. Miliary Service Manual
Contents
1. Removal 16 1 Disconnect CD Unit output lead 1 from ignition coil primary cable 2 2 Disconnect spark plug cap 1 from spark plug 2 3 Remove bolts 1 and remove ignition coil Cleaning and Inspection Clean mounting area with isopropyl alcohol Check for the following and repair or replace as required Remove spark plug s and inspect for fouling damaged electrodes or damaged ceramic insulator CD Unit output connectors and leads for integrity cut or cracked insulation Installation Install in reverse order of removal CD Unit NOTE Disconnect negative battery cable from battery before removing CD Unit Removal 20 1 Remove bolts 1 2 Remove CD Unit Cleaning and Inspection Examine electrical conductors and connectors Installation Install in reverse order of removal NOTE Make sure that all electrical conductors are properly routed before you insert CD Unit to avoid pinching them 61 STARTING SYSTEIVI WARNING Disable ignition system by disconnecting exciter coil terminals 4 and 5 to prevent accidental engine startup during testing of starter circuit SN CAUTION Use proper precautions when performing tests with the engine cover removed Do not wear loose clothing or jewelry Keep hair hands and clothing away from the fh wheel and other moving parts es CAUTION When repairs are complete make sure all ignition and electrical leads are properly routed2. 13 Install clutch push rod 19 so tapered end faces bevel gearA 14 Gompress the clutch spring by applying pressure to push rod 19 Align the holes of the clutch and spring holder and insert clutch pin 20 CAUTION Wear safety glasses and DO NOT hold spring end of propeller shaft towards face or body when compressing the clutch spring 15 Install new clutch pin snap spring 21 using the clutch pin snap tool Do not reuse old snap Spring Part number of clutch pin snap tool 40 345 172229 0 CAUTION DO NOT reuse clutch pin snap spring 21 it must be replaced Reusing clutch pin snap spring may cause severe damage to gears and other components 16 Make sure all necessary adjustment shims are installed on bevel gear 22 and install gear onto propeller shaft housing 2 3 Install washer 24 onto bevel gear 17 Apply genuine grease or equivalent to the propeller shaft housing o ring and oil seal Slide the propeller shaft into the propeller shaft housing 18 Lift the cam rod to the fully UP position and verify through the gearcase opening that clutch cam beveled side 25 faces gearcase opening 16 T1730 32 19 Align the clutch push rod with the clutch cam and slide the propeller shaft and housing into the gearcase opening Push forward and rotate the propeller shaft as needed until bevel gears have engaged Ensure the propeller shaft housing bolts
3. wind counterclockwise to seat 7 Side spring 4 and pinion collar 5 on motor shaft 7 8 Push down on pinion collar 2 and install locking ring 1 9 Tap pinion collar 1 in place Disassemble Starter Motor 12 1 Remove bolts 1 2 Remove motor base 21 68 1 Clean starter motor terminal and hardware 1 with isopropyl alcohol and fine emery cloth and replace brush assembly if terminal or hardware cannot be restored to original condition 13 14 15 2 Check brushes and Tor chips fractures and wear If not within specifications replace brush assembly The Raider 40 Original Length a is 0 295 inches 7 5 mm Repair Limit b is 0 177 inches 4 5 mm 3 Check spring tension If springs are weak replace brush assembly 4 Gheck continuity with analog multimeter between Brush 22 and 43 Replace brush assembly if meter indicates continuity Brush 3 and the motor base 4 Heplace brush assembly if meter indicates continuity Brush 3 and the starter motor terminal 1 Replace brush assembly if meter does not indicate continuity Brush 2 and the motor base 4 Replace brush assembly if meter does not indicate continuity 69 Remove Brush Assembly 1 Remove screws 1 Remove brush assembly 1 carefully guiding the starter 2 motor terminal 2 through the bushing 3 Install Brush Assembly 1 Apply genuine grease to bearing cup 1 2 I
4. 5 When the main key switch is in the START position and the start contacts of the neutral start switch are closed power is sent to the starter solenoid energizing it When the starter solenoid is energized a connection between the positive terminal of the battery and the starter motor is provided The connection between the starter motor and ground completes the circuit The fuse opens if the coil circuit of the starter solenoid shorts or overloads Charging System 13 The charging system consists of the alternator coil set 1 rectifier 2 10 or 15 A engine fuse and the battery When the flywheel is turning approximately 1500 RPM or higher the alternator coil set provides alternating current AC voltage to the rectifier regulator The rectifier transforms the AC voltage into direct current DC voltage Battery Care and Maintenance WARNING The Raider 40 outboard motor has a battery located internal located under the cowling This battery is a fully sealed lithium iron battery shown below 37 The battery has one plug with two connectors and It is constructed that it can be plugged into the mating connector one way Battery Size Length 5 83 inches x Width 2 63 x Height 4 13 inches Weight 2 5 pounds Cold Cranking Amps 270 Polarity Charging System Output of 13 1 Volts Lithium iron 18 Ah 12V eq L polarity Sealed Fastening System Slot in base of battery
5. Hepair Procedures Alternator Coils if the resistance is within the indicated range proceed to the next step 5 Connect one tester head to a clean engine ground and connect the other tester lead to terminals 4 and 6 one terminal at a time to check for any resistance to ground 6 the meter indicates any resistance to ground replace the alternator coils See Charging System Repair Procedures Alternator Coils the meter does not indicate any resistance to ground proceed to the next step BAN BLACIK WHIHITE Set the analog multimeter to 407 on the ACV scale 8 Insert the banana plug of the RED tester lead into the meter connection labeled and the banana plug of the BLACK tester lead into the meter connection labeled COM Connect the BLACK tester lead to a clean engine ground and the RED tester lead to terminals 4 and 6 one terminal at a time to check for any voltage to ground 10 Start engine 11 At idle and full throttle if the meter indicates any voltage to ground replace alternator coils See Charging System Repair Procedures Alternator Coils If voltage to ground is indicated the test is complete 12 Reconnect alternator terminals 74 Rectifier Regulator Tests NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure Check for continuity between chassis ground and
6. rust also 4 Install specified socked 6 Part No 345 72232 0 and wrench 7 Part No 346 7223 1 0 Hold bevel gear B nut with wrench and turn driveshaft clockwise to tighten the nut Torque bevel gear B nut to specification 5 Perce all adjustment steps before proceeding See Adjustments CAUTION Failure to perform the adjustment steps miy madi m poor engine performance premature wear of parts or sewers damage lo Qearcese components 6 Install the water pump See Water Pump this section NOTE 14 21 7 Install bevel gear A 8 so tapered roller bearing 9 is seated in outer race 22 B Replace cam rod bushing internal o rings 10 and external o nng 11 Coat the internal o rings and inner surface of bushing with specified gear oil Then fully assemble the cam rod components 8 Apply genuine grease or equivalent friction surface manne 4 grease to the exterior of the cam rod bushing and o ring 10 Insert the cam rod into the cam rod port on the gearcase and seat the bushing Install stopper with stopper bolt 11 Align hole in clutch with slot in propeller shaft Slide clutch onto shaft so the side with the groove 1 faces the side with bevel gear A 2 CAUTION The clutch is not symmetrical except 5 HP If installed backwards clutch and gears will be damaged 25 12 Insert clutch spring 16 and install spring holder 17 so hole in spring holder is aligned with clutch hole 15
7. Place propeller shaft open end against bench surface and push out clutch pin 18 Hemove clutch spring 19 and spring holder 20 WARNING Wear safety glasses and DO NOT hold open end of propeller shaft towards face or body when removing clutch pin Clutch spring and spring holder come out with great force 16 Pull clutch 21 off propeller shaft 12 Cleaning and Inspection NOTE 1 Discand ihe cuich pin snap spnng and all seals and o rings that 2 Liban all gaarcan components wih solverit and dry with pressure ar Afer deanmg apphy spectied gear ol io all mniema components 10 prevent rushing 3 Perform the following mspectians Gearcage Housing inspect internal and extemal surfaces of housing for cracks and other damage All threaded holes must be undamaged and Tree of comosion and sealing agents Gheckthe tim tab ford and erosion See Anodes Inspection and Testing in Section 2 Inspect the water intake screens for damage and blockage screens cannot be fully cleaned replace them Propeller and Shaft Verify the propeller is true and free of nicks chips and other damage that wil affect performance Inspect the thrust washer and mounting hardware for damage Propeller Shaft Housmg 118 Examine propeller shaft housing and components for weer damage and deterioration ff necessary dmassemble and as needed See Gearcase Repair Procedures this se
