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Raider 40 hp Service Manual

Manual is about: SUBMERSIBLE MOTOR

Summary of 40 hp

  • Page 1

    Service manual • two stroke low pressure • direct injection (tldi) • multi-fuel • submersible this manual has been prepared for the united states guardian angels for service of the multi-fuel, submersible outboard motor designed and manufactured under contract no. N61331⑩11⑩c-0008, dated 3/4/11. The...

  • Page 2: General Safety Warnings

    Copyright© 2013 raider outboard, inc. Copyright© 2013 raider outboard, inc. Copyright© 2013 raider outboard, inc. Copyright© 2013 raider outboard, inc. All rights reserved. No part of this manual may be reproduced or transmitted in all rights reserved. No part of this manual may be reproduced or tra...

  • Page 4

    Contents contents contents contents chapter 1 specifications chapter 1 specifications chapter 1 specifications chapter 1 specifications chapter 2 chapter 2 chapter 2 chapter 2 ---- servicing information servicing information servicing information servicing information chapter 3 inspection and mainte...

  • Page 5

    Chapter 1 specificat chapter 1 specificat chapter 1 specificat chapter 1 specifications ions ions ions ................................ ................................ ................................ ................................................................ ................................ ...

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    Chapter 8 tiller han chapter 8 tiller han chapter 8 tiller han chapter 8 tiller handle type dle type dle type dle type ................................ ................................ ................................ ................................................................ ....................

  • Page 7

    1-1 chapter 1 specifications specifications specifications specifications 1. S pecifications t able ..................................................................................................................................................................1-1 2. O utline d imensions .............

  • Page 8

    1-1 1. 1. 1. 1. Specifications table specifications table specifications table specifications table item raider 50 hp tldi overall length 1120 mm (44.1 in.) overall width 384 mm (15.1 in.) overall height 1514 mm (59.6 in.) weight 92.0 kg (203 lbs.) w/o composites/w/o starter & battery transom length...

  • Page 9

    1-2 2. O 2. O 2. O 2. Outline dimensions utline dimensions utline dimensions utline dimensions.

  • Page 10

    1-3 external dimensions external dimensions external dimensions external dimensions item 50a remarks a 495 mm (19.5 in) transom (5) 728 mm (28.7 in) b transom (l) 855 mm (33.7 in) transom (ul) 982 mm (38.7 in) transom (s) 403 mm (15.9 in) c transom (l) 530 mm (20.9 in) transom (ul) 657 mm (25.9 in) ...

  • Page 11

    1-4 3. 3. 3. 3. What is tldi? What is tldi? What is tldi? What is tldi? The abbreviation tldi stands for two-stroke low-pressure direct injection and is the name applied to direct fuel-injection system engines. A) two two two two----stroke low stroke low stroke low stroke low----pressure direct inje...

  • Page 12

    1-5 c) ecu control ecu control ecu control ecu control with tldi, a network of connected sensors enables the engine control unit (ecu) to precisely regulate fuel mixture, injection rate and ignition timing. The ecu also uses a stratified fuel feed process to provide lean combustion in the low-speed ...

  • Page 13

    1-6 inductive ignition system ( inductive ignition system ( inductive ignition system ( inductive ignition system (requires requires requires requires no battery) no battery) no battery) no battery) tldi tldi tldi tldi is nowusing the inductive ignition system to maximize combustion efficiency and f...

  • Page 14

    1-7 4.Fuel supply system 4.Fuel supply system 4.Fuel supply system 4.Fuel supply system starting the engine activates the fuel pump (3), which draws fuel from the fuel tank (1) and routes it through the fuel filter (2) to the vapor separator (4). The fuel is pressurized in the fuel-feed pump (ffp) (...

  • Page 15

    1-8 5. 5. 5. 5.Air supply system air supply system air supply system air supply system starting the engine operates the air compressor (2), draws air in through the air filter (1) and sends compressed air through to the air rail (3). The air regulator (4) regulates air at the optimum combustion pres...

  • Page 16

    1-9 6. 6. 6. 6. Oil supply system oil supply system oil supply system oil supply system starting the engine operates the oil pump (1), which draws oil from the oil tank (2) and routes it through the oil filter (3) to the oil pump (1). The oil pump channels the oil through four ports to #1 air box (4...

  • Page 17

    1-10

  • Page 18

    2-1 chapter 2 ----servicing information servicing information servicing information servicing information 1.General precautions for servicing................................ ................................ ................................ ...............................................................

  • Page 19

    2-2.

  • Page 20

    2-1.

  • Page 21

    2-2 1. 1. 1. 1. General precautions for servicing general precautions for servicing general precautions for servicing general precautions for servicing users of this manual should observe the following general precautions when conducting disa users of this manual should observe the following general...

  • Page 22

    2-3 (10) observe all necessary safety procedures to prevent accidents and injury during work operations. 2. 2. 2. 2.Specifications and standards used in servicing specifications and standards used in servicing specifications and standards used in servicing specifications and standards used in servic...

  • Page 23

    2-4 service limit servicing procedure 0.8 mm (0.031 in) or more 0.9 mm (0.035 in) or more replace with new piston ring if cylinder liner wear has not yet exceeded the repair limit. 0.05 mm (0.002 in) or more replace with new crankshaft. 2 mm (0.08 in) or more replace with new crankshaft assembly. Sc...

  • Page 24

    2-5 name of part item to check standard values magneto sparking performance measured using spark tester sparking order alternator (max.) charging performance alternator coil resistance value (y to y wire) • 10 mm (0.39 in) or more at 350 rpm • #1 #2 #3 • 280 w • 1,500 rpm l2v 16.5a • 5,500 rpm 12v 1...

