ELECTRICAL AND IGNITION

2 D

TIMING/SYNCHRONIZING/ADJUSTING

90-831996R1 JUNE 1996

ELECTRICAL AND IGNITION

2D-1

Table Of Contents
Page Page

Timing/Synchronizing/ Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . Checking for Top Dead Center (TDC) . . . . Checking Timing (At Cranking Speed) . . . Turn-Key Start Feature . . . . . . . . . . . . . . . . Synchronizing Carburetors to Ignition Timing for Turn-Key Start . . . . . . . . . . . . . . Setting Idle Timing . . . . . . . . . . . . . . . . . . . .

2D-1 2D-1 2D-1 2D-1 2D-1 2D-2 2D-2 2D-3

Check WOT Throttle Position with Engine Not Running . . . . . . . . . . . Check WOT Ignition Timing with Engine Running . . . . . . . . . . . . . . . Check WOT Ignition Timing with Engine Not Running . . . . . . . . . . . Adjusting Idle Mixture . . . . . . . . . . . . . . . . . Check Oil Pump Adjustment . . . . . . . . . . . .

2D-4 2D-5 2D-5 2D-6 2D-7

2D-0

ELECTRICAL AND IGNITION

90-831996R1 JUNE 1996

Timing/Synchronizing/ Adjusting
Specifications
MODEL 90/95/120 SPORT JET MAXIMUM TIMING @ 5000 RPM* @ CRANK SPEED IDLE RPM FULL THROTTLE RPM SPARK PLUG TYPE FIRING ORDER 90/95 HP FIRING ORDER 120 HP 30 BTDC 32 BTDC 950 - 1100 RPM 4700 5300 CHAMPION L76V CHAMPION QL76V 1-2-3 1 -3-2-4

4.

Check if mark on flywheel aligns with mark on pointer.

NOTE: If mark and pointer do not align, the flywheel key has been sheared.

Checking Timing (At Cranking Speed)

Timing Specifications HP 90/95/120 At Cranking Speed 32_ At Wide Open Throttle 30_

WARNING
Engine can start when turning flywheel to check timing. Remove all spark plugs from engine to prevent engine from starting. 1. 2.
Part Number *91-59339 *91-99379 91-850439

Remove spark plug leads from spark plugs, remove spark plugs. Attach spark tester (Special Tool No. 91-850439) to engine. Attach tester leads to corresponding spark plug leads.

Special Tools
Description Service Tachometer Timing Light Spark Gap Tester
*May be obtained locally.

Checking for Top Dead Center (TDC)

1. 2. 3. Remove spark plug wires and spark plugs. Install timing tool (Special Tool No. 91-58222A1). Turn flywheel in a clockwise direction until TDC is reached as shown on the dial indicator.
55117

3.

Move towershaft to wide open throttle position.

90-831996R1 JUNE 1996

ELECTRICAL AND IGNITION

2D-1

4.

Connect timing light (Special Tool No.91-99379) to the No. 1 spark plug lead.

IMPORTANT: The advance characteristics of this ignition system are such that the ignition timing will retard itself slightly at wide-open-throttle. Thus, setting maximum timing at 32_ BTDC at cranking speed should result in retardation to 30_ BTDC at 5300 RPM. Therefore, it is recommended that to be assured of maximum performance all timing adjustments made at cranking speed should be verified with the engine running. 5. Crank motor and observe timing marks.

IMPORTANT: The Turn Key Start feature is dependent on closed throttle shutters. If the throttle shutters are even slightly cracked open the Turn Key Start will be disabled.
COMPLETE THIS PROCEDURE IN SEQUENCE

1. Disconnect throttle link at towershaft end.

As Needed
6. 7. 8. 9. Adjust timing. Loosen locknut. Turn timing rod to adjust timing. Tighten locknut on timing rod.

a
a

b
a - Locknut b - Timing Rod a - Throttle Link

10. Remove test equipment and install spark plugs and propeller.

NOTE: If possible, test the motor and check the timing under actual operating conditions.

Turn-Key Start Feature

The Sport Jet utilizes an automatic enrichner to start a cold engine. Advancing the throttle will disable the auto enrichner.

Synchronizing Carburetors to Ignition Timing for Turn-Key Start

IMPORTANT: An engine idle speed of 950 - 1100 RPM is necessary to provide the engine with adequate cooling water.
2D-2 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996

2. Synchronize throttle movement on carburetors. This is done by :

4. Pivot throttle cam forward so it just contacts the roller.

b b

b - Mark

5. Inspect position of mark on cam in relation to roller. (90/95 HP Shown)

b - Tie Bar Screw(s)

NOTE: Mark on cam must align with the center of the roller, without moving it. NOTE: Throttle cam adjustments are critical to low speed engine timing. If the adjustment is off (too early or too late), the engine will not run properly at low speed.
6. If throttle cam pick up point requires adjustment: a. Loosen nut until screw can just be turned. You should feel slight friction between screw and throttle cam.

a. Rotate throttle cam away from roller on bottom carburetor. b. Loosen tie bar screw(s). c. Check that the carburetor shutters are closed. d. Tighten tie-bar screw(s). e. This adjustment is made with the throttle link disconnected from the towershaft (Step 1). IF REQUIRED: 3. Adjust idle stop screw to specified dimensions following:

a b

a - Cam b - Nut c - Eccentric Roller

b. Turn eccentric roller counterclockwise to correct adjustment as described in Step 3. c. Hold position of roller with screwdriver. 90 HP Shown d. Tighten nut.

