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4 cylinder mercruiser manualDiscover everything Scribd has to offer, including books and audiobooks from major publishers. Start Free Trial Cancel anytime. Report this Document Download Now save Save Mercruiser Manual GM 4 Cylinder For Later 37K views 23 23 upvotes 10 10 downvotes Mercruiser Manual GM 4 Cylinder Uploaded by talleyp Description: Full description save Save Mercruiser Manual GM 4 Cylinder For Later 23 23 upvotes, Mark this document as useful 10 10 downvotes, Mark this document as not useful Embed Share Print Download Now Jump to Page You are on page 1 of 348 Search inside document Browse Books Site Directory Site Language: English Change Language English Change Language. Exact model application: Models Application: Sterndrive (MCM) starting with serial number OM300000 and above, 5.0L MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo Horizon, MX 6.2 MPI, MX 6.2 MPI Horizon, Inboard and Dow Sports (MIE) starting with serial number OM310000, 350 MAG MPI Inboard, 350 MAG MPI Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard and 350 MAG MPI Tow Sports. Some Standard Bravo Transom Assemblies could have been converted to High Performance Transom Assemblies by use of a High Performance Gimbal Ring Kit (822374A2). Refer to Transom Assembly sections of this manual for identification information. Bravo One XR (Serial Number 0W240000 and Above). Bravo Two, Bravo Two X, Bravo Two X Diesel, Bravo Three, Bravo Three X, Bravo Three X Diesel (Serial Number 0M198373 and Above). Bravo Three XR (Serial Number 0W240000 and Above). Transom Standard (Serial Number 0W173658 and Above) Transom High Performance(Serial Number 0W150260 and Above) Inboard (MIE) Models: D2.8L D-Tronic (Serial Number 0K000001 and Above), D4.2L D-Tronic (Serial Number 0K000001 and Above). General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning the inboard engine or stern drive.http://weikiang.com/files/bosch-kgv2604-manual.xml

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Read and refer to the other sections in this manual for information regarding proper inspection and service procedures. If a modification has been made since then, differences may exist between the content of these manuals and the actual inboard or stern drive. Persons without such knowledge and skills should attempt with caution to service any component or engine by relying on this manual only. Never attempt to perform any work with out the assistance of a service manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the boat operator and passengers. However, individual operating habits and personal maintenance preferences can have an impact on the suggested intervals. In consideration of these factors, Mercury MerCruiser has adjusted some maintenance intervals and the corresponding tasks to be performed. In some cases, this may allow for more individual tasks in a single visit to the servicing dealer. Therefore, it is very important that the boat owner and the servicing dealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincide with the individual operating habits, the environment and the maintenance requirements. If operating in salt, brackish or polluted waters, flush the cooling system after each use. Check the drive unit oil level, the trim pump oil level and the power steering pump fluid level. Check the water inlets for debris or marine growth. Check the seawater strainer and clean. Check the coolant level. Clean the gauges. Replace the fuel filters. Check the steering system and the remote control for loose, missing or damaged parts. Lubricate the cables and the linkages. Inspect the U-joints, the splines and the bellows. Check the clamps. Check the engine alignment. Lubricate the U-joint splines. Lubricate the gimbal bearing and the engine coupler. Check the continuity circuit for loose or damaged connections. Test the MerCathode unit output on Bravo Models.http://fapobenas.com/assets/bosch-kgv24v00-manual.xml Replace the PCV valve. Check the electrical system for loose, damaged or corroded fasteners. Inspect both systems for damage or leaks. Disassemble and inspect the seawater pump and replace worn components. Clean the seawater section of the closed cooling system. Clean, inspect and test the pressure cap. Replace the coolant. This oil is a special blend of 25-weight and 40-weight oils for marine engines.The oil filter should always be changed when changing the engine oil. When the old plugs are replaced, replace the entire set. Perform plug service only on those plugs suitable for additional service, using the following procedures: Use compressed air to remove abrasives. 