MFS2A_cover_E_070524.qxd 07.5.

24 5:06 PM ページ 1

OB No.003-21058-0 OB No.003-21058-0
07-04 NB-2600
Printed in Japan 07-04 NB-2600
MFS2_sec00_070524.qxd 07.5.24 3:04 PM ページ 1

Introduction
Before reading this manual
This service manual provides information that is needed for inspection, service and repair of applicable
outboard motors. For information about operation of the products that are not described in this
document, refer to the owners manual. For our customers' safe and comfortable use of the products
for long term, it is essential to maintain the performance and quality of the outboard. To ensure this,
the maintenance and service have to be done properly by service technicians with fundamental
knowledge and skills. This manual is utilized so that our customers can always use their outboard
motor with full satisfaction.

Information for securing of safety

Safety Statements
The following safety statements are found throughout this manual and indicate information
which, if ignored, could result in fatal safety hazards or property damages:

DANGER
Indicates the presence of a hazard which, if
ignored, will result in severe injury or
death.

WARNING
Indicates the presence of a hazard or an
unsafe activity which, if ignored, could
result in severe injury or death.

CAUTION
Indicates the presence of a hazard or an
unsafe activity which, if ignored, could
result in minor personal injury or damage to
the products or facilities.

Provides an important one-point advice.

4st 2/2.5/3.5 2007 i

MFS2_sec00_070524.qxd 07.5.24 3:04 PM ページ 2

Description of Pictogram
The following symbols represent the contents of individual chapters.

Service Fuel System

Service Data Maintenance
Information (Carburetor)

Electrical
Power Unit Lower Unit Bracket
System

OK Wiring
r/min
Troubleshooting Accessories
Diagrams

The following symbols indicate items needed for the service.

Lubrication Tightening
Special Tool OIL Engine RPM
Oil Torque
RPM

Specified Specified
Test Run
Electrical Measurement Use Limit
Adjustment
Value Value

Example : 6 N·m ( 4 lb·ft ) [ 0.6 kgf·m ]

Specified Part

SI unit US unit Former units (conventional)

The following symbols indicate a point to which lubrication oil, sealing agent or screw-locking agent is to be applied.

4 stroke 2 stroke
Gear Oil ATF DEXRON III
Engine Oil Engine Oil
IL

IL

IL

IL
O

4st 2st GEAR ATF

Low
G G Temperature G G
RE RE RE Insulating RE
Waterproof AS Teflon® Grease AS AS AS
E E Resistant E Grease E
Grease TEFLON
Lithium INS
OBM TEF Grease LIT INS

O Screw Lock Gasket Seal

Oil Compound IL BO
-C [Konishi Bond] Agent Agent
[Shinetsu Silicon] O N
M • G17 D [Loctite®] [Loctite®]
P.
LT

LT

S.O.C
GM
SOC G17 • 271 271 • 518 518
271

Screw Lock Screw Lock

Gasket Seal
Agent Agent
Agent
B [Three Bond®] B [Three Bond®] B
1107 T 1342 T 1373B T
• 1107
• 1342 • 1373B

ii 4st 2/2.5/3.5 2007

MFS2_sec00_070524.qxd 07.5.24 3:04 PM ページ 3

1.Service Information 10)

11)
Inspection of Gear Case (for leakage) …… 3-11
Inspection of Spark Plug …………………… 3-12
1 Identification (Engine Serial Number) 1-2
12) Inspection of Compression Pressure …… 3-13
2 Securing of work safety ………………… 1-2
13) Inspection and Adjustment of Valve Clearances … 3-14
1) Fire Prevention ……………………………… 1-2
14) Adjustment of Throttle Cable ……………… 3-16
2) Ventilation …………………………………… 1-2
15) Inspection of Gear Shift Operation ……… 3-17
3) Protection …………………………………… 1-2
16) Flushing with Water ………………………… 3-18
4) Genuine Parts ……………………………… 1-2
17) Inspection of Idle Engine Speed ………… 3-18
5) Tools ………………………………………… 1-3
18) Inspection of Ignition Timing ……………… 3-19
6) Recommendations on Service …………… 1-3
19) Inspection of Anode ………………………… 3-19
7) Cautions in Disassembling and
20) Replacement of Anode …………………… 3-19
Assembling Components ………………… 1-4
21) Inspection of Propeller……………………… 3-19
22) Inspection of Thermostat ………………… 3-20
3 Tools and Instruments…………………… 1-5
23) Inspection of Cooling Water Passages…… 3-21
1) Test Propeller ……………………………… 1-5
24) Greasing Points …………………………… 3-22
2) Instruments ………………………………… 1-5
3) List of Special Tool ………………………… 1-6
4 Predelivery Inspection…………………… 1-7 4.Fuel System (Carburetor)
1) Steering Handle …………………………… 1-7 1 Special Tool ………………………………… 4-2
2) Gear Shift …………………………………… 1-7 2 Parts Layout ………………………………… 4-3
3) Engine Oil …………………………………… 1-7 Fuel Tank ……………………………………… 4-3
4) Gear Oil ……………………………………… 1-7 Carburetor ……………………………………… 4-4
5) Fuel Tank and Fuel Line …………………… 1-8 3 Inspection Items …………………………… 4-5
6) Rigging ……………………………………… 1-8 1) Inspection of Fuel Feed System Piping … 4-5
7) Inspection of Tilt Stopper ………………… 1-8 2) Draining Fuel………………………………… 4-6
8) Inspection of Stop Switch ………………… 1-9 3) Inspection of Fuel Tank and Fuel Tank Cap … 4-7
9) Cooling Water Check Port ………………… 1-9 4) Inspection of Fuel Cock …………………… 4-7
10) Idle Operation ……………………………… 1-9 5) Inspection of Fuel Filter …………………… 4-7
11) Propeller Selection ………………………… 1-10 6) Inspection of Carburetor …………………… 4-8
12) Inspection of Forward and Reverse Shifts 1-10 7) Assembling of Carburetor ………………… 4-9
5 Break-in Operation………………………… 1-11 8) Assembling Carburetor …………………… 4-10
6 Test Run ……………………………………… 1-11 9) Adjustment of Throttle Cable ……………… 4-11
7 Checks After Test Run…………………… 1-12 10) Inspection of Idle Engine Speed ………… 4-12
11) Adjustment of Idle Engine Speed ………… 4-12

2.Service Data
1 Outline Dimensons………………………… 2-2 5.Power Unit
1）Engine Dimensions ………………………… 2-2 1 Special Tools ……………………………… 5-2
2）Clamp Dimensions ………………………… 2-3 2 Parts Layout ………………………………… 5-3
2 Cooling Water System Diagram ……… 2-4 Engine …………………………………………… 5-3
3 Wiring Diagram……………………………… 2-5 Recoil Starter …………………………………… 5-4
4 Specifications ……………………………… 2-6 Oil Pan…………………………………………… 5-5
5 Maintenance Data ………………………… 2-8 Cylinder ………………………………………… 5-6
6 Tightening Torque Data ………………… 2-12 Cam Shaft & Valve …………………………… 5-7
7 Sealant Application Locations ……… 2-14 Piston & Crank Shaft…………………………… 5-8
3 Inspection Items …………………………… 5-9

3.Maintenance 1) Inspection of Compression Pressure …… 5-9

2) Inspection of Valve Clearance …………… 5-10
1 Special Tool ………………………………… 3-2
3) Removing Power Unit ……………………… 5-12
2 Inspection Schedule ……………………… 3-3
4) Removal and Disassembly of Crank Case Head … 5-13
3 Inspection Items …………………………… 3-4
5) Inspection of Crank Case Head…………… 5-14
1) Inspection of Top Cowl …………………… 3-4
6) Assembly of Crank Case Head …………… 5-14
2) Inspection of Fuel System ………………… 3-4
7) Installation of Crank Case Head ………… 5-14
3) Inspection of Fuel Tank …………………… 3-4
8) Disassembly of Power Unit………………… 5-15
4) Inspection of Fuel Cock (Fuel Filter) ……… 3-5
9) Removal of Rocker Arm …………………… 5-17
5) Inspection of Fuel Cock …………………… 3-5
10) Inspection of Rocker Arm and Pivot ……… 5-18
6) Replacement of Engine Oil………………… 3-6
11) Inspection of Push Rod Plate……………… 5-18
7) Inspection of Gear Oil Quantity …………… 3-8
12) Inspection of Push Rod …………………… 5-18
8) Inspection of Water Pump ………………… 3-8
13) Disassembly of Cylinder Block …………… 5-19
9) Replacement of Gear Oil ………………… 3-10
14) Inspection of Slinger (Splash Lubrication) … 5-20

4st 2/2.5/3.5 2007 iii

MFS2_sec00_070524.qxd 07.5.24 3:04 PM ページ 4

15) Inspection of Lifter ………………………… 5-20 21) Disassembly of Drive Shaft ……………… 6-14
16) Inspection of Cam Shaft …………………… 5-21 22) Inspection of Drive Shaft…………………… 6-14
17) Inspection of Piston Outer Diameter ……… 5-22 23) Inspection of Forward Gear and Pinion Gear
18) Inspection of Cylinder Inner Diameter …… 5-22 (A and B Gears) ……………………………… 6-15
19) Inspection of Piston Clearance …………… 5-22 24) Assembly of Drive Shaft …………………… 6-15
20) Inspection of Piston Ring Side Clearance … 5-23 25) Disassembly of Gear Case………………… 6-16
21) Inspection of Piston Rings ………………… 5-23 26) Inspection of Gear Case …………………… 6-17
22) Inspection of Piston Pin …………………… 5-24 27) Assembly of Gear Case …………………… 6-17
23) Inspection Connecting Rod Small End Inner Diameter … 5-24 28) Installation of Clutch Cam and Cam Rod … 6-18
24) Inspection of Connecting Rod Big End Inner Diameter … 5-24 29) Installation of Forward Gear and Pinion Gear
25) Inspection of Connecting Rod Big End Side Clearance … 5-25 (A and B Gears) ……………………………… 6-18
26) Inspection of Crank Shaft ………………… 5-25 30) Installation of Pump Case (Lower) ……… 6-18
27) Disassembly and Assembly of Crank Shaft… 5-26 31) Installation of Water Pump ………………… 6-19
28) Inspection of Crank Pin Oil Clearance …… 5-27 32) Installation of Propeller Shaft Housing …… 6-20
29) Installation of Piston and Connecting Rod … 5-28 33) Filling with Gear Oil ………………………… 6-21
30) Removal of Valves and Springs…………… 5-29 34) Installation of Lower Unit…………………… 6-21
31) Inspection of Valve Springs ……………… 5-29
32) Inspection of Valve ………………………… 5-30 7.Bracket
33) Inspection of Valve Guide ………………… 5-30 1 Parts Layout ………………………………… 7-2
34) Inspection of Valve Seat …………………… 5-31 Clamp Bracket & Swivel Bracket……………… 7-2
35) Correction of Valve Seat …………………… 5-32 Drive Shaft Housing & Gear Case …………… 7-3
36) Installation of Valves ……………………… 5-35 Shift ……………………………………………… 7-4
37) Assembly of Cylinder and Crank Case…… 5-36 Tiller Handle & Throttle ………………………… 7-5
38) Assembly to Power Unit …………………… 5-39 Cowl ……………………………………………… 7-6
39) Assembly of Rocker Arm ………………… 5-40 2 Assembling Procedure…………………… 7-7
40) Assembly of Power Unit …………………… 5-41 1) Assembly of Clamp Bracket ……………… 7-7
41) Disassembly of Recoil Starter …………… 5-42 2) Installation of Steering Stopper …………… 7-7
42) Inspection of Recoil Starter ……………… 5-42 3) Installation of Drive Shaft Housing ……… 7-8
43) Assembly of Recoil Starter ………………… 5-43 4) Installation of Water Pipe ………………… 7-8
5) Installation of Tiller Handle ………………… 7-9
6.Lower Unit 6) Adjustment of Throttle Cable ……………… 7-10
1 Special Tools ……………………………… 6-2
2 Parts Layout ………………………………… 6-3 8.Electrical System
Drive Shaft Housing & Gear Case …………… 6-3 1 Special Tools ……………………………… 8-2
Gear Case (Drive Shaft) ……………………… 6-4 2 Parts Layout ………………………………… 8-3
Gear Case (Propeller Shaft) ………………… 6-5 Magneto ………………………………………… 8-3
Shift ……………………………………………… 6-6 3 Ignition System and Ignition Control System … 8-4
3 Inspection Item …………………………… 6-7 1) Inspection of Ignition Spark ……………… 8-4
1) Draining Gear Oil …………………………… 6-7 2) Inspection of Plug Cap …………………… 8-5
2) Removing Propeller ………………………… 6-7 3) Inspection of Igniter ………………………… 8-6
3) Removing Lower Unit ……………………… 6-8 4) Inspection of Stop Switch ………………… 8-7
4) Disassembly of Water Pump ……………… 6-8
5) Inspection of Water Pump ………………… 6-9
6) Removing Propeller Shaft Housing Ass'y 6-10
9.Troubleshooting
1 Troubleshooting List……………………… 9-2
7) Disassembly of Propeller Shaft Ass'y …… 6-10
2 Power Unit …………………………………… 9-3
8) Inspection of Propeller Shaft ……………… 6-10
Trouble 1 Engine will not start or is a little hard to start.
9) Assembly of Propeller Shaft Ass'y ……… 6-11
(Recoil starter operates normally.) ……… 9-3
10) Disassembly of Propeller Shaft Housing … 6-11
Trouble 2 Engine starts but stalls soon. … 9-5
11) Inspection of Propeller Shaft Housing …… 6-11
Fuel System………………………… 9-5
12) Assembly of Propeller Shaft Housing …… 6-12
Ignition System …………………… 9-6
13) Removing Pump Case (Lower) …………… 6-12
Compression Pressure …………… 9-7
14) Disassembly of Pump Case (Lower)……… 6-13
Trouble 3 Idle engine speed will not stabilize. … 9-8
15) Assembly of Pump Case (Lower) ………… 6-13
Trouble 4 Rough acceleration.……………… 9-9
16) Removing Clutch Cam and Cam Rod …… 6-13
Trouble 5 Gear shifting cannot be made normally. … 9-10
17) Disassembly of Clutch Cam and Cam Rod 6-13
18) Inspection of Clutch Cam and Cam Rod … 6-13
19) Assembly of Clutch Cam and Cam Rod … 6-13
20) Removing Drive Shaft ……………………… 6-14

iv 4st 2/2.5/3.5 2007

MFS2_sec00_070524.qxd 07.5.24 3:04 PM ページ 5

INDEX

1 Service Information

2 Service Data

3 Maintenance

4 Fuel System (Carburetor)

5 Power Unit

6 Lower Unit

7 Bracket

8 Electrical System

9 Troubleshooting OK

4st 2/2.5/3.5 2007 v

MFS2_sec00_070524.qxd 07.5.24 3:04 PM ページ 6

vi 4st 2/2.5/3.5 2007

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 1

1
Service Information

1 Identification (Engine Serial Number) …… 1-2 2) Gear Shift ………………………………… 1-7

2 Securing of work safety …………… 1-2 3) Engine Oil ………………………………… 1-7
1) Fire Prevention …………………………… 1-2 4) Gear Oil …………………………………… 1-7
2) Ventilation ………………………………… 1-2 5) Fuel Tank and Fuel Line ………………… 1-8
3) Protection ………………………………… 1-2 6) Rigging …………………………………… 1-8
4) Genuine Parts …………………………… 1-2 7) Inspection of Tilt Stopper………………… 1-8
5) Tools ……………………………………… 1-3 8) Inspection of Stop Switch ……………… 1-9
6) Recommendations on Service ………… 1-3 9) Cooling Water Check Port ……………… 1-9
7) Cautions in Disassembling and 10) Idle Operation …………………………… 1-9
Assembling Components ……………… 1-4 11) Propeller Selection ……………………… 1-10
3 Tools and Instruments ………………… 1-5 12)Inspection of Forward and Reverse Shifts … 1-10
1) Test Propeller …………………………… 1-5 5 Break-in Operation ……………………… 1-11
2) Instruments ……………………………… 1-5 6 Test Run ……………………………………… 1-11
3) List of Special Tool ……………………… 1-6 7 Checks After Test Run ………………… 1-12
4 Predelivery Inspection ………………… 1-7
1) Steering Handle ………………………… 1-7
MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 2

Service Information
1. Identification (Engine Serial Number)
Engine serial number is stamped on the swivel bracket of
outboard motor body.

1 Model Name
2 Model Type Tokyo, Made in Japan
3 Serial Number 2006 Model F3.5A1 3BR 2
SERIAL No. XXXXXXXX 3
RATED POWER kW
FULL THROTTLE RANGE
5000 6000 r / min
MASS 18 20 kg

2. Securing of work safety

1) Fire Prevention
Gasoline is hazardous material and very flammable. Do not
handle gasoline near ignition source such as spark or static
electricity.

2) Ventilation
Exhaust gas or gasoline vapor is hazardous for human
health. Be sure to ventilate well when working indoors.

3) Protection
Wear a pair of goggles, working gloves and safety shoes to
protect your body from chemicals and oils and eyes from
particles generated by grinding or polishing. Avoid contact
with oil, grease or sealing agent to the skin. In case of
exposure to such matters, wash away with soap and warm
water immediately.

4) Genuine Parts
Use parts and/or chemicals that are genuine items or
recommended.

1-2 4st 2/2.5/3.5 2007

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 3

5) Tools
Use specified special tools to prevent damage to parts and
to perform work safely and correctly. Be sure to follow
installation procedures described in this manual and use
tightening torque specified.
1

3R0728150
3AC728710

6) Recommendations on Service
Remove foreign substances and dirt from outboard motor
and individual parts by cleaning. Apply recommended oil or
grease to rotating areas and sliding surfaces. Always
perform verifications such as ensuring smooth movement
and sealing.

4st 2/2.5/3.5 2007 1-3

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 4

Service Information
7) Cautions in Disassembling and
Assembling Components
(1) Secure outboard motor to dedicated stand firmly.

(2) Take special care not to scratch painted surface or mating

surfaces of cylinder and crankcase.

(3) Replace unreusable parts such as packings, gaskets, O

rings, oil seals, spring pins or split pins with new ones after
they were removed. Replace deformed snap rings with new
ones.
5 4
16 18 2
3
Fig.3-7 16

(4) When replacing parts, be sure to use genuine parts. For

4
fluids such as gear oil, use genuine product. 1-2
5

1-2 1-1
1-2 4
5

(5) Be sure to use special tools that are specified, and perform 1-2
1-4

the work properly. 1-3 1-1 1-1 14

8
1-3 1-4
7
6
(6) When reassembling parts, use their mating marks. For parts 1-2
1

without mating marks, simple marking makes reassembling

easier. Use applicable parts list for reference. Refer to
applicable parts list.

(7) Clean individual parts that have been removed, and check
their condition.

(8) When reassembling parts, take sufficient care also for details
such as fit, repair limits, air tightness, cleanliness of oil holes
for lubrication and greasing, packings, wirings and piping.
For components using many bolts and nuts for assembling,
such as cylinder head and crankcase, tighten all the
fasteners evenly to their specified torque clockwise in two or G
RE
AS
E

three stages, inner ones first and then outer ones. (Reverse LIT
LIT
the order when disassembling.)

(9) When installing bearings, bring the flat (numbered) side of

the component to the special assembling tool.

(10) When installing oil seals, be careful not to scratch the

surface of the lip that contacts with the shaft, and install them
in correct orientation. Apply recommended grease to the lip
before installation.
35
45
110
(11) When applying liquid packing, take sufficient care of the 200

thickness and quantity. Excessive application may ooze out, 66

adversely affecting interior of the crankcase. Use adhesive 200

after thoroughly reading the instructions. 50

ø66~ø70 hole
(12) When servicing power unit, use of wooden work board
makes the work easier.
Power Unit Work Table (mm)

1-4 4st 2/2.5/3.5 2007

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 5

3. Tools and Instruments

1) Test Propeller
P/N. 3AB-64111-0
Outer diameter : 120mm
Width : 16mm
(Reference value)
1
Speed at WOT
Model
(Wide Open Throttle) (r/min)

F2A/F2.5 A 4,500 - 5,500

F3.5 A 5,000 - 6,000

This test propeller has been designed for break-

in operation and load test operation.
The engine speed at WOT varies depending on
the conditions such as the level or water or air
temperature, and thus, the measurement is not
for confirmation or power of the engine.

2) Instruments
For the following measuring instruments, use commercially available ones.
Circuit tester (Resistance : 1Ω, 10Ω, 10 kΩ, AC voltage : 30 - 300V, DC voltage : 30V)
Vernier calipers (JIS B 7507 : M1 type, 300 mm)
Micrometer (JIS B 7502 : minimum graduation of 0.01 mm, outer, 0 - 25 mm, 25 - 50 mm, 50 - 75 mm)
Cylinder gauge (JIS B 7515 : 4 - 6 mm, 10 - 25 mm, 25 - 50 mm, 50 - 75 mm)
Ring gauge (JIS B 7420 : ø5.5, ø14, ø20, ø47, ø55)
Dial gauge (JIS B 7503 : minimum graduation of 0.01 mm)
Thickness gauge (JIS B 7524 : 0.03 - 0.3 mm)
V block (JIS B 7540)
Surface plate (JIS B 7513 : 500 mm x 500 mm)
Dial gauge magnet base or dial gauge stand

4st 2/2.5/3.5 2007 1-5

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 6

Service Information
3) List of Special Tool

Spring Pin Tool A Spring Pin Tool B Thickness Gauge Center Plate 3
P/N. 345-72227-0 P/N. 345-72228-0 P/N. 353-72251-0 P/N. 3AB-99701-0
Used in combination with driver rod and
Removing spring pin Installing spring pin Measuring gaps bearing attachment to locate lower gear
case bearing

Driver Rod 3 Bearing Attachment 3 Bearing Install Tool 2 Tachometer

P/N. 3AB-99702-0 P/N. 3AB-99905-0 P/N. 3AB-99900-0 P/N. 3AC-99010-0
Used in combination with center plate and Used in combination with driver rod and Measuring engine revolution
center plate to locate lower gear case Installing drive shaft bearing.
bearing attachment bearing speed

Compression Gauge Valve Spring Compressor Attachment Flywheel Holder Universal Puller Plate
P/N. 3AC-99030-0 P/N. 3AB-99076-0 P/N. 3AC-99200-0 P/N. 3AC-99750-0
Measuring compression Removing or installing valve Removing or installing
Removing bearings
pressure springs flywheel

3B7-72783-0 3B7-72784-0

Bearing Attachment 2 Bearing Attachment 4 Flywheel Puller Kit

P/N. 3BR-99905-0 P/N. 3BV-99905-0 P/N. 3C7-72211-1

Installing bearings Installing bearings Removing flywheel

Spark Tester
P/N. 3F3-72540-0

Inspecting sparks

1-6 4st 2/2.5/3.5 2007

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 7

4. Predelivery Inspection å ∫ c Lighter

1) Steering Handle
å Check installations for tension and play. d Heavier
∫ Adjust steering friction.
1
ç Check throttle grip for movement.
(Fully Open a / Fully Closed b)
ç ∂
c
1
∂ Adjust throttle friction.
a b
d
1 Steering Adjust Screw c Lighter d Heavier

2) Gear Shift
1. Check shift lever 1 and propeller shaft for smooth
N
movement of the shift between forward (F) and neutral (N)
while engine is operating.

3) Engine Oil
1. Set outboard motor straight ahead and vertical.

1
2. Fill with Engine Oil.

4 Stroke Engine Oil :

OIL 300cm3
300cm3 (10 fl.oz) 250cm3

3. Use oil level gauge to check oil quantity.

(Straight ahead and vertical) 1 Oil Filler Cap

CAUTION
Engine oil is removed before shipment to
prevent leakage during transportation.
IL
O

4st
4st OIL

4) Gear Oil
1. Check quantity of gear oil.
IL
O

GEAR
GEAR
Gear Oil :
OIL
180cm3 (6 fl.oz)

Spilling of oil from upper plug when removed 2

indicates that gear case is filled with specified
1
quantity of gear oil.

