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MODEL 120XR2 Sport Jet Starting Serial Number 0E345000 and Above Printed in U.S.A. W1998, Mercury Marine 90-858804 AUGUST 1998 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal in- jury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes 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 service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. 90-858804 AUGUST 1998 Page i It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. Page ii 90-858804 AUGUST 1998 Service Manual Outline Section 1 - General Information & Specifications Section 2 - Electrical and Ignition A - CDM Ignition B - Batery, Charging and Starting Systems C - Timing/Synchronizing/Adjusting Section 3 - Fuel System and Carburetion A - Carburetor B - Fuel Pump, Recirculation System, Reed Valve Assembly and Auto Enrichner C - Oil Injection System Section 4 - Powerhead Section 5 - Jet Pump Section 6 - Sport Jet Installation General Information & Specifications Electrical and Ignition Fuel System and Carburetion Powerhead Jet Pump Sport Jet Installation 90-858804 AUGUST 1998 Page iii GENERAL INFORMATION AND SPECIFICATIONS SECTION 1A – GENERAL INFORMATION AND SPECIFICATIONS Table of Contents 1 A How To Use This Manual . . . . . . . . . . . . . . . . . . . 1A-1 Out-of-Season Storage 1A-9. . . . . . . . . . . . . . . . . . Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 Out-of-Season Battery Storage . . . . . . . . . . 1A-10 Master Specifications . . . . . . . . . . . . . . . . . . . . . . 1A-2 How Weather Affects Engine Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6 Performance 1A-11 . . . . . . . . . . . . . . . . . . . . . . . . . Standard Hardware . . . . . . . . . . . . . . . . . . . . . 1A-6 Detonation: Causes and Prevention 1A-11 . . . . . Metric Hardware . . . . . . . . . . . . . . . . . . . . . . . 1A-7 Compression Check . . . . . . . . . . . . . . . . . . . 1A-12 Flushing Cooling System . . . . . . . . . . . . . . . . 1A-7 Water Pressure Check . . . . . . . . . . . . . . . . . 1A-12 Following Complete Submersion . . . . . . . . . 1A-8 How To Use This Manual The manual is divided into SECTIONS (shown right) which represents major components and systems. Some SECTIONS are further divided into PARTS. Each PART has a title page. A Table of Contents for the particular PART is printed on the back of the title page. SECTIONS and PARTS are listed on the Service Manual Outline sheet which immediately follows the cover of this book. Section Section Heading 1 2 3 4 5 6 General Information/Specifications Electrical and Ignition Fuel System and Carburetion Powerhead Jet Pump Sport Jet Installation 90-858804 AUGUST 1998 Page 1A-1 GENERAL INFORMATION AND SPECIFICATIONS Page Numbering Two number groups appear at the bottom of each page. The example below is self-explanatory. 90-826148R1 MAY 1994 Page 4A-7 Revision No. 1 Month of Printing Year of Printing Section Number Part of Section Letter Page Number EXAMPLE: Master Specifications 120 HORSEPOWER (KW) Model 120 120 (89.5) PH / PUMP WEIGHT 260 lbs. CYLINDER BLOCK Type Displacement 4 Cylinder In-Line 102.9 cu. in. (1687 cc) STROKE Length 2.876 in. (73.05 mm) CYLINDER BORE Diameter (Standard) Taper/Out of Round Max. Bore Type 3.375 in. (85.7 mm) 0.0015 Cast Iron PISTON Piston Type Standard 0.015 in. (0.378 mm) Oversize 0.030 in. (0.752 mm) Oversize Aluminum Diameter 3.3700 (85.598 mm) Diameter 3.3850 (85.979 mm) Diameter 3.4000 (86.360 mm) REEDS Reed Stand Open (Max.) 0.010 (0.254 mm) Page 1A-2 90-858804 AUGUST 1998 GENERAL INFORMATION AND SPECIFICATIONS PUMP Gear Ratio 1.25:1 HOUSING Drive Housing Capacity 750 cc Stator Capacity 500 cc Pinion Height 0.025 in. (0.64 mm) Gear Backlash 0.007 in. - 0.009 in. (0.177 mm - 0.228 mm) FUEL SYSTEM Fuel Recommended Gasoline Recommended Oil Gasoline/Oil Ratio Fuel Pressure- @ Idle - @ WOT Gasoline and Oil Automotive Lead-Free: 87 octane minimum Quicksilver TC-W 3 or TC-W II Outboard Oil Variable ratio oil injection 3.5 PSI 6 PSI STARTING Electric Start- Starter Draw SYSTEM Under Load 110 - 200 Amperes No Load 80 - 165 Amperes Battery Rating 670 Marine Cranking Amps (MCA) or (minimum) 520 Cold Cranking Amps (CCA) IGNITION SYSTEM Type Spark Plug Type Spark Plug Gap Optional (Resistor Plug) Capacitor discharge Champion L77JC4 .040 (1.0 mm) QL77JC4 CHARGING SYSTEM Alternator Output (Regulated) 15 Amp CARBURETOR Idle RPM Wide Open Throttle (WOT) RPM Idle Mixture Screw Adjustment (Preset – Turns Out) – All Carbs Float Setting Main Jet – Model 120 – Carb #1 – Carb #2 950 - 1100 RPM 4700 - 5300 1-1/2 turn out from a lightly seated position Set parallel to body flange .088 .090 TIMING Maximum BTDC @ Cranking Speed 32° BTDC @ 5000 RPM Firing Order 30° BTDC – Model 120 1-3-2-4 90-858804 AUGUST 1998 Page 1A-3 GENERAL INFORMATION AND SPECIFICATIONS 0.15 in. (3.81 mm) Measured 90 to piston pin center line 3.3700 .0005 2.910  .020 .77003 .76993 4.500 1.4991 0.9568 0.9573 1.4986 .005 Page 1A-4 90-858804 AUGUST 1998 GENERAL INFORMATION AND SPECIFICATIONS 1.3793 1.1813 1.3748 1.2495 1.3789 1.3752 1.2500 1.1818 CRANKSHAFT 90-858804 AUGUST 1998 Page 1A-5 GENERAL INFORMATION AND SPECIFICATIONS Torque Chart Special Items Torque Impeller Shaft Nut 150 lb. ft. (203 N·m) Drive Housing Cover Bolts 35 lb. ft. (47.5 N·m) Stator Bolts 35 lb. ft. (47.5 N·m) Nozzle to Stator Bolts 35 lb. ft. (47.5 N·m) Rudder Pivot Bolt 20 lb. ft. (27.1 N·m) Reverse Gate Pivot Bolt 20 lb. ft. (27.1 N·m) Powerhead to Drive Housing (M8 Nut) 20 lb. ft. (27.1 N·m) Powerhead to Drive Housing (M10 Nut) 35 lb. ft. (47.5 N·m) Steering Cable Mounting Bracket 200 lb. in. (22.6 N·m) Steering Lever Screw 180 lb. in. (20.2 N·m) Reverse Gate Stop Screw 120 lb. in. (13.6 N·m) Shift Bracket Screw 50 lb. in. (5.6 N·m) Inlet Screen Screw 75 lb. in. (8.5 N·m) Ride Plate Screw 75 lb. in. (8.5 N·m) Drive Shaft Nut 90 lb. in. (122 N·m) Cylinder Head 225 lb. in. (25.4 N·m) Then Turn Additional 90. Flywheel Nut 125 lb. ft. (169.47 N·m) Main Bearing Bolts 270 lb. in. (30.4 N·m) Connecting Rod Screws 120 lb. in. (13.6 N·m) Then Turn Additional 90. Transfer Port Cover 80 lb. in. (9.03 N·m) Exhaust Manifold 115 lb. in. (13 N·m) Carburetor Fuel Bowl Screw 30 lb. in. (3.5 N·m) Standard Hardware Screw or Nut Size Torque 6 - 32 9 lb. in. (1.0 N·m) 8 - 32 20 lb. in. (2.3 N·m) 10 - 24 30 lb. in. (3.4 N·m) 10 - 32 35 lb. in. (3.9 N·m) 12 - 24 45 lb. in. (5.0 N·m) 1/4 - 20 70 lb. in. (7.8 N·m) 5/16 - 18 160 lb. in. (18.1 N·m) 3/8 - 16 270 lb. in. (30.4 N·m) Page 1A-6 90-858804 AUGUST 1998 GENERAL INFORMATION AND SPECIFICATIONS Metric Hardware AA BB Torque Specification lb. in. lb. ft. N·m 8 mm M5 36 3 4 10 mm M6 70 6 8 12 mm M8 156 13 18 14 mm M10 312 26 36 17 mm M12 372 31 42 A B Flushing Cooling System Flushing the cooling system is essential after each use in salt water, after the boat has run aground, or when the overheat warning horn sounds (debris in jet powerhead). We recommend using Dealer Kit (P/N 22-820573) to flush the cooling system. 1. Disconnect the inlet water hose at the rear starboard corner of the pump housing. Install the Dealer Kit and attach water hose. a a-Dealer Flushing Kit (22-820573) 2. Turn water on and flush engine block for at least 10 minutes. 3. Remove water hose and dealer flushing kit. Re-install water inlet hose. 4. Flush outer surfaces of water outlet nozzle with water stream. 90-858804 AUGUST 1998 Page 1A-7 GENERAL INFORMATION AND SPECIFICATIONS Following Complete Submersion Submerged engine treatment is divided into three distinct problem areas. The most critical is submersion in salt water; the second is submersion while running; the third is submersion in fresh water with special instructions. SALT WATER SUBMERSION (SPECIAL INSTRUCTIONS) Due to the corrosive effect of salt water on internal engine components complete disassembly is necessary before any attempt is made to start the engine. SUBMERGED WHILE RUNNING (SPECIAL INSTRUCTIONS) When an engine is submerged while running, the possibility of internal engine damage is greatly increased. If, after engine is recovered and with spark plugs removed, engine fails to rotate freely when turning 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 (FRESH WATER) PLUS SPECIAL INSTRUCTIONS 1. Recover engine as quickly as possible. 2. Flush exterior of engine with fresh water to remove mud, weeds, etc. DO NOT attempt to start engine if sand has entered powerhead, as powerhead will be severely damaged. Disassemble powerhead if necessary to clean components. 3. Remove spark plugs and get as much water as possible out of powerhead by rotating flywheel. 4. Pour alcohol into carburetor throat (alcohol will absorb water). Again rotate flywheel. 5. Pour alcohol into spark plug openings and again rotate flywheel. 6. Pour engine oil into throats of carburetors while rotating flywheel to distribute oil throughout crankcase. 7. Pour approximately one teaspoon of engine oil into each spark plug opening. Rotate flywheel to distribute oil in cylinders. 8. Remove and clean carburetors and fuel pump assembly. 9. Reinstall spark plugs, carburetors and fuel pump. 10. Attempt to start engine, using a fresh fuel source. If engine starts it should be run for at least one hour to eliminate any water in engine. 11. If engine fails to start determine cause (fuel, electrical or mechanical). Engine should be run within two hours after recovery from water as serious internal damage may occur. If unable to start engine in this period disassemble engine and clean all parts and apply oil as soon as possible. Page 1A-8 90-858804 AUGUST 1998 GENERAL INFORMATION AND SPECIFICATIONS Out-of-Season Storage WARNING As a safety precaution, when boat is in storage, remove positive (+) battery cable. This will eliminate possibility of accidental starting of engine and resultant overheating and damage to engine from lack of water. In preparing for out-of-season storage, two precautions must be considered: 1) The engine must be protected from physical damage caused by freezing trapped water and 2) the engine must be protected from rust, corrosion and dirt. The following storage procedures should be followed to prepare the Sport Jet for out-of-season storage or prolonged storage (two months or longer). CAUTION Never start or run the Sport Jet (even momentarily) out of the water. Damage to the pump and engine will occur. FUEL SYSTEM IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being used contains alcohol, it is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system. Fill the fuel system (tank, hoses, fuel pump, and carburetors) with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with the following instructions. • Portable Fuel Tank: Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel. • Permanently Installed Fuel Tank: Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank. • Place the Sport Jet in the water. Run the engine for ten minutes to allow treated fuel to reach the carburetors. 1. With Sport Jet in the water, start the engine and let it warm up to operating temperature. 2. Disconnect the fuel line. When the engine starts to stall quickly spray Quicksilver Storage Seal into each carburetor throat. Continue to spray until engine dies from lack of fuel. 3. Remove spark plugs and inject a five second spray of Quicksilver Storage Seal around the inside of each cylinder. Manually turn engine over several times to distribute Storage Seal throughout cylinders. Reinstall spark plugs. 4. Drain and refill drive housing unit and stator assembly with Quicksilver Hi Performance Gear Lube as explained in “Jet Pump” section (see Table of Contents). 5. Clean engine thoroughly including all accessible powerhead parts and spray with Corrosion and Rust Preventive. 6. Remove water inlet hose and drain any trapped water. Reconnect hose. 90-858804 AUGUST 1998 Page 1A-9 GENERAL INFORMATION AND SPECIFICATIONS a a-Water Inlet Hose 7. Lubricate all lubrication points. 8. To prevent freeze damage, drain the speedometer system of water completely before storage. Remove tubing from speedometer fitting and blow through tubing to remove water. 9. Store battery as outlined in Out-of-Season Battery Storage following: IMPORTANT: Check and refill housings with Quicksilver Hi Performance Gear Lube before storage to protect against possible water leakage into housings which is caused by loose lubricant vent plug or loose grease fill plug. Inspect gaskets under lubricant vent and fill plugs replacing any damaged gaskets before reinstalling plugs. Out-of-Season Battery Storage 1. Remove battery as soon as possible and remove all grease, sulfate and dirt from top surface. 2. Cover plates with distilled water, but not over 3/16 in. (5 mm) above perforated baffles. 3. Cover terminal bolts well with grease. 4. Store battery in a cool, dry place in a dry carton or box. 5. Remove battery from storage every 60 days. Check water level and place on charge for 5 to 6 hours at 6 amperes. DO NOT fast charge. CAUTION A discharged battery can be damaged by freezing. Page 1A-10 90-858804 AUGUST 1998 GENERAL INFORMATION AND SPECIFICATIONS How Weather Affects Engine Performance It is a known fact that weather conditions exert a profound effect on power output of internal combustion engines. Therefore, established horsepower ratings refer to the power that the engine will produce at its rated RPM under a specific combination of weather conditions. Corporations internationally have settled on adoption of I.S.O. (International Standards Organization) engine test standards as set forth in I.S.O. 3046 standardizing the computation of horsepower from data obtained on the dynamometer correcting all values to the power that the engine will produce at sea level at 30% relative humidity at 77° F (25° C) temperature and a barometric pressure of 29.61 inches of mercury. Summer Conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as much as 2 or 3 miles-per-hour (3 or 5 km per hour) in some cases. Nothing will regain this speed for the boater, but the coming of cool, dry weather. In pointing out the practical consequences of weather effects, an engine running on a hot, humid, summer day may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk spring or fall day. The horsepower that any internal combustion engine produces depends upon the density of the air that it consumes and, in turn, this density is dependent upon the temperature of the air, its barometric pressure and water vapor (or humidity) content. Detonation: Causes and Prevention Detonation in a 2-cycle engine somewhat resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-link “rattling” or “plinking” sound. Detonation generally is thought of as spontaneous ignition, but it is best described as a noisy explosion in an unburned portion of the fuel/air charge after the spark plug has fired. Detonation creates severe, untimely shock waves in the engine and these shock waves often find or create a weakness: the dome of a piston, piston rings or piston ring lands, piston pin and roller bearings. While there are many causes for detonation in a 2-cycle engine emphasis is placed on those causes which are most common in marine 2-cycle application. A few which are not commonly understood are: 1. Over-advanced ignition timing. 2. Use of low octane gasoline. 3. Lean fuel mixture at or near wide open throttle. 4. Spark plugs (heat range too hot, incorrect reach, cross-firing). 5. Inadequate engine cooling (deteriorated cooling system). 6. Combustion chamber/piston deposits (result in higher compression ratio). Detonation usually can be prevented provided that (1) the engine is correctly set up and (2) diligent maintenance is applied to combat the preceding detonation causes listed. 90-858804 AUGUST 1998 Page 1A-11 GENERAL INFORMATION AND SPECIFICATIONS Compression Check 1. Remove spark plugs. 2. Install compression gauge in spark plug hole. 3. Hold throttle plates at W.O.T. 4. Crank engine through at least four compression strokes to obtain highest possible reading. 5. Check and record compression of each cylinder. Variation of more than 15 psi (103.5 kPa) between cylinders indicates that lower compression cylinder is in some way defective such as worn or sticking piston rings and/or scored piston and cylinder. 6. Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance. It is essential, therefore, that improper compression be corrected before proceeding with an engine tune-up. 7. Cylinder scoring: if powerhead shows any indication of overheating, such as discolored or scorched paint, visually inspect cylinders for scoring or other damage as outlined in Section 4: Powerhead. Water Pressure Check NOTE: To perform these checks a Water Pressure Gauge Kit P/N 91-79250A2 is recommended. 1. Water pressure at idle in NEUTRAL, is 1/2–1-1/2 psi (3.4-10.3 kPa). 2. Water pressure in FORWARD gear at 5000 RPM is 10-15 psi (69-103.5 kPa). CAUTION Static test requires the boat be stationary in the water secured to a dock or trailer and run in forward. Do not use a flushing device for this test. Page 1A-12 90-858804 AUGUST 1998 CDM IGNITION ELECTRICAL AND IGNITION Section 2A - CDM Ignition Table of Contents 2 A Special Tools Required . . . . . . . . . . . . . . . . . . . . . 2A-1 Torque Specifications . . . . . . . . . . . . . . . . . . 2A-10 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Ignition Components Removal andPrinciples of Operation . . . . . . . . . . . . . . . . . . . . . 2A-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-11 Capacitor Discharge Module (CDM)Removing Flywheel . . . . . . . . . . . . . . . . . . . . . . . 2A-12 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Installing Flywheel . . . . . . . . . . . . . . . . . . . . . . . . 2A-13 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Removing Stator . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14 Testing For Spark . . . . . . . . . . . . . . . . . . . . . . 2A-3 Installing Stator . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-15 Ignition Diagnostic Procedures . . . . . . . . . . . . . . 2A-5 Removing Trigger . . . . . . . . . . . . . . . . . . . . . . . . 2A-15 Testing Voltage Output to CDM . . . . . . . . . . . 2A-5 Installing Trigger . . . . . . . . . . . . . . . . . . . . . . . . . 2A-16 Testing Stator Resistance . . . . . . . . . . . . . . . 2A-8 Removing CDM (Capacitor DischargeIgnition Components Removal and Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-17 Installation 2A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing CDM . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-17 Quicksilver Lubrication/SealantWiring Diagram 120 HP . . . . . . . . . . . . . . . . . . . 2A-18 Application Points 2A-10. . . . . . . . . . . . . . . . . . . . . Special Tools Required Multimeter / DVA Tester 91-99750 Spark Tester 91-850439 55117 Ignition Test Harness 84-825207A2 90-858804 AUGUST 1998 Page 2A-1 CDM IGNITION General The ignition system is self-energizing (creates it’s own power for ignition) and has proven reliability. Should testing be required it is important to check all components in the order outlined. IMPORTANT: Read the entire procedure before attempting to test components. The procedures in this section are designed to test the complete ignition system. In an actual situation, test only the components that control the misfiring cylinder(s). WARNING When testing or servicing the ignition system high voltage is present; be extremely cautious! DO NOT TOUCH OR DISCONNECT any ignition components while engine is cranking or running. Principles of Operation Capacitor Discharge Module (CDM) Ignition System The ignition system is alternator driven with distributorless capacitor discharge. Major components of the ignition system are the flywheel, stator, trigger, capacitor discharge module, and spark plugs. The stator assembly is mounted stationary below the flywheel and has one capacitor charging coil. The flywheel is fitted with permanent magnets inside the outer rim. As the flywheel rotates the permanent magnets pass the capacitor charging coil. This causes the capacitor charging coils to produce AC voltage. The AC voltage is conducted to the CDM (Capacitor Discharge Module) where it is rectified and stored in a capacitor. The trigger assembly (also mounted under the flywheel) has one coil for each cylinder. The flywheel has a second set of permanent magnets located around the center hub. As the flywheel rotates the second set of magnets pass the trigger coils. This causes the trigger coils, in turn, to produce an AC voltage that is conducted to an electronic switch (SCR) in the CDM. The SCR switch discharges the capacitor voltage into the primary side of the ignition coil. The ignition coil multiplies this voltage to a value high enough to jump the gap at the spark plug. The preceding sequence occurs once per engine revolution for each cylinder. Spark timing is changed (advanced/retarded) by rotating the trigger assembly which changes each trigger coil position in relation to the permanent magnets on the flywheel hub. Page 2A-2 90-858804 AUGUST 1998 CDM IGNITION Test Procedures CAUTION Failure to comply with the following items may result in damage to the ignition system. • DO NOT reverse battery cable connections. The battery negative cable is (–) ground. DO NOT “spark” battery terminals with battery cable connections to check polarity. • DO NOT disconnect battery cables while engine is running. Before troubleshooting the ignition system: • Check that plug-in connectors are fully engaged and free of corrosion (trigger connectors are located behind the ignition plate). • Check that electrical components are grounded to the ignition plate and that ignition plate is grounded to the engine block. • Check for disconnected wires, short and open circuits. Testing For Spark 1. Adjust spark tester to a 7/16” gap setting. 