  • Page 25

    2-6 service limit servicing procedure 1) 1.0 mm (0.047 in) or more 2) when electrodes show excessive wear 1) repair so that plugs conform to standard values. 2) replace with new spark plug. • when sensor no longer conforms to standard value • repair so that sensor conforms to standard value. • when ...

  • Page 26

    2-7 name of part item to check standard values manual trim and tilt tilt cylinder • 19600 to 24500 kpa air compressor • cylinder bore • piston diameter measure at a point 10 mm above the lower edge of the piston skirt • piston ring and gap • reed valve tip clearance • drive belt • 39.00 to 39.02 mm ...

  • Page 27

    2-8 service limit servicing procedure • when parts no longer conform to standard values • when parts show excessive wear or damage • replace with new parts. • when parts show excessive wear or damage • when parts showed deterioration or contamination by fuel • replace with new parts. • when parts sh...

  • Page 28

    2-9 3. 3. 3. 3.Lis lis lis lists of points for applying sealant, adhesive and lubrication ts of points for applying sealant, adhesive and lubrication ts of points for applying sealant, adhesive and lubrication ts of points for applying sealant, adhesive and lubrication th re e bo nd th re e bo nd th...

  • Page 29

    2-10 shift lever stopper c ol d & h ea t r es is ta nt c ol d & h ea t r es is ta nt c ol d & h ea t r es is ta nt c ol d & h ea t r es is ta nt li th iu m g re as e li th iu m g re as e li th iu m g re as e li th iu m g re as e o il c en te r o il c en te r o il c en te r o il c en te r r es ea rc ...

  • Page 30

    2-11 o th re e bo nd th re e bo nd th re e bo nd th re e bo nd th re ad l oc k th re ad l oc k th re ad l oc k th re ad l oc k th re e bo nd th re e bo nd th re e bo nd th re e bo nd th re ad l oc k th re ad l oc k th re ad l oc k th re ad l oc k th re e bo nd th re e bo nd th re e bo nd th re e bo ...

  • Page 31

    2-12 c ol d & h ea t c ol d & h ea t c ol d & h ea t c ol d & h ea t r es is ta nt l ith iu m r es is ta nt l ith iu m r es is ta nt l ith iu m r es is ta nt l ith iu m gr ea se gr ea se gr ea se gr ea se o il c en te r o il c en te r o il c en te r o il c en te r r es ea rc h co ld r es ea rc h co ...

  • Page 32

    2-13 th re e bo nd th re e bo nd th re e bo nd th re e bo nd th re ad th re ad th re ad th re ad lo ck lo ck lo ck lo ck th re e bo nd th re e bo nd th re e bo nd th re e bo nd th re ad th re ad th re ad th re ad lo ck lo ck lo ck lo ck lo ci tit e lo ci tit e lo ci tit e lo ci tit e a dh es iv e a ...

  • Page 33

    2-14 c ol d & h ea t c ol d & h ea t c ol d & h ea t c ol d & h ea t re si st an t re si st an t re si st an t re si st an t li th iu m li th iu m li th iu m li th iu m gr ea se gr ea se gr ea se gr ea se o il c en te r o il c en te r o il c en te r o il c en te r r es ea rc h r es ea rc h r es ea r...

  • Page 34

    2-15 4. 4. 4. 4. Torque table torque table torque table torque table item part to tighten initial torque (n-m) full torque (n-m) lb-ft cylinder head cover - bolt (m6) 2.0 - 2.9 4.6 - 6.3 (0.5-0.6 kg-m) 3.6 - 4.4 cylinder head cover bolt (m8) 12 - 15 29-34 (3.0 - 3.5 kg-m) 22 - 25 crankcase bolt (m8)...

  • Page 35

    2-16 5. Special tools 5. Special tools 5. Special tools 5. Special tools.

  • Page 36

    2-17 1. 1. 1. 1.List of special tool list of special tool list of special tool list of special tool pressure gauge assembly 3t5-72880-o crimping pliers 3t5-72864-o drive pulley press 3t5-72868-o piston slider 3t5-72871 for measuring air rail fuel and air pressure for crimping oetiker make clamps. Fo...

  • Page 37

    2-18 drive pulley puller assembly 3t5-72890 flywheel puller kit 3c7-7221 1-1 for removing drive pulley. For removing and installing flywheel. Needle bearing puller kit 3c8-72700-o spring pin tool a 345-72227-0 spring pin tool b 345-72228-0 for removing and installing gear case needle bearing and pro...

  • Page 38

    2-19 2. 2. 2. 2.Using the special tool using the special tool using the special tool using the special tool pressure gage assembly pressure gage assembly pressure gage assembly pressure gage assembly measuring fuel and air pressure 1. Mover the lever for cock (3t5 mover the lever for cock (3t5 mover...

  • Page 39

    2-20 crankshaft holder (3t5 crankshaft holder (3t5 crankshaft holder (3t5 crankshaft holder (3t5----7281 5 7281 5 7281 5 7281 5----0) 0) 0) 0) removing pulley nut removing pulley nut removing pulley nut removing pulley nut 1. Disassemble the flywheel. (refer to section of this chapter.) 2. Install t...

  • Page 40

    2-21 drive pulley puller assembly drive pulley puller assembly drive pulley puller assembly drive pulley puller assembly removing drive pulley removing drive pulley removing drive pulley removing drive pulley begin the disassembly operation by removing the crankshaft from the power unit. 1. Remove p...

  • Page 41

    2-22 drive pulley press (3t5 drive pulley press (3t5 drive pulley press (3t5 drive pulley press (3t5----72868 72868 72868 72868----o) o) o) o) inserting drive pulley inserting drive pulley inserting drive pulley inserting drive pulley 1. Remove any oil or grease from crankshaft and drive pulley hole...

