MFS 40 - 50

1
.
Overall Length
Overall Width
Overall Height
Model
Transom Height
Weight*
MFS40A/50A specification
EPT
ET
EPG
EHG
Approx.
Approx.

Approx.

Approx.

Approx.

Approx.

Approx.

Approx.

Approx.
209 lb
220 lb
204 lb
Approx.
214 lb
225 lb
215 lb

208.3 lb
219 lb
Approx.
220 lb
Engine Type
Number of Cylinder
Piston Displacement
Bore Stroke
Max. Output
Max. Operating Range
Idle Speed
Compression ratio
Variable idling speed
Exhaust System
Engine Lubrication
Cooling System
Starting System
Valve System
Ignition System
Spark Plug
Alternator
kW(ps)
kW(ps)
232 lb
215 lb
4 stroke EFI
In line 3 cylinder
cm3 (ml)

W ( )
W ( )
r/min
/min
, , , r/min
Through hub exhaust
Wet sump (Trochoid pump)
Water cooling (with thermostat)
Electric starter motor
SOHC cross flow
Battery ignition

(4000 r/min)
226lb
MFS40A/50A specification
ET
Model
EPT
Steering angle
Trim angle
Trim position
Tilt up angle
Gear shift
Dog clutch ( )
Gear Reduction Ratio
()
Fuel
Unleaded regular gasoline : Pump posted

87 Octane (research octane rating of 91)
Grade
Engine Oil
ml (US qt)
Grade
Gear Oil
EPG
EHG
API standard SH, SJ, SL, 10W-30/40

2400
2200 (2.3)
Genuine Gear Oil or API GL5,SAE #80-90
ml (US qt) 500 (0.53)

/5HR CCA850
Battery
Cold
weather
spec.
/5HR CCA1000

TOHATSU
MFS50A ET
4 stroke
HONDA
BF50D LRTN
4stroke
YAMAHA
F50B L
4 stroke
SUZUKI
DF50ATL
4 stroke
Mercury
50ELPT Xri
4 stroke
866
808
966
941
995
70X75
70X70
6575
72.576
65X75
No. of cylinder
Max. output
3
50ps
3
50ps
4
50ps
3
50ps
4
50ps
Max. operation
range
5000-6000
5000-6000
5000-6000
5300-6300
5500-6000
Fuel injection
Fuel injection
Fuel injection
Fuel injection
Fuel injection
Starting system
Alternator
Weight
Gear ratio
Tilt
Electric
21A (*1)
97(214b)
2.08
PTT
Electric
17A(*2)
98(216lb)
2.08
PTT
Electric
17A(*1)
113(249lbs)
1.85
PTT
Electric
19A(*1)
106(234lb)
2.27
PTT
Electric
18A(*1)
112(247lb)
1.83
PTT
Transom
height(mm) (L)
538
521
534
531
541
Model name
Engine type
Piston
displacement(ml)
Bore
Stroke(mm)
Fuel supply
system
*1 Alternator performance
*2 Charging performance
Comparison of Weight (kg) by Brands: 4st 40ps Class

(lb) 104
(kg)
229 103
227 102
225 101
223 100
221
99
218
98
216
97
214
96
212
MFS40A
F40F
DF40A
40EFI
BF40
TOHATSU
YAMAHA
SUZUKI
MERCURY
HONDA
( ) 40 ..
(lb)
(kg)
256
247
238
229
221
212
( ) 50 ..
0 50
Acceleration 0-50m
: 4.45 (14.6 ft)

: 300 (661 lb)
sec
MFS40A
8,05
YAMAHA F40F
8,15
13inch
11inch
Acceleration 0-100m
sec
MFS40A
12,45
YAMAHA F40F
12,70
13nch
11inch
10
0 50
: 4.45 (14.6 ft)

: 300 (661 lb)
Acceleration 0-50m
sec
MFS50A
HONDA BF50
YAMAHA F50F
15inch
6,65
14inch
6,90
15inch
7,80
Acceleration 0-100m
sec
MFS50A
HONDA BF50
YAMAHA F50F
15inch
10,20
14inch
10,55
11,80
15inch
11
0 50
: 6.37 (21ft)
: 390 (860lb)
Acceleration 0-50m
sec
MFS50A
HONDA BF50
YAMAHA F50F
14inch
7,20
14inch
7,75
11inch
7,35
Acceleration 0-100m
sec
MFS50A
HONDA BF50
YAMAHA F50F
11,15
11,90
11,55
14inch
14inch
11inch
12

Max. power
Max. torque
FC Fuel
Consumption
Power
Torque
Power(Kw)
Torque(Nm)
FC(L/h)
MD50B2
13
: 4.45 (14.6 ft)

: 300k (661 lb)
14
: 4.45 (14.6 ft)

