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Page 3 This service manual provides information that is needed for inspection, service and repair of applicable outboard motors. For information about operation of the products that are not described in this document, refer to the owners manual. For our customers' safe and dependable use of the product for long term, it is essential to maintain the performance and quality of the outboard.
Page 4 This service manual is designed so that service persons are able to perform repairs correctly. Understand the following matters well for efficient service and repair. Each chapter begins with the introduction of special tools that are used for the work described. Parts that are serviced in each chapter and their details are presented by using a component composition diagram.
Page 5 This manual uses SI unit system (International System of Units) for pressure, force (load), torque and stress. This manual newly adopts the international unit construction system (SI unit system) followed by the conventional imperial and metric systems enclosed by ( ) and [ ] as described below. ( ) ...
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Page 7 12) Inspection of timing belt ………… 3-13 13) Replacement of timing belt ……… 3-13 14) Inspection of Spark Plugs ………… 3-17 15) Inspection of Compression Pressure ……………… 1-2 ……………………………………… 3-18 …… 1-2 1) Fire Prevention …………………… 1-2 16) Inspection and Adjustment of 2) Ventilation …………………………...
Page 8 1) Locations of warning buzzer 17) Inspection of Oil Pump …………… 5-35 and lamp (LED) …………………… 4-17 18) Installation of Valves ……………… 5-36 2) Warning notification, abnormality 19) Installation of Cam Shaft ………… 5-37 and action to be taken …………… 4-18 20) Installation of Rocker Arm Shaft …...
Page 9 19) Removing Drive Shaft Ass’y ……… 6-22 13) Removing PTT Unit/Gas Shock Absorber 20) Disassembly of Drive Shaft Ass’y …… 6-23 ……………………………………… 7-27 21) Inspection of Drive Shaft ………… 6-23 14) Removing PTT Motor …………… 7-28 22) Inspection of Pinion (B) Gear …… 6-23 15) Disassembling PTT Motor ………...
Page 10 5) Trouble Indication List ………………… 8-26 1) Inspection of Fuse ………………… 8-26 (Self Diagnosis • Mode 3) ………… 9-50 2) Inspection of Starter Solenoid …… 8-26 3) Disassembly of Starter Motor …… 8-27 2) Inspection of Armature …………… 8-30 5) Inspection of Brushes …………… 8-31 ……………...
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Page 13 2) Gear Shift ………………………………… 1-9 3) Engine Oil ………………………………… 1-9 1) Fire Prevention …………………………… 1-2 4) Gear Oil …………………………………… 1-9 5) Fuel Line ………………………………… 1-10 2) Ventilation …………………………………… 1-2 6) Rigging …………………………………… 1-10 3) Protection …………………………………… 1-2 7) Inspection of PTT unit …………………… 1-10 4) Genuine Parts ………………………………...
Page 14 Engine serial number is stamped on the bottom cowl of outboard motor body. Model Name Model Type Serial Number Gasoline is hazardous material and very flammable. Do not handle gasoline near ignition source such as spark or static electricity. Exhaust gas or gasoline vapor is hazardous for human health.
Page 15 Use specified special tools to prevent damaging to parts and to perform work safely and surely. Be sure to follow installation procedures described in this manual and use tightening torque specified. Remove foreign substances and dirt from outboard motor body and individual parts by cleaning. Apply recommended oil or grease to rotating areas and sliding surfaces.
Page 16 Secure outboard motor to dedicated stand firmly. Take special care not to scratch painted surface or mating surfaces of cylinder and crankcase. Replace unreusable parts such as packings, gaskets, O rings, oil seals, spring pins or split pins with new ones after they were removed .
Page 17 P/N. 3KY-64110-0 Outer diameter : 236 mm With : 21 mm Rotational speed at WOT Outboard motor model (Wide Open Throttle) (r/min) MFS40A 4500 - 5500 MFS50A 5000 - 6000 For the following measuring instruments, use commercially available ones. Circuit tester ( Resistance : 1Ω, 10Ω, 10 kΩ, AC voltage : 30 to 300V, DC voltage : 30V ) Vernier calipers ( M1 type, 300 mm ) Micrometer...
Page 18 Thickness Gauge Bevel Gear B Nut Wrench Bevel Gear B Nut Socket Bevel Gear Bearing Installation Tool P/N. 353-72251-0 P/N. 346-72231-0 P/N. 346-72232-0 P/N. 3AC-72719-0 Installing forward gear Measuring gaps Removing/installing Pinion Nut (B Gear Nut) (A gear) bearing Bevel Gear Bearing Puller Ass'y Piston Slider Vacuum/Pressure Gauge Compression Gauge...
Page 19 ø100 x ø79.5 x ø51.5 x ø61.5 ø28.6 x ø22 x ø17 x H75.5 Roller Bearing Attachment Center Plate Pressure Gauge Ass'y Driver Rod P/N. 3KZ-99710-2 P/N. 3T5-72880-0 P/N. 3AC-99702-0 P/N. 3AC-99701-0 Removing or installing propeller Removing or installing propeller Removing or installing propeller Measuring fuel pressure shaft housing bearing shaft housing roller bearing shaft housing bearing ø28.3 x ø22.15 x ø20 x H128 Propeller Shaft Housing Puller Ass'y...
Page 20 Flywheel Puller Kit P/N. 3T1-72211-0 Removing/installing flywheel 4st 40/50 2014...
Page 21 Check installations for clattering and play. Adjust steering friction. Check throttle grip for movement. (full open/full close). Adjust throttle friction. Check that gear shifts from neutral (N) to forward (F) and reverse (R) smoothly. Fill engine with engine oil. 4 Stroke Engine Oil : 2.2 L (2.3 US.qt) [without oil filter replacement] 2.4 L (2.5 US.qt) [oil filter replaced] Use oil level gauge to check oil quantity.
Page 22 Check that fuel tank contains sufficient amount of gasoline, fuel line is connected and is free of leak. Check that clamp bracket is fixed securely to hull. Check location of cavitation plate relative to boat bottom, and, if necessary, adjust to prevent decrease in propulsive force and engine overheating.
Page 23 Press start switch or turn main switch to START check that engine starts. Turn main switch to OFF to check that engine stops. Multi Tiller Handle Model Remote Control Model Set the shift lever or control lever to "F" and "R" position, to check taht engin not starts.
Page 24 Check that cooling water check port discharges water during engine runs. After engine has warmed up, use tachometer to check idle speed is as specified. Idle Speed : 850±30 r/min Tachometer : P/N. 3GF-72647-1 Select a propeller that is best-suited to type of boat and application.
Page 25 Adjustment of trim tab angle After installing outboard motor on the boat, use trim tab to achieve balance between port and starboard steering loads. Loosen trim tab bolt, adjust angle of trim tab as described below, and then tighten the bolt to specified torque. Trim tab bolt : 13 N ·...
Page 26 Start engine and check if gear shift can be made smoothly. After completing warm-up operation, check idling revolution speed. Idling Revolution Speed : 850±30 r/min Tachometer : P/N. 3GF-72647-1 Shift gear into forward (F) and run dead slow for approximately 10 minutes. Dead Slow Revolution Speed : 850±30 r/min Run at 3,000 r/min or half of WOT for initial 2 hours, then at...
Page 27 1) Engine Dimensions ………………………… 2-2 2) Transom Bolts ……………………………… 2-4 2-12 2-20 1) ECU Fuel Feed System …………………… 2-5 2-22...
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Page 29 ET (with Remote Control) ET (with Multi Tiller Handle) EG (with Multi Tiller Handle) Item Type Unit mm/in 20.35 20.35 20.35 mm/in 29.13 29.13 29.13 mm/in 34.37 34.37 34.37 mm/in 38.86 38.86 38.86 mm/in 15.94 15.94 15.94 mm/in 21.18 21.18 21.18 mm/in 25.67...
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Page 31 ECU uses various sensors to precisely control injected fuel amount and ignition timing. 4st 40/50 2014...
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Page 34 Model MFS40A MFS50A Item Unit (with Remote Control) (with Multi Tiller Handle) (with Multi Tiller Handle) Dimensions (approx.) Overall Length mm (in) with Remote Control : 783 (30.8) with Multi Tiller Handle : 1,382 (54.4) Overall Width mm (in) 404 (15.9) mm (in) 1,257 (49.5) Overall Height...
Page 35 Model MFS40A MFS50A Item Unit (with Remote Control) (with Multi Tiller Handle) (with Multi Tiller Handle) Fuel & Oil Type of Fuel Unleaded Gasoline (Research Octane Number 90 or over,Pump posted Octane Number 87 or over) Fuel Tank Capacity Fuel Priming System ECU (Electronic Control Unit) Fuel Pumping System Mechanical (Plunger) pump + Electric System...
Page 36 Model MFS40A MFS50A Item Unit (with Remote Control) (with Multi Tiller Handle) (with Multi Tiller Handle) Warning System Over-revolution Controls engine speed to approximately 6,200 r/min or Protection less (High Speed ESG). Warning buzzer sounds. Engine Hydraulic Controls engine speed to approximately 2,800 r/min or Pressure Low less (Low Speed ESG).
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Page 38 Cylinder Head Build up of carbon in combustion chamber Measure the cam journal clearance 42.000 to 42.025 mm (1.65354 to 1.65453 in) Distortion or damage on mating surface Distorsion Limit : 0.05 mm (0.0020 in) or less Corrosion on the mating surface Cooling water passage clogged Cylinder Deposition in water jacket...
Page 39 Clean to remove. 42.050 mm (1.65551 in) Replace if more than specified limit. 0.1 mm (0.004 in) Correct. (Use water proof sand paper of #240 to 400 on the surface plate to level. Use #600 to finish.) Correct if possible, or replace. Clean to remove.
Page 40 Intake Valve Valve Clearance IN 0.15 to 0.25 mm (0.006 to 0.010 in) Exhaust Valve EX 0.25 to 0.35 mm (0.010 to 0.014 in) Valve Stem Outer Diameter IN 5.48 mm (0.2157 in) EX 5.46 mm (0.2150 in) Valve Guide Inner Diameter IN 5.51 mm (0.2169 in) EX 5.51 mm (0.2169 in) IN 0.008 to 0.040 mm (0.00031 to 0.00157 in)
Page 41 Adjust into specified range. 5.46 mm (0.2150 in) Replace if less than specified limit. 5.44 mm (0.2142 in) 5.55 mm (0.2185 in) Replace if more than specified limit. 5.57 mm (0.2193 in) 0.070 mm (0.00276 in) Replace if more than specified limit. 0.100 mm (0.00394 in) 2.0 mm (0.08 in) Replace if more than specified limit.
Page 42 Magneto Ignition Timing (at 850 r/min) BTDC 2°±5° Spark Performance (at 500 r/min) 10mm (0.4in) or over (Use genuine spark tester.) Alternator Output (at 4,000 r/min) 12 V 252 W Alternator Resistance Between Yellow and Yellow (at 20°C) 0.28 to 0.42Ω Resistance Between Terminals Between Red/White and Black (at 20°C) 148 to 222Ω...
Page 43 10 mm (0.4 in) Replace if less than specified value. Replace if out of specified range. Replace if out of specified range. Adjust to specified range. Replace if out of specified range. Replace if out of specified range. Clean to remove carbon build up and dirt. Adjust with side electrode. Replace if electrodes are severely worn.
Page 44 Thermostat Valve Operation Starting Temperature (Submerged) 60°C ± 1.5°C (140 ± 3°F) Valve Full Open Temperature (Submerged) 75°C (167°F) Valve Full Open Lift (Submerged) 3.0 mm (0.12 in) or more Pump Impeller Wear, Crack Pump Case (Liner) Wear Guide Plate Wear Anode Gear Case Anode Consumption...
Page 45 Any opening under ambient temperature Replace if out of specified range. 75°C (167°F) because thermostat operation is delayed. Measure valve open lift after 5 minutes. 3.0 mm (0.12 in) Replace if less than specified limit. Wear, crack or damage on tips and upper and lower surface lips Replace pump case liner and guide plate as a set.
Page 46 Tightening Torque N•m Type of Fastened Components Wrench A Screw B x Pitch Fastener N•m lb•ft kg•m Engine First Tightening Torque : M10 x 1.25 Bolt Final Tightening Torque : Cylinder Head (Cylinder Block and Cylinder Head) First Tightening Torque : M8 x 1.25 Bolt Final Tightening Torque :...
Page 47 Tightening Torque N•m Type of Fastened Components Wrench A Screw B x Pitch Fastener N•m lb•ft kg•m Top Cowl Tilt Handle M6 x 1.0 Nylon Nut Tightening Torque N•m Type of Fastened Components Wrench A Screw B x Pitch Fastener N•m lb•ft kg•m...
