Raider 40 Assembly Manual
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Raider 40 Assembly Manual

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Raider 40
Raider 40 Parts/Assembly Manual
Part No. RPAM 40ES-001
Supplement to Raider Service Manual
No. R40 ES-001-15-3
Manual
C-130
Air Dropped
Submarine
Launched
Raider Part No. R40ES-001
Military version
RAIDER
Raider No R40ES-001-15-2
January 2015
0

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  • Page 1 Raider 40 Manual Military version Raider 40 Parts/Assembly Manual Part No. RPAM 40ES-001 RAIDER C-130 Air Dropped Submarine Launched Raider Part No. R40ES-001 Raider No R40ES-001-15-2 Supplement to Raider Service Manual January 2015 No. R40 ES-001-15-3...
  • Page 3 The Raider is a military only engine and will not be sold to commercial market. It is submersible and runs multiple fuels. An additive must be placed into JP-5/JP-8 to be in compliance with EPA.

  • Page 4: Table Of Contents

    3.15 Gear Case (Propeller Shaft) …………………… 3.16 Shifter ……………………………………………… 3.17 Transom Bracket ………………………………… 3.18 Reverse Lock (Transom Bracket) …………….. 3.19 Raider Motor Covering (Cowl) ………………… 3.20 Fuel Hose …………………………………………. 3.21 Two Raider Motor Configuration …………….. 3.22 Tool Kit …………………………………………… Engine Details …………………………………………..

  • Page 5: Checklist Prior To Mission

    Raider 40 Manual Military version Section 1. GENERAL PRECAUTIONS WARNING Gasoline is extremely flammable and can explode if mishandled. 1. Before performing any service work on the fuel system, read and understand Section 1 - Service Safety. 2. Before servicing the fuel system, disable the ignition system by removing all spark plug leads to prevent accidental starting of engine.

  • Page 6: Raider Break-In Procedures

    Raider 40 Manual Military version 1.2 RAIDER BREAK-in PROCEDURES CAUTION Failure to follow the Break-In Procedure in Owner’s Manual and special fuel mixture requirements for break-in may lead to serious engine damage and shortened engine life. To prevent serious engine damage and ensure long engine life, new engines, used engines with new powerhead, used engines with newly rebuilt powerhead, and engines coming out of storage must be run for a period of 10 hours in accordance with the break-in procedure.

  • Page 7: Raider Engine Overview

    5. Fuel additives to assist meeting EPA standards when operating JP-5 and JP-8 fuels Section 3 will describe the Raider 40 outboard in detail. This information includes part numbers, how to assemble/disassemble each part. Section 4 will present engine details including Tune-Up procedures, troubleshooting and special tools required for overhaul and maintenance.

  • Page 8: Engine Information

    Raider 40 Manual Military version Section 3. ENGINE INFORMATION 1. Cowl tilt handle 2. Motor Cover – Upper 3. Cooling Water Check Port 4. Water Plug 5. Tilt Stopper 6. Drive Shaft Housing 7. Anti-Cavitation Plate 8. Trim tab 9. Propeller 10.
  • Page 9 Raider 40 Manual Military version Front View Raider 40...
  • Page 10 Raider 40 Manual Military version Raider 40 Overview                                ...

