Keep gasoline off painted surfaces. Whenever a rotating part butts against a stationary part, look for a shim or washer. Use new gaskets if there is any doubt about the condition of the old ones. Unless otherwise specified, a thin coat of oil on gaskets may help them seal effectively. Heavy grease can be used to hold small parts in place if they tend to fall out during assembly.
However, keep grease and oil away from electrical components. High spots may be sanded off a piston with sandpaper, but fine emery cloth and oil will do a much more professional job. Carbon can be removed from the cylinder head, the piston crown and the exhaust port with a dull screwdriver. Do not scratch either surface. Wipe off the surface with a clean cloth when finished. The carburetor is best cleaned by disassembling it and soaking the parts in a commercial carburetor cleaner.
Never soak gaskets and rubber parts in these cleaners. Never use wire to clean out jets and air passages; they are easily damaged. Use compressed air to blow out the carburetor after the float has been removed. Take your time and do the job right. Do not forget that the break-in procedure on a newly rebuilt engine is the same as that of a new one. Use the break-in oil recommendations and follow other instructions given in your owner's manual..
Assembly Precautions No parts, except those assembled with a press fit, require unusual force during assembly. If a part is hard to remove or install, find out why before proceeding. When assembling two parts, start all fasteners, then tighten evenly in an alternating or crossing pattern if no specific tightening sequence is given. When assembling parts, be sure all shims and washers are installed exactly as they came out.
The following items are general suggestions that may improve the overall life of the machine and help avoid costly failures. Unless otherwise specified, use a locking compound, such as Loctite Threadlocker, on all bolts and nuts, even if they are secured with lockwashers. Be sure to use the specified grade. A screw or bolt lost from an engine coves or bearing retainer could easily cause serious and expensive damage before its loss is noticed.
When applying thread locking compound, use a small amount. If too much is used, it can work its way down the threads and stick parts together that were not meant to be stuck together.
Keep a tube of thread locking compound in your tool box; when used properly, it is cheap insurance. Use a hammer-driven impact tool to remove and install screws and bolts. These tools help prevent the rounding off of bolt heads and screw slots and ensure a tight installation. When straightening the fold-over type Iockwasher, use a wide-blade chisel, such as an old and dull wood chisel. Such a tool provides a better purchase on the folded tab, making straightening easier.
When installing the fold-over type lockwashel; always use a new washer if possible. If a new washer is not available, always fold over a part of the washer that has not been previously folded. Reusing the same fold may cause the washer to break, resulting in the loss of its Iocking ability and a loose piece of metal admft in the engine.
When folding the washer, start the fold with a screwdriver and finish it with a pair of pliers. If a punch is used to make the fold, the fold may be too sharp, thereby increasing the chances of the washer breaking under stress.
These washers are relatively inexpensive and it is suggested that you keep several of each size in your tool box for repairs. When replacing missing or broken fasteners bolts, nuts and screws , always use authorized replacement parts. They are specially hardened for each application. The wrong cent bolt could easily cause serious and expensive damage. When installing gaskets, always use authorized replacement gaskets without sealer, unless.
Many gaskets are designed to swell when they come in contact with oil. Gasket sealer will prevent the gaskets from swelling as jntended and can result- in oil leaks. Authorized replacement gaskets are cut from material of the precise thickness needed.
Installation of a too thick or too thin gasket in a critical area could cause equipment damage. Apply it liberally and allow it penetrate for minutes. Tap the fastener several times with a small hammer; do not hit it hard enough to cause damage. Reapply the penetrating oil if necessary. For frozen screws, apply penetrating oil as described, then insert a screwdriver in the slot and tap the top of the screwdriver with a hammer. This loosens the rust so the screw can be removed in the nomal way.
If the screw head is too chewed up to use a screwdriver, grip the head with locking pliers and twist the screw out. Avoid applying heat unless specifically instructed because it may melt, warp or remove the temper from parts.
