TOHATSU 2 Stroke Cylinder Series Service Manual Download

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SECTION 7

7-60

1-/ 2-Cylinder

Remove Brush Assembly

1. Remove screws

(1)

Remove brush assembly

(1)

carefully guiding the starter

motor terminal

(2)

through the bushing

(3)

Install Brush Assembly

1. Apply genuine grease to bearing cup

(1)

2. Install brush assembly

(1)

. Make sure that the starter motor

terminal

(2)

is fully seated in the bushing

(3)

Assemble Starter Motor

NOTE

Bolts for models 25 / 30 / 40 may not be available as
separate parts. Check current Parts Catalog for
availability.

1. Clean commutator

(1)

with fine emery cloth.

T1526

17 18

T1530

T1531

T1530

T1535

T1529

Summary of Contents for 2 Stroke Cylinder Series

Page 1: ...PNo 003 21035 1 0509 NB 1000 Printrd in Japan 1 05 8 23 1 33 PM 1...

Page 2: ...TABLE OF CONTENTS Service Safety General Service Information Fuel System Powerhead Midsection Gearcase Electrical System 1 2 3 4 5 6 7 1 2 Cylinder i...

Page 3: ...1 2 Cylinder 1 1 Introduction 1 2 Safety Statements 1 2 Safety Precautions 1 3 Workmanship Standards 1 5 Test Tank Guidlines 1 7 SECTION 1 SERVICE SAFETY TABLE OF CONTENTS...

Page 4: ...ervicing them This section discusses safe shop practices and general safety concerns relevant to the operations performed throughout this manual Read this section carefully and follow all safety state...

Page 5: ...nts such as spark plugs and coils Never wear jewelry or loose clothing near a running engine Keep hands arms and hair away from the flywheel Never touch electrical components when the engine is runnin...

Page 6: ...us burns Avoid contact with battery acid lf battery acid is spilled on skin thoroughly wash area with plenty of water If battery acid gets into eyes flush eyes with water for at least 15 minutes and g...

Page 7: ...Shop Environment Make sure the shop and your work area are properly ventilated Shops must be equipped with the proper tools and safety equipment such as fire extinguisher eye flushing device and firs...

Page 8: ...torque each bolt to final specification Special torque specifications are listed at the beginning of each section Standard torque specifications for common fasteners are listed in Section 3 11 Use lub...

Page 9: ...seizure Make sure water temperature in the tank does not exceed 77 F 25 C Repeated use introduces carbon into the water which can adhere to the engine cooling system and degrade its ability to cool t...

Page 10: ...ine Specifications 2 17 Lubrication Chart 2 20 Periodic Inspections 2 24 Break ln Procedure 2 27 Tune Up Procedure 2 28 Emergency Stop Switch and Lanyard 2 29 Synchronization and Linkage Adjustments 2...

Page 11: ...torque value for a certain fastener is not listed in the Special Torque Values chart at the beginning of each section Rather than just repairing a bad part use repair kits and overhaul kits when appl...

Page 12: ...nce U S per minute foot foot pound foot pound force per minute gram gallon U S per hour gallon U S gear lubricant General Motors Company horsepower U S inside diameter inch inch pound kilogram kilogra...

Page 13: ...f Torque ft lb x 1 3558 N m ft lb x 0 1383 kg m in Ib x 0 1130 N m in lb x 0 0115 kg m kg m x 7 2330 ft lb kg m x 86 8000 in lb kg m x 9 8070 N m N m x 0 7376 ft lb N m x 8 8510 in lb N m x 0 1020 kg...

Page 14: ...apply only when a special torque specification is not listed in the Special Torque Values chart at the beginning of each section Size Torque in lb ft lb N m kg m M4 10 17 0 8 1 4 1 2 0 1 0 2 M5 26 35...

Page 15: ...er 2 5 3 5 For 3 5B Tool Description Part No Components Flywheel Puller Assembly 309 72214 0 or 3V1 72211 0 Arm Adapter Pressing Bolt Bolts Spring Pin Tool 345 72227 0 Pin Punch Spring Pin Tool 345 72...

Page 16: ...bly 369 72900 0 Backlash Measuring Tool 369 72740 0 Kit Sub Assembly 369 72730 0 Except and Arm 369 72727 0 Clamp Assembly 3B7 72720 0 Spring Pin Tool 3 mm Dia 345 72227 0 Pin Punch Spring Pin Tool 3...

Page 17: ...72900 0 Backlash Measuring Tools 369 72740 0 Kit Sub Assembly 369 72730 0 Except and Arm 3B2 72727 0 clamp Assembly 3B7 72720 0 spring Pin Tool 3 mm Dia 345 72227 0 Pin Punch spring Pin Tool 3 mm Dia...

Page 18: ...Bevel Gear B Nut 346 72231 0 Socket Bevel Gear B Nut 350 72232 0 Needle Roller Bearing Puller 3C8 72700 0 Kit Flange A 3C8 72701 0 Shaft 346 72702 0 Shaft Stopper A 350 72704 0 Washer 346 72707 0 Nut...

Page 19: ...002 0 Collar 350 72245 0 Nut M10 930191 1000 2 nuts Clamp Assembly 3B7 72720 0 Bolt H625 910191 0625 for lower pump case Plate Dial Gauge 3B7 72729 0 Spring Pin Tool 3 mm Dia 345 72227 0 Pin Punch Spr...

Page 20: ...72231 0 Wrench Socket Bevel Gear B Nut 346 72232 0 Socket Needle Roller Bearing Puller 3C8 72700 0 Kit Flange A 3C8 72701 0 Shaft 346 72702 0 Shaft Stopper 346 72704 0 Washer 346 72707 0 Nut 12P 1 25...

Page 21: ...245 1 Cone Disk Spring d 12 3B7 72734 0 2pcs Nut M10 930191 1000 Clamp Assembly 3B7 72720 0 Bolt H625 910191 0625 for lower pump case Dial Gauge Plate 3B7 72729 0 Spring Pin Tool A 3 mm Dia 345 72227...

Page 22: ...cket Bevel Gear B Nut 345 72232 0 Socket Needle Roller Bearing Puller 3C8 72700 0 Kit Flange A 3C8 72701 0 Shaft 346 72702 0 Shaft Stopper A 346 72704 0 Washer 346 72707 0 Nut 12P 1 25 346 72706 0 Gui...

Page 23: ...Spring d 12 345 72763 0 3 pcs Nut M10 930191 1000 Clamp Assembly 3B7 72720 0 Bolt H625 910191 0625 for lower pump case Plate Dial Gauge 3B7 72729 0 Spring Pin Tool A 345 72227 0 Pin Punch Spring Pin...

Page 24: ...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 El...

Page 25: ...eaning Pads Scotch Brite Abrasive Pads Low Temperature Lithium Grease Genuine Grease or Equivalent Friction Surface Marine Grease Power Trim Tilt Fluid Nisseki power torque fluid or GM approved automa...

Page 26: ...64111 0 3 5B2 3F0 64111 0 5 369 64111 0 8 9 8 3B2 64111 0 9 9 15 18 362 64111 0 25 30 364 64111 5 40 348 64111 0 Powerhead Number of Cylinders 2 5 3 5 5 1 8 9 8 9 9 15 18 25 30 40 2 Displacement 2 5 3...

Page 27: ...S fl oz 420 mL T1044 1 2 Clutch System 2 5 3 5A None Forward gear only 3 5B Dog clutch type Forward gear and Neutral only 5 8 9 8 9 9 15 18 25 30 40 Dog clutch type Forward Neutral Reverse Electrical...

