Page 1 � � � � � � � � � � � � � � トーハツ船外機サービスマニュアル �� 2�2�� ｜ �� ｜ �� ...
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 8) Inspection of Water Pump …………… 3-9 9) Replacement of Gear Oil …………… 3-11 10) Inspection of Gear Case (for leakage) ………………………………………… 3-12 11) Inspection of Timing Belt …………… 3-13 1) Fire Prevention ………………………… 1-2 12) Replacement of Timing Belt ………… 3-13 2) Ventilation ………………………………...
Page 8 11) Inspection of Valve Spring …………… 5-35 12) Inspection of Valve …………………… 5-35 13) Inspection of Valve Guide …………… 5-35 4-20 1) Location of Warning Buzzer 14) Inspection of Valve Seat ……………… 5-36 15) Correction of Valve Seat ……………… 5-37 and Lamp (LED) ………………………...
Page 9 5) Inspection of Water Pump …………… 6-11 Bracket (Manual) ………………………… 7-18 6) Inspection of Water Pipe …………… 6-11 Bracket (PT) ……………………………… 7-22 7) Disassembly of Water Pump Case 7-26 (Lower) ………………………………… 6-12 1) Inspection of Throttle Cable ………… 7-26 8) Assembly of Water Pump Case (Lower) 2) Installation of Tiller Handle ……………...
Page 10 8) Inspection of Engine Temperature Sensor ………………………………………… 8-20 9-22 9) Inspection of Neutral Switch (Except MF) 1) Preparation …………………………… 9-22 ………………………………………… 8-20 9-23 10) Inspection of Start Switch (EF, EFT) 1) Start Up ………………………………… 9-23 ………………………………………… 8-21 2) Models and Menu Selection ………… 9-23 11) Inspection of Stop Switch ……………...
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Page 13 2) Gear Shift ……………………………… 1-9 3) Engine Oil ……………………………… 1-9 4) Gear Oil ………………………………… 1-9 1) Fire Prevention ………………………… 1-2 5) Fuel Line ………………………………… 1-10 2) Ventilation ……………………………… 1-2 6) Rigging ………………………………… 1-10 3) Protection ……………………………… 1-2 7) Inspection of PT unit (EFT, EPT) ……… 1-10 4) Genuine Parts …………………………...
Page 14 Engine serial number is stamped on the Swivel bracket 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. 3RS-64110-0 Outer diameter : 130 mm With : 20 mm Rotational speed at WOT Outboard motor model (Wide Open Throttle) (r/min) MFS9.9E Approx. 4000 MFS15E Approx. 5000 MFS20E Approx. 5800 For the following measuring instruments, use commercially available ones. Circuit tester (HIOKI 3000 Serise : Resistance : 1Ω, 10Ω, 10 kΩ, AC voltage : 30 to 300V, DC voltage : 30V ) Vernier calipers ( M1 type, 300 mm ) Micrometer...
Page 18 Torque Wrench Valve Clearance Driver Tachometer Compression Gauge P/N. 3AC-99010-0 P/N. 3AC-99030-0 P/N. 3AC-99070-0 P/N. 3AC-99071-0 Measuring engine Measuring compression Adjusting valve clearance Adjusting valve clearance revolution speed pressure Oil Filter Wrench Flywheel Puller Kit Vacuum/Pressure Gauge Pressure Gauge Ass'y P/N.
Page 19 ø110 x ø71 ø29.5 x ø16.5 Center Plate Driver Rod Universal Puller Plate Oil Seal Attachment P/N. 3AC-99702-0 P/N. 3AC-99701-0 P/N. 3AC-99750-0 P/N. 3AG-99820-0 Used in combination with Used in combination with a driver rod Used in combination with driver Removing reverse (C) gear center plate and roller bearing attaching oil seal of propeller shaft...
Page 20 Roller Bearing Press Bolt Roller Bearing Press Flange （）（） Bolt （） mark Wssher （） Roller Bearing Press Collar （） Stopper Roller Bearing mark Outer Press Guide （） Roller Bearing Press Rod （） Marking Side Roller Bearing Press （） Ring （） Roller Bearing Press Guide （） Backlash Measuring Tool Kit Roller Bearing Press Kit P/N.
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. Tiller Handle Model Remote Control Model Fill engine with engine oil.
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. Tiller Handle Model Remote Control Model Press stop switch hard or pull out lock from stop switch to check that engine stops.
Page 24 Check that cooling water check port discharges water during engine runs should be operation. After engine has warmed up, use tachometer or diagnostic program to check idle speed is as specified. Idle Speed : 950 r/min Tachometer : P/N. 3AC-99010-0 Select a propeller that is best-suited to type of boat and application.
Page 25 B r e a k - i n o p e r a t i o n i s n e e d e d f o r t h e p u r p o s e o f smoothening sliding surfaces between components such as pistons and cylinder, piston rings, piston pins, crank shaft, connecting rods, and intake and exhaust valves.
Page 26 Check that no water is present in gear oil. Check that no fuel leaks in the cowl. Check that no oil and water leak in the cowl and no water is present in engine oil. After test run, use hose joint and fresh water to wash cooling water path.
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 Maual Tilt Model Power Tilt Model MFS9.9/15/20E MFS9.9/15/20E Item Type Unit Item Type Unit mm/in 16.42 mm/in 16.42 mm/in 27.13 mm/in 27.13 mm/in 32.99 mm/in 32.99 mm/in 37.99 mm/in 37.99 mm/in 16.26 mm/in 16.26 mm/in 22.13 mm/in 22.13 mm/in 27.13 mm/in 27.13 mm/in...
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Page 31 ECU uses various sensors to precisely control injected fuel amount and ignition timing. Alternator Fuel Feed Pump (Exciter Coil) (FFP) Fuel Control Crank Position Sensor Fuel Injector (CPS) Idle MAP (Manifolde Pressure) (Idle Speed Control Valve) Air Control Sensor Electric Ignition Control MAT (Manifolde...
Page 32 Main Gallery 4st 9.9/15/20 2017...
Page 33 Cylinder Head Thermostat Thermostat Cylinder Fuel Cooler Cylinder Lower Section (Water Discharging Passage Cylinder Cylinder in Drive Shaft Housing) Head Interior of Drive Shaft Housing Cylinder Lower Section (Water Discharging Passage in Drive Shaft Housing) Discharging Fuel Cooler Water Pipe Idle Port Idle Port Pilot Water Hole...
Page 34 Model MFS9.9/15/20E Fi Item Unit (with Tiller (with Tiller (with Tiller (with Remote (with Remote Handle) Handle) Handle) Control) Control) Dimensions (approx.) Overall Length mm (in) with Remote Control : 635 (25.0) with Tiller Handle : 1,038 (40.9) Overall Width mm (in) Manual Tilt Model : 343 (13.5) Power Tilt Mode : 339 (13.4) mm (in)
Page 35 Model MFS9.9/15/20E Fi Item Unit (with Tiller (with Tiller (with Tiller (with Remote (with Remote Handle) Handle) Handle) Control) Control) Fuel & Oil Unleaded Gasoline (Research Octane Number 90 or over, Type of Fuel Pump posted Octane Number 87 or over) Fuel Tank Capacity L (gal) 12 (3.17)
Page 36 Model MFS9.9/15/20E Fi Item Unit (with Tiller (with Tiller (with Tiller (with Remote (with Remote Handle) Handle) Handle) Control) Control) Warning System Over-revolution Controls engine speed to approximately 6,300 r/min or less (High Speed ESG). Protection Warning lamp lits, and warning buzzer*2 sounds continuously. Engine Hydraulic Controls engine speed to approximately 2,800 r/min or less (Low Speed ESG).
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Page 38 Cylinder Head Build up of carbon in combustion chamber Pully side : Ø 18.010 to 18.025 mm (0.7091 to 0.7096 in) Measure the cam journal clearance Oil Pump side : Ø 32.00 to 32.05 mm (1.2598 to 1.2618 in) Distortion or damage on mating surface Distortion Limit : 0.05 mm (0.0020 in) or less Corrosion on the mating surface...
Page 39 Clean to remove. 18.050 mm (0.7016 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 Valve Clearance 0.13 to 0.17 mm (0.0051 to 0.0067 in) Intake Valve Exhaust Valve 0.18 to 0.22 mm (0.0071 to 0.0087 in) Valve Stem Outer Diameter 5.48 mm (0.2157 in) 5.46 mm (0.2150 in) Valve Guide Inner Diameter 5.51 mm (0.2169 in) 5.51 mm (0.2169 in) Clearance between valve guide 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 : BTDC 5°±5° (at 950 r/min) 9.9E : 5° to 25° 15-20E : 5° to 30° Spark Performance (at 500 r/min) 10mm (0.4in) or over (Use genuine spark tester.) Alternator Output (at 5,500 r/min) 12 V 145 W Alternator Resistance Between White and Yellow (at 20°C) 0.17 to 0.25Ω...
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. 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.
Page 44 Valve Operation Starting Temperature (Submerged) 52°C ± °C (126 ± 36°F) Thermostat Valve Full Open Temperature (Submerged) 65°C (149°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. 65°C (149°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 Cylinder Head Cover M6×1.0 Bolt First Tightening Torque : M8×1.25 Bolt Final Tightening Torque : Cylinder Block and Cylinder Head First Tightening Torque : M6×1.0 Bolt Final Tightening Torque :...
Page 47 Type of Tightening Torque N•m Fastened Components Wrench A Screw B x Pitch Fastener N•m lb•ft kg•m Drive Shaft Mount Rubber Upper — M8 x 1.25 Bolt Idle Port Cover — M6 x 1.0 Bolt Drain Bolt — M14 x 1.5 Bolt Gear Case Oil Plug (Gear Oil)
Page 48 Remarks Loctite Three Bond Loctite Konishi Tyuoh Yuka Shinetsu Suniko Mory 1373 Sentax Part Name 1342 1327 1401 past (271) ● ● Cam Head (When New, Apply Molybdenum Grease) Camshaft ● Bearing ● Oil Seal (Cam Shaft) ● Outer Surface, Press Fit Camshaft Pully Bolt Thread ●...
