![Tohatsu MFS 2.5 A2 S [23/165] Service data](/img/pdf.png)
Tohatsu MFS 2.5 A2 S [23/165] Service data
![Tohatsu MFS 2.5 A2 S [23/165] Service data](/views2/1240886/page23/bg17.png)
2-4
Service Data
4st 2/2.5/3.5 2007
1
3
4
5
6
7
8
9
0
q
w
2
1Thermostat
2Cylinder (with cylinder head)
3Crankcase
4Flushing Plug
5Cooling Water Check Port
6Water Feed Passage in Drive Shaft Housing
7Water Discharging Passage in Drive Shaft Housing
8Drive Shaft Housing
9Water Pipe
0Water Pump
qExhaust Gas and Discharged Water
wCooling Water Intake
Thermostat1
Cylinder
(with cylinder head)2
Water Pump0
Water Pipe9
Cooling Water
Intakew
Exhaust Gas and
Discharged Waterq
Drive Shaft
Housing8
6
Water Feed
Passage in Drive
Shaft Housing
7
Water Discharging
Passage in
Drive Shaft Housing
Cooling Water
Check Port5
2.Cooling Water System Diagram
MFS2_sec02_070524.qxd 07.5.24 3:12 PM ページ 4
Содержание
- Introduction p.2
- Information for securing of safety p.2
- Before reading this manual p.2
- B 1373b 1373b p.3
- Description of pictogram p.3
- The following symbols indicate items needed for the service p.3
- N m 4 lb ft 0 kgf m p.3
- Mfs2_sec00_070524 qxd 07 4 3 04 pm ページ 2 p.3
- The following symbols represent the contents of individual chapters p.3
- The following symbols indicate a point to which lubrication oil sealing agent or screw locking agent is to be applied p.3
- Example p.3
- Fuel system carburetor p.4
- Service data p.4
- Maintenance p.4
- Power unit p.4
- Service information p.4
- Lower unit p.5
- Troubleshooting p.5
- Electrical system p.5
- Bracket p.5
- Service information p.8
- Securing of work safet p.8
- Ventilation p.9
- Service information p.9
- Securing of work safety p.9
- Protection p.9
- Identification engine serial number p.9
- Genuine parts p.9
- Fire prevention p.9
- Recommendations on service p.10
- Service information p.11
- Cautions in disassembling and assembling components p.11
- Tools and instruments p.12
- Test propeller p.12
- Instruments p.12
- Service information p.13
- List of special tool p.13
- Gear shift p.14
- Steering handle p.14
- Predelivery inspection p.14
- Gear oil p.14
- Engine oil p.14
- Rigging p.15
- Service information p.15
- Inspection of tilt stopper p.15
- Fuel tank and fuel line p.15
- Inspection of stop switch p.16
- Idle operation p.16
- Cooling water check port p.16
- Inspection of forward and reverse shifts p.17
- Service information p.17
- Propeller selection p.17
- Break in operation p.18
- Test run p.18
- Service information p.19
- Checks after test run p.19
- Service data p.20
- Engine dimensions p.21
- Service data p.21
- Outline dimensons p.21
- Diameter p.22
- Clamp dimensions p.22
- Service data p.23
- Cooling water system diagram p.23
- Wiring diagram p.24
- Specifications p.25
- Service data p.25
- F2a f2 a f3 a p.26
- Engine oil gear oil p.26
- Outboard model p.26
- Maintenance data p.27
- Service data p.27
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 8 p.27
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 9 p.28
- Service data p.29
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 10 p.29
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 11 p.30
- Tightening torque data p.31
- Service data p.31
- Engine p.33
- Screw lock agent p.33
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 14 p.33
- Gear oil p.33
- Gasket seal agent p.33
- Adheasive p.33
- Waterproof grease p.33
- Teflon grease p.33
- Stroke engine oil p.33
- Silicon grease p.33
- Service data p.33
- Sealant application locations p.33
- Stroke engine oil p.34
- Silicon grease p.34
- Screw lock agent p.34
- Remarks p.34
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 15 p.34
- Lower unit p.34
- Gear oil p.34
- Gasket seal agent p.34
- Applied to p.34
- Adheasive p.34
- Waterproof grease p.34
- Teflon grease p.34
- Waterproof grease p.35
- Tiller handle p.35
- Teflon grease p.35
- Stroke engine oil p.35
- Silicon grease p.35
- Service data p.35
- Screw lock agent p.35
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 16 p.35
- Lower unit p.35
- Gear oil p.35
- Gasket seal agent p.35
- Fuel tank p.35
- Applied to remarks p.35
- Adheasive p.35
- Maintenance p.36
- Special tool p.37
- Maintenance p.37
- Inspection schedule p.38
- Maintenance p.39
- Inspection of top cowl p.39
- Inspection of fuel tank p.39
- Inspection of fuel system p.39
- Inspection items p.39
