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TOHATSU Manuals
Outboard Motor
NB-1000
Service manual
Table Of Contents - TOHATSU NB-1000 Service Manual
2 stroke 1&2 cylinder models
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Table Of Contents
269
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
Table Of Contents
2
Service Safety
3
Introduction
4
Safety Statements
4
Safety Precautions
5
Handling Outboard Engines
5
Lead Acid Batteries
6
Hazardous Materials
7
Shop Environment
7
Workmanship Standards
7
Test Tank Guidelines
9
General Service Information
10
General Precautions
11
Abbreviations And Symbols
12
Unit Conversions
13
Unit Prefixes
13
Units Of Length
13
Units Of Torque
13
Service Specifications
14
Standard Torque Values
14
Manufacturer Special Tools Required - 1-2 Cylinder
15
General Equipment Required
24
Consumables Required
25
Engine Specificati0Ns
26
Powerhead
26
Full Throttle Rpm Range
26
Test Propeller
26
Crankshaft Dimensions
27
Spark Plug Gap
27
Gearcase
27
Gear Ratio
27
Electrical System
27
Fuel And Lubricant System
28
Lgnition Coil Resistance (±25%)
28
Lubrication Chart
29
Lube Type
29
Periodic Inspecti0Ns
33
Break-Ln Procedure
36
First 10 Minutes (0 - 0.16 Hours)
36
Next 50 Minutes (0.16 To 1 Hour)
36
Next Hour (1 To 2 Hours)
36
Tune-Up Procedure
37
After Break-In
37
Emergency Stop Switch And Lanyard
38
Synchronization And Linkage Adjustments
39
Stop Switch Test
39
Single Cylinder Engines
39
Ignition Timing Adjustment
40
Twin Cylinder Engines
40
Carburetor Adjustment
45
Idling Adjustment
45
All Other Engine Carburetors
46
Jet Needle Adjustment
46
Adjustment Procedure
46
Anodes - Inspection And Testing
47
External Anodes
47
Powerhead Anode
47
Installation Test
47
Fuel System
48
Service Specificati0Ns
50
Special Torque Values
50
Fuel System Requirements
51
Consumable Supplies Required
51
Acceptable Fuel
51
Acceptable Lubricant
51
Mix Ratios
52
Premixing
52
Troubleshooting
53
Description Of Operation
55
2.5 / 3.5 Fuel Flow
55
5 - 40 Fuel Flow
56
Fuel Pump
57
Carburetors
57
Pilot System
57
Main System
58
Separate Fuel Tank
59
Fuel Hose And Primer
60
Cleaning And Inspection
60
Integral Fuel Tank
61
Fuel Filter
62
Ln-Line Fuel Filter Replacement
63
Bowl Type Fuel Filter Cleaning And Inspection
63
Butterfly Valve Carburetors
73
Reed Valve
79
Thermostat
90
Rpm Performance Test
91
Recoil Starter
92
Ratchet Load Requirements
98
Flywheel
100
Typical 1-Cylinder
103
Typical 2-Cylinder
104
Remote Control Models
105
Crankcase And Crankshaft
107
Exhaust Cover
107
Pistons
108
Midsection
117
Service Specifications
121
Tiller Steering Handle
122
9.9/15/18 Linkage Adjustment
127
Twist Handle And Linkage Inspection
131
Twist Handle And Linkage Assembly
131
Lower Engine Cover
136
Driveshaft Housing
137
Stern And Swivel Brackets
143
9.9/15/18 Stern Bracket
147
Swivel Bracket And Reverse Lock
151
Shift Position-Lock (For 8/9.8)
151
Water Pump
157
Disassembly And Assembly
158
Typical Gearcase – 2.5/3.5
162
Typical Gearcase – 3.5B
165
Typical Gearcase — 8/9.8/9.9/15/18/25/30/40
169
Bevel Gear B Adjustment - (25/30 And 40 Only)
181
Backlash Adjustment - Bevel Gears A And B
182
Gearcase Repair Procedures
188
Driveshaft Roller Bearings
188
Gearcase Needle Bearing
189
Propeller Shaft Needle Bearing
190
Bevel Gear A Bearing Outer Race
191
Electrical Servicing Standards
199
Electrical Connectors
199
Eiectrical Connector Drawings
199
Bullet Connectors
200
Disconnecting Bullet Connectors
200
Electrical Cable Color Codes
201
Eiectrical Drawings
201
Ignition System
203
Starting System
203
Descripti0N Of Operation
204
Magneto
205
Coil Plate
206
Exciter Coil
206
Pulser Coil
206
Alternator/Lighting Coil
206
Cd Unit
207
Ignition Coil
207
Main Key Switch And Emergency Stop Switch
207
Starting System - Optional Electric Start
208
Charging System
208
Battery Care And Maintenance
209
General Procedures
209
Corrected Specific Gravity = Msp + (Temperature - 20) X 0.0007
210
Charging Capacity Test
210
Terminal Voltage Test
211
Ignition System Performance Testing Flow Chart
214
Spark Test
215
Stop Circuit Test
216
Stop Circuit Main Key Switch Test
217
Stop Circuit Emergency Stop Switch Test
218
Pulser Coil Test
224
Cd Unit Output Test - Cranking Rpm
228
Ignition Coil Tests
230
Output Tests - Engine Running
231
Output Tests - Engine Running - Flow Chart
232
Ignition System Repair Procedures
233
Fiywheel
234
Bolts
240
Starter Circuit Tests
244
Inspect Brush Assembly
251
Remove Brush Assembly
252
Install Brush Assembly
252
Assemble Starter Motor
252
Install Starter Motor
254
Starter Solenoid Test
254
Main Key Switch Test
255
Choke Solenoid Test
258
Charging System Repair Procedupes
264
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Table of Contents
Troubleshooting
Troubleshooting
53
Troubleshooting
87
Troubleshooting
202
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This manual is also suitable for:
2 stroke cylinder series
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