ELECTRICAL AND

IGNITION

2
22480
C
TIMING/SYNCHRONIZING/ADJUSTING
Table Of Contents
Page Page
Timing/Synchronizing/ Timing/Synchronizing/
Adjusting (3 Cylinder Models) . . . . . . . . . . . 2C-1 Adjusting (4 Cylinder Models) . . . . . . . . . . . 2C-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2C-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 2C-6
Timing Pointer Alignment . . . . . . . . . . . . . . 2C-6
Timing Pointer Adjustment . . . . . . . . . . . . . 2C-1
Carburetor Synchronization . . . . . . . . . 2C-7
Carburetor Synchronization . . . . . . . . . 2C-2 Carburetor/Oil Pump
Carburetor/Oil Pump Synchronization . . . . . . . . . . . . . . . . 2C-8
Synchronization . . . . . . . . . . . . . . . . 2C-3 Timing Adjustments . . . . . . . . . . . . . . . . 2C-8
Timing Adjustments . . . . . . . . . . . . . . . . 2C-3 Idle Timing Adjustment . . . . . . . . . . . . . 2C-8
Idle Timing Adjustment . . . . . . . . . . . . . 2C-3 Maximum Timing . . . . . . . . . . . . . . . . . . 2C-9
Carburetor Specifications . . . . . . . . . . . . . . 2C-10
Maximum Timing . . . . . . . . . . . . . . . . . . 2C-4
Initial Starting Adjustments . . . . . . . . . . 2C-10
Maximum Throttle . . . . . . . . . . . . . . . . . 2C-4 Low Speed Mixture Adjustments . . . . . 2C-10
Idle Adjustment . . . . . . . . . . . . . . . . . . . . 2C-4 Idle Adjustment . . . . . . . . . . . . . . . . . . . . . . . 2C-11
Throttle Cable Installation . . . . . . . . . . . . . . 2C-5 Throttle Cable Installation . . . . . . . . . . . . . . 2C-11

90-13645--2 495
 Mariner 75 Marathon/Merc 75XD
Timing/Synchronizing/
Adjusting (3 Cylinder Models) Full Throttle RPM Range 4750 - 5250
Idle RPM (in “FORWARD” Gear) 650 - 700
Specifications Maximum Timing @ 5000 RPM 16
B.T.D.C.
70, 75 and 80 Models (@ Cranking Speed) (18
B.T.D.C.)
Serial Number and Above Idle Timing 0
- 4
B.T.D.C.
Spark Plug NGK BUHW-2
U.S. B239242
Firing Order 1-3-2
Belgium 9502135
Canada A730007 Special Tools

Full Throttle RPM Range 4750 - 5250 Part No. Description

Idle RPM (in “FORWARD” Gear) 650 - 700 *91-58222A1 Dial Indicator Gauge Kit
Maximum Timing @ 5000 RPM 26
B.T.D.C. *91-59339 Service Tachometer
(@ Cranking Speed) (28
B.T.D.C.) *91-99379 Timing Light
Idle Timing 0
- 4
B.T.D.C. 91-63998A1 Spark Gap Tool
Spark Plug NGK BUHW-2
Firing Order 1-3-2 * May be obtained locally.

70, 75 and 80 Models

Timing Pointer Adjustment
Serial Number and Below WARNING
U.S. B239241 Engine could start when turning flywheel to check
Belgium 9502134 timing pointer alignment. Remove spark plugs
from engine to prevent engine from starting.
Canada A730006
1. Install Dial Indicator P/N 91-58222A1 into no. 1
Full Throttle RPM Range 4750 - 5250 (top) cylinder.
Idle RPM (in “FORWARD” Gear) 650 - 700 2. Turn flywheel clockwise until no. 1 (top) piston is
at top dead center (TDC). Set Dial Indicator to “0”
Maximum Timing @ 5000 RPM 22
B.T.D.C.
(zero).
(@ Cranking Speed) (24
B.T.D.C.)
Idle Timing 0
- 4
B.T.D.C.
Spark Plug NGK BUHW-2
Firing Order 1-3-2

