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Raider 50, Service Manual

The Yamaha 50 Owner's Manual is a comprehensive guide that provides detailed instructions for operating and maintaining your Yamaha 50 product. Easily accessible for free download on our website, this manual offers invaluable insights and information to ensure optimal performance and longevity for your Yamaha 50.

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Lower Unit 

 

RO 

 

Gear Case (Drive Shaft, MWX50) 

  

 

OBM 

OBM 

 
 
 

A 

  

OBM 

LIT 

OBM 

OBM 

LIT 

OBM 

 

 

 

 

 

 

 

 

OBM 

OBM 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GEAR 

GEAR 

 

P/L Fig. 15 

 

TEF 

TEF 

GEAR 

GEAR 

OBM 

OBM 

G17 

G17 

1342 

1342  

 

 

 

OBM 

GEAR 

GEAR 

 

 

 

 

 

 

OBM 

OBM 

 

 

 

 

OBM 

OBM 

 

 

 

 

 

 

 

OBM 

OBM 

OBM 

G17 

G17 

GEAR 

GEAR 

 

 

 

 

OBM 

OBM  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1342  

1342  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1342  

1342  

 

 

 

 

 

 

1342  

1342 

 

 

Ref. 

No. 

 
 

Description 

Q'ty 

Remarks 

 
 

Ref. 

Description 

Q'ty 

Remarks 

No.  

1  Gear Case Ass'y 

1  with Sub Water Pipe 

14  Water Pipe Seal (Lower) 

1 

2  Roller Bearing 25-33-30 

1 

Do not reuse. 

15  Pump Case (Lower) 

1 

3  Bevel Gear B 

1 

16  Shim 36.9-30-0.5 

1 

4  Nut (Bevel Gear B) 

1 

17  Oil Seal 22-37-8 

2 

Do not reuse. 

5  Shim 44-50.5-0.1 

A 

18  O-Ring 3.2-47 

1 

Do not reuse. 

5  Shim 44-50.5-0.15 

A 

Selection if necessary 

19  Dowel Pin 4-10 

2 

5  Shim 44-50.5-0.3 

A 

20  Water Pump Guide Plate 

1 

6  Drive Shaft (L) 

1 

21  Guide Plate Gasket 

1 

Do not reuse. 

7  Ball Bearing 6205R 

2 

Do not reuse. 

22  Pump Case Gasket 

1 

Do not reuse. 

8  Drive Shaft Spring 

1 

23  Bolt 8-80 

4 

9  Drive Shaft Spring Guide 

1 

24  Washer 

4 

10  Water Pump Impeller 

1 

25  Sub-Water Inlet Strainer 

1 

11  Key 

1 

26  Screw 

2 

12 

Pump Case Sub-Ass'y (Upper) 

1 

27  Clutch Cam 

1 

13  Pump Case Liner 

1 

28  Cam Rod (L) 

1 

 

6-14 

2st  50D2  2011 

Summary of Contents for 50

Page 1: ...Two stroke Multi Fuel Submersible Outboard Motor Service Manual R50ES 002 11 RAIDER 50 SERVICE MANUAL January 2017 Rev 3 Part No SMR50ES 002 2 ...

Page 2: ...ssion To ensure this the maintenance and service have to be done properly by a service technician with fundamental knowledge and skills This manual is utilized so that our operators can always use their outboard motor with full satisfaction Raider Outboards are a Commercial Off The Shelf COTS based upon the Tohatsu MWX50D2 which uses the heavy duty gear case Modifications to this COTS product are ...

Page 3: ...etails are presented by using a component composition diagram 3 Fastening torques are described in the component composition diagram In the body text are critical points of the applicable work 4 Pictograms indicate that there is an important work instruction for the relevant parts It also shows the type of lubricant and its application point s 5 The component composition diagrams describe the name...

Page 4: ...hed later resulting in branching the metric system in different unit systems The new unit system is called International System of Units because it was established for the purpose of unifying the different unit systems Since the metric system was initially established in France and International Bureau of Weights and Measures IBWM is located in Paris General Conference of Weights and Measures GCWM...

Page 5: ...Corrosion Zero ...

Page 6: ...onization 3 26 12 Pilot screw adjustment 3 30 13 Replacement of Gear Oil 3 32 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 ...

Page 7: ...embly 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 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 Dis...

Page 8: ...erminal 8 12 3 Inspection of Ignition Coils 8 14 4 Inspection of Pulser Coil 8 14 5 Inspection of Exciter Coil 8 16 6 Inspection of C D unit 8 16 7 Inspection of Stop Switch 8 18 9 Troubleshooting 1 Troubleshooting Chart 9 2 2 Power Unit 9 3 1 Engine will not start 9 3 Starting System 9 3 Ignition System 9 4 Fuel System 9 6 Compression Pressure 9 7 2 Engine starts but stalls soon 9 8 Fuel System 9...

Page 9: ...INDEX 1 Service Information 2 Service Data 3 Maintenance 4 Fuel System 5 Power Unit 6 Lower Unit 7 Bracket 8 Electrical System 9 Troubleshooting 10 Wiring Diagram 11 Safety Jet ...

Page 10: ...ng 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...

Page 11: ...ar ignition source such as spark or static electricity 2 Ventilation Exhaust gas or gasoline vapor is hazardous Be sure to ventilate well when working indoors 3 Protection Wear a pair of goggles working gloves and safety shoes to protect skin from chemicals and oils and eyes from particles generated by grinding or polishing Avoid contact of oil grease or sealing agent to the skin In case of exposu...

Page 12: ...oles for oil feeding or greasing packings wirings pipings and other detailed parts For the components that use many bolts and nuts such as cylinder head or crank case tighten the fasteners in the order shown by the numbers to prevent uneven tightening If the numbers are not shown tighten the fasteners in diagonal or clockwise order from inner ones to outer ones evenly to specified torque In either...

Page 13: ...er Resistance 1Ω 10Ω 10 kΩ AC voltage 30 to 300V DC voltage 30V Internal voltage 3V or less Vernier calipers M1 type 300 mm Micrometer minimum graduation of 0 01 outer 0 to 25 mm 25 to 50 mm 50 to 75 mm Cylinder gauge 4 to 6 mm 10 to 25 mm 25 to 30 mm 50 to 75 mm Ring gauge ø5 5 ø16 ø25 ø30 ø61 Dial gauge minimum graduation of 0 01 Thickness gauge 0 03 to 0 3 mm V block Surface plate 500 mm x 500 ...

Page 14: ...ing pressure Removing or attaching flywheel Detaching and re attaching the piston 8 9 0 q Piston Ring Tool Eye Bolt Powerhead Lift Ring Universal Puller Plate Roller Setting Piece P N 353 72249 0 P N 3T9 72212 0 P N 3AC 99750 0 P N 3LC 72216 0 Detaching and re attaching the piston rings Used to hook power unit when hanging Removing main bearing and reverse C gear bearing Installing roller bearing ...

Page 15: ...r attaching gear case Removing or attaching gear case and Removing forward A gear bearing needle bearing propeller shaft housing needle bearing bearing outer race f Bevel Gear Bearing Puller Ass y g 3B7 72731 0 3B7 72732 0 3B7 72733 0 h Shimming Gauge j MX50 P N 3A3 72755 0 Bearing Outer Press Kit MX50 P N 3C8 72250 0 Thickness Gauge MWX50 P N 3B7 72755 0 P N 3B7 72739 1 MWX50 P N 353 72250 0 P N ...

Page 16: ... x c v Backlash Measuring Tool Kit Spark Tester Peak Voltage Adapter MWX50 P N 3A3 72255 0 P N 3F3 72540 0 P N 3AC 99550 0 Measuring backlash between pinion B gear and reverse C gear Inspecting spark Checking Peak Voltage ...

Page 17: ...the shift operations are smooth DANGER Remove lock plate of stop switch lanyard from stop switch before inspecting of gear shift and throttle operations This will prevent engine from accidental starting Turn propeller then operate shift lever to easily when will not shifting 3 Gear Oil Check quantity of gear oil Gear Oil OIL GEAR GEAR MX50D2 500 cm3 16 9 fl oz MWX50D2 700 cm3 23 65 fl oz Leaking o...

Page 18: ...s 50 1 For breaking period 25 1 mixture shall be used 5 Installation of Outboard Motor Rigging Check that outboard motor is fixed on the hull with Raider Transom plate Check location of anti ventilation plate relative to boat bottom Test run to determine the best installation height Anti ventilation plate standard position a 5 25 mm 0 2 1 0in below boat bottom a a 5 25 mm 0 2 1 0 in Heavy Fuel req...

Page 19: ...ection of propeller can cause adverse effects on engine life fuel consumption etc as well as on performance 2 2 Pitch Propeller No of Blades x Diameter x Pitch Raider 50 in mm 9P 3 x 12 0 x 9 0 3x305x229 10P 3 x 11 5 x 10 0 3x292x254 11P 3 x 11 5 x 11 0 3x292x279 12P 3 x 11 0 x 12 0 3x292x305 13P 3 x 11 5 x 13 0 3x292x330 14P 3 x 11 4 x 14 0 3x289x355 15P 3 x 11 0 x 15 0 3x280x381 16 5P 3 x 10 7 x...

Page 20: ... 2 Trim Tab Do not reuse 13 N m 9 lb ft 1 3 kgf m Example of Adjustment å If it is necessary to steer to starboard to make boat run straight or if boat steers itself to port when steering is held amidships move trailing edge of trim tab to port side or 3 If it is necessary to steer to port to make boat run å straight or if boat steers itself to starboard when steering is held amidships move traili...

Page 21: ...entered even in high sea states or night time operations When using dual or twin outboards the connecting pieces will always fit every time The transom plates also feature a cutout to insure the motor stays in place even if the turnbuckle gets loose during a mission especially when turning Available in single and dual configurations ...

Page 22: ...warming up the engine read tachometer to check idling engine speeds specified below Idling Speed Neutral RPM 950 r min Tachometer on Raider mounted 3 Shift gear into forward F and at idle slow for 1 approximately 10 minutes Trolling Speed Shift in RPM 750 r min 4 Run at 3 000 r min or half of WOT for initial 2 hours then at 4 000r min or 3 4 of WOT for 1 hour 5 Check that shifting into reverse R w...

Page 23: ...ta 1 Outboard Dimensions 2 2 3 Specifications 2 8 1 Body dimensions 2 2 4 Maintenance Data 2 12 2 Clamp Dimensions 2 4 5 Torque Specifications 2 16 2 Cooling Water System Diagram 2 6 6 Sealant And Lubricant 2 17 2 ...

Page 24: ...m in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in deg deg deg mm in deg R50ES 002 mm in 497 19 57 916 36 06 550 21 65 568 22 36 676 26 61 85 3 35 600 23 62 520 20 47 440 17 32 31 70 1 22 2 76 550 21 65 973 38 31 384 15 12 310 12 20 235 9 25 565 22 24 120 4 72 12 35 74 189 7 44 4 24 6 Raider 50 R50ES 002 ...

Page 25: ...Service Data 2 Clamp Dimensions Front View Looking at Raider from inside RIB ...

Page 26: ......

Page 27: ......

Page 28: ......

Page 29: ...Service Data 2 Cooling Water System Diagram ...

Page 30: ......

Page 31: ...verall Length 1 143 mm 45 inches Overall Width 384 mm 15 12 inches Overall Height Short Shaft 1 225 mm 46 23 inches Long Shaft 1 352 mm 53 23 inches Transom Height Short Shaft 403 mm 15 87 inches Long Shaft 530 mm 20 87 inches Weight 79 8 kg 176 pounds ...

