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Old 23 March 2013, 18:07   #11
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engine service

Mike if you mean resistance at the lever when pushing past 3/4 throttle ? i would suggest you check lever mechanisn is free, cable not kinked/snagged and also look at linkages under hood ,adjustment, free, nothing touching them . have just checked mine seems free all way to wot. lever tension can also be adjusted on mine. or do you mean engine is a bit hesitant past 3/4 s
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Old 23 March 2013, 22:51   #12
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Yes Trevor at the lever, engine is fine, but something is making it stick at 3/4.
i will check the connections at the engine and at the lever.
did you say you can adjust it at the lever?
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Old 24 March 2013, 05:43   #13
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engine service

Mike, try disconecting cable at engine end , move throttle lever at front back /forwards to check if any better?if better engine end prob, if no better either cable or lever it's self? when i said mine is adjustable i meant the tension can be adjusted to make lever hard /easy to push /pull. ps how come you are on comp in middle of night.
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Old 24 March 2013, 05:53   #14
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thanks Trevor ill try that...............middle of the night you say, that would be due my 2.5 year old insomniac fireman sam watching son!

awake from 2am until 6am..............ribnet you keep me sain! thanks
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Old 24 March 2013, 06:17   #15
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I have the same on mine (which is essentially the same box). When in the past I have striped it (and others) I seem to recall the shape of the cam inside changes at 3/4 to stop you going to wot to easily.

However as Trevor says if you disconnect the engine end make sure that's ok (I'm sure it will be), then it's for sure the box or cables.
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Old 19 April 2013, 16:19   #16
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have started servicing the engine this evening.
as per sticking throttle ,diconnecting the throttle at the engine, it is smooth, so the problem is at the engine end.

there is a cam mechanism on the triple carbs where it is clearly sticking, have tried greasing, no difference.

any advice?
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Old 19 April 2013, 16:34   #17
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Originally Posted by xs 400 View Post
have started servicing the engine this evening.
as per sticking throttle ,diconnecting the throttle at the engine, it is smooth, so the problem is at the engine end.

there is a cam mechanism on the triple carbs where it is clearly sticking, have tried greasing, no difference.

any advice?
Bear in mind the carbs have other bits on the side...from memory one changes the oil pump opening etc...so they don't spring strait back etc
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Old 19 April 2013, 16:49   #18
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have started servicing the engine this evening.
as per sticking throttle ,diconnecting the throttle at the engine, it is smooth, so the problem is at the engine end.

there is a cam mechanism on the triple carbs where it is clearly sticking, have tried greasing, no difference.

any advice?
File the apex off that cam or turn down on a lathe the small cam follower wheel if you are fussy. No idea why these engines do this but you will still get full throttle.
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Old 19 April 2013, 17:35   #19
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Just serviced my Tohatsu 60hp at the weekend. I had a fuel problem last year, in that the engine would cut out on one of my 25 litre fuel tanks. I opted to clean the inline fuel filter (on engine), replace fuel/water separator filter and install fuel pump diaphragm kit. Normally you'll get a warning if something is 'iffy'. I wouldn't normally replace the fuel pump... (on account of it being bleed'n expensive), but once you're aware of issue, then yes - replace.

Regards thermostat, the thermostat is probably okay, but remove to clean housing and renew gasket as a matter of course. Remember and lightly grease bolt threads.

If the engine is a pull start... then please replace starter cord too.
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Old 20 April 2013, 15:05   #20
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thanks guys
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