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Raider 50 Service Manual

Two stroke - multi-fuel – submersible outboard motor
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RAIDER 50 SERVICE MANUAL
Two stroke - Multi-Fuel – Submersible
Outboard Motor
Service Manual
R50ES-002-11
Part No. SMR50ES-002-2
January 2017
Rev. 3

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  • Page 1 RAIDER 50 SERVICE MANUAL Two stroke - Multi-Fuel – Submersible Outboard Motor Service Manual R50ES-002-11 Part No. SMR50ES-002-2 January 2017 Rev. 3...
  • Page 2 This service manual provides information that is needed for inspection, service and repair of the Raider 50 outboard motor. For information about operation of the products that are not described in this document, refer to the owner’s manual (Part No. OMR50ES-002). For our users we have built the best outboard motor for long term, it is essential for the maintainer to prepare the outboard prior to the mission.
  • Page 3 About this manual Composition and use of this manual This service manual is designed so that service personnel are able to perform repairs correctly. Understand the following subject matters well for efficient service and repair. 1 Each chapter begins with the introduction of special tools that are used for the work described. 2 Parts that are serviced in each chapter and their details are presented by using a component composition diagram.
  • Page 4 This manual uses the International System of Units (SI) unit system for the pressure, force (load), torque and stress. This manual adopts the international unit construction system (SI unit system) followed by the conventional imperial and metric systems enclosed by ( ) and [ ] as described below.
  • Page 5 Corrosion Zero...

  • Page 6: Table Of Contents

    Removing Cylinder Head / Head Cover . 5-48 11) Carburetor Synchronization..3-26 10) Inspection of Cylinder Head 12) Pilot screw adjustment .... . 3-30 .. 5-50 11) Removing Exhaust Cover 13) Replacement of Gear Oil ..3-32 . 5-50 12) Inspection of Exhaust Cover...
  • Page 7 16) Assembling tilt mechanism ..7-52 16) Disassembly of Propeller Shaft Ass’y 8.Electrical System .. 6-46 17) Inspection of Propeller Shaft Ass’y . 6-48 1. Special Tools ....8-2 18) Assembly of Propeller Shaft Ass’y .. 6-50 *What’s Peak Voltage...... . 8-2...
  • Page 8 Merit of adoption of peak voltage measurement ... . 8-2 Recommended tester...... . 8-2 2. Parts Layout ......... 8-4 Magneto ........8-4 Electric Parts (C.D. Unit) ....8-6 3. How to use Peak Voltage Adapter .8-8 Attention of measurement ...
  • Page 9 INDEX Service Information Service Data Maintenance Fuel System Power Unit Lower Unit Bracket Electrical System Troubleshooting Wiring Diagram Safety Jet...
  • Page 10 Service Information 3) Special Tools ......1-10 1. Identification (Engine Serial Number) ..4. Pre-delivery Inspection ..1-16 2. Work Safety ....1-2 1) Tiller Handle ..... 1-16 1) Fire Prevention....1-2 2) Gear Shift ....1-16 2) Ventilation ...

  • Page 11: Identification (Engine Serial Number)

    Avoid contact of oil, grease or sealing agent to the skin. In case of exposure to such matters, wash away with soap or warm water immediately. 4) Genuine Parts Use parts and/or chemicals that are genuine Raider items or recommended.

  • Page 12: Assembling Components

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

  • Page 13: Tools And Instruments

    ( M1 type, 300 mm ) Micrometer ( minimum graduation of 0.01, outer, 0 to 25 mm, 25 to 50 mm, 50 to 75 mm ) Cylinder gauge ( 4 to 6 mm, 10 to 25 mm, 25 to 30 mm, 50 to 75 mm ) Ring gauge ( ø5.5, ø16, ø25, ø30, ø61)

  • Page 14: Special Tools

    Service Information 3) Special Tools Spring Pin Tool A Spring Pin Tool B P/N. 345-72227-0 (ø3.0) P/N. 345-72228-0 (ø3.0) Tachometer Compression Gauge P/N. 369-72217-0 (ø3.5) P/N. 369-72218-0 (ø3.5) P/N. 3AC-99030-0 P/N. 3AC-99010-0 Measuring engine revolution Measuring compression Removing spring pin Installing spring pin pressure speed...
  • Page 15 Service Information ø31.5 x ø25 x H32 Roller Bearing Attachment MX50:P/N. 3MC-99710-0 Driver Rod Center Plate Bevel Gear Nut Socket MWX50:P/N. 3LC-99710-0 P/N. 346-72232-0 P/N. 3AC-99702-0 P/N. 3AC-99701-0 Removing or attaching pinion Used in combination with center Removing or installing propeller Used in combination with driver rod and center plate (B) gear nut place and various attachments...
  • Page 16 Service Information Peak Voltage Adapter Spark Tester Backlash Measuring Tool Kit P/N. 3AC-99550-0 MWX50:P/N. 3A3-72255-0 P/N. 3F3-72540-0 Measuring backlash between pinion Inspecting spark Checking Peak Voltage* (B) gear and reverse (C) gear...

  • Page 17: Pre-Delivery Inspection

    Service Information 4. Pre-delivery Inspection å ∫ 1) Tiller Handle å Check installations for clattering and play. ∫ Adjust steering friction. ç Check throttle grip for movement. (full open/full close). ∂ Adjust throttle friction. ç ∂ 2) Gear Shift Shift into forward (F), back to neutral (N) and then shift into reverse (R) to check that the shift operations are smooth.

  • Page 18: Fuel And Fuel Line

    Raider additive into a six gallon into fuel tank. Use fuel mixed with oil. bladder. Fuel and oil mixing ratio is 50:1. For breaking period, 25:1 mixture shall be used. 5) Installation of Outboard Motor (Rigging) Check that outboard motor is fixed on the hull with Raider Transom plate.

  • Page 19: Propeller Selection

    Miss-selection of propeller can cause adverse effects on engine life, fuel consumption, etc. as well as on performance. 2 Pitch Propeller (No. of Blades x Diameter x Pitch) Raider 50 (3 x 12.0 x 9.0 3x305x229 in/mm (3 x 11.5 x 10.0) 3x292x254 (3 x 11.5 x 11.0)

  • Page 20: Trim Tab

    Service Information 7) Cooling Water Check Port Check that cooling water check port 1 discharges water during engine operation. 8) Trim Tab Adjustment of trim tab angle After installing outboard motor on the boat, use trim tab to achieve balance between port and starboard steering loads.
  • Page 21 Transom Plates: Transom plates are centered on the manufactured Rubber Inflatable Boat and fastened. This insures the motor is always centered even in high sea states or night time operations. When using dual or twin outboards the connecting pieces will always fit every time. The transom plates also feature a cutout to insure the motor stays in place even if the turnbuckle gets loose during a mission –...

  • Page 22: Break-In Operation

    After warming up the engine, read tachometer to check idling engine speeds specified below. Idling Speed :- Neutral 950 r/min Tachometer – on Raider (mounted) Shift gear into forward (F) and at idle slow for approximately 10 minutes. Trolling Speed :- Shift in...

  • Page 23: Service Data

    Service Data 1. Outboard Dimensions ..2-2 3. Specifications......2-8 1) Body dimensions ... 2-2 4. Maintenance Data ....2-12 2) Clamp Dimensions ..2-4 .. 2-16 5. Torque Specifications . 2-6 6. Sealant And Lubricant ..2-17 Cooling Water System Diagram...
  • Page 24 Raider 50 (R50ES-002) R50ES-002 Item Type Unit R50ES-002 mm/in 19.57 mm/in 36.06 Transom (L) mm/in 21.65 Transom (L) mm/in 22.36 mm/in 26.61 mm/in 3.35 mm/in 23.62 mm/in 20.47 mm/in 17.32 mm/in 31 70 1.22 2.76 mm/in 21.65 mm/in 38.31 Transom (L) mm/in 15.12...

  • Page 25: Clamp Dimensions

    Service Data 2) Clamp Dimensions - Front View Looking at Raider from inside RIB...

  • Page 29: Cooling Water System Diagram

    Service Data 2. Cooling Water System Diagram...
  • Page 31 Item Raider R50ES-002 Overall Length 1,143 mm inches) Overall Width 384 mm (15.12 inches) Overall Height: Short Shaft 1,225 mm (46.23 inches) Long Shaft 1,352 mm (53.23 inches) Transom Height: Short Shaft 403 mm (15.87 inches) Long Shaft 530 mm (20.87 inches)
  • Page 32 Emergency Tool Kit: (3) Spark Plugs; 10/13/16 mm sockets; screw driver – flat/Phillips; crescent wrench; Starter rope; pliers; adapter (screw driver adapter to sockets); split pin – storage container Recommended Spare Part Kits for each Raider R50-ES-002 outboard: Kit A – R50ES-002-SPKA Part Number...
  • Page 33 Option Safety Jet To Replace propeller with “pump jet” Part No. KR011. This transforms the Raider 50 to a pump jet using this kit. Used for: training purposes; brown water missions; areas of rocks/coral.

