Outboard FourStroke I - Motooff.ru

Outboard FourStroke ITechnician’s Guide1

Table of ContentsSection 1 – General InformationSection 2 – PowerheadsSection 3 – Electrical SystemsSection 4 – Fuel SystemsSection 5 – Timing and SynchronizingSection 6 – Service BulletinsSection 7 – Tool Suppliers32

Section 1 - General Information1-190-8983113

Table of ContentsTable of Contents . 2Exhaust Emissions Standards . 4What Are Emissions?. 4Hydrocarbons - HC . 4Carbon Monoxide - CO . 4Oxides of Nitrogen - NOx . 5Controlling Emissions. 5Stoichiometric (14.7:1) Air/Fuel Ratio . 5Outboard Hydrocarbon Emissions Reductions. 68 1/3% PER YEAR OVER 9 MODEL YEARS. 6Emissions Information . 7Emissions Information . 8Manufacturer’s Responsibility . 8Dealer Responsibility . 8Owner Responsibility . 8EPA Emission Regulations . 9Engine Emission Certification Label. 10Inspection And Maintenance Schedule . 11Inspection And Maintenance Schedule . 12Before Each Use . 12After Each Use . 12Every 100 Hours Of Use Or Once Yearly, Whichever Occurs First . 13Every 300 Hours of Use or Three Years . 13Before Periods of Storage. 13Timing Belt Inspection 15 HP Only . 14Changing Engine Oil. 15Oil Draining Procedure (15 HP shown) . 15Changing Oil Filter . 15Oil Filling . 15Storage Preparation. 16Fuel System . 16Protecting External Outboard Components . 16Protecting Internal Engine Components . 16Gear Case. 17Positioning Outboard for Storage (15 HP shown) . 17Conditions Affecting Performance . 17Weather. 17Propeller Selection. 19Special Aluminum Propellers Required for 40/50/60 Bigfoot 4-Stroke Models. 20Models Affected . 20Mercury/Mariner 40 and 50 Bigfoot 4–Stroke 2.31:1 . 22Mercury/Mariner 60 Bigfoot 4–Stroke 2.31:1 . 22.Props for Pontoons . 22Props for Pontoons . 23Remote Control Cables. 24Measuring Throttle and Shift Cables. 24SHIFT EFFORT TOOL. 26Tool Installation . 262005/2006 Model Year Changes14 Pin Adapter and Control Harnesses. 29Battery Specification . 31Battery Rating System . 32Cold Cranking Amps (CCA) . 3290-8983111-24

Marine Cranking Amps (MCA).32Reserve Capacity .32Amperage/Hour Rating.32Charging Guide .33Effects of Temperature on a Standing Battery .33Battery Cable Wire Gauge Size.35Warning System Operation .36Warning System Activated .36Engine Overheat .361-390-8983115

NotesExhaust Emissions StandardsThrough the Environmental Protection Agency (EPA), the federal governmenthas established exhaust emissions standards for all new marine engines soldin the U.S.What Are Emissions?Emissions are what comes out of the exhaust system in the exhaust gas whenthe engine is running. They are formed as a result of the process ofcombustion or incomplete combustion.To understand exhaust gas emissions, remember that both air and fuel aremade of several elements. Air contains oxygen and nitrogen among otherelements; gasoline contains mainly hydrogen and carbon. These fourelements combine chemically during combustion.If combustion were complete, the mixture of air and gasoline would result inthese emissions: water, carbon dioxide and nitrogen, which are not harmful tothe environment.But combustion is not usually complete. Also, potentially harmful gases can beformed during and after combustion.All marine engines must reduce the emission of certain pollutants, orpotentially harmful gases in the exhaust to conform with levels legislated bythe EPA. Emissions standards become more stringent each year. Standardsare set primarily with regard to three emissions:1) Hydrocarbons (HC)2) Carbon Monoxide (CO)3) Oxides of Nitrogen (NOx).Hydrocarbons - HCGasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon areburned during combustion in combination with oxygen. But they are not totallyconsumed. Some pass through the combustion chamber and exit the exhaustsystem as unburned gases known as hydrocarbons.Carbon Monoxide - COCarbon is one of the elements that make up the fuel burned in the enginealong with oxygen during the combustion process. If the carbon in thegasoline could combine with enough oxygen (one carbon atom with twooxygen atoms), it would come out of the engine in the form of carbon dioxide(CO2). CO2 is a harmless gas. But carbon often combines with insufficientoxygen (one carbon atom with one oxygen atom). This forms carbonmonoxide, CO.Carbon monoxide is the product of incomplete combustion and is adangerous, potentially lethal gas.90-8983111-46

