Mercury 175xr2 SportJet Service Manual

MODELS
175XR2 Sport Jet
United States
With Starting Serial Numbers
Powerhead Pump Unit

0E203000 0E151580
Printed in U.S.A. 1997, Mercury Marine 90-852396R1 NOVEMBER 1997

Notice who uses a service procedure and/or tool, which is
not recommended by the manufacturer, first must
Throughout this publication, “Dangers”, “Warnings” completely satisfy himself that neither his nor the
and “Cautions” (accompanied by the International products safety will be endangered by the service
HAZARD Symbol ) are used to alert the mechanic procedure selected.
to special instructions concerning a particular service
All information, illustrations and specifications con-
or operation that may be hazardous if performed in-
tained in this manual are based on the latest product
correctly or carelessly. OBSERVE THEM CARE-
information available at the time of publication. As re-
FULLY!
quired, revisions to this manual will be sent to all deal-
These “Safety Alerts” alone cannot eliminate the haz- ers contracted by us to sell and/or service these prod-
ards that they signal. Strict compliance to these spe- ucts.
cial instructions when performing the service, plus
It should be kept in mind, while working on the prod-
“Common Sense” operation, are major accident pre-
uct, that the electrical system and ignition system are
vention measures.
capable of violent and damaging short circuits or se-
vere electrical shocks. When performing any work
DANGER where electrical terminals could possibly be
DANGER - Immediate hazards which WILL result grounded or touched by the mechanic, the battery
in severe personal injury or death. cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed
WARNING during service they should be covered to protect
WARNING - Hazards or unsafe practices which against accidental entrance of foreign material which
COULD result in severe personal injury or death. could enter the cylinders and cause extensive inter-
nal damage when the engine is started.
CAUTION It is important to note, during any maintenance proce-
Hazards or unsafe practices which could result dure replacement fasteners must have the same
in minor personal injury or product or property measurements and strength as those removed.
damage. Numbers on the heads of the metric bolts and on the
surfaces of metric nuts indicate their strength. Ameri-
can bolts use radial lines for this purpose, while most
American nuts do not have strength markings. Mis-
Notice to Users of This matched or incorrect fasteners can result in damage
Manual or malfunction, or possibly personal injury. There-
fore, fasteners removed should be saved for reuse in
This service manual has been written and published the same locations whenever possible. Where the
by the Service Department of Mercury Marine to aid fasteners are not satisfactory for re-use, care should
our dealers’ mechanics and company service per- be taken to select a replacement that matches the
sonnel when servicing the products described here- original.
in.
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 prod-
ucts which includes the use of mechanics’ common
hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service
trade of all conceivable procedures by which a ser-
vice might be performed and of the possible hazards
and/or results of each method. We have not under-
taken any such wide evaluation. Therefore, anyone
90-852396 MAY 1996 IMPORTANT INFORMATION - 1C-1

Cleanliness and Care of In addition, personnel should not work on or under an
engine which is suspended. Engines should be at-
Sport Jet tached to work stands, or lowered to ground as soon
as possible.
A marine power product is a combination of many
machined, honed, polished and lapped surfaces with We reserve the right to make changes to this manual
tolerances that are measured in the ten thousands of without prior notification.
an inch/mm. When any product component is serv- Refer to dealer service bulletins for other pertinent in-
iced, care and cleanliness are important. Throughout formation concerning the products described in this
this manual, it should be understood that proper manual.
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 specif-
ically stated.
Whenever components are removed for service,
Page Numbering
they should be retained in order. At the time of instal- Two number groups appear at the bottom of each
lation, they should be installed in the same locations page. The example below is self-explanatory.
and with the same mating surfaces as when re-
moved.
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 crank-
shaft 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.
EXAMPLE:
90-826148 R1 JANUARY 1993 POWERHEAD - 5A-7
Revision No. 1 Section Description
Month of Printing Section Number
Year of Printing Part of Section Letter
Page Number
1C-2 - IMPORTANT INFORMATION 90-852396 MAY 1996
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
Important
Information
1
C - General Information
D - Sport Jet Installation
Section 2 - Electrical
A - Ignition
Electrical
2
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
Section 3 - Fuel System
A - Fuel Pump & Fuel Primer
B - Carburetor
Fuel System
3
C - Oil Injection
D - Electronic Enrichment &
Turn Key Start Electronic Control Module
Section 4 - Powerhead
Powerhead
4
5
Section 5 - Pump Unit
Pump Unit

NOTES:

IMPORTANT INFORMATION 1
A
28237
SPECIFICATIONS
Table Of Contents
Page
Master Specifications . . . . . . . . . . . . . . . . . . . . . 1A-1
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
1A-0 - IMPORTANT INFORMATION 90-852396 MAY 1996

Master Specifications
Model 175
HORSEPOWER 175(130.5)
(KW)
SPORT JET Powerhead 205 lb. (93 kg)
WEIGHT Pump Unit 100 lb. (45 kg)
CYLINDER Type V-6 Cylinder, Two Cycle, Loop Charged
BLOCK Displacement 153.0 cu. in. (2507cc)
STROKE Length (All Models) 2.650 in. (67.31mm)
CYLINDER Diameter (Std) 3.501 in. (88.925mm)
BORE Taper/Out of Round/Maximum Wear 0.003 in. (0.076mm)
Bore Type Cast Iron
PISTON Piston Type Aluminum
Standard 3.494 in. ± 0.001 in.

(88.748mm ± 0.025mm)
0.015 in. (0.381 mm) Oversize 3.509 in. ± 0.001 in.
(89.129mm ± 0.025mm)
REEDS Reed Type Steel
Reed Stand 0pen (Max.) 0.020 in. (0.50mm)
Reed Stop (Max.) Not Adjustable
FUEL Fuel Gasoline w/Oil Injection
SYSTEM Recommended Gasoline Unleaded 87 Octane Minimum
Recommended Oil Quicksilver TC-W3 or TC-WII 2 Cycle
Outboard Oil Only
Gasoline/Oil Ratio 50:1 (25:1 Break-In)
Fuel Pressure – @ Idle 2 PSI
– @ WOT 8 PSI
STARTING Electric Start – All Models
SYSTEM Starter Draw (Under Load) 175 Amperes
Starter Load (No Load) 40 Amperes
Battery Rating 670 Marine Carnking Amps (MCA)

or 520 Cold Cranking Amps (CCA)
IGNITION Type Capacitor Discharge
SYSTEM Spark Plug Type NGK BU8H
Spark Plug Gap Surface Gap
CHARGING Alternator Output (Regulated) 12 Amperes @ 3000 RPM
SYSTEM
90-852396 MAY 1996 IMPORTANT INFORMATION - 1A-1

Master Specifications (Continued)
175XR2 Sport Jet (Continued)
Idle RPM 1000 - 1100 RPM
Wide Open Throttle (WOT) RPM 5000 - 5500
Idle Mixture Screw Adjustment
(Preset - Turns Out) 1-1/2 turns out from a lightly seated position
– All Carbs
Float Setting Set parallel to body flange
Main Jet
–Top Carb .076
Carburetor
–Middle Carb .076
–Bottom Carb .076
Idle Air Jet
–Top Carb .050
–Middle Carb .050
–Bottom Carb Port .054 Starbboard .050
Vent Jet
–Top Carb .080
–Middle Carb .080
–Bottom Carb .080
Maximum Timing BTDC
@ Cranking Speed 22° BTDC
@ 5000 RPM 20° BTDC
Timing Idle Timing
ATDC 0° 2° @ 1000 - 1100 RPM
Firing Order 1-2-3-4-5-6
1A-2 - IMPORTANT INFORMATION 90-852396 MAY 1996

Torque Chart Standard Hardware
Special Items Torque Screw or Nut Size Torque
PUMP UNIT 6 - 32 9 lb. in. (1.0 N·m)
Impeller Nut 150 lb. ft. (203 N·m) 8 - 32 20 lb. in. (2.3 N·m)
Impeller Gear Nut 90 lb. ft. (122 N·m) 10 - 24 30 lb. in. (3.4 N·m)
Pinion Shaft Assembly 180 lb. in. (20 N·m) 10 - 32 35 lb. in. (3.9 N·m)
Drive Housing 35 lb. ft. (47.5 N·m) 12 - 24 45 lb. in. (5.0 N·m)
Cover Nuts 1/4 - 20 70 lb. in. (7.8 N·m)
Stator Bolts 35 lb. ft. (47.5 N·m) 5/16 - 18 160 lb. in. (18.1 N·m)
Nozzle to Stator Bolts 35 lb. ft. (47.5 N·m) 3/8 - 16 270 lb. in. (30.4 N·m)
Rudder Pivot Bolt 50 lb. ft. (68 N·m)
Reverse Gate 50 lb. ft. (68 N·m)
Pivot Bolt Metric Hardware
Steering Lever Screw 180 lb. in. (20.2 N·m)
Torque Specification
Reverse Gate 120 lb. in. (13.6 N·m)
Stop Screw A B lb. in. lb. ft. N·m
Inlet Screen Screw 75 lb. in. (8.5 N·m) 8 mm M5 36 3 4
(6 mm) 10 mm M6 70 6 8
Inlet Screen Screw 200 lb. in. (23 N·m)
12 mm M8 156 13 18
(8 mm)
14 mm M10 312 26 36
Ride Plate Screw 75 lb. in. (8.5 N·m)
17 mm M12 372 31 42
POWERHEAD
Adaptor Plate to 35 lb. ft. (47.5 N·m)
Powerhead
Powerhead to Drive 35 lb. ft. (47.5 N·m) A B
Housing Nuts
Cylinder Head 225 lb. in. (25.4 N·m)
Then Turn Additional 90
Flywheel Nut 125 lb. ft. (169.5 N·m)
Main Bearing Bolts 270 lb. in. (30.4 N·m)
Connecting Rod Screws 120 lb. in. (13.6 N·m)
Then Turn Additional 90
Transfer Port Cover 80 lb. in. (9.03 N·m)
Exhaust Manifold 180 lb. in. (20 N·m)
90-852396 MAY 1996 IMPORTANT INFORMATION - 1A-3

B
MAINTENANCE
Table of Contents
Page
Flushing Cooling System . . . . . . . . . . . . . . . 1B-1
Following Complete Submersion . . . . . . . . . 1B-1
Salt Water Submersion
(Special Instructions) . . . . . . . . . . . . . . . . 1B-1
Submerged While Running
(Special Instructions) . . . . . . . . . . . . . . . . 1B-1
Submerged Engine (Fresh Water)
Plus Special Instructions . . . . . . . . . . . . . 1B-1
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2
Out-of-season Storage . . . . . . . . . . . . . . . . . 1B-2
Out-of-season Battery Storage . . . . . . . . . . 1B-2
Detonation: Causes And Prevention . . . . . . 1B-3
Compression Check . . . . . . . . . . . . . . . . . . . 1B-4
Water Pressure Check . . . . . . . . . . . . . . . . . 1B-4
1B-0 - IMPORTANT INFORMATION 90-852396 MAY 1996

Flushing Cooling System Following Complete Submersion
Flushing the cooling system is essential after each Submerged engine treatment is divided into three
use in salt water, after the boat has run aground, or distinct problem areas. The most critical is submer-
when the overheat warning horn sounds (possible sion in salt water; the second is submersion while
debris in jet powerhead). running; the third is submerged in fresh water.
1. Remove flush adaptor plug and attach water SALT WATER SUBMERSION (SPECIAL
hose. INSTRUCTIONS)
Due to the corrosive effect of salt water on internal
engine components complete disassembly is nec-
essary before any attempt is made to start the en-
gine.
a SUBMERGED WHILE RUNNING (SPECIAL
INSTRUCTIONS)
When an engine is submerged while running, the
possibility of internal engine damage is greatly in-
creased. 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 disas-
sembled.
a - Flush Adapter Plug FRESH WATER SUBMERSION (SPECIAL
2. The engine may be run using the Flushing At- INSTRUCTIONS)
tachment: DO NOT run the engine above idle 1. Recover engine as quickly as possible.
speeds.
2. Flush exterior of engine with fresh water to re-
3. Turn water on and flush engine block for at least move mud, weeds, etc. DO NOT attempt to start
10 minutes. engine if sand has entered powerhead, as pow-
4. Remove water hose and install flush adaptor erhead will be severely damaged. Disassemble
plug. powerhead if necessary to clean components.
5. Flush outer surfaces of pump with water stream. 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.
90-852396 MAY 1996 IMPORTANT INFORMATION - 1B-1

11. If engine fails to start determine cause (fuel, Permanently Installed Fuel Tank: Pour the re-
electrical or mechanical). Engine should be run quired amount of Quicksilver Gasoline Stabilizer
within two hours after recovery from water as se- (follow instructions on container) into a separate
rious internal damage may occur. If unable to container and mix with approximately one quart
start engine in this period disassemble engine (one liter) of gasoline. Pour this mixture into fuel
and clean all parts and apply oil as soon as pos- tank.
sible. Place the Sport Jet in the water or use the flushing
Out-of-Season Storage attachment. Run the engine for ten minutes to al-
low treated fuel to reach the carburetors.
WARNING 1. With Sport Jet in the water, start the engine and
let it warm up to operating temperature.
As a safety precaution, when boat is in storage,
remove positive (+) battery cable. This will 2. Disconnect the fuel line. When the engine starts
eliminate possibility of accidental starting of to stall quickly spray Quicksilver Storage Seal
engine and resultant overheating and damage to into each carburetor throat. Continue to spray
engine from lack of water. until engine dies from lack of fuel.
In preparing for out-of-season storage, two precau- 3. Remove spark plugs and inject a five second
tions must be considered: 1) The engine must be spray of Quicksilver Storage Seal around the in-
protected from physical damage caused by freezing side of each cylinder. Manually turn engine over
trapped water and 2) the engine must be protected several times to distribute Storage Seal
from rust, corrosion and dirt. throughout cylinders. Reinstall spark plugs.
The following storage procedures should be fol- 4. Drain and refill drive housing unit and stator as-
lowed to prepare the Sport Jet for out-of-season sembly with Quicksilver Hi Performance Gear
storage or prolonged storage (two months or long- Lube as explained in “Jet Pump” section (see
er). Table of Contents).
5. Clean engine thoroughly including all accessi-
ble powerhead parts and spray with Corrosion
CAUTION and Rust Preventive.
Never start or run the Sport Jet (even
6. Lubricate all lubrication points.
momentarily) without water circulating through
the cooling system to prevent damage to the 7. To prevent freeze damage drain the speedome-
unit. ter system of water completely before storage.
FUEL SYSTEM Remove tubing from speedometer fitting and
blow through tubing to remove water.
IMPORTANT: Gasoline containing alcohol (etha-
nol or methanol) can cause a formation of acid 8. Store battery as outlined in Out-of-Season Bat-
during storage and can damage the fuel system. tery Storage following:
If the gasoline being used contains alcohol, it is IMPORTANT: Check and refill housings with
advisable to drain as much of the remaining gas- Quicksilver Hi Performance Gear Lube before
oline as possible from the fuel tank, remote fuel storage to protect against possible water leak-
line, and engine fuel system. age into housings which is caused by loose lu-
Fill the fuel system (tank, hoses, fuel pump, and car- bricant vent or fill plug. Inspect gaskets under
buretors) with treated (stabilized) fuel to help pre- lubricant vent and fill plugs replacing any dam-
vent formation of varnish and gum. Proceed with the aged gaskets before reinstalling plugs.
following instructions. Out-of-Season Battery Storage
Portable Fuel Tank: Pour the required amount of
1. Remove battery as soon as possible and re-
Quicksilver Gasoline Stabilizer (follow instruc-
move all grease, sulfate and dirt from top sur-
tions on container) into fuel tank. Tip fuel tank
back and forth to mix stabilizer with the fuel. face.
2. Cover plates with distilled water, but not over
3/16 in. (5 mm) above perforated baffles.

3. Cover terminal bolts well with grease. Detonation: Causes and Prevention
4. Store battery in a cool, dry place in a dry carton Detonation in a 2-cycle engine resembles the “ping-
or box. ing” heard in an automobile engine. It can be de-
5. Remove battery from storage every 60 days. scribed as a “rattling” or “plinking” sound.
Check water level and place on charge for 5 to Detonation generally is thought of as spontaneous
6 hours at 6 amperes. DO NOT fast charge. ignition, but it is best described as a noisy explosion
in an unburned portion of the fuel/air charge after the
CAUTION spark plug has fired. Detonation creates severe, un-
timely shock waves in the engine and these shock
A discharged battery can be damaged by waves often find or create a weakness: the dome of
freezing. a piston, piston rings or piston ring lands, piston pin
How Weather Affects and roller bearings.
Engine Performance While there are many causes for detonation in a
2-cycle engine emphasis is placed on those causes
It is a known fact that weather conditions exert a pro- which are most common in marine 2-cycle applica-
found effect on power output of internal combustion tion. A few which are not commonly understood are:
engines. Therefore, established horsepower ratings
refer to the power that the engine will produce at its 1. Over-advanced ignition timing.
rated RPM under a specific combination of weather 2. Use of low octane gasoline.
conditions.
3. Lean fuel mixture at or near wide open throttle.
Corporations internationally have settled on adop-
tion of I.S.O. (International Standards Organization) 4. Spark plugs (heat range too hot, incorrect
engine test standards as set forth in I.S.O. 3046 reach, cross-firing).
standardizing the computation of horsepower from 5. Inadequate engine cooling (deteriorated cool-
data obtained on the dynamometer correcting all ing system).
values to the power that the engine will produce at
sea level at 30% relative humidity at 77° F (25° C) 6. Combustion chamber/piston deposits (result in
temperature and a barometric pressure of 29.61 in- higher compression ratio).
ches of mercury. Detonation usually can be prevented provided that
(1) the engine is correctly set up and (2) diligent
Summer Conditions of high temperature, low baro-
maintenance is applied to combat the preceding det-
metric pressure and high humidity all combine to re-
onation causes listed.
duce the engine power. This, in turn, is reflected in
decreased boat speeds--as much as 2 or 3 miles-
per-hour (3 or 5 km per hour) in some cases. Nothing
will regain this speed for the boater, but the coming
of cool, dry weather.
In pointing out the practical consequences of weath-
er effects, an engine running on a hot, humid, sum-
mer 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 humid-
ity) content.
90-852396 MAY 1996 IMPORTANT INFORMATION - 1B-3

Compression Check Water Pressure Check
1. Remove spark plugs. NOTE: To perform these checks a Water Pressure
Gauge Kit P/N 91-79250A2 is recommended. Wa-
2. Install compression gauge in spark plug hole.
ter pressure is taken at the top of the powerhead.
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 cylin-
der. Variation of more than 15 psi (103.5 kPa)
between cylinders indicates that lower com-
pression 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 perform-
ance. It is essential, therefore, that improper
compression be corrected before proceeding
with an engine tune-up.
7. Cylinder scoring: if powerhead shows any indi-
cation of overheating, such as discolored or a - Water Pressure Taken At This Location
scorched paint, visually inspect cylinders for
scoring or other damage as outlined in Section
4: Powerhead. 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.
RPM Water Pressure PSI
(kPa)
1,000 - 1,100 in neutral 1/2 - 1-1/2 (3.4 - 10)
5,300 boat on trailer 9 - 10 (62 - 69)
(static)
5,300 boat on plane 35 - 40 (241 - 276)

C

Page Number
GENERAL INFORMATION
Table Of Contents
Page
Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-1
Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Service Manual Outline . . . . . . . . . . . . . . . . . . . 1C-3

Notice who uses a service procedure and/or tool, which is
not recommended by the manufacturer, first must
Throughout this publication, “Dangers”, “Warnings” completely satisfy himself that neither his nor the
and “Cautions” (accompanied by the International products safety will be endangered by the service
HAZARD Symbol ) are used to alert the mechanic procedure selected.
to special instructions concerning a particular service
All information, illustrations and specifications con-
or operation that may be hazardous if performed in-
correctly or carelessly. OBSERVE THEM CARE-
information available at the time of publication. As re-
FULLY!
quired, revisions to this manual will be sent to all deal-
These “Safety Alerts” alone cannot eliminate the haz- ers contracted by us to sell and/or service these prod-
ards that they signal. Strict compliance to these spe- ucts.
cial instructions when performing the service, plus
It should be kept in mind, while working on the prod-
“Common Sense” operation, are major accident pre-
uct, that the electrical system and ignition system are
vention measures.
capable of violent and damaging short circuits or se-
vere electrical shocks. When performing any work
DANGER where electrical terminals could possibly be
DANGER - Immediate hazards which WILL result grounded or touched by the mechanic, the battery
in severe personal injury or death. cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed
WARNING during service they should be covered to protect
WARNING - Hazards or unsafe practices which against accidental entrance of foreign material which
COULD result in severe personal injury or death. could enter the cylinders and cause extensive inter-
nal damage when the engine is started.
CAUTION It is important to note, during any maintenance proce-
Hazards or unsafe practices which could result dure replacement fasteners must have the same
in minor personal injury or product or property measurements and strength as those removed.
damage. Numbers on the heads of the metric bolts and on the
surfaces of metric nuts indicate their strength. Ameri-
can bolts use radial lines for this purpose, while most
American nuts do not have strength markings. Mis-
Notice to Users of This matched or incorrect fasteners can result in damage
Manual or malfunction, or possibly personal injury. There-
fore, fasteners removed should be saved for reuse in
This service manual has been written and published the same locations whenever possible. Where the
by the Service Department of Mercury Marine to aid fasteners are not satisfactory for re-use, care should
our dealers’ mechanics and company service per- be taken to select a replacement that matches the
sonnel when servicing the products described here- original.
in.
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 prod-
ucts which includes the use of mechanics’ common
hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service
trade of all conceivable procedures by which a ser-
vice might be performed and of the possible hazards
and/or results of each method. We have not under-
taken any such wide evaluation. Therefore, anyone

Cleanliness and Care of In addition, personnel should not work on or under an
engine which is suspended. Engines should be at-
Sport Jet tached to work stands, or lowered to ground as soon
as possible.
A marine power product is a combination of many
machined, honed, polished and lapped surfaces with We reserve the right to make changes to this manual
tolerances that are measured in the ten thousands of without prior notification.
an inch/mm. When any product component is serv- Refer to dealer service bulletins for other pertinent in-
iced, care and cleanliness are important. Throughout formation concerning the products described in this
this manual, it should be understood that proper manual.
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 specif-
ically stated.
Whenever components are removed for service,
Page Numbering
they should be retained in order. At the time of instal- Two number groups appear at the bottom of each
lation, they should be installed in the same locations page. The example below is self-explanatory.
and with the same mating surfaces as when re-
moved.
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 crank-
shaft 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.
EXAMPLE:
Page Number
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
Important
Information
1
C - General Information
D - Sport Jet Installation
Section 2 - Electrical
A - Ignition
Electrical
2
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
Section 3 - Fuel System
A - Fuel Pump & Fuel Primer
B - Carburetor
Fuel System
3
C - Oil Injection
D - Electronic Enrichment &
Section 4 - Powerhead
Powerhead
4
5
Section 5 - Pump Unit
Pump Unit

NOTES:

D
28237
SPORT JET INSTALLATION

Table Of Contents
Page Page
General Information . . . . . . . . . . . . . . . . . . . . . . 1D-1 Bilge Siphon Feature . . . . . . . . . . . . . . . . . . . . 1D-13
Notice to Installer . . . . . . . . . . . . . . . . . . . . . . 1D-1 Installing Bilge Siphon . . . . . . . . . . . . . . . . . 1D-13
Installation Products . . . . . . . . . . . . . . . . . 1D-1 Installing Powerhead . . . . . . . . . . . . . . . . . . . . 1D-13
Torque Specifications . . . . . . . . . . . . . . . . . . 1D-1 Battery Connection . . . . . . . . . . . . . . . . . . . 1D-14
Serial Number Decal Location . . . . . . . . . . . 1D-2 Throttle Cable Adjustment . . . . . . . . . . . . . 1D-15
Corrosion Protection . . . . . . . . . . . . . . . . . . . 1D-2 Oil Injection System . . . . . . . . . . . . . . . . . . . 1D-15
Installation Requirements . . . . . . . . . . . . . . . . . 1D-2 Bleeding Air from Oil Injection Pump
Battery/Battery Cables . . . . . . . . . . . . . . . . . 1D-2 and Oil Injection Outlet Hose . . . . . . . . . . . 1D-16
Boat Construction . . . . . . . . . . . . . . . . . . . . . 1D-3 Adjusting Oil Injection Pump . . . . . . . . . . . 1D-16
Engine Compartment Ventilation . . . . . . . . . 1D-3 Turn-Key Start Feature . . . . . . . . . . . . . . . . . . . 1D-17
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Timing/Synchronizing/
Fuel Delivery System . . . . . . . . . . . . . . . . . . 1D-4 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Impeller Selection . . . . . . . . . . . . . . . . . . . . . 1D-6 Timing Pointer Adjustment . . . . . . . . . . 1D-17
Remote Control and Cables . . . . . . . . . . . . . 1D-6 Carburetor Synchronization . . . . . . . . . 1D-18
Steering Helm and Cable . . . . . . . . . . . . . . . 1D-6 Timing Adjustments . . . . . . . . . . . . . . . . . . . 1D-18
Sport Jet Hull Dimensions Maximum Timing Adjustment . . . . . . . . 1D-19
175XR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7 Primary Pickup Timing Adjustment . . . 1D-19
Installing Jet Pump . . . . . . . . . . . . . . . . . . . . . . . 1D-9 Idle Speed Adjustment . . . . . . . . . . . . . . 1D-20
Steering Cable Adjustment . . . . . . . . . . . . . 1D-10 Trim Plate Adjustment . . . . . . . . . . . . . . . . . . . 1D-20
Shift Cable Adjustment . . . . . . . . . . . . . . . . 1D-11 Pre-delivery Inspection . . . . . . . . . . . . . . . . . . . 1D-21
1D-0 - IMPORTANT INFORMATION 90-852396R1 NOVEMBER 1997

General Information All information, illustrations, and specifications con-
information available at time of publication. As re-
Notice to Installer quired, revisions to this manual will be sent to all
OEM boat companies.
Throughout this publication, “Warnings” and “Cau-
tions” (accompanied by the International Hazard
INSTALLATION PRODUCTS
Symbol ! ) are used to alert the installer to special
instructions concerning a particular service or opera- Loctite “271” 92-809820
tion that may be hazardous if performed incorrectly Liquid Neoprene 92-25711--2
or carelessly. –– Observe Them Dielectric Grease 92-823506--1
Carefully! Perfect Seal 92-34227--1
Special Lube 101 92-13872A1
These “Safety Alerts,” alone, cannot eliminate the
hazards that they signal. Strict compliance to these
special instructions when performing the service, Torque Specifications
plus “common sense” operation, are major accident
prevention measures. NOTE: Tighten all fasteners, not listed, securely.
10 mm Fasteners
WARNING (Powerhead to Pump) 35 lb. ft.
Hazards or unsafe practices which COULD result (47 N·m)
in severe personal injury or death. Reverse Stop Screw 120 lb. in.
(14 N·m)
CAUTION Forward Stop Screw 120 lb. in.
(14 N·m)
Hazards or unsafe practices which could result
in minor personal injury or product or property Ride Plate-to-Pump Screws 75 lb. in.
damage. (8.5 N·m)
IMPORTANT: Indicates information or instruc- Drive Housing Cover to Drive
tions that are necessary for proper installation Housing fasteners 35 lb. ft.
and/or operation. (47 N·m)
This installation manual has been written and pub-
lished by the service department of Mercury Marine
to aid installers when installing the products de-
scribed herein.
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’ com-
mon 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 in-
stallation 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 in-
stallation procedure selected.
90-852396 MAY 1996 IMPORTANT INFORMATION - 1D-1

Serial Number Decal Location Corrosion Protection
A serial number decal is located on the side of the fly- This power package is equipped with anodes to help
wheel cover and on top of the cylinder block. protect it from galvanic corrosion under moderate
conditions. See the Operator’s Manual for location of
anodes.
a OGXXXXXX
19XX b Installation Requirements
OGXXXXXX
IMPORTANT: The Sport Jet is considered an
d c INBOARD engine. The boat it is installed in must
XX
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
28238 the pull test requirements and that positive bat-
a - Engine Serial Number
tery terminal is properly insulated in accordance
b - Model Year with regulations.
c - Year Manufactured
d - Certified Europe
IMPORTANT: Engine electrical system is nega-
tive (–) ground. It is recommended (required in
IMPORTANT: The Pump Unit Serial Number stick- some states) that battery be installed in an en-
er must be taken out of the envelope affixed to the closed case. Refer to regulations for your area.
pump unit and applied to the flywheel cover de- 3. Select a battery that meets all of the following
cal. specifications:
The engine serial number and pump serial number a. 12-volt marine type.
are different and unique. The engine serial number
is located aft of the flywheel cover. The pump unit se- b. 670 Marine Cranking Amps (MCA) or
rial number is stamped in a plug located above the 520 Cold Cranking Amps (CCA) minimum.
shift cable hole on the starboard side of the pump c. Reserve capacity rating of at least 100 min-
housing. utes.
e
4. Select proper size positive (+) and negative (–)
battery cables using chart. Battery should be lo-
cated as close to engine as possible.
175 IMPORTANT: Terminals must be soldered to
cable ends to ensure good electrical contact. Use
electrical grade (resin flux) solder only. Do not
use acid flux solder, as it may cause corrosion
and a subsequent failure.
Cable Length Cable Gauge
Up to 3-1/2 ft. (1.1 m) 4 (25 mm2)
3-1/2 - 6 ft. (1.1-1.8 m) 2 (35 mm2)
6 - 7-1/2 ft. (1.8-2.3 m) 1 (50 mm2)
28237
7-1/2 - 9-1/2 ft. (2.3-2.9 m) 0 (50 mm2)
e - Pump Unit Serial Number
9-1/2 - 12 ft. (2.9-3.7 m) 00 (70 mm2)
12 - 15 ft. (3.7- 4.6 m) 000 (95 mm2)
15 - 19 ft. (4.6 - 5.8 m) 0000 (120 mm2)

Boat Construction Exhaust System
IMPORTANT: All applicable U.S. Coast Guard IMPORTANT: It is the responsibility of the boat
regulations for INBOARD engines must be com- manufacturer, or installing dealer, to properly
plied with, when constructing engine compart- locate the engine. Improper installation may
ment. allow water to enter the exhaust manifold and
combustion chambers and severely damage the
Care must be exercised in the design and construc-
engine. Damage caused by water in the engine
tion of the engine compartment. Seams must be lo-
will not be covered by Mercury Marine Limited
cated so that any rain water or splash, which may
Warranty, unless this damage is the result of
leak through the seams, is directed away from the
defective part(s).
engine and carburetor cover. Also, the passenger
compartment drainage system should not be routed The engine must be properly located to ensure that
directly to the engine compartment. Water that runs water will not enter the engine through the exhaust
on or is splashed in the carburetor cover may en- system. Determine the correct engine height by tak-
ter the engine and cause serious damage to inter- ing measurements (a) and (b), with boat at rest in the
nal engine parts. water and maximum load aboard. Subtract (b) from
(a) to find (c). If (c) is less than specified in chart, boat
IMPORTANT: Mercury Marine will not honor any
construction must be altered to properly lower water-
warranty claim for engine damage as a result of
line relative to exhaust elbow.
water entry.
Engine Compartment Ventilation

b
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 a
accordance with industry standards (ABYC, NMMA, c
etc.), federal standards and U.S. Coast Guard regu-
lations for inboard engines. Pressure differential d
(outside engine compartment versus inside engine
compartment) should not exceed 2 in. (51 mm) of wa-
ter (measured with a manometer) at maximum air
flow rate.
Engine Compartment Specifications 28237
Model Engine Air Require- Physical Engine a - From Waterline to Top of Transom
ments at Wide Volume* b - From Highest Point on Exhaust Manifold to Top of Transom
Open Throttle c - (a) minus (b) = (c)
d - Waterline at Rest (at Maximum Load)
175XR2 487 ft.3/min. 1.33 ft.3
(0.230 m3/sec.) (38 L) Model c = (a) minus (b)
* Physical engine volume is used in flotation calculations and
is representative of the amount of flotation the engine pro- 175XR2 (c) must be 8 in. (203 mm) or
vides. more.
For serviceability, it is recommended that an addi-
tional 6 inches minimum (152 mm) (per side) of clear-
ance be allowed between powerhead and engine
compartment walls.

Fuel Delivery System Instrumentation
WARNING CAUTION
Boating standards (NMMA, ABYC, etc.), federal If a fused accessory panel is to be used, it is rec-
standards and U. S. Coast Guard regulations for ommended that a separate circuit (properly
INBOARD engines must be adhered to when in- fused) be used from the battery to the fuse panel
stalling fuel delivery system. Failure to comply with sufficient wire size to handle the intended
could result in severe personal injury or death. current load.
CAUTION NOTE: The charging system on these engines is
capable of producing 12 amps maximum charge at
Remove plastic plug from fuel inlet fitting. Attach
3500 RPM. The electrical load of the boat should not
fuel line to fuel fitting with U.S. Coast Guard ap-
exceed this capacity.
proved hose clamp. Inspect for fuel leaks.
1. Fuel tank should be mounted below carburetor(s) We recommend the use of Quicksilver Instrumenta-
level (if possible) or gravity feed may cause car- tion and Wiring Harness(es). Refer to “Quicksilver
buretor fuel inlet needle(s) to unseat, and flood- Accessories Guide” for selection.
ing may result. If other than Quicksilver electrical accessories are to
2. Fuel pickup should be at least 1 in. (25 mm) from be used, it is good practice to use waterproof ignition
the bottom of the fuel tank to prevent picking up components (ignition switch, lanyard stop switch,
impurities. etc.). A typical jet boat of this nature will see water
splashed on these components. Therefore, precau-
3. Fuel lines used must be U.S. Coast Guard ap- tions must be taken to avoid ignition failure due to
proved (USCG type A1), fittings and lines must shorting out of ignition components.
not be smaller than 5/16 in. (8 mm) I.D.
4. On installations requiring long lines or numerous WARNING
fittings, larger size lines should be used.
Sudden stopping of engine (shorting ignition
5. Fuel line should be installed free of stress and components) while boat is underway will cause
firmly secured to prevent vibration and/or chaf- loss of steering control due to loss of thrust. This
ing. loss of steering control may cause property dam-
6. Sharp bends in fuel line should be avoided. age, personal injury or death.
7. A flexible fuel line must be used to connect fuel A warning horn must be incorporated in the wiring
line to engine fuel pump to absorb deflection harness (see wiring diagram) to alert the user of an
when engine is running. overheat, low oil condition or oil pump failure.
8. A primer bulb is not necessary with this applica- IMPORTANT: If a warning horn system is not
tion. If a primer bulb is used, it must be U.S. Coast installed by the boat manufacturer, Mercury
Guard approved for inboard engine applications. 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 en-
gine, 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.

