TOHATSU M 40 User manual

PNo. 003-21036-1
0509 NB 1000
Printrd in Japan
SERVICE3-4.qxd05.8.2411:48AMページ1

TABLE OF CONTENTS
Service Safety
General Service Information
Fuel System
Powerhead
Midsection
Gearcase
Electrical System
Power Trim/Tilt
1
2
3
4
5
6
7
8
3-/ 4-Cylinder

3-/ 4-Cylinder
1-1
Introduction ......................................................................................................................... 1-2
Safety Statements................................................................................................................ 1-2
Safety Precautions ............................................................................................................... 1-3
Workmanship Standards...................................................................................................... 1-5
Test Tank Guidlines .............................................................................................................. 1-7
SECTION 1
SERVICE SAFETY
TABLE OF CONTENTS

SECTION 1
1-2
3-/ 4-Cylinder
WARNING
Inadequate knowledge of safe shop practices
can result in severe injury or death. Review
general safety procedures and specific safety
information provided for each procedure prior to
beginning any repairs.
INTRODUCTION
Marine manufacturers are required to comply with special
regulations and standards to ensure their products are safe and
reliable for the consumer. As the marine technician, it is your
responsibility to keep these products safe when performing normal
rigging, repair, and maintenance operations.
It is not possible to foresee all safety hazards which may occur or
to include all the knowledge of an experienced technician in a
single service manual. Therefore, it is assumed that those using this
manual have a working knowledge of 2-cycle outboard engines
and the proper technical training for servicing them.
This section discusses safe shop practices and general safety
concerns relevant to the operations performed throughout this
manual. Read this section carefully and follow all safety statements
in this manual as they pertain to the procedures at hand.
Remember, always use common sense when servicing outboard
engines!
SAFETY STATEMENTS
The following safety statements are found throughout this manual
and indicate information which, if ignored, could result in safety
hazards or faulty service techniques:
DANGER
Indicates the presence of a hazard which, if
ignored, WILL result in severe injury or death.
WARNING
Indicates the presence of a hazard which, if
ignored, COULD result in severe injury or death.
CAUTION
Indicates the presence of a hazard which, if
ignored, COULD result in minor personal injury or
damage to product, equipment, or other property.
NOTE
Indicates special information to facilitate the
installation, operation, or maintenance of the product
or further clarify information which is important but
not hazard related.
KC-5030

SERVICE SAFETY
1-3
3-/ 4-Cylinder
SAFETY PRECAUTIONS
Handling Outboard Engines
•Never disable the neutral switch start-in-gear prevention system
to accommodate installation of a foot control or other option.
Always test the neutral switch and emergency stop switch before
returning an engine to the customer.
•Lifting devices and hardware must be of suitable capacity for the
weight of the outboard engine. Some models are equipped with
a fixed hanger on the powerhead. Hanger may be used to lift the
complete engine or to remove the powerhead unit. Be aware the
engine may swing outward when lifted by the hanger.
•Engine stands must be in good condition, of adequate size, and
mounted properly to prevent unexpected shifting or collapse.
•Engine covers are guards to prevent personal contact with the
spinning flywheel and high voltage components such as spark
plugs and coils. Never wear jewelry or loose clothing near a
running engine. Keep hands, arms and hair away from the
flywheel. Never touch electrical components when the engine is
running.
•Two people working on a running engine must use extreme
caution and be aware of one another. Never attempt to start an
engine or operate any controls, including steering, before
signaling your partner.
•To prevent accidental startup during operations which may
cause the flywheel to turn, always perform the following steps:
1. Turn the ignition key to OFF and remove the key.
2. Disable the engine ignition system.
3. Shift engine to NEUTRAL and verify propeller shaft is not in
gear.
•Rotating propellers are not equipped with guards and can cause
severe injury or dismemberment. Always stay clear of rotating
propellers and make sure there is no possibility of engine startup
before removing or installing a propeller. The propeller nut must
always be tightened to torque specification prior to starting the
engine.
KC-5000
KC-4090
KC-4075.3

