Small Boats Flashcards
(420 cards)
0
Q
Which number is used to determine the service manual required
A
Model/product number
1
Q
Outboard engines are labeled with
A
A serial number and a model/product number
2
Q
Sequentially ordered number issued by the manufacturer to track outboard engine production
A
Serial number
3
Q
Provides the information necessary to properly maintain and service the outboard engine
A
Manufacturers service manual
4
Q
Precautions that must be kept in mind whenever working on an outboard engine
A
General safety warnings
5
Q
Indicates a strong possibility of severe personal injury or death if instructions are not followed
A
Warning
6
Q
Indicates a possibility of personal injury or equipment damage if instructions are not followed
A
Caution
7
Q
Gives helpful information
A
Note
8
Q
Seven pieces of information normally contained within a service manual
A
Index of topics, engine specs, torque specs, safety precautions and warnings, procedures for servicing the outboard, troubleshooting procedures, drawings and schematics
9
Q
Means the engine burns fuel
A
Combustion
10
Q
Means the fuel is burned inside the engine
A
Internal combustion
11
Q
Creates a seal between the piston and cylinder wall
A
Metal rings
12
Q
Attached to the crankshaft and balances the crankshaft by offsetting the weight of the piston and connecting rod
A
Counterweight
13
Q
Heavily weighted wheel attached to one end of the crankshaft, the momentum keeps the crankshaft, connecting rod, and piston moving until the cylinder fires again
A
Flywheel
14
Q
As the piston is pulled down during the intake stroke, a fresh charge of air/fuel mixture is drawn into the cylinder
A
Intake
15
Q
The piston now begins to move upward and starts to compress the air/fuel mixture in the cylinder
A
Compression
16
Q
The fuel air mixture ignites and burns very rapidly. Increases in pressure generated by combustion force the piston downward in the cylinder
A
Power
17
Q
Upon completion of the power stroke, the piston starts to move upward again. The continuing upward movement forces the hot, burned gases out. Once the piston reaches the top, it starts to go back down and the cycle repeats
A
Exhaust
18
Q
Uses reed valves opened and closed by pressure differences
A
Carbureted two stroke engine
19
Q
Uses a camshaft driven by, and precisely timed to the crankshaft to mechanically open and close tappet valves via push rods and rocker arms
A
Four stroke engine
20
Q
This engine is fuel injected, and provides better efficiency and reduced emissions
A
Four stroke engine
21
Q
Develops significant torque at low RPMs
A
Four stroke engine
22
Q
Lacks burst of power experienced with the other engine
A
Four stroke engine
23
Q
Most outboard engines are
A
Two stroke
24
Rotating shaft driven by a crank and turned by a piston moving up and down in a cylinder, that changes the linear motion of the piston to rotary motion
Crankshaft
25
Metal casting containing the cylinders and cooling ducts of an engine
Cylinder block
26
Housing for the crankshaft with one side bolted to the cylinder block and the other side bolted to the intake manifold
Crankcase
27
Detachable plate bolted to the cylinder block containing part of the combustion chamber and the valves, spark plugs, and fuel injectors
Cylinder head
28
Network of passages that directs air to the cylinders
Intake manifold
29
Part of the two stroke engine that controls the intake of air into the crankcase
Leaf plate assembly (reed valves)
30
Changing pressures in the crankcase actuate this valve
Reed valve
31
Hole machined into the cylinder wall of a two stroke engine through which spent combustion gases exit. Piston movement opens and closes the port
Exhaust port
32
Pressurized air rushes into the cylinder forcing any remaining gases out the exhaust ports
Scavenging
33
Type of engine used on majority of coast guard small boats
Four stroke outboard
34
Engine oil is changed and recycled instead of being burned in the cylinders
Wet type sump
35
Additional parts of a four stroke engine
Camshaft, cam lobes, intake valve, exhaust valve, rocker arm
36
Cylindrical rod with protruding cam lobes that control the opening and closing of the intake and exhaust valves, and on some models the fuel injector pumps
Camshaft
37
Oblong eccentric projections on the camshaft that push against the rocker arms to open the valves as the camshaft rotates
Cam lobes
38
The part of the actuating assembly that admits air/fuel mixture into the cylinder
Intake valve
39
The part of the actuating assembly that opens to allow the discharge of exhaust gases from the cylinder
Exhaust valve
40
Transmits the motion of the cam to the valve, one end is in contact with the valve stem, and the camshaft actuates the other end
Rocker arm
41
Has a wet type oil sump with a filter that requires maintenance
Four stroke
42
Has a pulley on the end of the crankshaft to drive the cam belt
Four stroke
43
Has a camshaft which actuates the tappet valves
Four stroke
44
Has a rocker lever assembly to open and close the tappet valves
Four stroke
45
Burns its oil in combustion
Two stroke
46
May or may not have a cam
Two stroke
47
Uses reed valves and exhaust ports
Two stroke
48
Sides of the piston act like valves, covering and uncovering the intake and exhaust ports
Two stroke
49
On the compression stroke the fuel/air mixture is compressed approximately
One-ninth its original volume
50
