Important Information: Section 1C - General Information
Important Information: Section 1C - General Information
IMPORTANT INFORMATION 1
Section 1C - General Information C
Table of Contents
Serial Number Location . . . . . . . . . . . . . . . . . . 1C-1 Model 135/150 DFI Powerhead
Conditions Affecting Performance . . . . . . . . . 1C-2 Starboard View . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Model 135/150 DFI Powerhead Port View . . 1C-10
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Model 135/150 DFI Powerhead Top View . . . 1C-11
Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Model 135/150 DFI Powerhead Aft View . . . 1C-12
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-13
Engine Compression . . . . . . . . . . . . . . . . . . 1C-5 Cleaning & Painting Aluminum Propellers &
Following Complete Submersion . . . . . . . . . . 1C-6 Gear Housings . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Salt Water Submersion . . . . . . . . . . . . . . . . 1C-6 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . 1C-14
Submerged While Running . . . . . . . . . . . . 1C-6 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . 1C-14
Model 135/150 DFI Powerhead Instructions for Wet Application . . . . . . . . . 1C-14
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-8
e
d
XX
a - Serial Number
b - Model Year
c - Model Description
d - Year Manufactured
e - Certified Europe Insignia
Weather conditions exert a profound effect on power output of internal combustion en-
gines. Established horsepower ratings refer to the power that the engine will produce at
its rated RPM under a specific combination of weather conditions.
Corporations internationally have settled on adoption of I.S.O. (International Standards
Organization) engine test standards, as set forth in I.S.O. 3046, standardizing the compu-
tation of horsepower from data obtained on the dynamometer. All values are corrected
to the power that the engine will produce at sea level, at 30% relative humidity, at 77° F
(25°C) temperature and a barometric pressure of 29.61 inches of mercury.
Summer conditions of high temperature, low barometric pressure and high humidity all com-
bine to reduce engine power. This is reflected in decreased boat speeds – as much as 2 or
3 mph. Nothing will regain this speed for the boater but the coming of cool, dry weather.
In pointing out the consequences of weather effects, an engine – running on a hot, humid
summer day – may lose as much as 14% of the horsepower it would produce on a dry,
brisk spring or fall day. The horsepower that any internal combustion engine produces
depends upon the density of the air it consumes, and this density is dependent upon the
temperature of the air, its barometric pressure and water vapor (or humidity) content.
Accompanying this weather-inspired loss of power is a second but more subtle loss. At
rigging time in early spring, the engine was equipped with a propeller that allowed the
engine to run within its recommended RPM range at full throttle. With the coming of sum-
mer weather and the consequent drop in available horsepower, this propeller will, in effect,
become too large. Consequently, the engine operates at less than its recommended RPM.
Due to the horsepower/RPM characteristics of an engine, this will result in further loss of
horsepower at the propeller with another decrease in boat speed. This secondary loss
can be regained by switching to a smaller pitch propeller that allows the engine to run
again at recommended RPM.
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.
Boat
WEIGHT DISTRIBUTION
1. Proper positioning of the weight inside the boat (persons and gear) has a significant
effect on the boat’s performance, for example:
a. Shifting weight to the rear (stern)
(1.) Generally increases top speed.
(2.) If in excess, can cause the boat to porpoise.
(3.) Can make the bow bounce excessively in choppy water.
(4.) Will increase the danger of the following wave splashing into the boat when
coming off plane.
b. Shifting weight to the front (bow)
(1.) Improves ease of planing off.
(2.) Generally improves rough water ride.
(3.) If excessive, can make the boat veer back-and-forth (bow steer).
BOTTOM
1. Boat Bottom: For maximum speed, a boat bottom should be nearly a flat plane where
it contacts the water and particularly straight and smooth in fore-and-aft direction.
a. Hook: Exists when bottom is concave in fore-and-aft direction when viewed from
the side. When boat is planing, hook causes more lift on bottom near transom and
allows bow to drop, thus greatly increasing wetted surface and reducing boat
speed. Hook frequently is caused by supporting boat too far ahead of transom
while hauling on a trailer or during storage.
b. Rocker: The reverse of hook and much less common. Rocker exists if bottom is
convex in fore-and-aft direction when viewed from the side, and boat has strong
tendency to porpoise.
c. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of motor’s gear
housing increase skin friction and cause speed loss. Clean surfaces when neces-
sary.
d. Gear Housing: If unit is left in the water, marine vegetation may accumulate over
a period of time. This growth MUST be removed from unit before operation, as it
may clog the water inlet holes in the gear housing and cause the engine to over-
heat.
Trim
TRIMMING OUTBOARD OUT (UP)
WARNING
Excessive trim out may reduce the stability of some high speed hulls. To correct
instability at high speed, reduce power GRADUALLY and trim outboard in slightly
before resuming high speed operation. Rapid reduction in power will cause a
sudden change of steering torque and may cause additional momentary boat in-
stability.
1. Will lift bow of boat, generally increasing top speed.
2. Transfers steering torque harder to left on single outboard installations below 23 in.
(584mm) transom height.
