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Transportation · course plan

⚠ Pending professional review

This course plan, its lessons and its assessments has not yet been verified by a certified examiner or master technician in the trade or by a certification or approval body. It is a study draft and may contain errors. Do not use it as instructions for work on a job site or on live equipment. Always follow your instructor, your supervising professional, and current official references and regulations.

VoTechWorks program approval and accreditation are still in progress. Credentials are issued only by the certifying bodies named in each program, after their own exams.

Marine Engine / Outboard

9 courses · 1,350 clock hours · 6–9 mo full-time. Grading is competency-based: each course requires the written exam, a competent skills demonstration with zero safety faults, a signed log, and a passed safety audit; percentage weights only rank performance above the competency floor.

~~$14,945~~ COMPLIMENTARYprogram tuition

9courses

79lessons

1,350hours

31assessments

Development progressPlanCourses, lessons and assessments written for this tradeLessons79 of 79 lesson pages writtenPractice630 practice questionsResources117 reference entries (study list)Review0 lesson pages reviewed by a licensed professional

Study now: 79 lesson pages are open (lesson titles below are links).

TRN-MARI21-01 Universal core

Universal Core: Safety, Math, Communication & Career for Marine Engine Technology

148 hr · ~~$1,185~~ COMPLIMENTARY

This foundational course equips adult learners with the safety knowledge, trade mathematics, technical literacy, digital skills, and professional habits required to work safely and effectively in a marine engine and outboard repair facility. Students earn OSHA 10-Hour Maritime or General Industry recognition and hands-on first aid/CPR certification before touching any engine. Every skill is contextualized to the marine trade, preparing learners for subsequent technical courses and eventual ABYC and factory credentialing.

Outcomes

Complete OSHA 10-Hour training and demonstrate correct lockout/tagout, PPE selection, and hazard communication procedures specific to a marine service facility.
Perform first aid and CPR/AED procedures to the standard required for certification by an accredited provider.
Apply trade mathematics—including unit conversion, ratio and proportion, torque calculation, and measurement with hand tools—accurately to marine engine service scenarios.
Read and interpret marine engine service manuals, wiring diagrams, ABYC standards documents, and parts catalogs to locate specified information within a timed task.
Use shop management software, digital multimeters, scan tools, and manufacturer portals to retrieve and record service data correctly.
Construct a professional résumé, complete a mock job application, and demonstrate workplace communication behaviors that meet employer expectations in the marine industry.

Course text

How the course runs. 7 blocks: Marine Shop Safety: OSHA 10, Hazard Communication & PPE; First Aid, CPR & AED for the Marine Workplace; Trade Mathematics for Marine Technicians; Reading Service Manuals, ABYC Standards & Parts Catalogs; Digital Tools: Shop Software, Manufacturer Portals & Diagnostic Interfaces; Technical Communication: Writing, Workplace Documents & Digital Correspondence; Career Readiness: Résumé, Job Application, Workplace Professionalism & Industry Pathways.

What competent looks like. Complete OSHA 10-Hour training and demonstrate correct lockout/tagout, PPE selection, and hazard communication procedures specific to a marine service facility. Perform first aid and CPR/AED procedures to the standard required for certification by an accredited provider. Apply trade mathematics—including unit conversion, ratio and proportion, torque calculation, and measurement with hand tools—accurately to marine engine service scenarios. Read and interpret marine engine service manuals, wiring diagrams, ABYC standards documents, and parts catalogs to locate specified information within a timed task. Use shop management software, digital multimeters, scan tools, and manufacturer portals to retrieve and record service data correctly. Construct a professional résumé, complete a mock job application, and demonstrate workplace communication behaviors that meet employer expectations in the marine industry.

Lessons · 7 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Marine Shop Safety: OSHA 10, Hazard Communication & PPE	28	theory	Students will identify marine-specific workplace hazards, apply the hierarchy of controls, execute lockout/tagout procedures on shop equipment, and satisfy all requirements of the OSHA 10-Hour General Industry curriculum.	Complete all ten modules of the OSHA 10-Hour General Industry course using OSHA-authorized provider materials, discussing how each hazard category (electrical, chemical, fire, struck-by) appears in a marine engine shop environment. Conduct a guided shop walk to locate SDS binders, eyewash stations, fire extinguisher classes, emergency shutoffs, and ventilation controls, then complete a written Hazard Identification Checklist for the lab. Perform a documented lockout/tagout exercise on a shop hoist and a bench grinder using campus locks, tags, and a written energy-control procedure, with a peer auditor verifying each step.	OSHA 10 authorized provider courseware and completion cards, facility SDS binder (gasoline, two-stroke oil, battery acid, parts cleaner), class A/B/C/D/K fire extinguisher training units, personal lockout/tagout kits (hasp, locks, tags), PPE assortment (nitrile gloves, face shield, hearing protection, steel-toed boots), whiteboard and projector	Students pass the OSHA 10 provider final assessment (provider-set passing score, typically 70%) and score 80% or higher on the instructor's Marine Shop Hazard Identification Quiz; LOTO exercise is evaluated on a pass/fail checklist requiring all steps correct with zero critical errors.
2	First Aid, CPR & AED for the Marine Workplace	16	demo	Students will perform adult, child, and infant CPR, operate an AED, and manage marine-specific emergencies including electric shock, fuel burn, and carbon monoxide exposure to the skill standard required for accredited first aid/CPR/AED certification.	Watch instructor demonstration of high-quality CPR sequence on a manikin, then practice two-minute rotations on adult, child, and infant manikins with real-time feedback from a CPR feedback device until compression depth and rate fall within provider standards. Role-play three marine shop emergency scenarios—technician collapses after CO exposure in an engine test tank bay, fuel burn from pressurized fuel line, and electric shock from shore power—applying scene safety, call-for-help, and first aid steps while an observer scores actions on the provider skills checklist. Complete the written knowledge test and hands-on skills evaluation required by the accredited first aid/CPR/AED provider to earn certification cards.	Accredited first aid/CPR/AED provider curriculum and certification cards (e.g., American Red Cross or American Heart Association), adult/child/infant manikins, CPR feedback devices, training AED units, first aid kits, gloves and face shields for infection control, CO detector demonstration unit	Students must pass both the written test and the hands-on skills station at the passing threshold set by the certification provider; students who do not certify on the first attempt receive one remediation session before retesting.
3	Trade Mathematics for Marine Technicians	30	practice	Students will accurately solve marine service math problems involving unit conversion, ratio and proportion, torque specification, displacement calculation, gear ratio, and measurement with precision tools to within stated tolerances.	Work through an instructor-designed Marine Math Workbook covering 60 problems organized by topic—fraction/decimal conversion, metric-to-US unit conversion, percentage, area, volume (engine displacement), and torque—grading each section before moving to the next to build mastery progressively. Use a vernier caliper, outside micrometer, and feeler gauge to measure a set of ten labeled engine components (piston, wrist pin, bearing journal, valve clearance shim), record measurements to the correct decimal place, and compare results against a provided specification sheet to determine accept/reject. Solve five real-world marine scenarios—calculating the correct oil-to-fuel premix ratio for a two-stroke engine, determining gear ratio from a reduction gear spec, figuring a parts markup using a flat-rate labor guide, converting tightening specs between ft-lb and N·m, and computing battery reserve capacity—presented as shop work orders.	Marine Math Workbook (instructor-developed, keyed to marine applications), scientific calculators, 0–6 inch vernier calipers, 0–1 inch outside micrometers, feeler gauge sets, sample engine components for measurement, engine specification sheets, flat-rate labor guide excerpt, whiteboard	Students must score 80% or higher on each workbook section before proceeding; measurement lab is pass/fail requiring all ten measurements within ±0.001 inch of instructor master; scenario set scored as a graded quiz with 80% passing.
4	Reading Service Manuals, ABYC Standards & Parts Catalogs	20	theory	Students will locate specified technical data—torque values, wiring color codes, parts numbers, and applicable ABYC standard references—within manufacturer service manuals and parts catalogs within a set time limit.	Instructor demonstrates the anatomy of an outboard service manual (table of contents, general information, specifications section, wiring diagrams, exploded views, torque tables, troubleshooting charts) using a Yamaha or Mercury manual as the primary example; students annotate a provided index worksheet identifying where each information type lives. Complete a timed Scavenger Hunt: given twelve specific questions (e.g., 'What is the specified torque for the lower unit drain plug on this model?' 'Which wire color is the charging output?'), students locate and record the answer with page or figure number using both a printed service manual and the same manual in digital PDF form. Read a one-page excerpt from an ABYC standard relevant to the marine engine trade, identify the scope, applicable craft, and any specific technical requirement stated, then write a three-sentence plain-language summary and discuss how it would affect a repair decision on a customer boat.	Current outboard service manuals (Yamaha and Mercury, at least one per two students), ABYC standards excerpt packet (instructor-sourced, covering relevant engine and electrical standards), parts catalog (printed and online), tablets or lab computers for digital manual access, scavenger hunt worksheet	Scavenger Hunt scored at 80% correct answers with source cited; ABYC summary evaluated on a three-point rubric (accuracy of technical content, correct identification of scope, clarity of plain-language translation) with a minimum score of 2 of 3 on each criterion.
5	Digital Tools: Shop Software, Manufacturer Portals & Diagnostic Interfaces	20	lab	Students will navigate a marine shop management system to open and close a work order, access a manufacturer dealer portal to retrieve a technical service bulletin, and connect a diagnostic scan tool to an outboard engine to read and record fault codes.	Using a training instance of a marine shop management application (or a comparable point-of-sale/work-order system available to the program), students enter a simulated customer vehicle record, create a work order with labor and parts lines, and produce a printed estimate—mirroring the workflow described in the program's shop employer partners. Log into the Yamaha Marine or Mercury Marine dealer portal using program training credentials, search for the model and serial number of a shop outboard, locate the current technical service bulletin list, download one TSB, and write a one-paragraph summary of the required action. Connect a compatible marine diagnostic interface (e.g., Yamaha Diagnostic System or Mercury VesselView/CDS tool) to the shop outboard, retrieve any stored diagnostic trouble codes, record them with their description from the tool, and clear non-permanent codes under instructor supervision.	Lab computers with internet access, marine shop management software training account, Yamaha or Mercury dealer portal training credentials, compatible marine diagnostic interface and software, outboard engine on a test stand with a simulated fault code loaded by instructor, printer	Work order activity evaluated on a checklist: correct customer entry, accurate parts and labor lines, legible estimate—all three required to pass. TSB summary graded on accuracy (correct model applicability and action identified). Scan tool activity is pass/fail: correct DTC recorded with description, code cleared without creating new codes.
6	Technical Communication: Writing, Workplace Documents & Digital Correspondence	18	practice	Students will write a complete, accurate repair order narrative, compose a professional email to a parts supplier, and read and respond to a technical specification using correct grammar, trade terminology, and professional tone.	Given a brief scenario card describing the symptoms a customer reported and the findings from a mock inspection, students write a repair order narrative using correct marine trade terminology, active voice, and complete sentences—then trade papers with a peer for structured peer review against an instructor rubric before submitting a revised final draft. Draft a professional email to a fictional marine parts distributor requesting a back-ordered impeller kit, including part number, urgency, alternative part inquiry, and a courteous closing; instructor evaluates tone, completeness, and format against a professional email rubric. Read a two-page technical specification document and answer ten comprehension questions that require locating specific data, inferring meaning from context, and identifying the correct action to take—simulating the kind of reading required when consulting an ABYC standard or a service bulletin on the job.	Scenario cards for repair order exercise, professional email rubric, technical specification document (instructor-developed from marine content), peer-review worksheet, word processing software on lab computers, repair order blank forms	Repair order narrative scored on a four-criterion rubric (accuracy of technical content, use of trade terminology, grammar/mechanics, completeness) at 80% or higher; email rated pass/fail on professionalism rubric with all four required elements present; comprehension quiz at 80% or higher.
7	Career Readiness: Résumé, Job Application, Workplace Professionalism & Industry Pathways	16	field	Students will produce a trade-specific résumé and cover letter, complete a mock employment application, and demonstrate professional workplace behaviors—punctuality, appearance, communication—evaluated against criteria used by marine industry employers.	Using a résumé template and instructor coaching, each student drafts and revises a one-page résumé and a half-page cover letter targeting an entry-level marine technician position, incorporating any prior work experience, the program's credential pathway (ABYC, Yamaha/Mercury), and transferable skills; a career services or industry guest reviewer provides written feedback. Complete a realistic mock job application form for a fictitious marine dealership, then participate in a structured mock job interview (two students per industry-connected interviewer when possible) covering questions typical of marine service manager interviews—tool inventory, safety habits, learning from mistakes—with feedback provided on a standardized form. Attend (in person or virtually) a presentation by at least one working marine technician or service manager discussing career pathways—independent shops, OEM dealerships, yacht yards, military/government fleet positions, manufacturer field service rep roles—then write a one-page reflection connecting the presentation to the student's own career plan.	Résumé template and sample, cover letter template, mock job application form, mock interview question bank, industry guest contact list, career reflection worksheet, professional attire checklist (distributed one week in advance), video recording capability for optional self-review	Résumé and cover letter evaluated on a rubric (trade-relevant content, formatting, absence of errors, credential pathway included) requiring 80% or higher; mock interview scored by interviewer on a five-criterion behavioral rubric (communication, professionalism, content accuracy, enthusiasm, punctuality/appearance) with a passing average of 3 of 5 or higher on each criterion; career reflection graded complete/incomplete with all required elements present.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Safety & Regulatory Knowledge Exam	Written exam	25%	80% correct on a 50-question multiple-choice and short-answer exam	A closed-book written exam covering OSHA hazard categories, hierarchy of controls, lockout/tagout steps, SDS interpretation, PPE selection, and first aid/emergency response procedures as they apply to a marine engine service facility. Questions are drawn from OSHA 10 content and the marine-specific scenarios practiced in Lessons 1 and 2. Accuracy · Safety · Communication · Professionalism
Trade Math & Technical Reading Exam	Written exam	25%	80% correct on a 40-question exam combining calculation problems and document-interpretation questions	A timed closed-book exam in which students solve marine math problems (unit conversion, torque, displacement, gear ratio, premix ratio) and answer questions that require locating specific data in a provided service manual excerpt and parts catalog page. Measurement tool reading is tested with printed micrometer and caliper scale images. Accuracy · Safety · Communication · Professionalism
Digital Tools & Communication Portfolio	Project	25%	All four portfolio components scored at 80% or higher on their respective rubrics, with no component marked incomplete	Students submit a compiled portfolio containing: a completed and printed shop work order produced in the management software, a one-paragraph TSB summary with the source document attached, a final revised professional résumé and cover letter, and a screenshot or printout of a recorded diagnostic trouble code from the scan tool lab. Each component is evaluated on accuracy, completeness, and professional presentation. Accuracy · Safety · Communication · Professionalism
Career Readiness Oral Defense	Oral / panel	25%	Average score of 3 out of 5 or higher on each of five behavioral criteria, with no criterion scored below 2	A ten-minute structured oral interview conducted by an industry-connected evaluator (marine service manager or senior technician when available) in which each student presents their résumé, fields three to five behavioral interview questions, and explains how the ABYC and Yamaha/Mercury credentials they will pursue connect to their stated career goals. Evaluator scores communication clarity, trade knowledge demonstrated, professionalism, self-awareness, and goal specificity. Accuracy · Safety · Communication · Professionalism

TRN-MARI21-02 Trade course

2-Stroke and 4-Stroke Outboard Engine Systems

146 hr · ~~$2,100~~ COMPLIMENTARY

This course covers the design, diagnosis, and service of 2-stroke and 4-stroke outboard engines from powerhead to lower unit, with emphasis on manufacturer service procedures, precision measurement, and systematic troubleshooting. Students develop hands-on competence on actual outboard powerplants using industry-standard tools and factory service manuals, mapped directly to ABYC Marine Engine exam content areas and Yamaha/Mercury factory certification requirements.

Outcomes

Identify and explain the operating principles, components, and service intervals of both 2-stroke and 4-stroke outboard engine systems.
Perform precision measurements on powerhead components using micrometers, bore gauges, and feeler gauges, comparing results to factory service limits.
Diagnose fuel, ignition, compression, and cooling system faults on outboard engines using systematic test procedures and service data.
Remove, inspect, and reinstall a 2-stroke or 4-stroke outboard powerhead following factory torque sequences and reassembly specifications.
Execute safe fuel-system service, including carbureted and EFI/DEIS systems, while applying OSHA and ABYC fire and ventilation safety standards.
Document all inspection findings, measurements, and repairs on professional repair orders that meet ABYC and employer record-keeping expectations.