Require special lubricating oil to be mixed with the gasoline for proper lubrication
Two stroke engines
51
Unleaded gasoline can have how much ethanol
10% ethanol by volume
52
Unleaded gasoline can have how much methanol
5% methanol by volume
53
Only authorized source of information for repairs and maintenance to outboard engines fuel system
Manufacturers service manual
54
Two types of fuel tanks
Built in, portable
55
Filler tube and cap accessible to the operator
Built in tank
56
Vented to relieve the vacuum created by the fuel pump and pressure created by filling the tank
Built in tank
57
Installed level indicating float gauges that send a signal to a gas gauge on the console
Built in tank
58
Average portable tank holds how many gallons
6
59
Portable tanks are usually constructed of
Plastic
60
Has a filler cap with a vacuum vent
Portable tank
61
Has a fuel pickup tube with a strainer at the end, mounted inside the tank
Portable tank
62
Has a quick disconnect fitting to connect the outboards fuel supply hose
Portable tank
63
Has a float type level indicator
Portable tank
64
Must be USCG-approved type A1 or B1 fuel hose
Built in
65
Has an inline primer squeeze bulb which incorporates a one way check valve
Built in
66
Attachments via hose clamps or quick disconnect fittings
Built in
67
Fuel hoses ordered as complete units
Portable tanks
68
Utilize quick disconnect fittings with built in check valves at both ends of the hose
Portable tanks
69
Fuel hoses must be of what type to prevent damage from ethanol based fuels
Alcohol resistant type
70
Replace fuel hose at the first sign of
Damage, deterioration, or hardness
71
Generally boats with installed tanks have the following components
Mesh strainer on the pickup tube in the tank, bulkhead mounted fuel filter and/or water separator, secondary inline filter
72
Connected to the crankcase by a short hose or passage, and are operated by alternating pressure and vacuum pulses from the crankcase
Two stroke outboard fuel pumps
73
What kind of fuel pump does a four stroke outboard use
Mechanically driven diaphragm fuel pump
74
Supplies the engine with the correct air/fuel mixture and adjusts the amount of air/fuel mixture as necessary to accommodate various operating speeds and loads
Carburetor
75
To operate efficiently, the engine needs about ____ units of air for a single unit of fuel measured by ____
12, weight
76
Atomize the fuel prior to combustion by actively injecting fuel into the combustion chamber or intake manifold at an appropriate point in the piston cycle
Fuel injection system
77
Force the fuel through nozzles under pressure rather than using the force of air rushing through
Fuel injector
78
Fuel being mixed with air is more precisely controlled, and the mixture is more evenly atomized for engine load in this system
Fuel injection
79
Two types of fuel injection
Direct injection, indirect injection
80
Use an injector mounted on the cylinder head which delivers fuel under pressure directly into the combustion chamber
Direct injection system
81
Uses a fuel injector that is located on the intake manifold
Indirect ignition system
82
Uses smaller injections of lighter material and starts the atomization process of fuel and air outside of the combustion chamber
Indirect ignition system
83
Removes water from the fuel prior to the fuel filter
Water separator
84
Removes particulate debris from the fuel system
Fuel filter
85
Transfers fuel from the fuel tank to the vapor separator
Low pressure pump
86
Removes fuel vapors prior to the high pressure fuel pumps fuel supply to prevent damage to the pump
Vapor separator
87
Ensures proper operation of the fuel system, may also cool fuel returning from the fuel rail
Vapor separator
88
Supplies pressurized fuel to the fuel rail, cleans the fuel prior to it entering the injectors
High pressure fuel pump
89
Supplies pressurized fuel for the injectors
Fuel rail
90
Maintains a consistent pressure of fuel in the fuel rail
Pressure regulator
91
With a fuel injector, causes the armature to move upward
Pressure in the fuel system or the signal from the engine control module
92
Must regulate the amount of air entering the engine to maintain the correct mixture of air and fuel
Fuel injected engine
93
Uses a throttle body to regulate air flow
Air induction system
94
Butterfly valve which allows a predetermined amount of air into the engine based upon the throttle input
Throttle body
95
May be controlled by direct cable or the position may be monitored and controlled by the ECM
Throttle body
96
ECM
Engine control module
97
Device that allows a small amount of air into the engine when the engine is idling and the throttle is closed
Idle air control (IAC)
98
Uses a pump to draw oil from a reservoir, which is delivered to an oil injector
Oil injection system
99
Delivers a precise amount of oil to the inlet side of each cylinder
Oil injector
100
Delivers oil under pressure to an oil manifold which distributes the oil to the crankshaft bearings and other internal moving parts
Oil injector
101
Oil injection system is controlled by
The engines electronic control system
102
IAC
Idle air control
103
OIS
Oil injection system
104
Accompanies outboards equipped with an oil injection system (OIS)
Oil reservoir
105
When the oil level in the tank is below ____ , the contact washer makes an electrical connection between the contact clips
One fourth full
106
The warning horn for low oil sounds a tone every ____
