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MERCURY OPTIMAX 1. SERVICE MANUAL Pdf Download.
Opti. Max Direct Fuel Injection Starting Model Year 2. Starting Serial Number OG9. Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers. It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength.
American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Service Manual Outline General Information & Specifications Section 1 - General Information & Specifications A - Specifications B - Maintenance Ignition System C - General Information D - Outboard Installation Section 2 - Electrical A - Ignition Fuel System B - Charging & Starting System C - Timing, Synchronizing &..
SPECIFICATIONS IMPORTANT INFORMATION Section 1. A - Specifications Table of Contents Master Specifications ... A- 1 Master Specifications Model 1. DFI HORSEPOWER Model 1. SPECIFICATIONS Model 1. DFI Power Trim (Total Tilt Range) SECTION Power Trim (Tilt Range) Steering Pivot Range Tilt Pin Adjustment Positions Allowable Transom Thickness 2- 3/8 in. B- 1 Fuel System .
MAINTENANCE Special Tools 1. Grease Gun 9. 1- 3. A1 2. Flushing Attachment 4. A2 Quicksilver Lubricant/Sealant 1.
Gear Lubricant - Premium Blend 9. A2. 4 Page 1. B- 2 9. R1 JANUARY 1. 99. MAINTENANCE 2. Anti- Corrosion Grease 9. A6 3. 2- 4- C Marine Lubricant with Teflon 9.
A1. 2 4. SAE 3. 0W Motor Oil (Obtain Locally) 5. Quicksilver Power Trim and Steering Fluid 9. A1. 2) 9. 0- 8. 55. R1 JANUARY 1. 99. Page 1. B- 3.. MAINTENANCE Inspection and Maintenance Schedule Before Each Use 1. Check that lanyard stop switch stops the engine.
Visually inspect the fuel system for deterioration or leaks. Check outboard for tightness on transom. Check steering system for binding or loose components. MAINTENANCE Flushing Engine Flushing Cooling System – Using Cowl Flush Plug Flush the internal water passages of the outboard with fresh water after each use in salt, polluted or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages.
MAINTENANCE IMPORTANT: While and after flushing, keep outboard in upright position until all water has drained from drive shaft housing to prevent water from entering the pow- erhead via drive shaft housing and exhaust ports. Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. MAINTENANCE Corrosion Control Anode The gear case has two corrosion control anodes (a).
Another anode (b) is installed on the bottom of the transom bracket assembly. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. MAINTENANCE Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery.
Turn off the engine before servicing the battery. Add water as necessary to keep the battery full. MAINTENANCE Compressor Air intake Filter The filter should be changed every 1. Never run the engine without the air filter. Remove flywheel cover from the engine. Snap out the retainer (a) and remove filter (b).
MAINTENANCE Lubricate Point 2 with Quicksilver Anti- Corrosion Grease or 2- 4- C Marine Lubricant with Teflon. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. MAINTENANCE 6. Steering Cable Grease Fitting (If Equipped) – Rotate steering wheel to fully retract the steering cable end (a) into the outboard tilt tube. Lubricate through fitting (b). WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. MAINTENANCE Gear Case Lubrication When adding or changing gear case lubricant, visually check for the presence of water in the lubricant.
If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer. Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case. MAINTENANCE CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE NOTE: Some models may have the vent and fill/drain plugs on the opposite side. Place outboard in a vertical operating position. Remove vent plug (a).
Place lubricant tube (b) into the fill hole and add lubricant until it appears at the vent hole (c). MAINTENANCE 3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine at 2. PROTECTING INTERNAL ENGINE COMPONENTS NOTE: Make sure the fuel system has been prepared for storage. GENERAL INFORMATION IMPORTANT INFORMATION Section 1.
C - General Information Table of Contents Serial Number Location ... C- 1 Model 1. 35/1. DFI Powerhead Front View . F (2. 5 C) temperature and a barometric pressure of 2. Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce engine power.