90/95 HP: Set dimension (a) to 1/8 in. 120 HP: Set dimension (a) to 1/4 in.

NOTE: When this procedure is done ensure that there is clearance between the throttle cam and roller, so that the throttle shutters remain closed.

Setting Idle Timing

1. Connect the link rod to the tower shaft. 2. Start the engine.

90-831996R1 JUNE 1996

ELECTRICAL AND IGNITION

2D-3

3. Check engine timing at idle. Idle timing is 8_ to 10_ BTDC. 4. If adjustments are needed to obtain the 8_ to 10_ BTDC specifications, do the following: a. Turn the tower shaft screw in to increase timing, turn screw out to decrease timing.

Check WOT Throttle Position with Engine Not Running

1. Advance the tower shaft to WOT and check shutter position from horizontal, " 5_.

c - Tower Shaft Screw

a - Throttle Shutter b - Line On Throttle Shaft Corresponds To Shutter Position

b. Disconnect the link arm to adjust the clearance of the cam to roller (.005 - .015 in.). c. Re-connect the link arm. d. Re-start the engine and check the idle timing.

IF REQUIRED: 2. Adjust the WOT stop screw to obtain a horizontal shutter position, " 5_.

a
a - Timing Mark

e. Adjust carburetor idle mixture screws for best operation. Idle RPM will be between 950-1100.

a - WOT Stop Screw

2D-4

ELECTRICAL AND IGNITION

90-831996R1 JUNE 1996

Check WOT Ignition Timing with Engine Running

1. With engine running at WOT, check the timing (28_ - 30_).

Check WOT Ignition Timing with Engine Not Running

1. Remove spark plug leads from spark plugs.

a
a - Timing Mark

2. If adjustments are needed do the following: a. Turn off the engine. b. Loosen locknut. c. Turn timing rod: (1.) In to increase timing (2.) Out to decrease timing 3. Tighten locknut. 4. Re-check timing. 2. Remove spark plugs. 3. Attach spark tester (Special Tool No. 91-850439) to engine.

b
a - Locknut b - Timing Rod

55117

4. Connect spark plug leads to spark tester. 5. Connect timing light (Special Tool No. 91-99378) to the number 1 cylinder spark plug lead.

90-831996R1 JUNE 1996

ELECTRICAL AND IGNITION

2D-5

6. Hold towershaft in the wide open throttle (W.O.T.) position.

5. Starting with top carburetor, turn each of the idle mixture screws clockwise 1/8 turn at a time, allowing 10 seconds between each turn, until motor begins to pop from lean fuel/air setting.

1/8 Turn (Wait 10 Seconds)

a
a - Tower Shaft

7. Crank motor and observe timing marks. IMPORTANT: To attain 30 degrees timing while the engine is actually running, set timing at cranking speed to 32 degrees.

1/8 Turn (Until Engine Pops)

Adjusting Idle Mixture

IMPORTANT: Idle mixture screw adjustments should be made with motor in water. Idle cannot be properly set using a flushette or dynamometer. 1. Turn idle mixture screws clockwise until lightly seated.
3/16 Turn

6. Turn each idle mixture screw counterclockwise (richer) 3/16 turn. This should be very close to the optimum setting. 7. Advance throttle to W.O.T. to clear out the engine. 8. Return throttle to idle speed and allow engine to idle for at least one minute. 9. Quickly advance the throttle to W.O.T.. If the engine hesitates because of a rich fuel mixture, turn the idle mixture screws 1/6 turn clockwise to lean out the carburetors and repeat step 7-9 until the engine accelerates without hesitation.

CAUTION
Do not force idle screws. Tip damage could result. 2. Turn idle mixture screws out (counterclockwise) 1-1/2 turn. 3. Start motor and allow to warm up to operating temperature. 4. Move throttle control to the lowest reliable setting. IMPORTANT: Motor must idle for minimum of one minute to allow fuel recirculation system to begin functioning. IMPORTANT: The carburetors must be adjusted together. As you turn one idle mixture screw, turn the remaining carburetor idle mixture screws the same amount before proceeding.

2D-6

ELECTRICAL AND IGNITION

90-831996R1 JUNE 1996

Check Oil Pump Adjustment

1. Move towershaft to the Wide Open Throttle position. Inspect oil pump alignment mark with the oil pump lever. Adjust oil pump link rod to align with the last mark.

a - Oil Pump Lever b - Alignment Mark (At Wide Open Throttle)

2. Adjust oil pump link rod as required.

90-831996R1 JUNE 1996

ELECTRICAL AND IGNITION

2D-7