910103-0625 Tohatsu BOLT

This engine uses high voltage to control the fuel injectors.Disconnect electronic fuel injector enable circuit connector to prevent personal injury.Do not come in contact with the fuel injector terminals while the engine is running.
Note: Valve lash is measured between the rocker arm and the valve bridge. All measurements and adjustments must be made with the engine stopped and the valves fully closed.Valve Lash Check
An adjustment is not necessary if the measurement of the valve lash is in the acceptable range. Check the valve lash while the engine is stopped. The range is specified in Table 1.
Table 1
Quick Reference for Engine Valve Lash Setting
Inlet Valves Exhaust Valves
Valve Lash Setting 0.38 0.08 mm (0.015 0.003 inch) 0.76 0.08 mm (0.030 0.003 inch)
TC Compression Stroke of No. 1 Piston 1-2-3-7-8-10 1-2-5-6-9-10
TC Compression Stroke of No. 11 Piston(1) 4-5-6-9-11-12 3-4-7-8-11-12
Firing Order 1-10-9-6-5-12-11-4-3-8-7-2(2)
(1) 360° from TC compression stroke
(2) Refer to Illustration 1 in order to locate the No. 1 cylinder.If the measurement is not within this range, adjustment is necessary. Refer to "Valve Lash Adjustment".Valve Lash Adjustment
Illustration 1 g01386737
(A) Inlet valves
(B) Exhaust valves
(C) Left side of the engine
(D) Cylinder number
(E) Flywheel end of the engine
(F) Front of the engine
(G) Right side of the engine
Illustration 2 g06580941
Typical example
(1) Valve adjustment locknut
(2) Exhaust adjustment screw
(3) Exhaust rocker arm
(4) Inlet rocker arm
(5) Inlet adjustment screw
(6) Valve adjustment locknut
(7) Inlet valve bridge
(8) Exhaust valve bridge
Table 2
Valve Lash
Valves Thickness of Gauge
Inlet 0.38 mm (0.015 inch)
Exhaust 0.76 mm (0.030 inch) Adjust the valve lash while the engine is stopped. Use the following procedure in order to adjust the valves:
Put the No. 1 piston at the top center position.Note: See Testing and Adjusting, "Finding Top Center Position for the No. 1 Piston" for further details.
With No. 1 piston at the top center position of the compression stroke, an adjustment can be made to the valves.Before any adjustments are made, lightly tap each rocker arm at the top of the adjustment screw. Use a soft mallet to ensure that the lifter roller seats against the base circle of the camshaft.
Adjust the valve lash on the inlet valves for cylinders 1, 2, 3, 7, 8, and 10.
Loosen valve adjustment locknut (6).
Place the appropriate feeler gauge between the inlet rocker arm (4) and the inlet valve bridge (7). Turn inlet adjustment screw (5) while valve adjustment locknut (6) is being held from turning. Adjust the valve lash until the correct specification is achieved. Refer to Table 2.
After each adjustment, tighten valve adjustment locknut (6) while valve adjustment screw (5) is being held from turning. Tighten to a torque of 30 7 N m (22 5 lb ft). Recheck each adjustment.
Adjust the valve lash on the exhaust valves for cylinders 1, 2, 5, 6, 9, and 10.
Loosen valve adjustment locknut (1).
Place the appropriate feeler gauge between the exhaust rocker arm (3) and the exhaust valve bridge (8). Turn exhaust adjustment screw (2) while valve adjustment locknut (1) is being held from turning. Adjust the valve lash until the correct specification is achieved. Refer to Table 2.
After each adjustment, tighten valve adjustment locknut (1) while valve adjustment screw (2) is being held from turning. Tighten to a torque of 30 7 N m (22 5 lb ft). Recheck each adjustment.
Remove the timing bolt, and turn the flywheel by 360 degrees in the direction of engine rotation. This procedure will position the No. 11 piston at the top center at the beginning of the compression stroke. Install the timing bolt in the flywheel.
Adjust the valve lash on the inlet valves for the following cylinders 4, 5, 6, 9, 11, and 12.
Loosen valve adjustment locknut (6).
Place the appropriate feeler gauge between the inlet rocker arm (4) and the inlet valve bridge (7). Turn inlet adjustment screw (5) while valve adjustment locknut (6) is being held from turning. Adjust the valve lash until the correct specification is achieved. Refer to Table 2.
After each adjustment, tighten valve adjustment locknut (6) while valve adjustment screw (5) is being held from turning. Tighten to a torque of 30 7 N m (22 5 lb ft). Recheck each adjustment.
Adjust the valve lash on the exhaust valves for cylinders 3, 4, 7, 8, 11, and 12.
Loosen valve adjustment locknut (1).
Place the appropriate feeler gauge between the exhaust rocker arm (3) and the exhaust valve bridge (8). Turn exhaust adjustment screw (2) while valve adjustment locknut (1) is being held from turning. Adjust the valve lash until the correct specification is achieved. Refer to Table 2.
After each adjustment, tighten valve adjustment locknut (1) while valve adjustment screw (2) is being held from turning. Tighten to a torque of 30 7 N m (22 5 lb ft). Recheck each adjustment.
Remove the timing bolt from the flywheel after all valve lash adjustments have been made.