TOHATSU MFS 4 Service Manual page 8

19) Inspection of Piston Outer Diameter ............... 5-30
20) Inspection of Cylinder Inner Diameter............... 5-30
21) Inspection of Piston Clearance ..................... 5-30
22) Inspection of Piston Ring Side Clearance ......... 5-31
23) Inspection of Piston Rings ........................... 5-31
24) Inspection of Piston Pin................................. 5-32
25) Inspection Connecting Rod Small End
Inner Diameter .......................................... 5-32
26) Inspection of Connecting Rod Big End
Inner Diameter .......................................... 5-32
27) Inspection of Connecting Rod Big End
Side Clearance .......................................... 5-33
28) Inspection of Crank Shaft ..............................5-33
29) Disassembly and Inspection of Oil Pan ............ 5-34
30) Removal of Valves and Springs ..................... 5-35
31) Inspection of Valve Springs ........................... 5-35
32) Inspection of Valve....................................... 5-36
33) Inspection of Valve Guide .............................. 5-36
34) Inspection of Valve Seat .............................. 5-37
35) Correction of Valve Seat .............................. 5-38
36) Installation of Valves .................................... 5-41
37) Installation of Piston and Connecting Rod ......... 5-42
38) Assembly of Cylinder Oil Pan ........................ 5-43
39) Installation of Cylinder Head........................... 5-45
40) Installing Flywheel ....................................... 5-47
41) Installation of Power Unit .............................. 5-50
6.Lower Unit
1. Special Tools
2. Parts Layout
Drive Shaft Housing............................................. 6-4
3. Inspection Items
1) Draining Gear Oil .......................................... 6-8
2) Removing Propeller ....................................... 6-8
3) Removing Lower Unit .................................... 6-9
4) Disassembly of Water Pump ........................... 6-9
5) Inspection of Water Pump.............................. 6-10
6) Removing Propeller Shaft Housing Ass'y ......... 6-11
7) Disassembly of Propeller Shaft Housing ......... 6-12
8) Inspection of Propeller Shaft Housing............... 6-12
9) Assembly of Propeller Shaft Housing ............... 6-13
10) Removing Drive Shaft ................................. 6-13
11) Disassembly of Propeller Shaft Ass'y ............... 6-14
12) Inspection of Propeller Shaft ........................ 6-14
13) Assembly of Propeller Shaft Ass'y .................. 6-14
14) Removing Clutch Cam and Cam Rod............... 6-15
15) Disassembly of Clutch Cam and Cam Rod ...... 6-15
16) Inspection of Clutch Cam and Cam Rod ......... 6-15
17) Assembly of Clutch Cam and Cam Rod ............ 6-16
18) Removing Pump Case (Lower) ..................... 6-16
19) Disassembly of Pump Case (Lower) ............... 6-16
20) Assembly of Pump Case (Lower) .................. 6-16
21) Inspection of Drive Shaft .............................. 6-17
22) Inspection of Pinion (B) Gear and
Forward (A) Gea.......................................... 6-17
23) Disassembly of Gear Case ........................... 6-18
24) Inspection of Gear Case .............................. 6-19
25) Assembly of Gear Case .............................. 6-19
26) Installation of Forward Gear and
Pinion Gear (A and B Gears) ........................ 6-20
27) Reassembly of Pump Case (Lower) ............... 6-20
28) Installation of Clutch Cam and Cam Rod ......... 6-20
29) Determination of forward (A) gear backlash ...... 6-21
vi
............................................. 6-2
............................................. 6-3
.................................... 6-8
30) Installation of Water Pump ........................... 6-23
31) Installation of Propeller Shaft Housing ............ 6-24
32) Filling with Gear Oil .................................... 6-25
33) Installation of Lower Unit .............................. 6-25
7.Bracket
1. Parts Layout
............................................. 7-2
Bracket & Reverse Lock ....................................... 7-2
Drive Shaft Housing & Shift ................................. 7-4
Bottom Cowl & Tiller Handle ................................. 7-6
Cowl ............................................................... 7-8
2. Disassembling and Assembling
Procedure
................................................... 7-9
1) Removal and inspection of drive shaft housing ... 7-9
2) Removal and inspection of clamp bracket ............ 7-11
3) IInstallation of clamp bracket and drive shaft ... 7-12
4) Removal, inspection and installation of water pipe ... 7-14
5) Remove, inspection and installation of tiller handle ... 7-15
6) Adjustment of Throttle Cable ........................ 7-18
8.Electrical System
1. Special Tools
............................................. 8-2
Magneto............................................................ 8-3
Ignition System and Ignition
2.
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
5) Inspection of Oil Pressure Switch ..................... 8-7
6) Inspection of Rectifier .................................... 8-8
7) Inspection of Lighting Coil .............................. 8-8
9.Troubleshooting
1. Troubleshooting List
2. Power Unit
................................................ 9-3
1 Engine will not start or is a little hard to start.
(Recoil starter operates normally.) ........................ 9-3
2 Engine starts but stalls soon. .............................. 9-5
Fuel System ................................................ 9-5
Ignition System ............................................. 9-6
Intake • Compression Pressure ........................ 9-7
3 Idle engine speed will not stabilize. ..................... 9-8
4 Rough acceleration. .......................................... 9-9
5 Gear shifting cannot be made normally. ............... 9-10
10.Wiring Diagram
11.C Model
Service Information
1. Specification • Service Data
2. Parts Layout
.......................................... 11-12
3. Difference item
.................................... 11-30
.............................. 9-2
............ 11-2
4st 4/5/6 2011