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29) Inspection of Piston Clearance ⋯⋯⋯⋯⋯⋯⋯ 5-44
30) Inspection of Piston Ring Side Clearance ⋯⋯⋯⋯⋯ 5-44
31) Inspection of Piston Rings ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-44
32) Inspection of Piston Pins ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-45
33) Inspection of Connecting Rod Small End Inner Diameter ⋯ 5-45
35) Inspection of Crank Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-46
38) Inner Diameter of Cylinder/Crank Case
Bearing Holder (Inner Diameter Code) ⋯⋯⋯⋯⋯ 5-49
(Color of Inner Diameter Code) ⋯⋯⋯⋯⋯⋯⋯ 5-49
40) Assembling Piston and Connecting Rod ⋯⋯⋯⋯⋯ 5-50
41) Installation of Timing Belt ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-54
42) Installation of Starter Motor ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-57
43) Installing Intake Manifold ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-59
44) Installing Flywheel ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-62
45) Installation of Power Unit ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-63
46) Removing Recoil Starter ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-63
48) Inspection of Recoil Starter ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-65
49) Installation of Recoil Starter ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-66
Gear Case ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-4
Drive Shaft Housing⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-5
Drive System & Water Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-6
1) Draining Gear Oil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-8
2) Removing Propeller ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-8
3) Removing Lower Unit ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-9
4) Disassembly of Water Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-9
5) Inspection of Water Pump⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-10
7) Disassembly of Propeller Shaft Ass'y ⋯⋯⋯⋯⋯ 6-11
8) Inspection of Propeller Shaft ⋯⋯⋯⋯⋯⋯⋯⋯ 6-11
9) Assembly of Propeller Shaft Ass'y ⋯⋯⋯⋯⋯⋯ 6-11
10) Disassembly of Propeller Shaft Housing ⋯⋯⋯⋯⋯ 6-12
12) Assembly of Propeller Shaft Housing ⋯⋯⋯⋯⋯ 6-14
13) Removing Pump Case (Lower) ⋯⋯⋯⋯⋯⋯⋯ 6-15
14) Disassembly of Pump Case (Lower) ⋯⋯⋯⋯⋯ 6-15
15) Assembly of Pump Case (Lower) ⋯⋯⋯⋯⋯⋯ 6-15
16) Removing Clutch Cam and Cam Rod⋯⋯⋯⋯⋯ 6-15
17) Disassembly of Clutch Cam and Cam Rod ⋯⋯⋯⋯⋯ 6-15
18) Inspection of Cam Rod and Clutch Cam ⋯⋯⋯⋯⋯ 6-16
19) Assembly of Cam Rod and Clutch Cam ⋯⋯⋯⋯⋯ 6-16
20) Removing Drive Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-16
21) Disassembly of Drive Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-16
22) Inspection of Drive Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-17
23) Removing Forward (A) Gear ⋯⋯⋯⋯⋯⋯⋯⋯ 6-17
24) Inspection of Pinion (B) Gear and
Forward (A) Gear ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-18
25) Assembly of Forward (A) Gear⋯⋯⋯⋯⋯⋯⋯⋯ 6-18
26) Assembly of Drive Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-18
27) Disassembly of Gear Case ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-19
28) Inspection of Gear Case ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-20
29) Assembly of Lower Unit⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-20
30) Assembly of Gear Case ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-20
31) Installation of Pinion (B) Gear ⋯⋯⋯⋯⋯⋯⋯⋯ 6-23
32)Determination of Forward (A) Gear Backlash ⋯⋯⋯⋯⋯ 6-24
33) Reassembly of Pinion (B) Gear Nut ⋯⋯⋯⋯⋯ 6-26
34) Assembly of Propeller Shaft Housing ⋯⋯⋯⋯⋯ 6-26
35) Reassembly of Pump Case (Lower) ⋯⋯⋯⋯⋯ 6-27
36) Assembly of Water Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-27
37) Installation of Lower Unit ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-29
Drive Shaft Housing ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-2
Swivel Bracket ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-3
Clamp Bracket & Reverse Lock ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-4
Tiller Handle ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-5
vi
⋯⋯⋯⋯⋯⋯⋯ 5-64
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-2
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-4
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6-8
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-2
Bottom Cowl ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-6
Shift & Stop Swith⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-7
Shift (For Ep) ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-8
1) Inspection of Throttle Cable ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-10
2) Installation of Tiller Handle ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-10
3) Adjustment of Co-pilot Plate ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-11
4) Removing Drive Shaft Housing ⋯⋯⋯⋯⋯⋯⋯ 7-11
5) Disassembly of Drive Shaft Housing ⋯⋯⋯⋯⋯ 7-13
6) Assembly of Drive Shaft Housing ⋯⋯⋯⋯⋯⋯ 7-15
7) Installation of Drive Shaft Housing Ass'y ⋯⋯⋯⋯⋯ 7-15
8) Removing Steering Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-17
9) Installing Steering Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-18
(Mechanical Tile Model) ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-20
11) Assembly of Clamp Bracket ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-21
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-2
Port Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-3
Bow Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-4
Starboard Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-5
Top View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-6
Back View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-7
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-8
Magneto............................................................ 8-8
Electric Parts...................................................... 8-9
Starter Motor ................................................... 8-10
Shift & Stop Switch .......................................... 8-11
4. Ignition System and Ignition
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-12
Control System
1) Inspection of Ignition Sparks ⋯⋯⋯⋯⋯⋯⋯⋯ 8-12
2) Inspection of Plug Cap ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-13
3) Inspection of Ignition Coil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-13
4) Inspection of Pulser Coil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-14
5) Inspection of Exciter Coil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-15
6) Inspection of Oil Pressure Switch ⋯⋯⋯⋯⋯⋯ 8-15
9) Inspection of Stop Switch ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-17
1) Inspection of Fuse ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-17
2) Inspection of Starter Solenoid ⋯⋯⋯⋯⋯⋯⋯⋯ 8-17
3) Disassembly of Starter Motor ⋯⋯⋯⋯⋯⋯⋯⋯ 8-18
4) Inspection of Starter Motor Pinion ⋯⋯⋯⋯⋯⋯ 8-18
5) Inspection of Armature ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-18
6) Inspection of Brushes ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-19
7) Inspection of Starter Motor Operation ⋯⋯⋯⋯⋯ 8-20
1) Inspection of Charge Coil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-20
2) Inspection of Rectifier ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-20
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 9-3
1 Engine will not start .......................................... 9-3
Starting System⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 9-3
Ignition System ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 9-5
Fuel System ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 9-7
Compression Pressure ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 9-8
2 Engine starts but stalls soon.⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 9-9
Fuel System ................................................ 9-9
Ignition System .......................................... 9-10
Compression Pressure ................................. 9-11
3 Idle engine speed will not stabilize.⋯⋯⋯⋯⋯⋯⋯ 9-12
4 Rapid opening of throttle fails acceleration. ⋯⋯⋯⋯ 9-13
5 Gear shifting cannot be made normally. ............... 9-14
3. Warning Indication ... Display for
Abnormalities During Operation
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 10-2
MF Model
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 10-3
EF Model
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 10-4
EP Model
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7-10
⋯⋯⋯⋯ 8-3
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-17
⋯⋯⋯⋯⋯⋯ 8-20
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8-21
⋯⋯⋯⋯⋯⋯⋯⋯⋯ 9-2
⋯⋯⋯ 9-15
4st 9.9/15/20 2008
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Troubleshooting