  • Page 42

    2-23 0000----ring setting tool (o24) (3t5 ring setting tool (o24) (3t5 ring setting tool (o24) (3t5 ring setting tool (o24) (3t5----72863 72863 72863 72863----o) o) o) o) install the fuel injector 2.8-20.2 0-rings (3t5-1 0304-0). Apply engine oil to both the 0-rings and the 0-ring setting tool. Posi...

  • Page 43

    2-24.

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    3-1 chapter 3 inspecti inspecti inspecti inspection and maintenance on and maintenance on and maintenance on and maintenance chapter 3 inspection and main inspection and main inspection and main inspection and maintenance tenance tenance tenance ................................ ........................

  • Page 45

    3-2 1. 1. 1. 1.Periodic in periodic in periodic in periodic inspections spections spections spections inspection intervals c at eg or y inspection points 10 hrs. Or bimonthly 30 hrs or monthly 50 hrs. Or 3 months 100 hrs. Or 6 months yearly 1.5 years 200 hrs. Or 2 years inspection procedure remarks ...

  • Page 46

    3-3 2. 2. 2. 2.Inspecting engine oil system inspecting engine oil system inspecting engine oil system inspecting engine oil system bleeding air from oil pump bleeding air from oil pump bleeding air from oil pump bleeding air from oil pump conduct a visual check of the clear vinyl pipes connecting th...

  • Page 47

    3-4 cleaning bladder/fuel tank filter cleaning bladder/fuel tank filter cleaning bladder/fuel tank filter cleaning bladder/fuel tank filter fuel pickup elbow filter turn to the left to remove and clean . Cleaning bladder/fuel tank cleaning bladder/fuel tank cleaning bladder/fuel tank cleaning bladde...

  • Page 48

    3-5.

  • Page 49

    3-6 2. 2. 2. 2.Inspecting gear case are inspecting gear case are inspecting gear case are inspecting gear case areaaaa • to avoid accidental starting of engine while servicing, twist and remove all spark plug leads. Replacing propeller replacing propeller replacing propeller replacing propeller worn...

  • Page 50

    3-7.

  • Page 51

    3-8 corrosion protection corrosion protection corrosion protection corrosion protection whenever possible after use in sea water or submersion in sea water, wash entire engine with fresh water to remove salt deposits and wipe down with a dry cloth. Spray entire powerhead with a liberal coat of anti-...

  • Page 52

    3-9 valve operation start temperature 52③c ④ 1.5③c (126③f ④ 3③f) valve full open temperature 65③c ④ 1.5③c (149③f ④ 3③f) valve full open lift 3 mm or more replacing pump impeller replacing pump impeller replacing pump impeller replacing pump impeller remove the following components. Split pin special...

  • Page 53

    3-10 overview of cooling system overview of cooling system overview of cooling system overview of cooling system tubing tubing tubing tubing.

  • Page 54

    3-11.

  • Page 55

    3-12 5. 5. 5. 5.Inspecting tilt system inspecting tilt system inspecting tilt system inspecting tilt system checking lift cylinder checking lift cylinder checking lift cylinder checking lift cylinder note that the lift cylinder is located in the front of the raider outboard is checked by first tilti...

  • Page 56

    4-1 chapter 4 disassembling, disassembling, disassembling, disassembling, inspecting and reassembling inspecting and reassembling inspecting and reassembling inspecting and reassembling power unit power unit power unit power unit cha cha cha chapter 4 pter 4 pter 4 pter 4 disassembling, insp disasse...

  • Page 57

    4-2 1. 1. 1. 1.Power uni power uni power uni power unitttt.

  • Page 58

    4-3 a) removing power unit removing power unit removing power unit removing power unit disassemble the following components. • fuel connector • battery • ring gear cover battery cable (optional on raider) disassemble the following components. Begin by disassembling the oil tank; oil tank mounting bo...

  • Page 59

    4-4 disassemble apron (splash pan). Remove engine mounting bolts. Bolt: type h880 at 6 locations secure eyebolts to the flywheel; then use a sufficiently strong hoist to suspend the power unit while keeping it in the horizontal position. Suspend slowly, taking care not to catch the power unit on any...

  • Page 60

    4-5.

  • Page 61

    4-6 b) reassembling power unit reassembling power unit reassembling power unit reassembling power unit install the following components. Install the engine base gasket >replace with new gasket. Knock pin apply three bond #1107 (seal out) to both sides of engine base gasket secure eyebolts to the fly...

  • Page 62

    4-7 2. 2. 2. 2.Peripheral parts peripheral parts peripheral parts peripheral parts 1) 1) 1) 1) electrical system electrical system electrical system electrical system removing removing removing removing crankpositioning sensor crankpositioning sensor crankpositioning sensor crankpositioning sensor (...

  • Page 63

    4-8 remove the following components. Coil bracket cable clamp remove the following components. Solenoid switch bracket bolt: type h625 at 3 locations removing ecu removing ecu removing ecu removing ecu **** *ecu: abbreviation for the engine control unit. Remove the following components. Ecu connecto...

  • Page 64

    4-9 removing harness assembly removing harness assembly removing harness assembly removing harness assembly remove the following components. Remove harnesses in order starting from remote control side. Water temperature connector • remove by pressing down on hook and pulling out connector. Fuel inje...

  • Page 65

    4-10 removing ignition coil and rectifier regulator removing ignition coil and rectifier regulator removing ignition coil and rectifier regulator removing ignition coil and rectifier regulator remove the following components. Ignition coil #1 ignition coil #2 ignition coil #3 rectifier regulator.

  • Page 66

    4-11.

  • Page 67

    4-12 2) air supply system 2) air supply system 2) air supply system 2) air supply system prior to removing peripheral components prior to removing peripheral components prior to removing peripheral components prior to removing peripheral components (1) press on the core of the air valve located on t...

  • Page 68

    4-13.