7/16 in. 2. Secure spark tester to a good engine ground. 3. Remove leads from spark plugs. 4. Connect spark plug leads to corresponding spark tester leads. 5. Remove spark plugs. 6. Turn the ignition key to the “on” position. 7. Crank motor. NOTE: Battery voltage must be a minimum of 10 volts at the starter solenoid to adequately crank the engine. 90-858804 AUGUST 1998 Page 2A-3 CDM IGNITION Results: Action Required: Spark jumps 7/16” gap (all cylinders) Ignition system operational - If required, check timing & setup. No spark Go to next step. No spark on 1 or 2 cylinders Go to Ignition Diagnostic Procedures. 8. Disconnect all CDM plugs and verify that each ground lead has continuity to engine ground. a a-Each CDM ground wire is labeled “A”. 9. Re-connect all CDMs. 10. Check that safety stop switch lanyard is in place. If safety lanyard is NOT in place, spark plugs will not fire. 11. Isolate the rev limiter by disconnecting the black/yellow lead to the rev limiter. Tape back the black/yellow lead. Re-test for spark. If all cylinders spark, replace rev limiter. No spark: continue with next step. 12. Isolate the stop circuit by disconnecting black/yellow bullet connector located on the ignition plate wire bundle. IMPORTANT: Be sure this lead is not grounded. 13. Crank motor. Results: Action Required: All cylinders spark normally Repair stop circuit: ignition key switch and/ or boat wiring. No spark (all cylinders) Go to Ignition Diagnostic Procedures. 14. Re-connect rev limiter and/or stop circuit. NOTE: Each CDM is grounded through the engine wiring harness via the connector plug. It is not necessary to have the CDM mounted on the ignition plate for testing. Page 2A-4 90-858804 AUGUST 1998 CDM IGNITION IMPORTANT: The voltage return path for #1 and #2 CDM is through either #3 or #4 CDM. The return path for #3 and #4 is through either #1 or #2 CDM. #1 #3#4 #2 Ignition Diagnostic Procedures PROBLEM CORRECTION 1. No spark on one cylinder 1. Plug in a CDM that is known to be good. If spark returns, replace bad CDM. 2. No change: go to Testing Voltage Output to CDM. 3. No spark on all cylinders Go to Testing Voltage Output - Test all CDMs. Testing Voltage Output to CDM CAUTION To protect against meter and/or component damage, observe the following precautions: . INSURE that the Positive (+) meter lead is connected to the DVA receptacle on the meter. . DO NOT CHANGE meter selector switch position while engine is running and/or being “cranked”. NOTE: Each CDM is grounded through the engine wiring harness via the connector plug. It is not necessary to have the CDM mounted on the ignition plate for testing. 1. Make sure all CDMs are plugged in. 2. Test Stator and Trigger voltage to CDM: 90-858804 AUGUST 1998 Page 2A-5 CDM IGNITION a. Install test harness between Ignition Harness and CDM. c ba a-Stator/Trigger Harness b-Test Harness c-Capacitor Discharge Module b. Perform the following tests: CRANKING ENGINE: Test each CDM. Stator Output Test 400 DVA Scale Positive Meter Lead (+) Negative Meter Lead (–) DVA Reading Connect to Green Test Harness Lead Connect to Black Test Harness Lead 100 - 350 If only one CDM stator reading is below specifications, replace that CDM. If all CDM stator voltage readings are low, go to Testing Stator Resistance. GRNBLK Test each CDM. Page 2A-6 90-858804 AUGUST 1998 CDM IGNITION Trigger Output Test 2 DVA Scale Positive Meter Lead (+) Negative Meter Lead (–) DVA Reading White Test Harness Lead Black Test Harness Lead 0.2 - 2.0 If reading is below specifications replace trigger. If reading is above specifications check CDM. NOTE: If voltage remains low after installing a new trigger, replaced CDM. WHT BLK ENGINE RUNNING AT IDLE: It is not necessary to perform this test if the voltage output was tested in the previous step CRANKING ENGINE. Stator Output Test 400 DVA Scale Positive Meter Lead (+) Negative Meter Lead (–) DVA Reading Connect to Green Test Harness Lead Connect to Black Test Harness Lead 200 - 350 If stator output is low, go to Testing Stator Resistance. Trigger Output Test 20 DVA Scale Positive Meter Lead (+) Negative Meter Lead (–) DVA Reading White Test Harness Lead Black Test Harness Lead 2 - 8 Volts If reading is below specifications replace trigger. If reading is above specifications check CDM. NOTE: If voltage remains low after installing a new trigger, replaced CDM. 90-858804 AUGUST 1998 Page 2A-7 CDM IGNITION Testing Stator Resistance Disconnect stator leads. Stator Resistance Test R10 Oh S lR x 10 Ohms ScalePositive Meter Lead (+) Negative Meter Lead (–) Connect to White/Green stator lead Connect to Green/White stator lead 500 - 600 ± 10% Connect to White/Green stator lead Connect to engine ground No continuity Connect to Green/White stator lead Connect to engine ground No continuity IMPORTANT: If all CDM stator output voltage is low and stator resistance tests are within specifications, then each CDM (one at a time) must be replaced with a CDM known to be good until stator output voltage returns to proper levels. This process of elimination will reveal a defective CDM. RX10 TRIGGER A resistance test is not used on the trigger. Test trigger as outlined under “Testing Voltage Output to CDM”. Page 2A-8 90-858804 AUGUST 1998 CDM IGNITION CAPACITOR DISCHARGE MODULE AB CD A -Ground B -Black/Yellow C -Trigger Connection D -Stator Connection IMPORTANT: Spark plug wires are screwed into CDM. A resistance check, although not necessary for any troubleshooting procedure, can be made of the CDM as follows: NOTE: This test can be performed using the test harness (p/n 84-825207A2). Do Not connect the test harness plug to the stator/trigger engine wire harness. CAPACITOR DISCHARGE MODULE Connect Positive (+) Meter Lead To: Connect Negative (–) Meter Lead To: Ohms Scale Results: Ground Pin (A) / or Black test harness lead White (C) / or White test harness lead R x 100 1250  100 Ohms Green (D) / or Green test harness lead Ground Pin (A) / or Black test harness lead R x 1 Diode Reading* Continuity Ground Pin (A) or Black test harness lead Green (D) / or Green test harness lead R x 1 Diode Reading* No Continuity Green (D) / or Green test harness lead Black/Yellow (B) / or Black/ Yellow test harness lead R x 1 Diode Reading* No Continuity Black/Yellow (B) / or Black/ Yellow test harness lead Green (D) / or Green test harness lead R x 1 Diode Reading* Continuity Spark Plug Terminal (At Spark Plug Boot) Ground Pin (A) or Black test harness lead R x 10 1050  150 Ohms *Diode Readings: Due to the differences in test meters, results other than specified may be obtained. In such a case, reverse meter leads and re-test. If test results then read as specified CDM is O.K.. The diode measurements above will be opposite if using a Fluke equivalent multimeter. 90-858804 AUGUST 1998 Page 2A-9 CDM IGNITION Ignition Components Removal and Installation WARNING Engine could possibly start when turning flywheel during removal and installation; therefore, disconnect (and isolate) spark plug leads from spark plugs to prevent engine from starting. B 7b 6 5 4 3 2 1 a 1-Cap, Plastic 2-Flywheel Nut 3-Washer 4-Flywheel 5-Stator 6-Trigger 7-Screw Quicksilver Lubrication/Sealant Application Points B Loctite “271” (92-823089--1) Torque Specifications 125 lb. ft. (170 N·m) ab 50 lb. in. (5.6 N·m) Page 2A-10 90-858804 AUGUST 1998 CDM IGNITION 90-858804 AUGUST 1998 Page 2A-11 Ignition Components Removal and Installation 3 5 6 2 4 5 7 1 6 4 5 2 1 -CDM (Capacitor Discharge Module) 2 -Voltage Regulator 3 -20 Ampere Fuse 4 -CDM Wire Harness 5 -Engine Wire Harness 6 -Ignition Plate 7 -Rev Limiter CDM IGNITION Removing Flywheel WARNING Always disconnect battery and remove spark plug leads from spark plugs before working on motor. 1. Remove flywheel guard. 2. While holding flywheel with Flywheel Holder (91-52344), remove flywheel nut and washer. CAUTION Crankshaft damage may result if a protector cap is not used between crankshaft and puller. • Install a crankshaft Protector Cap (91-24161) on end of crankshaft, then install Flywheel Puller (91-73687A1) into flywheel. a b a-Flywheel Puller b-Protector Cap (Included in Flywheel Tool 91-73687A1) Page 2A-12 90-858804 AUGUST 1998 CDM IGNITION • Hold flywheel tool with wrench while tightening bolt down on protector cap. Tighten bolt until flywheel comes free. 51124 a a-Flywheel Puller (91-73687A1) NOTE: Neither heat nor hammer should be used on flywheel to aid in removal as damage to flywheel or electrical components under flywheel may result. • Remove flywheel. Remove flywheel key. a a-Flywheel Key 3. Inspect flywheel. • Carefully inspect flywheel for cracks or damage. WARNING A cracked or chipped flywheel must be replaced. At high RPM a damaged flywheel may fly apart and throw metal over a large area. • Inspect crankshaft and flywheel tapers for worn or damaged key ways. • Check for loose or damaged flywheel magnets (outer rim and center hub). Arc burns on magnets are normal. • Replace flywheel if necessary. Installing Flywheel 1. Clean tapered surfaces of flywheel and crankshaft with solvent. • Blow dry tapered surfaces with compressed air. If the flywheel key appears damaged in any way replace it. 90-858804 AUGUST 1998 Page 2A-13 CDM IGNITION 2. Install flywheel key in crankshaft slot with outer edge of key parallel to center line of crankshaft. a Parallel a-Flywheel Key 3. Install flywheel. • Place flywheel down over crankshaft. • Install flywheel nut. • Torque flywheel nut to 125 lb. ft. (169.5 N·m). Removing Stator 1. Remove flywheel. SEE “REMOVING FLYWHEEL” IN THIS SECTION. 2. Remove yellow stator leads from rectifier/regulator leads. 3. Disconnect all stator leads from CDM wire harness. Removal of ignition plate may be necessary to gain access to stator leads. 4. Remove screws and lift stator off bearing cage. a a a-Stator Screws Page 2A-14 90-858804 AUGUST 1998 CDM IGNITION Installing Stator 1. Set stator on bearing cage. Secure with screws. IMPORTANT: Be sure the stator is positioned so the wire harness is on the port side of the motor. 2. Connect yellow stator leads to yellow voltage regulator leads. 3. Connect all stator leads to corresponding CDM wire harness. 4. Install flywheel. Removing Trigger 1. Remove flywheel. SEE “REMOVING FLYWHEEL” IN THIS SECTION. 2. Remove stator. SEE “REMOVING STATOR” IN THIS SECTION. 3. Disconnect trigger leads from CDM wire harness. 4. Disconnect spark control link from tower shaft. 5. Lift trigger off bearing cage. a b a-Trigger b-Spark Control Link 90-858804 AUGUST 1998 Page 2A-15 CDM IGNITION Installing Trigger 1. Install spark control link on new trigger. a a-Spark Control Link 2. Lubricate outer ring of trigger with grease. 3. Place trigger on bearing cage. 4. Secure spark control link to towershaft. a a-Towershaft 5. Route lead wires under ignition plate and down to the CDM wire harness. 6. Connect corresponding trigger leads to CDM wire harness. 7. Install stator. SEE INSTALLING STATOR IN THIS SECTION. 8. Install flywheel. SEE INSTALLING FLYWHEEL IN THIS SECTION. 9. Check engine timing. SEE ENGINE TIMING IN THIS SECTION. Page 2A-16 90-858804 AUGUST 1998 CDM IGNITION Removing CDM (Capacitor Discharge Module) WARNING Always disconnect battery and disconnect spark plug leads from spark plugs be- fore working on motor. 1. Disconnect CDM wire harness plug. 2. Remove screws securing CDM to ignition plate. Installing CDM 1. Position CDM on ignition plate. Install screws. 2. Connect CDM wire harness plug to CDM. 90-858804 AUGUST 1998 Page 2A-17 #4 #3 #2 #1 a b c 3 2 1 4 5 6 7 8 BLK GRY YEL/RED RED/PUR BLK/YEL PUR TAN/LT.BLU GRN/WHT WHT/GRN YEL YEL BRN BLK/YEL YEL YEL BLK/YEL YEL YEL GRN/WHT WHT/GRN BRN RED/PUR RED BLK BLK YEL/RED RED RED BLK WHT WHT GRN/WHT PUR RED RED BLK BLK WHT/GRN PUR BLK BLK/YEL PUR PUR BLK/YEL WHT/GRN WHT BLK/YEL BLK GRN/WHT BRN BLK/YEL BLK TAN/GRN TAN/LT.BLU BLK BLK/YEL BRN PUR BRN BRN BRN YEL YEL BLK/YEL BLK/YEL YEL YEL GRN/WHT DRK.BLU BLK/YEL BLK WHT/GRN GRY GRY BLU DRK.BLU g h l e a - Flywheel b - Stator c - Trigger d - 20 Ampere Fuse e - Starter Motor f - Starter Solenoid g - Cylinder Head Temperature Sender h - Rev. Limiter i - Voltage Regulator j - Turn Key Start Valve k - Engine Wire Harness Connector l - CDM (Capacitor Discharge Module) a d f i h j k l CDM IGNITION Page 2A-18 90-858804 AUGUST 1998 Wiring Diagram 120 HP BATTERY, CHARGING AND STARTING SYSTEM ELECTRICAL AND IGNITION Section 2B – Battery, Charging and Starting System Table of Contents 2 B Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Recommended Battery. . . . . . . . . . . . . . . . . . 2B-2 Operating Engine Without Battery . . . . . . . . 2B-2 Specific Gravity Readings . . . . . . . . . . . . . . . 2B-2 Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Charging A Discharged Battery . . . . . . . . . . . 2B-3 Winter Storage of Batteries . . . . . . . . . . . . . . 2B-4 Battery Charging System. . . . . . . . . . . . . . . . . . . 2B-5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5 Battery Charging System Troubleshooting . 2B-5 Stator Ohms Test (Alternator Coils Only) . . 2B-5 Alternator System Test . . . . . . . . . . . . . . . . . . 2B-6 Testing Voltage Regulator . . . . . . . . . . . . . . . 2B-7 Sport Jet Stator Charging Diagram . . . . . . . . . . 2B-8 Special Tools Multimeter 91-99750 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Starting System Components . . . . . . . . . . . . 2B-9 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Troubleshooting the Starting Circuit . . . . . . . 2B-9 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 Testing Armature for Ground . . . . . . . . . . . . 2B-14 Testing Brushes and Terminals . . . . . . . . . . 2B-14 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-15 Installing Starter . . . . . . . . . . . . . . . . . . . . . . . 2B-16 Testing Starter Solenoid . . . . . . . . . . . . . . . . 2B-16 Starter Exploded View . . . . . . . . . . . . . . . . . . . . 2B-17 Precautions When charging batteries an explosive gas mixture forms in each cell. A portion of this gas escapes through holes in vent plugs and may form an explosive atmosphere around battery if ventilation is poor. This explosive gas may remain in or around battery for several hours after it has been charged. Sparks or flames can ignite this gas and cause an internal explosion which may shatter the battery. The following precautions should be observed to prevent an explosion. 1. DO NOT smoke near batteries being charged or which have been charged very recently. 2. DO NOT break live circuits at terminals of batteries because a spark usually occurs at the point where a live circuit is broken. Always be careful when connecting or disconnecting cable clamps on chargers. Poor connections are a common cause of electrical arcs which cause explosions. 3. DO NOT reverse polarity of battery cables on battery terminals. CAUTION If battery acid comes into contact with skin or eyes wash skin immediately with a mild soap. Flush eyes with water immediately and see a doctor. 90-858804 AUGUST 1998 Page 2B-1 BATTERY, CHARGING AND STARTING SYSTEM Recommended Battery A 12 volt battery with a minimum rating of 670 Marine Cranking Amps (MCA) or 520 Cold Cranking Amps (CCA). Operating Engine Without Battery If desired (or in an emergency), engines equipped with an alternator can be started and operated without a battery (either disconnected or removed) if WARNING is followed: WARNING Before operating engine with battery leads disconnected from battery, disconnect stator leads (yellow) from voltage regulator. Insulate (tape) stator leads. Specific Gravity Readings a 22532 a-Hydrometer Hydrometer measures percentage of sulfuric acid in battery electrolyte in terms of specific gravity. As a battery drops from a charged to a discharged condition acid leaves the solution and chemically combines with the plates causing a decrease in specific gravity of electrolyte. An indication of concentration of electrolyte is obtained with a hydrometer. When using a hydrometer observe the following points: 1. Hydrometer must be clean (inside and out) to insure an accurate reading. 2. Never take hydrometer readings immediately after water has been added. Water must be thoroughly mixed with electrolyte by charging for at least 15 minutes at a rate high enough to cause vigorous gassing. 3. If hydrometer has built-in thermometer draw liquid in several times to ensure correct temperature before taking reading. 4. Hold hydrometer vertically and draw in just enough liquid from battery cell so that float is free-floating. Hold hydrometer at eye level so that float is vertical and free of outer tube then take reading at surface of liquid. Disregard curvature where liquid rises against float stem due to capillary action. 5. Avoid dropping electrolyte on boat or clothing as it is extremely corrosive. Wash off immediately with baking soda solution. Page 2B-2 90-858804 AUGUST 1998 BATTERY, CHARGING AND STARTING SYSTEM Specific gravity of electrolyte varies not only with percentage of acid in liquid but also with temperature. As temperature drops electrolyte contracts so that specific gravity increases. Unless these variations in specific gravity are taken into account, specific gravity obtained by hydrometer may not give a true indication of concentration of acid in electrolyte. A fully charged battery will have a specific gravity reading of approximately 1.270 at an electrolyte temperature of 80° F (27° C). If electrolyte temperature is above or below 80° F, additions or subtractions must be made in order to obtain a hydrometer reading corrected to 80° F standard. For every 10° F (3.3° C) above 80° F, add 4 specific gravity points (.004) to hydrometer reading. Example: A hydrometer reading of 1.260 at 110° F (43° C) would be 1.272 corrected to 80° F indicating a fully charged battery. For every 10° below 80° F subtract 4 points (.004) from the reading. Example: A hydrometer reading of 1.272 at 0° F (-18° C) would be 1.240 corrected to 80° F indicating a partially charged battery. SPECIFIC GRAVITY CELL COMPARISON TEST This test may be used when an instrumental tester is not available. To perform this test, measure specific gravity of each cell, regardless of state of charge, and interpret results as follows: If specific gravity readings show a difference between highest and lowest cell of .050 (50 points) or more, battery is defective and should be replaced. Electrolyte Level Check electrolyte level in battery regularly. A battery in use in hot weather should be checked more frequently because of more rapid loss of water. If electrolyte level is found to be low then distilled water should be added to each cell until liquid level rises approximately 3/16” (4.8mm) over plate. DO NOT OVERFILL because this will cause loss of electrolyte and result in poor performance, short life and excessive corrosion. CAUTION During service only distilled water should be added to the battery, not electrolyte. Charging A Discharged Battery The following basic rules apply to any battery charging situation: 1. Any battery may be charged at any rate (in amperes) as long as spilling of electrolyte (from violent gassing) does not occur and as long as electrolyte temperature does not exceed 125° F (52° C). If spewing of electrolyte occurs, or if electrolyte temperature exceeds 125° F, charging rate (in amperes) must be reduced or temporarily halted to avoid damage to the battery. 2. Battery is fully charged when, over a two-hour period at a low charging rate (in amperes), all cells are gassing freely (not spewing liquid electrolyte), and no change in specific gravity occurs. Full charge specific gravity is 1.260-1.275, corrected for electrolyte temperature with electrolyte level at 3/16” (4.8mm) over plate. For most satisfactory charging, lower charging rates in amperes are recommended. 