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51534

C2

ELECTRICAL

TIMING, SYNCHRONIZINGAND ADJUSTING

2C-0 - ELECTRICAL 90-822900R3 DECEMBER 1997

Table of ContentsPage

Timing/Synchronizing/Adjusting 2C-1. . . . . . . . . . . . . . . . Special Tools 2C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 2C-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Cam Adjustment (Carburetor Models 1994/1995) 2C-5. . . . . . . . . . . . . Carburetor Synchronization(Carburetor Models 1994/1995) 2C-5. . . . . . . . . . . . . Carburetor/Oil Pump Synchronization1994/1995 Models 2C-6. . . . . . . . . . . . . . . . . . . . . . . . . Carburetor/Oil Pump Synchronization1996/1997/1998 Model 225 Carb 2C-6. . . . . . . . . . . . Carburetor Synchronization1996/1997/1998 Model 225 Carburetor 2C-7. . . . . . .

Timing Adjustments 2C-8. . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Position Sensor (TPS) Adjustmentfor Idle Timing 2C-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Position Sensor Adjustment 2C-9. . . . . . . . . . . Maximum Timing Adjustment 2C-9. . . . . . . . . . . . . . . Idle Speed Adjustment 2C-10. . . . . . . . . . . . . . . . . . . . Alternator Belt Tension Adjustment 2C-10. . . . . . . . .

Adjustments 2C-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Position Sensor Adjustment 2C-12. . . . . . . . . . Throttle Cam Adjustment 2C-12. . . . . . . . . . . . . . . . . . Carburetor/Oil Pump Synchronization 2C-13. . . . . . . Maximum Throttle 2C-13. . . . . . . . . . . . . . . . . . . . . . . . Throttle Position Sensor (TPS) Adjustment 2C-14. . Idle Speed 2C-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Belt Tension Adjustment 2C-15. . . . . . . . .

ELECTRICAL - 2C-190-822900R3 DECEMBER 1997

Timing/Synchronizing/Adjusting

Specifications

CARBURETOR MODELS

MODEL 3 LITRE WORK/225 CARBURETOR

FULL THROTTLE RPMRANGE

5000 - 5500

IDLE RPM (IN FORWARDGEAR)

600 - 700

MAXIMUM TIMING:@ WIDE OPENTHROTTLE1994 MODEL 225

1995 MODEL 3 LITREWORK/225

1996/97 MODEL 3 LITREWORK/225

22° BTDC @ 5500 RPM (ECU - 821717)25° - 27° BTDC @ 5500RPM (ECU - 824866-1)

20° BTDC @ 5000 RPM23° BTDC @ 5500 RPM

19° BTDC @ 5000 RPM26° BTDC @ 5500 RPM

IDLE TIMING 4° - 9° ATDC

SPARK PLUG 1994/95/96SPARK PLUG GAP

NGK - BPZ8H-N-100.040 in. (1.0mm)

SPARK PLUG 1997/98SPARK PLUG GAP

CHAMPION QL77CC0.035 in. (0.89mm)

FIRING ORDER 1-2-3-4-5-6

THROTTLE POSITIONSENSOR

@ IDLE@ W.O.T.

0.950 ± 0.050 VOLTS3.80 ± 0.10 VOLTS

Specifications

ELECTRONIC FUEL INJECTION MODELS

1995 MODEL 225 EFI


5000 - 5800


600 - 700

MAXIMUM TIMING:@ WIDE OPENTHROTTLEMODEL 225 EFI –

MODEL 250 EFI –

20° BTDC @ 5000 RPM23° BTDC @ 5800 RPM24° BTDC @ 5000 RPM28° BTDC @ 5800 RPM


SPARK PLUGSPARK PLUG GAP




@ IDLE@ W.O.T.

0.950 ± 0.050 VOLTS3.80 ± 0.25 VOLTS

1996/1997/1998 MODEL 225 EFI/250 EFI


5000 - 5800


600 - 700

MAXIMUM TIMING:@ WIDE OPENTHROTTLEMODEL 225 EFI –

MODEL 250 EFI –

24° BTDC @ 5000 RPM24° BTDC @ 5800 RPM24° BTDC @ 5000 RPM28° BTDC @ 5800 RPM


SPARK PLUGSPARK PLUG GAP




@ IDLE@ W.O.T.

0.950 ± 0.050 VOLTS3.80 ± 0.25 VOLTS

! WARNINGEngine could start when turning flywheel tocheck timing pointer adjustment. Remove allspark plugs from engine to prevent engine fromstarting.0


! WARNINGEngine could start when turning flywheel tocheck timing pointer adjustment. Remove allspark plugs from engine to prevent engine fromstarting.

