Tohatsu Outboard 1 2 Cylinders Full Service Repair Manual

TOHATSU CORPORATION 1&2 CYLINDER MODELS SERVICE MANUAL

California Proposition 65 Warning–Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING

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

1-/ 2-Cylinder 1-1 Introduction ·························································································································· 1-2 Safety Statements················································································································ 1-2 Safety Precautions ··············································································································· 1-3 Workmanship Standards······································································································ 1-5 Test Tank Guidlines ·············································································································· 1-7 SECTION 1 SERVICE SAFETY TABLE OF CONTENTS

SECTION 1 1-2 1-/ 2-Cylinder WARNING Inadequate knowledge of safe shop practices can result in severe injury or death. Review general safety procedures and speciﬁc safety information provided for each procedure prior to beginning any repairs. INTRODUCTION Marine manufacturers are required to comply with special regulations and standards to ensure their products are safe and reliable for the consumer. As the marine technician, it is your responsibility to keep these products safe when performing normal rigging, repair and maintenance operations. It is not possible to foresee all safety hazards which may occur or to include all the knowledge of an experienced technician in a single service manual. Therefore, it is assumed that those using this manual have a working knowledge of 2-cycle outboard engines and the proper technical training for servicing them. This section discusses safe shop practices and general safety concerns relevant to the operations performed throughout this manual. Read this section carefully and follow all safety statements in this manual as they pertain to the procedures at hand. Remember, always use common sense when servicing outboard engines! SAFETY STATEMENTS The following safety statements are found throughout this manual and indicate information which, if ignored, could result in safety hazards or faulty service techniques: DANGER Indicates the presence of a hazard which, if ignored, WILL result in severe injury or death. WARNING Indicates the presence of a hazard which, if ignored, COULD result in severe injury or death. CAUTION Indicates the presence of a hazard which, if ignored, COULD result in minor personal injury or damage to product, equipment, or other property. NOTE Indicates special information to facilitate the installation, operation, or maintenance of the product or further clarify information which is important but not hazard related. KC-5030

SERVICE SAFETY 1-3 1-/ 2-Cylinder SAFETY PRECAUTIONS Handling Outboard Engines • Never disable the neutral switch start-in-gear prevention system to accommodate installation of a foot control or other option. Always test the neutral switch and emergency stop switch before returning an engine to the customer. • Lifting devices and hardware must be of suitable capacity for the weight of the outboard engine. Some models are equipped with a fixed hanger on the powerhead. Hanger may be used to lift the complete engine or to remove the powerhead unit. Be aware the engine may swing outward when lifted by the hanger. • Engine stands must be in good condition, of adequate size, and mounted properly to prevent unexpected shifting or collapse. • Engine covers are guards to prevent personal contact with the spinning flywheel and high voltage components such as spark plugs and coils. Never wear jewelry or loose clothing near a running engine. Keep hands, arms and hair away from the flywheel. Never touch electrical components when the engine is running. • Two people working on a running engine must use extreme caution and be aware of one another. Never attempt to start an engine or operate any controls, including steering, before signaling your partner. • To prevent accidental startup during operations which may cause the flywheel to turn, always perform the following steps: 1. Turn the ignition key to OFF and remove the key. 2. Disable the engine ignition system. 3. Shift engine to NEUTRAL and verify propeller shaft is not in gear. • Rotating propellers are not equipped with guards and can cause severe injury or dismemberment. Always stay clear of rotating propellers and make sure there is no possibility of engine startup before removing or installing a propeller. The propeller nut must always be tightened to torque specification prior to starting the engine. KC-5000 KC-4090 KC-4075.3

SECTION 1 1-4 1-/ 2-Cylinder • Avoid running the engine at high RPM. Engine speed can easily increase to excessive RPM when under a no load condition. To avoid engine damage during testing, always use the correct test propeller and keep engine speed below 2000 RPM. • Run engines only in well ventilated areas to prevent exposure to Carbon Monoxide (CO) gas. Direct and prolonged exposure to CO wiII cause brain damage or death. • Always wear eye protection, protective clothing, gloves and use other applicable safety equipment when work activities present the risk of personal injury. Lead Acid Batteries • Never check battery charge by placing a metal object across the terminal posts; sparks may occur, resulting in serious burns. • Avoid contact with battery acid. lf battery acid is spilled on skin, thoroughly wash area with plenty of water. If battery acid gets into eyes, flush eyes with water for at least 15 minutes and get prompt medical attention. • Never remove charger cables from a battery when the charger is energized; sparks and explosion are possible. To remove charger cables, follow these steps: 1. Turn the charger to OFF. 2. Disconnect the charger power cord from its power source. 3. Remove the charger cables from the battery posts. • Batteries emit explosive vapor through the vented caps during charging. Never charge or test batteries near sparks or flames; explosion can result. Extinguish all smoking materials and flame producing devices before charging and make sure the charging area is weII ventilated. • Make sure battery vents are not clogged or pressure may build and cause battery to explode. KC-5032 KC-4080 KC-5050

