309-67006-0 Tohatsu SET PLATE, MOTOR COVER

Problem 1.
Engine Will Not Turn When Start Switch Is OnProbable Cause
Battery Has Low Output Check condition of battery. Charge battery or make replacement as necessary.
Wiring Or Switches Have Defect Make repairs or replacement as necessary.
Starter Motor Solenoid Has A Defect Install a new solenoid.
Starter Motor Has A Defect Make repair or replacement of starter motor
Internal Problem Prevents Engine Crankshaft From Turning If the crankshaft cannot be turned after disconnecting the driven equipment, remove the fuel nozzles and check for fluid in the cylinders while turning the crankshaft. If fluid in the cylinders is not the problem, the engine must be disassembled to check for other internal problems. Some of these internal problems are bearing seizure, piston seizure, or wrong pistons installed in the engine.Problem 2.
Starter Motor Does Not TurnProbable Cause
Battery Has Low Output Check condition of battery. Charge battery or make replacement as necessary.
Wiring Or Switch Has A Defect Make repairs or replacement as necessary.
Starter Motor Solenoid Has A Defect Install a new solenoid.
Starter Motor Has A Defect Make repair or replacement of starter motor.Problem 3.
Alternator Does Not ChargeProbable Cause
Loose Drive Belt For Alternator Adjust the drive belt to the correct tension.
Charging Or Ground Return Circuit Or Battery Connections Have A Defect Inspect all cables and connections. Clean and tighten all connections. Make replacement of parts that have a defect.
Alternator Brushes Have A Defect Install new brushes.
Rotor (Field Coil) Has A Defect Install a new rotor.Problem 4.
Alternator Charge Rate Is Low Or Not RegularProbable Cause
Loose Drive Belt For Alternator Adjust the drive belt to the correct tension.
Charging Or Ground Return Circuit Or Battery Connections Have A Defect Inspect all cables and connections. Clean and tighten all connections. Make replacement of parts that have a defect.
Alternator Regulator Has A Defect Make repair or replacement of alternator regulator.
Alternator Brushes Have A Defect Install new brushes
Rectifier Diodes Have A Defect Make replacement of rectifier diode that has a defect.
Rotor (Field Coil) Has A Defect Install a new rotor.Problem 5.
Alternator Charge Too HighProbable Cause
Alternator Or Alternator Regulator Has Loose Connections Tighten all connections to alternator or alternator regulator.
Alternator Regulator Has A Defect Install a new alternator regulator.Problem 6.
Alternator Has NoiseProbable Cause
Drive Belt For Alternator Is Worn Or Has A Defect Install a new drive belt for the alternator.
Loose Alternator Drive Pulley Check key groove in pulley for wear. If groove is worn, install a new pulley. Tighten pulley nut according to Specifications.
Drive Belt And Drive Pulley For Alternator Are Not In Alignment Adjust the drive belt and drive pulley in the correct alignment.
Worn Alternator Bearings Install new bearings in the alternator.
Armature Or Rotor Shaft Is Bent Make a replacement of the components.
Rectifiers In The Alternators Are Shorted Make a replacement of the diode assembly.Problem 31.
Rack Solenoid Does Not Stop Engine.Probable Cause
Electrical Connections Are Not Correct Correct electrical connections and wiring.
Adjustment For Plunger Shaft Is Not Correct Adjust the shaft.
Wrong Plunger In Solenoid Install the correct plunger in the solenoid.
Not Enough Plunger Travel Adjust the plunger shaft or replace the solenoid if necessary.
Defect In Solenoid Wiring Replacement the solenoid.Test Tools for the Electrical System
Table 1
Tools Needed
Quantity
4C-4911 Battery Load Tester 1
225-8266 Ammeter Tool Gp 1
237-5130 Digital Multimeter Gp 1 Most of the tests of the electrical system can be done on the engine. The wiring insulation must be in good condition. The wire and cable connections must be clean, and both components must be tight. Fully charge the battery. If the on-engine test shows a defect in a component, remove the component for more testing.
Illustration 1 g02231076
177-2330 Battery Analyzer
The portable 177-2330 Battery Analyzer can be used under field conditions and compensates for cold temperatures when testing batteries in extreme conditions. The 177-2330 Battery Analyzer tests batteries in the machine or the vehicle without disconnecting the battery cables. The battery analyzer eliminates the need to charge and discharge a battery to test the battery condition. Refer to Operating Manual, NEHS0764, "Using the 177-2330 Battery Analyzer" for detailed instruction on the use of the 177-2330 Battery Analyzer.
Illustration 2 g02231156
4C-4911 Battery Load Tester
The portable 4C-4911 Battery Load Tester is a portable unit in a metal case. The 4C-4911 Battery Load Tester can be used under field conditions and under high temperatures. The tester can be used to load test all 6, 8, and 12 V batteries. This tester has two heavy-duty load cables that can easily be fastened to the battery terminals. A load adjustment knob is located on the top of the tester. The load adjustment knob permits the current that is being drawn from the battery to be adjusted to a maximum of 1000 A. The tester is cooled by an internal fan that is automatically activated when a load is applied.The tester has a built-in LCD. The LCD is a digital voltmeter. The LCD is a digital meter that will also display the amperage. The digital voltmeter accurately measures the battery voltage at the battery through wires for tracing. These wires are buried inside the load cables. The digital meter, that displays the amperage, accurately displays the current that is being drawn from the battery which is being tested.Note: Refer to Operating Manual , SEHS9249 for more complete information for the use of the 4C-4911 Battery Load Tester.