Page 28: ...9 15 18 25 30 Y W 0 65 0 98 Y B 0 31 0 47 W B 0 37 0 55 40 Y W 0 65 0 98 Y B 0 31 0 47 W B 0 37 0 55 lgnition Coil Resistance 25 Primary Coil 2 5 3 5 0 18 0 24 5 0 2 0 38 9 9 15 18 25 30 40 0 2 0 3 S...

Page 29: ...se or equivalent Friction Surface Marine Grease Non flammable solvent Genuine Gear Oil or API Grade GL5 80 90 1 2 3 4 T1942 T1943 T1944 T1945 T1946 T1947 T1948 Lubrication Points and Lubricant Engine...

Page 30: ...quency Fig Location Lube Type 2 5 3 5 5 8 9 8 9 9 15 18 25 30 40 Hours Choke Mechanism 50 Clamp Screw 50 Grip 50 Handle 50 Hook Lever Mechanism 50 Propeller Shaft 50 Recoil Starter 50 Reverse Lock 50...

Page 31: ...ely dry all components and reassemble Lubrication Points and Lubricant Engine Model Frequency Fig Location Lube Type 2 5 3 5 5 8 9 8 9 9 15 18 25 30 40 Hours Reverse Lock 50 Shift Lever Stopper 50 Sta...

Page 32: ...urs of operation and prior to prolonged storage such as over the winter Lubrication Points and Lubricant Engine Model Frequency Fig Location Lube Type 2 5 3 5 5 8 9 8 9 9 15 18 25 30 40 Hours First Ge...

Page 33: ...applicable Driveshaft housing bolts Gearcase bolts Propeller shaft housing bolts Propeller nut Lower engine cover mounting bolts Engine mounting bolts Torque to specification Gearcase Check oil level...

Page 34: ...e following Water pump and impeller Water pipe Thermostat Exhaust cover Exhaust pipe Engine base Reverse gas passage Power head Cleaning Inspect and remove carbon deposits from the following Cylinder...

Page 35: ...allation Replace when anode has been reduced to 2 3 its original size 1 3 eroded See Anodes Inspection and Testing in this section Water Intake Screens Check for blockages Remove and clean as required...

Page 36: ...ne to oil premix Operatethe engine at minimum idle speed ONLY Verify a steady stream of water from the cooling water check port and idle port on the engine indicating the water pump is functioning pro...

Page 37: ...operation 1 Inspect engine for leaks missing loose or damaged parts or other visible defects 2 Remove each spark plug and check for fouling cracks in ceramic and incorrect gap Replace plugs if needed...

Page 38: ...er discharge from check port and idle port Fuel leaks from mating surfaces of crankcase Fuel leaks from mounting surface of intake manifold Cooling water leaks from mating surfaces of cylinder head Co...

Page 39: ...d before engine is operated SYNCHRONIZATION AND LINKAGE ADJUSTMENTS To ensure consistent engine idling and smooth operation throughout the full RPM range it is important that each procedure be perform...

Page 40: ...tes in the proper direction B 9 9 15 18 Engines 9 9 15 18 engines have timing marks on the side of the coil plate which must be aligned to the seam of the mating surfaces of the crankcase C 25 30 Engi...

Page 41: ...g using a timing light 2 Two marking lines are cast on top of the flywheel topand lead angle BTDC 30 3 Check the matching surface of the crankcase Throttle Setting Full Open Full Closed In Gear Engine...

Page 42: ...tle valve is closed fully when the advancer lever is moved 8 9 8 Adjustment Procedure 1 Move the advancer lever with a finger to fully open the carburetor throttle valve At this time adjust the length...

Page 43: ...ouches the full open stopper bolt when throttle is fuIIy opened Throttle Setting Full Open Full Closed In Gear Engine Match Mark Target RPM Match Mark Target RPM 9 9D BTDC 22 4500 5300 ATDC 3 800 9 9D...

Page 44: ...where the magneto coil plate timing mark fully closed side meets the ignition timing inspection line crank case mating surface CAUTION After making adjustments check that the advancer arm moves firml...

Page 45: ...R ADJUSTMENT There are two types of carburetor adjustments One applies to the 2 5 3 5 HP engines only The remaining one and two cylinder engines use a different carburetor adjustment procedure 2 5A 3...

Page 46: ...9 15 18 Models 25 30 Models 40 Model NOTE Adjust idling speed after warm up operation Adjustment Procedure Set the pilot adjust screw to the standard reverse turns and adjust the engine rpm by using t...

Page 47: ...water Inspect the sacrificial trim tab 1 for erosion Inspect the mid section or lower unit anode 2 for erosion Powerhead Anode The powerhead is protected by an anode mounted in the cylinder head or c...

Page 48: ...Requirements 3 4 Troubleshooting 3 6 Description of Operation 3 8 Separate Fuel Tank 3 12 Fuel Hose and Primer 3 13 Integral Fuel Tank 3 14 Fuel Filter 3 15 Fuel Pump 3 17 Carburetors 3 20 Butterfly...

Page 49: ...ne is fully assembled always run the engine momentarily to pressurize the fuel system Then check for leaks 4 Never attempt to run the engine with any fuel system component removed or disconnected 5 Ch...

Page 50: ...r Mounting Bolt 40 55 4 6 6 2 0 47 0 64 40 55 4 6 6 2 0 47 0 64 40 55 4 6 6 2 0 47 0 64 Air Silencer Cover Bo lt Screw 13 2 16 8 1 5 2 0 0 15 0 20 13 2 16 8 1 5 2 0 0 15 0 20 40 55 4 6 6 2 0 47 0 64 2...

Page 51: ...IREMENTS Acceptable Fuel Any premium gasoline with pump posted octane rating over 89 research octane rating of 91 and with no more that 10 Ethanol by volume Unacceptable Fuel Gasoline with more than 5...

Page 52: ...1 gasoline oil mixture is required during engine break in Refer to Break In Procedure in Section 2 Premixing A 50 1 gasoline oil mixture 2 oil is required New engines or reconditioned powerheads requi...

Page 53: ...ment in the fuel tank pickup tube Checks Symptom Empty fuel tank Low fuel in tank Fuel tank air vent closed Poor quality or old fuel Water in fuel system Fuel hose pinched or disconnected Restricted f...

Page 54: ...leakage Check valve sticking open or closed Ruptured diaphragm Warped inlet manifold Manifold gasket leakage Faulty reed valve operation or broken valve Reed valve gasket leakage OIL MIXTURE Hard to...

Page 55: ...p 2 5 3 5 Fuel Flow Prior to starting the air vent on fuel cap 1 and fuel cock 2 must be opened The difference in air pressure and gravity force fuel from the fuel tank to the float chamber 3 through...

Page 56: ...k 1 by vacuum pressure on the suction side of the fuel pump through the fuel filter 2 and into fuel pump 3 Fuel flows from the fuel pump into the carburetor float chamber 4 Fuel is drawn from the floa...

Page 57: ...ustion under varying operating conditions Pilot System The pilot system is a slow speed system consisting of the slow jet slow air jet pilot outlet bypass and pilot adjusting screw At 1 4 throttle and...

Page 58: ...main system in the carburetors is a high speed system consisting of the main jet main nozzle and main air jet As the throttle valve opens mixed fuel 14 enters the carburetor and flows from the carbur...

Page 59: ...ct fuel line from fuel tank 2 Empty remaining fuel from tank and properly dispose 3 Fill tank 1 4 with fresh gasoline and install cap Rigorously shake tank for 30 seconds to loosen dirt particles 4 Em...