20 - 40 seconds
107
Oil injection pump and manifold assembly consist of the following components
Oil injector pump, oil distribution manifold, pickup tube and filter, low oil sending unit, oil pressure switch
108
Incorporate most of the working parts of the oil reservoir
Oil injection pump and manifold assembly
109
What does the oil pass through on its way to the cylinders
Oil tank, oil inlet filter, oil pickup, oil injection pump, oil distribution manifold, oil distribution hose
110
Connect the intake port areas of the cylinders to circulate residual oil back to the block
Internal powerhead oil drain passages
111
Used to recirculate any accumulation of oil from various locations in the powerhed
External hoses and fittings, internal cylinder/crankcase passages, and intake manifold passages
112
Provided through internal powerhead oil drain passages, external fittings, and external inline check valves and hoses
Movement of oil through the upper, center, and lower main bearing
113
Work together to flow cooling water throughout an engine and keep the outboard engine running at a relatively cool but constant temperature
Cooling system components
114
Pushes the water into the pickup tube
Water pump
115
Located in the gearcase under the water pump
Water intake screen
116
Runs the length of the mid-section, carries the water into the exhaust manifold
Pickup tube
117
Allow the flow of cooling water around each of the cylinders
Cylinder block water jacket
118
Opens and allows passage through the cylinder head water jackets
Temperature regulator or thermostat
119
Carries the exiting engine exhaust and water to the propeller hub
Exhaust manifold
120
Passes the exiting water and engine exhaust out of the engine
Propeller hub
121
Located on the side of the gearcase, allow cooling water to enter the engine
Water intake holes
122
First component that water passes in the cooling system
Water intake holes
123
Plastic strainer basket located in the gearcase under the water pump, filters debris from the water before the cooling water enters the engine
Water intake screen
124
Supplies cooling water throughout the engine, driven by main driveshaft
Water pump
125
Have cast in double walls known as water jackets, permits passage of cooling water around the walls
Cylinder block and cylinder head
126
To keep cooling surfaces clean if marine growth and salt build up, the engine must be
Flushed with freshwater immediately after use in salt water or brackish water
127
At idle the thermostat will
Unseat to allow some cooling water flow
128
Works with the thermostat to cool the engine
Pressure sensing device
129
Provides the onboard computer with the coolant temperature information for fuel and ignition optimization
Engine coolant temperature sensor
130
Most temperature sensors are
Temperature dependent resistors
131
The resistance of the sensor _____ as the temperature increases
Decreases
132
High temperatures provide _____ voltage
Low signal
133
All temperature sensors have the same
Response curve
134
Bolted through the bottom of the mid-section, and is the power transmission portion of the outboard
Gearcase
135
Its function is to transmit the engine's power to the propeller
Gearcase
136
Moves the boat in forward or reverse
Propeller
137
Typical gear ratio of an outboard gearcase ranges from
1.87:1 to 2.4:1
138
Five main components of the gearcase
Reverse gear, pinion gear, clutch shifter, forward gear, shift mechanism
139
Splined to the crankshaft in the powerhead and turns at engine speed. Extends vertically down through the mid-section, and ends in the gearcase, just shy of the horizontal propeller shaft
Driveshaft
140
Pressed onto the bottom of the driveshaft, it is in constant mesh with the reverse and forward gears, and turns each one in opposite directions any time the engine is rotated
Pinion gear
141
The driveshaft is supported by
Two sets of bearings, an upper and a lower
142
Pressed into a housing that bolts to the top of the gearcase. This housing can be seen when the water pump is removed from the gearcase
Upper bearing
143
Upper gear housing also houses
Thrust bearing, thrust washer, and the shims
144
Used to adjust the height of the driveshaft and pinion gear
Shims
145
Height of the driveshaft and pinion gear is critical because
Controls the amount of mesh/contact between the pinion gear and the forward and reverse gears
146
Pressed into the gearcase housing at the bottom of the driveshaft
Lower bearing
147
Are in constant mesh with the pinion gear and are each turned in opposite directions any time the engine is rotated or running
Forward and reverse gears
148
Directly move the propeller shaft
Clutch shifter
149
Three things housed in the forward area of the gearcase
Forward gear, thrust bearing, thrust washer
150
When placed in the forward direction, the clutch shifter is moved into contact with and turned by the
Forward gear
151
When placed in the reverse direction, the clutch shifter is moved into contact with and turned by the
Reverse gear
152
Three things housed in the propeller shaft holder
Reverse gear, thrust bearing, and thrust washer
153
The propeller shaft holder contains ____ that retain the gearcase oil and prevent water from entering
O-rings and seals
154
Housed horizontally in the lower gearcase, it uses the same bearings for support as the forward and reverse gears
Propeller shaft
155
