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Raider 40 Parts/Assembly Manual

1. Raider 40 Manual 3 3 Intake Manifold Fuel Pump Reed Valve and Stopper Ref No Part No Description Q ty Remarks 915321 3 1 EC STUD 2 4 lt 3 2 5802010 INTAKE MANIFOLD 4 3 3 5 02104 INTAKE MANIFOLD GASKET 1 4 2 3 4 5 02105 INTAKE MANIFOLD GASKET 1 4 384 3 5 5 02100 REED VALVE ASSY 1 921521 _ 3 6 1412 SCREW 8 4 3 7 2702 LOGS PLATE 1 910121 3 8 7620 BOL 1 3 9 VALVE 2 3 9101 4 10 5630 BOLT 5 3 915321 11 0620 onan 2 3 930103 12 0600 4 3 941303 T SE SPRING WASHER 4 m RR THROTTLE CA Ref No 3 921503 m 15 0616 SCREW 1 ama ai BUSHING 6 2 16 5 1 2 6 16 1 5 941403 g 1000 WAVE WASHER 4 10 1 4 u 5 02011 CARBURETOR GASKET 1 3 345 67191 25 PRIME ROD 1 3 345 67192 2 S PRIME ROD 1 37 345 671934 PRIME ROD CONNECTER 1 22 0 3 921503 2 23 0408 SE 3 356 04000 Si 51 FUEL 55 1 3 334 04004 PUMP COVER 1 3 9225 2 p E 26 6528 SCREW 3 PUMP DIAPHRAGM 1 ER ER SE DIAPHRAGM GASKET 1 m DIAPHRAGM GASKET SET 1 Military version 10
2. Raider 40 Manual ds 356 04044 aun S 2d 5 CHECK VALV 3 921722 31 0306 SOREN 3 930222 2 32 0300 3 346 04901 5 GASKET Fuel Pump 3 921503 34 6640 F Connector Fuel 22227 HOSE Filter 98AB 501000 GE Fuel Filter Fuel 36 270 HOSE Pump 98AB 501000 gw Fuel Pump um A 50 HOSE Carburetor 98AB 501000 3 338 02215 S 5 CLIP 10 3 346 02230 2 FUEL FILTER ASSY rm 346 02237 10 0 346 02235 25 3 346 02234 15 FILTER 930103 43 0800 3 940103 29 WASHER 3 348 02231 ds PLATE uH INTAKE PROTECTION COVER a ce INTAKE SILENCER COVER 3 9101 4 48 0616 INTAKE SILENCER PLATE 3 921503 50 5508 poner INTAKE SILENCER LOCK PLATE 3 345 67195 um BUSHING Military version Note Lift height of each reed valve and stopper must be within specification Used reeds must never be turned over and reused Reed could break when returned to service causing serious powerhead damage Number of Valves 40 Strips 4 Valves Strip 3 Valves Strip 0 236 0 244 in Height 6 0 6 2 mm B Gap 0 0079 in Valve End Valve Seat 0 2 mm Valve Raider 40 Manual Military
3. 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 Housing 1 13 3 9301 13 0800 Nut Drive Shaft Housing 1 13 4 9161 13 0885 Bolt 8 13 5 3P0 66233 0 Washer 8 1 16 15 8 13 6 9101 13 5620 Bolt 1 13 7 345561110 0 Extension Housing UL 1 13 8 9101 13 5840 Bolt 6 13 9 345 61012 0 Gasket Drive Shaft Housing 1 13 10 345501301 0 Engine Base 1 13 11 345 01303 0 Gasket Engine Basement 1 13 12 345 01215 0 Oil Seal 17 30 8 1 13 13 345 671 16 0 2 13 14 910203 0640 Bolt Engine Base 2 13 15 941303 0600 Spring Washer 2 13 16 345 01 1 110 Knock 6 12 4 13 17 345 023 14 1 Exhaust Pipe s 1 361 02311 0 Exhaust Pipe amp UL 1 13 18 345 023 13 0 Lock Plate Exhaust Pipe 2 13 19 9101 13 0625 Bolt 4 13 20 910613 0808 Bolt 1 13 21 332 60006 0 Gasket 8 1 15 1 1 40 Raider 40 Manual Military version 3 14 Gear Case Drive Shaft Ratio 13 25 Lubricant Genuine manufacturer gear oil or GL5 SAE 80 90 Capacity Approximately 14 2 U S floz 420 ml Clutch System Dog clutch type Forward Neutral Reverse Raider 40 Military version Ref No Part No Description Q ty Remarks 14 1
4. BUSHING 8 14 4 2 WASHER 8 1 16 1 5 55 YLON NUT 8 1 25 ROD SNAP 3 5 2 ep ROD 5 75L for MF EF TAS ROD JOINTS for MF EF z ROD SNAP 5 2 5 er 5 for z 837195 WASHER 8 5 18 1 6 for MF EF 30 172 SNAP d 8 e1 11 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 It is critical that the dewatering valves are opened after submersion and pull start is firmly and slowly pulled at a minimum of eight times prior to using electric starter Starting engine after submersion without proper dewatering when using Electric start could damage crankshaft Service Information Dimension 1 2 071 0 in 52 6 0 mm 0 002 0 05 Dimension 2 1 591 0 002 in 40 4 0 05 mm 4 Connecting Rod Bearing small end 1 0669 in 17 mm 2 827in 21mm 3 1 03in 27 mm 4 0 079 in 2 mm Connecting Rod Bearing big end 1 0 984 25 mm 2 1 260in 32 mm 3 0 787 in 20 mm 4 0 138 in 3 5 mm Military version Manual Raider 40 3 2 Piston Crankshaft
5. 17 55 348 62143 0 Shaft Tilt Assistant 17 56 348 62107 0 ee U i Transom parts should be checked before missions for damage 54 Raider 40 Manual Military version 3 18 Reverse Lock Transom Bracket Fig 17 2 55 Raider 40 Manual Military version 3 19 Motor Cover 19 4 Spring Washer P N 9413030500M Washer P N 9401030500M Screw P N 9216030516M 9301030500M Nut 1 19 1 Tilt Handle 3455675210 19 6 Rubber Starter ASS Seal P N 3KM675030M Dewatering 7 Instructions 19 8 Rubber Seal P N 3F3675010M Upper Unit Lower Unit 56 Raider 40 Manual Military version Q ty Ref No Part No Description Remarks 192 saseniso Stongen 121825 Lal _ spacer Lal wa Lan el Lal sseniso wanen Lal 96 dl 19 10 345 67142 1 19 11 910103 661 2 19 12 3 0 66308 0 Washer 6 16 1 5 19 13 3 8 67146 0 Washer 14 22 1 19 14 345 671 61 0 Grommet 22 3 2 19 15 353 671 62 0 Grommet Battery Cable 1 19 16 345 83732 0 Grommet Cable 1 19 17 345 67117 0 Grommet 17 2 7 19 18 345 671 83 0 Baffle Air Intake 19 19 9101 140625 Bolt 19 20 9401 13 0600 Washer 19 21 361567500 4 Motor Cover upper 96958 19 21 1 345567521 0 t Tilt Handle 19 21 4 941303 0500 Spring Washer Washer 19 21
6. of Force x 4 4480 N x 0 4536 kgf 0 2248 Ibf 0 1020 kgf 2 2050 Ibf 9 8070 N x x x Units of Temperature F C 1 8 C 32 0 556 F 32 Units of Pressure Psi psi psi bar bar bar 60 F kPa kPa kPa kg cmz kg cmz kg cmz in Hg 60 F in Hg 60 F in Hg 60 F Lem p x 0 0689 bar x 6 8950 kPa x 0 0703 kg cm x 14 5030 psi x 100 0000 kPa x 29 5300 in Hg x 0 1450 psi x 0 0100 bar 0 0102 kg cmz 14 2200 psi x 0 9807 bar x 98 0700 kPa x 0 0333 bar 3 3770 kPa x 0 0344 3 wr r Raider 40 Manual Military version Standard Torque Values M10 204 274 17 22 23 31 2 3 3 1 These torque values apply only when a special torque specification is not listed in the Special Torque Values chart at the beginning of each section 66 Raider 40 Manual Military version 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 Timing Adjustment 2 Multi fuel Throttle Body Atomizer Synchronization WARNING Before beginning procedures disable the ignition system to prevent accidental engine startup NOTE The seam at the mating surfaces of the crankcase halves is the alignment point for ail ignit
7. Remarks Crank shaft assembly is difficult to assemble The component parts should be purchased as an assembly if possible 13 Military version Raider 40 Manual Ref No Part No Description Q ty Remarks 2 1 OIL SEAL 25 55 10 1 2 2 RETAINER 50 60 1 6 1 2 3 CRANKSHAFT SUB ASSY 1 2 4 CRANKSHAFT 1 2 5 CRANKSHAFT 1 2 6 Sc CRANKSHAFT 1 2 7 CRANKSHAFT D 1 2 8 PIN 2 2 9 CONNECTING ROD 2 2 10 ROLLER BEARING 25 32 20 2 2 11 aoe BIG END BEARING WASHER 4 2 12 oo 1451 MAIN BEARING 355520 1 Center 2 13 LABYRINTH PACKING 1 2 14 O RING 2 49 5 1 951407 2 15 SPRING PIN 3 6 1 2 16 MAIN BEARING 5206 1 Upper 11 2 17 00115 RETAINER 56 66 1 6 1 945107 _ 2 18 S000 C RING d 30 1 2 19 DIM 167 SPACER 30 2 40 2 3 1 1 1 2 20 00141 1 SHIM 31 42 A 2 21 MAIN BEARING 355520 1 Lower 2 22 ROLLER BEARING 17 21 27 2 2 23 PISTON REPAIR KIT 2 STD 87130 0 2 24 PISTON 1 STD 2 25 ern PISTON PIN 1 2 26 EE PISTON PIN CLIP 2 2 27 PISTON RING SET 2 STD 87123 0 2 28 via 1 a PISTON RING 1 STD 1st Raider 40 Manual Military version 345 00011 PISTON RING 1 STD 2 15