Page 49 Remarks Loctite Three Bond Loctite Konishi Tyuoh Yuka Shinetsu Suniko Mory 1373 Sentax Part Name 1342 1327 1401 past (271) Bolt (Drain Cover) ● Thread Bolt (Idle Exhaust Cover) ● Thread Water Pipe Seal (Upper) ● Outer Face Auxiliary Water Pipe Inner Face ●...
Page 50 Remarks Loctite Three Bond Loctite Konishi Tyuoh Yuka Shinetsu Suniko Mory 1373 Sentax Part Name 1342 1327 1401 past (271) Cylinder Pin Bush (Upper, Lower) ● Sliding Face PT Fluid （●） O-Ring （●） Throttle Arm Sliding Face ● Throttle Cam ●...
Page 51 16)Adjustment of Throttle Cable (Tiller handle model) …………………………… 3-20 17)Adjustment of Shift • Throttle Cable (Remote control model) ……………… 3-21 1) Inspection of Top Cowl ……………… 3-4 18)Inspection of Shift Lever Gear Operations 3-23 2) Inspection of Fuel Hoses …………… 3-4 19)Inspection of PT Unit Operation ……...
Page 52 Tachometer Compression Gauge Torque Wrench Valve Clearance Driver P/N. 3AC-99010-0 P/N. 3AC-99030-0 P/N. 3AC-99070-0 P/N. 3AC-99071-0 Measuring engine revolution Measuring compression Adjusting valve clearance Adjusting valve clearance speed pressure Oil Filter Wrench Flywheel Puller Kit P/N. 3AC-99090-0 P/N. 369-72211-0 Removing/installing oil filter Removing/installing flywheel 4st 9.9/15/20 2017...
Page 53 Inspection intervals First 20 Every 50 Every 100 Every 200 Every 400 Description Inspection procedure Remarks hours of 1 hours of 3 hours of 6 hours of 1 hours of 2 month months months year year ❍ Fuel Filter Check and Clean/Replace if Necessary ❍...
Page 54 Push top cowl to check for looseness and state of closing. C h e c k t h e f u e l s y s t e m p i p i n g f o r f u e l l e a k , d i r t , deterioration and damage, and replace or repair parts if necessary.
Page 55 R e m o v e f u e l p i c k u p e l b o w o f f u e l t a n k counterclockwise to remove the part, and clean the filter .
Page 56 Oil Level Quantity of Oil for Full Replacement When oil filter When oil filter is replaced is not replaced Upper Limit 1.2L (1.26 US qt.) 1.0L (1.05 US qt.) Lower Limit 0.95L (1.00 US qt.) 0.75L (0.79 US qt.) Oil Specification Recommended Engine Oil : 4 Stroke Engine Oil API : SH, SJ, SL...
Page 57 Drain engine oil. Place a piece of rag below oil filter area, and remove it by using oil filter wrench • Completely loosen the port side bolts first, then fully loose the starboard side bolts. • This bolt has a falling prevention structure, it can not be removed.
Page 58 Apply thin coat of engine oil to O-ring of filter before installing filter. Clean the cylinder at the location where the oil filter is installed. Install oil filter and tighten it to specified torque by using oil filter wrench Oil Filter : 18 N·m ( 13 lb·ft ) [1.8 kgf·m] Pour engine oil into oil inlet Recommended Engine Oil :...
Page 59 Tilt down outboard motor to make it vertical. Remove upper oil plug and check level of gear oil in the gear case. Some oil may spill 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. Remove pump upper case Remove impeller and check it. Check upper pump case for deformation. Replace if necessary. Check impeller and pump case liner for crack and wear.
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 case, and check if the pressure is maintained without further compression for 10 seconds. Specified Gear Case Maintained Pressure : 0.05 MPa ( 7 psi ) [ 0.5 kgf/cm •...
Page 63 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). Remove manual starter Loosen flywheel nut.
Page 64 Disconnect alternator coupler , pulser coil coupler, and connector and ground cable (three place), and then remove alternator and coil bracket ass'y. Turn the drive pulley in the clockwise, align the "● " mark of the drive pulley with the "▲" mark of the cylinder block, and move the "●...
Page 65 Remove timing belt from driven pulley side, and then, from timing pulley side. Check that "● 1" mark of driven pulley and "▲" mark of cylinder head are aligned Check that "●" mark of drive pulley and "●" mark of cylinder block are aligned with each other. No.1 piston is to be at top dead center of compression stroke.
Page 66 Turn drive pulley clockwise twice to adapt, and check that locating marks , and of pulleys are aligned with each other respectively. Secure align key slot of flywheel and crankshaft, and then install flywheel. Tighten flywheel nut to specified torque. Flywheel Puller Kit : P/N.
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 staerter lock cable, intake silencer, recoil starter, timing belt cover, spark plug. Driven Pulley Remove cylinder head cover.
Page 70 Set throttle cable to start (START) position. Set stopper on the throttle drum contact to stopper on the throttle bracket , then adjust throttle cable properly and tighten by the nut Make sure that the tension of the cable moves about 1 mm when lightly pressing with a finger.
Page 71 Set control 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 drum 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 72 Tighten nut , put it on the pin, and secure with washer and snap pin Check shift lever opration 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 73 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. Shift gear into reverse (R) to down the shift rod position.
Page 74 Reconnect remote control cable joint , attach snap pin , and tighten lock nut . (Remote Control Model) Check if gear shifts smoothly, and repeat steps 2. to 8. as necessary. Tilt up and down outboard motor several times to check that PT unit operates smoothly in full range.
Page 75 Fully tilt up outboard motor and lock with tilt stopper Remove reserve tank cap and check quantity of PT fluid contained in the tank. Quantity of PT fluid is normal when some fluid spills out of cap hole when cap is removed. Add recommended PT fluid to specified level if it is low.
Page 76 Adjusting system : Automatic control, requiring no manual adjustment. Run engine and use timing light to check ignition timing. 9 timings marks are found on the side of flywheel (TDC0°, ATDC5°, 10°, BTDC5°, 10°, 15°, 20°, 25°, 30°), and ignition timing is read with mark on the center of starter case window.
Page 77 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 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 corroded excessively.
Page 78 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 79 Measure valve lift of thermostat when prescribed temperature has been reached. Replace if valve lift is less than specified value. Water Temperature Valve Lift 65°C ( 149°F ) 3.0 mm ( 0.118 in ) or over Install thermostat, new gasket and cover. Thermostat Cover Bolt : 9 N·m ( 7 lb·ft ) [ 0.9 kgf·m] Check water strainer...
Page 80 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 81 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 82 Apply water proof grease to the parts shown below. 3-32 4st 9.9/15/20 2017...
Page 83 2) Warning Notification, Abnormality and Action to be taken …………………… 4-20 Fuel Hose, Vent Hose, Breather Hose, 4-21 Cooling Water Hose ………………………………4-3 1) Ignition Timing Controls ……………… 4-22 2) Ignition and Combustion Orders …… 4-22 Intake Manufold …………………………… 4-4 3) Ignition Timing ………………………… 4-22 Electric Parts ………………………………...
Page 84 Vacuum/Pressure Gauge Pressure Gauge Ass'y P/N. 3AC-99020-1 P/N. 3T5-72880-0 Inspecting pressure Measuring fuel pressure 4st 9.9/15/20 2017...
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 Idle Port) High Pressure Fuel Hose (Vapor Separator to Fuel Rail) 4st 9.9/15/20 2017...
Page 86 Fig.8-19 4st 9.9/15/20 2017...
Page 87 Ref. Description Q'ty Remarks Fuel Rail Assy Fuel Rail Fuel Injector Assy Seal Ring Valve Assy (Pressure Check) Nipple 8-6-13L O-ring 1.9-9.8 Do not reuse. Holding Plate Bolt M6 L=12 mm Bolt M6 L=25 mm Insulator Throttle Body Assy ISC Valve Map Sensor T-Map Sensor Screw...
Page 88 Fig.8-19 4st 9.9/15/20 2017...
Page 89 Ref. Description Q'ty Remarks Clip Screw Rubber Mount Collar Washer 6-16-1.5 Bolt M6 L=25mm Fuel Hose W/Protector VST-Fuel Rail Clamp ø16.8 Vent Hose W/Protector VST-Catch Tank Vent Hose W/Protector Catch Tank-Vent Vent Hose W/Protector Catch Tank-Exposure Fuel Pump Assy O-ring 3.5-25.7 Do not reuse.
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Page 91 Ref. Description Q'ty Remarks Flywheel M Type Flywheel W/Ring Gear EF/EP Type Alternator Assy M Type Alternator Assy EF/EP Type Pulsar Coil Bolt Pulsar M5 L=12 mm Key t=4 Washer 16-27-3.2 Bolt Alternator M6 L=25 mm Coil Bracket Bolt Coil Bracket M6 L=25 mm Clamp 6.5-47.5P Dowel Pin 6-12 Bolt...
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Page 93 Ref. Description Q'ty Remarks Spring Washer Solenoid Switch Cord (A) Solenoid Switch Cord (B) Terminal Cap 8-13-28 Terminal Cap 8-13-28 Black Bolt M6 L=12 mm Ground Cable L=120 Band 104 Do not reuse. Rubber Mount Collar Washer 6-16-1.5 Bolt M6 L=25 mm Starter Motor Assy Bolt Spring Washer...
Page 94 Fig.13-3 12-2 12-1 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Primer Bulb Assy 1 for USA Model 12-1 Fuel Tank Assy 12L 1 for USA Model 2 Joint Assy (Inlet) 12-2 Fuel Tank Assy 12L 3 Clamp 13 Fuel Tank Cap Assy 1 for USA Model 14 Retaining Ring 1 for USA Model...