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

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

SECTION 1
1-6
3-/ 4-Cylinder
8. Keep all removed parts separated for ease of identification
during assem bly.
9. Locate alignment marks on components being disassembled.
If marks are not present and should be, scribe or match mark them
yourself to ensure the pieces are assembled properly.
10. Follow torque sequences and specifications where they apply.
First, tighten each bolt in the specified sequence. Use the same
sequence to torque each bolt to final specification. Special torque
specifications are listed at the beginning of each section. Standard
torque specifications for common fasteners are listed in Section 2.
11. Use specified lubricant when assembling seals to prevent
damage to the seal lips. Make sure seal lips are facing the correct
direction.
12. Use the correct type and amount of sealing compound on metal
to metal surfaces.
13. When using compressed air to clean or dry parts, make sure air
supply is regulated not to exceed 25 psi [172 kPa / 1.76 kg/cm
2
].
14. Replace missing or damaged safety labels on the engine before
returning it to the customer.

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

3-/ 4-Cylinder
2-1
General Precautions ............................................................................................................ 2-2
Abbreviations and Symbols ................................................................................................ 2-3
Unit Conversions ................................................................................................................. 2-4
Service Specifications ......................................................................................................... 2-5
Engine Specifications .......................................................................................................... 2-8
Lubrication Chart .............................................................................................................. 2-11
Periodic Inspections .......................................................................................................... 2-14
Break-In Procedure ........................................................................................................... 2-18
Tune-Up Procedure ........................................................................................................... 2-20
Emergency Stop Switch and Lanyard ............................................................................... 2-21
Operator Alert Systems ..................................................................................................... 2-22
Synchronization and Linkage Adjustments ....................................................................... 2-25
Anodes - Inspection and Testing ...................................................................................... 2-39
SECTION 2
GENERAL SERVICE
INFORMATION
TABLE OF CONTENTS

SECTION 2
2-2
3-/ 4-Cylinder
GENERAL PRECAUTIONS
Before performing any service work on the outboard engine, read
and understand Section 1 - Service Safety.
Use only genuine factory replacement parts with equivalent
characteristics such as type, material, and strength. Failure to do
so may result in product malfunction and injury to the operator or
passengers.
Follow the
Standard Torque Values chart when a special torque
value for a certain fastener is not listed in the
Special Torque
Values
chart at the beginning of each section.
Rather than just repairing a bad part, use repair kits and overhaul
kits when applicable to ensure complete and efficient repair of the
complete component. Wear not readily noticed on other parts can
lead to malfunction soon after the repair.
When indicated in a procedure, use manufacturer special tools. In
some cases, the use of substitute tools will damage the part.
When using compressed air to clean ordry parts, make sure air
supply is regulated not to exceed 25 psi [172 kPa/ 1.76 kg/cm
2
].

GENERAL SERVICE INFORMATION
2-3
3-/ 4-Cylinder
ABBREVIATIONS AND SYMBOLS
Abbreviations
A
AC
AH
approx.
API
ATDC
BTDC
˚C
CCA
cm
cm
3
cm
3
/min
cu-in
DC
DVA
Kg-m
˚F
fl oz
fl oz/min
ft
ft-lb
ft-lbf/min
g
gal/hr
gal
GL
GM
HP
I.D.
in
in-lb
kg
kg/cm
2
ESG
kPa
kW
ampere
alternating current
ampere-hour
approximately
American Petroleum Institute
after top dead center
before top dead center
degree Celsius
cold cranking amp
centimeter
cubic centimeter
cubic centimeter per minute
cubic inch
direct current
direct volt adapter
kilogram meter
degree Fahrenheit
fluid ounce (U.S.)
fluid ounce (U.S.) per minute
foot
foot pound
foot pound force per minute
gram
gallon (U.S.) per hour
gallon (U.S.)
gear lubricant
General Motors Company
horsepower (U.S.)
inside diameter
inch
inch pound
kilogram
kilogram per square centimeter
electronic speed governor
kilopascal
kilowatt
L
L/hr
Ib
mL
mm
mV
N
N-m
NMMA
No.
O.D.
oz
PS
psi
qt
RPM
SAE
sec.
t
TDC
V
VAC
VDC
W
Symbols
˚
+
-
±
Ω
µ
%
liter
liter per hour
pound
milliliter
millimeter
millivolt
newton
newton meter
National Marine
Manufacturers Association
number
outside diameter
ounce
horsepower (metric)
pound per square inch
quart (U.S.)
revolution per minute
Society of Automotive Engineers
second
short ton 2000 Ib
top dead center
volt
volt alternating current
volt direct current
watt
angular degree
plus
minus
plus or minus
ohm
micro
percent

