Raider 40 Assembly Manual Download

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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.

3. Inspect pump covers

(3)

for cracks and surface deformation.

4. inspect guide plate

(4)

and spring

(5)

, if equipped, for deformation and tension.

5. Inspect gasket between crankcase and fuel pump for dryness (crankcase-mounted pumps).

Disassembly

NOTE:

Match mark parts before disassembly and reference

the illustrations in the Inspection

procedure to

ensure proper orientation of internal components.

1. Expand and move clips

(1)

on fuel hose(s)

(2)

2. Disconnect fuel hoses from fuel pump.
3. Loosen pump mounting screws

(3)

and remove fuel pump

(4)

and gasket from crankcase.

4. Remove fuel pump cover screws

(5)

and cover

(6)

. Gently separate the pump components.

Summary of Contents for 40

Page 1: ... version 0 Raider No R40ES 001 15 2 January 2015 Raider 40 Parts Assembly Manual Part No RPAM 40ES 001 C 130 Air Dropped Submarine Launched Raider Part No R40ES 001 RAIDER Supplement to Raider Service Manual No R40 ES 001 15 3 ...

Page 2: ......

Page 3: ... Service Manual No R40ES 001 15 3 that describes in detail how to remove repair and the Raider 40 For background purpose s the Raider 40 comes from a family of motors that have an extensive history of reliability and performance and are identical in parts except for the branding and pricing These motors are Mercury Nissan and Tohatsu Supporting Raider with common parts available at local dealers s...

Page 4: ...System 24 3 10 Dewatering System 29 3 11 Recoil Starter 31 3 12 Starter Lock 34 3 13 Drive Shaft Housing 39 3 14 Gear Case Drive Shaft 41 3 15 Gear Case Propeller Shaft 44 3 16 Shifter 47 3 17 Transom Bracket 51 3 18 Reverse Lock Transom Bracket 55 3 19 Raider Motor Covering Cowl 56 3 20 Fuel Hose 57 3 21 Two Raider Motor Configuration 59 3 22 Tool Kit 60 4 Engine Details 61 4 1 Tune Up procedures...

Page 5: ... with authorized factory replacement parts suitable for fuel systems 6 Clean up fuel spills immediately and store rags in approved containers Keep drained fuel in approved containers for proper disposal 7 When using compressed air to clean or dry parts make sure the air supply is regulated not to exceed 25 psi 172 kPa 1 76 kg cm2 1 1 Checklist prior to Mission 1 Fuel Oil System 50 1 Mix in bladder...

Page 6: ...hrottle every 15 minutes NOTE For boats which come onto plane easily use full throttle to quickly accelerate onto plane then immediately reduce throttle to 1 2 and maintain this speed Next Hour 1 to 2 Hours Use full throttle to quickly accelerate boat onto plane then immediately reduce throttle to 3 4 and maintain this speed At intervals run engine at 3 4 throttle for 1 10 minutes then return to 1...

Page 7: ...er 4 Wrap around grab bar for easier carrying engine protection 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 over...

Page 8: ...ve Shaft Housing 7 Anti Cavitation Plate 8 Trim tab 9 Propeller 10 Starter Handle 11 Shift Lever 12 Throttle Grip 13 Clamp Screw Handle 14 Stern Bracket 15 Thrust Rod 16 Oil Plug Lower 17 Water Strainer 18 Oil Plug Lower 19 Retainer to transom 20 Stop switch 21 Choke knob 22 Electric Starter button 23 Fuel connection 24 Dewatering lever 25 Wrap around grab rail 25 ...

Page 9: ...Raider 40 Manual Military version Front View Raider 40 6 24 23 20 11 19 25 25 ...

Page 10: ...Raider 40 Manual Military version 7 Raider 40 Overview ...

Page 11: ...Raider 40 Manual Military version 3 1 CYLINDER CRANKCASE ...

