TOHATSU MFS 4 Service Manual
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TOHATSU MFS 4 Service Manual

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FS
4
5
6B,C
/
/
odels
B No.003-21034-2
11-04 NB

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Questions and answers

Dennis Niemann
May 1, 2025

Tohatsu 15 hp 4 stroke fuel filter inside fuel tank,cleaning?

0
1 comments:
Mr. Anderson
May 16, 2025

To clean the fuel filter inside the fuel tank of a Tohatsu MFS 4 15 hp 4-stroke engine:

1. Remove dirt and water from the fuel tank if present.
2. Inspect the fuel filter for dirt, fuel residue buildup, foreign matter, or cracks.
3. If the filter is dirty or damaged, replace it.
4. When removing the fuel filter, avoid spilling fuel.
5. During installation, make sure the fuel filter is oriented in the correct direction—fuel flows in the direction of the arrow marked on the filter.

This answer is automatically generated

0
Stefan Craciun
June 3, 2025

In the Tohatsu 6 hp 4 stroke service manual I can't find the part code. Can you help me with some information; where can I find the part code?

0

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Summary of Contents for TOHATSU MFS 4

  • Page 1 6B,C odels B No.003-21034-2 11-04 NB...

  • Page 3: Service Information

    Introduction Before reading this manual This service manual provides information that is needed for inspection, service and repair of applicable outboard motors. For information about operation of the products that are not described in this document, refer to the owners manual. For our customers' safe and dependable use of the product for long term, it is essential to maintain the performance and quality of the outboard.
  • Page 4 About this manual This service manual is designed so that service persons are able to perform their work correctly. Understand the following matters well for efficient repairs. 1 Each chapter begins with the introduction of special tools that are used for the work described in the chapter so that the service persons are able to understand the tools needed.
  • Page 5 This manual uses SI unit system (International System of Units) for pressure, force (load), torque and stress. This manual newly adopts the international unit construction system (SI unit system) followed by the conventional imperial and metric systems enclosed by ( ) and [ ] as described below. Example : <Pressure>...

  • Page 6: Service Information

    Description of Pictograph The following symbols represent the contents of individual chapters. Service Fuel System Service Data Maintenance Information (Carburetor) Electrical Power Unit Lower Unit Bracket System Wiring Troubleshooting Accessories r/min Diagrams The following symbols indicate items needed for the service. Lubrication Tightening Special Tool...

  • Page 7: Table Of Contents

    1.Service Information 16) Inspection of Anode ……………………………… 3-18 17) Replacement of Anode …………………………… 3-18 1. Identification (Engine Serial Number) … 1-2 18) Inspection of Propeller …………………………… 3-19 2. Work Safety ……………………………………… 1-2 19) Inspection of Thermostat ………………………… 3-19 1) Fire Prevention ……………………………………… 1-2 20) Inspection of Cooling Water Passage……………...
  • Page 8 30) Installation of Water Pump ……………………… 6-23 19) Inspection of Piston Outer Diameter …………… 5-30 31) Installation of Propeller Shaft Housing ………… 6-24 20) Inspection of Cylinder Inner Diameter…………… 5-30 32) Filling with Gear Oil ……………………………… 6-25 21) Inspection of Piston Clearance ………………… 5-30 33) Installation of Lower Unit …………………………...
  • Page 9 INDEX Service Information Service Data Inspections and Adjustments Fuel System Power Unit Lower Unit Bracket Electrical System Troubleshooting Wiring Diagram C Model Service Information 4st 4/5/6 2011...
  • Page 10 viii 4st 4/5/6 2011...
  • Page 11 Service Information 1. Identification 1) Steering Handle ………………………… 1-8 (Engine Serial Number)……………………… 1-2 2) Gear Shift ………………………………… 1-8 2. Work Safety ………………………………… 1-2 3) Engine Oil ………………………………… 1-8 1) Fire Prevention …………………………… 1-2 4) Gear Oil …………………………………… 1-8 2) Ventilation ………………………………… 1-2 5) Fuel Tank Line ……………………………...

  • Page 12: Identification (Engine Serial Number)

    Service Information 1. Identification (Engine Serial Number) Engine serial number is stamped on the bottom cowl of outboard motor body. 1 Model Name 2 Model Type Made in Japan 3 Serial Number F5BD SERIAL No. RATED POWER 3.7 kW FULL THROTTLE RANGE 4500 5500 r / min...

  • Page 13: Tools

    5) Tools Use specified special tools to prevent damaging to parts and to perform work safely and surely. Be sure to follow installation procedures described in this manual and use tightening torque specified. 3AC728710 6) Recommendations on Service Remove foreign substances and dirt from outboard motor and individual parts by cleaning.

  • Page 14: Cautions In Disassembling And Assembling Components

    Service Information 7) Cautions in Disassembling and Assembling Components Secure outboard motor to dedicated stand firmly. Take special care not to scratch painted surfaces or mating surfaces of cylinder and crankcase. Replace parts such as packings, gaskets, O rings, oil seals, spring pins or split pins with new ones after they are removed.

  • Page 15: Tools And Instruments

    3. Tools and Instruments 1) Test Propeller P/N. 3B2-64110-1 Outer diameter : 164mm Width : 12mm (Reference value) Speed at WOT Model (Wide Open Throttle) (r/min) F 4B/5B 4,500 - 5,500 F 6B 5,000 - 6,000 This test propeller has been designed for break-in operation and load test operation.

  • Page 16: Special Tools

    Service Information 3) Special Tools Vacuum/Pressure Gauge Spring Pin Tool A Spring Pin Tool B Thickness Gauge P/N. 3AC-99020-0 P/N. 345-72227-0 P/N. 345-72228-0 P/N. 353-72251-0 Inspecting pressure Removing spring pin Installing spring pin Measuring gaps Center Plate 3 Driver Rod 3 Tachometer Compression Gauge P/N.
  • Page 17 69-72727-0 Needle Bearing Press Kit Backlash Measuring Tool Kit Clamp A Dial Gauge Plate P/N. 369-72900-0 P/N. 369-72740-0 P/N. 3B7-72720-0 P/N. 3B7-72729-0 Measuring gap between forward and Used to attach dial gauge Installing bearings Measuring backlash pinion gears (A and B gears) when measuring backlash Flushing Attachment P/N.

  • Page 18: Pre-Delivery Inspection

    Service Information 4. Pre-delivery Inspection å ∫ 1) Steering Handle å Check installations for clattering and play. ∫ Adjust steering friction. ç Check throttle grip for movement. (full open/full close). ç ∂ ∂ Adjust throttle friction. 1 Steering Adjust Screw c Lighter d Heavier 2) Gear Shift Check shift lever 1 and propeller shaft for smooth...

  • Page 19: Fuel Tank Line

    5) Fuel Tank Line Check that fuel tank contains sufficient amount of gasoline, fuel line is connected and is free of leak. CAUTION Since this is a four stroke engine model, do not use fuel mixed with engine oil. Use of fuel mixed with engine oil will cause engine trouble.

  • Page 20: Inspection Of Stop Switch

    Service Information 8) Inspection of Stop Switch Press stop switch 1 hard or pull out lock 2 from stop switch 1 to check that engine stops. 9) Cooling Water Check Port Check that cooling water check port 1 discharges water during engine runs.

  • Page 21: Propeller Selection

    11) Propeller Selection Select a propeller that is best-suited to type of boat and application. Range of operating engine revolution at WOT 4/5B : 4,500 - 5,500r/min 6B : 5,000 - 6,000r/min CAUTION Miss-selection of propeller can cause adverse effects on engine life, fuel consumption, etc. as well as on performance.

  • Page 22: Break-In Operation

    Service Information 5. Break-in Operation Break-in operation is needed for the purpose of smoothening sliding surfaces between components such as pistons and cylinder, piston rings, piston pins, crank shaft, connecting rods, and intake and exhaust valves. Break-in Operation…10 hours Time 10 minutes 2 hours 3 hours...

  • Page 23: Check After Test Run

    7. Checks After Test Run Check that power unit, lower unit and bracket are free of looseness or play. Check that no water is present in gear oil. Check that no fuel leakage exists in the cowl. Check that no oil and water leak in the cowl and no water is 1 Flushing Attachment (optional) present in engine oil.
  • Page 24 Service Information 1-14 4st 4/5/6 2011...

  • Page 25: Service Data

    Service Data 1. Outline Dimensons ……………………… 2-2 3. Cooling Water System Diagram……… 2-6 1) Engine Dimensions ……………………… 2-2 4. Specifications ……………………………… 2-8 2） Clamp Dimensions ……………………… 2-4 5. Maintenance Data………………………… 2-10 2. Engine Lubrication System 6. Tightening Torque Specifications … 2-14 Diagram ………………………………………...
  • Page 26 Service Data 1.Outline Dimensons 1）Engine Dimensions <Dual Tank model> Item Type Unit mm/in 16.46 mm/in 25.79 mm/in 30.79 mm/in 35.79 mm/in 17.13 mm/in 22.13 mm/in 27.13 mm/in 15.75 mm/in 20.08 mm/in 4.33 mm/in 12.99 mm/in 13.78 mm/in 13.19 mm/in 30-60 1.18-2.36 mm/in 10.83...
  • Page 27 <Sepalate Tank model> Item Type Unit mm/in 14.37 mm/in 25.79 mm/in 30.79 mm/in 35.79 mm/in 17.13 mm/in 22.13 mm/in 27.13 mm/in 15.75 mm/in 20.08 mm/in 4.33 mm/in 12.99 mm/in 13.78 mm/in 13.18 mm/in 30-60 1.18-2.36 mm/in 10.83 mm/in 25.91 mm/in 29.84 mm/in 33.78...

  • Page 28: Clamp Dimensions

    Service Data 2）Clamp Dimensions ENTER LINE 85mm (3.3in) 85mm (3.3in) TOP OF TRANSOM 55.5mm 55.5mm (2.2in) (2.2in) Allowable Transom Thikness 30~55mm(1.18~2.17in) 4st 4/5/6 2011...

  • Page 29: Engine Lubrication System Diagram

    2. Engine Lubrication System Diagram ylinder head rocker arm valve Push rod rankshaft upper bearing (Ball bearing) Rifter ylinder wall rank pin amshaft Piston Piston pin am shaft lower journa (Metal bearing) Oil regulator Oil pressure switch Main galley Oil pump Oil strainer Oil pan 4st 4/5/6 2011...

  • Page 30: Cooling Water System Diagram

    Service Data 3. Cooling Water System Diagram hermostat Cylinder head Cylinder Oil Pan Cooling Water Check Port Water Discharging Water Feed Passage in Passage in Drive Drive Shaft Housing Shaft Housing Water Pipe Drive Shaft Housing Water Pump Exhaust Gas and Cooling Water Discharged Water Intake...
  • Page 31 4st 4/5/6 2011...