Page 60: ...the engine Disassembly NOTE Note direction of fuel flow as indicated by the arrow on the primer bulb 1 Remove and discard hose clamps 1 and primer bulb clamps 2 as required 2 Remove tank connector 3 a...

Page 61: ...is provided with a 0 66 gal 2 5 L integral fuel tank NOTE The model 5BS engine has a standard 3 1 gal 12 L separate tank Removal 1 Close air vent 1 and fuel cock 2 2 Remove cover 2 5 and 3 5 HP Only...

Page 62: ...s is located in the fuel cock The fuel cock must be removed from fuel tank to inspect the fuel filter Installation 1 lnstaII fuel cock in fuel tank 2 Install fuel tank 1 3 Attach fuel line 2 to fuel t...

Page 63: ...filter 2 and slide down the hose 2 Separate the fuel filter from the hoses and discard 3 Replace with new fuel filter 4 Attach hoses and secure clips Bowl Type Fuel Filter Cleaning and Inspection 1 lf...

Page 64: ...Inspection procedure to ensure proper orientation of internal components NOTE Models 5 8 9 8 9 9 15 and 18 are equipped with carburetor mounted fuel pump Disconnect fuel hoses from pump remove the mou...

Page 65: ...resin film white opaque diaphragm 10 which no longer requires the guide plate and spring 4 Remove and discard all serviceable gaskets and diaphragms 5 Remove aIl check valves 11 from pump body Cleani...

Page 66: ...plate 4 and spring 5 if equipped for deformation and tension 5 Inspect gasket between crankcase and fuel pump for dryness crankcase mounted pumps Assembly 1 Install all check valves in pump body 2 Ful...

Page 67: ...r 2 Turn off fuel supply fuel cock and remove fuel hose 1 from carburetor 3 Remove carburetor cover 2 4 Loosen clamp bolt 3 and remove carburetor Disassembly CAUTION Use the following precautions duri...

Page 68: ...screw cap 6 and remove throttle assembly 7 If necessary disassemble throttle assembly 3 Remove float chamber 8 and float 9 4 Remove float valve assembly 10 and needle valve seat 11 5 Remove main jet a...

Page 69: ...ion CAUTION DO NOT inspect passages or holes with wire or similar materials Doing so may scratch or enlarge jet holes and alter the fuel air ratio NOTE Before inspection all carburetor components must...

Page 70: ...with isopropyl alcohol 6 Inspect aIl gasket surfaces for damage 7 Visually inspect the carburetor body float chamber drain screw and all other parts for damage Assembly CAUTION Fuel and air passages m...

Page 71: ...lf removed install choke assembly Use a drift to peen end of shaft screw to prevent nut from coming loose 8 If disassembled assemble the throttle assembly 9 Align the groove in the slide with the pin...

Page 72: ...4 Attach fuel hose 1 5 Install motor cover and open fuel cock Adiustments NOTE An access hole in the motor cover allows idle adjustment with the motor cover on 1 IDLE With the throttle in the START p...

Page 73: ...re richer BUTTERFLY VALVE CARBURETORS Removal 1 Remove the air silencer 1 2 Remove the carburetor throttle rod 2 and choke linkage 3 3 Disconnect the choke knob 4 or choke solenoid plunger hook as req...

Page 74: ...to avoid damaging the carburetor jets DO NOT disassemble the choke or throttle butterfly valve assembly components They are NOT serviceable Throttle stop screw spring has higher tension than pilot adj...

Page 75: ...OT expose plastic parts to carburetor cleaner 1 Clean aIl metal components using a mild aerosol solvent or isopropyl alcohol Use a soft bristle brush to remove gummy deposits 2 Clean plastic parts wit...

Page 76: ...nd seat must be replaced as an assembly lf the seat is non serviceable replace the carburetor Check float valve pin 1 and float chip if applicable for damage Check float 2 for damage and signs of fuel...

Page 77: ...uel and air passages must be kept clean Dust dirt gum and varnish cause poor running and increased wear NOTE Before proceeding be sure alI components are completely clean and dry and all replacement p...

Page 78: ...attern 9 Install drain screw and new o ring gasket lnstallation 1 Clean the carburetor mounting surfaces on the intake manifold with isopropyl alcohol 2 Install new carburetor base gasket dry 3 Mount...

Page 79: ...il starter or flywheel cover as applicable refer to Powerhead section 5 Remove the intake manifold 6 Remove the reed valve assemblies from the manifold or lift them from the crankcase as applicable DO...

Page 80: ...must be flat within 0 004 in 0 10 mm NOTE All intake manifold components must be perfectly clean before assembly Use isopropyl alcohol DO NOT use a carburetor cleaner or a soaking tank 2 5 3 5 5 8 9...

Page 81: ...eed valve screws to 6 1 7 8 in lb 0 7 0 9 N m 0 07 0 09 kg m NEVER reinstaII the used reed valve screws because the effect of the adhesive has been lost and may lead to reed valve failure during opera...

Page 82: ...4 2 Service Specifications 4 3 Troubleshooting 4 6 Description of Operation 4 7 Cylinder Compression Test 4 8 Thermostat 4 9 RPM Performance Test 4 10 Recoil Starter 4 11 Flywheel 4 20 Powerhead 4 23...

Page 83: ...hing or jewelry Keep hair hands and clothing away from the flywheel Check entire fuel system for leaks after servicing the powerhead to prevent fire or explosion Make sure all ignition and electricaI...

Page 84: ...18 0 33 78 2 539 5 5 0 002 0 05 1 575 0 002 40 0 05 N A 2 165 55 0 0008 0 0020 0 02 0 05 0 008 0 016 0 2 0 4 56 9 392 4 0 125 6 52 0 002 0 05 1 654 0 002 42 0 05 0 984 0 002 25 0 05 1 969 50 0 0008 0...

Page 85: ...2 0 413 10 5 0 551 14 0 591 15 0 069 1 75 0 630 16 0 866 22 0 472 12 0 118 3 0 551 14 0 709 18 0 787 20 0 079 2 0 787 20 1 024 26 0 472 12 0 118 3 0 551 14 0 709 18 0 787 20 0 079 2 0 669 17 0 906 23...

Page 86: ...range Analog Multimeter Electronic Specialties Model M 530 or equivalent Digital Pulse Tachometer 10 6000 RPM Electronic Specialties Model 321 or equivalent Industrial Thermometer minimum 300 F 150 C...

Page 87: ...ing crankcase Defective thermostat Fouled defective or incorrect spark plug wrong gap setting Worn or defective cylinder piston rings or warped head Blown cylinder head or engine base gasket Worn conn...

Page 88: ...piston starts to move toward top dead center TDC the interior of the crank case is made vacuum pressure causing the reed valve to open and the gas mixture to be taken into the crankcase As the piston...

Page 89: ...ecified pressure is obtained Compression variation among cylinders should not exceed 15 psi 103 kPa 1 05 kg cm2 on two cylinder engines If variation of cylinder compression on two cylinder engines exc...

Page 90: ...ith gasket sealant Mount gasket on cap 2 3 InstaIl thermostat cap and gasket and torque to specification Function Test 1 Suspend thermostat and thermometer in a heat resistant container filled with wa...

Page 91: ...ngine at NEUTRAL idle and verify specified RPM is obtained lf test tank conditions permit run engine in forward gear at trolling and full throttle speeds and check for correct RPM 4 lf test results va...

Page 92: ...em must be disabled to prevent accidental engine startup during servicing of the recoil starter Removal 5 8 9 8 9 9 15 18 25 30 40 1 Remove the neutral start mechanism components and remove the recoil...

