Abstract: An outboard marine drive includes a propulsor configured to generate a thrust force in water, and a monolithic supporting frame which supports the outboard marine drive relative to the marine vessel. The monolithic supporting frame includes a body, a support leg extending downwardly from the body and configured to support a propulsor housing for the propulsor, and a steering arm extending forwardly from the body for steering of the outboard marine drive. A power entry module coupled to the monolithic supporting frame, the power entry module being configured to regulate/control current and voltage for powering the propulsor. A service tray is removably coupled to the top of the monolithic supporting frame, the service tray supporting at least one serviceable component of the outboard marine drive.

Abstract: A marine drive is for propelling a marine vessel. The marine drive has a propulsor configured to generate a thrust force in a body of water; a battery that powers the propulsor; and a supporting frame which supports the marine drive relative to marine vessel. The supporting frame has a monolithic body defining a frame interior, and further has a support leg extending downwardly from the monolithic body and a steering arm extending forwardly from monolithic body. A cowling is fixed to the supporting frame via at least one hidden fastener that extends from the frame interior, through the supporting frame, and into engagement with the cowl body, wherein hidden fastener being accessible during installation.

Abstract: A catalyst system for a marine engine incorporates a catalyst device within a housing structure. The catalyst device has a rim portion that is disposed within first and second flange surfaces of first and second housing structures. A gasket is provided which is configured to have an opening that allows the rim portion of the catalyst device to be constrained between the first and second flange portions but not between the gasket and either of the first and second flange surfaces.

Abstract: An exhaust system of a marine propulsion device is provided with a bifurcated cooling passage in its elbow structure in order to limit the effect of cold water being disposed in thermal communication with exhaust gas passing through the elbow structure. This thermal communication between a stream of cold water and exhaust gas passing through the elbow structure is minimized in order to reduce the likelihood that water vapor will condense out of the stream of exhaust gas as it passes through the elbow structure. An obstruction, or water dam, is used to bifurcate the coolant chamber within the elbow structure while allowing passage of coolant through the obstruction.

Abstract: The present invention provides a relationship between the exhaust passages and coolant passages of the exhaust manifold and exhaust elbow which serves to maintain the joint of the exhaust passage at a higher temperature than would be possible with known exhaust manifolds and exhaust elbows. By providing a space between surfaces of a raised exhaust portion of the components and surfaces of the raised coolant portions of the exhaust system, leakage from the coolant conduits to the exhaust cavities is avoided. The space provided between exhaust portions of the manifold and elbow and coolant portions of the manifold and elbow, near the joint between these components, provides the two advantages of maintaining a higher exhaust connection between the manifold and elbow and also preventing coolant leakage from flowing from the coolant passages to the exhaust passages of the exhaust system.

Abstract: A gasket for an exhaust system comprises a metallic plate having an exhaust sealing segment and a coolant sealing segment which is attached to and extends from the exhaust sealing segment. Both segments have first and second planar surfaces on opposite sides thereof, with the first and second planar surfaces of the exhaust sealing segment being co-planar with the first and second planar surfaces of the coolant sealing segment, respectively. An exhaust opening is formed through the plate and first and second elastomeric seals, which can be silicone rubber and which are both integral parts of a common elastomeric element, are disposed on the first and second surfaces, respectively, of the coolant sealing segment. A raised portion of the exhaust opening through the metal plate extends at an angle from the exhaust sealing segment and away from the first surface to form a transition segment from a first opening to a second.

Abstract: A marine engine cooling system is provided with a valve in which a ball moves freely within a cavity formed within the valve. Pressurized water, from a sea pump, causes the ball to block fluid flow through the cavity and forces pumped water to flow through a preferred conduit which may include a heat exchanger. When the sea pump is inoperative, the ball moves downward within the cavity to unblock a drain passage and allow water to drain from the heat generating components of the marine engine.

Abstract: A thermostat housing assembly for a marine engine having a first inlet to receive sea water and an outlet that is connected to a circulating pump that circulated cooling water to the engine. A baffle is located in the housing and prevents direct flow between the sea water inlet and the outlet. The housing defines a pair of passages with a first of the passages providing communication between the sea water inlet and forms a first chamber which communicates with a pair of manifold outlets that are connected to the manifold. A second of the passages provides communication between the sea water inlet and the outlet to the circulation pump. The housing also includes a return inlet for returning water from the engine and the return inlet is connected to the second passages.