![Tohatsu MFS 3.5 A2 [5/165] Lower unit](/img/pdf.png)
Tohatsu MFS 3.5 A2 [5/165] Lower unit
iv
4st 2/2.5/3.5 2007
15) Inspection of Lifter ………………………… 5-20
16) Inspection of Cam Shaft …………………… 5-21
17) Inspection of Piston Outer Diameter……… 5-22
18) Inspection of Cylinder Inner Diameter …… 5-22
19) Inspection of Piston Clearance …………… 5-22
20)
Inspection of Piston Ring Side Clearance
… 5-23
21) Inspection of Piston Rings ………………… 5-23
22) Inspection of Piston Pin …………………… 5-24
23)
Inspection Connecting Rod Small End Inner Diameter
… 5-24
24)
Inspection of Connecting Rod Big End Inner Diameter
… 5-24
25)
Inspection of Connecting Rod Big End Side Clearance
… 5-25
26) Inspection of Crank Shaft ………………… 5-25
27)
Disassembly and Assembly of Crank Shaft
… 5-26
28) Inspection of Crank Pin Oil Clearance …… 5-27
29)
Installation of Piston and Connecting Rod
… 5-28
30) Removal of Valves and Springs…………… 5-29
31) Inspection of Valve Springs ……………… 5-29
32) Inspection of Valve ………………………… 5-30
33) Inspection of Valve Guide ………………… 5-30
34) Inspection of Valve Seat …………………… 5-31
35) Correction of Valve Seat …………………… 5-32
36) Installation of Valves ……………………… 5-35
37) Assembly of Cylinder and Crank Case…… 5-36
38) Assembly to Power Unit …………………… 5-39
39) Assembly of Rocker Arm ………………… 5-40
40) Assembly of Power Unit …………………… 5-41
41) Disassembly of Recoil Starter …………… 5-42
42) Inspection of Recoil Starter ……………… 5-42
43) Assembly of Recoil Starter ………………… 5-43
6.Lower Unit
1 Special Tools ……………………………… 6-2
2 Parts Layout ………………………………… 6-3
Drive Shaft Housing & Gear Case …………… 6-3
Gear Case (Drive Shaft) ……………………… 6-4
Gear Case (Propeller Shaft) ………………… 6-5
Shift ……………………………………………… 6-6
3 Inspection Item …………………………… 6-7
1) Draining Gear Oil …………………………… 6-7
2) Removing Propeller ………………………… 6-7
3) Removing Lower Unit ……………………… 6-8
4) Disassembly of Water Pump ……………… 6-8
5) Inspection of Water Pump ………………… 6-9
6) Removing Propeller Shaft Housing Ass'y 6-10
7) Disassembly of Propeller Shaft Ass'y …… 6-10
8) Inspection of Propeller Shaft ……………… 6-10
9) Assembly of Propeller Shaft Ass'y ……… 6-11
10) Disassembly of Propeller Shaft Housing … 6-11
11) Inspection of Propeller Shaft Housing …… 6-11
12) Assembly of Propeller Shaft Housing …… 6-12
13) Removing Pump Case (Lower) …………… 6-12
14) Disassembly of Pump Case (Lower)……… 6-13
15) Assembly of Pump Case (Lower) ………… 6-13
16) Removing Clutch Cam and Cam Rod …… 6-13
17) Disassembly of Clutch Cam and Cam Rod 6-13
18) Inspection of Clutch Cam and Cam Rod … 6-13
19) Assembly of Clutch Cam and Cam Rod … 6-13
20) Removing Drive Shaft ……………………… 6-14
21) Disassembly of Drive Shaft ……………… 6-14
22) Inspection of Drive Shaft…………………… 6-14
23)
Inspection of Forward Gear and Pinion Gear
(A and B Gears)
……………………………… 6-15
24) Assembly of Drive Shaft …………………… 6-15
25) Disassembly of Gear Case………………… 6-16
26) Inspection of Gear Case …………………… 6-17
27) Assembly of Gear Case …………………… 6-17
28) Installation of Clutch Cam and Cam Rod … 6-18
29)
Installation of Forward Gear and Pinion Gear
(A and B Gears)
……………………………… 6-18
30) Installation of Pump Case (Lower) ……… 6-18
31) Installation of Water Pump ………………… 6-19
32) Installation of Propeller Shaft Housing …… 6-20
33) Filling with Gear Oil ………………………… 6-21
34) Installation of Lower Unit…………………… 6-21
7.Bracket
1 Parts Layout ………………………………… 7-2
Clamp Bracket & Swivel Bracket……………… 7-2
Drive Shaft Housing & Gear Case …………… 7-3
Shift ……………………………………………… 7-4
Tiller Handle & Throttle ………………………… 7-5
Cowl ……………………………………………… 7-6
2 Assembling Procedure…………………… 7-7
1) Assembly of Clamp Bracket ……………… 7-7
2) Installation of Steering Stopper …………… 7-7
3) Installation of Drive Shaft Housing ……… 7-8
4) Installation of Water Pipe ………………… 7-8
5) Installation of Tiller Handle ………………… 7-9
6) Adjustment of Throttle Cable ……………… 7-10
8.Electrical System
1 Special Tools ……………………………… 8-2
2 Parts Layout ………………………………… 8-3
Magneto ………………………………………… 8-3
3
Ignition System and Ignition Control System …
8-4
1) Inspection of Ignition Spark ……………… 8-4
2) Inspection of Plug Cap …………………… 8-5
3) Inspection of Igniter ………………………… 8-6
4) Inspection of Stop Switch ………………… 8-7
9.Troubleshooting
1 Troubleshooting List……………………… 9-2
2 Power Unit …………………………………… 9-3
Trouble 1
Engine will not start or is a little hard to start.