  • Page 34: Specifications

    Service Data 1. Ignition Timing Adjustment – Raider 50 Ignition Timing link (1) to specified length: 3.86 in. (98 mm) Ignition throttle link (2) – 4.53 in. (115 mm) 2. Place advancer arm (3) in the maximum speed position (wide open throttle) and make sure the carburetor throttle Is fully open.
  • Page 35 Throttle cam (4). 3. Adjust the length of each carburetor throttle link rod (5) To specification: Raider 50 – 3,54 inches (90 mm) 4. Reconnect timing link (1). 5. Turn all throttle lever screws (6) clockwise to loosen. 6. Loosen throttle stop- screw (7) on top carburetor so it does not Make contact with throttle lever (8).

  • Page 37: Maintenance Data

    Service Data 4. Maintenance Data ‚...
  • Page 38 Service Data...

  • Page 39: Torque Specifications

    Service Data 5. Torque Specification...

  • Page 40: Sealant And Lubricant

    6. Sealant And Lubricant...

  • Page 41: Fuel System

    Service Data Fuel System – Torque Values Carburetor Mounting Bold: 53 in-lb (5-6 N-m) Intake Manifold Bolt: 53 in-lb. (0.6 kg-m) Carburetor Specifications: Main Jet: #135 Main Air Jet: #230 Slow Jet: #74 Slow air jet: #130 Pilot Screw Turn – Out: 2 ¾ turn + ¾ turn Neutral Idle Speed Adjustment (RPM) 900 Trolling Speed Adjustment (RPM) 750...

  • Page 42: Maintenance

    Maintenance 1. Special Tool....3-2 .. 3-20 8) Inspection of Thermostat ..3-2 2. Inspection Schedule 9) Adjustment of Throttle Cable..3-22 3. Inspection Items ... 3-6 10) Ignition Timing Adjustment ..3-24 1) Inspection of Top Cowl ..3-6 11) Carburetor Synchronization..

  • Page 43: Special Tool

    Maintenance 1. Special Tool Tachometer Compression Gauge Spring Pin Tool A Spring Pin Tool B P/N. 345-72227-0 (ø3.0) P/N. 345-72228-0 (ø3.0) P/N. 3AC-99030-0 P/N. 3AC-99010-0 Measuring compression Measuring engine revolution Removing spring pin Installing spring pin pressure speed 2. Inspection Schedule...

  • Page 46: Inspection Items

    Maintenance 3. Inspection Items 1) Inspection of Top Cowl Push cover to check for play, and crack. 2) Inspection of Fuel Hose (Motor to Bladder) Hose contains bladder connection at end of Hose; insert the Connector into Bladder. 10 foot Fuel hose provided. Attached to each hose is connector to bladed (fuel tank).

  • Page 47: Fuel System

    Maintenance 3) Fuel System Inspection of Fuel Pipes Check the fuel system piping for fuel leak, dirt, deterioration and damage, and replace or clean parts if necessary. Inspection of Fuel Filter Check fuel filter 1 for contamination, and fuel filter cup 2 for invasion of foreign matter and cracks.

  • Page 48: Inspection Of Cooling Water Passage

    Maintenance 4) Inspection of Cooling Water Passage Check that cooling water intake is not clogged. Clean if necessary. Set lower unit in the water and start engine. Check that cooling water check port 1 ejects water. 5) Flushing with Water WARNING MX50 Be careful not to touch rotating propeller.
  • Page 49 Maintenance Flushing using drive cleaner (Commercially Available Item) Put drive cleaner 1 on the gear case from the front so that the drive cleaner covers cooling water inlet as shown. Put water hose to drive cleaner and run water. Adjust water flow so that water leaks from driver cleaner a little.

  • Page 50: Inspection Of Compression Pressure

    Maintenance Check following parts. 7 Bolts : M8 4 pcs. 8 Washers 4 pcs. 9 Pump Case (Upper) 0 Pump Case Liner ➝ Replace with new one. q Pump Impeller w Key ➝ Replace with new one. e Gasket r Guide Plate ➝...
  • Page 51 Maintenance Install compression gauge 2 to plug hole. Compression Gauge: P/N. 3AC-99030-0 Set throttle grip to full open position, crank engine until compression gauge indication stabilizes, and then measure compression pressure. Compression Pressure (Reference): 0.80 MPa (117 psi) [8.2 kgf/cm Different between compression pressure of each cylinders: within 0.105 MPa (15 psi) [1.05 kgf/cm...

  • Page 52: Inspection Of Spark Plugs

    Maintenance 7) Inspection of Spark Plugs Remove plug caps and then spark plugs. Clean spark plug electrodes 1 by using spark plug cleaner. 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 53: Inspection Of Thermostat

    Maintenance 8) Inspection of Thermostat Loosen cover installation bolts 1, remove them, and then remove cover 2 and thermostat 3. Hang thermostat 3 in the water contained in vessel. Put thermometer in the water, and warm up water to measure valve opening temperature. Put a piece of thread in the closed valve gap and hang it in the water.

  • Page 54: Adjustment Of Throttle Cable

    Maintenance 9) Adjustment of Throttle Cable Remove throttle cable 1 from throttle cable bracket 2. Temporally attach the left side cable to wire bracket, and adjust a nut so that advancer arm 3 contacts the stopper 4, when throttle fully opened. Temporally attach the right side cable to wire bracket, and adjust a nut so that the throttle to be fully closed position.

  • Page 55: Ignition Timing Adjustment

    Maintenance 10) Ignition Timing Adjustment Adjust ignition link and throttle link. a Ignition Timing Link : 101 mm (3.976 in) b Throttle Link : 115 mm (4.528 in) Measure the length from ball joint center to shaft center. Place advancer arm in the maximum speed position (wide open throttle) and make sure the carburetor throttle is fully open a.

  • Page 56: Carburetor Synchronization

    Maintenance Place advancer arm in the minimum speed position (throttle fully closed) and adjust low, speed side stopper so ignition timing matches the following specifications. Ignition Timing-Throttle closed : ATDC 3° 11) Carburetor Synchronization Remove the intake silencer cover. Disconnect ignition timing link 1 and throttle link 2 so throttle lever roller dose not make contact with throttle cam.
  • Page 57 Maintenance Turn the No.2 and No.3 throttle lever screws 4 clockwise to loosen the throttle butterfly valves. Loosen throttle stop screw 5 on top carburetor so it dose not make contact with throttle lever 6. All throttle butterfly valve should return to a fully closed position a. Tighten the No.2 and No.3 throttle lever screw 7 counterclockwise while pulling upward throttle link rod 8 on the carburetor.

  • Page 58: Pilot Screw Adjustment

    Maintenance Turn throttle stop screw 5 until it touches throttle lever 6 then tighten the screw to 2-1/2 turns. 12) Pilot screw adjustment At first, 2-3/4 turns out (loosen) the pilot screw 1 all of the carburetors from fully tighten. Start and run engine up to normal operating temperature with an tachometer installed.

  • Page 59: Replacement Of Gear Oil

    Maintenance 13) Replacement of Gear Oil Tilt outboard motor a little as shown. Place drain oil pan below oil plug 1, remove lower oil plug 1 and then upper oil plug 2 to drain oil. Remove lower oil plug first when draining. Check gear oil for presence of metal particles, change of color (abnormal if clouded), and viscosity.

  • Page 60: Inspection Of Gear Case (For Leakage)

    Maintenance 14) 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 case, and check if the pressure is maintained without further compression for 10 seconds.

  • Page 61: Replacement Of Anode

    Maintenance 16) Replacement of Anode Dirt on Anode and Trim Tab Check if grease or oil is adhered to the components. Clean if necessary. CAUTION Anode protects outboard motor from galvanic corrosion. Do not paint or apply grease or oil to anode. Doing so disables the anode.

  • Page 62: Greasing

    Maintenance 17) Greasing Apply grease to throttle cable and sliding areas. Apply grease to shift cam sliding areas. Inject grease through grease nipple 1 until excessive grease appears from a. Apply grease to 2 thread of clamp screws. 3-38 2st X50D2 2011...
  • Page 63 Maintenance Apply grease to throttle cable b and sliding areas. c Do not lubricate here. Apply grease to seal ring and bushing 3 of hook lever. Apply grease to propeller shaft spline 4. 3-40 2st X50D2 2011...

  • Page 64: Fuel System

    Fuel System ....4-2 1. Special Tools 2) Disassembling Carburetors ..4-20 .. 4-4 2. Parts Layout ......3) Cleaning and Inspection ....4-22 Fuel line ..........4-4 4) Inspection of Fuel Pump and .. 4-6 Needle Valve ..... 4-24 Intake Silencer •...

  • Page 65: Special Tools

    Fuel System 1. Special Tools Vacuum Pressure gauge P/N. 3AC-99020-1 Inspecting pressure...

  • Page 66: Parts Layout

    Fuel System 2. Parts Layout P/L Fig.5 Fuel line Ref. No. Description Remarks Q'ty Fuel Filter Ass'y O-Ring Do not reuse. Filter Washer Hose Hose Clip Bracket 10 Bolt 2st 50D2 2011...

