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Raider 50 hp Service Manual

Submersible motor
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SERVICE MANUAL
• Two stroke Low pressure
• Direct Injection (TLDI)
• Multi-fuel
• Submersible
This manual has been prepared for the United States Guardian Angels for
service of the Multi-fuel, Submersible Outboard motor designed and manufactured
under Contract No. N61331⑩11⑩C-0008, dated 3/4/11. The data presented in this
manual was revised as of August 2013 representing the latest revision.
August 2013

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Summary of Contents for Raider 50 hp

  • Page 1 SERVICE MANUAL • Two stroke Low pressure • Direct Injection (TLDI) • Multi-fuel • Submersible This manual has been prepared for the United States Guardian Angels for service of the Multi-fuel, Submersible Outboard motor designed and manufactured under Contract No. N61331⑩11⑩C-0008, dated 3/4/11. The data presented in this manual was revised as of August 2013 representing the latest revision.
  • Page 2 Copyright© 2013 RAIDER Outboard, Inc. Copyright© 2013 RAIDER Outboard, Inc. Copyright© 2013 RAIDER Outboard, Inc. All rights reserved. No part of this manual may be reproduced or transmitted in All rights reserved. No part of this manual may be reproduced or transmitted in All rights reserved.
  • Page 4 CONTENTS CONTENTS CONTENTS CONTENTS 1 1 1 1 Chapter 1 Chapter 1 Specifications Specifications Chapter 1 Chapter 1 Specifications Specifications 2 2 2 2 Chapter 2 Chapter 2 - - - - Servicing Information Chapter 2 Chapter 2 Servicing Information Servicing Information Servicing Information 3 3 3 3...

  • Page 5: Table Of Contents

    ........................7 7 7 7 - - - - 1 1 1 1 ..............................7-2 OTOR PERATING NSTRUCTIONS RAIDER .................................7-3 FTER IS STARTED RAIDER ..................................7-4 TOPPING 4..O .....................................7-6 VERHEATING 5. E ..................................7-6 MERGENCY TARTING ................................7-8 UBMERSION ROCEDURE...
  • Page 6 CHAPTER 8 TILLER HAN CHAPTER 8 TILLER HANDLE TYPE DLE TYPE ....................................8 8 8 8 - - - - 1 1 1 1 CHAPTER 8 TILLER HAN CHAPTER 8 TILLER HAN DLE TYPE DLE TYPE ....................
  • Page 7 Chapter 1 Specifications Specifications Specifications Specifications 1. S ..................................1-1 PECIFICATIONS ABLE 2. O ..................................1-2 UTLINE IMENSIONS 3, W TLDI? ..................................1-4 HAT IS ..................................1-7 UPPLY YSTEM ..................................1-8 UPPLY YSTEM 6. O ..................................1-9 UPPLY YSTEM...

  • Page 8: Specifications Table

    1. 1. 1. 1. Specifications Table Specifications Table Specifications Table Specifications Table ITEM RAIDER 50 HP TLDI Overall length 1120 mm (44.1 in.) Overall width 384 mm (15.1 in.) Overall height 1514 mm (59.6 in.) Weight 92.0 kg (203 lbs.) w/o composites/w/o starter & battery Transom length 530 mm (20.9 in.)

  • Page 9: Outline Dimensions

    2. O 2. O 2. O 2. Outline Dimensions utline Dimensions utline Dimensions utline Dimensions...
  • Page 10 External Dimensions External Dimensions External Dimensions External Dimensions Item Remarks 495 mm (19.5 in) Transom (5) 728 mm (28.7 in) Transom (L) 855 mm (33.7 in) Transom (UL) 982 mm (38.7 in) Transom (S) 403 mm (15.9 in) Transom (L) 530 mm (20.9 in) Transom (UL) 657 mm (25.9 in) 568 mm (22.4 in)

  • Page 11: What Is Tldi

    Pressure Direct Injection (TLDI) Pressure Direct Injection (TLDI) TLDI is the name RAIDER uses for two-stroke engines that utilize the air-assisted, low-pressure direct injection system. The air-assisted, low-pressure direct injection system has been combined with the Inductive ignition system and Engine Control Unit (ECU), which performs precision control of fuel mixture, injection timing and ignition timing to maximize combustion efficiency in the TLDI engine.
  • Page 12 Below is a block diagram of the Engine Control Unit that allows the Raider 50 horsepower outboard to function as a multi-fuel engine.
  • Page 13 TLDI commercial models using L-CDI (Long Arc Duration CDI). This feature was added to insure a quicker start after submersion than any conventional CDI systems. The improved Inductive Ignition System in the Raider TLDI engine provides a smoother running outboard than any commercial outboard. Throttle...

  • Page 14: Fuel Supply System

    4.Fuel Supply System 4.Fuel Supply System 4.Fuel Supply System 4.Fuel Supply System Starting the engine activates the fuel pump (3), which draws fuel from the fuel tank (1) and routes it through the fuel filter (2) to the vapor separator (4). The fuel is pressurized in the fuel-feed pump (FFP) (5); then passes through the high- pressure filter (6) to the air rail (7), from there it is injected into the combustion chambers.

  • Page 15: Air Supply System

    5. 5. 5. 5.Air Supply System Air Supply System Air Supply System Air Supply System Starting the engine operates the air compressor (2), draws air in through the air filter (1) and sends compressed air through to the air rail (3). The air regulator (4) regulates air at the optimum combustion pressure of 550 kPa (80 psi) and the regulated air is injected into engine combustion chamber together with pressurized fuel.

  • Page 16: Oil Supply System

    6. 6. 6. 6. Oil Supply System Oil Supply System Oil Supply System Oil Supply System Starting the engine operates the oil pump (1), which draws oil from the oil tank (2) and routes it through the oil filter (3) to the oil pump (1).
  • Page 17 1-10...

