Stainless Steel
CORROSION PROTECTION Cathodic Anodes
INTAKE GRATE Stainless Steel Bars
STEERING SYSTEM (QUICKSILVER) Push / Pull Cable Actuation
REVERSE SYSTEM (MERCRUISER) Hydraulically Actuated
CONTROL SYSTEM (QUICKSILVER) Single Levery Actuated
WEIGHT (WATERJET & GEARBOX) 118 Kg (260 lb.)
ENGINE ‑ WATERJET COUPLING Unique to engine
ENGINE ‑ WATERJET MOUNTING Same as Sterndrive
Maintenance
Notes:
90-866211 FEBRUARY 2005 Page 1B-5
Maintenance
Page 1B-6 90-866211 FEBRUARY 2005
Cross Sectional View ‑ Jetdrive Lube Fittings
43
2
8
9
5
9
1210,11
1
10247
Maintenance
90-866211 FEBRUARY 2005 Page 1B-7
Cross Sectional View - Jetdrive Lube Fittings
Ref. No. QTY Description
11 LUBE BOTTLE
1 LUBE BOTTLE
2 1 BRACKET
3 2 SCREW SET, (M8 X Coarse @ 12 MM)
4 17 WASHER, (M8)
5 1 HOSE/BARB ELEBOW, (.25/ .125)
8 1 STRAP
9 2 PLUG, (.025)
10 1 HEAD SCREW, (M6 X Coarse @ 8 MM)
11 1 WASHER, (M6)
12 1 PLUG, (.125)
Maintenance
Page 1B-8 90-866211 FEBRUARY 2005
Cross Sectional View ‑ Jetdrive Inspection Cover and Trim Plate123
82
8384
79
78
107, 108
8180
87, 8886
85 105, 106
3435 10237
Maintenance
90-866211 FEBRUARY 2005 Page 1B-9
Cross Sectional View - Jetdrive Inspection Cover and Trim Plate
Ref. No. QTY Description
34 3 SCREW, (M10 X Coarse @ 20)
35 5 SCREW, (M6 Coarse @ 15)
78 1 STRIKER PLATE
79 1 INSPECTION COVER
80 1 SPLIT PIN, (M3 X 25)
81 3 WASHER, (M10)
82 1 SPRING
83 2 FLANGED BUSH
84 1 LOCK BOLT
85 1 O‑RING, Flange Seal
86 1 O‑RING, Inspection Cover
87 2 FLANGED PIN
88 2 BOLT, (M10 X Coarse @ 35)
105 14 BOLT, (M10 X 50)
106 14 WASHER, (M10)
107 28 WASHER, (M10 X 25)
108 28 NYLOC NUT, (M10)
Maintenance
Page 1B-10 90-866211 FEBRUARY 2005
Cross Sectional View ‑ Jetdrive Nozzle Assembly5
4
2, 3
1
138
10, 136
23
135
2726
141511
10, 136
1213
24 25
20, 21, 22
28
29
3330, 31, 32
654
2, 3
10235
Maintenance
90-866211 FEBRUARY 2005 Page 1B-11
Cross Sectional View - Jetdrive Nozzle Assembly
Ref. No. QTY Description
1 1 STEERING NOZZLE
2 2 SCREW, (M10 X Coarse @ 40)
3 6 WASHER, (M10) Coarse @ 40)
4 2 STEERING PIVOT BUSH
5 3 FLANGED BUSH
6 1 TILLER PIN , Upper Pivot
10 2 SCREW KIT, Drain
11 1 BOLT,(M10 X Coarse @ 30)
12 1 O‑RING, Shaft Sleeve Bolt
13 1 WASHER, (M14)
14 2 BEARING
15 1 SHAFT SLEEVE
20 6 STUD, (M10)
21 6 WASHER, (M10)
22 6 NYLOC NUT, (M10)
23 1 DISCHARGE NOZZLE
24 1 LINER PLASTIC
25 1 LINER STAINLESS STEEL
26 2 LIP SEALS
27 1 CIRCLIP
28 1 IMPELLER, Steel
29 1 KEY
30 2 SCREW, (M10 X Coarse @ 70)
31 2 WASHER, (M10) 32
32 4 WASHER, (M12)
33 1 TRIM PLATE
135 1 O‑RING, Lip Seal Spring
136 2 WASHER
138 1 PIN, Lower Pivot
Maintenance
Page 1B-12 90-866211 FEBRUARY 2005
LubricationMaintenance Intervals
Maintenance intervals and the corresponding tasks to be performed, as shown in thiscurrent schedule or as found in a previously printed schedule, are generally based on anaverage boating application and environment. However, individual operating habits andpersonal maintenance preferences can have an impact on the suggested intervals. Inconsideration of these factors, Mercury MerCruiser has adjusted some maintenanceintervals and the corresponding tasks to be performed. In some cases, this may allow formore individual tasks in a single visit to the servicing dealer. Therefore, it is very importantthat the boat owner and the servicing dealer discuss the current Maintenance Scheduleand develop appropriate maintenance intervals to coincide with the individual operatinghabits, the environment and the maintenance requirements. Refer to the appropriateCummins MerCruiser or Mercury MerCruiser engine service Manual for additionalinformation.