Page 32: ...Item Part Number Item 3C8650212M 1 Water Pump Impeller 3C8061601M 1 C D I 3B7760655M 1 Regulator BR0165 3 3 Carburetor De watering Valves 361760260M 1 Starter Switch 3T5B645320 1 Propeller RL HM026A 1 Tachometer Hour Meter 3C8050902M 1 Recoil Starter 346760400M 1 Starter Relay Kit C R50ES 002 SPKC Part Number Item Part Number Item 3E3 032001M 1 Top Carburetor 3E3 032074M 1 Middle Carburetor 3E3 03...

Page 33: ...Option Safety Jet To Replace propeller with pump jet Part No KR011 This transforms the Raider 50 to a pump jet using this kit Used for training purposes brown water missions areas of rocks coral ...

Page 34: ...Adjustments using throttle link 2 3 Adjust ignition timing link 1 so ignition timing at full Throttle is matches the following specifications BTDC 20 degrees 1 degree Align flat surface 4 of crankcase mold boss with Calibration marks on set ring 4 Place advancer arm 3 in the minimum speed Position throttle fully closed and adjust low speed Side stopper 5 so ignition timing matches the Following sp...

Page 35: ...throttle link rod 5 To specification Raider 50 3 54 inches 90 mm 4 Reconnect timing link 1 5 Turn all throttle lever screws 6 clockwise to loosen 6 Loosen throttle stop screw 7 on top carburetor so it does not Make contact with throttle lever 8 7 Starting with the second carburetor from the top of the engine Apply light upward pressure to linkage tab 9 and turn throttle Lever screw 6 counterclockw...

Page 36: ......

Page 37: ...Service Data 4 Maintenance Data ...

Page 38: ...Service Data ...

Page 39: ...Service Data 5 Torque Specification ...

Page 40: ...6 Sealant And Lubricant ...

Page 41: ...ting Bold 53 in lb 5 6 N m Intake Manifold Bolt 53 in lb 0 6 kg m Carburetor Specifications Main Jet 135 Main Air Jet 230 Slow Jet 74 Slow air jet 130 Pilot Screw Turn Out 2 turn turn Neutral Idle Speed Adjustment RPM 900 Trolling Speed Adjustment RPM 750 ...

Page 42: ...ith 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 14 Inspection of Gear Case for leakage 3 34 15 Inspection of Propeller 3 34 16 Replacement of Anode 3 36 17 G...

Page 43: ...ol A Spring Pin Tool B Compression Gauge Tachometer P N 345 72227 0 ø3 0 P N 345 72228 0 ø3 0 P N 3AC 99030 0 P N 3AC 99010 0 Removing spring pin Installing spring pin Measuring compression Measuring engine revolution pressure speed 2 Inspection Schedule ...

Page 44: ......

Page 45: ......

Page 46: ...Cowl Push cover to check for play and crack 2 Inspection of Fuel Hose Motor to Bladder Hose contains bladder connection at end of Hose insert the Connector into Bladder 10 foot Fuel hose provided Attached to each hose is connector to bladed fuel tank 1 ...

Page 47: ...ry Inspection of Fuel Filter Check fuel filter 1 for contamination and fuel filter cup 2 for invasion of foreign matter and cracks Clean fuel filter cup with gasoline and replace fuel filter 1 if necessary 1 Do not spill fuel when removing fuel filter cup 3 2 CAUTION If water is in the cup Remove the cup and 3 O Ring Do not reuse drain the water 3 8 2st X50D2 2011 ...

Page 48: ...h can cause intoxication if inhaled Do not operated engine in a closed space such as interior of boat house Flushing using flushing attachment P N3B7 60007 0 1 Remove the following parts Propeller and thrust holder 1 Water plug 2 Attach the following parts 2 Tape Two locations on the water strainer 3 Flushing attachment Put water hose from water outlet to 3 and run water Set shift lever to neutral...

Page 49: ...Set shift lever to neutral N and start engine 4 Check that cooling water check port discharges water and run engine for 3 to 5 minutes at idle speed Inspection of Water Pump 1 Remove the following part Drive out spring pin 1 by using spring pin tool 2 1 Spring Pin Tool A 2 P N 345 72227 0 ø3 0 6 Remove gear case ass y from drive shaft housing 2 1 Do not reuse 2 Remove the following parts 3 Gear Ca...

Page 50: ...f worn or damaged o Be sure to install oil seal in correct orientation etio Do not reuse 6 Inspection of Compression Pressure 1 Start and idle engine for 5 minutes to warm up and then stop 1 2 Shift gear into neutral N 3 Remove lock plate of stop switch lanyard from stop switch CAUTION To prevent accidental start of the engine remove lock plate of stop switch lanyard from stop switch before measur...

Page 51: ... If compression pressure is below specified value or varies much among cylinders put small amount of engine oil into cylinders and perform the test again If compression pressure increases after the above measure check pistons and piston rings for wear Replace if necessary Check cylinder head gasket if the compression pressure does not rise Adjust or replace if necessary If any of the following res...

Page 52: ...e Adjust gap if it is out of specified range Spark Plug Gap a Standard Value 0 9 1 0 mm 0 035 0 039 in Functional Limit 1 2 mm 0 0472 in Specified Spark Plug B8HS 10 Install spark plug fully hand tighten a and then use plug wrench to tighten to specified torque b Spark Plug 27 N m 20 lb ft 2 7 kgf m If a torque wrench is not available when you are fitting a spark plug a good estimate of the correc...

Page 53: ...read in the closed valve gap and hang it in the water Valve opening moment can be known when thermostat is released to drop due to opening with rise of temperature Valve Opening Temperature 58 5 61 5 C 137 143 F Measure valve lift a of thermostat when prescribed temperature has been reached Replace if the length is less than specified value Water Temperature Valve Lift a 75 C 167 F 4 5 mm 0 177 in...

Page 54: ...t so that advancer arm 3 contacts the stopper 4 when throttle fully opened 3 3 Temporally attach the right side cable to wire bracket and adjust a nut so that the throttle to be fully closed position 4 Tighten each lock nut and then fix the left and right cable 5 Adjust stopper bolt so that advancer arm contacts the stopper bolt when throttle fully closed 3 22 2st X50D2 2011 ...

Page 55: ...advancer arm in the maximum speed position wide open throttle and make sure the carburetor throttle is fully a open a If throttle is not fully open make fine adjustments using throttle link 3 Align flat surface of crankcase mold boss 1 with 18 15 10 5 0 calibration marks on set ring and adjust ignition timing so ignition timing matches the following specifications Ignition Timing Full Throttle BTD...

Page 56: ...Ignition Timing Throttle closed ATDC 3 11 Carburetor Synchronization 1 Remove the intake silencer cover 2 Disconnect ignition timing link 1 and throttle link 2 so throttle lever roller dose not make contact with throttle cam 2 3 Adjust the length of each carburetor throttle link rod 3 to following specification Link Length 90 mm 3 54 in 3 4 Reconnect timing link 3 26 2st X50D2 2011 ...

Page 57: ...sen throttle stop screw 5 on top carburetor so it dose not make contact with throttle lever 6 All throttle butterfly 5 valve should return to a fully closed position a 6 a 7 Tighten the No 2 and No 3 throttle lever screw 7 8 counterclockwise while pulling upward throttle link rod 8 on the carburetor 7 3 28 2st X50D2 2011 ...

Page 58: ... engine up to normal operating temperature with an tachometer installed Don t tighten too much strongly 2 Adjust the pilot screw of the No 1 carburetor check for setting highest in idle speed Then adjust 1 8 turns from there for cold engine starting 3 Adjust same procedure for No 2 and No 3 carburetor 4 Adjust the throttle stop screw 2 to obtain the specified RPM at neutral and trolling speeds Neu...

Page 59: ...oil from oil tube or pump through lower plug hole 1 until gear oil starts to leak from upper oil plug hole a without air bubble Gear Oil O Hypoid Gear Oil API GL 5 SAE 90 Gear Oil Quantity MX50 500 cm3 16 9 fl oz 1 5 a 3 2 3 MWX50 700 cm3 23 15 fl oz Use lower plug hole when filling with gear oil Upper hole cannot be used because doing so will not allow air to escape from gear case Full tilt down ...

Page 60: ... gear oil drained make it easy to find leakage due to wear of oil seal lip Depressurize gear case and cover oil plug area with a piece of rag before disconnecting leakage tester CAUTION Do not apply pressure to gear case over specified value Doing so can cause damage to oil seal 4 If the specified pressure cannot be maintained check oil seals of drive shaft and propeller shaft and O ring of shift ...

Page 61: ...components Clean if necessary CAUTION Anode protects outboard motor from galvanic corrosion Do not paint or apply 1 grease or oil to anode Doing so disables the anode 2 Check anode 1 2 a and trim tab 3 for deterioration Replace anode or trim tab if volume is reduced to 2 3 of new part 2 3 3 36 2st X50D2 2011 ...

Page 62: ... throttle cable and sliding areas OBM 2 Apply grease to shift cam sliding areas OBM OBM 3 Inject grease through grease nipple 1 until excessive grease appears from a a Apply grease to 2 thread of clamp screws 1 OBM OBM a 2 OBM OBM 3 38 2st X50D2 2011 ...

Page 63: ...ly grease to throttle cable b and sliding areas c b OBM OBM c Do not lubricate here 5 Apply grease to seal ring and bushing 3 of hook lever 3 OBM OBM 6 Apply grease to propeller shaft spline 4 4 OBM OBM 3 40 2st X50D2 2011 ...

Page 64: ...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 I...

Page 65: ...Fuel System 1 Special Tools 1 Vacuum Pressure gauge P N 3AC 99020 1 Inspecting pressure ...

Page 66: ...Parts Layout P L Fig 5 Fuel line Ref No Description Q ty Remarks 1 Fuel Filter Ass y 1 2 Cup 1 3 O Ring 1 Do not reuse 4 Filter 1 5 Nut 1 6 Washer 2 5 Hose 1 7 Hose 1 8 Clip 4 9 Bracket 1 10 Bolt 4 4 4 2st 50D2 2011 ...

Page 67: ... 5 30 7 19 Bolt 3 5 Carburetor Ass y 1 3LC 5 Upper 20 Gasket 3 Do not reuse X 3 6 Carburetor Ass y Second 1 3LC 5 Center 21 Main Nozzle 3 7 Main Jet 138 3 22 Carburetor Cover 3 8 Slow Jet 80 3 23 Carburetor Cover Gasket 3 9 Plug 3 24 Screw 6 10 Float Valve 3 25 Carburetor Ass y Third 1 3LC 11 Float Arm Pin 3 26 Pump Cover 1 Lower 12 Float 3 27 Screw 4 Lower 13 Screw 3 28 Pump Cover Gasket 1 Lower ...

Page 68: ...not reuse Lower 42 Ball Joint Connector 1 34 Pump Body 1 Lower 43 Ball Joint Connector 2 34a Lower Float Chamber 1 44 Nut 4 35 Carburetor Gasket 3 Do not reuse Lower 45 Choke Rod 3 90 1 36 Bolt 6 46 Intake Silencer 1 37 Spring Washer 6 47 Rod Snap 3 B 2 38 Washer 6 48 Intake Silencer Lock Plate 3 39 Hose 2 98AB 501000 49 Choke Rod 1 40 Clip ø10 4 50 Rod Snap 3 B 1 4 8 2st 50D2 2011 ...

Page 69: ...enters carburetor through air intake port runs through throat venturi and throttle valve and then is sucked into the vacuous area in the cylinder that is in air intake stroke The float chamber receives atmospheric pressure through air vent This pressure causes fuel to be sucked into vacuous area in the back of throttle valve The fuel is sent to main fuel well through main jet runs through idle pas...

