GENERAL INFORMATION AND SPECIFICATIONS

SECTION 1A – GENERAL INFORMATION 1

AND SPECIFICATIONS A
Table of Contents
How To Use This Manual . . . . . . . . . . . . . . . . . . . 1A-1 Out-of-Season Storage . . . . . . . . . . . . . . . . . . 1A-9
Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 Out-of-Season Battery Storage . . . . . . . . . . 1A-10
Master Specifications . . . . . . . . . . . . . . . . . . . . . . 1A-2 How Weather Affects Engine
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6 Performance . . . . . . . . . . . . . . . . . . . . . . . . . 1A-11
Standard Hardware . . . . . . . . . . . . . . . . . . . . . 1A-6 Detonation: Causes and Prevention . . . . . 1A-11
Metric Hardware . . . . . . . . . . . . . . . . . . . . . . . 1A-7 Compression Check . . . . . . . . . . . . . . . . . . . 1A-12
Flushing Cooling System . . . . . . . . . . . . . . . . 1A-7 Water Pressure Check . . . . . . . . . . . . . . . . . 1A-12
Following Complete Submersion . . . . . . . . . 1A-8

How To Use This Manual

The manual is divided into SECTIONS (shown right) which represents major components
and systems.
Some SECTIONS are further divided into PARTS. Each PART has a title page. A Table of
Contents for the particular PART is printed on the back of the title page.
SECTIONS and PARTS are listed on the Service Manual Outline sheet which immediately
follows the cover of this book.

Section Section Heading

1 General Information/Specifications
2 Electrical and Ignition
3 Fuel System and Carburetion
4 Powerhead
5 Jet Pump
6 Sport Jet Installation

90-858804 AUGUST 1998 Page 1A-1

GENERAL INFORMATION AND SPECIFICATIONS

Page Numbering
Two number groups appear at the bottom of each page. The example below is self-explana-
tory.
EXAMPLE:

90-826148R1 MAY 1994 Page 4A-7

Revision No. 1 Section Number

Month of Printing Part of Section Letter

Year of Printing Page Number

Master Specifications
120
HORSEPOWER Model 120 120
(KW) (89.5)
PH / PUMP
260 lbs.
WEIGHT
CYLINDER Type 4 Cylinder In-Line
BLOCK Displacement 102.9 cu. in. (1687 cc)
STROKE Length 2.876 in. (73.05 mm)
CYLINDER Diameter (Standard) 3.375 in. (85.7 mm)
BORE Taper/Out of Round Max. 0.0015
Bore Type Cast Iron
PISTON Piston Type Aluminum
Standard Diameter 3.3700 (85.598 mm)
0.015 in. (0.378 mm) Oversize Diameter 3.3850 (85.979 mm)
0.030 in. (0.752 mm) Oversize Diameter 3.4000 (86.360 mm)
REEDS Reed Stand Open (Max.) 0.010 (0.254 mm)

Page 1A-2 90-858804 AUGUST 1998

 GENERAL INFORMATION AND SPECIFICATIONS

PUMP Gear Ratio 1.25:1

HOUSING Drive Housing Capacity 750 cc
Stator Capacity 500 cc
Pinion Height 0.025 in. (0.64 mm)
Gear Backlash 0.007 in. - 0.009 in.
(0.177 mm - 0.228 mm)
FUEL Fuel Gasoline and Oil
SYSTEM Recommended Gasoline Automotive Lead-Free: 87 octane minimum
Recommended Oil Quicksilver TC-W 3 or TC-W II Outboard Oil
Gasoline/Oil Ratio Variable ratio oil injection
Fuel Pressure- @ Idle 3.5 PSI
- @ WOT 6 PSI
STARTING Electric Start- Starter Draw
SYSTEM Under Load 110 - 200 Amperes
No Load 80 - 165 Amperes
Battery Rating 670 Marine Cranking Amps (MCA) or
(minimum) 520 Cold Cranking Amps (CCA)
IGNITION Type Capacitor discharge
SYSTEM Spark Plug Type Champion L77JC4
Spark Plug Gap .040 (1.0 mm)
Optional (Resistor Plug) QL77JC4
CHARGING Alternator Output (Regulated) 15 Amp
SYSTEM
CARBURETOR Idle RPM 950 - 1100 RPM
Wide Open Throttle (WOT) RPM 4700 - 5300
Idle Mixture Screw Adjustment
(Preset – Turns Out)
(Preset – All Carbs 1-1/2 turn out from a lightly seated position

Float Setting Set parallel to body flange

Main Jet
– Model 120
– Carb #1 .088
– Carb #2 .090
TIMING Maximum BTDC
@ Cranking Speed 32° BTDC
@ 5000 RPM 30° BTDC

