Инструкция тохатсу 6 сил 4 такта

MFS4-5-6̲E̲cover̲110420.qxd 11.4.21 9:15 AM ページ 1
4/5/6B,C
MFS
4/5/6B,C
Models
MFS
4/5/6B,C
Models
OB No.003-21034-2
11-04 NB
Printed in Japan
OB No.003-21034-2
11-04 NB
MFS4-5-6̲E̲cover̲110420.qxd 11.4.21 9:15 AM ページ 2
MFS4-5-6̲E̲ch00̲110422.qxd 11.4.22 6:13 PM ページ 1
Introduction
Before reading this manual
This service manual provides information that is needed for inspection, service and repair of applicable
outboard motors. For information about operation of the products that are not described in this
document, refer to the owners manual. For our customers' safe and dependable use of the product for
long term, it is essential to maintain the performance and quality of the outboard. To ensure this, the
maintenance and service have to be done properly by service technicians with fundamental
knowledge and skills. This manual is utilized so that our customers can always use their outboard
motor with full satisfaction.
This service manual, it is produced B models to a base, and the service information for the C models
is addition on the end of the manual as supplementary information.
Safety Information
Safety Statements
The following safety statements are found throughout this manual and indicate information
which, if ignored, could result in fatal safety hazards or property damage:
DANGER
Indicates the presence of a hazard which, if
ignored, will result in severe injury or
death.
WARNING
Indicates the presence of a hazard or an
unsafe activity which, if ignored, could
result in severe injury or death.
CAUTION
Indicates the presence of a hazard or an
unsafe activity which, if ignored, could
result in minor personal injury or damage to
the products or facilities.
Attention:
4st 4/5/6 2011
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About this manual
This service manual is designed so that service persons are able to perform their work correctly.
Understand the following matters well for efficient repairs.
1 Each chapter begins with the introduction of special tools that are used for the work described in the
chapter so that the service persons are able to understand the tools needed.
2 Parts that are serviced in each chapter and their details are presented by using a component composition
diagram.
3 Fastening torques are described in the component composition diagram and in the body text and are
critical points of the applicable repair.
4 Pictograms indicate that there is an important instruction for the relevant parts. It also shows the type of
lubricant and its application point(s).
5 The component composition diagrams describe the names of the parts, the quantity of the parts used,
size of fasteners and special notes.
6 Specific works are described in detail by using illustrations and adding advice on the work.
1
2
Lower Unit
4
5
1. Special Tools
Lower Unit
P/L Fig. 8
Gear Case (Drive Shaft) & Gear Case (Propeller Shaft)
Spring Pin Tool A
P/N. 345-72227-0
Spring Pin Tool B
P/N. 345-72228-0
Center Plate 3
P/N. 3AB-99701-0
Driver Rod 3
P/N. 3AB-99702-0
Removing spring pin
Installing spring pin
Used in combination with driver rod and
bearing attachment to locate lower gear
case bearing
Used in combination with center plate and
bearing attachment
GRE
ASE
TEF
TEF
1342
342 TB
Bearing Press
P/N. 3H6-72769-0
Bearing Attachment 2
P/N. 3BR-99905-0
Bearing Attachment 4
P/N. 3BV-99905-0
Used in combination with driver rod and
center plate to remove lower gear case
bearing
Used in combination with driver rod and
center plate to locate lower gear case
bearing
Installing bearings
Installing bearings
1342
GRE
ASE
OBM
OBM
GEAR
OI
L
Bearing Press Collar
P/N. 3H6-72768-0
GEAR
GRE
ASE
OBM
OBM
GRE
ASE
OBM
OBM
Backlash Measuring Tool Kit
P/N. 369-72740-0
Clamp A
P/N. 3B7-72720-0
Dial Gauge Plate
P/N. 3B7-72729-0
Installing bearings
Measuring gap between forward and
pinion gears (A and B gears)
Measuring backlash
Used to attach dial gauge
when measuring backlash
GRE
ASE
OBM
OBM
GEAR
1342
342 TB
OI
L
Needle Bearing Press Kit
P/N. 369-72900-0
GEAR
1342
GRE
ASE
OBM
GEAR
OI
L
OBM
GEAR
GRE
ASE
LIT
LIT
OI
L
GEAR
GR
LIT
EA
SE
GR
EA
SE
OBM
LIT
GR
TEF
EA
SE
1342
B
1342
342 T
OBM
GEAR
TEF
Ref.
No.
1-1
1-2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17-1
17-2
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39-1
39-2
40
41
42
43-1
43-2
43-3
44
45
46
47-1
47-2
47-3
48
49
50
51
52
53
54
55
56
57
58
59-1
59-2
59-3
59-4
60
61
62
63
64
65-1
65-2
65-3
66
Description
Gear Case Ass'y
Gear Case Ass'y
Roller Bearing 14-20-12
Plug
Gasket 8.1-15-1
Anode
Bolt
Ball Bearing 6004
Propeller Shaft Housing Ass'y
Propeller Shaft Housing
Oil Seal 15-28-10
O-Ring 3.2-47
Ball Bearing 6002
Bevel Gear Ass'y (A)
Bevel Gear (B)
Bevel Gear Ass'y (C)
Washer 15.2-19-1.9
Shim 21-28-0.1
Shim 21-28-0.15
Propeller Shaft
Clutch
Pin 3.5-28
Spring Clutch
Spring Retainer Clutch
Push Rod Clutch
Water Strainer Sub
Screw
Water Pipe (Lower)
Seal Rubber Water Pipe Lower
Water Pump Impeller
Key Pump Impeller
Pump Case (Upper)
Pump Case Liner
Water Pump Guide Plate
Pump Case Gasket
Guide Plate Gasket
Bolt
Washer
Pump Case (Lower)
Oil Seal 10-24-8
Shim 28-34.8-0.1
Shim 26.5-34.8-0.15
Pump Case Gasket (Lower)
Bolt
Water Pipe Seal (Lower)
Drive Shaft Ass'y (S)
Drive Shaft Ass'y (L)
Drive Shaft Ass'y (UL)
Ball Bearing 6300
Clutch Cam
Spring Pin 3-10
Cam Rod (S)
Cam Rod (L)
Cam Rod (UL)
Spring Pin 3-12
Bushing Camshaft
O-Ring A 2.5-4.9
O-Ring 2.4-15.4
Stopper Cam Rod Bushing
Grommet
Bolt
Washer
Bolt
Washer
Bolt
Propeller Ass'y (6) Y
Propeller Ass'y (7)
Propeller Ass'y (8)
Propeller Ass'y (9)
Propeller Hardware Kit
Propeller Nut
Split Pin 3-18
Washer 10.5-28-2
Thrust Holder Ass'y
Water Pipe Ass'y (S)
Water Pipe Ass'y (L)
Water Pipe Ass'y (UL)
Grommet Water Pipe Upper
Q'ty
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
A
A
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
4
4
1
1
A
A
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Remarks
For 6ps UL
Do not reuse.
M6 L=16mm
Do not reuse.
M6 L=20mm
Do not reuse.
Do not reuse.
M6 L=45mm
6
Do not reuse.
M6 L=25mm
For Transom "S"
For Transom "L"
For Transom "UL"
For Transom "S"
For Transom "L"
For Transom "UL"
Do not reuse.
Do not reuse.
For 6ps UL
M6 L=45mm
M8 L=35mm
M6 L=16mm
STD:Sail Pro
STD:4ps "S,L"
STD:5/6ps "S,L"
Lower Unit
7) Disassembly of Propeller Shaft Housing
1.
Remove bearing 1 by using commercially available bearing
For Transom "S"
puller."L"
For Transom
For Transom "UL"
Before removing, check bearing for play or
deflection. Replace if necessary.
CAUTION
1
Do not reuse removed bearing.
1 Bearing Do not reuse.
3
2.
Remove oil seal 2.
2
6
2 Oil Seal Do not reuse.
8) Inspection of Propeller Shaft Housing
1.
Use cleaning oil and cleaning brush to clean propeller shaft
housing, and check it for crack or damage. Replace if
necessary.
2.
Check reverse (C) gear teeth and clutch for crack or
damage. Replace if necessary.
When reusing bearing without removing it, check
it for play or deflection. Replace if necessary.
ii
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MFS4-5-6̲E̲ch00̲110422.qxd 11.4.22 6:14 PM ページ 3
This manual uses SI unit system (International System of Units) for pressure, force (load), torque and stress.
This manual newly adopts the international unit construction system (SI unit system) followed by the
conventional imperial and metric systems enclosed by ( ) and [ ] as described below.
Example : <Pressure>
2
0.90 MPa (128 psi) [9.0 kgf/cm ]
Conventional system (kilo-gram meter unit)
Conventional system (US pound inch unit)
SI unit (1 kgf/cm2 = 0.0980665 MPa)
* Measurements are shown using SI unit followed by conventional units (US unit) and [Japanese domestic unit].
Example : <Torque>
18 N·m（13lb·ft）[1.8 kgf·m]
*
* The conventional unit for measurement of force uses "kgf (kilogram force)" to discriminate it from
"kg (mass kilogram)" of SI unit system.
Example : <Volume>
900 cm3（30.4 fl.oz）
Example : <Length>
10 mm（0.39 in）
<Reference>
What is the SI unit system?
Although the measurement unit is standardized mostly with metric system in the world, the metric system
includes different kinds of unit systems.
Though the metric system was established expecting that a single unit system would be used in the world,
various physical units were established 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) passed a
resolution of the international unit system as "Systéme International d'Unités (French)" that is abbreviated as
"SI unit".
For example, conventional metric system uses the unit of mass (kg) and unit of force (kg or kgf) without
discriminating them, but the SI unit system uses, for example, "kg" as the unit of mass, and "N" as the unit of
force, aiming to apply a kind of unit for a kind of physical quantity.
4st 4/5/6 2011
iii
MFS4-5-6̲E̲ch00̲110422.qxd 11.4.22 6:14 PM ページ 4
Description of Pictograph
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$
+
#& '
OK
) r/min
* '
'
#& $ ' & ,
#
OIL
RPM
# '& '
#(
# )- 6 Nám ( 4 lbáft ) [ 0.6 kgfám ]
Example :
%
' %
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+ ( < '
iv
# 5 #6
N
D
G17
ui
d
O-
LOR
Ri
ng
G
RE
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AS
E
OBM
G
RE
AS
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$ +
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2 37.8
1342
342
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B
2 3747
1373B T
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2 3=7
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O
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G
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AS
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2 34
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4st 4/5/6 2011
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1.Service Information
16)
17)
18)
19)
20)
21)
22)
1. Identification (Engine Serial Number) … 1-2
2. Work Safety ……………………………………… 1-2
Fire Prevention ……………………………………… 1-2
Ventilation …………………………………………… 1-2
Protection …………………………………………… 1-2
Genuine Parts ……………………………………… 1-2
Tools …………………………………………………1-3
Recommendations on Service …………………… 1-3
Cautions in Disassembling and
Assembling Components ………………………… 1-4
Tools and Instruments ……………………… 1-5
1) Test Propeller ……………………………………… 1-5
2) Instruments ………………………………………… 1-5
3) Special Tools………………………………………… 1-6
Pre-delivery Inspection …………………… 1-8
1) Steering Handle …………………………………… 1-8
2) Gear Shift …………………………………………… 1-8
3) Engine Oil …………………………………………… 1-8
4) Gear Oil ……………………………………………… 1-8
5) Fuel Tank Line ……………………………………… 1-9
6) Rigging ……………………………………………… 1-9
7) Inspection of Tilt Stoppe …………………………… 1-9
8) Inspection of Stop Switch ………………………… 1-9
9) Cooling Water Check Port ……………………… 1-10
10) Idle Operation ……………………………………… 1-10
11) Propeller Selection ………………………………… 1-11
12) Inspection of Forward and Reverse Shifts ……… 1-11
13) Trim Tab …………………………………………… 1-12
Break-in Operation …………………………… 1-12
Test Run …………………………………………… 1-12
Check After Test Run ……………………… 1-13
1)
2)
3)
4)
5)
6)
7)
3.
4.
5.
6.
7.
4.Fuel System
1. Special Tools …………………………………… 4-2
2. Parts Layout ……………………………………… 4-4
3.
4.
2.Service Data
1. Outline Dimensions …………………………… 2-2
2.
3.
4.
5.
6.
7.
1) Engine Dimensions ………………………………… 2-2
2) Clamp Dimensions ………………………………… 2-4
Engine Lubrication System Diagram …2-5
Cooling Water System Diagram ……… 2-6
Specifications …………………………………… 2-8
Maintenance Data …………………………… 2-10
Tightening Torque Specifications ………… 2-14
Sealant and Lubricant …………………… 2-15
3.Maintenance
1. Special Tools ……………………………………… 3-2
2. Inspection Schedule ………………………… 3-3
3. Inspection Items ……………………………… 3-4
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
4st 4/5/6 2011
Inspection of Top Cowl …………………………… 3-4
Fuel System ………………………………………… 3-4
Inspection of Fuel Tank …………………………… 3-5
Inspection of Fuel Filter …………………………… 3-5
Replacement of Engine Oil ………………………… 3-6
Inspection of Gear Oil Quantity …………………… 3-7
Inspection of Water Pump ………………………… 3-7
Replacement of Gear Oil ………………………… 3-9
Inspection of Gear Case (for leakage) …………… 3-10
Inspection of Spark Plugs ………………………… 3-11
Inspection of Compression Pressure …………… 3-12
Inspection and Adjustment of Valve Clearance… 3-13
Throttle Cable ……………………………………… 3-15
Inspection of Idle Engine Speed ………………… 3-17
Inspection of Ignition Timing……………………… 3-17
Inspection of Anode ……………………………… 3-18
Replacement of Anode …………………………… 3-18
Inspection of Propeller …………………………… 3-19
Inspection of Thermostat ………………………… 3-19
Inspection of Cooling Water Passage…………… 3-20
Flushing with Water ……………………………… 3-21
Greasing Points …………………………………… 3-22
Carburetor & Fuel Pump ………………………………… 4-4
Integral Fuel Tank ……………………………………… 4-6
Carburetor Inner Passages ……………… 4-8
1) Idling Passage ……………………………………… 4-8
2) Off-Idle Passage …………………………………… 4-9
3) High Speed Passage ……………………………… 4-10
4) Choking Passage ………………………………… 4-11
Inspection Items ……………………………… 4-12
1) Inspection of Fuel Feed System Piping ………… 4-12
2) Draining Fuel ……………………………………… 4-12
3) Inspection of Fuel Tank and Fuel Tank Cap …… 4-13
4) Inspection of Fuel Cock…………………………… 4-13
5) Inspection of Fuel Filter …………………………… 4-13
6) Removing Carburetor …………………………… 4-14
7) Disassembling Carburetor ……………………… 4-16
8) Inspection and clean of Carburetor ……………… 4-17
9) Inspection of Fuel Connector …………………… 4-18
10) Assembling of Carburetor ……………………… 4-18
11) Adjustment of Float Height ……………………… 4-19
12) Installing Carburetor ……………………………… 4-19
13) Removing Fuel Pump …………………………… 4-20
14) Disassembly and Inspection of Fuel Pump …… 4-20
15) Assembly of Fuel Pump ………………………… 4-21
5.Power Unit
1. Special tools ……………………………………… 5-2
2. Parts Layout ……………………………………… 5-3
3.
Engine …………………………………………………… 5-3
Magneto…………………………………………………… 5-4
Cylinder & Oil Pan ……………………………………… 5-6
Cylinder Head & Valve & Cam Shaft ………………… 5-8
Piston & Crank Shaft …………………………………… 5-10
Recoil Starter …………………………………………… 5-11
Top Cowl ………………………………………………… 5-12
Inspection Items ……………………………… 5-13
1) Inspection of Compression Pressure …………… 5-13
2) Inspection of Valve Clearance …………………… 5-14
3) Removing Power Unit …………………………… 5-16
4) Removal and Disassembly of Crank Case Head … 5-17
5) Inspection of Crank Case Head ………………… 5-18
6) Assembly of Crank Case Head ………………… 5-18
7) Installation of Crank Case Head ………………… 5-18
8) Disassembly of Power Unit ……………………… 5-19
9) Removal of Rocker Arm ………………………… 5-22
10) Removing Cylinder Head ………………………… 5-23
11) Inspection of Rocker Arm and Pivot …………… 5-23
12) Inspection of Push Rod Plate …………………… 5-23
13) Inspection of Push Rod …………………………… 5-23
14) Disassembly and Inspection of Oil Feed Pump…… 5-23
15) Disassembly of Cylinder and oil pan …………… 5-26
16) Disassembly and Inspection of Breather Chamber … 5-28
17) Inspection of Lifter………………………………… 5-28
18) Inspection of Cam Shaft ………………………… 5-29
v
MFS4-5-6̲E̲ch00̲110422.qxd 11.4.22 6:14 PM ページ 6
19)
20)
21)
22)
23)
24)
25)
26)
27)
28)
29)
30)
31)
32)
33)
34)
35)
36)
37)
38)
39)
40)
41)
Inspection of Piston Outer Diameter …………… 5-30
Inspection of Cylinder Inner Diameter…………… 5-30
Inspection of Piston Clearance ………………… 5-30
Inspection of Piston Ring Side Clearance ……… 5-31
Inspection of Piston Rings ……………………… 5-31
Inspection of Piston Pin…………………………… 5-32
Inspection Connecting Rod Small End
Inner Diameter …………………………………… 5-32
Inspection of Connecting Rod Big End
Inner Diameter …………………………………… 5-32
Inspection of Connecting Rod Big End
Side Clearance …………………………………… 5-33
Inspection of Crank Shaft …………………………5-33
Disassembly and Inspection of Oil Pan ………… 5-34
Removal of Valves and Springs ………………… 5-35
Inspection of Valve Springs ……………………… 5-35
Inspection of Valve………………………………… 5-36
Inspection of Valve Guide ………………………… 5-36
Inspection of Valve Seat ………………………… 5-37
Correction of Valve Seat ………………………… 5-38
Installation of Valves ……………………………… 5-41
Installation of Piston and Connecting Rod ……… 5-42
Assembly of Cylinder Oil Pan …………………… 5-43
Installation of Cylinder Head……………………… 5-45
Installing Flywheel ………………………………… 5-47
Installation of Power Unit ………………………… 5-50
6.Lower Unit
1. Special Tools ……………………………………… 6-2
2. Parts Layout ……………………………………… 6-3
Drive Shaft Housing……………………………………… 6-4
3. Inspection Items ……………………………… 6-8
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)
27)
28)
29)
vi
Draining Gear Oil …………………………………… 6-8
Removing Propeller ………………………………… 6-8
Removing Lower Unit ……………………………… 6-9
Disassembly of Water Pump ……………………… 6-9
Inspection of Water Pump………………………… 6-10
Removing Propeller Shaft Housing Ass'y ……… 6-11
Disassembly of Propeller Shaft Housing ……… 6-12
Inspection of Propeller Shaft Housing…………… 6-12
Assembly of Propeller Shaft Housing …………… 6-13
Removing Drive Shaft …………………………… 6-13
Disassembly of Propeller Shaft Ass'y …………… 6-14
Inspection of Propeller Shaft …………………… 6-14
Assembly of Propeller Shaft Ass'y ……………… 6-14
Removing Clutch Cam and Cam Rod…………… 6-15
Disassembly of Clutch Cam and Cam Rod …… 6-15
Inspection of Clutch Cam and Cam Rod ……… 6-15
Assembly of Clutch Cam and Cam Rod ………… 6-16
Removing Pump Case (Lower) ………………… 6-16
Disassembly of Pump Case (Lower) …………… 6-16
Assembly of Pump Case (Lower) ……………… 6-16
Inspection of Drive Shaft ………………………… 6-17
Inspection of Pinion (B) Gear and
Forward (A) Gea…………………………………… 6-17
Disassembly of Gear Case ……………………… 6-18
Inspection of Gear Case ………………………… 6-19
Assembly of Gear Case ………………………… 6-19
Installation of Forward Gear and
Pinion Gear (A and B Gears) …………………… 6-20
Reassembly of Pump Case (Lower) …………… 6-20
Installation of Clutch Cam and Cam Rod ……… 6-20
Determination of forward (A) gear backlash …… 6-21
30)
31)
32)
33)
Installation of Water Pump ……………………… 6-23
Installation of Propeller Shaft Housing ………… 6-24
Filling with Gear Oil ……………………………… 6-25
Installation of Lower Unit ………………………… 6-25
7.Bracket
1. Parts Layout ……………………………………… 7-2
Bracket & Reverse Lock ………………………………… 7-2
Drive Shaft Housing & Shift …………………………… 7-4
Bottom Cowl & Tiller Handle …………………………… 7-6
Cowl ……………………………………………………… 7-8
2. Disassembling and Assembling
Procedure …………………………………………… 7-9
1)
2)
3)
4)
5)
6)
Removal and inspection of drive shaft housing … 7-9
Removal and inspection of clamp bracket ………… 7-11
IInstallation of clamp bracket and drive shaft … 7-12
Removal, inspection and installation of water pipe … 7-14
Remove, inspection and installation of tiller handle … 7-15
Adjustment of Throttle Cable …………………… 7-18
8.Electrical System
1. Special Tools ……………………………………… 8-2
Magneto…………………………………………………… 8-3
2. Ignition System and Ignition
Control System ………………………………… 8-4
1)
2)
3)
4)
5)
6)
7)
Inspection of Ignition Spark………………………… 8-4
Inspection of Plug Cap……………………………… 8-5
Inspection of Igniter ………………………………… 8-6
Inspection of Stop Switch ………………………… 8-7
Inspection of Oil Pressure Switch ………………… 8-7
Inspection of Rectifier ……………………………… 8-8
Inspection of Lighting Coil ………………………… 8-8
9.Troubleshooting
1. Troubleshooting List ………………………… 9-2
2. Power Unit ………………………………………… 9-3
1 Engine will not start or is a little hard to start.
(Recoil starter operates normally.) …………………… 9-3
2 Engine starts but stalls soon. ………………………… 9-5
Fuel System ………………………………………… 9-5
Ignition System ……………………………………… 9-6
Intake • Compression Pressure …………………… 9-7
3 Idle engine speed will not stabilize. ………………… 9-8
4 Rough acceleration. …………………………………… 9-9
5 Gear shifting cannot be made normally. …………… 9-10
10.Wiring Diagram
11.C Model
Service Information
1. Specification • Service Data ………… 11-2
2. Parts Layout …………………………………… 11-12
3. Difference item ……………………………… 11-30
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MFS4-5-6̲E̲ch00̲110422.qxd 11.4.22 6:14 PM ページ 7
INDEX
4st 4/5/6 2011
1
Service Information
2
Service Data
3
Inspections and
Adjustments
4
Fuel System
5
Power Unit
6
Lower Unit
7
Bracket
8
Electrical System
9
Troubleshooting
OK
10
Wiring Diagram
11
C Model Service Information
vii
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viii
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1
1
Service Information
1. Identification
(Engine Serial Number)……………………… 1-2
2. Work Safety ………………………………… 1-2
1) Fire Prevention …………………………… 1-2
2) Ventilation ………………………………… 1-2
3) Protection ………………………………… 1-2
4) Genuine Parts …………………………… 1-2
5) Tools ………………………………………1-3
6) Recommendations on Service ………… 1-3
7) Cautions in Disassembling and
Assembling Components………………… 1-4
3. Tools and Instruments ………………… 1-5
1) Test Propeller …………………………… 1-5
2) Instruments ……………………………… 1-5
3) Special Tools ……………………………… 1-6
4. Pre-delivery Inspection ………………… 1-8
Steering Handle ………………………… 1-8
Gear Shift ………………………………… 1-8
Engine Oil ………………………………… 1-8
Gear Oil …………………………………… 1-8
Fuel Tank Line …………………………… 1-9
Rigging …………………………………… 1-9
Inspection of Tilt Stoppe ………………… 1-9
Inspection of Stop Switch ……………… 1-10
Cooling Water Check Port …………… 1-10
Idle Operation …………………………… 1-10
Propeller Selection ……………………… 1-11
Inspection of Forward and
Reverse Shifts…………………………… 1-11
5. Break-in Operation……………………… 1-12
6. Test Run …………………………………… 1-12
7. Check After Test Run ………………… 1-13
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
MFS4-5-6̲E̲ch01̲110422.qxd 11.4.22 5:41 PM ページ 2
Service Information
1. Identification (Engine Serial Number)
Engine serial number is stamped on the bottom cowl of
outboard motor body.
1 Model Name
2 Model Type
3 Serial Number
Made in Japan
F5BD 1 3H6 2
::::::::3
SERIAL No.
RATED POWER
3.7 kW
FULL THROTTLE RANGE
MASS
4500
24
5500
28
r / min
kg
2. Work Safety
1) Fire Prevention
Gasoline is hazardous material and very flammable. Do not
handle gasoline near 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 exposure to
such matters, wash away with soap or warm water
immediately.
4) Genuine Parts
Use parts and/or chemicals that are genuine items or
recommended.
1-2
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5) Tools
Use specified special tools to prevent damaging to parts and
to perform work safely and surely. Be sure to follow
installation procedures described in this manual and use
1
3R0728150
tightening torque specified.
3AC728710
6) Recommendations on Service
Remove foreign substances and dirt from outboard motor
and individual parts by cleaning. Apply recommended oil or
grease to rotating areas and sliding surfaces. After individual
assembly, always perform verifications such as ensuring
smooth movement and sealing.
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Service Information
7) Cautions in Disassembling and
Assembling Components
(1)
Secure outboard motor to dedicated stand firmly.
(2)
Take special care not to scratch painted surfaces or mating
surfaces of cylinder and crankcase.
(3)
Replace parts such as packings, gaskets, O rings, oil seals,
spring pins or split pins with new ones after they are
removed. Replace deformed snap rings with new ones.
1
1 Clamp screw
(4)
When replacing parts, be sure to use genuine parts. For
fluids such as gear oil, use genuine product.
O
IL
-C
O
M
(5)
(6)
When reassembling parts, use their mating marks. For parts
without mating marks, simple marking makes reassembling
easier. Use applicable parts list for reference.
(7)
Clean individual parts that have been removed, and check
their condition.
(8)
When assembling, be careful of the fit, repair limits, airtightness, clogging of oil holes 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 fastners in diagonal or clockwise
order from inner ones to outer ones evenly to specified
torque. In either case, tighten the fastners to the specified
torque in two or three steps. (Reverse the order when
disassembling.)
(9)
GM
SOC
Be sure to use special tools that are specified, and perform
the work properly.
P.
SOC
Liq
uid
1 2 O-R
LOR
in
g
LOR
G
RE
AS
E
LIT
LIT
When installing bearings, face the flat (numbered) side to the
special assembling tool.
(10) When installing oil seals, be careful not to scratch the
surface of the lip that contacts with the shaft, and install them
in correct orientation. Apply recommended grease to the lip
before installation.
(11) When applying liquid sealant, take care to use sparingly.
Excessive application may be oozed out, adversely affecting
interior of the crankcase. Use adhesive after thoroughly
reading the instructions.
(12) When servicing power unit, use of wooden work board
makes the work easier.
170
120
¿60
30
15
120
70
35
50
30
Power Unit Work Table
1-4
20
30
70
35
(mm)
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3. Tools and Instruments
1) Test Propeller
P/N. 3B2-64110-1
Outer diameter : 164mm
1
Width : 12mm
(Reference value)
Model
Speed at WOT
(Wide Open Throttle) (r/min)
F 4B/5B
4,500 - 5,500
F 6B
5,000 - 6,000
This test propeller has been designed for break-in
operation and load test operation.
The engine speed at WOT varies depending on
the conditions such as the level or water or air
temperature, and thus, the measurement is not
for confirmation or power of the engine.
2) Instruments
For the following measuring instruments, use commercially available ones.