  • Page 67: Intake Silencer • Carburetor

    Fuel System P/L Fig. 4 Intake Silencer • Carburetor 1342 1342 1342 1342 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Bolt 5-16 16 Adjust Screw Gasket Seal Rubber 17 Float Chamber 2 Upper, Center X 2 Do not reuse. Intake Silencer Cover 18 Float Chamber Gasket O-Ring...
  • Page 68 45 Choke Rod 3-90 Do not reuse. 36 Bolt 46 Intake Silencer 37 Spring Washer 47 Rod Snap 3-B 38 Washer 48 Intake Silencer Lock Plate 39 Hose 2 98AB-501000 49 Choke Rod 40 Clip ø10 50 Rod Snap 3-B 2st 50D2 2011...

  • Page 69: Carburetor Inner Passages

    Fuel System 3. Carburetor Inner Passages 1) Idling Passage å ∫ a - Air intake h - Fuel inlet b - Air-bleed inlet i - Main jet c - Slow air jet j - Slow jet d - Bypass port k - Choke valve e - Pilot screw å...

  • Page 70: Off-Idle Passage

    Fuel System 2) Off-Idle Passage å ∫ a - Air intake h - Fuel inlet b - Air-bleed inlet i - Main jet c - Slow air jet j - Slow jet d - Bypass port k - Choke valve e - Pilot screw å...

  • Page 71: High Speed Passage

    Fuel System 3) High Speed Passage å ∫ a - Air intake h - Fuel inlet b - Air-bleed inlet i - Main jet c - Slow air jet j - Slow jet d - Bypass port k - Choke valve e - Pilot screw å...

  • Page 72: Choking Passage (#2 And #3 Carburetor)

    Fuel System 4) Choking Passage (#2 and #3 carburetor) å ∫ a - Air intake h - Fuel inlet b - Air-bleed inlet i - Main jet c - Slow air jet j - Slow jet d - Bypass port k - Choke valve e - Pilot screw å...

  • Page 73: Inspection Items

    Fuel System 4. Inspection Items 1) Removing Carburetors WARNING Before working on fuel system, make sure to disconnect stop switch lanyard, electric sparks can occur, possibly igniting fuel or making fuel to explode. CAUTION To prevent fuel from dripping on the floor, use a vessel to catch the fuel.

  • Page 74: Disassembling Carburetors

    Fuel System 2) Disassembling Carburetors CAUTION To prevent fuel from dripping on the floor, use a vessel to catch the fuel. Remove float chamber 1. Remove carburetor cover 2. Remove float ass'y 3. Remove main jet 4, main nozzle 5 and slow jet 6. 4-20 2st 50D2 2011...

  • Page 75: Cleaning And Inspection

    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 main jet 1, main nozzle 2 and slow jet 3.

  • Page 76: Inspection Of Fuel Pump And Needle Valve

    Fuel System 4) Inspection of Fuel Pump and Needle Valve Connect vinyl hose 1 to inlet of fuel pump. Place carburetor body upside down to shut off needle valve. Apply pressure, and check if the pressure is maintained for 10 seconds. Disassemble and inspection if necessary. Vacuum Pressure Gauge P/N.

  • Page 77: Assembly Of Fuel Pump

    Fuel System 6) Assembly of Fuel Pump To achieve higher tightness of gasket, wet interior of fuel pump with small amount of gasoline. Attach check valves 1 as shown illustration. Locate cutaway part of check valve toward a. Attach new gasket and assemble fuel pump body using screws (4).

  • Page 78: Assembling Carburetors

    Fuel System 9) Assembling Carburetors Install slow jet 1, main nozzle 2, main jet 3 and rubber plug 4. Attach needle valve 5 to float hinge 6. Attach float ass’y with float arm pin 7 and secure with screw 4-28 2st 50D2 2011...

  • Page 79: Installing Carburetors

    Fuel System 10) Adjusting Float Height Measure float height as shown, and replace float if out of specification. Float Height a : 14.5 1mm 0.571 0.039in Install drain screw, float chamber 1 and cover 2. CAUTION Do not adjust float height by knotting the fishing line, etc.

  • Page 80: Power Unit

    Removing Cylinder Head / Head Cover 10) Inspection of Cylinder Head ... 5-48 34) Inspection of Recoil Starter ... 5-98 11) Removing Exhaust Cover ..5-50 35) Assembling of Recoil Starter ... 5-98 12) Inspection of Exhaust Cover ... 5-50...

  • Page 81: Special Tools

    Power Unit 1. Special tools 3T1-72781-0 3B7-72785-0 3B7-72783-0 3C7-72783-0 940191-0800 3B7-72784-0 Flywheel Puller Kit Piston Pin Tool Eye Bolt (Powerhead Lift Ring) P/N. 3T9-72212-0 P/N. 3T1-72211-0 P/N. 345-72215-0 Used to hook power unit when Removing or attaching flywheel Removing piston pin hanging Piston Ring Tool Universal Puller Plate...

  • Page 82: Parts Layout

    Power Unit 2. Parts Layout Engine Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty Power Unit Bolt Recoil Starter Assembly Washer Bolt Apron Washer 10 Seal Engine Basement Gasket 11 Screw Do not reuse. Dowel Pin 12 Nylon Nut 1 (5-P0.8)

  • Page 83: Magneto

    Power Unit Magneto P/L Fig. 8 1342 1342 1342 1 342 Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty Flywheel W/Ring Gear 1 F4T405-72 12 Band Coil Plate Ass'y W/Alternator 13 Screw Pulsar Coil & Plate Ass'y 14 Key Pulsar Holder 15 Nut 18-P1.5 Exciter Coil 16 Washer 19-34-3...

  • Page 84: Electric Parts

    Power Unit Electric Parts P/L Fig. 10 Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty Ignition Coil Ass'y W/Label 1 F6T530 13 Bracket Plug Cap 14 Cover Caution Decal (B) 15 Screw Ignition Coil W-Cap 2 F6T530 16 Mount 8.5-14-2.5 Band 17 Rubber Mount 8.5-14-2.5 Plug Cap Terminal...

  • Page 85: Recoil Starter

    Power Unit Recoil Starter P/L Fig. 7 1342 1342 1342 1 342 Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty Recoil Starter Ass'y 11 Sliding Plate Reel Ass'y 12 C-Ring Ratchet 13 Bolt Starter Spring 14 Starter Rope ø6-2250 Friction Spring 15 Starter Handle Return Spring 16 Rope Anchor...
  • Page 86 Power Unit P/L Fig. 7 1342 1342 1342 1 342 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 21 Washer 31 Starter Seal 22 Split Pin 32 Protector 23 Starter Lock Wire 33 Band 24 Cable Holder 34 Starter Pulley 25 Screw 35 Bolt 26 Pipe...

  • Page 87: Intake Manifold · Reed Valve

    Power Unit Intake Manifold · Reed Valve P/L Fig. 3 Ref. No. Description Remarks Q'ty Intake Manifold Ass'y Intake Manifold Gasket Do not reuse. Bolt Bolt Clamp 6.5-47.5P Hose 1 98AB-501000 Hose 1 98AB-501000 Clip ø10 Reed Valve Ass'y 10 Screw 5-14 2st X50D2 2011...

  • Page 88: Throttle

    Power Unit Throttle P/L Fig. 6 Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty Advancer Arm 12 Collar 6.5-10.5-26.3 Bolt 13 Ball Joint Washer 6.5-21-1 14 Rod 5-90 Collar 6.2-12-17 15 Ball Joint Connector Rod Snap 5-3 16 Throttle Rod 5-105 Throttle Cam 17 Ball Joint Connector Spring...
  • Page 89 Power Unit P/L Fig. 6 Ref. No. Description Remarks Q'ty 23 Collar 6.2-9-9.3 24 Throttle Limiter Rod 3.5-56 25 Rod Snap 3.5-4 26 Throttle Limiter Rod 3.5-56 27 Rod Snap 3.5-4 28 Starter Lock Arm 29 Bolt 30 Washer 31 Collar 6.2-9-9.3 5-18 2st X50D2 2011...
  • Page 90 32 Gasket 8.1-15-1 Do not reuse. 48 Nut 33 Anode 49 Engine Basement Gasket 34 Bolt Do not reuse. 50 Crankcase Head 35 Cover 51 O-Ring 1.7-59 36 Gasket Do not reuse. Do not reuse. 52 Oil Seal 25-40-8 37 Bolt Do not reuse.

  • Page 91: Piston & Crank Shaft

    Power Unit Piston & Crank Shaft P/L Fig. 2 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty Crankshaft Ass'y W/Gear Piston Ring (0.5 O/S) 3 OPT 2nd Main Bearing 6305...