Page 93: ...note of the direction in which the ratchet guides A and B are mounted Note position as it is essential they be returned in the same orientation during reassembly CAUTION Remove the starter shaft bolt...

Page 94: ...The 3 5B 2 engine is equipped with a gear shift allowing the engine to be set to NEUTRAL or FORWARD only Neither 2 5 or 3 5 is provided with a neutral LOCKOUT for STARTUP WARNING Ignition system must...

Page 95: ...it in the notch of the case 3 While holding the starter case 1 and the rope 4 turn the reel slowly to loosen the starter spring 2 4 Detach E ring 10 5 Remove the friction plate 9 friction spring 6 rat...

Page 96: ...andle for damage Assembly 5 8 9 8 9 9 15 18 25 30 40 For assembling use the procedure reverse to the disassembly while observing the following notes When setting the starter spring 2 on the starter sp...

Page 97: ...he starter locking rod the starter locking cam shaft and the starter handle 2 Verify that the ratchet operates when the proper load is applied to the ratchet Set ratchet face up apply grease and measu...

Page 98: ...d fix the starter handle When attaching the ratchet be careful of the direction Adjust the starter spring tension after completing the assembling by putting the rope into the notch of the reel and tur...

Page 99: ...SECTION 4 4 18 1 2 Cylinder T2201 16...

Page 100: ...led NEVER return engine to customer with mechanism disconnected or not functioning properly FLYWHEEL NOTE Flywheel magneto must be of a particular strength in order to run the ignition system Flywheel...

Page 101: ...ulley 2 Determine the direction of rotation for removing flywheel nut by running your thumbnail along the threads of the crankshaft CAUTION Past production models 9 9 15 18 and 40 may have reverse thr...

Page 102: ...t 2 Check flywheel key is inserted in crankshaft 3 Align flywheel keyway and install on crankshaft lnstall the flywheel washer 4 Install puller arm 1 on flywheel using bolts 2 Hold puller arm and torq...

Page 103: ...POWERHEAD 4 23 1 2 Cylinder POWERHEAD Typical 1 Cylinder T1676...

Page 104: ...SECTION 4 4 24 1 2 Cylinder Typical 2 Cylinder T1677...

Page 105: ...ical connections as applicable Remote control or main key switch wire harness Neutral safety switch 4 Disconnect fuel INPUT hose from fuel filter 5 Disconnect pilot water hose from exhaust cover 6 Com...

Page 106: ...dels is attached directly to the crankcase Therefore it is removed after dividing the crankcase Cylinder Head 3 Remove and inspect the thermostat See Thermostat this section 4 Remove the cylinder head...

Page 107: ...ase from the cylinder block NOTE Start with the bolts farthest from the center of the crankcase and work inwald 9 Tap the tapered portion of the crankshaft 3 with a rubber mallet to loosen it Lift the...

Page 108: ...pin clip 6 from both sides of each piston Discard the clips 12 Tap out the piston pins using specified piston pin tool 7 13 Remove the piston and bearing 8 from the connecting rod 14 Remove each pisto...

Page 109: ...apy water Air dry the cylinder block and crankcase Dry all holes and passages with low pressure compressed air 5 Coat the cylinder walls with genuine engine oil or certified TC W3 oil to protect them...

Page 110: ...sion V blocks or an alignment jig Slowly rotate crankshaft and record measurement at each crankshaft bearing 1 and at both ends of the crankshaft If deflection is more than 0 002 in 0 05 mm replace th...

Page 111: ...Install a universal bearing puller with bearing retainer plate and remove lower main bearing 2 from the crankshaft See powerhead Assembly procedure for installation NOTE DO NOT fully disassemble the c...

Page 112: ...iston to square the ring in the bore Use the thickness gauge set Part No 353 72251 0 to measure the ring end gap Model Standard Bore Diameter in mm Standard Piston Clearance in mm Repair Limit Piston...

Page 113: ...certified TC W3 oil All serviceable gaskets and seals must be replaced Model Standard Ring End Gap in mm Repair Limit Ring End Gap in mm 2 5 3 5 0 007 0 013 0 18 0 33 0 031 0 8 or over 5 0 008 0 016...

Page 114: ...removed slide and install the upper main bearing onto crankshaft 6 4 lf lower main bearing was removed coat lower end of crankshaft with genuine engine oil or TC W3 oil and install the bearing Piston...

Page 115: ...use old clips Cylinder Block and Crankcase 7 Coat the pistons rings and cylinder walls with genuine engine oil or TC W3 oil lnstall the bearing washers or thrust plates model 40 into cylinder block gu...

Page 116: ...block 10 Install crankcase mounting bolts and torque to specification NOTE Start with the bolts closest to the center of the crankcase and work outward Cylinder Head 11 Head gasket dressing not requi...

Page 117: ...ction 3 16 Install all carburetion ignition and electrical components on the powerhead using the following guidelines Assemble as much as possible before mounting powerhead to engine midsection Follow...

Page 118: ...propriate wiring diagram in Section 7 for electrical box connections Leave ignition system disabled 7 Complete the following operations Tiller models Connect starter lock rod 2 Secure throttle cable 3...

Page 119: ...Precautions 5 2 Service Specifications 5 3 Tiller Steering Handle 5 4 Lower Engine Cover 5 18 Driveshaft Housing 5 19 Stern and Swivel Brackets 5 25 Swivel Bracket and Reverse Lock 5 33 SECTION 5 MIDS...

Page 120: ...r to clean or dry parts make sure air supply is regulated not to exceed 25 psi 172 kPa 1 76 kg cm2 Always inspect and test the start in gear prevention system before returning engine to customer Most...

Page 121: ...scale 0 0001 in 0 01 mm Description Torque in Ib ft Ib N m kg m Threadlocker Model 2 5 3 5 5 8 9 8 9 9 15 18 25 30 40 Engine Mounting Bolt Bracket Bolt Nut Tilt Tube Nut 99 133 11 1 15 1 1 14 1 54 8 6...

Page 122: ...ressing Silicone Sealant Permatex Hi Temp RTV Silicone Gasket Super Bond Adhesive Permatex Super Glue Gel Cleaning Pads Scotch Brite Abrasive Pads Isopropyl Alcohol Cleaning Solvent Gasket Remover Gen...

Page 123: ...tle The 8 9 8 engine tiller arm steers and uses dual cables to control the throttle The 9 9 15 18 25 30 and 40 engine tiller arms steer control throttle through a pinion throttle linkage and can be se...

Page 124: ...ttle shaft 3 Fully disassemble all remaining components as illustrated Cleaning and Inspection All worn damaged or missing parts must be replaced 1 Wipe off aIl excess grease from components Thoroughl...

Page 125: ...spect all plastic and rubber bushings and spacers grip 2 and friction piece 5 for cracks or deformation caused by wear 4 Check all fasteners for thread damage aIl washers for deformation 5 Replace thr...

Page 126: ...DO NOT lubricate friction piece 5 1 Apply spray lubricant to the throttle cables Work the cables back and forth to ensure full coverage under the protective covering 2 Assemble aIl components onto thr...

Page 127: ...anism CAUTION Make this adjustment only after fitting the power unit to the lower unit CAUTION Apply grease on sliding parts and ball joints of the advancer arm bushing CAUTION Adjust link rods 5 60L...

Page 128: ...djusting when Throttle is Fully Open 1 Rotate the throttle grip fully toward the FAST side With advancer arm nearest the top stopper bolt 2 Adjust as shown in the preceding table using the link rod 5...

