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Mercury 200 OptiMax Jet Drive Service Manual Download Page 137

Charging and Starting System  

Page 2B-26

90-8M0050731   MAY  2011

Starter Circuit Troubleshooting

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Summary of Contents for 200 OptiMax Jet Drive

Page 1: ...tallation 2 Electrical A Ignition B Charging and Starting System C Timing Synchronizing and Adjusting 3 Fuel System A Fuel Pump B Direct Fuel Injection C Oil Injection D Emissions 4 Powerhead A Powerhead B Cooling 5 Pump Unit A Pump Unit Important Information 1 Electrical 2 Fuel System 3 Powerhead 4 Pump Unit 5 ...

Page 2: ...t S N 0E379931 90 8M0050731 MAY 2011 200 OptiMax Jet Drive www mercurymarine com au 41 71 Bessemer Drive Dandenong South Victoria 3175 Australia www mercurymarine com P O Box 1939 Fond du Lac WI 54936 1939 USA www marinepower com Parc Industriel de Petit Rechain B 4800 Verviers Belgium 2011 Mercury Marine All rights reserved Printed in U S A 90 8M0050731 MAY 2011 ...

Page 3: ...in the recommended service procedures of Mercury Marine Power Products including the use of mechanics common hand tools and the special Mercury Marine or recommended tools from other suppliers We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and or results of each method Therefore anyone who uses a service procedure and or tool whi...

Page 4: ...cury Marine Power Product is a combination of many machined honed polished and lapped surfaces with tolerances measured in the ten thousands of an inch mm When any product component is serviced care and cleanliness are important It should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure This is considered standard shop prac...

Page 5: ...Page iv ...

Page 6: ...nce Specifications 1A 2 Ignition Specifications 1A 3 Charging and Starting Specifications 1A 3 Fuel Specifications 1A 4 Fuel Lift Pump Specifications 1A 4 Fuel Rail Specifications 1A 4 Fuel System Specifications 1A 4 Air Compressor Specifications 1A 5 Powerhead Specifications 1A 6 Cooling System Specifications 1A 6 Wear Ring Impeller Specifications 1A 6 ...

Page 7: ...p alternator Cooling system Water cooled Lubrication system Multi port oil injection Engine oil reservoir capacity 0 71 liter 0 44 US quart Engine control system SmartCraft propulsion control module PCM Maintenance Specifications Maintenance Specifications Recommended fuel type Unleaded 87 octane minimum Recommended oil TC W3 Premium Plus or OptiMax 2 Cycle Outboard Oil Oil tank capacity Engine re...

Page 8: ...t the alternator at 2000 RPM 42 48 A Voltage set point 14 5 0 25 volts Regulator current draw1 Ignition switch OFF 0 585 mA Ignition switch ON 150 0 mA Starter draw Under load 200 A No load 65 A Average engine RPM when cranking 300 325 RPM Starter solenoid current at 12 6 volts Pull in coil 40 A Hold in coil 10 A Start solenoid current draw 4 A Starter brush length minimum 6 35 mm 0 25 in Battery ...

Page 9: ...si Maximum 68 9 kPa 10 psi Fuel lift pump amps 1 2 A Fuel Rail Specifications Fuel System Specifications Fuel pressure 751 5 14 kPa 109 2 psi Air pressure 655 14 kPa 95 2 psi Tracker valve spring pressure 103 5 kPa 15 psi Fuel injector ohm resistance 1 8 0 1 Ω Direct injector ohm resistance 1 3 0 3 Ω Direct injector color Gray Fuel rail water cooling None Fuel System Specifications Fuel Lift Pump ...

Page 10: ...mpressor Specifications Air compressor type Reciprocating piston Single cylinder oil lubricated water cooled Air compressor output 655 14 kPa 95 2 psi Displacement 116 cc 7 07 cid Cylinder bore 65 0 mm 2 559 in Cylinder bore taper maximum 0 025 mm 0 001 in Cylinder bore out of round maximum 0 025 mm 0 001 in Cylinder bore type Cast iron Stroke 34 9 mm 1 374 in Piston type Aluminum Piston diameter ...

Page 11: ...778 89 1032 mm 3 507 3 508 in Reed stand open maximum 0 51 mm 0 020 in Water pressure At 900 1000 RPM 1 4 41 kPa 0 2 0 6 psi At 5500 RPM boat on plane 69 103 kPa 10 15 psi Cooling System Specifications Cooling System Specifications Water pressure At 900 1000 RPM 1 4 41 kPa 0 2 0 6 psi Temperature sensor Between black and each tan black wire Refer to Temperature Sensors Between each lead and ground...

Page 12: ...er Separating Fuel Filter 1B 4 Fuses 1B 5 Battery Inspection 1B 6 Battery Information 1B 6 Spark Plug Inspection and Replacement 1B 6 Flywheel Cover Removal and Installation 1B 7 Removal 1B 7 Installation 1B 8 Compressor Air Intake Filter 1B 8 Removal 1B 9 Installation 1B 9 Flushing the Cooling System 1B 9 Corrosion Control Anodes 1B 10 Bilge Siphon Inspection 1B 10 Alternator Belt Inspection 1B 1...

Page 13: ...d stator assembly fill lubricant 92 858064K01 95 2 4 C with Teflon Tensioner pulley grease fitting 92 802859A 1 Inspection and Maintenance Schedule Prior to Every Use Check that lanyard stop switch stops the engine Visually inspect the fuel system for deterioration or leaks Check the engine compartment and use your nose to detect any fuel fumes Check the throttle shift and steering system for bind...

Page 14: ...ns a Hydro surge grate b Casted aluminum grate c Rock grate Manual Clearing WARNING Avoid injury resulting from contacting the rotating impeller or having hair clothing or loose objects drawn into the water intake and wrapping around the impeller shaft Stay away from the water intake and never insert an object into the water intake or water outlet nozzle when the engine is running If weeds or debr...

Page 15: ...eck for leaks before attempting to start the engine and wipe up any spilled fuel immediately Before servicing any part of the fuel system stop the engine and disconnect the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved receptacle Any fuel system servi...

Page 16: ... are protected from overload by fuses in the wiring If a fuse is open try to locate and correct the cause of the overload If the cause is not found the fuse may open again 1 Open the fuse holder and look at the silver colored band inside the fuse If the band is broken replace the fuse 2 Replace the fuse with a new fuse with the same rating The fuses and circuits are identified as follows a Good fu...

Page 17: ...Description Nm lb in lb ft Hex nuts 13 5 120 IMPORTANT Battery cable size and length is critical Refer to engine installation manual for size requirements The decal needs to be placed on or near the battery box for future service reference One 5 16 in and one 3 8 in hex nut is supplied per battery for wing nut replacement Metric hex nuts are not supplied NOTICE DTS OptiMax Engines DO NOT USE DEEP ...

Page 18: ...ng spark plugs clean off any dirt on the spark plug seats Install plugs finger tight and then tighten 1 4 turn or tighten to the specified torque Description Nm lb in lb ft Spark plug 27 20 7 Inspect the expansion chamber gasket on the adapter plate Do not remove the gasket from the adapter plate Replace if damaged 8 Install the expansion chamber Tighten the mounting nuts to the specified torque I...

Page 19: ... cover slides down onto the intake flange 2 Push the cover down onto the alignment pins and onto the air intake tube for the air compressor a Air plenum intake flange b Air intake tube for the air compressor 3 Attach the retaining strap to the cover a Retaining strap Compressor Air Intake Filter The filter should be changed every 100 hours of operation or once a season IMPORTANT Never run the engi...

Page 20: ...he jet drive without water circulating through the cooling system to prevent damage to the unit a Flushing attachment hull mount b Flushing attachment engine compartment mount 1 Locate the flush adapter in the boat Some boats may have the adapter mounted in the hull or mounted in the engine compartment 2 With engine OFF remove the cap from the flush adapter and attach a water hose IMPORTANT Do not...

Page 21: ...be slowly eroded instead of the Mercury Jet Drive metals a Anodes All anodes require periodic inspection especially in saltwater Inspect anodes periodically refer to the Inspection and Maintenance Schedule Replace any anodes before they are 50 corroded Never paint or apply protective coating on the anode as effectiveness of the anode will be reduced Bilge Siphon Inspection Inspect the bilge siphon...

Page 22: ...ning Lubricant NOTE When draining the drive housing lubricant visually check for water in the lubricant It may have settled to the bottom and will drain before the lubricant or it may have mixed with the lubricant giving it a milky color In either case have the drive housing checked by your authorized Mercury Marine dealer Water in the lubricant can cause premature gear or bearing failure or in fr...

Page 23: ...ator assembly d Screws securing stator assembly 4 e Vent plug f Fill drain hole and plug 1 Disconnect the shift and steering cables from the reverse gate and rudder Be careful not to change adjustments 2 Remove the four screws securing the nozzle assembly to the stator 3 Remove the nozzle 4 Remove the four screws securing the stator assembly to the drive housing and the two screws to the ride plat...

Page 24: ...tion may be felt in the control box and failure of the forward stop or other components will result Submerged Power Package A submerged power package requires prompt service by an authorized dealer after recovery This immediate attention is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine Storage Preparation The major consideration in prepa...

Page 25: ...g fill and drain plugs Apply Loctite 567 Pipe Sealant to the threads of the stator drain and fill plugs Tighten all plugs securely Drain and fill the drive housing and stator assembly with High Performance Gear Lubricant Refer to Drive Housing Lubricant and Stator Assembly Lubricant Lubricate all lubrication points Touch up any paint nicks See your dealer for touch up paint Tube Ref No Description...

Page 26: ...rmance 1C 12 Weather 1C 12 Weight Distribution Passengers and Gear Inside the Boat 1C 12 Bottom of Boat 1C 12 Water Absorption 1C 12 Cavitation 1C 12 Ventilation 1C 13 Detonation 1C 13 Following Complete Submersion 1C 13 Saltwater Submersion 1C 13 Submerged While Running 1C 13 Submerged Engine Freshwater 1C 13 Compression Check 1C 14 Cylinder Leakage Testing 1C 15 Analysis 1C 15 Shipping of Hazard...

Page 27: ... body aspiration Fuel system Computer controlled sequential multi port electronic direct fuel injection Ignition system SmartCraft propulsion control module PCM digital inductive Charging system Regulated belt driven 60 amp alternator Cooling system Water cooled Lubrication system Multi port oil injection Engine oil reservoir capacity 0 71 liter 0 44 US quart Engine control system SmartCraft propu...

Page 28: ...f manufacture d Pump serial number IMPORTANT For convenience stickers listing the pump model and serial number and the bar code information are supplied in an envelope affixed to the pump unit The pump unit serial number stickers must be taken out of the envelope and applied to the electrical plate a Pump unit model and serial number stickers 2 b Electrical plate a c a d 44931 XXXXXXX XL Mercury M...

Page 29: ...1 Flywheel 2 Alternator 3 Fuel lift pump 4 Fuel filter 5 Vapor separator tank VST 6 VST drain plug 7 VST fuel inlet hose 8 Oil pump inlet hose 9 Expansion chamber 10 Oil pump 11 14 pin engine harness connector 12 Starter motor solenoid 13 Manifold absolute pressure MAP sensor 45357 1 2 3 4 5 6 9 10 12 13 11 7 8 ...

Page 30: ...General Information Notes 90 8M0050731 MAY 2011 Page 1C 5 ...

Page 31: ...General Information Page 1C 6 90 8M0050731 MAY 2011 200 OptiMax SportJet Powerhead Port View 45359 1 2 3 4 5 6 7 9 15 14 8 10 11 12 13 21 22 17 16 18 23 24 25 26 28 29 30 31 32 33 34 35 36 19 20 27 ...

Page 32: ...r inlet hose 14 Air pressure test fitting 15 Fuel hose 16 Excess fuel return to vapor separator 17 Oil reservoir 18 Throttle lever 19 Fuse cover 20 Throttle stop 21 Excess air hose to adapter plate 22 2 psi check valve 23 Inlet oil hose filter 24 Oil reservoir hose 25 Low pressure fuel pump outlet hose 26 Water fuel separator 27 Low pressure electric fuel pump 28 Drain fitting 29 Vapor separator t...

Page 33: ...Air handler assembly 6 Positive 12 volt cable 7 Oil pump inlet hose 8 Oil pump 9 Fuel inlet hose 10 Engine control module ECM 11 Negative battery cable 12 Main power relay 13 Start solenoid 14 Positive 12 volt starter cable 15 Positive battery cable 16 Ignition coil 17 Oil fuel paddle wheel sensor connector 18 Expansion chamber 45358 1 2 3 4 5 6 6 7 8 9 14 15 16 11 10 17 18 12 13 ...

Page 34: ...owerhead Aft View 1 80 psi air hose 2 Water pressure sensor 3 SmartCraft connector 4 Cover 5 Expansion chamber 6 Expansion chamber coolant hose 7 Exhaust pipe coolant hose 8 T fitting 9 Water bypass hose 10 Air compressor inlet 11 Air compressor 45360 1 2 3 4 5 6 7 8 9 10 11 ...

Page 35: ...0 Fuel filter 11 Vapor separator tank VST vent fitting 12 Throttle position sensor TPS 13 Air temperature sensor 14 Manifold absolute pressure MAP sensor 15 90 psi fuel hose to fuel rail 16 Throttle plate assembly 17 Starter motor 18 Crankshaft position sensor CPS 19 Fuse cover 20 Oil return hose from air compressor 21 Oil hose to air compressor 22 SmartCraft connector 23 Water pressure sensor 24 ...

Page 36: ...c Hull d Shift cable assembly through the hull fitting e Water intake f Wear ring g Trim plate h Stator Mercury Jet Pump Port View a Reverse gate b Steering cable assembly c Hull d Steering cable assembly through the hull fitting e Water intake f Trim plate g Forward stop h Rudder 45362 a b d e f g h c a b d e f g h c 45363 ...

Page 37: ...r back and forth bow steer Bottom of Boat For maximum speed a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in the fore and aft direction Hook Exists when the bottom is concave in fore and aft direction when viewed from the side When the boat is planing hook causes more lift on the bottom near the transom and allows the bow to drop thus ...

Page 38: ...gine is recovered and with spark plugs removed the engine fails to turn over freely when turning the flywheel the possibility of internal damage bent connecting rod and or bent crankshaft exists If this is the case the powerhead must be disassembled Submerged Engine Freshwater IMPORTANT Engine should be run within two hours after recovery or serious internal damage may occur If unable to start eng...

Page 39: ...l source If the engine starts it should be run for at least one hour to eliminate any water in the engine 11 If the engine fails to start determine the cause fuel electrical or mechanical Compression Check 1 Remove spark plugs 2 Install compression gauge in spark plug hole 3 Hold throttle plate at WOT 4 Pull on the recoil rope or crank the engine over until the compression reading peaks on the gau...

Page 40: ...terial HazMat and Engine Components Containing Hazardous Material Outboard Service Bulletin 2008 07 There are a number of United States regulations regarding the shipment of hazardous material These regulations apply not only to shipments within the United States but to import and export shipments as well It is important to comply with all of these regulations This bulletin is intended to provide ...

Page 41: ...e to electric fuel pumps Carbureted engines must be completely run dry and have stalled due to lack of fuel All engines must have any remaining fluids oils drained including engine and gearcase oil and hydraulic fluids including power trim fluid and disconnected fluid pipes that previously contained fluid must be sealed with leakproof caps that are positively retained Major assemblies such as gear...

Page 42: ...where the decal will be positioned with the wetting solution 5 Position the prewetted decal on the wetted surface and slide into position 6 Starting at the center of the decal lightly squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface 7 Wip...

Page 43: ...General Information Notes Page 1C 18 90 8M0050731 MAY 2011 ...

Page 44: ... 9 Installing the Jet Pump 1D 10 Installing the Flush Kit 1D 14 Installing the Powerhead 1D 15 Flywheel Cover Removal and Installation 1D 16 Removal 1D 16 Installation 1D 17 Installing the Throttle Cable 1D 17 Fuel Hose and Vent Hose Connections 1D 18 Battery Cable Connections 1D 19 Battery Cable Installation Requirements 1D 19 Battery Cable Connections 1D 19 Remote Harness Connection 1D 20 Oil In...

Page 45: ...ngine or major component failure IMPORTANT Indicates information or instructions that are necessary for a particular step or action NOTE Indicates information that helps in the understanding of a particular step or action This installation section has been written and published by the service department of Mercury Marine to aid installers when installing the products described herein It is assumed...

Page 46: ...of gasoline IMPORTANT Oil must be NMMA certified TC W3 2 Cycle oil Periodically consult with your dealer to get the latest gasoline and oil recommendations If Mercury Precision or Quicksilver 2 Cycle Outboard Oil is not available substitute another brand of 2 Cycle outboard oil that is NMMA Certified TC W3 The use of an inferior 2 Cycle outboard oil can reduce engine durability Damage from use of ...

Page 47: ...urized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage The integrated fuel demand valve has a manual release The manual release can be used pushed in to open bypass the valve in case of a fuel blockage in the valve Integrated fuel demand valve a Manual release b Vent water drain hole c O ring seal Low Permeation Fuel Hose Outboard To meet the Environmenta...

Page 48: ...e damage resulting from the use of improper gasoline is considered misuse of the engine and damage caused will not be covered under the limited warranty Fuel Ratings Mercury engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications USA and Canada having a posted pump Octane Rating of 87 R M 2 minimum Premium gasoline 92 R M 2 Octane is a...

Page 49: ...cohol do not store the gasoline in the fuel tank for long periods Whereas cars normally consume alcohol blend fuels before they can absorb enough moisture to cause trouble boats often sit idle long enough for phase separation to take place In addition internal corrosion may take place during storage if alcohol has washed protective oil films from internal components Installation Requirements Insta...

Page 50: ...cable The length in the chart is for one way from battery to engine Use the longest length cable positive or negative when making a selection from the chart Battery Cable Length Minimum Cable Gauge 1 1 m up to 3 1 2 ft 25 mm 4 1 1 1 8 m 3 1 2 6 ft 35 mm 2 1 8 2 3 m 6 7 1 2 ft 50 mm 1 2 3 2 9 m 7 1 2 9 1 2 ft 50 mm 0 2 9 3 7 m 9 1 2 12 ft 70 mm 00 3 7 4 6 m 12 15 ft 95 mm 000 4 6 5 8 m 15 19 ft 120...