  • Page 92: Inspection Items

    Power Unit 3. Inspection Items 1) Removing Power Unit Remove recoil starter. Disconnect starter lock cable 1. Remove throttle cable 2, and shift link rod 3. Remove electric box cover and disconnect stop switch wire 4. Disconnect ground wire 5 from bottom cowl. 5-26 2st X50D2 2011...
  • Page 93 Power Unit Disconnect cooling water hose 6 (exhaust cover - water check port) Disconnect fuel hose 7 from fuel filter (fuel connector - fuel filter) Remove choke rod 8. Remove apron 9 and loosen engine mount bolts, then remove them. Carefully pry power unit by using steel pipe 0 to remove power unit.
  • Page 94 Power Unit 10. Loosen starter pully mounting bolts, and then remove starter pully q. 11. Hoist power unit by using eye bolt w. Eye Bolt : P/N. 3T9-72212-0 · Turn the flywheel to adjust, in order for installation position a of the eyebolt to be center.

  • Page 95: Removing Flywheel

    Power Unit 2) Removing Flywheel Attach flywheel puller kit 1 to flywheel. CAUTION Use 25mm bolts 2 for removing. Otherwise coil may be damaged and can short. Fly Wheel Puller Kit 1 : N. 3T1-72211-0 Loosen flywheel nut and remove it. Remove flywheel by using pressing bolt 3.

  • Page 96: Removing Throttle Link

    Power Unit Remove all spark plug caps, ignition coils 2 and ground wires. Disconnect ground wire 3 and CD unit 4, then remove electrical box 5. 4) Removing Throttle Link Remove throttle link rod 1, 2. · Remove each link rod at the rod snap side a first.
  • Page 97 Power Unit Disassemble advancer lever if necessary. Check spring 5 for wear and damage. Remove coil bracket plate 6 mounting bolt and remove them. 5-36 2st X50D2 2011...

  • Page 98: Removing Intake Silencer And Carburetors

    Power Unit 5) Removing Intake Silencer and Carburetors Remove intake silencer cover and loosen mounting bolts, then remove intake silencer 1. · Pry the tab a of lock plate as shown. · When reuse intake silencer mounting bolts, apply Three Bond’s thread lock # 1342. *Do not reuse lock plate.

  • Page 99: Removing Intake Manifold And Reed Valves

    Power Unit 6) Removing Intake Manifold and Reed valves Loosen intake manifold mounting bolts and remove intake manifold 1 in the order shown. Loosen reed valve mounting screws, remove them, and remove reed valve ass’y 2. 7) Inspection of Reed Valve Ass’y Check reed valve and valve seat surface for bend, wear and damage.

  • Page 100: Removing Thermostat And Engine Anode

    Power Unit 8) Removing Thermostat and Engine Anode Loosen thermostat cap mounting bolts 2, remove them, remove cap 1 , and take out thermostat 3. If thermostat cap is seized, tap lightly using a plastic hammer and then remove. 5-42 2st X50D2 2011...
  • Page 101 Power Unit Inspection of Thermostat 1) Put thermostat 3 in the vessel containing water, heat it, and measure the temperature at which the thermostat starts to open. Valve Opening Temperature : 58.5 - 61.5˚C (136.5 - 143.5˚F) Valve Full Open Temperature : 73.5 - 76.5˚C (163.5 - 170.5˚F) Replace thermostat if the valve is open even a little at ambient temperature.

  • Page 102: Removing Cylinder Head / Head Cover

    Power Unit 9) Removing Cylinder Head / Head Cover Loosen cylinder head / head cover mounting bolts in the order shown, remove them, and remove cylinder head / head cover. When loosening M8 bolts, loosen in descending order of the numbers shown embossed on the head cover.

  • Page 103: Inspection Of Cylinder Head

    Power Unit 10) Inspection of Cylinder Head Remove carbon deposit in the combustion chamber of cylinder head, and check the interior for degradation, damage and other defects. Check water jacket interior for deposits. When cleaning mating surfaces of cylinder head by using a means such as a scraper or wire brush, be careful not to scratch the surfaces.

  • Page 104: Removing Exhaust Cover

    12) Inspection of Exhaust Cover Check the removed outer exhaust cover and inner exhaust cover for damages such as distortion or scratches on their mating surface Remove clogs and debris from cooling water passage of exhaust cover. 5-50 2st X50D2 2011...

  • Page 105: Removing Crank Case

    Power Unit 13) Removing Crank Case Remove shift arm, starter motor bracket and disconnect recirculation hoses. Loosen crank case mounting bolts in the order shown, remove them, and remove crank case. When removing crank case, pry the gap at the groove of crank case by using a bladed screw driver.

  • Page 106: Removing Pistons

    Power Unit 14) Removing Pistons CAUTION Make sure that the piston, piston pin and needle bearing their original combination. Remove piston pin clip by using a pair of pointed nose pliers. Remove another piston pin clip. Be careful not to damage the piston pin hole.

  • Page 107: Disassembly Of Crank Shaft

    Power Unit 15) Disassembly of Crank Shaft Remove "C" ring 1 and pull out washer 2. Remove main bearing (lower) 3 by using universal puller plate and universal puller. Universal Puller Plate 4 : 3AC-99750-0 Puller 5 : Commercially Available Item Protecting Plate 6 : 16) Inspection of Crank Shaft Visually check crank shaft ass’y upper and lower end...
  • Page 108 Power Unit · Check if that main bearing rotates smoothly. Replace crank shaft ass’y if necessary. · Measure crank shaft deflection. Replace crank shaft if the deflection is over the specified value. Dial Gauge 1 : Commercially Available Item V Block 2 : Commercially Available Item Crank Shaft Deflection Limit : 0.05 mm (0.0020 in) Replace crank shaft ass’y if the deflection is over the...

  • Page 109: Inspection Of Engine Parts

    Cylinder Inner Diameters (D ) : Standard Value 68.00 mm (2.677 in) Oversize Piston : 68.50 mm (2.697 in) Functional Limit : 68.06 mm (2.68 in) Oversize Piston : 68.56 mm (2.699 in) ·...

  • Page 110: Inspection Of Pistons

    Power Unit 18) Inspection of Pistons Inspection of Piston Outer Diameter Measure piston outer diameter, and replace the piston if the outer diameter is less than the functional Limit. Measurement Point b : 12 mm (0.47 in) above bottom end of piston skirt. approximately 90 degrees from pin hole.
  • Page 111 Power Unit Inspection of Piston Ring Side Clearance 1) Attach a piston ring to piston, and measure piston ring side clearance. Replace piston ring if the clearance is over specified value. Piston Ring Tool : P/N. 353-72249-0 Piston Ring Side Clearance : Standard Value : Top Ring 0.04 - 0.08 mm...
  • Page 112 Power Unit Inspection of Piston Pins Measure piston pin outer diameter, and replace piston pin if the outer diameter is over the limit. Piston Pin Outer Diameter : Standard Value 17.55 mm (0.6909 in) Functional Limit : 22.97 mm (0.9045 in) Measuring Locations : and D 10 mm (0.394 in) from top end...

  • Page 113: Assembling Crank Shaft

    Power Unit 19) Assembling Crank Shaft Press-fitting Bearing 1) Insert a holding bar a in between crank webs and press-fit bearing 1. Bearing Press-Fitting Tool 2 : Inner Diameter : ø30 mm (1.181 in) Do not reuse removed bearing. 2st OIL 2st OIL 5-68 2st X50D2 2...

  • Page 114: Installing Needle Bearing And Pistons

    Power Unit 20) Installing Needle Bearing and Pistons CAUTION Make sure that the piston, piston pin and needle bearing their original combination. Installation of Piston Rings Complete 2nd piston first. When attaching a piston ring, face the side of the ring marked with "T"...
  • Page 115 Power Unit 2) Insert special tool 3 with needle bearing, and then insert remaining needle bearing. Then attach washers 4 to both side. · When assemble, attach two washers opposite side, for easy and even insert needle bearing. · After insert needle bearing, re-attach washer to both side.

  • Page 116: Assembling Power Unit Parts

    Power Unit 3) Fit piston pin clip 7 as shown. CAUTION Take care not to scratch to piston wall, when fit piston pin clip. Set the piston pin clip so that the gap of the clip is at the opposite side of the opening a located in the piston pin clip groove.

  • Page 117: Assembling Crank Ass'y And Crank Case

    Power Unit Positioning bearing Put the pin a of bearing (lower) on the cylinder. Face the pin of ball bearing of all, to upward. Rise crankshaft lightly, and then turn bearing to fit the pin in the cylinder grooves b. Positioning Bearing ·...

  • Page 118: Assembling Exhaust Cover Parts

    Power Unit Install crank case to cylinder. Before securing with bolts, fit crank case snugly to the cylinder by tapping with a plastic hammer not to make the gap between crank case and cylinder. Tighten crank case securing bolts and nuts (M8) in the order of the numbers shown.

  • Page 119: Assembling Cylinder Head Parts

    Power Unit 24) Assembling Cylinder Head Parts Attach dowel pins 1 to cylinder, and then attach gaskets, cylinder head and cylinder head cover. Tighten cylinder head cover securing bolts (M6) in the order of the numbers shown. Temporary Tightening : 6 N ·...

  • Page 120: Assembling Coil Bracket Parts

    Power Unit 25) Assembling Coil Bracket Parts Apply grease to sliding surface of coil bracket 1, guide plate 2 and bushing 3 surface, before installing. 26) Assembling Crank Case Head Parts Circumference Apply grease and oil to oil seal 1 16-28-7 and press-fit it 2st OIL to crank case head by using suitable press 2.