! CAUTIONAlways disconnect the battery cables from the battery before working around electricalsystem components to prevent injury and damage to the electrical system if a wire shouldaccidentally cause a short circuit.
Jetdrive MaintenanceRoutine Maintenance¹ Each Day Start Each Day End Weekly Every Two Months
Check engine oil level (interval can be extended based on experience). x
Check coolant level. x
Check power shift assist fluid level. x
Check jet drive unit oil level in gear lube monitor. x
Check trim pump oil level, if equipped. x
Check water pickups for debris or marine growth. Check water strainerand clean. x
If operating in salt, brackish, or polluted waters, flush cooling systemafter each use. x
Drain any water from fuel filter after each use (If operating in freezingtemperatures). x
Inspect sacrificial anodes on jetdrive and replace if 50 percent eroded. x
Check battery connections and fluid level. x
Operating in Saltwater Only: treat engine surface with corrosion guard. x
Inspect the air inlet.² x
Ensure the gauges and the wiring connections are secure. Clean thegauges. 3
x
¹ Only perform maintenance that applies to your particular powerpackage²Or every 50 hours, whichever occurs first.3Or every 50 hours, whichever occurs first. If operating in saltwater,interval is reduced to every 25 hours or 30 days whichever occurs first
Maintenance
90-866211 FEBRUARY 2005 Page 1B-13
Scheduled Maintenance4 After first 50 hours5 Every 100 hours or Annually5 Every 200 hours or Annually5
Check level and condition of drive shaft housingand stator lubricant. X
Check tightness of bolts, nuts, and otherfasteners. X
Change engine oil and filter. X X
Check Jetdrive anodes. X
Retorque exhaust riser clamp. X X
Remove impeller and lubricate impeller shaftwith Quicksilver or Mercury Precision 2‑4‑C w/Teflon to prevent impeller from seizing the shaft.
X
Lubricate the engine coupler shaft grease fitting. X
Change jet drive unit oil and discharge housingoil. X
Replace fuel filter(s). X
Check steering system and remote control forloose, missing or damaged parts. Lubricatecables and linkages.
X
Check engine to jetdrive alignment. X
Drain condensation from aftercooler. X
Check continuity circuit for loose or damagedconnections. Test MerCathode unit output, ifequipped.
X
Drain and replace stator housing lubricant. X
Touch‑up paint power package and spray withcorrosion guard. X
4Only perform maintenance that applies to yourparticular power package5Whichever Occurs First
Maintenance
Page 1B-14 90-866211 FEBRUARY 2005
ScheduledMaintenace 6(Continued)
Every 200 hours orAnnually7
Every 200 hours or 2years7
Every 300 hours or 3years7
Every 500 hours or 5years7
Every 1000 hours or5 years7
Retorque enginemounts. X
Check electricalsystem for loose,damaged orcorroded fasteners.
X
Inspect conditionand tension of belts. X
Check coolingsystem and exhaustsystem hose clampsfor tightness. Inspectboth systems fordamage or leaks.
X
Disassemble andinspect seawaterpump and replaceworn components.
X
Clean seawatersection of closedcooling system.Clean, inspect andtest pressure cap.Check anodes.
X
Replace coolant. X
Clean aftercoolercore. X
Inspect timing beltand pulleys. X
Replace timing belt. X
Check valveclearance. X
Clean fuel tank. X6Only performmaintenance whichapplies to yourparticular powerpackage7Whichever comesfirst
Maintenance
90-866211 FEBRUARY 2005 Page 1B-15
REVERSE BUCKET CABLE1. Extend the stainless rod eye of the cable and coat it with lubricant. Move it back and
forth to allow an even distribution of the lubricant.