Course text

How the course runs. 12 blocks: Outboard Fundamentals: 2-Stroke vs. 4-Stroke Operating Principles; Shop Safety for Outboard Service: Fuel, Electrical, and Lifting Hazards; Precision Measurement and Fastener Torque Fundamentals; 2-Stroke Powerhead: Disassembly, Inspection, and Reassembly; 4-Stroke Powerhead: Valvetrain, Cylinder Head, and Compression Testing; Ignition System Theory, Testing, and Diagnosis; Carburetion: Service, Jetting, and Synchronization (2-Stroke Focus); Electronic Fuel Injection and Engine Management Systems; Cooling and Exhaust Systems: Inspection, Testing, and Water-Pump Service; Lower Unit: Gear Lube Service, Shift Mechanism, and Seal Replacement; Systematic Troubleshooting: No-Start, No-Spark, and Overheating Case Studies; Service Documentation, Repair Order Writing, and Credential Exam Review.

What competent looks like. Identify and explain the operating principles, components, and service intervals of both 2-stroke and 4-stroke outboard engine systems. Perform precision measurements on powerhead components using micrometers, bore gauges, and feeler gauges, comparing results to factory service limits. Diagnose fuel, ignition, compression, and cooling system faults on outboard engines using systematic test procedures and service data. Remove, inspect, and reinstall a 2-stroke or 4-stroke outboard powerhead following factory torque sequences and reassembly specifications. Execute safe fuel-system service, including carbureted and EFI/DEIS systems, while applying OSHA and ABYC fire and ventilation safety standards. Document all inspection findings, measurements, and repairs on professional repair orders that meet ABYC and employer record-keeping expectations.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Outboard Fundamentals: 2-Stroke vs. 4-Stroke Operating Principles	10	theory	Students will compare the thermodynamic and mechanical operating cycles of 2-stroke and 4-stroke outboard engines and identify the major component groups of each.	Annotate cross-section diagrams of a 2-stroke reed-valve engine and a 4-stroke SOHC outboard, labeling every major component and tracing the gas-flow path through each cycle. Watch and pause manufacturer training videos (Yamaha Outboard Technology, Mercury MerCruiser Service Training library), recording one key technical observation per segment in a lab notebook. Complete a 20-question comparison worksheet matching engine events (intake, compression, power, exhaust) to crankshaft position for both engine types, reviewing answers as a class.	Yamaha and Mercury factory service manuals (current model year), ABYC Standards & Technical Information Reports (relevant sections), engine cross-section wall charts, manufacturer training videos, lab notebooks	Students correctly label all major components on a blank diagram and answer 16 of 20 worksheet questions accurately (80% pass mark).
2	Shop Safety for Outboard Service: Fuel, Electrical, and Lifting Hazards	8	theory	Students will apply OSHA general industry standards, ABYC fire and ventilation requirements, and lockout/tagout procedures specific to outboard service environments before handling any engine.	Walk through the lab identifying all chemical hazards (gasoline, 2-stroke oil, gear lube, battery acid); locate SDS sheets and match each hazard to the correct PPE from the shop PPE station. Demonstrate a complete lockout/tagout sequence on an outboard mounted on a test stand: battery disconnect, fuel shutoff, tag application, and verification of zero-energy state. Role-play a scenario in which a cracked fuel line is discovered during inspection; students write a written hazard report and identify the correct fire extinguisher class and placement per ABYC guidelines.	OSHA 29 CFR 1910 lockout/tagout quick-reference card, ABYC E-11 and H-33 standards excerpts, SDS binder, Class B fire extinguisher (trainer), PPE (nitrile gloves, safety glasses, face shield, ear protection), fuel-shutoff valve trainer	Students pass a written 10-question safety quiz at 80% or better AND correctly demonstrate the lockout/tagout procedure without prompting (pass = zero critical errors).
3	Precision Measurement and Fastener Torque Fundamentals	10	demo	Students will use micrometers, telescoping bore gauges, feeler gauges, and click-type torque wrenches to measure outboard powerhead components and compare readings to factory service specifications.	Instructor demonstrates zeroing and reading an outside micrometer, then each student measures the same set of three worn and unworn piston pins, recording results in a spec comparison table. Students measure cylinder bore diameter at three depths and two axes using a telescoping gauge and micrometer, calculating taper and out-of-round values against factory specs from the service manual. Practice torquing M8 fasteners to a specified value using a click-type torque wrench, then verify with an instructor torque-verification wrench; repeat until three consecutive readings fall within ±10% of target.	0–1 inch and 1–2 inch outside micrometers, set of telescoping bore gauges, feeler gauge set, click-type torque wrench set (in-lb and ft-lb), torque-verification wrench, practice cylinder blocks, piston pin assortment, Yamaha/Mercury factory service manual spec tables	Each student's recorded measurements fall within ±0.001 inch of instructor reference measurements; torque verification within ±10% on three consecutive attempts (80% task completion pass).
4	2-Stroke Powerhead: Disassembly, Inspection, and Reassembly	16	lab	Students will disassemble a 2-stroke outboard powerhead to the crankshaft level, inspect all wear items against service limits, and reassemble using factory torque sequences and sealant specifications.	Following the factory service manual procedure, students in pairs disassemble a V4 or inline 2-stroke powerhead, organizing all hardware in labeled containers and photographing each stage for their lab log. Inspect reed valves for warpage using a straight edge and feeler gauge, measure crankshaft bearing surfaces for wear, and check piston ring end gaps; record all measurements on a provided spec sheet and mark each item pass/fail. Reassemble the powerhead applying correct sealant (Yamaha Gasket Maker or Mercury Quicksilver equivalent), install head bolts using a torque wrench in the factory cross-pattern sequence, and complete a post-assembly checklist.	Donated or school-owned 2-stroke outboard powerhead on engine stand, full socket/wrench set (metric and SAE), service manual, reed valve straight-edge and feeler gauge, dial indicator, OEM or equivalent gasket sealant, torque wrench, parts tray set, lab log forms, camera or smartphone for photo documentation	Completed spec sheet with all measurements recorded; reassembly torque pattern verified by instructor; lab log photos submitted — pass requires all critical fasteners at factory torque (zero skipped steps per checklist).
5	4-Stroke Powerhead: Valvetrain, Cylinder Head, and Compression Testing	16	lab	Students will perform a cylinder-head service on a 4-stroke outboard including valve clearance measurement and adjustment, head-gasket inspection, and a complete compression and leak-down test with results interpreted against factory standards.	Remove and disassemble the cylinder head from a 4-stroke outboard (F115 or 4-stroke equivalent), measuring valve clearance with feeler gauges and recording whether each valve requires shim adjustment per the factory spec. Inspect the head gasket surface with a straight edge, measure warpage, and determine whether resurfacing or replacement is required; document the decision with supporting measurements in the lab log. Perform a dry and wet compression test and a cylinder leak-down test on each cylinder; interpret results (compression values, leak-down percentage, and leak location) to diagnose piston rings, valves, or head-gasket condition.	4-stroke outboard engine on stand (F115 class or similar), feeler gauge set, torque wrench, straight edge and feeler gauge for surface check, compression gauge set, cylinder leak-down tester with shop air, shim kit (if available), cylinder head gasket set, factory service manual	Valve clearances recorded and compared to spec; compression and leak-down results interpreted correctly in written diagnosis on lab log — pass requires accurate diagnosis on at least 75% of cylinders and 80% on written interpretation questions.
6	Ignition System Theory, Testing, and Diagnosis	12	demo	Students will explain CDI and TCI/coil-over-plug ignition system operation, use a digital multimeter and peak-reading voltmeter to test charging coils, trigger coils, CDI units, and ignition coils, and interpret results against factory test values.	Trace the ignition system schematic from the charging coil through the CDI/ECM to the spark plug on both a 2-stroke and a 4-stroke outboard wiring diagram, identifying each component and expected signal flow. Using a digital multimeter, measure stator charging coil resistance, trigger coil resistance, and primary/secondary coil resistance on bench components; compare to factory spec and mark serviceable or replace. Use a peak-reading voltmeter to capture CDI output voltage on a running 2-stroke engine at idle and at 2500 RPM; record both readings and use the ignition diagnostic flowchart in the service manual to reach a pass/fail conclusion.	Digital multimeter (FLUKE or equivalent), peak-reading voltmeter adapter (CDI Electronics or equivalent), ignition component bench set (stator, trigger coil, coil, CDI unit), wiring diagram sheets from Yamaha/Mercury service manual, running 2-stroke outboard on test stand with flushing ear muffs and water supply	All resistance and peak-voltage readings recorded; diagnosis matches instructor-planted fault on at least one component — pass = correct test sequence followed and correct diagnosis reached with supporting data (80% task score).
7	Carburetion: Service, Jetting, and Synchronization (2-Stroke Focus)	12	lab	Students will remove, disassemble, clean, jet, and reinstall a 2-stroke outboard carburetor, then synchronize multiple carburetors on a multi-carb powerhead using factory synchronization tools and procedures.	Remove a carb bank from a 2-stroke outboard, completely disassemble, clean passages with carburetor dip tank and compressed air, measure float height, and install a rebuild kit following factory float and needle settings. Reinstall carburetors, set pilot screws to factory base setting (turns out), and connect a vacuum gauge set to balance intake vacuum across carbs on a multi-carb engine at idle; adjust until all carbs are within factory balance specification. Document the complete service on a shop repair order including parts replaced, float height recorded, pilot screw turns out, and vacuum balance readings — compare initial and final idle RPM and mixture before/after sync.	2-stroke outboard with 2- or 3-carb bank on test stand, carburetor rebuild kit(s), carburetor dip tank, compressed air wand, float height gauge/drill bit set, vacuum gauge/synchronizer set, pilot screw tool set, factory service manual, repair order forms, eye protection, nitrile gloves	Carburetor passes bench flow test (no blocked passages), float height within factory spec ±0.5 mm, vacuum balance within factory tolerance at idle, and repair order complete — instructor verifies all four criteria for pass.
8	Electronic Fuel Injection and Engine Management Systems	12	demo	Students will describe the operation of an outboard EFI or direct-injection fuel system, use a factory or compatible scan tool to retrieve DTCs and read live data, and perform a fuel-pressure test on an injected outboard.	Connect a Yamaha Diagnostic System (YDS) or Mercury Smartcraft diagnostic interface to an injected outboard; navigate to live data and record coolant temperature, MAP sensor voltage, TPS voltage, and injector pulse width at idle. Plant an instructor-introduced fault (simulated coolant sensor open circuit); students retrieve the DTC, use the diagnostic flowchart in the service manual to isolate the faulty sensor, and verify repair by clearing the code and confirming no reoccurrence. Perform a fuel-rail pressure test using a factory-compatible fuel pressure gauge: record static pressure, key-on/engine-off pressure, idle pressure, and pressure drop-off after shutoff; compare all values to factory specifications and record pass/fail.	EFI or direct-injection outboard on test stand (F150 or similar, or Mercury Verado/OptiMax representative), Yamaha Diagnostic System (YDS) laptop dongle or Mercury CDS/BUDS interface, factory scan tool or compatible laptop software, fuel pressure gauge set (rated for marine EFI pressure), wiring diagrams and EFI section of service manual, fault-planting wiring harness adapter	Student correctly identifies DTC and traces fault to component per flowchart; fuel-pressure readings recorded and compared to spec — pass = correct fault isolation AND all four pressure readings documented with correct pass/fail determination.
9	Cooling and Exhaust Systems: Inspection, Testing, and Water-Pump Service	12	lab	Students will inspect and service an outboard water-pump assembly, pressure-test the cooling system, and inspect thermostat and tell-tale operation, identifying worn or failed components before they cause powerhead overheating.	Disassemble the lower-unit/mid-section water pump on a full outboard, inspect the impeller for cracked or deformed vanes, measure housing wear ring diameter, and reinstall a new impeller kit following factory orientation and sealant procedures. Perform a thermostat bench test by suspending the thermostat in a measured-temperature water bath and verifying opening temperature against factory specification using a calibrated thermometer. Run the outboard on a test stand with a hose connected to the flushing port; monitor tell-tale stream, verify thermostat opens within 10°F of spec using an infrared thermometer on the thermostat housing, and document findings on the repair order.	Outboard engine with lower unit and water pump (full engine preferred), water-pump impeller kit (OEM), housing wear ring, RTV marine sealant, water bath container and heat source for thermostat test, calibrated thermometer, infrared thermometer, test stand with flushing ear muffs or flush port, repair order forms, service manual	Impeller installed per factory orientation verified by instructor; thermostat opening temperature within ±5°F of spec; tell-tale flow confirmed on running engine — all three pass criteria must be met.
10	Lower Unit: Gear Lube Service, Shift Mechanism, and Seal Replacement	12	lab	Students will drain and inspect gear lube for contamination, disassemble and inspect the shift mechanism and forward/reverse gear set, and replace lower-unit seals following factory clearance and preload procedures.	Drain gear lube into a white pan; inspect color, smell, and presence of water or metallic particles; record observations and determine if findings indicate normal wear or a seal failure requiring immediate repair. Disassemble the lower unit to expose the forward gear, pinion gear, and dog clutch; measure backlash with a dial indicator and compare to factory specification; inspect shift shaft cam, detent spring, and plunger for wear. Replace the driveshaft upper seal and propeller shaft seals; reassemble the lower unit, refill with manufacturer-specified gear lube (type and quantity per service manual), and pressure-test the lower unit to factory specification before installation.	Complete outboard lower unit on bench stand, drain pan, gear lube sample collection pan, dial indicator with magnetic base, lower-unit seal kit, bearing preload shim set, factory-specified gear lube, hand pump gear-lube injector, lower-unit pressure test kit, torque wrench, service manual, repair order forms	Gear lube inspection documented; backlash measurement recorded vs. spec; pressure test passed (no pressure drop over hold period per factory spec) — all three criteria required for pass.
11	Systematic Troubleshooting: No-Start, No-Spark, and Overheating Case Studies	10	practice	Students will apply a documented, systematic diagnostic process to solve instructor-planted no-start, no-spark, and overheating faults on outboard engines, completing a written repair order for each case.	Given a no-start outboard with an unknown fault, students complete a 6-step diagnostic worksheet (verify complaint, gather data, narrow fault tree, test, repair, verify repair) before touching any component; instructor reviews worksheet before testing begins. Rotate through three fault stations (no spark on one cylinder, stuck-closed thermostat overheating fault, and a flooding carburetor causing a no-start); each student independently diagnoses and documents each fault with test results and corrective action. Debrief as a class: each student presents one fault diagnosis to the group, explaining test sequence, data collected, and repair; peers and instructor provide structured feedback using a diagnostic rubric.	Three outboards with instructor-planted faults on test stands, diagnostic worksheets, repair order forms, multimeter, compression tester, infrared thermometer, fuel pressure gauge, peak-reading voltmeter, service manuals for each engine, diagnostic rubric	Each repair order must show a complete documented test sequence; fault correctly identified and verified after repair on at least 2 of 3 stations — pass = correct diagnosis supported by test data on 2/3 stations.
12	Service Documentation, Repair Order Writing, and Credential Exam Review	16	theory	Students will complete professional repair orders for all work performed in the course, review ABYC Marine Engine and Yamaha/Mercury exam content areas relevant to outboards, and pass a 60-question practice exam at 75% or better.	Review the complete set of lab logs and repair orders from Lessons 4–10; rewrite any incomplete or inaccurate repair orders to professional standard (complaint–cause–correction format, parts listed with part numbers, labor time estimated), and submit a corrected portfolio. Instructor-led structured review of ABYC Marine Engine exam domains as they apply to outboard systems: engine systems, fuel systems, electrical systems, and general maintenance; students complete a domain-by-domain gap-identification checklist. Students sit a 60-question timed practice exam covering all outboard content from the course, then self-score using the answer key, identify weak domains, and complete a 30-minute targeted review on their two lowest-scoring areas.	Student lab log portfolios, repair order forms (electronic or paper), ABYC Standards reference set, Yamaha Marine Technical Academy and Mercury Marine Technician Certification study materials, 60-question practice exam (instructor-developed, mapped to ABYC/Yamaha-Mercury domains), answer key	Repair order portfolio accepted (all complaint–cause–correction fields complete, no blank measurement fields); practice exam score of 75% or higher — both criteria must be met for lesson pass.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Outboard Systems Knowledge Exam	Written exam	25%	75% (45 of 60 questions correct)	A 60-question multiple-choice and short-answer written exam covering 2-stroke and 4-stroke operating principles, ignition system theory, fuel system operation (carbureted and EFI), cooling system function, lower-unit theory, and systematic diagnostic reasoning, mapped to ABYC Marine Engine and Yamaha/Mercury factory exam content areas. Standard met · Safety · Time · Quality/finish · Documentation
Powerhead Service Skills Demonstration	Skills demonstration	45%	Pass on all critical steps; no more than 2 minor deductions on a 20-point rubric (minimum 16/20)	Each student independently performs an instructor-assigned powerhead task — either valve-clearance adjustment on a 4-stroke or reed-valve inspection and impeller replacement on a 2-stroke — within a set time limit, scored on correct tool selection, measurement accuracy, torque procedure, and work quality against a structured rubric. Standard met · Safety · Time · Quality/finish · Documentation
Lab Log and Repair Order Portfolio	Log	15%	All 8 required lab entries submitted; average score of 80% across entries on the portfolio rubric	Students submit a complete portfolio of lab log entries and repair orders from Lessons 4 through 11, each showing: documented measurements compared to factory specs, complaint–cause–correction repair order format, correct part numbers or descriptions, and photo documentation of key disassembly stages. Standard met · Safety · Time · Quality/finish · Documentation
Safety Compliance Check	Safety audit	15%	100% on all critical safety behaviors (zero tolerance for critical violations); no more than 1 minor procedural reminder across the entire practical portion of the course	Instructor observes and records each student's safety behaviors throughout all lab and demo lessons using a running safety checklist covering PPE use, lockout/tagout execution, fuel-handling procedures, fire extinguisher location awareness, and proper lifting and ergonomic practices in the outboard service environment. Standard met · Safety · Time · Quality/finish · Documentation

TRN-MARI21-03 Trade course

Inboard and Sterndrive Systems

146 hr · ~~$2,100~~ COMPLIMENTARY

This course covers the theory, diagnosis, and service of inboard gasoline engines and sterndrive (inboard/outboard) propulsion systems, including MerCruiser-style and Volvo Penta-style drive units. Students develop hands-on competence in engine removal, overhaul, sterndrive disassembly, lubrication systems, cooling, and troubleshooting to the standards required by ABYC and factory service procedures.

