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2002 Optimax 200 spark plug gap

P

Pullin Skirts

New member
Hello all,

Recently got a new (to me) boat with twin Merc Opti 200s (2002) and also ordered an optimax service manual so I could maintain it. The problem I found was that the service manual covers years 2000, 2001. When looking at plug info, each year has a different plug and different gaps, .040 on the 2000 and .043 on the 2001. My 02s have different plugs than the 00, and 01 also.
My question is, is there that much of a difference in the plugs and what is the gap for the 02? Also will the 2000, 2001 manual work for everything else like water pump and things like that on the 02 models.

Mike
 
For that model I'm showing an NGK PZFR5F-11 gapped at .040 as the correct plug (which also superseded the earlier Champion plugs), but there is a Merc Service bulletin out recommending that owners run Iridium plugs (NGK IZFR5-11's - expensive).

And yes, sometimes it matters quite a bit which sparkplug you run and how it's gapped.

With plugs it's mostly about the resistance of the individual plugs. In general, Champions work best with lower power coils (most OMC products) and NGK (or Autolites in the old days) work better in higher power coils (Merc/Yamaha).

The ignitions on the Opti's make the engine computer in your car look like something from the stone age. They have tweaked every last bit of performance out of them and they did go through a few changes in the early years of production (I believe that the engine computers on these are made by Motorolla), so it's best to check with a Merc dealer (or email Merc directly - even better - go to their website under tech support and you will get an answer in less than 48 hours in most cases) for the most "up to date" recommendation.

As to whether the manual is still valid - I would say "mostly" - as I noted, there was some changes and modifications in the early years. They partially re-designed the cooling system as well as changing some other minor components (new "hi-tech" gadgets always have bugs and the Opti's were not immune). But I suspect that most things you could "fix in the driveway" on these, would have remained pretty much the same..
 
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