1 Oil Plug 2 Gasket Do not reuse.

4st 2/2.5/3.5 2007 1-7

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 8

Service Information
5) Fuel Tank and Fuel Line
1. Check that fuel tank contains sufficient amount of gasoline,
fuel line is connected and is free of leaks.

CAUTION
Since this is a 4 stroke engine model, do
not use fuel mixed with engine oil. Use of
fuel mixed with engine oil will cause engine
trouble.

6) Rigging
1. Check that clamp bracket is fixed securely to hull.

2. Check location of anti-ventilation plate relative to boat

bottom, and, if necessary, adjust to prevent decrease in
performance force and engine overheating.
a
Test-run to determine the best installation
height.
a 30 - 50 mm ( 1.2 - 2.0 in )
Location of anti-ventilation plate : Standard value
30 - 50 mm (1.2 - 2.0in) from boat bottom

7) Inspection of Tilt Stopper

1. Fully tilt up the outboard motor 1, lock with the tilt stopper
2, and then check that the holding mechanism functions
normally.
2

1-8 4st 2/2.5/3.5 2007

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 9

8) Inspection of Stop Switch

1. Press stop switch 1 hard or pull out lock 2 from stop switch 2
1 to check that engine stops.
1

9) Cooling Water Check Port

1. Check that cooling water check port 1 discharges water
during engine runs.

10) Idle Operation

1. After engine has warmed up in neutral, use tachometer to
check idle engine speed is as specified.

· Use tachometer to measure after warm up

operation.
· Set the measurement mode to 4 stroke 2 1
cylinder · 2 stroke 1 cylinder.

Idle Engine Speed :

1 High Tension Cord
RPM
1,250 - 1,350 r/min

Tachometer :
P/N. 3AC-99010-0

4st 2/2.5/3.5 2007 1-9

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 10

Service Information
11) Propeller Selection
1. Select a propeller that is best-suited to type of boat and
application.

Range of operating engine revolution at WOT

RPM
F2/2.5 : 4,500 - 5,500r/min
F3.5 : 5,000 - 6,000r/min

CAUTION
Incorrect-selection of propeller can cause
adverse effects on engine life, fuel
consumption, etc. as well as on performance.

Propeller [Marking] ［ I 7］ 3 x 7 3／8 x 7 (3 x 188 x 178) Plastic Standard

No. of Blades x
［F6/B6］ 3 x 7 3／8 x 6 (3 x 188 x 145) Plastic/Aluminum Option
Diameter x Pitch
in (mm) ［ ］ 3 x 7 3／8 x 4.5 (3 x 188 x 110) Plastic Option

12) Inspection of Forward and Reverse Shifts

Use shift lever 1 to shift the gear to forward (F) and Neutral (N). 3
1. Forward
a
Return handle grip 2 to idle speed a, and then, move shift
lever 1 toward the operator (F) quickly. N
2

2. Reverse F
In the same way as forward shift inspection, set the engine to 1
idle speed, shift into 1 to neutral (N), put up handle 3, turn
1 Shift Lever
outboard motor 180 degrees, and then, shift into forward (F)
quickly.

3. Shallow water run

In shallow water, run at the lowest possible speed while
watching the depth and obstacles.

In reverse operation, run at low speed, and do

not increase the engine speed unnecessarily. 3

WARNING
Shifting at high engine speed may cause
fall of passenger due to abrupt acceleration
and damage to gear, clutch and other
components of the outboard motor. Shift at
the lowest engine speed.

CAUTION
Shear pin is designed to be broken when
the propeller receives damaging impact.
However, it may be broken when shifting at
high engine speed because of high shear
stress applied to the pin.

1-10 4st 2/2.5/3.5 2007

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 11

5. Break-in Operation
Break-in operation is needed to smooth sliding surfaces
between components such as pistons and cylinder, piston
rings, piston pins, crank shaft, connecting rods, and intake
and exhaust valves.
Break-in Operation…10 hours
1
Time 0 10 minutes 2 hours 3 hours 10 hours
1/2 of WOT or less at 3/4 of WOT or less at 3/4 of WOT at
Operation Dead Slow or Idling approximately 3,000 approximately 4,000 approximately 4,000 Regular Operation
r/min r/min r/min
Running at the slowest WOT run for approximately 1 WOT run for approximately 2
minute can be included every minute can be included every
possible speed 10 minutes of run. 10 minutes of run.

6. Test Run
1. Start engine and check if shifting is smooth.

2. After completing warm-up operation, check idle engine

speed.

· Use tachometer to measure after warm up 1

operation.
· Set the measurement mode to 4 stroke 2
cylinder · 2 stroke 1 cylinder.
1 High Tension Cord

Idle Engine Speed :

RPM
1,250 - 1,350 r/min

Tachometer :
P/N. 3AC-99010-0

3. Shift gear into forward (F) and run at idle speed

(for approximately 10 minutes).

Trolling Engine Speed :

RPM
1,150 - 1,250 r/min

4. Run at 3,000 r/min or half of WOT for initial 2 hours, then at

4,000 r/min or 3/4 of WOT for 1 hour.

5. Check that shifting into reverse will not tilt up outboard motor
and allow water to run into boat.

Complete test run during break-in operation.

4st 2/2.5/3.5 2007 1-11

MFS2_sec01_070524.qxd 07.5.24 3:05 PM ページ 12

Service Information
7. Checks After Test Run
1. Check that power unit, lower unit and bracket are free of
looseness or play.

1
2. Check that no water is present in gear oil.

3. Check that no fuel leakage exists in the cowl.

4. Check that no oil and water leak in the cowl and no water is
present in engine oil.
1
5. If using in salt water after test run, use flushing attachment
1 Flushing Attachment (optional)
1 (optional) and fresh water to wash cooling water path by
idling engine.

1-12 4st 2/2.5/3.5 2007

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 1

2
Service Data

1 Outline Dimensons ……………………… 2-2 4 Specifications ……………………………… 2-6

1） Engine Dimensions ……………………… 2-2 5 Maintenance Data………………………… 2-8
2） Clamp Dimensions ……………………… 2-3 6 Tightening Torque Data ………………… 2-12
2 Cooling Water System Diagram……… 2-4 7 Sealant Application Locations ……… 2-14
3 Wiring Diagram …………………………… 2-5
MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 2

Service Data
1.Outline Dimensons
1）Engine Dimensions

Item Type Unit mm in

A mm/in 377 14.84

S mm/in 649 25.55
B
L mm/in 776 30.55
S mm/in 435 17.13
C
L mm/in 562 22.13
O
D mm/in 446 17.56
E mm/in 108 4.25
F mm/in 354 13.94
G mm/in 336 13.23
H mm/in 303 11.93
I mm/in 58 2.28
M

J mm/in 208 8.19

N

K mm/in 628 24.72

L mm/in 363 14.29
M mm/in 340 13.39
N mm/in 276 10.87
O mm/in 453 17.83
F P deg. 65

G H
L
D

I
C
B

P
OIL LEVE

OIL

J
K

2-2 4st 2/2.5/3.5 2007

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 3

2）Clamp Dimensions

CENTER LINE

70.5mm
(2.77in)
2
63.5mm 63.5mm
(2.50in) (2.50in)

TOP OF BOAT TRANSOM

45.5mm 45.5mm
(1.69in)
43mm

(1.79in)
ER
DIAMET 2in)
.4
36mm(1

Allowable Transom
(5.91in)
150mm

Thickness
30-58mm(1.18-2.28 in)

4st 2/2.5/3.5 2007 2-3

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 4

Service Data
2.Cooling Water System Diagram
2
1

Thermostat1

4
5
6

7
Cylinder
(with cylinder head)2

8
9 7 6
Water Discharging Water Feed
Passage in Passage in Drive
Drive Shaft Housing Shaft Housing

Cooling Water Water Pipe9

Check Port5

q
Drive Shaft
w Water Pump0
Housing8

Exhaust Gas and Cooling Water

Discharged Waterq Intakew

1Thermostat 7Water Discharging Passage in Drive Shaft Housing

2Cylinder (with cylinder head) 8Drive Shaft Housing
3Crankcase 9Water Pipe
4Flushing Plug 0Water Pump
5Cooling Water Check Port qExhaust Gas and Discharged Water
6Water Feed Passage in Drive Shaft Housing wCooling Water Intake

2-4 4st 2/2.5/3.5 2007

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 5

3.Wiring Diagram

5
1 2 2

B Br

4
B
Br

3
6

1Flywheel B: Black
2Igniter Br: Brown
3Stop Switch
4Ground
5Spark Plug
6Stop Switch Lanyard

4st 2/2.5/3.5 2007 2-5

MFS2_sec02_070524.qxd 07.5.24 4:43 PM ページ 6

Service Data
4.Specifications
Outboard Model
Item Unit
F2A F2.5A F3.5A

Dimensions (approximate)
Overall Length mm (in) 690 (27.2)
Overall Width mm (in) 363 (14.3)
S mm (in) 1,026 (40.4)
Overall Height
L mm (in) 1,153 (45.4)
S mm (in) 435 (17.1)
Transom Length
L mm (in) 562 (22.1)

Weight (approximate)
S kg (lbs) 18.4 (41)
L kg (lbs) 19.4 (43)

Performance
Max. Output kW (ps) 1.47 (2.0) 1.8 (2.5) 2.6 (3.5)
Full-Throttle Revolution Speed Range r/min 4,500 - 5,500 5,000 - 6,000
Max. Fuel Consumption L(gal.)/hr 1.0 (0.26) 1.0 (0.26) 1.4 (0.37)
Idling Speed Range (Neutral Shift) r/min 1,250 - 1,350
Trolling (Forward Shift) r/min 1,150 - 1,250

Power Unit
Engine Type 4-Stroke Gasoline Engine
No. of Cylinders 1
Total Displacement ㎤ (cu in) 85.5 (5.2)
Valve System OHV　Cross Flow
Bore x Stroke mm (in) 55 x 36 (2.17 x 1.42)
Compression Ratio 9
Shift Operation System Side Shift (Manual)
Starting System Recoil Starting
Lubrication System Wet Sump
Cooling System Water Cooling (Impeller System)
Exhaust System Below-The-Water-Exhaust
Ignition System Digital CDI
Range of Ignition Angle BTDC 7ﾟ - BTDC 25ﾟ (Electronic Control)
Spark Plug DCPR6E [NGK]
Fuel Feed System Carburetor (Horizontal Butterfly Valve System)

2-6 4st 2/2.5/3.5 2007

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 7

Outboard Model
Item Unit
F2A F2.5A F3.5A

Fuel & Oil

Type of Fuel Unleaded Gasoline (Research Octan Number 90

or over, Pump posted Octane Number 87 or over)
Fuel Tank Capacity L (US gal.) 1.0 (0.26) [Integral Fuel Tank]
Starting Fuel Enrichment System
Fuel Pumping (Feed) System
Choke Valve System
None (Gravitational System)
2
Type 4-Stroke Engine (Motor) Oil
Engine Oil

API SF, SG, SH

Grade SAE 10W-30, 10W-40
NMMA FC-W Certified 10W-30
Quantity ㎤ (fl.oz) 300 (10)
Type Hypoid Gear Oil
Gear Oil

*1 API GL-5
Grade
*1 SAE #90
Quantity ㎤ (fl.oz) 180 (6)

Lower Unit
Gear Shift Positions Forward(F) - Neutral(N)
Gear Ratio 2.15(13 : 28)
Type of Gears Spiral Bevel Gear
Clutch Dog Clutch
Propeller Shaft Driving Shear Pin
Propeller Rotation Direction Clockwise at forward (F) shift as viewed from rear

Propeller (Standard) [Marking] [I7] 3 x 7 3 8 x 7

in(mm) (3 x 188 x 178) Plastic

Bracket
No. of Trim Steps Steps 4
Trim Angle (Transom 12°) *2 Degrees -7ﾟ- +8ﾟ
Max. Tilt Angle *3 Degrees 65°
Steering Angle *4 Degrees 360°
Max. Allowable Transom Thickness mm(in) 30 - 58 (1.18 - 2.28)
*1 Requirements of both API and SAE shall be met.
*2 Angle of propeller shaft relative to horizon when transom angle is 12 degrees.
*3 Range of tilt angle
*4 Starboard-port full steering range

Warning System

Over-revolution Protection Controls engine speed to 6,300 r/ min or lower

(High Speed ESG)

Optional Parts
[F6] 3 x 7 3 8 x 6
(3 x 188 x 145) ･ Plastic
Propeller [B6] 3 x 7 3 8 x 6 ･ Aluminum
[Marking]
(No. of Blades x Diameter x Pitch)
in(mm) (3 x 188 x 145)

[ ] 3 x 73 8 x 4.5
･ Plastic
(3 x 188 x 110)

4st 2/2.5/3.5 2007 2-7

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 8

Service Data
5.Maintenance Data
Description Item Standard Values
Build up of carbon in combustion chamber

Deposits in water jacket

Wear of bore : Use cylinder gauge to measure inner diameter. 55.00mm (2.1654in)
Cylinder Block/
Cylinder Head
Seizure, cylinder liner damage, or wear

Taper

Out-of-roundness

Outer Diameter 54.96mm (2.1638in)

・Measure outer diameter at 7mm (0.28in) above lower
end of piston skirt (at right angle to piston pin).
・Piston Clearance 0.020 - 0.060mm (0.00079 - 0.00236in)

Carbon build up on piston crown and in ring grooves

Scratch on the sliding surface

Piston
Top Ring : 0.04 - 0.08mm (0.0016 - 0.0031in)

Measure side clearance between piston ring and ring groove. Second Ring : 0.03 - 0.07mm (0.0012 - 0.0028in)

Oil Ring : 0.05 - 0.15mm (0.0020 - 0.0059in)

Measure piston pin hole diameter. Pin clearance to be 0.002 - 0.012mm (0.00008 - 0.00047in).

Piston Pin Outer Diameter 14.00mm (0.5512in)

Ring End Gap

Note : Measurement of ring end
Top Ring gap : If ring gauge is not Top Ring : 0.15 - 0.30mm (0.0059 - 0.0118in)
Piston Ring available, use cylinder bore top
Engine Parts

Second Ring or bottom where the wear is Second Ring : 0.30 - 0.45mm (0.0118 - 0.0177in)
small.
Oil Ring Oil Ring : 0.20 - 0.70mm (0.0079 - 0.0276in)

Small End Inner Diameter 14.01mm (0.5516in)

Big End Oil Clearance 0.015 - 0.041mm (0.00059 - 0.00161in)

Connecting Rod
Big End Side Clearance 0.10 - 0.25mm (0.0039 - 0.0098in)

Big End Inner Diameter 20.010mm (0.78780in)

Crank pin outer diameter 19.98mm (0.7866in)

Crankshaft
Crankshaft roundness : Use V blocks to support crankshaft at
Less than 0.05mm (0.0020in) at both ends
bearings of both ends.

IN 0.06 - 0.14mm (0.0024 - 0.0055in)

Valve Clearance
EX 0.11 - 0.19mm (0.0043 - 0.0075in)

IN 5.47mm (0.2154in)
Valve Stem Outer Diameter
EX 5.46mm (0.2150in)
Intake Valve IN 5.51mm (0.2169in)
Valve Guide Inner Diameter
Exhaust Valve EX 5.51mm (0.2169in)

IN 0.018 - 0.045mm (0.00071 - 0.00177in)

Clearance between valve guide and valve stem
EX 0.025 - 0.052mm (0.00098 - 0.00205in)

Width of contact with valve seat IN 1.0mm (0.04in)

EX 1.0mm (0.04in)

Valve Spring Free Length 35.0mm (1.38in)

Cam Height (Both IN and EX) 24.04mm (0.9464in)

Journal Outer Diameter Flywheel side 11.97mm (0.4713in)

Cam Shaft
Lower unit side 12.97mm (0.5106in)

Cam Shaft Swing

Compression Pressure
Engine Block (Reference) at 500r/min 1.13MPa (164psi) 11.5kgf/㎠

2-8 4st 2/2.5/3.5 2007

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 9

Functional Limit Action To Be Taken

Clean to remove.

Clean to remove.

55.06mm (2.1677in) Replace if over specified limit.

Replace if severely damaged on the piston sliding surface, which cannot be repaired
0.06mm (0.0024in) with sand paper of No. 400 to 600, or if damaged over specified limit.
0.06mm (0.0024in)

54.90mm (2.1614in) Replace if under specified limit.

2
0.150mm (0.00591in) Replace if over specified limit.

Clean to remove.

Correct if possible (with #400 to 600 water proof sand paper), or replace.

Top Ring : 0.10mm (0.0039in)

Second Ring : 0.09mm (0.0035in) Replace if over specified limit.

Replace oil ring when top ring or second ring is replaced.
Oil Ring : 0.17mm (0.0067in)

0.040mm(0.00157in) Replace if over specified limit.

13.97mm(0.5500in) Replace if under specified limit.

Top Ring : 0.50mm (0.0197in)

Replace if the gap is over specified limit only if cylinder liner wear is less than specified
Second Ring : 0.70mm (0.00276in) limit.
Replace oil ring when top ring or second ring is replaced.

14.04mm(0.5528in) Replace if over specified limit.

0.060mm (0.00236in) Replace if over specified limit.

0.60mm (0.0236in) Replace if over specified limit.

20.015mm (0.78799in) Replace if over specified limit.

19.95mm (0.7854in) Replace if under specified limit.

0.05mm (0.0020in) Replace if over specified limit.

Adjust into specified range.

5.45mm (0.2146in)
Replace if under specified limit.
5.44mm (0.2142in)

5.55mm (0.2185in)
Replace if over specified limit.
5.57mm (0.2193in)

0.070mm (0.00276in)
0.080mm (0.00315in) Replace if over specified limit.

2.0mm (0.08in)
Repair or replace if over specified limit.
2.0mm (0.08in)
33.2mm (1.31in) Replace if under specified limit.

23.78mm (0.9362in) Replace if under specified limit.

11.95mm (0.4705in) Replace if under specified limit.

12.95mm (0.5098in)

0.03mm (0.0012in) Replace if over specified limit.

Check if rotating parts, sliding parts and sealing parts cause compression leakage.

4st 2/2.5/3.5 2007 2-9

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 10

Service Data

Description Item Standard Values

F2A F2.5A F3.5A
Setting Mark 3BV 3AB 3BR
Fuel & Lubrication Parts

Venturi Diameter φ7.5 φ9 φ13

Throttle Bore Diameter φ16 φ16 φ19
Carburetor Main Jet (MJ) ＃58 ＃62 ＃68
Main Nozzle Inner Diam. (MN) φ1.4 φ1.4 φ1.8
Slow Jet (SJ) ＃38 ＃38 ＃38
Throttle Opening (at WOT) 76ﾟ 76ﾟ 76ﾟ
Oil Level (from flange surface to float marking) 10.0mm 10.0mm 10.0mm
Range of Ignition Timing BTDC7ﾟ - BTDC25ﾟ (Electronic Control)
Spark Performance at 500r/min 5mm (0.2in) or over
Air Gap 0.2 - 0.4mm (0.008 - 0.016in)

Igniter Diode Polarity 〔Reference〕 * Measurement value with HIOKI Analog 3030
・ Red tester lead to brown (Br) lead (100Ω range)
・ Black tester lead to black (B) lead Conductive (5 to 9kΩ)
Electrical Parts

Magneto/Igniter
* Measurement value with HIOKI Analog 3030
・ Red tester lead to black (B) lead 〔Reference〕
・ Black tester lead to brown (Br) lead (100Ω range)
Non-conductive (Resistance = Infinite)

Igniter Secondary Coil Resistance

・Between high tension cord and black 〔KΩ Range〕 2.0 - 3.0kΩ
 (B) lead 〔20℃〕
 Between spark plug cap and black 5.5 - 9.5kΩ
 (B) lead
Spark Plug Cap Resistance between terminals 〔20℃〕〔kΩ range〕 3.0 - 7.0kΩ
Plug Type DCPR6E [NGK]
Spark Plug Gap Spark Plug Gap 0.8 - 0.9mm (0.031 - 0.035in)

Valve Operation Starting Temperature (Submerged) 52℃±2℃ (125ﾟF±4ﾟF)

Thermostat Valve Full Open Temperature (Submerged) 65℃±2℃(150ﾟF±4ﾟF)

Cooling System

Valve Full Open Lift (Submerged) 3.0mm (0.12in) or over

Pump Impeller Wear, Crack

Pump Case (Liner) Wear

Guide Plate Wear
Anode Wear
Clutch Spring Free Length 25.0mm (0.984in)
Bearing Wear and Damage
Propeller Shaft Oil Seal Lip Wear
Propeller Shaft Runout
Lower Unit

Bevel Gears Backlash between forward gear and pinion (A and B gears) 0.05 - 0.15mm(0.0020 - 0.0059in)
Propeller Wear, Bend, Crack, Break 188 x 178mm (7 3/ x
8 7in)
Spline (Upper) Base Tangent Length, 2 Gears 3.85mm (0.1516in)
Bearing Wear and Damage
Drive Shaft
Oil Seal Lip Wear
Drive Shaft Runout
Drive Shaft Bushing Gap between the bushing and drive shaft 0.016 - 0.073mm (0.00062 - 0.00287in)
Other

Oil Seals Wear, Damage

2-10 4st 2/2.5/3.5 2007

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 11

Functional Limit Action To Be Taken

Adjust or replace.
2
5mm (0.2in) Replace if under specified limit.
Adjust into specified range.

Replace if out of specified range.

* A digital tester may display values of reversed polarity and/or
measurement values ranging from 2 - 6MΩ.

Replace if out of specified range.

* A digital tester may display values of reversed polarity.

Replace if out of specified range.

Replace if out of specified range.

Clean to remove carbon deposit and dirt.

1.0mm (0.039in) Adjust the gap by moving side electrode. Replace if electrodes are severely worn.

Valve opens even a little under ambient temperature. Replace if out of specified range.

Since the thermostat operation has a time delay, measure

the valve open lift after maintaining the temperature at
around 65ﾟC(150ﾟF) for approximately 5 minutes.

3.0mm (0.12in) Replace if under specified limit.

The impeller is worn cracked or damaged on the tips or

Replace pump case liner and guide plate as a set.
upper and lower surface lips.
Replace if severely worn.
Replace if severely worn.
Replace if severely worn.
23.5mm (0.925in) Replace if under specified limit.
Replace if necessary.
0.4mm (0.016in) Replace if over specified limit.
0.05mm (0.0020in) Replace if over specified limit.
0.03 - 0.20mm (0.0012 - 0.0079in) Adjust or replace.
State of outer diameter reduction, blade bend or damage Replace if necessary.
3.70mm (0.1457in) Replace if under specified limit.
Replace if necessary.
0.4mm (0.016in) Replace if over specified limit.
0.5mm (0.020in) Replace if over specified limit.
0.500mm (0.01968in) Replace if over specified limit.

Lip deteriorated, degraded or damaged, or tightening

margin reduced to 0.5mm (0.020in) due to wear Replace if out of specified range.

