Table Of Contents - TOHATSU MFS 4 Service Manual

1.Service Information
1. Identification (Engine Serial Number)
2. Work Safety
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) Test Propeller ............................................. 1-5
2) Instruments ................................................ 1-5
3) Special Tools................................................ 1-6
4. Pre-delivery Inspection
1) Steering Handle .......................................... 1-8
2) Gear Shift ................................................... 1-8
3) Engine Oil ................................................... 1-8
4) Gear Oil ...................................................... 1-8
5) Fuel Tank Line ............................................. 1-9
6) Rigging ...................................................... 1-9
7) Inspection of Tilt Stoppe ................................. 1-9
8) Inspection of Stop Switch .............................. 1-9
9) Cooling Water Check Port ........................... 1-10
10) Idle Operation ............................................. 1-10
11) Propeller Selection ....................................... 1-11
12) Inspection of Forward and Reverse Shifts ......... 1-11
13) Trim Tab ................................................... 1-12
5. Break-in Operation
6. Test Run
................................................... 1-12
7. Check After Test Run
2.Service Data
1. Outline Dimensions
1) Engine Dimensions ....................................... 2-2
2) Clamp Dimensions ....................................... 2-4
2. Engine Lubrication System Diagram
3. Cooling Water System Diagram
4. Specifications
5. Maintenance Data
6. Tightening Torque Specifications
7. Sealant and Lubricant
3.Maintenance
1. Special Tools
2. Inspection Schedule
3. Inspection Items
1) Inspection of Top Cowl ................................. 3-4
2) Fuel System ................................................ 3-4
3) Inspection of Fuel Tank ................................. 3-5
4) Inspection of Fuel Filter ................................. 3-5
5) Replacement of Engine Oil .............................. 3-6
6) Inspection of Gear Oil Quantity ........................ 3-7
7) Inspection of Water Pump .............................. 3-7
8) Replacement of Gear Oil
9) Inspection of Gear Case (for leakage) ............... 3-10
10) Inspection of Spark Plugs .............................. 3-11
11) Inspection of Compression Pressure ............... 3-12
12) Inspection and Adjustment of Valve Clearance... 3-13
13) Throttle Cable ............................................. 3-15
14) Inspection of Idle Engine Speed ..................... 3-17
15) Inspection of Ignition Timing........................... 3-17
4st 4/5/6 2011
............................................. 1-2
........................... 1-5
........................ 1-8
................................. 1-12
........................... 1-13
................................. 2-2
......... 2-6
.......................................... 2-8
................................. 2-10
............ 2-14
........................ 2-15
............................................. 3-2
.............................. 3-3
.................................... 3-4
.............................. 3-9
16) Inspection of Anode .................................... 3-18
17) Replacement of Anode ................................. 3-18
... 1-2
18) Inspection of Propeller ................................. 3-19
19) Inspection of Thermostat .............................. 3-19
20) Inspection of Cooling Water Passage............... 3-20
21) Flushing with Water .................................... 3-21
22) Greasing Points .......................................... 3-22
4.Fuel System
1. Special Tools
2. Parts Layout
Carburetor & Fuel Pump ....................................... 4-4
Integral Fuel Tank ............................................. 4-6
3. Carburetor Inner Passages
1) Idling Passage ............................................. 4-8
2) Off-Idle Passage .......................................... 4-9
3) High Speed Passage .................................... 4-10
4) Choking Passage ....................................... 4-11
4. Inspection Items
1) Inspection of Fuel Feed System Piping ............ 4-12
2) Draining Fuel ............................................. 4-12
3) Inspection of Fuel Tank and Fuel Tank Cap ...... 4-13
4) Inspection of Fuel Cock................................. 4-13
5) Inspection of Fuel Filter ................................. 4-13
6) Removing Carburetor ................................. 4-14
7) Disassembling Carburetor ........................... 4-16
8) Inspection and clean of Carburetor .................. 4-17
9) Inspection of Fuel Connector ........................ 4-18
10) Assembling of Carburetor
11) Adjustment of Float Height ........................... 4-19
12) Installing Carburetor .................................... 4-19
13) Removing Fuel Pump ................................. 4-20
14) Disassembly and Inspection of Fuel Pump ...... 4-20
15) Assembly of Fuel Pump .............................. 4-21
5.Power Unit
1. Special tools
2. Parts Layout
...2-5
Engine ............................................................ 5-3
Magneto............................................................ 5-4
Cylinder & Oil Pan ............................................. 5-6
Cylinder Head & Valve & Cam Shaft ..................... 5-8
Piston & Crank Shaft .......................................... 5-10
Recoil Starter ................................................... 5-11
Top Cowl ......................................................... 5-12
3. Inspection Items
1) Inspection of Compression Pressure ............... 5-13
2) Inspection of Valve Clearance ........................ 5-14
3) Removing Power Unit ................................. 5-16
4) Removal and Disassembly of Crank Case Head ... 5-17
5) Inspection of Crank Case Head ..................... 5-18
6) Assembly of Crank Case Head ..................... 5-18
7) Installation of Crank Case Head ..................... 5-18
8) Disassembly of Power Unit ........................... 5-19
9) Removal of Rocker Arm .............................. 5-22
10) Removing Cylinder Head .............................. 5-23
11) Inspection of Rocker Arm and Pivot ............... 5-23
12) Inspection of Push Rod Plate ........................ 5-23
13) Inspection of Push Rod ................................. 5-23
14) Disassembly and Inspection of Oil Feed Pump...... 5-23
15) Disassembly of Cylinder and oil pan ............... 5-26
16) Disassembly and Inspection of Breather Chamber ... 5-28
17) Inspection of Lifter....................................... 5-28
18) Inspection of Cam Shaft .............................. 5-29
.......................................... 4-2
............................................. 4-4
.................. 4-8
.................................... 4-12
........................... 4-18
............................................. 5-2
............................................. 5-3
.................................... 5-13
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