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TOHATSU 5 Service Manual

4-stroke cycle

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Owner's handbook manual (32 pages)

Service data (208 pages)

Table Of Contents

Table of Contents

Contents
Specifications
Outline Dimensions
Service Data and Maintenance Standards
Table of Points to Apply Sealants, Adhesives and Lubricants
Table of Tightening Torque
Tools and Instruments Required for Disassembly and Repair
How to Use Special Tools
Flywheel Cup Puller
Piston Pin Tool
Piston Slider
Drive Shaft Bearing Tool
Backlash Measuring Tool
Spring Pin Tool
Inspection and Maintenance
Periodical Inspections
Troubleshooting
Points to Apply Oil or Grease
Change of Engine Oil
Change of Gear Oil
Inspection of Ignition System
Inspection of Fuel System
Inspection of Compressor System
Inspection of Gear Shift and Propeller System
Inspection of Cooling System
Power Unit
Removing Power Unit
Removing Parts
Disassembling Engine
Cylinder Head, Valves and Relating Parts
Oil Pan (Exhaust Manifold), Oil Pump and Relating Parts
Crank Shaft, Cam Shaft, Piston, Cylinder and Related Parts
Inspection and Measurement of Engine Parts
Measurement with Vernier Calipers
Measurement with Depth Gauge or Calipers
Measurement with Micrometer
Measurement with Cylinder Gauge
Measurement with Thickness Gauge
Measurement with Plastigage
Measurement with Pressure Gauge
Other Inspections
Repair and Replacement of Engine Parts
Repair of Valve Seat
Reassembling Engine
Piston Ring
Lower Unit
Disassembling Gear Case
Removing Propeller
Disassembling Propeller Shaft and Clutch
Disassembling Water Pump Case
Removing Cam Rod, Drive Shaft and Bevel Gear
Inspection of Parts Related to Gear Case
Reassembling Gear Case
Clutch and Related Parts
Bevel Gears and Related Parts
Propeller Shaft Housing
Water Pump and Related Parts
Volume of Gear Oil Required to Pour in
Sectional View of Gear Case Assembly
Gear Shift
Gear Case, Shaft, Water Pump
Disassembling Lower Motor Cover and Drive Shaft Housing
Reassembling Lower Motor Cover and Drive Shaft Housing
Drive Shaft Housing, Gear Case, Motor Cover
Bracket, Reverse Lock Arm
Handle, Throttle
Recoil Starter Disassembling
Recoil Starter Reassembling
Recoil Starter, Starter Lock
Carburetor
Fuel Pump
Electrical System
Electric Circuit Diagram
Flywheel Inspection
Exciter Coil, Pulsator Coil, Ignition Coil Inspection
C.D. Unit Inspection
Manner to Check Ignition Timing
Magneto
Test Run and Inspection after Complete Assembly
Test Run Tank and Test Propeller
Items to be Checked During Test Run
Additional Tightening after Test Run
Break-In
Optional Parts
Remote Control System
Location of Remote Control Box
Installing Remote Control Cable (Control Box Side)
Installing the Remote Control Cable (Engine Side)
Optional Parts (Remote Control)
Lighting Coil and Rectifier Kit
Installing Rectifier Kit
Inspection of Rectifier and Fuse
Vertical Starter Kit

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Page 78 Copyright © 2007 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Tohatsu Corporation.

This manual is also suitable for:

M25c2 M30a3 M2.5a M3.5a M40d M50d

TOHATSU 5 Service Manual

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