  • Page 32: Specifications

    Service Data 4. Specifications Model Item Unit ual Tank Model Sepalate Tank Model Sail Pro 4/5/6B 5/6B imensions Overall length Overall width 1,073 1,020 Ñ Overall height 1,200 1,147 1,327 1,274 Ñ Transom height Weight Ñ Performance 4B : 2.9 (5,000r/min) [4] 4.4 (5,500r/min) [6] Maximum output 5B : 3.7 (5,000r/min) [5]...
  • Page 33 Model Item Unit Dual Tank Model Sepalate Tank Model Sail Pro 4/5/6B 5/6B uel and oil ype of fuel Unleaded regular octane gasoline (Research octane number 90 or more) Fuel tank capacity Starting fuel enrichment system Choke valve Fuel pump Mechanical (plunger pump) 4 stroke engine (motor) oil SE, SF, SG, SH, SJ, SL, SM...

  • Page 34: Maintenance Data

    Service Data 5. Maintenance Data art name Item Standard value Carbon deposition on combustion chamber wall Deformation of mating faces and flaws Cylinder head Corrosion of mating faces lugging of cooling water passages Deposition on water jacket interior walls Wear of bore : Measure bore by using 59.00mm (2.3228in) Seizure, cylinder liner damage, or wear Cylinder...
  • Page 35 Serviceable limit Action to be taken Clean to remove. 0.03 (0.0012) Correct. (Use #240 to 400 waterproof sand paper put of the surface plate to correct. Use #600 to finish.) Correct or replace if possible. Clean to remove. Clean to remove. 59.07mm (2.3256in) Replace if severely damaged on the piston sliding surface, which cannot be repaired with sand paper of No.
  • Page 36 Service Data Standard value art name Item Sail ro Sail ro (E A) (EU) Setting mark 3ATA 3ASA 3AUA 3DKA Venturi bore ¿10 ¿13 ¿15 ¿15 ¿15 Throttle bore ¿19 ¿19 ¿21 ¿21 ¿21 Main jet (MJ) Main air jet (MAJ) #135 #155 #140...
  • Page 37 Standard value Standard value 23.13mm over Replace if over upper limit. 0.25mm (0.0047 Ð 0.0079in) Replace if over upper limit. 5.96mm (0.2346in) Replace if under lower limit. 0.10mm (0.0039in) Wear of oil pump cover is included. Replace if over upper limit. Replace if under lower limit.

  • Page 38: Tightening Torque Specifications

    Service Data 6. Tightening Torque Specifications Tightening torque Wrench Thread B Type of Tightening location x Pitch fastener N·m lb·ft kg·m Engine Connecting rod M7x1.0 Bolt Cylinder head M8x1.25 Bolt Oil pan M8x1.25 Bolt M6x1.0 Bolt Oil drain bolt M10x1.25 Bolt Pivot bolt M8x1.25...

  • Page 39: Sealant And Lubricant

    7. Sealant and Lubricant Apply to Remarks Three Three Liquid Shin-Etsu Chuoh Yuka Konishi Bond Bond Chemical O-Ring Centax Bentax 1342 G17 G103 1741 2000 ● Camshaft Bearings and cams ● Rocker arm Sliding surface ● Valve (IN, EX) Stem and stem end Cylinder ●...
  • Page 40 Service Data Apply to Remarks Three Three Liquid Shin-Etsu Chuoh Yuka Konishi Bond Bond Chemical O-Ring Centax Bentax 1342 G17 G103 1741 2000 O ring (shift lever) ● Shift Shift lever ● Sliding surface Drive shaft Thread ● Taper plug 1/8 housing Drive shaft (spline) ●...

  • Page 41: Maintenance

    Maintenance 1. Special Tools ……………………………… 3-2 11) Inspection of Compression Pressure … 3-12 2. Inspection Schedule …………………… 3-3 12) Inspection and Adjustment of 3. Inspection Items ………………………… 3-4 Valve Clearance ………………………… 3-13 1) Inspection of Top Cowl ………………… 3-4 13) Throttle Cable …………………………… 3-15 2) Fuel System ………………………………...

  • Page 42: Special Tools

    Maintenance 1. Special Tools Tachometer Compression Gauge P/N. 3AC-99010-0 P/N. 3AC-99030-0 Measuring engine revolution Measuring compression speed pressure 4st 4/5/6 2011...

  • Page 43: Inspection Schedule

    Pressure ombustion Include valve lapping leaning hamber if necessary. Bend, damage, Propeller wear of blades TohatsuÕs genuine gear oil Replacement or GL5,SAE80 to 90 Gear Oil replenishment of oil, Replacement Replacement Replacement Replacement Replacement 195ml (6.6fl.oz) leak of water orrosion, Wear...

  • Page 44: Inspection Items

    Maintenance 3. Inspection Items 1) Inspection of Top Cowl Push top cowl using both hands to check for looseness and seal when cowl latched. 2) Fuel System Check piping Remove top cowl and check each section for fuel leak, dirt, deterioration and damages.

  • Page 45: Inspection Of Fuel Tank

    3) Inspection of Fuel Tank < For Dual Fuel Tank model > 1 if any. Remove dirt and water from fuel tank < For separate Fuel Tank model > Turn fuel pick up elbow 3 of fuel tank 2 counterclockwise to remove the part, and clean the filter 4.

  • Page 46: Replacement Of Engine Oil

    Maintenance 5) Replacement of Engine Oil Oil Level uantity of Oil for Full Replacement 0.45L pper Limit 0.35L Lower Limit Oil Specification Engine Oil : 4 Stroke Engine Oil API: SE, SF, SG, SH, SJ, SL, SM 10W Ð 40 SAE: 10W-30, 10W-40 10W Ð...

  • Page 47: Inspection Of Gear Oil Quantity

    5. Tighten drain bolt 1. 6. Pour new oil into oil inlet until oil level reaches upper limit mark of oil level gauge. 7. Start and run engine for 5 minutes to warm up. 8. Stop engine and check oil level and for oil leaks after 5 minutes.
  • Page 48 Maintenance Remove lower unit installation bolts 2, and pull lower unit ass'y downward to remove. Remove pump case (Upper) 3. Remove impeller 4 and check it. Check upper pump case for deformation. Replace if necessary. Check impeller 4 and pump case liner 5 for cracks and wear.

  • Page 49: Replacement Of Gear Oil

    8) Replacement of Gear Oil Tilt outboard motor a little as shown. Place drain oil pan below oil plug 1, remove lower oil plug 1 and then upper oil plug 2 to drain oil. Remove lower oil plug first when draining. Check gear oil for presence of metal particles, change of color (abnormal if clouded), and viscosity.

  • Page 50: Inspection Of Gear Case (For Leakage)

    Maintenance 9) Inspection of Gear Case (for leakage) Drain gear oil. Remove upper oil plug 1 and connect a commercially available leakage tester to this hole. Apply specified pressure to gear base, and check if the pressure is maintained without further compression for 10 seconds.

  • Page 51: Inspection Of Spark Plugs

    10) Inspection of Spark Plugs Remove plug caps and then spark plugs. Use spark plug cleaner or wire brush to clean spark plug electrodes 1. Replace if necessary. Check electrodes 1 for corrosion or excessive build up of carbon, and washer 2 for damage. Replace if necessary. Check spark plug gap a.

  • Page 52: Inspection Of Compression Pressure

    Maintenance 11) Inspection of Compression Pressure Start and run engine for 5 minutes to warm up, and then stop. Shift gear into neutral (N). Remove lock plate 1 (of stop switch lanyard) from stop switch. CAUTION Remove lock plate (of stop switch lanyard) from stop switch before measuring compression pressure.

  • Page 53: Inspection And Adjustment Of Valve Clearance

    12) Inspection and Adjustment of Valve Clearance · Perform inspection and adjustment of valve clearances when engine is cold. · #1 Set piston to top dead center of compression stroke. Remove cylinder head cover, fuel pump and spark plug. Align locating marks 1 of flywheel and crankcase with each other.
  • Page 54 Maintenance Hold pivot and loosen lock nut. Put thickness gauge 3 in the gap between rocker arm and valve. Valve Clearance (when engine is cold) : (IN) intake side : 0.06 - 0.14mm (0.0025 - 0.0055in) (EX) exhaust side : 0.11 - 0.19mm (0.0045 - 0.0075in) Rotate pivot to adjust valve clearance, and then, tighten lock nut.

  • Page 55: Throttle Cable

    13) Throttle Cable Adjustment of Throttle Cable Check position of cable at low speed and high speed sides. Set throttle grip to slowest position, and fully pull choke knob to close choke valve. Lock nut 1 while applying tension to outer wire by pulling it with a hand to fix low speed side wire.
  • Page 56 Maintenance Set throttle grip to full-open position, and check if throttle lever of carburetor makes contact with stopper. Set throttle grip to full-close position, and check if throttle lever of carburetor makes contact with stopper. 3-16 4st 4/5/6 2011...

  • Page 57: Inspection Of Idle Engine Speed

    14) Inspection of Idle Engine Speed Start engine and run for 5 minutes to warm up. Attach tachometer to spark plug high tension cord 1 to check idle speed. More accurate and stable reading can be obtained when tachometer lead is connected with high tension cords of individual cylinders linked with each other.

  • Page 58: Inspection Of Anode

    Maintenance 16) Inspection of Anode Replace anode 1 if it is corroded excessively. Replace anode if volume is reduced to 2/3 of new part. CAUTION Do not coat anode and trim tab with oil, grease or paint, or the anti-corrosion function does not work normally.

  • Page 59: Inspection Of Propeller

    18) Inspection of Propeller Check propeller blades and spline for cracks, damages, wear and corrosion. Replace if necessary. 19) Inspection of Thermostat Loose thermostat cover nut and remove thermostat 1. Hang thermostat 2 in the water container. Put thermometer in the water, warm up water and measure water temperature when valve opens.

  • Page 60: Inspection Of Cooling Water Passage

    Maintenance 20) Inspection of Cooling Water Passage Check water strainer 1 for clogging. Clean if necessary. Set outboard motor in the water and start engine. Check that cooling water is discharged from cooling water check port 2. If not, check water pump and cooling water passage in the engine.

  • Page 61: Flushing With Water

    21) Flushing with Water CAUTION Touching rotating propeller could lead to injury. Be sure to remove propeller before running engine on the land. WARNING Exhaust gas contains carbon monoxide, which will cause gas poisoning. Do not start engine with outboard motor placed in a closed area such as boat house.