Special ToolsDial Indicator Gauge Kit 91-58222A1

Service Tachometer 91-59339

Spark Gap Tool 91-63998A1

Timing Light 91-99379

Digital Diagnostic Terminal 91-823686A2

Cable [10 ft. (3.05m)] 84-825003A1*

1994 ECM Harness 84-822560A1


1995/96/96/98 ECM Harness (a) 84-822560A3;or(b) 84-822560A7 with (c) 84-822560A6+

a

b

c

Cartridge 91-822608-2 or -4

Tachometer Adaptor 91-825824A2

TPS/CDM Test Harness (3 Pin Connector) (w/CDMPN 822779) 84-825207A1

TPS/CDM Test Harness (4 Pin Connector) (w/CDMPN 827509) 84-825207A2

* Cable is provided with Digital Diagnostic Terminal91-823686A2+ 84-822560A6 must be used in conjunction with84-822560A7 to enable the Digital Diagnostic Tester toprovide accurate readouts.


Adjustment s

Carburetor Models


1. Remove flywheel cover by sliding back and liftingcover in a simultaneous motion. Remove carbu-retor air attenuator by releasing two latches atbottom of attenuator.

ab

54384

a - Attenuatorb - Flywheel Cover

51696

a

a - Latches

NOTE: To reinstall attenuator and flywheel cover, in-stall and latch attenuator first, then install flywheelcover.

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

53331

a

a - Dial Indicator Installed in No. 1 Cylinder

3. Turn flywheel in a clockwise direction until No. 1piston is at top dead center (TDC). Set dial indica-tor at “0” (zero) and tighten indicator set screw.

4. Turn flywheel counterclockwise until dial indica-tor needle is approximately 1/4-turn beyond0.526 in., then turn flywheel clockwise so that dialindicator reads 0.526 in. (11.7mm) exactly.

5. Reposition timing pointer (if necessary) so thattiming pointer is aligned with 0.526 in. mark on fly-wheel. Torque pointer attaching screw to 105 lb.in. (11.8 N·m).

53333

a

b

a - Timing Pointerb - Attaching Screw [Torque to 105 lb. in. (11.8 N·m)]

6. Remove dial indicator from cylinder.


Throttle Cam Adjustment (Carburetor Models 1994/1995)1. Loosen cam follower screw allowing cam follow-

er to move freely.

2. Allow roller to rest on throttle cam. Adjust idle stopscrew on throttle arm to align mark on throttlecam with center of roller. Tighten jam nut.

51534

c

f

b

ca

eb

d

f

a

a - Cam Follower Screwb - Rollerc - Throttle Camd - Idle Stop Screw e - Throttle Armf - Mark (Throttle Cam)

3. Proceed to “Carburetor Synchronization” (follow-ing) before tightening cam follower screw.

Carburetor Synchronization(Carburetor Models 1994/1995)1. Loosen two carburetor synchronization screws to

allow shutter plates to close completely.

2. Position throttle lever so that idle stop screw isagainst idle stop and move roller arm until rollerlightly touches throttle cam. Without moving rollerfrom this position, retighten carburetor synchro-nization screws and cam follower screw.

51534

a

d

a

b

c

a - Synchronizing Screw b - Rollerc - Cam Follower Screw d - Throttle Cam

3. Verify throttle shutter plates open and close si-multaneously during throttle lever operation.Readjust if necessary.


4. Move throttle lever to wide-open-throttle (W.O.T.)position and adjust full throttle stop screw to allowfull throttle shutter opening at W.O.T. Verify thatthrottle shutters do not act as a throttle stop. Allow0.010 in. – 0.015 in. (0.25mm – 0.38mm) clear-ance between roller and throttle cam at W.O.T.Retighten jam nut on adjustment screw.

51532

cb

a

a - Full Throttle Stop Screwb - Rollerc - Throttle Cam

5. Reinstall air box and flywheel cover.

Carburetor/Oil PumpSynchronization1994/1995 ModelsNOTE: 3 Liter WORK model IS NOT equipped withan oil injection pump and requires premix oil and fuelfor lubrication. The 225 model is equipped with an oilinjection pump. However, the 1994/1995 225 carbu-retor models DO NOT have an adjustable oil link rod.

Carburetor/Oil PumpSynchronization1996/1997/1998 Model 225 Carb1. Remove the shift rail assembly and inspect the oil

pump index marks. When throttle linkage is atidle position, the lower alignment mark on oil in-jection arm should be in-line with mark on castingas shown. If necessary, adjust link rod.