Page 12: ... 1 1 13 345 01005 1 CYLINDER HEAD GASKET 1 1 14 9161F9 0845 BOLT 10 1 15 345 01015 0 WASHER 8 5 19 5 3 2 10 1 16 9701 1 1015 SPARK PLUG BR7HS10 2 NGK 1 17 345 01030 0 THERMOSTAT 1 Mark 52A PRV 1 18 RH6B01031 0 DEWATERING VALVES 2 1 19 R46 01032 0 DEWATERING FLANGE 1 1 20 R101F4 5630 DEWATERING ROD 1 1 21 338 60218 2 ANODE 1 1 22 910103 0616 BOLT 1 1 23 345B02301 2 EXHAUST COVER OUTER 1 1 24 345 02...

Page 13: ...46 346 05234 0 ROD JOINTφ5 1 1 47 353 83728 1 PIN 1 1 48 951603 0800 SNAP PIN d 8 1 1 49 3AA 83719 0 WASHER 8 5 18 1 6 2 1 50 941303 0600 SPRING WASHER 1 1 51 930103 0600 NUT 1 1 52 915324 0825 STUD 1 1 53 940103 0800 WASHER 1 1 54 345 01015 0 WASHER 8 5 19 5 3 2 1 1 55 345 63713 0 BUSHING 8 14 4 2 1 56 930403 0800 NYLON NUT 8 P1 25 1 1 57 9101F4 0620 BOLT 1 1 58 940103 0600 WASHER 2 1 59 941403 1...

Page 14: ...16 1 5 1 1 72 930403 0800 NYLON NUT 8 P1 25 1 1 73 345 05223 1 ROD SNAP 3 5 2 1 1 74 348 63715 1 ROD 5 75L 1 for MF EF 1 75 346 05234 0 ROD JOINTφ5 1 for MF EF 1 76 3B7 63733 0 ROD SNAP 5 2 5 1 for MF EF 1 77 930103 0500 NUT 1 for MF EF 1 78 361 83728 0 PIN 1 for MF EF 1 79 3AA 83719 0 WASHER 8 5 18 1 6 1 for MF EF 1 80 951603 0800 SNAP PIN d 8 1 for MF EF 1 81 930103 0600 NUT 1 for MF EF ...

Page 15: ... are opened after submersion and pull start is firmly and slowly pulled at a minimum of eight times prior to using electric starter Starting engine after submersion without proper dewatering when using Electric start could damage crankshaft Dimension 1 2 071 0 in 52 6 0 mm 0 002 0 05 Dimension 2 1 591 0 002 in 40 4 0 05 mm Service Information 4 Connecting Rod Bearing small end 1 0669 in 17 mm 2 82...

Page 16: ...Raider 40 Manual Military version 13 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: ...WASHER 4 2 12 345 00114 0 MAIN BEARING 355520 1 Center 2 13 345 00051 0 LABYRINTH PACKING 1 2 14 345 00053 0 O RING 2 49 5 1 2 15 951407 0306 SPRING PIN 3 6 1 2 16 345 00113 0 MAIN BEARING 5206 1 Upper 2 17 345 00115 0 RETAINER 56 66 1 6 1 2 18 945107 3000 C RING d 30 1 2 19 345 00116 0 SPACER 30 2 40 2 3 1 2 20 345 00141 0 SHIM 31 42 A 2 21 345 00114 0 MAIN BEARING 355520 1 Lower 2 22 345 00042 0...

Page 18: ...Raider 40 Manual Military version 15 2 29 1 345 00011 0 PISTON RING 1 STD 2nd ...

Page 19: ...101F4 5630 BOLT 7 3 11 915321 0620 STUD 2 3 12 930103 0600 NUT 4 3 13 941303 0600 SPRING WASHER 4 3 14 348 63718 0 THROTTLE CAM Ref No 3 15 921503 0616 SCREW 1 3 16 346 63721 0 BUSHING 6 2 16 5 1 3 17 3C8 66308 0 WASHER 6 16 1 5 1 3 18 941403 1000 WAVE WASHER d 10 1 3 19 345 02011 3 CARBURETOR GASKET 1 3 20 345 67191 1 PRIME ROD 1 3 21 345 67192 0 PRIME ROD 1 3 22 345 67194 0 PRIME ROD CONNECTER 1...

