Page 1 �� OB No.003-21056-2 16-04 NB...
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 their work correctly. Understand the following matters well for efficient repairs. Each chapter begins with the introduction of special tools that are used for the work described in the chapter so that the service persons are able to understand the tools needed.
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 13) Inspection of Compression Pressure …………… 3-17 14) Inspection and Adjustment of Valve Clearance ………………………………………… 3-18 15) Throttle Cable For F type ………………………… 3-20 1) Fire Prevention …………………………………… 1-2 For P type ………………………… 3-22 2) Ventilation ………………………………………… 1-2 16) Inspection of Gear Shift Operation ……………… 3-26 3) Protection …………………………………………...
Page 8 6) Inspection of Plunger and Oil Strainer ………… 5-19 2) Removing Propeller ……………………………… 6-8 7) Flywheel and Electrical Components …………… 5-19 3) Removing Lower Unit …………………………… 6-9 8) Removing Timing Belt and Pulley ……………… 5-21 4) Disassembly of Water Pump …………………… 6-9 9) Inspection of Timing Belt …………………………...
Page 9 14) Inspection of Reverse Lock 4) Disassembly of Starter Motor …………………… 8-18 (MF, EF & EP Models) …………………………… 7-25 5) Inspection of Armature …………………………… 8-19 6) Inspection of Brushes …………………………… 8-20 7-27 Clamp Bracket 7) Inspection of Starter Motor Operation …………… 8-20 (For EFT &...
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Page 13 2) Gear Shift ………………………………… 1-8 3) Engine Oil ………………………………… 1-8 4) Gear Oil …………………………………… 1-9 1) Fire Prevention ………………………… 1-2 5) Fuel Line ………………………………… 1-9 2) Ventilation ………………………………… 1-2 6) Rigging …………………………………… 1-9 3) Protection ………………………………… 1-2 7) Manual Tilt ……………………………… 1-9 4) Genuine Parts ……………………………...
Page 14 Engine serial number is stamped on the Clamp Bracket or Swivel Bracket of outboard motor body. Model Type r o t Model Name Serial Number l a i Gasoline is hazardous material and very flammable. Do not handle gasoline near ignition source such as spark or static electricity.
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 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 surfaces or mating surfaces of cylinder and crankcase. Replace parts such as packings, gaskets, O rings, oil seals, spring pins or split pins with new ones after they are removed.
Page 17 P/N. 3B2-64110-1 Outer diameter : 164mm Width : 12mm Rotational speed at WOT (Wide Open Throttle) (r/min) 5,000~6,000 For the following measuring instruments, use commercially available ones. Circuit tester ( Resistance : 1Ω, 10Ω, 10 kΩ, AC voltage : 30 to 300V, DC voltage : 30V, Internal voltage 3V or less ) Vernier calipers ( M1 type, 300 mm ) Micrometer...
Page 18 Spring Pin Tool A (ø3.0) Spring Pin Tool B (ø3.0) Spring Pin Tool A (ø3.5) Spring Pin Tool B (ø3.5) P/N. 345-72227-0 P/N. 345-72228-0 P/N. 369-72227-0 P/N. 369-72228-0 Removing spring pin Installing spring pin Removing spring pin Installing spring pin Tachometer Vacuum/Pressure Gauge Flywheel Puller Kit...
Page 19 Bearing Outer Press Kit Backlash Measuring Tool Kit Spark Tester P/N. 3B7-72739-1 P/N. 369-72740-0 P/N. 3F3-72540-0 Installing forward gear (A) Measuring gap between forward and Inspecting sparks bearing outer race pinion gears (A and B gears) Needle bearing press Ass'y P/N.
Page 20 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. While rotating propeller Fill engine with engine oil. Upper Limit 4 Stroke Engine Oil :...
Page 21 Check quantity of gear oil. Gear Oil : 320 cm (10.8 fl.oz) Spill of some oil from upper plug hole as plug is removed indicates that gear case is filled with specified quantity of gear oil. Check that fuel tank contains sufficient amount of gasoline, fuel line is connected and is free of leak.
Page 22 Check that tilt stopper functions normally. Push PT switch “DN” to check that outboard motor fully tilts down. Press start switch or turn main switch to START check that engine starts. Tiller Handle Model — Push and hold to stop Remote Control Model Turn main switch to OFF to check that engine stops.
Page 23 Remote Control Model Check that cooling water check port discharges water during engine runs. After engine has warmed up, use tachometer to check idle speed is as specified. Idle Speed : 950 r/min Tachometer : P/N. 3AC-99010-0 High tension cord Select a propeller that is best-suited to type of boat and application.
Page 24 Adjustment of trim tab angle After installing outboard motor on the boat, use trim tab to achieve balance between port and starboard steering loads. Loosen trim tab bolt, adjust angle of trim tab described below, and then tighten the bolt to specified torque.
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. Gear oil turns to creamy white if mixed with water invading into gear case. 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.
Page 27 1) Engine Outer Dimensions ……………… 2-2 2-12 2) Transom Bolts …………………………… 2-4 2-20 2-22...
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Page 29 MF/EF/EFT EP/EPT MFS8/9.8B MFS8/9.8B Item Type Unit Item Type Unit mm/in 14.7 mm/in 14.7 mm/in 26.7 mm/in 26.7 mm/in 31.7 mm/in 31.7 mm/in 36.7 mm/in 36.7 mm/in 17.3 mm/in 17.3 mm/in 22.3 mm/in 22.3 mm/in 27.1 mm/in 27.1 mm/in 15.8 mm/in 22.7 MF/EF...
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Page 31 EFT/EPT CENTER LINE 76.6mm 76.6mm TOP OF (3.00in) (3.00in) TRANSOM 97.5mm 97.5mm (3.83in) (3.83in) 94.2mm 94.2mm (3.70in) (3.70in) 97mm 97mm (3.81in) (3.81in) 10mm (0.39in) 4st 8/9.8 2016...
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Page 36 Model Item Unit Propeller MFS8B Mark Mark Mark – – MFS8B Mark – – [For North America] Mark 7 (*2) 7 (*2) MFS9.8B Mark Mark Mark – – MFS9.8B Mark [For North America] Mark 7 (*2) 7 (*2) Mark 5 (*2) *2 4 Blade propeller Bracket No.
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Page 40 Part name Item Standard value Intake valve Valve clearance IN : Intake 0.13 – 0.17mm (0.0051 – 0.0067in) EX : Exhaust 0.18 – 0.22mm (0.0071 – 0.0087in) Exhaust valve Valve stem outer diameter IN : Intake 5.48mm (0.2157in) EX : Exhaust 5.46mm (0.2150in) Valve guide inner diameter IN : Intake...
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Page 48 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2-22 4st 8/9.8 2016...
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Page 51 14) Inspection and Adjustment of Valve Clearance ……………………………… 3-18 15) Throttle Cable For F type …………… 3-20 For P type …………… 3-22 1) Inspection of Top Cowl ………………… 3-4 16) Inspection of Gear Shift Operation … 3-26 2) Fuel System ……………………………… 3-4 17) Inspection of Idle Engine Speed ……...
Page 52 Spring Pin Tool A (ø3.0) Spring Pin Tool B (ø3.0) Spring Pin Tool A (ø3.5) Spring Pin Tool B (ø3.5) P/N. 345-72227-0 P/N. 345-72228-0 P/N. 369-72227-0 P/N. 369-72228-0 Removing spring pin Installing spring pin Removing spring pin Installing spring pin Tachometer Compression Gauge Torque Wrench...
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Page 54 Push top cowl using both hands to check for looseness and state of closing. Check the fuel system piping for fuel leak, dirt, deterioration and damage, and replace or clean parts if necessary. 4st 8/9.8 2016...
Page 55 Turn fuel pick up elbow of fuel tank counterclockwise to remove the part, and clean the filter . Remove dirt and water from fuel tank if any. Fuel pickup elbow Filter Check fuel filter for dirt, build up of fuel slag, and fuel filter for invasion of foreign matters and crack.
Page 56 Oil Level Quantity of Oil for Full Replacement Upper Limit 0.8L Lower Limi 0.6L Oil Specification Engine Oil : 4 Stroke Engine Oil API: SE, SF, SG, SH, SJ, SL, SM SAE: 10W-30, 10W-40 NMMA : FC-W Certified 10W-30/40 Quantity of Engine Oil : 0.8L (0.84qt) Use oil with viscosity that is suited to ambient air temperature of the operating region.
