TOHATSU NB-1000 User manual

PNo. 003-21035-1
0509 NB 1000
Printrd in Japan
ドキュメント105.8.231:33PMページ1

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

1-/ 2-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
1-/ 2-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
1-/ 2-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
1-/ 2-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 wiII 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. lf 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 weII 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
1-/ 2-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, cotter 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 aIl 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
1-/ 2-Cylinder
8. Keep all removed parts separated for ease of identification during
assembly.
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 3.
11. Use 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
1-/ 2-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 wiII 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 tankwhich
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 away from the
engine and work area.
•Water may splash out of the tank during testing. Maintain water
leveI
(3) in the tank as illustrated.
•Keep transom board
(4) at an approximately 75° angle to the
tank bottom to ensure near vertical engine position.
T1016

1-/ 2-Cylinder
2-1
General Precautions············································································································· 2-2
Abbreviations and Symbols ································································································· 2-3
Unit Conversions·················································································································· 2-4
Service Specifications·········································································································· 2-5
Engine Specifications········································································································· 2-17
Lubrication Chart ··············································································································· 2-20
Periodic Inspections··········································································································· 2-24
Break-ln Procedure ············································································································ 2-27
Tune-Up Procedure············································································································ 2-28
Emergency Stop Switch and Lanyard················································································ 2-29
Synchronization and Linkage Adjustments········································································ 2-30
Carburetor Adjustment······································································································· 2-36
Anodes - Inspection and Testing ······················································································· 2-38
SECTION 2
GENERAL SERVICE
INFORMATION
TABLE OF CONTENTS

SECTION 2
2-2
1-/ 2-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. ln
some cases, the use of substitute tools will damage the part.
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
].

GENERAL SERVICE INFORMATION
2-3
1-/ 2-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-Ibf/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
lb
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 lb
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
1-/ 2-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
mx3.2810 = 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 0.01 639 = 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
x1.00000 = 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 = lb
gx0.03527 = oz
Units of Force
lbf x 4.4480 = N
lbf x 0.4536 = kgf
Nx0.2248 = lbf
Nx0.1020 = kgf
kgf x 2.2050 = lbf
kgf x 9.8070 = N
Units of Torque
ft-lb x 1.3558 = N-m
ft-lb x 0.1383 = kg-m
in-Ib 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
x14.2200 = psi
kg/cm
2
x0.9807 = bar
kg/cm
2
x98.0700 = 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
Wx0.00134 = HP
Wx0.00136 = PS
Wx0.73760 = 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-Ibf/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
1-/ 2-Cylinder
SERVICE SPECIFICATIONS
Standard Torque Values
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.
Size
Torque
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

SECTION 2
2-6
1-/ 2-Cylinder
Manufacturer Special Tools Required - 1-2 Cylinder
2.5
/ 3.5
✳ : For 3.5B
Tool Description Part No. Components
Flywheel Puller
Assembly
309-72214-0
or
3V1-72211-0
Arm
Adapter
Pressing Bolt
Bolts
Spring Pin Tool
✳
345-72227-0 Pin Punch
Spring Pin Tool
✳
345-72228-0 HoIIow Punch
Tool Box 353-72254-0
1 1
2
3
4
2 1
2
2
T1900
1
T1902
2

GENERAL SERVICE INFORMATION
2-7
1-/ 2-Cylinder
5
Tool Description Part No. Components
Flywheel Puller
Assembly
369-72211-0 Arm
Adapter
Pressing Bolt
Bolts
Piston Pin Tool 332-72215-0
Piston Ring Tool 353-72249-0
Driveshaft Needle
Bearing Tool Assembly
369-72900-0
Backlash Measuring
Tool 369-72740-0 Kit
Sub Assembly 369-72730-0 Except
and
Arm 369-72727-0
Clamp Assembly 3B7-72720-0
Spring Pin Tool
(3 mm Dia.) 345-72227-0 Pin Punch
Spring Pin Tool
(3 mm Dia.) 345-72228-0 HoIIow Punch
Spring Pin Tool
(3.5 mm Dia.) 369-72217-0 Pin Punch
Spring Pin Tool
(3.5 mm Dia.) 369-72218-0 HoIIow Punch
Tool Box 353-72254-0
1
1
2
3
4
2
3
6
4 1
4 2
3
4 2
4 3
5
1
5 2
5
3
5 4
T1906
3
T1907
4
T1908
5
6
T1904
1
T1901
2