51535

a

c

b

a - Link Rodb - Lower Alignment Markc - Casting Mark


Carburetor Synchronization1996/1997/1998 Model 225 Carburetor1. Adjust idle stop screw until the bend in the carbu-

retor link is 1/4 in. (6.3mm) from the crankcasecasting. The threaded idle stop boss on the backside of the throttle arm should be close to themiddle of the idle stop screw.

a

b

a - Crankcaseb - Carburetor Link Rod

2. Loosen 3 carburetor synchronization screws toallow shutter plates to close completely.

3. Position throttle lever so that idle stop screw isagainst idle stop. Without moving throttle linkage,retighten center carburetor synchronizationscrew first and then upper and lower carburetorsynchronization screws.

a

a

a

b

c

a - Synchronizing Screwb - Idle Stop Screwc - Carburetor Link Rod [Approx. 8.3 in. (21.1cm) between

Pivot Centers]

4. Verify throttle shutter plates open and close si-multaneously during throttle lever operation.Readjust if necessary.


5. Move throttle lever to wide-open-throttle (W.O.T.)position and adjust full throttle stop screw to allowfull throttle shutter opening at W.O.T. Verify thatthrottle shutters do not act as a throttle stop. Allow0.010 in. – 0.015 in. (0.25mm – 0.38mm) clear-ance between throttle shaft arm and stop atW.O.T. Retighten jam nut on adjustment screw.

0.010 – 0.015

a

b

c

(0.25mm – 0.38mm)

54374

a - Full Throttle Stop Screwb - Throttle Shaft Armc - Stop

6. Reinstall air box and flywheel cover.

Timing Adjustments

Throttle Position Sensor (TPS)Adjustment for Idle TimingIMPORTANT: TPS can be adjusted using a digitalmeter. Analog (needle) type may be used al-though it may be difficult to read the low voltagesetting accurately with most meters.

TPS ADJUSTMENT USING DIGITALVOLTMETER

1. Disconnect TPS from ignition harness.

53456

a

a - TPS Plug

2. Connect digital voltmeter using TPS Test LeadAssembly 84-825207A1 between TPS connectorand ignition harness connector. 1994/1995 Models – Connect BLACK VOA leadto BLACK test harness connector. Connect REDVOA lead to WHITE test harness connector.1996/1997/1998 Models – Connect BLACKVOA lead to WHITE test harness connector.Connect RED VOA lead to RED test harnessconnector. Set voltmeter to 20 VDC.

��

53464

a

c b

a - TPI Test Lead Assemblyb - TPI Connectorc - Ignition Harness Connector


3. Turn key switch to the “ON” position.

4. Loosen screws securing TPS to bracket.

51535

a

a - Screws

5. Rotate TPS to attain voltage reading of 0.950 +/–.050.

6. Tighten TPS screws (holding correct tolerance).

7. Disconnect remote control cable from throttle le-ver.

8. Slowly move throttle lever to full open positionwhile monitoring voltage reading. Voltage read-ing should increase and decrease smoothly.

9. Check TPS at W.O.T. Maximum voltage readingat full throttle is approximately 3.80 ± 0.10 volts.

IMPORTANT: If voltage reading of TPS is not cor-rect @ W.O.T., verify W.O.T. stop is adjusted cor-rectly before replacing TPS.

10. Remove test lead and reconnect TPS harness toignition harness.

Crank Position Sensor Adjustment1. Remove flywheel cover.

2. Using a feeler gauge, measure the air gap be-tween the crank position sensor and a tooth onthe flywheel. It should be 0.040 in. ± 0.020 in.[1.02mm ± 51mm)]. If not, loosen bracket screws,set gap to specification, and retighten screws to105 lb. in. (11.8 N·m).

IMPORTANT: Crank Position Sensor must be per-pendicular to flywheel tooth.

3. Reinstall flywheel cover.

53455

d

c

ab

a - Air Gap [0.040 in. ± 0.020 in. (1.02mm ± 0.51mm)]b - Crank Position Sensorc - Flywheel Toothd - Bracket Screws [Torque to 105 lb. in. (11.8 N·m)]

Maximum Timing AdjustmentThe maximum spark timing is controlled by the igni-tion ECM (Electronic Control Model) and is non-ad-justable. As long as the ECM and sensors (Crank Po-sition Sensor and Throttle Position Sensor) arefunctioning properly, the maximum timing will be cor-rect.


Idle Speed Adjustment1. With engine in water, connect fuel line to engine.

Start engine and allow to warm up.