Has a set of splines machined into its surface at a point between the forward and reverse gears. Has a clutch shifter located on these splines
Propeller shaft
156
Long enough to allow the clutch shifter to slide forward and aft
Propeller shaft splines
157
Has castellations, or raised lobes, machined into both its front and backside. These are also known as drive lugs
Clutch shifter
158
Sets on the propeller shaft between the forward and reverse gears
Clutch shifter
159
Have castellated surfaces that match the drive lugs of the clutch shifter
Forward and reverse gears
160
_____ is transmitted to the propeller shaft as the clutch shifter is slid forward or aft into the forward or reverse gear
Torque
161
The pinion gear is constantly turning the forward and reverse gears in _____
Opposite directions
162
Splined to the propeller shaft, so when the forward or reverse gears turn it, the propeller shaft turns
Clutch shifter
163
The direction of propeller shaft rotation depends upon ____
Which direction the clutch shifter is moved
164
If the clutch shifter is slid forward
The propeller shaft will cause it to come in contact with the forward gear, and the propeller will spin in the forward direction
165
If the clutch shifter is slid aft
The propeller shaft will cause it to come in contact with the reverse gear, and the propeller will spin in the reverse direction
166
If the clutch shifter is held in the center position and not in contact with either gear
The propeller shaft will not move. This is the neutral position and the forward and reverse gears are still spinning
167
Used to slide the clutch shifter forward and aft on the propeller shaft splines
Shift rod and shift mechanism
168
Extends vertically from the shift mechanism in the gearcase up to the powerhead, where it links with the gearshift lever to allow the operator to shift gears
Shift rod
169
Has a pivoting lever that connects the shift rod to the clutch shifter
Shift mechanism assembly
170
Slides the clutch shifter through its range of travel on the propeller shaft splines
Pivoting lever or shift plate
171
Used to transmit the engines rotary motion into horizontal motion by rotating in and moving the surrounding water with blades set at a pitch
Propeller
172
Propellers are identified by two numbers
Diameter and pitch
173
Distance from blade tip to blade tip
Diameter
174
The amount of twist the blades have
Pitch
175
Theoretically this figured is the distance in inches the propeller would travel in one rotation through a solid
Pitch
176
Will determine which propeller provides the optimum speed while maintaining the proper engine RPMs
Water test
177
The proper RPMs for an engine will be found
In a table located in the service manual for that engine
178
RPMs will be stated as ____
A range
179
The proper propeller will cause the engine to
Run at the midpoint of the operating range (RPM), while allowing the boat to achieve best speed
180
Running an outboard above the operating range will
Cause certain damage to the powerhead
181
Running an outboard below the operating range will
Cause build up of carbon deposits in the powerhead, and may shorten its life
182
A propeller will generate _____ when the propeller shaft is not running parallel to the water's surface
Steering torque
183
Adjustable to compensate for steering torque, allowing the propeller shaft to run parallel to the water surface
Trim tab
184
If the boat pulls to the left, move the trim tab to the
Right
185
If the boat pulls to the right, move the trim tab to the
Left
186
Tighten the trim tab screw to a torque of
35 - 40 inch pounds
187
Installed on the gearcase to prevent corrosion
Zinc anodes
188
Additional anodes may be bolted to the lower portion of
The transom-mounting bracket
189
____ engine installations don't have trim tabs
Dual
190
Why don't dual engine installations have trim tabs
The torque generated by each engine cancels the other out
191
Do not do what to zinc anodes or their mounting surface
Paint or coat
192
This anode should be renewed anytime the gearcase is disassembled
Bolted to the driveshaft bearing housing on the cooling water side
193
Four advantages of water jets or jet drives
Higher overall efficiency at speeds over 25 kts, superior maneuverability, no underwater appendages, high thrust at low speeds
194
Intake water from beneath the vessel, then push that water out the nozzle for the purpose of forward movement
Function of jet drive propulsion
195
Positioned flat against the hull of the boat
Base plate of the inlet grate
196
Ahead/astern movement of boat is controlled with this, infinitely variable between three positions to obtain speed and control needed
Reversing bucket
197
Sideways movement of the boat controlled, three main positions with infinitely variable positions inbetween
Steering nozzle
198
Contains a section of vanes that reduce the torque that is created from the impeller
Guide vane chamber
199
Highly refined mixed flow type capable of pumping large volumes of water at relatively low pressures
Impeller
200
Coupling is mounted on the main shaft forward of the bearing housing
Impeller housing
201
Used to connect the drive shaft to the engine and marine gear/reduction gear which in turn drives the impeller
Shaft flange
202
Zero thrust is obtained when the bucket is lowered about
70%
203
Common steering system found on vessels with jet drives
Electro-hydraulic steering system
204
Full steering lock starboard means