Page 95 ECU uses various sensors to precisely control injected fuel amount and ignition timing. Fuel Tank Fuel Regulator Vapor Separator ④ Fuel Feed Pump （FFP） Ignition Coil Fuel Injector ⑧ ISC Valve T-MAP Sensor Engine TEMP. Sensor Oil Pressure Switch Pulser Coil Exciter Coil Charge Coil Rectifier / Regulator...
Page 96 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 97 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 lamp based on this information.
Page 98 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 electrically operated spring built-in type solenoid valve, and controls amount intake air that bypasses closed throttle valve.
Page 99 Accidental malfunction of ECU stops engine. ECU (Engine Control Unit) 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.
Page 100 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. Engine Revolution Speed and Crank Angle Pulser Coil Basic Injection...
Page 101 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 102 Warning System When an abnormality occurs on the engine, warning buzzer sounds and warning lamp (LED) is lit or blinks. In such case, engine speed is controlled but engine is not stopped. • Warning buzzer : In the remote control box for remote control model. (only for remote control model) •...
Page 103 For ignition system, CD 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 exciter coil of alternator. Which is input to ECU's regulator to feed power needed for operations of ignition coil, fuel injector and fuel feed pump (FFP).
Page 104 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 above mentioned sensors to generate ignition timing signal at the most suitable timings.
Page 105 Fuel pump (low pressure mechanical type) draws fuel from fuel tank, and feeds 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 106 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 107 Fuel regulator located on the inside section of vapor separator serves to keep regular fuel pressure. Fuel regulator consists of check valve 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. High Pressure Fuel from Fuel Feed Pump Excessive fuel returns to vapor separator.
Page 108 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 , T-Map (manifold pressure and temperature) sensor Intake manifold is provided with fuel rail and fuel injectors.
Page 109 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 cup for invasion of foreign matter and crack. Clean fuel filter cup with gasoline, and replace fuel filter necessary.
Page 110 Cleaning Fuel Tank Filter (for US) For US Remove the fuel pick up elbow of the fuel tank turning it counterclockwise to remove the part, and clean the filter Cleaning Fuel Filter Remove dirt and water from fuel tank if any. Cleaning Fuel Feed Pump (FFP) Filter Remove and clean fuel filter from fuel feed pump (FFP)
Page 111 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 : 0.05 MPa ( 7 psi ) [ 0.5 kgf/cm With the outlet closed, apply specified vacuum pressure to check that no air leaks.
Page 112 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) : 250±...
Page 113 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 114 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. Reinstall needle valve , float and float pin, and check that the parts moves smoothly.
Page 115 Attach float chamber to vapor separator. Reassemble all parts that were removed. Check that hose is reconnected correctly. Use diagnosis system to check operation of ISC (Idle Speed Control) valve. ISC Duty Rethio 10 to 20 % ( at idling speed) 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.
Page 116 4-34 4st 9.9/15/20 2017...
Page 117 23)Installation of Oil Pump ……………… 5-45 24)Installation of Cylinder Head ………… 5-46 5-3 Engine ……………………………………… 5-3 25)Disassembly of Cylinder Block ……… 5-47 Magneto & Electric Parts ………………… 5-4 26)Inspection of Piston Outer Diameter 5-48 Fuel Pump ………………………………… 5-8 27)Inspection of Cylinder Inner Diameter 5-48 Pulley &...
Page 118 Piston Slider Compression Gauge Torque Wrench Valve Clearance Driver P/N. 3AC-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 Piston Ring Tool Oil Filter Wrench P/N.
Page 119 15 N·m (11 lb·ft) [1.5 kgf·m] 30 N·m (22 lb·ft) [3.0 kgf·m] Ref. Description Remarks Q'ty 1 Recoil Starater 2 Power Unit 3 Engine Base Gasket Do not reuse. 4 Dowell Pin 5 Bolt 6 M8 6 Top Cowl Seal 7 Drive Shaft Housing Cover (L) 8 Drive Shaft Housing Cover (R) 9 Front Panel...
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Page 121 Ref. Description Q'ty Remarks Flywheel M Type Flywheel W/Ring Gear EF/EP Type Alternator Assy M Type Alternator Assy EF/EP Type Pulsar Coil Bolt Pulsar M5 L=12 mm Key t=4 Washer 16-27-3.2 Bolt Alternator M6 L=25 mm Coil Bracket Bolt Coil Bracket M6 L=25 mm Clamp 6.5-47.5P Dowel Pin 6-12 Bolt...
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Page 123 Ref. Description Q'ty Remarks Spring Washer Solenoid Switch Cord (A) Solenoid Switch Cord (B) Terminal Cap 8-13-28 Terminal Cap 8-13-28 Black Bolt M6 L=12 mm Ground Cable L=120 Band 104 Do not reuse. Rubber Mount Collar Washer 6-16-1.5 Bolt M6 L=25 mm Starter Motor Assy Bolt Spring Washer...
Page 124 Fig.8-19 4st 9.9/15/20 2017...
Page 125 Ref. Description Q'ty Remarks Fuel Rail Assy Fuel Rail Fuel Injector Assy Seal Ring Valve Assy (Pressure Check) Nipple 8-6-13L O-ring 1.9-9.8 Do not reuse. Holding Plate Bolt M6 L=12 mm Bolt M6 L=25 mm Insulator Throttle Body Assy ISC Valve Map Sensor T-Map Sensor Screw...
Page 126 Fig.8-19 5-10 4st 9.9/15/20 2017...
Page 127 Ref. Description Q'ty Remarks Clip Screw Rubber Mount Collar Washer 6-16-1.5 Bolt M6 L=25mm Fuel Hose W/Protector VST-Fuel Rail Clamp ø16.8 Vent Hose W/Protector VST-Catch Tank Vent Hose W/Protector Catch Tank-Vent Vent Hose W/Protector Catch Tank-Exposure Fuel Pump Assy O-ring 3.5-25.7 Do not reuse.
Page 128 Ref. Description Q'ty Remarks 1 Oil Level Gauge 2 Oil Level Gauge Guide 3 O-ring 1.9-9.8 Do not reuse. 4 Bolt 5 Drive Pulley (Timing Pulley) 6 Key 10-3.7-3 7 Key 10-3.7-3 8 Belt Guide 9 Lock Washer 10 Nut Pulley 11 Driven Pulley 12 Pre-coated Bolt 6-20 1 M6 L=20mm...
Page 129 4st 9.9/15/20 2017 5-13...
Page 130 5-14 4st 9.9/15/20 2017...
Page 131 Ref. Description Q'ty Remarks Spark Plug (DCPR6E) Cylinder Head Complete Cylinder Head Assy Dowel Pin 6-12 Oil Seal 18-35-8 Do not reuse. Camshaft Assy Rocker Arm Rocker Arm Adjusting Screw Adjusting Nut Rocker Arm Shaft Rocker Shaft Spring L=25 Washer 13.2-21.8-2 Collar Intake Valve Exhaust Valve...
Page 132 30 28 5-16 4st 9.9/15/20 2017...
Page 133 Ref. Description Q'ty Remarks Cyl Block & Crankcase Assy Oil Filter Bolt Pipe Dowel Pin 6-12 Cylinder Head Bolt 8-50 Crankcase Bolt M6 L = 30 mm Washer Oil Filter Hanger Bolt M8 L = 20 mm Thermostat Thermostat Cap Thermostat Cap Gasket Do not reuse.
Page 134 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Connecting Rod Assy 8 Piston 2 Connecting Rod Bolt 9 Piston Pin 10 Piston Pin Clip 3 Crankshaft Assy Do not reuse. 4-1 Plain Shaft Bearing A BLUE See page 5-54 11 Piston Ring Set 4-2 Plain Shaft Bearing A RED See page 5-54...
Page 135 Ref. Description Remarks Q'ty 1 Top Cowl Assy 2 Top Cowl Sub-assy 3 Air Guide 4 Tapping Screw 6-16 4 M6 L = 16 mm 5 Seal Rubber 6-1 Decal Set 1 9.9ps 6-2 Decal Set 1 15ps 6-3 Decal Set 1 20ps 7 Warning Decal 8 Caution Decal (A)
Page 136 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 1 Recoil Starter Assy 14 Starter Rope ø5-1800 1 L = 1800 mm 15 Starter Handle 2 Starter Case 3 Starter Lock Cam Spring 16 Rope Anchor 4 Starter Spring 17 Starter Lock 5 Reel 18 Starter Lock Spring 19 Starter Lock Wire...
Page 137 Refer to "Inspection of Compression Pressure" in chapter 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 138 Remove starter lock cable , recoil starter (three bolts) and driven Pulley cover Loosen flywheel nut. Flywheel Puller Kit P/N. 369-72211-0 Remove drive shaft housing cover and cowl seal · Loosen the port side bolt completely, then fully loose the starboard side bolt. ·...
Page 139 Disconnect throttle cable (for MF, EF, EFT models). Remove pin and then remove cable joint. (for EP, EPT models) Disconnect battely cables (two places). (except for MF model) Remove cable protector, then disconnect connetors (four places). (for EF, EFT models) 4st 9.9/15/20 2017 5-23...
Page 140 Remove lock tie, then disconnect PT motor leads (L, G) from PT solenoide. (for EFT, EPT models) Disconnect fuel hose. Remove oil level gauge. Disconnect PT switch couplers. (for EFT, EPT models) Disconnect cooling watrer hose (fuel cooler). 5-24 4st 9.9/15/20 2017...
Page 141 Disconnect shift rod (tiller handle side) (power unit side). Remove bolts (two bolts), then remove housing cover (front). Remove power unit by removing bolts (six bolts) and then hoisting it. · When hoisting power unit, perform the work carefully while checking if wires and hoses are caught by other parts.
