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Engine Service

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Details

UBUCid=AnnualEngineService
Category = Service
Optionality = recommended
Because = This procedure is done to avoid engine problems on trips and to train people to maintain them
Estimated Cost =
Frequency in Months = 12
Level = hard
Estimated time in hrs = 6

Procedure Log

This procedure has been completed on the following occasions.

Date	Member	Cost	Comment
2023-10-01	Lewis Hope	533.00	Engines serviced by the boat shed (All three)
2014-11-11	Dmitro Khroma	200.00	Marine engineers fee for overseeing course
2013-11-11	Tim Walsh	150.00	Budget estimate for engine service comes from sum of part costs=150
2013-11-11	Tim Walsh	180.00	Marine engineers fee for overseeing course=180
2012-01-01	Tim Walsh	754.00	Engines serviced by Samspeed neither worked on return wouldn't use Samspeed again

Itemlist

This procedure applies to the following items:

(be001), (be002), (be003),

Required Items

The following items are referenced in the procedure and will be required to complete it.

This table is populated automatically with the items that are referenced in the text in the instructions.

Item	Attributes	In Stores?
Small peen Hammer		true
multimeter		true
Gasket Scraper		true
10mm slot screwd		true
Engine muffs		true
Boat Spark Plugs	torque = 27Nm gap = 0.9-1.0mm NGKPartNo = NGK BR7HS-10	true
Spark Jump Tester		true
Engine Comp Guage		true
Engine Degreaser		true
engine trolley		true
Clamp Pad	TohatsuPartNo = 332-62101-0 PartListRef = 17-14	false
Small peen Hammer		true
Dead mans handle	TohatsuPartNo = 353-06821-0 PartListRef = 8-16-1	true
Motor Cover	TohatsuPartNo = 361S67500-4 PartListRef = 19-21	false
Trim Tab Anode	TohatsuPartNo = 348-60217-03 PartListRef = 15-24	false
Bracket Anode	TohatsuPartNo = 338-60218-2 PartListRef = 17-51	false
multimeter		true
Prop split pin	TohatsuPartNo = 951503-0325 MercuryPartNo = 18-8150264 length = 34mm thickness = 2.7mm PartListRef = 15-23	true
Small adjustable	nutsize = 22mm	true
Block of wood		false
Propeller Nut	TohatsuPartNo = 345-64121-0 torque = 29-39Nm PartListRef = 15-22	false
Propeller Washer	TohatsuPartNo = 345-64124-0 PartListRef = 15-21	false
Propeller Stopper	TohatsuPartNo = 348-64232-0 PartListRef = 15-20	false
Propeller shaft	TohatsuPartNo = 348-64211-0 PartListRef = 15-3	false
Propeller	PartListRef = 15-19	true
Thrust Hub	TohatsuPartNo = 3C8-64231-0 PartListRef = 15-18	false
Propeller	PartListRef = 15-19	true
Propeller shaft	TohatsuPartNo = 348-64211-0 PartListRef = 15-3	false
24C Marine Grease		true
Torque Wrench		true
Propeller Nut	TohatsuPartNo = 345-64121-0 torque = 29-39Nm PartListRef = 15-22	false
Bolt	TohatsuPartNo = 910114-5620 PartListRef = 1-15	false
Thermostat Cap	TohatsuPartNo = 3H6B01031-0 PartListRef = 1-13	false
Gasket Scraper		true
Thermostat Gasket	TohatsuPartNo = 346-01032-0 MercuryPartNo = 27-853702005 PartListRef = 1-14	true
Water Heater		true
pan or beaker		false
piece of string		false
Thermometer		false
Thermostat	TohatsuPartNo = 345-01030-0 open = 60 degrees C PartListRef = 1-12	false
101 Marine Grease		true
Fuel Pump Gasket	TohatsuPartNo = 346-04901-0 MercuryPartNo = 27-853702008 PartListRef = 5-2	false
clip	TohatsuPartNo = 9338-02215-0 PartListRef = 5-11	true
Fuel Pipe	TohatsuPartNo = 98AB-5-0210 PartListRef = 5-10	false
Choke link rod	TohatsuPartNo = 345-67191-1 PartListRef = 4-10	false
Carb Nuts	size = M6	false
Drain Screw	TohatsuPartNo = 345-03292-0 PartListRef = 4-1-2	true
fuel	type = unleaded	true
Drain Screw Seal	TohatsuPartNo = 336-03293-0 PartListRef = 4-1-3	true
Carb bowl screws	TohatsuPartNo = 922503-6412 PartListRef = 4-1-5	false
Float Chamber	TohatsuPartNo = 336-03221-0 PartListRef = 4-1-1	false
Carb Service Kit	TohatsuPartNo = 345-87122-0 MercuryPartNo = 853780A1 PartListRef = 24-3	true
Adjust Screw	TohatsuPartNo = 345-03266-0 PartListRef = 4-1-23	false
CarbCleaner		true
Fuel Line	diameter = 10mm	false
10mm slot screwd		true
Oil vent plug	TohatsuPartNo = 332-60005-2	true
Oil Container		false
Oil vent plug	TohatsuPartNo = 332-60005-2	true
Gear Oil	volume = 420ml type = API GL-5: SAE#80 to #90	true
Oil vent gasket	TohatsuPartNo = 332-60006-0 MercuryPartNo = 8M0082880 PartListRef = 14-4 thickness = 1.2mm	true
Gear oil pump		true
Gear Oil	volume = 420ml type = API GL-5: SAE#80 to #90	true
Punch	diameter = 2.4mm	false
Small peen Hammer		true
Spring Pin	TohatsuPartNo = 951403-0312 MercuryPartNo = 17-952189 length = 12mm thickness = 3mm PartListRef = 16-19	true
Gear box bolts	TohatsuPartNo = 910113-5840 PartListRef = 14-2	true
Water pump bolts	TohatsuPartNo = 910113-5652 PartListRef = 14-24	false
Water pump kit	TohatsuPartNo = 361-87322-0 MercuryPartNo = 853792T01 PartListRef = 24-9	true
101 Marine Grease		true
Engine Tuner		true
Starter Lock Rod	TohatsuPartNo = 345-05217-1 PartListRef = 12-12	false
Bolts	TohatsuPartNo = 910114-0625 PartListRef = 11-1-18	false
Bolt	TohatsuPartNo = 910114-0830 PartListRef = 11-1-12	false
Recoil Starter	TohatsuPartNo = 345-05000-1 PartListRef = 11-1	false
Starter rope	TohatsuPartNo = 345-05013-1 MercuryPartNo = 50-8126391 length = 205cm thickness = 4mm PartListRef = 11-1-21	true
Boat Spark Plugs	torque = 27Nm gap = 0.9-1.0mm NGKPartNo = NGK BR7HS-10	true
Timing Link Rod	TohatsuPartNo = 348-63715-0 PartListRef = 6-10	false
Throttle limit	TohatsuPartNo = 921506-0520 PartListRef = 6-6	false
Tacheometer		true
Marine Grease Gun		true