Wiring Diagrams
QUICKSILVER INSTRUMENTATION, TYPICAL INSTALLATION SHOWN
REFER TO GAUGE MANUFACTURER’S INSTRUCTIONS FOR SPECIFIC CONNECTIONS.
b h d
c
e f
i g
Temperature Sender
(Included With Gauge)
a - Temperature Gauge
b - Key Switch
c - Tachometer Gauge
d - Emergency Stop Switch
e - Tachometer Harness (P/N 84-86396A8) (Not Included
With Key/Choke Harness Kit)
f - Connect Wires Together With Screw and Hex Nut (2
Places) Apply Quicksilver Liquid Neoprene to Connections
and Slide Rubber Sleeve Over Each Connection.
g - To Neutral Start Safety Switch In Remote Control Box
h - Speedometer Gauge
i - Overheat/low oil horn
P Liquid Neoprene (92-25711--2)

T Dielectric Grease (92-823506--1)

Impeller Selection Protected against water intrusion and/or cor-
rosion as the cable end (at the pump) is sub-
IMPORTANT: Installed impeller must allow en- mersed in water with the boat at rest.
gine to run in its specified maximum wide-open-
throttle RPM range. A cable bellows is provided with the cable (P/N
64-835457A_). Follow installation procedures for
The jet drive comes equipped with a standard stain- proper sealing of cable.
less steel impeller which allows the engine to operate
in its specified operating range. A locking tab is provided by Mercury to be used with
a cable having threads and locknuts located 8 inches
If a different impeller is installed in place of the stan- (203 mm) from cable end at pump with cable at cen-
dard impeller, it is the responsibility of the installer to ter of travel.
ensure engine RPM remains in specified range. Spe-
cified engine WOT RPM range is listed in “Operation The shift cable end (at the pump) is submersed in
and Maintenance Manual” attached to the engine. 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.
Remote Control and Cables
Follow shift cable adjustment procedure for proper
To ensure proper shift and throttle operation, we rec- adjustment.
ommend the use of the Sport Jet Remote Control
THROTTLE CABLE
(P/N 850696). This remote control has been qualified
by Mercury Marine to be used with the Sport Jet and The throttle cable must have one end compatible with
provides the following required features: the control box. The other end must have Mercury
style connectors.
Start-in-gear protection
Follow throttle cable adjustment procedures for
Neutral RPM Limit at 2,000 RPM
proper adjustment.
NOTE: This applies to dual lever remote controls as
well as single lever remote controls. Steering Helm and Cable
High strength mechanism to accomodate STEERING HELM
loads transmitted to the remote control
The steering helm must limit steering cable travel to
Shift cable travel of 3 inches ± 1/8 inch (76 mm
± 3 mm) 3.50 ± .10 inches (88.9 ± 2.5 mm).
Ability to use a 40 series shift cable WARNING

If a remote control other than the Sport Jet Remote Failure to limit steering cable travel at the helm
Control (P/N 850696) is used, the remote control could pre-load the cable resulting in premature
must meet the above criteria as well as the design cri- failure of a steering component causing loss of
teria outlined in the ABYC manual pertaining to Mini- steering. This loss of steering could cause prop-
Jet Boats (Standard P-23). erty damage, personal injury or death.
SHIFT CABLE STEERING CABLE
The shift cable to be used MUST MEET the following The steering cable to be used MUST MEET the fol-
criteria: lowing criteria:
40-Series Cable 60 Series Steering Cable
40 Series bulkhead fitting at output end 60 Series bulkhead fitting at output end
Allow for a minimum of 3 inches (76 mm) of Allow for a minimum of 3.75 inches (95.3 mm)
travel. of travel.
A means of attaching and locking the cable to Cable end at pump must allow for a 5/16 in.
the shift cable bracket (provided w/ pump). threaded adaptor shouldered thru-bolt and
Cable end at pump must allow for a 1/4-28 lock nut to connect the cable to the steering
thread adaptor, clevis pin and cotter pin (all arm.
provided w/ pump) to connect cable to the re-
verse gate.

A means of attaching and locking the cable to Sport Jet Hull Dimensions
the steering cable bracket (provided w/
pump). 175XR2
Protected against water intrusion and/or cor-
rosion as the cable end (at the pump) is sub- HULL OPENING CUT OUT
mersed in water with the boat at rest. The pump to powerhead opening in the hull is the
The steering cable should be able to with- most important factor to consider in a Sport Jet instal-
stand the steering loads imparted on it by the lation. There are three areas of concern:
rudder. 1. Location (a) of the pump to powerhead hull cut
A cable bellows is provided with the cable (P/N out relative to the boat bottom for proper ride
64-835457A_). Follow installation procedures for plate seal fit.
proper sealing of cable. 2. Dimensional control of the cutout - corner radii
A locking tab is provided by Mercury to be used with (b), straightness (c) and size (d) for proper grom-
a cable having threads and locknuts located 11.31 met installation, and corner radii (e) for ride plate
inches (287 mm) from cable end at pump with cable seal fit.
at center of travel. 3. Flatness and thickness of the area around the
Follow steering cable adjustment procedure for hull cut out for proper grommet sealing (see
proper adjustment. drawing on next page ).
Tunnel Dimensions (in inches)
1 1/16 +/– 1/16
b 3/4 +/– 1/16

14 11/16 +/– 1/16
c
7 1/16 +/– 1/16
12 1/8 +/– 1/16 d
14 5/16 +/– 1/16

16 1/4 +/– 1/16
c
d
a 2 9/16 +/– 1/16

4.07 .06
a 3 13/16 +/– 1/16 a
3 5/8 +/– 1/16 a
a - Location
b and e - Corner Radii
c and d - Size and Straightness 28249

METHODS OF CONTROLLING LOCATION AND SIZE CHECKING MOUNTING FLANGE THICKNESS AND
If the tunnel area in the plug is correct, the boat bot- FLATNESS
tom mold should repeat and reproduce the tunnel Use a flat plate that will contact the flange at the refer-
area which will aid the cut out process. ence points (b) and a .030 in. feeler gauge to check
flatness.
A reference area for the cut out can be produced on
the plug and bottom mold as a raised area or a cutting Additional sanding and/ or resin/ filler may be re-
guide. quired to maintain the flatness specification.
A simple slotted go/ no go gauge (c) will check the
Location pins (a) that would project into the internal flange thickness.
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 ra-
dii and use of a reciprocating saw or router template
to connect the four holes.
b Recommended Flange Flatness: .030 Inch

Maximum Between Reference Points
A a a A
1 1/2 Inch Dia. Hole Saw
a a
1/2 1/2
1/2 1/2
1 Inch Minimum Flange Width
NO c
GO GO
Mounting Flange Thickness

Specifications Max. Size Min. Size
Use Grommet P/N:

Section A-A 28250
+0.050
1/4” 25-820663-250
–0.030
a - Location Pins in Hull Mold +0.050
b - Flange Flatness Specification 3/8” –0.030 25-820663-375
c - Go – No Go Gauge for Thickness
+0.070
1/2” 25-820663-500
–0.030

Installing Jet Pump 3. Install tab washer and nut on cable after guiding
through wear ring. Locate tab washer in tab hole.
Coarse cable adjustment is made using these
Hull Cutout nuts. Do not tighten until after final steering ad-
justment is made.
CAUTION
The hull cutout dimensions are critical for proper c
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 de-
pending on cutout thickness.
54899
e d
c - Tab Hole
d - Nut
e - Tab Washer
ÀÀ
ÀÀ
ÀÀ
ÀÀ
ÀÀ
a 28251 4. Repeat the same procedure for the shift cable on
ÀÀ
ÀÀ
ÀÀ
ÀÀ
ÀÀ Use Grommet P/N:
the starboard side of the pump housing.
IMPORTANT: Ensure that the shift lever in the
+0.050 control box is set for three (3) inches of travel.
1/4” 25-820663-250
–0.030 NOTE: It is easier to adjust the shift and steering
+0.050
cables before installing pump unit in boat.
3/8” 25-820663-375
–0.030 5. Spray soapy water on tunnel grommet, both side
+0.070
foam exhaust seals (f), ride plate and sides of
1/2” 25-820663-500 boat tunnel.
–0.030
g
CUTOUT THICKNESS
a - Tunnel Grommet
2. Route steering cable through port side hole in
flange of pump housing. Install nut on cable be-
fore routing cable through wear ring.
f 54633
f - Side Foam Exhaust Seals (One Each Side)
g - Grommet Flange
NOTE: When installing pump in tunnel, be sure
cables are below grommet flange on pump to prevent
pinching of cables between pump and boat.
6. Install jet pump by pushing unit through opening
in tunnel grommet. Ride plate seal should fit
snugly in boat tunnel without any gaps along pe-
rimeter.
54900
a b 7. Install gasket and cover on jet pump. Ensure gas-

ket lines up with water inlet hole in pump.
a - Shift Cable
b - Wear Ring

8. Secure with four (4) M10 x 1.5 nuts.
a
b c
54980
a
54902
a - Housing Cover Nut Location
b - Water Inlet Hole c - Cable End Adaptor
d - Steering Arm
NOTE: Before torquing fasteners, check side ex-
haust seals and ride plate seal for proper fit in tunnel. 3. Center rudder assembly on nozzle.
9. Torque housing cover nuts (a) to 35 lb. ft. (47 4. Center steering wheel by turning wheel lock to
N·m). lock and positioning wheel midway between
locks.
NOTE: Check cables for free movement after cover
plate is installed. DO NOT install powerhead without 5. Adjust cable end adaptor until thru-hole in adap-
making this check. If cables do not move freely, re- tor lines up with threaded hole in steering arm (d).
move pump and correct before proceeding. This is the steering cable fine adjustment. Cable
end adaptor MUST be installed on steering cable
a minimum of nine (9) turns.
Steering Cable Adjustment 6. Attach steering cable to steering arm with bolt
1. Slide bellows assembly over cable and thread on and locknut. Torque nut to 180 lb. in. (20.3 N·m).
cable completely. Do Not tighten. a
c
54456
2. Thread cable end adaptor (c) on steering cable

14 turns (to allow for adjustment).
d
WARNING
Cable end adaptor must be installed a minimum e
b
of nine (9) turns. Failure to install cable end adap-
54902
tor on steering cable a minimum of nine (9) turns
could result in loss of steering control of boat, a - Bellows Nut
personal injury, or death. b - Forward Stop
c - Bolt
d - Lock Nut
e - Cable Nuts
7. Tighten cable nuts.
8. Check steering adjustment to ensure that the
helm limits cable travel for maximum left and right
turns. Correct if required.
9. Secure cable nut with tab washer.

10. Apply perfect seal (92-34227-1) to end threads Shift Cable Adjustment
and cable conduit end.
IMPORTANT: The shift cable MUST BE properly
19 adjusted. The shift cable is adjusted so that the
reverse gate is not pre-loaded against either the
forward or reverse stop. Pre-load in either posi-
tion may cause failure of the stop and/or prema-
ture wear of the shift cable or control box compo-
nents. It may also cause stiffness of the throttle
control.
1. Slide bellows assembly over cable and thread on
cable completely. Do Not tighten.
19 Perfect Seal (92-34227-1)
11. Turn bellows nut out and tighten against cable 54456
end adaptor.
2. Thread adaptor on cable until threads are visible
a b through sight hole in adaptor. Thread adaptor on
an additional five (5) turns to allow for adjust-
ment.
54908
a - Bellows Clamp 54896
b - Bellows Nut Tight Against Cable End Adaptor b
12. Turn rudder to port to compress bellows as much a
as possible. Pull bellows over cable conduit and a - Sight Hole
secure with bellows clamp. b - Reverse Stop
13. Tighten steering cable thru-hull fitting (a) from in- 3. Shift remote control to forward.
side boat to prevent any leaks. 4. Lift reverse gate and temporarily install the clevis
a pin (without washer or cotter pin) through reverse
gate boss and cable end adaptor.
28240
a - Steering Cable Thru-Hull Fitting

5. Pull reverse gate (by hand) toward the neutral 9. Adjust the reverse stop (located on the starboard
position to take up the cable slack. With cable side of the nozzle) so the stop just touches the re-
slack pulled out, adjust the cable so that the lower verse gate with the control handle in reverse
edge of the reverse gate is positioned above the position. Torque reverse stop screw to 120 lb. in.
top edge of the rudder by 3/8 to 1/2 in. Use the (14 N·m).
cable nuts or the cable end adaptor to make this
10. Apply Prefect Seal (92-34227-1) to the exposed
adjustment. The cable end adaptor MUST be
cable end threads between the cable adaptor
installed so that the cable end is visible in the
and the bellows nut. Tighten the bellows nut
sight hole after final adjustments are made. It
against the cable adaptor.
may be necessary to adjust the forward stop to al-
low the reverse gate to reach the correct position
for forward.
a
a 54898
b
a - Bellows Nut
b - Bellows Clamp
54580
11. Shift the control box to forward. Apply Perfect
a - 3/8 to 1/2 in. Seal (92-34227-1) to the cable conduit just be-
hind the cable nut threads. Slide the forward end
WARNING of the bellows over the cable conduit up to the
The shift cable must be adjusted correctly so that threads. Secure bellows to the cable conduit with
the reverse gate does not interfere with water the bellows clamp provided.
flow coming out of the rudder. If the reverse gate
12. Shift control box through entire range several
hangs down into the water flow, a vibration may
times. Check for any cable binding or bellows
be felt in the control box. If this occurs, reduce
rubbing. Check stops for proper adjustment. Re-
throttle immediately and readjust the cable. Im-
check forward cable adjustment so that reverse
proper adjustment may result in pump damage
gate is clear of water flow with cable slack pulled
including loss of the reverse gate. Failure to
out. Re-adjust as necessary.
properly adjust the shift cable could result in loss
of neutral and reverse, property damage, person- 13. Tighten shift cable thru-hull fitting from inside
al injury or death. boat to prevent any leaks.
6. After adjusting the shift cable, tighten the cable a
nuts and secure them with the tab washer. Insure
forward nut is correctly located in wear ring cast-
ing to prevent rotation.
7. Adjust the forward stop so that it just touches the
reverse gate in the forward position with the slack
pulled out of the cable. Torque forward stop
screw to 120 lb. in. (14 N·m).
8. Check the cable adaptor sight hole to ensure that
adequate thread engagement of the cable end
has been maintained. Install clevis pin, washer, 28240
and cotter pin.
a - Shift Cable Thru Hull Fitting

Bilge Siphon Feature Installing Powerhead
The Sport Jet incorporates an automatic bilge si- 1. Install gasket (a) on drive housing cover (b).
phoning feature. The bilge siphon is working when- a b
ever the engine is running above idle speeds. Maxi-
mum performance of the bilge siphon is realized
above 3,000 rpm. A hose is attached to the jet pump
nozzle. The hose is routed to the engine compart-
ment and placed in the bilge. Water exiting the nozzle
creates a suction or vacuum in the hose creating the
bilge siphon, drawing water out of the boat.
Installing Bilge Siphon

28242
Uncoil siphon hose from clamp on exhaust manifold. c d
Hose should remain attached to clamp on manifold. a - Gasket
Loop siphon hose over clamp on exhaust manifold. b - Drive Housing Cover O–Ring
c - Slinger
Place siphon hose in bilge. d - “TOP” Facing Up
b 2. Check that slinger (c) is on drive shaft. Ensure
“TOP” is facing up (d) on gasket.
3. Lubricate drive shaft splines with Special Lube
101 (92-13872A1).
4. Lower powerhead on drive housing cover. Align
drive shaft splines with crank shaft splines, and
c powerhead mounting studs with adapter plate
holes.
d 28237
b - Siphon Break
c - Manifold Clamp
d - Pick Up Screen
The siphon break must be located above the water
line. The siphon break has a .020 in. hole which must
be kept open.
CAUTION
Failure to locate siphon break above the water
line and keep hole open could result in water en-
tering the bilge through the siphon when the en-
gine is not running.

5. Secure powerhead to drive housing cover with Battery Connection
eight (8) M10 x1.5 nuts (a). Torque fasteners to
35 lb. ft. (47 N·m) following the torque sequence NOTE: Engine electrical system is negative (–)
given. Repeat torque sequence to ensure all fas- ground.
teners retain their torque. 1. Connect positive (+) battery cable (usually red) to
starter solenoid using protective boot (provided).
2. Connect negative (–) battery cable (usually
black) to engine ground at forward starter motor
bolt (c).
WARNING
U.S. Coast Guard regulation #33 CFR 183.445 re-
quires that the “positive” battery cable connec-
tion at the starter solenoid terminal be protected
by either a boot (“b” shown following), or protec-
tive shield.
28237
a a
TOP VIEW
8
3
4 7
FORWARD
AFT
2 b 28238
5
1
6 a
28242
a - M10 x 1.5 Nuts – 35 lb. ft. (47 N·m) a - Positive Battery Cable Attaching Location
b - Boot Protector for Positive Battery Cable
6. Connect fuel line to fuel inlet fitting, secure with
U.S. Coast Guard approved hose clamp
(183.532).
28237
c
c - Forward Starter Bolt (Engine Ground)
3. Connect battery cables to battery. Make sure that
all battery terminal connections are tight; then,
b - Fuel Inlet Fitting
spray terminals with a battery connection sealant
to help retard corrosion.

4. Attach remote control harness plug to engine Oil Injection System
harness plug. Reinstall harness plug in clip.
CAUTION
Oil injected engines must be run on a 50:1 gaso-
line/oil mixture in the fuel tank for the first 30 gal-
lons of fuel. Refer to engine break-in procedures
in the Operation & Maintenance Manual.
1. Mount the oil reservoir in a suitable location. Use
the oil tank hold down kit provided.
28243
2. Oil hoses must be arranged so they cannot be-

28237
come pinched, kinked, sharply bent or stretched
a b during operation of the engine.
a - Engine Harness Plug
b - Clip
3. Remove (and discard) the shipping cap from
hose fitting (a).
Throttle Cable Adjustment (Using 4. Connect oil hose from remote oil tank (hose with
blue stripe) to fitting (a). Secure with sta-strap.
Morse MV2.5 Control Box)
NOTE: Fitting barb (b) is a vent and does not get con-
1. Insert throttle cable anchor in the top retainer nected to a hose.
hole and close retainer cover (b).
5. Remove (and discard) shipping cap from pulse
2. With throttle arm in the idle position (against stop) fitting (c).
and remote control in forward (with no throttle
advance), rotate throttle cable end until it lines up 6. Connect the second oil hose from remote oil tank
with anchor pin (a). Attach cable to pin and se- to pulse fitting. Secure with sta-strap.
cure with latch. Tighten jam nut (c).
a
b
28237
b a - Hose Fitting
c a b - Vent
a - Throttle Lever Anchor Pin c - Pulse Fitting
b - Barrel Retainer Cover
c - Jam Nut

7. Fill remote oil tank with Quicksilver TCW-3 BLEEDING AIR FROM OIL INJECTION PUMP
2-Cycle Oil. Tighten fill cap (a). OUTLET HOSE
Any air bubbles in outlet hose in most cases will be
purged out of the system during operation of the en-
a
gine.
NOTE: If air bubbles persist, they can be purged out
of the hose by removing link rod and rotating the
pump arm full clockwise while operating engine at
1000 to 1500 RPM: If necessary, gently pinch the fuel
line between the fuel tank and the fuel pump “Tee” fit-
ting. This will cause the fuel pump to provide a partial
28243
a - Fill Cap vacuum which will aid in removal of the air. Reinstall
link rod.
8. Remove fill cap (b) from the engine oil tank (c)
and fill the tank with oil. Reinstall the fill cap. a
b
c
b
d
50047
a - Bleed Screw
b - Outlet Hose
c - Link Rod
50047 d - Pump Arm
b - Fill Cap
c - Engine Mounted Oil Reservoir Adjusting Oil Injection Pump
9. Loosen the fill cap (b) on the engine mounted oil
tank. Run the engine until all the air has been When throttle linkage is at idle position, alignment
vented out of the tank and oil starts to flow out of mark on oil injection arm should be in-line with mark
the tank. Re-tighten fill cap. on casting as shown. If necessary, adjust link rod.
CAUTION
Be certain that the fill caps on the engine oil tank
and remote oil tank are installed tight. An air leak, a
at one of the caps on the remote oil tank, will pre-
vent oil flow to the engine oil tank. A loose fill cap b c
on the engine oil tank will cause oil leakage.
Bleeding Air from Oil Injection Pump 50060

a - Link Rod
and Oil Injection Outlet Hose b - Alignment Mark
c - Casting Mark
BLEEDING AIR FROM OIL INJECTION PUMP
With engine not running, place a shop towel below
the oil injection pump. Loosen bleed screw (a) three
to four turns and allow oil to flow from bleed hole. Re-
tighten bleed screw. This procedure allows the pump
to fill with oil.

Turn-Key Start Feature
The Sport Jet utilizes an automatic enrichner to start
a cold engine. The enrichner is controlled by the ECM
(Electronic Control Module). There are no adjust-
ments for the Turn Key Start Feature.
IMPORTANT: The Turn-Key Start relies on closed
throttle plates at idle. Ensure throttle plates are
fully closed at idle.
Timing/Synchronizing/
Adjusting
28244
Specifications
2. Turn flywheel in a clockwise direction until No. 1
Sport Jet 175XR2 piston is at top dead center (TDC). Set dial indica-
Full Throttle RPM Range 5000-5500 tor at “O” (zero) and tighten indicator set screw.
Idle RPM 1000 - 1100 3. Turn flywheel counterclockwise until dial indica-
tor needle is approximately 1/4-turn beyond .462
Maximum Timing:
in., then turn flywheel clockwise so that dial indi-
cator reads .462 in. (11.7mm ) exactly.
@ 5000 RPM 20° BTDC
Idle Speed/Pickup Timing 0° 2° ATDC 4. Reposition timing pointer (a) “if necessary” so
that timing pointer is aligned with .462 in. mark on
Spark Plug NGK-BU8H timing decal. Retighten pointer attaching screws
Firing Order 1-2-3-4-5-6 (b).
Adjustments
b b
TIMING POINTER ADJUSTMENT
WARNING
Engine could start when turning flywheel to
check timing pointer adjustment. Remove all
spark plugs from engine to prevent engine from
starting. a
1. Remove all spark plugs and install Dial Indicator
(91-58222A1 ) into No. 1 cylinder (top cylinder,
28245
starboard bank).
a - Timing Pointer
b - Pointer Attaching Screws
5. Remove dial indicator from cylinder.

CARBURETOR SYNCHRONIZATION 4. Move throttle lever to wide-open-throttle (W.O.T.)
position and adjust full throttle stop screw (a) to
1. Loosen 3 carburetor synchronization screws (a)
allow full throttle shutter opening at W.O.T. Verify
to allow shutter plates to close completely.
that throttle shutters do not act as a throttle stop.
2. Position throttle lever so that idle stop screw is Allow .010 in. - .015 in. (.25 mm - .38 mm) clear-
against idle stop and move roller arm until roller ance between throttle shaft arm(b) and stop (c) at
lightly touches throttle cam (b). Adjust idle stop W.O.T. Retighten jam nut on adjustment screw.
screw (c) on throttle arm to align mark (d) on
throttle cam with center of roller. Without moving
roller from this position, retighten carburetor syn- c
chronization screws.
d
a
b
a
55086
55087
b a - Full Throttle Screw
b - Throttle Shaft Arm
c c - Throttle Shaft Arm Stop
d - .010 - .015 in. (0.25 mm - 0.38 mm)
d Timing Adjustments
CAUTION
Engine may be timed while cranking engine with start-
a - Carburetor Synchronization Screws er motor. To prevent engine from starting when being
b - Throttle Cam cranked, remove all spark plug leads and attach to en-
c - Idle Stop Screw gine ground using spark gap tester.
d - Alignment Mark 1. Insert Spark Gap Tool (91-63998A1 ) into each
spark plug boot and attach alligator clips to good
3. Verify throttle shutter plates open and close si- engine ground.
multaneously during throttle lever operation. 2. Remove throttle cable barrel from barrel retainer.
Readjust if necessary.
IMPORTANT: The remaining timing adjustments
rely on a fully charged battery capable of crank-
ing the engine a minimum of 300 rpm. Battery
voltage should not drop below 9.5 volts at starter
solenoid while cranking.

IMPORTANT: If trigger link rod was disassembled PRIMARY PICKUP TIMING ADJUSTMENT
verify that 11/16 in. (17.5 mm) length is retained.
1. With engine in neutral, hold throttle arm so that
a idle stop screw (a) is against idle stop. Crank en-
gine with starter motor and adjust throttle primary
pickup screw (b) to align specified throttle prima-
ry pickup mark on timing decal with timing point-
er. Retighten jam nut on adjustment screw.
NOTE: Primary pickup timing also determines en-
gine idle RPM, refer to “Idle Speed Adjustment” fol-
lowing.
28246
a - 11/16 in. (17.5 mm) b

MAXIMUM TIMING ADJUSTMENT
1. Connect timing light to No 1 spark plug lead (TOP
STARBOARD BANK)
a
2. With engine in neutral, move throttle lever to
place maximum spark advance screw (b) against
stop. Crank engine with starter motor and adjust
maximum spark advance timing mark to obtain
22 BTDC. Retighten jam nut on adjustment
screw. 55087
a - Idle Stop Screw
b - Primary Pick-Up Screw
NOTE: All timing adjustments made to engine under
cranking speed conditions should be verified with en-
gine running and adjustments made if necessary.
This is due to advance characteristics of individual ig-
b nition systems.
2. Remove timing light from No. 1 spark plug lead.
3. Remove spark gap tools (91-63998A1) from
each spark plug boot and attach spark plug leads
28247 to spark plugs.
b - Spark Advance Screw

IDLE SPEED ADJUSTMENT Trim Plate Adjustment
1. With boat in water, start engine and allow to warm
The Sport Jet trim plate is factory set for general ap-
up. plications. Should a particular boat experience por-
2. With engine in neutral, monitor engine RPM. If poising problems, the trim plate can be adjusted as
RPM is above or below recommended RPM (see follows:
specifications), readjust primary pickup screw to
1. Loosen both jam nuts on trim plate (one star-
attain recommended engine speed. Retighten
board and one port).
jam nut. Re-install throttle cable barrel.
IMPORTANT: Below 3,000 RPM the TKS ECM ad-
vances idle timing 5 until the engine reaches
104F (40C). Above 3,000 RPM, the TKS ECM
does not affect ignition timing regardless of en-
gine temperature.
NOTE: If idle speed is checked with engine running
on flushing attachment, adjust idle speed 400-500
rpm higher than specified.
28248
a
a - Jam Nut w/Washer (Two: One On Each Side)
2. Turn both screws the exact same number of
turns. Tighten both jam nuts against trim plate.
The distance from top of nut to bottom of boss
should be equal on both sides.
WARNING
Adjusting the trim plate may affect boat handling
(steering). Overly sensitive steering or reduced
turning ability could result from trim plate adjust-
ments. Boat handling characteristics also vary
with the load distribution in the boat. Use caution
after adjusting: check for acceptable handling
characteristics under all loading conditions. Fail-
ure to adequately test the boat could result in in-
adequate steering control resulting in property
damage, personal injury or death.

Pre-delivery Inspection On the water test (continued)
Not Check/ Not Check/
Applicable Adjust CHECK BEFORE RUNNING Applicable Adjust
❏ ❏ Cover plate & adaptor plate ❏ ❏ Forward-Neutral-Reverse

fasteners torqued operational
❏ ❏ Battery charged & secure ❏ ❏ Steering operational throughout

entire range
❏ ❏ All electrical connections tight
❏ ❏ Acceleration test
❏ ❏ All fuel connections tight
❏ ❏ WOT:___________RPM
❏ ❏ Throttle, shift, & steering adjusted
❏ ❏ Boat handling
correctly and fasteners torqued
❏ ❏ Shift cable adjusted to keep

reverse gate 3/8-1/2 in. above Post water test
rudder in forward w/ slack pulled
out of cable ❏ ❏ No fuel, oil, water or exhaust
leaks
❏ ❏ Carb throttle shutters open
& close completely ❏ ❏ Re-torque adapter plate
fasteners
❏ ❏ Pump housing & stator oil levels
full (See Section 5)
❏ ❏ Oil injection system full and

bled
❏ ❏ Warning system(s) operational
On the water test
❏ ❏ Starter neutral safety switch

operational
❏ ❏ Lanyard stop switch operational
❏ ❏ All gauges read properly
❏ ❏ No fuel or oil leaks
❏ ❏ No water leaks
❏ ❏ No exhaust leaks
❏ ❏ Ignition timing set to specs
❏ ❏ Idle:____________RPM
❏ ❏ Idle mixture adjusted

ELECTRICAL
2
Fuel Primer
3A Fuse
A
IGNITION SYSTEM
Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . 2A-11
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Stator Assembly . . . . . . . . . . . . . . . . . . . 2A-11
Quicksilver Lubricant/Sealant . . . . . . . . . . . . . . 2A-1 Stator Test . . . . . . . . . . . . . . . . . . . . . . . . 2A-11
12 Ampere Stator . . . . . . . . . . . . . . . . . . 2A-11
Coil Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
Trigger Assembly Test . . . . . . . . . . . . . . 2A-12
Electrical Components . . . . . . . . . . . . . . . . . . . . 2A-4
Ignition Coil Test . . . . . . . . . . . . . . . . . . . 2A-12
Flywheel, Stator And Trigger Assembly . . . . . 2A-6 Ignition Components Removal and
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 2A-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 Flywheel Removal And Installation . . . 2A-12
Ignition Test Procedures . . . . . . . . . . . . . . . . . . . 2A-8 Stator Assembly Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . 2A-13
Direct Voltage Adaptor (DVA) . . . . . . . . . . . 2A-8 Trigger Plate Assembly Removal and
Troubleshooting Tips . . . . . . . . . . . . . . . . . . . 2A-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . 2A-14
Ignition Troubleshooting . . . . . . . . . . . . . . . . . . . 2A-8 Ignition Coil Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . 2A-15
Multimeter/DVA Tester 91-99750A1 . . . . . . 2A-8
Switch Box(es) Removal and
Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . 2A-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . 2A-15
Ignition System Test Chart . . . . . . . . . . . . . 2A-11 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2A-16
2A-0 - ELECTRICAL 90-852396 MAY 1996

Specifications Quicksilver
Ignition System
Lubricant/Sealant
Type Capacitor Discharge Description Part Number
Spark Plug Type NGK BU8H Loctite 271 92-809820
Spark Plug Gap Surface Gap Loctite Primer N 92-59327-1
Voltage @ Spark Plugs 40,000 Volts Liquid Neoprene 92-25711--2
Dielectric Grease 92-823506--1
Special Tools
Multi Meter DVA Tester 91-99750A1
Spark Gap Tester 91-63998A1
90-852396 MAY 1996 ELECTRICAL - 2A-1

Notes:
2A-2 - ELECTRICAL 90-852396 MAY 1996

COIL ASSEMBLY
10
9
2
13
3
8
5
12
11
7
13
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 2 BRACKET-Coil Mounting
2 12 NUT (#10-32)-Cover Screw
3 6 SCREW (.250-20 x .620)
4 6 COIL ASSEMBLY-Ignition
5 1 CABLE KIT-High Tension
6 6 BOOT KIT-High Tension Cable
6 SPARK PLUG (NGK # BU8H)
7
6 SPARK PLUG (NGK # BUZ8H) (RFI)
8 12 NUT (#10-32)-Ignition Coil Terminal
9 2 COVER-Ignition Coil
10 2 HARNESS ASSEMBLY (Black)
11 12 SCREW (#10-32 x 2.125)-Ignition Coil Cover
12 1 J CLIP (PORT)
13 2 J CLIP (STARBOARD)
90-852396 MAY 1996 ELECTRICAL - 2A-3

ELECTRICAL COMPONENTS
1
3
4
33 2
6
5
16
34 17
13
12 18
8 11
20
14
9
15 19
29
10 22 21
15
1
30
29
28 31
32 15
20
6
23 15
27 24
25
26
2A-4 - ELECTRICAL 90-852396 MAY 1996

ELECTRICAL COMPONENTS
TORQUE
REF.
REF
1 3 SCREW (#10-32 x .375)
2 1 HARNESS ASSEMBLY-Engine
3 1 COVER-Fuse
4 1 FUSE (20 AMP)
5 1 PLUG
6 2 CABLE ASSEMBLY (Black) (9.600 in.)
7 1 CABLE ASSEMBLY (Black) (6.250 in.)
8 1 CLIP
9 2 SCREW (.250-20 x 1.500)
10 1 REGULATOR-Voltage
11 1 SOLENOID KIT-Starter
12 2 BUSHING
13 2 SCREW (.250-20 x 1.00)
14 2 NUT (.250-20)
15 4 SCREW (#10-24 x .500)
16 2 NUT (.312-18)
17 2 LOCKWASHER (.312)
18 2 NUT (#10-32)
19 1 PLATE-Ignition Mount
20 2 SWITCH BOX ASSEMBLY
21 3 NUT (#10-32)
22 1 CLAMP
23 3 BUSHING
24 3 GROMMET
25 3 WASHER
26 3 SCREW (.312-18 x 1.120)
27 3 SCREW (#10-32 x 2.380)
28 3 SCREW (.250-20 x .875)
29 6 BUSHING
30 3 GROMMET
31 1 ECM ASSEMBLY-Turn Key Start
32 5 CABLE TIE (8.00 in.)
33 1 CLIP
34 1 CABLE ASSEMBLY
90-852396 MAY 1996 ELECTRICAL - 2A-5

FLYWHEEL, STATOR AND TRIGGER ASSEMBLY
2
3
4 5 1
11
12
6
13
7
8
9
10
14
TORQUE
REF.
REF
1 1 DECAL-Sport Jet 175XR2
2 1 PLUG
3 1 COVER KIT-Flywheel
4 2 WASHER
5 2 SCREW (.190-32 x .380)
6 1 MARKER-Timing
7 1 PLUG
8 1 NUT (.625-18) 120 163
9 1 WASHER
10 1 FLYWHEEL ASSEMBLY
11 4 SCREW (#10-32 x 1.00)
12 4 LOCKWASHER (#10)
13 1 STATOR ASSEMBLY
14 1 TRIGGER PLATE ASSEMBLY
2A-6 - ELECTRICAL 90-852396 MAY 1996