: 300k (661 lb)
SFC (km/L)
Fuel efficiency
8
MFS50A_15inch
Honda BF50_15inch
Yamaha F50F_13inch
5
4
3
2
1
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
Engine Speed (r/min)
15
: 6.37 (21ft)
: 390k (860lb)
Fuel Flow vs. Engine Speed
5600
5000
4000
3000
Yamaha F50F_11inch
2000
Honda BF50_14inch
MFS50A_14inch
800
0,0
2,0
4,0
6,0
8,0
10,0
Fuel Flow (L/h)
12,0
14,0
16,0
18,0
20,0
16
: 6.37 (21ft)
: 390k (860lb)
Fuel efficiency
9
MFS50A_14inch
Honda BF50_14inch
SFC (km/L)
Yamaha F50F_11inch
6
5
4
3
2
1
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
17

Maximum Speed
50
48
48.4
30.07mph
48.40
30.07mph
48.2
29.95mph
49
Speed [km/h]
: 6.37 (21ft)
: 390k (860lb)
48.30
30.01mph
47.0
29.2mph
48.05
29.9mph
47
46.8
29.08mph
46
46.85
29.11mph
45
44
44.5
27.65mph
44.05
27.37mph
43
42
41
MFS50A
HONDA BF50
YAMAHA F50F
40
4500
4700
4900
5100
5300
5500
5700
5900
6100
6300
6500
Engine speed [r/min]

18

Propeller
MFS50A
13
14
15
km/h
48.05
48.40
48.2
r/min
6062
5528
5196
13
14
15
km/h
48.4
48.30
47.0
r/min
6056
5567
5147
10
11
13
14
km/h
44.05
44.5
46.85
46.8
r/min
5917
5466
5027
4920
Propeller
HONDA_BF50
Propeller
YAMAHA F50
: 6.37 (21ft)
: 390k (860lb)
19

: 4.45 (14.6 ft)
: 300k (661 lb)
Maximum Speed
58
MFS50A
57
HONDA BF50
YAMAHA F50F
56
Speed [km/h]
55
54.05
33.59mph
54
53.40
33.18mph
52.7
32.75mph
53
52
52.10
32.37mph
51
52.65
32.72mph
52.40
32.56mph
52.35
32.53mph
50
49
48.9
30.38mph
48
4500
4700
4900
5100
5300
5500
5700
5900
6100
6300
6500
Engine speed [r/min]

20

Propeller
MFS50A
HONDA_BF50
14
15
16
km/h
52.7
53.40
54.05
r/min
5736
5393
5165
Propeller
14
15
km/h
52.35
52.40
r/min
5772
5380
11
13
15
km/h
48.9
52.65
52.10
r/min
5716
5324
5025
Propeller
YAMAHA F50
: 4.45 (14.6 ft)

: 300k (661 lb)
21
22

, ,
.
, .
.
23

Alternator performance
A
25
20
21.3A@4000rpm
18.6A@1500rpm
15
18
3
15A@1000rpm
10
6.9A@650rpm
:
4
0
0
1000
2000
3000
4000
5000
6000
Engine RPM
24
25
1. 4.
26
27
ISC
28
MAP/ MAT
29
,
( )

,
MD90C2.

.
30

,

- - - , ,
, .
. ,
, .
2nd ring
Expander
Side rail upper
Side rail lower
Top ring
31
Piston ring gap

,
,
(615% MD50)
- ,

( MW50)
32

( MD50B2).
3 6
( MD50B2)

19 20 ( MD50B2)
,

MW50D2 :80, MFS40/50 :84.5
M6M8
30.433.25
1920
6.758.5

8084.5
:2.08
33

650 950/
1 .,

* 850/,
3000 /

34

, .
.
35
(.)
,
,
(
).
,
.
1. . 3KY-72620-0
:
TILT LIMIT SWITCH
SCREW
NUT
WASHER
TILT LIMIT SWITCH PLATE
1
2
2
2
1
BOLT
TILT LIMIT SWITCH CAM
TILT LIMIT CAM HOLDER
PIN
SCREW
1
1
1
1
2
36
2.

3.
,

4.

5.
,

6. ,

,
7.
(

37
8.

9.
10.
,
11.
,

12.
,
13.
.

38
14.
,
.
!
39
-

(
)

1.
"ON",
5 .
,
2. ,
,

.
,

,
/.

/
3.
"ON",
1 .,

40
/
Lamp Indication
Engine Operating
Hours(h)
01
12
23
34
45
56
67
78
89
910
1020
2030
3040
4050
5060
6070
7080
8090
90100
100200
200300
300400
400500
500600
600700
700800
800900
9001,000
1,0002,000
2,0003,000
Tach. Indication(r/min)
1,000
2,000
3,000
4,000
5,000
6,000
7,000
800
900
1,000
2,000
3,000
4,000
5,000
6,000
7,000
800
900
1,000
2,000
3,000
4,000
5,000
6,000
7,000
800
900
1,000
2,000
3,000
Lamp A
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Lamp B
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Lamp C
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
Goes on.
41
4.
"OFF,

.

