Raider 50 User manual

Two stroke - Multi-Fuel –Submersible
Outboard Motor
Service Manual R50ES-002-1 1
RAIDER 50 SERVICE MANUAL
January 2017 Rev. 3
Part No. SMR50ES-002-2

GB
Introduction
Before reading this manual
This service manual provides information that is needed for inspection, service and repair of the
Raider 50 outboard motor. For information about operation of the products that are not
described in this document, refer to the owner’s manual (Part No. OMR50ES-002). For our
users we have built the best outboard motor for long term, it is essential for the maintainer to
prepare the outboard prior to the mission. To ensure this, the maintenance and service have to
be done properly by a service technician with fundamental knowledge and skills. This manual
is utilized so that our operators can always use their outboard motor with full satisfaction.
Raider Outboards are a Commercial Off The Shelf (COTS) based upon the Tohatsu MWX50D2
which uses the heavy duty gear case. Modifications to this COTS product are detailed in this
service manual.
Safety Information
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 damage.
Take Notice.

GB
About this manual
Composition and use of this manual
This service manual is designed so that service personnel are able to perform repairs
correctly. Understand the following subject matters well for efficient service and repair.
1 Each chapter begins with the introduction of special tools that are used for the work described.
2 Parts that are serviced in each chapter and their details are presented by using a component composition
diagram.
3 Fastening torques are described in the component composition diagram. In the body text are critical
points of the applicable work.
4 Pictograms indicate that there is an important work instruction for the relevant parts. It also shows the type
of lubricant and its application point(s).
5 The component composition diagrams describe the names of the parts, the number of pieces of the parts
used, size of fasteners and special notes.
6 Specific works are described in detail by using illustrations and adding advice on the work.

This manual uses the International System of Units (SI) unit system for the pressure, force (load),
torque and stress. This manual adopts the international unit construction system (SI unit system)
followed by the conventional imperial and metric systems enclosed by ( ) and [ ] as described
below.
<Reference>
What is the SI unit system?
Although the measurement unit is standardized mostly with metric system in the world, the metric
system includes different kinds of unit systems. Though the metric system was established expecting
that a single unit system is used in the world, various physical units were established later, resulting in
branching the metric system in different unit systems. The new unit system is called International System
of Units because it was established for the purpose of unifying the different unit systems.
Since the metric system was initially established in France, and International Bureau of Weights
and Measures (IBWM) is located in Paris, General Conference of Weights and Measures (GCWM)
passes a resolution of the international unit system as "Systéme International d'Unités (French)" that
is abbreviated as SI unit . For example, conventional metric system uses the unit of mass (kg) and
unit of force (kg or kgf) without discriminating them, but the SI unit system uses, for example, kg as the
unit of mass, and N as the unit of force, aiming to apply a kind of unit for a kind of physical quantity.