90 Models

Full Throttle RPM Range 5000 - 5500

Idle RPM (in “FORWARD” Gear) 650 - 700
Maximum Timing @ 5000 RPM 26
B.T.D.C.
(@ Cranking Speed) (28
B.T.D.C.)
Idle Timing 0
- 4
B.T.D.C.
Spark Plug NGK BUHW-2
Firing Order 1-3-2
91-58222A1
19062

3. Turn flywheel counterclockwise until Dial Indica-

tor needle reads approximately 0.550 (13.97mm)
BTDC, then turn flywheel clockwise so that
needle reads 0.491 in. (12.47 mm) BTDC exactly.
90-13645--2 1095 ELECTRICAL AND IGNITION 2C-1
4. Reposition timing pointer if necessary, so that tim-
ing pointer is aligned with 0.491 in. (12.47 mm) b
timing mark on flywheel. Retighten attaching
screws.

c b c
a

a b

20440
22480
a - Set Screw
a - Timing Pointer b - Synchronizing Screws
b - Timing Mark
c - Attaching Screws
9. Hold throttle arm so that throttle stop screw is
against stop.
5. Remove Dial Indicator, and reinstall spark plug
and high tension spark plug lead of no. 1 (top) 10. Place roller of cam follower against throttle cam
cylinder only. and adjust throttle stop screw to align raised mark
of throttle cam with center of cam follower roller.
CARBURETOR SYNCHRONIZATION Tighten locknut.
1. Disconnect remote fuel line from engine.
2. Connect remote control electrical harness to e
d
engine wiring harness.
3. Remove throttle cable barrel from barrel retainer.
4. Remove sound air box cover.
5. Loosen screw from throttle cam follower. c a
6. Loosen 4 synchronizing screws.
7. Look into throats of carburetors and make sure all
throttle shutters are completely closed. Tighten
synchronizing screws.
f
8. Recheck throttle shutters and make any b
necessary adjustments.
20428
a - Throttle Arm d - Throttle Cam
b - Throttle Stop Screw e - Raised Mark
c - Roller f - Lock Nut

2C-2 ELECTRICAL AND IGNITION 90-13645--2 1095

11. Holding throttle arm against throttle stop screw, TIMING ADJUSTMENTS
adjust cam follower, so that a clearance of 0.005
in. - 0.020 in. (0.127 - 0.508 mm) exists between
roller of cam follower and throttle cam. Tighten set CAUTION
screw securing cam follower. Engine is timed while cranking engine with starter
motor. To prevent engine from starting when
being cranked, all spark plugs must be removed,
0.005″ – 0.020″ b except no. 1 (top) cylinder plug.
a NOTE: If initial timing adjustments are made without
engine running, then final timing checks should be
made with engine running due to timing advance
c characteristics of ignition system. Minimum engine
RPM required to check maximum timing advance is
3000 RPM.
IDLE TIMING ADJUSTMENT
1. Connect timing light to no. 1 (top) spark plug.

52472 WARNING
a - Roller Before cranking engine, keep clear of propeller as
b - Throttle Cam it may rotate.
c - Set Screw
2. Shift engine to “Neutral”.
CARBURETOR/OIL PUMP SYNCHRONIZATION IMPORTANT: To accurately time engine at cranking
IMPORTANT: Some engines may have an addi- speed, a fully charged battery must be used.
tional stamped mark (d) which SHOULD NOT be 3. Holding throttle arm at idle position, crank engine
used. with starter motor and adjust idle timing screw to
1. While holding throttle arm at idle position, adjust align 2° BTDC timing mark of flywheel with timing
length of link rod so that stamped mark of oil pump pointer. Tighten locknut.
body aligns with stamped mark of oil pump lever.
2° BTDC
a 4 0 4

b a
b
c
d

22977 20442
a - Link Rod c - Mark of Oil Pump Lever a - Idle Timing Screw
b - Mark of Oil Pump Body d - Mark NOT Used b - Locknut

