ELECTRICAL. Section 2C - Timing, Synchronizing & Adjusting

Transcription

1 Tle of Contents TIMING, SYNCHRONIZING & ADJUSTING ELECTRICAL Setion 2C - Timing, Synhronizing & Adjusting Speifitions C HP Timing/Synhronizing/Adjusting... 2C-1 Speil Tools C-2 Adjustments C-3 Timing Pointer Adjustment C-3 Cruretor Synhroniztion C-4 Timing Adjustment C-6 Mximum Timing Adjustment C-6 Primry Pikup Timing Adjustment C-6 Idle Speed Adjustment C HP Timing/Synhronizing/Adjusting... 2C-8 Speil Tools C-8 Adjustments C-10 Speifitions Timing Pointer Adjustment C-10 Timing Adjustment C-11 Throttle Cm Adjustment C-11 Stti Idle Timing Adjustment (Crnking Engine with Strter) C-12 Stti Mximum Timing Adjustment (Crnking Engine with Strter) C-13 Mximum Throttle C-13 Throttle Position Sensor (TPS) Adjustment C-14 Idle Timing (Engine Running) C-16 Idle Adjustment C-17 Throttle Vlve/Oil Pump Synhroniztion 2C-18 2 C 210 HP Full Throttle RPM Rnge Idle RPM Mximum Crnking 5000 RPM Idle Speed/Pikup Timing 24 BTDC 22 BTDC 6 2 BTDC Sprk Plug NGK-BU8H or BUZ8H Surfe Gp Firing Order HP Full Throttle RPM Rnge Idle RPM Mximum Crnking Speed Idle Speed/Pikup Timing 26 BTDC 6 BTDC Sprk Plug Gp NGK-BPZ8H Firing Order NOVEMBER 1999 Pge 2C-1

2 210 HP TIMING, SYNCHRONIZING & ADJUSTING Speil Tools Dil Inditor A1 Timing Light Sprk Gp Tester Sprk Gp Led Wire Extension Kit (6 eh) A Pge 2C NOVEMBER 1999

3 Adjustments TIMING, SYNCHRONIZING & ADJUSTING Timing Pointer Adjustment WARNING Engine ould strt when turning flywheel to hek timing pointer djustment. Remove ll sprk plugs from engine to prevent engine from strting. 1. Remove ll sprk plugs nd instll Dil Inditor ( A1 ) into No. 1 ylinder (top ylinder, strord nk) Turn flywheel in lokwise diretion until No. 1 piston is t top ded enter (TDC). Set dil inditor t O (zero) nd tighten inditor set srew. 3. Turn flywheel ounterlokwise until dil inditor needle is pproximtely 1/4-turn eyond.462 in., then turn flywheel lokwise so tht dil inditor reds.462 in. (11.7mm) extly. 4. Reposition timing pointer () if neessry so tht timing pointer is ligned with.462 in. mrk on timing del. Retighten pointer tthing srews (). -Timing Pointer -Pointer Atthing Srews 5. Remove dil inditor from ylinder NOVEMBER 1999 Pge 2C-3

4 Cruretor Synhroniztion 1. Loosen 3 ruretor synhroniztion srews () to llow shutter pltes to lose ompletely. 2. Position throttle lever so tht idle stop srew is ginst idle stop nd move roller rm until roller lightly touhes throttle m (). Adjust idle stop srew () on throttle rm to lign mrk (d) on throttle m with enter of roller. Without moving roller from this position, retighten ruretor synhroniztion srews. d Cruretor Synhroniztion Srews -Throttle Cm -Idle Stop Srew d-alignment Mrk 3. Verify throttle shutter pltes open nd lose simultneously during throttle lever opertion. Redjust if neessry. Pge 2C NOVEMBER 1999

5 4. Move throttle lever to wide-open-throttle (W.O.T.) position nd djust full throttle stop srew () to llow full throttle shutter opening t W.O.T. Verify tht throttle shutters do not t s throttle stop. Allow.010 in in. (.25mm -.38mm) lerne etween throttle shft rm() nd stop () t W.O.T. Retighten jm nut on djustment srew. d -Full Throttle Srew -Throttle Shft Arm -Throttle Shft Arm Stop d in. (0.25 mm mm) CARBURETOR/OIL PUMP SYNCHRONIZATION 1. When ruretor linkge is t idle position, lignment mrk () on oil injetion rm should e in-line with mrk on sting () s shown. If neessry, djust link rod () Alignment Mrk -Csting Alignment Mrk -Link Rod NOVEMBER 1999 Pge 2C-5

