COLOR DIAGRAMS

COLOR DIAGRAMS
Table of Contents
150/175/200 EFI 2002 Model Year Typical SmartCraft Dual Outboard Installation
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . Page 8-3 2002 Model Year . . . . . . . . . . . . . . . . . . . . . . . Page 8-9
Typical SmartCraft System Tachometer & System 150/175/200 EFI 2002 Model Year
Speedometer Installation with System Link Gauges Oil & Fuel Flow Diagram . . . . . . . . . . . . . . . . Page 8-11
2002 Model Year . . . . . . . . . . . . . . . . . . . . . . . Page 8-5 150/175/200 EFI 2002 Model Year
Typical SmartCraft System Monitor/Tachometer Water Flow Diagram . . . . . . . . . . . . . . . . . . . . Page 8-13
Installation with System Link Gauges
2002 Model Year . . . . . . . . . . . . . . . . . . . . . . . Page 8-7

90-883728 MAY 2001 Page 8-1

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Notes:

Page 8-2 90-884294 OCTOBER 2001

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150/175/200 EFI
WIRING DIAGRAM
2002 MODEL YEAR

90-883728 MAY 2001 Page 8-3

150/175/200 EFI 2002 Model Year
1. ECM 35. Cowl Mounted Trim Switch
2. Top ECM Connector 36. To Remote Control Trim Switch
3. Middle ECM Connector 37. 12 Volt Accessory Power
4. Bottom ECM Connector 38. To Analog Temperature Gauge
5. Ignition Coils 39. Detonation Sensor - Port Head
6. Ignition Coil Harness Connection 40. Detonation Sensor - Starboard Head
7. Fuel Injectors 41. Engine Harness
8. Analog Head Temperature Sender - Port Head 42. 10-Pin SmartCraft Harness (Gauges)
9. Oil Pump 43. DDT Data Port
10. MAP Sensor 44. 8-Pin SmartCraft Harness (Boat Sensors)
11. Block Pressure Sensor
12. Water Sensor
13. Shift Switch
14. Digital Air Temperature Sensor
15. Digital Temperature Sensor - Starboard Head
16. Digital Temperature Sensor - Port Head
17. Yellow Identifier - 2.5 Liter Only
18. Throttle Position Sensor (TPS)
19. Crank Position Sensor (CPS)
20. Accessories 15 Ampere Fuse
21. Fuel System & Oil Pump 20 Ampere Fuse
22. Main Power Relay, Remote Control Harness &
Power Trim Circuit 20 Ampere Fuse
23. Ignition Coils 20 Ampere Fuse
24. Low Oil Switch
25. Starter Solenoid
26. Centrifugal Bendix Starter Motor (Early 2002
Models)
27. Solenoid Driven Bendix Starter Motor (Late
2002 Models)
28. 60 Ampere Alternator
29. Main Power Relay
30. Electric Fuel Pump
31. Trim Down Relay
32. Trim Up Relay
33. To Trim Pump
34. To 12 Volt Battery
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TYPICAL SMARTCRAFT
SYSTEM TACHOMETER &
SYSTEM SPEEDOMETER
INSTALLATION
WITH SYSTEM LINK GAUGES
2002 MODEL YEAR

90-883728 MAY 2001 Page 8-5

Typical SmartCraft System Tachometer & System Speedometer
with System Link Gauges 2002 Model Year
1. 8-Pin Digital Sensor Harness Extension, Connect 27. Analog Tachometer Harness (Not Used on CAN
to 8-Pin SmartCraft Harness on Engine Installation)
2. Digital Speedometer Sensor 28. Warning Horn
3. Digital Trim Sender 29. Analog Temperature Gauge Connection
4. 10-Pin Control Area Network (CAN) Harness Con- 30. Paddle Wheel/Lake/Sea Water Temperature
nects to Data Buss 10-Pin CAN Harness on En- Sender
gine
31. 4-Pin Digital Sensor Harness Connection to
5. Yellow Identifier Marking Resistor End of CAN Paddle Wheel
Harness
32. Digital Connections to Oil Sender
6. Resistors within CAN Harness (120Ω 1/4W 5%)
33. Digital Connections to Fuel Sender
7. Weather Proof Cap on Un-Used Junction Box Ter-
34. Connection for Analog Trim Sender
minals
35. Connection to Trim Relays
8. Resistor Cap in Junction Box Terminal
36. Connection for Analog Temperature Sender
9. 10-Pin Control Area Network (CAN) Harness Con-
nects to Junction Box 37. Remote Control Harness Connects to Engine Har-
ness
10. 10-Pin Control Area Network (CAN) Harness Con-
nection to Junction Box and System Speedometer 38. 6-pin Digital Sensor Harness
11. 10-Pin Control Area Network (CAN) Harness Con-
nection to Junction Box and System Tachometer
12. Ambient Air Temperature Sensor
13. System Speedometer
14. Connections for GPS
15. System Tachometer
16. Connections for Auxiliary Warning Horn for Depth
Sensor
17. System Link Series Connection
18. 2-1/4 in. System Link Gauges (Fuel, Temperature,
Trim etc.)
19. System Link Series Connection
20. 2-1/4 in. System Link Gauges (Fuel, Temperature,
Trim etc.)
21. Plugged Series Connection for Additional System
Link Gauges
22. 4000 Series Mechanical Panel Control (MPC
4000)
23. Connections for Lanyard Stop Switch
24. Connection for Power Trim Switch
25. Connections for Neutral Start Safety Switch
26. Ignition Key Switch
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TYPICAL SMARTCRAFT
SYSTEM MONITOR/TACHOMETER
INSTALLATION
WITH SYSTEM LINK GAUGES
2002 MODEL YEAR