  • Page 69

    4-14 removing air compressor removing air compressor removing air compressor removing air compressor remove the following components. Detach the oil pipe on the compressor side. Detach recirculation pipe on the compressor side. Detach cooling water pipe on compressor side. Remove air hose on compres...

  • Page 70

    4-15 air compressor configuration air compressor configuration air compressor configuration air compressor configuration.

  • Page 71

    4-16 inspecting air compressor inspecting air compressor inspecting air compressor inspecting air compressor no. Component points to check piston • wear and damage • check outer diameter of piston • connecting rod : confirm smooth operation • big end bearing : confirm smooth operation piston ring • ...

  • Page 72

    4-17.

  • Page 73

    4-18 assembling compressor assembling compressor assembling compressor assembling compressor using the piston slider, insert the piston into the cylinder. • prior to inserting piston, apply heat-resistant grease lor #101 and genuine engine oil mixed at a 1:3 ratio and apply to: • outer circumference...

  • Page 74

    4-19 assemble following components into the cylinder. Knock pins at 2 locations gasket >replace with new one. Bolt: type h625 at 4 locations cramp at 1 location • apply genuine engine oil to the big end of the connecting rod. • insert the crank pin in the big end of the connecting rod and install by...

  • Page 75

    4-20

  • Page 76

    4-21 disassembling air rail disassembling air rail disassembling air rail disassembling air rail remove the following components. Fuel hose assembly and nipples disassemble and pull out the stopper plate. Air hose assembly disconnect the hose joint on the compressor side. Cooling water outlet hose f...

  • Page 77

    4-22 air rail assembly configuration air rail assembly configuration air rail assembly configuration air rail assembly configuration.

  • Page 78

    4-23 inspecting air rail inspecting air rail inspecting air rail inspecting air rail no. Components points to check 1 air injector • wear, deterioration and damage on 0-rings and seal rings. Replace with new ones if problems are detected. • remove any carbon buildup on tip using wire brush. • refer ...

  • Page 79

    4-24 assembling air rail assembling air rail assembling air rail assembling air rail apply genuine engine oil to the 0-rings. Assemble the following components. Insert compression seal • take care to install with insert ~ facing in the proper direction as shown in view a to the right. Adapter fuel i...

  • Page 80

    4-25 assemble components air hose assembly collar nipple plate bolt installing hoses (see figure) from air compressor (air) to air compressor (cooling water) to ffp (fuel) to cylinder (air) from exhaust cover (cooling water) 3. 3. 3. 3.Fuel system fuel system fuel system fuel system disassembling fu...

  • Page 81

    4-26 disassembling vapor separator disassembling vapor separator disassembling vapor separator disassembling vapor separator drain the fuel from the vapor separator using the following procedures. Loosen the air vent screw. Loosen the drain screw. Hold a cloth in place to absorb spilling fuel when l...

  • Page 82

    4-27 vapor separator configuration vapor separator configuration vapor separator configuration vapor separator configuration inspecting vapor separator inspecting vapor separator inspecting vapor separator inspecting vapor separator no. Components points to check 1 0-rings • wear, deterioration and ...

  • Page 83

    4-28 assembling vapor separator assembling vapor separator assembling vapor separator assembling vapor separator assemble in the reverse order of disassembly. Air vent screw torque: 0.98 n-m: 0.1 kg-m: 0.7 lb-ft drain screw torque: 1.4 n-m: 0.14 kg-m: 1.0 lb-ft assembling vapor separator assembly as...

  • Page 84

    4-29 fuel feed pump ( fuel feed pump ( fuel feed pump ( fuel feed pump (ffp ffp ffp ffp)))) configuration configuration configuration configuration.

  • Page 85

    4-30 inspecting ffp inspecting ffp inspecting ffp inspecting ffp no. Components points to check 1 pipe grommet 2 upper cable terminal grommet 3 cable terminal grommet 4 0-rings • wear, deterioration and damage. Replace if defects are detected. 5 ffp case • clogging by foreign matter and water. 6 ffp...

  • Page 86

    4-31.

  • Page 87

    4-32 assembling assembling assembling assembling fuel feed pump ( fuel feed pump ( fuel feed pump ( fuel feed pump (ffp ffp ffp ffp)))) assemble the following components. Hose joint adapter torque: 14 to 16 n-m: 1.4 to 1.6 kg-m: 10 to 12 lb-ft adhesive to apply after degreasing thread area: three bo...

  • Page 88

    4-33 assemble the following components. Upper grommet cable terminal grommet grease to apply and genuine engine oil cable terminal (-): black cable cable terminal (+): red cable grease to apply terminals genuine engine oil connect to the flat connector cable terminal by lining up with the mark (+ an...

  • Page 89

    4-34 assemble the following components. Cable terminal upper grommet seal ring (0-ring) grease to apply and genuine engine oil uppercase bolt: type h518 at 4 locations torque: 2.6 to 3.5 n-rn: 0.27 to 0.36 kg-m:2.O to 2.6 lb-ft installing ffp assembly on cylinder installing ffp assembly on cylinder ...

  • Page 90

    4-35 4) oil pump oil pump oil pump oil pump disassembling oil pump and oil tank disassembling oil pump and oil tank disassembling oil pump and oil tank disassembling oil pump and oil tank disassemble the following components. Oil filter oil pump bolt oil pump oil pipe :4 remove by pulling the pipes ...

  • Page 91

    4-36 inspect the following components. Bushing oil pump driven gear check for wear and damage. Assembling oil pump assemble the following components bushing oil pump driven gear oil to apply and genuine engine oil • make sure that faces right side up. • section with large hole faces to the front. As...

  • Page 92

    4-37 4. 4. 4. 4.Throttle mechanism disassembling advancer arm disassembling advancer arm disassembling advancer arm disassembling advancer arm disassemble the following components. Throttle link rod tps~ link rod oil pump link rod * tps: abbreviation for throttle position sensor prior to removing , ...