8. and cable clamp 2 4 For models 9 9 15 18 25 30 40 ONLY Carefully slit coil plate assembly cable shield 3 NOTE Make sure you don t cut electrical conductors inside of coll plate assembly cable when you slit cable shield e Remove exciter coil screws 4 and exciter coil from the mounting bracket 56 Cleaning and Inspection 8 Clean coil plate assembly upper main bearing seal 1 set fing ignition timing link alternator coils pulser coils coil leads and coil connectors with isopropyl alcohol as required Check for the following and repair or replace as required Bent chipped cracked or corroded coil plate assembly Coil leads for integrity cut or cracked insulation and damaged connectors Broken or bent alternator coil Laminations damaged alternator coil windings and missing alternator coil screws Broken cracked or misaligned pulser coils and missing pulser coil screws Free motion of ignition timing link 1 Repair adjust and lubricate as needed see Section 2 Installation Install in reverse order of removal NOTE Use threadlocker on screw threads before installing Screws Use a length of shrink tube to fabricate new coil plate assembly cable shield as required Inside diameter of shrink tubing must be large enough to pass over the largest connector 57 Coil Plate Assembly Removal Hernove the flywheel 2 Disconnect the following ter
9. and clamped in their original positions and the start in gear prevention system must be tested before returning engine to custome r Starter System Testing The starter system may cause three types of problems The engine does not crank See Starter Circuit Tests in this section The starter motor runs but does not engage or disengage fram the fhywheeol see Starter Motor Test in this section The starter motor will not shut off see Starter Solenoid Test in this sectiorn Before you begin testing of starting system Check Battery fluid level and specific gravity Charge or replace as required See Battery Care and Maintenance this section Check the following electrical connections and make sure they are secure and free of corrosiorn Batterycables and clamps Starter solenoid wiring including ground connection Starter motor wiring including ground connection to engine block and or cowling Main key switch and neutral start switch cables Make sure shift lever or remote control lewer ix in NEUTRAL and it operates freely 62 BLACK GREEN YELLOW 2 3 Starter Circuit Tests These tests are designed to quickly isolate the faulty starter circuit component if the engine does not crank NOTE The electrical drawings have been simplified to show only those elements necessary to test the starter circuit Two types of starter circuits are used and illustrated in Models with remote
10. are completely clean and apply Loctite 242 to the bolt threads Install and torque the bolts evenly to prevent improper seating of the housing 33 20 Move the cam rod to each position and rotate the driveshaft to test gearcase function in all gears Check the propeller shaft for looseness in the fonvard and reverse directions looseness exceeds 0 016 in 0 40 mm replace bevel gear C washer 26 with one of correct thickness NOTE Hefer to current Parts Catalog for washer availability 21 Before adding gear oil pressure test and vacuum test the gearcase as follows Remove the oil level plug and install gearcase pressure tester Pump pressure tester until gauge indicates 3 6 psi 20 39 kPa 0 2 0 4 kg cme If pressure loss occurs determine source of leakage by submerging gearcase in water Make necessary repairs to correct the problem and retest Hemove the pressure tester and install gearcase vacuum tester 17 pump vacuum tester until gauge indicates 3 5 in 76 127mm of mercury If loss of vacuum occurs at ether range apply oil around suspected seal If leak stops or oil is drawn in the seal is defective and must be replaced Make necessary repairs to correct the problem and retest 22 Fill gearcase with specified gear lubncant See Engine Specifications in Section 2 for gearcase capacities 23 Apply genuine grease or equivalent to the propeller shaft and propeller mounting hardware Ins
11. control box 3 8 Models without remote control box 63 RED BLACK GREEN LIGHT GREEN BROWN L BLUE 1 Disconnect negative battery cable 3 from negative battery terminal 1 2 Set analog multimeter to check continuity Connect one tester lead to negative battery terminal 1 and the other tester lead to the around connection 2 for negative battery cable 3 If the meter does not indicate continuity clean connections and or replace negative battery cable If the meter indicates continuity go to the next step 4 Set analog multimeter to IDC and set range to 20 Connect BLACK tester lead to COM and the RED tester lead to VOT 4 Connect BLACK tester lead to clean engine ground 5 Connect RED tester lead to positive battery terminal 4 If meter does not indicate 11 8 to 13 2 VDC battery voltage see Battery Care and Maintenance this section If meter indicates battery voltage go to next step 6 Reconnect negative battery cable 3 to negative battery terminal 1 64 Connect RED tester lead to starter solenoid terminal 5 If meter does not indicate battery voltage replace battery cable 6 If meter indicates battery voltage go to next step 8 Disconnect lead 7 from starter solenoid 8 to starter motor 8 9 Connect HED tester lead to starter solenoid lead 7 and turn main key switch 10 to START position If meter indicates battery voltage repair or r
12. from housing Installation 1 Secure gearcase horizontally in padded vice or other fixture so propeller shaft opening faces upward 2 Verify bearing race seating surface in gearcase is clean and smooth 3 Apply specified gear oil to exterior of bearing race Position race in gearcase so stamped surface faces closed end of gearcase 4 Attach plate 1 to threaded end of rod 2 using spring washer 3 and nut 4 Tighten nut with wrench ect _ Bearing Outer Press Kit 3B7 72739 0 26 T1447 5 Insert rod 2 into gearcase so plate 1 is seated within the bearing race 6 Slide guide 5 onto rod and seat into position on gearcase Raised surface of guide must fit tighthy within the circumference of the gearcase opening 40 7 Fully seat bearing race in gearcase by hammering the rod end Bevel Gear A Roller Bearing Removal and Installation 11 1 Insert screwdrivers in notches of bevel gear A and gently pry gear and bearing apart 12 2 Use specified set tool 1 to press fit bearing onto bevel gear Set Tool Bevel Gear Bearing 8 72719 0 27 SECTION 7 ELECTRICAL SYSTEM General Precautions Before performing any service work on the electrical system read and understand the Service Safety section at the beginning of this manual Use the manufacturer and special tools as indicated during servicing of the electrical system Avoid electrical shock D
13. receptacle single screw at top General Procedures Inspection Inspect battery case for damage Inspect connector for corrosion Inspect cables Check battery mounting Cleaning Disconnect and remove battery Clean battery connectors Wash with water and let dry Place dielectric grease on both side of connector Replace battery tighten screw Do not plug in connector until ready for use Ignition System 38 CAUTION All cranking output tests must be performed with spark plugs installed and torqued in the cylinder head It necessary to remove the spark plugs be sure to keep the spark gap tester away from open spark plug holes CAUTION Avoid electrical shock Do not handle spark gap tester heads during performance testing Do not touch ignition coils exciter coil pulser colls or alternator coils vvhile the engine is cranking or running CAUTION Use proper precautions when performing tests with the engine cover removed Do not wear loose clothing or jewelry Keep hair hands and clothing away from the flywheel and other moving parts When repairs are complete make sure all ignition and electrical Leads are properly routed and clamped in their original systems And the in gear prevention system must be tested prior to delivering to units 39 Ignition System Performance Testing Ignition Performance Testing is divided into two sections The first section consists of a flow chart This char
14. recitier requlator Faulty charge circuit wiring DESCRIPTION OF OPERATION Ignition System 1 The ignition system consists ofthe magneto 1 Capacitive Discharge CD unit 2 ignition coil 3 main key switch 4 and emergency stop switch 5 The purpose of this system is to provide an electric spark inside each cylinder at the precise moment needed by the combustion chamber Magneto The electrical system consists of flywheel 1 coil plate assembly 2 CD unit 3 and an ignition coil 4 The 1 2 cylinder engines are comprised of seven basic electrical systems The following chart demonstrates not only the differences but the similarities Raider has 1 CD Unit 2 Coil Plate 3 Exciter Coil 4 Ignition Coil 5 Pulser Coil 6 Alternation Lighting 34 4 Flywheel Mounted radially inside the flywheel 1 are a number of high performance ferrite magnets As the flywheel rotates the magnets pass in front of the coils exciter alternator to produce voltage in the coils 5 Coil Plate The coil plate is a part to which exciter coil pulser coil and alternator coil are attache The coil plate is rotated for ignition advance 5 Exciter Coil The exciter coil 5 consists of many windings of wire wrapped around a metal lamination Once the flywheel exceeds a minimum cranking RPM the lines of force from the ferrite magnets contained within the flywheel cut th