Page 51: ...Distance between the highest point on the expansion chamber and the top of the transom c Distance between the highest point on the expansion chamber and the waterline d Waterline at rest at maximum load Measurement c 20 3 cm 8 in minimum Fuel Delivery System Low Permeation Fuel Hose Requirement Required for Mercury Jet Drives manufactured for sale sold or offered for sale in the United States The ...

Page 52: ...ion harness is required be sure to secure connection properly Fasten harnesses to the boat at least every 460 mm 18 in using appropriate fasteners Remote Control and Cables The remote control must provide the following required features Start in gear protection Neutral RPM limit at 2000 RPM This applies to dual lever remote controls as well as single lever remote controls High strength mechanism t...

Page 53: ...e of the tunnel This will ensure consistency of location as well as size Installing the Jet Pump CAUTION The location dimensions and thickness of the hull cut out opening is critical for preventing water and exhaust intrusion excessive engine or pump vibration and power package assembly movement Ensure the location dimensions and thickness of the hull cut out opening are witin the recommended spec...

Page 54: ...o Loctite 454 Prism Instant Adhesive Gel Front portion of grommet 3 Install the through the hull fitting bellow assemblies into the tunnel Tighten securely a Bellows b Clamp c Nut d Through the hull fitting 4 Insert the steering cable through the port side through the hull fitting and bellows 5 Route the steering cable through the holes in the port side flange on the side of the pump housing a b b...

Page 55: ...ension shown Do not tighten the nuts until after the final steering adjustment is made a Tab hole b Nut c Tab washer d 6 4 mm 0 25 in 9 Insert the shift cable through the starboard side through the hull fitting and bellows 10 Route the shift cable through the holes in the starboard flange on the side of the pump housing a Shift cable IMPORTANT Ensure that the shift lever in the control box is set ...

Page 56: ...les are below the tunnel grommet flange on the pump to prevent pinching of the cables between the pump and boat 12 Install the jet pump by pushing the unit through the opening in the tunnel grommet The ride plate seal should fit snug in the boat tunnel without any gaps along the perimeter a Tunnel grommet b Jet pump NOTE Before installing the drive housing cover check the ride plate seal for prope...

Page 57: ... with four M10 x 1 5 nuts Tighten the nuts to the specified torque a M10 x 1 5 nut 4 b Drive housing cover Description Nm lb in lb ft M10 x 1 5 nuts 47 35 Installing the Flush Kit 1 Attach the flush hose to the fitting and fasten with a cable tie Failure to fasten the hose will allow water to fill the boat a Fitting b Cable tie c Flush hose a b 44454 a a b a 20063 c a b 43945 ...

Page 58: ...of the motor compartment that has a mounting surface thicker than the depth of the mounting bracket screws 3 Locate an easily accessible area within the motor compartment to mount the flush adapter bracket Secure the bracket to the mounting surface with the three screws provided a Mounting surface b Bracket c Screw 3 4 Snap the flush adapter into the bracket as shown a Bracket b Flush adapter Inst...

Page 59: ... 5 Lower the powerhead onto the drive housing cover Align the driveshaft splines with the crankshaft 6 Secure the powerhead to the drive housing cover with eleven M10 x 1 5 nuts Follow the torque sequence shown and tighten the nuts to the specified torque a M10 x 1 5 nuts 11 Description Nm lb in lb ft M10 x 1 5 nuts First torque 27 20 Final torque 47 35 Flywheel Cover Removal and Installation Remo...

Page 60: ...ge Tilt the cover side to side until the cover slides down onto the intake flange 2 Push the cover down onto the alignment pins and onto the air intake tube for the air compressor a Air plenum intake flange b Air intake tube for the air compressor 3 Attach the retaining strap to the cover a Retaining strap Installing the Throttle Cable 1 Shift the remote control into the neutral position b a 44578...

Page 61: ...ollows a Shift the jet drive into gear a few times to activate the throttle linkage b Return the remote control to neutral c Place a thin piece of paper between the idle adjustment screw and the idle stop The adjustment is correct when the paper can be removed without tearing but has some drag on it IMPORTANT The idle stop screw must be touching the stop d Adjust the cable barrel if necessary a Id...

Page 62: ... required in some states that the battery be installed in an enclosed case Refer to regulations for your area IMPORTANT Engine electrical system is negative ground Battery Cable Installation Requirements 1 Battery cables must be routed above normal bilge water levels throughout their length 2 Battery cables must be routed to avoid contact with metallic fuel system components 3 The positive battery...

Page 63: ... Liquid Neoprene a Positive battery cable attaching location b Negative battery cable attaching location Tube Ref No Description Where Used Part No 25 Liquid Neoprene Battery cable connections 92 25711 3 Remote Harness Connection Connect the remote 14 pin wiring harness to the 14 pin connector located on the engine a 14 pin connector b Remote 14 pin wiring harness a b 44239 a b 44240 ...

Page 64: ...lter and connect the oil hose with the blue stripe to the fitting Secure the hose to the fitting with a cable tie a Oil hose with blue stripe b Oil filter 4 Remove the shipping cap from the hose fitting on the starboard side of the engine and connect the oil hose without the blue stripe to the fitting Secure the hose to the fitting with a cable tie a Hose fitting b Oil hose without blue stripe Ste...

Page 65: ...ng to a loss of steering control of the boat and possible personal injury or death 3 Center the rudder assembly on the nozzle 4 Center the steering wheel by turning the wheel lock to lock and positioning the wheel midway between each lock 5 Adjust the cable end adapter until the through the hole in the adapter lines up with the threaded hole in the steering arm This is the steering cable fine adju...

Page 66: ... Locknut 8 70 10 Apply Perfect Seal to the exposed threads 19 5562 Tube Ref No Description Where Used Part No 19 Perfect Seal End threads and the cable conduit end 92 34227Q02 11 Loosen the bellows nut and tighten against the cable end adapter 12 Turn the rudder to port to compress the bellows as much as possible 13 Pull the bellows over the cable conduit and secure with the bellows clamp a Bellow...

Page 67: ...and the cable conduit end 92 34227Q02 Shift Cable Adjustment NOTICE Pre load in forward or reverse position can damage the stop the shift cable or the control box components Adjust the shift cable to prevent the reverse gate from loading against the forward or reverse stop 1 Thread the cable barrel onto the shift cable a Cable barrel 2 Use a degreaser to clean off all oil film from the area on the...

Page 68: ...der 6 Install the shift cable end in the slot of the reverse gate and secure with the clevis pin flat washer and cotter pin Bend the ends of the cotter pin to secure WARNING If not properly installed the reverse gate can interfere with water coming off the rudder suddenly and unexpectedly slowing the boat This can cause serious injury or death from occupants being thrown within or out of the boat ...

Page 69: ...s non locking as they could vibrate off and disengage the shift cable a Reverse gate b Forward stop c Cable barrel d Locknuts e Shift cable retainer 8 Shift the control box into the reverse shift position Adjust the reverse stop located on the starboard side of the nozzle so that the stop just touches the reverse gate with the control handle in the reverse position Tighten the reverse stop screw t...

Page 70: ...that ran out of fuel or drained of fuel the fuel system should be filled as follows Turn the ignition key switch to the ON position for three seconds and then turn the key switch back to the OFF position for five seconds Continue this procedure five times This will allow the electric fuel pump to fill the fuel system Filling the Oil System Filling the Oil Tanks 1 Remove the fill cap from the remot...

Page 71: ...o prime the oil pump If air bubbles are present it will be necessary to prime the oil pump a Oil pump b Oil supply hose Priming the Oil Pump NOTE Prime the oil system using the computer diagnostic system CDS 1 Connect the computer diagnostic system CDS to the 10 pin plug on the side of the engine a Computer diagnostic system CDS b Connect to engine 2 Select model M2 Jet Drive 200 DFI drive 3 Look ...

Page 72: ...e one starboard and one port a Trim plate components one each side b Jam nut c Small diameter washer d Large diameter washer e Plate f Screw 2 Turn both screws the exact same number of turns Tighten both jam nuts against the trim plate The distance from top of nut to bottom of boss should be equal on both sides WARNING Adjusting the trim plate may affect boat handling resulting in sensitive steeri...

Page 73: ... boat to sink Installing the Bilge Siphon WARNING Installing the bilge siphon incorrectly can result in siphoning water directly into the boat can sink the vessel causing product damage serious injury or death Always install the bilge siphon break above the water line and keep the hole open 1 Uncoil the siphon hose from the exhaust manifold 2 Use a cable tie and fasten the bilge hose so that the s...

Page 74: ...hrough the hull fitting should be positioned so the water spray will be pointed downward 3 After the location has been selected for the through the hull fitting drill a 14 3 mm 9 16 in diameter hole 4 Apply Marine Sealer to the entire length of threads and under the head of the through the hull fitting Fasten the fitting into the transom with the brass nut provided a Through the hull fitting b Bra...

Page 75: ... hoses The mufflers and exhaust hoses must be adequately supported for proper orientation and to prevent overstressing the exhaust components The support requirements will vary with exhaust system design and the amount of G forces to be encountered Rubber hose should be connected to pipes with flares or beads or barbs to prevent the hose from sliding off the pipe under pressure Measuring the Exhau...

Page 76: ...piping between the expansion chamber and muffler must be made of 7 6 cm 3 0 in O D tubing Tubing must be either 5052 or 6061 14 gauge aluminum or type 304 14 gauge stainless steel to protect against corrosion Flange assembly two required or equivalent through transom fittings may extend 12 7 cm 5 in below the waterline for quiet idle operation Exhausting under a swim platform or other horizontal s...

Page 77: ...ht piping All exhaust hoses and or tubes must be secured with two clamps at each connection To minimize the backflow of exhaust gases into the cockpit or interior of boat the exhaust termination should be located as far outboard of the centerline as practical Final system installation shall be reviewed by a Mercury Marine field representative using a modified expansion chamber to ensure back press...

Page 78: ... muffler tube never gets within 5 1 cm 2 0 in of the maximum depth waterline When installing muffler assemblies a 5 1 cm 2 0 in minimum distance between bottom of muffler and waterline must be kept This minimum distance must be calculated with boat under its maximum load Tilt muffler assemblies back towards outlet to ensure self draining Covers may be placed over exhaust outlets to reduce exhaust ...

Page 79: ...ation location and requirements Material 6061 T6 14 gauge aluminum 44295 66 mm 2 6 in 76 mm 3 0 in 78 7 mm 3 10 in 68 6 mm 2 7 in 10 mm 0 4 in 51 mm 2 0 in 152 mm 6 0 in 10 mm 0 4 in 51 mm 2 0 in Recommended Predelivery Engine Break in Procedure NOTE Do not use premixed gas and oil in this engine Use straight gasoline during break in and after engine break in The recommended predelivery engine bre...

Page 80: ...inutes 4000 RPM Next 5 minutes 4500 RPM Next 5 minutes 5000 RPM Step 2 Next 14 minutes Remove the boat from the trailer and run on the water The run times for the first four wide open throttle encounters is very critical Keep the run time within the given range Run the engine at the listed run time and RPM speed Run Time Engine RPM Speed First 10 seconds 3 seconds wide open throttle 5600 RPM Next ...

Page 81: ...____ RPM All fuel connections tight Ignition timing set to specs Throttle shift and steering system adjusted correctly and fasteners torqued Boat handling Shift cable adjusted to keep the reverse gate above the rudder in forward with slack pulled out of cable and against stop AFTER ON WATER TEST Pump housing oil level full Torque adapter plate fasteners Oil injection reservoir full and bled No fue...

Page 82: ...tion 2A 16 Propulsion Control Module PCM 2A 17 Propulsion Control Module PCM Removal and Installation 2A 17 Ignition Coils 2A 18 Ignition Coil Test 2A 18 Ignition Coil Removal and Installation 2A 20 Crankshaft Position Sensor CPS 2A 21 Crankshaft Position Sensor CPS Removal and Installation 2A 22 Throttle Position Sensor TPS 2A 22 Throttle Position Sensor TPS Troubleshooting 2A 23 Throttle Positio...

Page 83: ...l systems for proper function diagnostics and calibration purposes For additional information pricing or to order the Computer Diagnostic System contact SPX Corporation 28635 Mound Rd Warren MI 48092 or call USA 1 800 345 2233 Canada 800 345 2233 Europe 49 6182 959 149 Australia 03 9544 6222 Extension Cable 84 825003A 1 4012 Data link extension harness 3 05 m 10 ft between the adapter harness and ...

Page 84: ...Ignition Notes 90 8M0050731 MAY 2011 Page 2A 3 ...

Page 85: ...Ignition Page 2A 4 90 8M0050731 MAY 2011 Electrical Components 44730 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26 27 28 29 30 1 31 ...

Page 86: ...mbly 9 1 Black cable assembly 10 1 Solenoid assembly 11 2 Lockwasher 12 2 Cap nut and nut 10 32 13 2 Nut 5 16 18 7 62 14 2 Grommet 15 2 Bushing 16 2 Screw M6 x 25 11 97 17 1 Yellow insulator boot 18 1 Bushing 19 1 Grommet 20 1 Bracket 21 1 Screw M6 x 25 7 62 22 1 Main power relay assembly 23 6 Screw 1 4 20 x 3 1 4 7 62 24 1 Clip 25 1 Water pressure sensor 26 6 Ignition coil 27 6 Spacer 28 1 High t...

Page 87: ...Ignition Page 2A 6 90 8M0050731 MAY 2011 Electrical Plate Hardware 44729 1 1 2 2 3 3 4 5 5 6 7 6 7 8 9 10 11 12 13 14 15 8 9 16 17 18 ...

Page 88: ...ion Torque Nm lb in lb ft 1 1 Electrical plate 2 2 Clip 3 2 Clip 4 2 Clip 5 4 Screw M6 x 10 4 35 6 4 Grommet 7 4 Bushing 8 2 Bushing 9 2 Stud M6 x 50 10 2 Washer 11 2 Nut M6 7 62 12 3 Cable tie clip 13 2 Clip 14 1 Clip 15 AR Cable tie 16 1 Cover 17 1 Sleeve 18 1 Flange screw M6 x 14 7 62 ...

Page 89: ...Ignition Page 2A 8 90 8M0050731 MAY 2011 Electrical Plate Engine Harness 44731 1 2 3 4 5 6 ...

Page 90: ...age 2A 9 Electrical Plate Engine Harness Ref No Qty Description Torque Nm lb in lb ft 1 1 Engine harness 2 1 Fuse cover 3 1 Weather cap connector 4 1 Fuse cover 5 3 Fuse 20 A yellow 1 Fuse 15 A blue 1 Fuse 5 A brown 6 1 Fuse 5 A brown ...

Page 91: ... or cut wires and chafing Secure the grounds and all connections involving ring terminals Apply Liquid Neoprene to all ring terminal connections Tube Ref No Description Where Used Part No 25 Liquid Neoprene All ring terminal connections 92 25711 3 Inspect the fuel pump harness connector for corrosion loose wires or pins pushed back into the connector Check the fuel pump pressure Check the air comp...

Page 92: ...lugs1 Remove fuel pump fuse Unplug all direct injector connectors Remove spark plugs one at a time from each cylinder Connect spark plug leads to spark gap tester Crank engine or use CDS output load test for each ignition coil and observe spark If no spark is present replace appropriate ignition coil If spark is present replace spark plugs 1 9 PCM not functioning Injection system Listen for inject...

Page 93: ...ect injector Refer to specifications for ohm test 3 4 Failed fuel injector Refer to specifications for ohm test 3 5 Bad coil weak spark Refer to specifications for ohm test 3 6 Flywheel misaligned during installation Remove flywheel and inspect 4 Engine Idles Fast RPM 700 or Surges Cause Action 4 1 Broken fuel pressure regulator or tracker diaphragm Measure fuel pressure Remove and inspect diaphra...

Page 94: ...or stop running Refer to Crankshaft Position Sensor Test 8 Engine RPM Reduced to Idle Only Cause Action 8 1 TPS failed Refer to 2 4 Use CDS to monitor system 9 Loss of Spark on One Cylinder Cause Action 9 1 Loose wire or pin connectors between PCM and coil primary Check connectors 9 2 Faulty ignition coil Replace coil 9 3 Faulty spark plug Replace spark plug 9 4 Faulty spark plug wire Replace spar...

Page 95: ...a signal to the coil driver to dwell and then provide spark When the engine is operating at lower RPM this process is repeated in quick succession to provide a multi strike spark for each combustion event The number of strikes per event is varied depending on RPM and load requirements The spark plug irridium electrode and ground extends into the combustion chamber Fuses IMPORTANT Always carry spar...

Page 96: ...er relay can be tested with the computer diagnostic system CDS Computer Diagnostic System CDS Order through SPX Adapter Harness 84 822560A13 Extension Cable 84 825003A 1 Use the DMT 2004 digital multimeter for all of the following tests DMT 2004 Digital Multimeter 91 892647A01 1 Disconnect the engine harness from the main power relay 2 Perform a visual inspection of the main power relay spade term...

Page 97: ...ning strap Installation 1 Lower the cover opening onto the air plenum intake flange Tilt the cover side to side until the cover slides down onto the intake flange 2 Push the cover down onto the alignment pins and onto the air intake tube for the air compressor a Air plenum intake flange b Air intake tube for the air compressor 3 Attach the retaining strap to the cover a Retaining strap b a 44578 b...

Page 98: ...he engine is not started the PCM completes the ground circuit for the main power relay and a 5 VDC reference to the engine sensors The PCM monitors engine sensors SmartCraft vessel sensors and will transmit fault information from these sensors to the helm Once the engine has started the PCM controls and monitors all engine functions Propulsion Control Module PCM Removal and Installation PCM Remova...

Page 99: ...oil Test The ignition coils used on OptiMax engines use an internal electronic spark trigger EST ignition coil driver Battery voltage is supplied to the ignition coils and coil drivers when the main power relay is engaged The crankshaft position sensor sends a position signal to the propulsion control module The propulsion control module calculates the exact position of the crankshaft and determin...

Page 100: ...y No Continuity EST Pin A No Continuity X 8500 12000 ohm No Continuity 29000 50000 ohm 11000 21000 ohm EST Low Pin B No Continuity 8500 12000 ohm X No Continuity 39000 51000 ohm 21000 31000 ohm Secondary Low Pin C No Continuity No Continuity No Continuity X No Continuity No Continuity Primary Ground Pin D No Continuity 20000 50000 ohm 31000 51000 ohm No Continuity X 13000 23000 ohm Battery Pin E N...