Page 48 Remarks B nd K nishi Tyu h Yuka Shinetsu Sunik B nd B nd M ry 1373 1207 1741 S n ax Part Name 1342 1327 1401 past (271) (7782) ● Cam head Camshaft ● Bearing ● Oil Seal (Cam Shaft) ●...
Page 49 Remarks B nd K nishi Tyu h Yuka Shinetsu Sun k B nd B nd M ry 1373 1207 1741 S ntax Part Name 1342 1327 1401 past (271) (7782) ● Thread Oil Pressure Switch ● Terminals ● Terminals Starter Motor ●...
Page 50 Remarks B nd K nishi Tyu h Yuka Shinetsu Sunik B nd B nd M ry 1373 1207 1741 S n ax Part Name 1342 1327 1401 past (271) (7782) ● Ball Bearing Outer surface, press fit ● Needle bearing Outer surface, press fit ●...
Page 51 15) Inspection of Compression Pressure … 3-18 16) Inspection and Adjustment of Valve Clearance ……… 3-19 17) Adjustment of shift • throttle cable ……… 3-20 1) Inspection of Top Cowl …………………… 3-4 18) Inspection of Shift Lever Gear Operations …… 3-22 2) Inspection of Fuel System Piping …………...
Page 52 Compression Gauge Torque Wrench Valve Clearance Driver Oil Filter Wrench P/N. 3AC-99030-0 P/N. 3AC-99070-0 P/N. 3AC-99071-0 P/N. 3AC-99090-0 Measuring compression Adjusting valve clearance Adjusting valve clearance Removing/installing oil filter pressure Flywheel Puller Kit P/N. 3T1-72211-0 Removing/installing flywheel 4st 40/50 2014...
Page 53 Inspection intervals Description Inspection procedure Remarks First 20 Every 50 Every 100 Every 200 hours of hours of hours of hours of 1 month 3 months 6 months 1 year Check and clean or ❍ ❍ Fuel ﬁlter Replace if necessary. Check and clean or ❍...
Page 54 Push top cowl to check for looseness and state of closing. Check the fuel system piping for fuel leak, dirt, deterioration and damage, and replace or repair parts if necessary. 4st 40/50 2014...
Page 55 Remove fuel pick up elbow of fuel tank counterclockwise to remove the part, and clean the filter . Remove dirt and water from fuel tank if any. Fuel Pick Up Elbow Filter Check fuel filter for dirt, build up of fuel slag, and fuel filter for invasion of foreign matters and crack.
Page 56 Oil Level Quantity of Oil for Full Replacement When oil filter When oil filter is replaced is not replaced Upper Limit 2.4L (2.5 US qt.) 2.2L (2.3 US qt.) Lower Limit 1.9L (2.0 US qt.) 1.7L (1.8 US qt.) Oil Specification Recommended Engine Oil : 4 Stroke Engine Oil API : SH, SJ, SL...
Page 57 As for "Engine oil replacement indicator function", informing the appropriate timing of engine oil replacement by blinking of the lamp, when beyond 100 hours operating. Be certain the safety lanyard is installed. Turn the key to the 'ON' position and with ib 1 second, pull the safety lanyard off.
Page 58 Drain engine oil. Place a piece of rag below oil filter area, and remove it by using oil filter wrench • Replace oil filter 5 minutes or more after stopping engine. • Wipe off spilt oil completely. Oil Filter Wrench P/N.
Page 59 Tilt down outboard motor to make it vertical. Remove upper oil plug and check level of gear oil in the gear case. Spill of some oil from plug hole as plug is removed indicates that gear case is filled with specified quantity of gear oil.
Page 60 Remove lower unit installation bolts, and pull lower unit ass'y downward to remove. Be sur to remove single bolt on back side of trim tab. Remove pump upper case Remove impeller and check it. Check upper pump case for deformation. Replace if necessary.
Page 61 Tilt outboard motor a little as shown. Place drain oil pan below drain bolt , remove lower oil plug and then upper oil plug 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 62 Drain gear oil. Remove upper oil plug and connect a commercially available leakage tester to this hole. Apply specified pressure to gear base, and check if the pressure is maintained without further compression for 10 seconds. Specified Gear Case Maintained Pressure : 0.069 MPa ( 10 PSi ) [ 0.7 kgf/cm •...
Page 63 Remove flywheel cover, and then check timing belt inner and outer surfaces for crackes, damages and wear while roating flywheel clockwise with hands. Replace if necessary. Bend limit Push belt center as shown. Replace if timing belt deflects more than 10 mm (0.394 in). Bolt Rubber Grommet Remove flywheel cover. Loosen flywheel nut. Flywheel Puller Kit : P/N. 3T1-72210-0 Remove flywheel nut and washer. Turn flywheel clockwise until the flywheel/crankshaft keyway faces rear cam pulley when it is lined up with "I"...
Page 64 Disconnect alternator coupler and pulser coil coupler and then remove alternator and coil bracket ass'y. Turn timing pulley clockwise to bring "▲" mark timing pulley to "▲" mark of cylinder block, and check that "● I" mark of cam shaft pulley and "▲" mark cylinder head are aligned with each other.
Page 65 Remove timing belt from cam shaft pulley side, and then, from timing pulley side. Check that "● I" mark of cam shaft pulley and "▲" mark of cylinder head are aligned Check that "▲" mark of timing pulley and "▲" mark of cylinder block are aligned with each other.
Page 66 Turn timing pulley clockwise twice to adapt, and check that locating marks , and of pulleys are aligned with each other respectively. Install coil bracket ass'y and alternator. Secure align key slot of flywheel and crankshaft, and then install flywheel. Tighten flywheel nut to specified torque.
Page 67 Remove plug cap and then spark plugs. Use spark plug cleaner or wire brush to clean spark plug electrodes . Replace if necessary. Check electrodes for corrosion or excessive build up of carbon, and washer for damage. Replace if necessary. Check spark plug gap .
Page 68 Start and run engine for 5 minutes to warm up, and then stop. Shift gear into neutral (N). Remove lock plate (stop switch lanyard) from stop switch. ① Compression gauge Remove all plug caps and then all spark plugs. Install compression gauge to plug hole. Compression Gauge : P/N.
Page 69 • Perform inspection and adjustment of valve clearances when engine is cold. • No.1 piston is to be at top dead center of compression stroke(make sure both valves are closed). ▲ Remove flywheel cover, spark plug, cylinder head cover, ignition coil connector and harness. Rotate flywheel clockwise to bring "●...
Page 70 Set shift lever to neutral (N) position. Set shift arm to forward (F) to neutral (N) to reverse (R), and check position, then set to neutral (N). Set throttle cam to fully close position. Adjust screw-in length of cable joint so that hole of cable joint is brought to throttle arm and shift arm pin •...
Page 71 Tighten nut , put it on the pin, and secure with washer and snap pin Check shift lever oprate to foward (F) to neutral (N) to reverse (R),. Check that shifting control lever fo rward (F) by approximately 32 degrees , where it is stopped once, makes the gear engage, and fully shifting the lever makes throttle valve fully open.
Page 72 Reconnect coupler (3 pices) and install holder cover. Shift gear from neutral (N) to forward (F), neutral (N), and then to reverse (R) while rotating propeller slowly to allow clutch engagement to check that shift operation is performed smoothly. Adjust shift link rod length, shift rod and cam rod position if necessary.
Page 73 Adjust length so that remote control cable joint hole aligns with set pin. (Remote Control Model) When adjusting remote control cable joint, adjust it with remote control cable fully pushed in. Reconnect remote control cable joint , attach snap pin and tighten lock nut .
Page 74 Tilt up and down outboard motor several times to check that gas assistant unit operates smoothly in full range. Fully tilt up outboard motor, lock with tilt stopper , and check that stopper lock mechanism functions normally. Tilt up outboard motor a little, set lock lever to locking position, and check that holding mechanism of gas shock absorber...
Page 75 Add recommended PTT fluid to specified level if it is lacking. Recommended PTT Fluid : ATF DEXRON III Attach reserve tank cap and tighten to specified torque. Reserve Tank Cap : 1.5 N·m (1.1 lb·ft) [0.15 kgf·m] Start engine and run for 5 minutes to warm up. Check idle speed to use tachometer or diagnostic program.
Page 76 Check anodes and trim tab for build up of scale and adherence of grease and oil. Clean, or replace if necessary. When it is necessary to disassemble outboard Replace anode and/or trim tab if they are corroded m o t o r f o r i n s p e c t i o n o f a n o d e , r e f e r t o excessively.
Page 77 Anodes protect outboard motor from galvanic corrosion (corrosion of metal due to very weak electric current). Anodes are used in the gear case, clamp bracket, and power unit cylinder. Replace anode if volume is reduced to 2/3 of new part. •...
Page 78 Measure valve lift of thermostat when prescribed temperature has been reached. Replace if valve lift is less than specified value. Water Temperature Valve Lift 75°C ( 167°F ) 3.0 mm ( 0.118 in ) or over Install thermostat, new gasket and cover. Thermostat Cover Bolt : 6 N·m ( 4 lb·ft ) [ 0.6 kgf·m] Check water strainer...
Page 79 Flushing with water using drive cleaner Remove propeller and thrust holder. Attach driver cleaner to water strainer area. Put water hose to drive cleaner and run water. Set gear shift to neutral (N) and start engine. Check that cooling water check port discharges water, and run engine for 3 to 5 minutes at low speed.
Page 80 Inspect electrolyte level. If lower than "LOW" mark , add distilled water until the level goes in between "UP" and "LOW" marks. Measure specific gravity of electrolyte. Charge battery if specific gravity is less than specified value. • Batteries are available with various types, varying among manufacturers.
Page 81 Apply water proof grease to the parts shown below. 4st 40/50 2014 3-31...
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Page 83 2) Warning notification, abnormality and action to be taken ………………… 4-18 Fuel Hose, Vent Hose, Breather Hose, 4-19 1) Ignition Timing Controls ………………… 4-20 Cooling Water Hose …………………………… 4-3 2) Ignition and Combustion Orders ………… 4-20 Intake Manufold …………………………… 4-4 3) Ignition Timing ……………………………...
Page 84 Vacuum/Pressure Gauge Clamp Plier Pressure Gauge Ass'y P/N. 3T5-72880-0 P/N. 3AC-99020-1 P/N. 3T5-72864-0 Inspecting pressure Caulking clamp Measuring fuel pressure 4st 40/50 2014...
Page 85 Ref. Description No.. Fuel Hose (Fuel Connector to Fuel Filter) Fuel Hose (Fuel Filter to Fuel Pump) Fuel Hose (Fuel Pump to Vapor Separator) Breather Hose (Cylinder Head to Throttle Body) Cooling Water Hose (Engine Base to Fuel Cooler) Cooling Water Hose (Fuel Cooler to Cooling Water Check Port) High Pressure Fuel Hose (Vapor Separator to Fuel Rail) 4st 40/50 2014...
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Page 87 Ref. Description Q'ty Remarks Intake Manifold ISC Valve Idle Speed Control Valve Bolt M6 L=20mm Map Sensor Manifold Air Temperature & Pressure Bolt M6 L=20mm Fuel Rail Ass'y Fuel Injector Ass'y Bolt M6 L=20mm Throttle Body Ass'y ø45 Gasket Do not reuse. Bolt M6 L=20mm Intake Silencer Ass'y...
Page 88 Fig.5-1 Fig.5-6 Fig.5-1 Fig.1 CYLINDER Fig.1 CYLINDER EXPOSURE Fig.16-19 Fig.15-16 4st 40/50 2014...
Page 89 Ref. Description Q'ty Remarks Rubber Mount Washer Pin ø8-22 Fuel Hose W/Protector V/Separator-Fuel Rail EPA-KRI-15G Clamp ø16.8 Fuel Hose 4-9 V/Separator-Exposure Fuel Hose W/Protector ø12 Fuel Pump-V/Separator USA EPA-KRI-15G Fuel Hose W/Protector ø12 Fuel Pump-V/Separator STD Clip ø11.3 Insulator O-ring 1.9-33.2 Do not reuse.
Page 90 8 N·m (6 lb·ft) [0.8 kgf·m] 4st 40/50 2014...
Page 91 Ref. Description Q'ty Remarks Oil Pressure Switch Engine Temp Sensor Bracket Electric Braket Rectiﬁer Complete Bolt M6 L=25mm Fuse Holder Bracket Screw M5 L=12mm Starter Solenoid Bolt M6 L=8mm PTT Solenoid Switch (A) Up 4 Side (Sb) for PTT Model Spring Washer Terminal Cap 8-13-28 Red for Gas Assist Model...