4. File the electrode surfaces to restore clean, sharp edges. Remove filings with compressed air. 5. Reset the gap to specifications by bending only the side electrode with the proper tool. This plug shows that the plug heat range is compatible with the engine, and the engine is electrically and mechanically in good running condition. With proper plug servicing (clean, file and regap), this plug can be reinstalled with good results. Worn piston rings, cylinder walls, valve guides or valve stem seals are causes of oil entering the combustion chamber. Only engine repairs will permanently relieve oil wet fouling. Such fouled plugs may be serviced (clean, file and regap) and reinstalled. Determine the cause of the excess water. 1.5 Improperly adjusted trim tabs or after planes 1.5 Adjust the trim tabs or after planes 1.6 Dirty boat bottom (marine growth) Repair the hull. Reinstall the water pickup or the through the ull fittings in the proper locations. Repair the transom. Reinstall the drive unit in the proper position. 1.5 Wrong gear ratio drive unit 1.5 Replace the drive unit with the appropriate gear ratio. If the problem persists, drain the fuel tank and refill. If the problem persists, check the remote control level NEUTRAL detent setting. 1.http://www.drupalitalia.org/node/680251 Battery charge low, damaged wiring, loose electrical connections 1.1 Check the electrical connections at the starter. Check the battery cable connections. Check the battery charge and recharge if necessary. 1.2 Circuit breaker tripped 1.2 Reset the circuit breaker. 1.3 Blown fuse 1.3 Replace the fuse. 1.4 Ignition switch faulty 1.4 Replace the ignition switch. 1.5 Slave solenoid faulty 1.5 Replace the slave solenoid. Noise will stop as soon as engine is turned off. 1.0 Wrong spark plugs 1.0 Change the spark plugs. 1.1 Cracked distributor cap 1.1 Check the distributor cap for cracks or marks. Replace the cap if necessary. 1.2 Cracked coil tower 1.2 Check the ignition coil for cracks or corrosion. Replace the throttle body if necessary. 1.2 Worn or leaking IAC hose or vacuum hose to the pressure regulator 1.2 Find and replace the leaking hose. 2. Low top speed or lack of power 2.0 Leaking idle air control (IAC), intake manifold or throttle body gaskets 2.0 Find and replace the leaking gaskets. 3. Poor cold engine operation 3.0 Engine is not reaching normal operating temperature 3.0 Replace thermostat or thermostat housing gasket. 3.1 Faulty engine temperature sensor (ECT) 3.1 Replace the ECT. 3.2. Fuel PSI too high or too low 3.2 Determine the cause and repair. 3.3 Throttle valves worn or damaged 3.3 Inspect the throttle valves. Replace the throttle body if necessary. 3.4 Engine flooding 3.4 Check the fuel pressure. If too high, find cause and correct. Clean the flame arrestor. Perform the cylinder balance test. 4. Engine stalls 4.0 Idle rpm too low 4.0 Clean the flame arrestor. Test the IAC to see if it opens and closes properly. 4.1 Engine flooding 4.1 Check the fuel pressure. If too high, find cause and correct. Inspect the fuel pressure regulator. Inspect the injectors. 4.2 Leaking idle air control (IAC), intake manifold or throttle body gaskets 4.2 Find and replace the leaking gaskets. 