SECTION 2
2-4
3-/ 4-Cylinder
UNIT CONVERSIONS
Unit Prefixes
Prefix Symbol Power
mega M x 1,000,000
kilo k x 1,000
centi c x 0.01
milli m x 0.001
micro
µ x 0.000001
Units of Length
mile x 1.6090 = km
ft x 0.3050 = m
in x 2.5400 = cm
in x 25.4000 = mm
km x 0.6210 = mile
m x 3.2810 = ft
cm x 0.3940 = in
mm x 0.0394 = in
Units of Volume
gal (U.S.) x 3.78540 = L
qt U.S.) x 0.94635 = L
cu-in x 0.01639 = L
cu-in x 16.38700 = mL
fl oz (U.S.) x 0.02957 = L
fl oz (U.S.) x 29.57000 = mL
cm
3
x 1.00000 = mL
cm
3
x 0.03382 = fl oz (U.S.)
Units of Mass
lb x 0.45360 = kg
oz x 28.35000 = g
kg x 2.20500 = Ib
gx0.03527 = oz
Units of Force
lbf x 4.4480 = N
lbf x 0.4536 = kgf
N x 0.2248 = Ibf
N x 0.1020 = kgf
kgf x 2.2050 = Ibf
kgf x 9.8070 = N
Units of Torque
ft-lb x 1.3558 = N-m
ft-lb x 0.1383 = kg-m
in-lb x 0.1130 = N-m
in-lb x 0.0115 = kg-m
kg-m x 7.2330 = ft-lb
kg-m x 86.8000 = in-lb
kg-m x 9.8070 = N-m
N-m x 0.7376 = ft-lb
N-m x 8.8510 = in-lb
N-m x 0.1020 = kg-m
Units of Pressure
psi x 0.0689 = bar
psi x 6.8950 = kPa
psi x 0.0703 = kg/cm
2
bar x 14.5030 = psi
bar x 100.0000 = kPa
bar x 29.5300 = in Hg (60˚F)
kPa x 0.1450 = psi
kPa x 0.0100 = bar
kPa x 0.0102 = kg/cm
2
kg/cm
2
x 98.0700 = psi
kg/cm
2
x 0.9807 = bar
kg/cm
2
x 14.2200 = kPa
in Hg (60˚F) x 0.0333 = bar
in Hg (60˚F) x 3.3770 = kPa
in Hg (60˚F) x 0.0344 = kg/cm
2
Units of Power
HP x 1.01400 = PS
HP x 745.70000 = W
HP x 550.00000 = ft-lbf/s
PS x 0.98630 = HP
PS x 735.50000 = W
PS x 542.50000 = ft-lbf/s
W x 0.00134 = HP
W x 0.00136 = PS
W x 0.73760 = ft-lbf/s
kW x 1.34100 = HP
kW x 1.36000 = PS
kW x 737.56000 = ft-lbf/s
ft-lbf/s x 0.00181 = HP
ft-lbf/s x 0.00184 = PS
ft-lbf/s x 1.35600 = W
Units of Temperature
˚F = (1.8 · ˚C) + 32
˚C = 0.556 · (˚F - 32)

