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96 Donzi Classic 22

Boat is out of the water. On the fuel pump, I drained the raw water pump via Hose removal. Does that tend to get all the water out of the fuel pump?

I have blue plugs on the manifolds, but it came with brass plus in some small adapter things on the block drains. Assuming they used to be blue plugs. Planning to put petcock drain things on the block drains.

Those are the only drain points I found before removing hoses. Are there other good Npt drain points?

On the antifreeze deal, I’m definitely planning to do that. Just hoping to do it once, not each time I pull it out during this time of the season.

What style throttle/shift cables do I have? How are those compatible with the newer stuff? Unfortunately, my shifter doesn’t have a neutral lock button, so I can’t rev it in neutral. Well, without just pulling in the throttle linkage at the motor.

Was hoping to find a newer compatible used stock shifter and swap mine out. Just need to understand what cable setup I have and what is a compatible swap. Eventually, I’d like a fancy shift and throttle setup, but a newer stock setup would be an upgrade for now.



the fuel pump is a complete separate section from the raw pump, pulling the bottom hose to the back of the pump does all you need....

i'd be curious to know what adapter is in the block.. those blue plugs are straight thread, thus the O-ring on them.... holla if you want the merc #'s for any of that... i'd be inclined to keep a blue plug setup, but i'm saltwater... it tends to crust up petcocks...

that shifter should have a "neutral only" feature.. you push the button at the center of the bottom round part and push the shifter forward.. some are hard to tell they are even a button... it should be operating the throttle only.... you'll feel it, it moves a bit easier and it doesn't have the detent going into gear..

all bravo shift assemblies are the same... a 2015 mechanical control head would hook right up to that motor... and sure, if you wanted to change the control head out at some point to something different, they make cables that go from the merc shift assembly up to various cable end configs to fit any control head......

the cables are standard "morse style"... teleflex, Sierra, couple other companies are the major suppliers.. and they aren't overly expensive.. yours will be short too, so prolly $35 or so... it will have the length printed on the sheath back a foot or 2 from one end.. usually the stoooopid boat builders put it up by the shifter, making it harder to spy.. that's a crapshoot.... you give me the full # and i'll tell you exactly what it is in my Kellogg book... they are often hard to read tho... even than, i can tell what "model" they are by the ends, than you just measure em...

stainless bravo props can be "tweaked" some, but it's pretty rare that is needed... same for the alums... as long as the mill is running right, getting all it's r's, boat is trimmed properly, the factory prop "should" perform correctly.. most of the time, the hull engineers do a pretty good job of tuning pitch/diameter to their hull..

those are the 2 main factor, diameter and pitch... and that is balanced between how well it'll get out of the hole vs top end... but the only thing a prop shop can do would be add/or take out a bit of cup (the curve of the blades)... i forget exactly how the cup effects em.. I don't do prop engineering, not my gig.. my 3 bosses know a ton more than me on the whole "prop theory" end of things... putting whatever on/off, that's my job... ;)

i would leave prop work (meaning a swap) till you feel you have too.. it can be a bit of a "voodoo guess" thing at times, I have seen mistake made by various people running the wrong props, or switching to a worse prop... i've seen guys drop 5 hundy and be worse off... but my boss does keep a few different ones around for verifying what prop is right for any bravo/alpha boat in question.. inboards? that ain't happening! :haha:

always remember, make sure that mill is running top notch and if you get 4600 out of it, that'll be pretty good...


oh, on that note, another question... what hr's are on the motor, and what yr was it again?
 
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99C9986C-04A9-418E-8CC4-ECF094E3A8CA.jpeg Thanks man. 1996

Will post pics of throttle. The spot in the middle of the pivot point that should be the neutral lock button is a rubber cap over a bolt.

Looks like a sea star sl3 from what I can research, but they all say they have neutral locks. Maybe I just need to look in the daylight.

Thanks!

