TIMING, SYNCHRONIZING & ADJUSTING ELECTRICAL...Gap NGK-BPZ8H510.040 Firing Order 1-2-3-4-5-6 TIMING, SYNCHRONIZING & ADJUSTING Page 2C-2 90-877837 NOVEMBER 1999 210 HP TIMING, SYNCHRONIZING

2C

TIMING, SYNCHRONIZING & ADJUSTING

90-877837 NOVEMBER 1999 Page 2C-1

ELECTRICALSection 2C - Timing, Synchronizing & Adjusting

Table of Contents

Specifications 2C-1. . . . . . . . . . . . . . . . . . . . . . . . . . 210 HP Timing/Synchronizing/Adjusting 2C-1. . . Special Tools 2C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 2C-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Pointer Adjustment 2C-3. . . . . . . . . . . . . Carburetor Synchronization 2C-4. . . . . . . . . . . .

Timing Adjustment 2C-6. . . . . . . . . . . . . . . . . . . . . . Maximum Timing Adjustment 2C-6. . . . . . . . . . Primary Pickup Timing Adjustment 2C-6. . . . . . Idle Speed Adjustment 2C-7. . . . . . . . . . . . . . . .

240 HP Timing/Synchronizing/Adjusting 2C-8. . . Special Tools 2C-8. . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 2C-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Pointer Adjustment 2C-10. . . . . . . . . . . . . Timing Adjustment 2C-11. . . . . . . . . . . . . . . . . . . . Throttle Cam Adjustment 2C-11. . . . . . . . . . . . . . Static Idle Timing Adjustment (Cranking Engine with Starter) 2C-12. . . . . . . . . Static Maximum Timing Adjustment (Cranking Engine with Starter) 2C-13. . . . . . . . . Maximum Throttle 2C-13. . . . . . . . . . . . . . . . . . . . Throttle Position Sensor (TPS) Adjustment 2C-14. . . . . . . . . . . . . . . . . . . . Idle Timing (Engine Running) 2C-16. . . . . . . . . . Idle Adjustment 2C-17. . . . . . . . . . . . . . . . . . . . . . Throttle Valve/Oil Pump Synchronization 2C-18

Specifications

210 HP

Full Throttle RPM Range 5000-5500

Idle RPM 1000 - 1100

Maximum Timing:@ Cranking Speed@ 5000 RPM

24° BTDC22° BTDC

Idle Speed/Pickup Timing 6° �2° BTDC

Spark Plug NGK-BU8H or BUZ8HSurface Gap

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

240 HP

Full Throttle RPM Range 5750-6250

Idle RPM 1000 - 1100

Maximum Timing:@ Cranking Speed 26° BTDC

Idle Speed/Pickup Timing 6° BTDC

Spark PlugGap

NGK-BPZ8H510.040

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


Page 2C-2 90-877837 NOVEMBER 1999

210 HP TIMING, SYNCHRONIZING & ADJUSTING

Special Tools

Dial Indicator 91-58222A1

Timing Light 91-99379

Spark Gap Tester 91-850439

55117

Spark Gap Lead Wire Extension Kit (6 each) 91-877870A1

58189


90-877837 NOVEMBER 1999 Page 2C-3

Adjustments

Timing Pointer Adjustment

WARNINGEngine could start when turning flywheel to check timing pointer adjustment. Re-move all spark plugs from engine to prevent engine from starting.

1. Remove all spark plugs and install Dial Indicator (91-58222A1 ) into No. 1 cylinder (topcylinder, starboard bank).

28244

2. Turn flywheel in a clockwise direction until No. 1 piston is at top dead center (TDC). Setdial indicator at “O” (zero) and tighten indicator set screw.

3. Turn flywheel counterclockwise until dial indicator needle is approximately 1/4-turn be-yond .462 in., then turn flywheel clockwise so that dial indicator 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 (b).

28245

a

bb

a - Timing Pointerb - Pointer Attaching Screws

5. Remove dial indicator from cylinder.


Page 2C-4 90-877837 NOVEMBER 1999

Carburetor Synchronization1. Loosen 3 carburetor synchronization screws (a) to allow shutter plates to close com-

pletely.

2. Position throttle lever so that idle stop screw is against idle stop and move roller arm untilroller lightly touches throttle cam (b). Adjust idle stop screw (c) on throttle arm to alignmark (d) on throttle cam with center of roller. Without moving roller from this position,retighten carburetor synchronization screws.

