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MODELS 1995 90/120 Sport Jet United States With Starting Serial Numbers Powerhead Pump Unit 90 HP 0E095088 0E080400 120 HP 0E093700 0E080400 1996 & 1997 95XR/120XR Sport Jet This Manual Supercedes 90-831996 95XR HP 0E141089 0E145580 120XR HP 0E141089 0E145580 1995 1996 1997 95XR HP 0E203000 0E151580 120XR HP 0E203000 0E151580 MODELS 1995 90/120 Sport Jet United States With Starting Serial Numbers Powerhead Pump Unit 90 HP 0E095088 0E080400 120 HP 0E093700 0E080400 1996 & 1997 95XR/120XR Sport Jet This Manual Supercedes 90-831996 95XR HP 0E141089 0E145580 120XR HP 0E141089 0E145580 1995 1996 1997 95XR HP 0E203000 0E151580 120XR HP 0E203000 0E151580 Printed in U.S.A. W1996, Mercury Marine 90-831996R1 JUNE 1996 Cleanliness and Care of Sport Jet 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. Before raising or removing an engine from a boat, the following precautions should be adhered to: 1. Check that flywheel is secured to end of crankshaft with a locknut and lifting eye is threaded into flywheel a minimum of 5 turns. 2. Connect a hoist of suitable strength to the lifting eye. In addition, personnel should not work on or under an engine which is suspended. Engine 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. Service Manual Outline Section 1 -General Information and Specifications Section 2 -Electrical and Ignition Part A -Ignition System Part B -CDM Ignition System Part C -Battery, Charging and Starting System Part D -Timing/Synchronizing/ Adjusting Section 3 -Fuel System and Carburetion Part A -Carburetor Part B -Fuel Pump Recirculation System Reed Valve Assembly Auto Enrichener Part C -Oil Injection System Section 4 -Powerhead Section 5 -Jet Pump Section 6 -Sport Jet Installation 90-831996R1 JUNE 1996 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 injury 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 product’s 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. 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 reuse, care should be taken to select a replacement that matches the original. 90-831996R1 JUNE 1996 GENERAL INFORMATION AND SPECIFICATIONS 1 Table Of Contents Page HowTo Use This Manual . . . . . . . . . . . . . . . 1-1 Page Numbering . . . . . . . . . . . . . . . . . . . . . . . 1-1 Master Specifications . . . . . . . . . . . . . . . . . . . 1-2 Flushing Cooling System . . . . . . . . . . . . . . 1-11 Following Complete Submersion . . . . . . . . 1-11 Salt Water Submersion (Special Instructions) . . . . . . . . . . . . . . . 1-11 Submerged While Running (Special Instructions) . . . . . . . . . . . . . . . 1-11 Page Submerged Engine (Fresh Water) Plus Special Instructions. . . . . . . . . . . . 1-11 Out-of-Season Storage . . . . . . . . . . . . . . . . 1-12 Out-of-Season Battery Storage . . . . . . . . . 1-13 Detonation: Causes and Prevention . . . . . 1-13 Compression Check . . . . . . . . . . . . . . . . . . . 1-14 Water Pressure Check . . . . . . . . . . . . . . . . . 1-14 90-831996R1 JUNE 1996 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 Page Numbering Two number groups appear at the bottom of each page. The example below is self-explanatory. 90-826148R1 MAY 1994 4A-7 Revision No. 1 Month of Printing Year of Printing Section Description Section Number Part of Section Letter Page Number EXAMPLE: POWER HEAD 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 Page Numbering Two number groups appear at the bottom of each page. The example below is self-explanatory. 90-826148R1 MAY 1994 4A-7 Revision No. 1 Month of Printing Year of Printing Section Description Section Number Part of Section Letter Page Number EXAMPLE: POWER HEAD 90-831996R1 JUNE 1996 GENERAL INFORMATION 1-1 Master Specifications 1995 Sport Jet 90 120 HORSEPOWER (KW) Model 90/120 90 (67.1) 120 (89.5) PH / PUMP WEIGHT 184 lbs. / 101 lbs. (83.46 kg / 45.8 kg) 203 lbs. / 101 lbs. (92.08 kg / 45.8 kg) CYLINDER BLOCK Type Displacement 3 Cylinder In-Line 75.1 cu. in. (1231 cc) 4 Cylinder In-Line 102.9 cu. in. (1687 cc) STROKE Length 2.80 in. (71.1 mm) 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 3.375 in. (85.7 mm) 0.0015 Cast Iron PISTON Piston Type Standard 0.010 in. (0.254 mm) Oversize 0.030 in. (0.762 mm) Oversize Aluminum Major Dia.- 3.3618 (85.34) Min.- 3.3578 (85.288) Major Dia.- 3.3718 (85.64) Min.- 3.3678 (85.54) Major Dia.- 3.3918 (86.15) Min.- 3.3878 (86.050) REEDS Reed Stand Open (Max.) 0.010 (0.254 mm) PUMP HOUSING Gear Ratio Drive Housing Capacity Stator Capacity Impeller Shaft Gear- No. of Teeth Pinion Gear - No. of Teeth Pinion Height Gear Backlash 1.14:1 18.6 fl. oz. (550 ml) 3.4 fl. oz. (100 ml) 24 21 0.025 in. (0.64 mm) 0.007 - 0.009 in. (0.177 mm - 0.228 mm) 1:1 18.6 fl. oz. (550 ml) 3.4 fl. oz. (100 ml) 24 24 0.025 in. (0.64 mm) 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 SYSTEM Electric Start- Starter Draw Under Load No Load Battery Rating (minimum) 110 - 200 Amperes 80 - 165 Amperes 670 Marine Cranking Amps (MCA) or 520 Cold Cranking Amps (CCA) IGNITION SYSTEM Type Spark Plug Type Spark Plug Gap Optional (Resistor Plug) Capacitor discharge Champion L76V Not Adjustable QL76V CHARGING SYSTEM Alternator Output (Regulated) 9 Amp 1-2 GENERAL INFORMATION 90-831996R1 JUNE 1996 Master Specifications (Continued) 1995 Sport Jet 90/120 CARBURETOR Idle RPM Wide Open Throttle (WOT) RPM – Model 90/120 Idle Mixture Screw Adjustment (Preset - Turns Out) Model 90/120 – All Carbs Float Setting Main Jet – Model 90 – Carb #1 – Carb #2 – Carb #3 – Model 120 – Carb #1 – Carb #2 950 - 1100 RPM 4700 - 5300 1 1/2 turns out from a lightly seated position Set parallel to body flange .072 .072 .074 .090 .092 Maximum BTDC @ Cranking Speed – Model 90/120 @ 5000 RPM 32° BTDC TIMING – Model 90/120 Firing Order 30° BTDC – Model 90 1-2-3 – Model 120 1-3-2-4 90-831996R1 JUNE 1996 GENERAL INFORMATION 1-3 Master Specifications (Continued) 1996 & 1997 Sport Jet 95 120 HORSEPOWER (KW) Model 95/120 95 (67.1) 120 (89.5) PH / PUMP WEIGHT 184 lbs. / 101 lbs. (83.46 kg / 45.8 kg) 203 lbs. / 101 lbs. (92.08 kg / 45.8 kg) CYLINDER BLOCK Type Displacement 3 Cylinder In-Line 75.1 cu. in. (1231 cc) 4 Cylinder In-Line 102.9 cu. in. (1687 cc) STROKE Length 2.80 in. (71.1 mm) 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 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) PUMP HOUSING Gear Ratio Drive Housing Capacity Stator Capacity Impeller Shaft Gear- No. of Teeth Pinion Gear - No. of Teeth Pinion Height Gear Backlash 1.14:1 18.6 fl. oz. (550 ml) 3.4 fl. oz. (100 ml) 24 21 0.025 in. (0.64 mm) 0.007 - 0.009 in. (0.177 mm - 0.228 mm) 1:1 18.6 fl. oz. (550 ml) 3.4 fl. oz. (100 ml) 24 24 0.025 in. (0.64 mm) 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 SYSTEM Electric Start- Starter Draw Under Load No Load Battery Rating (minimum) 110 - 200 Amperes 80 - 165 Amperes 670 Marine Cranking Amps (MCA) or 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 1-4 GENERAL INFORMATION 90-831996R1 JUNE 1996 Master Specifications (Continued) 1996 & 1997 Sport Jet 95/120 Idle RPM 950 - 1100 RPM Wide Open Throttle (WOT) RPM – Model 95/120 4700 - 5300 Idle Mixture Screw Adjustment (Preset - Turns Out) Model 95/120 – All Carbs 1 1/2 turn out from a lightly seated position Float Setting Set parallel to body flange CARBURETOR Main Jet – Model 95 – Carb #1 .072 – Carb #2 .072 – Carb #3 .074 – Model 120 – Carb #1 .090 – Carb #2 .092 Maximum BTDC @ Cranking Speed – Model 95/120 32° BTDC @ 5000 RPM TIMING – Model 95/120 30° BTDC Firing Order – Model 95 1-2-3 – Model 120 1-3-2-4 90-831996R1 JUNE 1996 GENERAL INFORMATION 1-5 90/120 Sport Jet Bottom Guided Rod Design 1-6 GENERAL INFORMATION 90-831996R1 JUNE 1996 90/120 Sport Jet (Continued) Bottom Guided Rod Design (3-Cylinder Shown) 90-831996R1 JUNE 1996 GENERAL INFORMATION 1-7 95XR/120XR Sport Jet Top Guided Rod Design 4.500 1.4991 0.9568 0.9573 1.4986 0.15 in. (3.81 mm) Measured 90 to piston pin center line 3.3700 .0005 .005 2.910  .020 .77003 .76993 95XR/120XR Sport Jet Top Guided Rod Design 4.500 1.4991 0.9568 0.9573 1.4986 0.15 in. (3.81 mm) Measured 90 to piston pin center line 3.3700 .0005 .005 2.910  .020 .77003 .76993 1-8 GENERAL INFORMATION 90-831996R1 JUNE 1996 95XR/120XR Sport Jet (Continued) Top Guided Rod Design (4-Cylinder Shown) 1.3793 1.1813 1.3748 1.2495 1.3789 1.3752 1.2500 1.1818 CRANKSHAFT 90-831996R1 JUNE 1996 GENERAL INFORMATION 1-9 Special Items Torque Impeller Gear Nut 90 lb. ft. (122 N·m) Pinion Gear Nut 90 lb. ft. (122 N·m) Drive Housing Cover Bolts 30 lb. ft. (40.7 N·m) Stator Bolts 30 lb. ft. (40.7 N·m) Nozzle to Stator Bolts 30 lb. ft. (40.7 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 90o 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 90o Transfer Port Cover 80 lb. in. (9.03 N·m) Exhaust Manifold 80 lb. in. (9.03 N·m) Torque Chart Standard Hardware Metric 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) 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 1-10 GENERAL INFORMATION 90-831996R1 JUNE 1996 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. Reinstall water inlet hose. 4. Flush outer surfaces of water outlet nozzle with water stream. 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. 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. 90-831996R1 JUNE 1996 GENERAL INFORMATION 1-11 1-12 GENERAL INFORMATION 90-831996R1 JUNE 1996 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. 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). Never start or run the Sport Jet (even momentarily) out of the water. Damage to the pump and engine will occur. CAUTION 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. 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. 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-perhour (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. 90-831996R1 JUNE 1996 GENERAL INFORMATION 1-13 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 5–7 psi (34–48 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. 1-14 GENERAL INFORMATION 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2 A IGNITION SYSTEM Table Of Contents Page Special Tools Required . . . . . . . . . . . . . . . . . . . 2A-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Principles of Operation . . . . . . . . . . . . . . . . . . . . 2A-1 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Testing For Spark . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Testing Primary Input Voltage . . . . . . . . . . . . . . 2A-2 Test Switch Box “Stop” Circuit. . . . . . . . . . . . . . 2A-3 Testing Stator Output . . . . . . . . . . . . . . . . . . . . . 2A-3 Testing Stator Resistance . . . . . . . . . . . . . . . . . 2A-3 Testing Switch Box Bias Circuit90 HP Only . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Testing Trigger Resistance . . . . . . . . . . . . . . . . 2A-4 Testing Ignition Coils . . . . . . . . . . . . . . . . . . . . . . 2A-5 Erratic/Misfire or No Fire Condition . . . . . . . . . 2A-6 Page Removing Flywheel . . . . . . . . . . . . . . . . . . . . . . 2A-7 Installing Flywheel . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 Removing Stator . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 Installing Stator . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 Removing Trigger . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 Installing Trigger . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9 Removing Switch Box . . . . . . . . . . . . . . . . . . . . 2A-9 Installing Switch Box . . . . . . . . . . . . . . . . . . . . . . 2A-9 Removing Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10 Installing Coils . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10 Ignition Diagram 90 HP Sport Jet . . . . . . . . . . 2A-11 Ignition Wiring Diagram 120 Sport Jet . . . . . . . . . . . . . . . . . . . . . . . . 2A-12 90-831996R1 JUNE 1996 Special Tools Required Multimeter/ DVA Tester 91-99750 Spark Tester 91-850439 55117 General The ignition system used on the Sport Jet engines 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 The ignition system is alternator driven with distributorless capacitor discharge. Major components of the ignition system are the flywheel, stator, trigger, switch box, ignition coils and spark plugs. The stator assembly is mounted stationary below the flywheel and has two capacitor charging coils. The flywheel is fitted with permanent magnets inside the outer rim. As the flywheel rotates the permanent magnets pass the capacitor charging coils. This causes the capacitor charging coils to produce AC voltage. The AC voltage then is conducted to the switch box where it is rectified and stored in a capacitor. The trigger assembly (also mounted under the flywheel) has 2 coils. The flywheel likewise 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 switch box. The 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. Test Procedures WARNING When testing or servicing the ignition system high voltage is present. Be extremely cautious! DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running, while key switch is on, or while battery cables are connected. 