Corrosion Zero

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1.Service Information
1. Identification
(Engine Serial Number)... ........ .1-2
2. Work Safety........................ .1-2
1) Fire Prevention................................... .1-2
2) Ventilation........................... .1-2
3) Protection ............................ 1-2
4) Genuine Parts ... ................. .. 1-2
5) Tools ... .................... ... 1-4
6) Recommendations on Service .... 1-4
7) Cautions in Disassembling and
Assembling Components ...... 1-6
3. Tools and Instruments ........... .1-8
1) Test Propeller ... ................ .. 1-8
2) Measuring Instruments ... ......... .1-8
3) Special Tools ... ................. .. 1-10
4. Pre-delivery Inspection ...... 1-16
1) Tiller Handle.................................. .. 1-16
2) Gear Shift ................................. ... 1-16
3) Gear Oil ... ...................... .1-16
4) Fuel and Fuel Line ........................ .. 1-18
5) Installation of Outboard Motor
(Rigging)... ..................... .1-18
6) Propeller Selection ........................ .. 1-20
7) Cooling Water Check Port .. 1-22
8) Trim Tab ... ....................... .1-22
5. Break-In Operation..................... .. 1-24
6. Test Run ... .................... .. 1-24
7. Checks After Test Run........... ... 1-24
2.Service Data
1. Outboard Dimensions ..................... .2-2
1) Body dimensions... ................. .2-2
2) Clamp Dimensions ... ........ ... 2-4
2. Cooling Water System Diagram ... 2-6
3. Specifications ............................ .. 2-8
4. Maintenance Data ... ....... ... 2-12
5. Torque Specifications... ....... .2-16
6. Sealant And Lubricant ........... ... 2-17
3.Maintenance
1. Special Tool ............................ ... 3-2
2. Inspection Schedule ... ....... .. 3-2
3. Inspection Items .................. .3-6
1) Inspection of Top Cowl ... ......... .3-6
2) Inspection of Fuel Tank ... ......... .3-6
3) Fuel System .................... ... 3-8
4) Inspection of Cooling Water Passage . 3-10
5) Flushing with Water ... ........ .. 3-10
6) Inspection of Compression Pressure .3-14
7) Inspection of Spark Plugs .. 3-18
8) Inspection of Thermostat ...... 3-20
9) Adjustment of Throttle Cable .... 3-22
10) Ignition Timing Adjustment ..... 3-24
11) Carburetor Synchronization..... 3-26
12) Pilot screw adjustment ... ......... .3-30
13) Replacement of Gear Oil ...... 3-32
14) Inspection of Gear Case (for leakage) .. 3-34
15) Inspection of Propeller ... ......... .3-34
16) Replacement of Anode............. .3-36
17) Greasing........................... .3-38
4.Fuel System
1. Special Tools .................. ... 4-2
2. Parts Layout ............................ ... 4-4
Fuel line ... .............................. .4-4
Intake Silencer • Carburetor ... .......... .4-6
3. Carburetor Inner Passages .... 4-10
1) Idling Passage.................................. .4-10
2) Off-Idle Passage........................ ... 4-12
3) High Speed Passage........................ .4-14
4) Choking Passage
(#2 and #3 carburetor) ............. .4-16
4. Inspection Items.................... ... 4-18
1) Removing Carburetors............. .4-18
2) Disassembling Carburetors .4-20
3) Cleaning and Inspection ...... 4-22
4) Inspection of Fuel Pump and
Needle Valve ..................................... .4-24
5) Disassembly and Inspection of Fuel
Pump ... ................... .. 4-34
6) Assembly of Fuel Pump ...... 4-26
7) Inspection of Fuel Connector .... 4-26
8) Inspection of Fuel Filter ............. ... 4-26
9) Assembling Carburetors ...... 4-28
10) Inspection of Float Height .. 4-30
11) Installing Carburetors ....................... .4-30
5.Power Unit
1. Special tools ... .............. ... 5-2
2. Parts Layout ............................ ... 5-4
Engine ... ........................... .5-4
Magneto............................................... ... 5-6
Electric Parts................................................ .5-8
Recoil Starter... ....................... .5-10
Intake Manifold · Reed Valve ...... 5-14
Throttle............................................... ... 5-16
Cylinder Crank Case.......................... ... 5-20
Piston & Crank Shaft ......................... ... 5-24
3. Inspection Items ... ............... .5-26
1) Removing Power Unit ............. .5-26
2) Removing Flywheel ............ .. 5-32
3) Removing Electric Parts ...... 5-32
4) Removing Throttle Link.............. ... 5-34
5) Removing Intake Silencer and
Carburetors..................................... .. 5-38
6) Removing Intake Manifold and
Reed valves.................................... .. 5-40
7) Inspection of Reed Valve Ass'y ... 5-40
8) Removing Thermostat and
Engine Anode..................................... .5-42
9) Removing Cylinder Head / Head Cover .. 5-46
10) Inspection of Cylinder Head .5-48
11) Removing Exhaust Cover .. 5-50
12) Inspection of Exhaust Cover .5-50