  • Page 121: Installing Reed Valve, Intake Manifold And Intake Silencer

    Power Unit 27) Installing Reed Valve, Intake Manifold and Intake Silencer. Attach reed valve, intake manifold and gaskets to crank case. Attach and tighten securing bolts specified torque in the order of the numbers shown. Bolts 1342 1342 9 N · m (7 lb · ft) [0.9 kgf · m] 1342 1342 ·...
  • Page 122 Power Unit Attach intake silencer 1 and lock plate 2, then tighten bolts to specified torque. Intake Silencer Bolts : 6 N · m (4 lb · ft) [0.6 kgf · m] · When reuse intake silencer mounting bolts, apply ThreeBond’s thread lock # 1342. ·...

  • Page 123: Attaching Recirculation Hoses

    Power Unit 28) Attaching Recirculation Hoses … † € … † € ‚ ‚ ƒ„ 5-88 2st X50D2 2011...

  • Page 124: Installing Throttle Link

    Power Unit 29) Installing Throttle Link Assembling advancer lever. Align spring 1 and slot of the advancer lever 2, and turnover the stopper a to install as shown. Apply grease to advancer lever spring and collar. Attach starter motor bracket 3, and tighten the nut to specified torque.

  • Page 125: Installing Electric Parts

    Power Unit 30) Installing Electric Parts As for the installation of the following part, refer to the step of their removal. • Ground wire • Electric box • Starter lock cable • CD unit • Ignition coil and ground wire •...

  • Page 126: Installing Power Unit

    Power Unit 32) Installing Power Unit Attach O ring 1 coated with two stroke engine oil to crank case head 2. 2st OIL Attach crank case head to cylinder ass’y taking care of the orientation. Install crank case head so that the mark "A" is at front side (crank case side) of engine.

  • Page 127: Disassembly Of Recoil Starter

    Power Unit 33) Disassembly of Recoil Starter Loosen screw and disconnect starter lock cable 1 (upper). Remove bolts, and then, remove recoil starter. Put rope 2 in the groove a of reel 3 and gently turn reel clockwise to release tension of starter spring. CAUTION Wear the glove to protect your hands.

  • Page 128: Inspection Of Recoil Starter

    Power Unit 34) Inspection of Recoil Starter Check ratchet, starter lock and all springs. Replace if any deformation, wear or damage is found. Check reel and starter case. Replace if any crack or damage is found. Check starter rope. Replace if any wear, unraveling or damage is found.
  • Page 129 Power Unit ●When attaching reel to starter case, put starter spring inner end hook c in the notch d of reel. ●Apply cold resistance lithium grease to the following parts. · Starter Spring · Reel Center Hole · Ratchet · Starter Lock ·...

  • Page 130: Lower Unit

    Lower Unit 1. Special Tools ....6-2 18) Assembly of Propeller Shaft Ass’y 6-50 2. Parts Layout ......6-6 19) Removing Drive Shaft Ass’y ... 6-52 20) Disassembly of Drive Shaft Ass’y . 6-54 Gear Case (Drive Shaft, MX50)..6-6 Gear Case (Drive Shaft, MWX50)...

  • Page 131: Special Tools

    Lower Unit 1. Special tools Spring Pin Tool A Spring Pin Tool B P/N. 345-72227-0 (ø3.0) P/N. 345-72228-0 (ø3.0) Driver Rod Propeller Shaft Housing Puller Ass'y P/N. 369-72217-0 (ø3.5) P/N. 369-72218-0 (ø3.5) P/N. 3A3-72259-0 P/N. 3AC-99702-0 Removing propeller shaft Used in combination with center Removing spring pin Installing spring pin housing...
  • Page 132 Lower Unit Shimming Gauge MX50:P/N. 3C8-72250-0 Thickness Gauge Backlash Measuring Tool Kit Backlash Measuring Tool Kit MWX50:P/N. 353-72250-0 P/N. 353-72251-0 MX50:P/N. 3C8-72234-1 MWX50:P/N. 3B7-72234-0 Used to attach dial gauge Adjusting pinion (B) gear Measuring backlash between forward Measuring gaps height when measuring backlash (A) gear and pinion (B) gear Dial Gauge Plate...

  • Page 133: Parts Layout

    Lower Unit P/L Fig. 14 2. Parts Layout Gear Case (Drive Shaft, MX50) GEAR GEAR GEAR GEAR GEAR G1 7 GEAR 1342 G1 7 1342 GEAR GEAR 1342 1342 1342 1342 1342 1342 Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty 1-1 Gear Case Ass'y 14 Nut...
  • Page 134 Do not reuse. 33 Drive Shaft Spring 48 Guide Plate Gasket Do not reuse. 34 Water Strainer Set 1 MX50D2 49 Pump Case Gasket Do not reuse. 35 Screw 50 Bolt 36 Nylon Nut 4-P0.7 51 Sub-Water Inlet Strainer 2st 50D2 2011...
  • Page 135 Lower Unit P/L Fig. 14 GEAR GEAR GEAR GEAR GEAR G1 7 GEAR 1342 G1 7 1342 GEAR GEAR 1342 1342 1342 1342 1342 1342 Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty 52 Bolt 65 Bolt 53 Push Rod Water Pipe (S) MX50D2 for Transom "S", 66-1...
  • Page 136 Lower Unit P/L Fig. 14 GEAR GEAR GEAR GEAR GEAR G1 7 GEAR 1342 G1 7 1342 GEAR GEAR 1342 1342 1342 1342 1342 1342 Ref. No. Description Remarks Q'ty 71 Thrust Holder 72 Stopper 73 Propeller Nut 74 Washer 17-32-3 75 Split Pin 3-25 6-12 2st 50D2 2011...

  • Page 137: Gear Case (Drive Shaft, Mwx50)

    15 Pump Case (Lower) Do not reuse. Bevel Gear B 16 Shim 36.9-30-0.5 Nut (Bevel Gear B) 17 Oil Seal 22-37-8 Do not reuse. Shim 44-50.5-0.1 18 O-Ring 3.2-47 Do not reuse. Shim 44-50.5-0.15 19 Dowel Pin 4-10 Selection if necessary Shim 44-50.5-0.3...
  • Page 138 Lower Unit P/L Fig. 15 GEAR GEAR 1342 GEAR GEAR 1342 GEAR GEAR GEAR GEAR 1342 1342 1342 1342 1342 1342 Ref. No. Description Remarks Q'ty 29 Spring Pin 3.5-14 Do not reuse. 30 Spring Pin 3.5-10 Do not reuse. 31 Cam Rod Bushing 32 O-Ring 1.9-6.8 Do not reuse.
  • Page 139 Lower Unit P/L Fig. 16 Gear Case (Propeller Shaft, MWX50) 1342 1342 1342 1342 Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty 14 Spring Retainer Tapered Roller Bearing 32007JR Do not reuse. 15 Spring Trim Tab 16 Snap Trim Tab Gasket Do not reuse.
  • Page 140 Lower Unit P/L Fig. 16 1342 1342 1342 1342 Ref. No. Description Remarks Q'ty Propeller Ass'y 16.5" 1 3 X 273 X 417 22-8 Propeller Ass'y 17.5" 1 3 X 276 X 447 22-9 23 Thrust Holder 24 Stopper 6-20 2st 50D2 2011...

  • Page 141: Inspection Items

    Lower Unit 3. Inspection Items 1) Draining Gear Oil Drain gear oil. Refer to “Replacement of Gear Oil” in Chapter 3. · Drain all gear oil, and check if any metal particle is found in the drained oil. · Check gear oil color. White or cream color possibly indicates that water is contained in the gear oil.

  • Page 142: Removing Lower Unit

    Lower Unit 3) Removing Lower Unit WARNING When working with outboard motor in tilt up position, be sure to lock with tilt stopper. · Removal of lower unit does not require removal of power unit from outboard motor body. · When removing lower unit from outboard motor, tilting the outboard motor makes the work easier.

  • Page 143: Inspection Of Clutch Cam

    Lower Unit 4) Disassembly of Cam Rod Remove stopper, pull out cam rod bushing, and take out cam rod from gear case. When removing cam rod bushing, put a bladed screw driver into groove of the bushing and pull out while lifting it. Remove shift rod joint 1 and clutch cam 2.

  • Page 144: Assembly Of Clutch Cam Parts

    Lower Unit 6) Assembly of Clutch Cam Parts Attach O rings 1.9-6.8 2 and O ring 3.5-27.7 3 to cam rod bushing 1. GEAR GEAR GEAR GEAR GEAR GEAR 23 O Rings Do not reuse. Attach cam rod bushing 1, shift rod joint 5 and clutch cam 6 to cam rod 4.

  • Page 145: Removing Water Pump

    Lower Unit 7) Removing Water Pump Loosen and remove pump case (upper) bolts, and remove pump case (upper) parts 1, 2, 3 and 4 in this order. Remove water pump impeller key 5. Remove guide plate 6, gasket 7 and pump case (lower) When removing pump case (lower), insert bladed screw driver into the groove of the case, and pry slowly to separate the part.