Outcomes

Explain the operating principles and power flow of inboard and sterndrive propulsion systems, including alpha and bravo-style drive units.
Perform a complete sterndrive disassembly, inspection, and reassembly using manufacturer torque specifications and service manuals.
Diagnose and repair raw-water and closed-loop cooling system faults on inboard marine engines.
Service inboard engine lubrication, oil, and sealing systems to factory specifications.
Apply ABYC standards and OSHA lockout/tagout procedures throughout all inboard and sterndrive service tasks.
Interpret diagnostic data from compression, cylinder leakdown, and oil pressure tests to write a documented repair order.

Course text

How the course runs. 12 blocks: Inboard and Sterndrive System Overview; Safety, LOTO, and ABYC Standards for Inboard Work; Inboard Engine Construction and Identification; Engine Removal, Mounts, and Alignment; Sterndrive Removal and Transom Seal Inspection; Sterndrive Disassembly and Gear Case Overhaul; Inboard Cooling Systems: Raw Water and Closed Loop; Inboard Lubrication, Oil Systems, and Seals; Compression and Cylinder Leakdown Testing; Shift and Throttle Linkage, Trim Systems, and Controls; Troubleshooting Inboard and Sterndrive Faults; Service Documentation, Repair Orders, and Final Practical Review.

What competent looks like. Explain the operating principles and power flow of inboard and sterndrive propulsion systems, including alpha and bravo-style drive units. Perform a complete sterndrive disassembly, inspection, and reassembly using manufacturer torque specifications and service manuals. Diagnose and repair raw-water and closed-loop cooling system faults on inboard marine engines. Service inboard engine lubrication, oil, and sealing systems to factory specifications. Apply ABYC standards and OSHA lockout/tagout procedures throughout all inboard and sterndrive service tasks. Interpret diagnostic data from compression, cylinder leakdown, and oil pressure tests to write a documented repair order.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Inboard and Sterndrive System Overview	10.5	theory	Students will identify the major components and power-flow path of inboard and sterndrive propulsion systems and distinguish between common drive configurations.	Label a cutaway diagram of a sterndrive unit, tracing power flow from crankshaft to propeller and identifying transom plate, gimbal housing, drive shaft, and gear cases. Compare alpha-style and bravo-style drives side-by-side using manufacturer service manuals, listing design differences in upper and lower gear cases. Watch a narrated video of a factory sterndrive installation, then answer a 15-question identification quiz covering part names and functions.	MerCruiser and Volvo Penta service manuals (current editions), cutaway display drive unit, ABYC standards reference, whiteboard diagrams	Score 75% or higher on a 20-question component-identification quiz; instructor verifies correct labeling of all major assemblies on the diagram.
2	Safety, LOTO, and ABYC Standards for Inboard Work	10.5	theory	Students will apply OSHA lockout/tagout procedures and identify applicable ABYC standards before beginning any inboard or sterndrive service task.	Demonstrate a six-step lockout/tagout sequence on a dockside inboard test boat: disconnect battery, close sea cocks, tag fuel shutoff, apply locks, verify zero-energy state, and document the lockout. Read the relevant ABYC engine-system standards and summarize in writing the key installation and service requirements for fuel, ignition, and ventilation systems. Role-play a shop safety audit in pairs: one student plays the technician, one plays the inspector, using a printed checklist of required PPE, ventilation, and fire-suppression items.	LOTO kit (locks, tags, hasp), ABYC standards reference, shop safety checklist, PPE (gloves, safety glasses, hearing protection), inboard test boat	100% correct completion of a witnessed LOTO procedure on the test boat; written summary of ABYC standards earns instructor sign-off; zero unsafe actions during role-play audit.
3	Inboard Engine Construction and Identification	10.5	demo	Students will identify the block, head, rotating assembly, valvetrain, and accessory components of a marine-adapted automotive-block inboard engine and explain how marine adaptations differ from automotive use.	Instructor disassembles a long-block display engine while narrating each component's marine-specific feature; students record differences (flame-arresting carburetor or EFI, raw-water-cooled exhaust manifold, heat exchanger) on a guided worksheet. Students locate and record model, serial, and displacement information from engine data plates on three different inboard engines in the shop, then look up the corresponding service manual section. Match ten engine components to their function in a card-sort exercise, then arrange them in disassembly order.	Display long-block engine, three shop inboard engines (varying makes), manufacturer data plates, service manuals, guided worksheet	Complete and accurate guided worksheet with instructor sign-off; correct identification of all ten components in card sort (100%).
4	Engine Removal, Mounts, and Alignment	15	lab	Students will safely remove an inboard engine from a test vessel, record mount and coupling measurements, and reinstall the engine within manufacturer alignment tolerance.	Perform a pre-removal documentation exercise: photograph and label all hose, wiring, and coupling connections before any fastener is loosened. Remove the engine using the shop overhead hoist; measure coupling face runout and shaft alignment with a dial indicator before unbolting the coupler, recording all readings on a lab form. Reinstall and realign the engine, shimming mounts as needed to achieve coupling face runout within the manufacturer's specified tolerance; verify with instructor before final torque.	Inboard test vessel, engine hoist and lifting sling, dial indicator with magnetic base, alignment tools, torque wrench set, service manual, lab documentation form	Lab form completed with all pre- and post-removal measurements; coupling runout within manufacturer specification confirmed by instructor; all fasteners torqued to spec and documented.
5	Sterndrive Removal and Transom Seal Inspection	13	lab	Students will remove a sterndrive unit from the transom, inspect the bellows, gimbal bearing, and transom plate seals, and document findings on a repair order.	Follow the service manual procedure to remove the sterndrive, using the manufacturer's special tool (or approved equivalent) to support the drive and avoid damaging the shift cable during extraction. Inspect the U-joint bellows, exhaust bellows, and trim cylinder bellows for cracking, delamination, and clamp condition; photograph defects and record condition on a repair order using standard service abbreviations. Inspect the gimbal bearing for roughness and side play using the manual procedure; record findings and write a recommendation (replace or reuse) with justification on the repair order.	Sterndrive unit on transom (test boat), drive removal tool, inspection light, digital camera or phone, service manual, repair order forms, PPE	Completed repair order with accurate condition descriptions and correct go/no-go decisions confirmed by instructor; no damage to bellows or cables during removal (instructor observation).
6	Sterndrive Disassembly and Gear Case Overhaul	17	lab	Students will disassemble a sterndrive upper and lower gear case, measure bearings and gears to specification, and reassemble with correct preload and torque.	Disassemble the lower gear case following the service manual sequence; lay parts on a numbered bench mat and photograph each stage to create a visual disassembly record. Measure pinion gear backlash shims, check bearing races for wear using a micrometer and feeler gauges, and record all measurements on a spec sheet comparing against service limits. Reassemble the gear case using the correct shim pack and new seals; use a bearing driver set to seat bearings squarely, torque all fasteners to spec, and perform a completed-assembly check with the instructor.	Sterndrive unit for overhaul, bearing driver set, inch-pound and foot-pound torque wrenches, micrometer, feeler gauges, bench mat, service manual, spec sheet, new seal and gasket kit	All measurements recorded and within spec or flagged as out-of-spec with correct disposition; reassembly torque values verified by instructor; no missing or reversed seals (inspector checklist, 100% compliance).
7	Inboard Cooling Systems: Raw Water and Closed Loop	13	demo	Students will trace the coolant flow path in both raw-water and closed-loop (freshwater) inboard cooling systems and perform a thermostat and impeller replacement.	Using a system diagram and the actual engine, trace and describe the raw-water flow path from sea cock through strainer, impeller pump, heat exchanger, manifold, and overboard exhaust with the engine off and LOTO applied. Replace the raw-water impeller on the demonstration engine: remove the pump cover, extract the impeller without tearing vanes, inspect housing for scoring, install a new impeller in the correct rotational orientation, and reassemble. Replace the thermostat on the demonstration engine, test it in a pot of water heated to the specified opening temperature using a thermometer, and confirm opening temperature before installation.	Inboard demonstration engine, cooling system flow diagram, raw-water impeller kit, thermostat, hot plate, thermometer, torque wrench, LOTO kit, service manual	Correct impeller orientation and full vane count confirmed by instructor before cover installation; thermostat opens within 5°F of rated temperature recorded on a signed lab sheet; LOTO maintained throughout (instructor observation).
8	Inboard Lubrication, Oil Systems, and Seals	10.5	lab	Students will perform an oil pressure test, change engine and sterndrive gear lubricant to specification, and replace a rear main seal on a practice engine.	Install a calibrated oil pressure gauge on the test engine, run the engine to operating temperature, and record idle and high-idle oil pressure; compare readings to the service manual specification and document results. Drain and refill the sterndrive lower gear oil, inspecting the drain plug magnetic tip for metallic debris and noting quantity and color of old oil; refill to the correct level using the specified lubricant grade. Replace the rear crankshaft seal on a practice short-block using a seal driver to seat the seal square and flush; verify correct depth with a depth gauge before reassembly.	Test engine with oil pressure port, calibrated oil pressure gauge, drain pan, sterndrive gear lube pump bottle, magnetic drain plug, rear main seal, seal driver set, depth gauge, service manual, PPE	Oil pressure readings within manufacturer specification, recorded and signed by instructor; gear lube drained and refilled to correct level verified by instructor; seal seated square and to correct depth (depth gauge measurement recorded).
9	Compression and Cylinder Leakdown Testing	10.5	lab	Students will perform compression and cylinder leakdown tests on an inboard engine, interpret results to locate internal faults, and document findings on a repair order.	Perform a dry and wet compression test on a four- or six-cylinder inboard engine: record all cylinder readings, note the percentage of variation between cylinders, and identify any cylinder falling below the manufacturer's minimum. Perform a cylinder leakdown test on the same engine using a regulated leakdown tester at TDC compression stroke for each cylinder; listen at the oil fill, exhaust, and air cleaner to identify whether leakage is past rings, valves, or head gasket. Write a complete repair order narrative summarizing test results, likely fault(s), and recommended corrective action using standard service abbreviations; compare findings with a classmate and discuss.	Inboard test engine, compression tester, cylinder leakdown tester with regulated air supply, socket set for spark plug removal, service manual with compression specifications, repair order forms	All cylinder compression values and leakdown percentages recorded accurately; correct diagnosis of seeded fault (instructor verified); repair order narrative earns instructor sign-off for accuracy and completeness.
10	Shift and Throttle Linkage, Trim Systems, and Controls	13	practice	Students will adjust sterndrive shift cable geometry and trim cylinder synchronization to achieve smooth, neutral-detent engagement according to the service manual procedure.	Remove, measure, and reinstall the shift cable on a sterndrive unit, setting the cable end length to the specification in the service manual and verifying correct neutral detent engagement before and after adjustment. Bleed the power-trim hydraulic system on a test unit following the manufacturer's bleed sequence; check fluid level and inspect hose fittings for seeping; document results. Perform a full throttle-and-shift function check at idle on a dock or in a flush tank: cycle through forward, neutral, and reverse confirming smooth engagement and no gear clash; record observations on a checklist.	Sterndrive with shift cable installed, service manual, cable adjustment tool, hydraulic fluid (type per manufacturer), power-trim pump, function-test checklist, flush tank or dock	Neutral detent adjustment verified by instructor with no gear clash in forward or reverse; hydraulic system bled with no air in lines confirmed by smooth trim travel; checklist completed with instructor sign-off.
11	Troubleshooting Inboard and Sterndrive Faults	13	practice	Students will apply a systematic diagnostic process to identify and document the root cause of three instructor-seeded inboard or sterndrive faults.	Using the manufacturer's diagnostic flowchart, work through an overheating complaint seeded by the instructor (such as a blocked raw-water strainer or failed impeller); document each test step and result on a diagnostic worksheet before naming the cause. Diagnose a seeded no-start or rough-running condition (ignition, fuel delivery, or compression related) using test instruments; record readings and compare against specifications before writing a root-cause statement. Diagnose a seeded sterndrive fault (such as gear noise, fluid leak, or failure to shift into gear) by inspection and measurement; write a repair recommendation with estimated parts and labor time using a flat-rate manual.	Inboard and sterndrive test platforms with seeded faults, multimeter, vacuum/fuel pressure gauge, stethoscope, diagnostic flowcharts, flat-rate labor manual, diagnostic worksheets	Correct root-cause identification for all three seeded faults confirmed by instructor; diagnostic worksheet entries show logical step-by-step reasoning; repair recommendation matches actual fault (100% accuracy on fault identification).
12	Service Documentation, Repair Orders, and Final Practical Review	9.5	practice	Students will complete a shop-standard repair order package for a composite inboard/sterndrive service scenario and demonstrate readiness for the course skills assessment.	Given a customer complaint narrative, write a complete repair order from write-up through cause, correction, and parts list using standard labor abbreviations and parts nomenclature, cross-referencing the service manual parts microfiche. Review the course's key torque specifications, seal orientations, and alignment tolerances by completing a 30-question written practice test under timed conditions, then self-check against an answer key. Pair with a classmate for a mutual walk-through of the sterndrive assembly station: each student explains the function of every major component and the consequence of incorrect assembly to their partner, then switches roles.	Blank repair order forms, parts microfiche or digital parts catalog, service manuals, practice test with answer key, sterndrive assembly display	Repair order is complete, accurate, and uses correct abbreviations, earning instructor sign-off; practice test score of 75% or higher; partner walk-through demonstrates accurate explanations confirmed by instructor observation.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Inboard/Sterndrive Systems Knowledge Exam	Written exam	25%	75% or higher (38 of 50 questions correct)	A 50-question written exam covering inboard engine construction, sterndrive drive configurations, cooling system operation, lubrication systems, diagnostic interpretation, and ABYC standards as addressed throughout the course. Questions are drawn from lesson content and mapped to ABYC Marine Engine credential exam topic areas including engine systems, cooling, and propulsion drives. Standard met · Safety · Time · Quality/finish · Documentation
Sterndrive Removal and Reassembly Skills Demonstration	Skills demonstration	45%	Pass requires correct completion of all critical steps (zero critical errors) and 85% or higher on the full rubric	Each student independently removes a sterndrive unit, inspects the bellows and gimbal bearing, disassembles and re-seals the lower gear case, and reinstalls the drive to manufacturer specification while maintaining LOTO and PPE compliance throughout. The instructor scores performance on a rubric covering safety practices, procedural accuracy, torque verification, and repair order documentation. Standard met · Safety · Time · Quality/finish · Documentation
Lab Log Portfolio	Log	15%	All 12 lab and practice lesson forms submitted; each form signed by instructor; average data accuracy score of 80% or higher across all entries	Students maintain a sequential lab log containing the completed worksheets, spec sheets, diagnostic forms, and repair orders from every hands-on lesson in the course. The portfolio demonstrates consistent application of measurement, documentation, and diagnostic skills and is reviewed holistically at the end of the course. Standard met · Safety · Time · Quality/finish · Documentation
Safety and LOTO Compliance Check	Safety audit	15%	100% correct on all critical LOTO steps; zero unsafe acts observed; any single critical error results in automatic re-check before skills demo may proceed	Before the skills demonstration assessment begins, the instructor conducts a dedicated safety check in which the student must correctly apply the full LOTO sequence on the test vessel, select and wear required PPE for the task, and verbally identify the ventilation requirement and fire hazard controls for inboard fuel system work. This check is a prerequisite for the skills demonstration and is scored pass/fail. Standard met · Safety · Time · Quality/finish · Documentation

TRN-MARI21-04 Trade course

Fuel Systems & Marine Electrical

146 hr · ~~$2,100~~ COMPLIMENTARY

This course develops competency in diagnosing, servicing, and repairing marine fuel delivery systems—carbureted and electronic fuel injection—and marine electrical systems including charging, ignition, starting, and accessory circuits. Students apply ABYC E-series and A-series electrical standards and ABYC H-series fuel system standards throughout. Lessons integrate safe handling of flammable fuels, lockout/tagout, and multimeter/oscilloscope use to build skills directly assessed on the ABYC Marine Engine credential exam.