- Carburetor p.40
- Inspection of fuel cock fuel filter p.40
- Inspection of fuel cock p.40
- Replacement of engine oil p.41
- Maintenance p.41
- Inspection of water pump p.43
- Inspection of gear oil quantity p.43
- Maintenance p.43
- Replacement of gear oil p.45
- Maintenance p.45
- Inspection of gear case for leakage p.46
- Maintenance p.47
- Inspection of spark plug p.47
- Inspection of compression pressure p.48
- Caution p.48
- Maintenance p.49
- Maintenance p.51
- Adjustment of throttle cable p.51
- Inspection of gear shift operation p.52
- Flushing with water p.53
- Maintenance p.53
- Inspection of idle engine speed p.53
- Caution p.53
- Warning p.53
- Replacement of anode p.54
- Inspection of propeller p.54
- Inspection of ignition timing p.54
- Inspection of anode p.54
- Maintenance p.55
- Inspection of thermostat p.55
- Nspection of cooling water passages p.56
- Maintenance p.57
- Greasing points p.57
- Fuel system carburetor p.58
- Fuel system carburetor p.59
- Special tool p.59
- Parts layout p.60
- P l fig 14 p.60
- Fuel tank p.60
- N m 7 lb ft 1 kgf m p.61
- Fuel system carburetor p.61
- Carburetor p.61
- 4 1 6 1 5 p.61
- 14 1 13 p.61
- Inspection of fuel feed system piping p.62
- Inspection items p.62
- Warning p.63
- Fuel system carburetor p.63
- Draining fuel p.63
- Inspection of fuel tank and fuel tank cap p.64
- Inspection of fuel filter p.64
- Inspection of fuel cock p.64
- Inspection of carburetor p.65
- Fuel system carburetor p.65
- Caution p.65
- Assembling of carburetor p.66
- Fuel system carburetor p.67
- Assembling carburetor p.67
- Adjustment of throttle cable p.68
- Inspection of idle engine speed p.69
- Fuel system carburetor p.69
- Adjustment of idle engine speed p.69
- Power unit p.70
- Special tools p.71
- Power unit p.71
- Parts layout p.72
- Engine p.72
- Recoil starter p.73
- Power unit p.73
- P l fig 8 p.73
- N m 4 lb ft 0 kgf m p.73
- St oil p.74
- Oil pan p l fig 4 p.74
- Power unit p.75
- Cylinder p l fig 1 p.75
- Cam shaft valve p l fig 5 p.76
- A view p.76
- Power unit p.77
- Piston crank shaft p l fig 2 p.77
- N m 4 lb ft 0 kgf m 2 10 n m 7 lb ft 1 kgf m p.77
- Inspection of compression pressure p.78
- Inspection items p.78
- Inspection of valve clearance p.79
- Power unit p.79
- Removing power unit p.81
- Power unit p.81
- Removal and disassembly of crank case head p.82
- Power unit p.83
- Installation of crank case head p.83
- Inspection of crank case head p.83
- Assembly of crank case head p.83
- Disassembly of power unit p.84
- Caution p.84
- Power unit p.85
- Removal of rocker arm p.86
- Power unit p.87
- Inspection of rocker arm and pivot p.87
- Inspection of push rod plate p.87
- Inspection of push rod p.87
- Disassembly of cylinder block p.88
- Power unit p.89
- Inspection of slinger p.89
- Inspection of lifter p.89
- Splash lubrication p.89
- Inspection of cam shaft p.90
- Power unit p.91
- Inspection of piston outer diameter p.91
- Inspection of piston clearance p.91
- Inspection of cylinder inner diameter p.91
- Inspection of piston rings p.92
- Inspection of piston ring side clearance p.92
- Power unit p.93
- Inspection of piston pin p.93
- Inspection of connecting rod big end inner diameter p.93
- Inspection connecting rod small end inner diameter p.93
- Inspection of crank shaft p.94
- Inspection of connecting rod big end side clearance p.94
- Disassembly and assembly of crank shaft p.95
- Caution p.95
- Power unit p.95
- Inspection of crank pin oil clearance p.96
- Power unit p.97
- Installation of piston and connecting rod p.97
- Caution p.97
- Removal of valves and springs p.98
- Inspection of valve springs p.98
- Power unit p.99
- Inspection of valve guide p.99
- Inspection of valve p.99
- Inspection of valve seat p.100
- Power unit p.101
- Correction of valve seat p.101
- Power unit p.103
- Caution p.103
- Installation of valves p.104
- Power unit p.105
- Assembly of cylinder and crank case p.105
- Power unit p.107
- Caution p.108
- Assembly to power unit p.108
- Power unit p.109
- Caution p.109
- Assembly of rocker arm p.109
- Assembly of power unit p.110
- Power unit p.111
- Inspection of recoil starter p.111
- Disassembly of recoil starter p.111
- Assembly of recoil starter p.112
- Power unit p.113
- Lower unit p.114
- Lower unit p.115
- Special tools p.115
- Parts layout p.116
- P l fig 9 p.116
- Drive shaft housing gear case p.116
