Table Of Contents; Fuel System; Service Data; Power Unit - TOHATSU MX 50D2 Service Manual

1.Service Information
1. Identification
(Engine Serial Number) ..................... 1-2
2. Work Safety ....................................... 1-2
1) Fire Prevention .............................. 1-2
2) Ventilation....................................... 1-2
3) Protection ....................................... 1-2
4) Genuine Parts ................................. 1-2
5) Tools ............................................. 1-4
6) Recommendations on Service ............ 1-4
7) Cautions in Disassembling and
Assembling Components .................. 1-6
3. Tools and Instruments ..................... 1-8
1) Test Propeller ................................. 1-8
2) Measuring Instruments ..................... 1-8
3) Special Tools ................................. 1-10
4. Pre-delivery Inspection .................. 1-16
1) Tiller Handle ................................. 1-16
2) Gear Shift .................................... 1-16
3) Gear Oil ....................................... 1-16
4) Fuel and Fuel Line ........................ 1-18
5) Installation of Outboard Motor
(Rigging) ....................................... 1-18
6) Propeller Selection ........................ 1-20
7) Cooling Water Check Port ............... 1-22
8) Trim Tab ....................................... 1-22
5. Break-In Operation ........................ 1-24
6. Test Run .......................................... 1-24
7. Checks After Test Run .................. 1-24
2.Service Data
1. Outboard Dimensions ..................... 2-2
1) Body dimensions .............................. 2-2
2) Clamp Dimensions ........................... 2-4
2. Cooling Water System Diagram ......... 2-6
3. Specifications ................................. 2-8
4. Maintenance Data ........................... 2-12
5. Torque Specifications ..................... 2-16
6. Sealant And Lubricant .................. 2-17
3.Maintenance
1. Special Tool .................................... 3-2
2. Inspection Schedule ........................ 3-2
3. Inspection Items .............................. 3-6
1) Inspection of Top Cowl ..................... 3-6
2) Inspection of Fuel Tank ..................... 3-6

3) Fuel System .................................... 3-8

4) Inspection of Cooling Water Passage ... 3-10
5) Flushing with Water ........................ 3-10
6) Inspection of Compression Pressure ... 3-14
7) Inspection of Spark Plugs ............... 3-18
8) Inspection of Thermostat .................. 3-20
9) Adjustment of Throttle Cable ............ 3-22
10) Ignition Timing Adjustment ............... 3-24
11) Carburetor Synchronization............... 3-26
12) Pilot screw adjustment ..................... 3-30
13) Replacement of Gear Oil .................. 3-32
2st X50D2 2011
14) Inspection of Gear Case (for leakage) ...... 3-34
15) Inspection of Propeller ..................... 3-34
16) Replacement of Anode..................... 3-36
17) Greasing ....................................... 3-38
4.Fuel System
1. Special Tools .................................... 4-2
2. Parts Layout .................................... 4-4
Fuel line ................................................4-4
Intake Silencer • Carburetor ..................... 4-6
3. Carburetor Inner Passages ............ 4-10
1) Idling Passage .............................. 4-10
2) Off-Idle Passage ........................... 4-12
3) High Speed Passage ..................... 4-14
4) Choking Passage
(#2 and #3 carburetor) ..................... 4-16
4. Inspection Items ........................... 4-18
1) Removing Carburetors ..................... 4-18
2) Disassembling Carburetors ............ 4-20
3) Cleaning and Inspection .................. 4-22
4) Inspection of Fuel Pump and
Needle Valve .............................. 4-24
5) Disassembly and Inspection of Fuel
Pump .......................................... 4-34
6) Assembly of Fuel Pump .................. 4-26
7) Inspection of Fuel Connector ............ 4-26
8) Inspection of Fuel Filter .................. 4-26
9) Assembling Carburetors .................. 4-28
10) Inspection of Float Height ............... 4-30
11) Installing Carburetors ..................... 4-30

5.Power Unit

1. Special tools .................................... 5-2
2. Parts Layout .................................... 5-4
Engine ................................................ 5-4
Magneto ............................................. 5-6
Electric Parts ....................................... 5-8
Recoil Starter ....................................... 5-10
Intake Manifold · Reed Valve .................. 5-14
Throttle ............................................. 5-16
Cylinder Crank Case ........................... 5-20
Piston & Crank Shaft ........................... 5-24
3. Inspection Items .............................. 5-26
1) Removing Power Unit ..................... 5-26
2) Removing Flywheel ........................ 5-32
3) Removing Electric Parts .................. 5-32
4) Removing Throttle Link .................. 5-34
5) Removing Intake Silencer and
Carburetors ................................. 5-38
6) Removing Intake Manifold and
Reed valves ................................. 5-40
7) Inspection of Reed Valve Ass'y ......... 5-40
8) Removing Thermostat and
Engine Anode .............................. 5-42
9) Removing Cylinder Head / Head Cover ...... 5-46
10) Inspection of Cylinder Head ............ 5-48
11) Removing Exhaust Cover ............... 5-50
12) Inspection of Exhaust Cover ............ 5-50
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