  • Page 11: Cylinder/Crankcase

    Raider 40 Manual Military version    3.1 CYLINDER/CRANKCASE...
  • Page 12 Raider 40 Manual Military version Ref.No. Part No. Description Q’ｔｙ Remarks M40C 361B01100- CYL BLOCK & CRANKCASE ASSY 393-01137- * NIPPLE 393-01131- * NIPPLE 5.5-5 345-00117- * DOWEL PIN Bearing 345-01150- * CHECK VALVE ASSY 916129- * BOLT 0850 916124-...
  • Page 13 Raider 40 Manual Military version 915324- STUD 0825 940121- WASHER 0800 930121- 0800 921503- SCREW 0520 930103- 0500 309-06972- CLAMP 6.5-47.5P 345-01303- ENGINE BASEMENT GASKET 361-05211- STARTER LOCK ARM 345-05213- THROTTLE LIMITER ARM 345-05223- ROD SNAP 3.5-2 345-05221- THROTTLE LIMITER ROD...
  • Page 14 Raider 40 Manual Military version 3B7-63733- ROD SNAP 5-2.5 348-63711- ADVANCER ARM 910121- BOLT 0840 345-63713- BUSHING 8-14-4 334-66233- WASHER 8.1-16-1.5 930403- NYLON NUT 8-P1.25 0800 345-05223- ROD SNAP 3.5-2 348-63715- ROD 5-75L for MF/EF 346-05234- ROD JOINTφ5 for MF/EF 3B7-63733- ROD SNAP 5-2.5...
  • Page 15 Military version Crankshaft Crankshaft is not an item that is addressed in the field. Raider Outboard should be sent back to depot or manufacturer for inspection. Critical concern would be starting the engine with the electric start prior to dispelling water between piston and heads. It is critical that the dewatering valves are opened after submersion and pull start is firmly and slowly pulled at a minimum of eight times prior to using electric starter.
  • Page 16 Raider 40 Manual Military version 3.2 Piston/Crankshaft Remarks: Crank shaft assembly is difficult to assemble. The component parts should be purchased as an assembly if possible.
  • Page 17 Raider 40 Manual Military version Q’ｔｙ Ref.No. Part No. Description Remarks 345-00122- OIL SEAL 25-55-10 345-00125- RETAINER 50-60-1.6 361-00069- CRANKSHAFT SUB-ASSY 361-00031- * CRANKSHAFT A 348-00032- * CRANKSHAFT B 348-00033- * CRANKSHAFT C 348-00034- * CRANKSHAFT D 348-00061- * CRANK PIN...
  • Page 18 Raider 40 Manual Military version 345-00011- 2-29 * PISTON RING STD 2nd...

  • Page 19: Intake Manifold/Fuel Pump

    Raider 40 Manual Military version 3.3 Intake Manifold/Fuel Pump Reed Valve and Stopper Ref.No. Part No. Description Q’ｔｙ Remarks 915321- STUD 0655 345B02010- INTAKE MANIFOLD 345-02104- INTAKE MANIFOLD GASKET 345-02105- INTAKE MANIFOLD GASKET 345-02100- REED VALVE ASSY 921521- SCREW 7412...
  • Page 20 Lift height of each reed valve and stopper must be within specification. Used reeds must never be turned over and reused. Reed could break when returned to service causing serious powerhead damage. Number of Valves - 40 Strips - 4 Valves/Strip - 3 Valves/Strip A = Valve –...

  • Page 22: Multi-Fuel (Throttle Body) Atomizer

    Raider 40 Manual Military version 3.4 Multi-fuel (Throttle Body) Atomizer The Fuel Induction System (FIS) was given a name replacing “carburetor” as it looks like a carburetor, however, has minimal moving parts. The key to the FIS is the slide as it is shaped larger at bottom; smaller at top; as both flat and round surfaces with serrations in two directions.
  • Page 23 Raider 40 Manual Military version Quantity Ref.No. Part No. Description Remarks RL4-32- MULTI-FUEL ATOMIZER RL4- SLIDE 3221-0 RL4-0322 PUSH PULL KNOB RL4-0323 CHOKE RETAINER BOOT RL4-0324 CHOKE ASSY COMPONENT 2709 RL4-0325 CHOKE ASSY COMPONENT 2709 RL4-0326 CABLE CHOKE ASSY 2719...