Page 70: ...valve b d f g c h i h Fuel inlet i Main jet j Slow jet k Choke valve å Air Air fuel mixture When throttle valve is turned to a position over bypass port the bypass port is exposed to vacuous pressure existing in the back of throttle valve The vacuous pressure causes the fuel to be ejected from bypass port and idle port 4 12 2st 50D2 2011 ...

Page 71: ...that runs through carburetor bore increase the whole space in the venturi becomes vacuous The vacuous pressure in this venturi causes large suction force in the main nozzle The fuel goes through main jet flows into main fuel well goes through main nozzle and ejects from venturi The fuel that runs through main nozzle is mixed with air that comes from air bleed hole made on the side of main nozzle t...

Page 72: ...ary to operate the handle of choke cable manually to set it to a proper position When attempting to start cold engine pull choke lever to close choke valve When engine starts low pressure vacuous area is formed in the venturi on the back of choke valve Then the fuel goes through main nozzle bypass port and idle port and sucked into carburetor bore where it is mixed with air that runs in from openi...

Page 73: ...e CAUTION 1 To prevent fuel from dripping on the floor use a vessel to catch the fuel 1 Remove Intake silencer 1 from carburetors Refer to Removing Intake Silencer and Carburetors in Chapter 5 2 2 Remove each drain screws 2 to drain fuel and then remove choke link rod 3 and carburetor link rod 4 from each carburetors 2 3 4 2 3 Disconnect fuel hoses 5 then remove carburetors from power unit 5 4 18 ...

Page 74: ...ors CAUTION 2 To prevent fuel from dripping on the floor use a vessel to catch the fuel 1 Remove float chamber 1 2 Remove carburetor cover 2 1 3 Remove float ass y 3 3 4 Remove main jet 4 main nozzle 5 and slow jet 6 5 6 4 4 20 2st 50D2 2011 ...

Page 75: ... cleaning solution to remove dirt Blow passages with compressed air to remove dirt Do not use wire to remove dirt 2 Check main jet 1 main nozzle 2 and slow jet 3 for dirt and replace if necessary 2 3 1 3 Check tip of needle valve and replace if necessary 4 Check float for crack and damage and replace if necessary 4 22 2st 50D2 2011 ...

Page 76: ... can instantly check to apply pressure by your breath when without pressure gauge 5 Disassembly and Inspection of Fuel Pump CAUTION To prevent fuel from dripping on the floor use a vessel to catch the fuel 1 Remove float chamber of 3 carburetor to disassemble Fuel Pump 2 Check diaphragm 1 for break crack and damage and 3 replace if necessary 2 3 Check check valve 2 for damage and deterioration and...

Page 77: ...p body using screws 4 After assembling check for air leak again 7 Inspection of Fuel Connector 1 Check fuel connector for crack and damage 2 Connect vacuum pressure gauge to outlet of fuel connector 3 Apply specified pressure and check if the pressure is maintained for 10 seconds Replace if necessary Vacuum Pressure Gauge P N 3AC 99020 1 Specified Pressure 0 029 MPa 4 psi 0 3 kgf cm2 8 Inspection ...

Page 78: ...ling Carburetors 1 Install slow jet 1 main nozzle 2 main jet 3 and rubber plug 4 2 1 3 4 2 Attach needle valve 5 to float hinge 6 6 5 3 Attach float ass y with float arm pin 7 and secure with screw 7 8 8 4 28 2st 50D2 2011 ...

Page 79: ...t Height a 14 5 1mm 0 571 0 039in 2 Install drain screw float chamber 1 and cover 2 1 CAUTION Do not adjust float height by knotting the fishing line etc It promotes wear of the needle valve and can cause malfunction of the engine 11 Installing Carburetors 1 Reverse carburetor removing steps to install 4 30 2st 50D2 2011 ...

Page 80: ...t Cover 5 50 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...

Page 81: ... N 3T1 72211 0 P N 345 72215 0 Used to hook power unit when hanging Removing or attaching flywheel Removing piston pin 4 5 6 7 Piston Ring Tool Universal Puller Plate Roller Setting Piece Piston Pin Tool P N 353 72249 0 P N 3AC 99750 0 P N 3LC 72216 0 P N 3LC 72215 0 Removing or attaching piston rings Removing main bearing Installing roller bearing Installing piston pin 5 2 2st X50D2 2011 ...

Page 82: ...ription Q ty Remarks Ref Description Q ty Remarks No 1 Power Unit 1 7 Bolt 6 2 Recoil Starter Assembly 1 8 Washer 6 3 Bolt 3 9 Apron 1 4 Washer 3 10 Seal 1 5 Engine Basement Gasket 1 Do not reuse 11 Screw 1 6 Dowel Pin 2 12 Nylon Nut 1 5 P0 8 5 4 2 ...

Page 83: ...5 72 12 Band 3 2 Coil Plate Ass y W Alternator 1 13 Screw 3 3 Pulsar Coil Plate Ass y 1 14 Key 1 4 Pulsar Holder 1 15 Nut 18 P1 5 1 5 Exciter Coil 1 16 Washer 19 34 3 1 6 Screw 6 17 Guide Plate 1 7 Alternator Ass y 1 18 Guide Plate Cover 2 8 Holder 1 19 Setting Ring 1 9 Screw 2 20 Ball Joint 1 10 Clamp 2 21 Spring Washer 1 11 Screw 2 22 Bolt 3 5 6 2st X50D2 2011 ...

Page 84: ...ap 1 14 Cover 1 3 Caution Decal B 1 15 Screw 5 4 Ignition Coil W Cap 2 F6T530 16 Mount 8 5 14 2 5 3 5 Band 3 17 Rubber Mount 8 5 14 2 5 3 6 Plug Cap Terminal 3 18 Spacer 6 2 9 15 7 3 7 Plug Cap 1 19 Bolt 3 8 Bolt 3 20 Washer 6 5 21 1 6 9 Gasket 6 2 11 1 3 21 Ground Cable L 270 1 10 Lead Wire Band 1 22 Bolt 1 11 CD Unit 1 F8T20572 23 Bolt 2 12 O Ring 3 1 94 4 1 5 8 2st X50D2 2011 ...

Page 85: ...ter Ass y 1 11 Sliding Plate 1 2 Reel Ass y 1 12 C Ring 1 3 Ratchet 1 13 Bolt 3 4 Starter Spring 1 14 Starter Rope ø6 2250 1 5 Friction Spring 1 15 Starter Handle 1 6 Return Spring 1 16 Rope Anchor 1 7 Friction Plate 1 17 Rope Guide 1 8 Bushing 1 18 Starter Lock 1 9 Washer 1 19 Starter Lock Cam 1 10 Sliding Plate 1 20 Starter Lock Spring 1 5 10 2st X50D2 2011 ...

Page 86: ...rks No Description Q ty Remarks 21 Washer 1 31 Starter Seal 1 22 Split Pin 1 32 Protector 1 23 Starter Lock Wire 1 33 Band 1 24 Cable Holder 1 34 Starter Pulley 1 25 Screw 1 35 Bolt 3 26 Pipe 1 36 Washer 3 27 Starter Roller 1 37 Bolt 3 28 Bolt 1 38 Washer 3 29 Washer 1 30 Collar 1 5 12 2st X50D2 2011 ...

Page 87: ...g 3 Ref No Description Q ty Remarks 1 Intake Manifold Ass y 1 2 Intake Manifold Gasket 3 Do not reuse 3 Bolt 11 4 Bolt 1 5 Clamp 6 5 47 5P 1 6 Hose 1 98AB 501000 7 Hose 1 98AB 501000 8 Clip ø10 4 9 Reed Valve Ass y 3 10 Screw 6 5 14 2st X50D2 2011 ...

Page 88: ...5 26 3 1 2 Bolt 1 13 Ball Joint 1 3 Washer 6 5 21 1 2 14 Rod 5 90 1 4 Collar 6 2 12 17 1 15 Ball Joint Connector 1 5 Rod Snap 5 3 2 16 Throttle Rod 5 105 1 6 Throttle Cam 1 17 Ball Joint Connector 1 7 Spring 1 18 Nut 2 8 Advancer Lever 1 19 Rod Snap 5 3 1 9 Bolt 1 20 Throttle Limiter Arm 1 10 Washer 6 16 1 5 2 21 Bolt 1 11 Spring Washer 1 22 Washer 2 5 16 2st X50D2 2011 ...

Page 89: ...T LIT LIT Ref No Description Q ty Remarks 23 Collar 6 2 9 9 3 1 24 Throttle Limiter Rod 3 5 56 1 25 Rod Snap 3 5 4 2 26 Throttle Limiter Rod 3 5 56 1 27 Rod Snap 3 5 4 2 28 Starter Lock Arm 1 29 Bolt 1 30 Washer 2 31 Collar 6 2 9 9 3 1 5 18 2st X50D2 2011 ...

Page 90: ... 43 Clip 3 29 Bolt 14 44 Spark Plug B8HS10 3 30 Washer 14 45 Clamp 6 5 47 5P 1 31 Bolt 1 46 Bolt 1 32 Gasket 8 1 15 1 1 Do not reuse 47 Bolt 1 33 Anode 1 48 Nut 1 34 Bolt 1 49 Engine Basement Gasket 1 Do not reuse 35 Cover 1 50 Crankcase Head 1 36 Gasket 1 Do not reuse 51 O Ring 1 7 59 1 Do not reuse 37 Bolt 2 52 Oil Seal 25 40 8 1 Do not reuse 38 Hose 1 98AL 401000 53 Oil Seal 16 28 7 1 Do not re...

Page 91: ... Ass y W Gear 1 7 2 Piston Ring 0 5 O S 3 OPT 2nd 2 Main Bearing 6305 1 Do not reuse 8 Piston Pin 3 3 C Ring d 25 1 Do not reuse 9 Needle Roller Bearing 75 4 Washer 1 10 Small End Bearing Washer 6 5 1 Piston 3 STD 11 Piston Pin Clip 6 5 2 Piston 0 5 O S 3 OPT 12 Main Bearing 1 6 1 Piston Ring 3 STD 1st 13 Oil Seal 32 42 6 1 Do not reuse 6 2 Piston Ring 0 5 O S 3 OPT 1st 14 O Ring 2 4 39 7 1 Do not...

Page 92: ...wer Unit 1 Remove recoil starter 1 Disconnect starter lock cable 1 2 Remove throttle cable 2 and shift link rod 3 2 3 3 Remove electric box cover and disconnect stop switch wire 4 4 4 Disconnect ground wire 5 from bottom cowl 5 5 26 2st X50D2 2011 ...

Page 93: ...m fuel filter fuel connector fuel filter 7 7 Remove choke rod 8 8 9 0 5 28 8 Remove apron 9 and loosen engine mount bolts then remove them 9 Carefully pry power unit by using steel pipe 0 to remove power unit Easy to remove when the part where the fulcrum and action point are close is raised 2st X50D2 2011 ...

Page 94: ...Turn the flywheel to adjust in order for installation position a of the eyebolt to be center Hoist power unit taking care not to catch wires and hoses a 12 Remove two crank case bolts Remove crank case head e Put the tip of bladed screw driver in the mating face of crank case head as shown to separate from the engine body evenly e 5 30 2st X50D2 2011 ...

Page 95: ...ly Wheel Puller Kit 1 P N 3T1 72211 0 2 Loosen flywheel nut and remove it 3 3 1 Remove flywheel by using pressing bolt 3 Turn center bolt clockwise to remove flywheel Remove flywheel installing with fly wheel puller kit 1 3 Removing Electric Parts 1 1 Remove coil plate ass y 1 from power unit D isconnect coil wire and ignition coil wire from CD unit 5 2st X50D2 2011 ...