Remedying Stripped Threads Occasionally, threads are stripped through carelessness or impact damage. Often the threads can be cleaned up by running a tap for internal threads on nuts or die for external threads on bolts through threads.
Removing Broken Screws or Bolts When the head breaks off a screw or bolt, several methods are available for removing the remaining portion. If a large portion of the remainder projects out, try gripping it with vise-grip pliers. If the projecting portion is too small, file it to fit a wrench. See Figurc If the head breaks off flush.
Drill a small hole in the screw and tap the extractor into the hole. Back the screw out with a wrench on the extractor. There are three basic requirements for all internal combustion engines to run: proper ignition, unrestricted fuel supply, and adequate compression. When troubleshooting a problem, keep it simple. Define the symptom as closely as possible to one of the three functions, and then isolate the problem.
Expensive equipment or complicated test gear is not necessary to detennine whether repairs can be attempted at home. A few simple tests could prevent a large repair bill and lost time while the vehicle sits in a service department.
However, do not attempt repairs beyond your abilities. Service departments tend to charge heavily for putting together a disassembled engine that may have been abused. This chapter covers test equipment, troubleshooting preparation and systems or component testing. Tables are located at the end of this chapter.
NOTE This manztalprovidespr-ocedures and specifications for standard products. The use of aftermarket equipment or modzfication of the engine can affect erzgine performatzce and tuning requirements. For information on aftermarket equipment, consult a dealerslzip ilzat handles such eqztipment or is fat7ziliar with encontact the gine modification.
Modern outboards use advanced electronic engine control systems that help optimize the performance, reliability, and fuel economy. A multimeter is necessary to accurately test these control systems.
A multimeter combines the functions of a voltmeter, ohmmeter, and ammeter into one unit. Perform all tests using either an analog or digital multimeter. Refer to this section any time a question arises on using a multimeter.
A digital multimeter displays the readings on an LCD screen on the front of the meter. An analog multimeter. This is a voltage drop test.
If rhe circuit has resisttince, there will be iio voltage drop the meter wiii read zero. Generally, voltage drop readings of one or more volts are considered unsatisfactory. A voltage d. To perfonn a voltage drop test, connect the positive meter lead to the voltage source where electricity is coming from and the negative meter lead to the load where electricity is going.
Resistance Resistance is the oppesition to the flow of current ahroi. Ohms are the unit ofmeasure for resis. Use a. Illat is isolated disconi3ected. The ahmmeter will be damaged if connticted to a circuitwith voltage present. To measure resistaxce; tile olimmeter is typically connected in a series conizer:rior? Figure 2. Because an ohmInerer is self-powered. Use a continuity. Phis is primarily because resistance tests do not siinulate actual operating conditions.
For example, he porn-er soarce in most ohmnlciers is only volts. An analog ohlmeter m i s t be calibrated before each use and each time the scale is changed. Digital ohmmeters? To calibrate an analog meter, totioh the test leads together and kiru the adjust l a o b until rhc ncedle points exact:y at zero. See Figure 3. Because resistance generally increases with temperature, perfosm resistance tests with the circuit or component cold room temperature.
Aresistance test performed on a hot component will indicate increased resistance and may result in unnecessary parts replacement without solving the basic problem.
Always isolate the circuit or component from voltage prior to attaching an ohmmeter or tlze meter will be damaged. Amperage Current is the flow of electricity in a circuit and is measured in amperes amps. Amps are measured using an ammeter attached in a simple series connection. To connect an ammeter, the circuit usually must be disconnected and ammeter spliced into the circuit. Always connect the positive ammeter lead to the source where electricity is coming from and the negative lead to the load where electricity is going.
Checking Diodes An ohmmeter is often used to check diodes within various engine components. Some meters have a diode test option. Diodes function like electrical check valves. First check for continuity by measuring between two leads or terminals. Then reverse the meter test leads and check for continuity again. No continuity when connected one way and continuity when the leads are reversed generally indicates a good diode.