15. the ground connection for the magneto plate CD Unit and ignition coils before conducting the following procedure Reference the following electrical drawings for the rectilier regulator test The rectifier regulator tests check whether the rectifier regulator 1 is shorted or open 1 Disconnect terminals 2 3 4 and 5 from all other wiring 2 Set analog multimeter to check continuity 3 Insert the banana plug of the RED tester lead into the meter connection labeled Vil and the banana plug of the BLACK tester lead into the meter connection labeled COMY 4 Connect the RED and BLACK tester leads to the terminals as shown and note the results Follow the tests listed in the chart starting at the TOP of each COLUMN and going DOWN Follow the tests listed in the chart starting at the LEFT of each ROW and going to the RIGHT rectifier regulator if continuity tests are not as shown If continuity checks are within specifications proceed to next step 75 BLACK A RED W WHITE Y YELLOW NOTE Continuity on chart means that the meter showed continuity some resistance indicated by meter exact value depends on fest conditions No Continuity on chart means thet meter had no deflection RED Tester Lead Terminal Continuity Continuity Continuity 5 Connect rectifier regulator leads Charging System Repair Procedures 5 N N WARNING Disable ignition syste
16. with lower seal 2 before seating gearcase on driveshaft housing 3 Apply Loctite 242 to threaded portion of gearcase mounting bolts Install the gearcase mounting bolts 3 and torque all bolts to specification 4 Inspect trim tab 5 and replace if corroded Install trim tab packing 4 and trim tab 5 5 Use spring pin tool B 6 Part No 345 72228 0 to install new upper spring pin in shift rod joint DO MOT reuse the old spring pin Shim Thickrezz rezraase shim thickness Decrease shim thickness QM D006 000114 D D38 LEO Fa O 042 Des Du 0415 DISSE T 1 t OJ 055 1 35 0 054 0 058 C2059 AS 1 81 f 23 GEARCASE REPAIR PROCEDURES CAUTION DO NOT attempt gearcase repairs without proper manufacturer special tools Use this section when service work requires disassembly or replacement of the following gearcase components Driveshaft roller bearings Gearcase needle bearing Propeller shaft housing needle bearing Bevel gear A bearing outer race Bevel gear A roller bearing Driveshaft Roller Bearings 1 CAUTION If it is determined after complete inspection that replacement of driveshaft roller bearing 1 is necessary all pressing operations during removal and installation must be performed at a qualified machine shop equipped with minimum 1 ton Press Gearcase Needle Bearing Note Obtain needle roller bearing
17. 1 Return to flow chart 15 Test 7 Output Tests Engine Running JA CAUTION The following tests must be performed with correct test propeller and with the engine in a test tank Mote that some performance problems cannot be duplicated in a test tank in these cases the tests must be conducted with the engine mounted on a boat and operated in open water ji NOTE Make sure a electrical terninals are connected during this test except those that are noted in the fest procedure Check for between chassis ground and ihe ground connection for the magneto plate CD Unt and coils before conducting he following procedure These series of tests are designed to efficiently find faulty ignition components that can cause an engine to run poorly Use the flow chart to systematically eliminate the possible causes to the problems The tests assume that The engine starts Tune Up Procedure has been performed see Section 2 Ignition Timing and the Carburetor Synchronization Procedure has been performed see Section 2 Engine is at operating temperature Tests are performed with engine running in fonvard gear Tachometer is installed 52 115 Output Tests Engine Running Flow Chart PROBLEM Engine Runs Poorly See Test 5 GO Unit Qutput Voltage and check CD Unit oulput voltage with engine running Compared ta output at cranking RPM does CD Unit vollage DROP while erre performa
18. Check for continuity between chassis ground and the ground connection for the magneto plate CD Unit and ignition cols before conducting the following procedure The following tests check the resistance of the primary and secondary windings in each ignition coil 1 1 Remove spark plug lead 2 2 Set digital multimeter to ohms 3 Disconnect terminals 4 and 5 4 Connect one tester lead to terminal 3 and the other terminal 4 5 The meter should indicate the following readings for the primary winding Repeat readings for each ignition coil 0 2 0 3 ohms 25 6 If primary winding for any ignition coil is not within the acceptable range replace the ignition coil See lgnition System Hepair Procedures Ignition Coil After repairs are made return to Ignition oystem Performance Testing Flow Chart If the primary windings are within the acceptable range proceed to the next step 7 Connect one tester lead to terminal 3 and the other to spark plug lead cap terminal 2 8 The meter should indicate the following readings for the secondary winding 4 1 6 1 kohms 2596 51 B lf secondary winding for any ignition coil ts not within the acceptable range replace the ignition coil See lbonition System Repair Procedures Ignition Coil After repairs are made return ig nition System Performance Testing Flow Chart 10 Reconnect all wires disconnected during test 1
19. SECTION 6 GEARCASE General Precautions Before performing any service work on the gearcase read and understand the Service Safety section at the beginning of this manual Full servicing of the gearcase requires manufacturer special tools Follow all special tool requirements as specified Substituting special tools with those not provided by the manufacturer may result in severe personal injury equipment or engine damage or faulty service work Perform bearing removal and installation operations exactly as specified to avoid damage to the bearing or housing during pressing operations Replace locking fasteners when their locking feature becomes weak Use only factory replacement parts When using compressed air to clean or dry parts make sure air supply is regulated not to exceed 25 psi 172 kPa 1 76 kg cm SERVICE SPECIFICATIONS Special Torque Values Raider 40 T Torque Thread Ini Fb 11 15 locker Description N m Propeller Nut l21 7 28 0 29 4 19 2 3 0 4 0 Pump case Bolts 41 55 4 0 0 2 100168 242 0 47 0 64 Bevel Gear B NutiBolt 1173 1988 7 1 4 2 Special Equipment Required EA Bevel Gear Beanng Puller Ass y 3B7 72731 0 Bearing Outer Press Guide Bevel Gear A Set Tool Bovel Gear A Sat Tol Backlash Measuring Tool Kit Backlash Measuring Tool Sub Ass y 369 72730 0 Backlash Measuring Tool Arm 360 72727 0 Backlash Measuring Measuring Too Shafi Back
20. b 0 17N m 0 1 7kg m Consumables Required Dieiectric Lubricant Perrnatex Dielectric Tune Up Grease Battery Spray Protector Perrnatex Battery Protector and Sealer Low Temperature Lithium Grease Genuine Grease or Equivalent Friction Surface Marine Grease Threadlocker Loctite 243 Isopropyl Alcohol Cleaning Solvent Thermomeit Stik 125 F 52 C and 163 F 73 C Electrical Shrink Fit Tubing various diameters 29 Electrical System Overview Ignition Type Flywheel Magneto Capacitor Discharge Ignition Timing Before Top Dead Center BTDC 25 Degrees 2 Degrees Spark Plug Pulstar Model SBE 1 10 Spark Plug Gap 033 No larger than 050 Battery Part No 365 265 001 Raider sealed Lithium Iron 265 CA Alternator 12V 80W Charging Performance 5500 5 Amps Ignition Coil Resistance Primary Coil 0 2 0 3 KOhms Secondary Coil 4 1 6 1 Ohms CD Unit Output Cranking 198 220 DVA Exciter Coil Output Cranking 100 DVA Mim Pulser Coil Output Cranking 4 75 5 0 Coil Resistance Exciter Coil 130 195 Ohms Alternator W Y Y W 0 65 0 98 Y B 0 31 0 47 W B 0 37 0 55 Electrical Connectors When you replace electrical components or perform diagnostic tests you must disconnect electrical connectors in many instances The following discussion will help you recognize connectors in electrical drawings and show you how to disconnect and connect them Electrical C
21. continuity between chassis ground and the ground connection for the magneto plate CD Unit and ignition coils before conducting the following procedure All continuity tests must be conducted or you may damage the meter Remove plug from Raider battery 44 2 Disconnect emergency stop switch terminals 1 2 3 and 4 3 Set analog multimeter to check continuity Connect one meter lead to terminal 1 and the other to terminal 3 6 4 Attach lanyard 5 to emergency stop switch 6 meter must not show continuity If it does replace emergency stop switch 5 Hemove lanyard 5 from emergency stop switch 6 meter must show continuity If not replace emergency stop switch 6 6 Disconnect CD Unit 9 terminals 7 and 8 7 Connect one meter lead to terminal B and the other to terminal 2 and check continuity If the meter does not show continuity replace the cable 6 8 Connect one meter lead to terminal 8 and the other to a clean engine ground If the meter shows continuity replace the cable 9 Reconnect all wires and return to Test 2 Stop Circuit Test flow chart BLACK Br BROWN Tats Test 3 Exciter Coil Test 45 3 5 System 2 5 3 5 WHITE NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure Check for continuity between chassis ground and he ground connection for the magneto place CD Uni