Outcomes

Diagnose and repair carbureted and EFI fuel delivery faults on outboard and inboard marine engines using manufacturer service data and pressure/volume testing.
Inspect, service, and pressure-test marine fuel tanks, lines, fittings, and vent systems to ABYC H-24 and H-33 standards.
Test and service marine battery banks, charging systems, and starting circuits, recording findings against ABYC E-10 standards.
Trace, test, and repair open, short, and high-resistance faults in marine DC accessory and ignition circuits using wiring diagrams, a digital multimeter, and an oscilloscope.
Select, size, and install marine-grade wire, terminals, fuses, and circuit breakers in compliance with ABYC E-11 standards.
Complete repair orders, wiring diagrams, and safety checklists that document compliance with applicable ABYC standards and OSHA 29 CFR 1910.303 electrical safety requirements.

Course text

How the course runs. 12 blocks: Marine Fuel System Safety & ABYC Standards Overview; Fuel Tanks, Lines, Fittings & Vent Systems; Carburetor Theory, Disassembly & Service; Electronic Fuel Injection (EFI) Fundamentals & Sensor Testing; Fuel Pressure, Volume & Injector Testing; Marine Battery Types, Testing & ABYC E-10 Compliance; Marine Charging Systems: Alternators & Stators; Starting Circuits, Solenoids & Relays; Marine Wiring: ABYC E-11 Standards, Wire Sizing & Termination; Circuit Protection, Fusing & Accessory Circuit Wiring; Ignition System Testing & Electronic Diagnostics; Integrated Fuel & Electrical System Diagnosis Capstone Lab.

What competent looks like. Diagnose and repair carbureted and EFI fuel delivery faults on outboard and inboard marine engines using manufacturer service data and pressure/volume testing. Inspect, service, and pressure-test marine fuel tanks, lines, fittings, and vent systems to ABYC H-24 and H-33 standards. Test and service marine battery banks, charging systems, and starting circuits, recording findings against ABYC E-10 standards. Trace, test, and repair open, short, and high-resistance faults in marine DC accessory and ignition circuits using wiring diagrams, a digital multimeter, and an oscilloscope. Select, size, and install marine-grade wire, terminals, fuses, and circuit breakers in compliance with ABYC E-11 standards. Complete repair orders, wiring diagrams, and safety checklists that document compliance with applicable ABYC standards and OSHA 29 CFR 1910.303 electrical safety requirements.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Marine Fuel System Safety & ABYC Standards Overview	10.5	theory	Students will identify marine fuel system hazards, required PPE, and applicable ABYC H-series standards and explain how each controls a specific risk.	Annotate a printed marine fuel system schematic, labeling each component and the ABYC standard section that governs it. Complete a written hazard-identification exercise on a mock boat layout, marking vapor accumulation zones, ignition sources, and required ventilation paths. Group discussion and quiz on OSHA requirements for flammable liquid handling in marine service facilities, lockout/tagout procedures for fuel systems, and correct fire extinguisher selection.	ABYC H-24, H-25, H-33 standards; OSHA 29 CFR 1910 flammable liquids reference; nitrile gloves, safety glasses, fire extinguisher demo unit; dry-erase fuel system diagrams	Written 20-question quiz on hazards, PPE selection, and standard references; passing score 75% or higher.
2	Fuel Tanks, Lines, Fittings & Vent Systems	12.5	lab	Students will inspect a portable and an integral marine fuel tank, test fuel lines and fittings for leaks and condition, and verify vent system compliance with ABYC H-24.	Perform a visual and pressure-decay test on an outboard portable fuel tank and hose assembly, recording results on a structured inspection form. Disassemble, inspect, and reassemble a fuel connector and primer bulb, checking for cracks, hardness, and correct check-valve operation. Trace and pressure-test the vent line on a bench-mounted integral tank mockup, verifying vapor separator and anti-siphon valve function.	Portable outboard fuel tank; integral tank bench mockup; low-pressure fuel test kit (0–15 psi); ABYC H-24 standard; nitrile gloves; safety glasses; shop fire extinguisher	Completed inspection form with all test results entered; no missed defects on instructor-seeded fault tank; instructor sign-off required to pass.
3	Carburetor Theory, Disassembly & Service	12.5	demo	Students will disassemble, clean, measure, and reassemble a marine carburetor using manufacturer specifications and adjust idle mixture and speed to spec.	Watch instructor disassembly of a two-barrel marine carburetor with commentary on each circuit's function; students identify circuits on an exploded-view diagram. Students disassemble their own carburetor on the bench, cleaning all passages with carburetor cleaner and compressed air, then mic float and needle dimensions against service data. Reassemble, install on a bench engine, start, and adjust idle mixture screw and throttle stop to manufacturer RPM spec using a shop tachometer.	Yamaha or Mercury outboard bench engine; carburetor rebuild kit; carburetor cleaner; compressed air; micrometer; shop tachometer; manufacturer service manual; nitrile gloves; safety glasses; fire extinguisher	Engine idles within ±50 RPM of manufacturer spec; instructor checks float level measurement recorded on lab sheet; pass requires both engine start and correct measurement.
4	Electronic Fuel Injection (EFI) Fundamentals & Sensor Testing	14.5	theory	Students will explain the operating principles of a marine EFI system and correctly test MAP, TPS, IAT, and CTS sensors using a digital multimeter and scan tool.	Read the EFI overview chapter from the Yamaha or Mercury service manual; complete a component-identification worksheet matching sensor names to locations on a labeled engine photo. Instructor-led demo of scan tool live-data interpretation; students record baseline sensor values on a running bench engine and flag any out-of-range readings. Using back-probe leads and a digital multimeter, students perform voltage and resistance tests on each sensor against service manual specifications, documenting findings on a diagnostic worksheet.	EFI-equipped outboard bench engine; digital multimeter; compatible marine scan tool; manufacturer EFI service manual; back-probe test leads; safety glasses	Diagnostic worksheet completed with measured vs. spec values for all four sensor types; all readings within 10% of accepted range for a known-good engine; instructor reviews for accuracy.
5	Fuel Pressure, Volume & Injector Testing	12.5	lab	Students will use a fuel pressure gauge and graduated cylinder to test fuel pump pressure and volume, and perform a balance-rate and injector pattern test using a scan tool.	Install fuel pressure gauge in the Schrader port of the EFI bench engine, record static and running pressure, and compare to manufacturer spec. Relieve system pressure safely, then perform a timed volume test into a graduated cylinder to verify pump delivery rate against manufacturer minimum. Using scan tool injector balance-rate function and a lab oscilloscope, capture injector pulse-width waveforms for all cylinders and identify a seeded faulty injector.	EFI outboard bench engine; fuel pressure gauge kit (0–100 psi); graduated cylinder; digital oscilloscope; marine scan tool; shop rags; drain pan; nitrile gloves; safety glasses; fire extinguisher	Correct identification of the seeded faulty injector and documented pressure/volume results within 5% of instructor reference values; pass requires positive fault identification.
6	Marine Battery Types, Testing & ABYC E-10 Compliance	10.5	theory	Students will select appropriate marine battery types for cranking and house applications, perform load and conductance tests, and document findings against ABYC E-10 requirements.	Compare flooded, AGM, and lithium marine batteries using manufacturer data sheets; complete a selection matrix for three different boat application scenarios. Perform a digital conductance test and a carbon-pile load test on a set of shop batteries in varying states of health, recording CCA, voltage, and temperature. Complete an ABYC E-10 compliance checklist on a bench battery bank mockup, identifying any deficiencies in hold-downs, venting, cable routing, and terminal protection.	Flooded, AGM, and lithium marine battery samples; digital conductance tester; carbon-pile load tester; ABYC E-10 standard; multimeter; insulated battery tools; safety glasses; acid-resistant gloves	Written compliance checklist signed by instructor with all seeded deficiencies identified; load test results recorded accurately; pass requires zero missed deficiencies.
7	Marine Charging Systems: Alternators & Stators	12.5	demo	Students will test a marine alternator and stator for output voltage, AC ripple, and diode function, and identify charging system faults from test data.	Instructor demonstrates belt-driven marine alternator testing sequence; students record no-load and full-load voltage on a running bench engine and calculate voltage rise. Using a digital multimeter set to AC voltage, students measure ripple voltage at the alternator output and compare to accepted thresholds to identify a diode fault seeded by the instructor. Test the stator of a direct-drive outboard charging system for peak AC output and winding resistance per manufacturer service data; compare results to a known-good baseline.	Belt-driven alternator bench engine; outboard with stator; digital multimeter; oscilloscope; manufacturer service manual; safety glasses; heat-resistant gloves	Correct identification of the seeded diode fault with supporting measured values documented; ripple measurement within ±0.1 V of instructor reference; instructor sign-off required.
8	Starting Circuits, Solenoids & Relays	12.5	lab	Students will perform a voltage-drop test on a complete marine starting circuit and diagnose a seeded fault using a wiring diagram and multimeter.	Trace the starting circuit from battery positive through the ignition switch, neutral safety switch, starter solenoid, and starter motor on a bench mockup using the OEM wiring diagram. Perform a four-point voltage-drop test on the cranking circuit under load, recording all drops and comparing totals to the accepted maximum per ABYC E-11 guidance. The instructor seeds one fault (corroded solenoid contact, open neutral switch, or high-resistance cable); students diagnose and document the fault with test values, then correct it and retest.	Marine starting circuit bench mockup (battery, cables, solenoid, starter, switches); digital multimeter with min/max function; OEM wiring diagram; ABYC E-11 standard; insulated hand tools; safety glasses	Correct fault identified and documented with supporting voltage-drop readings; repaired circuit total voltage drop within specification; lab sheet signed by instructor to pass.
9	Marine Wiring: ABYC E-11 Standards, Wire Sizing & Termination	12.5	demo	Students will select correct marine-grade wire gauge for a given circuit load and length, and terminate conductors with heat-shrink ring terminals and mechanical connectors to ABYC E-11 quality standards.	Use the ABYC E-11 ampacity table and voltage-drop chart to select correct wire gauge for three sample circuits (bilge pump, anchor windlass, running lights), showing calculations on a worksheet. Instructor demonstrates proper stripping, crimping with a ratchet crimper, and heat-shrinking of ring terminals; students then fabricate three custom-length cables and submit for pull-test. Inspect a deliberately faulty wiring panel (wrong gauge wire, automotive connectors, no chafe protection) against an ABYC E-11 checklist and write a corrective action list.	ABYC E-11 standard; marine-grade tinned copper wire (various gauges); heat-shrink ring terminals; ratchet crimper; heat gun; wire stripper; pull-test gauge; faulty wiring panel mockup; safety glasses	All three fabricated cables pass a 40-lb pull test without terminal failure; wire sizing worksheet correct for all three circuits; faulty panel checklist complete with all seeded deficiencies identified.
10	Circuit Protection, Fusing & Accessory Circuit Wiring	12.5	lab	Students will size and install appropriate fuses, circuit breakers, and bus bars for a marine accessory panel, then verify correct circuit protection operation.	Calculate fuse and breaker ratings for a set of marine accessories (VHF radio, depth sounder, bilge pump, cabin lighting) using ABYC E-11 ampacity data and manufacturer load specs. Wire a six-circuit accessory panel on the bench using the selected protection devices, tinned wire, and ring terminals, following the instructor-provided circuit diagram. Test each circuit protection device for correct trip current by applying a controlled overload, document trip time and current, and verify auto-reset breaker function where applicable.	Bench-mount marine accessory panel kit; assorted ATC and ANL fuses; marine-grade circuit breakers; bus bars; tinned wire; ratchet crimper; clamp-on ammeter; variable DC power supply; ABYC E-11 standard; safety glasses	Panel wired to diagram with correct protection devices; all six circuits trip within correct current range on overload test; instructor performs final inspection and signs lab sheet to pass.
11	Ignition System Testing & Electronic Diagnostics	12.5	lab	Students will test capacitor discharge ignition (CDI) components, read ignition primary and secondary waveforms on an oscilloscope, and diagnose a seeded ignition fault.	Perform static resistance tests on CDI trigger coils, charge coils, and ignition coils using a multimeter, comparing readings to manufacturer service data. Connect an oscilloscope to the primary ignition circuit of a running outboard and capture the primary waveform; annotate dwell, firing voltage, and burn time on a printed waveform template. Instructor seeds one ignition fault (weak coil, failed trigger, or open kill circuit); students diagnose using a systematic test procedure, document findings, correct the fault, and confirm engine starts.	CDI-equipped outboard bench engine; digital multimeter; dual-channel oscilloscope with ignition pickup; manufacturer service manual; waveform template worksheets; insulated probe leads; safety glasses; hearing protection	Seeded fault correctly identified with supporting resistance and waveform data; engine confirmed running after repair; waveform annotated correctly on template; instructor sign-off to pass.
12	Integrated Fuel & Electrical System Diagnosis Capstone Lab	10.5	lab	Students will diagnose and repair a multi-system fault scenario combining a fuel delivery problem and an electrical circuit fault on a running bench engine, completing a professional repair order.	Receive a repair order describing customer-reported symptoms on a bench engine with two instructor-seeded faults (one fuel, one electrical); develop and document a diagnostic plan before touching the engine. Execute the diagnostic plan—performing fuel pressure/volume tests, sensor tests, voltage-drop tests, and wiring inspections—recording all measurements on a structured diagnostic worksheet. Correct both faults, verify engine performance against manufacturer specifications, and complete the repair order with parts list, labor description, and a test-drive results section; present findings to instructor in a five-minute verbal review.	EFI or carbureted outboard bench engine with seeded faults; full tool set (multimeter, oscilloscope, scan tool, pressure gauge, graduated cylinder); manufacturer service manual; ABYC E-10 and H-24 standards; blank repair order forms; safety glasses; nitrile gloves; fire extinguisher	Both faults correctly identified and repaired; all measured values within manufacturer specification after repair; repair order complete and legible; verbal review demonstrates understanding of diagnostic logic; pass requires all four elements satisfactory.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Fuel & Electrical Systems Knowledge Exam	Written exam	25%	75% or higher on all sections; any section below 70% requires targeted remediation and retest of that section only.	A 60-question written exam covering ABYC H-series fuel system standards, EFI system theory, marine battery and charging theory, ABYC E-11 wiring and circuit protection, CDI ignition principles, and diagnostic methodology. Questions are formatted to match ABYC Marine Engine credential exam style, including multiple-choice and short-answer items aligned to ABYC exam content areas. Standard met · Safety · Time · Quality/finish · Documentation
Practical Skills Demonstration	Skills demonstration	45%	All critical steps marked satisfactory on the rubric; any step rated unsatisfactory must be re-demonstrated within one week.	The student performs three timed tasks observed by the instructor: (1) disassemble, service, and adjust a carburetor to manufacturer idle spec; (2) test a marine charging system for output and ripple and state a diagnosis; and (3) fabricate and install a fused accessory circuit using correct ABYC E-11 wire gauge and terminations. Each task is scored on a rubric covering safety practices, use of tools, accuracy of measurements, and quality of workmanship. Standard met · Safety · Time · Quality/finish · Documentation
Laboratory Log Portfolio	Log	15%	All 12 lesson lab sheets submitted; average score of 80% or higher across rubric criteria; any sheet below 70% must be corrected and resubmitted.	Students maintain a bound lab log containing the completed inspection form, measurement worksheet, diagnostic worksheet, and repair order from each lesson. The log is evaluated for completeness, accuracy of recorded measurements versus instructor reference values, legibility, and correct identification of ABYC standard references on each entry. Standard met · Safety · Time · Quality/finish · Documentation
Fuel & Electrical Safety Check	Safety audit	15%	Zero critical safety failures; any critical failure stops the evaluation immediately and requires remediation before reassessment.	The instructor observes the student setting up and performing a fuel system pressure test and an electrical voltage-drop test, scoring adherence to lockout/tagout procedures, correct PPE selection and use, proper fire extinguisher placement, safe fuel handling and spill response, and compliance with ABYC E-11 and H-24 safety requirements. Critical failures include working on a live fuel system without pressure relief, omitting required PPE, or bypassing a lockout step. Standard met · Safety · Time · Quality/finish · Documentation

TRN-MARI21-05 Trade course

Marine Rigging: Steering, Controls, and Running Hardware

146 hr · ~~$2,100~~ COMPLIMENTARY

Students install, adjust, and troubleshoot the complete rigging systems found on outboard and sterndrive vessels, including mechanical and hydraulic steering, throttle and shift cables, binnacle and tiller controls, fuel-delivery plumbing, and all running hardware from transom brackets to bow eyes. Emphasis is placed on ABYC standards for rigging, proper torque and fastener selection, and the safety practices required before working aboard any vessel. Upon completion, students are prepared for ABYC Marine Engine exam topics related to controls, steering, and on-boat systems.