- St oil p.117
- P l fig 10 p.117
- N m 4 lb ft 0 kgf m p.117
- Lower unit p.117
- Gear case drive shaft p.117
- A projection b note marked with sh2 c3 p.117
- P l fig 11 p.118
- N m 4 lb ft 0 kgf m p.118
- Gear case propeller shaft p.118
- N m 4 lb ft 0 kgf m p.119
- N m 3 lb ft 0 kgf m p.119
- Lower unit p.119
- Shift p l fig 12 p.119
- Removing propeller p.120
- Inspection item p.120
- Draining gear oil p.120
- Removing lower unit p.121
- Lower unit p.121
- Disassembly of water pump p.121
- Inspection of water pump p.122
- Removing propeller shaft housing ass y p.123
- Lower unit p.123
- Inspection of propeller shaft p.123
- Disassembly of propeller shaft ass y p.123
- Inspection of propeller shaft housing p.124
- Disassembly of propeller shaft housing p.124
- Caution p.124
- Assembly of propeller shaft ass y p.124
- Lower unit p.125
- Removing pump case lower p.125
- Disassembly of pump case lower p.125
- Assembly of propeller shaft housing p.125
- Removing clutch cam and cam rod p.126
- Inspection of clutch cam and cam rod p.126
- Disassembly of clutch cam and cam rod p.126
- Assembly of pump case lower p.126
- Assembly of clutch cam and cam rod p.126
- Removing drive shaft p.127
- Lower unit p.127
- Inspection of drive shaft p.127
- Disassembly of drive shaft p.127
- Caution p.127
- Caution p.128
- Assembly of drive shaft p.128
- Inspection of forward gear and pinion gear a and b gears p.128
- Lower unit p.129
- Disassembly of gear case p.129
- Caution p.129
- Assembly of gear case p.130
- Inspection of gear case p.130
- Lower unit p.131
- Installation of pump case lower p.131
- Installation of forward gear and pinion gear a and b gears p.131
- Installation of clutch cam and cam rod p.131
- Installation of water pump p.132
- Lower unit p.133
- Installation of propeller shaft housing p.133
- Installation of lower unit p.134
- Filling with gear oil p.134
- Lower unit p.135
- Warning p.135
- Bracket p.136
- Parts layout p.137
- P l fig 13 p.137
- Clamp bracket swivel bracket p.137
- Bracket p.137
- P l fig 9 p.138
- Drive shaft housing gear case p.138
- A note marked with sh2 c3 p.138
- Shift p l fig 12 p.139
- N m 4 lb ft 0 kgf m p.139
- N m 3 lb ft 0 kgf m p.139
- Bracket p.139
- Tiller handle throttle p l fig 7 p.140
- N m 4 lb ft 0 kgf m p.140
- A adjust p.140
- N m 4 lb ft 0 kgf m p.141
- N m 1 lb ft 0 kgf m p.141
- Cowl p l fig 15 p.141
- Bracket p.141
- Installation of steering stopper p.142
- C 5 d b p.142
- Assembly of clamp bracket p.142
- Assembling procedure p.142
- Installation of water pipe p.143
- Installation of drive shaft housing p.143
- Bracket p.143
- Installation of tiller handle p.144
- Bracket p.145
- Adjustment of throttle cable p.145
- Electrical system p.146
- Electrical system p.147
- Special tools p.147
- Parts layout p.148
- P l fig 6 p.148
- N m 4 lb ft 0 kgf m p.148
- N m 31 lb ft 4 kgf m p.148
- N m 13 lb ft 1 kgf m p.148
- N m 1 lb ft 0 3 kgf m p.148
- Magneto p.148
- B igniter clearance 0 0 mm 0 08 0 16in p.148
- A spark plug p.148
- Warning p.149
- Inspection of ignition spark p.149
- Ignition system and ignition control system p.149
- Electrical system p.149
- Inspection of plug cap p.150
- Electrical system p.151
- Inspection of igniter p.151
- Inspection of stop switch p.152
- Electrical system p.153
- Troubleshooting list p.155
- Troubleshooting p.155
- Warning p.156
- Trouble 1 p.156
- Power unit p.156
- Inspection of ignition system fuel system and compression pressure p.156
- Before working on the outboard motor check the hull rigging installation of outboard motor fuel level and wire connections for mechanical troubleshooting refer to relevant troubleshooting section in this chapter for checking and servicing outboard motor refer to service procedures described in this manual to perform the work safely p.156
- Troubleshooting p.157
- Inspection of fuel system ignition system compression pressure p.158
- Trouble 2 engine starts but stalls soon p.158
- Fuel system p.158
- Troubleshooting p.159
- Ignition system p.159
- Compression pressure p.160
- Troubleshooting p.161
- Trouble 4 rough acceleration p.162
- Rapid opening of throttle causes engine to stall acceleration is not smooth p.162
- Inspection of carburetor ignition system and compression pressure p.162
- Troubleshooting p.163
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