TOHATSU MFS 25D Service Manual page 4

About this manual
Composition and use of this manual
This service manual is designed so that service persons are able to perform repairs correctly.
Understand the following matters well for efficient service and repair.
1 Each chapter begins with the introduction of special tools that are used for the work described.
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. In the body text are critical
points of the applicable work.
4 Pictograms indicate that there is an important work 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 number of pieces 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.
Lower Unit
1. Special Tools
25
Spring Pin Tool A Spring Pin Tool B Bevel Gear B Nut Wrench Bevel Gear B Nut Socket
P/N. 345-72227-0 P/N. 345-72228-0 P/N. 346-72231-0 P/N. 346-72232-0
Removing spring pin Installing spring pin Removing and installing bevel gear B nut
ø79.5 x ø51.5
Thickness Gauge Center Plate Driver Rod Roller Bearing Attachment
P/N. 353-72251-1 P/N. 3VS-99701-0 P/N. 3AC-99702-0 P/N. 3AC-99710-0
Positioning propeller shaft Installing and removing Installing propeller shaft
Measuring gaps
housing roller bearing bearing and oil seal housing roller bearing
ø51.5 x ø24.5 ø27.5 x ø15.5 ø29.5 x ø16.5
3BJ-72732-0
Bearing Attachment Oil Seal Attachment Oil Seal Attachment Bearing Outer Press Kit
P/N. 3AC-99905-0 P/N. 3AD-99820-0 P/N. 3AG-99820-0 P/N. 3B7-72739-1
Installing bevel gear Installing oil seal of Installing pump case Bevel Gear Assy A
C ball bearing propeller shaft housing (lower) oil seal Installing bearing outer race
Backlash Measuring Tool Clamp Dial Gauge Plate Shimming Gauge Backlash Measuring Tool Kit
P/N. 3B7-72720-0 P/N. 3B7-72729-0 P/N. 346-72250-0 P/N. 3C8-72234-2
For installing dial gauge Adjusting height of Measuring bevel gear assy A,
Measuring backlash
during backlash measurement bevel gear B bevel gear B backlash
6-2
ii
1
2
Lower Unit
2. Parts Layout
Gear Case (Drive Shaft)
33
33
32
31
30
29
17
28
35
27
16 23
36
25
26
22
15
20
34
14 19
36 34
18
37
5 N·m (4 lb·ft) [0.5 kgf·m]
21
2
3
4
1
10
9
7
5
6
44
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8
9
13
43
12
4
3
5 N·m (4 lb·ft) [0.5 kgf·m]
19 N·m (14 lb·ft) [1.9 kgf·m] 35 N·m (25 lb·ft) [3.5 kgf·m]
6-4
3
4
Ref.
Part Name
No.
1 Gear Case Assy
2 Roller Bearing
40
3 Plug
4 Gasket
5 Trim Tab
6 Bolt
7 Water Strainer
41
8 Screw
9 Water Strainer
10 Screw
11 Nylon Nut
12 Nut
Fig.10-9
13 Bevel Gear B
38
14 Drive Shaft Spring Guide
39
15 Drive Shaft Spring
42 16-1 Drive Shaft (S)
16-2 Drive Shaft (L)
16-3 Drive Shaft (UL)
17 Key
18 Tapered Roller Bearing
24
19-1 Shim 35-41.9-0.1
19-2 Shim 35-41.9-0.15
19-3 Shim 35-41.9-0.3
19-4 Shim 35-41.9-0.5
20 Oil Seal 17-30-9
21 Pump Case Gasket (Lower)
22 Pump Case (Lower)
23 Dowel Pin 4-10
24 Water Seal Rubber
25 Water Seal Plate
26 Bolt
27 Guide Plate Gasket
28 Water Pump Guide Plate
29 Pump Case Gasket
30 Water Pump Impeller
31 Pump Case Liner
32 Pump Case (Upper)
33 Bolt
34 O-ring 2.4-5.8
35-1 Cam Rod (S)
35-2 Cam Rod (L)
35-3 Cam Rod (UL)
11
36 Spring Pin 3-12
37 Clutch Cam
38 Water Pipe Auxiliary Mount
39 Lock Plate
40 Water Pipe Seal (Upper)
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5
Q'ty Remarks
1
1
2
2
Do not reuse.
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
1
1 Do not reuse.
1
Do not reuse.
1
2 Lower Unit
1
1
3. Install the ball bearing 4.
2
Use the C gear bearing press tool 5 to assemble a new
1 Do not reuse.
bearing to the propeller shaft housing.
1
1
Do not reuse.
• Clean the bearing installation surface and apply
1
gear oil before installation.
1
• Install the bearing with the mark facing the tool
1
side.
4
2 Do not reuse.
C Gear Bearing Press Tool 5:
1
P/N. 3AC-99905-0
1
Driver Rod 6:
1
P/N. 3AC-99702-0
2 Do not reuse.
1 GEAR
1
GEAR GEAR
1
1
4 . Assemble the bevel gear C 7 to the bearing using a press
and an appropriate mandrel.
• Clean the bearing installation surface of
6-5
the bevel gear C and apply gear oil before
installation.
• Use a mandrel that contacts the inner face of
the bevel gear (not the clutch face).
GEAR
GEAR GEAR
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6
51.5 mm
4 Ball Bearing Do not reuse.
23.9 mm
6
4 Bearing Do not reuse.
6-20
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