Outcomes

Select, route, and secure throttle, shift, and steering cables to manufacturer and ABYC specifications, achieving smooth, binding-free operation across full travel range.
Install and bleed a hydraulic steering system, verify cylinder lock, and document fluid type and reservoir level per ABYC guidelines.
Mount and align an outboard engine on a transom bracket, set correct transom height and tilt-pin position, and torque all hardware to specification.
Inspect and replace running hardware—cleats, chocks, rub rail, fuel-fill fittings, and bilge-pump plumbing—applying correct sealants and fastener materials for the substrate.
Apply lockout/tagout and marine-specific PPE procedures before beginning any rigging task and pass a pre-task safety check without prompting.
Read and interpret a marine rigging wiring and plumbing diagram, identify all control-circuit components, and record completed work in a legible job order.

Course text

How the course runs. 12 blocks: Rigging Safety, Lockout/Tagout, and Shop Orientation; Reading Marine Rigging Diagrams and Job Orders; Fasteners, Sealants, and Marine Hardware Selection; Transom and Engine Mounting; Mechanical Steering Systems: Rack, Cable-Helm, and Tiller; Mechanical Steering Installation and Adjustment; Hydraulic Steering: Components, Fluid, and Bleeding; Throttle and Shift Cable Selection, Routing, and Adjustment; Binnacle and Remote Control Installation; Fuel-System Plumbing and Primer Bulb Installation; Running Hardware: Through-Hulls, Cleats, Rub Rail, and Bilge Plumbing; Complete Rigging Integration and Final Inspection.

What competent looks like. Select, route, and secure throttle, shift, and steering cables to manufacturer and ABYC specifications, achieving smooth, binding-free operation across full travel range. Install and bleed a hydraulic steering system, verify cylinder lock, and document fluid type and reservoir level per ABYC guidelines. Mount and align an outboard engine on a transom bracket, set correct transom height and tilt-pin position, and torque all hardware to specification. Inspect and replace running hardware—cleats, chocks, rub rail, fuel-fill fittings, and bilge-pump plumbing—applying correct sealants and fastener materials for the substrate. Apply lockout/tagout and marine-specific PPE procedures before beginning any rigging task and pass a pre-task safety check without prompting. Read and interpret a marine rigging wiring and plumbing diagram, identify all control-circuit components, and record completed work in a legible job order.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Rigging Safety, Lockout/Tagout, and Shop Orientation	7.5	theory	Students will state and apply marine-rigging-specific hazards, correct PPE selection, and the OSHA lockout/tagout procedure for boat-shop environments before touching any vessel.	Instructor-led review of OSHA 10 general-industry hazard recognition applied to the rigging bay: pinch points in cable runs, hydraulic-fluid injection risk, solvent vapors from adhesive sealants, and overhead lifting with engine hoists. Students complete a written LOTO scenario worksheet: identify energy sources (battery, hydraulic accumulator, fuel system), write the sequence to isolate each, and have a partner verify the lockout before simulated work begins. Table-top PPE station: students select correct glove type (cut-resistant vs. chemical-resistant), eye protection, and hearing protection for three rigging tasks; instructor scores selections against a rubric and corrects errors in class.	OSHA 10 student guide, shop-specific LOTO written program, assorted PPE samples, ABYC Standards & Technical Information Reports (relevant sections), whiteboard, scenario worksheets	Scored LOTO scenario worksheet; students must identify all energy sources and write a correct isolation sequence — 80% or higher to advance; any missed live-energy source triggers a mandatory redo.
2	Reading Marine Rigging Diagrams and Job Orders	7.5	theory	Students will interpret a factory rigging diagram and a dealer job order, correctly identifying all control-circuit components, cable routing paths, and fluid-line labels without reference assistance.	Instructor walks through a Yamaha or Mercury factory rigging guide page-by-page on a projector; students annotate a printed copy, labeling throttle cable, shift cable, steering helm, hydraulic lines, and fuel-primer bulb. Students decode three real dealer job orders — one outboard single-engine, one dual outboard, one sterndrive — circling ambiguous instructions and rewriting them in precise technical language. Pair exercise: one student describes a component location using only the diagram; the partner points to the physical component on a bench-mounted mockup; roles swap for a second diagram.	Yamaha Rigging Guide and Mercury Rigging Guide (current editions), sample dealer job orders, bench mockup of cable and helm assembly, colored pens, projector	Cold-call identification quiz: instructor points to ten symbols on an unmarked diagram; student must name each correctly — 8 of 10 correct is passing.
3	Fasteners, Sealants, and Marine Hardware Selection	9.5	demo	Students will select the correct fastener material, diameter, thread pitch, and sealant for a given substrate and load condition, explaining the reason for each choice.	Instructor demonstrates galvanic corrosion using a dissimilar-metal corrosion chart and wet-cell battery demonstration; students record which fastener-material pairings are prohibited below the waterline. Sealant comparison demo: instructor applies 3M 4200, 3M 5200, and a bedding compound to fiberglass coupons; students record open time, shore hardness, and removability characteristics, then match each sealant to an appropriate application. Fastener-selection exercise: students receive a list of ten rigging applications (transom drain plug, cleat through-bolt in balsa-core deck, outboard engine-mount bolt, aluminum rub-rail screw) and must specify correct material, length, and whether a backing plate is required, then compare against an answer key.	Fastener sample board (stainless 316, bronze, aluminum, zinc-plated), sealant samples, fiberglass coupons, corrosion chart, torque wrench set, backing-plate stock, answer key	Fastener-selection exercise scored: 9 of 10 applications correct with correct written rationale; common failure point — selecting 304 stainless for underwater use — is flagged and discussed.
4	Transom and Engine Mounting	13	lab	Students will mount a portable or remote-tilt outboard engine on a transom-height jig, set the correct clamp or bolt torque, and verify transom height within the manufacturer's published range.	Students measure a practice transom jig with a tape measure and verify transom height against the engine model's specification in the factory owner's manual; they record the measurement and state whether the height is within range. Guided installation: students install engine mounting bolts or tighten transom clamps in the correct sequence using a torque wrench, following the factory torque specification; instructor observes and does not intervene unless a safety stop is needed. Students recheck torque after simulated vibration (tapping the engine bracket with a rubber mallet ten times), record any change in torque-wrench reading, and write a brief finding in the job order.	Transom-height jig or boat hull, 25–60 hp outboard training engine, torque wrench, factory owner's manual, tape measure, job order forms	Instructor verifies torque on all mounting fasteners with a calibrated torque wrench; every fastener must be within ±10% of specification, and the transom height measurement must be documented correctly — both conditions required to pass.
5	Mechanical Steering Systems: Rack, Cable-Helm, and Tiller	13	demo	Students will describe the operating principle of rack-and-pinion, rotary-helm cable, and tiller steering systems and identify each component on a vessel or bench mockup.	Instructor disassembles a Teleflex/SeaStar rotary helm on a bench, names each part, and reassembles it while students follow along with an exploded-view diagram. Students rotate the helm from full lock to full lock on a mockup and measure total helm turns, recording the measurement and comparing it to the specification; they also check for cable kinks and note any binding points. Tiller-steer demo on an outboard: instructor shows friction adjustment and cable attachment at the engine tiller arm, then has students adjust tiller friction to eliminate slap without creating steering stiffness.	SeaStar or equivalent rotary helm unit (bench-stripped), steering cable, tiller-steer outboard, exploded-view diagrams, tape measure, adjustment tools	Student verbally identifies all components on the disassembled helm with 100% accuracy and demonstrates correct cable-end installation at the engine arm, confirmed by instructor inspection.
6	Mechanical Steering Installation and Adjustment	13	lab	Students will route, secure, and adjust a mechanical steering cable from helm to engine in a training boat, achieving full lock-to-lock travel with no binding and correct cable support per ABYC guidelines.	Students route a new steering cable from the helm through the boat, using grommets at any deck penetration, securing the cable every 18 inches (or per ABYC guidance) with appropriate clamps and ensuring no acute bends. Students attach the cable end to the engine tilt tube, adjust the cable-end guide and pivot bolt, and cycle the helm through full travel five times, noting any binding, slack, or stiff spot. Peer inspection: a second student follows a printed ABYC-aligned checklist to verify cable support intervals, grommet installation, and lock-nut torque; findings are recorded on the checklist and turned in with the job order.	Training boat or hull jig, new steering cable (correct length for hull), helm unit, clamps and grommets, torque wrench, ABYC-aligned inspection checklist, job order forms	Instructor pulls the helm through full lock-to-lock travel; cable must move freely with no binding; all supports must pass visual inspection; peer checklist must be complete and signed — all three required to pass.
7	Hydraulic Steering: Components, Fluid, and Bleeding	13	demo	Students will identify all components of a hydraulic steering system, select the correct fluid, and perform a complete bleed procedure, achieving a firm, drift-free helm with no trapped air.	Instructor presents a cut-away SeaStar hydraulic helm and cylinder, tracing the fluid path; students label a diagram and answer questions about what happens when air enters each segment of the circuit. Students observe and then repeat the manufacturer's bleed procedure: fill helm reservoir, rotate helm to push fluid toward cylinder, open bleed screw at cylinder to release air, close screw, repeat opposite direction; instructor demonstrates the difference between a hard helm (correct) and a spongy helm (air present). Students check fluid level and condition in a pre-used system containing intentionally darkened fluid; they drain a sample into a white cup and determine whether a fluid change is needed, recording their reasoning on a worksheet.	SeaStar or equivalent hydraulic helm and cylinder assembly (bench-mounted or in training boat), hydraulic steering fluid (manufacturer-specified type), bleed kit, catch container, gloves, fluid-condition worksheet	After student-performed bleed, instructor applies side load to the engine and checks for helm drift; helm must hold position for 30 seconds with no movement; fluid level must be at the full mark — both required.
8	Throttle and Shift Cable Selection, Routing, and Adjustment	13	lab	Students will select the correct cable length and type for a given helm-to-engine distance, route both throttle and shift cables, and adjust each to achieve full throttle travel and positive gear engagement without over-travel.	Cable-length calculation exercise: students measure helm-to-engine cable path on a training boat using a pull-tape or cable-routing tool, apply the manufacturer's add-on allowance, and identify the correct cable part number from a Mercury or Yamaha cable guide. Students install both cables through the control box and route them to the engine, securing with appropriate clips and ensuring no contact with hot exhaust components or rotating parts; instructor observes for safety stops only. Adjustment lab: students set throttle cable so wide-open throttle at the helm corresponds exactly to the carburetor or throttle body fully open, and set shift cable so forward and reverse engage positively with no partial-engagement detent felt; results are confirmed with a shift-feel test.	Binnacle or side-mount control box, throttle and shift cables (assorted lengths), training outboard or sterndrive, pull-tape, cable clips, Yamaha and Mercury cable selection guides, job order forms	Instructor operates the control box through neutral, forward, and reverse three times; shift must be positive with no partial engagement; throttle must reach full-open and return to idle — both verified before sign-off.
9	Binnacle and Remote Control Installation	11	lab	Students will mount a binnacle remote-control station, route all cables and wiring harness, and verify safety interlock (neutral start switch) function before connecting the engine harness.	Students cut the binnacle mounting hole in a fiberglass practice panel using a jigsaw, following the template in the control-box instructions; they deburr the edge, bed the control in sealant, and fasten with backing plate and hardware. Students route the engine wiring harness from the helm to the engine, securing per manufacturer intervals and avoiding pinch points at the engine well; they connect the neutral-start safety switch wiring and test that the engine will not crank in gear using a multimeter continuity test. Final function check: students operate the control box, verify that the safety lanyard kills the ignition circuit (if applicable), confirm that trim switch and horn function, and document each finding on the job order.	Binnacle remote-control assembly, fiberglass practice panel with backing material, jigsaw, sealant, backing plate, wiring harness, multimeter, safety lanyard switch, job order forms	Neutral-start interlock must prevent starter engagement in gear — confirmed by multimeter continuity check and live crank attempt; all documented checks on the job order must be initialed — both required.
10	Fuel-System Plumbing and Primer Bulb Installation	11	lab	Students will route and connect a portable or remote outboard fuel system from tank to engine, ensuring all connections are secure, the anti-siphon valve is correctly positioned, and there are no fuel leaks under hand-squeeze pressure.	Instructor reviews ABYC fuel-system requirements for below-deck fuel lines versus above-deck portable lines and identifies prohibited materials (e.g., non-marine-rated hose); students annotate a diagram to indicate where anti-siphon valves are required. Students connect a remote fuel tank to a training engine using the correct fuel line, primer bulb, and quick-connect fittings; they verify primer-bulb arrow is oriented toward the engine and that all clamps are tightened. Leak-check procedure: students squeeze the primer bulb until firm, then inspect every connection and fitting visually and by feel for fuel weeping; any wet spot requires disconnection, drying, and re-connection before a final re-check.	Portable and remote fuel tanks, marine-rated fuel hose, primer bulb assembly, quick-connect fittings, hose clamps, anti-siphon valve, ABYC fuel-system reference, gloves, eye protection	After student completes plumbing, instructor pressurizes the circuit with the primer bulb and inspects all joints; zero fuel weeping allowed — any leak is a fail requiring immediate rework.
11	Running Hardware: Through-Hulls, Cleats, Rub Rail, and Bilge Plumbing	11	lab	Students will install a through-hull fitting with a seacock, bed a cleat with a backing plate, and connect bilge-pump discharge plumbing, applying the correct sealant and fastener for each application.	Through-hull installation on a fiberglass practice panel: students drill the correct hole size, apply sealant, insert the bronze through-hull, thread the seacock, and verify the seacock opens and closes fully without binding. Cleat installation: students locate and mark a cleat position on a practice panel with balsa core, select a backing plate sized to distribute load, bed the cleat in an appropriate bedding compound, and torque bolts in a cross pattern. Bilge-pump plumbing: students connect a 12-volt bilge pump to a discharge through-hull using marine-rated hose and a check valve; they verify that the hose rises above the waterline before the check valve and that all hose clamps are doubled below the waterline per ABYC guidance.	Fiberglass and balsa-core practice panels, bronze through-hull with seacock, 316 stainless cleat, backing-plate stock, 3M 4200 and 3M 5200 sealant, bilge pump, check valve, marine hose, hose clamps, hole saws, drill, torque wrench	Instructor fills a water tray and submerges the practice panel to test through-hull and seacock for leaks; zero leakage allowed; cleat torque is verified with a torque wrench — both conditions required.
12	Complete Rigging Integration and Final Inspection	23.5	field	Students will perform a complete rigging sequence on an assigned training vessel, including engine mount, steering, controls, fuel, and running hardware, then conduct a full pre-delivery inspection and correct any deficiencies found.	Working in pairs, students rig an assigned vessel from scratch using all skills from lessons 4–11: mount engine, install steering cable or hydraulic system, install control box and route cables, connect fuel system, and verify all running hardware — each stage is documented on a staged job order. Students complete a manufacturer-style pre-delivery inspection (PDI) checklist adapted from Yamaha or Mercury guidelines, operating the control station through all functions, checking for leaks, binding, and missing hardware. Individual defense: each student explains to the instructor one system they installed, identifies what could go wrong if a specific step were skipped, and corrects one intentionally introduced deficiency the instructor has staged in the rigged boat.	Training vessel (outboard or sterndrive), full rigging kit (engine, steering system, control box, cables, fuel system, hardware), factory PDI checklist, torque wrench, multimeter, job order packet, ABYC reference	PDI checklist must be 100% complete with no open safety deficiencies; instructor verifies engine starts and shifts correctly, steering is free with no drift, fuel system has no leaks, and student can explain and defend their work during the individual defense — all four required for lesson completion.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Rigging Systems Knowledge Exam	Written exam	25%	75% or higher (minimum 38 of 50 questions correct)	A 50-question multiple-choice and short-answer exam covering ABYC rigging standards, fastener and sealant selection, hydraulic and mechanical steering theory, cable routing rules, fuel-system requirements, and component identification — directly mapped to ABYC Marine Engine exam content areas related to on-boat systems and controls. Students who score below 75% must complete targeted review and retake an alternate form before progressing. Standard met · Safety · Time · Quality/finish · Documentation
Rigging Skills Demonstration	Skills demonstration	45%	All critical steps performed correctly with no safety violations; rubric score of 80% or higher on non-critical steps	Each student individually rigs a steering cable or hydraulic steering system, adjusts both throttle and shift cables, and demonstrates the neutral-start interlock test on a training vessel or bench mockup while an instructor scores them against a factory-aligned rubric. Any missed LOTO step or uncorrected fuel or hydraulic leak is an automatic fail requiring a full redo. Standard met · Safety · Time · Quality/finish · Documentation
Lab Log Portfolio	Log	15%	All 12 lesson job orders submitted; average rubric score of 75% or higher; zero incomplete safety-check fields	Students submit all job orders and inspection checklists completed during lessons 4–12 as a portfolio, reviewed for completeness, accuracy of recorded measurements, legibility, and proper documentation of any deficiencies found and corrected. Incomplete safety-check fields and undocumented deficiencies are marked as automatic failures on that job order, requiring a written correction before the portfolio is accepted. Standard met · Safety · Time · Quality/finish · Documentation
Pre-Task Safety Check	Safety audit	15%	100% completion of all safety steps with no prompting from the instructor; any missed live-energy isolation is an automatic fail	The instructor presents an unrigged training vessel with the battery connected and the fuel system pressurized, then asks the student to set up safely to begin a steering-cable replacement. The student must independently identify all energy sources, perform LOTO, select and don correct PPE, and verify isolation before any rigging task begins — scored pass/fail with the result recorded in the student's competency file. Standard met · Safety · Time · Quality/finish · Documentation