8. 33 to the specified toque Raider 40 Manual Military version 3 12 Starter Lock Pull Starter Fig 16 1 34 Raider 40 Ref No 35 12 1 12 2 12 3 124 12 7 12 8 12 9 12 10 12 11 12 12 12 13 12 14 12 15 12 16 12 17 12 18 12 19 12 20 12 21 12 22 12 23 12 24 12 25 12 26 12 27 12 28 12 29 12 30 Manual Military version Part No Description F Remarks 361 05211 0 Lock Arm Starter Em 915314 0825 Stud Bolt xo waster d 345 63713 0 Bushing 8 144 930406 0800 Nylon Nut 8P 1 25 FB 345 05213 0 Stop Arm Throttle 346 63721 0 Bushing 6 2 16 5 910114 0620 Bolt 941403 1000 345 05217 1 Wave Washer Rod Starter Lock 940103 0400 Washer 345 05216 0 Spring Starter Lock mM 346 05209 0 Cap Starter Lock Lever FA 945303 0600 E Ring D 6 345 05221 1 Rod Throttle Stop Arm 1 353 83728 0 Pin Joint 1 941303 0600 Spring Wash er Fil 345 05224 0 Rod Snap 5 2 5 345052221 ting sunertock am al ww y d Lal FM 353 83719 0 Washer 8 5 18 1 6 930106 0600 Nut 345 05223 1 Rod Snap 3 5 2 951603 0800 R Pin d 8 921521 6510 Screw 1 1 EN ER H 345 01015 0 Washer 8 5 19 5 32 1 xo wa fa 345 05226 0 Lever Starter Lock 348 05233 0 Plate Throttle Adjust Raider 40 Manual Military version Fig
9. Part No Description Q ty Remarks 5 1 356 04000 1 Fuel Pump 1 5 1 1 334 04004 0 7 Pump Cover 1 5 1 2 922512 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 Set 1 5 1 6 356 04044 0 Check Valve 2 5 1 7 921722 0306 Screw 2 5 1 8 930222 0300 Nut 2 5 2 346 04901 0 Gasket Fuel Pump 1 5 3 921503 6640 Screw 5 4 346 02230 0 Fuel Filter 5 4 1 346 02234 0 Filter 542 34602235 0 Gasket 5 4 3 346 02237 0 Cup 5 5 9301 13 0800 Nut 5 6 9401 13 0800 Washer 5 7 348 02231 0 Plate Fuel Filter 5 8 98AB 5 0160 Fuel Pipe 5 9 98AB 5 0270 Fuel Pipe 5 10 98A B 5 0210 Fuel Pipe 5 11 338 0221 5 0 Clip 10 5 12 336 06973 0 Clamp 6 95L 5 13 910113 5612 Bolt 5 14 382 70260 1 Fuel Connector Engine Male 5 15 332 70261 0 Nut 10 25 5 16 336 70112 0 Gasket 10 2 16 0 5 16 Raider 40 Manual Military version 3 6 Throttle Mechanism Fia 7 16 317 2 Raider 40 Manual Military version Ref No Part No Description Q ty Remarks 6 1 348 63711 1 Advancer Arm 1 6 2 910121 0840 Bolt 1 6 3 345 63713 0 Bushing 8 14 4 2 6 4 930406 0800 Nylon Nut 8 1 25 1 334 66233 0 6 5 3 0 66233 0 Washer 8 1 16 1 5 1 6 6 921506 0520 Screw 1 Nut 6 7 930106 0500 1 6 8 361 83728 0 Cable Pin 1 Nut 6 9 9301
10. 9101 13 5618 Bolt 1 15 27 353 64036 0 Shim 36 44 03 353 64037 0 Shim 36 44 0 15 353 64038 0 Shim 36 44 01 Raider Outboards are equipped with seal sacrificial anodes to help protect metal parts from the effects of galvanic corrosion electrolysis Disintegration of the anodes indicates they are performing their function Anodes must be replaced when reduced to 2 3 its original size Engine corrosion will increase if eroded anodes are not replaced The powerhead anode provides protection to the powerhead It is located in the cylinder head The anode should be replaced whenever work requires removal of the cylinder head or when a complete overhaul of the engine is performed The following procedure is used to test for proper installation of the anode Make sure the surface of the anode is clean prior to testing 1 Calibrate an ohmmeter on the high ohms scale onnect one meter lead to a ground on the powerhead and the other lead to the anode The ohmmeter should show a low reading If not remove the anode clean the surface where it was mounted Install anode and retest Raider 40 Manual Military version Maintenance Procedure 1 Drain gear oil completely 2 Injectoil 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 the Rubber Inflatable boat
11. Replacement NOTE fuel filters cannot be serviced Replace in line fuel filters once a year or with each tune up When replacing an in line fuel filter note direction of fuel flow as indicated by the arrow on the filter housing for proper installation 1 Loosen clips 1 on each side of the filter 2 and slide down the hose 2 Separate the fuel filter from the hoses and discard 3 Replace with new fuel filter 4 Attach hoses and secure clips Fuel Gasoline Avgas JP 5 JP 8 Diesel 2 Note To comply with local EPA requirements when JP 5 or JP 8 fuels are used Raider Additive Must be added to reduce smoke and emissions 58 Raider 40 Manual Military version 3 21 Two Motor Configuration Dual Motor Control and Throttle DMCT 18 to 26 inches ke Raider can used in a two engine configuration power the conventional 15 passenger Rubber Inflatable Boat The motors are placed on the transom where the DMCT connecting rod can be screwed into the bolt located on each side of the Raider Simply place one on the first engine and move the second engine into position to accept the second screw After installation of the DMCT both engines can be controlled via a single tiller Then place the DMCT cable on both engines to provide throttle control of both engines by the throttle on the tiller arm Raider 40 Manual 3 22 Tool Kit Tools Tool bag Pliers 10 x 13 mm socket wrench 21 mm socket wrench Socket
12. Wear limits out Of specification Defective ignition Components Carbon Accumulation in 68 Raider 40 Manual Military version Engine revolu Over Engine Poor I Poor henting Possible cause idling sation abnor of start engine WS fuel 774 Clogged fuel iter fuel pump or carburator fe improper OO _____ Excessive oil in mixture supply gt _ Foor carburetor geet Recirculation pine broken __ Faulty thermostat 1 BCEE Damaged and bent propeller o Improper thrust rod position Unbalanced load position Transom too high or low Incorract adjustment of throttle link mechanism Incorrect adjustment of ignition timing Loose battery terminal Onnection corrosion Raider 40 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 used dictates more of some parts than others like propellers This list will be updated as required Engine Spark Plugs Thermostat Thermostat g
13. d 10 1 6 19 921503 0616 Screw 1 6 20 3R0 66308 0 Washer 6 16 1 5 1 6 21 353 83719 0 Washer 8 5 18 1 6 1 R Pin d 8 6 22 951603 0800 1 6 23 3B7 05243 0 Cap C Ball Joint 1 ES 6 24 346 05228 0 Ball Joint 1 20 Raider 40 Manual Military version 3 8 Magneto Raider 40 Manual Military version Ref No Part No Description Q ty Remarks FP5506 8 1 361 06091 0 Flywheel Cup 1 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 8 2 3 921521 6528 Screw 2 8 2 4 3G2 06021 0 Exciter Coil 1 8 2 5 921521 6522 Screw 2 8 2 6 350 06025 0 P Holder Magneto Cord 1 8 2 7 921521 6406 Screw 3 8 2 8 11 921521 6408 Screw 2 4 8 3 9215216510 Screw CU2503 8 4 361 06060 1 G D Unit l 8 5 910103 6625 Bolt 5 8 6 3R0 66308 0 Washer 6 16 1 5 4 8 7 930113 0600 Nut 4 8 8 3A0 06322 1 Plate Flectric 1 Rubber Mount 9 1643 8 9 3B7 06305 0 3 8 10 3F3 06920 0 Rubber Mount 9 12 2 3 8 11 3A0 76079 0 Collar 6 2 9 7 4 3 8 12 361 06040 1 Ignition Coil with Resistance 1 8 12 1 3C7 06921 0 4 Plug Cap with Resistance 2 8 13 910113 5620 Bolt 2 8 14 941 303 0600 Spring Washer 2 1 120 8 15 3 7 76142 0 Ground Cable 1 8 16 398 06830 0 Lanyard Stop Switch 1 8 16 1 353 06821 0 Lock Stop Switch 1 8 17 345 06