Oxides of Nitrogen - NOxNotesNOx is a slightly different byproduct of combustion. Nitrogen is one of theelements that makes up the air going into the engine. Under extremely hightemperatures it combines with oxygen to form oxides of nitrogen (NOx). Thishappens in the engine’s combustion chambers when temperatures are toohigh. NOx itself is not harmful, but when exposed to sunlight it combines withunburned hydrocarbons to create the visible air pollutant known as smog.Smog is a serious problem in California as well as many other heavilypopulated areas of the United States.Controlling EmissionsThere are two principle methods of reducing emissions from a two-strokecycle marine engine. The first method is to control the air/fuel ratio that goesinto the combustion chamber. The second is to control the time when thisair/fuel mixture enters the combustion chamber. Timing is important, toprevent any unburned mixture from escaping out of the exhaust port.Stoichiometric (14.7:1) Air/Fuel RatioIn the search to control pollutants and reduce exhaust emissions, engineershave discovered that they can be reduced effectively if a gasoline engineoperates at an air/fuel ratio of 14.7:1. The technical term for this ideal ratio isstoichiometric. An air/fuel ratio of 14.7:1 provides the best control of all threeelements in the exhaust under almost all conditions.The HC and CO content of the exhaust gas is influenced significantly by theair/fuel ratio. At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low,but with a ratio richer than 14.7:1 they rise rapidly. It would seem thatcontrolling HC and CO by themselves might not be such a difficult task; theair/fuel ratio only needs to be kept leaner than 14.7:1. However, there is alsoNOx to consider.As the air/fuel ratio becomes leaner, combustion temperatures increase.Higher combustion temperatures raise the NOx content of the exhaust. But,enrichening the air/fuel ratio to decrease combustion temperatures and reduceNOx also increases HC and CO, as well as lowering fuel economy. So thesolution to controlling NOx - as well as HC and CO - is to keep the air/fuelratio as close to 14.7:1 as possible.1-590-8983117

NotesOutboard Hydrocarbon EmissionsReductions8 1/3% PER YEAR OVER 9 MODEL YEARS90-8983111-68

NotesEmissions InformationManufacturer’s ResponsibilityBeginning with 1998 model year engines, manufacturers of all marinepropulsion engines must determine the exhaust emission levels for eachengine horsepower family and certify these engines with the United StatesEnvironmental Protection Agency (EPA). A certification decal/emissionscontrol information label, showing emission levels and engine specificationsdirectly related to emissions, must be placed on each engine at the time ofmanufacture.Dealer ResponsibilityWhen performing service on all 1998 and later outboards that carry acertification, attention must be given to any adjustments that are made thataffect emission levels.Adjustments must be kept within published factory specifications.Replacement or repair of any emission related component must be executedin a manner that maintains emission levels within the prescribed certificationstandards.Dealers are not to modify the engine in any manner that would alter thehorsepower or allow emission levels to exceed their predetermined factoryspecifications. Exceptions include manufacturers prescribed changes, such asthat for altitude adjustments.Owner ResponsibilityThe owner/operator is required to have engine maintenance performed tomaintain emission levels within prescribed certification standards.The owner/operator is not to modify the engine in any manner that would alterthe horsepower or allow emissions levels to exceed their predeterminedfactory specifications.Exceptions:Carburetor jets may be changed for high altitude use in accordance withfactory recommendations.Single engine exceptions may be allowed with permission from the EPA forracing and testing.90-8983111-89

EPA Emission RegulationsAll new 1998 and later outboards manufactured by Mercury Marine arecertified to the United States Environmental Protection Agency as conformingto the requirements of the regulations for the control of air pollution from newoutboard motors. This certification is contingent on certain adjustments beingset to factory standards. For this reason, the factory procedure for servicingthe product must be strictly followed and, whenever practicable, the productreturned to the original intent of the design.The responsibilities listed above are general and in no way a complete listingof the rules and regulations pertaining to the EPA laws on exhaust emissionsfor marine products. For more detailed information on this subject, you maycontact the following locations:NotesVIA U.S. POSTAL SERVICE:Office of Mobile SourcesEngine Programs and Compliance DivisionEngine Compliance Programs Group (6403J)401 M St. NWWashington, DC 20460VIA EXPRESS OR COURIER MAIL:Office of Mobile SourcesEngine Programs and Compliance DivisionEngine Compliance Programs Group (6403J)501 3rd St. NWWashington, DC 20001EPA INTERNET WEB SITE:http:/www.epa.gov/omswww1-990-89831110

Engine Emission Certification LabelNotesYour outboard has been labeled on the cowl with one of the following starlabels.The Star Label means Cleaner Marine Engines.The Symbol for Cleaner Marine Engines Means:Cleaner Air and Water – for a healthier lifestyle and environment.Better Fuel Economy – burns up to 30-40 percent less gas and oil thanconventional carbureted two-stroke engines, saving money and resources.Longer Emission Warranty – Protects consumer for worry free operation.The one-star label identifiesengines that meet the CARB's 2001exhaust emission standards.Engines meeting these standardshave 75% lower emissions thanconventional carbureted 2-strokeengines. These engines areequivalent to the U.S. EPA's 2006standardsThe two-star label identifies enginesthat meet the CARB's 2004 exhaustemission standards. Enginesmeeting these standards have 20%lower emissions than One Star Low Emission engines.The three-star label identifiesengines that meet the CARB's 2008exhaust emission standards.Engines meeting these standardshave 65% lower emissions thanOne Star - Low Emission engines.NOTE: Mercury’s FourStroke technology actually exceeds the EPA’semissions standards for the year 2006. And most models meet California’sstringent “Three-Star” rating, which means they’re in compliance with 2008’s91% reduction in emissions.90-8983111-1011