4st 2/2.5/3.5 2007 2-11

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 12

Service Data
6.Tightening Torque Data
Screw B Tightening Torque
Fastened Components Wrench x Type of
A Pitch Fastener
N・m lb・ft kgf・m

Crankcase First Tightening Torque

6 4 0.6
10 M6 x 1.0 Bolt
Second Tightening Torque

8.8 6.5 0.9

Oil Pan First Tightening Torque

6 4 0.6
10 M6 x 1.0 Bolt
Second Tightening Torque

8.8 6.5 0.9

Connecting Rod First Tightening Torque

5 4 0.5
10 M6 x 1.0 Bolt
Second Tightening Torque

Engine 10 7 1.0

Oil Drain Bolt 10 M8 x 1.25 Bolt 18 13 1.8

Pivot Bolt 13 M8 x 1.25 Bolt 25 18 2.5

Pivot Lock Nut 10 M6 x 0.75 Nut 10 7 1.0

Intake Manifold 10 M6 x 1.0 Bolt 10 7 1.0

Flywheel 17 M10 x 1.25 Nut 43 31 4.3

Spark Plug 16 M12 x 1.25 − 18 13 1.8

Igniter 10 M6 x 1.0 Bolt 6 4 0.6

Thermostat Cap 10 M6 x 1.0 Bolt 6 4 0.6

Cylinder Head Cover 10 M6 x 1.0 Bolt 6 4 0.6

1342
Fuel Tank 1342 T
B 10 M6 x 1.0 Bolt 6 4 0.6

Power Unit Installation 10 M6 x 1.0 Bolt 6 4 0.6

B A

2-12 4st 2/2.5/3.5 2007

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 13

Value enclosed by ( ) is hex hole size.

Screw B Tightening Torque

Fastened Components Wrench x Type of
A Pitch Fastener
N・m lb・ft kgf・m
1342
Bracket Bolt 1342 T
B 13 M8 x 1.25 Nylon Nut 7 5 0.7
1342
Swivel Swivel Bracket Bolt 1342 T
B 10 M6 x 1.0 Bolt 10 7 1.0
Clamp
1342
Bracket Distance Piece 1342 T
B 10 M6 x 1.0 Bolt 6 4 0.6

Steering Stopper

Exhaust Plug
1342 T
B

B
1342

1342
10

（3/16 in）
M6 x 1.0

PT1/8
Bolt

Plug
6

5
4

4
0.6

0.5
2
1342 T

Drive Shaft Shift Rod Lever 1342

8 M5 x 0.8 Bolt 4 3 0.4
Housing 1342 T
B

Water Plug 13 M8 x 1.25 Bolt 13 9 1.3

1342
1342 T
B 10 M6 x 1.0 Bolt 10 7 1.0
Lower Unit Installation
10 M6 x 1.0 Nut 6 4 0.6
Lower Unit Extension Housing 1342
10 M6 x 1.0 Bolt 10 7 1.0
Installation 1342 T
B

1342
Pump Case (upper) 1342 T
B 10 M6 x 1.0 Bolt 6 4 0.6
1342
Propeller Shaft Housing 1342 T
B 10 M6 x 1.0 Bolt 6 4 0.6
1342
Bottom Cowl 1342 T
B 10 M6 x 1.0 Bolt 6 4 0.6

Stop Switch − M16 x 1.5 Nut 2.3 1.7 0.23

Cowl
1342
Cowl Latch 1342 T
B 10 M6 x 1.0 Bolt 6 4 0.6
1342
Top Cowl (Tilt Handle) 1342 T
B 10 M6 x 1.0 Nut 2 1.5 0.2
1342
Tiller Handle Steering Bracket 1342 T
B 13 M8 x 1.25 Bolt 13 9 1.3

M5 Bolts and Nuts 8 M5 x 0.8 Bolts and Nuts 4 3 0.4

M6 Bolts and Nuts 10 M6 x 1.0 Bolts and Nuts 6 4 0.6

Standard
Torque M8 Bolts and Nuts 13 M8 x 1.25 Bolts and Nuts 13 9 1.3

M10 Bolts and Nuts 17 M10 x 1.25 Bolts and Nuts 27 20 2.7

4st 2/2.5/3.5 2007 2-13

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 14

Service Data
7.Sealant Application Locations

Screw Lock Agent

Gasket Seal Agent

Adheasive
Lithium Grease
Resistant
Low Temperature

Waterproof Grease
Teflon Grease
Silicon Grease
4-stroke Engine Oil
Gear Oil
Applied to Remarks

LIT

OBM
TEF
SOC
Three Three Shin
Loctite Loctite Konishi Chuo Yuka etsu
Bond Bond
Silicones

Centax FM- LM- KS-

271 1342 518 1107 G１７
L2 531 902 64

Camshaft ● Area of bearings, cams and gears

Lifter ● Cam sliding face, push rod insertion area

Push Rod ● Both ends

Push Rod Plate ● Push rod pass hole end face

Rocker Arm ● Push rod sliding area, pivot sliding area

Rocker Arm Pivot ● Locker arm sliding face

Valves (IN, EX) ● Shaft area, stem head area
Valve Spring ● Whole area of the part
Retainer, Cotter ● Whole area of the part
Valve Stem Seal (IN, EX） ● Lip area and interior
Slinger Pin ● Inner face of pin insertion hole
Cylinder Block/ O-Ring (Filler Cap)
Crankcase ● Whole area of the part
Cylinder Liner ● Inner wall
Piston ● Ring grooves and circumference
Piston Rings ● Whole area of the part
Piston Pins ● Outer circumference
Connecting Rod ● Inner surface of big and small ends
Engine

Connecting Rod Cap ● Inner surface

Crankshaft Sliding area, and areas of bearings and

● gears
Oil Seal Lip area
(Crankshaft) ●

Thrust Plate Whole area of the part

(Crankshaft) ●
Crank Case-Cylinder Mating Face ●
Oil Level Gauge ● Outer circumference
● Outer circumference
Oil Seal
● Lip area
Oil Pan
Oil Seals (2 pcs. In the crank case Lip area
head) ●
Engine Base Gasket ● Both faces
Throttle Drum ● Inner surface
Intake Throttle Opener Inner surface
Manifold ●
Throttle Rod ● Both ends hole insertion area

Electrical ● Spark plug insertion area

Spark Plug Cap
Parts High tension cord area
●

2-14 4st 2/2.5/3.5 2007

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 15

Screw Lock Agent

Gasket Seal Agent

Adheasive
Lithium Grease
Resistant
Low Temperature

Waterproof Grease
Teflon Grease
Silicon Grease
4-stroke Engine Oil
Gear Oil
Applied to Remarks

LIT

OBM
TEF
SOC
Three Three Shin
Loctite Loctite Konishi Chuo Yuka etsu
Bond Bond
Silicones

Centax FM- LM- KS-

271 1342 518 1107 G１７
L2 531 902 64

Shift Lever Body ● Betweenthe body and O-Ring

Shift O-Rings (2 pcs.) ● Whole area of the part
Lever Spring ● Whole area of the part
Ceramic Ball ● Whole area of the part

Exhaust Plug ● Outer circumference of insertion area

Drive Shaft ● Threaded areaof Lever bolt and shift rod

Housing Shift Rod Lever
● Inner area of shift lever shaft insertion hole

Grommet ● Drive shaft housing contact area

Extension Bolt,Stud Bolt (Drive Shaft Housing Joint) ● Threaded area

Housing Threaded area
Nut (Drive Shaft Housing Joint) ●
Drive Shaft ● Crankshaft side spline
Ball Bearings (2 pcs.) ● At press fit
Bolts (Lower Unit) ● Threaded area
Bolts (Pump Case) ● Threaded area
Gear Oil Seal ● Lip area
Case (Pump Case Lower) ● Outer circumference, at press fit
Grommet Insertion area outer circumference, at
● press fit
O-Rings 2 pcs.
Lower Unit

● Whole area of the part

(Cam Rod Bushing)
Bolts Threaded area
(Propeller Shaft Housing) ●
O-Ring ● Whole area of the part
Propeller Lip area
Shaft Housing ●
Oil Seal
● Outer circumference, at press fit
Propeller Shaft ● Propeller contact area
Clamp Screw ● Threaded area

Tilt Stopper ● Entire circumference of shaft area

Thrust Supporter ● Sliding area

Steering Bushing ● Sliding area
Thrust Bushing ● Sliding area
Steering Stopper ● Inner area of split pin insertion hole
Bolt (Steering Stopper) ● Threaded area
Bracket
Stopper Spring ● Coil area, both ends
Stopper Lever ● Inner area of split pin insertion hole
Friction Adjust Screw ● Threaded area
Clamp Bracket ● Inside of sliding area
Swivel Bracket ● Threaded area
Bolts (Bracket) Threaded area
Nylon Nuts ●
Bolts (Distance Piece) Nuts ● Threaded area

4st 2/2.5/3.5 2007 2-15

MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 16

Service Data

Screw Lock Agent

Gasket Seal Agent

Adheasive
Lithium Grease
Resistant
Low Temperature

Waterproof Grease
Teflon Grease
Silicon Grease
4-stroke Engine Oil
Gear Oil
Applied to Remarks

LIT

OBM
TEF
SOC
Three Three Shin
Loctite Loctite Konishi Chuo Yuka etsu
Bond Bond
Silicones

Centax FM- KS-

271 1342 518 1107 G１７ LM-902
L2 531 64

Steering Bracket ● Threaded area

Bushing (Tiller Handle) ● Inner and outer faces
Throttle Shaft ● Groove area, sliding area
Lower Unit

Tiller Spring (Friction) ● Whole area of the part

Handle Inner surface
Throttle Shaft Damper ●
Bushing Whole area of the part
(Throttle Shaft) ●

Throttle Wire ● Wire area

Bolts Threaded area

(Cowl Latch) ●

Bolts
Cowl (Bottom Cowl) ● Threaded area

Bolts Threaded area

(Tiller Handle) ●

Fuel Tank Bolts (Tank Installation) ● Threaded area

Grease Nipples ● Press fit area

Engine Oil ● Copacity：300J（10fl.oz）
Gear Oil ● Copacity：180J（6 fl.oz）

2-16 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 4:43 PM ページ 1

3 3

Maintenance

1 Special Tool ………………………………… 3-2 12) Inspection of Compression Pressure … 3-13

2 Inspection Schedule …………………… 3-3 13) Inspection and Adjustment of Valve Clearances … 3-14
3 Inspection Items ………………………… 3-4 14) Adjustment of Throttle Cable …………… 3-16
1) Inspection of Top Cowl ………………… 3-4 15) Inspection of Gear Shift Operation …… 3-17
2) Inspection of Fuel System ……………… 3-4 16) Flushing with Water ……………………… 3-18
3) Inspection of Fuel Tank ………………… 3-4 17) Inspection of Idle Engine Speed ……… 3-18
4) Inspection of Fuel Cock (Fuel Filter) …… 3-5 18) Inspection of Ignition Timing …………… 3-19
5) Inspection of Fuel Cock ………………… 3-5 19) Inspection of Anode ……………………… 3-19
6) Replacement of Engine Oil ……………… 3-6 20) Replacement of Anode ………………… 3-19
7) Inspection of Gear Oil Quantity ………… 3-8 21) Inspection of Propeller …………………… 3-19
8) Inspection of Water Pump ……………… 3-8 22) Inspection of Thermostat………………… 3-20
9) Replacement of Gear Oil………………… 3-10 23) Inspection of Cooling Water Passages … 3-21
10) Inspection of Gear Case (for leakage) … 3-11 24) Greasing Points ………………………… 3-22
11) Inspection of Spark Plug ………………… 3-12
MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 2

Maintenance
1. Special Tool

Tachometer Compression Gauge

P/N. 3AC-99010-0 P/N. 3AC-99030-0
Measuring engine revolution Measuring compression
speed pressure

3-2 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 3

2. Inspection Schedule
Inspection Period
Initial 20 hours 50 hours 100 hours 200 hours
Inspection Part Inspection Item Remarks
or initial or Every or Every or Every
1 month 3 months 6 months year

Carburetor o o Disassembly, cleaning and adjustment

Fuel System

Fuel Filter Checking,

o o o o Cleaning or replacement
(Fuel Cock) and removing clogging.
Pipe damage
Piping o o o o
Leak through pipe joint

Fuel Tank o o o o Dirt, water Cleaning

Gap 0.8 - 0.9mm 3

Ignition Starting
System System

Spark Plug o o o
Removing carbon （0.031 - 0.035in）

Starter Rope o o o o Wear

o o o
Engine Oil 300cm3（10fl.oz）
Replace. Replace. Replace.

Valve Clearance o o Inspection and adjustment

Engine

Compression Pressure o Inspection

Thermostat o Rust, closing, damage

Propeller o o o o Bending, damage and wear of blades

o o o o Oil replacement or replenishment GL5, SAE90

Gear Oil
Replace. Replace. Replace. Check for water leak 180cm3（6fl.oz）
Lower Unit

Anode o o o Corrosion and wear

Water Strainer o o o o Clogging Cleaning

Water Pump Impeller o Wear and crack Replacement

Bolts and Nuts o o o Retightening

Throttle Cable o o Elongation and damage Replacement

Sliding or Rotating Parts o o o o Application of grease

4st 2/2.5/3.5 2007 3-3

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 4

Maintenance
3. Inspection Items

1) Inspection of Top Cowl

1. Push top cowl to check for looseness and state of closing.

2) Inspection of Fuel System

Check piping
1. Remove top cowl and check each section for fuel leak, dirt,
deterioration and damages. Clean or replace parts if
necessary.

3) Inspection of Fuel Tank

1
1. Remove dirt and water from fuel tank 1 if any.

3-4 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 5

4) Inspection of Fuel Cock (Fuel Filter)

1. Check fuel cock 1 (fuel filter a ) for dirt and clogging, and
clean if necessary. Carburetor
a

Tank
1

5) Inspection of Fuel Cock

1. Check that fuel cock 1 can be opened and closed normally.

4st 2/2.5/3.5 2007 3-5

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 6

Maintenance
6) Replacement of Engine Oil
1. Oil Level

300cm3 Upper Limit (Center)

250cm3 Lower Limit

2. Oil Specification

OIL Engine Oil :

4 Stroke Engine Oil
API : SF, SG, SH

Engine Oil
10W – 40
SAE : 10W-30, 10W-40
NMMA : FC-W Certified 10W-30 10W – 30
Quantity of Engine Oil :
-20 -10 0 10 20 30 40 °C
300cm3（10 fl.oz）
Ambient air temperature

Use oil with viscosity that is suited to ambient air

temperature of the operating region.

3. Engine Oil Replacement Procedure

Use of engine oil containing dirt or water can significantly
1
shorten the lives of rotating and sliding parts of engine.
Replacement of Engine Oil :
1. Stop the engine and set outboard motor straight ahead
and vertical.
2. Remove top cowl and then oil filler cap 1.

3. Place drain oil pan below drain bolt 2.

4. Remove drain bolt 2 to drain oil.
5. Tighten drain bolt 2 to specified torque.

Apply oil to washer 3 of drain bolt 2.

3

Drain Bolt : 2
18N･m (13 lb･ft) [1.8kgf･m]

3Washer Do not reuse.

3-6 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 7

6. Pour new engine oil into oil inlet 3 until oil level
reaches upper limit mark (center) of oil level gauge 4.

300cm3 Upper Limit (Center)

250cm3 Lower Limit

IL
O
4st
4st OIL

Quantity of Engine Oil : 4

OIL
300cm3（10 fl.oz）
3

7. Attach oil filler cap 1, start engine and idle for 5

minutes to warm up.
3
8. Stop engine and check oil level and for oil leaks after 5
1
minutes.

4st 2/2.5/3.5 2007 3-7

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 8

Maintenance
7) Inspection of Gear Oil Quantity
1. Tilt down outboard motor down to the vertical position.

IL
O
GEAR
GEAR
2. Remove upper oil plug 1 and check level of gear oil in the
gear case.

Over flow of some oil from plug hole as plug is

removed indicates that gear case is filled with 2
specified quantity of gear oil.
1
3
3. Add recommended gear oil to specified level if it is Low.
2Gasket Do not reuse.

Gear Oil :
OIL
Hypoid Gear Oil
API : GL-5 SAE : # 90

If the oil is low, add through lower oil plug hole ③.

4. Attach upper oil plug 1.

8) Inspection of Water Pump

Inspection of water pump does not require
removal of power unit from outboard motor
body. Tilt up and lock with tilt stopper.

1. Remove grommet 1 and loosen bolt 2.

Bolt 2 should be loosened, but not removed from

joint 3. 1
2
IL
O

4st
4st OIL

3-8 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 9

2. Remove lower unit installation bolts 3 and nut 4, and pull

lower unit ass'y downward to remove.

Check drive shaft spline a for adhesion of oil, a

rust and wear.

3 4 3

3. Remove bolt, and then, pump case (upper) 1 while pushing

drive shaft downward b.

• When removing or attaching water pump and 1

pump case (lower), be careful that the drive
shaft is not pushed up. 4 3
• Pushing up the drive shaft causes pinion (B) b 2
gear to drop into the gear case. a c
5
4. Remove impeller 2. c

5. Check pump case (upper) 1 for deformation. Replace if

necessary.

6. Check impeller 2, pump case liner 3 and guide plate 5 for

cracks and wear. Replace if necessary.

a Projecton c Do not reuse.

7. Check key 4 and drive shaft groove d for wear. Replace if

necessary. d

8. Reinstall the components removed. For details, refer to Chapter 6.

• When replacing impeller, install it so that it rotates

in clockwise direction.
• Apply grease to the key to prevent it from 4 G
RE
AS
E

dropping when attaching. OBM

OBM

4st 2/2.5/3.5 2007 3-9

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 10

Maintenance
9) Replacement of Gear Oil
1. Set outboard motor vertical. 2
3
2. Place drain oil pan below oil plug 1, remove lower oil plug
1 and then upper oil plug 2 to drain oil.

Remove lower oil plug 1 first when draining. 3

1

3. Check gear oil for presence of metal particles, change of

color (abnormal if clouded), and viscosity. Check lower unit
internal components if necessary. 3Gasket Do not reuse.

4. Fill with gear oil (from oil tube or pump) through lower plug
hole 1 until gear oil starts to flow from upper oil plug 2 hole 2 a
a without air bubbles. 3

IL
O
GEAR
GEAR
Gear Oil :
OIL
Hypoid Gear Oil
API : GL-5 SAE : #90
Quantity of Gear Oil :
180 cm3 (6 fl.oz)

Use lower plug hole 1 when filling with gear oil. 3

Upper hole 2 should not be used because 1
doing so will not allow air to escape from gear 3Gasket Do not reuse.
case.

a
2

IL
O
GEAR
3 GEAR

3
1
3Gasket Do not reuse.

5. Attach new gasket 3 and upper oil plug 2, and then new
gasket 3 and lower oil plug 1 quickly.

When fully filled with oil, attach upper oil plug 2

first.

3-10 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 11

10) Inspection of Gear Case (for leakage)

1. Drain gear oil. Refer to "9) Replacement of Gear Oil" in 1
Chapter 3. 2

2. Remove upper oil plug 1 and connect a commercially

available leakage tester to this hole.

2Gasket Do not reuse.

3. Apply specified pressure to gear base, and check if the

pressure is maintained without further compression for 10 3
seconds.

Specified Gear Case Maintained Pressure :

0.049 MPa (7 psi) [0.5 kgf/cm2]

• Rotating propeller shaft while maintaining

pressure and testing with gear oil drained
make it easy to find leakage due to wear of oil
seal lip.
• Depressurize gear case and cover oil plug
area with a piece of rag before disconnecting
leakage tester.

CAUTION
Do not apply pressure to gear case over
specified value.
Doing so can cause damage to oil seal.

4. If the specified pressure cannot be maintained, check oil

seals of drive shaft and propeller shaft and O rings of cam
rod and propeller shaft housing for damage.

4st 2/2.5/3.5 2007 3-11

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 12

Maintenance
11) Inspection of Spark Plug
1. Remove plug cap and then spark plug.

2. Use spark plug cleaner or wire brush to clean spark plug

electrode 1. Replace if necessary.
1

3. Check electrode 1 for corrosion or excessive build up of

carbon, and washer 2 for damage. Replace if necessary.

4. Check spark plug gap a. Replace if the gap is over

specified value. Adjust gap if it is out of specified range.
2
Spark Plug Gap a : Standard
0.8 - 0.9 mm (0.031- 0.035 in)

Functional Limit :
1.0 mm (0.039 in)
a
Specified Spark Plug :
DCPR6E[NGK]

5. Install spark plug, fully hand-tighten b, and then use plug O

IL
-C
O
M

wrench to tighten to specified torque c.

P.
GM
SOC
SOC
Spark Plug :
18 N･m (13 lb･ft) [1.8 kgf･m]

b
c

3-12 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 13

12) Inspection of Compression Pressure

1. Start and idle engine for 5 minutes to warm up, and then stop.

2. Shift gear into neutral (N).

3. Remove lock plate (of stop switch lanyard) from stop switch.

CAUTION
To prevent accidental start of the engine,
remove lock plate (of stop switch lanyard)
from stop switch before measuring
compression pressure.

4. Remove plug cap and then spark plug.

CAUTION
3
Clean areas around spark plug on the
cylinder before removing spark plugs to 1
prevent dirt from entering cylinder.

5. Install compression gauge 1 to plug hole.

Compression Gauge :
P/N. 3AC-99030-0

6. Fully open throttle a, crank engine until compression gauge

indication 1 stabilizes, and then measure compression
pressure.

Compression Pressure (Reference) :

1.13 MPa (164 psi) [11.5 kgf/cm2]

a
• Compression pressure is affected much by
cranking speed, and normally changes
approximately 10%.
• Do not pull choke knob when measuring
compression pressure.

7. If compression pressure is below specified value, put small

amount of engine oil into cylinder, and perform the test again.

• If compression pressure increases after the

above measure, check pistons and piston rings
for wear. Replace if necessary.
• If compression pressure does not increase
after the above measure, check valve
clearances, valves, valve seats and cylinder
sleeve. Adjust or replace if necessary.

4st 2/2.5/3.5 2007 3-13

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 14

Maintenance
13) Inspection and Adjustment of Valve Clearances
1. Disconnect plug cap 1 connection, and then, remove spark
plug and cylinder head cover 2.

When removing or installing cylinder head cover 1

without removing power unit, use 10 mm box
wrench with large offset angle.

2. Pull recoil starter 3 to turn flywheel clockwise until flywheel

"T" mark a is brought to flywheel cover "▲" mark b.

• Set piston to top dead center of compression T

stroke.
• Remove oil filler cap and check that ø5 mm (0.2
in) hole c of cam shaft gear 4 can be seen.
b a

3. Check clearances of intake valve d and exhaust valve e.

Adjust gap if it is out of specified range.

Perform inspection and adjustment of valve d

clearances when engine is cold.
e
Valve Clearance (when engine is cold) :
(IN) Intake side d : 0.06 - 0.14 mm
(0.0024 - 0.0055 in)
(EX) Exhaust side e : 0.11 - 0.19 mm
(0.0043 - 0.0075 in)

3-14 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 15

4. Loosen pivot lock nut 5 and then turn the pivot 6 so that
6 5
valve clearance reaches specified value.
de
• Turning pivot 6 clockwise makes valve
clearance smaller.
• Turning pivot 6 counterclockwise makes valve
clearance larger.

5. Tighten pivot lock nut 5 to specified torque, and check valve

clearance again. Readjust if necessary.
8
Pivot Lock Nut 5 :
10 N･m (7 lb･ft) [1.0 kgf･m] 7
3
Torque Wrench 7 :
Use commercially available item.
Thickness Gauge 8 :
Use commercially available item.

• Perform inspection and adjustment of valve

clearances when engine is cold.
• After the adjustment, turn flywheel twice (top dead
center in compression stroke) to check the
clearance again.

Valve Clearance (when engine is cold) :

(IN) Intake Side d : 0.06 - 0.14 mm
(0.0024 - 0.0055 in)
(EX) Exhaust Side e : 0.11 - 0.19 mm
(0.0043 - 0.0075 in)

6. Install cylinder head cover 2, and then, spark plug.

When removing or installing cylinder head cover

without removing power head, use 10 mm box
wrench with large offset angle.
1

Cylinder Head Cover :

6 N･m (4 lb･ft) [0.6 kgf･m]

Spark Plug :
18 N･m (13 lb･ft) [1.8 kgf･m]

7. Reconnect plug cap 1.

4st 2/2.5/3.5 2007 3-15

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 16

Maintenance
14) Adjustment of Throttle Cable
1. Turn throttle grip 1 to full close position a.

2. Pull choke rod 2 fully d.

1
c a

2 d
b

3. Attach throttle cable 3 to throttle drum 4 taking care of the

4
positions of low speed side cable e and high speed cable side f.