14. e Compression variation among cylinders should not exceed 15 psi 103 kPa 1 05 kg cm2 e Length 38 18 inches 919 mm e Width 13 inches 330 mm e Height 49 inches 1245 mm e Weight 147 Ibs 63 5 kg e Maximum RPM range 5200 5800 e Piston Displacement 493 cc e Cooling system Water cooling Rotary rubber impeller e Tilt stage 6 e Gear Reduction ratio 13 25 e Battery 265 Cranking Amps sealed Lithium Iron Raider 40 Manual Military version 3 1 CYLINDERICRANKCASE Military version Raider 40 Manual Ref No Part No Description Q ty Remarks M40C 1 2522 CYL BLOCK CRANKCASE ASSY 1 F TERA 1 1 3 NIPPLE 5 5 5 1 e DOWEL PIN 2 Bearing 5 ap MEE CHECK VALVE ASSY 1 oes p es ABEE 1 9 2 WASHER 10 Sch DOWEL PIN 6 12 2 e CYLINDER HEAD 1 15 R50 01093 CYLINDER HEAD PLATE 1 15 CYLINDER HEAD 1 ia o Pour di WASHER 8 5 19 5 3 2 10 Ce 127 SPARK PLUG 8878510 2 Nek THERMOSTAT 1 Mark 52A PRV n DEWATERING VALVES 2 1 DEWATERING FLANGE 1 27 DEWATERING ROD 1 F SE ANODE g 5 xh EXHAUST CO
15. fuel valve Pull slowly 8 times on rope Even strokes Tilt engine back to standard position Pump primer two times Pump primer bulb until tight 0 Slide dewatering valve to front of engine close 10 1 1 Pull rope until engine starts Dewater and Start Procedure Electric Start Perform 1 thru 10 Press start button Caution Do not hit start button until water is cleared between pistons and head If this is done internal damage to the engine can occur 2992 Raider 40 Manual Military version Ref No Part No Description Q ty Remarks Da 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 DW50546 Carburetor dewater valve 1 10 8 DW50547 Dewatering valves 2 3 10 1 Dewatering System operation The dewatering system is utilized after total motor submersion After the Raider is installed on the transom and secured the dewatering lever located on the left side of the motor is pushed toward the back of the outboard motor The operator must depress the lever to full back position then press fuel bulb for four presses This evacuates all potential water that would be in the carburetor This action also opens up two dewatering valve located in the head of each cylinder The operator will slowly p
16. 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 as both flat and round surfaces with serrations in two directions As the fuel reaches the slide with harmonic frequency the fuel flows to the top of the slide and gets broken down into very small droplets that burn more effectively than carburetors 11 Raider 40 Manual Military version Ref No Part No Description Quantity Remarks 4 1 27 MULTI FUEL ATOMIZER 1 A 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 RL4 0326 CABLE CHOKE ASSY 2719 T 4 8 RL4 0327 MFA BODY 1 4 9 RL4 0328 IDLE KIT COMPONENT 1 4 10 RL4 0329 VENT LINE 2430 1 4 11 RL4 0330 IDLE KIT 2759 1 4 12 RL4 0331 VENT CLIP 1 4 13 RL4 0332 FLOAT DUIDE PIN 2280 1 4 14 RL4 0333 INDEPENDENT FLOAT LEFT 2202 1 1 4 15 RL4 0334 INDEPENDENT FLOAT RIGHT 2202 R 1 4 16 RL4 0335 FLOAT LEVER 2200 1 1 4 17 RL4 0336 F
17. 0 2 Swivel Bracket m 95605 17 16 348562010 0 Steering Shaft 17 17 345 62417 0 Bushing 26 32 Friction piate ______ 17 19 346 62421 1 Spring Friction Plate 17 20 910103 0830 Cae cd or 910113 0830 021 Thrust Piate 27 501 LJ 123 Jil 2 df 17 25 945103 2500 C Ring 4 25 17 26 344 671 77 0 Grease Nipple 17 27 345 61301 0 Rubber Mount Upper 2 52 Raider 40 Ref No Part No Manual Military version Description Remarks 17 28 345 61313 0 Stud Bolt Rubber Mount Upper Fm Retainer Rubber Mount F 17 29 345 61312 0 17 30 9101 13 5820 Bolt 17 31 345 61331 0 Damper Clamp 2 17 33 Po s 17 34 1 7 35 17 37 348 61309 0 Shim 33 40 7 0 5 17 38 945003 4000 17 39 940113 1000 Washer 21 17 40 Nylon Nut 1 5 EB 17 41 040 Lamm 1743 6613230 Lock Rubber owt Lal 17 44 EES uas ooo ts 17 46 REG ES 17 47 Ground Cable mE L 130 17 48 Bolt ny 17 49 Ground Cable 2 L 110 us Usi Lama 17 52 mE 17 53 L Tilt Assistant Transom UL 17 54 348 62142 0 Spring R Tilt Assistant mE for Transom UL 53 Raider 40 Manual Military version
18. 06 0600 1 6 10 348 63715 0 Link Rod 5 75L 2 6 11 3B7 63733 0 Rod Snap 5 3 2 6 12 346 05234 0 5 Rod Joint 1 Nut 6 13 930106 0500 2 6 14 348 63716 0 Throttle Link Rod 1 6 15 345 05223 1 Snap 3 5 2 2 6 16 348 63718 0 Throttle Cam 1 6 17 346 63721 0 Bushing 6 2 16 5 1 6 18 941403 1000 Wave Washer d 10 1 6 19 921503 0616 Screw 1 6 20 3R0 66308 0 Washer 6 16 1 5 1 6 21 353 83719 0 Washer 8 5 18 1 6 1 R Pin d 8 6 22 951603 0800 1 6 23 3B7 05243 0 Cap Ball Joint 1 ES 6 24 346 05228 0 Ball Joint 1 SES Raider 40 Manual Military version 3 7 Tiller Handle AU QA ig 19 Fig 17 16 l EAS HI AM q Y Raider 40 Manual Military version Ref No Part No Description Q ty Remarks 6 348 63711 1 Advancer Arm 1 6 2 910121 0840 Bolt 1 6 3 345 63713 0 Bushing 8 14 4 2 6 4 930406 0800 Nylon Nut 8P 1 25 1 or 334 66233 0 6 5 3 0 66233 0 Washer 8 1 16 1 5 1 6 6 921 506 0520 Screw 1 Nut 6 7 930106 0500 1 6 8 361 83728 0 Cable Pin 1 Nut 6 9 930106 0600 1 6 10 348 63715 0 Link 5 75L 2 6 11 3B7 63733 0 Rod Snap 5 3 2 6 12 346 05234 0 5 Joint 1 Nut 6 13 930106 0500 2 6 14 348 63716 0 Throttle Link 1 6 15 345 05223 1 Rod Snap 3 5 2 2 6 16 348 63718 0 Throttle Cam 1 6 17 346 63721 0 Bushing 6 2 16 5 1 6 18 941403 1000 Wave Washer
19. 1 11 1 14 940121 0800 Washer 2 3 910113 0800 11 1 15 930103 0800 Nut 1 11 1 16 941322 0800 T Spring Washer 1 11 1 17 336 050 140 Guide Starter Rope 1 1 1 1 18 9101 14 0625 Bolt 2 1 1 1 19 941303 0600 n Spring Washer 2 1 1 1 20 338 05019 0 Starter Handle 1 5 2000 11 1 21 345 05013 1 Starter Rope l 11 1 22 338 05131 0 Rope Anchor 1 11 1 23 350 05136 0 0 Ring 2 54 5 11 1 24 345 05134 0 Plate Rope Anchor 1 11 1 25 344 051 16 0 Seal Plate Starter I 11 1 26 345 05225 0 Shaft Starter Lock Lever 1 11 2 345 05901 1 Starter Pulley l 30 Raider 40 Manual Military version Ref No Part No Description Q ty Remarks 11 5 915314 0825 Stud Bolt 2 11 6 9301 21 0800 Nut 2 11 7 9401 21 0800 Washer 2 11 8 910114 0830 Bolt 1 11 9 941 303 0800 Spring Washer 1 11 10 910114 0625 Bolt 2 11 11 941 303 0600 Spring Washer 2 Recoil Starter Removal 1 Remove the neutral start mechanism components and remove the recoil starter from the engine 2 Rewind the reel and loosen the recoil starter spring Note use a screw driver to put the starter rope in the reel notch With the rope hooked in the notch rotate the reel slowly to loosen the rope Repeat this process until the starter spring does not pull the reel 3 Remove the handle 7 from the starter rope 8 WARNING The Raider 40 has a neutral start mechanism start in gear protection attached to the r
