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Raider 40 Assembly Manual

Other manuals for 40: Operator's Manual

Summary of 40

  • Page 1

    Raider 40 manual military version 0 raider no r40es - 001-15-2 january 2015 raider 40 parts/assembly manual part no. Rpam 40es-001 c-130 air dropped submarine launched raider part no. R40es-001 raider supplement to raider service manual no. R40 es-001-15-3.

  • Page 3

    Raider 40 manual military version raider parts and assembly manual r40es-001-15-2 describes part numbers and illustrates how the raider subassembly is put together. This manual is a supplement to the raider service manual r40es-001-15-3 that describes in detail all steps required to repair the raide...

  • Page 4

    Raider 40 manual military version 1 parts and assembly manual section description page no. 1 general precautions, break in procedures……………. 2 1. Checklist prior to mission 2. Raider break-in procedures 2 raider engine overview …………………………………. 4 3 engine information ……………………………………….. 5 3.1 cylinder/cr...

  • Page 5

    Raider 40 manual military version section 1. General precautions warning gasoline is extremely flammable and can explode if mishandled. 1. Before performing any service work on the fuel system, read and understand section 1 - service safety. 2. Before servicing the fuel system, disable the ignition ...

  • Page 6

    Raider 40 manual military version 3 1.2 raider break-in procedures caution failure to follow the break-in procedure in owner’s manual and special fuel mixture requirements for break-in may lead to serious engine damage and shortened engine life. To prevent serious engine damage and ensure long engin...

  • Page 7

    Raider 40 manual military version section 2. Raider engine overview the raider outboard 40 horsepower engine has been designed specifically for the military. It operates on gasoline, avgas, jp-5, jp-8, kerosene and diesel #2. It is a simple two-stroke; two-cylinder outboard. Special features: 1. Sub...

  • Page 8

    Raider 40 manual military version 5 section 3. Engine information 1. Cowl tilt handle 2. Motor cover – upper 3. Cooling water check port 4. Water plug 5. Tilt stopper 6. Drive shaft housing 7. Anti-cavitation plate 8. Trim tab 9. Propeller 10. Starter handle 11. Shift lever 12. Throttle grip 13. Cla...

  • Page 9: Front View Raider 40

    Raider 40 manual military version front view raider 40 6 24 23 20 11 19 25 25.

  • Page 10

    Raider 40 manual military version 7 raider 40 overview.

  • Page 11

    Raider 40 manual military version 3.1 cylinder/crankcase.

  • Page 12

    Raider 40 manual military version 9 ref.No. Part no. Description q’ｔｙ remarks m40c 1-1 361b01100- 2 cyl block & crankcase assy 1 1-2 393-01137- 0 * nipple 1 1-3 393-01131- 0 * nipple 5.5-5 1 1-4 345-00117- 0 * dowel pin 2 bearing 1-5 345-01150- 1 * check valve assy 1 1-6 916129- 0850 * bolt 1 1-7 91...

  • Page 13

    Raider 40 manual military version 32 0 1- 33 915324- 0825 stud 2 1- 34 940121- 0800 washer 2 1- 35 930121- 0800 nut 2 1- 36 921503- 0520 screw 1 1- 37 930103- 0500 nut 1 1- 38 309-06972- 0 clamp 6.5-47.5p 1 1- 39 345-01303- 1 engine basement gasket 1 1- 40 361-05211- 0 starter lock arm 1 1- 41 345-0...

  • Page 14

    Raider 40 manual military version 11 1- 67 3b7-63733- 0 rod snap 5-2.5 1 1- 68 348-63711- 1 advancer arm 1 1- 69 910121- 0840 bolt 1 1- 70 345-63713- 0 bushing 8-14-4 2 1- 71 334-66233- 0 washer 8.1-16-1.5 1 1- 72 930403- 0800 nylon nut 8-p1.25 1 1- 73 345-05223- 1 rod snap 3.5-2 1 1- 74 348-63715- ...

  • Page 15

    Raider 40 manual military version crankshaft crankshaft is not an item that is addressed in the field. Raider outboard should be sent back to depot or manufacturer for inspection. Critical concern would be starting the engine with the electric start prior to dispelling water between piston and heads...