Page 101: ...om the ignition coil 5 Disconnect the spark plug lead from the ignition coil 6 Remove the screw and nut securing the ignition coil a Coil cover b Sleeve and screw M6 x 14 flange c Screw 1 4 20 x 3 1 4 6 d Electrical plate e Water pressure sensor f Ignition coil 6 g Spacer 6 h Nut and washer 6 each i Spark plug lead 6 Ignition Coil Installation 1 Secure the ignition coil to the electrical plate Tig...

Page 102: ...ross the end if not replace the sensor 2 The tip of the sensor must be clear of metal debris ring gear filings NOTE A magnet is mounted in the sensor tip If the magnet is missing the sensor will not operate properly 3 Inspect the flywheel pattern for Excessive corrosion The teeth should have square edges Only one open space on either side of the pattern groups 4 Replace the flywheel if it does not...

Page 103: ...der block and secure with two M5 x 16 screws Tighten the screws to the specified torque 2 Connect the engine harness to the CPS a Screw M5 x 16 2 b Crankshaft position sensor CPS Description Nm lb in lb ft Screw M5 x 16 5 5 49 3 Connect the battery cables to the batteries Throttle Position Sensor TPS The throttle position sensor TPS transmits throttle angle information to the propulsion control mo...

Page 104: ...er is not pushing on the throttle if foot throttle is used or advancing the throttle only on the control box Check the throttle cam to roller adjustment If the roller is not down in the pocket valley area on the cam there is a tendency for the roller to ride up or down on the cam which causes the TPS link arm to push pull on the TPS lever resulting changing values Throttle Position Sensor TPS Remo...

Page 105: ...Sensor bracket b TPS c TPS cover d Screw 10 32 x 2 3 e Throttle link arm assembly f TPS lever g Screw M6 x 25 3 h Washer 3 i Grommet 3 j Bushing 3 k Throttle cam Description Nm lb in lb ft Screw M6 x 25 11 5 102 Screw 10 32 x 2 4 35 3 Connect the engine harness to the TPS 4 Connect the battery cables to the batteries 45713 k a b d c e f g h i j ...

Page 106: ...AP sensor does not appear to be indicating a pressure change shake or move the sensor harness and connector If the pressure begins to change look for broken loose or corroded wires Computer Diagnostic System CDS Order through SPX Adapter Harness 84 822560A13 Extension Cable 84 825003A 1 2 Turn the ignition key switch to the OFF position Disconnect the engine harness connector from the MAP sensor 3...

Page 107: ...ensors when the ignition key is in the run position The computer diagnostic system CDS can provide a numerical readout of the head temperature before and after the engine is started With the engine not running cylinder head coolant temperature should be approximately the same as the ambient air temperature After the engine is started the temperature sensor should indicate a rise in head coolant te...

Page 108: ...ss connector from the sensor harness connector 2 Remove the two screws securing the thermostat covers to the cylinder head 3 Remove the cover and O ring 4 Remove the sensor from the cylinder block Cylinder Head Coolant Temperature Sensor Installation 1 Inspect the sensor O ring for cuts or abrasions Replace the O ring as required 2 Apply Loctite 567 PST Pipe Sealant to the threads of the sensor Tu...

Page 109: ...hake or move the sensor harness and connector If the temperature begins to change look for a broken loose or corroded wire Computer Diagnostic System CDS Order through SPX 2 Disconnect the connector from the sensor 3 Perform a visual inspection of the pins at the sensor and the wires coming from the connector Look for broken bent or corroded pins at the sensor and loose broken or corroded wires at...

Page 110: ...der head and air compressor failure If a temperature sensor should fail or become disconnected power will be limited to a maximum of approximately 4500 RPM Battery voltage too high or too low Battery voltage greater than 16 volts or less than 10 volts will result in engine output power being reduced The higher or lower the voltage is outside of these parameters the greater the percentage of power ...

Page 111: ...t higher speeds Moving throttle lever back to idle resets the system Oil level is critically low Continuous Engine Guardian System is activated Power will be limited The oil level is critically low in the engine mounted oil reservoir Refill the engine mounted oil reservoir and the remote oil tank Oil pump failure Continuous Engine Guardian System is activated Power will be limited The warning horn...

Page 112: ...Winter Storage of Batteries 2B 10 Flywheel Removal and Installation 2B 11 Removal 2B 11 Installation 2B 12 Alternator System 2B 12 Alternator Description 2B 12 Diagnosis of Alternator System on the Engine 2B 13 Alternator System Circuitry Test 2B 14 Current Output 2B 16 Alternator Removal and Installation 2B 17 Belt Tensioner Removal and Installation 2B 21 Starter System 2B 23 Starter Removal and ...

Page 113: ...ranking amperes 1000 Cold cranking amperes 800 Ampere hour Ah 180 Lubricants Sealants Adhesives Tube Ref No Description Where Used Part No 25 Liquid Neoprene Starter brush lead connection Starter ground wire connection 92 25711 3 95 2 4 C with Teflon Bushing and belt tensioner arm assembly Battery terminal bolts Belt tensioner Solenoid actuating plunger 92 802859A 1 Special Tools Flywheel Holding ...

Page 114: ... 91 892647A01 A COM mA V Hz mV V Hz TEMP mA A IG IP OFF Hz TEMP 4516 Measures RPM on spark ignition SI engines ohms amperes AC and DC voltages records maximums and minimums simultaneously and accurately reads in high RFI environments Clamp on Current Probe 91 802650 1 4006 Measures the current output of battery charging systems or current draw of electric motors ...

Page 115: ...Charging and Starting System Page 2B 4 90 8M0050731 MAY 2011 Flywheel Alternator 1421 95 95 23 27 25 26 24 15 20 19 20 17 18 22 21 16 10 11 12 13 14 5 4 28 4 5 8 7 7 9 14 9 1 4 5 7 3 2 6 29 ...

Page 116: ...5 54 40 11 1 Cable assembly 12 1 Pin 13 1 Bracket 14 3 Screw 0 312 18 x 1 in stainless steel with nylon patch 20 180 15 15 1 Spring 16 1 Belt tensioner arm assembly 17 1 Stud M10 x 85 18 1 Nut M10 20 180 15 19 1 Bushing 20 2 Washer 21 1 Pulley assembly 22 1 Screw M10 x 35 stainless steel 34 25 23 1 Belt 24 1 Flywheel 25 1 Nut 0 625 18 170 125 26 1 Washer 0 641 x 1 250 x 0 190 27 1 Yellow plug 28 1...

Page 117: ...Charging and Starting System Page 2B 6 90 8M0050731 MAY 2011 Starter Motor Components 4253 2 2 5 6 3 7 8 9 10 1 11 12 4 4 14 13 ...

Page 118: ... Through bolt 12 5 110 3 1 Solenoid kit 4 1 Gear kit 5 1 Nut M8 stainless steel 9 80 6 1 Lockwasher 0 312 7 1 Nut M5 stainless steel 2 5 22 8 1 Lockwasher M5 9 1 Screw and lockwasher 0 250 20 x 0 625 stainless steel 11 97 10 1 Cable assembly 6 0 in black 11 1 Rubber stop 12 2 Starter motor collar 13 1 Start in gear caution decal 14 1 High voltage warning decal ...

Page 119: ...s than 10 VDC replace the battery NOTE The voltage reading in step 2 is the base voltage The base voltage reading will be compared to the voltage readings obtained in the following steps 3 With the key switch in the START position measure the voltage from the battery positive post not the cable clamp to the starter post the stud where the battery positive cable is connected Record the voltage read...

Page 120: ...andards to minimize risk of fire or explosion Do not use replacement electrical or fuel system components that do not comply with these standards When servicing the electrical and fuel systems properly install and tighten all components IMPORTANT Deep cycle batteries are not suitable for use as engine starting batteries or for use as accessory batteries that are connected to high output engine cha...

Page 121: ...occurs Full charge specific gravity is 1 260 1 275 corrected for electrolyte temperature with electrolyte level at 4 8 mm 3 16 in over plate unless electrolyte loss has occurred from age or overfilling in which case specific gravity reading will be lower For most satisfactory charging lower charging rates in amperes are recommended 3 If after prolonged charging specific gravity of at least 1 230 o...

Page 122: ...mage personal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing installing or removing engine or drive components 1 Disconnect both of the battery cables from the batteries 2 Remove the flywheel cover from the engine 3 Remove the alternator belt 4 Disconnect the spark plug leads fr...

Page 123: ...ridge contains six diodes which allows current to flow from the ground through the stator and to the output terminal but not in the opposite direction When current is supplied to the rotor field winding and the rotor is turned the movement of the magnetic fields created induces an alternating current into the stator windings The rectifier bridge changes this alternating current to direct current w...

Page 124: ...ystem wiring for defects Check all connections for tightness and cleanliness particularly the battery cable clamps and battery terminals 4 The alternator mounting bracket has rubber isolation mounts Ensure the alternator ground cable is secured to the alternator and the cylinder block IMPORTANT The red fusible link cable on the alternator must be tight A discolored insulator sleeve indicates the l...

Page 125: ...ates the alternator diodes are functional A reading above 0 25 AC volts indicates the diodes are faulty and the alternator must be replaced NOTE A voltage reading between 13 5 and 14 8 volts are for starting systems without a battery isolator installed A battery isolator will have a parasitic voltage drop and the alternator will compensate for the voltage drop The output voltage may be as high as ...

Page 126: ...the alternator 2 Connect the positive DMT lead to the red pin and the negative DMT lead to the alternator ground 3 The DMT should indicate the battery voltage If battery voltage is not present check the red lead for a loose or dirty connection or damaged wiring a Sensing circuit red lead b Alternator ground Excitation Circuit 1 Unplug the red and purple excitation sensing wire connector from the a...

Page 127: ...f install ammeter with clamp on current probe capable of reading 60 amperes onto the alternator charging conductor 10 AWG red wire 2 Start the engine and allow to warm up 3 Battery voltage should be between 14 0 and 15 0 VDC for all engine RPM s 4 Supply an external load to the battery until the battery voltage drops to 13 volts or less 5 Alternator output current should correspond with the table ...

Page 128: ...r Removal and Installation Removal WARNING Performing service or maintenance without first disconnecting the battery can cause product damage personal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing installing or removing engine or drive components 1 Disconnect the battery cables...

Page 129: ...ker bar 5 Remove the M10 x 55 bolt and nut securing the alternator ground wire and alternator to the cylinder block 6 Remove the M10 x 100 bolt securing the alternator to the cylinder block a Bolt M10 x 55 and nut b Bolt M10 x 100 7 Remove the M10 x 120 bolt and nut securing the isolation brackets to the alternator a Bolt M10 x 120 and nut b Isolation brackets a b 32050 a b 32051 a b 32054 ...

Page 130: ... and nut 2 Install a washer onto the M10 x 55 alternator bolt Install the alternator ground wire onto the alternator bolt 3 Install a washer between the alternator and the isolation bracket grommet 4 Secure the alternator to the isolation bracket with the M10 x 55 bolt a large washer and nut Do not tighten the bolt and nut at this time a Bolt M10 x 55 b Washer c Alternator ground wire d Washer e L...

Page 131: ... x 55 and nut 54 40 Bolt M10 x 120 and nut 54 40 8 Connect the excitation sensing wire connector to the alternator 9 Connect the fusible link cable to the alternator output terminal Secure the fusible link cable with a M6 nut Tighten the nut to the specified torque Protect the alternator output terminal with the insulator boot a Fusible link cable b Excitation sensing wire connector Description Nm...

Page 132: ...emoval and Installation NOTE The following procedure shows the alternator removed from the powerhead for installation clarity It is not necessary to remove the alternator to remove and install the belt tensioner Removal 1 Remove the alternator belt 2 Remove the flywheel 3 Remove the nut and washer securing the belt tensioner to the cylinder block Remove the belt tensioner spring and washer 30273 4...

Page 133: ...orroded a Bushing b Screw securing the pulley c Grease fitting Description Nm lb in lb ft Screw M10 x 35 34 25 Tube Ref No Description Where Used Part No 95 2 4 C with Teflon Belt tensioner 92 802859A 1 4 Lubricate the washer with 2 4 C with Teflon and install onto the belt tensioner stud NOTE Lubricate the belt tensioner spring contact surfaces on the tensioner arm with 2 4 C with Teflon The grea...

Page 134: ...n lb ft Nut M10 20 180 15 8 Lubricate the belt tensioner assembly with 2 4 C with Teflon through the grease fitting Tube Ref No Description Where Used Part No 95 2 4 C with Teflon Belt tensioner 92 802859A 1 Starter System Starter Removal and Installation Starter Removal WARNING Performing service or maintenance without first disconnecting the battery can cause product damage personal injury or de...

Page 135: ...enoid j Starter ground cable Starter Installation 1 Align the locating tab on the starter with the slot in the cylinder block a Starter b Locating tab c Slot hidden 2 Install the starter onto the cylinder block 3 Secure the starter to the cylinder block with a bracket cover and four bolts The upper right bolt must have the starter ground cable installed Tighten the bolts to the specified torque 4 ...

Page 136: ...bleshooting the starter circuit verify the following conditions The battery is fully charged The remote control lever or tiller handle shift control is in neutral All power and ground terminal connections are tight and free of corrosion Check all cables and wiring for frayed or worn insulation Check all of the fuses related to the operation of the engine Use the DMT 2004 digital multimeter or an e...

Page 137: ...14 S3 BLK BLK BLK RED BRN PUR BLK YEL BLK YEL PUR BLK RED BLK C10 BLK YEL YEL RED PUR BLK RED PUR WHT YEL RED BLK BLK BLK RED BLU RED BLU YEL RED YEL RED YEL RED YEL RED T12 BLK BLK T9 RED C14 RED RED RED BRN WHT T16 WHT DK BLU YEL RED PUR BLK GRY TAN LT BLU LT GRN WHT LT BLU WHT BLK YEL C1 A B C D E F G H J K L N P M a b d e f g 1 2 5 6 7 8 9 4 3 10 11 29916 c ...

Page 138: ...werhead ground Voltage reading should be the same as test point 2 Voltage reading less than test point 2 Ensure the nuts are torqued to specifications at test points 3 and 4 Ensure the cable connection is not corroded Disconnect the low pressure and high pressure electric fuel pumps from the engine harness This will prevent the fuel pumps from activation Disconnect the crankshaft position sensor f...

Page 139: ...witch is defective 6 Connect the meter at test point 7 between the start solenoid and a common powerhead ground Turn the key switch to the START position Battery voltage indicated and the starter solenoid does not click The starter solenoid is defective The wire between the start solenoid and the starter solenoid is open or corroded Check for continuity between test points 4 and 7 No battery volta...

Page 140: ... to the positive copper terminal and the black meter lead to engine ground This test should result in battery voltage If so proceed to step three If not inspect the cables and connections leading to the positive terminals If no problems are found replace the solenoid Example Description Reading 7720 Connect the red lead to the positive pin Place the black lead to engine ground Battery voltage 3 Me...

Page 141: ...measure the resistance across the silver terminals Example Description Reading 7733 Connect a meter lead on each silver pin 2 5 2 75 Ω Starter Disassembly Solenoid Driven Bendix 1 Remove the two collars rubber stops and the screw securing the starter ground wire a Rubber stops 2 b Collars 2 c Screw securing ground wire 2 Remove the nut and lockwasher securing the starter brush lead to the solenoid...

Page 142: ...g securing the pinion gear to the starter shaft 2 Remove the pinion gear from the starter shaft NOTE The removal of the pinion gear may require the use of a small gear puller a Pinion gear b Snap ring Starter Assembly Solenoid Driven Bendix Pinion Gear Installation 1 Verify the starter shaft splines are clear of debris Use a razor blade to clear debris from the root area of the starter shaft splin...

Page 143: ...he starter shaft splines and secure with a new snap ring IMPORTANT Always install a new snap ring to retain the pinion gear a Pinion gear b Snap ring Solenoid Installation 1 Push the solenoid actuating plunger into the solenoid When released the solenoid actuating plunger should return to a fully extended position 18282 2 Lubricate the end of the solenoid actuating plunger with 2 4 C with Teflon a...

Page 144: ...so the two solder joints are closest to starter assembly a Solder joints b Starter brush lead 5 Install the starter brush lead onto the solenoid terminal and secure with a lockwasher and nut Tighten the nut to the specified torque 6 Apply Liquid Neoprene to the starter brush lead connection to prevent corrosion a Starter brush lead b Nut and lockwasher Description Nm lb in lb ft Nut 9 80 Tube Ref ...

Page 145: ...sion a Rubber stops 2 b Collars 2 c Screw securing ground wire Description Nm lb in lb ft Stainless steel screw and washer 0 250 20 x 0 625 11 97 Tube Ref No Description Where Used Part No 25 Liquid Neoprene Starter ground wire connection 92 25711 3 Key Switch Test Three Position Key Switch a Pin A b Pin B c Pin C d Pin D e Pin E f Pin F Ref No Pin Wire Color Description a A Red 12 volts b B Black...

Page 146: ...ey Switch a Pin A b Pin B c Pin C d Pin D e Pin E f Pin F Ref No Pin Wire Color Description a A Red 12 volts b B Black Ground c C Purple white Accessory d D Purple Run e E Black yellow Off f F Yellow red Start Meter Test Leads Key Position Reading Ω Red Black Pin B Pin E Off Continuity Pin A Pin C Accessories Continuity Pin A Pin F Run Continuity Pin A Pin C Pin A Pin F Start Continuity Pin F Pin ...

Page 147: ...Charging and Starting System Notes Page 2B 36 90 8M0050731 MAY 2011 ...

Page 148: ...ctrical Section 2C Timing Synchronizing and Adjusting Table of Contents Throttle Cam Adjustment 2C 2 Maximum Throttle 2C 2 Throttle Plate Stop Screw 2C 4 Crankshaft Position Sensor Air Gap 2C 4 Throttle Position Sensor TPS Adjustment 2C 4 Idle Speed Adjustment All Models 2C 5 ...