Do not be concerned about test lead polarity, as variations exist from one meter to the next. It is essential that the model be identified correctly before servicing the engine. For most models, identification tags may be found on the clamp bracket. The information provided on the tag is required when purchasing replacement parts for the outboard. Most engine problems may be resolved by completing a basic inspection. Check the following tips and refer to Tables at the end of this chapter for starting, fuel and ignition troubleshooting.
Additional troubleshooting tips are provided in this chapter for the specific system or component. Inspect the engine for loose, corroded, broken, cracked, or disconnected wires. Make sure the engine has fresh fuel. Ensure the battery is fully charged and cable connections are tight and corrosion-free.
Check for ignition spark at each cylinder. Check the spark plug condition and make sure the spark gap setting is correct. Check the location of the lanyard switch; make sure it is in the run position. Verify that the boat hull is free of any obstructions. If the engine cranks but does not start, verify that the ignition system is operating.
Use a spark gap tester to make sure ignition spark is present at cranking speed. Use Stevens SC, S or equivalent. Check the fuel system if the ignition system is operating properly.
Spark test 1. Connect an alligator clip test lead A, Figure 5 to an engine ground. Remove the spark plug s B, Figure 5. Attach the spark plug leads to the spark gap tester C, Figure 5. Crank the engine while observing the spark tester Figure 6. A strong blue spark that jumps a 9 mm 0. Repeat Steps for all cylinders. Reinstall the spark plug s and connect the leads after the test is complete.
Refer to Table 2 for ignition system testing if spark is weak or absent on any cylinder. Refer to Table 4 for fuel system troubleshooting if the ignition system is working properly, but the engine will not start.
Fuel System Inspection Fuel-related problems are common on outboard engines. Fuel available today has a relatively short shelf life. Gasoline tends to lose some of its potency and becomes sour if it is stored for long periods. A sticky or gummy deposit may form in the carburetor and passages as the fuel evaporates. This deposit may also clog fuel line and fuel filters. Fuel stored in a tank may become contaminated by water from condensation or other sources.
The water will cause the engine to run erratically or not run at all. If the engine has been stored for a period of time and is hard to start, check the condition of the fuel. Carefully drain the fuel from the carburetor float bowl into a suitable container. Drawings that indicate specific locations of the float bowl drain plugs Figure 7 appear in Chapter Six.
Contaminated fuel has a unique odor; this is a sure sign of a problem. Debris, cloudiness or water in the fuel is a sure sign of a problem. If any of these signs are found, dispose of the old fuel in an environmentally safe manner. Contact a local marine dealership or automotive repair center for information on proper disposal of fuel. Clean the entire fuel system if contaminants are found in the. If any of these are lacking, the engine will not run properly or will not run at all. If no tile1 can 're be drained from the flcat bowl.
To check for a fuel pump pro5Iein. CAurmLv ,hTever rift? This typically is caused by a lea11 condition. Blocked jets, passzges. Operating the engine under a Iea. F;,mptoms of inadeqate lean or excess rich conditions include hesitation cr stalling during acceleration, rough idle, poor perfamance at high speed or surging. If the engine hesitates or stalls during acceleration, activate the choke to enrich the h e 1 mixbre while accelerating the engine.
The engine is operating under a lean fuel condition if the symptoms improve wi. Eh the enriched 5 x 1 mixture. If the syinptoms get worse, the fuel mixture is too rich.
In either case, clean and inspect the carburetor s as described in Chapter Six. If the engine is operated at higher elevations, carburetor jet changes may be required. Operation in extreme c!
Replace the stop button and harness tiller model only if readings are incorrect. Test the key switch and lanyard switch remote control models if either test in Step 3 or Step 4 fails. Refer to Chapter Seven for key switch and lanyard switch testing.
Repair or replace the harness remote control models connecting the controls to the engine if the key switch and lanyard switch function properly. Perform Steps 3 and 4 to verify proper operation before running the engine.
Reconnect all leads and operate the engine to verify proper switch operation. Replace the CDI unit if all other components operate properly, but the engine has no ignition or cannot be stopped. Spark Plug Cap Aproblem with the spark plug cap can cause an ignition misfire.
