Page 1 B No.003-21062-0 08-12 NB-2600...
Page 2 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 3 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 figure out the tools needed.
Page 4 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 5 Description of Pictograph The following symbols represent the contents of individual chapters. Service Inspections and Service Data Fuel System Information Adjustments Electrical Power Unit Lower Unit Bracket System Wiring r/min Troubleshooting Rigging Diagrams The following symbols indicate items needed for service. Lubrication Tightening Special Tool...
Page 6 ⋯⋯ 3-22 1.Service Information 18) Throttle Cable Adjustment of Throttle Link 19) Inspection of Gear Shift Operation ⋯⋯⋯⋯⋯⋯ 3-27 ⋯⋯ 1-2 1. Identification (Engine Serial Number) 20) Inspection of Idle Engine Speed ⋯⋯⋯⋯⋯⋯⋯ 3-29 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-2 2. Work Safety 21) Inspection of Ignition Timing⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-29 1) Fire Prevention ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯...
Page 7: Table Of Contents
Bottom Cowl ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-6 28) Inspection of Cylinder Inner Diameter⋯⋯⋯⋯⋯ 5-43 29) Inspection of Piston Clearance ⋯⋯⋯⋯⋯⋯⋯ 5-44 Shift & Stop Swith⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-7 30) Inspection of Piston Ring Side Clearance ⋯⋯⋯⋯⋯ 5-44 Shift (For EP) ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-8 31) Inspection of Piston Rings ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-44 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯...
Page 8 INDEX Service Information Service Data Inspections and Adjustments Fuel System Power Unit Lower Unit Bracket Electrical System Troubleshooting Wiring Diagram 4st 9.9/15/20 2008...
Page 9 viii 4st 9.9/15/20 2008...
Page 10 Service Information 2) Gear Shift ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9 1. Identification (Engine Serial Number) 3) Engine Oil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-2 2. Work Safety 4) Gear Oil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9 1) Fire Prevention ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-2 5) Fuel Line ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-10 2) Ventilation ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-2 6) Rigging ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯...
Page 11 Service Information 1. Identification (Engine Serial Number) Engine serial number is stamped on the bottom cowl of outboard motor body. 1 Model Name Tokyo, Made in Japan 2 Model Type 2008 F15C 3 Serial Number SERIAL No. XXXXXXXX 11. 0 kW RATED POWER FULL THROTTLE RANGE 5000...
Page 12 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 13 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 14 3. Tools and Instruments 1) Test Propeller P/N. 3R0-64111-0 Outer diameter : 180mm With : 16mm Rotational speed at WOT Model (Wide Open Throttle) (r/min) F 9.9 C approximately 4,500 F 15C approximately 5,400 F 20C approximately 5,700 2) Measuring Instruments For the following measuring instruments, use commercially available ones.
Page 15 Service Information 3) Special Tools Bevel Gear B Nut Wrench Bevel Gear B Nut Socket Spring Pin Tool A Spring Pin Tool B P/N. 346-72231-0 P/N. 346-72232-0 P/N. 345-72227-0 P/N. 345-72228-0 Removing/installing Pinion (B) Gear Nut Removing spring pin Installing spring pin Thickness Gauge Bevel Gear Bearing Puller Ass'y Bevel Gear Bearing Installation Tool...
Page 16 Torque Wrench Valve Clearance Driver Oil Filter Wrench Slide Hammer Kit P/N. 3AC-99070-0 P/N. 3AC-99090-0 P/N. 3AC-99071-0 P/N. 3AC-99080-0 Removing forward (A) gear Adjusting valve clearance Adjusting valve clearance Removing/installing oil filter bearing outer race ø110 x ø71 ø34.5 x ø17.5 Center Plate Driver Rod Oil Seal Attachment...
Page 17 Service Information ø51.5 x ø39.5 Crank Shaft Holder Spark Tester Oil Seal Attachment P/N. 3F3-72540-0 P/N. 3BJ-72815-0 P/N. 3UI-99820-0 Use in combination with driver rod. Inspecting sparks Holding crank shaft Use oil seal attachment to press fit ball bearing. Installing forward (A) gear and rever (C) gear bearings 4st 9.9/15/20 2008...
Page 18 4. Pre-delivery Inspection å ∫ 1) Steering Handle å Check installations for clattering and play. ∫ Adjust steering friction. ç ∂ ç Check throttle grip for movement. (full open/full close). ∂ Adjust throttle friction. 2) Gear Shift Check that gear shifts from neutral (N) to forward (F) and reverse (R) smoothly.
Page 19 Service Information 5) Fuel 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: Stop Switch
8) Inspection of Starting Switch and å Stop Switch Press start switch 1 or turn main switch to START 2 to check that engine starts. Turn main switch to OFF 3 to check that engine stops. å Tiller Handle Model — Push and hold to stop ∫...
Page 21 Service Information 9) Cooling Water Check Port Check that cooling water check port 1 discharges water during engine runs. 10) Idling After engine has warmed up, use tachometer to check idle speed is as specified. Idle Speed : 950 r/min Tachometer : P/N.
Page 22 12) Trim Tab Adjustment of trim tab angle After installing outboard motor on the boat, use trim tab to 1342 1342 1342 achieve balance between port and starboard steering loads. Loosen trim tab bolt, adjust angle of trim tab 1 as described below, and then tighten the bolt to specified torque.
Page 23: Test Run
Service Information 6. Test Run Start engine and check if gear shift can be moved smoothly. After completing warm-up operation, check idling revolution speed. Idling Revolution Speed : 950 r/min Tachometer : 1High tension cord P/N. 3AC-99010-0 Shift gear into forward (F) and run dead slow for approximately 10 minutes.
Page 24 After test run, use flushing kit and fresh water to wash cooling water path by idling engine. Tape 4st 9.9/15/20 2008 1-15...
Page 25 1-16 4st 9.9/15/20 2008...
Page 26 Service Data ⋯⋯⋯⋯⋯⋯⋯⋯ 2-2 1. Outline Dimensons ⋯ 2-6 4. Cooling Water System Diagram 1) Engine outer dimensions ⋯⋯⋯⋯⋯⋯⋯ 2-2 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-7 5. Specifications 2) Transom Bolts ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-3 ⋯⋯⋯⋯⋯⋯⋯⋯ 2-10 6. Maintenance Data ⋯⋯⋯⋯⋯⋯⋯⋯ 2-4 2. Fuel Feed System ⋯...
Page 27 Service Data 1. Outline Dimensions 1) Engine Outer Dimensions F9.9/15/20C Item Type Unit 14.76 27.17 33.07 38.07 16.26 22.13 27.13 14.57 24.41 4.72 18.50 20.08 Mechanical 12.60 40-60 1.57-2.36 16.73 29.13 34.65 36.02 MF/EF 14.37 13.58 12.80 8.27 18.90 deg. deg.
Page 28 2) Transom Bolts Mechanical Tilt Model CENTER LINE 68.5mm 66.5mm (2.70in) (2.62in) 135mm(5.31in) 98mm(3.86in) 96mm(3.78in) 194mm(7.64in) 4st 9.9/15/20 2008...
Page 29 Service Data 2. Fuel Feed System 1) Fuel Feed Route Fueltank 1 Fuel Connector 2 Fuel filter 3 Fuel pump 4 Carburetor 5 4st 9.9/15/20 2008...
Page 30 3. Engine Lubrication System Diagram Cam shaft Oil pressure switch upper bearing No.1 cylinder wall Cam shaft upper journal No.1 No.1 crank pin piston No.1 piston pin Rocker arm shaft Cam face rocker arm valve No.2 cylinder wall No.2 No.2 crank pin piston No.2...
Page 31 Service Data 4. Cooling Water System Diagram Thermostat Cylinder head Cylinder Thermostat Cylinder Cylinder head Pilot water outlet Pilot water outlet Water draining passage Water feeding passage in drive shaft housing in drive shaft housing located in lower part located in lower part of cylinder of cylinder Cooling water pipe...
Page 32: Specifications
5. Specifications Model Item Unit Dimensions Overall length mm (in) 980 (38.6) 640 (25.1) Overall width mm (in) 365 (14.4) 345 (13.6) mm (in) 1,065 (42) Overall height mm (in) 1,215 (48) mm (in) 1,342 (53) mm (in) 413 (16.3) Transom height mm (in) 562 (22.2)
Page 33 Service Data Model Item Unit Power unit Engine type 4 stroke No. of cylinders Total displacement (c.i) 351 (21.41) Valve system OHC Crossflow Bore x Stroke mm(in) 61 X 60 (2.40 X 2.36) Compression ratio Shift operation Front shift (manual) Remote control Starting system Recoil starter...
Page 34 Model Item Unit Bracket No. of trim steps No. of steps Trim angle (transom 12°) Degrees 5 - 25° Shallow water drive angle (transom 12°) Degrees 32° Maximum tilt angle Degrees 70° Steering angle Degrees 70° Maximum allowable transom mm (in) 40 - 60 (1.57 - 2.36) board thickness *2 Angle from horizontal line when transom is 12°.
Page 35 Service Data 6. Maintenance Data Part name Item Standard value Cylinder head Carbon deposition on combustion chamber wall Deformation of mating faces and flaws Corrosion of mating faces Plugging of cooling water passages Deposition on water jacket interior walls 61.00mm (2.4016in) Cylinder Wear of bore : Measure bore by using cylinder gauge.
Page 36 Serviceable limit Action to be taken Clean to remove. 0.1mm (0.004in) Correct. (Use #240 to 400 waterproof sand paper put of the surface plate to correct. Use #600 to ofinish.) Correct if possible, or replace. Clean to remove. Clean to remove. 61.06mm (2.4039in) Replace if over serviceable limit.
Page 37 Service Data Part name Item Standard value Valve clearance IN : Intake 0.13 - 0.17mm (0.0051 - 0.0067in) Intake valve Exhaust valve EX : Exhaust 0.18 - 0.22mm (0.0071 - 0.0087in) Valve stem outer diameter IN : Intake 5.48mm (0.2157in) EX : Exhaust 5.46mm (0.2150in) Valve guide inner diameter...