GENERAL SERVICE INFORMATION
2-5
3-/ 4-Cylinder
SERVICE SPECIFICATIONS
Standard Torque Values
Manufacturer Special Tools Required
Powerhead
Flywheel Puller Assembly Kit......................................... 3C7-72211-0
Plate, Flywheel Puller ........................ 3B7-72783-0, 3C7-72783-0
Bolt, M8 x 25 mm (3 pcs) ..........................................3B7-72786-0
Bolt, M8 x 40 mm (3 pcs) ..........................................3B7-72785-0
Washer (3 pcs) ...........................................................940191-0800
Pressing Bolt .............................................................3B7-72784-0
Powerhead Stand .......................................................... 353-72247-1
Piston Pin Tool ....................................... 345-7221 5-0, 353-72215-0
Piston Ring Tool ............................................................. 353-72249-0
Thickness Gauge Set .................................................... 353-72251-0
Gearcase
Socket, Bevel Gear B Nut ......................345-72232-0, 3B7-72232-0
Wrench, Bevel Gear B Nut ......................346-72231-0, 3B7-72231-0
Bevel GearA Bearing Puller Assembly .. 3A3-72755-0 , 3B7-72755-0
Bevel GearA Bearing Set Tool .............. 3C8-72719-0 , 3B7-72719-0
Bevel Gear A Bearing Outer Race Fitting Tool ..............3B7-72739-0
Needle Roller Bearing Puller Kit ............ 3C8-72700-0, 3B7-72700-0
Needle Bearing Press Kit ...............................................3C7-72900-1
Backlash Measurement Tool Kit (Gear A & B) ...... 3C8-72234-0, 3B7-72234-0
Backlash Measurement Tool Kit (Gear B & C) ..............................3B7-72255-0
Backlash Measuring Tool Clamp ...................................3B7-72720-0
Bolt for Lower Pump Case (4 pcs) ........910191-0830, 910191-0835
Dial Gauge Plate .............................................................3B7-72729-0
Shimming Gauge ............................................................3B7-72250-0
Thickness Gauge Set ................................................... (353-72251-0)
Shift Rod Joint Puller ..................................................... 353-72248-0
Spring Pin Tool A .................................... 345-72227-0, 369-72217-0
Spring Pin Tool B .................................... 345-72228-0, 369-72218-0
Clutch Pin Snap Tool ...................................................... 345-72229-0
Size in-lb ft-lb N·m kg-m
M4 10 - 17 0.8 - 1.4 1 - 2 0.1 - 0.2
M5 26 - 35 2.2 - 2.9 3 - 4 0.3 - 0.4
M6 44 - 52 3.6 - 4.3 5 - 6 0.5 - 0.6
M8 97 - 133 8 - 11 11 - 15 1.1 - 1.5
M10 204 - 274 17 - 22 23 - 31 2.3 - 3.1
Torque
These torque values apply only when a special torque specification is not listed in the Special Torque
Values chart at the beginning of each section.