Theory of Operation
Description The trigger assembly (also mounted under the fly-

wheel) has 3 coils. Each coil controls the spark to 2
The V-6 ignition system is alternator-driven with dis- cylinders -1 cylinder each bank. The flywheel also
tributor-less capacitor discharge. Major components has a second set of permanent magnets located
of the system are the flywheel, stator assembly, trig- around the center hub. As the flywheel rotates, the
ger assembly, 2 switch boxes, 6 ignition coils and 6 magnets pass the trigger coils producing AC voltage.
spark plugs. The AC voltage is conducted to an electronic switch
The stator assembly is mounted below the flywheel (SCR) in the switch box. The switch discharges the
and has 4 capacitor charging coils. The 4 capacitor capacitor voltage into the ignition coil at the correct
charging coils are composed of 2 high speed and 2 time and in firing order sequence.
low speed coils-1 high speed and1 low speed coil for Capacitor voltage is conducted to primary side of ig-
each switch box. The low speed coils provide primary nition coil. As this voltage goes to ground through the
voltage for the switch boxes from idle to approximate- primary circuit of the coil, it induces a voltage rise in
ly 2500 RPM. The high speed coils provide primary the secondary side of the ignition coil. This voltage
voltage from 2000 RPM to the maximum RPM the can increase to approximately 40,000 volts before
outboard is capable of achieving. bridging the spark plug gap and returning to ground.
The flywheel is fitted with permanent magnets inside The preceding sequence occurs once per engine
the outer rim. As the flywheel rotates, the permanent revolution for each cylinder.
magnets pass the capacitor charging coils producing
AC voltage. The AC voltage is conducted to the Spark timing is advanced or retarded by the move-
switch boxes where it is rectified and stored in a ca- ment of the trigger assembly attached to the throttle/
pacitor. spark arm.
90-852396 MAY 1996 ELECTRICAL - 2A-7

Ignition Test Procedures CAUTION
WARNING To protect against meter and/or component dam-
age, observe the following precautions:
When testing or servicing the V-6 ignition sys-
tem, high voltage is present. Be extremely cau- -- MAKE CERTAIN that Positive (+) lead/terminal
tious. DO NOT TOUCH OR DISCONNECT any ig- of DVA is connected to Positive (+) receptacle of
nition parts while engine is running, while key meter.
switch is on or while battery cables are con- -- 400 VDC test position (or higher) MUST BE
nected. used for all tests, except “switch box bias” test.
Failure to comply with the following items may result -- DO NOT CHANGE meter selector switch posi-
in damage to the ignition system. tion while engine is running and/or “cranked.”
1. DO NOT reverse battery cable connections. The -- Switch boxes MUST REMAIN GROUNDED dur-
battery negative cable is (-) ground. ing tests. Running or cranking engine with
2. DO NOT “spark” battery terminals with battery switch boxes ungrounded may damage switch
cable connections to check polarity. boxes. If removed for easier access, the ground
wire MUST BE INSTALLED.
3. DO NOT disconnect battery cables while engine
is running. WARNING
4. DO NOT crank engine when switch boxes are not DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do
grounded to engine. Not touch ignition components and/or metal test
A process of elimination must be used when check- probes while engine is running and/or
ing the ignition system without a voltmeter (capable “cranked.”
of measuring 400 volts DC, or higher) and Direct Volt- Test procedures and specifications are provided for
age Adaptor (91-89045), as the switch boxes and ig- checking primary ignition voltage while the engine is
nition coils cannot be thoroughly checked with con- running and/or being “cranked.”
ventional test equipment.
All other components can be tested with an ohmme-
ter. Before troubleshooting the ignition system, check Troubleshooting Tips
the following:
1. Intermittent, weak or no spark output at two spark
1. Make sure that electrical harness and ignition plugs (one plug from each bank of three cylin-
switch are not the source of the problem. ders) usually is caused by a bad TRIGGER.
2. Check that plug-in connectors are fully engaged 2. Intermittent, weak or no spark output at three
and terminals are free of corrosion. spark plugs (a complete bank of three cylinders)
usually is caused by a bad STATOR or SWITCH
3. Make sure that wire connections are tight and
BOX.
free of corrosion.
3. Intermittent, weak or no spark output at any one
4. Check all electrical components, that are
spark plug (single cylinder) usually is a bad COIL
grounded directly to engine, and all ground wires
or SWITCH BOX.
to see that they are grounded to engine.
5. Check for disconnected wires and short and
open circuits.
Ignition Troubleshooting
Direct Voltage Adaptor (DVA)
Multimeter/DVA Tester 91-99750A1
The DVA can be used with Quicksilver VOA Meter
91-99750A1, Quicksilver Volt/Ohm meter 91-93572, WARNING
or an equivalent volt meter (capable of measuring
400 volts DC or higher) to check primary ignition volt- DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do
age on Alternator Driven Ignition (ADI) systems. Not touch ignition components and/or metal test
(Models are specified in Test Charts, following.) probes while engine is running and/or
“cranked.”
2A-8 - ELECTRICAL 90-852396 MAY 1996

Test Sequence 1-D. If Steps 1-A, 1-B and 1-C check OK, check ig-
nition timing.
1-A. Check primary input voltage to coils. (See
Test Chart, following) 1. If ignition timing DOES NOT check to specifica-
tion (sudden and unexplained timing change),
check trigger advance linkage for loose or broken
parts and check trigger magnet ring in flywheel
(affixed to flywheel hub) for tightness and/or shift
in position.
2. If ignition timing is UNSTABLE (timing jumps
around, at “cranking” speed and/or low RPM),
proceed to Step 5-A.
3. If ignition timing checks to specification and en-
gine still does not run or runs poorly, trouble ex-
ists with fuel system or engine mechanical.
2-A. Check switch box “stop” circuit. (See Test
Chart, following.)
OHMS 60 40 30 20 15 10
100
200 5
20 0
10 30
10
5 15
0 40
VOLTS 0 4 6 8 20
2
DC AMPS 0 10
51843
1. If voltage readings to coil(s) are BELOW specifi- DCV ACV
cation, proceed with Step 2-A.

2. If voltage readings to coil(s) are WITHIN specifi-
cation, proceed with Step 1-B. DVA
1-B. Check coils for spark. [Connect Spark Gap

Tester (91-63998A1) between coil high voltage
tower and spark plug.]
1. If no spark or weak spark, COIL is bad.
2. If spark is OK, proceed with Step 1-C.
1-C. If Steps 1-A and 1-B check OK, replace spark
plugs.
If problem still is evident after replacing spark plugs,
54987
proceed with Step 1-D.
1. If reading is BELOW specification, proceed with

Step 2-B.
2. If reading is ABOVE specification, either the trig-
ger or switch box is bad (test trigger: if trigger
checks to specification replace switch box and
repeat check).
3. If reading is WITHIN specification, proceed with
Step 3-A.
90-852396 MAY 1996 ELECTRICAL - 2A-9

2-B. Check ignition switch/wiring, as follows: 2. If both the low speed and high speed readings are
WITHIN specification, proceed with Step 4-A.
WARNING 4-A. Check stator low speed and high speed in-
DANGER--HIGH VOLTAGE SHOCK/FIRE HAZ- put to INNER switch box. (See Test Chart, follow-
ARD. STAY CLEAR OF SPARK PLUG LEADS. To ing.)
assure personal safety, each individual spark 1. If either the low speed or high speed reading to
plug lead should be grounded to the engine. switch box is BELOW specification stator or
1. To prevent engine from starting, remove spark switch box is bad (test stator: if stator checks to
plug leads from ALL spark plugs, then ground specification replace switch box and repeat
ALL spark plug leads to the engine. check)
2. Remove ignition switch h lead wire(s) from switch 2. If both the low speed and high speed readings are
box(es) [lead wire(s) are connected to BLACK/ WITHIN specification, proceed with Step 5-A.
YELLOW bullet terminal]. 5-A. Check switch box bias. Bias circuit may
NOTE: Be sure to disconnect ignition switch lead checked using either a voltmeter or an ohmme-
wire from both switch boxes. ter. (To use a voltmeter, see Test Chart, following.
Use VOLT METER only; DVA not required.
3. With ignition switch ISOLATED (removed in pre-
ceding Step 2), repeat check in Step 2-A. Ohm Test:
a. If reading still is BELOW specification, pro- 1. Disconnect WHITE/BLACK wire from switch box
ceed with Step 3-A. at bullet connector.
b. If reading now is WITHIN specification, either 2. With ohmmeter set to 1K scale, connect one ohm
the ignition switch or wiring is bad. lead to WHT/BLK switch box terminal and one
ohm lead to switch box case ground.
3-A. Check stator low speed and high speed in-
put to switch box. (See Test Chart, following.) 3. Ohmmeter should indicate 1300 - 1500 ohms.
NOTE: This is OUTER switch box. Voltage Test
1. If either the low speed or high speed reading to NOTE: Switch Box Bias Voltage is NEGATIVE (-)
switch box is BELOW specification, stator or voltage applied to the ignition system to raise the trig-
switch box is bad (test stator: if stator checks to ger firing threshold as engine RPM is increased, thus
specification replace switch box and repeat stabilizing ignition timing and preventing random ig-
check). nition firing.
4. If bias reading is BELOW specification, one or
both switch boxes are bad.
Replace OUTER switch box and recheck bias; if nec-
essary, replace INNER switch box and recheck bias.
5. If bias reading is WITHIN specification, and en-
gine still does not run or runs poorly, one or both
switch boxes or trigger is bad. [Test trigger: if trig-
ger checks to specification replace switch
box(es) and repeat check.]
2A-10 - ELECTRICAL 90-852396 MAY 1996

Ignition System Test Chart
IMPORTANT: BEFORE attempting the ignition “Cautions”). ALL tests are performed with lead
system checks, below, thoroughly read the pre- wires connected--terminals exposed. SWITCH
ceding pages of these instructions to become fa- BOXES MUST BE GROUNDED (CASE TO EN-
miliar with the proper test sequence and proce- GINE BLOCK) FOR ALL TESTS--IF NOT, SWITCH
dures (particularly any “Warnings” and BOXES MAY BE DAMAGED.
Test Selection DVA Lead DVA Lead Scale Reading Scale Reading Scale Reading
Sw. Position RED BLACK @ 400 RPM @ 1000 RPM @ 3000 RPM
Coil 400 VDC* Coil (+) Coil (-) 90 - 145 125 - 175 175 - 240
Primary Terminal Terminal
Sw. Box - 400 VDC* Black/Yellow Ground 200 – 300 225 – 400 225 – 400
Stop Circuit Sw. Box Bullet
Stator 400 VDC* Blue Sw. Ground 100 – 265 195 – 265 255 – 345
Low Speed Box Bullet
Stator 400 VDC* Red Sw. Ground 25 – 50 120 – 160 230 – 320
High Speed Box Bullet
Sw. Box - 20VDC or [See Note 1] [See Note 1] 1–6 3 – 15 10 – 30
Bias 40VDC Ground White/Black
Sw. Box Bullet
(1) Using meter only, REVERSE LEAD POLARITY; 12 AMPERE STATOR

Connect leads as specified.
Test Resistance Scale
(*) If using a meter with a built-in DVA, place selector Leads to Ohms Reading
switch in the DVA/400 VDC position.
Between BLUE and
3500-4200 R x 1000
RED Stator Leads
Between BLUE/
Ignition System WHITE and RED/
3500-4200 R x 1000
WHITE Stator
STATOR ASSEMBLY Leads
The stator assembly has a BLACK ground wire which Between RED
grounds the stator to the engine. Stator Lead and 90-140 Rx1
BLACK Stator Lead
IMPORTANT: Stator must be grounded to engine.
Between RED/
STATOR TEST WHITE Stator Lead
90-140 Rx1
and BLACK Stator
1. To test, disconnect BLUE/WHITE and RED/ Lead
WHITE stator leads from outer switch box and
BLUE and RED stator leads from inner switch 3. If meter readings are other than specified, re-
box. place stator assembly. Refer to stator assembly
removal and installation (see “Table of Con-
2. Use an ohmmeter and perform the following
tents”).
tests:
CAUTION
Switch boxes must be grounded to engine before
cranking engine, or switch boxes will be dam-
aged.
90-852396 MAY 1996 ELECTRICAL - 2A-11

TRIGGER ASSEMBLY TEST 3. Use an ohmmeter and perform the following
tests:
1. Disconnect all trigger leads from switch boxes.
NOTE: Copper wire is an excellent conductor, but it
2. Use an ohmmeter and perform the following
will have a noticeable difference in resistance from
checks:
cold to hot temperatures. Reasonable variations
Test Resistance Scale from these specified readings are acceptable.
Leads to Ohms Reading
Test Resistance Scale
Between BROWN Leads to Ohms Reading
Trigger Lead (with-
out YELLOW Between (+) and (–)
1100-1400 R x 100 .02-.04 Rx1
Sleeve) and WHITE Coil Terminals
Trigger Lead (with On BLUE Color
YELLOW Sleeve) Coils Between Coil
Between WHITE Tower and Either (+)
800-1100 R x 100
Trigger Lead (with- or (–) Coil Terminal
out YELLOW (Mounted or Re-
Sleeve) and VIO- 1100-1400 R x 100 moved)
LET Trigger Lead 4. If meter readings are not as specified, replace ig-
(with YELLOW
nition coil. Refer to ‘‘Ignition Coil Removal and
Sleeve)
Installation,” following.
Between VIOLET
Trigger Lead (with-
out YELLOW Ignition Components Removal and
Sleeve) and 1100-1400 R x 100
BROWN Trigger Installation
Lead (with YELLOW
Sleeve) FLYWHEEL REMOVAL AND INSTALLATION
3. If meter readings are not as specified, replace Flywheel Removal

trigger assembly. Refer to “Trigger Assembly 1. Remove 3 wing nuts and lift flywheel cover off en-
Removal and Replacement,” following. gine.
2. While holding flywheel with Flywheel Holder (91-
CAUTION 52344), remove flywheel nut and washer.
Switch boxes must be grounded to engine before a
aged.
IGNITION COIL TEST

IMPORTANT: Ohmmeter tests can only detect
certain faults in the ignition coils. Replace igni-
tion coil, if ohmmeter readings (listed in chart,
54983
following) are not as specified. If coil tests OK,
and coil is still suspected of being faulty, use Mul- b
ti-Meter/DVA Tester (91-99750A1) or a voltmeter a - Flywheel
and Direct Voltage Adaptor (91-89045) to thor- b - Flywheel Holder (91-52344)
oughly check coil. 3. Install a crankshaft protector cap on end of crank-
1. Disconnect wires from the positive (+) and nega- shaft, then install Flywheel Puller (91-73687A2)
tive (-) coil terminals. into flywheel.
2. Remove the spark plug (hi-tension) lead from coil
tower.
2A-12 - ELECTRICAL 90-852396 MAY 1996

2. Remove 4 screws which secure stator to the up-
CAUTION per end cap.
Crankshaft damage may result if a protector cap
is not used between crankshaft and puller.
4. Remove flywheel by operating flywheel puller, as a
shown.
b
CAUTION
CAUTION DO NOT hammer on end of puller cen-
ter bolt to remove flywheel, or damage may result
to crankshaft or bearings. DO NOT use heat to aid
flywheel removal, as excessive heat may seize
flywheel to crankshaft.
54988
a a - Stator Attaching Screws
b - Stator
b 3. Disconnect all stator leads from their respective

terminals, cut sta-strap(s) and remove stator as-
sembly from engine.
Stator Assembly Installation
1. Clean stator attaching screw threads with Loctite
Primer T (92-59327--1 ) and apply Loctite 271
(92-809820). Install stator assembly in position
on upper end cap and secure with attaching
screws. Torque screws to 50 Ib. in. (5.5 N·m).
54984 2. Reconnect wires to proper terminals of voltage
a - Flywheel Puller (91-73687A2) regulator/rectifier and switch boxes. Reconnect
b - Crankshaft Protector Cap (Hidden)
ground lead to ground. Refer to wiring diagram,
Flywheel Installation following in this section. Wires with yellow identifi-
IMPORTANT: Do not apply oil to crankshaft taper cation sleeve must be connected to outer switch
or flywheel taper as flywheel will not seat proper- box.
ly against crankshaft when torqued.
CAUTION
1. Reinstall flywheel on crankshaft. Secure flywheel
with flat washer and locknut. While holding fly- Switch boxes must be grounded to engine before
wheel with Flywheel Holder (91-52344), torque cranking engine, or switch boxes will be dam-
flywheel nut to 120 Ib. ft. (163 N·m). aged.
2. Reinstall flywheel cover on engine. 3. Route stator wiring harness as shown. Secure
with sta-strap and clamp.
STATOR ASSEMBLY REMOVAL AND 4. Reinstall flywheel, as outlined in “Flywheel Re-
INSTALLATION moval and Installation,” preceding.
Stator Assembly Removal
1. Remove flywheel, as outlined in “Flywheel Re-
moval and Installation,” preceding.
90-852396 MAY 1996 ELECTRICAL - 2A-13

TRIGGER PLATE ASSEMBLY REMOVAL AND Trigger Plate Assembly Installation
INSTALLATION
1. If link rod swivel was disassembled or removed,
Trigger Plate Assembly Removal reassemble to trigger as shown.
1. Remove flywheel, as outlined in “Flywheel Re-
2. Remove 4 screws which secure stator assembly
to upper end cap. Lift stator off end cap and move
to the side. b
3. Remove locknut that secures link rod swivel into e
spark advance lever. Pull link rod out of lever. c d
4. Remove 3 screws and remove switches boxes
from ignition plate.
5. Disconnect all trigger leads from their respective
terminals. Cut sta-strap and remove trigger plate
assembly from engine.
6. If trigger assembly is faulty, remove and retain
link rod swivel from trigger. a
51840
a - Retain This [11/16 in. (17.5 mm)] Dimension
a b - Pivot
c - Link Rod
d - Hex Nut
b e - Ball Joint
2. Place trigger plate assembly in upper end cap.
Fasten link rod swivel to spark advance lever with
locknut.
51844
a - Trigger
b - Link Rod Swivel b
51840
a - Spark Advance Lever
b - Locknut
c - Trigger Harness
3. Route trigger wiring harness as shown. Recon-
nect wires to proper terminals of switch boxes.
Refer to wiring diagram, following in this section.
Wires with yellow identification sleeve must be
connected to outer switch box.
2A-14 - ELECTRICAL 90-852396 MAY 1996

4. Install switch boxes to ignition plate with 3 screws Ignition Coil Installation
retained from disassembly. Refer to switch
1. Place coil in coil cover and install to engine with
box(es) removal and installation (see “Table of
6 screws and nuts.
Contents”). Make sure that both switch boxes
are grounded to ignition plate thru mounting 2. Reconnect switch box wire to (+) terminal of coil
screws and spacers. and black ground wire to (-) terminal.
3. Pull the boot back and insert spark plug lead into
CAUTION coil. Caution must be taken to ensure a complete
Switch boxes must be grounded to engine before connection of lead into coil. Form a water tight
cranking engine, or switch boxes will be dam- seal between coil tower and spark plug lead us-
aged. ing Quicksilver Insulating Compound
(92-823506--1). Assemble boot over coil termi-
5. Clean stator attaching screw threads with Loctite nal.
Primer T (92-59327--1 ) and apply Loctite 222
(obtain locally). Install stator assembly in position
SWITCH BOX(ES) REMOVAL AND
on upper end cap and secure with attaching
INSTALLATION
screws. Torque screws to 50 Ib. in. (5.5 N m).
Switch Box(es) Removal
6. Secure wires with sta-strap and.
1. Remove 3 screws and lift switch boxes from en-
7. Reinstall flywheel as outlined in “Flywheel Re-
gine.
IGNITION COIL REMOVAL AND INSTALLATION

Ignition Coil Removal
1. Remove the spark plug (high tension) lead from
the defective coil.
2. Disconnect wires from (+) and (-) terminals on de-
fective coil.
3. Remove 6 screws and nuts, lift coil cover along
with coils from engine. Remove defective coil
from cover.
a
54989
a - Screws
a 2. Disconnect wires from switch boxes.
Switch Box(es) Installation
1. Reconnect wires to proper bullet terminals of
switch boxes. Secure a ground lead to ignition
plate using a screw. Refer to wiring diagram, fol-
b lowing. Wires with yellow identification sleeve
must be connected to outer switch box. Outer
switch box fires cylinders No. 2, 4 and 6.
2. Install switch boxes to ignition plate with 3 screws
and nuts. Make sure that both switch boxes are
grounded to engine through ground leads.
a - Cover
b - Screws CAUTION
Switch boxes must be grounded to engine before
aged.
90-852396 MAY 1996 ELECTRICAL - 2A-15

Wiring Diagram
Fuel Primer
3A Fuse
2A-16 - ELECTRICAL 90-852396 MAY 1996

ELECTRICAL
2
B
51806
BATTERY CHARGING SYSTEM

AND STARTING SYSTEM
Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Starter System . . . . . . . . . . . . . . . . . . . . . . . . 2B-8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Starter System Components . . . . . . . . . . 2B-8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Troubleshooting The Starter Circuit . . . . 2B-8
Specific Gravity Readings . . . . . . . . . . . . . . . . . 2B-2 Flywheel/Starter Assembly . . . . . . . . . . . . . . . . 2B-9
Specific Gravity Cell Comparison Test . . . . 2B-3 Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2B-10
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Starter Circuit Troubleshooting
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-11
Charging a Discharged Battery . . . . . . . . . . . . . 2B-3
Starter Removal and Installation . . . . . . . . 2B-12
Winter Storage of Batteries . . . . . . . . . . . . . . . . 2B-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12
Battery Charging System Description . . . . . . . 2B-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . 2B-13
Battery Charging System Troubleshooting . . . 2B-5 Disassembly . . . . . . . . . . . . . . . . . . . . . . 2B-13
General Troubleshooting . . . . . . . . . . . . . . . 2B-5 Starter Cleaning, Inspection and
Alternator System . . . . . . . . . . . . . . . . . . . . . 2B-5 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14
Stator Test (Alternator Coils Only) . . . . . 2B-5 Cleaning and Inspection . . . . . . . . . . . . 2B-14
Troubleshooting Alternator System . . . . . . . 2B-5 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14
Determining Cause Of Problem . . . . . . . 2B-6 Starter Reassembly . . . . . . . . . . . . . . . . 2B-16
Problem: Constant High Output . . . . . . . 2B-6 Starter Solenoid Test . . . . . . . . . . . . . . . 2B-18
Problem: No Output . . . . . . . . . . . . . . . . . 2B-6
Regulation Voltage Check . . . . . . . . . . . . 2B-6
Voltage Regulator Test
(Using Ohm Meter) . . . . . . . . . . . . . . . . . . 2B-7
Removal of Voltage Regulator . . . . . . . . 2B-7
Installation of Voltage
Regulator/Rectifier . . . . . . . . . . . . . . . . . . 2B-7
2B-0 - ELECTRICAL 90-852396 MAY 1996

Specifications Special Tools
Multi Meter DVA Tester 91-99750A1
Starter Draw (No Load) 40 Amperes

Starter Draw (Under 175 Amperes
Load)
Battery Rating 670 Marine Carnking
Amps (MCA)
or 520 Cold Cranking
Amps (CCA)
Alternator Output 12 Amperes @ 3000
RPM
Description Part Number

Hydrometer Obtain Locally
Ammeter Obtain Locally
90-852396 MAY 1996 ELECTRICAL - 2B-1

Battery 3. If hydrometer has built-in thermometer, draw liq-
uid in several times to ensure correct tempera-
ture before taking reading.
Precautions 4. Hold hydrometer vertically and draw in just
enough liquid from battery cell so that float is free-
WARNING floating. Hold hydrometer at eye level so that float
is vertical and free of outer tube, then take read-
If battery acid comes in contact with skin or eyes, ing at surface of liquid. Disregard curvature
wash skin immediately with a mild soap. Flush where liquid rises against float stem due to capil-
eyes with water immediately and see a doctor. larity.
When charging batteries, an explosive gas mixture
forms in each cell. Part of this gas escapes through
holes in vent plugs and may form an explosive atmo-
sphere around battery if ventilation is poor. This ex-
plosive gas may remain in or around battery for sev-
eral hours after it has been charged. Sparks or
flames can ignite this gas and cause an internal ex-
plosion which may shatter the battery.
The following precautions should be observed to pre-
vent 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 batter-
ies because a spark usually occurs at the point
where a live circuit is broken. Always be careful
when connecting or disconnecting cable clamps 22532
on chargers. Poor connections are a common 5. Avoid dropping electrolyte on boat or clothing, as
cause of electrical arcs which cause explosions. it is extremely corrosive. Wash off immediately
with baking soda solution.
3. DO NOT reverse polarity of battery terminal to
cable connections. Specific gravity of electrolyte varies not only with per-
centage of acid in liquid but also with temperature. As
temperature increases, electrolyte expands, so that
specific gravity is reduced. As temperature drops,
Specific Gravity Readings electrolyte contracts, so that specific gravity in-
Use a hydrometer to measure specific gravity of elec- creases. Unless these variations in specific gravity
trolyte in each cell. are taken into account, specific gravity obtained by
hydrometer may not give a true indication of acid in
Hydrometer measures percentage of sulfuric acid in
electrolyte.
battery electrolyte in terms of specific gravity. As a
battery drops from a charged to a discharged condi- A fully charged battery will have a specific gravity
tion, acid leaves the solution and enters the plates, reading of approximately 1.270 at an electrolyte tem-
causing a decrease in specific gravity of electrolyte. perature of 80° F (27° C). If electrolyte temperature
An indication of concentration of electrolyte is ob- is above or below 80° F, additions or subtractions
tained with a hydrometer. must be made in order to obtain a hydrometer read-
ing corrected to 80° F standard. For every 10° F (3.3°
When using a hydrometer, observe the following
C) above 80° F, add 4 specific gravity points (.004) to
points:
hydrometer reading. Example: A hydrometer reading
1. Hydrometer must be clean (inside and out) to in- of 1.260 at 110° F (43° C) would be 1.272 corrected
sure an accurate reading. to 80° F, indicating a fully charged battery.
2. Never take hydrometer readings immediately af- For every 10° below 80° F, subtract 4 points (.004)
ter water has been added. Water must be thor- from the reading. Example: A hydrometer reading of
oughly mixed with electrolyte by charging for at 1.272 at 0° F (-18° C) would be 1.240 corrected to 80°
least 15 minutes at a rate high enough to cause F, indicating a partially charged battery.
vigorous gassing.
2B-2 - ELECTRICAL 90-852396 MAY 1996

SPECIFIC GRAVITY CELL Charging a Discharged
COMPARISON TEST
Battery
This test may be used when an instrumental tester is
The following basic rules apply to any battery charg-
not available. To perform this test, measure specific
ing situation:
gravity of each cell, regardless of state of charge, and
interpret results as follows: If specific gravity read- 1. Any battery may be charged at any rate (in am-
ings show a difference between highest and lowest peres) or as long as spewing of electrolyte (from
cell of .050 (50 points) or more, battery is defective violent gassing) does not occur and for as long as
and should be replaced. electrolyte temperature does not exceed 125° F
(52° C). If spewing of electrolyte occurs, or if elec-
trolyte temperature exceeds 125° F, charging
rate (in amperes) must be reduced or temporarily
Electrolyte Level halted to avoid damage to the battery.
Check electrolyte level in battery regularly. A battery 2. Battery is fully charged when, over a 2-hour peri-
in use in hot weather should be checked more fre- od at a low charging rate (in amperes), all cells
quently because of more rapid loss of water. If elec- are gassing freely (not spewing liquid electro-
trolyte level is found to be low, then distilled water lyte), and no change in specific gravity occurs.
should be added to each cell until liquid level rises ap- Full charge specific gravity is 1.260-1.275, cor-
prox. 3/16 in. (4.8mm) over plate. DO NOT OVER- rected for electrolyte temperature with electrolyte
FILL, because this will cause loss of electrolyte and level at 3/16 in. (4.8mm) over plate, unless elec-
result in poor performance, short life and excessive trolyte loss has occurred (from age or over-filling)
corrosion. in which case specific gravity reading will be low-
er. For most satisfactory charging, lower charg-
CAUTION ing rates in amperes are recommended.
During service, only distilled water should be 3. If, after prolonged charging, specific gravity of at
added to the battery, not electrolyte. least 1.230 on all cells cannot be reached, battery
Liquid level in cells should never be allowed to drop is not in optimum condition and will not provide
below top of plates, as portion of plates exposed to optimum performance; however, it may continue
air may be permanently damaged with a resulting to provide additional service, if it has performed
loss in performance. satisfactorily in the past.
4. To check battery voltage while cranking engine
with electric starting motor, place RED (+) lead of
tester on POSITIVE (+) battery terminal and
BLACK (-) lead of tester on NEGATIVE (-) battery
terminal. If the voltage drops below 9-1/2 volts
while cranking, the battery is weak and should be
recharged or replaced.
90-852396 MAY 1996 ELECTRICAL - 2B-3

Winter Storage of Batteries Battery Charging System
Battery companies are not responsible for battery Description
damage either in winter storage or in dealer stock if
the following instructions are not observed: The battery charging system components are the fly-
wheel permanent magnets, stator, voltage regulator/
1. Remove battery from its installation as soon as rectifier and battery. The rotating permanent mag-
possible and remove all grease, sulfate and dirt nets induce an alternating current (AC) in the stator
from top surface by running water over top of bat- coils. The AC current is rectified to direct current (DC)
tery. Be sure, however, that vent caps are tight by the voltage regulator/rectifier. The DC output from
beforehand, and blow off all excess water thor- the voltage regulator/rectifier is used to charge the
oughly with compressed air. Check water level, battery. The voltage regulator/rectifier also senses
making sure that plates are covered. the battery voltage as a measure of the battery’s
2. When adding distilled water to battery, be ex- state of charge and thereby regulates the DC current
tremely careful not to fill more than 3/16 in. (4.8 flow to the battery. In this manner, the battery charge
mm) above perforated baffles inside battery. Bat- is maintained and the battery is protected from an
tery solution or electrolyte expands from heat overcharge condition.
caused by charging. Overfilling battery will cause
electrolyte to overflow (if filled beyond 3/16 in.
above baffles).
b
3. Grease terminal bolts well with 2-4-C Marine Lu- a
bricant and store battery in a COOL-DRY place.
Remove battery from storage every 30-45 days,
check water level and put on charge for 5 or 6 c
hours at 6 amperes. DO NOT FAST CHARGE.
4. If specific gravity drops below 1.240, check bat-
tery for reason and recharge. When gravity d
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, for
best possible maintenance during inactive peri-
ods to ensure a good serviceable battery in e
spring. When ready to place battery back in ser-
51806
vice, remove excess grease from terminals (a a - Stator
small amount is desirable on terminals at all b - Starter Solenoid
times), recharge again as necessary and reinstall c - To Tachometer
battery. d - Voltage Regulator/Rectifier
e - 12 Volt Battery
WARNING
Hydrogen and oxygen gases are produced dur-
ing normal battery operation or charging. Sparks
or flame can cause this mixture to ignite and ex-
plode, if they are brought near the vent openings.
Sulfuric acid in battery can cause serious burns,
if spilled on skin or in eyes. Flush or wash away
immediately with clear water.
2B-4 - ELECTRICAL 90-852396 MAY 1996

Battery Charging System Alternator System
Troubleshooting STATOR TEST (ALTERNATOR COILS ONLY)
NOTE: Stator can be tested without removing from
General Troubleshooting engine.
1. Disconnect 2 YELLOW stator leads from bullet
A fault in the battery charging system will usually
connectors to voltage regulator/rectifier.
cause the battery to become UNDERCHARGED. A
defective VOLTAGE REGULATOR may also allow 2. Use an ohmmeter and perform the following test:
the system to OVERCHARGE the battery.
Resistance Scale
If a problem exists in the charging system, visually Test Leads To-
(Ohms) Reading
check the following:
Connect test leads
1. Check for correct battery polarity [RED cable to between 2 YELLOW .25-.45* Rx1
(+) POSITIVE battery terminal]. stator leads
2. Check for loose or corroded battery terminals. RED test lead to 1
3. Check condition of the battery. YELLOW stator
lead, and BLACK
4. Visually inspect all wiring between stator and bat- test lead to engine No
R x 1000
tery for cuts, chafing and disconnected, loose or ground if stator is Continuity
corroded connections. mounted or to steel
frame of stator (if off
5. Excessive electrical load (from too many acces- engine)
sories) will cause battery to run down, even if the
system is operating correctly. * Resistance of these windings generally is less than
If the system is still OVERCHARGING the battery, one ohm. A reading, that resembles a short, is ac-
the VOLTAGE REGULATOR is most likely defective ceptable. Copper wire is an excellent conductor but
and should be replaced. will have noticeable differences from cold to hot.
Reasonable variation from specified reading is ac-
If the battery is UNDERCHARGED, proceed with ceptable.
REGULATOR, STATOR, and RECTIFIER tests, fol-
lowing. 3. If meter readings are other than specified, re-
place stator assembly Refer to stator assembly
replacement in Section 2A.
TROUBLESHOOTING ALTERNATOR
SYSTEM
WARNING
Before connecting or disconnecting any electri-
cal connection, battery cables MUST BE RE-
MOVED from battery to prevent possible person-
al injury or damage to equipment.
IMPORTANT: The charging system may be con-
nected to one or more batteries during these
tests. However, these batteries MUST BE fully
charged. These batteries MUST NOT BE con-
nected to any other charging source.
90-852396 MAY 1996 ELECTRICAL - 2B-5