  • Page 146: Inspection Of Water Pipe

    Lower Unit 8) Inspection of Water Pump Check pump case liner 1 and guide plate 2 for deformation and wear. Replace if necessary. Check pump impeller 3 for crack, damage and wear. Replace if necessary. · The impeller may show gloss or have melted area if it is rotated with insufficient water.

  • Page 147: Disassembly Of Water Pump Case (Lower)

    Lower Unit 10) Disassembly of Water Pump Case (Lower) Use bladed screw driver or seal remover to remove oil seal 1. · Two oil seals are used. Note that there is a shim in between oil seals. · Be careful not to give flaw to oil seal press fit face.

  • Page 148: Removing Propeller Shaft Housing Ass'y

    Lower Unit 12) Removing Propeller Shaft Housing Ass’y Loosen and remove bolts 1. Use propeller shaft housing puller to pull out propeller shaft housing to the position where O ring of the housing can be removed. Propeller Shaft Housing Puller Ass’y 2 : P/N.

  • Page 149: Disassembly Of Propeller Shaft Housing Ass'y

    Lower Unit 13) Disassembly of Propeller Shaft Housing Ass’y Pull out propeller shaft ass’y 1. Remove reverse (C) gear 2 by using bladed screw drivers 3. Check oil seal 4 for wear and crack. Replace if necessary. Remove bearing 5. CAUTION Heat propeller shaft housing by putting it in the hot water of approximately 60 - 70˚C...
  • Page 150 Lower Unit Use a press to remove oil seal 4 and roller bearing 6 at the same time. · Before removing, check bearing for play or deflection. Replace if necessary. · Direct the side of attachment without O-ring to roller bearing. 4 Oil Seal Do not reuse.
  • Page 151 Lower Unit 14) Inspection of Propeller Shaft Housing Clean the part by using a solvent and then check. Replace if necessary. Check reverse (C) gear for crack or abnormal wear of the teeth and dog. Replace if necessary. Check bearing for abnormality. Replace if necessary.
  • Page 152 Lower Unit Install oil seal 5. Use a suitable press 6 to install new oil seal to propeller shaft housing. · Install oil seal with the marking facing tool side. · Clean oil seal installation face and apply gear oil before installation.
  • Page 153 Lower Unit Attach shim 0 used on the reverse (C) gear 9 to the gear. GEAR Use a suitable press to install reverse (C) gear 9. GEAR Clean reverse (C) gear bearing installation face and apply gear oil before installation. Bevel Gear Bearing Install Tool q : P/N.

  • Page 154: Inspection Of Propeller Shaft Ass'y

    Lower Unit Pull out clutch pin 4, and remove clutch spring retainer 5, clutch spring 6, and clutch by referring to the figure. WARNING · When removing clutch pin, wear protective glasses, and do not point opening of propeller shaft to your face or body while holding the propeller shaft.

  • Page 155: Assembly Of Propeller Shaft Ass'y

    After assembling, check that clutch can be operated smoothly, taking care not to allow push rod to drop out. 3 Clutch Pin Snap Do not reuse. 6-50 2st 50D2 2011...

  • Page 156: Removing Drive Shaft Ass'y

    Lower Unit 19) Removing Drive Shaft Ass’y Remove pinion (B) gear nut 4, and then, remove pinion (B) gear 3 and drive shaft. · Degrease pinion (B) gear nut completely so that the nut wrench does not slip on the nut. ·...

  • Page 157: Disassembly Of Drive Shaft Ass'y

    Lower Unit 20) Disassembly of Drive Shaft Ass’y Remove outer shim 1. Remove drive shaft spring 2. Remove ball bearings 3 by using press and universal puller 4. CAUTION Do not reuse removed bearing. Be sure to replace with new one. ·...

  • Page 159: Assembly Of Drive Shaft Parts

    Lower Unit 23) Assembly of Drive Shaft Parts Attach pinion (B) gear nut 1 to drive shaft temporarily. Install bearing 2 by using press and a suitable pipe 3. Before installing bearing, be sure to clean drive shaft installation face and apply gear oil. CAUTION Do not press drive shaft thread a directly.
  • Page 161 Lower Unit Install another ball bearing 4 by using press and a suitable pipe 3. Before installing bearing, be sure to clean drive shaft installation face and apply gear oil. CAUTION Do not press drive shaft thread a directly. Put a piece of protector (steel plate) on the tip of the shaft.

  • Page 163: Removing Forward (A) Gear Ass'y

    Lower Unit 24) Removing Forward (A) Gear Ass’y Take out bearing 1 and forward (A) gear 2 by using a hand put in the gear case. · Put mid finger into forward (A) gear hole and take it between the finger and the first finger (thumb), and lift the thumb side of the gear to remove it.

  • Page 165: Inspection Of Forward (A) Gear

    Lower Unit MWX50 only Remove roller bearing 4. Drive out roller bearing from the gear by using a bladed screw driver or a punch and a hammer at teeth side of the gear. CAUTION · When removing roller bearing, take care not to scratch forward (A) gear bearing face.
  • Page 167 Lower Unit Attach shim 4 used before disassembly to taper roller bearing 5, and press-fit the part. Apply gear oil to press-fit face when press-fitting taper roller bearing. Bevel Gear Bearing Install Tool 3 : P/N. 3C8-72719-0 GEAR GEAR GEAR GEAR 6-64 2st 50D2 2011...

  • Page 169: Disassembly Of Gear Case

    Lower Unit 28) Disassembly of Gear Case Remove roller bearing 1 by using the following tools. Align following marks of the press guide 2 and installation hole of the pump case front-right side, then attach press guide. MWX50 MX50 1 Roller Bearing 1 Roller Bearing Do not reuse.

  • Page 170: Inspection Of Gear Case

    Lower Unit This work can be done also by using the following tool kit. MX50 MWX50 Roller Bearing Puller Kit : Roller Bearing Puller Kit : P/N. 3C8-72700-0 P/N. 3B7-72700-0 Remove taper roller bearing outer race w. Put the slide hammer in the gear case, hook claw of slide hammer on the outer race to fix it, and slide the hammer to pull out the outer race.

  • Page 172: Assembly Of Gear Case Parts

    Lower Unit 30) Assembly of Gear Case Parts CAUTION When gear case, forward (A) gear or bearing is replaced, measure backlash and attach a proper shim. Refer to “Chapter 6 Shim Adjustment”. Use the following tools to install taper roller bearing 1 outer race.
  • Page 174 Lower Unit Install roller bearing 7 by using the following tools. CAUTION Install bearing so that marked side faces upward. · Align following marks of the press guide 8 and installation hole of the pump case front-right side, then attach press guide. ·...
  • Page 176 Lower Unit MWX50 Roller Bearing Press Kit : P/N. 3LC-72900-0 Bearing Outer Press Guide 8 : P/N. 3T1-72765-0 Roller Bearing Press Rod 9 : P/N. 3LC-72767-0 Roller Bearing Press 0 : P/N. 3S7-72770-0 O Ring q : P/N. 6H6-07422-0 Washer M8 w : P/N.

  • Page 178: And Shim Selection

    Lower Unit 31) Measurement of Pinion (B) Gear Height and Shim Selection CAUTION When gear case, drive shaft or pump case (lower) is replaced, measure pinion (B) bear height and back lash between gears, and perform shim adjustment. Before measuring back lash of each gear, measure drive shaft pinion (B) gear height and adjust the height to proper value if necessary.
  • Page 180 Lower Unit MX50 MWX50 Shimming Gauge 3 : Shimming Gauge 3 : P/N. 3C8-72250-0 P/N. 353-72250-0 Thickness Gauge : Thickness Gauge : P/N. 353-72251-0 P/N. 353-72251-0 Add shim 6 to bottom of b pump case (lower) to adjust the gap a to specified value. MX50 MWX50 Pinion (B) Gear Height a :...
  • Page 182 Lower Unit 32) Measurement of Back Lash between Forward (A) and Pinion (B) Gears and Shim Selection CAUTION Before measuring backlash between forward (A) and pinion (B) gears, measure pinion (B) gear height. Refer to “Measurement of Pinion (B) Gear Height and Shim Selection”...
  • Page 184 Lower Unit Install backlash measuring tool parts 2 to 7 and secure them with installation bolts (M8 L=30mm) 8. MX50 MWX50 Dial Gauge Plate 1 : Dial Gauge Plate 1 : P/N. 3B7-72729-0 P/N. 3B7-72729-0 Backlash Measuring Tool Kit : Backlash Measuring Tool Kit : P/N.
  • Page 185 Lower Unit Attach backlash measuring tool clamp w to drive shaft. Turn drive shaft 9 clockwise / counterclockwise slowly while pulling it up, and read change of dial gauge e indication. · When measuring, contact dial gauge tip to inside of V groove located in the clamp ass’y.
  • Page 187 0.45 0.0177 1.80 1.95 0.0709 0.0768 0.45 0.0177 2.32 2.51 0.0913 0.0988 0.50 0.0196 1.96 2.11 0.0772 0.0831 0.50 0.0196 Add shim a into the gap between forward (A) gear t and Shim taper roller bearing y if necessary. CAUTION For removal or installation of taper roller bearing, refer to;...