6 Timing Adjustment CAUTION Engine my e timed while rnking engine with strter motor. To prevent engine from strting when eing rnked, ll sprk plugs must e removed. 1. Disonnet remote fuel line from engine. 2. Connet remote ontrol eletril hrness to engine wiring hrness. 3. Remove throttle le rrel from rrel retiner. 4. Remove sprk plugs nd tth sprk plug leds to the sprk gp tester. IMPORTANT: If trigger link rod ws disssemled verify tht 11/16 in. (17.5mm) length is retined. - 11/16 in. (17.5 mm) Mximum Timing Adjustment Connet timing light to No 1 sprk plug led (TOP STARBOARD BANK) 2. With engine in neutrl, move throttle lever to ple mximum sprk dvne srew () ginst stop. Crnk engine with strter motor nd djust mximum sprk dvne timing mrk to otin 24 BTDC. Retighten jm nut on djustment srew. -Sprk Advne Srew Primry Pikup Timing Adjustment With engine in neutrl, hold throttle rm so tht idle stop srew is ginst idle stop. Crnk engine with strter motor nd djust throttle primry pikup srew to lign speified throttle primry pikup mrk on timing del with timing pointer. Retighten jm nut on djustment srew. Pge 2C NOVEMBER 1999

7 NOTE: Primry pikup timing lso determines engine RPM, refer to Idle Speed Adjustment following. Idle Speed Adjustment NOVEMBER 1999 Pge 2C Idle Stop Srew -Primry Pik-Up Srew NOTE: All timing djustments mde to engine under rnking speed onditions should e verified with engine running nd djustments mde if neessry. This is due to dvne hrteristis of individul ignition systems. 2. Remove timing light from No. 1 sprk plug led. 3. Remove sprk gp tool from eh sprk plug oot. 4. Instll ll sprk plugs into ylinder heds. Torque sprk plugs to 20 I. ft. (27 N m) nd tth sprk plug leds to sprk plugs. 1. With engine in wter, onnet fuel line to engine. Strt engine nd llow to wrm up. 2. Ple engine in forwrd nd monitor engine RPM. If RPM is ove or elow reommended RPM (see speifitions), redjust primry pikup () srew to ttin reommended engine speed. Retighten jm nut. Re-instll throttle le. IMPORTANT: Below 3,000 RPM the TKS ECM dvnes idle timing 5 until the engine rehes 104 F (40 C). Aove 3,000 RPM, the TKS ECM does not ffet ignition timing regrdless of engine temperture. 3. With end of throttle le onneted to throttle lever, hold throttle lever ginst idle stop. Adjust throttle le rrel to slip into rrel retiner on le nhor rket with very light prelod of throttle lever ginst idle stop. Lok rrel in ple. 4. Chek prelod on throttle le y pling thin piee of pper etween idle stop srew nd idle stop. Prelod is orret when pper n e removed without tering ut hs some drg on it. Redjust le rrel, if neessry. IMPORTANT: Exessive prelod on throttle le will use diffiulty when shifting from forwrd to neutrl. (Redjust throttle le rrel, if neessry.) NOTE: Cruretors re equipped with idle mixture djustment srews. See ruretor speifitions for mixture srew djustment. NOTE: If suffiient throttle le rrel djustment is not ville, hek for orret instlltion of link rod etween the throttle lever nd throttle m. Eh end of this link rod must e threded into its plsti rrel until it ottoms ginst the throttle lever or throttle m sting, then turned out only fr enough to otin orret orienttion of link rod (less thn one turn). All timing djustments must e reset fter this proedure.