99C9986C-04A9-418E-8CC4-ECF094E3A8CA.jpeg
 
well, from the pic, it looks like a push button, make sure you operate the upper button too...

but the other style is a pull out... they will have an exposed edge to the sides of the handle, grab the lower portion of the shifter and pull it inboard.. it should pull out like a 1/2" , than push forward..
 
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oh, and the yr... keep in mind.... if that motor package is a 96, the first place i would look for a performance loss are the injectors.... after a fuel pressure check verifies good pressure feeding the rails.. all the mpfi get it at some point... the 496's started failing at 7, 8, 9 yr's RELIGIOUSLY... find a local place that clean em with the machine or send em out.. usually 2, $300...

you can get into merc software on a laptop and do injector testing, look at any codes, etc... . but that only does a dry check on the injector.. the cleaning machine will give a full flow report, and that is generally where the prob is 95% of the time... bad pattern, won't close, yada.. the laptop is telling you whether the injector is turning off/on correctly..

anyway, most of the 496's early demise issue come from there horrible fuel module engineering.. first it was the cooling fittings overheating them.. than they start losing black coating in the fuel regulator mounting.. well, that paint travels upstream thru the rails and injectors.. thus why in order for merc to warranty the replacement job, you have to either replace, or clean, the injectors, rails AND fuel hose feed leading out of the fuel module

you have poorly placed, but good functioning fuel module for what it is.. that's why i suspect the original injectors longevity... but even than, we all know every batch of fuel isn't always equal.... them little injector needles get cranky too... ;) we often find that, that last 1 to 300 rpm's was from a slightly bad injector or 2... nothing tells us this other than, experience... and the flow test after, to prove us correct...
 
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oh, and always remember the cardinal rule with Merc... they ASSUME that your fuel delivery is good at all times... no code will help you there...
 
Cool. You may be on to something with there pull out handle on the throttle, I’ll check it out.

The running issue I have is it stumbles under hard acceleration, and drops back to low rpm briefly. Never stalled out. Happpenes a few times.

Probably worth running some sea foam in the tank. May even put a bit in the fuel filter and run it through the injectors in a more concentrated form to see if that helps before removal.

Appreciate all the tips!
 
Cool. You may be on to something with there pull out handle on the throttle, I’ll check it out.

The running issue I have is it stumbles under hard acceleration, and drops back to low rpm briefly. Never stalled out. Happpenes a few times.

Probably worth running some sea foam in the tank. May even put a bit in the fuel filter and run it through the injectors in a more concentrated form to see if that helps before removal.

Appreciate all the tips!


now that I'm thinking about it, that yr range they where still using those a bunch.. not sure if anyones doing a pullout these days.. everything you see is push button.. but pull-out where relatively common in the 80's and 90's...

oh, check your fuel pressure.. schrader right up front under the plenum.... don't quote me on it, but iirc, that mechanical low/high setup runs about 35 psi.. i can check easy enough... i'll try to remember to check the book today... but if you're having issues, it will generally be obvious loss at load... you'll want to test run it with the gauge hooked up and someone watching it for a drop off.. should stay pretty steady...
 
oh, and you can fog it that way too... pour 1/2 that fuel filter out and fill it with 2-stroke oil and run it for like 15 minute right before hauling it... that's a cheat on merc's procedure for fogging mpfi's... they have us make a pre-mix of oil/gas and we run that thru from an carry-on outboard tank...

or even better, take a 1/2 hr and pull the plugs and squirt some engine-store in the cylinders.... that's mercs stuff that you use to fog carb'd motors.. spray can. it "clings" real nice to the cylinder walls...
 
oh, and you can fog it that way too... pour 1/2 that fuel filter out and fill it with 2-stroke oil and run it for like 15 minute right before hauling it... that's a cheat on merc's procedure for fogging mpfi's... they have us make a pre-mix of oil/gas and we run that thru from an carry-on outboard tank...

or even better, take a 1/2 hr and pull the plugs and squirt some engine-store in the cylinders.... that's mercs stuff that you use to fog carb'd motors.. spray can. it "clings" real nice to the cylinder walls...