Page 20: ...234 0 FILTER 1 3 43 930103 0800 NUT 1 3 44 940103 0800 WASHER 2 3 45 348 02231 0 PLATE 1 3 46 345 02411 0 INTAKE PROTECTION COVER 1 3 47 345 02415 0 INTAKE SILENCER COVER 1 3 48 9101F4 0616 BOLT 2 3 49 345 02416 0 INTAKE SILENCER PLATE 1 3 50 921503 5508 SCREW 2 3 51 345 02417 1 INTAKE SILENCER LOCK PLATE 1 3 52 345 67195 1 BUSHING 1 Note Lift height of each reed valve and stopper must be within s...

Page 21: ......

Page 22: ...uretor 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 As the fuel reaches the slide with harmonic frequency the fuel flows to the top of the slide and gets broken down into very small droplets that burn more effectively than carburetors ...

Page 23: ...5 RL4 0334 INDEPENDENT FLOAT RIGHT 2202 R 1 4 16 RL4 0335 FLOAT LEVER 2200 1 1 4 17 RL4 0336 FLOAT BOWL SCREW 2320 1 4 18 RL4 0337 FLOAT BOWL POWER JET 2300 PJ 1 4 19 RL4 0338 DUAL FLOAT ASSY 2200 D 1 4 20 RL4 0339 FLOAT BOWL GASKET 1 4 21 RL4 0340 NEEDLE SEAT GRAVITY 2500 030 1 4 22 RL4 0341 NEEDLE SEAT GASKET 2501 1 4 23 RL4 0342 TOP COVER GASKET 2010 G 1 4 24 RL4 0343 TOP COVER 1 4 25 RLS 0344 ...

Page 24: ... 4 and spring 5 if equipped for deformation and tension 5 Inspect gasket between crankcase and fuel pump for dryness crankcase mounted pumps Disassembly NOTE Match mark parts before disassembly and reference the illustrations in the Inspection procedure to ensure proper orientation of internal components 1 Expand and move clips 1 on fuel hose s 2 2 Disconnect fuel hoses from fuel pump 3 Loosen pum...

Page 25: ...iscard all serviceable gaskets and diaphragms 5 Remove ail check valves 11 from pump body Cleaning 1 Clean ail pump components with kerosene 2 lf necessary clean pump mounting surface on Multi fuel Throttle Body Atomizer with isopropyl alcohol 3 Dry all components with low pressure compressed air Assembly 1 Install all check valves in pump body 2 Fully assemble fuel pump Ail serviceable gaskets an...

Page 26: ...Raider 40 Manual Military version I I I I I I 5 I I I I I I _ __ _ _ _ _ _ _ __ _ _ I ...

Page 27: ... Nut 2 5 2 346 04901 0 Gasket Fuel Pump 1 5 3 921503 6640 Screw 2 5 4 346 02230 0 Fuel Filter 1 5 4 1 346 02234 0 Filter 1 5 4 2 346 02235 0 Gasket 1 5 4 3 346 02237 0 Cup 1 5 5 9301 13 0800 Nut 1 5 6 9401 13 0800 Washer 2 5 7 348 02231 0 Plate FuelFilter 1 5 8 98AB 5 0160 Fuel Pipe 1 5 9 98AB 5 0270 Fuel Pipe 1 5 10 98AB 5 0210 Fuel Pipe 1 5 11 338 0221 5 0 Clip 10 6 5 12 336 06973 0 Clamp 6 9 5L...

Page 28: ... 17 Raider 40 Manual Military version 3 6 Throttle Mechanism ...