Page 92 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 1-1 Primer Bulb Assy 11 Clamp 1-2 Primer Bulb Assy Low Permeation Parts for USA Model 12 Fuel Tank Assy 25L Joint Assy (Inlet) 13 Fuel Tank Assy 25L for USA Model Fuel Gauge Vent Cap Assy Joint Assy (Outlet) (25L)
Page 93 ECU uses various sensors to precisely control injected fuel amount and ignition timing. ① Fuel Tank ② Fuel Regulator ③ Vapor Separator ④ Fuel Feed Pump （FFP） ⑤ ECU ⑥ Ignition Coil ⑦ Fuel Injector ⑧ ISC Valve ⑨ MAP/MAT Sensor ⑩...
Page 94 Individual sensors detect engine operating conditions and sends signals regarding the information to ECU. Pulser Coil [Crank Position Sensor] Pulser coils function as crank position sensors. As flywheel rotates, pulser coil sends the crank position signals to ECU. ECU uses this signal to establish fuel injection amount and ignition timing.
Page 95 Oil Pressure Switch Oil pressure switch is located on the port side of engine block below oil filter, and is projected into oil passage. Oil pressure switch sends oil pressure low signal to ECU. ECU operates low speed ESG, warning buzzer and lamp based on this information.
Page 96 Actuator section receives signals from ECU to control air/fuel ratio, ignition timing and idle revolution speed. ISC (Idle Speed Control) Valve ISC is also referred to as IAC (Idle Air Control). ISC valve is the stepping motor with needle valve, and controls amount intake air that bypasses closed throttle valve.
Page 97 Accidental malfunction of ECU stops engine. ECU provides the following functions. 1. Calculates the most suitable fuel injection amount and ignition timing based on engine revolution speed, throttle position, intake vacuum, intake air temperature and engine cooling water temperature. 2. Controls fuel injectors, ignition coils and ISC (Idle Speed Control) valve. 3.
Page 98 ECU calculates intake air amount based on engine revolution speed and intake manifold pressure (intake vacuum pressure) to determine fuel injection amount. At engine starting, during warm-up, acceleration/deceleration, and idling, ECU performs correction control based on information from sensors. Fuel injection timings at starting and during normal operation are described in the following table. Cylinder No.
Page 99 At engine starting (cranking), amount of fuel injection of each cylinder is increased to facilitate starting. In addition to this basic correction, information including cooling water temperature, atmospheric pressure and intake air temperature in the manifold from individual sensors are used to correct the engine operation to the best operating conditions.
Page 100 Warning Indicators Description of faults Remarks Remedy Buzzer or notice A Lamp B Lamp C Lamp Engine speed exceeds maximum × × × High-Speed ESG Approx. 6,200 r/min Continuous allowable RPM × × Low-Speed ESG Low oil pressure Continuous × Flashing ①...
Page 101 For ignition system, battery ignition system is adopted, and ECU's electronic ignition timing control system controls the timing to the most suitable state according to current operating conditions. As engine is started, electric current is generated in the alternator and to charg the battery. Which is input to ECU's regulator to feed power needed for operations of ignition coil, fuel injector and fuel feed pump (FFP).
Page 102 ECU's microcomputer is programmed with ignition timings best suited to engine's operating conditions. ECU obtains information about engine operating state such as revolution speed, throttle opening, manifold pressure (air intake vacuum pressure) and cooling water temperature based on the signals from the abovementioned sensors to generate ignition timing signal at the most suitable timings.
Page 103 Fuel pump (low pressure mechanical type) draws fuel from fuel tank, and feed it to fuel feed pump (FFP) located in the vapor separator through fuel connector and fuel filter Highly pressurized fuel, fed into fuel rail and fuel injector, and then, injected into intake manifold. Excessive fuel that is not used by fuel injector passes through fuel regulator , and circulated in the vapor separator to keep fuel pressure constant.
Page 104 Fuel pump is diaphragm pump that is operated mechanically by camshaft and lifter. Pump base is plastic and insulates heat from the engine block to protect fuel pump and reduce vapor. IN : Fuel from Filter/Tank OUT : Fuel Outlet to Vapor Separator Vapor separator feeds only liquid fuel for internal fuel feed pump (FFP) (electrical high pressure pump).
Page 105 Fuel regulator located on the inside section of vapor separator serves to keep regular fuel pressure. Fuel regulator consists of diaphragm with built in spring that actuates valve/seat, and returns (pressurized) excessive fuel to vapor separator when the pressure exceeds certain value. Excessive fuel is returned to vapor separator through internal pipe below fuel level to prevent it from bubbling.
Page 106 Air intake system consists of components including intake manifold (passage to cylinders that is coupled with common air chamber), throttle position sensor , throttle body/shutter , ISC (idle speed control) valve , MAP (manifold pressure) sensor, and MAT (manifold temperature) sensor Intake manifold is provided with fuel rail and fuel injectors.
Page 107 Check the fuel system piping for fuel leak, dirt, deterioration and damage, and replace or repair parts if necessary. Check fuel filter for dirt, build up of fuel slag, and fuel filter for invasion of foreign matters and crack. Clean fuel filter cup with gasoline, and replace fuel filter if necessary.
Page 108 Cleaning Fuel Feed Pump (FFP) Filter Remove and clean fuel filter (suction side) and (discharge side) from fuel feed pump (FFP) bilted in vapor sepalator. 4-26 4st 40/50 2014...
Page 109 Remove fuel hoses (2) from fuel pump. Connect vacuum/pressure gauge to inlet of fuel pump. Close fuel pump outlet with a finger and apply specified pressure. Check if no air leaks. Vacuum/Pressure Gauge : P/N. 3AC-99020-1 Specified Pressure : 0.049 MPa ( 7 psi ) [ 0.5 kgf/cm With the outlet closed, apply specified vacuum pressure to check that no air leaks.
Page 110 Remove cap Connect pressure gauge as shown. Pressure Gauge Ass'y : P/N. 3T5-72880-0 Start engine run 5 minutes to warm up, and then measure fuel pressure. If the pressure is below specified value, check high pressure fuel passage and vapor separator. Fuel Pressure (Reference) : 0.29 MPa ( 43 psi ) [ 3.0 kgf/cm ] ±10%...
Page 111 Remove cap Connect pressure gauge as shown. Pressure Gauge Ass'y : P/N. 3T5-72880-0 Start engine and keep running at idle revolution speed. Fuel Pressure (Reference) : 0.29 MPa ( 43 psi ) [ 3.0 kgf/cm ] ±10% 4st 40/50 2014 4-29...
Page 112 Remove cap Connect pressure gauge ass'y as shown, place a vessel below pressure relief hose, and open pressure relief valve to release fuel pressure. Place a vessel below vapor separator drain hose, and loosen drain screw to drain fuel from vapor separator drain hose.
Page 113 Remove needle valve, float pin and float. Check needle valve for bend and wear. Replace if necessary. Check float for deformation. Replace if necessary. Check filter for inlet and outlet for dirt and clogging. Clean if necessary. Check grommet and O-ring condition.
Page 114 Check float drop as shown. Float Drop (Reference) 30.0 mm ( 1.181 in ) Check float height as shown. Replace float or needle valve if the height is out of the specified range. Do not press needle valve with float. Float Height 20.0 to 23.0 mm ( 0.787 to 0.906 in ) Attach float chamber to vapor separator.
Page 115 Use diagnosis system to check operation of ISC (Idle Speed Control) valve. Disconnect hose at intake silencer side of ISC valve, close the hole from which the hose was disconnected with a finger to check if engine speed is reduced. Replace ISC valve if not.
Page 116 4-34 4st 40/50 2014...
Page 117 17) Inspection of Oil Pump ………………… 5-35 18) Installation of Valves …………………… 5-36 19) Installation of Cam Shaft ………………… 5-37 Engine …………………………………………… 5-3 Magneto ………………………………………… 5-4 20) Installation of Rocker Arm Shaft ……… 5-38 Electric Parts …………………………………… 5-5 21) Installation of Oil Pump ………………… 5-38 22) Installation of Cylinder Head ……………...
Page 118 Piston Slider Compression Gauge Torque Wrench Valve Clearance Driver P/N. 3KY-72871-0 P/N. 3AC-99030-0 P/N. 3AC-99070-0 P/N. 3AC-99071-0 Measuring compression Installing piston Adjusting valve clearance Adjusting valve clearance pressure Crank Shaft Holder Flywheel Puller Kit Oil Filter Wrench P/N. 3KY-72815-0 P/N. 3T1-72211-0 P/N.
Page 119 Ref. Description Remarks Q'ty 1 Power Unit 2 Engine Base Gasket Do not reuse. 3 Dowell Pin 4 Bolt 8 M8 L=115mm 5 Tapping Screw 6 Bolt 1 M6 L=16mm 7 Apron 4st 40/50 2014...
Page 120 150 N·m (110 b·ft) [15.0 kgf·m] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Flywheel W/Gear 15 Bolt 6 M6 L=25mm 2 Alternator Ass'y 16 Dowel Pin 6-12 2 Cylinder Blok-CoilBraket 3 Key 19-7-5 17 Pulsar Coil 4 Nut 20-p1.25 1 M20 18 Pulsar Coil Guard 5 Washer 20.5-37-5...
Page 121 8 N·m (6 b·ft) [0.8 kgf·m] Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 12 Spring Washer Oil Pressure Switch Engine Temp Sensor 13 Terminal Cap 8-13-28 Red for Gas Assist Model Bracket Electric Braket 14 PTT Solenoid Switch (B) Down Side (P) for PTT Model Rectiﬁer Complete 15-1 ECU Ass'y...
Page 122 8 N·m (6 b·ft) [0.8 kgf·m] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 20 Terminal Cap 8-13-28 Red for PTT Model 29 Band 203 Do not reuse. 21 Cord Ass'y 30 Terminal Cap 8-13-28 Black for PTT Model 22 Grommet 31 Bolt M6 L=30mm 23 Relay...
Page 123 Fig.5-1 Fig.5-6 Fig.5-1 Fig.1 CYLINDER Fig.1 CYLINDER EXPOSURE Fig.16-19 Fig.15-16 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Rubber Mount 12 Bolt M6 L=25mm Washer Intake Manifold 13 Dowel Pin 6-16 Vapor Separator Assy Pin ø8-22 Fuel Hose W/Protector V/Separator-Fuel Rail EPA-KRI-15G 14 Bushing Clamp ø16.8 15 Fuel Pump Ass'y...
Page 124 Fig.5-1 Fig.5-6 Fig.5-1 Fig.1 CYLINDER Fig.1 CYLINDER EXPOSURE Fig.16-19 Fig.15-16 Ref. Description Q'ty Remarks 22 Clip ø9.4 23 Fuel Filter Ass'y 24 Cup 25 O-ring Do not reuse. 26 Filter 27 Float 28 O-ring Do not reuse. 29 Nut 30 Washer 31 Plate 32 Bolt M6 L=12mm...
Page 125 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 25 Grommet F.F.P. Lower Lower 16 Vapor Separator Ass'y 26 Filter (intlet) 17 Float 27 Fuel Regulator 18 Float Arm Pin 28 Holder 19 Float Valve Ass'y (W/valve pin) 20 Fuel Feed Pump Upper 29 O Ring Do not reuse.
Page 126 5-10 4st 40/50 2014...
Page 127 Ref. Description Q'ty Remarks Intake Manifold Isc Valve Idle Speed Control Valve Bolt M6 L=20mm Map Sensor Manifold Air Temperature & Pressure Bolt M6 L=20mm Fuel Rail Ass'y Fuel Injector Ass'y Bolt M6 L=20mm Throttle Body Ass'y ø45 Gasket Do not reuse. Bolt M6 L=20mm Intake Silencer Ass'y...
Page 128 27 N·m (20 lb·ft) [2.7 kgf·m] 150 N·m (110 lb·ft) [15.0 kgf·m] Ref. Description Remarks Q'ty Drive Pulley Timing Pulley Key t=4 Crankshaft Belt Guide Nut 39-p1.5 Driven Pulley Camshaft Pulley Washer 10.5-20-3.2 Bolt 10-p1.25 M10 L=30mm Timing Belt 5-12 4st 40/50 2014...
Page 129 30 N·m (22 b·ft) [3.0 kgf·m] 18 N·m (13 b·ft) [1.8 kgf·m] 60 N·m (44 b·ft) [6.0 kgf·m] 18 N·m (13 b·ft) [1.8 kgf·m] 7 N·m (5 b·ft) [0.7 kgf·m] Fig.5-12 14 16 19 18 32 46 15 N·m (11 b·ft) [1.5 kgf·m] 30 N·m (22 b·ft) [3.0 kgf·m] 18 N·m (13 b·ft) [1.8 kgf·m] 2 N·m (1.4 b·ft) [0.2 kgf·m]...
