TOHATSU M3.5A Manuals

Manuals and User Guides for TOHATSU M3.5A. We have 1 TOHATSU M3.5A manual available for free PDF download: Service Manual

TOHATSU M3.5A Service Manual

TOHATSU M3.5A Service Manual (80 pages)

4-Stroke Cycle

Brand: TOHATSU | Category: Outboard Motor | Size: 2.3 MB

Table of Contents

Contents
2
Specifications
4
Outline Dimensions
6
Service Data and Maintenance Standards
7
Table of Points to Apply Sealants, Adhesives and Lubricants
13
Table of Tightening Torque
16
Tools and Instruments Required for Disassembly and Repair
17
How to Use Special Tools
19
Flywheel Cup Puller
19
Piston Pin Tool
19
Piston Slider
19
Drive Shaft Bearing Tool
20
Backlash Measuring Tool
21
Spring Pin Tool
21
Inspection and Maintenance
22
Periodical Inspections
22
Troubleshooting
23
Points to Apply Oil or Grease
24
Change of Engine Oil
25
Change of Gear Oil
25
Inspection of Ignition System
26
Inspection of Fuel System
27
Inspection of Compressor System
28
Inspection of Gear Shift and Propeller System
29
Inspection of Cooling System
30
Power Unit
31
Removing Power Unit
32
Removing Parts
32
Disassembling Engine
34
Cylinder Head, Valves and Relating Parts
35
Oil Pan (Exhaust Manifold), Oil Pump and Relating Parts
36
Crank Shaft, Cam Shaft, Piston, Cylinder and Related Parts
37
Inspection and Measurement of Engine Parts
38
Measurement with Vernier Calipers
38
Measurement with Depth Gauge or Calipers
38
Measurement with Micrometer
39
Measurement with Cylinder Gauge
41
Measurement with Thickness Gauge
42
Measurement with Plastigage
43
Measurement with Pressure Gauge
44
Other Inspections
44
Repair and Replacement of Engine Parts
45
Repair of Valve Seat
45
Reassembling Engine
46
Piston Ring
46
Lower Unit
47
Disassembling Gear Case
47
Removing Propeller
47
Disassembling Propeller Shaft and Clutch
48
Disassembling Water Pump Case
48
Removing Cam Rod, Drive Shaft and Bevel Gear
49
Inspection of Parts Related to Gear Case
50
Reassembling Gear Case
51
Clutch and Related Parts
51
Bevel Gears and Related Parts
51
Propeller Shaft Housing
51
Water Pump and Related Parts
52
Volume of Gear Oil Required to Pour in
52
Sectional View of Gear Case Assembly
53
Gear Shift
54
Gear Case, Shaft, Water Pump
55
Disassembling Lower Motor Cover and Drive Shaft Housing
56
Reassembling Lower Motor Cover and Drive Shaft Housing
58
Drive Shaft Housing, Gear Case, Motor Cover
59
Bracket, Reverse Lock Arm
60
Handle, Throttle
61
Recoil Starter Disassembling
62
Recoil Starter Reassembling
62
Recoil Starter, Starter Lock
63
Carburetor
64
Fuel Pump
65
Electrical System
66
Electric Circuit Diagram
66
Flywheel Inspection
66
Exciter Coil, Pulsator Coil, Ignition Coil Inspection
66
C.D. Unit Inspection
67
Manner to Check Ignition Timing
67
Magneto
68
Test Run and Inspection after Complete Assembly
69
Test Run Tank and Test Propeller
69
Items to be Checked During Test Run
70
Additional Tightening after Test Run
70
Break-In
70
Optional Parts
71
Remote Control System
71
Location of Remote Control Box
71
Installing Remote Control Cable (Control Box Side)
71
Installing the Remote Control Cable (Engine Side)
72
Optional Parts (Remote Control)
73
Lighting Coil and Rectifier Kit
74
Installing Rectifier Kit
75
Inspection of Rectifier and Fuse
76
Vertical Starter Kit
77

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