1992-2009 Nissan/Tohatsu Outboards 2-Stroke Service & Repair Manual

Qutboanls 1992-09 REPAIR MANUAL ALL 2-SnOKE & 4-SWOKE MODELS

CONTENTS GENERAL INFORMATION, SAFETY AND TOOLS HOW TO USE THIS MANUAL 1-2 BOATING SAFETY 1-4 BOATING EQUIPMENT (NOT REQUIRED BUT RECOMMENDED) 1-tfl SAFETY IN SERVICE M2 TROUBLESHOOTING M3 SHOP EQUIPMENT M7 TOOLS 1-19 FASTENERS, MEASUREMENT, AND CONVERSIONS 1-27 SPECIFICATIONS 1-28 MAINTENANCE AND TUNE-UP LUBRICATION ENGINE MAINTENANCE BOAT MAINTENANCE TUNE-UP TIMING & SYNCHRONIZATION VALVE CLEARANCE (4-STROKE MODELS) STORAGE (WHAT TO DO BEFORE AND AFTER) CLEARING A SUBMERGED MOTOR SPECIFICATIONS 2-5 2-9 2-36 2-39 2-49 2-72 2-77 2-81 2-82 FUEL & COMBUSTION BASICS 3-2 FUEL TANK & LINES 3-6 CARBURETED FUEL SYSTEM 3-11 ELECTRONIC FUEL INJECTION SYSTEMS (EFI/TLDI) 3-35 SPECIFICATIONS IGNITION & ELECTRICAL SYSTEMS UNDERSTANDING & TROUBLESHOOTING ELECTRICAL SYSTEMS IGNITION SYSTEMS (ELECTRONIC) CHARGING CIRCUIT STARTING CIRCUIT WARNING SYSTEM WIRING DIAGRAMS SPECIFICATIONS 4-2 4-8 4-30 4-40 4-49 4-55 LUBRICATION & COOLING AUTOMIX OILING SYSTEM (2-STROKE MOTORS) LUBRICATION SYSTEM (4-STROKE MOTORS) COOLING SYSTEM SPECIFICATIONS 5-2 5-11 5-16 5-34

CONTENTS POWERHEAD POWERHEAD - 2-STROKE POWERHEAD - 4-STROKE POWERHEAD RECONDITIONING POWERHEAD BREAK-IN SPECIFICATIONS 6-2 6-59 6-73 6-74 LOWER UNIT GEARCASE 7-2 MECHANICAL TILT (UNASSISTED OR GAS-ASSIST) POWER TILT/TRIM SYSTEMS 8-2 8-12 TRIM & TILT SYSTEMS REMOTE CONTROLS TILLER HANDLE CONTROL CABLES 9-2 9-2 9-12 REMOTE CONTROLS HAND REWIND STARTER 10-2 HAND REWIND STARTER MASTER INDEX 10-17 MASTER INDEX