Page 29: ...lePin 1 6 9 930106 0600 Nut 1 6 10 348 63715 0 Link Rod 5 75L 2 6 11 3B7 63733 0 Rod Snap 5 3 2 6 12 346 05234 0 5 Rod Joint 1 6 13 930106 0500 Nut 2 6 14 348 63716 0 Throttle Link Rod 1 6 15 345 05223 1 Rod Snap 3 5 2 2 6 16 348 63718 0 Throttle Cam 1 6 17 346 63721 0 Bushing 6 2 16 5 1 6 18 941403 1000 Wave Washer d 10 1 6 19 921503 0616 Screw 1 6 20 3R0 66308 0 Washer 6 16 1 5 1 6 21 353 83719 ...

Page 30: ... 19 Raider 40 Manual Military version 15 25 6 21 3 7 Tiller Handle 3 Fig 19 1 ...

Page 31: ...lePin 1 6 9 930106 0600 Nut 1 6 10 348 63715 0 Link Rod 5 75L 2 6 11 3B7 63733 0 Rod Snap 5 3 2 6 12 346 05234 0 5 Rod Joint 1 6 13 930106 0500 Nut 2 6 14 348 63716 0 Throttle Link Rod 1 6 15 345 05223 1 Rod Snap 3 5 2 2 6 16 348 63718 0 Throttle Cam 1 6 17 346 63721 0 Bushing 6 2 16 5 1 6 18 941403 1000 Wave Washer d 10 1 6 19 921503 0616 Screw 1 6 20 3R0 66308 0 Washer 6 16 1 5 1 6 21 353 83719 ...

Page 32: ... 21 Raider 40 Manual Military version 3 8 Magneto 20 I 6 7 16 22 I 20 16 1 12 1 ...

Page 33: ...510 Screw 4 8 4 361 06060 1 G D Unit 1 CU2503 8 5 910103 6625 Bolt 5 8 6 3R0 66308 0 Washer 6 16 1 5 4 8 7 930113 0600 Nut 4 8 8 3A0 06322 1 Plate Electric 1 8 9 3B7 06305 0 Rubber Mount 9 16 4 3 3 8 10 3F3 06920 0 Rubber Mount 9 12 2 3 8 11 3A0 76079 0 Collar 6 2 9 7 4 3 8 12 361 06040 1 Ignition Coil with Resistance Cao 1 8 12 1 3C7 06921 0 Plug Cap with Resistance 2 8 13 910113 5620 Bolt 2 8 14...

Page 34: ...9101 13 0612 Bolt 1 8 23 353 76037 0 Plug Cable Terminal 1 8 24 336 76091 0 Band Lead Wire 1 8 25 931121 1600 Nut Magneto 16P 1 5 1 032986XD Clockwise 334 00132 0 Nut Magneto 16P 1 5L 1 028121XD Counterclockwise 8 26 345 00133 0 Washer 16 28 3 2 1 8 27 3C7 76142 0 Ground Cable 1 L 170 for MF Type Bolt 1 ...

Page 35: ...is recommended DO NOT attempt to continuously crank the battery more than 5 times Battery Installation requires removing cowling place battery on platform in engine front The battery has a hole underneath that will match the extended pin Place in position and install a Velcro strap Connect the battery cable to the cable inside the motor pan To remove do the process in reverse Storage Battery shoul...

Page 36: ...type 12 Volt W Hr Wh 24 Ah 2 Cold Cranking Amps 140 Engine Fuse none Rectifier 04KE03 Starter Solenoid 2J6 Starter Motor Part No 346760100m Starter Switch FS ST05 Moroso 74120 Alternator 12V 80W Charging Performance at 5500 RPM 5 Amps Number of Tachometer to Alternator Coil Impulses 4 Alternator Coil Resistance Y W 0 65 0 98 Ohms Y B 0 31 0 47 Ohms W B 0 37 0 55 Ohms lgnition Coil Resistance 25 Pr...

Page 37: ...ion Fig 11 4 __ 1 1 __ _ ___ J i 1 4 1 2 I 1 3 0 0 Fig 8 5 Bolt Position A B c D Color of lead wires Yellow White Blue Brown E Red Green Black Electrical Starter Starter Motor Battery Starter Button 9 35 9 36 Starter Button Safety ring ...