13) Removing Crank Case... ......... .5-52
14) Removing Pistons... ......... ... 5-54
15) Disassembly of Crank Shaft .5-56
16) Inspection of Crank Shaft .. 5-56
17) Inspection of Engine Parts ..... 5-60
18) Inspection of Pistons......................... .5-62
19) Assembling Crank Shaft ...... 5-68
20) Installing Needle Bearing and Pistons... 5-70
21) Assembling Power Unit Parts .... 5-74
22) Assembling Crank Ass'y and
Crank Case..................................... .. 5-76
23) Assembling Exhaust Cover Parts .. 5-78
24) Assembling Cylinder Head Parts .. 5-80
25) Assembling Coil Bracket Parts ... 5-82
26) Assembling Crank Case Head Parts .. 5-82
27) Installing Reed Valve, Intake
Manifold and Intake Silencer. .... 5-84
28) Attaching Recirculation Hoses ... 5-88
29) Installing Throttle Link ............ .5-90
30) Installing Electric Parts............ .5-92
31) Installing Flywheel............ ... 5-92
32) Installing Power Unit............ .. 5-94
33) Disassembly of Recoil Starter.... 5-96
34) Inspection of Recoil Starter ..... 5-98
35) Assembling of Recoil Starter .... 5-98
6.Lower Unit
1. Special Tools ... .............. ... 6-2
19) Removing Drive Shaft Ass’y .6-52
20) Disassembly of Drive Shaft Ass’y .. 6-54
21) Inspection of Drive Shaft ...... 6-54
22) Inspection of Pinion (B) Gear .... 6-54
23) Assembly of Drive Shaft Parts ... 6-56
24) Removing Forward (A) Gear Ass’y .6-60
25) Disassembly of Forward Gear (A) Gear
.. 6-60
26) Inspection of Forward (A) Gear ... 6-62
27) Assembly of Forward (A) Gear Parts
.. 6-62
28) Disassembly of Gear Case ..... 6-66
29) Inspection of Gear Case ...... 6-68
30) Assembly of Gear Case Parts.... 6-70
31) Measurement of Pinion (B) Gear Height
and Shim Selection ... ........ .. 6-76
32) Measurement of Back Lash between
Forward (A) and Pinion (B) Gears and
Shim Selection ... ................ .6-80
33) Measurement of Back Lash between
Pinion (B) and Reverse (C) Gears and
Shim Selection ... ................ .6-88
34) Assembly of Lower Unit Parts.... 6-92
35) Assembly of Pump Case ...... 6-94
36) Attaching Clutch Cam Ass’y .6-96
37) Measurement of Propeller Shaft Play and
Selection of Washer Thickness ... 6-98
38) Installation of Lower Unit .. 6-100
2. Parts Layout............................ ... 6-6
Gear Case (Drive Shaft, MX50) ... ......... .6-6
Gear Case (Drive Shaft, MWX50)...... 6-14
Gear Case (Propellor Shaft, MWX50) .... 6-18
3. Inspection Items .................. .6-22
1) Draining Gear Oil ... ......... ... 6-22
2) Removing Propeller ... ......... .. 6-22
3) Removing Lower Unit........................ .6-24
4) Disassembly of Cam Rod .. 6-26
5) Inspection of Clutch Cam...... 6-26
6) Assembly of Clutch Cam Parts ... 6-28
7) Removing Water Pump.............. ... 6-30
8) Inspection of Water Pump .. 6-32
9) Inspection of Water Pipe ...... 6-32
10) Disassembly of Water Pump Case
(Lower) .............................................. .6-34
11) Assembly of Water Pump Case
(Lower) .............................................. .6-34
12) Removing Propeller Shaft Housing
Ass’y............................................... .. 6-36
13) Disassembly of Propeller Shaft Housing
Ass’y............................................... .. 6-38
14) Inspection of Propeller Shaft Housing
.. 6-42
15) Assembly of Propeller Shaft Housing
.. 6-42
16) Disassembly of Propeller Shaft Ass’y
.. 6-46
17) Inspection of Propeller Shaft Ass’y .6-48
18) Assembly of Propeller Shaft Ass’y .. 6-50
7.Bracket
1. Parts Layout ............................ ... 7-2
Drive Shaft Housing .................................... .7-2
Bracket Manual Tilt... ................. .. 7-4
Manual Tilt............................................... .. 7-8
Tiller Handle ... ........................ .7-10
Bottom Cowl • Shift ... ................. .7-12
TOP COWL ... ........................ .7-16
2. Inspection Items.................... ... 7-18
1) Inspection of Throttle Cable .7-18
2) Removing of Tiller Handle .. 7-18
3) Installation of Tiller Handle ..... 7-20
4) Removing Bottom Cowl............. ... 7-24
5) Removing Drive Shaft Housing ... 7-26
6) Disassembly of Drive Shaft Housing .. 7-28
7) Inspection of Drive Shaft Housing ... 7-32
8) Assembly of Drive Shaft Housing Parts .. 7-34
9) Assembling Rubber Mounting.... 7-38
10) Assembling Extension Housing ... 7-40
11) Removing Steering Shaft Arm ... 7-42
12) Installing Steering Shaft............. ... 7-44
13) Disassembling Clamp Bracket ... 7-46
14) Assembling Clamp Bracket ..... 7-48
15) Disassembling tilt mechanism.... 7-50
16) Assembling tilt mechanism ..... 7-52
8.Electrical System
1. Special Tools ... .............. ... 8-2
*What’s Peak Voltage...................... .8-2

