1

.
Overall Length
Overall Width
Overall Height

Model

Transom Height
Weight*

MFS40A/50A specification
EPT
ET
EPG
EHG
Approx.
Approx.

Approx.

Approx.

Approx.

Approx.

Approx.

Approx.

Approx.
209 lb

220 lb

204 lb

Approx.
214 lb

225 lb

215 lb

208.3 lb

219 lb

Approx.
220 lb

Engine Type
Number of Cylinder
Piston Displacement
Bore Stroke
Max. Output
Max. Operating Range
Idle Speed
Compression ratio
Variable idling speed
Exhaust System
Engine Lubrication
Cooling System
Starting System
Valve System
Ignition System
Spark Plug
Alternator

kW(ps)
kW(ps)

232 lb

215 lb

4 stroke EFI
In line 3 cylinder
cm3 (ml)

W ( )
W ( )
r/min
/min

, , , r/min
Through hub exhaust
Wet sump (Trochoid pump)
Water cooling (with thermostat)
Electric starter motor
SOHC cross flow
Battery ignition

(4000 r/min)

226lb

MFS40A/50A specification
ET

Model

EPT

Steering angle

Trim angle

Trim position

Tilt up angle

Gear shift

Dog clutch ( )

Gear Reduction Ratio

()

Fuel

Unleaded regular gasoline : Pump posted

87 Octane (research octane rating of 91)
Grade

Engine Oil

ml (US qt)
Grade

Gear Oil

EPG

EHG

API standard SH, SJ, SL, 10W-30/40

2400
2200 (2.3)
Genuine Gear Oil or API GL5,SAE #80-90

ml (US qt) 500 (0.53)

/5HR CCA850

Battery

Cold
weather
spec.

/5HR CCA1000


TOHATSU
MFS50A ET
4 stroke

HONDA
BF50D LRTN
4stroke

YAMAHA
F50B L
4 stroke

SUZUKI
DF50ATL
4 stroke

Mercury
50ELPT Xri
4 stroke

866

808

966

941

995

70X75

70X70

6575

72.576

65X75

No. of cylinder
Max. output

3
50ps

3
50ps

4
50ps

3
50ps

4
50ps

Max. operation
range

5000-6000

5000-6000

5000-6000

5300-6300

5500-6000

Fuel injection

Fuel injection

Fuel injection

Fuel injection

Fuel injection

Starting system
Alternator
Weight
Gear ratio
Tilt

Electric
21A (*1)
97(214b)
2.08
PTT

Electric
17A(*2)
98(216lb)
2.08
PTT

Electric
17A(*1)
113(249lbs)
1.85
PTT

Electric
19A(*1)
106(234lb)
2.27
PTT

Electric
18A(*1)
112(247lb)
1.83
PTT

Transom
height(mm) (L)

538

521

534

531

541

Model name
Engine type
Piston
displacement(ml)
Bore
Stroke(mm)

Fuel supply
system

*1 Alternator performance
*2 Charging performance

Comparison of Weight (kg) by Brands: 4st 40ps Class

(lb) 104
(kg)
229 103
227 102
225 101
223 100
221

99

218

98

216

97

214

96

212

MFS40A

F40F

DF40A

40EFI

BF40

TOHATSU

YAMAHA

SUZUKI

MERCURY

HONDA

( ) 40 ..

(lb)

(kg)

256
247
238
229

221
212

( ) 50 ..

 0 50
Acceleration 0-50m

: 4.45 (14.6 ft)

: 300 (661 lb)

sec

MFS40A

8,05

YAMAHA F40F

8,15

13inch

11inch

Acceleration 0-100m
sec

MFS40A

12,45

YAMAHA F40F

12,70

13nch

11inch
10

 0 50

: 4.45 (14.6 ft)

: 300 (661 lb)

Acceleration 0-50m
sec

MFS50A
HONDA BF50
YAMAHA F50F

15inch

6,65

14inch

6,90

15inch

7,80

Acceleration 0-100m
sec

MFS50A
HONDA BF50
YAMAHA F50F

15inch

10,20

14inch

10,55
11,80

15inch
11

 0 50

: 6.37 (21ft)
: 390 (860lb)

Acceleration 0-50m
sec

MFS50A
HONDA BF50
YAMAHA F50F

14inch

7,20

14inch

7,75

11inch

7,35

Acceleration 0-100m
sec

MFS50A
HONDA BF50
YAMAHA F50F

11,15
11,90
11,55

14inch

14inch
11inch
12


Max. power
Max. torque

FC Fuel
Consumption

Power

Torque

Power(Kw)
Torque(Nm)
FC(L/h)
MD50B2

13

: 4.45 (14.6 ft)

: 300k (661 lb)

14

: 4.45 (14.6 ft)

: 300k (661 lb)

SFC (km/L)

Fuel efficiency
8

MFS50A_15inch

Honda BF50_15inch

Yamaha F50F_13inch

5
4
3
2
1
0
500

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

Engine Speed (r/min)

15

: 6.37 (21ft)
: 390k (860lb)

Fuel Flow vs. Engine Speed

Engine Speed (r/min)