20. 12 STARTER LOCK 21 M 2 22 4 Fig 16 uae 20 26 2728 25 23 A 1 24 Fig 16 1 36 Raider 40 Manual Military version Ref No Part No Description Remarks 12 1 361 05211 0 Lock Arm Starter 12 2 915314 0825 Stud Bolt 12 3 345 01015 0 Washer 8 5 19 5 32 124 345 63713 0 Bushing 8 144 12 5 9401 13 0800 Washer 12 6 930406 0800 Nylon Nut 8P 1 25 12 7 345 05213 0 Stop Arm Throttle 12 8 346 63721 0 Bushing 6 2 16 5 12 9 910114 0620 Washer 12 10 940113 0600 12 11 941403 1000 Wave Washer 12 12 345 0521 7 1 Rod Starter Lock 12 13 345 05226 0 Lever Starter Lock 12 14 940103 0400 Washer 12 15 345 05216 0 Spring Starter Lock 12 16 346 05209 0 Cap Starter Lock Lever 12 17 945303 0600 E Ring D 6 12 18 345 05223 1 Rod Snap 3 5 2 12 19 345 05221 1 Rod Throttle Stop Arm 12 20 353 83728 0 Pin Rod Joint Nut 12 21 930106 0600 12 22 941303 0600 Spring Wash er 12 23 345 05224 0 Rod Snap 5 2 5 12 24 345 05222 1 Link Starter Lock Arm 12 25 930106 0500 Nut 12 26 346 05234 0 5 Rod Joint 12 27 353 83719 0 Washer 8 5 18 1 6 12 28 951603 0800 348 05233 0 37 Raider 40 Manual Military version 12 30 921521 6510 Screw 12 31 921 503 05 30 Screw 12 32 930106 0500 Nut 38 Raider 40 Manual Military version 3 13 Drive Shaft Housing 30
21. 3 345 66031 1 Bushing Cam Rod i 14 35 332 66032 0 0 Ring 2 4 1 5 4 14 36 301 66024 1 Stopper Cam Rod Bushing 14 37 301 66025 0 Gasket 6 2 11 1 14 38 345 66241 0 Joint Shift Rod 14 39 951403 0312 Spring Pin 3 12 Raider 40 Manual Military version Section 15 GEAR CASE PROPELLER SHAFT 44 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 7 345 64221 0 Spring Clutch 1 15 8 345 64222 0 Spring Holder Clutch 1 15 9 345 64223 0 Push rod Clutch 1 15 10 345560101 1 Housing Propeller Shaft 1 15 11 345 60211 0 Needle Bearing 22 30 30 1 15 12 334 60223 0 Oil Seal 22 36 10 1 15 13 9601 0 6007 Ball Bearing 6007 1 15 14 345 60103 0 ring 353 69 44 1 15 15 348 64030 0 Bevel Gear 1 15 16 345 64032 0 Washer 22 1 28 3 1 15 17 9101 13 5830 Bolt 2 15 18 3C8 64231 0 Thrust Holder Propeller 1 15 19 348W64108 0 Propeller 1 Raider Standard 15 20 348 64232 0 Stopper Propeller 1 15 21 345 64124 0 Washer 17 32 3 1 15 22 345 64121 0 Nut Propeller 1 15 23 951503 0325 SplitPin 3 25 1 15 24 348 60217 0 Trim Tab 1 15 25 353 60219 0 Gasket Trim Tab 1 15 26
22. 361 560000 0 1 345 602 11 0 Needle Bearing 22 30 30 1 14 2 910113 5840 6 14 3 332 60005 2 Oil Plug 2 144 332 60006 0 Gasket 8 1 15 1 2 145 345 60206 0 Water Strainer 2 14 6 921503 0440 Screw 1 14 7 930406 0400 Nylon Nut 4 0 7 1 14 8 345 64302 0 Drive Shaft 1 14 9 345 602 13 0 Bearing 32304 1 14 10 345 64020 1 1 14 11 345 64025 0 Bolt Bevel Gear 1 14 12 345 64081 0 Shim 41 51 5 0 1 345 64082 0 Shim 41 51 5 0 15 AR 345 64083 0 Shim 41 51 5 0 3 AR 345 64084 0 Shim 41 51 5 0 5 AR 14 13 332 65022 0 Key Pump Impeller 1 14 14 345 65021 0 Impeller Water Pump 1 14 15 348 6501 6 1 Pump Case Upper 1 14 16 348 65011 0 Liner Pump Case 1 14 17 348 65017 1 Pump Case Lower 1 14 18 332 601 11 0 Seal 17 33 9 5 1 14 19 345 65015 0 0 Ring 3 2 47 1 14 20 348 65025 0 Guide Plate Water Pump 1 14 21 348 65029 1 Gasket Pump Guide Plate 1 14 22 348 65018 0 Gasket Pump Case Upper 1 14 23 334 6501 2 0 Knock 4 10 2 14 24 91011 3 5652 Bolt 4 1 42 Raider 40 Manual Military version Ref No Part No Description Q ty Remarks 14 26 345 65206 0 Seal Rubber Upper Water Pipe 14 27 345 65205 0 Set Ring Seal Rubber 14 28 345 65204 0 Lock Rubber Water 14 29 345 65110 1 Water Pipe 14 30 348 66011 0 Clutch Cam i 14 31 348 66013 0 Cam Rod L i 14 32 951403 031 6 Spring Pin 3 16 14 3
23. 6 344 67503 0 Seal Rubber Starter 19 21 7 361587801 1 Decal Set 19 21 8 3F3 67501 0 Seal Rubber Motor Cover Upper 19 21 5 940103 0500 19 22 369 61016 0 Grommet 29 3 56 4 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 primer bulb maintain fuel flow in one direction only from the tank to the engine Disassembly 1 Remove and discard hose clamps 1 and primer bulb clamps 2 as required 2 Remove tank connector 3 and hose 4 3 Remove engine connector 5 and hose 6 4 Remove primer bulb assembly 7 Remove check valves 8 and 9 from primer bulb 10 NOTE Note direction of fuel flow as indicated by the arrow on the primer bulb 1 Clamp P N 2 Clamps P N 3 Fuel Connector Bladder P N 9999800MA2 4 5 Fuel Connector Engine P N 3B2702501M 6 7 8 9 e 5 Hose P N Primer Bulb P N Connector Connector EL 10 Primer Bulb Cleaning and Inspection 11 System P N 3 070 2001 1 Clean components using soap and water 2 Dry all components with low pressure compressed air Make sure all parts and passages are completely dry in Line Fuel Filter
24. 917 1 Clamp 9 20U 1 8 18 9101 140820 Bolt 1 8 19 9301 13 0800 Nut l SO Raider 40 Military version Clamp 6 5 47 5P 8 20 309 06972 0 4 8 21 922503 6510 Screw 1 8 22 9101 13 0612 1 8 23 353 76037 0 Plug Cable Terminal 1 8 24 336 76091 0 Band Lead Wire l 032986 0 8 25 931121 1600 Nut Magneto 16P 1 5 1 Clockwise 028121 0 334 00132 0 Nut Magneto 16P 15L 1 Counterclockwise 8 26 345 00133 0 Washer 16 28 3 2 1 1170 for 8 27 3 7 76142 0 Ground Cable l Type Bolt 2 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 Raider battery should be removed when not used To maintain use it must be charged every six months Prior to mission check to insure the battery voltage is not lower than 12 8 V This battery is completely sealed and requires no topping of any fluid Never attempt to open the battery Short cranking of the Raider 40 is recommended DO NOT attempt to continuously crank the battery more than 5 times Battery Installation requires removing cowling place battery on platform in engine front The battery has a hole underneath that will match the extended pin Place in positio
25. LOAT BOWL SCREW 2320 1 4 18 RL4 0337 FLOAT BOWL POWER JET 2300 PJ 1 4 19 RL4 0338 DUAL FLOAT ASSY 2200 D 1 4 20 RL4 0339 FLOAT BOWL GASKET 1 4 21 RL4 0340 NEEDLE amp SEAT GRAVITY 2500 030 1 4 22 RL4 0341 NEEDLE amp SEAT GASKET 2501 1 4 23 RL4 0342 TOP COVER GASKET 2010 G 1 4 24 RL4 0343 TOP COVER 1 B 4 25 RLS 0344 EES SCREWS 9PKG 3 1 4 26 RLS 0345 BRASS CABLE ADJUSTORS 1 4 27 RL4 0346 CABLE WEATHER SEAL 2150 1 4 28 RL4 0347 POWER JET NOZZLE LONG 2810 L 1 4 29 RL4 0348 POWER JET 2800 1 4 30 RL4 0349 PJ CAP SCREW amp GASKET 2709 1 431 RL4 0350 METERING ROD 2600 1 4 32 RL4 0351 SLIDE SPRING 2022 T 4 33 RLS 0352 FUEL SCREEN 1 4 34 RL4 0353 FUEL SCREEN ENCAPSULATOR 2335 1 Raider 40 Manual Military version 3 5 Fuel 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 covers 3 for cracks and surface deformation 4 inspect guide plate 4 and spring 5 if equipped for deformation and tension 5 Inspect gasket between crankcase and fuel pump for dryness crankcase mounted pumps Disassembly NOTE Match mark parts before disassembly and reference the illustrations in the Inspection procedure to ensure proper orientation of internal components 1 Expand