Page 38 Serviceable limit Action to be taken Adjust to specified range 5.46mm (0.2150in) Replace if under lower limit. 5.44mm (0.2142in) 5.55mm (0.2185in) Replace if over upper limit. 5.57mm (0.2193in) 0.070mm (0.00276in) Replace if over upper limit. 0.100mm (0.00394in) 2.0mm (0.08in) Replace if over upper limit. 2.0mm (0.08in) 33.5mm (1.32in) Replace if under lower limit.
Page 39 Service Data Part name Item Standard value Ignition timing BTDC 5° - BTDC 35° Spark performance (@500r/min) 10mm (0.4in) or over (Use genuine spark tester to measure.) Alternator output (@5,000 r/min） 12V - 140W Magneto Stator coil resistance Exciter coil Black/Red - Blue 12.5 - 18.8Ω...
Page 40 Serviceable limit Action to be taken 10mm (0.4in) Replace if below specified value. Replace if out of specified range. Replace if out of specified range. Replace if out of specified range. Replace if out of specified range. 1.2mm (0.047in) Clean to remove carbon deposit and dirt. Adjust gap by moving side electrode.
Page 41 Service Data Part name Item Standard value Thermostat Valve operation starting temperature (submerged) 60°C±1.5°C (140±3°F) Valve full open temperature (submerged) 75°C (167°F) Valve full open lift (submerged) 3.0mm (0.12in) or over Pump impeller Wear, crack Pump case (liner) Wear Wear Guide plate Anode Gear case anode, wear...
Page 42 Serviceable limit Action to be taken Open even a little at ambient temperature Replace if out of specified range. Because thermostat operates with some time lag, measure the lift of open valve after maintaining at around 75°C(167°F) for approximately 5 minutes. 3.0mm(0.12in) Replace if under lower limit.
Page 43: Tightening Torque Specifications
Service Data 7. Tightening Torque Specifications Tightening torque Wrench Thread B Type of Tightening location x +Pitch fastener N ・ m lb ・ ft kg ・ m Engine M6 x1.0 Bolt Cylinder block-Cylinder head bolts M8 x1.25 Bolt M6 x1.0 Bolt 11.5 Cylinder block-Crank case bolt...
Page 44 8. Sealant and Lubricant Apply to Remarks SUMICO LOC- LOC- Shin-Etsu ThreeBond ThreeBond Konishi LUBRI- Chemical TITE TITE CANT 1342 1373 1361 1207B 1741 G17 Centax L2 KS-64 500 Camshaft ○ Bearings and cams (cam lobe, and fuel pump driving section) ○...
Page 45 Service Data Apply to Remarks SUMICO LOC- LOC- Shin-Etsu ThreeBond ThreeBond Konishi LUBRI- Chemical TITE TITE CANT 1342 1373 1361 1207B 1741 G17 Centax L2 KS-64 Starter case ○ Sliding face ○ Starter spring Whole area ○ Sliding face Ratchet Friction plate ○...
Page 46 Apply to Remarks SUMICO LOC- LOC- Shin-Etsu ThreeBond ThreeBond Konishi LUBRI- Chemical TITE TITE CANT 1342 1373 1361 1207B 1741 G17 Centax L2 KS-64 500 Bolt (propeller shaft housing) ○ ○ Thread ○ O ring ○ Oil seal ○ Periphery, at press fitting Propeller shaft ○...
Page 47 Service Data 2-22 4st 9.9/15/20 2008...
Page 48 Maintenance 15) Inspection of Compression Pressure ⋯ 3-18 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-2 1. Special Tools ⋯⋯⋯⋯⋯⋯⋯ 3-3 2. Inspection Schedule 16) Inspection and Adjustment of Valve Clearance ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-19 ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-4 3. Inspection Items 17) Throttle Cable For F type ⋯⋯⋯⋯⋯⋯ 3-20 1) Inspection of Top Cowl ⋯⋯⋯⋯⋯⋯⋯...
Page 49 Maintenance 1.Special Tools Spring Pin Tool A Spring Pin Tool B Tachometer Compression Gauge P/N. 345-72227-0 P/N. 345-72228-0 P/N. 3AC-99010-0 P/N. 3AC-99030-0 Measuring engine revolution Measuring compression Removing spring pin Installing spring pin speed pressure Torque Wrench Valve Clearance Driver Flywheel Puller Kit Oil Filter Wrench P/N.
Page 50 Include valve lapping Cleaning if necessary. Chamber Wear, Damage, Timing Belt Elongation Bend, damage, wear Propeller of blades Tohatsu’s genuine gear Replacement or replenishment Gear Oil of oil, leak of water oil (GL5,SAE80 to 90) Replacement Replacement Replacement Replacement Replacement...
Page 51 Maintenance 3. Inspection Items 1) Inspection of Top Cowl Push top cowl using both hands to check for looseness and state of closing. 2) Fuel System Check piping Check the fuel system piping for fuel leak, dirt, deterioration and damage, and replace or clean parts if necessary. 4st 9.9/15/20 2008...
Page 52 3) Inspection of Fuel Tank 2 of fuel tank 1 counterclockwise Turn fuel pick up elbow to remove the part, and clean the filter 3. Remove dirt and water from fuel tank 1 if any. 2 Fuel pickup elbow 3 Filter 4) Inspection of Fuel Filter Check fuel filter for dirt, build up of fuel slag, and fuel filter for invasion of foreign matters and crack.
Page 53 Maintenance 5) Replacement of Engine Oil Oil Level Oil Level Gauge Quantity of Oil for Full Replacement When oil filter is When oil filter is not replaced replaced Upper Limit 1.2L 1.0L Lower Limit 0.95L 0.75L Oil Specification Engine Oil : 4 Stroke Engine Oil API: SE, SF, SG, SH, SJ, SL, SM 10W –...
Page 54 6) Replacement of Oil Filter Drain engine oil. Place a piece of rag below oil filter area, and remove oil filter by using oil filter wrench 1. · Leakage Replace oil filter 5 minutes or more after stopping engine. · Wipe off spilled oil completely. Oil Filter Wrench 1 : P/N.
Page 55 Maintenance 7) Inspection of Gear Oil Quantity Tilt down outboard motor to make it vertical. GEAR GEAR GEAR Remove upper oil plug 1 and check level of gear oil in the gear case. a as plug is Spill of some oil from plug hole removed indicates that gear case is filled with specified quantity of gear oil.
Page 56 Remove lower unit installation bolts, 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 crack and wear.
Page 57 Maintenance 9) Replacement of Gear Oil Tilt outboard motor a little as shown. Place drain oil pan below lower 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 58 10) 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 59 Maintenance 11) Inspection of Timing Belt Disconnect starter lock cable, and then remove recoil starter and belt cover. Check timing belt inner and outer surfaces for cracks, damages and wear while rotating flywheel clockwise with hands. Replace if necessary. "●1" mark a of cam shaft Rotate flywheel clockwise to bring pulley to "▲"...
Page 60 12) Replacement of Timing Belt Disconnect starter lock cable 1. Remove recoil starter, belt cover and starter pulley. Rotate flywheel 1 clockwise to bring "●1" mark a of cam shaft pulley 2 to "▲" mark b of cylinder head. #1 piston is to be at top dead center of compression stroke.
Page 61 Maintenance Use flywheel puller bolt to remove flywheel and then key. CAUTION To prevent damages to engine and special tools, tighten flywheel puller set bolts evenly and keep flywheel puller parallel to flywheel while working. Screw puller onto crankshaft end until flywheel is disengaged from tapered section of crankshaft.
Page 62 13) Installatin of Timing Belt Align locating lines a of new timing belt 1 as shown, face part number side up, and engage belt with timing pulley 2 and then with cam shaft pulley 3. CAUTION · Be careful not to damage timing belt when installing.
Page 63 Maintenance Reinstall hanger 4 and tighten bolt to specified torque. Hanger Bolt : 23 N · m (17 lb · ft) [2.3 kgf · m] Install coil bracket ass'y and alternator, apply "Three Bond" 1342 to bolts, and tighten them to specified torque. Reconnect couplers (4) of alternator and pulser coil.
Page 64 14) 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 65 Maintenance 15) 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 (of stop switch lanyard) from stop switch. CAUTION Remove lock plate (of stop switch lanyard) from stop switch before measuring compression pressure.
Page 66 16) Inspection and Adjustment of Valve ○ Clearance · Perform inspection and adjustment of valve clearances when engine is cold. · #1 piston is to be at top dead center of compression stroke. ▲Marka Disconnect starter lock cables, and then recoil starter, belt cover, spark plugs, fuel pump and cylinder head cover.
Page 67 Maintenance 17) Throttle Cable For F type Turn throttle grip to START position. Bring alignment mark 1 of throttle drum to pointer 2 located on the bottom cowl, adjust throttle cable properly, and tighten with nut 3. Adjust cable tension so that it moves approximately 1mm when pushed lightly with a finger.
Page 68 Attach throttle rod 4 to throttle drum 5, and push the rod toward direction shown with arrow. Open throttle to a position where carburetor link 6 touches full open stopper 7. When carburetor’s full open position and throttle rod position are determined, fix with screw 8.
Page 69 Maintenance 18) Throttle Cable Adjustment of Throttle Link Remove bolt of remote control stay cover 1 and bolt. Remove bolt of cable clip 2 and bolt. Loosen throttle link rod stop screw 3. Set carburetor’s throttle link 4 to full open position while holding throttle lever at full open position.
Page 70 Set throttle lever to full open position. Check that throttle lever touches throttle lever stopper 5. Set carburetor’s throttle lever to full open position. Check that throttle lever touches stopper 6. After checking full open stopper of throttle lever side and carburetor side, fix throttle rod’s stop screw 7 at full open position.
Page 71 Maintenance Set shift arm to forward (F), neutral (N), reverse (R) and then to neutral (N) positions. Set throttle lever 0 to full close position. Check that throttle lever contacts with full close stopper 1. Run remote control cable through bottom cowl grommet q. Bring cable clip w to groove of cable, and fix cable clip to lower cowl by using bolt.