6626
Tube Ref No. Description Where Used Part No.
95 2-4-C Marine Lubricant withTeflon Cable shafts and eyes 92-802859A1
STEERING SYSTEM1. Lubricate the steering cable.
a. If cable is equipped with a grease fitting, use the fitting and a grease gun tolubricate cable. Move it back and forth to allow an even distribution of the lubricant.
b. If cable is not equipped with a grease fitting, extend the stainless rod eye of thecable and coat the shaft with lubricant. Move it back and forth to allow an evendistribution of the lubricant.
7393
a
a - Steering cable shaft
Maintenance
Page 1B-16 90-866211 FEBRUARY 2005
2. Remove the steering rod anchor bolt from the tiller. Coat with lubricant and replace.Torque the nut.
b
7388
a - Steering rod anchor bolt
Description Nm lb. in. lb. ft.
Steering rod anchor bolt 35 26
Checking and Adding Jetdrive Lubricant1. Check the discharge nozzle lubricant periodically for contamination and fluid level.
a. Put the reverse gate in the forward position.b. Using a flat blade screwdriver, remove the top vent screw.c. Use a small screwdriver to dip into the lubricant to check it for contamination and/
or discoloration.d. If the lubricant is contaminated or discolored, the shaft sleeve, bushes and seals
must be inspected and replaced if defective. Refer to Section 3 for details.e. Lubricant is added through the top vent hole until it reaches this level and flows
out. The rear bearing requires 370ml of Premium Gear Lube.
9072
a
a - Top vent hole
Maintenance
90-866211 FEBRUARY 2005 Page 1B-17
Tube Ref No. Description Where Used Part No.
82 Premium Gear Lubricant Stator 92-802846A1
f. Inspect the condition of the vent screw washer and replace if required.g. Install the vent screw.
2. Check the gear lube monitor periodically for contamination and proper fluid level. Addlubricant if low.
Changing Jetdrive LubricantCHANGING THE GEARBOX LUBRICANT
NOTE: Trim a section of aluminium, cardboard or metal angle section to fit neatly underthe drain hole as shown. A piece of rag or sponge may be used to seal the section ifnecessary.
Maintenance
Page 1B-18 90-866211 FEBRUARY 2005
1. Remove the drain plug and drain the lubricant from the gearbox.
9075
a
b
a - Vent hole plug b - Drain plug
9076
a
b
a - Drain hole b - Angle section
2. If the lubricant is contaminated or discolored, the shaft sleeve, bushes and seals mustbe inspected and replaced if necessary. Refer to Section 3.
Maintenance
90-866211 FEBRUARY 2005 Page 1B-19
3. Install the drain plug into the gearbox housing.
9075
a
b
a - Vent hole plug b - Drain plug
NOTE: Filling completely through the gear lube monitor bottle will require the oil toprogressively drain across into the gear case cavity. To speed up this process most of theoil can be added directly into the gear case through the breather port. Ensure that thebreather is re‑installed after this process. Allow the oil to settle to its level and add anyresidual lubricant through the oil lube bottle.
Maintenance
Page 1B-20 90-866211 FEBRUARY 2005
4. Fill up the Gear case cavity with 1100 ml (1.16 quart) of Premium gear Lube until therequired level is reached on the lube monitor bottle.
9125
a
Filling through the gear case breather porta - Breather port (breather removed)
9126
b
Filling through the gear lube monitora - Gear lube reservior
Tube Ref No. Description Where Used Part No.
82 Premium Gear Lubricant Gear case cavity 92-802846A1
CHANGING THE DISCHARGE NOZZLE REAR BEARING LUBRICANT1. Put the reverse gate in the forward position.2. Elevate the front of the jetdrive unit slightly to aid with the draining.3. Insert a container under the discharge nozzle to catch the lubricant as it escapes from
the reservoir.
Maintenance
90-866211 FEBRUARY 2005 Page 1B-21
4. Remove the vent plug and the drain plug from the discharge nozzle.
9031
a
a - Drain plug
5. Drain lubricant into a suitable container and discard properly.6. If the lubricant is contaminated or discolored, the shaft sleeve, bushes and seals must
be inspected and replaced if damaged. Refer to section 3 for inspection procedures.7. Return unit to level.8. Inspect the condition of the drain plug washer and replace if required.9. Install the drain plug.
