TOHATSU MFS 305A Outboard Motor Manuals

Manuals and User Guides for TOHATSU MFS 305A Outboard Motor. We have 1 TOHATSU MFS 305A Outboard Motor manual available for free PDF download: Service Manual

TOHATSU MFS 305A Service Manual

TOHATSU MFS 305A Service Manual (162 pages)

4 stroke

Brand: TOHATSU | Category: Engine | Size: 6.3 MB

Table of Contents

Service Information

3
- Table of Contents
  4
Identification (Engine Serial Number)

8
Securing of Work Safety

8
- Fire Prevention
  8
- Ventilation
  8
- Protection
  8
- Genuine Parts
  8
- Tools
  9
- Recommendations on Service
  9
- Cautions in Disassembling and Assembling Components
  10
Tools and Instruments

11
- Test Propeller
  11
- Instruments
  11
- List of Special Tool
  12
Predelivery Inspection

13
- Steering Handle
  13
- Gear Shift
  13
- Engine Oil
  13
- Gear Oil
  13
- Fuel Tank and Fuel Line
  14
- Rigging
  14
- Inspection of Tilt Stopper
  14
- Inspection of Stop Switch
  15
- Cooling Water Check Port
  15
- Idle Operation
  15
- Propeller Selection
  16
- Inspection of Forward and Reverse Shifts
  16
Break-In Operation

17
Test Run

17
Checks after Test Run

18
Service Data

19
Outline Dimensons

20
- 1）Engine Dimensions
  20
- 2）Clamp Dimensions
  21
Cooling Water System Diagram

22
Wiring Diagram

23
Specifications

24
Maintenance Data

26
Tightening Torque Data

30
Sealant Application Locations

32
Maintenance

35
Special Tool

36
Inspection Schedule

37
Inspection Items

38
- Inspection of Top Cowl
  38
- Inspection of Fuel System
  38
- Inspection of Fuel Tank
  38
- Inspection of Fuel Cock (Fuel Filter)
  39
- Inspection of Fuel Cock
  39
- Replacement of Engine Oil
  40
- Inspection of Gear Oil Quantity
  42
- Inspection of Water Pump
  42
- Replacement of Gear Oil
  44
- Inspection of Gear Case (for Leakage)
  45
- Inspection of Spark Plug
  46
- Inspection of Compression Pressure
  47
- Inspection and Adjustment of Valve Clearances
  48
- Adjustment of Throttle Cable
  50
- Inspection of Gear Shift Operation
  51
- Flushing with Water
  52
- Inspection of Idle Engine Speed
  52
- Inspection of Ignition Timing
  53
- Inspection of Anode
  53
- Replacement of Anode
  53
- Inspection of Propeller
  53
- Inspection of Thermostat
  54
- Inspection of Cooling Water Passages
  55
- Greasing Points
  56
Fuel System (Carburetor)

57
Special Tool

58
Parts Layout

59
- Fuel Tank
  59
- Carburetor
  60
Inspection Items

61
- Inspection of Fuel Feed System Piping
  61
- Draining Fuel
  62
- Inspection of Fuel Tank and Fuel Tank Cap
  63
- Inspection of Fuel Cock
  63
- Inspection of Fuel Filter
  63
- Inspection of Carburetor
  64
- Assembling of Carburetor
  65
- Assembling Carburetor
  66
- Adjustment of Throttle Cable
  67
- Inspection of Idle Engine Speed
  68
- Adjustment of Idle Engine Speed
  68
Power Unit

69
Special Tools

70
Parts Layout

71
- Engine
  71
- Recoil Starter
  72
- Oil Pan
  73
- Cylinder
  74
- Cam Shaft & Valve
  75
- Piston & Crank Shaft
  76
Inspection Items

77
Lower Unit

112
- Special Tools
  113
Parts Layout

114
- Drive Shaft Housing & Gear Case
  114
- Gear Case (Drive Shaft)
  115
- Gear Case (Propeller Shaft)
  116
- Shift
  117
Inspection Item

118
- Draining Gear Oil
  118
- Removing Propeller
  118
- Removing Lower Unit
  119
- Disassembly of Water Pump
  119
- Inspection of Water Pump
  120
- Removing Propeller Shaft Housing Ass'y
  121
- Disassembly of Propeller Shaft Ass'y
  122
- Inspection of Propeller Shaft
  122
- Assembly of Propeller Shaft Ass'y
  122
- Disassembly of Propeller Shaft Housing
  122
- Inspection of Propeller Shaft Housing
  122
- Assembly of Propeller Shaft Housing
  123
- Removing Pump Case (Lower)
  123
- Disassembly of Pump Case (Lower)
  123
- Assembly of Pump Case (Lower)
  124
- Removing Clutch Cam and Cam Rod
  124
- Disassembly of Clutch Cam and Cam Rod
  124
- Inspection of Clutch Cam and Cam Rod
  124
- Assembly of Clutch Cam and Cam Rod
  124
- Removing Drive Shaft
  125
- Disassembly of Drive Shaft
  125
- Inspection of Drive Shaft
  125
- Inspection of Forward Gear and Pinion Gear (a and B Gears)
  126
- Assembly of Drive Shaft
  126
- Disassembly of Gear Case
  127
- Inspection of Gear Case
  128
- Assembly of Gear Case
  128
- Installation of Clutch Cam and Cam Rod
  129
- Installation of Forward Gear and Pinion Gear (a and B Gears)
  129
- Installation of Pump Case (Lower)
  129
- Installation of Water Pump
  130
- Installation of Propeller Shaft Housing
  131
- Filling with Gear Oil
  132
- Installation of Lower Unit
  132
7 Bracket

135
Parts Layout

135
- Clamp Bracket & Swivel Bracket
  135
- Drive Shaft Housing & Gear Case
  136
- Shift
  137
- Tiller Handle & Throttle
  138
- Cowl
  139
Assembling Procedure

140
- Assembly of Clamp Bracket
  140
- Installation of Steering Stopper
  140
- Installation of Drive Shaft Housing
  141
- Installation of Water Pipe
  141
- Installation of Tiller Handle
  142
- Adjustment of Throttle Cable
  143
Electrical System

145
Special Tools

145
Parts Layout

146
Ignition System and Ignition Control System

147
- Inspection of Ignition Spark
  147
- Inspection of Plug Cap
  148
- Inspection of Igniter
  149
- Inspection of Stop Switch
  150
Troubleshooting

152
Troubleshooting List

152
Power Unit

153
Trouble 1 Engine will Not Start or Is a Little Hard to Start.

155
- Trouble 2 Engine Starts but Stalls Soon
  155
  - Fuel System
    155
  - Ignition System
    156
  - Compression Pressure
    157
  - Trouble 3 Idle Engine Speed will Not Stabilize
    158
  - Trouble 4 Rough Acceleration
    159
  - Trouble 5 Gear Shifting Cannot be Made Normally
    160

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