(¢3|MARINER {OUTBOARDS \ a a OUTBOARDS SERVICE MANUAL MODELS 70 #75 80° 90 + 100° 115 1987-1993 70 + 75 ©75 Marathon + ‘75XD © 75 Seapro « 80 90 (3 Cylinder) with Serial Numbers UNITED STATES S/N 0A996142 thru 00283221 BELGIUM SIN 09502135 thru 09793576 | BELGIUM CANADA ‘SIN 08722297 and Above | CANADA 1988-1993 100 + 115 (4 Cylinder) with Serial Numbers UNITED STATES S/N 08209468 thru 00283221 SIN 09523034 thru 09793576 SIN 0A731673 and Above Protod USA. 995, Brunewi Corporation 90-13645-2 1095Notice Throughout this publication, “Dangers", “Warnings” and “Cautions” (outlined in a border and accompa- nied by the International HAZARD Symbol AM ) are usedto alert the mechanicto special instructions con ceming a particular service or operation that may be hazardous it performed incorrectly or carelessly OBSERVE THEM CAREFULLY! These "Safety Alerts’ alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “common sense” operation, are major accident prevention measures. Pa DANGER — Immediate hazards which WILL result severe personal injury or death. WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death. A CAUTION CAUTION — Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the service department of Mercury Marine to aid our dealers’ mechanics and company service person- nel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mer- cury Marine, that they have been trained in the recom- mended servicing procedures of these products which includes the use of mechanic's common hand tools and the special Mercury Marine or recom- mended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a ser- vice might be performed and of the possible hazards and/or results of each method, We have not under- taken any such wide evaluation. Therefore, anyone who uses a service procedure andior 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 service procedure selected, All information, illustrations and specifications con- tained in this manual are based on the latest product information available at the time of publication. As re- quired, revisions to this manual will be sentto all deal- ers contracted by us to sell and/or service these prod- ucts. It should be kept in mind, while working on the product, that the electrical system and ignition system is capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables shouldbe disconnectedat the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive inter- ‘nal damage when the engine is started Itis important to note that, during any maintenance procedure, replacement fasteners must have the same measurements and strength as those re moved, whether metric or customary. Numbers on the heads of the metric bolts and on surfaces of metric nuts indicate their strength. Customary bolts use ra dial lines for this purpose, while most customary nuts do not have strength markings. Mismatched or incor- rect fasteners can result in damage or malfunction, or possible personal injury. Therefore, fasteners re- moved should be saved for re-use in the same loca- tions whenever possible. Where the fasteners are not satisfactory for re-use care should be taken to select a replacement that matches the original.Cleanliness and Care of Outboard Motor ‘A marine power product is a combination of many ma chined, honed, polished and lapped surfaces with tol- erances that are measured in the ten thousands of an Inch. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is consid- ered standard shop practice even if not specifically stated Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed, Bofore raising or removing an outboard engine from a boat, the following precautions shouldbe adhered to: 1. Chock that fiywheel is secured to ond of crankshaft with a locknut and lifting eye is threaded into flywheel a minimum of 5 turns. 2. Connect a hoist of suitable strength to the lifting eye. In addition, personnel should not work on or under an engine which is suspended. Engines should be at- tached to work stands, or lowered to ground as soon as possible We reserve the right to make changes to this manual without prior notification, Refer to dealer service bulletins for other pertinent in- formation conceming the products described in this manual, Service Manual Outline 1 General Information and Specifications 2 Electrical and ignition A = Ignition System B - _ Battery, Charging System and Starting System © - Timing/Synchronizing and Adjusting D - Wiring Diagrams 3A - Fuel System and Carburetion B - Oilinjection System 4 A. ~ Powernead (3-Cylinder Engines) B= Powerhead (4-Cylinder Engines) 5 = Lower Unit A - Gear Housing B - Mid Section © - Shock Absorter 6 = Power Trim A ~ Design | (Side Fill Reservoir) B - Design It (Aft Fill Reservoir) © Single Ram Outboard Motor Installation/Attachments A ~ Engine Attachments/Engine Installation B - Tiller Handle and Co-PilotGENERAL INFORMATION AND SPECIFICATIONSTable Of Contents General Specification Cow! Removal . Filling Oil Injection System Power Trim General Information . Trim “in” Angle Adjustment . Models with Power Trim Checking Trim System Fluid Level Tilt Angle Adjustment Models without Power Trim Connecting Engine Wiring Harness and Routing of Engine Battery Cables Ride-Guide Steering Cable and Pivot Points Lubrication . z 16 17 Following Complete Submersion Salt Water Submersion (Special Instructions) ‘Submerged While Running (Special Instructions) Submerged Engine (Fresh Water) (Plus Specia! Instructions) ut-of-Season Outboard Storage How Weather Affects Engine Performance Conditions Affecting Operation Detonation: Causes and Prevention Compression Check 18 19 1-10 a) 112 442 90-13645-2 495,General Specification NOTE: Other specification (torques, etc.) are listed in the respective sections. Model 70 Model 75 Model 80 Model 90 Horsepower 70 (e22kw) | 75(659kw) | 80(69.6kw) | 90 (67.1 kw) Tale RPM (in forward gear) 650 - 700 Full Throttle RPM Range 4750 - 5250 ‘5000 - 5500 Piston Replacement 71.12 (1165.760) Oylinder Bore 3.375 (@5.7mm) Stroke 2.65 (7.8mm) Engine Type 3 Oylinder, 2 Cycle Tgnition Type C.D. Breakerless Recommended Spark Plug NGK BUEW2 of Va FFK or Inductor Fuge NGK BUZAW. Zor (Cylinder Firing Order 132 ‘Quicksiver Power Trim & Steering Fluid or Automotive Transmission Recommended Power Trim Fiuid Fluid (ATF) Type F. FA or Dexron Il Regular Leaded, Premium, Low-Lead and Lead Free automotive gaso- Recommended Gasoline lines with a minimum pump posted octane rating of 86 Recommended Oil Quicksilver TC-WIl or TC-WS 2-Cycle Outboard Oi Engine Weight ELO 260 bs, ELOPT 280 Ibs, 66 US. Galions Fuol Tank Capacity (Imp. Gals.; 25 Liters) (Gear Housing Lubricant Capacity 22.5 ft oz. (665.3ml) Gasoline/Oil Ratio at idle 80: (Gasoline/Oil Ratio at W.O.T. 501 ‘Gear Ratio 23:1 (Oil Injection Tank Capacity Tank Capacity 1 gal. (8.78 liter) Maximum operation per tank full of oll at W.0.T. Oil remaining when warning buzzer sounds Operating time remaining at wide open throttle when warn- 4 Hour ing buzzer sounds 6 hours 1 qt. (95 liter) 90-13645-2 1095, GENERAL INFORMATION AND SPECIFICATIONS. roGeneral Specification (continued) NOTE: Other specification (torques, etc.) are listed in the respective sections. Model 100 Model 115 Horsepower 100 (74.6 kw) 175 (858 kw) Tale RPM (in forward gear) 650-700 Full Throttle RPM Range “4750 - 5250 Piston Replacement 105 (1720.8¢0) Cylinder Bore 3.375 (657mm) troke 2.980 (744mm) Engine Type 4 Oyiinder, 2 Cycle Ignition Type CD. Breakerless Recommended Spark Plug NGK-BPH8H-N-10" Gap - 0.040 in. (10mm) Inductor Plug NGK BPZ 8H-N-10* Gap - 0.040 in. (1.0mm) NGK-BUHW Gylinder Firing Order 1324 Recommended Power Trim Fluid Quicksilver Power Trim & Steering Fluid or Automotive Transmission Fluid (ATF) Type F, FA or Dexron Il Recommended Gasoline Regular Leaded, Premium, Low-Lead and Lead Free automotive gaso- lines with a minimum pump posted octane rating of 86 Recommended Oi ‘Quicksilver 2-Cycle Outboard Oi Fuel Tank Capacity Engine Weight ELO 340 ibs, ELOPT 360 Ibs, 66 U.S. Gallons (6 Imp. Gals.; 25 Liters) Gear Housing Lubricant Capacity 225 fi, o2, (665.2mi) Gasoline/Oil Ratio at Idle 80:1 Gasoine/Oil Ratio at W.0.T. 501 Gear Ratio 2.074 Oil Injection Tank Capacity Tank Capacity 1.4 gal. (6.3 liters) Maximum operation per tank full of oil at W.0.T. S hours Oil remaining when warning) ~ > buzzer sounds 1 qt. (.95 liter) Operating time remaining at wide open throttle wnen warn- ing buzzer sounds 50 min. approx. “Improves running quality between 1800 ~ 2000 RPM. 12 GENERAL INFORMATION AND SPECIFICATIONS. 90-13645-2 1095ey Cowl Removal Filling Oil Injection System Pull outward on starboard side af front shield (a). Open starboard cowl (refer to cowl removal on this page). Some earlier outboards will have a cow! brack- et to hold cow! open as shown, Fill tank with recommended oil Remove spring (b) from latch and open cowls. 18291 8-1 Tank Tube seos2 90-13645-2 495 GENERAL INFORMATION AND SPECIFICATIONS. 13Power Trim System GENERAL INFORMATION The power trim system is filled at the manufacturer and is ready for use. Trim outboard through entire trailering range several times to remove any air from the system. The trim system is pressurized and is not externally vented. The outboard can be raised or lowered manu- ally by loosening the manual release valve four turns. The trim “out” angle of this outboard is not adjustable. The trim system has an internal valve which will automatically stop the outward trim travel at 20° when engine RPM is approximately 2000 RPM or higher: outboard also has to be in water and in gear. ‘The outboard can be operated beyond the 20° trim imit for operating outboard in shallow water if engine RPM is kept below approximately 2000 RPM. 2 Fill Sorew (System is Pressurized, OO NOT Open Unies Outboard is Tited to Full Up Position) b- Manual Release Valve 14 GENERAL INFORMATION AND SPECIFICATIONS. ry Trim “In” Angle Adjustment MODELS WITH POWER TRIM Operating some boats with outboard trimmed to the full “in” trim angle [not using trim adjustment bolt (a)] at planing speed will cause undesirable and/or unsafe steering conditions. Each boat MUST BE water tested for handling characteristics after outboard installation and after any trim adjust- ments. IMPORTANT: Some boatmotor combinations, that do notuse the trim adjustment bolt (a) and are trimmed to the full “in” trim angle, will not experi ence any undesirable andior unsafe steering conditions during planing speed. Thus, not using trim adjustment bolt may be desired. However, ‘some boats with outboard trimmed to the full “in” trim angle at planing speeds will cause undesir- able andior unsafe steering conditions. If these steering conditions are experienced, under no circumstances should the outboard be operated without the trim adjustment bolt and without the bolt adjusted in the proper holes to prevent un- safe handling characteristics. Water test the boat not using the trim adjustment bolt. If undesirable and/or unsafe steering conditions are experienced (boat runs with nose down), install trim adjustment bolt in proper hole to prevent unsafe han- ding characteristics. zane 90-13645-2 495ey Checking Trim System Fluid Level IMPORTANT: This trim system is pressurized. Remove fill screw (b) when outboard is trimmed to the full “up” position. Retighten fill screw securely. 1. Trim outboard to full up” position. Engage tilt lock lever. Trim system fluid can only be checked when ‘outboard is in this position, 2. Remove fill scrow and check fluid level. Fiuid level should be visibie in fill tube. 3. It necessary, add Quicksilver Power Trim and ‘Steoring Fluid; or Automatic Transmission Fluid (ATF) Type F, FA or Dextron IL 20319 = Ti Lock Lever b= Fil Secow 90-13645-2 495 GENERAL INFORMATION AND SPECIFICATIONS. Tilt Angle Adjustment MODELS WITHOUT POWER TRIM Operating some boats at minimum trim “In” at planing speeds will cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle. DO NOT OPERATE motor with tlt lock pin removed, Adjust tlt angle of motor on transom with tit lock pin so that ant-ventilation plate is about parallel and even with bottom of boat. Speed sometimes may be im proved by titing motor outone tilt pin hole to raise bow and reduce wetted surface. If motor is tilted in, boat will ride bow down, wetting more of the bottom and re- ducing speed, which generally will improve operation in rough water. Under ideal conditions, efficiency is best with lower unit operating in level position. Opera- tion with excessive tit angle will reduce performance noticeably and may induce ventilation. itis preferable to level boat by proper loading rather than by extreme agjustment of tilt angle. 2074s Tit Lock Pin 18Connecting Engine Wiring Harness and Routing of Engine Battery Cables Cables passing through cow! must be protected from chafing or being cut, by using the neoprene sheet as described in the following steps. Failure to protect cables as described could result in electrical system failure and/or possible injury to ‘occupants of boat. Models without Power Trim a Wiring Hames b- Neoprene Shee - Sta-Straps 16 GENERAL INFORMATION AND SPECIFICATIONS. 