Page 130 30 N·m (22 b·ft) [3.0 kgf·m] 18 N·m (13 b·ft) [1.8 kgf·m] 60 N·m (44 b·ft) [6.0 kgf·m] 18 N·m (13 b·ft) [1.8 kgf·m] 7 N·m (5 b·ft) [0.7 kgf·m] Fig.5-12 14 16 19 18 32 46 15 N·m (11 b·ft) [1.5 kgf·m] 30 N·m (22 b·ft) [3.0 kgf·m] 18 N·m (13 b·ft) [1.8 kgf·m] 2 N·m (1.4 b·ft) [0.2 kgf·m]...
Page 131 短長短 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks Cyl Block & Crankcase Ass'y 12 Exhaust Cover Gasket Do not reuse. Oil Filter Bolt 13 Bolt M6 L=25mm Dowel Pin 6-12 Crankcase-Cylinder Block 14 Oil Filter Bolt 8-90 15 Thermostat Mark 60 Washer...
Page 132 mark 15 N·m (11 lb·ft) [1.5 kgf·m] 30 N·m (22 lb·ft) [3.0 kgf·m] mark Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Crankshaft A'ssy 9-1 Piston 2-1 Plain Shaft Bearing (Brown) Brown see Service Manual 9-2 Piston (0.5 O/S) 2-2 Plain Shaft Bearing (Black) Black see Service Manual 10 Piston Pin 2-3 Plain Shaft Bearing (Blue)
Page 133 Ref. Description Remarks Q'ty Caution Decal (A) Oil Caution Decal for EU Top Cowl Assy (Service) Top Cowl Sub-Ass'y Top Cowl Seal Tilt Handle Gray Nylon Nut 6-p1.0 Washer 6-16-1.5 9-1 Decal Set (MFS40A) 9-2 Decal Set (MFS50A) 10 Front Decal 4st 40/50 2014 5-17...
Page 134 Refer to "Inspection of Compression Pressure" in chapter 3. Compression Pressure (Reference) : 1.4 MPa (203 PSI) [ 14.3 kgf/cm ] ±10 % Spread rag below oil pressure switch. Remove oil pressure switch and connect oil pressure gauge to switch hole. Use commercially available oil pressure gauge (Thread spec : R 1/8).
Page 135 Disconnect battery cables Open the cable terminal holder cover and disconnect connecter (3). Remove the electrical box cover and disconnect PTT motor leads and PTT switch coupler Disconnect neutral switch leads (green) Remove the pin and then remove the cable joint. 4st 40/50 2014 5-19...
Page 136 Disconnect the fuel hose and flushing hose Remove oil level gauge Disconnect cooling water (fuel cooler) hose Remove tapping screws (L = 4 pieces. S = 3 pieces.) and bolt (one piece.), then remove apron. Remove power unit by removing bolts (8) and then lifting it.
Page 137 Remove flywheel and key. Flywheel Holder : Commercially available item Flywheel Puller : Use puller contained in the following puller kit. Flywheel Puller Kit : P/N. 3T1-72211-0 Screw puller onto crankshaft end until flywheel is disengaged from tapered section of crankshaft. Disconnect alternatorr and pulser coilr Remove bolts of alternator...
Page 138 Turn timing pulley clockwise to bring "▲" mark timing pulley to "▲" mark of cylinder block, and check that "● I" mark of cam shaft pulley and "▲" mark cylinder head are aligned with each other. No.1 piston is to be at top dead center of compression stroke.
Page 139 Check that "▲" mark of timing pulley and "▲" mark of cylinder block are aligned with each other. No.1 piston is to be at top dead center of compression stroke. Install cam shaft pulley, bring "● I" mark of cam shaft pulley to "▲"...
Page 140 Turn timing pulley clockwise twice, and check that locating marks , and of pulleys are aligned with each other respectively. • No.1 piston is to be at top dead center of compression stroke. • Removal or installation of parts can be made easier when some of them are assembled together.
Page 141 Remove fuel system parts and intake manifold ass'y. Remove electrical system parts from power unit. 4st 40/50 2014 5-25...
Page 142 Remove camshaft pulley, cylinder head cover and hose. To remove, refer to the "Removing Timing Belt and Pulley" section in Chapter 5. Remove cylinder head bolts in the reverse sequence of order shown, and remove cylinder head. To loosen "No. 7" bolt, loosen fuel pump lift bolt, and then remove fuel pump lift.
Page 143 Compress valve spring by using compressor , remove cotter , and then, spring and valve Valves, springs and other related parts should be arranged in the order they are removed. Valve Spring Compressor Commercially available item Measure valve spring free length .
Page 144 Check valve for dent and wear on the face. Replace if necessary. Measure valve stem outer diameter . Replace if the diameter is less than specified value. Valve Stem Outer Diameter : Standard Value Intake Side : 5.48 mm (0.216 in) Exhaust Side : 5.46 mm (0.215 in) Functional Limit : Intake Side : 5.46 mm (0.215 in)
Page 145 Remove carbon built up on the valve. Apply thin coat of red lead on the valve seat. Use valve lapper (commercially available item) as shown to push valve onto valve seat lightly. Measure width of area where valve face contacted with valve seat that can be identified with red lead adhered to valve face.
Page 146 Use valve seat cutter (commercially available item) to correct valve seat. Turn 45 degree cutter clockwise to cut valve seat surface to make it smooth. Be careful not to over-cut valve seat. Turn valve seat cutter while pushing down evenly. Carbon build-up or uneven surface.
Page 147 Use 45 degree cutter to adjust contact width of valve seat to specified value. Width before correction Specified width Valve seat contact area is located on the center, which should be adjusted to specified value by cutting upper and lower ends by using 30 degree and 60 degree seat cutters respectively if the area is too wide.
Page 148 Apply thin coat of abrasive compound on the overall valve seat contact area, and turn valve lapper (commercially available item) while tapping valve. • Use finer abrasive compound to finish. • When changing abrasive compound to finer one, remove present one completely. •...
Page 149 Measure cam height. Replace if the height is less than specified value. Cam Height at Both Intake and Exhaust Sides : Standard Value Intake side : 35.78 mm (1.4087 in) Exthoust side : 35.81 mm (1.4078 in) Functional Limit : Cam Height at Both Intake and Exhaust Sides Intake side : 35.40 mm (1.3937 in) Extaust side : 35.43 mm (1.3957 in) Measure cam shaft runout.
Page 150 Remove carbon build-up of combustion chamber, and check for deterioration. Use straight edge and thickness gauge to check distortion of cylinder head in the directions shown. Replace if the distortion is over specified value. Cylinder Head Distortion Limit : 0.10 mm (0.004 in) 5-34 4st 40/50 2014...
Page 151 Use micrometer, cylinder gauge, depth gauge and thickness gauge to measure dimensions shown below. Replace oil pump if over specified value. Functional Limit : Clearance between Outer Rotor and Body 0.25 mm ( 0.0098 in ) Clearance between outer and inner rotors 0.16 mm ( 0.0063 in) Clearance between sides of rotor and body 0.11 mm (0.0043 in) (including wear of oil pump cover)
Page 152 Apply oil to valve guide and attach new valve stem seal. Intake Side : Black Exhaust Side : Green Install valve , valve spring seat , valve spring retainer in the order shown, and then, attach valve spring compressor Valve Spring Compressor Commercially available item With valve spring being compressed, use small screw...
Page 153 Apply engine oil to periphery of new oil seal and install it. Driver Rod : P/N. 3AC-99702-0 Oil Seal Attachment : P/N. 3AC-99820-0 Apply grease to lip of oil seal before installing it. Oil seal 50-68-9 Install cam shaft from direction shown. Tighten camshaft locating bolt to specified torque.
Page 154 Install rocker arms , springs , washers and collar from lower side of cylinder head while installing rocker arm shaft. It is easy to assemble and kept together each rocker arm with tie wraps. Tighten rocker arm shaft locating bolt to specified torque. Rocker Arm Shaft Bolt : 18 N·m (13 lb·ft) [ 1.8 kgf·m ] Align cuts of oil pump drive shaft...
Page 155 No.1 piston is to be at top dead center of compression stroke. After installing cam shaft pulley, bring " " mark of pulley to "▲" mark of cylinder head. Check that "▲" mark of belt guide and "▲" mark cylinder block are aligned with each other. Install cylinder head with new gasket, and tighten bolts in the order shown in two steps to specified torque.
Page 156 Remove thermostat cover bolt and the cover exhaust cover Remove oil filter Wipe off spilled oil completely. Oil Filter Wrench : P/N. 3AC-99090-0 Loosen crank case bolts in several steps in the reverse sequence of order shown, and remove crank case. Remove connecting rod bolts and connecting rod cap and then, crankshaft...
Page 157 Secure crankshaft holder with vice, and then insert crankshaft. Crankshaft Holder P/N. 3KY-72815-0 It may help to heat the nut with a small torch to be able to remove easier. Also, many front wheel drive auto sockets work well for removal/ installation drive belt pulley nuts.
Page 158 Measure piston outer diameter between points specified. Replace if the diameter is less than specified value. Piston Outer Diameter : Standard Value 69.97 mm (2.7547 in) Measurement Points 9mm ( 0.35 in) above piston skirt bottom Functional Limit : 69.90 mm ( 2.7520 in) Measure cylinder inner diameters (D1 to D6) at in crankshaft directions (D1, D3 and D5 respectively),...
Page 159 Measure piston side clearance. Replace piston and piston rings as a set if the clearance is over specified value. Piston Side Clearance : Top Ring : 0.04 to 0.08mm (0.0016 to 0.0031 in) Second Ring : 0.03 to 0.08mm (0.0012 to 0.0031 in) Oil Ring : 0.03 to 0.13mm (0.0012 to 0.0051 in) Functional Limit :...
Page 160 Measure piston pin outer diameter. Replace piston pin if outer diameter is less than specified value. Piston Pin Outer Diameter : Standard Value 17.00 mm (0.6693 in) Functional Limit : 16.970 mm (0.66811 in) Measure piston pin inner diameter . Replace piston pin if the inner diameter is over specified value.
Page 161 Measure crankshaft journal outer diameter and crank pin outer diameter . Replace crankshaft if either outer diameter is less than specified value. Crankshaft Journal Outer Diameter : Standard Value 39.97 mm (1.5744 in) Crank Pin Outer Diameter : Standard Value 37.99 mm (1.4957 in) Functional Limit : Crankshaft Journal Outer Diameter...
Page 162 Clean connecting rod and metal bearing, and then install metalbearing. Place cylinder block upside down on the work bench. Install piston to connecting rod Do not attach piston rings. Install crankshaft on the cylinder block. Place plasti-gauge on each crank pin parallel to crankshaft.
Page 163 Clean bearings, crankshaft main journal, and bearing installation areas of crank case and cylinder block. Place cylinder block on the work bench with cylinder head side facing downward. Install bearing and crankshaft to cylinder block • Be sure that individual bearings are installed to their original locations.
Page 164 Loosen bolts in reverse order in several steps. Remove crank case and measure width of crushed plasti-gauge on each main journal. Replace bearing if the width is over specified value. Crankshaft Main Journal Oil Clearance : 0.020 to 0.041 mm (0.00079 to 0.00161 in) Functional Limit : 0.060 mm (0.00236 in) If the clearance is less than specified value,...
Page 165 Check that maching chart of crank jounal metal bearing code as shown below chart, and then select crank jounal metal bearing. Code Brown Brown Black Brown Black Black Black Black Blue Crank journal metal bearing thicness Parts No. Color Thickness 1.996 to 2.000 mm 3KY-07707-0 Brown...
Page 166 Connecting rod metal bearing thicness Parts No. Color Thickness 1.491 to 1.495 mm 3KY-00080-0 Brown (0.05870 to 0.05886 in) 1.495 to 1.500 mm 3KY-00081-0 Black (0.05886 to 0.05906 in) 1.500 to 1.505 mm 3KY-00082-0 Blue (0.05906 to 0.05925 in) Install connecting , piston pin , and piston pin clip piston...
Page 167 Put pistons into cylinder with piston "UP" mark directing flywheel side and piston slider set on the pistons. Before installing, apply engine oil to piston peripheral surfaces, piston rings and piston sliders. Piston Slider P/N. 3KY-72871-0 Clean and remove grease on bearing holder of crankscase (x).
Page 168 Install bearing half to crank case. • Be sure that individual bearings are installed to their original locations. • Install bearings with their projection fit into crank case groove. • Remove grease from surface of crankcase and outside of bearing half. Apply 4 stroke engine oil to bearings.