  • Page 62: Greasing Points

    Maintenance 22) Greasing Points Apply grease to throttle cable and sliding areas. Apply grease through grease nipples 1 until excessive grease appears from bushing a. Apply grease to thread of clamp screws 2. Apply grease to throttle cable b and sliding areas. c Do not lubricate here.
  • Page 63 Apply grease to seal ring and bushing 4 of hook lever. Apply grease to propeller shaft spline 5. 4st 4/5/6 2011 3-23...
  • Page 64 Maintenance 3-24 4st 4/5/6 2011...

  • Page 65: Fuel System

    Fuel System 1. Special Tools ……………………………… 4-2 4) Inspection of Fuel Cock ………………… 4-13 2. Parts Layout ……………………………… 4-4 5) Inspection of Fuel Filter ………………… 4-13 Carburetor & Fuel Pump……………………… 4-4 6) Removing Carburetor ………………… 4-14 Integral Fuel Tank …………………………… 4-6 7) Disassembling Carburetor………………...

  • Page 66: Special Tools

    Fuel System 1. Special Tools Vacuum/Pressure Gauge P/N. 3AC-99020-0 Inspecting pressure 4st 4/5/6 2011...
  • Page 67 4st 4/5/6 2011...

  • Page 68: Parts Layout

    Fuel System P/L Fig. 4 2. Parts Layout Carburetor & Fuel Pump Fig.1-50 Fig.1-51 Fig.1-9 Fig.10-51 4st OIL ark D Fig.10-25 4st OIL 4st 4/5/6 2011...
  • Page 69 Ref. Description Q'ty Remarks Intake Manifold Ass'y Intake Manifold Gasket Do not reuse. Bolt Dual Tank Mode M6 L=25mm Bolt Separate Tank Model M6 L=25mm Bolt Dual Tank Mode M6 L=30mm Carburetor Ass'y Carburetor Ass'y Carburetor Ass'y Carburetor Ass'y 5ps for EU Carburetor Ass'y 4ps for EU Carburetor Ass'y...

  • Page 70: Integral Fuel Tank

    Fuel System P/L Fig. 13 Integral Fuel Tank PUMP TANK Fig. 0-48 Fig.4-45 Fig. 0-44 Fig. 0-4 Fig. 0-43 4st 4/5/6 2011...
  • Page 71 Ref. Description Q'ty Remarks Fuel Hose C Fuel Hose Protector Fuel Tank Hose 98AB-501000 Clip Fuel pipe Fuel Tank Holding Plate Mount Motor Cover Lower Rubber Mount 9-23-4 Spacer 6.2-9-15.7 Spacer 6.2-9-11.5 Washer 6.5-21-1 Bolt M6 L=25mm Bolt M6 L=20mm Bracket (Rear) Fuel Tank Cap Ass'y Tank Filler Cap Gasket...

  • Page 72: Carburetor Inner Passages

    Fuel System 3. Carburetor Inner Passages 1) Idling Passage a - Air intake b - Air vent inlet c - Main air jet <Over view> d - Pilot air jet e - Bypass port f - Pilot outlet g - Throttle valve h - Fuel inlet i - Main jet j - Pilot jet...

  • Page 73: Off-Idle Passage

    2) Off-Idle Passage a - Air intake b - Air vent inlet c - Main air jet <Over view> d - Pilot air jet e - Bypass port f - Pilot outlet g - Throttle valve h - Fuel inlet i - Main jet j - Pilot jet k - Choke valve...

  • Page 74: High Speed Passage

    Fuel System 3) High Speed Passage a - Air intake b - Air vent inlet c - Main air jet <Over view> d - Pilot air jet e - Bypass port f - Pilot outlet g - Throttle valve h - Fuel inlet i - Main jet j - Pilot jet k - Choke valve...

  • Page 75: Choking Passage

    4) Choking Passage a - Air intake b - Air vent inlet c - Main air jet <Over view> d - Pilot air jet e - Bypass port f - Pilot outlet g - Throttle valve h - Fuel inlet i - Main jet j - Pilot jet k - Choke valve...

  • Page 76: Inspection Items

    Fuel System 4. Inspection Items 1) Inspection of Fuel Feed System Piping Remove top cowl and check each section for fuel leak, dirt, deterioration and damages. Clean or replace parts if necessary. 2) Draining Fuel WARNING Remove fuel tank, fuel hose and carburetor after fully drain the fuel from these parts.

  • Page 77: Inspection Of Fuel Tank And Fuel Tank Cap

    3) Inspection of Fuel Tank and Fuel Tank Cap Check fuel tank and fuel tank cap for crack, leakage and damage. Replace if necessary. 4) Inspection of Fuel Cock Check fuel cock for leakage. 5) Inspection of Fuel Filter Check fuel filter for dirt and clogging, and clean if necessary. 4st 4/5/6 2011 4-13...

  • Page 78: Removing Carburetor

    Fuel System 6) Removing Carburetor WARNING Before working on fuel system, make sure to disconnect battery cables from the battery, or electric sparks can occur, possibly igniting fuel or making fuel to explode. Remove fuel tank 1. Remove starter lock rod 2. Disconnect choke link wire.
  • Page 79 Remove recoil starter ass'y 4. Disconnect breather hose 5 from intake silencer. Remove fuel hose 6 from fuel pump. Before disconnecting fuel hose, place a piece of cloth below fuel pump to blot leaking fuel. Loosen carburetor mounting bolts and remove carburetor When removing throttle rod and carburetor, perform the work as shown taking care not to give damage to the parts.

  • Page 80: Disassembling Carburetor

    Fuel System 7) Disassembling Carburetor Remove drain screw 1 to drain fuel. CAUTION Use rag to absorb fuel flowing out from hose. Remove float bowl 2. Remove float ass'y 3. Remove jets and nozzle. CAUTION When removing any jets, be careful not to damage or distort jet surface.

  • Page 81: Inspection And Clean Of Carburetor

    8) Inspection and clean of Carburetor Check air and fuel passages for dirt in the jet and foreign substances. Clean carburetor body with cleaning fluid. Squirt all passages and jet passages with compressed air. CAUTION · Point the compressed air downward, taking care that detergent and dust do not enter the eyes and do not damage small parts of the carburetor.

  • Page 82: Inspection Of Fuel Connector

    Fuel System 9) Inspection of Fuel Connector Check fuel connector for crack and damage. Connect vacuum/pressure gauge to outlet of fuel connector. Apply specified pressure, and check if the pressure is maintained for 10 seconds. Replace if necessary. Vacuum/Pressure Gauge : P/N.

  • Page 83: Adjustment Of Float Height

    11) Adjustment of Float Height Measure height a of float 1. Adjust height a of float 1 by bending tab b if the height is out of specified range. Float Height a : 9.0 - 10.0 mm (0.354 - 0.394 in) Bring tab b of float 1 into light contact with top of float valve 2.

  • Page 84: Removing Fuel Pump

    Fuel System 13) Removing Fuel Pump Remove fuel hose from fuel pump. Place a piece of cloth below fuel pump to blot leaking fuel. Loose fuel pump mounting screw and remove fuel pump. 14) Disassembly and Inspection of Fuel Pump CAUTION To prevent fuel from dripping on the floor, use a cloth to catch the fuel.

  • Page 85: Assembly Of Fuel Pump

    Check diaphragm 1 for break, crack and damage, and replace if necessary. Check check valve 2 for damage and deterioration, and replace if necessary. fuel pump body for crack and damage, and replace if necessary. Check push rod 3 for wear on the slipper surface a, and replace if severely worn.
  • Page 86 Fuel System 4-22 4st 4/5/6 2011...

  • Page 87: Power Unit

    Power Unit 1. Special Tools ………………………… 5-2 19) Inspection of 2. Parts Layout ………………………… 5-3 Piston Outer Diameter ……………… 5-30 Engine …………………………………… 5-3 20) Inspection of Magneto…………………………………… 5-4 Cylinder Inner Diameter …………… 5-30 Cylinder & Oil Pan ……………………… 5-6 21) Inspection of Piston Clearance …… 5-30 Cylinder Head &...

  • Page 88: Power Unit

    Power Unit 1.Special Tools Piston Slider Compression Gauge Valve Spring Compressor Attachment Flywheel Puller Kit P/N. 3H6-72871-0 P/N. 3AC-99030-0 P/N. 3AB-99076-0 P/N. 369-72211-0 Measuring compression Removing or installing valve Installing piston Removing/installing flywheel pressure springs Thickness Gauge P/N. 353-72251-0 Measuring gaps 4st 4/5/6 2011...

  • Page 89: Parts Layout

    2.Parts Layout Engine 7 Nám (5 lbáft) [0.7 kgfám] Ref. Description Remarks Q'ty Recoil Starter Fuel Tank Oil Level Gauge Do not reuse. Dowel Pin Bolt 6 M6 L=30mm Gasket Do not reuse. 4st 4/5/6 2011...

  • Page 90: Magneto

    Power Unit Magneto P/L Fig. 6 0 Nám (3.7 lbáft) [ .0 kgfám] 4st 4/5/6 2011...
  • Page 91 Ref. Description Q'ty Remarks Flywheel MF54 (Mark48) Flywheel MF54 (Mark50) "for Sail Pro (with Alternater)" Alternator Ass'y Screw M5 L=25mm Washer Clamp Screw M4 L=8mm Washer Nut 12-P1.25 Igniter W/R-Cap Plug Cap W/Resistance Bolt M6 L=30mm 12-1 Clamp 6.5-67P 12-2 Clamp 6.5-47.5P Screw M6 L=12mm...

  • Page 92: Cylinder & Oil Pan

    Power Unit P/L Fig. 1 Cylinder & Oil Pan Cylinder Head Comp 2 Nám (9 lbáft) [ .2 kgfám] 25 Nám ( 8 lbáft) [2.5 kgfám] 8 Nám ( 3 lbáft) [ .8 kgfám] 4st OIL 9 Nám (7 lbáft) [0.9 kgfám] G103 G103 G103...
  • Page 93 Ref. Description Q'ty Remarks Cylinder Block Oil Seal 20-35-7 Ball Bearing 6205 Breather Chamber Cover Gasket Breather Chamber Cover Collar Breather (5A New) Wave Washer d=5 Screw M6 L=16mm Clamp 6.5-14 Oil pan Sub-Ass'y Oil Seal 25-40-8 Grommet Oil pan Dowel Pin 6-12 Oil Pump Rotor (Inner) Oil Pump Rotor (Outer)

  • Page 94: Cylinder Head & Valve & Cam Shaft

    Power Unit Cylinder Head & Valve & Cam Shaft P/L Fig. 3 0 Nám (7 lbáft) [ .0 kgfám] 4st OIL 25 Nám ( 8 lbáft) [2.5 kgfám] Fig. 0-35 2 Nám (9 lbáft) [ .2 kgfám] 25 Nám ( 8 lbáft) [2.5 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] 4st OIL 8 Nám ( 3 lbáft) [ .8 kgfám]...
  • Page 95 Ref. Description Q'ty Remarks Cylinder Head Ass'y Intake Valve Exhaust Valve Valve Spring Seat Valve Spring Retainer Cotter Dowel Pin 6-12 Cylinder Head Gasket Do not reuse. Cylinder Head Bolt Cylinder Head Bolt Exhaust Cover Gasket Do not reuse. Cylinder Head Cover Cylinder Head Cover Gasket Do not reuse.