  • Page 189: Shim Selection

    Lower Unit MWX50 only 33) Measurement of Back Lash between Pinion (B) and Reverse (C) Gears and Shim Selection CAUTION Before measuring backlash between pinion (B) and reverse (C) gears, establish pinion (B) gear height. Refer to “Measurement of Pinion (B) Gear Height and Shim Selection”...
  • Page 190 0.0709 0.0768 0.45 0.0177 1.96 2.11 0.0772 0.0831 0.50 0.0196 Add shim(s) into gap b between reverse (C) gear t and bearing y if necessary. CAUTION For removal or installation of reverse (C) gear, refer to; “Disassembly of Propeller Shaft Housing Ass’y”...

  • Page 191: Assembly Of Lower Unit Parts

    Lower Unit 34) Assembly of Lower Unit Parts After installing forward (A)gear with taper roller bearing 1, install drive shaft ass'y 2, pinion (B) gear 3 and pinion (B) gear nut 4, and tighten the nut to specified torque. MX50 1342 1342 1342...

  • Page 192: Assembly Of Pump Case

    Lower Unit MX50 MWX50 Bevel Gear B Nut Wrench 7 : Bevel Gear B Nut Wrench 7 : P/N. 353-72231-0 P/N. 346-72231-0 Drive Shaft Socket 8 : Drive Shaft Socket 8 : P/N. 346-72232-0 P/N. 346-72232-0 Pinion (B) Gear Nut 6 : 54N ·...

  • Page 193: Attaching Clutch Cam Ass'y

    Lower Unit Attach water pump liner 0 to pump case (upper) q. CAUTION Align pump liner 0 protrusion a with pump case (upper) q concave b. Apply OBM grease to inside of water pump liner. Put pump case (upper) q and gasket (2 pcs.) on the drive shaft, and install them on the pump case (lower) w.

  • Page 194: Measurement Of Propeller Shaft Play And Selection Of Washer Thickness

    Lower Unit Attach O ring 4 to propeller shaft housing 5. Apply OBM grease to O ring. Attach steel ball 6, clutch push rod 7 and washer 8 that was removed when disassembling to propeller shaft 9. Install propeller shaft 9 to propeller shaft housing 5, and install the assembly to gear case.

  • Page 195: Installation Of Lower Unit

    Lower Unit Select washer 1 thickness so that the play is within the specified range. Specified Value of Play : 0.2 - 0.4 mm (0.0078 - 0.0157 in) Type of Washers : 3.0 mm (0.118 in) P/N. 353-64032-0 2.75 mm (0.1083 in) P/N. 353-64034-0 2.5 mm (0.0984 in) P/N.
  • Page 196 Lower Unit Put lower unit ass’y into drive shaft housing. Connect and align positions of water pipe and water pipe seal 2. Apply OBM grease to O ring. Tighten lower unit ass’y installation bolts and nut to specified torque. CAUTION To make centering of lower unit ass’y to drive shaft housing, attach bolts to two locations...
  • Page 197 Lower Unit Connect shift rod joint 3 and shift rod 4, and drive in spring pin 5. · Do not reuse spring pin. · Replace with new one when removed. Spring Pin Tool B 6 : (ø3.0) P/N. 345-72228-0 5 Spring Pin Do not reuse.

  • Page 198: Bracket

    13) Disassembling Clamp Bracket .. 7-46 2) Removing of Tiller Handle ..7-18 14) Assembling Clamp Bracket ... 7-48 15) Disassembling tilt mechanism .. 7-50 3) Installation of Tiller Handle..7-20 4) Removing Bottom Cowl ..7-24 16) Assembling tilt mechanism..7-52...

  • Page 199: Parts Layout

    Bracket 1.Parts Layout P/L Fig. 13 Drive Shaft Housing € 1741 1741 1741 1741 € 1342 1342 1342 1342 1342 1342 1342 1 342 1741 1741 1741 1741 Ref. Ref. Description Remarks Remarks Q'ty Q'ty Description 1-1 Drive Shaft Housing (L) 16 Engine Basemen MX50D2 for Transom “L”, “UL”...

  • Page 200: Bracket Manual Tilt

    Swivel Bracket Shaft Ass'y Bracket Bolt Bolt Nylon Nut 7/8 Steering Shaft Ass'y Bushing 26-32 Bushing 26-32 Bushing 22-25-35.5 Thrust Plate (Upper) 27-50-1 Cap Nut Distance Piece Thrust Plate (Lower) 26.5-46-1 1 O-Ring 3.5-25.7 Do not reuse. C-Ring d=25 Washer...
  • Page 201 46 Bolt Damper (Lower) 47 Ground L=210 Bolt Washer 13-34-3 48 Ground L=130 49 Bolt Damper 21-36-5 50 Ground L=110 Nylon Nut 12-P1.75 Washer 51 Bolt 52 Anode 1 OPT Mount Holding Plate (Lower) Rubber Mount Cap (Lower) 53 Bolt...

  • Page 202: Manual Tilt

    Bracket P/L Fig. 18 Manual Tilt Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty Tilt Stopper Ass'y 15 Reverse Lock Rod Bushing 10.2-12-29.5 16 Split Pin 2-12 Setting Plate 17 Tilt Stopper Lever Bolt 18 Reverse Lock Spring (L) 2 for Transom “L”, “UL” Friction Spring 19 Reverse Lock Spring (S) 2 for Transom “S”...

  • Page 203: Tiller Handle

    Bracket P/L Fig. 21 Tiller Handle Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty Steering Bracket 18 Bolt Nylon Nut 8-P1.25 19 Throttle Decal Washer 20 Bushing Tiller Handle Ass'y 21 Washer 30-45-1 Tiller Handle 22 Wave Washer 30-45-1.2 Grip 23 Bushing Throttle Shaft 24 Washer...

  • Page 204: Bottom Cowl • Shift

    Bracket P/L Fig. 22 Bottom Cowl • Shift Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty Mount 8.5-14-2.5 14 Grommet Spacer 6.2-9-15.7 15 Grommet Choke Rod 16 Grommet Bushing 17 Clamp 6.5-14L Hook Lever 18 Bolt Washer 14-22-1 19 Nut Seal Ring 20 Clamp 6.5-47.5P Hook Lever Bushing...
  • Page 205 Bracket P/L Fig. 22 Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty 27 Shift Lever 39 Bolt 28 Shift Arm 40 Washer 6.5-21-1 29 Bushing 41 Grommet 17-3 30 Wave Washer d=12 42 Shift Rod Shift Rod Lever 1 for MX50D2 43 Spring Pin 3-12 31-1 Shift Rod Lever...

  • Page 206: Top Cowl

    Bracket P/L Fig. 23 TOP COWL Ref. No. Description Remarks Q'ty Top Cowl Ass'y Tilt Handle Nylon Nut 6-P1.0 Washer 6-16-1.5 Top Cowl Seal Decal Set 1 for MX50D2 Decal Set 1 for MWX50D2 Caution Decal (A) 1 for MX50D2 7-16 2st X50D2 2011...

  • Page 207: Inspection Items

    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) Removing of Tiller Handle Remove advancer arm 1. Remove throttle wire mounting clamp 2 and screw 3. Remove throttle grip 4 and throttle shaft supporter 5.

  • Page 208: Installation Of Tiller Handle

    Bracket Remove tiller handle and throttle shaft 7. 3) Installation of Tiller Handle Install bushing 1, wave washer 2 and washer 3 on the steering bracket 4. Install throttle cable as shown. 7-20 2st X50D2 2011...
  • Page 209 Bracket Install throttle shaft 3 with cable to Tiller handle. Be careful of location of throttle friction 4, throttle shaft spacer 5, throttle shaft damper 6 and bushing 7. 1342 Attach Tiller handle ass'y to steering bracket 8, and tighten nut 9 to specified torque. Arrange throttle cable as shown.

  • Page 210: Removing Bottom Cowl

    Bracket 4) Removing Bottom Cowl Remove power unit. Refer to “Removing Power Unit” in chapter 5. Remove snap retainer 1. And then, remove shift rod lever Remove shift rod 3. Loosen and remove four bolts that secure bottom cowl to engine base.

  • Page 211: Removing Drive Shaft Housing

    Bracket 5) Removing Drive Shaft Housing Use the following steps to remove drive shaft housing. Loosen and remove upper rubber mount cap installation bolts to remove mount cap 1. Loosen and remove upper rubber mount installation bolts to remove rubber mount 2. Loosen right and left rubber mount installation bolts in several steps alternately and equally.

  • Page 212: Disassembly Of Drive Shaft Housing

    Bracket 6) Disassembly of Drive Shaft Housing Remove bolts that secure engine base to drive shaft housing. Remove M6 installation bolt located in the area shown by the arrow. Tap lightly with a plastic hammer to separate engine base from the housing if it is seized. If necessary, use a bladed screw driver to pry the engine base taking care not to scratch mating surface.
  • Page 213 Bracket When removing drive shaft housing 3, be careful not to lose dowel pin 4 for locating engine base 2. Loosen and remove bolts that secure exhaust housing 5 to engine base and remove exhaust housing. Loosen and remove bolts 7 that secure exhaust pipe 6 to engine base and remove exhaust pipe.

