TOHATSU EverRun MX 18E2 Service Manual page 11

1.Service Information
1. Identification
(Engine Serial Number) ..................... 1-2
2. Work Safety ....................................... 1-2
1) Fire Prevention .............................. 1-2
2) Ventilation....................................... 1-2
3) Protection ....................................... 1-2
4) Genuine Parts ................................. 1-2
5) Tools ............................................. 1-4
6) Recommendations on Service ............ 1-4
7) Cautions in Disassembling and
Assembling Components .................. 1-6
3. Tools and Instruments ..................... 1-8
1) Test Propeller ................................. 1-8
2) Measuring Instruments ..................... 1-8
3) Special Tools ................................. 1-10
4. Pre-delivery Inspection .................. 1-14
1) Tiller Handle ................................. 1-14
2) Gear Shift .................................... 1-14
3) Gear Oil ....................................... 1-14
4) Fuel and Fuel Line ........................ 1-16
5) Installation of Outboard Motor
(Rigging) ....................................... 1-16
6) Propeller Selection ........................ 1-18
7) Cooling Water Check Port ............... 1-18
8) Trim Tab ....................................... 1-20
5. Break-In Operation ........................... 1-20
6. Test Run .......................................... 1-22
7. Checks After Test Run ..................... 1-22
2.Service Data
1. Outboard Dimensions ..................... 2-2
1) Body dimensions .............................. 2-2
2) Clamp Dimensions ........................... 2-4
2. Cooling Water System Diagram ......... 2-6
3. Specifications ................................. 2-8
4. Maintenance Data ........................... 2-12
5. Torque Specifications ..................... 2-16
6. Sealant And Lubricant .................. 2-17
3.Maintenance
1. Special Tool .................................... 3-2
2. Inspection Schedule ........................ 3-2
3. Inspection Items .............................. 3-6
1) Inspection of Top Cowl ..................... 3-6
2) Inspection of Fuel Tank ..................... 3-6
3) Fuel System .................................... 3-6
4) Inspection of Cooling Water
Passage ....................................... 3-8
5) Flushing with Water ........................ 3-10
6) Inspection of Compression
Pressure ....................................... 3-10
7) Inspection of Spark Plugs ............... 3-14
8) Inspection of Thermostat .................. 3-16
9) Ignition Timing Adjustment ............... 3-16
10) Throttle Link Adjustment .................. 3-18
11) Advancer Arm Adjustment ............... 3-18
2st X18E2 2012
12) Opening Throttle Adjustment
(in reverse) .................................... 3-18
13) Inspection of starter locking cam ...... 3-20
14) Replacement of Gear Oil .................. 3-20
15) Inspection of Gear Case
(for leakage) ................................. 3-22
16) Inspection of Propeller ..................... 3-24
17) Replacement of Anode..................... 3-24
18) Greasing ....................................... 3-26
4.Fuel System
1. Special Tools .................................... 4-2
2. Parts Layout .................................... 4-4
Intake Manifold .................................... 4-4
Carburetor .......................................... 4-6
3. Carburetor Inner Passages ............... 4-8
1) Idling Passage ................................. 4-8
2) Off-Idle Passage ........................... 4-10
3) High Speed Passage ..................... 4-12
4) Choking Passage ........................... 4-14
4. Inspection Items ........................... 4-16
1) Removing Carburetor ..................... 4-16
2) Disassembling Carburetor ............... 4-18
3) Cleaning and Inspection .................. 4-20
4) Inspection of Fuel Pump and
Needle Valve ................................. 4-22
5) Disassembly and Inspection of
Fuel Pump .................................... 4-22
6) Assembly of Fuel Pump .................. 4-24
7) Inspection of Fuel Connector ............ 4-24
8) Inspection of Fuel Filter .................. 4-24
9) Assembling Carburetor .................. 4-26
10) Adjusting Float Height ..................... 4-28
11) Installing Carburetor ........................ 4-28
5.Power Unit
1. Special tools .................................... 5-2
2. Parts Layout .................................... 5-4
Engine ................................................ 5-4
Recoil Starter ....................................... 5-6
Magneto • Electric Parts........................... 5-8
Intake Manifold .................................... 5-12
Cylinder Crank Case ........................... 5-14
Piston & Crank Shaft ........................... 5-20
3. Inspection Items ........................... 5-22
1) Removing Power Unit ..................... 5-22
2) Removing Recoil Starter .................. 5-24
3) Removing Flywheel ........................ 5-26
4) Removing Electric Parts .................. 5-26
5) Inspection of Magneto Basement ...... 5-30
6) Removing Advancer Arm.................. 5-30
7) Removing Intake Silencer and
Carburetors ................................. 5-30
8) Removing Oil Recirculation Hoses...... 5-32
9) Removing Intake Manifold and
Reed valves ................................. 5-34
10) Inspection of Reed Valve Assy ......... 5-34
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