5600

5000

4000

3000
Yamaha F50F_11inch
2000

Honda BF50_14inch
MFS50A_14inch

800
0,0

2,0

4,0

6,0

8,0

10,0

Fuel Flow (L/h)

12,0

14,0

16,0

18,0

20,0

16

: 6.37 (21ft)
: 390k (860lb)

Fuel efficiency
9

MFS50A_14inch

Honda BF50_14inch

SFC (km/L)

Yamaha F50F_11inch

6
5
4
3
2
1

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

Engine Speed (r/min)

17


Maximum Speed

50

48

48.4
30.07mph

48.40
30.07mph

48.2
29.95mph

49

Speed [km/h]

: 6.37 (21ft)
: 390k (860lb)

48.30
30.01mph

47.0
29.2mph

48.05
29.9mph

47
46.8
29.08mph

46

46.85
29.11mph

45
44

44.5
27.65mph

44.05
27.37mph

43
42
41

MFS50A

HONDA BF50

YAMAHA F50F

40
4500

4700

4900

5100

5300

5500

5700

5900

6100

6300

6500

Engine speed [r/min]

18



Propeller
MFS50A

13

14

15

km/h

48.05

48.40

48.2

r/min

6062

5528

5196

13

14

15

km/h

48.4

48.30

47.0

r/min

6056

5567

5147

10

11

13

14

km/h

44.05

44.5

46.85

46.8

r/min

5917

5466

5027

4920

Propeller
HONDA_BF50

Propeller
YAMAHA F50

: 6.37 (21ft)
: 390k (860lb)

19


: 4.45 (14.6 ft)
: 300k (661 lb)

Maximum Speed
58

MFS50A

57

HONDA BF50

YAMAHA F50F

56

Speed [km/h]

55

54.05
33.59mph

54

53.40
33.18mph

52.7
32.75mph

53
52
52.10
32.37mph

51

52.65
32.72mph

52.40
32.56mph

52.35
32.53mph

50
49

48.9
30.38mph

48
4500

4700

4900

5100

5300

5500

5700

5900

6100

6300

6500

Engine speed [r/min]

20



Propeller
MFS50A

HONDA_BF50

14

15

16

km/h

52.7

53.40

54.05

r/min

5736

5393

5165

Propeller

14

15

km/h

52.35

52.40

r/min

5772

5380

11

13

15

km/h

48.9

52.65

52.10

r/min

5716

5324

5025

Propeller
YAMAHA F50

: 4.45 (14.6 ft)

: 300k (661 lb)

21

22


, ,
.
, .
.

23



Alternator performance

A
25

20

21.3A@4000rpm
18.6A@1500rpm

15

18
3

15A@1000rpm
10

6.9A@650rpm

:
4

0
0

1000

2000

3000

4000

5000

6000

Engine RPM

24

25

1. 4.

26

27

ISC

28

MAP/ MAT

29

 ,
( )

,
MD90C2.

.

30


,

- - - , ,
, .
. ,
, .

2nd ring
Expander

Side rail upper

Side rail lower

Top ring

31
Piston ring gap


,
,
(615% MD50)
- ,

( MW50)

32


( MD50B2).
3 6
( MD50B2)

19 20 ( MD50B2)
,

MW50D2 :80, MFS40/50 :84.5

M6M8

30.433.25
1920
6.758.5

8084.5
:2.08

33



650 950/
1 .,

* 850/,
3000 /

34


, .
.

35

 (.)
,
,
(
).
,
.

1. . 3KY-72620-0
:
TILT LIMIT SWITCH
SCREW
NUT
WASHER
TILT LIMIT SWITCH PLATE

1
2
2
2
1

BOLT
TILT LIMIT SWITCH CAM
TILT LIMIT CAM HOLDER
PIN
SCREW

1
1
1
1
2

36

2.

3.
,

4.

5.
,

6. ,

,

7.
(

37

8.

9.

10.
,

11.
,

12.
,

13.
.

38

14.
,
.
!

39

 -

(
)

1.
"ON",
5 .
,

2. ,
,

.
,

,
/.

/

3.
"ON",
1 .,

40

 /
Lamp Indication

Engine Operating
Hours(h)
01
12
23
34
45
56
67
78
89
910
1020
2030
3040
4050
5060
6070
7080
8090
90100
100200
200300
300400
400500
500600
600700
700800
800900
9001,000
1,0002,000
2,0003,000

Tach. Indication(r/min)
1,000
2,000
3,000
4,000
5,000
6,000
7,000
800
900
1,000
2,000
3,000
4,000
5,000
6,000
7,000
800
900
1,000
2,000
3,000
4,000
5,000
6,000
7,000
800
900
1,000
2,000
3,000

Lamp A

Goes on.
Goes on.
Goes on.
Goes on.
Goes on.

Lamp B

Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.

Lamp C

Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.

41

4.
"OFF,

.

.

,
ON, 1 .
,
.
,
,

, ,
.
/,
, .