.
,
ON, 1 .
,
.
,
,

, ,
.
/,
, .
42

Fault Log
Malfunction/Failure Indication
Fault
Fault log (Yes)
Description of Problem
Remedy
Tachometer Indication(r/min)
Lamp
Lamp
Lamp
Off
No malfunction of failure
Off
Off
1,000
On
Fuel injector malfunction
2,000
On
3,000
On
1,000
Flashing
Ignition coil manfunction
2,000
Flashing
3,000
Flashing
500
Off
Oil pressure low
500
On
Battery voltage low
Lighting means that battery

voltage is low.
Lighting means that the battery

voltage was once low.
5,000
Off
malfunction
Lighting means that the

wiring is broken or a
component malfunction.(*2)

component was once broken.
5,500
Off
malfunction

component malfunction
Lighting means that the wiring

was once broken or a component
once malfunctioned.
*1 Only the fault log can be found
(*1)
(*1)
(*1)
(*1)
Lighting of the lamp means that *1 Only the fault log can be found
the wiring was once broken or a
component once malfunctioned. *1 Only the fault log can be found
(*1)
(*1)
(*1)
Oil pressure was once low
*2 No lighting when the wiring is

broken.
43
Fault Log
Malfunction/Failure Indication
Fault
Fault log (Yes)
Description of Problem
Tachometer Indication(r/min)
Lamp
5,500
On
5,500
Remedy
Lamp
Lamp
Sensor power valtage high

power voltage high
Lighting means that the power

voltage was once high
Flashing
Sensor power voltage low

power voltage low
Lighting means that the power

voltage was once low
6,500
Off
Engine temp. sensor malfunction


component was once broken.
6,500
On
Engine temp. high

cooling water tem. is high
Lighting means that the cooling

100
water tem. was once high
6,500
Flashing
Engine temp. abnormally

cooling water tem. is
abnormally high
Lighting means that the cooling

water tem. was once abnormally 140
high
7,000
Off
malfunction
4,500
On
sensor malfunction

Lighting means that the wiring

was once broken or a component
once malfunctioned.
4,500
Off
T sensor malfunction
44

100 /
.
!!!
!

1
9 .

1.
,
ON, 1 .
.
2. 5-10 . ( 3. 5-10 .
7 .) ,

0,5 0,5 . .
.
45
4. 5-10 .
,
,
.
5.

OFF
.

100/,

.
46
47
ECU
ISC
MAP/MAT
TPS
48

Power
Battery
Power
Pulser Coil
(Crank
Position
Sensor)
MAP
Sensor
Engine
speed
Crank
position
Control
Ignition timing,
Fuel injection amount
and
Idle Speed Control Valve
Fuel feed Pump

(FFP)
Fuel
Injector
Manifold
pressure
Manifold
temperature
Atmosphere
pressure
before starting
Engine
(Water) Temp
Sensor
Throttle
Position
Sensor
(TPS)
Oil
pressure
switch
Engine
temperature
Throttle
opening
angle
Oil
pressure
Ignition
Coil
Correction
Ignition timing
and
Fuel injection amount
Control
Warning lump,
Buzzer
and
ESG working
Idle speed
Control
Valve
Warning lamp
Buzzer
ECU
49

ECU
ECU
1.

.
2. ,
ISC.
3. .
4.
Crank Position Sensor (CPS)

,

,

Engine (Water) Temp Sensor
.
.
,
50
MAP (Manifold absolute pressure)

(
) ,

Throttle Position Sensor

,
.
Oil Pressuer Switch

,

51
ISC (Idle Speed Control Valve)

,
,

,

Fuel Injector

,
.
Ignition Coil
I ,

.
.
52
53

,
. .
.
.
54

OUT
IN
. ( )
:
. ( )
.
( )
.
( )
55

.
,
.
.
56
Out
Return
In
57
58
CPS
.
: 0.8
59

.
(
)
:
20/
:
100/

Intake/
:
0.15-0.25
Exhaust/
:
0.25-0.35
60

,
(
)
,
.
11
Start
9
10
12
Nm
kgfm
No.1~8
M10
No.9~12
M8
Nm
kgfm
30
3.0
60
6.0
15
1.5
30
3.0
61
:
CBBC
:
1111
62
: CBBC, 1111
, , ,
XXX
: XXX, 322
, ,
63

,
.
:
: 30Nm(3.0kgfm)
:13Nm(1.3kgfm)

..
Lock tight
271
64

,
MFS25/30B (
MFS25/30B)
,
MFS25/30.