Page 57 Tilt down outboard motor to make it vertical. Remove upper oil plug and check level of gear oil in the gear case. Spill of some oil from plug hole as plug is removed indicates that gear case is filled with specified quantity of gear oil.
Page 58 Remove lower unit installation bolts, and pull lower unit ass'y downward to remove. Remove pump case (Upper) 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 59 Tilt outboard motor a little as shown. Place waste oil container below lower oil plug , and then, loosen upper oil plug to release inner pressure and retighten upper oil plug. Then, remove lower oil plug and then upper oil plug to drain oil.
Page 60 Drain gear oil. Remove upper oil plug and connect a commercially available leakage tester to this hole. Apply specified pressure to gear base, and check if the pressure is maintained without further compression for 10 seconds. Specified Gear Case Maintained Pressure : 0.069 MPa (10 psi) [0.7 kgf/cm ·...
Page 61 Remove belt cover , and then check timing belt inner and outer surfaces for cracks, damages and wear while rotating flywheel clockwise with hands. Replace if necessary. Elongation limit Press belt at the center, and replace if deflected over 10mm. Remove recoil starter and belt cover.
Page 62 Remove bolts of alternator and exciter coil , and remove alternator and exciter coil. Turn timing pulley clockwise to bring “▲” mark timing pulley to “▲” mark of cylinder block, and check that “●1” mark of cam shaft pulley and “▲” mark of cylinder head are aligned with each other.
Page 63 Attach crankshaft holder to crankshaft and secure it. Loosen timing pulley nut and remove it. Remove belt guide · U s e 3 2 m m s o c k e t w r e n c h a n d 3 0 m m spanner wrench for this step.
Page 64 Check that “▲” mark of timing pulley and “▲” mark of cylinder head are alighened with each other. # 1 p i s t o n i s t o b e a t t o p d e a d c e n t e r o f compression stroke.
Page 65 Tighten timing pulley nut to specified torque. · Put pulley nut with chamfered face down. · Use 32mm socket wrench and 30mm spanner wrench for this step. Crankshaft holder P/N. 3V1-72815-0 Timing Pulley Nut : 50 N · m (36 lb · ft) [5.0 kgf · m] Install alternator and exiter coil.
Page 66 Attach grommet to crank case, and then, install recoil starter, fuse holder, cable terminal holder, and belt cover. · Use port side bolt to secure fuse holder. · Install fuse holder with hook face directed bow side Remove plug caps and then spark plugs. 3-16 4st 8/9.8 2016...
Page 67 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 . Replace if it is over specified value.
Page 68 Fully open throttle, crank engine until compression gauge indication stabilizes, and then measure compression pressure. Compression Pressure (Reference) : 500 r/min : 0.88 MPa (128 psi) [0.9 kgf/cm Compression pressure varies depending on the cranking speed, and normally changes at least as much as approximately 10%.
Page 69 Pull starter rope slowly to bring “●1” mark of cam shaft pulley to “▲” mark of cylinder head. #1 piston is to be at top dead center of compression stroke. Check and adjust #1 cylinder's intake and exhaust valve clearances. Valve Clearance (when engine is cold) : (IN) intake side : 0.13 - 0.17mm (0.0051 - 0.0067in)
Page 70 Rotate flywheel clockwise to bring “2” mark of cam shaft pulley to “▲” mark of cylinder head. Check and adjust #2 cylinder's intake and exhaust valve clearance in the same procedure as #1 cylinder. ● 1 ( ) 2( ) Mark Reconnect starter lock cable (upper).
Page 71 Put throttle cable with more projection of inner into upper recess of throttle drum, and secure temporarily with nut. Locate the part at the center of threaded section. Set throttle grip to full close position. Like step 3, put other throttle cable into lower recess of throttle drum, and secure temporarily with nut.
Page 72 Set throttle grip to full open position, and secure throttle with screw with carburetor link touching full open stopper Set throttle grip to full close position, and check if carburetor link touches full close stopper Repeat above steps 8. and 9. several times to check if carburetor link touches full close stopper.
Page 73 Set remote control lever to full open position. Contact throttle drum with full open stopper , and then bring remote control cable end nut to position of cable joint Screw on cable joint to position of remote control cable nut. Fit cable joint into throttle drum , and set remote...
Page 74 Set remote control lever to neutral (N), and check that free acceleration lever is at full close position Full open Full close Set shift arm to forward (F), neutral (N), reverse (R) and then to neutral (N) positions. Run remote control cable (shift side) into grommet, and like throttle cable, bring nut of cable to position of joint...
Page 75 Check that shifting control lever forward (F) approximately 32 degrees, where it is stopped once, makes the gear engage, and then, fully shifting the lever makes throttle valve fully open 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 76 Secure remote control stay cover with screws. Shift gear from neutral (N) to forward (F), neutral (N), and then to reverse (R) to check that shift operation is performed smoothly. Adjust shift link rod length and shift cable position if necessary. Shift gear into neutral (N).
Page 77 Put rod joint on shift arm , and align position of nut of remote control cable with rod joint. When adjusting position of cable joint, push in remote control cable by the amount of the play. Screw on cable joint to position of remote control cable nut.
Page 78 Adjusting system : Automatic control, no adjustment required Run engine and use timing light to check ignition timing. 11 timings marks are found on the side of flywheel (TDC0°, ATDC5°, 10°, BTDC5°, 10°, 15°, 20°, 25°, 30°, 35° and 40°), and ignition timing is read with mark on the center of starter case window.
Page 79 Check propeller blades and spline for cracks, damages, wear and corrosion. Replace if necessary. Loose thermostat cover nut and remove thermostat Hang thermostat in the water contained in vessel. Put thermometer in the water, warm up water and measure water temperature when valve opens. Put a piece of thread in the closed valve gap and hang it in the water.
Page 80 Check water strainer for clogging. Clean if necessary. Set outboard motor in the water and start engine. Check that cooling water is discharged from cooling water check port . If not, check water pump and cooling water passage in the engine. Flushing with water using flusher Remove propeller and thrust holder.
Page 81 Inspect battery liquid level. If lower than “LOW” mark , add distilled water until the level goes in between “UP” and “LOW” marks. Measure specific gravity of battery liquid. Charge battery if specific gravity is less than specified value. UPPER LOWER ·...
Page 82 Apply grease to throttle cable and sliding areas. Put grease through grease nipples until excessive grease appears from bushing Apply grease to throttle cable and sliding areas. Do not lubricate here. 3-32 4st 8/9.8 2016...
Page 83 Raise pinion and lube worm gear. (Grease on teeth will collect dirt cause early failure) Apply grease to terminals of starter motor, starter solenoid and PT solenoid. Apply grease to propeller shaft spline. 4st 8/9.8 2016 3-33...
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Page 85 Remote Control Model ……………… 4-10 Tiller Handle Model …………………… 4-11 3) Disassembling Carburetor …………… 4-13 Intake Manifold & Fuel Pump ………… 4-3 4) Cleaning and Inspection ……………… 4-14 Carburetor ……………………………… 4-4 5) Disassembly and Inspection of Fuel Pump 4-15 6) Assembly of Fuel Pump ……………… 4-16 1) Idling Passage ……………………………...
Page 86 Vacuum/Pressure Gauge P/N. 3AC-99020-0 Inspecting pressure 4st 8/9.8 2016...
Page 87 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Intake Manifold Ass’y 26 O-ring 2.4-35.2 Do not reuse. 2 Spring Pin 3-10 27 Bolt 2 Carburetor 3 Intake Manifold Gasket 28 Washer Do not reuse. 29 Fuel Pump Ass’y 4 Clamp 6.5-14L 5 Bolt 30 Check Valve 1 White...
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Page 89 Ref. Description Q'ty Remarks Carburetor Ass’y for MF & EF/EFT (mark : 3V2FB) MFS9.8 Carburetor Ass’y (EP) for EP/EPT (mark : 3V2PB) Carburetor Ass’y for MF & EF/EFT (mark : 3V1FB) MFS8 Carburetor Ass’y (EP) for EP (mark : 3V1PB) Float Chamber Float Chamber Gasket Do not reuse.
Page 90 a - Air intake h - Fuel inlet b - Air vent inlet i - Chamber drain c - Air-bleed inlet j - Main jet d - Slow air jet k - Slow jet e - Bypass port m - Choke valve f - Idle Port g - Throttle valve Air-fuel mixture...
Page 91 a - Air intake h - Fuel inlet b - Air vent inlet i - Chamber drain c - Air-bleed inlet j - Main jet d - Slow air jet k - Slow jet e - Bypass port m - Choke valve f - Idle Port g - Throttle valve Air-fuel mixture...