the steering nozzle is turned 30 degrees to starboard side
205
Keeps the hydraulic temperatures within parameters
Oil cooler
206
HPU
Hydraulic power unit
207
Oil cooler is mounted _____ and is connected to _____
On the side of the engine, HPU
208
Mounted on the main driveshaft forward of the bearing housing, where the engine connects to the jet drive shaft
Shaft flange
209
The driveshaft to the water jet must have
Axial and radial flexibility
210
Also called cardan shafts
Double universal slip-jointed driveshafts
211
Bolted directly to the engine reduction gear and shaft flange
Universal joints
212
Aid in the alignment of engine/reduction gear and the jet drive
Universal joints
213
The flange end of the shaft is held in the bearing housing by
An oil lubricated axial bearing
214
Keeps water from entering the bearing housing
Mechanical seal
215
On the underside of the bearing housing, there is an inspection hole which is checked ____
Monthly to ensure the seals are working propely
216
Before the engine is stopped, set the reversing bucket ______
Full ahead position so that the piston rod is inside the cylinder to prevent fouling and corrosion
217
Water jet unit must not be operated dry because
Rubber bearing and mechanical sealing require water lubrication
218
Engine starting systems consist of
Battery, key switch, starter solenoid, and starter motor
219
Basic theory of the starter systems operation and testing procedures for its basic components are found in
Manufacturer's service manual
220
Supplies the needed voltage to turn the starter motor
Battery
221
Dictates the batteries type and rating
The size of the outboard engine
222
See this for the correct selection of replacement batteries
Manufacturer's service manual
223
Never use ____ to fasten cables, always use ____
Wing nuts, lock washers and hex nuts
224
The positive terminal of the battery is connected to
One of the solenoid contacts
225
The negative terminal of the battery connects to
A common ground on the powerhead or engine section on the outboard engine
226
Operated by the boat driver, uses 12 volts from the battery to energize the coil inside of the starter solenoid
Key switch
227
Used only to energize the coil inside of the starter motor
Key switch
228
Key switch uses what gauge of wire
12 - 14 gauge
229
Opens the circuit to the starter solenoid and closes the stop circuit
Off position
230
Opens the circuit to the starter solenoid and keeps the stop circuit open
Run position
231
Closes the circuit to the starter solenoid and opens the stop circuit
Start positon
232
Protects the low amperage part of the starting system from damage due to faulty wiring or operator error
In-line fuse
233
Located in the wire supplying the voltage to the key switch, runs from the battery side of the solenoid contacts to the input side of the key switch
In-line fuse
234
Remotely operated, semiautomatic switch used to relay power from the battery to the starter motor
Starter solenoid
235
Has two separate circuits, both are 12 volts, but each requires a different amperage draw
Starter solenoid
236
This circuit uses two small terminals, which receive voltage from the key switch, and energizes the solenoids internal coil
Low amperage circuit
237
This circuit uses the two large terminals on the solenoid, and carries battery power from the positive terminal of the battery to the input of the solenoid
High amperage circuit
238
The output of the starter solenoid is connected to
The starter motor terminal
239
When the key is released from the start position, ____ pushes the copper washer away from the contacts, de-energizing the starter motor
A spring
240
Has an engine engagement gear mounted to the upper portion of its shaft
Starter motor
241
Cause the engine engagement gear to move upward along the starter shaft until it engages the engine
Spiral grooves along with centrifugal force
242
The engine engagement gear engages with
Ring gear that is cast into outer portion of the flywheel
243
Metal frame wound with wire, bolted to the top of the powerhead, directly under the rotating flywheel
Charge coil
244
On smaller HP outboards, the charging system use
Magneto
245
Charging system uses magnets bonded to the flywheel rotating around stationary coils to produce electricity
Magneto
246
When the magnetic poles and bosses on the coils align in the magneto
The magnetic field flows through the metal core of the coil
247
As the flywheel magnets rotate past the coil, they continually change the
Magnetic polarity of the coil bosses
248
The constantly changing magnetic field produces
AC electricity
249
The battery and accessories require electricity that is flowing
In only one direction
250
On larger HP applications, ____ is used to generate electricity by the same principle as
An alternator, DC generators
251
Uses a series of diodes to change AC electricity into DC electricity
Rectifier
252
Can be thought of as a one way check valve for electron flow
Diode
253
Current can only flow through a diode when the arrow side is more ____ than the vertical line side
Positive
254
Arrow side of a diode
Anode
255
Vertical line side of a diode
Cathode
256
Configuration of diodes that allow current flow if either input wire is positive
Full wave rectifier
257
Located within the voltage regulator/rectifier and changes AC electricity to DC electricity for the purpose of charging the battery
Full wave rectifier
258