90-13645--2 1095 ELECTRICAL AND IGNITION 2C-3

MAXIMUM TIMING 2. Install remaining spark plugs and high tension
spark plug leads.
1. Hold control arm so that maximum spark advance
screw is against stop.
2. Crank engine with starter motor and adjust maxi-
mum spark advance screw to align the specified
BTDC timing mark on flywheel with timing pointer
(due to the advance characteristic of this ignition
system, this cranking speed adjustment will auto-
matically be reduced by 2° at an engine speed of
5000 RPM). Tighten locknut.
b c
a

b c 20443
a - Throttle Arm
b - Full Throttle Stop Screw
a c - Locknut
20441
a - Control Arm IDLE ADJUSTMENT
b - Maximum Spark Advance Screw 1. With engine in water, connect electrical harness
c - Locknut and fuel line to engine. Start engine and allow to
NOTE: If initial timing adjustments are made without warm up.
engine running, then final timing checks should be
made with engine running due timing advance char-
acteristics of ignition system. Minimum engine RPM
required to check maximum timing advance is 3000
RPM.
MAXIMUM THROTTLE
1. Hold throttle arm against full throttle stop screw.
Adjust full throttle stop screw to allow throttle shut-
ters to open fully, then turn stop screw in (clock-
wise) an additional 1/2 turn, to prevent throttle le-
ver of center carburetor from acting as a stop.
Tighten locknut.

2C-4 ELECTRICAL AND IGNITION 90-13645--2 1095

2. Shift into “Forward” gear and adjust carburetor Throttle Cable Installation
low speed mixture screws properly (refer to “Car-
buretor” section). 1. With end of throttle cable connected to throttle le-
ver, hold throttle lever against idle stop. Adjust
throttle cable barrel to slip into barrel retainer on
cable anchor bracket with a very light preload of
throttle lever against idle stop. Lock barrel in
place.
IMPORTANT: Excessive preload on throttle cable
will cause difficulty when shifting from forward to
neutral. (Readjust throttle cable barrel, if neces-
sary.)
2. Check preload on throttle cable by placing a thin
piece of paper between idle stop screw and idle
Lightly seated stop. Preload is correct when paper can be re-
moved without tearing but has some drag on it.
(Readjust throttle cable barrel, if necessary.)

1-1/2 turns out

3. Holding throttle arm (NO TAG) at idle position, ad-
just idle timing screw (NO TAG) to attain an en-
gine idle RPM of 650-700 RPM in “Forward” gear.
Tighten locknut (NO TAG) and turn off engine.

2° BTDC

4 0 4

b
c

20442
a - Throttle Arm
b - Idle Timing Screw
c - Locknut

NOTE: On this type of engine, idle RPM is adjusted

exclusively with ignition timing.

90-13645--2 1095 ELECTRICAL AND IGNITION 2C-5

Timing/Synchronizing/ Timing Pointer Alignment
Adjusting (4 Cylinder Models) WARNING
Specifications Engine could start when turning flywheel to check
timing pointer alignment. Remove all spark plugs
Models 100/115
from engine to prevent engine from starting.
Full Throttle RPM Range 4750 - 5250 1. Remove aft cowl support bracket.
Idle RPM (in “FORWARD” Gear) 650 - 700 2. Install Dial Indicator 91-58222A1 into no. 1 (top)
Maximum Timing @ 3000 RPM 23
B.T.D.C. cylinder.
(@ Cranking Speed) (25
B.T.D.C.)
3. Turn flywheel in a clockwise direction until no. 1
Idle Timing 2
- 4
B.T.D.C. piston is a TDC, then set Dial Indicator at “0” (zero).
Spark Plug NGK
BP8H-N-10*
[0.040 in.
(1.0mm) gap]

NGK
BPZ8H-N-10*
[0.040 in.
(1.0mm) gap]

NGK BUHW
Firing Order 1-3-2-4

*Improves running quality between 1800 – 2000 RPM 91-58222A1

19062
Special Tools
4. Turn flywheel counterclockwise until Dial Indica-
Part No. Description tor needle reads approximately 0.600 in. BTDC,
then turn flywheel clockwise, so that needle reads
*91-58222A1 Dial Indicator Gauge Kit 0.554 in. BTDC exactly.
*91-59339 Service Tachometer
5. Reposition timing pointer, if necessary, so that
*91-99379 Timing Light 0.554 in. mark is aligned with groove in timing
pointer.
* May be obtained locally.
6. Remove Dial Indicator and reinstall spark plug
and spark plug lead on no. 1 cylinder.