Circuit tester
( Resistance : 1Ω, 10Ω, 10 kΩ, AC voltage : 30 to 300V, DC voltage : 30V )
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 50 mm, 50 to 75 mm )
Ring gauge
( ø5.5, ø14, ø20, ø47, ø55 )
Dial gauge
( minimum graduation of 0.01 )
Thickness gauge
( 0.03 to 0.3 mm )
V block
Surface plate
( 500 mm x 500 mm )
Dial gauge magnet base or dial gauge stand
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Service Information
3) Special Tools
Vacuum/Pressure Gauge
P/N. 3AC-99020-0
Spring Pin Tool A
P/N. 345-72227-0
Spring Pin Tool B
P/N. 345-72228-0
Thickness Gauge
P/N. 353-72251-0
Inspecting pressure
Removing spring pin
Installing spring pin
Measuring gaps
Center Plate 3
P/N. 3AB-99701-0
Driver Rod 3
P/N. 3AB-99702-0
Tachometer
P/N. 3AC-99010-0
Compression Gauge
P/N. 3AC-99030-0
Used in combination with driver rod and
bearing attachment to locate lower gear
case bearing
Used in combination with center plate and
bearing attachment
Measuring engine revolution
speed
Measuring compression
pressure
Valve Spring Compressor Attachment
P/N. 3AB-99076-0
Flywheel Puller Kit
P/N. 369-72211-0
Spark Tester
P/N. 3F3-72540-0
Piston Slider
P/N. 3H6-72871-0
Inspecting spark
Installing piston
Removing or installing valve
Removing/installing flywheel
springs
Bearing Press Collar
P/N. 3H6-72768-0
Bearing Press
P/N. 3H6-72769-0
Bearing Attachment 2
P/N. 3BR-99905-0
Bearing Attachment 4
P/N. 3BV-99905-0
Used in combination with driver rod and
center plate to remove lower gear case
bearing
Used in combination with driver rod and
center plate to locate lower gear case
bearing
Installing bearings
Installing bearings
1-6
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1
369-72727-0
Needle Bearing Press Kit
P/N. 369-72900-0
Backlash Measuring Tool Kit
P/N. 369-72740-0
Clamp A
P/N. 3B7-72720-0
Dial Gauge Plate
P/N. 3B7-72729-0
Installing bearings
Measuring gap between forward and
pinion gears (A and B gears)
Measuring backlash
Used to attach dial gauge
when measuring backlash
Flushing Attachment
P/N. 336-60007-0
Flushing cooling water
passage with fresh water
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Service Information
4. Pre-delivery Inspection
∫
å
1) Steering Handle
c
å Check installations for clattering and play.
ç Check throttle grip for movement. (full open/full close).
1
d
∫ Adjust steering friction.
ç
∂
c
∂ Adjust throttle friction.
a
d
b
1 Steering Adjust Screw
c Lighter d Heavier
2) Gear Shift
1.
Check shift lever 1 and propeller shaft for smooth
movement of the shift between forward (F) and neutral (N)
while engine is operating.
N
F
R
1
3) Engine Oil
1
1.
Set outboard motor straight ahead and vertical.
2.
Fill with Engine Oil.
OIL
3.
4 Stroke Engine Oil :
450cm3 (15.2 fl.oz)
Use oil level gauge 1 to check oil quantity.
CAUTION
1 Oil Level Gauge
Engine oil is removed before shipment to
4st
O
IL
prevent leakage during transportation.
4st OIL
4) Gear Oil
1.
Check quantity of gear oil.
OIL
Gear Oil :
195 cm3 (6.6 fl.oz)
Spill of some oil from upper plug hole as plug is
removed indicates that gear case is filled with
specified quantity of gear oil.
2 1
1 Oil Plug 2 Gasket
1-8
Do not reuse.
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5) Fuel Tank Line
1.
Check that fuel tank contains sufficient amount of gasoline,
fuel line is connected and is free of leak.
CAUTION
1
Since this is a four stroke engine model, do
not use fuel mixed with engine oil. Use of
fuel mixed with engine oil will cause engine
trouble.
Dual Tank model
Separate Tank model
6) Rigging
1.
Check that clamp bracket is fixed securely to hull.
2.
Check location of anti-ventilation plate relative to boat
bottom, and, if necessary, adjust to prevent decrease in
propulsive force and engine overheating.
a
Test-run to determine the best installation height.
a 30 - 50 mm (1.2 - 2.0 in)
Anti-ventilation plate standard position a :
Cavitation plate located 30 - 50 mm (1.2 2.0in) below boat bottom
7) Inspection of Tilt Stopper
1.
Fully tilt up the outboard motor, lock with the tilt stopper 1,
and then check that the holding mechanism functions
normally.
1
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Service Information
8) Inspection of Stop Switch
1.
Press stop switch 1 hard or pull out lock 2 from stop switch
1 to check that engine stops.
1
2
1
2
9) Cooling Water Check Port
1.
Check that cooling water check port 1 discharges water
during engine runs.
1
10) Idle Operation
1.
After engine has warmed up in neutral, use tachometer to
1
check idle engine speed is as specified.
RPM
Idle Engine Speed :
1,300 r/min
Tachometer :
P/N. 3AC-99010-0
1 High Tension Cord
1-10
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11) Propeller Selection
1.
Select a propeller that is best-suited to type of boat and
application.
Range of operating engine revolution at WOT
4/5B : 4,500 - 5,500r/min
6B : 5,000 - 6,000r/min
RPM
1
CAUTION
Miss-selection of propeller can cause adverse
effects on engine life, fuel consumption, etc.
as well as on performance.
Propeller [Marking]
No. of Blades x
Diameter x Pitch
mm (in)
[6"]
3 x 212 x 160
(3 x 8.3" x 6.3")(Sail Pro)
[6"]
3 x 200 x 152
(3 x 7.9" x 6.0")
[7"]
3 x 200 x 178
(3 x 7.9" x 7.0")
[8"]
3 x 200 x 203
(3 x 7.9" x 8.0")
[9"]
3 x 200 x 229
(3 x 7.9" x 9.0")
12) Inspection of Forward and Reverse Shifts
Use shift lever 1 to shift the gear to forward (F), Neutral (N)
and Reverse (R).
1.
a
N
F
Forward
2
Return handle grip 2 to idle speed a, and then, move shift
1
lever 1 toward the operator (F) quickly.
2.
Reverse
Return handle grip 2 to slow side a, and then, when the
1 Shift Lever
engine reached the lowest speed, set shift lever 1 toward
the reverse side (R) quickly.
3.
a
N
Shallow water run
In shallow water, run at the lowest possible speed while
R
2
watching the depth and obstacles.
In reverse operation, run at low speed, and do not
increase the engine speed unnecessarily.
1
WARNING
Shifting at high engine speed may cause
fall of passenger due to abrupt acceleration
and damage to gear, clutch and other
components of the outboard motor. Shift at
the lowest engine speed.
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Service Information
5. Break-in Operation
1.
Break-in operation is needed for the purpose of smoothening
sliding surfaces between components such as pistons and
cylinder, piston rings, piston pins, crank shaft, connecting
rods, and intake and exhaust valves.
Break-in Operation…10 hours
Time
Operation
0
10 minutes
Dead Slow or Idling
2 hours
1/2 of WOT or less at
approximately 3,000
r/min
Running at the slowest
possible speed
3 hours
3/4 of WOT or less at
approximately 4,000 r/min
WOT run for approximately 1
minute can be included every
10 minutes of run.
10 hours
3/4 of WOT at
approximately 4,000
r/min
Regular Operation
Short period WOT run
can be included.
6. Test Run
1.
Start engine and check if gear shift can be moved smoothly.
2.
After completing warm-up operation, check idling revolution
1
speed.
RPM
Idling Revolution Speed : - Neutral
1,300 r/min
Tachometer :
P/N. 3AC-99010-0
3.
1 High Tension Cord
3.Shift gear into forward (F) and run dead slow for
approximately 10 minutes.
RPM
4.
Dead Slow Revolution Speed :
1,150 r/min
Run at 2,000 r/min or half of WOT or less for initial 2 hours,
then at 3,000 r/min or 3/4 of WOT or less for 1 hour.
5.
Check that shifting into reverse (R) will not tilt up outboard
motor and allow water to run into boat.
Complete test run during break-in operation.
1-12
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7. Checks After Test Run
1.
Check that power unit, lower unit and bracket are free of
1
looseness or play.
2.
Check that no water is present in gear oil.
3.
Check that no fuel leakage exists in the cowl.
4.
Check that no oil and water leak in the cowl and no water is
1
1
1 Flushing Attachment (optional)
present in engine oil.
5.
If using in salt water after test run, use flushing attachment
1 (optional) and fresh water to wash cooling water path by
idling engine.
Flushing Attachment :
P/N. 336-60007-0
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Service Information
1-14
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2
2
Service Data
1. Outline Dimensons ……………………… 2-2
1) Engine Dimensions ……………………… 2-2
2） Clamp Dimensions ……………………… 2-4
2. Engine Lubrication System
Diagram ……………………………………… 2-5
3.
4.
5.
6.
7.
Cooling Water System Diagram……… 2-6
Specifications ……………………………… 2-8
Maintenance Data………………………… 2-10
Tightening Torque Specifications … 2-14
Sealant and Lubricant ………………… 2-15
MFS4-5-6E̲ch02̲110422.qxd 11.4.22 6:58 PM ページ 2
Service Data
1.Outline Dimensons
1）Engine Dimensions
<Dual Tank model>
Item
A
B
C
S
L
UL
S
L
UL
N
P
D
E
F
G
H
I
J
K
L
S
L
UL
S
O
M
N
O
P
Q
R
S
T
U
G
H
Type
Unit
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
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
deg.
deg.
deg.
deg.
mm/in
mm
418
655
782
909
435
562
689
400
510
110
330
350
335
30-60
275
658
758
858
325
265
210
445
110
in
16.46
25.79
30.79
35.79
17.13
22.13
27.13
15.75
20.08
4.33
12.99
13.78
13.19
1.18-2.36
10.83
25.91
29.84
33.78
12.8
10.43
8.27
17.52
120
12
75
75
4.33
M
D
F
A
E
Q
J
R
U
B
C
T
L
2-2
K
I
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<Sepalate Tank model>
Item
A
B
C
S
L
UL
S
L
UL
N
P
D
E
F
G
H
I
J
K
L
S
L
UL
S
O
M
N
O
P
Q
R
S
T
U
G
H
Type
Unit
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
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
deg.
deg.
deg.
deg.
mm/in
mm
365
655
782
909
435
562
689
400
510
110
330
350
335
30-60
275
658
758
858
325
265
210
445
110
in
14.37
25.79
30.79
35.79
17.13
22.13
27.13
15.75
20.08
4.33
12.99
13.78
13.18
1.18-2.36
10.83
25.91
29.84
33.78
12.8
10.43
8.27
17.52
120
12
75
75
4.33
2
M
D
F
A
E
Q
J
R
U
B
C
T
L
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K
I
2-3
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Service Data
2）Clamp Dimensions
'&
$
(
$
& &%
$ !
"#
$ $# $%
2-4
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2. Engine Lubrication System Diagram
2
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Service Data
3. Cooling Water System Diagram
2
3
1
4
1
5
2
6
7
3
4
5
9
8
7
0
6
9
q
8
! w
w
1 2
3
4 5 2-6
7 ）
8 9 0 0
q
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2
4st 4/5/6 2011
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MFS4-5-6E̲ch02̲110427.qxd 11.4.27 8:51 AM ページ 8
Service Data
4. Specifications
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4st 4/5/6 2011
MFS4-5-6E̲ch02̲110422.qxd 11.4.22 6:58 PM ページ 9
Item
Unit
Dual Tank Model
4/5/6B
Model
Sepalate Tank Model
5/6B
Sail Pro
6B
Fuel and oil
! ) &'(
!&)
1$$&
0 34
+ + & A
A
&'(
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& 0 34
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+ " # #
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./0* ./%
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6./* 5 737
2
Lower unit
+ + ' # ' ' < =
B @ : 3 @
' 818
35 0 9 6
! # : ! "; #; ; % 9 >? 0 @ @ >6
7? 0 @ @ 7
5* 7 9 6? 0 @ @ 0
Bracket
13 D
:
! ; ; # D :
$ @ :
A
A0
! :
$ @ ; A A0 ! / 7
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5
0 E 55 36 E 3>
Warning system
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2-9
MFS4-5-6E̲ch02̲110422.qxd 11.4.22 6:58 PM ページ 10
Service Data
5. Maintenance Data
9 7 2-10
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%$%( 3 %$%4 &%$%%0' 3 %$%%')*
. %$%0 3 %$0) &%$%%%5 3 %$%%40*
%$%%' 3 %$%0' &%$%%%%)〜%$%%%54*
01$%% &%$1'##*
- %$0" 3 %$(" &%$%%"# 3 %$%0()*
%$(% 3 %$"% &%$%00) 3 %$%0#4*
. %$'% 3 %$5% &%$%%4# 3 %$%0"4*
01$%0 &%$1(%(*
%$%5% 3 %$%11 &%$%%0"4 3 %$%%'1%*
%$'% 3 %$5% &%$%%4# 3 %$%0"4*
'#$#" &0$04#0*
- %$%" &%$%%'%* $
%$%1 3 %$05 &%$%%'5 3 %$%%""*
%$00 3 %$0# &%$%%5( 3 %$%%4"*
"$54 &%$'0"5*
"$55 &%$'05'*
"$"% &%$'01"*
"$"% &%$'01"*
%$%'% 3 %$%55 &%$%%%4# 3 %$%%04(*
%$%5" 3 %$%4' &%$%%044 3 %$%%')(*
%$) &%$%(0"*
%$) &%$%(0"*
("$% &0$()*
')$(( &0$00"54*
0($#)% &%$""%5*
%$(5
%$#(
&5#$( * =($">'? @0%A
&0(4$) * =#$">'? @0%A
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MFS4-5-6E̲ch02̲110422.qxd 11.4.22 6:58 PM ページ 11
%$%( &%$%%0'*
"#$%4 &'$('"1*
%$%1 &%$%%'5*
%$%1 &%$%%'5*
%$%( &%$%%0'*
")$#% &'$(0)#*
%$0"% &%$%%"#0*
C $
$ &D E'5% 5%% $ D E1%% $*
$
$
$
2 ,
8$ 5%% 1%%, $
$ &D E'5% 5%% $ D E1%% $**
2 $
2 $
D 8$ 5%% 1%% , $
- %$0% &%$%%(#*
%$%# &%$%%("*
. %$'0 &%$%%)(*
2 $
2 $
%$%5 &%$%%0"4*
0"$#4 &%$1')4*
2 $
2 $
- %$"% &%$%0#4*
%$4% &%$%'41*
2 $
2 $
2 $
2 $
2 $
2 $
2 $
01$%5 &%$1(05)*
%$%)% &%$%%(0"*
%$4% &%$%'41*
'#$#' &0$04)%*
%$%" &%$%%'%*
C "$5" &%$'051*
"$50 &%$'0(%*
"$"5 &%$'0)0*
"$"4 &%$'0#(*
%$%4% &%$%%'41*
%$0%% &%$%%(#5*
0$) &%$%4%#*
0$) &%$%4%#*
(($' &0$(0*
')$%4 &0$0%"0*
0($#"% &%$"5#(*
%$%( &%$%%0'*
2 $
2 $
2 $
$
2 $
2 $
2 $
2 $
, $
4st 4/5/6 2011
2-11
2
MFS4-5-6E̲ch02̲110422.qxd 11.4.22 6:58 PM ページ 12
Service Data
Part name
Fuel and lubrication parts
Electrical parts
Cooling system parts
& ' (
' #(
)) *
' (
' #(
+ , ! > ? >
@ ? >
B322
#
# C !!
DB52; E
FG? G A G? G
!!
I !! DB52; E DH E
> 8
!!
& ! !
!
! " #
! Lower unit parts
Other
parts
2-12
Item
& !
& !
+= +
+
+ + !
! ! ? ? # "
"
? ? ! # ! ? ! ! ! += = = $ ! ! + $
C +
$ $ ! ! " ? ! ! !!
+= 4B
-# #
012
014
672
61-3
0197
6-3
6112
:7;
5B
-##
01014
673
6133
0592
6-8
6112
:3;
Standard value
Sail Pro
6B
(EPA)
-#.#
013
013
051
051
678
678
61 2
61 2
0595
0595
6-8
6-8
6152
6152
::;-2<< ::;-2<<
1292
1=-22
Sail Pro
(EU)
-$/#
013
051
678
61 2
0595
6-8
6152
::;-2<<
5-924 29424
2915 A 2952 2922 : A 2922:4
3944 295-38
2925 A 292: 292228 A 292258
$ A $ 53;
12 29 293 29252
15&72+
29 7 A 2978H
8
-92 A :92H
$ 7JD*"/E
298 A 294 292-1 A 292-3
32 A 3 ; 151 A 154;,
7- A 7:; 1 7 A 13 ;,
-92 2915 2923 A 2913 292252 A 292234
$ K2917 A 29 4 29227- A 29214-
292-2 A 29238 292215 A 29225-
292 2 A 292: 292217 A 292258
K522L1:8 :94L:92
3= 7 K522L52- :94L892
-97: 291 3
7 K
515L172 89-L79-
29217 A 292:- 2922275 A 292258:
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MFS4-5-6E̲ch02̲110422.qxd 11.4.22 6:58 PM ページ 13
2
5-91- 2953 2922 : A 2922:4
3947 295- 7
2912 2922-4 + ! 9
12 29 ? 9
#'! ! 9
195 292 :
9
9
? 9
9
! ! 9 #'! > !
9 ! !> 9
! ! ! ? ! = ! 73; 132;, L> 3 !9
-92 2915
! ?= ! ? 2923 292252
29- 292118 2948 292-87 291 2922-4 ! 9
! 9
? 9
! ! !9
!> ?
!> ?
!> ?
!!>9
9
291 2922-4 9
= -9:2 291 3:
295 29228
293 29252
!!>9
? 9
!!>9
9
9
!> ?
C ! = = = ! 9
! 293 29252 !! > ?9
4st 4/5/6 2011
2-13
MFS4-5-6E̲ch02̲110422.qxd 11.4.22 6:58 PM ページ 14
Service Data
6. Tightening Torque Specifications
Tightening location
Engine
Connecting rod
Wrench
Thread B
Type of
A
x Pitch
fastener
10
M7x1.0
Bolt
Tightening torque
N·m
lb·ft
kg·m
1st
6
4
0.6
2nd
12
Cylinder head
13
M8x1.25
Bolt
9
1.2
1st
12
9
1.2
2nd
25
Oil pan
13
M8x1.25
Bolt
18
2
1st
12
9
1.2
2nd
25
10
M6x1.0
Bolt
18
2.5
1st
5
4
0.5
2nd
Lower unit
Specified torque
9
7
0.9
Oil drain bolt
10
M10x1.25
Bolt
18
13
1.8
Pivot bolt
13
M8x1.25
Bolt
25
18
2.5
Pivot adjust nut
10
M6x0.5
Nut
10
7
1.0
Oil pressure switch
10
PT1/8
Bolt
9
7
0.9
Flywheel
19
M12x1.25
Nut
50
37
5.0
Spark plug
16
M12x1.25
—
18
13
1.8
Recoil starter
10
M5x0.8
Bolt
4
3
0.4
Power unit mounting bolt
10
M6x1.0
Bolt
7
5
0.7
Sturn bracket
13
M8x4.25
Bolt
13
9
1.3
Extension housing bolt
10
M6x1.0
Bolt
6
4
0.6
13
M8x1.25
Bolt
13
9
1.3
M5 Bolt, Nut
8
M5x0.8
Bolt, Nut
4
3
0.4
M6 Bolt, Nut
10
M6x1.0
Bolt, Nut
6
4
0.6
M8 Bolt, Nut
13
M8x1.25
Bolt, Nut
13
9
1.3
M10 Bolt, Nut
17
M10x1.25
Bolt, Nut
27
20
2.7
B
2-14
A
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MFS4-5-6E̲ch02̲110422.qxd 11.4.22 6:58 PM ページ 15
7. Sealant and Lubricant
Shin-Etsu
Chemical
Centax FM- Bentax LML2
2
531
902
KS64
●
Bearings and cams
●
Sliding surface
Valve (IN, EX)
●
Stem and stem end
Valve spring
●
Whole area
Valve spring seat
●
Whole area
Retainer cotter
●
Whole area
Pivot
●
Whole area
Cylinder liner
●
Inner wall
Piston
●
Ring grooves and periphery
Piston ring
●
Whole area
Piston pin
●
Periphery
Connecting rod
●
Big and small end bores
Connecting rod cap
●
Inside
Crankshaft
●
Sliding surface, Bearing and Gear
Ball bearing (crankshaft)
●
Sliding surface, Outer surface
Bush (crankshaft)
●
Inside and outside
●
Oil seal (crankshaft)
Lip
Engine block
●
Outer surface (at press fitting)
Plunger
●
Spring and O rings
Oil pump
●
Outer and Inner rotor
Fuel pump
●
Plunger top surface
O ring (fuel pump)
●
Screw (oil strainer)
●
●
Lip
●
●
Outer surface (at press fitting)
Thread
●
Oil strainer pipe
Seal rubber
●
Exhaust cover gasket
Starter case
●
Sliding surface
Starter spring
●
Whole area
Ratchet
●
Sliding surface
Friction plate
●
Sliding surface
Real
●
Sliding surface
Starter shaft (bolt)
●
Oil pressure switch
at reusing bolt
●
Frange surface
●
Plug cap
4st 4/5/6 2011
2
Rocker arm
Oil seal (crankcase)
Electrical
components
Remarks
Camshaft
O ring (filler cap)
Recoil
starter
Tohatsu genuine gear oil
Chuoh Yuka
4 stroke engine oil
2000
Silicone grease SOC
1741
Teflon grease TEF
Cylinder
&
Oil pan
G103
Rubber grease RUB
Cylinder
Head
G17
Three Liquid
Bond O-Ring
Water resistant grease OBM
1342
Konishi
Cold resistant lithium grease LIT
Three
Bond
Sealing agent
Instantaneous adhesive
Adhesive
Screw locking agent
Apply to
●
Spark plug bore
High tension cord bore
●
Thread
●
Terminal
2-15
MFS4-5-6E̲ch02̲110422.qxd 11.4.22 6:58 PM ページ 16
Service Data
●
Shift lever
●
Sliding surface
Thread
●
Crankshaft spline
●
● at press fitting
Ball bearing
● at press fitting
Needle bearing inner
Thread
●
Bolt (gear case)
Lip
●
Oil seal (pump case lower)
● Outer surface, at press fitting
Impeller sliding surface
●
Pump case liner
Gear case
●
Cam rod bushing
O ring (cam rod bushing)
●
Bolt (cam rod bushing)
●
Bolt (cam rod bushing)
●
Thread
Thread
● at press fitting
Ball bearing
Lower unit
● at press fitting
Needle bearing
Propeller
shaft
housing
Propeller shaft housing
●
inlow
Bolt (propeller shaft housing)
●
Thread
●
O ring
Lip
●
Oil seal
● Outer surface, at press fitting
Spline
●
Propeller shaft
● at press fitting
Ball bearing
Bracket
Tiller
handle
Cowl
Stern bracket plate
●
Washer, 8.5-28-1.0
Clamp screw
●
Thread
Swivel bracket (bracket bolt)
●
Sliding surface
Swivel bracket (tilt stopper mount)
●
Sliding surface
Steering bush
●
all area
Thrust plate
●
all area
Tiller handle
●
Grip sliding face
Throttle burden
●
Inner
Bushing (tiller handle)
●
Inner and outer surfaces
Throttle shaft
●
Sliding face (except slide adjusting section)
Throttle wire
●
Wire
Choke rod grommet
●
Inner
Bush (hook lever)
●
Inner and outer surfaces
Seal ring (hook lever)
●
Lip
●
Starter seal rubber
Nipples
Amount of engine oil
Gear oil
2-16
Tohatsu genuine gear oil
4 stroke engine oil
Centax FM- Bentax LM- KSL2
2
531
902 64
Drive shaft (spline)
Drive
shaft
Remarks
Shin-Etsu
Chemical
Chuoh Yuka
O ring (shift lever)
Drive shaft
Taper plug 1/8
housing
Silicone grease SOC
2000
Teflon grease TEF
1741
Rubber grease RUB
Shift
G103
Three Liquid
Bond O-Ring
Water resistant grease OBM
1342 G17
Cold resistant lithium grease LIT
Konishi
Sealing agent
Three
Bond
Instantaneous adhesive
Adhesive
Screw locking agent
Apply to
●
Press fit section
●
450ml when replaced
● Oil capacity 195ml
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MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 1
3
3
Maintenance
1. Special Tools ……………………………… 3-2
2. Inspection Schedule …………………… 3-3
3. Inspection Items ………………………… 3-4
1) Inspection of Top Cowl ………………… 3-4
2) Fuel System ……………………………… 3-4
3) Inspection of Fuel Tank ………………… 3-5
4) Inspection of Fuel Filter ………………… 3-5
5) Replacement of Engine Oil ……………… 3-6
6) Inspection of Gear Oil Quantity ………… 3-7
7) Inspection of Water Pump ……………… 3-7
8) Replacement of Gear Oil ……………… 3-9
9) Inspection of Gear Case (for leakage) … 3-10
10) Inspection of Spark Plugs
…………… 3-11
11) Inspection of Compression Pressure … 3-12
12) Inspection and Adjustment of
Valve Clearance ………………………… 3-13
13) Throttle Cable …………………………… 3-15
14) Inspection of Idle Engine Speed ……… 3-17
15) Inspection of Ignition Timing …………… 3-17
16) Inspection of Anode …………………… 3-18
17) Replacement of Anode ………………… 3-18
18) Inspection of Propeller ………………… 3-19
19) Inspection of Thermostat ……………… 3-19
20) Inspection of Cooling Water Passage … 3-20
21) Flushing with Water …………………… 3-21
22) Greasing Points ………………………… 3-22
MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 2
Maintenance
1. Special Tools
Tachometer
P/N. 3AC-99010-0
Compression Gauge
P/N. 3AC-99030-0
Measuring engine revolution
speed
Measuring compression
pressure
3-2
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MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 3
2. Inspection Schedule
Part to be
inspected
Inspection period
+) -) ,))
+)) ,
+
, ( . , Inspection item
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
!
o
o
o
o
Fuel System
Ignition Starting
System System
o
o
o
o
o
o
Engine
o
o
01
o
o
Lower System
o
o
o
o
o
o
o
8 $
o
o
o
o
o
o
o
o
o
o
o
/ % %
!
o
o
o
o
o
! 0
! )*2 3 )*4
5)*)(, 3 )*)(- 6
3
7-)
o
Remarks
*
& 89-02) 4)
,4- 5.*. *:6
0 Sliding areas, rotating o
o
o
o
o
o
1 part, grease nipple
"# $%& ' ()) *
Bolts and Nuts
4st 4/5/6 2011
o
o
o
3-3
MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 4
Maintenance
3. Inspection Items
1) Inspection of Top Cowl
Push top cowl using both hands to check for looseness and
seal when cowl latched.
2) Fuel System
Check piping
Remove top cowl and check each section for fuel leak, dirt,
deterioration and damages. Clean or replace parts if
necessary.
3-4
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MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 5
3) Inspection of Fuel Tank
< For Dual Fuel Tank model >
1
Remove dirt and water from fuel tank 1 if any.
< For separate Fuel Tank model >
Turn fuel pick up elbow 3 of fuel tank 2 counterclockwise
to remove the part, and clean the filter 4. Remove dirt
and water from fuel tank 2 if any.
3
3
4
2
3 Fuel Pickup Elbow
4 Filter
4) Inspection of Fuel Filter
Check fuel filter for dirt, build up of fuel residue, and fuel filter
for invasion of foreign matter and cracks. Replace fuel filter if
necessary.
· Do not spill fuel when removing fuel filter.
· Be careful to instllation direction. Fuel flows to
the direction of the arrow mark.
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3-5
MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 6
Maintenance
5) Replacement of Engine Oil
1.
Oil Level
Upper Limit
Lower Limit
Oil Specification
OIL
Engine Oil :
4 Stroke Engine Oil
API: SE, SF, SG, SH, SJ, SL, SM
SAE: 10W-30, 10W-40
NMMA : FC-W Certified 10W-30/40
Quantity of Engine Oil :
0.45L (0.5qt)
2.
0.45L
0.35L
Use oil with viscosity that is suited to ambient air
temperature of the operating region.
3.
Engine Oil Replacement Procedure
1. Stop engine and wait till it cools down.
Position outboard motor so that engine oil can be drained
from drain bolt 1 easily.
1
2
2. Remove oil level gauge 2.
3. Place drain oil pan below drain bolt 1.
4. Remove drain bolt 1 to drain oil.
3-6
1
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MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 7
5. Tighten drain bolt 1.
6. Pour new oil into oil inlet until oil level reaches upper
limit mark of oil level gauge.
1
7. Start and run engine for 5 minutes to warm up.
8. Stop engine and check oil level and for oil leaks after 5
minutes.
1.
2.
a
Tilt down outboard motor to make it vertical.
GEAR
O
6) Inspection of Gear Oil Quantity
IL
3
GEAR
Remove upper oil plug 1 and check level of gear oil in the
gear case.
Spill of some oil from plug hole a as plug is
removed indicates that gear case is filled with
specified quantity of gear oil.
3.
2
1
Add recommended gear oil to specified level if it is low.
OIL
Gear Oil :
Hypoid Gear Oil
API : GL-5
SAE : 80W-90, 90
2 Washer
Do not reuse.
If the oil is low, add through lower oil plug hole.
4.
Attach upper oil plug 1.
7) Inspection of Water Pump
1.
Loosen shift rod joint bolt and separate shift rod pieces.
1
(Disconnect shift rod at lower side of shift rod joint 1.)
Be careful not to drop shift rod joint and bolt when
they are removed.
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MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 8
Maintenance
2.
Remove lower unit installation bolts 2, and pull lower unit
ass'y downward to remove.
2
2
3.
Remove pump case (Upper) 3.
4.
Remove impeller 4 and check it.
5.
Check upper pump case for deformation. Replace if
6.
3
necessary.