  • Page 16

    Raider 40 manual military version 13 3.2 piston/crankshaft remarks: crank shaft assembly is difficult to assemble. The component parts should be purchased as an assembly if possible..

  • Page 17

    Raider 40 manual military version ref.No. Part no. Description q’ｔｙ remarks 2-1 345-00122- 0 oil seal 25-55-10 1 2-2 345-00125- 0 retainer 50-60-1.6 1 2-3 361-00069- 1 crankshaft sub-assy 1 2-4 361-00031- 0 * crankshaft a 1 2-5 348-00032- 0 * crankshaft b 1 2-6 348-00033- 0 * crankshaft c 1 2-7 348-...

  • Page 18

    Raider 40 manual military version 15 2-29 1 345-00011- 0 * piston ring 1 std 2nd.

  • Page 19

    -10 - raider 40 manual military version 3.3 intake manifold/fuel pump reed valve and stopper ref.No. Part no. Description q’ｔｙ remarks 3-1 915321- 0655 stud 2 3-2 345b02010- 0 intake manifold 1 3-3 345-02104- 0 intake manifold gasket 1 3-4 345-02105- 0 intake manifold gasket 1 3-5 345-02100- 1 reed ...

  • Page 20

    - 9 - raider 40 manual military version 3- 30 356-04044- 0 * check valve 2 3- 31 921722- 0306 * screw 2 3- 32 930222- 0300 * nut 2 3- 33 346-04901- 2 gasket 1 fuel pump 3- 34 921503- 6640 screw 2 3- 35 98ab-50- 160 hose 1 f/connector-fuel filter 98ab-501000 3- 36 98ab-50- 270 hose 1 fuel filter-fuel...

  • Page 22

    - 11 - raider 40 manual military version 3.4 multi-fuel (throttle body) atomizer the fuel induction system (fis) was given a name replacing “carburetor” as it looks like a carburetor, however, has minimal moving parts. The key to the fis is the slide as it is shaped larger at bottom; smaller at top;...

  • Page 23

    -12- raider 40 manual military version ref.No. Part no. Description quantity remarks 4-1 rl4-32- 200 multi-fuel atomizer 1 4-2 rl4- 3221-0 slide 1 4-3 rl4-0322 push pull knob 1 4-4 rl4-0323 choke retainer boot 1 4-5 rl4-0324 choke assy component 2709 1 4-6 rl4-0325 choke assy component 2709 1 4-7 rl...

  • Page 24

    Raider 40 manual military version 3.5 fuel pump/oil system fuel pump caution: before servicing the fuel pump, disconnect the fuel hose from the engine to prevent excessive fuel spillage. Inspection 1. Inspect pump body (1) for cracks. 2. Inspect check valves (2) for deformation. 3. Inspect pump cove...

  • Page 25

    -14- raider 40 manual military version past production model contained an internal guide plate (7) and spring (8) assemblies under tension. The rubber diaphragm (9) that required the guide plate and spring has been replaced by a resin film (white opaque) diaphragm (10) which no longer requires the g...

  • Page 26

    Raider 40 manual military version i i \..... ..... - i i i i - - -5 i i i -- i i i _ _ _ _ _ _ _ _ _ _ _ _ _ .! I.

  • Page 27

    -16- raider 40 manual military version ref. No. Part no. Description q’ty remarks 5-1 356 - 04000 - 1 fuel pump 1 5 - 1 - 1 334-04004-0 * pump cover 1 5-1-2 92251 2 - 6528 * screw 3 5-1 - 3 334-04005-0 * diaphragm 1 5-1-4 334 - 04007-0 . * gasket "b", diaphragm 1 5-1 - 5 356 - 04030-0 * diaphragm se...

  • Page 28

    -17 - raider 40 manual military version 3.6 throttle mechanism.