SECTION 2
2-6
3-/ 4-Cylinder
Power Trim/Tilt
Tilt Rod Guide Wrench ...........................................3C8-72791-0
Trim Rod Guide Wrench .........................................3B7-72792-0
General Equipment Required
Water Pressure Gauge, 0 - 15 psi [0 - 103 kPa / 0 - 1 kg/cm
2
]
Fuel Pressure Gauge, 0 - 15 psi [0 - 103 kPa / 0 - 1 kg/cm
2
]
Torque Wrench, 0 - 150 in-lb [0 - 17 N
⋅ m / 0- 1.7 kg-m]
Torque Wrench, 0 - 750 ft-lb [0 - 1000 N
⋅ m / 0 - 102 kg-m]
Dial Gauge, minimum scale 0.0001 in [0.01 mm]
Micrometer Set or Dial Caliper, minimum scale 0.0001 in [0.01 mm]
Telescoping Gauge, Inside Micrometer Set, or Dial Caliper, minimum scale 0.0001 in [0.01 mm]
Variable Load High Rate Discharge Tester,
Electronic Specialties
®
Model 700 or equivalent
Analog Multimeter, Electronic Specialties
®
Model M-530 or equivalent
Digital Multimeter, Electronic Specialties
®
Model KD 3200 or equivalent
Digital Pulse Tachometer, 10 - 6000 RPM,
Electronic Specialties
®
Model 321 or equivalent
Ammeter, 0 - 100A
Gearcase Pressure Tester,
Stevens
®
S-34 or equivalent
Gearcase Vacuum Tester,
Stevens
®
V-34 or equivalent
Engine Compression Gauge, 0 - 300 psi [0 - 2000 kPa / 0 - 20 kg/cm
2
]
Spark Gap Tester,
Stevens
®
S-13C, S-48, or equivalent
Flexible Fuel Tubing, 1/4 in I.D. x 5 in [6 mm I.D. x 127 mm]
Flexible Fuel Tubing, 3/8 in I.D. x 5 in [9.5 mm I.D. x 127mm]
Industrial Thermometer, minimum 300˚F [150˚C]
Heat-Resistant Container,
Pyrex
®
Bearing Puller
Seal Pullers
Seal Installers
HeatGun
Hydrometer

GENERAL SERVICE INFORMATION
2-7
3-/ 4-Cylinder
Consumables Required
Threadlocker, Loctite
®
242
Threadlocker, Loctite
®
243
Gasket Dressing, Permatex
®
Hylomar
®
Aerosol High-Temp Gasket Dressing
Gasket Sealant, Permatex
®
High Tack Gasket Sealant
Anaerobic Gasket Maker, Loctite
®
518
Silicone Sealant, Permatex
®
Hi-Temp RTV Silicone Gasket
Super Bond Adhesive, Permatex
®
Super Glue Gel
Cleaning Pads, Scotch-Brite
®
Abrasive Pads
Low Temperature Lithium Grease
Genuine Grease or Equivalent Friction Surface Marine Grease
Power Trim/Tilt Fluid,
Nisseki
®
power torque fluid or GM approved automatic transmission fluid
Isopropyl Alcohol
Cleaning Solvent
Gasket Remover
Gear Lubricant,
Genuine gear oil or API grade GL5, SAE #80 - #90
Engine Lubricant, Genuine engine oil or NMMA certified TC-W3 oil
Automotive Crankcase Oil, flashpoint above 300˚F [150˚C]
Battery Spray Protector,
Permatex
®
Battery Protector & Sealer
Electrical Shrink Tubing, various diameters