Page 142 Remove flywheel, and then remove key. Flywheel Puller Kit : P/N. 369-72211-0 Screw puller onto crankshaft end until flywheel is disengaged from tapered section of crankshaft. Disconnect alternator coupler Remove bolts of alternator bolt and coil bracket bolt then remove alternator and coil bracket. 5-26 4st 9.9/15/20 2017...
Page 143 Place the removed power unit ass'y on table with left side (port side) facing down. Remove oil strainer from power unit ass'y B e f o r e r e m o v i n g o i l s t r a i n e r h o s e , n o t e arrangement of the hose.
Page 144 Flatten down drive pulley nut lock washer's tab. Attach crankshaft holder to crankshaft and secure it. Loosen drive pulley nut · Use 36mm socket wrench and ring wrench for this step. · When loosening nut of drive pulley hold driven pulley to prevent it from being turned.
Page 145 Remove nut , lock washer , belt guide , timing pulley and key Check timing belt for crack, damage and wear on both faces. Replace if necessary. Check drive pulley and driven pulley for crack, damage and wear. Replace if necessary. Install key , drive pulley , belt guide...
Page 146 Check that "●" mark of belt guide and "●" mark cylinder block are aligned with each other. This position is compression top dead center of No. 1 cylinder. Install driven pulley, check that "●" mark of drive pulley to "▲" mark of cylinder head are aligned with each other.
Page 147 Tighten timing pulley nut to specified torque. Bend up the tab of the lock washer. Use two 36mm wrenches for this step. (Spanner wrench and socket wrench) Crankshaft holder P/N. 3BJ-72815-0 Drive Pulley Nut : 64 N · m (47 lb · ft) [6.4 kgf · m] Crankshaft holder Deep socket 36mm Magneto key...
Page 148 · No.1 piston is to be at top dead center of compression stroke. · Removal or installation of parts can be made easier when some of them are assembled together. Remove power unit. (Refer to the section for removing power unit.) Remove fuel system parts from power unit.
Page 149 Remove electrical system parts from power unit. Remove driven pulley, fuel pump, 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.
Page 150 Loosen rocker arm lock nut, and loosen adjusting screw as much as possible. Remove oil pump ass'y Remove rocker arm shaft ass'y , collar , spring washer and rocker arm shaft • Use a flat-blade screwdriver as a guide tool and slowly pull out rocker arm shaft.
Page 151 Measure valve spring free length . Replace if the length is less than specified value. Valve Spring Free Length : Standard Value 32.85 mm (1.29 in) Functional Limit : 31.5 mm ( 1.24 in) Check valve for dent and wear on the face. Replace if necessary.
Page 152 Obtain clearance between valve guide and valve stem by calculating as described below. Replace cylinder head and/or valve if the clearance is over specified value. Clearance between valve guide and valve stem = Valve Guide Inner Diameter - Valve Stem Outer Diameter Intake Side : 0.008-0.040 mm (0.00031-0.00157 in) Exhaust Side : 0.025-0.057 mm (0.00098-0.00224 in)
Page 153 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 154 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 70 degree seat cutters respectively if the area is too wide.
Page 155 Apply thin coat of abrasive compound on the overall valve seat contact area, and turn valve lapper (commercially available item) while lapping valve. · Use finer abrasive compound to finish. · When changing abrasive compound to finer one, remove present one completely. ·...
Page 156 Measure cam height. Replace if it is less than specified value. Cam Height at Both Intake and Exhaust Sides : Standard Value Intake side : 23.63 mm (0.9303 in) Exthoust side : 23.80 mm (0.9370 in) Functional Limit : Cam Height at Both Intake and Exhaust Sides Intake side : 23.5 mm (0.9252 in) Extaust side : 23.5 mm (0.9252 in) Measure cam shaft runout.
Page 157 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 : 0.1 mm (0.004 in) 4st 9.9/15/20 2017 5-41...
Page 158 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 0.36 mm ( 0.0142 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 159 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 ·...
Page 160 Apply engine oil to periphery of new oil seal and install Oil Seal Attachment : Commercially available item Apply seal grease to lip of oil seal before installing it. ①オイルシール 50-68-9 Apply engine oil to camshaft, install cam shaft from direction shown. Apply sufficient amount oil to cam surface of cam shaft and journal of rocker arm shaft.
Page 161 Install rocker arms , collar , springs , and washers from lower side of cylinder head while installing rocker arm shaft · Only for # 2 EX rocker arm on oil pump side is different in shape. · Apply sufficient amount of engine oil to rocker arm and adjust screw after installing rocker arm.
Page 162 No.1 piston is to be at top dead center of compression stroke. After installing driven pulley, bring "●1" mark of pulley to "▲" mark of cylinder head. Check that "●" mark of drive Pulley and "●" mark of 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 163 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 164 Measure piston outer diameter between points specified. Replace if the diameter is less than specified value. Piston Outer Diameter : Standard Value 60.960 mm (2.4000 in) Measurement Points 12 mm ( 0.47 in) above piston skirt bottom Functional Limit : 69.90 mm ( 2.7520 in) Measure cylinder inner diameters (D1 to D6) at in crankshaft directions...
Page 165 Measure piston side clearance. Replace piston and piston rings as a set if the clearance is over specified value. Piston Side Clearance : Top Ring : 0.03 to 0.08 mm (0.0012 to 0.0031 in) Second Ring : 0.02 to 0.06 mm (0.0008 to 0.0024 in) Oil Ring : 0.03 to 0.13 mm (0.0012 to 0.0051 in) Functional Limit :...
Page 166 Measure piston pin outer diameter. Replace piston pin if outer diameter is less than specified value. Piston Pin Outer Diameter : Standard Value 16.00 mm (0.62992 in) Functional Limit : 15.97 mm (0.62874 in) Measure piston pin inner diameter . Replace piston pin if the inner diameter is over specified value.
Page 167 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 39.988 to 33.996 mm (1.3381 to 1.3384 in) Crank Pin Outer Diameter : Standard Value 28.927 to 28.985 mm (1.1406 to 1.1411 in) Functional Limit :...
Page 168 Clean connecting rod and metal bearing, and then install metal bearing. 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 169 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 170 Loosen bolts in reverse order in several steps. Remove crank case and measure width of crushed plasti-gauge on each main journal. Replace bearing if the width is over specified value. Crankshaft Main Journal Oil Clearance : 0.012 to 0.044 mm (0.00047 to 0.00173 in) Functional Limit : 0.060 mm (0.00236 in) If the clearance is less than specified value,...
Page 171 Install connecting , piston pin , and piston pin clip to piston • Point "❍" mark of connecting rod and "UP" mark of piston at the same direction. • Be sure to use new piston pin clip, and place clip gap away from piston pin groove shown.
Page 172 Put pistons into cylinder with piston "❍" 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. • Clean and remove piston carbon. Piston Slider P/N.
Page 173 Degrease bearing holder surface of the crankcase and the bearing contact surface, and 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. •...
Page 174 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 oil pressure switch •...
Page 175 Install oil level gauge Do not reuse O-ring. Install vapor separator Ass'y and throttle bracket Tiller Handle Model Remote Control Model Install throttle body Ass'y Do not reuse gasket. Install injector No.1 , No.2 and fuel rail Connect fuel system hose and pipes. 4st 9.9/15/20 2017 5-59...
Page 176 Install oil strainer • Place power unit Ass'y on the table with left side (port side) facing downward, and install oil strainer • Complete this work in a short period. Doing this work for long time can cause engine oil to flow from breather pipe.
Page 177 Install alternator Install motor band and starter cable to the starter motor (except for MF model). Connect main harness – ground lead and pulser coil coupler Connect ECU cpupler , oil pressure switch sensor cord , ground lead and cover grommet When installing grommet , be careful not to plug the small hole...
Page 178 Install flywheel with flywheel engaged with crankshaft key. Tighten flywheel nut to specified torque. Flywheel Puller Kit : P/N. 369-72211-0 Flywheel Nut : 80 N · m (58 lb · ft) [8.0 kgf · m] Clean power unit mating surface, and install dowel pin and gasket Install power unit , and tighten bolts...
Page 179 Tighten housing cover (front) bolts. Install shift rod (power unit side) to shift lever (handle side) (for MF, EF, EFT models). Connect vent hose , cooling water hose (fuel cooler) and drain hose Install timing belt cover , connect breather hose vent hoses to timing belt cover, and then install oil level gauge...
Page 180 Connect PT switch coupler ( For EFT model). Connect shift rod (lower unit). Connect PT motor leads and clamp to electrical bracket with band (for EFT, EPT models). PT Motor Lead Nut : 4 N · m (3 lb · ft) [0.4 kgf · m] Connect starter switch leads, neutral switch leads (for EF, EFT models ), engine stop switch leads (for MF, EF, EFT models) and engine oil warning lamp leads, then bundle...
Page 181 Connect (+) battery cable (except for MF model). Connect main harness cable (for EF, EP models), PT solenoid jumper cord and battery cord. (+) Battery Cord Nut : 4 N · m (3 lb · ft) [0.4 kgf · m] Connect throttle joint , throttle cable and starter lock cable...
Page 182 Install intake silencer (three bolts). Install housing cover and seal Check the mating surface of housing covers with it completely. Fill with specified amount of engine oil. Recommended Engine Oil : 4 Stroke Engine Oil API : SH, SJ, SL SAE : 10W-30 , 10W-40 Quantity of Engine Oil: When oil filter is not replaced : 1.0 L (1.05 US qt).
Page 183 Shift gear into neutral (N). Check that maximum diameter section of slide is at neutral start mark If not, adjust lower side of cable (power unit side). Slide Perform shift operation to check that recoil starter is Neutral start mark locked at other than neutral (N) position.