5.0 Engine misses 5.0 Fault in the ignition system 5.0 Check the spark plugs.https://www.acoustiguard.com/images/4-cylinder-engine-short-block-high-performance-manual.pdf Check the spark plug wires. Check the distributor cap for cracks or marks. Check the ignition coil operation. Replace the faulty component. You do not need any suction, no swap, no pre-fill fuel. Just turn the key in the ignition and the engineEngines with multipoint fuel injection areDiesel engines can also be used with turntables (Sterndrives), as wellWhether it is the Alpha and BravoCould you help me?Can anyone help?Thank you in advance.I am also looking for the manual for the Bravo III. Can someone help me with this? Thx!I replaced the front cover but realised that the hole might beCan you please advise if I'm right. Regards RS. Starboard side is right side; port side is left side. In this maintenance manual, all directional references are given as they appear when viewing boat from stern looking toward bow. Do not apply antifouling a - Hook paint to MerCruiser drive unit or transom assembly. IMPORTANT: If antifouling protection is required, Tri-Butyl-Tin-Adipate (TBTA) base antifouling A “rocker” is the reverse of a hook. The bottom is con- paints are recommended on MerCruiser boating vex or bulged in the fore-and-aft direction. For best top speed, open-throttle power of an engine. Since air (contain- all movable weight - cargo and passengers - should ing oxygen) gets thinner as elevation increases, the be as far aft as possible to allow the bow to come up engine begins to starve for air. To Be Done by Owner TASK INTERVAL Cooling System - Flush seawater section Saltwater: After each use Seawater strainer Clean as required. MCM (Stern Drive) Model All Models Crankcase Oil (with filter) 4 U.S. Qts. (3.8 L) Seawater Cooling System 9 U.S. Qts. (3.8 L) Closed Cooling System 9 U.S. Qts. (8.5 L) Always use dipstick to determine exact quantity of oil required Seawater cooling system capacity information is for winterization use only Index. If not available, a good grade, straight weight, de- tergent automotive oil of correct viscosity, with an API classification of SF or SG, may be used. The over-full 7. Add required amount of oil to bring level up to, but condition results in the engine crankshaft splashing not over, the FULL mark on dipstick. Tighten filter securely (following filter man- and ADD mark on dipstick.Do not over-tighten. 72518 a - Proper Fluid Level with Engine Warm 4. Sudden loss of pressure could cause sure that all air is bled from the system. IMPORTANT: MerCruiser recommends that pro- pylene glycol antifreeze (nontoxic and biode- gradable, which makes it friendly to lakes and riv- ers) be used in sea-water section of the cooling system for cold weather or extended storage. Cooled (Coolant) Models NOTICE Refer to “Cold Weather or Extended Storage,” “Precautions,” in this section, BEFORE proceeding. After seawater section of cooling system has vent holes and water drain holes and passages been drained completely, coat threads of drain (as shown) are unobstructed and open.Tighten drain plugs securely. BEFORE working on fuel system to prevent fire or explosion. Under certain conditions, severe deto- viceability of spark plug. Spark plug condition also nation also can split insulator firing ends. Plug must can suggest a variety of possible engine malfunc- be replaced. Clogged flame arrestor, flooding car- that temperatures suddenly have risen, usually dur- buretor, sticky choke or weak ignition components ing hard, fast acceleration under heavy load. Center electrode melts first, followed delayed tune-up, accumulate after a long period of by ground electrode. Normally, insulators are white misfiring. When normal combustion temperatures but may be dirty if plug has been misfiring. Remove coil 1. First, determine which engine system is causing wire from tower on distributor cap. Hold coil wire the problem. To make an engine run, basic com- near ground and check for spark while cranking ponents fuel, spark (ignition), and compression engine over. Is spark normal? Is the spark plug normal. Replace the spark plug. Parts other than the DDIS are defective. Is spark plug wire good. Replace spark plug wire. The engine harness, battery Is the ignition amplifier power Is the engine harness ignition key, ignition amplifier. Replace the spark plug. Parts other than the DDIS are defective. Is spark plug wire good. Replace spark plug wire. Is the ignition coil normal? (Check the primary and Replace the ignition secondary resistor insulation coil. Water test boat for proper operating RPM at wide open throttle 4. Noise will stop as soon as engine is tributor cap; cracked coil tower; leaking spark turned off.This can help determine Important Information which components are at fault. No definite rule or test will positively determine 5. Sometimes noises can be caused by moving source of engine noise;. Do not rely on the oil pressure gauge in the boat. 2. Check engine oil level with boat at rest in the 2. Oil level should be between the ADD and FULL water marks 3. Refer to SECTION 4D for instrument testing. 