On/Off
65
650 to 950
Up to 10%
60 to 65
-700 to -600 hPa
Approx. 0.5L to 16
66
B, : 0.60-0.64 mm
A B
(in)
.
+ .
- .
(in)
0.00 - 0.01(0.00-0.0004)
0.02 - 0.17(0.0008-0.0067)
0.18 - 0.30(0.0071-0.0118)
0.31 - 0.62(0.0122-0.0244)
0.63 - 0.75(0.0248-0.0295)
0.76 - 0.91(0.0299-0.0358)
0.92 - 1.07(0.0362-0.0421)
1.08 - 1.22(0.0425-0.0480)
1.23- 1.38(0.0484-0.0543)
1.39 - 1.53(0.0547-0.0602)
1.54 - 1.69(0.0606-0.0665)
- 0.15(0.0059)
- 0.10(0.0039)
- 0.05(0.0019)
0
+ 0.05(0.0019)
+ 0.10(0.0039)
+ 0.15(0.0059)
+ 0.20(0.0078)
+ 0.25(0.0098)
+ 0.30(0.0118)
+ 0.35(0.0137)
1.70 - 1.84(0.0669-0.0724)
+ 0.40(0.0157)
()()
67
.
Part No.
3KY-72815-0
3KY-72871-0
3AB-99702-0
3AC-99702-0
3KY-99905-0
3KY-99710-0
3KZ-99710-0
Part name
CRANKSHAFT
HOLDER
PISTON SLIDER
DRIVER ROD
DRIVER ROD
BEARING
ATTACHMENT
ROLLER BEARING
ATTACHMENT
ROLLER BEARING
ATTACHMENT
Purpose
Part No.
Holding crank shaft
3B7-72234-1
Installing piston
Use with attachment
Installing gear case roller
bearing/ bevel gear A outer
race
bearing
Installing propeller shaft
housing roller bearing
Use with bearing attachment
to hold bearing
Installing propeller shaft
housing roller bearing
bearing
Measuring bevel gear B
height
Measuring gap
332-66032-0
O-RING
3AC-99701-0
CENTER PLATE
3C8-72719-0
BEVEL GEAR BRG

INSTALL TOOL
3KY-72250-0
SHIMMING GAUGE
353-72251-0
THICKNESS GAUGE
BEVEL GEAR NUT
Removing bevel gear B nut
WRENCH
BEVEL GEAR NUT
Removing bevel gear B nut
SOCKET
BEARING OUTER
Installing bevel gear A outer
PRESS KIT
race
BEARING OUTER
PRESS ROD
race
BEARING OUTER
PRESS PLATE
race
ROLLER BEARING OTR Installing bevel gear A outer
PRESS GUIDE
race
SPRING WASHER
race
NUT
race
346-72231-0
346-72232-0
3B7-72739-1
3B7-72731-0
353-72732-0
3BJ-72733-0
941392-1000
930191-1000
3B7-72720-0
3B7-72729-0
3T1-72211-0
345-72227-0
345-72228-0
369-72217-0
369-72218-0
353-72248-0
3KY-72229-0
3KY-72920-0
3AC-99070-0
3AC-99080-0
3AC-99090-0
Part name
Purpose
BACKLASH
MEASURING TOOL KIT
*BACKLASH
MEASURING TOOL
SHAFT
Measuring gap between bevel

gear A and B
gear A and B

gear A and B
*CONED DISC SPRING
gear A and B
*MEASURING SETTING Measuring gap between bevel
PIECE
gear A and B
*O-RING
gear A and B
*BACKLASH
MEASURING TOOL
gear A and B
PLATE
BACKLASH
MEASURING TOOL
gear A and B
CLAMP
DIAL GAUGE PLATE
gear A and B
FLYWHEEL PULLER KIT Removing/Installing flywheel
SPRING PIN TOOL
Removing spring pin(3)
SPRING PIN TOOL
Installing spring pin(3)
SPRING PIN TOOL
Removing spring pin(3.5)
SPRING PIN TOOL
Installing spring pin(3.5)
SHIFT ROD JOINT
Pulling shift rod
PULLER
CLUTCH PIN SNAP
Attaching snap pin
TOOL
DIAGNOSTIC TOOL KIT Diagnosing engine trouble
TORQUE WRENCH
Adjusting valve clearance
Removing bevel gear A
SLIDE HAMMER ASSY
bearing outer race
OIL FILTER WRENCH Removing/Installing oil filter
*NUT
Yellow means newly added
68

Warning Indicators
ESG
Fault Description
Reference
Buzzer Sounding
Indicator A Indicator B Indicator C
Countinuous
Countinuous
Constant
High speed
Engine over-rev
ESG
Low speed ESG Low oil level
Countinuous
Flashing
Low speed ESG Cooling water temp. high
Countinuous
Constant
Constant
Constant
Flashing
Approx. 6,200 r/min
100 (*2) Activate 1 sec.
Forced idling Cooling water temp. abnormally high

-
150
Approx. 9V or less. Idling speed
up
Battery voltage low
Flashing Flashing Flashing Low speed ESG Sensor power supply malfunction
Flashing Flashing Flashing
Ignition coil malfunction
FFP malfunction
CPS malfunction*1
TPS malfunction
Flashing Flashing Flashing Low speed ESG Temp sensor malfunction
Flashing Flashing Flashing Low speed ESG MAP sensor malfunction
MAT sensor malfunction
Countinuous(*2)
Constant(*2) Constant(*2) Constant(*2)
(*1) No flashing when the wiring

is broken.
Flashing
Short sound 1
When the key is turned On

Indicate oil replacement period every
100hrs
Lowest idling speed of variable system
Short sound 2
Highest idling speed of variable system
0.3 .
ON 0.3 .-OFF 0.3.-ON 0.3.
ON 1 ., OFF 1 .
ON 1 , OFF 9 .
(*2) Activate 1 sec.