5
Check impeller 4 and pump case liner 5 for cracks and
4
a
wear. Replace if necessary.
a Projection
7.
Check pin 6 and drive shaft groove b for wear. Replace if
necessary.
8.
b
Reinstall the part. For details, refer to Chapter 6.
6
3-8
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MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 9
8) Replacement of Gear Oil
1.
Tilt outboard motor a little as shown.
2.
Place drain oil pan below oil plug 1, remove lower oil plug
3
2
1 and then upper oil plug 2 to drain oil.
Remove lower oil plug first when draining.
3.
Check gear oil for presence of metal particles, change of
3
1
color (abnormal if clouded), and viscosity.
3 Gasket
a
hole 4 until gear oil starts to spill from upper oil plug hole a
IL
3
Fill with gear oil (from oil tube or pump) through lower plug
GEAR
O
4.
Do not reuse.
GEAR
without air bubbles.
OIL
Gear Oil :
Hypoid Gear Oil
API : GL-5 SAE : 80W-90, 90
Quantity of Gear Oil :
195 cm3 (6.6fl.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.
2
4
3 Gasket
Do not reuse.
a
gasket and lower oil plug 1 immediately.
IL
Attach new gasket and upper oil plug 2, and then new
GEAR
O
5.
3
GEAR
When fully filled with oil, attach upper oil plug first.
3
2
3
3 Gasket
4st 4/5/6 2011
Do not reuse.
3-9
MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 10
Maintenance
9) Inspection of Gear Case (for leakage)
1.
Drain gear oil.
2.
Remove upper oil plug 1 and connect a commercially
1
available leakage tester to this hole.
3.
Apply specified pressure to gear base, and check if the
pressure is maintained without further compression for 10
seconds.
Specified Gear Case Maintained Pressure :
0.049 MPa (7 psi) [0.5 kgf/cm2]
· Rotating propeller shaft while maintaining
pressure and testing with 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
shaft, and propeller shaft housing and water pump case
lower for damages.
3-10
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10) Inspection of Spark Plugs
1.
Remove plug caps and then spark plugs.
2.
Use spark plug cleaner or wire brush to clean spark plug
electrodes 1. Replace if necessary.
3.
1
3
Check electrodes 1 for corrosion or excessive build up of
carbon, and washer 2 for damage. Replace if necessary.
2
4.
Check spark plug gap a. Replace if it is over specified
value. Adjust gap if it is out of specified range.
2
Spark Plug Gap a : Standard value
0.8 - 0.9mm (0.031 - 0.035in)
Functional Limit :
1.2mm (0.047in)
Specified Spark Plug :
DCPR6E [NGK]
5.
a
Install spark plug, fully hand-tighten, and then use plug
wrench to tighten to specified torque.
Spark Plugs :
18 N · m (13 lb · ft) [1.8 kgf · m]
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3-11
MFS4-5-6̲E̲ch03̲110422.qxd 11.4.22 5:45 PM ページ 12
Maintenance
11) Inspection of Compression Pressure
1.
Start and run engine for 5 minutes to warm up, and then
stop.
2.
Shift gear into neutral (N).
3.
Remove lock plate 1 (of stop switch lanyard) from stop
switch.
1
CAUTION
Remove lock plate (of stop switch lanyard)
from stop switch before measuring
compression pressure. This will prevent
engine from accidental starting.
4.
Remove all plug caps and then all spark plugs.
CAUTION
Clean areas around spark plugs on the
cylinder before removing spark plugs to
prevent dirt from entering cylinder.
5.
2
Install compression gauge 2 to plug hole.
Compression Gauge 2 :
P/N. 3AC-99030-0
6.
Fully open throttle, crank engine until compression gauge 2
indication stabilizes, and then measure compression
pressure.
Compression Pressure (Reference) : 500 r/min
With decompressor : 0.34 MPa (49.3 psi) [3.5 kgf/cm2] ±10%
Without decompressor : 0.93 MPa (137.8 psi) [9.5 kgf/cm2] ±10%
(*Remove Exhaust rocker arm)
· Compression pressure is affected much by
cranking speed, and normally changes
approximately 10%.
· Do not pull choke knob when measuring
compression pressure.
7.
If compression pressure is below specified value, put small
amount of engine oil into cylinder, and perform the test again.
· If compression pressure increases after the
above measure, check pistons and piston rings
for wear. Replace if necessary.
· If compression pressure does not increase
after the above measure, check valve
clearances, valves, valve seats and cylinder
head. Adjust or replace if necessary.
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12) Inspection and Adjustment of Valve
Clearance
· Perform inspection and adjustment of valve
clearances when engine is cold.
· #1 Set piston to top dead center of compression
stroke.
1.
Remove cylinder head cover, fuel pump and spark plug.
3
2.
Align locating marks 1 of flywheel and crankcase with each
other.
①
3.
When fuel pump is removed, cam shaft can be seen. If
projection 2 of cam shaft can be seen, it can be known that
the piston is at top dead center.
2
4.
The piston is at top dead center of compression stroke when
locating marks 1 of flywheel a and cylinder that are found
on the starboard side of crank case are aligned with each
a
other.
1
1
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Maintenance
5.
6.
Hold pivot and loosen lock nut.
Put thickness gauge 3 in the gap between rocker arm and
valve.
Valve Clearance (when engine is cold) :
(IN) intake side
: 0.06 - 0.14mm (0.0025 - 0.0055in)
(EX) exhaust side : 0.11 - 0.19mm (0.0045 - 0.0075in)
3
7.
Rotate pivot to adjust valve clearance, and then, tighten lock
nut.
Pivot Adjust Nut :
10 N · m (7 lb · ft) [1.0 kgf · m]
8.
3-14
Check valve clearance again.
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13) Throttle Cable
Adjustment of Throttle Cable
1.
Check position of cable at low speed and high speed sides.
2.
Set throttle grip to slowest position, and fully pull choke knob
to close choke valve.
3
3.
Lock nut 1 while applying tension to outer wire by pulling it
with a hand to fix low speed side wire.
1
The wire is in proper state if pushing inner wire at
the center makes deflection of about 1mm.
4.
Repeat above steps for high speed side wire, and fix it.
5.
Return choke knob to home position to fully open choke
valve.
To confirm slowest position of throttle grip, check gap
between projection of throttle drum and dent of opener
section. The gap is acceptable if it is in the range between
0.5mm and 1mm.
Repeat steps 2. to 4. if necessary.
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Maintenance
6.
Set throttle grip to full-open position, and check if throttle
lever of carburetor makes contact with stopper.
7.
Set throttle grip to full-close position, and check if throttle
lever of carburetor makes contact with stopper.
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14) Inspection of Idle Engine Speed
1.
Start engine and run for 5 minutes to warm up.
2.
Attach tachometer to spark plug high tension cord 1 to
1
check idle speed.
More accurate and stable reading can be
obtained when tachometer lead is connected with
high tension cords of individual cylinders linked
with each other.
Tachometer :
P/N. 3AC-99010-0
RPM
3
Idle Speed :
1300 r/min
15) Inspection of Ignition Timing
Adjusting system : Automatic control, no adjustment required
Run engine and use timing light to check ignition timing.
8 timings marks are found on the side of flywheel (TDC0°,
ATDC5°, BTDC5°, 10°, 15°, 20°, 25°, 30°), and ignition
timing is read with mark on the center of starter case a
window.
a
a
Model
F 4/5/6B
4st 4/5/6 2011
Range of Ignition Angle
Engine Starting
Idling
Accelerating
TDC 0° — BTDC 25°
TDC 0°
TDC 0°
BTDC 25°
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Maintenance
16) Inspection of Anode
1.
Replace anode 1 if it is corroded excessively.
Replace anode if volume is reduced to 2/3 of new part.
CAUTION
Do not coat anode and trim tab with oil,
grease or paint, or the anti-corrosion
function does not work normally.
1
· Do not coat anode with oil or paint.
· Since periphery of anode installation bolt is
corroded more than other areas, be sure to
retighten bolt at every inspection.
17) Replacement of Anode
1.
Anode protects outboard motor from galvanic corrosion
(corrosion of metal due to very weak electric current).
Anodes are used in the gear case, clamp bracket (PT
models), and power unit cylinder.
Replace anode if volume is reduced to 2/3 of new part.
· Do not coat anode with oil or paint.
· Since periphery of anode installation bolt is
corroded more than other areas, be sure to
retighten bolt at every inspection.
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18) Inspection of Propeller
1.
Check propeller blades and spline for cracks, damages,
wear and corrosion. Replace if necessary.
19) Inspection of Thermostat
1.
Loose thermostat cover nut and remove thermostat 1.
2.
Hang thermostat 2 in the water container.
3.
1
3
Put thermometer in the water, warm up water and measure
water temperature when valve opens.
2
Put a piece of thread 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 :
50 - 54°C (121 - 129°F)
(Valve starts to open at this temperature.)
4.
Measure valve lift of thermostat when prescribed
temperature has been reached. Replace if the length is
less than specified value.
a
Water Temperature :
63 - 67°C (146 - 154°F)
Valve lift a :
3.0mm (0.12in) or over
5.
Install thermostat, new gasket and cover.
Thermostat Cover Bolt :
6 N · m (4 lb · ft) [0.6 kgf · m]
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Maintenance
20) Inspection of Cooling Water Passage
1.
Check water strainer 1 for clogging. Clean if necessary.
1
2.
Set outboard motor in the water and start engine.
3.
Check that cooling water is discharged from cooling water
check port 2. If not, check water pump and cooling water
passage in the engine.
2
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21) Flushing with Water
CAUTION
Touching rotating propeller could lead to
injury. Be sure to remove propeller before
running engine on the land.
WARNING
Exhaust gas contains carbon monoxide,
which will cause gas poisoning. Do not
start engine with outboard motor placed in
a closed area such as boat house.
3
2
Flushing with water
1.
Remove propeller and thrust holder.
2.
Attach optional flushing attachment 1.
3.
Cover water strainer with tape.
4.
Put water hose on flushing attachment 1 and run water.
5.
Set gear shift to neutral (N) and start engine.
6.
1
Check that cooling water check port 2 discharges water,
and run engine for 3 to 5 minutes at low speed.
7.
Stop engine and stop water supply, remove flushing
attachment 1, remove tape, and then, reinstall propeller.
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Maintenance
22) Greasing Points
1.
G
RE
AS
E
Apply grease to throttle cable and sliding areas.
OBM
OBM
2.
Apply grease through grease nipples 1 until excessive
grease appears from bushing a.
a
Apply grease to thread of clamp screws 2.
1
G
RE
AS
E
RUB
RUB
RVB
VB
a
2
G
RE
AS
E
OBM
OBM
3.
Apply grease to throttle cable b and sliding areas.
c
b
G
RE
AS
E
OBM
OBM
c Do not lubricate here.
4.
Thinly apply grease to spring 3 of tilt stopper.
3
G
RE
AS
E
OBM
OBM
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5.
Apply grease to seal ring and bushing 4 of hook lever.
4
G
RE
AS
E
OBM
OBM
6.
Apply grease to propeller shaft spline 5.
3
5
G
RE
AS
E
OBM
OBM
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Maintenance
3-24
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4
Fuel System
1. Special Tools ……………………………… 4-2
2. Parts Layout ……………………………… 4-4
Carburetor & Fuel Pump……………………… 4-4
Integral Fuel Tank …………………………… 4-6
3. Carburetor Inner Passages …………… 4-8
1) Idling Passage …………………………… 4-8
2) Off-Idle Passage ………………………… 4-9
3) High Speed Passage …………………… 4-10
4) Choking Passage ……………………… 4-11
4. Inspection Items ………………………… 4-12
1) Inspection of Fuel Feed System Piping … 4-12
2) Draining Fuel …………………………… 4-12
3) Inspection of Fuel Tank and Fuel
Tank Cap ………………………………… 4-13
Inspection of Fuel Cock ………………… 4-13
Inspection of Fuel Filter ………………… 4-13
Removing Carburetor ………………… 4-14
Disassembling Carburetor……………… 4-16
Inspection and clean of Carburetor …… 4-17
Inspection of Fuel Connector ………… 4-18
Assembling of Carburetor …………… 4-18
Adjustment of Float Height …………… 4-19
Installing Carburetor …………………… 4-19
Removing Fuel Pump ………………… 4-20
Disassembly and Inspection of
Fuel Pump ……………………………… 4-20
15) Assembly of Fuel Pump………………… 4-21
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
4
MFS4-5-6̲E̲ch04̲110422.qxd 11.4.22 5:48 PM ページ 2
Fuel System
1. Special Tools
Vacuum/Pressure Gauge
P/N. 3AC-99020-0
Inspecting pressure
4-2
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4
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Fuel System
P/L Fig. 4
2. Parts Layout
Carburetor & Fuel Pump
29
28
20
40
17
18
25
Fig.1-50 Fig.1-51
Fig.1-9
7
2
24 22
19
5
6
42 23 30
41
9
10
8
15
4
11
13
Fig.10-51
16
44
12
14
43
44
39
32
36
IL
33
1
20
4st
34
O
26
27
21
3
4st OIL
35
37
A
Fig.10-25
44
45
46
44
31
38
44 mark D
4-4
O
IL
4st OIL
4st
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Ref.
No.
1
2
3-1
3-2
3-3
4-1
4-2
4-3
4-4
4-5
4-6
5-1
5-2
5-3
5-4
5-5
5-6
6-1
6-2
6-3
6-4
7-1
7-2
8
9
10
11
12
13
14
15
16
17
18
19-1
19-2
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Description
Intake Manifold Ass'y
Intake Manifold Gasket
Bolt
Bolt
Bolt
Carburetor Ass'y
Carburetor Ass'y
Carburetor Ass'y
Carburetor Ass'y
Carburetor Ass'y
Carburetor Ass'y
Main Nozzle
Main Nozzle
Main Nozzle
Main Nozzle
Main Nozzle
Main Nozzle
Main Jet (#65)
Main Jet (#60)
Main Jet (#58)
Main Jet (#68)
Slow Jet (#38)
Slow Jet (#35)
Float
Float Valve
Clip
Float Arm Pin
Float Chamber
Float Chamber O-Ring
Screw
Drain Screw
O-Ring Drain Screw
Stop Screw
Spring Stop Screw
Pilot Screw
Pilot Screw (EU)
Carburetor Gasket
Insulator
Intake Silencer
Flame Arreste
Collar 6.2-9-7.4
Collar 6.2-9-7
Bolt
Washer
Cable Holder
Bolt
Nut
Fuel Pump Ass'y
Check Valve P
Check Valve
Pump Body Gasket
Pump Diaphragm
Screw
Screw
O-Ring 2.62-18.72
Screw
Choke Wire
Washer 6.5-21-1
Bolt 6-12
Fuel Hose 4.5L-115
Clip Fuel pipe
Fuel Filter Ass'y
Hose
4st 4/5/6 2011
Q'ty
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
2
1
2
2
1
1
1
1
1
1
1
1
2
4
1
2
1
1
1
1
5
1
1
Remarks
Do not reuse.
Dual Tank Mode M6 L=25mm
Separate Tank Model M6 L=25mm
Dual Tank Mode M6 L=30mm
5ps
4ps
6ps
5ps for EU
4ps for EU
6ps for EU
5ps
4ps
6ps
5ps for EU
4ps for EU
6ps for EU
5ps
4ps
4ps for EU
6ps
5/6ps
4ps
4
Do not reuse.
M4 L=12mm
Do not reuse.
for EU
Do not reuse.
M6 L=85mm
M6 L=16mm
M6
Do not reuse.
M3 L=8mm
M4 L=18mm
Do not reuse.
M6 L=30mm
M6 L=12mm
98AB-501000
4-5
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Fuel System
P/L Fig. 13
Integral Fuel Tank
4-6
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Ref.
No.
Description
Q'ty
1
Fuel Hose C
1
2
Fuel Hose Protector
1
3
Fuel Tank
1
4
Hose
1
5
Clip Fuel pipe
2
6
Fuel Tank Holding Plate
1
7
Mount Motor Cover Lower
4
8
Rubber Mount 9-23-4
1
Remarks
98AB-501000
9
Spacer 6.2-9-15.7
2
10
Spacer 6.2-9-11.5
1
11
Washer 6.5-21-1
4
12
Bolt
2
13
Nut
1
M6
14
Bolt
1
M6 L=20mm
15
Bracket (Rear)
1
16
Fuel Tank Cap Ass'y
1
17
Tank Filler Cap Gasket
1
18
Fuel Tank Seal
1
19
Clamp 6.5-47.5P
2
20
Screw
1
21
Washer
1
22
Clamp 6.5-14
1
23
Fuel Hose 4.5S-310
1
24
Hose
1
25
Fuel Hose 4.5L-20
1
26
Fuel Hose 4.5L-115
1
27
Band 158
2
28
Pipe Joint
1
29
Non-Return Valve
1
30
Clip Fuel pipe
12
31
Screw
1
4st 4/5/6 2011
M6 L=25mm
4
Do not reuse.
M5 L=10mm
M6 L=12mm
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Fuel System
3. Carburetor Inner Passages
1) Idling Passage
a - Air intake
b - Air vent inlet
c - Main air jet
<Over view>
d - Pilot air jet
a
e - Bypass port
e
f - Pilot outlet
g - Throttle valve
g
d
h - Fuel inlet
f
i - Main jet
j - Pilot jet
k - Choke valve
j
l - Main nozzle
b
m - Air bleed
c
å Air
k
∫ Air-fuel mixture
å
l
<Side view>
m
l
∫
h
i
As engine rotates, intake valve opens and piston moves from top dead center toward bottom dead center, the piston
movement causes vacuum or low pressure area to occur in the back of throttle valve.
Then, the air enters carburetor through air intake port, runs through throat venturi and throttle valve, and then is sucked into
the combustion chamber 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 low
pressure area in the back of throttle valve. The fuel is sent to main fuel well through main jet, runs through idle passage and
pilot jet bypass (off idle) port, and then is ejected from pilot outlet. When this fuel goes through bypass port, it is mixed with air
in the carburetor bore to be air-fuel mixture which is sucked into the cylinder.
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2) Off-Idle Passage
a - Air intake
b - Air vent inlet
c - Main air jet
<Over view>
d - Pilot air jet
a
e - Bypass port
e
f - Pilot outlet
g - Throttle valve
g
d
h - Fuel inlet
f
i - Main jet
j - Pilot jet
k - Choke valve
j
l - Main nozzle
4
b
m - Air bleed
c
å Air
k
∫ Air-fuel mixture
å
l
<Side view>
m
l
h
∫
i
When throttle valve is turned to a position over bypass port, the bypass port is exposed to low pressure existing in the back
of throttle valve. The low pressure causes the fuel to be ejected from bypass port and idle port.
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Fuel System
3) High Speed Passage
a - Air intake
b - Air vent inlet
c - Main air jet
<Over view>
d - Pilot air jet
a
e - Bypass port
e
f - Pilot outlet
g - Throttle valve
g
d
h - Fuel inlet
f
i - Main jet
j - Pilot jet
k - Choke valve
j
l - Main nozzle
b
m - Air bleed
c
å Air
k
∫ Air-fuel mixture
å
l
<Side view>
m
l
∫
h
i
As throttle valve is turned to a position over bypass port, the low pressure produced in the back of throttle valve extends to
an area near main nozzle. At the same time, as flow of air that runs through carburetor bore increase, the whole space in
the venturi becomes low pressure. The low 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 to
make the fuel/air (atomized). When throttle valve is fully open, the amount of fuel is determined by the size of main jet.
The idle and off-idle passages keep feeding fuel as well as air to the engine.
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4) Choking Passage
a - Air intake
b - Air vent inlet
c - Main air jet
<Over view>
d - Pilot air jet
a
e - Bypass port
e
f - Pilot outlet
g - Throttle valve
g
d
h - Fuel inlet
f
i - Main jet
j - Pilot jet
k - Choke valve
j
l - Main nozzle
4
b
m - Air bleed
c
å Air
k
∫ Air-fuel mixture
å
l
<Side view>
m
l
∫
h
i
Choke system consists of choke valve, detent and push-pull cable. When starting cold engine, the operator should judge
whether it is necessary to operate the choke to make engine starting easier, and if necessary, to operate the handle of
choke cable manually to set it to a proper position.
When engine is cold, pull choke lever to close choke valve. When engine starts, low pressure (vacuum) area is formed in
the venturi on the back of choke valve. Then, the fuel goes through main nozzle, bypass port and pilot outlet, and sucked
into carburetor bore, where it is mixed with air that runs in from opening of the choke valve to form thick air-fuel mixture.
When engine warms up, set choke lever to home position.
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Fuel System
4. Inspection Items
1) Inspection of Fuel Feed System Piping
1.
Remove top cowl and check each section for fuel leak, dirt,
deterioration and damages. Clean or replace parts if
necessary.
2) Draining Fuel
1
WARNING
Remove fuel tank, fuel hose and carburetor
after fully drain the fuel from these parts.
1.
Remove fuel tank cap 1 and use fuel pump to remove fuel.
2.
Set fuel cock knob 2 to full open position a.
a
2
a
3.
Place a piece of rag below the carburetor, and loosen drain
screw 3 to drain all fuel.
4.
Retighten drain screw 3.
3
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MFS4-5-6̲E̲ch04̲110422.qxd 11.4.22 5:48 PM ページ 13
3) Inspection of Fuel Tank and Fuel
Tank Cap
1.
Check fuel tank and fuel tank cap for crack, leakage and
damage. Replace if necessary.
4) Inspection of Fuel Cock
1.
Check fuel cock for leakage.
4
5) Inspection of Fuel Filter
1.
Check fuel filter for dirt and clogging, and clean if necessary.
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Fuel System
6) Removing Carburetor
1
WARNING
Before working on fuel system, make sure
to disconnect battery cables from the
battery, or electric sparks can occur,
possibly igniting fuel or making fuel to
explode.
1.
Remove fuel tank 1.
2.
Remove starter lock rod 2.
2
3.
Disconnect choke link wire.
Be careful not to bend wire tip 3 when disconnecting.
(For easiness of explanation, the picture shows the scene
with recoil starter removed.)
3
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4.
Remove recoil starter ass'y 4.
4
5.
Disconnect breather hose 5 from intake silencer.
5
4
6.
Remove fuel hose 6 from fuel pump.
6
Before disconnecting fuel hose, place a piece of
cloth below fuel pump to blot leaking fuel.
7.
Loosen carburetor mounting bolts and remove carburetor
7.
7
When removing throttle rod and carburetor, perform the
work as shown taking care not to give damage to the
parts.
Since throttle rod is bent at the tip, remove
carburetor by inclining and pulling it as shown.
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Fuel System
7) Disassembling Carburetor
1.
Remove drain screw 1 to drain fuel.
CAUTION
Use rag to absorb fuel flowing out from
hose.
2.
1
Remove float bowl 2.
2
3.
Remove float ass'y 3.
3
4.
Remove jets and nozzle.
CAUTION
When removing any jets, be careful not to
damage or distort jet surface.
4-16
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8) Inspection and clean of Carburetor
1.
Check air and fuel passages for dirt in the jet and foreign
substances. Clean carburetor body with cleaning fluid.
2.
Squirt all passages and jet passages with compressed air.
CAUTION
· Point the compressed air downward,
taking care that detergent and dust do
not enter the eyes and do not damage
small parts of the carburetor.
· Do not use wire to clean the jet. Doing so
may enlarge the jet hole, resulting in
significantly reducing the performance.
3.
Check main jet 1 and main nozzle 2 for dirt. Clean or
replace if necessary.
4
1
2
4.
Check float valve for bend and wear. Replace if necessary.
5.
Check float for deformation. Replace if necessary.
6.
Check float bowl's O ring for damage, and replace if
necessary.
4st 4/5/6 2011
4-17
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Fuel System
9) 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-99020-0
Specified Pressure :
0.029 MPa (4 psi) [0.3 kgf/cm2]
10) Assembling of Carburetor
1.
2.
Attach main nozzle 1 and main jet 2 to carburetor body as
2
shown.
1
Attach float valve, float 3 and float arm pin 4 as shown,
and check if float 3 moves smoothly.
3.
4-18
Attach float ass'y firmly to float arm pin 4.
4
3
4
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11) Adjustment of Float Height
1.
Measure height a of float 1. Adjust height a of float 1 by
1
b
a
bending tab b if the height is out of specified range.
Float Height a :
9.0 - 10.0 mm (0.354 - 0.394 in)
2
Bring tab b of float 1 into light contact with top
of float valve 2.
2.
Attach drain screw to float bowl 3.
4
3
12) Installing Carburetor
1.
Reverse carburetor removing steps to install.
4st 4/5/6 2011
4-19
MFS4-5-6̲E̲ch04̲110422.qxd 11.4.22 5:48 PM ページ 20
Fuel System
13) Removing Fuel Pump
1.
Remove fuel hose from fuel pump.
Place a piece of cloth below fuel pump to blot
leaking fuel.
2.
Loose fuel pump mounting screw and remove fuel pump.
14) Disassembly and Inspection of Fuel Pump
CAUTION
To prevent fuel from dripping on the floor,
use a cloth to catch the fuel.
1.
Remove screws (4) to disassemble fuel pump body.
B
A Plastic Sheet
2.
A
B Rubber
Remove diaphragm from fuel pump body by unlocking push
rod.
While holding push rod, turn diaphragm
approximately 90 degrees to left or right while
pushing it using a finger to remove it from push
rod.
4-20
90°
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3.
Check diaphragm 1 for break, crack and damage, and
replace if necessary.
4.
2
Check check valve 2 for damage and deterioration, and
replace if necessary.
5.
fuel pump body for crack and damage, and replace if
necessary.
6.
1
Check push rod 3 for wear on the slipper surface a, and
replace if severely worn.
7.
3
Clean fuel pump body.
4
a
15) Assembly of Fuel Pump
1.
Assemble parts by reversing disassembling steps.
After assembling, check movement of push rod 1 by
pushing it with a finger.
A
B
1
A Plastic Sheet
4st 4/5/6 2011
B Rubber
4-21
MFS4-5-6̲E̲ch04̲110422.qxd 11.4.22 5:48 PM ページ 22
Fuel System
4-22
4st 4/5/6 2011
MFS4-5-6̲E̲ch05̲110425.qxd 11.4.25 1:20 PM ページ 1
5
Power Unit
5
1. Special Tools ………………………… 5-2
2. Parts Layout ………………………… 5-3
Engine …………………………………… 5-3
Magneto…………………………………… 5-4
Cylinder & Oil Pan ……………………… 5-6
Cylinder Head & Valve & Cam Shaft … 5-8
Piston & Crank Shaft …………………… 5-10
Recoil Starter …………………………… 5-11
Top Cowl ………………………………… 5-12
3. Inspection Items …………………… 5-13
1)Inspection of Compression Pressure 5-13
2)Inspection of Valve Clearance ……… 5-14
3)Removing Power Unit ………………… 5-16
4)Removal and Disassembly of
Crank Case Head ……………………… 5-17
5)Inspection of Crank Case Head ……… 5-18
6)Assembly of Crank Case Head ……… 5-18
7)Installation of Crank Case Head …… 5-18
8)Disassembly of Power Unit…………… 5-19
9)Removal of Rocker Arm ……………… 5-22
10) Removing Cylinder Head…………… 5-23
11) Inspection of Rocker Arm and Pivot 5-23
12) Inspection of Push Rod Plate ……… 5-23
13) Inspection of Push Rod …………… 5-23
14) Disassembly and Inspection of
Oil Feed Pump ……………………… 5-23
15) Disassembly of
Cylinder and oil pan ………………… 5-26
16) Disassembly and Inspection of
Breather Chamber ………………… 5-28
17) Inspection of Lifter…………………… 5-28
18) Inspection of Cam Shaft …………… 5-29
19) Inspection of
Piston Outer Diameter ……………… 5-30
20) Inspection of
Cylinder Inner Diameter …………… 5-30
21) Inspection of Piston Clearance …… 5-30
22) Inspection of
Piston Ring Side Clearance………… 5-31
23) Inspection of Piston Rings ………… 5-31
24) Inspection of Piston Pin …………… 5-32
25) Inspection Connecting Rod
Small End Inner Diameter ………… 5-32
26) Inspection of Connecting Rod
Big End Inner Diameter …………… 5-32
27) Inspection of Connecting Rod
Big End Side Clearance …………… 5-33
28) Inspection of Crank Shaft ………… 5-33
29) Disassembly and Inspection of
Oil Pan ……………………………… 5-34
30) Removal of Valves and Springs …… 5-35
31) Inspection of Valve Springs………… 5-35
32) Inspection of Valve ………………… 5-36
33) Inspection of Valve Guide ………… 5-36
34) Inspection of Valve Seat …………… 5-37
35) Correction of Valve Seat …………… 5-38
36) Installation of Valves………………… 5-41
37) Installation of Piston and
Connecting Rod……………………… 5-42
38) Assembly of Cylinder Oil Pan ……… 5-43
39) Installation of Cylinder Head ……… 5-45
40) Installing Flywheel…………………… 5-47
41) Installation of Power Unit …………… 5-50
MFS4-5-6̲E̲ch05̲110425.qxd 11.4.25 11:39 AM ページ 2
Power Unit
1.Special Tools
Flywheel Puller Kit
P/N. 369-72211-0
Piston Slider
P/N. 3H6-72871-0
Compression Gauge
P/N. 3AC-99030-0
Valve Spring Compressor Attachment
P/N. 3AB-99076-0
Removing/installing flywheel
Installing piston
Measuring compression
pressure
Removing or installing valve
springs
Thickness Gauge
P/N. 353-72251-0
Measuring gaps
5-2
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2.Parts Layout
Engine
5
Ref.