1. Plug remote control hamess connector into en: gine harness connector, then secure connector in place with retainer as shown. 2. Wrap neoprene sheet around cable bundle and secure each end with a sta-strap. Secure bracket with retainer. IMPORTANT: On Models without Power Trim, the neoprene sheet must be folded once and then wrapped around cables as shown. 12 -Engine Connector b-Retaner ¢- Hamess Connector t d- Hames Retainer ‘@- Neoprene Sheet Sta Stao(s) Models with Power Trim 90-13645-2 495Lubrication Points Lubricant Used or No.| Description Maintenance _| Fresh Water Frequency | Salt Water Frequency 1 | Ride-Guide Steering Cable 2 | Throttie-Shitt Linkage Quicksilver [Upper Shit Shai 2-40 Every 60 Days Every 30 Days wiTetion 2 [Tit Tube 3 | Swivel Pin 6 [Tit Look Lever uicksWver Propeller Shaft C wiTefion Once in Season Every 60 Days Ant-Corrasion Grease Check and fil afer 1st 10 days, then every 30 days 8 |Gear Housing Quicksilver Gear Lube | Drain and Refi ater 1st 25 hours, then after every 100 hours, or ance a year belore storing ‘Steering Link Rod 9 [Steering Lin SAE 80W Engine Oil Every 60 Days, Every 30 Days Power trim Pump | Quicksiver Power Tam | Every 100 hours . 10 JoitLevet and Steering Fluid aronce in season _| Same as Fresh Wate = [Engine Crankshaft a . uioksiver Spines to Drive 2c er ‘nee in Season by Dealer Shaft Splines Accelerator Pump ‘Quicksiver 24-6 * | Stem/Tnrottie Cam wiTeflon Once in Season Every 60 Days 90-13645-2 495 Ride-Guide Steering Cable and Pivot Points Lubrication Core of steering cable (transom end) must be fully retracted into cable housing before lubricating cable. If cable is lubricated while extended, hydraulic lock of cable could occur. With core of Ride-Guide Steering cable (transom end) fully retracted, lubricate transom end of steering cable thru grease fitting and exposed portion of cable 27068 J end with Quicksivver 2-4-C w/Teflon. Lubricate all piv- ot points with SAE 30W engine cil 2asi9 GENERAL INFORMATION AND SPECIFICATIONS. 17NOTE:4 CYL. MODELS Following Complete Submersion ‘Submerged engine treatment is divided into 3 distinct problem areas. The most critical is submersion in salt water; the second is submersion while running Salt Water Submersion (Special Instructions) Due to the corrosive effect of salt water an internal en: gine components, complete disassembly is neces- sary before any attempt is made to start the engine, Submerged While Running (Special Instructions) When an engine is submerged while running, the possibilty of internal engine damage is greatly in- creased. If, after engine is recovered and with spark 11 — Lubsicaton Points for Accelerator Pump Camon4 Cynder J PUgS removed, engine fails to tum over freely when Models Only turning flywheel, the possibility of internal damage {bent connecting rod andior bent crankshaft) exsts. If this is the case, the powerhead must be disas- sembled ‘Submerged Engine (Fresh Water) (Plus Special Instructions) 1, Recover engine as quickly as possible. 2. Remove cowling. 3. Flush outside of engine with fresh water to re- move mud, weeds. etc. DO NOT attempt to start engine it sand has entered powerhead, as power- head will be severely damaged. Disassemble powerhead if necessary to clean components 4, Remove spark plugs and get as much water as Possible out of powernead. Most water can be eliminated by placing engine in a horizontal posi- tion (with spark plug holes down) and rotating fiy- wheel 5. Pour alcohol into carburetor throat (alcohol will absorb water). Again rotate flywheel 6. Tum engine over and pour alcohol into spark plug ‘openings and again rotate fywnee! Tum engine over (place spark plug opening down) and pour engine oil into throat of carbure- tors while rotating fiywneel to distribute oil throughout crankcase. 2 Lubrication Points are ingcated wih Arrows 8. Again turn engine over and pour approximately ‘one teaspoon of engine oil into each spark plug ‘opening. Again rotate flywheel to distribute oil in cylinders. 9. Remove and clean carburetors and fuel pump assembly. 18 GENERAL INFORMATION AND SPECIFICATIONS. 90-13645-2 49510. Reinstall spark plugs, carburetors and fuel pump. 11. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for at least one hour to eliminate any water in engine. 12. engine fails to start, determine cause (fuel, elec: trical or mechanical). DO NOT allow engine to re- main idle for more than 2 hours, as serious inter- nal damage will occur. if unable to start engine in this period, disassemble engine and clean all parts and apply oil as soon as possible. Out-of-Season Outboard Storage As a safety precaution, when boat is in storage, remove positive (+) battery cable. This will eliminate possibility of accidental starting of engine and resultant overheating and damage to engine from lack of water. In preparing an outboard for out-of-season storage, 2 precautions must be considered: 1) The engine must be protected from physical damage and 2) the engine must be protected from rust, corrosion and dirt. 4. Remove cowling from engine. 2. Place outboard in water or install Quicksilver Flushing Attachment over water intake by follow- ing instructions outlined in “Flushing Cooling Sys- tem” (see “Table of Contents’) 3. Start engine and allow to warm up. Disconnect fuel line. When engine starts to stall quickly spray Quicksilver Storage Seal into each carburetor throat. Continue to spray until engine dies from lack of fuel. 4. Remove spark plugs and inject a 5 second spray Of Quicksiiver Storage Seal around the inside of each cylinder. Manually turn engine over several times to distribute Storage Seal throughout cylin- ders. Reinstall spark plugs. 5. If engine fuel fiter appears to be contaminated, re- move and replace. Refer to Section 3 "Fuel System and Carburetion.” 90-13645-2 495 Drain and refill lower unit with Quicksilver Gear Lube, as explained in "Gear Housing Lubrication’ (see “Table of Contents’) 7. Clean outboard thoroughly. including all accessi- ble powerhead parts, and spray with Corrosion and Rust Preventive, 8. Refer to lubrication chart in this section (see “Table of Contents") and lubricate all lubrication points. 9. Remove propeller. Apply Quicksilver Anti-Corrosion Grease or 2-4-C wiTetion to propeller shaft and re- instal propelier. Refer to *Propeler Installation” (see “Table of Contents”) 10. If the water pickup is clogged, the speedometer will be inoperative. Clean the pickup with a piece of wire or biow out with compressed air. Before blowing out with air, disconnect the tubing from the speedometer. 11. To prevent freeze damage, drain the speedome- ter system of water completely before storage Remove tubing from speedometer fitting and blow thru the tubing to remove water. 12, Store battery as outlined in “Out-of-Season Bat- tery Storage,” following, 18.For out-of-season storage information on Autoblend units, refer to Section & in this service manual. IMPORTANT: When storing outboard for the win- ter, be sure that all water drain holes in gear hous ing are open and free so that all water will drain out. If a speedometer is installed in the boat, di connect the pickup tube and allow it to drain. Re- connect the tube after draining. Trapped water may freeze and expand, thus cracking gear hous- ing andior water pump housing. Check and refill gear housing with Quicksilver Gear Lube before storage to protect against possible water leakage into gear housing which is caused by loose lubri- cant vent plug oF loose grease fill plug. Inspect gaskets under lubricant vent and fill plugs, re- placing any damaged gaskets, before reinstalling plugs. GENERAL INFORMATION AND SPECIFICATIONS. 19Out-of-Season Battery Storage 1. Remove battery as soon as possible and remove all grease, sulfate and dirt from top surface. 2. Cover PLATES with distilled water, but not over 3116 in. (5mm) above perforated baftes. Cover terminal bolts well wth grease. Store battery in a COOL, DRY place in a dry car- ton or box. 5. Remove battery from storage every 60 days. Check water level and place on charge for 5 to 6 hours at 6 amperes. DO NOT fast charge. A CAUTION Adischarged battery can be damaged by freezing. How Weather Affects Engine Performance Tater Itis a known fact that weather conditions exert a pro: found effect on power output of internal combustion engines. Therefore, established horsepower ratings refer to the power that the engine will produce at its rated RPM under a specific combination of weather conditions. 110 GENERAL INFORMATION AND SPECIFICATIONS. Corporations internationally have settled on adoption of 1.3.0. (Intemational Standards Organization) engine test standards, as set forth in 1.8.0. 3048 standardizing the computation of horsepower from data obtained on the dynamometer, correcting all values to the power that the engine will produce at sea level, at 30% relative humidity at 77° F (25° C) temperature and a barometric pressure of 29.61 inches of mercury. ‘Summer Conditions of high temperature, low baro- metric pressure and high humidity all combine to re- duce the engine power. This, in turn, is reflected in de- creased boat speeds~-as much as 2 or 3 miles-per: hour (3 or § Km per-hour) in some cases. (Refer to previous chart.) Nothing will regain this speed for the boater, but the coming of cool, dry weather. In pointing out the practical consequences of weather effects, an engine-running on a hot, humid summer day--may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk spring or fall day. The horsepower, that any internal combus- tion engine produces, depends upon the density of the air that it consumes and, in turn, this density is de- pendent upon the temperature of the air, its baromet- rig pressure and water vapor (or humidity) content. ‘Accompanying this weather-inspired loss of power is ‘a second but more subtle loss. At rigging time in early spring, the engine was equipped with a propeller that allowed the engine to turn within its recommended RPM range at full throttle, With the coming of the sum- mer weather and the consequent drop in available horsepower, this propeller wil, in effect, become too large. Consequently, the engine operates at less than its recommended RPM. Due to the horsepower/RPM characteristics of an en- gine, this willresultin further loss of horsepower at the propeller with another decrease in boat speed, This secondary joss, however, can be regained by switch- ing to a smaller pitch propeller that allows the engine to again run at recommended RPM. 90-13645-2 495For boaters to realize optimum engine performance under changing weather conditions, itis essential that the engine have the proper propeller to allow it to op- erate at or near the top end of the recommended max- imum RPM range at wide-open-throttle with a normal boat load, Not only does this allow the engine to develop full power, but equally importants the fac that he engine also will be operating in an RPM range that discour- ages damaging detonation. This, of course, en hanees overall lability and durabilty ofthe engine. Conditions Affecting Operation 1. Proper positioning of the weight inside the boat (persons and gear) has a significant effect on the boat's performance, for example a. Shifting weight to the rear (stern) (1.) Generally increases top speed. (2) If in excess, can cause the boat to por- poise. (3) Can make the bow bounce excessively in choppy water. (4) Will increase the danger of the following - wave splashing into the boat when coming off plane. b. Shifting weight to the front (bow) (1.) Improves ease of planing off (2) Generally improves rough water ride. 90-13645-2 495 (3) If excessive, can make the boat voor left and right (bow steer) Boat Bottom: For maximum speed, a boat bot- tom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore-and-aft direction. a. Hook: Exists when bottom is concave in fore- and-ait direction when viewed from the side. When boat is planing, "hook" causes more lift on botiom near transom and allows bow to drop, thus greatly increasing wetted surface and reducing boat speed. “Hook” frequently is. caused by supporting boat too far ahead of transom while hauling on a trailer or during stor- age. b. Rocker: The reverse of hook and much less common. “Rocker” ex'sts if bottom is convex in fore-and-aft direction when viewed from the side, and boat has strong tendency to porpoise. ©. Surface Roughness: Moss, barnacles, etc. on boat or corrosion of outboard's gear housing increase skin friction and cause speed loss. Clean surfaces when necessary. Gear Housing: If unit is lettin the water, marine vegetation may accumulate over a period of time in certain types of water. This growth must be re- moved from unit before operation, as it may clog the water inlet holes in the gear housing and cause the engine to overheat GENERAL INFORMATION AND SPECIFICATIONS. anDetonation: Causes and Prevention Detonation in a 2-cycle engine somewhat resembles the “pinging” heard in an automobile engine. Itcan be otherwise described as a tin-like “rattling” or “plinking” sound. Detonation generally is thought of as spontaneous ig nition, but itis best described as a noisy explosion in an unburned portion of the fuel/air charge after the spark plug has fired. Detonation creates severe, un timely, shock waves in the engine, and these shock waves offen find or create a weakness: The dome of a piston, piston rings or piston ring lands, piston pin and roller bearings. While there are many causes for detonation in a 2-cycle engine, emphasis is placed on those causes which are most common in marine 2-cycle applica- tion. A few, which are not commonly understood, are: 1. Over-advanced ignition timing 2. Use of low octane gasoline, 3. Propeller pitch too high (engine RPM below rec- ‘ommended maximum range}. Lean fuel mixture at or near wide-open-throttl. Spark plugs (heat range too hot — incorrect reach = cross-fring). 