Page 184 Remove start shaft bolt , and then, friction plate spring Take out reel carefully. Friction Spring Friction Plate Starter Shaft Bolt Remove bushing and tapping screw , and then, ratchet , ratchet guide , and return spring Bushing Ratchet Tapping screw Ratchet Guide Reel Return Spring...
Page 185 Check ratchet, starter lock and all springs. Replace if any deformation, wear or damage is found. Check reel and starter case. Replace if any crack or damage is found. Check starter rope. Replace if any wear, unraveling or damage is found. ●...
Page 186 5-70 4st 9.9/15/20 2017...
Page 187 18) Assembly of Propeller Shaft Ass'y … 6-19 19) Removing Drive Shaft Ass'y ………… 6-20 Gear Case ………………………………… 6-4 20) Disassembly of Drive Shaft Ass'y … 6-21 21) Inspection of Drive Shaft …………… 6-21 1) Draining Gear Oil ……………………… 6-8 22) Inspection of Pinion (B) Gear ………...
Page 188 Spring Pin Tool A Spring Pin Tool B Bevel Gear B Nut Wrench Bevel Gear Nut Socket P/N. 345-72227-0 (ø3.0) P/N. 345-72228-0 (ø3.0) P/N. 346-72231-0 P/N. 346-72232-0 Removing spring pin Installing spring pin Removing or attaching pinion (B) gear nut ø110 x ø71 Center Plate Universal Puller Plate...
Page 189 Roller Bearing Press Bolt Roller Bearing Press Flange （）（） Bolt （） mark Wssher （） Roller Bearing Press Collar （） Stopper Roller Bearing mark Outer Press Guide （） Roller Bearing Press Rod （） Marking Side Roller Bearing Press （） Ring （） Roller Bearing Press Guide （） Backlash Measuring Tool Kit Roller Bearing Press Kit P/N.
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Page 191 Ref. Description Q'ty Remarks Gear Case Assy Roller Bearing Do not reuse. Ball Bearing 6205HS Do not reuse. Plug 8-8 Gasket 8.1-15-1 Do not reuse. Water Strainer Screw M4 L=30mm Nylon Nut 4-P0.7 Anode Bolt M6 L=20mm Nylon Nut 6-P1.0 Bolt 8-31 M8 L=31mm Water Seal Rubber...
Page 192 4st 9.9/15/20 2017...
Page 193 Ref. Description Q'ty Remarks Shim 35-41.9-0.1 t = 0.1 Shim 35-41.9-0.15 t = 0.15 Select as necessary. Shim 35-41.9-0.3 t = 0.3 t = 0.5 Shim 35-41.9-0.5 Drive Shaft (S) Drive Shaft (L) Drive Shaft (UL) Ball Bearing Do not reuse. Cam Rod Transom S&L Cam Rod (UL) Clutch Cam...
Page 194 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 195 · 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 196 Loosen mounting bolt in the pump case (upper), then remove pump case (upper) - - - . Remove water pump impeller key Remove guide plate , gasket and pump case (lower) from gear case. When removing pump case (lower), insert bladed screw driver into the groove of the case, and pry slowly to separate the part.
Page 197 Remove stopper and cam rod , and then remove O- ring from pump case (upper). 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 198 Remove oil seal Be careful not to damage the seal mating surface on the case. Install oil seal by using suitable press and then press-fit perpendicularly. · Apply gear oil to oil seal circumference before installing oil seal. · Apply OBM grease to oil seal lip. 6-12 4st 9.9/15/20 2017...
Page 199 Remove clutch cam Spring Pin Tool A (ø3.0) : P/N. 345-72227-0 Check the part for wear and damage. Replace if necessary. Check especially for wear on the face that scrapes against push rod and flaws on the circumference Attach clutch cam to cam rod Spring Pin Tool B (ø3.0) :...
Page 200 Remove propeller shaft ass'y. Use a plastic hammer to remove the part if it cannot be removed by inserting a bladed screw driver. When using commercially available puller, refer to 2. Use commercially available puller to remove as following illustration. Hold propeller shaft and remove propeller shaft housing ass’y.
Page 201 Remove reverse gear (C gear) by putting two bladed screw drivers into the gap to force the gap to open. Use commercially available universal puller plate to remove ball bearing. Before removing, check bearing for play or deflection. Replace if necessary. Remove oil seal from propeller shaft housing.
Page 202 Use cleaning oil and cleaning brush to clean propeller shaft housing, and check it for crack or damage. Replace if necessary. Check reverse (C) gear teeth and clutch for crack or damage. Replace if necessary. When reusing bearing without removing it, check it for play or deflection.
Page 203 Install bearing to propeller shaft housing. Use a suitable mandrel to install new bearing to propeller shaft housing. · Clean reverse (C) gear bearing installation face and apply gear oil before installation. · Install ball bearing with manufacturer’s marking facing attachment side. Install reverse (C) gear ass'y into propeller shaft housing.
Page 204 After taking out clutch spring , remove clutch from propeller shaft. Check propeller shaft for bend, wear and damage. Replace if necessary. Measure propeller shaft runout. Runout Limit : Supporting Points 0.05 mm (0.0020 in) Check clutch claw and push rod for crack and wear.
Page 205 Attach spring , push rod , clutch and clutch pin to propeller shaft. · When attaching clutch, face the narrower claw to push rod side. · Install clutch pin while applying preload to push rod. · Be careful not to allow ball to ﬂy out by spring Clutch Pin Snap tension.
Page 206 Attach new clutch pin snap by using a bladed screw driver to turn the snap. · When attaching clutch pin snap, do not apply excessive force to the part, or the snap may expand during operation of the engine, resulting in damaging gear and/or other parts severely.
Page 207 Pull out drive shaft from gear case. · When removing drive shaft, be careful not to give damage to shim on the bearing outer race and not to lose the part. · Replace shim with new one of the same thickness if any deformation or damage is found on it.
Page 208 Check gear teeth and dog for crack, wear and damage. Replace if necessary. 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.
Page 209 Use universal puller plate to make gap between ball bearing and forward gear. Put two bladed screw drivers in the gap and pry out forward (A) gear from bearing. Before removing, check bearing for play or deflection. Replace if necessary. Check forward (A) gear teeth and clutch claws for crack, damage, and wear.
Page 210 Remove roller bearing by using the following tools. Roller Bearing Press Kit : P/N. 3AC-72900-1 Bearing Outer Press Flange P/N. 3AC-72900-2 Bearing Outer Press Guide P/N. 3AC-72765-2 Roller Bearing Press Rod P/N. 3RS-72769-0 Roller Bearing Press P/N. 3BJ-72770-0 Roller Bearing Press Guide P/N.
Page 211 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 : 0.05 MPa ( 7 PSi ) [ 0.5 kgf/cm •...
Page 212 Use the following tools to install ball bearing Bearing Outer Press Kit P/N. 3B7-72739-1 Bearing Outer Press Plate P/N. 3BJ-73723-0 Fix gear case on a holder with its propeller shaft opening facing upward. Clean outer race installation face in the gear case and apply gear oil.
Page 213 Fixing gear case on the vice with its propeller shaft opening facing upward makes the work easier. Install roller bearing by using the following tools. Roller Bearing Press Kit : P/N. 3AC-72900-1 Bearing Outer Press Flange P/N. 3AC-72900-2 Bearing Outer Press guide P/N.
Page 214 Clean gear case interior. After installing forward (A) gear into bear case, install drive shaft ass'y , pinion (B) gear and pinion (B) gear nut , and tighten the nut to specified torque. Pinion (B) Gear Nut : 35 N · m (25 lb · ft) [3.5 kgf · m] Bevel Gear B Nut Socket P/N.
Page 215 Backlash Measuring Tool Kit : P/N. 3C8-72234-2 Measuring Tool Set Piece : P/N. 3BJ-72245-0 Backlash Measuring Tool Clamp : P/N. 3B7-72765-2 Dial Gauge Plate : P/N. 3B7-72729-0 Assemble the pump case (lower) refer to procedure in "Chapter 6 Assembling the lower unit". Perform measurement of backlash between forward (A) gear and pinion (B) gear with propeller shaft housing, propeller shaft and reverse (C) gear removed from gear...
Page 216 Perform shim adjustment as necessary based on the Shim thickness to Dial Gauge Reading increase / decrease gauge value obtained. The table shows relation between dial gauge readings and shim adjustments. 0.00 to 0.25 – 0.15 1. Values in this table indicate dial gauge readings 0.26 to 0.52 –...
Page 217 Assemble drive shaft ass’y , pinion (B) gear pinion (B) gear nut, and tighten the nut to specified torque. Bevel Gear B Nut Socket P/N. 346-72232-0 Bevel Gear B Nut Wrench P/N. 346-72231-0 Pinion (B) Gear Nut : 35 N · m (25 lb · ft) [3.5 kgf · m] ·...
Page 218 Install shim that is removed when disassembly. Install O-ring , camrod , stopper and gasket pump case (lower) and install pump case (lower) to gear case. • Insert cam rod into pump case (lower) and turn it by 90 °. •...
Page 219 Attach water pump liner to pump case (upper) Apply OBM grease to inside of water pump liner. Install pump case (upper) and gasket on the drive shaft, and install them on the pump case (lower) 8. Attach water pipe seal Apply OBM grease thinly on the inside water pipe seal so that water pipe can be inserted smoothly.
Page 220 Tilt-up outboard motor and lock with tilt stopper. Set shift rod to up position (into Reverse position). · Apply thin coat of TEFLON grease to spline of drive shaft before assembling. · Apply thin coat of OBM grease to water pipe seal rubber.
Page 221 Tighten lower unit ass’y installation bolts to specified torque. Lower Unit Bolt : 24 N · m (17 lb · ft) [2.4 kgf · m] Tighten the shift cam joint nut, and then connect shift rod and camrod. Make sure to check for shift rod pulling completely.
Page 222 6-36 4st 9.9/15/20 2017...
