TOHATSU M 40 Bedienungsanleitung

PNo. 003-21036-1

0509 NB 1000

Printrd in Japan

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TABLE OF CONTENTS

Service Safety

General Service Information

Fuel System

Powerhead

Midsection

Gearcase

Electrical System

Power Trim/Tilt

3-/ 4-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

3-/ 4-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

3-/ 4-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

3-/ 4-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 will 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. If 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 well 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

3-/ 4-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, split 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 all 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

3-/ 4-Cylinder

8. Keep all removed parts separated for ease of identiﬁcation

during assem bly.

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 2.

11. Use speciﬁed 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

14. Replace missing or damaged safety labels on the engine before

returning it to the customer.

SERVICE SAFETY

1-7

3-/ 4-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 will 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 tank which

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 from the engine

and work area.

•Water may splash out of the tank during testing. Maintain water

level

(3)

in the tank as illustrated.

•Keep transom board

(4)

at an approximate angle of 75˚ to the

tank bottom to ensure near vertical engine position.

T1016

3-/ 4-Cylinder

2-1

General Precautions ............................................................................................................ 2-2

Abbreviations and Symbols ................................................................................................ 2-3

Unit Conversions ................................................................................................................. 2-4

Service Speciﬁcations ......................................................................................................... 2-5

Engine Speciﬁcations .......................................................................................................... 2-8

Lubrication Chart .............................................................................................................. 2-11

Periodic Inspections .......................................................................................................... 2-14

Break-In Procedure ........................................................................................................... 2-18

Tune-Up Procedure ........................................................................................................... 2-20

Emergency Stop Switch and Lanyard ............................................................................... 2-21

Operator Alert Systems ..................................................................................................... 2-22

Synchronization and Linkage Adjustments ....................................................................... 2-25

Anodes - Inspection and Testing ...................................................................................... 2-39

SECTION 2

GENERAL SERVICE

INFORMATION

TABLE OF CONTENTS

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