22. ction Drive shaft Check driveshaft threads and spines for wear caps cracks Sever spline weer or the appesrance of spline witing the gesrcase or exhaust housing been distorted possibly by impact damage Bearings must be free of damage corrosion and decoloration Replace beanng s as regured See Gearcese Repair Procedures this section Ingpect internal components for signs of wear chipping petting distortion and discolorebon due to mmproper lubrication Special attention to the following Check the bevel gear A tapered rofer bearing outer race f darneged or comoded repiace both the race and the bearing See Repair Procedures in thes section Inspect clutch and geer teeth and the clutch cam for chips and signis of metal transfer Heplace parts as needed 13 1 Install new gearcase needle beanng bevel gear B roller bening and outer race and driveshatt bearings d ary of these section 2 Secure gearcass in holding fixture with water pump side facing 19 3 Apply Loctite 242 to the thread of bevel gaar B nut 3 Side bevel gear E Hj onto driveshalt 5 as shown from propeller shaft side of geancase Hand tighten 3 to secure the maar m place NOTE Before applying Loctite 242 remove grease from lapered portion of bevel gear B and with and thread of drrveshafr and bevel gear B
23. d on engine block 5 Secure spark plug gap tester to a clean ground on engine block WARNING To avoid possible shock hazard do not handle Ignition coils or spark gap tester during cranking tests 49 To prevent possible arcing of high voltage route tester leads At least 2 inches from any metal surface Ground unused test leads to a clean engine ground 5 Set the tested to 400 on the DVA scale Insert the banana plug of the RED tester head into the meter connection labeled and the banana plus of the BLACK tester lead into the meter connection labeled COM Connect the BLACK tester lead to terminal 3 12 8 Carefully slide the RED tester into the bullet connector terminal 4 sleeve until it makes contact with the terminal NOTE DO NOT disconnect the CD Unit output connector terminals 4 and 8 Damage to the CD Unit may result 9 Attach lanyard to emergency stop switch 10 Crank engine At cranking RPM the tester should show the following result for each CD Unit output 100 DVA minimum If the test results for any CD Unit output is not within acceptable range replace the CED Unit See Ignition System Repair Procedures CD Unit Reconnect all wires disconnected during test Return to flow chart 50 Test 6 Ignition Coil Tests NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure
24. e complete make sure all ignition and electrical leads are properly routed and clamped in their original positions and the start in gear prevention system must be tested before returning engine to customer Flywheel Replacing the exciter coil or coil plate assembly requires the removal of the flywheel see Section 4 Flywheel for the proper procedure NOTE 3 Flywheel magnets must be of a particular strength in order ta run the ignition system Weak magnets can cause low ignition voltage which may affect engine performance Flywheels seldom go bad and would only be replaced as a last resort in solving an ignition problem Trad 2 Carefully inspect flywheel 1 for cracks chips and worn taper after it is removed Also inspect the magnets 2 for cracks and chips and make sure they are firmly attached to the flywheel Exciter Coil NOTE Disconnect negative battery cable from battery before removing exciter coil This procedure assumes exciter coil 15 available as a separate replaceable component Some engine configurations might require replacement of entire coil plate assernbly Check current Parts Catalog for availability 55 Removal 1 Remove the flywheel FN 2 Disconnect terminals 4 5 6 and 7 for exciter coil 1 connectors Note that these terminals interconnect cable from coil plate assembly 2 to cable from CD Unit 3 5 3 Remove coil plate assembly cable clamp screws 1
25. e nuts against each other so outer nut can be used to tighten shaft 13 B Look the nuts 15 Mount clamp assembly 16 on driveshaft as close as sible 5 pee to lower pump case Install dial gauge plate 17 on gearcase with appropriate size bolts 18 21 Tres 10 Mount a magnetic base and dial gauge obtain locally as shown Lift driveshaft upward and tap down on gearcase with rubber mallet to eliminate all looseness and proceed to adjust the setup so dial gauge 19 is aligned with V notch 20 11 Set dial gauge to zero Lift dmnveshaft upward and rotate driveshaft in both directions and record the dial gauge reading If the dial gauge reading is not within the specified range adjust shim thickness between bevel gear A 21 and tapered roller bearing 22 in accordance with the Backlash Shim Adjustment Table this section See Gearcase Hepair Procedures in this section for removal and installation of the bevel gearA roller bearing Acceptable Dial Gauge Reading Raider 40 0 0236 0 0394 0 60 1 00 22 Installation WARNING Ignition system must be disabled to prevent accidental engine start up during installation of the gearcase 1 Lighth coat the driveshaft splines with genuine engine oil or TC W 3 oil and apply silicone spray lubricant to water pipe lower seal 1 44 2 Slide driveshaft into lower crankcase head Align water pipe
26. efully pull the removable end 2 straight out without twisting or bending NOTE Never twist or bend bullet connectors or damage to lhe connectors will occur Always PULL these connectors apart 31 Electrical Cable Color Codes cables have color coded conductors so you can locate the comect conductor during troubleshooting and repair procedures All conductor colors are in capital letters in this manual conductors have a background color and a different color stripe that runs the length of the conductor These conductors are designated as follows NB Where A Background Color B Stipe Color Example BLACK WHITE This conductor has a BLACK background with a WHITE stripe Electrical Drawings electrical drawings shown in this manual have been simplified to clarify the circuit that is being tested They represent typical configurations and may not look exactly like the electrical wiring for your engine Complete electrical schematics are provided in the Outboard Motors Service Data publication Troubleshooting Electrical The troubleshooting chart lists common engine symptoms related to problems with the electrical system It also indicates specific malfunctions in the electrical system which may be causing a problem so it can be isolated more effectively Before beginning major troubleshooting on the electrical system perform the following operations Check battery fluid level and
27. eplace starter motor see Starter Motor Tests in this section If meter does not indicate battery voltage go to next step 10 Connect RED tester lead to connector closest to fuse holder 11 If meter does not indicate battery voltage repair or replace cable between 5 and 11 if meter indicates battery voltage go to next step 11 Connect RED tester lead to connector closest to fuse holder 12 If meter does not indicate battery voltage find source of overload or short and replace 15 A engine fuse 13 Possible sources of short or overload Short in starter circuit wiring or components such as starter solenoid main key switch or neutral start switch Short in charging circuit wiring or components such the alternator coils or rectifier regulator Short in accessories Short in starter motor If meter indicates battery voltage go to next step 12 Connect RED tester lead to connector closest to main key switch 14 NOTE For models with remote contro box Aake sure you test ihe correct tenrninial in this step Terrine 244 is connected Girectly to the mann Mey switch 710 and Me RED lead that cornes out of the farge cable Xa iat connects the engine compartment 76 to fhe remote contro box 7 DU NOT CONFUSE TERMINAL F lt TERMINAL 143 NOTE For moder without remote contro box You might Aave to pull conector 715 apart and measure viage aft ternal Take sure wou
28. ervice for any length of time See Water Pump this section 3 Remove propeller mounting nut washers and propeller 4 Hemove propeller shaft housing bolts 1 5 Hemove propeller shaft and housing from gearcase Make sure clutch push rod 3 is also removed The push rod and spring may pop out with removal Set the assembly aside EJ 6 Install socket 4 Part No 9 9 15 18 350 722320 25 30 346 722320 40 345 72232 0 and wrench 5 Part Mo 346 2231 0 Hold bevel gear B nut with wrench and tum driveshaft counterclockwise to loosen the nut Remove bevel gear B 6 and nut 7 from gearcase 10 Lift the driveshaft from the gearcase and set it aside 110 9 Reach inside gearcase and remove roller bearing 8 and bevel gear A 8 NOTE Taper beanng for bevel gear is only used on Model 40 111 10 Remove the stopper and lift cam rod 10 from gearcase Fullydisassemble the cam rod components including the cam rod bushing internal and external o nngs 11 Hemove clutch push rod 11 and ball 12 from propeller shaft Pull propeller shaft out of housing 113 12 Remove washer 13 bevel gear A 14 and all shims 15 25 30 and 40 from propeller shaft 11 TIJE 13 Remove bevel gear C 16 from the propeller shaft housing 15 14 Insert screwdriver under one end of clutch pin snap spring 17 Remove spring from groove by unwrapping it from clutch Discard the spring 15