SAFETY NOTICE Proper service and repair procedures are vital to the safe, reliable operation of all marine engines, as well as the personal safety of those performing repairs. This manual outlines procedures for servicing and repairing engines and drive systems using safe, effective methods. The procedures contain many NOTES, CAUTIONS and WARNINGS which should be followed, along with standard procedures, to minimize the possibility of personal injury or improper service which could damage the vehicle or compromise its safety. It is important to note that repair procedures and techniques, tools and parts for servicing these engines, as well as the skill and experience of the individual performing the work, vary widely. It is not possible to anticipate all of the conceivable ways or conditions under which the engine may be serviced, or to provide cautions as to all possible hazards that may result. Standard and accepted safety precautions and equipment should be used during cutting, grinding, chiseling, prying, or any other process that can cause material removal or projectiles. Some procedures require the use of tools specially designed for a specific task. Before substituting another tool or procedure, you must be completely satisfied that neither your personal safety, nor the performance of the vessel, will be endangered. All procedures covered in this manual requiring the use of special tools will be noted at the beginning of the procedure by means of an OEM symbol Additionally, any procedure requiring the use of an electronic tester or scan tool will be noted at the beginning of the procedure by means of a DVOM symbol Although information in this manual is based on industry sources and is complete as possible at the time of publication, the possibility exists that some manufacturers made later changes which could not be included here. While striving for total accuracy, Seloc Publishing cannot assume responsibility for any errors, changes or omissions that may occur in the compilation of this data. We must therefore warn you to follow instructions carefully, using common sense. If you are uncertain of a procedure, seek help by inquiring with someone in your area who is familiar with these motors before proceeding. PART NUMBERS Part numbers listed in this reference are not recommendations by Seloc Publishing for any particular product brand name, simply iterations of the manufacturer's suggestions. They are also references that can be used with interchange manuals and aftermarket supplier catalogs to locate each brand supplier's discrete part number. SPECIAL TOOLS Special tools are recommended by the manufacturers to perform a specific job. Use has been kept to a minimum, but, where absolutely necessary, they are referred to in the text by the part number of the manufacturer if at all possible; and also noted at the beginning of each procedure with one of the following symbols: OEM or DVOM. The OEM symbol usually denotes the need for a unique tool purposely designed to accomplish a specific task, it will also be used, less frequently, to notify the reader of the need for a tool that is not commonly found in the average tool box. The DVOM symbol is used to denote the need for an electronic test tool like an ohmmeter, multi-meter or, on certain later engines, a scan tool. These tools can be purchased, under the appropriate part number, from your local dealer or regional distributor, or an equivalent tool can be purchased locally from a tool supplier or parts outlet. Before substituting any tool for the one recommended, read the SAFETY NOTICE at the top of this page. Providing the correct mix of service and repair procedures is an endless battle for any publisher of "How-To" information. Users range from first time do-it yourselfers to professionally trained marine technicians, and information important to one is frequently irrelevant to the other. The editors at Seloc Publishing strive to provide accurate and articulate information on all facets of marine engine repair, from the simplest procedure to the most complex. In doing this, we understand that certain procedures may be outside the capabilities of the average DIYer. Conversely we are aware that many procedures are unnecessary for a trained technician.

SKILL LEVELS In order to provide all of our users, particularly task before tackling it we have included a rating s performing a particular procedure. One of the foil procedures: EASY. These proced the most part, as basic maintenance procedures; any experience level, they will generally be of littl MODERATE. These working knowledge of mechanical procedures. Ev occasionally refer to these procedures. They will adjustments and minor rebuilds. DIFFICULT. These p technician. They will deal with diagnostics, rebuilc require special tools. le SKILLED. These pro be attempted without previous experience. They gear case rebuilds. Please remember one thing when considering t of a given procedure and are subjective in nature you will know when a procedure may be outside technician, we all approach repair and service differently procedure for another, regardless of experience I Use them to help make a judgement before unde the procedure first and make your own decision— and repair easier for everyone whether you are cl DIYers, with a feeling for the scope of a given procedure or /stem denoting the suggested skill level needed when wing icons will be included at the beginning of most ires are aimed primarily at the DIYer and can be classified, for oattery, fluids, filters, plugs, etc. Although certainly valuable to importance to a technician. )rocedures are suited for a DIYer with experience and a sn an advanced DIYer or professional technician will enerally consist of component repair and service procedures, ocedures are aimed at the advanced DIYer and professional s and internal engine/drive components and will frequently ;edures are aimed at highly skilled technicians and should not usually consist of machine work, internal engine work and ie above ratings—they are a guide for judging the complexity Only you will know what your experience level is, and only ie realm of your capability. First time DIYer, or life-long marine so an easy procedure for one person may be a difficult vel. All skill level ratings are meant to be used as a guide only! taking a particular procedure, but by all means read through after all, our mission at Seloc is to make boat maintenance anging the oil or rebuilding an engine. Enjoy boating! ALL RIGHTS RESERVED

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1992-2009 Nissan/Tohatsu Outboards 2-Stroke Service & Repair Manual

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