No.
1
2
3
4
5
6
Description
Recoil Starter
Fuel Tank
Oil Level Gauge
Dowel Pin
Bolt
Gasket
4st 4/5/6 2011
Remarks
Q'ty
1
1
Do not reuse.
1
2
6 M6 L=30mm
Do not reuse.
5-3
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Power Unit
Magneto
P/L Fig. 6
50 Nám (3.7 lbáft) [5.0 kgfám]
8
O
IL
-C
O
M
P.
7
GM
SOC
SOC
BO
N
D
2
G17
3
4
3
4
9
1
6
5
G17
10
11
2
23
21
24
12
16
22
13
20
14
25
17
19
18
15
G17
BO
N
D
G17
SOC
O
IL
-C
O
GM
SOC
5-4
M
P.
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Ref.
No.
Description
Q'ty
1-1
Flywheel MF54 (Mark48)
1
1-2
Flywheel MF54 (Mark50)
1
2
Alternator Ass'y
1
3
Screw
4
4
Washer
4
5
Clamp
1
6
Screw
1
7
Washer
1
8
Nut 12-P1.25
1
9
Igniter W/R-Cap
1
10
Plug Cap W/Resistance
1
11
Bolt
2
12-1
Clamp 6.5-67P
2
12-2
Clamp 6.5-47.5P
1
Remarks
"for Sail Pro (with Alternater)"
M5 L=25mm
M4 L=8mm
M6 L=30mm
13
Screw
1
14
Rectifier Complete
1
15
Fuse (10A)
1
16
Clamp 7-80P
1
17
Battery Cable
1
18
Cable Terminal Plug
1
19
Grommet 17-3
1
20
Pilot Lamp Ass'y
1
21
Stop Switch Ass'y
1
22
Stop Switch Lanyard Ass'y
1
23
Clamp 6.5-14
1
24
Bolt with Washer
1
M6 L=12mm
25-1
Protector Wireharness
1
For Separate Tank Model
25-2
Protector Wireharness
1
For Integral Tank Model
4st 4/5/6 2011
M6 L=12mm
5
5-5
MFS4-5-6̲E̲ch05̲110425.qxd 11.4.25 11:39 AM ページ 6
Power Unit
P/L Fig. 1
Cylinder & Oil Pan
1 !"#
2 !"#
4st
O
IL
-C
O
M
P.
GM
SOC
BO
N
D
G103
B
1342 T
G103
G103
1342
SOC
G103
BO
N
D
B
1342 T
1342
Liq
uid
1342
O-
LOR
Rin
g
LOR
O
IL
4st
B
1342 T
4st OIL
!"#
O
IL
!"#
4st OIL
G
RE
AS
1 !"#
2 !"#
E
LIT
LIT
4st OIL
G
RE
AS
E
TEF
TEF
4st
O
IL
4st
O
IL
4st OIL
IL
-C
O
M
4st OIL
!"#
G103
BO
N
D
G103
uid
5-6
LIT
AS
TEF
RE
E
G
RE
E
TEF
Liq
O-
LOR
AS
G
LIT
O
4st
1342
B
1342 T
P.
IL
SOC
O
GM
SOC
Rin
g
Liquid
O-Ring
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MFS4-5-6̲E̲ch05̲110425.qxd 11.4.25 11:39 AM ページ 7
Ref.
No.
Description
Q'ty
1
Cylinder Block
1
2
Oil Seal 20-35-7
1
3
Ball Bearing 6205
1
4
Breather Chamber Cover
1
5
Gasket Breather Chamber Cover
1
6
Collar Breather (5A New)
2
7
Wave Washer d=5
2
8
Screw
2
9
Clamp 6.5-14
1
10
Oil pan Sub-Ass'y
1
11
Oil Seal 25-40-8
1
12
Grommet Oil pan
1
13
Dowel Pin 6-12
2
14
Oil Pump Rotor (Inner)
1
15
Oil Pump Rotor (Outer)
1
16
Pin Oil Pump
1
17
O-Ring
1
18
Oil Pump Cover
1
19
Bolt
3
20
Plunger Control
1
21
Spring Pressure
1
22
Seat Spring
1
23
O-Ring 1.9-6.8
1
24
Plunger Cover
1
25
Drain Bolt
1
26
Washer 10.2-19-1
1
Remarks
M6 L=16mm
Do not reuse.
M6 L=16mm
27
Strainer Body
1
28
Strainer Cap
1
29
Mesh Strainer
1
30
Pipe Strainer
1
31
Seal Rubber Strainer
2
32
Strainer Stopper
1
33
Screw
1
34
Bolt 5-1
2
35
Washer
2
36
Oil pan Gasket
1
Do not reuse.
37
Exhaust Cover Gasket
1
Do not reuse.
38
Exhaust Cover (Inner)
1
39
Bolt
3
M6 L=20mm
40
Bolt
3
M6 L=40mm
41
Bolt
6
M8 L=40mm
42
Oil Pressure Switch
1
43
Grommet Oil Pressure Switch
1
44
Oil Pressure Switch Lead Wire
1
45
Crankcase Head
1
46
Oil Seal 10.1-25-7
2
47
Spacer 19-24.8-1.0
1
48
Crankcase Head Gasket
1
49
Bolt
2
50
Breather Hose
1
51
Clip
2
52
Oil Level Gauge
1
53
O-Ring 2.62-18.72
1
54
Bolt with Washer
1
55
Clamp 6.5-47.5P
1
4st 4/5/6 2011
5
Do not reuse.
M5 L=12mm
Do not reuse.
M6 L=20mm
Do not reuse.
M6 L=12mm
5-7
MFS4-5-6̲E̲ch05̲110425.qxd 11.4.25 11:39 AM ページ 8
Power Unit
Cylinder Head & Valve & Cam Shaft
P/L Fig. 3
4st
4st OIL
O
IL
1 2 IL
O
4st
4st OIL
SOC
4st OIL
1 2 Liq
uid
Rin
g
4st OIL
IL
4st
LOR
O
O-
LOR
IL
4st
O
4st
O
IL
O
IL
-C
O
M
P.
GM
SOC
4st OIL
4st OIL
O
IL
4st
SOC
O
IL
-C
O
M
P.
GM
SOC
Liq
uid
O-
LOR
5-8
Rin
g
Liquid
O-Ring
4st 4/5/6 2011
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Ref.
No.
Description
Q'ty
1
Cylinder Head Ass'y
1
2
Intake Valve
1
3
Exhaust Valve
1
4
Valve Spring Seat
2
5
Valve Spring
2
6
Retainer
2
7
Cotter
4
8
Dowel Pin 6-12
2
9
Cylinder Head Gasket
1
10
Cylinder Head Bolt
2
11
Cylinder Head Bolt
2
12
Exhaust Cover Gasket
1
13
Cylinder Head Cover
1
14
Cylinder Head Cover Gasket
1
15
Bolt
4
16
Washer 6-16-1.5
4
17
Thermostat
1
18
Thermostat Cap
1
19
Thermostat Cap Gasket
1
20
Camshaft Ass'y (F6A)
1
21
Lifter
2
22
Push Rod
2
23
Plate Push Rod
1
24
Pivot Bolt
2
25
Rocker Arm
2
26
Pivot Rocker Arm
2
27
Adjusting Nut
2
28
Throttle Drum
1
29
Throttle Opener
1
30
Collar Drum
1
31
Bolt
1
32
Washer 6-16-1.5
1
33
Bolt
2
34
Throttle Rod
1
35
Spark Plug (DCPR6E)
1
4st 4/5/6 2011
Remarks
Do not reuse.
Do not reuse.
Do not reuse.
M6 L=16mm
5
Do not reuse.
M6 L=35mm
M6 L=45mm
5-9
MFS4-5-6̲E̲ch05̲110425.qxd 11.4.25 11:39 AM ページ 10
Power Unit
Piston & Crank Shaft
P/L Fig. 2
4st
O
IL
1
2
4st
O
IL
4st OIL
4st
O
IL
4st OIL
4st OIL
4st
O
IL
4st OIL
4st
O
IL
4st OIL
Ref.
No.
1
2
3-1
3-2
4-1
4-2
5-1
5-2
Description
Crankshaft Ass'y
Thrust Plate
Piston
Piston (0.5 O/S)
Piston Ring (STD) 1st
Piston Ring (0.5O/S) 1st
Piston Ring (STD) 2nd
Piston Ring (0.5O/S) 2nd
5-10
Q'ty
1
1
1
1
1
1
1
1
Remarks
Ref.
No.
6-1
6-2
7
8
9
10
11
Description
Piston Ring-Oil (STD)
Piston Ring-Oil (0.5 O/S)
Piston Pin
Piston Pin Clip
Connecting Rod Ass'y
Connecting Rod Bolt
Key Magneto
Q'ty
O
IL
4st OIL
4st
Remarks
1
1
1
2
1
2
1
4st 4/5/6 2011
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Recoil Starter
P/L Fig. 5
G
RE
AS
E
LIT
LIT
5
G
RE
AS
E
LIT
LIT
1342
TB
G
RE
AS
E
LIT
LIT
1342
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
Recoil Starter Ass'y
Starter Case
Starter Spring Case
Starter Spring
Reel
Return Spring
Ratchet
Friction Spring
Bolt Starter Shaft
Friction Plate
Starter Rope
Starter Handle
Rope Anchor
Sealing Plate Starter
Starter Lock
4st 4/5/6 2011
Q'ty
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
Remarks
1342
Ref.
No.
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Description
Collar 4-6-21
Starter Lock Spring
Starter Lock Cam
Washer
Screw
Rod Snap
Collar 6.1-8-6.5
Starter Lock Cam Spring
Screw
Bolt
Spring Washer
Clamp 6.5-47.5P
Caution Decal (B)
Starter Lock Rod
Rod Snap 3.5-2
B
1342 T
Q'ty
1
1
1
1
1
1
1
1
1
3
3
1
1
1
1
G
RE
AS
E
LIT
LIT
Remarks
M6 L=16mm
M4 L=30mm
M6 L=23mm
5-11
MFS4-5-6̲E̲ch05̲110425.qxd 11.4.25 11:39 AM ページ 12
Power Unit
Top Cowl
P/L Fig. 11
%
"
#
!
H
D
1741 A
1741
Separate Tank
"
$
Sail Pro Decal
!
H
D
1741 A
1741
Integral Tank
H
1741
D
1741 A
Ref.
No.
1
2
Description
Top Cowl Ass'y
Top Cowl
(Integral Tank)
3 Top Cowl Seal
4 Starter Seal
5-1 Decal Set (F4B)
5-2 Decal Set (F5B)
5-3 Decal Set (F6B)
5-12
Remarks
Q'ty
1
For Separate Tank Model
1
1
1
1
1
1
For Integral Tank Model
Ref.
No.
6
7
Description
Q'ty
Sail Pro Decal
Caution Decal (A)
2
1
Remarks
4ps
5ps
6ps
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3. Inspection Items
1) Inspection of Compression Pressure
1.
Run engine 5 minutes to warm up, and then stop.
2.
Shift gear into neutral (N).
3.
Remove lock plat 1 (of stop switch lanyard) from stop
switch.
CAUTION
1
Remove lock plate (of stop switch lanyard)
from stop switch before measuring
compression pressure. This will prevent
engine from accidental starting.
4.
Remove all plug caps and then all spark plugs.
CAUTION
Clean areas around spark plugs on the
cylinder before removing spark plugs to
2
prevent dirt from entering cylinder.
5.
5
Install compression gauge 2 to plug hole.
Compression gauge 2 :
P/N. 3AC-99030-0
6.
Fully open throttle, crank engine until compression gauge 2
indication stabilizes, and then measure compression
pressure.
Compression Pressure (Reference) :500 r/min
With decompressor : 0.34 MPa (49.3 psi) [3.5 kgf/cm2] ± 10%
Without decompressor : 0.93 MPa (137.8 psi) [9.5 kgf/cm2] ± 10%
(*Remove Exhaust rocker arm)
· Compression pressure is affected much by
cranking speed, and normally changes
approximately 10%.
· Do not pull choke knob when measuring
compression pressure.
7.
If compression pressure is below specified value, put
small amount of engine oil into cylinder, and perform the
test again.
· If compression pressure increases after the
above measure, check pistons and piston rings
for wear. Replace if necessary.
· If compression pressure does not increase
after the above measure, check valve
clearances, valves, valve seats and cylinder
sleeves. Adjust or replace if necessary.
4st 4/5/6 2011
5-13
MFS4-5-6̲E̲ch05̲110425.qxd 11.4.25 11:39 AM ページ 14
Power Unit
2) Inspection of Valve Clearance
1.
Disconnect plug cap 1 connection, and then, remove
spark plug and cylinder head cover 2.
1
2
2.
Pull recoil starter 3 to turn flywheel clockwise until flywheel
“T” mark a is brought to cylinder mark b.
· This step brings piston to top dead center of
compression stroke.
· The compression stroke can be known visually
when fuel pump is removed. Projection mark
4 on the cam shaft is seen in this stroke.
· The piston is at top dead center of
compression stroke when flywheel mark and
cylinder mark “T” are aligned with each other.
a
b
3
4
3.
Check clearances of intake valve c and exhaust valve d.
Adjust gap if it is out of specified range.
Perform inspection and adjustment of valve
clearances when engine is cold.
c
d
Valve Clearance (when engine is cold) :
(IN) Intake Side c : 0.06 - 0.14 mm (0.0024 - 0.0055 in)
(EX) Exhaust Side d : 0.11 - 0.19mm (0.0043 - 0.0075 in)
5-14
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4.
Loosen pivot adjust nut 5 and then pivot nut.
5
5.
Put thickness gauge 6 into valve clearance, and then,
tighten pivot nut temporarily.
6
6.
5
Tighten pivot adjust nut 7 to specified torque, and check
valve clearance again.
Pivot Lock Nut 7 :
10 N · m (7 lb · ft) [1.0 kgf · m]
Torque Wrench :
Use commercially available item.
Thickness Gauge :
Use commercially available item.
7
· Perform inspection and adjustment of valve
clearances when engine is cold.
· After the adjustment, turn flywheel twice (top
dead center in compression stroke) to check
the clearance again.
Valve Clearance (when engine is cold) :
(IN) Intake Side c : 0.06 - 0.14 mm (0.0024 - 0.0055 in)
(EX) Exhaust Side d : 0.11 - 0.19mm (0.0043 - 0.0075 in)
7.
Install cylinder head cover 2, and then, spark plug.
Cylinder Head Cover2 :
6 N · m (4 lb · ft) [0.6 kgf · m]
Spark Plug :
18 N · m (13 lb · ft) [1.8 kgf · m]
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Power Unit
3) Removing Power Unit
1.
2
Turn fuel cock 1 to OFF and remove fuel tank ass'y 2
and fuel cock ass'y 1.
1
2.
Remove choke cable 4 from carburetor 3.
4
3
3.
Disconnect rubber hose 5 from fuel pump.
5
4.
Disconnect wiring connectors and earth wire located on the
port side.
5-16
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5.
Turn throttle grip to full close position, and disconnect
throttle cables 7 (2 pcs.) from throttle drum 6.
6.
6
7
Remove bolts 8 (6 pcs.), and then, lift power unit to
remove.
When lifting power unit, perform the work carefully
while checking if cables and hoses are caught by
other parts.
8
5
4) Removal and Disassembly of Crank
Case Head
1.
Remove bolts and remove crank case head ass'y 1.
2.
Remove gasket 2.
1
2
②
3.
Do not reuse.
Remove two oil seals 3.
3
③
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Power Unit
5) Inspection of Crank Case Head
1.
Check crank case head for crack, damage and corrosion.
Replace if necessary.
6) Assembly of Crank Case Head
1.
Attach new oil seal 1 to crank case head by using a
commercially available mandrel. Apply lithium grease to
the lip of oil seal.
G
RE
AS
E
LIT
LIT
G
RE
AS
E
LIT
1
LIT
1
Do not reuse.
7) Installation of Crank Case Head
1.
Attach a new Gasket 1.
1
1
2.
Do not reuse.
Install crank case head ass'y to cylinder block ass'y.
Crank Case Head Bolt :
6 N · m (4 lb · ft) [0.6 kgf · m]
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8) Disassembly of Power Unit
1.
Place power unit on the work bench a.
2.
Remove recoil starter 1 and flywheel cover 2.
12
a
3.
Remove flywheel nut 3.
Flywheel Holder 4 : (Commercially use)
Flywheel Puller Kit 6 :
P/N. 369-72211-0
M6, L = 60mm, Bolts (3 pcs.)
(or recoil starter bolts and washers)
3
4
CAUTION
Apply forces to tools toward directions as
shown, and perform work taking care not to
allow flywheel holder to slip.
4.
Remove flywheel 5 and key.
Flywheel Holder 4 : (Commercially use)
Flywheel Puller Kit 6 :
P/N. 369-72211-0
M6, L = 60mm, Bolts (3 pcs.)
(or recoil starter bolts and washers)
5
5
4
6
CAUTION
Apply forces to tools toward directions as
shown, and perform work taking care not to
allow flywheel holder to slip.
· Screw puller onto crank shaft end until flywheel
is disengaged from tapered section of crank
shaft.
· If bolts with specified size are not available,
use recoil starter bolts, or if they are deformed,
use new bolts.
· Set flywheel holder before attaching flywheel
puller.
CAUTION
To prevent damages to engine and special
tools, tighten flywheel puller set bolts
evenly and keep flywheel puller parallel to
flywheel while working.
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Power Unit
5.
Remove fuel hose 7 from carburetor.
7
6.
Loosen carburetor mounting bolts 8 and remove carburetor.
8
7.
Loosen intake manifold mounting bolts and then remove
manifold 9.
9
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8.
Loosen thermostat cap mounting bolts, remove cap 0 and
then thermostat q.
0
q
9.
5
Loosen igniter mounting bolts and then remove igniter w.
w
10.
Loosen fuel pump mounting screws and then remove fuel
pump e.
e
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Power Unit
9) Removal of Rocker Arm
1.
Check position of flywheel marking “T” to confirm that piston
is at top dead center.
2.
Remove bolts and then cylinder head cover.
3.
Remove adjust nut 1, and then pivot 2 and rocker arm 3.
T
3
1
2
4.
Remove push rod 4.
Store “IN” side and “EX” side rocker arms and
push rods separately.
4
5.
Remove pivot bolt 5, and then push rod plate 6.
5
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6
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10) Removing Cylinder Head
1.
Remove cylinder head bolts in the order shown, and then,
"
remove cylinder head.
!
11) Inspection of Rocker Arm and Pivot
1.
1
Check rocker arm 1 and pivot 2 for crack, wear and
2
damage. Replace if necessary.
5
12) Inspection of Push Rod Plate
1.
Check push rod plate for crack and damage. Replace if
necessary.
13) Inspection of Push Rod
1.
Check push rod for bend, wear and damage. Replace if
necessary.
14) Disassembly and Inspection of Oil
Feed Pump
1.
Loosen oil feed pump cover mounting bolts and then pump
cover 1.
1
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Power Unit
2
Remove oil feed pump cover O ring 2 carefully.
2
3.
Remove oil pump rotors (inner and outer) and oil pump pin,
check rotors 3 for damages, and replace if necessary.
3
4.
Measure gap a between inner and outer rotors. Replace
outer or inner rotor if the gap is over specified value.
Standard Value:
0.15 mm (0.0059 in)
Functional Limit :
0.2 mm (0.0078 in)
b
a
Measure gap b between outer rotor and body. Replace
outer rotor or crank case if the gap is over specified value.
Standard Value:
0.12 - 0.20 mm (0.0047 - 0.0079 in)
Functional Limit :
0.25 mm (0.0098 in)
5.
Measure oil pump outer rotor height. Replace outer rotor if
the height is less than specified value.
Standard Value:
5.99 mm (0.2358 in)
Functional Limit :
5.96 mm (0.2346 in)
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6.
Measure pump body depth by using depth gauge or vernier
caliper. Replace if over specified limit.
Standard Value:
6.00mm (0.2362 in)
Functional Limit :
6.06 mm (0.2386 in)
7.
Measure side clearance between pump rotor and body by
using depth gauge or vernier caliper. Replace if over
specified limit.
Standard Value:
0.02 - 0.07 mm (0.0008 - 0.0028 in)
Functional Limit :
Replace if over 0.10 mm (0.0039 in)
5
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Power Unit
15)Disassembly of Cylinder and oil pan
1.
9
Loosen oil pan bolts in the order reverse to the numbers
8
shown, and remove oil pan 9 — 1
· Wipe off spilt oil completely.
· When tightening bolts, follow the numbers
shown.
7
1
6
3
4
5
2
2.
Remove crankshaft washer 1 and then cam shaft 2.
1
2
3.
Remove lifter 3.
3
Store “IN” side and “EX” side parts identifiably.
4.
Loosen cylinder head mounting bolts, and then remove
cylinder head.
5-26
1
3
4
2
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5.
Turn crankshaft to a position where connecting rod bolts 4
and connecting rod cap 5 can be removed, remove the
bolts, and then remove the cap.
5
6.
4
Remove connecting rod 6 and piston ass'y from cylinder
block.
· Removed bearings should be arranged in the
order they are removed.
· Do not reuse piston pin clips. Be sure to
replace with new ones.
7.
Remove piston pin clip 7 and piston pin from piston 8
and connecting rod ass'y, and then remove piston 9.
6
5
7
8
9
7
8
8.
Take out crankshaft 0 from crankcase.
0
9.
Remove bearing from crankcase by using a commercially
available bearing puller.
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Power Unit
16)Disassembly and Inspection of
Breather Chamber
1.
Loosen breather cover mounting screws and then remove
the cover.
2.
Remove two breather collars 1 and two wave washers 2,
check the parts, and replace if necessary.
3.
1
2
Attach breather collars 3 and wave washers 4.
Position breather collar so that the hole a is directed as
a
shown.
34
a
17) Inspection of Lifter
1.
5-28
Check lifter for bend and wear. Replace if necessary.
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18) Inspection of Cam Shaft
1.
Check cam shaft gear and decompressor for damage and
wear. Replace if necessary.
2.
Measure cam height. Replace if the diameter is less than
specified value.
Cam Height a, both intake and exhaust :
Standard value
28.33 mm (1.1154 in)
a
Functional Limit :
28.07 mm (1.1051 in)
3.
5
Measure cam shaft run out. Replace if it is over specified
value.
Cam Shaft Runout Limit :
0.03 mm (0.0012 in)
4.
Measure cam shaft journal outer diameter b. Replace if it
is less than specified value.
Cam Shaft Journal Outer Diameter b : Standard value
13.980 mm (0.5503 in)
Functional Limit b :
13.950 mm (0.5492 in)
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Power Unit
19) Inspection of Piston Outer Diameter
1.
Measure piston outer diameter between points specified.
Replace if it is less than specified value.
b
Piston Outer Diameter a : Standard value
58.960 mm (2.3213 in)
Measuring Point b :
7mm (0.28 in) upward from the bottom of piston skirt
a
Functional Limit :
58.90 mm (2.3189 in)
20) Inspection of Cylinder Inner Diameter
1.
Measure cylinder inner diameters (D1 - D6) at a, b and c in
crank shaft directions d (D1, D3 and D5 respectively), and in
crank web directions e (D2, D4 and D6 respectively). Replace
cylinder block if the inner diameters are over specified value.
Cylinder Inner Diameter (D1 - D6) : Standard value
59.00 mm (2.3228 in)
Functional Limit :
59.07 mm (2.3256 in)
Note : Measure at the maximum wear points.
2.
Obtain taper through calculation described below. Replace
cylinder block if taper is over specified value.
3.
Taper Limit :
D1—D5 (Direction d)
D2—D6 (Direction e)
D2
D1
Functional Limit :
0.06 mm (0.0024 in)
D4
D3
D6
D5
Obtain out-of-roundness through calculation described
a
b
c
below. Replace cylinder block if out-of-roundness is over
specified value.
d
Out-Of-Roundness :
D2—D1 (Measuring Point a)
D6—D5 (Measuring Point c)
Functional Limit :
0.06 mm (0.0024 in)
e
a 5mm
b 30mm
c 60mm
(0.2in)
(1.2in)
(2.4in)
d Crank Shaft Direction
e Crank Web Direction
21) Inspection of Piston Clearance
1.
If piston clearance is over specified limit, replace cylinder
block, piston and piston rings as a set, or both.
Piston Clearance :
0.020 - 0.055 mm (0.00079 - 0.00217 in)
Functional Limit :
0.150 mm (0.00591 in)
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22) Inspection of Piston Ring Side
Clearance
1.
a
Measure piston ring side clearance. Replace piston and
b
piston rings as a set if the clearance is over specified value.
Piston Ring Side Clearance :
Top Ring a : 0.04 - 0.08mm (0.0016 - 0.0031 in)
Second Ring b : 0.03 - 0.07mm (0.0012 - 0.0028 in)
Oil Ring c : 0.01 - 0.18mm (0.0004 - 0.0071 in)
c
Functional Limit
Top Ring a : 0.10 mm (0.0039 in)
Second Ring b : 0.09 mm (0.0035 in)
Oil Ring c : 0.21 mm (0.0083 in)
23) Inspection of Piston Rings
1.
Push piston ring 1 into ring gauge 55.000mm (2.16535in)
parallel to top edge. If the gauge is not available, measure
at the top or bottom of cylinder bore with no wear.
2.
When ring gauge is not available, use piston crown to
push piston ring 1 into to cylinder parallel to top edge.
5
Measure at the top or bottom of cylinder bore with
no wear.
3.
Measure piston ring closed gap a. Replace if it is over
specified value.
Piston Ring Closed Gap a :
Top Ring : 0.15 - 0.30 mm (0.0059 - 0.0138 in)
Second Ring : 0.30 - 0.50 mm (0.0118 - 0.0197 in)
Oil Ring : 0.20 - 0.40 mm (0.0079 - 0.0157 in)
1
a
Functional Limit :
Top Ring : 0.50 mm (0.0197 in)
Second Ring : 0.70 mm (0.0276 in)
Replace oil ring together with top ring or second
ring when the ring is replaced.
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Power Unit
24) Inspection of Piston Pin
1.
Measure piston pin outer diameter. Replace if it is less
than specified value.
Piston Pin Outer Diameter : Standard value
16.00 mm (0.6299in)
Functional Limit :
15.97 mm (0.6287 in)
2.
Measure piston pin boss inner diameter a.
3.
Obtain clearance between piston pin and pin boss.
a
Replace piston pin or piston if the clearance is over
specified value.
Clearance between Piston Pin and Pin Hole :
0.002 - 0.012 mm (0.00008 - 0.00047 in)
Functional Limit :
0.040 mm (0.00157 in)
25) Inspection Connecting Rod Small
End Inner Diameter
1.
a
Measure connecting rod small end inner diameter a.
Replace if it is over specified value.
Connecting Rod Small End Inner Diameter a :
Standard value
14.01 mm (0.5516 in)
Functional Limit :
14.04 mm (0.5528 in)
26) Inspection of Connecting Rod Big
End Inner Diameter
1.
1
Wipe off oil from crankshaft and connecting rod big end
bearing.
2.
Set plastic gauge 1 on the crank pin.
3.
Install connecting rod and tighten bolts to specified torque.
Connecting Rod Bolts 2 :
1st tightening torque : 6 N · m (4 lb · ft) [0.6 kgf · m]
2nd tightening torque : 12 N · m (7 lb · ft) [1.2 kgf · m]
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4.
Remove connecting rod and measure plastic gauge.
0.051
0.076
0.102
0.127
0.152
Connecting rod big end and crankshaft clearance:
corresponding value
0.040 - 0.066 mm (0.00157 - 0.00260 in)
mm
0.002
0.003
0.004
0.005
0.006
in
Functional Limit :
0.08 mm (0.00315 in)
27) Inspection of Connecting Rod Big
End Side Clearance
1.
Measure connecting rod big end side clearance a by
using a commercially available thickness gauge. Replace
a
connecting rod and/or crank shaft if the clearance is over
specified value.
Connecting Rod Big End Side Clearance a :
0.20 - 0.40 mm (0.0079 - 0.0157 in)
Functional Limit :
0.70 mm (0.0276 in)
5
28) Inspection of Crank Shaft
1.
Check crank shaft gear 1 and bearing 2 for damage and
wear. Replace crank shaft ass'y or bearing if necessary.
1
2
2.
Measure crank pin outer diameter. Replace crank shaft if
outer diameter is less than specified value.
