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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 ... ....................
... 1-4
6) Recommendations on Service .... 1-4
7) Cautions in Disassembling and
Assembling Components ...... 1-6
3.
Tools and Instruments ... ........
. 1-8
1) Test Propeller ... ................
.. 1-8
2) Measuring Instruments ... .........
. 1-8
3) Special Tools ... .................
.. 1-10
4.
Pre-delivery Inspection ...... 1-16
1) Tiller Handle ..................................
.. 1-16
2) Gear Shift .................................
... 1-16
3) Gear Oil ... ......................
. 1-16
4) Fuel and Fuel Line ........................
.. 1-18
5) Installation of Outboard Motor
(Rigging)... .....................
. 1-18
6) Propeller Selection ........................
.. 1-20
7) Cooling Water Check Port
.. 1-22
8) Trim Tab ... .......................
. 1-22
5. Break-In Operation.....................
.. 1-24
6.
Test Run ... ....................
.. 1-24
7.
Checks After Test Run...........
... 1-24
2.Service Data
1. Outboard Dimensions .....................
. 2-2
1) Body dimensions... .................
. 2-2
2) Clamp Dimensions ... ........
... 2-4
2.
Cooling Water System Diagram
... 2-6
3. Specifications ............................
.. 2-8
4. Maintenance Data ... .......
... 2-12
5. Torque Specifications... .......
. 2-16
6. Sealant And Lubricant ...........
... 2-17
3.Maintenance
1. Special Tool ............................
... 3-2
2. Inspection Schedule ... .......
.. 3-2
3. Inspection Items ... ...............
. 3-6
1) Inspection of Top Cowl ... .........
. 3-6
2) Inspection of Fuel Tank ... .........
. 3-6
3) Fuel System ... .................
... 3-8
4) Inspection of Cooling Water Passage . 3-10
5) Flushing with Water ... ........
.. 3-10
6) Inspection of Compression Pressure
. 3-14
7) Inspection of Spark Plugs
.. 3-18
8) Inspection of Thermostat ...... 3-20
9) Adjustment of Throttle Cable .... 3-22
10) Ignition Timing Adjustment ..... 3-24
11) Carburetor Synchronization..... 3-26
12) Pilot screw adjustment ... .........
. 3-30
13) Replacement of Gear Oil ...... 3-32
14) Inspection of Gear Case (for leakage) .. 3-34
15) Inspection of Propeller ... .........
. 3-34
16) Replacement of Anode... ..........
. 3-36
17) Greasing...........................
. 3-38
4.Fuel System
1. Special Tools ..................
... 4-2
2. Parts Layout ............................
... 4-4
Fuel line ... ..............................
.4-4
Intake Silencer • Carburetor ... ..........
. 4-6
3. Carburetor Inner Passages .... 4-10
1) Idling Passage ..................................
. 4-10
2) Off-Idle Passage ........................
... 4-12
3) High Speed Passage ........................
. 4-14
4) Choking Passage
(#2 and #3 carburetor) ... ..........
. 4-16
4. Inspection Items ....................
... 4-18
1) Removing Carburetors... ..........
. 4-18
2) Disassembling Carburetors
. 4-20
3) Cleaning and Inspection ...... 4-22
4) Inspection of Fuel Pump and
Needle Valve .....................................
. 4-24
5) Disassembly and Inspection of Fuel
Pump ... ...................
.. 4-34
6) Assembly of Fuel Pump ...... 4-26
7) Inspection of Fuel Connector .... 4-26
8) Inspection of Fuel Filter .............
... 4-26
9) Assembling Carburetors ...... 4-28
10) Inspection of Float Height
.. 4-30
11) Installing Carburetors .......................
. 4-30
5.Power Unit
1. Special tools ... ..............
... 5-2
2. Parts Layout ............................
... 5-4
Engine ... ...........................
. 5-4
Magneto ...............................................
... 5-6
Electric Parts ................................................
. 5-8
Recoil Starter... .......................
. 5-10
Intake Manifold · Reed Valve ...... 5-14
Throttle ...............................................
... 5-16
Cylinder Crank Case..........................
... 5-20
Piston & Crank Shaft .........................
... 5-24
3. Inspection Items ... ...............
. 5-26
1) Removing Power Unit ... ..........
. 5-26
2) Removing Flywheel ... .........
.. 5-32
3) Removing Electric Parts ...... 5-32
4) Removing Throttle Link ..............
... 5-34
5) Removing Intake Silencer and
Carburetors.....................................
.. 5-38
6) Removing Intake Manifold and
Reed valves ....................................
.. 5-40
7) Inspection of Reed Valve Ass'y ... 5-40
8) Removing Thermostat and
Engine Anode .....................................
. 5-42
9) Removing Cylinder Head / Head Cover .. 5-46
10) Inspection of Cylinder Head
. 5-48
11) Removing Exhaust Cover
.. 5-50
12) Inspection of Exhaust Cover
. 5-50
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