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TIMING, SYNCHRONIZING &
ADJUSTING
Page 2C-2
90-884294 OCTOBER 2001
Special T
ools
1.
Digital Diagnostic T
erminal (DDT) 91-823686A2
2.
Software Cartridge 91-8801
18A2
3.
DDT Reference Manual 90-881204-1
4.
Adaptor Harness 84-822560A5 (use with DDT)
145
147
Table of Contents
Main Page
Important Information 1
10
Table of Contents
10
Inspection and Maintenance Schedule
12
Before each Use
12
After each Use
12
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
12
Flushing Engine
13
Flushing Cooling System - Using Cowl Flush Plug
13
Flushing Cooling System - Using Flushing Attachment 44357A2
13
Fuel System
14
Fuel Line Inspection
14
Water Separating Fuel Filter - EFI Models
14
Corrosion Control Anode
15
Battery Inspection
16
Fuse Replacement
16
Lubrication Points
17
Checking Power Trim Fluid
18
Gear Case Lubrication
19
Storage Preparation
20
Important Information 1
22
Conditions Affecting Performance
23
Weather
23
Boat
24
Trim
24
Engine
26
Engine Compression
26
Following Complete Submersion
27
Salt Water Submersion
27
Submerged While Running
27
Model 3 Liter Work/225 EFI/250 EFI Powerhead Front View
29
Model 3 Liter Work/225 EFI/250 EFI Powerhead Starboard View
30
Model 3 Liter Work/225 EFI/250 EFI Powerhead Port View
31
Model 3 Liter Work/225 EFI/250 EFI Powerhead Top View
32
Model 3 Liter Work/225 EFI/250 EFI Powerhead Aft View
33
Painting Procedures
34
Color Impregnated Top Cowls
34
Cleaning & Painting Aluminum Propellers & Gear Housings
34
Decal Application
36
Decal Removal
36
Instructions for "Wet" Application
36
Important Information 1
38
Installing Outboard to Boat Transom
39
Determining Recommended Outboard Mounting Height
39
Installing Outboard
40
Drilling Outboard Mounting Holes
40
Securing Outboard to Boat Transom
41
Steering Cable
41
Steering Link Rod
42
Electrical, Hoses and Control Cables
43
Installation Note
43
Remote Wiring Harness
43
Battery Cables
44
Fuel Hose Connection
45
Oil Hose Connections
45
Speedometer Tubing Connection
45
Water Pressure Tubing Connection
45
Shift Cable
46
Counter Rotation Outboards
46
Installation
47
Throttle Cable
49
Installation
49
Front Clamp Reassembly
50
Oil Injection Set-Up
51
Installing Remote Oil Tank
51
Filling
52
Priming the Oil Pump
53
Priming Procedure - Method 1
54
Purging Air from the Engine Oil Reservoir
55
Trim in Stop Adjustment
55
Trim Tab Adjustment
56
Models Without Power Steering
56
Models with Power Steering
56
Electrical 2
57
Specifications
58
Ignition Coil Ohms Test
58
Manifold Absolute Pressure (MAP) Sensor Ohms Test
59
Port and Starboard Temperature Sensors; Air Temperature Sensor
60
Special Tools
61
Coil Plate Assembly
64
Electrical Plate Assembly
66
Theory of Operation
70
Ignition Component Description
71
Fuses
71
Charging System Alternator
72
Ignition Coil
72
Electronic Control Module
73
Flywheel
74
Crank Position Sensor
74
Throttle Position Sensor (TPS)
75
Throttle Position Sensor (TPS) Troubleshooting
75
Cylinder Head Temperature Sensor
76
Air Temperature Sensor
76
Port and Starboard Temperature Sensors; Air Temperature Sensor
77
Manifold Absolute Pressure (MAP) Sensor
78
Ignition Troubleshooting and Fault Chart
79
Ignition Coil Ohms Test
83
Idle Speed Control
84
Manifold Absolute Pressure (MAP) Sensor Ohms Test
84
RPM-Limit Circuit
84
Detonation Circuit Test
85
EFI Detonation Control System (200 Work Model Only)
85
Flywheel Removal
86
Ignition Component Removal and Installation 2A-30
86
Flywheel Installation
87
Ignition Coil Removal
87
Electronic Control Module Installation
88
Electronic Control Module Removal
88
Ignition Coil Installation
88
Engine Head Temperature Sensor Installation
89