3. Thin or diluted oil 3. Oil broken down; contains water or gas; wrong viscosity;. Important Information If the water is contained to crankcase only, it is usu- ally caused by a cracked or porous block, a flooded IMPORTANT: First determine location of water in bilge, or condensation. Antifreeze not mixed properly 15. Heat exchanger cores plugged 17. Water hoses reversed at the water distribution 17. Refer to water flow diagram in SECTION 6 block Poor, Erratic, or No Assist Cause. Refer to Stern Drive Ser- vice Manual. Engine Removal 1. Disconnect battery cables from battery. 50738 a - Fuel Pump b - Disconnect Fuel Inlet Line Here - Plug inlet hose 4. Loosen hose clamps and disconnect exhaust el- (coming from transom assembly) from engine bow hose. harness. 13. Remove both shift cables from shift plate. Retain NOTE: After wires are disconnected be sure to loos- locknuts and hardware. Inspect fi- ber washers. DO NOT use to lift entire engine. CAUTION DO NOT allow lifting sling to hook or compress engine components or damage will occur. Shift cable outer casing can FREELY all the way in and out of engine cou- be crushed causing difficult or improper shifting. IMPORTANT: When routing all wire harnesses and hoses, be sure they are routed and secured to avoid coming in contact with hot spots on en- gine and avoid contact with moving parts. Tighten clamp securely.Tighten cable end guide locknut until it bottoms out and then back off a. Place remote control handle(s) in neutral, idle one full turn. Apply contacts idle speed adjustment screw.This code number is 72001 stamped on all MerCruiser power packages and re-. Refer to Section 7B for removal. 1. Disconnect crankcase ventilation hoses. 2. Remove any items that interfere with the removal of rocker arm covers. Replace all damaged parts. The head gasket may be holding cylinder head to block. Use care when prying off cylinder heads. IMPORTANT: Do not turn crankshaft while valve DO NOT damage gasket surfaces. When head resurfacing is required, cylinder head-to-intake manifold gasket surface on head must be milled to provide proper align- ment between intake manifold and head. The recommendation of the man- Valve seat reconditioning is very important, since ufacturer of the equipment being used should be seating of valves must be perfect for engine to deliver carefully followed to attain proper results. Installation 1. Install pump, with extension shaft, to rear main bearing, aligning extension shaft with distributor drive shaft. IMPORTANT: Correct rotation oil seal must be used to prevent oil leak. 1. Apply Quicksilver Perfect Seal to seal retainer mating surface and apply grease to seal lips. 2. Torque front cover 1. Apply grease to seal lips.After all bearings is a graduated scale which is correlated in thou- have been checked, rotate the crankshaft to see sandths of an inch. Without removing the gauging that there is no excessive drag. Posi- IMPORTANT: Before you remove the connecting tion the gauging plastic in the middle of the rod cap, mark the side of the rod and cap with the bearing shell. If clearance cannot be brought to within specifications, the crankpin will have to be 1. Therefore, when fitting new PISTONS AND PISTON PINS rings, clearances between ring and groove sur- faces should be measured. See “Specifications.” IMPORTANT: When reassembling pistons and connecting rods, the following must be kept in mind. Be sure that ring is square with cylinder wall. Install with connecting rod bearing tangs toward outside of cylinder block. Use piston ring compressor to compress rings. Installation Guide connecting rod into place on crankshaft journal with connecting rod bolt guide. Remove crankshaft gear as shown. a. Oil pump. b. Dipstick and oil pan. c. Cylinder heads. d. Intake manifold. e. Distributor. 