3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannot be reached, battery is not in optimum condition and will not provide optimum performance; however, it may continue to provide additional service, if it has performed satisfactorily in the past. 4. To check battery voltage while cranking engine with electric starter motor, place RED (+) lead of tester on POSITIVE (+) battery terminal and BLACK (–) lead of tester on NEGATIVE (–) battery terminal. If the voltage drops below 9-1/2 volts while cranking, the battery is weak and should be recharged or replaced. 90-858804 AUGUST 1998 Page 2B-3 BATTERY, CHARGING AND STARTING SYSTEM Winter Storage of Batteries Battery companies are not responsible for battery damage, either in winter storage or in dealer stock, if the following instructions are not observed: 1. Remove battery from its installation as soon as possible and remove all grease, sulfate and dirt from top surface by running water over top of battery. Be sure, however, that vent caps are tight beforehand, and blow off all excess water thoroughly with compressed air. Check water level, making sure that plates are covered. 2. When adding distilled water to battery, be extremely careful not to fill more than 3/16” (4.8mm) over plate inside battery. Battery solution or electrolyte expands from heat caused by charging. Overfilling battery will cause electrolyte to overflow (if filled beyond 3/16” over plate). 3. Grease terminal bolts well with Quicksilver 2-4-C Marine Lubricant, and store battery in COOL, DRY place. Remove battery from storage every 30-45 days, check water level (add water if necessary), and put on charge for 5 or 6 hours at 6 amperes. DO NOT FAST CHARGE. 4. If specific gravity drops below 1.240, check battery for reason, and then recharge. When gravity reaches 1.260, discontinue charging. To check specific gravity, use a hydrometer, which can be purchased locally. 5. Repeat preceding charging procedure every 30-45 days, as long as battery is in storage. When ready to place battery back in service, remove excess grease from terminals (a small amount is desirable on terminals at all times), recharge again as necessary and re-install battery. WARNING Hydrogen and oxygen gases are produced during normal battery operation or charging. Sparks or flame can cause this mixture to ignite and explode, if they are brought near the battery. Sulfuric acid in battery can cause serious burns, if spilled on skin or in eyes. Flush or wash away immediately with clear water. Page 2B-4 90-858804 AUGUST 1998 BATTERY, CHARGING AND STARTING SYSTEM Battery Charging System Description The battery charging system components are the stator, voltage regulator and battery. Alternating current (generated in stator alternator coils) flows to the voltage regulator, which changes the alternating current to direct current for charging the battery. RED SLEEVE 52684 a b c a-Stator b-Voltage Regulator c-Battery The charging system may be damaged by: 1) reversed battery cables, 2) an open circuit, such as a broken wire or loose connection. Battery Charging System Troubleshooting A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See “Electrolyte Level”, and “Charging a Discharged Battery”. If battery will NOT accept a satisfactory charge, replace battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows. 1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. 2. Check for loose or corroded battery connections. 3. Visually inspect wiring between stator and battery for cuts, chafing, disconnected, loose or corroded connection. 4. Excessive electrical load (from too many accessories) will cause the battery to run down. If visual inspection determines that battery connections and wiring are OK perform the following stator and voltage regulator tests. Stator Ohms Test (Alternator Coils Only) NOTE: Stator can be tested without removing from engine. 1. Disconnect both yellow (stator leads) from bullet connectors to voltage regulator. 2. Use an ohmmeter and perform the following test. 90-858804 AUGUST 1998 Page 2B-5 BATTERY, CHARGING AND STARTING SYSTEM IMPORTANT: If stator is mounted on engine, black stator lead (if provided) must be grounded to powerhead when testing. 3. Replace stator if readings are outside ranges shown. 9 AMPERE STATOR Test Leads Resistance (Ohms) Ohm Scale Between Yellow Leads .8 - 1.1* R x 1 Between either Yellow Lead and Ground No Continuity R x 1000 15 AMPERE STATOR Between Yellow stator leads .15 – .20 (R x 1) Between either Yellow stator lead and engine ground** No Continuity R x 1000 *DC Resistance of these windings generally is less than 1.5 Ohms. If a reading resembling a short is obtained, this would be acceptable. Alternator System Test 1. Check battery voltage at battery with engine running. 2. If battery voltage is above 14.5 volts, replace voltage regulator/rectifier. Check condition of battery as overcharging may damage battery. 3. If battery voltage is below 14.5 volts, charge battery; refer to “Charging a Discharged Battery”, preceding. If battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine; refer to “Charging a Discharged Battery”, preceding. If cranking voltage is not acceptable, replace battery. 5. If cranking voltage is acceptable, disconnect larger diameter Red wire from STARTER SOLENOID terminal. 6. Connect RED (+) ammeter lead to larger diameter RED wire, and BLACK (–) ammeter lead to POSITIVE terminal on STARTER SOLENOID. 7. Secure wires away from flywheel. 8. With engine running at the indicated RPM’s, the ammeter should indicate the following approximate amperes: 9 Ampere9 Ampere Stator RPM AMPERES 1200 0.2 2000 6.5 3000 9 RPM AMPERES 15 Ampere15 Ampere Stator 1200 8 2000 12 3000 14 9. If proper ampere readings are not obtained, replace stator. Page 2B-6 90-858804 AUGUST 1998 BATTERY, CHARGING AND STARTING SYSTEM Testing Voltage Regulator 51000 DIODE TEST: 1. Set Ohm meter to R X 10 scale. 2. Connect Red (+) meter lead to RED regulator lead. 3. Connect Black (–) meter lead to YELLOW regulator lead. TEST RESULTS: 100 - 400 Ohms DIODE TEST: 1. Set Ohm meter to R X 1k scale. 2. Connect Black (–) meter lead to RED regulator lead. 3. Connect Red (+) meter lead to YELLOW regulator lead. Test. Then change Red (+) meter lead to the other YELLOW regulator lead for 2ND test reading. TEST RESULTS (1ST READING): 40,000 to Ohms TEST RESULTS (2ND READING): Ohms (No needle movement) SCR TEST: 1. Set Ohm meter to R X 1k scale. 2. Connect Red (+) meter lead to regulator case. 3. Connect Black (–) meter lead to one YELLOW regulator lead. Test. Connect Black (–) meter lead to the other YELLOW lead. TEST RESULTS (BOTH TESTS): 10,000 Ohms (10k -) TACHOMETER CIRCUIT TEST: 1. Set Ohm meter to R X 1k scale. 2. Connect Red (+) meter lead to GREY regulator lead. 3. Connect Black (–) meter lead to regulator case. TEST RESULTS: 10,000 - 30,000 Ohms (10k - 30k) 90-858804 AUGUST 1998 Page 2B-7 BATTERY, CHARGING AND STARTING SYSTEM Sport Jet Stator Charging Diagram BLK •Black GRY •Gray RED •Red YEL •Yellow RED SLEEVE a b d f e c a-Stator/Alternator Assembly b-Voltage Regulator c-20 Amp Fuse d-Starter Solenoid e-Gray Wire to Tachometer f-To Engine Wire Harness (red/purple lead) Page 2B-8 90-858804 AUGUST 1998 BATTERY, CHARGING AND STARTING SYSTEM Starting System Starting System Components The starting system consists of the following components. 1. Battery 2. Starter Solenoid 3. Neutral Start Switch 4. Starter Motor 5. Ignition Switch Description The function of the starting system is to crank the engine. The battery supplies electrical energy to crank the starter motor. When the ignition switch is turned to “START” position, the starter solenoid is activated and completes the starting circuit between the battery and starter. The neutral start switch opens the start circuit when the shift control lever is not in neutral. This prevents accidental starting when engine is in gear. CAUTION The starter motor may be damaged if operated continuously. DO NOT operate continuously for more than 10 seconds. Allow a 30 second cooling period between starting attempts. Troubleshooting the Starting Circuit Before beginning the starting circuit troubleshooting flow chart, following, check first for the following conditions: 1. Make sure that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3. Check bullet connectors for corrosion and loose connections. 4. Check cables and wiring for frayed and worn insulation. 5. Check in-line fuse in RED wire; see diagram. The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to troubleshooting the starting circuit. This flow chart will accurately locate any existing malfunction. Location of “TEST POINTS” (called out in the chart) are numbered in diagram below. 90-858804 AUGUST 1998 Page 2B-9 BATTERY, CHARGING AND STARTING SYSTEM NEUTRAL START SWITCH (LOCATED IN CONTROL HOUSING) RED SLEEVE RED SLEEVE B C M M A S VOLTAGE REGULATOR 52904 1 3 6 2 7 5 4 Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect RED (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads be- tween NEGATIVE (-) battery post and common powerhead ground. No continuity indicated; there is an open circuit in the BLACK NEGATIVE (-) battery cable between the NEGATIVE (-) battery post and the powerhead. • Check cable for loose or corroded connections. • Check cable for open. Continuity Indicated Proceed to TEST 2, on next page. Page 2B-10 90-858804 AUGUST 1998 BATTERY, CHARGING AND STARTING SYSTEM a. Disconnect BLACK ground wire(s) from Test Point 2. b. Connect voltmeter between common engine ground and Test Point 2. c. Turn ignition key to “Start” position. * Battery Voltage TEST 2 TEST 3 TEST 4 TEST 5 TEST 6 TEST 7 TEST 8 12 Volt Reading* 12 Volt Reading 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* No voltage reading; proceed to TEST 4. No voltage reading; proceed to TEST 5. No voltage reading; proceed to TEST 6. a. Reconnect BLACK ground wire(s). b. Connect voltmeter between common engine ground and Test Point 3. c. Turn ignition key to “Start” position. Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to starter solenoid; proceed to TEST 7. Neutral start switch is open, or YELLOW/RED wire is open between Test Points 4 and 3. a. Connect voltmeter between common engine ground and Test Point 4. b. Turn ignition key to “Start” position. Defective starter solenoid. Connect voltmeter between common engine ground and Test Point 5. Defective ignition switch. Connect voltmeter between common engine ground and Test Point 6. No voltage reading; check RED wire between battery (+) positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6. a. Connect voltmeter between common engine ground and Test Point 1. b. Turn ignition key to “Start” position. No voltage reading; De- fective starter solenoid. Should hear solenoid click; proceed to TEST 8. a. Reconnect RED (starter motor) cable to starter solenoid Test Point 1. b. Connect voltmeter between common engine ground and Test Point 7 c. Turn ignition key to “Start” position. No voltage reading; check BLACK cable for poor connection or open circuit. Check BLACK ground cable at starter for loose or corroded connection, or open circuit. If cable is O.K., check starter motor. No voltage reading; proceed to TEST 3. 90-858804 AUGUST 1998 Page 2B-11 BATTERY, CHARGING AND STARTING SYSTEM Starter Motor Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs be- fore working on motor. 1. Remove stop nuts securing starter to upper starter bracket. 2. Remove screw securing starter to upper starter bracket. 3. Remove lead from starter. a a-Starter Lead 4. Remove starter. 5. Remove lead wire from terminal on starter. 6. Remove lower starter bracket. a b a-Terminal b-Bracket Page 2B-12 90-858804 AUGUST 1998 BATTERY, CHARGING AND STARTING SYSTEM Disassembly 1. Remove stop nut from end of shaft. 2. Remove spacer, spring and drive from starter. 3. Remove thru bolts from drive end cap assembly. 4. Remove end cap and commutator cap assemblies. 5. Disassemble commutator end cap assembly. 6. Remove brushes. Remove springs from holders. 7. Pull armature from housing. As Needed 1. Replace worn or cracked brushes. 2. Check brush spring for freedom of movement and good tension. 3. Inspect bearing in commutator end cap and drive end cap. Replace as necessary. 4. Clean dirty commutator with No. 400 or fine sandpaper. CAUTION Never use emery cloth to clean commutator. 90-858804 AUGUST 1998 Page 2B-13 BATTERY, CHARGING AND STARTING SYSTEM 5. Inspect armature for loose connections at the point where armature windings are attached to commutator bars. • Re-solder any poor connections. Testing Armature for Ground 1. Set ohm meter to RX1 scale. Place one lead on armature core (or shaft) and the other lead on commutator as shown. 2. If meter indicates continuity, armature is grounded and must be replaced. Testing Brushes and Terminals 1. Connect ohm meter, RX1 scale, leads between positive brushes. 2. Ohm meter must indicate full continuity (zero resistance). If resistance is indicated, check lead to positive terminal solder connection. If connection cannot be repaired, brushes must be replaced. Page 2B-14 90-858804 AUGUST 1998 BATTERY, CHARGING AND STARTING SYSTEM 3. Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on the negative brush and the other lead on the end cap (bare metal). If the meter indicates NO continuity, replace the negative brush. Repeat this procedure on the other negative brush. Reassembly 1. Lubricate armature shaft with one drop of SAE 10W oil. 2. Install armature in housing. 3. Assemble end cap. • Place brushes against springs and hold in place with a retainer (fabricate from thin metal). c a b a-End Cap b-Retainer, Brush c-Housing 4. Place frame and field assembly on top of end cab. 5. When armature contacts brush retainer, remove retainer. 6. Turn commutator end cap assembly on housing so that notch on cap is lined up with and recessed into starter. 90-858804 AUGUST 1998 Page 2B-15 BATTERY, CHARGING AND STARTING SYSTEM 7. Install drive end cap assembly so that notch in housing lines up with notch in cap. 8. Install thru bolts. Install bracket and tighten nuts. 9. Install starter drive, spring, spacer and stop nut. Tighten stop nut. Installing Starter 1. Connect lead from solenoid to terminal on starter. 2. Line up thru bolts with holes in upper starter bracket. 3. Install lower bracket. 4. Install nuts on thru bolts and on lower starter bracket. Tighten securely. Testing Starter Solenoid Test starter solenoid as follows: 1. Disconnect all leads from solenoid terminals. 2. Use an ohmmeter, set to (R x 1 scale) and connect between solenoid terminals. 3. Connect a 12-volt supply between solenoid terminals 1 and 2. Solenoid should click and meter should read zero ohms. 4. If meter does not read zero ohms (full continuity), replace solenoid. 1 2 b a b a a-Ohm Meter b-12-Volt Supply Page 2B-16 90-858804 AUGUST 1998 BATTERY, CHARGING AND STARTING SYSTEM Starter Exploded View 90-858804 AUGUST 1998 Page 2B-17 TIMING/SYNCHRONIZING/ADJUSTING ELECTRICAL AND IGNITION Section 2C – Timing/Synchronizing/Adjusting Table of Contents 2 C Timing/Synchronizing/Adjusting . . . . . . . . . . . . . 2C-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Checking for Top Dead Center (TDC) . . . . . 2C-2 Checking Timing (At Cranking Speed) . . . . . 2C-2 As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 Turn-Key Start Feature . . . . . . . . . . . . . . . . . . 2C-3 Synchronizing Carburetors to Ignition Timing for Turn-Key Start . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 Setting Idle Timing . . . . . . . . . . . . . . . . . . . . . . 2C-5 Check WOT Throttle Position with Engine Not Running . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-6 Check WOT Ignition Timing with Engine Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7 Check WOT Ignition Timing with Engine Not Running . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-8 Adjusting Idle Mixture . . . . . . . . . . . . . . . . . . . 2C-9 Check Oil Pump Adjustment . . . . . . . . . . . . 2C-10 Timing/Synchronizing/Adjusting Specifications MAXIMUM TIMING @ 5000 RPM* @ CRANK SPEED 30° BTDC 32° BTDC IDLE RPM 950 - 1100 RPM FULL THROTTLE RPM 4700 – 5300 SPARK PLUG TYPE CHAMPION L76V CHAMPION QL76V FIRING ORDER 120 HP 1 - 3 - 2 - 4 WARNING Engine can start when turning flywheel to check timing. Remove all spark plugs from engine to prevent engine from starting. Special Tools Description Part Number Service Tachometer *91-59339 Timing Light *91-99379 Spark Gap Tester 91-850439 Timing Tool 91-58222A1 *May be obtained locally. 90-858804 AUGUST 1998 Page 2C-1 TIMING/SYNCHRONIZING/ADJUSTING Checking for Top Dead Center (TDC) 1. Remove spark plug wires and spark plugs. 2. Install timing tool (Special Tool No. 91-58222A1). 3. Turn flywheel in a clockwise direction until TDC is reached as shown on the dial indicator. 4. Check if mark on flywheel aligns with mark on pointer. NOTE: If mark and pointer do not align, the flywheel key has been sheared. Checking Timing (At Cranking Speed) Timing Specifications At Cranking Speed At Wide-Open-Throttle 34. 30. 1. Remove spark plug leads from spark plugs, remove spark plugs. 2. Attach spark tester (Special Tool No. 91-850439) to engine. Attach tester leads to corresponding spark plug leads. 3. Move towershaft to wide-open-throttle position. 55117 4. Connect timing light (Special Tool No.91-99379) to the No. 1 spark plug lead. IMPORTANT: The advance characteristics of this ignition system are such that the ignition timing will retard itself slightly at wide-open-throttle. Thus, setting maximum timing at 34 BTDC at cranking speed should result in retardation to 30 BTDC at WOT RPM. Therefore, it is recommended that to be assured of maximum performance all timing adjustments made at cranking speed should be verified with the engine running. 5. Crank motor and observe timing marks. Page 2C-2 90-858804 AUGUST 1998 TIMING/SYNCHRONIZING/ADJUSTING As Needed 1. Adjust timing. 2. Loosen both locknuts. 3. Turn timing rod to adjust timing. 4. Tighten both locknuts on timing rod. 57331 b a a-Locknuts b-Timing Rod 5. Remove test equipment and install spark plugs and propeller. NOTE: If possible, test the motor and check the timing under actual operating conditions. Turn-Key Start Feature The Sport Jet utilizes an automatic enrichner to start a cold engine. Advancing the throttle will disable the auto enrichner. Synchronizing Carburetors to Ignition Timing for Turn-Key Start IMPORTANT: An engine idle speed of 950 - 1100 RPM is necessary to provide the engine with adequate cooling water. IMPORTANT: The Turn Key Start feature is dependent on closed throttle shutters. If the throttle shutters are even slightly cracked open the Turn Key Start will be disabled. 90-858804 AUGUST 1998 Page 2C-3 TIMING/SYNCHRONIZING/ADJUSTING Page 2C-4 90-858804 AUGUST 1998 COMPLETE THIS PROCEDURE IN SEQUENCE 1. Disconnect throttle link at towershaft end. 2. Synchronize throttle movement on carburetors. This is done by : 57172 a b a - Throttle Link b - Tie Bar Screw a. Rotate throttle cam away from roller on bottom carburetor. b. Loosen tie bar screw(s). c. Check that the carburetor shutters are closed. d. Tighten tie-bar screw(s). e. This adjustment is made with the throttle link disconnected from the towershaft (Step 1). IF REQUIRED: 3. Adjust idle stop screw to specified dimensions following: a Set dimension (a) to 1/4 in. TIMING/SYNCHRONIZING/ADJUSTING 4. Pivot throttle cam forward so it just contacts the roller. 57173 a a-Mark 5. Inspect position of mark on cam in relation to roller. NOTE: Mark on cam must align with the center of the roller, without moving it. NOTE: Throttle cam adjustments are critical to low speed engine timing. If the adjustment is off (too early or too late), the engine will not run properly at low speed. 6. If throttle cam pick up point requires adjustment: a. Loosen nut until screw can just be turned. You should feel slight friction between screw and throttle cam. a b c a-Cam b-Nut c-Eccentric Roller b. Turn eccentric roller counterclockwise to correct adjustment as described in Step 3. c. Hold position of roller with screwdriver. d. Tighten nut. NOTE: When this procedure is done ensure that there is clearance between the throttle cam and roller, so that the throttle shutters remain closed. Setting Idle Timing 1. Connect the link rod to the tower shaft. 2. Start the engine. 