26. RTV Silicone Gasket Super Bond Adhesive Permatexe Super Glue Gel Cleaning Pads Scotch Britee Abrasive Pads Low Temperature Lithium Grease Genuine Grease or Equivalent Friction Surface Marine Grease Power Trim Tilt Fluid Nissekie power torque fluid or GM approved automatic transmission fluid Isopropyl Alcohol Cleaning Solvent Gasket Remover Gear Lubricant Genuine gear oil or grade GL5 SAE 80 90 Engine Lubricant Genuine engine oil or NMMA certified TC W3 oil Automotive Crankcase flashpoint above 300 F 150 C Battery Spray Protector Permatexe Battery Protector amp Sealer Electrical Shrink Tubing various diameters 4 2 3 Operational Information Power Raider 40 HP 29 4 kW Throttle Setting Full Throttle RPM Range Raider 40 5200 5800 Full Open Match Mark 25 deg Full Closed in gear ATDC 4 deg Target RPM 850 for full closed Fuel Consumption at Full Throttle 3 49 g hr Test Propeller 348 64111 0 In Idle RPM GEAR NEUTRAL Raider 40 850 1000 56 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 advancer arm touches the full open stopper bolt when throttle is fully opened 4 Turn the throttle grip toward SLOW side 5 Ad
27. Raider 40 Parts Assembly Manual Part No RPAM 40ES 001 Launched RAIDER C 130 Submarine ry Raider Part No RAOES 001 Raider R40ES 001 15 2 Supplement to Raider Service Manual No R40 ES 001 15 3 January 2015 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 Raider 40 Raider Outboard makes no warranty express or implied regarding the use of this data Raider Inc assumes no responsibility for errors or omissions nor assumes any liability for damages resulting from the use of the information contained herein In some cases part design may have changed since this manual was published or may not apply to your particular engine serial number or a service parts bulletin may have been issued containing important information pertaining to this model and or a particular part Some parts may be serial number and or model number specific You are strongly advised to contact Raider for all up to date information 321 403 3585 This Raider 40 manual has all parts and assembly data contained herein It has been presented to help the user identify parts identify part numbers how that part has been assembled and tools required to repair the part or secure a new part if required Th
28. Recoil starter a Check wear or damage on starter rope b Check state of ratchet gear 5 Clutch propeller a Check wear or damage on propeller b Check condition of split pin 6 Other check points a Condition of trim tab anode b Corrosion or damage Raider 40 Manual Military version 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 engine life new engines used engines with new powerhead used engines with newly rebuilt powerhead and engines coming out of storage must be run for a period of 10 hours in accordance with the break in procedure First 10 Minutes Operate the engine at minimum idle speed Verify a steady stream of water from the cooling water check port and idle port on the engine indicating the water pump is functioning properly Next 50 Minutes 0 16 to 1 Hour DO NOT operate the engine above 1 2 throttle DO NOT maintain a constant throttle setting Vary engine speed from 1 4 to 1 2 throttle every 15 minutes NOTE For boats which come onto plane easily use full throttle to quickly accelerate onto plane then immediately reduce throttle to 1 2 and maintain this speed Next Hour 1 to 2 Hours Use full throttle to quickly accelerate boat onto plane then immediately reduce throttle to 3 4 and
29. VER OUTER 1 E EXHAUST COVER 1 z ar Ce a HOSE 98AL 401000 x ee 1 ME CLIPo8 1 u 1 Es SE CLAMP 6 9 51 1 n mmo es 345B05101 BRACKET 1 Military version Raider 40 32 0 55 oss 518 2 WASHER ss oso Ia se 0520 ____ SCREW 57 NT s CLAMP 6 5 47 5P RUE ENGINE BASEMENT GASKET 40 ONU STARTER LOCK ARM 1 THROTTLE LIMITER ARM ROD SNAP 3 5 2 i 345 05221 ZHROTTLE LIMITER ROD T 345 05222 STARTER LOCK ROD is osop In 5 S a ROD JOINT 5 1 353 63728 pry 48 SNAP PIN det WASHER 8 5 18 1 6 F 2 SPRING WASHER s oco In 52 oss 57 E HA WASHER WASHER 8 5 19 5 3 2 r E d BUSHING 8 14 4 22 NYLON NUT 8 1 25 57 oo Lei 4 22 WASHER 22 WAVE WASHER 4 10 346 63721 FISHING 6 2 16 5 RR ROD SNAP 5 2 5 348 63715 5 757 25005 BALL JOINT 7 THROTTLE ROD ROD SNAP 3 5 2 nm Raider 40 Manual Military version 2 Bt eee ROD SNAP 5 2 5 2 ADVANCER ARM
30. and move clips 1 on fuel hose s 2 2 Disconnect fuel hoses from fuel pump 3 Loosen pump mounting screws 3 and remove fuel pump 4 and gasket from crankcase 4 Remove fuel pump cover screws 5 and cover 6 Gently separate the pump components Raider 40 Manual Military version Ld 24 9920 3 19 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 guide plate and spring 4 Remove and discard all serviceable gaskets and diaphragms 5 Remove ail check valves 11 from pump body a Cleaning 1 Clean ail pump components with kerosene 2 If necessary clean pump mounting surface on Multi fuel Throttle Body Atomizer with isopropyl alcohol 3 Dry all components with low pressure compressed air Assembly 1 Install all check valves in pump body 2 Fully assemble fuel pump Ail serviceable gaskets and diaphragms must be replaced 3 install fuel pump Use Loctite 242 on mounting screw threads 4 Connect fuel hoses to fuel pump 14 Raider 40 Manual Military version COR hr Fig 1 1 en UT dx 27 LM Fig 37 Sech S 3 e Se Raider 40 Manual Military version Ref No
31. asket Fuel Pump Electric Starter Push button starter switch Kill switch assembly Fuel Induction Unit Rebuild Kits FIU Throttle Cables Recoil manual pull Starter Water pump impellers Props Batteries Sealed Maintainers for batteries 2 Primer Cable Rubber Impellers Emergency tool kit Spark Plugs 2 Pliers Screwdriver Plug Socket Pull Starter socket Pull Rope Spare emergency stop Cotter Key Emergency Kit plastic bag L Socket tool JA 8 Additive Oil Additive Q E WUN E Ground delivered Ground delivered 7 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 Street Titusville FL 32796 321 403 3585 Other Manuals Available Owner User Manual R40 ES 001 15 1 Service Manual R40 ES 001 15 3 Raider 40
32. e Raider is a military only engine and will not be sold to commercial market It is submersible and runs multiple fuels An additive must be placed into JP 5 JP 8 to be in compliance with EPA This manual Parts Assembly Manual 40 ES 001 15 2 provides detailed drawings and part numbers for the Raider outboard motor This is a supplement to the Service Manual No R40ES 001 15 3 that describes in detail how to remove repair and the Raider 40 For background purpose s the Raider 40 comes from a family of motors that have an extensive history of reliability and performance and are identical in parts except for the branding and pricing These motors are Mercury Nissan and Tohatsu Supporting Raider with common parts available at local dealers supports a low life cycle cost for the Government with worldwide support The Mercury Nissan and Tohatsu outboards are Commercial Off The Shelf COTS engines with a long history of performance and reliability Raider takes the basic COTS and modifies the outboards specifically for the military We have eliminated as many electrical components as possible and use only the highest reliable mechanical parts Key components of the Raider features a fuel induction system FIS which allows burning of multiple fuels To go from gasoline to heavy fuels three knobs are turned on the FIS unit Second key component is the dewatering system New heads were developed with special valves that allows water to be quick