Page 129: ...ard the SLOW side Advancer Arm closest to lower stopper screw Adjust the stopper bolts at the position where the timing mark 1 3 ATDC of the magneto coil plate and the ignition timing inspection line...

Page 130: ...m the steering bracket 3 Remove the Spring pin 12 from the universal pinion 1 4 Remove the R pin 13 from the cable pin 14 5 Remove the throttle shaft supports 3 6 Remove the throttle shaft B 2 and the...

Page 131: ...nstalling the tip of inner throttle shaft in the proper orientation for the link rod 4 lnstall the universal pinion 3 after coating with grease Maintain the relationship between inner throttle shaft a...

Page 132: ...vancer Arm 2 Stud Bolt 3 Advancer Arm Bushing 4 5 Rod Joint 5 BaIl Joint Cap 6 BalI Joint B 7 Advancer Link Rod 5 50L 8 Handle Link Rod 5 75L 9 Throttle Cam 10 Throttle Cam Bushing 11 Wave Washer 12 T...

Page 133: ...5 Starter Lock Arm Rod 6 Starter Lock Arm Rod Snap 7 Starter Lock Lever Shaft 8 Starter Lock Lever Shaft E ring 9 Starter Lock Lever Item Description 10 Starter Lock Spring 11 Starter Lock Rod 12 Sta...

Page 134: ...link rod so that the START 1 match mark on the handle grip is aligned to the START position on the tiller handle NOTE The R mark is the specified opening position for reversing the engine 3 Set the i...

Page 135: ...to the crankcase mating surface Under this state adjust the advancer arm stopper bolts 1 so that the advancer arm stops at the throttle valve full open and full close positions and lock the bolts wit...

Page 136: ...e 2 and grommet 3 9 9 15 18 Throttle Shaft Removal 1 Remove throttle shaft support 1 2 Remove throttle shaft 2 25 30 40 Throttle Shaft Removal 1 Remove throttle shaft ball joint 1 2 Remove upper and l...

Page 137: ...wn remove the nut from each lower rubber mount bolt 2 Do not remove the bolts CAUTION Driveshaft housing is free to fall if lower rubber mount bolts are removed 7 Hold driveshaft housing securely and...

Page 138: ...riveshaft housing are aligned with dowel pins and may be difficult to separate Avoid damage to the mating surfaces and gently pry sections apart if necessary Model 40 only 3 Remove exhaust pipe 1 wate...

Page 139: ...IDSECTION 5 21 1 2 Cylinder NOTE The 5 engine does not have an exhaust pipe Water is drawn through an inlet located in front of the propeller and pumped out through a tube beneath the engine T1619 7 7...

Page 140: ...SECTION 5 5 22 1 2 Cylinder 8 T1620...

Page 141: ...r Verify all carbon deposits gasket adhesives and threadlocker residue have been removed 3 Inspect water pipe 5 for kinks or obstruction Replace as needed 4 Inspect exhaust pipe 6 engine base 7 and dr...

Page 142: ...ousing 2 Assemble the lower rubber mount components and install them into the drive shaft housing 3 Apply Loctite 243 to bolt threads and torque to specification 4 Install clip 5 Assemble the upper ru...

Page 143: ...llustrated Models 2 5 3 5 Model 5 Models 8 9 8 Models 9 9 15 18 Type l NOTE TYPE I has a metal rod type stem bracket bolt similar to smaller engines TYPE ll has a pipe style stem bracket bolt similar...

Page 144: ...5 3 5 Stern and Swivel Bracket Disassembly 1 Remove the thrust rod 4 2 Remove stern bracket bolt nut and washers 1 9 2 3 Remove distance shaft nuts and washers 5 6 7 4 Remove thrust support 3 5 Separa...

Page 145: ...arm lock and springs 12 3 Remove swivel bracket bolts 13 4 Remove drive shaft housing 5 Remove thrust plates 9 6 Remove both upper and lower bushings 7 8 7 Remove the thrust rod 6 8 Remove the stern...

Page 146: ...ON 5 5 28 1 2 Cylinder 8 9 8 Stern Bracket Disassembly 1 Remove tilt stop assembly 1 2 Remove stern bracket bolt 2 nut 3 and washers 4 and 5 3 Remove thrust rod 6 4 Remove distance plate 7 T1644 3 3 3...

Page 147: ...pe stern bracket bolt similar to the smaller engines Typel lI has a pipe style stern bracket bolt similar to larger engines Type ll stern bracket bolts have nylon caps on both ends AIl Type ll stern b...

Page 148: ...tern Bracket 1 Remove thrust rod 1 2 Remove nuts 2 3 Remove pipe caps on bracket bolt 3 4 Holding bracket bolt nut 4 with wrench remove bracket bolt nut 5 5 Remove bracket bolt 6 6 Remove ground wires...

Page 149: ...Stern Bracket Disassembly NOTE Only minor variations exist between 25 30 and 40 model brackets 1 Remove the reverse lock spring 1 2 Remove the split pin from the reverse lock rod 2 and remove the rev...

Page 150: ...everse lock arm 6 5 Remove the reverse lock link 7 6 Remove the reverse lock lever shafts 8 and remove the reverse lock lever 9 7 Remove the thrust rod 10 8 Remove the bracket distance piece nuts 11 a...

Page 151: ...rs may not prevent full assembly of the bracket components Reference preceding illustrations to ensure correct orientation of parts NOTE During assembly apply genuine grease or equivalent friction sur...

Page 152: ...st rod 4 Install the reverse lock lever and shaft 5 Install the reverse lock link if applicable and cotter pin 6 Install reverse lock arm and shaft 7 Install reverse lock lever spring 8 Install the re...

Page 153: ...1 2 Cylinder 6 1 General Precautions 6 2 Service Specifications 6 3 Water Pump 6 5 Gearcase 6 10 Backlash Shim AdjustmentTable 6 34 Gearcase Repair Procedures 6 36 SECTION 6 GEARCASE TABLE OF CONTENTS...

Page 154: ...ecial tools with those not provided by the manufacturer may result in severe personal injury equipment or engine damage or faulty service work Perform bearing removal and instaIIation operations exact...

Page 155: ...Threadlocker Model 2 3 5 8 9 8 9 9 15 18 25 30 40 PropelIer Nut 21 7 28 9 29 4 39 2 3 0 4 0 21 7 28 9 29 4 39 2 3 0 4 0 Pump case Bolts 41 55 4 6 6 2 0 47 0 64 41 55 4 6 6 2 0 47 0 64 41 55 4 6 6 2 0...

Page 156: ...ash Measuring TooI Kit 3B7 72740 0 Backlash Measuring Tool Sub Ass y 369 72730 0 Backlash Measuring Tool Arm 369 72727 0 Backlash Measuring Tool Arm 3B2 72727 0 Backlash Measuring Tool Kit 3C8 72234 0...

Page 157: ...ubricant Genuine gear oil or APl grade GL5 SAE 80 90 Cleaning Pads Scotch Brite Abrasive Pads Gasket Remover WATER PUMP If the engine has been run without water for any length of time the water pump s...

Page 158: ...and verify the kit parts match the originals before discarding old parts NOTE Lower pump case dowel pins are difficult to remove and should only be pulled out if replacement is necessary 5 6 7 8 9 2...

Page 159: ...appropriate size seal puller and installer to avoid damaging new seals and seating surfaces in lower pump case Apply silicone spray lubricant to seals and install so lips face direction indicated 5 A...