All electric start outboards produced after ____ are equipped with a regulated charging system
1990
259
This system has all the components of a non-regulated charging system and performs the same function, except that it has the ability to turn on and off as needed, depending upon battery voltage
Regulated charging system
260
Key to a regulated charging system
Voltage regulator/rectifier
261
Voltage regulator/rectifier contains
Full wave rectifier, switchgear, wires for other accessories
262
Turns the charging system on when the battery reaches a low set point, and off when the battery voltage reaches a high set point
Switchgear
263
When in the off position the regulator/rectifier diverts the charging current
Safely to ground
264
For ease of component replacement, this is attached to the side of the powerhead. The alternator, regulator/rectifier, tachometer, and various other components are wired together using this
Terminal block
265
Most coast guard installed outboards use an ignition system known as
Capacitor discharge ignition
266
Stores the systems electricity in a capacitor until it is discharged to the ignition coil
Capacitor discharge ignition
267
Four advantages to capacitor discharge ignition systems
Less maintenance, more voltage, quicker spark, each cylinder has its own ignition coil
268
How much voltage created in a capacitor discharge ignition system
Up to 40000 volts
269
How quickly is the spark forced across the gap in a CD ignition system
Six microseconds
270
CD ignition system consists of five major components
Magneto or alternator, sensor/pulser coils, ignition control module or engine control module, ignition coils, spark plugs
271
Firing signal produced when
A magnet passes the sensor/pulser coil producing a small amount of voltage
272
The firing signal is processed by ___ then energizes the ____ to complete the circuit through the capacitor and primary winding of the ignition coil
Gate circuit, silicon-controlled rectifier
273
In the ignition coil the large, rapid current flow through the primary winding induces
Much higher voltage in the secondary windings, approximately 100 times more
274
The flywheel has ____ attached to its underside
Magnets
275
Coil of wire wrapped around a metal core. Mounted under the flywheel
Charge/exciter coil
276
As the flywheel magnets pass by the coil, they continually change the ____ of the metal core
Magnetic polarity
277
Magnet in the center of the flywheel, or under the cam pulley
Hub/cam magnet
278
Metal sleeves around the hug/cam magnet
Pole shoes
279
Wrap around the hub magnet and concentrate the magnetic flux at their ends
Pole shoes
280
The brain of the CD system
Ignition/engine control module (ICM/ECM)
281
Works in conjunction with the other components to produce an extremely fast, hot spark, sending it to the spark plug at the correct time
ICM/ECM
282
The diodes, full wave rectifier, capacitor, silicon controlled rectifier, and gate circuit are integrally cast into the body of ______
ICM/ECM
283
Capacitors cannot store
AC electricity
284
Used to rectify the current
Diodes
285
Direct electricity so when a charge coil wire is positive, that wire is connected to the positive side of the capacitor
Diodes
286
Configuration of diodes that allow current flow if either wire is positive
Full wave rectifier
287
The conversion of AC to DC current in the ignition system is used to
Charge and store current in the capacitor
288
In order to harness enough electricity that will provide a good spark, the electricity must be stored or collected in a device called
Capacitor
289
Can provide short powerful bursts of electrical energy
Capacitor
290
Sometimes called a thyristor
Silicon controlled rectifier
291
SCR
Silicon controlled rectifier
292
Very similar to a diode, but it has an additional lead called a gate
SCR
293
Will not pass current until the lead gate is energized
SCR
294
The gate lead is energized by
Pulser/sensor coil
295
Once the gate lead is energized, the SCR allows the capacitor to
Discharge or dump its charge to the ignition coil
296
Low voltage side of the ignition system
Primary circuit
297
Parts of the primary circuit
Charge/exciter coil, ICM/ECM, sensor/pulser coil
298
Does not create enough voltage to jump the spark plug gap
Primary circuit
299
Converts electricity from low voltage to very high voltage at the expense of amperage
Ignition coil
300
The ignition coil uses _____ to raise voltage
Electromagnetic induction
301
From the coil the electricity travels through what to the spark plug
High tension lead
302
Constructed of two coils of wire placed next to each other
Ignition coil
303
_____ winding has more windings than the ____. In the ignition coil
Secondary, primary
304
This winding produces higher voltage
Secondary
305
Typical ignition coil on an outboard has ____ turns of wire in the secondary and _____ turns of wire in the primary
2500, 25
306
Ignition coil winding ratio
100:1
307
To stop ignition
Alternate path for electricity stopped in the capacitor to discharge harmlessly into ground
308
Identifies the piston location in the cylinder while setting the timer pointer
Piston stop tool
309
First piston to receive spark in the ignition firing sequence
#1
310
Components of the piston stop tool
Adapter, stop rod, lock wheel
311
Used to check idle timing and maximum spark advance
Strobe timing light
312
Attaches to and flashes a light in synchronization with the spark plug wire