8 240 HP TIMING, SYNCHRONIZING & ADJUSTING Speil Tools Dil Inditor A1 Timing Light Digitl Dignosti Terminl (DDT) A2 DDT Adptor Cle A5 DDT Interfe Cle A1 Pge 2C NOVEMBER 1999

9 DMT 2000 Digitl Thometer/Multi-Meter A1 TIMING, SYNCHRONIZING & ADJUSTING TPS Test Hrness Sprk Gp Led Wire Extension Kit (6 eh) A NOVEMBER 1999 Pge 2C-9

10 Adjustments Timing Pointer Adjustment WARNING Engine ould strt when turning flywheel to hek timing pointer djustment. Remove ll sprk plugs from engine to prevent engine from strting. 1. Remove ll sprk plugs nd instll Dil Inditor ( A1 ) into No. 1 ylinder (top ylinder, strord nk). 2. Turn flywheel in lokwise diretion until No. 1 piston is t top ded enter (TDC). Set dil inditor t O (zero) nd tighten inditor set srew. 3. Turn flywheel ounterlokwise until dil inditor needle is pproximtely 1/4 turn eyond in., then turn flywheel lokwise so tht dil inditor reds in. (11.7mm) extly. 4. Reposition timing pointer (if neessry) so tht timing pointer is ligned with in. mrk on timing del. Retighten pointer tthing srews. -Timing Pointer in. Mrk -Atthing Srews 5. Remove dil inditor from ylinder. Pge 2C NOVEMBER 1999

11 Timing Adjustment TIMING, SYNCHRONIZING & ADJUSTING CAUTION Engine is initilly timed while rnking engine with strter motor. To prevent engine from strting when eing rnked, ll sprk plugs must e removed, exept No.1 ylinder (top ylinder strord nk) plug. IMPORTANT: Control rm link rod () must mintin length of 11/16 in. (17.5 mm). Mke ny neessry djustments to link rod efore proeeding with timing djustments mm (11/16 in.) Throttle Cm Adjustment 1. Remove ll sprk plugs exept No.1 ylinder (top ylinder strord nk) plug. 2. Disonnet remote fuel line from engine. 3. Connet remote ontrol eletril hrness to engine wiring hrness. 4. Remove throttle le rrel from rrel retiner. 1. Loosen m follower srew () llowing m follower to move freely. 2. Allow roller () to rest on throttle m (). Adjust idle stop srew (d) on throttle rm (e) to lign mrk (f) on throttle m () with enter of roller (). Tighten jm nut (g). 3. While holding throttle rm ginst idle stop, tighten m follower srew () with roller lightly touhing m (). e d f g NOVEMBER 1999 Pge 2C-11

12 Stti Idle Timing Adjustment (Crnking Engine with Strter) 1. Disonnet WHITE/BLACK led from idle stilizer ox t ullet onnetor. Disonnet ECU hrness for ignition timing proedure. -Idle Stilizer Led 2. Connet timing light to No 1 sprk plug led (TOP STARBOARD BANK) WARNING While rnking engine, keep ler of propeller, s it my rotte. IMPORTANT: To urtely time engine rnking speed, fully hrged ttery must e used. 3. Connet timing light to no.1 ylinder sprk plug led. Crnk engine with strter (out 300 RPM) while holding throttle rm ginst idle stop. Adjust the primry pikup srew to ttin pproprite setting. Tighten loknut. -Hold Throttle Arm Aginst Idle Stop -Primry Pikup Srew -Loknut Pge 2C NOVEMBER 1999

13 Stti Mximum Timing Adjustment (Crnking Engine with Strter) TIMING, SYNCHRONIZING & ADJUSTING NOTE: WHITE/BLACK led nd ECM hrness remin disonneted for mximum timing djustment. Timing light remins hooked up to no.1 ylinder. 1. Hold throttle rm so tht mximum sprk dvne srew is ginst stop. Crnk engine with strter. Adjust mximum sprk dvne srew to set timing to ttin pproprite setting. Tighten mximum sprk djustment loknut. -Throttle Arm -Sprk Advne Srew -Loknut Mximum Throttle 1. Hold throttle rm ginst full throttle stop srew. Adjust full throttle stop srew to llow full throttle vlve opening, while mintining lerne etween rm of throttle shft nd stop on indution ox. Tighten loknut. 2. Chek for slight free ply (roller lifter from m) etween roller nd m t full throttle to prevent linkge from inding. Redjust full throttle stop srew, if neessry. 3. Reonnet WHITE/BLACK led from idle stilizer ox. Reonnet ECM hrness. Disonnet timing light nd instll sprk plugs nd fuel line. d e -Throttle Arm -Full Throttle Stop Srew -Throttle Shft Arm d-stop e -Loknut NOVEMBER 1999 Pge 2C-13