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. • DO NOT crank engine when switch box is not grounded to engine. The switch box cannot be thoroughly checked with conventional test equipment. If a Multimeter/DVA Tester is not used systematically check the switch box. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2A-1 All other components can be tested with an ohmmeter. Before troubleshooting the ignition system: • Make sure the electrical harness and ignition switch are not the source of the problem. • Check that plug-in connectors are fully engaged and terminals are free of corrosion. • Make sure that wire connections are tight and free of corrosion. • Check that all electrical components and separate ground wires are grounded directly to engine. • 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. Engine must be able to crank at 600 RPM minimum for the following tests. 6. Crank motor. Results: Action Required: Spark jumps 7/16 in. gap (all cylinders) Ignition system is operational, check timing sequence if required No spark Go to next step 7. Check all grounds and wire connections. Repair as needed. 8. Recheck spark output. Check that safety stop switch lanyard is in place. If safety lanyard is NOT in place, spark plugs will not fire. 9. Isolate the stop circuit by disconnecting black/ yellow bullet connector from the switch box. IMPORTANT: Be sure this lead is not grounded. 10. Crank motor. Results: Action Required: All cylinders spark normally Repair stop circuit:ignition key switch and/or boat wiring. No spark Go to next step Testing Primary Input Voltage 1. Prepare multimeter. • Plug meter leads in as shown. • Set dial to 400 DVA scale. 2. Connect red meter lead to #1 coil (+) terminal. 3. Connect black meter lead to #1 coil (–) terminal. 4. Crank motor and observe meter. 5. Repeat test for each coil. IMPORTANT: DO NOT use a common ground. Connect black meter lead to the ground of coil being tested. Results: Action Required: 150 - 250 volts Go to Testing Coils Less than 150 volts Go to Next Step 2A-2 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 Test Switch Box “Stop” Circuit. 1. Prepare multimeter as shown. RED METER LEAD • Disconnect black/yellow lead form switch box. • Attach red meter lead to black/yellow lead from switch box. • Attach black meter lead to ground. 2. Crank motor and observe meter. Results: Action Required: 200-360 volts Go to Testing Trigger. If checks O.K., replace switch box. Less than 200 volts Go to next step Testing Stator Output IMPORTANT: All leads must remain connected to the switch box for the following DVA tests. 1. Stator low speed input to switch box. • Connect red meter lead to blue lead from stator. • Connect black meter lead to a good engine ground. • Set meter to 400 DVA scale. 2. Crank motor while reading meter. 90 and 120 HP Results: Action Required: 200-300 volts Low speed stator is O.K.: Go to Testing Trigger Less than 200 volts or intermittent Go to next step. If stator tests O.K., replace switch box. 3. Stator high-speed input to switch box. • Connect red meter lead to red stator lead. • Connect black meter lead to a good ground. • Set meter to 400 DVA scale. 4. Crank motor while reading meter. 90 and 120 HP Results: Action Required: 20-90 volts High speed stator is O.K.: Go to Testing Trigger. Less than 20 volts or intermittent Go to next step Testing Stator Resistance 1. Prepare multimeter (Special Tool No. 91-99750). Plug in meter leads as shown. Set dial to X1K ohm position. Calibrate meter. 2. Low speed resistance test. NOTE: This test is not polarity sensitive. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2A-3 90 HP: • Disconnect blue and red stator leads from switch box. • Connect meter leads between blue and red stator leads. Results: Action Required: 3600 - 4200* ohms Go to next test Above or below Replace stator 3600 - 4200 ohms *Copper is an excellent conductor, but resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. 120 HP: • Disconnect blue and blue/white stator leads from switch box. • Connect meter leads between blue and blue/ white stator leads. 3. Observe meter reading. Results: Action Required: 6800 - 7600* ohms Go to next test Above or below Replace stator 6800 - 7600 ohms *Copper is an excellent conductor, but resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. 4. High speed resistance test. • Set meter scale to X1 ohm. 90 HP: • Disconnect red stator lead from switch box. • Connect meter leads between red and engine ground (if stator has been removed from engine connect meter leads between red stator lead and stator ground). 120 HP: • Disconnect red and red/white stator leads from switch box. • Connect meter between red stator lead and red/ white stator leads. 5. Observe meter reading. Testing Switch Box Bias Circuit90 HP Only 1. Prepare multimeter as shown. BLACK 20 DCV METER SCALE LEAD NOTE: White/black lead must remain connected to switch box for this test. • Attach Black meter lead to white/black lead from switch box. • Attach Red meter lead to ground. 2. Crank motor and observe meter reading. RED METER LEAD Results: Action Required: 2 - 10 volts Go to testing Trigger. If trigger tests O.K. replace switch box. Below 2 volts Replace switch box. Testing Trigger Resistance 1. Prepare multimeter. • Plug meter leads in as shown. • Set dial to x100 ohm. • Calibrate meter. Results: Action Required: 90 - 140 ohms Stator O.K., continue electrical testing Above or below 90 - 140 ohms Replace stator 2A-4 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 2. Disconnect trigger leads. Test resistance between trigger leads as shown in the following chart. This test is not polarity sensitive. 90 HP Meter Leads Meter Reading Between Brown and White/Black 1100 1400 Oh 1100 - 1400 Ohms Between White and White/Black Between Violet and White/Black 120 HP Meter Leads Meter Reading Between Violet and White 700 1000 Oh 700 - 1000 OhmsBetween Brown and White/Black *Copper is an excellent conductor, but resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. 3. Replace trigger as necessary. Testing Ignition Coils 1. Check primary resistance. • Prepare multimeter as shown. • Set dial to X1 scale. • Calibrate meter • Disconnect coil input leads. 2. Connect meter leads. • Red meter lead to #1 coil (+) terminal. • Black meter lead to #1 coil (–) terminal. This test is not polarity sensitive. 3. Observe meter. Results: Action Required: .02 - .04* ohms Go to next step Above or below .02 - .04 ohms Replace coil *The primary DC resistance of these coils generally is less than one ohm. If a reading resembling a short is obtained, this would be acceptable. 4. Repeat test for each coil. 5. Check secondary resistance. • Remove spark plug wire from coil tower. • Set dial to X100 scale. • Calibrate meter. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2A-5 • Connect meter leads between coil tower and coil Erratic/Misfire or No Fire positive (+) terminal. Condition Occasionally a problem may occur that will not show when testing at cranking speed. Some tests can be performed with the engine running at the particular RPM when the problem occurs. “Running” tests use the same procedures as “cranking” tests. Refer to the chart following for running test readings. • Observe meter reading. Results: Action Required: 800 - 1100* Go to next section Above or below 800 Replace coil 1100 ohms *Copper is an excellent conductor, but resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. Test Selector DVA Leads Voltage Reading Voltage Reading Position Red Black @ 300-1000 RPM(1) @ 1000-4000 RPM Coil Coil (+) Coil (–) Primary 400VDC* Terminal Terminal 150-250 180-280 Sw. Box Black/Yellow Stop circuit 400VDC* Sw. Box Connector Ground 200-360 200-360 Stator Blue Sw. Low Speed 400VDC* Box Connector Ground 200-300 200-330 Stator Red Sw. High Speed 400VDC* Box Connector Ground 20-90 130-300 *If using a meter with a built-in DVA, place selector in the DVA/400 VDC position. (1)Readings at cranking speed and/or idle speed. 2A-6 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 Removing Flywheel WARNING Always disconnect battery and remove spark plug leads from spark plugs before working on motor. 1. Remove flywheel nut. Use a suitable flywheel holder to keep flywheel from turning. 2. Install puller (Special Tool No. FT-8948-1). Perform the following step while holding the puller bar. This will prevent the puller plate from turning. 3. Turn pressure screw until it is tight against the crankshaft. a a -Pressure Screw a 5. Remove flywheel from crankshaft. CAUTION Do not strike the screw too hard. This may damage the crankshaft and bearings. 4. Strike top of pressure screw (a) with hammer. 6. Remove puller form flywheel. 7. Remove flywheel key. a a -Flywheel Key 8. 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2A-7 • Check for loose magnet or damaged timing magnet laminations. Arc burns on timing magnet laminations 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. 2. Install flywheel key in crankshaft slot with outer edge of key parallel to center line of crankshaft. a 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 switch box leads. Removal of switch box mounting bracket may be necessary to gain access to stator leads. 4. Remove screws and lift stator off bearing cage. a a a -Stator Screws 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 rectifier/regulator leads. 3. Connect all stator leads to corresponding switch box leads. 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 all trigger leads from switch box leads. 4. Disconnect spark control link from tower shaft. 5. Lift trigger off bearing cage. b a a -Trigger b -Spark Control Link 2A-8 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 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 harness guard and down to switch box. 6. Connect corresponding trigger leads to switch box leads: 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. Removing Switch Box WARNING Always disconnect battery and disconnect spark plug leads from spark plugs before working on motor. 1. Remove three screws and clamp. 2. Remove switch box from bracket. 3. Remove lead wires from switch box. a b a -90 HP Switch Box b -120 HP Switch Box Installing Switch Box 1. Position switch box on bracket. 2. Install screws and clamp. The clamp is attached with the lower forward mounting screw. 3. Attach lead wires. Switch box leads are identified by color. Stator Leads Red, Blue, Red/White, Blue/White Coil Leads Green, Green/White, Green/Red, Green/Black Stop Lead Black/Yellow Trigger Leads Brown, Violet, White, White/ Black 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2A-9 Removing Coils WARNING Always disconnect battery and disconnect spark plug leads from spark plugs before working on motor. 1. Remove screws holding coil cover. a a -Screw 2. Remove coil/cover assembly from bracket. 3. Remove coil input wire (+) and ground wire (–) from coil. 4. Slide coil out of cover. NOTE: Coils are serviced individually. Installing Coils 1. Attach wires to coil: • #1 Green • #2 Green/White • #3 Green/Red • #4 Green/Black (120 HP) Positive (+) terminal is down. 2. Position coil/cover assembly on bracket. NOTE: 90 HP shown a b c a -#1 Green Terminal b -#2 Green/White Terminal c -#3 Green/Red Terminal 3. Slide coil into cover. 4. Position coil/cover assembly on bracket. 5. Install cover screws, tighten all fasteners. 2A-10 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 LowOil Switch TemperatureSwitchAuto Enrichner Ignition Diagram 90 HP Sport Jet LowOil Switch TemperatureSwitchAuto Enrichner Ignition Diagram 90 HP Sport Jet 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2A-11 LowOil Switch TemperatureSwitchAuto Enrichner Ignition Wiring Diagram 120 Sport Jet LowOil Switch TemperatureSwitchAuto Enrichner Ignition Wiring Diagram 120 Sport Jet 2A-12 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2 B CDM IGNITION Table Of Contents Page Special Tools Required . . . . . . . . . . . . . . . . . . . 2B-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Principles of Operation . . . . . . . . . . . . . . . . . . . . 2B-1 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Testing For Spark . . . . . . . . . . . . . . . . . . . . . 2B-2 Ignition Diagnostic Procedures . . . . . . . . . . . . . 2B-3 Testing Voltage Output to CDM . . . . . . . . . 2B-3 Testing Stator Resistance - 95/120 HP . . . 2B-5 Trigger - 95/120 . . . . . . . . . . . . . . . . . . . 2B-5 Capacitor discharge Module . . . . . . . . 2B-6 Ignition Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 2B-7 Page Removing Flywheel . . . . . . . . . . . . . . . . . . . . . . 2B-8 Installing Flywheel . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Removing Stator . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Installing Stator . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Removing Trigger . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Installing Trigger . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Removing CDM . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Installing CDM . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Wiring Diagram 95 HP . . . . . . . . . . . . . . . . . . . 2B-12 Wiring Diagram 120 HP . . . . . . . . . . . . . . . . . . 2B-13 90-831996R1 JUNE 1996 Special Tools Required Multimeter/ DVA Tester 91-99750 Spark Tester 91-850439 55117 Ignition Test Harness 84-825207A2 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. 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: 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-1 • 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. No spark Go to next step. No spark on 1 or 2 cylin- ders Go to Ignition Diagnos- tic 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. Results: Action Required: Spark jumps 7/16” gap (all cylinders) Ignition system operational - If required, check timing & setup. 2B-2 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 10. Check that safety stop switch lanyard is in place. If safety lanyard is NOT in place, spark plugs will not fire. 11. Sport Jet Models Only: 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. 95 HP IMPORTANT: The voltage return path for #1 CDM is through either #2 or #3 CDM. The return path for #2 and #3 is through #1 CDM. If the #1 CDM is disconnected the engine will loose fire on all cylinders as the capacitors cannot be charged. #1 #2#3 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. 120 HP 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 dam age, 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-3 1. Make sure all CDMs are plugged in. 2. Test Stator and Trigger voltage to CDM: a. Install test harness between Ignition Harness and CDM. Trigger Output Test 2 DVA Scale Positive Meter Lead (+) Negative Meter Lead (–) DVA Reading White Test Har- ness Lead Black Test Har- ness Lead 0.2 - 2.0 ba c a -Stator/Trigger Harness b -Test Harness c -Capacitor Discharge Module 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. b. Perform the following tests: CRANKING ENGINE: Test each CDM. WHT BLK ENGINE RUNNING AT IDLE: If only one CDM stator reading is below specifications, It is not necessary to perform this test if the voltage out- replace that CDM. If all CDM stator voltage readings put was tested in the previous step CRANKING EN- are low, go to Testing Stator Resistance. GINE. 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 GRNBLK 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 trig- Test each CDM. ger, replaced CDM. 2B-4 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 Testing Stator Resistance - 95/120 HP Disconnect stator leads. Stator Resistance Test Rx10Ohms R 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 - 95/120 A resistance test is not used on the trigger. Test trigger as outlined under “Testing Voltage Output to CDM”. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-5 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 fol- lows: 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. 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 fol- lows: 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. 2B-6 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 Ignition Components Removal and Installation a b B 1 2 3 4 6 1 -Cap, Plastic 2 -Flywheel Nut 3 -Washer 4 -Flywheel 5 -Stator 6 -Trigger 7 -Screw 7 WARNING Engine could possibly start when turning flywheel during removal and installation; therefore, dis- connect (and isolate) spark plug leads from spark plugs to prevent engine from starting. Quicksilver Lubrication/Sealant Torque Specifications Application Points B b a 125 lb. ft. (170 N·m) Loctite “271” (92-823089--1) 50 lb. in. (5.6 N·m) 5 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-7 1 3 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 6 2 4 5 7 2B-8 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 Ignition Components Removal and Installation (4 - Cylinder Shown) 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. • 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 flywheelto aid in removal as damage to flywheel or electrical components under flywheel may result. Remove flywheel. Remove flywheel key. a 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) 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-9 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. 2. Install flywheel key in crankshaft slot with outer edge of key parallel to center line of crankshaft. a 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 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. 2B-10 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 5. Lift trigger off bearing cage. b a a -Trigger b -Spark Control Link 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. Removing CDM (Capacitor Discharge Module) WARNING Always disconnect battery and disconnect spark plug leads from spark plugs before 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-11 2B-12 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 123 4 5 6 7 8 BLK GRY YEL/RED RED/PUR BLK/YEL PUR GRN/WHTWHT/GRNYEL BRN BLK/YEL YEL YEL GRY BLK/YEL YEL YEL GRY GRN/WHTWHT/GRNBRN RED/PURREDBLK BLKYEL/REDREDRED BLK WHTWHT GRN/WHT PUR RED RED BLKBLK WHT/GRNPURBLKBLK/YEL PURPUR BLK/YEL GRN/WHTWHTBLK/YELBLK GRN/WHTBRNBLK/YELBLK TAN/LT.BLUTAN/GRN BLKBLK/YELBRN PUR BRNBRNBRN BLK/YELBLK/YEL a b c d e f g hij l k YEL YELYEL YELYEL Wiring Diagram 95 HP #1 #2 #3 TAN/LT.BLU 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 l - CDM (Capacitor Discharge #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 d f g i h j k 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) 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-13 Wiring Diagram 120 HP ELECTRICAL AND IGNITION 2 C BATTERY, CHARGING AND STARTING SYSTEM Table Of Contents Page Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Recommended Battery . . . . . . . . . . . . . . . . 2C-1 Operating Engine Without Battery . . . . . . . 2C-1 Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . 2C-2 Charging A Discharged Battery . . . . . . . . . 2C-2 Winter Storage of Batteries . . . . . . . . . . . . . 2C-2 Battery Charging System . . . . . . . . . . . . . . . . . . 2C-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 Battery Charging System Troubleshooting . . . . . . . . . . . . . . . . . . . 2C-3 Stator Ohms Test (Alternator Coils Only) . . . . . . . . . . . . . . 2C-4 Alternator System Test . . . . . . . . . . . . . . . . 2C-4 Testing Voltage Regulator . . . . . . . . . . . . . . 2C-4 Page Sport Jet Stator Charging Diagram . . . . . . . . . 2C-6 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7 Starting System Components . . . . . . . . . . . 2C-7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7 Troubleshooting the Starting Circuit . . . . . 2C-7 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2C-10 Testing Armature for Ground . . . . . . . . . . 2C-11 Testing Brushes and Terminals . . . . . . . . 2C-11 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2C-12 Installing Starter . . . . . . . . . . . . . . . . . . . . . 2C-12 Testing Starter Solenoid . . . . . . . . . . . . . . 2C-12 90-831996R1 JUNE 1996 Special Tools Multimeter 91-99750 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. 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2C-1 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. 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. 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. 2C-2 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 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. 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. b c RED SLEEVE a 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2C-3 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. 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: Ampere9 99 Ampere StatorStator RPM AMPERES 1200 0.2 2000 6.5 3000 9 RPM AMPERES Ampere15 1515 Ampere StatorStator 1200 8 2000 12 3000 14 9. If proper ampere readings are not obtained, replace stator. Testing Voltage Regulator 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. 2C-4 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 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) 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2C-5 Sport Jet Stator Charging Diagram BLK •Black GRY •Gray RED •Red YEL •Yellow RED SLEEVE a b c d e f 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) 2C-6 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2C-7 2C-8 90-831996R1 JUNE 1996ELECTRICAL AND IGNITION 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. NEUTRAL START SWITCH (LOCATED IN CONTROL HOUSING) RED SLEEVE RED SLEEVE 4 54 74 B C M M A S VOLTAGE4 REGULATOR4 Starting Circuit Troubleshooting Flow Chart 52904 The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to trouble- shooting 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. 64 34 14 24 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. 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2C-9 Starter Motor Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs before 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 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. 2C-10 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 4. Clean dirty commutator with No. 400 or fine sand- Testing Brushes and Terminals paper. 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. CAUTION Never use emery cloth to clean commutator. 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. 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2C-11 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). a c 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. 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. a -Ohm Meter b -12-Volt Supply 2C-12 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 Starter Exploded View 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2C-13 ELECTRICAL AND IGNITION 2 D TIMING/SYNCHRONIZING/ADJUSTING Table Of Contents Page Timing/Synchronizing/ Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2D-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1 Checking for Top Dead Center (TDC) . . . . 2D-1 Checking Timing (At Cranking Speed) . . . 2D-1 Turn-Key Start Feature . . . . . . . . . . . . . . . . 2D-2 Synchronizing Carburetors to Ignition Timing for Turn-Key Start . . . . . . . . . . . . . . 2D-2 Setting Idle Timing . . . . . . . . . . . . . . . . . . . . 2D-3 Page Check WOT Throttle Position with Engine Not Running . . . . . . . . . . . 2D-4 Check WOT Ignition Timing with Engine Running . . . . . . . . . . . . . . . 2D-5 Check WOT Ignition Timing with Engine Not Running . . . . . . . . . . . 2D-5 Adjusting Idle Mixture . . . . . . . . . . . . . . . . . 2D-6 Check Oil Pump Adjustment . . . . . . . . . . . . 2D-7 90-831996R1 JUNE 1996 Timing/Synchronizing/ Adjusting Specifications MODEL 90/95/120 SPORT JET 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 90/95 HP 1 - 2 - 3 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 *May be obtained locally. 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 HP At Cranking Speed At Wide Open Throttle 90/95/120 32° 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. 55117 3. Move towershaft to wide open throttle position. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2D-1 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 32 BTDC at cranking speed should result in retardation to 30° BTDC at 5300 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. As Needed 6. Adjust timing. 7. Loosen locknut. 8. Turn timing rod to adjust timing. 9. Tighten locknut on timing rod. b a a -Locknut b -Timing Rod 10. 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. COMPLETE THIS PROCEDURE IN SEQUENCE 1. Disconnect throttle link at towershaft end. a a -Throttle Link 2D-2 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 2. Synchronize throttle movement on carburetors. This is done by : b b (90/95 HP Shown) b -Tie Bar Screw(s) 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: 90 HP Shown a 90/95 HP: Set dimension (a) to 1/8 in. 120 HP: Set dimension (a) to 1/4 in. 4. Pivot throttle cam forward so it just contacts the roller. b b -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. b c a 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2D-3 3. Check engine timing at idle. Idle timing is 8 to 10o BTDC. 4. If adjustments are needed to obtain the 8 to 10o BTDC specifications, do the following: a. Turn the tower shaft screw in to increase timing, turn screw out to decrease timing. c c -Tower Shaft Screw 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. a a -Timing Mark e. Adjust carburetor idle mixture screws for best operation. Idle RPM will be between 950-1100. Check WOT Throttle Position with Engine Not Running 1. Advance the tower shaft to WOT and check shutter position from horizontal,  5. a -Throttle Shutter b -Line On Throttle Shaft Corresponds To Shutter Position IF REQUIRED: 2. Adjust the WOT stop screw to obtain a horizontal shutter position,  5. a- a WOT Stop Screw 2D-4 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 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. b a a -Locknut b -Timing Rod 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. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2D-5 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 32 degrees. 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. As you turn one idle mixture screw, turn the remaining carburetor idle mixture screws 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 (Wait 10 Seconds) 1/8 Turn (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 mixture, turn the idle mixture screws 1/6 turn clockwise to “lean out” the carburetors and repeat step 7-9 until the engine accelerates without hesitation. 2D-6 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996 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 -Oil Pump Lever b -Alignment Mark (At Wide Open Throttle) 2. Adjust oil pump link rod as required. 90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2D-7 FUEL SYSTEM & CARBURETION 3 A CARBURETOR Table Of Contents Page Removing Carburetor . . . . . . . . . . . . . . . . . . . . . 3A-1 Disassembling Carburetor . . . . . . . . . . . . . . . . . 3A-1 Assembling Carburetor . . . . . . . . . . . . . . . . . . . 3A-3 High Altitude Jetting . . . . . . . . . . . . . . . . . . . . . . 3A-5 Exploded View Carburetor - 90/95/120 HP . . . . . . . . . . . . . 3A-6 90-831996R1 JUNE 1996 Removing Carburetor 1. Remove nut securing throttle cam to stud. a a -Nut, Throttle Cam 2. Remove throttle cam form stud. NOTE:Carburetors and cover may be removed as an assembly. 3. Remove “E” clips from throttle arm. a -“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). a Disassembling Carburetor 1. Remove idle mixture screw and spring. ab a -Screw, Idle Mixture b -Spring 2.Remove screw, gasket, fuel bowl, and gasket. a c d b a -Gasket b -Fuel Bowl c -Gasket d -Screw 3. Remove fuel bowl gasket from groove in carburetor. a a -Gasket 90-831996R1 JUNE 1996 FUEL SYSTEM AND CARBURETION 3A-1 4. Remove float. • Drive out float pin. NOTE: Drive float pin through so that knurled end comes out first. a b a -Float b -Pin, Knurled End • Remove float. 5. Remove inlet needle. a a -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 de a -Screws and Washers d -Return Spring b -Shutter, Throttle e -Throttle Shaft c -E-Clip 7. Remove main fuel jet. a a -Main Fuel Jet 8. 90/95 HP - Remove idle air jet. 120 HP - Remove sealing screw and intermediate fuel jet. bc a 90/95 HP a -Idle Air Jet b -Intermediate Fuel Jet 120 HP c -Sealing Screw 3A-2 FUEL SYSTEM AND CARBURETION 90-831996R1 JUNE 1996 9. Remove elbow. a a -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. 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. 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. 90-831996R1 JUNE 1996 FUEL SYSTEM AND CARBURETION 3A-3 • Carefully tap cup plug into opening with punch. b a 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. 5. Install main fuel jet. a a -Main Fuel Jet a b c d e f g h a -Throttle Shaft b -Return Spring c -Housing Ledge d -E-Clip 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. e -Throttle Shaft Arm f -Throttle Shaft with Flat Side Facing Up g -Shutter h -Screws 7. Install inlet needle. a a -Needle 3A-4 FUEL SYSTEM AND CARBURETION 90-831996R1 JUNE 1996 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 a -Float b -Pin 9. Measure float height. NOTE:To adjust, bend inlet needle tab on float until float sits parallel to flange. a b a -Parallel to Flange b -Float Tab 10. Install gasket in groove at bottom of carburetor. a 11. Install fuel bowl assembly: bowl, gaskets, and screw. 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. 1995 - 1997 MAIN FUEL JET SIZE 90/95XR HP Sport Jet O ti Operating Elevation Carburetor Top Middle Bottom Sea Level-2500 ft. .072 .072 .074 2500-5000 ft. .070 .070 .072 5000-7500 ft. .068 .068 .070 7500-10,000 ft. .066 .066 .068 1995 MAIN FUEL JET SIZE 120 HP Sport Jet O ti Operating Elevation Carburetor Top Bottom Sea Level-1500 ft. .090 .092 1500-3000 ft. .088 .090 3000-4500 ft. .086 .088 4500-6000 ft. .084 .086 6000-10,000 ft. .082 .084 1996 - 1997 MAIN FUEL JET SIZE 120XR HP Sport Jet O ti 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 a -Gasket 90-831996R1 JUNE 1996 FUEL SYSTEM AND CARBURETION 3A-5 Exploded View - Carburetor - 90/95/120 HP 1 -Gasket 2 -Plug 3 -Plug 3a -Tube, Idle 4 -Elbow 5 -E-Clip 6 -Carburetor 7 -Idle Jet 7a -Sealing Screw 8 -Needle 10 -Pin 11 -Gasket 12 -Gasket 13 -Bowl 13a Bowl (Top Carb) 14 -Gasket 15 -Screw 16 -Float 17 -Main Nozzle 18 -Main Jet 19 -Idle Mixture Screw 20 -Spring 21 -Screw 22 -Roller 23 -Nut 24 -Shaft 25 -Spring 26 -Throttle Shutter 27 -Screw (2) 3A-6 90-831996R1 JUNE 1996FUEL SYSTEM AND CARBURETION Quicksilver Lubrication/Sealant 1 2 3 4 6 14 15 16 17 18 19 22 23 25 26 21 20 B B 8 10 11 13 12 24 27 5 13a2 7 7a 3 3a2 7 120 HP Application Points Loctite 271 (92-823089--1) FUEL SYSTEM & CARBURETION B 3 FUEL PUMP RECIRCULATION SYSTEM REED VALVE ASSEMBLY AUTO ENRICHNER Table Of Contents Page Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 General Information . . . . . . . . . . . . . . . . . . . 3B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Removing/Disassembling Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Assembling and Installing Fuel Pump. . . . . . . 3B-3 Fuel Pump Exploded View . . . . . . . . . . . . . . . . 3B-5 Fuel Recirculation System . . . . . . . . . . . . . . . . . 3B-6 System Description . . . . . . . . . . . . . . . . . . . 3B-6 Testing Fuel Recirculation System . . . . . . 3B-6 Fuel Recirculation System 90/95 HP . . . . . . . . 3B-6 Fuel Recirculation System 1995 120 HP . . . . 3B-7 Fuel Recirculation System 1996 120 HP . . . . 3B-8 Reed Valve Assembly . . . . . . . . . . . . . . . . . . . . 3B-9 Removing and Inspecting Reed Valve Assembly . . . . . . . . . . . . . . 3B-9 Page Inspecting and Installing Reed Block Assembly . . . . . . . . . . . . . . 3B-9 Reed Plate, Intake Manifold and Auto Enrichner - 90/95 HP . . . . . . . . 3B-10 Reed Plate, Adaptor Plate and Auto Enrichner - 120 HP . . . . . . . . . . . . . . 3B-12 Auto Enrichner . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-14 System Description . . . . . . . . . . . . . . . . . . 3B-14 Testing Auto Enrichner . . . . . . . . . . . . . . . 3B-14 90-831996R1 JUNE 1996 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. 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 anti-siphon 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”. 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-1 Description Part Number Hose Clamp Pliers FT-8900 RTV Sealant 92-90113--2 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. Special Tools Removing/Disassembling Fuel Pump 1. Loosen screw on sediment bowl. 2. Remove bowl from pump body. a a -Screw 3. Remove gasket and screen. a b a -Gasket b -Screen 3B-2 FUEL SYSTEM 90-831996R1 JUNE 1996 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. cj i h g b e f d a a -Fuel Pump Fitting f -Booster Spring b -Screw and Washer g -Diaphragm c -Nut h -Gasket d -Fuel Pump Body i -Spacer e -Booster Spring Retainer j -Spacer Plate Gasket 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. c b a d e a -Center Check Valve c -Gasket b -Second Stage Check d -Screws Valve 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. b a a -Spring b -Retainer 2. Position diaphragm and gasket on pump body. 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-3 3. Compress spring using a putty knife. Install screws in pump body. a b a a -Long Screws b -Short Screws 4. Install spacer plate, nuts and gasket. b a c a -Spacer Plate b -Nuts c -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. a a -Fitting 6. Install fuel hoses. a b c a -Fuel Outlet Hose b -Fuel Inlet Hose Connected to Sediment Bowl c -Pulse Hose 7. Install screen in sediment bowl. Install sediment bowl on fuel pump. a a -Screen - Edge Turned Toward Engine 8. Install gasket on pump body. a a -Gasket, Aligned On Pump Body Keyway 3B-4 FUEL SYSTEM 90-831996R1 JUNE 1996 90-831996R1 JUNE 1996 3B-5FUEL SYSTEM IMPORTANT: Position sediment bowl with hose fitting at the 4 o’clock position. a a -Hose Fitting At 4 O’Clock Position Fuel Pump Exploded View RTV Sealant 92-90113--2 90-831996R1 JUNE 1996 3B-5FUEL SYSTEM IMPORTANT: Position sediment bowl with hose fitting at the 4 o’clock position. a a -Hose Fitting At 4 O’Clock Position Fuel Pump Exploded View RTV Sealant 92-90113--2 3B-6 90-831996R1 JUNE 1996FUEL SYSTEM 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 in- dicated by arrows. Fuel Recirculation System 90/95 HP 3B-6 90-831996R1 JUNE 1996FUEL SYSTEM 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 in- dicated by arrows. Fuel Recirculation System 90/95 HP Fuel Recirculation System 1995 120 HP 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-7 3B-8 FUEL SYSTEM 90-831996R1 JUNE 1996 Fuel Recirculation System 1996 & 1997 120 HP b d e c NOTE:90/95 HP Shown a -Reed Block Assembly b -Gasket c -Reed Plate Adaptor 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. a d -Gasket e -Manifold 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 .010” (.254 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. 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-9 Reed Plate, Intake Manifold and Auto Enrichner - 90/95 HP 1 2 19 20 13 4 5 6 7 8 9 10 11 12 13 14 15 16 17 13 13 13 19 21 232425 26 3 22 3B-10 FUEL SYSTEM 90-831996R1 JUNE 1996 Item Qty. Description Torque Lb. In. Lb. Ft. N·m 3 Reed Block Assembly 1 Gasket (Top) 2 Gasket (Center/Bottom) 1 Adapter, Reed Plate 1 Gasket, Intake Manifold 1 Manifold Assembly, Intake 8 Screw (1/4-20 x 1”) 6 Stud (5/16-18 x 1-1/4”) With Dri Loc 6 Nut (5/16-18) 1 Elbow 6 Screw (1/4-20 x 1-1/2”) 2 Fitting 6 Clamp 1 Hose, Molded (Top) Connect to Upper Manifold Elbow 1 Bracket 2 Grommet 2 Bushing 2 Screw (M6 x 30) 4 Washer 1 Hose (4-3/4”) Connect to Middle Carburetor 1 Auto Enrichner 1 Hose, Molded (Bottom) Connect to Lower Manifold Elbow 2 Fitting 1 Clamp 1 Stud (1/4-20 x 1-1/4”) With Dri Loc 4 Screw (1/4-20 x 1-1/4”) 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-11 Reed Plate, Adaptor Plate and Auto Enrichner - 120 HP 1 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 1 1 15 2 4 6 13 Reed Plate, Adaptor Plate and Auto Enrichner - 120 HP 1 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 1 1 15 2 4 6 13 3B-12 FUEL SYSTEM 90-831996R1 JUNE 1996 Item Qty. Description Torque Lb. In. Lb. Ft. N·m 4 Clamp 1 Hose (2-1/4 in.) 1 Fitting 2 Clamp 1 Hose, Molded 1 Hose (2-3/4 in.) 1 Gasket 4 Reed Plate Assembly 1 Plate 8 Screw (1/4-20 x 5/8 in.) With Dri Loc 1 Gasket 1 Adapter Assembly (Upper) Lower Adapter Not Shown 14 Screw (1/4-20 x 7/8 in.) 2 Screw (M6 x 30) 2 Washer 2 Bushing 2 Grommet 1 Bracket 2 Screw (1/4-20 x 1-1/4 in.) 1 Auto Enrichner 4 Nut (3/8-16) 4 Stud (3/8-16 x 1-5/8 in.) With Dri Loc 2 Gasket 1 Stud (1/4-20 x 1 in.) With Dri Loc 1 Clamp 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-13 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. 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) i -Fuel Inlet b -Return Spring j -Tapered Needle c -Actuator Rod k -Fuel/Air Mixture Outlet d -Plastic Spring Guide (Not All Outlets Are Used) e -O-ring l -Compensating Spring f -Slide Valve m-Brass Guide g -Air Inlet n -Wax Pellet h -Rubber Seat 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. 3B-14 FUEL SYSTEM 90-831996R1 JUNE 1996 OIL INJECTION SYSTEM 3 C Table Of Contents Page Operation of the Injection System . . . . . . . . . . 3C-1 Oil Pump Description . . . . . . . . . . . . . . . . . . . . . 3C-1 Oil Pump Output Specifications . . . . . . . . . . . . 3C-1 Oil Injection Components . . . . . . . . . . . . . . . . . 3C-2 Carburetor/Oil Pump Synchronization . . . . . . . . . . . . . . . . . . . . . . 3C-3 Bleeding Air from Oil Injection System . . . . . . 3C-3 90-831996R1 JUNE 1996 Operation of the Injection System 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 Description There are two different pumps used on the Sport Jet product line. The lever can be used to identify which model the pump is calibrated for. The 90 HP is stamped with “90” on the pump lever. The 120 HP is stamped with “120” on the pump lever. Oil Pump Output Specifications The following table lists the oil pump output capacity in cc per three minutes engine running time. Lever Stamp t “90” “120” Part Number 820658 819438 Volume @ Idle* 3.37 cc  10% 4.75 cc  10% Full Volume** 11.25 cc  10% 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 90-831996R1 JUNE 1996 OIL INJECTION SYSTEM 3C-1 Oil Injection Components 1 2 3 4 5 6 8 9 10 11 12 13 3 7 REF. NO. PART NO. QUAN. DESCRIPTION TORQUE lb. in. lb. ft. NVm 1 54F698772 2 Clamp 2 21826122 1 Valve, Check 3 54815504104 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 820658 819438 1 1 Oil Pump (90 HP) 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) 3C-2 OIL INJECTION SYSTEM 90-831996R1 JUNE 1996 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. 