Re: too large prop cause damage in Z drive?
The reason your boat gets better fuel economy propped to turn at the bottom of it?s recommended RPM range is the same reason your car gets better fuel economy in overdrive.
Short and sweet: A given speed requires a given amount of power, which requires a given amount of fuel and air. A bigger prop (or taller gear ratio in your car) requires the engine to turn at a lower RPM to deliver the same speed. This lower RPM requires a bigger throttle opening to deliver the same amount of fuel and air through the engine, thus reducing pumping losses and increasing the engine?s efficiency.
Making the same power at lower RPM also increases cylinder pressures and temperatures. As Bondo pointed out, if you go too far then you destroy pistons and burn valves. This is why you don?t lug your car through the 15 MPH school zones in top gear or prop your boat with a prop that?s too big.
As a side note, one of the main reasons a diesel engine is more efficient than a gas engine is because the diesel does NOT have a throttle valve. It is running "WOT" (Wide Open Throttle) all the time and therefore has no pumping losses due to throttle flow restrictions. Power delivery is controlled solely by how much fuel is injected into the cylinder.