Page 169 Install oil filter and tighten it to specified torque by using oil filter wrench. Apply thin coat of engine oil to O-ring before installing oil filter. Oil Filter Wrench : P/N. 3AC-99090-0 Oil Filter : 18 N·m (13 lb·ft) [ 1.8 kgf·m ] Install thermostat, new gasket, thermostat cover exthoust cover Exhaust cover Bolt :...
Page 170 Clean power unit mating surface, and install dowel pin and gasket Install power unit , and tighten bolts in two or three steps to specified torque. Power Unit Installation Bolt : First Tightening Torque : 15 N·m (11 lb·ft) [1.5 kgf·m ] Final Tightening Torque : 30 N·m (22 lb·ft) [ 3.0 kgf·m ] Install apron Reconnect cooling water (fuel cooler) hose...
Page 171 Install PTT switch coupler and PTT motor leads Positive Battery Cable Nut : 4 N·m ( 3 lb·ft) [ 0.4 kgf·m ] PTT Motor Lead Bolt : 4 N·m ( 3 lb·ft) [ 0.4 kgf·m ] Reconnect coupler (3 pices), and then place them into cable terminal holder and install holder cover.
Page 172 5-56 4st 40/50 2014...
Page 173 20) Disassembly of Drive Shaft Ass’y ……… 6-23 21) Inspection of Drive Shaft ………………… 6-23 Gear Case (Drive Shaft) …………………… 6-4 22) Inspection of Pinion (B) Gear …………… 6-23 Gear Case (Propeller Shaft) ………………… 6-6 23) Assembly of Drive Shaft Parts ………… 6-24 24) Removing Forward (A) Gear Ass’y ………...
Page 174 ø100 x ø79.5 x ø51.5 x ø61.5 ø28.6 x ø22 x ø17 x H75.5 Roller Bearing Attachment Propeller Shaft Housing Puller Ass'y Driver Rod Center Plate P/N. 3KZ-99710-2 P/N. 3A3-72259-0 P/N. 3AC-99702-0 P/N. 3AC-99701-0 Removing or installing propeller Removing propeller shaft Removing or installing propeller Removing or installing propeller shaft housing roller bearing housing shaft housing bearing shaft housing bearing...
Page 175 ø28.3 x ø22.15 x ø20 x H128 Driver Rod Roller Bearing Attachment Bearing Attachment Clutch Pin Snap Tool P/N. 3AB-99702-0 P/N. 3KY-99710-0 P/N. 3KY-99905-0 P/N. 3KY-72229-0 Removing or instaing gear case Removing or instaing gear case Removing or instaing gear case Installing clutch pin roller bearing roller bearing roller bearing Spring Pin Tool A...
Page 176 Fig.16-34 Fig.16-36 50 N·m (37 lb·ft) [5.0 kgf·m] 4st 40/50 2014...
Page 177 Ref. Description Q'ty Remarks Water Pipe (L) for Transom "L" Water Pipe (S) for Transom "S" Water Pipe (UL) for Transom "UL" Water Pipe Seal (UPPER) Lock Plate Water Pipe Auxiliary Mount Bolt Gear Case Assy Roller Bearing Plug 8-8 Gasket 8.1-15-1 Trim Tab Bolt...
Page 178 35 N·m (26 lb·ft) [3.5 kgf·m] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Bevel Gear Assy (A) 17 O-ring 18 Oil Seal 22-37-8 2-1 Shim 36-44-0.1 A t=0.1 2-2 Shim 36-44-0.15 A t=0.15 19 Bolt 2-3 Shim 36-44-0.3 A t=0.3 20-1 Propeller Assy (7") 1 OPT 4 x 290 x 180...
Page 179 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 180 · 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. Shift the gear into forward (F) to set shift rod to upper position.
Page 181 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 and clutch cam Spring Pin Tool A (ø3.0) :...
Page 182 Attach O rings 2.4-5.8 and O ring 3.5-21.7 to cam rod bushing O Rings Do not reuse. Attach cam rod bushing , shift rod joint and clutch to cam rod Spring Pin Tool B (ø3.0) : P/N. 345-72228-0 Spring Pin Do not reuse.
Page 183 Loosen and remove pump case (upper) bolts, and remove pump case (upper) parts in this order. Remove water pump impeller key Remove guide plate , gasket 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 184 Check pump case liner and guide plate deformation and wear. Replace if necessary. Check pump impeller 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 185 Use bladed screw driver or seal remover to remove oil seal · Two oil seals are used. Note that there is a shim in between oil seals. · Be careful not to damage the seal mating surface on the case. Install oil seal and shim by using suitable press...
Page 186 Loosen and remove bolts 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 P/N. 3A3-72259-0 Propeller Shaft Housing Ass’y Hold propeller shaft and remove propeller shaft housing ass’y.
Page 187 Pull out propeller shaft ass’y Remove reverse (C) gear by using bladed screw drivers Check oil seal for wear and crack. Replace if necessary. Remove bearing Heating of propeller shaft housing can also be Bearing Do not reuse. made by using a heat gun or heat lamp. 4st 40/50 2014 6-15...
Page 188 Use a press to remove oil seal and roller bearing 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. Roller Bearing Attachment P/N. 3KZ-99710-0 Driver Rod P/N.
Page 189 Use a press to push new roller bearing into propeller shaft bearing to specified depth. · Install roller bearing with the manufacturer’s mark facing the tool side. · Screw in roller bearing attachment lightly by a hand so that no gap is made at driver rod ·...
Page 190 Install oil seals Use a suitable press 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. · Apply grease to lip of oil seal after installing it. Oil seal Do not reuse.
Page 191 Attach shim used on the reverse (C) gear to the gear. Use a suitable press to install reverse gear (C) to new bearing · Clean reverse (C) gear bearing installation face and apply gear oil before installation. · Put in reverse gear (C), your hands canbe used. When use a suitable press, ﬁt the reverse gear (C) inner as shown.
Page 192 Pull out clutch pin , and remove clutch spring retainer , clutch spring , and clutch by referring to the figure. After taking out clutch spring retainer and clutch spring , remove clutch from propeller shaft. Check propeller shaft for bend, wear and damage. Replace if necessary.
Page 193 Attach spring , spring retainer , steel ball , push rod , clutch and clutch pin to propeller shaft. · When attaching clutch, face the narrower claw to push rod side. · When installing spring retainer, direct the end father away from the hole toward foward gear (FWD).
Page 194 Remove pinion (B) gear nut , and then, remove pinion (B) gear and drive shaft. · Degrease pinion (B) gear nut completely so that the nut wrench does not slip on the nut. · Loosen and remove the nut by using a drive shaft socket and a wrench and turning the wrench counterclockwise.
Page 195 Remove outer shim Remove drive shaft spring Remove taper ball bearings by using press and universal puller · Check bearing for play or deflection before removing, and replace if necessary. · When putting universal puller plate on the bearing, hook the tip of puller’s claw on the inner race of bearing correctly.
Page 196 Attach pinion (B) gear nut to drive shaft temporarily. Install bearing by using press and a suitable pipe Before installing bearing, be sure to clean drive shaft installation face and apply gear oil. A nut that ﬁts the thread can be used to protect the shaft tip when pressing.
Page 197 Remove pinion (B) gear. (Refer to 6-22 page) Take out bearing and forward (A) gear 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 198 Check forward (A) gear teeth and clutch claws for crack, damage and wear. Replace if necessary. Attach shim used before disassembly to taper roller bearing , and press-fit the part. Apply gear oil to press-ﬁt face when press-ﬁtting taper roller bearing. Bevel Gear Bearing Install Tool P/N.
Page 199 Remove roller bearing by using the following tools. Bearing Attachemnt P/N. 3KY-99905-0 Driver Rod P/N. 3AB-99702-0 Roller Bearing Attachemnt P/N. 3KY-99710-0 O Ring P/N. 332-66032-0 Roller Bearing Do not reuse. Remove taper roller bearing outer race 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 200 Check skeg and torpedo-like area for crack and other damage. Replace if necessary. Remove upper oil plug and connect a commercially available leakage tester to this hole. Apply specified pressure to gear base, and check if the pressure is maintained without further compression for 10 seconds.
Page 201 Use the following tools to install taper roller bearing outer race. Bearing Attachemnt P/N. 3KY-99905-0 Bearing Outer Press Kit : P/N. 3B7-72739-1 Bearing Outer Press Plate P/N. 353-72732-0 Bearing Outer Press Rod P/N. 3B7-72731-0 Nut M10 P/N. 930191-1000 Spring Washer P/N.
Page 202 Install roller bearing by using the following tools. · Before installing bearing, be sure to clean bearing installation face and apply gear oil. · Do not reuse roller bearing. Use new part. Bearing Attachemnt P/N. 3KY-99905-0 Driver Rod P/N. 3AB-99702-0 Roller Bearing Attachemnt P/N.
Page 203 Before measuring back lash of each gear, measure drive shaft pinion (B) gear height and adjust the height to proper value if necessary. In accordance with procedure described in “Assembly of Lower Unit Parts” on Chapter 6, install the parts up to pump case , and secure it by using M8 bolt (L=30mm) and flat washer...
Page 204 Add shim to bottom of pump case (lower) to adjust the gap to specified value. Pinion (B) Gear Height 0.60 - 0.64 mm (0.0236 - 0.0252 in) Type of Shims Applicable : 0.1 mm (0.0039 in) P/N. 345-64081-0 0.15 mm (0.0059 in) P/N. 345-64082-0 0.3 mm (0.0118 in) P/N.
Page 205 Install backlash measuring tool parts and secure them with installation bolts (M8 L=30mm) Dial Gauge Plate P/N. 3B7-72729-0 Backlash Measuring Tool Kit : P/N. 3B7-72234-0 Backlash Measuring Tool Shaft P/N. 3B7-72723-0 Backlash Measuring Tool Plate P/N. 3B7-72724-0 P/N. 3B7-72735-0 Coned Disk Spring P/N.
Page 206 Attach backlash measuring tool clamp to drive shaft. Turn drive shaft clockwise / counterclockwise slowly while pulling it up, and read change of dial gauge indication. · When measuring, contact dial gauge tip to inside of V groove located in the clamp ass’y. ·...
Page 207 After installing forward (A)gear with taper roller bearing install drive shaft ass'y , pinion (B) gear and pinion (B) gear nut , and tighten the nut to specified torque. · Tighten the nut by using a drive shaft socket and a wrench and turning the wrench clockwise. Cover the wrench with rag to prevent it from hitting the case directly.
Page 208 Bevel Gear B Nut Wrench P/N. 346-72231-0 Bevel Gear Nut Socket P/N. 346-72232-0 Pinion (B) Gear Nut 50 N · m (37 lb · ft) [5 kgf · m] Attach shim that is removed when disassembly. Attach O ring to pump case (lower) and install pump case (lower) to gear case.
Page 209 Attach water pump liner to pump case (upper) Apply OBM grease to inside of water pump liner. Put pump case (upper) and gasket (2 pcs.) on the drive shaft, and install them on the pump case (lower) 7. Attach water pipe seal Apply OBM grease thinly on the inside water pipe seal so that water pipe can be inserted smoothly.
Page 210 Attach O ring to propeller shaft housing Apply OBM grease to O ring. Attach steel ball , clutch push rod and washer that was removed when disassembling to propeller shaft Install propeller shaft to propeller shaft housing , and When bolts are reused install the assembly to gear case.
Page 211 Replace the washer , if the washer thickness out of specification. Specified Value of Thickness : 2.85 - 3.00 mm (0.1122 - 0.1181 in) Replace washer between propeller shaft and reverse (C) gear if necessary. Play of propeller shaft in forward-reverse direction out of the speciﬁed range can cause revolution of propeller even in neutral gear while engine is operating.
Page 212 Install dowell pins (2 pices). Dowell pin Put lower unit ass’y into drive shaft housing. Align the position of water pipe, water pipe seal dowel pin Apply OBM grease to O ring. Tighten lower unit ass’y installation bolts and nut to specified torque.
Page 213 Tighte the shift cam joint nut, and then connect shift rod and camrod. Make sure to check for shift ro pullig compleatly. And check for shift lever is shifted in forward (F). If joint is tightened when not in forward, it will not shift correctly.
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Page 215 10) Installing Steering Shaft …………………… 7-25 11) Removing Clamp Bracket (PTT or Gas Assistant Model) …………… 7-26 12) Installation of Clamp Bracket Manual Tilt Operation ………………………… 7-3 (PTT or Gas Assistant Model) …………… 7-27 Tilt up Operation ……………………………… 7-4 Tilt down/Trim in ……………………………… 7-5 13) Removing PTT Unit/Gas Shock Absorber ……...