Page 72 Adjust screw-in length of cable joint i so that hole of cable joint e is brought to throttle lever and shift arm pin r. After adjusting remote control cable joint, fix it with remote control cable fully pushed in. CAUTION Screw-in remote control cable joint at lease 10mm i.
Page 73 Maintenance Reconnect cord ass'y connectors. CAUTION Do not disconnect cord ass'y while engine operates. Run cord ass’y and remote control cable though bottom cowl grommet. Attach bracket to remote control cable groove securely, and then fix it to bottom cowl. Secure remote control stay cover with screws.
Page 74 19) Inspection of Gear Shift Operation Shift gear from neutral (N) to forward (F), neutral (N), and then to reverse (R) to check that shift operation is performed smoothly. Adjust shift link rod length and shift cable position if necessary. Shift gear into neutral (N).
Page 75 Maintenance Loosen lock nut 1, remove snap pin and washer, and then remote control cable joint. (Throttle lever is not shown to make the working procedure more comprehensible. Adjust remote control cable length so that the cable joint 2 hole aligns with set pin. WARNING Screw-in remote control cable joint at lease 10mm a.
Page 76 20) Inspection of Idle Engine Speed Start engine and run for 5 minutes to warm up. Attach tachometer to 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 77 Maintenance 22) Inspection of Anode Check anode 1 and trim tab 2 for build up of scale and adherence of grease and oil. Clean, or replace if necessary. CAUTION Do not coat anode and trim tab with oil, grease or paint, or their anti-corrosion function does not work normally.
Page 78 24) Inspection of Propeller Check propeller blades and spline for cracks, damages, wear and corrosion. Replace if necessary. 25) Inspection of Thermostat Loose thermostat cover nut and remove thermostat 1. Hang thermostat 2 in the water contained in vessel. Put thermometer in the water, warm up water and measure water temperature when valve opens.
Page 79 Maintenance 26) Inspection of Cooling Water Passage Check water strainer 1 and sub water strainer 2 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 3. If not, check water pump and cooling water passage in the engine.
Page 80 27) 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 81 Maintenance 28) Inspection of Battery Inspect battery liquid level. If lower than "LOW" mark a, add distilled water until the level goes in between "UP" and "LOW" marks. Measure specific gravity of battery liquid. Charge battery if specific gravity is less than specified value. WARNING Electrolyte contains sulfuric acid that is poisonous and highly corrosive, and so it is...
Page 82 29) Greasing Points Apply grease to throttle cable and sliding areas. Put grease through grease nipples 1 until excessive grease appears from bush a. Apply grease to throttle cable and sliding areas. b Do not lubricate here. No oil on teeth. Apply grease to terminals of starter motor, starter solenoid and PTT solenoid.
Page 83 Maintenance Apply grease to propeller shaft spline. 3-36 4st 9.9/15/20 2008...
Page 84 Fuel System 1) Removing Carburetor ⋯⋯⋯⋯⋯⋯⋯ 4-11 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-2 1. Special Tools Remote Control Model ⋯⋯⋯⋯⋯⋯⋯ 4-11 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-3 2. Parts Layout Tiller Handle Model ⋯⋯⋯⋯⋯⋯⋯⋯ 4-12 Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-3 2) Disassembling Carburetor ⋯⋯⋯⋯⋯ 4-14 Intake Manifold & Fuel Pump ⋯⋯⋯⋯⋯ 4-5 3) Cleaning and Inspection ⋯⋯⋯⋯⋯⋯...
Page 85 Fuel System 1.Special Tools Vacuum/Pressure Gauge P/N. 3AC-99020-0 Inspecting pressure 4st 9.9/15/20 2008...
Page 86 Fuel System P/L Fig. 5 2.Parts Layout Carburetor 1-21 1-19 1-20 1-22 1-23A 1-23B 1-12 1-13 1-24 1-25 15/9.9 1-26 1-27 1-28 1-10 1-17 1-11 1-18 1-15 1-36 1-35 1-14 1-37 1-37 1-29 1-16 1-38 1-30 1-31 1-32 1-34 1-33 4st 9.9/15/20 2008...
Page 87 Fuel System Ref. Description Q'ty Remarks Carburetor for MF & EF (3BJFA) Carburetor for EP (3BAPA) Carburetor for MF & EF (3BHFA) Carburetor for EP (3AZPA) Carburetor for MF & EF (3FSFA) Main Jet #121 Plug Main Jet #99 Main Jet #88 Plug O-Ring Do not reuse.
Page 88 P/L Fig. 4 Intake Manifold & Fuel Pump 9 N·m (7 lb·ft) [0.9 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 4st OIL 4st OIL Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Intake Manifold 15 Fuel Pump Intake Manifold Gasket 16 O-Ring, 3.5-25.7 Do not reuse.
Page 89 Fuel System 3.Carburetor Inner Passages 1) Idling Passage a - Air intake h - Fuel inlet b - Air vent inlet i - Chamber drain c - Air-bleed inlet j - Main jet d - Slow air jet k - Slow jet e - Bypass port l - Outlet check valve - Accelerator pump circuit f - Idle Port...
Page 90 2) Off-Idle Passage a - Air intake h - Fuel inlet b - Air vent inlet i - Chamber drain c - Air-bleed inlet j - Main jet d - Slow air jet k - Slow jet e - Bypass port l - Outlet check valve - Accelerator pump circuit f - Idle Port m - Choke valve...
Page 91 Fuel System 3) High Speed Passage a - Air intake f - Main nozzle b - Float chamber inlet g - Main jet c - Air-bleed inlet h - Slow jet d - Slow air jet i - Air bleed hole e - Bypass port As throttle valve is turned to a position over bypass port, the vacuum produced in the back of throttle valve extends to an area near main nozzle.
Page 92 4) Acceleration Passage a - Air intake f - Diaphragm b - Inlet check valve g - Diaphragm rod c - Jet h - Outlet check valve - Accelerator pump circuit d - Drain i - Pump discharge nozzle e - Return spring When throttle valve is rapidly opened for attempting quick acceleration, the amount of air and vacuous pressure change almost simultaneously, but there is a tendency that the fuel delays a little because the fuel density is larger than the air, resulting in making the air-fuel mixture lean instantaneously.
Page 93 Fuel System 5) Choking Passage a - Air intake d - Idle Port b - Choke valve e - Main nozzle c - Bypass port Choke system consists of choke valve, detent and push-pull cable or electric solenoid. When starting cold engine, the operator should judge whether it is necessary to operate the choke to make engine starting easier, and if necessary, to operate the handle of choke cable manually to set it to a proper position or to activate the solenoid for electric starting model.
Page 94 4. Inspection Items 1) 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. Remote control model Loosen throttle link rod set screw 1. Remove throttle link rod 2 from link drum 3.
Page 95 Fuel System Loosen intake manifold installation bolts, and remove carburetor ass’y and silencer cover at the same time. Loosen solenoid mount plate screws. Loosen solenoid mount plate bolts and then remove carburetor. Tiller Handle Model Loosen throttle link rod set screw 1. Remove throttle link rod 2 from link drum.
Page 96 Remove air silencer head hose 1 from intake manifold. Remove breather hose 2 from carburetor. Remove rectifier lead wire band and then remove rectifier 3. Loosen intake manifold installation bolts, and remove carburetor ass’y and silencer cover at the same time. Loosen air silencer mount bolts and then remove carburetor.
Page 97 Fuel System 2) Disassembling Carburetor Remove drain screw 1 to drain fuel. CAUTION To prevent fuel from dripping on the floor, use a vessel to catch the fuel. Remove float chamber 2. Remove carburetor cover 3. Remove float ass'y 4. 4-14 4st 9.9/15/20 2008...
Page 98 Remove jets and nozzle. 15 / 9.9 Remove acceleration pump diaphragm 1. 4st 9.9/15/20 2008 4-15...
Page 99 Fuel System 3) Cleaning and Inspection Check carburetor body for crack, damage and dirt. Replace or clean as necessary. CAUTION Use cleaning solution to remove dirt. Blow passages with compressed air to remove dirt. Do not use wire to remove dirt. Check jets and nozzle for dirt, and replace if necessary.
Page 100 Clean and check filter 1 in the carburetor, and replace with new one if necessary. 4) Inspection of Fuel Pump Remove fuel hoses (2) from fuel pump. Connect vacuum/pressure gauge to inlet of fuel pump. Close fuel pump outlet with a finger and apply specified pressure.
Page 101 Fuel System 5) 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 102 Install jets and nozzle. 15 / 9.9 b to float hinge a. Attach needle valve Attach float ass’y with float arm pin a and secure with screw 4st 9.9/15/20 2008 4-19...
Page 103 Fuel System 7) Adjusting Float Height Measure float height as shown, and replace float if out of specification. Float Height a : 26.2mm (1.0314in) Install drain screw, float chamber 1 and cover 2. 8) Installing Carburetor Reverse carburetor removing steps to install. 4-20 4st 9.9/15/20 2008...
Page 104: Inspection Of Connecting Rod Small End Inner Diameter ⋯
Power Unit 21) Installation of Valves ⋯⋯⋯⋯⋯⋯⋯⋯ 5-38 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-2 1. Special tools 22) Installation of Cam Shaft ⋯⋯⋯⋯⋯⋯ 5-39 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-3 2. Parts Layout 23) Installation of Rocker Arm Shaft ⋯⋯⋯ 5-39 Engine ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-3 24) Installation of Oil Pump ⋯⋯⋯⋯⋯⋯⋯ 5-40 Magneto ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯...
Page 105 Power Unit 1.Special tools Flywheel Puller Kit Piston Slider Compression Gauge Torque Wrench P/N. 369-72211-0 P/N. 3AC-72871-0 P/N. 3AC-99030-0 P/N. 3AC-99070-0 Measuring compression Removing/installing flywheel Installing piston Adjusting valve clearance pressure ø34.5 x ø17.5 Valve Clearance Driver Oil Filter Wrench Driver Rod Oil Seal Attachment P/N.