IMPORTANT: Check that all connections are tight PROBLEM: NO OUTPUT
prior to starting tests. Ensure that the battery
IMPORTANT: Regulator MUST have a good
posts and terminals are clean and making good
ground. Verify a clean contact surface exists be-
contact. Verify with test equipment that wiring
tween regulator case, powerhead and attaching
harnesses are not at fault.
hardware.
DETERMINING CAUSE OF PROBLEM 1. Check voltage on either RED wire to regulator
(bullet connectors). These leads must indicate
1. Connect outboard battery leads to battery(s) that battery voltage when the key is in the RUN posi-
are known to be in good condition and are fully tion. If battery voltage is NOT present, the key
charged. switch or wiring between the key switch and the
2. Check voltage at battery(s) with an analog volt test point is defective. Refer to Wiring Diagram,
meter. Digital voltmeters are not recommended Section 2A.
as they may be inaccurate due to interference 2. Connect an AC voltmeter to YELLOW lead bullet
from ignition system. connector on the regulator. If the AC voltage at
3. Start engine and run at 1000 RPM. Voltage at bat- idle or above is greater than 16 VAC, the regula-
tery should rise to and stabilize at approximately tor is defective.
14.5 volts if system is operating properly. If volt- NOTE: The tachometer signal is provided by the reg-
age does not increase from previously checked ulator. It is possible to still have an accurate tachome-
battery voltage values, refer to “NO OUTPUT,” ter signal with a defective regulator.
following, for troubleshooting procedures. If volt-
age exceeds 16 volts and DOES NOT return
REGULATION VOLTAGE CHECK
down to and stabilize at 14.5 volts, refer to “CON-
STANT HIGH OUTPUT,” following for trouble- NOTE: Battery must be fully charged before testing
shooting procedures. regulation voltage. A low battery will not allow an ac-
curate reading of regulation voltage.
PROBLEM: CONSTANT HIGH OUTPUT 1. Turn on all electrical accessories and crank en-
1. Remove flywheel and visually inspect stator. Dis- gine for 20 seconds with the ignition lanyard
coloration of one or more poles, or burned wind- switch turned off. This will discharge battery
ings will require replacement of stator. slightly.
2. If no visual defects of stator are found, reinstall 2. Start engine and observe battery voltage. Volt-
flywheel. Temporarily install ammeter (of suffi- age should slowly rise to approximately 14 to 15
cient size to carry 50 amperes) in series with the volts. If voltage does not rise, repeat previous
RED output lead (MALE bullet lead) of the regula- tests for stator and regulator.
tor and the starter solenoid. NOTE: If a digital voltmeter is used for this reading,
3. Remove 1 YELLOW stator lead from bullet con- measure voltage at the battery and keep meter as far
nector. Run engine at 1000-2000 RPM. Any out- away from engine as possible. This will reduce the
put current indicates stator is shorted to ground. possibility of erroneous readings from ignition noise.
Replace stator.
4. If there is no output with YELLOW lead discon-
nected, the regulator is defective.
2B-6 - ELECTRICAL 90-852396 MAY 1996

VOLTAGE REGULATOR TEST (USING OHM REMOVAL OF VOLTAGE REGULATOR
METER)
1. Disconnect all voltage regulator wires. Remove
IMPORTANT: Make sure meter is “zeroed” by two screws securing voltage regulator to ignition
shorting meter leads together after changing se- plate.
lector knob to appropriate setting. The meter
reading must read “0” Ohms.
IMPORTANT: The following regulator tests
should be performed as soon as possible after
suspected regulator failure. A “cold” regulator
may test “GOOD” when in fact it is defective
when “warm”.
Disconnect all voltage regulator wires.
Using Ohm meter, perform each Ohms test listed be-
low:
Resistance Scale
Test Leads To-
(Ohms) a
Diode Check: Con-
nect NEGATIVE (–)
ohm lead to either
YELLOW lead. Con- 100-400 R x 10
nect POSITIVE (+)
test lead to thick
RED lead.
Diode Check: Con-
nect NEGATIVE (–) a - Voltage Regulator/Rectifier
ohm lead to thick
RED lead. Connect 40K to ∞ R x 1K 2. Remove voltage regulator/rectifier from power-
POSITIVE (+) ohm head.
lead to either YEL-
LOW lead.
SCR Checks: Con- INSTALLATION OF VOLTAGE
nect NEGATIVE (–) REGULATOR/RECTIFIER
ohm lead to either
10K to ∞ R x 1K 1. Position regulator over ignition plate. Secure with
YELLOW lead. Con-
nect POSITIVE (+) two screws.
ohm lead to case 2. Connect YELLOW, RED and GRAY (as required)
ground. leads to their respective bullet connectors.
Tachometer Circuit
Check: Connect
NEGATIVE (–) ohm
lead to case ground. 10K to 30K R x 1K
Connect POSITIVE
(+) ohm lead to
GRAY lead.
90-852396 MAY 1996 ELECTRICAL - 2B-7

Starter System CAUTION
STARTER SYSTEM COMPONENTS The starter motor may be damaged if operated
continuously. DO NOT operate continuously for
1. Battery more than 30 seconds. Allow a 2 minute cooling
2. Starter Solenoid period between starting attempts.
3. Neutral Start Switch TROUBLESHOOTING THE STARTER CIRCUIT
4. Starter Motor Before beginning the troubleshooting flow chart,
5. Ignition Switch verify the following conditions:
1. Confirm that battery is fully charged.
DESCRIPTION
2. Check that control lever is in “NEUTRAL” posi-
The function of the starting system is to crank the en- tion.
gine. The battery supplies electricity to activate the
starter motor. When the ignition switch is turned to 3. Check terminals for corrosion and loose connec-
the “START” position, the starter solenoid is ener- tions.
gized and completes the starter circuit between the 4. Check cables and wiring for frayed and worn in-
battery and starter. sulation.
The neutral start switch opens the starter circuit when 5. Check 20 amp fuse.
the shift control lever is not in neutral thus preventing
accidental starting when the engine is in gear. Location of “Test Points” (called out in flow chart) are
numbered below.
g
2 a
6 1
3
e
2
6 1
5 4 c
a - Starter Solenoid
b - Starter
c - Neutral Start Switch
d - Ignition Switch
e - 20 Ampere Fuse
f - Starter Solenoid
g - Battery
2B-8 - ELECTRICAL 90-852396 MAY 1996

FLYWHEEL/STARTER ASSEMBLY
2
25 3
15 4 5 1
11
24 6 12
13
23 7
16 8
22
9
21 17 10
14
19 20
18
15
TORQUE
REF.
REF
1 1 DECAL-Sport Jet 175XR2
2 1 PLUG
3 1 COVER KIT-Flywheel
4 2 WASHER
5 2 SCREW (.190-32 x .380)
6 1 MARKER-Timing
7 1 PLUG
8 1 NUT (.625-18) 120 163
9 1 WASHER
10 1 FLYWHEEL ASSEMBLY
11 4 SCREW (#10-32 x 1.00)
12 4 LOCKWASHER (#10)
13 1 STATOR ASSEMBLY
14 1 TRIGGER PLATE ASSEMBLY
15 2 COLLAR-Starter Cap
16 1 DECAL-Start In Gear
17 1 DECAL-High Voltage
18 1 WIRE ASSEMBLY (12.500 in.) (BLACK)
19 1 NUT (.250-20)
21 1 STARTER ASSEMBLY
22 1 BOOT (Red)-Starter Lead
23 1 SCREW W/ LOCKWASHER (.250-20 x .625)
24 1 WIRE ASSEMBLY (6.00 in.) (BLACK)
25 2 STOP (Rubber)
90-852396 MAY 1996 ELECTRICAL - 2B-9

STARTER ASSEMBLY
2
8
3 5
4
1
6
8
9
7 11 10
9
9
13
14
12
TORQUE
REF.
REF
1 1 STARTER ASSEMBLY
2 1 DRIVE KIT-Pinion
3 1 PINION ASSEMBLY-Drive
4 1 CAP ASSEMBLY-Drive End
5 2 THRU BOLT
6 2 O RING-Thru Bolt
7 1 ARMATURE
8 2 O RING-Starter Frame
9 1 BRUSH/SPRING KIT
10 2 SCREW-Brush Holder
11 1 HOLDER-Brush
12 1 CAP-Comm End
13 1 WASHER-Insulator-Brush Post
14 1 NUT-Brush Post
2B-10 - ELECTRICAL 90-852396 MAY 1996

Starter Circuit Troubleshooting Flow
Chart
Starter Motor Does Not Turn
SAFETY WARNING: Disconnect YELLOW (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 (Rx1 scale) and connect meter leads
between NEGATIVE (-) battery post and common pow-
erhead ground.
No Continuity Indicated - There is an open circuit in the Continuity Indicated

BLACK NEGATIVE (-) battery cable between the NEGATIVE (-) Proceed to TEST 2
battery post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.
Test 2
a. Disconnect BLACK ground wire(s) from Test Point 2.
No voltage reading: b. Connect voltmeter between common engine ground and Test Point 2.
proceed to TEST 3. c. Turn ignition key to “Start” position.
TEST 3 12 Volt Reading*

a. Reconnect BLACK ground wire. Check BLACK ground wire for poor connection
b. Connect voltmeter between common engine ground and Test Point 3. or open circuit.
Reconnect ground wire to starter solenoid.
c. Turn ignition key to “Start” position. Proceed to TEST 7.
No voltage reading: 12 Volt Reading

Proceed to TEST 4 Defective starter solenoid
TEST 4
a. Connect voltmeter between common 12 Volt Reading*
No voltage reading: engine ground and Test Point 4. Neutral start switch is open or YELLOW/RED
Proceed to TEST 5 b. Turn ignition key to “Start” position. wire is open between Test Points 4 and 3.
TEST 5
No voltage reading: Connect voltmeter between common 12 Volt Reading*
Proceed to Test 6. engine ground and Test Point 5 Defective ignition switch.
TEST 6
Check for voltage between common engine ground and Test Point 6.
No voltage reading: 12 Volt Reading*

Check RED wire between battery (+) Check fuse in RED wire between Test Points
POSITIVE terminal and Test Point 6.
5 and 6.
Check for open RED wire between Test Points
5 and 6.
*Battery Voltage
90-852396 MAY 1996 ELECTRICAL - 2B-11

TEST 7
a. Connect voltmeter between common engine and Test Point 1.
b. Turn ignition key to “Start” position.
No voltage reading: 12 Volt Reading*

Defective starter solenoid Should hear solenoid click: proceed to TEST 8
TEST 8
a. Reconnect BLACK cable (with YELLOW sleeve) 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 (with YELLOW
12 Volt Reading*
sleeve) for poor connection or open circuit. If starter motor does not turn, check starter motor.
*Battery Voltage
Starter Removal and Installation 3. Remove 4 bolts and upper and lower starter
REMOVAL clamps. Lift starter from engine.
CAUTION
Disconnect battery leads from battery before re-
moving starter.
1. Disconnect BLACK ground cable from starter.
2. Disconnect BLACK (with YELLOW sleeve) cable a
from starter.
a - BLACK (with YELLOW sleeve) POSITIVE (+) 12-

b - BLACK Ground Cable
2B-12 - ELECTRICAL 90-852396 MAY 1996

INSTALLATION a. Remove hex nut and washers from POSI-
TIVE (+) terminal and remove POSITIVE
1. Slide rubber collars on starter.
brushes and terminal as an assembly.
2. If the removed starter was equipped with a
b. Remove 2 bolts securing NEGATIVE (-)
spacer replace spacer on upper collar.
brushes and brush holder to end cap.
a
a c
b a
11645
a - Rubber Collar e
b - Spacer (If Equipped)
e
3. Install starter to engine with starter clamps. Make
sure that black ground cable is fastened, along
with lower mounting bolts. Torque bolts to 210 lb.
in. (23.5 N·m).
c
4. Reconnect yellow cable to positive (+) terminal d b
on starter. 11656
a - Brush Holder
5. Reconnect black ground cable to terminal on b - POSITIVE Brushes
starter. c - NEGATIVE Brushes
d - POSITIVE Terminal
e - Bolts (Fasten NEGATIVE Brushes and Holder)
DISASSEMBLY
5. Remove armature (with drive end cap) from start-
1. Remove starter as outlined in “Starter Removal
er frame.
and Installation”.
6. Remove locknut and remove drive assembly
2. Remove 2 through bolts from starter.
from armature shaft.
a
b 11646
a - Through Bolts a
b - Commutator End Cap
3. Tap commutator end cap to loosen and remove
from frame. Do not lose brush springs.
4. Brush replacement is recommended if brushes
are pitted, chipped or worn to less than 0.25 in.
(6.4 mm). If necessary, remove brushes as fol-
lows:
a - Hold Armature Shaft with Wrench on Hex Portion of Drive

Assembly
90-852396 MAY 1996 ELECTRICAL - 2B-13

Then remove parts from shaft. c. Sand the commutator lightly with No. 00
sandpaper to remove burrs, then clean the
e f g commutator.
d. Recheck the armature on a growler for shorts
as specified in the following procedure (“Test-
ing”).
8. Open-circuited armatures often can be repaired.
The most likely place for an open circuit is at the
a b c d commutator bars, as a result of long cranking pe-
riods. Long cranking periods overheat the starter
motor so that solder in the connections melts and
11658 is thrown out. The resulting poor connections
a - Locknut then cause arcing and burning of the commutator
b - Spacer
c - Spring
bars.
d - Drive Assembly 9. Repair bars, that are not excessively burned, by
e - Drive End Cap
f - Armature Shaft
resoldering the leads in bars (using rosin flux sol-
g - Washer der) and turning down the commutator in a lathe
to remove burned material, then undercut the
mica.
Starter Cleaning, Inspection and 10. Clean out the copper or brush dust from slots be-
Testing tween the commutator bars.
11. Check the armature for ground. See the following
CLEANING AND INSPECTION procedure (“Testing”).
1. Clean all starter motor parts.
TESTING
2. Check pinion teeth for chips, cracks or excessive
wear. Armature Test for Shorts
3. Replace the drive clutch spring and/or collar if Check armature for short circuits by placing on growl-
tension is not adequate or if wear is excessive. er and holding hack saw blade over armature core
while armature is rotated. If saw blade vibrates, ar-
4. Inspect brush holder for damage or for failure to mature is shorted. Recheck after cleaning between
hold brushes against commutator. commutator bars. If saw blade still vibrates, replace
5. Replace brushes that are pitted or worn to less armature.
than 1/4 in. (6.4mm) in length.
6. Inspect the armature conductor (commutator bar
junction) for a tight connection. A loose connec-
tion (excessive heat from prolonged cranking
melts solder joints) results in a burned commuta-
tor bar.
7. Resurface and undercut a rough commutator as
follows:
CAUTION
Do not turn down the commutator excessively.
a. Resurface the commutator and undercut the
insulation between the commutator bars 1/32
in. (0.8mm) to the full width of the insulation 11669
and so that the undercut is flat.
b. Clean the commutator slots after undercut-
ting.
2B-14 - ELECTRICAL 90-852396 MAY 1996

Armature Test for Ground Testing Negative Brushes for Ground
1. Set ohmmeter to (R x 1 scale). Place one lead of Set ohmmeter to (R x1 scale). Place one lead of the
ohmmeter on armature core or shaft and other ohmmeter on the NEGATIVE brush and the other
lead on commutator. lead on the end cap (bare metal). If the meter indi-
cates NO continuity, replace the NEGATIVE brush.
2. If meter indicates continuity, armature is
Repeat this procedure on the other NEGATIVE
grounded and must be replaced.
brush.
a b
11675
11674
Checking Positive Brushes and Terminal a - NEGATIVE (-) Brushes
Set ohmmeter to (R x 1 scale). Connect meter leads b - End Cap
between POSITIVE brushes. Meter must indicate full
continuity or zero resistance. If resistance is indi-
cated, inspect lead to brush and lead to POSITIVE
terminal solder connection. If connection cannot be
repaired, brushes must be replaced.
11673
a - POSITIVE (+) Brushes
90-852396 MAY 1996 ELECTRICAL - 2B-15

STARTER REASSEMBLY b. Install NEGATIVE brushes (along with brush
holder).
1. If brushes were removed, replace as follows:
a. Install POSITIVE brushes (along with POSI-
TIVE terminal) into commutator end cap. b
a c
a
b
i
d d
h
d
b a
e 11656
c a - POSITIVE (+)Brushes
f b - NEGATIVE (-) Brushes
c - Brush Holder
d - Bolts (Fasten NEGATIVE Brushes and Holder)
g
2. If removed, reinstall parts on armature shaft. Use
a new locknut and tighten securely on end of
shaft.
11660 e f g
a - End Cap
b - POSITIVE Brushes
c - POSITIVE Terminal
d - Insulating Bushing
e - Washer
f - Split Washer
g - Hex Nut
h - Long Brush Lead
i - Push Lead into Slot
a b c d
11658
a - Locknut
b - Spacer
c - Spring
d - Drive Assembly
e - Drive End Cap
f - Armature Shaft
g - Washer
3. Lubricate helix threads on armature shaft with a
drop of SAE 10W oil.
4. Lubricate bushing in drive end plate with a drop
of SAE 10W oil.
2B-16 - ELECTRICAL 90-852396 MAY 1996

5. Position armature into starter frame. 8. Place springs and brushes into brush holder and
hold in place with brush retainer tool
6. To prevent damage to brushes and springs when
installing commutator end cap, it is recom- a
mended that a brush retaining tool be made as
shown:
11661
a - Brush Retainer Tool
b - Bushing (DO NOT over lubricate)
9. Install armature into starter frame and align
match marks (a). Install commutator end cap
onto starter frame and align match marks (b). Re-
move brush retainer tool. Install through bolts (c)
and torque to 70 lb. in. (8.0 N·m)
c c
b
18-Gauge Sheet Metal METRIC SCALE
3” = 76.2mm
2” = 50.8mm
1-3/4” = 44.5mm
1-11/16” = 42.9mm 11648
3/4” = 19.1mm
1/2” = 12.7mm a - Alignment Marks
b - Alignment Marks
c - Bolts [Torque to 70 lb. in. (8.0 N·m)]
7. Lubricate bushing (located in commutator end

cap) with one drop of SAE 10W oil. DO NOT over
lubricate.
90-852396 MAY 1996 ELECTRICAL - 2B-17

STARTER SOLENOID TEST
1. Disconnect all wires from solenoid.
2. Use an ohmmeter (R x1 scale) and connect me-
ter leads between solenoid terminals 1 and 2.
3. Connect a 12-volt power supply between sole-
noid terminals 3 and 4. Solenoid should click and
meter should read 0 ohms (full continuity).
4. If meter does not read 0 ohms (full continuity), re-
place solenoid.
b
1 3a
4
a
2 b
51809
a - 12-VOLT Supply
b - VOA Leads
2B-18 - ELECTRICAL 90-852396 MAY 1996

ELECTRICAL
2
C
28245
TIMING, SYNCHRONIZING
& ADJUSTING
Table of Contents
Page
Timing/Synchronizing/
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2
Timing Pointer Adjustment . . . . . . . . . . . . . 2C-2
Carburetor Synchronization . . . . . . . . . . . . 2C-2
Carburetor/Oil Pump
Synchronization . . . . . . . . . . . . . . . . . . . . . . 2C-3
Timing Adjustments . . . . . . . . . . . . . . . . . . . . 2C-4
Maximum Timing Adjustment . . . . . . . . . . 2C-4
Primary Pickup Timing Adjustment . . . . . . 2C-5
Idle Speed Adjustment . . . . . . . . . . . . . . . . 2C-5
2C-0 - ELECTRICAL 90-852396 MAY 1996

Timing/Synchronizing/ Timing Light 91-99379
Adjusting
Specifications
Sport Jet 175XR2
Full Throttle RPM Range 5000-5500
Idle RPM 1000 - 1100
Maximum Timing:
@ 5000 RPM 20° BTDC
Idle Speed/Pickup Timing 0° 2° ATDC
Spark Plug NGK-BU8H
Firing Order 1-2-3-4-5-6
Special Tools
Remote Starter Switch 91-52024A1
Dial Indicator 91-58222A1
90-852396 MAY 1996 ELECTRICAL - 2C-1

Adjustments 5. Remove dial indicator from cylinder.
TIMING POINTER ADJUSTMENT CARBURETOR SYNCHRONIZATION

1. Loosen 3 carburetor synchronization screws (a)
! WARNING to allow shutter plates to close completely.
Engine could start when turning flywheel to 2. Position throttle lever so that idle stop screw is
check timing pointer adjustment. Remove all against idle stop and move roller arm until roller
spark plugs from engine to prevent engine from lightly touches throttle cam (b). Adjust idle stop
starting. screw (c) on throttle arm to align mark (d) on
throttle cam with center of roller. Without moving
1. Remove all spark plugs and install Dial Indicator
roller from this position, retighten carburetor syn-
(91-58222A1 ) into No. 1 cylinder (top cylinder,
chronization screws.
starboard bank).
28244
55087
2. Turn flywheel in a clockwise direction until No. 1 b
piston is at top dead center (TDC). Set dial indica-
tor at “O” (zero) and tighten indicator set screw. c
3. Turn flywheel counterclockwise until dial indica-
tor needle is approximately 1/4-turn beyond .462
d
in., then turn flywheel clockwise so that dial indi-
cator reads .462 in. (11.7mm ) exactly.
4. Reposition timing pointer (a) “if necessary” so
that timing pointer is aligned with .462 in. mark on
timing decal. Retighten pointer attaching screws
a - Carburetor Synchronization Screws
(b). b - Throttle Cam
c - Idle Stop Screw
d - Alignment Mark
b b
3. Verify throttle shutter plates open and close si-
multaneously during throttle lever operation.
Readjust if necessary.
28245
a - Timing Pointer
b - Pointer Attaching Screws
2C-2 - ELECTRICAL 90-852396 MAY 1996

4. Move throttle lever to wide-open-throttle (W.O.T.) CARBURETOR/OIL PUMP SYNCHRONIZATION
position and adjust full throttle stop screw (a) to
1. When carburetor linkage is at idle position, align-
allow full throttle shutter opening at W.O.T. Verify
ment mark (a) on oil injection arm should be
that throttle shutters do not act as a throttle stop.
in-line with mark on casting (b) as shown. If nec-
Allow .010 in. - .015 in. (.25mm - .38mm) clear-
essary, adjust link rod (c).
ance between throttle shaft arm(b) and stop (c) at
W.O.T. Retighten jam nut on adjustment screw.
c
d
a
b
a b
a - Alignment Mark
55086 b - Casting Alignment Mark
c - Link Rod
a - Full Throttle Screw
b - Throttle Shaft Arm
c - Throttle Shaft Arm Stop
d - .010 - .015 in. (0.25 mm - 0.38 mm)
90-852396 MAY 1996 ELECTRICAL - 2C-3

Timing Adjustments MAXIMUM TIMING ADJUSTMENT
1. Connect timing light to No 1 spark plug lead (TOP
! CAUTION STARBOARD BANK)
Engine may be timed while cranking engine with start- 2. With engine in neutral, move throttle lever to
er motor. To prevent engine from starting when being place maximum spark advance screw (b) against
cranked, all spark plugs must be removed. stop. Crank engine with starter motor and adjust
1. Insert Spark Gap Tool (91-63998A1 ) into each maximum spark advance timing mark to obtain
spark plug boot and attach alligator clips to good 22 BTDC. Retighten jam nut on adjustment
engine ground screw.
2. Disconnect remote fuel line from engine.
3. Connect remote control electrical harness to en-
gine wiring harness.
4. Remove throttle cable barrel from barrel retainer.
IMPORTANT: If trigger link rod was disassembled b
verify that 11/16 in. (17.5mm) length is retained.
a
28247
b - Spark Advance Screw
28246
a - 11/16 in. (17.5 mm)
2C-4 - ELECTRICAL 90-852396 MAY 1996

PRIMARY PICKUP TIMING ADJUSTMENT IDLE SPEED ADJUSTMENT
1. With engine in neutral, hold throttle arm so that 1. With engine in water, connect fuel line to engine.
idle stop screw (a) is against idle stop. Crank en- Start engine and allow to warm up.
gine with starter motor and adjust throttle primary
2. Place engine in forward and monitor engine
pickup screw (b) to align specified throttle prima-
RPM. If RPM is above or below recommended
ry pickup mark on timing decal with timing point-
RPM (see specifications), readjust primary pick-
er. Retighten jam nut on adjustment screw.
up (b) screw to attain recommended engine
NOTE: Primary pickup timing also determines en- speed. Retighten jam nut. Re-install throttle
gine RPM, refer to “Idle Speed Adjustment” following. cable.
vances idle timing 5 until the engine reaches
104F (40C). Above 3,000 RPM, the TKS ECM
gine temperature.
b 3. With end of throttle cable connected to throttle le-
ver, hold throttle lever against idle stop. Adjust
throttle cable barrel to slip into barrel retainer on
cable anchor bracket with a very light preload of
a throttle lever against idle stop. Lock barrel in
place.
4. Check preload on throttle cable by placing a thin
piece of paper between idle stop screw and idle
stop. Preload is correct when paper can be re-
moved without tearing but has some drag on it.
55087 Readjust cable barrel, if necessary.
a - Idle Stop Screw
b - Primary Pick-Up Screw IMPORTANT: Excessive preload on throttle cable
NOTE: All timing adjustments made to engine under will cause difficulty when shifting from forward
cranking speed conditions should be verified with en- to neutral. (Readjust throttle cable barrel, if nec-
gine running and adjustments made if necessary. essary.)
This is due to advance characteristics of individual ig- NOTE: Carburetors are equipped with idle mixture
nition systems. adjustment screws. See carburetor specifications for
2. Remove timing light from No. 1 spark plug lead.
mixture screw adjustment.
3. Remove spark gap tools (91-63998A1) from

NOTE: If sufficient throttle cable barrel adjustment is
each spark plug boot. not available, check for correct installation of link rod
between the throttle lever and throttle cam. Each end
4. Install all spark plugs into cylinder heads. Torque of this link rod must be threaded into its plastic barrel
spark plugs to 20 Ib. ft. (27 N·m) and attach spark until it bottoms against the throttle lever or throttle
plug leads to spark plugs. cam casting, then turned out only far enough to ob-
tain correct orientation of link rod (less than one turn).
All timing adjustments must be reset after this proce-
dure.
90-852396 MAY 1996 ELECTRICAL - 2C-5

FUEL SYSTEM
3
A
52362
FUEL PUMP & FUEL PRIMER

Table of Contents
Page
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . . 3A-2
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4
General Information . . . . . . . . . . . . . . . . . . . . 3A-4
Fuel Pump Description/Operation . . . . . . . . . . 3A-4
Fuel Pump Specifications . . . . . . . . . . . . . . . . . 3A-4
Checking for Restricted Fuel Flow
Caused by Anti-Siphon Valves . . . . . . . . . . 3A-4
Testing Fuel Pump . . . . . . . . . . . . . . . . . . . . . 3A-5
Fuel Pump Removal/Disassembly . . . . . . . 3A-6
Cleaning/Inspection . . . . . . . . . . . . . . . . . . . . 3A-6
Reassembly/lnstallation . . . . . . . . . . . . . . . . 3A-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-7
Fuel Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8
3A-0 - FUEL SYSTEM 90-852396 MAY 1996

Notes:
90-852396 MAY 1996 FUEL SYSTEM - 3A-1

FUEL PUMP ASSEMBLY
12 19
11 1 4
3
5
5 6 2
3
4
20 7
8
15
17
22
13
16
14 18
9
23
10
28 29 18
28
30
21
27 31
24 39
38
26
32 37
25
40
33
24 36
34 35
24
3A-2 - FUEL SYSTEM 90-852396 MAY 1996

FUEL PUMP ASSEMBLY
TORQUE
REF.
1 1 PUMP ASSEMBLY-Fuel
2 1 DIAPHRAGM KIT
3 2 CHECK VALVE-Rubber
4 2 CHECK VALVE
5 2 RETAINER
6 1 GASKET-Boost
7 1 CAP-Spring End
8 1 SPRING
9 2 DIAPHRAGM
10 1 GASKET-Pulse
11 1 SPRING
12 1 CAP-Spring End
13 1 GASKET-Base
14 1 BASE-Fuel Pump
15 1 PLATE-Fuel Pump
16 1 ELBOW
17 2 SCREW (M5 x 40)-Fuel pump 36 4
19 1 FITTING (45)
20 1 FITTING
21 1 ELBOW
22 2 SCREW (M6 x 50)-Fuel Pump To Crankcase 70 8
23 1 TUBING (28.00 in. Bulk) (Cut 6.00 in.)
24 3 CLAMP
25 1 HOSE (11.00 in.)
26 2 NUT (#10-32) 35 3.9
27 1 PLATE-Pump Mount
28 6 BUSHING
29 3 GROMMET
30 3 WASHER
31 3 SCREW (#10-32 x 1.12) 35 3.9
32 1 ELBOW
33 1 PUMP ASSEMBLY-Electric
34 2 WASHER
35 2 SCREW (#10-32 x .625) 35 3.9
36 1 FILTER-Fuel
37 1 HARNESS ASSEMBLY-Fuel Pump
38 1 FUSE (3 AMP) (Violet)
39 1 COVER-Fuse Holder
90-852396 MAY 1996 FUEL SYSTEM - 3A-3

Fuel Pump CHECKING FOR RESTRICTED FUEL FLOW
CAUSED BY ANTI-SIPHON VALVES
While anti-siphon valves may be helpful from a safety
General Information stand-point, they clog with debris, they may be too
small, or they may have too heavy a spring. The pres-
FUEL PUMP DESCRIPTION/OPERATION sure drop across these valves can create operational
problems and/or powerhead damage by restricting
The fuel pump is a crankcase-pressure-operated, di- fuel flow to the fuel pump and carburetor(s). Some
aphragm-type pump. Crankcase pulsating pressure symptoms of restricted (lean) fuel flow which could
(created by the up-and-down movement of piston) is be caused by use of an anti-siphon valve are:
transferred to fuel pump by way of a passage (hole)
between crankcase and fuel pump. 1. Loss of fuel pump pressure
When piston is in an upward motion, a vacuum is 2. Loss of power

created in the crankcase, thus pulling in a fuel/air 3. High speed surging
mixture (from carburetor) into crankcase. This vacu-
um also pulls in on the fuel pump diaphragm, thus the 4. Pre-ignition/detonation (piston dome erosion)
inlet check valve (in fuel pump) is opened and fuel 5. Engine cuts out or hesitates upon acceleration
(from fuel tank) is drawn into fuel pump.
6. Engine runs rough
Downward motion of the piston forces the fuel/air
7. Engine quits and cannot be restarted
mixture out of the crankcase into the cylinder. This
motion also forces out on the fuel pump diaphragm, 8. Engine will not start
which closes the inlet check valve (to keep fuel from
9. Vapor lock
returning to fuel tank) and opens the outlet check
valve, thus forcing fuel to the carburetors. Since any type of anti-siphon device must be located
between the engine fuel inlet and fuel tank outlet, a
FUEL PUMP SPECIFICATIONS simple method of checking [if such a device (or bad
fuel) is a problem source] is to operate the engine
NOTE: Fuel pressure should be measured between with a separate fuel supply which is known to be
in-line fuel filter and carburetors. good, such as a remote fuel tank.
Fuel Pump Pressure at Wide Open Throttle: If it is found that the anti-siphon valve is the cause of
Maximum: 10 PSI the problem, replace it with a solenoid-operated fuel
Normal: 6 - 8 PSI shut off valve.
Fuel Pump Pressure at Idle:
Normal : 2 - 3 PSI
Minimum: 1 PSI
Electric Fuel Pump Pressure, if used, must be limited
to no more than 4 PSI.
3A-4 - FUEL SYSTEM 90-852396 MAY 1996

Testing Fuel Pump
Install clear fuel hose(s) between fuel pump and car-
buretor(s). Run engine and inspect fuel passing thru
hose(s) for air bubbles. If air bubbles are found, see
“Air Bubbles in Fuel Line” below. If air bubbles are
NOT found, see “Lack of Fuel Pump Pressure”
below.
Problem: Air Bubbles in Fuel Line

Low fuel in tank. Fill tank with fuel.
Loose fuel line connection. Check and tighten all connectors.
Fuel pump fitting loose. Tighten fitting.
A hole or cut in fuel line. Check condition of all fuel lines and replace
Fuel Pump anchor screw(s) loose. Tighten all screws evenly and securely.
Fuel pump gasket(s) worn out. Rebuild fuel pump.
Problem: Lack of Fuel Pump Pressure
An anti-siphon valve. See ‘‘Checking for Restricted Fuel Flow” preceding.
Air in fuel line. See ‘‘Air Bubbles in Fuel Line”, above.
A dirty or clogged fuel filter. Clean or replace fuel filter.
The fuel pickup in fuel tank is clogged or dirty. Clean or replace pickup.
Worn out fuel pump diaphragm. Rebuild fuel pump.
Worn out check valve(s) in fuel pump. Rebuild fuel pump.
A leaky check valve gasket. Rebuild fuel pump.
Pulse hole(s) plugged. Remove fuel pump and clean out holes.
Hole in pulse hose. Replace pulse hose.
Loose pulse hose. Tighten connection(s).
Excessive fuel hose length. Cut fuel hose to proper length.
Fuel hose internal diameter too small. Use 5/16 I.D. fuel hose.
90-852396 MAY 1996 FUEL SYSTEM - 3A-5

Fuel Pump Removal/Disassembly Cleaning/Inspection
IMPORTANT: Fuel pump diaphragm and gaskets 1. Clean fuel pump housing, check valves, pulse
should not be re-used once fuel pump is disas- chamber and pump base in solvent and dry all but
sembled. check valves with compressed air.
1. Disconnect fuel hoses from fuel pump. 2. Inspect each check valve for splits or chips.
2. Disconnect pulse hose. 3. Inspect boost springs for weakness or breakage.
3. Remove two mounting screws. 4. Inspect fuel pump housing, pulse chamber and
base for cracks or rough gasket surface and re-
4. Remove fuel pump from engine.
place if any are found.
5. Inspect fitting on fuel pump housing for loosening
or any signs of fuel or air leaks. Replace or tighten
fitting if a leak is found.
b
Reassembly/lnstallation
d ASSEMBLY
1. Insert retainer thru plastic disc and rubber check
valve.
c
b
a
a c
a - Fuel Inlet
b - Fuel hose from fuel pump to carburetors
c - Pulse hose 23601
d - Mounting screws a - Retainer
b - Plastic Disc
5. Disassemble fuel pump. c - Rubber Check Valve
2. Install check valves and retainers into fuel pump
Reverse View of Pump Body body.
52362
50161
3A-6 - FUEL SYSTEM 90-852396 MAY 1996