3. Increases clearance over submerged objects.
4. In excess, can cause porpoising and/or ventilation.
5. If trimmed out beyond the water pickup, reduced water supply can cause overheating
resulting in engine damage.
TRIMMING OUTBOARD IN (DOWN)
WARNING
Excessive speed at minimum trim in may cause undesirable and/or unsafe steer-
ing conditions. Each boat should be tested for handling characteristics after any
adjustment is made to the angle (trim adjustment bolt relocation.)
1. Will help planing off, particularly with a heavy load.
2. Usually improves ride in choppy water.
3. In excess, can cause boat to veer to the left or right (bow steer).
4. Transfers steering torque harder to right (or less to left) on single outboard installations.
5. Improves planing speed acceleration (by moving trim adjustment bolt one hole closer
to transom).
WATER ABSORPTION
It is imperative that all through hull fasteners be coated with a quality marine sealer at time
of installation. Water intrusion into the transom core and/or inner hull will result in addition-
al boat weight (reduced boat performance), hull decay and eventual structural failure.
CAVITATION
Cavitation is caused by water vapor bubbles forming from a sharp edge or angle on the
gearcase, or from an irregularity in the propeller blade itself. These vapor bubbles flow back
and collapse when striking the surface of the propeller blade, resulting in erosion of the pro-
peller blade surface. If allowed to continue, eventual blade failure (breakage) will occur.
VENTILATION
Ventilation occurs when air is drawn from the water’s surface (excessive trim out angle)
or from the engine exhaust flow (wrong propeller/propeller hardware installed or gear
case labyrinth seal worn) into the propeller blades. These air bubbles strike the propeller
blade surface and cause erosion of the blade surface. If allowed to continue, eventual
blade failure (breakage) will occur.
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. Detonation creates severe shock waves in the engine, and these shock
waves often find or create a weakness: The dome of a piston, cylinder head/gasket, piston
rings or piston ring lands, piston pin and roller bearings.
A few of the most common causes of detonation in a marine 2-cycle application are as
follows:
• Over-advanced ignition timing.
• Use of low octane gasoline.
• Propeller pitch too high (engine RPM below recommended maximum range).
• Lean fuel mixture at or near wide-open-throttle.
• Spark plugs (heat range too hot – incorrect reach – cross-firing).
• Inadequate engine cooling (deteriorated cooling system).
Detonation usually can be prevented if:
1. The engine is correctly set up.
2. Diligent maintenance is applied to combat the detonation causes.
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Engine Compression
Engine compression should be checked with engine block warm, throttle shutter wide
open, all spark plugs removed and using a fully charged battery. Normal compression for
all cylinders should be 110 to 130 psi (758.5 to 896.4 kPa). Cylinders should not vary more
than 15 psi (103.4 kPa) between one another. A variance of more than 15 psi would indi-
cate the need for a power head inspection/disassembly.
c. Within the first 10 seconds after the key switch has been turned on, move the re-
mote control handle from NEUTRAL (“N”) into FORWARD (“F”) gear 3 to 5 times.
This will automatically start the priming process.
N
F
NOTE: Audible click from the oil pump will tell you the pump is priming. It may take a few
minutes for the pump to complete the priming process.
11. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for
at least one hour to eliminate any water in engine.
12. If engine fails to start, determine cause (fuel, electrical or mechanical).
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8
4 5
57314
18
17
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24
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15 5
20
14
23
22 7
19
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8
10 9
57317
1 - Fuel Pressure Test Valve 14 - Starter Solenoid
2 - Air Compressor Oil Return Line 15 - Oil Pump Fuse
3 - Crank Position Sensor 16 - Harness Fuse (20 Ampere)
4 - Throttle Plate/Air Plenum Assembly 17 - ECM Fuse (20 Ampere)
5 - Digital Diagnostic Terminal Connector 18 - Electric Fuel Pump Fuse (20 Ampere)
6 - Oil Hose from Oil Reservoir to Oil Pump 19 - Air Hose
7 - Oil Pump 20 - Starboard Fuel Rail
8 - Main Power Relay(1998 Model)* 21 - Fuel Hose
9 - Trim DOWN Relay 22 - #5 Fuel Injector
10 - Trim UP Relay (1998 Model)* 23 - #3 Fuel Injector
11 - Temperature Sensor 24 - #1 Fuel Injector
12 - Electronic Control Module 25 - Air Hose from Air Compressor
13 - Starter Motor
NOTE: *The location for 1999 Model Main Power Relay and Trim UP Relay are reversed.