  • Page 18: Chapter 2

    2 2 2 2 Chapter 2 - - - - Servicing Information Servicing Information Servicing Information Servicing Information 1.GENERAL PRECAUTIONS FOR SERVICING..............................2 2 2 2 - - - - 1 1 1 1 ............................
  • Page 21 (3) Always replace packing, gaskets, 0-rings and split pins with new ones when reassembling engine parts. Make a point of replacing snap rings as well. (4) When replacing, be sure to use genuine Raider brand parts and lubricants or products recommended by RAIDER. (5) Always use the recommended special tools to ensure work is done properly.
  • Page 22 (10) Observe all necessary safety procedures to prevent accidents and injury during work operations. 2. 2. 2. 2.Specifications and Standards Used in Servicing Specifications and Standards Used in Servicing Specifications and Standards Used in Servicing Specifications and Standards Used in Servicing Name of Part Item to check Standard values...
  • Page 23 Service limit Servicing procedure 0.8 mm (0.031 in) or more Replace with new piston ring if cylinder liner wear has not yet exceeded the repair limit. 0.9 mm (0.035 in) or more 0.05 mm (0.002 in) or more Replace with new crankshaft. 2 mm (0.08 in) or more Replace with new crankshaft assembly.
  • Page 24 Name of Part Item to check Standard values Sparking performance Measured using spark 10 mm (0.39 in) or more at 350 rpm • tester • Sparking order 280 W • Magneto Alternator (max.) 1,500 rpm l2V 16.5A • Charging performance 5,500 rpm 12V 18.5A •...
  • Page 25 Service limit Servicing procedure 1) 1.0 mm (0.047 in) or more 1) Repair so that plugs conform to standard values. 2) When electrodes show excessive wear 2) Replace with new spark plug. When sensor no longer conforms to standard value Repair so that sensor conforms to standard value.
  • Page 26 Name of Part Item to check Standard values Tilt Cylinder 19600 to 24500 kPa Manual Trim and Tilt • Cylinder bore 39.00 to 39.02 mm (1.53 to 1,54 in.) • • Piston diameter 38.97 to 38.99 mm (1.534 to 1.535 in.) •...
  • Page 27 Service limit Servicing procedure • When parts no longer conform to standard values • Replace with new parts. • When parts show excessive wear or damage Replace with new parts. • When parts show excessive wear or damage • When parts showed deterioration or contamination by fuel •...
  • Page 28 3. 3. 3. 3.Lis Lists of Points for Applying Sealant, Adhesive and Lubrication ts of Points for Applying Sealant, Adhesive and Lubrication ts of Points for Applying Sealant, Adhesive and Lubrication ts of Points for Applying Sealant, Adhesive and Lubrication 1342 1373B Adhesive 648...
  • Page 29 Shift lever stopper Remarks Remarks Remarks Remarks LT-2 LOR#101 KS-64 Ring groove, piston pin hole and skirt Skirt Inwall Apply Loctite 648 to the punched side after applying primer to the shaft and punched surface Sliding surface Sliding surface Sliding surface Sliding surface Lip area Lip area (on oil seal in crankcase head)
  • Page 30 1342 1107 1373B Adhesive 64B 1741 Application points Application points Application points Application points Primer 7471 Air rail Air rail Air rail Air rail Air injector 0-ring Fuel injector 0-ring Fuel regulator 0-ring Air regulator 0-ring Compressions seal Spark plug 0-ring Air hose L nipple 0-ring Fuel hose L nipple 0-ring Valve assembly...
  • Page 31 Remarks Remarks Remarks Remarks LT-2 LOR#101 KS-64 O-rings at 2 locations O-rings at 2 locations O-rings at 2 locations O-rings at 2 locations Air rail, 6 locations Air rail, 3 locations O-rings at 2 locations O-rings at 2 locations Taper screw Entire outer surface Entire outer surface Apply when inserting pin...
  • Page 32 1342 1373B Adhesive 648 1741 Application points Application points Application points Application points Primer 7471 Gear case Gear case Cam rod bushing Gear case Gear case Cam rod bushing O-ring, 2.4 to 5.9 Cam rod bushing O-ring, 3.5 to 21.7 Cam rod bushing stopper bolt Gear case lubricating oil Gear case bolt...
  • Page 33 Remarks LT-2 LOR#101 KS-64 Entire surface Under-neck surface Oil capacity 500 ml Under-neck surface Under-neck surface Under-neck surface Fill with grease, apply grease to tapped hole Inner surface Both surfaces Fill interior with grease Sliding surface Sliding surface Sliding surface Thread Spline surface Sliding surface...

  • Page 34: Torque Table

    4. 4. 4. 4. Torque Table Torque Table Torque Table Torque Table Item Part to tighten Initial torque (N-m) Full torque (N-m) lb-ft Cylinder head cover - Bolt (M6) 2.0 - 2.9 4.6 - 6.3 (0.5-0.6 kg-m) 3.6 - 4.4 Cylinder head cover Bolt (M8) 12 - 15...

  • Page 35: Special Tools

    5. Special Tools 5. Special Tools 5. Special Tools 5. Special Tools 2-16...
  • Page 36 1. 1. 1. 1. List of Special Tool List of Special Tool List of Special Tool List of Special Tool Pressure gauge assembly Crimping pliers Drive pulley press Piston slider 3T5-72880-O 3T5-72868-O 3T5-72871 3T5-72864-O For crimping For measuring air rail fuel and OETIKER make For installing the piston in air pressure...
  • Page 37 Drive Flywheel puller kit pulley puller assembly 3C7-7221 1-1 3T5-72890 For removing drive pulley. For removing and installing flywheel. Needle bearing puller kit Spring pin tool A Spring pin tool B 3C8-72700-O 345-72227-0 345-72228-0 For removing and installing gear case needle bearing For removing and Installing spring pins.
  • Page 38 2. 2. 2. 2. Using the Special Tool Using the Special Tool Using the Special Tool Using the Special Tool Pressure Gage Assembly Pressure Gage Assembly Pressure Gage Assembly Pressure Gage Assembly Measuring Fuel and Air Pressure 1. Mover the lever for cock (3T5 Mover the lever for cock (3T5- - - - 72883 72883- - - - O) to position A shown in the figure below.
  • Page 39 Crankshaft Holder (3T5 Crankshaft Holder (3T5- - - - 7281 5 Crankshaft Holder (3T5 Crankshaft Holder (3T5 7281 5 7281 5 7281 5- - - - 0) 0) 0) 0) Removing Pulley Nut Removing Pulley Nut Removing Pulley Nut Removing Pulley Nut 1.
  • Page 40 Drive Pulley Puller Assembly Drive Pulley Puller Assembly Drive Pulley Puller Assembly Drive Pulley Puller Assembly Removing Drive Pulley Removing Drive Pulley Removing Drive Pulley Removing Drive Pulley Begin the disassembly operation by removing the crankshaft from the power unit. 1.
  • Page 41 Drive Pulley Press (3T5 Drive Pulley Press (3T5- - - - 72868 72868- - - - O) Drive Pulley Press (3T5 Drive Pulley Press (3T5 72868 72868 Inserting Drive Pulley Inserting Drive Pulley Inserting Drive Pulley Inserting Drive Pulley 1. Remove any oil or grease from crankshaft and drive pulley hole. Apply Loctite Primer 7471; wait 5 minutes; then apply Loctite 648 to the hole.
  • Page 42 0 0 0 0 - - - - ring Setting Tool (o24) (3T5 ring Setting Tool (o24) (3T5- - - - 72863 72863- - - - O) ring Setting Tool (o24) (3T5 ring Setting Tool (o24) (3T5 72863 72863 Install the fuel injector 2.8-20.2 0-rings (3T5-1 0304-0). Apply engine oil to both the 0-rings and the 0-ring setting tool.
  • Page 43 2-24...
  • Page 44 Chapter 3 Inspecti Inspecti Inspecti Inspection and Maintenance on and Maintenance on and Maintenance on and Maintenance CHAPTER 3 INSPECTION AND MAIN INSPECTION AND MAINTENANCE TENANCE ..............................3 3 3 3 - - - - 1 1 1 1 INSPECTION AND MAIN INSPECTION AND MAIN TENANCE...

  • Page 45: Periodic Inspections

    1. 1. 1. 1. Periodic In Periodic In Periodic Inspections Periodic In spections spections spections Inspection intervals 50 hrs. 100 hrs. Inspection 10 hrs. 30 hrs 200 hrs. Inspection procedure Remarks points Yearly years bimonthly monthly 2 years months months High press.