(Recoil starter operates normally.)
……… 9-3
Trouble 2 Engine starts but stalls soon. … 9-5
Fuel System………………………… 9-5
Ignition System …………………… 9-6
Compression Pressure …………… 9-7
Trouble 3
Idle engine speed will not stabilize.
… 9-8
Trouble 4 Rough acceleration.……………… 9-9
Trouble 5
Gear shifting cannot be made normally.
… 9-10
MFS2_sec00_070524.qxd 07.5.24 3:04 PM ページ 4
Содержание
- Before reading this manual 2
- Information for securing of safety 2
- Introduction 2
- B 1373b 1373b 3
- Description of pictogram 3
- Example 3
- Mfs2_sec00_070524 qxd 07 4 3 04 pm ページ 2 3
- N m 4 lb ft 0 kgf m 3
- The following symbols indicate a point to which lubrication oil sealing agent or screw locking agent is to be applied 3
- The following symbols indicate items needed for the service 3
- The following symbols represent the contents of individual chapters 3
- Fuel system carburetor 4
- Maintenance 4
- Power unit 4
- Service data 4
- Service information 4
- Bracket 5
- Electrical system 5
- Lower unit 5
- Troubleshooting 5
- Securing of work safet 8
- Service information 8
- Fire prevention 9
- Genuine parts 9
- Identification engine serial number 9
- Protection 9
- Securing of work safety 9
- Service information 9
- Ventilation 9
- Recommendations on service 10
- Cautions in disassembling and assembling components 11
- Service information 11
- Instruments 12
- Test propeller 12
- Tools and instruments 12
- List of special tool 13
- Service information 13
- Engine oil 14
- Gear oil 14
- Gear shift 14
- Predelivery inspection 14
- Steering handle 14
- Fuel tank and fuel line 15
- Inspection of tilt stopper 15
- Rigging 15
- Service information 15
- Cooling water check port 16
- Idle operation 16
- Inspection of stop switch 16
- Inspection of forward and reverse shifts 17
- Propeller selection 17
- Service information 17
- Break in operation 18
- Test run 18
- Checks after test run 19
- Service information 19
- Service data 20
- Engine dimensions 21
- Outline dimensons 21
- Service data 21
- Clamp dimensions 22
- Diameter 22
- Cooling water system diagram 23
- Service data 23
- Wiring diagram 24
- Service data 25
- Specifications 25
- Engine oil gear oil 26
- F2a f2 a f3 a 26
- Outboard model 26
- Maintenance data 27
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 8 27
- Service data 27
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 9 28
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 10 29
- Service data 29
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 11 30
- Service data 31
- Tightening torque data 31
- Adheasive 33
- Engine 33
- Gasket seal agent 33
- Gear oil 33
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 14 33
- Screw lock agent 33
- Sealant application locations 33
- Service data 33
- Silicon grease 33
- Stroke engine oil 33
- Teflon grease 33
- Waterproof grease 33
- Adheasive 34
- Applied to 34
- Gasket seal agent 34
- Gear oil 34
- Lower unit 34
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 15 34
- Remarks 34
- Screw lock agent 34
- Silicon grease 34
- Stroke engine oil 34
- Teflon grease 34
- Waterproof grease 34
- Adheasive 35
- Applied to remarks 35
- Fuel tank 35
- Gasket seal agent 35
- Gear oil 35
- Lower unit 35
- Mfs2_sec02_070524 qxd 07 4 3 12 pm ページ 16 35
- Screw lock agent 35
- Service data 35
- Silicon grease 35
- Stroke engine oil 35
- Teflon grease 35
- Tiller handle 35
- Waterproof grease 35
- Maintenance 36
- Maintenance 37
- Special tool 37
- Inspection schedule 38
- Inspection items 39
- Inspection of fuel system 39
- Inspection of fuel tank 39
- Inspection of top cowl 39
- Maintenance 39
- Carburetor 40
- Inspection of fuel cock 40
- Inspection of fuel cock fuel filter 40
- Maintenance 41
- Replacement of engine oil 41
- Inspection of gear oil quantity 43
- Inspection of water pump 43
- Maintenance 43