  • Page 29

    -18- raider 40 manual military version ref. No. Part no. Description q’ty remarks 6-1 348-63711-1 advancer arm 1 6-2 9101 21 - 0840 bolt 1 6 - 3 345-63713 - 0 bushing:. 8 - 14 -4 2 6-4 930406 - 0800 nylon nut. 8p-1.25 1 6 - 5 3p0-66233 - 0 washer . 8 . 1 - 16-1.5 1 or 334-66233-0 6 - 6 921 506 - 052...

  • Page 30

    -19 - raider 40 manual military version 15 25 6 2 1 · ..:.::---· 3.7 tiller handle 3 fig. 19-1.

  • Page 31

    -20- raider 40 manual military version ref. No. Part no. Description q’ty remarks 6-1 348-63711-1 advancer arm 1 6-2 9101 21 - 0840 bolt 1 6 - 3 345-63713 - 0 bushing:. 8 - 14 -4 2 6-4 930406 - 0800 nylon nut. 8p-1.25 1 6 - 5 3p0-66233 - 0 washer . 8 . 1 - 16-1.5 1 or 334-66233-0 6 - 6 921 506 - 052...

  • Page 32

    -21 - raider 40 manual military version 3.8 magneto 20 i \ 6 7 . / 16 -22 i 20 16-1 12-1.

  • Page 33

    -22- raider 40 manual military version ref. No. Part no. Description q’ty remarks 8-1 361 - 06091 - 0 f l ywheel cup 1 fp5506 #91569 8 - 2 3a0-06002-0 coil plate ass'y 1 8-2-1 3g2-06022-0 * pulser coil 1 8 - 2 - 2 3a0-06023-0 * alternator 1 8-2 - 3 921521 - 6528 * screw 2 8-2 - 4 3g2-06021-0 * excit...

  • Page 34

    -23 - raider 40 manual military version 8-20 309 - 06972 - 0 clam p, 6.5-47.5p 4 8-21 922503-6510 screw 1 8 - 22 9101 13 - 061 2 bolt 1 8-23 353 - 76037 - 0 plug:. Cab l e terminal 1 8-24 336 - 76091-0 band, lead wire 1 8-25 931121 - 1600 nu t. Magneto ( 16p-1.5 ) 1 #032986xd- clockwise 334 - 00132 ...

  • Page 35

    -24- raider 40 manual military version 3.9 electrical system the raider 40 electrical system is very straight forward. For the user the secondary starting process is the built in self starter which consists of a protected starter button supported by a small lightweight battery. 3.8.1 battery. The ra...

  • Page 36

    -25 - raider 40 manual military version electrical system overview ignition type - flywheel magneto capacitor discharge spark plug (with resistor) - sbe1/10 (pulstar) spark plug wires – 2 x 23 015 002 051(nology) spark plug gap - 0.040 in [0.9 - 1.0 mm] battery - sealed type 12 volt w/hr (wh) – 24 (...

  • Page 37

    -26- raider 40 manual military version f ig. 11 -4 _ _ 1 - 1 _ _ : : _ .!_ _ _ (j) : : ! ' ' @ i ' ' ' ' ' : ' : ' ' ,. .... ' ·-·····::: ' . . . ... :. ! ' 1- 4 1-2 : i 1-3 : ....., 0 ' ! ' ' ' · . . . 0 ' ' ' ' · . ... - .. - ....- . . ' fig. 8-5 bolt position a b c d color of lead wi res yellow w...

  • Page 38

    -27 - raider 40 manual military version ref. No. Part no. Description q’ty remarks 9 - 1 346 - 76010 - 0 starter motor 1 9 - 1 - 1 346-76015-0 * pinion 1 9 - 1 - 2 346 - 76012-0 * carbon brush ( + ) 2 9 - 1 - 3 346 - 76013-0 * carbon brush ( - ) 1 9 - 1 - 4 346 - 76014-0 * brush holder 1 9 - 2 91610...

  • Page 39

    -28- raider 40 manual military version emergency stop switch and lanyard the emergency stop switch and lanyard should be inspected and tested after servicing outboard. The operator should perform emergency stop function test with the boat in the water prior to leaving the launch area. Warning do not...

