Lower Unit; Electrical System - TOHATSU MX 50D2 Service Manual

13) Removing Crank Case ..................... 5-52
14) Removing Pistons ........................... 5-54
15) Disassembly of Crank Shaft ............ 5-56
16) Inspection of Crank Shaft ............... 5-56
17) Inspection of Engine Parts ............... 5-60
18) Inspection of Pistons ..................... 5-62
19) Assembling Crank Shaft .................. 5-68
20) Installing Needle Bearing and Pistons......... 5-70
21) Assembling Power Unit Parts ............ 5-74
22) Assembling Crank Ass'y and
Crank Case ................................. 5-76
23) Assembling Exhaust Cover Parts ...... 5-78
24) Assembling Cylinder Head Parts ...... 5-80
25) Assembling Coil Bracket Parts ......... 5-82
26) Assembling Crank Case Head Parts ...... 5-82
27) Installing Reed Valve, Intake
Manifold and Intake Silencer. ............ 5-84
28) Attaching Recirculation Hoses ......... 5-88
29) Installing Throttle Link ..................... 5-90
30) Installing Electric Parts..................... 5-92
31) Installing Flywheel........................... 5-92
32) Installing Power Unit........................ 5-94
33) Disassembly of Recoil Starter............ 5-96
34) Inspection of Recoil Starter ............... 5-98
35) Assembling of Recoil Starter ............ 5-98

6.Lower Unit

1. Special Tools .................................... 6-2
2. Parts Layout .................................... 6-6
Gear Case (Drive Shaft, MX50) ..................... 6-6
Gear Case (Drive Shaft, MWX50).................. 6-14
Gear Case (Propellor Shaft, MWX50) ............ 6-18
3. Inspection Items .............................. 6-22
1) Draining Gear Oil ........................... 6-22
2) Removing Propeller ........................ 6-22
3) Removing Lower Unit ..................... 6-24
4) Disassembly of Cam Rod ............... 6-26
5) Inspection of Clutch Cam.................. 6-26
6) Assembly of Clutch Cam Parts ......... 6-28
7) Removing Water Pump .................. 6-30
8) Inspection of Water Pump ............... 6-32
9) Inspection of Water Pipe .................. 6-32
10) Disassembly of Water Pump Case
(Lower) ....................................... 6-34
11) Assembly of Water Pump Case
(Lower) ....................................... 6-34
12) Removing Propeller Shaft Housing
Ass'y .......................................... 6-36
13) Disassembly of Propeller Shaft Housing
Ass'y .......................................... 6-38
14) Inspection of Propeller Shaft Housing
................................................... 6-42
15) Assembly of Propeller Shaft Housing
................................................... 6-42
16) Disassembly of Propeller Shaft Ass'y
................................................... 6-46
17) Inspection of Propeller Shaft Ass'y ... 6-48
18) Assembly of Propeller Shaft Ass'y ...... 6-50
xi
19) Removing Drive Shaft Ass'y ............ 6-52
20) Disassembly of Drive Shaft Ass'y ...... 6-54
21) Inspection of Drive Shaft .................. 6-54
22) Inspection of Pinion (B) Gear ............ 6-54
23) Assembly of Drive Shaft Parts ......... 6-56
24) Removing Forward (A) Gear Ass'y ... 6-60
25) Disassembly of Forward Gear (A) Gear
................................................... 6-60
26) Inspection of Forward (A) Gear ......... 6-62
27) Assembly of Forward (A) Gear Parts
................................................... 6-62
28) Disassembly of Gear Case ............... 6-66
29) Inspection of Gear Case .................. 6-68
30) Assembly of Gear Case Parts............ 6-70
31) Measurement of Pinion (B) Gear Height
and Shim Selection ........................ 6-76
32) Measurement of Back Lash between
Forward (A) and Pinion (B) Gears and
Shim Selection .............................. 6-80
33) Measurement of Back Lash between
Pinion (B) and Reverse (C) Gears and
Shim Selection .............................. 6-88
34) Assembly of Lower Unit Parts............ 6-92
35) Assembly of Pump Case .................. 6-94
36) Attaching Clutch Cam Ass'y ............ 6-96
37) Measurement of Propeller Shaft Play and
Selection of Washer Thickness ......... 6-98
38) Installation of Lower Unit ............... 6-100
7.Bracket
1. Parts Layout .................................... 7-2
Drive Shaft Housing .............................. 7-2
Bracket Manual Tilt ................................. 7-4
Manual Tilt .......................................... 7-8
Tiller Handle ....................................... 7-10
Bottom Cowl • Shift .............................. 7-12
TOP COWL ....................................... 7-16
2. Inspection Items ........................... 7-18
1) Inspection of Throttle Cable ............ 7-18
2) Removing of Tiller Handle ............... 7-18
3) Installation of Tiller Handle ............... 7-20
4) Removing Bottom Cowl .................. 7-24
5) Removing Drive Shaft Housing ......... 7-26
6) Disassembly of Drive Shaft Housing ...... 7-28
7) Inspection of Drive Shaft Housing ......... 7-32
8) Assembly of Drive Shaft Housing Parts ...... 7-34
9) Assembling Rubber Mounting............ 7-38
10) Assembling Extension Housing ......... 7-40
11) Removing Steering Shaft Arm ......... 7-42
12) Installing Steering Shaft .................. 7-44
13) Disassembling Clamp Bracket ......... 7-46
14) Assembling Clamp Bracket ............... 7-48
15) Disassembling tilt mechanism............ 7-50
16) Assembling tilt mechanism ............... 7-52

8.Electrical System

1. Special Tools .................................... 8-2
*What's Peak Voltage.............................. 8-2
GB
2st X50D2 2011