Instructions

Check Tools

Perform the CheckToolBox as these tools are required during the engine service. Tools Small peen Hammer, multimeter, Gasket Scraper and 10mm slot screwd are also vital.

Pre-Service Tasks

This step involves turning the engine over so it must be connected to a cooling water supply using the Engine muffs to prevent damage to the water pump impeller

Keep clear of the prop in case the engine hasn't been drained of fuel and starts Remove the Boat Spark Plugs and inspect for condition against the Spark Colour Chart

Using the Spark Jump Tester check the spark jump on each HT lead in turn. The spark should jump at least 2cm and its shape should be straight with a violet blue colour. A red or curved spark may indicate a coil defect. Using the Engine Comp Guage measure and record the compression of both engine cylinders they should be within 15% of each other. Clean the engine thoroughly using a Engine Degreaser.

Set up

Mount the engine securely on its engine trolley. If the Clamp Pad fall off then replace and tighten onto the ball of the Small peen Hammer to fix.

Remove Dead mans handle It is vital that the engine is not accidently started during this operation

Remove Motor Cover Engine Manual, Seamanship Manual

Inspect Anodes

Refer to Engine Manual and SELCO.

Inspect: Trim Tab Anodeand Bracket Anode if they've degraded more than 30% then replace. Using tool multimeter verify an electrical connection between each anode and the engine body.

Grease Propeller Shaft

Refer to Engine Manual page="2-28". Remove and discard Prop split pin.