55087

b

d

a

a

a

c

a - Carburetor Synchronization Screwsb - Throttle Camc - Idle Stop Screwd - Alignment Mark

3. Verify throttle shutter plates open and close simultaneously during throttle lever opera-tion. Readjust if necessary.


90-877837 NOVEMBER 1999 Page 2C-5

4. Move throttle lever to wide-open-throttle (W.O.T.) position and adjust full throttle stopscrew (a) to allow full throttle shutter opening at W.O.T. Verify that throttle shutters donot act as a throttle stop. Allow .010 in. - .015 in. (.25mm - .38mm) clearance betweenthrottle shaft arm(b) and stop (c) at W.O.T. Retighten jam nut on adjustment screw.

55086

b

d

c

a

a - Full Throttle Screwb - Throttle Shaft Armc - Throttle Shaft Arm Stopd - .010 - .015 in. (0.25 mm - 0.38 mm)

CARBURETOR/OIL PUMP SYNCHRONIZATION

1. When carburetor linkage is at idle position, alignment mark (a) on oil injection arm shouldbe in-line with mark on casting (b) as shown. If necessary, adjust link rod (c).

a b

c

a - Alignment Markb - Casting Alignment Markc - Link Rod


Page 2C-6 90-877837 NOVEMBER 1999

Timing Adjustment

CAUTIONEngine may be timed while cranking engine with starter motor. To prevent engine from start-ing when being cranked, all spark plugs must be removed.

1. Disconnect remote fuel line from engine.

2. Connect remote control electrical harness to engine wiring harness.

3. Remove throttle cable barrel from barrel retainer.

4. Remove spark plugs and attach spark plug leads to the spark gap tester.

IMPORTANT: If trigger link rod was disassembled verify that 11/16 in. (17.5mm) lengthis retained.

28246

a

a - 11/16 in. (17.5 mm)

Maximum Timing Adjustment1. Connect timing light to No 1 spark plug lead (TOP STARBOARD BANK)

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 tim-ing mark to obtain 24� BTDC. Retighten jam nut on adjustment screw.

28247

b

b - Spark Advance Screw

Primary Pickup Timing Adjustment1. With engine in neutral, hold throttle arm so that idle stop screw is against idle stop. Crank

engine with starter motor and adjust throttle primary pickup screw to align specifiedthrottle primary pickup mark on timing decal with timing pointer. Retighten jam nut onadjustment screw.


90-877837 NOVEMBER 1999 Page 2C-7

NOTE: Primary pickup timing also determines engine RPM, refer to “Idle Speed Adjust-ment” following.

55087

a

b

a - Idle Stop Screwb - Primary Pick-Up Screw

NOTE: All timing adjustments made to engine under cranking speed conditions should beverified with engine running and adjustments made if necessary. This is due to advancecharacteristics of individual ignition systems.

2. Remove timing light from No. 1 spark plug lead.

3. Remove spark gap tool from each spark plug boot.

4. Install all spark plugs into cylinder heads. Torque spark plugs to 20 Ib. ft. (27 N·m) andattach spark plug leads to spark plugs.

Idle Speed Adjustment1. With engine in water, connect fuel line to engine. Start engine and allow to warm up.

2. Place engine in forward and monitor engine RPM. If RPM is above or below recom-mended RPM (see specifications), readjust primary pickup (b) screw to attain recom-mended engine speed. Retighten jam nut. Re-install throttle cable.

IMPORTANT: Below 3,000 RPM the TKS ECM advances idle timing 5 � until the enginereaches 104 �F (40�C). Above 3,000 RPM, the TKS ECM does not affect ignition timingregardless of engine temperature.

3. With end of throttle cable connected to throttle lever, hold throttle lever against idle stop.Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a verylight preload of 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 screwand idle stop. Preload is correct when paper can be removed without tearing but hassome drag on it. Readjust cable barrel, if necessary.

IMPORTANT: Excessive preload on throttle cable will cause difficulty when shiftingfrom forward to neutral. (Readjust throttle cable barrel, if necessary.)

NOTE: Carburetors are equipped with idle mixture adjustment screws. See carburetorspecifications for mixture screw adjustment.

NOTE: If sufficient throttle cable barrel adjustment is not available, check for correct installa-tion of link rod between the throttle lever and throttle cam. Each end of this link rod must bethreaded into its plastic barrel until it bottoms against the throttle lever or throttle cam cast-ing, then turned out only far enough to obtain correct orientation of link rod (less than oneturn). All timing adjustments must be reset after this procedure.