90-831996R1 JUNE 1996 OIL INJECTION SYSTEM 3C-3 POWERHEAD 4 Table Of Contents Page Powerhead Specifications BOTTOM GUIDED PISTON . . . . . . . . . . . . . 4-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Finished Hone Bore Size . . . . . . . . . . . . . . . 4-1 Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Powerhead Specifications TOP GUIDED PISTON . . . . . . . . . . . . . . . . . 4-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Finished Hone Bore Size . . . . . . . . . . . . . . . 4-2 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . . 4-3 Powerhead Disassembly . . . . . . . . . . . . . . . . . . . 4-4 Removing Crankshaft . . . . . . . . . . . . . . . . . . 4-5 Disassembling Crankshaft . . . . . . . . . . . . . . 4-5 Disassembling Piston . . . . . . . . . . . . . . . . . . . 4-6 Disassembling Cylinder Head . . . . . . . . . . . 4-6 Inspecting and Repairing . . . . . . . . . . . . . . . . . . . 4-7 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Page Connecting Rods . . . . . . . . . . . . . . . . . . . . . . 4-7 Bottom/Top Guided Pistons . . . . . . . . . . . . 4-10 Bottom Guided Piston . . . . . . . . . . . . . . 4-10 Top Guided Piston . . . . . . . . . . . . . . . . . 4-10 Cylinder Block and Crankcase Cover . . . . 4-11 Powerhead Reassembly . . . . . . . . . . . . . . . . . . 4-11 Assembling Bottom Guided Piston - 1995-1/2 Model Year S/N 0E125508 and Below . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Assembling Top Guided Piston - 1996 Model Year S/N 0E125509 and Above . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Assembling Crankshaft . . . . . . . . . . . . . . . . 4-14 Installing Pistons Into Cylinder Block . . . . 4-15 Assembling Cylinder Head . . . . . . . . . . . . . 4-19 Completing Assembly . . . . . . . . . . . . . . . . . . . . . 4-20 Installing Powerhead . . . . . . . . . . . . . . . . . . . . . 4-20 Powerhead Components 90/95 HP . . . . . . . . . 4-22 Crankshaft Components 90/95/120 HP . . . . . 4-24 Powerhead Components 120 HP . . . . . . . . . . 4-26 90-831996R1 JUNE 1996 Powerhead Specifications BOTTOM GUIDED PISTON Special Tools Description Part No. 12-point Socket FT 2953 Piston Tool FT 2990-1 Ring Remover/Installer FT 8926 Ring Compressor FT 2996 Lockring Installer FT 11291 Compression Tester 91-29287 *Torque Wrench (0–200 lb. ft.) 91-32610 *Torque Wrench (0–150 lb. in.) 91-66274 Flywheel Puller FT 8948-1 Lifting Hook FT 8933 *May Be Obtained Locally Finished Hone Bore Size Standard Size Fraction in. (mm) 3-3/8 3.375 (85.725) .010 Oversize in. (mm) 3.385 (85.979) .030 Oversize in. (mm) 3.405 (86.487) TOP CENTER BOTTOM NOTE: Measure cylinder bore at Top, Center and Bottom. IMPORTANT: Measure piston skirt at right angle (90°) to piston pin center-line, 2.0 in. (50.8 mm) up from bottom edge of skirt. (50.8 mm) 2.0 in. Major Diameter measured 90o to piston pin center line 2.0 in. (50.8 mm) Minor Diameter measured parallel to piston pin center line Piston Ring 90/120 HP End Gap Top Piston Ring 0.010 - 0.020 in. (0.254 - 0.508 mm) Bottom Piston Ring 0.006 - 0.016 in. (0.15 - 0.4 mm) 90-831996R1 JUNE 1996 POWERHEAD 4-1 Powerhead Specifications TOP GUIDED PISTON Special Tools 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 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. Measured 90 to piston pin center line (3.81 mm) PISTON RING 95/120 HP End Gap Top Piston Ring 0.010 - 0.020 in. (0.254 - 0.508 mm) 4-2 POWERHEAD 90-831996R1 JUNE 1996 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. a b 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 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/2B* Ignition Components (Switch Box, Stator, Trigger) 2A/2B* 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. 90-831996R1 JUNE 1996 POWERHEAD 4-3 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. a b c d e a -Cylinder Block (120 HP Shown) b -Transfer Port Cover (4 on the 120 HP) c -Cylinder Head d -Exhaust Manifold e -Bearing Cage 5.Remove bearing cage. 6. Remove oil injection pump and driven gear. a b a -Oil Injection pump b -Driven Gear 7. Remove crankcase cover screws. a b a -Cover Screws (120 HP) b -Cover Screws (90/95 HP) 4-4 POWERHEAD 90-831996R1 JUNE 1996 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. 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 neces- sary, remove using univeral bearing puller Special Tool 91-37241. Press new bearing onto crank- shaft. 90-831996R1 JUNE 1996 POWERHEAD 4-5 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. 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 4-6 POWERHEAD 90-831996R1 JUNE 1996 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. 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 90-831996R1 JUNE 1996 POWERHEAD 4-7 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 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 4-8 POWERHEAD 90-831996R1 JUNE 1996 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. 8. Clean connecting rods as necessary. a b d c a -Attached to Drill Motor b -Crocus Cloth c -Torque to 16 lb. ft. (21.7 N·m) d -Use 320 Carborundum Cloth 90-831996R1 JUNE 1996 POWERHEAD 4-9 Bottom/Top Guided Pistons IMPORTANT: There are two types of piston/rod assemblies available: – Bottom Guided (centered in bore by crankshaft) 1995-1/2 Model Year S/N 0E123456 and Below Bottom Guided Piston a b c 51536 a -Ridged Washer b -Smooth c -Scalloped – Top Guided (centered in bore by piston) 1995-1/2 Model Year S/N 0E123456 and Above Top Guided Piston a b c a -Flat Washer b -Scalloped c -Smooth 4-10 POWERHEAD 90-831996R1 JUNE 1996 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. • 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. 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. Powerhead Reassembly Assembling Bottom Guided Piston 1995- 1/2 Model Year S/N 0E125508 and Below 1. Install piston pin needle bearings in pin bore of connecting rod using. Lubricate needle bearings with Quicksilver Needle Bearing Lubricant. a a -Bearings (26 per set) Refer to Specifications for Finished Hone Bore Size for Bottom Guided pistons and Top Guided pistons. 90-831996R1 JUNE 1996 POWERHEAD 4-11 CAUTION DO NOT intermix new needle bearings with used needle bearings. Needle bearings MUST BE REPLACED AS A SET. DO NOT intermix needle bearings from one connecting rod with those of another connecting rod. 2. Install alignment pin (Special Tool No. FT-2990B) through one side of piston. a b a -Spacer b -Alignment Pin 3. Install first spacer with small end toward the inside of piston. 4. Install connecting rod in piston. • Slide connecting rod with bearings over alignment tool. • Install second spacer with small end toward inside of piston. • Push alignment pin through second spacer and through piston bore. 5. Place piston on pillow block (Special Tool No. FT-2990D). 6. Install piston pin. a a -Block (Special Tool FT 2990D) WARNING Eye protection must be worn while installing piston pin lockrings. IMPORTANT: Use only new piston pin lockrings. 7. Install NEW piston lockrings (one at each end of piston pin) with lockring installation tool (Special Tool No. FT 11291) as shown. a b a -Lockring b -Special Tool FT 11291 IMPORTANT: Be sure piston pin lockrings are properly seated in piston grooves. 4-12 POWERHEAD 90-831996R1 JUNE 1996 8. Install piston rings (Special Tool No. FT-8926). b a a -Upper Piston Ring b -Lower Piston Ring IMPORTANT: Gaps in piston rings must fit over pins in ring grooves. Assembling Top Guided Piston - 1996 Model Year S/N 0E125509 and Above 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 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”). 1 1a b 51083 a -Scribed Identification Number b -Locating Washer 3. Insert piston pin tool through piston in the direction shown, pushing out sleeve. 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. a b 19537 a -Needle Bearings (29) b -Sleeve [From Piston Pin Tool (91-74607A3)] a b a -Sleeve b -Piston Pin Tool (91-74607A3) 90-831996R1 JUNE 1996 POWERHEAD 4-13 4. Place piston pin over end of tool, and tap into position (driving tool out other side). 51086 a b a -Piston Pin b -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. a b 51086 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. 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. a a -Garter Spring (Faces Up Toward Flywheel When Installed) 4-14 POWERHEAD 90-831996R1 JUNE 1996 3. Scrape old Loctite off upper bearing. Clean bearing surfaces with Locquic Primer 92-59327--1. 4. Install new crankshaft seals on crankshaft. a a -Crankcase Seals 5.Install center main bearings on crankshaft with alignment holes of bearing race between snap ring groove and crankcase seal. a b c a -Snap Ring Groove b -Alignment Hole NOTE:Position snap ring on center main bearings so thatthe gap is not over the fracture area of the bearings. c -Crankcase Seal 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. a a -Alignment Pin 90-831996R1 JUNE 1996 POWERHEAD 4-15 3. Install piston in cylinder bore. Position piston so that piston dome faces intake port of cylinder block. a b a -Intake Ports b -Piston Dome 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. a a b b 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. a a -Bearing Seated Against Cylinder Block Flange 10. Install one half of bearing cage in connecting rod. • Apply Needle Bearing Lubricant 92-825265A1 to cage half to hold needle bearings in place (Bottom Guided rods, not necessary on Top Guided rods). NOTE:Bottom Guided rods use loose needle bearing with a cage. Top Guided rods use a cage that contains the needle bearings. • Install nine rollers (Bottom Guided rods). 4-16 POWERHEAD 90-831996R1 JUNE 1996 IMPORTANT: Do Not intermix rollers. Rollers can only be replaced as a set. a b a -Bearing Cage Half b -Roller (9) 11. Carefully align connecting rod with crankshaft. 12. Install second half of bearing cage in connecting rod. • Apply Needle Bearing Lubricant 92-825265A1 to cage half to hold needle bearings in place. • Install remaining seven rollers (Bottom Guided). 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. 16. Apply Loctite 92-823089--1 to the exposed portion of the upper bearing. 90-831996R1 JUNE 1996 POWERHEAD 4-17 17. Apply Sealer 92-90113--2 on seal surface and around main bolt holes on block. a a -Sealer (92-90113--2) 18. Install crankcase cover on cylinder block, aligning corner dowel pins. a a a -Dowel Pins 19. Install crankcase bolts. Following torque pattern torque bolts to 270 lb. in. (30.5 N·m). 7 3 1 8 4 2 5 90/95 HP 6 • Check crankshaft for free rotation. 10 6 2 3 78 4 1 5 91 120 HP 20. Using new gasket, install adapter plate on bottom of cylinder block. Torque bolts to 30 lb. ft. (40.7 N·m). 4-18 POWERHEAD 90-831996R1 JUNE 1996 Assembling Cylinder Head 1. Install cylinder head cover on cylinder head. Torque center attaching screws to 70 lb. in. (7.91 N·m). a b c a -Cylinder Head Cover c -Cylinder Head Gasket b -Cylinder Head NOTE:90/95 HP Shown. 2. Apply sealant 92-90113--2 to cylinder head cover on cylinder block side of cover. 3. Using new gasket, install cylinder head. 1995-1/2 Model Year S/N 0E125508 and below: 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. 1413 121 41 61 2 8 10 1 11 5 3 7 9 90/95 HP 18 14 10 61 2 3 7 11 1516 12 8 4 1 5 9 13 17 120 HP 90-831996R1 JUNE 1996 POWERHEAD 4-19 Completing Assembly 1995-1/2 Model Year S/N 0E125508 and below: 1. Install exhaust manifold using new gasket. Torque bolts in sequence from center out to 100 lb. in. (11.3 N·m). For S/N numbers 0E125509 and above 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. NOTE: Stainless steel bolts are torqued to 100lb.in. (11.3 N·m). Grade 8 bolts are torqued to 115 lb. in. (13 N·m). Stainless steel bolts are not magnetic, grade 8 bolts are magnetic. 1 13 14 16 15 6 7 2 17 18 19 12 20 3 21 4 11 5 10 9 8 90/95 HP 12 3 64 10 14 22 2521 17 13 9 5 8 12 16 20 2423 19 15 11 7 18 120 HP 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/2B* Ignition Components (Switch Box, Stator, Trigger) 2A/2B* Carburetor and Linkage 3A Fuel Pump, Reed Valves 3B *1996/97 Models, CDM Ignition NOTE: All ignition and electrical components can be removed and installed as an assembly. Installing Powerhead 1. Install top exhaust boot and clamp. Install O-ring in counterbore of drive housing cover. c b a d a -Exhaust Boot c -Drive Housing Cover b -O-Ring d -Large O-Ring 2. Lubricant driveshaft splines with 2-4-C w/Teflon Lubricant 92-825407A12. NOTE: DO NOT apply lubricant toTOP 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). 4-20 POWERHEAD 90-831996R1 JUNE 1996 5. Connect water inlet hose to fitting on drive hous-REFER TO SECTION 6 “ENGINE INSTALLATION” ing cover. Snug nut with wrench, then tighten one TO COMPLETE INSTALLATION OF WIRE HAR- additional flat (60 degrees). NESS, CONTROL CABLES, SET-UP AND TIMING. IMPORTANT: Follow Break-In procedure as out lined in Section 6: Engine Installation. a a -Water Inlet Hose 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). CAUTION SEVERE DAMAGE to your engine can result by not complying with the proper break-in procedure. 