Often very humid conditions contribute to the misfire. Replace the spark plug cap if external arcing is noted at the spark plug connection. Corrosion at the connections can cause high resistance and result in an ignition misfire. Visually inspect all spark plug caps.
Replace any cap that is corroded, cracked or has breaks in the insulating material. The spark plug caps covered in this manual all screw on and off the secondary lead. To remove the spark plug cap. Ignition Coil. Secondary resistance A problem with an ignition coil can cause or contribute to an intermittent or constant ignition misfire.
Perform a visual inspection on all ignition coils. Replace any coil that has corroded terminals or cracks on its body. A coil resistance test can be performed for all models. Coil removal and installation procedures are provided in Chapter Seven. Primary resistance 1. Disconnect the primary leads and the secondary lead from the ignition coil.
Connect the negative lead of the ohmmeter to the black lead Figure 11 of the ignition coil. Connect the positive lead of the ohmmeter to the blacldwhite lead Figure 11 of the ignition coil. Compare the reading with primary resistance specification at the end of Chapter Seven. Repeat the test for all ignition coils on the engine. Replace any coil that does not meet the indicated specification. Disconnect the primary leads and secondary lead from the ignition coil.
Connect the negative lead of the ohmmeter to the black lead Figure 12 of the ignition coil. Connect the positive lead of the ohmmeter to the secondary lead Figure 12 of the ignition coil.
Coinpare the reading with the secondary resistance specification in the tables at the end of Chapter Seven. Install the coil onto the power head and connect the leads to proper location. Pulser Coil The pulser coil is located under the flywheel. An electrical pulse is created as magnets attached to the flywheel pass near the coil.
This electrical pulse initiates the spark at the plug. If a pulser coil is faulty, the flywheel Figure 13 must be removed to access the coil. Flywheel removal. Connect the positive and negative ohmmeter leads Figure 13 to the correct color leads as indicated in the wiring diagrams at the end of this manual.
NOTE Pulser coil resistance test reszdts are not a f fected by polarity of the test leads. Compare the pdser coil resistance with the specification provided in Tables in Chapter Seven. Replace the pulser coil if the resistance is not w i t h specification.
Removal and installation of the pulser coil are provided in Chapter Seven. Attach the leads to the proper location s when testing is complete. Pulser coilpeak voltage output When performing this test, all leads must be connected into the main engine harness. Using a test harness or probing the wire connections Figure 14 allows voltage testing while sunning the engine.
This test will identify a faulty pulser coil or CDI unit during running conditions. As a safety precaution, remove the propeller before performing the test. Connect a peak-reading voltmeter to the pulser coil wires.
Refer to the appropriate table at the end of this chapter for the wire colors. Run the engine on a suitable testlflush device or in a test tank. Record the voltage output at the indicated engine speed. See Tables in Chapter Seven. NOTE voltage reading is excessively low, reverse the meter test leads and run the test again before determining the test results. A faulty pulser coil can cause an intermittent or constant ignition misfire. Follow the test procedures carefully to avoid misdiagnosis and unnecessary flywheel removal.
Refer to Tables in Chapter Seven for the pulser coil specifications. A peak-reading voltmeter is needed to test peak voltage on all models. Compare the output with the specification listed in Tables at the end of Chater Seven. Replace the CDI unit if the voltage reading is above the specification. Replace the pulser coil if the reading is below the specification. CDI unit and pulser coil replacement are provided in Chapter Seven.
Remove the test harness and attach all leads to the proper locations. Install a test propeller to run the engine in a test tank. Ignition Exciter Coil The ignition exciter coil powers the ignition syslen:. This cuxerxt is directed to the CDI unit n-here it is stored for use to create ignition. A faulty ignition exciter coil can cause a. The to flywheel does not have to be removed during testing siiicc the coil leads are accessible.