3 8
31 18
23
19 9
24
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31
15 11
20
25
1
29 26 13
21
17
32
30 12
27
28
22
14
16
57312
1 - High Pressure Electric Fuel Pump 17 - Excess Fuel Return to Fuel Cooler
2 - Fuel Out (90 psi) 18 - Air Pressure Test Port
3 - Crank Position Sensor 19 - 40 psi Check Valve
4 - Fuel Return from Fuel Cooler 20 - Fuel Cooler
5 - Water Out (tell-tale) from Air Compressor 21 - Oil Reservoir
6 - Air Restrictor/Air Inlet to Air Compressor 22 - Neutral Shift Interrupt Switch
7 - Air Compressor 23 - 60 Ampere Alternator
8 - Air Pressure Out from Air Compressor 24 - Throttle Position Sensor (2 each)
9 - Temperature Sensor (Air Compressor) 25 - Low Pressure Electric Fuel Pump
10 - #2 Fuel Injector 26 - Fuel/Water Separator
11 - #4 Fuel Injector 27 - Fuel/Water Sensor
12 - #6 Fuel Injector 28 - Low Pressure Fuel Pump Inlet Hose
13 - Excess Air to Adaptor Plate 29 - Vapor Separator
14 - Water Inlet to Fuel Cooler from Adaptor Plate 30 - Vapor Separator Drain Plug
15 - Port Fuel Rail 31 - Vent Canister
16 - Water Out to Poppet Valve 32 - Idle Stop Screw
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18 19
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17 15
5
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6
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22 4
13
12 11 23
10
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28
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Painting Procedures
Cleaning & Painting Aluminum Propellers & Gear Housings
WARNING
Avoid serious injury from flying debris. Avoid serious injury from airborne par-
ticles. Use eye and breathing protection with proper ventilation.
PROPELLERS
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-
Brite, disc or belts.
2. Feather edges of all broken paint edges. Try not to sand through the primer.
3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Re-
mover or equivalent (Xylene or M.E.K.).
4. If bare metal has been exposed, use Light Gray Primer.
5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish
coat.
6. Apply the finish coat using Propeller Black.
GEAR HOUSINGS
The following procedures should be used in refinishing gear housings. This procedure will
provide the most durable paint system available in the field. The materials recommended
are of high quality and approximate marine requirements. The following procedure will
provide a repaint job that compares with a properly applied factory paint finish. It is recom-
mended that the listed materials be purchased from a local Ditzler Automotive Finish Sup-
ply Outlet. The minimum package quantity of each material shown following is sufficient
to refinish several gear housings.
Procedure:
1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine
growth, and rinse with water, if necessary.
2. Wash gear housing with soap and water, then rinse.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove
paint blisters only. Feather edge all broken paint edges.
4. Clean gear housing thoroughly with (DX-330) wax and grease remover.
5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment.
IMPORTANT: Do not use any type of aerosol spray paints as the paint will not prop-
erly adhere to the surface nor will the coating be sufficiently thick to resist future
paint blistering.
6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufac-
turers instructions, allowing proper induction period for permeation of the epoxy prim-
er and catalyst.
7. Allow a minimum of one hour drying time and no more than one week before top coat-
ing assemblies.
8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Gray, and
DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four
colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label.
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.
9. The type of spray gun used will determine the proper reduction ratio of the paint.
IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode.
10. Cut out a cardboard plug for trim tab pocket to keep paint off of mating surface to main-
tain good continuity circuitry between trim tab and gear housing.
Decal Application
Decal Removal
1. Mark decal location before removal to assure proper alignment of new decal.
2. Carefully soften decal and decal adhesive with a heat gun or heat blower while re-
moving old decal.
3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water.
4. Thoroughly dry decal contact area and check for a completely cleaned surface.
Instructions for Wet Application
NOTE: The following decal installation instructions are provided for a wet installation. All
decals should be applied wet.
TOOLS REQUIRED
1. Plastic Squeegee*
2. Stick Pin
3. Dish Washing Liquid/Detergent without ammonia. Do not use a soap that contains
petroleum based solvents.
** Automotive Body Filler Squeegee
SERVICE TIP: Placement of decals using the wet application will allow time to posi-
tion decal. Read entire installation instructions on this technique before proceeding.
TEMPERATURE
IMPORTANT: Installation of vinyl decals should not be attempted while in direct
sunlight. Air and surface temperature should be between 60°F (15°C) and 100°F
(38°C) for best application.
SURFACE PREPARATION
IMPORTANT: Do not use a soap or any petroleum based solvents to clean applica-
tion surface.
Clean entire application surface with mild dish washing liquid and water. Rinse surface
thoroughly with clean water.
DECAL APPLICATION
1. Mix 1/2 ounce (16 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. This will ensure that the vinyl decal keeps its shape during installation.
2. Place the decal face down on a clean work surface and remove the paper backing
from adhesive side of decal.
3. Using a spray bottle, flood the entire adhesive side of the decal with the pre-mixed
wetting solution.
4. Flood area where the decal will be positioned with wetting solution.
5. Position pre-wetted decal on wetted surface and slide into position.
6. Starting at the center of the decal, LIGHTLY squeegee out the air bubbles and wetting
solution with overlapping strokes to the outer edge of the decal. Continue going over
the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface.
7. Wipe decal surface with soft paper towel or cloth.
8. Wait 10 - 15 minutes.
9. Starting at one corner, CAREFULLY AND SLOWLY pull the masking off the decal sur-
face at a 180° angle.
NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with
stick pin and press out the entrapped air or wetting solution with your thumb (moving to-
ward the puncture).