29. fest fhe correct tentiinal in tis step 65 If meter does not indicate battery voltage repair or replace cable between 12 and 14 If meter indicates battery voltage go to next step 13 Connect RED tester lead to main button starter switch and push Raider start button 14 Connect HELD tester lead to neutral start switch lead 20 and turn main key switch 10 to START position If meter does not indicate battery voltage test neutral start switch 21 Refer to Neutral Start Switch Test in this section If meter indicates battery voltage go to next step 15 For models with remote control box ONLY Connect RED tester lead to starter solenoid lead 22 and turn main key switch 10 to START position if meter does not indicate battery voltage repair or replace cable between 20 and 22 If meter indicates battery voltage go to next step 16 Connect RED tester lead to starter solenoid lead 7 and turn main key switch 10 to START position If meter does not indicate battery voltage test starter solenoid B Refer to Starter Solenoid Test in this section Starter Motor Tests if the engine does not crank and you completed the Starter Circuit Tests previously described remove the starter motor and inspect the brush assembly lf the brush assembly meets specifications replace the starter motor or have it rebuilt If the starter motor runs but the starter motor does not engage or disengage from the flywhee
30. g of high voltage route tester leads at least 2 in 51 mm from any metal surface Ground unused test leads to a clean engine ground 9 Attach lanyard to emergency stop switch 6 Crank engine A spark should jump across the gap for each cylinder and alternate from one gap to another 7 Reconnect all wires disconnected during test 8 Return to Ignition System Performance Testing Flow Chart Test 2 Stop Circuit Test 42 T1888A Stop circuit malfunction can cause Raider not to start or preventing it from stopping Several component failures can cause the stop circuit to malfunction Use this flow Chart to isolate and repair all component failures Note After you complete each stop circuit test refer back to this flow chart for the Next step see Test 2a if so equipped does main key switch function normally Yes No Repair or replace main key switch components or wiring as required see Test 2b Does emergency stop switch function normally Y es No Repair or replace emergency stop switch components or Wiring as required Only problem is with stopping engine Yes No Return to Ignition Performance Testing Flow Chart Test 2b Stop Circuit Emergency Stop Switch Test 43 The emergency stop switch test is used to determine whether it is functioning normally Note sure all electrical terminals are connected during this test except those that are noted in the test procedure Check for
31. il ment specifications at cranking AP Yes Mo is there spark in AT LEAST ONE of the tester gaps So to Test 4 Does fee at each pulser exi crs xa io Tess 3 Does the mripat ol ihm exciir cec meet z pues i lica bn ans bo Test 2 Does the Elt circuli Function nomrmnally pecans Tex Fa Tom Ho Repair or replace Roane res Repair of replace compoererisu Aupair ar rug uu STs Go to Test 3 Doas i of the excitmr Gods prem Go to Test amp Dices each coll meet specdications os Fo Go to Test 7 The eutput bor each cyllinecem rue gBpecicabona with the engine running Yes Repair of ignitsn gygberm 41 Test 1 Spark Test NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure Check for continuity between chassis ground and the ground connection for the magneto plate CD Unit and ignition coils before conducting the following procedure 1 Remove all spark plug leads and spark plugs 3 2 2 Adjust spark gap tester 1 to 7 16 in 11 mm 3 Connect each spark plug lead to spark gap tester 2 4 Secure spark gap tester to a clean ground on engine block AA WARNING To avoid possible shock hazard do not handle ignition coils or spark gap tester during cranking tests NOTE To prevent possible arcin
32. ing tool clamp assembly Part No 3B7 72720 0 on driveshaft Compress the spring and tighten the clamp to maintain the spring compression and provide constant upward pressure against driveshaft With all looseness eliminated measure the gap between collar 7 and bevel gear B using thickness gauge set B Part No 353 72251 0 gap measurement is not within 0 023 0 025 in 0 60 0 64 mm remove the lower pump case and install correct size shim onto roller beanng outer race at location 9 NOTE Hefer to current Parts Catalog for shim availability 4 f shimming was necessary re install the lower pump case before proceeding with Backlash Adjustment Bevel Gears and B Backlash Adjustment Bevel Gears and B Backlash opecial tools are required for measuring backlash The following describes how to measure and correct backlash in the Raider 40 outboard 20 5 With the tapered roller bearing installed position bevel gear A in gearcase so bearing is Tully seated in outer bearing race Rotate the driveshaft to ensure gears are property meshed 6 Assemble the following backlash tool components Note the correct cuantity and orientation of conedisk spring washers Assemble three conedisk spring washers 10 o ring 11 and collar 12 7 Insert shaft 13 into gearcase and seat collar guide end in 04 bevel gear A Install plate 14 using appropriate size bolts Turn shaft nuts 15 onto shaft Tighten th
33. l remove the starter motor and inspect the pinion assembly the pinion assembly meets specifications inspect the flywheel for chipped or worn teeth and replace as needed 66 He TEHE Remove Starter Motor NOTE Disconnect negative battery cable from battery before removing starter motor 4 1 Disconnect starter solenoid cable and ground cable 2 Remove starter motor bolts 3 3 elide starter motor out of bracket 4 Glean bracket with cleaning solvent Inspect and Remove Pinion Assembly 1 Grasp pinion collar 1 and wind pinion gear 2 in a clockwise direction Make sure gear moves freely and returns to original position If any binding Is noted remove and replace pinion assembly 6 2 Release pinion collar 1 by tapping it with a socket 2 with same outside diameter as pinion collar and clearance for motor shaft and mallet 3 7 3 Push down on pinion collar 2 and remove locking ring 1 Note After disassembly prior to assembly spray Corrosion Zero on all parts 67 9 n ove pinion gear 9 spring 6 and pinion collar 5 Clean removed components with cleaning solvent and examine pinion gear for wear and chipped teeth and spring for tension or distortion and replace assembly as required Do not allow cleaning solvent to come in contact with starter motor 6 Apply a light coat of low temperature lithium grease to motor shaft 7 and slide on pinion gear 3
34. lash Measuring Plate 3A3 72724 0 Backlash Measuring Tool Collar 353 72245 1 EA 348 72250 0 72250 0 General Equipment Required TorqueWrench 0 150 in Ib O 17 N m 0 1 7 kg m TorqueWrench 0 150 ft lb D 200 M m 0 20 kg m Dial Gauge minimum scale0 0001 in 0 01 mm Gearcase Pressure lester Stevens 5 34 or equivalent Gearcase Vacuum Tester Stevens V 34 or equivalent Seal Pullers Seal hiStallers Heat Gun Consumables Required Threadlocker Loctite 242 Gasket Sealant Permatex High Tack Gasket Sealant Anaerobic Gasket Maker l octite 518 Silicone Spray Lubricant Permatex Silicone Spray Lubricant Genuine Grease or Equivalent Friction Surface Marine Grease Isopropyl Alcohol Cleaning Solvent Engine Lubricant Genuine engine oil or certified ail Gear Lubricant Genuine gear oil or grade GL5 SAE 80 90 Cleaning Pads Scotch Brite Abrasive Pads Gasket Hemover WATER PUMP If the engine has been run without water for any length of time the water pump should be serviced with a water pump repair kit Use the following procedures to install the repair kit Removal 1 Hemove the gearcase See Gearcase this section 1 2 Hemove water pump mounting bolts 1 3 Hold upper pump case 2 securely and rotate driveshaft clockwise to free impeller from upper pump case CAUTION Do not rotate driveshaft counterclockwise Doing so will bend impel
35. ler fins in wrong direction and may weaken or damage the impeller 4 Slide upper pump case off driveshaft and remove pump impeller 3 and impeller key 4 4 5 Insert a screwdriver in each lower pump case notch 5 and gently pry upward to remove Slide lower pump case off driveshaft Water Pump Assembly 1 Disassemble the water pump component as illustrated and verify the kit parts match the originals before discarding old parts 2 Remove all gasket residue from lower pump case with abrasive cleaning pads and gasket remover Do not scrape the gasket surface with metal scraper Thoroughly clean all components with isopropyl alcohol and dry with lou pressure compressed air 3 Inspect the upper and lower pump cases for signs of melting and cracks Replace as needed 4 Examine lower pump case oil seals 1 for signs of damage and deterioration NOTE necessary to replace seals use appropriate size seal puller and installer to avoid damaging new seals and seating surfaces in lower pump case Apply silicone spray lubricant to seals and install so lips face direction indicated 5 Apply anaerobic gasket maker to seating surface of water pipe lower seal 2 6 Install seal in upper pump case so locking tabs 3 align with holes 4 7 Slide pump case liner 5 partially into upper pump case housing so locking tab 5 is aligned with notch in housing NOTE Pump case liner must be flush with flanged s