2. Place outboard in gear and monitor engine RPM.If RPM is above or below recommended RPM(600-700), verify carburetor synchronization iscorrect and/or readjust idle mixture screws. Ifnecessary, Throttle Position Sensor lock screwsmay be loosened and TPS readjusted to attainrecommended engine speed. A 0.05 volt changein TPS setting results in a 1 degree change in tim-ing. Retighten TPS screws.

51535

a

a - TPI Screws

! CAUTIONThe unit must be set up to have an “IN GEAR” idlespeed no greater than 700 RPM. Higher “INGEAR” idle speeds will result in increased shiftloads that could ultimately prevent shifting of thegear case assembly.

3. With end of cable connected to throttle lever, holdthrottle lever against idle stop. Adjust throttlecable barrel to slip into barrel retainer on cableanchor bracket with a very light preload of throttlelever against idle stop. Lock barrel in place.

4. Check preload on throttle cable by placing a thinpiece of paper between idle stop screw and idlestop. Preload is correct when paper can be re-moved without tearing but has some drag on it.Readjust cable barrel, if necessary.

IMPORTANT: Excessive preload on throttle cablewill cause difficulty when shifting from forwardto neutral. (Readjust throttle cable barrel if nec-essary.)

NOTE: Carburetors are equipped with idle mixtureadjustment screws. See page for mixture screw ad-justment.

Alternator Belt Tension Adjustment1. Belt tension is correct if belt deflects 1/2 in.

(12.7mm) from center under a 22 lb. (30.0 N) sideload.

2. If belt tension is not correct, loosen pivot bolt andtension adjustment bolt. Move alternator awayfrom flywheel to increase tension.

3. Tighten tension adjustment bolt [Torque to 40 lb.ft. (54.0 N·m)] and pivot bolt [Torque to 40 lb. ft.(54.0 N·m)].

NOTE: A belt tensioning tool (obtain locally) may alsobe used to adjust belt tension. Adjust belt tension to80 lb. (356.0 N).

51533

a c

b

a - Deflection [1/2 in. (12.7mm) under 22 lb. ft. (30.0 N·m) side load]

b - Tension Bolt [Torque to 40 lb.ft. (54.0 N·m)]c - Pivot Bolt [Torque to 40 lb. ft. (54.0 N·m)]


Adjustment s

Electronic Fuel Injection Models


1. Remove flywheel/alternator cover by lifting rearof cover and sliding cover aft and off of attenuator.

53634

a

b

a - Flywheel/Alternator Coverb - Attenuator

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

53331

a

a - Dial Indicator Installed in No. 1 Cylinder

3. Turn flywheel in a clockwise direction until No. 1piston is at top dead center (TDC). Set dial indica-tor at “0” (zero) and tighten indicator set screw.

4. Turn flywheel counterclockwise until dial indica-tor needle is approximately 1/4-turn beyond0.526 in., then turn flywheel clockwise so that dialindicator reads 0.526 in. (11.7mm) exactly.

5. Reposition timing pointer (if necessary) so thattiming pointer is aligned with 0.526 in. mark on fly-wheel. Torque pointer attaching screw to 105 lb.in. (11.8 N·m).

53333

a

b

a - Timing Pointerb - Attaching Screw [Torque to 105 lb. in. (11.8 N·m)]

6. Remove dial indicator from cylinder.


Crank Position Sensor Adjustment1. Remove flywheel cover.

2. Using a feeler gauge, measure the air gap be-tween the crank position sensor and a tooth onthe flywheel. It should be 0.040 in. ± 0.020 in.[1.02mm ± 0.51mm)]. If not, loosen bracketscrews, set gap to specification, and retightenscrews to 105 lb. in. (11.8 N·m).

IMPORTANT: Crank Position Sensor must be per-pendicular to flywheel tooth.

3. Reinstall flywheel cover.

51533

d

c

ab

a - Air Gap [0.040 in. ± 0.020 in.(1.02mm ± 0.51mm)]b - Crank Position Sensorc - Flywheel Toothd - Bracket Screws [Torque to 105 lb. in.(11.8 N·m)]

Throttle Cam Adjustment1. Loosen cam follower screw allowing cam follow-

er to move freely.

2. Allow roller to rest on throttle cam. Adjust idle stopscrew on throttle arm to align mark on throttlecam with center of roller.