  • Page 93

    4-38 assembling advancer arm assembling advancer arm assembling advancer arm assembling advancer arm assemble the following components. • advancer arm • throttle link rod • tps link rod • oil pump link rod • bolt: type h635 • washers • collar install the following components. • throttle link ball jo...

  • Page 94

    4-39 assembling tps assembling tps assembling tps assembling tps assemble in the reverse order of disassembly. Disassembling air box and throttle body disassembling air box and throttle body disassembling air box and throttle body disassembling air box and throttle body disassemble the following com...

  • Page 95

    4-40 inspect the following component. Reed valve assembly valve stopper height: 9.3 to 9.5 mm: 0.366 to 0.374 in check whether valve closes properly, is worn or damaged. Inspect the following component. Throttle body • check throttle cam for wear. • check cam roller for wear. • confirm that and oper...

  • Page 96

    4-41 5. 5. 5. 5.Disassembling engine block disassembling engine block disassembling engine block disassembling engine block cylinder and crankcase assembly cylinder and crankcase assembly cylinder and crankcase assembly cylinder and crankcase assembly.

  • Page 97

    4-42 piston and crankshaft piston and crankshaft piston and crankshaft piston and crankshaft.

  • Page 98

    4-43 removing thermostat removing thermostat removing thermostat removing thermostat remove the following components. Bolt: type h625 at 2 locations thermostat cap thermostat inspect the following components. • check to see whether foreign matter has entered valve. • confirm valve operates within de...

  • Page 99

    4-44 inspecting cylinder head inspecting cylinder head inspecting cylinder head inspecting cylinder head inspect the following components. Cylinder head inspecting: inspecting: inspecting: inspecting: check for carbon deposit in combustion chamber. Check for sediment in water jacket. Inspecting: ins...

  • Page 100

    4-45 disassembling exhaust cover disassembling exhaust cover disassembling exhaust cover disassembling exhaust cover remove the following components. Bolt: type h630 at 2 locations bolt: type h630 at 12 locations remove in order starting from the highest embossed number. Outer exhaust cover inner ex...

  • Page 101

    4-46 remove the following component. Crankshaft assembly disassembling drive pulley disassembling drive pulley disassembling drive pulley disassembling drive pulley remove the following components. Pulley nut (36 mm) special tool crankshaft holder (36mm) 3t5-72815-0 magneto key magneto nut • install...

  • Page 102

    4-47 removing piston removing piston removing piston removing piston remove the following components. • piston pin clip at 2 locations remove both and take care not to scratch the pinhole. Remove the following component. Piston pin special tool piston pin tool 345-72215-0 • position against piston p...

  • Page 103

    4-48 inspecting engine components i inspecting engine components i inspecting engine components i inspecting engine components i inspecting cylinders inspecting cylinders inspecting cylinders inspecting cylinders • cylinder bore (using cylinder gauge) standard value service limit 68.05 mm (2.679 in)...

  • Page 104

    4-49 inspecting piston rings inspecting piston rings inspecting piston rings inspecting piston rings piston ring ring gauge thickness gauge • piston ring end gap ring standard value service limit top 0.22 to 0.37 mm (0.009 to 0.015 in) replace when 0.8 mm (0.032 in) or more 2nd,3rd 0.33 to 0.48mm (0...

  • Page 105

    4-50 crankcase assembling piston crankcase assembling piston crankcase assembling piston crankcase assembling piston assemble the following components. Top ring (keystone ring: it) 2nd and 3rd rings (plain rings: stamped 2t) special tool piston ring tool 353-72249-0 • install starting from the 3rd r...

  • Page 106

    4-51.

  • Page 107

    4-52 assembling assembling assembling assembling short short short short block block block block assemble in reverse order of disassembly. Apply genuine engine oil to the following parts. • big end of connecting rod • small end of connecting rod and pin boss oil hole • main bearing • piston ring and...

  • Page 108

    4-53 assembling assembling assembling assembling crankcase crankcase crankcase crankcase degrease the mating surface of the crankcase. Caution: caution: caution: caution: insufficient degreasing will render sealant less effective,resulting in oil leakage. Apply sealant evenly 0ver the mating surface...

  • Page 109

    4-54 the following components. • thermostat • thermostat cap gasket replace with new one. • thermostat cap • bolt :at 2 locations torque :4.6to6.3n-m:0.47 to0.64kg-m :3.4to4.6lb-ft caution: caution: caution: caution: be sure to tighten m6 bolts only after tightening the m8 bolts on the head cover .N...

  • Page 110

    5-1 chapter 5 installing and inspecting electrical components installing and inspecting electrical components installing and inspecting electrical components installing and inspecting electrical components chapter 5 chapter 5 chapter 5 chapter 5 installing and insp installing and insp installing and...

  • Page 111

    5-2 1. 1. 1. 1.Wire routing wire routing wire routing wire routing.

  • Page 112

    5-3.

  • Page 113

    5-4.

  • Page 114

    5-5.

  • Page 115

    5-6.

  • Page 116

    5-7 wiring diagram 40b/50b epto.

  • Page 117

    5-8.

  • Page 118

    5-9.

  • Page 119

    5-10

  • Page 120

    5-11.

  • Page 121

    5-12.

  • Page 122

    5-13 408/508 epto no component no . Component 1 alternator assembly 24 cable assemblya 2 rectifier complete 25 ground cable 3 battery (obtain locally) 26 lower motorcover 4 ptt switchb 27 cable assemblyb 5 oil level sensor 28 neutral switch 6 throttle position sensor 29 warning horn(buzzer) 7 water ...