1 2 4 35 6 7 8 90-831996R1 JUNE 1996 POWERHEAD 4-21 Powerhead Components 90/95 HP Quicksilver Lubrication/Sealant Application Points RTV Sealant 92-90113--2 U U U U 24 25 1 5 67 10 11 21 221 26 29 31 3233 34 35 28 36 37 38 39 40 41 42 43 191 2 4 3 8 9 12 13 14 15 16 17 18 23 27 30 45 44 Powerhead Components 90/95 HP Quicksilver Lubrication/Sealant Application Points RTV Sealant 92-90113--2 U U U U 24 25 1 5 67 10 11 21 221 26 29 31 3233 34 35 28 36 37 38 39 40 41 42 43 191 2 4 3 8 9 12 13 14 15 16 17 18 23 27 30 45 44 Item Qty. Description Torque Lb. In. Lb. Ft. N·m 1* 21 Bolt (1/4-20x1-1/8) 1995-1/2 Model Year S/N 0E125508 and Below 100 11.3 1* 21 Bolt (1/4-20x1-1/8) S/N 0E125509 and Above - Apply Light Oil to Bolt Head & Threads 115 13 2 1 Manifold 3 Delete 4 1 Bolt (5/16-18x3/4) 13 17.6 5 1 Washer 6 2 Clamp 7 1 Bellows 8 1 Cylinder Block * Refer to torque sequence listed on page 4-20. 4-22 POWERHEAD 90-831996R1 JUNE 1996 Powerhead Components 90/95 HP (Continued) Item Qty. Description Torque Lb. In. Lb. Ft. N·m 9 1 Stud 10 7 Washer 11 1 Lock Washer 12 1 Nut (3/8-16) 270 30.5 13 1 Bolt (3/8-16x2-3/4) 270 30.5 14 4 Bolt (3/8-16x3) 270 30.5 15 8 Bolt (1/4-20x3/4) 70 7.9 16 2 Bolt (3/8-16x1-3/4 17 7 Washer 18 2 Bolt (1/4-20x1-1/4) 70 7.9 19 1 Gasket 21 2 Gasket 22 2 Bolt (1/4-20x5/8) 70 7.9 23 2 Cover 24 2 Tube 25 2 Pin 26 1 Gasket 27 1 Head 28 1 Cover 29 14 Washer - Only Used On 1995-1/2 S/N 0E125508 and Below 30* 14 Bolt (5/16-18x2-3/8) 1995-1/2 Model Year S/N 0E125508 and Below 225 25.4 30* 14 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 90o 31 3 Bolt (1/4-20x5/8) 70 7.9 32 4 Bolt (1/4-20x3/4) 70 7.9 33 1 Cover 34 1 Gasket 35 1 Spring, (Silver) 36 1 Thermostat (130°) 37 1 Spacer 38 1 Seal 39 1 Plug 40 1 Pin 41 1 Bolt (1/4-20x3/4) 70 7.9 42 1 Tube 43 1 Gasket 44 4 Plug (1/2-14) 45 21 Washer - Only Used On 1995-1/2 S/N 0E125508 and Below * Refer to torque sequence listed on page 4-19. 90-831996R1 JUNE 1996 POWERHEAD 4-23 Crankshaft Components 90/95/120 HP C V 10 2 3 40 5 6 7 8 90 10 110 120 1316 V C E E 250 V V26 1995-1/2 S/N 0E125508 and Below One Circle Mark - Faces Up Two Circle Marks - Face Up 18 18a 190 20 210 220 23 23a 210 220 190 20 18a 17 240 27 90/120 HP 90/95 3-CYLINDER SHOWN - 120 4-CYLINDER NOT SHOWN 140 150 Quicksilver Lubrication/Sealant Direction of Application Points UP or DOWN major sealing lip C V E Needle Bearing Assy. Lub. (92-42649A1) Loctite #601 (FT-8938-1) 2 Cycle Outboard Oil (92-13249A24) 4-24 POWERHEAD 90-831996R1 JUNE 1996 Item Qty. Description Torque Lb. In. Lb. Ft. N·m 1 1 Cap 2 1 Seal 3 5 Screw (1/4-20x3/4) 70 7.9 4 1 Cage Assembly 1 Key 6 1 Crank Shaft (90/95 HP Shown) 7 1 Bearing 8 3 Cage/Roller 9 3 Rod Cap 6 Bolt - Apply Light Oil to Bolt Head & Threads 120 lb. in. (13.5 N·m) Then Turn An Additional 90o 11 2 Cage/Roller 12 2 Main Bearing Race 13 3 Locating Pin 14 1 Bearing 1 Seal 16 2 Crank Case Seal 17 2 Snap Ring 18 6 Flat Washer (2 Each) S/N 0E125509 and Above 18a 6 Spacer (2 Each) S/N 0E125508 and Below 19 3 Piston 3 Piston Ring (2 Each) 21 6 Retainer (2 Each) 22 3 Piston Pin 23 3 Needle Bearing (29 Each) S/N 0E125509 and Above 23a 3 Needle Bearing (26 Each) S/N 0E125508 and Below 24 3 Connecting Rod 1 Nut, Flywheel 125 112 26 1 Washer - Only Used On S/N 0E125509 and Above 90-831996R1 JUNE 1996 POWERHEAD 4-25 Powerhead Components 120 HP 18 19 20 21 22 2324 25 26 123 4 5 6 7 8 9 11 12 13 14 15 16 17 6 6 10 29 30 31 32 33 34 35 28 27 28 289 U U U Quicksilver Lubrication/Sealant Application Points U RTV Sealant 92-90113--2 4-26 POWERHEAD 90-831996R1 JUNE 1996 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) 1995-1/2 Model Year S/N 0E125508 and Below 225 25.4 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 90o 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 * Refer to torque sequence listed on page 4-19. 90-831996R1 JUNE 1996 POWERHEAD 4-27 Powerhead Components (Continued) Exhaust Manifold 120 HP 1 2 3 4 6 7 8 9 5 Not Used on 1996 Models 10 10 11 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) - 1995-1/2 Model Year S/N 0E125508 and Below 100 11.3 6* 21 Bolt (1/4-20x3) - S/N 0E125509 and Above - 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 4-20. 4-28 POWERHEAD 90-831996R1 JUNE 1996 90-831996R1 JUNE 1996 JET PUMP 5-–1 5 JET PUMP Table Of Contents Page General Information . . . . . . . . . . . . . . . . . . . . . . . 5-1 Principles of Operation . . . . . . . . . . . . . . . . . 5-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Servicing Impeller . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Removing Impeller . . . . . . . . . . . . . . . . . . . . . 5-3 Inspecting Components . . . . . . . . . . . . . . . . . 5-4 Installing Impeller . . . . . . . . . . . . . . . . . . . . . . 5-5 Page Removing Jet Drive From Boat . . . . . . . . . . . . . . 5-6 Drive Housing Disassembly . . . . . . . . . . . . . . . . 5-7 Pinion Shaft Removal . . . . . . . . . . . . . . . . . . 5-7 Impeller Shaft Removal . . . . . . . . . . . . . . . . . 5-9 Shimming Procedures . . . . . . . . . . . . . . . . . 5-11 Nozzle/Rudder Components . . . . . . . . . . . . . . . 5-16 Pinion and Impeller Shaft Components . . . . . 5-18 90-831996R1 JUNE 1996 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. 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. d a a -Forward Motion b -Water Thrust c -Nozzle (Rudder) 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. 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. b c d -Reverse Gate (Shown In the Forward Position) a a -Reverse Gate (Shown In the Reverse Position) a a -Reverse Gate (Shown In the Forward Position) 90-831996R1 JUNE 1996 JET PUMP 5-1 Special Tools Jet Pump Tool Kit 91-820619A2 Description Part Number a Pre-Load Kit Pinion Shaft 91-824827A1 b Pre-Load Kit Impeller Shaft 91-824871A1 c Thread Extender Kit used w/ Backlash Kit 91-824869A1 d Flushing Adaptor 22-820573 e Seal Protector Impeller Shaft 91-830103 f Impeller Nut Wrench 91-824872 g Pinion Gear Location Tool 91-824890 h Bearing Installer press ball bearing into pinion shaft housing 91-820552 small O.D. shaft i Bearing Installer press ball bearing into pinion shaft housing 91-820552-1 large O.D. shaft j Bushing Installer stator bushings 91-820558 k Seal Installer stator seals 91-820554 l Seal Installer pinion shaft seals in drive housing 91-820559 m Bearing Installer impeller shaft ball bearing in drive housing 91-820557 n Puller Bar used for pulling drive housing seals 91-824870 o Ring Guide Installer installs ring guide on drive housing cover 91-820555 p Bearing Cup Installer pinion shaft housing and drive housing front cover 91-820556 q Bearing Installer taper roller bearing on pinion shaft 91-827983 r Handle Driver 91-824892 s Bushing Installer installs reverse gate pivot bushings 91-824886 t Bushing Press installs rudder pivot bushings 91-824883 a b c d e f g h i j m lk n o p q r s t Special Tools Jet Pump Tool Kit 91-820619A2 Description Part Number a Pre-Load Kit Pinion Shaft 91-824827A1 b Pre-Load Kit Impeller Shaft 91-824871A1 c Thread Extender Kit used w/ Backlash Kit 91-824869A1 d Flushing Adaptor 22-820573 e Seal Protector Impeller Shaft 91-830103 f Impeller Nut Wrench 91-824872 g Pinion Gear Location Tool 91-824890 h Bearing Installer press ball bearing into pinion shaft housing 91-820552 small O.D. shaft i Bearing Installer press ball bearing into pinion shaft housing 91-820552-1 large O.D. shaft j Bushing Installer stator bushings 91-820558 k Seal Installer stator seals 91-820554 l Seal Installer pinion shaft seals in drive housing 91-820559 m Bearing Installer impeller shaft ball bearing in drive housing 91-820557 n Puller Bar used for pulling drive housing seals 91-824870 o Ring Guide Installer installs ring guide on drive housing cover 91-820555 p Bearing Cup Installer pinion shaft housing and drive housing front cover 91-820556 q Bearing Installer taper roller bearing on pinion shaft 91-827983 r Handle Driver 91-824892 s Bushing Installer installs reverse gate pivot bushings 91-824886 t Bushing Press installs rudder pivot bushings 91-824883 a b c d e f g h i j m lk n o p q r s t 5-2 JET PUMP 90-831996R1 JUNE 1996 Special Tools (Continued) Part Number Backlash Indicator Flag use MCII line 91-53459 Impeller Shaft Holder 91-820657 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 92-823089--1 Loctite, #242 Obtain Locally Perfect Seal 92-342271-1 2-4-C Lubricant w/ Teflon 92-90018A1 Servicing Impeller Removing Impeller 1. Disconnect spark plug leads from spark plugs. 2. Disconnect shift and steering cables. Remove shift cable bracket. a b c a -Steering Cable c -Shift Cable b -Shift Cable Bracket 3. Remove four screws securing nozzle assembly to stator. Remove nozzle assembly. ab c a -Stator Assembly c -Screws (4) b -Nozzle Assembly 4. Remove two screws securing stator assembly to ride plate. ba a a -Screws (2) to Stator Assembly 5. Remove four screws securing stator assembly to drive housing. Remove stator assembly and wear ring. a -Wear Ring b -Stator Assembly NOTE:Tilt stator back to prevent oil from running out. 6. Remove inlet screen on bottom of drive housing to allow access to machined flats on impeller shaft. If using Special Tool 91-820657 to hold impeller shaft, inlet screen does not need to be removed. a a -Inlet Screen 7.Straighten tabs on impeller tab washer. 90-831996R1 JUNE 1996 JET PUMP 5-3 8. Hold impeller shaft with a wrench on machined flats. 9. Remove impeller nut using Special Tool or appropriate size wrench. Remove impeller. Impeller nut is a left hand thread: turn clockwise to loosen. a b c 53798 a -Impeller Shaft b -Impeller Machined Flats c -Special Tool 91-824872 Inspecting Components 1. Inspect wear ring for excessive scoring and/or grooves. Replace wear ring if deep grooves are present or severe scoring has taken place. 2. Insure O-ring is in counterbore before installing wear ring to drive housing. a 3. Inspect seals in stator for wear/damage. 4. If replacement is required, remove stator seals using Puller 91-83165M shown below. a a -Puller 91-83165M 5. Install new stator seals using Special Tool 91-820554. Outer seal: lip faces out. Inner seal: lip faces in. 53800 b a c a -Handle Driver 91-824892 b -Seal Installer 91-820554 c -Seals (Top Seal Faces UP, Bottom Seal Faces Down) b a -O-ring b -Inspect Surface for Grooves/Scoring 5-4 JET PUMP 90-831996R1 JUNE 1996 Installing Impeller 1. Lubricate splines of impeller shaft with 2-4-C w/ teflon grease. 2. Install thrust washer, impeller, tab washer and nut on impeller shaft. Torque impeller nut to 70 lb. ft. (95 N·m). Bend both tabs of tab washer against flats on nut. 3. Install inlet screen. Apply Loctite 242 to threads of screws. Torque screws to 75 lb. in. (8.5 N·m). 4. Install wear ring and stator. Apply Perfect Seal to threads of four screws. Torque screws to 30 lb. ft. (40.7 N·m). ba a -Wear Ring b -Stator Assembly 5. Remove stator fill screw with washer and fill stator with High Performance Gear Lube. Capacity is 3.4 oz. (100 cc). Install fill screw and washer. a a -Fill Hole 6. Apply Loctite 242 to screws (2) securing stator to the ride plate. Torque screws to 75 lb. in. (8.5 N·m). a d b c a -Screws (2) to Stator Assembly b -Anode c -Nozzle Assembly d -Screws (4) to Nozzle Assembly 7. Install nozzle assembly and anode. Apply Loctite #271 to threads of screws. Torque all four (4) screws to 30 lb. ft. (40.7 N·m). 8. Attach shift and steering cables. REFER TO SECTION 6: SPORT JET INSTALLATION FOR SHIFT AND STEERING INSTALLATION AND ADJUSTMENT. 90-831996R1 JUNE 1996 JET PUMP 5-5 Removing Jet Drive From Boat REMOVE POWERHEAD AS OUTLINED IN SECTION 4. 1. Disconnect shift and steering cables. Remove shift cable bracket. a b c a -Steering Cable b -Shift Cable Bracket c -Shift Cable 2. Loosen shift and steering cable thru hull fittings. 3. Support pump. WARNING The pump unit must be supported to prevent it from dropping through the opening when the remaining fasteners are removed. 4. Remove three screws securing steering cable bracket to drive housing. 5. Remove bracket from steering cable. 6. Remove remaining four nuts from drive housing cover. Remove drive housing cover and gasket. a a -Nuts 7.Lower drive housing and place on bench or suit- able work stand for disassembly/repair. 5-6 JET PUMP 90-831996R1 JUNE 1996 Drive Housing Disassembly Pinion Shaft Removal 1. Remove four screws securing pinion shaft housing to drive housing. Remove pinion shaft assembly. a a -Pinion Shaft Assembly NOTE:Take care not to damage or misplace colored shims. 2.Remove rubber ring, O-ring and shims. b a c 53797 b -Shims a -Rubber Ring 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. 5. Remove pinion shaft outer race from pinion shaft housing using slide hammer 91-34569A1. 