Page 96: ...ottle link rod 1 2 b 2 a Remove each link rod at the rod snap side a first When removing each link rod at the ball joint side b be careful not to apply force to the arm b 1 3 4 2 Loosen bolts and then remove advancer arm 3 and advancer lever 4 Check ball joint cap rod snap for wear and damage link rod for bend After removal use rubber band on bolt to keep assembly together 5 34 2st X50D2 2011 ...

Page 97: ...Power Unit 3 Disassemble advancer lever if necessary Check spring 5 for wear and damage 5 4 Remove coil bracket plate 6 mounting bolt and remove 6 them LIT LIT 5 36 2st X50D2 2011 ...

Page 98: ...lts then remove intake silencer 1 Pry the tab a of lock plate as shown When reuse intake silencer mounting bolts apply Three Bond s thread lock 1342 a Do not reuse lock plate 2 Loosen carburetor mounting bolts and remove the carburetors 1 Loosen carburetor mounting bolts from 3 and 2 to 1 2 3 5 38 2st X50D2 2011 ...

Page 99: ...10 9 11 12 7 8 3 4 2 Loosen reed valve mounting screws remove them and remove reed valve ass y 2 2 7 Inspection of Reed Valve Ass y 1 Check reed valve and valve seat surface for bend wear and damage Replace if the bend is out of the specified range Reed Valve Stopper Height b 9 3 9 5 mm 0 366 0 374 in Reed Valve Bend a 0 4 mm 0 016 in 5 40 2st X50D2 2011 ...

Page 100: ...Thermostat and Engine Anode 2 1 Loosen thermostat cap mounting bolts 2 remove them remove cap 1 and take out thermostat 3 If thermostat cap is seized tap lightly using a 1 plastic hammer and then remove 2 3 5 42 2st X50D2 2011 ...

Page 101: ...en Temperature 73 5 76 5 C 163 5 170 5 F Replace thermostat if the valve is open even a little at ambient temperature 2 Measure valve lift of thermostat when prescribed temperature has been reached Replace if the length is less than specified value Water Temperature Valve Lift a 75 C 167 F 4 5mm 0 177in or over a a 2 Remove engine anode 4 and check it 4 Replace it if it is reduced to 2 3 of the or...

Page 102: ...er of the numbers shown embossed on the head cover Handle cylinder head head cover taking care not to scratch their mating surfaces a Pry the gap a of the cover at two grooves one by one by using a bladed screw driver The cover can be removed easier if parts cleaning agent is applied in the gap one by one from the top one Be careful to pry the gap evenly or the cover may be damaged or warped a 5 4...

Page 103: ...ful not to scratch the surfaces Use straight edge 2 and thickness gauge 3 to check distortion of cylinder head 1 in the directions shown Repair or replace if the distortion is over the specified limit Thickness Gauge Commercially Available Item Functional Limit 0 03 mm 0 00118 in 4 If the distortion is over the limit lap the component by using a sheet of sand paper 240 400 placed on a surface plat...

Page 104: ... by one by using a bladed screw driver The cover can be removed easier if parts cleaning agent is applied in the gap one by one from the top one Be careful to pry the gap evenly or the cover may be damaged or warped 12 Inspection of Exhaust Cover 1 Check the removed outer exhaust cover and inner exhaust cover for damages such as distortion or scratches on their mating surface Remove clogs and debr...

Page 105: ...ase by using a bladed screw driver Note that there are two knock pins on the mating surface of crank case 3 Remove crank shaft ass y Put a pipe of ø13 5mm 0 532 in in the drive shaft side of crank shaft ass y hold the crank shaft ass y using both hands lift it in parallel with the cylinder block to remove taking care not to damage the piston rings The crank shaft ass y can be removed easier by lif...

Page 106: ...areful not to damage the piston pin hole Remove piston pin 1 Use piston pin tool if the pin cannot be removed with the pliers Put the piston pin tool on the piston pin and tap is lightly taking care not to apply force to the connecting rod Do not tap small end washer Check needle bearing quantity 1set 25pieces Piston Pin Tool 2 P N 345 72215 0 Remove piston rings 3 Use piston ring remover Piston R...

Page 107: ...ller Universal Puller Plate 4 3AC 99750 0 1 Puller 5 Commercially Available Item Protecting Plate 6 4 5 6 16 Inspection of Crank Shaft 1 Visually check crank shaft ass y upper and lower end bearings for flaws wear and other damages Replace a crank shaft ass y if necessary Specified Value a 1 Top ø40 0 mm 1 574 in 3 Bottom ø40 0 mm 1 574 in a 5 56 2st X50D2 2011 ...

Page 108: ...place crank shaft if the deflection is over the specified value Dial Gauge 1 Commercially Available Item 2 V Block 2 Commercially Available Item Crank Shaft Deflection Limit 0 05 mm 0 0020 in 3 Replace crank shaft ass y if the deflection is over the standard value Connecting Rod Deflection Limit 2 0 mm 0 0800 in 5 58 2st X50D2 2011 ...

Page 109: ...t wear D2 D1 a The measurement heights b and c represent b location 5 mm above and below exhaust port d D4 D3 c represents diameter in crank shaft direction e represents the one in crank web direction D6 D5 Replace the cylinder in any of the following cases the piston sliding surface is severely damaged such as deeply scratched or scuffed so that it cannot be repaired with water proof d sand paper...

Page 110: ... replace piston or any of piston rings replace cylinder or use oversized piston Piston Clearance Standard Value 0 08 0 12 mm 0 00315 0 00472 in Functional Limit 0 21 mm 0 00827 in Calculation of Piston Clearance Cylinder Inner Diameter Piston Outer Diameter Use the maximum value of the cylinder inner diameter measured 3 Inspection of Piston Rings 1 Push a piston ring into the cylinder by using top...

Page 111: ...Piston Ring Tool P N 353 72249 0 Piston Ring Side Clearance Standard Value Top Ring Second Ring 0 04 0 08 mm 0 0016 0 0032 in Functional Limit c Top Ring c d Second Ring 0 10 mm 0 0039 in d 5 Inspection of Piston Pin Hole Measure piston pin hole inner diameter and replace piston if the inner diameter is over the limit Piston Pin Hole Standard Value 17 55 mm 0 6909 in 5 64 2st X50D2 2011 ...

Page 112: ...from top end and bottom end respectively D2 35 mm 1 378 in from the end Inspection of Piston Pin Clearance Calculate piston pin clearance and replace piston and piston pin together if the clearance is over the limit Calculation of Piston Pin Clearance Piston Pin Hole Inner Diameter Piston Pin Outer Diameter Standard Value 0 003 0 007 mm 0 0001181 0 0002756 in Functional Limit 0 020mm 0 000787 in U...

Page 113: ...t 1 Press fitting Bearing 1 Insert a holding bar a in between crank webs and press fit bearing 1 1 a 30 2 1 2st 2st OIL 2st Bearing Press Fitting Tool 2 Inner Diameter ø30 mm 1 181 in Do not reuse removed bearing 2st OIL 5 68 2st X50D2 2 ...

Page 114: ...st 2 1 When attaching a piston ring face the side of the ring marked with T upward 1 Bring piston ring gap to knock pin 2 2 Installation of needle bearing Check that the quantity of needle bearing 25 pieces before assembling 1 Apply grease to special tool 3 and then attach needle 3 bearing When in this procedure need not attach all of needle bearing Roller Setting Piece 3 P N 3LC 72216 0 3 5 70 2s...

Page 115: ...tach piston pin 5 to special tool 6 and apply two stroke engine oil Place the piston to small end of connecting rod and then insert piston pin with special tool 6 into them Piston Pin Tool 6 P N 3LC 72215 0 Assemble the parts so that the side marked with UP on the piston head faces flywheel side When a new piston is used apply two stroke engine oil to piston pin hole and piston pin 2st OIL 2st 2st...

Page 116: ...ts before assembling them Big End of Connecting Rod Small End of Connecting Rod Main Bearing and ball bearing Piston Ring and Entire Circumference of Piston and Entire Cylinder Wall O Ring of Upper Bearing CAUTION When the piston skirt enters into cylinder liner thrust plate 2 is inserted in groove and then crank shaft is lowered slowly 2 When installing crank shaft ass y lower the ass y gradually...

Page 117: ...bearing is provided with a oil journal c on the opposite side of knock hole to check the location 22 Assembling Crank Ass y and Crank Case 1 Degrease crank case and cylinder mating faces 2 Apply sealing agent to crank case s mating surface Crank Case Mating Surface 518 Loctite 518 Be careful not to allow sealing agent to squeeze out Apply sealing agent on the area inside of the bolt holes continuo...

Page 118: ...ced assemblies rotate crankshaft with flywheel after torquing crankcase bolts to ensure nothing binding Tighten crank case securing bolts in two steps to their specified torque 23 Assembling Exhaust Cover Parts 1 Assemble exhaust cover inner exhaust cover outer and gaskets 2 Attach exhaust cover securing bolts 1 to 14 and tighten them in the order of their numbers shown to specified torque in two ...

Page 119: ...der Tighten cylinder head securing bolts M8 1 to 14 in the order of the numbers shown Temporary Tightening 12 N m 9 lb ft 1 2 kgf m Final Tightening 32 N m 23 lb ft 3 2 kgf m Tighten cylinder head securing bolts in two steps to specified torque 3 Tighten bolts M6 1 to to specified final torque Final Tightening 6 N m 4 lb ft 0 6 kgf m Tighten head cover bolts M6 after tightening bolts M8 Never tigh...

Page 120: ... 26mm 4 38mm 3 A Lip B Circumference LIT 2st LIT 2st OIL 1 A Lip B Circumference LIT LIT 2st 2st OIL 26 Assembling Crank Case Head Parts 1 Apply grease and oil to oil seal 1 16 28 7 and press fit it to crank case head by using suitable press 2 2 Apply grease and oil to oil seal 3 25 40 8 and press fit it to crank case head by using suitable press 4 2st OIL 2st LIT LIT 5 82 2st X50D2 2011 ...

Page 121: ...d tighten securing bolts 1 to 12 to specified torque in the order of the numbers shown Bolts 1 12 9 N m 7 lb ft 0 9 kgf m Use new gaskets When reusing reed valve mounting screw apply screw lock 1342 1 Gasket Do not reuse 9 10 5 6 2 1 4 3 8 7 12 11 2 Install new o ring and carburetor Tighten bolts to specified torque Bolts 6 N m 4 lb ft 0 6 kgf m 5 84 2st X50D2 2011 ...

Page 122: ...to specified torque Intake Silencer Bolts 6 N m 4 lb ft 0 6 kgf m When reuse intake silencer mounting bolts apply ThreeBond s thread lock 1342 Use new lock plate After tightening bolts ply the tab of lock plate as shown Attach intake silencer cover 3 then tighten screws 3 5 86 2st X50D2 2011 ...

Page 123: ...Power UnitGB 28 Attaching Recirculation Hoses 1 A B 1 C D 1 E F 2 ƒ 1 1 C 5 88 A 1 E F B 1 D 2st X50D2 2011 ...

Page 124: ... LIT a 2 3 3 4 4 5 90 Attach starter motor bracket 3 and tighten the nut to specified torque Starter Motor Bracket Bolts 12 N m 9 lb ft 1 2 kgf m Attach coil plate bracket 4 to cylinder ass y and secure them with bolts Coil Bracket Bolts 6 N m 4 lb ft 0 6 kgf m As for the installation of the following part refer to the step of their removal Advancer arm Throttle link rod Apply grease to collar of ...