3. With retainer installed in pump body, break re- 5. Place boost spring into pump body and place cap
tainer rod from retainer by bending sideways. onto boost spring.
c
a
a
b
23601
a - Rod
b - Retainer Cap 50161
a - Boost Spring
4. Reinstall rod into retainer cap and, use a small b - Pump Body
hammer or hammer and punch to tap rod down c - Cap
into retainer until flush with top of retainer.
6. Assemble remainder of components as shown
and install retaining screws thru to align.
Reverse View of Pump Body
23601
a - Rod
b - Retainer Cap
52362
INSTALLATION
1. Install pump onto engine. Torque to 55 Ib. in. (6
N·m).
2. Install hoses onto proper fittings and secure with
sta-straps.
3. Run engine and check for leaks.
90-852396 MAY 1996 FUEL SYSTEM - 3A-7

Fuel Primer
The fuel primer is an electric fuel pump used to sup-
ply fuel to the engine driven fuel pump while the en-
gine is being cranked.
b
a - Fuel Primer
b - Fuel Filter
Electrical power is supplied to the fuel primer from the
starter solenoid positive terminal (starter side). A
three (3) amp fuse is used to protect the electrical cir-
cuit.
3A-8 - FUEL SYSTEM 90-852396 MAY 1996

FUEL SYSTEM
3
B
CARBURETORS
Table of Contents
Page
Fuel System - Troubleshooting . . . . . . . . . . . . . 3B-1
General Information . . . . . . . . . . . . . . . . . . . . 3B-1
Reed Valve Specifications . . . . . . . . . . . . 3B-2
Attenuator And Carb Throttle Levers . . . . . . . . 3B-3
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-4
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8
Carburetor Fuel Circuits . . . . . . . . . . . . . . . . . . . 3B-9
Carburetor Specifications . . . . . . . . . . . . . . 3B-12
Synchronizing Carburetors . . . . . . . . . . 3B-12
Idle Mixture Screw . . . . . . . . . . . . . . . . . 3B-12
Float Level Adjustment . . . . . . . . . . . . . 3B-12
Jet Location For Each Cylinder . . . . . . 3B-12
Carburetor Placement and
Jet Location for Each Cylinder . . . . . . . . . . 3B-13
Carburetor Jet Placement . . . . . . . . . . . . . . 3B-14
Jet Part Number Chart . . . . . . . . . . . . . . . . 3B-15
Removing Carburetor(s) from Engine . . . . . . 3B-16
Installing Carburetor(s) to Engine . . . . . . . 3B-17
3B-0 - FUEL SYSTEM 90-852396 MAY 1996

Fuel System - Troubleshooting
General Information 1. Impeller
Problems, that are thought to be caused by the fuel 2. Spark plugs

system, may be, in reality, something completely 3. Ignition timing
different. Items, that are shown in the list on the right,
could give the impression that there is a problem in 4. Ignition spark voltage
the fuel system. 5. Cylinder compression
6. Reed valves
Problem: Engine Turns Over But Will Not Start Or Starts Hard When Cold
Possible Cause Corrective Action
Improper starting procedure used. Check proper starting procedure, as outlined in “Op-
eration and Maintenance Manual.”
Fuel tank empty or too low. Improperly mixed fuel. Check fuel in fuel tank and replace or add whichever
Contaminants (water, dirt, etc.) in fuel is necessary.
Fuel tank air vent closed or restricted. Check air vent on fuel tank. Air vent must be open
all-the-way and free from any contaminants.
A pinched, cut or restricted fuel line. Also loose fuel Check all fuel lines and replace as needed. Check
line connection. and tighten all fuel line connections.
Dirty or restricted fuel filter. Check and replace or clean all fuel filters.
Low fuel pump pressure. Refer to Section 3A.
An anti-siphon valve. Refer to “Checking for Restricted Fuel Flow” in Sec-
tion 3A.
Choke solenoid, or enrichment valve not operating. Check choke solenoid or valve, and electrical wiring
to solenoid or valve. Replace if necessary.
A needle and seat (in carburetor) that is either stuck Refer to “Carburetor Disassembly” in this section.
open or closed. Open=Flooding - Closed=Starving
Improper carburetor jets, restricted jet or idle mixture Refer to “Carburetor Adjustments” in this section.
screw out of adjustment.
Improper carburetor float level. Refer to “Carburetor Adjustments” in this section.
Problem: Engine Idles Rough and Stalls.
Problem: Engine Hesitates Upon Acceleration.
Problem: Engine Runs Uneven or Surges.
Improperly mixed fuel. Contaminants (water, dirt, Check fuel in fuel tank and replace if necessary.
etc.) in fuel.
Fuel tank air vent closed or restricted. Check air vent on fuel tank. Air vent must be open
all-the-way and free from restrictions.
A pinched, cut or restricted fuel line. Also loose fuel Check all fuel lines and replace as needed. Check
line connection. and tighten all fuel line connections.
A dirty or restricted fuel filter. Check and replace or clean all fuel filters.
90-852396 MAY 1996 FUEL SYSTEM - 3B-1

Low fuel pump pressure. Refer to Section 3A.
An anti-siphon valve. Refer to Section 3A.
A needle and seat (in carburetor) that is either stuck Refer to ‘‘Carburetor Adjustments” in this section.
open or closed. Open=Flooding - Closed=Starving
Improper carburetor jets, restricted jet or idle mixture Refer to ‘‘Carburetor Adjustments” in this section.
screw out of adjustment.
Improper carburetor float level. Refer to ‘‘Carburetor Adjustments” in this section.
Carburetor loose on reed block housing. Tighten carburetor nuts securely.
Reed block housing loose, or gaskets are defective. Using a pressure oil can, spray 2-cycle oil around
reed block housing/crankcase housing matching
surfaces and carburetor base. If engine RPM
changes, tighten or replace reed block housing gas-
kets or carburetor base gaskets, as needed.
Improperly routed or restricted bleed hose(s). Refer to bleed line routing in this section.
REED VALVE SPECIFICATIONS
REED VALVE OPENING

1 - Max. 0.020 in. (0.59 mm)
51851
3B-2 - FUEL SYSTEM 90-852396 MAY 1996

ATTENUATOR AND CARB THROTTLE LEVERS
2
11
1312
1
7
9
12 11
13
14
6
10
5
11
12
13
8
4 3
TORQUE
REF.
REF
1 1 ATTENUATOR-Sound
2 3 GASKET-Attenuator to Carb
3 6 SCREW (.250-28 x 2.500)
4 6 WASHER
5 3 CAP
6 1 LEVER KIT-Throttle
7 1 LEVER-Throttle
8 1 LEVER-Throttle
9 1 LINK-Throttle
10 1 ROLLER
11 3 SCREW (#10-32 x .750)
12 3 WASHER
13 3 LOCKWASHER (#10 External)
14 1 DECAL-Caution
90-852396 MAY 1996 FUEL SYSTEM - 3B-3

FUEL LINES
13 7
3 2
15
5
4 6
4
A
C
16 9 B
10
13 8
17
11
D 12
18
17 13
14
13
13
A = TO TOP CARB
B = TO MIDDLE CARB
C = TO BOTTOM CARB
14
D = TO FUEL PRIMER PUMP
13
3B-4 - FUEL SYSTEM 90-852396 MAY 1996

FUEL LINES
TORQUE
REF.
REF
1 1 BRACKET-Cold Start Solenoid
2 1 SOLENOID-Cold Start
4 2 CLAMP
5 1 HOSE (2.750 in.)
7 3 HOSE (26.00 in. Bulk) (Cut 8.750 in.)
8 6 NUT (.250-28)
9 6 STUD (.250 x 1.125)
10 3 GASKET-Carburetor Mount
12 6 SCREW (.250-20 x .875)
13 6 CLAMP
16 1 HOSE (9.00 in.)
90-852396 MAY 1996 FUEL SYSTEM - 3B-5

CARBURETOR
4
11
5
2
3
13
12
6
7
9 10 14
8
17 16 15
18
19
22
23
24
25
20
26
21
3B-6 - FUEL SYSTEM 90-852396 MAY 1996

CARBURETOR
TORQUE
REF.
REF
1 CARBURETOR (TOP) (WMV-9-1)
1 1 CARBURETOR (CENTER) (WMV-9-2)
1 CARBURETOR (BOTTOM) (WMV-9-3)
2 6 COVER-Idle Circuit
3 6 GASKET-Idle Circuit Cover
4 12 SCREW-Idle Circuit Cover
5 3 GASKET-Carburetor Mount
2 JET-Idle Air Vent (.050) (TOP & CENTER) (PORT)
6
1 JET-Idle Air Vent (.054) (BOTTOM) (PORT)
7 3 JET-Bowl Vent (.080)
8 3 JET-Idle Air Vent (.050) (STARBOARD)
9 3 CAP-Limiter
10 6 SCREW & SPRING-Idle Mixture
11 3 LEVER KIT
12 3 SPACER
13 3 SPRING-Throttle Return
14 3 GASKET-Fuel Bowl
15 3 FLOAT ASSEMBLY
16 3 SHAFT-Float
17 3 SCREW-Float Pin
18 3 VALVE SEAT KIT
19 3 GASKET-Valve Seat
1 BOWL-Fuel (TOP)
20
2 BOWL-Fuel (CENTER & BOTTOM)
21 18 SCREW-Fuel Bowl
22 6 PLUG KIT-Drain
23 6 GASKET-Drain Plug
24 6 JET-Main Fuel (.076) (PORT & STBD)
25 2 FITTING-Tee (TOP & CENTER)
26 1 ELBOW (BOTTOM)
90-852396 MAY 1996 FUEL SYSTEM - 3B-7

Carburetor
1 3
3
2
8
5
5
54350
1 - Enrichener Hose Fitting

2 - Carburetor Number
3 - Fuel Mixture Adjustment Screw
4 - Back Draft Vent Jet
5 - Idle Air Bleed Jet
6 - High Speed Fuel Jet Access Plug (2)
7 - Fuel Line Fitting
8 - Main Nozzle Well Vent (2)
3B-8 - FUEL SYSTEM 90-852396 MAY 1996

Carburetor Fuel Circuits Idle Circuit
a b
Float Bowl Circuit c
n d
e
m l
k
a f
b c Key
Air
Fuel
Key
Air g
Fuel j h
i j i
g d
a – Idle Passage
h b – Idle Mixture Screw
f e c – Back Draft Jet
d – Idle Air Jet
a – To Engine Crankcase e – Thermal Air Valve (open)
b – Throttle Plate f – Air Flow
c – Carburetor Venturi g – Float Bowl
d – Float h – Idle Tube
e – Float Bowl i – Main Fuel Jet
f – Main Fuel Well j – Main Fuel Well
g – Main Jet k – Secondary Idle Air Bleed
h – Fuel from Fuel Pump l – Throttle Plate
i – Inlet Seat m– Off-Idle Ports
j – Inlet Needle n – Off-Idle Passage
Fuel from the fuel pump enters the carburetor As the engine rotates, the piston moves away from
through the fuel inlet fitting and fills the bowl until the the crankcase. This movement creates a low pres-
float moves the inlet needle against the fuel inlet seat. sure area behind the throttle plate. Atmospheric
With the inlet needle against the inlet seat, the fuel in- pressure pushes air through the carburetor throat
side the float bowl is at it’s maximum level. Fuel inside (venturi), past the throttle plate (small hole in plate)
the bowl flows through the main fuel jet and fills the and into the low pressure area inside the crankcase.
main fuel well. Atmospheric pressure enters the float bowl chamber
through the back draft jet. This pressure forces fuel
toward the low pressure area behind the throttle
plate. Fuel flows:
a. Through the main fuel jet into the main fuel
well,
(1.) Up the idle tube,
(2.) Through the off-idle passages,
(3.) Past the idle mixture screw,
(4.) Into the idle passage
(5.) And into the carburetor throat.
90-852396 MAY 1996 FUEL SYSTEM - 3B-9

Air enters the idle circuit through the idle air jet and Off-Idle Circuit
secondary idle air bleed. This air mixes with the fuel
inside the idle passage before the sir/fuel mixture is d
discharged into the engine. Rotating the idle mixture
screw will change the air/fuel mixture at idle speeds.
a c
b
Cold Start Circuit
f e
a
Key
Air
b Fuel
Key
Air a – Off-Idle Ports
Fuel b – Off-Idle Passage
c – Idle Air Jet
d – From Open Thermal Air Valve
e – Air Flow
f – Throttle Plate
As the throttle plates rotate past the off-idle ports, the
ports are exposed to the low pressure area behind
a – Thermal Air Valve (closed)
b – Air Flow the throttle plate. Additional fuel flows through the off-
idle passage; through the rear port; and as the
A cold engine will require a richer mixture. Fuel is throttle plate continues to rotate, through the forward
supplied to the carburetors by the solenoid operated port.
enrichner valve.
3B-10 - FUEL SYSTEM 90-852396 MAY 1996

Main Circuit Back Draft Circuit
a
a b
b
c
f c
h d d
i
g
Key Key
Air Air
Fuel e Fuel
g
e
f NOTE: Fuel Flow Not Shown For Clarity
a – From Open Thermal Air Valve a – Back Draft Port
b – Air Flow b – Back Draft Jet
c – Venturi c – Air Flow
d – Main Discharge Air Inlet Tube d – Main Discharge Tube
e – Cross Holes e – Fuel Bowl
f – Main Fuel Well f – Fuel Bowl Vent Passage
g – Main Fuel Jet g – Throttle Plate
h – Main Discharge Nozzle At partial throttle settings, the back draft circuit leans
i – Throttle Plate
out the mixture for increased fuel economy. The back
As the throttle plate rotates past the off-idle ports, the draft circuit uses the float bowl vent circuit and bowl
low pressure area extends to the main discharge vent jet to lean out the air/fuel mixture. The bowl vent
nozzle. In addition, the increased air flow through the jet limits the amount of air entering the float bowl vent
carburetor bore creates a low pressure area inside circuit. With the throttle plate positioned correctly, the
the venturi. These combined forces create a strong low pressure area is exposed to the back draft port
suction over the main discharge tube. Fuel flows: inside the carburetor bore. The float bowl vent circuit
is connected by passages to the back draft port. The
1.Through the main fuel jet into the
low pressure area pulls air out of the bowl vent circuit.
main fuel well,
Due to the size of the vent jet and the air loss through
2.Up the main discharge nozzle, the back draft port, the air pressure on the fuel inside
the fuel bowl is lowered to below atmospheric pres-
3.Into the venturi.
sure. Lower pressure on the fuel inside the float bowl,
Air is mixed with the fuel to make it lighter, air enters lowers the amount of fuel being forced out of the main
the main fuel well through the main discharge air inlet discharge tube.
tube. Cross holes are drilled in the main discharge
tube, allowing the air to mix with the fuel inside the
main well. As the throttle plate continues to open,
additional fuel is drawn out of the main discharge
tube, exposing additional cross holes. At full throttle,
the fuel mixture is controlled by the size of the main
fuel jet.
90-852396 MAY 1996 FUEL SYSTEM - 3B-11

Carburetor Specifications JET LOCATION FOR EACH CYLINDER
Carburetor jets and adjustment screw installed in the
SYNCHRONIZING CARBURETORS starboard side of the carburetor supply fuel to the port
To synchronize carburetors, refer to “Timing/Syn- cylinder, jets and adjustment screw installed in the
chronizing/Adjusting” section. port side supply fuel to the starboard cylinder.
NOTE: The idle jet and back draft jet affect both cylin-
IDLE MIXTURE SCREW ders.
For best running quality, the adjustable idle mixture
screws are set at the factory with the limit tabs point-
ing straight up. If adjustment is required, all idle mix-
ture screws must be turned the same amount and the
same direction. Turning the idle mixture screws (rec-
ommended 1/8 turn at a time) clockwise will lean the
idle mixture. Turning the idle mixture screws counter-
clockwise will richen the idle mixture.
FLOAT LEVEL ADJUSTMENT

There is one float and one float bowl for 2 cylinders.
To set float height, invert float bowl and adjust float
tang until top of float is even with top of float bowl.
3B-12 - FUEL SYSTEM 90-852396 MAY 1996

Carburetor Placement and Jet Location for Each Cylinder
WMV
9-1
TOP
Cylinder Cylinder
#2 #1
WMV
MIDDLE 9-2
Cylinder Cylinder
#4 #3
WMV
BOTTOM 9-3
Cylinder Cylinder
#6 #5
54349
A – Backdraft Jet Affects Both Cylinders

NOTE: Carburetor jets and adjustment screw installed in the starboard side of the carburetor supply fuel to the
port cylinder, jets and adjustment screw installed in the port side supply fuel to the starboard cylinder.
90-852396 MAY 1996 FUEL SYSTEM - 3B-13

Carburetor Jet Placement
Note: Jets listed are for engine operation from 0-5000 feet (0-1524m) of elevation.
Carburetor Main Idle Air Back Draft
Identification Jet Bleed Jet Vent Jet
Number a b c
PORT Bore .076 .050
WMV 9-1 .080
STBD Bore .076 .050
PORT Bore .076 .050
WMV 9-2 .080
STBD Bore .076 .050
PORT Bore .076 .054
WMV 9-3 .080
STBD Bore .076 .050
b c b
PORT CYL. BORE STBD. CYL. BORE

CYLINDERS 2,4,6 CYLINDERS 1,3,5
STBD. SIDE of PORT SIDE of
ENGINE ENGINE
a a
3B-14 - FUEL SYSTEM 90-852396 MAY 1996

Jet Part Number Chart
JET ORIFICE SIZE/PART NUMBER CHART 10-32

Jet Jet Jet Jet
Orifice Orifice Orifice Orifice
Size Part Number Size Part Number Size Part Number Size Part Number
(inch) (inch) (inch) (inch)
.040 19266040 .058 1395-7831 .076 1399-3796 .094 1395-8423

.042 1399-5315 .060 1395-6487 .078 1395-6680 .096 1399-6249
.044 1395-7394 .062 1399-4217 .080 1395-6201 .098 1395-7355
.046 1399-5317 .064 1399-4216 .082 1399-3518
.048 1395-6246 .066 1399-4215 .084 1399-3517
.050 1395-6028 .068 1395-6029 .086 1395-5815
.052 1395-6359 .070 1395-6030 .088 1395-6202
.054 1399-5225 .072 1395-6207 .090 1395-6247
.056 1399-5213 .074 1399-3794 .092 1395-5733
JET ORIFICE SIZE/PART NUMBER CHART 8-32

Jet Jet Jet Jet
Orifice Orifice Orifice Orifice
Size Part Number Size Part Number Size Part Number Size Part Number
(inch) (inch) (inch) (inch)
.030 810741 .038 815633038 .046 815633046 .054 815633054
.032 1399-3252 .040 1399-7570 .048 815633048 .070 815633070
.034 1395-3251 .042 815633042 .050 815633050 .076 815633076
.036 1399-3026 .044 810742 .052 815633052
NOTE: Thread size for V-6 model carburetor main, idle air and back draft jets are 10-32
NOTE: Thread size for V-6 model carburetor progression jets are 8-32
90-852396 MAY 1996 FUEL SYSTEM - 3B-15

Removing Carburetor(s) 5. Remove fuel hose and fuel enrichment valve
hose from carburetors.
from Engine
a
1. Remove top cowling.
IMPORTANT: Place an identifying mark on each
carburetor before removal as each carburetor
must be reinstalled in same location from which
removed. b
NOTE: As each carburetor is removed from intake
manifold, their respective fuel enrichment hose
should be disconnected.
2. Remove air box cover and heat shield from en- b
gine.
3. Remove throttle linkage from throttle levers as
shown.
4. Remove oil pump link rod from throttle lever.
55003
a - Fuel Hose
a b - Enrichment Valve Hoses
6. Carburetors may now be removed individually.
Mark location of each carburetor and reinstall in
same location. Remove carburetor(s) secured by
two nuts and two allen head type bolts.
b Throttle Shaft Screws

NOTE: It is recommended that the screws securing
the throttle plates to the throttle shaft NOT BE RE-
MOVED due to the difficulty in obtaining correct
alignment of throttle plates during reassembly. If
screws must be removed, apply Loctite 271 to screw
threads before reinstalling screws.
51706
a - Throttle Linkage
b - Oil Pump Link Rod
c
a
b
51860
a - Throttle Shaft
b - Throttle Shutter Plate
c - Screws
3B-16 - FUEL SYSTEM 90-852396 MAY 1996

Float Adjustment Installing Carburetor(s) to Engine
NOTE: Float height adjustment is the only adjust- 1. Place new carburetor gaskets onto carburetor
ment made to adjust float setting. mounting studs on intake manifold.
1. Adjust float height by turning fuel bowl upside- 2. Install carburetors (in respective locations) onto
down, then adjust float tab until float is level with mounting studs and secure in place with nuts and
edge of fuel bowl. Adjust float tab if necessary. allen type bolts.
3. Connect enrichment hoses and fuel hoses. Se-
a cure hoses in place using sta-straps.
c 55003
a - Fuel Hose
b - Enrichment Valve Hose
51713
a - Float (Adjust by bending tab)
b - Fuel Bowl (Upside-Down)
c - Float Level Even with Bowl Edge
d - Float Tab
90-852396 MAY 1996 FUEL SYSTEM - 3B-17

4. Attach throttle linkage and oil pump link rod to
carburetors as shown.
51706
a - Throttle Linkage
b - Oil Pump Link Rod
5. Re-synchronize carburetors following carburetor
installation. Refer to “Timing/Synchronizing/Ad-
justing” Section 2C.
IMPORTANT: Inspect all fuel hose connections,
and carburetor float bowl split lines for fuel leaks
with engine running. Also inspect each carbure-
tor throat, with outboard running at low RPM, for
fuel dribbling out of vent tube which would be in-
dicative of a float and/or needle and seat assem-
bly not functioning properly.
IMPORTANT: Engine should not be operated
above 3000 RPM with air box cover removed as
engine will run too lean and internal damage
could result.
3B-18 - FUEL SYSTEM 90-852396 MAY 1996

FUEL SYSTEM
3
C
51893
OIL INJECTION
Table of Contents
Page Page
Operation of the Oil Injection System . . . . . . . 3C-1 Adjusting Oil Injection Pump . . . . . . . . . . . . 3C-9
Final Checks Before Operation Operation Of The
Of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 Oil Injection System . . . . . . . . . . . . . . . . . 3C-9
Checking Operation Of The Oil Check Operation Of The
Injection System (Engine Running) . . . . 3C-1 Oil Injection System
Oil Injection Components . . . . . . . . . . . . . . . . . . 3C-2 (Engine Running) . . . . . . . . . . . . . . . . . . . 3C-9
Oil Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . 3C-9
Oil Injection Components . . . . . . . . . . . . . . . . . . 3C-4
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . 3C-9
Remote Oil Tank . . . . . . . . . . . . . . . . . . . . 3C-4
Oil Pick Up Tube . . . . . . . . . . . . . . . . . . . . 3C-4 Worm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-10
Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . 3C-4 Worm Bushing Removal . . . . . . . . . . . . . . . 3C-10
Oil Injection Pump . . . . . . . . . . . . . . . . . . . 3C-4 Worm Bushing Installation . . . . . . . . . . . . . 3C-10
2 PSI Check Valve . . . . . . . . . . . . . . . . . . 3C-4
Oil Injection Pump Installation . . . . . . . . . . 3C-10
2 PSI Check Valve . . . . . . . . . . . . . . . . . . 3C-4
Installing Drive Gear
Low Oil (Float) Sensor . . . . . . . . . . . . . . . 3C-4
(for Oil Injection Pump)
Motion Sensor . . . . . . . . . . . . . . . . . . . . . . 3C-4 Onto Crankshaft . . . . . . . . . . . . . . . . . . . . . . 3C-11
TKS ECM . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-4
Removal Of Drive Gear . . . . . . . . . . . . . 3C-11
Oil Injection Flow System . . . . . . . . . . . . . . . . . . 3C-5
Installation Of New Drive Gear . . . . . . . 3C-11
Pump Drive Assembly . . . . . . . . . . . . . . . . . . . . 3C-6 Motion Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-11
Pump Drive System . . . . . . . . . . . . . . . . . . . . . . 3C-6 Oil Injection System
Set Up Instructions Trouble Shooting Chart . . . . . . . . . . . . . . . . 3C-12
for Oil Injection System . . . . . . . . . . . . . . . . . 3C-7 Trouble Shooting
Installing Remote Oil Tank . . . . . . . . . . . 3C-7 The Oil Injection System . . . . . . . . . . . . 3C-12
Installing Oil Hoses To Engine . . . . . . . . 3C-7 Oil Pump Volume (Flow) Test . . . . . . . . . . . . . 3C-14
Filling The Oil Injection System . . . . . . . 3C-8 Engine Mounted Oil Reservoir . . . . . . . . . . 3C-14
Bleeding Air from Oil Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-14
and Oil Injection Outlet Hose . . . . . . . . . . . . 3C-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . 3C-14
3C-0 - FUEL SYSTEM 90-852396 MAY 1996

FINAL CHECKS BEFORE OPERATION OF
CAUTION ENGINE
Be careful not to get dirt or other contamination • Make sure fill cap gaskets are in place and caps
in tanks, hoses or other components of the oil in- are tight on engine oil reservoir and remote oil
jection system during installation. tank.
CAUTION • Mix a gasoline and oil mixture of 50:1 in the re-
mote fuel tank during the initial break-in of the en-
Engines with oil injection must be run on a fuel gine.
mixture of 50:1 for the first 30 gallons of fuel. Re-
fer to engine break-in procedure in the Operation • Be certain the warning horn is installed and is op-
and Maintenance Manual. erational. Refer to Instrument and Warning Horn
Installation.
CAUTION • Each time the key switch is turned from the “off”
If an electric fuel pump is to be used on engines to “on” position (engine not running); the warning
with oil injection, the fuel pressure at the engine horn will sound momentarily. This tells you the
must not exceed 6 psig. If necessary, install a warning system for the oil injection system is
pressure regulator between electrical fuel pump functional and the warning horn is operational. If
and engine and set at 6 psig maximum. warning horn does not sound or horn stays on
when key is turned to the “ON” position, refer to
oil injection system troubleshooting chart follow-
ing to correct the problem.
Operation of the Oil Injection CHECKING OPERATION OF THE OIL

INJECTION SYSTEM (ENGINE RUNNING)
System 1. Operate engine following the break-in procedure
The oil injection system delivers oil mixture on engine outlined in the Operation and Maintenance Man-
demand, from 100 to 1 at idle to 50 to 1 at wide open ual. If warning horn should sound an intermittent
throttle. “beep,” “beep,” “beep” during operation, this indi-
The remote oil tank can be removed from the boat for cates a problem occurred in the oil injection sys-
easy refilling. The remote tank holds enough oil for tem. Refer to troubleshooting following, to correct
over 150 gallons of fuel at wide open throttle. the problem.
The remote oil tank supplies the oil reservoir 2. After engine has been run for a short time, check
mounted on the engine. The oil reservoir feeds the oil that no oil is leaking out of engine oil reservoir fill
pump and contains enough oil for at least 30 minutes cap.
of full throttle running after the remote tank is empty.
The warning horn will sound if the oil level in oil reser-
voir is low.
The oil injection pump feeds oil into the fuel just be-
fore 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.
The motion sensor will sound the warning horn if the
drive system for the injection pump becomes inop-
erative.
90-852396 MAY 1996 FUEL SYSTEM - 3C-1

OIL INJECTION COMPONENTS
3C-2 - FUEL SYSTEM 90-852396 MAY 1996

OIL INJECTION COMPONENTS
TORQUE
REF.
REF
1 1 TANK-Oil
2 1 BRACKET KIT-Oil Tank Hold Down
3 1 CORD/HOOK KIT
4 3 BRACKET-Hold Down
5 6 SCREW (#12-11 x .750)
6 1 CAP ASSEMBLY-Oil Tank
7 1 O RING-Cap
8 1 HOUSING ASSEMBLY-Adaptor
9 1 CAP ASSEMBLY-Housing Adaptor
10 1 O RING
11 1 TUBE-Oil Pick Up
12 1 HOSE-Oil Line
14 1 SENSOR ASSEMBLY
15 1 BEARING ASSEMBLY-Drive Gear
16 1 SCREW (#10-16 x .600)-Sensor Attaching
17 1 CHECK VALVE (CRANKCASE)
18 1 PLUG
19 1 LINK-Throttle Lever To Oil Pump
20 1 SCREW (#10-32 x .625)
20 1 SCREW (#10-32 x 1.125)
21 1 PUMP ASSEMBLY-Oil
22 1 BUSHING-Worm
23 1 O RING
24 1 GEAR-Driven
25 1 CAP ASSEMBLY-Oil Reservoir
26 1 FLOAT ASSEMBLY
27 1 PUSHNUT
28 1 GASKET-Reservoir Cap
29 1 RESERVOIR-Oil
30 1 DECAL-Reservoir Warning
33 3 SCREW (#10-32 x .875)
34 6 WASHER-Oil Reservoir Screw
35 3 GROMMET-Oil Reservoir Screw
36 3 BUSHING-Oil Reservoir Screw
37 1 PLUG
38 1 FITTING-Oil Tubing
90-852396 MAY 1996 FUEL SYSTEM - 3C-3

Oil Injection Components 2 PSI CHECK VALVE
This valve prevents gasoline from being forced
1 REMOTE OIL TANK into the oil lines.
Holds 3 gallons of oil.
LOW OIL (FLOAT) SENSOR
The tank is pressurized by air from crankcase
pressure thus forcing oil up the outlet hose to the If oil level drops in oil reservoir, the sensor will sig-
oil reservoir on engine. nal the warning module to sound the warning
horn.
OIL PICK UP TUBE
MOTION SENSOR
A filter screen is located in end of tube to prevent
dirt or other particles from entering the system. Senses the rotation of the oil injection pump drive
system. If the drive system for the injection pump
OIL RESERVOIR becomes inoperative, the sensor will signal the
warning module to sound the warning horn.
The oil reservoir feeds the oil pump and contains
enough oil for at least 30 minutes of full throttle TKS ECM
running after the remote tank is empty. The warn-
ing horn will sound if the oil level in oil reservoir • Sounds the warning horn briefly when key switch
is low. is turned on, to indicate that the system is opera-
tional.
OIL INJECTION PUMP • While engine is running, the module continuously
monitors the rotation of the drive system for the
Injection pump is driven off the crankshaft.
oil injection pump by picking up pulses from the
The oil injection pump is a variable metering motion sensor. If drive system becomes inopera-
pump. At idle the pump will meter the oil at ap- tive, the module will sound the warning horn.
proximately 100 to 1 gasoline to oil ratio and at
• If oil level drops in the engine oil reservoir, the low
WOT, 50 to 1 ratio.
oil (float) sensor will signal the module to sound
the warning horn.
2 PSI CHECK VALVE
If oil flow to reservoir is obstructed and injection
pump continues to pump oil, the 2 PSI valve will
open to allow air to enter reservoir to prevent a
vacuum.
3C-4 - FUEL SYSTEM 90-852396 MAY 1996

Oil Injection Flow System
Magnetic
Float
Oil
2 PSI Reservoir
Check To Powerhead
Valve Motion Heat Sensor
Sensor
To 12 Volt
Supply
To Switch Box
Oil
Oil
Inlet Oil Injection Pump Turn Key Start
Electronic Control Module
Oil Line
“Blue Stripe” Fuel - Oil Mixture
Fuel Pump
Fuel Inlet
Air Pressure
Crankcase Outlet
Fuel Pump
Crankcase Pressure
With One Way
Check Valve
Filler Cap
Oil Tank
90-852396 MAY 1996 FUEL SYSTEM - 3C-5

Pump Drive Assembly
b
g a
c
d
e
b
a - Oil Pump
b - Retaining Bolts (2)
c - O-ring
d - Magnet
e - Coupler
f - Driven Gear
g - Oil Pump (Installed)
Pump Drive System

Retaining
Retaining Nut Screw
Magnet
Motion
Sensor
Coupler Bushing
Driven Gear
Drive Gear
Bushing
3C-6 - FUEL SYSTEM 90-852396 MAY 1996

Set Up Instructions for Oil Injection NOTE: An oil hose extension kit (41729A3) is avail-
able for the remote oil tank.
System
CAUTION
Be careful not to get dirt or other contamination
in tanks, hoses or other components of the oil in-
jection system during installation.
CAUTION
Oil injected engines additionally, must be run on
22750
a 50:1 gasoline/oil mixture in the fuel tank for the
first 30 gallons of fuel. Refer to engine break-in
procedures in the Operation & Maintenance Man- Quick Disconnect Type Hose Connection
ual.
INSTALLING OIL HOSES TO ENGINE
CAUTION Route remote oil tank hoses to starboard side of en-
If an electric fuel pump is to be used on engines gine.
with oil injection, the fuel pressure at the engine 4. Remove (and discard) the shipping cap from
must not exceed 6 psig. If necessary, install a hose fitting (a).
pressure regulator between electrical fuel pump
and engine and set at 6 psig maximum. 5. Connect oil hose from remote oil tank (hose with
blue stripe) to fitting (a). Secure with sta-strap.
INSTALLING REMOTE OIL TANK NOTE: Fitting barb (b) is a vent and does not get con-
nected to a hose.
1. The remote oil tank should be installed in an area
in the boat where there is access for refilling. 6. Remove (and discard) shipping cap from pulse
fitting (c).
The tank should be restrained to keep it from moving
around, causing possible damage. 7. Connect the second oil hose from remote oil tank
to pulse fitting. Secure with sta-strap.
An acceptable means of restraining the tank would
be the use of eye bolts and an elastic retaining strap
about the mid-section of the tank taking care that any a
metal hooks do not puncture the tank. b
Keep in mind, when installing in tight areas, that this
tank will be under pressure when the engine is oper-
ating and will expand slightly.
2. Oil hoses when routed thru engine well, must be
able to extend to the hose fittings on engine.
3. Oil hoses must be arranged so they cannot be-
come pinched, kinked, sharply bent or stretched c
during operation of the engine.
28237
a - Hose Fitting
b - Vent
c - Pulse Fitting
90-852396 MAY 1996 FUEL SYSTEM - 3C-7