Page 38: ...lenoid 1 9 8 345 76081 0 Bracket Neutral Switch 1 9 9 910103 0618 Bolt 2 9 10 930113 0600 Nut 2 9 11 941303 0600 Spring Washer 2 9 12 3G2 76060 0 Rectifier 1 9 13 921503 0525 Screw 1 9 14 930103 0500 Nut 1 9 15 941303 0500 Spring Washer 1 9 16 353 06281 0 Holder Cable Terminal 1 9 17 353 06283 0 Collar 6 4 10 4 7 2 9 18 9101 13 0620 Bolt 2 9 19 309 06972 0 Clamp 6 5 47 5P 3 9 2 0 941303 060 0 Spri...

Page 39: ...For signs of wear and make sure the switch has adequate spring tension to hold the lanyard lock clip in place Stop Switch Test 1 Attach the lanyard lock clip to the stop switch 2 Start the engine 3 With engine running puII the lanyard to disengage the lock clip Engine should stop running NOTE The stop switch also operates as a push button switch with the lanyard left attached 4 Repeat the test but...

Page 40: ...ring against fuel valve 6 Pull slowly 8 times on rope Even strokes 7 Tilt engine back to standard position 8 Pump primer two times 9 Pump primer bulb until tight 10 Slide dewatering valve to front of engine close 10 1 11 Pull rope until engine starts Dewater and Start Procedure Electric Start Perform 1 thru 10 Press start button Caution Do not hit start button until water is cleared between piston...

Page 41: ...ck position then press fuel bulb for four presses This evacuates all potential water that would be in the carburetor This action also opens up two dewatering valve located in the head of each cylinder The operator will slowly pull the starter rope a minimum of eight SLOW pulls This eliminates all water trapped between pistons and the head Following instructions located on the motor cowling the Rai...

Page 42: ... 31 Raider 40 Manual Military version 3 11 Recoil Starter 1 18 1 19 I I 11 23 I 1 1 21 I l 1 22 1 24 I 11 I 1 9 I 1 2 I 3 2 ...

Page 43: ...1 6 Spine Pin 3 16 1 1 1 1 1 1 345 05132 0 Starter Shaft 1 11 1 12 910114 0830 Bolt 1 11 1 13 941322 0800 Spring Washer 1 11 1 14 940121 0800 Washer 2 11 1 15 930103 0800 Nut 1 or 910113 0800 11 1 16 941322 0800 Spring Washer 1 11 1 17 336 050 14 0 Guide Starter Rope 1 1 1 1 18 9101 14 0625 Bolt 2 1 1 1 19 941303 0600 Spring Washer 2 1 1 1 20 338 0501 9 0 Starter Handle 1 1 1 1 21 345 05013 1 Star...

Page 44: ...reverse If the electric start is used it will not start the engine unless it is in neutral Cleaning and Inspection All worn damaged or missing parts must be replaced 1 Clean metal parts with solvent and dry with low pressure compressed air Clean plastic parts with dry cloth 2 Inspect following components as follows Starter rewind spring for cracked or broken end loops Ratchet and reel stopper spri...

Page 45: ... 34 Raider 40 Manual Military version 3 12 Starter Lock Pull Starter 12 ...

Page 46: ... 345 05217 1 Rod Starter Lock 1 12 13 345 05226 0 Lever Starter Lock 1 12 14 940103 0400 Washer 2 12 15 345 05216 0 Spring Starter Lock 1 12 16 346 05209 0 Cap Starter Lock Lever 1 12 17 945303 0600 E Ring D 6 1 12 18 345 05223 1 Rod Snap 3 5 2 3 12 19 345 05221 1 Rod Throttle Stop Arm 1 12 20 353 83728 0 Pin Rod Joint 1 12 21 930106 0600 Nut 1 12 22 941303 0600 Spring Washer 1 12 23 345 05224 0 R...

Page 47: ... 36 Raider 40 Manual Military version Fig 12 STARTER LOCK 12 ...