SECTION 2
2-8
3-/ 4-Cylinder
Standard Bore
40, 50 ............................................ 2.677 in [68 mm]
60, 70 ............................................ 2.913 in [74 mm]
80, 90 ............................................ 3.386 in [86 mm]
115, 120, 140 ................................ 3.465 in [88 mm]
Stroke
40, 50 .............................................. 2.52 in [64 mm]
60, 70, 80, 90, 115, 120, 140 ......... 2.86in [72.7mm]
Piston Clearance
40, 50 .............. 0.0012 - 0.0028 in [0.03 - 0.07 mm]
60, 70 .............. 0.0016 - 0.0031 in [0.04 - 0.08 mm]
80, 90 .............. 0.0031 - 0.0051 in [0.08 - 0.13 mm]
115, 120, 140 .. 0.0039 - 0.0055 in [0.10 - 0.14 mm]
Piston Ring End Gap
40, 50 Top Ring ... 0.009 - 0.015 in [0.22 - 0.37 mm]
40, 50 2nd Ring .. 0.013 - 0.019 in [0.33 - 0.48 mm]
60, 70 .................. 0.009 - 0.015 in [0.22 - 0.37 mm]
80, 90 .................. 0.010 - 0.016 in [0.25 - 0.40 mm]
115, 120, 140....... 0.011 - 0.019 in [0.28 - 0.49 mm]
Crankshaft Dimensions
Dimension
40, 50 ...................
60, 70 ...................
80, 90 ...................
115, 120, 140 .......
Dimension
80, 90 only ...........
T1756
1
1*
ENGINE SPECIFICATIONS
Operation
2.598 0 in
- 0.001 [66 0 mm]
- 0.02
Power
40 ...................................................40 HP [29.4 kW]
50 ...................................................50 HP [36.8 kW]
60 ...................................................60 HP [44.1 kW]
70 ...................................................70 HP [51.5 kW]
80 ...................................................80 HP [58.8 kW]
90 ...................................................90 HP [66.2 kW]
115 ...............................................115 HP [84.6 kW]
120 ...............................................120 HP [88.3 kW]
140 ...............................................140 HP [103 kW]
Full Throttle RPM Range
40D ...................................................... 4500 - 5500
40D
2
..................................................... 5000 - 5700
50D ...................................................... 5000 - 5700
50D
2
..................................................... 5150 - 5850
60B, 70B .............................................. 4900 - 5600
60C, 70C .............................................. 5150 - 5850
80, 90 ................................................... 5000 - 5500
115, 120, 140 ....................................... 5200 - 5700
IN
Idle RPM
GEAR NEUTRAL
40, 50 ........................................... 750 900
60, 70 ........................................... 750 900
80, 90, 115, 120, 140 ................... 700 900
Fuel Consumption at Full Throttle
40 ..................................................4.5 g/hr [17 L/hr]
50 ..................................................5.6 g/hr [21 L/hr]
60 ..................................................6.3 g/hr [24 L/hr]
70 ..................................................7.4 g/hr [28 L/hr]
80, 90 ............................................9.5 g/hr [36 L/hr]
115 ..............................................13.2 g/hr [50 L/hr]
120 ..............................................13.2 g/hr [50 L/hr]
140 ..............................................15.3 g/hr [58 L/hr]
Test Propeller
40, 50 ................................................. 3C8-64111-0
60B, 70B .............................................3F3-64111-0
60C, 70C ............................................ 3B7-64111-0
80, 90 ................................................. 3B7-64111-0
115, 120, 140 ..................................... 3C7-64111-0
Powerhead
Number of Cylinders
40, 50, 60, 70, 80, 90 .............................................3
115, 120, 140 .........................................................4
Displacement
40, 50 .................................... 42.5 cu. in [697 cm
3
]
60, 70 .................................... 57.2 cu. in [938 cm
3
]
80, 90 .................................... 77.3 cu. in [1267 cm
3
]
115, 120, 140 ...................... 107.9 cu. in [1768 cm
3
]
2.087 0 in
- 0.001 [53 0 mm]
- 0.02
2.362 - 0.008 in
- 0.009 [60 - 0.20 mm]
- 0.22
2.677 0 in
- 0.001 [68 0 mm]
- 0.02
2.677 0 in
- 0.001 [68 0 mm]
- 0.02