3. Check engine timing at idle. Idle timing is 5 to 7 BTDC. 90-858804 AUGUST 1998 Page 2C-5 TIMING/SYNCHRONIZING/ADJUSTING 4. If adjustments are needed to obtain the 5 to 7 BTDC specifications, do the following: a. Turn the tower shaft screw in to increase timing, turn screw out to decrease timing. b. Disconnect the link arm to adjust the clearance of the cam to roller (.005 - .015 in.). c. Re-connect the link arm. d. Re-start the engine and check the idle timing. b a a-Tower Shaft Screw b-Timing Mark e. Adjust carburetor idle mixture screws for best operation. Idle RPM should be between 950-1100. Check WOT Throttle Position with Engine Running 1. Advance the tower shaft to WOT and check shutter position from horizontal. Shutter can be just short of horizontal (c) to horizontal (d). Shutter must never be allowed to go “over center” (e). That condition will result in loss of power from poor fuel distribution. 57333 a a b b bc e d a-Throttle Shutter b-Line On Throttle Shaft Corresponds To Shutter Position Page 2C-6 90-858804 AUGUST 1998 TIMING/SYNCHRONIZING/ADJUSTING IF REQUIRED: 2. Adjust the WOT stop screw to obtain the correct shutter position as described in step 1. a a-WOT Stop Screw Check WOT Ignition Timing with Engine Running 1. With engine running at WOT, check the timing (28 - 30). a a-Timing Mark 2. If adjustments are needed do the following: a. Turn off the engine. b. Loosen locknut. c. Turn timing rod: (1.) In to increase timing (2.) Out to decrease timing 3. Tighten locknut. 4. Re-check timing. 57331 b a a-Locknut b-Timing Rod 90-858804 AUGUST 1998 Page 2C-7 TIMING/SYNCHRONIZING/ADJUSTING Check WOT Ignition Timing with Engine Not Running 1. Remove spark plug leads from spark plugs. 2. Remove spark plugs. 3. Attach spark tester (Special Tool No. 91-850439) to engine. 55117 4. Connect spark plug leads to spark tester. 5. Connect timing light (Special Tool No. 91-99378) to the number 1 cylinder spark plug lead. 6. Hold towershaft in the wide-open-throttle (W.O.T.) position. a a-Tower Shaft 7. Crank motor and observe timing marks. IMPORTANT: To attain 30 degrees timing while the engine is actually running, set timing at cranking speed to 34 degrees. Page 2C-8 90-858804 AUGUST 1998 TIMING/SYNCHRONIZING/ADJUSTING Adjusting Idle Mixture IMPORTANT: Idle mixture screw adjustments should be made with motor in water. Idle cannot be properly set using a flushette or dynamometer. 1. Turn idle mixture screws clockwise until lightly seated. CAUTION Do not force idle screws. Tip damage could result. 2. Turn idle mixture screws out (counterclockwise) 1-1/2 turn. 3. Start motor and allow to warm up to operating temperature. 4. Move throttle control to the lowest reliable setting. IMPORTANT: Motor must idle for minimum of one minute to allow fuel recirculation system to begin functioning. IMPORTANT: The carburetors must be adjusted together. If you turn one idle mixture screw, turn the other carburetor idle mixture screw the same amount before proceeding. 5. Starting with top carburetor, turn each of the idle mixture screws clockwise 1/8 turn at a time, allowing 10 seconds between each turn, until motor begins to pop from lean fuel/ air setting. 1/8 Turn 1/8 Turn (Wait 10 Seconds) (Until Engine Pops) 3/16 Turn 6. Turn each idle mixture screw counterclockwise (richer) 3/16 turn. This should be very close to the optimum setting. 7. Advance throttle to W.O.T. to “clear out” the engine. 8. Return throttle to idle speed and allow engine to idle for at least one minute. 9. Quickly advance the throttle to W.O.T. If the engine hesitates because of a rich fuel mix- ture, turn the idle mixture screws 1/8 turn clockwise to “lean out” the carburetors and repeat step 7-9 until the engine accelerates without hesitation. 90-858804 AUGUST 1998 Page 2C-9 TIMING/SYNCHRONIZING/ADJUSTING Check Oil Pump Adjustment 1. Move towershaft to the Wide-Open-Throttle position. Inspect oil pump alignment mark with the oil pump lever. Adjust oil pump link rod to align with the last mark. a b a-Oil Pump Lever b-Alignment Mark (At Wide-Open-Throttle) 2. Adjust oil pump link rod as required. Page 2C-10 90-858804 AUGUST 1998 CARBURETION FUEL SYSTEM & CARBURETION Section 3A – Carburetor Table of Contents Removing Carburetor . . . . . . . . . . . . . . . . . . . . . . 3A-1 High Altitude Jetting . . . . . . . . . . . . . . . . . . . . . . . 3A-9 Disassembling Carburetor . . . . . . . . . . . . . . . . . . 3A-2 Exploded View - Carburetor . . . . . . . . . . . . . . . 3A-10 As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3 Quicksilver Lubrication/SealantAssembling Carburetor . . . . . . . . . . . . . . . . . . . . . 3A-6 Application Points . . . . . . . . . . . . . . . . . . . . . 3A-10 3 A Removing Carburetor 1. Remove nut securing throttle cam to stud. 2. Remove throttle cam form stud. NOTE: Carburetors and cover may be removed as an assembly. 3. Remove “E” clips from throttle arm. a b a-Nut, Throttle Cam b-“E” Clips 4. Remove throttle bar assembly. 5. Disconnect fuel line. 6. Remove primer hoses from carburetor. 7. Remove carburetor flange nuts. 8. Remove carburetor(s). 90-858804 AUGUST 1998 Page 3A-1 CARBURETION Disassembling Carburetor 1. Remove idle mixture screw and spring. a b a-Screw, Idle Mixture b-Spring 2. Remove screw, gasket, fuel bowl, and gasket. a b c d a-Gasket b-Fuel Bowl c-Gasket d-Screw 3. Remove fuel bowl gasket from groove in carburetor. a a-Gasket Page 3A-2 90-858804 AUGUST 1998 CARBURETION 4. Remove float. • Drive out float pin. NOTE: Drive float pin through so that knurled end comes out first. • Remove float. 5. Remove inlet needle. c a b a-Float b-Pin, Knurled End c-Inlet Needle As Needed 6. Remove throttle assembly. • Remove screws and washer from shutter. • Hold throttle in wide open position. • Pull throttle shutter out of housing. • Remove E-clip. • Unhook return spring from drive pin on carburetor. • Pull throttle shaft out of housing. a b c e d a-Screws and Washers b-Shutter, Throttle c-E-Clip d-Return Spring e-Throttle Shaft 90-858804 AUGUST 1998 Page 3A-3 CARBURETION 7. Remove main fuel jet. a a-Main Fuel Jet 8. Remove sealing screw and intermediate fuel jet. a b a-Intermediate Fuel Jet b-Sealing Screw 9. Remove elbow. 10. Remove welch plug. • Drill hole through welch plug. IMPORTANT: Do not drill into carburetor body. • Insert a small screwdriver in hole and pry plug out of housing. ab a-Elbow b-Welch Plug Page 3A-4 90-858804 AUGUST 1998 CARBURETION 11. Remove idle tube. • Place punch on bottom end of idle tube. IMPORTANT: Note the depth of the idle tube prior to removal. It must be installed to this position. • Carefully tap on punch until cup plug and idle tube come free of body channel. 12. Unscrew main nozzle and remove it from body channel. a a-Main Nozzle NOTE: In some cases, the position of the idle tube may make it necessary to remove the tube prior to removing the nozzle. 13. Inspect the following: Inspect: Look For: Idle mixture screw Rings or grooves on point Inlet needle Rings or grooves on point Idle spring Compressed spring Primer connectors Clogging Body Pitting Jets Clogging 14. Clean entire carburetor with solvent. IMPORTANT: Do not allow non-metal parts to come in contact with solvent. WARNING Follow solvent manufacturer’s directions for use. 90-858804 AUGUST 1998 Page 3A-5 CARBURETION Assembling Carburetor 1. Thread main nozzle into body channel. IMPORTANT: Idle tube must contact nozzle in front or carburetor will run lean. NOTE: Be sure nozzle is threaded in completely. Do not over tighten nozzle. 2. Install idle tube. • Slide idle tube (flanged end up) into body channel. IMPORTANT: Idle tube must contact nozzle in front or engine will run lean. • Carefully tap cup plug into opening with punch. a b a-Idle Tube b-Cap Plug • Seal plug with nail polish. 3. Place welch plug into recess of carburetor body. • Carefully tap center of welch plug. NOTE: Tapping will spread the plug and hold it in place. a b a-Welch Plug b-Elbow • Seal top of plug with nail polish. 4. Install elbow. Page 3A-6 90-858804 AUGUST 1998 CARBURETION 5. Install main fuel jet. a a-Main Fuel Jet 6. Install throttle assembly. • Slide throttle shaft into carburetor housing. • Lay end of return spring on ledge of housing. • Secure throttle shaft with E-clip. • Turn throttle shaft arm clockwise until flat side of shaft faces up. • Slide shutter into slot of shaft with numbered side facing out. • Apply Loctite (Special Tool No. FT-8936-1) to screws and install in throttle shutter. a b c d f e g h a-Throttle Shaft b-Return Spring c-Housing Ledge d-E-Clip e-Throttle Shaft Arm f-Throttle Shaft with Flat Side Facing Up g-Shutter h-Screws 90-858804 AUGUST 1998 Page 3A-7 CARBURETION 7. Install inlet needle. 8. Install float. • Position float on carburetor. • Carefully slide pin through bracket and float. • Tap pin until knurled end is retained in carburetor casting. a b c a-Needle b-Float c-Pin 9. Measure float height. NOTE: To adjust, bend inlet needle tab on float until float sits parallel to flange. 10. Install gasket in groove at bottom of carburetor. a b c a-Parallel to Flange b-Float Tab c-Gasket 11. Install fuel bowl assembly: bowl, gaskets, and screw. 12. Torque fuel bowl screw to 30 lb. in. (3.5 N·m). Page 3A-8 90-858804 AUGUST 1998 CARBURETION High Altitude Jetting The carburetor jet is for engine operation at sea level through 2500 feet (762 m) above sea level. For engine operation above 2500 feet re-jet the carburetor to the size and altitude specified below. MAIN FUEL JET SIZE Sport Jet Operating Elevation Carburetor Top Bottom Sea Level-1500 ft. .088 .090 1500-3000 ft. .086 .088 3000-4500 ft. .084 .086 4500-6000 ft. .082 .084 6000-10,000 ft. .080 .082 90-858804 AUGUST 1998 Page 3A-9 CARBURETION Exploded View - Carburetor B 120 HP 1 2 3 4 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2526 2728 29 1-Gasket 11 -Pin 21 -Idle Mixture Screw 2-Plug 12 -Gasket 22 -Spring 3-Plug 13 -Gasket 23 -Screw 4-Tube, Idle 14 -Bowl 24 -Roller 5-Elbow 15 -Bowl (Top Carb) 25 -Nut 6-E-Clip 16 -Gasket 26 -Shaft 7-Carburetor 17 -Screw 27 -Spring 8-Idle Jet 18 -Float 28 -Throttle Shutter 9-Sealing Screw 19 -Main Nozzle 29 -Screw (2) 10 -Needle 20 -Main Jet Quicksilver Lubrication/Sealant Application Points B Loctite 271 (92-823089--1) Page 3A-10 90-858804 AUGUST 1998 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER FUEL SYSTEM & CARBURETION Section 3B – Fuel Pump, Recirculation System, Reed Valve Assembly and Auto Enrichner Table of Contents Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 System Description 3B-7. . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . 3B-1 Testing Fuel Recirculation System 3B-7. . . . . . . . Fuel Pump Description/Operation . . . . . . . . 3B-1 Reed Valve Assembly 3B-8. . . . . . . . . . . . . . . . . . . . . . Checking for Restricted Fuel Flow CausedRemoving and Inspecting Reed Valve by Anti-Siphon Valves . . . . . . . . . . . . . . . . . . 3B-2 Assembly 3B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Inspecting and Installing Reed BlockTroubleshooting Fuel Pump . . . . . . . . . . . . . . . . 3B-2 Assembly 3B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-3 Reed Plate, Adaptor Plate and AutoRemoving/Disassembling Fuel Pump . . . . . . . . 3B-3 Enrichner 3B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling and Installing Fuel Pump . . . . . . . . 3B-4 Auto Enrichner 3B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump Exploded View . . . . . . . . . . . . . . . . . . 3B-6 System Description 3B-11 . . . . . . . . . . . . . . . . . . . . Fuel Recirculation System . . . . . . . . . . . . . . . . . . 3B-7 Testing Auto Enrichner 3B-12. . . . . . . . . . . . . . . . . 3 B DANGER FIRE AND EXPLOSION HAZARD. Observe fire prevention rules, particularly NO SMOKING. Before servicing any part of the fuel system, disconnect electrical system at the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Materials used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. FUEL LEAKAGE FROM ANY PART OF THE FUEL SYSTEM CAN BE A FIRE AND EXPLOSION HAZARD WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH. Careful periodic inspection of the entire fuel system is mandatory, particularly after engine storage. All fuel components, including fuel tanks, whether plastic, metal, or fiberglass, fuel lines, primer bulbs, fittings, swelling, and must be inspected for corrosion. Any sign of leakage or deterioration necessitates replacement before further engine operation. Fuel Pumps General Information Fuel Pump Description/Operation The fuel pump is a crankcase-pressure-operated, diaphragm-type pump. Crankcase pulsating pressure is transferred by way of a passage (hole) from the crankcase to the fuel pump. When the piston travels upward a vacuum is created in the crankcase. This vacuum pulls in the fuel pump diaphragm, the inlet check valve (in fuel pump) is opened fuel is drawn into fuel pump. Downward motion of the piston forces out the fuel pump diaphragm, closes the inlet check valve (to keep fuel from returning to fuel tank) and opens the outlet check valve, forcing fuel to the carburetors. 90-858804 AUGUST 1998 Page 3B-1 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves While anti-siphon valves are helpful from a safety stand-point they clog, may be too small, or they may have too heavy a spring. The pressure drop that occurs with these valves can create operational problems and/or powerhead damage by restricting flow of fuel. Some symptoms of restricted (lean) fuel flow are: 1-Loss of fuel pump pressure 2-Loss of power 3-High speed surging 4-Preignition/detonation (piston dome erosion) 5-Engine hesitates upon acceleration 6-Engine runs rough 7-Engine quits and cannot be restarted 8-Engine will not start 9-Vapor lock Any type of anti-siphon device must be located between the engine fuel inlet and fuel tank outlet. A method of checking [if such a device (or bad fuel) is a problem source] is to operate the engine with a separate fuel supply which is known to be good. If it is found that the anti-siphon valve is the cause of the problem, either 1) replace the antisiphon valve, or 2) replace it with a solenoid-operated fuel shutoff valve. Testing Install clear fuel hose(s) between fuel pump and carburetor(s). Run engine, and inspect hose(s) for air bubbles. If air bubbles are found, see “Air Bubbles in Fuel Line”. If air bubbles are NOT found, see “Lack of Fuel Pump Pressure”. Troubleshooting Fuel Pump PROBLEM: Air Bubbles in Fuel Line Possible Cause Corrective Action Low fuel in tank. Fill tank. Loose fuel line connection. Inspect and tighten connections. Fuel pump fitting loose. Tighten fitting. A hole or cut in fuel line. Inspect condition of fuel lines and replace any found bad. Fuel pump anchor screws loose. Inspect and tighten all screws. Fuel pump gaskets worn out. Rebuild fuel pump. PROBLEM: Lack of Fuel Pump Pressure Possible Cause Corrective Action Anti-siphon valve. Refer to “Checking for Restricted Fuel Flow Caused by Anti-siphon Valves” preceding. Air in fuel line. “Air Bubbles in Fuel Line” preceding. Dirty or clogged fuel filter. Clean or replace filter. Dirty or clogged fuel pickup in fuel tank. Clean or replace pickup. Worn out fuel pump diaphragm. Rebuild pump. Defective check valves in fuel pump. Rebuild pump. Pulse hole plugged. Remove fuel pump and and clean out hole. Diaphragm gasket distorted or out of place. Align or replace gasket as necessary. Page 3B-2 90-858804 AUGUST 1998 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER Special Tools Description Part Number Hose Clamp Pliers FT-8900 RTV Sealant 92-90113--2 Removing/Disassembling Fuel Pump 1. Loosen screw on sediment bowl. 2. Remove bowl from pump body. 3. Remove gasket and screen. b c a a-Screw b-Gasket c-Screen 4. Remove and disassemble fuel pump fitting, screws and washer, nuts, fuel pump body, booster spring retainer, booster spring, diaphragm, gasket, spacer, and spacer plate gasket. a b c d e f g h i j f-Booster Spring g-Diaphragm h-Gasket i-Spacer j-Spacer Plate Gasket a-Fuel Pump Fitting b-Screw and Washer c-Nut d-Fuel Pump Body e-Booster Spring Retainer 90-858804 AUGUST 1998 Page 3B-3 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER 5. Test fuel check valves by lightly pressing on plastic seats. • Be sure check valve seats when tension is released. 6. Replace fuel pump check valves as necessary. a b c d e a-Center Check Valve b-Second Stage Check Valve c-Gasket d-Screws e-First Stage Check Valve NOTE: Removal of the second stage check valve may cause permanent damage to the pump body, therefore, if replacement is necessary it may be necessary to replace the pump body. 7. Replace bowl gasket, fuel pump body gasket, and center check valve gasket. IMPORTANT: Replace all worn and/or damaged parts. Assembling and Installing Fuel Pump 1. Install booster spring and retainer. 2. Position diaphragm and gasket on pump body. b a a-Spring b-Retainer Page 3B-4 90-858804 AUGUST 1998 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER 3. Compress spring using a putty knife. Install screws in pump body. 4. Install spacer plate, nuts and gasket. b a a e c d a-Long Screws b-Short Screws c-Spacer Plate d-Nuts e-Gasket 5. Position fuel pump assembly on transfer port cover. Tighten screws securely. • Apply sealant (p/n 92-90113--2) to threads of fitting. Install fitting. 6. Install fuel hoses. a c b d a-Fitting b-Fuel Outlet Hose c-Fuel Inlet Hose Connected to Sediment Bowl d-Pulse Hose 7. Install screen in sediment bowl. Install sediment bowl on fuel pump. a a-Screen - Edge Turned Toward Engine 90-858804 AUGUST 1998 Page 3B-5 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER 8. Install gasket on pump body. IMPORTANT: Position sediment bowl with hose fitting at the 4 o’clock position. a b a-Gasket, Aligned On Pump Body Keyway b-Hose Fitting At 4 O’Clock Position Fuel Pump Exploded View RTV Sealant 92-90113--2 Page 3B-6 90-858804 AUGUST 1998 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER 90-858804 AUGUST 1998 Page 3B-7 Fuel Recirculation System System Description At idle, unburned fuel collects and puddles in the crankcase behind the reed valves. The recirculation system is a means to route this excess, unburned fuel back to the combustion chamber. One way check valves are located on the crankcase cover, typically below the carburetors. Crankcase pressure forces the puddled fuel through the check valves. A hose connected to the check valve routes the fuel to the transfer port cover, whereby the fuel is introduced back to the combustion chamber. Testing Fuel Recirculation System 1. Test for proper air flow through check valves as indicated by arrows. FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER Reed Valve Assembly Removing and Inspecting Reed Valve Assembly WARNING Always disconnect battery and remove spark plug leads from spark plugs before working on motor. 1. Remove attenuator cover. 2. Remove carburetors. SEE CARBURETOR SECTION FOR MORE INFORMATION 3. Remove auto enrichner. 4. Remove recirculation hose from manifold. 5. Remove bolts securing manifold assembly to crankcase cover. 6. Remove manifold assembly from cylinder block. 7. Remove reed block assembly from reed plate adaptor. Page 3B-8 90-858804 AUGUST 1998 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER Inspecting and Installing Reed Block Assembly 1. Inspect reeds for any chipping or cracking. NOTE: The reeds are not serviceable, replace reed block assembly if any discrepancies are found. 2. Inspect reed opening. Replace reed block assembly if reed is standing open more than .020” (.508 mm). a b c d a-Maximum Opening .010” (.254 mm) b-Reed Stop c-Reed d-Reed Block 3. Clean all gasket surfaces. 4. Using new gaskets, install reed block assembly to reed plate adaptor. 5. Using new gasket, install manifold and reed plate assembly into cylinder block. Secure assembly to cylinder block with screws. 6. Install auto enrichner. 7. Install recirculation hose to manifold. 8. Install carburetors. SEE CARBURETOR SECTION FOR MORE INFORMATION 9. Install attenuator cover. 90-858804 AUGUST 1998 Page 3B-9 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER Reed Plate, Adaptor Plate and Auto Enrichner 1 1 1 1 2 3 44 5 6 7 8 9 10 11 12 13 14 15 16 17 18 15 19 20 21 22 23 24 25 13 Page 3B-10 90-858804 AUGUST 1998 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER Item Qty. Description Torque Lb. In. Lb. Ft. N·m 1 4 Clamp 2 1 Hose (2-1/4 in.) 3 1 Fitting 4 2 Clamp 5 1 Hose, Molded 6 1 Hose (2-3/4 in.) 7 1 Gasket 8 4 Reed Plate Assembly 9 1 Plate 10 8 Screw (1/4-20 x 5/8 in.) With Dri Loc 11 1 Gasket 12 1 Adapter Assembly (Upper) Lower Adapter Not Shown 13 14 Screw (1/4-20 x 7/8 in.) 14 2 Screw (M6 x 30) 15 2 Washer 16 2 Bushing 17 2 Grommet 18 1 Bracket 19 2 Screw (1/4-20 x 1-1/4 in.) 20 1 Auto Enrichner 21 4 Nut (3/8-16) 22 4 Stud (3/8-16 x 1-5/8 in.) With Dri Loc 23 2 Gasket 24 1 Stud (1/4-20 x 1 in.) With Dri Loc 25 1 Clamp Auto Enrichner System Description The Sport Jet utilizes an automatic enrichner to start the engine. The auto enrichner is a self contained unit with three hose connections to allow for 1) fuel inlet, 2) air inlet, 3) fuel/air mixture outlet. Fuel is supplied to the auto enrichner by a hose connection to the carburetor float bowl. Air is supplied to the valve by a hose connection to the sound attenuator. When the engine is cranked a fuel/air mixture is drawn into the engine from the auto enrichner by a hose connection to the balance tubes. The carburetor shutters must be completely closed for the engine to draw the fuel/air mixture from the auto enrichner. 