  • Page 24: Fuel Pump/Oil System

    Raider 40 Manual Military version 3.5 Fuel Pump/Oil System Fuel Pump CAUTION: Before servicing the fuel pump, disconnect the fuel hose from the engine to prevent excessive fuel spillage. Inspection 1. Inspect pump body (1) for cracks. 2. Inspect check valves (2) for deformation.
  • Page 25 Raider 40 Manual Military version Past production model contained an internal guide plate (7) and spring (8) assemblies under tension. The rubber diaphragm (9) that required the guide plate and spring has been replaced by a resin film (white opaque) diaphragm (10) which no longer requires the guide plate and spring.
  • Page 26 Raider 40 Manual Military version \.._ _ _ _ _ _ _ _ _ _ _ _ _ .!
  • Page 27 Raider 40 Manual Military version Ref. No. Part No. Description Q’ty Remarks 356-04000-1 Fuel Pump 5-1-1 334-04004-0 Pump Cover 5-1-2 92251 2-6528 Screw 5-1-3 334-04005-0 Diaphragm 5-1-4 334-04007-0 Gasket "B", Diaphragm 5-1-5 Diaphragm Set 356-04030-0 5-1-6 356-04044-0 Check Valve 5-1 -7...

  • Page 28: Throttle Mechanism

    Raider 40 Manual Military version 3.6 Throttle Mechanism...
  • Page 29 Raider 40 Manual Military version Ref. No. Part No. Description Q’ty Remarks 348-63711-1 Advancer Arm 9101 21 -0840 Bolt 345-63713-0 Bushing:. 8-14-4 930406-0800 Nylon Nut. 8P-1.25 or 334-66233-0 3P0-66233-0 Washer. 8.1-16-1.5 921 506-0520 Screw 930106-0500 361 -83728-0 Cable Pin 930106-0600...

  • Page 30: Tiller Handle

    Raider 40 Manual Military version 3.7 Tiller Handle · ..:.::---· Fig. 19-1...
  • Page 31 Raider 40 Manual Military version Ref. No. Part No. Description Q’ty Remarks 348-63711-1 Advancer Arm 9101 21 -0840 Bolt 345-63713-0 Bushing:. 8-14-4 930406-0800 Nylon Nut. 8P-1.25 or 334-66233-0 3P0-66233-0 Washer. 8.1-16-1.5 921 506-0520 Screw 930106-0500 361 -83728-0 Cable Pin 930106-0600...

  • Page 32: Magneto

    Raider 40 Manual Military version 3.8 Magneto 12-1 16-1...
  • Page 33 Raider 40 Manual Military version Ref. No. Part No. Description Q’ty Remarks FP5506 361-06091 -0 Flywheel Cup #91569 3A0-06002-0 Coil Plate Ass'y 8-2-1 3G2-06022-0 Pulser Coil 8-2-2 3A0-06023-0 Alternator 8-2-3 921521 -6528 Screw 8-2-4 3G2-06021-0 Exciter Coil 8-2-5 921521-6522 Screw...
  • Page 34 Raider 40 Manual Military version Clam p, 6.5-47.5P 309-06972-0 8-20 8-21 922503-6510 Screw 8-22 9101 13-061 2 Bolt 8-23 353-76037 Plug:. Cable Terminal 8-24 336-76091-0 Band, Lead Wire #032986XD- 8-25 931121 -1600 Nut. Magneto (16P-1.5) Clockwise #028121XD- 334-00132-0 Magneto (16P-1.5L)

  • Page 35: Electrical System

    Prior to mission check to insure the battery voltage is not lower than 12.8 V. This battery is completely sealed and requires no topping of any fluid. Never attempt to open the battery. Short cranking of the Raider 40 is recommended.
  • Page 36 Raider 40 Manual Military version Electrical System Overview Ignition type - Flywheel magneto capacitor discharge Spark Plug (with resistor) - SBE1/10 (Pulstar) Spark Plug wires – 2 x 23 015 002 051 (Nology) Spark Plug Gap - 0.040 in [0.9 - 1.0 mm] Battery - Sealed type 12 Volt W/Hr (Wh) –...
  • Page 37 Raider 40 Manual Military version Electrical Starter Position Color of lead wires Yellow White Blue/Brown Green/Black Fig. 11-4 .!__ _ · -·· · · ·:: : ....,0 Starter Motor · · ..- Fig. 8-5 Bolt...
  • Page 38 Raider 40 Manual Military version Ref. No. Part No. Description Q’ty Remarks 346-76010-0 Starter Motor Pinion 9-1-1 346-76015-0 346-76012-0 Carbon Brush Carbon Brush ( -) 346-76013-0 9-1 -4 346-76014-0 Brush Holder 916103-0830 Bolt 345-06971-0 Clamp, 9-1 2U 9301 1 3-0800...