6. Inadequate engine cooling (deteriorated cooling system). 7. Combustion chamberipiston deposits (result in higher compression ratio) Detonation usually can be prevented, provided that 1) the engine is correctly set up and2) diligent mainte- nance is applied to combat the detonation causes, isted, preceding. 5int5 Damaged Piston Resulting from Detonation 112 GENERAL INFORMATION AND SPECIFICATIONS. Compression Check 1 Remove spark plugs. Install compression gauge in spark plug hole. Hold throttle plates at W.0.T. Crank engine thru at least 4 compression strokes to obtain highest possible reading, Check and record compression of each cylinder. Variation of more than 15 psi (103.5 kPa) between cylinders indicates that lower compression cylin- der is in some way defective, such as worn or sticking piston rings andlor scored piston and cyl- inder. Compression check is important because an en- gine with low or uneven compression cannot be tuned successiully to give peak performance. Itis essential, therefore, that improper compression be corrected before proceeding with an engine tune-up. Cylinder scoring: if powerhead shows any indica- tion of overheating, such as discolored or ‘scorched paint, visually inspect cylinders for scor- ing or other damage as outlined in Section 4 “Powerhead. 90-13645-2 495ELECTRICAL AND IGNITIONTable Of Contents Description Test Procedures Direct Voltage Adapter (DVA) Tests Troubleshooting Tips Test Sequence . Ignition System Test Chart Stator Test 9/18/24 Ampere Stators Ignition Coil Test Trigger Test Ignition (Key) Switch Test Commander 2000 Key Switch Commander Key Switch Ignition Components Removal and Installation Flywheel Removal Installation (or Removal . Installation Trigger Removal . Installation Igniton Coils (3 Cylinder Models) Ignition Coils (4 Cylinder Models) Switch Box 90-13645~2 Page 206 2A6 206 206 2a7 207 2A7 2A8 28 2A8 209 2A.9 2A-10 1095Table Of Contents Description Test Procedures Direct Voltage Adapter (DVA) Tests Troubleshooting Tips Test Sequence . Ignition System Test Chart Stator Test 9/18/24 Ampere Stators Ignition Coil Test Trigger Test Ignition (Key) Switch Test Commander 2000 Key Switch Commander Key Switch Ignition Components Removal and Installation Flywheel Removal Installation (or Removal . Installation Trigger Removal . Installation Igniton Coils (3 Cylinder Models) Ignition Coils (4 Cylinder Models) Switch Box 90-13645~2 Page 206 2A6 206 206 2a7 207 2A7 2A8 28 2A8 209 2A.9 2A-10 1095Description The outboard ignition system is alternator-driven with istributor-less capacitor discharge. Major compo- rents of the ignition system are the flywheel, stator, trigger. switch box, ignition coils and spark plugs. The stator assembly is mounted stationary below the flywheel and has 2 capacitor charging coils. The flywheel is fitted with permanent magnets inside the outer rim. As the flywhee! rotates the permanent magnets pass the capacitor charging coils. This causes the capacitor charging coils to produce AC votage. The AC voltage then is conducted to the switch box where it is rectified and stored in a capacitor. The ‘rigger assembly (also mounted under the flywheel) has 3 coils. The flywheel has a second set of permanent magnets (located around the center hub). As the flywheel rotates the second set of magnets pass the trigger coils. This causes the trigger coils to produce an AC voltage that is conducted to an electric Silicon Controlled Rectifier (SCR) in the switch box. The switch discharges the capacitor voltage into the ignition coil at the correct time and fring order sequence. Capacitor voltage is conducted to the primary side of the ignition coil. The ignition coil multiplies this voltage high enough to jump the gap at the spark plug, The preceding sequence occurs once:per-engine- revolution for each cylinder Spark timing is changed (advancediretarded) by rotating the trigger assembly which changes each trigger coil position in relation to the permanent magnets on the flywheel center hub. IMPORTANT: If the engine misfires, runs rough or does not start, the ignition system should be checked using a Multi-Meter/DVA Tester (91-99750), or a voltmeter (capable of measuring 400 volts DG, or higher) and Direct Voltage Adap- tor (91-89048). 90-13645-2 1095, Test Procedures Direct Voltage Adapter (DVA) Tests DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components andior metal test probes while engine is running andior being “cranked.” STAY CLEAR OF SPARK PLUG LEADS. To assure personal safely, each individual spark plug lead should be grounded to engine, A CAUTION To protect against meter andior component damage, observe the following precautions: ‘+ 400 VDC* test position (or higher) MUST BE used for all tests. + INSURE the Positive (+) lead/terminal of DVA is. e (+) receptacle of + DO NOT CHANGE meter selector switch “cranked.” + Switch box MUST BE GROUNDED during tests. Running or “cranking” engine with switch box ungrounded may damage switch box. * Musing ameter with builtin DVA, the OVA400 VOC testposi ‘von should be used. ‘NOTE: Test leads are not supplied with the DVA. Use test leads supplied with meter. Test procedures and specifications are provided for checking primary ignition voltage while the engine is running andior being “cranked.” ‘TROUBLESHOOTING TIPS: 4. Intermittent, weak, or no spark output at two spark plugs usually indicates a bad TRIGGER. 2. Intermittent, weak, or no spark output at all three ‘spark plugs usually indicates a bad STATOR or ‘SWITCH BOX. 3. Intermittent. weak. or no spark at any one spark plug usually indicates a bad SPARK PLUG, COIL, or SWITCH BOX. ELECTRICAL AND IGNITION 2aTest Sequence 1-A) Check primary input voltage to coils. (See Test Chart), 1. If voltage readings to coil(s) are BELOW specifi- cation, proceed with Step 2-A. 2. If voltage readings to coil(s) are WITHIN specifi- cations, proceed with Step 1-B. 1-B) Check coils for spark. [Connect Spark Gap Tester (91-63998A1) between coil high voltage tower and spark plug.] 1. No spark or weak spark. COIL is bad. 2. Spark is OK, proceed with Step 1-C. 1-C) If Step 1-A and 1-B check OK, replace spark plugs. If problem exists after replacing spark plugs. proceed with Step 1-D. 4-D) If Steps 1-A, 1-B, and 1-C check OK, check ignition timing, 41. ignition timing does not check to specification (or a sudden or unexplained timing change ‘occurs) check trigger advance linkage for loose andior broken parts and check trigger magnet ring (on fywheel hub) for looseness andior a shift in position, 2. ignition checks to specification and engine does ‘not run or runs poory, trouble exists with fuel system or engine mechanical. 2A) Check switch box “stop” circuit. (See Test Chart), 1. Ifreading is BELOW specifications, proceed with Step 2-B. 2, If teading is ABOVE specifications, the Trigger or Switch Box's bad (test vigger as outlined inthis ser- vice manual section; if trigger checks OK, replace switch box and repeat check). 3. Ifreading is WITHIN specifications, proceed with Step 3-A. 2-B) Check ignition switchiwiring, as follows: A CAUTION To prevent engine from starting, remove spark plug leads from ALL spark plugs and ground leads to engine. 1. Disconnect In switch and stop switch leads from ewitch box and isolate the leads. 2. Repeat check in Step 2-A. a2 ELECTRICAL AND IGNITION ay 3. Ifreading is still BELOW specification, proceed with Step 3-A. 4.If reading is WITHIN specification, either the ignition switch, stop switch, or wiring is bad. 3-A) Check stator low speed and high speed input to switch box. (See Test Chart). 1. If either the low speed ar high speed reading to switch box is BELOW specification, Stator or ‘Switch Box is bad (test stator as outlined in this service manual section: if stator checks to specif- cation replace switch box and repeat check) 2. If both the low speed and high speed reading are WITHIN specification, replace switch box and re- peat test 90-13645-2 1095Ignition System Test Chart IMPORTANT: BEFORE attempting the ignition system checks, following, thoroughly read the preceding pages of these instructions to become familiar with the proper Automatic Distributorless Ignition (ADI) test sequence and procedures (particularly any “Safety Warnings” and “Cautions"). ALL tests are per- formed with lead wires connected - terminals exposed. SWITCH BOX MUST BE GROUNDED (CASE TO ENGINE BLOCK) FOR ALL TESTS - IF NOT, SWITCH BOXES MAY BE DAMAGED. 3 Cylinder Stators - 398-9710A 13/14/28 and all 398-8778A-— Stators 4 Cylinder Stators — 398-9710A15/31 and all 398-8778A- Stators ‘ADI Test Seloctor Sw. DVA Leads Voltage Reading | Voltage Reading Seq. Tost Position Red Black @ 300-1000 RPM_| @ 1000-4000 RPM TA [ColPamary | —400VDO" | Gale) Terminal | Col) Terminal 150250 780-280, ‘Sw Box Black Yetiow (3) 2a [eer | Moovocr | Seren Gl, Ground 200-360 200-360 SA | Stator > Blue Sw. gh eee oes | 400 VOC eu Ground 200-300 200-330 SA | Stator Ras Sw. GR [See See0a | 400 VOC cae Ground 20-90 130-300 [Seen Fy ‘Sw Box 20VDC or i sa Su 0 VOC 9 Ground Writersiack | 20 100 ‘Sw, Box Terminal (1) Using meter only, REVERSE LEAD POLARITY, connect leads as speciieg *"‘Itusing a meter wih a buit-in DVA, place selector switch in the DVA/400 VOC position. 3 Cylinder Stator - 9 Ampere 398-9873A21 & 15 Ampere 398-9873A24 ‘ADITest ‘Selector Sw. DVA Leads Voltage Reading | Voltage Reading Seq. | _Test__ | “Poston fed Black @ 300-1000 REM_| @ 1000-4000 RPM TA[ Col Primary —[ 400 vDo"—| Cole) Teminal | Care) Teena 45-050 210-240 2A [Sep crun | 400v00" | Seton toma Ground 215-840 80-320 en coe Ground nes 250 320 $A [Stator Fes Sw Fh [EB speoa | doovoo | QFeeSe. Ground 1085 45255 sa [gusor- | 2avocor een toack a0 1030 Bias #0 VDC Grouna ‘Sw, Box Terminal (1) Using meter only, REVERSE LEAD POLARITY: connect leads as specified *“rusing a meter with a buitin DVA, place selector switch in the DVAV400 VDC position, 4 Cylinder Stator — 16 Ampere 398-9710A33 ‘ADI Test ‘Selector Sw. BVA Leads Voltage Reading‘) | Voltage Reading Seq. Test Position, Red Black @ 300-1000 RPM _| @ 1000-4000 RPM TA [SolPrimary | 400 VDC" | Col) Terminal | Cal) Terminal 710-300 215-265 ‘Sw Box~ ~ | BiackYaiow (3) . a ee Ground 160385 270-330 BA | Stator Blue Sw. TR Ee SSe0s | 400 VOC ese Ground 160-385 270-330 BA |Siator— o Res Sw. oun 4A__|HighSpeea__| 400 VOC" ox Terminal Ground 833 88208 TSE ROT ‘Sw. Box 20 VDC or A Su voce Ground WriterBiac 230 1030 ‘Sw. Box Terminal (1) Using meter only, REVERSE LEAD POLARITY: connect leads as speotfieg "fusing a meter wih a buitin DVA, place selector switch in the DVAV400 VDC positon, 90-13645-2 1095, ELECTRICAL AND IGNITION 2a3When testing or servicing the ignition system, high voltage is present, be extremely cautious! DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running, while key switch is on, or while battery cables are connected. A CAUTION Failure to comply with the following items may result in damage to the ignition system. 1. DO NOT reverse battery cable connections. The battery negative cable is (-) ground. 2. DONOT “spark” battery terminals with battery cable connections to check polarity. 3. DO NOT disconnect battery cables while en- is running. 4, DO NOT crank engine when switch box is not grounded to engine. process of elimination must be used when checking the ignition system without a Multi-Meter/DVA Tester (91-99750) or a voltmeter (capable of measuring 400, volts DC, or higher) and Direct Voltage Adaptor (91-89045), as the switch box and ignition coils cannot be thoroughly checked with conventional test equipment. All other components can be tested with an ohmmeter. Before troubleshooting the ignition system, check the following: 1. Make sure that electrical harness and ignition switch are not the source of the problem. 2. Check that plug-in connectors are fully engaged and terminals are free of corrosion. 3. Make sure that wire connections are tight and free of corrosion. 4. Check all electrical components, that are grounded directly to engine, and all ground wires to see that they are grounded to engine. 5. Check for disconnected wires, and short and open circuits. a4 ELECTRICAL AND IGNITION NOTE: Stator can be tested without removing from engine. 