  • Page 40

    -29 - raider 40 manual military version 10-1 10-3 10-4 10-5 10-6 10-1 10-7 10-6 dewater and start procedure: (pull start) 1. Connect fuel line. 2. Tilt engine into boat 3. Push dewatering valve toward rear of engine – hold back 10-7 4. Pump primer bulb clearing old fuel 5. Release dewatering against...

  • Page 41

    -30- raider 40 manual military version 10-8 ref. No. Part no. Description q’ty remarks 10-1 dw50540 dewatering lever 1 10-2 dw50541 head dewatering lever 1 10-3 dw50542 shoulder bolt 1 10-4 dw50543 lock washer 1 10-5 dw50544 carburetor dewatering valve depressor 1 10-6 dw50545 dewatering rod 1 10-7 ...

  • Page 42

    -31 - raider 40 manual military version 3.11 recoil starter --, 1-18 1-19 i i 11-23 i 1 1-21 i l 1-22 1-24 i 1 1 i 1 -9 i 1-2 i 3 2.

  • Page 43

    -30 - raider 40 manual military version ref. No. Part no. Description q’ty remarks 1 1 - 1 345-05000- 1 reco il starter 1 1 1 - 1 - 1 345 - 05105 - 1 * starter case 1 1 1 - 1 - 2 345 - 05105 - 1 * reel 1 1 1 - 1 - 3 345 - 05003- 1 * ratchet 1 1 1 - 1 - 4 345 - 051 35-1 * bushing, ratchet 1 1 1 - 1 -...

  • Page 44

    -33 - raider 40 manual military version ref. No. Part no. Description q’ty remarks 11 - 5 91 5314-0825 stud bolt 2 11-6 9301 21 - 0800 nut 2 1 1-7 9401 21-0800 washer 2 11-8 910114-0830 bolt 1 1 1-9 941 303-0800 spring: washer 1 1 1-10 910114-0625 bolt 2 1 1-11 941 303 - 0600 spring: washer 2 recoil...

  • Page 45

    -34- raider 40 manual military version 3.12 starter lock (pull starter) 12.

  • Page 46

    - 35 - raider 40 manual military version ref. No . Part no. Description q'ty remarks 40 r 12 - 1 361-05211-0 lock arm. Starter 1 12-2 915314-0825 stud bolt 1 12 - 3 345-01015-0 washer, 8.5-19.5 - 3 . 2 1 12-4 345-63713 - 0 bushing, 8-14-4 2 12 - 5 9401 13-0800 washer 1 12-6 930406-0800 nylon nut. 8p...

  • Page 47

    -36- raider 40 manual military version fig . 12 starter lock 1 2.

  • Page 48

    - 37 - raider 40 manual military version ref. No. Part no. Description q’ty remarks 12 - 1 361-05211-0 lock arm. Starter 1 12-2 915314-0825 stud bolt 1 12 - 3 345-01015-0 washer, 8.5-19.5 - 3 . 2 1 12-4 345-63713 - 0 bushing, 8-14-4 2 12 - 5 9401 13-0800 washer 1 12-6 930406-0800 nylon nut. 8p - 1 ....

  • Page 49

    -38- raider 40 manual military version 12 - 30 921521-6510 screw 2 1 2 - 31 921 503-0530 screw 1 1 2-32 930106 - 0500 nut 1.

  • Page 50

    - 39 - raider 40 manual military version i 3.13 drive shaft housing 10 ;- - -- 9 ' i i i i i i i i i i i i 17 i i i i i i 16 , i i i i i i i i i i _ _ _ ...J 6 1.

  • Page 51

    -40 - raider 40 manual military version ref. No. Part no. Description q’ty remarks 13 - 1 345s61030-1 drive shaft housing "l" 1 13 - 2 345-61 1 11-1 stud bolt. Drive shaft hous ing: 1 13 - 3 9301 1 3-0800 nut , drive shaft housing 1 13 - 4 9161 13 - 0885 bolt 8 13 - 5 3p0 - 66233 - 0 washer, 8.1-16-...

