Table of Contents Important Information Section 1C - Troubleshooting Troubleshooting 1 C Jetdrive Troubleshooting...1C-2 Jetdrive Unit Troubleshooting...1C-2 Performance Troubleshooting...1C-4 Hard Steering...1C-5 Corrosion Protection...1C-6 90-866211 FEBRUARY 2005 Page 1C-1
Jetdrive Troubleshooting Jetdrive Unit Troubleshooting This section is a guide for performance and product troubleshooting. Referrals to specific sections of this manual are made where special tests or repairs procedures are to be performed. Because of the relationship between power package components (engine and jetdrive) it will be necessary in some cases to simultaneously refer to the appropriate Engine Service Manual for further troubleshooting information. Effective troubleshooting is best enhanced by: Personal product knowledge and experience of the trained mechanic / technician Allowing adequate time for testing and analysis Utilizing these charts as a "guide" a starting point. JETDRIVE DOES NOT GO INTO REVERSE / FORWARD; REMOTE CONTROL SHIFT HANDLE MOVES Shift cable improperly adjusted Shift cable not connected Inner core wire broken or loose Reverse gate tie rod improperly adjusted s Adjust shift cable Install and adjust shift cable Reconnect or replace inner core wire Adjust tie rod linkages NOTE: Note: For additional information on troubleshooting, refer to SECTION 3A POOR, ERRATIC, OR NO ASSIST WHEN SHIFTING INTO FORWARD / REVERSE; REMOTE CONTROL SHIFT HANDLE MOVES Low fluid level Air in system Leaking hoses Restriction in hydraulic hoses Control valve not positioned properly, not balanced properly, or the mounting nut is loose Mounting bracket adjusting screw loose or mounting tube loose Faulty pump Worn piston ring or scored housing bore in cylinder Leaking valve body or loose fitting spool Check fluid level and top up if needed Air leak in lines, pump, or from installation. Ref to engine service manual for further details Refer to engine service manual for bleeding procedure s loss of pressure Adjust the cable or tighten mounting nut Tighten mounting bracket adjusting screw or mounting tube Flow control valve maybe sticking s loss of pressure Repair or replace NOTE: For additional information refer to engine service manual "power steering" section JETDRIVE DOES NOT GO INTO REVERSE / FORWARD; REMOTE CONTROL SHIFT HANDLE DOES NOT MOVE Control box not properly assembled Broken or damaged linkage in control box Debris blocking the reverse bucket Properly reassemble control box Repair linkage Clear debris from reverse bucket NOTE: For additional information on troubleshooting, refer to SECTION 3A Page 1C-2 90-866211 FEBRUARY 2005
JETDRIVE DOES NOT GET FULL REVERSE / FORWARD SHIFT POSITION Shift cable improperly adjusted Gate tie rod improperly adjusted Alignment pin and bushing not properly positioned Adjust shift cable Adjust tie rod linkages Check alignment pin is correctly seated NOTE: For additional information on troubleshooting, refer to SECTION 3A JETDRIVE STUCK IN REVERSE POSITION Shift cable broken Cable end not connected to shift mechanism Remote control damaged Shift cylinder not working Control arm disconnected at shift cylinder or tie rod Replace cable and adjust Remove and reinstall cable Repair or replace remote control Repair or replace is necessary Connect control arm GEAR BOX NOISE NOTE: For additional information on troubleshooting, refer to SECTION 3A Metal particles in drive unit lubricant Incorrect gear shimming Water in gear oil Disassemble, clean and inspect and replace necessary components. Check gear housing backlash Disassemble, clean and inspect and replace necessary components. OIL FOAMS OUT OF VENT PLUG NOTE: For additional information on troubleshooting, refer to SECTION 3C Contaminated oil Oil level low or high s Determine cause of contamination and fix. Flush system with clean oil, and refill. Check for cause and correct. NOTE: For additional information on troubleshooting, refer to SECTION 3B OIL FOAMS OUT OF BREATHER CAP OR TRIM RESERVOIR (IF EQUIPPED) Contaminated oil Oil level low or high s Flush system with clean oil refill pump and bleed trim system Check for cause of low oil level and correct. Add oil to pump and bleed system. NOTE: For additional information on troubleshooting, refer to SECTION 5A TRIM NOZZLE MOTOR WILL NOT RUN IN THE UP OR DOWN DIRECTION, SOLENOIDS DO NOT CLICK 20 amp fuse blown Replace fuse See also Power Trim topics in section 5B of Mercury Outboard Service Manual for Optimax Outboards, part number 90 897725. 90-866211 FEBRUARY 2005 Page 1C-3