TRN-MARI21-06 Trade course

Propulsion Systems: Props, Shafting, and Drive Trains

145 hr · ~~$2,090~~ COMPLIMENTARY

This course covers the theory, inspection, service, and replacement of marine propulsion components from the engine output shaft to the water, including propellers, shafting, couplings, sterndrive gearboxes, outboard lower units, jet drives, and thrust calculations. Students develop hands-on proficiency in prop selection, lower-unit rebuild, and drive-train alignment using industry-standard procedures. Lessons are mapped to ABYC Marine Engine exam content areas and reinforce Yamaha and Mercury factory service practices.

Outcomes

Select the correct propeller pitch, diameter, and material for a given hull, engine, and application using manufacturer specification charts.
Disassemble, inspect, measure, and reassemble an outboard lower unit and a sterndrive gearcase to OEM torque and clearance specifications.
Diagnose propulsion-system complaints—including vibration, cavitation, ventilation, and poor WOT RPM—using a systematic diagnostic process and test equipment.
Perform driveshaft, propshaft, and coupler alignment checks on an inboard installation to within acceptable tolerance.
Inspect and service a personal-watercraft jet-drive pump assembly, including wear-ring clearance measurement and impeller removal.
Complete all propulsion service work in compliance with applicable lockout/tagout procedures, PPE requirements, and ABYC standards, and document work on a professional repair order.

Course text

How the course runs. 12 blocks: Propulsion System Overview and Safety Protocols; Propeller Theory: Pitch, Diameter, Slip, and Thrust; Cavitation, Ventilation, and Propeller Damage Diagnosis; Outboard Lower Unit: Construction and Fluid Service; Outboard Lower Unit: Disassembly and Inspection; Outboard Lower Unit: Reassembly and Pressure Test; Sterndrive Gearcase: Service and Shift-Cable Adjustment; Inboard Shaft, Cutlass Bearing, and Strut Inspection; Driveshaft and Engine Alignment: Inboard Systems; Jet Drive Systems: Theory, Impeller Service, and Wear-Ring Measurement; Propulsion System Vibration Diagnosis; Credential Review, Practical Competency Demonstration, and Course Assessment.

What competent looks like. Select the correct propeller pitch, diameter, and material for a given hull, engine, and application using manufacturer specification charts. Disassemble, inspect, measure, and reassemble an outboard lower unit and a sterndrive gearcase to OEM torque and clearance specifications. Diagnose propulsion-system complaints—including vibration, cavitation, ventilation, and poor WOT RPM—using a systematic diagnostic process and test equipment. Perform driveshaft, propshaft, and coupler alignment checks on an inboard installation to within acceptable tolerance. Inspect and service a personal-watercraft jet-drive pump assembly, including wear-ring clearance measurement and impeller removal. Complete all propulsion service work in compliance with applicable lockout/tagout procedures, PPE requirements, and ABYC standards, and document work on a professional repair order.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Propulsion System Overview and Safety Protocols	10	theory	Students will identify every major propulsion sub-system—outboard lower unit, sterndrive gearcase, inboard shaft-and-strut, and jet drive—and correctly apply lockout/tagout and PPE requirements before any hands-on work begins.	Instructor-led tour of shop floor propulsion training stations; students label a cut-away diagram of each drive type, identifying power-flow path from crankshaft to thrust. Table-exercise: students fill out a LOTO procedure card for an outboard on a stand, a sterndrive unit on a hoist, and a shaft-drive vessel on jack stands, then peer-review each other's cards against OSHA 29 CFR 1910.147 general requirements. Video case study of a propeller-strike injury; class discussion links blade exposure hazards to specific PPE (face shield, cut-resistant gloves) and shop rules posted at each station.	Cut-away outboard lower unit, sterndrive display unit, LOTO station with tags and locks, OSHA 29 CFR 1910.147 reference card, ABYC standards binder (relevant propulsion standards), whiteboard, student shop-safety handout.	Instructor verifies each student's completed LOTO card against a four-point checklist (energy source identified, isolation method correct, verification step listed, tag signed); all four points correct = pass (100% required for safety items).
2	Propeller Theory: Pitch, Diameter, Slip, and Thrust	12	theory	Students will calculate theoretical boat speed, percent slip, and thrust force from propeller pitch, diameter, RPM, and gear ratio data, and explain how each variable affects performance.	Lecture with worked examples: students solve five pitch-speed-slip problems using the standard formula (Theoretical Speed = Pitch × RPM / Gear Ratio; convert to MPH) on whiteboards, checking answers against an answer key. Prop library exercise: students examine twelve different propellers (aluminum 3-blade, stainless 3-blade, 4-blade high-rake, cleaver, weedless) and record measured pitch, measured diameter, blade count, rake angle, and cup using a pitch gauge and dial calipers, completing a comparison table. Case-study worksheet: given engine max-RPM spec, gear ratio, and desired WOT RPM window, students select the correct propeller from a Yamaha or Mercury prop guide and justify their choice in two written sentences.	Assorted prop collection (minimum 8 props), propeller pitch gauge, dial calipers, Yamaha and Mercury propeller selection guides, scientific calculators, student worksheet packet.	Five-problem quiz on propeller math; students must score 80% or higher; each wrong answer is reviewed individually before moving on.
3	Cavitation, Ventilation, and Propeller Damage Diagnosis	10	demo	Students will correctly distinguish between propeller cavitation and ventilation, identify the visual evidence of each on used propellers, and match each condition to its likely cause and repair.	Instructor demonstrates visual inspection of six damaged props under magnification and workshop lighting, narrating identification of cup erosion (cavitation damage), leading-edge impact dings, tip curling, and blade cracking; students take notes on a diagnostic reference card they keep. Students individually examine the same six props and complete a damage log for each: damage type, probable cause (cavitation erosion vs. impact vs. electrolysis vs. fatigue), and recommended action (dress, repair, replace). Whole-class comparison of completed logs against instructor answer key; discrepancies discussed; instructor demonstrates use of a prop repair station file and grinder to dress a minor leading-edge nick on an aluminum prop.	Six pre-selected damaged propellers representing different failure modes, magnifying glass and work light, prop damage identification poster, prop repair station (bench vise, mill file, grinder with guard, PPE), student diagnostic reference cards.	Damage-log accuracy: student must correctly identify damage type and cause on at least five of six props; instructor initials completed log at 83% threshold.
4	Outboard Lower Unit: Construction and Fluid Service	12	lab	Students will drain, inspect, and refill an outboard lower-unit gearcase to OEM specifications, correctly interpreting the drained fluid for contamination and recording findings on a repair order.	Pre-work: students retrieve OEM service manual section for the assigned lower unit (Yamaha or Mercury), identify drain and vent plug locations, required gear-oil grade and capacity, and torque spec for plugs; record on repair order. Hands-on fluid service: each student drains the lower unit into a clear container, examines the fluid for milky appearance (water intrusion) and metallic particles (bearing wear), documents findings, then refills from the bottom plug up using a gear-oil pump until oil appears at the vent, installing and torquing plugs to spec. Seal inspection: with lower unit on stand, students inspect the prop-shaft seal area and water-pump cavity for oil seepage evidence; record any defects; discuss with instructor how water in the lube circuit correlates to prop-shaft seal failure.	Outboard lower units on bench stands (at least one per two students), OEM service manuals, gear lube pump, manufacturer-specified gear oil, drain pan, clear sample jar, torque wrench (inch-pound and foot-pound), shop rags, repair order forms.	Instructor spot-checks: correct plug torque verified with calibrated torque wrench; repair order complete with fluid condition noted and correct oil grade and quantity recorded; pass = zero untorqued plugs and fully completed RO.
5	Outboard Lower Unit: Disassembly and Inspection	14	lab	Students will fully disassemble an outboard lower unit, measuring bearing preload and gear backlash at each stage, and compare all measurements to OEM service limits.	Using OEM service manual procedure, students remove the propeller (noting spline and hub kit condition), then remove the lower unit from the midsection, systematically disassemble the gearcase following the manual sequence, laying parts in order on a labeled bench mat. Students measure: forward gear and reverse gear backlash with a dial indicator; pinion gear height with a depth micrometer or manufacturer shim gauge; carrier bearing race fit in the housing using a bore gauge compared to OEM limit. Parts cleaning station: students clean all metal components in parts washer, inspect each gear tooth for pitting, spalling, and chipping under magnification, and record serviceable/replace decision on a parts-condition sheet.	Complete lower-unit assemblies for disassembly (Yamaha or Mercury units recommended), OEM service manual, dial indicator with magnetic base, depth micrometer, bore gauge set, parts washer (aqueous, ventilated), parts mat with numbered zones, magnifying glass, parts-condition recording sheets.	Instructor reviews recorded measurements against OEM spec table; all three measurements (backlash, pinion height, bore gauge reading) must be within 10% of spec limit to confirm calibration technique; parts-condition sheet fully completed = pass.
6	Outboard Lower Unit: Reassembly and Pressure Test	14	lab	Students will reassemble a lower-unit gearcase to OEM torque specifications, select correct shims from measurement data, and pressure-test the completed assembly to confirm seal integrity.	Using shim-selection chart from OEM manual, students calculate required shim thickness from their pinion-height measurement taken in Lesson 5, select shims from shop inventory, and install pinion gear and bearing assembly. Students complete full assembly sequence per OEM procedure, torquing all fasteners to spec and recording each torque value on the reassembly checklist; instructor witnesses prop-shaft nut torque and cotter pin or tab washer installation. Pressure test: students connect a lower-unit pressure tester to the drain plug port, pressurize to the manufacturer-specified test pressure, apply soapy water to all seals and plug threads, and hold pressure for the OEM-specified time; any bubble indicates a failed seal requiring re-inspection.	Lower-unit assemblies from Lesson 5 disassembly, shim assortment kit, OEM service manual, torque wrench set, lower-unit pressure tester, soapy water spray bottle, reassembly checklist forms.	Unit holds pressure for full OEM hold time with no audible leak or bubble; reassembly checklist signed by instructor; any failed pressure test requires student to locate and re-seal before signing off.
7	Sterndrive Gearcase: Service and Shift-Cable Adjustment	12	lab	Students will perform a fluid service on a sterndrive upper and lower gearcase and correctly adjust the shift cable so the unit achieves positive engagement in forward, neutral, and reverse.	Students drain upper and lower gearcase oil on a Mercruiser or Volvo Penta sterndrive unit mounted on a service stand, inspect for water contamination, and refill to OEM specs; record findings on repair order. Shift cable adjustment exercise: with the drive unit installed on the transom display fixture, students loosen the shift cable clamp, work through the OEM adjustment procedure (using the specified alignment pin or measurement method for the unit), then verify engagement quality by moving the shift lever through all positions. Function verification: with the unit in a test tank or test plug installed, students run the engine at low RPM (instructor-supervised) and confirm forward and reverse thrust with no unexpected noise; report any slippage or grinding discovered.	Sterndrive unit on display/training transom fixture, OEM service manual (Mercruiser or Volvo Penta), gear oil pump, manufacturer-specified oil, shift cable tool set, alignment pin (if applicable to unit), torque wrench, test tank or flush-muffs, repair order forms.	Shift engagement verified by instructor in all three positions with no slipping or grinding; gearcase oil level confirmed correct; repair order complete = pass.
8	Inboard Shaft, Cutlass Bearing, and Strut Inspection	12	field	Students will inspect a shaft-drive inboard propulsion system—including propeller, shaft, strut, cutlass bearing, and stuffing box or shaft seal—measuring shaft runout and cutlass bearing wear and documenting findings for a yard work order.	Dockside or haulout-yard inspection (or on a shop trailer-mounted vessel): students visually inspect propeller for damage, check shaft for corrosion banding, and check strut hardware for looseness while following confined-space awareness and slip/trip PPE protocols. With dial indicator on a magnetic base, students measure propeller-shaft runout at a point aft of the strut bearing; compare reading to an acceptable maximum and record; separately, students measure cutlass bearing ID with calipers and compare wear to the shaft OD to determine if clearance is within serviceable range. Students inspect the stuffing box or dripless shaft seal for proper drip rate or diaphragm condition, document findings on a yard work order form, and give a verbal summary of recommended actions to the instructor acting as the customer.	Trailer-mounted or blocked inboard vessel (or shop shaft-drive mockup), dial indicator with magnetic base, inside calipers, outside calipers, flashlight, mirror, PPE (non-slip footwear, safety glasses), yard work order forms.	Instructor evaluates: runout measurement technique (indicator zeroed, shaft rotated through 360°, reading recorded), cutlass-bearing clearance calculation correct, work order fully completed with all findings; pass = all three elements complete and mathematically accurate.
9	Driveshaft and Engine Alignment: Inboard Systems	12	demo	Students will demonstrate the use of a flexible coupling alignment procedure to bring a simulated inboard engine-to-shaft coupling into angular and parallel alignment within acceptable tolerance.	Instructor demonstrates the use of feeler gauges at four points around the coupling faces to check angular misalignment, then demonstrates use of a straight edge across the coupling OD halves to check parallel (offset) misalignment; students sketch the setup with tolerance zones labeled. Students rotate roles on the alignment trainer rig (engine mockup on adjustable mounts): one student adjusts motor mount bolts while a second reads feeler gauge measurements at 12, 3, 6, and 9 o'clock positions; they alternate until angular misalignment is within the commonly accepted limit stated in the rig reference sheet. Group debrief: students complete a one-page written explanation of how a misaligned shaft causes vibration, bearing wear, and stuffing-box leakage, citing at least one measurement from their alignment exercise.	Shaft-alignment trainer rig with adjustable engine mounts and flexible coupling, feeler gauge set, straight edge, torque wrench, alignment data recording sheet, student alignment reference notes.	Angular misalignment reading at all four clock positions must be within the tolerance stated on the reference sheet; instructor confirms feeler gauge technique is correct (gauge slides with light drag, not forced); written explanation graded pass/fail on completeness.
10	Jet Drive Systems: Theory, Impeller Service, and Wear-Ring Measurement	12	lab	Students will remove, inspect, and reinstall a personal-watercraft jet-pump assembly, measuring impeller-to-wear-ring clearance and comparing it to the OEM service limit.	Lecture and diagram review: instructor explains jet-pump operation (intake, impeller, stator, nozzle, deflector), the role of the wear ring in efficiency, and the relationship between clearance growth and thrust loss; students label a pump cross-section diagram. Pump removal: using OEM service procedure on a training PWC or bench-mounted pump unit, students remove the pump housing, extract the impeller with the correct tool (impeller tool—do not use screwdrivers), and remove the wear ring; PPE includes safety glasses and gloves throughout. Measurement: students measure the impeller blade tip-to-wear-ring clearance using the OEM-specified method (feeler gauge or specified gap measurement), record the reading, compare to OEM limit, and make a written service recommendation; reassemble pump to OEM torque spec.	PWC on stand or bench-mounted jet pump assembly (Yamaha WaveRunner or Sea-Doo unit preferred), OEM service manual, impeller removal tool, feeler gauge set, torque wrench, inside-outside calipers, PPE, lab recording sheets.	Clearance measurement recorded and correctly compared to OEM spec; service recommendation written and logically supported; pump reassembled with no missing hardware and impeller nut torqued to spec; instructor signs off.
11	Propulsion System Vibration Diagnosis	12	practice	Students will apply a systematic diagnostic sequence to identify the root cause of a propulsion vibration complaint—distinguishing prop damage, cavitation, shaft imbalance, loose hardware, and engine-related vibration—using a written diagnostic worksheet.	Instructor presents five written complaint scenarios with symptom descriptions (vibration at WOT only; vibration at idle only; vibration with load; vibration after striking object; vibration accompanied by RPM drop); students independently complete a diagnostic tree for each scenario, listing tests in order and expected findings. Hands-on fault-finding station rotation: four stations are set up with deliberately introduced faults (bent prop on outboard, loose prop nut, incorrect pitch prop causing RPM outside WOT window, loose motor mount on sterndrive); students identify the fault, state the diagnostic test that confirmed it, and record corrective action. Students write a customer-facing explanation (three to five sentences) for one of the fault-station findings, demonstrating professional technical communication appropriate to an ABYC-compliant repair order.	Outboard and sterndrive units at bench stations with introduced faults, tachometer, torque wrench, prop removal tool, written scenario worksheets, diagnostic tree template, repair order forms.	Four of four fault stations correctly diagnosed and documented; customer explanation reviewed by instructor for accuracy and clarity; pass = 75% of diagnostic steps in correct order and all four faults correctly identified.
12	Credential Review, Practical Competency Demonstration, and Course Assessment	13	practice	Students will demonstrate timed, unaided competency in three propulsion tasks—prop removal and selection, lower-unit fluid service, and a vibration diagnosis—and pass a written knowledge exam covering all course content areas aligned to the ABYC Marine Engine and factory certification exam domains.	Timed skills rotation (30 minutes per station): students independently perform prop removal and correct-replacement selection using a spec chart; lower-unit fluid drain, inspection, and refill with completed repair order; and written vibration diagnostic on an assigned scenario card. Written knowledge exam: 40 multiple-choice and short-answer questions covering propeller math, gear-case service procedures, alignment principles, jet-drive service, and diagnosis; individually completed under exam conditions. Debrief: instructor returns graded exams, reviews every missed item with whole class, maps each question to its ABYC exam content area on the board, and issues individual remediation assignments for any student below 80%.	Timed-skills station equipment (prop, lower unit, scenario cards), OEM service manuals available for reference only on fluid service station, written exam packets, answer keys, ABYC content-area map handout.	Written exam: 80% or higher to pass. Skills stations: all three tasks completed within time limit with no safety violations and no uncorrected errors on repair order; any failed station requires one supervised repeat before the course grade is finalized.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Propulsion Knowledge Exam	Written exam	25%	80% or higher (32 of 40 questions correct)	A 40-question written exam in multiple-choice and short-answer format covering propeller theory and math, lower-unit and sterndrive gearcase construction and service, shaft alignment, jet-drive operation, and vibration diagnosis; questions are mapped to ABYC Marine Engine exam content areas and Yamaha/Mercury factory certification domains. Students sit the exam individually under timed, closed-book conditions. Standard met · Safety · Time · Quality/finish · Documentation
Propulsion Skills Demonstration	Skills demonstration	45%	All three stations completed within the allotted time with zero uncorrected safety violations and a fully completed, accurate repair order	Students rotate through three timed practical stations—propeller removal and spec-based selection, outboard lower-unit fluid service with contamination assessment, and written vibration diagnostic for an assigned complaint scenario—assessed by the instructor using a standardized rubric aligned to ABYC and factory service procedures. Any station not passed on the first attempt must be repeated under instructor supervision before a course grade is awarded. Standard met · Safety · Time · Quality/finish · Documentation
Lab Log: Propulsion Service Portfolio	Log	15%	All 12 lesson lab logs submitted, each with complete measurements, repair-order entries, and instructor initials; no more than one resubmission allowed per log	Throughout the course students maintain a bound lab log containing the completed recording sheets, measurements, repair orders, and reflective notes from every hands-on lesson; entries must include actual measured values (not placeholder text), comparison to OEM specifications, and a service recommendation. The portfolio is collected at the end of the course and evaluated for completeness, measurement accuracy, and professional documentation quality. Standard met · Safety · Time · Quality/finish · Documentation
Propulsion Safety Check	Safety audit	15%	100% on all critical safety items; any single failure stops the assessment and requires a full supervised retry	Before any graded practical work, the instructor administers a safety compliance checklist covering LOTO procedure execution, correct PPE selection and use for the specific task (e.g., face shield for pressure testing, cut-resistant gloves during prop handling), correct use of torque tools, and safe handling of gear oil and cleaning solvents; this check is a prerequisite gate—students who fail do not proceed to the skills demonstration until all items are demonstrated correctly. Standard met · Safety · Time · Quality/finish · Documentation

