OUTBOARD MOTORS - Pacific Community
OUTBOARD MOTORSFOR PACIFIC ISLAND MARINERSRESTRICTED CLASS 6-MASTER/ENGINEERSPC O22CLEARNER’S GUIDESECRETARIAT OF THE PACIFIC COMMUNITYGOVERNMENT OF TAIWAN/ROC
TABLE OF CONTENTSTABLE OF CONTENTSPART A GENERAL INFORMATIONPART B COURSE INFORMATION234SECTION 1 OUTBOARD MOTOR OPERATION5THE OUTBOARD MOTORFUEL SYSTEM (portable)FUEL SYSTEM (fixed)COOLING SYSTEMINTERNAL LUBRICATION SYSTEMMOUNTING AN OUTBOARD MOTORSTARTING PROCEDURE6789101112SECTION 2 TROUBLESHOOTING14ENGINE FAILS TO STARTENGINE OVERHEATSELECTRICAL FAULTENGINE HAS BEEN SUBMERGED15151516SECTION 3 OUTBOARD MOTOR MAINTENANCE17FUEL SYSTEMGEAR-BOX OIL CHANGEEXTERNAL LUBRICATIONCOOLING SYSTEMSPARK PLUGSFUSESBATTERIESPROPELLERSZINC ANODESPERIODIC INSPECTION AND SERVICE18202122232424242425
PART A1.GENERAL INFORMATIONIntroductionThe Outboard Motors module of the Class 6 Master/Engineer certificate has beendesigned and is intended for the skippers of small boats (less than 15 meters inlength), powered by outboard motors and operating in near coastal waters. Thecontent of the module has been modeled on section 3 of the Engineering module(SPC 022) of the Class 6 Master/Engineer course developed by the RegionalMaritime Programme of Secretariat of the Pacific Community. It has beenmodified to meet the requirements of small-boat skippers in Pacific Islandcountries and territories who primarily use outboard motors as the main form ofboat propulsion.This Learner’s Guide is designed for students who are being trained andassessed on the Outboard Motors module (SPC 022C), as part of a Class 6Master/Engineer course. Attendance at the module sessions and studying of theLearner’s Guide should be sufficient for understanding the operation of a smalloutboard motor and being well skilled in trouble shooting and maintenanceprocedures.2.Programme developmentThe resources materials were produced with financial support from theGovernment of Taiwan/ROC and compiled by Grant Carnie, Manager of Fishing &Maritime Programmes, Australian Fisheries Academy, Adelaide, South Australia.The materials were developed through consultation with staff of the FisheriesTraining Section, Coastal Fisheries Programme, Secretariat of the PacificCommunity and regional experts on fishing and maritime training. Resources fromAustralia and New Zealand, SPC training materials and valuable resourcematerial such as the Australian Boating Manual by Captain Dick Gandy wereused as a guideline in developing materials that were relevant to small-boatoperators in the Pacific Island region.-3-
PART B1.COURSE INFORMATIONModule nameOutboard Motors SPC 022C.2.PrerequisitesThere are generally no prerequisites for completing the Outboard Motors modulehowever, the prerequisites for the Class 6 Master/Engineer certificate (Full orRestricted) are a Safety Certificate and some sea time. Refer to local regulationsfor any specific country requirements.3.Course durationTwo days (at the discretion of the course provider).4.AssessmentCandidates doing the Outboard Motor module will be assessed as they arecompleting the competencies.5.Recognition of Prior Learning (RPL)If students have been assessed previously for some of the learning outcomes orbelieve that they are already competent in certain areas, they can apply to thetrainer/assessor to have these particular skills recognised.6.ResourcesThe resources required by anyone attending the Outboard module are minimal.An in-depth study of this Learner’s Guide and attendance at all sessions of thetraining should be sufficient for a candidate to successfully complete the module.Candidates should check with the training institution offering the course withregard to clothing requirements for the practical components.Anyone wanting additional resource materials could borrow or purchase a copy ofThe Australian Boating Manual by Captain Dick Gandy or FAD Fishing SkillsWorkshops, SPC Module 2, “Safety at sea and Small Boat FAD Fishing” orSection 3 (Outboard Motors) of the Engineering module (SPC 022) from SPC.-4-
SECTION 1OUTBOARD MOTOROPERATION-5-