  • Page 46: Inspecting Engine Oil System

    2. 2. 2. 2. Inspecting Engine Oil System Inspecting Engine Oil System Inspecting Engine Oil System Inspecting Engine Oil System Bleeding Air from Oil Pump Bleeding Air from Oil Pump Bleeding Air from Oil Pump Bleeding Air from Oil Pump Conduct a visual check of the clear vinyl pipes connecting the oil pump to the oil tank to inspect for the presence of air.

  • Page 47: Inspecting Compression System

    Fuel pickup elbow Filter Turn to the left to remove and clean . Cleaning Bladder/Fuel Tank Cleaning Bladder/Fuel Tank.(Not supplied with RAIDER ) .(Not supplied with RAIDER ) Cleaning Bladder/Fuel Tank Cleaning Bladder/Fuel Tank .(Not supplied with RAIDER ) .(Not supplied with RAIDER ) Clean the bladder/fuel tank whenever there is a buildup of water or foreign matter.
  • Page 49 2. 2. 2. 2. Inspecting Gear Case Are Inspecting Gear Case Are Inspecting Gear Case Area a a a Inspecting Gear Case Are To avoid accidental starting of engine while servicing, twist and • remove all spark plug leads. Replacing Propeller Replacing Propeller Replacing Propeller Replacing Propeller...

  • Page 51: Washing Procedure

    Corrosion Protection Corrosion Protection Corrosion Protection Corrosion Protection Whenever possible after use in sea water or submersion in sea water, wash entire engine with fresh water to remove salt deposits and wipe down with a dry cloth. Spray entire powerhead with a liberal coat of Anti-Corrosion Spray penetrant/lubricant or equivalent.
  • Page 52 Valve operation start temperature 52③C 1.5③C (126③F 3③F) ④ ④ Valve full open temperature 65③C 1.5③C (149③F 3③F) ④ ④ Valve full open lift 3 mm or more Replacing Pump Impeller Replacing Pump Impeller Replacing Pump Impeller Replacing Pump Impeller Remove the following components.
  • Page 53 Overview of Cooling System Overview of Cooling System Overview of Cooling System Overview of Cooling System Tubing Tubing Tubing Tubing 3-10...
  • Page 54 3-11...

  • Page 55: Inspecting Tilt System

    The cylinder should work freely. No maintenance can be completed on this item as it is a replaceable. At the back of the Raider insure all lock handles work freely.

  • Page 56: Power Unit

    Chapter 4 Disassembling, Disassembling, Disassembling, Inspecting and Reassembling Disassembling, Inspecting and Reassembling Inspecting and Reassembling Inspecting and Reassembling Power Unit Power Unit Power Unit Power Unit CHAPTER 4 PTER 4 DISASSEMBLING, INSP DISASSEMBLING, INSPECTING AND REASSEMBL ECTING AND REASSEMBLING POWER UNIT ING POWER UNIT ....
  • Page 57 1. 1. 1. 1. Power Uni Power Uni Power Unit t t t Power Uni...
  • Page 58 Fuel connector • Battery • Ring gear cover • Battery cable (Optional on Raider) Disassemble the following components. Begin by disassembling the oil tank; Oil tank mounting bolts Fuel hose (remove from fuel filter inlet) • Reinstall the oil tank with oil tank mounting bolts after then.
  • Page 59 Disassemble apron (splash pan). Remove engine mounting bolts. Bolt: type H880 at 6 locations Secure eyebolts to the flywheel; then use a sufficiently strong hoist to suspend the power unit while keeping it in the horizontal position. Suspend slowly, taking care not to catch the power unit on any of the wiring or hoses.
  • Page 61 b) Reassembling Power Unit Reassembling Power Unit Reassembling Power Unit Reassembling Power Unit Install the following components. Install the engine base gasket >Replace with new gasket. Knock pin Apply three bond #1107 (Seal out) to both sides of engine base gasket Secure eyebolts to the flywheel;...

  • Page 62: Peripheral Parts

    2. 2. 2. 2. Peripheral Parts Peripheral Parts Peripheral Parts Peripheral Parts 1) 1) 1) 1) Electrical System Electrical System Electrical System Electrical System CrankPositioning Sensor CrankPositioning Sensor CrankPositioning Sensor CrankPositioning Sensor (CPS) (CPS) (CPS) (CPS) Removing Removing Removing Removing , , , , Flywheel and Alternator Flywheel and Alternator...
  • Page 63 Remove the following components. Coil bracket Cable clamp Remove the following components. Solenoid switch bracket Bolt: type H625 at 3 locations * * * * Removing ECU Removing ECU Removing ECU Removing ECU *ECU: abbreviation for the engine control unit. Remove the following components.
  • Page 64 Removing Harness Assembly Removing Harness Assembly Removing Harness Assembly Removing Harness Assembly Remove the following components. Remove harnesses in order starting from remote control side. Water temperature connector • Remove by pressing down on hook and pulling out connector. Fuel injector connector •...
  • Page 65 Removing Ignition Coil and Rectifier Regulator Removing Ignition Coil and Rectifier Regulator Removing Ignition Coil and Rectifier Regulator Removing Ignition Coil and Rectifier Regulator Remove the following components. Ignition coil #1 Ignition coil #2 Ignition coil #3 Rectifier regulator 4-10...
  • Page 66 4-11...
  • Page 67 2) Air Supply System 2) Air Supply System 2) Air Supply System 2) Air Supply System Prior to Removing Peripheral Components Prior to Removing Peripheral Components Prior to Removing Peripheral Components Prior to Removing Peripheral Components (1) Press on the core of the air valve located on the air rail to release pressure from the air lines.
  • Page 68 4-13...
  • Page 69 Removing Air Compressor Removing Air Compressor Removing Air Compressor Removing Air Compressor Remove the following components. Detach the oil pipe on the compressor side. Detach recirculation pipe on the compressor side. Detach cooling water pipe on compressor side. Remove air hose on compressor side. Compressor bolts: at 3 locations Remove the following components.
  • Page 70 Air Compressor Configuration Air Compressor Configuration Air Compressor Configuration Air Compressor Configuration 4-15...
  • Page 71 Inspecting Air Compressor Inspecting Air Compressor Inspecting Air Compressor Inspecting Air Compressor Component Points to check Piston Wear and damage • Check outer diameter of piston • Connecting rod : Confirm smooth operation • Big end bearing : Confirm smooth operation •...
  • Page 72 4-17...
  • Page 73 Assembling Compressor Assembling Compressor Assembling Compressor Assembling Compressor Using the piston slider, insert the piston into the cylinder. Special Tool Piston slider 3T5-72871 -o Prior to inserting piston, apply • heat-resistant grease LOR #101 and genuine engine oil mixed at a 1:3 ratio and apply Outer circumference of piston •...
  • Page 74 Assemble following components into the cylinder. Knock pins at 2 locations Gasket >Replace with new one. Bolt: type H625 at 4 locations Cramp at 1 location Apply genuine engine oil to the • big end of the connecting rod. Insert the crank pin in the big •...
  • Page 75 4-20...
  • Page 76 Disassembling Air Rail Disassembling Air Rail Disassembling Air Rail Disassembling Air Rail Remove the following components. Fuel hose assembly and nipples Disassemble and pull out the stopper plate. Air hose assembly Disconnect the hose joint on the compressor side. Cooling water outlet hose Fuel return hose Air discharge hose Cooling water inlet hose...
  • Page 77 Air Rail Assembly Configuration Air Rail Assembly Configuration Air Rail Assembly Configuration Air Rail Assembly Configuration 4-22...
  • Page 78 Inspecting Air Rail Inspecting Air Rail Inspecting Air Rail Inspecting Air Rail Components Points to check Air injector Wear, deterioration and damage on 0-rings and seal rings. Replace • with new ones if problems are detected. Remove any carbon buildup on tip using wire brush. •...
  • Page 79 Assembling Air Rail Assembling Air Rail Assembling Air Rail Assembling Air Rail Apply genuine engine oil to the 0-rings. Assemble the following components. Insert Compression seal Take care to install with insert ~ facing in the proper direction as shown in •...