4. Pull outer cable g of throttle cable 3 to the side shown with

the arrow by hand, and lock it with the nut while applying
tension to the cable. f h
Push inner cable h with a finger to check that
3 e
the cable deflects approximately 1 mm (0.04 in) g
at the center.

5. Attach high speed side f cable and low speed side e cable
by using the same way.

6. Push back choke rod 2 fully c. (wide open choke)

7. Turn throttle grip 1 to full close position a.

Check that the gap i between the projection of

throttle drum 4 and dent of throttle opener 5 is
within the range from 0.5 - 1.0 mm (0.020 - 0.040 in).

8. Turn throttle grip 1 from full close position a to full open

position b, and check that the throttle lever of carburetor 6
touches the full open stopper j. Then, return the throttle
grip 1 from full open position b to full close position a, and L
check that the throttle lever of carburetor touches the full
k
close stopper k (throttle stop screw L).
j 6

3-16 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 17

15) Inspection of Gear Shift Operation

Shift the lever 1 from neutral (N) to while rotating propeller,
1 N
and then back to neutral (N) to check that shift operation is
performed smoothly. Adjust positions of shift rod 2 and joint
3 if necessary.
F

1. Shift lever 1 into neutral (N).

Check that propeller shaft rotates smoothly at

neutral (N) position when turned by hand.

2. Remove grommet 4 and loosen bolt 5.

Bolt 5 should be loosened, not be removed 3

from joint 3. 4
5

IL
O
4st
4st OIL
3. Check positions of cam rod 2 and joint 3, and adjust if
necessary.
5
Joint Bolt :
6 N･m (4 lb･ft) [0.6 kgf･m]
3
4. Attach grommet 4. 2

4st 2/2.5/3.5 2007 3-17

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 18

Maintenance
16) Flushing with Water
CAUTION
Touching rotating propeller could lead to injury.
Be sure to remove propeller before running
engine on the land.

WARNING
Exhaust gas contains carbon monoxide,
which will cause gas poisoning. Do not
start engine with outboard motor placed in
a closed area such as boat house.

Flushing with water using flushing attachment 1 (hose adapter)

1. Remove propeller.

2. Remove water plug 2 of outboard motor, and attach 1

flushing attachment 1.
2
3. Put water hose on flushing attachment 1 and run water.
3
4. Set shift lever 3 to neutral (N) and start engine.
1
5. Check that cooling water check port discharges water, and
run engine for 3 to 5 minutes at low speed.
1Flushing Attachment (optional)

6. Stop engine and stop water supply, remove flushing

attachment 1, attach and tighten water plug 2, and then,
reinstall propeller.

Water Plug :
13 N･m (9 lb･ft) [1.3 kgf･m]

17) Inspection of Idle Engine Speed

1. Start engine and run for 5 minutes to warm up.

2. Attach tachometer to high tension cord 1 to check idle

engine speed.

· Use tachometer to measure after warm up 1

operation.
· Set the measurement mode to 4 stroke 2
cylinder · 2 stroke 1 cylinder.
1High Tension Cord

Tachometer :
P/N. 3AC-99010-0

Idle Engine Speed :

RPM
1,250 - 1,350r/min

3-18 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 19

18) Inspection of Ignition Timing

Adjusting system :
Automatic control, requiring no manual adjustment.
Run engine and use timing light to check ignition timing. 7
timings marks are found on the top of flywheel (TDC0ﾟ ("T"),
BTDC5ﾟ, 10ﾟ, 15ﾟ, 20ﾟ, 25ﾟ, 30ﾟ). Read ignition timing with
mark on the center of flywheel cover window.
T
Model Range of Timing Angle
F2/2.5/3.5A BTDC 7ﾟ - BTDC 25ﾟ

19) Inspection of Anode

1. Check anode 1 for build up of scale and adherence of 3
grease and oil. Clean, or replace if necessary.

CAUTION
Do not coat anode with oil, grease or paint, or the
anti-corrosion function does not work normally. 1

When it is necessary to disassemble outboard

motor for inspection of anode, refer to
disassembly described in this manual.

2. Replace anode 1 if it is corroded excessively.

20) Replacement of Anode

Anode protects outboard motor from galvanic corrosion
(corrosion of metal due to very weak electric current).
The anode is attached to gear case.
Replace anode if volume is reduced to 2/3 of new part.

Do not coat anode with oil or paint.

21) Inspection of Propeller

1. Check propeller blades and shear pin for cracks, damages,
wear and corrosion. Replace if necessary.

4st 2/2.5/3.5 2007 3-19

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 20

Maintenance
22) Inspection of Thermostat
1. Remove bolts, and then thermostat cap 1 and thermostat 2.
2
3

2. Hang thermostat 2 in the water contained in vessel.

3. Put thermometer in the water, and warm up water to measure

valve opening temperature.
2
Put a piece of thread in the closed valve gap and
hang it in the water. Valve opening moment can be
known when thermostat 2 is released to drop due
to opening with rise of temperature.

Valve Opening Temperature :

52˚C±2˚C(125˚F±4˚F)
(Valve starts to open at this temperature.)

4. Measure valve lift a of thermostat 2 when prescribed

temperature has been reached. Replace if the length is less
a
than specified value.

Water Temperature Valve Lifta

65˚C±2˚C(150˚F±4˚F ) 3.0 mm (0.12 in) or more

Since thermostat starts to open a few minutes after

the opening temperature is reached, measure the
lift a after maintaining it for approximately 5
minutes at around 65˚C(150˚F).

5. Install thermostat 2, new gasket 3 and then cap 1.

Thermostat Cap Bolt :

6 N･m (4 lb･ft) [0.6 kgf･m]

3-20 4st 2/2.5/3.5 2007

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 21

23) Inspection of Cooling Water Passages

1. Check water strainer 1 for clogging. Clean if necessary.

2. Set outboard motor in the water and start engine.

3. Check that cooling water is discharged from cooling water

check port 2. If not, check water pump and cooling water
3
passage in the engine.

4st 2/2.5/3.5 2007 3-21

MFS2_sec03_070524.qxd 07.5.24 3:16 PM ページ 22

Maintenance
24) Greasing Points G
RE
AS
E

1. Apply grease to throttle cable and sliding areas. OBM

OBM

G
RE
AS
E

OBM
OBM

G
RE
AS
E

OBM
OBM
aDo not lubricate here.

2. Apply grease to pin of tilt stopper 2 and thrust supporter 3.

2

G
RE
AS
E

OBM
OBM

3. Apply grease to propeller shaft.

G
RE
AS
E

OBM
OBM

3-22 4st 2/2.5/3.5 2007

MFS2_sec04_070524.qxd 07.5.24 4:44 PM ページ 1

4
Fuel System (Carburetor) 4

1 Special Tool ………………………………… 4-2 4) Inspection of Fuel Cock ………………… 4-7

2 Parts Layout………………………………… 4-3 5) Inspection of Fuel Filter ………………… 4-7
Fuel Tank ……………………………………… 4-3 6) Inspection of Carburetor ………………… 4-8
Carburetor ……………………………………… 4-4 7) Assembling of Carburetor ……………… 4-9
3 Inspection Items ………………………… 4-5 8) Assembling Carburetor ………………… 4-10
1) Inspection of Fuel Feed System Piping … 4-5 9) Adjustment of Throttle Cable …………… 4-11
2) Draining Fuel ……………………………… 4-6 10) Inspection of Idle Engine Speed ……… 4-12
3) Inspection of Fuel Tank and Fuel Tank Cap … 4-7 11) Adjustment of Idle Engine Speed ……… 4-12
MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 2

Fuel System (Carburetor)

1.Special Tool

Tachometer
P/N. 3AC-99010-0
Measuring engine revolution
speed

4-2 4st 2/2.5/3.5 2007

MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 3

2. Parts Layout P/L Fig. 14

Fuel Tank

16

6 N·m (4 lb·ft) [0.6 kgf·m]

15-1 17
B
1342 T
15 1342

15-2

4
3

4
12
Carburetor
2
11

14
6
13
10
12
7 18

14
9

1342
B
1342 T

Ref.
No. Description Q'ty Remarks

1 Fuel Tank 1
2 Fuel Tank Cover 1
3 Collar, 6.2-9-10.7 3
4 Washer, 6-16-1.5 3
5 Bolt 3 M6 L=25mm
6 Fuel Cock 1
7 Fuel Cock Rod 1
8 Seal Ring 1
9 Fuel Cock Knob 1
10 Fuel Cock Rod Hose 1
11 Fuel Hose 1
12 Clip, ø9.5 2
13 Fuel Hose 1
14 Clip, ø15 2
15 Fuel Tank Cap 1
15-1 Tank Cap Gasket 1
15-2 Tank Cap Hook 1
16 Fuel Tank Seal 1
17 Caution Decal "B" 1
18 Fuel Hose Protector 1

4st 2/2.5/3.5 2007 4-3

MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 4

Fuel System (Carburetor)

Carburetor Fig. 3

10 N·m (7 lb·ft) [1.0 kgf·m]

20
6
14

4
13 2
3
2
17

10 1-13 1-3
1-14
1-15A

9 7 1
1-15B
12
11 1-1

1-2 1-5
8 1-6
15 1-4
1-7
1-11
20
19 1-9
18
1-12
1-8
16
1-10

Ref. Ref.
No. Description Q'ty Remarks No. Description Q'ty Remarks

1 Carburetor 1 9 Collar, 6.2-9-7.5 2

1-1 Main Nozzle 1 10 Collar, 6.2-9-7 1
1-2 Main Jet 1 11 Bolt 2 M6 L=85mm
1-3 Slow Jet 1 12 Washer 2
1-4 Float 1 13 Cable Holder 1
1-5 Float Valve 1 14 Bolt 1 M6 L=16mm
1-6 Clip 1 15 Nut 1 M6
1-7 Float Arm Pin 1 16 Choke Rod 1
1-8 Float Chamber 1 17 Choke Link Cable 1
1-9 Float Chamber O-Ring 1 Do not reuse. 18 Washer, 6.5-21-1 1
1-10 Screw 2 19 Bolt 1 M6 L=12mm
1-11 Drain Screw 1 20 Rubber Hose 2
1-12 Drain Screw O-Ring 1 Do not reuse.
1-13 Stop Screw 1
1-14 Stop Screw Spring 1
1-15A Pilot Screw Set 1
1-15B Pilot Screw Set (for EU) (1) for EUROPE
2 Carburetor Gasket 2 Do not reuse.
3 Insulator 1
4 Intake Manifold 1
5 Intake Manifold Gasket 1 Do not reuse.
6 Bolt 2 M6 L=30mm
7 Intake Silencer 1
8 Flame Arrester 1

4-4 4st 2/2.5/3.5 2007

MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 5

3. Inspection Items
1) Inspection of Fuel Feed System Piping
1. Remove top cowl and check each section for fuel
leak, dirt, deterioration and damages. Clean or
replace parts if necessary.

4st 2/2.5/3.5 2007 4-5

MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 6

Fuel System (Carburetor)

2) Draining Fuel

WARNING
Remove fuel tank, fuel hose and carburetor
after fully drain the fuel from these parts.

1. Remove fuel tank cap 1 and use fuel pump to remove fuel.
1

2. Set fuel cock knob 2 to full open position b.

3. Place a piece of rag below the carburetor, and loosen c

drain screw 3 to drain all fuel.

3
4. Retighten drain screw 3.

4-6 4st 2/2.5/3.5 2007

MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 7

3) Inspection of Fuel Tank and Fuel

Tank Cap
1. Check fuel tank and fuel tank cap for crack, leakage and
damage. Replace if necessary.

4) Inspection of Fuel Cock

Carburetor
1. Check fuel cock for leakage.
Tank

5) Inspection of Fuel Filter

1. Check fuel filter (fuel cock ) for dirt and clogging, and clean if
necessary.

4st 2/2.5/3.5 2007 4-7

MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 8

Fuel System (Carburetor)

6) Inspection of Carburetor
1. Check air and fuel passages for dirt in the jet and foreign
substances. Clean carburetor body with cleaning fluid.

2. Squirt all passages and jet with compressed air.

CAUTION
· Point the compressed air downward,
taking care that detergent and dust do
not enter the eyes and do not damage
small parts of the carburetor.
· Do not use wire to clean the jet. Doing so
may enlarge the jet hole, resulting in
significantly reducing the performance.

3. Check main jet 1, main nozzle 2 and slow jet 3 for dirt.
Clean or replace if necessary.
3

4. Check float valve for bend and wear. Replace if necessary.

5. Check float for deformation. Replace if necessary.

4-8 4st 2/2.5/3.5 2007

MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 9

6. Measure height a of float 4. Adjust height a of float 4 by

5 4
bending tab b if the height is out of specified range. b
Float Height a : a
9.0 - 10.0 mm (0.354 - 0.394 in) c 5

· Bring tab b of float 4 into light contact with

top of float valve 5.
· Measure the height at the marking line that is
located opposite to pivot c side.

7) Assembling of Carburetor
1. Attach main nozzle 1 and main jet 2 to carburetor body as
shown. 2
1
4

2. Attach float valve, float 4 and float arm pin 3 as shown,

and check if float 4 moves smoothly.

3 4
· When attaching float to carburetor body, put
float valve 5 in the valve seat. 5
· Put float arm pin in the horizontal hole on the
carburetor, and tap lightly to set the location.

3. Attach slow jet and float chamber.

4st 2/2.5/3.5 2007 4-9

MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 10

Fuel System (Carburetor)

8) Assembling Carburetor
1. Attach carburetor ass'y to intake manifold.

Carburetor Bolt :
6N · m (4 lb · ft) [0.6kgf · m]

Put carburetor gaskets 1 and 3 and insulator

2 together with their projections a at the same
side, and install carburetor.

3
2
1

a Projections 1 and 3 Do not reuse.

a
3
a
2
a
1

a Projections 1 and 3 Do not reuse.

2. Attach choke wire 4 to choke lever 5 of carburetor.

5 6

6 10 mm Wrench

4-10 4st 2/2.5/3.5 2007

MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 11

9) Adjustment of Throttle Cable

1. Turn throttle grip 1 to full close position a.

2. Pull choke rod 2 fully d.

1
c a

2 d
b

3. Attach throttle cable 3 to throttle drum 4 taking care of

4
the positions of low speed side e and high speed side f.

4. Pull outer cable g of throttle cable 3 to the side shown

with the arrow by hand, and lock it with the nut while
applying tension to the cable. f h
Push inner cable h with a finger to check that
3 e
4
the cable deflects approximately 1mm (0.04in)
g
at the center.

5. Attach high speed side f cable and low speed side e cable
by using the same way.

6. Push back choke rod 2 fully c. (wide open choke)

7. Turn throttle grip 1 to full close position a.

Check that the gap i between the projection of

throttle drum 4 and dent of throttle opener 5 is
within the range from 0.5 - 1.0 mm (0.020 - 0.040 in).

8. Turn throttle grip 1 from full close position a to full open

position b, and check that the throttle lever of carburetor 6
touches the full open stopper j. Then, return the throttle
grip 1 from full open position b to full close position a, and
L
check that the throttle lever of carburetor touches the full
close stopper k (throttle stop screw L ). k

j 6
4st 2/2.5/3.5 2007 4-11
MFS2_sec04_070524.qxd 07.5.24 3:17 PM ページ 12

Fuel System (Carburetor)

10) Inspection of Idle Engine Speed
1. Start engine and run for 5 minutes to warm up.

2. Check idle engine speed.

· Use tachometer to measure after warm up

operation.
· Set the measurement mode to 4 stroke 2
cylinder · 2 stroke 1 cylinder.

Tachometer : 1
P/N. 3AC-99010-0

Idle Engine Speed :

RPM
1,250 - 1,350r/min

11) Adjustment of Idle Engine Speed

1. Start engine and run for 5 minutes to warm up.

2. Turn throttle stop screw 4 to direction c or d to adjust idle

engine speed.
4
· Turning throttle stop screw to direction c
c
increases the idle speed.
· Turning throttle stop screw to direction d
decreases the idle speed.
d
Idle Engine Speed :
RPM
1,250 - 1,350r/min

3. After adjusting idle engine speed, open throttle several

times, and then, continue idle operation for more than 15
seconds to check that engine idles consistantly.

4-12 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 4:45 PM ページ 1

5
Power Unit

1 Special Tools ……………………………… 5-2 18) Inspection of Cylinder Inner Diameter … 5-22
2 Parts Layout………………………………… 5-3 19) Inspection of Piston Clearance ………… 5-22
Engine ………………………………………… 5-3 20) Inspection of Piston Ring Side Clearance … 5-23
Recoil Starter ………………………………… 5-4 21) Inspection of Piston Rings ……………… 5-23
Oil Pan ………………………………………… 5-5 22) Inspection of Piston Pin ………………… 5-24
Cylinder ………………………………………… 5-6 23) Inspection Connecting Rod Small End Inner Diameter … 5-24
Cam Shaft & Valve …………………………… 5-7 24) Inspection of Connecting Rod Big End Inner Diameter … 5-24
Piston & Crank Shaft ………………………… 5-8 25) Inspection of Connecting Rod Big End Side Clearance … 5-25
3 Inspection Items ………………………… 5-9 26) Inspection of Crank Shaft ……………… 5-25
1) Inspection of Compression Pressure … 5-9 27) Disassembly and Assembly of Crank Shaft… 5-26
2) Inspection of Valve Clearance ………… 5-10 28) Inspection of Crank Pin Oil Clearance … 5-27
3) Removing Power Unit …………………… 5-12 29) Installation of Piston and Connecting Rod … 5-28
4) Removal and Disassembly of Crank Case Head … 5-13 30) Removal of Valves and Springs ………… 5-29
5) Inspection of Crank Case Head ………… 5-14 31) Inspection of Valve Springs …………… 5-29
6) Assembly of Crank Case Head ………… 5-14 32) Inspection of Valve ……………………… 5-30
7) Installation of Crank Case Head ……… 5-14 33) Inspection of Valve Guide ……………… 5-30
8) Disassembly of Power Unit ……………… 5-15 34) Inspection of Valve Seat ………………… 5-31
9) Removal of Rocker Arm ………………… 5-17 35) Correction of Valve Seat ………………… 5-32
10) Inspection of Rocker Arm and Pivot …… 5-18 36) Installation of Valves …………………… 5-35
11) Inspection of Push Rod Plate …………… 5-18 37) Assembly of Cylinder and Crank Case … 5-36
12) Inspection of Push Rod ………………… 5-18 38) Assembly to Power Unit ………………… 5-39
13) Disassembly of Cylinder Block ………… 5-19 39) Assembly of Rocker Arm………………… 5-40
14) Inspection of Slinger (Splash Lubrication) … 5-20 40) Assembly of Power Unit ………………… 5-41
15) Inspection of Lifter ……………………… 5-20 41) Disassembly of Recoil Starter ………… 5-42
16) Inspection of Cam Shaft ………………… 5-21 42) Inspection of Recoil Starter……………… 5-42
17) Inspection of Piston Outer Diameter …… 5-22 43) Assembly of Recoil Starter ……………… 5-43
MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 2

Power Unit
1.Special Tools

Thickness Gauge Compression Gauge Valve Spring Compressor Attachment Flywheel Holder
P/N. 353-72251-0 P/N. 3AC-99030-0 P/N. 3AB-99076-0 P/N. 3AC-99200-0
Measuring compression Removing or installing valve Removing or installing
Measuring gaps
pressure springs flywheel

3B7-72783-0 3B7-72784-0

Flywheel Puller Kit

P/N. 3C7-72211-1

Removing flywheel

5-2 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 3

2.Parts Layout
Engine

6
5 6 N·m (4 lb·ft) [0.6 kgf·m]

B
1342 T

6 1342

6 N·m (4 lb·ft) [0.6 kgf·m]

B
1342 T

1342

5
3 3

2
B
1107 T
1342

1107 G
RE
AS
E

TEF
TEF

G
RE
AS
E
TEF
TEF

6 N·m (4 lb·ft) [0.6 kgf·m] 1107

B
1107 T

1342
B
1342 T

Ref.
No. Part Name Q'ty Remarks

1 Power Unit 1
2 Gasket 1 Do not reuse.
3 Dowel Pin 2
4 Bolt 7 M6 L=30mm
5 Fuel Tank 1
6 Bolt 3 M6 L=25mm

4st 2/2.5/3.5 2007 5-3

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 4

Power Unit
Recoil Starter P/L Fig. 8

2
6 N·m (4 lb·ft) [0.6 kgf·m]

3
4
2

1 BO
N
D

G17

G17

1-3

G
RE
AS
E

LIT
LIT

1-1
1-11

1-12
1-2

1-9
1-10

1-5
1-5

1-4 1-4

1-8

1-6
G
RE
AS
E
5 N·m (4 lb·ft) [0.5 kgf·m]
LIT
LIT
1-7

G
RE
AS
E
LIT
LIT

BO
N
G17
D

G17

Ref. Ref. Remarks

No. Part Name Q'ty Remarks No. Part Name Q'ty

1 Recoil Starter 1 1-12 Starter Seal 1 Do not reuse.

1-1 Starter Spring 1 2 Bolt 3 M6 L=60mm
1-2 Reel 1 3 Washer, 6-16-1.5 3
1-3 Starter Rope 1 ø3.5-L=1200 4 Clamp, 6.5-67P 1
1-4 Ratchet 2
1-5 Return Spring 2
1-6 Friction Plate 1
1-7 Starter Shaft Screw 1
1-8 Friction Spring 1
1-9 Starter Handle 1
1-10 Rope Anchor 1
1-11 Rope Anchor Plate 1

5-4 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 5

Oil Pan P/L Fig. 4

14
15

6 N·m (4 lb·ft) [0.6 kgf·m]

7
16 13
14
17
18 8

18

IL
O
4st
4st OIL

18 N·m (13 lb·ft) [1.8 kgf·m] 5

IL
O

4st
4st OIL 3 2
4

1-1
1

6
1 6 N·m ( 4 lb·ft) [0.6 kgf·m]
2
2 8.8 N·m (6.5 lb·ft) [0.9 kgf·m]
6
19 6
6
1 6 N·m ( 4 lb·ft) [0.6 kgf·m] 6 G
RE
AS

11
E

LIT
2 8.8 N·m (6.5 lb·ft) [0.9 kgf·m] LIT
10
G
RE
AS
E

10
IL

LIT
O

4st
4st OIL LIT
9
G
RE
AS
E

12 LIT
LIT 4st OIL
IL
O

4st
6 N·m (4 lb·ft) [0.6 kgf·m]
G
RE
AS
E
LIT
LIT

Ref. Ref.
No. Part Name Q'ty Remarks No. Part Name Q'ty Remarks

1 Oil Pan Ass'y 1 12 Bolt 2 M6 L=20mm

1-1 Oil Level Gauge 1 Do not reuse. 13 Stopper Bracket 1
2 Dowel Pin, 6-12 2 14 Rubber Damper 2
3 Drain Bolt 1 M10 - P1.25 15 Collar, 6.2-9-7.4 2
4 Washer, 10.2-19-1 1 Do not reuse. 16 Bolt 2 M6 L=20mm
5 Oil Pan Gasket 1 Do not reuse. 17 Rubber Hose 1
6 Bolt 8 M6 L=35mm 18 Clip, ø10 2
7 Engine Oil Filler Cap 1 19 Oil Seal, 20-35-7 1 Do not reuse.
8 O-Ring, 3.1-24.4 1
9 Crank Case Head 1
10 Oil Seal, 10.1-20-7 2 Do not reuse.
11 O-Ring, 2.4-35.2 1 Do not reuse.