1. Disconnect stator leads from switch box. 2. Use an ohmmeter and perform the following tests. IMPORTANT: If stator is mounted on engine, black stator lead must be grounded to powethead when testing. 9/18/24 AMPERE STATORS (3 CYLINDER) Resistance | Seale Reading Test Leads coums)” | i ) Belwoon Blue Stator Lead 300-4200 | 3.6.42 apaad Str Laaa ow | BNE? | ita pee Detwoon Red Siator Load and 0120 Engine Ground" (Hi-Speed) | 9°40 xt) 9/18/24 AMPERE STATORS (4 CYLINDER) Resistance | Scale Reading Test ends coin)” | Tan Bie Sor Cad seooreo0 | 6878 FeScawne Sar Cove , anu ieoruoy | (ic Beivoon eg Sao Leader Rovumeshortear th | son | 90180 Speed) * Connecttestleadto black statorleadit stators removed from engine. NOTE: Above readings are for a cold engine (room temperature). Resistance will increase slightly, if en gine is warm, 3. Ifmeter readings are other than specified, replace stator assembly. 90-13645-2 1095IMPORTANT: Ohmmeter tests can only detect cer- tain faults in the ignition coil. Replace ignition coil, if ohmmeter readings (listed in chart, follow- ing) are not as specified. I coil tests OK, and coil is still suspected of being faulty, use Multi-Meter/ DVA Tester (91-99750) or a voltmeter (capable of measuring 400 volts DC, or higher) and Direct Voltage Adaptor (31-89045) to thoroughly check coil. 1. Disconnect wires from coil terminals, 2. Pull spark plug lead out of coil tower. 3. Use an chmmoter and perform the following tests. Tosistance | Scale Reading Test Leads (OHMS) | Between (») an ~ | 0208 ()Coi Terminals 2-08 (Bet) Between Col Tower and ~ | etm ()Coil Terminal 00-100" | (ex 100) * The primary DC resistance of these cols general is less than ‘one (1) OHM a reading resembling a short is obiained, this ‘would be acceptable. “Copper wie isan excellant conductor, butitwillnave a notice ‘able difeconoa in resistance from eaid to hol tamparalures Reasonable vaviaions irom these readings are acceplable, 4. If meter readings are not as specified, replace ignition coil TRIGGER TEST (3 CYLINDER) Resistance | Scale Roading ‘est Leads conms) | & Tazwaon Brown Tigger Lead 7d [and Black Tigger Lead 700-1000 | (Rx 100) Batwoen White Trager ead Tit and Vole Tigger Lead 700-1000 | (Rx 100) NOTE: Above readings are for a cold engine (room temperature). Resistance will increase slightly. if en- gine is warm, 3. If meter readings are not as speciied, replace trigger. IGNITION (KEY) SWITCH TEST 1. Disconnect remote control wiring harness and instrument panel connector. NOTE: Wiring diagram for control boxes is located in SECTION 20 2. Set ohmmeter on Rx 1 scale for the following tests: COMMANDER 2000 KEY SWITCH COMMANDER KEY SWITCH BiK® BLACK. (puny 1. Disconnect all trigger leads from switch box. ae ae YEL* YELLOW geet 1M. (8tK) 2. Use an Ohmmeter and perform the following (euevel) My tests. re0) B 'g WELRED) Resistance | Scale Reading Test Leads corms) | ‘ELEN Beween Brown Trager T=5 T-ss00.1400 | TT and WhitoBlack Tagger Lead (ax i00) ‘CONTINUITY SHOULD BE INDICATED Bewwoon Write Taper Lead Tog-ta00 | TTT key ‘AT THE FOLLOWING POWTS: nd WhtaBiack Tagger Lead ax i00) Position! Lx | eukiveL| RED |YELRED| PUR | YELeLK| Benween Valet Tigger Lead | Tr OFF 7 andwrerBiack Trager toad | "0%400 |e i00 RUN NOTE: Above readings are for a cold engine (room temperature). Resistance will increase sightly ifen- J | starr gine is warm ee ae 4 trigger. TRIGGER TEST (4 CYLINDER) 4. Disconnect all trigger leads from switch box. 2. Use an Ohmmeter and perform the following tests. 90-13645-2 1095, Key swich mast be positonedto"RUN'or'STAAT and ay pushed into actuate choke rhe contin tet, 8. If meter readings are other than specified in the preceding test, verity that switch and not wiring is faulty. If wiring checks OK, replace switch. ELECTRICAL AND IGNITION 2a5Ignition Components Removal and Installation Flywheel REMOVAL 1. Remove flywheel cover from engine. Engine could possibly start when turning flywheel during removal and installation; therefore, disconnect (and isolate) spark plug leads from spark plugs to prevent engine from starting. 2. Disconnect spark plug leads from spark plugs. 3. White holding flywheel with Fiywheel Holder (81-5284), remove flywheo! nut and washer. 8 Flywhoe! Holder (91-52844) 4, Install Crankshaft Protector Cap (91-24161) on the end of crankshaft, then install Fiywhee! Puller (91-73687A1) into flywheel. 5. Remove flywheel NOTE: Neither heat or hammer should be used on fly- wheel to aid in removal as damage to flywheel or elec- trical components under flywheel may result 2 Flywheel Puller b= Flywnee! 2A6 ELECTRICAL AND IGNITION ay INSTALLATION Engine could possibly start when turning flywheel during installation; therefore, disconnect (and isolate) spark plug leads from spark plugs to prevent engine from starting. 1. Disconnect spark plug leads from spark plugs. 2. Place flywheel key into slot in crankshaft a - Flywheel Key 3. Align slot in fiywheel center bore with fiywheel key and install wheel onto crankshaft, Install washer and locknut. Hold flywheel with Flywheel Holder (91-52344), torque locknut to 120 lb. ft. (162.7 N.m}, 2 - Flywhoe! Holder (91-5284) 6. Install flywheel cover. 90-13645-2 1095ay Stator INSTALLATION REMOVAL 1. Install stator as shown. 1. Remove flywheel: refer to “Flywheel Removal.” 2. Remove screws a Sorews: apply Locite Grade “A” on threads (unless Patch Screw used) and torque to 60 Is. in. (6.6 Nm) a- Screws b= Stator 3. Remove starter motor as outlined in Section 2B, | 2 Connect stator leads: refer to wiring diagrams in Section 20. 4. Remove sta-strap, 5D leads f box and 3. Install sta-strap. isconnect stator leads from switch box and re- move siator 4. Install starter motor; refer to Section 28. 19453 a. SiaStrap a StaSrap 5. Install flywheel: refer to “Flywheel Installation’ preceding, 90-13645-2 1095, ELECTRICAL AND IGNITION 2a7Trigger INSTALLATION REMOVAL 1. Install trigger and connect link arm. 1. Remove fi hee! and stator; refer to “Flywheel and *Stator” removal, preceding, 2. Disconnect link arm and remove trigger. a-Tigger D-Link arm 2, Connect rigger leads to switch box; refer to wiring a tink Arm diagrams in Section 2D. Trigger 3, Remove starter motor: refer to Section 28. 3. Install etz-etrap 4, Install starter motor; refer to Section 2B. 4, Remove sta-strap 5, Disconnect trigger leads from switch box and re- move tigger. 19483 a Stastrap 5. Install stator; refer to “Stator Installation,” a Stasvap Preceding. 6. Install flywheel: refer to “Flywheel Installation,” preceding 2A8 ELECTRICAL AND IGNITION 90-13645-2 1095Ignition Coils (3 Cylinder Models) Ignition Coils (4 Cylinder Models) 1. Refer to wiring diagrams in Section 2D when con- J 1. Refer to wiring diagrams in Section 2D when con- necting wires. necting wires 25991 Coils b- Cover - Hex Nuts; Torque to 30. i. (3.4 Nem, coat with Quicksiver Liquid Neoprene 4 Botts: torque to 20 I. in. (2.3 Nm) {= Col Towar Boots: form a watertight seal between col tower and spark plug lead using Quicksiver Insulating Compound - Cover Hex Nuls; Tergue to 30 1b in (3.4 Nm), coat with Quicksiver| Liquid Neoprene Botts; torque to 20. in. (2.3 Nm) + Coil Tower Boots; form a watertight seal between col ower ‘and spark plug lead using QuicksiverInsuating Compound 90-13645-2 1095, ELECTRICAL AND IGNITION 2n9Switch Box 1. Refer to wiring diagrams in Section 2D when con- necting wires, 2-10 ELECTRICAL AND IGNITION 90-13645-2 1095ELECTRICAL AND IGNITION BATTERY, CHARGING SYSTEM, AND STARTING SYSTEMTable of Contents Battery Precautions Recommended Battery . Operating Engine without Battery Specific Gravity Readings Specific Gravity Cell ‘Comparison Test Electrolyte Level Charging a Discharged Battery Winter Storage of Batteries Optional Voltage Regulator Test Battery Charging System (9 Ampere Alternator) Description Models Equipped with Rectifier Models Equipped with Reguiator Battery Charging System Troubleshooting Stator Ohms Test (Alternator Coils Oniy) Standard Stator (Alternator Coils) 9 Amperes Output, 16 Amp Alternator System Test . (Large Finned votage feguiator/Reetiier) 16 Ampere Alternator System Test (Small Voltage Regulator/Rectitier) Optional 24 Amp Alternator System Test (Large Finned Voltage Reguiator/Recttier) ‘Tachometer Terminal Biock (Design 1) Description Testing Tachometer Terminal Block (Design 1) . Tachometer Terminal Biock (Design 2) Description Tachometer Terminal Block (Design 1 and 2) Removal Installation Page 28-1 28-1 28-1 28-1 28-2 28.2 28.2 28-3 28-3 28-4 28-4 28-4 28-4 28-4 28-5 28-5 28-6 28-6 28-6 28-7 28-7 287 28-7 28-8 28-8 288 28-8 28-8 28-8 288 28-8 3 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram 3 Cylinder 16 Ampere Battery Charging Wing Diagram (win Small Vorage Regulatorifeciiier) 4 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram 4 Cylinder 16 Ampere Battery Charging Wiring Diagram (with Small Voltage Reguiator/Rectifier) 3 Cylinder Battery Charging Diagram with Battery Isolator 3 Cylinder Battery Charging Diagram ‘with Battery oiator (Smal Voltage Regulator) 4 Cylinder Battery Charging Diagram with Battery Isolator 4 Cylinder Battery Charging Diagram with Battery Isolator (Small Voltage Regulator) Rectifier Test Starting System Starting System Components Description Troubleshooting the Starting Circuit Starting Circuit Troubleshooting Flow Chart Starter Motor Removal Disassembly Starter Cleaning, Inspection and Testing Cleaning and Inspection Testing Armature Test for Shorts ‘Armature Test for Ground Checking Positive Brushes and Terminal Testing Negative Brushes for Ground Starter Solenoid Test Brush Replacement Starter Reassembly Installation Page 28.9 =. 2B-40 28-11 28-12 28-13 28-14 28-15 28-16 28-17 28-18 28-18 28-18 28-18 28-19 28-21 28-21 28-21 28.22 28.22 28-22 28.22 28-22 28.23 28.23 28-23 28.24 28-24 28-26 90-13645-2 495Battery Precautions When charging batteries, an explosive gas mixture forms in each cell. A portion of this gas escapes thru holes in vent plugs and may form an explosive atmo- sphere around battery if ventilation is poor. This ex- plosive gas may remain in or around battery for sever- al hours after it has been charged. Sparks or flames can ignite this gas and cause an internal explosion which may shatter the battery. The following precautions should be observed to pre- vent an explosion. 1. DO NOT smoke near batteries being charged or which have been charged very recently. 2. DONOT break live circuits at terminals of batter- ies because a spark usually occurs at the point where a live circuit is broken. Always be careful when connecting or disconnecting cable clamps on chargers. Poor connections are a common cause of electrical arcs which cause explosions. 3. DONOT reverse polarity of battery cables on bat- tery terminals, 90-13645~-2 495 Recommended Battery ‘The 2-cycle Outboard type engine requires a 12 volt battery with a “Cold Cranking Amperage" rating for cranking and a “Reserve Capacity” rating. The mini- mum should be a "Cold Cranking Amperage” of 350 amperes and a "Reserve Capacity" of 100 minutes for engines outlined in this manual Operating Engine Without Battery If desired (or in an emergency}, engines equipped with an alternator can be started and operated with- out a battery (either disconnected or removed) it “Warning”, below, is followed. ELECTRICAL AND IGNITION 281Specific Gravity Readings Use a hydrometer to measure specific gravity of elec: troly'e in each cell 22592 a Hydrometer Hydrometer measures percentage of sulphuric acid in battery electrolyte in terms of specific gravity. As a battery drops from a charged to a discharged condi- tion, acid leaves the solution and chemically com- bines with the plates, causing a decrease in specific gravity of electrolyte. An indication of concentration of electrolyte is obtained with a hydrometer. When using a hydrometer, observe the following points: 1. Hydrometer must be clean (inside and out) to in: sure an accurate reading 2. Never take hydrometer readings immediately af: ler water has been added. Water must be thor- ‘oughly mixed with electrolyte by charging for at least 15 minutes at a rate high enough to cause vigorous gassing. 