  • Page 123

    5-14 408/508 e f t o no. Component no. Component 1 alternator assembly 19 ffp 2 rectifier complete 20 ffp cable 3 battery(obtain locally) 21 battery cable 4 ptt switch b 22 starter cable 5 oil level sensor 23 ground cable 6 throttle position sensor 24 cable assembly a 7 water temperature sensor 25 g...

  • Page 124

    5-15 40b/50b efo no . Component no . Component 1 alternator assembly 19 ffp 2 rectifier complete 20 ffp cable 3 battery(obtain locally) 21 battery cable 4 - 22 starter cable 5 oil level sensor 23 - 6 throttle position sensor 24 cable assembly a 7 water temperature sensor 25 ground wire 8 crank posit...

  • Page 125

    5-16 no component cablecoloraddreviat i ons 1 tps1 lir blue/red 2 3 keyswitch (push) l blue 4 cps(crankpositionsensor) l/b blue/black 5 warninglamp(oil) l/g lightgreen 6 warninglamp(temp.) y/r yellow/red 7 warninglamp(battery) gir green/red 8 9 buzzer y yellow 10 tachometer w white 11 12 cps(crankpo...

  • Page 126

    5-17 note: slash(/)shows stripe color of cable. 2. 2. 2. 2.Assembly assembly assembly assembly.

  • Page 127

    5-18 wiring around solenoid bracket.

  • Page 128

    5-19.

  • Page 129

    5-20

  • Page 130

    5-21.

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    5-22 3. Inspection fly wheel magneto precautions avoid applying shock or impact to the fly wheel, such as that from the tapping of a hammer. Be sure to use the recommended tool or equivalent only .Do not use standard pulley puller obtained locally. Always replace the fly wheel if it has been dropped...

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    5-23 note: measure using the hioki hi tester model 3030 or equivalent product. Do not use an insulation tester. The tester needle moving represents an on reading and not moving represents an off reading. The () contain approximate values for the1 kΩ range. Note that values will vary depending on tes...

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    5-24 starter motor brushes and springs check the brushes for wear. When brush length is 9.5 mm(0.37in) or less replace with new one. Inspect insulation between brush holders. If conductive, determine cause or replace insulation. Brush spring tension when there is a loss of tension replace spring. Ar...

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    5-25 5. Multi-fuel electrical layout connectors and wire pin outs throttle positioning sensor air pressure sensor rs 232 pig tail rs 232 pig tail.

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    5-26 fuel injector (3) fuel injector (2) fuel injector (1) water temp sensor compressor water temp sensor natural safety switch.

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    5-27 kill switch crank sensor oil level sensor grounds air injector (1).

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    5-28 air injector (2) air injector (3) coil (1) coil (2) coil (3).

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    5-29 fuel pump fuse box- regulator - stator complete wiring harness.

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    6-1 chapter 6 disassembly, inspection and reassembly lower unit disassembly, inspection and reassembly lower unit disassembly, inspection and reassembly lower unit disassembly, inspection and reassembly lower unit chapter 6 chapter 6 chapter 6 chapter 6 disassembly, inspec disassembly, inspec disass...

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    6-2 1. 1. 1. 1.Configuration configuration configuration configuration gearcase(driveshaft).

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    6-3 gearcase(propellershaft).

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    6-4 2. 2. 2. 2.Disassembly disassembly disassembly disassembly caution: • begin the procedure by first removing the spark plug caps and then removing the sparkplugs. • when working with the outboard engine tilted full up,make sure to secure the engine firmly in place using a tilt up stopper. • in ca...

  • Page 143

    6-5 disassembling water pump case disassembling water pump case disassembling water pump case disassembling water pump case remove the lower section of the water pump case. Remove by inserting a flathead screw driver along the case removal groove. Disassembling propeller shaftand clutch disassemblin...

  • Page 144

    6-6 removing bevel gear and drive shaft removing bevel gear and drive shaft removing bevel gear and drive shaft removing bevel gear and drive shaft remove the following components. 1. Bevel gear b nut 2. Bevel gear b 3. Drive shaft 4. Bevel gear a 5. Bevel gear a bearing 6. Bevel gear c removal proc...

  • Page 145

    6-7 3. 3. 3. 3. Inspection inspection inspection inspection inspect the following components. Component inspection points remarks bevel gears a,b,c and clutch • wear and damage on pawls of bevel gears a and c. • wear and damage on clutch pawl. • meshing of bevel gears a,b and c and back lash* . • we...

  • Page 146

    6-8 gear gear gear gear backlash backlash backlash backlash positioningbevelgear8:shimminggauge positioningbevelgear8:shimminggauge positioningbevelgear8:shimminggauge positioningbevelgear8:shimminggauge positioning of bevel gear b must be performed prior to the back lash measurement. Special tool s...

  • Page 147

    6-9 inspecting inspecting inspecting inspecting bevel bevel bevel bevel gear gear gear gear backlash backlash backlash backlash backlash measuringtool backlash measuringtool backlash measuringtool backlash measuringtool install the clamp assembly on the drive shaft . Lineupthetipofthedialgaugewithce...

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    6-10 4. 4. 4. 4.Reassembly reassembly reassembly reassembly assemblinggearcase assemblinggearcase assemblinggearcase assemblinggearcase observetheprecautionarynotesprovidedatvariousstepswhileassemblingint hereverseorderofdisassembly. Installingbevelgearondriveshaft installingbevelgearondriveshaft in...

  • Page 149

    6-11 assemblingclutch cam, camrodand clutchcamrodbushing assemblingclutch cam, camrodand clutchcamrodbushing assemblingclutch cam, camrodand clutchcamrodbushing assemblingclutch cam, camrodand clutchcamrodbushing installthefollowingcomponents. Clutchcam clutchcamrod camrodbushing clutchcamspringpin:...