90-883728 MAY 2001 Page 8-7

Typical SmartCraft System Monitor/Tachometer with System
Link Gauges 2002 Model Year
1. 8-Pin Digital Sensor Harness Extension, Connect 27. 4-Pin Digital Sensor Harness Connection to
to 8-Pin SmartCraft Harness on Engine Paddle Wheel
2. Digital Speedometer Sensor 28. Digital Connections to Oil Sender
3. Digital Trim Sender 29. Digital Connections to Fuel Sender
4. 6-pin Digital Sensor Harness
5. Connection for Analog Temperature Sender
6. Connection to Trim Relays
7. Connection for Analog Trim Sender
8. Remote Control Harness Connects to Engine Har-
ness
9. 10-Pin Control Area Network (CAN) Harness Con-
nects to Data Buss 10-Pin CAN Harness on En-
gine
10. Resistors within CAN Harness (120Ω 1/4W 5%)
11. Connections for Auxiliary Warning Horn for Depth
Sensor
12. Yellow Identifiers Marking Resistor End of CAN
Harness
13. Either System Monitor or System Tachometer is
Used. If System Tachometer is Used, Tachometer
Link Gauge is not Used
14. System Link Series Connection
15. 3-1/4 in. System Link Gauges (Tachometer and
Speedometer)
16. 2-1/4 in. System Link Gauges (Fuel, Temperature,
Trim etc.)
17. Plugged Series Connection for Additional System
Link Gauges
18. 4000 Series Mechanical Panel Control (MPC
4000)
19. Connections for Lanyard Stop Switch
20. Connection for Power Trim Switch
21. Connections for Neutral Start Safety Switch
22. Ignition Key Switch
23. Analog Tachometer Harness (Not Used on CAN
Installation)
24. Warning Horn
25. Analog Temperature Gauge Connection
26. Paddle Wheel/Lake/Sea Water Temperature
Sender
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TYPICAL SMARTCRAFT
DUAL OUTBOARD
INSTALLATION
2002 MODEL YEAR

90-883728 MAY 2001 Page 8-9

Typical SmartCraft Dual Outboard Installation 2002 MY
1. 8-Pin Harness from Port Outboard 28. 10-Pin Control Area Network (CAN) Connection
from System Tachometer Starboard Outboard to
2. Digital Sensor Harness Extension Port Outboard
Junction Box
3. Digital Speedometer Sensor Port Outboard
29. 10-Pin Control Area Network (CAN) Junction Box
4. Digital Trim Sender Port Outboard
30. 10-Pin Control Area Network (CAN) Connection
5. Digital Sensor Harness Extension Port Outboard from Junction Box to Port Outboard 10-Pin Data
to 6-pin Digital Sensor Harness Buss CAN Harness
6. 6-pin Digital Sensor Harness Port Outboard (Only 31. 10-Pin Control Area Network (CAN) Connection
if Duel Fuel and Oil Tanks are Used) from Junction Box to Starboard Outboard 10-Pin
7. Digital Connections for Fuel Sender Data Buss CAN Harness