3. If hydrometer has bult-in thermometer, draw liq- uid in several times to ensure correct temperature before taking reading 4. Hold hydrometer vertically and draw in just enough liquid from battery cell so that floats free- floating. Hold hydrometer at eye level so that float is vertical and free of outer tube, then take reading at surface of liquid. Disregard curvature where liq- Uid rises against float stem due to capillary action, 2B2 ELECTRICAL AND IGNITION 5. Avoid dropping electrolyte on boat or clothing, as it is extremely corrosive. Wash off immediately with baking soda solution. Specitic gravity of electrolyte varies not only with per- centage of acid in liquid but also with temperature. AS temperature drops, electrolyte contracts, so that spe- cific gravity increases. Unless these variations in spe- cific gravity are taken into account, specific gravity ob- tained by hydrometer may not give a true indication of concentration of acid in electrolyte, A fully charged battery will have a specific gravity reading of approximately 1.270 at an electrolyte temperature of 80° F (27° C). If electrolyte tempera- ture is above or below 80° F. additions or subtractions must be made in order to obiain a hydrometer reading corrected to 80° F standard. For every 10° F (3.3° C) above 80° F, add 4 specific gravity points (.004) to hydrometer reading. Example: A hydrometer reading f 1.260 at 110° F (43° C) would be 1.272 corrected to 80° F, indicating a fully charged battery. For every 10° below 80° F, subtract 4 points (.004) from the reading. Example: A hydrometer reading of 1.272 at 0° F (18° C) would be 1.240 corrected to 80° F, indicating a partially charged battery. ‘SPECIFIC GRAVITY CELL COMPARISON TEST This test may be used when an instrumental tester is not available. Ta perform this test, measure specific gravity of each cell, regardless of state of charge, and interpret results as follows: f specific gravity readings show a difference between highest and lowest cell of (050 (50 points) or more, battery is defective and should be replaced. Electrolyte Level Check electrolyte level in battery regularly. A battery in use in hot weather should be checked more fre- quently because of more rapid loss of water. If electro- lyte level is found to be low, then distilled water should bbe added to each cell until liquid level rises approxi- mately 3/16" (4.8mm) over plate. DO NOT OVER- FILL, because this will cause loss of electrolyte and result in poor performance, short life and excessive corrosion. 90-13645-2 495Charging a Discharged Battery The following basic rules apply to any battery charg ing situation: 4. Any battery may be charged at any rate (in am peres) as long as spilling of electrolyte (fram vio- lent gassing) does not occur and as long as elec- trolyte temperature does not exceed 125° F (62° C). IF spewing of electrolyte occurs, or if elec- trolyte temperature exceeds 125° F, charging rate (in amperes) must be reduced or temporarily halted to avoid damage to the battery. 2. Battery is fully charged when, over a 2-hour peri- (od ata low charging rate (in amperes). all cells are gassing freely (not spewing liquid electrolyte), and no change in specific gravity occurs. Full charge specific gravity is 1.260-1.275, corrected for electrolyte temperature with electrolyte level at 3/16" (4.8mm) over plate. For most satisfactory charging, lower charging rates in amperes are recommended, 3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannotbe reached, battery is notin optimum condition and will not provide op- timum performance: however. it may continue to provide additional service, if it has performed sat- isfactorily in the past. 4. To check battery voltage while cranking engine with electric starter motor, place red (+) lead of tester on positive (+) battery terminal and black (-) lead of tester on negative (-) battery terminal. If the voltage drops below 9-1/2 volts while crank- ing, the battery is weak and should be recharged or replaced, Winter Storage of Batteries Battery companies are not responsible for battery damage, either in winter storage or in dealer stock, if the following instructions are not observed: 90-13645~-2 495 ELECTRICAL AND IGNITION Remove battery from its installation as soon as possible and remove all grease, sulfate and dirt from top surface by running water over top af bat- tery. Be sure, however, that vent caps are tight be- forehand, and biow off all excess water thorough ly with compressed air. Check water level, making sure that plates are covered, When adding distilled water to battery, be ex- tremely careful not to fill more than 3/16” (4.8mm) over plate inside battery. Battery solution or elec- trolyte expands from heat caused by charging Overfiling battery will cause electrolyte to over- flow (if filled beyond 3/16” over plate). Grease terminal bolts well with Quicksilver 2-4-C witefion, and store battery in COOL-DRY place. Remove battery from storage every 30-45 days, check water level (add water if necessary), and put on charge for 5 or 6 hours at 6 amperes. DO NOT FAST CHARGE. It specific gravity drops below 1.240, check bat- tery for reason, and then recharge. When gravity reaches 1.260, discontinue charging. To check specific gravity, use a hydrometer, which can be purchased locally. Repeat preceding charging procedure every 30-45 days, as long as battery is in storage. When ready to place battery back in service, remove ex- cess grease from terminals (a small amounts de- sirable on terminals at all times), recharge again as necessary and reinstall battery. 233Optional Voltage @ Regulator Test 4. Check battery vottage at Lead battery wih engine running, vy 2. Itbattery voltage s above 14.5 vot, replace volt age regulator. Check conditon of bate as ove- charging may have damaged battery. 3. If battery votage is below 14.5 vot, charge bat tery: refer to “Charging a Discharged Battery’ preceding. It battery can NOT be satistactorly charged, replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine: refer ta “Charging a ‘Discharged Battery" preceding. It cranking votage is not acceptable, replace bat- tery. 5. If cranking voltage is acceptable, disconnect end of RED wire (located between rectifier (+) terminal and starter solenoid) from rectifier. Secure RED wire (from voltage regulator) to rectifier (+) termi- ral with hex nut. 6. Connect RED (+) ammeter lead to (+) terminal of rectifier and BLACK (-) ammeter lead to RED wire (disconnected in last step), IMPORTANT: For accurate test results the voltage at battery with engine running, in next step, must be 13.5 volts or less. It may be necessary to oper- ate electrical accessories to drop voltage to 13.5 volts or less. 7. Run engine at 3000 RPM. 8. Meter should read between 7 - 9 amperes. 9. If meter reads 7 - 9 amperes, this indicates the charging system is functioning properly and the battery 's being discharged because the amper- age draw on the system is greater than the amper- age output of the system. NOTE: With engine running at the following RPM'S. the ammeter should indicate the following approxi- mate amperes: RPM AMPERES IDLE 1 1000 4 2000 8 3000 9 10. If the meter reads less than 7 amperes, test the stator; refer to "Standard Stator (Alternator Coils) ‘Amperes Output", following, If stator tests OK, re. place voltage regulator. 284 ELECTRICAL AND IGNITION Battery Charging System (9 Ampere Alternator) Description ‘The battery charging system components are the sta tor, rectifier, and battery. Alternating current (gener- ated in stator alternator coils) flows to the rectifier. which changes the alternating current to direct cur- rent for charging the battery. MODELS EQUIPPED WITH RECTIFIER a Stator b- Rector Battery MODELS EQUIPPED WITH REGULATOR Stator - Regulator ¢-Batery The charging system may be damaged by: 1) re- versed battery cables, 2) running the engine with bat- tety cables disconnected and stator leads connected to rectifier, and 3) an open circuit, such as a broken wire or loose connection. 90-13645-2 495Battery Charging System Troubleshooting A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See “Electrolyte Level, and “Charging a Discharged Batten If battery will NOT accept a satisfactory charge, re- place battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows. 1. Cheek for correct battery polarity [RED cable to positive (+) battery terminal). If polarity was incor- rect, check for damaged reetier. See “Rectiier Test’ following. Check for loose or corroded battery connections. Visually inspect wiring between stator and battery for cuts, chafing; and disconnected, loose or cor- roded connection. 4, Excessive electrical load [rom too many acces sories) will cause battery to run down If visual inspection determines that battery connec- tions and wiring are OK, perform the following stator and rectifier tests. Stator Ohms Test (Alternator Coils Only) NOTE: Stator can be tested without removing from engine 1. Disconnect both YELLOW (stator leads) from ter- minals on rectifier (or terminal block). 90-13645~-2 495 2. Use an ohmmeter and perform the following test. IMPORTANT: If stator is mounted on engine, black stator lead (if provided) must be grounded to pow- ethead when testing, 3. Replace stator if readings are outside ranges shown. 5 Scale TestLeads | Fesistance | peeing &__) ‘9 AMPERE STATOR Between YELLOW |g y4- | 6-11" stator leads (Rx) Bolweon either No No YELLOW stator lead | Gouiny | Continuity and engine ground"* ¥_ | (x 1000) 16 AMPERE STATOR Beween YELLOW | 37-4 ] 47-19 stator leads (Rx) Between either No No YELLOW statorlead | continuity | Continuity and engine ground’ (Rx 1000) 24 AMPERE STATOR Botwoen YELLOW 05-15 stator leads 95— 18 | iat) Between either No No YELLOW statorlead | continuity | Continuity and engine ground"* (Rx 1000) * DC resistance of these windings generally is less than 1.5 ohms. If a reading (resembling a short) is, obtained, this would be acceptable. ** Ifstatoris removed from engine, connect test lead to black stator lead, if provided 4. Ifmeter readings are other than specified, replace stator. ELECTRICAL AND IGNITION 285Standard Stator (Alternator Coils) 9 Amperes Output IMPORTANT: Rectifier must be functioning prop- erly for accurate test results to be obtained. 1. If engine is equipped with a voltage regulator, disconnect voltage regulator leads at rectifier; reinstall hex nut on rectier terminal that nas yellow stator ead Remove red wire from (+) terminal of rectifier. Connect RED (+) ammeter lead to rectifier (+) termi- nal and BLACK (-) ammeter lead to red rectifier wire. Run engine at 3000 RPM, Meter should read 7 - 9 amperes; if not, replace stator. 16 Amp Alternator System Test (LARGE FINNED VOLTAGE REGULATOR/RECTIFIER) 1. Check battery voltage at battery with engine running. 2. Ibattery voltage is above 14.5 volts, replace volt- age regulatorirectifier. Check condition of battery as overcharging may have damaged battery. 3. If battery voltage is below 14.5 volts, charge bat- tery; refer to “Charging a Discharged Battery’, preceding. If battery can NOT be satisfactorily charged. replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine: refer to “Charging a Discharged Battery’, preceding, If cranking voltage is not acceptable, replace battery. 5. Iferanking voltage is acceptable, disconnect RED harness wire from center terminal. Secure RED wire (d) on terminal (¢) using hex nut. Connect RED (+) ammeter lead to terminal (c) and BLACK (-) ammeter lead to RED harness wire (b). 8. Secure wires away from flywheel IMPORTANT: For accurate test results the voltage at battery with engine running, in next step, must be 13.5 volts or less. It may be necessary to oper- ate electrical accessories to drop voltage to 13.5 volts or less. 286 ELECTRICAL AND IGNITION 9. With engine running at the indicated RPM's, the ammeter should indicate the following approxi- mate amperes: RPM AMPERES IDLE 2 1000 10 2000 7 3000 18 10. If ammeter indicates approximately 18 amperes at 3000 RPM, this indicates the charging system is functioning properly and the battery is being discharged because the amperage draw on the systemis greater than the amperage output of the system. 11. It ammeter reads less than 18 amperes, test the stator; efor to "Stator Ohms Test (Alternator Coils Only)" [18 Ampere Stator], preceding. If stator tests OK, replace voltage regulator/rectifer. 21619 '8- Voltage Regulator ectiier ¢ - Center Terminal b-RED Hamess Wire RED Sense Lead NOTE: If one or more of the 3 terminals on the termi- nal block are shorted to ground. the battery charging system output will be reduced 26001 Terminal Block 90-13645-2 49516 Ampere Alternator System Test (SMALL VOLTAGE REGULATOR/RECTIFIER) 1. Check battery voltage at battery with engine run- ning, 2. It battery voltage is above 14.5 volts, replace volt- age regulatorirectifier. Check condition of battery as overcharging may damage battery. 3. If battery voltage is below 14.5 volts, charge bat- tery: refer to “Charging a Discharged Battery’, preceding. if battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a salistactory charge, check battery voltage while cranking engine; refer to “Charging a Discharged Battery’, preceding. If ‘cranking voltage is not acceptable, replace battery. 5. If cranking voltage is acceptable, disconnect larg- er diameter Red wire from STARTER SOLENOID terminal. 6. Remove smaller diameter RED wire (SENSE LEAD) from STARTER SOLENOID terminal and connect to the POSITIVE (+) terminal of a9 VOLT transistor battery. Ground the NEGATIVE (-) ter- minal of the 9 VOLT battery to the engine. 7. Connect RED (+) ammeterlead tolarger diameter RED wire, and BLACK (-) ammeter lead to POS- ITIVE terminal on STARTER SOLENOID. Secure wires away from flywheel With engine running at the indicated RPM's, the ammeter should indicate the following approxi- mate amperes: RPM AMPERES IDLE 2 1000 10 2000 7 3000 18 10. A reading of 18 amperes at 3000 RPM indicates the charging system is functioning properly. The battery is discharging due to the amperage draw on the system is greater than the amperage out- put of the engine charging system. 