  • Page 80: Fuel System

    Assemble components Air hose assembly Collar Nipple plate Bolt Installing Hoses (See figure) From air compressor (air) To air compressor (cooling water) To FFP (fuel) To cylinder (air) From exhaust cover (cooling water) 3. 3. 3. 3. Fuel System Fuel System Fuel System Fuel System Disassembling Fuel Hose Assembly...
  • Page 81 Disassembling Vapor Separator Disassembling Vapor Separator Disassembling Vapor Separator Disassembling Vapor Separator Drain the fuel from the vapor separator using the following procedures. Loosen the air vent screw. Loosen the drain screw. Hold a cloth in place to absorb spilling fuel when loosening Detach the following hoses.
  • Page 82 Vapor Separator Configuration Vapor Separator Configuration Vapor Separator Configuration Vapor Separator Configuration Inspecting Vapor Separator Inspecting Vapor Separator Inspecting Vapor Separator Inspecting Vapor Separator Components Points to check 0-rings Wear, deterioration and damage. • Float valve Wear, deterioration and damage. •...
  • Page 83 Assembling Vapor Separator Assembling Vapor Separator Assembling Vapor Separator Assembling Vapor Separator Assemble in the reverse order of disassembly. Air vent screw Torque: 0.98 N-m: 0.1 kg-m: 0.7 lb-ft Drain screw Torque: 1.4 N-m: 0.14 kg-m: 1.0 lb-ft Assembling Vapor Separator assembly Assembling Vapor Separator assembly Assembling Vapor Separator assembly Assembling Vapor Separator assembly...
  • Page 84 Fuel Feed Pump (FFP Fuel Feed Pump ( FFP) ) ) ) Configuration Configuration Fuel Feed Pump ( Fuel Feed Pump ( Configuration Configuration 4-29...
  • Page 85 Inspecting FFP Inspecting FFP Inspecting FFP Inspecting FFP Components Points to check Pipe grommet Upper cable terminal grommet Wear, deterioration and damage. Replace if defects are • detected. Cable terminal grommet 0-rings FFP Case Clogging by foreign matter and water. •...
  • Page 86 4-31...
  • Page 87 Assembling Fuel Feed Pump ( Assembling Fuel Feed Pump (FFP FFP) ) ) ) Assembling Assembling Fuel Feed Pump ( Fuel Feed Pump ( Assemble the following components. Hose joint adapter Torque: 14 to 16 N-m: 1.4 to 1.6 kg-m: 10 to 12 lb-ft Adhesive to apply after degreasing thread area: Three Bond 1342 Metal washers Always replace after disassembly.
  • Page 88 2.0 to 2.6 lb-ft Assemble the following components. Upper grommet Cable terminal grommet Grease to apply Genuine engine oil Cable terminal (-): black cable Cable terminal (+): Red cable Terminals Grease to apply Genuine engine oil Connect to the flat connector cable terminal by lining up with the mark (+ and/or -)on the FFP.
  • Page 89 Assemble the following components. Cable terminal upper grommet Seal ring (0-ring) Grease to apply Genuine engine oil Uppercase Bolt: type H518 at 4 locations Torque: 2.6 to 3.5 N-rn: 0.27 to 0.36 kg-m:2.O to 2.6 lb-ft Installing FFP Assembly on Cylinder Installing FFP Assembly on Cylinder Installing FFP Assembly on Cylinder Installing FFP Assembly on Cylinder...
  • Page 90 Oil Pump Oil Pump Oil Pump Oil Pump Disassembling Oil Pump and Oil Tank Disassembling Oil Pump and Oil Tank Disassembling Oil Pump and Oil Tank Disassembling Oil Pump and Oil Tank Disassemble the following components. Oil filter Oil pump bolt Oil pump Oil pipe :4 Remove by pulling the pipes (4) out from oil pump.
  • Page 91 • Rubber mount Inspect the following components. Bushing Oil pump driven gear Check for wear and damage. Assembling Oil Pump Assemble the following components Bushing Oil pump driven gear Oil to apply Genuine engine • Make sure that faces right side up. Section with large hole faces to the front.

  • Page 92: Throttle Mechanism

    4. 4. 4. 4. Throttle Mechanism Disassembling Advancer Arm Disassembling Advancer Arm Disassembling Advancer Arm Disassembling Advancer Arm Disassemble the following components. Throttle link rod TPS~ link rod Oil pump link rod TPS: abbreviation for throttle position sensor Prior to removing it will be necessary to disconnect the rod snaps from the advancer arm.
  • Page 93 Assembling Advancer Arm Assembling Advancer Arm Assembling Advancer Arm Assembling Advancer Arm Assemble the following components. Advancer arm • Throttle link rod • TPS link rod • Oil pump link rod • Bolt: type H635 • Washers • Collar • Install the following components.
  • Page 94 Assembling TPS Assembling TPS Assembling TPS Assembling TPS Assemble in the reverse order of disassembly. Disassembling Air Box and Throttle Body Disassembling Air Box and Throttle Body Disassembling Air Box and Throttle Body Disassembling Air Box and Throttle Body Disassemble the following components. •...
  • Page 95 Inspect the following component. Reed valve assembly Valve stopper height: 9.3 to 9.5 mm: 0.366 to 0.374 in Check whether valve closes properly, is worn or damaged. Inspect the following component. Throttle body Check throttle cam for wear. • Check cam roller for wear.