4st 2/2.5/3.5 2007 5-5

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 6

Power Unit
Cylinder P/L Fig. 1

6 N·m (4 lb·ft) [0.6 kgf·m]

13

11

12

6 N·m (4 lb·ft) [0.6 kgf·m]

15
20
16
20 19
Fig.3-7 16
5 4
18 2
1 6 N·m ( 4 lb·ft) [0.6 kgf·m] 3
2 8.8 N·m (6.5 lb·ft) [0.9 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m]

4
5
1-2
1-2 1-1 4
1-2 5

1-2 18 N·m (13 lb·ft) [1.8 kgf·m]

1-4 O
IL
-C
O
M
P.
GM
SOC
SOC
1-3 1-1 14
1-1 6 N·m (4 lb·ft) [0.6 kgf·m]
8
1-3 1-4
7
6
1-2
LT

518
271

518 1

4st OIL
IL
O

4st

10 O
IL
-C SOC
O
IL

LT
O

4st M
271 P.
GM
SOC
4st OIL 271
9 10 271
17
LT

271

518
LT

518
271

Ref. Ref.
No. Part Name Q'ty Remarks No. Part Name Q'ty Remarks

1 Cylinder-Crankcase 1 with Nipple 9 Clamp, 6.5-67P 1

1-1 Dowel Pin, 6-12 3 10 Bolt 2 M6 L=30mm
1-2 Bolt 6 M6 L=35mm 11 Breather Chamber Cover 1
1-3 Bolt 2 M6 L=75mm 12 Breather Chamber Cover Gasket 1 Do not reuse.
1-4 Washer 2 13 Bolt 2 M6 L=16mm
2 Cylinder Head Cover 1 14 Spark Plug M12-P1.25 1 DCPR6E [NGK]
3 Cylinder Head Cover Gasket 1 Do not reuse. 15 Breather Hose 1
4 Bolt 4 M6 L=16mm 16 Clip, ø12 2
5 Washer, 6-16-1.5 4 17 Slinger 1
6 Thermostat 1 52˚C Mark 5B or 52B 18 Throttle Cable Bracket 1
7 Thermostat Cap 1 19 Clamp, 6.5-67P 1
8 Thermostat Cap Gasket 1 Do not reuse. 20 Bolt 2 M6 L=25mm

5-6 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 7

Cam Shaft & Valve P/L Fig. 5

8
7
IL
O

4st
4st OIL

IL
O
4st
6 4st OIL
9
2
16
4 15
14

25 N·m (18 lb·ft) [2.5 kgf·m]

8
IL
O

4st
4st OIL
7 10 N·m (7 lb·ft) [1.0 kgf·m]
IL
O

4st
4st OIL
6
9 11
3 13

5 10

IL
O
4st

1
12
4st OIL
5
11
IL
O

4st
4st OIL
IL
O

4st
4st OIL

10

mark
A-view
A

4st OIL
IL
O

4st

Ref. Ref.
No. Part Name Q'ty Remarks No. Part Name Q'ty Remarks

1 Camshaft Ass'y 1 13 Pivot Bolt 2 M8 P1.25

2 Intake Valve Stem Seal 1 Black Do not reuse. 14 Rocker Arm 2
3 Exhaust Valve Stem Seal 1 Green Do not reuse. 15 Rocker Arm Pivot 2
4 Intake Valve 1 IT Mark 16 Adjusting Nut M6 P0.5 2
5 Exhaust Valve 1 E Mark
6 Valve Spring 2 L=35
7 Retainer 2
8 Cotter 4
9 Valve Spring Seat 2
10 Lifter 2
11 Push Rod 2
12 Push Rod Plate 1

4st 2/2.5/3.5 2007 5-7

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 8

Power Unit
Piston & Crank Shaft P/L Fig. 2

G
RE
AS
E

LIT
LIT
4
6

10 8

IL
O
4st

1-1 4st OIL

IL
O
4st

3 4st OIL
IL
O

4st
4st OIL 8

IL
O
4st
11 4st OIL

9-1 9

1 5 N·m (4 lb·ft) [0.5 kgf·m] mark

2 10 N·m (7 lb·ft) [1.0 kgf·m]
IL
O

4st
4st OIL

2 4st OIL
IL
O

4st

G
RE
AS
E
LIT
LIT

Ref.
No. Part Name Q'ty Remarks

1 Crankshaft Ass'y 1 with Gear

1-1 Ball Bearing, 6204 1 Do not reuse.
2 Thrust Plate, 20.2-32-1 1
3 Piston 1
4 Piston Ring Top 1
5 Piston Ring 2nd 1
6 Piston Ring Oil 1
7 Piton Pin 1
8 Piton Pin Clip 2 Do not reuse.
9 Connecting Rod Ass'y 1
9-1 Connecting Rod Bolt 2
10 Oil Seal, 20-35-7 1 Do not reuse.
11 Magneto Key 1

5-8 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 9

3. Inspection Items
1) Inspection of Compression Pressure
1. Start and idle engine for 5 minutes to warm up, and then
stop.

2. Shift gear into neutral (N).

3. Remove lock plate (of stop switch lanyard) from stop

switch.

CAUTION
To prevent accidental start of the engine,
remove lock plate (of stop switch lanyard)
from stop switch before measuring
compression pressure.

4. Remove plug cap and then spark plug.

CAUTION 1
Clean areas around spark plug on the
cylinder before removing spark plug to
prevent dirt from entering cylinder.
5
5. Install compression gauge 1 to plug hole.
Compression Gauge :
P/N. 3AC-99030-0

6. Fully open throttle a, crank engine until compression

gauge indication 1 stabilizes, and then measure
compression pressure.

Compression Pressure (Reference) :

1.13 MPa (164 psi) [11.5 kgf/cm2]

· Compression pressure is affected much by

cranking speed, and normally changes a
approximately 10%.
· Do not pull choke knob when measuring
compression pressure.

7. If compression pressure is below specified value, put

small amount of engine oil into cylinder, and perform the
test again.

· If compression pressure increases after the

above measure, check pistons and piston
rings for wear. Replace if necessary.
· If compression pressure does not increase
after the above measure, check valve
clearances, valves, valve seats and cylinder
sleeves. Adjust or replace if necessary.

4st 2/2.5/3.5 2007 5-9

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 10

Power Unit
2) Inspection of Valve Clearance
1. Disconnect plug cap 1 connection, and then, remove
spark plug and cylinder head cover 2.

When removing or installing cylinder head cover 1

without removing power unit, use 10 mm box
wrench with large offset angle.

2. Pull recoil starter 3 to turn flywheel clockwise until

flywheel "T" mark a is brought to flywheel cover "▲" mark
b.
T
· Set piston to top dead center of compression
stroke.
· Remove oil filler cap and check that ø5 mm (0.2
in) hole c of cam shaft gear 4 can be seen. b a

3. Check clearances of intake valve d and exhaust valve e.

Adjust gap if it is out of specified range.
d
Perform inspection and adjustment of valve
clearances when engine is cold.
e
Valve Clearance (when engine is cold) :
(IN) Intake Side d : 0.06 - 0.14 mm (0.0024 - 0.0055 in)
(EX) Exhaust Side e : 0.11 - 0.19mm (0.0043 - 0.0075 in)

5-10 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 11

4. Loosen pivot lock nut 5 and then turn the pivot 6 so that
6 5
valve clearance reaches specified value.
de
· Turning pivot 6 clockwise makes valve
clearance smaller.
· Turning pivot 6 counterclockwise makes
valve clearance larger.

5. Tighten pivot lock nut 5 to specified torque, and check

valve clearance again. Readjust if necessary. 8
Pivot Lock Nut 5 :
7
10 N · m (7 lb · ft) [1.0 kgf · m]

Torque Wrench 7 :
Use commercially available item.
Thickness Gauge 8 :
Use commercially available item.
5
· Perform inspection and adjustment of valve
clearances when engine is cold.
· After the adjustment, turn flywheel twice (top
dead center in compression stroke) to check
the clearance again.

Valve Clearance (when engine is cold) :

(IN) Intake Side d : 0.06 - 0.14 mm (0.0024 - 0.0055 in)
(EX) Exhaust Side e : 0.11 - 0.19mm (0.0043 - 0.0075 in)

6. Install cylinder head cover 2, and then, spark plug.

When removing or installing cylinder head cover

without removing power head, use 10 mm box 1
wrench with large offset angle.

Cylinder Head Cover :

6 N · m (4 lb · ft) [0.6 kgf · m]

Spark Plug :
18 N · m (13 lb · ft) [1.8 kgf · m]

7. Reconnect plug cap 1. 2

4st 2/2.5/3.5 2007 5-11

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 12

Power Unit
3) Removing Power Unit
1. Turn fuel cock 1 to OFF and remove fuel tank ass'y 2 2
and fuel cock ass'y 1.

2. Remove choke cable 4 from carburetor 3.

3 4

3. Turn throttle grip to full close position, and disconnect

throttle cables 6 (2 pcs.) from throttle drum 5.

4. Remove bolt 7 and disconnect leads (black) 8 of igniter

and stop switch.

5. Disconnect lead 9 (brown) of igniter.

8 9

6. Remove bolts 0 (7 pcs.), and then, lift power unit to

remove.

When lifting power unit, perform the work

carefully while checking if cables and hoses are
caught by other parts.

5-12 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 13

4) Removal and Disassembly of Crank

Case Head
1. Remove bolts and remove crank case head ass'y.

2. Remove O ring.

Do not reuse.

3. Remove oil seal.

5

Do not reuse.

4st 2/2.5/3.5 2007 5-13

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 14

Power Unit
5) Inspection of Crank Case Head
1. Check crank case head for crack, damage and corrosion.
Replace if necessary.

6) Assembly of Crank Case Head

1. Attach new oil seal 1 to crank case head by using a
commercially available mandrel. Apply lithium grease to
the lip of oil seal.

G
RE
AS
E
1
LIT
LIT

1 Do not reuse.

7) Installation of Crank Case Head

1. Attach a new O ring.

IL
O
4st
4st OIL

Do not reuse.

2. Install crank case head ass'y to cylinder block ass'y.

Crank Case Head Bolt :

6 N · m (4 lb · ft) [0.6 kgf · m]

5-14 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 15

8) Disassembly of Power Unit

1
1. Place power unit on the work bench a.

2. Remove recoil starter 1 and flywheel cover 2.

2
a

3. Remove flywheel nut 3.

3
Flywheel Holder 4 :
P/N. 3AC-99200-0

CAUTION
Apply forces to tools toward directions as
shown, and perform work taking care not to
allow flywheel holder to slip. 5 4

4. Remove flywheel 5 and key.

5
6 5
Flywheel Holder 4 :
P/N. 3AC-99200-0
Flywheel Puller Kit 6 :
P/N. 3C7-72211-1
4
M6, L = 60mm, Bolts (3 pcs.)
(or recoil starter bolts and washers)

CAUTION
Apply forces to tools toward directions as
shown, and perform work taking care not to
allow flywheel holder to slip.

· Screw puller onto crank shaft end until

flywheel is disengaged from tapered section of
crank shaft.
· If bolts with specified size are not available,
use recoil starter bolts, or if they are deformed,
use new bolts.
· Set flywheel holder before attaching flywheel
puller.

CAUTION
To prevent damages to engine and special
tools, tighten flywheel puller set bolts
evenly and keep flywheel puller parallel to
flywheel while working.

4st 2/2.5/3.5 2007 5-15

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 16

Power Unit
5. Remove bolts, and then igniter 7.

6. Remove breather pipe 8. 0

q
7. Remove intake manifold 9 and carburetor 0.
8

8. Remove throttle cable bracket q.

5-16 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 17

9) Removal of Rocker Arm

1. Remove bolts and then cylinder head cover.

2. Remove lock nut 1, and then pivot 2, rocker arm 3 and

push rod 4.

3. Remove pivot bolt 5, and then push rod plate 6.

1
2

5
4
1
2

3
5

4st 2/2.5/3.5 2007 5-17

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 18

Power Unit
10) Inspection of Rocker Arm and Pivot
1. Check rocker arm 1 and pivot 2 for crack, wear and 1
2
damage. Replace if necessary.

11) Inspection of Push Rod Plate

1. Check push rod plate for crack and damage. Replace if
necessary.

12) Inspection of Push Rod

1. Check push rod for bend, wear and damage. Replace if
necessary.

5-18 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 19

13) Disassembly of Cylinder Block 1 6

1. Remove thermostat cap bolts, and then thermostat cap
and thermostat. 7
2. Remove breather cover. 3
3. Loosen oil pan bolts in the order reverse to the numbers
8
shown, and remove oil pan. 8 - 1
5
Wipe off spilled oil completely. 4
2

4. Loosen crank case bolts in the order reverse to the 6 7

numbers shown, and remove crank case. 8 - 1

2 3

1 4

5 8

5. Remove cam shaft 1 and lifter 2.

7 5
1

6. Remove connecting rod bolts 3 and connecting rod cap

3
4, and then, crank shaft 5 and oil seal 6.
4

7. Remove oil slinger 7.

5
8. Remove connecting rod 8 and piston ass'y from cylinder
block.

· Removed bearings should be arranged in the 6 7

order they are removed.
· Do not reuse piston pin clips. Be sure to
6 Do not reuse.
replace with new ones.
9
q
9. Remove piston pin clip 9 and piston pin from piston and 0
connecting rod ass'y, and then remove piston q.
8

9
9 Do not reuse.
4st 2/2.5/3.5 2007 5-19
MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 20

Power Unit
14) Inspection of Slinger
Splash Lubrication
Adopts splash lubrication system that is simple in
structure.
Slinger is driven by the gear of crank shaft, and splashes
oil collected in oil pan over the crank case parts.

1. Check slinger for crack, damage and wear. Replace if

necessary.

15) Inspection of Lifter

1. Check lifter for bend and wear. Replace if necessary.

5-20 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 21

16) Inspection of Cam Shaft

1. Check cam shaft gear and decompressor for damage and
wear. Replace if necessary.

2. Measure cam height. Replace if the diameter is less than

specified value.

Cam Height a, both intake and exhaust :

Standard value
24.04 mm (0.9464 in) a
Functional Limit :
23.78 mm (0.9362 in)

3. Measure cam shaft run out. Replace if it is over specified

value.
5
Cam Shaft Runout Limit :
0.03 mm (0.0012 in)

4. Measure cam shaft journal outer diameters b and c.

Replace if it is less than specified value.

Cam Shaft Journal Outer Diameter b : Standard value

11.97 mm (0.4713 in)
Cam Shaft Journal Outer Diameter c : Standard value
12.97 mm (0.5106 in)

c b
Functional Limit b :
11.95 mm (0.4705 in)
Functional Limit c :
12.95 mm (0.5098 in)

4st 2/2.5/3.5 2007 5-21

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 22

Power Unit
17) Inspection of Piston Outer Diameter
1. Measure piston outer diameter between points specified.
Replace if it is less than specified value.

Piston Outer Diameter a : Standard value b

54.96 mm (2.1638 in)
Measuring Point b : a
7mm (0.28 in) upward from the bottom of piston skirt
Functional Limit :
54.90 mm (2.1614 in)

18) Inspection of Cylinder Inner Diameter

1. Measure cylinder inner diameters (D1 - D6) at a, b and c in
crank shaft directions d (D1, D3 and D5 respectively), and in D2 D1
a
crank web directions e (D2, D4 and D6 respectively). Replace b
cylinder block if the inner diameters are over specified value. D4 D3 c
Cylinder Inner Diameter (D1 - D6) : Standard value D6 D5
55.00mm (2.1654in)
Functional Limit :
55.06mm (2.1677in)
Note : Measure at the maximum wear points.
d

2. Obtain taper through calculation described below. Replace e

cylinder block if taper is over specified value. a 5mm (0.2in) d Crank Shaft Direction
b 30mm (1.2in) e Crank Web Direction
Taper Limit : c 60mm (2.4in)
D1−D5 (Direction d)
D2−D6 (Direction e)
Functional Limit :
0.06 mm (0.0024 in)

3. Obtain out-of-roundness through calculation described

below. Replace cylinder block if out-of-roundness is over
specified value.

Out-Of-Roundness :
D2−D1 (Measuring Point a)
D6−D5 (Measuring Point c)
Functional Limit :
0.06 mm (0.0024 in)

19) Inspection of Piston Clearance

1. If piston clearance is over specified limit, replace cylinder
block, piston and piston rings as a set, or both.

Piston Clearance :
0.020 - 0.060 mm (0.00079 - 0.00236 in)
Functional Limit :
0.150 mm (0.00591 in)

5-22 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 23

20) Inspection of Piston Ring Side

Clearance a
1. Measure piston ring side clearance. Replace piston and
piston rings as a set if the clearance is over specified value. b
Piston Ring Side Clearance :
Top Ring a : 0.04 - 0.08mm (0.0016 - 0.0031 in) c
Second Ring b : 0.03 - 0.07mm (0.0012 - 0.0028 in)
Oil Ring c : 0.05 - 0.15mm (0.0020 - 0.0059 in)
Functional Limit
Top Ring a : 0.10 mm (0.0039 in)
Second Ring b : 0.09 mm (0.0035 in)
Oil Ring c : 0.17 mm (0.0067 in)

21) Inspection of Piston Rings

1. Push piston ring 1 into ring gauge 55.000mm (2.16535in)
parallel to top edge. If the gauge is not available, measure
at the top or bottom of cylinder bore with no wear.

2. When ring gauge is not available, use piston crown to

push piston ring 1 into to cylinder parallel to top edge.

3. Measure piston ring closed gap a. Replace if it is over

5
specified value.

Piston Ring Closed Gap a :

Top Ring : 0.15 - 0.30 mm (0.0059 - 0.0118 in)
1
Second Ring : 0.30 - 0.45 mm (0.0118 - 0.0177 in)
Oil Ring : 0.20 - 0.70 mm (0.0079 - 0.0276 in)
Functional Limit : a
Top Ring : 0.50 mm (0.0197 in)
Second Ring : 0.70 mm (0.0276 in)

Replace oil ring together with top ring or second

ring when the ring is replaced.

4st 2/2.5/3.5 2007 5-23

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 24

Power Unit
22) Inspection of Piston Pin
1. Measure piston pin outer diameter. Replace if it is less
than specified value.

Piston Pin Outer Diameter : Standard value

14.00 mm (0.5512in)
Functional Limit :
13.97 mm (0.5500 in)

2. Measure piston pin boss inner diameter a.

a

3. Obtain clearance between piston pin and pin boss.

Replace piston pin or piston if the clearance is over
specified value.

Clearance between Piston Pin and Pin Hole :

0.002 - 0.012 mm (0.00008 - 0.00047 in)
Functional Limit :
0.040 mm (0.00157 in)

23) Inspection Connecting Rod Small

End Inner Diameter a
1. Measure connecting rod small end inner diameter a.
b
Replace if it is over specified value.

Connecting Rod Small End Inner Diameter a :

Standard value
14.01 mm (0.5516 in)
Functional Limit :
1
14.04 mm (0.5528 in)

24) Inspection of Connecting Rod Big

End Inner Diameter
1. Tighten connecting rod cap bolts to specified torque, and
measure connecting rod big end inner diameter b.
Replace if it is over specified value.

Connecting Rod Bolts 1 :

1st tightening torque : 5 N · m (4 lb · ft) [0.5 kgf · m]
2nd tightening torque : 10 N · m (7 lb · ft) [1.0 kgf · m]

Connecting Rod Big End Inner Diameter b :

Standard value
20.010 mm (0.78780 in)
Functional Limit :
20.015 mm (0.78799 in)

5-24 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 25

25) Inspection of Connecting Rod Big

End Side Clearance
1. Measure connecting rod big end side clearance a by
using a commercially available thickness gauge. Replace
connecting rod and/or crank shaft if the clearance is over
specified value.

Connecting Rod Big End Side Clearance a :

0.10 - 0.25 mm (0.0039 - 0.0098 in)
a

Functional Limit :
0.60 mm (0.0236 in)

26) Inspection of Crank Shaft 2

1. Check crank shaft gear 1 and bearing 2 for damage and
wear. Replace crank shaft ass'y or bearing if necessary.
1
Flywheel side a bearing can be replaced with
new one as a single unit.
a

5
2. Measure crank pin outer diameter. Replace crank shaft if
outer diameter is less than specified value.

Crank Pin Outer Diameter : Standard value

19.98mm (0.7866 in)

Functional Limit :
19.95mm (0.7854 in)

3. Measure crank shaft runout. Replace crank shaft or

bearing if outer diameter is less than specified value.

Crank Shaft Runout Limit :

0.05 mm (0.0020 in)

Use V blocks to support crank shaft at bearings.

4st 2/2.5/3.5 2007 5-25

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 26

Power Unit
27) Disassembly and Assembly of Crank
Shaft
1. Remove bearing 1 from crank shaft by using a
commercially available bearing puller.
CAUTION
Do not reuse removed bearing. Replace
with new one.
1

Only flywheel side bearing 1 can be replaced. 1 Do not reuse.

2. Install new bearing 1 to crank shaft.

Pipe 2 :
2
ø22mm
Flat Bar 3 1

1 Do not reuse.

5-26 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 27

28) Inspection of Crank Pin Oil Clearance

1. Clean crank shaft 1 and connecting rod parts 2 and 3.

2. Place cylinder block upside down on the work bench.

Install piston 4 to connecting rod 2, and then, install the 4
assembly to cylinder block. 2

Do not attach piston rings in this step. 3

7

3. Install crank shaft 1 to cylinder block.

5
When installing, bring projection of bearing to notch 6
1
of cylinder block.

4. Place a commercially available plasti-gauge 5 on the

crank pin 6 so that is parallel to crank shaft 1.

5. Install connecting rod 2 and cap 3 to crank pin 6.

· Be sure to install the cap 3 in original position

(direction).
· Be sure that connecting rod "▲ " mark a a
5
points crank shaft flywheel side.

6. Tighten connecting rod bolts 7 in two steps to specified

torque.
7
Do not move connecting rod and crankshaft until
oil clearance measurement is completed.

Connecting Rod Bolts :

1st tightening torque : 5 N · m (4 lb · ft) [0.5 kgf · m]
5
2nd tightening torque : 10 N · m (7 lb · ft) [1.0 kgf · m]

7. Remove connecting rod cap 3 and measure width of

crushed plasti-gauge 5 on the crank pin 6. Replace
connecting rod 2 or crank shaft 1 if the measurement
(converted value) is over the limit.
6
Big End Oil Clearance : Converted value
0.015 - 0.041 mm (0.00059 - 0.00161 in)
Functional Limit :
0.060 mm (0.00236 in)

4st 2/2.5/3.5 2007 5-27

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 28

Power Unit
29) Installation of Piston and
Connecting Rod b
1. Install connecting rod 2, piston pin 3, and piston pin clip 4 UP

4 to piston 1.

· Point "3AB-UP" mark a of connecting rod and

3
"UP" mark b of piston to the same direction.
· Be sure to use new piston pin clip, and place 2
clip gap away from piston pin groove c as a
shown. 1
· Be sure to install the connecting rod cap in
4
original position (direction).

IL
O
4st
4st OIL c

6 Do not reuse.

2. Put expander 5 (#4) in the oil ring groove, and check that
5
ring end makes gap as shown.

3. While holding expander 5 (#4) gap with thumb, put upper

side rail (#3) into the groove so that the gap is away from
gap of expander 5 (#4) to the left by 90 degrees.
5

4. In similar way, put lower side rail (#5) into the groove so that
the gap is away from gap of expander 5 (#4) to the right by
90 degrees.

#2 45° 45°
#3
5. Install second ring (#2 taper) and top ring (#1) to piston. #4 UP
5
Install top Ring (#1) and Second Ring (#2) so that their side d T

with manufacturer's identification d (T) faces upward (valve

side). #5 #1
＃5
＃4
U
P
＃3
＃2
6. Bring their gaps are away from each other as shown. ＃1 d

CAUTION
5 T
Be careful not to scratch piston surface
and damage rings.

· Install piston rings so that their gaps are away

also from thrust direction of piston and
direction piston pin.
· After installing piston rings, check that they
move smoothly.

5-28 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 29

30) Removal of Valves and Springs

1. Place cylinder block on the work bench 1. Push in valve
spring retainer 2 by using valve spring compressor
1
attachment 3, remove cotter pin 4, and then, remove
spring 5 and valve 6.