GENERAL SERVICE INFORMATION
2-9
3-/ 4-Cylinder
Spark Plug (with resistor)
40 ............... NGK BR7HS-10 or Champion RL-82C
50, 60, 70, 80, 90, 115, 120, 140 ...NGK BR8HS-10
or Champion RL-78C
Spark Plug (without resistor)
40 .................... NGK B7HS-10 or Champion L-82C
50, 60, 70, 80, 90, 115, 120, 140 ..... NGK B8HS-10
or Champion L-78C
Spark Plug Gap ...... 0.035 - 0.039 in [0.9 -1.0 mm]
Battery ................ 12 V, 500 CCA with 105 minutes
[70 AH] reserve capacity
Engine Fuse .................................................... 20 A
Alternator
40, 50, 60, 70, 80, 90 ............................ 12 V 130 W
115, 120, 140 ....................................... 12 V 330 W
Charging Performance (at 1500 RPM)
40, 50, 60, 70, 80, 90 ......................................... 3 A
115, 120, 140 .................................................... 12A
Charging Performance (at 5500 RPM)
40, 50, 60, 70, 80, 90 .................................. 9 - 11 A
115, 120, 140 ...................................... 24.5 - 27.5 A
Number of Tachometer-to-Alternator
Coil Impulses
40, 50, 60, 70, 80, 90 .............................................6
115, 120, 140 .......................................................12
Alternator Coil Resistance
40, 50 ........................................... W - Y, 0.2 - 0.3 Ω
60, 70 ............................................. W-Y, 0.2 - 0.3 Ω
80, 90 ......................................................0.2 - 0.3 Ω
115, 120, 140 ......................................0.26 - 0.40 Ω
Ignition Coil Resistance (±25%)
Primary Coil
40, 50 ..................................................0.18 - 0.24
Ω
60, 70 ..................................................0.18 - 0.24 Ω
80, 90 ..................................................0.19 - 0.25 Ω
115, 120, 140 .....................................0.18 - 0.24 Ω
Secondary Coil
40, 50 ....................................................2.7 - 3.7 k
Ω
60, 70 ....................................................2.7 - 3.7 k Ω
80, 90 ....................................................3.6 - 4.8 k Ω
115, 120, 140 .......................................2.7 - 3.7 k Ω
Dimension
40,50 ....................
60,70 ....................
80,90 ....................
115,120, 140 ........
Dimension
40, 50 ......................................... 9.173 in [233 mm]
60, 70 .................................... 10.020 in [254.5 mm]
80, 90 ....................................... 11.339 in [288 mm]
115, 120, 140 ........................... 15.669 in [398 mm]
Gearcase
Gear Ratio
40, 50 ............................................... 13 : 24 (0.542)
60B, 70B .......................................... 13 : 23 (0.565)
60C, 70C .......................................... 13 : 28 (0.464)
80, 90, 115, 120, 140 ....................... 13 : 26 (0.500)
Lubricant .............................Genuine manufacturer
gear oil or API GL5, SAE #80 - #90
Capacity
40, 50 ...................... Approx. 17 U.S. fl oz [500 mL]
60B, 70B ................. Approx. 24 U.S. fl oz [700 mL]
60C, 70C ................. Approx. 30 U.S. fl oz [900 mL]
80, 90, 115,120, 140 .............. Approx. 30 U.S. fl oz
[900 mL]
Clutch System ..............................Dog clutch type
(Forward-Neutral-Reverse)
Electrical System
Ignition Type ............. Flywheel magneto capacitor
discharge
Ignition Timing
40D .............................ATDC 3˚ ± 1˚ - BTDC 18˚ ± 1˚
40D
2
...........................ATDC 3˚ ± 1˚ - BTDC 18˚ ± 1˚
50D .............................ATDC 3˚ ± 1˚ - BTDC 24˚ ± 1˚
50D
2
...........................ATDC 3˚ ± 1˚ - BTDC 20˚ ± 1˚
60B .............................ATDC 3˚ ± 1˚ - BTDC 16˚ ± 1˚
60C ..........................ATDC 3˚ ± 1˚ - BTDC 17.5˚ ± 1˚
70B .............................ATDC 3˚ ± 1˚ - BTDC 20˚ ± 1˚
70C ..........................ATDC 3˚ ± 1˚ - BTDC 17.5˚ ± 1˚
80 ...............................ATDC 5˚ ± 1˚ - BTDC 20˚ ± 1˚
90 ...............................ATDC 5˚ ± 1˚ - BTDC 20˚ ± 1˚
115 .............................. ATDC 10˚ - BTDC 17.5˚ ± 1˚
120 .............................. ATDC 10˚ - BTDC 17.5˚ ± 1˚
140 ................................. ATDC 10˚ - BTDC 20˚ ± 1˚
2
3
1.457 + 0.002 in
0 [37 + 0.05mm]
0
1.467 + 0.002 in
0 [
37.25
+ 0.05mm]
0
1.732 + 0.002 in
0 [44 + 0.05 mm]
0
1.654 + 0.002 in
0 [42 + 0.05 mm]
0

