Abstract: A grommet assembly for an outboard motor includes a grommet having a step, a flexible sleeve having a step and a connector configured to engage the step on the grommet and the step on the flexible sleeve. Preferably, the connector is in the form of an annular connector formed of two semicircular members connected to one another. Additionally, the step formed on the sleeve preferably is defined by a helical groove formed on the flexible sleeve. The connector preferably includes a helical wall defining a step that corresponds to the helical step formed on the flexible sleeve. The grommet assembly may also be in the form of a kit including a grommet having a step and a connector configured to engage the step on the grommet and a step formed on an existing flexible sleeve.

Abstract: An outboard motor has a quieter operating recoil starter arrangement. The recoil starter has a starter drum with a dog clutch arrangement having two dog cam members. The dog cam members rotate between an initial position and an extended position under the influence of a clutch drive member. Specifically, the dog cams each have a portion which engages a starter pulley when a starter rope is pulled. The dog cams are configured to extend minimally into a corresponding slot of the starter pulley when in their extended position. Such configuration results in less chatter when the starter pulley speed exceeds the starter drum speed upon ignition of the engine.

Abstract: An improved cowling arrangement for an outboard motor powered by an internal combustion engine. The improved arrangement includes a flywheel cover and cowling that incorporate upwardly and downwardly extending ribs which are positioned along an air path between the air vent of the outboard motor and the throttle body of the motor. These ribs act as labyrinth-type seals which prevent water entering the air vent from contacting the throttle body. Also disclosed is an improved cowling arrangement that prevents water pooled on the flywheel cover from draining onto the throttle body when the motor is tilted, such as when the watercraft banks into a turn.

Abstract: Several embodiments of combustion chamber configurations for direct injected engines having a substantial recess in the cylinder head in which the fuel injector is positioned and injects. The injector is arranged so as to be disposed over the exhaust port and to spray toward the auxiliary scavenge port. However, the spray pattern is such that fuel will not impinge upon the cylinder head surface and so that the scavenge flow will direct the fuel away from the cylinder walls and toward the head of the piston for cooling and better vaporization. This also ensures that fuel will not pass out of the exhaust port.

Abstract: A feed back control system and method for direct injected engines useful in a start up operation that utilizes a fuel pressure condition sensor. At the commencement of cranking, the feed back control system adjusts at least the initiation of fuel injection based upon the output from the fuel pressure condition sensor. This removes a great shift in the fuel pressure between before and after starting of the engine and eventually promotes operator's feeling and also improves exhaust emissions.

Abstract: A fuel injection system for an engine includes an improved construction to inhibit heating of the fuel. A fuel reservoir is arranged to store the fuel therein. A fuel pump is provided for delivering the fuel in the reservoir to a fuel injector which sprays fuel toward a combustion chamber of the engine. The fuel pump is driven by an electric motor that is intermittently powered. In one embodiment, a control device is provided for controlling the duration for which the electric motor is powered. A duty ratio of the duration is preferably determined in response to an amount of the fuel that is required to be sprayed by the fuel injector.

Abstract: A control device and method of injected fuel for a direct cylinder injected, internal combustion engine. The control device primarily increases the fuel amount to a certain amount under the conditions that the engine load is increasing such as an acceleration condition. The device, however, when a quick change of the load increase occurs, reduces the increase amount of the fuel at the first combustion cycle or cycles. Although there may be other controls, the device then gradually increases the fuel amount to the amount until the primary amount at intervals of at least one combustion cycle. The quick change of the load increase is, in one aspect of the invention, defined as that a crankshaft rotational speed is within a predetermined range and the throttle valve opening is larger than a predetermined value.

Abstract: A cooling system for an outboard motor having a water propulsion device and an internal combustion engine positioned in a cowling, the engine having an output shaft arranged to drive the water propulsion device, is disclosed. The cooling system includes a coolant delivery mechanism driven by the engine, the delivery mechanism arranged to deliver coolant selectively to at least one of two coolant jackets of the engine. One coolant jacket is associated with at least one combustion chamber of the engine. The other cooling jacket is associated with an exhaust manifold for that combustion chamber. The cooling system also includes at least one coolant drain line through which coolant may drain from each of the cooling jackets of the engine.