Temperature Sensor Removal
89
Air Temperature Sensor Installation
90
Air Temperature Sensor Removal
90
Manifold Absolute Pressure (MAP) Sensor Installation
90
Manifold Absolute Pressure (MAP) Sensor Removal
90
Crank Position Sensor Installation
91
Crank Position Sensor Removal
91
Electrical 2
92
Specifications
93
Special Tools
94
Battery Cable Size
95
Recommended Battery
95
Replacement Parts
95
Battery
96
Precautions
96
Charging a Discharged Battery
96
Winter Storage of Batteries
97
Flywheel Removal and Installation
98
Removal
98
Installation
99
Notes
100
Flywheel/Alternator
101
System Components
102
Precautions
103
Alternator Description
103
Diagnosis of Alternator System on Engine
104
Alternator System Circuitry Test
105
Output Circuit
105
Sensing Circuit
106
Voltage Output
107
Current Output
108
Current Output Troubleshooting
109
Repair
109
Removal
109
Alternator Belt Tension Adjustment
111
Starter System
112
Starter Motor Amperes Draw
112
Starter System Components
112
Description
112
Starter Motor (Centrifugal Bendix)
113
Troubleshooting the Starter Circuit (Centrifugal Bendix)
115
Starter Circuit Troubleshooting Flow Chart (Centrifugal Bendix)
116
Flow Chart (Continued)
117
Starter Installation (Centrifugal Bendix)
118
Starter Removal (Centrifugal Bendix)
118
Starter Disassembly (Centrifugal Bendix)
119
Starter Cleaning, Inspection and Testing
121
Starter Reassembly
124
Starter Motor (Solenoid Driven Bendix)
129
Troubleshooting the Solenoid Driven Bendix Starter Circuit
131
Starter Circuit Troubleshooting Flow Chart (Solenoid Driven Bendix)
132
Starter Installation (Solenoid Driven Bendix) 2B-43
134
Starter Removal (Solenoid Driven Bendix)
134
Disassembly (Solenoid Driven Bendix Starter) 2B-45
136
Cleaning and Inspection
139
Reassembly (Solenoid Driven Bendix Starter) 2B-49
140
Commander 2000 Key Switch Test
144
Electrical 2
151
Power Trim Wiring Diagram
152
Instrument Wiring Connections
153
Commander 3000 Classic Panel Remote Control
154
Commander 3000 Panel Remote Control
155
4000 Series Mechanical Panel Control
156
Instrument/Lanyard Stop Switch Wiring Diagram
157
Oil Level Gauge Wiring Diagram
158
Notes
159
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
160
QSI Gauge Wiring Diagrams
162
Tachometer Wiring Diagram
162
Water Temperature Gauge
163
Oil Level Gauge Wiring
164
Engine Synchronizer Wiring Diagram
166
Maintenance
167
Warning System Signals
168
Guardian Protection System
169
Guardian System Operation with Gauges 2D-19
169
Guardian System Activation
169
Analog Gauge Panel Mount Remote Control Wiring Installation
171
System Monitor V2.0
172
Basic Operation
172
Initial Power up (or after Master Reset) . 2D-22
172
Standard Information Display Screens
173
Display of Range and Depth Information
175
Warning System
176
Warning Display Screens
177
CAL1 Calibration
180
CAL2 Calibration
182
Master Reset Command
185
System Tach & Speed
186
Basic Operation and Features
186
Speedometer Display Screens
187
Tachometer Display Screens
188
Troll Control
189
Warning System
190
Alarm Messages
191
Auto-Detection Engine Function
195
Master Reset Command
195
Tachometer Calibration
196
Speedometer Calibration
200
Smartcraft Gauge Operation
202
Basic Operation and Features
202
Speedometer Display Screen
203
Tachometer Display Screens
204
Troll Control
205
Warning System
206
Alarm Messages
207
Tachometer Calibration
211
Speedometer Calibration
214
Smartcraft Gauge Test Specifications
216
Test Equipment Required
216
Liter Work/225 EFI/250 EFI Wiring Diagram
217
Fuel System
218
Special Tools
219
Specifications
219
Fuel Pump Pressure @ W.O.T
219
Fuel Pump Pressure @ Idle
219
Notes
220
Fuel Pump Assembly
221
Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
223
Fuel Pump Description/Operation
223
Checking Fuel Pump Lift (Vacuum)
224
Fuel Pump Capability Test
225
Fuel System Leak Test
225
Vacuum Test
225
Fuel Pump Removal/Disassembly
226
Cleaning/Inspection
227
Reassembly/Lnstallation
227
Fuel System
230
Specifications
231
Special Tools
232
Notes
234
Fuel Management System
235
Vapor Separator Components
239
Electronic Fuel Injection (Efl) System
241
Introduction
241
Using the Test Procedures
241
EFI System Tests
241
Safety Precautions
241
Fuel Injection System Function
242
Preliminary Checks
242
Ignition Spark Check
242
Electronic Fuel Injection Set up
243
Fresh Quality Fuel
243
Low Battery Voltage
243
Fuel Flow Diagram
244
Fuel Flow Component Description
245
EFI Electrical Components
246
EFI Fuel Management (Low Pressure Fuel Route)
248
EFI Fuel Management (High Pressure Fuel Route)
249
Fuel Rail Electrical/Fuel Determination
250
EFI System Test Procedures
251
Fuel Gauge Connection/Pressure Test
251
Vapor Separator Fuel Delivery Test
252
Pulse Fuel Pump Delivery Test
253
Water Separating Filter Inspection
254
Vapor Separator Float Test
255
Pressure Regulator Test
258
Injector Electrical Harness Test
260
Injector Load Test
261
Fuel Rail Assembly Leakage Test
261
Air Temperature Sensor and Head Temperature Sensor Test
262
Detonation Control System Test (200 Work Models Only)
263
Throttle Position Sensor Test
264
MAP Sensor Test
265
Problem Diagnosis
266
Engine Head Temperature Sensor Installation
269
Fuel Management Assembly Removal
270
Fuel Rail Removal
274
Fuel Rail Installation
276
Reed Block Assembly Removal
278
Reed Block Assembly Installation
278
Air Temperature Sensor Removal
279
Air Temperature Sensor Installation
279
Manifold Absolute Pressure (MAP) Sensor Removal
279
Manifold Absolute Pressure (MAP) Sensor Installation
279
Throttle Plate Assembly Removal
280
Throttle Plate Assembly Installation
280
Vapor Separator Disassembly
280
Vapor Separator Reassembly
282
Air Plenum Installation
283
Vapor Separator (VST) Installation
284
Water Separating Filter Assembly Removal
285
Water Separating Filter Assembly Installation
285
Throttle Position Sensor Removal
286
Throttle Position Sensor Installation
286
Oil Reservoir Removal
287
Oil Reservoir Installation
287
Fuel Pressure Regulator Removal
288
Fuel Pressure Regulator Disassembly
289
Fuel Pressure Regulator Reassembly
289
EFI System Cleaning and Inspection
290
Cleaning
290
Inspection
290
Fuel System
291
Default Chapter
292
Operation of the Oil Injection System
292
Final Checks before Operation of Engine
292
Checking Operation of the Oil Injection
292
Specifications
298
Oil Injection Components
294
Oil Pump Removal and Installation
298
Oil Injection
298
Table of Contents
300
Priming the Oil Pump
300
Priming Procedure - Method 1
301
Remote Oil Hose Connections
302
Filling the Oil Tanks
303
And Remote Oil Hose
303
Oil Warning Systems
304
Oil System Troubleshooting
305
Low Oil Warning System Is Activated
305
Fuel System
306
Controlling Emissions
307
Outboard Hydrocarbon Emissions Reductions
307
Oxides of Nitrogen - Nox
307
Stoichiometric (14.7:1) Air/Fuel Ratio
307
Stratified Vs Homogenized Charge
308
Homogenized Charge
308
Stratified Charge
309
Emissions Information
309
Manufacturer's Responsibility
309
Dealer Responsibility
310
Owner Responsibility
310
EPA Emission Regulations
310
Manufacturer's Certification Label
311
Service Replacement Certification Label
312
Removal
312
Date Code Identification
312
Installation
312
Decal Location
312
Section 4A - Powerhead
313
Specifications
314
Block
314
Reed Valve Opening
314
Cylinder Bore
314
Piston
314
Special Tools
315
Powerhead Repair Stand
316