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Page 217 • The power tilt system has an electric motor built in the system that drives the hydraulic pump to feed pressurized oil into the tilt cylinder. • The power trim switch located on the tiller handle or remote control box is used to tilt-up or down the outboard motor. •...
Page 218 Pressing "UP" side of PTT switch causes the PTT motor (gear of gear pump) to rotate clockwise. Check valve opens to cause oil to flow from reservoir toward gear pump and spool valve. This oil flow shifts spool valve right side to open down-pressure main check valve. Oil in the cylinder upper chamber is returned to gear pump. As a result of the above operations, piston rod is pushed up to tilt up the outboard motor.
Page 219 Pressing "DOWN" side of PTT switch causes the PTT motor (gear pump) to rotate counterclockwise. Check valve opens to cause oil to flow from reservoir toward gear pump and spool valve. This oil flow shifts spool valve left side to open up-pressure main check valve. Oil in the cylinder lower chamber is returned to gear pump. As a result of the above operations, piston rod is pushed down to tilt down the outboard motor.
Page 220 The PTT unit is provided with a shock absorber that protects the drive unit from an impact in case it hits underwater obstacle during cruising. In case drive unit hits an underwater obstacle, the hydraulic pressure in the cylinder upper chamber is increased suddenly. The high pressure opens shock valve of piston.
Page 221 Thermal valve protects drive unit from excessive force that attempts to push down tilt rod when the outboard motor is at full tilt up position. The piston rod to which excessive force is applied is pressed into the cylinder, resulting in increasing hydraulic pressure in the lower cylinder chamber over a rated value.
Page 222 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 14-1 Drive Shaft Housing Ass'y (S) Engine Basement Ass'y 1 for Transom "L"&"UL" 14-2 Drive Shaft Housing Ass'y (L) 1 for Transom "S" Oil Seal 16-28-6 Do not reuse. 15 Drain Bolt 14-20 Cooling Hose Engine Basement-Fuel Cooler 16 Washer 14.5-24-1...
Page 223 Ref. Description Q'ty Remarks 26 Plate 27 Idle Exhaust Port Gasket Inside Do not reuse. 28 Idle Exhaust Port Gasket Outside Do not reuse. 29 Bolt M6 L=20mm 30 Extension Housing for Transom "UL" 31 Dowel Pin 6-12 for Transom "UL" 32 Studm 10-145 for Transom "UL"...
Page 224 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 14 Damper 21-36-5 Rubber Mount (Upper) Bolt M10-P1.25-130 15 Nylon Nut 12-P1.25 Do not reuse. 16 Washer Nut Side M12 Nut 10-P1.25 17 Damper (Lower) Mount Bracket Washer 18 Mount Holding Plate (Lower) Lock Plate 19 Bolt M8 L=20mm...
Page 225 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 27 PTT Thrust Rodptt 38 C-ring d=28 Do not reuse. 28 Snap Pin 39 Mount Bracket 29-1 Swivel Bracket Ass'y for Transom "S" 40 Anode Mount Bracket 29-2 Swivel Bracket Ass'y for Transom "L"&"UL" 41 Bolt M6 L=16mm 30 Grease Fitting...
Page 226 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 51 Band 203 for PTT Model 64 Washer 18.2-34-1 52 Clamp 6.5-14L for PTT Model 65 C-ring d=18 Do not reuse. 53 Washer for Gas Assist Model M6 66 Rigging Bolt Set 54 Nut for Gas Assist Model M6 67 Bolt 12-105 P1.25...
Page 227 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks Motor Ass'y for PTT Model 15 Manual Valve Ass'y 16 Seal Washer Armature Ass'y 17 C-ring Motor Bracket Ass'y Do not reuse. O-ring 2-55.5 18 Joint Do not reuse. Breaker 19 Coupling 20 O-ring 1.8-69.6 Brush Do not reuse.
Page 228 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks Tiller Handle Kit 13 Shift Decal Throttle Wire 14 Warning Lamp Decal Shift Cable 15 Stop Switch Decal 16 Instruction Decal Stop Switch Ass'y Stop Switch Lanyard Ass'y 17 Tiller Handle Cover Ptt Switch Ass'y 18 Grommet Main Switch Ass'y...
Page 229 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 27 Spacer 10.5-23-9 41 Washer 8.1-20-0.8 28 Bushing 10.5-12.7-13.5 42 Bolt 8-32 P1.25 29 Washer 43 Screw Set 30 Lock Nut 10-P1.25 44 Grip Parts Kit 31 Cord Holder 45 Throttle Shaft Kit 32 Tapping Screw 6-16 46 Throttle Link Ass'y 945303-0400 E-Ring...
Page 230 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 14 Fuel Connector Protector Bottom Cowl Hook Lever 15 Bolt M6 L=30mm Seal Ring 13.8-22-3.7 Fuel Connector-Fuel Filter 16-1 Hose STD 98AB-501000 L=450mm Hook Lever Bushing 14-16.5-17.7 16-2 Low Permeation Hose Fuel Connector-Fuel Filter USA EPA-KRI-15G Wave Washer d=14 17 Clip ø10 Fuel Connector Side...
Page 231 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 25 Cover 38 Grommet Trim Sender 26 Flushing Connector 39 Grommet Drain 27 Seal Ring 40 Mount 8.5-14-2.5 28 O-ring 3.1-24.4 41 Spacer 6.2-9-15.7 Do not reuse. 29 Flushing Connector Cap 42 Bolt M6 L=30mm 30 Flushing Hose 43 Washer 6.5-21-1...
Page 232 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Throttle Cam 14 Collar 6.5-10.5-9.3 Spring 15 Bolt M6 L=25mm 16 Washer 6.5-21-1 Collar 6.5-10.5-22.6 Bolt M6 L=35mm 17 Bracket Washer 6.5-21-1 18 Bolt Shift Arm Bracket M6 L=16mm Washer 6.5-23-1.5 19 Bolt Cable Clip M6 L=16mm 20 Shift Lever Rod Washer 6.5-21-1...
Page 233 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 27 Holder 39 Snap Pin d=8 28 Bolt M6 L=12mm 29 Remote Control Cable Stay Cover M6 L=25mm 30 Bolt 31 Grommet 32 Cable Clip 33 Grommet 17-3 34-1 Shift Rod (S) Shift Rod 34-2 Shift Rod (L) for Transom "S"...
Page 234 Check operation of throttle cable and shift cable. Check cable inner wire and outer wire for bend and damage. Replace if necessary. Turn the throttle full open to full close to check operation the throttle cam turned full open and full close (the throttle cam is not full open, because adjust it at full closed).
Page 235 Remove lower mount nuts and bolts Remove upper mount nut , and then, remove drive shaft housing Ass'y . P u t i n t h e n u t t o d a m p e r g r o m e t a n d lockplate and loosen the bolt to holding bolt.
Page 236 Remove three bolts, and then remove upper mount rubber. Remove three bolts , and then reemove engine base from drive shaft housing ass'y. Remove oil strainer from engine base ass'y Before removing engine base ass'y, note arrangement of oil strainer hose. Remove idle port , plate , gasket...
Page 237 Remove screws, then remove water pipe Check filter for dirt and sediment. Clean, or replace if necessary. Install water pipe into drive shaft housing Install gasket (inner), plate , gasket (outer), idle port and oilpan guide plate to drive shaft housing. •...
Page 238 Install new gasket and engine base Ass'y to drive sahft housing To install, be careful to correctly place the oil strainer hose. Tighetn four bolts to specified torque. Attach upper mount bolts into the upper mount rubber , before tighten four bolts. Engine Base Bolts Tempraly tighten :15 N•m (11 lb•ft) [1.5 kgf•m] Final tighten : 30 N•m (22 lb•ft) [3.0 kgf•m]...
Page 239 Remove drive shaft housing ass'y. For the procedure, refer to "Removing Drive Shaft Housing" in Chapter 7. Remove "C" ring Remove mount bracket by tapping it with plastic hammer. Pull out steering shaft from swivel bracket ass'y to remove. Put thrust plate and bushing onto steering shaft Stand swivel bracket ass'y...
Page 240 Assemble steering shaft and mount bracket in the same directions Attach "C" ring Put grease through grease nipple until grease leaks from bushing (upper) Remove PTT unit or gas shock absorber. Refer to "Removing PTT Unit/Gas Shock Absorber" described later in this chapter.
Page 241 Install swivel bracket shaft to clamp bracket Assemble swivel bracket and clamp bracket , and tighten nylon nut to specified torque. Nylon Nut 24N·m ( 17 lb·ft ) [ 2.4kgf·m ] Install PTT unit or shock absorber. Refer to "Installation of PTT Unit/Shock Absorber".
Page 242 Remove thrust rod Remove bolt and remove cylinder pin (upper) Perform tilt down operation to retract tilt rod a little. Disconnect PTT motor leads from PTT solenoid. Remove "C" ring , and then cylinder pin (lower) Hold PTT unit or gas shock absorber with a hand, and use another hand to pull out cylinder pin (lower) and remove PTT unit rearward.
Page 243 Remove bolt , and then remove stator Cover armature shaft end with clean cloth, hold the shaft using a pair of pliers, and remove armature from stator carefully. Remove armature from PTT motor base. Do not apply grease or oil to commutator. Disconnect PTT motor lead wire Remove screw , disconnect PTT motor lead...
Page 244 Measure brush length. Replace if it is less than specified value. Brush Wear Limit 5.0 mm (0.1969 in.) Check electrical conductivity of brush and circuit breaker. Replace if not conductive. Measure diameter of commutator. Replace if the following specification is not met. Lower Limit of Commutator Diameter 20.4 mm (0.8032 in.) Check electrical conductivity of armature.
Page 245 Connect PTT motor leads and secure them with screws. Put brushes into brush holders, and attach armature Install stator to base. Cover armature shaft end with clean cloth, hold the shaft using a pair of pliers, and install armature to stator carefully. Remove manual valve and filter then PTT pump ass'y...
Page 246 Clean piston and ball, and check them for damages and wear. Replace PTT pump if necessary. Check drive gear and driven gear for damages and wear. Replace PTT pump if necessary. Check valve for damage and clogging. Replace if necessary. Loosen reserver tank cap and then drain PTT fluied.
Page 247 Check reservoir and upper oil seal for dameges and wear. Replace reserve tank if necessary. Check tilt rod for bend, any scratched of sliding surface and wear. Replace tilt rod if necessary. Check tilt rod for bend and hard rusting. If lightly rusting, finish by using sand paper #400 - #600, and or replace tilt rod if necessary.
Page 248 Use vise to fix PTT unit that is protected at both sides with wood pieces or aluminum plates. Assemble valve ass'y , releaf valve ass'y and PTT pump ass'y , and tighten bolt to specified torque. PTT Pump Bolt : 5.2 N·m ( 3.8 lb·ft ) [ 0.52 kgf·m ] Install filter to PTT unit.
Page 249 Turn manual valve counterclockwise fully. Extend tilt rod to upmost position. Place PTT unit vertically. PTT unit must be in vertical position as shown. Remove cap and check fluid level in the reservoir tank. Add recommended PTT fluid, if disassemble PTT unit. Spill of some fluid from plug hole as cap is removed indicates that gear case is filled with specified quantity of gear oil.
Page 250 Reverse connection of PTT motor lead wires to battery terminals to fully stretch tilt rod. Battery Terminals Tilt Rod PTT Motor Lead Wires Blue (L) + : Positive Terminal Stretch Green (G) – : Negative Terminal • Repeat above steps several times to move up and down tilt rod (When reversing motor lead wire connection, keep the connection open for two or three seconds.).
Page 251 Install outboard motor on the boat. Fully tilt up outboard motor and lock with tilt stopper. Remove cap and check fluid level in the reservoir tank. Turn manual valve counterclockwise fully. Release tilt stopper while holding in the UP position and let the motor drop down gravitationally.
Page 252 Add recommended PTT fluid to specified level if it is lacking. Recommended PTT Fluid : ATF DEXRON III Reservoir tank cap and tighten to specified torque. Reserve Tank Cap : 1.2 N·m ( 0.9 lb·ft ) [ 0.12 kgf·m ] Repeat steps from 5.
Page 253 As shown in diagram , connect pink (P) terminal to positive battery terminal, and black (B) lead wire to negative battery terminal. Check electrical conductivity between terminals . If non conductive, replace DOWN side PTT solenoid. Check electrical conductivity of PTT switch. Replace if other than specified conditions.