Merit of adoption of
peak voltage measurement ... ......... 8-2
Recommended tester... .................... 8-2
2. Parts Layout ................................. 8-4
Magneto ....................................... 8-4
Electric Parts (C.D. Unit) ................ 8-6
3. How to use Peak Voltage Adapter .8-8
Attention of measurement ... .......... 8-8
Measurement procedure: ... ........... 8-8
4. Inspection date ... .......................... . 8-10
Resistance test reference.............. .8-10
Peak voltage out put test reference ... 8-10
5. Inspection Items....................... ... 8-12
1) Inspection of Ignition and spark ... 8-12
2) Inspection of Plug Cap Terminal .. 8-12
3) Inspection of Ignition Coils ..... 8-14
4) Inspection of Pulser Coil ...... 8-14
5) Inspection of Exciter Coil .. 8-16
6) Inspection of C.D.unit .............. .8-16
7) Inspection of Stop Switch .. 8-18
9.Troubleshooting
1. Troubleshooting Chart ... ............... . 9-2
2. Power Unit ... ................................ . 9-3
1 Engine will not start ... ............. .. 9-3
Starting System ........................9-3
Ignition System .........................9-4
Fuel System ...................... ... 9-6
Compression Pressure ............ . 9-7
2 Engine starts but stalls soon......................... ... 9-8
Fuel System ...................... ... 9-8
Ignition System .........................9-9
Compression Pressure........... . 9-10
3 Idle engine speed will not stabilize..... 9-11
4 Rapid opening of throttle fails acceleration... 9-12
5 Gear shifting cannot be made normally. .. 9-13
10. Safety Jet - Optional

INDEX
1
Service Information
2
Service Data
3
Maintenance
4
Fuel System
5
Power Unit
6
Lower Unit
7
Bracket
8
Electrical System
9
Troubleshooting
10
Wiring Diagram
11
Safety Jet

ES
1
Service Information
1. Identification
(Engine Serial Number) ..... 1-2
2. Work Safety ... ............. .. 1-2
1) Fire Prevention... ........ ... 1-2
2) Ventilation ... ............... …1-2
3) Protection ... ............... .. 1-2
4) Genuine Parts ... ........ ... 1-2
5) Tools ........................ . 1-4
6) Recommendations on Service .. 1-4
7) Cautions in Disassembling and
Assembling Components . 1-6
3. Tools and Instruments ..... 1-8
1) Test Propeller........................ ... 1-8
2) Measuring Instruments .. 1-8
3) Special Tools ........................ ... 1-10
4. Pre-delivery Inspection ..... 1-16
1) Tiller Handle ... ................. .1-16
2) Gear Shift ... ............... .. 1-16
3) Gear Oil ... ................ ... 1-16
4) Fuel and Fuel Line ....................... .1-18
5) Installation of Outboard Motor
(Rigging) .................................... .. 1-18
6) Propeller Selection ... ......... .1-20
7) Cooling Water Check Port .... 1-22
8) Trim Tab ................................... .. 1-22
5. Break-In Operation ........... .1-24
6. Test Run........................ .1-24
7. Checks After Test Run ..... 1-24