Page 149: ...Loosen the roller arm screw 2 Allow the cam roller to rest on the throttle cam Adjust the idle stop screw on the throttle arm to align the cam roller in the pocket of the throttle cam 3 Verify there is 0 127 0 127 mm 0 005 0 005 in clearance between the cam roller and throttle cam Tighten the roller arm screw a Roller arm screw b Roller c Throttle cam d Idle stop screw Maximum Throttle 1 Hold the ...

Page 150: ...op screw 4 Verify the roller can be lifted off the cam at full throttle to prevent the linkage from binding Adjust the throttle stop screw if necessary a Throttle shaft arm b 0 508 mm 0 020 in clearance c Stop on attenuator box d Roller e Throttle cam f Throttle stop screw g Throttle arm 45433 b f g c a d e ...

Page 151: ...nspect sensor for damage from foreign debris Replace sensor as required 1 Remove flywheel cover Refer to Section 2A Flywheel Cover Removal and Installation 2 Inspect for damage or debris a Crankshaft position sensor b Bracket screw Description Nm lb in lb ft Crankshaft position sensor bracket screw 5 44 3 Install flywheel cover Throttle Position Sensor TPS Adjustment The TPS is not adjustable The ...

Page 152: ...731 MAY 2011 Page 2C 5 Idle Speed Adjustment All Models Engine idle speed is not adjustable The parameters affecting idle speed can be checked and monitored with the computer diagnostic system CDS Computer Diagnostic System CDS Order through SPX ...

Page 153: ...Timing Synchronizing and Adjusting Notes Page 2C 6 90 8M0050731 MAY 2011 ...

Page 154: ...ions 3A 2 Fuel Pump System Components 3A 4 Anti Siphon Valves 3A 6 Fuel Lift Pump Description Operation 3A 6 Testing the Fuel Lift Pump Vacuum 3A 6 Fuel Lift Pump System Troubleshooting 3A 7 Vacuum Test 3A 7 Pressure Test 3A 7 Fuel Lift Pump Removal Inspection Installation 3A 8 Removal 3A 8 Filter Replacement 3A 9 Fuel Lift Pump Installation 3A 9 ...

Page 155: ...rd Oil or Premium Plus 2 cycle TC W3 Outboard Oil Gasoline oil ratio At idle 300 400 1 At wide open throttle 40 1 Fuel Lift Pump Specifications Fuel Lift Pump Specifications Fuel lift pump pressure at idle Normal 6 9 13 8 kPa 1 2 psi Maximum 68 9 kPa 10 psi Fuel lift pump amps 1 2 A Special Tools Hose Clamp Tool Kit 91 803146A04 5819 Aids in the installation of high pressure Oetiker hose clamps Cl...

Page 156: ...Fuel Pump Notes 90 8M0050731 MAY 2011 Page 3A 3 ...

Page 157: ...Fuel Pump Page 3A 4 90 8M0050731 MAY 2011 Fuel Pump System Components 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 19 21 17 18 7 7 20 7 7 7 46118 ...

Page 158: ...11 5 102 4 1 Screw M6 x 35 11 5 102 5 1 Hose 6 1 Hose 7 A R Hose clamp 18 3 mm 8 1 Lift pump and filter 9 11 Bracket 10 1 Wire assembly 11 1 Bracket kit 12 1 Grommet 13 1 Low pressure fuel pump boost pump 14 1 90 elbow 15 1 O ring 16 1 Fitting 17 1 O ring 18 1 Hose 19 1 Water sensor 20 3 Screw M8 x 35 and washer 16 142 21 1 Vapor separator tank VST assembly ...

Page 159: ... one that has a lighter spring tension or 2 replace it with a solenoid operated fuel shutoff valve NOTE If the fuel tank is pressurized a fuel demand valve is required Refer to Section 1D Fuel Demand Valve Requirements or Integrated Fuel Demand Valve Requirements Fuel Lift Pump Description Operation The fuel lift pump is an electric fuel pump that supplies fuel from the fuel tank to the low pressu...

Page 160: ... Test This test is normally performed at idle speed As engine speed increases vacuum increase slightly The increased vacuum reading should not exceed the specification Vacuum Test Normal reading Less than 2 5 in Hg of vacuum Reading greater than 2 5 in Hg of vacuum Restricted anti siphon valve Restriction within the primer bulb Kinked or collapsed fuel hose Plugged water separating fuel filter in ...

Page 161: ...e internal diameter too small Use 5 16 I D fuel hose Excessive fuel lift required Fuel lift exceeds 2 5 in of vacuum mercury Problem No fuel flow Blown fuse Check the 3 amp fuse Low or no voltage at harness connection Check for loose corroded or damaged wires or connections 12 volts present and pump is not running Replace the fuel lift pump 12 volts present and pump is running Inspect fuel hose co...

Page 162: ...r there is a replaceable fuel filter on the pump which should be replaced every 100 hours or once a season Use a strap wrench to remove the filter Fuel Lift Pump Installation 1 Install the fuel pump inside the retaining clamp Secure the clamp with screw Tighten the screw to the specified torque Description Nm lb in lb ft Fuel lift pump retaining clamp screw M6 x 35 16 142 2 Connect the harness con...

Page 163: ...fuel hose to the fuel pump Secure the hose with an 18 3 mm hose clamp a Fuel lift pump clamp b Filter c Hose clamp d Harness connector e Screw M6 x 35 f Hose to VST g Hose clamp 18 3 mm Hose Clamp Tool Kit 91 803146A04 5 Run the engine and check for leaks a b d c g f e 45447 ...

Page 164: ...l 3B 30 Reed Block Assembly Removal 3B 33 Throttle Body Assembly Removal 3B 33 Air Management Assembly and Installation 3B 34 Vapor Separator Tank 3B 38 VST Removal 3B 38 VST Disassembly 3B 40 VST Assembly 3B 43 VST Installation 3B 47 Fuel Rail 3B 49 Fuel Pressure Regulator 3B 49 Fuel Pressure Regulator Cutaway 3B 50 Air Pressure Regulator 3B 51 Tracker Valve 3B 51 Fuel Injectors 3B 53 Fuel Rail R...

Page 165: ... 0 006 0 0010 in Middle ring 0 15 0 25 mm 0 006 0 0010 in Bottom ring 0 10 0 35 mm 0 004 0 014 in Reed stand open maximum 0 25 mm 0 0010 in Fuel System Specifications Fuel Lift Pump Specifications Fuel lift pump pressure at idle Normal 6 9 13 8 kPa 1 2 psi Maximum 69 kPa 10 psi Fuel lift pump amps 1 2 A Low Pressure Boost Pump Specifications Low pressure boost pump pressure at idle 41 62 kPa 6 9 p...

Page 166: ...p O rings O rings on the fuel rail air compressor hose fitting 92 858021K01 34 Special Lubricant 101 Fuel pump body seal and fuel pump outlet seal Fuel pump body seal Water separator fuel filter seal 92 802865Q02 66 Loctite 242 Threadlocker VST mounting screw threads VST ground wire screw threads 92 809821 95 2 4 C with Teflon Fuel injector O rings and screw threads Tracker diaphragm O ring and sc...

Page 167: ...47A01 A COM mA V Hz mV V Hz TEMP mA A IG IP OFF Hz TEMP 4516 Measures RPM on spark ignition SI engines ohms amperes AC and DC voltages records maximums and minimums simultaneously and accurately reads in high RFI environments Direct Injector Removal Tool 91 883521 8290 Aids in the removal of direct injectors from the fuel rail Direct Injector Harness 84 879346A49 45245 Connects to the direct injec...

Page 168: ...ector pintle Dial Indicator 91 58222A 1 9479 Used to obtain a variety of measurements including gear backlash pinion gear location and TDC Seal Teflon Ring Installation Tool 91 851980 3 8285 Aids in the installation of Teflon seals on direct injectors Seal Teflon Ring Sizing Tool 91 851980 2 8286 Compresses the Teflon seal on direct injectors after seal installation ...

Page 169: ...Direct Fuel Injection Page 3B 6 90 8M0050731 MAY 2011 Vapor Separator Components 4260 1 2 3 4 5 6 7 7 8 9 9 10 11 12 13 14 15 16 22 22 23 18 21 17 19 20 ...

Page 170: ... elbow fitting 4 1 Seal 5 1 Pump outlet fitting kit 6 1 O ring 7 7 Screw and washer 8 32 x 0 750 in 3 5 31 8 1 Gasket 9 1 Float kit 10 1 Pin 11 1 Needle valve 12 1 Screw 8 32 x 0 187 in 1 9 13 1 Pump kit 14 1 Sleeve 15 1 Bowl kit 16 1 Seal 17 1 Plug kit 18 1 O ring 19 2 Elbow fitting 20 1 Elbow fitting 21 1 Elbow fitting 22 1 Fuel filter kit 23 1 Water sensing probe ...

Page 171: ...Direct Fuel Injection Page 3B 8 90 8M0050731 MAY 2011 Air Handler and Flywheel Cover 30053 1 2 3 4 5 6 7 8 10 11 12 13 14 2 9 ...

Page 172: ...Qty Description Torque Nm lb in lb ft 1 1 Cover assembly 2 2 Grommet 3 1 Air filter 4 1 Cover 5 1 Grommet 6 1 Plug 7 1 Grommet 8 1 Start in gear decal 9 1 Crankshaft position sensor 10 2 Screw M5 x 16 5 5 49 11 1 Special pin 5 5 49 12 2 J clamp 13 12 Screw 1 4 20 x 1 1 2 in 20 177 14 1 J clamp ...

Page 173: ...Direct Fuel Injection Page 3B 10 90 8M0050731 MAY 2011 Air Handler Components 8338 1 2 3 4 5 6 7 8 9 10 11 12 8 10 13 14 15 7 16 17 19 20 21 18 22 ...

Page 174: ...in 11 5 102 6 1 Oil pump 7 6 Bushing 8 6 Grommet 9 3 Screw M8 x 35 16 142 10 6 Washer 0 344 x 1 00 x 0 063 in 11 1 Air plenum kit 12 3 Screw M8 x 30 16 142 13 1 Manifold air temperature MAT sensor 16 142 14 1 O ring 15 2 Screw M4 x 16 2 5 22 16 1 Throttle body assembly 17 1 O ring 18 4 Screw M6 x 40 7 5 66 19 1 Screw M6 x 16 4 5 40 20 1 Manifold absolute pressure MAP sensor 21 1 MAP sensor bracket...

Page 175: ...el Injection Page 3B 12 90 8M0050731 MAY 2011 Fuel Rail Components S N 0T178500 and Above 8335 110 6 6 18 16 15 17 19 24 23 7 3 3 25 4 4 4 4 4 4 4 4 5 14 22 11 31 32 8 13 10 12 9 7 5 6 6 20 21 1 27 29 30 2 28 26 ...

Page 176: ... Clamp 10 4 Clamp 11 6 Fuel injector 12 1 O ring kit 13 1 O ring kit 14 2 Clamp 15 1 Clamp 16 1 Air regulator 17 1 O ring kit 18 2 Clamp 19 4 Screw M5 x 16 8 71 20 1 Cover 21 1 Spring 22 1 Diaphragm assembly 23 2 O ring 24 1 Starboard plug 25 1 Fitting 26 1 O ring kit 27 6 Direct injector 28 6 Seal kit 29 4 Stud M10 x 91 30 4 Nut M10 45 33 31 6 Injector washer 32 4 Clip Tube Ref No Description Whe...

Page 177: ...Direct Fuel Injection Page 3B 14 90 8M0050731 MAY 2011 Fuel Hose Components 4256 3 8 1 8 8 5 8 8 8 8 8 6 7 4 4 2 ...

Page 178: ...MAY 2011 Page 3B 15 Fuel Hose Components Ref No Qty Description Torque Nm lb in lb ft 1 1 Hose 21 6 cm 8 5 in 2 1 Fuel return hose assembly 3 1 Fuel supply hose assembly 4 1 O ring kit 5 1 Hose 6 1 Hose 7 2 Sleeve 8 8 Hose clamp 18 3 mm ...

Page 179: ...Direct Fuel Injection Page 3B 16 90 8M0050731 MAY 2011 Air Hose Components 4257 1 1 2 3 6 4 5 7 8 9 ...

Page 180: ... Hose Components Ref No Qty Description Torque Nm lb in lb ft 1 2 Hose clamp 18 3 mm 2 1 Air supply hose 3 1 Insulation sleeve 4 1 Air balance hose assembly 5 1 Air bypass hose assembly 6 2 Cable tie 7 1 Worm gear clamp 8 1 Fitting 1 8 27 9 1 90 elbow fitting ...

Page 181: ... Injection Page 3B 18 90 8M0050731 MAY 2011 Air Compressor Components 29987 7 1 2 4 5 3 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38 40 40 39 39 41 17 42 43 ...

Page 182: ...iston assembly 12 1 Oil scraper ring 13 1 Top ring 14 1 Oil ring 15 1 Wrist pin 16 1 Piston with wrist pin 17 2 Lockring 18 1 Reed plate assembly 19 2 O ring 20 1 O ring 21 1 Seal 22 1 Compressor head kit 23 1 Fitting 24 4 Screw M8 x 14 27 20 25 1 Temperature sensor 26 1 Retainer 27 1 Screw M8 x 14 27 20 28 1 O ring 29 1 Fitting 30 2 Check valve fitting 31 1 Fitting 32 1 Fitting 33 1 Instruction d...

Page 183: ...31 MAY 2011 Ref No Qty Description Torque Nm lb in lb ft 39 4 Special washer 40 2 Nut 0 312 24 34 25 41 1 Pulley 42 1 Clamp 43 1 Washer Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Air compressor end cap screws 92 809819 ...

Page 184: ... Injection 90 8M0050731 MAY 2011 Page 3B 21 Air Compressor Components 29987 7 1 2 4 5 3 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38 40 40 39 39 41 17 42 43 ...

Page 185: ... the vapor separator tank then pushes the fuel through a water separating fuel filter This filter removes contaminants and water before the fuel reaches the vapor separator tank Fuel vapors are vented through a hose into the air compressor inlet on the front of the flywheel cover The electric fuel pump inside the VST is different than the fuel pump that is utilized on the standard EFI engine non D...

Page 186: ...ged into a machined cavity inside the air chamber of the air fuel rail This mixes the fuel with the air charge Next the direct injector will open discharging the air fuel mixture into the combustion chamber The direct injector directs the mixture at the bowl located in top of the piston The piston s bowl directs the air fuel mixture into the center of the combustion chamber This air fuel mixture i...

Page 187: ...stem test valve d Starboard fuel rail e Tracker valve f Fuel injector 6 g Direct injector h Water into fuel rail i Port fuel rail j Air pressure regulator k Fuel pressure regulator l Low pressure boost pump m Lift pump assembly n Water separating fuel filter o Fuel filter p High pressure fuel pump 46219 a b c d f h i j k l n o p g e m ...

Page 188: ...der valve T fitting 4 Turn the ignition key to the ON position The pressure must be within the specifications a Outlet fuel hose b Boost pump c Fuel hose d Schrader valve Low Pressure Electric Fuel Pump Boost Pump Low pressure fuel pump output 41 62 kPa 6 9 psi Schrader Valve Tee 22 849606 Digital Pressure Meter 91 892651A01 Dual Fuel Air Pressure Gauge Kit 91 881834A 1 Fuel Pressure Gauge Kit 91 ...

Page 189: ...pecification Pressure 751 5 14 kPa 109 2 psi Air Pressure Specification Pressure 655 14 kPa 95 2 psi Digital Pressure Meter 91 892651A01 Dual Fuel Air Pressure Gauge Kit 91 881834A 1 Fuel Pressure Gauge Kit 91 881833A03 Air Compressor Pressure Test Install the pressure gauge assembly to fuel rail pressure test valves The fuel pressure and air pressure test valves are located on the starboard rail ...

Page 190: ...the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately 1 If you suspect the fuel rails or a component of the fuel delivery system electronic fuel pumps VST fuel lines fuel rails air system connect a dual pressure liquid filled gauge to the port and starb...

Page 191: ...t injector Injector may be damaged or stuck open Perform a resistance check or leak test to determine cause Check O ring for nicks or cuts Fuel pressure and air pressure are both low Air regulator Provide 80 psi of shop air to the air rail test Schrader valve This should be the last component to check remove Visually inspect the air regulator cover If air is escaping through the small hole the reg...

Page 192: ...he fuel return line to the high pressure fuel pump VST The pressure at the fuel test valve should exceed 110 psi If necessary check the high pressure pump amperage draw in series Normal draw is 6 9 amps If the draw is below 2 amps check the fuel pump filter at the base of the pump for debris If filter is clean and the draw is below 2 amps replace the pump If the draw is above 9 amps replace the pu...

Page 193: ...nspect the offending rail valves and regulators If all components check out replace the rail Fuel Management Assembly Removal WARNING Performing service or maintenance without first disconnecting the battery can cause product damage personal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining ...

Page 194: ... plug and remove the plug 3 Disconnect the water separator sensor lead 4 Disconnect the electric fuel pump harness connectors a Drain plug b Sensor lead c Harness connectors Dual Fuel Air Pressure Gauge Kit 91 881834A 1 Fuel Pressure Gauge Kit 91 881833A03 5 Remove the fuel inlet hose from the fuel lift pump 6 Remove the vapor separator vent hose 7 Remove the fuel outlet hose and fuel return hose ...

Page 195: ...10 Disconnect the throttle cam link rod and the throttle position sensor TPS link rod 11 Disconnect the manifold absolute pressure MAP sensor from the air management assembly 12 Disconnect the engine harness connector from the manifold air temperature MAT sensor connector a Throttle link rod b TPS link rod c MAP sensor d MAT sensor 13 Disconnect the oil hoses from the oil pump 14 Remove and plug t...

Page 196: ... 12 Reed Block Assembly Removal 1 Remove the two screws securing the air plenum to the reed plate assembly 2 Remove the 12 screws securing the reed blocks to the reed plate assembly a Screw 1 4 20 x 7 8 in 12 b Screw M4 x 16 2 Throttle Body Assembly Removal NOTE The throttle body assembly is calibrated and preset at the factory Other than complete assembly removal from the air plenum no further di...

Page 197: ...specified torque 3 Install a new gasket onto the air plenum Secure the reed block plate to the air plenum with two M4 x 16 screws Tighten the screws to the specified torque a Screw 1 4 20 x 7 8 in 12 b Screw M4 x 16 2 Description Nm lb in lb ft Screw 1 4 20 x 7 8 in 11 5 102 Screw M4 x 16 2 5 22 4 Install a new O ring onto the throttle body Secure the throttle body assembly to the air plenum assem...