42


Fault Log

Malfunction/Failure Indication

Fault

Fault log (Yes)

Description of Problem

Remedy

Tachometer Indication(r/min)

Lamp

Lamp

Lamp

Off

No malfunction of failure

Off

Off

1,000

On

Fuel injector malfunction

2,000

On

Fuel injector malfunction

3,000

On

Fuel injector malfunction

1,000

Flashing

Ignition coil manfunction

2,000

Flashing

Ignition coil manfunction

3,000

Flashing

Ignition coil manfunction

500

Off

Oil pressure low

500

On

Battery voltage low

Lighting means that battery

voltage is low.

Lighting means that the battery

voltage was once low.

5,000

Off

malfunction

Lighting means that the

wiring is broken or a
component malfunction.(*2)

Lighting means that the

component was once broken.

5,500

Off

malfunction

Lighting means that the

wiring is broken or a
component malfunction

Lighting means that the wiring

was once broken or a component
once malfunctioned.

*1 Only the fault log can be found

(*1)

*1 Only the fault log can be found

(*1)
(*1)
(*1)

Lighting of the lamp means that *1 Only the fault log can be found
the wiring was once broken or a
component once malfunctioned. *1 Only the fault log can be found
*1 Only the fault log can be found

(*1)

*1 Only the fault log can be found

(*1)
(*1)

Oil pressure was once low

*1 Only the fault log can be found

*2 No lighting when the wiring is

broken.

43

Fault Log

Malfunction/Failure Indication

Fault

Fault log (Yes)

Description of Problem

Tachometer Indication(r/min)

Lamp

5,500

On

5,500

Remedy

Lamp

Lamp

Sensor power valtage high

Lighting means that the

power voltage high

Lighting means that the power

voltage was once high

Flashing

Sensor power voltage low

Lighting means that the

power voltage low

Lighting means that the power

voltage was once low

6,500

Off

Engine temp. sensor malfunction

Lighting means that the

wiring is broken or a
component malfunction

Lighting means that the

component was once broken.

6,500

On

Engine temp. high

Lighting means that the

cooling water tem. is high

Lighting means that the cooling

100
water tem. was once high

6,500

Flashing

Engine temp. abnormally

Lighting means that the

cooling water tem. is
abnormally high

Lighting means that the cooling

water tem. was once abnormally 140
high

7,000

Off

malfunction

4,500

On

sensor malfunction

Lighting means that the

wiring is broken or a
component malfunction

Lighting means that the wiring

was once broken or a component
once malfunctioned.

4,500

Off

T sensor malfunction

44

100 /
.
!!!
!

1
9 .

1.
,
ON, 1 .
.

2. 5-10 . ( 3. 5-10 .
7 .) ,

0,5 0,5 . .
.

45

4. 5-10 .
,
,
.

5.

OFF
.

100/,


.

46

47

ECU

ISC

MAP/MAT

TPS

48


Power
Battery
Power

Pulser Coil
(Crank
Position
Sensor)
MAP
Sensor

Engine
speed
Crank
position

Control
Ignition timing,
Fuel injection amount
and
Idle Speed Control Valve

Fuel feed Pump

(FFP)

Fuel
Injector

Manifold
pressure

Manifold
temperature
Atmosphere
pressure
before starting
Engine
(Water) Temp
Sensor

Throttle
Position
Sensor
(TPS)
Oil
pressure
switch

Engine
temperature

Throttle
opening
angle

Oil
pressure

Ignition
Coil

Correction
Ignition timing
and
Fuel injection amount

Control
Warning lump,
Buzzer
and
ESG working

Idle speed
Control
Valve

Warning lamp
Buzzer

ECU
49


ECU

ECU
1.

.
2. ,
ISC.
3. .
4.

Crank Position Sensor (CPS)

,

,

Engine (Water) Temp Sensor
.
.
,

50

MAP (Manifold absolute pressure)

(
) ,

Throttle Position Sensor

,
.

Oil Pressuer Switch

,

51

ISC (Idle Speed Control Valve)

,
,

,

Fuel Injector


,
.

Ignition Coil
I ,



.
.

52

53


,
. .

.
.

54


OUT

IN

. ( )

:
. ( )

.
( )

.
( )

55


.
,
.
.

56

Out

Return

In

57

58

 CPS
.
: 0.8

59



.
(
)
:
20/
:
100/

Intake/
:

0.15-0.25

Exhaust/
:

0.25-0.35

60


,
(
)
,
.

11
Start
9

10

12

Nm
kgfm

No.1~8
M10
No.9~12
M8

Nm
kgfm

30

3.0

60

6.0

15

1.5

30

3.0

61

:
CBBC

:
1111

62

: CBBC, 1111
, , ,

XXX

: XXX, 322
, ,

63


,
.
:
: 30Nm(3.0kgfm)
:13Nm(1.3kgfm)

..

Lock tight
271

64


,
MFS25/30B (
MFS25/30B)
,
MFS25/30.