Page 106 2.Parts Layout Engine 30 N·m (22 lb·ft) [3.0 kgf·m] Ref. Description Remarks Q'ty Power Unit Oil Level Gauge Gasket Do not reuse. Dowel Pin Bolt 6 M8 L=105mm Drive Shaft Housing Cover (Right) Drive Shaft Housing Cover (Left) Screw 2 M6 L=60mm Recoil Starter 10 Belt Cover 11 Battery Cable...
Page 107 Power Unit Magneto P/L Fig. 8 80 N·m (58 lb·ft) [8.0 kgf·m] 26-1 6 N·m (4 lb·ft) [0.6 kgf·m] 26-1 1342 1342 8 N·m (6 lb·ft) [0.8 kgf·m] 1342 1342 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 17-1 1342 1342 1342 Ref.
Page 108 P/L Fig. 9 Electric Parts 25-1 25-1 13 N·m (9 lb·ft) [1.3 kgf·m] 1342 24-1 24-1 13 N·m (9 lb·ft) [1.3 kgf·m] 34-1 34-3 34-2 1342 30-1 1342 1342 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Starter Motor for EP & EF 24-1 Fuse (20A) Bolt 25 Fuse Cable...
Page 109 Power Unit P/L Fig. 4 Intake Manifold & Fuel Pump 9 N·m (7 lb·ft) [0.9 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 4st OIL 4st OIL Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Intake Manifold 15 Fuel Pump Intake Manifold Gasket 16 O-Ring, 3.5-25.7 Do not reuse.
Page 110 Camshaft & Oil Pump P/L Fig. 6 11 N·m (8lb·ft) [1.1 kgf·m] 1342 1342 1342 64 N·m (46 lb·ft) [6.4 kgf·m] 4st OIL 4st OIL 1342 1342 1342 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Camshaft Ass'y 10 Bolt, 20 Pre-Coated 1 M6 L=20mm Oil Pump 11 Washer, 6.5-19-3.2...
Page 111 Power Unit Cylinder Head P/L Fig. 1 4st OIL 4st OIL 1 6 N·m (4 lb·ft) [0.6 kgf·m] 2 9 N·m (7 lb·ft) [0.9 kgf·m] 1 6 N·m (4 lb·ft) [0.6 kgf·m] 2 10 N·m (7 lb·ft) [1.0 kgf·m] 1 10 N·m ( 7 lb·ft) [1.0 kgf·m] 2 30 N·m (22 lb·ft) [3.0 kgf·m] 1 6 N·m (4 lb·ft) [0.6 kgf·m] 2 10 N·m (7 lb·ft) [1.0 kgf·m]...
Page 112 Intake Valve & Exhaust Valve P/L Fig. 7 4st OIL 7 N·m (5 lb·ft) [0.7 kgf·m] 4st OIL 7 N·m (5 lb·ft) [0.7 kgf·m] 4st OIL 4st OIL 4st OIL 7 N·m (5 lb·ft) [0.7 kgf·m] 4st OIL 4st OIL 4st OIL Ref.
Page 113 Power Unit Cylinder P/L Fig. 2 1342 1342 1342 9 N·m (7 lb·ft) [0.9 kgf·m] 10 N·m ( 7 lb·ft) [1.0 kgf·m] 2 23.5 N·m (17 lb·ft) [2.4 kgf·m] 4st OIL WATER NIPPLE 18 N·m (13 lb·ft) [1.8 kgf·m] 6 N·m ( 4 lb·ft) [0.6 kgf·m] 4st OIL 2 11.5 N·m (8.5 lb·ft) [1.2 kgf·m] 1342...
Page 114 Piston & Crankshaft P/L Fig. 3 4st OIL 4st OIL 4st OIL [UP] mark 1 6 N·m (4 lb·ft) [0.6 kgf·m] [UP] mark 2 12 N·m (9 lb·ft) [1.2 kgf·m] 4st OIL 4st OIL Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 9-1 Connecting Rod Bolt...
Page 115 Power Unit Recoil Starter P/L Fig. 11 1-16 1-13 1-15 1-14 1-12 1-10 1-11 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 1342 1342 1342 1342 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Recoil Starter Starter Lock Cable 1-1 Starter Case Starter Seal 1-2 Starter Spring 1-3 Reel...
Page 116 Top Cowl P/L Fig. 21 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Top Cowl Ass'y UNIQUE 1-5 Decal Set UNIQUE 1-1 Top Cowl Seal L=1520 Decal Set UNIQUE 1-2 Tilt Handle Decal Set 1-3 Washer, 6-16-1.5 1-6 Caution Decal "A" 1-4 Nut 1-7 Oil Pressure Decal 4st 9.9/15/20 2008...
Page 117 Power Unit 3. Inspection Items 1) Inspection of Compression Pressure Run engine 5 minutes to warm up, and then stop. Shift gear into neutral (N). Remove lock plate (of stop switch lanyard) from stop switch. CAUTION Remove lock plate (of stop switch lanyard) from stop switch before measuring compression pressure.
Page 118 2) Inspection of Oil Pressure Spread rag below oil pressure switch. Remove oil pressure switch and connect oil pressure gauge 1 to switch hole. Use commercially available oil pressure gauge (1/8" npt test port). Use the instrument applicable to 1 MPa (142 [10 kgf/cm psi) Start engine and run 5 minutes to warm up at idling...
Page 119 Power Unit 3) Inspection of Valve Clearance Perform adjustment of valve clearances when engine is cold. Remove upper starter lock cable, and then recoil starter and belt cover. Remove fuel pump 1. Disconnect plug cap connection, and then, remove spark plug and cylinder head cover 2.
Page 120 Tighten rocker arm lock nut 5 to specified torque, and check valve clearance again. Readjust if necessary. Rocker arm lock nut 5 : 7 N · m (5 lb · ft) [0.7 kgf · m] Valve Clearance (when engine is cold) (IN) Intake valve : 0.13 - 0.17 mm (0.0051 - 0.0067 in) (EX) Exhaust valve : 0.18 - 0.22 mm (0.0071 - 0.0087 in) Rotate flywheel 3 clockwise to bring "2"...
Page 121 Power Unit 4) Removing Power Unit Disconnect upper starter lock cable. Disconnect battery cords 1 (2). (Electric start model) Disconnect warning lamp, starter switch and stop switch. (Tiller Handle Model) Disconnect remote controller harness coupler 2. (Remote Control Model) Remove spring pin 3 and disconnect shift link rod. 5-18 4st 9.9/15/20 2008...
Page 122 Remove oil level gauge 4. Disconnect lower breather hose 5. Disconnect cooling water (pilot water) hose 6 and fuel hose 7. Remove bolt 8 (4), and then, remove drive shaft housing cover 9. Remove power unit by removing bolts 0 (6) and then hoisting it.
Page 123 Power Unit 5) Removing Plunger and Oil Strainer Put removed power head ass’y 1 upside down on the work bench. Remove plunger 2 from power head ass'y 1. Remove oil strainer 3 from power head ass'y 1. Before oil strainer hose, note arrangement of the hose.
Page 124 Remove flywheel and key. Flywheel puller kit : P/N. 369-72211-0 Screw puller onto crankshaft end until flywheel is disengaged from tapered section of crankshaft. CAUTION To prevent damages to engine and special tools, tighten flywheel puller set bolts evenly and keep flywheel puller parallel to flywheel while working.
Page 125 Power Unit 8) Removing Timing Belt and Pulley Turn timing pulley 1 clockwise to bring "●" mark a of belt guide to "●" mark b of cylinder block, and check that "●1" mark c of cam shaft pulley 2 and "▲" mark d of cylinder head are aligned with each other.
Page 126 Remove cam shaft pulley 2 bolt 6, and then, remove cam shaft pulley 2. When loosening cam shaft pulley bolt, be careful not to turn cam shaft pulley. Remove nut 7, lock washer 8, belt guide 9, timing pulley 0 and key q. 9) Inspection of Timing Belt Check timing belt for crack, damage and wear on both faces.
Page 127 Power Unit 10) Installation of Pulley and Timing Belt Install cam shaft pulley, bring "●1" mark a of cam shaft pulley 1 to "▲" mark b of cylinder head, and then, tighten bolt 2 to specified torque. No.1 piston is to be at top dead center of compression stroke.
Page 128 Attach timing belt 9 to timing pulley with its part number side facing upward, and then to cam shaft pulley. CAUTION · Be careful not give damage to timing belt when installing. · Do not twist timing belt, bring inside out, or bend sharp, or it may be damaged.
Page 129 Power Unit Turn timing pulley r clockwise twice, and check that locating marks ab and cd of pulleys r and t are aligned with each other respectively. 5-26 4st 9.9/15/20 2008...
Page 130 11) Removing Cylinder Head · No.1 piston is to be at top dead center of compression stroke. · Removal or installation of parts can be made easier when some of them are assembled together. Remove power unit. (Refer to the section for removing power unit.) Remove magneto related parts from power unit.
Page 131 Power Unit Remove cam pulley and cylinder head cover. Remove hose. Remove cylinder head bolts in the reverse sequence of order shown, and remove cylinder head. CAUTION Do not scratch or give damage to mating surfaces of cylinder head and cylinder block. Loosen rocker arm lock nut, and loosen adjusting screw as much as possible.
Page 132 Compress valve spring 5 using a commercially available valve spring compressor 6, remove cotter 7, and then, remove spring 5 and valve 8. Valves, springs and other related parts should be arranged in the order they are removed. Remove stem seal 9. 12) Inspection of Valve Spring Measure valve spring free length a.
Page 133 Power Unit 13) Inspection of Valve Check valve for dent and wear on the face. Replace if necessary. Measure valve stem outer diameter b. Replace if it is less than specified value. Valve Stem Outer Diameter b : Standard Value Intake Side : 5.48 mm (0.2157 in) Exhaust Side : 5.46 mm (0.2150 in)
Page 134 15) Inspection of Valve Seat Remove carbon built up on the valve. Apply thin coat of red lead on the valve seat evenly. Use valve lapper (commercially available item) as shown to push valve 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 135 Power Unit 16) Correction of Valve Seat Use valve seat cutter (commercially available item) to correct valve seat. Be careful not to over-cut valve seat. Turn valve seat cutter while pushing down evenly. 30˚ 45˚ 60˚ Turn 45° degree cutter clockwise to cut valve seat surface to make it smooth.