  • Page 214: Inspection Of Drive Shaft Housing

    Bracket 7) Inspection of Drive Shaft Housing Check mount rubber 1 and dumper rubber 2 for crack and deterioration. Replace if necessary. Check water pipe 3 for corrosion and deformation. Replace if necessary. Check engine base 4, exhaust housing 5 and drive shaft housing 6 for corrosion for damage.

  • Page 215: Assembly Of Drive Shaft Housing Parts

    Bracket 8) Assembly of Drive Shaft Housing Parts Install exhaust pipe 1 and gasket 2 to engine base 3 and tighten bolts 4 to specified torque. Exhaust Pipe Bolts 4 : 13 N · m (9 lb · ft) [1.3 kgf · m] Install exhaust housing grommet 5 to exhaust housing When installing the grommet by using adhesive, clean adhering area to remove dirt and oil and dry the...
  • Page 216 Bracket Install water pipe auxiliary mount 8 to drive shaft housing. Install water pipe to drive shaft housing, and attach gasket after confirming that dowel pins 9 are on the drive shaft housing. Check that drive shaft housing dowel pin is placed and secured to engine base properly.

  • Page 217: Assembling Rubber Mounting

    Bracket Install engine base 3 to drive shaft housing 0 by tightening installation bolts to specified torque. Engine Base Bolts : 20 N · m (14.5 lb · ft) [2.0 kgf · m] 9) Assembling Rubber Mounting When assembling drive shaft housing parts, reverse the disassembling procedure.

  • Page 218: Assembling Extension Housing

    Bracket MWX50 Only 10) Assembling Extension Housing Align notches a inside the tube joint 1 with hole b of the extension pipe 2, then insert. Passage c for adjusting water flow. Check the passage for clogged by salt, clean if necessary. Insert tube joint 1 and extension pipe 2 to extension housing 3, as shown.

  • Page 219: Removing Steering Shaft Arm

    Bracket 11) Removing Steering Shaft Arm Remove "C" ring 1 that supports mount bracket 2. Remove mount bracket 2. When mount bracket cannot be removed, tap the bracket at both ends alternately by using a plastic hammer. Pull up steering shaft arm 3 to remove. Do not lose bushing and O-ring.

  • Page 220: Installing Steering Shaft

    Bracket 12) Installing Steering Shaft Attach thrust plate 1 and bushing 2 friction piece 3 to steering shaft. Stand swivel bracket ass'y vertically, and insert steering shaft into swivel bracket ass'y. Attach bushing 4, new O ring 5, and thrust plate 6 to swivel bracket.

  • Page 221: Disassembling Clamp Bracket

    Bracket 13) Disassembling Clamp Bracket WARNING · When disassembling clamp bracket, be sure to fully tilt up outboard motor. If outboard motor is fully tilt down it can pop out spring suddenly and result in severe injury. · When tilting up outboard motor without power unit installed, be careful to operate tilt lock lever to prevent swivel bracket rise up easy.

  • Page 222: Assembling Clamp Bracket

    Bracket 14) Assembling Clamp Bracket Apply grease to swivel bracket, swivel bracket shaft, bushing. Put bushing to swivel bracket, and then, insert swivel bracket shaft 1 into clamp bracket 2 and tilt assistant spring 3. Set the tilt stop lever to “Release” position, then install swivel bracket shaft and assistant spring.

  • Page 223: Disassembling Tilt Mechanism

    Bracket 15) Disassembling tilt mechanism Set tilt stopper lever to "release" side, and then, remove tilt stopper setting plate 1. Remove tilt stopper 2, bushing 3, set piece 4 and spring 5. 7-50 2st X50D2 2011...

  • Page 224: Assembling Tilt Mechanism

    Bracket Remove springs 6. Remove E-rings, and then, remove reverse lock shaft 7 by using screw driver. 16) Assembling tilt mechanism Install reverse lock link 1 and arm 2 as shown and then, install reverse lock shaft. Install reverse lock spring 3 and spring 4 springs in reverse procedures of disassembling.
  • Page 225 Bracket Install tilt stopper 5, bushing 6, set piece 7 and spring 7-54 2st X50D2 2011...

  • Page 226: Electrical System

    Electrical System ....8-10 ....8-2 4. Inspection date 1. Special Tools Resistance test reference....8-10 *What’s Peak Voltage ...... 8-2 Peak voltage out put test reference ... 8-10 Merit of adoption of ..

  • Page 227: Special Tools

    Electrical System 1.Special Tools Spark Tester Peak Voltage Adapter Tachometer P/N. 3F3-72540-0 P/N. 3AC-99550-0 P/N. 3AC-99010-0 Measuring engine revolution Inspecting spark Checking Peak Voltage* speed *What’s Peak Voltage It is the method peak voltage measurement, at one of decision method of ignition system and charge system, of turning the flywheel and peak voltage (instantaneous maximum voltage) measuring dynamically.
  • Page 228 Electrical System 2.Parts Layout P/L Fig. 8 Magneto 1342 1342 Ref. Ref. Description Remarks Q'ty Description Remarks Q'ty Flywheel W/Ring Gear 1 F4T405-72 12 Band Coil Plate Ass'y W/Alternator 13 Screw Pulsar Coil & Plate Ass'y 14 Key Pulsar Holder 15 Nut 18-P1.5 Exciter Coil 16 Washer 19-34-3...
  • Page 230 Electrical System 3.How to use Peak Voltage Adapter Attention of measurement • Before measuring the peak voltage, check each wiring for proper connection and corrosion. • Connected and disconnected, there is the respective value in peak voltage. • As for usual system measurement in connected, as for coil single item measures in disconnected.

  • Page 231: Resistance Test Reference

    Electrical System 6) Measure peak voltage at engine cranking or engine starting. • When measuring peak voltage at engine cranking, remove spark plug cap from spark plug and spark plug is attached. • Variation occurs in output value with cranking speed.

  • Page 232: Inspection Items

    System Electrical 5. Inspection Items 1) Inspection of Ignition and spark WARNING · Do not touch any connection of wires of “Spark Tester”, while checking ignition spark. · When testing, put electrode cap assuredly to prevent direct contact with spark tester wiring and leak of electrical current, and perform test carefully.

  • Page 233: Inspection Of Pulser Coil

    Electrical System 3) Inspection of Ignition Coils This test can be made without removing parts. Measure ignition coil resistance. Replace if other than specified value. Ignition Coil Resistance : Primary Side : Between a and b 0.4 - 0.6 Ω Secondary Side : Between c and b 6.8 - 10.2 k Ω...

  • Page 234: Inspection Of Exciter Coil

    Electrical System 5) Inspection of Exciter Coil • Measurement of resistance Disconnect all connectors from coil plate ass`y, and measure resistance between terminals. Replace exciter coil if the resistance is out of specified range. Exciter Coil Resistance : White/Green (W/G) - Black (B): Orange (Or) - Black (B): 520 - 720 Ω...

  • Page 235: Inspection Of Stop Switch

    Check conduction of stop switch, and replace if not conductive. This test can be made without removing parts. Switch Position Brown (Br) Black (B) Remove lock a Attach lock b Press switch c Raider 50 Wiring Diagram 8-18 2st 50D2 2011...

  • Page 236: Troubleshooting

    Troubleshooting 1. Troubleshooting Chart ..9-2 2 Engine starts but stalls soon....9-8 ......9-3 2. Power Unit Fuel System ...... 9-8 ......9-3 Ignition System ...... 9-9 1 Engine will not start Starting System...
  • Page 237 Troubleshooting...
  • Page 238 Before working on the engine, check that hull, rigging and engine installation are normal. 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. 2.Power Unit...
  • Page 240 Compression...

  • Page 241: Ignition System

    Troubleshooting State 2 Engine starts but stalls soon. • Inspection of Fuel System, Ignition System, Compression Pressure. Fuel System Check connection to bladder Is hose securely Secure hose to bladder. connected? Check if fuel contain water fuel filter is clogged. Does fuel contain Check fuel hose for bend or water, or is fuel...

  • Page 242: Fuel System

    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 243: Compression Pressure

    Troubleshooting Compression Pressure No Power. Insure dewatering Valves are closed. Close dewatering Check compression Valve Replace defective parts and seal with new one. 9-10 2st X50D2 2011...
  • Page 244 Dewatering System Trouble shooting: 1. Compression Loss. Check de-watering valves as they are not properly closing. Replace not closing valve. 2. Dewatering system not working. Check rods to insure working properly. Tighten as required. The dewatering system is mechanical and should not be prone to failure. 3.
  • Page 245 Troubleshooting...

  • Page 246: Safety Jet

    Safety Jet Option to Raider 50 – Part No. SJ-001 Cone P/N SJ-001-A4 Stator Impeller Shroud P/N SJ-001-A1 P/N SJ-001-A2 P/N SJ-001-A5 Coupler P/N SJ-001-A3...

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