FILLING THE OIL INJECTION SYSTEM Bleeding Air from Oil Injection Pump
Quicksilver 2-Cycle Outboard Oil is recommended and Oil Injection Outlet Hose
for this oil injection system. In emergency, when
Quicksilver oil is not available, substitute a high quali- BLEEDING AIR FROM OIL INJECTION PUMP
ty 2cycle oil that is intended for outboard use and With engine not running, place a shop towel below
meets BIA rating TC-W3, shown on oil container. BIA the oil injection pump. Loosen bleed screw (a) three
rating TC-W3 is the Boating Industry Association’s to four turns and allow oil to flow from bleed hole. Re-
designation for approved, 2-cycle water-cooled out- tighten bleed screw. This procedure allows the pump
board oils. to fill with oil.
1. Fill remote oil tank with Quicksilver TCW-3 BLEEDING AIR FROM OIL INJECTION PUMP
2-Cycle Oil. Tighten fill cap (a). OUTLET HOSE
Any air bubbles in outlet hose in most cases will be
purged out of the system during operation of the en-
a gine.
NOTE: If air bubbles persist, they can be purged out
of the hose by removing link rod and rotating the
pump arm full clockwise while operating engine at
1000 to 1500 RPM: If necessary, gently pinch the fuel
line between the fuel tank and the fuel pump “Tee” fit-
ting. This will cause the fuel pump to provide a partial
28243 vacuum which will aid in removal of the air. Reinstall
a - Fill Cap
link rod.
2. Remove fill cap (b) from the engine oil tank (c) a
and fill the tank with oil. Reinstall the fill cap.
b
c
b
d
50047
a - Bleed Screw
b - Outlet Hose
c - Link Rod
50047 d - Pump Arm
b - Fill Cap
c - Engine Mounted Oil Reservoir
3. Loosen the fill cap (b) on the engine mounted oil
tank. Run the engine until the all the air has been
vented out of the tank and oil starts to flow out of
the tank. Re-tighten fill cap.
CAUTION
Be certain that the fill caps on the engine oil tank
and remote oil tank are installed tight. An air leak,
at one of the caps on the remote oil tank, will pre-
vent oil flow to the engine oil tank. A loose fill cap
on the engine oil tank will cause oil leakage.
3C-8 - FUEL SYSTEM 90-852396 MAY 1996

Adjusting Oil Injection Pump Oil Injection Pump
When throttle linkage is at idle position, alignment
mark on oil injection arm should be in-line with mark
on casting as shown. If necessary, adjust link rod. Oil Pump Removal
1. Disconnect and plug inlet hose to oil pump.
2. Disconnect outlet hose on oil pump.
3. Disconnect link arm from oil pump injection arm.
a
4. Remove two bolts securing oil pump to power-
head and remove pump.
b c
50060
a - Link Rod
b - Alignment Mark
c - Casting Mark
ff
OPERATION OF THE OIL INJECTION SYSTEM
b e
1. Make sure fill cap gaskets or O-rings are in place ee
and caps are tight on engine reservoir tank and
remote oil tank.
2. Make sure a remote gasoline and oil mixture of
50:1 is used during the initial break-in of the en-
gine or after extended storage.
d a
3. Be certain the warning horn is operational.
Each time the key switch is turned from the “off” to
“on” position (engine not running); the warning horn c
will sound momentarily. This tells you the warning
51892
system for the oil injection system is functional and a - Inlet Hose
the warning horn is operational. If warning horn does b - Outlet Hose
not sound or horn stays on when key is turned to the c - Link Arm
“ON” position, refer to oil in injection system trouble- d - Injection Arm
shooting chart following to correct the problem. e - Bolts
f - Oil Pump
The oil injection warning sound is an intermittent
“beep”, “beep”, “beep”, etc. The overheat warning
sound is a continuous “beep” (not intermittent).
CHECK OPERATION OF THE OIL INJECTION

SYSTEM (ENGINE RUNNING)
1. Operate engine following the break-in procedure
outlined in the Operation and Maintenance Man-
ual. If warning horn should sound an intermittent
“beep”, “beep”, “beep” during operation, this indi-
cates a problem occurred in the oil injection sys-
tem. Refer to troubleshooting following, to correct
the problem.
2. After engine has been run for a short time check
that no oil is leaking out of engine mounted oil res-
ervoir fill cap.
90-852396 MAY 1996 FUEL SYSTEM - 3C-9

Worm Bushing 1. Inspect bushing O-rings for cuts and abrasions.
Replace O-rings if necessary.
Worm Bushing Removal

1. Grasp bushing and remove from oil pump.
NOTE: If seal is defective, seal and bushing are re- a b
placed as an assembly.
51782
a a - O-rings
2. Reinstall bushing/seal assembly.
Oil Injection Pump Installation

1. Align oil pump worm shaft with coupler in power-
head.
51782
a - Bushing
b - Seal
Worm Bushing Installation a

IMPORTANT: If worm shaft is removed from oil
pump with worm bushing, verify thrust washer is
positioned in center of worm shaft pocket before
reinstalling worm shaft. b
51782
a - Worm Shaft
b - Coupler
c 2. Apply Loctite 271 to threads of attaching bolts

a and secure oil pump to powerhead. Torque bolts
to 25 Ib. in. (2.8 N·m).
3. Connect inlet and outlet hoses to oil pump. Se-
cure hoses with clamps.
b 4. Connect link arm to oil pump arm.
51782 5. Prior to starting engine, refer to “BLEEDING AIR
a - Worm Shaft
FROM OIL INJECTION PUMP” and “ADJUST-
b - Thrust Washer
c - Pocket ING OIL INJECTION PUMP,” SECTION 1D, for
proper procedures.
3C-10 - FUEL SYSTEM 90-852396 MAY 1996

Installing Drive Gear (for Oil Injection CAUTION
Pump) Onto Crankshaft
Gear tooth mismatch at split line must not exceed
IMPORTANT: Oil pump drive gear retaining .020 in. (0.50 mm) or gear failure will result.
screws ARE STAKED after installation. DO NOT
remove drive gear from crankshaft unless gear is
damaged or shows signs of excessive wear.
REMOVAL OF DRIVE GEAR

1. Rotate crankshaft to gain access to two drive
gear retaining allen screws.
2. Remove two screws and remove drive gear from
crankshaft. DO NOT reuse retaining screws as
screw threads may be damaged by factory stak-
ing process.
50755
Motion Sensor
Testing Procedure--Refer to “Oil Injection System
Trouble Shooting Chart,” following:
Removal--Remove screw securing sensor to oil
pump Disconnect WHITE and BLUE/WHITE leads
b from WARNING MODULE. Remove BLACK LEAD
from engine ground. Remove MOTION SENSOR
a from powerhead.
c
Installation--Insert MOTION SENSOR into pocket
behind oil pump. Secure sensor with screw. Torque
51892 screw to 30 Ib. in. (3.4 N·m). Connect WHITE and
a - Retaining Nut BLUE/WHITE leads to respective leads of WARN-
b - Allen Screw ING MODULE. Secure BLACK sensor lead to engine
c - Center Main Bearing (Hidden) ground.
INSTALLATION OF NEW DRIVE GEAR
1. Align drive gear halves on crankshaft with retain-
ing screw access holes towards center main a
bearing.
2. Clean retaining screw threads with Loctite Primer
T (92-59327-1). Apply Loctite 680 (obtain locally) b
to screw threads.
3. Secure drive gear halves together with retaining
nuts and allen screws. Torque screws to 8 Ib. in.
(0.9 N·m)
4. Check gear halve split lines. Split should be
drawn tight together (zero clearance) if gear 51893
halves are properly installed. a - Motion Sensor
b - Screw [Torque to 30 Ib. in. (3.4 N·m)]
90-852396 MAY 1996 FUEL SYSTEM - 3C-11

Oil Injection System Trouble after the low oil warning is sounded that allows
you enough oil for 30 to 40 minutes of full throttle
Shooting Chart operation. Refer to trouble shooting chart to cor-
rect the problem.
TROUBLE SHOOTING THE OIL INJECTION
SYSTEM 2. If engine reservoir is full of oil, then the problem
may be in the oil injection pump. DO NOT run en-
If a problem occurs with the oil injection system and gine on straight gas when a problem may be in
the warning horn sounds in a pulsating manner, stop the oil injection pump. Engine can be run by con-
engine and check if problem is caused by (1) low oil necting a remote tank of 50:1 fuel and oil mixture
level, (2) the oil injection pump, or (3) a faulty warning to engine or in an emergency add (approx. a 50:1
sensor or module. ratio) of oil from the 3 gallon remote oil tank to the
1. Check oil level in engine reservoir tank. If oil level straight gas. Refer to trouble shooting chart to
is not to the top of tank the problem is low oil level. correct the problem.
There is a safety reserve of oil left in the reservoir
Problem: Oil Level in Engine Oil Reservoir Tank is Low But Not Low in Remote Oil Tank.
Fill cap is leaking air on the remote tank. Make sure O-rings or gaskets are in place and caps are
tight
Quick disconnect on remote oil tank is not fully Re-connect
connected
Remote oil hose (blue stripe) is blocked Check length of hose for a kink
Remote pulse hose (second hose) is blocked or Check length of hose for a kink
punctured.
Remote pulse hose check valve is faulty (this valve is Replace check valve.
located at the engine end of the hose).
A restricted oil outlet filter in the remote tank. Remove filter and clean.
Problem: Warning Horn Does Not Sound When Ignition Key is Turned to “ON” Position.
Horn malfunction or open (tan) wire between horn Use a jumper wire to ground tan lead (at engine terminal
and Engine. block) to engine ground. Warning horn should sound. If
not, check tan wire between horn and engine for open
circuit and check horn.
Faulty TKS ECM Check if all TKS ECM leads are connected to
harness leads. If so, module may be faulty.
Using incorrect side mount remote control or ignition/ See info on remote control SECTION 1D.
choke assembly.
Problem: Warning Horn Stays on When Ignition Key is Turned to “ON” Position.
Engine overheat sensor If horn sounds a continuous signal, the engine overheat
sensor may be faulty. Disconnect overheat sensor and
turn ignition key to “ON” position. If horn still sounds a
continuous signal, the ECM is faulty. Replace
module and re-test. If signal does not sound, then engine
overheat sensor is faulty. Replace and re-test.
Faulty TKS ECM Check connections - replace module.
3C-12 - FUEL SYSTEM 90-852396 MAY 1996

Problem: Warning Horn sounds when Engine is Running and Oil Level in Engine Reservoir is Full.
Faulty engine ignition system (incorrect voltage pulse Look at the ignition coil lead connections on the ignition
being sent to the ECM switch box and determine what coil lead has the green wire
from the ECM connected to it. Check that coil
for correct voltage using DVA. If the voltage to the coil
is correct, then the voltage to the warning module is
correct.
Defective low oil sensor (located in fill cap of engine oil Do not remove cap from oil reservoir. Disconnect both
reservoir.) low oil sensor leads from terminal connectors.
Connect an ohmmeter between leads. There should be
NO continuity thru sensor. If continuity exists, sensor is
faulty. Replace cap assembly.
Defective motion sensor at the oil injection pump All spark plugs must be removed and spark leads
grounded to prevent engine from starting when
checking motion sensor.
1. Disconnect white lead from module assembly. Check

voltage from the white lead from module. Voltage
should be 12V ± 1V.
2. Re-connect white lead from module. Sensor leads
must be connected to module for remaining checks.
Insert probe into wire connection for voltage checks.
3. Check output voltage to the sensor by connecting volt-
meter to (blue/white) sensor lead. Remove spark
plugs and ground spark plug leads. Turn ignition to
“ON”. Use emergency start rope and rotate flywheel
while observing voltmeter. Output voltage should peak
at 5V ± 1V and then drop to less than 1.0 volt during
every 2 revolutions of the engine.
4. If NO voltage is present, then one of two possibilities
exists:
a. Motion sensor defective -- replace and repeat test
for voltage.
b. Drive system defective -- test as in following sec-
tion.
Drive system of the oil injection pump. Check drive system as follows:
1. Use a 50:1 gas and oil mixture and start engine. Be
sure engine has proper cooling water.
2. Disconnect link rod connected between oil injection
pump and carburetor linkage.
3. Disconnect outlet hose of oil injection pump and ob-
serve if injection pump is pumping oil. If pump is not
pumping oil, the drive system to the pump is faulty.
If all of the checks are positive, the ECM is faulty. Replace Module and re-test.
90-852396 MAY 1996 FUEL SYSTEM - 3C-13

Oil Pump Volume (Flow) Test Engine Mounted Oil Reservoir
NOTE: The following specifications are determined
REMOVAL
with the engine running off a remote fuel supply with
pre-mix fuel. The oil pump output hose (clear) must NOTE: If oil reservoir contains oil, the clear oil hose
be disconnected from the input fuel line TEE fitting going to the oil pump should be plugged upon remov-
and directed into a graduated container. The input al to prevent oil spillage.
fuel line TEE fitting from which the oil line was re-
1. Disconnect input oil hose to oil reservoir.
moved MUST BE CAPPED OFF to prevent fuel leak-
age while the engine is running. 2. Remove oil reservoir cap BLACK and LIGHT
BLUE leads from their respective connections.
3. Disconnect clear input hose to oil pump and plug
off hose.
e 4. Remove three bolts securing oil reservoir to pow-
erhead and remove reservoir.
c a
c
b d
d
a aa
b
b a
d
c
a - Oil Pump Output Hose (Clear)

b - Tee Fitting
c - Link Arm
d - Input Fuel Line
e - Oil Pump
Flow specifications are as follows:
51893
@ 1500 RPM with oil pump link arm ATTACHED = a - Bolts
6.8cc ± 10% in 3 MINUTES b - Input Oil Hose
c - Oil Pump Input Hose (Clear)
@ 1500 RPM with oil pump link arm DISCON- d - Oil Cap
NECTED =17cc ± 10%in 3 minutes
INSTALLATION
1. Apply Loctite 222 (obtain locally) to threads of 3
attaching bolts and secure oil reservoir to power-
head. Torque bolts to 25 Ib. in. (2.8 N·m).
2. Install input oil hose to top of oil reservoir and se-
cure with sta-strap.
3. Connect oil cap BLACK lead to engine ground
and LIGHT BLUE LEAD to TKS ECM.
4. Connect clear output hose from oil reservoir to oil
pump. Secure hose with STA-STRAPS.
3C-14 - FUEL SYSTEM 90-852396 MAY 1996

FUEL SYSTEM
3
D
ELECTRONIC ENRICHMENT &

TURN KEY START
ELECTRONIC CONTROL MODULE
Table of Contents
Page
Enrichment System . . . . . . . . . . . . . . . . . . . . . . . 3D-1
Manual Operation of
Enrichment Valve . . . . . . . . . . . . . . . . . . . 3D-1
Enrichment Valve Test . . . . . . . . . . . . . . . . . . 3D-2
DVA Test of Fuel Enrichment Valve . . . . . . 3D-2
Enrichment Valve Replacement . . . . . . . 3D-3
Enrichment Valve “Clicks”
But Fuel Does Not Drain from Port . . . . 3D-3
Enrichment Valve “Clicks”
and Fuel Drains from Port . . . . . . . . . . . . 3D-3
Engine Temperature Sensor . . . . . . . . . . 3D-3
(TKS ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-4
3D-0 - FUEL SYSTEM 90-852396 MAY 1996

Enrichment System Fuel Enrichment operates as a function of time and
block temperature.
The Turn Key Start (TKS) Electronic Control Module
a. Enrichment valve will continue to provide fuel
(ECM) electrically controls the enrichment valve to
provide a rich fuel charge for starting a cold engine. while engine is cranking until block tempera-
ture reaches approximately 122° F (50° C), at
TheTKS ECM monitors engine coolant temperature which point it will no longer provide fuel.
(thru the temperature sensor) and ignition timing
b. When block is hot (normal operating temper-
(thru the crank position sensor).
ature – 140° to 155° F) enrichment valve will
The TKS ECM electronically opens the enrichment provide fuel for approximately 1/2 second
valve for varying lengths of time – the colder the en- when key is turned to “ON” position. The
gine, the longer the valve remains open. The TKS valve will not provide fuel during cranking at
ECM also advances ignition timing – Below 3,000 temperatures above 122° F (50° C).
RPM the TKS ECM advances idle timing 5 until the
engine reaches 104F (40C). Above 3,000 RPM, MANUAL OPERATION OF ENRICHMENT VALVE
the TKS ECM does not affect ignition timing regard-
less of engine temperature. IMPORTANT: Manual use of enrichment valve if
engine is warm could result in engine flooding.
Fuel is gravity fed to the enrichment valve from the
top carburetor float bowl. When the valve is opened, Should enrichment circuit of TKS ECM fail, press but-
fuel is drawn to outlet ports on each carburetor flange ton on enrichment valve and hold approximately 5
by crankcase vacuum. During cold start, throttle seconds. Release button. Start engine.
shutters should be closed – maximizing crankcase
vacuum – to draw ample fuel from the enrichment
valve.
g
d c
e
d f g
e
b g
a
a - Enrichment Valve f - Outlet Ports

b - Enrichment Valve Harness (to ECM) g - Inlet Fuel Ports
c - Inlet Fuel
d - Vent
e - Manual Button
90-852396 MAY 1996 FUEL SYSTEM - 3D-1

Enrichment Valve Test
1. Remove top cowl.
2. Disconnect YELLOW/BLACK bullet connector
(b) to enrichment valve.
55003
a - Purple
b - Yellow/Black
DVA Test of Fuel Enrichment Valve

Tested Part DVA Leads Connected To Scale Reading
Fuel Enrichment RED YELLOW/BLACK When engine is ini-
Solenoid Valve 200 DVA tially started, DVA
BLACK Engine Ground meter will deflect to
25 – 50 VDC.
This will last only a
short period and will
then indicate 10 –
15 VDC.
If above results are
not obtained, valve
is defective.
3D-2 - FUEL SYSTEM 90-852396 MAY 1996

3. Disconnect PURPLE bullet connector lead of en- ENGINE TEMPERATURE SENSOR
richment valve and touch MALE end to
GROUND.
4. Remove one outlet hose from enrichment valve
and place container under valve.
5. Turn ignition key to “ON” position.
6. While holding key ON, enrichment valve should
click and fuel drain from exposed port.
7. If valve does not click, replace valve.
ENRICHMENT VALVE REPLACEMENT

1. Disconnect YELLOW/BLACK and PURPLE bul- a
let connectors.
2. Place container under valve and remove 3 outlet
hoses and 1 inlet hose. 55009
a - Engine Temperature Sensor
3. Remove valve from clamp
4. Dispose of caught fuel in proper container.
5. Reconnect hoses to new valve. Secure hoses
with sta-straps.
6. Place valve into clamp.
7. Reconnect YELLOW/BLACK and PURPLE bul-
let connectors.
ENRICHMENT VALVE “CLICKS” BUT FUEL

DOES NOT DRAIN FROM PORT
Inspect drain hose and top carburetor float bowl for
blockage. Refer to SECTION 3B for carburetor disas-
sembly.
ENRICHMENT VALVE “CLICKS” AND FUEL

DRAINS FROM PORT
1. Inspect wiring between valve and TKS ECM, be-
tween TKS ECM and TEMPERATURE SENSOR
for breaks or loose connections. Refer to SEC-
TION 2A for engine wiring diagram.
2. If wiring is functional, refer to TEMPERATURE
SENSOR OHM CHART, following, for proper
functioning of sensor.
90-852396 MAY 1996 FUEL SYSTEM - 3D-3

Insert digital or analog ohmmeter test leads into both Turn Key Start
TAN/BLACK sensor leads. With engine at tempera-
ture (C or F) indicated, ohm readings should be as Electronic Control Module
indicated ± 10%.
(TKS ECM)
Block Temperature Resistance The Turn Key Start Electronic Control Module (TKS
C F (Ohms) ECM) provides four major functions:
–15 5 7465 • Electrically controls the enrichment valve to pro-

vide a rich fuel charge for starting a cold engine.
–10 14 5636
• Provides spark advance of 5 to start a cold en-
–5 23 4288
gine.
0 32 3287
5 41 2551 vances idle timing 5 until the engine reaches
10 50 1996 104F (40C). Above 3,000 RPM, the TKS ECM
15 59 1574
gine temperature.
20 68 1250
• Monitors and provides warning horn sounds for:
25 77 1000
a. System Start Up Test
30 86 805
b. Low Oil in Engine Mounted Oil Tank
35 95 652
c. Oil Pump Drive Failure
40 104 532
d. Over heat condition (cylinder head tempera-
45 113 436
ture)
50 122 360
• Provides engine over-rev protection by progres-
55 131 298 sively cutting off spark to ignition coils.
60 140 248 NOTE: There is no troubleshooting for the TKS ECM.
65 149 208 The engine will run without the TKS ECM. If the TKS
70 158 175 ECM is suspect, disconnect and run the engine to
systematically troubleshoot.
75 167 148
80 176 126
85 185 107
90 194 92
95 203 79
100 212 68
105 221 59
110 230 51
115 239 44
120 248 38
125 257 34
Engine Temperature Sensor and Ground

Between Black and No
EACH Tan/Blk wire. Continuity
3D-4 - FUEL SYSTEM 90-852396 MAY 1996

POWERHEAD
28237
Table of Contents
Page Page
Powerhead Specifications . . . . . . . . . . . . . . . . . . 4-1 Pistons and Piston Rings . . . . . . . . . . . . . . . . . . 4-26
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Cleaning Piston Ring Grooves . . . . . . . . 4-26
Measuring Piston Roundness . . . . . . . . . 4-27
Crankshaft, Pistons And
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Cylinder Heads and Exhaust Divider Plate . . . 4-27
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Cylinder Block Assembly . . . . . . . . . . . . . . . . . . . 4-6
Crankshaft (and End Cap) Bearings . . . . . . . . . 4-28
Reed Block And Cylinder Head . . . . . . . . . . . . . 4-8
Reed Block Assembly . . . . . . . . . . . . . . . . . . . . . 4-28
Manifold Assembly And
Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Reed Block Housing . . . . . . . . . . . . . . . . . . . . . . . 4-28
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Throttle Lever And Shift Shaft . . . . . . . . . . . . . . 4-12
Powerhead Reassembly and Installation . . . . 4-31
Bleed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Bleed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . 4-34
Bleed Line Routing . . . . . . . . . . . . . . . . . . . . . . . 4-15
Piston and Connecting Rod Reassembly . . . . . 4-35
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Piston and Piston Ring Combinations . . . . . . . . 4-36
General Information . . . . . . . . . . . . . . . . . . . . . . 4-17 Piston Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Powerhead Removal from Pump Unit . . . . . . . 4-17 Crankcase Cover Installation . . . . . . . . . . . . . . . 4-39
Removing Engine Components . . . . . . . 4-18 Assembly of Reed Blocks to
Powerhead Disassembly . . . . . . . . . . . . . . . . . . 4-18 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Upper End Cap . . . . . . . . . . . . . . . . . . . . . 4-19 Assembly of Exhaust Manifold to Block . . . . . . 4-40
Lower End Cap . . . . . . . . . . . . . . . . . . . . . 4-19 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 4-41
Crankcase Cover Removed . . . . . . . . . . 4-20
Cylinder Block and Crankcase Cover . . . . . . . . 4-41
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 4-24
Cylinder Head Installation . . . . . . . . . . . . 4-41
Cylinder Block and Crankcase Cover . . . . . . . . 4-24
Adaptor Plate Installation . . . . . . . . . . . . . . . . . . 4-42
Special Service Information . . . . . . . . . . . . . . . . 4-25
Reinstalling Engine Components . . . . . . . . . . . . 4-42
Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Powerhead Installation On Pump Unit . . . . . . . 4-42
Honing Procedure . . . . . . . . . . . . . . . . . . . 4-25
Break-ln Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-42
Break-in Fuel Mixture . . . . . . . . . . . . . . . . 4-42
4-0 - POWERHEAD 90-852396 MAY 1996

Powerhead Specifications Special Tools
Block Lifting Eye 91-90455
Type . . . . . . . . . . . . . . . . . . . . . 60° V, 2 Cycle
Displacement . . . . . . . . . . . . . 153 cu. in. (2.5 Litre)
Reed Valve Opening
Reed Stand Open (Max.) . . . 0.020 in. (0.50 mm)
Cylinder Bore
Piston
Dia. Standard . . . . . . . 3.494 in. ± .001 in.
(88.748 mm ± .025 mm) Flywheel Holder 91-52344
Dia. .015 in. Oversize . 3.509 in. ± .001 in.
(89.129 mm ± .025 mm)
91–52344
IMPORTANT: Using a micrometer, measure di-
mension “B” at location shown. Dimension “B”
should be .008 in. or less than dimension “A”.
54964
Dimension “A” Protector Cap 91-24161
at Right Angle
(90°) to Piston
Pin
1/2 in.
(12.7mm)
Flywheel Puller 91-73687A2
Dimension “B” ( in
line with Piston Pin)
90-852396 MAY 1996 POWERHEAD - 4-1

Powerhead Stand 91-30591A1 Snap Ring Pliers 91-24283
Piston Ring Expander 91-24697 Lockring Installation Tool 91-91-77109A3
Piston Ring Compressor 91-818773

Lockring Removal Tool 91-52952A1
Piston Pin Tool 91-74607A3
Universal Puller Plate 91-37241 Compression Tester 91-29287
54965
Powerhead Repair Stand

A powerhead repair stand may be purchased from:
Bob Kerr’s Marine Tool Co.
P.O. Box 1135
Winter Garden, FL 32787
Telephone: (305) 656-2089
4-2 - POWERHEAD 90-852396 MAY 1996

Notes:
90-852396 MAY 1996 POWERHEAD - 4-3

CRANKSHAFT, PISTONS AND CONNECTING RODS
95
14 13 15
14 17
11 9
95
19
17
7
13 92
6
4
5
95
14
18 15
16
8
8
8
95
18
7
1
14
2
14
3
7 Loctite “271” (92-809820)
14 2 Cycle Outboard Oil (92-13249A24)
92 Loctite 7649 Primer (92-809824)
95 2-4-C w/Teflon (92-825407A12)
4-4 - POWERHEAD 90-852396 MAY 1996

CRANKSHAFT, PISTONS AND CONNECTING RODS
TORQUE
REF.
REF
1 1 CRANKSHAFT ASSEMBLY
2 1 BEARING-Ball (LOWER)
3 1 RING-Retaining
4 2 GEAR KIT-Drive
5 2 SCREW (#6-32 x .620) 8 1
6 2 NUT-Special (#6-32)
7 7 RING-Sealing-Crankshaft
8 2 BEARING KIT-Crankshaft
9 3 PISTON ASSEMBLY (STARBOARD) (STANDARD)
OPT PISTON ASSEMBLY (STARBOARD) (.015 O.S.)
10 3 PISTON ASSEMBLY (PORT) (STANDARD)
OPT PISTON ASSEMBLY (PORT) (.015 O.S.)
11 1 RING KIT (12 Rings) (STANDARD)
12 OPT RING KIT (8 Rings) (.015 O.S.)
13 12 RING-Lock
14 6 PIN-Piston
15 6 CONNECTING ROD KIT
16 12 SCREW-Connecting Rod 1st Torque - 15 lb. in. (1.5 N·m)
2nd Torque - 30 lb. ft. (40.5 N·m)
Turn bolt additional 90° after 2nd torque
17 12 WASHER-Needle Locating
18 6 BEARING KIT-Roller
19 174 BEARING-Needle-Piston End
90-852396 MAY 1996 POWERHEAD - 4-5

CYLINDER BLOCK ASSEMBLY
11
12
13
14 95
19
15 7
18
16
17
12
24 11
23
12
4 25
9 26
20 7
21 27
3
95
22
41 2
28
40
10
18 42 39
38
6 5 29
1 30
31
7 34
95 32
8
35
14
7 Loctite “271” (92-809820)
33
12 Loctite Master Gasket (92-12564-2)
36
14 2 Cycle Outboard Oil (92-13249A24)
37
95 2-4-C w/Teflon (92-825407A12)
4-6 - POWERHEAD 90-852396 MAY 1996

CYLINDER BLOCK ASSEMBLY
TORQUE
REF.
REF
– 1 POWERHEAD ASSEMBLY
1 1 CYLINDER BLOCK ASSEMBLY
2 2 PIN-Dowel-Locating
3 2 PIN-Dowel (Center Main)
4 2 GASKET-Crankcase Sealing
5 1 COVER-Starter Motor (UPPER)
6 2 SCREW (.312-18 x 1.500) 210 17.5 23.5
7 1 COVER-Starter Motor (LOWER)
8 2 SCREW (.312-18 x 2.00) 210 17.5 23.5
9 1 BUSHING
10 2 SCREW (.375-16 x 3.250) 38 51.5
11 3 NUT-Wing (#10-32)
12 3 WASHER
13 1 SPACER
14 1 J CLIP
15 1 FITTING (.500-14)
16 1 STUD (.190-32 x 1.870)
17 1 SCREW, Ground
20 1 END CAP ASSEMBLY-Upper
21 1 O RING
22 1 BEARING KIT (Top Main)
23 1 SEAL-Oil
24 4 SCREW (.312-18 x 1.00) 150 12.5 17
25 2 STUD (#10-32 x 1.00)
26 1 BRACKET-Flywheel Cover
27 2 SCREW (.250-20 x .750) 80 9
28 6 SCREW (.375-18 x 1.250)
29 1 CAP-Nylon
30 1 NUT (.250-20)
31 1 SCREW-Special (.250-20 x 2.125)
32 6 SCREW (.375-16 x 3.250)
33 1 END CAP ASSEMBLY-Lower
34 1 O RING (3.250 I.D.)
35 2 SEAL-Oil
37 4 SCREW (.250-20 x .750) 80 9
38 1 FITTING
39 1 COVER
40 1 GASKET-Cover
41 4 SCREW (.312-18 x .875)
42 1 SCREW (#6-32 x .250)
90-852396 MAY 1996 POWERHEAD - 4-7

REED BLOCK AND CYLINDER HEAD
4 12
1 2 3
5 3
6
25 8
9
7 10 11
13
15
16
To Bottom Adapter Plate
10
18
19 21
17 22
20
23
24
4-8 - POWERHEAD 90-852396 MAY 1996

REED BLOCK AND CYLINDER HEAD
TORQUE
REF.
REF
1 4 SCREW (.312-18 x 1.00)
2 1 ELBOW-90 Brass (.250-18)
5 2 COVER KIT-Thermostat
6 2 GASKET-Thermostat
7 1 Sender, Temperature
8 24 SCREW (.375-16 x 2.30) Apply light oil to screw head and threads 40 54
9 2 HEAD-Cylinder
10 4 PIN-Dowel (.250 x .625)
11 2 GASKET-Cylinder Head
12 1 FITTING
14 1 SENSOR ASSEMBLY-Temperature (PORT)
15 1 RETAINER-Sensor
16 2 SCREW (.312-18 x .500)
17 6 REED BLOCK ASSEMBLY
18 1 GASKET-Adaptor Plate
19 1 PLATE ASSEMBLY-Adaptor
20 6 STUD (.250 x 1.125)
NS 2 FITTING-Barbed
NS 1 CHECK VALVE
21 1 CLIP
22 8 SCREW (.250-20 x .875)
23 6 SCREW (.250-20 x 2.00) Plate to Crankcase
24 6 SCREW (.250-20 x .875) Carb Mounting
25 2 WASHER
90-852396 MAY 1996 POWERHEAD - 4-9

MANIFOLD ASSEMBLY AND ADAPTER PLATE
2
3 17
16
4 18
5
15 19
1
1 20
14 21
6
7 22
10 13
8 12 23
20
9
11
24
35
37
35
36
38
25
39
35 40
33 34 26
31 27
28
29
32 29
31 30
4-10 - POWERHEAD 90-852396 MAY 1996

MANIFOLD ASSEMBLY AND ADAPTER PLATE
TORQUE
REF.
REF
1 1 ADAPTER ASSEMBLY-Flushing
2 1 PLUG-Top
3 1 WASHER
4 1 O RING
5 1 VALVE-Check
6 1 CONNECTOR
7 1 CLAMP
9 1 CLAMP
10 1 FITTING (90)
11 2 SCREW With WASHER (.312-18 x 1.500) 180 20
12 1 J CLIP
13 1 SCREW (.250-20 x .500) 180 20
14 18 WASHER
15 18 SCREW (.312-18 x 5.250) 180 20
16 1 DECAL-Flushing Adapter
17 2 SCREW (#10-32 x .620)
18 1 CLIP-Flushing Assembly Holder
19 1 COVER-Exhaust Manifold
20 2 TUBE-Strainer
21 1 GASKET-Exhaust Manifold Cover
22 1 MANIFOLD-Exhaust
23 1 GASKET-Exhaust Manifold
24 1 SEAL-Exhaust Manifold (12.500 in.)
25 1 GASKET-Adapter To Block
26 1 HOSE ASSEMBLY-Water Inlet
27 1 FITTING-Water Inlet Hose
28 1 ADAPTER-Engine To Pump
29 12 WASHER
30 4 SCREW (.375-16 x 2.250) 35 47
31 2 PIN-Dowel
32 8 SCREW (.375-16 x 1.620) 35 47
33 1 FITTING (45)
34 1 ELBOW (90)
36 1 HOSE-Syphon (9.00 ft. Bulk) (Cut 42.00 in.)
37 1 SYPHON BREAK
38 1 HOSE-Syphon (9.00 ft. Bulk) (Cut 18.00 in.)
39 1 CLAMP
40 1 FILTER-Syphon Hose
90-852396 MAY 1996 POWERHEAD - 4-11

THROTTLE LEVER AND SHIFT SHAFT
13 11
10
1
12
4
3
8 7
14
15
2 16 18
5 6 17
25 24
21 22
20 23
30 19
31
26
29
27
39
32
28
38
33
37
36
35
34
4-12 - POWERHEAD 90-852396 MAY 1996

THROTTLE LEVER AND SHIFT SHAFT
TORQUE
REF.
REF
1 1 LEVER ASSEMBLY-Spark Advance
2 1 SCREW (.250-20 x 2.125)
3 1 NUT (.250-20)
4 1 CAP
5 1 SCREW (.190-32 x 1.250)
6 1 NUT (#10-32)
7 1 CAP
8 1 WASHER
9 1 NUT (#10-32)
10 1 ROD-Link
11 1 NUT (#10-32)-Brass
12 1 BALL JOINT ASSEMBLY
13 1 PIVOT
14 1 SPRING
15 1 BUSHING
16 1 LEVER-Throttle Control
17 1 SCREW (.375-16 x 1.750)
18 1 BUSHING
19 1 SCREW (.250-20 x 2.125)
20 1 NUT (.250-20)
21 1 CAP
22 1 LATCH-Cable End
23 1 SCREW (.250-28 x .880)
24 1 SPRING
25 1 NUT (.250-28)
26 1 BARREL
27 1 ROD-Throttle Control
28 1 BUSHING-Swivel
29 1 CAM-Throttle
30 1 STUD (.250-28 x 1.750)
31 1 NUT (.250-28)
32 1 BRACKET ASSEMBLY-Cable Anchor
33 1 LATCH-Control Cable
34 1 NUT (#12-24) (Service Replacement Brkt)
35 1 WASHER (Service Replacement Bracket)
36 1 STUD (Service Replacement Bracket)
37 2 SCREW (Special)-(Original Bracket)
38 1 CUP-Barrel Retainer
39 3 SCREW (.312-18 x .880)
90-852396 MAY 1996 POWERHEAD - 4-13