  • Page 96: Piston & Crank Shaft

    Power Unit Piston & Crank Shaft P/L Fig. 2 6 Nám (4 lbáft) [0.6 kgfám] 1 Nám (9 lbáft) [1. kgfám] 4st OIL 4st OIL 4st OIL 4st OIL 4st OIL 4st OIL Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Crankshaft Ass'y 6-1 Piston Ring-Oil (STD)

  • Page 97: Recoil Starter

    Recoil Starter P/L Fig. 5 17 16 1 18 1342 1342 1342 1342 4 Nám (3 lbáft) [0.4 kgfám] 1342 1342 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Recoil Starter Ass'y 16 Collar 4-6-21 Starter Case 17 Starter Lock Spring Starter Spring Case 18 Starter Lock Cam Starter Spring...

  • Page 98: Top Cowl

    Power Unit Top Cowl P/L Fig. 11 " 1741 1741 1741 Separate Tank " Sail Pro Decal 1741 1741 1741 Integral Tank 1741 1741 1741 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Top Cowl Ass'y For Separate Tank Model Sail Pro Decal Top Cowl Caution Decal (A)

  • Page 99: Inspection Items

    3. Inspection Items 1) Inspection of Compression Pressure Run engine 5 minutes to warm up, and then stop. Shift gear into neutral (N). 1 (of stop switch lanyard) from stop Remove lock plat switch. CAUTION Remove lock plate (of stop switch lanyard) from stop switch before measuring compression pressure.

  • Page 100: Inspection Of Valve Clearance

    Power Unit 2) Inspection of Valve Clearance Disconnect plug cap 1 connection, and then, remove spark plug and cylinder head cover 2. Pull recoil starter 3 to turn flywheel clockwise until flywheel a is brought to cylinder mark b. “T” mark ·...
  • Page 101 Loosen pivot adjust nut 5 and then pivot nut. Put thickness gauge 6 into valve clearance, and then, tighten pivot nut temporarily. Tighten pivot adjust nut 7 to specified torque, and check valve clearance again. Pivot Lock Nut 7 : 10 N ·...

  • Page 102: Removing Power Unit

    Power Unit 3) Removing Power Unit Turn fuel cock 1 to OFF and remove fuel tank ass'y 2 and fuel cock ass'y 1. Remove choke cable 4 from carburetor 3. Disconnect rubber hose 5 from fuel pump. Disconnect wiring connectors and earth wire located on the port side.

  • Page 103: Removal And Disassembly Of Crank Case Head

    Turn throttle grip to full close position, and disconnect throttle cables 7 (2 pcs.) from throttle drum 6. Remove bolts 8 (6 pcs.), and then, lift power unit to remove. When lifting power unit, perform the work carefully while checking if cables and hoses are caught by other parts.

  • Page 104: Inspection Of Crank Case Head

    Power Unit 5) Inspection of Crank Case Head Check crank case head for crack, damage and corrosion. Replace if necessary. 6) Assembly of Crank Case Head Attach new oil seal 1 to crank case head by using a commercially available mandrel. Apply lithium grease to the lip of oil seal.

  • Page 105: Disassembly Of Power Unit

    8) Disassembly of Power Unit Place power unit on the work bench a. Remove recoil starter 1 and flywheel cover 2. Remove flywheel nut 3. Flywheel Holder 4 : (Commercially use) Flywheel Puller Kit 6 : P/N. 369-72211-0 M6, L = 60mm, Bolts (3 pcs.) (or recoil starter bolts and washers) CAUTION Apply forces to tools toward directions as...
  • Page 106 Power Unit Remove fuel hose 7 from carburetor. Loosen carburetor mounting bolts 8 and remove carburetor. Loosen intake manifold mounting bolts and then remove manifold 9. 5-20 4st 4/5/6 2011...
  • Page 107 Loosen thermostat cap mounting bolts, remove cap 0 and then thermostat q. Loosen igniter mounting bolts and then remove igniter w. Loosen fuel pump mounting screws and then remove fuel pump e. 4st 4/5/6 2011 5-21...

  • Page 108: Removal Of Rocker Arm

    Power Unit 9) Removal of Rocker Arm Check position of flywheel marking “T” to confirm that piston is at top dead center. Remove bolts and then cylinder head cover. Remove adjust nut 1, and then pivot 2 and rocker arm 3. Remove push rod 4.

  • Page 109: Removing Cylinder Head

    10) Removing Cylinder Head Remove cylinder head bolts in the order shown, and then, " remove cylinder head. 11) Inspection of Rocker Arm and Pivot Check rocker arm 1 and pivot 2 for crack, wear and damage. Replace if necessary. 12) Inspection of Push Rod Plate Check push rod plate for crack and damage.
  • Page 110 Power Unit Remove oil feed pump cover O ring 2 carefully. Remove oil pump rotors (inner and outer) and oil pump pin, check rotors 3 for damages, and replace if necessary. Measure gap a between inner and outer rotors. Replace outer or inner rotor if the gap is over specified value.
  • Page 111 Measure pump body depth by using depth gauge or vernier caliper. Replace if over specified limit. Standard Value: 6.00mm (0.2362 in) Functional Limit : 6.06 mm (0.2386 in) Measure this gap by using thickness gauge. Measure side clearance between pump rotor and body by lock gauge using depth gauge or vernier caliper.

  • Page 112: Disassembly Of Cylinder And Oil Pan

    Power Unit 15)Disassembly of Cylinder and oil pan Loosen oil pan bolts in the order reverse to the numbers shown, and remove oil pan — · Wipe off spilt oil completely. · When tightening bolts, follow the numbers shown. Remove crankshaft washer 1 and then cam shaft 2. Remove lifter 3.
  • Page 113 Turn crankshaft to a position where connecting rod bolts 4 and connecting rod cap 5 can be removed, remove the bolts, and then remove the cap. Remove connecting rod 6 and piston ass'y from cylinder block. · Removed bearings should be arranged in the order they are removed.

  • Page 114: Disassembly And Inspection Of Breather Chamber

    Power Unit 16)Disassembly and Inspection of Breather Chamber Loosen breather cover mounting screws and then remove the cover. Remove two breather collars 1 and two wave washers 2, check the parts, and replace if necessary. 2 2 2 Attach breather collars 3 and wave washers 4. Position breather collar so that the hole a is directed as shown.

  • Page 115: Inspection Of Cam Shaft

    18) Inspection of Cam Shaft Check cam shaft gear and decompressor for damage and wear. Replace if necessary. Measure cam height. Replace if the diameter is less than specified value. Cam Height a, both intake and exhaust : Standard value 28.33 mm (1.1154 in) Functional Limit : 28.07 mm (1.1051 in)

  • Page 116: Inspection Of Piston Outer Diameter

    Power Unit 19) Inspection of Piston Outer Diameter Measure piston outer diameter between points specified. Replace if it is less than specified value. Piston Outer Diameter a : Standard value 58.960 mm (2.3213 in) Measuring Point b : 7mm (0.28 in) upward from the bottom of piston skirt Functional Limit : 58.90 mm (2.3189 in) 20) Inspection of Cylinder Inner Diameter...

  • Page 117: Inspection Of Piston Ring Side Clearance

    22) Inspection of Piston Ring Side Clearance Measure piston ring side clearance. Replace piston and piston rings as a set if the clearance is over specified value. Piston Ring Side Clearance : Top Ring a : 0.04 - 0.08mm (0.0016 - 0.0031 in) Second Ring b : 0.03 - 0.07mm (0.0012 - 0.0028 in) Oil Ring c : 0.01 - 0.18mm (0.0004 - 0.0071 in) Functional Limit...

  • Page 118: Inspection Of Piston Pin

    Power Unit 24) Inspection of Piston Pin Measure piston pin outer diameter. Replace if it is less than specified value. Piston Pin Outer Diameter : Standard value 16.00 mm (0.6299in) Functional Limit : 15.97 mm (0.6287 in) Measure piston pin boss inner diameter a. Obtain clearance between piston pin and pin boss.

  • Page 119: Inspection Of Connecting Rod Big End Side Clearance

    Remove connecting rod and measure plastic gauge. 0.002 0.051 Connecting rod big end and crankshaft clearance: 0.003 0.076 0.004 0.102 corresponding value 0.005 0.127 0.006 0.152 0.040 - 0.066 mm (0.00157 - 0.00260 in) Functional Limit : 0.08 mm (0.00315 in) 27) Inspection of Connecting Rod Big End Side Clearance Measure connecting rod big end side clearance a by...

  • Page 120: Disassembly And Inspection Of Oil Pan

    Power Unit 29)Disassembly and Inspection of Oil Pan Remove oil pressure switch 1 from oil pan. Loosen oil strainer cover mounting bolts and strainer pipe mounting bolts, and then remove cover 2. Check oil strainer cover screen mesh 3 for dirt and clogging.

  • Page 121: Removal Of Valves And Springs

    30) Removal of Valves and Springs Place cylinder block on the work bench. Push in valve spring retainer 1 by using valve spring compressor attachment 2, remove cotter pin 3, and then, remove spring 4 and valve 5. · Place a piece of cloth below cylinder head to prevent valves from moving downward.

  • Page 122: Inspection Of Valve

    Power Unit 32) Inspection of Valve Check valve for dent and wear on the face. Replace if necessary. Measure valve stem outer diameter a. Replace if it is less than specified value. Valve Stem Outer Diameter a : Standard value Intake Side (IT) : 5.47 mm (0.2154 in) Exhaust Side (E) : 5.44 mm (0.2142 in)

  • Page 123: Inspection Of Valve Seat

    34) Inspection of Valve Seat Remove carbon built up on the valve. Apply thin coat of red lead on the valve seat. Use valve lapper 1 (commercially available item) as shown to push valve 2 onto valve seat lightly. Measure width of area where valve face contacted with valve seat a that can be identified with red lead adhered to valve face.