Strobe timing light
313
The strobe timing light will flash up to ____ per minute
5500
314
Aim the strobe light at
The timer pointer
315
Used to determine the RPMs of the flywheel
Handheld electronic tachometer
316
Use ____ with the handheld electronic tachometer
Retro reflective tape
317
Mounted on the prop shaft in place of the standard propeller
Test wheel (test propeller)
318
Designed to put a load on the engine while creating only minimal water movement, allowing technicians to run the engine at maximum speed in a test tank
Test wheel
319
Two procedures that require a test wheel
Check engine operation by verifying minimum test propeller RPM rate, check maximum spark advance
320
Maximum test RPM rate can be found in
Engine specifications
321
Hand tool used to remove the fuel jets or orifices from carburator
Orifice driver
322
Measures the discharge pressure of high pressure fuel pump within the fuel rail
Pressure gauge
323
Measures the suction sides of the fuel system
Vacuum gauge
324
Tool indicates an excessive restriction in the fuel supply
Vacuum gauge
325
Contains a set of tools that bolt onto the flywheel and push on the crankshaft, pulling the flywheel from the powerhead
Universal puller kit
326
Doubles as a powerhead lifting device
Universal puller kit
327
Used to check total voltage output during ignition system checks
Spark tester
328
Hook the ____ to the spark tester
Spark plug wires
329
Meter that stabilizes and reads the uneven and spiked voltages from the flywheel magnets and associated coils during ignition system testing
Peak-reading voltmeter
330
Performs some of the same functions as the ohmmeter
Test light (continuity tester)
331
Comprised of a tiny light bulb with a small battery and two leads
Test light
332
The test light creates a _____ circuit
Series
333
Handheld instrument that performs some of the same functions as a heat sensitive marker, but measures heat electronically using infrared technology
Infrared temperature gun
334
Some infrared temperature guns include a ____ to increase accuracy
Laser pointer
335
Used to check the integrity of the oil and water seals in the lower unit
Geargase pressure/vacuum tester
336
Comprised of a hand operated reciprocating pump, pressure gauge with a one way valve, and an attached hose with a threaded adapter for installation into gearcase oil drain plug bore
Gearcase vacuum/pressure tester
337
Used to check the gearcase seals ability to hold a vacuum
Vacuum tester
338
Tool that provides a convenient way to fill gearcases with oil, and consists of a three gallon tank, pump, and quick disconnect hose assembly
Gearcase filler
339
The gearcase filler plug valve must be turned how far to change supply from full flow to closed
Quarter turn
340
Gearcase oil check should be done every ____
50 operational hours
341
Gearcase oil replacement should be done every _____
100 operational hours
342
only tool needed to perform an oil change
Flat head screwdriver
343
Weights of oil used for gearcase
80 or 90 weight
344
Avoid accidental starting of engine while servicing by
Disconnecting the battery and tagging engine out
345
Ensure air supply does not exceed ____ when using shop air for cleaning or drying
25 psi
346
Wen performing a lower unit or gearcase oil change, ensure the outboard is in a _____ position
Vertical or upright
347
Oil drain plug has what build in to collect metal chips
Magnet
348
Why does the oil drain plug have a magnet to collect metal chips
To alert technicians of possible internal gear problems
349
What happens when the top oil level plug is removed
Releases the vacuum that exists and allows the oil to drain freely from the lower unit
350
How long to drain all oil completely from lower unit
Five to ten minutes
351
While oil is draining, inspect ____
The seals (usually o-ring type) on both drain plugs for dry rot, cracks or tears. And inspect used oil
352
If drain plug o-ring/seal has dry rot, cracks, or tears
Replace with a new seal
353
If drain plug o-ring/seal does not have dry rot, cracks, or tears
Lubricate and reuse
354
If used gearcase oil appears milky indicating the presence of moisture
Consult with your supervisor, as internal problems may exist
355
If used gearcase oil is gray or smells burnt
Consult with your supervisor, as internal problems may exist
356
Milky oil indicates
The presence of moisture
357
If oil drain plug has large metal chips
Consult with your supervisor, as internal problems may exist
358
If the oil drain plug has fine metal filings
This indicates normal gear wear
359
One of the more popular oil filling methods
Squeeze bottle
360
Insert the gearcase filler into
The bottom drain hole
361
Tighten the oil drain plugs how tight
Hand tight
362
Maximum allowable variation between compression of different cylinders
15 psi
363
Possible causes of uneven cylinder compression
Damaged head gasket, damaged pistons, broken or stuck piston rings, scored cylinder walls, stuck valves, incorrectly adjusted valves
364
Tool used to measure proper compression pressures within the engine's cylinders
Compression tester
365
Comprised of a pressure gauge with an attached hose. The end of the hose has an adapter for threading into spark plug holes. The gauge has a built in check valve
Compression tester
366
Two types of common compression testers
Threaded and hand held
367
First step to obtain compression reading
Run the engine until it reaches normal operating temperature