  • Page 39: Dewatering System

    Raider 40 Manual Military version EMERGENCY STOP SWITCH AND LANYARD The emergency stop switch and lanyard should be inspected and tested after servicing outboard. The operator should perform Emergency Stop function test with the boat in the water prior to leaving the launch area.
  • Page 40 Raider 40 Manual Military version 10-6 10-1 10-4 10-3 10-6 10-5 10-7 10-5 10-1 Dewater and Start Procedure: (Pull Start) Connect fuel line. Tilt engine into boat Push dewatering valve toward rear of engine – hold back 10-7 Pump primer bulb clearing old fuel Release dewatering against fuel valve Pull slowly 8 times on rope.
  • Page 41 DW50547 3.10-1 Dewatering System operation The dewatering system is utilized after total motor submersion. After the Raider is installed on the transom and secured the dewatering lever, located on the left side of the motor, is pushed toward the back of the outboard motor.

  • Page 42: Recoil Starter

    Raider 40 Manual Military version 3.11 Recoil Starter 1-18 1-19 11-23 1-21 1-22 1-24...
  • Page 43 Raider 40 Manual Military version Ref. No. Part No. Description Q’ty Remarks 1 1-1 345-05000- Recoil Starter 1-1-1 345-05105-1 Starter Case 1-1-2 345-05105-1 Reel 1-1-3 345-05003-1 Ratchet 1 1-1-4 345-051 35-1 Bushing, Ratchet -1-5 345-05122-0 Washer. 6.5-23-1.5 E-Ring, d=5 1 1 -1-6...
  • Page 44 3. Remove the handle (7) from the starter rope (8). WARNING: The Raider 40 has a neutral start mechanism (start-in-gear protection) attached to the recoil WARNING: The Raider 40 has a neutral start mechanism (start-in- starter.
  • Page 45 Raider 40 Manual Military version 3.12 Starter Lock (Pull Starter) -34-...
  • Page 46 Raider 40 Manual Military version Q'ty Ref. Part No. Description Remarks 12-1 361-05211-0 Lock Arm. Starter 12-2 915314-0825 Stud Bolt 12-3 345-01015-0 Washer, 8.5-19.5-3.2 12-4 345-63713-0 Bushing, 8-14-4 12-5 9401 13-0800 Washer 12-6 930406-0800 Nylon Nut. 8P-1.25 12-7 345-05213-0 Stop...

  • Page 47: Starter Lock

    Raider 40 Manual Military version Fig.12 STARTER LOCK -36-...
  • Page 48 Raider 40 Manual Military version Ref. No. Part No. Description Q’ty Remarks 12-1 361-05211-0 Lock Arm. Starter 12-2 915314-0825 Stud Bolt 12-3 345-01015-0 Washer, 8.5-19.5-3.2 12-4 345-63713-0 Bushing, 8-14-4 12-5 9401 13-0800 Washer 12-6 930406-0800 Nylon Nut. 8P-1.25 12-7 345-05213-0...
  • Page 49 Raider 40 Manual Military version 12-30 921521-6510 Screw 1 2-31 921 503-0530 Screw 1 2-32 930106-0500 -38-...

  • Page 50: Drive Shaft Housing

    Raider 40 Manual Military version 3.13 Drive Shaft Housing _ _ _ ...J...
  • Page 51 Raider 40 Manual Military version Ref. No. Part No. Description Q’ty Remarks 13-1 345S61030-1 "L" Drive Shaft Housing 13-2 345-61 1 11-1 Stud Bolt. Drive Shaft Housing: 13-3 9301 13-0800 Nut, Drive Shaft Housing 13-4 9161 13-0885 Bolt 13-5 3P0-66233-0 Washer, 8.1-16-1.5...