I usually pull the plugs spray each cylinder for about 10 seconds, put the plugs back in and pull the safety lanyard and turn the engine over a couple of times.
 
I usually pull the plugs spray each cylinder for about 10 seconds, put the plugs back in and pull the safety lanyard and turn the engine over a couple of times.

Yep. This is my standard fogging plan on the other boat. Plan to do the same here.
 
How does mercruiser want you to change oil? book says with their pump, is that through the dipstick hose, or somewhere else?

Is there a standard drain plug on the pan?

The indmar setup has an easy oil change hose attached to the drain plug. I have an extractor, but have been using it connected directly to the drain hose, rather than through the dipstick. That way, i don't end up with sludge sitting in the bottom of the pan.

Thanks!
 
So, no worries about a bit of straight sea foam through the fuel filter?

Running 91 octane.
 
ok, first off... my apologies for skimming posts... when i was original suggesting injector cleaning (i'll get to seafoam in a sec) i was figuring the boat was performing ok, just shy a few hundy rpm's... not stumbling, etc... start with a fuel pressure check...

sure, you can dump off some out of the filter and do Seafoam... but don't expect miracles... to be honest, as a professional, who has to justify time and make things work correctly the first time, and quickly.. we gave up on that kind of stuff years ago... could it help an iffy injector, sure... but that's maybe 10% of the time, and I'm being very generous there..... this is ASSUMING it's a problem you're trying to fix.. as far as a maintenance item now and than? great idea...


anyway... I only do plug removal in special circumstances, maybe a boat or 2 a fall, if that.. and some times we'll charge additional if i do it, depending on how hard/easy they are to do...

if the mill doesn't have a whip hose off the pan (you may need to actually look down under and trace out where someone may have run it if it's there).. the end is supposed to be up high on the port side of the motor.. but i've seen em tucked in the back by the exhaust yoke too... just a hose with a safety-wired NPT plug in the end...

but that's a 50/50 whether it has a whip... some packages have em, some don't... if not, yes the dipstick is fine.... here's the sucker i've been using lately.. i like it... we just hook that clear hose right over the tube.. we don't use the stupid garden hose thread deal they have on the merc tubes...



http://www.alloymarine.com/index/suckup.htm
 
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oh, and don't run the boat under load with the seafoam douche.. just idle, or high idle, it for a good while....
 
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oh, and if you're daring, and gymnastic :haha:, you could install a merc whip hose if you don't have one... i have the #'s, if you have the gumption, and long arms.. ;)
 
oh, and if you're daring, and gymnastic :haha:, you could install a merc whip hose if you don't have one... i have the #'s, if you have the gumption, and long arms.. ;)

Need to check it out. Have that suckup extractor, it rocks. I’ll let you know what I find.

I will definitely add a whip if it doesn’t have one. I have a air hose quick disconnect on my extraction tank, and the corresponding fitting to attach to my Indmar drain hose. Makes sucking oil out really clean
 
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if i get a couple minutes tomorrow at work, i'll grab the # for that hose setup... couldn't even think about doing it today.. pounding me with shrinks right up till I get my intestines tucked back in on nov 16.... throw in the shredded rib cartilage from mondays "incident", and my lifes a trainwreck right now..
 
if i get a couple minutes tomorrow at work, i'll grab the # for that hose setup... couldn't even think about doing it today.. pounding me with shrinks right up till I get my intestines tucked back in on nov 16.... throw in the shredded rib cartilage from mondays "incident", and my lifes a trainwreck right now..
What’d you do to your rib cage? Missed that
 
first mention... my dippy boss had me go in a hole I had no biz going in, and got stuck.. they had to pull me out.. got all busted up... meh....
 
Funny story. There was a hole in the nut behind he throttle plug thing. The button actuator was gone. Made one, now have neutral Lock!

Lots of progress and cleanup. Mounted stereo remote, relocated exhaust switch, cleaned carpet and interior, tore out foam, wife is cleaning seats. Good day.

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