Crank Pin Outer Diameter : Standard value
29.95 mm (1.1791 in)
Functional Limit :
29.92 mm (1.1780 in)
3.
Measure crank shaft runout. Replace crank shaft or
bearing if outer diameter is less than specified value.
Crank Shaft Runout Limit :
0.05 mm (0.0020 in)
Use V blocks to support crank shaft at bearings.
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Power Unit
29)Disassembly and Inspection of
Oil Pan
1.
Remove oil pressure switch 1 from oil pan.
1
2.
Loosen oil strainer cover mounting bolts and strainer pipe
mounting bolts, and then remove cover 2.
2
3.
Check oil strainer cover screen mesh 3 for dirt and
clogging.
Clean, or replace if necessary.
3
4.
Disassemble oil pressure control. Loosen plunger cover
mounting bolt 4 and remove the cover.
4
5.
Remove spring seat 5, O ring 6, pressure spring 7 and
plunger control 8 and check the parts.
Replace if necessary.
5
6
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7
8
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30) Removal of Valves and Springs
1.
Place cylinder block on the work bench. Push in valve
spring retainer 1 by using valve spring compressor
3
1
2
attachment 2, remove cotter pin 3, and then, remove
4
spring 4 and valve 5.
· Place a piece of cloth below cylinder head to
prevent valves from moving downward.
· Valves, springs and other related parts should
be arranged in the order they are removed.
5
Valve Spring Compressor Attachment 2 :
P/N. 3AB-99076-0
31) Inspection of Valve Springs
1.
Measure valve spring free length a. Replace if the length
5
is less than specified value.
Valve Spring Free Length a : Standard value
35.0 mm (1.38 in)
Functional Limit :
33.2 mm (1.31 in)
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Power Unit
32) Inspection of Valve
1.
Check valve for dent and wear on the face. Replace if
necessary.
2.
Measure valve stem outer diameter a. Replace if it is less
than specified value.
a
Valve Stem Outer Diameter a : Standard value
Intake Side (IT) : 5.47 mm (0.2154 in)
Exhaust Side (E) : 5.44 mm (0.2142 in)
Functional Limit :
Intake Side (IT) : 5.45 mm (0.2146 in)
Exhaust Side (E) : 5.41 mm (0.2130 in)
33) Inspection of Valve Guide
Before inspecting valve guide, check that valve
stem outer diameter is within specified range.
1.
Measure valve guide inner diameter a. Replace cylinder
a
block if it is over specified value.
Valve Guide Inner Diameter a : Standard value
Intake and Exhaust Sides : 5.51 mm (0.2169 in)
Functional Limit :
Intake Side (IT)
Exhaust Side (E)
2.
: 5.54 mm (0.2181 in)
: 5.57 mm (0.2193 in)
Obtain clearance between valve guide and valve stem by
calculating as described below. Replace cylinder head
b
and/or valve if the clearance is over specified value.
Clearance between Valve Guide and Valve Stem =
Valve Guide Inner Diameter a - Valve Stem Outer Diameter b :
Intake Side (IT) : 0.024 - 0.044 mm (0.00079 - 0.00173 in)
Exhaust Side (E) : 0.045 - 0.072 mm (0.00177 - 0.00283 in)
Functional Limit
Intake Side (IT) : 0.070 mm (0.00276 in)
Exhaust Side (E) : 0.100 mm (0.00394 in)
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34) Inspection of Valve Seat
1.
Remove carbon built up on the valve.
2.
Apply thin coat of red lead on the valve seat.
3.
Use valve lapper 1 (commercially available item) as
1
shown to push valve 2 onto valve seat lightly.
4.
Measure width of area where valve face contacted with
valve seat a that can be identified with red lead adhered
2
to valve face. Correct valve seat if contact area is above or
below the center or contact area of valve seat is over
specified limit.
Valve Seat Contact Width a : Standard value
Intake and Exhaust Sides : 0.8 mm (0.0315 in)
Functional Limit :
Intake and Exhaust Sides : 1.8 mm (0.0709 in)
· Thinly apply lapping compound on the valve
seat, and perform lapping by rotating and
tapping valve lapping tool.
· Use coarse lapping compound first, then medium
and fine in this order.
· When changing abrasive compound to finer one,
remove present one completely.
· After completing lapping, wipe off compound and
then clean the parts.
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a
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Power Unit
35) Correction of Valve Seat
1.
Use valve seat cutter 1 (commercially available item) to
correct valve seat.
1
30˚
2.
45˚
60˚
Turn 45 degree cutter clockwise to cut valve seat surface
to make it smooth.
45˚
a
Be careful not to over-cut valve seat. Turn valve
seat cutter while pushing down evenly.
a Carbon build-up or uneven surface.
3.
Use 30 degree cutter to adjust contact position of valve
seat upper end.
b
30˚
b Width before correction
4.
Use 60 degree cutter to adjust contact position of valve
seat lower end.
b
60˚
b Width before correction
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5.
Use 45 degree cutter to adjust contact width of valve seat
c to specified value.
b
c
45˚
b Width before correction
c Specified width
6.
Valve seat contact area is located on the center, which
should be adjusted to specified value by cutting upper and
lower ends by using 30 degree and 60 degree seat cutters
30˚
respectively if the area is too wide.
b
60˚
b Width before correction
7.
5
If valve seat contact area is narrow and is located nearer
to valve face upper end, use 30 degree seat cutter to cut
upper end. If necessary, use 45 degree cutter to adjust
30˚
b
contact width of valve seat to specified value.
b Width before correction
8.
If valve seat contact area is narrow and is located nearer
to valve face lower end, use 60 degree seat cutter to cut
lower end. If necessary, use 45 degree cutter to adjust
contact width of valve seat to specified value.
b
60˚
b Width before correction
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Power Unit
9.
Apply thin coat of abrasive compound on the overall valve
seat contact area, and turn valve lapper 2 (commercially
available item) while tapping valve.
2
CAUTION
Perform the work by taking care not to
allow abrasive compound to adhere to
valve stem and valve guide.
· Use finer abrasive compound to finish.
· When changing abrasive compound to finer
one, remove present one completely.
· After completion of lapping, wipe off the
compound and then clean.
10.
After ending the work, remove the compound completely
b
c
from cylinder head and valve.
11.
Check valve seat contact width c.
Valve Seat Contact Width c : Standard value
0.8 mm (0.0315 in)
45˚
b Width before correction
c Specified width
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Apply oil to valve guide and attach new valve stem seal.
4st
O
1.
IL
36) Installation of Valves
4st OIL
Intake Side : Black
Exhaust Side : Green
Do not reuse the seal. Use new one.
2.
O
IL
4st OIL
4st
Assemble valve 3, valve spring seat 4, valve spring 5 and
retainer 6 in this order, and then, push in the assembly by
1
using valve spring compressor attachment 1.
Valve Spring Compressor Attachment 1 :
P/N. 3AB-99076-0
· Valve spring can be put from any end.
· Place a piece of cloth 2 below cylinder head
to prevent valve from lowering.
3.
2
With valve spring 5 being pushed in, use small screw driver
7
with small amount of grease at the tip to put cotter 7.
6
5
4
3
4.
Remove cylinder block from work bench. Tap valve 3 with
plastic hammer to fix cotter 7 securely.
7
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Power Unit
37) Installation of Piston and
Connecting Rod
Install connecting rod 2, piston pin 3, and piston pin clip
4
4 to piston 1.
3
· Point "3AB-UP" mark a of connecting rod and
"UP" mark b of piston to the same direction.
· Be sure to use new piston pin clip, and place
clip gap away from piston pin groove c as
shown.
· Be sure to install the connecting rod cap in
original position (direction).
2
a
IL
1
4st
O
1.
b
UP
4st OIL
4
4st
O
IL
4st OIL
c
4
2.
Do not reuse.
Put expander 5 (#4) in the oil ring groove, and check that
5
ring end makes gap as shown.
3.
While holding expander 5 (#4) gap with thumb, put upper
side rail (#3) into the groove so that the gap is away from
5
gap of expander 5 (#4) to the left by 90 degrees.
4.
In similar way, put lower side rail (#5) into the groove so that
the gap is away from gap of expander 5 (#4) to the right by
90 degrees.
5.
#2
#4
Install second ring (#2 taper) and top ring (#1) to piston.
d
Install top Ring (#1) and Second Ring (#2) so that their side
＃5
P
U
#5
＃4
Bring their gaps are away from each other as shown.
CAUTION
Be careful not to scratch piston surface
5
#3
#1
＃3
＃2
6.
45°
UP
5
T
with manufacturer's identification d (T) faces upward (valve
side).
45°
d
＃1
T
and damage rings.
· Install piston rings so that their gaps are away
also from thrust direction of piston and
direction piston pin.
· After installing piston rings, check that they
move smoothly.
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38) Assembly of Cylinder Oil Pan
1.
Press fit bearing into cylinder block.
2.
Install crankshaft 1 on the cylinder block.
Before installing, apply engine oil to mating
surface between bearing and crankshaft.
1
3.
O
IL
4st OIL
4st
5
Use piston slider 2 as shown to install piston ass’y into
cylinder block.
· Before assembling, apply engine oil to piston
pin, piston rings, outer surface of piston, and
inner surface of cylinder liner.
· Be sure that piston is installed with “UP” mark
side up.
· When assembling, take care that connecting
rod big end does not touch crankshaft.
2
Piston Slider2:
P/N. 3H6-72871-0
4.
Install oil pressure switch 3 to oil pan and tighten to
specified torque.
Oil Pressure Switch:
9 N · m (7 lb · ft) [0.9 kgf · m]
3
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Power Unit
5.
Attach connecting rod cap 4 to connecting rod, and
tightening connecting rod bolts 5 in two steps to specified
torque.
· Install connecting rod cap 4 after applying
engine oil to inside of the part.
· Bring locating marks a of connecting rod cap
4 and connecting rod, and install in original
position (direction).
5
4
Connecting Rod Bolts 5 :
1st tightening torque : 6 N · m (4 lb · ft) [0.6 kgf · m]
2nd tightening torque : 12 N · m (9 lb · ft) [1.2 kgf · m]
a
6.
Install lifter 6 to cylinder block.
Apply much engine oil to face of valve lifter that
contacts cam shaft.
O
IL
4st OIL
4st
6
valve lifter and bearing.
4st
4st
4st OIL
O
IL
Apply much engine oil to faces of cam shaft that contacts
O
IL
7.
4st OIL
8.
O
IL
4st OIL
4st
Install cam shaft 7 to cylinder block as shown.
Bring crank shaft mark d to cam shaft w mark
e.
7
5
b
c
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39) Installation of Cylinder Head
1.
4
Attach gasket and cylinder head ass’y to cylinder block, and
then, tighten bolts to specified torque in two steps in the
2
order as shown.
1
Cylinder head ass’y installation bolts:
1st tightening torque : 12 N • m (9 lb • ft)[1.2 kgf • m]
2nd tightening torque : 25 N • m (18lb • ft)[2.5 kgf • m]
2
3
Install strainer cover 1 and secure with bolts.
1
3.
Attach gasket and oil pan to cylinder block, and then, tighten
a
bolts to specified torque in two steps in the order as shown.
M8 : 1st Tightening Torque :
12 N · m (9 lb · ft) [1.2 kgf · m]
2nd Tightening Torque :
25 N · m (18 lb · ft) [2.5 kgf · m]
M6 : 1st Tightening Torque :
5 N · m (4 lb · ft) [0.5 kgf · m]
2nd Tightening Torque :
9 N · m (7 lb · ft) [0.9 kgf · m]
5
a
a
'
When positioning oil pan on the cylinder block,
use dowel pins a.
&
%
$
!
"
#
4.
Attach oil pump parts including oil pump pin 2, oil pump
rotor (inner) 3 and oil pump rotor (outer) 4 to oil pan.
2
3
Attach oil pump (inner) so that ● mark b can be
seen.
b
4
5
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Power Unit
5.
Attach O ring 5 and oil pump cover 6 and secure with
bolts.
Apply much engine oil to oil pump and rotors
(outer and inner).
6
6.
Attach push rods 7, rocker arms 8, rocker arm pivots 9
and adjusting nuts to cylinder head.
7
Ensure that push rods 7 are engaged with valve
lifters.
Perform tappet adjustment.
8
Refer to "5-17".
9
7.
Attach cylinder head cover 0.
0
8.
Attach cylinder head cover, and tighten bolts to specified
torque in the order shown.
4
2
1
3
Cylinder Head Cover Bolts :
6 N · m (4 lb · ft) [0.6 kgf · m]
5-46
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40) Installing Flywheel
1.
Attach key to crankshaft and install flywheel. Tighten
flywheel nut to specified torque.
Flywheel puller kit :
P/N. 369-72211-0
Flywheel Nut :
50 N · m (37 lb · ft) [5.0 kgf · m]
2.
5
Attach igniter.
Thickness Gauge:
P/N. 353-72251-0
Igniter clearance:
0.5mm (0.020 in)
Be careful not to scratch periphery of flywheel, or
sparking performance may be deteriorated.
3.
Attach thermostat 1, gasket 2 and thermostat cap 3,
and tighten bolts to specified torque.
Thermostat cap mounting bolts:
6 N · m (4 lb · ft) [0.6 kgf · m]
Old
3
3
2
1
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Power Unit
4.
Attach intake manifold to cylinder and tighten bolts to
specified torque.
Ensure that O ring is attached properly.
Intake manifold installation bolt:
6 N · m (4 lb · ft) [0.6 kgf · m]
5.
Install carburetor.
6.
Install fuel pump and connect fuel hose.
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7.
Install recoil starter.
8.
Attach blow-by hose 4.
4
9.
5
Apply Three Bond 1342 and then attach oil pressure switch
5. Apply SOC grease to terminal and then attach pressure
switch code.
Oil Pressure Switch 5 :
9 N · m (7 lb · ft) [0.5 kgf · m]
1342
B
1342 T
SOC
O
IL
-C
O
GM
SOC
10.
M
5
P.
Attach crankcase head 6.
6
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Power Unit
41) Installation of Power Unit
1.
Hold power unit as shown.
2.
Clean mating surface of power unit and attach new gasket
1.
3. Install power unit 2 , and tighten bolts 3 in two or three steps
to specified torque.
Power Unit Installation Bolt :
7 N · m (5 lb · ft) [0.7 kgf · m]
Be careful not to catch wires and hoses and other
parts between power unit and engine base.
2
1
3
4.
Connect lead wires 4 of igniter and stop switch.
4
5.
Connect throttle wire 5. Refer to "3-15".
5
5-50
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6.
7.
Connect rod 6 and choke wire 7.
6
7
Install fuel tank 8 and connect pipe.
8
5
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Power Unit
5-52
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6
Lower Unit
1. Special Tools ……………………………… 6-2
2. Parts Layout ……………………………… 6-3
Drive Shaft Housing…………………………… 6-4
3. Inspection Item …………………………… 6-8
1) Draining Gear Oi ………………………… 6-8
2) Removing Propeller ……………………… 6-8
3) Removing Lower Unit …………………… 6-9
4) Disassembly of Water Pump …………… 6-9
5) Inspection of Water Pump……………… 6-10
6) Removing Propeller Shaft Housing Ass'y … 6-11
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
Disassembly of Propeller Shaft Housing … 6-12
Inspection of Propeller Shaft Housing… 6-12
Assembly of Propeller Shaft Housing … 6-13
Removing Drive Shaft ………………… 6-13
Disassembly of Propeller Shaft Ass'y … 6-14
Inspection of Propeller Shaft…………… 6-14
Assembly of Propeller Shaft Ass'y …… 6-14
Removing Clutch Cam and Cam Rod … 6-15
Disassembly of Clutch Cam and Cam Rod … 6-15
Inspection of Clutch Cam and Cam Rod … 6-15
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)
Assembly of Clutch Cam and Cam Rod… 6-16
Removing Pump Case (Lower) ……… 6-16
Disassembly of Pump Case (Lower) … 6-16
Assembly of Pump Case (Lower) …… 6-16
Inspection of Drive Shaft ……………… 6-17
Inspection of Pinion (B) Gear and
Forward (A) Gea ………………………… 6-17
Disassembly of Gear Case …………… 6-18
Inspection of Gear Case ……………… 6-19
Assembly of Gear Case………………… 6-19
Installation of Forward Gear and
Pinion Gear (A and B Gears) ………… 6-20
Reassembly of Pump Case (Lower) … 6-20
27)
28) Installation of Clutch Cam and Cam Rod … 6-20
29) Determination of forward (A) gear backlash … 6-21
30) Installation of Water Pump …………… 6-23
31) Installation of Propeller Shaft Housing … 6-24
32) Filling with Gear Oil …………………… 6-25
33) Installation of Lower Unit ……………… 6-25
6
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Lower Unit
1. Special Tools
Spring Pin Tool A
P/N. 345-72227-0
Spring Pin Tool B
P/N. 345-72228-0
Center Plate 3
P/N. 3AB-99701-0
Driver Rod 3
P/N. 3AB-99702-0
Removing spring pin
Installing spring pin
Used in combination with driver rod and
bearing attachment to locate lower gear
case bearing
Used in combination with center plate and
bearing attachment
Bearing Press Collar
P/N. 3H6-72768-0
Bearing Press
P/N. 3H6-72769-0
Bearing Attachment 2
P/N. 3BR-99905-0
Bearing Attachment 4
P/N. 3BV-99905-0
Used in combination with driver rod and
center plate to remove lower gear case
bearing
Used in combination with driver rod and
center plate to locate lower gear case
bearing
Installing bearings
Installing bearings
369-72727-0
Needle Bearing Press Kit
P/N. 369-72900-0
Backlash Measuring Tool Kit
P/N. 369-72740-0
Clamp A
P/N. 3B7-72720-0
Dial Gauge Plate
P/N. 3B7-72729-0
Installing bearings
Measuring gap between forward and
pinion gears (A and B gears)
Measuring backlash
Used to attach dial gauge
when measuring backlash
6-2
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6
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Lower Unit
P/L Fig. 7
2. Parts Layout
Drive Shaft Housing
RE
AS
E
OBM
OBM
G
B
1342
342 T
1342
B
1342
342 T
1342
G
RE
AS
OBM
E
OBM
1342
B
1342 T
6-4
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Ref.
No.
Description
Q'ty
Remarks
1-1
Drive Shaft Housing Ass'y (S)
1
For Transom "S"
1-2
Drive Shaft Housing Ass'y (L)
1
For Transom "L"
1-3
Drive Shaft Housing Ass'y (UL)
1
For Transom "UL"
Bushing Shift Lever
1
2
Exhaust Plug
1
4-1
3
Drive Shaft Bushing Ass'y
1
For Transom "L"
4-2
Drive Shaft Bushing Ass'y
1
For Transom "UL"
5-1
Drive Shaft Bushing
1
For Transom "L"
5-2
Drive Shaft Bushing
1
For Transom "UL"
6
Stopper Drive Shaft
1
7
Screw Pre-coated 5-25
2
8
Washer
2
9
Screw
2
10
Grommet Cam Rod
1
M5 L=10mm
11
Dowel Pin 6-12
2
12
Bolt
1
M8 L=8mm
13
Gasket 8.1-15-1
1
Do not reuse.
14
Grommet 29.3
1
15
Bolt
6
16
Drive Shaft Housing Gasket
1
17
Extension Housing
1
18
Bolt
1
19
Washer
1
20
Stud Bolt
1
21
Washer
1
22
Nut
1
M8
23-1
Shift Rod (S)
1
For Transom "S"
23-2
Shift Rod (L)
1
For Transom "L"
M6 L=30mm
Do not reuse.
M6 L=25mm
24
Shift Rod Lever
1
25
Pin Shift Lever
1
26
Split Pin
1
27
Shift Rod Joint Ass'y
1
28
Washer
1
29
Bolt 5-16
1
M6 L=16mm
30
Bolt
1
M4 L=16mm
31
Shift Lever
1
32
O-Ring 1.9-8.8
2
33
Ceramic Ball 7.7
1
34
Spring Shift Lever Stopper
1
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6
M8 L=25mm
Do not reuse.
6-5
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Lower Unit
P/L Fig. 8
Gear Case (Drive Shaft) & Gear Case (Propeller Shaft)
G
RE
AS
E
TEF
TEF
B
1342
342 T
1342
RE
A
G
SE
OBM
OBM
IL
G
RE
A
OBM
G
RE
A
SE
OBM
OBM
G
RE
A
B
1342
342 T
SE
OBM
1342
SE
OBM
OBM
IL
GEAR
O
O
GEAR
GEAR
GEAR
G
RE
A
SE
OBM
OBM
O
IL
GEAR
GEAR
G
RE
AS
E
LIT
LIT
G
RE
AS
E
OBM
O
OBM
GEAR
G
RE
LIT
6-6
AS
E
LIT
G
RE
AS
E
1342
B
1342 T
IL
GEAR
TEF
TEF
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Ref.
No.
1-1
1-2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17-1
17-2
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39-1
39-2
40
41
42
43-1
43-2
43-3
44
45
46
47-1
47-2
47-3
48
49
50
51
52
53
54
55
56
57
58
59-1
59-2
59-3
59-4
60
61
62
63
64
65-1
65-2
65-3
66
Description
Gear Case Ass'y
Gear Case Ass'y
Roller Bearing 14-20-12
Plug
Gasket 8.1-15-1
Anode
Bolt
Ball Bearing 6004
Propeller Shaft Housing Ass'y
Propeller Shaft Housing
Oil Seal 15-28-10
O-Ring 3.2-47
Ball Bearing 6002
Bevel Gear Ass'y (A)
Bevel Gear (B)
Bevel Gear Ass'y (C)
Washer 15.2-19-1.9
Shim 21-28-0.1
Shim 21-28-0.15
Propeller Shaft
Clutch
Pin 3.5-28
Spring Clutch
Spring Retainer Clutch
Push Rod Clutch
Water Strainer Sub
Screw
Water Pipe (Lower)
Seal Rubber Water Pipe Lower
Water Pump Impeller
Key Pump Impeller
Pump Case (Upper)
Pump Case Liner
Water Pump Guide Plate
Pump Case Gasket
Guide Plate Gasket
Bolt
Washer
Pump Case (Lower)
Oil Seal 10-24-8
Shim 28-34.8-0.1
Shim 26.5-34.8-0.15
Pump Case Gasket (Lower)
Bolt
Water Pipe Seal (Lower)
Drive Shaft Ass'y (S)
Drive Shaft Ass'y (L)
Drive Shaft Ass'y (UL)
Ball Bearing 6300
Clutch Cam
Spring Pin 3-10
Cam Rod (S)
Cam Rod (L)
Cam Rod (UL)
Spring Pin 3-12
Bushing Camshaft
O-Ring A 2.5-4.9
O-Ring 2.4-15.4
Stopper Cam Rod Bushing
Grommet
Bolt
Washer
Bolt
Washer
Bolt
Propeller Ass'y (6) Y
Propeller Ass'y (7)
Propeller Ass'y (8)
Propeller Ass'y (9)
Propeller Hardware Kit
Propeller Nut
Split Pin 3-18
Washer 10.5-28-2
Thrust Holder Ass'y
Water Pipe Ass'y (S)
Water Pipe Ass'y (L)
Water Pipe Ass'y (UL)
Grommet Water Pipe Upper
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Q'ty
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
A
A
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
4
4
1
1
A
A
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Remarks
For 6ps UL
Do not reuse.
M6 L=16mm
Do not reuse.
M6 L=20mm
Do not reuse.
Do not reuse.
M6 L=45mm
6
Do not reuse.
M6 L=25mm
For Transom "S"
For Transom "L"
For Transom "UL"
For Transom "S"
For Transom "L"
For Transom "UL"
Do not reuse.
Do not reuse.
For 6ps UL
M6 L=45mm
M8 L=35mm
M6 L=16mm
STD:Sail Pro
STD:4ps "S,L"
STD:5/6ps "S,L"
For Transom "S"
For Transom "L"
For Transom "UL"
6-7
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Lower Unit
3. Inspection Item
1) Draining Gear Oil
1.
Remove oil plugs 2 and then 1 to drain gear oil. Refer to
"Replacement of Gear Oil" in Chapter 3.
3
Remove lower oil plug 1 first.
2
3
1
3 Gasket
Do not reuse.
2) Removing Propeller
1.
Shift into reverse (R).
2.
Put a piece of wooden block between anti-cavitation plate
and propeller 4 to prevent rotation of propeller 4, and then
remove propeller nut 2 and then propeller 4.
WARNING
· Before removing or installing propeller,
4
2
be sure to disconnect spark plug cap and
remove stop switch lock plate.
· When removing or installing propeller, do
not handle propeller with bare hands.
1
· Put a piece of wooden block between anticavitation plate and propeller to prevent
2
rotation of propeller.
3
4
5
7
6
1 Split Pin
2 Propeller Nut
3 Washer
4 Propeller
5 Thrust Holder
6 Propeller Shaft
7 Propeller Shaft Housing
6-8
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3) Removing Lower Unit
2
Removal of lower unit does not require removal of
power unit from outboard motor body. Tilt up and
lock with tilt stopper. Shift in reverse.
1.
2
3
1
Remove grommet 1 and loosen bolt 2.
Bolt 2 should be loosened, not removed from
joint 3.
2.
Remove lower unit installation bolts 45, and pull lower unit
ass'y downward to remove.
Check drive shaft spline a for adhesion of oil,
rust and wear.
A
5
4
6
å UL-Transom Model
4) Disassembly of Water Pump
1.
Remove bolts, then remove pump case (upper) 1.
1
When removing or attaching water pump and
pump case (lower), be careful that the drive shaft
is not pushed up.
Pushing up the drive shaft causes pinion (B) to
drop into the gear case.
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Lower Unit
2.
Remove impeller 2.
2
5) Inspection of Water Pump
1.
Check pump case (upper) 1 for deformation. Replace if
1
necessary.
2.
Check impeller 2 and pump case liner 3 for crack and
wear. Replace if necessary.
3
2
3.
Check key 4 and drive shaft installation face a for wear.
Replace if necessary.
4
6-10
a
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4.
Check water pump guide plate 5 for cracks and wear.
Replace if necessary.
5
6) Removing Propeller Shaft Housing Ass'y
1.
Remove bolts 1 and pull out propeller shaft housing ass'y
2
2.
When the ass'y is pulled out a little, put bladed
screw driver 3 in the mating surface of lower
gear case to separate it from the case.
3
2.
Remove propeller shaft ass'y.
6
1
2
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Lower Unit
7) Disassembly of Propeller Shaft Housing
1.
Remove bearing 1 by using commercially available bearing
puller.
Before removing, check bearing for play or
deflection. Replace if necessary.
CAUTION
1
Do not reuse removed bearing.
1 Bearing
2.
Do not reuse.
Remove oil seal 2.
2
2 Oil Seal
Do not reuse.
8) Inspection of Propeller Shaft Housing
1.
Use cleaning oil and cleaning brush to clean propeller shaft
housing, and check it for crack or damage. Replace if
necessary.
2.
Check reverse (C) gear teeth and clutch for crack or
damage. Replace if necessary.
When reusing bearing without removing it, check
it for play or deflection. Replace if necessary.
6-12
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9) Assembly of Propeller Shaft Housing
1.
2
Apply gear oil to outside of new oil seal 1, and attach it to
propeller shaft housing 3 by using a commercially available
1
mandrel 2.
GEAR
O
IL
3
GEAR
O
IL
GEAR
GEAR
1
Do not reuse.
Install new bearing 4 to propeller shaft housing 3.
6
Do not reuse removed bearing.
4
3
GEAR
IL
Bearing Attachment 2 5 :
P/N. 3BR-99905-0
Driver Rod 3 6 :
P/N. 3AB-99702-0
5
GEAR
O
2.
1
G
RE
AS
E
OBM
OBM
O
IL
GEAR
GEAR
3.
Apply OBM grease to lip of oil seal 1.
G
RE
AS
E
4
Do not reuse.
6
OBM
OBM
10) Removing Drive Shaft
1.
Pull up pump case (lower) and drive shaft ass'y 1,
1
remove pinion (B) gear 2, and then pull out forward (A)
gear 3.
· When removing forward (A) gear 3, be careful
not to damage the existing shims or lose them.
Shim is reusable.
· Replace shim with new one of the same
thickness if any deformation or damage is
found on it.
2
3
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Lower Unit
11) Disassembly of Propeller Shaft Ass'y
1.
Pull out clutch pin 2 while pushing push rod 1. Remove
clutch 3, push rod 1, spring retainer 4, and spring 5.
2
· Take care not to allow parts to fly out by easing
spring tension gradually.
· Do not reuse removed clutch pin.
Spring Pin Tool A :
P/N. 345-72227-0
2.
1
2
Do not reuse.
Check clutch 3, spring retainer 4, ball, and push rod 1 for
crack and wear. Replace if necessary.
2
5
3
1
2
4
Do not reuse.
12) Inspection of Propeller Shaft
1.
Check propeller shaft for bend and wear. Replace if
necessary.
2.
a
a
Measure propeller shaft runout.