Page 125: ...o power unit and tighten mounting screw When reusing coil ass y mounting screw apply screw lock 1342 Connect coil plate ass y wire and ignition coil wire to CD unit 1342 1342 31 Installing Flywheel 1 1 Attach key and flywheel to crank shaft and tighten the nut 2 to specified torque CAUTION Use 25mm long bolts 2 for removing Otherwise coil may be damaged and can short Flywheel Puller Kit 1 P N 3T1 ...

Page 126: ...2st OIL 2st 3 Clean mating faces of engine base and cylinder ass y and then attach dowel pins 3 gasket Use new engine base gasket 4 Install power unit securely and tighten engine mount bolts 4 specified torque Engine Mount Bolts 4 20 N m 14 5 lb ft 2 kgf m Be careful not to catch wires and hoses and other parts between engine base mating surfaces 5 Install other parts reverse of their removing ste...

Page 127: ...r spring CAUTION Wear the glove to protect your hands For replacing starter rope 2 only do not remove reel Loosen the tension spring and then replace rope Then install new rope and put in groove 2 and turn counterclockwise 5 or 6 rounds to get tension on spring 4 Remove starter shaft bolt 4 and then remove all of illustrations CAUTION The starter spring 5 can pop out suddenly do not nearby your fa...

Page 128: ...s as shown enough 1 LIT LIT LIT LIT When setting new starter spring 1 into starter case face starter spring outer edge hook a to the right and set it into round projection b of starter case Since newly delivered starter spring is bound by wire cut the wire to release the tension after setting outer end hook in the case When reinstalling starter spring 1 as same into starter case face starter sprin...

Page 129: ...n the bold to specified torque Starter Shaft Bolt 6 N m 4 lb ft 0 6 kgf m 1342 1342 When winding starter spring turn reel 5 to 6 rounds to direction to which the reel rotates when pulling out starter rope counterclockwise Then set the spring so that the reel additionally turns 1 4 of a rotation to one rotation and 1 4 when the rope is fully pulled out approximately 5 to 6 rotations After installin...

Page 130: ...ction of Propeller Shaft Ass y 6 48 18 Assembly of Propeller Shaft Ass y 6 50 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 Forwa...

Page 131: ...r attaching pinion shaft housing bearing Attaching propeller shaft housing needle bearing bearing B gear nut 9 0 q w 28 Bevel Gear B Nut Wrench Bevel Gear B Nut Wrench Universal Puller Plate Roller Bearing Press Kit MX50 P N 346 72231 0 MWX50 P N 353 72231 0 P N 3AC 99750 0 P N 3LC 72900 0 Removing or attaching pinion Removing or attaching pinion Removing reverse C gear Removing or attaching gear ...

Page 132: ...on B gear height Measuring gaps Used to attach dial gauge when measuring backlash Measuring backlash between forward A gear and pinion B gear a s d Dial Gauge Plate Backlash Measuring Tool Clamp Backlash Measuring Tool Kit P N 3B7 72729 0 P N 3B7 72720 0 MWX50 P N 3A3 72255 0 Used to attach dial gauge when measuring backlash Measuring backlash Measuring backlash between pinion B gear and reverse C...

Page 133: ...y 1 for Transom UL with 15 Bevel Gear C 1 Sub Water Pipe 16 Washer 22 1 28 3 1 2 Roller Bearing 22 30 30 1 Do not reuse 17 1 Shim 41 51 5 0 1 A 3 Tapered Roller Bearing 32007 1 Do not reuse 17 2 Shim 41 51 5 0 15 A 4 Plug 2 17 3 Shim 41 51 5 0 3 A 5 Plug 1 17 4 Shim 41 51 5 0 5 A Selection if necessary 6 Gasket 10 1 15 1 1 Do not reuse 18 1 Shim 36 44 0 3 A 7 Gasket 8 1 15 1 2 Do not reuse 18 2 Sh...

Page 134: ...not reuse 40 Pump Case Liner 1 28 Oil Seal 22 36 10 1 Do not reuse 41 Water Pipe Seal Lower 1 29 Ball Bearing 6007 1 Do not reuse 42 Pump Case Lower 1 30 O Ring 3 5 69 4 1 Do not reuse 43 Shim 32 9 26 0 5 1 31 1 Drive Shaft S 1 for Transom S 44 Oil Seal 17 33 6 2 Do not reuse 31 2 Drive Shaft L 1 for Transom L 45 O Ring 3 2 47 1 Do not reuse 31 3 Drive Shaft UL 1 for Transom UL 46 Dowel Pin 4 10 2...

Page 135: ... S 1 for Transom S 66 3 Water Pipe UL 1 MX50D2 for Transom UL 56 2 Cam Rod L 1 for Transom L 67 Water Pipe Seal Upper 1 56 3 Cam Rod UL 1 for Transom UL 68 Collar 18 20 4 5 1 57 Spring Pin 3 12 2 Do not reuse 69 1 Propeller Ass y 7 1 4 X 290 X 180 58 Cam Rod Bushing 1 69 2 Propeller Ass y 9 1 3 X 307 X 229 59 O Ring 2 4 5 8 1 Do not reuse 69 3 Propeller Ass y 11 1 3 X 295 X 279 60 O Ring 3 5 21 7 ...

Page 136: ...7 OBM OBM OBM OBM GEAR GEAR OBM OBM TEF TEF GEAR GEAR OBM OBM G17 G1 7 1342 1342 OBM OBM 1342 1342 OBM 1342 OBM 1342 1342 1342 OBM OBM OBM OBM OBM OBM OBM OBM Ref No Description Q ty Remarks 71 Thrust Holder 1 72 Stopper 1 73 Propeller Nut 1 74 Washer 17 32 3 1 75 Split Pin 3 25 1 6 12 2st 50D2 2011 ...

Page 137: ... Bevel Gear B 1 16 Shim 36 9 30 0 5 1 4 Nut Bevel Gear B 1 17 Oil Seal 22 37 8 2 Do not reuse 5 Shim 44 50 5 0 1 A 18 O Ring 3 2 47 1 Do not reuse 5 Shim 44 50 5 0 15 A Selection if necessary 19 Dowel Pin 4 10 2 5 Shim 44 50 5 0 3 A 20 Water Pump Guide Plate 1 6 Drive Shaft L 1 21 Guide Plate Gasket 1 Do not reuse 7 Ball Bearing 6205R 2 Do not reuse 22 Pump Case Gasket 1 Do not reuse 8 Drive Shaft...

Page 138: ... 1342 1342 1342 1342 1342 Ref No Description Q ty Remarks 29 Spring Pin 3 5 14 1 Do not reuse 30 Spring Pin 3 5 10 1 Do not reuse 31 Cam Rod Bushing 1 32 O Ring 1 9 6 8 2 Do not reuse 33 O Ring 3 5 27 7 1 Do not reuse 34 Shift Rod Joint 1 35 Bolt 8 35 4 36 Washer 4 37 Bolt 10 40 2 38 Washer 2 39 Extension Pipe 1 40 Joint Hose 1 41 Collar 18 20 4 5 1 42 Water Strainer Set 1 6 16 2st 50D2 2011 ...

Page 139: ... 25 33 30 1 Do not reuse 6 Pre Coated Bolt 8 30 2 19 Oil Seal 25 38 10 1 Do not reuse 7 Bevel Gear Ass y A 1 20 O Ring 3 5 74 6 1 Do not reuse 8 Roller Bearing 202720 1 Do not reuse 21 Push Rod 1 9 Bevel Gear C 1 22 1 Propeller Ass y 9 1 3 X 305 X 229 10 1 Washer t 3 0 A 22 2 Propeller Ass y 10 1 3 X 292 X 254 10 2 Washer t 2 75 A 22 3 Propeller Ass y 11 1 3 X 292 X 279 10 3 Washer t 2 5 A 22 4 Pr...

Page 140: ...2 OBM OBM OBM OBM OBM OBM 1342 1342 OBM OBM OBM OBM OBM OBM OBM OBM Ref No Description Q ty Remarks 22 8 Propeller Ass y 16 5 1 3 X 273 X 417 22 9 Propeller Ass y 17 5 1 3 X 276 X 447 23 Thrust Holder 1 24 Stopper 1 6 20 2st 50D2 2011 ...

Page 141: ... removing or installing propeller be sure to remove stop switch lock plate When removing or installing propeller do not handle propeller with bare hands Put a piece of wooden block between anti cavitation plate and propeller to prevent rotation of propeller when removing or installing propeller 1 5 2 4321 5 6 Shift gear into forward F Put a piece wood between anti cavitation plate and propeller 5 ...

Page 142: ...isconnect shift rod at upper side of shift rod joint 1 Use spring pin tool A 2 to remove spring pin Do not reuse removed spring pin To hold lower unit keep spring pin tool inserted until the step of removal of lower unit Spring Pin Tool A 2 ø3 0 3 Spring Pin Do not reuse P N 345 72227 0 3 Remove lower unit installation bolts 4 and pull lower unit ass y downward to remove CAUTION Hold lower unit wh...

Page 143: ...joint 1 and clutch cam 2 1 1 3 6 6 3 2 2 4 Spring Pin Tool A 3 ø3 0 P N 345 72227 0 3 5 5 6 6 Spring Pin Tool A 3 ø3 0 P N 345 72227 0 Spring Pin Tool A 4 ø3 5 P N 369 72217 0 Remove O ring 5 from cam rod bushing 6 5 O Ring Do not reuse 5 Inspection of Clutch Cam a 1 Check the part for wear and damage Replace if necessary Check especially for wear on the face a that scrapes against push rod and fl...

Page 144: ...e 2 Attach cam rod bushing 1 shift rod joint 5 and clutch cam 6 to cam rod 4 5 5 1 1 9 9 7 7 4 4 6 6 8 7 Spring Pin Do not reuse 7 Spring Pin Do not reuse Spring Pin Tool B 7 ø3 0 Spring Pin Tool B 7 ø3 0 P N 345 72228 0 P N 345 72228 0 Spring Pin Tool B 8 ø3 5 P N 369 72218 0 3 Drive spring pin 9 4 CAUTION Drive spring pin 9 so that it is flush with clutch cam surface as shown 9 1 6 28 2st 50D2 2...

Page 145: ...olts and remove pump case upper parts 1 2 3 and 4 in this order 1 2 Remove water pump impeller key 5 5 6 7 3 Remove guide plate 6 gasket 7 and pump case lower 8 8 When removing pump case lower insert bladed screw driver into the groove of the case and pry slowly to separate the part 6 30 2st 50D2 2011 ...

Page 146: ...rface the blade s may be separated from the hub Replace guide plate if a groove s of 0 5 mm or over is produced on it due to wear by impeller OBM OBM 3 Check impeller key 4 and key groove for wear Replace if necessary 9 Inspection of Water Pipe 1 Remove water pipe 1 from drive shaft housing Refer to 7 24 7 28 1 2 Check water pipe 1 for corrosion deformation and stuffing 1 For MWX50 Extension water...

Page 147: ...tween oil seals Be careful not to give flaw to oil seal press fit face 11 Assembly of Water Pump Case Lower 1 Install oil seal 1 and shim 2 by using suitable press 3 and then press fit perpendicularly Apply gear oil to oil seal circumference before installing oil seal Apply OBM grease to oil seal lip OBM OBM GEAR GEAR OBM OBM 3 1 A 1 2 1 1 2 1 GEAR GEAR 6 34 2st 50D2 2011 ...

Page 148: ...ousing to the position where O ring of the housing can be removed Propeller Shaft Housing Puller Ass y 2 P N 353 72252 0 3 3 Propeller Shaft Housing Ass y 3 Hold propeller shaft and remove propeller shaft housing ass y When pulling out propeller shaft housing ass y remove clutch push rod and steel balls together with the housing ass y 6 36 2st 50D2 2011 ...