Valves, springs and other related parts should

be arranged in the order they are removed.

Valve Spring Compressor Attachment 3 :

P/N. 3AB-99076-0

4
2
3
5

6
5

31) Inspection of Valve Springs

1. Measure valve spring free length a. Replace if the length
is less than specified value.

Valve Spring Free Length a : Standard value

35.0 mm (1.38 in)
Functional Limit :
33.2 mm (1.31 in)
a

2. Measure valve spring inclination b. Replace if it is over

b
specified value.

Valve Spring Inclination Limit b :

1.5 mm (0.06 in)

4st 2/2.5/3.5 2007 5-29

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 30

Power Unit
32) Inspection of Valve
1. Check valve for dent and wear on the face. Replace if
necessary.

2. Measure valve stem outer diameter a. Replace if it is less

than specified value.
a
Valve Stem Outer Diameter a : Standard value
Intake Side (IT) : 5.47 mm (0.2154 in)
Exhaust Side (E) : 5.46 mm (0.2150 in)
Functional Limit :
Intake Side (IT) : 5.45 mm (0.2146 in)
Exhaust Side (E) : 5.44 mm (0.2142 in)

3. Measure valve stem runout. Replace if it is over specified

value.

Valve Stem Runout Limit :

Intake Side (IT) : 0.05 mm (0.0020 in)
Exhaust Side (E) : 0.03 mm (0.0012 in)

33) Inspection of Valve Guide

Before inspecting valve guide, check that valve
stem outer diameter is within specified range.

1. Measure valve guide inner diameter b. Replace cylinder

b
block if it is over specified value.

Valve Guide Inner Diameter b : Standard value

Intake and Exhaust Sides : 5.51 mm (0.2169 in)
Functional Limit :
Intake Side (IT) : 5.55 mm (0.02185 in)
Exhaust Side (E) : 5.57 mm (0.02193 in)

2. Obtain clearance between valve guide and valve stem by

calculating as described below. Replace cylinder head
and/or valve if the clearance is over specified value. a

Clearance between Valve Guide and Valve Stem =

Valve Guide Inner Diameter b - Valve Stem Outer Diameter a :
Intake Side (IT) : 0.018 - 0.045 mm (0.00071 - 0.00177 in)
Exhaust Side (E) : 0.025 - 0.052 mm (0.00098 - 0.00205 in)
Functional Limit
Intake Side (IT) : 0.070 mm (0.00276 in)
Exhaust Side (E) : 0.080 mm (0.00315 in)

5-30 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 31

34) Inspection of Valve Seat

1. Remove carbon built up on the valve.

2. Apply thin coat of red lead on the valve seat.

1

3. Use valve lapper 1 (commercially available item) as

shown to push valve 2 onto valve seat lightly.
2
4. Measure width of area where valve face contacted with
valve seat a that can be identified with red lead adhered
to valve face. Correct valve seat if contact area is above or
below the center or contact area of valve seat is over
specified limit.

Valve Seat Contact Width a : Standard value

Intake and Exhaust Sides : 1.0 mm (0.04 in)
Functional Limit :
Intake and Exhaust Sides : 2.0 mm (0.08 in)

5
a

4st 2/2.5/3.5 2007 5-31

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 32

Power Unit
35) Correction of Valve Seat
1. Use valve seat cutter 1 (commercially available item) to
correct valve seat.

30û 45û 60û

2. Turn 45 degree cutter clockwise to cut valve seat surface

to make it smooth.
45˚
a
Be careful not to over-cut valve seat. Turn valve
seat cutter while pushing down evenly.

a Carbon build-up or uneven surface.

3. Use 30 degree cutter to adjust contact position of valve

seat upper end.
b

30˚

b Width before correction

4. Use 60 degree cutter to adjust contact position of valve

seat lower end.
b

60˚

b Width before correction

5-32 4st 2/2.5/3.5 2007
MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 33

5. Use 45 degree cutter to adjust contact width of valve seat

c to specified value.
b
c

45˚

b Width before correction

c Specified width
6. Valve seat contact area is located on the center, which
should be adjusted to specified value by cutting upper and
lower ends by using 30 degree and 60 degree seat cutters 30˚
b
respectively if the area is too wide.

60˚

b Width before correction

7. If valve seat contact area is narrow and is located nearer

to valve face upper end, use 30 degree seat cutter to cut
5
upper end. If necessary, use 45 degree cutter to adjust 30˚ b
contact width of valve seat to specified value.

b Width before correction

8. If valve seat contact area is narrow and is located nearer

to valve face lower end, use 60 degree seat cutter to cut
lower end. If necessary, use 45 degree cutter to adjust
contact width of valve seat to specified value. b

60˚

b Width before correction

4st 2/2.5/3.5 2007 5-33

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 34

Power Unit
9. Apply thin coat of abrasive compound on the overall valve
seat contact area, and turn valve lapper 1 (commercially
1
available item) while tapping valve.

CAUTION
Perform the work by taking care not to
allow abrasive compound to adhere to
valve stem and valve guide.

· Use finer abrasive compound to finish.

· When changing abrasive compound to finer
one, remove present one completely.
· After completion of lapping, wipe off the
b
compound and then clean.
c

10. After ending the work, remove the compound completely

from cylinder head and valve.
45˚
11. Check valve seat contact width c.
b Width before correction
Valve Seat Contact Width c : Standard value c Specified width
1.0 mm (0.04 in)

5-34 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 35

36) Installation of Valves 1

1. Place cylinder block on the work bench. Apply oil to valve

IL
O
4st
guide and attach new valve stem seal 1. 4st OIL

Intake Side : Black

Exhaust Side : Green
Do not reuse the seal. Use new one.

1 Do not reuse.

2. Assemble valve 2, valve spring seat 3, valve spring 4 and

7
retainer 5 in this order, and then, push in the assembly by
using valve spring compressor attachment 6. 5
Valve Spring Compressor Attachment 6 : 4
P/N. 3AB-99076-0

IL
O
4st
4st OIL
3
Valve spring can be put from any end.

5
3. With valve spring 4 being pushed in, use small screw driver
with small amount of grease at the tip to put cotter 7.

7 G
RE
AS
E

OBM
OBM

4. Remove cylinder block from work bench. Tap valve 2 with

plastic hammer to fix cotter 7 securely.

4st 2/2.5/3.5 2007 5-35

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 36

Power Unit
37) Assembly of Cylinder and Crank Case
1. Place cylinder block upside down on the work bench. UP
1 3
3
2. Bring piston crown 1 "UP" mark to flywheel side ←, set
piston ass'y 3 on the cylinder block 2 to assemble.
1
Before assembling, apply engine oil to piston
peripheral surfaces, piston rings and cylinder

IL
O
4st
liner. 4st OIL
2

3. Attach slinger 4.

IL
O
4st
2 4st OIL
4. Install oil seal 5 to crank shaft ass'y 6. 5 4
G
RE
AS
6
Apply grease to lip of oil seal before installing it. LIT
E

LIT a
b
7 7
5. Install crank shaft ass'y 6 to cylinder block 2 as shown.

When installing, bring projection a of bearing 7 b

a
to notch b of cylinder block 2.

6. Apply engine oil to bearing, crank shaft and connecting

rod big end.

7. Attach connecting rod cap 8 to connecting rod 0, and

8
tightening connecting rod bolts 9 in two steps to specified
IL

torque.
O

4st
4st OIL

· Install connecting rod cap 8 after applying

engine oil to inside of the part.
· Bring locating marks c of connecting rod cap 9
8 and connecting rod 0 , and install in
original position (direction).

Connecting Rod Bolts 9 : 0 c

1st tightening torque : 5 N · m (4 lb · ft) [0.5 kgf · m]
2nd tightening torque : 10 N · m (7 lb · ft) [1.0 kgf · m]

5-36 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 37

8. Install lifter q to cylinder block.

IL
O
4st
4st OIL

9. Install cam shaft w to cylinder block 2 as shown.

2

IL
O
4st
Bring crank shaft mark d to cam shaft w mark 4st OIL d
e.

10. Apply 4 stroke engine oil to crank shaft and cam shaft. e
w w

11. Apply Loctite 518 to crank case e mating face (one side) 5
with width of 1.0 mm (0.04 in). e f
· Degrease mating surfaces of cylinder and
crank case.
1.0mm
· Be careful not to allow sealing agent to adhere 1.0mm
to journal area f.
LT

518

LT
· Apply Loctite 518 to mating surface of one of 518 518

518
crank case halves. Be careful not to apply the
agent excessively.

12. Install crank case e to cylinder block 2.

e 6 7

13. Tighten crank case bolts in two steps to specified torque in 3

2
the order shown.

Crank Case Bolts 1 - 8 :

1 4
1st tightening torque : 6 N · m (4 lb · ft) [0.6 kgf · m]
2nd tightening torque : 8.8 N · m (6.5 lb · ft) [0.9 kgf · m]
5 8

4st 2/2.5/3.5 2007 5-37

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 38

Power Unit
14. Attach dowel pin, new gasket and thrust plate.

15. Install oil pan r and tighten bolts to specified torque.

Do not reuse removed gasket. Replace with

r 1 6
new one.
7
Oil Pan Bolts : 1 - 8 3
1st tightening torque : 6 N · m (4 lb · ft) [0.6 kgf · m] G
RE
AS
E

2nd tightening torque : 8.8 N · m (6.5 lb · ft) [0.9 kgf · m] TEF 8

TEF
5
Apply Teflon grease to crank shaft spline. 4
2

16. Reconnect rubber hose t.

5-38 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 39

38) Assembly to Power Unit

1. Install thermostat 1, new gasket and thermostat cover 2.
3 4
2. Install breather cover 3.
a
3. Install throttle cable bracket 4.

Thermostat Cap Bolts : 1

Breather Cover Bolts : b
Throttle Cable Bracket Bolts :
6 N · m (4 lb · ft) [0.6 kgf · m]
2

a bGaskets Do not reuse.

4. Install intake manifold 5 and carburetor ass'y 6 and
tighten the bolts to specified torque. 6
Intake Manifold Bolts :
10 N · m (7 lb · ft) [1.0 kgf · m]
7

5. Attach breather hose 7. 5

6. Reinstall key and flywheel 8 and tighten flywheel nut to

specified torque. 5
CAUTION
Apply forces to tools toward directions as
shown, and perform work taking care not to 8
allow flywheel holder to come off.

Flywheel Holder 9 : 9
P/N. 3AC-99200-0

Flywheel Nut :
43 N · m (31 lb · ft) [4.3 kgf · m]

0
7. Attach igniter 0.

Thickness Gauge q :
P/N. 353-72251-0

Igniter Clearance :
0.2 - 0.4mm (0.008 - 0.016in)

q
8. Install flywheel cover w and recoil starter e.

Recoil Starter Bolts : e

6 N · m (4 lb · ft) [0.6 kgf · m]

9. Tighten spark plug to specified torque and connect plug

cap.
w
Spark Plug :
18 N · m (13 lb · ft) [1.8 kgf · m]

4st 2/2.5/3.5 2007 5-39

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 40

Power Unit
39) Assembly of Rocker Arm
1. Direct magneto key groove 1 to piston top dead center.

Set piston to top dead center of compression 1

stroke. Remove oil filler cap and check that ø5mm
(0.2 in) hole a of cam shaft gear 2 can be seen.

2. Install push rod plate 3 and tighten pivot bolt 4 to

specified torque.
2
Pivot Bolt :
25 N · ｍ (18 lb · ft) [2.5 kgf · m]

a
3. Attach push rod 5, rocker arm 6 and pivot 7, and then,
attach pivot lock nut 8.
4
3
4. Adjust valve clearance. 5

IL
O
4st
Valve Clearance (when engine is cold) 4st OIL
IN : 0.06 - 0.14 mm(0.0024 - 0.0055 in)
EX : 0.11 - 0.19 mm(0.0043 - 0.0075 in)
8
Perform adjustment of valve clearances when 7
engine is cold. 6

5. Tighten pivot lock num 8 to specified torque.

CAUTION
Do not turn flywheel while the locker arm is
free. Doing so can make push rod and
rocker arm interfere with each other,
resulting in damages to these parts.

Pivot Lock Nut

10 N · m (7 lb · ft) [1.0 kgf · m]

6. Install cylinder head cover 9 and tighten to specified

torque.

Cylinder Head Cover Bolts :

9
6 N · m (4 lb · ft) [0.6kgf · m]

5-40 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 41

40) Assembly of Power Unit

1. Apply ThreeBond 1107 to both faces of new gasket, and
attach dowel pins 3 (2 pcs.) and gasket 1. 3

2. Install power unit 3, and tighten bolts 4 (7 pcs.) in two or

three steps to specified torque. 2
2 1
Power Unit Installation Bolt : 1107 T
B

1107
6 N · m (4 lb · ft) [0.6 kgf · m] 4

3. Connect igniter leads and stop switch leads (two leads

respectively).

5
4. Connect choke wire 5.

5. Connect throttle cable 6. Refer to 3.4.7.

G
RE
5
AS
E

OBM
OBM
6. Apply grease to sliding parts such as rods and cables.
6
7. Install fuel tank 7 and fuel cock ass'y 8, and tighten the
bolts to specified torque.

Fuel Tank Bolts :

6 N · m (4 lb · ft) [0.6 kgf · m]

1342
B
1342 T

7 1342 T
B

1342

8. Fill with specified amount of engine oil.

Engine Oil :
OIL
4 Stroke Engine Oil
IL
O

4st
API : SF, SG, SH 4st OIL
SAE : 10W-30, 10W-40
NMMA : FC-W Certified 10W-30
Quantity of Engine Oil : 300 cm3 (10 fl.oz)

4st 2/2.5/3.5 2007 5-41

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 42

Power Unit
41) Disassembly of Recoil Starter
1. Remove bolts and recoil starter and flywheel cover ass'y. a
1

b
2. Put rope in the groove a of reel 1 and gently turn reel 1
clockwise b to release tension of starter spring.

1 Reel

3. Remove starter shaft screw 4, and then, friction plate 3,

4
ratchet and spring 2. G
RE
AS
E
1342 T
B
LIT
1342
LIT 3 2

2 Friction Spring
3 Friction Plate
4 Starter Shaft Screw

4. Take out reel 1 carefully.

5
5. Remove starter spring 5.

It is not necessary to remove starter spring from

reel if it is not necessary to replace it. Starter
spring can be inspected without removing from
reel.

G
RE
AS
E

LIT
LIT

5 Starter Spring

42) Inspection of Recoil Starter

1. Check ratchet and all springs. Replace if any deformation,
wear or damage is found.

2. Check reel and starter case. Replace if any crack or

damage is found.

3. Check starter rope. Replace if any wear, unraveling or

damage is found.

5-42 4st 2/2.5/3.5 2007

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 43

43) Assembly of Recoil Starter 1

Reverse disassembly procedure to assemble by
taking care of the following matters.
1. When setting starter spring into reel 1, face starter spring
outer edge hook to the right and set it into peripheral cut of
starter case.
G
RE

2 LIT
AS
E

2. Run starter rope through rope guide 2 and connect to reel

LIT
1.
2 Rope Guide

3. When installing reel 1 into starter case, set projection of

G
4
B
starter case in the internal hook of starter spring. RE
AS
E
1342 T
LIT
1342
LIT 3
4. Apply low temperature resistant lithium grease.
· Starter Spring
· Friction Plate

5. Put starter shaft screw and tighten to specified torque.

Starter Shaft Screw :

3 Friction Plate
5 N · m (4 lb · ft) [0.5 kgf · m]

5
4 Starter Shaft Screw

a
6. When applying tension to starter spring, hook starter rope
1
into reel groove a, and turn reel 4 to 5 times to direction
to which the reel rotates when pulling out starter rope
(counterclockwise).

4st 2/2.5/3.5 2007 5-43

MFS2_sec05_070524.qxd 07.5.24 3:18 PM ページ 44

Power Unit

5-44 4st 2/2.5/3.5 2007

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 1

6
Lower Unit

1
2
Special Tools ……………………………… 6-2
Parts Layout………………………………… 6-3
16) Removing Clutch Cam and Cam Rod ……… 6-13
17) Disassembly of Clutch Cam and Cam Rod … 6-13
6
Drive Shaft Housing & Gear Case…………… 6-3 18) Inspection of Clutch Cam and Cam Rod …… 6-13
Gear Case (Drive Shaft) ……………………… 6-4 19) Assembly of Clutch Cam and Cam Rod …… 6-13
Gear Case (Propeller Shaft) ………………… 6-5 20) Removing Drive Shaft ………………………… 6-14
Shift……………………………………………… 6-6 21) Disassembly of Drive Shaft…………………… 6-14
3 Inspection Item …………………………… 6-7 22) Inspection of Drive Shaft ……………………… 6-14
1) Draining Gear Oil ………………………… 6-7 23) Inspection of Forward Gear and Pinion Gear
2) Removing Propeller ……………………… 6-7 (A and B Gears) ……………………………… 6-15
3) Removing Lower Unit …………………… 6-8 24) Assembly of Drive Shaft ……………………… 6-15
4) Disassembly of Water Pump …………… 6-8 25) Disassembly of Gear Case …………………… 6-16
5) Inspection of Water Pump ……………… 6-9 26) Inspection of Gear Case ……………………… 6-17
6) Removing Propeller Shaft Housing Ass'y … 6-10 27) Assembly of Gear Case ……………………… 6-17
7) Disassembly of Propeller Shaft Ass'y … 6-10 28) Installation of Clutch Cam and Cam Rod …… 6-18
8) Inspection of Propeller Shaft …………… 6-10 29) Installation of Forward Gear and Pinion Gear
9) Assembly of Propeller Shaft Ass'y ……… 6-11 (A and B Gears) ……………………………… 6-18
10) Disassembly of Propeller Shaft Housing … 6-11 30) Installation of Pump Case (Lower)…………… 6-18
11) Inspection of Propeller Shaft Housing … 6-11 31) Installation of Water Pump …………………… 6-19
12) Assembly of Propeller Shaft Housing … 6-12 32) Installation of Propeller Shaft Housing ……… 6-20
13) Removing Pump Case (Lower) ………… 6-12 33) Filling with Gear Oil …………………………… 6-21
14) Disassembly of Pump Case (Lower) …… 6-12 34) Installation of Lower Unit ……………………… 6-21
15) Assembly of Pump Case (Lower) ……… 6-13
MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 2

Lower Unit
1. Special Tools

Spring Pin Tool A Spring Pin Tool B Center Plate 3 Driver Rod 3
P/N. 345-72227-0 P/N. 345-72228-0 P/N. 3AB-99701-0 P/N. 3AB-99702-0
Used in combination with driver rod and Used in combination with center plate and
Removing spring pin Installing spring pin bearing attachment to locate lower gear
case bearing bearing attachment

Bearing Attachment 3 Bearing Install Tool 2 Universal Puller Plate Bearing Attachment 2
P/N. 3AB-99905-0 P/N. 3AB-99900-0 P/N. 3AC-99750-0 P/N. 3BR-99905-0
Used in combination with driver rod and
center plate to locate lower gear case Installing drive shaft bearing. Removing bearings Installing bearings
bearing

Bearing Attachment 4
P/N. 3BV-99905-0

Installing bearings

6-2 4st 2/2.5/3.5 2007

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 3

2. Parts Layout P/L Fig. 9

Drive Shaft Housing & Gear Case
2 B
2 1107 T
4 1107 6 N·m (4 lb·ft) [0.6 kgf·m]
1-1

1 3 13 N·m (9 lb·ft) [1.3 kgf·m]

6
5

24 23 13 N·m (9 lb·ft) [1.3 kgf·m]

5 N·m (4 lb·ft) [0.5 kgf·m] 22
B
1342 T

B
4st
IL
O 1342
1342 T
4st OIL
1342

13 6 N·m (4 lb·ft) [0.6 kgf·m]

7

B
1342 T
6 N·m (4 lb·ft) [0.6 kgf·m] 1342
12
11 25
10 6 N·m (4 lb·ft) [0.6 kgf·m]
9 G
RE
AS
E

OBM B
1342 T
IL

OBM
O

GEAR
8 1342
GEAR
a
10 N·m (7 lb·ft) [1.0 kgf·m]

B
14 1342 T
15 16-1
16 1342
25

6
10 N·m (7 lb·ft) [1.0 kgf·m] 18
19
GEAR
B
1342 T 17

IL
O
GEAR
1342
G
RE OBM
20 AS
E
6 N·m (4 lb·ft) [0.6 kgf·m] OBM
7 N·m (5 lb·ft) [0.7 kgf·m] 21
17 1107
B
1107 T

a Note: Marked with "SH2 C3"

19 1342
18 B
1342 T

Ref. Ref.
No. Description Q'ty Remarks No. Description Q'ty Remarks

1 Drive Shaft Housing "S" 1 23 Bolt 2 M8 L=35mm

1-1 Exhaust Plug 1 PT 1/8 24 Rubber Hose 1
2 Dowel Pin, 6-12 2 25 Dowel Pin, 6-12 2
3 Bolt 7 M6 L=30mm
4 Drive Shaft Housing Gasket 1 Do not reuse.
5 Water Plug 1 M8 P1.25
6 Gasket, 8.1-15-1 1 Do not reuse.
7 Grommet, 29-3 1
8 Extension Housing " L" 1 for "L"
9 Drive Shaft Bushing 1
10 Drive Shaft Bushing Stopper 1
11 Grommet, 13-2 1
12 Bolt 2 M6 L=12mm
13 Stud Bolt, 6-171 1 M6 L=171mm
14 Nut 1 M6
15 Bolt, 6-30 Pre-coated 1 M6 L=30mm
16 Gear Case 1
16-1 Ball Bearing, 6000 1 Do not reuse.
17 Bolt, 6-30 Pre-coated 2 M6 L=30mm
18 Oil Plug 2 ø6
19 Gasket, 8.1-15-1 2 Do not reuse.
20 Anode 1
21 Bolt 1 M6 L=16mm
22 Steering Bracket 1

4st 2/2.5/3.5 2007 6-3

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 4

Lower Unit
Gear Case (Drive Shaft) P/L Fig. 10

G
RE
AS
17-1
E

TEF
TEF

IL
O
4st
4st OIL
17

6 N·m (4 lb·ft) [0.6 kgf·m]

B
1342 T

10 1342
1 18
12
11
4

IL
O
4st
5
1-1 4st OIL
G
RE
AS
E

b 6 OBM
OBM
3
IL
O

GEAR
GEAR
7
a
19
8

13 4st OIL

IL
O
4st

G
RE
AS
E
GEAR

IL
OBM
14

O
GEAR
OBM
G
RE
AS
OBM
2 E

15 OBM

G
RE
AS
TEF
16 E

TEF

1342
b Note: Marked with "SH2 C3" a Projection B
1342 T

Ref.
No. Description Q'ty Remarks

1 Drive Shaft "S" 1 for "S"

Drive Shaft "L" 1 for "L"
1-1 Ball Bearing, 6000 1 Do not reuse.
2 Pinion Gear ("B"Gear) 1
3 Water Pump Impeller 1
4 Water Pump Impeller Key 1
5 Pump Case (Upper) 1
6 Pump Case Liner 1
7 Pump Case Gasket (Upper) 1 Do not reuse.
8 Water Pump Guide Plate 1
9 Pump Guide Plate Gasket 1 Do not reuse.
10 Bolt 4 M6 L=45mm
11 Washer 4
12 Spring Washer 4
13 Dowel Pin, 2-11 2
14 Pump Case (Lower) 1 with Bushing & O-ring
15 Oil Seal, 10-22-8 1 Do not reuse.
16 Pump Case Gasket (Lower) 1 Do not reuse.
17 Water Pipe "S" 1 for "S"
Water Pipe "L" 1 for "L"
17-1 Water Pipe Grommet (Upper) 1
18 Water Pipe Grommet (Lower) 1
19 Spacer, 10.1-15-72 1

6-4 4st 2/2.5/3.5 2007

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 5

Gear Case (Propeller Shaft) P/L Fig. 11

G
RE
AS
E

OBM
OBM

IL
O

GEAR
6 4
GEAR 7
G
RE
AS
E

OBM
OBM

5
G
RE
AS
E

OBM
G
RE
AS
E
OBM
OBM
OBM

6 N·m (4 lb·ft) [0.6 kgf·m]

1342 T
B 6
1342
GEAR

IL
O
GEAR
IL
O

GEAR
GEAR G
RE
AS
E
OBM
OBM

1342
B
1342 T

Ref.
No. Description Q'ty Remarks

1 Ball Bearing, 6004 1 Do not reuse.

2 Forward Gear( "A"Gear) 1
3 Shim, 21-28-0.1 AR
Shim, 21-28-0.15 AR
4 Propeller Shaft 1
5 Clutch 1
6 Clutch Spring 1
7 Clutch Push Rod 1
8 Propeller Shaft Housing 1
9 Oil Seal, 12-24-8 1 Do not reuse.
10 O-Ring, 3.2-47 1 Do not reuse.
11 Ball Bearing, 6001 1 Do not reuse.
12 Bolt 2 M6 L=20mm
13 Propeller 7(Plastic), 3 x 7.4 x 7 1 Standard
Propeller 6(Aluminum), 3 x 7.4 x 6 1 Option
Propeller 6(Plastic), 3 x 7.4 x 6 1 Option
Propeller 4.5(Plastic), 3 x 7.4 x 4.5 1 Option
14 Shear Pin, 4-24 1 Do not reuse.
15 Split Pin, 4-35 1 Do not reuse.