On/Off

65

650 to 950
Up to 10%
60 to 65
-700 to -600 hPa
Approx. 0.5L to 16

66

B, : 0.60-0.64 mm

A B

(in)

.
+ .
- .
(in)

0.00 - 0.01(0.00-0.0004)
0.02 - 0.17(0.0008-0.0067)
0.18 - 0.30(0.0071-0.0118)
0.31 - 0.62(0.0122-0.0244)
0.63 - 0.75(0.0248-0.0295)
0.76 - 0.91(0.0299-0.0358)
0.92 - 1.07(0.0362-0.0421)
1.08 - 1.22(0.0425-0.0480)
1.23- 1.38(0.0484-0.0543)
1.39 - 1.53(0.0547-0.0602)
1.54 - 1.69(0.0606-0.0665)

- 0.15(0.0059)
- 0.10(0.0039)
- 0.05(0.0019)
0
+ 0.05(0.0019)
+ 0.10(0.0039)
+ 0.15(0.0059)
+ 0.20(0.0078)
+ 0.25(0.0098)
+ 0.30(0.0118)
+ 0.35(0.0137)

1.70 - 1.84(0.0669-0.0724)

+ 0.40(0.0157)

()()

67

 .
Part No.
3KY-72815-0
3KY-72871-0
3AB-99702-0
3AC-99702-0
3KY-99905-0
3KY-99710-0
3KZ-99710-0

Part name
CRANKSHAFT
HOLDER
PISTON SLIDER
DRIVER ROD
DRIVER ROD
BEARING
ATTACHMENT
ROLLER BEARING
ATTACHMENT
ROLLER BEARING
ATTACHMENT

Purpose

Part No.

Holding crank shaft

3B7-72234-1

Installing piston
Use with attachment
Installing gear case roller
bearing/ bevel gear A outer
race
Installing gear case roller
bearing
Installing propeller shaft
housing roller bearing
Use with bearing attachment
to hold bearing
Installing propeller shaft
housing roller bearing
Installing gear case roller
bearing
Measuring bevel gear B
height
Measuring gap

332-66032-0

O-RING

3AC-99701-0

CENTER PLATE

3C8-72719-0

BEVEL GEAR BRG

INSTALL TOOL

3KY-72250-0

SHIMMING GAUGE

353-72251-0

THICKNESS GAUGE
BEVEL GEAR NUT
Removing bevel gear B nut
WRENCH
BEVEL GEAR NUT
Removing bevel gear B nut
SOCKET
BEARING OUTER
Installing bevel gear A outer
PRESS KIT
race
BEARING OUTER
Installing bevel gear A outer
PRESS ROD
race
BEARING OUTER
Installing bevel gear A outer
PRESS PLATE
race
ROLLER BEARING OTR Installing bevel gear A outer
PRESS GUIDE
race
Installing bevel gear A outer
SPRING WASHER
race
Installing bevel gear A outer
NUT
race

346-72231-0
346-72232-0
3B7-72739-1

3B7-72731-0
353-72732-0
3BJ-72733-0
941392-1000
930191-1000

3B7-72720-0
3B7-72729-0
3T1-72211-0
345-72227-0
345-72228-0
369-72217-0
369-72218-0
353-72248-0
3KY-72229-0
3KY-72920-0
3AC-99070-0
3AC-99080-0
3AC-99090-0

Part name

Purpose

BACKLASH
MEASURING TOOL KIT
*BACKLASH
MEASURING TOOL
SHAFT

Measuring gap between bevel

gear A and B
Measuring gap between bevel
gear A and B

Measuring gap between bevel

gear A and B
Measuring gap between bevel
*CONED DISC SPRING
gear A and B
*MEASURING SETTING Measuring gap between bevel
PIECE
gear A and B
Measuring gap between bevel
*O-RING
gear A and B
*BACKLASH
Measuring gap between bevel
MEASURING TOOL
gear A and B
PLATE
BACKLASH
Measuring gap between bevel
MEASURING TOOL
gear A and B
CLAMP
Measuring gap between bevel
DIAL GAUGE PLATE
gear A and B
FLYWHEEL PULLER KIT Removing/Installing flywheel
SPRING PIN TOOL
Removing spring pin(3)
SPRING PIN TOOL
Installing spring pin(3)
SPRING PIN TOOL
Removing spring pin(3.5)
SPRING PIN TOOL
Installing spring pin(3.5)
SHIFT ROD JOINT
Pulling shift rod
PULLER
CLUTCH PIN SNAP
Attaching snap pin
TOOL
DIAGNOSTIC TOOL KIT Diagnosing engine trouble
TORQUE WRENCH
Adjusting valve clearance
Removing bevel gear A
SLIDE HAMMER ASSY
bearing outer race
OIL FILTER WRENCH Removing/Installing oil filter
*NUT

Yellow means newly added

68


Warning Indicators
ESG

Fault Description

Reference

Buzzer Sounding
Indicator A Indicator B Indicator C

Countinuous

Countinuous

Constant

High speed
Engine over-rev
ESG
Low speed ESG Low oil level

Countinuous

Flashing

Low speed ESG Cooling water temp. high

Countinuous

Constant

Constant

Constant

Flashing

Approx. 6,200 r/min

100 (*2) Activate 1 sec.