Bleed System
10
9
8
8
4 7
3 1
9
7
4
8
8
5
9
2 1
7 2
7
8
9
6
8
7
7
7
Bleed System
TORQUE
REF.
REF
1 2 TUBING (9 in.)
2 2 TUBING (12-1/2 in.)
3 1 TUBING (14 in.)
4 2 TUBING (19 in.)
5 1 TUBING (24 in.)
6 1 TUBING (26 in.)
7 7 CHECK VALVE
8 6 ELBOW
9 4 FITTING–Barbed
10 1 CHECK VALVE
4-14 - POWERHEAD 90-852396 MAY 1996

Bleed Line Routing STARBOARD SIDE VIEW
FRONT VIEW
50801
50801
PORT SIDE VIEW
50802
90-852396 MAY 1996 POWERHEAD - 4-15

Torque Sequence CYLINDER HEAD BOLTS
Retorque head bolts after outboard has
CRANKCASE COVER BOLTS (AND TORQUE been run for approximately 1/2 - 1 hour
SEQUENCE) Apply light oil to threads and bolt face:
8 7 40 lb. ft. (54 N·m)
10 9
Apply light oil to
threads and bolt face:
8 Bolts (3/8 in. - 16 in.
38 lb. ft. (51.5 N·m)
4
1 6 5
2 1
3 2
Bolts (5/16 in. - 18)
180 lb. in. (20.3 N·m) 3 4
7 8
5 6
EXHAUST COVER/MANIFOLD BOLTS 11 12
180 lb. in. (20 N·m)
Apply light oil to threads and bolt face
19 18
20 15
14 13
10
9
6
5
3
1
2
4
7
8
11
12
16 17 50806
4-16 - POWERHEAD 90-852396 MAY 1996

General Information 2. Disconnect remote oil tank hose connector.
Powerhead “Disassembly” and “Reassembly” in- 3. Disconnect remote control harness from power-
structions are printed in a sequence that should be head harness connector and wires.
followed to assure best results when removing or re- 4. Remove throttle cable.
placing powerhead components. If complete disas-
5. Remove fuel inlet line.
sembly is not necessary, start reassembly at point
disassembly was stopped. (Refer to “Table of Con-
tents,” preceding.) Usually, complete disassembly of
powerhead will be required.
If major powerhead repairs are to be performed, re-
move powerhead from the pump unit.
Powerhead Removal from a

Pump Unit
1. Disconnect battery cables from battery terminals.
Remove positive battery cable from starter sole-
noid. Remove negative battery cable from lower
front starter mounting bolt.
55087
b
a - Fuel Inlet
b - Throttle Cable
6. Remove eight (8) nuts (four on each side) secur-
ing powerhead to housing cover.
b 28238
a - Positive Battery Cable Attaching Location

b - Boot Protector for Positive Battery Cable
28237
a a
a - M10 x 1.5 Nuts
28237
a
a - Forward Starter Bolt (Engine Ground)
90-852396 MAY 1996 POWERHEAD - 4-17

7. Remove plastic cap from center of flywheel and Powerhead Disassembly
install LIFTING EYE (91-90455) into flywheel at
least five full turns. Using a hoist, lift powerhead 1. Place powerhead in repair stand or on a bench.
assembly from pump unit. 2. Remove thermostat covers and washers.
51804
REMOVING ENGINE COMPONENTS

Remove the following engine components:
a
Section 2 51852
Starter Motor a - Thermostat Cover
*Ignition Switch Boxes b - Washer
*Ignition Coil
3. Remove cylinder heads from engine block.
*Starter Solenoid
*Voltage regulator/rectifier a
Flywheel
*Stator Assembly
*Trigger Assembly
*Turn Key Start Module
b
Section 3
Air Silencer
Carburetors and Linkage c
Fuel Pump
Fuel Primer
Fuel Enrichment Valve
Engine Mounted Oil Tank
Oil Pump
* All ignition and electrical components should
remain attached to electrical plate. Plate with
components can be removed as an assembly.
51847
a - Cylinder Head
b - Gasket
c - Engine Block
4-18 - POWERHEAD 90-852396 MAY 1996

4. Remove exhaust manifold and seal. 7. Remove bolts from end caps.
a c UPPER END CAP

b
51852
a - Exhaust Manifold
b - Seal
51854
c - Gasket
a - Crankcase Attaching End Cap Bolts
5. Remove reed block housing from cylinder block.
LOWER END CAP
51845
a - Reed Block Housing 51849
a - Crankcase Attaching End Cap Bolts
8. Remove bolts which secure crankcase cover to
cylinder block.
6. Inspect reeds as outlined in “Cleaning and In-
spection”.
90-852396 MAY 1996 POWERHEAD - 4-19

9. Pry crankcase cover off cylinder block using pry 11. Using an awl or electric pencil, scribe the cylinder
bars in locations shown. identification number on each connecting rod as
shown. Reassemble connecting rods in same
b cylinder.
a
Ä
Ä
Ä
a
51845
a - Pry Points
b - Crankcase Cover
CRANKCASE COVER REMOVED
51849
12. Use a 5/16 in. 12 point socket to remove connect-
ing rod bolts, then remove rod cap, roller bear-
ings and bearing cage from connecting rod.
51848
10. Use Powerhead Stand (91-30591A1) for rotating
crankshaft to desired position for removal of con-
necting rods.
51850
a - Connecting Rod Bolts
13. Push piston out of cylinder block.
4-20 - POWERHEAD 90-852396 MAY 1996

14. After removal, reassemble each piston and con- 17. Using an awl, scribe identification number of con-
necting rod assembly. necting rod on inside of piston (1). Reassemble
piston on same connecting rod.
CAUTION
Each connecting rod and end cap are a matched
machined set and must never be mismatched.
51851
18. Using tool (91-52952A1), remove piston pin lock-
rings from both ends of piston pin. Never re-use
piston pin lockrings.
51849
15. Inspect pistons as outlined in “Cleaning and In-
spection” following.
16. Use Piston Ring Expander (91-24697) to remove
piston rings. Always install new piston rings. a
51083
a - Lockring
IMPORTANT: Warming the piston dome using a
torch lamp will ease removal and installation of
piston pin.
51081
90-852396 MAY 1996 POWERHEAD - 4-21

19. Support piston and tap out piston pin using ser- 21. Remove upper end cap and lower end cap from
vice tool (91-76159A1) as shown. crankshaft.
a
b a
b
51853
a - Piston Pin
b - Piston Pin Tool (91-76159A1)
20. Remove piston pin needle bearings (29 per pis-
51848
ton) and locating washers (2 per piston) as a - Upper End Cap
shown. b - Lower End Cap
IMPORTANT: We recommend that you use new 22. Remove and discard O-ring seals from each end
needle bearings at reassembly for lasting repair. cap.
However, if needle bearings must be re-used,
23. Remove oil seal(s) from end of each end cap by
keep each set of bearings identified for reas-
driving seal out with a punch and hammer.
sembly on same connecting rod.
24. Inspect roller bearing in upper end cap as out-
lined in “Cleaning and Inspection”.
NOTE: If roller bearing is damaged, replace upper
end cap and roller bearings as an assembly.
a
51088
a - Needle Bearing Locating Washers
a 51853
a - O-Ring
b - Seal
4-22 - POWERHEAD 90-852396 MAY 1996

25. Remove crankshaft and place in powerhead 27. Remove bearing race halves and roller bearings
stand as shown. from crankshaft.
IMPORTANT: DO NOT remove crankshaft sealing IMPORTANT: Keep same bearing races and roller
rings from crankshaft, unless replacement of a bearings together.
sealing ring(s) is necessary. Usually, crankshaft
sealing rings do not require replacement, unless
broken.
CAUTION
Safety glasses should be worn when removing or
installing crankshaft sealing rings.
a
IMPORTANT: DO NOT remove oil pump drive
gear on crankshaft unless gear is damaged; i.e.
cracked, gear teeth chipped or fretting, or exces-
sive looseness. Refer to “Section 8” for proper oil a
drive gear installation procedures.
51850
a a - Bearing Race Halves
b - Roller Bearings
b Inspect crankshaft ball bearing as outlined in “Clean-

ing and Inspection,” following.
IMPORTANT: DO NOT remove crankshaft ball
bearing, unless replacement is required.
28. Remove lower ball bearing from crankshaft as
follows:
a. Remove retaining ring using a pair of snap
ring pliers.
51847
a - Sealing Rings b
a
b - Oil Pump Drive Gear
26. Remove retaining ring as shown.
51854
a - Crankshaft Ball Bearing
51850 b - Pliers
a - Retaining Ring c - Retaining Ring
90-852396 MAY 1996 POWERHEAD - 4-23

b. Press crankshaft out of lower ball bearing as Cleaning and Inspection
shown.
a Cylinder Block and Crankcase Cover

IMPORTANT: Crankcase cover and cylinder
block are a matched, line-bored assembly and
never should be mismatched by using a different
crankcase cover or cylinder block.
b
51081
a - Press
b - Powerhead Stand (91-30591A1)
c - Crankshaft Ball Bearing
d - Universal Puller Plate (91-37241)
29. If necessary, remove water pressure relief valve
cover as shown.
CAUTION
It crankcase cover or cylinder block is to be sub-
merged in a very strong cleaning solution, it will
be necessary to remove the crankcase cover/cy-
linder block bleed system from crankcase cover/
cylinder block to prevent damage to hoses and
check valves.
1. Thoroughly clean cylinder block and crankcase
cover. Be sure that all sealant and old gaskets are
removed from matching surfaces. Be sure that
carbon deposits are removed from exhaust ports.
2. Inspect cylinder block and crankcase cover for
cracks or fractures.
3. Check gasket surfaces for nicks, deep grooves,
cracks and distortion that could cause compres-
sion leakages.
50803
4. Check all water and oil passages in cylinder block
and crankcase cover to be sure that they are not
obstructed and that plugs are in place and tight.
a - Bolt
b - Cover
c - Gasket
4-24 - POWERHEAD 90-852396 MAY 1996

Special Service Information d. Localize stroking in the smallest diameter un-
til drill speed is constant throughout length of
Grooves in Cylinder Block Caused By Crank- bore. Expand stones, as necessary, to com-
shaft Sealing Rings pensate for stock removal and stone wear.
Grooves in cylinder block caused by crankshaft seal- Stroke at a rate of 30 complete cycles per
ing rings are not a problem, except if installing a new minute to produce best cross-hatch pattern.
crankshaft and the new sealing rings on crankshaft Use honing oil generously.
do not line up with existing grooves in cylinder block. e. Thoroughly clean cylinder bores with hot wa-
If installing a new crankshaft, refer to crankshaft inter and detergent. Scrub well with a stiff
stallation, Powerhead Reassembly section to deter- bristle brush and rinse thoroughly with hot
mine if powerhead can be used. water. A good cleaning is essential. If any of
the abrasive material is allowed to remain in
the cylinder bore, it will cause rapid wear of
Cylinder Bores new piston rings and cylinder bore in addition
to bearings. After cleaning, bores should be
1. Inspect cylinder bores for scoring, scuffing or a
swabbed several times with engine oil and a
transfer of aluminum from piston to cylinder wall.
clean cloth, then wiped with a clean, dry cloth.
Scoring or scuffing, if NOT TOO SEVERE, can
Cylinders should not be cleaned with kero-
normally be removed by honing. If a transfer of
sene or gasoline. Clean remainder of cylinder
aluminum has occurred, an acidic solution such
block to remove excess material spread dur-
as “TIDY BOWL CLEANER” should be applied to
ing honing operation.
the areas of the cylinder bore where transfer of
aluminum has occurred. After the acidic solution 2. Hone all cylinder walls just enough to de-glaze
has removed the transferred aluminum, thor- walls.
oughly flush the cylinder bore(s) to remove any 3. Measure cylinder bore diameter (with a snap
remaining acid. Cylinder walls may now be gauge micrometer) of each cylinder, as shown
honed to remove any glaze and to aid in the seat- below. Check for tapered, out-of-round
ing of new piston rings. (egg-shaped) and oversize bore.
HONING PROCEDURE
a. When cylinders are to be honed, follow the
hone manufacturer’s recommendations for
use of the hone and cleaning and lubrication
during honing.
b. For best results, a continuous flow of honing
oil should be pumped into the work area. If
pumping oil is not practical, use an oil can.
Apply oil generously and frequently on both
stones and work area.
CAUTION
When honing cylinder block, remove hone fre-
quently and check condition of cylinder walls.
DO NOT hone any more than absolutely neces-
sary, as hone can remove cylinder wall material
rapidly.
c. Start stroking at smallest diameter. Maintain 51846
firm stone pressure against cylinder wall to
assure fast stock removal and accurate re-
sults.
90-852396 MAY 1996 POWERHEAD - 4-25

175 Models CLEANING PISTON RING GROOVES
NOTE: Cleaning instructions differ between the rect-
Models Cylinder Block
Finish Hone angular ring groove and keystone (tapered) ring
groove. Pistons may have two keystone ring grooves
175 with a Standard Piston 3.501 in. or one keystone ring groove and one rectangular ring
(88.93 mm) groove as shown.
175 with a .015 in. 3.516 in.
Rectangular ring grooves
(0.381mm) Oversize Piston (89.31 mm)
1. A broken rectangular piston ring can be used as
4. If a cylinder bore is tapered, out-of-round or worn a tool for scraping carbon from ring grooves.
more than .006 in. (0.152 mm) from standard Carefully scrape carbon from ring grooves with-
“Cylinder Block Finish Hone” diameter (refer to out scratching the side surfaces of grooves.
chart, preceding), it will be necessary to re-bore
that cylinder(s) to .015 in. (0.381 mm) or .030 in. Keystone (tapered) ring grooves
(0.762 mm) oversize or re-sleeve and install
oversize piston(s) and piston rings during reas- CAUTION
sembly. Care must be taken not to scratch the side sur-
NOTE: The weight of an oversize piston is approxi- faces of the ring groove. Scratching the side sur-
mately the same as a standard size piston; therefore, face of the ring groove will damage the ring
it is not necessary to re-bore all cylinders in a block groove.
just because one cylinder requires re-boring. 1. Use a bristle brush and carbon remover solution
5. After honing and thoroughly cleaning cylinder to remove carbon from side surfaces.
bores, apply light oil to cylinder walls to prevent 2. A tool can be made for cleaning the inner diame-
rusting . ter of the tapered ring grooves. The tool can be
made from a broken tapered piston ring with the
side taper removed to enable the inside edge of
Pistons and Piston Rings the ring to reach the inner diameter of the groove.
Carefully scrape carbon from inner diameter of
IMPORTANT: If engine was submerged while en-
ring grooves. Care must be taken not to damage
gine was running, piston pin and/or connecting
the grooves by scratching the side surfaces of the
rod may be bent. If piston pin is bent, piston must
grooves.
be replaced. (Piston pins are not sold separately
because of matched fit into piston.) If piston pin Piston with two half keystone (half tapered) rings
is bent, connecting rod must be checked for (175 Models)
straightness (refer to “Connecting Rods,” fol-
lowing, for checking straightness).
1. Inspect pistons for scoring and excessive piston
skirt wear.
Enlarged View of
2. Check tightness of piston ring locating pins. Lo- Piston Ring Grooves
cating pins must be tight.
3. Thoroughly clean pistons. Carefully remove car-
bon deposits from pistons, with a soft wire brush
or carbon remove solution. Do not burr or round
off machined edges.
Inspect piston ring grooves for wear and carbon ac-
cumulation. If necessary, scrape carbon from piston
ring grooves being careful not to scratch sides of
grooves. Refer to procedure following for cleaning
piston ring grooves.
4-26 - POWERHEAD 90-852396 MAY 1996

MEASURING PISTON ROUNDNESS Crankshaft
Piston has a barrel profile shape and is not a true di- 1. Inspect crankshaft to drive shaft splines for wear.
ameter. (Replace crankshaft, if necessary.)
175 - 153 cu. in. (2508 cc) 2. Check crankshaft for straightness. (Replace as
1. Using a micrometer, measure dimension “A” at necessary.)
location shown. Dimension “A” should be as indi- 3. Inspect crankshaft oil seal surfaces. Sealing sur-
cated in chart following. faces must not be grooved, pitted or scratched.
(Replace as necessary.)
Piston Dimension “A”
4. Check all crankshaft bearing surfaces for rust,
Standard Piston 3.494 in. ± .001 in.
water marks, chatter marks, uneven wear and/or
.015 in. Oversize Piston 3.509 in. ± .001 in. overheat-ing. (Refer to “Connecting Rods”.)
2. Using a micrometer, measure dimension “B” at 5. If necessary, clean crankshaft surfaces with cro-
location shown. Dimension “B” should be within cus cloth .
.008 in. of dimension “A.”
a b
Dimension “A”
at Right Angle c
(90 °) to Piston
Pin c
1/2 in.
(12.7mm)
Dimension “B” ( in
line with Piston Pin)
51847
Cylinder Heads and Exhaust Divider a - Crankshaft Journals
Plate b - Crocus Cloth
c - Work Cloth “Back-and-Forth”
1. Inspect internal surface of cylinder heads for pos-
sible damage (as a result of piston or foreign ma- WARNING
terial striking cylinder heads). DO NOT spin-dry crankshaft ball bearing with
IMPORTANT: Cylinder head warpage should not compressed air.
exceed .004 in. (.1mm) over the ENTIRE length of 6. Thoroughly clean (with solvent) and dry crank-
the cylinder head. If measured warpage, as deter- shaft and crankshaft ball bearing. Recheck sur-
mined on a surface block, exceeds .004 in. faces of crankshaft. Replace crankshaft, if sur-
(.1mm) or a discontinuity of up to .004 in. (.1 mm) faces cannot be properly “cleaned up.” If
exists in a narrow portion of the cylinder head’s crankshaft will be re-used, lubricate surfaces of
surface length, then the cylinder head may be re- crankshaft with light oil to prevent rust. DO NOT
surfaced up to .010 in. (.25mm). lubricate crankshaft ball bearing at this time.
2. Replace cylinder head(s) as necessary.
3. Thoroughly clean gasket surfaces of exhaust di-
vider plate.
4. Inspect exhaust divider plate for deep grooves,
cracks or distortion that could cause leakage. Re-
place parts as necessary.
90-852396 MAY 1996 POWERHEAD - 4-27

Crankshaft (and End Cap) Bearings Reed Block Assembly
1. After cleaning crankshaft, grasp outer race of IMPORTANT: Reed block assembly is not ser-
crankshaft ball bearing (installed on lower end of viceable. If reeds are damaged replace reed block
crankshaft) and attempt to work race back-and- assembly.
forth. There should not be excessive play.
1. Thoroughly clean gasket surfaces of reed blocks
2. Lubricate ball bearing with light oil. Rotate outer and reed block housing. Check for deep grooves,
bearing race. Bearing should have smooth action cracks and distortion that could cause leakage.
and no rust stains. If ball bearing sounds or feels Replace parts as necessary.
“rough” or has “catches,” remove and discard
2. Check for wear (indentations) on face of each
bearing. (Refer to “Powerhead Removal and Dis-
reed block. Replace reed block assembly if reeds
assembly - Crankshaft Removal and Disassem-
have made indentations.
bly”.)
3. Check for chipped and broken reeds.
Lower Ball
Bearing
3. Thoroughly clean (with solvent) and dry crank-

shaft center main roller bearings. Lubricate bear-
ings with 2-Cycle Outboard Oil.
CAUTION
51851
DO NOT intermix halves of upper and lower
crankshaft center main roller bearings. Replace
Allowable reed opening is .020 in. (.51 mm) or less.
bearings in pairs only. Replace reed block assembly if any reed is standing
4. Thoroughly inspect center main roller bearings. open more than .020 in. (.51 mm).
Replace bearings if they are rusted, fractured,
worn, galled or badly discolored.
Reed Block Housing
Center main
Roller Bearing 1. Check rubber bleed hoses. Replace any hose
that is cracked, cut or deteriorating.
2. Check operation of bleed system check valves in
reed block housing. If valves are working proper-
5. Clean (with solvent) and dry crankshaft roller ly, air can be drawn thru check valves “one way”
bearing that is installed in upper end cap. Lubri- only. If air can pass thru a check valve both ways,
cate bearing with light oil. valve is not working properly and must be re-
6. Thoroughly inspect upper end cap roller bearing. placed.
If roller bearing is rusted, fractured, worn, galled,
badly discolored or loose inside of end cap re-
place end cap and roller bearing as an assembly.
Upper Roller
Bearing
4-28 - POWERHEAD 90-852396 MAY 1996

3. Check that bleed system check valves are 4. Water Marks: When bearing surfaces are sub-
pressed tight into reed housing. jected to water contamination, a bearing surface
“etching” occurs. This etching resembles the size
4. Inspect passages in reed block housing to be
of the bearing.
sure that they are not obstructed.
51853
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 con-
necting rod in line with the “I” beam. General
bearing surface deterioration could be caused by
or accelerated by improper lubrication.
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
a
slight wobble on plate, or if a .002 in. (0.051mm)
51853
feeler gauge can be inserted between any ma-
chined surface and surface plate, rod is bent and
a - Spalling
must be discarded.
2. Overheating: Overheating is visible as a bluish
bearing surface color that is caused by inade-
quate lubrication or excessive RPM.
3. Rust: Rust formation on bearing surfaces
causes uneven pitting of surface(s).
a
51853
a - Pitting
90-852396 MAY 1996 POWERHEAD - 4-29

6. Chatter Marks: Chatter marks are the result of a 8. If necessary, clean connecting rod bearing sur-
combination of low speed - low load - cold water faces, as follows:
temperature operation, aggravated by inade-
a. Be sure that “etched” marks on connecting
quate lubrication and/or improper fuel. Under
rod (crankshaft end) are perfectly aligned
these conditions, the crankshaft journal is ham-
with “etched” marks on connecting rod cap.
mered by the connecting rod. As ignition occurs
Tighten connecting rod cap attaching bolts
in the cylinder, the piston pushes the connecting
securely.
rod with tremendous force, and this force is trans-
ferred to the connecting rod journal. Since there
is little or no load on the crankshaft, it bounces
CAUTION
away from the connecting rod. The crankshaft Crocus cloth MUST BE USED to clean bearing
then remains immobile for a split second until the surface at crankshaft end of connecting rod. DO
piston travel causes the connecting rod to catch NOT use any other type of abrasive cloth.
up to the waiting crankshaft journal, then ham- b. Clean CRANKSHAFT END of connecting
mers it. The repetition of this action causes a rod by using CROCUS CLOTH placed in a
rough bearing surface(s) which resembles a tiny slotted 3/8 in. (9.5 mm) diameter shaft, as
washboard. In some instances, the connecting shown. Chuck shaft in a drill press and opera-
rod crank pin bore becomes highly polished. Dur- tion press at high speed while keeping con-
ing operation, the engine will emit a “whirr” and/or necting rod at a 90 angle to slotted shaft.
“chirp” sound when it is accelerated rapidly from
idle speed to approximately 1500 RPM, then IMPORTANT: Clean connecting rod just enough
quickly returned to idle. If the preceding condi- to clean up bearing surfaces. DO NOT continue
tions are found, replace both the crankshaft and to clean after marks are removed from bearing
connecting rod(s). surfaces.
a
51853
a - Chatter Marks Between Arrows

7. Uneven Wear: Uneven wear could be caused by 51083
a bent connecting rod. c. Clean PISTON PIN END of connecting rod,
using same method as in Step “b”, preceding,
but using 320 grit carborundum cloth instead
of crocus cloth.
d. Thoroughly wash connecting rods to remove
abrasive grit. Recheck bearing surfaces of
connecting rods. Replace any connecting
rod(s) that cannot be properly “cleaned up.”
Lubricate bearing surfaces of connecting
rods (which will be re-used) with light oil to
a 51853 prevent rust.
a - Uneven Wear Between Arrows
4-30 - POWERHEAD 90-852396 MAY 1996

Powerhead Reassembly and 1. If removed, press lower crankshaft ball bearing
onto crankshaft as shown. Be sure bearing is
Installation pressed firmly against counterweight.
d
General
Before proceeding with powerhead reassembly, be
sure that all parts to be re-used have been carefully
cleaned and thoroughly inspected, as outlined in
“Cleaning and Inspection,” preceding. Parts, which c
have not been properly cleaned (or which are ques-
tionable), can severely damage an otherwise per-
fectly good powerhead within the first few minutes of a b
operation. All new powerhead gaskets MUST BE in-
stalled during reassembly.
During reassembly, lubricate parts with Quicksilver
2-Cycle Outboard Lubricant whenever “light oil” is
specified. Quicksilver part numbers of lubricants,
sealers and locking compounds and tools are listed 51852
in “Powerhead General Information,” preceding. a - Crankshaft
b - Crankshaft Ball Bearing
A torque wrench is essential for correct reassembly c - Suitable Mandrel
of powerhead. DO NOT attempt to reassemble pow- d - Press
erhead without using a torque wrench. Attaching
2. Reinstall retaining ring using a suitable pair of
bolts for covers, housings and cylinder heads MUST
Snap Ring Pliers.
BE torqued by tightening bolts in 3 progressive steps
(following specified torque sequence) until specified
torque is reached (see “Example,” following). a
EXAMPLE: If cylinder head attaching bolts require a
torque of 40 Ib. ft. (54 N·m), a) tighten all bolts to 10
Ib. ft. (13.5 N·m), following specified torque se-
quence, b) tighten all bolts to 20 Ib. ft. (27 N·m), fol-
lowing torque sequence, then finally c) tighten all
bolts to 40 Ib. ft. (54 N·m), following torque se-
quence.
51854
a - Retaining Ring
90-852396 MAY 1996 POWERHEAD - 4-31

3. If removed, spread new crankshaft sealing rings 5. Lubricate center main crankshaft roller bearings
just enough to slide over crankshaft journal. and races with light oil.
51854
a
Install so Larger of Make Sure Retain-
the 3 Holes is to- ing Ring Bridges the
ward bottom End of Separating Lines of
Crankshaft the Bearing Race
51854
a - Crankshaft Sealing Rings 6. Place center main crankshaft roller bearings on
4. Use Piston Ring Expander (91-24697) and install upper and lower main bearing journals as shown.
crankshaft sealing rings into groove. 7. Install center main bearing races as shown.
FLYWHEEL END
51849 BOTTOM END

51850
4-32 - POWERHEAD 90-852396 MAY 1996

8. Secure center main bearing races together with
retaining rings. Make sure retaining ring bridges
the separating lines of the bearing race.
a 51849
a - O-ring
a 10. Install oil seal into upper end cap as follows:
a. Apply a thin bead of Loctite 271 (92-809820)
to outer diameter of upper end cap oil seal.
a b. Use a suitable mandrel, press oil seal into up-
per end cap (lip facing down) until bottomed
out on lip of end cap. Remove any excess
Loctite.
c. Lubricate oil seal lip with Quicksilver Needle
Bearing Assembly Lubricant (92-825265A1).
d. Lubricate O-ring with Quicksilver Needle
51847 Bearing Assembly Lubricant (92-825265A1)
a - Center main Bearing Races and install on end cap.
9. Install oil seals into lower end cap as follows:
a. Apply a thin bead of Loctite Type “A” a
(92-809820) to outer diameter on 2 lower end
cap oil seals (a).
b. Using driver head (91-55919) press one oil
seal (lip facing down) into lower end cap until
firmly seated. Remove any excess Loctite.
b
c. Press second oil seal (lip facing down) until
firmly seated on first oil seal. Remove any ex- a- Oil Seal
cess Loctite. b - Lip of End Cap
d. Lubricate oil seal lips with Quicksilver Needle
Bearing Assembly Lubricant (92-825265A1).
e. Apply a light coat of Perfect Seal
(92-34227-1) to end cap flange.
f. Lubricate O-ring seal with Quicksilver Needle
Bearing Assembly Lubricant (92-825265A1)
and install over lower end cap.
a
a
a - Oil Seal 51849
a - O-ring
90-852396 MAY 1996 POWERHEAD - 4-33

Crankshaft Installation 5. Gently push crankshaft down into position mak-
ing sure that the dowel pins are lined up with the
SPECIAL INFORMATION holes in center main bearings and crankshaft
seal rings are in place.
Installing A New Crankshaft Assembly Into Cylin-
der Block
Check the crankshaft sealing ring mating surfaces in
the cylinder block and crankcase cover for wear
grooves that were caused by the crankshaft sealing
rings from the previous crankshaft. If wear grooves
are present, the sealing rings on the new crankshaft
will have to fit into the grooves without binding the
crankshaft.
Before installing crankshaft, remove any burrs that
may exist on groove edges.
Lubricate sealing rings with light oil and install new
crankshaft as instructed.
Install upper and lower end caps and then inspect fit
between sealing rings and grooves. Temporarily in- a
stall crankcase cover and rotate crankshaft several 51848
a - Dowel Pin
times to check if sealing rings are binding against
crankshaft. (You will feel a drag on the crankshaft.) If 6. Lubricate crankshaft ends (oil seal areas) with
sealing rings are binding, recheck grooves for burrs. light oil, then install upper and lower end caps (“a”
If this does not correct the problem, it is recom- and “b”). Secure end caps to cylinder block with
mended that the cylinder block be replaced. attaching bolts. DO NOT tighten end cap bolts at
Install crankshaft as follows: this time.
a
1. Lubricate crankshaft sealing rings with light oil.
b
2. Check cylinder block to be sure that dowel pins
are in place.
a
51848
a - Upper End Cap
b - Lower End Cap
51848
a - Dowel Pins
3. Position all crankshaft seal ring gaps straight up.
4. Align hole in each center main bearing race with
dowel pin.
4-34 - POWERHEAD 90-852396 MAY 1996

Piston and Connecting Rod 4. Insert piston pin tool (91-74607A3) and push
sleeve out of piston. Keep piston pin tool in pis-
Reassembly ton.
1. Place needle bearings on a clean piece of paper
and lubricate with Quicksilver Needle Bearing
Assembly Lubricant (92-825265A1). a b
NOTE: There are 29 needle bearings per piston.
2. Place sleeve which is part of piston pin tool (91-
74607A3) into connecting rod and install needle
bearings around sleeve as shown.
51080
a - Piston Pin Tool (91-74607A3)
b - Sleeve
5. Use a mallet and tap piston pin into piston and
push piston pin tool out.
51851
a - Sleeve (Part of Tool Assy. 91-74607A3)
3. Place locating washers on connecting rod. a
IMPORTANT: Position connecting rod part num-
ber facing towards flywheel. b
Carefully position piston over end of rod. Make sure
locating washers remain in place.
51086
a - Piston Pin
b - Piston Pin Tool
6. Install new piston pin lockrings (one each end of
piston pin) with Lockring Installation Tool
a 51851 (91-77109A3).
a - Locating Washers
90-852396 MAY 1996 POWERHEAD - 4-35

7. Make sure lockrings are properly seated in piston
grooves.
b
a
51086
a - Lockring Installation Tool

51086
a - Lockring Installation Tool (91-77109A3)
b - Lockring
Piston and Piston Ring Combinations
.056 in.
Half Keystone (ta- Enlarged View of

pered) Piston Ring Piston Ring
Grooves
.056 in.
All 153 cu. in. (2508 cc) models have two half keystone (half tapered) rings.
4-36 - POWERHEAD 90-852396 MAY 1996

Piston Installation 5. Lubricate piston, rings and cylinder wall with
2-Cycle Outboard Oil.
1. Before installing new piston rings, check gap be-
tween ring ends by placing each ring in its respec-
tive cylinder, then pushing ring about 1/2 in. a
(12.7mm) into cylinder using piston to assure
proper position.
2. Check end gap of each new piston ring with a
feeler gauge. End gap must be within .018 in. to
.025 in. (0.45mm to 0.64mm). If end gap is great-
er, check other piston rings in cylinder bore, until b
rings (within tolerance) are found.
51081
a - Piston Ring Expander

a b - Dot Side “Up” on Piston Ring
6. Rotate each piston ring so end of ring is aligned
b with locating pin as shown.
7. Install Piston Ring Compressor.
8. Remove screws and connecting rod cap from
piston rod assembly being installed.
IMPORTANT: Piston must be correctly installed
c d and positioned as shown.
Pistons marked with the word “UP” and with the letter
“P” or “S” on top of piston.
Pistons with the letter “P” must be installed in the port
side of engine and the word “UP” facing toward top
of engine.
51852 Pistons with the letter “S” must be installed in the star-
a - Piston Ring board side of engine and the word “UP” toward top of
b - Dots (Faces Up) engine.
c - Feeler Gauge
d - Ring End Gap
IMPORTANT: Piston ring side with dot or letter UP UP
must be facing up. CYL 2 CYL 1
P S
Dot or Letter UP UP
CYL 4 CYL 3
P S
Piston Ring
UP UP
CYL 6 CYL 5
3. Use Piston Ring Expander (91-24697) and install P S
piston rings (dot side up) on each piston. Spread
rings just enough to slip over piston.
4. Check piston rings to be sure that they fit freely
in ring groove.
90-852396 MAY 1996 POWERHEAD - 4-37

