TOHATSU MFS 25D Service Manual page 7

1. Service Information
1. Identification (Engine Serial Number) ... 1-2
2. Securing of Work Safety .................. 1-2
1) Fire Prevention ................................. 1-2
2) Ventilation ....................................... 1-2
3) Protection ....................................... 1-2
4) Genuine Parts ................................. 1-3
5) Tools ............................................. 1-3
6) Recommendations on Service ............ 1-3
7) Cautions in Disassembling and
Assembling Components .................. 1-4
3. Tools and Instruments ..................... 1-5
1) Test Propeller ................................. 1-5
2) Measuring Instruments ..................... 1-5
3) Special Tools .................................... 1-6
4. Pre-delivery Inspection..................... 1-9
1) Steering Handle .............................. 1-9
2) Gear Shift ....................................... 1-9
3) Engine Oil ....................................... 1-10
4) Gear Oil .......................................... 1-10
5) Fuel Line ....................................... 1-10
6) Rigging .......................................... 1-10
7) Inspection of PTT Unit (EFT, EHT, EPT) ... 1-11
8) Inspection of Gas Shock Absorber (EFG) ... 1-11
9) Inspection of Manual Tilt (MF, EF) ......... 1-11
10) Inspection of Starting Stop Switch and
Stop Switch .................................... 1-12
11) Cooling Water Check Port .................. 1-14
12) Idling ............................................. 1-14
13) Propeller Selection ........................... 1-14
14) Trim Tab .......................................... 1-15
5. Break-in Operation ........................... 1-16
6. Test Run .......................................... 1-16
7. Checks After Test Run ..................... 1-17
2. Service Data
1. Outline Dimensions ........................ 2-2
1) Engine Dimensions ........................... 2-2
2) Transom Bolts ................................. 2-8
2. Fuel Injection System ..................... 2-9
1) ECU Fuel Feed System ..................... 2-9
3. Engine Lubrication System Diagram ... 2-10
4. Cooling Water System Diagram ...... 2-11
5. Specifications ................................. 2-12
6. Maintenance Data ........................... 2-16
7. Tightening Torque Data .................. 2-24
8. Sealant Application Locations ......... 2-26
3. Maintenance
1. Special Tools .................................... 3-2
2. Inspection Schedule ........................ 3-3
3. Inspection Items .............................. 3-4
1) Inspection of Top Cowl ..................... 3-4
2) Fuel System
Inspection of Fuel Hose ..................... 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 ............ 3-9
8) Inspection of Water Pump .................. 3-9
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9) Replacement of Gear Oil .................. 3-11
10) Inspection of Gear Case (for leakage) ... 3-12
11) Inspection of Timing Belt ..................... 3-12
12) Replacement of Timing Belt ............... 3-13
13) Inspection of Spark Plugs .................. 3-18
14) Inspection of Compression Pressure ... 3-19
15) Inspection and Adjustment of
Valve Clearance .............................. 3-20
16) Adjustment of Throttle Cable
(Basic Tiller Handle Model) ............... 3-21
17) Adjustment of Shift • Throttle Cable
(Multi-Function Tiller Handle Model) ...... 3-22
18) Adjustment of Shift • Throttle Cable
(Remote Control Model) ..................... 3-25
19) Inspection of Shift Lever Gear Operations ... 3-28
20) Inspection of PT Unit Operation............ 3-29
21) Inspection of Gas Shock Absorber Operation ... 3-29
22) Inspection of Manual Tilt Operations ... 3-30
23) Inspection of PT Fluid Quantity ............ 3-30
24) Inspection of Idle Speed ..................... 3-31
25) Inspection of Ignition Timing ............... 3-31
26) Inspection of Anodes ........................ 3-32
27) Replacement of Anodes ..................... 3-33
28) Replacement of Cooling Water
Passage Anode (Cylindrical Shape) ...... 3-33
29) Inspection of Propeller ..................... 3-34
30) Inspection of Thermostat .................. 3-34
31) Inspection of Cooling Water Passage ...
32) Inspection of Cooling Water Pressure ...... 3-35
33) Flushing with Water ........................... 3-36
34) Inspection of Battery ........................ 3-37
35) Grease points ................................. 3-38
4. Fuel System
(Fuel Injection)
1. Special Tools .................................... 4-2
2. Piping Arrangement Diagram ......... 4-3
Fuel Hose, Vent Hose, Breather Hose,
Cooling Water Hose .............................. 4-3
3. Parts Layout .................................... 4-4
Intake Manifold .................................... 4-4
Fuel System ....................................... 4-6
Magneto ............................................. 4-10
Electrical Parts .................................... 4-12
Fuel Tank ............................................. 4-16
4. ECU System .................................... 4-18
(1) Configuration of ECU System ...... 4-18
1) Sensors .......................................... 4-19
2) Actuators ....................................... 4-20
3) Control System (ECU) ........................ 4-21
(2) Control System ........................... 4-21
(3) Fuel Injection Control .................. 4-22
1) Fuel Injection Timing ........................ 4-22
2) Start Up Fuel Mapping ..................... 4-23
3) Acceleration Fuel Mapping .................. 4-23
4) Deceleration Fuel Mapping ............... 4-23
5) Correction Based On Intake
Air Temperature .............................. 4-23
6) Engine Temperature Correction ............ 4-23
(4) Control of Fuel Feed Pump (FFP) ... 4-23
(5) Control of Tachometer ............... 4-23
3-35
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