TIMING, SYNCHRONIZING, & ADJUSTING ELECTRICALww2.justanswer.com/uploads/OL/oldnewenglandmarine/2015-04-05_… · 2015-04-05 · Page 2C-4 90-881980R1 NOVEMBER 2001 Special Tools

2C

TIMING, SYNCHRONIZING, & ADJUSTING

90-881980R1 NOVEMBER 2001 Page 2C-1

ELECTRICALSection 2C - Timing, Synchronizing, & Adjusting

Table of Contents

Specifications 2C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 2C-4. . . . . . . . . . . . . . . . . . . . . . . . . . . Timing 2C-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Shutter Synchronization 2C-7. . . . . . . Throttle Cam Adjustment 2C-11. . . . . . . . . . . . . . Throttle Position Sensor (TPS) andThrottle Shaft Adjustment 2C-13. . . . . . . . . . . . . .


Page 2C-2 90-881980R1 NOVEMBER 2001

Specifications

IGNITIONSYSTEM

Readings taken @68°F (20°C).

TypeSpark Plug:

TypeGapHex SizeTorqueHole Size

Firing OrderIgnition Timing:

@ Idle (750 rpm)@ WOT (6000 rpm)

Stator Coil Output - Peak Voltage:@ 400 rpm (Cranking)@ 750 rpm (Idle) @ 1500 rpm@ 3500 rpm

Stator Coil ResistanceCrank Position Sensor - Peak Voltage:

@ 400 rpm (Cranking)@ 750 rpm (Idle)@ 1500 rpm@ 3500 rpm

Crank Position Sensor ResistanceECM (Coil Primary) - Peak Voltage:

@ 400 rpm (Cranking)@ 750 rpm (Idle)@ 1500 rpm@ 3500 rpm

Ignition Coil ResistancePrimarySecondary (Between Boots)

Coil for Cylinders 1 & 4Coil for Cylinders 2 & 3

Engine Protection Controls:Engine Speed Limiter

Spark Cut-Out to Cylinders #1 or #4#1 and #4#1, #4, and #2 or #3#1, #2, #3, and #4

Overheat/Low Oil Pressure Engine Speed Control (Spark Cut-Out to Cylinders #1 and #4).

Water Temperature Sensor:Warning Horn/rpm Reduction.Reset Temperature and Closed Throttle.

Engine Oil Pressure Switch:Warning Horn/rpm Reduction

Microcomputer-ECM

NGK LFR6A-110.039 - 0.043 in. (1.0 - 1.1 mm)

5/8 in. (16 mm)18 lb-ft (25 Nm)

14 mm1-3-4-2

4° A.T.D.C20° B.T.D.C

10 - 18 V16 - 24 V16 - 24 V16 - 24 V

0.2 - 0.8 Ω

3.0 -6.3 V9 - 16 V

18 - 28 V35 - 55 V

445 - 565 Ω

180 - 320 V180 - 235 V230 -290 V280 - 340 V

1.8 - 2.6 Ω

18.97 - 35.23 kΩ18.55 - 34.45 kΩ

6200 rpm6250 rpm 6350 rpm6450 rpm

Gradually Lowers to 2000 rpm

194°F (90°C)

167°F (75°C)

Continuity Below 21.78 psi (150 kPa)



IGNITIONSYSTEM

Readings taken @68°F (20°C).

Reset Pressure and Closed Throttle.

Engine Water Temperature SensorResistance:

@ 41°F (5°C)@ 68°F (20°C)@ 212°F (100°C)

Throttle Position Sensor (TPS):Input Voltage @ Idle (750 rpm)Output Voltage@ Idle (750 rpm)

No Continuity Above 21.78 psi (150 kPa)

4.62 kΩ2.44 kΩ0.19 kΩ

5.0 ± 0.25 V0.718 - 0.746 V

NOTE: The 115 four stroke ECM unit electronically controls the ignition timing, thereforemaking the ignition timing non adjustable. When initially running the outboard, use a timinglight to verify that the ignition timing falls within the timing windows. If the ignition timing doesnot stay within the timing windows, replace the ignition ECM unit and retest.



Special Tools

1. New Style Vacuummate Carburetor Tuner P/N 91-809871-1

2. Old Style Mercury Filled Carburetor Tuner P/N 91-809641A1Filters (4) P/N 35-18206

3. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1

4. Timing Light P/N 91-99379



Timing

WARNINGTo prevent personal injury or possible death, from loss of balance or stability whileservicing the motor, DO NOT attempt to check timing while boat is in motion. Failureto follow one of the recommended servicing procedures may result in the personfalling overboard or causing personal injury from fall in boat.