9. Fill crankcase with oil.Flywheel housing. k. Starter. 10. Install new oil filter. Fill crankcase with oil. Crankshaft Sprocket Removal 72359 1. Remove torsional damper and crankcase front a - Lower Bearing Insert cover as previously outlined.Be sure that push rod is in lifter socket. 74438 72907 a - Ball Socket Adaptor Tool (J-8520-1) a - Timing Marks 6. Measure camshaft end play.001 -.005 Position thrust plate so that woodruff key in shaft in. (0.03-0.1 mm) does not damage plate when shaft is pressed out of gear. Backlash should not be less than 1. Install camshaft and gear assembly in engine.004 in. (0.010 mm) or more than.006 in. (0.15 block, being careful not to damage camshaft bearings or camshaft. Be sure Removal grooves and drilled oil passages are clean. Camshaft bearings can be replaced while engine is disassembled for overhaul or without complete disas- Installation sembly. Be tool on drive handle.NOTE: These plugs may be removed with a sharp 72385 punch, or they may be drilled and pried out. A cylinder bore of more than.005 in. wear or taper may not clean up entirely when fitted to a high limit piston. IMPORTANT: Handle pistons with care and do not attempt to force them through cylinder until cylin- der is honed to correct size, as this type piston can be distorted by careless handling. Be sure that battery tured to comply with U.S. Coast Guard Rules and area is well ventilated and that bilge blower is in Regulations to minimize risks of fire and explo- operation when charging. If battery shows off by battery are hazardous. Check with DC volt- 1. CHARGING CHARGED 2. Check fluid level and fill if low. 3. Cover terminals and bolts with light coat of grease. 4. Set battery on wood or in carton; store in cool, dry place. These en- gines use a standard type solenoid; do not substi- tute a switch type solenoid. The other engines use a slave solenoid to energize the starter motor sole- noid. Field coils should be re- Check armature for shorts by placing on growler and moved only where defects are indicated by tests. IMPORTANT: Be sure that positive brushes and leads do not contact field frame assembly during test, or false reading will result. 1. With continuity meter, place one lead on field con- nector bar and other lead on grounded brush. Place thrust collar and retainer next to snap After all parts are thoroughly tested and inspected ring and using two pliers squeeze both until and worn or damaged parts replaced, reassemble snap ring is forced into retainer. Pinion clearance must be checked as follows after 6. If clearance is not within limits of.010-.140 in. reassembly of motor to insure proper adjustment. The Delco PG 200 and PG260 starter motor features 3. It can do this only for a short time, since considerable heat accumulates and can PG200 Disassembly cause serious damage. Check that bearings roll freely. If any roughness is felt, replace bearings. 5. Inspect planetary gear assembly. Gears must mesh easily and roll freely with no binding. Armature Tests TEST FOR SHORTS Check armature for shorts by placing on growler and. IMPORTANT: Brush holder must be installed on armature before installing armature bearing. Using the correct size driver, press on inner bearing race until it contacts shoulder of armature shaft. Gear Bearing REMOVAL Using the correct size driver, press bearing out of. IMPORTANT: Roller bearing is not replaceable. If bearing is defective, replace entire shaft assem- bly. Apply Quicksilver 2-4-C Marine Lubricant with Teflon to bearing before starter reassembly. Align holes of end frame with holes of brush holder. Tighten 2. Remove brush holder.Strike wood block with hammer, thus forcing snap ring over end of shaft. IMPORTANT: Install special mounting shim (if 5. Momentarily touch a jumper lead from solenoid equipped) between starter motor and engine motor to starter motor frame. Basic initial timing must be added to chart for total advance MCM 3.0L with Prestolite curve.When performing the following procedure, be 4. Clean spark plug seating area. DO NOT use gas- sure to observe the following: kets on taper seat plugs. Install spark plugs and Be sure that engine compartment is well ven- torque to 15 lb. Dirty points should be cleaned.Normal point condition is an overall grey color on 3. IMPORTANT: Carefully wipe protective film from point set prior to installation. Install main shaft in distributor housing. 