9071
a
a - Drain plug
Maintenance
Page 1B-22 90-866211 FEBRUARY 2005
10. Lubricant is added through the top vent hole until it reaches this level and subsequentlyflows out. The rear bearing requires 370 ml (12.5 oz.) of Premium Gear Lube.
9072
a
a - Top vent hole
Tube Ref No. Description Where Used Part No.
82 Premium Gear Lubricant Stator 92-802846A1
11. Inspect the condition of the vent plug washer and replace if damaged.12. Install the top vent plug.
General MaintenancePower Package Exterior Surfaces
1. Spray entire power package at recommended intervals with Corrosion Guard. Followinstructions on can for proper application.
Tube Ref No. Description Where Used Part No.
120 Corrosion Guard Painted surfaces 92-802878-55
2. Clean entire power package. External surfaces that have become bare should berepainted with Primer and Spray Paint at recommended intervals.
Description Part Number
Mercury Light Gray PrimerPainted surfaces
92‑802878 52
Mercury Phantom Black 92‑802878Q 1
Steering Nozzle and Reverse BucketLubricate cables, attaching points, and remote control with 2‑4‑C Marine Lubricant withTeflon. Inspect steering tiller, reverse bucket controls, and throttle for ease of operation.Refer to Section 3A.
Jetdrive AnodesEach jetdrive unit is equipped with sacrificial anodes to help protect underwater metal partsfrom galvanic corrosion. Because of the self sacrificing nature, anodes must be replacedif eroded 50% or more. Refer to Section 7.
Maintenance
90-866211 FEBRUARY 2005 Page 1B-23
Boat Bottom CareTo achieve maximum performance and fuel economy, the boat bottom must be kept clean.Accumulation of marine growth or other foreign matter can greatly reduce boat speed andincrease fuel consumption. To ensure best performance and efficiency, periodically cleanthe boat bottom in accordance with manufacturer's recommendations.In some areas, it may be advisable to paint the bottom to help prevent marine growth. Referto the following information for special notes about the use of anti‑fouling paints.
Jetdrive Corrosion ProtectionMercury MerCruiser and Cummins MerCruiser Diesel power packages are equipped withanodes, to help protect them from galvanic corrosion under moderate conditions. However,for severe conditions, it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System be installed. Refer to the appropriate Diesel, Mercury, orQuicksilver parts and accessory guide for part numbers.Boats which are connected to AC shore power, require additional protection to preventdestructive low voltage galvanic currents from passing through the shore power groundwire. A Quicksilver Galvanic Isolator can be installed to block the passage of these currentswhile still providing a path to ground for dangerous fault (shock) currents. Refer to theappropriate Diesel, MerCruiser, or Quicksilver parts and accessory guide for part number.IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode Systemand anodes may be unable to handle the increased galvanic corrosion potential.
ANTIFOULING PAINTIMPORTANT: Corrosion damage that results from the improper application of anti‑foulingpaint will not be covered by the limited warranty.Painting Boat Hull or Boat Transom: Antifouling paint may be applied to boat hull and boattransom but you must observe the following precautions:IMPORTANT: Do not paint anodes or MerCathode system reference electrode and anode,as this will render them ineffective as galvanic corrosion inhibitors.
Maintenance
Page 1B-24 90-866211 FEBRUARY 2005
IMPORTANT: If anti‑fouling protection is required for boat hull or boat transom, copper ortin base paints, if not prohibited by law, can be used. If using copper or tin based anti‑foulingpaints, observe the following:• Avoid an electrical interconnection between the Cummins MerCruiser Diesel Product,
anodic blocks, or MerCathode system and the paint by allowing a minimum of 40 mm(1‑1/2 in.) UNPAINTED area on transom of the boat around these items.
7192
a b
a - Painted boat transom b - Minimum 40 mm (1‑1/2 in.)UNPAINTED area around transomassembly
NOTE: The jetdrive assembly can be painted with a good quality marine paint or ananti‑fouling paint that does not contain copper or any other material that could conductelectrical current. Do not paint drain holes, anodes, MerCathode system, and itemsspecified by boat manufacturer.
Gear Box BreatherIn the event that gear lube starts to leak from the breather, verify that the gear case is notoverfilled, then replace the breather.1. Secure the gear box breather shaft and remove the gear box breather by turning
counterclockwise.