WARNINGTo prevent personal injury from spinning flywheel, Do Not attempt to remove fly-wheel cover or place hands on top of cover when checking ignition timing.

Ignition timing is not adjustable. The ECM unit electronically controls the ignition timing.

When initially running the outboard, use a timing light to verify that the ignition timing fallswithin the timing windows as described within the following tests. If the ignition timing doesnot stay within the timing windows, replace the ignition ECM unit and retest. (Refer to theIgnition Diagnostic Procedures tests in Section 2A.)

IMPORTANT: When checking the timing with the engine running, one of the followingtest procedures must be followed.

Check maximum timing per specification while running the outboard:

• IN A TEST TANK (with a cut down propeller).

• ON A DYNAMOMETER.

• ON A BOAT SECURED ON A TRAILER “Backed in W ater” (with a cut down propeller).

1. Attach timing light to #1 spark plug lead.

2. Place the outboard in “Forward” gear and check timing at idle “Retarded.” (If not withinspecification window, refer to Diagnostic Test Procedures Section 2A.)

a

b58684

a - Timing Mark (4° ATDC) (Full Retarded)b - Pointer



3. Slowly increase the engine rpm while watching the ignition timing marks. The timingshould increase to the maximum timing specification “Full Advance” at approximately6000 RPM. (If not within specification window, refer to Diagnostic Test Procedures Sec-tion 2A.)

a

b

20

a - Timing Mark (26° BTDC) (Full Advance)b - Timing Pointer



Throttle Shutter SynchronizationNOTE: The cylinders are synchronized by adjusting the intake manifold vacuum on the in-take manifold. Use Carburetor Tuner (91-809641A1) or Vacuummate Tuner (91-809871--1)to measure the vacuum.

1. Remove four plugs from the intake manifold.

a

a

58673

a

a

a

a - Plugs (4)



2. Install intake manifold hose adaptor in each plug hole. Tighten securely.

3. Connect the Vacuummate to the hose adaptors.

4. If using Carburetor Tuner (91-809641A1), install filters to prevent mercury being drawninto engine during an abrupt throttle change.

a

b

c

58682

a - Intake Manifold Hose Adaptor (4) From Vacuummate Carb. Tunerb - Intake Manifold Hose Adaptor (4) From Mercury Filled Carb Tunerc - Vacuummate Carb. Tuner (91-809871--1)

CAUTIONDo not run engine at high rpm or abruptly change throttle position when using theold style liquid mercury filled carb. tuner (91-809641). The possibility exists of draw-ing liquid mercury from the carb tuner into the engine during high rpm running oran abrupt throttle change. Installing filters (4) (35-18206) in each line will help to pre-vent liquid mercury from being drawn into engine during an accidental abruptthrottle change.



5. With the outboard in water, start engine and allow to warm up until engine idles at 750± 50 rpm in neutral.

6. Connect a tachometer onto the spark plug lead of cylinder #4.

7. Turn the synchronizing screw so that vacuum pressures on cylinders #3 and #4 are with-in 3 cm Hg (40 mbar, 1.18 in Hg) of minimum and maximum vacuum pressures of cylin-ders #1 and #2. It’s not important to be at any specific vacuum setting.

NOTE: The vacuum pressure of cylinders #3 and #4 will most likely never be exactly thesame as cylinders #1 and #2 due to mechanical tolerances and different operating efficien-cies of individual cylinders.

58682

Example

32 cm

30 cm

28 cm

26 cm

Cyl.# 4

Cyl.#3

Cyl.# 2

If the vacuum reading of Cyl. #1 and #2 (base vacuum) is 30cm, then adjust synchronization screw to achieve 30 cm forcylinders #3 and #4.

Cyl.# 1

NOTE: Tighten screw to increase vacuum. Loosen screw to decrease vacuum.


Page 2C-10 90-881980R1 NOVEMBER 2001

a

58641

a - Synchronizing Screw

8. Rev engine a few times and then allow engine to idle for 15 seconds.

9. Check that vacuum reading of each cylinder did not change more than 30 mm Hg (40mbar, 1.18 in Hg). Readjust if necessary.

10. Verify idle speed is 750 ± 50 rpm in neutral.

11. Stop engine, remove adaptors and reinstall plugs.


90-881980R1 NOVEMBER 2001 Page 2C-11

Throttle Cam AdjustmentRemove screws attaching sound attenuator. Remove attenuator to provide access tothrottle cam.