Reset by stop switch
3000 /
. : 6200 /
69

Tightening Location
Screw B X
Pitch
Type of
Fastner
M101.25
Bolt
M81.25
Bolt
Spark Plug
M121.25
Tappet Adjusting Nut
M60.75
Nut
Cylinder Head
Rocker Shaft Bolt
M81.25
Bolt
Thrust Bolt
M61.0
Bolt
Anode Plug
M161.5
Anode Installation Bolt
M50.8
Screw
Oil Filter
Cylinder Block
M201.5
M81.25
Bolt
Crank Case Installation Bolt
Crank Case
M61.0
Bolt
Connecting Rod Bolt
M80.75
Bolt
Flywheel Nut
M201.25
Nut
Crank Shaft
Timing Pulley Nut
M391.5
Nut
Oil Pressure Switch
PT1/8
Engine Short Block Power Unit Installation Bolt M81.25
Bolt
Bracket Shaft
Cramp Bracket
7/8-14UNF-2A Nylon Nut
Manual Valve
PTT Assy
M12
Cylinder Head Installation
Bolt
Engine Basement
Drive Shaft
Gear Case
Top Cowl
Upper Mount Rubber

Installation Bolt(Center)
Oil Pan Drain Bolt
M81.25
Bolt
M141.5
Bolt
Bolt, Nylon
nut
Nut
Nut
Nylon Nut
Lower Mount Rubber Bolt
M121.25
Bevel Gear B Nut

Propeller Nut
Tilt Handle Installation Nut
M121.0
M161.5
M61.0
Temporary Driving
Torque
Nm
kgfm
30
3.0
15
1.5
12-15
1.2-1.5
6
0.6
15
1.5
15
1.5
-
Driving Torque N-m

Nm
60
30
18
7
18
9
18
2
23-25
11.5
30
150
120
8
30
24
1.8
kgfm
6.0
3.0
1.8
0.7
1.8
0.9
1.8
0.2
3/4 rotating(270)
after finger tighten
2.3-2.5
1.15
3.0
15.0
12.0
0.8
3.0
2.4
0.18
15
1.5
30
3.0
24
2.4
40
4.0
50
35
2
5.0
3.5
0.2
70
Oil seal (cam shaft)
Cylinder head
ATF
Mori
KS-64 paste
500
Cam
Bearing
Lip
Periphery
Thread end
Thread
Bearing, slipper head
Periphery
Entire
Entire
Shaft, Stem head
Entire
Entire
Entire
Lip, inner
Entire
Approx. 2cc from intake port and discharge port.
Plunger tip
Periphery
Thread
Thread, seat
Periphery
Thrust bolt (cam shaft holding)

Cam shaft pulley bolt
Rocker arm
Rocker arm shaft
Rocker arm spring
Washer(rocker arm)
ValveINT,EX
Valve spring
Valve spring seat
Retainer cotter
Valve stem seal INT,EX
Tappet adjusting screw
Oil pump
Fuel pump
O-ring(fuel pump)
O-ring(anode plug)
Taper plug
Cylinder head bolt
Cylinder head O-ring(filler cap)
cover
Screw(breather chamber cover)
Cylinder linder
Piston
Piston ring
Piston pin
Connecting rod
Connecting rod metal bearing
Cylinder block &
Crank shaft
crank case
Crank shaft metal bearing
Oil seal(crank shaft upper lower)
Cylinder block/crank case mating surface
Bolt(oil filter)
Oil filter
Taper plug
LM902
Cam shaft
Remark
Shinetsu
Sumico
silicones
Chuo yuka
LOR Centax FM#101

L2
531
PTT fluid
G17
Tohatsu genuine gear oil
1207B 1741
4st engine oil
518
Molybdenum grease
LOR
#2000
Silicone grease
1342 1373B 1401
Teflon grease
Oil
Oil
Three Three Three
Three Three
center Loctite
Konishi center
bond bond bond research
bond bond
research
Waterproof grease OBM
Low temperature resistant lithium

grease
Heat resistant grease
Adhesive
Instaneous adhesive
Gasket seal agent
271
Rusting and leaking prevention screw

lock agent
Part name
High-strength screw lock agent
Loctite
Low-strength screw lock agent
Item name
Inner wall
Peripheryring groove
Entire
Periphery
Small end inner
Sliding surface *Degrease periphery
Sliding surface, thrust receiving surface
Sliding surface *Degrease periphery
Lip
Mating surface
Thread
Seat surface (O-ring)
Thread
71
* TB 1207B ,
LOR Centax FM#101