Page 198: ...MAP sensor bracket screw M6 x 16 4 5 40 MAT sensor 16 142 8 Install the air plenum assembly onto the crankcase cover Secure the plenum with 12 1 4 20 x 1 5 in screws Tighten the screws to the specified torque in the sequence shown a Screw 1 4 20 x 1 5 in 12 b Air plenum Description Nm lb in lb ft Screw 1 4 20 x 1 5 in 20 177 9 Install three rubber grommets onto the air plenum assembly Insert three...

Page 199: ...e oil pump air compressor discharge port and secure with a cable tie IMPORTANT Verify the oil line to the air compressor is connected to the correct oil pump discharge port The air compressor receives less oil than the engine a Oil pump discharge port for the air compressor 12 Install the oil hoses to the oil pump and secure with cable ties 13 Connect the engine harness to the oil pump connector 1...

Page 200: ...tle position sensor link rod 17 Install the vapor separator and secure with three M8 x 35 screws and washers Tighten the screws to the specified torque Description Nm lb in lb ft Vapor separator mounting screws M8 x 35 16 142 18 Install the fuel high pressure fuel outlet hose and fuel return hose 19 Connect the engine harness to the electric fuel pump connectors 20 Connect the engine harness to th...

Page 201: ...ry before maintaining servicing installing or removing engine or drive components CAUTION Failure to release pressure from the fuel system will result in fuel spraying out which can cause a fire or explosion Allow the engine to cool completely and release all fuel pressure before servicing any part of the fuel system Always protect eyes and skin from pressurized fuel and vapors WARNING Fuel may st...

Page 202: ...h pressure fuel outlet hose and the low pressure fuel return hose Remove the fuel hoses from the fittings 5 Remove the air vent hose and lift pump fuel inlet hose 6 Remove the cable tie securing the hoses a High pressure fuel outlet hose b Fuel return hose from fuel regulator c Drain plug d Air vent hose to fuel tank e Lift pump fuel inlet f High pressure fuel pump electrical connector g Cable tie...

Page 203: ...sure fuel pump connector c Fuse holder d Cable tie 10 Remove the engine harnesses from behind the low pressure fuel pump hose 11 Remove the screw securing the VST ground to the plenum 12 Remove the three screws and washers securing the VST to the plenum a Screw and washer b Ground screw c Water sensor connector VST Disassembly 1 Remove the two metal hose clamps securing the lift pump to water sepa...

Page 204: ...e tie c Low pressure electric fuel pump outlet hose 3 Remove the four screws securing the low pressure electric fuel pump and lift pump brackets to the VST Remove the brackets a Ground cable b Low pressure electric fuel pump bracket c Lift pump bracket d Screw M6 x 35 1 e Screw M6 x 16 3 4 Remove the water separator fuel filter a Water separator fuel filter 5 Cut the cable tie securing the vent ho...

Page 205: ...nk Remove the cover a Screw 7 8 Loosen the screw securing the float pin Remove the float float pin and needle NOTE It is not necessary to remove the screw when removing the float float pin and needle a Float b Float pin c Screw 9 Carefully remove the fuel pump from the VST cover Disconnect the fuel pump electrical harness a Fuel pump electrical harness connector b Fuel pump a b 32668 a a a a a a a...

Page 206: ...ecuring the low pressure electric fuel pump to the bracket Remove the low pressure fuel pump a Low pressure electric fuel pump bracket b Cable ties c Grommet VST Assembly 1 Install the new fuel pump body seal and the new fuel pump outlet seal into the VST cover Lubricate the seals with Special Lubricant 101 a Fuel pump body seal b Fuel pump outlet seal Tube Ref No Description Where Used Part No 34...

Page 207: ... the VST cover Insert the pin into the float arm Secure the float pin with the float pin screw Tighten the float pin screw to the specified torque a Float b Float pin c Screw Description Nm lb in lb ft Float pin screw 1 9 6 Lubricate the inside diameter of the fuel pump body seal with Special Lubricant 101 a Fuel pump body seal Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Fu...

Page 208: ...nstall a 18 3 mm hose clamp onto the lift pump hose 11 Install the lift pump hose onto the VST cover Secure the hose with a 18 3 mm hose clamp using a hose clamp tool IMPORTANT Use tool 91 803146T or Snap On equivalent YA3080 to crimp the full circle hose clamp Using a different tool could result in a crimp that is too loose or too tight Do not use a screw type hose clamp as it may damage the hose...

Page 209: ... the fuel pump bracket Secure the pump with two cable ties IMPORTANT If the low pressure electric fuel pump does not have a sleeve or grommet refer to Service Bulletin 98 8 a low pressure electric fuel pump bracket b Cable ties c Grommet 15 Install the VST ground wire onto the screw as shown 16 Install the low pressure electric fuel pump bracket and lift pump bracket onto the VST Secure the bracke...

Page 210: ...hree M8 x 35 screws and washers Apply Loctite 242 Threadlocker to the threads of the VST mounting screws Tighten the screws to the specified torque 2 Secure the VST ground wire to the plenum with a M6 x 10 screw Apply Loctite 242 Threadlocker to the threads of the VST ground wire screw Tighten the screw to the specified torque 3 Connect the engine harness water sensor connector to the water separa...

Page 211: ...ool could result in a crimp that is too loose or too tight Do not use a screw type hose clamp as it may damage the hose 3924 9 Secure the high pressure fuel hose and the low pressure fuel return hose together with a cable tie Do not overtighten the cable tie 10 Install the air vent hose to the VST Secure the hose with a cable tie 11 Install the fuel hose to the lift pump inlet Secure with a hose c...

Page 212: ...e air pressure or the PCM calibrations will be incorrect The fuel pressure regulator maintains the higher pressure over the air pressure in the fuel rail and allows the excess fuel to return into the vapor separator The fuel pressure regulator diaphragm is held closed with a spring that requires a specific pressure to force the diaphragm off the diaphragm seat The backside of the diaphragm is expo...

Page 213: ... Expansion plug 3 O ring 4 Spring retainer 5 Spring 6 O ring 7 Diaphragm seat 8 Air rail 9 Air passage from air compressor 10 Fuel return passage to vapor separator 11 Fuel inlet passage from electric fuel pump 12 Diaphragm assembly 13 Calibration screw do not adjust 1 13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 10200 ...

Page 214: ... holds the diaphragm against the diaphragm seat The air must reach a pressure that is equal to or greater than the spring pressure holding the diaphragm closed When the air pressure exceeds the pressure of the spring the diaphragm is lifted off the diaphragm seat allowing the excess air pressure to dump into the discharge hose Tracker Valve 16133 The tracker valve is located on the starboard fuel ...

Page 215: ...ragm will expand into the lower pressure chamber side of the fuel rail when a pressure spike occurs NOTE To prevent excessive wear in the seat the tracker is calibrated to allow the diaphragm to be slightly away from the seat during normal operation Engine off no pressure a Top cover b Spring retainer not shown c Spring d O ring e Diaphragm seat f Air rail g Air passage h Fuel inlet passage i Diap...

Page 216: ... Meter Scale Reading Ω Red Black Injector pin Injector pin Ω 1 7 1 9 Ω Fuel Rail Removal WARNING Performing service or maintenance without first disconnecting the battery can cause product damage personal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing installing or removing engi...

Page 217: ...er a Fuel air pressure gauge kit b Fuel pressure test valve Dual Fuel Air Pressure Gauge Kit 91 881834A 1 NOTE It is recommended that the expansion chamber be removed to provide improved access to the fuel rails 3 Remove the coolant hose between the air compressor and expansion chamber 40 20 60 80 100 120 140 160 40 20 60 80 100 120 140 160 a b 16015 ...

Page 218: ...jector harness from each fuel injector by compressing the spring clip with a flat tip screwdriver and pulling on the connector a Port fuel rail b Air pressure test valve c Fuel pressure test valve d Fuel injector e Harness connector hidden f Spring clip 6 Cut the cable tie securing the compressor water inlet hose to the fuel rail Remove the water inlet hose 46082 a b a b f a d c e 47409 ...

Page 219: ...se to compressor b Fuel hose retainer c Screw 2 d Air hose e Air hose retainer f Screw 2 8 Remove the screws securing the retainers for the fuel hose and air hose at the bottom of the fuel rails a Water inlet hose to fuel rail b Air hose c Fuel hose retainer screw 2 d Fuel hose e Air hose f Air hose retainer screw 2 g Fuel hose fitting a b d e c f 16087 16088 a b c d e f g ...

Page 220: ...jector is removed from the cylinder head This expansion may cause installation difficulty or require the replacement of the seal a Fuel rail b Direct injectors The starboard fuel rail contains three fuel injectors and a tracker valve The port fuel rail contains three fuel injectors one fuel regulator and one air regulator NOTE Each fuel air inlet or outlet hose adapter has two O ring seals These O...

Page 221: ...gital multimeter to check the resistance between the fuel injector pins and the fuel injector steel body Replace the fuel injector if it is not within the specifications NOTE The fuel injector ohm test is not polarity sensitive a Fuel injector Meter Test Leads Meter Scale Reading Ω Red Black Injector pin Injector pin Auto 1 8 0 1 Injector pin Injector steel body Auto No continuity DMT 2004 Digital...

Page 222: ...ashers provide tension for the direct injectors between the cylinder head and fuel rails a Cupped washer b Retainer 4 Inspect the direct injector white teflon sealing ring for signs of combustion blowby The teflon ring will be streaked with carbon The carbon color can range from light brown to black If blowby is present replace the teflon sealing ring 5 Inspect the O rings and teflon ring for cuts...

Page 223: ... Meter Test Leads Meter Scale Reading Ω Red Black Injector pin Injector pin Auto 1 1 6 Each injector pin Ground Auto 1000 DMT 2004 Digital Multimeter 91 892647A01 Direct Injector Harness 84 879346A49 Direct Injector Tests Direct Injector Leak Test 1 Attach the leakage tester kit to the discharge side of the direct injector 2 Pump up the leakage tester to 172 4 206 8 kPa 25 30 psi 3 The direct inje...

Page 224: ...st Leads Meter Scale Reading Ω Red Black Injector pin Injector pin Ω 1 3 0 3 2 Connect one meter lead to either injector pin and the other meter lead to the direct injector metal case Replace the direct injector if the resistance is out of specification O U C H ON OFF 27185 Short to metal case test Meter Test Leads Meter Scale Reading Ω Red Black Injector pin Metal case Ω 1000 Ω or greater DMT 200...

Page 225: ... into the end of the dial indicator plunger a Dial indicator b Plunger c Nose piece d Tolerance pointers 4 Connect the harness connector to the direct injector 5 Install a 9 V battery into the battery holder 6 Install the dial indicator into the test fixture housing Tighten the screw to the specified torque 7 Adjust the dial indicator bezel to point towards zero 8 Press and release the button on t...

Page 226: ... Dial indicator set at zero Pintle Test Fixture 91 899883A08 Dial Indicator 91 58222A 1 Description Nm lb in lb ft Screw 1 7 15 Direct Injector Specification Direct injector pintle movement 0 020 0 031 mm 0 008 0 012 in 13 If the test result is not within specification the direct injector is defective Fuel Pressure Regulator Removal 1 Remove the four screws securing the fuel pressure regulator cov...

Page 227: ...0 and Above 1 Remove the two screws securing the air pressure regulator to the fuel rail 2 Inspect the air pressure regulator O rings for damage NOTE The air pressure regulator is not serviceable a Screws b Air pressure regulator c O rings d Retainer Tracker Valve Removal 1 Remove the four screws securing the tracker valve to the fuel rail 2 Inspect the tracker diaphragm for damage b a a 16104 c d...

Page 228: ...ation 1 Inspect the fuel injector plastic body for heat damage Replace as needed 2 Inspect the fuel injector nozzle for debris Replace as needed 3 Install new O rings onto the fuel injector a O rings b Fuel injector nozzle 4 Lubricate the fuel injector O rings with 2 4 C with Teflon 5 Install the fuel injector into the fuel rail Turn the injector back and forth slightly to seat the fuel injector O...

Page 229: ...spring and O ring onto the fuel rail 4 Install the cover and secure with four screws Tighten the screws to the specified torque a Diaphragm b Spring c O ring d Cover e Screws Tube Ref No Description Where Used Part No 95 2 4 C with Teflon Tracker diaphragm O ring and screw threads 92 802859A 1 Description Nm lb in lb ft Screw 4 8 71 Air Pressure Regulator Installation S N 0T178500 and Above 1 Inst...

Page 230: ...Nm lb in lb ft Air pressure regulator screw 2 8 71 Fuel Pressure Regulator Installation 1 Lubricate the fuel pressure regulator diaphragm and O ring with 2 4 C with Teflon 2 Install the O ring onto the fuel rail 3 Install the diaphragm onto the fuel rail 4 Install the spring onto the diaphragm and the cup onto the spring a Fuel pressure regulator diaphragm b Spring c Cup d O ring Tube Ref No Descr...

Page 231: ...e cover retaining screws Thread the two screws in until the head of the screws contact the cover Do not torque the screws at this time a Screw 2 9 Remove the air regulator installation tool screws and install the two remaining screws Tighten the screws in the sequence shown in two steps to the specified torque 1 2 3 4 32732 Description Nm lb in lb ft Screw 4 First 5 5 50 Final 8 71 Fuel Rail Insta...

Page 232: ...the fuel rail onto the mounting studs and secure with two washers and M10 nuts Tighten the nuts to the specified torque Description Nm lb in lb ft Fuel rail mounting nuts M10 45 33 6 Install new O rings onto the fuel rail air hose and fuel hose fittings 7 Lubricate the O rings with oil and install onto the fuel rail 8 Secure the fittings to the fuel rail with a retainer and two screws Tighten the ...

Page 233: ...he fittings to the fuel rail with a retainer and two screws Tighten the screws to the specified torque 13 Install the compressor water inlet hose to the fuel rail and secure with a cable tie a Water inlet hose to compressor b Fuel hose retainer c Screw 2 d Air hose e Air hose retainer f Screw 2 Tube Ref No Description Where Used Part No 14 2 cycle Premium Outboard Oil Air hose and fuel hose fittin...

Page 234: ...aring f Compressor inlet g Compressor water inlet h Fuel pressure test valve i Port fuel rail j Excess fuel return to VST k Air pressure test valve l Excess air return to exhaust adapter plate m Water inlet to fuel rail n High pressure fuel hose o Air hose p Air regulator valve of 655 14 kPa 95 2 psi q Fuel regulator valve of 751 5 14 kPa 109 2 psi 46132 a b c d e f g i h j l m n p q r t u v s o k...

Page 235: ...ttery cables from the battery before maintaining servicing installing or removing engine or drive components 1 Disconnect both of the battery cables from the battery 2 Remove the vent hose from the flywheel cover Remove the flywheel cover 3 Use a 3 8 in square drive on the belt tension arm to remove the belt a Belt tensioner b 3 8 in square drive 4 Disconnect the air compressor bullet connectors 5...

Page 236: ... compressor hose from the fitting on the air compressor Removing the hose from the fitting will damage the air compressor hose a Water hose b Air compressor to fuel rail hose c Cable tie d Plastic J clamp 9 Remove the two nuts and washers securing the air compressor to the cylinder block 10 Remove the water hose to the expansion chamber 11 Remove the oil hoses from the air compressor NOTE Mark or ...

Page 237: ...the air compresser pulley and remove the six screws securing the pulley to the air compressor crankshaft 26410 2 Remove the screw securing the air compressor temperature sensor Remove the sensor 3 Remove the four screws securing the air compressor cylinder head to the cylinder block Remove the cylinder head a Air compressor temperature sensor b Screw c Screws securing the air compressor cylinder h...

Page 238: ... and nut securing the two J clamps b Oil supply fitting c Check valves 2 7 Remove the four screws securing the air compressor end cap Remove the end cap a Screw 4 8 Push the piston connecting rod assembly out of the air compressor Air Compressor Assembly 1 Clean the threaded holes on the air compressor with a M6 x 1 0 tap and solvent to remove debris and oil Clear the threaded holes with compresse...

Page 239: ...compressor end cap Lubricate the O rings with 2 cycle Premium Outboard Oil 30319 Tube Ref No Description Where Used Part No 14 2 cycle Premium Outboard Oil Air compressor end cap O rings 92 858021K01 7 Install the end cap onto the air compressor Ensure the crank journal is engaged with the connecting rod by turning the drive sheave The piston should move in the cylinder bore 8 Ensure the arrow on ...

Page 240: ...r with a bolt and nut Tighten the bolt and nut securely NOTE Later models will use either a plastic clip or cable ties in place of the two J clamps a Bolt and nut securing the two J clamps b Oil supply fitting c Check valves 2 12 Install the O rings onto the reed plate assembly 13 Install the reed plate assembly with the five petal side towards the piston a Reed plate b O rings 14 Install the air ...

Page 241: ...ley 18 Apply Loctite 271 Threadlocker to the six M6 x 12 screw threads and secure the compressor pulley with the screws Tighten the screws to the specified torque 26410 Description Nm lb in lb ft Screw M6 x 12 6 19 170 Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Air compressor pulley screw threads 92 809819 Air Compressor Installation 1 Install the oil line coming from th...

Page 242: ... 5 Install the two top screws M10 x 25 finger tight and then tighten to the first specified torque IMPORTANT Do not overtighten This is the first of a two stage torque process Description Nm lb in lb ft Screw M10 x 25 2 First 1 5 13 Final 56 41 3 a Screw M10 x 25 flange 2 6 Install the water dump hose to the air compressor and secure with a cable tie 7 Install a washer and nut onto each stud and t...

Page 243: ...h a cable tie a Water hose b Air compressor to fuel rail hose c Cable tie d Plastic J clamp 10 Install two O rings onto the fuel rail air compressor hose fitting Lubricate the O rings with 2 cycle Premium Outboard Oil 11 Install the fitting into the fuel rail and secure with a retainer and two screws Tighten the screws to the specified torque a Retainer b Screw 2 c Air compressor hose Tube Ref No ...

Page 244: ...ompressor temperature sensor bullet connectors to the wire harness connector a Water inlet hose b Bullet connectors 14 Use a 3 8 in square drive on the belt tension arm and install the belt to the air compressor pulley a Belt tensioner b 3 8 in square drive 45934 a b 45924 a b ...