Page 2C-8 90-877837 NOVEMBER 1999

240 HP TIMING, SYNCHRONIZING & ADJUSTING

Special Tools

Dial Indicator 91-58222A1

Timing Light 91-99379

Digital Diagnostic Terminal (DDT) 91-823686A2

DDT Adaptor Cable 84-822560A5

DDT Interface Cable 84-825003A1


90-877837 NOVEMBER 1999 Page 2C-9

DMT 2000 Digital Tachometer/Multi-Meter 91-854009A1

TPS Test Harness 91-816085

Spark Gap Lead Wire Extension Kit (6 each) 91-877870A1

58189


Page 2C-10 90-877837 NOVEMBER 1999

Adjustments

Timing Pointer Adjustment

WARNINGEngine could start when turning flywheel to check timing pointer adjustment. Re-move all spark plugs from engine to prevent engine from starting.

1. Remove all spark plugs and install Dial Indicator (91-58222A1 ) into No. 1 cylinder (topcylinder, starboard bank).

2. Turn flywheel in a clockwise direction until No. 1 piston is at top dead center (TDC). Setdial indicator at “O” (zero) and tighten indicator set screw.

3. Turn flywheel counterclockwise until dial indicator needle is approximately 1/4 turn be-yond 0.462 in., then turn flywheel clockwise so that dial indicator reads 0.462 in.(11.7mm) exactly.

4. Reposition timing pointer (if necessary) so that timing pointer is aligned with 0.462 in.mark on timing decal. Retighten pointer attaching screws.

a

bc c

a - Timing Pointerb - 0.462 in. Markc - Attaching Screws

5. Remove dial indicator from cylinder.


90-877837 NOVEMBER 1999 Page 2C-11

Timing Adjustment

CAUTIONEngine is initially timed while cranking engine with starter motor. To prevent enginefrom starting when being cranked, all spark plugs must be removed, except No.1cylinder (top cylinder starboard bank) plug.

IMPORTANT: Control arm link rod (a) must maintain a length of 11/16 in. (17.5 mm).Make any necessary adjustments to link rod before proceeding with timing adjust-ments.

17.5 mm(11/16 in.)a

1. Remove all spark plugs except No.1 cylinder (top cylinder starboard bank) plug.

2. Disconnect remote fuel line from engine.

3. Connect remote control electrical harness to engine wiring harness.

4. Remove throttle cable barrel from barrel retainer.

Throttle Cam Adjustment1. Loosen cam follower screw (a) allowing cam follower to move freely.

2. Allow roller (b) to rest on throttle cam (c). Adjust idle stop screw (d) on throttle arm (e)to align mark (f) on throttle cam (c) with center of roller (b). Tighten jam nut (g).

3. While holding throttle arm against idle stop, tighten cam follower screw (a) with rollerlightly touching cam (c).

a

b c

d

e

fg


Page 2C-12 90-877837 NOVEMBER 1999

Static Idle Timing Adjustment (Cranking Engine with Starter)1. Disconnect WHITE/BLACK lead from idle stabilizer box at bullet connector. Disconnect

ECU harness for ignition timing procedure.

a

a - Idle Stabilizer Lead2. Connect timing light to No 1 spark plug lead (TOP STARBOARD BANK)

WARNINGWhile cranking engine, keep clear of propeller, as it may rotate.

IMPORTANT: To accurately time engine cranking speed, a fully charged battery mustbe used.

3. Connect timing light to no.1 cylinder spark plug lead. Crank engine with starter (about300 RPM) while holding throttle arm against idle stop. Adjust the primary pickup screwto attain appropriate setting. Tighten locknut.

a

b

c

a - Hold Throttle Arm Against Idle Stopb - Primary Pickup Screwc - Locknut


90-877837 NOVEMBER 1999 Page 2C-13

Static Maximum Timing Adjustment (Cranking Engine with Starter)NOTE: WHITE/BLACK lead and ECM harness remain disconnected for maximum timingadjustment. Timing light remains hooked up to no.1 cylinder.

1. Hold throttle arm so that maximum spark advance screw is against stop. Crank enginewith starter. Adjust maximum spark advance screw to set timing to attain appropriatesetting. Tighten maximum spark adjustment locknut.

a

b

c

a - Throttle Armb - Spark Advance Screwc - Locknut

Maximum Throttle1. Hold throttle arm against full throttle stop screw. Adjust full throttle stop screw to allow

full throttle valve opening, while maintaining a clearance between arm of throttle shaftand stop on induction box. Tighten locknut.

2. Check for slight free play (roller lifter from cam) between roller and cam at full throttleto prevent linkage from binding. Readjust full throttle stop screw, if necessary.

3. Reconnect WHITE/BLACK lead from idle stabilizer box. Reconnect ECM harness. Dis-connect timing light and install spark plugs and fuel line.

a

b

c

d

e

a - Throttle Armb - Full Throttle Stop Screwc - Throttle Shaft Armd - Stope - Locknut


Page 2C-14 90-877837 NOVEMBER 1999

Throttle Position Sensor (TPS) AdjustmentUSING DIGITAL DIAGNOSTIC TOOL (DDT)

IMPORTANT: Engine must be OFF before connecting the DDT adaptor cable to theECM.