8. Digital connections for Oil Sender 32. Resistor in Port CAN Harness (120Ω 1/4W 5%)

9. Weather Proof Cap for 6-Pin Harness 33. Yellow Resistor Identifier on Harness End

10. Weather Proof Cap for System Link Gauges 34. 10-Pin Control Area Network (CAN) Connection
from Junction Box to Port Outboard 10-Pin Data
11. 2-1/4 in. System Link Gauges (Fuel, Temp, Trim, Buss CAN Harness
etc.) Port Outboard
35. 10-Pin Data Buss CAN Harness Port Outboard
12. System Tachometer Port Outboard
36. 3-Pin Data Buss CAN Connection for Power
13. System Speedometer
37. Resistor in Port CAN Harness (120Ω 1/4W 5%)
14. System Tachometer Starboard Outboard
38. Yellow Resistor Identifier on Harness End
15. System Link Series Connections Port Outboard
39. 10-Pin Control Area Network (CAN) Connection
16. 10-Pin Control Area Network (CAN) Connection to from Junction Box to Starboard Outboard 10-Pin
System Tachometer Port Outboard Data Buss CAN Harness
17. Connections for Auxiliary Warning Horn for Depth 40. 10-Pin Data Buss CAN Harness Starboard Out-
Sensor board
18. Ambient Air Temperature Sensor 41. 3-Pin Data Buss CAN Connection for Power, Must
19. 10-Pin Control Area Network (CAN) Connection to be Disconnected and Capped on Dual Installation
System Speedometer 42. Digital Trim Sender Starboard Outboard
20. Connections for GPS 43. Digital Speedometer Sensor Starboard Outboard
21. Connections for Auxiliary Warning Horn for Depth 44. 8-Pin Harness from Starboard Outboard
Sensor
45. Digital Sensor Harness Extension Starboard Out-
22. 10-Pin Control Area Network (CAN) Connection to board
System Tachometer Starboard Outboard
46. Digital Sensor Harness Extension Starboard Out-
23. System Link Series Connections Starboard Out- board to 6-pin Digital Sensor Harness
board
47. 6-pin Digital Sensor Harness Starboard Outboard
24. 2-1/4 in. System Link Gauges (Fuel, Temp, Trim,
etc.) Starboard Outboard 48. Digital Connections for Fuel Sender

25. Weather Proof Cap for System Link Gauges 49. Digital connections for Oil Sender

26. 10-Pin Control Area Network (CAN) Connection 50. 4-Pin Digital Sensor Harness Connection to
from System Tachometer Port Outboard to Junc- Paddle Wheel
tion Box 51. Paddle Wheel/Lake/Sea Water Temperature
27. 10-Pin Control Area Network (CAN) Connection Sender
from System Speedometer to Junction Box 52. Weather Proof Cap for Junction Box Terminal
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48 59276
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150/175/200 EFI
OIL & FUEL FLOW DIAGRAM
2002 MODEL YEAR

90-883728 MAY 2001 Page 8-11

150/175/200 EFI Oil & Fuel Flow 2002 Model Year
1. Fuel inlet from primer bulb
2. Engine Pulse Fuel Pump
3. Fuel line to Water Separating Fuel Filter - 2-8 psi (14-55 kPa)
4. Water Separating Fuel Filter in Vapor Separator Tank (VST) Assembly
5. Fuel outlet from Needle and Seat
6. Fuel Level Float in VST
7. Pulse Pressure from Cylinder Block
8. On-Board Oil Tank
9. Check Valve in Outlet Hose from Oil Tank
10. Outboard Oil Tank
11. Oil Inlet Hose to Electronic Oil Pump
12. Electronic Oil Pump
13. Oil Outlet Hose from Oil Pump to VST
14. Oil is Mixed with Gas in VST
15. Gas/Oil Mixture is Drawn into High Pressure Fuel Pump
16. Fuel Drain
17. High Pressure Fuel Pump
18. Schrader Valve
19. Fuel Passage to Fuel Regulator
20. Fuel Regulator
21. Ambient Air Pressure
22. Fuel Blow-Off from Fuel Regulator to VST
23. In-Line Fuel Filter
24. High Pressure Fuel Line to Reed Valve Plate Assembly
25. Reed Valve Plate Assembly
26. Fuel Rail Assembly
27. Fuel Injectors
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58847
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150/175/200 EFI
WATER FLOW DIAGRAM
2002 MODEL YEAR

90-883728 MAY 2001 Page 8-13

150/175/200 EFI Water Flow 2002 Model Year
1. Water Inlet
2. Water Pump
3. Wall of Water - If water level height is insufficient, water pump may draw in air resulting in an overheated
engine
4. Water Tube
5. Main Water Feed to Powerhead from Water Tube
6. Water by-pass prevents air/steam pockets at top of powerhead
7. Cylinder Head Cover - Removed from head for illustration, normally part of head casting
8. Thermostats (2) 143° F (61.7° C) - If stuck closed, engine will overheat at low speed. If stuck open,
engine will not warm up at idle speed.
9. Poppet Valve - Controls water flow at high RPM. If poppet valve is stuck open at low RPM, the engine
will not reach proper operating temperature (run cold) and will run rough at idle
10. Primary water discharge into driveshaft housing.
11. Water Dump Holes for exhaust cooling (2 each) 1/8 in. (3.175 mm) - if holes are plugged, tuner pipe
will melt and bearing carrier prop shaft seals will be damaged.
12. Water Pressure Sensor
13. Check Valve for powerhead flush
14. Water passing through thermostats dump into adaptor plate, then discharges down the exhaust.
15. Tell-Tale Outlet
16. Excess water from wall of of water around exhaust bucket exits around anodes.
17. Water Exits with Exhaust Discharge
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