  • Page 52: Gear Case (Drive Shaft)

    Raider 40 Manual Military version 3.14 Gear Case (Drive Shaft) Ratio: 13 : 25 Lubricant - Genuine manufacturer gear oil or API GL5, SAE #80 - #90 Capacity - Approximately 14.2 U.S. fl oz [420 ml] Clutch System - Dog clutch type (Forward-Neutral-Reverse...
  • Page 53 Raider 40 Manual Military version Ref. No. Part No. Description Q’ty Remarks 14-1 361 S60000-0 Gear Case 345-602 11-0 Needle Bearing, 22-30-30 14-2 910113-5840 Bolt 14-3 332-60005-2 Oil Plug 14-4 332-60006-0 Gasket, 8.1-15-1 14-5 345-60206-0 Water Strainer 921503-0440 14-6 Screw...
  • Page 54 Raider 40 Manual Military version Ref. No. Part No. Description Q’ty Remarks 14-26 345-65206-0 Seal Rubber Upper, Water Pipe 14-27 345-65205-0 Ring, Seal Rubber 14-28 345-65204-0 Lock Rubber Water Pipe 14-29 345-65110- 1 Water Pipe "L" 14-30 348-66011 -0 Clutch Cam...

  • Page 55: Gear Case (Propeller Shaft)

    Raider 40 Manual Military version Section 15. GEAR CASE (PROPELLER SHAFT) Fig. 14-...
  • Page 56 353-64038-0 Shim 36-44-01 Raider Outboards are equipped with seal sacrificial anodes to help protect metal parts from the effects of galvanic corrosion (electrolysis). Disintegration of the anodes indicates they are performing their function. Anodes must be replaced when reduced to 2/3 its original size.
  • Page 57 Raider 40 Manual Military version Maintenance Procedure: 1. Drain gear oil completely 2. Inject oil into lower 3. Replace upper plug, then By removing both upper oil plug hole until it lower plug after withdrawing And lower plugs. Flows from upper oil injector.

  • Page 58: Shifter

    Raider 40 Manual Military version 3.16 Shifter Fig. 14-38...
  • Page 59 The shifter is a mechanical front mounted, easy fit, rugged device. For movement it can be pushed into the Raider to minimize size. The shifter also has a safety device which only allows the motor to be started into neutral. The primary pull starter must be in neutral for the primary start.

  • Page 60: Transom Bracket

    Raider 40 Manual Military version 3.17 Transom Bracket...
  • Page 61 Raider 40 Manual Military version Q'ty Ref. Part No. Description Remarks 17-1 349S62112-0 Stern Bracket (Right) Starboard 17-2 349S62113-0 Stern Bracket (Left) Port 17-3 346-62191 -0 Bracket Bolt 17-4 346-62124-0 Nylon Nut. 17-5 349-62126-0 Bushing, Bracket Bolt 17-6 346-62127-0 17-7...
  • Page 62 Raider 40 Manual Military version Q'ty Part No. Ref. Description Remarks 17-28 345-61313-0 Stud Bolt Rubber Mount (Upper) 17-29 345-6131 2-0 Retainer, Rubber Mount 17-30 9101 13-5820 Bolt 17-31 345-61331-0 Damper Clamp 17-32 345-61332-0 20- O 31.7-3mm Damper Collar 17-33...
  • Page 63 Raider 40 Manual Military version 17-55 348-62143-0 Shaft. Tilt Assistant 17-56 348-62107-0 Raider transom safety support Transom parts should be checked before missions for damage. -54-...

  • Page 64: Reverse Lock (Transom Bracket)

    Raider 40 Manual Military version 3.18 Reverse Lock (Transom Bracket)

  • Page 65: Lower Unit

    Raider 40 Manual Military version 3.19 Motor Cover 19-4 Spring Washer P/N: 9413030500M Washer P/N: 9401030500M Screw – P/N: 9216030516M 9301030500M - Nut 19-1 Tilt Handle P/N 345S675210 19-6 Rubber Starter Seal P/N: 3KM675030M Dewatering Instructions 19-8 Rubber Seal P/N: 3F3675010M...
  • Page 66 Raider 40 Manual Military version Q'ty Ref. Remarks Part No. Description 19-1 345S67100-2 Motor Cover Lower 93201 - 19-2 345-671 13-0 Rubber Mount. 12-18-2.5 19-3 3C7-67114-0 Spacer, 8.4-12-17 19-4 9101 13-0835 Bolt 19-5 345-671 15-0 Washer, Rubber Mount 19-6 338S67141-0...