  • Page 124: Correction Of Valve Seat

    Power Unit 35) Correction of Valve Seat Use valve seat cutter 1 (commercially available item) to correct valve seat. 30˚ 45˚ 60˚ Turn 45 degree cutter clockwise to cut valve seat surface to make it smooth. 45˚ Be careful not to over-cut valve seat. Turn valve seat cutter while pushing down evenly.
  • Page 125 Use 45 degree cutter to adjust contact width of valve seat c to specified value. 45˚ b Width before correction c Specified width Valve seat contact area is located on the center, which should be adjusted to specified value by cutting upper and 30˚...
  • Page 126 Power Unit Apply thin coat of abrasive compound on the overall valve seat contact area, and turn valve lapper 2 (commercially available item) while tapping valve. CAUTION Perform the work by taking care not to allow abrasive compound to adhere to valve stem and valve guide.

  • Page 127: Installation Of Valves

    36) Installation of Valves Apply oil to valve guide and attach new valve stem seal. 4st OIL Intake Side : Black Exhaust Side : Green Do not reuse the seal. Use new one. 4st OIL Assemble valve 3, valve spring seat 4, valve spring 5 and retainer 6 in this order, and then, push in the assembly by using valve spring compressor attachment 1.

  • Page 128: Installation Of Piston And Connecting Rod

    Power Unit 37) Installation of Piston and Connecting Rod Install connecting rod 2, piston pin 3, and piston pin clip 4 to piston 1. · Point "3AB-UP" mark a of connecting rod and "UP" mark b of piston to the same direction. ·...

  • Page 129: Assembly Of Cylinder Oil Pan

    38) Assembly of Cylinder Oil Pan Press fit bearing into cylinder block. Install crankshaft 1 on the cylinder block. Before installing, apply engine oil to mating surface between bearing and crankshaft. 4st OIL Use piston slider 2 as shown to install piston ass’y into cylinder block.
  • Page 130 Power Unit Attach connecting rod cap 4 to connecting rod, and tightening connecting rod bolts 5 in two steps to specified torque. · Install connecting rod cap 4 after applying engine oil to inside of the part. · Bring locating marks a of connecting rod cap 4 and connecting rod, and install in original position (direction).

  • Page 131: Installation Of Cylinder Head

    39) Installation of Cylinder Head Attach gasket and cylinder head ass’y to cylinder block, and then, tighten bolts to specified torque in two steps in the order as shown. Cylinder head ass’y installation bolts: 1st tightening torque : 12 N • m (9 lb • ft)[1.2 kgf • m] 2nd tightening torque : 25 N •...
  • Page 132 Power Unit Attach O ring 5 and oil pump cover 6 and secure with bolts. Apply much engine oil to oil pump and rotors (outer and inner). Attach push rods 7, rocker arms 8, rocker arm pivots 9 and adjusting nuts to cylinder head. Ensure that push rods 7 are engaged with valve lifters.

  • Page 133: Installing Flywheel

    40) Installing Flywheel Attach key to crankshaft and install flywheel. Tighten flywheel nut to specified torque. Flywheel puller kit : P/N. 369-72211-0 Flywheel Nut : 50 N · m (37 lb · ft) [5.0 kgf · m] Attach igniter. Thickness Gauge: P/N.
  • Page 134 Power Unit Attach intake manifold to cylinder and tighten bolts to specified torque. Ensure that O ring is attached properly. Intake manifold installation bolt: 6 N · m (4 lb · ft) [0.6 kgf · m] Install carburetor. Install fuel pump and connect fuel hose. 5-48 4st 4/5/6 2011...
  • Page 135 Install recoil starter. Attach blow-by hose 4. Apply Three Bond 1342 and then attach oil pressure switch 5. Apply SOC grease to terminal and then attach pressure switch code. Oil Pressure Switch 5 : 9 N · m (7 lb · ft) [0.5 kgf · m] 1342 1342 1342...

  • Page 136: Installation Of Power Unit

    Power Unit 41) Installation of Power Unit Hold power unit as shown. Clean mating surface of power unit and attach new gasket 3. Install power unit 2 , and tighten bolts 3 in two or three steps to specified torque. Power Unit Installation Bolt : 7 N ·...
  • Page 137 Connect rod 6 and choke wire 7. Install fuel tank 8 and connect pipe. 4st 4/5/6 2011 5-51...
  • Page 138 Power Unit 5-52 4st 4/5/6 2011...

  • Page 139: Lower Unit

    Lower Unit 1. Special Tools ……………………………… 6-2 17) Assembly of Clutch Cam and Cam Rod… 6-16 2. Parts Layout ……………………………… 6-3 18) Removing Pump Case (Lower) ……… 6-16 Drive Shaft Housing…………………………… 6-4 19) Disassembly of Pump Case (Lower) … 6-16 3.

  • Page 140: Special Tools

    Lower Unit 1. Special Tools Spring Pin Tool A Spring Pin Tool B Center Plate 3 Driver Rod 3 P/N. 345-72227-0 P/N. 345-72228-0 P/N. 3AB-99701-0 P/N. 3AB-99702-0 Used in combination with driver rod and Used in combination with center plate and Removing spring pin Installing spring pin bearing attachment to locate lower gear...
  • Page 141 4st 4/5/6 2011...

  • Page 142: Parts Layout

    Lower Unit P/L Fig. 7 2. Parts Layout Drive Shaft Housing 26 30 4 Nám (3 lbáft) [0.4 kgfám] 1342 1342 1342 7 Nám (5 lbáft) [0.7 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] Fig. -33 13 Nám (9 lbáft) [1.3 kgfám] 1342 1342 1342...
  • Page 143 Ref. Description Q'ty Remarks Drive Shaft Housing Ass'y (S) For Transom "S" Drive Shaft Housing Ass'y (L) For Transom "L" Drive Shaft Housing Ass'y (UL) For Transom "UL" Bushing Shift Lever Exhaust Plug Drive Shaft Bushing Ass'y For Transom "L" Drive Shaft Bushing Ass'y For Transom "UL"...
  • Page 144 Lower Unit P/L Fig. 8 Gear Case (Drive Shaft) & Gear Case (Propeller Shaft) 1342 1342 1342 GEAR GEAR GEAR GEAR Sail Pro 53 GEAR GEAR GEAR GEAR 1342 1342 1342 6 Nám (4 lbáft) [0.6 kgfám] 3 Nám (9 lbáft) [ .3 kgfám] GEAR GEAR GEAR...
  • Page 145 Ref. Description Q'ty Remarks Gear Case Ass'y Gear Case Ass'y For 6ps UL Roller Bearing 14-20-12 Plug Gasket 8.1-15-1 Do not reuse. Anode Bolt M6 L=16mm Ball Bearing 6004 Propeller Shaft Housing Ass'y Propeller Shaft Housing Oil Seal 15-28-10 O-Ring 3.2-47 Do not reuse.

  • Page 146: Inspection Items

    Lower Unit 3. Inspection Item 1) Draining Gear Oil 2 and then 1 to drain gear oil. Refer to Remove oil plugs "Replacement of Gear Oil" in Chapter 3. Remove lower oil plug 1 first. 3 Gasket Do not reuse. 2) Removing Propeller Shift into reverse (R).

  • Page 147: Removing Lower Unit

    3) Removing Lower Unit Removal of lower unit does not require removal of power unit from outboard motor body. Tilt up and lock with tilt stopper. Shift in reverse. Remove grommet 1 and loosen bolt 2. Bolt 2 should be loosened, not removed from joint 3.

  • Page 148: Inspection Of Water Pump

    Lower Unit Remove impeller 2. 5) Inspection of Water Pump Check pump case (upper) 1 for deformation. Replace if necessary. Check impeller 2 and pump case liner 3 for crack and wear. Replace if necessary. Check key 4 and drive shaft installation face a for wear. Replace if necessary.

  • Page 149: Removing Propeller Shaft Housing Ass'y

    Check water pump guide plate 5 for cracks and wear. Replace if necessary. 6) Removing Propeller Shaft Housing Ass'y Remove bolts 1 and pull out propeller shaft housing ass'y When the ass'y is pulled out a little, put bladed screw driver 3 in the mating surface of lower gear case to separate it from the case.

  • Page 150: Disassembly Of Propeller Shaft Housing

    Lower Unit 7) Disassembly of Propeller Shaft Housing Remove bearing 1 by using commercially available bearing puller. Before removing, check bearing for play or deflection. Replace if necessary. CAUTION Do not reuse removed bearing. 1 Bearing Do not reuse. Remove oil seal 2. 2 Oil Seal Do not reuse.

  • Page 151: Assembly Of Propeller Shaft Housing

    9) Assembly of Propeller Shaft Housing Apply gear oil to outside of new oil seal 1, and attach it to propeller shaft housing 3 by using a commercially available mandrel 2. GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR Do not reuse. Install new bearing 4 to propeller shaft housing 3.

  • Page 152: Disassembly Of Propeller Shaft Ass'y

    Lower Unit 11) Disassembly of Propeller Shaft Ass'y Pull out clutch pin 2 while pushing push rod 1. Remove clutch 3, push rod 1, spring retainer 4, and spring 5. · Take care not to allow parts to fly out by easing spring tension gradually.

  • Page 153: Removing Clutch Cam And Cam Rod

    Using bladed screw driver, shorten spring 1 by referring to illustration, insert spring pin tool A 4 into hole of clutch 2 to secure spring. Slowly press fit new spring pin 3 from the other side, putting it on the spring pin tool A and by using spring pin tool B 5.

  • Page 154: Assembly Of Clutch Cam And Cam Rod

    Lower Unit 17) Assembly of Clutch Cam and Cam Rod Install clutch cam 3 and spring pin 2 to cam rod 1. Spring Pin Tool B : P/N. 345-72228-0 Be careful of direction of cam rod. 18) Removing Pump Case (Lower) Remove pump case (lower) 1 and drive shaft 2 while holding pinion (B) gear with hand.

  • Page 155: Inspection Of Drive Shaft

    21) Inspection of Drive Shaft Check drive shaft for bend and wear or twisted splines. Replace if necessary. Measure drive shaft runout. Runout Limit (Max) : 0.2 mm (0.008 in) a Supporting Points 22) Inspection of Pinion (B) Gear and Forward (A) Gear Check pinion (B) gear, forward (A) gear, reverse (C) gear teeth and clutch for crack and wear.

  • Page 156: Disassembly Of Gear Case

    Lower Unit 23) Disassembly of Gear Case Check bearings 1 for cracks and generation of abnormal noise. Replace if necessary. CAUTION Do not reuse removed bearing. · Do not remove bearing unless it is replaced with new one. · Before removing, check bearing for play or deflection.