Page 92 a - Air intake f - Main nozzle b - Float chamber inlet g - Main jet c - Air-bleed inlet h - Slow jet d - Slow air jet i - Air bleed hole e - Bypass port Air-fuel mixture As throttle valve is turned to a position over bypass port, the vacuum produced in the back of throttle valve extends to an area near main nozzle.
Page 93 a - Air intake d - Idle Port b - Choke valve e - Main nozzle c - Bypass port Air-fuel mixture Choke system consists of choke valve, detent and push-pull cable or electric solenoid. When starting cold engine, the operator should judge whether it is necessary to operate the choke to make engine starting easier, and if necessary, to operate the handle of choke cable manually to set it to a proper position or to activate the solenoid for electric starting model.
Page 94 <Refer to inspection items of Chapter 8.> Loosen throttle link rod set screw . Remove throttle link from link drum Separate choke link rod from carburetor. Cut band that secures solenoid wire of intake silencer head hose. Disconnect choke solenoid wire from engine wireharness.
Page 95 Loosen intake manifold installation bolts, and remove carburetor ass’y and silencer cover at the same time. Loosen solenoid mount plate screws Loosen solenoid mount plate bolts and then remove carburetor. Loosen throttle link rod set screw . Remove throttle link from link drum.
Page 96 Remove air silencer head hose from intake manifold. Loosen intake manifold installation bolts, and remove carburetor ass’y and silencer cover at the same time. Loosen air silencer mount bolts and then remove carburetor. 4-12 4st 8/9.8 2016...
Page 97 Remove drain screw to drain fuel. Remove float chamber Remove carburetor cover Remove float ass'y 4st 8/9.8 2016 4-13...
Page 98 Remove jets and nozzle. Check carburetor body for crack, damage and dirt. Replace or clean as necessary. Check jets and nozzle for dirt, and replace if necessary. Check tip of needle valve, and replace if necessary. 4-14 4st 8/9.8 2016...
Page 99 Check float for crack and damage, and replace if necessary. Check accelerator plunger (some models only), O rings and gaskets for damage, and replace if necessary. Remove screws (4) to disassemble fuel pump body. Remove diaphragm from fuel pump body. While holding push rod, turn diaphragm approximately 90 degrees to left or right while pushing it using a finger to remove it from push...
Page 100 Check diaphragm for break, crack and damage, and replace if necessary. Check check valve for damage and deterioration, and replace if necessary. fuel pump body for crack and damage, and replace if necessary. Check push rod for wear on the slipper surface , and replace if severely worn.
Page 101 Attach new gasket and assemble fuel pump body using screws (4). After assembling, check for air leak again. Check fuel connector for crack and damage. Connect vacuum/pressure gauge to outlet of fuel connector. Apply specified pressure, and check if the pressure is maintained for 10 seconds.
Page 102 Install jets and nozzle Attach needle valve to float hinge Attach float ass’y with float arm pin and secure with screw 4-18 4st 8/9.8 2016...
Page 103 Measure float height as shown, and replace float if out of specification. Float Height 10.0±0.5mm (0.3937±0.0197in) Install drain screw, float chamber and cover Thinly apply G17 to gasket before attaching it to float chamber side to prevent it from moving. Reverse carburetor removing steps to install.
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Page 105 25) Installation of Cylinder Head ………… 5-37 26) Disassembly of Cylinder Block ……… 5-38 27) Inspection of Piston Outer Diameter 5-39 Engine ………………………………………… 5-3 Magneto • Electric Parts …………………… 5-5 28) Inspection of Cylinder Inner Diameter …5-40 29) Inspection of Piston Clearance ……… 5-40 Intake Manifold &...
Page 106 Flywheel Puller Kit Piston Slider Compression Gauge Torque Wrench P/N. 3V1-72211-0 P/N. 3V1-72871-0 P/N. 3AC-99030-0 P/N. 3AC-99070-0 Measuring compression Removing/installing flywheel Installing piston Adjusting valve clearance pressure ø34.5 x ø17.5 Crank Shaft Holder Valve Clearance Driver Driver Rod Oil Seal Attachment P/N.
Page 107 Ref. Description Remarks Q'ty 1 Power Unit 2 Oil Level Gauge 3 Gasket Do not reuse. 4 Dowel Pin 5 Bolt 6 M8 L=35 mm 6 Apron Ass'y 7 Screw 2 M5 L=30 mm 8 Recoil Starter 9 Belt Cover 10 Battery Cable 4st 8/9.8 2016...
Page 108 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Flywheel W/Gear 1 FF-51 21 Washer 6-16-1.5 3 for EF/EFT & EP/EPT 22 Collar 6.2-9-7.4 2 Exciter Coil 23 Bolt 3 Alternator Ass’y 1 for EF/EFT & EP/EPT 24 CD Unit 4 Pulsar Coil 25 Pre-coated Bolt 6-16 5 Key...
Page 109 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 42 Terminal Cap 8-13-28 2 PTT Cord for EFT & EPT 63 Bolt 43 Solenoid Switch Cord (B) L=150 1 Black for EFT & EPT 64 Battery Cable L=2500 1 for EF/EFT & EP/EPT 44 Ignition Coil W/R-cap 65 Bolt 45 Plug Cap W/Resistance...
Page 110 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Intake Manifold Ass’y 26 O-ring 2.4-35.2 Do not reuse. 2 Spring Pin 3-10 27 Bolt 2 Carburetor 3 Intake Manifold Gasket 28 Washer Do not reuse. 4 Clamp 6.5-14L 29 Fuel Pump Ass’y 30 Check Valve 1 White 5 Bolt...
Page 111 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Oil Level Gauge 10 Key 1 Crankshaft 2 Throttle Drum Ass’y 11 Belt Guide 3 Spacer 6.2-9-15.7 12 Nut 13 Driven Pulley 1 Camshaft Pulley 4 Washer 6-16-1.5 5 Bolt 14 Key 10-3.7-3 1 Camshaft 6 Throttle Rod 15 Washer 6.5-19-3.2...
Page 112 18 N·m (13 lb·ft) [1.8 kgf·m] 10 N·m ( 7 lb·ft) [1.0 kgf·m] 30 N·m (22 lb·ft) [3.0 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 10 N·m (7 lb·ft) [1.0 kgf·m] 7 N·m (5 lb·ft) [0.7 kgf·m] Fig.1-9 4 N·m (3 lb·ft) [0.4 kgf·m] 9 N·m (7 lb·ft) [0.9 kgf·m] Ref.
Page 113 18 N·m (13 lb·ft) [1.8 kgf·m] 10 N·m ( 7 lb·ft) [1.0 kgf·m] 30 N·m (22 lb·ft) [3.0 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 10 N·m (7 lb·ft) [1.0 kgf·m] 7 N·m (5 lb·ft) [0.7 kgf·m] Fig.1-9 4 N·m (3 lb·ft) [0.4 kgf·m] 9 N·m (7 lb·ft) [0.9 kgf·m] Ref.
Page 114 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Cyl Block & Crankcase Ass’y 13 Anode Plug 14 Gasket 2 Nipple 10-32 Do not reuse. 15 Bolt 3 Dowel Pin 6-12 16 Plunger Ass’y 4 Cylinder Head Bolt 8-50 17 Oil Strainer Ass’y 5 Thermostat 1 Mark 60 18 Hose...
Page 115 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Connecting Rod Ass’y 8 Piston Pin 2 Connecting Rod Bolt 9 Piston Pin Clip Do not reuse. 3 Crankshaft Ass’y 10 Piston Ring Set 2 STD 4 Plain Shaft Bearing 30-33-15 4 t=1.5 0.006-0.012 Piston Ring Set (0.5 O/S) 2 OPT...
Page 116 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Recoil Starter Ass’y 20 Starter Lock Cam 2 Starter Case Ass’y 21 Starter Lock Lever 3 Wave Washer 22 Starter Lock Cam Spring 4 Starter Spring 23 Washer 5 Starter Spring Case 24 Screw 6 Reel ø140 25 Collar 6.2-9-12.3...
Page 117 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Ptt Decal 2 for EFT/EPT 7 Stop Switch Decal 1 for EF/EFT 8 Decal Set (MFS8B) 2 Top Cowl Ass’y 3 Top Cowl Sub-Ass’y Decal Set (MFS9.8B) Decal Set (MFS6BZ) 4 Top Cowl Seal L=1295 9 Caution Decal 1 for EU Model 5 Caution Decal (A)
Page 118 Run engine 5 minutes to warm up, and then stop. Shift gear into neutral (N). Remove lock plate (of stop switch lanyard) from stop switch. Remove all plug caps and then all spark plugs. Install compression gauge to plug hole. Compression gauge P/N.