9. Coat cylinder bore with 2-cycle oil. Match piston 12. Tighten connecting rod bolts (using a 5/16 in. - 12
assembly with cylinder it was removed from, and point socket) First torque to 15 lb. in. (1.7 N·m)
position piston as described below. Push piston then 30 lb. ft. (40.6 N·m). Turn each bolt an addi-
into cylinder. tional 90° after 2nd torque is attained. Recheck
alignment between rod cap and rod as shown.
a
a
50802
51850
a - Connecting Rod Screws
10. Apply Quicksilver Needle Bearing Assembly Lu- 13. Rotate crankshaft several times (using power-
bricant to bearing surface of connecting rod and head stand) to assure free operation (no binds
install bearing assembly, as shown. and catching).
11. Place connecting rod cap on connecting rod. Ap- Connecting Rod Cap Alignment
ply light oil to threads and face of connecting rod Check each connecting rod cap for correct alignment. If
bolts. Thread connecting rod bolts finger-tight not aligned, a ridge can be seen or felt at the separating
while checking for correct alignment of the rod line as shown below. Correct any misalignment.
cap as shown.
Side View
Side View Incorrect-Cap
IMPORTANT: Connecting rod and connecting rod Correct on Backwards
caps are matched halves. Do not torque screws
before completing the following procedure.
• Run a pencil lightly over
ground area.
• If pencil stops at fracture
point, loosen bolts, retigh-
ten, and check again.
End View End View
NOTE: If you still feel the fracture point, discard the rod. End View Incorrect- Incorrect-Cap
Correct Not Aligned on Backwards
ÄÄ ÄÄ Ä
ÄÄ ÄÄ Ä
ÄÄ ÄÄ
4-38 - POWERHEAD 90-852396 MAY 1996

14. Verify that no piston rings were broken during in-
stallation by pressing in on each piston ring thru
exhaust port using a screwdriver. If no spring ten-
sion exists (ring fails to return to position), it’s like-
ly ring is broken and must be replaced.
a
51846
a - Loctite Master Gasket (92-12564-2)

4. Place crankcase cover in position on cylinder
block. Turn the 8 center main bolts in a LITTLE at
a time, (following torque sequence) compressing
51852 crankshaft seal rings until crankshaft cover has
a - Screwdriver been drawn down to cylinder block. Tighten eight
bolts (a) evenly in three progressive steps (fol-
lowing torque sequence).
Crankcase Cover Installation
5. Install remaining crankcase cover flange bolts.
1. Thoroughly remove all oil from mating surfaces of 6. Tighten end cap bolts to specified torque.
crankcase cover and cylinder block with Loctite
Primer ‘T’ (92-5327-1). Upper End Cap Bolts
150 lb. in. (17 N·m)
2. Install gasket strips into grooves in crankcase
cover. Trim end of each gasket strip flush with
edge of cover as shown.
Add light oil to threads

and bolt face:
a b 8 Bolts (3/8 in. - 16 in.
38 lb. ft. (51.5 N·m)
51852 Bolts (5/16 in. - 18)

180 lb. in. (20.3 N·m)
a - Gasket Strips
b - Edge of Cover
3. Apply a thin, even coat of Loctite Master Gasket
#203 on mating surfaces of crankcase cover and
cylinder block.
Lower End Cap Bolts

80 lb. in. (9 N·m)
90-852396 MAY 1996 POWERHEAD - 4-39

Assembly of Reed Blocks to Intake 5. Torque exhaust manifold cover bolts in following
sequence.
Manifold
EXHAUST MANIFOLD COVER BOLTS
180 lb. in. (20 N·m)
105 lb. in. (11.8 N·m) Apply light oil to threads and bolt head
19 18
20 15
14 13
10 9
6
5
3
1
2
4
7
8
11
12
80 lb. in. (9 N·m) 50806 50806
16 17
Assembly of Exhaust Manifold to 6. If removed, install water pressure relief valve
Block cover as shown.
1. Place exhaust divider seal into slot in block.
2. Install exhaust manifold with gasket.
3. Install gasket and exhaust manifold cover.
4. Apply light oil to bolt threads and torque bolts to
180 Ib. in. (20 N·m).
50803
d
c
a - Bolt
b - Cover
b c - Gasket
a - Divider Seal
b - Exhaust Manifold
c - Gasket c
d - Exhaust Cover
a
4-40 - POWERHEAD 90-852396 MAY 1996

Cleaning and Inspection CYLINDER HEAD INSTALLATION
1. Install each cylinder head to engine block with
thermostat pocket “UP”. Apply light oil to cylinder
Cylinder Block and Crankcase Cover head bolt threads and torque bolts to 40 Ib. ft. (54
N·m).
IMPORTANT: Crankcase cover and cylinder
block is a matched, line-bored assembly and IMPORTANT: After first 1/2 to 1 hour of running
should never be mismatched by using a different time, each cylinder head bolt should be loosened
crankcase cover or cylinder block. one at a time, 1/4 turn, and re-torqued in se-
quence shown.
2. Install thermostat washer into each cylinder

head.
3. Install overheat temperature sensor into STAR-
BOARD cylinder head below #1 spark plug.
d c
b
e a
CAUTION f
g
It crankcase cover or cylinder block is to be sub-
merged in a very strong cleaning solution, it will
be necessary to remove the crankcase cover/cy-
linder block bleed system from crankcase cover/ h
cylinder block to prevent damage to hoses and i
check valves.
1. Thoroughly clean cylinder block and crankcase
cover. Be sure that all sealant and old gaskets are j
removed from matching surfaces. Be sure that
carbon deposits are removed from exhaust ports.
2. Inspect cylinder block and crankcase cover for
cracks or fractures.
3. Check gasket surfaces for nicks, deep grooves, a - Washer
cracks and distortion that could cause compres- b - Thermostat Cover
sion leakages. c - Hose
d - Clamp
4. Check all water and oil passages in cylinder block e - Bolt (Torque to 200 Lb. in. - 22.6 N·m)
and crankcase cover to be sure that they are not f - 90° Elbow
g - Temperature Sensor
obstructed and that plugs are in place and tight.
h - Bolt (Torque to 200 Lb. in. - 22.6 N m)
i - Retainer
j - Bolt [Apply Light Oil to Threads - Torque to 40 lb. ft.
(54.2 N·m)]
90-852396 MAY 1996 POWERHEAD - 4-41

Adaptor Plate Installation Break-ln Procedure
1. Using new gasket, install adaptor plate to bottom
of powerhead. BREAK-IN FUEL MIXTURE
2. Torque screws to 35 lb. ft. (47 N·m). During the break-in period, operate the engine with
the first 30 gallons of fuel by mixing gasoline- oil in the
fuel tank at a 50:1 ratio as described in chart below.
Reinstalling Engine Components
NOTE: The 50:1 ratio gasoline - oil in the fuel tank
Reinstall the following engine components: combined with the metered oil supplied by the oil in-
Section 2 jection system will supply the necessary gasoline-oil
Starter Motor mixture required for break-in lubrication.
Ignition Switch Boxes
Ignition Coils Type of U.S. Imperial Metric
Starter Solenoid Oil Measure Measure Measure
Voltage regulator/rectifier 15 Imp. oz.
Quicksilver 16 U.S. oz. 400cc to
Flywheel to each 5
2-Cycle to each 6 each 20 li-
Stator Assembly Imp.
Outboard gallons of ters of
Trigger Assembly gallons of
Oil gasoline gasoline
Turn Key Start Module gasoline
Section 3 Other Ac-
Air Silencer ceptable
Carburetors and Linkage BIA
Use at Manufacturer’s Recommen-
Fuel Pump TC-W3
dations. DO NOT EXCEED 50:1.
Fuel Primer and
Fuel Enrichment Valve TC-W II
Oils
Engine Mounted Oil Tank
Oil Pump Operate the engine at varied throttle settings - not to
exceed 1/2 throttle (2500-3500 RPM) during the first
Powerhead Installation On hour or the first ten gallons of break-in fuel. Refer to
“Fuel Mixture and Gasoline/Oil Recommendations”
Pump Unit - “Break-ln Fuel Mixture.”
1. Install Lifting Eye (91-90455) into flywheel. During the second hour of operation, or the second
10 gallons of break-in fuel, operate the engine at var-
WARNING ied throttle settings not to exceed 4500 RPM.
BE SURE that Lifting Eye is threaded into fly- DO NOT OPERATE THE ENGINE AT FULL
wheel a minimum of five (5) turns BEFORE lifting THROTTLE UNTIL THE SECOND HOUR OF
powerhead. BREAK-IN IS COMPLETED. This includes full
2. Using a hoist, lift powerhead high enough to allow throttle acceleration, pulling water skiers, or wide
removal of powerhead from repair stand. Re- open throttle running.
move powerhead from repair stand, being careful After the first two hours of running, approximately 20
not to damage gasket surface of adaptor plate. gallons of fuel, full throttle operation may be attained,
3. Apply a small amount of Special Lube 101 but not sustained, for the remaining break-in fuel (ap-
(92-13872A1) onto driveshaft splines. proximately 10 gallons).
Refer to Section 1D, Sport Jet Installation to com- After the 30 gallons of 50:1 break-in fuel has been
plete powerhead installation and cable adjustment. consumed, it is no longer necessary to mix oil to the
gasoline in the remote fuel tank.
Following Timing, Synchronizing and Adjusting as
outlined in Section 2C. For the next five hours of operation, full throttle oper-
ation may, again, be attained, but it is strongly not
recommended for sustained use. (Not more than 5
minutes of continuous wide open throttle.)
4-42 - POWERHEAD 90-852396 MAY 1996

JET PUMP
28237
Table Of Contents
Page
General Information . . . . . . . . . . . . . . . . . . . . . . . 5-1
Principles Of Operation . . . . . . . . . . . . . . . . . . 5-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drive Housing Components . . . . . . . . . . . . . . . . . 5-4
Pinion & Impeller Shaft . . . . . . . . . . . . . . . . . . . . . 5-6
Nozzle/Rudder Components . . . . . . . . . . . . . . . . 5-8
Servicing Stator, Impeller And Wear Ring . . . . 5-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Removing Reverse Gate, Rudder And
Nozzle As An Assembly . . . . . . . . . . . . . . 5-10
Stator Removal . . . . . . . . . . . . . . . . . . . . . 5-10
Impeller Removal . . . . . . . . . . . . . . . . . . . 5-11
Inspecting Components . . . . . . . . . . . . . . . . 5-11
Installing Impeller . . . . . . . . . . . . . . . . . . . . . . 5-11
Removing Jet Drive From Boat . . . . . . . . . . . . . 5-12
Drive Housing Disassembly And Reassembly 5-13
Pinion Shaft Removal . . . . . . . . . . . . . . . . . . 5-13
Impeller Shaft Removal . . . . . . . . . . . . . . . . . 5-14
Shimming Procedures . . . . . . . . . . . . . . . . . . 5-17
5-0 - PUMP UNIT 90-852396 MAY 1996

Forward and reverse drive and the neutral position
General Information are achieved by the position of a reverse gate lo-
NOTE: Due to running changes, some illustrations cated just aft of the nozzle. Forward drive has the
may not be exactly the same as your drive unit. Ser- reverse gate clearing the nozzle to allow all the
vice procedures remain the same unless otherwise thrust to be directed straight back. Reverse drive
noted. has the reverse gate covering the entire opening
enough to divert the thrust forward. Neutral position
Principles of Operation has the reverse gate covering 75 percent of the
The jet pump operates by drawing water into a nozzle to direct the water stream forward and down-
housing forward of the impeller. The water is pres- ward, as well as backward. The shift position is con-
surized within the specially designed housing and trolled at the control box in the boat.
then directed to the rear to provide thrust and mo-
tion.
a
c
a
54896
b
a - Reverse Gate (Shown In the Reverse Position)
54898
a - Forward Motion c - Reverse Gate
b - Water Thrust (Shown In the Forward
Position)
The jet pump is equipped with a steerable nozzle

(rudder) at the aft end of the pump housing that di-
rects the thrust of water. The jet of water can be di-
rected right or left when the operator turns the steer-
ing wheel in the respective direction. When the op-
erator turns the steering wheel to the right, for exam-
ple, the nozzle turns to the right and the jet force
from the nozzle pushes the stern of the boat to the
left causing the bow of the boat to turn right.
90-852396 MAY 1996 PUMP UNIT - 5-1

Special Tools
Jet Pump Tool Kit 91-809957A1 a b
Description Part Number
a Pre-Load Kit 91-824871A2
Impeller Shaft
b Thread Extender Kit 91-824869A1
used w/ Backlash Kit
c Seal Protector 91-850233 c d
Impeller Shaft
d Impeller Shaft Wrench 91-832093A1
e
e Impeller Nut Socket 91-850297
f Pinion Gear Location Tool 91-831897
g Bearing Installer 91-832016
press ball bearing and
seals into pinion shaft
housing g
f
h Bushing Installer 91-850831 h
stator bushings & seal
i Seal Installer 91-832019
impeller shaft seals in
drive housing
j Bearing Installer 91-832017
impeller shaft ball
bearing in drive housing i j
k Bearing Cup Installer 91-832018
pinion shaft housing and
drive housing front cover
l Handle Driver 91-824892 k
Backlash Indicator Flag 91-53459

use MCII line
Dial Indicator Kit 91-58222A1
l
Dial Indicator Adapter Kit 91-83155
Slide Hammer 91-34569A1
Bearing Puller Kit 91-83165M
Retaining Ring Pliers 91-25081
Lubricants/Adhesives Part Number
Loctite, #271 92-809820
Loctite, #242 Obtain Locally
Perfect Seal 92-34227--1
2-4-C Lubricant w/ Teflon 92-825407A12
Special Lube 101 92-13872A1
Hi Performance Gear Lube 92-19007A24
5-2 - PUMP UNIT 90-852396 MAY 1996

NOTES:
90-852396 MAY 1996 PUMP UNIT - 5-3

DRIVE HOUSING COMPONENTS
16
15
6
5
4 7 2
14 5 1
6 3
7
13
17 5
12
18
4
11
18
21
8 20
8 19
9
10 22
23
25
24 26
66
27
28
85 29
31
66 Loctite “242” (Purchase Locally)

30 66
85 RTV Silicone Sealer (92-809825)
5-4 - PUMP UNIT 90-852396 MAY 1996

DRIVE HOUSING COMPONENTS
TORQUE
REF.
1 1 HOUSING ASSY-Drive (Basic) (Painted)
2 1 PIN-Dowel
3 1 FITTING-Syphon Drain Hose
4 2 FOAM-Exhaust Deflector w/ 3-M #874 Adhesive
5 6 STUD (M10 x 76) w/ 271 Loctite
6 12 NUT (M10) 35 47
7 4 STUD (M10 x 55) w/ 271 Loctite
8 2 SEAL-Oil
9 1 BEARING-Ball
10 1 RING-Snap
11 1 GASKET-Drive Housing
12 1 COVER ASSY W/Gaskets-Drive Housing (Painted)
13 2 STUD (M10 x 66)
14 1 O RING
15 1 GASKET-Cover To Adapter Plate
16 AR GROMMET-Pump Mount (.250)
AR GROMMET-Pump Mount (.375)
AR GROMMET-Pump Mount (.500)
17 1 NUT (M8)
18 2 BAFFLE ASSEMBLY-Exhaust
19 1 SCREW (M8 x 240))
20 2 SCREW KIT
21 2 WASHER-Sealing
22 1 SEAL-Ride Plate, Self Locking
23 1 SCREEN-Inlet (Painted)
24 2 SCREW (M8 x 16) w/ Loctite 242 200 23
25 2 SCREW With Nylon Patch (M6 x 20) w/ Loctite 242 75 8.5
26 1 PLATE-Trim
27 2 NUT (M8)
28 2 WASHER
29 2 SCREW (M8 x 35) 35 47
30 1 RIDE PLATE KIT (Painted)
31 16 SCREW With Nylon Patch (M6 x 13) w/ Loctite 242 75 8.5
90-852396 MAY 1996 PUMP UNIT - 5-5

PINION & IMPELLER SHAFT
1
4 7
5
2
9
3
6
95
7
95
11
16
13 12 10 108
17
14
18 15
7 Loctite “271” (92-809820)
95 2-4-C w/Teflon (92-825407A12)
108 Special Lubricant 101 (92-13872A1)
5-6 - PUMP UNIT 90-852396 MAY 1996

PINION & IMPELLER SHAFT
TORQUE
REF.
1 1 RING-Rubber
2 4 SCREW (M8 x 25) 180 20.3
3 1 HOUSING ASSEMBLY-Pinion Shaft (Painted)
4 2 SEAL-Pinion Shaft Housing
5 1 BEARING-Ball
6 1 BEARING SET
7 1 O RING
AR SHIM (Red) (.002)
AR SHIM (Beige) (.004)
AR SHIM (Blue) (.005)
8
AR SHIM (Frost/Clear) (.0075)
AR SHIM (Brown) (.010)
AR SHIM (Yellow) (.020)
9 1 GEAR/SHAFT ASSEMBLY-Pinion
10 1 SHAFT-Impeller
11 1 GEAR-Impeller Shaft
12 1 WASHER
13 1 NUT (M14) 90 122
AR SHIM (Red) (.002)
AR SHIM (Beige) (.004)
AR SHIM (Blue) (.005)
14
AR SHIM (Frost/Clear) (.0075)
AR SHIM (Brown) (.010)
AR SHIM (Yellow) (.020)
15 1 COVER ASSEMBLY-Impeller Shaft (Painted)
16 1 BEARING SET
17 1 O RING
18 4 SCREW (M8 x 25) 180 20.3
90-852396 MAY 1996 PUMP UNIT - 5-7

NOZZLE/RUDDER COMPONENTS
1 2
3
4
5
7
10
7
6
87
10 9
25 24 7 11 9
12
20 19
2122
13
23 14
12 7
15
26
22 16
21 20
17 7
18
29
30
28
35 27
31
36 31
32
37
33
40
39
38
34
7 Loctite “271” (92-809820)
5-8 - PUMP UNIT 90-852396 MAY 1996

NOZZLE/RUDDER COMPONENTS
TORQUE
REF.
1 1 PIN-Clevis
2 1 CONNECTOR-Cable End
3 1 WASHER
4 1 PIN-Cotter
5 1 GATE ASSEMBLY (Painted)
6 1 SCREW (M6 x 13)
7 1 ANODE
8 1 LOCKWASHER (.250 Internal)
9 2 BUSHING-Pivot
10 4 BOLT-Pivot w/ Loctite 271 50 68
11 1 RUDDER KIT (Painted)
12 2 BUSHING-Pivot
13 1 LOCKWASHER (.250 Internal)
14 1 ANODE
15 1 SCREW (M6 x 13)
16 2 SCREW (M10 x 45) 35 47
17 1 ANODE
18 2 LOCKWASHER (.437 External)
19 2 SCREW (M10 x 35) 35 47
20 2 SCREW (M8 x 30) 120 13.5
21 2 WASHER
22 2 STOP-Reverse Gate
23 1 NOZZLE ASSY-W/Pivot Bushings (Painted)
24 1 FITTING-Nozzle
25 1 HOSE-Syphon (12.00 In.)
26 4 SCREW (M10 x 150) 35 47
27 1 STATOR ASSEMBLY (Painted)
28 1 PLUG-Pipe
29 1 SCREW KIT 50 5.6
30 1 WASHER-Sealing
31 2 BUSHING-Stator Rear
32 1 SEAL
33 2 WASHER-Tab
34 1 RING KIT-Wear (Painted)
35 1 PLUG-Pipe (.750-14)
36 1 O RING
37 1 O RING
38 1 IMPELLER KIT-SS-5 Blade
39 1 TAB WASHER-Impeller Shaft
40 1 NUT-Impeller Shaft 150 203
90-852396 MAY 1996 PUMP UNIT - 5-9

Servicing Stator, Impeller STATOR REMOVAL
4. Remove two screws securing trim plate to ride
and Wear Ring plate and wear ring.
Disassembly
1. Disconnect spark plug leads from spark plugs.
2. Disconnect shift and steering cables at Reverse
gate and Rudder.
a b
b
a 28252
a - Screws (2) to Trim Plate & Wear Ring

b - Trim Plate
5. Remove four screws securing stator assembly to
drive housing. Remove stator assembly.
54896
a - Shift Cable
b - Steering Cable
IMPORTANT: This procedure lists the dissas-
sembly of external pump components. If servic-
ing a specific component, follow the procedure in
that section.
c
REMOVING REVERSE GATE, RUDDER AND 28253
NOZZLE AS AN ASSEMBLY c - Stator
3. Remove four screws securing nozzle to stator. 6. Drain stator by tilting stator forward and allowing
Remove reverse gate/rudder/nozzle assembly. the oil to drain over the impeller shaft seals.
Complete oil draining by removing stator fill
screw and pour the remaining oil out the fill screw
hole.
c 54579
c - Screws (4)
5-10 - PUMP UNIT 90-852396 MAY 1996

IMPELLER REMOVAL 3. Inspect seal in stator for wear/damage.
7. If removed, install wear ring to support impeller 4. Inspect bellows on cables for wear.
and shaft during impeller removal.
5. Inspect anodes, replace as necessary.
8. Remove inlet screen on bottom of drive housing
6. Inspect pivot pins and bushings, replace as nec-
to allow access to machined flats on impeller
essary. Torque on reverse gate and rudder pivot
shaft. If using Special Tool 91-832093A1 to hold
pins is 50 lb. ft. (68 N·m). Use Loctite 271 on
impeller shaft, inlet screen does not need to be
threads.
removed.
7. Inspect impeller for cracks and damaged blades.
9. Straighten tabs on impeller tab washer.
8. Inspect stator vanes for cracks and/or damage.
10. While holding impeller shaft, remove impeller nut
using Special Tool 91-850297. Impeller nut is a 9. If replacement is required, remove stator seal us-
standard right hand thread. Remove impeller. ing Puller 91-83165M.
a 28252
a - Special Tool 91-850297

b - Special Tool 91-832093A1
11. Remove wear ring.

28256
Inspecting Components
10. Install new seal using Special Tool 91-850831.
1. Inspect wear ring for excessive scoring and/or Smaller diameter seal lip faces out.
grooves. Replace wear ring if deep grooves are
present or if severe scoring has taken place.
2. Ensure O-ring is in counterbore before installing Installing Impeller
wear ring to drive housing. 1. Lubricate splines of impeller shaft with Special
c Lube 101 (92-13872A1).
2. Install impeller, tab washer and nut on impeller
shaft. Locate bent tab in impeller slot. Torque im-
peller nut to 150 lb. ft. (203 N·m). Bend one tab
against flat on nut.
3. Install inlet screen. Apply Loctite 242 to threads
of screws and bolts. Torque the two 6 mm screws
to 75 lb. in. (8.5 N·m). Torque the two 8 mm bolts
to 200 lb. in. (22.5 N·m).
4. Install wear ring and stator. Apply Perfect Seal to
threads of four bolts. Torque to 35 lb. ft. (47 N·m).
d 28255
c - O-rings
d - Inspect Surface for Grooves/Scoring
90-852396 MAY 1996 PUMP UNIT - 5-11

5. Remove stator fill screw with washer and fill sta- 1. Disconnect shift and steering cables from re-
tor with High Performance Gear Lube verse gate and rudder. Remove cable adaptors
(92-13783A24) until oil flows out fill hole (capac- and bellows assemblies. Loosen shift and steer-
ity is 19 fl. oz. / 550 cc). Install fill screw and ing cables at wear ring.
washer.
a b
54896
a - Shift Cable
a b - Steering Cable
54894 2. Loosen shift and steering cable thru hull fittings.
a - Fill Screw 3. Support pump.
6. Apply Loctite 242 to screws (2) securing trim
plate to the ride plate. Torque screws to 75 lb. in.
(8.5 N·m).
28257
WARNING
b
a 28252 The pump unit must be supported to prevent it
a - Screws (2) to Trim Plate & Wear Ring from dropping through the opening when the re-
b - Trim Plate maining fasteners are removed.
7. Install nozzle assembly and anode. Apply Loc- 4. Remove remaining four nuts from drive housing
tite 271 to threads of screws. Torque all four (4) cover. Remove drive housing cover and gasket.
screws to 35 lb. ft. (47 N·m).
a
8. Attach shift and steering cables.
REFER TO SECTION 1D: SPORT JET INSTALLA-
TION FOR SHIFT AND STEERING INSTALLATION
AND ADJUSTMENT.
Removing Jet Drive From

Boat
54980
REMOVE POWERHEAD AS OUTLINED IN SEC-
TION 4. a - Nuts (4)
5-12 - PUMP UNIT 90-852396 MAY 1996

5. Lower drive housing while sliding cables out. 3. Press pinion shaft out of pinion shaft housing.
Place on bench or suitable work stand for disas-
sembly/repair.
Drive Housing Disassembly

and Reassembly
Pinion Shaft Removal
1. Remove four screws securing pinion shaft hous-
ing to drive housing. Remove pinion shaft as-
sembly. 53796
4. Remove pinion shaft ball bearing and two seals

using Puller 91-83165M.
28257
NOTE: Take care not to damage or misplace colored

shims.
2. Remove rubber ring, O-ring and shims.
a 28264
b 5. Remove pinion shaft outer race from pinion shaft

housing using slide hammer 91-34569A1.
c
53797
a - Rubber Ring
b - Shims
c - O-ring 28265
90-852396 MAY 1996 PUMP UNIT - 5-13

6. Press new outer race into pinion shaft housing 10. Press pinion shaft into pinion housing.
using mandrel 91-832018.
28264
7. Remove tapered roller bearing from pinion shaft

using universal puller plate 91-37241.
28267
8. Press new tapered roller bearing onto pinion
shaft using Special Tool 91-827983. 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.
28265
9. Press new ball bearing into pinion shaft housing 28268

using Special Tool 91-832016.
a - Special Tool 91-820552
Impeller Shaft Removal

1. Remove Stator, Wear Ring and Impeller as de-
scribed in “Servicing Impeller”.
2. Remove stator fill screw, drain oil into a suitable
container.
3. Remove ride plate.
28266
5-14 - PUMP UNIT 90-852396 MAY 1996

4. Remove four screws securing impeller shaft cov- 6. Pull impeller shaft from drive housing.
er to drive housing. Remove cover.
28259
7. Remove bearing retaining ring from drive hous-

28257
ing.
NOTE: Take care not to damage or misplace colored
shims.
28258 28262
a - O-ring 8. Remove bearing using Puller 91-83165M.

b - Shims
5. Remove nut and washer from end of impeller
shaft. Remove impeller shaft gear.
28263
9. Remove impeller shaft seals using Slide Ham-

mer 91-34569A1.
28259
90-852396 MAY 1996 PUMP UNIT - 5-15

10. Install new seals using Special Tool 91-832019. 14. Press new bearing on gear using an appropriate
size mandrel.
28260
11. Install new bearing using Special Tool 28270

91-832017.
15. If replacing bearing, remove outer race from
front cover using slide hammer. Press new outer
race in cover using suitable mandrel.
28261
12. Install retaining ring in drive housing after bear-

ing is installed.
13. If replacing impeller shaft gear bearing, remove
using universal plate.
a
54985
b
28269
a - Suitable Mandrel
b - Universal Plate
5-16 - PUMP UNIT 90-852396 MAY 1996

Shimming Procedures 5. Insert feeler gauge through hole in pinion loca-
tion tool between gauging surface of tool and
NOTE: Pinion gear shimming and backlash proce- flats on bottom of pinion gear teeth.
dures must be preformed when any of the following
components have been replaced: IMPORTANT: The correct clearance is .025 inch
(0.64 mm).
a. Jet Drive Housing
6. Use .025 inch (.064 mm) feeler gauge as a start-
b. Pinion Gear ing thickness. Adjust thickness of feeler gauge
c. Pinion Gear Bearing Assembly until a slight drag is felt as gauge is drawn out be-
tween gauging surface of tool and pinion gear.
d. Pinion Shaft Housing
NOTE: Once the thickness is determined, the differ-
e. Impeller Gear ence between feeler gauge thickness and .025 inch
f. Impeller Gear Bearing Assembly (0.64mm) required clearance must be either added
or subtracted from the total thickness of shims be-
g. Impeller Shaft Front Cover tween pinion shaft housing and drive housing.
NOTE: Shims are color coded to represent different • Remove the screws securing the pinion shaft
thicknesses. These color codes apply to both pinion housing assembly to the drive housing. Lift as-
housing shims and impeller cover shims. sembly out of the drive housing.
Red .002 in. (.05 mm) • Adjust shim thickness as required.
Beige .004 in. (.10 mm) 7. Install seal protector, Special Tool 91-850233,
Blue .005 in. (.127 mm) on impeller shaft. Install impeller shaft in drive
housing, then remove seal protector.
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. Torque screws to 180 lb. in. (20.3 N·m).
a 54986
a - Seal Protector, Special Tool 91-850233
28271
3. Rotate pinion shaft ten revolutions to properly

seat roller bearings.
4. Insert Pinion Location Tool (Special Tool
91-824890) in drive housing.
NOTE: Carefully inspect location tool to make sure it
is seated in drive housing bearing.
90-852396 MAY 1996 PUMP UNIT - 5-17

8. Install gear/bearing assembly and washer on im- 11. Install impeller shaft pre-load tool
peller shaft. Apply Loctite 271 to threads of im- (91-824871A2).
peller shaft. Hold impeller shaft with Special Tool
91-832093A1. Install nut and torque to 90 lb. ft.
(122 N·m).
54983
a b c
a - Spring Seat, Rear
b - Spring
c - Spring Seat, Forward
12. Install wear ring and stator on impeller shaft. Se-
28257
cure assembly with two bolts (opposite corners).
Torque bolts to 35 lb. ft. (47 N·m).
9. Install original shims on impeller shaft cover. • Rotate impeller shaft ten revolutions to properly
Install O-ring on impeller shaft cover. seat roller bearings.
NOTE: If original shims are not available, start with 13. Install Backlash Indicator Rod (Special Tool No.
.030 in. (.76 mm) shims (three brown colored shims). 91-53459) on pinion shaft.
• Lubricate O-ring and bore with Quicksilver lubri-
cant 2-4-C.
• Lubricate cone bearing with gearcase lubricant.
10. Install impeller shaft cover. Torque screws to 180
lb. in. (20.3 N·m).
54987
28257
14. Install Dial Indicator Kit, Adapter Kit and Thread
Extender Kit.
• Position rod from dial indicator on the center
mark “II” of the backlash indicator rod.
5-18 - PUMP UNIT 90-852396 MAY 1996

15. Rotate pinion shaft back and forth lightly to con-
tact 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 be-
tween impeller cover and drive housing.
• If reading is more than maximum remove shims
between impeller cover and drive housing.
• Ratio of backlash reading to shims is 1:1.
16. Install impeller, wear ring and stator as outlined
in “Installing Impeller” in this section.
17. Apply RTV Sealant (92-809825) on rideplate.
Install rideplate. DO NOT reuse screws. Apply
Loctite 242 to threads of new screws. Torque to
75 lb. in. (8.5 N·m).
18. Install nozzle/reverse gate assembly and anode.
Apply Loctite #271 to threads of screws. Torque
all four (4) screws to 35 lb. ft. (47 N·m).
19. Remove fill and vent screws from bottom of drive
housing. Fill drive housing with High Perfor-
mance Gear Lube. Capacity is 27 oz. (825 cc).
b
c
28272
a
a - Fill/Drain Screw
b - Vent Screw
c - RTV Sealant 92-809825
NOTE: To obtain correct oil level pump housing must
be level and upright.
REFER TO SECTION 1D: SPORT JET INSTALLA-
TION TO COMPLETE INSTALLATION OF DRIVE
HOUSING, SHIFT AND STEERING CABLE INSTAL-
LATION AND ADJUSTMENT.
90-852396 MAY 1996 PUMP UNIT - 5-19

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MODELS

175XR2 Sport Jet

Powerhead Pump Unit

Printed in U.S.A. 1997, Mercury Marine 90-852396R1 NOVEMBER 1997

90-852396 MAY 1996 IMPORTANT INFORMATION - 1C-1

90-826148 R1 JANUARY 1993 POWERHEAD - 5A-7

Revision No. 1 Section Description

Month of Printing Section Number

Year of Printing Part of Section Letter

90-852396 MAY 1996 IMPORTANT INFORMATION - 1C-3

1C-4 - IMPORTANT INFORMATION 90-852396 MAY 1996

1A-0 - IMPORTANT INFORMATION 90-852396 MAY 1996

Standard 3.494 in. ± 0.001 in.

Battery Rating 670 Marine Carnking Amps (MCA)

90-852396 MAY 1996 IMPORTANT INFORMATION - 1A-1

Float Setting Set parallel to body flange

Firing Order 1-2-3-4-5-6

1A-2 - IMPORTANT INFORMATION 90-852396 MAY 1996

90-852396 MAY 1996 IMPORTANT INFORMATION - 1A-3

1B-0 - IMPORTANT INFORMATION 90-852396 MAY 1996

90-852396 MAY 1996 IMPORTANT INFORMATION - 1B-1

1B-2 - IMPORTANT INFORMATION 90-852396 MAY 1996

90-852396 MAY 1996 IMPORTANT INFORMATION - 1B-3

1B-4 - IMPORTANT INFORMATION 90-852396 MAY 1996

90-826148 R1 JANUARY 1993 POWERHEAD - 5A-7

Revision No. 1 Section Description

Month of Printing Section Number

Year of Printing Part of Section Letter

1C-0 - IMPORTANT INFORMATION 90-852396 MAY 1996

90-852396 MAY 1996 IMPORTANT INFORMATION - 1C-1

90-826148 R1 JANUARY 1993 POWERHEAD - 5A-7

Revision No. 1 Section Description

Month of Printing Section Number

Year of Printing Part of Section Letter

90-852396 MAY 1996 IMPORTANT INFORMATION - 1C-3

1C-4 - IMPORTANT INFORMATION 90-852396 MAY 1996

SPORT JET INSTALLATION

1D-0 - IMPORTANT INFORMATION 90-852396R1 NOVEMBER 1997

90-852396 MAY 1996 IMPORTANT INFORMATION - 1D-1

1D-2 - IMPORTANT INFORMATION 90-852396R1 NOVEMBER 1997

Engine Compartment Ventilation

Engine Compartment Specifications 28237

90-852396 MAY 1996 IMPORTANT INFORMATION - 1D-3

1D-4 - IMPORTANT INFORMATION 90-852396R1 NOVEMBER 1997

P Liquid Neoprene (92-25711--2)

90-852396 MAY 1996 IMPORTANT INFORMATION - 1D-5

Ability to use a 40 series shift cable WARNING

1D-6 - IMPORTANT INFORMATION 90-852396R1 NOVEMBER 1997

Tunnel Dimensions (in inches)

1 1/16 +/– 1/16

b 3/4 +/– 1/16

14 5/16 +/– 1/16

a 2 9/16 +/– 1/16

90-852396 MAY 1996 IMPORTANT INFORMATION - 1D-7

b Recommended Flange Flatness: .030 Inch

1 Inch Minimum Flange Width

Mounting Flange Thickness

Use Grommet P/N: