![Tohatsu MFS 30 [12/319] Service information](/img/pdf.png)
Tohatsu MFS 30 [12/319] Service information
![Tohatsu MFS 30 [12/319] Service information](/views2/1240939/page12/bgc.png)
1-2
Service Information
25/30 2006
1.
Identification (Engine Serial Number)
Engine serial number is stamped on the bottom cowl of
outboard motor body.
2. Securing of work safety
1) Fire Prevention
Gasoline is hazardous material and very flammable. Do not
handle gasoline near ignition source such as spark or static
electricity.
2) Ventilation
Exhaust gas or gasoline vapor is hazardous for human
health. Be sure to ventilate well when working indoors.
3) Protection
Wear a pair of goggles, working gloves and safety shoes to
protect human body from chemicals and oils and eyes from
particles generated by grinding or polishing works. Avoid
adhesion of matters such as oil, grease or sealing agent to
the skin. In case of exposure to such matters, wash away
with soap or warm water immediately.
4) Genuine Parts
Use parts and/or chemicals that are genuine items or
recommended.
Tokyo, Made in Japan
2006 Model
SERIAL No. XXXXXXXX
RATED POWER
FULL THROTTLE RANGE
MASS
5000
71. 5 86 kg
6000 r / min
18. 4 kW
25B
3AD
12
3
1 Model Name
2 Model Type
3 Serial Number
MFS25_30_ch01.qxd 06.3.9 4:30 PM ページ 2
Содержание
- Ob no 03 21054 1 06 02 nb 2600 1
- Before reading this manual 3
- Information for securing of safety 3
- Introduction 3
- B 1373b 1373b 4
- Description of pictogram 4
- Mfs25_30_ch00 qxd 06 0 2 33 pm ページ 2 4
- The following symbols indicate a point to which lubrication oil sealing agent or screw locking agent is to be applied 4
- The following symbols indicate items needed for the service 4
- The following symbols represent the contents of individual chapters 4
- Break in operation 5
- Checks after test run 5
- Cooling water system diagram 5
- Ecu syste 5
- Fuel injection syste 5
- Fuel system fuel injection 5
- Inspection items 5
- Inspection schedule 5
- Maintenance 5
- Maintenance data 5
- Outline dimension 5
- Parts layou 5
- Piping arrangement diagra 5
- Pre delivery inspectio 5
- Sealant application locations 5
- Securing of work safet 5
- Service data 5
- Service information 5
- Special too 5
- Special tool 5
- Specifications 5
- Test run 5
- Tightening torque data 5
- Tools and instrument 5
- Ignition syste 6
- Inspection item 6
- Inspection items 6
- Lower unit 6
- Outline of fuel injection syste 6
- Parts layou 6
- Power unit 6
- Special tool 6
- Bracket 7
- Electrical component layou 7
- Electrical system 7
- Fuel control syste 7
- Inspection items 7
- Parts layou 7
- Ptt wiring and layout diagra 7
- Special tool 7
- Special tools 7
- Starting syste 7
- 3ac diagnosis 8
- Accessories 8
- Battery charging syste 8
- Ecu couple 8
- Ef efg eft model 8
- Ep epg ept model 8
- Mf mfg model 8
- Operation 8
- Power uni 8
- Ptt uni 8
- Remote control component 8
- Troubleshooting 8
- Troubleshooting lis 8
- Wiring chart 8
- Wiring diagram 8
- Break in operatio 11
- Checks after test ru 11
- Pre delivery inspectio 11
- Securing of work safet 11
- Service information 11
- Test ru 11
- Tools and instrument 11
- Fire prevention 12
- Genuine parts 12
- Identification engine serial number 12
- Protection 12
- Securing of work safety 12
- Service information 12
- Ventilation 12
- Recommendations on service 13
- Cautions in disassembling and assembling components 14
- Service information 14
- Measuring instruments 15
- Test propeller 15
- Tools and instruments 15
- List of special tool 16
- Service information 16
- Service information 18
- Engine oil 20
- Gear oil 20
- Gear shift 20
- Pre delivery inspection 20
- Service information 20
- Steering handle 20
- Caution 21
- Fuel line 21
- Inspection of gas shock absorber 21
- Inspection of ptt unit 21
- Rigging 21
- Inspection of starting switch and stop switch 22
- Service information 22
- Caution 23
- Cooling water check port 23
- Idling 23
- Propeller marking no of blades x diameter in mm x pitch in mm 23
- Propeller selection 23
- Break in operation 24
- Service information 24
- Trim tab 24
- Checks after test run 25
- Test run 25
- Service information 26
- Fuel injection syste 27
- Maintenance dat 27
- Outline dimension 27
- Service data 27
- Specification 27
- Tightening torque dat 27
- Engine dimensions 28
- L size 28
- Outline dimensions 28
- Service data 28
- Center line 29
- Mechanical tilt model 29
- Ptt or gas assisted model 29
- Transom bolts 29
- Ecu fuel feed system 30
- Fuel injection system 30
- Service data 30
- Engine lubrication system diagram 31
- Cooling water system diagram 32
- Service data 32
- Specifications 33
- Service data 34
- Engine parts 36
- Maintenance data 36
- Service data 36
- Functional limit action to be taken 37
- Engine parts fuel and lubrication parts 38
- Service data 38
- Functional limit action to be taken 39
- Electrical parts 40
- Part name item standard value 40
- Service data 40
- Functional limit action to be taken 41
- Cooling system parts 42
- Lower unit parts other parts ptt parts 42
- Part name item standard value 42
- Service data 42
- Functional limit action to be taken 43
- Service data 44
- Tightening torque data 44
- Standard tightening 45
- Sealant application locations 46
- Service data 46
- Service data 48
- Inspection items 49
- Inspection schedule 49
- Maintenance 49
- Special too 49
- Maintenance 50
- Special tool 50
- Inspection schedule 51
- Inspection items 52
- Inspection of fuel system piping 52
- Inspection of top cowl 52
- Maintenance 52
- Inspection of fuel filter 53
- Inspection of fuel tank 53
- Maintenance 54
- Replacement of engine oil 54
- Replacement of oil filter 55
- Inspection of gear oil quantity 56
- Inspection of water pump 56
- Maintenance 56
- Maintenance 58
- Replacement of gear oil 58
- Inspection of gear case for leakage 59
- Inspection of timing belt 60
- Maintenance 60
- Caution 61
- Replacement of timing belt 61
- Caution 62
- Maintenance 62
- Caution 63
- Installation of timing belt 63
- Caution 64
- Maintenance 64
- Inspection of spark plugs 65
- Caution 66
- Inspection of compression pressure 66
- Maintenance 66
- Inspection and adjustment of valve clearance 67
- Mark a 67
- Maintenance 68
- Throttle cable adjustment of throttle link 68
- Maintenance 70
- Warning 70
- Inspection of shift lever gear operations 71
- Maintenance 72
- Warning 72
- Inspection of gas assistant unit operations 73
- Inspection of ptt unit operation 73
- Inspection of ptt fluid quantity 74
- Maintenance 74
- Warning 74
- Inspection of idle speed 75
- Inspection of ignition timing 75
- Caution 76
- Inspection of anodes 76
- Maintenance 76
- Replacement of anodes 76
- Inspection of propeller 77
- Inspection of thermostat 77
- Inspection of cooling water passage 78
- Maintenance 78
- Caution 79
- Flushing with water 79
- Warning 79
- Maintenance 80
- Inspection of battery 81
- Lower a 81
- Warning 81
- Greasing points 82
- Maintenance 82
- Ecu system 83
- Fuel system fuel injection 83
- Ignition syste 83
- Inspection item 83
- Parts layou 83
- Piping arrangement diagra 83
- Special tool 83
- Fuel system fuel injection 84
- Special tools 84
- Fuel hose vent hose breather hose cooling water hose 85
- Piping arrangement diagram 85
- Rear section port side 85
- Starboard side 85
- Fuel pump fuel rail vapor separator 86
- Fuel system fuel injection 86
- P l fig 5 86
- Parts layout 86
- Fuel pump fuel rail vapor separator 87
- N m 4 lb ft 0 kgf m 87
- P l fig 5 87
- St oil 87
- Fuel pump fuel rail vapor separator 88
- Fuel system fuel injection 88
- P l fig 5 88
- St oil 88
- Intake manifold 89
- P l fig 4 89
- St oil 89
- Fuel system fuel injection 90
- Magneto ecu 90
- N m 4 lb ft 0 kgf m 90
- P l fig 8 90
- Electric parts 91
- P l fig 9 91
- Electric parts 92
- Fuel system fuel injection 92
- P l fig 9 92
- P l fig 24 93
- Separate fuel tank 93
- 1 configuration of ecu system 94
- Ecu system 94
- Fuel system fuel injection 94
- Sensors 95
- Fuel system fuel injection 96
- Actuators 97
- 2 control system 98
- Control system ecu 98
- Fuel system fuel injection 98
- 3 fuel injection control 99
- Fuel injection timing 99
- Injection timing diagram 99
- 4 control of fuel feed pump ffp 100
- 5 control of tachometer 100
- Acceleration fuel increase correction 100
- Correction based on cylinder cooling water temperature 100
- Correction based on intake air temperature 100
- Deceleration fuel decrease correction 100
- Fuel system fuel injection 100
- Starting fuel increase correction 100
- Locations of warning buzzer and lamp led 101
- Warning buzzer and lamp led and control of engine revolution speed 101
- Warning notification abnormality and action to be taken 101
- 1 configuration of ignition system 102
- Fuel system fuel injection 102
- Ignition system 102
- 2 ignition control 103
- Ignition and combustion orders 103
- Ignition timing 103
- Ignition timing controls 103
- Operations 103
- 3 fuel feed system 104
- Fuel air 104
- Fuel system fuel injection 104
- Components of fuel feed system 105
- Fuel pump low pressure mechanical pump 105
- Vapor separator 105
- Fuel cooler 106
- Fuel regulator 106
- Fuel system fuel injection 106
- Air intake system 107
- Outline of fuel injection system 107
- Fuel system fuel injection 108
- Inspection items 108
- Inspection of filter 108
- Fuel system fuel injection 110
- Inspection of fuel connector 110
- Inspection of fuel pump 110
- Measuring fuel pressure 111
- Warning 111
- Fuel system fuel injection 112
- Inspection of fuel regulator 112
- Warning 112
- Disassembly of vapor separator 113
- Draining fuel 113
- Warning 113
- Fuel system fuel injection 114
- Inspection of vapor separator 114
- Inspection of idle speed 115
- Inspection of isc idle speed control 115
- Reassembly of vapor separator 115
- Inspection items 117
- Parts layou 117
- Power unit 117
- Special tool 117
- Power unit 118
- Special tools 118
- Engine 119
- Parts layout 119
- P l fig 11 120
- Power unit 120
- Recoil starter 120
- Magneto ecu 121
- N m 4 lb ft 0 kgf m 121
- P l fig 8 121
- Electric parts 122
- P l fig 9 122
- Power unit 122
- Electric parts 123
- P l fig 9 123
- Fuel pump fuel rail vapor separator 124
- N m 4 lb ft 0 kgf m 124
- P l fig 5 124
- Power unit 124
- St oil 124
- Fuel pump fuel rail vapor separator 125
- N m 4 lb ft 0 kgf m 125
- P l fig 5 125
- St oil 125
- Fuel pump fuel rail vapor separator 126
- P l fig 5 126
- Power unit 126
- St oil 126
- Intake manifold 127
- P l fig 4 127
- St oil 127
- Cam shaft oil pump 128
- P l fig 6 128
- Power unit 128
- St oil 128
- Cylinder head 129
- P l fig 1 129
- St oil 129
- Intake valve exhaust valve p l fig 7 130
- Power unit 130
- St oil 130
- Cylinder 131
- P l fig 2 131
- St oil 131
- P l fig 3 132
- Piston crankshaft 132
- Power unit 132
- St oil 132
- P l fig 23 133
- Top cowl 133
- Inspection items 134
- Inspection of compression pressure 134
- Power unit 134
- Inspection of oil pressure 135
- I a ii d 136
- Inspection of valve clearance 136
- Mark b 136
- Power unit 136
- Caution 138
- Power unit 138
- Removing power unit 138
- Caution 140
- Power unit 140
- Caution 141
- Removing timing belt and pulley 141
- Inspection of timing belt 142
- Power unit 142
- 4 5 6 7 143
- Caution 143
- Installation of pulley and timing belt 143
- Caution 144
- Power unit 144
- Power unit 146
- Removing cylinder head 146
- Caution 147
- Inspection of valve spring 148
- Power unit 148
- Inspection of valve 149
- Inspection of valve guide 149
- Inspection of valve seat 150
- Power unit 150
- Correction of valve seat 151
- Power unit 152
- Caution 153
- Inspection of rocker arm and rocker arm shaft 153
- Inspection of cam shaft 154
- Power unit 154
- Inspection of cylinder head 155
- Inspection of oil pump 156
- Power unit 156
- Installation of valves 157
- Installation of cam shaft 158
- Installation of rocker arm shaft 158
- Power unit 158
- Installation of oil pump 159
- Installation of cylinder head 160
- Power unit 160
- Disassembly of cylinder block 161
- Inspection of cylinder inner diameter 162
- Inspection of piston clearance 162
- Inspection of piston outer diameter 162
- Power unit 162
- Inspection of piston ring side clearance 163
- Inspection of piston rings 163
- Inspection of connecting rod big end side clearance 164
- Inspection of connecting rod small end inner diameter 164
- Inspection of piston pins 164
- Power unit 164
- A a a a 165
- Inspection of crankshaft 165
- Inspection of crank pin oil clearance 166
- Power unit 166
- Inspection of crank shaft main journal oil clearance 167
- A a a a 168
- Bearing holder inner diameter code 168
- I ii iii iv 168
- Inner diameter of cylinder crank case 168
- Power unit 168
- Thickness of bearing color of inner diameter code 168
- Assembling piston and connecting rod 169
- Power unit 170
- Power unit 172
- Installation of power unit 173
- Caution 174
- Power unit 174
- Disassembly of recoil starter 175
- Removing recoil starter 175
- Inspection of recoil starter 176
- Power unit 176
- Installation of recoil starter 177
- Power unit 178
- Inspection items 179
- Lower unit 179
- Parts layout 179
- Special tool 179
- Lower unit 180
- Special tools 180
- Gear case 182
- Lower unit 182
- P l fig 14 182
- Parts layout 182
- A projection b hole 183
- Drive system water pump 183
- N m 18 lb ft 2 kgf m 183
- N m 4 lb ft 0 kgf m 183
- P l fig 15 183
- A projection b hole 184
- Drive system water pump 184
- Lower unit 184
- N m 18 lb ft 2 kgf m 184
- N m 4 lb ft 0 kgf m 184
- P l fig 15 184
- P l fig 16 185
- Draining gear oil 186
- Inspection items 186
- Lower unit 186
- Removing propeller 186
- Disassembly of water pump 187
- Removing lower unit 187
- Inspection of water pump 188
- Lower unit 188
- Removing propeller shaft housing ass y 188
- Assembly of propeller shaft ass y 189
- Caution 189
- Disassembly of propeller shaft ass y 189
- Inspection of propeller shaft 189
- Disassembly of propeller shaft housing 190
- Lower unit 190
- Inspection of propeller shaft housing 191
- Assembly of propeller shaft housing 192
- Lower unit 192
- Assembly of pump case lower 193
- Disassembly of clutch cam and cam rod 193
- Disassembly of pump case lower 193
- Removing clutch cam and cam rod 193
- Removing pump case lower 193
- Assembly of cam rod and clutch cam 194
- Disassembly of drive shaft 194
- Inspection of cam rod and clutch cam 194
- Lower unit 194
- Removing drive shaft 194
- Assembly of forward gear a gear 195
- Disassembly of forward gear a gear 195
- Inspection of drive shaft 195
- Inspection of pinion gear b gear and forward gear a gear 195
- Assembly of drive shaft 196
- Caution 196
- Disassembly of gear case 196
- Lower unit 196
- Assembly of lower unit 197
- Inspection of gear case 197
- 72732 0 198
- 72733 0 198
- B7 72731 0 198
- Installation of pinion gear b gear 198
- Lower unit 198
- Settling pinion gear b gear height 199
- Lower unit 200
- Lower unit 202
- Settling forward gear a gear backlash 202
- Lower unit 204
- Assembly of propeller shaft housing 205
- Reassembly of pinion gear nut b gear nut 205
- Assembly of water pump 206
- Lower unit 206
- Reassembly of pump case lower 206
- Installation of lower unit 208
- Lower unit 208
- Warning 209
- Lower unit 210
- Bracket 211
- Inspection items 211
- Parts layou 211
- Ptt wiring and layout diagra 211
- Special tools 211
- Bracket 212
- Mount puller kit p n 361 72760 0 212
- Removing upper mount 212
- Special tools 212
- Ptt wiring and layout diagram 213
- Bracket 214
- Drive shaft housing 214
- P l fig 13 214
- Parts layout 214
- P l fig 19 215
- Swivel bracket mechanical tilt 215
- 5 2 8 9 216
- 6 34 33 216
- Bracket 216
- Clamp bracket reverse lock 216
- N m 8 lb ft 1 kgf m 216
- P l fig 18 216
- Bracket ptt gas assistant 217
- N m 17 lb ft 2 kgf m 217
- N m 8 lb ft 1 kgf m 217
- P l fig 20 217
- Bracket 218
- Bracket ptt gas assistant p l fig 20 218
- N m 17 lb ft 2 kgf m 218
- N m 8 lb ft 1 kgf m 218
- A chamfer 219
- N m 1 lb ft 0 kgf m 219
- N m 112 lb ft 15 kgf m 219
- N m 18 lb ft 3 kgf m 219
- N m 4 lb ft 0 kgf m 219
- N m 5 lb ft 0 kgf m 219
- P l fig 21 219
- Power trim tilt 219
- 25 8 7 220
- Bracket 220
- P l fig 12 220
- Tiller handle 220
- Bottom cowl 221
- P l fig 22 221
- Bracket 222
- P l fig 16 222
- N m 30 lb ft 4 kgf m 223
- P l fig 17 223
- Bracket 224
- Inspection items 224
- Inspection of throttle cable 224
- Installation of tiller handle 224
- Adjustment of co pilot plate 225
- Bracket 226
- Removing drive shaft housing 226
- Disassembly of drive shaft housing 227
- Pulling out upper mount 227
- Assembly of drive shaft housing 228
- Bracket 228
- Inspection of oil strainer 228
- Installation of drive shaft housing ass y 229
- Bracket 230
- Installing steering shaft 230
- Removing steering shaft 230
- Removing clamp bracket mechanical tilt model 231
- Removing clamp bracket ptt or gas assistant model 231
- Bracket 232
- Installation of clamp bracket ptt or gas assistant model 232
- Installation of clamp bracket mechanical tilt model 233
- Bracket 234
- Removing ptt unit gas shock absorber 234
- Caution 235
- Inspection of ptt pump and valves 235
- Removing ptt motor 235
- Removing ptt pump and valves 235
- Bracket 236
- Caution 236
- Inspection of tilt cylinder 236
- Removing tilt cylinder 236
- Inspection of valve 237
- Installation of ptt pump and motor 237
- Assembly of tilt cylinder 238
- Bracket 238
- Air purging ptt unit separated from outboard motor 240
- Bracket 240
- Warning 240
- Bracket 242
- Installation of ptt unit gas shock absorber 242
- Air purging ptt unit installed on the outboard motor 243
- Warning 243
- Bracket 244
- Inspection of ptt solenoid 244
- Up down 244
- Inspection of ptt switch 245
- Battery charging system 247
- Ecu coupler 247
- Electrical component layout 247
- Electrical system 247
- Fuel control system 247
- Parts layout 247
- Special tools 247
- Starting syste 247
- Electrical system 248
- Special tools 248
- Electrical component layout port side view 249
- Bow side view 250
- Electrical system 250
- Starboard side view 251
- Electrical system 252
- Top view 252
- Tiller handle model 253
- Electrical system 254
- Magneto ecu 254
- P l fig 8 254
- Parts layout 254
- Electric parts 255
- P l fig 9 255
- Electric parts 256
- Electrical system 256
- P l fig 9 256
- 13 1 7 257
- P l fig 10 257
- Starter motor 257
- Electrical system 258
- Fuel pump fuel rail vapor separator 258
- N m 4 lb ft 0 kgf m 258
- P l fig 5 258
- St oil 258
- Fuel pump fuel rail vapor separator 259
- N m 4 lb ft 0 kgf m 259
- P l fig 5 259
- St oil 259
- Electrical system 260
- Ignition system ignition control system 260
- Inspection of ignition sparks 260
- Inspection of plug cap 260
- Inspection of alternator 261
- Inspection of ignition coils 261
- Electrical system 262
- Inspection of oil pressure switch 262
- Inspection of pulser coil 262
- Inspection of neutral switch tiller handle model 263
- Inspection of start switch tiller handle model 263
- Inspection of water temperature sensor 263
- Off on 263
- Electrical system 264
- Inspection of stop switch 264
- Fuel control system 265
- Inspection of injectors 265
- Inspection of isc valve 265
- Electrical system 266
- Inspection of fuel feed pump ffp 266
- Inspection of mat manifold temperature sensor 266
- Inspection of throttle position sensor 266
- Disassembly of starter motor 267
- Inspection of fuse 267
- Inspection of starter solenoid 267
- Starting system 267
- 3 3 3 3 3 1 268
- Electrical system 268
- Inspection of armature 268
- Inspection of starter motor pinion 268
- Inspection of brushes 269
- Inspection of starter motor operation 269
- Battery charging system 270
- Electrical system 270
- Inspection of alternator 270
- Inspection of rectifier 270
- Ecu coupler 271
- Electrical system 272
- Troubleshooting 274
- Troubleshooting list 274
- Power unit 275
- Starting system 275
- Troubleshooting 276
- Ignition system 277
- Warning 277
- Yes yes 277
- Troubleshooting 278
- Fuel system 279
- Troubleshooting 280
- State 2 281
- Ignition system 282
- Troubleshooting 282
- Fuel system 283
- Yes yes 283
- Lubrication system 284
- Troubleshooting 284
- Cooling system 285
- Troubleshooting 286
- Ignition system 287
- Warning 287
- Fuel system 288
- Troubleshooting 288
- Ptt unit 289
- State 1 ptt will not operate 289
- Troubleshooting 290
- Ac diagnosis 291
- Caution 291
- Set up 291
- Warning 291
- Software install 292
- Troubleshooting 292
- Diagnosis file information 293
- If putting cd into cd drive will not cause installation software to start 293
- Hardware connection 294
- Troubleshooting 294
- Position of on off switch for function test and running drop test 295
- Operating procedure 296
- Troubleshooting 296
- Setting communication com port rs232c port 297
- Monitoring ecu data 298
- Troubleshooting 298
- Monitoring history and failure code retrieval 299
- Function test 300
- Troubleshooting 300
- Running test drop test 301
- Troubleshooting 302
- Exit diagnostic 303
- Explanation of error code 303
- Troubleshooting 304
- Accessories 305
- Accessories 306
- Remote control components 306
- Remote control model 306
- Warning 307
- Accessories 308
- Caution 308
- Installation of battery 309
- Installation of meters 309
- Installation of meters and battery 309
- Accessories 310
- Wiring diagram of remote and control meters 310
- Operation 311
- Warning indication 311
- Accessories 312
- Ef efg eft model 313
- Ep epg ept mode 313
- Mf mfg mode 313
- Wiring char 313
- Wiring diagram 313
- Wiring diagram 314
- Ob no 03 21054 1 06 02 nb 2600 319
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