33. e 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 system by removing all spark plug leads to prevent accidental starting of engine 3 Fuel leakage can contribute to a fire or explosion After service work is complete and engine is fully assembled always run the engine momentarily to pressurize the fuel system Then check for leaks 4 Never attempt to run the engine with any fuel system component removed or disconnected 5 Check fuel hoses and other nonmetallic components for indications of damage or deterioration Always replace components with authorized factory replacement parts suitable for fuel systems 6 Clean up fuel spills immediately and store rags in approved containers Keep drained fuel in approved containers for proper disposal 7 When using compressed air to clean or dry parts make sure the air supply is regulated not to exceed 25 psi 172 kPa 1 76 kg cm 1 1 Checklist prior to Mission 1 Fuel Oil System 50 1 Mix in bladder a Fuels must be premixed b Insure additive is placed in bladder if JP 5 or JP 8 is used EPA 2 Electrical System a Clean spark plugs replace if necessary check gap b Check condition of battery Check stop switch operation 3 Control wires and linkage a Dewatering linkage works smoothly b Check state of linkages c Check choke control 4
34. ecoil starter This feature disables the engine from starting while in gear forward reverse If the electric start is used it will not start the engine unless it is in neutral Cleaning and Inspection All worn damaged or missing parts must be replaced 1 Clean metal parts with solvent and dry with low pressure compressed air Clean plastic parts with dry cloth 2 Inspect following components as follows Starter rewind spring for cracked or broken end loops Ratchet and reel stopper springs for deformation or poor tension Sliding plates stopper components and busing for cracks or signs of wear Reel assembly for wear Starter housing for sharp or rough edges which could fray starter rope Starter rope for frays and rope handle for damage Assembly For assembling use the procedure reverse to the disassembly following notes When setting the starter spring 2 on the starter spring case 1 direct the outer edge hook of the coil spring to the right and set it in the notch of the starter spring case outer circumference When winding the starter spring 2 rotate the reel 3 to the direction of turn left turn at pulling out the rope Then set the spring so that the reel rotates 1 4 of a turn to one and 1 4 of a turn when rope is fully pulled out Apply anti freeze grease to both ends of the starter spring 2 and sliding area between the starter shaft bolt 14 and friction plate Tighten the starter shaft
35. 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 Lanyard P N 361 06305 1 Emergency Kit Stop P N 361 06305 2 WARNING Do not attempt to repair worn or faulty stop switch and lanyard Replace only with genuine parts Do not substitute Inspection 1 Inspect lanyard 1 for cuts or fraying lock clip 2 for cracks 2 Inspect stop switch assembly 3 For signs of wear and make sure the switch has adequate spring tension to hold the lanyard lock clip in place Stop Switch Test 1 Attach the lanyard lock clip to the stop switch 2 Start the engine 3 With engine running pull the lanyard to disengage the lock clip Engine should stop running NOTE The stop switch also operates as a push button switch with the lanyard left attached 4 Repeat the test but do not remove the lanyard Press down firmly and hold the stop switch until engine stops running If engine continues to run in either test the stop switch or wiring are faulty and must be replaced before engine is operated 3 10 Dewatering System 10 2 22 Raider 40 Manual Military version Dewater and Start Procedure Pull Start Connect fuel line Tilt engine into boat Push dewatering valve toward rear of engine hold back 10 7 Pump primer bulb clearing old fuel Release dewatering against
36. eto Mm 21 39 Electrical System 24 3 10 Dewatering System 29 3 11 Recoil Starter 31 3 12 Starter Lock EE 34 3 13 Drive Shaft Housing 39 3 14 Gear Case Drive Shaft 44 3 15 Gear Case Propeller Shaft 44 3 146 Shifter u ee 47 3 17 Transom Bracket 51 3 18 Reverse Lock Transom Bracket 55 3 19 Raider Motor Covering Cowl 56 2 20 Fuel T ra ks ERE 57 3 24 Two Raider Motor Configuration 59 3 22 EE E 60 4 Engine Details s nger NEE Eege 61 4 1 Tune Up procedures 61 4 2 Lubrication 61 4 3 General Service Information 62 4 3 1 General Equipment Required 62 4 3 2 Consumables Required 63 4 3 3 Operational Information 63 4 3 4 Unit Conversions 65 4 3 5 Standard Torque Values 66 4 3 6 Trouble shooting 68 5 Recommended Spare Parts Kit 70 Raider 40 Manual Military version Section 1 GENERAL PRECAUTIONS WARNING Gasoline is extremely flammabl
37. fails to run straight adjust the trim tab which you will find underneath the anti cavitation plate If the boat has a tendency to pull to the right move the trim tab in direction A as shown in the drawing If it pulls to the left move the trim tab towards B Note A trim tab is a sacrificial anode that protects against corrosion Do not paint it as this makes it ineffective Turning to starboard 46 Raider 40 Manual Military version 3 16 Shifter 27 16 ec V Je ig 14 38 I e S 34 Fig 13 1 844 3s SPT 36 3 Gei 33 Raider 40 Manual Military version Ref No Part No Description Q ty Remarks 16 1 345566110 2 Shift Lever l 16 2 345 66137 0 Oil 10204 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 8425 1 16 6 945303 0800 E Ring 4 8 1 16 7 332 61315 0 Washer 10 5 18 1 5 1 16 8 345 66225 0 Shift Rod Lever 1 16 9 930403 1000 Nylon Nut 105 1 5 1 16 10 345 661 15 0 Holder shift Lever Stopper 1 16 11 965002 1605 Steel Ball 5 16 1 16 12 332 661 12 0 Spring shift Lever Stopper 1 16 13 345 661 190 Shim shift Lever Stopper AR Toss 16 14 9101 14 0618 Bolt 2 16 15 9401 13 0600 Washer 2 16 16 348 66211 0 Shift Rod 1 16 17 345 66226 0 Grommet Shift 1 16 18 332 66021 0 O Ring 2 4 5 8 1 16 19 951403 0312 Spring Pin 3 12 i Shif
