TOHATSU MFS 25D Service Manual page 9

6) Inspection of Water Pipe ..................... 6-13
7) Disassembly of Water Pump Case (Lower) ... 6-14
8) Assembly of Water Pump Case (Lower) ... 6-14
9) Disassembly of Cam Rod .................. 6-14
10) Inspection of Clutch Cam .................. 6-15
11) Assembly of Clutch Cam .................. 6-15
12) Removal of Propeller Shaft Housing Assy ... 6-16
13) Disassembly of Propeller Shaft
Housing Assy ................................. 6-16
14) Inspection of Propeller Shaft Housing ... 6-18
15) Assembly of Propeller Shaft Housing ... 6-18
16) Disassembly of Propeller Shaft Assy ... 6-21
17) Inspection of Propeller Shaft Assy ...... 6-22
18) Assembly of Propeller Shaft Assy ......... 6-23
19) Removal of Bevel Gear Assy A ............ 6-24
20) Disassembly of Bevel Gear Assy A ...... 6-24
21) Inspection of Bevel Gear Assy A ......... 6-25
22) Assembly of Bevel Gear Assy A ......... 6-25
23) Removal of Drive Shaft ..................... 6-26
24) Disassembly of Drive Shaft ............... 6-27
25) Inspection of Drive Shaft ..................... 6-27
26) Inspection of Bevel Gear B .................. 6-28
27) Assembly of Drive Shaft ..................... 6-28
28) Disassembly of Gear Case .................. 6-29
29) Inspection of Gear Case ..................... 6-30
30) Assembly of Gear Case ..................... 6-30
31) Assembly of Bevel Gear B .................. 6-32
32) Bevel Gear B Height Measurement and
Shim Selection ................................. 6-33
33) Backlash Measurement Between Bevel
Gear Assy A and Bevel Gear B and Shim
Selection ....................................... 6-35
34) Installation of Pump Case .................. 6-37
35) Installation of Propeller Shaft Housing Assy ... 6-38
36) Inspection of Gear Case (for Leakage) ... 6-39
37) Installation of Lower Unit .................. 6-40
7. Bracket
1. PT Wiring Diagram and Layout ......... 7-2
2. Parts Layout .................................... 7-4
Drive Shaft Housing .............................. 7-4
Bracket (Manual Tilt) .............................. 7-6
Bracket (PT · Gas Assist) ........................ 7-10
Power Tilt ............................................. 7-12
Tiller Handle ....................................... 7-14
Multi-Function Tiller Handle ..................... 7-18
Bottom Cowl ....................................... 7-22
Shift ................................................... 7-24
Remote Control .................................... 7-26
3. Inspection Items .............................. 7-28
1) Inspection of Throttle Cable and Shift Cable ... 7-28
2) Installation of Tiller Handle .................. 7-28
3) Adjustment of Friction Lever ............... 7-29
4) Removal of Drive Shaft Housing ......... 7-30
5) Disassembly of Drive Shaft Housing ... 7-31
6) Assembly of Drive Shaft Housing ......... 7-32
7) Installation of Drive Shaft Housing Assy ... 7-33
8) Removal of Steering Shaft .................. 7-34
9) Installation of Steering Shaft ............... 7-35
10) Disassembly of Clamp Bracket
(Power Tilt Model, Gas Assist Model) ... 7-36
11) Installation of Clamp Bracket
(Power Tilt Model, Gas Assist Model) ... 7-38
4st 25/30 2022
12) Disassembly of Clamp Bracket
(Manual Tilt Model) ........................... 7-38
13) Installation of Clamp Bracket
(Manual Tilt Model) ........................... 7-39
14) Removal of PT Unit / Gas Shock Absorber ... 7-40
15) Removal of PT Motor ........................ 7-41
16) Inspection of PT Motor ..................... 7-42
17) Assembly of PT Motor ........................ 7-43
18) Removal of PT Pump and Valve ......... 7-44
19) Inspection of PT Pump and Valve ......... 7-44
20) Removal of Tilt Cylinder ..................... 7-45
21) Inspection of Tilt Cylinder .................. 7-45
22) Inspection of Valve ........................... 7-46
23) Installation of PT Pump and Motor ...... 7-46
24) Assembly of Tilt Cylinder .................. 7-47
25) Installation of PT Unit / Gas Shock Absorber ... 7-49
26) Air-Purging of PT Unit
(With Outboard Motor Installed) ......... 7-50
27) Inspection of PT Solenoid .................. 7-51
28) Inspection of PT Switch ..................... 7-51
8. Electrical System
1. Special Tools .................................... 8-2
2. Electrical Component Layout ......... 8-3
Port Side View .................................... 8-3
Bow Side View .................................... 8-4
Starboard Side View .............................. 8-5
Housing Cover (Front) ........................... 8-6
3. Parts Layout .................................... 8-8
Magneto ............................................. 8-8
Electrical Parts .................................... 8-10
Intake Manifold .................................... 8-14
Fuel System ....................................... 8-16
4. The Ignition System and the
Ignition Control System .................. 8-20
1) Inspection of the Ignition Spark ............ 8-20
2) Inspection of the Plug Cap .................. 8-20
3) Inspection of the Ignition Coil ............... 8-21
4) Inspection of the Exciter Coil and ECU
Charge Coil .................................... 8-21
5) Inspection of the Pulser Coils ............ 8-22
6) Adjustment of the Pulser Coil Air Gap ... 8-22
7) Inspection of the Oil Pressure Switch ... 8-23
8) Inspection of the Engine Temperature Sensor 8-24
9) Inspection of the Neutral Switch
(Except for MF) ................................. 8-24
10) Inspection of the Start Switch (EF, EFT) ... 8-25
11) Inspection of the Main (Key) Switch ...... 8-25
12) Inspection of the Stop Switch
(Except for MF) ................................. 8-26
5. The Fuel Control System .................. 8-27
1) Inspection of the Injector ..................... 8-27
2) Inspection of the ISC Valve ............... 8-27
3) Inspection of the T-MAP Sensor ......... 8-28
4) Inspection of the Fuel Feed Pump (FFP) ... 8-28
5) Inspection of the Throttle Position
Sensor (TPS) ................................. 8-29
6. The Starting System (Except for MF) ... 8-29
1) Inspection of the Fuse ........................ 8-29
2) Inspection of the Starter Solenoid ......... 8-29
3) Disassembly of the Starter Motor ......... 8-30
4) Inspection of the Starter Motor Pinion ... 8-30
5) Inspection of the Armature .................. 8-30
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