  • Page 96: Disassembling Engine Block

    5. 5. 5. 5. Disassembling Engine Block Disassembling Engine Block Disassembling Engine Block Disassembling Engine Block Cylinder and Crankcase Assembly Cylinder and Crankcase Assembly Cylinder and Crankcase Assembly Cylinder and Crankcase Assembly 4-41...
  • Page 97 Piston and Crankshaft Piston and Crankshaft Piston and Crankshaft Piston and Crankshaft 4-42...
  • Page 98 Removing Thermostat Removing Thermostat Removing Thermostat Removing Thermostat Remove the following components. Bolt: type H625 at 2 locations Thermostat cap Thermostat Inspect the following components. • Check to see whether foreign matter has entered valve. Confirm valve operates within designated temperature range. •...
  • Page 99 Inspecting Cylinder Head Inspecting Cylinder Head Inspecting Cylinder Head Inspecting Cylinder Head Inspect the following components. Cylinder head Inspecting: Inspecting: Inspecting: Inspecting: Check for carbon deposit in combustion chamber. Check for sediment in water jacket. Inspecting: Inspecting: Inspecting: Inspecting: Use components to measure distortion.
  • Page 100 using a plastic hammer. Disassembling Exhaust Cover Disassembling Exhaust Cover Disassembling Exhaust Cover Disassembling Exhaust Cover Remove the following components. Bolt: type H630 at 2 locations Bolt: type H630 at 12 locations Remove in order starting from the highest embossed number. Outer exhaust cover Inner exhaust cover Remove by prying gently with a flathead screwdriver alternately along the 4...
  • Page 101 Remove the following component. Crankshaft assembly Disassembling Drive Pulley Disassembling Drive Pulley Disassembling Drive Pulley Disassembling Drive Pulley Remove the following components. Pulley nut (36 mm) Special tool Crankshaft holder (36mm) 3T5-72815-0 Magneto key Magneto nut Install the magneto key on the crankshaft holder and secure using the •...
  • Page 102 Removing Piston Removing Piston Removing Piston Removing Piston Remove the following components. Piston pin clip at 2 locations • Remove both and take care not to scratch the pinhole. Remove the following component. Piston pin Special tool Piston pin tool 345-72215-0 Position against piston pin;...
  • Page 103 Inspecting Engine Components I Inspecting Engine Components I Inspecting Engine Components I Inspecting Engine Components I Inspecting Cylinders Inspecting Cylinders Inspecting Cylinders Inspecting Cylinders Cylinder bore (using cylinder gauge) • Standard value Service limit 68.05 mm Replace when 68.11 mm (2.679 in) (2.682 in) or more Measure the area showing the greatest wear.
  • Page 104 Inspecting Piston Rings Inspecting Piston Rings Inspecting Piston Rings Inspecting Piston Rings Piston ring Ring gauge Thickness gauge • Piston ring end gap Ring Standard Value Service Limit 0.22 to 0.37 mm Replace when 0.8 mm (0.009 to 0.015 in) (0.032 in) or more 2nd,3rd 0.33 to 0.48mm...
  • Page 105 Crankcase Assembling Piston Crankcase Assembling Piston Crankcase Assembling Piston Crankcase Assembling Piston Assemble the following components. Top ring (Keystone ring: iT) 2nd and 3rd rings (plain rings: stamped 2T) Special Tool Piston ring tool 353-72249-0 Install starting from the 3rd ring. •...
  • Page 106 4-51...
  • Page 107 Assembling Short Assembling Short Block Block Assembling Assembling Short Short Block Block Assemble in reverse order of disassembly. Apply genuine engine oil to the following parts. Big end of connecting rod • Small end of connecting rod and pin boss oil hole •...
  • Page 108 Assembling Crankcase Assembling Crankcase Assembling Assembling Crankcase Crankcase Degrease the mating surface of the crankcase. Caution: Caution: Caution: Caution: Insufficient degreasing will render sealant less effective,resulting in oil leakage. Apply sealant evenly 0ver the mating surface on the cylinder Sealant: Loctite #518 Apply evenly inside the bolt holes so that there are no bare patches.Be careful not to apply too much.
  • Page 109 Insure proper installation of the The following components. check valve inside the hose. Thermostat • Thermostat cap gasket Replace with new one. • Thermostat cap • Bolt :at 2 locations • Torque :4.6to6.3N-m:0.47 to0.64kg-m :3.4to4.6lb-ft Caution: Caution: Caution: Caution: Be sure to tighten M6 bolts only after tightening the M8 bolts on the head cover .Never tighten the M6 bolts first.
  • Page 110 Chapter 5 Installing and inspecting electrical components Installing and inspecting electrical components Installing and inspecting electrical components Installing and inspecting electrical components CHAPTER 5 INSTALLING AND INSP CHAPTER 5 INSTALLING AND INSPECTING ELECTRICAL CO ECTING ELECTRICAL COMPONENTS MPONENTS............5 5 5 5 - - - - 1 1 1 1 CHAPTER 5 CHAPTER 5 INSTALLING AND INSP...

  • Page 111: Wire Routing

    1. 1. 1. 1. Wire Routing Wire Routing Wire Routing Wire Routing...
  • Page 116 Wiring Diagram 40B/50B EPTO...
  • Page 119 5-10...
  • Page 120 5-11...
  • Page 121 5-12...

  • Page 122: Ignition

    408/508 EPTO NO Component Component 1 Alternator assembly 24 Cable assemblyA 2 Rectifier complete 25 Ground cable 3 Battery (obtain locally) 26 Lower motorcover 4 PTT switchB 27 Cable assemblyB 5 Oil level sensor 28 Neutral switch 6 Throttle position sensor 29 Warning horn(Buzzer) 7 Water temperature sensor 30 Main switch...

  • Page 123: Ignition

    408/508 E F T O NO. Component NO. Component Alternator assembly 19 FFP 2 Rectifier complete 20 FFP cable 3 Battery(obtain locally) 21 Battery cable 4 PTT switch B 22 Starter cable 5 Oil level sensor 23 Ground cable 6 Throttle position sensor 24 Cable assembly A 7 Water temperature sensor 25 Ground cable...

  • Page 124: Ignition

    40B/50B EFO Component Component Alternator assembly 19 FFP 2 Rectifier complete 20 FFP cable 3 Battery(obtain locally) 21 Battery cable 22 Starter cable 5 Oil level sensor 23 - 6 Throttle position sensor 24 Cable assembly A 7 Water temperature sensor 25 Ground wire 8 Crank position sensor 26 Lower motor cover...
  • Page 125 NO Component Cablecoloraddreviations TPS1 Blue/Red Keyswitch Blue (PUSH) CPS(Crankpositionsensor) Blue/Black Warninglamp(Oil) lightgreen Warninglamp(Temp.) Yellow/Red Warninglamp(Battery) Green/Red Buzzer Yellow 10 Tachometer White 12 CPS(crankpositionsensor) Green/Red 13 TPS1 Black/Red 14 TPS1 15 keyswitch(Powersource) Red/Yellow 17 #1Fuel injector Yellow/Red Fuelinjector Yellow/White Fuelinjector Yellow/Black 21 WTS(Watertemp.sensor) Green/Yellow 22 WTS(Watertemp.sensor,TPS2andOillevelsensorGround)