Forced idling Cooling water temp. abnormally high

-

150
Approx. 9V or less. Idling speed
up

Battery voltage low

Flashing Flashing Flashing Low speed ESG Sensor power supply malfunction

Flashing Flashing Flashing

Fuel injector malfunction

Flashing Flashing Flashing

Ignition coil malfunction

Flashing Flashing Flashing

FFP malfunction

Flashing Flashing Flashing

CPS malfunction*1

Flashing Flashing Flashing

TPS malfunction

Flashing Flashing Flashing Low speed ESG Temp sensor malfunction

Flashing Flashing Flashing Low speed ESG MAP sensor malfunction

Flashing Flashing Flashing

MAT sensor malfunction

Countinuous(*2)

Constant(*2) Constant(*2) Constant(*2)

(*1) No flashing when the wiring

is broken.

Flashing

Short sound 1

When the key is turned On

Indicate oil replacement period every
100hrs
Lowest idling speed of variable system

Short sound 2

Highest idling speed of variable system

0.3 .
ON 0.3 .-OFF 0.3.-ON 0.3.

ON 1 ., OFF 1 .
ON 1 , OFF 9 .

(*2) Activate 1 sec.

Reset by stop switch

3000 /
. : 6200 /

69



Tightening Location

Screw B X
Pitch

Type of
Fastner

M101.25
Bolt
M81.25
Bolt
Spark Plug
M121.25
Tappet Adjusting Nut
M60.75
Nut
Cylinder Head
Rocker Shaft Bolt
M81.25
Bolt
Thrust Bolt
M61.0
Bolt
Anode Plug
M161.5
Anode Installation Bolt
M50.8
Screw
Oil Filter
Cylinder Block
M201.5
M81.25
Bolt
Crank Case Installation Bolt
Crank Case
M61.0
Bolt
Connecting Rod Bolt
M80.75
Bolt
Flywheel Nut
M201.25
Nut
Crank Shaft
Timing Pulley Nut
M391.5
Nut
Oil Pressure Switch
PT1/8
Engine Short Block Power Unit Installation Bolt M81.25
Bolt
Bracket Shaft
Cramp Bracket
7/8-14UNF-2A Nylon Nut
Manual Valve
PTT Assy
M12
Cylinder Head Installation
Bolt

Engine Basement
Drive Shaft
Gear Case
Top Cowl

Upper Mount Rubber

Installation Bolt(Center)
Oil Pan Drain Bolt

M81.25

Bolt

M141.5

Bolt
Bolt, Nylon
nut
Nut
Nut
Nylon Nut

Lower Mount Rubber Bolt

M121.25

Bevel Gear B Nut

Propeller Nut
Tilt Handle Installation Nut

M121.0
M161.5
M61.0

Temporary Driving
Torque
Nm
kgfm
30
3.0
15
1.5
12-15
1.2-1.5
6
0.6
15
1.5
15
1.5
-

Driving Torque N-m

Nm
60
30
18
7
18
9
18
2
23-25
11.5
30
150
120
8
30
24
1.8

kgfm
6.0
3.0
1.8
0.7
1.8
0.9
1.8
0.2
3/4 rotating(270)
after finger tighten

2.3-2.5
1.15
3.0
15.0
12.0
0.8
3.0
2.4
0.18

15

1.5

30

3.0

24

2.4

40

4.0

50
35
2

5.0
3.5
0.2

70

Oil seal (cam shaft)

Cylinder head

ATF

Mori
KS-64 paste
500

Cam
Bearing
Lip
Periphery
Thread end
Thread
Bearing, slipper head
Periphery
Entire
Entire
Shaft, Stem head
Entire
Entire
Entire
Lip, inner
Entire

Approx. 2cc from intake port and discharge port.

Plunger tip
Periphery

Thread
Thread, seat
Periphery

Thrust bolt (cam shaft holding)

Cam shaft pulley bolt
Rocker arm
Rocker arm shaft
Rocker arm spring
Washer(rocker arm)
ValveINT,EX
Valve spring
Valve spring seat
Retainer cotter
Valve stem seal INT,EX
Tappet adjusting screw

Oil pump
Fuel pump
O-ring(fuel pump)
O-ring(anode plug)
Taper plug
Cylinder head bolt
Cylinder head O-ring(filler cap)
cover
Screw(breather chamber cover)
Cylinder linder
Piston
Piston ring
Piston pin
Connecting rod
Connecting rod metal bearing
Cylinder block &
Crank shaft
crank case
Crank shaft metal bearing
Oil seal(crank shaft upper lower)
Cylinder block/crank case mating surface
Bolt(oil filter)
Oil filter
Taper plug

LM902

Cam shaft

Remark

Shinetsu
Sumico
silicones

Chuo yuka

LOR Centax FM#101

L2
531

PTT fluid

G17

Tohatsu genuine gear oil

1207B 1741

4st engine oil

518

Molybdenum grease

LOR
#2000

Silicone grease

1342 1373B 1401

Teflon grease

Oil
Oil
Three Three Three
Three Three
center Loctite
Konishi center
bond bond bond research
bond bond
research

Waterproof grease OBM

Low temperature resistant lithium

grease

Heat resistant grease

Adhesive

Instaneous adhesive

Gasket seal agent

271

Rusting and leaking prevention screw

lock agent

Part name

High-strength screw lock agent

Loctite

Low-strength screw lock agent

High-strength screw lock agent

Item name

Inner wall
Peripheryring groove
Entire
Periphery
Small end inner
Sliding surface *Degrease periphery
Sliding surface, thrust receiving surface
Sliding surface *Degrease periphery
Lip
Mating surface
Thread
Seat surface (O-ring)
Thread