Page 223 10)Disassembling Clamp Bracket (EFT, EPT models) …………………… 7-36 11) Assembling Clamp Bracket (EFT, EPT models) …………………… 7-37 ……………………………… 12)Disassembling Clamp Bracket Manual Tilt Operation …………………… 7-3 (MF, EF models) ……………………… 7-38 Tilt Up Operation ………………………… 7-4 13)Assembling Clamp Bracket Tilt Down Operation ………………………...
Page 224 4st 9.9/15/20 2017...
Page 225 • 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. • T he power tilt switch located on the tiller handle or remote control box is used to tilt-up or down the outboard motor. Turning the manual operation valve counterclockwise to open completely the manual operation circuit.
Page 226 Pressing "UP" side of PT switch causes the PT 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 downward to open down-pressure main check valve. Oil in the cylinder upper chamber is returned to gear pump, hydraulic pressure of oil passage is increased to open up-pressure main check valve, and the oil flows into cylinder lower chamber.
Page 227 Pressing "DOWN" side of PT switch causes the PT 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 upward to open up-pressure main check valve. Oil in the cylinder lower chamber is returned to gear pump, hydraulic pressure of oil passage is increased to open down-pressure main check valve, and the oil flows into cylinder upper chamber.
Page 228 The PT 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 229 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 230 24 N·m (18 lb·ft) [2.4 kgf·m] 24 N·m (18 lb·ft) [2.4 kgf·m] 4st 9.9/15/20 2017...
Page 231 Ref. Description Q'ty Remarks Drive Shaft Housing Assy (S) Drive Shaft Housing Assy (L) Drive Shaft Housing Assy (S) PT Type Oil Seal 12.8-25-7 Do not reuse. Drain Bolt 14-14 M14 L=14mm Washer 14.5-24-1 Dowel Pin 6-12 Dowel Pin 6-12 Dowel Pin 6-12 Extension Housing Water Pipe (S)
Page 232 37 7-10 4st 9.9/15/20 2017...
Page 233 Ref. Description Q'ty Remarks Throttle Drum Assy Ball Joint Collar Washer 6-16-1.5 Bolt M6 L = 40 mm Throttle Wire Bracket Bolt M6 L = 16 mm Link Rod Assy (Throttle) Throttle Rod Ball Joint Connector Grommet Shift Lever Stopper Shift Lever Stopper t=0.8 Bolt M6 L = 12 mm...
Page 234 37 7-12 4st 9.9/15/20 2017...
Page 235 Ref. Description Q'ty Remarks Throttle Decal PT Switch Assy PT Type Switch Box PT Type Screw PT Type M5 L = 16 mm Clamp 6-9.5L PT Type Screw PT Type M5 L = 12 mm Bushing Bushing Washer Cover Washer Throttle Wire Steering Bracket Grease Fitting...
Page 236 EPT TYPE 7-14 4st 9.9/15/20 2017...
Page 237 Ref. Description Q'ty Remarks Front Panel Pilot Lamp Assy Fuel Connector (Male) Bolt M6 L = 16 mm Grommet 17-2.7 Main Switch Hole M type Grommet Shift Rod Hole F type Grommet 40-18-3 Cover Stay (Front) Rivet 4-12.9-2.4 Main Switch Assy E type Grommet 22-3 Shift Rod Hole P type...
Page 238 7-16 4st 9.9/15/20 2017...
Page 239 Ref. Description Q'ty Remarks Drag Link Assy Spacer 9.6-19-13 Bolt 3/8-35 Nylon Nut 3/8-24UNF Washer 9.6-18-2 Seal Ring Remote Control Fitting Assy Grommet P type Cable Clip Assy Bolt M6 L=16mm Cable Joint Washer 8.5-18-1.6 Washer 8.5-18-1.6 Snap Pin d=8 Shift Arm Collar 6.5-10.5-9.3 Washer 6-16-1.5...
Page 240 51 52 Fig.8-15 7-18 4st 9.9/15/20 2017...
Page 241 Ref. Description Q'ty Remarks Clamp Bracket (R) Clamp Bracket (L) Co-pilot Decal Anode Anode Bolt M6 L = 20 mm Distance Piece Washer Washer Swivel Bracket Shaft Assy Nylon Nut 7/8-14 Bushing Cap Nut Thrust Rod Assy Thrust Rod Spring Swivel Bracket Transom S Swivel Bracket...
Page 242 51 52 Fig.8-15 7-20 4st 9.9/15/20 2017...
Page 243 Ref. Description Q'ty Remarks Washer 6-16-1.5 Reverse Lock (R) Reverse Lock Arm Reverse Lock Shaft E-ring d=6 Reverse Lock Rod Split Pin 2-12 Reverse Lock Link Reverse Lock Spring (S) Reverse Lock Spring Steering Shaft Assy Steering Shaft Assy (L & UL) Bushing 28-31-35 Thrust Plate (Upper) O-ring 3.5-25.7...
Page 244 Fig.10 Fig.10 Fig.10 Fig.10 59 60 63 64 Fig.10 7-22 4st 9.9/15/20 2017...
Page 245 Ref. Description Q'ty Remarks Anode Ground L=130 Clamp Bracket (L)-PT Ground L=130 Clamp Bracket (R)-Swivel Bracket Nylon Nut 8-P1.25 Washer 8.1-16-1.5 Clamp Bracket (PT-R) Clamp Bracket (PT-L) Trim Lock Pin Bolt M6 L = 16 mm Washer 22-36-1 Nylon Washer 8.5-28-1 Swivel Bracket Assy Tilt Stopper Tilt Stopper Grip...
Page 246 Fig.10 Fig.10 Fig.10 Fig.10 59 60 63 64 Fig.10 7-24 4st 9.9/15/20 2017...
Page 247 Ref. Description Q'ty Remarks O-ring Do not reuse. Valve Assy O-ring 1.5-3.5 Do not reuse. O-ring 1.5-3.5 Do not reuse. Pump Bolt Bolt Bolt Filter Coupling O-ring 2-62.5 Do not reuse. O-ring Do not reuse. Band Do not reuse. Pre-coated Screw M5 L = 12 mm Breaker Breaker Holder...
Page 248 Check operation of throttle cable. Check throttle cable inner wire and outer wire for bend and damage. Replace if necessary. Operate throttle fully closed and fully opened, and it is confirmed whether throttle drum is fully closed or fully opened. (Since the cam is fully closed when adjustment of throttle cable, cam may not be fully opened even if the throttle is fully opened) Install the stop switch lead...
Page 249 Install throttle shaft with cable attached to tillar handle. Pay attention to installation position of throttle friction Install the bushing to steering bracket Attach tiller handle ass'y to steering bracket , and tighten nut to specified torque. Arrange throttle cable as shown. Install cable of which inner wire is stretched when acceleration grip is set to full closed position.
Page 250 WA R N I N G Install friction plate and tiller handle ass'y. Move friction lever to left to slide it to tightening position. Tighten nylon nut until steering load becomes heavy. Tighten nylon nut to approximately 6 N · m (4 lb ·...
Page 251 Drain engine oil completely by referring to “Chapter 5) Remove power head" and remove power unit. Remove cowl seal from drive shaft housing. Remove grounding wires Remove bolts lower mount bracket. Check that damper and rubber mount are normal. Replace if abnormal. 4st 9.9/15/20 2017 7-29...
Page 252 Remove nuts of upper rubber mount Remove drive shaft housing from clamp bracket ass’y. Be careful not to drop drive shaft housing when removing the housing from clamp bracket. Remove upper rubber mount installation bolts then remove rubber mount , damper from drive shaft housing.
Page 253 Remove idle exhaust cover , gasket and check that idle exhaust cover has no abnormality such as cracks or flaws and internal sludge . Remove bolts , and then remove water pipe from drive shaft housing. Check water pipe auxiliary mount for abnormality such as crack.
Page 254 Install water pipe into drive shaft housing. Attach new gasket and exhaust cover securing bolts and tighten them in the order of their numbers shown to specified torque. Idle Exhaust Installation Bolt : 6.0 N · m (4.3 lb · ft) [0.6 kgf · m] Install upper mount and damper on the drive shaft...
Page 255 Insert damper and drive shaft housing ass’y into stud bolt hole of upper rubber mount of swivel bracket Correctly align bolt hole position of damper when installing. Install rubber mount and lower dumper and mount bracket to drive shaft housing. Tighten bolts and nuts specified torque.
Page 256 Attach ground wire Be careful not to paint ground wire attaching surface or the anti-corrosion effect will be disabled. Remove drive shaft housing by referring to “Chapter 7 Removing Drive Shaft Housing”. Loosen co-pilot handle nut and remove handle Pull out steering shaft from swivel bracket ass'y to remove.
Page 257 Attach thrust plate and bushing to steering shaft. Stand swivel bracket ass'y vertically, and insert steering shaft into swivel bracket ass'y. Attach bushing , new O-ring , and thrust plate swivel bracket. · Push bushing by using flat head screw driver until it stops.
Page 258 Install co-pilot handle, and adjust co-pilot. Remove drive shaft housing, steering shaft and co-pilot before beginning this procedure. Loosen nut of swivel bracket shaft . Loosen bolt of distance piece and remove bolt . Pull out swivel bracket shaft, and then, remove clamp bracket from swivel bracket Check swivel bracket shaft and other parts for abnormality,...
Page 259 Reassemble components of swivel bracket , and then insert distance piece into clamp brackets Install clamp bracket to swivel bracket , insert swivel bracket shaft , and then tighten nylon nut , and nut to their specified torque respectively. Nylon Nut 24 N ·...
Page 260 Remove thrust rod from clamp bracket Loosen and remove nut of swivel bracket shaft Pull out swivel bracket shaft then remove clamp bracket from swivel bracket 7-38 4st 9.9/15/20 2017...