  • Page 126: Assembly

    Note: Slash(/)shows stripe color of cable. 2. 2. 2. 2. Assembly Assembly Assembly Assembly 5-17...
  • Page 127 Wiring around solenoid Bracket 5-18...
  • Page 128 5-19...
  • Page 129 5-20...
  • Page 130 5-21...
  • Page 131 3. Inspection Fly wheel Magneto Precautions Avoid applying shock or impact to the fly wheel, such as that from the tapping of a hammer. Be sure to use the recommended tool or equivalent only .Do not use standard pulley puller obtained locally. Always replace the fly wheel if it has been dropped on the floor or any other hard surface.
  • Page 132 Note: Measure using the Hioki Hi Tester model 3030 or equivalent product. Do not use an insulation tester. The tester needle moving represents an On reading and not moving represents an Off reading. The () contain approximate values for the1 range.
  • Page 133 Starter Motor Brushes and Springs Check the brushes for wear. When brush length is 9.5 mm(0.37in) or less Replace with new one. Inspect insulation between brush holders. If conductive, determine cause or replace insulation. Brush spring tension When there is a loss of tension replace spring.
  • Page 134 5. Multi-Fuel Electrical layout Connectors and wire pin outs Throttle Positioning Sensor Air Pressure Sensor RS 232 Pig Tail RS 232 Pig Tail 5-25...
  • Page 135 Fuel Injector (3) Fuel Injector (2) Fuel Injector (1) Water Temp Sensor Compressor Water Temp Sensor Natural safety switch 5-26...
  • Page 136 Kill Switch Crank Sensor Oil Level Sensor Grounds Air Injector (1) 5-27...
  • Page 137 Air Injector (2) Air Injector (3) Coil (1) Coil (2) Coil (3) 5-28...
  • Page 138 Fuel Pump Fuse Box- Regulator - Stator Complete Wiring harness 5-29...
  • Page 139 Chapter 6 Disassembly, Inspection and Reassembly Lower Unit Disassembly, Inspection and Reassembly Lower Unit Disassembly, Inspection and Reassembly Lower Unit Disassembly, Inspection and Reassembly Lower Unit CHAPTER 6 CHAPTER 6 DISASSEMBLY, INSPEC CHAPTER 6 CHAPTER 6 DISASSEMBLY, INSPEC DISASSEMBLY, INSPECTION AND REASSEMBLY DISASSEMBLY, INSPEC TION AND REASSEMBLY TION AND REASSEMBLY...

  • Page 140: Configuration

    1. 1. 1. 1. Configuration Configuration Configuration Configuration GEARCASE(DRIVESHAFT)
  • Page 141 GEARCASE(PROPELLERSHAFT)

  • Page 142: Disassembly

    2. 2. 2. 2. Disassembly Disassembly Disassembly Disassembly Caution: Begin the procedure by first removing the spark plug caps and then removing the sparkplugs. • When working with the outboard engine tilted full up,make sure to secure the engine firmly in place using a tilt •...
  • Page 143 Disassembling Water Pump Case Disassembling Water Pump Case Disassembling Water Pump Case Disassembling Water Pump Case Remove the lower section of the water pump case. Remove by inserting a flathead screw driver along the case removal groove. Disassembling Propeller Shaftand Clutch Disassembling Propeller Shaftand Clutch Disassembling Propeller Shaftand Clutch Disassembling Propeller Shaftand Clutch...
  • Page 144 Removing Bevel Gear and Drive Shaft Removing Bevel Gear and Drive Shaft Removing Bevel Gear and Drive Shaft Removing Bevel Gear and Drive Shaft Remove the following components. 1. Bevel gear B nut 2. Bevel gear B 3. Drive shaft 4.

  • Page 145: Inspection

    3. 3. 3. 3. Inspection Inspection Inspection Inspection Inspect the following components. Component Inspection points Remarks Wear and damage on pawls of bevel gears A and C. Replace. • Wear and damage on clutch pawl. Replace. Bevel gears A,B,C and •...
  • Page 146 Gear Gear Backlash Gear Gear Backlash Backlash Backlash PositioningBevelGear8:ShimmingGauge PositioningBevelGear8:ShimmingGauge PositioningBevelGear8:ShimmingGauge PositioningBevelGear8:ShimmingGauge Positioning of bevel gear B must be performed prior to the back lash measurement. Special Tool Shimming gauge 387-72250-0 Thickness gauge 353-72251-0 Checking Checking Checking Checking 1. Instal lower pump case to fix driveshaft. 1.
  • Page 147 Inspecting Inspecting Inspecting Inspecting Bevel Bevel Bevel Bevel Gear Gear Gear Gear Backlash Backlash Backlash Backlash Backlash MeasuringTool Backlash MeasuringTool Backlash MeasuringTool Backlash MeasuringTool Install the clamp assembly on the drive shaft on the clamp assembly. .LineupthetipofthedialgaugewithcenteroftheVgroove Driveshaft Special Tool Clampassembly:3B7-72720-0 Plate :3A3-72713-0 Shaft :345-72723-0...

  • Page 148: Reassembly

    4. 4. 4. 4. Reassembly Reassembly Reassembly Reassembly AssemblingGearCase AssemblingGearCase AssemblingGearCase AssemblingGearCase Observetheprecautionarynotesprovidedatvariousstepswhileassemblingint hereverseorderofdisassembly. InstallingBevelGearonDriveShaft InstallingBevelGearonDriveShaft InstallingBevelGearonDriveShaft InstallingBevelGearonDriveShaft Installthefollowingcomponents. BevelgearAbearing • Usetheouterracetopressfitthebearinginplace. Driveshaft BevelgearB BevelgearBnut Torque:40to58N-m(4to6kg-m)(29to43lb-ft} Special Tool BevelgearBnutwrench:346⑩72231⑩0 BevelgearBnutsocket:346⑩72232⑩0 ApplyingAdhesive ApplyingAdhesive ApplyingAdhesive ApplyingAdhesive Driveshaft* Overentirethreadarea ThreeBond1373B BevelgearBnut *:Becarefulnottogetanyadhesiveonthesplineandtaperedsurfacearea. AssemblingPropellerShaftandClutch AssemblingPropellerShaftandClutch AssemblingPropellerShaftandClutch AssemblingPropellerShaftandClutch...
  • Page 149 AssemblingClutch Cam, CamRodand ClutchCamRodBushing AssemblingClutch Cam, CamRodand ClutchCamRodBushing AssemblingClutch Cam, CamRodand ClutchCamRodBushing AssemblingClutch Cam, CamRodand ClutchCamRodBushing Installthefollowingcomponents. Clutchcam Clutchcamrod Camrodbushing Clutchcamspringpin:3-12 0-ring:2.4to5.8 0-ring:3.5to21.7 Special Tool SpringpintoolB 345-72228-0 Springpinsmustneverbereused.Applygearoiltothe0-rings. Installsothatthespringpindoesnotprotrudeoutfromtheclutch cam Installthefollowingcomponentsonthegearcase. Camrodassembly Camrodbushingstopper Onceinstallationiscompleted,operatethecamrodtoconfirmthatitmoves freelyupanddown 6-11...
  • Page 150 AssemblingWater Pump AssemblingWater Pump AssemblingWater AssemblingWater Pump Pump Installthefollowingcomponents.Refertosection7(InspectingCoolingSys tem)ofChapter3(Inspection andMaintenance)fordetaileddescriptionsofcomponents. Confirmoilseals arefacingrightsideup. Besuretoinsertshim betweentheoilseals Whiletakingcarenottoscratchthelipareaoftheoilseals ,insertthedri veshaftintothepumpcase. Carefullyfittheprotrudingsideofthepumpcaseliner intotherece ssionintheupperpump case . Insertthepumpimpellerkey firmlyontothedriveshaft. ApplyOBMgreaseinthepumpcaseliner Wheninstallingthepumpimpeller intheupperpumpcase ,dosobyrotatingthedriveshaftasshownint hebottomfiguretotheright. (Make surethatthepumpimpeller bladesarefacingrightsideup.) 6-12...
  • Page 151 Adding Gear oil Adding Gear oil Adding Gear oil Adding Gear oil Refer to section 5 (Inspecting Gear Case Area) of Chapter 3 (Inspection and Maintenance)for detailed description of gear oil replacement procedure. Assembling Gear Case Assembly Assembling Gear Case Assembly Assembling Gear Assembling Gear Case Assembly...
  • Page 152 6-14...
  • Page 153 6-15...
  • Page 154 ..7 7 7 7 - - - - 1 1 1 1 TRIM AND TILT TRIM AND TILT ......................................................................7-2 OTOR PERATING NSTRUCTIONS RAIDER .................................7-3 FTER IS STARTED 3. S RAIDER ..................................7-4 TOPPING ..................................7-6 VERHEATING 7 7 7 7...