4st 2/2.5/3.5 2007 6-5

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 6

Lower Unit
Shift P/L Fig. 12

G
4 N·m (3 lb·ft) [0.4 kgf·m]
RE

1 AS
E

OBM
B
OBM 1342 T

1342

5 16
15
7
2

3
4

G
RE
AS
E
2
OBM
OBM
6

12
G
RE
AS
14
E

11 OBM
OBM
13

17
10
9
17 6 N·m (4 lb·ft) [0.6 kgf·m]
18
IL
O

GEAR
GEAR

GEAR
10 GEAR IL
O
8
G
RE
AS
E
OBM
OBM

1342
B
1342 T

Ref.
No. Description Q'ty Remarks

1 Shift Lever 1
2 O-Ring, 1.9-6.8 2 Do not reuse.
3 Ceramic Ball, 7.7 1
4 Shift Lever Stopper Spring 1
5 Washer, 10.5-18-1.5 1
6 Shift Rod Lever 1
7 Bolt 1 M6 L=12mm
8 Clutch Cam 1
9 Cam Rod "S" 1 for "S"
Cam Rod "L" 1 for "L"
10 Spring Pin, 3-8 2 Do not reuse.
11 Cam Rod Bushing 1
12 O-Ring, 2.5-4.9 1 Do not reuse.
13 O-Ring, 2.4-9.5 1 Do not reuse.
14 Shift Rod 1
15 Washer 1
16 Split Pin, 2-12 1 Do not reuse.
17 Shift Rod Joint 1set
18 Bolt 1 M6 L=16mm

6-6 4st 2/2.5/3.5 2007

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 7

3. Inspection Item
2
1) Draining Gear Oil
3
1. Set outboard motor vertical.

2. Remove oil plugs 2 and then 1 to drain gear oil. Refer to

"Replacement of Gear Oil" in Chapter 3.
3
1
Remove lower oil plug 1 first.

3 Gasket Do not reuse.

2) Removing Propeller
1. Shift gear into neutral (N).

2. Remove lock plate (of stop switch lanyard) from stop switch. 3

3. Straighten and pull out split pin 1, and then, remove shear
pin 3 and propeller 2.
4
2 1
5
WARNING
1 Split Pin
Before removing or installing propeller, be
2 Propeller
sure to disconnect spark plug cap and 3 Shear Pin
remove stop switch lock plate. 4 Propeller Shaft
5 Propeller Shaft Housing
6

4st 2/2.5/3.5 2007 6-7

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 8

Lower Unit
3) Removing Lower Unit
Removal of lower unit does not require removal
of power unit from outboard motor body. Tilt up
and lock with tilt stopper.

1. Remove grommet 1 and loosen bolt 2.

1
Bolt 2 should be loosened, not removed from 2
joint 3.

IL
O
4st
4st OIL 3

2. Remove lower unit installation bolts 5 and nut 4, and pull

lower unit ass'y downward to remove.

Check drive shaft spline a for adhesion of oil, a

rust and wear.

4 5

4) Disassembly of Water Pump

1. Remove bolt, and then, pump case (upper) 1 while pushing
drive shaft downward b. 1
When removing or attaching water pump and
4 3
pump case (lower), be careful that the drive
2
shaft is not pushed up. b a
Pushing up the drive shaft causes pinion (B) to
drop into the gear case. 5

2. Remove impeller 2.

a Projection
6-8 4st 2/2.5/3.5 2007
MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 9

5) Inspection of Water Pump

1. Check upper pump case (upper) 1 for deformation. Replace
if necessary.

2. Check impeller 2 and pump case liner 3 for cracks and

wear. Replace if necessary.
2 3

3. Check key 4 and drive shaft installation face a for wear.

Replace if necessary. a

6
4

4. Check water pump guide plate 5 for cracks and wear.

Replace if necessary.
5

4st 2/2.5/3.5 2007 6-9

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 10

Lower Unit
6) Removing Propeller Shaft Housing
Ass'y
1. Remove bolt 1 and pull out propeller shaft housing ass'y 2.

When the ass'y is pulled off a little, put bladed 1

screw driver 3 in the mating surface of lower
gear case to separate it from the case.
2
2. Remove propeller shaft ass'y. 3

7) Disassembly of Propeller Shaft Ass'y 2

1. Remove clutch push rod 1 and then clutch 2 and clutch 1
spring 4.

When removing clutch, push down clutch spring

by using bladed screw driver 3 with thin tip.
3
4

2. Check clutch 2, clutch push rod 1, and clutch spring 4 for

cracks and wear. Replace if necessary.

2
1

8) Inspection of Propeller Shaft

1. Check propeller shaft for bend and wear. Replace if
necessary.

2. Measure propeller shaft runout.

Propeller Shaft Runout Limit :

0.05 mm (0.0020 in)

a a

6-10 4st 2/2.5/3.5 2007

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 11

9) Assembly of Propeller Shaft Ass'y

1. Put clutch spring 1 and attach clutch 3 to propeller shaft 2.

When installing clutch 3, push down clutch

spring 1 by using a bladed screw driver 4.

4 3
1
2

10) Disassembly of Propeller Shaft

Housing
1. Remove bearing 1 by using commercially available bearing
puller.

CAUTION
· Do not reuse removed bearing.
· When reusing bearing without removing it,
check it for play or deflection. Replace if
necessary.

6
1
2 Do not reuse.

2. Remove oil seal 2.

Do not reuse.

11) Inspection of Propeller Shaft

Housing
1. Use cleaning oil and cleaning brush to clean propeller shaft
housing, and check it for cracks or damage. Replace if
necessary.

2. When reusing bearing without removing it, check it for play

or deflection. Replace if necessary.
4st 2/2.5/3.5 2007 6-11
MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 12

Lower Unit
12) Assembly of Propeller Shaft
Housing
1. Apply gear oil to outside of new oil seal 1, and attach it to 2
propeller shaft housing 3 by using a commercially available 1
mandrel 2. 3

IL
O
GEAR
GEAR

1 Do not reuse.

2. Install new bearing 4 to propeller shaft housing 3.

6
5 4
Do not reuse removed bearing.

IL
O
GEAR

3 GEAR
G
RE
AS
E

Bearing Attachment 2 5 : OBM

OBM
P/N.3BR-99905-0
Driver Rod 3 6 :
P/N.3AB-99702-0

4 Do not reuse.

3. Apply OBM grease to lip of oil seal 1.

13) Removing Pump Case (Lower)

1. Remove pump case (lower) and cam rod bushing while
pressing down drive shaft.

When removing or attaching water pump and

pump case (lower), be careful that the drive
shaft is not pushed up.
Pushing up the drive shaft causes pinion (B) to
drop into the gear case.

14) Disassembly of Pump Case (Lower) G

RE
AS

1
E

1. Use bladed screw driver to remove oil seal 1. OBM

OBM

1 Do not reuse.

6-12 4st 2/2.5/3.5 2007

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 13

15) Assembly of Pump Case (Lower) G

RE
AS

2
E

1. Apply gear oil to outside of new oil seal 1, and attach it to OBM
OBM
pump case (lower) 3 with numbered side down by using a 3
commercially available mandrel 2. 1
1

IL
O
GEAR
2. Apply OBM grease to lip of oil seal 1. GEAR

2 Do not reuse.

16) Removing Clutch Cam and Cam Rod

1. Pull cam rod ass'y 1 upward to remove.

1
17) Disassembly of Clutch Cam and
Cam Rod
1. Remove spring pin 2 and clutch cam 3 from cam rod 1.

Use spring pin tool A to remove spring pin.

Do not reuse removed spring pin.

Spring Pin Tool A :

P/N. 345-72227-0

18) Inspection of Clutch Cam and Cam

6
1
Rod
1. Check cam rod 1 and clutch cam 3 for cracks and wear. 2
Replace if necessary.
IL
O

GEAR

19) Assembly of Clutch Cam and Cam GEAR

Rod
1. Install clutch cam 3 and spring pin 2 to cam rod 1.

Spring Pin Tool B : 2

P/N. 345-72228-0
3

2 Do not reuse.

4st 2/2.5/3.5 2007 6-13

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 14

Lower Unit
20) Removing Drive Shaft
1. Pull up drive shaft ass'y 1, remove pinion (B) gear 2 , and
pull out forward (A) gear 3.
1

· When removing forward (A) gear, be careful

not to damage the existing shims or lose them.
Shim is reusable.
· Replace shim with new one of the same 2
thickness if any deformation or damage is
found on it.

21) Disassembly of Drive Shaft

1. Remove drive shaft bearing 1.
1
· Before removing, check bearing for play or
deflection. Replace if necessary.
· Be sure to remove or install from bearing of
pinion (B) gear side.
2
2
CAUTION
Do not reuse bearing. Be sure to replace
① Do not reuse.
with new one.

Universal Puller Plate 2 :

P/N. 3AC-99750-0

22) Inspection of Drive Shaft

1. Check drive shaft for bend and wear. Replace if necessary.

2. Measure drive shaft runout.

Drive Shaft Runout Limit :

0.5 mm (0.020 in) a a

a Supporting Points

6-14 4st 2/2.5/3.5 2007

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 15

23) Inspection of Forward Gear and

Pinion Gear (A and B Gears)
1. Check teeth and jaw of forward (A) gear and pinion (B) gear
and jaw of clutch for cracks and wear. Replace if necessary.

24) Assembly of Drive Shaft

1. Use a press device to install new drive shaft bearing 1 to
drive shaft 2 with the numbered side up.
2

IL
O
GEAR
GEAR
Bearing Install Tool 2 3 :
P/N. 3AB-99900-0 1

CAUTION
Do not reuse bearing. Be sure to replace
with new one. 3
3
Installation Depth a : a
92.00 mm±0.15 mm (3.6220 in±0.0006 in) a

If a special tool is not available and thus the

above depth cannot be maintained, order shaft
ass'y and gear case ass'y.
6
① Do not reuse.

4st 2/2.5/3.5 2007 6-15

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 16

Lower Unit
25) Disassembly of Gear Case
1. Check bearings 1 and 2 for cracks and generation of
abnormal noise. Replace if necessary.
2
CAUTION
Do not reuse removed bearing.

· Do not remove bearing unless it is replaced

with new one.
· Before removing, check bearing for play or
deflection. Replace if necessary.

2. Remove bearing 1 by using commercially available bearing

puller.

1 Do not reuse.

3. Remove bearing 4.

Bearing Attachment 3 3 :
P/N. 3AB-99905-0
Driver Rod 3 4 : 4
P/N. 3AB-99702-0

3
2

3
2

2 Do not reuse.

6-16 4st 2/2.5/3.5 2007

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 17

26) Inspection of Gear Case

1. Check skeg area a and torpedo-like front area b for cracks
and damage. Replace if necessary.

27) Assembly of Gear Case

Do not reuse removed bearing. 5

2 4
1. Install bearing 1 with numbered side up to gear case 2 to
specified depth.

Installation Depth a :
88.10 mm±0.05 mm (3.4685 in±0.0020 in) 3 a
1
· If a special tool is not available and thus the
above depth cannot be maintained, order shaft
5
ass'y and gear case ass'y.
3
Bearing Attachment 3 3 :
1
P/N. 3AB-99905-0
6

IL
O
Center Plate 3 4 : GEAR
GEAR
P/N. 3AB-99701-0
Driver Rod 3 5 :
P/N. 3AB-99702-0 1 Do not reuse.

2. Install new bearing 6 with numbered side up.

Bearing Attachment 4 7 :
P/N. 3BV-99905-0
Center Plate 3 8 :
P/N. 3AB-99701-0
Driver Rod 3 9 :
P/N. 3AB-99702-0

7
IL
O

GEAR
GEAR
6

6 Do not reuse.

4st 2/2.5/3.5 2007 6-17

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 18

Lower Unit
28) Installation of Clutch Cam and Cam
Rod 1
1. Install cam rod ass'y 1 to gear case as
OBM
shown.

IL
O
GEAR
GEAR
Be careful of direction of cam rod.

29) Installation of Forward Gear and

Pinion Gear (A and B Gears)
2
1. Install removed shims and forward (A) gear 1 , and then,
drive shaft ass'y 2 and pinion (B) gear 3.

· Replace shim with new one of the same

thickness if any deformation or damage is
found on removed shim. 3

30) Installation of Pump Case (Lower)

1. Apply OBM grease to oil seal.
G
RE
AS
E

OBM

2. Install new gasket 2 and pump case (lower) 1. 1 OBM

2 Do not reuse.

6-18 4st 2/2.5/3.5 2007

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 19

31) Installation of Water Pump 2

1. Attach new gaskets 1 and 2, water pump guide plate 3 a
and dowel pin 4. 3

1 4

G
RE
AS
E

OBM
OBM

a Projection 1 and 2 Do not reuse.

2. Attach key 5 to drive shaft.

G
RE
AS

3. Bring impeller 6 groove b to key 5 and install impeller to OBM

E

OBM
drive shaft.
5
· Apply grease to the key to prevent it from 6
dropping when attaching.
6
b

4. Attach pump case liner 7 to pump case (upper) 8, and

apply grease to interior of pump case liner 7. d

Bring pump case liner projection c to pump

case (upper) groove d.
8

7 G
RE
AS
E

c OBM
OBM

4st 2/2.5/3.5 2007 6-19

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 20

Lower Unit
5. Install pump case (upper) ass'y 8 on the gear case, and
tighten bolts 0 in two or three steps to specified torque. 9 G
RE
AS

0
E

OBM
OBM
Apply grease to interior of pump case liner, and
install pump case (upper) by pushing it down B
1342 T
e
with hand while turning drive shaft clockwise. 1342
f

IL
O
4st

Pump Case (Upper) Bolts 9 : 4st OIL

6 N · m (4 lb · ft) [0.6 kgf · m]

8
1342
B
1342 T

6. Bring grommet 0 projection e to hole f, and install it to

pump case (upper) ass'y 8.

32) Installation of Propeller Shaft 1

Housing
1. Check that OBM grease is applied to housing ass'y 1 oil
seal 2. 7

2. Install propeller shaft ass'y 3 to propeller shaft housing

5 2 4
1342 T
B

1342
ass'y 1.
3 G
RE
AS
E

OBM
OBM
3. Apply grease to new O-ring 4 and install it.

4. Apply grease to clutch push rod 5 and install it to propeller

shaft ass'y 3.

5. Attach propeller shaft housing ass'y 4 to gear case, and

tighten bolts 7 to specified torque.

Propeller Shaft Housing Bolts 7 :

6 N · m (4 lb · ft) [0.6 kgf · m]

1342
B
1342 T

· Apply grease to clutch push rod to prevent it

from dropping when attaching.
· When installing housing ass'y to gear case,
tighten upper and lower bolts in 2 or 3 steps
evenly to specified torque.

6-20 4st 2/2.5/3.5 2007

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 21

33) Filling with Gear Oil

2 2
1. Feed gear oil to specified quantity 2. "Refer to Chapter 3."
3

IL
O
GEAR
GEAR
Perform "Inspection of Gear Case (Leakage)" in
Chapter 3 if necessary.

3
1
3 Gasket Do not reuse.

2
2

IL
O
GEAR
3 GEAR

3
1
3 Gasket Do not reuse.

34) Installation of Lower Unit

1. Set cam rod 1 to neutral (N) position.
1
F
6
N

4st 2/2.5/3.5 2007 6-21

MFS2_sec06_070524.qxd 07.5.24 3:20 PM ページ 22

Lower Unit
2. Attach lower unit ass'y to drive shaft housing, and tighten
lower unit installation bolts 2 (nut 3 ) to specified torque.

· Connect water pipe securely.

· Move flywheel a little to align the drive shaft
spline to crank shaft spline.

Lower Unit Installation Bolts 2 :

1342
10 N · m (7 lb · ft) [1.0 kgf · m] B
1342 T
B
Lower Unit Installation Nut 3 : 1342 T
1342
1342
6 N · m (4 lb · ft) [0.6 kgf · m]

1342
B
1342 T
1342 A

2 2

å L-Transom Model

3. Install cam rod 1 to joint 4 and tighten bolt 3 to specified

torque.

Joint Bolt 3 : 6
6 N · m (4 lb · ft) [0.6 kgf · m]
3

4. Attach grommet 6 to drive shaft housing.

3

5. Attach shear pin and propeller, insert split pin, and bend the
tip.
4
IL
O

4st

WARNING 4st OIL

1
Before removing or installing propeller, be
sure to disconnect spark plug cap and
remove stop switch lock plate.

G
RE
AS
E

OBM
OBM

6-22 4st 2/2.5/3.5 2007

MFS2_sec07_070524.qxd 07.5.24 3:21 PM ページ 1

7
Bracket

1 Parts Layout………………………………… 7-2 2 Assembling Procedure ………………… 7-7

Clamp Bracket & Swivel Bracket …………… 7-2 1) Assembly of Clamp Bracket …………… 7-7
Drive Shaft Housing & Gear Case…………… 7-3 2) Installation of Steering Stopper ………… 7-7
Shift……………………………………………… 7-4 3) Installation of Drive Shaft Housing……… 7-8

7
Tiller Handle & Throttle ……………………… 7-5 4) Installation of Water Pipe ……………… 7-8
Cowl …………………………………………… 7-6 5) Installation of Tiller Handle ……………… 7-9
6) Adjustment of Throttle Cable …………… 7-10
MFS2_sec07_070524.qxd 07.5.24 3:21 PM ページ 2

Bracket
1. Parts Layout P/L Fig. 13
Clamp Bracket & Swivel Bracket

6 N·m (4 lb·ft) [0.6 kgf·m]

B
1342 T
13 G
RE
AS
G
RE
AS
G
RE
AS 10 N·m (7 lb·ft) [1.0 kgf·m]
1342
E E E

OBM OBM OBM

OBM OBM OBM B
1342 T

4 21 24 25 1342
22 19
1
17
23 27
30
18
14 20 26
6 29
8 16
9
28
15 G
RE
AS

6 N·m (4 lb·ft) [0.6 kgf·m] OBM

E

G
RE
AS 7 OBM
E
B
1342 T OBM
6
1342 OBM 1
G
RE
AS
E
7 N·m (5 lb·ft) [0.7 kgf·m]
OBM
OBM
B
1342 T
5
1342
11
10 6 N·m (4 lb·ft) [0.6 kgf·m]
2-1
B
9 1342 T
8 1342
G 2
RE
AS
E 2-3
OBM
OBM 2-2 G
RE
AS
E
3
OBM
OBM
12

G
RE
AS
E
OBM
OBM

1342
B
1342 T

Ref. Ref.
No. Part Name Q'ty Remarks No. Part Name Q'ty Remarks

1 Clamp Bracket 2 22 Washer 1

2 Clamp Screw Ass'y 2 23 Steering Busing 1
2-1 Clamp Screw 2 24 Thrust Bushing 1
2-2 Clamp Screw Handle 2 25 Bolt, 6-35 Pre-coated 4 M6 L=35mm
2-3 Rivet, 3-22 2 Do not reuse. 26 Pivot Bushing 1
3 Clamp Screw Pad 2 27 Friction Plate Screw 1
4 Bolt, 8-122 1 M8 L=122mm 28 Friction Plate 1
5 Nylon Nut, 8-P1.25 1 M8 29 Friction Spring 1
6 Washer, 8.5-28-1 2 30 Washer 1
7 Distance Piece 1 M6
8 Nut 2 M6
9 Washer 2 M6 L=12mm
10 Thrust Supporter 1
11 Damper (Lower) 1
12 Thrust Rod 1
13 Tilt Stopper Knob 1 Do not reuse.
14 Tilt Stopper 1
15 Swivel Bracket "A" 1
16 Swivel Bracket "B" 1
17 Steering Stopper 1
18 Stopper Lever 1
19 Spring Pin, 2-12 1 Do not reuse.
20 Stopper Lever Spring 1
21 Bolt 1 M6 L=50mm

7-2 4st 2/2.5/3.5 2007

MFS2_sec07_070524.qxd 07.5.24 3:21 PM ページ 3

Drive Shaft Housing & 26-1 P/L Fig. 9

Gear Case

IL
O
4st

26 4st OIL

B
1107 T

1107
2
2
4
1-1 6 N·m (4 lb·ft) [0.6 kgf·m]

1 3
6
5
13 N·m (9 lb·ft) [1.3 kgf·m]
24 23

5 N·m (4 lb·ft) [0.5 kgf·m] 22

13 N·m (9 lb·ft) [1.3 kgf·m]
IL
O

4st
B
1342 T
4st OIL B
1342 1342 T

1342
13
7 6 N·m (4 lb·ft) [0.6 kgf·m]

B
1342 T
6 N·m (4 lb·ft) [0.6 kgf·m]
1342
12
11 25
10 6 N·m (4 lb·ft) [0.6 kgf·m]
9 G
RE
AS
E

OBM B
1342 T
IL

OBM
O

GEAR
8 1342
GEAR
a
10 N·m (7 lb·ft) [1.0 kgf·m]

B
14 1342 T
15 16-1
16 1342
25
10 N·m (7 lb·ft) [1.0 kgf·m] 18
19 GEAR

IL
O
B GEAR
1342 T 17
1342 G
RE
AS
E
OBM
20 6 N·m (4 lb·ft) [0.6 kgf·m] OBM

7
7 N·m (5 lb·ft) [0.7 kgf·m] 21
1107
17 B
1107 T

a Note: Marked with "SH2 C3" 19 1342

18 B
1342 T

Ref. Ref.
No. Part Name Q'ty Remarks No. Part Name Q'ty Remarks

1 Drive Shaft Housing "S" 1 23 Bolt 2 M8 L=35mm

1-1 Exhaust Plug 1 PT 1/8 24 Rubber Hose 1
2 Dowel Pin, 6-12 2 25 Dowel Pin, 6-12 2
3 Bolt 7 M6 L=30mm 26 Water Pipe "S" 1 for "S"
4 Drive Shaft Housing Gasket 1 Do not reuse. Water Pipe "L" 1 for "L"
5 Water Plug 1 M8 P1.25 26-1 Water PipeGrommet (Upper) 1
6 Gasket, 8.1-15-1 1 Do not reuse.
7 Grommet, 29-3 1
8 Extension Housing " L" 1 for "L"
9 Drive Shaft Bushing 1
10 Drive Shaft Bushing Stopper 1
11 Grommet, 13-2 1
12 Bolt 2 M6 L=12mm
13 Stud Bolt, 6-171 1 M6 L=171mm
14 Nut 1 M6
15 Bolt, 6-30 Pre-coated 1 M6 L=30mm
16 Gear Case 1
16-1 Ball Bearing, 6000 1 Do not reuse.
17 Bolt, 6-30 Pre-coated 2 M6 L=30mm
18 Oil Plug 2 ø6
19 Gasket, 8.1-15-1 2 Do not reuse.
20 Anode 1
21 Bolt 1 M6 L=16mm
22 Steering Bracket 1

