TOHATSU MFS 35D Manuals

Manuals and User Guides for TOHATSU MFS 35D. We have 1 TOHATSU MFS 35D manual available for free PDF download: Service Manual

TOHATSU MFS 35D Service Manual

TOHATSU MFS 35D Service Manual (413 pages)

4 Stroke

Brand: TOHATSU | Category: Outboard Motor | Size: 69.45 MB

Table of Contents

1 Service Information

13
- Table of Contents
  13
- Identification (Engine Serial Number)
  14
- Fire Prevention
  14
- Ventilation
  14
- Protection
  14
- Genuine Parts
  15
- Tools
  15
- Recommendations on Service
  15
- Cautions in Disassembling and Assembling Components
  16
- Tools and Instruments
  17
- Test Propeller
  17
- Measuring Instruments
  17
- Special Tools
  18
- Pre-Delivery Inspection
  21
- Steering Handle
  21
- Gear Shift
  21
- Rigging
  22
- Fuel Line
  22
- Gear Oil
  22
- Engine Oil
  22
- Inspection of PTT Unit (EFT, EHT, EPT)
  23
- Inspection of Gas Shock Absorber (EFG)
  23
- Inspection of Manual Tilt (MF, EF)
  23
- Stop Switch
  24
- Cooling Water Check Port
  26
- Idling
  26
- Propeller Selection
  26
- Trim Tab
  27
- Break-In Operation
  28
- Test Run
  28
- Checks after Test Run
  29
2 2 Service Data

31
- Engine Dimensions
  32
- Outline Dimensions
  32
- Transom Bolts
  38
- ECU Fuel Feed System
  39
- Fuel Injection System
  39
- Engine Lubrication System Diagram
  40
- Cooling Water System Diagram
  41
- Specifications
  42
- Maintenance Data
  46
- Tightening Torque Data
  54
- Sealant Application Locations
  56
3 3 Maintenance

65
4 Fuel System (Fuel Injection) 4

103
- Special Tools
  104
- Fuel Hose, Vent Hose, Breather Hose, Cooling Water Hose
  105
- Piping Arrangement Diagram
  105
- Fuel System
  106
- Intake Manifold
  106
- Parts Layout
  106
- Magneto
  112
- Electrical Parts
  114
- Fuel Tank
  118
- Configuration of ECU System
  120
- ECU System
  120
- Sensors
  121
- Actuators
  122
- Control System
  123
- Control System (ECU)
  123
- Fuel Injection Control
  124
- Fuel Injection Timing
  124
- Acceleration Fuel Mapping
  125
- Control of Fuel Feed Pump (FFP)
  125
- Control of Tachometer
  125
- Correction Based on Intake Air Temperature
  125
- Deceleration Fuel Mapping
  125
- Engine Temperature Correction
  125
- Start up Fuel Mapping
  125
- Location of Warning Buzzer and Lamp (LED)
  126
- Waring Notification, Abnormality and Action to be Taken
  126
- Warning Buzzer and Lamp (LED), and Control of Engine Revolution Speed
  126
- Configuration of Ignition System
  127
- Ignition System
  127
- Ignition and Combustion Order
  128
- Ignition Control
  128
- Ignition Timing
  128
- Ignition Timing Control
  128
- Operations
  128
- Fuel Feed System
  129
- Components of Fuel Feed System
  130
- Vapor Separator
  130
- Fuel Cooler
  131
- Fuel Regulator
  131
- Air Intake System
  132
- Outline of Fuel Injection System
  132
- Inspection Items
  133
- Inspection of Filter
  133
- Inspection of Fuel Supply System
  133
- Inspection of Fuel Connector
  135
- Inspection of Fuel Pump
  135
- Measurement of Fuel Pressure
  136
- Draining Fuel
  137
- Disassembly of Vapor Separator
  138
- Inspection of Vapor Separator
  139
- Reassembly of Vapor Separator
  139
- Inspection of Idle Speed
  140
- Inspection of ISC (Idle Speed Control)
  140
6 Lower Unit

231
- Gear Case (Drive Shaft)
  234
- Parts Layout
  234
- Gear Case (Propeller Shaft)
  238
- Draining Gear Oil
  240
- Inspection Items
  240
- Removal of Propeller
  240
- Removal of Lower Unit
  241
- Removal of Water Pump and Cam Rod
  242
- Inspection of Water Pipe
  243
- Inspection of Water Pump
  243
- Assembly of Water Pump Case (Lower)
  244
- Disassembly of Cam Rod
  244
- Disassembly of Water Pump Case (Lower)
  244
- Assembly of Clutch Cam
  245
- Inspection of Clutch Cam
  245
- Disassembly of Propeller Shaft Housing Assy
  246
- Removal of Propeller Shaft Housing Assy
  246
- Assembly of Propeller Shaft Housing
  248
- Inspection of Propeller Shaft Housing
  248
- Disassembly of Propeller Shaft Assy
  251
- Inspection of Propeller Shaft Assy
  252
- Assembly of Propeller Shaft Assy
  253
- Disassembly of Bevel Gear Assy a
  254
- Removal of Bevel Gear Assy a
  254
- Assembly of Bevel Gear Assy a
  255
- Inspection of Bevel Gear Assy a
  255
- Removal of Drive Shaft
  256
- Disassembly of Drive Shaft
  257
- Inspection of Drive Shaft
  257
- Assembly of Drive Shaft
  258
- Inspection of Bevel Gear B
  258
- Disassembly of Gear Case
  259
- Assembly of Gear Case
  260
- Inspection of Gear Case
  260
- Assembly of Bevel Gear B
  262
- Bevel Gear B Height Measurement and Shim Selection
  263
- Backlash Measurement between Bevel Gear Assy a and Bevel Gear B and Shim Selection
  265
- Installation of Pump Case
  267
- Installation of Propeller Shaft Housing Assy
  268
- Inspection of Gear Case (for Leakage)
  269
- Installation of Lower Unit
  270
7 Bracket