Page 136 Use 45° degree cutter to adjust contact width of valve seat c to specified value. 45˚ bContact width before correction cSpecified width Valve seat contact area is located on the center, which should be adjusted to specified value by cutting upper and 30˚...
Page 137 Power Unit Apply thin coat of abrasive compound on the overall valve seat contact area, and turn valve lapper (commercially available item) while lapping valve. CAUTION Perform the work by taking care not to allow abrasive compound to adhere to valve stem and valve guide.
Page 138 18) Inspection of Cam Shaft Measure cam height. Replace if it is less than specified value. Cam Height a at Both Intake and Exhaust Side : Standard Value 24.28 mm (0.9559 in) Functional Limit : Cam Height a at Both Intake and Exhaust Sides 24.00 mm (0.9449 in) Measure cam shaft runout.
Page 139 Power Unit 19) Inspection of Cylinder Head Remove carbon build-up of combustion chamber, and check for deterioration. Use straight edge 1 and thickness gauge 2 to check distortion of cylinder head in the directions shown. Replace if the distortion is over specified value. Cylinder Head Distortion Limit : 0.10 mm (0.004 in) 5-36...
Page 140 20) Inspection of Oil Pump Use micrometer, cylinder gauge, depth gauge and thickness gauge to measure dimensions shown below. Replace oil pump if over specified value. Functional Limit : Clearance between Outer Rotor and Body a : 0.36 mm (0.0142 in) Clearance between outer and inner rotors b : 0.16 mm (0.0063 in) Side clearance between rotor and body c :...
Page 141 Power Unit 21) Installation of Valves Apply oil to valve guide and attach new valve stem seal 1. 4st OIL Intake Side : Black Exhaust Side : Green Do not reuse. Install valve 2, valve spring seat 3, valve spring 4 and retainer 5 in the order shown, and then, attach commercially available valve spring compressor 6.
Page 142 22) Installation of Cam Shaft Apply engine oil to periphery of new oil seal 1 and install it. 4st OIL Driver Rod : P/N. 3AC-99702-0 Oil Seal Attachment : P/N. 3AC-99820-0 Apply grease to lip of oil seal before installing it. Install cam shaft 2 from direction a shown.
Page 143 Power Unit 24) Installation of Oil Pump Feed engine oil of approximately 1mL to oil 4st OIL passages c before installing oil pump. Align cuts of oil pump drive shaft a and cam shaft pin b with each other to install oil pump 1. 4st OIL Apply engine oil to oil pump O-ring and cam shaft lower side journal, and install oil pump.
Page 144 25) Installation of Cylinder Head No.1 piston is to be at top dead center of compression stroke. After installing cam shaft pulley, bring "●1" mark of pulley 1 to "▲" mark b of cylinder head. Check that "●" mark c of belt guide and "●" mark d of cylinder block are aligned with each other.
Page 145 Power Unit Install cylinder head cover, apply "Three Bond" 1342 to bolts, and tighten them to specified torque. Cylinder Head Cover Bolts : First tightening torque: 6 N · m (4 lb · ft) [0.6 kg · 1342 1342 1342 e Install downward.
Page 146 Remove piston pin clips 6 and piston pin, and then, piston. Write cylinder number a on the mating piston. Do not reuse piston pin clips. Be sure to replace with new ones. Do not reuse. 27) Inspection of Piston Outer Diameter Measure piston outer diameter between points specified.
Page 147 Power Unit 29) Inspection of Piston Clearance Obtain piston clearance through calculation described below. If piston clearance is over specified limit, replace cylinder block, or piston and piston rings as a set, or both cylinder block, piston and piston rings. Piston clearance = Cylinder inner diameter (maximum) - Piston outer diameter a 0.020 - 0.055 mm (0.00079 - 0.00217 in)
Page 148 32) Inspection of Piston Pins Measure piston pin outer diameter. Replace piston pin if outer diameter 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. Piston Pin Boss Inner Diameter: Standard value 16.002 mm (0.63000 in) Obtain clearance between piston pin and pin boss.
Page 149 Power Unit 35) Inspection of Crank Shaft Measure crankshaft journal outer diameter a and crank pin outer diameter b. Replace crankshaft if either outer diameter is less than specified value. Crankshaft Journal Outer Diameter a : Standard Value 35.99 mm (1.4169 in) Crank Pin Outer Diameter b : Standard Value 29.98mm (1.1803 in) Functional Limit :...
Page 150 36) Inspection of Crank Pin Oil Clearance Clean connecting rod. Place cylinder block upside down on the work bench. Install piston 2 to connecting rod 1, and install the assembly to cylinder block. Piston rings are not to be attached to piston. Install crankshaft on the cylinder block.
Page 151 Power Unit 37) Crankshaft Main Journal Oil Inspection of clearance Clean bearings, crankshaft main journal, and bearing installation areas of crank case and cylinder block. Place cylinder block on the work bench with cylinder head side facing downward. Install bearing 1 and crankshaft 2 to cylinder block 3. ·...
Page 152 Loosen bolts in reverse order in several steps. Remove crank case and measure width of crushed plasti-gauge on each main journal. Replace bearing if the width is over specified value. Crankshaft Main Journal Oil Clearance : 0.012 - 0.044 mm (0.00047 - 0.00173 in) Functional Limit : 0.060 mm (0.00236 in) If the clearance is less than specified value,...
Page 153 Power Unit 40) Assembling Piston and Connecting Rod Install connecting rod 2, piston pin 3, and piston pin clip 4 to piston 1. · Point "3RO-UP" mark a of connecting rod and 4st OIL "UP" mark b of piston at the same direction. ·...
Page 154 Put pistons into cylinder with piston crown 1 "UP" mark directing flywheel side f, set pistons on the piston slider 6, install the piston into the cylinder. Before installing, apply engine oil to piston peripheral surfaces, piston rings and piston sliders. Piston Slider 6 : P/N.
Page 155 Power Unit Install bearing half to crank case. · Be sure that individual bearings are installed to their original locations. · Install bearings with their projection fit into crank case groove. Apply 4 stroke engine oil to bearings. Apply sealing agent to mating surface of crank case (one side).
Page 156 Install exhaust cover r, and then install thermostat t, new gasket and thermostat cover y. Install thermostat with the notch (shown by arrow) facing upward. Install oil filter and tighten it to specified torque by using oil filter wrench. Apply thin coat of engine oil to O-ring before installing oil filter.
Page 157 Power Unit 41) Installation of Timing Belt Attach timing belt to crankshaft pulley and cam shaft pulley. For the procedure, refer to : Chapters 1 and 3 12) Replacement of Timing Belt 13) Attaching timing belt Attach plunger cover 1 and plunger 2 before performing the next step.
Page 158 Install stator coil 5. Bundle wires from stator coil and pulser coil with clamp 6 and install. Install anode 7 and anode cap 8. Install CD unit bracket 9 and secure CD unit 0 using bolts. 4st 9.9/15/20 2008 5-55...
Page 159 Power Unit Attach ground wire q from CD unit. Install ignition coil w and connect wire to wireharness from CD unit. Connect ignition coil wire and oil pressure sensor wire to CD unit cord as shown, and secure the wires with lead wire band e.
Page 160 Attach ground wire t from CD unit. 42) Installation of Starter Motor Attach starter cord to starter motor as shown. 30° Attach terminal cap 1 and protector 2 to starter cord. Fix starter motor with bolts temporarily, and position starter motor damper 3 on the locating groove (marked with arrow) on the crank case.
Page 161 Power Unit Install starter solenoid. Secure ground wire 5 from solenoid to solenoid bracket by using existing solenoid bracket bolt. Connect cord wire 6 from starter motor to solenoid as shown. Attach fuse cord 7. Install cable terminal holder 8. To attach cable terminal to holder, install clamps 9 (RC model only) and 0 to cylinder block.
Page 162 Put cable terminal in the holder in accordance with description on the sticker q located on the back of holder cover. 43) Installing Intake Manifold Install gasket 2, insulator 3, carburetor 4, O ring 5 and intake silencer 6 to intake manifold 1 in this order and secure with bolts.
Page 163 Power Unit Install intake manifold ass’y to cylinder block. Use knock pin a to locate intake manifold ass’y on the cylinder block. Secure intake manifold ass’y by tightening bolts in the specified order to specified torque. Intake manifold ass’y securing bolts : 9 N ·...
Page 164 Prepare for installation of rectifier. Collect wires from rectifier as shown. Install rectifier 0 to intake manifold. Connect wire couplers, and bind them using lead wire band q located on the rectifier. Secure wires w and carburetor breather hose e using clamp r.
Page 165 Power Unit 44) Installing Flywheel Install flywheel with flywheel engaged with crankshaft key. Tighten flywheel nut to specified torque. Flywheel puller ass’y : P/N. 369-72211-0 Flywheel Nut : 80 N · m (58 lb · ft) [8.0 kgf · m] Install flywheel cover.
Page 166 45) Installation of Power Unit Hoist power unit with rope as shown. Clean surface of power unit that contacts with the engine base, and install dowel pin 1 and new gasket 2. Install power unit 3, and tighten bolts 4 in two or three steps to specified torque.
Page 167 Power Unit 47) Disassembly of Recoil Starter Disconnect upper starter lock cable. Remove bolts, and then, recoil starter and belt cover. Put rope in the groove of reel 1 and gently turn reel 1 clockwise to release tension of starter spring. 1 Reel Remove start shaft bolt 4, and then, friction plate 3 and spring 2.
Page 168 Remove starter spring q. It is not necessary to remove starter spring from starter case if it is not necessary to replace it. Starter spring can be inspected without removing from starter case. q Starter Spring 48) Inspection of Recoil Starter Check ratchet, starter lock and all springs.