Runout Limit a (Max) :
0.05 mm (0.0020 in)
a Support point
13) Assembly of Propeller Shaft Ass'y
1.
Fix propeller shaft with vice, and install spring 1 and clutch
2.
3
· Assemble parts with clutch and propeller shaft
holes aligned with each other.
· Set spring pin with groove directing 90 degrees
from axial direction of propeller shaft.
· Apply gear oil before assembling.
· Use vice jaw protectors or wood to protect
propeller shaft from damage from vice.
6-14
1
2
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2.
Using bladed screw driver, shorten spring 1 by referring to
7
6
illustration, insert spring pin tool A 4 into hole of clutch 2 to
3
secure spring. Slowly press fit new spring pin 3 from the
other side, putting it on the spring pin tool A and by using
spring pin tool B 5.
4
4
CAUTION
Do not reuse removed spring pin.
6
5
· Drive spring pin into clutch hole to depth of
approximately 0.5mm from the surface.
· After setting spring pin, check operations of
clutch.
Spring Pin Tool A :
P/N. 345-72227-0
Spring Pin Tool B :
P/N. 345-72228-0
14) Removing Clutch Cam and Cam Rod
1.
Remove bolt 1, stopper 2, and then pull cam rod ass'y
1
3 upward to remove.
2
3
15) Disassembly of Clutch Cam and
Cam Rod
1.
6
1
Remove spring pins 2 and clutch cam 3 from cam rod 1.
2
GEAR
O
IL
· Use spring pin tool A to remove spring pins.
· Do not reuse removed spring pins.
Forward
direction
GEAR
Spring Pin Tool A :
P/N. 345-72227-0
2
3
2
Do not reuse.
16) Inspection of Clutch Cam and Cam Rod
1.
Check cam rod 1 and clutch cam 3 for crack and wear.
Replace if necessary.
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6-15
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Lower Unit
17) Assembly of Clutch Cam and Cam Rod
1.
Install clutch cam 3 and spring pin 2 to cam rod 1.
Spring Pin Tool B :
P/N. 345-72228-0
Be careful of direction of cam rod.
18) Removing Pump Case (Lower)
1.
Remove pump case (lower) 1 and drive shaft 2 while
1
holding pinion (B) gear with hand.
2
Pinion gear (B) will drop into gear case when
drive shaft is removed.
2.
Remove forward (A) gear from gear case.
3.
Remove pump case (lower) 1 from drive shaft 2.
2
1
19) Disassembly of Pump Case (Lower)
1.
Use bladed screw driver to remove oil seal 1.
1
20) Assembly of Pump Case (Lower)
1.
1
Do not reuse.
Apply gear oil to outside of new oil seal 1, and attach it to
pump case (lower) 3 with numbered side down by using a
G
RE
A
SE
OBM
commercially available mandrel 2.
OBM
GEAR
O
IL
1
3
1
GEAR
2.
GEAR
Apply OBM grease to lip of oil seal 1.
G
RE
AS
E
O
IL
GEAR
2
OBM
OBM
1
6-16
Do not reuse.
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21) Inspection of Drive Shaft
1.
Check drive shaft for bend and wear or twisted splines.
Replace if necessary.
2.
Measure drive shaft runout.
Runout Limit (Max) :
0.2 mm (0.008 in)
a
a
a Supporting Points
22) Inspection of Pinion (B) Gear and
Forward (A) Gear
1.
*
Check pinion (B) gear, forward (A) gear, reverse (C) gear
teeth and clutch for crack and wear. Replace if necessary.
)
+
6
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Lower Unit
23) Disassembly of Gear Case
1.
1
Check bearings 1 for cracks and generation of abnormal
noise. Replace if necessary.
CAUTION
Do not reuse removed bearing.
· Do not remove bearing unless it is replaced
with new one.
· Before removing, check bearing for play or
deflection. Replace if necessary.
2.
Remove bearing 1 by using commercially available bearing
1
Do not reuse.
puller.
3.
Remove bearing 2.
6
Bearing Press 3 :
P/N. 3H6-72769-0
Bearing Press Collar 4 :
P/N. 3H6-72768-0
Center Plate 3 5 :
P/N. 3AB-99701-0
Driver Rod 3 6 :
P/N. 3AB-99702-0
5
3
4
2
3
2
2
Do not reuse.
Needle bearing press Ass'y 7 :
P/N. 369-72900-0
7
2
3
2
6-18
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24) Inspection of Gear Case
1.
Check skeg area a and torpedo-like front area b for cracks
and damage. Replace if necessary.
b
a
25) Assembly of Gear Case
Do not reuse removed bearing.
5
1.
Install bearing 1 with numbered side up to gear case 2 to
4
specified depth.
Installation Depth a :
100 mm ± 0.15 mm (3.9370 in ± 0.0059 in)
6
a
3
1
If a special tool is not available and thus the
above depth cannot be maintained, order gear
case ass'y.
2
3
GEAR
XXX XX
XX
6
O
IL
X
GEAR
IL
1
GEAR
O
Bearing press 3 :
P/N. 3H6-72769-0
Center Plate 3 4 :
P/N. 3AB-99701-0
Driver Rod 3 5 :
P/N. 3AB-99702-0
GEAR
1
Do not reuse.
Needle bearing press Ass'y 6 :
P/N. 369-72900-0
2.
5
Install new bearing 6 with numbered side up.
Bearing Attachment 4 7 :
P/N. 3BV-99905-0
Center Plate 3 4 :
P/N. 3AB-99701-0
Driver Rod 3 5 :
P/N. 3AB-99902-0
4
7
6
6
4st 4/5/6 2011
Do not reuse.
6-19
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Lower Unit
26) Installation of Forward Gear and
Pinion Gear (A and B Gears)
1.
4
Install shim 1 and forward (A) gear 2 that were removed
previously.
2.
Install pinion (B) gear 3 and drive shaft ass'y 4.
3
Replace shim with new one of the same thickness
if any deformation or damage is found on
removed shim.
3.
1
When replacing shims placed between forward (A) gear
and bearing, measure thickness of original shims and use
2
shims with the same thickness.
Sizes of Adjusting Shims :
For pinion (A) gear side : 0.1, 0.15mm
Since the shims are for canceling machining
error, use the ones with thickness of original
parts.
27) Reassembly of Pump Case (Lower)
1.
3
Apply grease to lip of oil seal 1 after installing it.
G
RE
AS
E
LIT
1
LIT
2.
2
Attach new O-ring 2 and pump case (lower) 3.
G
RE
AS
E
LIT
LIT
2
Do not reuse.
28) Installation of Clutch Cam and Cam Rod
1.
Install cam rod ass'y 1 to gear case as shown.
Be careful of direction of cam rod.
1
6-20
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29) Determination of forward (A) gear
backlash
1
2
Backlash Measuring Tool Kit :
P/N. 369-72740-0
Backlash Measuring Tool Ass’y 1 :
P/N. 369-72730-0
Measuring Tool Set Piece 2 :
P/N. 369-72727-0
Clamp A :
P/N. 3B7-72720-0
Dial Gauge Plate :
P/N. 3B7-72729-0
1
4 Pump Case
5 Pinion (B) Gear
1
Perform measurement of backlash between
forward (A) gear and pinion (B) gear with propeller
shaft housing, propeller shaft and reverse (C)
gear removed from gear case.
1.
Install pump case 4 to gear case, and assemble backlash
measuring tool 1 as illustrated.
· Fix gear case with vice.
· Clean drive shaft with new rag before
assembling the tool.
· Assemble all parts of pump case except
impeller and key, and tighten to specified
torque.
· Perform measurement of backlash between
forward (A) gear and pinion (B) gear with
propeller shaft housing, propeller shaft and
reverse (C) gear removed from gear case.
6
4
5
1
Proper Backlash Obtained from Gauge Reading :
0.16 - 0.49mm (0.0063 - 0.0193 in)
Sizes of Adjusting Shims :
For Pinion (B) Gear Side : 0.1, 0.15mm
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Lower Unit
2.
First, pull up drive shaft by using hand.
Fix shaft B with bladed screw driver, and tighten nut while
pushing the shaft. At this time, be careful not to overtighten
90°
the nut, or shaft B is locked.
Tighten nut fully by using fingers, and then, additionally
tighten approximately 90 degrees by using spanner wrench.
During the work, fix shaft B by using bladed screw driver.
3.
Secure clamp halves A and B to shaft B using bolts. Move
clamp A while pushing arm in direction a, and read dial
a
gauge at notch groove b position.
Proper Backlash Obtained from Gauge Reading :
0.16 - 0.49mm (0.0063 - 0.0193 in)
Sizes of Adjusting Shims :
For Pinion (B) Gear Side : 0.1, 0.15mm
4.
Perform shim adjustment at pinion (B) gear side as
necessary based on the gauge value obtained. The table
90°
b
Gauge Reading
mm
Shim Adjustment
mm
0.00 - 0.15
-0.10
0.16 - 0.49
0
0.50 - 0.52
+0.25
0.53 - 0.59
+0.30
0.60 - 0.65
+0.35
0.66 - 0.71
+0.40
0.72 - 0.77
+0.45
shows relation between dial gauge readings and shim
adjustments.
1.Values in this table indicate dial gauge readings
that are obtained when using special tool.
2.Change gear engagement position and
measure backlash again for check.
6-22
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30) Installation of Water Pump
1.
Attach new gaskets 1 and 2, water pump guide plate 3
1
3
2
and dowel pin.
12 Gasket
2.
Attach key 4 to drive shaft.
3.
Bring impeller 5 groove a to key 4 and install impeller to
Do not reuse.
G
RE
AS
E
OBM
OBM
drive shaft.
· When reusing impeller, install it so that it
rotates in original direction.
· Apply grease to the key to prevent it from
dropping when attaching.
G
RE
AS
E
4
5
a
OBM
OBM
4.
6
c
Attach pump case liner 6 to pump case (upper) 7, and
apply grease to interior of pump case liner 6.
Bring pump case liner projection b to pump case
(upper) groove c.
7
b
G
RE
AS
E
OBM
4st 4/5/6 2011
OBM
6
G
RE
AS
E
OBM
OBM
6-23
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Lower Unit
5.
Install pump case (upper) ass'y 8 on the gear case, and
tighten bolts 9 in two or three steps to specified torque.
Apply grease to interior of pump case liner, and
install pump case (upper) by pushing it down with
hand while turning drive shaft clockwise.
9
Pump Case (Upper) Bolts 9 :
6 N · m (4 lb · ft) [0.6 kgf · m]
G
RE
AS
E
OBM
OBM
6.
8
Bring grommet 0 projection d to hole e, and install it to
pump case (upper) ass'y 8.
O
IL
4st OIL
0
G
RE
AS
E
RE
AS
E
OBM
d
OBM
IL
G
OBM
4st
9
OBM
1342
B
1342 T
O
4st
4st OIL
e
B
1342
342 T
1342
8
31) Installation of Propeller Shaft Housing
1.
1
Check that OBM grease is applied to lip of oil seal of
6
G
RE
A
SE
housing ass'y 1.
OBM
OBM
G
RE
AS
E
OBM
2.
Install propeller shaft ass'y 2 to propeller shaft housing
OBM
3
ass'y 1.
3.
Apply grease to new O-ring 3 and install it.
4.
Apply grease to clutch push rod 4 and install it to propeller
2
shaft ass'y 2.
4
G
RE
A
SE
OBM
OBM
5.
Attach propeller shaft housing ass'y 1 to gear case, and
tighten bolts 6 to specified torque.
Propeller Shaft Housing Bolts 6 :
6 N · m (4 lb · ft) [0.6 kgf · m]
G
RE
AS
E
OBM
OBM
· Apply grease to clutch push rod to prevent it
from dropping when attaching.
· When installing housing ass'y to gear case,
tighten upper and lower bolts in 2 or 3 steps
evenly to specified torque.
6-24
6
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32) Filling with Gear Oil
Feed gear oil to specified quantity a. "Refer to Chapter 3."
GEAR
O
IL
1.
GEAR
Perform "Inspection of Gear Case (Leakage)" in
Chapter 3 if necessary.
GEAR
a
O
IL
1
GEAR
1
Do not reuse.
GEAR
O
IL
1 Gasket
GEAR
a
1
1
1 Gasket
33) Installation of Lower Unit
1.
Set cam rod 1 to reverse (R) position.
4st 4/5/6 2011
6
Do not reuse.
1
F
N
R
6-25
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Lower Unit
2.
Attach lower unit ass'y to drive shaft housing, and tighten
lower unit installation bolts 2 (nut 3 ) to specified torque.
Connect water pipe securely. Move flywheel a
little to align the drive shaft spline to crank shaft
spline.
Lower Unit Installation Bolts (M8)2 :
6 N · m (4 lb · ft) [0.6 kgf · m]
Lower Unit Installation Bolt, Nut (M8)3 :
13 N · m (9 lb · ft) [1.3 kgf · m]
1
)
B
1342
342 T
1342
1342
B
1342 T
3
2
B
1342
342 T
1342
å UL-Transom Model
3.
Install cam rod 1 to joint 4 and tighten bolt 5 to specified
torque.
5
6
Joint Bolt 5 :
6 N · m (4 lb · ft) [0.6 kgf · m]
4.
Attach grommet 6 to drive shaft housing.
5.
Apply OBM grease to propeller shaft 7.
G
RE
AS
E
4
w
OBM
9
OBM
6.
0
q
Attach thrust holder 8, propeller 9, washer 0 and propeller
nut q to propeller shaft. Put a piece of wooden block
between anti-cavitation plate and propeller to prevent
7
rotation of propeller, and tighten propeller nut to specified
torque.
G
RE
A
SE
8
OBM
WARNING
OBM
Before removing or installing propeller, be
sure to disconnect spark plug cap and
remove stop switch lock plate.
6-26
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7.
Turn propeller nut q to tightening direction to align one of
grooves to propeller shaft hole, and attach split pin w.
If propeller nut groove cannot be aligned with split
pin hole, loosen nut and repeat steps 6 and 7.
q
8.
Check gear oil level. "Refer to Chapter 3."
Perform "Inspection of Lower Unit (Air Leakage)"
in Chapter 3 if necessary.
6
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Lower Unit
6-28
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7
Bracket
1. Parts Layout ……………………………… 7-2
Bracket & Reverse Lock ……………………… 7-2
Drive Shaft Housing & Shift ………………… 7-4
Bottom Cowl & Tiller Handle ………………… 7-6
Cowl …………………………………………… 7-8
2. Disassembling and Assembling
Procedure …………………………………… 7-9
1) Removal and inspection of drive
shaft housing ……………………………… 7-9
2) Removal and inspection of clamp bracket … 7-11
3) IInstallation of clamp bracket and
drive shaft ……………………………………… 7-12
4) Removal, inspection and installation of
water pipe ……………………………… 7-14
5) Remove, inspection and installation of
tiller handle ……………………………… 7-15
6) Adjustment of Throttle Cable ………… 7-18
7
MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 2
Bracket
1. Parts Layout
P/L Fig. 9
Bracket & Reverse Lock
'
G
RE
A
SE
RUB
!
RUB
!
G
RE
AS
E
$
&
%
&
% '
OBM
OBM
#
G
RE
AS
E
OBM
OBM
&
!
#
$
"
$
!
!
%
!#
G
RE
A
SE
RUB
RUB
'
!
"
G
RE
A
!!
!"
SE
OBM
OBM
!
"
!&
#
!'
!
!$
!%
G
RE
AS
E
OBM
OBM
G
RE
AS
E
RUB
RUB
7-2
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Ref.
No.
Description
Q'ty
Remarks
1
Swivel Bracket A
1
2
Swivel Bracket B
1
3
Clamp Bracket (R)
1
4-1
Clamp Screw Ass'y
1
R
4-2
Clamp Screw Ass'y
1
L
5-1
Clamp Screw
1
R
5-2
Clamp Screw
1
L
6-1
Clamp Screw Handle
1
R
6-2
Clamp Screw Handle
1
L
7-1
Rivet 3-22
1
R
7-2
Rivet 3-22
1
L
8-1
Clamp Screw Pad
1
R
8-2
Clamp Screw Pad
1
L
9
Clamp Bracket (L)
1
10
Bolt 8-122
1
11
Nylon Nut 8P1.25
1
12
Washer
1
13
Washer 8.5-28-1
2
14
Distance Plate Bracket
1
15
Screw
2
16
Stern Bracket Spring
1
17
Screw
1
18
Washer 4.3-16-1.5
1
19
Thrust Rod
1
20
Thrust Rod Spring
1
21
Bolt
4
22
Thrust Bushing
1
23
Bushing Upper Steering
1
24
Bushing Lower Steering
1
25
Friction Band Ass'y
1
26
Thrust Plate (Lower)
2
27
Spring Co-Pilot
1
28
Wing Nut M6
1
29
Washer 6-16-1.5
1
30
Tilt Stopper Ass'y
1
31
Tilt Stopper Grip
1
32
Bushing Tilt Stopper
2
33
Setting Plate Tilt Stopper
1
34
Bolt
2
35
Grease Fitting
2
36
Reverse Lock Arm
1
37
Bolt
2
38
Reverse Lock Spring (R)
1
39
Reverse Lock Spring (L)
1
4st 4/5/6 2011
M8
M6 L=12mm
M4 L=6mm
M6 L=40mm
7
M6 L=12mm
M6 L=14mm
7-3
MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 4
Bracket
Drive Shaft Housing & Shift
P/L Fig. 7
RE
AS
E
OBM
OBM
G
B
1342
342 T
1342
B
1342
342 T
1342
G
RE
AS
OBM
E
OBM
1342
B
1342 T
7-4
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Ref.
No.
Description
Q'ty
Remarks
1-1
Drive Shaft Housing Ass'y (S)
1
For Transom "S"
1-2
Drive Shaft Housing Ass'y (L)
1
For Transom "L"
1-3
Drive Shaft Housing Ass'y (UL)
1
For Transom "UL"
Bushing Shift Lever
1
2
Exhaust Plug
1
4-1
3
Drive Shaft Bushing Ass'y
1
For Transom "L"
4-2
Drive Shaft Bushing Ass'y
1
For Transom "UL"
5-1
Drive Shaft Bushing
1
For Transom "L"
5-2
Drive Shaft Bushing
1
For Transom "UL"
6
Stopper Drive Shaft
1
7
Screw Pre-coated 5-25
2
8
Washer
2
9
Screw
2
10
Grommet Cam Rod
1
11
Dowel Pin 6-12
2
12
Bolt
1
M8 L=8mm
13
Gasket 8.1-15-1
1
Do not reuse.
14
Grommet 29.3
1
15
Bolt
6
16
Drive Shaft Housing Gasket
1
17
Extension Housing
1
18
Bolt
1
19
Washer
1
20
Stud Bolt
1
21
Washer
1
22
Nut
1
M8
23-1
Shift Rod (S)
1
For Transom "S"
23-2
Shift Rod (L)
1
For Transom "L"
24
Shift Rod Lever
1
25
Pin Shif Lever
1
26
Split Pin
1
27
Shift Rod Joint Ass'y
1
28
Washer
1
29
Bolt 5-16
1
M6 L=16mm
30
Bolt
1
M4 L=16mm
31
Shift Lever
1
32
O-Ring 1.9-8.8
2
33
Ceramic Ball 7.7
1
34
Spring Shift Lever Stopper
1
4st 4/5/6 2011
M5 L=10mm
M6 L=30mm
Do not reuse.
M6 L=25mm
M8 L=25mm
7
Do not reuse.
7-5
MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 6
Bracket
P/L Fig. 10
Bottom Cowl & Tiller Handle
G
RE
A
SE
OBM
OBM
G
RE
A
SE
OBM
OBM
G
RE
AS
E
OBM
OBM
G
RE
A
RE
A
SE
OBM
G
SE
RUB
OBM
RUB
G
RE
AS
E
OBM
OBM
G
RE
AS
E
OBM
OBM
G
RE
AS
E
RUB
RUB
7-6
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Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Description
Bottom Cowl
Bottom Cowl (Integral Tank)
Hook Lever
Seal Ring Hook Lever
Hook Lever Bushing
Wave Washer d=14
Cover Hook
Bolt
Washer 6-16-1.5
Grommet Starter Lock Rod
Grommet Throttle Lever
Grommet 18-2.5
Clamp 6.5-47.5P
Screw
Grommet 17-2.7
Tiller Handle Sub-Ass'y
Tiller Handle
Stud
Grip
Throttle Shaft Damper
Bushing 14-15.8-7
Screw
Throttle Shaft Support
Screw
Friction Piece
Adjusting Screw
Washer
Nut
Throttle Shaft
Throttle Decal
Plastic Rivet 6.5
Spacer Handle
Washer 30-45-1
Spring Washer
Throttle Wire
Protector Wireharness
Bushing Steering
Steering Handle Stopper
Plastic Rivet 6.5
Nut
Fuel Connector (Engine Male
Fuel Connector Protector
Fuel Hose 4.5L-75
Clip Fuel pipe
Screw
Fuel Hose F
Clip Fuel pipe
Fuel Cock Ass'y
Grommet
Bolt
Choke Rod
Choke Rod Bushing
Storage Decal
Label Oil Pressure
Spark Plug Decal
Fuel Lever Decal
Bolt
Washer
4st 4/5/6 2011
Q'ty
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
2
1
1
2
1
1
1
1
2
1
1
1
2
4
1
1
1
1
1
1
1
1
Remarks
M6 L=12mm
M6 L=12mm
M5 L=18mm
M6 L=12mm
M6
7
M6
M4 L=10mm
M6 L=16mm
M6 L=40mm
7-7
MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 8
Bracket
Cowl
P/L Fig. 11
%
"
#
!
D
1741 A
H
1741
Separate Tank
"
$
Sail Pro Decal
D
1741 A
!
H
1741
Integral Tank
H
1741
D
1741 A
Ref.
No.
1
2
Description
Top Cowl Ass'y
Top Cowl
(Integral Tank)
3 Top Cowl Seal
4 Starter Seal
5-1 Decal Set (F4B)
5-2 Decal Set (F5B)
5-3 Decal Set (F6B)
7-8
Remarks
Q'ty
1
For Separate Tank Model
1
1
1
1
1
1
For Integral Tank Model
Ref.
No.
6
7
Description
Q'ty
Sail Pro Decal
Caution Decal (A)
2
1
Remarks
4ps
5ps
6ps
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MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 9
2. Disassembling and Assembling
Procedure
1) Removal and inspection of drive shaft housing
1.
Tilt up drive shaft housing.
2.
Remove reverse lock arm 1.
1
3.
Remove thrust rod 2.
2
7
4.
Remove wing nut 3 for co-pilot.
Loosed four swivel bracket (B) bolts 4.
3
Hold drive shaft to prevent it from dropping.
4
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Bracket
5.
Remove drive shaft housing 5.
5
6.
Check steering bushing 6 and thrust place 7 for wear
and damage, and replace if necessary.
6
7
7-10
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2) Removal and inspection of clamp bracket
1.
Loosen clamp bracket mounting nut 1 and remove bolt.
1
2.
Remove bracket distance place 2 mounting screws 3.
2
3
3.
Remove tilt stopper 5 mounting bolt 6 from swivel
bracket 4, and then remove tilt stopper 5.
4
5
6
7
4.
Check tilt stopper and bracket for damages.
Replace if damaged.
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MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 12
Bracket
3) Installation of clamp bracket and
drive shaft
1.
Install tilt stopper 1 to swivel bracket (A).
1
Apply grease to sliding areas of tilt stopper.
2.
Install clamp bracket to swivel bracket (A).
Apply grease to both sides of washer 2.
G
RE
AS
E
OBM
OBM
2
G
RE
AS
E
OBM
OBM
3.
Install distance plate 3 to clamp bracket.
3
4.
Install thrust bushing 5 , thrust place 6 , steering
bushings 7 and 8 and friction plate 9 on the drive shaft
housing 4.
5
7
4
9
8
6
7-12
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5.
Install drive shaft housing and swivel bracket (B) to swivel
bracket.
Attach wing nut 0 , and check operation of
steering friction.
0
6.
Install reverse lock arm q on the swivel shaft.
q
7
7.
Check operation of each part, and put grease through
swivel shaft grease nipple w.
w
Keep putting grease until excessive grease
appears from thrust bushing.
G
RE
AS
E
OBM
OBM
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7-13
MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 14
Bracket
4) Removal, inspection and installation
of water pipe
1.
Remove water pipe 1 from drive shaft housing 2.
2.
Check water pipe for crack and damage.
3.
Install water pipe 1 into drive shaft housing 2.
1
· Apply grease to water pipe grommet (3) before
installation.
· Attach water pipe surely to drive shaft bushing.
G
RE
AS
E
1
OBM
OBM
2
1
3
G
RE
AS
E
OBM
OBM
7-14
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5) Remove, inspection and installation
of tiller handle.
1.
1
Loosen stud bolt 1 of tiller handle, and remove tiller
handle from bottom cowl.
2.
Check tiller handle spacer 2 and bushings 3 for wear
and damage.
3
3.
2
Loosen throttle grip screw 4 and remove the grip 5.
Remove throttle shaft supporter 6 screw.
Check bushing 7 and throttle shaft dumper 8 for
damage.
7
4.
9
8
Check throttle wire 9 for break, bend and crack, and
replace if necessary.
6
5
4
4st 4/5/6 2011
7-15
7
MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 16
Bracket
5.
Attach throttle wire 9 to throttle shaft 0 as shown.
G
RE
AS
E
OBM
OBM
0
G
RE
A
SE
9
OBM
OBM
6.
Attach throttle shaft 0 with throttle wire 9 to tiller handle
q, and tighten adjusting screw w securely.
Tighten throttle supporter.
q
G
RE
AS
E
e
w
9
OBM
0
OBM
Be careful of location of throttle friction e.
G
RE
AS
E
OBM
OBM
7.
Install throttle grip r to tiller handle, and secure with
screw.
r
8.
Install tiller handle bushing t and spacer y to tiller
handle.
Apply grease to tiller handle bushing t and
spacer y.
G
RE
AS
E
OBM
OBM
t
G
RE
AS
E
y
OBM
OBM
7-16
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MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 17
9.
Install tiller handle to bottom cowl.
Tighten nut 1 to specified torque.
Tiller handle securing nut 1 :
6 N · m (4 lb · ft) [0.6 kgf · m]
1
Arrange throttle cable 9 as shown.
a<High speed side>, b<Low speed side>
b
9
a
10.
Check operations of tiller handle and throttle grip.
7
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7-17
MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 18
Bracket
6) Adjustment of Throttle Cable
1.
Check position of cable at low speed and high speed
sides.
2.
Set throttle grip to slowest position, and fully pull choke
knob to close choke valve.
3.
Adjust lock nut 1 while applying tension to outer wire by
pulling it with a hand to fix low speed side wire.
1
The wire is in proper state if pushing inner wire at
the center makes deflection of about 1 mm.
4.
Repeat above steps for high speed side wire, and fix it.
5.
Return choke knob to home position to fully open choke
valve.
To confirm slowest position of throttle grip, check gap
between projection of throttle drum and dent of opener
section. The gap is acceptable if it is in the range between
0.5 mm and 1 mm.
Repeat steps 2. to 4. if necessary.
7-18
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6.
Set throttle grip to full-open position, and check if throttle
lever of carburetor makes contact with stopper.
7.
Set throttle grip to full-close position, and check if throttle
lever of carburetor makes contact with stopper.
7
4st 4/5/6 2011
7-19
MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 20
Bracket
7-20
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MFS4-5-6̲E̲ch08̲110422.qxd 11.4.22 6:00 PM ページ 1
8
Electrical System
1. Special Tools ……………………………… 8-2
Magneto………………………………………… 8-3
2. Ignition System and Ignition
Control System …………………………… 8-4
1) Inspection of Ignition Spark……………… 8-4
2) Inspection of Plug Cap…………………… 8-5
3)
4)
5)
6)
7)
Inspection of Igniter ……………………… 8-6
Inspection of Stop Switch ……………… 8-7
Inspection of Oil Pressure Switch ……… 8-7
Inspection of Rectifier …………………… 8-8
Inspection of Lighting Coil ……………… 8-8
8
MFS4-5-6̲E̲ch08̲110422.qxd 11.4.22 6:00 PM ページ 2
Electrical System
1. Special Tools
Vacuum/Pressure Gauge
P/N. 3AC-99020-0
Spark Tester
P/N. 3F3-72540-0
Thickness Gauge
P/N. 353-72251-0
Inspecting pressure
Inspecting spark
Measuring gaps
8-2
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MFS4-5-6̲E̲ch08̲110422.qxd 11.4.22 6:00 PM ページ 3
Magneto
P/L Fig. 6
50 Nám (3.7 lbáft) [5.0 kgfám]
8
O
IL
-C
O
7
GM
SOC
M
P.
SOC
BO
N
2
D
G17
3
4
3
4
9
1
6
5
G17
10
11
2
23
21
24
12
16
22
13
20
G17
BO
N
D
17
G17
IL
-C
O
GM
SOC
M
15
P.
Ref.
No.