THE OUTBOARD MOTORMost outboard motors are petrol-driven, two-stroke engines although four-strokeengines are becoming more common. Outboard motors may have from one to eightcylinders.A 2-CYLINDER 25 HP YAMAHA OUTBOARD1. Manual start recoil handle2. Choke knob3. Overheat warning lamp4.5.6.7.8.9.10.11. Cooling water inlet12. Propeller13. Zinc anode used for steeringadjustmentElectric start button14. Anti-cavitation plateGear-shift lever (usually absent on 15. Rod for adjusting trim anglevery small motors which arepivoted by 180 for reverse drive)Throttle control & steering handle16. Rope attachmentEmergency-stop (kill) switch, lock 17. Shallow-water lever for raisingplate and lanyardmotorEngine securing clamp18. Battery leadTilt lock for preventing accidental 19. Wiring harnesstiltingAnti-splash plates20. Remote control attachment-6-
FUEL SYSTEM (portable)Portable fuel tanks for outboard motors are fitted with a manual priming bulb. It issqueezed a few times to draw fuel when first starting the engine or to continue toprovide fuel to the engine in case of fuel pump failure. Care must be taken to ensurethat the bulb is not over squeezed as this may cause leaks in the fuel system or floodthe engine with too much fuel, making it difficult to start. The bulb should besqueezed only until it becomes firm.The tank is also fitted with a breather screw, which must be loosened to vent thetank when operating the engine. Ensure the breather screw is fully closed whentransporting the tank to prevent spillage.The fuel line connection to the tank should be self-locking, and the connection to themotor should be either the quick-release type or automatic shut- off type when thefuel line is disconnected.Portable fuel tanks should not be left partially empty for long periods as the fuel canbecome contaminated with moisture buildup and algae growth. They should be filledashore to avoid spillage on board and secured on board to prevent movement.PORTABLE FUEL SYSTEM1. Filler cap2. Breather screw-7-
FUEL SYSTEM (fixed)FIXED FUEL TANKabcdFuel filling point/capAnti-siphon fittingFuel tank breatherFuel level indicator (float)efg-8-Manual priming bulbExternal fuel filterFlexible fuel line
COOLING SYSTEMThe outboard cooling system is the direct, raw water type. Sea water is drawn up byan impeller pump, made of plastic or rubber, which is located in the lower leg. It thenpasses through the galleries in the engine and out through the exhaust.A small stream of water is also bled off somewhere in the system as a tell tale sign,indicating to the operator that water is circulating throughout the cooling system. Athermostat maintains a minimum operating temperature. An audio alarm and a “hotlight” are also sometimes fitted.THE OUTBOARD MOTOR COOLING SYSTEM-9-
INTERNAL LUBRICATION SYSTEMTwo-stroke engines need their crankcase for compression, therefore, a circulating oilsystem is not possible. Their lubrication is achieved by mixing oil with petrol in one oftwo systems. Oil is either poured into the fuel tank and mixed by shaking or mixed asrequired by an oil injection pump known as the “Variable Ratio Oiling” (VRO). Moderntwo-stroke engines are usually fitted with such precision blend systems. Diesel andfour-stroke petrol engines are lubricated by oil circulation from the sump (crankcase).Insufficient oil will cause the engine to overheat and eventually seize. Excessive oilwill foul the spark plugs, cause smoky exhaust and heavy carbon deposits. Both willcause engine failure.The required amount of oil per litre of petrol varies between 1:100 and 2:100. Themanufacturer’s recommendations should be followed. Paint the correct oil/petrol ratioon the fuel tank and use only the recommended two-stroke outboard motor oil.With oil injection systems, the VRO pump automatically adjusts and mixes theamount of oil required by the engine under different conditions and speeds. It mayeven be fitted with a no-oil alarm to warn the operator when the engine is receivingno oil. If the reservoir of the VRO pump runs dry during engine operation, theoperator should stop the engine and refill it.YAMAHA PRECISION BLEND LUBRICATION SYSTEM (VRO)1. Lube oil tank2. Oil injection pump3. Carburetors4. Fuel filter5. Fuel pump- 10 -