Page 48: ...er 1 12 12 345 05217 1 Rod Starter Lock 1 12 13 345 05226 0 Lever Starter Lock 1 12 14 940103 0400 Washer 2 12 15 345 05216 0 Spring Starter Lock 1 12 16 346 05209 0 Cap Starter Lock Lever 1 12 17 945303 0600 E Ring D 6 1 12 18 345 05223 1 Rod Snap 3 5 2 3 12 19 345 05221 1 Rod Throttle Stop Arm 1 12 20 353 83728 0 Pin Rod Joint 1 12 21 930106 0600 Nut 1 12 22 941303 0600 Spring Washer 1 12 23 345...

Page 49: ... 38 Raider 40 Manual Military version 12 30 921521 6510 Screw 2 12 31 921 503 0530 Screw 1 12 32 930106 0500 Nut 1 ...

Page 50: ... 39 Raider 40 Manual Military version I 3 13 Drive Shaft Housing 10 9 I I I I I I I I I I I I 17 I I I I I I 16 I I I I I I I I I I _ _ _ J 6 1 ...

Page 51: ...nsion Housing UL 1 13 8 9101 13 5840 Bolt 6 13 9 345 61012 0 Gasket Drive Shaft Housing 1 13 10 345S01301 0 Engine Base 1 13 11 345 01303 0 Gasket Engine Basement 1 13 12 345 01215 0 Oil Seal 17 30 8 1 13 13 345 67116 0 2 13 14 910203 0640 Bolt Engine Base 2 13 15 941303 0600 Spring Washer 2 13 16 345 01 1 11 0 Knock 6 12 4 13 17 345 02314 1 Exhaust Pipe s 1 361 02311 0 Exhaust Pipe L UL 1 13 18 3...

Page 52: ...ual 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: ...t Bevel Gear B 1 14 12 345 64081 0 Shim 41 51 5 0 1 AR 345 64082 0 Shim 41 51 5 0 15 AR 345 64083 0 Shim 41 51 5 0 3 AR 345 64084 0 Shim 41 51 5 0 5 AR 14 13 332 65022 0 Key Pump Impeller 1 14 14 345 65021 0 Impeller Water Pump 1 14 15 348 65016 1 Pump Case Upper 1 14 16 348 6501 1 0 _ Liner Pump Case 1 14 17 348 65017 1 Pump Case Lower 1 14 18 332 601 11 0 Oil Seal 17 33 9 5 1 14 19 345 65015 0 0...

Page 54: ...ater Pipe 1 14 29 345 65110 1 Water Pipe L 1 14 30 348 66011 0 Clutch Cam 1 14 31 348 66013 0 Cam Rod L 1 14 32 951403 031 6 Spring Pin 3 16 2 14 33 345 66031 1 Bushing Cam Rod 1 14 34 345 66021 0 0 Ring 1 9 6 8 2 14 35 332 66032 0 0 Ring 2 4 15 4 1 14 36 301 66024 1 Stopper Cam Rod Bushing 1 14 37 301 66025 0 Gasket 6 2 11 1 1 14 38 345 66241 0 Joint Shift Rod 1 14 39 951403 0312 Spring Pin 3 12 ...

Page 55: ... 44 Raider 40 Manual Military version Fig 14 1 19 18 10 16 Section 15 GEAR CASE PROPELLER SHAFT ...

Page 56: ...217 0 Trim Tab 1 15 25 353 60219 0 Gasket Trim Tab 1 15 26 9101 13 5618 Bolt 1 15 27 353 64036 0 Shim 36 44 03 AR 353 64037 0 Shim 36 44 0 15 AR 353 64038 0 Shim 36 44 01 AR 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 b...

Page 57: ...er oil injector Oil plug Adjusting Trim Tab If the Rubber Inflatable boat fails to run straight adjust the trim tab which you will find underneath the anti cavitation plate If the boat has a tendency to pull to the right move the trim tab in direction A as shown in the drawing If it pulls to the left move the trim tab towards B Note A trim tab is a sacrificial anode that protects against corrosion...

Page 58: ... 47 Raider 40 Manual Military version 3 16 Shifter 1 Fig 14 38 19 17 ...

