Abstract: A fuel storage and supply apparatus (22) for a watercraft (10) incorporating a plurality of connections (50,66) penetrating a housing (32) in a single opening in a fuel tank (12). Each connection is sealed by a radial O-ring (56,68) so that the connection may be rotated about a longitudinal axis without adversely affecting the seal. A single opening (34) in the tank may thereby be used to provide connections for a fill tube (66), fuel tube (50), vent (86), and electrical penetrations (150) for an in-tank pump (136) or level sensor (156).

Abstract: A method for storing and/or transporting outboard marine motors utilizes a rack having a rigid, substantially planar, horizontal base with parallel horizontal channels for insertion of fork lift tines. The base supports a pair of upright opposing frames, each frame in turn supporting a respective motor mounting beam. Preferably the frames and base are made of metal, while the motor mounting beams comprise a plywood plank with a metal sheath. At least two outboard motors can be mounted to each beam. Then a forklift is used to lift a fully loaded rack and load it onto a trailer or other carrier vehicle. A multiplicity of loaded racks are transported to a shipping destination. At the shipping destination, the outboard motors are removed from the racks. The empty racks are then returned to the point of origin.

Abstract: The present invention, in one aspect, relates to a propeller shaft housing for being secured in the gear case bore and configured for being securely engaged to the gear case bore by threaded screws that pass through bosses in the housing and into threaded holes in the gear case. More specifically, in an exemplary embodiment, the propeller shaft housing includes at least two bosses having compound angle holes therethrough, and at least two threaded holes in the gear case are arranged to align with one of the respective holes through the bosses. Respective screws extend through the holes in the bosses of the propeller shaft housing and into threaded engagement with the threaded holes in the gear case. In the exemplary embodiment, one of the threaded holes in the gear case is adjacent a skeg, and one of the threaded holes is adjacent a strut.

Abstract: An encapsulated device and method for making such encapsulated device containing a bladder disposed between a wall of the case and the encapsulant. The bladder defines a space devoid of encapsulant and contains a collapsible insert such as an open cell foam material, thereby allowing the unimpeded thermal expansion of the encapsulant. By reducing thermal expansion stresses on the encapsulated devices, the reliability of the encapsulated device is improved.

Abstract: A steering arm yoke and trunnion assembly for a marine propulsion system includes a steering arm and a yoke including integral fluid paths for trim actuator fluids and for cooling water for an outboard powerhead mounted to a horizontal mounting plate within a platform extending from a boat hull. The steering arm and yoke include a drum extending through the horizontal mounting plate for rotating an attached propeller drive unit. The fluid paths extend through the drum, which is rotatably mounted to the horizontal mounting plate. The yoke includes pivot arms for attachment to a trunnion that includes actuator brackets for trim actuators fluidly connected to the actuator fluid paths of the drum.

Abstract: The present invention, in one form, is a skeg having an airfoil shape which facilitates maintaining engine control even at high speed but does not adversely affect engine performance. In one embodiment, the skeg includes a fore end, an aft end, and opposing sidewalls extending from the fore end and the aft end. One sidewall includes a camber, or curved surface, and the outer surface of the other sidewall is flat, or planar.

Abstract: An inboard/outboard powered watercraft (10) incorporating a transmission (30, 80) in its vertical drive unit (24) for providing two forward speeds plus reverse. The transmission is packaged to fit within the vertical drive unit (24) by incorporating a bevel gear apparatus (44, 120). In one embodiment, the transmission (30) also includes a planetary gear apparatus (46) together with two hydraulic clutches (70, 72) and a ring gear brake (56). In a second embodiment, three hydraulic clutches (98, 100, 114) are utilized with bevel gears (94,96,106,110,112) alone to provide the two forward and reverse speeds.

Abstract: A throttle assembly for an internal combustion engine includes a throttle body that defines an airflow passage, a throttle shaft rotatably mounted to the throttle body and extending though the airflow passage, a throttle plate coupled to the throttle shaft, and a seal member coupled to the throttle shaft. More specifically, one end of the throttle shaft extends through the throttle body, and a seal member surrounds the throttle shaft between the throttle body and the shaft. The seal member extending into the airflow passage and effectively forms a standpipe extending into the airflow passage for a length sufficient to prevent pooled engine fluid from seeping out of said throttle body along said throttle shaft.