1. Remove condenser and breaker points from breaker plate. It may be necessary to ro- 1. Timing must be set on the “before” side of “0” (Top Dead Center). 72328 a - Degree Marks b - Timing Mark 5. Adjust timing by loosening distributor clamp and rotating distributor body as required until timing mark on damper or pulley lines up with the mark on tab specified in “Specifications.”. The ignition coil is actually two coils in one with four A motion sensor replaces the conventional distributor high voltage towers. There is no ad- IMPORTANT: Advance curve charts do not in- justment. Initial timing must be set below 1000 clude the initial engine timing. Basic initial timing RPM. There is no ad- IMPORTANT: Advance curve charts do not in- justment. Initial timing must be set below 1000 clude the initial engine timing. Basic initial timing RPM. With ignition switch in the “RUN” position, check voltage at terminal from engine harness. IMPORTANT: Check spark plugs and spark plug Reading should be battery voltage.Use Multi-Meter 91-99750 to test DDIS components. Minimum re- perature, 68 F (20 C), when testing.Install new gasket. Apply Quicksilver 2-4-C Marine Lubricant with Teflon to Removal gear. 1. Disconnect wires (a). 74390 74537 a - Hole b - Notch in Motion Sensor Housing a - Wires NOTE: When installing motion sensor it may be nec- 2. Inside the distributor, the pick-up coil attaches to the module at a molded prong connector. Connect ohmmeter to 12 volt terminal (b) and to coil high The following tests can be made with the distributor tension post (a). Reading should be between and coil mounted on or off the engine. The test proce- 7800 and 8800 ohms. DO NOT add initial timing degrees to total advance degrees. MAX. MIN. 1000 1500 2000 2500 3000. Temporarily join the engine harness wires together. IMPORTANT: Failure to follow the timing proce- dure instructions will result in improper timing causing performance problems and possible se- IMPORTANT: Do not fail to reconnect these two vere engine damage. Use of replacement electrical, ignition or fuel sys-. Failure to observe tery, the ignition switch and the wiring which connects these precautions may result in serious damage to these components. Alternator CAUTION 1. Meter should indicate approximate (Alternator on Engine) battery voltage and should not vary. If no reading is obtained, or if reading varies, check alternator Use the following tests in conjunction with the “Trou- output circuit for loose or dirty connections or bleshooting”. If bat- circuit probably is shorted or grounded.Reading should engine speed to 1500-2000 RPM and observe be at least 30 amps. Remove regulator cover and install wires and nuts for testing. Connect a jumper wire from the ground stud to the brush ter- Removal minal on the lower right- hand side of the brush assembly. Remove front bearing from front end frame using this point, stator, rectifier, diodes, and rotor may an arbor press and a suitable size mandrel. (Dis- be tested, as explained under “Component Test- card bearing.) ing,”. Bearing should turn 1. Test rotor field circuit for opens, shorts or high re- freely without binding or evidence of rough sistance (Test 1), using an ohmmeter (set on R x1 spots. Inspect slip rings to be sure that they are IMPORTANT: Stator leads MUST BE discon- not bent and touching outer slip ring. Also, be nected from rectifier for this test.Hand-press end frames together, then install four screws. Install cover with one Phillips head screw and two frame cavity and secure with two mounting nuts. Install two leads with nuts.Re- move drill bit to release brushes against slip rings. 