Page 149: ...3 Check oil seal 4 for wear and crack 4 Replace if necessary 4 Remove bearing 5 5 CAUTION Heat propeller shaft housing by putting it in the hot water of approximately 60 70 C 140 158 F and remove bearing 4 CAUTION Be careful not to burn Heating of propeller shaft housing can also be 5 Bearing Do not reuse 6 38 made by using a heat gun or heat lamp 2st 50D2 2011 ...

Page 150: ... reuse MX50 MWX50 Roller Bearing Attachment 7 Roller Bearing Attachment 7 P N 3MC 99710 0 P N 3LC 99710 0 Driver Rod 8 Driver Rod 8 P N 3AC 99702 0 P N 3AC 99702 0 This work can be done also by using the following tool kit MX50 MWX50 Needle Bearing Puller Kit Needle Bearing Puller Kit P N 3C8 72700 0 P N 3B7 72700 0 6 When removing only oil seal use bladed screw driver to pry apart Be careful not ...

Page 151: ...e manufacturer s 2 GEAR GEAR 4 mark a facing the tool side Screw in roller bearing attachment 2 lightly by a hand so that no gap is made at driver rod 1 Clean roller bearing installation face and apply gear oil before installation 4 Roller Bearing Do not reuse MX50 MWX50 Roller Bearing Attachment 2 Roller Bearing Attachment 2 P N 3MC 99710 0 P N 3LC 99710 0 Driver Rod 1 Driver Rod 1 P N 3AC 99702 ...

Page 152: ...6 before installation Apply grease to lip of oil seal after installing it 5 5 OBM OBM GEAR GEAR 5 Oil seal Do not reuse 6 1 5 OBM OBM Lip 5 GEAR GEAR Circumference 5 Oil Seal Do not reuse 3 1 8 7 GEAR GEAR Install bearing 7 Use a suitable press 8 to install new bearing to propeller shaft housing Clean bearing installation face and apply gear oil before installation GEAR GEAR 7 Bearing Do not reuse...

Page 153: ... gear oil before installation Bevel Gear Bearing Install Tool q P N 3C8 72719 0 GEAR GEAR 7 Bearing 2 1 Do not reuse 16 Disassembly of Propeller Shaft Ass y 1 Remove push rod 1 and steel ball 2 3 7 6 5 4 3 Clutch Pin Snap Do not reuse 2 Put a bladed screw driver into one of clutch pin snap 3 3 end and take the snap out from the clutch groove while winding it 3 Clutch Pin Snap Do not reuse 6 46 2st...

Page 154: ...y quickly Install push rod 1 and pull out pin 4 while pushing propeller shaft onto a plane to prevent retainer 5 and spring 6 from flying out After taking out clutch spring retainer 5 and clutch spring 6 remove clutch 7 from propeller shaft 17 Inspection of Propeller Shaft Ass y 1 2 a a Check propeller shaft for bend wear and damage Replace if necessary Measure propeller shaft runout Runout Limit ...

Page 155: ...le toward forward gear a Install clutch pin while applying preload to push rod Apply OBM grease to spring retainer to prevent ball from dropping Be careful not to allow ball to fly out by spring tension OBM OBM Attach new clutch pin snap 3 by using a bladed screw driver to turn the snap When attaching clutch pin snap do not apply excessive force to the part or the snap may expand during operation ...

Page 156: ... it from hitting the case directly This work can be made easier when the opening of gear case of propeller shaft side is faced upward and fixed horizontally with a holder Drive Shaft Socket 1 P N 345 72232 0 Bevel Gear B Nut Wrench 2 MX P N 346 72231 0 MWX P N 353 72231 0 2 Pull out drive shaft from gear case When removing drive shaft be careful not to give damage to shim on the bearing outer race...

Page 157: ...moving and replace if necessary When putting universal puller plate on the bearing hook the tip of puller s claw on the inner race of bearing correctly Universal Puller Plate 4 P N 3AC 99750 0 3 4 3 Bearings Do not reuse 21 Inspection of Drive Shaft 1 Check drive shaft for bend and wear Replace if necessary 2 Measure drive shaft runout a a Runout Limit 0 4 mm 0 016 in a Supporting Points 22 Inspec...

Page 158: ......

Page 159: ...3 Before installing bearing be sure to clean drive shaft installation face and apply gear oil CAUTION Do not press drive shaft thread a directly Put a piece of protector steel plate on the tip of the shaft A nut that fits the thread can be used to protect the shaft tip when pressing GEAR GEAR GEAR a GEAR 1 2 3 GEAR GEAR A 2 Bearing Do not reuse 2 Bearing Do not reuse 6 56 2st 50D2 2011 ...

Page 160: ......

Page 161: ... CAUTION Do not press drive shaft thread a directly Put a piece of protector steel plate on the tip of the shaft GEAR GEAR a 4 GEAR GEAR 3 GEAR GEAR 4 GEAR GEAR 4 3 GEAR GEAR 4 Bearing Do not reuse 5 b 4 5 4 Bearing Do not reuse Attach drive shaft spring 5 CAUTION When attaching the spring face the side b toward pinion B gear side Attach spring as illustrated 6 58 2st 50D2 2011 ...

Page 162: ......

Page 163: ...t taking care not to hit pinion B gear For MWX50 models Can not remove forward A gear when removed pinion B gear Refer to P6 52 remove pinion B gear and then remove forward A gear 1 2 25 Disassembly of Forward Gear A 1 Gear 1 Remove taper roller bearing 1 Use two bladed screw drivers to remove taper roller bearing from forward gear A gear Put the drivers into grooves of forward A gear and pry out ...

Page 164: ...6 ...

Page 165: ... A Gear 1 Check forward A gear teeth and clutch claws for crack damage and wear Replace if necessary 27 Assembly of Forward A Gear Parts CAUTION When gear case forward A gear or bearing is replaced measure backlash and attach a proper shim Refer to Chapter 6 Shim Adjustment MWX50 only 1 Install roller bearing 1 Apply gear oil to press fit face when press fitting roller bearing CAUTION When press f...

Page 166: ...6 ...

Page 167: ...Attach shim 4 used before disassembly to taper roller bearing 5 and press fit the part Apply gear oil to press fit face when press fitting taper roller bearing Bevel Gear Bearing Install Tool 3 P N 3C8 72719 0 GEAR GEAR 6 64 2st 50D2 2011 ...

Page 168: ......

Page 169: ...2 P N 3T1 72765 0 P N 3T1 72765 0 Roller Bearing Press Rod 3 Roller Bearing Press Rod 3 P N 3LC 72767 0 P N 3LC 72767 0 Roller Bearing Press 4 Roller Bearing Press 4 P N 3Z5 72770 0 P N 3S7 72770 0 O Ring 5 O Ring 5 P N 6B3 32529 0 P N 6H6 07422 0 Washer M8 6 Washer M8 6 P N 940191 0800 P N 940191 0800 Roller Bearing Outer Press Collar 7 Roller Bearing Outer Press Collar 7 P N 3C7 72768 0 P N 3C7 ...

Page 170: ... of slide hammer on the outer race to fix it and slide the hammer to pull out the outer race Slide Hammer Ass y P N 3AC 99080 0 Confirm the position of insertion groove in the back of outer race and put the claw of slide hammer in the groove This work can also be done by using the following tool Bevel Gear Bearing Puller Ass y MX50 P N 3A3 72755 0 MWX50 P N 3B7 72755 0 29 Inspection of Gear Case 1...

Page 171: ...6 ...

Page 172: ...31 0 Nut M10 5 P N 930191 1000 Spring Washer 6 P N 941392 1000 2 Fix gear case on a holder with its propeller shaft opening facing upward 3 Clean outer race installation face in the gear case and apply gear oil 4 Apply gear oil to external face of outer race and put the outer race in the center of the housing with the marked face of the race facing in the housing GEAR GEAR 4 5 Put rod ass y into g...

Page 173: ...6 ...

Page 174: ...er Bearing Do not reuse MX50 Roller Bearing Press Kit P N 3LC 72900 0 Bearing Outer Press Guide 8 P N 3T1 72765 0 Roller Bearing Press Rod 9 P N 3LC 72767 0 Roller Bearing Press 0 P N 3Z5 72770 0 O Ring q P N 6B3 32529 0 Washer M8 w P N 940191 0800 Roller Bearing Outer Press Collar e P N 3C7 72768 0 Roller Bearing Outer Press Bolt r P N 3C7 72766 0 Bolt M8 110 t P N 3C7 72773 0 Roller Bearing Pres...

Page 175: ...6 ...

Page 176: ...422 0 Washer M8 w P N 940191 0800 Roller Bearing Outer Press Collar e P N 3C7 72768 0 Roller Bearing Outer Press Bolt r P N 3C7 72766 0 Bolt M8 110 t P N 3C7 72773 0 Roller Bearing Press Flange y P N 3AC 72901 1 Roller Bearing Press Guide u P N 3S7 72905 0 GEAR 6 74 u GEAR Installation Depth a 201 mm 7 913 in This work can be done also by using the following tool kit MWX50 Roller Bearing Puller Ki...

Page 177: ...6 ...

Page 178: ...rts up to pump case 1 and secure it by using M8 bolt L 30mm and flat washer 2 Remove forward A gear before beginning the work M8 Bolt L 30mm Flat Washer 2 13N m 9 0 lb ft 1 3kgf m 2 This work can be made easier when the opening of gear case of propeller shaft side is faced upward and fixed horizontally with a holder Put a shimming gauge 3 into gear case and measure gap a between shimming gauge 3 a...

Page 179: ...6 ...

Page 180: ...lue a 3 b 6 MX50 MWX50 Pinion B Gear Height a Pinion B Gear Height a 0 60 0 64 mm 0 0236 0 0252 in 0 95 1 00 mm 0 03740 0 03937 in Type of Shims 6 Applicable Type of Shims 6 Applicable 0 1 mm 0 0039 in P N 345 64081 0 0 1 mm 0 0039 in P N 353 64081 0 0 15 mm 0 0059 in P N 345 64082 0 0 15 mm 0 0059 in P N 353 64082 0 0 3 mm 0 0118 in P N 345 64083 0 0 3 mm 0 0118 in P N 353 64083 0 0 5 mm 0 0197 i...

Page 181: ...6 ...

Page 182: ...ar height Refer to Measurement of Pinion B Gear Height and Shim Selection in Chapter 6 1 In accordance with procedure described in Assembly of Lower Unit Parts on Chapter 6 install parts up to pump case lower 2 Install dial gauge plate 1 and secure it with bolt M8 35 and flat washer 8 M8 Bolt L 35mm Flat Washer 8 13N m 9 0 lb ft 1 3kgf m 8 8 1 1 3 4 3 4 2 2 7 7 6 6 5 5 6 80 2st 50D2 2011 ...

Page 183: ......

Page 184: ...e 6 P N 3A3 72245 0 O Ring 7 P N 332 60002 0 Fixing gear case on the holder with its propeller shaft opening facing upward makes the work easier Be sure that cone discs 5 are arranged as illustrated Put three of the parts aligned in the same direction and then put both sets of the parts with their convex sides face to face Tighten shaft 2 until drive shaft 9 starts to move rotate When drive shaft ...

Page 185: ... P N 3B7 72720 0 Dial Gauge e Commercially Available Item Magnetic Stand r Commercially Available Item 7 Select proper thickness of shim based on the backlash measured with dial gauge and on the table shown Confirm dial gauge reading and adjust backlash by using thickness of shim selected Measure backlash several times while changing gear teeth contact position When measuring backlash make drive s...