Adigital ineter is required for a peak voltage resistailce tests. Resistance speciiicatioils and peak voltage readings are provided in Chapter Seven. Perform both tests to ensure accurate lest results. Disconnect all ignition exciter coil le ds from the engine harness. Connect the ineter test leads to the exciter coil leads Figure 15 as indicated.
Chapter Sever;. Compare the resistame xvi'l-l-ithe specificatioil listed ig Tables ill Chapter Seven, Replace the ignition exciter coil if it is not within the specification.
Connect all Izads to the proper locetinn. Using a test haness or probiag "I. Connect a peak-reading boilmeter to the pulses col! Refer to the appropriate table at the elid of Chapter Seven for the wire co! Electrical pulses ge! On some models, tl-iis is accompiishrd by rotating the pulser coil in relationship to the triggering magnets in the flywheel. Automatic spark advance is provided with increased engine speed. The CDT unit on some models performs other important functions in addition to ignition control.
There is a third type of speed limitation used on the , and hp rnodels. A peak-reading 1,oltmeter Model M or equivalent is required to test peak voltage on all models. The use of a test harness or probing wire connections Figure 14 allows voltage testing while running the engine. If necessary, attach a test harness to the engine wiring harness at the CDX unit connector.
Connect a peak-reading voltmeter to the unit wires specified in the appropriate table in Chapter Seven. Record the voltage at the engine speed specified in Tables at the end of Chapter Seven.
Compare the output with the specification listed in Tables at the end of Chapter Seven. Replace the ignition coil if the voltage reading is above the specification. Measure the exciter coil output voltage and measure the lighting coil output if it falls below the specification.
CDI unit, pulses coil and lighting coil replacement are provided in Chapter Seven. Continued operation with the warning system activated can lead to serious and expensive engine damage. The systems vary by model and horsepower. The warning lamp is mounted on the front surface of the lower engine cowling. Turn the main key switch to the ON position.
Remove the electrical box cover. Disconnect the bullet connector from the oil level sensor Figure Connect the bullet connector main switch side to a clean engine ground and verify that the pilot lamp illuminates. Replace the lamp or wiring if the lamp fails to illuminate. Connect the bullet connector main switch side to an engine ground to make sure the warning horn sounds.
Replace the horn or wiring if the horn fails to sound. Oil Level Sensor Test An oil level sensor is used on all hp engines and is mounted inside the remote oil tank.
Each engine has an LCD display Figure 18 mounted in the boat dash which monitors the engine speed, trim angle, engine temperature and oil level.
Disconnect the oil level sensor leads from the electrical box and remove the sensor from oil tank. Reconnect the sensor leads. Place the remote control lever in the forward or reverse gear position. Turn the ignition switch to the ON position. Move the float on the oil level indicator into contact with the sensor switch.
When the float 5, Figure 18 contacts the sensor switch 6 , the upper oil level indicator 4 should illuminate. Warning Horn Test A warning horn is used on hp models.
On tiller handle models, the horn is mounted in the lower cowling of the engine. The remote control model has the warning horn mounted inside the control box. The horn sounds a constant tone to alert the operator of critical operating conditions such as a clogged or obstructed cooling water intake, overheating engine or low oil level.
Reinstall the oil level sensor by reversing the removal procedure. Apply RTV sealant to the sensor cap during installation. Manual start is offered on 2. Both systems are available on hp models. The hp models use only electric start. The common components of the electric starting system include the battery, start button or ignition switch, starter solenoid, starter motor, neutral switch and wires. The electric starter motor Figure 19 is similar in design to what is commonly used on automotive applications.
Its mounting position on the power head allows the starter drive gear Figure 19 to engage a flywheel-mounted ring gear when the starter is operated. Neutral switch 3, Starter solensid 4. Battery connection to solenoid 5. Cable connection to starter motor 6. The starter motor is capable of producing a tremendou. A fillly charged battery of sufficient capacity is necessary- to provide the torque required to crank the engine.
Battery maintenance and testillg procedures are provided in Chapter Four. Refer to Table 1 for starting system trou-. Starter Cranking Voltage Test This test measures the voltage available at the starter itor while craidsing.