L2
531
LM902
Engine basement
Drive shaft housing
Drive shaft
Oil seal (pump case lower)

Gear case
Propeller shaft
Propeller shaft housing
Oil seal (engine basement)

Seal rubber (engine basement)
Bolt (Drain cover)
Bolt (Idle exhaust cover)
Screw (oil pan guide plate)
Water pipe seal (upper)
Water pipe auxially (support) mount
Bolt (engine)
Stud for
Drive shaft (spline)
Nut (bevel gear B)
Bolt (Gear case)
Bolt (pump case)
Pump case upper (liner)
O-ring pump case lower
Water pipe seal (lower)

O-ring (cam rod bushing)
Bolt (cam rod bushing)
Tapered roller bearing (outer)
Needle bearing (gear case)
Needle bearing (bevel gear A)
Propeller shaft (spline)
Clutch
Push rod
Ball
Retaner
Spring
O-ring
Oil seal
Roller bearing
Needle bearing
Spark plug insertion area

High tension cable
Thread
Terminal
Terminal
Pinion
Terminal
Lip
Periphery (when installation),
Periphery, Inner
Thread
Thread
Thread
Periphery
Inner
Thread
Inner thread
Crank shaft side spline
Thread
Thread
Thread
Impeller sliding surface
Starter solenoid
Remark
ATF
Mori
KS-64 paste
500
Starter motor
PTT fluid
Shinetsu
Sumico
silicones
Chuo yuka
G17
4st engine oil
1207B 1741
Molybdenum grease
518
Silicone grease
LOR
#2000
Teflon grease
1342 1373B 1401

grease
Oil pressure switch
Oil
Oil
Three Three Three
Three Three
center Loctite
Konishi center
bond bond bond research
bond bond
research
Plug cap
Electrical
components
Adhesive
Instaneous adhesive
Gasket seal agent
271
Rusting and leaking prevention

screw lock agent
Part name
Loctite
Item name
Lip
Periphery (when installation)
Inner surface
Thread
Spline
Spline
Entire
Entire
Entire
Entire
Lip
72
G17
LOR Centax FM#101

L2
531
Bracket
Steering shaft
arm
PTT
Bottom cowl
Oil seal
Seal rubber (apron)
Sliding surface
Spline
When installing
Inner thread
Thread (after degrease)
Sliding surface
Center
Shift arm
Shift lever shaft
Apron
Cylinder pin bushing (upper lower)

PT oil
O-ring
Bushing (hook lever)
Seal ring (hook lever)
Throttle arm
Throttle cam
Link rod assy
Lip
Fill with grease from nipple
Fill with grease from nipple
Sliding surface
Roller bearing
Needle bearing
Swivel bracket steering shaft
Swivel bracket (bracket bolt)
Tilt stopper bushing
Tilt stopper grip
Tilt stopper (shaft)
Mount bracket
O-ring (steering shaft)
Co-pilot bolt
Nut 7/8(bracket bolt)
Upper mount bolt, nut
Remark
ATF
Mori
LMKS-64 paste
902
500
O-ring
Propeller shaft
housing
PTT fluid
1207B 1741
518
Shinetsu
Sumico
silicones
4st engine oil
LOR
#2000
Molybdenum grease
1401
1373B
Chuo yuka
Silicone grease
1342
Teflon grease
Oil
Oil
Three
Three Three
center Loctite
Konishi center
bond research
bond bond
research
Three Three
bond bond

grease
Adhesive
Instaneous adhesive
Gasket seal agent
271
Rusting and leaking prevention

screw lock agent
Part name
Loctite
Item name
Inner, outer
Lip
Sliding surface
Sliding surface
Joint
Sliding surface
Sliding surface, shift rod insertion area
Bonded part apron and seal rubber
Bottom cowl groove
73

Part Name
Engine
Item
Compression Pressure (400r/min )
*Remove all spark plugs and measure after
warming with the throttle fully open and safety
lanyard removed.
Valve clearance
Valve Stem Outer Diameter
Valve (IN/EX)
Valve Guide Inner Diameter

Clearance between valve guide and valve stem
Width of contact with valve seat
Valve spring
Rocker arm
Piston
Free Length
Rocker Arm Inner Diameter
Shaft Outer Diameter
Shaft Clearance
Outer Diameter (Measure outer diameter at
12mm above lower end of piston skirt)
Clearance between piston and cylinder liner
Carbon build up on piston crown and in ring
grooves
Standard Value
1.4 Mpa (14.27 /c)
IN 0.150.25 mm
EX 0.250.35 mm
IN 5.4755.490 mm
EX 5.4555.470 mm
IN 5.5005.512 mm
EX 5.5005.512 mm
IN 0.0100.037mm
EX 0.0300.057mm
IN 1.311.51 mm
EX 1.311.51 mm
IN 38.68mm
EX 38.68mm
16.00016.018 mm
15.98315.994 mm
0.0060.035mm
69.9669.98 mm
0.0200.055 mm
Engine Parts
Piston ring
Action to be taken
Adjust into specified range.