MOUNTING AN OUTBOARD MOTORThere are two methods of securing an outboard motor to the stern of a vessel. Oneinvolves the use of hand-tightened screw thread clamps. These clamp the transom ofthe vessel between the engine mounting bracket and the screw thread plates. Theirtightness should be checked each time the engine is used. A safety rope or chainshould also be used to secure the motor to the vessel and prevent the motor fromdropping from the stern if the clamps get loose during vessel operation. On largeroutboard motors, the mounting bracket is usually bolted through the transom plate.This is a more secure method, but regular checks must be made for looseness.Trim AngleBy changing the outboard motor’s drive angle, thevessel’s bow can be made to rise or fall. Theperformance and stability of a vessel depends agreat deal on correctly trimming the outboard. Thecorrect trim angle depends on the vessel’s handlingcharacteristics, the size of the outboard, the seaand loading conditions. Care must therefore betaken to ensure the outboard is trimmed correctlyunder different sea and loading conditions.On smaller outboards, the trim angle is adjustedmanually by moving an adjusting rod to differentholes in the mounting bracket. The bigger outboardsusually have a Trim Switch fitted on the remotecontrol lever.YAMAHA’S TRIM ANGLEADJUSTING RODINSUFFICIENT ANGLECORRECT ANGLEEXCESSIVE ANGLE(Bow digs)(Top performance)(Transom drags)- 11 -
STARTING PROCEDURE1.2.3.4.5.6.7.Lower engine to running position and check the following Fuel level Oil level (if separate lube oil tank) Engine mount secure Propeller clearLoosen air-vent screw on fuel tank cap by 2 or 3 turns (if fitted)Firmly connect fuel hose to both fuel tank and engineSqueeze primer bulb until it becomes firmMake sure engine is in neutral, and throttle grip on handle in START positionClip lock plate onto emergency-stop switch and tie lanyard to your wristPull out choke if starting cold engineSTARTING A YAMAHA OUTBOARD- 12 -
8.9.10.Start motor by pulling starter handle (manual) or pushing starter switch(electric)Push choke back inCheck for “tell tale” water stream and allow engine to warm up before movingoffSTARTING A YAMAHA OUTBOARD (CONTINUED)- 13 -
SECTION 2TROUBLESHOOTING- 14 -
ENGINE FAILS TO START1.2.3.4.5.6.7.8.9.10.11.12.Check level of fuel in tankCheck air vent screw on tank openCheck arrow on primer bulb to ensure fuel line is connected the right wayCheck fuel lines connected tightly and bulb primedCheck engine is in neutral and throttle control in START positionInspect battery and connections (electric start)Check emergency-stop (kill) lock plate connected correctly to switchInspect fuel filters (fuel tank, external, internal) and clean if necessaryCheck internal fuel filter to ensure filter casing is tightly screwedInspect spark plugs and clean if necessaryCheck fuel pump to ensure membrane is not torn outCheck carburetor to ensure that draining screw is not openedIf engine starts but stops almost immediately:1.Check choke has been pushed back in2.Checks 1 to 12 aboveIf engine starts but stops when gear is engaged:1.Check propeller is not blocked2.Inspect spark plugs and clean if necessaryIf engine still fails to start seek mechanical adviceENGINE OVERHEATS1.2.3.Check water pump and thermostat operating correctly by checking if “tell tale”water stream is at normal rateInspect/clear water intakes (plastic bags?)Check oil level if separate lube oil tank is fittedIf problem cannot be rectified seek mechanical adviceELECTRICAL FAULT1.2.3.4.5.Check for loose or dirty battery connectionsCheck electrolyte in battery at correct levelCheck level of charge of battery with hydrometerCheck “kill” switch is connected correctlyInspect spark plugs and connections and clean or replace if necessaryIf problem cannot be rectified seek mechanical advice- 15 -