Page 169 Power Unit 49) Installation of Recoil Starter Reverse disassembly procedure to assemble by taking care of the following matters. ●When setting starter spring into starter case, face starter spring outer edge hook to the right and set it into peripheral cut of starter case.
Page 170 Lower Unit 17) Disassembly of Clutch Cam and Cam Rod ⋯ 6-15 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-2 1. Special Tools 18) Inspection of Cam Rod and Clutch Cam ⋯ 6-16 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-4 2. Parts Layout 19) Assembly of Cam Rod and Clutch Cam ⋯ 6-16 Gear Case⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯...
Page 171 Lower Unit 1.Special Tools Spring Pin Tool A Spring Pin Tool B Bevel Gear B Nut Wrench Bevel Gear B Nut Socket P/N. 345-72227-0 P/N. 345-72228-0 P/N. 346-72231-0 P/N. 346-72232-0 Removing spring pin Installing spring pin Removing/installing Pinion (B) Gear Nut Bevel Gear Bearing Installation Tool Thickness Gauge Bevel Gear Bearing Puller Ass'y...
Page 172 ø25.5 x ø12.5 ø51.5 x ø39.5 930191-1000 345-72723-0 332-60002-0 3A3-72713-0 3BJ-72245-0 3B7-72734-0 Backlash Measuring Tool Kit Oil Seal Attachment Oil Seal Attachment 3 P/N. 3C8-72234-1 P/N. 3UI-99820-0 P/N. 3BJ-99820-0 Use in combination with driver rod. Installing pump case (lower) Measuring gap between forward and pinion Use oil seal attachment to press fit ball bearing.
Page 173: Gear Case
Lower Unit P/L Fig. 14 2.Parts Layout Gear Case 19 N·m (14 lb·ft) [1.9 kgf·m] 1342 1342 14 N·m (10 lb·ft) [1.4 kgf·m] 1342 1342 1342 1342 GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR 24 N·m (17 lb·ft) [2.4 kgf·m] 1342 1342 1342...
Page 174 P/L Fig. 13 Drive Shaft Housing 1342 13 N·m (9 lb·ft) [1.3 kgf·m] 24 N·m (17 lb·ft) [2.4 kgf·m] 24 N·m (17 lb·ft) [2.4 kgf·m] 1342 19 N·m (14 lb·ft) [1.9 kgf·m] 4 N·m (3 lb·ft) [0.4 kgf·m] 1342 1342 1342 1342 1342...
Page 175 Lower Unit P/L Fig. 15 Drive System & Water Pump GEAR GEAR GEAR 1342 1342 1342 1342 1342 1342 1342 35 N·m (25 lb·ft) [3.5 kgf·m] GEAR GEAR GEAR 1373B 1373B 1373B 1373B 12 N·m (9 lb·ft) [1.2 kgf·m] GEAR GEAR GEAR 1373B...
Page 176 Ref. Description Q'ty Remarks Drive Shaft "S" for Transom "S" Drive Shaft "L" for Transom "L" Drive Shaft "UL" for Transom "UL" Ball Bearing, 7302A Do not reuse. Bevel Gear "A" Bevel Gear "B" Bevel Gear "B" Nut Bevel Gear "C" Washer, 17-22-1.5 Shim, 35-41.9-0.1 Shim, 35-41.9-0.15...
Page 177 Lower Unit 3. Inspection Items 1) Draining Gear Oil Drain gear oil. Refer to "Replacement of Gear Oil" in Chapter 3. 2) Removing Propeller Shift gear into neutral (N). Put a piece of wooden block between anti-cavitation plate and propeller 4 to prevent rotation of propeller 4, and then remove propeller nut 2 and then propeller 4.
Page 178 3) Removing Lower Unit Removal of lower unit does not require removal of power unit from outboard motor body. Remove spring pin and disconnect shift rod. · Disconnect shift rod at lower side of shift rod joint 1. · Use spring pin tool A2 to remove spring pin. ·...
Page 179 Lower Unit 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, water pump guide plate 5 and drive shaft groove a for wear.
Page 180 7) Disassembly of Propeller Shaft Ass'y Push small bladed screw driver into clutch pin snap 1 to remove it while rotating propeller shaft. Then, push clutch pin 2 lightly while applying preload to push rod 4 to remove the pin. Remove clutch 3, push rod 4, ball, spring retainer 5, and spring 6.
Page 181 Lower Unit 10) Disassembly of Propeller Shaft Housing Tighten universal puller plate to make gap between reverse gear (C gear) and propeller shaft housing. Universal Puller Plate : P/N. 3AC-99750-0 Remove reverse gear (C gear) ass'y by putting two bladed screw drivers into the gap to force the gap to open.
Page 182 When removing only oil seal, use bladed screw driver to pry apart. 11) Inspection of Propeller Shaft Housing Use cleaning oil and cleaning brush to clean propeller shaft housing, and check it for crack or damage. Replace if necessary. Check reverse (C) gear teeth and clutch for crack or damage.
Page 183 Lower Unit 12) Assembly of Propeller Shaft Housing Use a press to push new needle bearing into propeller shaft bearing to specified depth. · Install needle bearing with manufacturer's marking a facing reverse (C) gear side. · Screw needle bearing attachment 2 into driver rod 1 gently by using hand without making gap.
Page 184 13) Removing Pump Case (Lower) Remove pump case (lower). 14) Disassembly of Pump Case (Lower) Use bladed screw driver to remove oil seal 1. 1 Oil seal Do not reuse. 15) Assembly of Pump Case (Lower) Apply engine oil to periphery of new oil seal, and install into pump case (lower) with number side facing downward.
Page 185 Lower Unit 18) Inspection of Cam Rod and Clutch Cam Check cam rod 1 and clutch cam 2 for crack and wear. Replace if necessary. 19) Assembly of Cam Rod and Clutch Cam Forward Reassemble. direction Be careful of direction of cam rod. GEAR GEAR GEAR...
Page 186 22) Inspection of Drive Shaft Check drive shaft for bend and wear. Replace if necessary. Measure drive shaft runout. Runout Limit : 0.5 mm（0.020 in） a Support point 23) Removing Forward (A) Gear Use commercially available bearing puller 1 to remove forward (A) gear from gear case.
Page 187 Lower Unit 24) Inspection of Pinion (B) Gear and Forward (A) Gear Check pinion (B) gear and forward (A) gear teeth and clutch for crack and wear. Replace if necessary. Measure forward (A) gear bushing inner diameter a. If worn severely, replace gear with new one.
Page 188 27) Disassembly of Gear Case Remove needle bearing 1 by using the following tools. Needle bearing press Ass'y : P/N. 3AC-72764-0 Bearing outer press guide 2 : P/N. 3BJ-72765-0 Needle Bearing Press Rod 3 : P/N. 3BJ-72767-0 Needle Bearing Press 4 : P/N.
Page 189 Lower Unit 28) Inspection of Gear Case Check skeg area a and torpedo-like area b for crack and damage. Replace if necessary. 29) Assembly of Lower Unit Perform shim adjustment when ball bearing, gear, drive shaft, propeller shaft or gear case is replaced.
Page 190 Fix gear case on the vice with its propeller shaft opening facing upward. Clean outer race installation face in the gear case and apply gear oil. Apply gear oil to external face of outer race, and put the outer race in the center of the housing with the marked face GEAR GEAR GEAR...
Page 191 Lower Unit Install needle bearing 1 by using the following tools. Needle Bearing Press Ass'y : P/N. 3AC-72764-0 Bearing Outer Press Guide 2 : P/N. 3BJ-72765-0 Needle Bearing Press Rod 3 : P/N. 3BJ-72767-0 Needle Bearing Press 4 : P/N. 3BJ-72770-0 O ring 5：...
Page 192 31) Installation of Pinion (B) Gear Clean gear case interior. After installing forward (A) gear into bear case, install drive shaft ass'y 1, pinion (B) gear 2 and pinion (B) gear nut 3, and tighten the nut to specified torque. Pinion (B) Gear Nut : 35 N ·...
Page 193 Lower Unit 32) Determination of Forward (A) Gear Backlash Backlash Measuring Tool Kit : P/N. 3C8-72234-1 Backlash Measuring Tool Shaft 1 : P/N. 345-72723-0 O-Ring 2 : P/N. 332-60002-0 Measuring Tool Set Piece 3 : P/N. 3BJ-72245-0 Backlash Measuring Tool Plate 4 : P/N.
Page 194 Perform shim adjustment as necessary based on the gauge Gauge Reading Shim Adjustment value obtained. The table shows relation between dial gauge readings and shim adjustments. 0.60 - 1.00 1.Values in this table indicate dial gauge readings 1.01 - 1.15 that are obtained when using special tool.
Page 195 Lower Unit 33) Reassembly of Pinion (B) Gear Nut Assemble drive shaft ass’y 1, pinion (B) gear 2 and pinion (B) gear nut, and tighten the nut to specified torque. Bevel Gear B Nut Socket 3 : P/N. 346-72232-0 Bevel Gear B Nut wrench 4 : P/N.
Page 196 35) Reassembly of Pump Case (Lower) Remove pump case (lower) and apply OBM grease to oil seal. Attach new O-ring 1 and pump case (lower) 2. 36) Assembly of Water Pump Assemble water pump guide plate 1 and impeller 2. Use plastic hammer to install key 3 to drive shaft.
Page 197 Lower Unit Install pump case (upper) ass'y 7 on the gear case, and tighten bolts 8 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 1342 1342 1342...
Page 198 37) Installation of Lower Unit Set cam rod to reverse (R) position. Connect water pipe securely. Move flywheel a little or shift gear into reverse (R), install propeller, turn propeller shaft counterclockwise to engage spline. Attach lower unit ass'y to drive shaft housing, and tighten lower unit installation bolts (nuts) 1 to specified torque.
Page 199 Lower Unit Apply grease to propeller shaft 3. Attach thrust holder 4, propeller 5, washer 6 and propeller nut to propeller shaft 7. Put a piece of wooden block between anti-cavitation plate and propeller to prevent rotation of propeller, and tighten propeller nut to specified Turn propeller nut to tightening direction to align one of grooves to propeller shaft hole, and attach split pin 8.