Performance Troubleshooting LOW WOT ENGINE RPM Damaged or fouled impeller. Gear ratio incorrect. Clean, repair or replace. Verify gear ratio. HIGH WOT ENGINE RPM Impeller ventilating. Damaged or fouled impeller. Gear ratio incorrect. Engine coupler hub spun. Determine cause for ventilation. Clean, repair or replace. Verify gear ratio. Replace coupler. POOR BOAT PERFORMANCE OR POOR MANEUVERABILITY-BOW TOO LOW Boat is underpowered. Boat is bow heavy. Check horsepower to weight ratio. Contact the boat manufacturer. Redistribute boat load to stern or contact the boat manufacturer. Permanent hook in boat bottom (some boats are built with a slight hook for correct boat performance). Check for a hook in the boat bottom by placing a straight edge, at least 6 ft. (2m) long, under the bottom edge of the transom. If a hook is found, contact the boat manufacturer. Power rocker or weak boat bottom. Water test boat. Boat will perform normally until hook develops at high speed, then loss of speed will occur. Contact boat manufacturer. POOR BOAT PERFORMANCE OR POOR MANEUVERABILITY-BOW TOO HIGH Boat is stern heavy. Redistribute boat load to bow. If stern overweight is caused by permanently installed fuel tank(s), contact the boat manufacturer. Permanent rocker in boat bottom (some boats are built with a slight rocker for correct boat performance). Wrong gear ratio Check for a rocker in the boat bottom by placing a straight edge, at least 6 ft. (2m) long, under bottom edge of the transom. If a rocker is found, contact the boat manufacturer. Power rocker or weak boat bottom. Water test boat. Boat will perform normally until hook develops at high speed, then loss of speed will occur. Contact boat manufacturer. Page 1C-4 90-866211 FEBRUARY 2005
POOR BOAT PERFORMANCE Blockage in inlet Damaged or fouled impeller. Boat is overloaded. Boat is overloaded. Power rocker or weak boat bottom Inspect inlet and remove any foreign objects Clean, repair or replace. Redistribute boat load to stern, or contact the boat manufacture Redistribute boat load to bow, or contact boat manufacture. Water test boat. Boat will perform normally until hook develops at high speed, then loss of speed will occur. Contact boat manufacture JETDRIVE VENTILATING / CAVITATING Impeller cavitating when underway Damaged or fouled impeller. Check delta plane is correct. (Refer to Section 2A, Jetdrive Installation Manual) Clean, repair or replace. Hard Steering Damaged steering cable Replace cable (Refer to Section 2A) Steering cable too short (sharp bends) or too long (loops and long bends) Steering cable corroded or not lubricated Not getting full steering from lock to lock Select and install proper length cable. (Refer to Section 2A) Lubricate or replace the cable Check Jetdrive tie rod adjustment procedure (Refer to Section 2A) 90-866211 FEBRUARY 2005 Page 1C-5
Corrosion Protection CORROSION ON UNDERWATER PARTS, WITHOUT MERCATHODE OR IMPRESSED CURRENT PROTECTION Sacrificial anode(s) consumed. Sacrificial anode(s) not grounded to jetdrive. Loss of continuity between underwater parts & ground. Shore power causing overload of anode(s) Paint on drive heavily worn (exposing more metal). Sacrificial anode(s) painted. Only power trim cylinders are corroded. Replace anode(s) when 50% consumed. Remove anode(s), clean contact surface, reinstall and check continuity. Provide good ground connections. Disconnect shore power or install Quicksilver isolator. Prime and repaint and/or install additional anode(s). Remove paint or replace anode(s). Provide good ground to jetdrive. All parts must be grounded. Corrosion occurring after unit removed from saltwater. Wash exterior and flush interior with fresh water. Corrosion and/or salt build up between mating parts. Exclude moisture from between mating parts with Quicksilver 2 4 C with Teflon or Perfect Seal. Stainless Steel parts corroding: Tightly wrapped fishing line or foreign material excludes oxygen, causing corrosion. Iron particles, such as from a wire brush, cause rusting. Impeller pitting can occur if electrical continuity is lost. Clean parts, remove foreign material, ensure continuity. Page 1C-6 90-866211 FEBRUARY 2005