Page 160: ...r pump case gasket 11 Mount gasket on guide plate Installation 1 Apply a light coating of genuine grease or equivalent friction surface marine grease to the lower pump case driveshaft passage oil seal...

Page 161: ...Do not rotate driveshaft counterclockwise Doing so will bend impeIIer blades in wrong direction and may weaken or damage the impeller 6 Ensure upper pump case is aligned and fuIIy seated on the dowel...

Page 162: ...SECTION 6 6 10 1 2 Cylinder GEARCASE Typical Gearcase 2 5 3 5 T1709...

Page 163: ...bolts 4 and gearcase assembly 6 from the drive shaft housing 5 3 Drain aIl gearcase oil into a container and inspect the oil for metal chips NOTE Small metal fragments may indicate normal wear of gea...

Page 164: ...mpeller key Remove the water pump case 9 Install a water pump repair kit if gearcase has been in service for any length of time See Water Pump this section 6 Lift up the lower drive shaft 10 and remov...

Page 165: ...GEARCASE 6 13 1 2 Cylinder Typical Gearcase 3 5B T1714...

Page 166: ...oosened Do not remove it from the shift rod 3 Remove gearcase bolts 8 4 Remove gearcase assembly 5 Remove split pin 1 and propeller 2 6 Drain all gearcase oil into a container by removing the lower 3...

Page 167: ...e 7 from the drive shaft housing 9 Remove the propeller shaft housing bolts 10 10 Remove the propeller shaft housing 11 Note the push rod dropping and check the o ring 12 for damage 11 Remove the clut...

Page 168: ...mp impeller 15 13 Install a water pump repair kit if gearcase has been in service for any length of time See Water Pump this section 14 Remove the cam 19 and cam rod Pull them up together with the low...

Page 169: ...GEARCASE 6 17 1 2 Cylinder Typical Gearcase 8 9 8 9 9 15 18 25 30 40 T1723...

Page 170: ...he gearcase 1 Place engine in FORWARD gear so shift rod joint 1 is accessible 2 Use spring pin tooI A 3 Part No 345 72227 0 to remove upperspring pin from shift rod joint Discard the spring pin 3 Remo...

Page 171: ...ll a water pump repair kit if gearcase has been in service for any length of time See Water Pump this section 3 Remove propeller mounting nut washers and propeller 4 Remove propeller shaft housing bol...

Page 172: ...sed on Model 40 10 Remove the stopper and lift cam rod 10 from gearcase Fullydisassemble the cam rod components including the cam rod bushing internal and external o rings 11 Remove clutch push rod 11...

Page 173: ...ch Discard the spring 15 Place propeller shaft open end against bench surface and push out clutch pin 18 Remove clutch spring 19 and spring holder 20 WARNING Wear safety glasses and DO NOT hold open e...

Page 174: ...washer and mounting hardware for damage Check the propeller shaft threads and splines for wear and damage Propeller Shaft Housing Examine propeller shaft housing and components for wear damage and de...

Page 175: ...ing pin and insert it into the gear case Also insert the drive shaft and install the lower pump case 4 Lift the drive shaft a little and install the bevel gear B 5 Install the pump guide plate gasket...

Page 176: ...shaft side of gearcase Hand tighten nut 3 to secure the gear in place NOTE Before applying Loctite 242 remove all grease from tapered portion of bevel gear B and driveshaft with solvent and thread of...

Page 177: ...to the exterior of the cam rod bushing and o ring 10 Insert the cam rod into the cam rod port on the gearcase and seat the bushing Install stopper with stopper bolt 11 Align hole in clutch with slot i...

Page 178: ...18 350 72229 0 25 30 346 72229 0 40 345 72229 0 CAUTION DO NOT reuse clutch pin snap spring 21 it must be replaced Reusing clutch pin snap spring may cause severe damage to gears and other components...

Page 179: ...in all gears Check the propeller shaft for looseness in the forward and reverse directions If looseness exceeds 0 016 in 0 40 mm replace bevel gear C washer 26 with one of correct thickness NOTE Refer...

Page 180: ...ropeller thrust holder is installed and seated against the propeller shaft oil seal before installing propeller lf installed improperly propeller may be pushed into gearcase housing during tightening...

Page 181: ...imming gauge 3 into gearcase 25 30 gauge 346 72250 0 40 gauge 3C8 72250 0 NOTE Correct positioning of the shimming gauge in the gearcase is critical Make sure tapered side 4 is fully seated I n bevel...

Page 182: ...ant upward pressure against driveshaft With alI looseness eliminated measure the gap between collar 7 and bevel gear B using thickness gauge set 8 Part No 353 72251 0 If gap measurement is not within...

Page 183: ...spring washers Assemble three conedisk spring washers 10 o ring 11 and collar 12 7 Insert shaft 13 into gearcase and seat collar guide end in bevel gear A Install plate 14 using appropriate size bolt...

Page 184: ...l gauge reading If the dial gauge reading is not within the specified range adjust shim thickness between bevel gear A 21 and tapered roIIer bearing 22 in accordance with the Backlash Shim Adjustment...

Page 185: ...o lower crankcase head Align water pipe with lower seal 2 before seating gearcase on driveshaft housing 3 Apply Loctite 242 to threaded portion of gearcase mounting bolts Install the gearcase mounting...

Page 186: ...0260 0 0283 0 0284 0 0307 0 0308 0 0330 0 0331 0 0354 0 0355 0 0480 0 0 15 0 16 0 49 0 50 0 52 0 53 0 59 0 60 0 65 0 66 0 71 0 72 0 77 0 78 0 83 0 84 0 89 0 90 1 22 0 0 0011 0 0012 0 0055 0 0056 0 016...

Page 187: ...61 1 75 1 76 1 90 1 91 2 05 2 06 2 25 0 0 002 0 002 0 006 0 006 0 O14 0 O14 0 O18 0 O18 0 023 0 024 0 039 0 04 0 041 0 042 0 045 0 045 0 047 0 048 0 053 0 054 0 059 0 059 0 065 0 065 0 071 0 071 0 07...

Page 188: ...nts Driveshaft roller bearings Gearcase needle bearing Propeller shaft housing needle bearing Bevel gear A bearing outer race Bevel gear A roller bearing Driveshaft Roller Bearings CAUTION If it is de...

Page 189: ...se 2 Attach retainer 2 from propeller shaft side of gearcase to shaft groove 3 Make sure retainer is fully seated in groove with raised surface facing bearing 3 Slide guide 4 onto shaft from water pum...

Page 190: ...rom water pump side of gearcase Make sure guide is seated in bearing 5 Install stopper 6 plate flange 7 washer 8 and nut 9 onto shaft from water pump side of gearcase 6 Hold end of threaded shaft with...

Page 191: ...e B 5 6 Remove tools and verify needle bearing is fully seated in housing Bevel Gear A Bearing Outer Race Removal 1 lnstall bevel gear A bearing puller assembly Part No 3A3 72755 0 2 Tighten bolt 1 un...

Page 192: ...of the gearcase opening 7 Fully seat bearing race in gearcase by hammering the rod end Bevel Gear A Roller Bearing Removal and Installation 1 Insert screwdrivers in notches of bevel gear A and gently...

Page 193: ...ing Standards 7 7 Troubleshooting 7 10 Description of Operation 7 12 Battery Care and Maintenance 7 17 See 3 4 Cylinder Manual Section 7 Ignition System 7 20 Ignition System Repair Procedures 7 41 Sta...

Page 194: ...he engine is cranking or running Use the spark gap tester to prevent the engine from starting when performing static ignition performance tests Use caution when performing tests with the engine cover...