368
When checking compression crank engine at least this many times through the compression stroke
Four
369
Spark plugs should be replaced when the engine reaches its first _____ hours
100
370
Most spark plug insulators are made of
Porcelain or ceramic
371
When replacing spark plugs, set the gap toward
The tight end of the spectrum
372
The center electrode of a spark plug is made of
A nickel-iron alloy
373
The basic types of spark plug fouling
Carbon fouling, lead fouling, oil/carbon fouling
374
Caused from low speed operation or a fuel mixture that is too rich. Causes missing or roughness and creates soft black soot that is easily removed (spark plug)
Carbon fouling
375
Caused by tetraethyl lead used in some fuels and by high speed operation (spark plug)
Lead fouling
376
Appears as a heavy, crusty formation, or as tiny globules (spark plug)
Lead fouling
377
Found on four stroke engines that are so badly worn that excess oil reaches the combustion chamber past the piston ring or the valve guides (spark plug)
Oil/carbon fouling
378
Set the gap clearance of a spark plug with
Wire-type feeler gauge
379
When reinstalling used spark plugs, tighten them ___ after the spark plug seats
1/8 - 1/4 turn
380
When installing new spark plugs, tighten them ____ after the spark plugs seat
1/2 turn
381
Apply a thin coat of ___ to the ribbed portion of the spark plug insulator and the opening of the spark plug wiring boot
Waterproof grease
382
Size of socket bolt securing the ignition coil
6 x 25 mm
383
Adjust the air gap between the points on the spark tester to
1/2 inch
384
To prevent possible arcing, route the leads ___ from any metal surface for the spark tester
Two inches
385
Most common type of fuel filter in the coast guard
Spin on type
386
Fuel filters are rated by
Micron size or gallons per hour
387
Clean the fuel strainer with
Low pressure air
388
Install the fuel suspension to the strainer; align the "I" mark on the tube with
The direction of exit side of the fuel tube joint
389
Test the water level sensor in the water separator by
Connecting a fluke meter on the two leads to the 2P connector and setting the meter to read continuity
390
If the sensor is level (the float is down) on the water separator
There should be no continuity
391
If the sensor is turned upside down (the float is up) on the water separator
There should be continuity
392
To measure belt tension using a belt tension gauge, pull at
The center between the pulleys
393
Size of flange bolt located behind the alternator
10 x 90 mm
394
Size of flange nut located behind the alternator
8 mm
395
Use this bolt to adjust alternator belt tension
Special adjuster bolt
396
Controls the valve timing in four stroke engines
Timing belt
397
The crankshaft drives the camshaft via
The timing belt
398
After aligning the timing belt driven pulleys no. 1 TDC marks with the marks of the timing belt back cover, slowly turn the crankshaft pulley counter clockwise further by _____ teeth of the timing belt driven pulley gear
5
399
Apply a force of _____ at the midpoint between the left side timing belt driven pulley and the idler pulley B
19.6 N (4.4 foot pounds)
400
To adjust the timing belt loosen the timing belt tensioner bolt _____
Approximately one and one half turns
401
If the ignition pops or backfires during starting
The ignition may be out of time
402
Assures timing pointer is aligned with the correct spot on the flywheel grid during ignition checks
Set timing pointer
403
Sets carburetor's linkage so the throttle plates in the throats of the carburetors begin to open at the same time and travel the same distance
Synchronize throttle plate
404
Sets the throttle linkage so the carburetor's throttle plates begin to move at the correct moment in relationship to the advancement of the ignition timing
Cam follower pickup
405
Sets the throttle linkage so the carburetor's throttle plates begin to move at the correct moment in relationship to the movement of the throttle cable
Throttle cam
406
Sets a limit on throttle movement
Wide open throttle stop
407
Requires a strobe type timing light and allows the technician to set the timer base so the spark plugs fire at the optimum moment during idling
Idle timing
408
For most four stroke engines, the only synchronization needed is
A simple adjustment of the throttle control cable and shift control cable
409
Occurs when at least two different metals are brought into electrical contact underwater and form a galvanic couple
Galvanic corrosion
410
Once the galvanic couple forms, the weaker metal in the couple becomes the ____ and corrodes faster, while the other becomes the ____ and corrodes slower
Anode, cathode
411
Act as a sacrificial metal to prevent galvanic corrosion
Anodes
412
Test anodes for proper installation with
An ohmmeter
413
Replace water pump at least _____
Annually
414
Lock the new impeller liner in the new impeller housing for the water pump with ___
The square index tab
415
Install the new impeller for the water pump with what motion
Counterclockwise rotation
416
Verify the impeller for the water pump engages the
Impeller cam
417
Install the water tube grommet with ____ facing up
the inside chamfered edge
418
Apply ____ to the groove of the impeller housing grommet for the water pump
Thin bead of adhesive sealant
419
The _____ edge of the cam is the leading edge during driveshaft rotation for the water pump
Sharp edge