90-858804 AUGUST 1998 Page 3B-11 FUEL PUMP, RECIRCULATION SYSTEM, REED VALVE ASSEMBLY AND AUTO ENRICHNER A wax pellet controls the position of a slide valve and tapered needle. The stator supplies electrical current to a heater element inside the auto enrichner. As the heater element melts the wax pellet the fuel/air mixture is slowly closed off by the slide valve/tapered needle. The engine continues to run from the fuel/air mixture supplied by the carburetor idle circuit. a b c d e f g h i j k l m n o a-Stator Leads (Yellow) b-Return Spring c-Actuator Rod d-Plastic Spring Guide e-O-ring f-Slide Valve g-Air Inlet h-Rubber Seat i-Fuel Inlet j-Tapered Needle k-Fuel/Air Mixture Outlet (Not All Outlets Are Used) l-Compensating Spring m-Brass Guide n-Wax Pellet o-Heater Element Testing Auto Enrichner On a cold engine the tapered needle will move from full open to full closed after approximately 2 - 2.5 minutes of engine running. On a cold engine resistance between the two yellow leads is 18 - 20 ohms. As the engine warms up the resistance reading will approach infinity. Page 3B-12 90-858804 AUGUST 1998 OIL INJECTION SYSTEM FUEL SYSTEM & CARBURETION Section 3C – Oil Injection System Table of Contents Operation of the Injection System . . . . . . . . . . . 3C-1 Carburetor/Oil Pump Synchronization . . . . . . . . 3C-3 Oil Pump Output Specifications . . . . . . . . . . . . . 3C-1 Bleeding Air from Oil Injection System . . . . . . . 3C-3 Oil Injection Components. . . . . . . . . . . . . . . . . . . 3C-2 Operation of the Injection System 3 C The oil injection system delivers an oil mixture, on engine demand, from 100 to 1 at idle to 50 to 1 at wide open throttle. The oil reservoir holds 4.5 quarts of oil which will provide 4.5 hours of running time at wide open throttle. A low oil warning horn will be activated when approximately 1/3 of oil remains in the reservoir. This will provide approximately one full gas tank of wide open throttle running. The oil injection pump feeds oil into the fuel just before the fuel pump. The oil injection pump is driven by the crankshaft and is connected to the throttle linkage for metering the varied flow of oil per engine RPM. Oil Pump Output Specifications The following table lists the oil pump output capacity in cc per three minutes engine running time. Lever Stamp . “120” Part Number 819438 Volume @ Idle* 4.75 cc  10% Full Volume** 14.25 cc 10% *1500 RPM w/oil link rod attached = cc in 3 minutes **1500 RPM w/oil link rod disconnected and pump arm rotated full clockwise and help against pump casting= cc in 3 minutes 90-858804 AUGUST 1998 Page 3C-1 OIL INJECTION SYSTEM Oil Injection Components 1 2 3 4 5 6 7 8 9 10 11 12 3 13 REF. NO. PART NO. QUAN. DESCRIPTION TORQUE lb. in. lb. ft. NVm 1 54F698772 2 Clamp 2 21826122 1 Valve, Check 3 5481550410 3 Sta-Strap 4 F748316 1 Driven Gear 5 23819743 1 Bearing 6 826593 1 Link Rod 7 3293370- 70 1 Tubing (from Oil Tank - 48 in.) 8 819438 1 Oil Pump (120 HP) 9 817428 2 Socket 10 1168219 2 Nut (10-32) 11 32828217- 13 1 Tubing (4 in. - cut as required) 12 32827228- 81 1 Hose (to fuel pump 2 3/4 in. - cut as required) 13 12001200820664-- 1 820664--2 1 1 Oil Tank (3 qt. 7-1/2 in. high) Oil Tank (4 qt. 9-7/8 in. high) Page 3C-2 90-858804 AUGUST 1998 OIL INJECTION SYSTEM Carburetor/Oil Pump Synchronization 1. Move towershaft to the Wide-Open-Throttle position. Inspect oil pump alignment mark with the oil pump lever. Adjust oil pump link rod to align with the last mark. a b a-Oil Pump Lever b-Alignment Mark (At Wide Open Throttle) 2. Adjust oil pump link rod as required. Bleeding Air from Oil Injection System 1. With engine not running, place s shop towel below the oil pump. Loosen bleed screw three to four turns and allow oil to flow from bleed hole until no air bubbles are present in inlet house. Torque bleed screw to 25 lb. in. (2.8 N·m). This procedure also allows the oil pump to fill with oil. a b a-Outlet Hose b-Bleed Screw 2. Purge air from outlet hose by running engine at idle speed until no air bubbles are present in outlet hose. 90-858804 AUGUST 1998 Page 3C-3 POWERHEAD SECTION 4A – POWERHEAD Table of Contents Powerhead Specifications . . . . . . . . . . . . . . . . . . 4A-1 Cylinder Block and Crankcase Cover . . . . 4A-12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Powerhead Reassembly . . . . . . . . . . . . . . . . . . 4A-13 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Assembling Piston . . . . . . . . . . . . . . . . . . . . . 4A-13 Finished Hone Bore Size . . . . . . . . . . . . . . . . 4A-2 Assembling Crankshaft . . . . . . . . . . . . . . . . . 4A-15 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . . 4A-3 Installing Pistons Into Cylinder Block . . . . . 4A-16 Powerhead Disassembly . . . . . . . . . . . . . . . . . . . 4A-4 Assembling Cylinder Head . . . . . . . . . . . . . . 4A-20 Removing Crankshaft . . . . . . . . . . . . . . . . . . . 4A-6 Completing Assembly . . . . . . . . . . . . . . . . . . . . . 4A-21 Disassembling Crankshaft . . . . . . . . . . . . . . . 4A-6 Installing Powerhead . . . . . . . . . . . . . . . . . . . . . 4A-22 Disassembling Piston . . . . . . . . . . . . . . . . . . . 4A-7 Powerhead Components 120 HP . . . . . . . . . . . 4A-24 Disassembling Cylinder Head . . . . . . . . . . . . 4A-8 Quicksilver Lubrication/Sealant ApplicationInspecting and Repairing . . . . . . . . . . . . . . . . . . . 4A-8 Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-24 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-8 Powerhead Components (Continued) Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . 4A-9 Exhaust Manifold 120 HP . . . . . . . . . . . . . . . . . 4A-26 Powerhead Specifications Special Tools 4 A Description Part No. 12-point Socket FT2953 Piston Tool 91-74607A3 Ring Remover/Installer 91-24697 Ring Compressor FT2996 Lockring Removal Tool 91-52952A1 Lockring Installation Tool 91-77109A2 Flywheel Puller 91-73687A1 Powerhead Lifting Ring 91-90455 90-858804 AUGUST 1998 Page 4A-1 POWERHEAD Specifications Finished Hone Bore Size Standard Size Fraction in. (mm) 3-3/8 3.375 (85.725) .015 Oversize in. (mm) 3.390 (86.10) .030 Oversize in. (mm) 3.405 (86.487) PISTON IMPORTANT: A zero minus tolerance and a plus .001 tolerance is acceptable. IMPORTANT: Measure piston skirt at right angle (90°) to piston pin center-line, .15 in. (3.81 mm) up from bottom edge of skirt. 0.15 in. (3.81 mm) to piston pin center line Measured 90 PISTON RING End Gap Top Piston 0.010 - 0.020 Ring in. (0.254 0.508 mm) Page 4A-2 90-858804 AUGUST 1998 POWERHEAD Powerhead Removal 1. Disconnect battery lead form battery. 2. Remove spark leads from spark plugs. 3. Disconnect remote control harness from engine. 4. Disconnect fuel line to fuel pump. 5. Remove throttle and shift cables. 6. Disconnect water inlet hose from pump cover. 7. Loosen top exhaust boot clamp. b a a-Exhaust Boot Clamp b-Water Inlet Hose 8. Remove four 13-mm nuts from studs that hold powerhead adapter plate to pump cover. 9. Remove four 15-mm nut from studs that hold adapter plate to pump cover. 10. Install lifting ring on end of crankshaft. If lifting hook has less than five turns of engagement remove flywheel nut. a a-Lifting Ring 90-858804 AUGUST 1998 Page 4A-3 POWERHEAD 11. Lift powerhead off pump cover. WARNING DO NOT leave powerhead suspended from hoist. Powerhead should be installed on a suitable stand or lowered to the floor upon removal from pump cover. NOTE: Refer to appropriate sections in service manual for removal of individual fuel and electrical subassemblies from powerhead. Component/Assembly Section Starter Motor 2C Flywheel 2A* Ignition Components (Switch Box, Stator, Trigger) 2A* Carburetor and Linkage 3A Fuel Pump 3B *1996 Models, CDM Ignition NOTE: All ignition and electrical components can be removed and installed as an assembly. Powerhead Disassembly 1. Remove intake manifold and reed assemblies. See Section 3B. 2. Remove exhaust manifold. Discard gasket. Clean all gasket surfaces. 3. Remove cylinder head. Discard gasket. Clean all gasket surfaces. 4. Remove transfer port covers. Discard gasket. Clean all gasket surfaces. d c b e a a-Cylinder Block (120 HP Shown) b-Transfer Port Cover (4 on the 120 HP) c-Cylinder Head d-Exhaust Manifold e-Bearing Cage Page 4A-4 90-858804 AUGUST 1998 POWERHEAD 5. Remove bearing cage. 6. Remove oil injection pump and driven gear. b a a-Oil Injection pump b-Driven Gear 7. Remove crankcase cover screws. a a-Cover Screws (120 HP) 8. Install four bolts in cylinder block to protect gasket surface on cylinder block. 9. Remove bolts securing adapter plate to bottom of cylinder block. Remove adapter plate. Remove and discard gasket. Clean all gasket surfaces. 10. With all cover screws removed, pry crankcase apart starting at corner locations. 90-858804 AUGUST 1998 Page 4A-5 POWERHEAD Removing Crankshaft IMPORTANT: Mark rod caps and pistons as to the cylinder they are removed from. 1. Remove connecting rod screws with 12-point socket. 2. Remove bearing cage half. Rotate crankshaft and remove remaining bearing cage half. IMPORTANT: DO NOT use a magnet to retrieve bearings. 3. Push connecting rod down to clear crankshaft. 4. Repeat steps 1 through 3 for each cylinder. 5. Lift crankshaft out of cylinder block. Disassembling Crankshaft 1. Remove snap rings from center main bearings. Remove bearing races and caged rollers. IMPORTANT: Keep bearings separated, do not intermix components. 2. Remove and discard crankcase seals. a a-Crankshaft Seals 3. If replacement of the upper ball bearing is necessary, remove using universal bearing puller Special Tool 91-37241. Press new bearing onto crankshaft. Page 4A-6 90-858804 AUGUST 1998 POWERHEAD 4. Remove lower crankcase seal. a. Slide lower main bearing to end of crankshaft. b. Pry seal out. a a-Seal 5. If replacement of the oil injection drive gear is necessary, the gear can be remove using universal bearing puller Special Tool 91-37241. The new gear must be pressed on the crankshaft. Disassembling Piston 1. Hold connecting rod so that it does not scratch cylinder bore. Push piston out of cylinder block. 2. Remove piston ring using ring expander. AS NEEDED WARNING Eye protection MUST be worn when removing piston pin lockrings. 1. Snap out and discard piston lockring from both ends of piston pin. 2. Press piston pin out using Special Tool FT 2990-1 on Bottom Guided piston. Use Special Tool 91-74607A3 on Top Guided piston. 90-858804 AUGUST 1998 Page 4A-7 POWERHEAD Disassembling Cylinder Head 1. Remove thermostat housing and components. a b c d e f g a-Screw (4) b-Housing c-Gasket d-Spring e-Thermostat f-Retainer g-Seal NOTE: Test the thermostat by removing the rubber grommet and placing the thermostat in hot water. The thermostat should open at the temperature stamped on it. AS NEEDED 2. Remove thermoswitch by removing snap ring retainer and pry/pull thermoswitch from cavity. 3. Remove bolts from cylinder head cover. Remove cover. Discard gasket. Clean all gasket surfaces. Inspecting and Repairing Crankshaft 1. Inspect crankshaft to drive shaft splines for wear. Replace crankshaft if necessary. 2. Inspect upper and lower crankshaft bearings for roughness and excessive looseness. Replace as necessary. 3. Check all crankshaft bearing surfaces for rust, water marks, chatter marks, uneven wear and/or overheating. • If necessary clean surfaces with crocus cloth as shown. Page 4A-8 90-858804 AUGUST 1998 POWERHEAD 4. Thoroughly clean (with solvent) and dry crankshaft and crankshaft ball bearings. Recheck surfaces of crankshaft. Replace crankshaft if surfaces cannot be properly cleaned up. If crankshaft will be reused lubricate surfaces with 2 cycle oil to prevent rust. Connecting Rods 1. Check connecting rods for alignment by placing rods on a surface plate. If light can be seen under any portion of machined surfaces, if rod has a slight wobble on plate, or if a 0.002 in. (0.051mm) feeler gauge can be inserted between any machined surface and surface plate, rod is bent and must be discarded. 2. Overheating: Overheating is visible as a bluish bearing surface color that is caused by inadequate lubrication or excessive RPM. 3. Rust: Rust formation on bearing surfaces causes uneven pitting of surface(s). a a-Pitting 4. Water Marks: When bearing surfaces are subjected to water contamination, a bearing surface “etching” occurs. This etching resembles the size of the bearing. 5. Spalling: Spalling is the loss of bearing surface, and it resembles flaking or chipping. Spalling will be most evident on the thrust portion of the connecting rod in line with the “I” beam. General bearing surface deterioration could be caused by or accelerated by improper lubrication. a a-Spalling 90-858804 AUGUST 1998 Page 4A-9 POWERHEAD 6. Chatter Marks: Chatter marks are the result of a combination of low speed - low load -cold water temperature operation, aggravated by inadequate lubrication and/or improper fuel. Under these conditions, the crankshaft journal is hammered by the connecting rod. 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, then hammers it. The repetition of this action causes a rough bearing surface(s) which resembles a tiny washboard. In some instances, the connecting rod crank pin bore becomes highly polished. During operation, the engine will emit a “whirr” and/or “chirp” sound when it is accelerated rapidly from idle speed to approximately 1500 RPM, then quickly returned to idle. If the preceding conditions are found, replace both the crankshaft and connecting rod(s). a a-Chatter Marks Between Arrows 7. Uneven Wear: Uneven wear could be caused by a bent connecting rod. a a-Uneven Wear CAUTION Crocus cloth MUST BE USED to clean bearing surface at CRANKSHAFT END OF CONNECTING ROD. 320 grit Carborundum cloth MUST BE USED to clean bearing surface at PISTON PIN END OF CONNECTING ROD. VERIFY CAP TO ROD ALIGNMENT BEFORE TORQUING ROD BOLTS. DO NOT continue to clean connecting rod bearing surfaces after marks have been removed. Page 4A-10 90-858804 AUGUST 1998 POWERHEAD 8. Clean connecting rods as necessary. a b c d a-Attached to Drill Motor b-Crocus Cloth c-Torque to 16 lb. ft. (21.7 N·m) d-Use 320 Carborundum Cloth Top Guided (centered in bore by piston) 51536 a b c a-Flat Washer b-Scalloped c-Smooth 90-858804 AUGUST 1998 Page 4A-11 POWERHEAD Cylinder Block and Crankcase Cover 1. Inspect cylinder head gasket surface for erosion across gasket surface. Excessive erosion requires cylinder head replacement. 2. Inspect cylinder head for warpage. (3 Cylinder Shown) • A cylinder head with 0.012 in. (0.305 mm) or less can be resurfaced. • If warped more than 0.012 in. (0.305 mm) replace cylinder head. 3. Measure cylinder bore diameter at top, middle and bottom of each cylinder as shown. Check for tapered, out-of-round and oversized bore. • Refer to Specifications for Finished Hone Bore Size for Bottom Guided pistons and Top Guided pistons. 4. Measure piston ring end gap. NOTE: Refer to Specifications for dimensions. If gap is too small widened with a file. If gap is too wide recheck bore measurements. Page 4A-12 90-858804 AUGUST 1998 POWERHEAD Powerhead Reassembly Assembling Piston Place clean needle bearings on a clean sheet of paper and lubricate with Quicksilver Needle Bearing Lubricant (92-42649A1). NOTE: There are 29 needle bearings per piston. CAUTION Never intermix new needle bearings with used needle bearings at the same connecting rod end. Never intermix needle bearings on one connecting rod with those of another connecting rod. Should one (or more) piston pin needle bearing of a connecting rod require replacement (or should one or more be lost), replace all of that connecting rod’s piston pin needle bearings. 1. Place sleeve, which is part of Piston Pin Tool (91-74607A3), into connecting rod and install needle bearing around sleeve, as shown. 19537 a b a-Needle Bearings (29) b-Sleeve [From Piston Pin Tool (91-74607A3)] 2. Place flat washers on connecting rod; keeping washers in place, carefully place piston over end of rod. Use disassembly marks for matching rod to piston and direction of insertion (which side of rod is “UP”). 51083 1 1 b a a-Scribed Identification Number b-Locating Washer 90-858804 AUGUST 1998 Page 4A-13 POWERHEAD 3. Insert piston pin tool through piston in the direction shown, pushing out sleeve. 4. Place piston pin over end of tool, and tap into position (driving tool out other side). 51086 c d a b 51080 a-Sleeve b-Piston Pin Tool (91-74607A3) c-Piston Pin d-Piston Pin Tool WARNING Eye protection must be worn while installing piston pin lockrings. 5. Install new piston pin lockrings (each side of piston) using Lockring Tool (91-77109A2). Make sure lockrings are properly seated in piston grooves. CAUTION Do not reuse piston pin lockrings. Use only new lockrings and make sure they are properly seated in piston grooves. 51086 51086 a b a-Lockring Installation Tool (91-77109A2) b-Lockring (2) 6. Install piston rings. Top piston ring has one dot: install facing up. Bottom piston ring has two dots and a white stripe: install with dots facing up. Page 4A-14 90-858804 AUGUST 1998 POWERHEAD Assembling Crankshaft 1. Install new seal into lower main bearing. Press seal into bearing with garter spring facing up. Use Special Tool FT 8925. 2. Apply Needle Bearing Lubricant 92-825265A1 between libs of seal and slide bearing on crankshaft. 3. Scrape old Loctite off upper bearing. Clean bearing surfaces with Locquic Primer 92-59327--1. a a-Garter Spring (Faces Up Toward Flywheel When Installed) 4. Install new crankshaft seals on crankshaft. 5. Install center main bearings on crankshaft with alignment holes of bearing race between snap ring groove and crankcase seal. a b c d a-Crankcase Seals b-Snap Ring Groove c-Alignment Hole d-Crankcase Seal NOTE: Position snap ring on center main bearings so that the gap is not over the fracture area of the bearings. 90-858804 AUGUST 1998 Page 4A-15 POWERHEAD 6. Install lower bearing on crankshaft with seal. a b a-Lower Bearing b-Seal Installing Pistons Into Cylinder Block 1. Coat pistons, rings, and cylinder bores with 2-cycle oil. 2. Install piston in ring compressor, Special Tool FT 2996. IMPORTANT: Be sure to position end gap of rings at the ring alignment pin. NOTE: Pins are 180° apart on piston. 3. Install piston in cylinder bore. Position piston so that piston dome faces intake port of cylinder block. a a-Alignment Pin b-Intake Ports c-Piston Dome c b Page 4A-16 90-858804 AUGUST 1998 POWERHEAD 4. Push piston into cylinder bore. NOTE: Be sure piston is installed in the same bore it was removed from. 5. Install cylinder head to prevent pistons from falling out. Do Not torque the cylinder head bolts at this time. 6. Clean cylinder block upper bearing bore with Locquic Primer 92-59327--1. 7. Apply Loctite to upper main bearing bore. 8. Install crankshaft in cylinder block. • Align holes in center main bearings with location pins in cylinder block. b b a a a-Center Main Bearing Hole b-Locating Pin IMPORTANT: Install crankshaft with sealing ring gaps facing up. When the crankshaft is seated the ends of the sealing rings must be able to touch. IMPORTANT: Make sure crankshaft is fully seated by pushing ends of crankshaft: there should be no rocking. 9. Spin crankshaft seals so that openings face down. IMPORTANT: Seal rings break easily; handle carefully when turning. IMPORTANT: Make sure upper crankshaft bearing is fully seated against the flange in the cylinder block. Tap on end of crankshaft to ensure seating. 10. Install one half of bearing cage in connecting rod. 11. Carefully align connecting rod with crankshaft. a a-Bearing Seated Against Cylinder Block Flange 90-858804 AUGUST 1998 Page 4A-17 POWERHEAD 12. Install second half of bearing cage in connecting rod. 13. Install connecting rod cap. IMPORTANT: Connecting rods and connecting rod caps are matched halves. Do not torque screws before checking alignment. NOTE: Do Not re-use old rod cap screws, always use new rod cap screws. • Install new rod cap screws and thread until cap and rod fit together. Inspect for alignment. a b c a-Correct Fit b-Incorrect Fit - Gap Present c-Incorrect Fit - Ridge Present • Correct any misalignment. 14. Remove cap screws and apply Loctite FT 8936-1 to cap screw threads. Hand tight cap screws and check alignment. If alignment is good torque cap screws in increments of 50 lb. in. (5.65 N·m) until a torque of 120 lb. in. (13.55 N·m) is reached, then turn an additional 90°. 