Notes
317
Cylinder Block Assembly
318
Exhaust Adaptor Plate
322
Crankshaft, Pistons and Connecting Rods
324
Starboard Bleed System Routing
326
Port Bleed System Routing
328
Torque Sequence
330
General Information
332
Powerhead Removal from Driveshaft Housing
333
Removing Engine Components
339
Removing Engine Components Individually
339
Vapor Separator Tank (VST) Removal
340
Air Plenum Removal
342
Starter Motor
345
Electrical Plate Removal
346
Alternator Removal
347
Powerhead Disassembly
348
Cleaning and Inspection
359
Cylinder Block and Crankcase Cover
359
Special Service Information
359
Cylinder Bores
360
Pistons and Piston Rings
361
Cylinder Heads
363
Crankshaft
363
Crankshaft (and End Cap) Bearings
364
Reed Block Assembly
365
End Bearing Bleed System
365
Connecting Rods
365
Thermostats (120 F) (49 C)
367
Powerhead Reassembly and Installation
368
General
368
Crankshaft Installation
371
Piston and Piston Ring Combinations
374
Piston Installation
375
Crankcase Cover Installation
379
Assembly of Reed Blocks to Reed Block Adaptor Plate
381
Notes
385
Powerhead Installation on Driveshaft Housing
388
Shift Cable
394
Counter Rotation Outboards
394
Installation
395
Throttle Cable
397
Installation
397
Front Clamp Reassembly
398
Engine Break-In Procedure
399
Gasoline/Oil Break-In Mixture
399
Break-In Procedure
399
Powerhead
400
Specifications
401
Water Pressure
401
Thermostat
401
Digital Port and Starboard Temperature Sensor
402
Analog Temperature Sensor
403
Special Tools
404
Water Flow
405
Description
405
Water Flow Diagram
406
Notes
407
Thermostat Test
408
Troubleshooting
408
Water Pressure Check
409
Water Pump Cleaning and Inspection
410
Problem Diagnosis
411
MID-Section
412
Swivel Bracket and Steering Arm
413
Transom Brackets
415
Drive Shaft Housing and Exhaust Tube
417
Drive Shaft Housing and Dyna-Float Suspension
419
Removal and Disassembly
419
Reassembly and Installation
423
MID-Section
427
Special Tools
428
Power Trim Components (Oildyne)
430
Power Trim Motor (Oildyne)
432
Power Trim - General Information
433
Description
433
Trimming Characteristics
433
Trailering Outboard
434
Tilting Outboard Manually
434
Trim "In" Angle Adjustment
435
Striker Plate Replacement
435
Anode Plate
436
Trim Indicator Gauge
436
Check, Fill and Purge - Power Trim System
436
Trim Circuit
438
Tilt Circuit
440
Down Circuit
442
Trail over and Shock Absorber
445
Manual Tilt
447
Troubleshooting
448
Power Trim System with Relays and 2 Wire Trim Motor
450
Electrical System Troubleshooting
451
General Checks
451
Troubleshooting the "Down Circuit
451
Troubleshooting the "Up" Circuit
452
Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
453
Power Trim Assembly Removal and Installation
454
Removal
454
Installation
457
Testing Power Trim System with Test Gauge Kit (91-52915A6)
459
UP" Pressure Check
459
DOWN" Pressure Check
462
Hydraulic Repair
464
Trim Rod End Cap Seal
465
Tilt Ram
467
Disassembly
468
Memory Piston Removal
470
Cleaning/Inspection/Repair
471
Scraper Seal Replacement
471
Power Trim Disassembly
475
Trim Motor Removal
476
Pump and Component Removal
477
Motor and Electrical Tests/Repair
479
Trim Pump Motor Test
479
Motor Disassembly
479
Armature Tests
480
Motor Repair
481
Reassembly
484
Reassembly - Motor and Pump
486
Priming Power Trim System
488
Analog Trim Sender Test
488
Digital Trim Sender
489
Troubleshooting Digital Trim Sender
490
Trim Indicator Wiring Diagrams
491
Lower Unit
492
Special Tools
493
Gear Housing (Drive Shaft)(Standard Rotation)
497
Gear Housing (Prop Shaft)(Standard Rotation)
499
General Service Recommendations
501
Removal, Disassembly, Cleaning and Inspection - Standard Rotation
502
Removal
502