71
* TB 1207B ,

LOR Centax FM#101

L2
531

LM902

Engine basement

Drive shaft housing

Drive shaft

Oil seal (pump case lower)

Gear case

Propeller shaft

Propeller shaft housing

Oil seal (engine basement)

Seal rubber (engine basement)
Bolt (Drain cover)
Bolt (Idle exhaust cover)
Screw (oil pan guide plate)
Water pipe seal (upper)
Water pipe auxially (support) mount
Bolt (engine)
Stud for
Drive shaft (spline)
Nut (bevel gear B)
Bolt (Gear case)
Bolt (pump case)
Pump case upper (liner)
O-ring pump case lower

Water pipe seal (lower)

O-ring (cam rod bushing)
Bolt (cam rod bushing)
Tapered roller bearing (outer)
Needle bearing (gear case)
Needle bearing (bevel gear A)
Propeller shaft (spline)
Clutch
Push rod
Ball
Retaner
Spring
O-ring
Oil seal
Roller bearing
Needle bearing

Spark plug insertion area

High tension cable
Thread
Terminal
Terminal
Pinion
Terminal
Lip
Periphery (when installation),
Periphery, Inner
Thread
Thread
Thread
Periphery
Inner
Thread
Inner thread
Crank shaft side spline
Thread
Thread
Thread
Impeller sliding surface

Starter solenoid

Remark

ATF

Mori
KS-64 paste
500

Starter motor

PTT fluid

Shinetsu
Sumico
silicones

Chuo yuka

Tohatsu genuine gear oil

G17

4st engine oil

1207B 1741

Molybdenum grease

518

Silicone grease

LOR
#2000

Teflon grease

1342 1373B 1401

Waterproof grease OBM

Low temperature resistant lithium

grease

Oil pressure switch

Heat resistant grease

Oil
Oil
Three Three Three
Three Three
center Loctite
Konishi center
bond bond bond research
bond bond
research

Plug cap
Electrical
components

Adhesive

Instaneous adhesive

Gasket seal agent

271

Rusting and leaking prevention

screw lock agent

Part name

High-strength screw lock agent

Loctite

Low-strength screw lock agent

High-strength screw lock agent

Item name

Lip
Periphery (when installation)
Inner surface
Thread
Periphery (when installation)
Periphery (when installation)
Periphery (when installation)
Spline
Spline
Entire
Entire
Entire
Entire
Lip
Periphery (when installation)
Periphery (when installation)
Periphery (when installation)

72

G17

LOR Centax FM#101

L2
531

Bracket

Steering shaft
arm

PTT

Bottom cowl

Oil seal

Seal rubber (apron)

Sliding surface
Spline
When installing
Inner thread

Thread (after degrease)

Sliding surface

Center

Shift arm
Shift lever shaft
Apron

Cylinder pin bushing (upper lower)

PT oil
O-ring
Bushing (hook lever)
Seal ring (hook lever)
Throttle arm
Throttle cam
Link rod assy

Lip
Periphery (when installation)
Periphery (when installation)
Periphery (when installation)
Fill with grease from nipple
Fill with grease from nipple
Sliding surface

Roller bearing
Needle bearing
Swivel bracket steering shaft
Swivel bracket (bracket bolt)
Tilt stopper bushing
Tilt stopper grip
Tilt stopper (shaft)
Mount bracket
O-ring (steering shaft)
Co-pilot bolt
Nut 7/8(bracket bolt)
Upper mount bolt, nut

Remark

ATF

Mori
LMKS-64 paste
902
500

O-ring
Propeller shaft
housing

PTT fluid

1207B 1741

Tohatsu genuine gear oil

518

Shinetsu
Sumico
silicones

4st engine oil

LOR
#2000

Molybdenum grease

1401

1373B

Chuo yuka

Silicone grease

1342

Teflon grease

Oil
Oil
Three
Three Three
center Loctite
Konishi center
bond research
bond bond
research

Waterproof grease OBM

Three Three
bond bond

Low temperature resistant lithium

grease

Heat resistant grease

Adhesive

Instaneous adhesive

Gasket seal agent

271

Rusting and leaking prevention

screw lock agent

Part name

High-strength screw lock agent

Loctite

Low-strength screw lock agent

High-strength screw lock agent

Item name

Inner, outer
Lip
Sliding surface
Sliding surface

Joint

Sliding surface
Sliding surface, shift rod insertion area
Bonded part apron and seal rubber
Bottom cowl groove

73


Part Name
Engine

Item
Compression Pressure (400r/min )
*Remove all spark plugs and measure after
warming with the throttle fully open and safety
lanyard removed.
Valve clearance
Valve Stem Outer Diameter

Valve (IN/EX)

Valve Guide Inner Diameter

Clearance between valve guide and valve stem
Width of contact with valve seat

Valve spring
Rocker arm

Piston

Free Length
Rocker Arm Inner Diameter
Shaft Outer Diameter
Shaft Clearance
Outer Diameter (Measure outer diameter at
12mm above lower end of piston skirt)
Clearance between piston and cylinder liner
Carbon build up on piston crown and in ring
grooves

