Service Manual 115-200 HP E-TEC Installation And Predelivery [Water Test And Final Adjustments]

An in the water test is required to make sure the outboard(s) and boat are rigged correctly, propeller selection is correct, and that all accessories function properly.

Pay special attention to the following, especially if the boat is repowered with new outboard(s):

• Engine mounting height
• Jack plate adjustment
• Correct propeller selection and WOT RPM
• Fuel system vacuum
• Engine water pressure/optional water screens Make all needed adjustments or repairs and retest before delivery.

When ready for delivery, give all instruction sheets, operating instructions and user guides provided with accessories to the owner. Advise the owner of any special operation or maintenance information contained in the instructions.

IMPORTANT: Complete the Predelivery Check list and obtain owner’s signature at the time of delivery. The Predelivery Checklist must be kept on file for seven years.

Goals include:

• Engine RPM within the full throttle operating range
• Best acceleration and top speed
• No excessive ventilation while boat is coming onto plane.

Start with the engine lower on the transom. Make a test run, taking note of engine RPM, water pres sure, trim level and boat speed. Refer to the Water Pressure Chart on p. 78.

Raise the engine or jack plate and repeat the process until the best acceleration and boat speed are achieved.

Test fuel system vacuum. Refer to the appropriate service manual. The maximum inlet fuel vacuum should not exceed 4 in. Hg. (13.5 kPa) at the inlet to the fuel lift pump under any operating conditions (IDLE to WOT).

A higher vacuum indicates an excessive restriction in the fuel supply. Repair as needed.

Check engine water pressure. Confirm adequate water pressure at all engine speeds and in turns. Refer to the Water Pressure Chart on p. 78.

If water pressure falls below acceptable levels, adjust outboard alignment (multiple engine installations), or consider installing optional high flow water screens. Refer to appropriate parts catalog for available water screens.

This chart lists typical water pressure readings for 2010 model outboards. Water pressure readings may vary depending on water inlet screen type, hull design, set up, and operating conditions.

Water pressure is listed in psi and in (kPa).

If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in the course of such outboard movement. Injuries could result from loss of boat control.

Adjust the tilt limit switch on all new outboard installations.

Check the clearance between outboard(s) and the boat’s motor well and transom area. Tilt out board(s) to highest point of clearance and turn the steering system lock to lock.

If the outboard contacts the boat's motor well when fully tilted, adjust the tilt limit cam to reduce full-tilt position.

The tilt limit cam will not prevent the outboard from overriding the adjustment if the outboard is tilted manually.

Place the outboard in normal operating position.

Rotate the LOWER adjustment tab UP to reduce the maximum tilt. Rotate the UPPER adjustment tab DOWN to increase the maximum tilt position.

• 1. Lower adjustment tab
• 2. Upper adjustment tab

Check the adjustment by tilting the outboard fully.

Repeat this procedure until the tilt limit switch stops the outboard's upward travel before it contacts the motor well.

To prevent damage to equipment, provide additional motor well clearance when needed. Consider either changing the outboard mounting position or modifying the boat if the possibility for interference and damage exists.

Adjusting the tilt limit cam will NOT prevent the outboard from tilting fully and contacting the motor well if the gearcase hits an object at high speed. Such contact could damage the outboard and boat and injure boat occupants.

Tilt the outboard and engage the tilt support.

Temporarily install a thrust rod, P/N 436541, in the number 3 hole.

Loosen the sending unit screws, to allow the sending unit to pivot.

• 1. Screws

Disengage the tilt support. Lower the outboard against the thrust rod.

Observe the trim gauge. If the needle does not show center position, tilt the outboard up and adjust the sending unit by pivoting it up or down.

• 1. Needle at center position

Lower the outboard against the thrust rod to check adjustment. Repeat adjustment, if necessary.

After adjustment is correct, tilt the outboard up, tighten the two sending unit screws, and remove the thrust rod.

Trim Limiter Rod

The trim limiter rod prevents excessive trim down. As the engine is trimmed to the full down position, the bow of the boat goes deeper into the water.

• If the trim limiter rod is left out, the bow could plow into the water causing the boat to “bow steer” resulting in a loss of control.
• If the trim limiter rod is set too far out, the propeller could ventilate, resulting in poor acceleration when the boat is coming onto plane.

Set the trim limiter rod to prevent excessive trim down and provide good acceleration. The trim limiter rod can be used to prevent the gearcase or spray deflector from contacting the transom.

When the outboard is returned to the customer, the trim limiter rod must be installed and in the same location as it was when the motor was brought in for service. Leaving the trim limiter rod out, or changing the adjustment, could allow the motor to unexpectedly trim in too far and cause loss of control.

Improper trim tab adjustment can cause difficult steering and loss of control.

A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface. The trim tab is adjustable to com pensate for this steering torque.

IMPORTANT: A single trim tab adjustment will relieve steering effort under only one set of speed, outboard angle and load conditions. No single adjustment can relieve steering effort under all conditions.

If the boat pulls to the left or right when its load is evenly distributed, adjust the trim tab as follows:

• With the remote control in NEUTRAL and the engine OFF, loosen the trim tab screw.
• If the boat pulled to the right, move rear of the trim tab slightly to the right.
• If the boat pulled to the left, move rear of the trim tab slightly to the left.

Tighten the trim tab screw as follows:

• 115 – 200 HP: 35 to 40 ft. lbs. (47 to 54 N·m).

• 1. Trim tab screw

Test the boat and, if needed, repeat the procedure until steering effort is as equal as possible.

Outboards with High Transom Heights

The trim tab may be above the surface of the water when the outboard is trimmed out. Steering effort might increase. Lower the trim setting to submerge the trim tab and to reduce steering effort.

Dual Standard Rotation Outboards

Move both trim tabs equally and in the same direction.

Dual Outboards, One Counter and One Standard Rotation

Set both trim tabs to the center position.

Dual outboards must be connected with a tie bar and adjusted to align the outboards for correct water flow to the gearcases and propellers.

Incorrect outboard alignment could cause one or more of the following:

• Propeller ventilation
• Reduction of top speed
• Improper boat tracking
• Engine overheat and powerhead damage

Follow the instructions provided by the tie-bar manufacturer for tie bar installation and adjustment.

Measure Alignment

The “toe-in” (gearcase leading edges closer together than propeller shaft centers) or “toe-out” (gearcase leading edges farther apart than pro peller shaft centers) is determined as follows:

• Position outboards straight with the anti-ventila tion plates parallel with the bottom of the boat.
• Measure between propeller shaft centers.

• Measure between leading edges of gearcase.

Alignment Adjustment

Various boat/motor combinations respond differently to dual-outboard alignments. Each application must be thoroughly tested until the ideal combination of performance, steering, and cooling is found.

A common practice is to set-up the outboards parallel, or with a small amount of “toe-out,” and adjust inward until best results are achieved.

• A typical set-up with 2-stroke outboards mounted directly on the transom often runs best with a slight amount of “toe-in.”
• Outboards mounted behind the transom on motor brackets usually require “parallel” alignment or “toe-out.”

Adjust the outboard alignments by adjusting tie bar. Follow the tie bar manufacturer’s adjustment procedures.

Check steering operation. Make sure that the steering system operates properly at various trim angles.

Confirm Alignment

To confirm proper alignment, perform the follow ing steps:

• Water test the boat.
• Monitor the water pressure for both outboards.
• Run the boat at various trim angles.
• Perform steering maneuvers and vary the throttle settings.
• Monitor boat and outboard performance.

A sudden loss of water pressure or excessive propeller ventilation on one or both outboards may indicate a misalignment of the gearcases. Reset the outboard alignment and retest.