Tohatsu MFS 3.5 A2 [4/165] Fuel system carburetor

iii
4st 2/2.5/3.5 2007
1.Service Information
1 Identification (Engine Serial Number) 1-2
2 Securing of work safety ………………… 1-2
1) Fire Prevention ……………………………… 1-2
2) Ventilation …………………………………… 1-2
3) Protection …………………………………… 1-2
4) Genuine Parts ……………………………… 1-2
5) Tools ………………………………………… 1-3
6) Recommendations on Service …………… 1-3
7) Cautions in Disassembling and
Assembling Components ………………… 1-4
3 Tools and Instruments…………………… 1-5
1) Test Propeller ……………………………… 1-5
2) Instruments ………………………………… 1-5
3) List of Special Tool ………………………… 1-6
4 Predelivery Inspection…………………… 1-7
1) Steering Handle …………………………… 1-7
2) Gear Shift …………………………………… 1-7
3) Engine Oil …………………………………… 1-7
4) Gear Oil ……………………………………… 1-7
5) Fuel Tank and Fuel Line …………………… 1-8
6) Rigging ……………………………………… 1-8
7) Inspection of Tilt Stopper ………………… 1-8
8) Inspection of Stop Switch ………………… 1-9
9) Cooling Water Check Port ………………… 1-9
10) Idle Operation ……………………………… 1-9
11) Propeller Selection ………………………… 1-10
12) Inspection of Forward and Reverse Shifts 1-10
5 Break-in Operation………………………… 1-11
6 Test Run ……………………………………… 1-11
7 Checks After Test Run…………………… 1-12
2.Service Data
1 Outline Dimensons………………………… 2-2
1Engine Dimensions ………………………… 2-2
2Clamp Dimensions ………………………… 2-3
2 Cooling Water System Diagram ……… 2-4
3 Wiring Diagram……………………………… 2-5
4 Specifications ……………………………… 2-6
5 Maintenance Data ………………………… 2-8
6 Tightening Torque Data ………………… 2-12
7 Sealant Application Locations ……… 2-14
3.Maintenance
1 Special Tool ………………………………… 3-2
2 Inspection Schedule ……………………… 3-3
3 Inspection Items …………………………… 3-4
1) Inspection of Top Cowl …………………… 3-4
2) Inspection of Fuel System ………………… 3-4
3) Inspection of Fuel Tank …………………… 3-4
4) Inspection of Fuel Cock (Fuel Filter)……… 3-5
5) Inspection of Fuel Cock …………………… 3-5
6) Replacement of Engine Oil………………… 3-6
7) Inspection of Gear Oil Quantity …………… 3-8
8) Inspection of Water Pump ………………… 3-8
9) Replacement of Gear Oil ………………… 3-10
10) Inspection of Gear Case (for leakage) …… 3-11
11) Inspection of Spark Plug…………………… 3-12
12) Inspection of Compression Pressure …… 3-13
13)
Inspection and Adjustment of Valve Clearances
3-14
14) Adjustment of Throttle Cable ……………… 3-16
15) Inspection of Gear Shift Operation ……… 3-17
16) Flushing with Water ………………………… 3-18
17) Inspection of Idle Engine Speed ………… 3-18
18) Inspection of Ignition Timing ……………… 3-19
19) Inspection of Anode………………………… 3-19
20) Replacement of Anode …………………… 3-19
21) Inspection of Propeller……………………… 3-19
22) Inspection of Thermostat ………………… 3-20
23) Inspection of Cooling Water Passages…… 3-21
24) Greasing Points …………………………… 3-22
4.
Fuel System (Carburetor)
1 Special Tool ………………………………… 4-2
2 Parts Layout ………………………………… 4-3
Fuel Tank ……………………………………… 4-3
Carburetor ……………………………………… 4-4
3 Inspection Items …………………………… 4-5
1) Inspection of Fuel Feed System Piping 4-5
2) Draining Fuel………………………………… 4-6
3)
Inspection of Fuel Tank and Fuel Tank Cap
4-7
4) Inspection of Fuel Cock …………………… 4-7
5) Inspection of Fuel Filter …………………… 4-7
6) Inspection of Carburetor …………………… 4-8
7) Assembling of Carburetor ………………… 4-9
8) Assembling Carburetor …………………… 4-10
9) Adjustment of Throttle Cable ……………… 4-11
10) Inspection of Idle Engine Speed ………… 4-12
11) Adjustment of Idle Engine Speed ………… 4-12
5.Power Unit
1 Special Tools ……………………………… 5-2
2 Parts Layout ………………………………… 5-3
Engine …………………………………………… 5-3
Recoil Starter …………………………………… 5-4
Oil Pan…………………………………………… 5-5
Cylinder ………………………………………… 5-6
Cam Shaft & Valve …………………………… 5-7
Piston & Crank Shaft…………………………… 5-8
3 Inspection Items …………………………… 5-9
1) Inspection of Compression Pressure …… 5-9
2) Inspection of Valve Clearance …………… 5-10
3) Removing Power Unit ……………………… 5-12
4)
Removal and Disassembly of Crank Case Head
5-13
5) Inspection of Crank Case Head…………… 5-14
6) Assembly of Crank Case Head …………… 5-14
7) Installation of Crank Case Head ………… 5-14
8) Disassembly of Power Unit………………… 5-15
9) Removal of Rocker Arm …………………… 5-17
10) Inspection of Rocker Arm and Pivot ……… 5-18
11) Inspection of Push Rod Plate……………… 5-18
12) Inspection of Push Rod …………………… 5-18
13) Disassembly of Cylinder Block …………… 5-19
14) Inspection of Slinger
(Splash Lubrication)
5-20
MFS2_sec00_070524.qxd 07.5.24 3:04 PM ページ 3

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