- Maintenance 45
- Replacement of gear oil 45
- Inspection of gear case for leakage 46
- Inspection of spark plug 47
- Maintenance 47
- Caution 48
- Inspection of compression pressure 48
- Maintenance 49
- Adjustment of throttle cable 51
- Maintenance 51
- Inspection of gear shift operation 52
- Caution 53
- Flushing with water 53
- Inspection of idle engine speed 53
- Maintenance 53
- Warning 53
- Inspection of anode 54
- Inspection of ignition timing 54
- Inspection of propeller 54
- Replacement of anode 54
- Inspection of thermostat 55
- Maintenance 55
- Nspection of cooling water passages 56
- Greasing points 57
- Maintenance 57
- Fuel system carburetor 58
- Fuel system carburetor 59
- Special tool 59
- Fuel tank 60
- P l fig 14 60
- Parts layout 60
- 14 1 13 61
- 4 1 6 1 5 61
- Carburetor 61
- Fuel system carburetor 61
- N m 7 lb ft 1 kgf m 61
- Inspection items 62
- Inspection of fuel feed system piping 62
- Draining fuel 63
- Fuel system carburetor 63
- Warning 63
- Inspection of fuel cock 64
- Inspection of fuel filter 64
- Inspection of fuel tank and fuel tank cap 64
- Caution 65
- Fuel system carburetor 65
- Inspection of carburetor 65
- Assembling of carburetor 66
- Assembling carburetor 67
- Fuel system carburetor 67
- Adjustment of throttle cable 68
- Adjustment of idle engine speed 69
- Fuel system carburetor 69
- Inspection of idle engine speed 69
- Power unit 70
- Power unit 71
- Special tools 71
- Engine 72
- Parts layout 72
- N m 4 lb ft 0 kgf m 73
- P l fig 8 73
- Power unit 73
- Recoil starter 73
- Oil pan p l fig 4 74
- St oil 74
- Cylinder p l fig 1 75
- Power unit 75
- A view 76
- Cam shaft valve p l fig 5 76
- N m 4 lb ft 0 kgf m 2 10 n m 7 lb ft 1 kgf m 77
- Piston crank shaft p l fig 2 77
- Power unit 77
- Inspection items 78
- Inspection of compression pressure 78
- Inspection of valve clearance 79
- Power unit 79
- Power unit 81
- Removing power unit 81
- Removal and disassembly of crank case head 82
- Assembly of crank case head 83
- Inspection of crank case head 83
- Installation of crank case head 83
- Power unit 83
- Caution 84
- Disassembly of power unit 84
- Power unit 85
- Removal of rocker arm 86
- Inspection of push rod 87
- Inspection of push rod plate 87
- Inspection of rocker arm and pivot 87
- Power unit 87
- Disassembly of cylinder block 88
- Inspection of lifter 89
- Inspection of slinger 89
- Power unit 89
- Splash lubrication 89
- Inspection of cam shaft 90
- Inspection of cylinder inner diameter 91
- Inspection of piston clearance 91
- Inspection of piston outer diameter 91
- Power unit 91
- Inspection of piston ring side clearance 92
- Inspection of piston rings 92
- Inspection connecting rod small end inner diameter 93
- Inspection of connecting rod big end inner diameter 93
- Inspection of piston pin 93
- Power unit 93
- Inspection of connecting rod big end side clearance 94
- Inspection of crank shaft 94
- Caution 95
- Disassembly and assembly of crank shaft 95
- Power unit 95
- Inspection of crank pin oil clearance 96
- Caution 97
- Installation of piston and connecting rod 97
- Power unit 97
- Inspection of valve springs 98
- Removal of valves and springs 98
- Inspection of valve 99
- Inspection of valve guide 99
- Power unit 99
- Inspection of valve seat 100
- Correction of valve seat 101
- Power unit 101
- Caution 103
- Power unit 103
- Installation of valves 104
- Assembly of cylinder and crank case 105
- Power unit 105
- Power unit 107
- Assembly to power unit 108
- Caution 108
- Assembly of rocker arm 109
- Caution 109
- Power unit 109
- Assembly of power unit 110
- Disassembly of recoil starter 111
- Inspection of recoil starter 111
- Power unit 111
- Assembly of recoil starter 112
- Power unit 113
- Lower unit 114
- Lower unit 115
- Special tools 115
- Drive shaft housing gear case 116
- P l fig 9 116