Page 119 Spread rag below oil pressure switch. Remove oil pressure switch and connect oil pressure gauge to switch hole. Use commercially available oil pressure gauge (1/8" npt test port). Use the instrument applicable to 1 MPa (142 psi) [10 kgf/cm Start engine and run 5 minutes to warm up at idling revolution speed.
Page 120 Loosen rocker arm lock nut , and turn adjusting screw so that valve clearances are within the specified range. · Turning adjust screw clockwise makes valve clearance smaller. · Turning adjust screw counterclockwise makes valve clearance larger. Valve clearance driver P/N.
Page 121 Attach new O ring, cylinder head cover , fuel pump , all spark plugs, recoil starter, and belt cover Reconnect starter lock cable (Upper). Reconnect plug cap Disconnect starter lock cable (upper). Disconnect throttle wire and choke link rod . (Tiller handle model) Remove throttle cable and shift cable.
Page 122 Disconnect all electrical leads. Remove cord holder bolts (2) , and then, remove all leads from cord holder . (PT Model) Remove oil level gauge. Disconnect cooling water (pilot water) hose and fuel hose Remove screw (2), and then, remove Apron Ass'y Remove power unit by removing bolts (6) and then hoisting it.
Page 123 Remove gasket and dowel pins (2). Put removed power head ass’y upside down on the work bench. Remove plunger from power head ass'y Remove oil strainer from power head ass'y Check plunger for clogging and deposition. Use small bladed screw driver to check operation of plunger valve by pushing it down.
Page 124 Loosen flywheel nut. Flywheel puller kit : P/N. 3V1-72210-0 Remove flywheel and key. Flywheel puller kit : P/N. 3V1-72210-0 Screw puller onto crankshaft end until flywheel is disengaged from tapered section of crankshaft. Disconnect alternator, exciter coil and pulsar coil lead wires. Remove bolts of alternator and exciter coil (2 each),...
Page 125 Turn timing pulley clockwise to bring "▲" mark of belt guide to "▲" mark of cylinder block, and check that "●1" mark of cam shaft pulley and "▲" mark of cylinder head are aligned with each other. No.1 piston is to be at top dead center of compression stroke.
Page 126 Remove timing belt from cam shaft pulley side, and then, from timing pulley side. Remove timing pulley and then key Remove timing pulley and cam shaft pulley while lifting them up horizontally. Check timing belt for crack, damage and wear on both faces.
Page 127 Attach key and then timing pulley Check that “▲” mark of timing pulley is aligned with “▲” mark of cylinder block. No.1 piston is to be at top dead center of compression stroke. Attach timing belt to timing pulley with its part number side facing upward, and then to cam shaft pulley.
Page 128 Tighten cam shaft pulley to specified torque. Tighten bolt while holding crank shaft with crank shaft holder to fix timing belt. Cam Shaft Pulley Bolt 11 N · m (8 lb · ft) [1.1 kgf · m] Put belt guide , and secure it with nut by tightening the nut temporarily.
Page 129 · 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 magneto related parts from power unit.
Page 130 Remove cam pulley and cylinder head cover. Remove hose. For the procedure, refer to "Removing Timing Belt and Pulley" in Chapter 5. Remove cylinder head bolts in the reverse sequence of order shown, and remove cylinder head. Loosen rocker arm lock nut , and loosen adjusting screw as much as possible.
Page 131 Compress valve spring using a commercially available valve spring compressor , remove cotters , and then, remove spring and valve · Valves, springs and other related parts should be arranged in the order they are removed. · Use attachment with inner diameter of 23.5mm.
Page 132 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 133 Use valve seat cutter (commercially available item) to correct valve seat. Be careful not to over-cut valve seat. Turn valve seat cutter while pushing down evenly. Turn 45° degree cutter clockwise to cut valve seat surface to make it smooth. Carbon or uneven surface Use 30°...
Page 134 Use 45° degree cutter to adjust contact width of valve seat to specified value. Contact 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°...
Page 135 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 136 Measure cam height. Replace if it is less than specified value. Cam Height at Both Intake and Exhaust Side : Standard Value 23.63 mm (0.9303 in) Functional Limit : Cam Height at Both Intake and Exhaust Sides 23.38 mm (0.9205 in) Measure cam shaft journal outer diameters Replace cam shaft or cylinder head if either of the diameters is less than specified value.
Page 137 Remove carbon build-up of combustion chamber, and check for deterioration. Use straight edge and thickness gauge to check distortion of cylinder head in the directions shown. Replace if the distortion is over specified value. Cylinder Head Distortion Limit : 0.10 mm (0.004 in) Use micrometer, cylinder gauge, depth gauge and thickness gauge to measure dimensions shown below.
Page 138 Apply oil to valve guide and attach new valve stem seal Intake Side : Black Exhaust Side : Green Do not reuse. Install valve , valve spring seat , valve spring and retainer in the order shown, and then, attach commercially available valve spring compressor ·...
Page 139 With valve spring being compressed, use small screw driver with small amount of grease at the tip to put cotter Tap valve stem end with plastic hammer to fix cotter securely. Apply engine oil to periphery of new oil seal and install it.
Page 140 Apply sufficient amount engine oil to cam surface of cam shaft and journal of rocker arm shaft. Install rocker arms , springs , washers and collar from lower side of cylinder head while installing rocker arm shaft Apply sufficient amount of engine oil to rocker arm and adjust screw after installing rocker arm.
Page 141 Secure oil pump using three M6 bolts by tightening them to specified torque in the order specified below. → → Order of tightening : Oil Pump Bolts : First tightening torque: 4 N · m (3 lb · ft) [0.4 kg · m] Second Tightening Torque : 9 N ·...
Page 142 Install cylinder head with new gasket, and tighten bolts in the order shown in two steps to specified torque. · First, tighten M8 bolts in two steps to specified torque. · Then, tighten M6 bolts in two steps to specified torque. ·...
Page 143 Remove connecting rod bolts and connecting rod cap and then, crank shaft and oil seal The mating connecting rods and caps should be arranged as pairs in the order they are removed. Removed parts should be marked and arranged so that they can be reassembled in their original positions and orientations.
Page 144 Measure cylinder inner diameters (D1 to D6) at in crank shaft directions (D1, D3 and D5 respectively), and in crank web directions (D2, D4 and D6 respectively). Cylinder Inner Diameters (D1 to D6) : Standard Value 55.00 mm (2.1654 in) Functional Limit : 55.06 mm (2.1677 in) Maximum value –...
Page 145 Push piston ring into ring gauge 55.000mm (2.1654in) parallel to top edge. When ring gauge is not available, use piston crown to push piston ring into to cylinder. Measure at the top or bottom of cylinder bore with no wear. Measure piston ring closed gap .
Page 146 Measure connecting rod small end inner diameter . Replace connecting rod if the diameter is over specified value. Connecting Rod Small End Inner Diameter : Standard Value 14.01 mm (0.5516 in) Functional Limit : 14.04 mm (0.5526 in) Measure connecting rod big end side clearance .
Page 147 Measure crankshaft runout. Replace crankshaft if runout is over specified value. Crankshaft Runout Limit : 0.05 mm (0.0020 in) Use commercially available thickness gauge to measure side clearance. Side Clearance : 0.10 - 0.30 mm (0.0039 - 0.0118 in) Functional Limit : 0.6 mm (0.024 in) If side clearance is over specified value, measure crank case (cylinder side) width...
Page 148 Clean connecting rod. Place cylinder block upside down on the work bench. Install piston to connecting rod , and install the assembly to cylinder block. Piston rings are not to be attached to piston. Install crankshaft on the cylinder block. Place plasti-gauge on each crank pin parallel to...
Page 149 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 150 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 - 0.044 mm (0.00047 - 0.00173 in) Functional Limit : 0.060 mm (0.00236 in) If the clearance is less than specified value,...
Page 151 Install connecting rod , piston pin , and piston pin clip to piston · Point "3V1-UP" 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 152 Put pistons into cylinder with piston crown "UP" mark directing flywheel side , set pistons on the piston slider install the piston into the cylinder. Before installing, apply engine oil to piston peripheral surfaces, piston rings and piston sliders. Piston Slider P/N.
Page 153 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. Apply engine oil to bearings. Apply sealing agent to mating surface of crank case (one side).