Make sure the battery is fully charged and in good condition prior to performing this test. Connect a voltmeter between the starter motor tenniiial 5: Figure 20 and a good engine ground. Crank tl:e engine while observing the voltmeter. Repair or replace t? Test the starter solenoid and check all starting systein wires for loose or conodzd coilnections if the voltage is less than?.
Test the barrely again if all conilections are : 1 goo6. Check the swltc! Perform Steps! Rcrnoie the access coyer Figure 22 from the lower side of the control.
Calibrate ail ohrnnieter on the R x 1 scale. Connect the ohmmeter between the black and brown switch terminals. Wit11 the switch ir, the OFF position. Place the switch in the ON position. No continuity should now be noted. Connect the ohmmeter between the blue and red terminals Figure No continuity should be present with the switch in the OFF position. Connect the ohmmeter between the brown and red terminals Figure Replace the ignition switch if it fails to function as described.
Start Button Test Tiller Models On electric start tiller handle models, the start button Figure 28 mount to the front of the lower cowl. Disconnect the starter button from the engine wiring harness. Remove the threaded retainer from inside the motor cowl and remove the button. Connect the ohmmeter between the start button wires or terminals. With the button deactivated, the meter should indicate no continuity. With the button activated, the meter should indicate continuity.
Replace the start button if it does not function as described. Starter Solenoid Test The starter solenoid allows a large amount of current to pass from the battery to the starter motor. When the start switch or button is operated, current flows through the neutral switch and on to the solenoid. This current passes through a coil of wire in the solenoid. The magnetic force moves a plunger that closes contact points in the solenoid, allowing current to flow directly from the battery to the starter motor.
Remove the solenoid as described in Chapter Seven. The body of the Tohatsu engine is protected by several layers of special coatings, after which four layers of paint and a layer of special varnish are applied.
Tohatsu Corporation offers outboard engines ranging from 2. For our country, the fact that Tohatsu motors are undemanding to the quality of fuel and oils is important. On the boats with the engines of this Japanese company, many records were set.
One of them, no one in the world can beat for the past 10 years - in on a boat with a Tohatsu engine with a capacity of 2. The Atlantic Ocean was crossed. Unlike manufacturers of other brands, the company Tohatsu does not refuse the production of two-stroke engines, but on the contrary, improves and expands its model range.
Tohatsu two-stroke outboard motors have a reputation for powerful and reliable outboard motors with moderate weight and compactness. The sales hit is the updated Tohatsu 5BDS, which has two fuel tanks - built-in, 2.
A distinctive feature of the TLDI system is the dual throttle position sensor TPS , which provides an accurate balance of air and fuel. Outboard outboard motors with direct fuel injection TLDI series have fuel consumption of 4-stroke models and 2-stroke performance. The TLDI system makes it possible to run smooth and steady at low revs with much less vibration, and provides the engine with good acceleration. Tohatsu company has established itself as a manufacturer of highly reliable 2-stroke engines of low and medium power.
They are distinguished from competitors by their simplicity of construction, the use of reliable and proven technologies, and an excellent weight-to-power ratio. Wiring Diagram contains several in depth illustrations that show the connection of various things.
It contains guidelines and diagrams for various types of wiring methods and other items like lights, windows, and so on. Each one of such suggestions are illustrated with sensible examples. Wiring Diagram not merely offers in depth illustrations of everything you can perform, but additionally the procedures you should follow while performing so.
Not only are you able to find different diagrams, but you can also get step-by-step instructions for a particular undertaking or subject that you would prefer to know more about. In addition, Wiring Diagram gives you the time frame in which the assignments are to be accomplished.
You will be capable to know exactly when the projects needs to be accomplished, which makes it much simpler for you personally to properly control your time and efforts. Wiring diagram also offers beneficial suggestions for assignments which may require some additional gear. This guide even contains suggestions for additional provides that you might require as a way to finish your assignments.
0コメント