  • Page 52

    - 41 - raider 40 manual military version 3.14 gear case (drive shaft) ratio: 13 : 25 lubricant - genuine manufacturergear oil or api gl5, sae #80 - #90 capacity - approximately 14.2 u.S. Fl oz [420 ml] clutch system - dog clutch type (forward-neutral-reverse.

  • Page 53

    -42 - raider 40 manual military version ref. No. Part no. Description q’ty remarks 14 - 1 361 s60000 - 0 gear case 1 345 - 602 11 - 0 * needle bearing , 22 - 30 - 30 1 14-2 910113 - 5840 bolt 6 1 4-3 332 - 60005 -2 oil plug 2 14-4 332-60006 - 0 gasket , 8 . 1-15-1 2 14-5 345 - 60206 - 0 water strain...

  • Page 54

    - 43 - raider 40 manual military version ref. No. Part no. Description q’ty remarks 14 - 26 345-65206 - 0 sea l rubber upper , water pipe 1 14 - 27 345-65205 - 0 set ring, seal rubber 1 14 - 28 345-65204-0 lock rubber , water pipe 1 14 - 29 345-65110- 1 water pipe "l" 1 14 - 30 348-66011 - 0 c l utc...

  • Page 55

    -44 - raider 40 manual military version f ig. 14 - 1 - 19 18 10 16 section 15. Gear case (propeller shaft).

  • Page 56

    - 45 - raider 40 manual military version gear case/propeller ref. No. Part no. Description q’ty remarks 15-1 345-60215-0 bearing 32007 1 15-2 348010-1 bevel gear “a” 1 15-3 348-64211-0 propeller shaft 1 15-4 348-64215-0 clutch 1 15-5 345-64217-0 clutch pin 1 15-6 345-64219-0 snap, clutch pin 1 15-7 ...

  • Page 57

    -46 - raider 40 manual military version maintenance procedure: 1. Drain gear oil completely 2. Inject oil into lower 3. Replace upper plug, then by removing both upper oil plug hole until it lower plug after withdrawing and lower plugs. Flows from upper oil injector. Oil plug. Adjusting trim tab if ...

  • Page 58

    - 47 - raider 40 manual military version 3.16 shifter 1 fig . 14-38 19 17.

  • Page 59

    - 50 - raider 40 manual military version ref. No. Part no. Description q’ty remarks 16-1 345s66110 - 2 shift lever 1 16 - 2 345-66137-0 oi l seal , 10 - 20 - 4 1 16-3 345 - 66121 - 0 stopper plate , shift lever 1 16 - 4 910903-6512 bolt 2 16-5 345 - 67101 - 0 bushing , 10-12 . 8-42 . 5 1 16 - 6 9453...

  • Page 60

    - 49 - raider 40 manual military version 3.17 transom bracket.

  • Page 61

    -52- raider 40 manual military version ref. No. Part no. Description q'ty remarks 40 r 17 - 1 349s62112-0 stern bracket (right) 1 starboard 17-2 349s62113 - 0 stern bracket (left) 1 port 17 - 3 346-62191 - 0 bracket bolt 1 17-4 346-62124 - 0 nylon nut. 7 / 8 1 17 - 5 349-62126-0 bushing , bracket bo...

  • Page 62

    - 53 - raider 40 manual military version ref. No. Part no. Description 1 q'ty remarks 40 r 17-28 345 - 61313-0 stud bolt , rubber mount (upper) 2 17 - 29 345-6131 2-0 retainer, rubber mount 2 17-30 9101 13 - 5820 bolt 2 17-31 345 - 61331-0 damper clamp 2 17-32 345 - 61332 - 0 damper collar 2 o 20- o...

  • Page 63

    -54- raider 40 manual military version 17-55 17-56 348 - 62143 - 0 348-62107-0 shaft. Tilt assistant raider transom safety support 1 1 transom parts should be checked before missions for damage..

  • Page 64

    - 55 - raider 40 manual military version 3.18 reverse lock (transom bracket).