- Parts layout 116
- A projection b note marked with sh2 c3 117
- Gear case drive shaft 117
- Lower unit 117
- N m 4 lb ft 0 kgf m 117
- P l fig 10 117
- St oil 117
- Gear case propeller shaft 118
- N m 4 lb ft 0 kgf m 118
- P l fig 11 118
- Lower unit 119
- N m 3 lb ft 0 kgf m 119
- N m 4 lb ft 0 kgf m 119
- Shift p l fig 12 119
- Draining gear oil 120
- Inspection item 120
- Removing propeller 120
- Disassembly of water pump 121
- Lower unit 121
- Removing lower unit 121
- Inspection of water pump 122
- Disassembly of propeller shaft ass y 123
- Inspection of propeller shaft 123
- Lower unit 123
- Removing propeller shaft housing ass y 123
- Assembly of propeller shaft ass y 124
- Caution 124
- Disassembly of propeller shaft housing 124
- Inspection of propeller shaft housing 124
- Assembly of propeller shaft housing 125
- Disassembly of pump case lower 125
- Lower unit 125
- Removing pump case lower 125
- Assembly of clutch cam and cam rod 126
- Assembly of pump case lower 126
- Disassembly of clutch cam and cam rod 126
- Inspection of clutch cam and cam rod 126
- Removing clutch cam and cam rod 126
- Caution 127
- Disassembly of drive shaft 127
- Inspection of drive shaft 127
- Lower unit 127
- Removing drive shaft 127
- Assembly of drive shaft 128
- Caution 128
- Inspection of forward gear and pinion gear a and b gears 128
- Caution 129
- Disassembly of gear case 129
- Lower unit 129
- Assembly of gear case 130
- Inspection of gear case 130
- Installation of clutch cam and cam rod 131
- Installation of forward gear and pinion gear a and b gears 131
- Installation of pump case lower 131
- Lower unit 131
- Installation of water pump 132
- Installation of propeller shaft housing 133
- Lower unit 133
- Filling with gear oil 134
- Installation of lower unit 134
- Lower unit 135
- Warning 135
- Bracket 136
- Bracket 137
- Clamp bracket swivel bracket 137
- P l fig 13 137
- Parts layout 137
- A note marked with sh2 c3 138
- Drive shaft housing gear case 138
- P l fig 9 138
- Bracket 139
- N m 3 lb ft 0 kgf m 139
- N m 4 lb ft 0 kgf m 139
- Shift p l fig 12 139
- A adjust 140
- N m 4 lb ft 0 kgf m 140
- Tiller handle throttle p l fig 7 140
- Bracket 141
- Cowl p l fig 15 141
- N m 1 lb ft 0 kgf m 141
- N m 4 lb ft 0 kgf m 141
- Assembling procedure 142
- Assembly of clamp bracket 142
- C 5 d b 142
- Installation of steering stopper 142
- Bracket 143
- Installation of drive shaft housing 143
- Installation of water pipe 143
- Installation of tiller handle 144
- Adjustment of throttle cable 145
- Bracket 145
- Electrical system 146
- Electrical system 147
- Special tools 147
- A spark plug 148
- B igniter clearance 0 0 mm 0 08 0 16in 148
- Magneto 148
- N m 1 lb ft 0 3 kgf m 148
- N m 13 lb ft 1 kgf m 148
- N m 31 lb ft 4 kgf m 148
- N m 4 lb ft 0 kgf m 148
- P l fig 6 148
- Parts layout 148
- Electrical system 149
- Ignition system and ignition control system 149
- Inspection of ignition spark 149
- Warning 149
- Inspection of plug cap 150
- Electrical system 151
- Inspection of igniter 151
- Inspection of stop switch 152
- Electrical system 153
- Troubleshooting 155
- Troubleshooting list 155
- 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 156
- Inspection of ignition system fuel system and compression pressure 156
- Power unit 156
- Trouble 1 156
- Warning 156
- Troubleshooting 157
- Fuel system 158
- Inspection of fuel system ignition system compression pressure 158
- Trouble 2 engine starts but stalls soon 158
- Ignition system 159
- Troubleshooting 159
- Compression pressure 160
- Troubleshooting 161
- Inspection of carburetor ignition system and compression pressure 162
- Rapid opening of throttle causes engine to stall acceleration is not smooth 162
- Trouble 4 rough acceleration 162
- Troubleshooting 163
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