Page 59: ...2 16 15 9401 13 0600 Washer 2 16 16 348 66211 0 Shift Rod 1 16 17 345 66226 0 Grommet Shift Rod 1 16 18 332 66021 0 O Ring 2 4 5 8 1 16 19 951403 0312 Spring Pin 3 12 2 Shifter Developed to be similar to existing military outboards to maintain familiarity for the soldier The shifter is a mechanical front mounted easy fit rugged device For movement it can be pushed into the Raider to minimize size ...

Page 60: ... 49 Raider 40 Manual Military version 3 17 Transom Bracket ...

Page 61: ...d 1 17 13 398S62100 0 Clamp Screw Ass y 2 17 13 1 398 62103 0 Clamp Screw 2 17 13 2 332S62102 1 Handle Clamp Screw 2 17 13 3 3C8 62104 1 Rivet 3 22 2 17 14 332 62101 0 Pad Clamp Screw 2 17 15 349S62310 2 Swivel Bracket 1 95605 17 16 348S62010 0 Steering Shaft 1 17 17 345 62417 0 Bushing 26 32 2 17 18 345 62441 0 Friction Plate Bracket 1 17 19 346 62421 1 Spring Friction Plate 1 17 20 910103 0830 B...

Page 62: ...2 O 21 O 40 3 4mm 17 37 348 61309 0 Shim 33 40 7 0 5 AR 17 38 945003 4000 C Ring d 40 2 17 39 940113 1000 Washer 2 17 40 930403 1000 Nylon Nut lOP 1 5 2 17 41 345 61322 2 Washer Rubber Mount Lower 2 17 42 930103 1000 Nut 2 17 43 346 61 323 0 Lock Plate Rubber Mount 2 17 44 916113 0885 Bolt 2 17 45 940113 0800 Washer 4 17 46 930113 0800 Nut 2 17 47 3C8 62158 0 Ground Cable 1 L 130 17 48 910113 5612...

Page 63: ... 54 Raider 40 Manual Military version 17 55 17 56 348 62143 0 348 62107 0 Shaft Tilt Assistant Raider transom safety support 1 1 Transom parts should be checked before missions for damage ...

Page 64: ... 55 Raider 40 Manual Military version 3 18 Reverse Lock Transom Bracket ...

Page 65: ...Cover Upper Unit 19 1 Tilt Handle P N 345S675210 Screw P N 9216030516M 9301030500M Nut 19 4 Spring Washer P N 9413030500M Washer P N 9401030500M 19 8 19 6 Rubber Starter Seal P N 3KM675030M Rubber Seal P N 3F3675010M Dewatering Instructions Lower Unit ...

Page 66: ... 1 19 12 3R0 66308 0 Washer 6 16 1 5 1 19 13 3C8 67146 0 Washer 14 22 1 1 19 14 345 671 61 0 Grommet 22 3 2 19 15 353 671 62 0 Grommet Battery Cable 1 19 16 345 83732 0 Grommet Cable 1 19 17 345 67117 0 Grommet 17 2 7 2 19 18 345 67183 0 Baffle Air Intake 1 19 19 9101 14 0625 Bolt 2 19 20 940113 0600 Washer 2 19 21 361S67500 4 Motor Cover upper 1 96958 19 21 1 345S67521 0 Tilt Handle 1 19 21 2 921...

Page 67: ... Dry all components with low pressure compressed air Make sure all parts and passages are completely dry in Line Fuel Filter Replacement NOTE In line fuel filters cannot be serviced Replace in line fuel filters once a year or with each tune up When replacing an in line fuel filter note direction of fuel flow as indicated by the arrow on the filter housing for proper installation 1 Loosen clips 1 o...

Page 68: ... 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 After installation of the DMCT both engines can be controlled via a single tiller Then place the DMCT cable on both engines to provide throttle control of both engines...

