TIMING, SYNCHRONIZING, & ADJUSTING

ELECTRICAL
Section 2C - Timing, Synchronizing, & Adjusting
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Throttle Shutter Synchronization . . . . . . . 2C-7
C
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 Throttle Cam Adjustment . . . . . . . . . . . . . . 2C-11
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5 Throttle Position Sensor (TPS) and
Throttle Shaft Adjustment . . . . . . . . . . . . . . 2C-13

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TIMING, SYNCHRONIZING, & ADJUSTING

Specifications
Type Microcomputer-ECM
Spark Plug:
Type NGK LFR6A-11
Gap 0.039 - 0.043 in. (1.0 - 1.1 mm)
Hex Size 5/8 in. (16 mm)
Torque 18 lb-ft (25 Nm)
Hole Size 14 mm
Firing Order 1-3-4-2
Ignition Timing:
@ Idle (750 rpm) 4° A.T.D.C
@ WOT (6000 rpm) 20° B.T.D.C
Stator Coil Output - Peak Voltage:
@ 400 rpm (Cranking) 10 - 18 V
@ 750 rpm (Idle) 16 - 24 V
@ 1500 rpm 16 - 24 V
@ 3500 rpm 16 - 24 V
Stator Coil Resistance 0.2 - 0.8 Ω
Crank Position Sensor - Peak Voltage:
@ 400 rpm (Cranking) 3.0 -6.3 V
@ 750 rpm (Idle) 9 - 16 V
@ 1500 rpm 18 - 28 V
@ 3500 rpm 35 - 55 V
Crank Position Sensor Resistance 445 - 565 Ω
IGNITION ECM (Coil Primary) - Peak Voltage:
SYSTEM @ 400 rpm (Cranking) 180 - 320 V
Readings taken @ @ 750 rpm (Idle) 180 - 235 V
68°F (20°C). @ 1500 rpm 230 -290 V
@ 3500 rpm 280 - 340 V
Ignition Coil Resistance
Primary 1.8 - 2.6 Ω
Secondary (Between Boots)
Coil for Cylinders 1 & 4 18.97 - 35.23 kΩ
Coil for Cylinders 2 & 3 18.55 - 34.45 kΩ
Engine Protection Controls:
Engine Speed Limiter
Spark Cut-Out to Cylinders
#1 or #4 6200 rpm
#1 and #4 6250 rpm
#1, #4, and #2 or #3 6350 rpm
#1, #2, #3, and #4 6450 rpm
Overheat/Low Oil Pressure Engine
Speed Control (Spark Cut-Out to
Cylinders #1 and #4). Gradually Lowers to 2000 rpm
Water Temperature Sensor:
Warning Horn/rpm Reduction. 194°F (90°C)
Reset Temperature and Closed
Throttle. 167°F (75°C)
Engine Oil Pressure Switch:
Warning Horn/rpm Reduction Continuity Below 21.78 psi (150 kPa)

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 TIMING, SYNCHRONIZING, & ADJUSTING

Reset Pressure and Closed

Throttle. No Continuity Above 21.78 psi (150 kPa)
Engine Water Temperature Sensor
IGNITION Resistance:
SYSTEM @ 41°F (5°C) 4.62 kΩ
Readings taken @ @ 68°F (20°C) 2.44 kΩ
68°F (20°C). @ 212°F (100°C) 0.19 kΩ
Throttle Position Sensor (TPS):
Input Voltage @ Idle (750 rpm) 5.0 ± 0.25 V
Output Voltage@ Idle (750 rpm) 0.718 - 0.746 V

NOTE: The 115 four stroke ECM unit electronically controls the ignition timing, therefore
making the ignition timing non adjustable. When initially running the outboard, use a timing
light to verify that the ignition timing falls within the timing windows. If the ignition timing does
not stay within the timing windows, replace the ignition ECM unit and retest.

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Special Tools
1. New Style Vacuummate Carburetor Tuner P/N 91-809871-1

2. Old Style Mercury Filled Carburetor Tuner P/N 91-809641A1

Filters (4) P/N 35-18206

3. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1

4. Timing Light P/N 91-99379

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 TIMING, SYNCHRONIZING, & ADJUSTING

Timing
WARNING
To prevent personal injury or possible death, from loss of balance or stability while
servicing the motor, DO NOT attempt to check timing while boat is in motion. Failure
to follow one of the recommended servicing procedures may result in the person
falling overboard or causing personal injury from fall in boat.