Page 186: ...6 ...

Page 187: ... 15 0 0394 0 0453 0 20 0 0078 1 34 1 52 0 0528 0 0598 0 25 0 0098 1 16 1 31 0 0457 0 0516 0 25 0 0098 1 53 1 72 0 0602 0 0677 0 30 0 0118 1 32 1 47 0 0520 0 0579 0 30 0 0118 1 73 1 92 0 0681 0 0756 0 35 0 0137 1 48 1 63 0 0583 0 0642 0 35 0 0137 1 93 2 11 0 0760 0 0831 0 40 0 0157 1 64 1 79 0 0646 0 0705 0 40 0 0157 2 12 2 31 0 0835 0 0909 0 45 0 0177 1 80 1 95 0 0709 0 0768 0 45 0 0177 2 32 2 51 ...

Page 188: ...6 ...

Page 189: ... 2 and flat washer 2 3 Attach backlash measuring tool kit parts 3 to 9 to propeller shaft housing ass y 0 put the assembly in the gear case and secure it using bolt M8 L 30mm q and flat washer q Make sure to locate center of propeller shaft housing 0 matches center of backlash measuring tool plate 7 Backlash Measuring Tool Kit P N 3A3 72255 0 Backlash Measuring Tool Shaft 3 P N 3A3 72726 0 Measuri...

Page 190: ...backlash several times while changing gear teeth contact position When measuring backlash make drive shaft 0 68 0 83 0 0268 0 0327 0 10 0 0039 pulling up force equal among the measurements 0 84 0 99 0 0331 0 0390 0 15 0 0059 1 00 1 15 0 0394 0 0453 0 20 0 0078 1 16 1 31 0 0457 0 0516 0 25 0 0098 1 32 1 47 0 0520 0 0579 0 30 0 0118 This work can be made easier when the opening of gear case of prope...

Page 191: ...n the nut by using a drive shaft socket 5 and a wrench and turning the wrench clockwise Cover the wrench 6 with rag to prevent it from hitting the case directly This work can be made easier when the opening of gear housing of propeller shaft side is faced upward and fixed horizontally with a holder Before tightening pinion B gear and nut apply ThreeBond 1342 to the thread Degrease taper area of dr...

Page 192: ... 1 that is removed when disassembly 2 Attach O ring 2 to pump case lower 3 and install pump case lower to gear case Apply OBM grease to O ring OBM 7 6 5 4 3 2 1 OBM OBM 9 5 7 6 5 4 3 2 OBM OBM 1 OBM 3 Put dowel pin 4 on the pump case lower 3 and attach pump case guide plate gasket 5 and pump case guide plate 6 8 7 4 9 Attach water pump impeller key 7 to drive shaft 8 align the key with the water p...

Page 193: ...ump case q turn drive shaft 8 clockwise to bend all impeller blades in counterclockwise on power unit direction OBM OBM 7 Attach water pipe seal e RP Apply OBM grease thinly on the inside c of water pipe seal so that water pipe can be inserted smoothly 36 Attaching Clutch Cam Ass y 3 1 Install clutch cam ass y 1 1 2 Apply OBM grease to O ring of clutch cam ass y and install the assembly by pushing...

Page 194: ...1342 1342 6 98 Apply ThreeBond 1342 to thread of propeller shaft housing installation bolts MWX50 Propeller Shaft Housing Bolts 13 N m 9 lb ft 1 3 kgf m MWX50 only 37 Measurement of Propeller Shaft Play and Selection of Washer Thickness CAUTION Before measuring propeller shaft play adjust backlash between forward A and pinion B gears and reverse C and pinion B gears Refer to Measurement of Backlas...

Page 195: ...mbling Lower Unit Parts in Chapter 6 Play of propeller shaft in forward reverse direction out of the specified range can cause revolution of propeller even in neutral gear while engine is operating 38 Installation of Lower Unit 1 Tilt up outboard motor and lock with tilt stopper TEF TEF 2 Set shift rod 1 to up position Apply thin coat of OBM grease to spline of drive 1 shaft before assembling Appl...

Page 196: ...y installation bolts and nut to specified torque CAUTION To make centering of lower unit ass y to drive shaft housing attach bolts to two locations B marked on the lower unit ass y first After all bolts are attached tighten the two bolts first M8 6pcs M8 4pcs M10 2pcs M8 25N m 18 lb ft 2 5kgf m OBM OBM 6 102 25N m 18 lb ft 2 5kgf m M10 40N m 29 lb ft 4 0kg m OBM OBM 2st 50D2 2011 ...

Page 197: ...talling propeller do not handle propeller with bare hands Put a piece of wooden block between anti ventilation plate and propeller to prevent rotation of propeller when 8 Split Pin Do not reuse 7 removing or installing propeller Propeller Nut 7 35 N m 25 lb ft 3 5 kgf m Attach split pin 8 CAUTION If propeller shaft pin hole and propeller nut pin groove do not align additionally tighten the nut unt...

Page 198: ... 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...

Page 199: ...nt 1 Water Pipe Locking Rubber 20 Exhaust Pipe 1 5 Extension Housing 1 MX50D2 for Transom UL 21 Bolt 8 30 3 6 Water Pipe Auxiliary Mount 1 MX50D2 for Transom UL 22 Exhaust Pipe Gasket 1 Do not reuse 7 Cam Rod Holder 1 MX50D2 for Transom UL 23 Exhaust Housing 1 8 Stopper 1 MX50D2 for Transom UL 24 Bolt 4 9 Bolt 1 MX50D2 for Transom UL 25 Exhaust Housing Gasket 1 Do not reuse 10 Bolt 6 MX50D2 for Tr...

Page 200: ...1 Cap Nut 2 Distance Piece 1 Nut 1 Washer 1 Bolt 8 170 1 Thrust Rod 1 Ref Remarks No SternBracket Right StarboardSide 16 17 Stern Bracket Left Port Side 18 19 20 Bracket Bolt 21 22 23 24 25 26 27 28 29 30 Description Q ty Remarks Thrust Rod Spring 1 Swivel Bracket 1 Grease Fitting 1 Washer 1 Friction Piece 1 Friction Spring 1 Bolt 1 Steering Shaft Ass y 1 Bushing 26 32 2 Thrust Plate Upper 27 50 1...

Page 201: ...r Mount Upper Bolt Damper Upper Washer Lock Plate Mount Holding Plate Upper Q ty Remarks 1 2 2 2 2 4 2 Rubber Mount Cap Lower 4 2 2 2 2 2 1 1 Rubber Mount Cap Upper Ref Description Q ty Remarks No 46 Bolt 3 47 Ground L 210 1 48 Ground L 130 1 49 Bolt 2 50 Ground L 110 1 51 Bolt 1 52 Anode 1 OPT 53 Bolt 2 OPT 54 Spring Washer 2 OPT 55 Clamp Screw Kit 2 56 Clamp Screw 1 57 Clamp Screw Handle 1 58 Ri...

Page 202: ...Lock Spring S 2 for Transom S 6 Setting Piece 1 20 Shoulder Bolt 6 8 1 7 Tilt Assistant Spring R 1 MX50D2 for Transom UL 21 Washer 6 16 1 5 1 8 Tilt Assistant Spring L 1 MX50D2 for Transom UL 22 Washer 1 9 Tilt Assistant Shaft 1 MX50D2 for Transom UL 23 Bushing 8 1 20 1 10 Reverse Lock L 1 24 Washer 8 5 18 1 6 1 11 Reverse Lock R 1 25 Link 1 12 Reverse Lock Arm 1 26 Spring 1 13 Reverse Lock Shaft ...

Page 203: ... 5 Tiller Handle 1 22 Wave Washer 30 45 1 2 1 6 Grip 1 23 Bushing 1 7 Throttle Shaft 1 24 Washer 1 8 Throttle Shaft Damper 1 25 Nut 10 P1 5 1 9 Spacer 1 26 Throttle Wire 2 10 Spring Pin 3 10 1 Do not reuse 27 Clip 1 11 Bushing 8 4 10 11 1 28 Throttle Wire Bracket 1 12 Screw 1 29 Bolt 2 13 Throttle Shaft Support 1 30 Washer 2 14 Bolt 1 31 Washer 6 16 1 5 1 15 Friction Piece 1 32 Screw 1 16 Adjustin...

Page 204: ... 7 4 15 Grommet 1 3 Choke Rod 1 16 Grommet 1 4 Bushing 1 17 Clamp 6 5 14L 1 5 Hook Lever 1 18 Bolt 1 6 Washer 14 22 1 1 19 Nut 1 7 Seal Ring 2 20 Clamp 6 5 47 5P 1 8 Hook Lever Bushing 1 21 Bolt 3 9 Wave Washer d 14 1 22 Grommet 1 10 Cover Hook 1 23 Nipple 1 11 Bolt 1 24 Hose 1 98AB 501000 12 Washer 6 16 1 5 1 25 Stop Switch Ass y 1 13 Spring Washer 1 26 Stop Switch Lanyard Ass y 1 7 12 2st X50D2 ...

Page 205: ...41 Grommet 17 3 1 30 Wave Washer d 12 1 42 Shift Rod 1 31 1 Shift Rod Lever 1 for MX50D2 43 Spring Pin 3 12 1 31 2 Shift Rod Lever 1 for MWX50D2 44 Clamp 1 32 Snap Retainer d 8 1 45 Bolt 1 ALL 33 Shift Lever Stopper 1 46 Spark Plug Decal 1 B8HS 10 34 Shift Lever Stopper 1 47 Bottom Cowl 1 35 Bolt 1 48 Grommet 1 36 Fuel Connector Male 1 37 Nut 10 P1 25 1 38 Gasket 10 2 16 0 5 1 Do not reuse 7 14 2s...

Page 206: ...23 Ref No Description Q ty Remarks 1 Top Cowl Ass y 1 2 Tilt Handle 1 3 Nylon Nut 6 P1 0 4 4 Washer 6 16 1 5 4 5 Top Cowl Seal 1 6 Decal Set 1 for MX50D2 7 Decal Set 1 for MWX50D2 8 Caution Decal A 1 for MX50D2 7 16 2st X50D2 2011 ...

Page 207: ... cable inner wire and outer wire for bend and damage Replace if necessary 2 Removing of Tiller Handle 1 Remove advancer arm 1 1 2 Remove throttle wire mounting clamp 2 and screw 3 3 2 3 Remove throttle grip 4 and throttle shaft supporter 5 4 5 4 Remove tiller handle holder installation nut 6 6 7 18 2st X50D2 2011 ...

Page 208: ...2 1 a 5 Remove tiller handle and throttle shaft 7 3 Installation of Tiller Handle 1 Install bushing 1 wave washer 2 and washer 3 on the steering bracket 4 OBM OBM 2 Install throttle cable as shown b a b b a 7 20 2st X50D2 2011 ...

Page 209: ...to specified torque Arrange throttle cable as shown Tiller Handle Bolt 9 6 N m 4 lb ft 0 6 kgf m OBM OBM 5 Install advancer arm and adjust position of lock nuts 0 of throttle cable 6 Adjust position of lock nuts of throttle cable so that throttle 0 grip can reach full open and full close positions Adjust cable tension so that it moves approximately 1mm when pushed lightly with a finger For more de...

Page 210: ...er unit Refer to Removing Power Unit in 2 chapter 5 2 Remove snap retainer 1 And then remove shift rod lever 2 1 3 Remove shift rod 3 3 4 Loosen and remove four bolts that secure bottom cowl to engine base 5 Remove bottom cowl 7 24 2st X50D2 2011 ...