Firing Order
– Model 120 1-3-2-4

90-858804 AUGUST 1998 Page 1A-3

GENERAL INFORMATION AND SPECIFICATIONS

2.910 .77003

.020 .76993

0.15 in.
(3.81 mm)

3.3700
 .0005
Measured 90

to piston pin
center line

0.9568
0.9573

4.500
.005

1.4986
1.4991

Page 1A-4 90-858804 AUGUST 1998

 GENERAL INFORMATION AND SPECIFICATIONS

1.2495
1.3748 1.2500
1.3752
1.3793
1.3789

1.1813
1.1818 CRANKSHAFT

90-858804 AUGUST 1998 Page 1A-5

GENERAL INFORMATION AND SPECIFICATIONS

Torque Chart
Special Items Torque
Impeller Shaft Nut 150 lb. ft. (203 N·m)
Drive Housing Cover Bolts 35 lb. ft. (47.5 N·m)
Stator Bolts 35 lb. ft. (47.5 N·m)
Nozzle to Stator Bolts 35 lb. ft. (47.5 N·m)
Rudder Pivot Bolt 20 lb. ft. (27.1 N·m)
Reverse Gate Pivot Bolt 20 lb. ft. (27.1 N·m)
Powerhead to Drive Housing (M8 Nut) 20 lb. ft. (27.1 N·m)
Powerhead to Drive Housing (M10 Nut) 35 lb. ft. (47.5 N·m)
Steering Cable Mounting Bracket 200 lb. in. (22.6 N·m)
Steering Lever Screw 180 lb. in. (20.2 N·m)
Reverse Gate Stop Screw 120 lb. in. (13.6 N·m)
Shift Bracket Screw 50 lb. in. (5.6 N·m)
Inlet Screen Screw 75 lb. in. (8.5 N·m)
Ride Plate Screw 75 lb. in. (8.5 N·m)
Drive Shaft Nut 90 lb. in. (122 N·m)
Cylinder Head 225 lb. in. (25.4 N·m)
Then Turn Additional 90

Flywheel Nut 125 lb. ft. (169.47 N·m)
Main Bearing Bolts 270 lb. in. (30.4 N·m)
Connecting Rod Screws 120 lb. in. (13.6 N·m)
Then Turn Additional 90

Transfer Port Cover 80 lb. in. (9.03 N·m)
Exhaust Manifold 115 lb. in. (13 N·m)
Carburetor Fuel Bowl Screw 30 lb. in. (3.5 N·m)

Standard Hardware
Screw or Nut Size Torque
6 - 32 9 lb. in. (1.0 N·m)
8 - 32 20 lb. in. (2.3 N·m)
10 - 24 30 lb. in. (3.4 N·m)
10 - 32 35 lb. in. (3.9 N·m)
12 - 24 45 lb. in. (5.0 N·m)
1/4 - 20 70 lb. in. (7.8 N·m)
5/16 - 18 160 lb. in. (18.1 N·m)
3/8 - 16 270 lb. in. (30.4 N·m)

Page 1A-6 90-858804 AUGUST 1998

 GENERAL INFORMATION AND SPECIFICATIONS

Metric Hardware
Torque Specification
A B lb. in. lb. ft. N·m
8 mm M5 36 3 4
10 mm M6 70 6 8
12 mm M8 156 13 18
14 mm M10 312 26 36
17 mm M12 372 31 42

A B

Flushing Cooling System

Flushing the cooling system is essential after each use in salt water, after the boat has run
aground, or when the overheat warning horn sounds (debris in jet powerhead). We recom-
mend using Dealer Kit (P/N 22-820573) to flush the cooling system.
1. Disconnect the inlet water hose at the rear starboard corner of the pump housing. Install
the Dealer Kit and attach water hose.

a
a - Dealer Flushing Kit (22-820573)

2. Turn water on and flush engine block for at least 10 minutes.

3. Remove water hose and dealer flushing kit. Re-install water inlet hose.
4. Flush outer surfaces of water outlet nozzle with water stream.