  • Page 157: Inspection Of Gear Case

    24) Inspection of Gear Case Check skeg area a and torpedo-like front area b for cracks and damage. Replace if necessary. 25) Assembly of Gear Case Do not reuse removed bearing. Install bearing 1 with numbered side up to gear case 2 to specified depth.

  • Page 158: Installation Of Forward Gear And Pinion Gear (A And B Gears)

    Lower Unit 26) Installation of Forward Gear and Pinion Gear (A and B Gears) Install shim 1 and forward (A) gear 2 that were removed previously. Install pinion (B) gear 3 and drive shaft ass'y 4. Replace shim with new one of the same thickness if any deformation or damage is found on removed shim.

  • Page 159: Determination Of Forward (A) Gear Backlash

    29) Determination of forward (A) gear backlash Backlash Measuring Tool Kit : P/N. 369-72740-0 Backlash Measuring Tool Ass’y 1 : P/N. 369-72730-0 Measuring Tool Set Piece 2 : P/N. 369-72727-0 Clamp A : P/N. 3B7-72720-0 Dial Gauge Plate : P/N. 3B7-72729-0 4 Pump Case 5 Pinion (B) Gear Perform measurement of backlash between...
  • Page 160 Lower Unit First, pull up drive shaft by using hand. Fix shaft B with bladed screw driver, and tighten nut while pushing the shaft. At this time, be careful not to overtighten 90° 90° the nut, or shaft B is locked. Tighten nut fully by using fingers, and then, additionally tighten approximately 90 degrees by using spanner wrench.

  • Page 161: Installation Of Water Pump

    30) Installation of Water Pump Attach new gaskets 1 and 2, water pump guide plate 3 and dowel pin. 12 Gasket Do not reuse. Attach key 4 to drive shaft. Bring impeller 5 groove a to key 4 and install impeller to drive shaft.

  • Page 162: Installation Of Propeller Shaft Housing

    Lower Unit Install pump case (upper) ass'y 8 on the gear case, and tighten bolts 9 in two or three steps to specified torque. Apply grease to interior of pump case liner, and install pump case (upper) by pushing it down with hand while turning drive shaft clockwise.

  • Page 163: Filling With Gear Oil

    32) Filling with Gear Oil Feed gear oil to specified quantity a. "Refer to Chapter 3." GEAR GEAR GEAR Perform "Inspection of Gear Case (Leakage)" in Chapter 3 if necessary. GEAR GEAR GEAR GEAR 1 Gasket Do not reuse. GEAR GEAR GEAR 1 Gasket...
  • Page 164 Lower Unit Attach lower unit ass'y to drive shaft housing, and tighten lower unit installation bolts 2 (nut 3 ) to specified torque. Connect water pipe securely. Move flywheel a little to align the drive shaft spline to crank shaft spline.
  • Page 165 Turn propeller nut q to tightening direction to align one of grooves to propeller shaft hole, and attach split pin w. If propeller nut groove cannot be aligned with split pin hole, loosen nut and repeat steps 6 and 7. Check gear oil level.
  • Page 166 Lower Unit 6-28 4st 4/5/6 2011...

  • Page 167: Bracket

    Bracket 1. Parts Layout ……………………………… 7-2 2) Removal and inspection of clamp bracket … 7-11 Bracket & Reverse Lock ……………………… 7-2 3) IInstallation of clamp bracket and Drive Shaft Housing & Shift ………………… 7-4 drive shaft ……………………………………… 7-12 Bottom Cowl & Tiller Handle ………………… 7-6 4) Removal, inspection and installation of Cowl ……………………………………………...

  • Page 168: Parts Layout

    Bracket 1. Parts Layout P/L Fig. 9 Bracket & Reverse Lock & & & " " " " & 4st 4/5/6 2011...
  • Page 169 Ref. Description Q'ty Remarks Swivel Bracket A Swivel Bracket B Clamp Bracket (R) Clamp Screw Ass'y Clamp Screw Ass'y Clamp Screw Clamp Screw Clamp Screw Handle Clamp Screw Handle Rivet 3-22 Rivet 3-22 Clamp Screw Pad Clamp Screw Pad Clamp Bracket (L) Bolt 8-122 Nylon Nut 8P1.25 Washer...

  • Page 170: Drive Shaft Housing & Shift

    Bracket Drive Shaft Housing & Shift P/L Fig. 7 26 30 4 Nám (3 lbáft) [0.4 kgfám] 1342 1342 1342 7 Nám (5 lbáft) [0.7 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] Fig. -33 13 Nám (9 lbáft) [1.3 kgfám] 1342 1342 1342...
  • Page 171 Ref. Description Q'ty Remarks Drive Shaft Housing Ass'y (S) For Transom "S" Drive Shaft Housing Ass'y (L) For Transom "L" Drive Shaft Housing Ass'y (UL) For Transom "UL" Bushing Shift Lever Exhaust Plug Drive Shaft Bushing Ass'y For Transom "L" Drive Shaft Bushing Ass'y For Transom "UL"...

  • Page 172: Bottom Cowl & Tiller Handle

    Bracket P/L Fig. 10 Bottom Cowl & Tiller Handle Fig.3-28 Fig.3-18 ntegral tank 4st 4/5/6 2011...
  • Page 173 Ref. Description Q'ty Remarks Bottom Cowl Bottom Cowl (Integral Tank) Hook Lever Seal Ring Hook Lever Hook Lever Bushing Wave Washer d=14 Cover Hook Bolt M6 L=12mm Washer 6-16-1.5 Grommet Starter Lock Rod Grommet Throttle Lever Grommet 18-2.5 Clamp 6.5-47.5P Screw M6 L=12mm Grommet 17-2.7...

  • Page 174: Cowl

    Bracket Cowl P/L Fig. 11 " 1741 1741 1741 Separate Tank " Sail Pro Decal 1741 1741 1741 Integral Tank 1741 1741 1741 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Top Cowl Ass'y For Separate Tank Model Sail Pro Decal Top Cowl Caution Decal (A) (Integral Tank)

  • Page 175: Disassembling And Assembling Procedure

    2. Disassembling and Assembling Procedure 1) Removal and inspection of drive shaft housing Tilt up drive shaft housing. Remove reverse lock arm 1. Remove thrust rod Remove wing nut 3 for co-pilot. Loosed four swivel bracket (B) bolts 4. Hold drive shaft to prevent it from dropping. 4st 4/5/6 2011...
  • Page 176 Bracket Remove drive shaft housing 5. Check steering bushing 6 and thrust place 7 for wear and damage, and replace if necessary. 7-10 4st 4/5/6 2011...

  • Page 177: Removal And Inspection Of Clamp Bracket

    2) Removal and inspection of clamp bracket Loosen clamp bracket mounting nut 1 and remove bolt. Remove bracket distance place 2 mounting screws 3. Remove tilt stopper 5 mounting bolt 6 from swivel bracket 4, and then remove tilt stopper 5. Check tilt stopper and bracket for damages.

  • Page 178: Iinstallation Of Clamp Bracket And Drive Shaft

    Bracket 3) Installation of clamp bracket and drive shaft Install tilt stopper 1 to swivel bracket (A). Apply grease to sliding areas of tilt stopper. Install clamp bracket to swivel bracket (A). Apply grease to both sides of washer 2. Install distance plate 3 to clamp bracket.
  • Page 179 Install drive shaft housing and swivel bracket (B) to swivel bracket. Attach wing nut 0 , and check operation of steering friction. Install reverse lock arm q on the swivel shaft. Check operation of each part, and put grease through swivel shaft grease nipple w.

  • Page 180: Removal, Inspection And Installation Of Water Pipe

    Bracket 4) Removal, inspection and installation of water pipe Remove water pipe 1 from drive shaft housing 2. Check water pipe for crack and damage. Install water pipe 1 into drive shaft housing 2. · Apply grease to water pipe grommet (3) before installation.

  • Page 181: Remove, Inspection And Installation Of Tiller Handle

    5) Remove, inspection and installation of tiller handle. Loosen stud bolt 1 of tiller handle, and remove tiller handle from bottom cowl. Check tiller handle spacer 2 and bushings 3 for wear and damage. Loosen throttle grip screw 4 and remove the grip 5. Remove throttle shaft supporter 6 screw.
  • Page 182 Bracket Attach throttle wire 9 to throttle shaft 0 as shown. Attach throttle shaft 0 with throttle wire 9 to tiller handle q, and tighten adjusting screw w securely. Tighten throttle supporter. Be careful of location of throttle friction e. Install throttle grip r to tiller handle, and secure with screw.
  • Page 183 Install tiller handle to bottom cowl. Tighten nut 1 to specified torque. Tiller handle securing nut 1 : 6 N · m (4 lb · ft) [0.6 kgf · m] Arrange throttle cable 9 as shown. a<High speed side>, b<Low speed side> Check operations of tiller handle and throttle grip.

  • Page 184: Adjustment Of Throttle Cable

    Bracket 6) Adjustment of Throttle Cable Check position of cable at low speed and high speed sides. Set throttle grip to slowest position, and fully pull choke knob to close choke valve. Adjust lock nut 1 while applying tension to outer wire by pulling it with a hand to fix low speed side wire.
  • Page 185 Set throttle grip to full-open position, and check if throttle lever of carburetor makes contact with stopper. Set throttle grip to full-close position, and check if throttle lever of carburetor makes contact with stopper. 4st 4/5/6 2011 7-19...
  • Page 186 Bracket 7-20 4st 4/5/6 2011...
  • Page 187 Electrical System 1. Special Tools ……………………………… 8-2 3) Inspection of Igniter ……………………… 8-6 Magneto………………………………………… 8-3 4) Inspection of Stop Switch ……………… 8-7 2. Ignition System and Ignition 5) Inspection of Oil Pressure Switch ……… 8-7 Control System …………………………… 8-4 6) Inspection of Rectifier …………………… 8-8 1) Inspection of Ignition Spark………………...

  • Page 188: Special Tools

    Electrical System 1. Special Tools Thickness Gauge Vacuum/Pressure Gauge Spark Tester P/N. 353-72251-0 P/N. 3AC-99020-0 P/N. 3F3-72540-0 Measuring gaps Inspecting pressure Inspecting spark 4st 4/5/6 2011...

  • Page 189: Magneto

    Magneto P/L Fig. 6 0 Nám (3.7 lbáft) [ .0 kgfám] Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks Flywheel MF54 (Mark48) 13 Screw M6 L=12mm Flywheel MF54 (Mark50) "for Sail Pro (with Alternater)" 14 Rectifier Complete Alternator Ass'y 15 Fuse (10A) Screw M5 L=25mm 16 Clamp 7-80P...