TRN-MARI21-07 Capstone

Capstone Project: Full Marine Engine Service and Documentation

162 hr · ~~$1,620~~ COMPLIMENTARY

Students perform an end-to-end diagnostic, service, and verification sequence on an assigned outboard or sterndrive powerplant, producing shop-quality documentation and defending their work before an industry panel. The capstone integrates every prior course—safety protocols, two-stroke and four-stroke service, fuel and electrical systems, rigging, and propulsion—into one supervised, graded project. Successful completion demonstrates job-entry readiness and produces a portfolio artifact used in the externship and credential exam stages.

Outcomes

Perform a complete pre-service inspection and write a documented diagnostic work order that accurately identifies all faults on an assigned marine engine to industry standards.
Execute a full manufacturer-specified service procedure—including fuel system service, electrical diagnosis, cooling system flush, and lower-unit inspection—within flat-rate time guidelines and with zero safety violations.
Produce a complete, legible service record package (work order, parts list, labor log, and post-service test results) that meets ABYC documentation practices.
Verify post-service engine performance using diagnostic tools and interpret data against manufacturer specifications, recording pass/fail results for each parameter.
Identify and correct at least one seeded electrical or fuel fault under timed conditions, demonstrating systematic diagnostic reasoning consistent with ABYC Marine Engine exam competency areas.
Defend all diagnostic and repair decisions orally before an evaluator panel, explaining safety precautions taken and referencing applicable ABYC standards and manufacturer service data.

Course text

How the course runs. 4 blocks: Project Intake, Safety Planning, and Pre-Service Inspection; Full Engine Service Execution and Parts Documentation; Post-Service Performance Verification and Final Documentation; Project Defense and Reflection.

What competent looks like. Perform a complete pre-service inspection and write a documented diagnostic work order that accurately identifies all faults on an assigned marine engine to industry standards. Execute a full manufacturer-specified service procedure—including fuel system service, electrical diagnosis, cooling system flush, and lower-unit inspection—within flat-rate time guidelines and with zero safety violations. Produce a complete, legible service record package (work order, parts list, labor log, and post-service test results) that meets ABYC documentation practices. Verify post-service engine performance using diagnostic tools and interpret data against manufacturer specifications, recording pass/fail results for each parameter. Identify and correct at least one seeded electrical or fuel fault under timed conditions, demonstrating systematic diagnostic reasoning consistent with ABYC Marine Engine exam competency areas. Defend all diagnostic and repair decisions orally before an evaluator panel, explaining safety precautions taken and referencing applicable ABYC standards and manufacturer service data.

Lessons · 4 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Project Intake, Safety Planning, and Pre-Service Inspection	30	lab	Students write a complete pre-service inspection report and a job-specific safety plan for their assigned engine, identifying all known and suspected faults before any disassembly begins.	Receive an assigned engine (outboard or sterndrive with seeded faults); perform a visual walk-around using an ABYC-based inspection checklist, recording every observed deficiency on a formatted work order. Draft a written safety plan that identifies all hazards present—fuel vapor, stored electrical energy, pressurized cooling circuits, heavy component handling—and lists the lockout/tagout steps, PPE required, and ventilation procedures for each phase of the upcoming service. Present the completed inspection report and safety plan to the instructor for sign-off; revise any missed hazards or omitted fault notations before advancing to service work.	Assigned engine on run stand or hoist, digital multimeter, compression tester, vacuum/pressure gauge set, fuel system pressure gauge, ABYC standards reference binder, manufacturer service manual for assigned engine, formatted work order forms, PPE (nitrile gloves, safety glasses, hearing protection), LOTO locks and tags	Instructor reviews completed work order and safety plan; pass requires all seeded external faults documented, all major hazard categories addressed in the safety plan, and correct LOTO sequence listed—80% checklist score minimum to advance.
2	Full Engine Service Execution and Parts Documentation	72	lab	Students complete every manufacturer-specified service task for their assigned engine, documenting each step in real time on the work order and maintaining zero safety violations throughout.	Execute the full service sequence in logical order: fuel system service (filter replacement, carburetor or fuel-injection service, vapor separator check on EFI units), ignition and spark plug service, cooling system thermostat and impeller inspection or replacement, lower-unit gear oil change and seal inspection, and corrosion-control treatment—logging each task with actual torque values, measurements, and parts used as work proceeds. Diagnose and repair the seeded electrical fault (chosen from: faulty charging circuit, bad ground, failed sensor, or wiring continuity break) using a systematic pinpoint test procedure from the service manual; record all meter readings, test steps, and the root-cause finding on a dedicated diagnostic worksheet. Complete a parts and labor log listing every part number used, quantity, and labor time per task; cross-reference the parts list against the manufacturer parts catalog to confirm correct part numbers before logging.	Full shop tool set (hand tools, torque wrenches, snap-ring pliers, seal drivers), digital multimeter, lab-scope or engine analyzer (if available), flush muffs or run-tank, manufacturer-specified lubricants and replacement parts, parts catalog (print or manufacturer dealer portal), work order continuation sheets, labor time reference guide, PPE throughout	Instructor conducts two unannounced station checks during this lesson block; each check verifies correct task sequence, real-time documentation completeness, and active PPE compliance—both checks must score 80% or higher; any safety violation (missing LOTO, fuel near ignition source, unguarded rotating part) triggers an immediate stop and mandatory re-brief before work resumes.
3	Post-Service Performance Verification and Final Documentation	36	lab	Students start and run the serviced engine, record all performance parameters against manufacturer specifications, and assemble a complete, submission-ready service record package.	Perform a pre-start safety checklist (fuel system leak check, cooling water supply confirmed, all fasteners torqued, safety lanyard installed), then start the engine and bring it to operating temperature on the run stand; use the engine analyzer or diagnostic software to capture RPM, idle quality, charging voltage, cooling water outlet temperature, and fuel pressure, and record each value alongside the manufacturer's specified range. Conduct a timed wide-open-throttle test at the run stand (or water test if facility allows) to verify peak RPM falls within the manufacturer's published specification for the test propeller; document actual versus specified values and note any remaining discrepancies with a recommended follow-up action. Compile the full service record package: pre-service inspection report, safety plan, diagnostic worksheet, step-by-step work order, parts and labor log, and post-service performance data sheet; format and organize the package as it would be presented to a dealership service manager or marina employer.	Flush muffs or run-tank, tachometer or engine analyzer, thermometer or thermal gun, digital multimeter for charging voltage check, fuel pressure gauge, manufacturer specification table for assigned engine, documentation package from Lessons 1–2, binder or digital folder for final submission, PPE	Post-service data sheet is graded against manufacturer specs: all recorded values must fall within specification or have a written explanation of any out-of-spec reading with a corrective recommendation; documentation package is checked for completeness—missing any of the six required documents scores below 80% and requires remediation before the oral defense.
4	Project Defense and Reflection	24	field	Students present and verbally defend all diagnostic and service decisions to an evaluator panel, demonstrating the ability to explain technical reasoning, cite applicable standards, and reflect on what they would do differently.	Deliver a structured 10-minute oral presentation to the panel (instructor plus at least one industry evaluator) walking through the engine's initial condition, the diagnostic path taken, each major service decision, the safety measures applied, and the final performance results—using the documentation package as the primary exhibit. Respond to a minimum of five technical challenge questions from the panel covering topics drawn from all prior courses (e.g., why a specific torque value matters, how a particular circuit was isolated, what ABYC standard applies to fuel system venting, or what the gear oil viscosity specification means for lower-unit protection). Complete a written self-evaluation rubric immediately after the defense, identifying one technical area executed well with evidence from the project, one area needing further development, and a specific action plan for improvement during the externship.	Completed and bound service record package, whiteboard or projected display for any diagrams, ABYC standards reference (available for consultation during defense), evaluator scoring rubric, self-evaluation form	Panel scores the defense on a rubric with four categories: technical accuracy of explanations, correct citation of standards or manufacturer data, professional communication clarity, and completeness of answers to challenge questions—minimum 80% overall to pass; a score below 80% in any single category requires a focused remediation session and a second defense attempt before the student advances to the externship.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Capstone Service Project	Project	60%	80% on the combined rubric scoring inspection report, service execution quality, post-service performance data, and documentation package completeness; zero unresolved safety violations	The graded project encompasses all physical work performed across Lessons 1 through 3: the pre-service inspection, full service execution, diagnostic fault resolution, post-service run test, and the complete assembled documentation package. Instructors use a weighted rubric that mirrors ABYC Marine Engine competency areas—fuel systems, electrical systems, cooling, lower unit, and documentation—so deficiencies map directly to exam content the student must address in Course 9. Meets specification · Within estimate · Workmanship · Safety · Documentation
Service Documentation Portfolio	Portfolio	20%	All six required documents present and legible; no blank required fields; parts numbers verified against catalog; 80% or higher on the documentation accuracy rubric	The portfolio is the student's complete paper and digital record of the capstone project—pre-service inspection report, safety plan, diagnostic worksheet, step-by-step work order, parts and labor log, and post-service performance data sheet—organized and formatted as a professional dealership service file. It is evaluated independently from the physical work quality to emphasize that accurate, complete documentation is a non-negotiable job skill and a direct requirement of ABYC service standards. Completeness · Organization · Evidence quality
Oral Project Defense	Oral / panel	20%	80% overall on the four-category panel rubric with no single category below 80%; satisfactory self-evaluation form submitted	The oral defense in Lesson 4 is assessed by the instructor and an industry evaluator using a structured rubric; students must correctly explain their technical decisions, cite at least two applicable ABYC standards or manufacturer specification references by name during the presentation or Q&A, and demonstrate professional communication suitable for customer-facing or team settings. A failed defense triggers one remediation opportunity before the student is cleared to begin the externship. Explains decisions · Answers technical questions · Professional communication

TRN-MARI21-08 Externship / clinical

Externship / Worksite Placement – Marine Engine & Outboard

243 hr · ~~$970~~ COMPLIMENTARY

Students complete 243 supervised hours at an approved marine dealership, repair yard, or marina service department, applying classroom skills to real customer work orders under the direct oversight of a journeyman or master marine technician. The placement bridges instructional training and independent employment, exposing students to production-shop pace, warranty documentation, customer communication, and the full range of engine systems covered in the program. Employer evaluations and a structured daily log provide evidence of occupational readiness aligned with ABYC Marine Engine and Yamaha/Mercury factory-certification competency areas.

Outcomes

Perform diagnosis, service, and repair tasks on outboard, inboard, and sterndrive engines in a live shop environment to employer quality and time standards.
Complete accurate work orders, parts requests, and labor documentation consistent with marine-industry billing practices.
Apply lockout/tagout, PPE selection, and fuel/electrical safety procedures on every job without prompting.
Demonstrate professional conduct—punctuality, communication, and teamwork—as rated satisfactory or above on the mid-term and final employer evaluation forms.
Identify and document at least two diagnostic or repair situations that connect directly to ABYC Marine Engine or Yamaha/Mercury factory-certification content areas.
Receive a final employer evaluation score of 75% or higher across all rated competency categories to qualify for program completion.

Course text

How the course runs. 4 blocks: Externship Orientation and Site Integration; Supervised Diagnostic and Service Work – Outboard and Four-Stroke Systems; Supervised Diagnostic and Service Work – Inboard, Sterndrive, Electrical, and Rigging Systems; Final Evaluation, Portfolio Completion, and Site Closeout.

What competent looks like. Perform diagnosis, service, and repair tasks on outboard, inboard, and sterndrive engines in a live shop environment to employer quality and time standards. Complete accurate work orders, parts requests, and labor documentation consistent with marine-industry billing practices. Apply lockout/tagout, PPE selection, and fuel/electrical safety procedures on every job without prompting. Demonstrate professional conduct—punctuality, communication, and teamwork—as rated satisfactory or above on the mid-term and final employer evaluation forms. Identify and document at least two diagnostic or repair situations that connect directly to ABYC Marine Engine or Yamaha/Mercury factory-certification content areas. Receive a final employer evaluation score of 75% or higher across all rated competency categories to qualify for program completion.