SECTION 2
2-10
3-/ 4-Cylinder
CD Unit Output (Cranking)
40, 50, 60, 70, 80, 90, 115, 120, 140...........130 Min
Exciter Coil Output (Cranking)
40, 50, 60C, 70C, 80, 90, 115, 120, 140 ... 130 DVAMin
60B, 70B .... 10-15 DVA (Brown/White to White/Yellow)
100-200 DVA (White/Green to White/Yellow)
Pulser Coil Output (Cranking)
40, 50, 60, 70, 80, 90, 115, 120, 140 ...........3.0 Min
note
Magneto for Model 60 / 70
Magneto style for Model 60/70 was
changed and they are not interchangeable
between both parts. The following
Serial Numbers indicate breakpoints
between older and newer magneto
models.
Remark) Magneto consists a flywheel cup, coil
plate assembly, CD unit and ignition coils.
Fuel System
Required Fuel, Lubricant, and Mix Ratio
See Fuel System Requirements in Section 3
Oil Pump
Plunger type with internal worm gear, crankshaft
driven
Oil Pump Output at 1500 RPM (Engine Speed)
Note: Lever opening position is 50˚ to full.
40, 50 ....................... 0.049 fl oz/min [1.45 cm
3
/min]
60, 70 ....................... 0.085 fl oz/min [2.50 cm
3
/min]
80, 90 ....................... 0.123 fl oz/min [3.65 cm
3
/min]
115, 120, 140 ........... 0.192 fl oz/min [5.67 cm
3
/min]
Oil Pump Mix Ratio
At Trolling Speed ................. 120-100 gasoline:1 oil
At Full Throttle Speed ....................50 gasoline:1 oil
Model Magneto Serial number
60B / 70B Older All of Engines
60C Older and Newer Newer : 10840 or
higher
70C Older and Newer Newer : 13002 or
higher
Oil Automixing Tank Capacity
40, 50 ................................................ 2.11 qt [2.0 L]
60, 70 ................................................ 2.75 qt [2.6 L]
80, 90 ................................................ 3.70 qt [3.5 L]
115, 120, 140 .................................... 6.34 qt [6.0 L]
Carburetor
40, 50, 60, 70, 80, 90 .............3 butterfly valve type
carburetors, float feed
115, 120, 140 .........................4 butterfly valve type
carburetors, float feed
Power Trim/Tilt
Lubricant
Nisseki power torque fluid (as shipped from factory)
or any GM approved automatic transmission fluid:
• Mobil DTE #22 or Mobil AFT 220
• Shell Dextron II orShell Tellus Oil #22 K22
• Esso Automatic Transmission Fluid

GENERAL SERVICE INFORMATION
2-11
3-/ 4-Cylinder
LUBRICATION CHART
Low temperature lithium grease
Genuine grease or equivalent friction surface marine grease
Location
Type
of
Lubricant
Frequency
Fresh
Water
Salt
Water
Advancer Arm,
Throttle Cam, and
Linkage Ball Joints
Every
50 hours
(3 month
)
Every
30 hours
(1 months)
Shitt Lever and Shift
Arm
Guide Plate and Set
Ring
Starter Motor Pinion
Throttle Cables
Manual Choke Lever
Carburetor Choke
Valve Control Levers
Throttle Shaft and
Steering Handle
Bushings
Steering Handle Grip
Portion
11
21
31
42
52
62
72
82
92
1
2
T1045 T1046 T1047
T1048
T1049
T1050
T1051T1053 T1052