Standard Value
1.4 Mpa (14.27 /c)
IN 0.150.25 mm
EX 0.250.35 mm
IN 5.4755.490 mm
EX 5.4555.470 mm
IN 5.5005.512 mm
EX 5.5005.512 mm
IN 0.0100.037mm
EX 0.0300.057mm
IN 1.311.51 mm
EX 1.311.51 mm
IN 38.68mm
EX 38.68mm
16.00016.018 mm
15.98315.994 mm
0.0060.035mm
69.9669.98 mm
0.0200.055 mm

Engine Parts

Piston ring

Action to be taken

Adjust into specified range.

Replace if over specified limit.
Replace if over specified limit.
Replace if over specified limit.
Replace or repair if over specified limit.
Replace if over specified limit.
Replace if over specified limit.
Replace if over specified limit.
Replace if over specified limit.
Replace if over specified limit.
Replace with new parts.

Top 0.040.08 mm
Second 0.040.08 mm
Oil 0.030.13 mm
Piston pin hole inner diameter
17.00217.008 mm
Piston pin outer diameter
16.99617.000 mm
Clearance between piston pin and pin hole
0.0020.012 mm
Ring end gap
Top 0.200.35 mm
*Measurement of ring end gap : If ring gauge Second 0.350.50 mm
is not available, use cylinder bore top or bottom
Third 0.200.70 mm
with small wear.
Cam rod bearing inner diameter
42.00042.025 mm

Replace with new parts.

Clean and remove built up. Replace if
nessesary.
Replace with new parts.
Replace with new parts.
Replace with new parts.
Replace with new parts.
Replace with new parts.
Replace with new parts.
Replace with new parts.
Replace with new parts.

Replace with new parts.

Distortion or damage on cylinder head mating

surface

0.05 mm or less

Deflection of 0.06 mm or more. There is

scraches that affect sealing performance.

Build up of carbon in combustion chamber

Cooling water passage clogged

Corrosion on the mating surface

Cylinder liner inner diameter

70.00070.015 mm

Distortion or damage on cylinder head mating

surface

0.05 mm or less

Deflection of 0.06 mm or more. There is

scraches that affect sealing performance.

Deposits in water jacket

Replace with new parts.

Repair by posishing the surface plate, starting
with #240 to #400 grit sandpaper and finishing
with #600 grit sand paper.
Replace if over specified limit.
Clean and remove built up.
Clean and remove built up.
Repair or replace depending on the extent of
damage.
Replace if over specified limit.
Repair by posishing the surface plate, starting
with #240 to #400 grit sandpaper and finishing
with #600 grit sand paper.
Replace if over specified limit.
Clean and remove built up.

Clearance between piston ring and piston ring

Piston pin

Functional limit
When the difference in compression between
cylinders exceeds 0.1 Mpa (14.9 psi) 1.05 kg/cm2 When abnormally higher than standard value

Cylinder head

Cylinder block
Mating surface scratches and wear

Engine Anode

When the cylinder liner cannot be repaired using

#400 to #600 grift sandpaper due to deep
scratching or scuffing to the sliding surface in
contact with the piston or when the difference
Replace if over specified limit.
between the minimum and maximum points of
wear in the liner bore is 0.06mm (0.0024 in) or
more.
When anodes shows excessive corrosion(erode
Replace with new parts.
1/3 of original size)

74

Part Name
Connecting rod

Engine Parts

Crank shaft

Item
Small End Inner Diameter
Big End Oil Clearance
Big End Side Clearance
Crankshaft runout : Use V blocks to support
crankshaft at journals of both ends.
Main journal outer diameter
Crank pin outer diameter
Metal bearing oil clearance
Thrust clearance
Oil seal damage
Cam Height

Cam shaft
Journal Outer Diameter
Wear, damage and stretch

Standard Value
17.00517.018 mm
0.0200.045 mm
0.0100.020 mm

Functional limit
-

Fuel parts

less than 0.05 mm

0.05 mm

Replace with new crank shaft assy.

39.98640.000 mm
37.98638.000 mm
0.0200.041 mm
0.050.15 mm
IN 20.72520.825mm
EX 20.75520.855mm
Pulley side 41.91541.925mm
Middle and oil pump side 41.94541.955mm

Replace with new parts.

Replace with new parts.
Replace with new parts.
Replace with new parts.
Replace with new parts.
Replace if over specified limit.
Replace if over specified limit.
Replace if over specified limit.
Replace if over specified limit.
Replace with new parts if part is worn, damage or
stretched out of shape.
Replace with new parts.
Replace with new parts.