Page 195: ...ast production models 9 9 15 18 and 40 Refer to Section 2 for Standard Torque Values chart Manufacturer Special Tools Required None Description Torque in Ib ft Ib N m kg m Threadlocker Model 2 5 3 5 5...

Page 196: ...Protector and Sealer Low Temperature Lithium Grease Genuine Grease or Equivalent Friction Surface Marine Grease Threadlocker Loctite 243 lsopropyl Alcohol Cleaning Solvent Thermomelt Stik 125 F 52 C a...

Page 197: ...AH Recommended 8 9 8 9 9 15 18 25 30 None Optional 12V 40 AH Recommended 40 None Optional 12V 70 AH Recommended Engine Fuse 2 5 3 5 None 5 None with Optional Battery Charger 10A 8 9 8 9 9 15 18 25 30...

Page 198: ...3 5B 5B 5BS 9 9 15 18 25 30 40C 100 DVA Mim Pulser Coil Output Cranking 3 5B 5B 5BS 9 9 15 18 25 30 40C 4 75 5 0 DVA Coil Resistance Coil 2 5 3 5 5 8 9 8 9 9D 15D 18E 9 9D2 15D2 18E2 25C2 30A3 25C3 30...

Page 199: ...s has been eliminated to clarify testing procedures A typical electrical drawing illustrates several connectors Items 1 2 3 4 7 and 8 are terminals that are located inside of electrical connectors The...

Page 200: ...gs Disconnecting Bullet Connectors 1 Carefully examine the connector to determine which end is removable and which end is fixed Typically the insulation surrounding the removable end is tapered so it...

Page 201: ...runs the length of the conductor These conductors are designated as follows A B Where A Background Color B Stripe Color Example BLACK WHITE This conductor has a BLACK background with a WHITE stripe E...

Page 202: ...tem perform the following operations Check battery fluid level and specific gravity Charge or replace as required See Battery Care and Maintenance this section Check the foIIowing electrical connectio...

Page 203: ...arburetor synchronization See Section 2 CHECKS SYMPTOM Cranks but will not start Wilt not start and pops or backfi res Starts but stops immediately Low or high speed miss Poor accel eration low top en...

Page 204: ...l 3 main key switch 4 and emergency stop switch 5 The purpose of this system is to provide an electric spark inside each cylinder at the precise moment needed by the combustion chamber Blown fuse Shor...

Page 205: ...The chart demonstrates that the 2 5 3 5 non CD engine have different components all other engines are all basicaIly similar The basic units are described as follows Flywheel Mounted radially inside t...

Page 206: ...indings of a wire wrapped around it The flywheel is equipped with a metallic cam called an interrupter molded into it When the interrupter passes in close proximity to the pulser coil the permanent ma...

Page 207: ...a primary and secondary terminal connection and a ground plate Through mutual induction the ignition coil transforms the output from the CD Unit to as much as 20 000 30 000 volts to fire the spark plu...

Page 208: ...rgized a connection between the positive terminal of the battery and the starter motor is provided The connection between the starter motor and ground completes the circuit The fuse opens if the coil...

Page 209: ...sing fresh water and seek medical help immediately If injested do not induce vomiting Drink large amounts of Milk of Magnesia beaten eggs or vegetable oil Seek medical help immediately General Procedu...

Page 210: ...remove ALL filler caps WARNING Remove battery from boat whenever charging WARNING When removing battery cables ALWAYS remove the negative cable first 1 Check electrolyte levels 2 Test specific gravity...

Page 211: ...conds 5 HP 30 35 Ampere Hour Rating Discharge Rate 90 to 105 8 9 8 9 9 15 18 25 30 40 Ampere Hour Rating Discharge Rate 120 40 70 Ampere Hour Rating Discharge Rate 210 4 Measure voltage at battery ter...

Page 212: ...e testing Do not touch ignition coils exciter coil pulser coils or alternator coils while the engine is cranking or running CAUTION Use proper precautions when performing tests with the engine cover r...

Page 213: ...ch problem These tests are described in detail in the section which follows the flow chart The performance tests identified as Test 1 through Test 7 contain specific instructions for testing and servi...

Page 214: ...SECTION 7 7 22 1 2 Cylinder Ignition System Performance Testing Flow Chart 1 T1557 1...

Page 215: ...t each spark plug lead to spark gap tester 2 4 Secure spark gap tester to a clean ground on engine block WARNING To avoid possible shock hazard do not handle ignition coils or spark gap tester during...

Page 216: ...he engine not to start or prevent it from stopping Several component failures can cause the stop circuit to malfunction Use this flow chart to isolate and repair all component failures NOTE After you...

Page 217: ...e magneto plate CD Unit and ignition coils beAore conducting the following procedure All continuity tests must be conducted with negative lead kom battery disconnected or you may damage the meter 1 Re...

Page 218: ...cuit Test flow chart Test 2b Stop Circuit Emergency Stop Switch Test This test is used to determine whether the emergency stop switch and connecting wiring are functioning normally NOTIE Make sure aIl...

Page 219: ...ergency stop switch 5 Remove lanyard 5 from emergency stop switch 6 meter must show continuity lf not replace emergency stop switch 6 Disconnect CD Unit 9 terminals 7 and 8 7 Connect one meter lead to...

Page 220: ...ground connection for the magneto plate CD Unit and ignition coils before conducting the following procedure Reference the following electrical drawings for the exciter coil test The pulser and altern...

Page 221: ...digital multimeter to ohms and connect the leads between the following terminals to read the resistance of the exciter coil Engine Models Disconnect Terminals 2 5 3 5 4 and 5 5 8 9 8 4 5 6 and 7 9 9D...

Page 222: ...Repair Procedures Exciter Coil After repairs are made return to Ignition System Performance Testing Flow Chart If the resistance is within indicated range proceed to the next step Engine Models Resul...

Page 223: ...he RED tester lead to terminal 6 and BLACK tester lead to terminal 4 for models 5 8 9 8 9 9 15 18 25 30 40 6 Attach lanyard to emergency stop switch 7 Crank engine Engine Models Connect Multimeter Bet...

Page 224: ...s are connected during this test except those that are noted in the test procedure Check for continuity between chassis ground and the ground connection for the magneto plate CD Unit and ignition coil...

Page 225: ...ly 2 to the CD Unit 3 while you are cranking the engine 1 Disconnect the following terminals 2 Set the digital multimeter to ohms and connect the leads to test the resistance of the pulser coil Engine...

Page 226: ...Performance Testing Flow Chart If the resistance is within the indicated range proceed to the next step 5 Set the analog multimeter to 20 on the DVA scale 6 Insert the banana plug of the RED tester l...

Page 227: ...d to emergency stop switch 9 Crank engine 10 At cranking RPM the tester should show the following results Minimum 3 0 DVA 11 If the pulser coil test results are not within the acceptable range replace...

Page 228: ...ing procedure Reference the following electrical drawings for the CD Unit Output Test Cranking RPM Models 2 5 3 5 5 8 9 8 9 9 15 18 25 30 and 40 The CD Unit Output Test Cranking RPM is used to determi...

Page 229: ...o the meter connection labeled COM 7 Connect the BLACK tester lead to terminal 3 8 Carefully slide the RED tester into the bullet connector terminal 4 sleeve until it makes contact with the terminal N...

Page 230: ...erminal 3 and the other terminal 4 5 The meter should indicate the following readings for the primary winding Repeat readings for each ignition coil 6 If primary winding for any ignition coil is not w...