Abstract: An outboard motor comprises an internal combustion engine and a protective cowling that surrounds the engine. The cowling comprises at least an upper portion and a lower portion. The engine comprises a cylinder block that defines a cylinder bore. A cylinder head member is fixed at one end of the cylinder block and encloses one end of the cylinder bore. A crankcase member is fixed at the other end of the cylinder block and encloses the other end of the cylinder bore. The crankcase member forms a crankcase chamber. A piston is positioned within the cylinder bore. A crankshaft is rotably journaled in the crankcase chamber and is connected to the piston. The piston, the cylinder bore and the cylinder head together define a combustion chamber. The cylinder block, the cylinder head member and the crankcase member together defining an engine body. A first air intake conduit communicates with the engine and extends generally along a side of the engine body.

Abstract: A marine propulsion housing arrangement includes an improved construction for inhibiting an influx of water into the housing and for protecting the components thereof. A marine outboard drive comprises a drive unit and at least a swivel bracket that supports the drive unit for pivotal movement with a steering shaft. At least one mount assembly is provided for unifying the drive unit and the steering shaft. The mount assembly includes at least one mount members affixed to the drive unit and a hub member united with the mount member. The hub member is connected to both the drive unit and the steering shaft so as to unify them. A mount cover generally covers both of the mount member and the hub member.

Abstract: A crankcase arrangement for an engine includes an improved construction that allows lubricant to more freely flow through the crankcase and to quickly return to a lubricant reservoir even though the engine has a compact construction. A cylinder body of an exemplifying engine includes at least an upper bearing portion, intermediate bearing portion and lower bearing portion. A crankcase member, which defines a crankcase cavity with the cylinder body, includes an upper bearing section and a lower bearing section. An upper main bearing journal of a crankshaft is rotatably journaled between the upper bearing portion and the upper bearing section and a lower main bearing journal of the crankshaft is rotatably journaled between the lower bearing portion and the lower bearing section. A bearing cap is arranged to rotatably journal the crankshaft with the intermediate bearing portion. In a preferred form, the bearing cap includes a plurality of cap sections that are joined together.

Abstract: An internal combustion engine includes an improved feedback control system and method for operating the engine to provide the desired air/fuel ratio under all running conditions without causing unsettling variations in engine speed and torque as adjustments to the air/fuel ratio are made. The feedback control operates to modify the fuel/air ratio from that achieved by a basic setting that is derived from parameters of engine performance so as to maintain the desired ratio. The control system also adjust the ignition timing while the air and fuel ratio is adjusted toward the desired ratio to maintain generally constant engine speed and torque.

Abstract: A fuel supply system is disclosed for a direct injected “V” type engine powering an outboard motor. The fuel supply system includes a pump for supplying fuel from a tank to a vapor separator. An electrical pump delivers fuel from the vapor separator to a mechanical high pressure pump, which delivers fuel under high pressure to a fuel manifold and further to a pair of fuel rails. The fuel rails supply fuel to fuel injectors for delivering fuel to the combustion chambers of the engine. Recesses are formed on a side of each cylinder head and one fuel rail is positioned within each recess. The mechanical high pressure pump is positioned vertically above the uppermost fuel injector so that any fuel vapor within the fuel rails will rise toward the fuel pump. Fuel vapor that accumulates within the high pressure fuel pump is returned to the vapor separator.

Abstract: An engine includes an improved induction system which reduces the girth of the engine, simplifies assembly, and improves better power output balance between the cylinders of the engine. The illustrated engine is a multi-cylinder engine and is designed to power an outboard motor; hence, the cylinders of the engine are arranged above one another. Thus, the engine comprises at least first and second combustion chambers. The induction system selectively communicates with the combustion chambers to supply a fuel/air charge thereto. The induction system includes a first intake passage leading to the first combustion chamber and having a first fuel injector communicating therewith, and a second intake passage leading to the second combustion chamber and having a second fuel injector communicating therewith.