36. m by disconnecting exciter coil terminals 4 5 6 7 to prevent accidental engine startup during removal and replacement of the flywheel 76 CAUTION Flywheel is under high torque and requires the use of special tools for removal and installation Failure to use the specified tools can result in injury or damage to the flywheel or coil plate electrical components CAUTION The force needed to loosen and tighten the flywheel nut requires flywheel be removed and installed with engine mounted and secured on an engine stand B CAUTION Use proper precautions when performing tests with the engine cover removed Do not wear loose clothing or jewelry Keep hair hands and clothing away from the flywheel and other moving parts CAUTION When repairs are complete make sure all ignition and electrical leads are properly routed and clamped in their original positions and the start in gear prevention system must be tested before returning engine to customer Flywheel Replacing the exciter coil or coil plate assembly requires the removal of the fhywheel see Section 4 Flywheel for the proper procedure NOTE Flywhee magnets must be of a particular strength in order to run the ignition system Weak magnets can cause low ignition voltage which may affect engine performance Flywheels seldom go bad and would only be replaced as a last resort in solving an ignition problem Carefully inspect flywheel 1 for c
37. minals 10 Exciter coil 1 terminals Note that these terminals interconnect cable from coil plate assembly 2 to cable from CD Unit 3 Disconnect terminals 4 5 6 and 7 58 pulser coil 1 terminals Note that these terminals Interconnect cable from coil plate assembly 2 to cable from CD Unit 3 Disconnect terminals 4 5 6 7 8 8 10 and 11 12 Alternator coil 1 terminals Mote that these terminals interconnect cable from coil plate assembly 2 to rectifier regulator 3 Disconnect terminals 4 5 6 and 7 Y YELLOW W WHITE 59 13 4 Remove the screws 1 and remove coil plate assembly 2 from the set ring Cleaning and Inspection Clean upper main bearing seal 1 guide plate 2 and set ring 3 with dry cloth Check for the following and repair or replace as required Bent chipped cracked or corroded guide plate Broken or bent set ring Apply light coat of low temperature lithium grease to guide plate 2 Istallation Install in reverse order of removal NOTE Disconnect negative battery cable from battery before installing plate assembly Use threadlocker on screw threads before installing screws Apply light coat of low temperature lithium grease to the guide plate Ignition Coil NOTE Disconnect negative battery cable from battery before removing ignition coil 60 E n L i 4 gt
38. nce problem is noticed Yes No Replace CD Unit Does engine perform property See Test 3 and check exciter output voltage with engine running if Yea you are done NOTE Check voltage WITHOUT DISCONNECTING TERMINALS Compared to output a cranking does exciter coil cnni output voltage DAOP while engine problem 15 Replace ignition Coil Goes engine property Reolace Exciter Coil Does angine perform properly If Yes you are If Yes you are done It No go to next step No go to next step Replace Pulser Ignition System Repair Procedures 53 NAN WARNING Disable ignition system by disconnecting exciter coil terminals 4 5 6 7 to prevent accidental engine startup during removal and replacement of the flywheel CAUTION Flywheel is under high torque and requires the use of special tools for removal and installation Failure to use the specified tools can result in injury or damage to the flywheel or coil plate electrical components CAUTION The force needed to loosen and tighten the flywheel nut requires flywheel be removed and installed with engine mounted and secured on an engine stand 54 CAUTION Use proper precautions when performing tests with the engine cover removed Do not wear loose clothing or jewelry Keep hair hands and clothing away from the flywheel and other moving parts CAUTION When repairs ar
39. ng RPM the tester should show the following results 100 DVA Minimum If the exciter coil test results are not within the acceptable range replace the exciter coil set See Ignition System Repair Procedures Exciter Coil Reconnect all wires disconnected during test Return to flow chart Test 4 Raider Pulser Coil Test NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure Neck 10 21111111 DOCLWOCIICIIC ana ground connection for the magneto plate CD Unit and Te AIF inne REAR AA LIRA A AED 23 H BLACK BLUI P The Raider pulser coil test is used to determine the output voltage in DVA from the pulser coil 1 located on the coil plate assembly 2 to the CD unit 3 while you are cranking the engine Disconnect the following terminals 4 5 6 7 8 and 9 Set the digital multimeter to ohms and connect the leads to test the resistance of the coil Connect multimeter between 6 and 8 terminals Multimeter should indicate 30 45 ohms 25 If the resistance is not within the indicated range replace the Raider pulser coil See Ignition System Repair Procedures Pulser Coil After repairs are made return to Ignition System Performance Testing Flow Chart If the resistance is within the indicated range proceed to the next step Set the analog multimeter to 20 on
40. nstall brush assembly 1 Make sure that the starter motor terminal 2 is fully seated in the bushing 3 Assemble Starter Motor NOTE Bolts for models 25 30 40 may not be available as separate parts Check current Parts Catalog for availability 1 Clean commutator 1 with fine emery cloth 70 2 Retract brushes as you slide motor base 1 123 over commutator 2 Align notch 3 in motor base with tab 4 in motor body 5 and seat motor baseto motor body 26 3 Grasp pinion collar 1 and rotate several times to make sure brushes are seated Install Starter Motor 1 Slide starter motor into bracket apply threadlocker to bolt threads and install mounting bolts 2 Connect starter solenoid cable and ground cable 3 Coat terminals with battery spray protector Starter Solenoid Test 1 Disconnect terminals 4 and 5 and disconnect terminal 3 from chassis ground 71 2 Set analog multimeter for continuity Check for continuity between terminals 3 and 5 If meter does not show continuity replace starter solenoid 1 5 and clean chassis ground meter shows continuity replace starter solenoid 3 and clean chassis ground meter shows continuity replace starter solenoid 3 Disconnect positive battery lead B and RED starter switch lead 8 from starter terminal 2 and disconnect starter motor lead 7 from starter terminal 6 4 Check for con
41. o not handle spark gap tester leads during performance testing Do not touch ignition coils exciter coil pulser coils or alternator coils while the engine is cranking or running Use the spark gap tester to prevent the engine from starting when performing static ignition performance tests Use caution when performing tests with the engine cover removed Do not wear loose clothing or jewelry Keep hair hands and clothing away from the flywheel and other moving parts After repairs are complete make sure all ignition and electrical leads are properly routed and clamped in their original positions Replace locking fasteners when their locking feature becomes weak Use only factory replacement parts Always inspect and test the start in gear prevention system before returning engine to customer SERVICE SPECIFICATIONS Special Torque Values Torque in Ib 11 15 H m kg m Spark Plug 19 21 25 29 2 6 3 0 Flywheel Nut B 101 118 137 12 14 NOTE Verify direction of flywheel nut rotation Most are nght hand threads however some will have left hand threads past production models 9 9 15 18 and 40 Refer to Section 2 for Standard Torque Values chart Manufacturer Special Tools Required Mone 28 General Precautions Before performing any service work on the Raider electrical system read and understand the Service Safety section at the beginning of this Service Manual Use the manufacturer and
42. onnector Drawings In most of the electrical drawings in this section the physical shape of electrical connectors has been eliminated to clarify testing procedures r4 A typical electrical drawing illustrates several connectors Items 1 2 3 4 7 and 8 are terminals that are located inside of electrical connectors The dashed line between two terminals e q between terminal 7 and 8 means that they are a part of the same connector but have been disconnected for testing Note that Terminal 7 is directly connected to the CD Unit 9 no connectors between the terminal and CD Unit When you disconnect an electrical connector to test a component it is very important that you disconnect the FIRST CONNECTOR Terminals 1 3 and 7 are examples of how the first connector is illustrated 30 TuS Special cases are the connectors used to test components located on the coil plate assembly For testing purposes the first connector is located at the far end of the cable away from the coil plate assembly Bullet Connectors NOTE 3 Bullet connectors 1 are shown like this in electrical drawings Disconnecting Bullet Connectors 1 Carefully examine the connector to determine which end is removable and which end is fixed Typically the insulation surrounding the removable end is tapered so it fits inside of the insulation for the fixed end EJ 2 Grasp the fixed end 1 of the connector and car