Page 245: ...Direct Fuel Injection Notes Page 3B 82 90 8M0050731 MAY 2011 ...

Page 246: ...mp Installation 3C 8 Engine Oil Reservoir Removal and Installation 3C 8 Removal 3C 8 Installation 3C 10 Priming the Oil Injection Pump 3C 11 Purging Air from the System 3C 11 Method 1 Computer Diagnostic System Break in Clock Reset 3C 12 Method 2 Computer Diagnostic System Oil Pump Prime 3C 12 Remote Oil Tank Hose Connections 3C 12 Filling the Oil Tanks 3C 13 Purging Air from the Engine Oil Reserv...

Page 247: ...Oil Injection Page 3C 2 90 8M0050731 MAY 2011 Special Tools Leakage Tester Kit FT8950 29497 Used for pressure testing of closed systems gearcase fuel lines cooling ...

Page 248: ...Oil Injection Notes 90 8M0050731 MAY 2011 Page 3C 3 ...

Page 249: ...Oil Injection Page 3C 4 90 8M0050731 MAY 2011 Oil Injection Components 1 3 5 2 4 6 24424 1 2 3 4 5 5 6 7 8 9 7 10 7 11 12 13 14 14 15 16 17 18 8 8 8 8 8 8 8 19 20 21 22 23 24 25 26 27 28 29 8 30 ...

Page 250: ...tie 14 cm 5 5 in 8 AR Cable tie 20 3 cm 8 in Cable tie 10 cm 4 in 9 1 Hose 61 cm 24 in 10 1 Hose 81 3 cm 32 in 11 1 Check valve to block 12 1 Fitting 13 1 Hose 15 3 cm 6 in 14 2 Cap 15 1 Hose 16 2 Connector 17 1 In line oil filter 18 1 Hose 5 cm 2 in 19 1 Reservoir assembly 20 1 Reservoir decal 21 3 Grommet 22 3 Washer 23 3 Screw 0 312 18 x 1 250 24 3 Bushing 25 1 Switch assembly 26 1 Screw 0 164 ...

Page 251: ...enum Serial number 0T178500 and above the air compressor has two oil return ports These two ports return oil to the top and bottom main bearings on the engine The PCM is programmed to increase the oil supply to the engine during the initial engine break in period The oil ratio is doubled during the first 120 minutes of operation whenever the engine is under a load At idle the oil pump is providing...

Page 252: ...e a Remote oil tank b Engine mounted oil reservoir c Filter d Oil hose to the oil pump e Oil hose to lower main bearing f Oil pump g Oil hoses to the cylinders h Check valve i Oil hose to upper main bearing j Oil hose to the air compressor k Air compressor l Fitting l j i g f e d c b k l a h 16410 ...

Page 253: ...m assembly oil pump opening 2 Connect the oil hoses to the oil pump and secure with cable ties 3 Insert two screws through the 14 pin mounting bracket and install washers on the screws 4 Thread the three M8 x 35 screws into the oil pump and tighten the screws to the specified torque a Oil pump b Bushing c Washer d Screw M8 x 35 Description Nm lb in lb ft Screw M8 x 35 3 15 8 140 5 Fill the oil res...

Page 254: ...w oil switch harness 2 Screw 0 164 18 x 0 375 3 Washer 0 203 x 0 562 x 0 060 4 Low oil switch 5 Reservoir decal 6 Oil reservoir 7 Bushing 3 8 Grommet 3 9 Clamp 10 Washer 3 11 Screw 0 312 18 x 1 250 12 Fitting 13 Cable tie 20 3 cm 8 in 14 Hose 5 cm 2 in 15 Oil filter 16 Hose 15 3 cm 6 in 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 2 13 13 13 35005 ...

Page 255: ... Low oil switch bullet connectors h Oil reservoir oil inlet fitting 2 Install the oil reservoir onto the cylinder block and secure with two 0 312 18 x 1 250 inch screws and washers Tighten the screws to the specified torque Description Nm lb in lb ft Screws 0 312 18 x 1 250 in 2 19 2 170 3 Install the oil hose and secure the oil hose with a cable tie 4 Connect the oil tank low oil switch bullet co...

Page 256: ...he Oil Injection Pump Priming the Oil Injection Pump Purging Air from the System If a new powerhead is being installed or oil hoses oil pump has been removed it is recommended all air be purged from the oil pump oil lines using gearcase leakage tester kit FT 8950 Connect the leakage tester to the inlet T fitting on the onboard oil reservoir While clamping off the inlet hose manually pressurize the...

Page 257: ... Follow the procedures in the computer diagnostic system for resetting the break in clock Method 2 Computer Diagnostic System Oil Pump Prime This method should be used when the break in clock does not need to be reset Use this method if the oil injection system ran out of oil the hose supplying the oil pump was leaking or removed the oil pump was replaced or if any of the oil supply hoses were lea...

Page 258: ...s loose and the engine is idling to prevent leakage from overfilling Tighten the vent cap securely when the reservoir is full IMPORTANT The engine mounted oil tank must be completely filled prior to the initial operation The boat mounted remote oil tank will not displace the air in the engine mounted oil reservoir unless the vent cap is loosened a Remote oil tank cap b Engine mounted oil tank rese...

Page 259: ...ooling system problem Continuous Engine Guardian System is activated Power limit will vary with level of overheat Stop engine and check water intake for obstruction The Guardian System must be reset before engine will operate at higher speeds Moving throttle lever back to idle resets the system Oil level is critically low Continuous Engine Guardian System is activated Power will be limited The oil...

Page 260: ...heck valve Hose connections Check all hose connections for leaks Low oil level in engine mounted oil reservoir and vessel mounted remote oil tank Lack of proper periodic maintenance Fill both tanks Purge the air from the engine mounted oil tank and oil hose Refer to the Operation Manual for the maintenance schedule Oil level in both tanks is OK Low oil switch in the engine mounted oil reservoir is...

Page 261: ...Oil Injection Notes Page 3C 16 90 8M0050731 MAY 2011 ...

Page 262: ...n Monoxide CO 3D 2 Oxides of Nitrogen NOx 3D 2 Controlling Emissions 3D 2 Stoichiometric 14 7 1 Air Fuel Ratio 3D 2 Emissions Information 3D 2 Models Affected 3D 2 Manufacturer s Responsibility 3D 3 Dealer Responsibility 3D 3 Owner Responsibility 3D 3 EPA Emission Regulations 3D 3 Service Replacement EPA Decal 3D 3 Removal 3D 3 Emission Certification Label 3D 4 Installation 3D 4 ...

Page 263: ...lly lethal gas Oxides of Nitrogen NOx NOx is a slightly different by product of combustion Nitrogen is one of the elements that makes up the air going into the engine Under extremely high temperatures it combines with oxygen to form oxides of nitrogen NOx This happens in the engine s combustion chambers when temperatures are too high NOx itself is not harmful but when exposed to sunlight it combin...

Page 264: ...specifications Single engine exceptions may be allowed with permission from the EPA for racing and testing EPA Emission Regulations All new 1998 and newer outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is cont...

Page 265: ...it for the engine family i Recommended spark plug and gap j Percent of fuel line permeation Installation Apply the decal on a clean surface in the original factory location SPARK PLUG GAP EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES CALIFORNIA AND U S EPA REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS ID...

Page 266: ...t 4A 41 Crankshaft and End Cap Bearings 4A 42 Connecting Rods 4A 43 Reed Block Assembly 4A 45 End Bearing Bleed System 4A 45 Powerhead Assembly 4A 46 Powerhead Preassembly Cleaning Recommendations 4A 46 Crankshaft Bearings Installation 4A 46 Crankshaft Installation 4A 49 Piston and Connecting Rod Assembly 4A 50 Piston and Piston Ring Combinations 4A 52 Piston Installation 4A 52 Crankcase Cover Ins...

Page 267: ...ker Divider plate screw threads Lower end cap oil seals 92 809819 12 Loctite Master Gasket Kit Crankcase cover and cylinder block mating surface Crankcase cover and cylinder block mating surface 92 12564 2 14 2 cycle Premium Outboard Oil Upper end cap bearing and end cap O ring surface Cylinder head screw threads and face Connecting rod screws lower ball bearing piston rings Cylinder bores after h...

Page 268: ...linder block mating surface Divider plate screw threads 92 809824 Special Tools Fuel Pressure Gauge Kit 91 881833A03 2807 Tests the fuel pump pressure can be used to relieve fuel pressure Dual Fuel Air Pressure Gauge Kit 91 881834A 1 5822 Tests fuel and air pressure the dual gauges allow the viewing of both pressures simultaneously Digital Pressure Meter 91 892651A01 5786 Connects to the fuel syst...

Page 269: ...nkshaft Powerhead vise stand 8 spline Universal Puller Plate 91 37241 8505 Removes bearings from gears and the driveshaft Piston Pin Tool 91 74607A 3 20637 Aids in the removal and installation of the piston wrist pin Lockring Installation Tool 91 77109A3 8527 Installs the lockrings to secure the piston wrist pin in the piston Lockring Installation Tool 91 93004A 2 8527 Installs the lockrings to se...

Page 270: ...werhead 90 8M0050731 MAY 2011 Page 4A 5 Lifting Eye 91 90455 1 2756 Threads into the flywheel to remove the powerhead assembly from the driveshaft housing or to lift entire engine for removal installation ...

Page 271: ... Page 4A 6 90 8M0050731 MAY 2011 Cylinder Block and End Caps 12 14 95 95 29743 95 95 33 33 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 35 37 36 38 34 33 32 39 31 1 40 41 42 14 ...

Page 272: ... 1 Nylon cap 13 1 Screw 0 25 20 x 1 75 in 14 1 Nut 0 25 20 in 15 1 End cap assembly 16 1 O ring 2 80 x 0 103 in 17 1 Bearing kit 18 1 Bearing race 19 1 Seal 20 4 Screw 0 312 18 x 1 0 in 23 17 21 1 End cap assembly 22 1 O ring 3 237 x 0 103 in 23 2 Seal 24 4 Screw 0 25 20 x 0 75 in 9 80 25 4 Lockwasher 0 25 in 26 1 Throttle position indicator bracket 27 1 Throttle position indicator lever 28 3 Scre...

Page 273: ... 14 in Tube Ref No Description Where Used Part No 12 Loctite Master Gasket Kit Crankcase cover and cylinder block mating surface 92 12564 2 14 2 cycle Premium Outboard Oil Upper end cap bearing and end cap O ring surface 92 858021K01 33 Loctite 680 Retaining Compound Cylinder block stud threads 92 809833 95 2 4 C with Teflon Upper and lower end cap seal lips and O rings 92 802859A 1 ...

Page 274: ... 90 8M0050731 MAY 2011 Page 4A 9 Cylinder Block and End Caps 12 14 95 95 29743 95 95 33 33 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 35 37 36 38 34 33 32 39 31 1 40 41 42 14 ...

Page 275: ...Powerhead Page 4A 10 90 8M0050731 MAY 2011 Exhaust Manifold and Exhaust Plate 7 44904 1 2 3 4 5 6 8 10 9 7 ...

Page 276: ...er plate assembly 3 1 Seal 12 5 in 4 16 Screw and washer 0 312 18 x 1 50 in 18 160 13 5 2 Screw 0 312 18 x 1 00 in 18 160 13 6 1 Relief valve cover 7 4 Screw 0 312 18 x 1 375 in 15 133 8 1 Gasket 9 1 Screw 0 312 18 x 1 75 in 10 1 Plug 0 50 14 in Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Divider plate screw threads 92 809819 ...

Page 277: ...Powerhead Page 4A 12 90 8M0050731 MAY 2011 Cylinder Head 14 44903 1 2 3 3 4 5 6 7 8 9 10 ...

Page 278: ...2 24 Screw 0 375 16 x 2 75 in First 40 5 30 Final Turn an additional 90 3 4 Dowel pin 0 25 x 0 625 in 4 2 Gasket 5 2 Cover 6 6 Seal 7 4 Screw M6 x 25 mm 13 5 120 10 8 2 Temperature sensor assembly 17 150 12 9 2 O ring 1 78 mm x 0 08 mm 10 2 Seal Tube Ref No Description Where Used Part No 14 2 cycle Premium Outboard Oil Cylinder head screw threads and face 92 858021K01 ...

Page 279: ...Powerhead Page 4A 14 90 8M0050731 MAY 2011 Crankshaft Pistons and Connecting Rods 14 14 95 95 95 95 95 14 2305 10 13 17 15 15 14 8 9 7 1 3 4 5 2 6 16 11 12 12 ...

Page 280: ...t piston assembly 0 015 in oversize 11 1 Ring set standard AR Ring set 0 015 in oversize 12 12 Lockring 13 6 Connecting rod assembly 14 12 Screw 0 312 24 x 0 875 in First 4 0 35 Second 27 20 Final Turn screw an additional 90 after the second torque 15 12 Thrust washer 16 6 Bearing kit 17 204 Needle bearing Tube Ref No Description Where Used Part No 14 2 cycle Premium Outboard Oil Connecting rod sc...

Page 281: ...Page 4A 16 90 8M0050731 MAY 2011 Expansion Chamber and Adapter Plate Components 44905 29 1 2 4 5 6 24 25 26 24 27 24 28 30 31 32 33 14 15 13 12 16 18 35 36 38 37 34 39 23 21 42 41 40 17 20 16 22 19 11 10 9 8 7 3 ...

Page 282: ...1 4 47 35 12 1 Strainer fitting 13 1 O ring 14 2 Washer 15 2 Screw 3 8 16 x 3 3 4 47 35 16 11 Nut M10 47 35 17 1 Cover assembly 18 5 Stud M10 x 53 40 30 19 1 Gasket engine adapter 20 6 Stud M10 x 101 40 30 21 1 Barbed connector 22 1 O ring 23 1 O ring 24 3 Cable tie 25 1 Siphon hose 106 7 cm 42 in 26 1 Siphon break 27 1 Siphon hose 45 7 cm 18 in 28 1 Cable tie 29 1 Siphon hose strainer 30 1 Flushi...

Page 283: ...Powerhead Page 4A 18 90 8M0050731 MAY 2011 Ref No Qty Description Torque Nm lb in lb ft 41 1 Hose 42 1 Worm gear clamp ...

Page 284: ...90 8M0050731 MAY 2011 Page 4A 19 Expansion Chamber and Adapter Plate Components 44905 29 1 2 4 5 6 24 25 26 24 27 24 28 30 31 32 33 14 15 13 12 16 18 35 36 38 37 34 39 23 21 42 41 40 17 20 16 22 19 11 10 9 8 7 3 ...

Page 285: ...battery terminals 2 Remove the positive battery cable from the starter solenoid Remove the negative battery cable from the lower front starter mounting bolt 3 Disconnect the remote oil tank hose 4 Disconnect the remote control harness from the powerhead harness connector a Positive battery cable b Negative battery cable c Remote oil tank hose hidden d Remote control harness connection 5 Remove the...

Page 286: ...l turns Lift the powerhead assembly from the pump unit 45537 11 Remove the exhaust outlet coolant hose from the air compressor 12 Remove six nuts securing the expansion chamber and remove the expansion chamber a Coolant hose b Nuts 6 Removing Powerhead Components Individual Components NOTE Engine components can be removed individually or in some cases as an assembly 1 Refer to Section 2A Ignition ...

Page 287: ...lt in fuel spraying out which can cause a fire or explosion Allow the engine to cool completely and release all fuel pressure before servicing any part of the fuel system Always protect eyes and skin from pressurized fuel and vapors WARNING Fuel may still remain in the fuel rails and hoses after draining the vapor separator tank VST To avoid a possible fire or explosion follow normal precautionary...

Page 288: ...fuel return from the fuel rails the lower fuel hose is the fuel inlet from the electric circulating pump beside the fuel water separator 6 Remove the fuel inlet hose from the fuel lift pump 7 Remove the vapor separator vent hose 8 Remove the high pressure fuel outlet hose and the low pressure fuel return hose from the fuel rails 9 Remove the vapor separator ground lead 45541 a b c ...

Page 289: ...ove the electrical plate cover 2 Disconnect the temperature sensor connectors 3 Remove the spark plug boots from the spark plugs 4 Disconnect the fuel injector connectors 5 Disconnect the direct injector connectors on the starboard fuel rail 6 Disconnect the wiring harness retainers a Screw and bushing b Electrical plate cover c Temperature sensor connectors 2 d Direct injector connectors 6 e Fuel...

Page 290: ...kshaft position sensor connector b Water pressure sensor c Nut M8 10 Disconnect the air temperature sensor connector 11 Disconnect the MAP sensor connector 12 Disconnect the yellow red lead from the starter solenoid 13 Disconnect the harness ground lead below the starter motor a MAP sensor connector b Air temperature sensor connector c Yellow red wire d Harness ground lead 14 Disconnect the oil pu...

Page 291: ...rnator output lead b TPS harness connection c Alternator sense lead d Low oil sensor bullet connectors 20 Remove the electrical harness assembly from the engine Fuel Rail Removal WARNING Performing service or maintenance without first disconnecting the battery can cause product damage personal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect th...

Page 292: ...ways protect eyes and skin from pressurized fuel and vapors 1 Disconnect both battery leads from the battery 2 Install the fuel air pressure gauge kit Relieve the fuel pressure into an appropriate container a Fuel air pressure gauge kit b Fuel pressure test valve Dual Fuel Air Pressure Gauge Kit 91 881834A 1 Digital Pressure Meter 91 892651A01 3 Remove the coolant hose between the port fuel rail a...

Page 293: ...oolant hose b Incoming coolant hose 5 Remove two screws securing the compressor air hose and remove the hose from the starboard fuel rail a Air hose b Screw 2 6 Remove two nuts and coil plate spacers securing the fuel rails 7 Remove both fuel rails as an assembly a Nuts b Coil plate spacers 45572 a b 45573 a b 45574 a b ...

Page 294: ... components 1 Disconnect both of the battery cables from the battery 2 Remove the vent hose from the flywheel cover Remove the flywheel cover 3 Use a 3 8 in square drive on the belt tension arm to remove the belt a Belt tensioner b 3 8 in square drive 4 Disconnect the air compressor bullet connectors 5 Cut the cable tie securing the water inlet hose to the air compressor Remove the water inlet hos...