  • Page 150

    6-12 assemblingwater assemblingwater assemblingwater assemblingwater pump pump pump pump installthefollowingcomponents.Refertosection7(inspectingcoolingsys tem)ofchapter3(inspection andmaintenance)fordetaileddescriptionsofcomponents. O confirmoilseals arefacingrightsideup. O besuretoinsertshim betwe...

  • Page 151

    6-13 adding gear oil adding gear oil adding gear oil adding gear oil refer to section 5 (inspecting gear case area) of chapter 3 (inspection and maintenance)for detailed description of gear oil replacement procedure. Assembling gear assembling gear assembling gear assembling gear case assembly case ...

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    6-14.

  • Page 153

    6-15.

  • Page 154

    7-1 chapter 7 trim and tilt trim and tilt trim and tilt trim and tilt chapter 7 trim and tilt trim and tilt trim and tilt trim and tilt ................................ ................................ ................................ ................................................................ ...

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    7-2 overview overview overview overview the raider has a uniquely designed transom mount that allows the operator easier mounting of the outboard on the rubber inflatable boats. The design allows the motor to be slid over the transom and mounted even in high sea states. This mount is lightweight and...

  • Page 156

    7-3 2. 2. 2. 2.After raider is started after raider is started after raider is started after raider is started a) check the water pump indicator. Check the water pump indicator. Check the water pump indicator. Check the water pump indicator. A steady stream of water indicates the water pump is worki...

  • Page 157

    7-4 3. 3. 3. 3.Stopping raider stopping raider stopping raider stopping raider 1. Slow engine to idle speed. 2. Move shift lever to neutral position. 3. Press and hold stop button until the engine stops running. A) trim angle trim angle trim angle trim angle engine should be perpendicular to water w...

  • Page 158

    7-5 h) shallow water operation shallow water operation shallow water operation shallow water operation do not do not do not do not operate engine with gear case dragging on sea bottom. This can result in propeller or water pump damage. 1. Place engine in shallow water drive position. Refer to shallo...

  • Page 159

    7-6 l) freezing weather freezing weather freezing weather freezing weather: : : : to avoid engine damage, keep the gear case submerged in the water at all times. Before operating in freezing temperatures, check gear case lubricant. If leakage is found, gear case seals will need service. Refer to sec...

  • Page 160

    7-7 the raider has three starting modes. 1. Battery start battery start battery start battery start - the battery located under cowling, this is the primary starting mode. If the battery is dead use the conventional pull start..The battery will recharge very quickly. 2. Pull start pull start pull st...

  • Page 161

    7-8 6. 6. 6. 6.Pre pre pre pre----submersion procedure submersion procedure submersion procedure submersion procedure the raider has been designed for submersion. Insure dewatering valves are closed. • insure the oil tank is complete filled. • dewatering is discussed in chapter dewatering is discuss...

  • Page 162

    8-1 chapter 8 tiller tiller tiller tiller handle handle handle handle type type type type chapter 8 tillerhandlety tillerhandlety tillerhandlety tillerhandletype pe pe pe ................................ ................................ ................................ .................................

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    8-2 1. Tiller handle, shifter and emergency stop tiller handle, shifter and emergency stop tiller handle, shifter and emergency stop tiller handle, shifter and emergency stop the raider tiller handle, shifter and emergency stop is designed as one unit with the capability of each to be serviced indep...

  • Page 164

    8-3 caution: caution: caution: caution: the motor will start if the shift lever is in reverse. Throttle throttle throttle throttle----friction lock friction lock friction lock friction lock: after a speed is selected this option minimizes the workload on operator over long duration missions. Operate...

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    8-4 advantages of the raider dmct design: advantages of the raider dmct design: advantages of the raider dmct design: advantages of the raider dmct design: • features a one-motor kick up feature in case only one of the motors hits a below water obstacle; • ease of connection even if the motors are n...

  • Page 166

    9-1 chapter 9 dewatering dewatering dewatering dewatering chapter 9 dewatering dewatering dewatering dewatering ................................ ................................ ................................ ................................................................ ...........................

  • Page 167

    9-2 the raider outboard is a submersible engine. Due to the extreme operating conditions this engine may experience during combat, raider has incorporated three vales that open drains: crankcase, cylinders and air/fuel drain systems to allow the engine to be de-watered. This de-watering system will ...

  • Page 168

    9-3 three valves are located in each cylinder head connected to a single unit. The valves are opened when the operator reaches in the back of the cowling where a knob is located and turns the valve counterclockwise, which opens the three cylinder dewatering valves. These valves, when opened, allows ...

  • Page 169

    9-4 4. Tilt the outboard to full tilt position into the rib; and turn so the drain valves are on the lowest side. 5. Allow the water from the front valve drain out. 6. Pull starter handle slowly until starter engages. Continue pulling with firm pressure to force water out of the engine as water is e...

  • Page 170

    9-5 if your raider has the internal lead acid battery under the cowling; simply open the dewatering valves; tilt the motor into the rib; press the starter button on the pan for a few seconds. After a few seconds close the valves, press the rubber fuel ball to inject new fuel; and push the start butt...

  • Page 171

    10-6 chapter 10 troubleshooting troubleshooting troubleshooting troubleshooting chapter 10 troubleshooting troubleshooting troubleshooting troubleshooting................................ ................................ ................................ ..................................................

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    10-7 1. Troubleshooting table troubleshooting table troubleshooting table troubleshooting table thissectionontroubleshootingcoversthevariousmalfunctionsandfailuresthatcanoccurintheengine'selectr i calcomponents.Not ificationofmalfunctionsandfailuresisprovidedusingasystemofwarningbeep(buzzer)andindic...

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    10-8 cause remedy(see chapter one)servicing information for specs.) 1-1-1. Gear shift in forward or reverse position. Shift to neutral position. 1-2-1. Battery low; or battery cables or circuit line connections maybe loose or corroded. Recharge or replace battery. Check battery terminal and cable co...