90-858804 AUGUST 1998 Page 1A-7

GENERAL INFORMATION AND SPECIFICATIONS

Following Complete Submersion

Submerged engine treatment is divided into three distinct problem areas. The most critical
is submersion in salt water; the second is submersion while running; the third is submersion
in fresh water with special instructions.
SALT WATER SUBMERSION (SPECIAL INSTRUCTIONS)
Due to the corrosive effect of salt water on internal engine components complete disassem-
bly is necessary before any attempt is made to start the engine.
SUBMERGED WHILE RUNNING (SPECIAL INSTRUCTIONS)
When an engine is submerged while running, the possibility of internal engine damage is
greatly increased. If, after engine is recovered and with spark plugs removed, engine fails
to rotate freely when turning flywheel, the possibility of internal damage (bent connecting
rod and/or bent crankshaft) exists. If this is the case the powerhead must be disassembled.
SUBMERGED ENGINE (FRESH WATER) PLUS SPECIAL INSTRUCTIONS
1. Recover engine as quickly as possible.
2. Flush exterior of engine with fresh water to remove mud, weeds, etc. DO NOT attempt
to start engine if sand has entered powerhead, as powerhead will be severely damaged.
Disassemble powerhead if necessary to clean components.
3. Remove spark plugs and get as much water as possible out of powerhead by rotating
flywheel.
4. Pour alcohol into carburetor throat (alcohol will absorb water). Again rotate flywheel.
5. Pour alcohol into spark plug openings and again rotate flywheel.
6. Pour engine oil into throats of carburetors while rotating flywheel to distribute oil through-
out crankcase.
7. Pour approximately one teaspoon of engine oil into each spark plug opening. Rotate fly-
wheel to distribute oil in cylinders.
8. Remove and clean carburetors and fuel pump assembly.
9. Reinstall spark plugs, carburetors and fuel pump.
10. Attempt to start engine, using a fresh fuel source. If engine starts it should be run for at
least one hour to eliminate any water in engine.
11. If engine fails to start determine cause (fuel, electrical or mechanical). Engine should
be run within two hours after recovery from water as serious internal damage may occur.
If unable to start engine in this period disassemble engine and clean all parts and apply
oil as soon as possible.

Page 1A-8 90-858804 AUGUST 1998

 GENERAL INFORMATION AND SPECIFICATIONS

Out-of-Season Storage
WARNING
As a safety precaution, when boat is in storage, remove positive (+) battery cable.
This will eliminate possibility of accidental starting of engine and resultant over-
heating and damage to engine from lack of water.
In preparing for out-of-season storage, two precautions must be considered: 1) The engine
must be protected from physical damage caused by freezing trapped water and 2) the en-
gine must be protected from rust, corrosion and dirt.
The following storage procedures should be followed to prepare the Sport Jet for out-of-sea-
son storage or prolonged storage (two months or longer).

CAUTION
Never start or run the Sport Jet (even momentarily) out of the water. Damage to the
pump and engine will occur.
FUEL SYSTEM
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a forma-
tion of acid during storage and can damage the fuel system. If the gasoline being
used contains alcohol, it is advisable to drain as much of the remaining gasoline as
possible from the fuel tank, remote fuel line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pump, and carburetors) with treated (stabilized) fuel
to help prevent formation of varnish and gum. Proceed with the following instructions.
• Portable Fuel Tank: Pour the required amount of Quicksilver Gasoline Stabilizer (follow
instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with
the fuel.
• Permanently Installed Fuel Tank: Pour the required amount of Quicksilver Gasoline Sta-
bilizer (follow instructions on container) into a separate container and mix with approxi-
mately one quart (one liter) of gasoline. Pour this mixture into fuel tank.
• Place the Sport Jet in the water. Run the engine for ten minutes to allow treated fuel to
reach the carburetors.
1. With Sport Jet in the water, start the engine and let it warm up to operating temperature.
2. Disconnect the fuel line. When the engine starts to stall quickly spray Quicksilver Stor-
age Seal into each carburetor throat. Continue to spray until engine dies from lack of
fuel.
3. Remove spark plugs and inject a five second spray of Quicksilver Storage Seal around
the inside of each cylinder. Manually turn engine over several times to distribute Storage
Seal throughout cylinders. Reinstall spark plugs.
4. Drain and refill drive housing unit and stator assembly with Quicksilver Hi Performance
Gear Lube as explained in “Jet Pump” section (see Table of Contents).
5. Clean engine thoroughly including all accessible powerhead parts and spray with Corro-
sion and Rust Preventive.
6. Remove water inlet hose and drain any trapped water. Reconnect hose.