SERVICE SAFETY 1-5 1-/ 2-Cylinder Hazardous Materials • Gasoline vapors are highly flammable and can cause an explosion. Never smoke or allow sparks or flames nearby when handling fuel Always store gasoline in a shaded, well ventilated area in an approved safety container. • Ventilate gasoline fumes as soon as detected. Be aware that appliance pilot lights, such as those in furnaces and water heaters, can ignite gasoline vapors and cause explosion. • Never use gasoline as a cleaner, and always clean up fuel spills immediately and properly dispose of rags in an approved safety container. • Read and follow the safety labels on products used around the shop. Adhesives, lubricants, solvents, and fuel additives are usually poisonous and flammable. Store and dispose of these products properly. Shop Environment • Make sure the shop and your work area are properly ventilated. • Shops must be equipped with the proper tools and safety equipment such as fire extinguisher, eye flushing device, and first aid kit. • Keep the shop clean and free of clutter. Clean up spills on the floor as soon as possible to prevent someone from slipping. WORKMANSHIP STANDARDS 1. Avoid damage to the mating surfaces of crankcase and cylinder assembly. Do not use a sharp metal scraper to clean these areas. 2. Replace gaskets, O-rings, seals, cotter pins, lock nuts, and spring pins when removed during repair operations. 3. Use only genuine factory replacement parts and accessories. 4. Use recommended special tools when specific repairs require them. 5. Calibrate measurement tools and test equipment on a regular basis. 6. Clean aIl metal parts with solvent before inspection and assembly operations. 7. Use penetrating solvents when necessary to remove rusted or seized hardware. KC-5040 KC-0135 KC-5001 KC-5055

SECTION 1 1-6 1-/ 2-Cylinder 8. Keep all removed parts separated for ease of identification during assembly. 9. Locate alignment marks on components being disassembled. If marks are not present and should be, scribe or match mark them yourself to ensure the pieces are assembled properly. 10. Follow torque sequences and specifications where they apply. First, tighten each bolt in the specified sequence. Use the same sequence to torque each bolt to final specification. Special torque specifications are listed at the beginning of each section. Standard torque specifications for common fasteners are listed in Section 3. 11. Use lubricant when assembling seals to prevent damage to the seal lips. Make sure seal lips are facing the correct direction. 12. Use the correct type and amount of sealing compound on metal to metal surfaces. 13. When using compressed air to clean or dry parts, make sure air supply is regulated not to exceed 25 psi [172 kPa /1.76 kg/cm 2 ]. 14. Replace missing or damaged safety labels on the engine before returning it to the customer.

SERVICE SAFETY 1-7 1-/ 2-Cylinder TEST TANK GUIDELINES When properly setup, test tanks provide a safe and controlled environment in which to perform outboard engine adjustment and testing procedures. Test tanks must be setup to the minimum dimensions shown. If multiple engines wiII be installed in the tank, secure partition plate (1) so that the minimum dimensions are maintained for each outboard engine installed. In addition, adhere to the following guidelines to prevent engine damage: • Continuous usage raises the water temperature in the tankwhich can lead to engine seizure. Make sure water temperature in the tank does not exceed 77°F [25°C]. • Repeated use introduces carbon into the water which can adhere to the engine cooling system and degrade its ability to cool the engine. Always replace dirty tank water at regular intervals with clean, fresh water. • Exhaust gases produced during engine operation can collect around the engine, causing suction into the carburetors and affecting engine performance. To prevent this condition, install forced ventilation equipment (2) to remove gases away from the engine and work area. • Water may splash out of the tank during testing. Maintain water leveI (3) in the tank as illustrated. • Keep transom board (4) at an approximately 75° angle to the tank bottom to ensure near vertical engine position. T1016

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Tohatsu Outboard 1 2 Cylinders Full Service Repair Manual

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