41. If ammeter reads less than 18 amperes, test the stator; refer to “Stator Ohms Test (Alternator Coils Oniy)’, [18 Ampere Stator], preceding. If stator tests OK, replace voltage regulatorirectitier. 90-13645~-2 495 ELECTRICAL AND IGNITION Optional 24 Amp Alternator System Test (LARGE FINNED VOLTAGE REGULATORIRECTIFIER) 4. Check battery voltage at battery with engine running, 2. Itbattery voltage is above 14.5 volts, replace volt- age regulator/rectifier (a). Check condition of bat- tery as overcharging may have damaged battery. 3. If battery voltage is below 14.5 volts, charge bat- tery; refer to “Charging a Discharged Battery’, preceding. If battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge. check battery voltage while cranking engine: refer to “Charging a Discharged Battery’, preceding. If cranking voltage is not acceptable, replace battery. 5. Ifcranking voltage is acceptable, disconnect RED harness wire (b) from terminal (¢). Secure RED wire (d) on terminal (e) using hex nut. Connect RED (+) ammeter lead to terminal (c) and BLACK (-) ammeter lead to RED hamess wire (D) 8. Secure wires away from flywheel. IMPORTANT: For accurate test results the voltage at battery with engine running, in next step, must be 13.5 volts or less. It may be necessary to oper- ate electrical accessories to drop voltage to 13.5 volts or less. 9. Run engine at 3000 RPM 10. Meter should read 20 or more amperes. 41. If meter reads 20 or more amperes, this indicates the charging system is functioning properly and the battery is being discharged because the am- erage draw on the system is greater than the am- erage output of the system, 12, If meter reads less than 20 amperes, test the sta- tor; refer to "Optional 24 Amp Stator (Alternator Coils) Amperes Output’, following. If stator tests OK, replace voltage regulator rectifier (2).Tachometer Terminal Block (Design 1) DESCRIPTION Contains a diode which blocks high voltage AC Pulses (180 VAC) coming from the stator and allows iow voltage DC pulses (20-30 VDC) to pass through to be counted by the tachometer. This terminal block (with diode) is only used with large, finned type regu- fators. This block is BLACK in color. HIGH VOLTAGE is present at the tachometer block's stator side terminals, while the outboard is running. To avoid electrical shock, physical contact should not be made on these terminals or ANY IGNITION RELATED COMPONENT WHILE ‘THE OUTBOARD IS RUNNING. IMPORTANT: The following ohm testis used to de- termine the proper functioning of the diode lo- cated in the tachometer block. If the diode is OPEN (NO CONTINUITY IN EITHER DIRECTION), the tachometer will be inoperative. ‘TESTING TACHOMETER TERMINAL BLOCK (DESIGN 1) With outboard NOT running, remove all leads from block. Using an ohmmeter, test block as shown, fol- lowing. Continuity should be observed on the ohm- meter with the needle swinging in only ONE direction. NO CONTINUITY should be observed when test leads are reversed. If CONTINUITY is observed in BOTH directions or NO CONTINUITY is observed in either direction when leads are reversed, diode is de fective and MUST BE REPLACED. NOTE: Thereis only one diode located in the tachom eter block. It may be located either between the cen- ter (TACH) terminal and the top (ALT) terminal or be- tween the center (TACH) terminal and the lower (ALT) terminal Nn. 50646 288 ELECTRICAL AND IGNITION 50644 Tachometer Terminal Block (Design 2) DESCRIPTION This block is junction point for stator and tachometer signal wiring. It contains no electrical components This block is LIGHT GREY in color and is to be used ONLY with small, non-finned voltage regulators. No testis required for this terminal block Tachometer Terminal Block (Design 1 and 2) REMOVAL 1, Remove two YELLOW alternator wires from block. Remove GREY tachometer wire from block. Remove two attaching screws and remove diode block. INSTALLATION 1. Secure diode block to powerhead with two screws. Torque screws to $0 Ib. in. (3.4 Nom). 2. Attach two YELLOW wires to ‘ALT YEL terminals, 3, Attach GREY wire to “GREY TACH terminal 90-13645-2 495ry 3 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-2571), to avoid corro- sion. BLK eBLACK BLU eBLUE GRY eGRAY RED eRED YEL e YELLOW 50805 a Stator ‘¢- To Remote Contol Hames = Terminal Block 1-20 Ampere Fuso -ToTachometer 9 To Battory d-- Voltage Reguiator/ectiier 1 - Starter Solenoid 90-13645~-2 495 ELECTRICAL AND IGNITION 2393 Cylinder 16 Ampere Battery Charging Wiring Diagram (with Small Voltage Regulator/Rectifier) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- BLK eBLACK BLU eBLUE GRY eGRAY RED eRED YEL eYELLOW 51000 a. Stator @ - To Remote Cont! Hames Terminal Block f-20 Ampere Fuse - ToTachometer 9 - Battery (+) Postive Terminal 4. Volage Regulator Recitior 1 Starter Solanoia 28-10 ELECTRICAL AND IGNITION 90-13645-2 4954 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion. Bu BLL GR’ REI YE! “ x g al om” 1 e 50406 a- Stator To Remote Cont Hamess b= Terminal Block 120 ampare Fuse ¢Tolachomotr 49 Baty (+) Postve Trina 4- Votage RegultorRectfer nh Star Solero g013645-2 495 ELECTRICAL AND IGNITION zen4 Cylinder 16 Ampere Battery Charging Wiring Diagram (with Small Voltage Regulator/Rectifier) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- er Liquid Neoprene (92-2571), to avoid corro- BLK eBLACK BLU eBLUE GRY eGRAY RED eRED YEL eYELLOW re 08 51001 a Stator 1 To Remote Contra! Hamass, - Terminal Block 1-20 Ampere Fuse - ToTachameter 9 - Battery (+) Postive Terminal 6. Voltage Regulatorectiir = Starter Solenois 28-12 ELECTRICAL AND IGNITION 90-13645-2 4953 Cylinder Battery Charging Diagram with Battery Isolator IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-2571), to avoid corro- sion. BLK eBLACK BLU BLUE GRY eGRAY RED eRED YEL YELLOW Stator Terminal Block To Tachometer Voltage ReguiatorRectiior Bator Isolator 90-13645~-2 495 Move Red Load Fom Star Selena te Postion Snown User upoted RedLens {Fa Gaugo nmr Dametr ‘wih roccho abrashe Seve inno Wove Load From Ros ae ‘Stud to Position Shown PI 062560 50403 1 - Avsliary Batory g- Star Battery 1 To Remote Control Hamess i =20 Ampere Fuso j Starter Solenoid ELECTRICAL AND IGNITION 28-133 Cylinder Battery Charging Diagram with Battery Isolator (Small Voltage Regulator) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- BLK eBLACK BLU eBLUE GRY eGRAY RED eRED YEL YELLOW 51051 a Stator 1 - Auxiiary Battery b= Terminal Block 9 Start Batery To Tachometer h= To Remote Control Hamass. Voltage Reguiatorectiier i +20 Ampere Fuse 1 - Batter Isolator | - Starter Solero B14 ELECTRICAL AND IGNITION 90-13645-2 4954 Cylinder Battery Charging Diagram with Battery Isolator IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-2571), to avoid corro- sion. BLK eBLACK BLU BLUE GRY eGRAY RED eRED YEL YELLOW Stator Terminal Block To Tachometer Votage ReguiatorRectiier Battory Isolator 90-13645~-2 495 User Supplied Red eed (lo Gauge Minimam Dimsior wih Prototve Roresve Stove installed) ovo Load From Ro ‘Sudo Pesion Shown PR r.c2s68 50408 1 - Auxiliary Batory 9 Start Battery 1 To Remote Control Hamess 1-20 Ampere Fuse j ~ Starter Solenoid ELECTRICAL AND IGNITION 28154 Cylinder Battery Charging Diagram with Battery Isolator (Small Voltage Regulator) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- er Liquid Neoprene (92-25711), to avoid corro- BLK @BLACK BLU eBLUE GRY eGRAY RED eRED YEL eYELLOW ve. Sia Fea (Sense) bes g 51050 a. Stator 1 Auxitay Battery - Terminal Block 9 Start Batty o- To Tachometer hh To Remote Conro! Harness 4 Voltage Regulatorectiir 1-20 Ampere Fuso (Battery Islator j + Staner Solencic 28-16 ELECTRICAL AND IGNITION 90-13645-2 495Rectifier Test Disconnect battery leads from battery before testing rectifier. NOTE: Rectifier can be tested without removing from engine. 1. Disconnect all wires from t rminals on rectifier. 2. Use an ohmmeter (R x 1000 scale) and perform the following test. Refer to illustration for rectifier terminal identification. Rectifier Test 07300 Terminal - Stator Terminals b- Terminal ‘2 Positive Terminal Terminal + Ground Connect RED meter lead to ground, BLACK lead alternately to terminals ‘a’ and “c’ Continuity Indicated, Connect BLACK meter lead to ground, RED lead alternately to terminals ‘a’ andc" No Continuity Indicated. Connect BLACK meter lead to terminal ‘b’, RED lead alternately to terminals ‘a and Bi No Continuity Indicated. Replace Rectifier. Continuity Indicated, Connect RED meter lead to terminal BLACK lead alternately to terminals “a” and te H Continuity Indicated, Replace Rectifier. No Continuity indicated. Rectifier tests OK. Continuity Indicated Replace Rectifier. 90-13645~-2 495 Continuity Indicated Replace Rectifier. No Continuity indicated. ELECTRICAL AND IGNITION ——1 ______ No Continuity indicated. Connect BLACK meter lead to ground, RED lead alternately to terminals “a” and Continuity Indicated Connect BLACK meter lead to terminal RED lead alternately to terminals “a” and te No Continuity indicated, Replace Rectifier. ‘No Continuity Indicated. Connect RED meter lead to terminal “b’, BLACK lead alternately to terminals “a” and Continuity Indicated. Replace Rectifier. Rectifier tests OK. 2817Starting System Starting System Components ‘The starting system consists of the following compo- nents: Battery Starter Solenoid Neutral Start Switch Starter Motor Ignition Switch Description ‘The function of the starting system is to crank the en- gine. The battery supplies electrical energy to crank the starter motor. When the ignition switch is turned to “Start” position, the starter solenoid is activated and completes the starting circuit between the battery and starter. ‘The neutral start switch opens the start circuit when the shift control lever is not in neutral. This prevents accidental starting when engine is in gear. 2B18 ELECTRICAL AND IGNITION ey A CAUTION ‘The starter motor may be damaged if operated continuously. DO NOT operate continuously for more than 30 seconds. Allow a 2 minute cooling period between starting attempts. Troubleshooting the Starting Circuit Before beginning the starting circuit troubleshooting flow chart, following, check frst for the following conditions: 1. Make sure that battery is fuly charged 2. Check that contrl lever is in “neutral postion. 3. Check terminals for corrosion and loose connec- tions, Check cables and wiring for frayed and worn in- sulation| 5. Check in-line fuse in red wire; see diagram. 90-13645-2 495Fuse Holder AW Equipped) (20 Amp Peso) Neutral Stat teh ery (Cocstee in Cont Housing) Starter Circuit Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn i ‘SAFETY WARNING: Disconnect BLACK (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking. TESTI Use an chmmeter (Rx 1 scale) and connect meter leads between NEGATIVE (-) battery post and common poweread ground. F 1 No continuity indicated; there is an open circuit in the Continuity indicated BLACK negative (-) battery cable between the nega- tive (-) battery post and the powerhead. Proceed to TEST 2, on next page + Check cable for loose or corroded connections. + Check cable for open. 90-13645~-2 495 ELECTRICAL AND IGNITION 28-19ey TEST 2 No voltage reading a- Disconnect BLACK ground wire(s) from Test Point 2. proceed to TEST 3. b- Connect voltmeter between common engine ground and Test Point 2. c- Tur ignition key to “Start” position TEST3 12 Volt Reading" a- Reconnect BLACK ground wire(s). Check BLACK ground wire for b-Connect voltmeter between common engine ground and Test Point 3. | | PoOr connection or open circuit ° Reconnect ground wire to start- ¢-Turn ignition key to “Start” position. creoleneld: proceedto TEST, — No vottage reading: | | 12 Volt Reading proceed to TEST 4. Defective starter solenoid. er TEST 4 12 Volt Reading* a- Connect voltmeter between common Neutral start switch is open, No voltage reading engine ground and Test Point 4 or YELLOWIRED wire. is proceed to TEST 5. b- Tum ignition key to “Start” position. open between Test Points 4 —_——! and TESTS No voltage reading: Connect voltmeter between common Proceed to TEST 6. engine ground and Test Point 5 1 12 Volt Reading" Defective ignition switch TEST6 Connect voltmeter between common engine ground and Test Point 6. ¥2 Volt Reading® Mee ages) doctve ternal and Test Check fuse in RED wire between test points 5 and 6 meen Check for open RED wire between test points § and [Poms |S TEST? a- Connect voltmeter between common engine ground and Test Point 1 b- Turn ignition key to “Start” position T No voltage reading 12 Volt Reading” Defective starter solenoid. ‘Should hear solenoid click; proceed to Test 8. T TESTS a- Reconnect BLACK (starter motor) cable to starter solenoid Test Point 1 b- Connect voltmeter between common engine ground and Test Point 7 - Turn ignition key to “Start” position. ————————————————— No voltage reading; check BLACK cable for 12 Volt Reading’ poor connection or open circuit. Check BLACK ground cable at starter for loose or cor- roded connection, or open citcutt. If cable is OK, check * Battery Voltage starter motor. 