  • Page 190: Ignition System And Ignition Control System

    Electrical System 2. Ignition System and Ignition Control System 1) Inspection of Ignition Spark Disconnect plug cap from spark plug. Connect plug cap to spark tester. Connect spark tester clip to spark plug tip electrode. Spark Tester: P/N. 3F3-72540-0 Spark Performance: 10 mm (0.4 in) or over 5 10 Start engine and check spark.

  • Page 191: Inspection Of Plug Cap

    2) Inspection of Plug Cap Remove the part and test it as a separate unit. Disconnect plug cap from spark plug. Remove plug cap from high tension cable. Measure plug cap resistance. Replace if other than specified value. Plug Cap Resistance (at 20˚C) : 3.0 - 7.0 kΩ...

  • Page 192: Inspection Of Igniter

    Electrical System 3) Inspection of Igniter Remove igniter, and turn plug cap counterclockwise to remove it from high tension cord. Measure igniter resistance. Replace if other than specified value. LED(White) Stop terminal ND(non-coated face) Remove the part and test it as a separate unit. Igniter tester check table ester Ò+Ó...

  • Page 193: Inspection Of Stop Switch

    4) Inspection of Stop Switch Check conduction of stop switch, and replace if not conductive. This test can be made without removing parts. Lead Wire Color Switch Position Brown (Br) Black (B) Remove lock plate. a Attach lock plate. b Press switch.

  • Page 194: Inspection Of Rectifier

    Electrical System 6) Inspection of Rectifier Check conduction of fuse (10 A) contained in the fuse box 2. Replace if non-conductive. Check conduction between rectifier terminals. Replace if out of specification. Rectifier Tester Check Chart ester Ò+Ó terminal Yellow Non-conductive Yellow Conductive 7) Inspection of Lighting Coil...

  • Page 195: Troubleshooting O K

    Troubleshooting 1. Troubleshooting List …………………… 9-2 Ignition System ……………………………… 9-6 2. Power Unit ………………………………… 9-3 Intake • Compression Pressure …………… 9-7 1 Engine will not start or is a little hard to start. 3 Idle engine speed will not stabilize. ……… 9-8 (Recoil starter operates normally.) …………...

  • Page 196: Troubleshooting

    Troubleshooting 1. Troubleshooting List Probable Cause Fuel level is low in the tank. ○ ○ Fuel system connection is incomplete. ○ ○ ○ ○ ○ ○ ○ Air suctioned through fuel system. ○ ○ ○ ○ ○ ○ ○ Fuel pipe is twisted. ○...

  • Page 197: Power Unit

    Before working on the outboard motor, check the hull, rigging, installation of outboard motor, fuel level, and wire connections. For mechanical troubleshooting, refer to relevant troubleshooting section in this chapter. For checking and servicing outboard motor, refer to service procedures described in this manual to perform the work safely.

  • Page 198: Troubleshooting

    Troubleshooting Check valve clearance. Adjust valve clearance. Normal ? Check valves, cylinder block and/or piston ass’y. 4st 4/5/6 2011...

  • Page 199: Engine Starts But Stalls Soon

    Trouble 2 Engine starts but stalls soon. • Inspection of Fuel System, Ignition System, Compression Pressure Fuel System Check air vent screw of fuel tank. Open air vent screw. Open? Check if fuel contains water and fuel filter is clogged. Check fuel hose for bend Does fuel contains water, and fuel leak.

  • Page 200: Ignition System

    Troubleshooting Ignition System Use spark tester to check ignition sparks. Check igniter Normal ? and/or plug cap. WARNING • When testing, put electrode cap assuredly to prevent Replace spark plug direct contact with spark tester wiring and leak of with new one. electrical current.

  • Page 201: Intake • Compression Pressure

    Intake • Compression Pressure Check if secondary air is sucked through mating surface of carburetor or intake manifold. Check compression Is secondary air pressure. sucked? Replace defective part and seal with new ones. 4st 4/5/6 2011...

  • Page 202: Idle Engine Speed Will Not Stabilize

    Troubleshooting Trouble 3 Idle engine speed will not stabilize. • Inspection of Intake Manifold, Air Intake System and Ignition System Check operations of throttle cable and drum. Normal ? Adjust throttle cable. Check ignition timing. Check gaskets Out of specified if secondary air is range? sucked through them.

  • Page 203: Rough Acceleration

    Trouble 4 Rough acceleration. Rapid opening of throttle causes engine to stall. Acceleration is not smooth. Inspection of Carburetor, Ignition System and Compression Pressure • Check operation of throttle cable. Is the throttle Adjust throttle cable. valve tuned ? Disassemble carburetor, and check internal components for clogging, dirt and damage.

  • Page 204: Gear Shifting Cannot Be Made Normally

    Troubleshooting Trouble 5 Gear shifting cannot be made normally. Check operations of shift lever. Normal ? Check spring and ball. Check shift rod joint. Normal ? Replace shift rod. Disassemble lower unit and check operation of clutch. Replace defective part Normal ? with new one.

  • Page 205: Wiring Diagram

    Wiring Diagram...
  • Page 206 WIring Diagram F 4B/5B/6B B ------- Black OPTION Br ----- Brown R ------- Light Green LIGHT EXTENSION CORD W ------ White Lg ----- Light Green ALTERNATOR RECTIFIER MAGNETO FUSE MAGNETO IGNITER WARNING LIGHT PRESSURE STOP SWITCH SWITCH BATTERY 10-2 4st 4/5/6 2011...
  • Page 207 OPTION IGNITER STOP SWITCH STOP SWITCH ASSEMBLY REMOTE CONTROL 4st 4/5/6 2011 10-3...
  • Page 208 WIring Diagram 10-4 4st 4/5/6 2011...

  • Page 209: C Model Service Information

    C model Service Information...
  • Page 211 Introduction The following pages are added to describe service information about four stroke gasoline engine 4/5/6 Model C that is different from those of Model B. Each chapter and section of this supplement should be replaced with those of the service manual for 4/5/6B (2010 model) when servicing model C. For your convenience, page number of corresponding section of the manual is shown in parenthesis.

  • Page 212: Specification • Service Data

    1. Specification • Service Data 1.Outline Dimensons <Dual Tank model> Item Type Unit mm/in 15.67 mm/in 25.79 mm/in 30.79 mm/in 35.79 mm/in 17.13 mm/in 22.13 mm/in 27.13 mm/in 15.08 mm/in 19.57 mm/in 4.33 mm/in 16.61 mm/in 14.21 mm/in 13.74 mm/in 30-60 1.18-2.36 mm/in...
  • Page 213 <Sepalate Tank model> Item Type Unit mm/in 15.12 mm/in 25.79 mm/in 30.79 mm/in 35.79 mm/in 17.13 mm/in 22.13 mm/in 27.13 mm/in 15.08 mm/in 19.57 mm/in 4.33 mm/in 16.61 mm/in 14.21 mm/in 13.74 mm/in 30-60 1.18-2.36 mm/in 10.83 mm/in 25.91 mm/in 29.84 mm/in 33.78...
  • Page 214 1. Specification • Service Data 2.Specifications Model Item Unit ual Tank Model Sepalate Tank Model Sail Pro 4/5/6C 5/6C imensions Overall length Overall width 1,053 1,039 Ñ Overall height 1,180 1,166 1,307 1,293 Ñ Transom height Weight 26.1 25.6 Ñ 26.6 26.1 27.1...
  • Page 215 Model Item Unit Dual Tank Model Sepalate Tank Model Sail Pro 4/5/6C 5/6C uel and oil ype of fuel Unleaded regular octane gasoline (Research octane number 90 or more) Fuel tank capacity 1.15 Starting fuel enrichment system Choke valve Fuel pump Mechanical (plunger pump) 4 stroke engine (motor) oil SE, SF, SG, SH, SJ, SL, SM...
  • Page 216 1. Specification • Service Data 3.Maintenance Data art name Item Standard value Carbon deposition on combustion chamber wall Deformation of mating faces and flaws Cylinder head Corrosion of mating faces lugging of cooling water passages Deposition on water jacket interior walls Wear of bore : Measure bore by using 59.00mm (2.3228in) Seizure, cylinder liner damage, or wear...
  • Page 217 Serviceable limit Action to be taken Clean to remove. 0.03 (0.0012) Correct. (Use #240 to 400 waterproof sand paper put of the surface plate to correct. Use #600 to finish.) Correct or replace if possible. Clean to remove. Clean to remove. 59.07mm (2.3256in) Replace if severely damaged on the piston sliding surface, which cannot be repaired with sand paper of No.
  • Page 218 1. Specification • Service Data Standard value art name Item Sail ro Setting mark 3JDA 3GRA 3JEA Venturi bore ¿10 ¿13 ¿15 ¿15 Throttle bore ¿19 ¿19 ¿21 ¿21 Main jet (MJ) Main air jet (MAJ) #135 #150 #155 #155 arburetor Main nozzle bore (MN) ¿1.6...
  • Page 219 Standard value Standard value Replace if over upper limit. 23.13mm over Replace if over upper limit. 0.25mm (0.0047 Ð 0.0079in) Replace if under lower limit. 5.96mm (0.2346in) Replace if over upper limit. 0.10mm (0.0039in) Wear of oil pump cover is included. Replace if under lower limit.
  • Page 220 1. Specification • Service Data 4.Sealant and Lubrican Remarks Apply to Three Three Liquid Shin-Etsu Chuoh Yuka Konishi Bond Bond O-Ring Chemical Centax Bentax 1342 G17 G103 1741 2000 ● Camshaft Bearings and cams Rocker arm ● Sliding surface Valve (IN, EX) ●...
  • Page 221 Apply to Remarks Three Three Liquid Shin-Etsu Chuoh Yuka Konishi Bond Bond Chemical O-Ring Centax Bentax 1342 G17 G103 1741 2000 ● O ring (shift lever) Shift Shift lever ● Sliding surface Drive shaft Thread Taper plug 1/8 ● housing Drive shaft (spline) ●...