Lessons · 4 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Externship Orientation and Site Integration	30	field	The student successfully completes site-specific safety orientation, reviews employer shop policies and documentation systems, and begins logging supervised tasks on real work orders.	Attend employer-led facility walkthrough covering emergency exits, eyewash stations, fire suppression locations, fuel-storage rules, and the employer's lockout/tagout procedures; sign the site safety acknowledgment form. Shadow the assigned mentor technician through at least three complete work orders, recording each job type, time spent, tools used, and outcome in the externship daily log. Meet with the site supervisor and school externship coordinator (in person or via video call) to review evaluation rubric categories, attendance expectations, and the mid-term check-in schedule.	Externship daily log booklet, site safety acknowledgment form, school externship handbook, personal PPE kit (safety glasses, nitrile gloves, steel-toe footwear), employer orientation packet, digital time-tracking app or paper timesheet	Signed site safety acknowledgment returned to school coordinator within the first five working days; daily log entries present for every shift, each with job description, hours, and mentor initials; pass = all three items complete and no unexcused absences in the first 30 hours.
2	Supervised Diagnostic and Service Work – Outboard and Four-Stroke Systems	81	field	Under mentor supervision, the student performs diagnosis and scheduled service on two-stroke and four-stroke outboard engines, producing documentation accurate enough for employer billing, while connecting each job to ABYC Marine Engine or Yamaha/Mercury competency areas.	Complete at least six outboard-specific jobs (e.g., annual service, lower-unit fluid change, compression/leak-down test, fuel-system diagnosis, thermostat replacement, or trim/tilt service) selected by the mentor from the live work order queue; document each job on a shop work order and cross-reference the relevant ABYC standard or factory service manual section in the daily log. Conduct a mid-placement self-assessment using the program's competency checklist, identifying two skills still needing development, and discuss the results with the mentor to adjust job assignments for the remaining hours. Participate in at least one customer interaction (phone estimate, vehicle check-in, or parts discussion) under mentor guidance, then write a one-paragraph reflection in the daily log on professional communication observed.	Manufacturer service manuals (Yamaha and/or Mercury), ABYC technical standards references available at the site, multimeter, compression tester, vacuum/pressure gauge set, scan tool or outboard diagnostic interface, shop torque wrenches, personal PPE, daily log booklet, work order forms	Mentor initials on each completed work order confirming quality meets shop standard; daily log shows job description, time, tools, and credential cross-reference for every shift; mid-term employer evaluation form returned to school coordinator with a score of 75% or higher on all rated categories; pass = both documentation complete and mid-term score ≥ 75%.
3	Supervised Diagnostic and Service Work – Inboard, Sterndrive, Electrical, and Rigging Systems	100	field	The student independently initiates and completes—with mentor oversight—service and repair tasks spanning inboard engines, sterndrives, marine electrical systems, and rigging components, demonstrating progressively less direct supervision as competence is confirmed.	Complete at least eight jobs across the inboard/sterndrive, electrical, and rigging categories (e.g., bellows and gimbal-bearing inspection, alternator or battery-charging system diagnosis, ignition-system service, throttle and shift cable replacement, propeller R&R, bilge-pump circuit test, or bonding/grounding continuity check); document each on a shop work order with parts used, labor time, and applicable ABYC or factory standard noted. With mentor approval, take primary ownership of one complete customer job from write-up to final quality check, presenting findings to the mentor before returning the vessel; log the full sequence including any parts ordered, delays encountered, and corrective actions taken. Prepare a two-page typed externship progress report summarizing jobs completed to date, skills gained, challenges overcome, and two specific ways the worksite experience reinforced or extended program coursework—submit to school coordinator at the 213-hour mark.	Manufacturer service manuals, ABYC technical standards, marine-grade multimeter, clamp-on ammeter, cable tension gauge, rigging hardware, sterndrive bellows kit (as applicable to live jobs), alignment tools, daily log booklet, laptop or tablet for progress report, personal PPE	Work orders signed by mentor for each job; progress report submitted on time and demonstrates specific connections to credential exam content areas; mentor confirms student required only general (not step-by-step) supervision on the independently owned job; pass = all work orders signed, report submitted, and mentor confirms reduced supervision level.
4	Final Evaluation, Portfolio Completion, and Site Closeout	32	field	The student compiles the complete externship log and work order documentation into a portfolio, receives and discusses the final employer evaluation, and closes out the placement in a professional manner that demonstrates career-readiness behaviors.	Organize all daily log entries, work order copies, mid-term evaluation, and the progress report into a single externship portfolio (physical binder or digital folder per school format); verify that hours are fully documented and that the credential cross-reference column is completed for each job. Participate in a formal final evaluation meeting with the site supervisor: review each rubric category, receive written feedback, discuss areas of strength and areas for continued development after program completion, and ask at least two questions about career pathways at the site or in the industry. Write a one-to-two page typed externship reflection covering: most challenging diagnostic problem encountered, safety decision made independently, how the experience connects to the upcoming ABYC and factory certification exams, and a professional goal for the first year of employment—submit to school coordinator within five days of the final shift.	Complete daily log booklet, copies of all work orders, final employer evaluation form, school externship portfolio rubric, laptop or tablet for reflection writing, externship completion certificate (issued by school upon passing evaluation)	Portfolio contains entries for all 243 hours with mentor initials; final employer evaluation form returned to school with overall score ≥ 75%; reflection submitted on time and addresses all four required points; pass = all three items met, triggering issuance of externship completion certificate.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Employer Skills Demonstration Evaluation	Skills demonstration	70%	A score of 75% or higher on the employer's standardized evaluation rubric across all rated competency categories (technical skill, safety practices, documentation accuracy, professionalism, and teamwork), assessed at mid-term and again at the final closeout meeting.	The site supervisor rates the student on each competency category using a school-provided rubric at the midpoint (approximately 120 hours) and at the end of the placement (243 hours); both forms are submitted to the school externship coordinator. If the mid-term score falls below 75% in any category, the student and coordinator develop a written improvement plan within five business days, and the student must demonstrate improvement by the final evaluation to pass the externship. Competency · Safety · Attendance · Conduct · Initiative
Externship Daily Log and Portfolio	Log	30%	All 243 hours documented with a job description, mentor initials, tools used, and ABYC or factory-standard cross-reference for every shift; portfolio organized per school format; progress report and final reflection submitted on time and meeting content requirements—all items complete earns a passing grade.	The daily log and associated documents (work order copies, progress report, and final reflection) form the student's externship portfolio, which is reviewed by the school externship coordinator at the 30-hour, 120-hour, and 243-hour marks. The portfolio serves as the primary evidence that the student engaged in the breadth of engine systems required by the program and made intentional connections between worksite tasks and the ABYC Marine Engine and Yamaha/Mercury certification exam content areas. Complete · Verified

TRN-MARI21-09 Exam prep

Certification Exam Preparation: ABYC Marine Engine & Factory Technician Credentials

68 hr · ~~$680~~ COMPLIMENTARY

Students systematically review every content domain tested on the ABYC Marine Engine certification exam and the Yamaha/Mercury factory technician assessments, identifying and closing individual knowledge gaps before sitting for credentials. The course alternates between domain-focused review sessions and timed, full-length mock exams with scored debriefs so students enter exam day with realistic pacing experience and verified competency across all tested areas.

Outcomes

Demonstrate mastery of ABYC Marine Engine exam domains—including two-stroke and four-stroke outboard systems, inboard/sterndrive systems, fuel systems, electrical systems, rigging, and propulsion—by scoring at or above the ABYC passing threshold on at least two consecutive timed mock exams.
Correctly interpret and apply relevant ABYC standards language to diagnostic and repair scenario questions at a passing rate of 80% or higher.
Identify personal weak-domain scores from diagnostic data and produce a written self-study remediation plan with specific references to course materials and ABYC technical references.
Apply systematic test-taking strategies—process of elimination, keyword analysis, and time management—to complete a full-length timed mock exam without leaving questions unanswered.
Demonstrate readiness for Yamaha and/or Mercury factory technician assessments by achieving a passing score on a factory-format mock exam covering engine diagnosis, electronic fuel injection, and computer-based diagnostic tool interpretation.
Complete all exam registration logistics—application, required documentation, and scheduling—so that no administrative barrier delays credential attainment after course completion.

Course text

How the course runs. 4 blocks: Diagnostic Assessment & Domain Mapping; Domain Deep-Review: Systems, Standards & Diagnostic Reasoning; Factory Credential Focus: Electronic Diagnostics & Manufacturer-Specific Systems; Full Mock Certification Exams & Exam-Day Readiness.

What competent looks like. Demonstrate mastery of ABYC Marine Engine exam domains—including two-stroke and four-stroke outboard systems, inboard/sterndrive systems, fuel systems, electrical systems, rigging, and propulsion—by scoring at or above the ABYC passing threshold on at least two consecutive timed mock exams. Correctly interpret and apply relevant ABYC standards language to diagnostic and repair scenario questions at a passing rate of 80% or higher. Identify personal weak-domain scores from diagnostic data and produce a written self-study remediation plan with specific references to course materials and ABYC technical references. Apply systematic test-taking strategies—process of elimination, keyword analysis, and time management—to complete a full-length timed mock exam without leaving questions unanswered. Demonstrate readiness for Yamaha and/or Mercury factory technician assessments by achieving a passing score on a factory-format mock exam covering engine diagnosis, electronic fuel injection, and computer-based diagnostic tool interpretation. Complete all exam registration logistics—application, required documentation, and scheduling—so that no administrative barrier delays credential attainment after course completion.

Lessons · 4 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Diagnostic Assessment & Domain Mapping	10	theory	Students complete a full-length diagnostic pre-test, score it by domain, and produce a written gap-analysis plan that prioritizes their lowest-scoring ABYC and factory exam content areas.	Students sit a full-length, timed ABYC-format diagnostic exam covering all credential domains (two-stroke/four-stroke outboards, inboard/sterndrive, fuel systems, electrical, rigging, propulsion, and shop safety); instructor scores and returns results with a domain-by-domain breakdown. Using their scored reports, students plot a personal competency heat map on a provided domain grid, coloring each area green (≥80%), yellow (65–79%), or red (<65%) to visualize priority study targets. Each student writes a two-page Remediation Plan specifying which ABYC standards chapters, textbook sections, and hands-on lab activities they will revisit during the remaining lessons, with a self-set target score for each red or yellow domain.	Full-length ABYC-format diagnostic exam (instructor-developed per published domain outlines), domain scoring rubric, personal competency heat-map template, ABYC Technical Information Reports (member access), Yamaha and Mercury factory technician study guides, student course binders from Courses 1–8	Student submits a completed Remediation Plan that lists every domain, a color rating, a specific reference source for each gap area, and a target score; plan is reviewed by instructor and returned with written feedback before next lesson. Pass mark: all domains rated and all red/yellow domains have at least one actionable remediation step identified.
2	Domain Deep-Review: Systems, Standards & Diagnostic Reasoning	28	theory	Students review all major ABYC and factory credential content domains through structured mini-lectures, worked exam questions, and small-group problem-solving, achieving a domain quiz average of 80% or higher across all areas.	Instructor delivers seven targeted 2-hour review blocks—one per domain (two-stroke/four-stroke outboards, inboard/sterndrive, fuel systems, electrical systems, rigging, propulsion, and safety/environmental regulations)—using released-style sample questions as the teaching vehicle: instructor reads a question, students commit to an answer, then the group unpacks why each distractor is wrong using the applicable ABYC standard or manufacturer specification. Students work in rotating pairs on 'standard language' cards: each card presents a paraphrased ABYC requirement and a repair scenario; pairs must identify which answer complies and cite the relevant standard section by topic title, reinforcing the skill of translating regulatory language into shop decisions. Students complete a 20-question timed domain quiz at the end of each review block; quiz results are entered into a shared class tracking sheet so students can compare personal trends over the seven blocks and adjust individual study plans.	Instructor-developed domain review slide decks, ABYC Technical Information Reports and standards (member portal), Yamaha Outboard Service Manual (current generation), Mercury Marine Service Manual (current generation), domain quiz sets (20 questions each), electronic fuel injection and computer-based diagnostic tool reference guides, class domain tracking spreadsheet	Average score across all seven domain quizzes must reach 80% or higher; any student averaging below 80% on two or more domains receives a required one-on-one instructor conference and a revised remediation assignment before the mock exam lesson. Individual quiz scores are recorded in the grade book.
3	Factory Credential Focus: Electronic Diagnostics & Manufacturer-Specific Systems	14	lab	Students demonstrate proficiency in computer-based diagnostic tool operation, electronic fuel injection interpretation, and network communication diagnosis as tested on Yamaha and Mercury factory technician assessments, achieving 80% or higher on a factory-format practice exam.	Students connect Yamaha Diagnostic System (YDS) and/or Mercury's computer-based diagnostic software to shop engines, navigate fault-code menus, interpret live sensor data, and document findings on factory-style diagnostic worksheets—mirroring the task format used in factory certification practical assessments. Instructor presents six representative factory exam scenarios (e.g., hard-start, lean-fuel-trim fault, CAN-bus communication error) displayed on a projector; students work individually to select the correct diagnostic path on a decision-tree worksheet, then compare answers in a structured debrief that references the manufacturer service manual step by step. Students complete a 40-question timed factory-format practice exam covering EFI diagnosis, digital throttle and shift systems, trim/tilt electrical circuits, and emissions system components; instructor scores exams and holds a whole-class debrief focusing on the five most commonly missed questions.	Yamaha Diagnostic System (YDS) software and interface cable, Mercury computer-based diagnostic software and interface, shop outboard engines with seeded faults, factory-style diagnostic worksheets, Yamaha and Mercury EFI and digital system service manuals, factory-format 40-question practice exam, projection system	Factory-format practice exam score of 80% or higher required to proceed; students below 80% complete a targeted re-study assignment and may retest once with instructor approval before the final mock exam. Practical diagnostic worksheet must have all required fields completed accurately and legibly.
4	Full Mock Certification Exams & Exam-Day Readiness	16	practice	Students complete two full-length, strictly timed mock exams—one ABYC-format and one factory-format—under real exam conditions, score at or above passing on both, and confirm all registration and documentation requirements are met before exam day.	Students sit a full-length ABYC Marine Engine mock exam under strict testing conditions (no notes, timed per the published exam duration, separate seating); immediately after, students sit the factory technician mock exam the same day; both exams are hand-scored by the instructor using an answer key, and each student receives a printed score report with domain-level feedback within 24 hours. Instructor facilitates a structured debrief session: the five most-missed questions from each exam are projected one at a time; students nominate the correct answer with rationale, and the group discusses the underlying ABYC standard or manufacturer specification that governs the correct response—this debrief is the primary remediation event for the course. Students complete an Exam-Day Readiness Checklist confirming: ABYC exam application submitted (or scheduled), factory credential registration completed, valid government-issued ID available, any required documentation of training hours assembled, and exam site location and logistics confirmed; instructor reviews and signs off each checklist.	Full-length ABYC-format mock exam (instructor-developed per published domain outline), full-length factory-format mock exam, printed answer sheets, stopwatch/exam timer, exam-day readiness checklist, ABYC exam registration information (current from ABYC website), Yamaha/Mercury factory certification registration information	Pass mark: ABYC mock exam score at or above the published ABYC passing threshold; factory mock exam score of 80% or higher. Students who do not pass one or both mocks are not blocked from sitting the credential exam but receive a written instructor recommendation letter with a targeted study plan. Exam-Day Readiness Checklist must be fully signed off by the final class session.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Full Mock Certification Exam Battery (ABYC Marine Engine + Factory Technician)	Mock certification exam	100%	ABYC mock exam: score at or above the current ABYC published passing threshold across all domains; Factory mock exam: 80% or higher overall; both exams completed within the allotted time limits with no external references.	Students complete a full-length, timed ABYC Marine Engine mock exam followed by a full-length, timed Yamaha/Mercury factory technician mock exam in a single proctored session, replicating actual credential exam conditions. Scores are reported by domain so each student and the instructor can confirm readiness and address any remaining gaps before the student sits for the live credentialing exams. Score · Time management

Program completion

External credential: ABYC Marine Engine; Yamaha/Mercury Factory Cert

Students sit the ABYC Marine Engine certification exam, administered by the American Boat and Yacht Council, and may also complete Yamaha Marine and/or Mercury Marine factory technician certification assessments administered through those manufacturers' respective dealer-training programs. Pass standard: Credential issued by the body.

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