Page 295: ...essor hose from the fitting on the air compressor Removing the hose from the fitting will damage the air compressor hose a Water hose b Air compressor to fuel rail hose c Cable tie d Plastic J clamp 9 Remove the two nuts and washers securing the air compressor to the cylinder block 10 Remove the water hose to the expansion chamber 11 Remove the oil hoses from the air compressor NOTE Mark or identi...

Page 296: ...oil pump to the plenum 2 Cut the cable ties securing the oil hoses to the oil pump and remove the oil hoses Use an appropriate container to capture the oil that may drip from the oil hoses a 14 pin connector mounting bracket newer models only b Screws 3 Remove the three screws and washers securing the oil reservoir to the cylinder block a Screw and washer securing oil reservoir b Screw and washer ...

Page 297: ...enum a Screw 4 2 Remove the 12 screws securing the air plenum to the cylinder block assembly a Clamp 3 b Screw 12 3 Remove the two screws securing the air plenum to the reed plate assembly 4 Remove the 12 screws securing the reed blocks to the reed plate assembly a Screw 0 250 20 x 0 88 in 12 b Screw M4 x 16 2 a 33719 a a a b 33720 a b 16044 ...

Page 298: ...e cylinder heads Remove the cylinder heads a Cylinder head b O rings c Engine block 3 Remove the screws securing the exhaust manifold Remove the exhaust manifold a Exhaust manifold b Seal c Gasket 4 Remove the four screws securing the upper end cap Do not remove the end cap at this time a Screws 4 46719 a b c UP S UP S UP S S UP a c b 37152 a 17013 a ...

Page 299: ...ews that secure the crankcase cover to the cylinder block 7 Pry the crankcase cover off the cylinder block with pry bars at the locations shown a Pry locations b Crankcase cover 8 Use paint or indelible ink to identify each connecting rod location a Cylinder number 9 Remove the connecting rod cap screws and the connecting rod cap a 17017 a a b a 17018 a 1 8627 ...

Page 300: ...reassemble the connecting rod NOTICE Connecting rods and end caps are matched sets Mismatching the original pairs will result in catastrophic engine damage Install all connecting rods with their matched end caps 12 Use a piston ring expander to remove the piston rings 8630 Piston Ring Expander 91 24697 13 On the inside of the piston use paint or indelible ink to identify the location a 8628 ...

Page 301: ... pin 16 Support the piston and remove the piston pin using service tool 91 76159A1 for serial number 0T178499 and below or service tool 91 92973A1 for serial number 0T178500 and above a Piston pin b Piston pin tool c Needle bearings and locating washers Piston Pin Tool 91 76159A1 Piston Pin Tool 91 92973A 1 Torch Lamp 91 63209 17 Remove the upper and lower end caps from the crankshaft 18 Remove an...

Page 302: ... 20 Install the crankshaft onto a powerhead stand and inspect the sealing rings IMPORTANT Do not remove the crankshaft sealing rings unless the sealing ring is broken Powerhead Stand 91 30591T 1 21 Remove the retainer ring holding the main bearing races together a Sealing rings 9 b Retainer ring 2 c Main bearing 2 a b 8635 a b b 47365 c c ...

Page 303: ...bearing unless replacement is required Lower Crankshaft Ball Bearing Removal 1 Remove the crankshaft ball bearing retaining ring with a snap ring pliers a Pliers b Crankshaft ball bearing c Retaining ring 2 Install the universal puller plate onto the crankshaft Press the crankshaft ball bearing off with the powerhead stand a Press b Powerhead stand c Crankshaft ball bearing d Universal puller plat...

Page 304: ...l Service Information Grooves in the Cylinder Block Caused by Crankshaft Sealing Rings Grooves in the cylinder block caused by crankshaft sealing rings are not a problem unless installing a new crankshaft and the new sealing rings do not line up with the existing grooves in the cylinder block If installing a new crankshaft refer to Crankshaft Installation to determine if the powerhead can be used ...

Page 305: ...e finished hone diameter it will be necessary to bore the cylinder oversize NOTE The weight of an oversize piston is approximately the same as a standard size piston It is not necessary to bore all the cylinders oversize 8 After measuring the cylinder bores apply 2 Cycle Premium Outboard Oil to the cylinder bores to prevent corrosion Tube Ref No Description Where Used Part No 14 2 Cycle Premium Ou...

Page 306: ...or foreign material striking the cylinder heads IMPORTANT Cylinder head warpage must not exceed 0 025 mm 0 001 in over the entire length of the cylinder head If the warpage exceeds 0 025 mm 0 001 in in the narrow portion of the cylinder head the cylinder head must be replaced The cylinder head must not be resurfaced as the O ring groove depth in the head will be reduced which will result in cylind...

Page 307: ...d longevity 1 After cleaning the crankshaft grasp the outer race of the crankshaft ball bearing installed on the lower end of the crankshaft and work the race back and forth There should not be excessive play 2 Lubricate the ball bearing with light oil Rotate the outer bearing race The bearing should have smooth action and no rust stains If the ball bearing sounds or feels rough or has catches rem...

Page 308: ... is rusted fractured worn galled badly discolored or loose inside of the end cap replace the end cap and roller bearing as an assembly a Upper roller bearing Connecting Rods 1 Check the connecting rods for alignment by placing the rods on a surface plate If light can be seen under any portion of the machined surfaces if the rod has a slight wobble on the plate or if a 0 051 mm 0 002 in feeler gaug...

Page 309: ...od As ignition occurs in the cylinder the piston pushes the connecting rod with tremendous force and this force is transferred to the connecting rod journal Since there is little or no load on the crankshaft it bounces away from the connecting rod The crankshaft then remains immobile for a split second until the piston travel causes the connecting rod to catch up to the waiting crankshaft journal ...

Page 310: ...d as in step b e Thoroughly wash the connecting rods to remove abrasive grit Recheck the bearing surfaces Replace any connecting rod that cannot be properly cleaned up Lubricate the bearing surfaces of the connecting rods being reused with light oil to prevent rust Reed Block Assembly IMPORTANT Do not remove the reeds from reed blocks unless replacement is necessary Do not turn used reeds over for...

Page 311: ...ris and honing compound Dry the cylinder block with compressed air Failure to thoroughly clean the cylinder block of honing compound and debris will result in premature engine failure Crankshaft Bearings Installation 1 If the lower crankshaft ball bearing has been removed press it onto the crankshaft as shown Ensure that the bearing is pressed firmly against the shoulder 2 Reinstall the retaining ...

Page 312: ...end b Retaining ring c Separating line Tube Ref No Description Where Used Part No 14 2 cycle Premium Outboard Oil Center main crankshaft roller bearings and races 92 858021K01 8 Place the center main crankshaft roller bearings on the upper and lower main bearing journals as shown 9 Install the center main bearing races as shown 10 Secure the center main bearing races together with the retaining ri...

Page 313: ...mium Outboard Oil O ring seal surface of end cap 92 858021K01 95 2 4 C with Teflon Oil seal lips 92 802859A 1 12 Install the oil seal into the upper end cap bearing carrier as follows a Apply a light film of 2 4 C with Teflon to the outer diameter of the upper end cap oil seal This eases the seal into the carrier b Lubricate the oil seal lip with 2 4 C with Teflon c Using a suitable mandrel press ...

Page 314: ...Cycle Premium Outboard Oil and install the new crankshaft as instructed Tube Ref No Description Where Used Part No 14 2 cycle Premium Outboard Oil Crankshaft sealing rings 92 858021K01 4 Install the upper and lower end caps and inspect the fit between the sealing rings and grooves 5 Temporarily install the crankcase cover and rotate the crankshaft several times to check if the sealing rings are bi...

Page 315: ...p bolts at this time a Lower end cap installed but not tightened Piston and Connecting Rod Assembly 1 Place the needle bearings on a clean piece of paper and lubricate them with 2 4 C with Teflon NOTE There are 29 needle bearings per piston for the 175 Pro XS and for S N 0T178499 and below S N 0T178500 and above have 34 needle bearings per piston Tube Ref No Description Where Used Part No 95 2 4 C...

Page 316: ...92973A1 for S N 0T178500 and above and push the sleeve out of the piston Ensure the piston pin tool remains in the piston assembly 6 Install the piston pin and tap the piston pin into the piston with a mallet a Sleeve b Piston pin tool c Piston pin tool d Piston pin Piston Pin Tool 91 74607A 3 Piston Pin Tool 91 92973A 1 7 Install two new piston pin lockrings using lockring installation tool 91 77...

Page 317: ... 4 mm 0 056 in b Enlarged view of piston ring grooves Piston Installation 1 Before installing the new piston rings check the ring gap by placing each ring in its respective cylinder and pushing the ring 12 7 mm 1 2 in into the cylinder using the piston 2 Check the end gap of each piston ring with a feeler gauge The end gap must be within specification If the end gap is greater than the specificati...

Page 318: ...the piston rings with the dot side up onto the piston 4 Verify the piston rings rotate in the ring groove 5 Lubricate the piston and rings with 2 Cycle Premium Outboard Oil a Piston ring expander b Dot side up on piston ring Piston Ring Expander 91 24697 Tube Ref No Description Where Used Part No 14 2 cycle Premium Outboard Oil Piston and cylinder wall 92 858021K01 6 Align the piston ring end gap ...

Page 319: ...h Teflon to the bearing surface of the connecting rod and rod cap Install the connecting rod bearing Tube Ref No Description Where Used Part No 95 2 4 C with Teflon Bearing surfaces of connecting rod and rod cap 92 802859A 1 13 Install the connecting rod cap Lubricate the threads and face of the connecting rod screws with 2 Cycle Premium Outboard Oil Thread the screws into the connecting rod finge...

Page 320: ...ns to verify there is no binding or catching 17 Verify if the piston rings were broken during installation by pressing in on each piston ring through the exhaust port with a screwdriver If the ring fails to return to spring back position it is likely the ring is broken and must be replaced a Screwdriver Crankcase Cover Installation 1 Ensure the mating surfaces of the crankcase cover and cylinder b...

Page 321: ... Install the crankcase cover onto the cylinder block 6 Apply 2 Cycle Premium Outboard Oil to the eight center main screw threads and face Install the eight center main screws and tighten the screws progressively and in the sequence shown until the crankshaft cover contacts the cylinder block 7 Apply 2 Cycle Premium Outboard Oil to the perimeter screw threads and face Install the crankcase cover pe...

Page 322: ...ews 9 80 Center main screws 51 37 Perimeter screws 20 180 15 Reed Block Assembly IMPORTANT Do not remove the reeds from reed blocks unless replacement is necessary Do not turn used reeds over for reuse Replace reeds in sets 1 Thoroughly clean the gasket surfaces of the reed blocks and reed block housing Check for deep grooves cracks or distortion that could cause leakage Replace parts as necessary...

Page 323: ...n lb ft Screw 0 250 20 x 0 880 in 12 11 5 100 Exhaust Divider Assembly 1 Install the exhaust divider seal into the slot in the cylinder block 2 Install the exhaust divider gasket onto the cylinder bock and install the exhaust divider 3 Clean the screw threads with Loctite 7649 Primer N 4 Apply Loctite 271 Threadlocker to the screw threads 5 Secure the exhaust divider with the screws a Divider seal...

Page 324: ...Installation 1 Install the cylinder head combustion chamber seal with the grooved side towards the cylinder block 2 Install the cylinder head seal 3 Install the cylinder head with the thermostat towards the flywheel 4 Apply 2 Cycle Premium Outboard Oil to the new cylinder head screw threads and face 5 Install the thermostat cover and gasket onto the cylinder head Secure the thermostat cover and tw...

Page 325: ...or S N 0T178499 and below i Temperature sensor S N 0T178500 and above j O ring k Gasket l Cover m Screw M6 x 25 2 n Cylinder head seal direction Tube Ref No Description Where Used Part No 14 2 cycle Premium Outboard Oil Cylinder head screw threads and face 92 858021K01 Description Nm lb in lb ft Cylinder head screw First 40 5 30 Final Turn additional 90 Screw M8 x 12 23 203 17 Screw 6M x 25 23 203...

Page 326: ...Powerhead 90 8M0050731 MAY 2011 Page 4A 61 Starboard Side Oil Hose Routing 45579 ...

Page 327: ...Powerhead Page 4A 62 90 8M0050731 MAY 2011 Port Side Oil Hose Routing 45580 ...

Page 328: ...ividually refer to the following sections 1 Refer to Section 2A Ignition to install the following components Flywheel cover Electronic control module Ignition coils 2 Refer to Section 2B Charging and Starting System to install the following components Flywheel Alternator Starter motor Starter solenoid 3 Refer to Section 3A Fuel Pump to install the following components Fuel lift pump 4 Refer to Sec...

Page 329: ...rew 0 312 18 x 1 25 in 3 20 177 15 NOTE Attach the air compressor oil hose to the extended fitting on the oil pump 2 Install the oil hoses onto the oil pump and secure with cable ties a Oil hose for the air compressor b Oil delivery hose c Plenum d Oil pump e Extended fitting 3 Install the oil pump onto the plenum Secure the oil pump with three M8 x 30 screws washers and the 14 pin connector mount...

Page 330: ...ie a Cable tie securing the oil line coming from 5 reed block b Cable tie securing the oil line coming from the top main bearing c Cable tie securing the oil delivery line coming from the oil pump 4 Install the air compressor onto the studs 5 Install the two top screws M10 x 25 finger tight and then tighten to the first specified torque IMPORTANT Do not overtighten This is the first of a two stage...

Page 331: ...10 x 25 securing the air compressor assembly to the cylinder block to the specified torque Description Nm lb in lb ft Screw M10 x 25 2 First 1 5 13 Final 56 41 3 9 Secure the air compressor hose to the air compressor with a J clamp and cable tie Secure the water hose and air compressor hose to the air compressor with a cable tie a Water hose b Air compressor to fuel rail hose c Cable tie d Plastic...

Page 332: ...ose Tube Ref No Description Where Used Part No 14 2 cycle Premium Outboard Oil O rings on the fuel rail air compressor hose fitting 92 858021K01 Description Nm lb in lb ft Screw 8 71 12 Secure the water inlet hose to the air compressor with a cable tie 13 Connect the air compressor temperature sensor bullet connectors to the wire harness connector a Water inlet hose b Bullet connectors a b c 32810...

Page 333: ...on 1 Install the electrical harness assembly onto the engine 2 Connect the low oil sensor bullet connectors 3 Install the sense lead onto the alternator 4 Connect the TPS harness connection 5 Install the output lead onto the alternator a Alternator output lead b TPS harness connection c Alternator sense lead d Low oil sensor bullet connectors 6 Install the nut and screw securing the electrical pla...

Page 334: ...s to the starter solenoid 10 Connect the MAP sensor connector 11 Connect the air temperature sensor connector a MAP sensor connector b Air temperature sensor connector c Yellow red wire d Harness ground lead 12 Connect the crankshaft position sensor connector 13 Connect the water pressure sensor harness and sensor retainer 14 Install two nuts securing the aft portion of the electrical plate 45918 ...

Page 335: ... plate cover c Temperature sensor connectors 2 d Direct injector connectors 6 e Fuel injector connectors 6 f Spark plug boots 6 g Wiring harness retainers 4 Powerhead Installation on the Pump Unit 1 Install the lifting eye into the flywheel 2 Lift powerhead high enough to allow removal of the powerhead from the stand Remove the powerhead from the stand being careful not to damage gasket surface of...

Page 336: ...ich secure powerhead to exhaust extension plate driveshaft housing Tighten the nuts in three progressive steps until the final torque specification is reached a M10 nuts 11 Description Nm lb in lb ft M10 nuts 11 Final 47 35 6 Disconnect the hoist from lifting eye and remove the lifting eye from flywheel 7 Install the plastic cap into the center of the flywheel cover 8 Connect the positive battery ...

Page 337: ...e clamp a Throttle cable b Fuel inlet c Vent hose d Water bypass hose NOTE Refer to Section 2C Timing Synchronizing and Adjusting for engine set up procedures 16 Connect the battery cables to the battery Engine Break in Procedure After Powerhead Assembly IMPORTANT The service technician must complete the following break in procedure before delivery to the owner Do not use premixed gas and oil in t...

Page 338: ...throttle 5600 RPM NOTE After this break in procedure is completed the owner should follow the Recommended Break in Procedure Recommended Break in Procedure IMPORTANT Failure to follow the engine break in procedures can result in poor performance throughout the life of the engine and can cause engine damage Always follow break in procedures Fuel Requirements Do not use premixed gas and oil in this ...

Page 339: ...Powerhead Notes Page 4A 74 90 8M0050731 MAY 2011 ...

Page 340: ...stem Specifications 4B 2 Temperature Sensor Location and Function 4B 2 Temperature Sensors 4B 3 4 and 2 Wire Temperature Sensor 4B 3 2 Pin Connector Cylinder Head Temperature Sensor 4B 4 Water Pressure Check 4B 5 Problem Diagnosis 4B 6 Model 200 Water Flow 4B 6 Description 4B 6 Water Flow Diagram 4B 8 ...

Page 341: ...environments Computer Diagnostic System CDS Order through SPX 4520 Monitors all electrical systems for proper function diagnostics and calibration purposes For additional information pricing or to order the Computer Diagnostic System contact SPX Corporation 28635 Mound Rd Warren MI 48092 or call USA 1 800 345 2233 Canada 800 345 2233 Europe 49 6182 959 149 Australia 03 9544 6222 Temperature Sensor...

Page 342: ...est of the temperature sensor would be as follows Disconnect the temperature sensor harness and check continuity with digital or analog ohmmeter test leads between both connector pins Readings should be within 10 of specified There should be no continuity between each connector pin and ground DMT 2004 Digital Multimeter 91 892647A01 Computer Diagnostic System CDS Order through SPX 4 and 2 Wire Tem...

Page 343: ...5 131 231 50 122 279 45 113 338 40 104 412 35 95 505 30 86 623 25 77 774 20 68 968 15 59 1218 10 50 1544 5 41 1974 0 32 2544 5 23 3319 10 14 4362 15 5 5778 2 Pin Connector Cylinder Head Temperature Sensor S N 0T801000 and above model year 2004 and newer Threaded brass housing a M10 1 5 thread b Brass housing c 2 pin connector a b c 40459 ...