Abstract: A marine drive transmission includes an improved shock-absorbing coupling mechanism. Engine power is transmitted to a propulsion device through a drive shaft and driven shaft. The drive shaft is coupled to the driven shaft by a coupling arrangement which has a first coupling mechanism and a second coupling mechanism. The second coupling mechanism is spaced apart from the first coupling mechanism in a direction along a common axis of the shafts. The shafts are coupled with each other selectively by one of the first and second coupling mechanisms. The first coupling mechanism desirably includes an elastic member or a viscosity coupling. The second coupling mechanism desirably includes a toothed mechanism, which functions as the primary coupling between the drive and driven shafts (i.e., overrides the first coupling) once a predetermines load has been applied to the drive shaft.

Abstract: A lubrication system for a direct injected two-cycle engine is disclosed having a lubricant pump adapted to discharge lubricant into each crankcase chamber of the engine through a port positioned immediately adjacent the downstream side of reed valves of the air intake system. The lubricant is injected in a direction generally coincident with the rotational direction of the crankshaft. Drain ports are positioned in the lowermost scavenge passage of each cylinder and communicate lubricant from the scavenge passage to a return port formed through the wall of a crankcase chamber.

Abstract: A direct injected engine includes a multi-layer support that attaches injector drivers to the engine while substantially isolating the injector drivers from high and low frequency vibrations. One layer of the support is formed of a relatively hard material so as to dampen high frequency vibrations produced by the engine when running at high speeds (e.g., 5300 rpm). A second layer of the support is formed of a softer material so as to dampen low frequency vibrations produced by another electronic control component, such as, for example, an electronic control unit (ECU), which the support also attaches to the engine. The ECU is disposed between the engine and a housing containing the injector drivers. The first layer of the support in this structure substantially isolates both the electronic control unit and the injector drivers from engine vibrations, and the second layer of the support substantially isolates the injector drivers from ECU-produced vibrations.

Abstract: A mounting assembly for an anode of a corrosion protection system extends the useful life of the anode and hence the effectiveness of the system. The anode is mounted within an opening of an outboard motor engine. The engine also includes a coolant passage that extends through the engine and forms a portion of a cooling system. A biasing device biases the anode to contact the engine body. The anode also includes multiple contact surfaces which establish a plurality of electrical connections between the anode and the engine. In one mode, an electrically conductive cover links the anode to the engine at a point outside the opening. A seal is positioned between the opening and the cover to protect this electrical coupling. This outside connection thus ensures good electrical coupling between the anode and the engine body outside the presence of the coolant (e.g., salt water) flowing through the coolant passage.

Abstract: An outboard motor includes various protective covers for engine components. The outboard motor can include a protective cover for electrical wires which extend around an outer periphery of the engine, so as to protect the wires from being inadvertently dislodged when installing or removing an upper cowling. The outboard motor may also include a protective sleeve extending vertically, and through which wires are arranged to prevent the wires from contacting water which may collect in a lower portion of a powerhead of the outboard motor. Additionally, the outboard motor can also include a protective casing for electrical components including relays, fuses, and associated connectors. The protective casing includes a main storage portion and a substorage portion. The main storage portion includes a lid and is configured to have a watertight seal around only a portion of its outer periphery.

Abstract: A power tilt and trim system for an outboard drive includes an improved construction that can be formed in compact nature without significantly reducing its strength. The system includes a support member that couples to the outboard motor. The support member has a pair of bracket arms spaced apart from each other and one of the bracket arms has an opening. An actuator is nested between the bracket arms to tilt the outboard drive. A powering assembly is disposed next to the actuator and arranged to power the actuator. At least a portion of the powering assembly lies within the opening.