Replace if over specified limit.
Replace or repair if over specified limit.
Replace with new parts.
Top 0.040.08 mm
Second 0.040.08 mm
Oil 0.030.13 mm
Piston pin hole inner diameter
17.00217.008 mm
Piston pin outer diameter
16.99617.000 mm
Clearance between piston pin and pin hole
0.0020.012 mm
Ring end gap
Top 0.200.35 mm
*Measurement of ring end gap : If ring gauge Second 0.350.50 mm
is not available, use cylinder bore top or bottom
Third 0.200.70 mm
with small wear.
Cam rod bearing inner diameter
42.00042.025 mm

Clean and remove built up. Replace if
nessesary.
Distortion or damage on cylinder head mating

surface
0.05 mm or less
Deflection of 0.06 mm or more. There is

scraches that affect sealing performance.
Build up of carbon in combustion chamber

Cooling water passage clogged
Corrosion on the mating surface
Cylinder liner inner diameter
70.00070.015 mm
Distortion or damage on cylinder head mating

surface
0.05 mm or less
Deflection of 0.06 mm or more. There is

scraches that affect sealing performance.
Deposits in water jacket

Repair by posishing the surface plate, starting
with #240 to #400 grit sandpaper and finishing
with #600 grit sand paper.
Clean and remove built up.
Repair or replace depending on the extent of
damage.
Repair by posishing the surface plate, starting
with #240 to #400 grit sandpaper and finishing
with #600 grit sand paper.
Clearance between piston ring and piston ring
Piston pin
Functional limit
When the difference in compression between
cylinders exceeds 0.1 Mpa (14.9 psi) 1.05 kg/cm2 When abnormally higher than standard value
Cylinder head
Cylinder block
Mating surface scratches and wear
Engine Anode
When the cylinder liner cannot be repaired using

#400 to #600 grift sandpaper due to deep
scratching or scuffing to the sliding surface in
contact with the piston or when the difference
between the minimum and maximum points of
wear in the liner bore is 0.06mm (0.0024 in) or
more.
When anodes shows excessive corrosion(erode
1/3 of original size)
74
Part Name
Connecting rod
Engine Parts
Crank shaft
Item
Small End Inner Diameter
Big End Oil Clearance
Big End Side Clearance
Crankshaft runout : Use V blocks to support
crankshaft at journals of both ends.
Main journal outer diameter
Crank pin outer diameter
Metal bearing oil clearance
Thrust clearance
Oil seal damage
Cam Height
Cam shaft
Journal Outer Diameter
Wear, damage and stretch
Standard Value
17.00517.018 mm
0.0200.045 mm
0.0100.020 mm
Functional limit
-
Fuel parts
less than 0.05 mm
0.05 mm
Replace with new crank shaft assy.
39.98640.000 mm
37.98638.000 mm
0.0200.041 mm
0.050.15 mm
IN 20.72520.825mm
EX 20.75520.855mm
Pulley side 41.91541.925mm
Middle and oil pump side 41.94541.955mm

Replace with new parts if part is worn, damage or
stretched out of shape.
Wear and damage on O-rings

Fuel pressure
Wear and damage on seal ring
289299MPa (2946.983048.95/c)
-
Float
Standard plug
DCPR6E
Plug gap
Primary coil resistance
Charge coil resisrtanceBetween Y-Y-Y

Resistance Between Terminals
0.8mm0.9mm
4.5 k0.67520
19.5 k3.920
24.5 k5.1 (with spark plug cap
Approx. 3,000 r/min
Approx. 6,200 r/min
252W
1500r/min 12V - 18A or more
4000r/min 12V - 21A or more
0.3520 20
11.412.66 (25)
Operating condition
Wear and damage on seals and grommets
Operating condition
T.P.S
Clearance between encoder ring and CPS

Pulser coil resistanceBetween L/B-G/R
Resistance between terminals
ISC valve
Engine temp. sensor
0.70.9 mm
18520% 20
5kor less
between S1-S2 30 k3
between S3-S4 30 k3
4.244.86k (46)
1.902.10 k (2426)
When parts are worn or damaged

When oarts show deterioration or contamination by
fuel
When electrodes show excessive wear, carbon
deposit or damage on insulator.
No clicking sound when volts is applied to the
terminal.
No operating noise when volts is applied to the
terminal.
-
T-MAP sensor
Rectifire
Timing belt
Fuel rail
Fuel regulator
Vapor separator
Spark plug
Ingition coil
E.C.U
Magneto (Alternator)
Fuel injector
F.F.P
Electric parts
Crank position sensor
Secondary Coil Resistance

Low speed ESG
High speed ESG
Alternator Output
Generation performance
Action to be taken