a
22480
a - Timing Pointer

2C-6 ELECTRICAL AND IGNITION 90-13645--2 1095

 http://motorka.org

CARBURETOR SYNCHRONIZATION
1. Remove sound box cover. b
2. Loosen cam follower adjustment screw.
3. Loosen 6 synchronizing screws.
a
4. Look into throats of carburetors and make sure all
throttle shutters are completely closed. c
5. Apply light down pressure on carburetor synchro-
nizing shaft and tighten 6 synchronizing screws
from top to bottom.
6. Recheck throttle shutters and make any neces-
sary adjustment.
52483
7. Hold throttle arm so that the throttle stop screw is
a - Roller
against stop.
b - Throttle Cam
8. Place roller of cam follower against throttle cam c - Screw
and adjust throttle stop screw to align raised mark 10. Hold throttle arm against full throttle stop. Adjust
of throttle cam with center of cam follower roller. full throttle stop screw to allow throttle shutters to
Tighten locknut. open fully. To prevent throttle shutters to act as a
stop, screw in stop screw clockwise 1/2 turn and
tighten locknut.
b

e
f
a

b
b
a

d
23004
b
c a - Throttle Arm
25498 b - Full Throttle Stop Screw
a - Cam Follower Adjustment d - Idle Stop Screw
Screw e - Roller
b - Synchronizing Screws f - Throttle Cam
c - Throttle Arm g - Locknut

9. Holding throttle arm at idle position, adjust cam

follower so that a clearance of 0.005 in. - 0.020 in.
(0.127mm - 0.508mm) exists between roller and
throttle cam. Tighten screw securing cam follow-
er.

90-13645--2 1095 ELECTRICAL AND IGNITION 2C-7

11. Hold throttle cam in full throttle position. If neces- CARBURETOR/OIL PUMP SYNCHRONIZATION
sary adjust acceleration pump adjusting bolts po-
IMPORTANT: Some engines may have an addi-
sition so that a gap of 0.030 in. (0.762mm) exists
tional stamped mark (d) which SHOULD NOT be
between throttle cam and top of acceleration
used.
pump aluminum housing.
1. While holding throttle arm at idle position, adjust
length of link rod so that stamped mark of oil pump
body aligns with stamped mark of oil pump lever.
2. Move throttle arm from idle to wide open throttle
while checking link rod for any interference with
hoses, cable ties, etc.

a a

c
d
b b

22509
c
d

a - Throttle Cam
b - Bolts 22977
c - 0.030 in. (0.762mm) Gap a - Link Rod c - Mark of Oil Pump Lever
d - Accelerator Pump b - Mark of Oil Pump Body d - Mark NOT Used
TIMING ADJUSTMENTS

CAUTION
Engine can be timed while cranking engine with
starter motor. To prevent engine from starting
when being cranked, all spark plugs should be
removed.
NOTE: If initial timing adjustments are made without
engine running, then final timing checks should be
made with engine running due timing advance char-
acteristics of ignition system. Minimum engine RPM
required to check maximum timing advance is 3000
RPM.
1. Insert Spark Gap Tool (91-63998A1) in no. 1 (top)
cylinder spark plug boot and attach alligator clip
to good ground.
2. Remove throttle cable barrel from barrel retainer.
IDLE TIMING ADJUSTMENT

WARNING
Before cranking engine, keep clear of propeller,
as it may rotate.
IMPORTANT: To accurately time engine at crank-
ing speed, a fully charged battery must be used.