Page 200 Bracket 3) Adjustment of Co-pilot Plate ⋯⋯⋯⋯⋯ 7-11 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-2 1. Parts Layout 4) Removing Drive Shaft Housing ⋯⋯⋯ 7-11 Drive Shaft Housing⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-2 5) Disassembly of Drive Shaft Housing ⋯ 7-13 Swivel Bracket ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-3 6) Assembly of Drive Shaft Housing ⋯⋯ 7-15 Clamp Bracket &...
Page 201 Bracket P/L Fig. 13 1.Parts Layout Drive Shaft Housing 1342 13 N·m (9 lb·ft) [1.3 kgf·m] 24 N·m (17 lb·ft) [2.4 kgf·m] 24 N·m (17 lb·ft) [2.4 kgf·m] 1342 19 N·m (14 lb·ft) [1.9 kgf·m] 4 N·m (3 lb·ft) [0.4 kgf·m] 1342 1342 1342...
Page 202: Swivel Bracket
P/L Fig. 18 Swivel Bracket 26N·m (18 lb·ft) [2.7 kgf·m] Drive Shaft Housing 910103-5610 Bolt Swivel Bracket 13 N·m (9 lb·ft) [1.3 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] Clamp Bracket "R" Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Nylon Nut Swivel Bracket Washer...
Page 203 Bracket P/L Fig. 19 Clamp Bracket & Reverse Lock 11 N·m (8 lb·ft) [1.1 kgf·m] 1342 1342 1342 24 N·m (17 lb·ft) [2.4 kgf·m] 11-1 27 N·m (20 lb·ft) [2.7 kgf·m] 1342 1342 1342 1342 1342 1342 Ref. Ref. Description Remarks Description Remarks...
Page 204: Tiller Handle
P/L Fig. 12 Tiller Handle 6 N·m (4 lb·ft) [0.6 kgf·m] 4 N·m (30 lb·ft) [4.1 kgf·m] 1373B 1373B 1373B 1373B 1373B 1373B 1373B 1373B Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 14 Nut Tiller Handle for MF & EF 15 Washer Plastic Rivet, 6.5 Stud Bolt...
Page 205 Bracket P/L Fig. 20 Bottom Cowl 6 N·m (4 lb·ft) [0.6 kgf·m] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 14 Fuel Connector (Engine, Male) 1 Bottom Cowl 15 Bolt Bolt 16 Fuel Connector Protector Rubber Mount Washer Rubber Mount, 8.5-14-2.5 17 Rubber Hose 18 Fuel Hose Protector ø10.7-280...
Page 206 P/L Fig. 16 Shift & Stop Switch 6 N·m (4 lb·ft) [0.6 kgf·m] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Neutral Switch Bracket 14 Bolt Shift Lever Shaft Holder 15 Shift Lever Bolt 16 Collar, 6.5-10.5-22.6 for MF & EF Shift Lever Shaft 17 Bolt Shift Lever Stopper...
Page 207 Bracket P/L Fig. 17 Shift (For EP) Cylinder 1373B 1373B 1373B 1373B 27 N·m (20 lb·ft) [2.7 kgf·m] 36-3 36-4 36-5 36-1 27 N·m (20 lb·ft) [2.7 kgf·m] 36-4 36-4 36-2 36-3 1373B 1373B 1373B 1373B 4st 9.9/15/20 2008...
Page 208 Ref. Description Q'ty Remarks Shift Lever Shaft Shift Lever Stopper Shift Lever Stopper Plate Bolt Shift Arm (Remote Control) for EP Remote Control Cable Stay Bolt Cable Clip for EP Bolt Cable Grommet Remote Control Stay Cover Bolt, 5-35 (with Washer) Shift Lever Rod for EP Spacer, 5-9.5-5...
Page 209 Bracket 2. Inspection Items 1) Inspection of Throttle Cable Check operation of throttle cable. Check throttle cable inner wire and outer wire for bend and damage. Replace if necessary. 2) Installation of Tiller Handle 1 as shown. Attach cables to throttle shaft Install throttle shaft 1 with cable to Tiller handle.
Page 210 Install cable b of which inner wire is stretched when acceleration grip is set to full close position. Then, install another cable a (of which inner wire is stretched when acceleration grip is set to full open position. Adjust position of lock nuts 6 of throttle cable so that throttle grip can reach full open and full close positions.
Page 211 Bracket Loosen four bolts 1 and remove bottom cowl from drive shaft housing. Remove grounding wires 2. Remove bolts and nuts 3 lower mount bracket. Check that dumper 4 and rubber mount 5 are normal. Replace if abnormal. 7-12 4st 9.9/15/20 2008...
Page 212 Remove nuts of upper rubber mount 6. Remove drive shaft housing 7 from clamp bracket ass’y. Be careful not to drop drive shaft housing when removing the housing from clamp bracket. 5) Disassembly of Drive Shaft Housing Remove upper rubber mount installation bolts 1 and then remove rubber mount from drive shaft housing.
Page 213 Bracket Remove idle exhaust cover 3, and check that idle exhaust port plate 4 has no abnormality such as cracks or flaws. Remove water pipe 5 from drive shaft housing. Check water pipe auxiliary mount 6 for abnormality such as crack. 7-14 4st 9.9/15/20 2008...
Page 214 6) Assembly of Drive Shaft Housing Install water pipe 1 into drive shaft housing. Insert pipe into drive shaft housing taking care of orientation of water pipe auxiliary mount 2. Attach exhaust cover securing bolts and tighten them in the order of their numbers shown to specified torque.
Page 215 Bracket 7) Installation of Drive Shaft Housing Ass'y Insert drive shaft housing ass’y into stud bolt 3 of upper rubber mount 2 of swivel bracket 1. Install rubber mount and lower dumper and mount bracket to drive shaft housing. Tighten bolts and nuts to specified torque.
Page 216 1 When assembling lower mount bracket, watch arrow mark of lower mount bracket rubber mount 6. 2 When assembling, watch spigot joint 7 for installation on the mount bracket. Attach earth wire 8. Be careful not to paint earth wire attaching surface, or the anti-corrosion effect will be disabled.
Page 217 Bracket Loose co-pilot handle nut and remove handle 1. Pull out steering shaft 2 from swivel bracket ass'y to remove. 9) Installing Steering Shaft Attach thrust plate 1 and bushing 2 to steering shaft. Stand swivel bracket ass'y vertically, and insert steering shaft into swivel bracket ass'y.
Page 218 Put bushing and O ring into swivel bracket surely. Put grease into bushing 7 through grease nipple 6 until it overflows. 4st 9.9/15/20 2008 7-19...
Page 219 Bracket 10) Disassembling Clamp Bracket (Manual Tilt Model) Remove thrust rod 1 from clamp bracket. Remove nut cap 3 of swivel bracket shaft 2, and then, loosen nut 4. Loose nut 6 of distance piece 5, and then, remove nut. Pull out swivel bracket shaft, and then, remove clamp bracket 7 from swivel bracket 8.
Page 220 11) Assembly of Clamp Bracket Insert distance piece 2 into clamp bracket 1. Install clamp bracket 1 to swivel bracket 3, insert swivel bracket shaft 4, and then, tighten nylon nut 5 and nut to their specified torque respectively. Nylon Nut 5 : 24 N ·...
Page 221 Bracket 7-22 4st 9.9/15/20 2008...
Page 222 Electrical System 6) Inspection of Oil Pressure Switch ⋯⋯ 8-15 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-2 1. Special Tools ⋯ 8-3 7) Inspection of Neutral Switch 2. Electrical Component Layout (Tiller Handle Model) ⋯⋯⋯⋯⋯⋯⋯⋯ 8-16 Port Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-3 Bow Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-4 8) Inspection of Start Switch (Tiller Handle Model) ⋯⋯⋯⋯⋯⋯⋯⋯...
Page 223 Electrical System 1.Special Tools Vacuum/Pressure Gauge Spark Tester P/N. 3AC-99020-0 P/N. 3F3-72540-0 Inspecting pressure Inspecting sparks 4st 9.9/15/20 2008...
Page 224: Electrical Component Layout Port Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
2. Electrical Component Layout Port Side View < EP Model > 1 Starter Motor 2 Ignition Coil 3 C.D. Unit 4 Oil Pressure Switch 5 Fuse 6 Alternator 4st 9.9/15/20 2008...
Page 225: Bow Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
Electrical System Bow Side View < EP Model > 1 Starter Motor 2 Cable Terminal Holder 3 Alternator 4 Choke Solenoid 4st 9.9/15/20 2008...
Page 226: Starboard Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
Starboard Side View < EP Model > 1 Rectifier 2 Choke Solenoid 3 Alternator 4 Fuse Holder 4st 9.9/15/20 2008...
Page 227: Top View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
Electrical System Top View < EP Model > 1 Rectifier 2 Choke Solenoid 3 Ignition Coil 4 Starter Motor 5 Oil Pressure Switch 6 Alternator 7 Fuse 8 Pulser Coil 4st 9.9/15/20 2008...
Page 228: Back View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
Back View 1 Rectifier 2 Ignition Coil 3 C.D. Unit 4 Fuse Holder 5 Alternator 4st 9.9/15/20 2008...
Page 229: Magneto
Electrical System 3.Parts Layout P/L Fig. 8 Magneto 80 N·m (58 lb·ft) [8.0 kgf·m] 26-1 6 N·m (4 lb·ft) [0.6 kgf·m] 26-1 1342 1342 8 N·m (6 lb·ft) [0.8 kgf·m] 1342 1342 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 17-1 1342 1342...
Page 230: Electric Parts
P/L Fig. 9 Electric Parts 25-1 25-1 13 N·m (9 lb·ft) [1.3 kgf·m] 1342 24-1 24-1 13 N·m (9 lb·ft) [1.3 kgf·m] 34-1 34-3 34-2 30-1 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Starter Motor for EP & EF 24-1 Fuse (20A) Bolt 25 Fuse Cable...