15. Repeat procedure for the remaining connecting rods. • Rotate the crankshaft after each rod is installed to check for binding. If any binding is present remove rod cap and check alignment. Page 4A-18 90-858804 AUGUST 1998 POWERHEAD 16. Apply Loctite 92-823089--1 to the exposed portion of the upper bearing. 17. Apply Sealer 92-90113--2 on seal surface and around main bolt holes on block. 18. Install crankcase cover on cylinder block, aligning corner dowel pins. a b b a-Sealer (92-90113--2) b-Dowel Pins 90-858804 AUGUST 1998 Page 4A-19 POWERHEAD 19. Install crankcase bolts. Following torque pattern torque bolts to 270 lb. in. (30.5 N·m). • Check crankshaft for free rotation. 10 6 2 3 78 4 1 5 9 20. Using new gasket, install adapter plate on bottom of cylinder block. Torque bolts to 30 lb. ft. (40.7 N·m). Assembling Cylinder Head 1. Install cylinder head cover on cylinder head. Torque center attaching screws to 70 lb. in. (7.91 N·m). 2. Apply sealant 92-90113--2 to cylinder head cover on cylinder block side of cover. 3. Using new gasket, install cylinder head. 4. Torque bolts as shown to 75 lb. in. (8.5 N·m), then torque 50 lb. in. (5.6 N·m) at a time until bolts are torqued to 225 lb. in. (29.14 N·m). For S/N numbers 0E125509 and above apply light oil to threads and bolt head. Torque in sequence to 120 lb. in. (13.5 N·m). Then turn an additional 90. 18 14 10 6 2 3 7 11 1516 12 8 4 1 5 9 13 17 Page 4A-20 90-858804 AUGUST 1998 POWERHEAD Completing Assembly 1. Install exhaust manifold using new gasket. Torque bolts in sequence from center out. Apply light oil to threads and bolt head. Torque bolts in sequence to 115 lb. in. (13 N·m). Then re-torque #’s 1 - 6. 12 3 64 10 14 22 2521 17 13 9 5 8 12 16 20 2423 19 15 11 7 18 NOTE: Refer to appropriate sections in service manual for installation of individual fuel and electrical subassemblies on powerhead. Component/Assembly Section Starter Motor 2C Flywheel 2A Ignition Components (Switch Box, Stator, Trigger) 2A Carburetor and Linkage 3A Fuel Pump, Reed Valves 3B NOTE: All ignition and electrical components can be removed and installed as an assembly. 90-858804 AUGUST 1998 Page 4A-21 POWERHEAD Installing Powerhead 1. Install top exhaust boot and clamp. Install O-ring in counterbore of drive housing cover. a b c d a-Exhaust Boot b-O-Ring c-Drive Housing Cover d-Large O-Ring 2. Lubricant driveshaft splines with 2-4-C w/Teflon Lubricant 92-825407A12. NOTE: DO NOT apply lubricant to TOP of drive shaft as grease may pre-load drive shaft/ crankshaft resulting in damage to powerhead and/or pump housing. 3. Lower powerhead on drive housing cover. Align exhaust boot with exhaust elbow, driveshaft splines, and mounting studs. 4. Torque exhaust bellows clamp screws to 50 lb. in. (5.6 N·m). 5. Connect water inlet hose to fitting on drive housing cover. Snug nut with wrench, then tighten one additional flat (60 degrees). a a-Water Inlet Hose Page 4A-22 90-858804 AUGUST 1998 POWERHEAD 6. Secure powerhead to drive housing cover with nuts. 7. Torque nuts in sequence shown below. The forward and aft nuts (7, 8 and 5, 6) are torqued to 35 lb. ft. (47.5 N·m). The left and right nuts (1, 2 and 3, 4) are torqued to 20 lb. ft. (27.1 N·m). 1 2 4 35 6 7 8 REFER TO SECTION 6 “ENGINE INSTALLATION” TO COMPLETE INSTALLATION OF WIRE HARNESS, CONTROL CABLES, SET-UP AND TIMING. IMPORTANT: Follow Break-In procedure as out lined in Section 6: Engine Installation. CAUTION SEVERE DAMAGE to your engine can result by not complying with the proper break-in procedure. 90-858804 AUGUST 1998 Page 4A-23 POWERHEAD Powerhead Components 120 HP U U U 12 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 31 32 33 3435 28 28 6 9 6 Quicksilver Lubrication/Sealant Application Points U RTV Sealant 92-90113--2 Page 4A-24 90-858804 AUGUST 1998 POWERHEAD Item Qty. Description Torque Lb. In. Lb. Ft. N·m 1 1 Cylinder Block 2 1 Bolt (3/8-16x3-1/8) 270 22.5 30.5 3 1 Bolt (3/8-16x2-3/4) 270 22.5 30.5 4 2 Bolt (3/8-16x3) 270 22.5 30.5 4 Bolt (3/8-16x2) 270 22.5 30.5 6 10 Washer 7 2 Bolt (3/8-16x1-3/4) 22.5 30.5 8 2 Bolt (1/4-20x1-1/4) 70 7.9 9 2 Dowel Pin (3/8x5/8) 3 Tube 11 1 Tube 12 1 Pin 13 3 Pin 14 1 Gasket Set 1 Gasket 16 1 Bolt (5/16-18x3/4) 13 17.6 17 1 Lock Washer (5/16) 18 1 Gasket 19 1 Cylinder Head 1 Cover 21 4 Bolt (1/4-20x5/8) 70 7.9 22 18 Bolt (5/16-18x2-3/8) S/N 0E125509 and Above - Apply Light Oil to Bolt Head & Threads 120 lb. in. (13.5 N·m) Then Turn An Additional 90. 23 18 Washer - Only Used On 1995-1/2 S/N 0E125508 and Below 24 3 Cover Kit 1 Plug 26 12 Bolt (1/4-20x5/8) 70 7.9 27 3 Gasket 28 24 Bolt (1/4-20x7/8) 70 7.9 29 1 Cover 4 Bolt (1/4-20x3/4) 70 7.9 31 1 Gasket 32 1 Spring (RED) 33 1 Thermostat (130°) 34 1 Spacer 1 Seal 90-858804 AUGUST 1998 Page 4A-25 POWERHEAD Powerhead Components (Continued) Exhaust Manifold 120 HP Not Used on 1996 Models 1 5 6 7 8 9 3 4 2 10 11 10 Item Qty Description Torque Lb. In. Lb. Ft. N·m 1 1 Manifold 2 1 Gasket 3 1 Strainer Tube 4 4 Plug (3/4-14) 5 25 Washer Only Used On 1995-1/2 S/N 0E125508 and Below 6* 21 Bolt (1/4-20x3) Apply Light Oil to Bolt Head & Threads 115 13 7 4 Bolt (1/4-20x4) 115 13 8 1 Retainer 9 2 Clip 10 2 Clamp 11 1 Bellows * Refer to torque sequence listed on page 4A-21. Page 4A-26 90-858804 AUGUST 1998 JET PUMP SECTION 5A – JET PUMP Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Servicing Stator, Impeller and Wear Ring . . . . 5A-10 General Information . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-10 Principles of Operation . . . . . . . . . . . . . . . . . . 5A-1 Inspecting Components . . . . . . . . . . . . . . . . 5A-12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Installing Impeller . . . . . . . . . . . . . . . . . . . . . . 5A-13 Drive Housing Components . . . . . . . . . . . . . . . . . 5A-4 Removing Jet Drive From Boat . . . . . . . . . . . . . 5A-14 Drive Housing Components . . . . . . . . . . . . . . . . . 5A-5 Drive Housing Disassembly andPinion & Impeller Shaft . . . . . . . . . . . . . . . . . . . . . 5A-6 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-15 Pinion & Impeller Shaft . . . . . . . . . . . . . . . . . . . . . 5A-7 Pinion Shaft Removal . . . . . . . . . . . . . . . . . . 5A-15 Nozzle/Rudder Components . . . . . . . . . . . . . . . . 5A-8 Impeller Shaft Removal . . . . . . . . . . . . . . . . 5A-17 Nozzle/Rudder Components . . . . . . . . . . . . . . . . 5A-9 Shimming Procedures . . . . . . . . . . . . . . . . . 5A-19 General Information NOTE: Due to running changes, some illustrations may not be exactly the same as your drive unit. Service procedures remain the same unless otherwise noted. 5 A Principles of Operation The jet pump operates by drawing water into a housing forward of the impeller. The water is pressurized within the specially designed housing and then directed to the rear to provide thrust and motion. 57329 c a b a-Forward Motion b-Water Thrust c-Reverse Gate (Shown In the Forward Position) The jet pump is equipped with a steerable nozzle (rudder) at the aft end of the pump housing that directs the thrust of water. The jet of water can be directed right or left when the operator turns the steering wheel in the respective direction. When the operator turns the steering wheel to the right, for example, the nozzle 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. 90-858804 AUGUST 1998 Page 5A-1 JET PUMP Page 5A-2 90-858804 AUGUST 1998 Forward and 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 thrust to be directed straight back. Reverse drive has the reverse gate covering the entire opening enough to divert the thrust forward. Neutral position has the reverse gate covering 75 percent of the nozzle to direct the water stream forward and downward, as well as backward. The shift position is controlled at the control box in the boat. 57330 a a - Reverse Gate (Shown In the Reverse Position) Special Tools Jet Pump Tool Kit 91-809957A1 Description Part Number a Pre-Load Kit Impeller Shaft 91-824871A2 b Thread Extender Kit used w/ Backlash Kit 91-824869A1 c Seal Protector Impeller Shaft 91-850233 d Impeller Shaft Wrench 91-832093A1 e Impeller Nut Socket 91-850297 f Pinion Gear Location Tool 91-831897 g Bearing Installer press ball bearing and seals into pinion shaft housing 91-832016 h Bushing Installer stator bushings & seal 91-850831 i Seal Installer impeller shaft seals in drive housing 91-832019 j Bearing Installer impeller shaft ball bearing in drive housing 91-832017 k Bearing Cup Installer pinion shaft housing and drive housing front cover 91-832018 l Handle Driver 91-824892 JET PUMP 90-858804 AUGUST 1998 Page 5A-3 a b d e f l k c d e g h i j Backlash Indicator Flag use MCII line 91-53459 Dial Indicator Kit 91-58222A1 Dial Indicator Adapter Kit 91-83155 Slide Hammer 91-34569A1 Bearing Puller Kit 91-83165M Retaining Ring Pliers 91-25081 Lubricants/Adhesives Part Number Loctite, #271 92-809820 Loctite, #242 Obtain Locally Perfect Seal 92-34227--1 2-4-C Lubricant w/ Teflon 92-825407A12 Special Lube 101 92-13872A1 Hi Performance Gear Lube 92-19007A24 JET PUMP Page 5A-4 90-858804 AUGUST 1998 Drive Housing Components 1 2 3 4 5 6 7 9 8 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 8 8 8 7 7 7 11 9 32 24 10 22 37 3 JET PUMP REF REFREF . NO. PART NO. SYM. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 854668A6 . 1 HOUSING KIT-Drive (COMPLETE) (Painted) (NO IMPELLER) 854668A8  . 1 HOUSING ASSY-Drive (BASIC) (Painted) 2 22-63186 1 FITTING-Syphon Drain Hose 3 831976 w 2 FOAM-Exhaust Deflector 4 26-76868 w 2 SEAL-Oil 5 30-63742 1 BEARING-Ball 6 53-55626 1 RING-Snap 7 16-823358--1 5 STUD (M10 x 72) 8 11-826292 8 NUT (M10) 35 47.5 9 11-826365 4 NUT (M8) 20 27.1 16-820640 2 STUD (M10 x 55) 11 16-820639 1 STUD (M10 x 98) 12 27-854644 . w 1 GASKET-Drive Housing 13 10-79953A2 2 SCREW KIT 14 12-19183 w 2 WASHER-Sealing 15 854475A2 . 1 COVER KIT-Drive Hsg (Painted) (Also Includes Gasket Ref # 12) 16 16-820451--1 4 STUD (M8 x 55) 17 824015 1 CUP-Barrel Retainer 18 25-20826 . w 1 O RING 19 25-38101 . w 1 O RING 22-852523 . 1 ELBOW (.125-27) 21 22-820452--1 1 FITTING-Water Hose 2222 25-820663250 AR GROMMET-Pump Mount (.250) 25-820663375 AR GROMMET-Pump Mount (.375) 25-820663500 AR GROMMET-Pump Mount (.500) 23 11-826365 1 NUT (M8) 156 18 24 832811 2 BAFFLE ASSEMBLY-Exhaust 25 10-832043 1 SCREW (M8 x 240) 156 18 26 830123--1 1 SEAL-Ride Plate 27 10-40107-25 2 SCREW (M8 x 25) 200 22.6 28 853905 1 PLATE-Trim 29 11-40063--5 2 NUT (M8) 156 18 10-850047 2 SCREW (M8 x 35) 35 47.5 31 831856A1 1 RIDE PLATE KIT (Painted) 32 10-832838 16 SCREW With Nylon Patch (M6 x 20) 75 8.5 33 856627T . 1 FRAME-Inlet Grate 34 856629T . 1 TINES-Inlet Grate 35 10-856732 . 2 SCREW-Pivot (Special) 36 24-856628T . 1 SPRING-Inlet Grate 37 54-816311 2 CABLE TIE (8.00 Inch) 38 22-826702 1 SYPHON BREAK 39 54-23567 1 CLIP-Syphon Hose 35-826703 1 FILTER-Syphon Hose 41 32-16789-78 1 HOSE-Syphon (9.00 Feet Bulk) (Cut 42.00 Inches) 42 98889 1 LATCH-Control Cable 43 32-820448 1 HOSE ASSEMBLY-Water Inlet 44 854444T . 1 PLATE-Adapter (Painted) 45 10-40106-10 2 SCREW (M6 x 10) 70 8 46 820339 1 BRACKET-Towershaft Bearing 47 23-F40689-1 1 BEARING-Towershaft Lower 48 12-856774 10 WASHER 49 10-19925125 10 SCREW (.375-16 x 1.25) With Dri Lok 270 30.4 32-16789-78 1 HOSE-Syphon (9.00 Feet Bulk) (Cut 18.00 Inches) 51 54-41582--7 1 CLAMP 52 54-41582--5 1 CLAMP – 26-803834A1 1 SEAL/GASKET SET-Drive Housing – 854668A6 1 HOUSING KIT-Drive (COMPLETE) (Painted) (NO IMPELLER) . = NEW PART NUMBER LISTED FOR FIRST TIME w = COMPONENT OF JET DRIVE SEAL/GASKET KIT (26-803834A1) . = COMPONENT OF COMPLETE JET DRIVE HOUSING KIT (854668A6) AR = As Required 90-858804 AUGUST 1998 Page 5A-5 JET PUMP Page 5A-6 90-858804 AUGUST 1998 Pinion & Impeller Shaft 1 2 4 3 5 7 6 8 9 10 11 13 12 14 15 17 4 108 7 95 95 4 4 5 2 6 7 9 18 15 14 17 13 12 16 11 10 7 Loctite “271” (92-809820) 95 2-4-C w/Teflon (92-825407A12) 108 Special Lubricant 101 (92-13872A1) JET PUMP Pinion & Impeller Shaft REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 RING-Rubber 2 4 SCREW (M8 x 25) 180 20.3 3 1 HOUSING ASSEMBLY-Pinion Shaft (Painted) 4 2 SEAL-Pinion Shaft Housing 5 1 BEARING-Ball 6 1 BEARING SET 7 1 O RING 8 88 AR SHIM (Red) (.002) AR SHIM (Beige) (.004) AR SHIM (Blue) (.005) AR SHIM (Frost/Clear) (.0075) AR SHIM (Brown) (.010) AR SHIM (Yellow) (.020) 9 1 GEAR/SHAFT ASSEMBLY-Pinion 10 1 SHAFT-Impeller 11 1 GEAR-Impeller Shaft 12 1 WASHER 13 1 NUT (M14) 90 122 14 1414 AR SHIM (Red) (.002) AR SHIM (Beige) (.004) AR SHIM (Blue) (.005) AR SHIM (Frost/Clear) (.0075) AR SHIM (Brown) (.010) AR SHIM (Yellow) (.020) 15 1 COVER ASSEMBLY-Impeller Shaft (Painted) 16 1 BEARING SET 17 1 O RING 18 4 SCREW (M8 x 25) 180 20.3 90-858804 AUGUST 1998 Page 5A-7 JET PUMP Page 5A-8 90-858804 AUGUST 1998 Nozzle/Rudder Components 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 27 28 29 30 31 32 33 34 36 37 38 39 40 41 42 43 44 45 46 47 48 49 8 12 10 34 35 JET PUMP REF REFREF . NO. PART NO. SYM. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 855329A1 . 1 REVERSE GATE KIT (Painted) 2 17-68402 . 1 PIN-Clevis (.250 x 1.13) 3 12-29245 . 1 WASHER 4 18-21071 . 1 PIN-Cotter 5 10-832838 1 SCREW (M6 x 20) 70 8 6 820503--1 1 ANODE 7 13-78968 1 LOCKWASHER (.250 Internal) 8 23-832048 2 BUSHING-Pivot 9 37-826817-18 . 1 DECAL (120XR2 Mercury Sport Jet) 10 10-831922 4 BOLT (Special)-Pivot 50 68 11 831241A1 1 RUDDER KIT (Painted) 12 23-832048 2 BUSHING-Pivot 13 13-78968 1 LOCKWASHER (.250 Internal) 14 820503--1 1 ANODE 15 10-832838 1 SCREW (M6 x 20) 70 8 16 820674A1 1 END KIT (Screw - Nut - Swivel) 17 10-40108-45 2 SCREW (M10 x 45) 35 47 18 856581C . 1 ANODE (With Cast in Bushings) 19 10-40108-35 2 SCREW (M10 x 35) 35 47 20 32-850829 1 HOSE-Syphon (12.00 Inch) 21 10-40071-54 1 SCREW (M8 x 30) 120 13.5 22 12-36001 1 WASHER 23 820564 1 STOP-Adjustable-Reverse Gate 24 831253A1 1 NOZZLE ASSEMBLY-With Pivot Bushings (Painted) 25 22-826701 1 FITTING-Nozzle 26 856772 . 1 STOP-Non Adjustable-Reverse Gate 27 10-40107-25 . 1 SCREW (M8 x 25) 28 12-34931  . 4 WASHER 29 10-832929 . 4 SCREW (M10 x 150) 35 47 30 300-831256A5  . 1 STATOR ASSEMBLY (Painted) 31 10-79953A2 1 SCREW KIT (Special) 50 5.6 32 12-19183 w 1 WASHER-Sealing 33 22-73379 1 PLUG-Pipe (.250-18) 34 23-835473 2 BUSHING-Stator Rear 35 26-14381 w 1 SEAL 36 853950 1 PROTECTOR-Seal 37 14-832983 1 WASHER-Tab 38 856814A2  . 1 WEAR RING KIT (Painted) 39 22-42861--1 1 PLUG-Pipe (.750-14) 40 16-816194--8 . 2 STUD (M6 x 36) 41 11-826833--6 . 2 NUT (M6) 42 25-38101 w 1 O RING 43 25-832062 w 1 O RING 44 856997T . 1 LATCH-Shift Cable Retainer 45 856998T . 1 RETAINER-Shift Cable (Brass) 46 11-835464 1 NUT-Impeller Shaft 150 203 47 54-857019T . 1 RING-Retaining 48 857000A2 . 1 DAMPER ASSEMBLY-Impeller 49 47-854670T . 1 IMPELLER ASSEMBLY-SS-3 Blade – 26-803834A1 1 SEAL/GASKET SET-Drive Housing – 854668A6 1 HOUSING KIT-Drive (COMPLETE) (Painted) (NO IMPELLER) = NEW PART NUMBER LISTED FOR FIRST TIME w = COMPONENT OF JET DRIVE SEAL/GASKET KIT (26-803834A1) = COMPONENT OF COMPLETE JET DRIVE HOUSING KIT (854668A6) 90-858804 AUGUST 1998 Page 5A-9 JET PUMP Page 5A-10 90-858804 AUGUST 1998 Servicing Stator, Impeller and Wear Ring Disassembly 1. Disconnect spark plug leads from spark plugs. 2. Disconnect shift and steering cables at Reverse gate and Rudder. 57330 a b a - Shift Cable b - Steering Cable IMPORTANT: This procedure lists the disassembly of external pump components. If servicing a specific component, follow the procedure in that section. REMOVING REVERSE GATE, RUDDER AND NOZZLE AS AN ASSEMBLY 1. Remove four screws securing nozzle to stator. Remove reverse gate/rudder/nozzle assembly. 54579 c c - Screws (4) JET PUMP STATOR REMOVAL 1. Remove two screws securing trim plate to ride plate and wear ring. 2. Remove four screws securing stator assembly to drive housing. Remove stator assembly. 28253 28252 b a c a-Screws (2) to Trim Plate & Wear Ring b-Trim Plate c-Stator 3. Drain stator by tilting stator forward and allowing the oil to drain over the impeller shaft seals. Complete oil draining by removing stator fill screw and pour the remaining oil out the fill screw hole. IMPELLER REMOVAL 1. If removed, install wear ring to support impeller and shaft during impeller removal. 2. Remove inlet screen on bottom of drive housing to allow access to machined flats on impeller shaft. 3. Use Special Tool 91-832093A1 to hold impeller shaft. 4. While holding impeller shaft, remove impeller nut using Special Tool 91-850297. Impeller nut is a standard right hand thread. Remove impeller. 28252 a b a-Special Tool 91-850297 b-Special Tool 91-832093A1 5. Remove wear ring. 90-858804 AUGUST 1998 Page 5A-11 JET PUMP Page 5A-12 90-858804 AUGUST 1998 Inspecting Components 1. Inspect wear ring for excessive scoring and/or grooves. Replace wear ring if deep grooves are present or if severe scoring has taken place. 2. Ensure O-ring is in counterbore before installing wear ring to drive housing. 28255 a b a - O-rings b - Inspect Surface for Grooves/Scoring 3. Inspect seal in stator for wear/damage. 4. Inspect bellows on cables for wear. 5. Inspect anodes, replace as necessary. 6. Inspect pivot pins and bushings, replace as necessary. Torque on reverse gate and rudder pivot pins is 50 lb. ft. (68 N·m). Use Loctite 271 on threads. 7. Inspect impeller for cracks and damaged blades. 8. Inspect stator vanes for cracks and/or damage. 9. If replacement is required, remove stator seal using Puller 91-83165M. 28256 10. Install new seal using Special Tool 91-850831. Smaller diameter seal lip faces out. JET PUMP Installing Impeller 1. Lubricate splines of impeller shaft with Special Lube 101 (92-13872A1). 2. Install impeller and nut on impeller shaft. Locate bent tab in impeller slot. Torque impeller nut to 150 lb. ft. (203 N·m). Bend one tab against flat on nut. 3. Install inlet screen. Apply Loctite 242 to threads of screws and bolts. Torque the two 6 mm screws to 75 lb. in. (8.5 N·m). Torque the two 8 mm bolts to 200 lb. in. (22.5 N·m). 4. Install wear ring and stator. Apply Loctite 242 to threads of four bolts. Torque to 35 lb. ft. (47 N·m). 5. Remove stator fill screw with washer and fill stator with High Performance Gear Lube (92-13783A24) until oil flows out fill hole (capacity is 19 fl. oz. / 550 cc). Install fill screw and washer. 54894 a a-Fill Screw 6. Apply Loctite 242 to screws (2) securing trim plate to the ride plate. Torque screws to 75 lb. in. (8.5 N·m). 28252 b a a-Screws (2) to Trim Plate & Wear Ring b-Trim Plate 7. Install nozzle assembly and anode. Apply Loctite 271 to threads of screws. Torque all four (4) screws to 35 lb. ft. (47 N·m). 8. Attach shift and steering cables. REFER TO SECTION 1D: SPORT JET INSTALLATION FOR SHIFT AND STEERING INSTALLATION AND ADJUSTMENT. 90-858804 AUGUST 1998 Page 5A-13 JET PUMP Page 5A-14 90-858804 AUGUST 1998 Removing Jet Drive From Boat REMOVE POWERHEAD AS OUTLINED IN SECTION 4. 1. Disconnect shift and steering cables from reverse gate and rudder. Remove cable adaptors and bellows assemblies. Loosen shift and steering cables at wear ring. 2. Loosen shift and steering cable thru hull fittings. 3. Support pump. 28257 57330 a b a - Shift Cable b - Steering Cable WARNING The pump unit must be supported to prevent it from dropping through the opening when the remaining fasteners are removed. 4. Remove remaining four nuts from drive housing cover. Remove drive housing cover and gasket. 54980 a a - Nuts (4) 5. Lower drive housing while sliding cables out. Place on bench or suitable work stand for disassembly/repair. JET PUMP 90-858804 AUGUST 1998 Page 5A-15 Drive Housing Disassembly and Reassembly Pinion Shaft Removal 1. Remove four screws securing pinion shaft housing to drive housing. Remove pinion shaft assembly. NOTE: Take care not to damage or misplace colored shims. 2. Remove rubber ring, O-ring and shims. 53797 28257 a b c a - Rubber Ring b - Shims c - O-ring 3. Press pinion shaft out of pinion shaft housing. 4. Remove pinion shaft ball bearing and two seals using Puller 91-83165M. 28264 53796 JET PUMP 5. Remove pinion shaft outer race from pinion shaft housing using slide hammer 91-34569A1. 6. Press new outer race into pinion shaft housing using mandrel 91-832018. 2826428265 7. Remove tapered roller bearing from pinion shaft using universal puller plate 91-37241. 8. Press new tapered roller bearing onto pinion shaft using Special Tool 91-827983. 9. Press new ball bearing into pinion shaft housing using Special Tool 91-832016. 28266 28265 10. Press pinion shaft into pinion housing. 11. Press new seals into pinion shaft housing, one at a time, using Special Tool 91-820552. Inner seal faces in, outer seal faces out. 28268 28267 a a-Special Tool 91-820552 Page 5A-16 90-858804 AUGUST 1998 JET PUMP 90-858804 AUGUST 1998 Page 5A-17 Impeller Shaft Removal 1. Remove Stator, Wear Ring and Impeller as described in “Servicing Impeller”. 