1
2
2
3
4
5
6
7
8
9
10
11
12-1
12-2
8
19
18
SOC
O
14
25
Description
Flywheel MF54 (Mark48)
Flywheel MF54 (Mark50)
Alternator Ass'y
Screw
Washer
Clamp
Screw
Washer
Nut 12-P1.25
Igniter W/R-Cap
Plug Cap W/Resistance
Bolt
Clamp 6.5-67P
Clamp 6.5-47.5P
4st 4/5/6 2011
Q'ty
1
1
1
4
4
1
1
1
1
1
1
2
2
1
Remarks
"for Sail Pro (with Alternater)"
M5 L=25mm
M4 L=8mm
M6 L=30mm
Ref.
No.
Description
13
14
15
16
17
18
19
20
21
22
23
24
25-1
25-2
Screw
Rectifier Complete
Fuse (10A)
Clamp 7-80P
Battery Cable
Cable Terminal Plug
Grommet 17-3
Pilot Lamp Ass'y
Stop Switch Ass'y
Stop Switch Lanyard Ass'y
Clamp 6.5-14
Bolt with Washer
Protector Wireharness
Protector Wireharness
Q'ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Remarks
M6 L=12mm
M6 L=12mm
For Separate Tank Model
For Integral Tank Model
8-3
MFS4-5-6̲E̲ch08̲110422.qxd 11.4.22 6:00 PM ページ 4
Electrical System
2. Ignition System and Ignition
Control System
1) Inspection of Ignition Spark
1.
Disconnect plug cap from spark plug.
2.
Connect plug cap to spark tester.
3.
Connect spark tester clip to spark plug tip electrode.
Spark Tester:
P/N. 3F3-72540-0
Spark Performance:
10 mm (0.4 in) or over
a
0
5
1
0
4.
5
10
Start engine and check spark. If spark is weak, check
igniter (including igniter clearance) and/or plug cap.
This test can be made without removing parts.
WARNING
OK
· When testing, put electrode cap assuredly
to prevent direct contact with spark
tester wiring and leak of electrical
current, and perform test carefully.
· Keep flammable gas, fuel and oil away
from tester to prevent them from catching
sparks.
8-4
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2) Inspection of Plug Cap
Remove the part and test it as a separate unit.
BO
N
D
G17
G17
1.
Disconnect plug cap from spark plug.
2.
Remove plug cap from high tension cable.
3.
Measure plug cap resistance. Replace if other than
specified value.
Plug Cap Resistance (at 20˚C) :
3.0 - 7.0 kΩ
8
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8-5
MFS4-5-6̲E̲ch08̲110422.qxd 11.4.22 6:00 PM ページ 6
Electrical System
3) Inspection of Igniter
1.
Remove igniter, and turn plug cap counterclockwise to
remove it from high tension cord.
2.
Measure igniter resistance. Replace if other than specified
value.
Remove the part and test it as a separate unit.
- .. / '! *! $%
! # $%
,&(+&( $%
(& + $%
',( $%
!"# $%
"&#'&# $%
(& + $%
"(")( $%
!, + $%
0 . 1. 2&
0 3 . . 2 .
,&*)&( $%
,(+( $%
1 4
%&
Circuit tester: HIOKI3030 (Measurement range:1kΩ)
The measurement varies depending on the measurement range of the circuit tester or voltage due to diode
used in the unit.
This check provide only a reference, and it is impossible to perform perfect check.
3.
Install plug cap onto high tension cord by twisting
clockwise.
4.
Install igniter so that specified clearance is achieved, and
connect plug cap to spark plug.
1
Thickness Gauge 1:
P/N. 353-72251-0
Igniter Clearance:
0.2 - 0.4 mm (0.008 - 0.016 in)
Igniter Bolts:
6 N · m (4 lb · ft) [0.6 kgf · m]
5.
8-6
Connect igniter lead to stop switch.
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MFS4-5-6̲E̲ch08̲110422.qxd 11.4.22 6:00 PM ページ 7
4) Inspection of Stop Switch
1.
Check conduction of stop switch, and replace if not
a
b
conductive.
This test can be made without removing parts.
Switch Position
Lead Wire Color
Brown (Br)
Black (B)
Remove
lock plate. a
Attach
lock plate. b
Press
switch. c
c
5) Inspection of Oil Pressure Switch
Remove the part and test it as a separate unit.
1.
Check electrical conductivity of oil pressure switch.
Replace if no conductivity.
2.
Connect vacuum/pressure gauge to oil pressure switch.
B
1342
342 T
1342
Vacuum/Pressure Gauge :
P/N. 3AC-99020-0
3.
Apply pressure slowly with vacuum/pressure gauge.
4.
Check that oil pressure switch is not conductive with
8
specified pressure applied. Replace if conductive.
Specified Pressure :
0.020 - 0.029 MPa (2.8 - 4.0 psi) [0.2 - 0.3 kgf/cm2]
5.
Reinstall the part.
Oil Pressure Switch :
8 N · m (6 lb · ft) [0.8 kgf · m]
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8-7
MFS4-5-6̲E̲ch08̲110422.qxd 11.4.22 6:00 PM ページ 8
Electrical System
6) Inspection of Rectifier
1.
Check conduction of fuse (10 A) contained in the fuse box
1
2. Replace if non-conductive.
b
a
2.
Check conduction between rectifier terminals. Replace if
out of specification.
2
Rectifier Tester Check Chart
a
b
a
b
7) Inspection of Lighting Coil
1.
Measure resistance between lighting coil terminals a and
b. Replace if out of specification.
b
This test can be made without removing parts.
a
Range of normal lighting coil resistance :
46 - 68 Ω
8-8
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MFS4-5-6̲E̲ch09̲110422.qxd 11.4.22 7:00 PM ページ 1
OK
9
Troubleshooting
OK
1. Troubleshooting List …………………… 9-2
2. Power Unit ………………………………… 9-3
1 Engine will not start or is a little hard to start.
(Recoil starter operates normally.) ………… 9-3
2 Engine starts but stalls soon. ……………… 9-5
Fuel System ………………………………… 9-5
Ignition System ……………………………… 9-6
Intake • Compression Pressure …………… 9-7
3 Idle engine speed will not stabilize. ……… 9-8
4 Rough acceleration. ………………………… 9-9
5 Gear shifting cannot be made normally.… 9-10
9
MFS4-5-6̲E̲ch09̲110422.qxd 11.4.22 7:00 PM ページ 2
OK Troubleshooting
1. Troubleshooting List
" ! ○
○
Fuel level is low in the tank.
Fuel system connection is incomplete.
Air suctioned through fuel system.
Fuel pipe is twisted.
Air vent screw is closed.
Fuel filter, fuel pump or carburetor is clogged.
Low quality engine oil
Low quality gasoline
Engine oil level is too high.
Engine oil lacks. (Oil warning lamp is lit.)
Fuel is fed excessively.
Carburetor is maintained poorly.
Oil pump malfunction.
Use of spark plugs not specified
Spark plug carbon deposit or bridge
No sparks or weak spark
Stop switch short-circuited
Ignition timing is not properly adjusted. (Ignighteor, valve timing)
Stop switch lock is not in place.
Disconnection of lead wires or loose earth wire.
Valve clearance is wrong.
Cylinderhead sealing is defective.
Valve seat sealing is defective. (Intake and exhaust)
Piston, piston ring and/or cylinder is worn excessively.
Combustion chamber excessive carbon deposits.
Spark plug is loose.
○
○
Cooling water is not fed or low due to malfunction or clogging of pump.
○
○
○
○
Thermostat operation is defective.
Anti-cavitation plate is damaged.
Use of mismatched propeller.
Propeller is damaged or deformed.
Thrust rod position is not correct.
Boat is unbalanced by load position.
Transom installation height is too high or too low.
Throttle link adjustment is defective.
○
○
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9-2
○
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Before working on the outboard motor, check the hull, rigging, installation of outboard motor, fuel level, and
wire connections. For mechanical troubleshooting, refer to relevant troubleshooting section in this chapter.
For checking and servicing outboard motor, refer to service procedures described in this manual to perform
the work safely.
2. Power Unit
Trouble 1
Engine will not start or is a little hard to start. (Recoil starter operates normally.)
• Inspection of Ignition System, Fuel System and Compression Pressure
Check electrical conductivity of
stop switch.
(with lock plate attached)
NO
Replace stop switch.
Normal ?
YES
Use spark tester to check
ignition sparks.
WARNING
• When testing, put electrode cap assuredly to prevent
direct contact with spark tester wiring and leak of
electrical current.
• Keep flammable gas, fuel and oil away from tester to
prevent them from catching sparks.
NO
Normal ?
Check igniter and/or
plug cap.
YES
Check spark plug.
NO
Good?
Clean spark plug
and adjust gap,
or replace with new one.
YES
9
Check compression pressure.
Out of specified
range?
To next page
4st 4/5/6 2011
NO
Check fuel system.
YES
9-3
MFS4-5-6̲E̲ch09̲110422.qxd 11.4.22 7:00 PM ページ 4
OK Troubleshooting
Check valve clearance.
NO
Normal ?
Adjust valve clearance.
YES
Check valves,
cylinder block
and/or piston ass’y.
9-4
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MFS4-5-6̲E̲ch09̲110422.qxd 11.4.22 7:00 PM ページ 5
Trouble 2
Engine starts but stalls soon.
• Inspection of Fuel System, Ignition System, Compression Pressure
Fuel System
Check air vent screw of fuel tank.
NO
Open air vent screw.
Open?
YES
Check if fuel contains water
and fuel filter is clogged.
Does fuel contains water,
or is fuel filter clogged?
NO
Check fuel hose for bend
and fuel leak.
YES
Clean fuel tank.
Is fuel hose bent
or does fuel leak
from the hose?
NO
Check carburetor.
YES
Replace defective part
with new one.
9
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9-5
MFS4-5-6̲E̲ch09̲110422.qxd 11.4.22 7:00 PM ページ 6
OK Troubleshooting
Ignition System
Use spark tester to check
ignition sparks.
NO
Normal ?
YES
Replace spark plug
with new one.
9-6
Check igniter
and/or plug cap.
WARNING
• When testing, put electrode cap assuredly to prevent
direct contact with spark tester wiring and leak of
electrical current.
• Keep flammable gas, fuel and oil away from tester to
prevent them from catching sparks.
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MFS4-5-6̲E̲ch09̲110422.qxd 11.4.22 7:00 PM ページ 7
Intake • Compression Pressure
Check if secondary air
is sucked through mating surface
of carburetor or intake manifold.
Is secondary air
sucked?
NO
Check compression
pressure.
YES
Replace defective part
and seal with new ones.
9
4st 4/5/6 2011
9-7
MFS4-5-6̲E̲ch09̲110422.qxd 11.4.22 7:00 PM ページ 8
OK Troubleshooting
Trouble 3
Idle engine speed will not stabilize.
• Inspection of Intake Manifold, Air Intake System and Ignition System
Check operations
of throttle cable and drum.
NO
Normal ?
Adjust throttle cable.
YES
Check ignition timing.
Out of specified
range?
NO
Check gaskets
if secondary air is
sucked through them.
YES
Check igniter clearance.
9-8
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MFS4-5-6̲E̲ch09̲110422.qxd 11.4.22 7:00 PM ページ 9
Trouble 4
Rough acceleration.
Rapid opening of throttle causes engine to stall.
Acceleration is not smooth.
• Inspection of Carburetor, Ignition System and Compression Pressure
Check operation of throttle cable.
Is the throttle
valve tuned ?
NO
Adjust throttle cable.
YES
Disassemble carburetor,
and check internal components
for clogging, dirt and damage.
Any clogging,
dirt and/or damage?
NO
Check ignition system and
compression pressure.
YES
Clean carburetor
and/or replace
defective part(s)
with new one(s).
9
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MFS4-5-6̲E̲ch09̲110422.qxd 11.4.22 7:00 PM ページ 10
OK Troubleshooting
Trouble 5
Gear shifting cannot be made normally.
Check operations of shift lever.
NO
Normal ?
Check spring and ball.
YES
Check shift rod joint.
NO
Normal ?
Replace shift rod.
YES
Disassemble lower unit
and check operation of clutch.
NO
Normal ?
Replace defective part
with new one.
YES
Check forward gear and
pinion (A and B gears)
and clutch.
9-10
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MFS4-5-6E̲ch10̲110422.qxd 11.4.22 6:57 PM ページ 1
10
Wiring Diagram
10
MFS4-5-6E̲ch10̲110422.qxd 11.4.22 6:57 PM ページ 2
WIring Diagram
F 4B/5B/6B
B ------- Black
OPTION
Br ----- Brown
Y
R ------- Light Green
LIGHT EXTENSION CORD
W ------ White
Y
Lg ----- Light Green
RECTIFIER
ALTERNATOR
Y
Y
Y
Y
MAGNETO
FUSE
MAGNETO
IGNITER
WARNING LIGHT
R
Y
R
Y
Lg
Lg
OIL
PRESSURE
SWITCH
R
W
W
STOP SWITCH
B
BATTERY
10-2
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MFS4-5-6E̲ch10̲110422.qxd 11.4.22 6:57 PM ページ 3
OPTION
IGNITER
Br
STOP SWITCH
Br
B
STOP SWITCH
ASSEMBLY
B
B
Br
Br
REMOTE
CONTROL
BOX
10
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MFS4-5-6E̲ch10̲110422.qxd 11.4.22 6:57 PM ページ 4
WIring Diagram
10-4
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 1
11
C model Service Information
11
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 2
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 3
Introduction
The following pages are added to describe service information about four stroke gasoline engine 4/5/6
Model C that is different from those of Model B. Each chapter and section of this supplement should be
replaced with those of the service manual for 4/5/6B (2010 model) when servicing model C. For your
convenience, page number of corresponding section of the manual is shown in parenthesis.
Contents
1. Specification • Service Data .................................................................. 11-2
2. Parts Layout .......................................................................................... 11-12
3. Difference item ...................................................................................... 11-30
Chapter 1 Predelivery Inspection..................................................................... 11-30
1) Gear Shift (P1-8) ..................................................................................................................................... 11-30
2) Fuel Tank and Fuel Line (P1-9) .............................................................................................................. 11-30
3) Inspection of Forward and Reverse Shifts (P1-11) ................................................................................. 11-30
Chapter 3 Inspection Items ........................................................................... 11-31
1) Fuel System (P3-4) ................................................................................................................................. 11-31
Check piping ........................................................................................................................................... 11-31
2) Inspection of Fuel Tank (P3-5)................................................................................................................ 11-31
Chapter 4 Inspection Items ........................................................................... 11-32
1) Inspection of Fuel Feed System Piping (P4-12)...................................................................................... 11-32
2) Draining Fuel (P4-12).............................................................................................................................. 11-32
3) Inspection of Fuel Tank and Fuel Tank Cap (P4-13) .............................................................................. 11-32
4) Inspection of Fuel Cock (P4-13).............................................................................................................. 11-32
5) Removing Carburetor (P4-14)................................................................................................................. 11-33
Chapter 5 Inspection Items ........................................................................... 11-35
1) Removing Power Unit (P5-16) ................................................................................................................ 11-35
Chapter 8 Inspection Item ............................................................................. 11-37
1) Inspection of Igniter (P8-6)...................................................................................................................... 11-37
2) Inspection of Rectifier (P8-8)................................................................................................................... 11-37
Chapter 10 Wiring diagram ............................................................................ 11-40
11
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 2
1. Specification • Service Data
1.Outline Dimensons
<Dual Tank model>
Item
A
Type
S
L
UL
S
L
UL
B
D
E
F
G
H
I
J
K
S
L
UL
N
P
C
S
O
L
H
M
N
O
P
Q
R
S
T
U
Unit
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
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
deg.
deg.
deg.
deg.
mm/in
mm
398
655
782
909
435
562
689
383
497
110
422
361
349
30-60
275
658
758
858
343
273
267
545
110
in
15.67
25.79
30.79
35.79
17.13
22.13
27.13
15.08
19.57
4.33
16.61
14.21
13.74
1.18-2.36
10.83
25.91
29.84
33.78
13.50
10.75
10.51
21.46
134
12
75
75
4.33
G
M
D
A
E
Q
F
J
T
U
B
C
R
K
L
11-2
I
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 3
<Sepalate Tank model>
Item
A
Type
S
L
UL
S
L
UL
B
D
E
F
G
H
I
J
K
S
L
UL
N
P
C
S
O
L
H
M
N
O
P
Q
R
S
T
U
Unit
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
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
mm/in
deg.
deg.
deg.
deg.
mm/in
mm
384
655
782
909
435
562
689
383
497
110
422
361
349
30-60
275
658
758
858
343
273
267
545
110
in
15.12
25.79
30.79
35.79
17.13
22.13
27.13
15.08
19.57
4.33
16.61
14.21
13.74
1.18-2.36
10.83
25.91
29.84
33.78
13.50
10.75
10.51
21.46
134
12
75
75
4.33
G
M
D
A
E
Q
F
J
T
U
B
C
R
K
L
4st 4/5/6 2011
I
11
11-3
MFS4-5-6̲E̲ch11̲110427.qxd 11.4.27 9:12 AM ページ 4
1. Specification • Service Data
2.Specifications
!
!
"
"
"
+, - !- .-
"/
)0.*
+, - 1- 2! - . !
' / !. ! !. ' ' 4 &5- % )5*(
! &6!% )6*(
' ' 7 8.
5!# !1 28
! .2 9 8 :! , !"
$! . ! !
1 !. !
8 -<2 ! 8 $!! 8 7, - 8 4 ! 8 4 ! ." .-
C ! !- .6- 1 8 11-4
2 &2-#(
&(
#
#
#
#
$ % # &' ( )*
$ % # &' ( )*
$ % # &' ( )*
$ % # &' (
$ % # &' (
$ % # &' (
$ % 3 $ % 3 $ % 3 #
#
# &' ( )*
!"
& #(
09 $! 1!
, &#,# (
#
+-
;2! / - . & !2 ! .- .(
$!! &-<< .(
-= -< , - 8 68 ! &$> !(
:>$? 3 :>$?
[email protected] >$B;7
&. !%9 /(
$<- ! &9 2 <- 18 8 (
# &' (
3 9 /
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 5
Item
Unit
Dual Tank Model
4/5/6C
Model
Sepalate Tank Model
5/6C
Sail Pro
6C
Fuel and oil
# + ()*
#(+
3&&(
2 5
- - ( @
@
()*
#(+
( 2 5
@ A ()*
#(+ B - !
"
$ % %
& ' #+, #, #-, #., #/, #, #&
012, 01'
0$ 0124'
'! ! "
. -1!
601, ! 7 7
Lower unit
- - ) % ) ) ; <
A ? 9 ?
) 131 " ! 2 8 "6
# % 9 # $: %: : ' 8 => 2 ? " ? =6
7> 2 ? "" ? 7
!, 7 8 6> 2 ? " ? "2
Bracket
3 "C
9
# : : % "C 9
& ? 9
@"
@2
# 9
& ? : @" @2 # 1 7
' D "'
2" !
=!
!
2 D !! 6 D " =
Warning system
+ %1% + 4
7,2E
F 1 0 Optional parts
) ; <
G 4st 4/5/6 2011
A ? 9 ?
) 7> 2 ? " ? !"
=> 2 ? " ? =6
6> 2 ? " ? "2
> 2 ? " ? ""
"G70
7> 2 ? "" ? 7
11
H
H
$ 8 " D 7
11-5
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 6
1. Specification • Service Data
3.Maintenance Data
9 7 11-6
+ , , -
. / . B 4 &%$')*
$
B ; $
$
. 8 2 - . $
6 6 7 7 8 : 9 7 8 : 9 7 8 : 9 8 : 9 8 : 9 ; & 8 :*
< ; &2 * /$
"%% >
/$
"#$%% &'$('')*
")$#1 &'$('0(*
%$%'% 3 %$%"" &%$%%%4# 3 %$%%'04*
- %$%5 3 %$%) &%$%%01 3 %$%%(0*
%$%( 3 %$%4 &%$%%0' 3 %$%%')*
. %$%0 3 %$0) &%$%%%5 3 %$%%40*
%$%%' 3 %$%0' &%$%%%%)〜%$%%%54*
01$%% &%$1'##*
- %$0" 3 %$(" &%$%%"# 3 %$%0()*
%$(% 3 %$"% &%$%00) 3 %$%0#4*
. %$'% 3 %$5% &%$%%4# 3 %$%0"4*
01$%0 &%$1(%(*
%$%5% 3 %$%11 &%$%%0"4 3 %$%%'1%*
%$'% 3 %$5% &%$%%4# 3 %$%0"4*
'#$#" &0$04#0*
- %$%" &%$%%'%* $
%$%1 3 %$05 &%$%%'5 3 %$%%""*
%$00 3 %$0# &%$%%5( 3 %$%%4"*
"$54 &%$'0"5*
"$55 &%$'05'*
"$"% &%$'01"*
"$"% &%$'01"*
%$%'% 3 %$%55 &%$%%%4# 3 %$%%04(*
%$%5" 3 %$%4' &%$%%044 3 %$%%')(*
%$) &%$%(0"*
%$) &%$%(0"*
("$% &0$()*
')$(( &0$00"54*
0($#)% &%$""%5*
%$(5
%$#(
&5#$( * =($">'? @0%A
&0(4$) * =#$">'? @0%A
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 7
%$%( &%$%%0'*
"#$%4 &'$('"1*
%$%1 &%$%%'5*
%$%1 &%$%%'5*
%$%( &%$%%0'*
")$#% &'$(0)#*
%$0"% &%$%%"#0*
C $
$ &D E'5% 5%% $ D E1%% $*
$
$
$
2 ,
8$ 5%% 1%%, $
$ &D E'5% 5%% $ D E1%% $**
2 $
2 $
D 8$ 5%% 1%% , $
- %$0% &%$%%(#*
%$%# &%$%%("*
. %$'0 &%$%%)(*
2 $
2 $
%$%5 &%$%%0"4*
0"$#4 &%$1')4*
2 $
2 $
- %$"% &%$%0#4*
%$4% &%$%'41*
2 $
2 $
2 $
2 $
2 $
2 $
2 $
01$%5 &%$1(05)*
%$%)% &%$%%(0"*
%$4% &%$%'41*
'#$#' &0$04)%*
%$%" &%$%%'%*
C "$5" &%$'051*
"$50 &%$'0(%*
"$"5 &%$'0)0*
"$"4 &%$'0#(*
%$%4% &%$%%'41*
%$0%% &%$%%(#5*
0$) &%$%4%#*
0$) &%$%4%#*
(($' &0$(0*
')$%4 &0$0%"0*
0($#"% &%$"5#(*
%$%( &%$%%0'*
2 $
2 $
2 $
$
2 $
2 $
2 $
2 $
11
, $
4st 4/5/6 2011
11-7
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 8
1. Specification • Service Data
Part name
Fuel and lubrication parts
Electrical parts
Cooling system parts
& ' (
' #(
)) *
' (
' #(
+ , ! = > =
? > =
A211
#
# B !!
CA41: D
EF> F @ F> F
!!
H !! CA41: D CG D
= !!
& ! !
!
! " #
! Lower unit parts
& !
& !
+< +
+
+ + !
! ! > > # " > > ! # ! " > ! ! ! +< < < 4C
-($#
/01
/03
564
50-2
/096
5-7
5042
86:-1;
Standard value
5C
6C
Sail Pro
-"#
-(.#
/0/02
/02
/03
/40
/40
567
581
581
5021
5022
5022
/491
/494
/494
5-7
5-7
5-7
5002
5001
5001
82:
87:
87:
0191
0<-11
4-913 19313
1904 @ 1941 1911 8 @ 191183
2933 194-27
1914 @ 1918 191117 @ 191147
$ -: @ $ 42:
01 19 19- 19104
04&61+
19 6 @ 1967G
7
-91 @ 891G
$ 6.C*"ID
197 @ 193 191-0 @ 191-2
7
21 @ 2 : 040 @ 043:,
6- @ 68: 0 6 @ 02 :,
-91 1904 1912 @ 1902 191141 @ 191123
$ J1906 @ 19 3 19116- @ 19103-
191-1 @ 19127 191104 @ 19114-
191 1 @ 1918 191106 @ 191147
J411K087 893K891
2< 6 J411K41- 893K791
-968 190 2
$ ! ! ! + $
B +
$ " > ! ! 19106 @ 1918- 1911164 @ 1911478
!!
+< $ ! Other
parts
11-8
Item
6 J
404K061
79-K69-
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 9
4-90- 1942 1911 8 @ 191183
2936 194- 6
1901 1911-3 + ! 9
01 19 > 9
#'! ! 9
! 9
! 9
094 191 8
9
9
> 9
9
! 9
! ! 9 #'! = !
9 ! != 9
! 9
! ! ! > ! < ! ! 9
62: 021:, K= 2 !9
-91 1904
! >< ! > > 9
! ! !9
!= >
!= >
!= >
!= >
!!=9
1912 191141
19- 191007 1937 191-76 9
190 1911-3 190 1911-3 9
< !!=9
-981 190 28
194 19117
192 19141
!= >
> 9
!!=9
9
9
B ! < < < ! 9
! 192 19141 !! = >9
4st 4/5/6 2011
11
11-9
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 10
1. Specification • Service Data
4.Sealant and Lubrican
Shin-Etsu
Chemical
Centax FM- Bentax LML2
2
531
902
KS64
●
Bearings and cams
Rocker arm
●
Sliding surface
Valve (IN, EX)
●
Stem and stem end
Valve spring
●
Whole area
Valve spring seat
●
Whole area
Retainer cotter
●
Whole area
Pivot
●
Whole area
Cylinder liner
●
Inner wall
Piston
●
Ring grooves and periphery
Piston ring
●
Whole area
Piston pin
●
Periphery
Connecting rod
●
Big and small end bores
Connecting rod cap
●
Inside
Crankshaft
●
Sliding surface, Bearing and Gear
Ball bearing (crankshaft)
●
Sliding surface, Outer surface
Bush (crankshaft)
●
Inside and outside
●
Oil seal (crankshaft)
Engine block
Outer surface (at press fitting)
Plunger
●
Spring and O rings
Oil pump
●
Outer and Inner rotor
Fuel pump
●
Plunger top surface
O ring (fuel pump)
●
O ring (filler cap)
●
●
Lip
●
●
Outer surface (at press fitting)
Thread
●
Oil strainer pipe
Seal rubber
●
Exhaust cover gasket
Starter case
●
Sliding surface
Starter spring
●
Whole area
Ratchet
●
Sliding surface
Friction plate
●
Sliding surface
Real
●
Sliding surface
Starter shaft (bolt)
●
Oil pressure switch
at reusing bolt
●
Frange surface
●
Plug cap
11-10
Lip
●
Screw (oil strainer)
Electrical
components
Remarks
Camshaft
Oil seal (crankcase)
Recoil
starter
Tohatsu genuine gear oil
Chuoh Yuka
4 stroke engine oil
2000
Silicone grease SOC
1741
Teflon grease TEF
Cylinder
&
Oil pan
G103
Rubber grease RUB
Cylinder
Head
G17
Three Liquid
Bond O-Ring
Water resistant grease OBM
1342
Konishi
Cold resistant lithium grease LIT
Three
Bond
Sealing agent
Instantaneous adhesive
Adhesive
Screw locking agent
Apply to
●
Spark plug bore
High tension cord bore
●
Thread
●
Terminal
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 11
●
Shift lever
●
Sliding surface
Thread
●
Crankshaft spline
●
● at press fitting
Ball bearing
● at press fitting
Needle bearing inner
Thread
●
Bolt (gear case)
Lip
●
Oil seal (pump case lower)
● Outer surface, at press fitting
Impeller sliding surface
●
Pump case liner
Gear case
●
Cam rod bushing
O ring (cam rod bushing)
●
Bolt (cam rod bushing)
●
Bolt (cam rod bushing)
●
Thread
Thread
● at press fitting
Ball bearing
Lower unit
● at press fitting
Needle bearing
Propeller
shaft
housing
Propeller shaft housing
●
inlow
Bolt (propeller shaft housing)
●
Thread
●
O ring
Lip
●
Oil seal
● Outer surface, at press fitting
Spline
●
Propeller shaft
● at press fitting
Ball bearing
Bracket
Tiller
handle
Cowl
Stern bracket plate
●
Washer, 8.5-28-1.0
Clamp screw
●
Thread
Swivel bracket (bracket bolt)
●
Sliding surface
Swivel bracket (tilt stopper mount)
●
Sliding surface
Steering bush
●
all area
Thrust plate
●
all area
Tiller handle
●
Grip sliding face
Throttle burden
●
Inner
Bushing (tiller handle)
●
Inner
Throttle shaft
●
Sliding face (except slide adjusting section)
Throttle wire
●
Wire
Choke rod grommet
●
Inner
Bush (hook lever)
●
Inner and outer surfaces
Seal ring (hook lever)
●
Lip
Nipples
Amount of engine oil
Gear oil
11
●
Starter seal rubber
4st 4/5/6 2011
Tohatsu genuine gear oil
4 stroke engine oil
Centax FM- Bentax LM- KSL2
2
531
902 64
Drive shaft (spline)
Drive
shaft
Remarks
Shin-Etsu
Chemical
Chuoh Yuka
O ring (shift lever)
Drive shaft
Taper plug 1/8
housing
Silicone grease SOC
2000
Teflon grease TEF
1741
Rubber grease RUB
Shift
G103
Three Liquid
Bond O-Ring
Water resistant grease OBM
1342 G17
Cold resistant lithium grease LIT
Konishi
Sealing agent
Three
Bond
Instantaneous adhesive
Adhesive
Screw locking agent
Apply to
●
Press fit section
●
450ml when replaced
● Oil capacity 195ml
11-11
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 12
2. Parts Layout
P/L Fig. 1
Cylinder & Oil Pan
1 2 D
G103
G103
B
1342
342 T
1342
B
1342
342 T
B
1342
342 T
1342
4st OIL
G103
4st
SOC
D
G103
BO
N
P.
