Tohatsu charging system install on 2005 4HP 4-stroke

[vt17]

I ordered the charging system/rectifier for my 4HP Tohatsu, and it's here. The instructions it came with have rather unintuitive cad sketches ...and no description of disassembly is given. Is there a good full outline of the steps I need to take anywhere? Ideally with a picture or two?

My guess is that I need to remove the fuel line that runs over the recoil. Then remove the neutral interlock that goes to the recoil. Then remove the 3 bolts that hold the recoil on (is this easy or does some coil spring try to explode like on some of the older OMCs?).
Then ...I can't see any more but based on some things I've read I also need to remove the flywheel ...what tools do I need to do that? Then does it start becoming intuitive?
As for the rectifier ...which side of the motor does it mount to? I see a threaded hole on each side, but the picture in the instructions does not look anything like either side of my engine. I'm guessing it's mounted on the same side as the FNR shifter but not sure.
In the picture, the wires appear to exit where the staus LED is ...but there's no hole near there. Where should they exit?

Any help - full or partial - would be very much appreciated! Thanks in advance!

- Patrick

 

[pvanv]

Re: Tohatsu charging system install on 2005 4HP 4-stroke

Patrick,

You will want a Factory service manual, available at any Tohatsu/Nissan dealer. Also a parts catalog, available on Elvin's website at http://www.internetoutboards.com/PartsCatalogMenu.htm

Yes, you're on the right track: The coil goes under the flywheel, and the rectifier fastens outside.

 

[vt17]

Re: Tohatsu charging system install on 2005 4HP 4-stroke

Thanks Paul!

The exploded diagrams from the parts manual helped a lot. Everything seemed to go smoothly, though removing the flywheel was a little hairy. I used a combination of a puller and a hammer and I don't think there are any issues. The engine still runs, at least....

Just so it's out there, if anyone is trying to do this with a puller, you will need three 6mm (x1mm) screws for the flywheel. Length depends, obviously, on the puller you use. They have smaller heads than what will work well with most of the $20 pullers out there, so I'd get some fender washers as well.

 

[pvanv]

Re: Tohatsu charging system install on 2005 4HP 4-stroke

Glad it went OK. If you will be doing a few of these, Tohatsu parts has a puller made for the job. Too much shock to the flywheel can crack it -- easier than you think. I believe that if you drop the flywheel on the floor, the factory says to replace it, for example.