2. Remove stator fill screw, drain oil into a suitable container. 3. Remove ride plate. 4. Remove four screws securing impeller shaft cover to drive housing. Remove cover. NOTE: Take care not to damage or misplace colored shims. 28258 28257 b a a - O-ring b - Shims 5. Remove nut and washer from end of impeller shaft. Remove impeller shaft gear. 6. Pull impeller shaft from drive housing. 28259 28259 JET PUMP 7. Remove bearing retaining ring from drive housing. 8. Remove bearing using Puller 91-83165M. 28263 28262 9. Remove impeller shaft seals using Slide Hammer 91-34569A1. 10. Install new seals using Special Tool 91-832019. 11. Install new bearing using Special Tool 91-832017. 28260 28261 12. Install retaining ring in drive housing after bearing is installed. 13. If replacing impeller shaft gear bearing, remove using universal plate. b a a-Suitable Mandrel b-Universal Plate 28269 Page 5A-18 90-858804 AUGUST 1998 JET PUMP 14. Press new bearing on gear using an appropriate size mandrel. 15. If replacing bearing, remove outer race from front cover using slide hammer. Press new outer race in cover using suitable mandrel. 5498528270 Shimming Procedures NOTE: Pinion gear shimming and backlash procedures must be preformed when any of the following components have been replaced: a. Jet Drive Housing b. Pinion Gear c. Pinion Gear Bearing Assembly d. Pinion Shaft Housing e. Impeller Gear f. Impeller Gear Bearing Assembly g. Impeller Shaft Front Cover NOTE: Shims are color coded to represent different thicknesses. These color codes apply to both pinion housing shims and impeller cover shims. Red .002 in. (.05 mm) Beige .004 in. (.10 mm) Blue .005 in. (.127 mm) Frost (Clear) .0075 in. (.19 mm) Brown .010 in. (.25 mm) Yellow .020 in. (.51 mm) 90-858804 AUGUST 1998 Page 5A-19 JET PUMP 1. Install original shims on pinion shaft housing. Install O-ring on pinion shaft housing. NOTE: If original shims are not available, start with .030 in. (.76 mm) shims (three brown colored shims). 2. Install pinion shaft assembly into drive housing bore. Torque screws to 180 lb. in. (20.3 N·m). 28271 3. Rotate pinion shaft ten revolutions to properly seat roller bearings. 4. Insert Pinion Location Tool (Special Tool 91-824890) in drive housing. NOTE: Carefully inspect location tool to make sure it is seated in drive housing bearing. 5. Insert feeler gauge through hole in pinion location tool between gauging surface of tool and flats on bottom of pinion gear teeth. IMPORTANT: The correct clearance is .025 inch (0.64 mm). 6. Use .025 inch (.064 mm) feeler gauge as a starting thickness. Adjust thickness of feeler gauge until a slight drag is felt as gauge is drawn out between gauging surface of tool and pinion gear. NOTE: Once the thickness is determined, the difference between feeler gauge thickness and .025 inch (0.64mm) required clearance must be either added or subtracted from the total thickness of shims between pinion shaft housing and drive housing. • Remove the screws securing the pinion shaft housing assembly to the drive housing. Lift assembly out of the drive housing. • Adjust shim thickness as required. 7. Install seal protector, Special Tool 91-850233, on impeller shaft. Install impeller shaft in drive housing, then remove seal protector. 54986 a a-Seal Protector, Special Tool 91-850233 Page 5A-20 90-858804 AUGUST 1998 JET PUMP 90-858804 AUGUST 1998 Page 5A-21 8. Install gear/bearing assembly and washer on impeller shaft. Apply Loctite 271 to threads of impeller shaft. Hold impeller shaft with Special Tool 91-832093A1. Install nut and torque to 90 lb. ft. (122 N·m). 28257 9. Install original shims on impeller shaft cover. Install O-ring on impeller shaft cover. NOTE: If original shims are not available, start with .030 in. (.76 mm) shims (three brown colored shims). • Lubricate O-ring and bore with Quicksilver lubricant 2-4-C. • Lubricate cone bearing with gearcase lubricant. 10. Install impeller shaft cover. Torque screws to 180 lb. in. (20.3 N·m). 11. Install impeller shaft pre-load tool (91-824871A2). 54983 28257 a b c a - Spring Seat, Rear b - Spring c - Spring Seat, Forward 12. Install wear ring and stator on impeller shaft. Secure assembly with two bolts (opposite corners). Torque bolts to 35 lb. ft. (47 N·m). • Rotate impeller shaft ten revolutions to properly seat roller bearings. JET PUMP Page 5A-22 90-858804 AUGUST 1998 13. Install Backlash Indicator Rod (Special Tool No. 91-53459) on pinion shaft. 54987 14. Install Dial Indicator Kit, Adapter Kit and Thread Extender Kit. • Position rod from dial indicator on the center mark “II” of the backlash indicator rod. 15. Rotate pinion shaft back and forth lightly to contact gear teeth in each direction. NOTE: Average total amount of reading of indicator backlash specification is .007 inch (.18 mm) to .009 inch (.23 mm). • If reading is less than minimum, add shims between impeller cover and drive housing. • If reading is more than maximum remove shims between impeller cover and drive housing. • Ratio of backlash reading to shims is 1:1. 16. Install impeller, wear ring and stator as outlined in “Installing Impeller” in this section. 17. Apply RTV Sealant (92-809825) on rideplate. Install rideplate. DO NOT reuse screws. Apply Loctite 242 to threads of new screws. Torque to 75 lb. in. (8.5 N·m). 18. Install nozzle/reverse gate assembly and anode. Apply Loctite #271 to threads of screws. Torque all four (4) screws to 35 lb. ft. (47 N·m). 19. Remove fill and vent screws from bottom of drive housing. Fill drive housing with High Performance Gear Lube. Capacity is 27 oz. (825 cc). 28272 b c a a - Fill/Drain Screw b - Vent Screw c - RTV Sealant 92-809825 NOTE: To obtain correct oil level pump housing must be level and upright. Refer To Section 1d: Sport Jet Installation To Complete Installation Of Drive Housing, Shift And Steering Cable Installation And Adjustment. 6 A SPORT JET INSTALLATION 90-858804 AUGUST 1998 Page 6A-1 SECTION 6A – SPORT JET INSTALLATION Table of Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Notice to Installer . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 3 Serial Number Decal Location . . . . . . . . . . . . . . . 3 Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . 4 Installation Requirements . . . . . . . . . . . . . . . . . . . . . 4 Battery/Battery Cables . . . . . . . . . . . . . . . . . . . . . 4 Boat Construction . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Compartment Ventilation . . . . . . . . . . . . 5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel Delivery System . . . . . . . . . . . . . . . . . . . . . . 6 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Impeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remote Control and Cables . . . . . . . . . . . . . . . . 9 Steering Helm and Cable . . . . . . . . . . . . . . . . . . 10 Sport Jet Hull Dimensions . . . . . . . . . . . . . . . . . 10 Installing Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hull Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Steering Cable Adjustment . . . . . . . . . . . . . . . . 14 Shift Cable Adjustment . . . . . . . . . . . . . . . . . . . . 15 Bilge Siphon Feature . . . . . . . . . . . . . . . . . . . . . . . . 18 Installing Bilge Siphon . . . . . . . . . . . . . . . . . . . . 18 Water By-Pass System . . . . . . . . . . . . . . . . . . . . . . . 18 Installing Powerhead . . . . . . . . . . . . . . . . . . . . . . . . 20 Throttle Cable Adjustment . . . . . . . . . . . . . . . . . 21 Battery Connection . . . . . . . . . . . . . . . . . . . . . . . 22 Oil Injection System . . . . . . . . . . . . . . . . . . . . . . 22 Check Oil Pump Adjustment . . . . . . . . . . . . . . . 23 Trim Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . 23 Pre-delivery Inspection . . . . . . . . . . . . . . . . . . . . . . . 24 Check Before Running . . . . . . . . . . . . . . . . . . . . 24 On the Water Test . . . . . . . . . . . . . . . . . . . . . . . . 24 Post Water Test . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SPORT JET INSTALLATION General Information Notice to Installer Throughout this publication, “Warnings” and “Cautions” (accompanied by the International Hazard Symbol ! ) are used to alert the installer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. –– Observe Them Carefully! These “Safety Alerts,” alone, cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “common sense” operation, are major accident prevention measures. WARNING Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. IMPORTANT: Indicates information or instructions that are necessary for proper in- stallation and/or operation. This installation manual has been written and published by the service department of Mercury Marine to aid installers when installing the products described herein. It is assumed that these personnel are familiar with the installation procedures of these products, or like or similar products manufactured and marketed by Mercury Marine. Also, that they have been trained in the recommended installation procedures of these products which includes 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 by which an installation might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses an installation procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the product’s safety will be endangered by the installation procedure selected. All information, illustrations, and specifications contained in this manual are based on the latest product information available at time of publication. As required, revisions to this manual will be sent to all OEM boat companies. INSTALLATION PRODUCTS Loctite “271” 92-823089--1 Quicksilver Anti-Corrosion Grease 92-78376A6 Liquid Neoprene 92-25711--2 Dielectric Grease 92-823506--1 Perfect Seal 92-34227--1 Page 6A-2 90-858804 AUGUST 1998 SPORT JET INSTALLATION 90-858804 AUGUST 1998 Page 6A-3 Torque Specifications NOTE: Tighten all fasteners, not listed, securely. Exhaust Bellows Clamps 50 lb. in. (5.6 N·m) Shift Cable Swivel Screws 50 lb. in. (5.6 N·m) Shift Cable Mounting Bracket Screws 50 lb. in. (5.6 N·m) 8 mm Fasteners(Powerhead to Pump) 20 lb. ft. (27 N·m) 10 mm Fasteners (Powerhead to Pump) 35 lb. ft. (47 N·m) Cooling Waterline Nut Snug with Wrench, Then Tighten One Addition Flat (60 degrees) Steering Cable Mounting Bracket Screws 200 lb. in. (23 N·m) Reverse Stop Screw 120 lb. in. (14 N·m) Forward Stop Screw 120 lb. in. (14 N·m) Ride Plate-to-Pump Screws 75 lb. in. (8.5 N·m) Drive Housing Cover to Drive Housing fasteners 35 lb. ft. (47 N·m) Serial Number Decal Location A serial number decal is located on the flywheel cover. OGXXXXXX IMPORTANT: The Pump Unit Serial Number sticker must be taken out of the envelope affixed to the pump unit and applied to the flywheel cover decal. The engine serial number and pump serial number are different and unique. The engine serial number is located aft of the flywheel cover. The pump unit serial number is stamped in a plug located above the shift cable hole on the port side of the pump housing. 19XX XX OGXXXXXX a b c d e a - Engine Serial Number b - Model Year c - Year Manufactured d - Certified Europe e - Pump Unit Serial Number SPORT JET INSTALLATION Corrosion Protection This power package is equipped with anodes to help protect it from galvanic corrosion under moderate conditions. See the Operator’s Manual for location of anodes. Installation Requirements IMPORTANT: The Sport Jet is considered an INBOARD engine. The boat it is installed in must meet industry standards (ABYC, NMMA, etc.), federal standards and Coast Guard regulations for INBOARD engine installations Battery/Battery Cables IMPORTANT: Boating industry standards (ABYC, NMMA, etc.), federal standards and Coast Guard regulations must be adhered to when installing battery. Be sure battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. IMPORTANT: Engine electrical system is negative (–) ground. It is recommended (required in some states) that battery be installed in an enclosed case. Refer to regulations for your area. 1. Select a battery that meets all of the following specifications: a. 12-volt marine type. b. 670 Marine Cranking Amps (MCA) or 520 Cold Cranking Amps (CCA). c. Reserve capacity rating of at least 100 minutes. 2. Select proper size positive (+) and negative (–) battery cables using chart. Battery should be located as close to engine as possible. IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder, as it may cause corrosion and a subsequent failure. Cable Length Cable Gauge Up to 3-1/2 ft. (1.1 m) 4 (25 mm2) 3-1/2 - 6 ft. (1.1-1.8 m) 2 (35 mm2) 6 - 7-1/2 ft. (1.8-2.3 m) 1 (50 mm2) 7-1/2 - 9-1/2 ft. (2.3-2.9 m) 0 (50 mm2) 9-1/2 - 12 ft. (2.9-3.7 m) 00 (70 mm2) 12 - 15 ft. (3.7-4.6 m) 000 (95 mm2) 15 - 19 ft. (4.6-5.8 m) 0000 (120 mm2) Boat Construction IMPORTANT: All applicable Coast Guard regulations for INBOARD engines must be complied with, when constructing engine compartment. Care must be exercised in the design and construction of the engine compartment. Seams must be located so that any rain water or splash, which may leak through the seams, is directed away from the engine and carburetor cover. Also, the passenger compartment drainage system should not be routed directly to the engine compartment. Water that runs on or is splashed in the carburetor cover may enter the engine and cause serious damage to internal engine parts. IMPORTANT: Mercury Marine will not honor any warranty claim for engine damage as a result of water entry. Page 6A-4 90-858804 AUGUST 1998 SPORT JET INSTALLATION Engine Compartment Ventilation Engine compartment must be designed to provide a sufficient volume of air for engine breathing and also must vent off any fumes in engine compartment in accordance with industry standards (ABYC, NMMA, etc.), federal standards and Coast Guard regulations for inboard engines. Pressure differential (outside engine compartment versus inside engine compartment) should not exceed 2 in. (51 mm) of water (measured with a manometer) at maximum air flow rate. Engine Compartment Specifications Model Engine Air Requirements at Wide Open Throttle Physical Engine Volume* 95 HP 230 ft.3/min. (0.109m3/sec.) 0.60 ft.3 (17 L) 120 HP 304 ft.3/min. (0.143 m3/sec.) 0.67 ft.3 (19 L) * Physical engine volume is used in flotation calculations and is representative of the amount of flotation the engine provides. For serviceability, it is recommended that an additional 6 inches minimum (152 mm) (per side) of clearance be allowed between powerhead and engine compartment walls. Exhaust System IMPORTANT: It is the responsibility of the boat manufacturer, or installing dealer, to properly locate the engine. Improper installation may allow water to enter the exhaust manifold and combustion chambers and severely damage the engine. Damage caused by water in the engine will not be covered by Mercury Marine Limited Warranty, unless this damage is the result of defective part(s). The engine must be properly located to ensure that water will not enter the engine through the exhaust system. Determine the correct engine height by taking measurements (a) and (b), with boat at rest in the water and maximum load aboard. Subtract (b) from (a) to find (c). If (c) is less than specified in chart, boat construction must be altered to properly lower waterline relative to exhaust elbow. a b c d a-From Waterline to Top of Transom b-From Highest Point on Exhaust Elbow to Top of Transom c-(a) minus (b) = (c) d-Waterline at Rest (at Maximum Load) Model c = (a) minus (b) 95/120 HP (c) must be 7.5 in. (330 mm) or more. 90-858804 AUGUST 1998 Page 6A-5 SPORT JET INSTALLATION Fuel Delivery System WARNING Boating standards (NMMA, ABYC, etc.), federal standards and U. S. Coast Guard regulations for INBOARD engines must be adhered to when installing fuel delivery system. Failure to comply could result in severe personal injury or death. CAUTION Remove plastic plug from fuel inlet fitting. Attach fuel line to fuel fitting with U.S. Coast Guard approved hose clamp. Inspect for fuel leaks. 1. Fuel tank should be mounted below carburetor(s) level (if possible) or gravity feed may cause carburetor fuel inlet needle(s) to unseat, and flooding may result. 2. Fuel pickup should be at least 1 in. (25 mm) from the bottom of the fuel tank to prevent picking up impurities. 3. Fuel lines used must be Coast Guard approved (USCG type A1), fittings and lines must not be smaller than 5/16 in. (8 mm) I.D. 4. On installations requiring long lines or numerous fittings, larger size lines should be used. 5. Fuel line should be installed free of stress and firmly secured to prevent vibration and/or chafing. 6. Sharp bends in fuel line should be avoided. 7. A flexible fuel line must be used to connect fuel line to engine fuel pump to absorb deflection when engine is running. 8. A primer bulb is not necessary with this application. If a primer bulb is used, it must be Coast Guard approved for inboard engine applications. 9. Mount the fuel primer pump in a suitable location in the boat. Follow the installation instructions which are provided with the fuel primer pump. a a-Fuel Primer Pump IMPORTANT: Fuel Primer Pump must be mounted within 12” of the powerhead per U.S. Coast Guard regulation. Page 6A-6 90-858804 AUGUST 1998 SPORT JET INSTALLATION Instrumentation CAUTION If a fused accessory panel is to be used, it is recommended that a separate circuit (properly fused) be used from the battery to the fuse panel with sufficient wire size to handle the intended current load. NOTE: The charging system on these engines is capable of producing 9 amps maximum charge at 3500 RPM (4.5 amps minimum at 1000 RPM). The electrical load of the boat should not exceed this capacity. If loads higher than the capacity of the charging system are anticipated, refer to “Quicksilver Accessory Guide” for a high output alternator. We recommend the use of Quicksilver Instrumentation and Wiring Harness(es). Refer to “Quicksilver Accessories Guide” for selection. If other than Quicksilver electrical accessories are to be used, it is good practice to use waterproof ignition components (ignition switch, lanyard stop switch, etc.). A typical jet boat of this nature will see water splashed on these components. Therefore, precautions must be taken to avoid ignition failure due to shorting out of ignition components. WARNING Sudden stopping of engine (shorting ignition components) while boat is underway will cause loss of steering control due to loss of thrust. This loss of steering control may cause property damage, personal injury or death. A warning horn must be incorporated in the wiring harness (see wiring diagram) to alert the user of an overheat or low oil condition. IMPORTANT: If a warning horn system is not installed by the boat manufacturer, Mercury Marine will not honor any warranty claims for engine damage as a result of overheating or lack of engine oil. Route instrumentation wiring harness back to engine, making sure that harness does not rub or get pinched. If an extension harness is required, be sure to secure connection proper- ly. Fasten harness(es) to boat at least every 18 in. (460 mm), using appropriate fasteners. 