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Charlie · 31-10-2018, 08:58

Hello all,

I volunteered to teach a class in outboard motor maintenance and repair to the junior program at our yacht club (Richmond Yachy Club in SF Bay Area). I need to create a syllabus for the Board to review.

My idea is to have a max of 8 kids to teach:

1) Engine theory. Four strokes. Intake compression combustion exhaust (or suck, squeeze, bang blow)

2) Tool and Parts Identification

3) Maintenance: 1) changing spark plus, 2)replacing fuel filters, 3)replacing impellers, 4) changing oil, 5)replacing shear pin and prop, 6) Winterizing

4) Diagnosing no start situations: 1) check for fuel, 2) check for spark 3)flooding a carb

5) Rebuilding a carb

6) Finally I would like to break the kids into two groups of four and take a non functioning engine each and tear it apart and get it to work again.

Can people critique this brief syllabus and either provide links or other useful teaching aids.

motion30 · 31-10-2018, 09:02

Definitely teach them how to rebuild the carburetor

**GordMay** · 31-10-2018, 09:04

Good on ya!
See also "OUTBOARD MOTORS FOR PACIFIC ISLAND MARINERS" ➥ http://coastfish.spc.int/Sections/tr...oard_lg_en.pdf

Dsanduril · 31-10-2018, 09:07

Flushing with fresh water after use
Lower unit lubrication
Grease nipples and greasing
Idle adjustment

Charlie · 31-10-2018, 12:08

Thanks for the comments these are helpful and will be added to the sylabus. As usual Gord you are a wealth of information. The booklet will be the starting point for my text.

NoTies · 31-10-2018, 13:01

The teaching resource Gord posted is brilliant. I have used it for teaching courses in the South Pacific extensively. It is designed to be accompanied by practical demonstration as it is primarily designed for English as a second language students.

Charlie · 31-10-2018, 14:28

I agree NoTies. The only problem I have with it is that it is based on two stroke engines and in Kalifornia 2 strokes are mostly banned.

Charlie · 31-10-2018, 15:36

Here is my updated Syllabus. Please comment

RYC Small Outboard Motor Class Syllabus
Draft
1) Engine Theory
a. Two vs Four Stroke
b. Intake Compression Combustion Exhaust (suck, squeeze, bang, blow)
c. Cooling system
i. Air Cooled
ii. Water Cooled
d. Lubrication
i. Power Head
ii. Lower Unit
e. Zinc
f. Fuel System
g. Electrical System
2) Tools and Parts Identification
a. Tools needed to work on engine
b. Parts of an outboard
3) How to start an outboard
a. Attach to boat/safety strap
b. Fuel level
c. Oil level
d. Propeller clear
e. Loosen air vent
f. Connect fuel hose (if needed)
g. Primer Bulb
h. Place engine in Neutral and throttle poisiton
i. Emergency stop switch
j. Choke
k. Pull cord
l. Check for pee stream
m. Place engine in idle and put it in Forward and Reverse
4) Troubleshooting
a. Check for fuel
b. Check air vent
c. Primer bulb pushing fuel the correct way
d. Neutral and throttle on start
e. Emergency stop connected
f. Fuel filter is clear
g. Check carb for leaks
h. Engine starts but stops after a short run
i. Air vent screw
ii. Fuel lever on
iii. Choke too far open
i. Engine Flooded
i. Open choke all the way XXXX
ii. Remove kill switch
iii. Slowly pull rip cord
j. Check for spark
5) Shut down Procedure
a. Run down carb
b. Flush Engine (especially after salt water run)
6) Maintenance
a. Changing Spark Plus
i. Remove/Install
ii. Gap
iii. Diagnose by color
b. Replacing Fuel Filter
c. Replacing impeller
d. Changing Oil Power Head
e. Changing Gear Oil
f. Grease Nipples
g. General wash
h. Zincs
i. Shear Pins
j. Propeller Removal and Instalation
k. Rebuild/Clean Carb
i. Adjust idle
7) Outboard goes swimming
a. Remove engine Cover
b. Disconnect electrical
c. Flush with fresh wate
d. Remove spark plug
e. Disconnect fuel lines.
i. Drain and clean fuel lines and tank
f. Place engine horizontal with spark plug down. Slowly pull cord to remove water from cylinder
g. Spray cylinder with WD 40 pull cord a few more times
h. Drain Carb, disassemble and service
i. Clean all electrical parts with fresh water then treat with water displacing electrical spray.
j. Inject oil into spark plug hole
k. If engine shows evidence that sand may have entered do not attempt to start the engine. Requires full disassembly
l. Reassemble engine and start. Run for 30 minutes in fresh water.
m. If engine fails to start check plugs for water if present blow out water and reinstall/replace plugs. Repeat starting procedure.
8) Take two non-running outboards and in groups of 4 do what is needed to get them running.

NoTies · 31-10-2018, 16:46

Quote:

Originally Posted by Charlie

I agree NoTies. The only problem I have with it is that it is based on two stroke engines and in Kalifornia 2 strokes are mostly banned.

I thought about that after I posted. If you use what's there and add 4 stroke stuff using the same course structure you can't go wrong. I always find it important to ask yourself the question "what am I trying to achieve" in teaching. I don't bother teaching principles of combustion to village students as it is completely lost on them, instead I simply point out the relative advantages and disadvantages of 4 or 3 stroke etc. FWIW in villages 2 strokes always win. If your students are more academically inclined then it would be appropriate to teach them the ottoman cycle etc. but if the outcome of the course is to be able to fix a broken outboard then concentrate on troubleshooting and fixing.

Nicholson58 · 31-10-2018, 17:25

I suggest a bit of discussion around the probable failures due to ethanol in older motors. We have lost three fuel primer bellows in our two stroke Mercury, one fuel hose, one fuel tank dip tube.

Charlie · 01-11-2018, 08:42

No Ties thanks for the advise "what am I trying to achieve." I will have to ponder that for awhile.

Nicholsan58 that is good advice. I will need to research that a little bit