ENGINE HAS BEEN SUBMERGEDIf outboard motor mounts are not checked regularly, the engine can shake loose andfall overboard. The safety rope or chain should be short enough to prevent theengine going underwater. If these measures are not followed, you will have to dealwith an outboard motor which has been fully submerged.Once an outboard has been immersed in sea water, it must be serviced immediatelyas electrical components and internal parts will begin to corrode. If the engine cannotbe serviced immediately, it should be re-submerged in fresh water to preventcorrosion until it can be serviced.Servicing after submersion1.2.3.4.5.6.7.8.9.10.Remove engine cover and rinse powerhead with fresh waterDisconnect spark plug leads and remove spark plugsDisconnect fuel lines from engine. Drain and clean all fuel lines and fuel tankPlace engine in horizontal position (spark plug openings down) and work allwater out by slowly rotating flywheel about 20 times or until there is no sign ofwaterDrain carburetor: place engine in upright position and remove carburettor fordisassembly and drainingDisassemble, clean and flush the starter, electrical connectors and allelectrical equipment with fresh water. Then treat them with a water displacingelectrical spray and thoroughly dry them before assemblyInject outboard lubricant into spark plug holesIf engine shows evidence that sand may have entered it (sand under theengine cover or a slight grinding or scraping when the flywheel is rotated) donot attempt to start the engine. It must be disassembled and cleaned.Reassemble the parts. Start the engine and run for 30 minutes in fresh water.If engine fails to start, remove spark plugs again and see if water is present onelectrodes, if so, blow out water and reinstall or replace with new plugs.Repeat starting procedure- 16 -
SECTION 3OUTBOARD MOTORMAINTENANCE- 17 -
FUEL SYSTEMThe fuel system should be regularly inspected for leaks, cracks or malfunction.FUEL SYSTEM INSPECTION1.2.3.4.Carburetor leakageFuel pump malfunction or leakageFuel tank leakageFuel hose joint leakage5.6.7.8.- 18 -Fuel hose cracks or other damageFuel filter leakageFuel connector leakagePrimer bulb leakage or damage
Cleaning the portable fuel tank and its filterAt least once every six months, empty the fuel tank, pour a small quantity ofdetergent, and clean the tank thoroughly by shaking it. Flush the inside with freshwater and drain it completely. Repeat the flushing and draining procedures severaltimes until all the detergent has been removed from inside the tank.Thoroughly clean the tank filter (located at the end of the suction pipe) with detergentand air dry.FUEL TANK AND TANK FILTER CLEANINGCleaning the engine fuel filterThe engine fuel filter should be cleaned every 20 hours of operation or every month.In some countries, the fuel quality is poor so cleaning of the filter should be carriedout more frequently.Stop the engine before removing thefilter. Keep away from sparks, cigarettes,flames or other sources of ignition.Remove the fuel hoses and clean thefilter with detergent. Air dry the filter thenput it back in place making sure the filtercase is tightly screwed.FUEL FILTER CLEANING- 19 -
GEAR-BOX OIL CHANGEGear-box oil should be changed every 100 hours of operation or six monthly,whatever comes first.Drain the gear-box into a container by opening the oil-drain plug (2) then the oil-levelplug (1). With the outboard motor in the upright position, inject the recommendedgear-box oil into the oil-drain plug hole (2) until it starts to flow out of the oil-level plughole (1). Insert and tighten both the drain plugs.CHANGING THE GEAR-BOX OIL- 20 -
EXTERNAL LUBRICATIONEvery three months, a recommended (marine) grease should be injected throughthe specified points (grease nipples) on the outboard motor. This procedure willensure all moving parts operate smoothly.YAMAHA GREASE POINTS- 21 -
COOLING SYSTEMThe outboard motor cooling system is the part of the engine most likely to causeproblems due to salt, sand and dirt entering the system. Water pumps should beinspected and the pump impeller changed every 200 hours of operation or once ayear, whatever comes first.It is important to keep an eye on the tell tale water stream as a drop in flow is likely toindicate a problem with the cooling system. It could be a blockage around waterintakes (plastic bags in the water are a common cause), sand in the system, waterpump failure, damaged pump impeller and so on. It may also simply be a blockage ofthe outflow (sand) from the tell tale although the