273
- Wiring Diagram and Layout
  274
- Drive Shaft Housing
  276
- Parts Layout
  276
- Bracket (Manual Tilt)
  278
- Bracket (PT · Gas Assist)
  282
- Power Tilt
  284
- Tiller Handle
  286
- Multi-Function Tiller Handle
  290
- Bottom Cowl
  294
- Shift
  296
- Remote Control
  298
- Inspection Items
  300
- Inspection of Throttle Cable and Shift Cable
  300
- Installation of Tiller Handle
  300
- Adjustment of Friction Lever
  301
- Removal of Drive Shaft Housing
  302
- Disassembly of Drive Shaft Housing
  303
- Assembly of Drive Shaft Housing
  304
- Installation of Drive Shaft Housing Assy
  305
- Removal of Steering Shaft
  306
- Installation of Steering Shaft
  307
- Disassembly of Clamp Bracket (Power Tilt Model, Gas Assist Model)
  308
- Disassembly of Clamp Bracket (Manual Tilt Model)
  310
- Installation of Clamp Bracket (Power Tilt Model, Gas Assist Model)
  310
- Installation of Clamp Bracket (Manual Tilt Model)
  311
- Removal of PT Unit / Gas Shock Absorber
  312
- Removal of PT Motor
  313
- Inspection of PT Motor
  314
- Assembly of PT Motor
  315
- Inspection of PT Pump and Valve
  316
- Removal of PT Pump and Valve
  316
- Inspection of Tilt Cylinder
  317
- Removal of Tilt Cylinder
  317
- Inspection of Valve
  318
- Installation of PT Pump and Motor
  318
- Assembly of Tilt Cylinder
  319
- Installation of PT Unit / Gas Shock Absorber
  321
- Air-Purging of PT Unit (with Outboard Motor Installed)
  322
- Inspection of PT Solenoid
  323
- Inspection of PT Switch
  323
8 Electrical System

325
- Special Tools
  326
- Electrical Component Layout
  327
- Port Side View
  327
- Bow Side View
  328
- Starboard Side View
  329
- Housing Cover (Front)
  330
- Magneto
  332
- Parts Layout
  332
- Electrical Parts
  334
- Intake Manifold
  338
- Fuel System
  340
- Inspection of the Ignition Spark
  344
- Inspection of the Plug Cap
  344
- The Ignition System and the Ignition Control System
  344
- Inspection of the Exciter Coil and ECU Charge Coil
  345
- Inspection of the Ignition Coil
  345
- Adjustment of the Pulser Coil Air Gap
  346
- Inspection of the Pulser Coils
  346
- Inspection of the Oil Pressure Switch
  347
- Inspection of the Engine Temperature Sensor
  348
- Inspection of the Neutral Switch (Except for MF)
  348
- Inspection of the Main (Key) Switch
  349
- Inspection of the Start Switch (EF, EFT)
  349
- Inspection of the Stop Switch (Except for MF)
  350
- Inspection of the Injector
  351
- Inspection of the ISC Valve
  351
- The Fuel Control System
  351
- Inspection of the Fuel Feed Pump (FFP)
  352
- Inspection of the T-MAP Sensor
  352
- Inspection of the Fuse
  353
- Inspection of the Starter Solenoid
  353
- Inspection of the Throttle Position Sensor (TPS)
  353
- The Starting System (Except for MF)
  353
- Disassembly of the Starter Motor
  354
- Inspection of the Armature
  354
- Inspection of the Starter Motor Pinion
  354
- Inspection of the Brush
  355
- Inspection of the Charge Coil
  356
- Inspection of the Rectifier
  356
- Starter Motor Operation Test
  356
- The Charging System (Except for MF)
  356
- ECU Coupler
  357
9 Troubleshooting

359
- Troubleshooting List
  360
- Power Unit
  361
- Starting System
  361
- State 1 Engine will Not Start or Is
  361
- Ignition System
  363
- Fuel System
  365
- (Defective Acceleration or Deceleration)
  367
- State 2 Full Throttle Engine Revolution
  367
- Ignition System
  368
- Fuel System
  369
- Lubrication System
  370
- Cooling System
  371
- State 3 Engine Rotation Is Unstable or
  372
- Ignition System
  373
- Fuel System
  374
- State 1 PT Unit will Not Operate
  375
- Unit
  375
- State 2 PT Unit Is Not Capable of
  376
- Diagnosis
  377
10 Rigging R/Min

379
- Boat Mounting Restriction
  380
- Mounting Dimensions
  380
- Service Data
  380
- Service Information
  380
- Transom Dimensions
  381
- Installation of the Outboard Motor
  382
- Lifting up the Outboard Motor
  382
- Engine Oil
  384
- Fuel
  384
- Fuel System
  384
- Installation of the Fuel Tank
  384
- Connections to the Outboard Motor
  385
- Steering Cable
  385
- Drag Link
  386
- Installation of the Remote Control Cable (Remote Controller Side)
  387
- Remote Control Components
  387
- Installation of the Remote Control Cable (Engine Side) Remote Control Model
  388
- Installation of the Propeller
  393
- Lower Unit
  393
- Installation of Meters
  394
- Meters
  394
- Battery Capacity
  395
- Installation of the Battery
  395
- The Electrical System
  395
- Wiring Diagram of the Remote Controller and Meters
  396
- Installation of the Trim Sensor
  398

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