14 Throttle Position Sensor (TPS) Adjustment USING DIGITAL DIAGNOSTIC TOOL (DDT) IMPORTANT: Engine must e OFF efore onneting the DDT dptor le to the ECM. 1. Connet the DDT dptor le to ECM dignosti port s shown. Atth the ttery lips to 12v ttery. 2. Connet the DDT interfe le etween the DDT nd DDT dptor le if required. NOTE: Apply smll mount of dieletri grese to the 25 pin ends of interfe les. This will minimize orrosion in sltwter environment. -ECM Dignosti Port -DDT Adptor Cle -DDT Interfe Cle 3. Turn key to the ON position. 4. Loosen srews seuring TPS to mnifold. -Loosen Two (2) Srews nd Rotte TPS 5. Rotte TPS fully lokwise (holding throttle shft in losed position). Strt to rotte TPS ounterlokwise until reding etween volts is hieved. Pge 2C NOVEMBER 1999

15 NOTE: If engine ppers to run too rih or too len, TPS n e re-djusted. Deresing voltge yields lener mixture. Inresing voltge yields riher mixture. Allowle TPS rnge is volts. 6. Tighten TPS srews holding orret tolerne. 7. Disonnet remote ontrol le from throttle lever. 8. Slowly move throttle lever to full open position while monitoring voltge reding. Voltge should inrese nd derese smoothly. 9. Mximum voltge reding t full throttle is pproximtely 7.46 volts. USING DMT 2000 DIGITAL TACHOMETER/MULTI-METER 1. Disonnet TPS from EFI hrness TPS/EFI Hrness Connetor 2. Connet digitl meter using TPS Test Led Assemly (P/N ) etween TPS onnetor nd EFI hrness onnetor. Set voltmeter to 2 DC volts. IMPORTANT: TAN/BLACK hed temperture leds must e disonneted from port ylinder hed efore djusting TPS. 3. Disonnet TAN/BLACK engine hed temperture sensor leds loted on port ylinder hed. -Disonnet TAN/BLACK Leds NOVEMBER 1999 Pge 2C-15

16 4. Turn key to the ON position. 5. Loosen srews seuring TPS to mnifold. 6. Rotte TPS fully lokwise (holding throttle shft in losed position). Strt to rotte TPS ounterlokwise until reding etween volts is hieved Loosen Two (2) Srews nd Rotte TPS NOTE: If engine ppers to run too rih or too len, TPS n e re-djusted. Deresing voltge yields lener mixture. Inresing voltge yields riher mixture. Allowle TPS rnge is volts. 7. Tighten TPS srews holding orret tolerne. 8. Disonnet remote ontrol le from throttle lever. 9. Slowly move throttle lever to full open position while monitoring voltge reding. Voltge should inrese nd derese smoothly. 10. Set volt meter to 20 DC volts. Mximum voltge reding t full throttle is pproximtely 7.46 volts. 11. Remove test led nd reonnet TPS hrness to EFI hrness. Idle Timing (Engine Running) 1. WHITE/BLACK led from idle stilizer must e disonneted. -Idle Stilizer Led 2. With engine in wter, strt engine nd llow to wrm up. 3. Shift engine into FORWARD ger. Pge 2C NOVEMBER 1999

17 4. Hold throttle rm ginst idle stop (throttle le rrel removed from rrel retiner). Adjust idle timing srew to ttin pproprite setting. Tighten loknut. Idle Adjustment -Throttle Arm -Idle Timing Srew -Loknut 5. Reonnet WHITE/BLACK led of idle stilizer t ullet onnetor. 1. With Jet Unit in wter, strt nd llow to wrm up. 2. Loosen m follower srew, llowing free movement of m. Hold throttle rm ginst idle stop. Adjust idle speed srew y inresing or deresing ir vlve opening to ttin pproprite setting. -Idle Speed Srew NOVEMBER 1999 Pge 2C-17

18 Throttle Vlve/Oil Pump Synhroniztion 1. While holding throttle rm ginst idle stop, djust length of link rod so tht stmped mrk of oil pump lever ligns with stmped mrk of oil pump ody. -Link Rod -Oil Pump Lever Mrk -Oil Pump Body Mrk Pge 2C NOVEMBER 1999