4st 2/2.5/3.5 2007 7-3

MFS2_sec07_070524.qxd 07.5.24 3:21 PM ページ 4

Bracket
Shift P/L Fig. 12

G
4 N·m (3 lb·ft) [0.4 kgf·m]
RE

1 AS
E

OBM
B
OBM 1342 T

1342

5 16
15
7
2

3
4

G
RE
AS
E
2
OBM
OBM
6

12
G
RE
AS
14
E

11 OBM
OBM
13

17
10
9
17 6 N·m (4 lb·ft) [0.6 kgf·m]
18
IL
O

GEAR
GEAR

GEAR
10
IL
GEAR O
8
G
RE
AS
E
OBM
OBM

1342
B
1342 T

Ref.
No. Part Name Q'ty Remarks

1 Shift Lever 1
2 O-Ring, 1.9-6.8 2 Do not reuse.
3 Ceramic Ball, 7.7 1
4 Shift Lever Stopper Spring 1
5 Washer, 10.5-18-1.5 1
6 Shift Rod Lever 1
7 Bolt 1 M6 L=12mm
8 Clutch Cam 1
9 Cam Rod "S" 1 for "S"
Cam Rod "L" 1 for "L"
10 Spring Pin, 3-8 2 Do not reuse.
11 Cam Rod Bushing 1
12 O-Ring, 2.5-4.9 1 Do not reuse.
13 O-Ring, 2.4-9.5 1 Do not reuse.
14 Shift Rod 1
15 Washer 1
16 Split Pin, 2-12 1 Do not reuse.
17 Shift Rod Joint 1set
18 Bolt 1 M6 L=16mm

7-4 4st 2/2.5/3.5 2007

MFS2_sec07_070524.qxd 07.5.24 3:21 PM ページ 5

Tiller Handle & Throttle P/L Fig. 7

6 N·m (4 lb·ft) [0.6 kgf·m]

22

23
24
G
21 RE
AS
E

OBM

20 OBM

19

G
RE
AS
E

OBM
15
OBM 15

Fig.1-18
6 N·m (4 lb·ft) [0.6 kgf·m]

G
RE
AS
E

18 3 OBM
2 OBM

2
4

G
RE
AS
E 1
OBM
OBM G
RE
AS
E

OBM

16 G
RE
OBM
AS
E

6 OBM
11 OBM
5
14
7
12 9
13
a 10

8 17 7
6 N·m (4 lb·ft) [0.6 kgf·m]
G
RE
AS
E
OBM
a Adjust. OBM

Ref.
No. Part Name Q'ty Remarks

1 Tiller Handle 1
2 Tiller Handle Bushing 2
3 Cover 1
4 Bolt 2 M6 L=16mm
5 Grip 1
6 Throttle Shaft Damper 1
7 Bushing, 14-15.8-7 1
8 Screw 1 ø5 L=18mm
9 Throttle Shaft Supporter 1
10 Screw 1 ø6 L=21mm
11 Friction Piece 1
12 Adjusting Nut 1
13 Spring 1
14 Bolt 1 M6 L=25mm
15 Throttle Cable 2
16 Throttle Decal 1
17 Throttle Shaft 1
18 Throttle Cable Protector 1
19 Throttle Drum 1
20 Throttle Opener 1
21 Collar, 6.5-10.5-22.6 1
22 Bolt 1 M6 L=35mm
23 Washer, 6-16-1.5 1
24 Throttle Rod 1

4st 2/2.5/3.5 2007 7-5

MFS2_sec07_070524.qxd 07.5.24 3:21 PM ページ 6

Bracket
Cowl P/L Fig. 15

2 N·m (1.5 lb·ft) [0.2 kgf·m]

B
13-7
1342 T 13-2
1342
13-3
13-4
13-5
13-6

13-6

13-6
13-6 6 N·m (4 lb·ft) [0.6 kgf·m]
13-1
B
1342 T

13 4 1342

7 3 2
6 N·m (4 lb·ft) [0.6 kgf·m]
8
1342 T
B 11 6
1342
9

10
1

12
15

14

1342
B
1342 T

Ref.
No. Part Name Q'ty Remarks

1 Bottom Cowl 1
2 Cowl Latch 1
3 Collar, 6.2-9-7.4 1
4 Bolt 1 M6 L=16mm
5 Choke Rod Bushing 1
6 Collar, 6.4-10-4.7 4
7 Bolt 4 M6 L=16mm
8 Washer, 6-16-1.5 4
9 Spark Plug Decal (with Resistance) 1
10 Shift Decal (F-N) 1
11 Fuel Lever Decal 1
12 Storage Decal 1
13 Top Cowl 1
13-1 Top Cowl Seal 1 L=1100
13-2 Tilt Handle 1
13-3 Washer 4
13-4 Spring Washer 4 M6
13-5 Nut 4
13-6 Decal Set 1set
13-7 Caution Decal "A" 1
14 Rope 1 ø4-L=1000
15 Tool 1

7-6 4st 2/2.5/3.5 2007

MFS2_sec07_070524.qxd 07.5.24 3:21 PM ページ 7

2. Assembling Procedure 3 1
G
RE
AS
E

OBM

1) Assembly of Clamp Bracket OBM

1. Attach distance piece 2 and bracket bolt 3 to clamp 4

bracket 1.
7
B 5
2. Assemble swivel bracket 4 and clamp bracket 5, thrust 1342 T

1342 2 7
supporter 6,and tighten nylon nut 7 and nut 8 to specified
torque.
B
1342 T
Nylon Nut 7 and Bracket Bolt 3 : 6 0 1342
7 N · m (5 lb · ft) [0.7 kgf · m] 8
G G
RE RE
AS AS
E E

1342 OBM OBM

B OBM OBM 9
1342 T

Distance Piece Nut 8 :

6 N · m (4 lb · ft) [0.6 kgf · m]

1342
B
1342 T

3. Install thrust rod 9 and tighten clamp screw 0.

2) Installation of Steering Stopper

1. Align holes a of steering stopper 1 and stopper lever 2,
1 b d c5 4
and press fit pin 3.

e
6 G
RE
AS
E

a3 OBM

2 OBM

7
2. Put steering stopper ass'y 1 into swivel bracket 4 hole b, 4
and align it with stopper lever 2 and swivel bracket 4 holes 1
c
c, and insert bolt 5.

Hook spring 6 on the part e of stop lever 2, b 5

and insert bolt 5 while pushing the spring
against swivel bracket 4 part d.
2 1342 T
B

1342

3 Tighten steering stopper bolt 5 to specified torque.

Steering Stopper Bolt:

6 N · m (4 lb · ft) [0.6 kgf · m]
5
1342 B
B 1342 T
1342 T
1342

4st 2/2.5/3.5 2007 7-7

MFS2_sec07_070524.qxd 07.5.24 3:21 PM ページ 8

Bracket
3) Installation of Drive Shaft Housing
1. Install drive shaft housing 1 to swivel bracket 2 and tighten
bolts 3 to specified torque.

Swivel Bracket Bolts 3 :

10 N · m (7 lb · ft) [1.0 kgf · m] 2
3
1342 3
B B
1342 T
1342 T B
1342 T 1342
1342 1
Bring projection steering bushing to dent of
swivel bracket when installing the part.

4) Installation of Water Pipe

IL
1. Install water pipe 1 into drive shaft housing 2.

O
4st
4st OIL

7-8 4st 2/2.5/3.5 2007

MFS2_sec07_070524.qxd 07.5.24 3:21 PM ページ 9

5) Installation of Tiller Handle

1. Attach throttle cable 2 to throttle shaft 1 as shown.

1 2
2 G
RE

OBM
AS
E

OBM
G
RE
AS
E

OBM
OBM
2

2. Install throttle shaft 1 with throttle cable 2 to tiller handle 3,

and tighten screw 4 securely.
3 5
G
RE
AS
E
4
Be careful of location of throttle friction 5. OBM
OBM 1

5 Do not apply grease here.

3. Install throttle grip 6 to tiller handle.

b
4. Install bushing 7 on the steering bracket 8.

5. Attach tiller handle 3 ass'y to steering bracket 8, and 9

a 2
tighten bolt 9 to specified torque.
3
Arrange throttle cable 2 as shown. 8
〈a : High Speed Side b : Low Speed Side〉

Cover Bolt 9 :
0 G
RE

OBM
AS
E
7
OBM
6 N · m (4 lb · ft) [0.6 kgf · m]

3 8
B
6. Install tiller handle 3 and steering bracket 4 ass'y to drive 1342 T

6 1342
shaft housing 0.

Steering Bracket Bolt :

13 N · m (9 lb · ft) [1.3 kgf · m]

1342
B
1342 T

4st 2/2.5/3.5 2007 7-9

MFS2_sec07_070524.qxd 07.5.24 4:49 PM ページ 10

Bracket
6) Adjustment of Throttle Cable
1. Turn throttle grip 1 to full close position a.

2. Pull choke rod 2 fully d.

1
c a

2 d
b

3. Attach throttle cable 3 to throttle drum 4 taking care of

4
positions of low speed side e and high speed side f.

4. Pull outer cable g of throttle cable 3 to the side shown with

the arrow by hand, and lock it with the nut while applying
tension to the cable. f h
Push inner cable h with a finger to check that e
3
the cable deflects approximately 1mm (0.04in) g
at the center.

5. Attach high speed side f cable and low speed side e cable
by using the same way.

6. Push back choke rod 2 fully c. (wide open choke)

7. Turn throttle grip 1 to full close position a.

Check that the gap i between the projection of

throttle drum 4 and dent of throttle opener 5 is
within the range from 0.5 - 1.0 mm (0.020 - 0.040 in).

8. Turn throttle grip 1 from full close position a to full open

position b, and check that the throttle lever of carburetor 6
touches the full open stopper j. Then, return the throttle
grip 1 from full open position b to full close position a, and
L
check that the throttle lever of carburetor touches the full
close stopper k (throttle stop screw L ). k

j 6
7-10 4st 2/2.5/3.5 2007
MFS2_sec08_070524.qxd 07.5.24 3:22 PM ページ 1

8
Electrical System

1 Special Tools ……………………………… 8-2 3 Ignition System and Ignition Control System … 8-4
2 Parts Layout………………………………… 8-3 1) Inspection of Ignition Spark……………… 8-4
Magneto ………………………………………… 8-3 2) Inspection of Plug Cap…………………… 8-5
3) Inspection of Igniter ……………………… 8-6
4) Inspection of Stop Switch ……………… 8-7

8
MFS2_sec08_070524.qxd 07.5.24 3:22 PM ページ 2

Electrical System
1. Special Tools

Spark Tester
P/N. 3F3-72540-0

Inspecting sparks

8-2 4st 2/2.5/3.5 2007

MFS2_sec08_070524.qxd 07.5.24 3:22 PM ページ 3

2. Parts Layout P/L Fig. 6

Magneto

6 N·m (4 lb·ft) [0.6 kgf·m]

43 N·m (31 lb·ft) [4.3 kgf·m] 8

4
6 3
9

b
1
BO
N
D

G17

G17

2-1

a
2
O
IL
-C
O
M
P.
GM
SOC
SOC

18 N·m (13 lb·ft) [1.8 kgf·m]

2.3 N·m (1.7 lb·ft) [0.23 kgf·m] 8

7
7-1

BO
N
G17
D

G17
a Spark Plug
O
IL
-C SOC
b Igniter Clearance 0.2 - 0.4mm(0.008 - 0.016in) GM
SOC
O
M
P.

Ref.
No. Part Name Q'ty Remarks

1 Flywheel 1
2 Igniter 1
2-1 Plug Cap (with Resistance) 1
3 Bolt 2 M6 L=20mm
4 Bolt 1 M6 L=12mm
5 Flywheel Cover 1
6 Collar, 6.2-9-35 3
7 Stop Switch 1
7-1 Stop Switch Lanyard 1
8 Magneto Nut (10P-1.25) 1 M10
9 Washer 1

4st 2/2.5/3.5 2007 8-3

MFS2_sec08_070524.qxd 07.5.24 3:22 PM ページ 4

Electrical System
3. Ignition System and Ignition
Control System
1) Inspection of Ignition Spark
1. Disconnect plug cap from spark plug.

2. Connect plug cap to spark tester.

3. Connect spark tester clip to spark plug tip electrode.

Spark Tester:
P/N. 3F3-72540-0

Spark Performance:
5mm (0.2in) or over

0 5 1

0 5 10

4. Start engine and check spark. If spark is weak, check igniter

(including igniter clearance) and/or plug cap.

This test can be made without removing parts.

WARNING
OK
• When testing, put electrode cap assuredly
to prevent direct contact with spark tester
wiring and leak of electrical current, and
perform test carefully.
• Keep flammable gas, fuel and oil away
from tester to prevent them from catching
sparks.

8-4 4st 2/2.5/3.5 2007

MFS2_sec08_070524.qxd 07.5.24 3:22 PM ページ 5

2) Inspection of Plug Cap

Remove the part and test it as a separate unit.

BO
N
D

G17

G17
1. Disconnect plug cap from spark plug.

2. Remove plug cap from high tension cable.

3. Measure plug cap resistance. Replace if other than specified

value.

Plug Cap Resistance (at 20˚C) :

3.0 - 7.0 kΩ

4st 2/2.5/3.5 2007 8-5

MFS2_sec08_070524.qxd 07.5.24 3:22 PM ページ 6

Electrical System
3) Inspection of Igniter
BO
N

1. Remove igniter, and turn plug cap counterclockwise to G17

D

G17
remove it from high tension cord.

2. Measure igniter resistance. Replace if other than specified

value.

Remove the part and test it as a separate unit.

Igniter Resistance (at 20˚C) :

Secondary Coil:Between High Tension Cord and
BO
N

Black (B) G17

D

2.0 - 3.0 kΩ G17

Secondary Coil:Between Plug Cap and Black (B)

5.5 - 9.5 kΩ
Igniter Diode Polarity (at 20˚C):
Primary Circuit:Between Black (B) and Brown (Br)
No conduction
Primary Circuit:Between Brown (Br) and Black (B)
Conductive

Use of analog tester is suitable for checking the

polarity. The instrument HIOKI3030 indicates a
resistance ranging from 5 to 9kΩ. A digital tester
may indicate reversed polarity and resistance
ranging from 2 to 6MΩ.

3. Install plug cap onto high tension cord by twisting clockwise.

4. Install igniter so that specified clearance is achieved, and

connect plug cap to spark plug.

Thickness Gauge 1:
P/N. 353-72251-0

Igniter Clearance:
0.2 - 0.4mm(0.008 - 0.016in)

Igniter Bolts: 1
6 N · m (4 lb · ft) [0.6 kgf · m]

5. Connect igniter lead to stop switch.

8-6 4st 2/2.5/3.5 2007

MFS2_sec08_070524.qxd 07.5.24 3:22 PM ページ 7

4) Inspection of Stop Switch a b

1. Check conduction of stop switch, and replace if not
conductive.

This test can be made without removing parts.

Lead Wire Color

Switch Position
Brown (Br) Black (B)
Remove
c
lock plate. a
Attach
lock plate. b
Press
switch. c

4st 2/2.5/3.5 2007 8-7

MFS2_sec08_070524.qxd 07.5.24 3:22 PM ページ 8

Electrical System

8-8 4st 2/2.5/3.5 2007

MFS2_sec09_070524.qxd 07.5.24 3:23 PM ページ 1

OK
9
Troubleshooting

OK
1 Troubleshooting List …………………… 9-2 Ignition System …………………… 9-6
2 Power Unit ………………………………… 9-3 Compression Pressure…………… 9-7
Trouble 1 Engine will not start or is a little hard to start. Trouble 3 Idle engine speed will not stabilize. … 9-8
(Recoil starter operates normally.) ………… 9-3 Trouble 4 Rough acceleration. …………… 9-9
Trouble 2 Engine starts but stalls soon. … 9-5 Trouble 5 Gear shifting cannot be made normally. … 9-10
Fuel System ……………………… 9-5

9
MFS2_sec09_070524.qxd 07.5.24 3:23 PM ページ 2

OK Troubleshooting
1.Troubleshooting List

Boat cannot run at high

Engine speed is very high causing
Engine stalls immediately

Defective acceleration.

Engine speed is low.

Engine will not start.

high speed ESG to operate.

Engine overheats.
Idles abnormally.
after starting.

speed.
Probable Cause

○ ○ Fuel level is low in the tank.

○ ○ ○ ○ ○ ○ ○ Fuel system connection is incomplete.

Fuel & Lubrication System

○ ○ ○ ○ ○ ○ ○ Fuel pipe is twisted.

○ ○ ○ ○ ○ ○ ○ Air vent screw is closed.

○ ○ ○ ○ ○ ○ ○ Fuel cock or carburetor is clogged.

○ ○ ○ ○ ○ ○ ○ Low quality gasoline

○ ○ ○ ○ Fuel is fed excessively.

○ ○ ○ ○ ○ ○ ○ Carburetor is maintained poorly.

○ ○ ○ ○ ○ Engine oil is deteriorated.

○ ○ ○ ○ Engine oil level is too high.

○ ○ Engine oil lacks.

○ ○ ○ ○ ○ ○ ○ Use of spark plugs not specified

Ignition System

○ ○ ○ ○ ○ ○ Spark plug carbon deposit or bridge

○ ○ ○ ○ ○ ○ No sparks or weak spark

○ Stop switch short-circuited

○ Stop switch lock is not in place.

○ ○ ○ ○ ○ ○ Ignition timing is not properly adjusted.

○ ○ ○ ○ ○ ○ Valve timing is wrong.

○ ○ ○ ○ ○ ○ Valve clearance is wrong.

Compression

○ ○ ○ ○ ○ ○ Valve seat sealing is defective.

○ ○ ○ ○ ○ ○ Piston, piston ring and/or cylinder is worn excessively.

○ ○ Combustion chamber excessive carbon deposits.

○ ○ ○ ○ Spark plug is loose.

○ ○ ○ (Cooling water is lacking.) Water pump is defective or clogged.

○ ○ ○ Thermostat operation is defective.

○ ○ ○ ○ Anti-cavitation plate is damaged.

○ ○ ○ ○ ○ Use of mismatched propeller.

Others

○ ○ ○ ○ ○ ○ Propeller is damaged or deformed.

○ ○ ○ ○ ○ Thrust rod position is not correct.

○ ○ ○ ○ ○ Boat is unbalanced by load position.

○ ○ ○ ○ ○ Transom installation height is too high or too low.

○ ○ ○ ○ ○ ○ Throttle link adjustment is defective.

9-2 4st 2/2.5/3.5 2007

MFS2_sec09_070524.qxd 07.5.24 3:23 PM ページ 3

Before working on the outboard motor, check the hull, rigging, installation of outboard motor, fuel
level, and wire connections. For mechanical troubleshooting, refer to relevant troubleshooting
section in this chapter. For checking and servicing outboard motor, refer to service procedures
described in this manual to perform the work safely.

2. Power Unit
Trouble 1 Engine will not start or is a little hard to start. (Recoil starter operates normally.)

• Inspection of Ignition System, Fuel System and Compression Pressure

Check electrical conductivity of

stop switch.
(with lock plate attached)

NO
Normal ? Replace stop switch.

YES WARNING
• When testing, put electrode cap assuredly to prevent
Use spark tester to check direct contact with spark tester wiring and leak of
ignition sparks. electrical current.
• Keep flammable gas, fuel and oil away from tester to
prevent them from catching sparks.

NO
Check igniter and/or
Normal ?
plug cap.

YES

Check spark plug.

NO Clean spark plug

Good? and adjust gap,
or replace with new one.

YES

Check compression pressure.

9

NO
Out of specified
Check fuel system.
range?

To next page YES

4st 2/2.5/3.5 2007 9-3

MFS2_sec09_070524.qxd 07.5.24 3:23 PM ページ 4

OK Troubleshooting

Check valve clearance.

NO
Normal ? Adjust valve clearance.

YES
Check valves,
cylinder block
and/or piston ass’y.

9-4 4st 2/2.5/3.5 2007

MFS2_sec09_070524.qxd 07.5.24 3:23 PM ページ 5

Trouble 2 Engine starts but stalls soon.

• Inspection of Fuel System, Ignition System, Compression Pressure

Fuel System

Check air vent screw of fuel tank.

NO
Open? Open air vent screw.

YES

Check if fuel contains water

and fuel filter is clogged.

NO
Does fuel contains water, Check fuel hose for bend
or is fuel filter clogged? and fuel leak.

YES
Is fuel hose bent NO
or does fuel leak Check carburetor.
Clean fuel tank.
from the hose?

YES

Replace defective part

with new one.

4st 2/2.5/3.5 2007 9-5

MFS2_sec09_070524.qxd 07.5.24 3:23 PM ページ 6

OK Troubleshooting
Ignition System

Use spark tester to check

ignition sparks.

NO Check igniter
Normal ?
and/or plug cap.

YES WARNING
• When testing, put electrode cap assuredly to prevent
Replace spark plug
direct contact with spark tester wiring and leak of
with new one.
electrical current.
• Keep flammable gas, fuel and oil away from tester to
prevent them from catching sparks.

9-6 4st 2/2.5/3.5 2007

MFS2_sec09_070524.qxd 07.5.24 3:23 PM ページ 7

Compression Pressure

Check if secondary air

is sucked through mating surface
of carburetor or intake manifold.

NO
Is secondary air Check compression
sucked? pressure.

YES

Replace defective part

and seal with new ones.

4st 2/2.5/3.5 2007 9-7

MFS2_sec09_070524.qxd 07.5.24 3:23 PM ページ 8

OK Troubleshooting
Trouble 3 Idle engine speed will not stabilize.

• Inspection of Intake Manifold, Air Intake System and Ignition System

Check operations
of throttle cable and drum.

NO
Normal ? Adjust throttle cable.

YES

Check ignition timing.

NO Check gaskets
Out of specified
if secondary air is
range?
sucked through them.

YES

Check igniter clearance.

9-8 4st 2/2.5/3.5 2007

MFS2_sec09_070524.qxd 07.5.24 3:23 PM ページ 9

Trouble 4 Rough acceleration.

Rapid opening of throttle causes engine to stall.

Acceleration is not smooth.
• Inspection of Carburetor, Ignition System and Compression Pressure

Check operation of throttle cable.

NO
Is the throttle
Adjust throttle cable.
valve tuned ?

YES

Disassemble carburetor,
and check internal components
for clogging, dirt and damage.

NO
Any clogging, Check ignition system and
dirt and/or damage? compression pressure.

YES
Clean carburetor
and/or replace
defective part(s)
with new one(s).

4st 2/2.5/3.5 2007 9-9

MFS2_sec09_070524.qxd 07.5.24 3:23 PM ページ 10

OK Troubleshooting
Trouble 5 Gear shifting cannot be made normally.

Check operations of shift lever.

NO
Normal ? Check spring and ball.

YES

Check shift rod joint.

NO
Normal ? Replace shift rod.

YES
Disassemble lower unit
and check operation of clutch.

NO
Normal ? Replace defective part
with new one.

YES
Check forward gear and
pinion (A and B gears)
and clutch.

9-10 4st 2/2.5/3.5 2007

MFS2A_cover_E_070524.qxd 07.5.24 5:06 PM ページ 2

Copyright © 2007 Tohatsu Corporation. All rights reserved. No part of this manual
may be reproduced or transmitted in any form or by any means without the express
written permission of Tohatsu Corporation.
MFS2A_cover_E_070524.qxd 07.5.24 5:06 PM ページ 1

OB No.003-21058-0 OB No.003-21058-0
07-04 NB-2600
Printed in Japan 07-04 NB-2600