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    10-9 symptom item self- diagnosable points beeps disabled warning indicator disabled warning indicator disabled warning battery disabled low fuel pressure in airrail [normal:600to640kpa] 2-2. Fuel system high fuel pressure in airrail [standard:600to 640kpa]87to93psi low air pressure in airrail [stan...

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    10-10 cause remedy (see chapter one servicing information for specs.) 2-2-12. Fuel regulator leakage. Replace. 2-2-13. Fuel leakage . Inspect piping and connectors for damage. 2-2-14 . Return circuit from fuel regulator outlet to vapor separator is clogged . Inspect and repair. 2-2-15. Faulty fuel r...

  • Page 176

    10-11 symptom item self - diagnosable points beeps disabled warning indicator disabled warning indicator disabled warning (battery) disabled spark plug cap. Crank position sensor . Ecu self-diagnosing function indicates low (abnormal) battery voltage. 0 flashing self-diagnosing function indicates fa...

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    10-12 cause remedy (see chapter on servicing information for specs.) 2-4-6. Loose cap. Inspect. 2-4-7. Faulty cap. Replace. 2-4-8. Incorrect gap with encoder (flywheel). Inspect and adjust. 2-4-9. Ecu not functioning. Replace ecu. 2-4-10. Battery low or less than 1ov during turn over due to faulty s...

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    10-13 symptom item self - diagnosablepoin ts beeps disabled warningindicat or(oil) disabled warningindicator8 (watertempdosab;ed warning(battery) disabled lowfuelpressureinairrail.[standard: 600to640mpa]87to93psi 3-2 . Fuelsystem highfuelpressureinairrail . [standar d:600to640kpa] lowairpressureinai...

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    10-14 cause remedy (seechapteronservicinginformationforspecs.) 3-2-8. Fuelregulatorleakage. Refertosteps2-2-12. 3-2-9. Fuelleakage . Refertostep2-2-13. 3-2-10. Lowcompressioninairrail. Refertostep2-3. 3-2-11. Faultyfuelregulator. Replace. 3-2-12. Returncircuitfrom fuel regulatoroutlettovaporseparato...

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    10-15 symptom item self - diagnosablepoin ts beeps disabled warningindicat ora(oil) disabled warningindicator8 (watertemp)disabled warning(battery) disabled 6-1. Powerhead faultycompression lowairpressureinairrail 6-2. Airsystem highairpressureinairrail fueltank fuelhose fuelfilter 6-3. Fuelsystem l...

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    10-16 cause remedy (seechapteronservicinginformationforspecs.) 6-1-6 . Faultyoilsealoncrankcase. Inspectandrepairasnecessary. 6-2-1. Refertostep2-3. 6-3-1. Fuelisloworemptyintank. Refertostep2-2-1. 6-3-2. Airventisclogged. Refertostep2-2-2. 6-3-3. Airbeingsuckedinthroughcrack s orfaultyconnectors. I...

  • Page 182

    10-17 symptom item self - diagnosable points beeps disabled warning indicator a (oil) disabled warning indicator 8 (watertemp) disabled warning indicator (battery)disabled 0 continuous flashing cooling water temperature too high (temp.Indicator flashes) 0 continuous flashing 0 flashing flashing flas...

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    10-18 cause remedy (see chapter on servicing information for specs.) 9-1-1. Cooling water inlet is clogged. Inspect. 9-1-2. Faulty water pump. Inspect, repair and replace as necessary. 9-1-3. Faulty battery if used in raider. Inspect. 9-1-4. Faulty rectifier regulator. Inspect and replace as necessa...

  • Page 184

    10-19 2. 2. 2. 2.Tldi tldi tldi tldi self self self self diagnosing diagnosing diagnosing diagnosing functions functions functions functions the tldi raider engine u se s a self diagnosing function maintain detailed information of faults that occur on missions t h a t h a v e b e e n detected by the...

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    10-20

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    0211-1 chapter 11 servicing servicing servicing servicing chapter 11 servicing servicing servicing servicing................................ ................................ ................................ ................................................................ ...............................

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    11-2 1. 1. 1. 1. General overview general overview general overview general overview---- servicing the raider outboard servicing the raider outboard servicing the raider outboard servicing the raider outboard the most critical step in maintaining longevity of outboard motors is the break in period. ...

  • Page 188

    11-3 3. 3. 3. 3.Inspection inspection inspection inspection • items to check prior to test run • fuel line condition • gear shift lever operation • electrical wiring,connections and clamps • operation,including catch,of reverse lock • integrity of self-diagnosing function • oil line condition • item...

  • Page 189

    11-4 next nine hours • avoid continuous full throttle operation • verify water pump operation bring rib onto plane and operate engine below 3/4 throttle. Do not exceed do not exceed do not exceed do not exceed 4500 rpm. Every 30 minutes, operate engine at full throttle for approximately one minute. ...

  • Page 190

    11-5 2. Stop engine and remove all spark plugs. Spray a liberal amount of storage fogging oil into the spark plug holes. 3. Pull starter to distribute the fogging oil throughout the cylinders. Install and torque the spark plugs. ! Leave leave leave leave spark plug leads disconnected to prevent acci...

  • Page 191

    11-6 • damaged head gasket • damaged pistons • broken or stuck piston rings • scored cylinder walls. If if if if the engine has equal compression and runs normally, continue the tune-up procedure. 3. Clean and regap or replace spark plugs. Make certain ceramic portion of plug is not cracked. Make ce...

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    11-7 5. If the fuel hose has been disconnected, reinstall it. 6. Check fuel system for leaks check fuel system for leaks check fuel system for leaks check fuel system for leaks..

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    11-8.