28-20 ELECTRICAL AND IGNITION 90-13645-2 495Starter Motor Removal A CAUTION Disconnect battery leads from battery before removing starter. Disconnect battery leads from battery. Disconnect YELLOW cable. Remove 4 bolts and remove starter clamps. Remove starter. Remove BLACK cable. 1 2. 3 4 5. a- YELLOW Cable - Startor Clamps bb Batis (4) d- BLACK Cable 6. Remove 2 rubber collars and 2 rubber bumpers. 11685, ‘a Rubber Collar Spacer if Equipped 90-13645-2 495 Disassembly 1. Remove 2 thru bolts and commutator end cap, taking care not to lose brush springs. 11646 a Thu Bolts b- Commutator End Cap 2. Pull armature from starter frame. 3. Remove locknut. 11859 ‘Hold Armature Shaft With Wrench on Hex Porton of Dive Assembly 4, Remove components from armature. 11658 8 Locknut b- Spacer - Spring 9 Drve Assembly ELECTRICAL AND IGNITION 28-21Starter Cleaning, Inspection and Testing CLEANING AND INSPECTION 4. Clean all starter motor pats 2. Check pinion teeth for chips, cracks or excessive wear. 3. Replace the drive clutch spring andior collar if ten- sion is not adequate or if wear is excessive, 4, Inspect brush holder for damage or for failure to hold brushes against commutator. 5. Replace brushes that are pitted or worn to less than 1/4” (6.4mm) in length. 6. Inspect the armature conductor (commutator bar junction) for a tight connection. A loose connec- tion (excessive heat from prolonged cranking melts solder joins) results in a burned commuta- tor bar. 7. Resurface and undercut a rough commutator as follows: A CAUTION Do not turn down the commutator excessively. a. Resurface the commutator and undercut the in sulation between the commutator bars 1/32” (0.8mm) to the full width of the insulaton and so that the undercut is flat b. Clean the commutator slots after undercutting . Sand the commutator lightly with No. 00 sand- paper to remove burrs, then clean the commu- tator. 4. Recheck the armature on a growler for shorts as specified in the following procedure (“Test- ing’) 8, Open-circuited armatures often can be repaired. The most lkely place for an open circuit is at the ‘commutator bars, as a result of long cranking peri- ‘ods. Long cranking periods overheat the starter motor so that solder in the connections melts and is thrown out. The resulting poor connections then cause arcing and burning of the commutator bars. 9. Repair bars, that are not excessively burned, by resoldering the leads in bars (using rosin flux sol- der) and turning down the commutator in a lathe to remove burned material, then undercut the mica, 10. Clean out the copper or brush dust from slots be- ‘tween the commutator bars. 2B.22 ELECTRICAL AND IGNITION ey 411. Check the armature for ground. See the following procedure (‘Testing’) Testing ARMATURE TEST FOR SHORTS Check armature for short circuits by placing on growler and holding hack saw blade over armature core while armature is rotated. If saw blade vibrates, armature is shorted. Recheck after cleaning between commutator bars. If saw blade stil vibrates, replace armature. 11668 ARMATURE TEST FOR GROUND 1. Set ohmmeter to (R x 1 scale). Place one lead of ‘ohmmeter on armature core or shaft and other lead on commutator. 2. If meter indicates continuity, armature is grounded and must be replaced. 11678 90-13645-2 495reat Set ohmmeter to (R x 1 scale). Connect meter leads between POSITIVE brushes. Meter must indicate full continuity or zero resistance. If resistance is indi- cated, inspect lead to brush and lead to POSITIVE terminal solder connection. If connection cannot be repaired, brushes must be replaced. Ve 4 11673 8 - POSITIVE (1) Brushes TESTING NEGATIVE BRUSHES FOR GROUND Set ohmmeter to (R x 1 scale). Place one lead of the ohmmeter on the NEGATIVE brush and the other lead on the end cap (bare metal). If the meter indi cates NO continuity, replace the NEGATIVE brush. Repeat this procedure on the other NEGATIVE brush. 1674 - NEGATIVE (-) Brushes b- End Cap 90-13645~-2 495 ELECTRICAL AND IGNITION STARTER SOLENOID TEST 1. Disconnect all wires from solenoid. 2. Use an ohmmeter (Rx: scale) and connect meter leads between solenoid terminals 1 and 2. 3. Connect a 12-volt power supply between sole- noid terminals 3 and 4. Solenoid should click and meter should read 0 ohms (full continuity) 4. If meter does not read 0 ohms (full continuity), re- place solenoid, 51809 a 12.Vok Supply b-VOA Leads. 28-23ey Brush Replacement 2. removed, reinstall pars on armature shaft. Use anew lockvut and ighten securely on end of STARTER REASSEMBLY ane 1. If brushes were removed, replace as follows: e t g a. Install POSITIVE brushes (along with POS- - et / LAE VAS abc d 11658 Lose 2 Seaw Sera 5 Bahco Bie crac ¢ Rmare sak Wester 8. Lubricate helix threads on armature shaft with a drop of SAE 10W oi 11680 . . 4. Lubricate bushing in drive end plate with a drop of a-End Cap 1 Spit Washer POSITIVE Brushes @- Hox Nut SAE 10W oll ¢ - POSITIVE Terminal 1 Long Brish Lead Insulating Busting i - Push Lead into Siot @- Washer b Install NEGATIVE brushes (along with brush holder) 2 - POSITIVE (x) Brushes b- NEGATIVE (-) Brushos - Brush Halder Bolts (Fasten NEGATIVE Brushes and Holder) 2B.24 ELECTRICAL AND IGNITION 90-13645-2 4955. Position armature into starter frame. 7. 6. To prevent damage to brushes and springs when installing commutator end cap. itis recommended that a brush retaining tool be made as shown: ke \ ne wa 9 1a vA Brush Retainer Tool Layout (Full Size) ' Matic Seale 90-13645~-2 495 ELECTRICAL AND IGNITION Lubricate bushing (located in commutator end cap} with one drop of SAE 10W oil. DO NOT over lubricate, 8. Place springs and brushes into brush holder and hold in place with brush retainer tool 11681 bo: ff a- Bush Retainer Too! b- Bushing (D0 NOT Over Lubricate) Install armature into starter frame and align match marks (a). Install commutator end cap onto starter frame and align match marks (b). Remove brush retainer tool. Install through bolts (c) and torque to 70 Ib. in. (7.9 Nem). 140 ‘Alignment Marks bb Alignmant Marks € = Bolts [Torque to 70 fb. in. (7.8 Nery] 28-25Installation 2 1. Install 2 rubber collars and 2 rubber bumpers. 3 ‘2 Rubber Collars b- Rubber Bumpers Install components as shown Connect battery leads to battery. + Starter ubder Yount, ol tank Clamp, upper BLACK Cable Bolt and Lockwashar Clamp lower -Cip {i Equippec} BLACK Negatve (} Battery Cable Botts [Torque to 14.5 lb. .(18.7 Nm] «Fuse Holder (if Equioped) + YELLOW Cable [Torque 1 rut to 60 bin. (6.7 Nm + Fuse Holder if Equipped) 28-26 ELECTRICAL AND IGNITION 90-13645-2 495Installation 2 1. Install 2 rubber collars and 2 rubber bumpers. 3 ‘2 Rubber Collars b- Rubber Bumpers Install components as shown Connect battery leads to battery. + Starter ubder Yount, ol tank Clamp, upper BLACK Cable Bolt and Lockwashar Clamp lower -Cip {i Equippec} BLACK Negatve (} Battery Cable Botts [Torque to 14.5 lb. .(18.7 Nm] «Fuse Holder (if Equioped) + YELLOW Cable [Torque 1 rut to 60 bin. (6.7 Nm + Fuse Holder if Equipped) 28-26 ELECTRICAL AND IGNITION 90-13645-2 495ELECTRICAL AND IGNITION TIMING/SYNCHRONIZING/ADJUSTINGTable Of Contents Timing/Synchronizingy ‘Adjusting (3 Cylinder Models) Specifications Special Tools Timing Pointer Adjustment Carburetor Synchronization Carburetor/Oil Pump ‘Synchronization Timing Adjustments Idle Timing Adjustment Maximum Timing .. Maximum Tarottie Idle Adjustment Throttle Cable Installation Page 2c 2c 20-1 20-1 20-2 20-3 20-3 20-3 20-4 20-4 20-4 20-5 Timing/Synehronizingy ‘Adjusting (4 Cylinder Models) Specifications Special Tools Timing Pointer Alignment Carburetor Synchronization Carburetor/Oil Pump Synchronization Timing Adjustments Idle Timing Adjustment Maximum Timing Carburetor Specifications Initial Staring Adjustments Low Speed Mixture Adjustments . Idle Adjustment Throttie Cable Installation . Page 20-6 20-6 20-6 206 20-7 2-8 2c-8 20-8 20-9 126-10 120-10 520-10 20-11 = 20-11 90-13645-2 495ay Timing/Synchronizing/ Mariner 75 MarathoniMerc 75XD Adjusting (3 Cylinder Models) | [Fat troite Ren Range 4750-5250 Specificati Tale RPM (in "FORWARD" Gear) | _ 650-700 pecifications Maximum Timing @ 5000 RPM | 16° BTC. 70, 75 and 80 Models (@ Cranking Speed) (18° B.T.0.C.) Serial Number and Above tale Timing 0° 4° BTD.C, ‘Spark Plug NGK BUHW-2 US. B299242 Firing Order 132 Beigum | 9502735 Canada | ~A730007 Special Tools Full Throttle RPM Range 4750 - 5250 Part No. Description Tale RPM (in FORWARD” Gear) | _ 650-700 *91-S8222A1__| Dial Indicator Gauge Kit Maximum Timing @ 5000 RPM | _26° BDC. *91-59839 ‘Service Tachometer (@ Cranking Speed) (28° BTD.C) *91-99379 Timing Light {ale Timing 0° - 4° BTD.C. 9T-63998AT ‘Spark Gap Too! ‘Spark Plug NGK BUHW-2 Firing Order 732 * May be obtained locally 70, 75 and 80 Models Timing Pointer Adjustment US. B2s9241 Engine could start when turning flywheel to check Baigum | a50573e timing pointer alignment. Remove spark plugs SS from engine to prevent engine from starting. 1. Install Dial Indicator PN 91-58222A1 into no. 1 Full Throttle RPM Range 4750 - 5250 (top) cylinder. Tale RPM (in FORWARD” Gear) | 650-700 2. Tum fywheel clockwise unt no. + (top) piston is Maximum Timing @ S00 RPM | 22° BDC. at top dead center (TDC). Set Dial Indicator to (@ Cranking Speed) (24° BTD.C) (zero), Tale Timing 0 -F BIDC. ‘Spark Plug NGK BURW-2 Firing Order 132 90 Models Full Throtte RPM Range 5000-6500 g Tale RPM (in “FORWARD” Gear) | _ 650-700 Maximum Timing @ 6000 RPM | 26° BID. oe (@ Cranking Speed) (28° BTD.C) Te Tring “FETDS Le ‘Spark Plug NGK BUHW-2 CJ Firing Order 132 | CGE A 91-58222A1 | 19062 90-13645-2 1095 3. Turn flywheel counterclockwise until Dial Indica- tor needle reads approximately 0.550 (13.97mm) BTDC, then tum fiywnee! clockwise so that needle reads 0.491 in. (12.47 mm) BTDC exactly. ELECTRICAL AND IGNITION 2c4. Reposition timing pointer ifnecessary, so that tim ing pointer is aligned with 0.491 in. (12.47 mm) timing mark on flywheel. Retighten attaching screws. 22400 a Timing Pointar Timing Mare Attaching Screws 5, Remove Dial Indicator, and reinstall spark plug and high tension spark plug lead of no. 1 (top) cylinder only CARBURETOR SYNCHRONIZATION 1. Disconnect remote fuel line from engine. 2. Connect remote control electrical harness to engine wiring harness. Remove throttle cable barrel from barrel retainer. Remove sound air box cover. Loosen screw from thrattle cam follower. Loosen 4 synchronizing screws, Look into throats of carburetors and make sure all throttle shutters are completely closed. Tighten synchronizing screws. 8 Recheck throttle shutters. and make any necessary adjustments. 20-2 ELECTRICAL AND IGNITION a Set Screw 'b- Synchronizing Serews 9. Hold throttle arm so that throtlle stop screw is against stop. 10. Place roller of cam follower against throttle cam and adjust throttle stop screw to align raised mark of throttle cam with center of cam follower roller. Tighten locknut. a Throttle Arm 1b Throttle Stop Screw Roller d- Throttle Cam (@- Raised Mark 1 Lock Nut 90-13645-2 1095,adjust cam follower, so that a clearance of 0.005 in.-0.020 in, (0.127 - 0.508 mm) exists between roller of cam follower and throttle cam. Tighten set screw securing cam follower. 5472 bb Throtle Cam = Sat Serew CARBURETOR/OIL PUMP SYNCHRONIZATION IMPORTANT: Some engines may have an addi- tional stamped mark (d) which SHOULD NOT be used. 4. While holding throttle arm at idle position, adjust length of link rod so that stamped mark of oll pump body aligns with stamped mark of oil pump lever. 22077 TIMING ADJUSTMENTS A CAUTION Engine is timed while cranking engine with starter motor. To prevent engine from starting when being cranked, all spark plugs must be removed, except no. 1 (top) cylinder plug. NOTE: If initial timing adjustments are made without engine running, then final timing checks should be made with engine running due to timing advance characteristics of ignition system. Minimum engine RPM required to check maximum timing advance is 3000 RPM. IDLE TIMING ADJUSTMENT 1. Connect timing light to no. 1 (top) spark plug Before cranking engine, keep clear of propeller as it may rotate. 2. Shift engine to “Neutral”, IMPORTANT: To accurately time engine at cranking ‘speed, a fully charged battery must be used. 3. Holding throttle arm at idle position, crank engine with starter motor and adjust idle timing screw to align 2° BTDC timing mark of flywheel with timing pointer. Tighten locknut. 2°BTDC uafiitiitn a = Link Rod (¢- Mark of ll Pump Lever lala Timing Serow b+ Mark of il Pump Sedy d= Mark NOT Use bb Locknut 90-13645-2 1095 ELECTRICAL AND IGNITION 20-3MAXIMUM TIMING 1. Hold control arm so that maximum spark advance screw is against stop. 2. Crank engine with starter motor and adjust maxi- mum spark advance screw to align the specified BTDC timing mark on flywheo! with timing pointer (due to the advance characteristic of this ignition system, this cranking speed aduustment will auto- matically be reduced by 2° at an engine speed of ‘5000 RPM). Tighten locknut. 