Page 154 Install exhaust cover , and then install thermostat , new gasket and thermostat cover · For air bleeding, install the part with concave of valve facing upward. · When reusing thermostat, check the part by referring to Chapter 3. Install new gasket, anode and anode cap Apply thin coat gasket with grease before attaching it.
Page 155 Install fuel pump Apply engine oil to fuel pump cam surface. Attach timing belt to crankshaft pulley and cam shaft pulley. · For installation procedure, refer to "Installation of pulley and timing belt" in Chapter 5. · Ensure crankshaft rotates with no binding. Install starter motor bracket and tighten bolts to specified torque.
Page 156 Install ignition coil Install CD unit bracket and secure CD unit using bolts. Install rectifier and attach ground wire from main harness. (Other than MF model) · Use rectifier mounting bolt to secure ground wire. · Direct ground wire to stern side. Connect main harness coupler to CD unit.
Page 157 Attach sensor wire to oil pressure sensor, and install grommet · When installing grommet, be careful not to plug small hole of switch with grease. · Direct ground wire to Bow side. Use clamp bolt to secure ground wire from ignition coil. Use crank case bolt to secure main harness ground wires (black and light green) and rectifier ground wire.
Page 158 Run two cords from alternator through back of starter motor, install starter motor and secure temporarily with bolts. · Install starter motor with sticker side directing toward you. · Before installing bolts, coat the thread with ThreeBond 1342. · Check that two cords from alternator are not caught between starter motor and crank case.
Page 159 Install flywheel with flywheel engaged with crankshaft key. Tighten flywheel nut to specified torque. Flywheel Puller Kit P/N. 3V1-72211-0 Flywheel Nut : 55 N · m (40 lb · ft) [5.5 kgf · m] Attach grommet to crank case, and then, install recoil starter, fuse holder, and cable terminal holder.
Page 160 Put cable terminal in the holder in accordance with description on the sticker located on the back of holder cover. Tiller Handle Model Remote Control Model Install gasket , insulator , carburetor , O ring intake silencer to intake manifold in this order and secure with bolts.
Page 161 Install choke solenoid bracket ass’y to intake manifold by using screws. (Remote Control Model) Attach new gasket and intake manifold ass’y to cylinder block. Use dowel pin to locate intake manifold ass’y on the cylinder block. Secure intake manifold ass’y by tightening bolts in the specified order to specified torque.
Page 162 With power unit and recoil starter attached, put power head ass’y upside down on the work bench, and install plunger and 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 163 Shift gear into neutral (N). Check that starter lock lever pushes up starter lock If the state described in 2. does not exist, use starter lock wire adjusting groove to adjust. Perform shift operation to check that recoil starter is locked at other than neutral (N) position.
Page 164 Remove starter spring Insert tool like bladed screw driver to remove starter case containing starter spring. It is not necessary to remove starter spring from starter case if it is not necessary to replace it. Starter spring can be inspected without removing from starter case.
Page 165 • When attaching reel to starter case, put starter spring inner end hook in the notch of starter case bearing. • Apply cold resistance lithium grease to the following parts. · Starter Spring · Reel Center Hole · Ratchet · Starter Lock ·...
Page 166 5-62 4st 8/9.8 2016...
Page 167 16) Assembly of Propeller Shaft Ass'y … 6-13 17) Disassembly of Propeller Shaft Housing … 6-13 18) Inspection of Propeller Shaft Housing … 6-14 Drive Shaft Housing ………………………… 6-3 19) Assembly of Propeller Shaft Housing … 6-14 Lower Unit …………………………………… 6-4 20) Removing Drive Shaft ………………...
Page 168 Spring Pin Tool A (ø3.0) Spring Pin Tool B (ø3.0) Spring Pin Tool A (ø3.5) Spring Pin Tool B (ø3.5) P/N. 345-72227-0 P/N. 345-72228-0 P/N. 369-72227-0 P/N. 369-72228-0 Removing spring pin Installing spring pin Removing spring pin Installing spring pin Dial Gauge Plate Bearing Outer Press Kit Backlash Measuring Tool Clamp...
Page 169 Ref. Description Remarks Q'ty 1 Drive Shaft Housing Ass’y (S) 1 for Transom S Drive Shaft Housing Ass’y (L) 1 for Transom L&UL 2 Guide Plate 3 Screw 4 Oil Seal 12-28-5 Do not reuse. 5 Drain Bolt 14-14 6 Washer 14.5-24-1 7 Dowel Pin 6-12 8 Grommet 10.7-3.5 9 Idle Exhaust Port Cover...
Page 170 → → → 締付順序 4st 8/9.8 2016...
Page 171 Ref. Description Q'ty Remarks Gear Case Ass’y Roller Bearing 15-21-16 Ball Bearing 6204 Do not reuse. Plug 8-8 Gasket 8.1-15-1 Do not reuse. Trim Tab Bolt Water Strainer W=17 Mark A Screw Nylon Nut 4-P0.7 Propeller Shaft Housing Ass’y O-ring 3.2-47 Do not reuse.
Page 172 → → → 締付順序 4st 8/9.8 2016...
Page 173 Ref. Description Q'ty Remarks Cam Rod Bushing O-ring 2.5-4.9 Do not reuse. O-ring 2.4-15.4 Do not reuse. Stopper Bolt Bolt 6-35 Water Seal Rubber Water Seal Plate Water Pipe (S) for Transom S Water Pipe (L) for Transom L Water Pipe (UL) for Transom UL Water Pipe Seal (Upper) Lock Plate...
Page 174 Drain gear oil. Refer to "Replacement of Gear Oil" in Chapter 3. Shift gear into neutral (N). Put a piece of wooden block between anti-cavitation plate and propeller to prevent rotation of propeller , and then remove propeller nut and then propeller Split pin Propeller nut Washer...
Page 175 • 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. Remove spring pin and disconnect shift rod. • Disconnect shift rod at lower side of shift rod joint •...
Page 176 Check pump case (upper) for deformation. Replace if necessary. Check impeller and pump case liner for crack and wear. Replace if necessary. Check key , water pump guide plate and drive shaft groove for wear. Replace if necessary. Remove cam rod bushing bolt , plate , and pull cam rod ass'y...
Page 177 Remove spring pin , clutch cam and cam rod bushing from cam rod • Use spring pin tool A to remove spring pin. • Do not reuse removed spring pin. Spring Pin Tool A (ø3.0) : P/N. 345-72227-0 Check cam rod and clutch cam for crack and wear.
Page 178 Apply gear oil to periphery of new oil seal, and install into pump case (lower) with number side facing downward. Apply LITHIUM grease to lip of oil seal. Remove propeller shaft ass'y. Use a plastic hammer to remove the part if it cannot be removed by inserting a bladed screw driver.
Page 179 Check propeller shaft for bend and wear. Replace if necessary. Measure propeller shaft runout. Runout Limit : 0.05 mm (0.0020 in) Support point Fix propeller shaft with vice, and attach spring and clutch • Install clutch with groove facing push rod side.
Page 180 Use commercially available universal puller plate to remove ball bearing. Before removing, check bearing for play or deflection. Replace if necessary. When removing only oil seal, use bladed screw driver to pry apart. Oil seal Do not reuse. Use cleaning oil and cleaning brush to clean propeller shaft housing, and check it for crack or damage.
Page 181 Use a press and suitable mandrel to install new ball bearing onto propeller shaft housing. Install ball bearing with manufacturer’s marking facing attachment side. Install reverse (C) gear ass'y onto propeller shaft housing. Remove pinion (B) gear nut, remove drive shaft ass'y pinion (B) gear , and draw out forward (A) gear.
Page 182 Pull out forward (A) gear by using bladed screw driver with the tip covered with rag and putting it on inner surface of forward (A) gear bushing. • When removing forward (A) gear, be careful not to give damage to shim placed between gear and ball bearing and not to lose the part.
Page 183 Remove needle bearing by using the following tools. Needle bearing press Ass'y : P/N. 3AC-72900-1 Bearing outer press guide Needle Bearing Press Rod Needle Bearing Press O ring Needle Bearing Press Bolt Bolt M8-110 Collar Washer Needle Bearing Press Flange "...
Page 184 Perform shim adjustment when ball bearing, gear, drive shaft, propeller shaft or gear case is replaced. Install needle bearing by using the following tools. Needle Bearing Press Ass'y : P/N. 3AC-72900-1 Bearing Outer Press Guide Needle Bearing Press Rod Needle Bearing Press O ring Needle Bearing Press Guide Needle Bearing Press Bolt...