43. owel pins Hold the upper pump case in position and rotate driveshaft clockwise to ensure free movement CAUTION Make sure impeller blades are not caught or pinched between upper and lower pump cases when upper pump case is fully seated Apply genuine grease or equivalent friction surface marine grease to neck portion of water pump mounting bolts Install the bolts 8 Install the gearcase See Gearcase this section GEARCASE um Removal AS WARNING Ignition system must be disabled to prevent accidental engine start up during removal of the gearcase 4 1 Place engine in FORWARD gear so shitt rod joint 1 is accessible 2 Use spring pin tool A 3 Part No 345 72227 0 to remove upperspring pin from shift rod joint Discard the spring pin 3 Hemove gearcase mounting bolts 4 from both sides of gearcase 4 Separate gearcase from driveshaft housing Disassembly A CAUTION Gearcase must be secured in a suitable holding fixture during disassembly 1 Drain all gearcase oil into a container and inspect the oil for metal chips NOTE Small metal fragments may indicate normal wear of gears bearings and shafts Large metal chips usually indicate extensive internal damage your observations for future reference when inspecting internal components 2 Hemove the water pump and install a water pump repair kit if gearcase has been in s
44. puller kit P N 3C8 72700 0 24 Removal 2 1 Insert shaft 1 through needle bearing from water pump side of gearcase 25 2 Attach retainer 2 from propeller shaft side of gearcase to shaft groove 3 Make sure retainer is fully seated in groove with raised surface facing bearing 2 3 Slide guide 4 onto shaft from water pump side of gearcase Make sure guide is seated in bearing 4 install plate flange 5 washer 6 and nut 7 onto shaft 5 Hold end of threaded shaft with wrench and tighten nut 7 until bearing releases from housing Installation 3 1 Insert shaft 1 through needle bearing housing in gearcase 2 Coal the new needle bearing with genuine gear oil Slide bearing onto shaft from propeller shaft side of gearcase so bearing stamped surface 2 faces propeller shaft side N CAUTION Stamped surface of needle bearing must face propeller shaft side of gearcase or bearing could be damaged during installation Es 3 Attach retainer 3 from propeller shaft side of gearcase to aa F specified shaft groove 4 Make sure retainer is fully seated in groove with raised surface facing bearing 3 4 Slide guide 5 onto shaft from water pump side of gearcase Make sure guide is seated in bearing 5 Install stopper 6 plate flange 7 washer B and nut 8 onto shaft from water pump side of gearcase 6 Hold end of threaded shaft wi
45. racks chips and worn taper after it is removed Also inspect the magnets for cracks and chips and make sure they are firmly attached to the flywheel 77 Alternator Coils NOTE Disconnect negative battery cable from battery before removing alternator This procedure assumes alternator coils are avartable as a separate replaceable component Some engine configurations might require replacement of entire coil plate assembly Check current Parts Catalog for availability Removal 1 Remove the flywheel 2 Disconnect terminals 3 4 5 and 6 for alternator coils 1 Alternator coils are located on the coil plate assembly 2 78 3 Remove coil plate assembly cable clamp screws 1 and cable clamp 2 0 Make sure you don t cut electrical conductors inside of coil plate assembly cable when you slit cable shield Carefully slit coil plate assembly cable shield 1 NOTE Make sure you don t cut electrical conductors inside of coil plate assembly cable when you slit cable shield 5 Gut tie wrap 10 6 Remove alternator coil screws 4 and alternator coil 5 from J the mounting bracket Ld Cleaning and Inspection 11 Clean coil plate assembly upper main bearing housing set ring ignition timing link exciter coil pulser coil coil leads and connectors with isopropyl alcohol as required Check for the following and repair or replace as required Ben
46. rough the exciter coil windings This will produce about 100 DVA or over peak voltage at cranking speed A minimum of 100 DVA peak voltage at cranking speed must be detected The output of the exciter coil provides power to the CD Unit 35 T1983 T2212 5 Pulser Coil The pulser coil 6 consists of an iron core with numerous windings ofa wire wrapped around it The flywheel is equipped with a metallic cam called an interrupter molded into it When the interrupter passes in close proximity to the pulser coil the permanent magnet s lines of force collapse momentarily At cranking speed this produces a 4 75 to 5 0 DVA signal in the coil A minimum of 3 DVA must be detected during testing The output voltage from the pulser coil is used to control a srnall electronic switch SCR located inside the CD Unit When the CD Unit receives an output from pulser coil it directs an output approximately 220 DVA to the appropriate ignition coil primary 5 Alternator Lighting Coil The larger 1 2 cylinder engines 9 9 40 are provided with an alternator coil 7 mounted on the coil plate which may be used to power a lighting circuit and or recharging circuit if equipped with this option An Alternator Lighting Coil is available as an add on to the 5 and 8 9 8 models CD Unit The CD Units incorporate a printed circuit board PCB encased ina black resin housing to protect the circuitry from water and vibration Major component
47. s include a diode used to rectify current generated by the exciter coil a capacitor which charges the voltage supplied a thyristor which serves as a breaker and a zener diode used to control the thyristor Additional components such as resistors and SCH s are also provided depending upon the model 6 Ignition Coil Each ignition coil 4 consists of two windings or wire wrapped around a compacted ferrite material The coil has a primary and secondary terminal connection and a ground plate Through mutual induction the ignition coil transforms the output from the CD Unit to as much as 20 000 30 000 volts to fire the spark plug The ignition coil is generally adjacent to the CD Unit and attached to its mounting bracket with the exception of the 8 9 8 CD Unit where the ignition coil is molded as together as part of the CD Unit Main Key Switch and Emergency Stop Switch The emergency stop switch is connected to the CD Unit through an engine wiring harness When lanyard is removed from the emergency stop switch an input to the CD Unit is grounded This deactivates the CD Unit and the engine shuts down If the engine is fitted with the Remote Control feature pressing the stop switch on the Remote Control Unit will also around the CD Unit 36 Starting System Optional Electric Start 11 The starting system consists of the battery main key switch neutral start switch starter solenoid 3 starter motor 4 and 15 A engine fuse
48. special tools as indicated during servicing of the electrical system Avoid electrical shock e Do not handle spark gap tester during performance testing e Do not tough ignition coils exciter coil pulser coils or alternator coils while engine is cranking or running Use the spark gap tester to prevent the engine from starting when performing static ignition performance tests Use caution when performing tests with the engine cowling removed Do not wear loose clothing or jewelry Keep hair hands and clothing away from the flywheel and other moving parts After repairs are complete make sure all ignition and electrical leads are properly routed and clamped in their original positions Replace locking fasteners when their locking feature becomes weak Use only COTS factory parts Mercury Nissan or Tohatsu or Raider replacement parts Always inspect and test the start in gear prevention system before returning engine to mission readiness Always disconnect battery when not in use General Equipment Required Analog Multimeter Electronic Specialties Model 4 530 or equivalent Digital Multimeter Electronic Specialties Model KD 3200 or equivalent opark Gap Tester Stevens 5 13C 5 48 or equivalent Digital Pulse Tachometer 10 6000 RPM Electronic Specialties Model 327 or equivalent Variable Load High Rate Discharge Tester Electronic Specialties Model 700 or equivalent Hydrometer Heat Gun Torgue Wrench 150 in I
49. specific gravity Charge or replace as required See Battery Care and Maintenance this section Check the following electrical connections and make sure they are secure and free of corrosion Battery cables Starter solenoid wiring Starter motor wiring including ground connection Spark plug leads Ignition circuit wiring stop circuit wiring Charge circuit wiring Make sure shift lever or remote control lever operates freely e Attach lanyard to emergency stop switch see Section 2 32 Ignition System SYMPTOM Wilt not start Starts but Cranks but Low or high Peor accel Engine will d pops or stops eration low not shut Il not st pop speed miss CHECKS will not start backfires immediately top end RPM off Faulty stop circuit see Test 2 stop Circuit Test this section Faulty ignition system see Ignition System Performance Testing this section Faulty spark plug s See Section 2 Incorrect ignition timing or carburetor synchronization B See Section 2 Wl not crank CHECKS Internal battery Fou any Switch Not Neutral Qetectiye Neutral witch Faufty battery starter solenced starter motor cable Fauty starter solenced Faulty starter motor Damaged piron assembly 33 Charging System ave rom Battery does not maintain CHECKS charge archarges Wiring Connector Faulty