2oaat ‘8 Control Arm Maximum Spark Advance Serew -Locknut NOTE: If inital timing adjustments are made without engine running, then final timing checks should be made with engine running due timing advance char- acteristics of ignition system. Minimum engine RPM required to check maximum timing advance is 3000 RPM. MAXIMUM THROTTLE 1. Hold throtte arm against full throttle stop screw. ‘Adjust ul throte stop screw to allow throttle shut- ters to open fully, then turn stop serew in (clock- wise) an additional 1/2 tur, to prevent throttiele- ver of center carburetor from acting as a stop. Tighten locknut 20-4 ELECTRICAL AND IGNITION ey 2. Install remaining spark plugs and high tension spark plug leads, be 24a 3 Throtle Arm 'b- Full Throttle Stop Serew = Locknut IDLE ADJUSTMENT 1. With engine in water, connect electrical harness and fuel line to engine. Start engine and allow to warm up, 90-13645-2 1095,low speed mixture screws properly (refer to “Car- buretor” section), ye seated 3 Cr tile tums out 3. Holding throtle arm (NO TAG) atidle position, ad- just ide timing serew (NO TAG) to attain an en- gine idle RPM of 650-700 RPM in “Forward” gear. Tighten locknut (NO TAG) and turn off engine. 2° BTDC a Tot fm king Seow ¢ Locket NOTE: On this type of engine, idle RPM is adjusted exclusively with ignition timing. 90-13645-2 1095 Throttle Cable Installation 4. With end of throttle cable connected to throttle le- ver, hold throttle lever against idle stop. Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop. Lock barrel in place. IMPORTANT: Excessive preload on throttle cable will cause difficulty when shifting from forward to neutral. (Readjust throttle cable barrel, if neces- sary.) 2. Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop. Preload is correct when paper can be re- moved without tearing but has some drag on it, (Readjust throttle cable barrel, if necessary.) ELECTRICAL AND IGNITION 20-5Timing/Synchronizing/ Adjusting (4 Cylinder Models) Specitications Models 100/115 Full Throttle RPM Range 4750 - 5250 Idle RPM (in “FORWARD” Gear) 650 - 700 Maximum Timing @ S000 APM | 23° B. TD. (@ Cranking Speed) (25° BTD.C) Tae Timing 2 -F ETDS Spark Plug NGK BPSHN-10" {0.040 in (1.0mm) gap] NGK BPZBH-N-10" {0.049 in (1.0mm) gap] NGK BUHW. Firing Order 1-3-2-4 “Improves running quality between 1800 — 2000 RPM Special Tools Part No. Description "SI-SEZAT | Dial Indicator Gauge Kit "37-5059 Service Tachometer *91-99379 Timing Light * May be obtained locally 20-6 ELECTRICAL AND IGNITION ry Timing Pointer Alignment Engine could start when turning flywheel to check timing pointer alignment. Remove all spark plugs from engine to prevent engine from starting. 1, Remove aft cow! support bracket. 2. Install Dial Indicator 91-58222A1 into no. 1 (top) cylinder. 3. Turn flywheel in a clockwise direction until no. 1 pistonisa TDC, then set Dial Indicator at"0" (zero), 4. Turn fiywheel counterclockwise until Dial Indica- tor needle reads approximately 0.600 in. BTDC, then turn flywheel clockwise, so that needle reads 0.554 in, BTDC exactly. 5. Reposition timing pointer, if necessary. so that 0.554 in. mark is aligned with groove in timing pointer. 6. Remove Dial Indicator and reinstall spark plug and spark plug lead on no. 1 cylinder. {a Timing Pointer 90-13645-2 1095,CARBURETOR SYNCHRONIZATION 1. Remove sound box cover. Loosen cam flower adustment sere 2. 3. Loosen 6 synchronizing screws, 4, Look into throats of carburetors and make sure all throttle shutters are completely closed. 5. Apply light down pressure on carburetor synchro- nizing shaft and tighten 6 synchronizing screws from ‘op to bottom. 6. Recheck throttle shutters and make any neces- sary adjustment. 7. Hold throttle arm so that the throttie stop screw is against stop, 8. Place roller of cam follower against throttle cam and adjust throttle stop screw to align raised mark of throttle cam with center of cam follower roller. Tighten locknut. ° WN 25488 a-Cam Follower Agjustment d= ldo Stop Screw Scrow Foler b- Synchronizing Serews —_f » Throtle Cam = Throtte Arm g Locknut 9. Holding throttle arm at idle position, adjust cam follower so that a clearance of 0.005 in. - 0.020 in. (0.127mm - 0.508mm) exists between roller and throttle cam. Tighten screw securing cam follow er. 90-13645-2 1095 eRe OS soa Pate 2 ete Cam 2 eee 10. Hold throttle arm against full throttle stop. Adjust {ull throttle stop screw to allow throttle shutters to ‘open fully. To prevent throttle shutters to act as a ‘stop, screw in stop screw clockwise 1/2 tum and tighten locknut. gy) > (ff Gs 2200s a Throte Arm bb - Full Throttle Stop Serow ELECTRICAL AND IGNITION 20-711. Hold throttle cam in full throttle position. If neces: ‘sary adjust acceleration pump adjusting bolts po- sition so that a gap of 0.030 in. (0.762mm) exists between throttle cam and top of acceleration pump aluminum housing. a Throtte Cam b- Botts 6 - 0.090 in. (0.762mm) Gap 6 Accolerator Pump 20-8 ELECTRICAL AND IGNITION IMPORTANT: Some engines may have an addi- nal stamped mark (d) which SHOULD NOT be used. 1. While holding throttle arm at idle position, adjust length of link rad so that stamped mark of oll pump body aligns with stamped mark of oil pump lever. 2. Move throttle arm from idle to wide open throttle while checking link rod for any interference hoses, cable ties, etc. 2977 (o- Mark of Ol Pump Lover d- Mark NOT Used a Link Rod 1b Mark of Ol Pump Body TIMING ADJUSTMENTS A CAUTION Engine can be timed while cranking engine with starter motor. To prevent engine from starting when being cranked, all spark plugs should be removed. NOTE: I initial timing adjustments are made without engine running, then final timing checks should be made with engine running due timing advance char- acteristics of ignition system. Minimum engine RPM required to check maximum timing advance is 3000 RPM. 1. Insert Spark Gap Tool (91-63998A1) in no. 1 (top) cylinder spark plug boot and attach alligator clip, to good ground. 2, Remove throttle cable barrel from barrel retainer. IDLE TIMING ADJUSTMENT Before cranking engine, keep clear of propeller, as it may rotate. IMPORTANT: To accurately time engine at crank- ing speed, a fully charged battery must be used. 90-13645-2 1095,1. Connect ming ight. 1 op) sparkplug lead 2. Shift engine into neutral. 3. Holding throttle arm at idle position, crank engine with starter motor and adjust idle timing screw to align 2 degrees BTDC timing mark of flywheel with timing pointer. Tighten locknut MAXIMUM TIMING 1. Hold control arm against maximum advance stop. Crank engine with starter motor and adjust maxi- mum advance screw to align 25° BTDC mark on flywheel with timing pointer (due to the advance characteristics of ignition system, this cranking speed adjustment will automatically be reduced to 23° BTDC at engine speed of 5000 RPM). Tighten locknut. NOTE: If initial timing adjustments are made without engine running, then final timing checks should be ‘made with engine running due timing advance char- acteristics of ignition system. Minimum engine RPM required to check maximum timing advance is 3000 RPM. | FO | © ls a= te Ting Serow | D- Locknut i, © i? © S Q 23008 = Conta! Arm Maximum Revanee Serew -Locknut 90-13645--2 1095 ELECTRICAL AND IGNITION 29Carburetor Specifications ey Carburetor number stamped at TOP of carburetor mounting flange NOTE: Early model engines may have identification stamped on face of air box mounting flange. Carb Number Location ModelHP | Main Jet” | Bow Vent Jet WME-17, 20- 7 | — Top Carburetor 2 | Top Center Carburetor 3 | Bottom Genter Carburetor 100 054 None Bottom Carburetor WME14, 27-7 | Top Carburetor 2 | Top Center Carburetor 3 | Bottom Center Carburetor 18 o76 None Bottom Carburetor * Standard jts listed are for operation of engine from 0-762 m (0-2500 tt) of elevation (see jet size char’ INITIAL STARTING ADJUSTMENTS NOTE: For adjusting carburetor throttle linkage and synchronizing carburetors, see section “Timing/ ‘Synchronizing/Adjusting’ of this manual. Ater service or replacement of carburetor, turn low speed mixture screw adjustment in (clockwise) until it seats lightly, then back off (each carburetor) to speci- fications (100-1-8/4 turns or 118-1-1/2 turns). This wil permit engine start-up. LOW SPEED MIXTURE ADJUSTMENTS NOTE: Only the top two carburetors on four cylinder models have an adjustable low speed mixture screw. 1. Start engine and allow to warm up (run for several minutes). Throttle back to idle for about one min- Ute to allow RPM to stabilize. With engine running at idle speed (in water) in “Forward! gear (prop on), turn law speed mixture ‘screw, IN (clockwise) until engine starts to “bog” down and misfire. Back out 1/4 turn or more, 8. Check for too lean mixture on acceleration 2c-10 ELECTRICAL AND IGNITION 4, DO NOT adiust leaner than necessary to attain reasonable smooth idling. When in doubt, stay on the slightly rich side of the adjustment. 2 Low Speed Mixture Screw 90-13645-2 1095,Idle Adjustment 1. With engine in water, connect electrical hamess and fuel line to engine. Start engine and allow to warm up, 2. Properly adjust carburetor low speed mixture screws. Refer to “Carburetor Adjustments” sec- tion 3A, 3. Holding throttle arm at idle position (throttie cable barrel removed from barrel retainer), adjust idle timing screw to attain an engine idle RPM of 650-700 RPM in “Forward” gear. Tighten locknut and turn off engine. 8 Idle Timing Screw bb-Locknut 90-13645-2 1095 Throttle Cable Installation 4. With end of throttle cable connected to throttle le- ver, hold throttle lever against throttle stop, Adjust throttle cable barrel to slip into barrel retainer on able anchor bracket with a very light preload of throttle lever against throttle stop. Lock barrel in place. IMPORTANT: Excessive preload on throttle cable will cause difficulty when shifting from forward to neutral. (Readjust throttle cable barrel, if neces- sary.) 2. Check preload on throttle cable by placing a thin piece of paper between throttle stop screw and stop. Preload is correct when paper can be re- moved without tearing, but has some drag on it. Readjust throttle cable barrel, if necessary.) 8. Reinstall sound box cover. ELECTRICAL AND IGNITION 2cELECTRICAL AND IGNITION WIRING DIAGRAMSTable Of Contents Engine Wiring Diagram (3 Cylinder Models with Low Oil Warning Module) Engine Wiring Diagram (3 Cylinder Models without Low Oil Warning Module) Engine Wiring Diagram (3 Cylinder Models ‘with Small Voltage Regulator/Rectifier) Engine Wiring Diagram (4 Cylinder Models) Engine Wiring Diagram (4 Cylinder Models ‘with Small Voltage RegulatorRectifior) Power Trim System Wiring Diagram (3 Cylinder Models using COMMANDER 2000 Side Mount Remote Control) Power Trim System Wiring Diagram (8 Cylinder Models using COMMANDER: Side Mount Remote Control} Page 2D-1 20-2 20-3 20-4 20-5 20-6 20-7 ay Page Power Trim System Wiring Diagram (4 Cylinder Models using COMMANDER. 2000 Side Mount Remote Control) 20-8 Tachometer (with Adjustable Dial) and ‘Trim Indicator Gauge Wiring Diagram ..... 20-9 Key/Choke Switch Continuity Test (COMMANDER 2000 Side Mount jemote Control) 20-10 COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with, Warning Horn) Wiring Diagram 20-11 COMMANDER 2000 Side Mount Remote Control (Electri¢ Start With Warning Horn) Wiring Diagram 20-12 COMMANDER Side Mount Remote Control (Power TrimTilt Electric Start with Warning Horn) Wiring Diagram 20.13 90-13645-2 495Engine Wiring Diagram (3 Cylinder Models With Low Oil Warning Module) a- Stator = Trigger «Switch Box 4 Ignition Col Cyinder No. 1 @ = Ignition Col Cylinder No. 2 {= Igniton Cod Cylinder No. 3 9 Mercury (Tit) Stop Switch h- Starter Motor | Staner Solenoid 90-13645-2 495 weosg-xe ELECTRICAL AND IGNITION BLK © BLACK BLU © BLUE BRN ¢ BROWN GRY © GRAY GRN © GREEN PUR © PURPLE RED ¢ RED TAN © TAN VIO © VIOLET WHT © WHITE YEL ¢ YELLOW 50388 Vottage ReguiatorRecitior Fuse Holder (20 Amp Fuse) Battery \Winrg Harness Connector ichmant Valve Terminal Block Temperature Switch — Opens [170°F Closes (190°F Low Ol Waring Module Low Oil Sensor 8 77°08"), 8° (88°C + 8°)] 20-1Engine Wiring Diagram (3 Cylinder Models Without Low Oil Warning Module) 8 Stator Trigger - Switch Box Ignition Coil Cynder No. 1 Ignition Col Cynder No. 2 £ = Ignition Col Cynder No. 3 @ = Mercury (Tit) Stop Switch h- Starter Motor 1 Starter Solenoid 20-2 ve inEngine Wiring Diagram (3 Cylinder Models With Small Voltage Regulator/Rectifier) se F BROWN GRY © GRAY GRN © GREEN VIO © VIOLET WHT © WHITE YEL © YELLOW 51008 a Stator Vottage RegulatorRecitior Trigger 20Amp Fuse Switch Box Battery 4 Ignition Col Cyinder No. 1 Fuel Enrichment Valve Ignition Col Cylinder No. 2 Torminal Bock 1 = Ignition Col Gyinder No. 3 = Mercury Switch = Starter Motor 1 Starter Solenoid (verheat Temperature Sensor Warning Module Low Oil Sensor (Float) 90-13645-2 495 ELECTRICAL AND IGNITION 20-3