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3B-7 90-13645--2 495 OIL INJECTION SYSTEM
Oil Injection System
Troubleshooting Chart
(Models with Warning Module)
Troubleshooting the Oil Injection
System
If a problem occurs with the oil injection system and
the warning horn sounds in a pulsating manner, stop
engine and check if problem is caused by (1) low oil
level – 1 quart remaining, (2) the oil injection pump,
or (3) a faulty warning module.
1. Open the engine cowling and check oil level in en-
gine reservoir. If oil level is approximately one
quart or less, the problem is low oil level. Add oil
to reservoir.
NOTE: There is a safety reserve of oil left in the reser-
voir after the low oil warning is sounded. There is
enough oil for approximately 50 minutes of full throttle
operation on four cylinder engines and approximately
1 hour of full throttle operation on three cylinder en-
gines.
2. If there is more than 1 quart of oil in the reservoir,
then the problem may be in the oil injection pump.
DO NOT run engine on straight gas when a prob-
lem may be in the oil injection pump. Engine can
be run by connecting a remote fuel tank of 50:1
gas and oil mixture to engine.
Troubleshooting Chart
PROBLEM: Warning horn does not sound when ignition key is turned to “ON” position.
POSSIBLE CAUSE CORRECTIVE ACTION
Horn malfunction or open (TAN) wire between horn
and engine Disconnect tan lead from main engine wiring harness
at terminal block on engine. Ground this tan lead to en-
gine ground. Warning horn should sound. If not, check
tan wire between horn and engine for open circuit and
check horn.
Warning Module Check if all warning module leads are connected to
harness leads. If so, warning module may be faulty.
Using incorrect side mount remote control or ignition/
choke assembly. Refer to Quicksilver Accessory Guide for correct com-
ponents
PROBLEM: Warning horn stays on when ignition key is turned to “ON” position.
POSSIBLE CAUSE CORRECTIVE ACTION
Engine overheat sensor If horn sounds a continuous “beep”, the engine over-
heat sensor may be faulty. Disconnect overheat sen-
sor (BLACK Wire) and turn ignition key to “ON” posi-
tion. If horn still sounds a continuous “beep”, the warn-
ing module is faulty. Replace module and retest. If
“beep” does not sound, then engine overheat sensor
is faulty. Replace and retest.
Warning Module If horn continues to sound on intermittent “beep”, the
warning module is faulty or oil level is too low.
PROBLEM: Warning horn sounds when engine is running. Oil level in engine reservoir is full.
POSSIBLE CAUSE CORRECTIVE ACTION
Defective low oil sensor Disconnect both low oil sensor leads (LIGHT BLUE)
from bullet connectors. Connect an ohmmeter be-
tween leads. There should be no continuity through
sensor. If continuity exists, sensor is faulty.
Drive system of oil injection pump Refer to page 3B-3, “Oil Pump Test” to determine if oil
pump is operating properly.
Warning Module Replace warning module.