WARNING
To prevent personal injury from spinning flywheel, Do Not attempt to remove fly-
wheel cover or place hands on top of cover when checking ignition timing.
Ignition timing is not adjustable. The ECM unit electronically controls the ignition timing.
When initially running the outboard, use a timing light to verify that the ignition timing falls
within the timing windows as described within the following tests. If the ignition timing does
not stay within the timing windows, replace the ignition ECM unit and retest. (Refer to the
Ignition Diagnostic Procedures tests in Section 2A.)
IMPORTANT: When checking the timing with the engine running, one of the following
test procedures must be followed.
Check maximum timing per specification while running the outboard:
• IN A TEST TANK (with a cut down propeller).
• ON A DYNAMOMETER.
• ON A BOAT SECURED ON A TRAILER “Backed in Water” (with a cut down propeller).
1. Attach timing light to #1 spark plug lead.
2. Place the outboard in “Forward” gear and check timing at idle “Retarded.” (If not within
specification window, refer to Diagnostic Test Procedures Section 2A.)

58684
b
a - Timing Mark (4° ATDC) (Full Retarded)
b - Pointer

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3. Slowly increase the engine rpm while watching the ignition timing marks. The timing
should increase to the maximum timing specification “Full Advance” at approximately
6000 RPM. (If not within specification window, refer to Diagnostic Test Procedures Sec-
tion 2A.)

20

b
a - Timing Mark (26° BTDC) (Full Advance)
b - Timing Pointer

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Throttle Shutter Synchronization

NOTE: The cylinders are synchronized by adjusting the intake manifold vacuum on the in-
take manifold. Use Carburetor Tuner (91-809641A1) or Vacuummate Tuner (91-809871--1)
to measure the vacuum.
1. Remove four plugs from the intake manifold.

a
a

58673

a - Plugs (4)

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2. Install intake manifold hose adaptor in each plug hole. Tighten securely.
3. Connect the Vacuummate to the hose adaptors.
4. If using Carburetor Tuner (91-809641A1), install filters to prevent mercury being drawn
into engine during an abrupt throttle change.

58682
a - Intake Manifold Hose Adaptor (4) From Vacuummate Carb. Tuner
b - Intake Manifold Hose Adaptor (4) From Mercury Filled Carb Tuner
c - Vacuummate Carb. Tuner (91-809871--1)

CAUTION
Do not run engine at high rpm or abruptly change throttle position when using the
old style liquid mercury filled carb. tuner (91-809641). The possibility exists of draw-
ing liquid mercury from the carb tuner into the engine during high rpm running or
an abrupt throttle change. Installing filters (4) (35-18206) in each line will help to pre-
vent liquid mercury from being drawn into engine during an accidental abrupt
throttle change.

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5. With the outboard in water, start engine and allow to warm up until engine idles at 750
± 50 rpm in neutral.
6. Connect a tachometer onto the spark plug lead of cylinder #4.
7. Turn the synchronizing screw so that vacuum pressures on cylinders #3 and #4 are with-
in 3 cm Hg (40 mbar, 1.18 in Hg) of minimum and maximum vacuum pressures of cylin-
ders #1 and #2. It’s not important to be at any specific vacuum setting.
NOTE: The vacuum pressure of cylinders #3 and #4 will most likely never be exactly the
same as cylinders #1 and #2 due to mechanical tolerances and different operating efficien-
cies of individual cylinders.

58682

Example
If the vacuum reading of Cyl. #1 and #2 (base vacuum) is 30
cm, then adjust synchronization screw to achieve 30 cm for
cylinders #3 and #4.

32 cm
30 cm

28 cm
26 cm
Cyl. Cyl. Cyl. Cyl.
#1 #2 #3 #4

NOTE: Tighten screw to increase vacuum. Loosen screw to decrease vacuum.

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TIMING, SYNCHRONIZING, & ADJUSTING

58641

a - Synchronizing Screw

8. Rev engine a few times and then allow engine to idle for 15 seconds.
9. Check that vacuum reading of each cylinder did not change more than 30 mm Hg (40
mbar, 1.18 in Hg). Readjust if necessary.
10. Verify idle speed is 750 ± 50 rpm in neutral.
11. Stop engine, remove adaptors and reinstall plugs.