  • Page 67: Fuel Hose

    3. Replace with new fuel filter. 4. Attach hoses and secure clips. Fuel: Gasoline; Avgas; JP-5; JP-8; Diesel #2 Note: To comply with local EPA requirements when JP-5 or JP-8 fuels are used Raider Additive Must be added to reduce smoke and emissions. -58-...
  • Page 68 Rubber Inflatable Boat. The motors are placed on the transom where the DMCT connecting rod can be screwed into the bolt located on each side of the Raider. Simply place one on the first engine and move the second engine into position to accept the second screw.

  • Page 69: Tool Kit

    Raider 40 Manual Military version 3.22 Tool Kit Tools: Tool bag Pliers 10 x 13 mm socket wrench 21 mm socket wrench Socket wrench handle Slotted-head screwdriver Spare Parts: Starter rope Spark Plugs (2) Split Pin (Cotter Key) Other: Plastic emergency clip...

  • Page 70: Engine Details

    Raider 40 Manual Military version Section 4. RAIDER ENGINE DETAILS 4.1 TUNE-UP PROCEDURE WARNING Deteriorated or damaged parts identified during engine tune-up must be replaced in order to maintain safe engine operation. 1. Inspect engine for leaks, missing, loose or damaged parts, or other visible defects.

  • Page 71: General Equipment Required

    Raider 40 Manual Military version 4.2.1 General Equipment Required Water Pressure Gauge - 0 - 15 psi [0 - 103 kPa / 0 - 1 kg / cm2] Fuel Pressure Gauge - 0 - 15 psi [0 - 103 kPa / 0 - 1 kg / cm2] Torque Wrench 0 - 150 in-lb [0 - 17 N·m / 0- 1.7kg-m]...

  • Page 72: Consumables Required

    Throttle Setting Power - Raider 40 HP [29.4 kW] Full Throttle RPM Range - Raider 40 - 5200 – 5800 - Full Open: Match Mark –BTDC 25 deg. Full Closed (in gear) – ATDC 4 deg. Target RPM – 850 for full closed Fuel Consumption at Full Throttle - 3.49 g/hr...
  • Page 73 Raider 40 Manual Military version Adjustment Procedure: Rotate the throttle grip to the FAST side until Throttle Stops 2. Adjust ignition timing link so that the timing full open match mark is aligned with the fitting line (Crankcase Mating Surfaces).

  • Page 74: Unit Conversions

    Raider 40 Manual Military version UNIT CONVERSIONS Prefix Symbol Power mega x 1,000,000 kilo x 1,000 centi x 0.01 milli x 0.001 micro μ x 0.000001 Units of Length Units of Volume mile x 1.6090 = km gal (U.S.) x 3.78540 = L x 0.3050 = m...
  • Page 75 Raider 40 Manual Military version -66-...

  • Page 76: Troubleshooting

    Raider 40 Manual Military version Section 4. ENGINE DETAILS SYNCHRONIZATION AND LINKAGE ADJUSTMENTS To ensure consistent engine idling and smooth operation throughout the full RPM range, it is important that each procedure be performed exactly as written and in the following sequence: 1.
  • Page 77 TROUBLESHOOTING - Powerhead The troubleshooting chart list common engine symptoms related to problems with the powerhead. It also indicates specific component failures which may be causing the problem so it can be isolated more effectively for the Raider 40. Symptom Hard to...
  • Page 78 Raider 40 Manual Military version Fuel Additive not included Raider 40...

  • Page 79: Recommended Spare Parts Kit

    Where the Raider is used dictates more of some parts than others – like propellers. This list will be updated as required.
  • Page 80 Raider 40 Manual Military version If any discrepancies are found the manual can be updated by called (321) 403-3585 – Raider Outboards. Updates will be automatically done on line. www.raideroutboards.com Manuals will be listed. Password is required for entry. Raider Outboards...

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