Using Small adjustable with Block of wood between the propeller and anti-cavitation plate to stop the propeller turning undo Propeller Nut.
Slide parts Propeller Washer and Propeller Stopper from the splines of the Propeller shaft.
Remove Propeller.
Remove Thrust Hub noting its orientation.
Clean and grease the Propeller and Propeller shaft using 24C Marine Grease.
Reassemble using Torque Wrench to torque Propeller Nut to its specification.

Verify Thermostat

Refer to Engine Manual section="5-27"

Undo Bolt. Remove Thermostat Cap and using Gasket Scraper remove and discard Thermostat Gasket.
Using a suitable Water Heater the thermostat suspended in a pan or beaker of water suspended on a piece of string clamped in the thermostat valve.
Using a Thermometer verify that Thermostat opens and drops at the correct temperature.
Reassemble using 101 Marine Grease

Check Fuel Pump

Unbolt the Fuel Pump.
Replace item Fuel Pump Gasket.
Check fuel pump is not leaking

Service carb

Refer to SELCO section="3-20" and Engine Parts List

Undo the clip
disconnect Fuel Pipe.
Disconnect the Choke link rod.
Remove the 4 Carb Nuts and withdraw the carburettor.
Undo the Drain Screw to drain fuel from the carb and replace the Drain Screw Seal
Undo the 4 Carb bowl screws.
Drop the Float Chamber down.
Replace the parts in Carb Service Kit.
Carefully turn the Adjust Screw in (clockwise) counting the turn until it gently reaches its end.
Record the number of turns taken and then remove it.
Clean and dry all parts with CarbCleaner and reassemble.

Replace Fuel Line

If any of the fuel line is old it should be replaced using Fuel Line

Replace Gear Oil

Ensure the engine is upright.
Using the 10mm slot screwd Loosen the top vent Oil vent plug.
Place an Oil Container under the skeg
Remove the lower fill Oil vent plug to let the oil drain.
Look for any metal particles on the magnet.
Check the Gear Oil for water. If significant metal or water is present then the gearbox must be disassembled and inspected.
Replace the two Oil vent gasket.
Using the Gear oil pump fill the gearbox with 420ml of Gear Oil from the lower vent plug Engine Manual, then replace the top to hold the oil in through suction then replace lower.

Remove lower leg

Refer to SELCO section="7-15"

Move the engine into forward gear.
Using Punch and Small peen Hammer drive out Spring Pin
Remove the 4 bolts and washers Gear box bolts
Pull down on the gearbox and pull the drive-shaft and separate it from the exhaust housing.
Guide the gear shift rod and drive-shaft out of the exhaust housing.

Replace Water pump

Refer to SELCO section="5-17"

Remove the bolts Water pump bolts
Replace the parts in the Water pump kit and assemble gaskets and bolts with 101 Marine Grease

Decarbonise

Refer to SELCO section="2-40" and SELCO section="6-5" and SELCO section="6-59"

During combustion carbon is deposited within the combustion chamber there are various ways of removing it, this procedure uses a chemical method. Start the engine up and use a can of Engine Tuner into the carb intake of a running engine.

Replace Starter Cord

Disconnect the Starter Lock Rod.
Remove the two Bolts and the Bolt at the back of the starter unit.
Lift off the Recoil Starter.
Replace the Starter rope

Refer to SELCO section="10-9"

Tune up

Remove and replace the two Boat Spark Plugs checking they have the correct gap before re-installing. SELCO section="2-57" With the engine set up and running, check and adjust ignition timing Timing Link Rod. Then adjust the Throttle limit so that the engine idles at 850 RPM (SELCO section="2-19") measured using a Tacheometer.

lubricate

Using the Marine Grease Gun lubricate all grease nipples and apply grease to all sliding surfaces

APPartNo	AP5
id	bdp01
store	false

APPartNo	AP5A
id	bdp02
store	true

APPartNo	AP18A
id	bdp03
store	true

APPartNo	AP14
id	bdp04
store	true

APPartNo	AP19
id	bdp05
store	true

PartListRef	15-22
TohatsuPartNo	345-64121-0
id	bep20
store	false
torque	29-39Nm

MikesNo	APA48
PartNo	AP50/24
colour	black
id	rgp03
length	24inch
store	true

MercuryPartNo	27-853702005
PartListRef	1-14
TohatsuPartNo	346-01032-0
id	bep03
store	true

PartListRef	1-12
TohatsuPartNo	345-01030-0
id	bep04
open	60 degrees C
store	false

MercuryPartNo	853780A1
PartListRef	24-3
TohatsuPartNo	345-87122-0
id	bep07
store	true

MercuryPartNo	8M0082880
PartListRef	14-4
TohatsuPartNo	332-60006-0
id	bep25
store	true
thickness	1.2mm

MercuryPartNo	17-952189
PartListRef	16-19
TohatsuPartNo	951403-0312
id	bep26
length	12mm
store	true
thickness	3mm

MercuryPartNo	853792T01
PartListRef	24-9
TohatsuPartNo	361-87322-0
id	bep29
store	true

MercuryPartNo	27-853702008
PartListRef	5-2
TohatsuPartNo	346-04901-0
id	bep30
store	false

MercuryPartNo	50-8126391
PartListRef	11-1-21
TohatsuPartNo	345-05013-1
id	bep38
length	205cm
store	true
thickness	4mm

PartListRef	8-12-1
TohatsuPartNo	3C7-06921-0
id	bep39
resistance	5 Ohm
store	true
type	LB05EP

MercuryPartNo	18-8150264
PartListRef	15-23
TohatsuPartNo	951503-0325
id	bep40
length	34mm
store	true
thickness	2.7mm

InsideDiameter	1.78mm
Section	21.78mm
Size	BS003
TypicalUse	Some HP swivels
hardness	60
id	or002
store	true

InsideDiameter	2.900
Section	1.78
Size	BS006
TypicalUse	BC power inflate
hardness	60
id	or003
store	true

InsideDiameter	6.070
Section	1.78
Size	BS010
TypicalUse	Low-Pressure Hose/2nd Stage, Regulator Cylinder Valve Stem
hardness	60
id	rgp13
store	true

InsideDiameter	7.660
Section	1.78
Size	BS011
TypicalUse	Standard Low-Pressure Port/Hose (3/8 UNF)
hardness	60
id	rgp11
store	true

InsideDiameter	9.250
Section	1.78
Size	BS012
TypicalUse	High-Pressure Port/Hose (7/16 UNF), Manifold and Manifold Port Plugs
hardness	90
id	rgp12
store	true

InsideDiameter	10.82
Section	1.78
Size	BS013
TypicalUse	Large Low-Pressure Port/Hose (1/2 UNF)
hardness	60
id	or007
store	true

InsideDiameter	12.42
Section	1.78
Size	BS014
TypicalUse	Standard Yoke Regulator/K-valve
hardness	90
id	cpp23
store	true

InsideDiameter	14.00
Section	1.78
Size	BS015
TypicalUse	Cylinder Valve Bonnet Nut
hardness	60
id	or009
store	true

InsideDiameter	9.190
Section	2.62
Size	BS110
TypicalUse	MDE Yoke Valves
hardness	90
id	or010
store	true

InsideDiameter	10.78
Section	2.62
Size	BS111
TypicalUse	Small DIN Regulator/Valve
hardness	90
id	or011
store	true

InsideDiameter	12.37
Section	2.62
Size	BS112
TypicalUse	Standard DIN Regulator/Valve (Nearly all DIN regulators)
hardness	90
id	or012
store	true

InsideDiameter	18.72
Section	2.62
Size	BS116
TypicalUse	Cylinder with Small Neck/Valve (7/8 UNF - 'Genesis' 3500 psi Steel cylinders)
hardness	90
id	or013
store	true

InsideDiameter	18.64
Section	3.53
Size	BS210
TypicalUse	BC dump valves
hardness	60
id	or014
store	true

InsideDiameter	25.00
Section	3.53
Size	BS214
TypicalUse	Cylinder with Large Neck/Valve (3/4 NPS - All Aluminum, most Steel cylinders)
hardness	90
id	or015
store	true

InsideDiameter	26.70
Section	1.78
Size	BS023
TypicalUse
hardness	60
id	or016
store	true

InsideDiameter	20.35
Section	1.78
Size	BS019
TypicalUse
hardness	60
id	or017
store	true

InsideDiameter	21.89
Section	2.62
Size	BS118
TypicalUse
hardness	60
id	or018
store	true

InsideDiameter	2.570
Section	1.78
Size	BS005
TypicalUse
hardness	60
id	or019
store	true