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Page 255 9) Inspection of Neutral Switch …………… 8-22 10) Inspection of Main (key) Switch ………… 8-23 Port Side View ………………………………… 8-3 11) Inspection of Stop Switch ……………… 8-23 Bow Side View ………………………………… 8-4 8-24 1) Inspection of Injectors …………………… 8-24 Starboard Side View …………………………… 8-5 2) Inspection of ISC Valve …………………...
Page 256 Vacuum/Pressure Gauge Spark Tester P/N. 3AC-99020-1 P/N. 3F3-72540-0 Inspecting pressure Inspecting sparks 4st 40/50 2014...
Page 257 Rectifire Fuse (30A) Fuse (20A) Starter Solenoid Ignition Coil Oil Pressure Switch PTT Solenoid Switch A (tilt up) PTT Solenoid Switch B (tilt down) ECU (Electronic Control Unit) 4st 40/50 2014...
Page 258 ISC (Idle Speed Control) Valve Starter Motor Throttle Position Sensor Vapor Separator 4st 40/50 2014...
Page 259 Fuel injector ISC (Idle Speed Control) Valve Vapor Separator Ignition Coil 4st 40/50 2014...
Page 260 Engine Temperature Sensor Fuse (20A) Fuse (30A) Rectifier Crank Position Sensor (CPS) Starter Motor T-MAP (Manifold Pressure) Sensor Alternator 4st 40/50 2014...
Page 261 Neutral Switch 4st 40/50 2014...
Page 262 150 N·m (110 b·ft) [15.0 kgf·m] Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 1 Flywheel W/Gear 15 Bolt 6 M6 L=25mm 2 Alternator Ass'y 16 Dowel Pin 6-12 2 Cylinder Blok-CoilBraket 3 Key 19-7-5 17 Pulsar Coil 4 Nut 20-p1.25 1 M20 18 Pulsar Coil Guard 5 Washer 20.5-37-5...
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Page 264 8 N·m (6 lb·ft) [0.8 kgf·m] 8-10 4st 40/50 2014...
Page 265 Ref. Description Q'ty Remarks Oil Pressure Switch Engine Temp Sensor Bracket Electric Braket Rectiﬁer Complete Bolt M6 L=25mm Fuse Holder Bracket Screw M5 L=12mm Starter Solenoid Bolt M6 L=8mm PTT Solenoid Switch (A) Up 4 Side (Sb) for PTT Model Spring Washer Terminal Cap 8-13-28 Red for Gas Assist Model...
Page 266 Ref. Description Remarks Q'ty 1 Starter Motor Ass'y 2 Brush Holder 3 Internal Gear 4 Pinion Assy 5 Planet Gear 6 Washer Set 7 Shift Lever Set 8 Magnetic Switch 9 Dust Cover Set 10 Starter Motor Band 11 Damper 12 Bolt 2 M6 L=16mm 13 Battery Cable...
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Page 269 Ref. Description Q'ty Remarks Intake Manifold Isc Valve Idle Speed Control Valve Bolt M6 L=20mm Map Sensor Manifold Air Temperature & Pressure Bolt M6 L=20mm Fuel Rail Ass'y Fuel Injector Ass'y Bolt M6 L=20mm Throttle Body Ass'y ø45 Gasket Do not reuse. Bolt M6 L=20mm Intake Silencer Ass'y...
Page 270 Fig.5-1 Fig.5-6 Fig.5-1 Fig.1 CYLINDER Fig.1 CYLINDER EXPOSURE Fig.16-19 Fig.15-16 8-16 4st 40/50 2014...
Page 271 Ref. Description Q'ty Remarks Rubber Mount Washer Pin ø8-22 Fuel Hose W/Protector V/Separator-Fuel Rail EPA-KRI-15G Clamp ø16.8 Fuel Hose 4-9 V/Separator-Exposure Fuel Hose W/Protector ø12 Fuel Pump-V/Separator USA EPA-KRI-15G Fuel Hose W/Protector ø12 Fuel Pump-V/Separator STD Clip ø11.3 Insulator O-ring 1.9-33.2 Do not reuse.
Page 272 Disconnect plug caps from spark plugs. Connect plug cap to spark tester. Connect spark tester clip to spark plug tip electrode. Spark Tester : P/N. 3F3-72540-0 Spark Performance : 10 mm (0.4 in) or over Start engine and check sparks. Check spark system when sparks are weak.
Page 273 Remove ignition coil coupler. Measure ignition coil resistance. Replace if other than specified value. This test can be made without removing parts. Ignition Coil Resistance : Puraimaly Coil : Between Couplers 3.82 - 5.18 Ω (at 20°C) Secondary Coil : Between High Tension Cord 15.6 to 23.4 kΩ...
Page 274 Disconnect #1 CPS coupler 1 (2 pin) of Port side. Measure #1 CPS resistance. Replace if other than specified value. This test can be made without removing parts. Crank Position Sensor Resistance (Reference Value) : Between Red/White (R/W) - Black (B) 148 to 222 Ω...
Page 275 Remove oil pressure switch to test it as a separate unit. Remove oil pressure switch Check electrical conductivity of oil pressure switch (Between the terminal connection and the threaded area of the switch base.). Replace if no conductivity. Connect vacuum/pressure gauge to oil pressure switch. Vacuum/Pressure Gauge : P/N.
Page 276 Remove engine temperature sensor to test it as a separate unit. Remove engine temperature sensor from engine. Test sensor when cold and then place in warm water and increase the temperature slowly while conducting your test. Measure the engine temperature sensor resistance. Replace if out of specifications.
Page 277 Open tiller handle or remote control box to access to the switch. Check electrical conductivity of main switch. Replace if no conductivity. Disconnect the part and test it as a separate unit. Lead Wire Color Switch Position B Br R R G L START Valiable PUSH ON...
Page 278 Measure injector resistance. • This test can be made without removing parts. • Injector operation test can be made by using "Function, or Running (Drop) Stop Test" of diagnosis system. Injector Resistance (Reference Value) : (at 25°C) 11.40 to 12.66 Ω Measure ISC valve resistance.
Page 279 Measure MAT sensor resistance. Replace T-MAP sensor if out of specification. ±12.7％ 24710 This test can be made without removing parts. ±10％ 2000 ±13％ MAT (Intake Air TEMP) Sensor Resistance (Reference Value) : −30 at 25°C Between TEMP to GND （℃）...
Page 280 1 2 3 Check electrical conductivity of fuse. Replace if no conductivity. Small blade fuse of the ﬂat type is used. Connect tester lead wires to both terminal of starter solenoid. Connector green (G) lead wire to battery positive terminal. Connector black (B) lead wire to battery negative terminal.
Page 281 Remove starter motor from power unit. Refer to “Removing Starter Motor” in chapter 5. Loosen M8 nut of magneto switch terminal, and then, remove motor lead. Loosen bolts (M5, 2 pcs.) of starter motor rear cover and then, remove the cover. Take care not to give damage to permanent magnets of yoke when pulling out armature.
Page 282 Loosen bolts (M6, 2 pcs.) on the upper part of magneto switch , and then, remove magneto switch ass’y. Remove yoke and center bracket A from gear case After removing dust rubber from gear case , remove shift lever together with center bracket ass’y Check dust rubber for cracks and damages.
Page 283 Remove clip from pinion shaft, and then, remove pinion clutch. ・ Move pinion stopper fully to clutch side. ・ Use bladed screw driver to remove clip from groove of shaft. ・ Do not reuse clip. Remove E clip from groove of pinion shaft. Remove pinion shaft , and 2 washers from...
Page 284 Check commutator for dirt. If necessary, clean by using sand paper of No. 600 or by air-blowing. Measure commutator outer diameter. Replace starter motor ass’y if outer diameter is less than specified value. Commutator Outer Diameter : Standard Value 29.0 mm (1.142 in) Wear Limit : 28.0 mm (1.102 in) Measure undercut...
Page 285 Measure brush length , and replace brush if the length is less than specified value. Brush Length : Standard Value 16.0 mm (0.630 in) Wear Limit : 12.0 mm (0.472 in) Check conductivity between brush and starter terminal. Replace brush ass’y if any of the following conditions are not met.
Page 286 Attach washer , pinion shaft and washer to center bracket in this order. Apply TEF grease or molybdenum grease to pinion shaft. Attach E clip to groove of pinion shaft. Attach pinion clutch to pinion shaft, and secure with clip ·...
Page 287 Attach shift lever and pinion shaft ass’y to center bracket ass’y , and then, put outer gear and planetary gear · Align center bracket ass’y and outer gear with bolt through holes, and attach to location shown. · Put outer gear with chamfered side facing bracket.
Page 288 • Check wire harness for disconnection of lead wire and defective connection. • Check conductivity between each point by referring to the following table. • Perform the measurement with all connections disconnected to make the component a separated unit. This test can be made without removing parts. Rectifier Tester Check Chart Between Terminal Resistance Terminal No.
Page 289 • Check wire harness for disconnection of lead wire and defective connection. • Terminals are arranged and numbered as shown. • The following table names of terminals, their numbers and lead wire colors. Terminal Name Leads Wire (Color) — — Com.
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Page 291 9-13 9-32 State 1 : Engine will not start or 1) Preparation ……………………………… 9-32 is a little hard to start. ………………………… 9-13 9-33 Starting System …………………………… 9-13 1) Start Up …………………………………… 9-33 Ignition System …………………………… 9-15 2) Models and Menu Selection …………… 9-33 Fuel System …………………………………...
Page 292 This troubleshooting information covers malfunctions and abnormalities of electrical parts which are warned of by the buzzer and warning lamp. For the operations of the buzzer and warning lamp, refer to “Warning Indication List”. Warning Warning Warning indicator A lamp B lamp C Self- Symptom...
Page 293 Action to be taken Cause (Refer to reference value or service data.) 1-1-1. Shift is in "F" or "R" position. Shift into neutral position. Battery is low, or battery cable or circuit connection is loose or Replace battery or charge. 1-2-1.
Page 294 Warning Warning Warning indicator A lamp B lamp C Self- Symptom Item diagnosable Beep (❍) Fuel pressure is low. 0.29 MPa (43 psi) [3.0 kgf/cm ±10%] 2-2. Fuel system Fuel pressure is high. 0.29 MPa (43 psi) [3.0 kgf/cm ±10%] Fuse Stop switch Fuel injector...
Page 295 Action to be taken Cause (Refer to reference value or service data.) 2-2-12. Fuel regulator is faulty. Replace. 2-2-13. Fuel leak Check hose damage and joints. 2-2-14. Vapor separator to fuel regulator inlet passage is obstructed. Check, and repair if necessary. 2-2-15.
Page 296 Warning Warning Warning indicator A lamp B lamp C Self- Symptom Item diagnosable Beep (❍) Engine revolution is slow (seizure). 3-1. Power Head Compression insufficient Fuel tank Fuel filter 3-2. Engine can be Fuel System Fuel pressure is low. cranked and starts, but idling cannot 0.29 MPa (43 psi) [3.0 kgf/cm ±10%]...
Page 297 Action to be taken Cause (Refer to reference value or service data.) 3-1-1. Piston has a scratch or a cause that produces resistance. 3-1-2. Piston ring(s) is seized. 3-1-3. In or Ex valve have a gap, is worn or damaged. Check, and repair if necessary.
Page 298 Warning Warning Warning indicator A lamp B lamp C Self- Symptom Item diagnosable Beep (❍) 5-1. Spark plug Engine speed is controlled. 5-2. Engine revolution is (due to ESG) unstable at 2800rpm or higher. 5-3. Fuel pressure is low. 5-4. TPS (*2) function is faulty.
Page 299 Action to be taken Cause (Refer to reference value or service data.) 5-1-1. Refer to 2-4-3. Refer to 2-4-3. 5-1-2. Refer to 10-1. Refer to 10-1. 5-1-3. Refer to 3-2. Refer to 3-2. 5-1-4. Refer to 2-4-12. Refer to 2-4-12. 6-1-1.
Page 300 Warning Warning Warning indicator A lamp B lamp C Self- Symptom Item diagnosable Beep (❍) Propeller Installation 7-1. Engine accelerates Outboard but boat will not. Motor Boat Main Switch 8-1. Turning of main Electrical Stop Switch switch will not stop engine.
Page 301 Action to be taken Cause (Refer to reference value or service data.) 7-1-1. Incorrect propeller selection 7-1-2. Propeller slips on the shaft. Check, and repair or replace if necessary. 7-1-3. Propeller is deformed or damaged. 7-1-4. Shaft length - boat transom mismatching Check, and adjust if necessary.
Page 302 Probable Cause ● Fuel level is low in the tank. ● ● ● Fuel system connection is incomplete. Fuel system sucks air. ● ● ● ● ● ● Fuel pipe is twisted, damaged. Cap vent is closed. ● ● ● ●...