1. Connect the DDT adaptor cable to ECM diagnostic port as shown. Attach the batteryclips to a 12v battery.

2. Connect the DDT interface cable between the DDT and DDT adaptor cable if required.

NOTE: Apply a small amount of dielectric grease to the 25 pin ends of interface cables. Thiswill minimize corrosion in saltwater environment.

ca

b

a - ECM Diagnostic Portb - DDT Adaptor Cablec - DDT Interface Cable

3. Turn key to the “ON” position.

4. Loosen screws securing TPS to manifold.

a

a - Loosen Two (2) Screws and Rotate TPS5. Rotate TPS fully clockwise (holding throttle shaft in closed position). Start to rotate TPS

counterclockwise until a reading between .200 - .300 volts is achieved.


90-877837 NOVEMBER 1999 Page 2C-15

NOTE: If engine appears to run too rich or too lean, TPS can be re-adjusted. Decreasingvoltage yields leaner mixture. Increasing voltage yields richer mixture. Allowable TPS rangeis .200 - .300 volts.

6. Tighten TPS screws holding correct tolerance.

7. Disconnect remote control cable from throttle lever.

8. Slowly move throttle lever to full open position while monitoring voltage reading. Voltageshould increase and decrease smoothly.

9. Maximum voltage reading at full throttle is approximately 7.46 volts.

USING DMT 2000 DIGITAL TACHOMETER/MULTI-METER

1. Disconnect TPS from EFI harness.

58055

a

a - TPS/EFI Harness Connector2. Connect digital meter using TPS Test Lead Assembly (P/N 91-816085) between TPS

connector and EFI harness connector. Set voltmeter to 2 DC volts.

IMPORTANT: TAN/BLACK head temperature leads must be disconnected from portcylinder head before adjusting TPS.

3. Disconnect TAN/BLACK engine head temperature sensor leads located on port cylinderhead.

a

a - Disconnect TAN/BLACK Leads


Page 2C-16 90-877837 NOVEMBER 1999

4. Turn key to the “ON” position.

5. Loosen screws securing TPS to manifold.

6. Rotate TPS fully clockwise (holding throttle shaft in closed position). Start to rotate TPScounterclockwise until a reading between .200 - .300 volts is achieved.

58055

a

a - Loosen Two (2) Screws and Rotate TPSNOTE: If engine appears to run too rich or too lean, TPS can be re-adjusted. Decreasingvoltage yields leaner mixture. Increasing voltage yields richer mixture. Allowable TPS rangeis .200 - .300 volts.

7. Tighten TPS screws holding correct tolerance.

8. Disconnect remote control cable from throttle lever.

9. Slowly move throttle lever to full open position while monitoring voltage reading. Voltageshould increase and decrease smoothly.

10. Set volt meter to 20 DC volts. Maximum voltage reading at full throttle is approximately7.46 volts.

11. Remove test lead and reconnect TPS harness to EFI harness.

Idle Timing (Engine Running)1. WHITE/BLACK lead from idle stabilizer must be disconnected.

a

a - Idle Stabilizer Lead2. With engine in water, start engine and allow to warm up.

3. Shift engine into “FORWARD” gear.


90-877837 NOVEMBER 1999 Page 2C-17

4. Hold throttle arm against idle stop (throttle cable barrel removed from barrel retainer).Adjust idle timing screw to attain appropriate setting. Tighten locknut.

a

b

c

a - Throttle Armb - Idle Timing Screwc - Locknut

5. Reconnect WHITE/BLACK lead of idle stabilizer at bullet connector.

Idle Adjustment1. With Jet Unit in water, start and allow to warm up.

2. Loosen cam follower screw, allowing free movement of cam. Hold throttle arm againstidle stop. Adjust idle speed screw by increasing or decreasing air valve opening to attainappropriate setting.

a

a - Idle Speed Screw


Page 2C-18 90-877837 NOVEMBER 1999

Throttle Valve/Oil Pump Synchronization1. While holding throttle arm against idle stop, adjust length of link rod so that stamped

mark of oil pump lever aligns with stamped mark of oil pump body.

a

b c

a - Link Rodb - Oil Pump Lever Markc - Oil Pump Body Mark

Documents

TIMING, SYNCHRONIZING & ADJUSTING ELECTRICAL...Gap NGK-BPZ8H510.040 Firing Order 1-2-3-4-5-6 TIMING, SYNCHRONIZING & ADJUSTING Page 2C-2 90-877837 NOVEMBER 1999 210 HP TIMING, SYNCHRONIZING