Page 211: ... in several steps alternately and equally 3 Loosen and remove lower rubber mount cap installation bolts to remove mount cap 3 4 Loosen lower rubber mount installation bolt and remove the nut CAUTION Drive shaft housing drops if mount bolt is removed in this step Fully tilt down outboard motor when loosening mount bolt Remove only the nut and do not remove mount bolt 5 Pull out lower rubber mount b...

Page 212: ...shaft housing Remove M6 installation bolt located in the area shown by the arrow 2 Tap lightly with a plastic hammer to separate engine base from the housing if it is seized If necessary use a bladed screw driver to pry the engine base taking care not to scratch mating surface 7 28 2st X50D2 2011 ...

Page 213: ... lose dowel pin 4 for locating engine base 2 2 3 4 4 Loosen and remove bolts that secure exhaust housing 5 to engine base and remove exhaust housing 5 5 Loosen and remove bolts 7 that secure exhaust pipe 6 to engine base and remove exhaust pipe 6 7 7 30 2st X50D2 2011 ...

Page 214: ...ng 5 and drive shaft housing 6 for corrosion for damage 3 5 6 4 Check if drive shaft housing is distorted Place the housing on the surface plate and use dial gauge to measure distortion on the upper face of the housing Replace if the difference is over 0 228mm 0 0090in on each measuring point CAUTION Use of distorted drive shaft housing may cause severe wear of drive shaft spline which may lead to...

Page 215: ...1 3 kgf m 4 2 3 2 Install exhaust housing grommet 5 to exhaust housing 5 6 6 When installing the grommet by using adhesive clean adhering area to remove dirt and oil and dry the area before applying adhesive 1741 1741 7 3 3 Install exhaust housing 6 and gasket 7 to engine base 3 and tighten bolts to specified torque Exhaust Housing Bolts 13 N m 9 lb ft 1 3 kgf m 7 34 2st X50D2 2011 ...

Page 216: ...BM 8 8 5 9 9 Install water pipe to drive shaft housing and attach gasket after confirming that dowel pins 9 are on the drive shaft housing 6 Check that drive shaft housing dowel pin is placed and secured to engine base properly Check that water pipe is at joint of engine base 7 36 2st X50D2 2011 ...

Page 217: ... side of longer size a facing forward Upper Rubber Mount Bolts 2 29 N m 22 lb ft 2 9 kgf m 2 Install upper mount holding plate 3 3 Install dumper rubber 5 to mount bracket 4 CAUTION Install dumper rubber with the grooved side c facing drive shaft housing b 4 Put lower rubber mount 6 to drive shaft housing and tighten bolts 7 and nuts 8 to specified torque CAUTION Install the mount with the side of...

Page 218: ...e 2 then insert 1 a Passage c for adjusting water flow Check the passage for clogged by salt clean if necessary 1 OBM OBM a 2 b 2 c 2 Insert tube joint 1 and extension pipe 2 to extension 1 housing 3 as shown 3 2 3 Insert tube joint 1 to the water pipe 4 and attach extension housing 4 1342 1342 1342 1 1342 3 7 40 2st X50D2 2011 ...

Page 219: ... C ring 1 that supports mount bracket 2 2 Remove mount bracket 2 When mount bracket cannot be removed tap the bracket at both ends alternately by using a plastic hammer 3 Pull up steering shaft arm 3 to remove Do not lose bushing and O ring 7 42 2st X50D2 2011 ...

Page 220: ...aft into swivel bracket ass y 3 3 Attach bushing 4 new O ring 5 and thrust plate 6 to swivel bracket 4 Push bushing by using flat head screw driver until it stops Put O ring until it contacts bushing OBM OBM 4 Put bushing and O ring into swivel bracket surely 5 OBM OBM 6 5 Put OBM grease into bushing a through grease nipple 7 until it overflows a OBM OBM 7 a 7 44 2st X50D2 2011 ...

Page 221: ... in severe injury When tilting up outboard motor without power unit installed be careful to operate tilt lock lever to prevent swivel bracket rise up easy Remove drive shaft housing steering shaft thrust rod and copilot before beginning this procedure Loosen nut 2 of swivel bracket shaft 1 Remove ground cable on the swivel bracket 4 Remove swivel bracket shaft with spring and swivel bracket 7 46 2...

Page 222: ...into clamp bracket 2 and tilt assistant 2 spring 3 1 Set the tilt stop lever to Release position then install swivel bracket shaft and assistant spring Tilt assistant spring 3 is discontinuing products for after January in 2012 3 3 Install tilt assistant shaft 4 and bushing 5 And then tighten nylon nut to the specified torque Nylon Nut 5 25 N m 18 lb ft 2 5 kgf m 4 5 7 48 2st X50D2 2011 ...

Page 223: ...GB 15 Disassembling tilt mechanism 1 Set tilt stopper lever to release side and then remove tilt stopper setting plate 1 1 2 Remove tilt stopper 2 bushing 3 set piece 4 and spring 5 5 4 3 2 7 50 2st X50D2 2011 ...

Page 224: ...erse lock shaft 7 by using screw driver 7 1 2 16 Assembling tilt mechanism 1 Install reverse lock link 1 and arm 2 as shown and then install reverse lock shaft 2 Install reverse lock spring 3 and spring 4 springs in reverse procedures of disassembling 7 52 2st X50D2 2011 ...

Page 225: ... Bracket GB 3 Install tilt stopper 5 bushing 6 set piece 7 and spring 8 4 8 67 OBM OBM OBM OBM 5 3 3 7 54 2st X50D2 2011 ...

Page 226: ...Adapter 8 8 Attention of measurement 8 8 Measurement procedure 8 8 4 Inspection date 8 10 Resistance test reference 8 10 Peak voltage out put test reference 8 10 5 Inspection Items 8 12 1 Inspection of Ignition and spark 8 12 2 Inspection of Plug Cap Terminal 8 12 3 Inspection of Ignition Coils 8 14 4 Inspection of Pulser Coil 8 14 5 Inspection of Exciter Coil 8 16 6 Inspection of C D unit 8 16 7 ...

Page 227: ... which is higher than past of decision and defective place or parts can be executed much faster 2 Good or faulty condition can be checking without removing the parts Recommended tester Notes 1 Use HIOKI HiTESTER MODEL 3030 or equivalent tester for this measurement and do not use megger or other instrument 2 Disconnect all connections and measure as an independent unit 3 When the tester s pointer m...

Page 228: ... 1 F4T405 72 12 Band 3 2 Coil Plate Ass y W Alternator 1 13 Screw 3 3 Pulsar Coil Plate Ass y 1 14 Key 1 4 Pulsar Holder 1 15 Nut 18 P1 5 1 5 Exciter Coil 1 16 Washer 19 34 3 1 6 Screw 6 17 Guide Plate 1 7 Alternator Ass y 1 18 Guide Plate cover 2 8 Holder 1 19 Setting Ring 1 9 Screw 2 20 Ball Joint 1 10 Clamp 2 21 Spring Washer 1 11 Screw 2 22 Bolt 3 2st 50D2 2011 ...

Page 229: ......

Page 230: ... the outboard motor in test tank for ready to engine starting 2 Attach tachometer to outboard motor without cranking 3 Attach peak voltage adapter to tester The peak voltage adapter plug a there is a positive pin and negative pin Connect Red V positive pin of peak voltage adapter to positive terminal of digital circuit tester 4 Set selector of digital circuit tester to DCV mode a 5 Connect pin a o...

Page 231: ...age is the lower limit if it is above this as for good condition The faulty part it specifies input voltage being properly if there is a unit whose output voltage is not properly that is the faulty part 4 Inspection date Resistance test reference Ignition coil Primary 0 4 0 6Ω Secondary 6 8 10 2 kΩ Pulser Coil L W B 1 160 220Ω WB B 2 160 220Ω WR B 3 160 220Ω Exciter Coil W G B Or B Or W G 520 720Ω...

Page 232: ...uel injector connectors when checking spark 1 This test can be made without removing parts 1 Disconnect plug cap 1 from spark plugs 2 Connect plug cap 1 to spark tester 3 Connect spark tester clip to spark plug tip electrode Spark Tester P N 3F3 72540 0 4 Start engine and check spark Check spark system when sparks are weak Spark Performance 10 mm 0 4 in or over 2 Inspection of Plug Cap Terminal Re...

Page 233: ...l plate ass y and measure resistance between terminals Replace pulser coil if the resistance is out of specified range Pulser Coil Resistance Blue L White W Black B 1 White W Black B Black B 2 White W Red R Black B 3 160 220 Ω Measurement of peak volts 1 Connect Peak Voltage adapter to pulser coil connectors 2 Measure peak volts at shown below Replace pulser coil or check connection of wire harnes...

Page 234: ...k volts at shown below Replace exciter coil or check connection of wire harness if the peak volts out of specified range Exciter Coil Peak Volts Reference Orange Or White W Green G 185 V at cranking 210 V at idling 210 V at 1 500 r min 6 Inspection of C D unit Measurement of peak volts 1 Connect Peak Voltage adapter to C D unit connectors 2 Measure peak volts at shown below Replace C D unit or che...

Page 235: ...Stop Switch 1 Check conduction of stop switch and replace if not conductive This test can be made without removing parts Switch Position Brown Br Black B c Remove lock a Attach lock b Press switch c 8 18 2st 50D2 2011 Raider 50 Wiring Diagram ...

Page 236: ...ystem 9 3 Ignition System 9 4 Fuel System 9 6 Compression Pressure 9 7 2 Engine starts but stalls soon 9 8 Fuel System 9 8 Ignition System 9 9 Compression Pressure 9 10 3 Idle engine speed will not stabilize 9 11 4 Rapid opening of throttle fails acceleration 9 12 5 Gear shifting cannot be made normally 9 13 ...

Page 237: ...OK Troubleshooting ...

Page 238: ...and engine installation are normal For mechanical troubleshooting refer to relevant troubleshooting section in this chapter For checking and servicing the machine refer to service procedures described in this manual to perform the works safely 2 Power Unit 9 ...

Page 239: ......

Page 240: ...Compression ...

Page 241: ...hose securely connected YES Check if fuel contain water fuel filter is clogged Does fuel contain NO water or is fuel filter clogged NO Check fuel hose for bend or fuel leak Secure hose to bladder YES Is fuel hose bent NO Clean fuel bladder or does fuel leak Check carburetor Flush fuel system from the hose YES Replace defective part with new one 9 8 2st X50D2 2011 ...

Page 242: ...ace WARNING When testing put electrode cap assuredly to prevent direct contact with spark tester wiring and leak of electrical current Keep inflammable gas fuel oil and fat away from tester to prevent them from catching sparks YES Check fuel system NO Normal YES Check ignition coil resistance Normal YES Check CD unit 2st X50D2 2011 Repair or replace plug cap NO Replace ignition coil 9 9 9 ...

Page 243: ...OK Troubleshooting Compression Pressure NO Check compression YES Replace defective parts and seal with new one 9 10 2st X50D2 2011 No Power Insure dewatering Valves are closed Close dewatering Valve ...

Page 244: ...ystem not working Check rods to insure working properly Tighten as required The dewatering system is mechanical and should not be prone to failure 3 Fuel is not discharging after submersion Check brass valves that get initiated when the dewatering slide is moved toward back of engine Blow out line if still does not work replace all three valves one assembly ...

Page 245: ...OK Troubleshooting ...

Page 246: ...Safety Jet Option to Raider 50 Part No SJ 001 Stator P N SJ 001 A1 Impeller P N SJ 001 A2 Shroud P N SJ 001 A5 Coupler P N SJ 001 A3 Cone P N SJ 001 A4 ...

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