Page 231: Starter Motor
Electrical System 1741 P/L Fig. 10 Starter Motor 1-12 1-13 1-11 1-10 Ref. Description Remarks Q'ty Starter Motor 1-1 Pinion Ass'y 1-2 Washer 1-3 Brush Holder 1-4 Screw 1-5 Bushing #1 1-6 Bushing #2 1-7 O-Ring 1-8 Washer 1-9 Spring Washer 1-10 Nut 1-11 Bolt 1-12 Washer...
Page 232: Shift & Stop Switch
P/L Fig. 16 Shift & Stop Switch 6 N·m (4 lb·ft) [0.6 kgf·m] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Neutral Switch Bracket 15 Shift Lever Shift Lever Shaft Holder 16 Collar, 6.5-10.5-22.6 for MF & EF Bolt 17 Bolt Shift Lever Shaft 18 Shift Lever Rod for MF &...
Page 233: Ignition System And Ignition ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
Electrical System 4. Ignition System and Ignition Control System 1) Inspection of Ignition Sparks Disconnect plug caps from spark plugs. Connect plug cap 1 to spark tester 2. Connect spark tester clip 3 to spark plug tip electrode. Spark Tester 2 : P/N.
Page 234: Inspection Of Plug Cap ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
2) Inspection of Plug Cap Remove the part and test it as a separate unit. Disconnect plug caps from spark plugs. Remove plug cap from high tension cable. (Cap screws on to wire) Remove by twisting counterclockwise. Measure plug cap resistance. Replace if out of specification. Plug Cap Resistance : 3.0 - 7.0 kΩ...
Page 235: Inspection Of Pulser Coil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
Electrical System 4) Inspection of Pulser Coil Remove cable terminal holder cover. Disconnect cable coupler from pulser coil, and measure resistance. This test can be made without removing parts. Pulser Coil Resistance (Reference value) : Between Red/White (R/W) - Black (B) : 148 - 222Ω Check the connection by referring to coupler connection chart located on the back of cable terminal holder cover.
Page 236: Inspection Of Exciter Coil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
5) Inspection of Exciter Coil Remove cable terminal holder cover. Disconnect cable coupler from exciter coil, and measure resistance. This test can be made without removing parts. Exciter Coil Resistance (Reference value) : Between Black/Red (B/R) - Blue (L) : 12.5 - 18.8 kΩ Check the connection by referring to coupler connection chart located on the back of cable terminal holder cover.
Page 237: Inspection Of Neutral Switch (Tiller Handle Model) ⋯
Electrical System Apply pressure slowly with vacuum/pressure gauge. Check that oil pressure switch is not conductive with specified pressure applied. Replace if conductive. Specified Pressure : 0.020 - 0.029 MP(2.8 - 4.0 psi) [0.2 - 0.3 kgf/cm Reinstall the part. Uses tapered threads —...
Page 238: Inspection Of Stop Switch ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
9) 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 a Attach lock b Press switch c 5.
Page 239: Disassembly Of Starter Motor ⋯⋯⋯⋯⋯⋯⋯⋯
Electrical System 3) Disassembly of Starter Motor Put locating mark between starter motor body and cap. (This mark facilitates reassembly.) Slide pinion stopper 1 downward as shown and remove clip 2. Use small bladed screw driver to remove clutch. Be careful not to cut hand because clip is secured firmly.
Page 240: Inspection Of Brushes ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
Measure commutator 1 outer diameter. Replace starter motor ass'y if outer diameter is less than specified value. Commutator Outer Diameter : Standard Value 30.0 mm (1.181 in) Wear Limit : 29.0 mm (1.142 in) Measure undercut a of commutator 1. Replace starter motor ass'y if less than specified value.
Page 241: Inspection Of Starter Motor Operation ⋯⋯⋯⋯⋯
Electrical System 7) Inspection of Starter Motor Operation Assemble starter motor, and check, before and after installing it on the power unit, by applying voltage between points "+" and "-" that it operates normally. Energizing starter motor produces sparks, and thus, any inflammable matter must be kept away from the motor.
Page 242: Cd Unit Coupler ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
· Measurement condition Circuit tester to be used : HIOKI3030 Measurement Range : 1kΩ · Permissible Error of Resistance : ±20% Note) 1 It is recommended to use "HIOKI HiTESTER MODEL 3030" for this measurement. Use of other instrument model for the measurement can cause indication of abnormal value for normal condition, resulting in inaccurate measurement.
Page 243 Electrical System 8-22 4st 9.9/15/20 2008...
Page 244 Troubleshooting ⋯⋯⋯⋯⋯⋯ 9-2 1. Troubleshooting Chart Fuel System ……………………………… 9-9 ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 9-3 2. Power Unit Ignition System ………………………… 9-10 1 Engine will not start ………………………… 9-3 Compression Pressure ………………… 9-11 3 Idle engine speed will not stabilize. ⋯⋯ 9-12 Starting System⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 9-3 Ignition System ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯...
Page 245: Troubleshooting Chart ⋯⋯⋯⋯⋯⋯⋯⋯⋯
Troubleshooting 1. Troubleshooting Chart Estimated Cause Refer to page ○ ○ Fuel level is low in the tank. Chapter 1 ○ ○ ○ ○ ○ ○ ○ Fuel system connection is incomplete. Chapter 2 ○ ○ ○ ○ ○ ○ ○...
Page 246: Power Unit ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
Before working on the engine, check that hull, rigging and engine installation are normal, and then battery is fully charged. For mechanical troubleshooting, refer to relevant troubleshooting section in this chapter. For checking and servicing the machine, refer to service procedures described in this manual to perform the works safely.
Page 247: Engine Will Not Start
Troubleshooting （State 1 : Engine will not start.） Check electrical conductivity of neutral switch. Replace neutral switch. Conductive? Check start switch or main switch. Replace start switch or Normal? main switch. Check electrical conductivity of wire harness. Repair or replace wire Conductive? harness.
Page 248: Ignition System
（State 1 : Engine will not start.） Ignition System Check spark plugs. Clean and adjust spark Normal? plugs, or replace. WARNING · When testing, put electrode cap assuredly to prevent direct Use spark tester to check contact with spark tester wiring and leak of electrical current. ignition sparks.
Page 249 Troubleshooting （State 1 : Engine will not start.） Replace ignition coil. Normal? Check alternator (exciter coil) resistance. Normal? Replace alternator. Replace CD unit. 4st 9.9/15/20 2008...
Page 250: Fuel System ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
（State 1 : Engine will not start.） Fuel System Check air vent screw of fuel tank. Is air vent Open air vent screw. screw open? Check if fuel contain water or fuel filter is clogged. Does fuel contain Check fuel hose for bend or water, or is fuel fuel leak.
Page 251: Compression Pressure ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
Troubleshooting （State 1 : Engine will not start.） Compression Pressure Check for intake airleak Check compression at carb or intake manifold pressure gasket Check ignition or fuel system 4st 9.9/15/20 2008...
Page 252: Engine Starts But Stalls Soon.⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
State 2 Engine starts but stalls soon. • Inspection of Fuel System, Ignition System, Compression Pressure. Fuel System Check air vent screw of fuel tank. Is air vent Open air vent screw. screw open? Check if fuel contain water fuel filter is clogged. Does fuel contain Check fuel hose for bend or water, or is fuel...
Page 253: Ignition System
Troubleshooting （State 2 : Engine starts but stalls soon.） Ignition System Check spark plugs. Clean and adjust spark Normal? plugs, or replace. WARNING Use spark tester to check · When testing, put electrode cap assuredly to prevent direct ignition sparks. contact with spark tester wiring and leak of electrical current.
Page 254: Compression Pressure
（State 2 : Engine starts but stalls soon.） Compression Pressure Check for intake airleak Check compression at carb or intake manifold pressure gasket Check ignition or fuel system 4st 9.9/15/20 2008 9-11...
Page 255: Idle Engine Speed Will Not Stabilize.⋯⋯⋯⋯⋯⋯⋯
Troubleshooting State 3 Idle engine speed will not stabilize. • Inspection of Intake Manifold, Air Intake System and Ignition System. Check operations of throttle cable and drum. Adjust throttle cable. Normal? Check ignition timing. Check gaskets if Is the timing out secondary air is sucked of specification? through them.
Page 256: Rapid Opening Of Throttle Fails Acceleration. ⋯⋯⋯⋯
State 4 Rapid opening of throttle fails acceleration. Rapid opening of throttle causes engine to stall. (Stops.) Acceleration is not smooth. • Inspection of Carburetor, Ignition System and Compression Pressure. Check operation of throttle cable. Are throttle valve Adjust throttle cable. synchronized? Disassemble carburetor, and check internal components for...
Page 257: Gear Shifting Cannot Be Made Normally
Troubleshooting State 5 Gear shifting cannot be made normally. Check operations of shift lever. Check shift lever Normal? stopper. Adjust shift cable. Check shift rod joint. Normal? Replace shift rod. Disassemble lower unit and check operation of clutch. Replace defective part Normal? with new one.
Page 258: Warning Indication ... Display For ⋯⋯⋯
3. Warning Indication … Display for Abnormalities During Operation Warning Indication Estimated cause ESG revolution and action Condition Reference control to be taken Tachometer lamp Buzzer Cowl lamp Engine over-rev. Controls to × × − High speed ESG Check propeller. (operates at 6400rpm) 6400±100rpm or less Oil pressure reduced...
Page 259 Troubleshooting 9-16 4st 9.9/15/20 2008...
Page 260: Wiring Diagram
Wiring Diagram MF Model ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 10-2 EF Model⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 10-3 EP Model⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 10-4...
Page 261 配線図 10-2 4st 9.9/15/20 2008...
Page 262 F 9.9C/15C/20C MF �� ...
Page 263 �� F 9.9C/15C/20C EF � �� ...
Page 264 F 9.9C/15C/20C EP �� ...
Page 265 Copyright © 2008 Tohatsu Corporation. 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 Corporation.
Page 266 OB No.003-21062-0 08-12 NB-2600 Printed in Japan...

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