  • Page 155: Motor Operating Instructions

    Overview The Raider has a uniquely designed transom mount that allows the operator easier mounting of the outboard on the Rubber Inflatable Boats. The design allows the motor to be slid over the transom and mounted even in high sea states.

  • Page 156: After Raider Is Started

    2. 2. 2. 2. After RAIDER is started After RAIDER is started After RAIDER is started After RAIDER is started a) Check the water pump indicator. Check the water pump indicator. A steady stream of water indicates the Check the water pump indicator.

  • Page 157: Stopping Raider

    Drive ater Drive controlled by the position of the angle adjusting lever. The Raider features a shallow water drive system that allows for multiple positions for shallow water drive. As the RIB with loads can vary we have made the shallow water drive “adjustable”...
  • Page 158 h) Shallow Water Operation Shallow Water Operation Shallow Water Operation Shallow Water Operation DO NOT DO NOT operate engine with gear case dragging on sea bottom. This can DO NOT DO NOT result in propeller or water pump damage. 1. Place engine in shallow water drive position. Refer to Shallow Water Drive.

  • Page 159: Emergency Starting

    The RAIDER does not have the normal overheat warning sounding device. The RAIDER will not initiate a warning to prevent powerhead damage. If you suspect the engine is overheating or has overheated, STOP the engine only when it is safe only when it is safe.
  • Page 160 Insert the knot end of rope into the flywheel notch; wrap rope around flywheel clockwise; tighten rope until pressure is felt, pull hard on the wooden handle with a quick solid motion to start the Raider. Note:...