GENERAL INFORMATION To obtain optimum engine performance under changing weather conditions, the engine MUST be propped to allow it to operate at or near the top end of the recommended maxi- mum RPM range at wide- open- throttle with a normal boat load. This will allow the engine to develop full power while operating in an RPM range that dis- courages damaging detonation. GENERAL INFORMATION Trim TRIMMING OUTBOARD “OUT” (“UP”) WARNING Excessive trim “out” also may reduce the stability of some high speed hulls. To correct instability at high speed, reduce the power GRADUALLY and trim the out- board “in” slightly before resuming high speed operation. Each boat should be tested for handling characteristics after any adjustment is made to the angle (trim adjustment bolt relocation.) 1. GENERAL INFORMATION Engine DETONATION Detonation in a 2- cycle engine resembles the “pinging” heard in an automobile engine.
It can be otherwise described as a tin- like “rattling” or “plinking” sound. Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug has fired.
GENERAL INFORMATION Following Complete Submersion Salt Water Submersion Due to the corrosive effect of salt water on internal engine components, complete disas- sembly is necessary before any attempt is made to start the engine. Submerged While Running When an engine is submerged while running, the possibility of internal engine damage is greatly increased.
GENERAL INFORMATION 8. Drain water from the oil injection system as follows: a. Remove remote oil hose (black without blue stripe) from pulse fitting on starboard side of engine. Drain any water from hose and reconnect. If water was present in hose, check for water in the remote oil tank. Drain tank if water is present.
GENERAL INFORMATION Model 1. DFI Powerhead Front View 5. High Pressure Electric Fuel Pump (Inside Vapor Separator) Vapor Separator Vapor Separator Drain Plug Air Temperature Sensor Fuel Hose Outlet from Low Pressure Electric Fuel Pump Fuel Return Hose from Fuel Cooler Electric Fuel Pump Harness Connection Electric Oil Pump (Hidden) Digital Diagnostic Terminal Harness Connection.. GENERAL INFORMATION Model 1. DFI Powerhead Starboard View 5. Fuel Pressure Test Valve 1.
Starter Solenoid Air Compressor Oil Return Line 1. Oil Pump Fuse Crank Position Sensor 1.
Harness Fuse (2. 0 Ampere) Throttle Plate/Air Plenum Assembly 1. ECM Fuse (2. 0 Ampere) Digital Diagnostic Terminal Connector.. GENERAL INFORMATION Model 1. DFI Powerhead Port View 5. High Pressure Electric Fuel Pump 1.
Excess Fuel Return to Fuel Cooler Fuel Out (9. Air Pressure Test Port Crank Position Sensor 1. Check Valve Fuel Return from Fuel Cooler 2. Fuel Cooler.. GENERAL INFORMATION Model 1. DFI Powerhead Top View 5.
Air Compressor Inlet Nozzle 1. MAP Sensor Hose Water Outlet (Tell- Tale) Hose 1.
Oil Return Hose from Air Compressor Thermostat Outlet Hose to Adaptor Plate 1. Starter Motor Fuel (9. PSI) to Fuel Rails 1. Oil Hose from Oil Pump to Air Compressor..
GENERAL INFORMATION Model 1. DFI Powerhead Aft View 5. Air Compressor Restrictor/Air Inlet 1. Ignition Coil Water Out (tell- tale) from Air Compressor 1. Ignition Coil Air Compressor Oil Inlet from Oil Pump 1. Ignition Coil Air Compressor 1. Water Inlet to Air Compressor..
Allow a minimum of one hour drying time and no more than one week before top coat- ing assemblies. Use Ditzler Urethane DU9. Mercury Black, DU3. Mariner Grey, and DU3. Force Charcoal, and DU3. M for Sea Ray White. Catalyze all four colors with Ditzler DU5 catalyst mixed 1: 1 ratio.
GENERAL INFORMATION CAUTION Be sure to comply with instructions on the label for ventilation and respirators. Using a spray gun, apply one half to one mil even film thickness. Let dry, flash off for five minutes and apply another even coat of one half to one mil film thickness. This urethane paint will dry to the touch in a matter of hours, but will remain sensi- tive to scratches and abrasions for a few days. GENERAL INFORMATION DECAL APPLICATION 1. Mix ounce (1. 6 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution.
NOTE: Leave protective masking, if present, on the face of decal until final steps of decal installation. OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1. D - Outboard Motor Installation Table of Contents Installation Specifications ... D- 1 Dual Outboard .
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