90-831996R1 JUNE 1996 JET PUMP 5-7 6. Press new outer race into pinion shaft housing using mandrel 91-820556. 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 91-820552. 10. Press pinion shaft into pinion housing. 5-8 JET PUMP 90-831996R1 JUNE 1996 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. a a -Special Tool 91-820552 Impeller Shaft Removal 1. Remove Stator, Wear Ring and Impeller as described in “Servicing Impeller”. 2. Remove fill and vent screws, drain oil into a suitable container. 3. Remove ride plate. a a -Ride Plate 4.Remove four screws securing impeller shaft cov- er to drive housing. Remove cover. Remove O- ring 53804 NOTE:Take care not to damage or misplace colored shims. a b a -O-ring b -Shims 5. Install seal protector on impeller shaft. a -Seal Protector 6.Push impeller shaft assembly out through front off drive housing. 7.Remove bearing retaining ring from drive hous- ing. 90-831996R1 JUNE 1996 JET PUMP 5-9 8. Remove bearing using Puller 91-83165M. 9. Remove impeller shaft seals using Slide Hammer 91-34569A1. 10. Install new seals using Special Tool 91-820559. 11. Install new bearing using Special Tool 91-820557. 12. Install retaining ring in drive housing after bearing is installed. 13. Clamp an open end wrench in a vise. Place flats of impeller shaft in wrench. 14. Remove nut, washer and gear/bearing assembly. 15. If replacing bearing, remove using universal plate. b a a -Mandrel (15/16 in. socket) b -Universal Puller Plate (91-37241) 16. Press new bearing on gear using an appropriate size mandrel. a a -Mandrel (1-1/8 in. socket) 17. Install gear/bearing assembly and washer on impeller shaft. Apply Loctite 271 to threads of impeller shaft. Install nut and torque to 90 lb. ft. (122 N·m). 5-10 JET PUMP 90-831996R1 JUNE 1996 18. Do not install impeller shaft if shimming is required (See next section). Install seal protector (90-820553) on impeller shaft. Install impeller shaft in drive housing using a twisting motion. 19. Remove outer race from front cover using Puller 91-83165M. 20. Press new outer race into front cover using Special Tool 91-820556. 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) 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. 3. Torque screws to 180 lb. in. (20.3 N·m). 4. Rotate pinion shaft ten revolutions to properly seat roller bearings. 5. Insert Pinion Location Tool (Special Tool 91-824890) in drive housing. NOTE:Carefully inspect location tool to made sure it is seated in drive housing bearing. 90-831996R1 JUNE 1996 JET PUMP 6. 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). 7. 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. 8. Install Impeller Shaft Seal Protector (Special Tool 91-820553) over impeller threads of impeller shaft assembly. 9. Using a twisting motion install impeller shaft assembly in drive housing. 10. 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. 11. Install impeller shaft cover. Torque screws to 180 lb. in. (20.3 N·m). • Rotate impeller shaft ten revolutions to properly seat roller bearings. 12. Install impeller shaft pre-load tool (91-824871A1). • Remove seal protector from impeller shaft. • Install impeller thrust washer, spring, and spring seat on impeller shaft. a b c a -Thrust Washer b -Spring c -Spring Seat 13. Install wear ring and stator on impeller shaft. Secure assembly with two bolts (opposite corners). Torque bolts to 30 lb. ft. (40.7 N·m). a b a -Wear Ring b -Stator 5-12 JET PUMP 90-831996R1 JUNE 1996 14. Install Backlash Indicator Rod (Special Tool No. 91-53459) on pinion shaft. a -Backlash Indicator Rod 91-53459 15. 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. 16. 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. 17. Install impeller as outlined in “Installing Impeller” in this section. 18. Install wear ring and stator. Apply Loctite 271 to four screws. Torque screws to 30 lb. ft. (40.7 N·m). ba a -Wear Ring b -Stator Assembly 19. Remove stator fill screw with washer and fill stator with High Performance Gear Lube. Capacity is 3.4 oz. (100 cc). Install fill screw and washer. a a -Fill Hole 20. Install rideplate. DO NOT reuse screws. Apply Loctite 242 to threads of new screws. Torque to 75 lb. in. (8.5 N·m). 90-831996R1 JUNE 1996 JET PUMP 21. Apply Loctite 242 to screws (2) securing stator to the ride plate. Torque screws to 75 lb. in. (8.5 N·m). d a b c a -Screws (2) to Stator Assembly b -Anode c -Nozzle Assembly d -Screws (4) to Nozzle Assembly 22. Install nozzle/reverse gate assembly and anode. Apply Loctite #271 to threads of screws. Torque all four (4) screws to 30 lb. ft. (40.7 N·m). 23. Remove fill and vent screws from bottom of drive housing. Fill drive housing with High Performance Gear Lube. Capacity is 18.6 oz. (550 cc). NOTE: To obtain correct oil level pump housing must be level and upright. 24. Attach shift and steering cables. REFER TO SECTION 6: SPORT JET INSTALLATION FOR SHIFT AND STEERING INSTALLATION AND ADJUSTMENT. 5-14 JET PUMP 90-831996R1 JUNE 1996 90-831996R1 JUNE 1996 JET PUMP Nozzle/Rudder Components Loctite 271 (92-823089--1) Quicksilver Lubrication/Sealant Application Points B A 2-4-C w/Teflon (92-825407A12) Item Qty Description Torque Lb. In. Lb. Ft. N·m 1 2 Screw M6 x 1 x 13 2 1 Lockwasher, External 3 1 Anode 4 1 Gate 5 1 Screw, Pivot 6 2 Screw (10-24 x 3/8 in.) 7 1 Tab Lock 8 1 Bracket 9 1 Swivel 5-16 JET PUMP 90-831996R1 JUNE 1996 Item Qty Description Torque Lb. In. Lb. Ft. N·m 10 2 Screw 1/4-20 x 5/8 in. 50 5.6 11 1 Tab, Locking 12 1 Bracket 13 1 Nut 1/4-20 70 7.9 14 4 Bolt, Pivot 25 33.9 15 4 Screw M10 x 1.50 x 100 30 40.7 16 1 O-ring 17 1 Screw Plug 18 2 Plug, Pipe 19 1 Stator 20 1 Plug 21 2 Bushing 22 2 Seal 23 1 Wear Ring 24 1 Impeller Nut 70 95 25 1 Tab Lock Washer 26 1 Impeller 27 1 Washer 28 1 O-ring 29 2 Screw M10 x 1.50 x 45 30 1 Anode 31 4 Bushing 32 1 Nozzle 33 2 Fitting 34 1 Syphon Hose 35 2 Sta-strap 36 2 Screw M8 x 1.25 x 30 37 2 Washer 38 2 Reverse Gate Stop 39 2 Screw M10 x 1.50 x 35 40 1 Rudder/Steering Lever (One Piece) 41 1 Cotter Pin 42 1 Washer 43 1 Clevis Pin 44 3 Screw M8 x 1.25 x 25 45 1 Steering Lever 46 1 Rudder 47 2 Lockwasher, External 90-831996R1 JUNE 1996 JET PUMP Pinion and Impeller Shaft Components 1 20 30 40 50 60 70 80 9 10 11 14 15 16 17 12 130 B B 180 A A A A A B Quicksilver Lubrication/Sealant Application Points B A 2-4-C w/Teflon (92-825407A12) Loctite 271 (92-823089--1) 5-18 JET PUMP 90-831996R1 JUNE 1996 Item Qty Description Torque Lb. In. Lb. Ft. N·m 4 Bolt (M8 x 1.25 x 25) 15 20.3 1 Rubber Ring 2 Seal 1 Ball Bearing 1 Housing Assy. AR Shim 1 O-ring 1 Bearing Assy. 1 Gear Shaft Assy 1 Impeller Shaft 1 Gear 1 Bearing Assy. 1 Washer 1 Nut (M14 x 1.5) 90 122 1 Cover Assy. AR Shim 1 O-ring 4 Bolt (M8 x 25) 15 20.3 90-831996R1 JUNE 1996 JET PUMP Printed in U.S.A. 6-–1 - 90-823860961 495 6 SPORT JET INSTALLATION Table Of Contents Page General Information . . . . . . . . . . . . . . . . . . . . . . . 6-1 Notice to Installer . . . . . . . . . . . . . . . . . . . . . . 6-1 Installation Products . . . . . . . . . . . . . . . . 6-1 Torque Specifications . . . . . . . . . . . . . . . . . . . 6-1 Serial Number Decal Location . . . . . . . . . . . 6-2 Corrosion Protection . . . . . . . . . . . . . . . . . . . 6-2 Installation Requirements . . . . . . . . . . . . . . . . . . 6-2 Battery/Battery Cables. . . . . . . . . . . . . . . . . . 6-2 Boat Construction. . . . . . . . . . . . . . . . . . . . . . 6-3 Engine Compartment Ventilation . . . . . . . . . 6-3 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . 6-3 Fuel Delivery System . . . . . . . . . . . . . . . . . . . 6-3 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Instrumentation Wiring Diagram . . . . . . . . . . 6-5 Impeller Selection . . . . . . . . . . . . . . . . . . . . . . 6-6 Remote Control and Cables . . . . . . . . . . . . . 6-6 Steering Helm and Cable . . . . . . . . . . . . . . . 6-6 Page Sport Jet Hull Dimensions . . . . . . . . . . . . . . . . . . 6-7 Installing Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Hull Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Cutout thickness. . . . . . . . . . . . . . . . . . . . 6-9 Steering Cable Adjustment . . . . . . . . . . . . . 6-10 Shift Cable Adjustment . . . . . . . . . . . . . . . . 6-12 Bilge Siphon Feature . . . . . . . . . . . . . . . . . . . . . 6-14 Installing Bilge Siphon . . . . . . . . . . . . . . . . . 6-14 Installing Powerhead . . . . . . . . . . . . . . . . . . . . . 6-15 Throttle Cable Adjustment . . . . . . . . . . . . . . 6-16 Battery Connection. . . . . . . . . . . . . . . . . . . . 6-16 Oil Injection System . . . . . . . . . . . . . . . . . . . 6-17 Check Oil Pump Adjustment. . . . . . . . . . . . 6-17 Ride Plate Adjustment . . . . . . . . . . . . . . . . . . . . 6-18 Pre-delivery Inspection . . . . . . . . . . . . . . . . . . . . 6-19 90-831996R1 JUNE 1996 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 installation 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 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) 90-831996R1 JUNE 1996 SPORT JET INSTALLATION 6-1 6-2 SPORT JET INSTALLATION 90-831996R1 JUNE 1996 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 b c OGXXXXXX a d e a - Engine Serial Number d - Certified Europe b - Model Year e - Pump Unit Serial Number c - Year Manufactured 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 (25mm2) 3-1/2 - 6 ft. (1.1-1.8 m) 2 (35mm2) 6 - 7-1/2 ft. (1.8-2.3 m) 1 (50mm2) 7-1/2 - 9-1/2 ft. (2.3-2.9 m) 0 (50mm2) 9-1/2 - 12 ft. (2.9-3.7 m) 00 (70mm2) 12 - 15 ft. (3.7- 4.6 m) 000 (95mm2) 15 - 19 ft. (4.6 - 5.8 m) 0000(120mm2) 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. 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. (51mm) 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* 90/95 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. b c a d a -From Waterline to Top of Transomb -From Highest Point on Exhaust Elbow to Top of Transomc -(a) minus (b) = (c) d -Waterline at Rest (at Maximum Load) Model c = (a) minus (b) 90/95/120 HP (c) must be 7.5 in. (330 mm) or more. Fuel Delivery System ! WARNING Boating standards (NMMA, ABYC, etc.), federal standards and Coast Guard regulations for INBOARD engines must be adhered to when installing fuel delivery system. ! CAUTION Remove plastic plug from fuel inlet fitting. Attach fuel line to fuel fitting with 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. 90-831996R1 JUNE 1996 SPORT JET INSTALLATION 6-3 6-4 SPORT JET INSTALLATION 90-831996R1 JUNE 1996 2. Fuel pickup should be at least 1 in. (25mm) 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. (8mm) 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. a a - Fuel Inlet 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 properly. Fasten harness(es) to boat at least every 18 in. (460 mm), using appropriate fasteners. Instrumentation Wiring Diagram QUICKSILVER INSTRUMENTATION, TYPICAL INSTALLATION SHOWN REFER TO GAUGE MANUFACTURER’S INSTRUCTIONS FOR SPECIFIC CONNECTIONS. (Included With Gauge) Temperature Sender 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 T P Liquid Neoprene (92-25711--2) Dielectric Grease (92-823506--1) 90-831996R1 JUNE 1996 SPORT JET INSTALLATION 6-5 Impeller Selection IMPORTANT: Installed impeller must allow engine to run in its specified maximum wide-openthrottle 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 a Morse MV2 “special” remote control. This control has been qualified by Mercury to be used for the Sport Jet and provides the following features: • Start-in-Neutral Protection • Fast Idle Speed Limit at 1800 RPM • Increased Strength to Compensate for Higher Shift Loads Transmitted Through the Shift Cable • Shift Cable Travel of 2.50 inches (63.5 mm) If a control other than the Morse MV2 “special” remote control is to be used, the control must meet the above criteria as well as be approved by Mercury Marine Engineering. Contact Mercury Marine Distribution for availability of this control box. SHIFT 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. 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. • Allow for a minimum of 3.75 inches (95.3 mm) of travel. • Cable end at pump must allow for a shouldered thru-bolt to connect the cable to the steering arm. • A means of attaching and locking the cable to the steering cable bracket (provided). • Protected against water intrusion and/or corrosion as the cable end (at the pump) is submersed in water with the boat at rest. A locking tab is provided by Mercury to be used with a cable having threads and locknuts located 11.31 inches (287 mm) from cable end at pump with cable at center of travel. 6-6 SPORT JET INSTALLATION 90-831996R1 JUNE 1996 a 1. Location (a) of the pump to powerhead hull cut out Sport Jet Hull Dimensions relative to the boat bottom for proper ride plate seal fit. 90/95/120 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 HULL OPENING CUT OUT The pump to powerhead opening in the hull is the seal fit. most important factor to consider in a Sport Jet installation. There are three areas of concern: 3. Flatness and thickness of the area around the hull cut out for proper grommet sealing (see drawing on next page ). 