38. ion timing degree measurements TROUBLESHOOTING The troubleshooting chart lists common engine symptoms related to problems with the fuel system It also indicates specific malfunctions in the fuel system which may be causing the problem so it can be isolated more effectively Before beginning major troubleshooting operations on the fuel system perform the following operations Disconnect fuel tank hose from the engine Connect a known good tank and hose and determine if the problem persists Remove and clean the engine fuel filter assembly and replace the filter element Replace filter element in the fuel tank pickup tube 67 s 2 Raider 40 Manual Military version TROUBLESHOO TING 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 acceleration Runs or fails to noisy or Low cylinder get full has compression erratically poorly RPM decreases overheats vibration Poor crankcase Seal Ignition timing or Throttle linkage Out of adjustment Water entering Crankcase Defective Thermostat Fouled defect Or incorrect Spark plug Wrong gap Setting Worn or Defective Cylinder Piston rings Or warped Head Blown cylinder Head or Engine base Gasket Worn connecting Rod or crankshaft Bearings internal
39. just the stopper for full close adjustment so that it hits the stopper bolt at the position where the magneto coil plate timing mark fully closed side meets the ignition timing inspection line crank case mating surface NOTE After making adjustments check that the advancer arm moves firmly and smoothly Tighten adjusting nut after completing adjustments 6 Atthe neutral and reverse position the starter lock arm and neutral stop arm controls the engine speed 7 8 Adjust the engine ignition timing and Multi fuel Throttle Body Atomizer See Synchronization and Linkage Adjustments this section 9 Remove propeller and inspect propeller shaft oil seal for leakage Inspect propeller thrust washer and other propeller shaft hardware for damage Replace as needed 10 Drain and refill the Gearcase with specified gear oil See Engine Specifications in this section 11 Lubricate all engine components as specified in the Lubrication Chart this section 12 Verify that all bolts and screws are torque to specification by applying a torque wrench to each 13 Run engine in test tank with proper test propeller and check for the following Abnormal engine noise Improper clutch operation Little or no cooling water discharge from check port and idle port Fuel leaks from mating surfaces of crankcase Fuel leaks from mounting surface of intake manifold Cooling water leaks from mating surfaces of cylinder head Coo
40. kg m Torque Wrench 0 750 ft lb 0 1000 0 100 kg m Dial Gauge minimum scale 0 0001 in 0 01 mm Micrometer Set or Dial Caliper minimum scale 0 0001 in 0 01 mm Telescoping Gauge Inside Micrometer Set or Dial Caliper minimum scale 0 0001 in 0 01 mm Variable Load High Rate Discharge Tester Electronic Specialties Model 700 or equivalent Analog Multimeter Electronic Specialties Model M 530 or equivalent Digital Multimeter Electronic Specialties Model KD 3200 or equivalent Digital Pulse Tachometer 10 6000 RPM Electronic Specialties Model 321 or equivalent Ammeter 0 100A Gearcase Pressure Tester Stevens S 34 or equivalent Gearcase Vacuum Tester Stevens V 34 or equivalent Engine Compression Gauge 300 psi 0 2000 kPa 0 20 kg cm2 Spark Gap Tester Stevens S 13C S 48 or equivalent Flexible Fuel Tubing 1 4 in I D x 5 in 6 mm 1 0 x 127 mm Flexible Fuel Tubing 3 8 in I D x 5 in 9 5 mm 1 0 x 127 mm Industrial Thermometer minimum 300 F 150 C Heat Resistant Container Pyrex Bearing Puller Seal Pullers Seal Installers Heat Gun Hydrometer 62 Raider 40 Military version 4 2 2 Consumables Required Thread locker Loctites 242 Thread locker Loctites 243 Gasket Dressing Permatexe Hylomare Aerosol High Temp Gasket Dressing Gasket Sealant Permatexe High Tack Gasket Sealant Anaerobic Gasket Maker Loctites 518 Silicone Sealant Permatexe Hi Temp
41. ling water leaks from engine mounting surfaces Cooling water leaks from exhaust cover mounting surfaces Improper idle RPM and stability Defective stop switch 64 Raider 40 Units of Length mile ft in in km m cm mm Units of Mass Ib 02 kg g Military version Units of Volume Manual UNIT CONVERSIONS Prefix Symbol Power mega M x 1 000 000 kilo k x 1 000 centi 0 01 milli m x 0 001 micro H x 0 000001 x 1 6090 km gal U S x 0 3050 m qt U S x 2 5400 cm cu in x 25 4000 mm cu in x 0 6210 mile fl oz U S x 3 2810 ft fl oz U S x 0 3940 in cms x 0 0394 in cms Units x 0 45360 kg Lbf x 28 35000 g Ibf x 2 20500 Ib N x 0 03527 oz N kgf kgf Units of Torque ft Ib ft in Ib Ib m kg m kg m N m N m N m x 1 3558 N m x 0 1383 lt kg m x 0 1130 N m x 0 0115 lt kg m x 7 2330 ft lb x 86 8000 in Ib x 9 8070 N m x 0 7376 ft Ib 8 8510 in Ib x 0 1020 kg m Units of Power ft Ibf s ft Ibf s ft Ibf s x 1 01400 PS 745 70000 W 0 98630 735 50000 W 542 50000 ft Ibf s x 0 00134 x 0 00136 PS 0 73760 ft Ibf s 1 34100 HP 1 36000 PS x x x x x 0 00181 HP 0 00184 PS 1 35600 W x x X x x 550 00000 ft Ibf s 737 56000 ft Ibf s x 3 78540 L x 0 94635 L x 0 01 639 L x 16 38700 mL x 0 02957 L x 29 57000 mL x 1 00000 mL x 0 03382 fl oz U S
42. ly eliminated between the heads and the pistons Another key component is a high performance spark plug made of stainless steel with a robust spark This spark plug was developed to allow submersion without the need to replace spark plugs after submersion A secondary start system has been installed that uses a battery to provide quicker starts The battery is located under the cowling A grab rail has been installed to easily carry the motor and the second is protection of the Raider outboard when dropped A new slide plate has been installed in the COTS engine to allow for easier placement on the rubber inflatable boat especially in higher sea states Raider 40 Manual Military version 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 Crankcase 8 32 Cylinder Crankshaft 9 3 3 Intake Manifold Fuel Pump 10 34 Multi fuel Throttle Body Atomizer 11 35 Fuel Pump Oil System 13 3 6 Throttle Mechanism 17 37 Tiller Handle 19 3 8 Magn
43. maintain this speed At intervals run engine at 3 4 throttle for 1 10 minutes then return to 1 2 throttle for a cooling period Vary engine speed every 15 minutes Check for water discharge from cooling water check port Next Eight Hours 2 to 10 Hours Run engine at 3 4 throttle For short periods of time run engine at full throttle and then reduce speed back to 3 4 throttle As this part of the break in period progresses open to full throttle for longer and longer periods of time but never longer than 5 minutes Vary engine speed every 15 minutes DO NOT exceed the Full Throttle RPM Range of the engine See Engine Specifications After Break in Re torque cylinder head bolts to specification after engine has been run and cylinder head has cooled to the touch 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 5 JP 8 kerosene and diesel 2 is a simple two stroke two cylinder outboard Special Features Submersible Multi fuel capability Special transom mount adapter Wrap around grab bar for easier carrying engine protection Fuel additives to assist meeting EPA standards when operating JP 5 and JP 8 fuels Section 3 will describe the Raider 40 outboard in detail This information includes part numbers how to assemble disassemble each par