Abstract: A flywheel having a molded cage formed around a plurality of magnets attached to the flywheel. The cage extends into one or more grooves formed in the flywheel to resist the shrinkage of the cage inside diameter as it cools following an injection molding process. The gap between the cage and magnets and an adjacent stator is precisely controlled and minimized. Shutoff surfaces formed on the flywheel function as a portion of the die for injection molding of the cage.

Abstract: The present invention provides a system and method to adjust temporarily the quantity of fuel delivered to the cylinders of a fuel injected engine. The present invention allows a service technician to temporarily adjust the quantity of fuel being delivered to each cylinder or all cylinders of an internal combustion engine. The system includes an internal combustion engine having therein an electronic control unit capable of controlling the fuel quantity delivered to each cylinder and a general service computer connectable thereto and capable of transmitting data to the ECU. When instructed by the service technician, the service computer sends signals to the ECU to adjust fuel injector data to the fuel injectors of so as to increase or decrease the amount of fuel being delivered to the fuel injected engine.

Abstract: An internal combustion engine that utilizes a control system for improving operation of the engine under a variety of conditions. The control system includes a sensor that directly senses a combustion condition. The output of the sensor is utilized in adjusting the air-fuel mixture delivered to each cylinder to optimize engine operation.

Abstract: A marine propulsion unit drive train including two oppositely facing driven bevel gears having a common rotational axis and different numbers of teeth engaged with a bevel pinion drive gear having a single diametral pitch. Both driven gears have the same pitch diameter but different diametral pitches so that the driven gears rotate at different rates to boost performance when the propulsion unit is operated. The drive train is applicable to single propeller marine propulsion units and dual propeller stem drive units, and a method for fabricating a reduced-tooth driven gear to mesh with a drive pinion of a different diametral pitch is disclosed.

Abstract: A catalyst exhaust system includes a catalyst housing having an inlet end, an outlet end, and a passage therethough. The outlet end includes a valve seat, and a water jacket surrounds the catalyst housing. A valve housing is in flow communication with the outlet end and in flow communication with said water jacket to accommodate a valve configured to allow passage of exhaust gases but prevent water from entering the catalyst housing passage and reaching a catalyst therein.

Abstract: A propulsion system having a low-friction exhaust bellows relative to an engine located in the interior of a marine vessel is provided. The engine has an exhaust discharge member in communication with a propulsion unit, and an exhaust passage having an exterior coupling member flexibly connected to pass exhaust from the exhaust discharge member to the propulsion unit. The interior surface of the passage is configured to provide a relatively smooth surface to the exhaust passing therein.

Abstract: A control unit is provided for an internal combustion engine including an engine block comprising a plurality of cylinders operable in a homogenous combustion mode and a stratified combustion mode in response to an engine throttle position. The control unit is programmed to switch the engine cylinders to the homogenous combustion mode at a throttle position of greater than about 20% of wide open throttle. As such, the combustion mode is switched form the stratified combustion mode to the homogenous combustion mode at a higher throttle opening that more capably supports increased fuel injection quantities of homogenous combustion in the engine cylinders. Problematic conditions of conventional pontoon boat systems due to switching of engine cylinders to homogenous combustion at high RPMs and restricted throttle openings is therefore avoided.

Abstract: A method and apparatus are disclosed for controlling ignition timing during startup of a two-stroke internal combustion engine while avoiding ignition timing errors caused by engine speed fluctuations. A rotational component of the engine, such as a flywheel, bears a plurality of spaced indicator markers including a plurality of ignition triggering markers, each of which designates a position on the rotational component that is acceptable for triggering ignition in a respective cylinder of the engine. Ignition in each cylinder is triggered upon detecting the associated ignition triggering marker and without taking engine velocity into account. Ignition timing errors that could otherwise be introduced due to erroneous assumptions based on engine speed therefore are avoided.