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Throttle Cam Adjustment

Remove screws attaching sound attenuator. Remove attenuator to provide access to
throttle cam.

a
a

58681

a - Screws (9)
Check throttle pickup timing (using “Checking Steps” below, adjust if incorrectly set using
“Adjustment Steps” below).
CHECKING STEPS
1. Move throttle control lever to the full retard position (throttle arm against throttle stop at
idle).
2. Verify idle speed arm is against idle speed screw.

d
b
c

58576

a - Throttle Control Lever d - Idle Speed Arm

b - Throttle Stop e - Idle Speed Screw
c - Throttle Arm

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3. Pointer on cam should align with center of cam follower while maintaining a 0.020 in.
(0.5 mm) gap between follower and cam.

58683
a - Pointer c - 0.020 in. (0.5 mm)
b - Cam Follower

ADJUSTMENT STEPS
1. If 0.020 in. (0.5 mm) gap does not exist, unsnap ball connector from ball on cam.
2. Thread connector in or out to obtain proper clearance. Tighten jam nut on connector.
NOTE: Proper clearance between cam follower and cam will take precedence to exact
alignment of pointer on cam to center of cam follower.
e
a
b

58683
a - Ball Connector d - Cam Follower
b - Throttle Cam e - Jam Nut
c - Pointer

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 TIMING, SYNCHRONIZING, & ADJUSTING

3. Reinstall sound attenuator. Tighten screws to specified torque.

Sound Attenuator Screw Torque

70 lb-in. (8 Nm)

Throttle Position Sensor (TPS) and Throttle Shaft Adjustment

The Throttle Position Sensor and throttle shaft are pre-set at factory during emission calibra-
tion.
No adjustments should normally be made to these components as emission performance
will be compromised.
However, should it be necessary to replace the Throttle Position Sensor or throttle body, the
new components should be adjusted to initial factory emission specifications as follows:
1. Remove 9 screws attaching sound attenuator and remove attenuator.
2. Disconnect the Throttle Position Sensor harness.
3. Install TPS Test Harness (91-881827) between TPS and TPS harness.

b c

91-881827

58659
a - Throttle Position Sensor 58659
b - TPS Test Harness (91-881827)
c - TPS Harness

4. Turn ignition switch to the “RUN” position.

5. Connect DMT 2000 (91-854009A1) test leads to the TPS Test Harness – RED to PINK;
BLACK to BLACK.

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TIMING, SYNCHRONIZING, & ADJUSTING

6. Loosen synchronizing screw to allow cylinders #3 and #4 throttle shutter to open.

7. Loosen throttle plate screw to fully close cylinders #1 and #2 throttle shutter.

58641
a - Synchronizing Screw
b - Throttle Plate Screw

8. Adjust the position of Throttle Position Sensor until the (DC) output voltage is 0.7 ± 0.01
volts.
9. Operate the throttle shaft several times.
10. Record the value.
11. Slowly tighten the synchronizing screw until throttle shutters for cylinders #3 and #4 just
close.
12. Slowly tighten the throttle plate screw until a 0.032 ± 0.004 volt increase over the pre-
viously recorded value is observed.
13. Operate the throttle shaft several times.

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14. With the throttle arm against the throttle stop, verify throttle cam mark is aligned with the
center of the cam follower while maintaining a 0.020 in. (0.5 mm) gap between follower
and cam. Check that output voltage has not changed.
NOTE: Proper clearance between cam follower and cam will take precedence to exact
alignment of pointer on cam to center of cam follower.

d f
c

58576 h

58683

a - Synchronizing Screw e - Cam Mark

b - Throttle Plate Screw f - Cam
c - Throttle Arm g - Cam Follower
d - Throttle Stop h - 0.020 in. (0.5 mm)

15. Reinstall sound attenuator. Tighten attaching screws to specified torque.

Sound Attenuator Screw Torque

70 lb-in. (8 Nm)

16. Start engine.

17. Check output voltage of Throttle Position Sensor. If TPS voltage is not within 0.718 –
0.746 volts, readjust TPS sensor.
18. Verify throttle shutters are synchronized. Refer to “Throttle Shutter Synchronization,”
preceding.

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