![Tohatsu MFS 30 [162/319] Power unit](/img/pdf.png)
Tohatsu MFS 30 [162/319] Power unit
![Tohatsu MFS 30 [162/319] Power unit](/views2/1240939/page162/bga2.png)
5-46
Power Unit
25/30 2006
24) Inspection of Piston Outer Diameter
1. Measure piston outer diameter between points specified.
Replace if the diameter is less than specified value.
Piston Outer Diameter a : Standard Value
60.96 mm ( 2.4000 in )
Measurement Points b :
9mm ( 0.35 in ) above piston skirt bottom
Functional Limit :
60.90 mm ( 2.3976 in )
a
b
d
e
a
b
c
25)
Inspection of Cylinder Inner Diameter
1. Measure cylinder inner diameters (D1 to D6) at a, b and c
in crankshaft directions d (D1, D3 and D5 respectively), and
in crank web directions e (D2, D4 and D6 respectively).
2. Obtain taper through calculation described below. Replace
cylinder block if taper is over specified value.
3. Obtain out-of-roundness through calculation described
below. Replace cylinder block if out-of-roundness is over
specified value.
Piston Clearance :
0.020 to 0.055 mm ( 0.00079 to 0.00217 in )
Functional Limit :
0.150 mm ( 0.00591 in )
26) Inspection of Piston Clearance
1. If piston clearance is over specified limit, replace cylinder
block, piston and piston rings as a set, or both.
Note : Measure at the maximum wear points.
Cylinder Inner Diameters (D1 to D6) : Standard Value
61.00 mm ( 2.4016 in )
Functional Limit :
Replace if over 61.06 mm ( 2.4039 in ).
Taper :
D1
–
D5 ( Measurement Point a )
D2
–
D6 ( Measurement Point c )
Functional Limit :
0.08 mm ( 0.0032 in )
Out-of-roundness :
D2
–
D1 ( Direction d )
D6
–
D5 ( Direction e )
Functional Limit :
0.06 mm ( 0.0024 in )
a 15mm ( 0.6in )
b 35mm ( 1.4in )
c 55mm ( 2.2in )
MFS25_30_ch05.qxd 06.3.9 4:49 PM ページ 46
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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