90-858804 AUGUST 1998 Page 1A-9

GENERAL INFORMATION AND SPECIFICATIONS

a - Water Inlet Hose

7. Lubricate all lubrication points.

8. To prevent freeze damage, drain the speedometer system of water completely before
storage. Remove tubing from speedometer fitting and blow through tubing to remove
water.
9. Store battery as outlined in Out-of-Season Battery Storage following:
IMPORTANT: Check and refill housings with Quicksilver Hi Performance Gear Lube
before storage to protect against possible water leakage into housings which is
caused by loose lubricant vent plug or loose grease fill plug. Inspect gaskets under
lubricant vent and fill plugs replacing any damaged gaskets before reinstalling
plugs.
Out-of-Season Battery Storage
1. Remove battery as soon as possible and remove all grease, sulfate and dirt from top
surface.
2. Cover plates with distilled water, but not over 3/16 in. (5 mm) above perforated baffles.
3. Cover terminal bolts well with grease.
4. Store battery in a cool, dry place in a dry carton or box.
5. Remove battery from storage every 60 days. Check water level and place on charge for
5 to 6 hours at 6 amperes. DO NOT fast charge.

CAUTION
A discharged battery can be damaged by freezing.

Page 1A-10 90-858804 AUGUST 1998

 GENERAL INFORMATION AND SPECIFICATIONS

How Weather Affects Engine Performance

It is a known fact that weather conditions exert a profound effect on power output of internal
combustion engines. Therefore, established horsepower ratings refer to the power that the
engine will produce at its rated RPM under a specific combination of weather conditions.
Corporations internationally have settled on adoption of I.S.O. (International Standards Or-
ganization) engine test standards as set forth in I.S.O. 3046 standardizing the computation
of horsepower from data obtained on the dynamometer correcting all values to the power
that the engine will produce at sea level at 30% relative humidity at 77° F (25° C) tempera-
ture and a barometric pressure of 29.61 inches of mercury.
Summer Conditions of high temperature, low barometric pressure and high humidity all
combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as
much as 2 or 3 miles-per-hour (3 or 5 km per hour) in some cases. Nothing will regain this
speed for the boater, but the coming of cool, dry weather.
In pointing out the practical consequences of weather effects, an engine running on a hot,
humid, summer day may encounter a loss of as much as 14% of the horsepower it would
produce on a dry, brisk spring or fall day. The horsepower that any internal combustion en-
gine produces depends upon the density of the air that it consumes and, in turn, this density
is dependent upon the temperature of the air, its barometric pressure and water vapor (or
humidity) content.
Detonation: Causes and Prevention
Detonation in a 2-cycle engine somewhat resembles the “pinging” heard in an automobile
engine. It can be otherwise described as a tin-link “rattling” or “plinking” sound.
Detonation generally is thought of as spontaneous ignition, but it is best described as a noisy
explosion in an unburned portion of the fuel/air charge after the spark plug has fired. Detona-
tion creates severe, untimely shock waves in the engine and these shock waves often find
or create a weakness: the dome of a piston, piston rings or piston ring lands, piston pin and
roller bearings.
While there are many causes for detonation in a 2-cycle engine emphasis is placed on those
causes which are most common in marine 2-cycle application. A few which are not common-
ly understood are:
1. Over-advanced ignition timing.
2. Use of low octane gasoline.
3. Lean fuel mixture at or near wide open throttle.
4. Spark plugs (heat range too hot, incorrect reach, cross-firing).
5. Inadequate engine cooling (deteriorated cooling system).
6. Combustion chamber/piston deposits (result in higher compression ratio).
Detonation usually can be prevented provided that (1) the engine is correctly set up and (2)
diligent maintenance is applied to combat the preceding detonation causes listed.

90-858804 AUGUST 1998 Page 1A-11

GENERAL INFORMATION AND SPECIFICATIONS

Compression Check
1. Remove spark plugs.
2. Install compression gauge in spark plug hole.
3. Hold throttle plates at W.O.T.
4. Crank engine through at least four compression strokes to obtain highest possible read-
ing.
5. Check and record compression of each cylinder. Variation of more than 15 psi (103.5
kPa) between cylinders indicates that lower compression cylinder is in some way defec-
tive such as worn or sticking piston rings and/or scored piston and cylinder.
6. Compression check is important because an engine with low or uneven compression
cannot be tuned successfully to give peak performance. It is essential, therefore, that
improper compression be corrected before proceeding with an engine tune-up.
7. Cylinder scoring: if powerhead shows any indication of overheating, such as discolored
or scorched paint, visually inspect cylinders for scoring or other damage as outlined in
Section 4: Powerhead.
Water Pressure Check
NOTE: To perform these checks a Water Pressure Gauge Kit P/N 91-79250A2 is recom-
mended.
1. Water pressure at idle in NEUTRAL, is 1/2–1-1/2 psi (3.4-10.3 kPa).
2. Water pressure in FORWARD gear at 5000 RPM is 10-15 psi (69-103.5 kPa).

CAUTION
Static test requires the boat be stationary in the water secured to a dock or trailer
and run in forward. Do not use a flushing device for this test.

Page 1A-12 90-858804 AUGUST 1998