TOHATSU MFS 4D Service Manual page 4

About this manual
This service manual is designed so that service persons are able to perform their work correctly.
Understand the following matters well for efficient repairs.
1 Each chapter begins with the introduction of special tools that are used for the work described in the chapter so that
the service persons are able to understand the tools needed.
2 Parts that are serviced in each chapter and their details are presented by using a component composition
diagram.
3 Fastening torques are described in the component composition diagram and in the body text and are
critical points of the applicable repair.
4 Pictograms indicate that there is an important instruction for the relevant parts. It also shows the type of
lubricant and its application point(s).
5 The component composition diagrams describe the names of the parts, the quantity of the parts used,
size of fasteners and special notes.
6 Specific works are described in detail by using illustrations and adding advice on the work.
1
Lower Unit
1. Special Tools
Spring Pin Tool A Spring Pin Tool B Center Plate
P/N. 345-72227-0 P/N. 345-72228-0 P/N. 3AB-99701-0
Used in combination with driver rod and Used in combination with center plate and
Removing spring pin Installing spring pin
bearing attachment to locate lower gear
case bearing
Bearing Attachment Needle Bearing Press Kit Backlash Measuring Tool Kit
P/N. 3BV-99905-0 P/N. 369-72900-0 P/N. 369-72740-0
Measuring gap between forward and
Installing bearings Installing bearings
pinion gears (A and B gears)
Dial Gauge Plate
P/N. 3B7-72729-0
Used to attach dial gauge
when measuring backlash
ii
Lower Unit
Gear Case (Drive Shaft) • Gear Case (Propeller Shaft)
Driver Rod
P/N. 3AB-99702-0
bearing attachment
TEF
TEF
43
Clamp A
OBM OBM
OBM
P/N. 3B7-72720-0
47
35
Measuring backlash
OBM OBM
OBM 36
41
30
GEAR GEAR
GEAR
44
29
49
51
6
48
5
B 50
52
Sail Pro
A
2
45
46
3
4
56
54
55
24
OBM OBM
53
OBM
25
20
3 4
13
1
17
14
6 N·m (4 lb·ft) [0.6 kgf·m]
19
13 N·m (9 lb·ft) [1.3 kgf·m]
22
23
7
GEAR GEAR
GEAR
12
15
16
LIT
LIT
3
2
4
P/C Fig. 8
Ref.
No.
58 1-1 Gear Case Assy
59
1-2 Gear Case Assy
2 Roller Bearing 14-20-12
3 Plug 8-8
4 Gasket
5 Anode
6 Bolt
7 Ball Bearing 6004
8 Propeller Shaft Housing Assy
9 Propeller Shaft Housing
10 Oil Seal 15-28-10
11 O-Ring 3.2-47
12 Ball Bearing 6002
26
42
13 Bevel Gear Assy (A)
14 Bevel Gear B
15 Bevel Gear Assy (C)
16 Washer 15.2-19-1.9
27
30a
17-1 Shim 21-28-0.1
30a
31
A
17-2 Shim 21-28-0.15
28
18 Propeller Shaft
GEAR GEAR
OBM OBM
GEAR 19 Clutch
OBM
33
20 Pin 3.5-28
32
21 Spring
22 Spring Retainer
34
B
23 Push Rod
37
24 Water Strainer
25 Screw
LIT
LIT
38
26 Water Pipe (Lower)
27 Seal
39
GEAR GEAR
GEAR
28 Water Pump Impeller
40
61 Key φ 2-11
29
OBM OBM
OBM
30 Pump Case (Upper)
65
30a Dowel Pin
31 Pump Case Liner
32 Water Pump Guide Plate
18 62
64
33 Pump Case Gasket
21 63
34 Guide Plate Gasket
35 Bolt
60
36 Washer
57
11 9 37 Pump Case (Lower)
10
38 Oil Seal 10-24-8
8
39-1 Shim 26.5-34.8-0.1
39-2 Shim 26.5-34.8-0.15
OBM OBM
40 Pump Case Gasket (Lower)
OBM
41 Bolt
GEAR OBM
42 Water Pipe Seal (Lower)
GEAR GEAR OBM OBM
LIT TEF
LIT
TEF
6
5
Description Q'ty Remarks
1 STD
1 for Sail Pro
1
2
2 Do not reuse.
1
1 M6 L=16mm
1
1
1
1
1 Do not reuse.
1
1
1
1
1
A
A
1
1
1
1
1
1
1
1 M6 L=20mm
1
2
1
1 Pump Impeller
1
2
1
1
1 Do not reuse.
1 Do not reuse.
4 M6 L=45mm
4 M6
1
1
A
Lower Unit
A
1 Do not reuse.
1 M6 L=25mm
7) Disassembly of Propeller Shaft Housing
1
Remove bearing 1 by using commercially available bearing
1.
puller.
Before removing, check bearing for play or
deflection. Replace if necessary.
CAUTION
Do not reuse removed bearing.
Remove oil seal 2.
2.
8) Inspection of Propeller Shaft Housing
1. Use cleaning oil and cleaning brush to clean propeller shaft
housing, and check it for crack or damage. Replace if
necessary.
2. Check reverse (C) gear teeth and clutch for crack or
damage. Replace if necessary.
When reusing bearing without removing it, check
it for play or deflection. Replace if necessary.
6
1
1 Bearing
Do not reuse.
2
2 Oil Seal
Do not reuse.
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