Four-stroke outboards and exotic, computer-controlled fuel-injection systems have become mainstream. What hasn't changed, however, is that proper maintenance and an intimate knowledge of the inner workings of your outboard are prerequisites for trouble-free boating and maximum engine longevity..
Outboard Engines 2nd Edition fills the gap between owner's manuals that don't even tell you how to change a spark plug and professional shop guides that detail how to do a complete rebuild. It covers basic operating principles, maintenance procedures, and troubleshooting techniques for two- and four-stroke engines from 2 to 300 horsepower.
With Ed Sherman's help, you'll be perfectly capable of performing your own engine maintenance, repairing minor problems, and diagnosing problems you can't tackle yourself. His methodical approach can save you a world of frustration?and peril?as well as time-and-a-half weekend mechanics' charges.
Table of Contents
THE BASICS: WHAT MAKES YOUR ENGINE TICK
Your Engines Four Basic Needs | Inside Your Engine?The Basic Components | Basic Two-Stroke and Four-Stroke Cycles: The Four-Stroke; The Two-Stroke | The Basics of Troubleshooting
BREAKING IN A NEW ENGINE
General Break-in Guidelines: Additives; Oil Grades; Mix Ratio; Operating Procedure
Daily Checks and Maintenance | Monthly Checks and Maintenance | Seasonal Checks and Maintenance | Three-Month (or Seasonal) Service Checks: Grease Points; Propeller Inspection ; Gearcase-Oil Change; Cooling System; Impeller Replacement; Cylinder Compression; Fuel System; Automatic Oiler; Steering; Battery; Two Final Adjustments | Special Considerations for Four-Stroke Engines: Sump-Oil Change; Timing-Belt Wear; Valve Clearance Check | Maintenance in a Nutshell: Daily Checks; Monthly Checks; Seasonal Checks; Additional Four-Stroke Annual Service | Off-Season Storage and Spring Commissioning: Winter Storage; Spring Commissioning
HOW TO FIND THE TROUBLE
Listen, Look, and Feel for Trouble | A Troubleshooting Plan of Attack: Ten Categories of Trouble | Symptoms and Probable Causes: Engine Will Not Start; Engine Runs Irregularly or Stalls; Rough Idle; Engine Speed Will Not Increase; Engine Overheats; Engine Speed Higher than Normal; Engine Speed Lower than Normal; Boat Speed Low; Steering Pulls to One Side; Excessive Blue Smoke
ISOLATING IGNITION SYSTEM PROBLEMS
Ignition Components and What They Do | Ignition Tests | Testing for Spark | Testing the Plugs | Ignition Problems?Tests and Procedures: Ignition Problems Checklist | Testing Spark-Plug Wires | Testing High-Tension Coils | Testing Charge and Sensor Coils and Ignition Module: Testing the Charge Coil; Testing the Sensor Coil; Testing Coil Voltages; Charge-Coil Test; Sensor-Coil Test; Ignition-Module Test; Under-the-Flywheel Systems | Some Additional Checks: Testing Your Stop Switch; Testing a Mercury (Tilt) Stop Switch | Final Checks and Ignition Timing: Checking the Timing; CDI Unit Problems; Optical Timing Systems; Summing It Up
THE CHARGING and STARTING SYSTEMS
Charging?The Key Components: How It All Works | Testing Your Battery: Battery Capacity Test; Battery Drain Test | Charging System Problems and Possible Causes: Verifying Charging-System Output; Testing Your AC Voltage Rectifier | Testing the Stator Windings: The Sequence to Follow | Troubleshooting Electric Starter Circuits: Voltage-Drop Test | Testing the Neutral Safety Switch: Neutral Switch Misadjustment | Testing an Ignition Switch: Other Starter-Related Problems | Manual Starters: Winding On a New Pull Cord; Replacing the Coil Spring
THE FUEL and LUBRICATION SYSTEMS
Fuel-Delivery Systems | The Spin-On Fuel/Water Separator | Fuel System Safety Considerations | Fuel-System Basics and Common Problems: Fuel-Tank Strainer; Anti-Siphon Valve; Flushing the Tank; Portable-Tank Strainers; The Fuel/Water Separator; The Primer Bulb; Fuel Pump Strainer | Fuel Supply Problems: The Fuel Pump; Checking the Seal; Fuel Pump Removal and Disassembly | Fuel Delivery Step by Step | Classic Symptoms of Carburetor Problems: Mixing Air and Fuel | How a Carburetor Works: The Float Circuit; The Idle Circuit; The Intermediate Circuit; The High-Speed Circuit; The Choke Circuit | Removing Your Carburetor | Disassembling Your Carburetor | Choke and Primer Systems: Further Checks; Manual Primers; Electric Primers; Electric Chokes; Thermal Wax Valves; Changing Technology | Lubrication Systems: The Pre-Mix Method; OMCs VRO System; Mechanical Oil-Pump Systems; Oil Recirculation Systems; Four-Stroke Engine Lubrication
SERVICING THE STEERING and TRIM SYSTEMS
Tiller Steering: Steering-Tension Adjustment; Trim Tab Adjustment | Cable-Controlled Steering: Measuring for a New Steering Cable | Hydraulic Steering: Routine Servicing; Symptoms of Problems; Bleeding a Hydraulic System; Trim and Tilt Systems; Electrical Troubleshooting
THE COOLING SYSTEM, LOWER UNIT, and PROPELLER
Air Cooling: Air-and-Water Cooling | Water Cooling: Symptoms of Overheating; Causes of Overheating; Thermostat Removal and Testing; Flushing Your Cooling System; Servicing the Water Pump; Reinstalling the Lower Unit | Testing the Overheat Alarm | The Shifting System: Diagnosing Shifting Problems | Lower-Unit Maintenance | Choosing a Propeller: Propeller Terms
DEALING WITH CORROSION
Sacrificial Zincs: The Galvanic Series | Touching Up Paint Chips and Corrosion | Dealing with Hardware Corrosion: Releasing Fasteners and Preventing Corrosion | Frozen Bolts | Saving a Drowned Engine
Johnson and Evinrude: Johnson, Evinrude, Maintenance Schedule | Mercury Marine: CARB Ratings, Ethanol Worries?, Routine Maintenance | Nissan Marine/Tohatsu | Honda: Maintenance | Suzuki: Maintenance | Yamaha: Unusual Maintenance Check
About the Author:
Ed Sherman is a marine surveyor and technician and senior writer for the American Boat and Yacht Council. The author of five books, he also writes for Professional Boatbuilder, Cruising World, Boating, and other nautical magazines. He operates his center console fishing boat on Narragansett Bay.