58681

a

a

a

a

a

a - Screws (9)Check throttle pickup timing (using “Checking Steps” below, adjust if incorrectly set using“Adjustment Steps” below).

CHECKING STEPS1. Move throttle control lever to the full retard position (throttle arm against throttle stop at

idle).

2. Verify idle speed arm is against idle speed screw.

58576

a

bc

d

e

a - Throttle Control Leverb - Throttle Stopc - Throttle Arm

d - Idle Speed Arme - Idle Speed Screw


Page 2C-12 90-881980R1 NOVEMBER 2001

3. Pointer on cam should align with center of cam follower while maintaining a 0.020 in.(0.5 mm) gap between follower and cam.

58683

a

b

c

a - Pointerb - Cam Follower

c - 0.020 in. (0.5 mm)

ADJUSTMENT STEPS

1. If 0.020 in. (0.5 mm) gap does not exist, unsnap ball connector from ball on cam.

2. Thread connector in or out to obtain proper clearance. Tighten jam nut on connector.

NOTE: Proper clearance between cam follower and cam will take precedence to exactalignment of pointer on cam to center of cam follower.

58683

a

b

c

d

e

a - Ball Connectorb - Throttle Camc - Pointer

d - Cam Followere - Jam Nut


90-881980R1 NOVEMBER 2001 Page 2C-13

3. Reinstall sound attenuator. Tighten screws to specified torque.

Sound Attenuator Screw Torque

70 lb-in. (8 Nm)

Throttle Position Sensor (TPS) and Throttle Shaft AdjustmentThe Throttle Position Sensor and throttle shaft are pre-set at factory during emission calibra-tion.

No adjustments should normally be made to these components as emission performancewill be compromised.

However, should it be necessary to replace the Throttle Position Sensor or throttle body, thenew components should be adjusted to initial factory emission specifications as follows:

1. Remove 9 screws attaching sound attenuator and remove attenuator.

2. Disconnect the Throttle Position Sensor harness.

3. Install TPS Test Harness (91-881827) between TPS and TPS harness.

91-881827

58659

b

a

c

58659a - Throttle Position Sensorb - TPS Test Harness (91-881827)c - TPS Harness

4. Turn ignition switch to the “RUN” position.

5. Connect DMT 2000 (91-854009A1) test leads to the TPS Test Harness – RED to PINK;BLACK to BLACK.


Page 2C-14 90-881980R1 NOVEMBER 2001

6. Loosen synchronizing screw to allow cylinders #3 and #4 throttle shutter to open.

7. Loosen throttle plate screw to fully close cylinders #1 and #2 throttle shutter.

a

58641

b

a - Synchronizing Screwb - Throttle Plate Screw

8. Adjust the position of Throttle Position Sensor until the (DC) output voltage is 0.7 ± 0.01volts.

9. Operate the throttle shaft several times.

10. Record the value.

11. Slowly tighten the synchronizing screw until throttle shutters for cylinders #3 and #4 justclose.

12. Slowly tighten the throttle plate screw until a 0.032 ± 0.004 volt increase over the pre-viously recorded value is observed.

13. Operate the throttle shaft several times.


90-881980R1 NOVEMBER 2001 Page 2C-15

14. With the throttle arm against the throttle stop, verify throttle cam mark is aligned with thecenter of the cam follower while maintaining a 0.020 in. (0.5 mm) gap between followerand cam. Check that output voltage has not changed.

NOTE: Proper clearance between cam follower and cam will take precedence to exactalignment of pointer on cam to center of cam follower.

58683

g

e

h

f

58576

c

b

d

a

a - Synchronizing Screwb - Throttle Plate Screwc - Throttle Armd - Throttle Stop

e - Cam Markf - Camg - Cam Followerh - 0.020 in. (0.5 mm)

15. Reinstall sound attenuator. Tighten attaching screws to specified torque.

Sound Attenuator Screw Torque

70 lb-in. (8 Nm)

16. Start engine.

17. Check output voltage of Throttle Position Sensor. If TPS voltage is not within 0.718 –0.746 volts, readjust TPS sensor.

18. Verify throttle shutters are synchronized. Refer to “Throttle Shutter Synchronization,”preceding.

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TIMING, SYNCHRONIZING, & ADJUSTING ELECTRICALww2.justanswer.com/uploads/OL/oldnewenglandmarine/2015-04-05_… · 2015-04-05 · Page 2C-4 90-881980R1 NOVEMBER 2001 Special Tools