engine cooling system is operatingcorrectly.Flushing the cooling system with fresh waterYou can help prevent some of the problems caused by salt buildup in and around themotor by washing the body and flushing the cooling system with fresh water afteruse. To clean the cooling water passages, mount the motor in a tank partly filled withfresh water (water level above the anti-cavitation plate). Put the motor into neutral,start and run at low speed for a few minutes. This procedure should be carried out atleast once every month. If possible, run the engine in fresh water on completion ofeach trip.THE COOLING SYSTEM1. Water surface2. Lowest water level- 22 -
SPARK PLUGSCleaning or replacing spark plugsThe spark plugs of an outboard motor can become oily and coated in a black depositin a short time. When this happens the motor will run roughly or may even fail to start.Spark plugs should therefore be removed and inspected after 20 hours of operationor once a month. If spark plugs are dirty they should be cleaned or replaced withnew ones as recommended for that type of motor.SPARK PLUG CONDITIONChecking for sparkIf an outboard turns over but does not start, the spark plug should be checked forspark to find the problem. To do this, you should first make sure that there is goodventilation and no fuel vapour present. Remove the spark plug from the engine andreconnect it to its lead. Hold its body against the engine block (to earth it) and turnthe engine over. Spark should be seen across the gap. Keep the spark plug awayfrom the plug hole to safeguard against the risk of ignition.If spark present: Plugs are dry - check fuel supply, lines, filtersPlugs are dirty - clean or replace plugsPlugs are wet - engine flooded, let stand for a while and try againIf no spark: Loose or wet wiring. Check all wiring connections for tightness, shouldbe clean and dry. Spray dirty, wet wiring with water-repellent spray. If engine stilldoes not start, seek mechanical advice.Take care when replacing spark plugs not to over tighten as this may damage theplug or make it difficult to unscrew.- 23 -
FUSESFuses protect electrical wiring and equipment from damage or fire due to electricaloverloads. A fuse is designed to melt when overheated due to excessive currentflowing through an electrical circuit. The circuit becomes open, no more current flowsthrough it and therefore the electrical equipment is protected.If a fuse does “blow”, it should be replaced with one that is recommended for thatpurpose. Some spare fuses should be carried on board in case this happens. If afuse repeatedly “blows”, it indicates a serious problem which should be looked at bya qualified person to find the cause.BATTERIESBatteries should be inspected regularly to make sure they are secured in place tostop movement as a vessel rolls. They should also be kept topped up with distilledwater to just above the plates. Batteries must be kept dry and clean, and theconnections tight. The terminal posts should be coated in Vaseline to prevent themfrom corroding.Batteries contain hydrogen gas, which is highly explosive so must be kept clear ofsparks, heat, flames, lit cigarettes and so on. T
THE OUTBOARD MOTOR Most outboard motors are petrol-driven, two-stroke engines although four-stroke engines are becoming more common. Outboard motors may have from one to eight cylinders. A 2-CYLINDER 25 HP YAMAHA OUTBOARD 1. Manual start recoil handle 11. Cooling water inlet 2. Choke knob 12. Propeller 3. Overheat warning lamp 13.
Manual - Tohatsu M120A2 Outboard Motor Manual for Tohatsu M120A2 Outboard Motor. View and download the pdf, find answers to frequently asked Can I use motoroil for my car in my 2-stroke Tohatsu outboard motor? Is my Tohatsu outboard motor also suited for saltwater use? Verified Yes, all Tohatsu outboard motors are able to tohatsu 2 stroke .
A full demonstration of this model outboard operation has been performed with the new owner or operator of this outboard. All safety aspects of operating this outboard have been explained and demonstrated in detail. The outboard has been correctly installed to the Owner’s boat.
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