Page 231: ...sure all electrical terminals are connected during this test except those that are noted in the test procedure Check for continuity between chassis ground and the ground connection for the magneto pla...

Page 232: ...TION 7 7 40 1 2 Cylinder NOTE Some steps refer to other ignition tests After you complete those tests return to the flow chart for further instructions Output Tests Engine Running Flow Chart 15 T1992...

Page 233: ...ement of the flywheel CAUTION Flywheel is under high torque and requires the use of special tools for removal and installation Failure to use the specified tools can result in injury or damage to the...

Page 234: ...procedure NOTE Flywheel magnets must be of a particular strength in order to run the ignition system Weak magnets can cause low ignition voltage which may affect engine performance Flywheels seldom go...

Page 235: ...3 Remove coil plate assembly cable clamp screws 1 and cable clamp 2 4 For models 9 9 15 18 25 30 40 ONLY Carefully slit coil plate assembly cable shield 3 NOTE Make sure you don t cut electrical cond...

Page 236: ...aged connectors Broken or bent alternator coil Laminations damaged alternator coil windings and missing alternator coil screws Broken cracked or misaligned pulser coils and missing pulser coil screws...

Page 237: ...te Assembly Removal l Remove the flywheel 2 Disconnect the following terminals Exciter coil 1 terminals Note that these terminals interconnect cable from coil plate assembly 2 to cable from CD Unit 3...

Page 238: ...nect cable from coil plate assembly 2 to cable from CD Unit 3 Disconnect terminals 4 5 6 7 8 9 10 and 11 Alternator coil 1 terminals Note that these terminals interconnect cable from coil plate assemb...

Page 239: ...ed guide plate Broken or bent set ring Apply light coat of Iow temperature lithium grease to guide plate 2 Istallation Install in reverse order of removal NOTE Disconnect negative battery cable from b...

Page 240: ...on coil Cleaning and Inspection Clean mounting area with isopropyl alcohol Check for the following and repair or replace as required Remove spark plug s and inspect for fouling damaged electrodes or d...

Page 241: ...removing CD Unit Removal 1 Remove bolts 1 2 Remove CD Unit Cleaning and Inspection Examine electrical conductors and connectors Installation lnstall in reverse order of removal NOTE Make sure that al...

Page 242: ...ECTION 7 7 50 1 2 Cylinder STARTING SYSTEM WARNING Disable ignition system by disconnecting exciter coil terminals 4 and 5 to prevent accidental engine startup during testing of starter circuit T1790...

Page 243: ...rter motor runs but does not engage or disengage from the flywheel see Starter Motor Test in this section The starter motor will not shut off see Starter Solenoid Test in this section Before you begin...

Page 244: ...rter circuit component if the engine does not crank NOTE The electrical drawings have been simplified to show only those elements necessary to test the starter circuit Two types of starter circuits ar...

Page 245: ...negative battery cable 3 from negative battery terminal 1 2 Set analog multimeter to check continuity Connect one tester lead to negative battery terminal 1 and the other tester lead to the ground co...

Page 246: ...nnect negative battery cable 3 to negative battery terminal 1 7 Connect RED tester lead to starter solenoid terminal 5 If meter does not indicate battery voltage replace battery cable 6 If meter indic...

Page 247: ...lead to connector closest to main key switch 14 NOTE For models with remote control box Make sure you test the correct terminal in this step Terminal 14 is connected directly to the main key switch 1...

Page 248: ...main key switch 10 to START position If meter does not indicate battery voltage repair or replace cable between 20 and 22 If meter indicates battery voltage go to next step 16 Connect RED tester lead...

Page 249: ...th cleaning solvent Inspect and Remove Pinion Assembly 1 Grasp pinion collar 1 and wind pinion gear 2 in a clockwise direction Make sure gear moves freely and returns to original position If any bindi...

Page 250: ...ter motor 6 Apply a light coat of low temperature lithium grease to motor shaft 7 and slide on pinion gear 3 wind counterclockwise to seat 7 Slide spring 4 and pinion collar 5 on motor shaft 7 8 Push...

Page 251: ...eak replace brush assembly 4 Check continuity with analog multimeter between Brush 2 and 3 Replace brush assembly if meter indicates continuity Brush 3 and the motor base 4 Replace brush assembly if m...

Page 252: ...ly 1 Apply genuine grease to bearing cup 1 2 Install brush assembly 1 Make sure that the starter motor terminal 2 is fully seated in the bushing 3 Assemble Starter Motor NOTE Bolts for models 25 30 40...

Page 253: ...es as you slide motor base 1 over commutator 2 Align notch 3 in motor base with tab 4 in motor body 5 and seat motor baseto motor body 3 Grasp pinion collar 1 and rotate several times to make sure bru...

Page 254: ...s not show continuity replace starter solenoid 1 5 and clean chassis ground lf meter shows continuity replace starter solenoid 3 and clean chassis ground lf meter shows continuity replace starter sole...

Page 255: ...ime If meter shows continuity in any of these tests replace main key switch 3 With main key switch set to the OFF position check for continuity between terminals 4 and 6 lf meter does not show continu...

Page 256: ...ween terminals 4 and 6 lf meter does not show continuity replace main key switch Check for continuity between all remaining terminals if meter shows continuity replace main key switch Check for contin...

Page 257: ...replace neutral start switch 1 For models with remote control box Set analog multimeter fol continuity With remote control lever set at NEUTRAL FORWARD and REVERSE positions check for continuity betwe...

Page 258: ...terminals 2 and 3 lf meter does not show continuity replace choke solenoid CHARGING SYSTEM CAUTION Avoid electrical shock Do not handle spark gap tester leads during performance testing Do not touch i...

Page 259: ...Care and Maintenance in this section 2 Check 15A 10A 5 model only engine fuse lf it is blown check the following short or overload conditIons Short in charging circuit wiring or components such as the...

Page 260: ...rence the following electrical drawings for the alternator coil test The pulser and exciter coils have been removed from both illustrations for clarity The alternator coil test is used to determine wh...

Page 261: ...lead to terminals 4 and 6 one terminal at a time to check for any resistance to ground 6 lf the meter indicates any resistance to ground replace the alternator coils See Charging System Repair Proced...

Page 262: ...ed COM 9 Connect the BLACK tester lead to a clean engine ground and the RED tester lead to terminals 4 and 6 one terminal at a time to check for any voltage to ground 10 Start engine 11 At idle and fu...

Page 263: ...rectifier regulator 1 is shorted or open 1 Disconnect terminals 2 3 4 and 5 from all other wiring 2 Set analog multimeter to check continuity 3 Insert the banana plug of the RED tester lead into the...

Page 264: ...stem Repair Procedupes WARNING Disable ignition system by disconnecting exciter coil terminals 4 5 6 7 to prevent accidental engine startup during removal and replacement of the flywheel RED Tester Le...

Page 265: ...en repairs are complete make sure all ignition and electrical leads are properly routed and clamped in their original positions and the start in gear prevention system must be tested before returning...

Page 266: ...alternator coils are available as a separate replaceable component Some engine configurations might require replacement of entire coil plate assembly Check current Parts Catalog for availability Remo...

Page 267: ...l 5 from the mounting bracket Cleaning and Inspection Clean coil plate assembly upper main bearing housing set ring ignition timing link exciter coiI pulser coil coil leads and coil connectors with is...

Page 268: ...SECTION 7 7 76 1 2 Cylinder Installation Install in reverse order of removal NOTE Use threadlocker on screw threads before installing screws...

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TOHATSU 2 Stroke Cylinder Series, Service Manual

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