Page 261 Check swivel bracket shaft and other parts for abnormality, and replace if necessary. Reassemble components of swivel bracket then install clamp brackets 4st 9.9/15/20 2017 7-39...
Page 262 Install clamp bracket to swivel bracket, insert swivel bracket shaft , and then tighter nylon nut to specified torque. Nylon Nut : 24 N · m (17lb · ft) [2.4 kgf · m] Apply OBM grease to swivel bracket shaft sufficiently.
Page 263 Fully tilt up outboard motor and lock with tilt stopper WA R N I N G • • C A U T I O If PT unit will not operate, open manual valve and lift up outboard motor with hands. When manual valve is opened, be sure to tighten it with specified torque after tilting up outboard motor.
Page 264 Remove bolt and washer located on the starboard side of the outboard motor then upper cylinder pin Upper cylinder pin can be removed easily when tilt rod is retracted a little by performing tilt down operation. Remove cap, loosen nylon nut of the port side bracket and clamp screw, and make the bracket clearance.
Page 265 Loosen fill cap of PT unit slowly, and then remove it. Fully extend tilt rod before removing fill cap. Drain power tilt fluid from filler cap outlet. Remove manual valve C-ring and turn manual valve counterclockwise to remove. Remove O-ring (2 pcs) from manual valve , check O-ring for damages and deterioration, and replace with new part if...
Page 266 Attach O-rings (2 pcs) to manual valve. Attach manual valve to power tilt ass'y. Attach C-ring Remove two inner hex bolts , and then remove motor ass'y from PT pump and cylinder ass'y Before disassembling power tilt motor, drain power tilt fluid.
Page 267 Check electrical conductivity of armature . Replace armature ass'y if other than specification. Armature Conductivity : Non-conductive Commutator ∞ Armature shaft Meter Armature Commutator Armature ass'y Replace brush if it is damaged or if gap between brush end in the groove of brush holder and brush holder end is 1.6 mm or less.
Page 268 Attach circuit breaker to motor bracket Attach circuit breaker holder securely by using screws. Attach blue wire to terminal post of circuit breaker Place green wire along bore of bracket. Attach brush holder by using screw Attach green wire and brush wire end to motor bracket securely by using screw Wire (blue) Spring...
Page 269 Attach yoke ass'y by using two screws Yoke ass'y Screw (2) Motor bracket WA R N I N G Remove PT ass'y from outboard motor. Remove PT motor ass'y from PT ass'y Filter Pump/motor coupling Remove pump coupling Remove filter from PT ass'y.
Page 270 Remove three screws that secure PT pump assembly. Power tilt pump Internal hex screw (5mm × 20) Internal hex screw (5mm × 25) Remove UP side relief valve , DOWN relief orifice and O-ring (2 pcs) from power tilt housing. Up relief valve component Down relief orifice O-ring...
Page 271 Coat new O-rings (2 pcs) with oil and attach it to PT housing. Coat new O-ring with oil and attach it to orifice Attach filter and orifice Attach up side relief valve to PT pump housing. Recommended PT Fluid : ATF DEXRON III Up relief valve ass'y Down orifice ass'y...
Page 272 Attach cleaned screen Attach pump coupling to pump. Install motor ass'y to PT pump and cylinder ass'y. Attach wireharness mounting screws. Pump filter Pump/motor coupler Install motor ass'y to cylinder ass'y and PT pump using screws , and tighten screws to specified torque. Motor ass'y installation screws: 5 N ·...
Page 273 Turn manual valve clockwise fully. Put PT unit on the work bench vertically, remove cap and check level of fluid in the reservoir. WA R N I N G Add recommended PT fluid to specified level if it is lacking. Recommended PT Fluid : ATF DEXRON III Put cap...
Page 274 Fully tilt up outboard motor and lock with tilt stopper WA R N I N G • • Install bushing on the tilt cylinder rod Power tilt cylinder Cylinder rod eye Bushing Attach pivot bushings (2) to clamp bracket Expand the port side clamp bracket slightly and position PT assembly between clamp bracket Put tilt cylinder pivot pin (lower)
Page 275 Put washer and bolt on the pin (lower) then tighten the bolt to specified torque. Retaining bolt : 13 N · m (1.9 lb · ft) [1.3 kgf · m] Attach bushings (2) to swivel bracket Extend power tilt cylinder rod to align tilt cylinder rod and swivel bracket.
Page 276 Attach electrical cord of power tilt unit to PT relay Unlock tilt stopper, and repeat tilting up and down outboard motor to bleed air from hydraulic circuit. < Refer to 3) Air-Purging PT Unit > Check power tilt fluid level, and replenish if necessary. This test can be made without removing parts.
Page 277 Inspection of UP side relay As shown in the figure, connect blue terminal (L) in the coupler to battery positive terminal and black terminal (B) to negative terminal, and then, connect circuit tester leads to PT relay terminals Check electrical conductivity between terminals Replace relay if non-conductive.
Page 278 7-56 4st 9.9/15/20 2017...
Page 279 8-22 1) Inspection of Injectors ………………… 8-22 Port Side View …………………………… 8-3 2) Inspection of ISC Valve ……………… 8-22 Bow Side View …………………………… 8-4 3) Inspection of T-MAT Sensor ………… 8-23 Starboard Side View ……………………… 8-5 4) Inspection of Fuel Feed Pump Top View ……………………………………...
Page 280 Vacuum/Pressure Gauge Spark Tester P/N. 3AC-99020-1 P/N. 3F3-72540-0 Inspecting pressure Inspecting Ignition 4st 9.9/15/20 2017...
Page 281 PT Solenoid Switch A (tilt up side) (for EFT, EPT models) PT Solenoid Switch B (tilt down side) (for EFT, EPT models) Engine Temperature Sensor Rectifier (except for MF model) Ignition coil Oil Pressure Switch Fuse (20A) (except for MF model) ECU (Electronic Control Unit) Starter Solenoid (except for MF model) 4st 9.9/15/20 2017...
Page 282 Exciter Coil / Charge Coil (charge coil : except for MF model) Pulser Coil Neutral Switch (only for EF, EFT models) Starter Motor (except for MF model) Vapor Separator ISC (Idle Speed Control) Valve 4st 9.9/15/20 2017...
Page 283 T-Map Sensor ISC (Idle Speed Control) Valve Vapor Separator Fuel Injector 4st 9.9/15/20 2017...
Page 284 Rectifier (except for MF model) Engine Temperature Sensor Pulser Coil Starter Motor (except for MF model) Exciter Coil / Charge Coil (charge coil : except for MF model) ISC (Idle Speed Control) Valve TPS (Throttle Position Sensor) T-Map Sensor 4st 9.9/15/20 2017...
Page 285 Start Switch (only for EF, EFT models) Warning Lamp Engine Stop Switch (for MF, EF, and EFT models) 4st 9.9/15/20 2017...
Page 286 4st 9.9/15/20 2017...
Page 287 Ref. Description Q'ty Remarks Flywheel M Type Flywheel W/Ring Gear EF/EP Type Alternator Assy M Type Alternator Assy EF/EP Type Pulsar Coil Bolt Pulsar M5 L=12 mm Key t=4 Washer 16-27-3.2 Bolt Alternator M6 L=25 mm Coil Bracket Bolt Coil Bracket M6 L=25 mm Clamp 6.5-47.5P Dowel Pin 6-12 Bolt...
Page 288 8-10 4st 9.9/15/20 2017...
Page 289 Ref. Description Q'ty Remarks Spring Washer Solenoid Switch Cord (A) Solenoid Switch Cord (B) Terminal Cap 8-13-28 Terminal Cap 8-13-28 Black Bolt M6 L=12 mm Ground Cable L=120 Band 104 Do not reuse. Rubber Mount Collar Washer 6-16-1.5 Bolt M6 L=25 mm Starter Motor Assy Bolt Spring Washer...
Page 290 Fig.8-19 8-12 4st 9.9/15/20 2017...
Page 291 Ref. Description Q'ty Remarks Fuel Rail Assy Fuel Rail Fuel Injector Assy Seal Ring Valve Assy (Pressure Check) Nipple 8-6-13L O-ring 1.9-9.8 Do not reuse. Holding Plate Bolt M6 L=12 mm Bolt M6 L=25 mm Insulator Throttle Body Assy ISC Valve Map Sensor T-Map Sensor Screw...
Page 292 Fig.8-19 8-14 4st 9.9/15/20 2017...
Page 293 Ref. Description Q'ty Remarks Clip Screw Rubber Mount Collar Washer 6-16-1.5 Bolt M6 L=25mm Fuel Hose W/Protector VST-Fuel Rail Clamp ø16.8 Vent Hose W/Protector VST-Catch Tank Vent Hose W/Protector Catch Tank-Vent Vent Hose W/Protector Catch Tank-Exposure Fuel Pump Assy O-ring 3.5-25.7 Do not reuse.
Page 294 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 spark. Check ignition system when sparks are weak.
Page 295 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 : Primary Coil : Between Black(B) - Orange(Or) 0.26 - 0.35 Ω (at 20°C) Secondary Coil : Between High Tension Cord - High Tension Cord 6.8 to 10.2 kΩ...
Page 296 Disconnect pulser coil coupler (2 pin) of Bow side. Measure pulser coil resistance. Replace if other than specified value. This test can be made without removing parts. Pulser Coil Resistance (Reference Value) : Between Red/White (R/W) - Black (B) 148 to 222 Ω Loosen pulser coil mounting screw, and insert the thickness gauge between pulser coil...
Page 297 Remove oil pressure switch to test it as a separate unit. 1. 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 298 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 299 Check electrical conductivity of start switch. Replace if no conductivity. This test can be made without removing parts. Lead Wire Color Switch Position Green (G) Red (R) Free : OFF Pushed : ON Check electrical conductivity of stop switch. Replace if no conductivity.
Page 300 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) 12.0 ± 0.5 Ω Measure ISC valve between terminal resistance.