  • Page 65: Lower Unit

    -56- raider 40 manual military version 3.19 motor cover upper unit 19-1 tilt handle p/n 345s675210 screw – p/n: 9216030516m 9301030500m - nut 19-4 spring washer p/n: 9413030500m washer p/n: 9401030500m 19-8 19-6 rubber starter seal p/n: 3km675030m rubber seal p/n: 3f3675010m dewatering instructions ...

  • Page 66

    Raider 40 manual military version 56 ref. No . Part n o. Description q ' ty remarks 40 c 19-1 345s67100-2 motor cover lower 1 # 93201 - 19-2 345-671 13 - 0 rubber mount. 12 -1 8 - 2.5 8 19 - 3 3c7-67114-0 spacer, 8.4-12-17 4 19 - 4 9101 13-0835 bolt 4 19 - 5 345 - 671 1 5-0 washer, rubber mount 4 19...

  • Page 67

    -58- raider 40 manual military version 3.20 fuel hose fuel hose and primer separate fuel tanks are connected to the engines by a hose with a primer bulb. The primer bulb forces fuel into the multi-fuel (throttle body) atomizer float chamber for engine starting. Check valves on each side of the prime...

  • Page 68

    Raider 40 manual military version 56 3.21 two motor configuration dual motor control and throttle (dmct) 18 to 26 inches raider can be used in a two engine configuration to power the conventional 15 passenger rubber inflatable boat. The motors are placed on the transom where the dmct connecting rod ...

  • Page 69

    -60- raider 40 manual military version 3.22 tool kit tools: tool bag pliers 10 x 13 mm socket wrench 21 mm socket wrench socket wrench handle slotted-head screwdriver spare parts: starter rope spark plugs (2) split pin (cotter key) other: plastic emergency clip.

  • Page 70

    Raider 40 manual military version 56 section 4. Raider engine details 4.1 tune-up procedure warning deteriorated or damaged parts identified during engine tune-up must be replaced in order to maintain safe engine operation. 1. Inspect engine for leaks, missing, loose or damaged parts, or other visib...

  • Page 71

    -62- raider 40 manual military version 4.2.1 general equipment required water pressure gauge - 0 - 15 psi [0 - 103 kpa / 0 - 1 kg / cm2] fuel pressure gauge - 0 - 15 psi [0 - 103 kpa / 0 - 1 kg / cm2] torque wrench - 0 - 150 in-lb [0 - 17 n·m / 0- 1.7kg-m] torque wrench - 0 - 750 ft-lb [0 - 1000 n·m...

  • Page 72

    Raider 40 manual military version 56 4.2.2 consumables required thread locker, loctite ® 242 thread locker, 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...

  • Page 73

    -64- raider 40 manual military version adjustment procedure: 1. Rotate the throttle grip to the fast side until throttle stops 2. Adjust ignition timing link so that the timing full open match mark is aligned with the fitting line (crankcase mating surfaces). 3. Adjust the stopper bolt so that the a...

  • Page 74: Unit Conversions

    Raider 40 manual military version 56 unit conversions 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...

  • Page 75

    -66- raider 40 manual military version.

  • Page 76

    Raider 40 manual military version 56 section 4. Engine details synchronization and linkage adjustments to ensure consistent engine idling and smooth operation throughout the full rpm range, it is important that each procedure be performed exactly as written and in the following sequence: 1. Ignition...

  • Page 77

    -68- raider 40 manual military version troubleshooting - powerhead the troubleshooting chart list common engine symptoms related to problems with the powerhead. It also indicates specific component failures which may be causing the problem so it can be isolated more effectively for the raider 40. No...

  • Page 78

    Raider 40 raider 40 manual military version fuel additive not included.

  • Page 79

    -70- raider 40 manual military version section 5. Recommended spare parts kit the raider 40 horsepower multi-fuel/submersible outboard engine has been reviewed and all the possible spare parts for sixteen units that can be supported by the users are identified in this section. Where the raider is us...

  • Page 80

    Raider 40 raider 40 manual military version if any discrepancies are found the manual can be updated by called (321) 403-3585 – raider outboards. Updates will be automatically done on line. Www.Raideroutboards.Com manuals will be listed. Password is required for entry. Raider outboards 707 main stre...