2C-8 ELECTRICAL AND IGNITION 90-13645--2 1095

1. Connect timing light to no. 1 (top) spark plug lead. MAXIMUM TIMING
2. Shift engine into neutral. 1. Hold control arm against maximum advance stop.
Crank engine with starter motor and adjust maxi-
3. Holding throttle arm at idle position, crank engine
mum advance screw to align 25° BTDC mark on
with starter motor and adjust idle timing screw to
flywheel with timing pointer (due to the advance
align 2 degrees BTDC timing mark of flywheel with
characteristics of ignition system, this cranking
timing pointer. Tighten locknut.
speed adjustment will automatically be reduced
to 23° BTDC at engine speed of 5000 RPM).
Tighten locknut.
NOTE: If initial timing adjustments are made without
engine running, then final timing checks should be
made with engine running due timing advance char-
acteristics of ignition system. Minimum engine RPM
required to check maximum timing advance is 3000
RPM.
c
a

23005
a - Idle Timing Screw
b - Locknut

23005
a - Control Arm
b - Maximum Advance Screw
c - Locknut

90-13645--2 1095 ELECTRICAL AND IGNITION 2C-9

Carburetor Specifications
Carburetor number stamped at TOP of carburetor mounting flange
NOTE: Early model engines may have identification stamped on face of air box mounting flange.

Carb Number Location Model HP Main Jet* Bowl* Vent Jet

WME-11, 20- 1 Top Carburetor
2 Top Center Carburetor
100 .054 None
3 Bottom Center Carburetor
Bottom Carburetor
WME-14, 21- 1 Top Carburetor
2 Top Center Carburetor
115 .076 None
3 Bottom Center Carburetor
Bottom Carburetor

* Standard jets listed are for operation of engine from 0-762 m (0-2500 ft.) of elevation (see jet size chart).

INITIAL STARTING ADJUSTMENTS 4. DO NOT adjust leaner than necessary to attain

reasonable smooth idling. When in doubt, stay on
NOTE: For adjusting carburetor throttle linkage and
the slightly rich side of the adjustment.
synchronizing carburetors, see section “Timing/
Synchronizing/Adjusting” of this manual. a
After service or replacement of carburetor, turn low
speed mixture screw adjustment in (clockwise) until it
seats lightly, then back off (each carburetor) to speci-
fications (100-1-3/4 turns or 115-1-1/2 turns). This will
permit engine start-up.
LOW SPEED MIXTURE ADJUSTMENTS
NOTE: Only the top two carburetors on four cylinder
models have an adjustable low speed mixture screw.
1. Start engine and allow to warm up (run for several
minutes). Throttle back to idle for about one min-
ute to allow RPM to stabilize.
2. With engine running at idle speed (in water) in
“Forward” gear (prop on), turn low speed mixture
screw, IN (clockwise) until engine starts to “bog”
down and misfire. Back out 1/4 turn or more.
3. Check for too lean mixture on acceleration.

22990
a - Low Speed Mixture Screw

2C-10 ELECTRICAL AND IGNITION 90-13645--2 1095

Idle Adjustment Throttle Cable Installation
1. With engine in water, connect electrical harness 1. With end of throttle cable connected to throttle le-
and fuel line to engine. Start engine and allow to ver, hold throttle lever against throttle stop. Adjust
warm up. throttle cable barrel to slip into barrel retainer on
2. Properly adjust carburetor low speed mixture cable anchor bracket with a very light preload of
screws. Refer to “Carburetor Adjustments” sec- throttle lever against throttle stop. Lock barrel in
tion 3A. place.

3. Holding throttle arm at idle position (throttle cable IMPORTANT: Excessive preload on throttle cable
barrel removed from barrel retainer), adjust idle will cause difficulty when shifting from forward to
timing screw to attain an engine idle RPM of neutral. (Readjust throttle cable barrel, if neces-
650-700 RPM in “Forward” gear. Tighten locknut sary.)
and turn off engine. 2. Check preload on throttle cable by placing a thin
piece of paper between throttle stop screw and
stop. Preload is correct when paper can be re-
moved without tearing, but has some drag on it.
Readjust throttle cable barrel, if necessary.)
3. Reinstall sound box cover.

23005
a - Idle Timing Screw
b - Locknut

90-13645--2 1095 ELECTRICAL AND IGNITION 2C-11