  • Page 222: Parts Layout

    2. Parts Layout P/L Fig. 1 Cylinder & Oil Pan 12 Nám (9 lbáft) [1.2 kgfám] 2 Nám (18 lbáft) [2. kgfám] 18 Nám (13 lbáft) [1.8 kgfám] 9 Nám (7 lbáft) [0.9 kgfám] 4st OIL G103 G103 G103 G103 G103 G103 G103...
  • Page 223 Ref. Description Q'ty Remarks Cylinder Block Oil Seal 20-35-7 Ball Bearing 6205 Breather Chamber Cover Gasket Breather Chamber Cover Collar Breather Wave Washer d=5 Screw M6 L=16mm Bolt M6 L=12mm Oilpan Sub-Ass'y Oil Seal 25-40-8 Grommet Oilpan Dowel Pin 6-12 Oil Pump Rotor (Inner) Oil Pump Rotor (Outer) Pin Oil Pump...
  • Page 224 2. Parts Layout Cylinder Head & Valve & Cam Shaft P/L Fig. 3 0 Nám (7 lbáft) [ .0 kgfám] Fig.4-4 4st OIL 25 Nám ( 8 lbáft) [2.5 kgfám] Fig. 0-55 2 Nám (9 lbáft) [ .2 kgfám] 25 Nám ( 8 lbáft) [2.5 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] 4st OIL 8 Nám ( 3 lbáft) [ .8 kgfám]...
  • Page 225 Ref. Description Q'ty Remarks Cylinder Head Ass'y Intake Valve Exhaust Valve Bolt M6 L=35mm Valve Spring Seat Valve Spring L=35 Retainer Cotter Dowel Pin 6-12 Cylinder Head Gasket Do not reuse. Cylinder Head Bolt 8-90 Cylinder Head Bolt 8-60 Exhaust Cover Gasket Do not reuse.
  • Page 226 2. Parts Layout P/L Fig. 4 Carburetor & Fuel Pump Fig.1-51 Fig.1-50 Fig.10-20 Fig.10-2 4st OIL Fig.1 -6 Fig.1 -7 Fig.1 -14 4st OIL 11-16 4st 4/5/6 2011...
  • Page 227 Ref. Description Q'ty Remarks Intake Manifold Ass'y Intake Manifold Gasket Do not reuse. Bolt M6 L=25mm Carburetor Ass'y Carburetor Ass'y Carburetor Ass'y Main Nozzle Main Nozzle Main Nozzle Main Jet (#68) Main Jet (#62) Main Jet (#70) Slow Jet (#38) 4/5/6ps Float Float Valve...
  • Page 228 2. Parts Layout Recoil Starter P/L Fig. 5 18 17 1741 1741 1741 1741 1342 1342 1342 1342 4 Nám (3 lbáft) [0.4 kgfám] 1342 1342 1741 1741 1741 1741 Ref. Ref. Description Remarks Q'ty Description Q'ty Remarks Recoil Starter Ass'y 16 Starter Lock Starter Case 17 Collar 4-6-21...
  • Page 229 Top Cowl P/L Fig. 11 Dual Fuel Tank Sail Pro Decal Separate Fuel Tank Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Top Cowl Ass'y Dual Fuel Tank / Integral 8-2 Decal Set F5C Top Cowl Ass'y Separate Fuel Tank 8-3 Decal Set F6C Tilt Handle Caution Decal (A)
  • Page 230 2. Parts Layout Magneto P/L Fig. 6 50 Nám (3.7 lbáft) [5.0 kgfám] 11-20 4st 4/5/6 2011...
  • Page 231 Ref. Description Q'ty Remarks Flywheel MF54 (Mark48) STD with out Alternator Flywheel MF54 (Mark50) for Sail Pro (with Alternater) Alternator Ass'y for Sail Pro 12V60W (with Alternater) Screw for Sail Pro (with Alternater) M5 L=25mm Washer for Sail Pro (with Alternater) M5 Clamp 4.2-3-8 for Sail Pro (with Alternater) Screw...
  • Page 232 2. Parts Layout P/L Fig. 7 Drive Shaft Housing & Shift 25 29 4 Nám ( lbáft) [0.4 kgfám] 7 Nám (5 lbáft) [0.7 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] Fig.8-47 1 Nám (9 lbáft) [1. kgfám] 1342 1342 1342 1 Nám (9 lbáft) [1.
  • Page 233 Ref. Description Q'ty Remarks Drive Shaft Housing Ass'y (S) for Transom “S” Drive Shaft Housing Ass'y (L) for Transom “L” Use 369-60003-0 Drive Shaft Housing Ass'y (L) for Transom “UL” Use 3AB-60003-0 Bushing Shift Lever Drive Shaft Bushing Ass'y for Transom “L” Drive Shaft Bushing Ass'y for Transom “UL”...
  • Page 234 2. Parts Layout Bracket & Reverse Lock P/L Fig. 9 " & & " " & " " " & 11-24 4st 4/5/6 2011...
  • Page 235 Ref. Description Q'ty Remarks Swivel Bracket A Swivel Bracket B Clamp Bracket (R) Stern Bracket Right Starboard Side Clamp Screw Kit Clamp Screw Clamp Screw Handle Rivet 3-22 Clamp Screw Pad Shoulder Bolt Clamp Bracket (L) Stern Bracket Left Port Side Bolt 8-122 Nylon Nut 8P1.25 Washer...
  • Page 236 2. Parts Layout P/L Fig. 10 Bottom Cowl & Tiller Handle Fig.3-29 Fig.3-19 11-26 4st 4/5/6 2011...
  • Page 237 Ref. Description Q'ty Remarks Bottom Cowl Grommet ø5.5-ø9.5-44 Cowl Latch Ass'y Bolt M6 L=16mm Grommet ø10.5-ø15.5-ø20.5-32 Grommet 18-2.5 Grommet 25-5 Dual Fuel Tank Grommet 17-2.7 Plastic Rivet 6.5 Fuel Connector (Engine Male) Protector Fuel Connector Bolt M6 L=25mm Washer Fuel Hose W/Protector USA/Separate Fuel Tank Fuel Hose STD/Separate Fuel Tank...
  • Page 238 2. Parts Layout P/L Fig. 13 Integral Fuel Tank Fig. 10-17 Fig. 4- 6 Fig. 10-10 11-28 4st 4/5/6 2011...
  • Page 239 Ref. Description Q'ty Remarks Fuel Tank Ass'y Dual Fuel Tank Sealing Plate Dual Fuel Tank Fuel Tank Seal Dual Fuel Tank Fuel Hose Dual Fuel Tank STD Fuel Hose W/Protector Dual Fuel Tank/For USA Fuel Hose Dual Fuel Tank STD Fuel Hose W/Protector Dual Fuel Tank/For USA Fuel Hose...

  • Page 240: Difference Item

    3. Difference item Chapter 1. Predelivery Inspection 1) Gear Shift (P1-8) 1 and propeller shaft for smooth Check shift lever movement of the shift between forward (F) and neutral (N) while engine is operating. 2) Fuel Tank and Fuel Line (P1-9) Check that fuel tank contains sufficient amount of gasoline, fuel line is connected and is free of leaks.

  • Page 241: Chapter 3 Inspection Items

    Chapter 3. Inspection Items 1) Fuel System (P3-4) Check piping Remove top cowl and check each section for fuel leak, dirt, deterioration and damages. Clean or replace parts if necessary. 2) Inspection of Fuel Tank (P3-5) <For Dual Tank Model> Remove dirt and water from fuel tank 1 if any.

  • Page 242: Chapter 4 Inspection Items

    3. Difference item Chapter 4. Inspection Items 1) Inspection of Fuel Feed System Piping (P4-12) Remove top cowl and check each section for fuel leak, dirt, deterioration and damages. Clean or replace parts if necessary. 2) Draining Fuel (P4-12) WARNING Remove fuel tank, fuel hose and carburetor after fully draining the fuel from these parts.

  • Page 243: Removing Carburetor (P4-14)

    5) Removing Carburetor (P4-14) WARNING Before working on fuel system, make sure to disconnect battery cables from the battery, or electric sparks can occur, possibly igniting fuel or causing fuel to explode. Disconnect choke link wire. Be careful not to bend wire tip 1 when disconnecting.
  • Page 244 3. Difference item Loosen carburetor mounting bolts and remove carburetor 5. Be careful not to bend throttle rod when removing the rod and carburetor. 11-34 4st 4/5/6 2011...

  • Page 245: Chapter 5 Inspection Items

    Chapter 5. Inspection Items 1)Removing Power Unit (P5-16) Remove fuel from fuel tank before disconnecting fuel hose from fuel cock 1 at fuel tank side. Remove fuel tank mounting bolts and then remove fuel tank Disconnect choke wire 4 from carburetor 3. Remove choke wire fixing bracket 5 from stay 6.
  • Page 246 3. Difference item Disconnect rod snaps above and below starter lock rod, and then remove start lock rod. Disconnect wires from igniter 8. Disconnect ground wire from cylinder. In the same way as B model; Disconnect throttle wire, Remove engine mounting bolts, and then, dismount power unit.

  • Page 247: Chapter 8 Inspection Item

    Chapter 8. Inspection Item 1) Inspection of Igniter (P8-6) ED teminal (small) ED teminal (small) Measure igniter resistance. Replace if other than specified value. Remove the part and test it as a separate unit. Stop switch terminal Stop switch terminal (large) (large) GND (non painted)

  • Page 248: Inspection Of Rectifier (P8-8)

    3. Difference item 2) Inspection of Rectifier (P8-8) Check conduction of fuse (10 A) contained in the fuse box 1. Replace if non-conductive. Check conduction between rectifier terminals. Replace if out of specification. Rectifier tester check chart (3GR-76060-0) ester Ò+Ó terminal Yellow Black Yellow...
  • Page 249 MEMO 4st 4/5/6 2011 11-39...

  • Page 250: Chapter 10 Wiring Diagram

    3. Difference item Chapter 10 Wiring diagram F 4C/5C/6C OPTION LIGHT EXTENSION CORD ALTERNATOR B ------- Black Br ----- Brown RECTIFIER MAGNETO R ------- Light Green W ------ White Lg ----- Light Green FUSE MAGNETO IGNITER FLAT TERMINAL FLAT (Large) TERMINAL (Small) WARNING LIGHT...
  • Page 251 OPTION IGNITER STOP SWITCH STOP SWITCH ASSEMBLY REMOTE CONTROL 4st 4/5/6 2011 11-41...
  • Page 252 MEMO 11-42 4st 4/5/6 2011...
  • Page 253 MEMO 4st 4/5/6 2011 11-43...
  • Page 254 MEMO 11-44 4st 4/5/6 2011...
  • Page 255 MEMO 4st 4/5/6 2011 11-45...
  • Page 256 MEMO 11-46 4st 4/5/6 2011...
  • Page 257 MEMO 4st 4/5/6 2011 11-47...
  • Page 258 MEMO 11-48 4st 4/5/6 2011...
  • Page 259 © 2011 Tohatsu orporation. All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Tohatsu orporation.
  • Page 260 6B,C odels OB No.003-21034-2 11-04 NB Printed in Japan...

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