Page 303 Before working on the engine, check that full, rigging and engine installation are normal, and then battery is fully charged. For mechanical troubleshooting, refer to relevant troubleshooting section in this chapter. For checking and servicing outboard motor, refer to service procedures described in this manual to perform the works safely.
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Page 319 Read this manual thoroughly, connect diagnosis cable to computer, and then, perform software operations. • Check that computer is normal. • Fully charge battery (12 V or more). • Clean battery terminal to remove dirt and corrosion, and connect Diagnosis Tool Kit battery cables securely.
Page 320 After entering the dealer-only page, then click the download of diagnostic software. Double-click the "diag". Double-click the "install". Click "Next". Click "Next" put a check in "to create a shortcut to Desktop." Shortcut of diagnostic software is created on the desktop by clicking the "Finish".
Page 321 By the manufacturer of the serial converter, how to install the driver of the serial converter is also vary depending on the computer you are using. The following is an example, detailed procedure of installation to refer to the instruction manual of the converter to be used. Connect serial adapter to USB port (It should be a mark on the USB port which connects to for later).
Page 322 Diagnosis Harness Not in the battery cable terminal. Battery (12V) It is necessary to connect the battery to the Computer battery cable of the engine. RC232C Port (9 Pins) USB Port If your computer is not provided with RS232C Port (9 Pins), use USB conversion cable as shown. •...
Page 323 Double-click "3AC_DIAGNOSTICS" in "PROGRAM" or its short-cut icon. Model select appears. Use " ↑ " or " ↓ " key on the keyboard or press the "1" to "9" number to move cursor to list to be executed, and press "Enter" key. Thoroughly read notes described in "Set Up"...
Page 324 • COM port of the following "5" in the automatic is assigned. • COM port of 5 or less is used when all the diagnostic cable is not connected switches to manual setup screen (next page). * it is necessary to turn ON the engine key. 9-34 4st 40/50 2014...
Page 325 "Com port No = " Current COM port number appears. "New Com Port No = " New COM port number can be input. Input COM port number of your computer. Press "Enter" key to return to "Menu" screen. • Current COM port number can be known by going through "Control Panel"...
Page 326 Current states of engine can be seen on the screen. Press "F1" key to return to "Menu" screen. ※1 ※2 *1 Currently, it is displayed as "failure" if the problem has occurred. *2 If there is a problem in the past, I indicates the time at which the failure occurred at the end.. 9-36 4st 40/50 2014...
Page 327 Malfunction history of engine can be seen on the screen. Press "F1" key to return to "Menu" screen. ※1 ※2 ※3 ※4 ※5 *1 Engine temperature is raised or how much to the highest in the past as shown. In addition, the time of occurrence. *2 Number of times that something goes ploblem.
Page 328 Malfunction of injectors or their operating state can be checked. Enter the number of item to be checked. "1" : Operation (on/off) of #1 injector "2" : Operation (on/off) of #2 injector "3" : Operation (on/off) of #3 injector "4" : Operation (on/off) of ISC valve "5"...
Page 329 This test stops operation injector or ignition coil temporarily during engine operation for checking operating state according to reduction or operating noise level and engine speed. Enter the number of item to be diagnosed. "1" : Temporary stop of #1 injector "2"...
Page 330 Description of error code appears on the screen. Example : Error code : 1 Communication Error Communication with ECU is not ready. Check following items. * Connection between computer and ECU * Connection with battery * Setting of computer COM port number. Use "Setup Communication port"...
Page 331 The self-diagnosis function detects a trouble(s) of electrical system of engine and displays the part by using ECU installed in the engine. This engine requires no instruments and special equipment such as personal computer when executing the self- diagnosis function that uses key switch operation, tachometer’s RPM indication and a combination of three warning lamps to show information necessary for troubleshooting through the following four modes.
Page 332 * The self-diagnosis function is enabled only when the engine is stopped state. * The self-diagnosis function is stopped at any moment during the following procedure when the key switch is set to “OFF”. → 9-42 4st 40/50 2014...
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Page 336 Warning Indicators Speed Control Buzzer Sounding Indicator A Indicator B Indicator C Countinuous × × × High speed ESG (*8) Countinuous Lightning × × Low speed ESG (*9) Countinuous × Flashing × Low speed ESG (*9) Countinuous Flashing Flashing Flashing Foced idling —...
Page 337 Fault Description Reference Remedy Engine over-rev Approx. 6,200 r/min Readjust propeller, outboard engine mounting height and/or trim. Low oil level Replenish engine oil. Engine temp. high 100 ºC (212̊F) Engine temp. abnormally high 140 ºC (284̊F) Refer to troubleshooting. Approx. 9V or less. Idling Battery voltage low speed up Sensor power supply malfunction...
Page 338 Lamp Indication Engine Operating Hours(h) Tach. Indication(r/min) Lamp A Lamp B Lamp C − − − 0 – 1 1,000 − − − 1 – 2 2,000 − − − 2 – 3 3,000 − − − 3 – 4 4,000 −...
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Page 340 Fault Log Malfunction / Failure Indication Fault Fault Log (Yes) Description of Problem Tachometer Indication Indicator A Indicator B Indicator C (r/min) No malfunction of failure 1,000 # 1 Fuel injector malfunction 2,000 # 2 Fuel injector malfunction 3,000 # 3 Fuel injector malfunction Lighting of the lamp means that 1,000 Flashing...
Page 341 Remedial Measures and Added Notes *1 B lamp does not goes on even a malfunction in the engine stopped, because of the abnormality determination impossible. *2. If the lamp C goes on, the wiring may be broken or a component may be faulty at present. →...
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Page 343 2) Drag Link ………………………………… 10-9 10-2 3) Installation of Remote Control Cable 10-2 (Engine Side) …………………………… 10-10 1) Load Limit of Boat ………………………… 10-2 2) Installation Dimensions …………………… 10-2 10-13 3) Clamp Dimensions ………………………… 10-3 1) Installation of Propeller ………………… 10-13 4) Hanging Outboard Motor …………………...
Page 344 The persons who perform the rigging should take sufficient care for prevention of damages to himself or herself and the products, prevention of fire, and ventilation of the shop. The persons who operate the boat equipped with this product for test run should read the operating instructions of the outboard, and be familiar with the operating procedure.
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Page 346 * Full scale transom dimensions and drilling template is shown at the end of this manual. 10-4 4st 40/50 2014...
Page 347 Installation of an outboard motor at higher position can cause the matters described below. 1) Sucking in air from the cooling water inlet causing an overheat 2) Possible loss of steering control. 3) Propeller can easily run above water surface (over-revs) during planing or when the boat is turning causing a loss of control.
Page 348 Install outboard motor(s). Secure the outboard motor by using fasteners contained in the package of the product. : 12mm diameter, Bolts (4 pcs.) : Flat Washers (4 pcs.) : Lock Nuts (4 pcs.) : Flat Washers (4 pcs.) : Marine Sealant : Apply to the bolts’ surface excluding their threaded area.
Page 349 Fill the fuel system as described below before initially starting new engine, after engine exhausted fuel, or after draining fuel from engine. Squeeze priming bulb of fuel hose until it becomes stiff. Set key switch to “ON” position for three seconds to operate electric fuel feed pump.
Page 350 Cable arranged on the starboard side Apply thin coat of grease to entire area of cable end. Run steering cable into tilt tube. Tighten nut to specified torque. Nut : 48 N · m (35 lb · ft) [4.8 kgf · m] Be sure to attach drag link seal ring 10-8 4st 40/50 2014...
Page 351 Attach drag link as shown. When installing steering rod that connects engine and steering cable, be sure to use special bolt , nylon lock nuts washer coller . Do not use regular bolts and non-lock type nuts in place of these bolts and lock nuts, or the nuts may be loosened due to mechanical vibration resulting in disconnection of the link rod.
Page 352 Turn top cowl hook levers and remove top cowl. Remove bolts and then remove remote control cable stay cover Remove air scilencer to easlly remove bolts Remove bolts and then remove cable clip Remove grommet Shift cable Throttle cable Main harness Meter cord Ass'y Trim sensor Battery cables...
Page 353 Screw cable joint on the tip of remote control cable by approximately 12 mm (0.47 in). Open the cut of grommet and run meter cord ass’y and cord ass’y B attached to remote control box from front of lower motor cover. Then, run two remote control cables.
Page 354 Set shift arm to forward (F), neutral (N), reverse (R) and then to neutral (N) positions. Set throttle cam to full close position. Adjust screw-in length of cable joint so that hole of cable joint is brought to throttle arm pin and shift arm pin Lock joint with nut , put in on the pin, and secure with washer and R-pin...
Page 355 Check the shift lever operation.to forward (F), neutral (N) and reverse (R) position. Set shift lever to neutral (N) position. Remove spark plug caps from spark plugs. Apply grease to propeller shaft. Put propeller parts on the propeller shaft in the order as shown.
Page 356 12V100 AH/5HR or more CCA : 850 12V120 AH/5HR or more (in cold regions) CCA : 1000 Single Outboard Installation : Red Sleeve (Positive Side) : Black Sleeve (Negative Side) : Starting Battery Twin Outboard Installation Be sure to connect negative terminals of the starting batteries by using common earth lead of which size is equal to that of the main battery cables.
Page 357 Start In-Gear Protection (Neutral Safe Starting Switch) Neutral safety switch on the bottom cowl disables the engine starting when shift gear is engaged. For this outboard motor, use the manufacturer’s genuine parts and accessories. For safety reasons, it is not recommended to use parts and accessories supplied by other than the manufacturer. Before using any accessories, thoroughly read the installation manual and operation manual.
Page 358 Set selector to “4P” on the back of the meter. Connect cord ass’y B and meter lead wire to cord ass’y A. B : Black L : Blue Lg : Light green P : Pink R : Red W : White Y : Yellow Y/R : Yellow/Red G/R : Green/Black...
Page 359 When an abnormality occurs on the engine, warning buzzer sounds and warning lamp is lit or blinks. Take actions described below if abnormal state has occurred. When engine started, warning lamp is lit for 5 seconds and warning buzzer operates for two seconds (generating intermittent sound) indicating that operation warning system is operating normally.
Page 360 Oil Pressure Warning When Oil pressure is reduced below setting value during operation, warning buzzer operates (generating continuous sound), warning lamp is lit, and at the same time, low speed ESG operates to reduce the speed to 2,800 r/min or less.
Page 361 11-2 11-7 11-3 11-9 11-5...
Page 362 Name Remarks Lead Wire Color − − Alternator Charge Coil Yellow Yellow Palser Coil Red/White Black − − Crankcase Ground Black Black − − Rectiﬁre/Regurator Yellow − Main Relay Br/Y Brown/Yellow Blue − Fuse Holder Blue − − Neutral Switch Bottom Cowl Green Green...
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Page 367 INDEX <A> Drive Shaft Ass’y Disassembly …………………………… 6-23 Actuators …………………………………………………… 4-14 Drive Shaft Ass’y Removing ……………………………… 6-22 Air Intake System …………………………………………… 4-24 Drive Shaft Housing Assembly …………………………… 7-23 Alternator Inspection ……………………………………… 8-19 Drive Shaft Housing Ass'y Installation …………………… 7-24 Anodes Inspection ………………………………………… 3-26 Drive Shaft Housing Removing ……………………………...
Page 368 Gear Case Inspection(for leakage) ……………………… 3-12 <P> Gear Case Parts Assembly ………………………………… 6-29 Pinion (B) Gear Height and Gear Oil Draining …………………………………………… 6-7 Shim Selection Measurement ……………………………… 6-31 Gear Oil Quantity Inspection ……………………………… 3-9 Pinion (B) Gear Inspection ………………………………… 6-23 Gear Oil Replacement ………………………………………...
Page 369 Self-Diagnosis Function Operation Procedure ………… 9-42 Vapor Separator Reassembly ……………………………… 4-32 Self-diagnosis function terms ……………………………… 9-41 Sensors …………………………………………………… 4-12 <W> Serial Number (Identification) ……………………………… 1-2 Warning buzzer and lamp (LED) locations ……………… 4-17 Shift • throttle cable Adjustment …………………………… 3-20 Warning Buzzer and Lamp (LED), and Control of Engine Shift Lever Gear Operations Inspection …………………...
Page 371 Copyright © 2014 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Tohatsu Corporation.
Page 372 Address : 5-4, Azusawa 3-Chome, Itabashi-Ku Tokyo, Japan Phone : TOKYO +81-3-3966-3117 FAX : TOKYO +81-3-3966-2951 URL : www.tohatsu.co.jp 40/50A OB No.003-21067-0 14-09 NB Printed in Japan...

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