3. Tighten roller arm screw to provide clearance of0.005 in. ± 0.005 in. (0.13mm ± 0.13mm) be-tween roller and cam.

53635

f f

a

e

b

d

c

a - Cam Follower Screwb - Rollerc - Throttle Camd - Idle Stop Screw e - Mark f - 0.005 in. ± 0.005 in. (0.13mm ± 0.13mm)


Carburetor/Oil PumpSynchronizationNOTE: On 1996/1997 models, the shift rail assemblymust be removed in order to check the alignment ofcasting marks.

1. When carburetor linkage is at idle position, align-ment mark on oil injection arm should be in-linewith mark on casting as shown. If necessary, ad-just link rod.

51535

ca

b

a - Link Rodb - Alignment Markc - Casting Mark

Maximum Throttle1. Hold throttle arm against full throttle stop screw.

2. Adjust full throttle stop screw to allow full throttlevalve opening while maintaining a 0.010 in.(0.25mm) clearance between arm of throttleshaft and stop on attenuator box.

3. Tighten jam nut.

4. Check for free play (roller lifts from cam) betweenroller and cam at full throttle to prevent linkagefrom binding. Readjust full throttle stop screw, ifnecessary.

53636

e

ba

gf

d

c

a - Throttle Armb - Full Throttle Stop Screwc - Throttle Shaft Armd - Stope - Locknutf - Rollerg - Cam


Throttle Position Sensor (TPS)AdjustmentIMPORTANT: TPS can be adjusted using a digitalmeter. Analog (needle) type may be used al-though it may be difficult to read the low voltagesetting accurately with most meters.

TPS ADJUSTMENT USING A DIGITALVOLTMETER

1. Disconnect TPS from ignition harness.

53329

a

b

a - TPSb - TPS Harness

2. Connect digital voltmeter using TPS/CDM TESTLEAD ASSEMBLY (84-825207A1) between TPSconnector and EFI harness connector.

3. Connect RED voltmeter lead to RED lead of har-ness assembly and BLACK voltmeter lead toWHITE lead of harness assembly for a TPS mea-surement. Set voltmeter to 20VDC.

4. Turn ignition key to “ON” position.

5. With throttle shaft at the close position, voltmetershould read 0.95 ± 0.05 volts. Loosen TPS setscrews and adjust as necessary.

53330c

a

b

a - TPSb - Set Screwsc - TPS/CDM TEST HARNESS (84-825207A1)

6. Slowly move throttle lever to WIDE OPENTHROTTLE position and then back to IDLE whilemonitoring voltage reading. Voltage readingshould increase (throttle opens) and decrease(throttle closes) smoothly.

7. At WIDE OPEN THROTTLE, maximum voltagereading should be approximately 3.80 ± 0.25volts using a digital voltmeter.

8. Torque TPS screws to 20 lb. in. (2.3 N·m).

NOTE: If using the DIGITAL DIAGNOSTIC TERMI-NAL to monitor TPS voltage, the maximum voltagereading at WIDE OPEN THROTTLE will be 4.00 ±0.25 volts. The idle TPS voltage will be the same –0.95 ± 0.050 volts – whether the DIGITAL DIAGNOS-TIC TERMINAL or digital voltmeter is used.

9. Remove test harness and reconnect TPS har-ness to EFI harness.

10. Reinstall spark plugs. Torque spark plugs to 20lb. ft. (27.0 N·m).


Idle SpeedEngine idle speed should be 600 – 700 RPM in gear.

1. If idle speed is not correct, adjust idle air flowscrew at lower throttle shaft on PORT side of in-duction manifold.

2. Secure idle air flow screw with jam nut.

3. After adjusting idle speed, recheck TPS voltageand reset (if necessary) to 0.95 ± 0.05 VDC.Torque TPS screws to 20 lb. in. (2.3 N·m).

53335

a

a

a - Idle Air Screw

Alternator Belt Tension Adjustment1. Belt tension is correct if belt deflects 1/2 in.

(12.7mm) from center under a 22 lb. (30.0 N) sideload.

2. If belt tension is not correct, loosen pivot bolt andtension adjustment bolt. Move alternator awayfrom flywheel to increase tension.

3. Tighten tension adjustment bolt [Torque to 40 lb.ft. (54.0 N·m)] and pivot bolt [Torque to 40 lb. ft.(54.0 N·m)].

NOTE: A belt tensioning tool (obtain locally) may alsobe used to adjust belt tension. Adjust belt tension to80 lb. (356.0 N·m).

51533

a c

b

a - Deflection [1/2 in. (12.7mm) under 22 lb. ft. (30.0 N·m) side

load]b - Tension Bolt [Torque to 40 lb.ft. (54.0 N·m)]c - Pivot Bolt [Torque to 40 lb. ft. (54.0 N·m)]

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