Table Of Contents - TOHATSU MFS25 Service Manual

1.Service Information
1 Identification (Engine Serial Number)
2 Securing of 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) Measuring instruments ........................ 1-5
3) List of Special Tool .............................. 1-6
4 Pre-delivery Inspection
1) Steering Handle ................................. 1-10
2) Gear Shift .......................................... 1-10
3) Engine Oil .......................................... 1-10
4) Gear Oil ............................................. 1-10
5) Fuel Line .......................................... 1-11
6) Rigging ............................................. 1-11
7) Inspection of PTT unit ........................... 1-11
8) Inspection of gas shock absorber ............ 1-11
9) Inspection of starting switch and stop switch ... 1-12
10) Cooling water check port ..................... 1-13
11) Idling ................................................ 1-13
12) Propeller Selection .............................. 1-13
13) Trim Tab .......................................... 1-14
5 Break-in Operation .....................
6 Test Run .......................................
7 Checks After Test Run ...............
2.Service Data
1 Outline Dimensions
1) Engine Dimensions .............................. 2-2
2) Transom Bolts .................................... 2-3
2 Fuel Injection System
1) ECU Fuel Feed System ........................ 2-4
3 Engine Lubrication System Diagram ...
4 Cooling Water System Diagram ...
5 Specifications ..............................
6 Maintenance Data ........................
7 Tightening Torque Data ...............
8 Sealant Application Locations ...
3.Maintenance
1 Special Tool
2 Inspection Schedule
3 Inspection Items
1) Inspection of Top Cowl ........................ 3-4
2) Inspection of Fuel System Piping ............ 3-4
3) Inspection of Fuel Tank ........................ 3-5
4) Inspection of Fuel Filter ........................ 3-5
5) Replacement of Engine Oil..................... 3-6
6) Replacement of Oil Filter ..................... 3-7
7) Inspection of Gear Oil Quantity ............... 3-8
25/30 2006
...... 1-2
............... 1-2
.................. 1-5
.................. 1-10
1-14
1-15
1-15
........................ 2-2
..................... 2-4
2-5
2-6
2-7
2-10
2-18
2-20
.................................... 3-2
..................... 3-3
........................... 3-4
8) Inspection of Water Pump.................. 3-8
9) Replacement of Gear Oil .................. 3-10
10) Inspection of Gear Case (for leakage) ... 3-11
11) Inspection of Timing Belt .................. 3-12
12) Replacement of Timing Belt ............... 3-13
13) Installation of Timing Belt .................. 3-15
14) Inspection of Spark Plugs .................. 3-17
15) Inspection of Compression Pressure ... 3-18
16) Inspection and Adjustment of Valve Clearance ... 3-19
17) Throttle Cable Adjustment of Throttle Link ... 3-20
18) Inspection of Shift Lever Gear Operations ... 3-23
19) Inspection of PTT Unit Operation ...... 3-25
20) Inspection of Gas Assistant Unit Operations ... 3-25
21) Inspection of PTT Fluid Quantity ......... 3-26
22) Inspection of Idle Speed .................. 3-27
23) Inspection of Ignition Timing............... 3-27
24) Inspection of Anodes ........................ 3-28
25) Replacement of Anodes .................. 3-28
26) Inspection of Propeller ..................... 3-29
27) Inspection of Thermostat .................. 3-29
28) Inspection of Cooling Water Passage... 3-30
29) Flushing with Water ........................ 3-31
30) Inspection of Battery ........................ 3-33
31) Greasing Points .............................. 3-34
4.Fuel System (Fuel Injection)
1 Special Tools
.............................. 4-2
2 Piping Arrangement Diagram
Fuel Hose, Vent Hose, Breather Hose, Cooling Water Hose ...... 4-3
3 Parts Layout
................................. 4-4
Fuel Pump, Fuel Rail, Vapor Separator ... 4-4
Intake Manifold .................................... 4-7
Magneto & ECU ................................. 4-8
Electric Parts....................................... 4-9
Separate Fuel Tank .............................. 4-11
4 ECU System
................................. 4-12
(1) Configuration of ECU System ...
1) Sensors ....................................... 4-13
2) Actuators ....................................... 4-15
3) Control System (ECU) ..................... 4-16
(2) Control System ........................... 4-16
(3) Fuel Injection Control ............... 4-17
1) Fuel Injection Timing ........................ 4-17
2) Starting Fuel Increase Correction ...... 4-18
3) Acceleration Fuel Increase Correction ... 4-18
4) Deceleration Fuel Decrease Correction ... 4-18
5) Correction Based On Intake Air Temperature ... 4-18
6) Correction Based On Cylinder Cooling Water Temperature ... 4-18
(4) Control of Fuel Feed Pump (FFP) ... 4-18
(5) Control of Tachometer ............... 4-18
(6) Warning Buzzer and Lamp (LED),and
Control of Engine Revolution Speed...... 4-19
1) Locations of warning buzzer and lamp (LED) ... 4-19
2) Warning notification, abnormality and action to be taken ... 4-19
... 4-3
4-12
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