Draining and Inspecting Gear Housing Lubricant
504
Water Pump
505
Oil Seal Carrier Assembly
507
Drive Shaft Assembly
518
Propeller Shaft Assembly and Forward Gear Bearing Cup
523
Forward Gear Assembly
526
Shift Spool Assembly
529
Propeller Shaft Assembly
531
Shift Shaft Assembly
532
Pinion Bearing
535
Gear Housing Reassembly
536
Gear Housing Inspection
536
Pinion Bearing
537
Forward Gear Bearing Cup
538
Shift Shaft Assembly
539
Propeller Shaft Assembly
541
Drive Shaft and Pinion Gear
542
Gear Location/Backlashes/Checking and Adjustment
545
Drive Shaft - Bearing Preload Tool
545
Pinion Gear Location
546
Bearing Carrier Assembly
549
Forward Gear Backlash
551
Reverse Gear Backlash
552
Drive Shaft - Bearing Preload Tool
554
Bearing Carrier Assembly
555
Final Installation
555
Oil Seal Carrier Assembly
558
Water Pump Assembly
558
Gear Lubricant Filling Instructions
561
Propeller Installation
562
Speedometer Tube Installation
564
Lower Unit
565
Special Tools
566
Gear Housing (Drive Shaft)(Counter Rotation)
572
Gear Housing (Prop Shaft)(Counter Rotation)
574
General Service Recommendations
576
Removal, Disassembly, Cleaning and Inspection of
577
Pre-Disassembly Inspection
580
Propeller Shaft
580
Water Pump
581
Oil Seal Carrier Assembly
583
Forward Gear Bearing Adaptor Assembly
597
Drive Shaft Assembly
599
Propeller Shaft Assembly
604
Reverse Gear Assembly
608
Shift Spool Assembly
611
Reverse Gear Bearing Adaptor Assembly
614
Shift Shaft Assembly
616
Pinion Bearing
619
Gear Housing Reassembly
620
Gear Housing Inspection
620
Pinion Bearing
621
Reverse Gear Bearing Adaptor Assembly
622
Shift Shaft Assembly
624
Gear Location/Backlashes Checking and Adjustment
625
Reverse Gear
625
Drive Shaft and Pinion Gear
626
Gear Location/Backlashes/Checking and Adjustment
629
Pinion Gear Location
630
Reverse Gear Backlash
634
Forward Gear/Bearing Carrier Assembly
636
Forward Gear Backlash
642
Propeller Shaft Assembly
644
Component Reassembly
644
Propeller Shaft Assembly
646
Installation
646
Drive Shaft and Pinion Gear
649
Final Installation
649
Bearing Carrier Assembly
651
Final Installation
651
Oil Seal Carrier Assembly
660
Water Pump Assembly
661
Gear Lubricant Filling Instructions
664
Propeller Installation
666
Speedometer Tube Installation
667
Attachments / Control Linkage
668
Ride Guide Steering Cable/Attaching Kit Installation (92876A10)
668
Maintenance Instructions
669
(92876A8)
670
Dual Cable - Single Outboard
670
Super Ride-Guide Steering Kit Installation
671
Steering Cable Mounting Tube Installation
672
Installing Steering Cables
673
Coupler Installation
674
Installing Link Rod
674
Maintenance Instructions
676
Ride Guide Steering Cable/Attaching Kit Installation
670
(92876A9)
677
Dual Cable - Dual Outboard
677
Ride Guide Steering Cable/Attaching Kit Installation
677
Parallel Routed Steering Cables and Attaching Kit Installation
678
Opposite Side Routed Steering Cables and Attaching Kit Installation
685
Ride Guide Steering Attachment Extension Couplers
692
Trim Tab Adjustment
692
Maintenance Instructions
693
Attaching Kit Installation
695
Transom Mounted Ride Guide Attaching Kit Installation (73770A1)
695
Maintenance Instructions
698
Clevis Attaching Kit Installation (A-70599A5)
699
Installation Instructions
699
Maintenance Instructions
699
225/250/3.0 Litre Work EFI 2002 Model Year
702
Wiring Diagram
702
Typical Smartcraft System Tachometer & System
706
Typical Smartcraft System Monitor/Tachometer
708
Installation with System Link Gauges
708
Typical Smartcraft Dual Outboard Installation 2002 Model Year
711
225/250/3.0 Litre Work EFI 2002 Model Year
714
Oil & Fuel Flow Diagram
714
Water Flow Diagram
717
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