  • Page 161: Pre Submersion Procedure

    Pre- - - - Submersion Procedure Submersion Procedure Submersion Procedure Submersion Procedure The Raider has been designed for submersion. Insure dewatering valves are closed. Insure the oil tank is complete filled. • Dewatering is discussed in Chapter 9. 9. 9. 9.
  • Page 162 Chapter 8 Tiller Tiller Tiller Tiller Handle Handle Handle Type Handle Type Type Type CHAPTER 8 TILLERHANDLETY TILLERHANDLETY TILLERHANDLETY TILLERHANDLETYPE PE ..........................................................................8 8 8 8 - - - - 1 1 1 1 ..........................8-2 ILLER ANDLE...
  • Page 163 • the operator to use minimum force for the tilting. The system is robust to allow the operator to tilt the Raider outboard into the RIB for dewatering or beaching very quickly during the mission. The tiller arm has been designed to allow operation of two outboards on the same RIB.
  • Page 164 No special tools are required to install the dual motor assembly. The DMCT is designed to link up the dual configuration Raider Outboards with ease...
  • Page 165 Advantages of the Raider DMCT design: Advantages of the Raider DMCT design: Advantages of the Raider DMCT design: Advantages of the Raider DMCT design: features a one-motor kick up feature in case only one of the motors • hits a below water obstacle;...
  • Page 166 Chapter 9 Dewatering Dewatering Dewatering Dewatering CHAPTER 9 DEWATERING DEWATERING ..........................................9 9 9 9 - - - - 1 1 1 1 DEWATERING DEWATERING ........................................................9-2 OCATION OF THREE DEWATERING ALVES THE OPERATOR MUST OPEN AFTER SUBMERSION ................................9-3 ATERING...
  • Page 167 Raider has develop this de-water procedure to quickly purge the engine of water and to lubricate the critical components of the engine. This will allow the operator to return the Raider to normal operation without damage to the engine.
  • Page 168 The Raider outboard dewatering process is as follows: Reach and open rear dewatering valve. Tilt the Raider into a horizontal position into the I-CRC or I-CAC. Turn the front valve to counterclockwise to open. Front port side in pan Turn the Mid-Valve in a counterclockwise motion to open.
  • Page 169 Continue until no more water is ejected. 7. Close the three valve ports in a clockwise rotation. 8. Two pulses on the rubber fuel ball inject new fuel into the Raider. CAUTION CAUTION...
  • Page 170 If your Raider has the internal lead acid battery under the cowling; simply open the dewatering valves; tilt the motor into the Rib; press the starter button on the pan for a few seconds. After a few seconds close the valves, press the rubber fuel ball to inject new fuel;...
  • Page 171 Chapter 10 Troubleshooting Troubleshooting Troubleshooting Troubleshooting CHAPTER 10 TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING........ TROUBLESHOOTING ............................................................10 ......10- - - - 6 6 6 6 ................................10-7 ROUBLESHOOTING ABLE TLDI – S ............................10-19 IAGNOSING UNCTIONS 10-6...
  • Page 172 This Raider Outboard has silenced all alarms to avoid mission compromise. The signals and warnings are recorded in the Electronics Control Unit that can be downloaded at the maintenance shop. The Raider on the mission should have fuel and oil reserve full.
  • Page 173 Battery low; or battery cables or circuit line Recharge or replace battery. Check battery terminal 1-2-1. connections maybe loose or corroded. and cable condition. No Fuse in Raider Configuration Maintenance shop repair. 1-3-1. Severed wire or loose connection. 1-4-1. Faulty main switch, neutral switch, starter Inspect and replace as necessary.
  • Page 174 Warning Warning Warning Self- indicator indicator Battery Beeps Symptom Item diagnosable Disabled Disabled Disabled Disabled points 2-2. Low fuel pressure in airrail Engine turns over Fuel system [normal:600to640kPa] but won't start High fuel pressure in airrail [standard:600to 640kPa]87to93psi 2-3. Airsystem Low air pressure in airrail [standard:530to570kPa]77to83ps High air pressure in airrail...
  • Page 175 Remedy Cause (See chapter one Servicing Information for specs.) 2-2-12. Fuel regulator leakage. Replace. 2-2-13. Fuel leakage. Inspect piping and connectors for damage. Return circuit from fuel regulator outlet to Inspect and repair. 2-2-14. Vapor separator is clogged. 2-2-15. Faulty fuel regulator. Replace.
  • Page 176 Warning Warning Warning Self- indicator indicator (battery) Beeps Symptom Item diagnosable Disabled Disabled Disabled Disabled points Spark plug cap. Crank position sensor. Self-diagnosing function 4.Electricalsyst indicates low (abnormal) Flashing Engine turns over Battery voltage. but does not start Self-diagnosing function Indicates faulty components.
  • Page 177 Remedy Cause (See chapter on Servicing Information for specs.) 2-4-6. Loose cap. Inspect. 2-4-7. Faulty cap. Replace. 2-4-8. Incorrect gap with encoder (flywheel). Inspect and adjust. 2-4-9. ECU not functioning. Replace ECU. Battery low or less than 1OV during turn over Recharge or replace battery.Check condition of 2-4-10.
  • Page 178 Warningindicat Warningindicator8 Warning(battery) Self- or(oil) Beeps (watertempDosab;ed Disabled Symptom Item diagnosablepoin Disabled Disabled Lowfuelpressureinairrail.[standard: Enginestartsbutidli 600to640MPa]87to93psi 3-2. Fuelsystem faltersorisunstable Highfuelpressureinairrail.[standar d:600to640kPa] Lowairpressureinairrail. 3-3. [standard:530to570kPa] Airsystem Highairpressureinairrai Sparkplugs Sparkplugcaps Self- diagnosingfunctionindicatesfaulty 4.Electricalsyst components. Self-diagnosing Flashing Flashing Rashing functionindicatesfaultyTPSidling position. Airinjector Variablei d lingswitch Engineidlestoohig Self-diagnosing...
  • Page 179 Remedy Cause (seechapteronServicingInformationforspecs.) 3-2-8. Fuelregulatorleakage. Refertosteps2-2-12. 3-2-9. Fuelleakage. Refertostep2-2-13. 3-2-10. Lowcompressioninairrail. Refertostep2-3. 3-2-11. Faultyfuelregulator. Replace. 3-2-12. Returncircuitfrom fuel Inspectandrepair. regulatoroutlettovaporseparatorisclogged. 3-3-1. Refertostep2-3. 3-3-2. 3-4-1. Refertostep2-4-3. 3-4-2. Loosecap. Inspect. 3-4-3. Faultycap. Replace. 3-4-4. Inspect,repairandreplaceasnecessary.Refertostep2-4- Faultycomponentsorconnections. 3-4-5. TPSinitialvaluesincorrect. Refertostep2-4-13. 3-4-6. TPS(*1)andforECUhavebeenreplaced. Refertostep2-4-13. 3-4-7.
  • Page 180 Warningindicat Warningindicator8 Warning(battery) orA(oil) Self- Beeps (watertemp)Disabled Disabled Disabled Symptom Item diagnosablepoin Disabled 6-1. Faultycompression Powerhead 6-2. Lowairpressureinairrail Airsystem Highairpressureinairrail Fueltank FuelHose Fuelfilter 6-3. Noaccelerationatfull Fuelsystem throttle Lowairpressureinairrail[standard: 550kPa④7%] (5.6kgf/cm 2 , 80psi) Sparkplugs 6-4. Airinjector Electricalsyste Self- diagnosingfunctionIndicatesfaulty components. Propeller Installation 7-1.
  • Page 181 Remedy Cause (SeechapteronServicingInformationforspecs.) 6-1-6. Faultyoilsealoncrankcase. Inspectandrepairasnecessary. 6-2-1. Refertostep2-3. 6-3-1. Fuelisloworemptyintank. Refertostep2-2-1. 6-3-2. Airventisclogged. Refertostep2-2-2. 6-3-3. Airbeingsuckedinthroughcrack Inspectandrepairasnecessary. s orfaultyconnectors. 6-3-4. Waterinfuelfilter. Inspectandcleanasnecessary. 6-3-5. Inspectfueltank,boatandenginefuelfiltersandcleanandreplaceasnece Fuelfilterisclogged. ssary. 6-3-6. Fuellinesareclogged. Checkfortwisted,flattenedorbentfuellines. 6-3-7. Liftpump(*1)notfunctioning. Inspect,repairandreplaceasnecessary. 6-3-8. Inspectrubbersealoninternalcomponentsandinspectelectricfuel Leak inFFP(*1)case. pump. 6-3-9. Leakageinfuelregulator. Replace. 6-3-10.
  • Page 182 Warning Warning indicator Warning indicator A (oil) 8 (watertemp) indicator Self-diagnosable Beeps Symptom Item Disabled Disabled (battery)Disabled points Disabled Cooling water temperature Continuous Flashing too high (temp.indicator 9-1. Continuous Flashing flashes) Electrical Battery voltage abnormally Flashing Flashing Flashing Poor acceleration control high (battery indicator...
  • Page 183 Cooling water inlet is clogged. Inspect. 9-1-2. Faulty water pump. Inspect, repair and replace as necessary. 9-1-3. Faulty battery if used in Raider. Inspect. 9-1-4. Faulty rectifier regulator. Inspect and replace as necessary. Faulty TPS, faulty wiring connections or 9-1-5.
  • Page 184 2. 2. 2. 2. TLDI TLDI Self Self Diagnosing Diagnosing Functions Functions TLDI TLDI Self Self Diagnosing Diagnosing Functions Functions The TLDI R a i d e r engine u s e s a self diagnosing function maintain detailed information of faults that occur on missions t h a t h a v e b e e n detected by the engine control unit (ECU).
  • Page 185 10-20...
  • Page 186 Chapter 11 Servicing Servicing Servicing Servicing CHAPTER 11 SERVICING SERVICING..........................................11 11- - - - 1 1 1 1 SERVICING SERVICING ..........................................·2.T ..............................11-2 ANKAND ROPELLER ..................................11-3 NSPECTION 0211-1...
  • Page 187 The most critical step in maintaining longevity of outboard motors is the break in period. Proper break in when first acquired and installed on the RIB is paramount to a long, successful militarized Raider outboard. Each Raider outboard is started and tested prior to delivery, however, the break in has not been completed. It is vital proper break in be completed on the new and rebuilt Raider.
  • Page 188 3. 3. 3. 3. Inspection Inspection Inspection Inspection • Items to Check Prior to Test Run • Fuel line condition • Gear shift lever operation • Electrical wiring,connections and clamps • Operation,including catch,of reverse lock • Integrity of self-diagnosing function •...
  • Page 189 Alternate fuel: gasoline, gasohol/ethanol Storage Storage Storage Storage of the Raider Outboard of the Raider Outboard of the Raider Outboard of the Raider Outboard Use the following procedure to properly prepare the engine for extended periods of nonuse. These steps are intended to protect the engine during storage and simplify the out of storage servicing procedure.
  • Page 190 The following is described in the outboard does not meet specifications. It is a first step to decide if a tune-up is all that is required verses a major overhaul of the Raider. 1. Visually inspect engine for leaks, missing or loose parts, or other obvious defects.
  • Page 191 The mounting screws and the anode itself should also be cleaned. Install and retest. Never paint or coat the anodes or their mounting surfaces, as this will prevent them from functioning properly. When taking Raider When taking Raider Out of Storage Out of Storage and back into and back into Service...
  • Page 192 5. If the fuel hose has been disconnected, reinstall it. 6. Check fuel system for leaks Check fuel system for leaks. Check fuel system for leaks Check fuel system for leaks 11-7...
  • Page 193 11-8...

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