Page 69: ...ary 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: ...gap Replace plugs if needed 3 Check engine compression Refer to Cylinder Compression Test in Section 4 4 Check ail wiring connectors and clamps for damage Replace parts as needed 5 Replace fuel filter and inspect Multi fuel Throttle Body Atomizer Check fuel hoses for deterioration Replace as needed 6 Check for proper clutch engagement and make shift linkage adjustments as need 4 2 Lubrication for ...

Page 71: ...Model 700 or equivalent Analog Multimeter Electronic Specialties Model M 530 or equivalent Digital Multimeter Electronic Specialties Model KD 3200 or equivalent Digital Pulse Tachometer 10 6000 RPM Electronic Specialties Model 321 or equivalent Ammeter 0 100 A Gearcase Pressure Tester Stevens S 34 or equivalent Gearcase Vacuum Tester Stevens V 34 or equivalent Engine Compression Gauge 0 300 psi 0 ...

Page 72: ...seki power torque fluid or GM approved automatic transmission fluid Isopropyl Alcohol Cleaning Solvent Gasket Remover Gear Lubricant Genuine gear oil or APl grade GL5 SAE 80 90 Engine Lubricant Genuine engine oil or NMMA certified TC W3 oil Automotive Crankcase Oil flashpoint above 300 F 150 C Battery Spray Protector Permatex Battery Protector Sealer Electrical Shrink Tubing various diameters 4 2 ...

Page 73: ...just the engine ignition timing and Multi fuel Throttle Body Atomizer See Synchronization and Linkage Adjustments this section 9 Remove propeller and inspect propeller shaft oil seal for leakage Inspect propeller thrust washer and other propeller shaft hardware for damage Replace as needed 10 Drain and refill the Gearcase with specified gear oil See Engine Specifications in this section 11 Lubrica...

Page 74: ... 735 50000 W PS x 542 50000 ft lbf s W x 0 00134 HP W x 0 00136 PS W x 0 73760 ft lbf s kW x 1 34100 HP kW x 1 36000 PS kW x 737 56000 ft lbf s ft lbf s x 0 00181 HP ft Ibf s x 0 00184 PS ft lbf s x 1 35600 W Units of Volume gal U S x 3 78540 L qt U S x 0 94635 L cu in x 0 01 639 L cu in x 16 38700 mL fl oz U S x 0 02957 L fl oz U S x 29 57000 mL cm3 x 1 00000 mL cm3 x 0 03382 fl oz U S Units of F...

Page 75: ... 66 Raider 40 Manual Military version ...

Page 76: ...g surfaces of the crankcase halves is the alignment point for ail ignition timing degree measurements TROUBLESHOOTING The troubleshooting chart lists common engine symptoms related to problems with the fuel system lt also indicates specific malfunctions in the fuel system which may be causing the problem so it can be isolated more effectively Before beginning major troubleshooting operations on th...

Page 77: ...der or Idles get full RPM Engine has Check start compression erratically poorly RPM decreases overheats vibration Poor crankcase o Seal Ignition timing or Throttle linkage o o o Out of adjustment Water entering Crankcase o o o Defective Thermostat o o Fouled defect Or incorrect Spark plug o o o o o Wrong gap Setting Worn or Defective Cylinder o o o o Piston rings Or warped Head Blown cylinder Head...

Page 78: ...Raider 40 Raider 40 Manual Military version Fuel Additive not included ...

Page 79: ...as required Engine Spark Plugs 32 Thermostat 3 Thermostat gasket 3 Fuel Pump 1 Electric Starter 3 Push button starter switch 3 Kill switch assembly 3 Fuel Induction Unit 1 Rebuild Kits FIU 16 Throttle Cables 4 Recoil manual pull Starter 1 Water pump impellers 16 Props 2 Batteries Sealed 4 Maintainers for batteries 2 6 Primer Cable 2 Rubber Impellers 16 Emergency tool kit 1 Spark Plugs 2 Pliers Scr...

Page 80: ...led 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 707 Main Street Titusville FL 32796 321 403 3585 Other Manuals Available Owner User Manual R40 ES 001 15 1 Service Manual R40 ES 001 15 3 ...

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