Page 185 Use the following tools to install taper roller bearing outer race. Bearing Outer Press Kit : P/N. 3B7-72739-1 Bearing Outer Press Plate Bearing Outer Press Guide Bearing Outer Press Rod Fix gear case on the vice with its propeller shaft opening facing upward.
Page 186 Put forward (A) gear and shims into gear case by using propeller shaft, and install them onto ball bearing. Install pinion (B) gear while lifting up drive shaft ass’y little. Tilting gear case a little makes installation of pinion (B) gear easier. 6-20 4st 8/9.8 2016...
Page 187 Backlash Measuring Tool Kit : P/N. 369-72740-0 Backlash Measuring Tool Ass’y Measuring Tool Set Piece Backlash Measuring Tool Clamp A P/N. 3B7-72720-0 Dial Gauge Plate P/N. 3B7-72729-0 Pump Case (Lower) Pinion (B) Gear Install pump case to gear case, and assemble backlash measuring tool as illustrated.
Page 188 First, pull up drive shaft by using hand. Fix shaft B with bladed screw driver, and tighten nut while pushing the shaft. At this time, be careful not to overtighten 90° the nut, or shaft B is locked. Tighten nut fully by using fingers, and then, additionally tighten approximately 90 degrees by using spanner wrench.
Page 189 After adjustment, remove backlash measuring tool, turn gear case upside down, and check that drive shaft can be turned by hand smoothly. If not, reduce shim thickness 0.05mm and adjust backlash again. • When removing backlash measuring tool, loosen nut, and remove from forward (A) gear bearing while tapping shaft lightly with plastic hammer.
Page 190 Remove pump case (lower) and apply LITHIUM grease to oil seal. Attach new O-ring and pump case (lower) Use new rag to clean drive shaft, before installation. Put new gasket , water pump guide plate and impeller Apply small amount of OBM grease to recess of drive shaft, and put pin in it temporarily.
Page 191 Attach pump case liner to pump case (upper) , and apply grease to interior of pump case liner Bring pump case liner projection to pump case (upper) groove Install pump case (upper) ass'y on the gear case, and tighten bolts in two or three steps to specified torque.
Page 192 Feed gear oil to specified quantity . "Refer to Chapter 3." P e r f o r m " I n s p e c t i o n o f G e a r C a s e ( A i r Leakage)"...
Page 193 Attach lower unit ass'y to drive shaft housing, and tighten lower unit installation bolts (nuts) to specified torque. Gear Case Installation Bolt (Nut) 11.5 N · m (8.5 lb · ft) [1.2 kgf · m] "UL" Transom Model Set both engine side and gear case side gear shifts to neutral (N).
Page 194 Apply OBM grease to propeller shaft Attach thrust holder , propeller , washer propeller nut to propeller shaft . Put a piece of wooden block between anti-cavitation plate and propeller to prevent rotation of propeller, and tighten propeller nut to specified torque.
Page 195 Clamp Bracket 7-27 Drive Shaft Housing ………………………… (For EFT & EPT Models) ………………… 7-30 Clamp Bracket (For MF & EF Models) …… Power Tilt Ass'y …………………………… 7-31 Clamp Bracket (For EP Models) …………… 7-31 Tiller Handle ………………………………… 7-31 Manual Tilt Operation ……………………… Bottom Cowl …………………………………...
Page 196 Ref. Description Remarks Q'ty 1 Drive Shaft Housing Ass’y (S) 1 for Transom S Drive Shaft Housing Ass’y (L) 1 for Transom L&UL 2 Guide Plate 3 Screw 4 Oil Seal 12-28-5 Do not reuse. 5 Drain Bolt 14-14 6 Washer 14.5-24-1 7 Dowel Pin 6-12 8 Grommet 10.7-3.5 9 Idle Exhaust Port Cover...
Page 197 13 N·m (9 lb·ft) [1.3 kgf·m] 14 N·m (10 lb·ft) [1.4 kgf·m] 9 N·m (7 lb·ft) [0.9 kgf·m] 14 N·m (10 lb·ft) [1.4 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Clamp Bracket (R) 1 Starboard Side 15 Grease Fitting 16 Friction Piece...
Page 198 13 N·m (9 lb·ft) [1.3 kgf·m] 14 N·m (10 lb·ft) [1.4 kgf·m] 9 N·m (7 lb·ft) [0.9 kgf·m] 14 N·m (10 lb·ft) [1.4 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 29 Bushing 24-30-30 43 Bolt 30 Thrust Plate (Upper) 44 Tilt Stopper Ass’y...
Page 199 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 12 Spring 1 Clamp Bracket (R) 1 Starboard Side 2 Trim Position Decal 13 Screw 14 Swivel Bracket 3 Lower Tilt Limit Decal 15 Grease Fitting 3 for EP & EFT/EPT 4 Clamp Bracket (L) 1 Port Side 5 Tilt Lock Decal 16 Tilt Stopper Body...
Page 200 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 23 Washer 10.5-18-1.5 34 Plate 1 for EP & EFT/EPT 24 Tilt Stopper (L) 35 Carrying Handle 1 for EP & EPT 25 Bolt 6-12.5-9.5-2.5 36 Rigging Bolt Set 26 Wave Washer d=10 37 Bolt 27 Reverse Lock 38 Washer...
Page 201 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 45 Bushing 24-30-30 56 Bolt 46 Thrust Plate (Upper) 57 Ground L=110 1 Drive Shaft Housing-Mount Bracket (R) 47 O-ring 3.5-22 58 Ground L=110 1 Swivel Bracket-Mount Bracket (R) Do not reuse. 48 Rubber Mount (Upper) 59 Bolt 49 Bolt...
Page 202 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Tiller Handle Ass’y 1 for EFT 18 Switch Box 1 for EFT 19 Screw 2 for EFT 2 Tiller Handle Ass’y 1 for MF/EF 20 Clamp 6-9.5L 1 for EFT 3 Tiller Handle 21 Screw 1 for EFT 4 Plastic Rivet 6.5...
Page 203 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Bottom Cowl 16-2 Grommet 17-2.7 2 Main Swich, Stop Swich for EP/EPT 17 Grommet 40-18-3 2 Shift Rod PTT Cord 2 Fuel Connector Protector 18 Grommet 16-17.5 1 for MF & EF/EFT Throttle Shaft 3 Neutral Switch 1 for EF/EFT 4 Neutral Switch Actuator...
Page 204 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Shift Lever 16 Seal Ring 23-29-3.7 17 Shift Lever Stopper t=0.5 2 Collar 6.5-10.5-10 18 Shift Lever Stopper t=0.8 3 Washer 6.5-21-1 19 Shift Rod 4 Nut 20 Shift Rod Joint 5 Shift Lever Rod 21 Spring Pin 3-10 6 Cable Joint 4.5-40.5...
Page 205 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Grommet 1 for EP 17 Washer 2 Grommet 1 for EPT 18 Remote Cont Cable Stay Cover 3 Wave Washer d=14 19 Ptt Switch Ass’y 4 Pivot 20 Cable Clip Ass’y 5 Hook Lever Bushing 21 Bolt 6 Seal Ring 13.8-22-3.7...
Page 206 Check operation of throttle cable. Check throttle cable inner wire and outer wire for bend and damage. Replace if necessary. Attach cables to throttle shaft as shown. Install throttle shaft with cable to Tiller handle. Be careful of location of throttle friction Install bushing on the steering bracket Attach Tiller handle ass'y to steering bracket...
Page 207 Install cable of which inner wire is stretched when acceleration grip is set to full close position. Then, install another cable (of which inner wire is stretched when acceleration grip is set to full open position. Adjust position of lock nuts of throttle cable so that throttle grip can reach full open and full close positions.
Page 208 Drain engine oil by referring to “Removing Power Unit” in Chapter 5, and then, remove power unit. Loosen four bolts and remove bottom cowl from drive shaft housing. Remove ground wires Remove bolts and nuts lower mount bracket. Check that damper and rubber mount are normal.
Page 209 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 and then remove rubber mount , damper from drive shaft housing.
Page 210 Remove idle exhaust cover and gasket , and check idle exhaust cover for sludge in it, and abnormalities such as cracks. Remove screw , and remove water pipe from drive shaft housing. Check water pipe auxiliary mount abnormality such as crack. 7-16 4st 8/9.8 2016...
Page 211 Install water pipe into drive shaft housing. Put new gasket, and then, attach idle exhaust cover securing bolts and tighten them in the order of their numbers shown to specified torque. Idle Exhaust Installation Bolt : 6 N · m (4 lb · ft) [0.6 kgf · m] Put upper mount and damper on drive shaft housing,...