IL
-C
O
M
GM
SOC
BO
N
O
IL
O
Liq
uid
1342
O-
LOR
Rin
g
LOR
O
IL
4st
4st OIL
G
RE
A
SE
LIT
4st
O
IL
1 2 LIT
4st OIL
G
RE
A
SE
TEF
IL
4st
O
TEF
4st OIL
SOC
O
IL
-C
O
M
IL
4st OIL
G103
BO
N
D
G103
uid
11-12
RE
AS
E
LIT
G
RE
AS
E
TEF
TEF
Liq
O-
LOR
G
LIT
O
4st
1342
B
1342 T
P.
GM
SOC
Rin
g
Liquid
O-Ring
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 13
Ref.
No.
Description
Q'ty
Remarks
1
Cylinder Block
1
2
Oil Seal 20-35-7
1
3
Ball Bearing 6205
1
4
Breather Chamber Cover
1
5
Gasket Breather Chamber Cover
1
6
Collar Breather
2
7
Wave Washer d=5
2
8
Screw
2
M6 L=16mm
9
Bolt
1
M6 L=12mm
10
Oilpan Sub-Ass'y
1
11
Oil Seal 25-40-8
1
12
Grommet Oilpan
1
13
Dowel Pin 6-12
2
14
Oil Pump Rotor (Inner)
1
15
Oil Pump Rotor (Outer)
1
16
Pin Oil Pump
1
17
O-Ring Oil Pump Cover ø3.1
1
18
Oil Pump Cover
1
19
Bolt 6-16
3
20
Plunger Control
1
21
Spring Pressure
1
22
Seat Spring
1
23
O-Ring 1.9-6.8
1
24
Plunger Cover
1
25
Drain Bolt
1
26
Washer 10.2-19-1
1
27
Strainer Body
1
28
Strainer Cap
1
29
Mesh Strainer
1
30
Pipe Strainer
1
31
Seal Rubber Strainer
2
32
Strainer Stopper
1
33
Screw
1
M5 L=12mm
M5
Do not reuse.
M6 L=16mm
Do not reuse.
34
Bolt 5-16 (Precoated)
2
35
Washer
2
Do not reuse.
36
Oilpan Gasket
1
Do not reuse.
37
Exhaust Cover Gasket
1
38
Exhaust Cover (Inner)
1
39
Bolt 6-20
3
M6 L=20mm
40
Bolt
3
M6 L=40mm
41
Bolt
6
M8 L=40mm
42
Oil Pressure Switch
1
43
Grommet Oil Pressure Switch
1
44
Oil Pressure Switch Lead Wire L=390
1
45
Crankcase Head
1
46
Oil Seal 10.1-25-7
2
47
Spacer 19-24.8-1.0
1
48
Crankcase Head Gasket
1
Do not reuse.
49
Bolt
2
M6 L=20mm
50
Breather Hose
1
51
Clip ø12
2
52
Oil Level Gauge
1
53
O-Ring 2.62-18.72
1
Do not reuse.
54
Bolt Washer
1
M6 L=12mm
55
Clamp 6.5-47.5P
1
56
Clamp Holder
1
57
Clamp
1
4st 4/5/6 2011
11
11-13
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 14
2. Parts Layout
Cylinder Head & Valve & Cam Shaft
P/L Fig. 3
4st
4st OIL
O
IL
1 2 IL
O
4st
4st OIL
4st
O
IL
4st OIL
O
IL
O
M
P.
SOC
-C
GM
SOC
1 2 Liq
uid
Rin
g
LOR
4st OIL
IL
4st
O
O-
LOR
4st
4st OIL
4st OIL
IL
O
O
IL
4st
SOC
O
IL
-C
O
M
GM
SOC
P.
Liq
uid
O-
LOR
11-14
Rin
g
Liquid
O-Ring
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 15
Ref.
No.
Description
Q'ty
Remarks
1
Cylinder Head Ass'y
1
2
Intake Valve
1
3
Exhaust Valve
1
4
Bolt
1
5
Valve Spring Seat
2
6
Valve Spring L=35
2
7
Retainer
2
8
Cotter
4
9
Dowel Pin 6-12
2
10
Cylinder Head Gasket
1
11
Cylinder Head Bolt 8-90
2
12
Cylinder Head Bolt 8-60
2
13
Exhaust Cover Gasket
1
14
Cylinder Head Cover
1
15
Cylinder Head Cover Gasket
1
Do not reuse.
16
Bolt
4
M6 L=16mm
17
Washer 6-16-1.5
4
18
Thermostat
1
19
Thermostat Cap
1
20
Thermostat Cap Gasket
1
21
Camshaft Ass'y
1
22
Lifter
2
23
Push Rod
2
24
Plate Push Rod
1
25
Pivot Bolt
2
26
Rocker Arm
2
27
Pivot Rocker Arm
2
28
Adjusting Nut
2
29
Throttle Drum
1
30
Throttle Opener
1
31
Collar Drum
1
32
Washer 6-16-1.5
1
33
Bolt
2
34
Throttle Rod
1
35
Spark Plug (DCPR6E)
1
M6 L=35mm
Do not reuse.
Do not reuse.
Mark 5B or 52B
Do not reuse.
Mark 6
M6 L=45mm
11
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11-15
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 16
2. Parts Layout
P/L Fig. 4
Carburetor & Fuel Pump
3
20
43
35
25
20
17
7
18
Fig.1-50
23
21
1
Fig.1-51
2
19
22
43
5
24
9
6
37
11
15
36
Fig.10-20
4
10
8
13
16
Fig.10-2
44
40
12
39
14
44
38
44
41
34
44
31
IL
27
4st
29
O
28
45
42
4st OIL
30
32
A
Fig.13-6
Fig.13-7
26
33
Fig.13-14
11-16
O
IL
4st OIL
4st
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 17
Ref.
No.
1
2
3
4-1
4-2
4-3
5-1
5-2
5-3
6-1
6-2
6-3
7
8
9
10
11
12
13
14
15
16
17
18
19-1
19-2
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Description
Intake Manifold Ass'y
Intake Manifold Gasket
Bolt
Carburetor Ass'y
Carburetor Ass'y
Carburetor Ass'y
Main Nozzle
Main Nozzle
Main Nozzle
Main Jet (#68)
Main Jet (#62)
Main Jet (#70)
Slow Jet (#38)
Float
Float Valve
Clip
Float Arm Pin
Float Chamber
Float Chamber O-Ring
Screw
Drain Screw
O-Ring Drain Screw
Stop Screw
Spring Stop Screw
Pilot Screw
Pilot Screw
Carburetor Gasket
Insulator
Intake Silencer
Collar 6.2-9-7.4
Bolt 6-85
Washer
Fuel Pump Ass'y
Check Valve (P)
Check Valve (R)
Pump Body Gasket
Pump Diaphragm
Screw
Screw
O-Ring 2.62-18.72
Screw
Choke Wire
Cable Holder
Screw
Fuel Filter Ass'y
LowPermeationHose
Fuel Hose
LowPermeationHose
Fuel Hose
Hose
Clip
Mount Rubber 9-16-4.3
Q'ty
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
2
2
2
1
1
1
1
1
2
4
1
2
1
1
1
1
1
1
1
1
2
4
1
Remarks
Do not reuse.
M6 L=25mm
4ps
5ps
6ps
5ps
4ps
6ps
5ps
4ps
6ps
4/5/6ps
Do not reuse.
M4 L=12mm
Do not reuse.
4ps
5/6ps
Do not reuse.
M6 L=85mm
M6
Mark “D”
Black
White
M3 L=8mm
M4 L=18mm
Do not reuse.
M6 L=30mm
M5 L=10mm
USA
STD
USA
STD
L=270mm
11
4st 4/5/6 2011
11-17
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 18
2. Parts Layout
Recoil Starter
P/L Fig. 5
RE
AS
E
LIT
B
1741 T
1741
G
LIT
G
RE
AS
E
LIT
G
LIT
B
1342 T
1342
RE
AS
E
LIT
G
LIT
RE
AS
LIT
E
LIT
1342
B
1342 T
H
1741
D
1741 A
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
Recoil Starter Ass'y
Starter Case
Starter Spring Set
Starter Spring
Reel
Return Spring
Ratchet
Friction Spring
Bolt Starter Shaft
Friction Plate
Starter Rope ø4.5-1620
Starter Handle
Rope Anchor
Sealing Plate Starter
Starter Seal
11-18
Q'ty
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
Remarks
Ref.
No.
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Description
Starter Lock
Collar 4-6-21
Starter Lock Spring
Starter Lock Cam
Washer
Screw
Rod Snap
Collar 6.1-8-6.5
Starter Lock Cam Spring
Screw
Pre Coated Bolt
Clamp 6.5-47.5P
Caution Decal (B)
Starter Lock Rod
Rod Snap 3.5-2
Q'ty
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
Remarks
M6
M6 L=16mm
M4 L=30mm
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MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 3:14 PM ページ 19
Top Cowl
P/L Fig. 11
Ref.
No.
Description
Q'ty
1
2
3
4
5
6
7
8-1
Top Cowl Ass'y
Top Cowl Ass'y
Tilt Handle
Tapping Screw
Washer
Top Cowl Seal
Sail Pro Decal (F6)
Decal Set F4C
1
1
1
4
4
1
1
1
4st 4/5/6 2011
Remarks
Dual Fuel Tank / Integral
Separate Fuel Tank
Ref.
No.
Description
8-2 Decal Set F5C
8-3 Decal Set F6C
9 Caution Decal (A)
Remarks
Q'ty
1
1
1
5ps
6ps
11
M6
4ps
11-19
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 20
2. Parts Layout
Magneto
P/L Fig. 6
O
IL
-C
O
GM
SOC
M
P.
SOC
BO
N
G17
D
G17
G17
BO
N
D
G17
SOC
O
IL
-C
O
M
GM
SOC
11-20
P.
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 21
Ref.
No.
Description
Q'ty
Remarks
1-1
Flywheel MF54 (Mark48)
1
STD with out Alternator
1-2
Flywheel MF54 (Mark50)
1
for Sail Pro (with Alternater)
2
Alternator Ass'y
1
for Sail Pro 12V60W (with Alternater)
3
Screw
4
for Sail Pro (with Alternater) M5 L=25mm
4
Washer
4
for Sail Pro (with Alternater) M5
5
Clamp 4.2-3-8
1
for Sail Pro (with Alternater)
6
Screw
1
for Sail Pro (with Alternater) M4 L=8mm
7
Washer
1
M12
8
Nut 12-P1.25
1
9
Igniter W/Resistance Cap
1
10
Plug Cap W/Resistance
1
11
Bolt
2
12-1
Clamp 6.5-67P
2
12-2
Clamp 6.5-47.5P
1
M6 L=30mm
13
Screw
1
M6 L=12mm
14
Rectifier Complete
1
for Sail Pro or OPT
15
Fuse (10A)
1
16
Battery Cable L=494
1
with Alternator Sail Pro Only
with Alternator Sail Pro Only
17
Cable Terminal Plug
1
18
Grommet 17-3
1
19
Pilot Lamp Ass'y
1
20
Stop Switch Ass'y
1
21
Stop Switch Lanyard Ass'y (W/Curl)
1
22
Clamp 6.5-14
1
23
Bolt W/Washer
1
M6 L=12mm
24
Clamp 6.5-14
1
Sail Pro
25
Bolt W/Washer
1
Sail Pro M6 L=12mm
26
Protector Wire Harness
1
27
Electric Bracket Ass'y
1
Sail Pro
28
Clamp 6.5-14
1
Sail Pro
29
Bolt
4
Sail Pro M6 L=14mm
30
Band Lead Wire 135
1
Sail Pro
11
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11-21
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 22
2. Parts Layout
P/L Fig. 7
Drive Shaft Housing & Shift
G
RE
AS
E
OBM
OBM
B
1342
342 T
1342
G
RE
AS
OBM
E
OBM
1342
B
1342 T
11-22
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Ref.
No.
Description
Q'ty
Remarks
1-1
Drive Shaft Housing Ass'y (S)
1
for Transom “S”
1-2
Drive Shaft Housing Ass'y (L)
1
for Transom “L” Use 369-60003-0
1-3
Drive Shaft Housing Ass'y (L)
1
for Transom “UL” Use 3AB-60003-0
Bushing Shift Lever
1
2
3-1
Drive Shaft Bushing Ass'y
1
for Transom “L”
3-2
Drive Shaft Bushing Ass'y
1
for Transom “UL”
4-1
Drive Shaft Bushing (Slate Color)
1
for Transom “L”
4-2
Drive Shaft Bushing (Dark Brown)
1
for Transom “UL”
5
Stopper Drive Shaft
1
6
Screw Pre coated 5-25
2
for Transom “L/UL”
7
Washer
2
M5
8
Screw
2
for Transom “S” M5 L=10m
9
Grommet Cam Rod
1
10
Dowel Pin 6-12
2
11
Bolt
1
M8 L=8mm
12
Gasket 8.1-15-1
1
Do not reuse.
13
Grommet 29.3
1
14
Bolt
6
M6 L=30mm
15
Drive Shaft Housing Gasket
1
Do not reuse.
16
Extension Housing
1
for Transom “UL”
17
Bolt
1
for Transom “UL” M6 L=25mm
18
Washer
1
for Transom “UL” M6
19
Stud Bolt
1
for Transom “UL” M8 L=25mm
20
Washer
1
for Transom “UL” M8
Nut
1
for Transom “UL” M8
22-1
21
Shift Rod (S)
1
for Transom “S”
22-2
Shift Rod (L)
1
for Transom “L”
23
Shift Rod Lever
1
24
Pin Shift Lever
1
25
Split Pin
1
26
Shift Rod Joint Ass'y
1
27
Washer
1
28
Bolt 5-16
1
M6 L=16mm
29
Bolt
1
M4 L=16mm
30
Shift Lever Shaft Ass'y
1
31
O-Ring 1.9-8.8
2
32
Ceramic Ball 7.7
1
33
Spring Shift Lever Stopper
1
34
Shift Lever Rod
1
35
Pin Shift Rod Lever
1
36
Snap Pin
1
M6
Do not reuse.
11
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11-23
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 24
2. Parts Layout
Bracket & Reverse Lock
P/L Fig. 9
!
G
RE
A
SE
OBM
RUB
!
!
RUB
G
RE
AS
"
%
'
E
'
& !
OBM
OBM
&
!$
$
"
G
RE
#
AS
E
OBM
OBM
"
$
&
#
'
%
!!
G
RE
A
SE
OBM
RUB
RUB
!!
%
"
G
!#
RE
A
!"
SE
OBM
OBM
!
!'
" #
$
!
!%
!&
G
RE
AS
E
OBM
OBM
G
RE
AS
E
RUB
RVB
11-24
4st 4/5/6 2011
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 25
Ref.
No.
Description
Q'ty
1
Swivel Bracket A
1
2
Swivel Bracket B
1
3
Clamp Bracket (R)
1
4
Clamp Screw Kit
2
5
Clamp Screw
1
6
Clamp Screw Handle
1
7
Rivet 3-22
1
8
Clamp Screw Pad
1
Remarks
Stern Bracket Right Starboard Side
9
Shoulder Bolt
1
10
Clamp Bracket (L)
1
11
Bolt 8-122
1
12
Nylon Nut 8P1.25
1
M8
13
Washer
1
M8
14
Washer 8.5-28-1
2
15
Distance Plate Bracket
1
16
Screw
2
17
Stern Bracket Spring
1
18
Screw
1
19
Washer 4.3-16-1.5
1
20
Thrust Rod
1
21
Thrust Rod Spring
1
22
Bolt
4
23
Thrust Bushing
1
24
Bushing Upper Steering
1
25
Bushing Lower Steering
1
26
Friction Band Ass'y
1
27
Thrust Plate (Lower)
2
28
Spring Co-pilot
1
29
Wing Nut M6
1
30
Washer 6-16-1.5
1
31
Tilt Stopper Ass'y
1
32
Tilt Stopper Grip
1
33
Bushing Tilt Stopper
2
34
Setting Plate Tilt Stopper
1
35
Bolt
2
36
Grease Fitting
2
37
Reverse Lock Arm
1
38
Bolt
2
39
Reverse Lock Spring (R)
1
40
Reverse Lock Spring (L)
1
Stern Bracket Left Port Side
M6 L=12mm
M4 L=6mm
M6 L=40mm
M6 L=12mm
M6 L=14mm
11
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11-25
MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 26
2. Parts Layout
P/L Fig. 10
Bottom Cowl & Tiller Handle
G
RE
A
SE
OBM
OBM
55
Fig.3-29
56
59
55
37
Fig.3-19
57
5
29
58
35
36
1
4
3
7
60
RE
AS
E
OBM
31
9
28
G
OBM
33
34
17
21
20
6
G
RE
A
22 30
2
13
8
57
12
10
SE
19
OBM
OBM
53
18
32
54
G
RE
A
16
15
25
27
23
SE
27
OBM
RUB
RUB
26
40
24
11
39
43
14
48
51
44
41
52
38
G
RE
AS
E
OBM
OBM
49 50
47
42
46
45
G
RE
AS
E
OBM
OBM
G
RE
AS
E
RUB
RVB
11-26
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MFS4-5-6̲E̲ch11̲110425.qxd 11.4.25 11:21 AM ページ 27
Ref.
No.
Description
Q'ty
1
Bottom Cowl
1
2
Grommet ø5.5-ø9.5-44
1
3
Cowl Latch Ass'y
1
4
Bolt
1
5
Grommet ø10.5-ø15.5-ø20.5-32
1
6
Grommet 18-2.5
1
7
Grommet 25-5
1
8
Grommet 17-2.7
1
1
Remarks
M6 L=16mm
Dual Fuel Tank
9
Plastic Rivet 6.5
10
Fuel Connector (Engine Male)
1
11
Protector Fuel Connector
1
12
Bolt
1
13
Washer
1
M6
14
Fuel Hose W/Protector
1
USA/Separate Fuel Tank
15
Fuel Hose
1
STD/Separate Fuel Tank
16
Clip
2
Separate Fuel Tank
17
Fuel Cock Ass'y
1
Dual Fuel Tank
18
Screw
2
Dual Fuel Tank
19
Grommet
1
Separate Fuel Tank
20
Choke Rod
1
21
Choke Rod Bushing
1
22
Grommet 21-38.5
1
23
Shift Lever
1
24
Collar 15.9-17.9
1
25
Washer 30-45-1
1
26
Bolt
1
27
Washer 6.5-23-1.5
2
28
Cable Terminal Plug
1
29
Storage Decal
1
30
Oil Pressure Decal
1
31
Spark Plug Decal
1
32
Fuel Lever Decal
1
33
Bolt
2
34
Washer 6.5-23-1.5
2
35
Bolt
1
Separate Fuel Tank STD M6 L=12mm
36
Washer 6.5-23-1.5
1
Separate Fuel Tank STD
37
Bolt
4
M6 L=16mm
38
Tiller Handle Ass'y
1
39
Tiller Handle
1
40
Plastic Rivet 6.5
1
41
Grip
1
42
Throttle Shaft
1
43
Throttle Shaft Damper
1
44
Bushing 14-15.8-7
1
45
Screw
1
M5 L=18mm
46
Screw
1
M6 L=12mm
47
Throttle Shaft Supporter
1
48
Friction Piece
1
49
Adjusting Nut
1
50
Tiler Handle Spring
1
51
Bolt
1
52
Throttle Decal
1
53
Spacer ø33.5-ø55
1
54
Washer 30-45-1
1
55
Throttle Wire
2
56
Protector
1
57
Bushing Steering
2
58
Cover
1
59
Bolt
2
60
Shift Decal
1
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M6 L=25mm
M6 L=12mm
M6 L=25mm
11
M6 L=16mm
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2. Parts Layout
P/L Fig. 13
Integral Fuel Tank
11-28
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Ref.
No.
Description
Q'ty
Remarks
1
Fuel Tank Ass'y
1
Dual Fuel Tank
2
Sealing Plate
1
Dual Fuel Tank
3
Fuel Tank Seal
1
Dual Fuel Tank
4
Fuel Hose
1
Dual Fuel Tank STD
5
Fuel Hose W/Protector
1
Dual Fuel Tank/For USA
6
Fuel Hose
1
Dual Fuel Tank STD
7
Fuel Hose W/Protector
1
Dual Fuel Tank/For USA
8
Fuel Hose
1
Dual Fuel Tank STD
9
LowPermeationHose
1
Dual Fuel Tank/For USA
10
Fuel Hose
1
Dual Fuel Tank STD
11
Low Permeation Hose
1
Dual Fuel Tank/For USA
12
Fuel Hose
1
Dual Fuel Tank STD
13
Low Permeation Hose
1
Dual Fuel Tank/For USA
14
Clip
10
Dual Fuel Tank
15
Bolt
2
Dual Fuel Tank M6 L=30mm
16
Washer 6.5-23-1.5
2
Dual Fuel Tank
17
Spacer 7.2-10-6
2
Dual Fuel Tank
18
Fuel Tank Cap Ass'y
1
Dual Fuel Tank
19
Fuel Tank Cap Gasket
1
Dual Fuel Tank
20
Cap Hook
1
Dual Fuel Tank
21
Pipe Joint
1
Dual Fuel Tank
22
Non Retun Valve
1
Dual Fuel Tank
Do not reuse.
11
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3. Difference item
Chapter 1.
Predelivery Inspection
R
1) Gear Shift (P1-8)
1.
N
F
Check shift lever 1 and propeller shaft for smooth
movement of the shift between forward (F) and neutral (N)
1
while engine is operating.
2) Fuel Tank and Fuel Line (P1-9)
1.
Check that fuel tank contains sufficient amount of gasoline,
fuel line is connected and is free of leaks.
CAUTION
Since this is a 4 stroke engine model, do
not use fuel mixed with engine oil. Use of
fuel mixed with engine oil will cause engine
trouble.
Dual Tank Model
3) Inspection of Forward and Reverse Shifts
(P1-11)
3
a
Use shift lever 1 to shift the gear to forward (F), Neutral (N)
N
and Reverse (R).
1.
Forward
F
Return handle grip 2 to idle speed a, and then, move shift
lever 1 toward the operator (F) quickly.
2.
2
1
1 Shift Lever
Reverse
Return handle grip 2 to slow side a, and then, when the
3
engine reached the lowest speed, set shift lever 1 toward
the reverse side (R) quickly.
3.
N
R
Shallow water run
a
2
In shallow water, run at the lowest possible speed while
watching the depth and obstacles.
In reverse operation, run at low speed, and do not
increase the engine speed unnecessarily.
1
WARNING
Shifting at high engine speed may cause
fall of passenger due to abrupt acceleration
and damage to gear, clutch and other
components of the outboard motor. Shift at
the lowest engine speed.
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Chapter 3. Inspection Items
1) Fuel System (P3-4)
Check piping
Remove top cowl and check each section for fuel leak, dirt,
deterioration and damages. Clean or replace parts if
necessary.
2) Inspection of Fuel Tank (P3-5)
<For Dual Tank Model>
Remove dirt and water from fuel tank 1 if any.
1
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3. Difference item
Chapter 4. Inspection Items
1) Inspection of Fuel Feed System Piping
(P4-12)
1.
Remove top cowl and check each section for fuel leak, dirt,
deterioration and damages. Clean or replace parts if
necessary.
2) Draining Fuel (P4-12)
1
WARNING
Remove fuel tank, fuel hose and carburetor
after fully draining the fuel from these
parts.
1.
Remove fuel tank cap 1 and remove fuel.
3) Inspection of Fuel Tank and Fuel
Tank Cap (P4-13)
1.
Check fuel tank and fuel tank cap for crack, leakage and
damage.
Replace if necessary.
4) Inspection of Fuel Cock (P4-13)
1.
11-32
Check fuel cock for leakage.
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5) Removing Carburetor (P4-14)
1
WARNING
Before working on fuel system, make sure
to disconnect battery cables from the
battery, or electric sparks can occur,
possibly igniting fuel or causing fuel to
explode.
1.
Disconnect choke link wire.
Be careful not to bend wire tip 1 when
disconnecting.
2
2.
Disconnect breather hose 2 from intake silencer.
3.
Remove two air vent hoses 3 from carburetor.
3
4.
Remove fuel hose 4 from fuel pump.
Before disconnecting fuel hose, place a piece of
cloth below fuel pump to absorb leaking fuel.
4
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3. Difference item
5.
Loosen carburetor mounting bolts and remove carburetor 5.
Be careful not to bend throttle rod when removing
the rod and carburetor.
5
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Chapter 5. Inspection Items
1)Removing Power Unit (P5-16)
1.
Remove fuel from fuel tank before disconnecting fuel hose
from fuel cock 1 at fuel tank side.
1
2.
Remove fuel tank mounting bolts and then remove fuel tank
2.
3.
2
Disconnect choke wire 4 from carburetor 3.
4
3
4.
Remove choke wire fixing bracket 5 from stay 6.
Remove by catching hook on the back of stay by
using a pair of pliers.
5
5.
6
Remove fuel hose 7 from fuel pump.
7
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3. Difference item
6.
Disconnect rod snaps above and below starter lock rod, and
then remove start lock rod.
7.
Disconnect wires from igniter 8.
Disconnect ground wire from cylinder.
8
8.
In the same way as B model;
Disconnect throttle wire, Remove engine mounting bolts, and
then, dismount power unit.
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Chapter 8. Inspection Item
1) Inspection of Igniter (P8-6)
1.
LED teminal (small)
Measure igniter resistance. Replace if other than specified
value.
Remove the part and test it as a separate unit.
Stop switch terminal
(large)
GND (non painted)
Spark plug cap
# $ $ %&'(')*&'
!
!
!
"
!
" !
" "
"
!
"
! + ,!
$ . , + $ $ $/
・ ! 0 1#2#'' 3 0 ・ $ , + + $ . $ , + + + + $ ・ $ $ , + 4 . 5 + 6 . . $・
・
2.
Install igniter so that specified clearance is achieved, and
connect plug cap to spark plug.
Thickness Gauge 1 :
P/N. 353-72251-0
1
Igniter Clearance :
0.3 mm (0.012 in)
Igniter Bolts :
6 N · m (4 lb · ft) [0.6 kgf · m]
3.
Connect stop switch lead and warning lamp lead to igniter.
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3. Difference item
2) Inspection of Rectifier (P8-8)
1.
b
Check conduction of fuse (10 A) contained in the fuse box
1. Replace if non-conductive.
2.
a
Check conduction between rectifier terminals. Replace if
out of specification.
c
1
!"#"#!#
a
a
a
b
c
ON
a
b
c
ON
ON
ON
ON
ON
$ % & '()*(## + % ,&-
% . / , % , % . ,
% % % 0
・ /. 1 2 / 3 / / 0
・
・
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MEMO
11
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3. Difference item
Chapter 10 Wiring diagram
F 4C/5C/6C
OPTION
Y
LIGHT EXTENSION CORD
Y
ALTERNATOR
RECTIFIER
Y
Y
Y
Y
B ------- Black
Br ----- Brown
MAGNETO
R ------- Light Green
W ------ White
Lg ----- Light Green
FUSE
MAGNETO
R
IGNITER
FLAT
TERMINAL
(Large)
B
R
FLAT
TERMINAL
(Small)
B
W
WARNING LIGHT
R
B
BATTERY
11-40
Lg
Lg
OIL
PRESSURE
SWITCH
W
STOP SWITCH
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OPTION
IGNITER
Br
STOP SWITCH
Br
B
STOP SWITCH
ASSEMBLY
B
B
Br
Br
REMOTE
CONTROL
BOX
11
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MEMO
11-42
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MEMO
11
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MEMO
11-44
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MEMO
11
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MEMO
11-46
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MEMO
11
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MEMO
11-48
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MFS4-5-6̲E̲cover̲110420.qxd 11.4.21 9:15 AM ページ 2
MFS4-5-6̲E̲cover̲110420.qxd 11.4.21 9:15 AM ページ 1
4/5/6B,C
MFS
4/5/6B,C
Models
MFS
4/5/6B,C
Models
OB No.003-21034-2
11-04 NB
Printed in Japan
OB No.003-21034-2
11-04 NB

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