44. n and install a Velcro strap Connect the battery cable to the cable inside the motor pan To remove do the process in reverse Storage Battery should be stored with 70 percent charge level Store in dry cool location away from rain furnaces of other heat sources The electric start function is considered a secondary starting method NEVER use battery to dewater engine as this will cause critical internal damage to the engine when the piston tries to quickly push water out of dewatering valves This will potentially destroy the internal parts of the engine 24 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 Ah 2 Cold Cranking Amps 140 Engine Fuse none Rectifier 04KE03 Starter Solenoid 2J6 Starter Motor 346760100m Starter Switch FS ST05 Moroso 74120 Alternator 12V 80W Charging Performance at 5500 RPM 5 Amps Number of Tachometer to Alternator Coil Impulses 4 Alternator Coil Resistance Y W 0 65 0 98 Ohms Y B 0 31 0 47 Ohms W B 0 37 0 55 Ohms Ignition Coil Resistance 25 Primary Coil 0 2 0 3 Ohms Secondary Coil 4 1 6 1 KOhms 25 ex Raider 40 Manual Military version Electrical Starter Posi
45. t Section 4 will present engine details including Tune Up procedures troubleshooting and special tools required for overhaul and maintenance Section 5 provides a list of recommended spare parts that supports the Raider 40 outboard and is included in each spare parts kit Raider 40 Manual Section 3 ENGINE INFORMATION 25 1 2 3 4 5 6 7 8 9 e O NNNN NN k RP amp 0 F O o 00 OU P Military version Cowltilt handle Motor Cover Upper Cooling Water Check Port Water Plug Tilt Stopper Drive Shaft Housing Anti Cavitation Plate Trim tab Propeller Starter Handle Shift Lever Throttle Grip Clamp Screw Handle Stern Bracket Thrust Rod Oil Plug Lower Water Strainer Oil Plug Lower Retainer to transom Stop switch Choke knob Electric Starter button Fuel connection Dewatering lever Wrap around grab rail Raider 40 Manual Military version Front View Raider 40 24 2 3 Oat T h kee aN 1 Cl 19 Raider 40 Manual Military version Raider 40 Overview e Cylinders 2 e Displacement 30 08 cu in 493 cm3 e Standard Bore 2 76 in 70 mm Stroke 2 520 64 mm e Piston Clearance 0 0020 0 0039 in 0 05 0 10 mm e Piston Ring End Gap 0 008 0 016 in 0 20 0 40 mm Compression 106 6 PSI 735 0 kPa 7 5 kg cm 3
46. ter Developed to be similar to existing military outboards to maintain familiarity for the soldier The shifter is a mechanical front mounted easy fit rugged device For movement it can be pushed into the Raider to minimize size The shifter also has a safety device which only allows the motor to be started into neutral The primary pull starter must be in neutral for the primary start For electric start caution must be taken It is possible the motor could start in gear with the electric start The electric start button has protection against accidental starting however caution should be taken to insure the shifter is in neutral Raider 40 Manual Military version 3 17 Transom Bracket 49 Raider 40 Manual Military version Q ty Ref No Part No Description Remarks 17 1 349S62112 0 Stern Bracket Right mE Starboard 17 2 349862113 0 Stern Bracket Left 17 3 346 62191 0 Bracket 1 174 346 62124 0 Nylon Nut 7 8 l 17 5 349 62126 0 Bushing Bracket Bolt 2 17 6 346 62127 0 Cap 346621171 Dose rice a 17 8 940113 0600 Washer us osonsoso sue dl sa 041 17 12 345 62122 2 Spring Thrust 17 13 398562100 0 Clamp Screw Ass y 17 13 1 398 62103 0 Clamp Screw 17 13 2 332862102 1 Handle Clamp Screw 17 13 3 3C8 62104 1 Rivet 3 22 PE vas 33262101 0 pad ciempserew Jol 17 15 34956231
47. tion Color of lead wires B we el Blue Brown Green Black LDA N Starter Button 9 35 Fig 19 1 9 36 Starter Button Safety ring 26 Raider 40 Manual Military version Ref No Part No Description Q ty Remarks 9 1 346 1601 0 0 Starter Motor 1 9 1 1 346 7601 5 0 Pinion 1 9 1 2 346 7601 2 0 CarbonBrush 4 2 Sec 346 76013 0 carbon 6 1 9 1 4 346 7601 4 0 Brush Holder 1 9 2 916103 0830 Bolt 2 9 3 345 06971 0 Clamp 91 2U 2 9 4 9301 1 3 0800 Nut 2 9 5 941 303 0800 Spring Washer 2 9 6 346 76040 0 Starter Solenoid 1 9 7 361 76055 0 Bracket Choke Solenoid 1 9 8 345 76081 0 Bracket Neutral Switch 1 9 9 910103 0618 Bolt 2 9 10 9301 13 0600 Nut 2 9 11 941 303 0600 Spring Washer 2 9 12 3G2 76060 0 Rectifier 9 13 921503 0525 Screw 9 14 930103 0500 Nut 9 15 941303 0500 Spring Washer 9 16 353 06 281 0 Holder Cable Terminal 9 17 353 06 283 0 Collar 6 4 10 4 2 9 18 9101 13 0620 Bolt 2 9 19 309 0697 2 0 Clamp 65 475P 3 9 20 941 303 0600 Spring Washer 2 9 21 930113 0600 Nut 2 9 22 91 01 03 0645 Bolt 1 or 910103 6645 9 23 941 303 0600 Spring Washer 9 24 128 02605 1 6 8 28 5 1 9 25 910903 6616 Bolt 2 352 76062 0 Fuse Wire eliminated L 355 074 Raider 40 Manual Military version EMERGENCY STOP SWITCH AND LANYARD The
48. ull the starter rope a minimum of eight SLOW pulls This eliminates all water trapped between pistons and the head Following instructions located on the motor cowling the Raider should start within five minutes using the pull start It is critical after submersion the motor is turned over by hand for a minimum of eight slow pulls insure the rope is engaged prior to pulling as to not put pressure on the pull starter NEVER use the electric start immediately after submersion as the water trapped will cause internal damage to the outboard Picture of rear of Raider motor showing head Dewatering Valves P N DW 50546 O Rings on Valves P N DW50546 A Military version Manual Raider 40 3 11 Recoil Starter Raider 40 Manual Military version Ref No Part No Description Q ty Remarks 11 1 345 05000 1 Recoil Starter l 1 1 1 1 345 05105 1 Starter Case 1 1 1 2 345 05105 1 Reel 1 1 1 1 3 345 05003 1 Ratchet 1 1 1 1 4 3450513521 Bushing Ratchet 1 11 15 345 051220 Washer 6 5 23 15 1 EE 945303 0500 E Ring 4 5 1 11 1 7 345 05123 0 Ratchet Guide A 2 11 18 345 051240 Ratchet Guide B 1 11 1 9 345 05004 0 Starter Spring 1 1 1 1 10 951403 0316 Spine Pin 3 16 1 11 1 11 345 05132 0 Starter Shaft 1 11 1 12 9101 14 0830 Bolt 1 11 1 13 941322 0800 i Spring Washer
49. wrench handle Slotted head screwdriver Spare Parts Starter rope Spark Plugs 2 Split Pin Cotter Key Other Plastic emergency clip Military version 60 Raider 40 Manual Military version 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 visible defects 2 Remove each spark plug and check for fouling cracks in ceramic and incorrect gap Replace plugs if needed 3 Check engine compression Refer to Cylinder Compression Test in Section 4 4 Check ail wiring connectors and clamps for damage Replace parts as needed 5 Replace fuel filter and inspect Multi fuel Throttle Body Atomizer Check fuel hoses for deterioration Replace as needed 6 Check for proper clutch engagement and make shift linkage adjustments as need 4 2 Lubrication for Raider 40 Lubrication Lubrication Chart Lube Lubrication Points and Lubricant Type 1 Figure 1 Shift Lever Mechanism 50 2 Throttle Cable 50 1 Figure 2 Throttle Linkage 50 61 56 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 Ib 0 17 N m O 1 7

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