Abstract: An exhaust manifold is for an internal combustion engine on an outboard marine engine that is configured to power a propulsor to provide a thrust in a longitudinal direction. The exhaust manifold comprises an exhaust runner that transversely and longitudinally rearwardly conveys the exhaust gas from the internal combustion engine, an exhaust log that vertically upwardly conveys the exhaust gas from the exhaust runner, and an exhaust elbow that conveys the exhaust gas from the exhaust log vertically upwardly, longitudinally forwardly, and then vertically downwardly.

Abstract: An outboard marine propulsion device comprises an internal combustion engine having a cylinder head and a cylinder block; and an exhaust manifold that discharges exhaust gases from the engine towards a vertically extending catalyst housing. The exhaust manifold has a plurality of horizontally extending inlet runners upwardly that receive the exhaust gases from the engine, and a vertically extending collecting passage that conveys the exhaust gases from the plurality of horizontally extending inlet runners to a bend that redirects the exhaust gases downwardly towards the catalyst housing.

Abstract: A catalyzed exhaust system for an outboard motor engine rotates its catalyst device in a catalyst housing above an adapter plate which supports the engine and separates it from the driveshaft housing. The exhaust gas is directed initially in an upwardly direction and then is turned downwardly to provide space for location and easy access to the catalyst device. A coolant, such as water drawn from a body of water, is reversed in direction of flow several times in order to advantageously fill certain cooling channels in an upward direction. In addition, various coolant channels are vented to remove potential pockets of air in their upper regions.

Abstract: A cooling system for an internal combustion engine of a marine propulsion system is provided with a poppet that is overmolded with a resilient sealing material to enhance its sealing capacity. As a result, the pressure within the internal combustion engine cooling passages can be maintained more accurately. Because undesirable leakage past the poppet is more successfully prevented by the overmolded poppet, the cooling system can more accurately regulate the temperature of the engine.

Abstract: A lubrication system for an internal combustion engine provides drain openings at locations within individual crankcase portions where residual oil collects during normal operation. The drain openings are connected to orifices formed through cylinder walls of other crankcase portions of the engine. Conduits connect preselected drain openings to associated orifice check valves to pump the residual oil from the collecting regions to the cylinder walls of other crankcase portions using differential pressures that occur naturally between the associated crankcase portions. The drain openings located at the collecting regions can be located directly under primary oil entry points of the crankcase portions, but this relationship is not absolutely necessary as long as the drain openings are placed at the collecting regions or, alternatively stated, as long as the drain openings are placed at locations where oil will tend to flow from the points of primary oil entry into the crankcase portions.

Abstract: The assembled evaporable pattern, which is substantially identical in shape to the cast metal two-cycle engine block, includes a plurality of in-line cylinders each having an end open to the crankcase end of the pattern. Each cylinder includes an exhaust passage that communicates with an exhaust manifold that extends to the exterior of the pattern and each cylinder has at least one longitudinally extending transfer passage. The assembled pattern also includes cooling passages that surround each cylinder, as well as surrounding the exhaust manifold passage. The foam pattern is composed of a plurality of separate foam sections joined together by an adhesive along planar interfaces. A first of the sections extends from the crankcase end of the pattern to the lower end of the transfer passages, and a second section extends from the lower end of the transfer passages to a location intersecting the exhaust passages of the cylinders. A third section extends from the exhaust passages to the cylinder heads.