TOHATSU 120 Manuals

Manuals and User Guides for TOHATSU 120. We have 1 TOHATSU 120 manual available for free PDF download: Service Manual

TOHATSU 120 Service Manual

TOHATSU 120 Service Manual (329 pages)

2 Stroke

Brand: TOHATSU | Category: Outboard Motor | Size: 67.68 MB

Table of Contents

Section 1 Service Safety

3
- Table of Contents
  3
- Introduction
  4
- Safety Statements
  4
- Safety Precautions
  5
- Workmanship Standards
  7
- Test Tank Guidlines
  9
Section 2 General Service Information

10
- General Precautions
  11
- Abbreviations and Symbols
  12
- Unit Conversions
  13
- Service Specifications
  14
- Engine Specifications
  17
- Lubrication Chart
  20
- Periodic Inspections
  23
- Break-In Procedure
  27
- Tune-Up Procedure
  29
- Emergency Stop Switch and Lanyard
  30
- Operator Alert Systems
  31
- Synchronization and Linkage Adjustments
  34
- Anodes - Inspection and Testing
  48
Section 3 Fuel System

49
- General Precautions
  50
- Service Specifications
  51
- Fuel System Requirements
  52
- Troubleshooting
  54
- Description of Operation
  56
- Fuel Tank
  59
- Fuel Line and Primer
  60
- Fuel and Oil Filters
  61
- Fuel Pump
  62
- Automixing System
  65
- Carburetor
  68
- Intake Manifold
  72
Section 4 Powerhead

75
- General Precautions
  76
- Service Specifications
  77
- Troubleshooting
  81
- Description of Operation
  82
- Cylinder Compression Test
  83
- RPM Performance Test
  84
- Overheat Sensor
  85
- Water Pressure Sensor
  86
- Thermostat
  88
- Recoil Starter
  89
- Powerhead
  91
Section 5 Midsection

115
- General Precautions
  116
- Service Specifications
  117
- Tiller Steering Handle
  119
- Lower Engine Cover
  123
- Driveshaft Housing
  124
- Stern and Swivel Brackets
  130
Section 6 Gearcase

138
- General Precautions
  139
- Service Specifications
  140
- Water Pump
  141
- Gearcase
  142
- Backlash - Shim Adjustment Table
  164
- Gearcase Repair Procedures
  167
Section 7 Electrical System

180
- General Precautions
  181
- Service Specifications
  182
- Electrical Servicing Standards
  186
- Troubleshooting
  190
- Description of Operation
  192
- Battery Care and Maintenance
  196
- Ignition System
  201
- RPM Limitation Test
  226
- Ignition System Repair Procedures
  238
- Starting System
  253
- Charging System
  285
- General Precautions
  301
- Air Bleeding Procedure
  305
- Trim Sender/Trim Meter Test
  306
- Power Trim/Tilt
  308
- Troubleshooting
  318

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