72963 a - Phillips Head Screw b - Nuts (4) DO NOT tighten on your MerCruiser are designed and manufac- bolt at this time.As long as the voltage is reg- Housing Screws ulated within the prescribed limits, the alternator can- Pulley Nut. Also observe “Precau- 1. Do not use solvent, or electrical components may be dam- Removal aged. 1. Remove snap ring. 2. Inspect the following: 2. Use an arbor press to remove bearing from hous- a. Do not bend terminals or pinch wires. grounded. Inspect slip ring terminals to be sure that they are not bent and touching rotor 3. Check for poor connections be- nected from rectifiers and diode-trio for this test.If all other electrical components test shorted or open. In- sert two screws and tighten securely. 73085 a - Insulating Washers b - Insulators c - Negative Rectifier. Install insulator cap on regulator clamp alternator in vise as shown. Tighten pulley terminal.The auxiliary battery is primarily used as a power NOTE: MerCruiser engines equipped with a 3-wire, source for various accessories installed on the boat. Splice Sufficient Guage Wire To The ORANGE Wire And Connect As Shown. Index 4C - 38 - CHARGING SYSTEM 90-816462 2-695. Aside from different gauge face appear- ances and styling, the back of the gauges and wiring COMMODORE AND INTERNATIONAL SERIES connections are different as shown. The following test involves the use of intense heat. Failure to follow appropriate procedures or warnings can cause burns which can result in se- vere personal injury. While performing the follow- ing test, observe these general precautions: Wear personal protective clothing such as rubber gloves, a non-flammable apron, and. Fuel capsule is defective if not within TESTING specifica- 1. Disconnect wire from terminal on fuel tank cap- tions. sule. 2. WARNING Refer to Section 4E for switch locations. Switch is nor- mally closed. The following test involves the use of intense heat. Failure to follow appropriate procedures or TESTING warnings can cause burns which can result in se- vere personal injury. Allow sand to cool. Note thermometer reading to ensure switch “opens” up at specified temperature. Tighten securely and coat with Liquid Neoprene to help control corrosion: when dry, slide neoprene sleeve over connection. NOTE 2: Power for a fused accessory panel may be taken from this connection. Load must not exceed 40 amps. Panel ground wire must be connected to instrument terminal that has an 8-gauge BLACK (ground) har ness wire connected to it. Tighten securely and coat with Liquid Neoprene to help control corrosion: when dry, slide neoprene sleeve over connection. NOTE 2: Power for a fused accessory panel may be taken from this connection. Load must not exceed 40 amps. Panel ground wire must be connected to instrument terminal that has an 8-gauge BLACK (ground) harness wire connected to it. Also can be used for an accessory (limit 5 amps). Also can be used for an accessory (limit 5 amps). Also can be used for an accessory (limit 5 amps). Boating industry standards (BIA, ABYC, etc.) fed- WARNING eral standards and Coast Guard regulations MUST BE adhered to when installing fuel delivery Be careful when changing fuel system compo- system. DO NOT attempt to flush out filter. FUEL SYSTEM Replacement NOTICE Refer to “Precautions,” in this section, BE- FORE proceeding. 1. Disconnect battery cables from battery. 2. Refer to “Precautions,” in this section, BE- FORE proceeding. Testing Fuel Pump Replacement NOTICE Refer to “Precautions,” in this section, BE- INSPECTION FORE proceeding. Tighten secure- 1. Remove fuel inlet and outlet lines at fuel pump. 2. Remove sight tube. 7. Use of replacement electrical, ignition or fuel sys-. If engine is running too rich at higher elevation, order a smaller jet from the chart. A jet stamped “165” is a 1.65 mm jet. The hole closest to the lever’s shaft will give the same amount of fuel as the single hole lever Flooding at Idle RPM did. Rod should just slide cover is in line with long case mark on choke housing. through. Be sure not to lose spacer on anchor stud. Start engine and check for gasoline leaks. If leaks exist, STOP ENGINE IMMEDIATELY and re- check connections. Piv- ot rod (as required) until retaining ear on rod and slot in pump shaft and lever assembly align, al- lowing rod to be pulled out. 72286 a - Choke Rod b - Choke Lever c - Slot 4. Slide pump shaft and lever assembly (and washer) out of air horn, then remove accelerator pump assembly. 72398 72287 a - Setscrew a - Needle Assembly b - Lever Assembly b - Needle Seat c - Pump Assembly 11.