CORROSION ON UNDERWATER PARTS, WITH MERCATHODE OR IMPRESSER CURRENT PROTECTION - DRIVE CORRODING (IF EQUIPPED) Poor connection between reference electrode (BRN) lead or anode (ORN) lead and MerCathode controller. Faulty MerCathode reference electrode. Faulty MerCathode controller. Too much cathode (such as stainless steel). Loss of continuity between jetdrive components and ground. Sacrificial anodes consumed, painted or inoperative. MerCathode reference electrode or anode painted. Clean and/or tighten connection. Repair wiring. Disconnect reference electrode lead (BRN) from the controller "R" terminal. Connect the lead to positive (+) terminal of a digital multi meter (set on 0 2000 millivolt scale). Connect negative ( ) meter lead to negative ( ) battery terminal. Note meter reading; then repeat the test with a test silver / silver chloride reference electrode held behind the drive. The same reading should be obtained in both cases. If not, replace the reference electrode. With anode and reference electrode leads connected to controller, connect a jumper wire between "R" and negative( ) terminals on controller. Connect positive (+) lead of volt meter (set on 0 20 scale) to "A" terminal on controller. Connect the negative ( ) meter lead to the negative ( ) controller terminal. Reading should be as follows: D Freshwater Areas = 11.5 volts minimum D Seawater Areas = 3.55 volts minimum If the reading is low, replace the controller. MerCathode system overpowered by large quantity of stainless steel below the waterline. Ensure continuity (check continuity wires and washers). Replace anodes. Remove paint or replace anode or MerCathode reference electrode. 90-866211 FEBRUARY 2005 Page 1C-7
CORROSION ON UNDERWATER PARTS, WITH MERCATHODE OR IMPRESSER CURRENT PROTECTION - DRIVE OVER-PROTECTED (IF EQUIPPED) Faulty MerCathode reference electrode. Faulty MerCathode controller. Stray current corrosion (electrical current leaves a metal conductor and creates a path through the water). Poor connection between the MerCathode reference electrode lead (BRN) and the "R" terminal on the controller. MerCathode system not functioning. Disconnect reference electrode lead (BRN) from "R" terminal on controller. Connect the lead to the positive (+) terminal of a digital multimeter (set on 0 2000 millivolt scale). Connect the negative ( ) meter lead to the negative ( ) battery terminal. Note the meter reading; then repeat the test with a test silver / silver chloride reference electrode held behind the drive. The same reading should be obtained in both cases. If not, replace the reference electrode. Check controller output. If the hull potential indicates overprotection, remove the reference electrode lead from the controller. If the controller is off (no impressed current called for) the voltage between the negative (BLK) and the anode should be less than 1 volt. Measure amperage; with the reference electrode disconnected, the amperage between the negative on the controller and the anode terminal should be less than 1 milli amp. Replace the controller if needed. Disconnect electrical components one at a time and observe the multimeter reading until you eliminate the high reading. Correct the source of the stray current. Clean and/or tighten the connection. Repair wiring as needed. Check the fuse in the hot lead. Check the battery. Check for loose connections at controller and battery. Check the grounding wire between the jetdrive and the controller. Page 1C-8 90-866211 FEBRUARY 2005