Wear and damage on O-rings

Fuel pressure
Wear and damage on seal ring

289299MPa (2946.983048.95/c)
-

Float

Standard plug

DCPR6E

Plug gap
Primary coil resistance

Charge coil resisrtanceBetween Y-Y-Y

Resistance Between Terminals

0.8mm0.9mm
4.5 k0.67520
19.5 k3.920
24.5 k5.1 (with spark plug cap
Approx. 3,000 r/min
Approx. 6,200 r/min
252W
1500r/min 12V - 18A or more
4000r/min 12V - 21A or more
0.3520 20
11.412.66 (25)

Operating condition

Wear and damage on seals and grommets

Operating condition

T.P.S

Clearance between encoder ring and CPS

Pulser coil resistanceBetween L/B-G/R
Resistance between terminals

ISC valve

Resistance between terminals

Engine temp. sensor

Resistance between terminals

0.70.9 mm
18520% 20
5kor less
between S1-S2 30 k3
between S3-S4 30 k3
4.244.86k (46)
1.902.10 k (2426)

When parts are worn or damaged

When parts are worn or damaged
When oarts show deterioration or contamination by
fuel
When electrodes show excessive wear, carbon
deposit or damage on insulator.
No clicking sound when volts is applied to the
terminal.
When parts are worn or damaged
No operating noise when volts is applied to the
terminal.
-

T-MAP sensor

Resistance between terminals

Rectifire

Timing belt
Fuel rail
Fuel regulator
Vapor separator

Spark plug

Ingition coil
E.C.U

Magneto (Alternator)

Fuel injector

F.F.P
Electric parts

Crank position sensor

Secondary Coil Resistance

Low speed ESG
High speed ESG
Alternator Output
Generation performance

Action to be taken
Replace with new parts.

Replace with new parts.

Replace with new parts.
Adjust into specified range.
Replace with new parts.
Replace with new parts.

Replace with new parts.

Adjust into specified range.
Replace with new parts.
Replace with new parts.

Replace with new parts.

Replace with new parts.

Replace with new parts.

Resistance between terminals

Output
Brush length
Commutator undercut
Commutator outer diameter
Rated voltage
Rated timing
Exciting current
Exciting coil resistance

between Vout TEMP. - Vout MAP Open

between Vout TEMP. - Vcc Open
Refer tester check chart
12 V 1.4kW
16 mm
0.50.8 mm
29 mm
12DC
30sec80A
4A
4.420%

12 mm
0.2 mm
28 mm
-

Replace with new parts.

-

Capacity

20A2, 30A1

Blown

between Vout TEMP. - GND 2k10% 25

Starter motor

Starter solenoid

Fuse

Replace with new parts.

Replace with new parts.

75

After repaireng the cause of the burn-out, replace

with a new fuse.

Part Name

Pump assy

Power Trim & Tilt parts

Motor

Trim cylinder

Tilt cylinder

PTT solenoid

Item
Standard Value
Oil pump
Gear pump
Relief valve opening pressure (Tilted UP)
12.315.7MPa
Relief valve opening pressure (Tilted DN)
4.96.9MPa
Spool check valve opening pressure
0.2MPa
Oil capacity
325
Recommended oil type
ATF(DEXRON
Rated voltage
12VDC
Rated timing
60sec
Output
250W
Direction of rotation
Forward/Reverse
Circuit breaker (Type)
Bimetal
ONOFF 40 sec or more 36A30 sec or less25
Brush length
9.75
Commutator (Outer diameter)
22.0
Undercut depth 1.8
Piston diameter
48
Piston rod diameter
41
Stroke
46mm
Piston diameter
32
Piston rod diameter
16
Stroke
101mm
Shock absorber valve opening pressure
19.624.5MPa
Rated voltage
12VDC
Rated timing
60sec
Exciting current
4A or less
Exciting coil resistance
4.16 - 6.24
Wax type with pressure relief valve

Cooling system

Thermostat

Opening and closing of thermostat valve

Valve opening starting temperature 58.5

61.5
Valve full open temperature 75 or more

Lower unit

Pump impeller

Wear and cracks

Pump case liner

Guide plate
Anode

Wear
Wear
Corrosion
Damage to bearing
Wear and damage on lip of oil seal
Backlash
Damage to bearing

Other

Drive shaft

Shaft runout

Propeller

Wear on lip of oil seal

Wear, wraping, cracking, chipping

0.3 mm or less (Using both center holes for

reference)
-

Oil seals

Wear, damage

Propeller shaft

Functional limit
5.00
20.4
1.0mm
When the valve opens even slightly at ambient
temperature.

Action to be taken
Replace with new parts.
Replace with new parts.
Replace with new parts.
-

Check valve opening temperature by immersing

the thermostat in water and gradually increasing
water temperature

Replace with new parts.

Wear, crack or damage on tips and upper and

lower surface lips
When anode shows excessive corrosion
0.4mm
When depth of wear is 0.1mm
When lip area shows deterioration, heat
discoloration, or damage or when reduces
interference to 0.5mm (0.02 in) or less

Replace with new parts.

Replace when wear is excessive.
Replace when wear is excessive.
Replace with new parts.
Replace with new parts.
Adjust or replace
Replace with new parts.
Replace with new parts.
Replace with new parts.

76

77

78

79

80

81


Blade X

Pitch
X
(mm)

Dia.
(mm)

Part No.

Remedy

17

X X

Newly added

16

X X

Newly added

15

X X

14

X X

13

X X

12

X X

11

X X

X X

X X

B1

4 blade

82

83


,


!
, .

84

85