Page 212 Insert drive shaft housing ass’y into stud bolt of upper rubber mount of swivel bracket Align dumper bolt holes accurately. Install rubber mount and lower damper and mount bracket to drive shaft housing. Tighten bolts and nuts to specified torque. Steering Bracket Installing Nut M8 13N ·...
Page 213 Attach ground wire · Be careful not to paint earth wire attaching surface, or the anti-corrosion effect will be disabled. · If there are two ground wires, split them 90 degrees as illustrated. Remove drive shaft housing by referring to “Chapter 7 Removing Drive Shaft Housing”.
Page 214 Attach thrust plate and bushing friction piece 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 215 Install copilot handle, and adjust copilot. Remove drive shaft housing, steering shaft and copilot 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 216 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 25 N ·...
Page 217 Remove thrust rod from clamp bracket Remove distance plate Loosen and remove nut of swivel bracket shaft Pull out swivel bracket shaft, and then, remove clamp bracket from swivel bracket 4st 8/9.8 2016 7-23...
Page 218 Check swivel bracket shaft and other parts for abnormality, and replace if necessary. Reassemble components of swivel bracket , and then, insert distance plate into clamp brackets 7-24 4st 8/9.8 2016...
Page 219 Install clamp bracket swivel bracket, insert swivel bracket shaft , and then, tighten nylon nut to specified torque. Nylon Nut ： 14 N・m (10 lb・ft)［1.4 kgf・m］ Apply OBM grease to swivel bracket shaft sufficiently. Attach thrust rod Check operation of reverse lock after disassembling and reassembling bracket.
Page 220 Check that outboard motor cannot be tilted up at neutral (N) or reverse (R) shift. 7-26 4st 8/9.8 2016...
Page 221 9 N·m (7 lb·ft) [0.9 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 14 N·m (10 lb·ft) [1.4 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 25 N·m (18 lb·ft) [2.5 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] Ref.
Page 222 9 N·m (7 lb·ft) [0.9 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 14 N·m (10 lb·ft) [1.4 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 25 N·m (18 lb·ft) [2.5 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] Ref.
Page 223 9 N·m (7 lb·ft) [0.9 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 14 N·m (10 lb·ft) [1.4 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 25 N·m (18 lb·ft) [2.5 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] Ref.
Page 224 5 N·m (4 lb·ft) [0.5 kgf·m] 1.5 N·m (1.1 lb·ft) [0.15 kgf·m] 2 N·m (1.5 lb·ft) [0.2 kgf·m] 5 N·m (4 lb·ft) [0.5 kgf·m] Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 1 Cap Ass’y 18 O-ring 2-62.5 Do not reuse. 2 O-ring 19 Band Do not reuse.
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. ・ The 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 2 or 3 times opens 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 Fully tilt up outboard motor and lock with tilt stopper 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. Manual valve 2 N・m (1.5 lb・ft) [0.2 kgf・m] Disconnect PT cable...
Page 231 Remove bolt and washer located on the starboard side of the outboard motor, and 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, and loosen nylon nut of port side bracket and clamp screw.
Page 232 Loosen fill cap of power tilt unit slowly, and then remove Fully extend tilt rod when 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 233 Attach O rings (2 pcs) to manual valve. Attach manual valve to power tilt ass'y. Attach C ring ） Remove 2 inner hex bolts , and then remove motor ass'y from power tilt pump and cylinder ass'y Before disassembling power tilt motor, drain power tilt fluid.
Page 234 ） 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 1.6mm or less.
Page 235 ） 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)
Page 236 Attach yoke ass'y by using 2 screws with holding armature's shaft from the back side of motor bracket. Yoke ass'y Screw (2) Motor bracket ） Remove power tilt ass'y from outboard motor. Remove power tilt motor ass'y from power tilt ass'y Filter Pump/motor coupling Remove pump coupling...
Page 237 Remove 3 screws that secure power tilt 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 from power tilt housing. Up relief valve component Down relief orifice O ring Check down side orifice screen...
Page 238 ） Coat new O rings (2) with oil, and attach it to power tilt housing. Coat new O ring with oil, and attach it to orifice Attach filter and orifice Attach up side relief valve to power tilt pump housing. Recommended PT Fluid : ATF DEXRON II Up relief valve ass'y...
Page 239 Attach cleaned screen Attach pump coupling to pump. Install motor ass'y to power tilt pump and cylinder ass'y. Attach wireharness mounting screws. Pump filter Pump/motor coupler Install motor ass'y to cylinder ass'y and power tilt pump by using screws , and tighten screws to specified torque.
Page 240 ） Turn manual valve clockwise fully. Put PT unit on the work bench vertically, remove cap and check level of fluid in the reservoir. Add recommended PT fluid to specified level if it is lacking. Recommended PT Fluid : ATF DEXRON II Put cap and tighten to specified torque.
Page 241 ） Fully tilt up outboard motor and lock with tilt stopper Install bushing on the tilt cylinder rod Power tilt cylinder Bushing Cylinder rod eye Attach pivot bushings (2) to clamp bracket Place power tilt ass'y between clamp brackets Put tilt cylinder pivot pin (lower) in the hole of clamp bracket to secure power tilt ass'y...
Page 242 Put washer and bolt on the pin (lower) and tighten the bolt to specified torque. Retaining Bolt 13N ･ m (9.4lb ･ ft) [1.3kgf ･ m] Attach bushings (2) to swivel bracket Extend power tilt cylinder rod to align tilt cylinder rod and swivel bracket.
Page 243 Attach electrical cord of power tilt unit to power tilt relay Up relay terminal (blue) Negative terminal (black) Positive terminal (red) Down relay terminal (green) Unlock tilt stopper, and repeat tilting up and down outboard motor to bleed air from hydraulic circuit. <...
Page 244 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 245: Table Of Contents
8-16 1) Inspection of PT Relay ……………… 8-16 2) Inspection of PT Switch ……………… 8-17 Port Side View ……………………………… 8-3 Bow Side View ……………………………… 8-4 8-17 Top View ……………………………………… 8-5 1) Inspection of Fuse …………………… 8-17 2) Inspection of Starter Solenoid ……… 8-18 Magneto ………………………………………...
Page 246 Vacuum/Pressure Gauge Spark Tester P/N. 3AC-99020-0 P/N. 3F3-72540-0 Inspecting pressure Inspecting sparks 4st 8/9.8 2016...
Page 247 < EPT Model > Starter Motor Ignition Coil C.D. Unit Oil Pressure Switch Fuse Alternator Rectifier 4st 8/9.8 2016...
Page 248 < EPT Model > Starter Motor Cable Terminal Holder Alternator 4st 8/9.8 2016...
Page 249 < EPT Model > Choke Solenoid Ignition Coil Starter Motor Oil Pressure Switch Alternator Fuse Pulser Coil 4st 8/9.8 2016...
Page 250: Magneto
Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Flywheel W/Gear 1 FF-51 21 Washer 6-16-1.5 3 for EF/EFT & EP/EPT 22 Collar 6.2-9-7.4 2 Exciter Coil 23 Bolt 3 Alternator Ass’y 1 for EF/EFT & EP/EPT 24 CD Unit 4 Pulsar Coil 25 Pre-coated Bolt 6-16 5 Key...
Page 251 Ref. Ref. Description Q'ty Remarks Description Q'ty Remarks 42 Terminal Cap 8-13-28 2 PTT Cord for EFT & EPT 63 Bolt 43 Solenoid Switch Cord (B) L=150 1 Black for EFT & EPT 64 Battery Cable L=2500 1 for EF/EFT & EP/EPT 44 Ignition Coil W/R-Cap 65 Bolt 45 Plug Cap W/Resistance...
Page 252: Tiller Handle
Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Tiller Handle Ass’y 1 for EFT 18 Switch Box 1 for EFT 19 Screw 2 for EFT 2 Tiller Handle Ass’y 1 for MF/EF 20 Clamp 6-9.5l 1 for EFT 3 Tiller Handle 21 Screw 1 for EFT 4 Plastic Rivet 6.5...
Page 253: Bottom Cowl
Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Bottom Cowl 16-2 Grommet 17-2.7 2 Main Swich, Stop Swich for EP/EPT 17 Grommet 40-18-3 2 Shift Rod PTT Cord 2 Fuel Connector Protector 3 Neutral Switch 1 for EF/EFT 18 Grommet 16-17.5 1 for MF &...