Page 301 MAP (manifold pressure) sensor and MAT (intake air temperature) sensor are integrated in this sensor. Measure ambient temperature. Connect computer to outboard motor, and use diagnosis system to display "Air Temperature (Intake Air Temperature)". Replace T-MAP sensor if difference between ambient t e m p e r a t u r e a n d "...
Page 302 Check throttle position sensor resistance. Replace throttle body with throttle position sensor if other than specified value. Throttle Position Sensor Resistance : 5 kΩ or less Apply 5V between terminals Vta and E2 , and measure output voltage between terminals E2 and Vc TPS output is proportional to the degree of opening the main valve fully closed - fully open.
Page 303 Put locating mark between starter motor body and cap. (This mark facilitates reassembly.) Slide pinion stopper downward as shown and remove clip Use small bladed screw driver to remove clutch. Be careful not to cut hand because clip is secured ﬁrmly.
Page 304 Measure commutator outer diameter. Replace starter motor ass'y if outer diameter is less than specified value. Commutator Outer Diameter : Standard Value 30.0 mm ( 1.181 in ) Wear Limit : 29.0 mm ( 1.142 in ) Measure undercut of commutator .
Page 305 Assemble starter motor and check before and after installing it on the power unit by applying voltage between points "+" and "-" that it operates normally. Energizing starter motor produces sparks, and thus, any inﬂammable matter must be kept away from the motor.
Page 306 · Measurement condition Circuit tester to be used : HIOKI3030 Measurement Range : 1kΩ · Permissible Error of Resistance : ±20% Note) It is recommended to use "HIOKI HiTESTER MODEL 3030" for this measurement. Use of other instrument model for the measurement can cause indication of abnormal value for normal condition, resulting in inaccurate measurement.
Page 307 9-19 9-19 State 1 : Engine will not start or 1) Diagnosis Software Install …………… 9-20 is hard to start. ………………………… 9-3 2) Installing USB to serial converter driver Starting System ……………………… 9-3 (If there is no RS232 port) …………… 9-21 Ignition System ………………………...
Page 308 * Low speed ESG operates. Probable Cause Fuel level is low in the tank. Fuel system connection is incomplete. Fuel system sucks air. Fuel pipe is twisted. Cap vent is closed. Fuel filter, fuel pump or injector is clogged. Low quality gasoline is used. Primer bulb is clogged.
Page 309 Before working on the engine check that full rigging and engine installation are normal and 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 work safely.
Page 310 Check electrical conductivity of neutral switch. Conductive? Check start switch or main switch. Normal? Check electrical conductivity of wire harness. Conductive? 4st 9.9/15/20 2017...
Page 311 4st 9.9/15/20 2017...
Page 312 4st 9.9/15/20 2017...
Page 313 Check operation of fuel feed pump (FFP). Check electrical conductivity Operating noise of wire harness and fuse. heard? Conductive? Check output from ECU to fuel feed pump (FFP). Output signal exists? Measure fuel pressure. Check fuel filter for clogging Specified range? and dirt, and piping for leak.
Page 314 Check mechanical fuel pump. Normal? Check vapor separator needle valve for bend or wear. Normal? 4st 9.9/15/20 2017...
Page 315 Check battery cables for defective contact, and ground lead wire securing bolt for looseness or disconnection. Normal? Check throttle position sensor and ISC valve connectors for connections. Normal? Check throttle valve for bend, and shaft if it is seized. Normal? Check compression pressure.
Page 316 Check spark plugs. Normal? Use spark tester to check ignition sparks. Check pulser coil resistance or Normal? air gap. Normal? Check stop switch and main switch key. Normal? Check connection of plug cap and resistance. Normal? Check ignition coil resistance. Normal? 9-10 4st 9.9/15/20 2017...
Page 317 Measure fuel pressure. Check injector clogging and Specified range? resistance. Normal? Check fuel regulator of vapor separator. Normal? Check fuel pump. Normal? Check needle valve of vapor separator. Normal? 4st 9.9/15/20 2017 9-11...
Page 318 Check engine oil level. Within specified range? Check oil pressure switch. Normal? Measure hydraulic pressure. Check oil pump for damage Normal? and oil leak. Clogging or leak? 9-12 4st 9.9/15/20 2017...
Page 319 Check cooling water passage for clogging or leak. Normal? Check thermostat. Normal? Measure engine temperature sensor resistance. Normal? Check water pump. Normal? 4st 9.9/15/20 2017 9-13...
Page 320 Check throttle position sensor and ISC valve connectors for connections and resistances. Normal? Check throttle link and throttle valve for play and wear. Normal? Check intake manifold for air leak. Normal? 9-14 4st 9.9/15/20 2017...
Page 321 Check spark plugs. Normal? Use spark tester to check ignition spark. Normal? Check connection of plug cap and resistance. Normal? Check ignition coil resistance. Normal? 4st 9.9/15/20 2017 9-15...
Page 322 Check fuel filter for clogging and dirt, and piping for leak. Normal? Check fuel pump. Normal? Check vapor separator needle valve for bend or wear. Normal? Check injector clogging and resistance. Normal? 9-16 4st 9.9/15/20 2017...
Page 323 Check operation of PT motor. Operating Check battery and fuse. noise heard? Normal? Check electrical conductivity of PT switch. Conductive? Check electrical conductivity of PT solenoid. Conductive? Check wire harness between battery, PT solenoid and PT switch. Conductive? Check that manual valve is closed.
Page 324 9-18 4st 9.9/15/20 2017...
Page 325 Diagnosis Tool Kit P/N. 3RS-72920-0 Used to engine diagnosis 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 battery cables securely.
Page 326 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 327 The manufacture of the serial converter will provide instructions for that serial converter and may vary depending on the computer being used. The following is an example, for a detailed procedure of converter installation refer to the instruction manual of converter being used.
Page 328 If your computer is not provided with RS232C Port (9 Pins), use USB conversion cable as shown. • When using USB conversion cable, install necessary software in accordance with the instructions, and then proceed to next operation. • USB cable operates only on OS of Windows 98 and after.
Page 329 Double-click "3AC_DIAGNOSTICS" in "PROGRAM" or its short-cut icon. Model selection 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 330 • 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. 9-24 4st 9.9/15/20 2017...
Page 331 "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 332 Current status 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 it indicates the time at which the failure occurred at the end. 9-26 4st 9.9/15/20 2017...
Page 333 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 shows highest recorded temperature and at what time it occurred. *2 Number of times that failure occurred. *3 Problem is active failure.
Page 334 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 ISC valve "4" : Operation (on/off) of fuel feed pump (FFP). "5"...
Page 335 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 336 When operating a new engine or a long-term storage engine, electromagnetic FFP is operated to fill the fuel line with fuel Press "F1" key to return to "Menu" screen. 9-30 4st 9.9/15/20 2017...
Page 337 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 338 9-32 4st 9.9/15/20 2017...
Page 339 2) Installation of Battery ………………… 10-6 10-2 1) Installation of Remote Control Cable (Engine Side) 3) Wiring Diagram of Remote and Control Meters ………………………… 10-7 Remote Control Model ……………… 10-2 10-8 1) Warning Indication …………………… 10-8 10-6 1) Installation of Meters ………………… 10-6...
Page 340 Release drive shaft housing cover latch and remove top cowl. Loosen drive shaft housing cover bolts (Port side). · Loosen the port side bolts completely, then fully loose the starboard side bolts. · There bolts are a falling prevention structure it can not be removed.
Page 341 Screw cable joint on the end of remote control cable by approximately 10mm. (10mm is equivalent to 9 threads.) Shift cable is the one of which tip is moved earlier than throttle cable when remote control lever is set to forward (F) side until it stops once (approx.
Page 342 Set remote control lever to neutral (N) , and check that neutral throttling lever is at full close position Adjust screw-in length of cable joint so that hole of cable joint is brought to shift arm pin After adjusting remote control cable joint, fix it with remote control cable fully pushed in.
Page 343 Check that shifting control lever forward (F) by approximately 32 degrees ( ), where it is stopped once, makes the gear engage, and fully shifting the lever makes throttle valve fully open, and then check that shifting the lever reverse (R) by approximately 32 degrees ( ), where it is stopped once, makes the gear engage, and fully shifting the lever makes throttle valve fully open.
Page 344 When installing meters, select a place on the dash board where operator can watch them easily and they are not exposed to water spray. The meters can be installed on the dash board of 2 to 11mm thick. When the thickness is over 11mm, cut fitting plate so that the meters can be installed.
Page 345 Color Code B : Black Br : Brown L : Blue Lg : Light Green P : Pink R : Red Sb : Sky Blue W : White Y : Yellow G : Green Note : Leads marked with are connected with meter lamp switch (option).
Page 346 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. * Remote control model only, warning buzzer inside remote control is equipped. Warning lamp is inside tachometer and drive shaft housing cover of outboard motor.
Page 347 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 2,800r/min or less. •...
Page 348 10-10 4st 9.9/15/20 2017...
Page 349 ……………………………… 11-2 11-3 11-5 11-4...
Page 350 Name Remarks Lead Wire Color Exciter Coil Blue Black/Red Magneto Charge Coil (except for MF model) − Yellow Black − Pulser Coil Red/White Black Rectiﬁer/Regulator (except for MF model) − Yellow − Engine Temperature Sensor Green/Yellow Black/Blue Throttle Position Sensor Red/White Blue/White G/Or...
Page 351 4st 9.9/15/20 2017 4st 9.9/15/20 2017 11-4 11-3...
Page 352 4st 9.9/15/20 2017 4st 9.9/15/20 2017 11-6 11-4...
Page 353 4st 9.9/15/20 2017 4st 9.9/15/20 2017 11-8 11-5...
Page 355 Copyright © 2018 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 356 � � � � � � � � � � � � � � トーハツ船外機サービスマニュアル �� 2�2�� ...

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