SECTION 2
2-8
1-/ 2-Cylinder
8 / 9.8
Tool Description Part No. Components
Flywheel Puller
Assembly
369-72211-0 Arm
Adapter
pressing Bolt
Bolts
Piston Pin Tool 332-72215-0
Piston Ring Tool 353-72249-0
Driveshaft Needle
Bearing Tool Assembly
3B2-72900-0
Backlash Measuring
Tools 369-72740-0 Kit
Sub Assembly 369-72730-0 Except
and
Arm 3B2-72727-0
clamp Assembly 3B7-72720-0
spring Pin Tool
(3 mm Dia.) 345-72227-0 Pin Punch
spring Pin Tool
(3 mm Dia.) 345-72228-0 HoIIow Punch
spring Pin Tool
(3.5 mm Dia.) 369-72217-0 Pin Punch
spring Pin Tool
(3.5 mm Dia.) 369-72218-0 HoIIow Punch
Tool Box 353-72254-0
1 1
2
3
4
2
3
4
5 1
5 2
3
5 2
5 3
6
1
6
2
6
3
6 4
T1906
3
4
T1907
5
T1908
6
T1904
1
T1910
2

GENERAL SERVICE INFORMATION
2-9
1-/ 2-Cylinder
9.9 / 15 / 18
Tool Description Part No. Components
Flywheel Puller
Assembly
369-72211-0 Arm
Adapter
pressing Bolt
Bolts
Piston Pin Tool 332-72215-0
Piston Ring Tool 353-72249-0
Wrench, Bevel Gear B
Nut 346-72231-0
Socket, Bevel Gear B
Nut 350-72232-0
Needle Roller Bearing
Puller 3C8-72700-0 Kit
Flange A 3C8-72701-0
Shaft 346-72702-0
Shaft Stopper A 350-72704-0
Washer 346-72707-0
Nut, 12P=1.25 346-72706-0
Guide A 350-72705-0
Retainer A 350-72703-0
Flange B 346-72701-5
Shaft B 350-72702-5
Guide B 350-72705-5
1 1
2
3
4
2
3
4
4
5
5
1
5
2
5
3
5
5
5
6
5
7
5
8
5
13
5
14
5
15
T1906
3
T1918
4
5
T1904
1
T1910
2

SECTION 2
2-10
1-/ 2-Cylinder
9.9 / 15 / 18 Continued
Tool Description Part No. Components
Backlash Measuring
Tool Kit 3C8-72234-0 Kit
Shaft 345-72723-0
Plate 3A3-72724-0
O-ring 332-60002-0
Collar 350-72245-0
Nut, M10 930191-1000 , 2 nuts
Clamp Assembly 3B7-72720-0
Bolt, H625 910191-0625 for lower
pump case
Plate, Dial Gauge 3B7-72729-0
Spring Pin Tool
(3 mm Dia.) 345-72227-0 Pin Punch
Spring Pin Tool
(3 mm Dia.) 345-72228-0 Hollow Punch
Clutch Pin Snap Tool 350-72229-0 = 1.85 in
47 mm
Tool Box 353-72254-0
6
6 1
6 2
6 3
6 4
6 8
7 1
7 2
7 3
8
8
9 1
6
7
T1800
8
T1799
9

GENERAL SERVICE INFORMATION
2-11
1-/ 2-Cylinder
25 / 30
Tool Description Part No. Components
Flywheel Puller
Assembly
369-72211-0 Arm
Adapter
Pressing Bolt
Bolts
Piston Pin Tool 345-72215-0
Piston Ring Tool 353-72249-0
Wrench, Bevel Gear
B Nut 346-72231-0 Wrench
Socket, Bevel Gear B
Nut 346-72232-0 Socket
Needle Roller
Bearing Puller 3C8-72700-0 Kit
Flange A 3C8-72701-0
Shaft 346-72702-0
Shaft Stopper 346-72704-0
Washer 346-72707-0
Nut, 12P=1.25 346-72706-0
Guide A 346-72705-0
Retainer A 346-72703-0
Flange B 346-72701-5
Guide B 346-72705-5
Retainer B 346-72703-5
Spacer 346-72708-0
1 1
2
3
4
2
3
4
4
5
5 1
5 2
5 4
5 5
5 6
5 9
5 10
5 13
5 16
5 17
5 18
T1906
3
T1918
4
5
T1904
1
T1910
2