90-858804 AUGUST 1998 Page 6A-7 SPORT JET INSTALLATION Wiring Diagrams QUICKSILVER INSTRUMENTATION, TYPICAL INSTALLATION SHOWN Refer to gauge manufacturer’s instructions for specific connections. NOTE: When fastening bullet connectors use force to ensure a positive connection. NOTE: If gauge options are not used, tape back unused wiring harness leads. (Included With Gauge) Temperature Sender ia b c d e f g h i a-Temperature Gauge b-Key Switch c-Tachometer Gauge d-Emergency Stop Switch e-Tachometer Harness (P/N 84-86396A8) (Not Included with Key/Choke Harness Kit) f-Connect Wires Together with Screw and Hex Nut (2 places). Apply Quicksilver Liquid Neoprene to connections and slide rubber sleeve over each connection. g-To Neutral Start Safety Switch in Remote Control Box h-Speedometer Gauge i-Overheat/Low Oil Horn P T Liquid Neoprene (92-25711--2) Dielectric Grease (92-823506--1) Page 6A-8 90-858804 AUGUST 1998 SPORT JET INSTALLATION Impeller Selection IMPORTANT: Installed impeller must allow engine to run in its specified maximum wide- open-throttle RPM range. The jet drive comes equipped with a standard stainless steel impeller which allows the engine to operate in its specified operating range. If a different impeller is installed in place of the standard impeller, it is the responsibility of the installer to ensure engine RPM remains in specified range. Specified engine WOT RPM range is listed in “Operation and Maintenance Manual” attached to the engine. Remote Control and Cables To ensure proper shift and throttle operation, we recommend the use of the Sport Jet Re- mote Control (P/N 802755). This remote control has been qualified by Mercury Marine to be used with the Sport Jet and provides the following required features: • Start-in-gear protection • Neutral rpm limit at 2,000 rpm NOTE: This applies to dual lever remote controls as well as single lever remote controls • High strength mechanism to accommodate loads transmitted to the remote control • Shift cable travel of 3 inches 1/8 inch (76 mm 3 mm) • Ability to use 40 series shift cable If a remote control other than the Sport Jet Remote Control (P/N 802755) is used, the remote control must meet the above criteria as well as the design criteria outlined in the ABYC manual pertaining to Mini-Jet Boats (Standard P-23). SHIFT CABLE The shift cable to be used MUST MEET the following criteria: • 40-Series Cable • Allow for a minimum of 3 inches (76 mm) of travel. • A means of attaching and locking the cable to the wear ring. • Cable end at pump must allow for a clevis pin and cotter pin (all provided) to connect cable to the reverse gate. • Protected against water intrusion and/or corrosion as the cable end (at the pump) is submersed in water with the boat at rest. A cable bellows is provided with the cable (P/N 64-858342A_). Follow installation procedures for proper sealing of cable. The shift cable end (at the pump) is submersed in water. It should be sealed against water intrusion, protected against corrosion and be able to withstand the shift loads imparted on it by the reverse gate. Follow shift cable adjustment procedure for proper adjustment. THROTTLE CABLE The throttle cable must have one end compatible with the control box. The other end must have Mercury style connectors. Follow throttle cable adjustment procedures for proper adjustment. 90-858804 AUGUST 1998 Page 6A-9 1 1/16 +/– 1/16 3/4 +/– 1/167 1/16 +/– 1/16 16 1/4 +/– 1/16 14 5/16 +/– 1/16 2 9/16 +/– 1/16 12 1/8 +/– 1/16 3 13/16 +/– 1/16 3 5/8 +/– 1/16 Tunnel Dimensions (in inches) e c d c d b a-Location b & e -Size and Straightness c & d -Size and Straightness 1 1/16 +/– 1/16 3/4 +/– 1/167 1/16 +/– 1/16 16 1/4 +/– 1/16 14 5/16 +/– 1/16 2 9/16 +/– 1/16 12 1/8 +/– 1/16 3 13/16 +/– 1/16 3 5/8 +/– 1/16 Tunnel Dimensions (in inches) e c d c d b a-Location b & e -Size and Straightness c & d -Size and Straightness SPORT JET INSTALLATION Steering Helm and Cable STEERING HELM The steering helm must limit steering cable travel to 3.50 ± .10 inches (88.9 ± 2.5 mm). WARNING Failure to limit steering cable travel at the helm could pre-load the cable resulting in premature failure of a steering component causing loss of steering. This loss of steering could cause property damage, personal injury or death. STEERING CABLE The steering cable to be used MUST MEET the following criteria: • 60 Series Steering Cable • 60 Series bulkhead fitting at output end • Allow for a minimum of 3.75 inches (95.3 mm) of travel. • Cable end at pump must allow for a 5/16 in. threaded adaptor shouldered thru-bolt and lock nut to connect the cable to the steering arm. • A means of attaching and locking the cable to the steering cable bracket (provided). Sport Jet Hull Dimensions HULL OPENING CUT OUT The pump to powerhead opening in the hull is the most important factor to consider in a Sport Jet installation. There are three areas of concern: 1. Location (a) of the pump to powerhead hull cut out relative to the boat bottom for proper ride plate seal fit. 2. Dimensional control of the cutout - corner radii (b), straightness (c) and size (d) for proper grommet installation, and corner radii (e) for ride plate seal fit. 3. Flatness and thickness of the area around the hull cut out for proper grommet sealing (see drawing on next page). 14 11/16 +/– 1/16 a a a Page 6A-10 90-858804 AUGUST 1998 SPORT JET INSTALLATION METHODS OF CONTROLLING LOCATION AND SIZE If the tunnel area in the plug is correct, the boat bottom mold should repeat and reproduce the tunnel area which will aid the cut out process. A reference area for the cut out can be produced on the plug and bottom mold as a raised area or a cutting guide. Location pins (a) that would project into the internal hull area could simplify the cut out process. These location pin holes could allow the use of a 1-1/2 inch diameter hole saw to cut the four corner radii and use of a reciprocating saw or router template to connect the four holes. Section A-A 25-820663-250 25-820663-375 Mounting Flange Thickness Specifications 1 Inch Minimum Flange Width Recommended Flange Flatness: .030 Inch Maximum Between Reference Points AA 1/2 1/2 1/2 1/2 1 1/2 Inch Dia. Hole Saw GO NO GO Max. Size Min. Size 1/4” +0.050 –0.030 3/8” +0.050 –0.030 Use Grommet P/N: b a a a a 1/2” +0.070 –0.030 25-820663-500 a-Location Pins in Hull Mold b-Flange Flatness Specification c-Go – No Go Gauge for Thickness CHECKING MOUNTING FLANGE THICKNESS AND FLATNESS Use a flat plate that will contact the flange at the reference points (b) and a .030 in. feeler gauge to check flatness. Additional sanding and/or resin / filler may be required to maintain the flatness specification. A simple slotted go / no go gauge (c) will check the flange thickness. 90-858804 AUGUST 1998 Page 6A-11 SPORT JET INSTALLATION Installing Jet Pump Hull Cutout CAUTION The hull cutout dimensions are critical for proper sealing between Jet Pump and boat. Measure cutout thickness and overall dimensions before attempting a Jet Pump installation. 1. Install tunnel grommet (a) in cut-out of boat. Three different size grommets are available depending on cutout thickness. a ÀÀÀÀÀÀÀÀÀÀÀÀÀ Use Grommet P/N: 1/4” +0.050 25-820663-250 –0.030 +0.050 3/8” 25-820663-375 –0.030 1/2” +0.070 25-820663-500 –0.030 Cutout Thickness 2. Route steering cable through the port side hole in flange of pump housing. Install nut on cable before routing cable through wear ring. 3. Install tab washer and nut on cable after guiding through wear ring. Locate tab washer in tab hole. Coarse cable adjustment is made using these nuts. Do not tighten until after final steering adjustment is made. 54899 54900 a b c de a-Shift Cable b-Wear Ring c-Tab Hole d-Nut e-Tab Washer Page 6A-12 90-858804 AUGUST 1998 SPORT JET INSTALLATION 90-858804 AUGUST 1998 Page 6A-13 4. Route shift cable through the starboard side hole in flange of pump housing. IMPORTANT: Ensure that the shift lever in the control box is set for three (3) inches of travel. NOTE: It is easier to adjust the shift and steering cables before installing pump unit in boat. 5. Spray soapy water on tunnel grommet, both side foam exhaust seals, ride plate seal and sides of boat tunnel. d b c a a - Tunnel Grommet b - Boat Tunnel c - Foam Exhaust Seals (One Each Side) d - Ride Plate Seal NOTE: When installing pump in tunnel, be sure cables are below tunnel grommet flange on pump to prevent pinching of cables between pump and boat. 6. Install jet pump (a) by pushing unit through opening in tunnel grommet (b). Ride plate seal should fit snug in boat tunnel without any gaps along perimeter. 7. Install gasket and cover (d) on jet pump. Align holes in cover with locating pins in housing and secure with four (4) M10 x 1.5 nuts (c). b a d c a - Jet Pump c - Nuts b - Tunnel Grommet d - Cover NOTE: Before torquing fasteners, check side exhaust seals and ride plate seal for proper fit in tunnel. 8. Torque housing cover nuts (c) to 35 lb. ft. (47 N·m). SPORT JET INSTALLATION Page 6A-14 90-858804 AUGUST 1998 Steering Cable Adjustment 1. Slide bellows assembly over cable and thread on cable completely. Do Not tighten. 54456 2. Thread cable end adaptor (a) on steering cable 14 turns (to allow for adjustment). WARNING Cable end adaptor must be installed a minimum of nine (9) turns. Failure to install cable end adaptor on steering cable a minimum of nine (9) turns could result in loss of steering control of boat, personal injury, or death. 54902 b a a - Cable End Adaptor b - Steering Arm 3. Center rudder assembly on nozzle. 4. Center steering wheel by turning wheel lock to lock and positioning wheel midway between locks. 5. Adjust cable end adaptor until thru-hole in adaptor lines up with threaded hole in steering arm. This is the steering cable fine adjustment. Cable end adaptor MUST be installed on steering cable a minimum of nine (9) turns. 6. Attach steering cable to steering arm with bolt and locknut. Torque nut to 180 lb. in. (20.3 N·m). 54902 b a c d e a - Bellows Nut b - Forward Stop c - Bolt d - Lock Nut e - Cable Nuts SPORT JET INSTALLATION 90-858804 AUGUST 1998 Page 6A-15 7. Tighten cable nuts. 8. Check steering adjustment to ensure that the helm limits cable travel for maximum left and right turns. Correct if required. 9. Secure cable nut with tab washer. 10. Apply perfect seal (92-34227-1) to end threads and cable conduit end. 11. Turn bellows nut out and tighten against cable end adaptor. 54908 19 19 Perfect Seal (92-34227-1) a b a - Bellows Clamp b - Bellows Nut Tight Against Jam Nut 12. Turn rudder to port to compress bellows as much as possible. Pull bellows over cable conduit and secure with bellows clamp. 13. Seal the thru-hull fitting. a a - Thru-Hull Fitting Shift Cable Adjustment IMPORTANT: The shift cable MUST BE properly adjusted. The shift cable is adjusted so that the reverse gate is not pre-loaded against either the forward or reverse stop. Pre-load in either position may cause failure of the stop and/or premature wear of the shift cable or control box components. It may also cause stiffness of the throttle control. 1. Thread the cable barrel onto the shift cable. aa a - Cable Barrel 2. Use a degreaser and clean off all oil film from the area on the shift cable shown. SPORT JET INSTALLATION Page 6A-16 90-858804 AUGUST 1998 NOTE: Removing the oil film from the shift cable is necessary to prevent the bellows from sliding on the cable. 3. Apply Perfect Seal (92-34227-1) to cable conduit ahead of the threads. 4. Slide the bellows over the shift cable end. Position and install the bellows onto the cable conduit as shown. Fasten ends with clamp and sta-strap. 1 in. (25.4 mm) b d c a 19 Perfect Seal (92-34227-1) 19 a - Remove Oil Film From This Area b - Bellows c - Clamp d - Sta-Strap 5. Loosen the lock nuts and unfasten the top end of the shift cable retainer. NOTE: Locknuts do not have to be removed to open retainer. 6. Install shift cable end in slot of the reverse gate and secure with clevis pin, flat washer, and cotter pin. Bend over ends of cotter pin. a c d e b a - Shift Cable Retainer b - Plastic Barrel Holder c - Clevis Pin d - Flat Washer e - Cotter Pin WARNING The shift cable must be adjusted correctly so that the reverse gate does not interfere with water flow coming out of the rudder. If the reverse gate hangs down into the water flow, a vibration may be felt in the control box. If this occurs, reduce throttle immediately and readjust the cable. Improper adjustment may result in pump damage including loss of the reverse gate. Failure to properly adjust the shift cable could result in loss of neutral and reverse, property damage, personal injury or death. SPORT JET INSTALLATION 90-858804 AUGUST 1998 Page 6A-17 7. Adjust shift cable as follows: a. Position the control box into forward position. b. Position the bottom edge of the reverse gate 3/8 in. to 1/2 in. (9.5 - 12.7 mm) above the rudder. With the reverse gate at this position, adjust the cable barrel to fit into the barrel holder. c. After adjusting the shift cable, secure the cable barrel in place with the shift cable retainer. Fasten the retainer by tightening both locknuts. IMPORTANT: The shift cable retainer must be fastened with self locking nylon insert locknuts. These locknuts must never be replaced with common nuts (non locking) as they could vibrate off, freeing the shift cable to disengage. WARNING Disengagement of the shift cable can result in the boat suddenly shifting into reverse. This unexpected action could cause occupants to be thrown forward in the boat or to be ejected overboard. Serious injury or death could result. 3/8 in. – 1/2 in. (9.5 – 12.7 mm) b c a b a - Cable Barrel b - Locknuts c - Shift Cable Retainer 8. Check shift cable/reverse gate adjustment as follows: a. Shift the control box a few times from the forward position to reverse position. b. Return the control handle back to forward and check for the 3/8 to 1/2 in. clearance space between the reverse gate and rudder. If necessary, readjust the cable barrel. 9. Seal the thru-hull fitting to prevent any water leaks. a a - Steering Cable Thru-Hull Fitting SPORT JET INSTALLATION Bilge Siphon Feature The Sport Jet incorporates an automatic bilge siphoning feature. The bilge siphon is working whenever the engine is running above idle speeds. Maximum performance of the bilge si- phon is realized above 3,000 rpm. A hose is attached to the jet pump nozzle. The hose is routed to the engine compartment and placed in the bilge. Water exiting the nozzle creates a suction or vacuum in the hose creating the bilge siphon, drawing water out of the boat. Installing Bilge Siphon 1. Attach the hose supplied to the hose barb located at the center rear of the drive housing cover. 2. Attach the hoses to the transom with the hose clip supplied. 3. Position siphon break (a) a minimum of 8 in. (203 mm) above pump cover. 8 in. minimum (203 mm)a Water By-Pass System The water by-pass system is designed to improve powerhead cooling at idle speed. 1. Locate the water by-pass components (provided). a b c a-Thru-Hull Fitting b-Brass Nut c-Hose Clamp Page 6A-18 90-858804 AUGUST 1998 SPORT JET INSTALLATION 90-858804 AUGUST 1998 Page 6A-19 IMPORTANT: The thru-hull fitting must be correctly positioned in the boat transom as instructed in Step 3. 2. Cut the sta-strap and uncoil the water by-pass hose. 3. Select the mounting location for the thru-hull fitting as follows: A 2 in. (50 mm) Minimum Top View of Transom A Back View of Transom a a - Water By-Pass Hose • The thru-hull fitting must be mounted in either side of the transom within the zones marked A. • The thru-hull fitting must be located a Minimum of 2 in. (50 mm) above the water line when boat is at its maximum load. • The water by-pass hose must slope down towards the thru-hull fitting at a minimum rate of 1 in. (25 mm) drop per 12 inches (300 mm) of hose. • The thru-hull fitting should be positioned so the water spray will be pointed downward. 4. After the location has been selected for the thru-hull fitting, drill a 9/16 in. (14.3 mm) dia. hole. 5. Apply Marine Sealer to entire length of threads and under the head of the thru-hull fitting. Fasten the fitting into the transom with the brass nut (provided). 6. Connect the water by-pass hose to the thru-hull fitting with the hose clamp (provided). Make sure the hose slopes at a minimum rate of 1 in. (25 mm) drop per 12 inches (300 mm) of hose. d e b c a b a - Thru-Hull Fitting b - Brass Nut c - Marine Sealer d - Hose Clamp e - Water By-Pass Hose SPORT JET INSTALLATION Page 6A-20 90-858804 AUGUST 1998 Installing Powerhead 1. Remove exhaust bellows from exhaust elbow and install on drive housing cover. 2. Check that o-rings are in drive housing cover, and slinger is on drive shaft. 3. Lubricate drive shaft splines with anti-corrosion grease. Lubricate Exhaust Bellows with soapy water. 4. Lower powerhead on drive housing cover. Align exhaust boot with exhaust elbow, drive shaft splines with crank shaft splines, and powerhead mounting studs with adapter plate holes. 5. Torque clamp screws on exhaust bellows to 50 lb. in. (5.6 N·m). 6. Connect water line hose to fitting on drive housing cover. Snug nut with wrench then tighten nut one additional flat (60 degrees). e a b d a b c d a - Exhaust Bellows b - Drive Housing Cover c - O-Rings d - Slinger e - Waterline Hose Fitting 7. Secure powerhead to drive housing cover with four (4) M10 x1.5 (a) and four (4) M8 x 1.25 nuts. (b) Torque fasteners following the torque sequence given. Repeat torque sequence to ensure all fasteners retain their torque. 1 2 3 4 5 6 7 8 9 10 11 12 TOP VIEW FORWARD AFT b a b a a a a a a a b b a - M10 x 1.5 Nuts – 35 lb. ft. (47 N·m) b - M8 x 1.25 Nuts – 20 lb. ft. (27 N·m) SPORT JET INSTALLATION 8. Attach positive (a) and negative (c) battery cables to starter solenoid and engine ground respectively. WARNING U.S. Coast Guard regulation #33 CFR 183.445 requires that the “positive” battery cable connection at the starter solenoid terminal be protected by either a boot (“a” shown following), or protective shield. 9. Attach remote control harness plug (b) to engine harness plug. 10. Attach throttle cable to towershaft arm (a) with washer and cotter pin. d a b c a-Positive Battery Cable Boot b-Engine and Remote Harness Connection c-Negative Battery Cable d-Towershaft Arm Throttle Cable Adjustment 1. With towershaft in the idle position and remote control in neutral (with no throttle advance), rotate throttle cable barrel until it lines up with barrel retainer (a). Turn cable barrel an additional 1 to 2 turns to pre-load cable. Insert cable in retainer and close retainer cover. a a-Throttle Cable Retainer 90-858804 AUGUST 1998 Page 6A-21 SPORT JET INSTALLATION Page 6A-22 90-858804 AUGUST 1998 Battery Connection NOTE: Engine electrical system is negative (–) ground. 1. Connect engine positive (+) battery cable (usually red) to positive (+) battery terminal. 2. Connect engine negative (–) battery cable (usually black) to negative (–) battery terminal. 3. Make sure that all battery terminal connections are tight; then, spray terminals with a battery connection sealant to help retard corrosion. 4. Some states require that the positive battery terminal be properly insulated. Oil Injection System IMPORTANT: The oil injection system is setup and bled at the factory. Bleed only if air bubble are present in the oil line from the reservoir to the oil pump. 1. Cut the sta-straps that are temporarily holding the oil reservoir to the engine. 2. Uncoil the oil line. Select a mounting location in the boat for the oil reservoir that is in reach of the oil hose and where the bottom on the reservoir is higher than the oil pump. Mount the oil reservoir. aa b a - Oil Reservoir b - Bottom of Reservoir Must Be Higher Than the Oil Pump IMPORTANT: Oil Reservoir must be mounted higher than the oil pump. Oil is gravity fed to the oil pump. 3. Follow the oil line from the reservoir to the oil pump. There should be no air in the line. If air is present, loosen bleed screw (c) and bleed air out until oil is present. Tighten bleed screw. a b a b c a - Oil Inlet Hose b - Oil Outlet Hose c - Bleed Screw SPORT JET INSTALLATION 90-858804 AUGUST 1998 Page 6A-23 Check Oil Pump Adjustment IMPORTANT: The oil injection system is setup and bled at the factory. 1. Move towershaft to the Wide Open Throttle position. Inspect oil pump alignment mark with the oil pump lever. If necessary, adjust oil pump link rod to align with the last mark. a b b a - Oil Pump Lever b - Alignment Mark (At Wide Open Throttle) Trim Plate Adjustment The Sport Jet trim plate is factory set for general applications. Should a particular boat experience porpoising problems, the trim plate can be adjusted as follows: 1. Loosen both jam nuts on trim plate (one starboard and one port). a a - Jam Nut w/Washer (Two: One On Each Side) 2. Turn both screws the exact same number of turns. Tighten both jam nuts against 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 (steering). Overly sensitive steering or reduced turning ability could result from trim plate adjustments. Boat handling characteristics also vary with the load distribution in the boat. Use caution after adjusting: check for acceptable handling characteristics under all loading conditions. Failure to adequately test the boat could result in inadequate steering control resulting in property damage, personal injury or death. SPORT JET INSTALLATION Pre-delivery Inspection Not Check/ Applicable Adjust Check Before Running . Water hose connection/torqued . Cover plate & adaptor plate fasteners torqued . Battery charged & secure . All electrical connections tight . Exhaust hose clamps tight . All fuel connections tight . Throttle, shift, & steering adjusted correctly and fasteners torqued . Carb throttle shutters open & close completely . Pump housing oil level full (See Owner’s Manual) . Oil injection reservoir full and bled . Warning system(s) operational On the Water Test . Starter neutral safety switch operational . Lanyard stop switch operational . All gauges read properly . No fuel or oil leaks . No water leaks . No exhaust leaks . Ignition timing set to specs . Idle:____________RPM . Idle mixture adjusted . Forward-Neutral-Reverse operational . Steering operational throughout entire range . Acceleration test . WOT:___________RPM . Boat handling Post Water Test . No fuel, oil, water or exhaust leaks . Re-torque adapter plate fasteners Page 6A-24 90-858804 AUGUST 1998