Output
Brush length
Commutator undercut
Commutator outer diameter
Rated voltage
Rated timing
Exciting current
Exciting coil resistance
between Vout TEMP. - Vout MAP Open

between Vout TEMP. - Vcc Open
Refer tester check chart
12 V 1.4kW
16 mm
0.50.8 mm
29 mm
12DC
30sec80A
4A
4.420%
12 mm
0.2 mm
28 mm
-

-
Capacity
20A2, 30A1
Blown
between Vout TEMP. - GND 2k10% 25
Starter motor
Starter solenoid
Fuse
75
After repaireng the cause of the burn-out, replace

with a new fuse.
Part Name
Pump assy
Power Trim & Tilt parts
Motor
Trim cylinder
Tilt cylinder
PTT solenoid
Item
Standard Value
Oil pump
Gear pump
Relief valve opening pressure (Tilted UP)
12.315.7MPa
Relief valve opening pressure (Tilted DN)
4.96.9MPa
Spool check valve opening pressure
0.2MPa
Oil capacity
325
Recommended oil type
ATF(DEXRON
Rated voltage
12VDC
Rated timing
60sec
Output
250W
Direction of rotation
Forward/Reverse
Circuit breaker (Type)
Bimetal
ONOFF 40 sec or more 36A30 sec or less25
Brush length
9.75
Commutator (Outer diameter)
22.0
Undercut depth 1.8
Piston diameter
48
Piston rod diameter
41
Stroke
46mm
Piston diameter
32
Piston rod diameter
16
Stroke
101mm
Shock absorber valve opening pressure
19.624.5MPa
Rated voltage
12VDC
Rated timing
60sec
Exciting current
4A or less
Exciting coil resistance
4.16 - 6.24
Wax type with pressure relief valve
Cooling system
Thermostat
Opening and closing of thermostat valve
Valve opening starting temperature 58.5

61.5
Valve full open temperature 75 or more
Lower unit
Pump impeller
Wear and cracks
Pump case liner

Guide plate
Anode
Wear
Wear
Corrosion
Damage to bearing
Wear and damage on lip of oil seal
Backlash
Damage to bearing
Other
Drive shaft
Shaft runout
Propeller
Wear on lip of oil seal

Wear, wraping, cracking, chipping
0.3 mm or less (Using both center holes for

reference)
-
Oil seals
Wear, damage
Propeller shaft
Functional limit
5.00
20.4
1.0mm
When the valve opens even slightly at ambient
temperature.
Action to be taken
-
Check valve opening temperature by immersing

the thermostat in water and gradually increasing
water temperature
Wear, crack or damage on tips and upper and

lower surface lips
When anode shows excessive corrosion
0.4mm
When depth of wear is 0.1mm
When lip area shows deterioration, heat
discoloration, or damage or when reduces
interference to 0.5mm (0.02 in) or less

Replace when wear is excessive.
Replace when wear is excessive.
Adjust or replace
76
77
78
79
80
81

Blade X
Pitch
X
(mm)
Dia.
(mm)
Part No.
Remedy
17
X X
Newly added
16
X X
Newly added
15
X X
14
X X
13
X X
12
X X
11
X X
X X
X X
B1
4 blade
82
83

,

!
, .
84
85

MFS 40 - 50

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1

Gear Reduction Ratio

Unleaded regular gasoline : Pump posted

API standard SH, SJ, SL, 10W-30/40

ml (US qt) 500 (0.53)

Comparison of Weight (kg) by Brands: 4st 40ps Class

: 4.45 (14.6 ft)

: 4.45 (14.6 ft)

: 4.45 (14.6 ft)

: 4.45 (14.6 ft)

Engine Speed (r/min)

Fuel Flow vs. Engine Speed

Engine Speed (r/min)

Fuel Flow (L/h)

Engine Speed (r/min)

Engine speed [r/min]

Engine speed [r/min]

: 4.45 (14.6 ft)

Side rail upper

Side rail lower

Fault log (Yes)

Fuel injector malfunction

Fuel injector malfunction

Fuel injector malfunction

Ignition coil manfunction

Ignition coil manfunction

Ignition coil manfunction

Oil pressure low

Battery voltage low

Lighting means that battery

Lighting means that the battery

Lighting means that the

Lighting means that the

Lighting means that the

Lighting means that the wiring

*1 Only the fault log can be found

*1 Only the fault log can be found

*1 Only the fault log can be found

Oil pressure was once low

*1 Only the fault log can be found

*2 No lighting when the wiring is

Fault log (Yes)

Sensor power valtage high

Lighting means that the

Lighting means that the power

Sensor power voltage low

Lighting means that the

Lighting means that the power

Engine temp. sensor malfunction

Lighting means that the

Lighting means that the

Engine temp. high

Lighting means that the

Lighting means that the cooling

Engine temp. abnormally

Lighting means that the

Lighting means that the cooling

Lighting means that the

Lighting means that the wiring

Fuel feed Pump

Crank Position Sensor (CPS)

MAP (Manifold absolute pressure)

Constant(2) Constant(2) Constant(*2)