Page 344: ...67 40 104 5325 35 95 6530 30 86 8056 25 77 10000 20 68 12493 15 59 15713 10 50 19902 5 41 25391 0 32 32640 5 23 42292 10 14 55253 15 5 72809 Water Pressure Check Water pressure may be checked by using a computer diagnostic system CDS or if the boat is so equipped with SmartCraft gauges Water pressure 900 1000 RPM 1 4 4 kPa 0 2 0 6 psi 5500 and boat on plane 69 103 kPa 10 15 psi ...

Page 345: ...amber to muffler Kinked hose strainer to starboard fuel rail Plugged strainer adapter plate Kinked hose compressor to expansion chamber Model 200 Water Flow Description Water is pumped up through the adapter plate 9 and into the powerhead by the jet pump impeller which is constantly turning whenever the engine is running Water flows through the center of the block around the cylinder sleeves and t...

Page 346: ...Cooling Notes 90 8M0050731 MAY 2011 Page 4B 7 ...

Page 347: ...Cooling Page 4B 8 90 8M0050731 MAY 2011 Water Flow Diagram 1 16 18 17 10 15 2 3 20 14 11 11 10 10 6 8 8 7 7 4 5 19 12 12 20 13 9 6 45587 ...

Page 348: ...ats are removed on the jet drive powerhead 9 Water bypass discharged outside of boat 10 Water flows from bottom of cylinder head through passage in cylinder block to adapter plate 11 Water flows from block through adapter plate cooling exhaust passages in adapter 12 Water flows from adapter to expansion chamber water jacket 13 Cooling water from expansion chamber is emptied back into adapter plate...

Page 349: ...Cooling Notes Page 4B 10 90 8M0050731 MAY 2011 ...

Page 350: ... Adapter Plate Components 5A 16 General Service Recommendations 5A 20 Bearings 5A 20 Shims 5A 20 Seals 5A 20 Principles of Operation 5A 20 Servicing the Stator Impeller and Wear Ring 5A 21 Disassembly 5A 21 Inspecting the Wear Ring and Impeller 5A 24 Wear Ring 5A 24 Impeller 5A 25 Impeller and Stator Installation 5A 25 Removing Jet Drive from Boat 5A 28 Drive Housing Disassembly and Assembly 5A 29...

Page 351: ...eads 92 809819 9 Loctite 567 PST Pipe Sealant Stator fill plugs Stator fill drain and vent plugs 92 809822 34 Special Lubricant 101 Pinion shaft seals and impeller shaft splines Wear ring O ring Impeller shaft splines and wear ring O rings Between shaft seals Impeller shaft splines and seal protector 92 802865Q02 66 Loctite 242 Threadlocker Ride plate screws inlet screen screws and rock grate scre...

Page 352: ...the removal of various engine components Use with puller jaws Bearing Cup Installer 91 832018 25450 Installs the bearing cup into the pinion shaft housing and drive housing cover Universal Puller Plate 91 37241 8505 Removes bearings from gears and the driveshaft Bearing Installer 91 827983T 25453 Installs the taper roller bearing onto the pinion shaft Bearing Installer 91 832016T 25442 Installs th...

Page 353: ...8 25440 Aids in determining the exact pinion gear height location for the 1 15 1 gear ratio jet drive 250 hp Seal Protector 91 850233 25456 Protects the impeller shaft seal during installation Impeller Shaft Preload Kit 91 824871A 1 25417 Applies a preload to the impeller shaft when checking gear lash Backlash Indicator Rod 91 53459 10452 Aids in checking gear backlash Dial Indicator 91 58222A 1 9...

Page 354: ...24871A2 Pinion gear height location tool 91 831897 Pinion shaft bearing installer 91 832016T Impeller shaft bearing installer 91 832017 Bearing cup installer 91 832018 Impeller shaft seal installer 91 832019T Impeller shaft wrench 91 832093A1 Seal protector 91 850233 Impeller nut socket 91 850297 Oil seal installer 91 850830 Stator bushing and seal installer 91 850831 ...

Page 355: ...Pump Unit Page 5A 6 90 8M0050731 MAY 2011 Pinion and Impeller Shaft Components 1 4 4 5 2 3 8 7 6 9 18 15 14 17 13 16 12 11 10 95 95 7 47166 34 34 ...

Page 356: ...002 0 010 in 9 1 Pinion shaft assembly 10 1 Impeller shaft 11 1 Gear 12 1 Washer 13 1 Nut 122 90 14 AR Shim 0 002 0 010 in 15 1 Cover 16 1 Bearing set 17 1 O ring 18 4 Screw M8 x 25 20 5 181 Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Impeller shaft nut 92 809819 34 Special Lubricant 101 Pinion shaft seals and impeller shaft splines 92 802865Q02 95 2 4 C with Teflon Pinio...

Page 357: ...8M0050731 MAY 2011 Nozzle and Rudder Components 18 19 10 1 7 9 8 6 52 11 5 5 4 2 12 3 29 28 30 27 31 13 32 26 13 25 24 22 23 14 15 16 21 17 20 33 34 36 35 47 42 43 44 48 49 45 46 50 51 41 40 39 37 38 37 45329 7 7 9 87 34 7 7 ...

Page 358: ...t bushing 14 1 Lockwasher 15 1 Anode 16 1 Screw M6 x 20 8 71 17 1 Swivel end kit 18 1 Washer 19 1 Screw and nut kit 20 1 Nut 1 4 20 21 2 Flange screw M10 x 45 47 35 22 1 Anode with bushing in casting 23 1 Screw M8 x 25 24 1 Stop 25 2 Special washer 26 2 Flange screw M10 x 35 47 35 27 1 Nozzle assembly with pivot bushing 28 1 Fitting 29 1 Siphon hose 30 1 Screw M8 x 30 13 5 120 31 1 Washer 32 1 Rev...

Page 359: ...rel retainer cup 50 1 Impeller shaft nut 1 1 4 12 203 150 51 1 Four blade impeller 52 2 Special pivot bolt 68 50 Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Nozzle assembly bolts pivot bolts stator assembly bolts anode bolts 92 809819 9 Loctite 567 PST Pipe Sealant Stator fill plugs 92 809822 34 Special Lubricant 101 Wear ring O ring 92 802865Q02 87 High Performance Gear ...

Page 360: ...MAY 2011 Page 5A 11 Nozzle and Rudder Components 18 19 10 1 7 9 8 6 52 11 5 5 4 2 12 3 29 28 30 27 31 13 32 26 13 25 24 22 23 14 15 16 21 17 20 33 34 36 35 47 42 43 44 48 49 45 46 50 51 41 40 39 37 38 37 45329 7 7 9 87 34 7 7 ...

Page 361: ...p Unit Page 5A 12 90 8M0050731 MAY 2011 Jet Drive Housing Components 12 1 11 3 3 13 14 15 24 25 26 17 18 19 20 6 5 4 4 34 8 7 21 22 23 32 33 31 30 29 28 23 27 21 16 2 9 10 66 66 66 66 87 142 142 7 7 47167 ...

Page 362: ...ion Inlet grate kit 18 1 Spring 19 1 Tines 20 1 Frame 21 2 Screw with nylon patch M6 x 20 8 5 75 22 2 Special pivot screw 8 5 75 23 2 Screw M8 x 25 23 17 24 Option Rock grate kit 12 tines 25 2 Screw with nylon patch M6 x 20 26 2 Screw M8 x 25 27 2 Nut M8 18 159 28 2 Washer 29 2 Washer 30 1 Trim plate 31 2 Screw M8 x 35 32 1 Ride plate kit 33 16 Screw with nylon patch M6 x 20 8 5 75 34 1 Ride plate...

Page 363: ...Pump Unit Page 5A 14 90 8M0050731 MAY 2011 Tube Ref No Description Where Used Part No 142 Loctite 598 RTV Sealant Ride plate and inlet grate screws Obtain Locally ...

Page 364: ...p Unit 90 8M0050731 MAY 2011 Page 5A 15 Jet Drive Housing Components 12 1 11 3 3 13 14 15 24 25 26 17 18 19 20 6 5 4 4 34 8 7 21 22 23 32 33 31 30 29 28 23 27 21 16 2 9 10 66 66 66 66 87 142 142 7 7 47167 ...

Page 365: ...Page 5A 16 90 8M0050731 MAY 2011 Expansion Chamber and Adapter Plate Components 44905 29 1 2 4 5 6 24 25 26 24 27 24 28 30 31 32 33 14 15 13 12 16 18 35 36 38 37 34 39 23 21 42 41 40 17 20 16 22 19 11 10 9 8 7 3 ...

Page 366: ...1 4 47 35 12 1 Strainer fitting 13 1 O ring 14 2 Washer 15 2 Screw 3 8 16 x 3 3 4 47 35 16 11 Nut M10 47 35 17 1 Cover assembly 18 5 Stud M10 x 53 40 30 19 1 Gasket engine adapter 20 6 Stud M10 x 101 40 30 21 1 Barbed connector 22 1 O ring 23 1 O ring 24 3 Cable tie 25 1 Siphon hose 106 7 cm 42 in 26 1 Siphon break 27 1 Siphon hose 45 7 cm 18 in 28 1 Cable tie 29 1 Siphon hose strainer 30 1 Flushi...

Page 367: ...Pump Unit Page 5A 18 90 8M0050731 MAY 2011 Ref No Qty Description Torque Nm lb in lb ft 41 1 Hose 42 1 Worm gear clamp ...

Page 368: ...90 8M0050731 MAY 2011 Page 5A 19 Expansion Chamber and Adapter Plate Components 44905 29 1 2 4 5 6 24 25 26 24 27 24 28 30 31 32 33 14 15 13 12 16 18 35 36 38 37 34 39 23 21 42 41 40 17 20 16 22 19 11 10 9 8 7 3 ...

Page 369: ...t Do not lubricate the tapered bearing cups until after inspection Inspect all bearings for roughness catches and bearing race side wear Work the inner bearing race in and out while holding the outer race to check for side wear When inspecting the tapered bearings determine the condition of the rollers and the inner bearing race by inspecting the bearing cup for pits scoring grooves uneven wear im...

Page 370: ...le turns to the right and the jet force from the nozzle pushes the stern of the boat to the left causing the bow of the boat to turn right Forward reverse drive and the neutral position are achieved by the position of a reverse gate located just aft of the nozzle Forward drive has the reverse gate clearing the nozzle to allow all the water to be directed straight back Reverse drive has the reverse...

Page 371: ... four screws securing nozzle to stator Remove the reverse gate rudder nozzle assembly a Screw M10 x 35 flange 2 b Screw M10 x 45 flange 2 c Anode 4 Remove two screws securing the trim plate to the ride plate and wear ring a Screws M6 x 20 2 30 Torx b Ride plate c Trim plate 5 Remove the fill drain plug and allow the lubricant to drain into a suitable container Install the fill drain plug 6 Remove ...

Page 372: ... plug hole 9 If removed install the wear ring to support the impeller and shaft during impeller removal 10 Remove the inlet screen on the bottom of the drive housing to allow access to machined flats on the impeller shaft a Screw M8 x 25 b Screw M6 x 20 11 While holding the impeller shaft remove the impeller nut using special tool 91 850297 Impeller nut is a standard right hand thread 12 Remove th...

Page 373: ...Components for the following a Inspect the seal in the stator for wear damage b Inspect the bellows on cables for wear c Inspect the anodes replace as necessary d Inspect the pivot pins and bushings replace as necessary Tighten the reverse gate pivot pins and rudder pivot pins to the specified torque Use Loctite 271 Threadlocker on the threads Description Nm lb in lb ft Reverse gate pivot pins 68 ...

Page 374: ...ually accounts for 75 of the wear Reducing the clearance can improve both top speed and acceleration performance a Clearance b Impeller c Wear ring Impeller Component Dimensions Wear ring bore diameter 184 73 184 98 mm 7 273 7 283 in Impeller outside diameter 183 52 183 77 mm 7 225 7 235 in Clearance between wear ring and impeller 0 96 1 47 mm 0 038 0 058 in 3 Inspect the leading edges of the impe...

Page 375: ...Impeller c Nut 1 12 Impeller Nut Socket 91 850297 Impeller Shaft Wrench 91 832093A 1 Description Nm lb in lb ft Impeller nut 1 12 203 150 5 Install the inlet screen Apply Loctite 242 Threadlocker to threads of screws Tighten the screws and bolts to the specified torque a Screw M8 x 25 2 b Screw M6 x 20 2 30 Torx Tube Ref No Description Where Used Part No 66 Loctite 242 Threadlocker Inlet screen sc...

Page 376: ...e the stator vent plug Use a small screwdriver to dip into the oil to check it for contamination discoloration and level If oil is low add oil If oil is contaminated or discolored shaft seals and bushings must be inspected and or replaced before refilling stator with new oil After filling the stator with oil apply Loctite 567 PST Pipe Sealant to the plug threads and install the plug a Screw M10 x ...

Page 377: ...e screws 92 809819 Description Nm lb in lb ft Nozzle assembly and anode screws 47 35 11 Attach the shift and steering cables Refer to Section 1D Removing Jet Drive from Boat 1 Remove the powerhead Refer to Section 4A Powerhead Removal from the Pump Unit 2 Disconnect the shift and steering cables from the reverse gate and rudder Remove the cable adapters and bellows assemblies Loosen the shift and ...

Page 378: ... amount of fine metal particles resembling powder indicates normal wear Presence of larger particles or a large quantity of fine particles indicates need for gear housing disassembly and inspection 4 Note the color of the gear lubricant White or cream color indicates the presence of water in the lubricant Check the drain pan for water separation from the lubricant Presence of water in the gear lub...

Page 379: ...ing the Drive Housing IMPORTANT The drive housing must be level and upright to obtain the correct fluid level 1 Remove the fill drain plugs 2 Slowly fill the drive housing through the fill hole with High Performance Gear Lubricant until lubricant flows out of the vent hole and no air bubbles are visible 3 Install the vent screw into the vent hole IMPORTANT Do not lose more than 30 cc 1 fl oz of ge...

Page 380: ...bber ring O ring and shims a Rubber ring b Shims c O ring 3 Press the pinion shaft out of the pinion shaft housing 45267 4 Remove the pinion shaft ball bearing and two seals using the bearing puller assembly 45268 Bearing Puller Assembly 91 83165T 45266 a c b ...

Page 381: ... new outer race into the pinion shaft housing using the mandrel 45271 Bearing Cup Installer 91 832018 7 Remove the tapered roller bearing from the pinion shaft using the universal puller plate 8 Press a new tapered roller bearing onto the pinion shaft using the pinion shaft taper roller bearing installer 45272 Universal Puller Plate 91 37241 Bearing Installer 91 827983T ...

Page 382: ...o the pinion shaft housing one at a time using the seal installer Inner seal faces in outer seal faces out Fill between the seals with Special Lubricant 101 a Seal installer 91 820552 1 Bearing Installer 91 820552 1 Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Between shaft seals 92 802865Q02 Impeller Shaft Removal 1 Remove the stator wear ring and impeller Refer to Servicin...

Page 383: ...ve the ride plate 4 Remove the four screws securing the impeller shaft cover to the drive housing Remove the cover a Screw b Cover c Shim d O ring NOTE Take care not to damage or misplace the shims 45277 5 Remove the nut and washer from the end of the impeller shaft Remove the impeller shaft gear 45279 45276 a b c d ...

Page 384: ...m the drive housing 45280 7 Remove the bearing retaining ring from the drive housing 45281 8 Remove the bearing using the bearing puller 45282 Bearing Puller Assembly 91 83165T 9 Remove the impeller shaft seals using the slide hammer and puller jaws Slide Hammer 91 34569A 1 ...

Page 385: ...g the bearing installer tool 45284 Bearing Installer 91 832017 Seal Installer 91 832019T 12 Install the retaining ring in the drive housing after the bearing is installed 13 If replacing the impeller shaft gear bearing remove using the universal puller plate a Bearing b Plate c Mandrel Universal Puller Plate 91 37241 a b c 28155 ...

Page 386: ...med when any of the following components have been replaced Jet drive housing Pinion gear Pinion gear bearing assembly Pinion shaft housing Impeller gear Impeller gear bearing assembly Impeller shaft front cover 1 Install the original shims onto the pinion shaft housing Install the O ring on the pinion shaft housing NOTE If the original shims are not available start with 0 76 mm 0 030 in shims 2 L...

Page 387: ...n tool into the drive housing NOTE Carefully inspect the location tool to ensure it is seated in the drive housing bearing a Pinion location tool Pinion gear Backlash specification 0 64 mm 0 025 in Pinion Gear Height Location Tool 91 831897 NOTE 250 hp models 1 15 gear ratio use pinion height location tool 91 882758 Pinion Gear Height Location Tool 91 882758 8 Insert the feeler gauge through the h...

Page 388: ...ecial Lubricant 101 2 Install the seal protector onto the impeller shaft Install the impeller shaft in the drive housing then remove the seal protector 45288 Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Impeller shaft splines and seal protector 92 802865Q02 Seal Protector 91 850233 3 Install the gear bearing assembly and washer onto the impeller shaft Apply Loctite 271 Threa...

Page 389: ...2859A 1 7 Loctite 271 Threadlocker Pinion shaft housing screws M8 x 25 92 809819 Description Nm lb in lb ft Impeller shaft cover screws M8 x 25 4 20 5 181 7 Install the impeller shaft preload tool 8 Install the wear ring and stator onto the impeller shaft Secure the assembly with two bolts opposite corners Tighten the bolts to the specified torque a Bolt M10 x 150 b Washer c Stator d Wear ring e R...

Page 390: ... Ratio of backlash reading to shims is 1 1 13 Remove the backlash indicator rod from the pinion shaft 14 Remove the dial indicator kit adapter kit and thread extending kit 15 Remove the stator and remove the impeller shaft preload tool Final Assembly 1 Install the impeller wear ring and stator Fill the stator housing with High Performance Gear Lubricant Refer to Impeller and Stator Installation 2 ...

Page 391: ...e reverse gate assembly and anode bolt threads 92 809819 66 Loctite 242 Threadlocker Ride plate bolt threads M6 x 20 16 92 809821 87 High Performance Gear Lubricant Stator and drive housing 92 858064K01 142 Loctite 598 RTV Sealant Ride plate Obtain Locally Description Nm lb in lb ft Ride plate bolts M6 x 20 16 8 5 75 Nozzle bolts M10 x 35 2 47 35 Anode bolts M10 x 45 2 47 35 5 Install the drive ho...

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