50. t and ignition coils before conducting the following procedure Reference the following electrical drawings for the exciter coil test The pulser and alternator coils have been removed from both illustrations for clarity Test 3 Exciter Coil Test 46 RED E 239 Be ALALT 4 oP L BLUE p aci JU ac ac o um L ba e 1 Y W 5 n Fi LER j 3 B Ui 8 9 The exciter coil test is used to determine the output voltage in DVA from the exciter Coll Located on the coil plate assembly 2 to the CD Unit while you are cranking the engine Disconnect terminals 4 5 8 and 9 Set the digital multimeter to ohms and connect the leads between the following Terminals to read the resistance of the exciter coil Connect multimeter between 4 and 8 terminals The meter should read 200 300 ohms 25 If the resistance is not within the indicated range replace the exciter coil set See Ignition System Repair Procedures Exciter Coil After repairs are made return to Ignition System Performance Flow Chart If the resistance is within indicated range proceed to the next step Connect multimeter between these terminals 4 and 8 set the analog multimeter to 400 on the scale Connect the RED tester lead to terminal 4 and BLACK tester lead to termanal 8 Attach lanyard to emergency stop switch Crank Raider outboard engine At cranki
51. t chipped cracked or comoded coil plate assembly Goil leads for integrity cut or cracked insulation and damaged connectors Broken or bent exciter coil laminations damaged exciter coil windings and missing xciter coil screws Broken cracked or misaligned pulser coils and missing pulser coil Screws Free motion of ignition timing link 1 Repair adjust and lubricate as needed see Section 2 79
52. t presents the correct sequence of performing ignition system performance tests to effectively and efficiently check for problems in starting and running the engine Follow the steps in the order listed until the problem is resolved and the ignition system meets specifications while the engine is running The chart references specific performance tests that must be completed to resolve each problem These tests are described in detail in the section which follows the flow chart The performance tests identified as Test 1 through Test 7 contain specific instructions for testing and servicing various ignition system components Use this section to perform the tests correctly in accordance with the factory recommendations NOTE After you complete each performance test refer back to the flow chart for the next step You must follow the flow chart until the ignition system meets specifications while the engine is running The only way to be sure that you have uncovered and repaired all ignition system problems is to follow these procedures in a systematic fashion If you have problems stopping Raider outboard proceed directly to test 2 Stop Circuit Test Ignition System Performance Testing Flow Chart 40 PROBLEM Engine will mot or run poorly See Test t Dees a Shark jump across Yes EACH spark gap no 3 to Test 5 Daeg ihe CD Unit output for EACH co
53. tall the propeller and propeller mounting hardware CAUTION Make sure propeller thrust holder is installed and seated against the propeller shaft oil seal before installing propeller f installed improperly propeller may be pushed into gearcase housing during tightening Adjustments CAUTION DO NOT attempt gearcase adjustments without proper manufacturer special tools and adequate knowledge of gearcase setup NOTE Specific assembly steps must be completed in order to perform the gearcase adjustments if these steps have not been performed refer to Assembly this section NOTE Unless otherwise indicated al gearcase adjustment specifications are based on measurements obtained with manufacturer special tools 1 Slide lower pump case onto driveshaft and seat into position on gearcase Secure lower pump case with bolts 1 and plain washers 2 18 36 2 Insert shimming gauge 3 into gearcase 40 gauge 368 72250 0 NOTE Comect positioning of the shimming gauge in the gearcase is cntical Make sure tapered side 4 is fully seated n bevel gearA bearing outer race with wat side 5 and notch 6 facing upward 19 3 Eliminate all looseness between dnveshatt and gearcase using one of the following methods Lift dnveshaft upward and tap down on gearcase with rubber mallet Slide acompression spring obtain locally over driveshaft and seat onto lower pump case Install backlash measur
54. th wrench and tighten nut 9 until stopper 6 contacts plate flange 7 7T Ramma tne sna meensle hearann m filu eaaten in hoi Propeller Shaft Needle Bearing Removal 1 Remove oil seal from propeller shaft housing 2 Remove roller bearing from propeller shaft housing by heating the housing with hot water 3 Place shaft 1 through needle bearing 4 Attach retainer A 2 to shaft groove 3 with raised surface of retainer facing bearing 5 Slide quide B 4 and flange B 5 onto shaft and secure with washer 6 and nut 7 6 Tighten nut 7 until needle bearing releases from housing 25 5 Installation 1 Attach retainer A 2 to shaft groove 3 with raised surface of retainer facing bearhg 2 Coat new needle bearing with gear oll Slide bearing onto shaft so bearing stamped surface faces retainer A 2 CAUTION Stamped surface of needle bearing must face retainer or bearing could be damaged during installation 3 Slide stopper B B and guide B 4 onto shaft and insert shaft in propeller shaft housing 4 Slide flange 5 onto shaft and secure with washer 6 and nut 7 5 Tighten nut 7 until stopper B B contacts flange B 5 6 Remove tools and verify needle bearing is fully seated in housing Bevel Gear A Bearing Outer Removal 1 Install bevel gear A bearing puller assembly Part Mo 33 72 755 0 2 Tighten bolt 1 until bearing race releases
55. the scale Insert the banana plug of the RED tester lead into the meter connection labeled DVA and the banana plug of the BLACK tester lead into the meter connection labeled COM Black lead to Terminal 6 and Red Lead to Terminal 8 Attached lanyard to emergency stop switch Crank engine At the cranking RPM the tester should show the following results minimum of 3 0 DVA If the pulser coil test results are not within the acceptable range replace the pulser coil 48 set See Ignition System Repair Procedures Pulser Coil Reconnect all wires disconnected during test Test 5 CD Unit Output test Cranking RPM B BLACK BLACK YELLOW NOTE Make sure all electrical terminals on Raider are connected during this test except those that are noted in the test procedure Check for continuity between chassis ground and the ground connection for the magneto plate DC Unit and Ignition Coil before conducting the following procedure Reference the electrical drawings for the CDE Unit Output Test Cranking RPM 12 The CD Unit Output Test Cranking RPM is used to determine the output voltage in DVA from the CD Unit 1 to the ignition coil 2 while you are cranking the engine 1 Remove two spark plug leads and remove spark plugs 3 13 2 Adjust spark gap tester 1 to 7 16 inches 11 mm 3 Connect each spark plug lead to spark gap tester 2 4 Secure spark gap tester to a clean groun
56. tinuity between terminals 2 and 8 If meter shows continuity replace starter solenoid 2 and clean chassis ground If the meter shows continuity replace starter solenoid 6 and clean chassis ground If the meter shows continuity replace starter solenoid 72 RED B BLACK G GREEN W WHITE YELLOW Alternator Coil Tests NOTE sure al electncal terminals are connected during this test except those that are noted in the fest procedure Check for continuity between chassis ground and the ground connection for the magneto plate CD Unit and ignition before conducting the following procedure Reference the following electrical drawings for the alternator test The pulser and exciter cols have been removed from both illustrations for clarity The alternator coil test is used to determine whether the alternator coils 1 located on the coil plate assembly 2 are open or shorted The output from the alternator coil goes to the rectifier requlator 9 1 1 Disconnect terminals 3 4 5 and 6 4 2 Set the digital multimeter to ohms and connect the leads between terminals 4 and 6 to read the resistance of the alternator coil The meter should indicate the following resistance Y W 0 65 0 98 73 0 31 0 47 W B 0 37 0 55 4 the resistance is not within the indicated range replace the alternator See Charging System
57. urface of upper pump case If not remove liner and re align locking tab with notch in upper pump case housing B Install lower pump case dowel pins 7 if removed o ring 8 117 9 Apply gasket sealant to both sides of guide plate gasket 8 Mount gasket and guide plate 10 on lower pump case 18 10 Apply gasket sealant to guide plate side of upper pump case gasket 11 Mount gasket on guide plate Installation 1 Apply a light coating of genuine grease or equivalent friction surface marine grease to the lower pump case driveshaft passage oil seal lips 1 and o ring 2 Apply an aerobic gasket maker to flanged surface 3 to provide adequate seal between lower pump case and 20 2 Slide lower pump case down dnveshaft and seat into position on gearcase 3 Slide the impeller down the driveshaft onto lower pump case 4 Insert impeller key 4 in driveshaft and align impeller slot with key Hold the impeller key in place and push impeller down until seated in position 5 Lubricate the impeller blades with soapy water and slide upper pump case down driveshaft Hold pump case securely and push downward while rotating driveshaft clockwise to seat the impeller CAUTION Do not rotate driveshaft counterclockwise Doing so will bend impeller blades in wrong direction and may weaken or damage the impeller 6 Ensure upper pump case is aligned and fully seated on the d
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