Page 254 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty 1 Grommet 1 for EP 17 Washer 2 Grommet 1 for EPT 18 Remote Cont Cable Stay Cover 3 Wave Washer d=14 19 Ptt Switch Ass’y 4 Pivot 20 Cable Clip Ass’y 5 Hook Lever Bushing 21 Bolt 6 Seal Ring 13.8-22-3.7...
Page 255 Disconnect plug caps from spark plugs. Connect plug cap to spark tester Connect spark tester clip to spark plug tip electrode. Spark Tester P/N. 3F3-72540-0 Spark Performance : 10 mm (0.4 in) or over Start engine and check sparks. Check spark system if sparks are weak.
Page 256 Remove the part and test it as a separate unit. Disconnect plug caps from spark plugs. Remove plug cap from high tension cable. (Cap screws on to wire) Remove by twisting counterclockwise. Measure plug cap resistance. Replace if out of specification. Plug Cap Resistance : 3.0 - 7.0 kΩ...
Page 257: Tiller Handle Model
Remove cable terminal holder cover. Disconnect cable coupler from pulser coil, and measure resistance. This test can be made without removing parts. Pulser Coil Resistance (Reference value) : Between Red/White (R/W) - Black (B) : 148 - 222Ω Check the connection by referring to coupler connection chart located on the back of cable terminal holder cover.
Page 258: Tiller Handle Model
Remove cable terminal holder cover. Disconnect cable coupler from exciter coil, and measure resistance. This test can be made without removing parts. Exciter Coil Resistance (Reference value) : Between Black/Red (B/R) - Blue (L) : 236 - 354 kΩ Check the connection by referring to coupler connection chart located on the back of cable terminal holder cover.
Page 259 Apply pressure slowly with vacuum/pressure gauge. Check that oil pressure switch is not conductive with specified pressure applied. Replace if conductive. Specified Pressure : 0.020 - 0.029 MPa 2.8 - 4.0 psi) [0.2 - 0.3 kgf/cm Reinstall the part. Oil Pressure Switch : 8 N ·...
Page 260 Check conduction of stop switch, and replace if not conductive. This test can be made without removing parts. Lead Wire Color Switch Position Brown (Br) Black (B) Remove lock Attach lock Press switch This test can be made without removing parts. Disconnect positive terminal (R) and negative terminal (B) cables from battery.
Page 261 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 262 Connect tester lead wires to both terminals of starter solenoid. Connector green (G) lead wire to battery positive terminal. Connector black (B) lead wire to battery negative terminal. Check electrical conductivity between terminals of starter solenoid. Replace if no conductivity. Remove battery terminal from green (G) or black (B) lead wire, and check there is no conductivity between starter solenoid terminals.
Page 263 Check commutator for dirt. If necessary, clean by using sand paper of No. 600 or by air-blowing. Measure commutator outer diameter. Replace starter motor ass'y if outer diameter is less than specified value. Commutator Outer Diameter : Standard Value 20.0 mm (0.788 in) Wear Limit : 19.7 mm (0.776 in) Measure undercut...
Page 264 Measure brush length. Replace brush holder ass'y if brush length is less than specified value. Brush Length : Standard Value 7.5 mm (0.295 in) Wear limit 4.0 mm (0.157 in) Check conductivity of brush holder ass'y. Replace if out of specification.
Page 265 Remove cable terminal holder cover. Disconnect cable coupler from charge coil, and measure resistance. This test can be made without removing parts. Alternator (Charge Coil) Resistance : Reference Value (at 20°C) White (W) – Yellow (Y) 0.58 - 0.86 Ω •...
Page 266 ⑩ Check wire harness for disconnection of lead wire and defective connection. • Terminals are arranged and numbered as shown. • The following table shows names of terminals and lead wire colors. Name Lead Wire Color Warning Lamp White/Red Oil Pressure Switch Light Green Vacant —...
Page 267 Compression Pressure ……………… 9-11 3 Idle engine speed will not stabilize. …… 9-12 1 Engine will not start ………………………… 9-3 4 Rapid opening of throttle fails acceleration. 9-13 Starting System ………………………… 9-3 5 Gear shifting cannot be made normally. 9-14 Ignition System …………………………...
Page 268 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 269 Before working on the engine, check that hull, rigging and engine installation are normal, and then battery is fully charged. For mechanical troubleshooting, refer to relevant troubleshooting section in this chapter. For checking and servicing the machine, refer to service procedures described in this manual to perform the works safely.
Page 270 4st 8/9.8 2016...
Page 271 4st 8/9.8 2016...
Page 272 4st 8/9.8 2016...
Page 273 4st 8/9.8 2016...
Page 274 4st 8/9.8 2016...
Page 275 • Inspection of Fuel System, Ignition System, Compression Pressure. 4st 8/9.8 2016...
Page 276 9-10 4st 8/9.8 2016...
Page 277 4st 8/9.8 2016 9-11...
Page 278 • Inspection of Intake Manifold, Air Intake System and Ignition System. 9-12 4st 8/9.8 2016...
Page 279 Rapid opening of throttle causes engine to stall. (Stops.) Acceleration is not smooth. • Inspection of Carburetor, Ignition System and Compression Pressure. 4st 8/9.8 2016 9-13...
Page 280 9-14 4st 8/9.8 2016...
Page 281 4st 8/9.8 2016 9-15...
Page 282 9-16 4st 8/9.8 2016...
Page 283 4st 8/9.8 2016 9-17...
Page 284 9-18 4st 8/9.8 2016...
Page 285 MF/EF Model …………………………………… 10-3 EP Model ………………………………………… 10-4 EFT Model ………………………………………… 10-5 EPT Model ………………………………………… 10-4...
Page 286 10-2 4st 8/9.8 2016...
Page 287 Cord Color C.D. Unit Black Black/Red Blue Blue/Red Brown Blue/White Green White/Red Orange Brown/White White Yellow Light Green Pink Sky Blue Option Ignition Coupler Conecting Decal Coil Tachometer Magneto Cylinder (Ignition Coil) Crankcace (Pulser) Cylinder (Ignition coil) Warning Lamp OIL Pressure Switch Cylinder Rectiﬁer/ Regulator Stop Switch Main Switch Ass'y Starter Motor Solenoid Starter Motor Cylinder...
Page 288 Cord Color Coupler Conecting Decal Black Black/Red Blue Blue/Red C.D. Unit Brown Blue/White Green White/Red Orange Brown/White White Yellow Light Green Pink Sky Blue Ignition Coil Option Magneto Tachometer Crankcace Cylinder (Pulser) Cylinder (Ignition Coil) (Ignition coil) Boat Outboard Motor Warning Lamp OIL Pressure Switch Cylinder Neutral Switch Circuit Rectiﬁer/ Main Switch Circuit Regulator Stop Switch Starter Motor Solenoid...
Page 289 Cord Color C.D. Unit Black Black/Red Blue Blue/Red Brown Blue/White Green White/Red Orange Brown/White White Yellow Light Green Pink Sky Blue Option Ignition Coupler Conecting Decal Coil Tachometer Magneto Cylinder (Ignition Coil) Crankcace (Pulser) Cylinder Boat (Ignition coil) Outboard Warning Lamp Motor OIL Pressure Switch Cylinder Rectiﬁer/ Regulator Stop Switch Main Switch Ass'y Starter Motor Solenoid...
Page 290 Cord Color C.D. Unit Coupler Conecting Decal Black Black/Red Blue Blue/Red Brown Blue/White Green White/Red Orange Brown/White White Yellow Light Green Pink Sky Blue Option Ignition Coil Magneto Tachometer Cylinder (Ignition Coil) Crankcace (Pulser) Cylinder (Ignition coil) Warning Lamp Outboard Motor Boat OIL Pressure Switch Neutral Switch Circuit Main Switch Circuit Cylinder Rectiﬁer/ Regulator Stop Switch Starter Motor Solenoid...
Page 291 Copyright © 2016 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 292 Address : 5-4, Azusawa 3-Chome, Itabashi-Ku Tokyo, Japan Phone : TOKYO +81-3-3966-3117 �� FAX : TOKYO +81-3-3966-2951 URL : www.tohatsu.co.jp �� ...

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Mfs 9.8b

TOHATSU MFS 8B Service Manual

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Summary of Contents for TOHATSU MFS 8B

Page 245: Table Of Contents

Page 250: Magneto

Page 252: Tiller Handle

Page 253: Bottom Cowl

Page 257: Tiller Handle Model

Page 258: Tiller Handle Model

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