Maintenance
90-866211 FEBRUARY 2005 Page 1B-25
2. Replace the gear box breather by tuning it clockwise until tight.
10630
a
a - Gear box breather
Cleaning and Inspecting the ImpellerPerform this procedure in the event of a loss of power due to debris getting caught in theimpeller, to inspect the impeller for damage or debris, or to clean the impeller of debris. Donot open the inspection cover with the engine running.Perform inspection or maintenance as necessary.
! WARNINGAvoid injury: A rotating impeller, especially when driven by an operating engine, cancause injury. Prior to opening the inspection port, ensure that the engine is off, the lanyardswitch, if equipped, is in the off position, and the ignition switch is in the off position withthe key removed from the switch.
Maintenance
Page 1B-26 90-866211 FEBRUARY 2005
Access to the front of the impeller can be gained through the inspection port, located onthe top of the jetdrive,
9337
b
a
b
c
a - Inspection port coverb - Bolt
c - Safety lever
! WARNINGTo prevent accidental engine starting, remove battery cables from battery beforeremoving or installing gear housing.
1. Disconnect the negative battery cable and ensure that the engine is off, the lanyardswitch, if equipped, is in the off position, and the ignition switch is in the off position withthe key removed from the switch.
2. Loosen, but do not remove, the bolts securing inspection port cover to the jetdrivehousing.
a
a
9339
a - Bolt
Maintenance
90-866211 FEBRUARY 2005 Page 1B-27
3. Pull the safety lever back.
9340
1
4. While holding the safety lever back, turn the inspection port cover counterclockwiseuntil the flanges of the cover are out from under the securing bolts.
9341
2
Maintenance
Page 1B-28 90-866211 FEBRUARY 2005
5. Lift the cover from the jet housing. Do not damage the seals.
9342
6. Inspect the impeller and clean as necessary.7. Place the inspection port cover in inspection port, carefully pushing all the way down.
Do not damage the seals.8. With the safety lever pulled back, turn the cover clockwise until the flanges are under
the bolts, and the cover is fully seated.
9345
Maintenance
90-866211 FEBRUARY 2005 Page 1B-29
9. Release the safety lever. Adjust the inspection port cover until the safety lever locksinto the jet housing hole.
9346
10. Torque the bolts.
a
a
9339
Description Nm lb. in. lb. ft.
Inspection cover bolts 27 20
11. Reconnect the battery.
Power Package Extended Storage and RecommissioningPower Package Extended StorageENGINE
Refer to appropriate Mercruy MerCruiser or Cummins MerCruiser Diesel Engine ServiceManual for cold weather (freezing temperature), seasonal, or extended storageprocedures.
JETDRIVE1. Lubricate the steering system. Refer to Section 1B or 6A.
Maintenance
Page 1B-30 90-866211 FEBRUARY 2005
2. Lubricate reverse bucket cables and attachment points. See Section 3A3. Check engine alignment. Refer to appropriate procedures in Section 2A, depending on
engine.4. Change jetdrive unit oil. Refer to Section 1B.5. Inspect jetdrive for damage. Repair or replace damaged components.6. Lubricate jetdrive unit coupler splines. Refer to Section 3A.
Tube Ref No. Description Where Used Part No.
91 Engine Coupler Spline Grease Jetdrive unit coupler 92-802869A1
7. Clean jetdrive exterior surfaces and repaint any bare metal surfaces with QuicksilverPrimer and Spray Paint. Refer to Section 1B.
Description Where Used Part Number
Mercury Light Gray PrimerPainted Surface
92‑802878 52
Mercury Phantom Black 92‑802878Q 1
8. After paint has dried, spray entire jetdrive with Quicksilver Corrosion Guard.9. Ensure that impeller area is clear of debris. Refer to Section 1B.10. Store battery. Refer to battery manufacturer's instructions.
Power Package RecommissioningENGINE
Refer to appropriate Engine Service Manual for appropriate recommissioning procedure.JETDRIVE
1. Perform ALL maintenance specified for completion "Annually" in "Maintenance Chart"except items which were performed at the time of jetdrive storage..
2. Install fully‑charged battery.
! CAUTIONWhen installing battery, connect the positive (+) battery cable to the positive (+) batteryterminal first, and the negative (‑) battery cable to the negative (‑) battery terminal last.If battery cables are reversed, or connection order is reversed, electrical system damagewill result.
3. Clean battery cable clamps and terminals.4. Reconnect battery cables. Be sure to tighten clamps securely.5. Apply a thin coat of petroleum based grease to clamps and terminals to help retard
corrosion.6. After recommissioning and starting engine, check steering system and shift control for