6-790-831996R1 JUNE 1996 SPORT JET INSTALLATION 1 1/16 +/– 1/16 3/4 +/– 1/16 7 1/16 +/– 1/16 16 1/4 +/– 1/16 14 11/16 +/– 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 a b c d d c a b and e - Corner Radii c and d - Size and Straightness a - Location Tunnel Dimensions (in inches) e Mounting Flange Thickness Specifications 1 Inch Minimum Flange Width Recommended Flange Flatness: .030 Inch Maximum Between Reference Points AA Section A-A 1/2 1/2 1/2 1/2 1 1/2 Inch Dia. Hole Saw GO NO GO Max. Size Min. Size a c b a a a a - Location Pins in Hull Mold b - Flange Flatness Specification c - Go – No Go Gauge for Thickness 1/2” +0.070 –0.030 1/4” +0.050 –0.030 3/8” +0.050 –0.030 Use Grommet P/N: 25-820663-250 25-820663-375 25-820663-500 METHODS OF CONTROLLING LOCATION AND SIZE If the tunnel area in the plug is correct, the boat bot- tom 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 con- nect the four holes. CHECKING MOUNTING FLANGE THICKNESS AND FLATNESS Use a flat plate that will contact the flange at the refer- ence points (b) and a .030 in. feeler gauge to check flatness. Additional sanding and/ or resin/ filler may be re- quired to maintain the flatness specification. A simple slotted go/ no go gauge (c) will check the flange thickness. 6-8 SPORT JET INSTALLATION 90-831996R1 JUNE 1996 2. Spray soapy water on tunnel grommet, both side Installing Jet Pump foam exhaust seals (a) ride plate seal (b) and sides of boat tunnel. 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 ÀÀÀÀÀÀÀÀÀÀÀÀ1/4” +0.050 –0.030 3/8” +0.050 –0.030 Use Grommet P/N: 25-820663-250 25-820663-375 1/2” +0.070 25-820663-500 –0.030 CUTOUT THICKNESS b a Bottom View a -Side Foam Exhaust Seals (One Each Side) b -Ride Plate Seal 3. Route steering cable (b) through port side hole (a) in flange of pump housing. Route shift cable (d) through starboard side hole (c) in flange of pump housing. b a d c NOTE: When installing pump in tunnel, be sure cables are below flange on pump to prevent pinching of cables between pump and boat. 90-831996R1 JUNE 1996 SPORT JET INSTALLATION 6-9 c d NOTE: Before torquing fasteners, check side ex- haust seals and ride plate seal for proper fit in tunnel. 6.Torque housing cover nuts (c) to 35 lb. ft. (47 N·m). a b d c a -Steering Cable Attaching Nuts and Tab Washer b -Mounting Bracket c -Mounting Bracket Screws (3) d -Shift cable 4. 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. b a a -Jet Pump b -Tunnel Grommet 5.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). Steering Cable Adjustment 1. Loosen steering cable thru-hull fitting. Pull steering cable out as far as possible to allow enough room to work. Attach steering cable mounting bracket (b) to cable (d) using two (2) nuts (a) and one tab washer (e). Position bracket so that when nuts are tighten securely, 1/16 to 1/8 in. of cable threads are exposed. This is the preliminary coarse adjustment. Tighten nuts securely, bend washer against flats of each nut. bc a d e 2. Apply Loctite 271 (red) to three (3) screws (c) and attach bracket (b) to pump housing. Torque screws to 200 lb. in. (23 N·m). SPORT JET INSTALLATION 90-831996R1 JUNE 1996 3. 3. Center rudder assembly on nozzle. 4. Thread jam nut (a) and cable end adaptor (b) on steering cable. b a 5. Center steering wheel by turning wheel lock to lock and positioning wheel midway between locks. 6. Adjust cable end adaptor (a) until thru-hole in adaptor lines up with threaded hole in steering arm (b). This is the steering cable fine adjustment. Cable end adaptor MUST be installed on steering cable a minimum of nine (9) turns. Tighten jam nut against adaptor. b a ! WARNING 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. 7. If additional adjustment is required, the steering cable can be re-adjusted as described in step 1., preceding. Be sure to tighten nuts and bend tab washer after adjustment is made. 8. Attach steering cable to steering arm with bolt (a) and locknut (b). a b 9. Tighten steering cable thru-hull fitting (a) from inside boat to prevent any leaks. a a -Steering Cable Thru-Hull Fitting 90-831996R1 JUNE 1996 SPORT JET INSTALLATION 6-11 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 the stop in forward or reverse. Pre-load in either position will cause failure of the stop and/or premature wear of the shift cable/control box components. 1. Install shift cable end (b) in slot of reverse gate (a) and secure with clevis pin (c), washer (d), and cotter pin (e). Bend over ends of cotter pin. b c d e a a -Reverse Gate Slot b -Shift Cable End c -Clevis Pin d -Washer e -Cotter Pin 2. Mount shift cable adjustment bracket (a) to stator with screws (b) and locking tab (c). Do not tighten screws at this time. a b c 3. Install shift cable and secure with clamp (a), tab lock (b), and two (2) screws (c) making sure that thru-hole (e) in swivel is located below cable. The radius portion of the tab lock (b) must face towards the reverse gate. Torque screws to 50 lb. in. (5.6 N·m). Bend tabs (d) over flats of screw heads. b a c d d e 6-12 SPORT JET INSTALLATION 90-831996R1 6JUNE 199 4. 4. Shift remote control to forward. 5. Position reverse gate (a) with cupped edge at or slightly above rudder I.D. (b). b a a -Reverse Gate Cupped Edge b -Rudder I.D. 6. Loosen forward stop screw (a) and rotate forward stop (located on port side of nozzle) clockwise until it just contacts reverse gate (b). Torque forward stop screw to 120 lb. in. (14 N·m). b a IMPORTANT: Forward stop must be correctly adjusted so that reverse gate does not interfere with water flow coming out of rudder. IMPORTANT: Check that upper edge of reverse gate does not interfere with steering arm attaching screws throughout steering range when reverse gate is in the forward position. 7. Adjust shift cable bracket (c) so that reverse gate touches forward stop but does not pre-load shift cable. Torque bracket screws (d) to 50 lb. in. (5.6 N·m). Bend locking tabs against flats of screw head. c d IMPORTANT: Inspect position of reverse gate in forward gear, reverse gate must not interfere with water flow coming out of rudder. 8. Shift remote control to reverse. 9. Loosen reverse stop screw (e) and rotate stop (located on starboard side of nozzle) clockwise until it just contacts reverse gate. Torque screw to 120 lb. in. (14 N·m). e 90-831996R1 JUNE 1996 SPORT JET INSTALLATION 6-13 10. Check shift cable/reverse gate adjustments as follows: a. Shift control box to forward gear. b. Pivot reverse gate up and down using light pressure. Gate should be able to move within the clearance between the shift cable end and clevis pin (a). If not, gate is pre-loaded against the stop. Repeat steps 2 through 11. a c. Shift control box to reverse and repeat step b. (above). NOTE: In neutral, the reverse gate covers approximately 3/4 of the rudder opening. IMPORTANT: After any adjustments are made shift control box through entire range and recheck reverse gate clearance to rudder (step 5 preceding) and reverse gate stops (step 11 ). NOTE: Be sure shift cable swivel does not interfere with stator mounting bolt (b) through-out entire shift range. 11. Tighten shift cable thru-hull fitting (a) from inside boat to prevent any leaks. a Bilge Siphon Feature The Sport Jet incorporates an automatic bilge siphoning feature. The bilge siphon is working whenever the engine is running. Two hoses are attached to the jet pump nozzle. The hoses are routed to the engine compartment and placed on each side of the jet tunnel. Water exiting the nozzle creates a suction or vacuum in the hoses creating the bilge siphon. Installing Bilge Siphon 1. Attach the two hoses supplied to the hose barbs located at the center rear of the drive housing cover. 2. Attach the hoses to the transom with the hose clips supplied. IMPORTANT: 3. Position each siphon break (a) a minimum of 8 in. (203 mm) above pump cover. b 8 in. minimum (203 mm)a SPORT JET INSTALLATION 90-831996R1 JUNE 1996 90-831996R1 JUNE 1996 SPORT JET INSTALLATION 6-15 Installing Powerhead 1. Remove exhaust bellows (a) from exhaust elbow and install on drive housing cover (b). 2. Check that o-rings (c) are in drive housing cover (b), and slinger (d) is on drive shaft. b a c d a - Exhaust Bellows b - Drive Housing Cover c - O–Rings d - Slinger 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 (a) on drive housing cover. Snug nut with wrench then tighten nut one additional flat (60 degrees). a a - 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 a b a a b a a a - M10 x 1.5 Nuts – 35 lb. ft. (47 N·m) b - M8 x 1.25 Nuts – 20 lb. ft. (27 N·m) 8. Attach positive and negative 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. b c a a -Positive Battery Cable Boot b -Engine and Remote Harness Connection c -Negative Battery Cable 10. Attach throttle cable to towershaft arm (a) with washer and cotter pin. a a -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 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. SPORT JET INSTALLATION 90-831996R1 JUNE 1996 Oil Injection System ! CAUTION Oil injected engines must be run on a 50:1 gasoline/ oil mixture in the fuel tank for the first 12 gallons of fuel. Refer to engine break-in procedures in the Operation & Maintenance Manual. 1. Mount the oil reservoir in a suitable location. IMPORTANT: Oil Reservoir must be mounted higher than the oil pump. Oil is gravity fed to the oil pump. 2. Connect reservoir oil hose (a) to inlet barb on oil pump. c b a a -Oil Inlet Hose b -Oil Outlet Hose c -Bleed Screw 3. Low oil switch in reservoir is wired as follows: a. Connect the black lead to a good engine ground. Connect the white lead to the power- head wire harness (tan/blue lead located by ignition plate). b a a -Oil Reservoir b -Low Oil Switch 4. Temporarily connect battery cable leads making sure all leads are connected correctly. 5. Test the low oil warning alarm by turning the key switch to the “ON” position. With no oil in the reservoir, the alarm should sound a constant tone. If no warning is emitted check wiring and battery leads. 6. Fill the reservoir with recommended two cycle oil. Turn the key switch to “ON” and recheck alarm system, no alarm should sound. If the warning does sound, there is a problem with the float switch. Make sure the switch is mounted in a vertical position. 7. 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 and bleed air out until oil is present. Tighten bleed screw. 8. Secure oil inlet hose at oil pump and oil reservoir with sta-straps provided. The oil injection system is now operational. 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. Oil Pump Lever ab -Alignment Mark (At Wide Open Throttle) 2. Adjust oil pump link rod as required. 90-831996R1 JUNE 1996 SPORT JET INSTALLATION 6-17 Ride Plate Adjustment NOTE: The trailing edge of the ride plate can be adjusted to act as a trim tab in certain boat applica- tions (to correct porpoising, etc.). IMPORTANT: When bending ride plate, be careful to bend only at notches on sides of ride plate. It will be necessary to remove ride plate and install it in a holding fixture. Damage to ride plate and/or boat performance loss may occur if ride plate is bent at any location other than at notches. 1. Remove two (2) ride plate-to-stator screws (a), and eight (8) ride plate-to-pump housing screws (b). b aPort Side View of Pump a - Ride Plate Notch (One Each Side) b - Intake Screen (Bottom of Pump) a b b a - Ride Plate-to-Stator Screws b -Ride Plate-to-Pump Housing Screws 2.Bend trailing edge of ride plate at notches (a) to appropriate level. 3. Install necessary shims between ride plate and stator bosses (a). a a - Add Shims Here (Two Sides) 4. Apply loctite 242 (blue) to all ten (10) ride plate screws and install. Torque to 75 lb. in. (8.5 N·m). SPORT JET INSTALLATION 90-831996R1 JUNE 1996 Pre-delivery Inspection Not Check/ Applicable Adjust CHECK BEFORE RUNNING oo Water hose connection/torqued oo Cover plate & adaptor plate fasteners torqued oo Battery charged & secure oo All electrical connections tight oo Exhaust hose clams tight oo All fuel connections tight oo Throttle, shift, & steering adjusted correctly and fasteners torqued oo Carb throttle shutters open & close completely oo Pump housing oil level full (See Owner’s Manual) oo Oil injection reservoir full and bled oo Warning system(s) operational On the water test oo Starter neutral safety switch operational oo Lanyard stop switch operational oo All gauges read properly oo No fuel or oil leaks oo No water leaks oo No exhaust leaks oo Ignition timing set to specs oo Idle:____________RPM oo Idle mixture adjusted oo Forward-Neutral-Reverse operational On the water test (continued) Not Check/ Applicable Adjust oo Steering operational throughout entire range oo Acceleration test. oo WOT:___________RPM oo Boat handling Post water test o. No fuel, oil, water or exhaust leaks o. Re-torque adapter plate fasteners 90-831996R1 JUNE 1996 SPORT JET INSTALLATION 6-19