TOHATSU MFS 5 Portable Outboard Motor Manuals

Manuals and User Guides for TOHATSU MFS 5 Portable Outboard Motor. We have 1 TOHATSU MFS 5 Portable Outboard Motor manual available for free PDF download: Service Manual

TOHATSU MFS 5 Service Manual

TOHATSU MFS 5 Service Manual (260 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 11.19 MB

Table of Contents

1.Service Information

7
- Service Information
  3
- Service Data
  6
  - Table of Contents
    7
  - Identification (Engine Serial Number)
    12
  - Work Safety
    12
    
    Fire Prevention
    12
    
    Genuine Parts
    12
    
    Protection
    12
    
    Ventilation
    12
    
    Recommendations on Service
    13
    
    Tools
    13
    
    Cautions in Disassembling and Assembling Components
    14
  - Tools and Instruments
    15
    
    Instruments
    15
    
    Test Propeller
    15
    
    Special Tools
    16
  - Pre-Delivery Inspection
    18
    
    Engine Oil
    18
    
    Gear Oil
    18
    
    Gear Shift
    18
    
    Steering Handle
    18
    
    Fuel Tank Line
    19
    
    Inspection of Tilt Stoppe
    19
    
    Rigging
    19
    
    Cooling Water Check Port
    20
    
    Idle Operation
    20
    
    Inspection of Stop Switch
    20
    
    Inspection of Forward and Reverse Shifts
    21
    
    Propeller Selection
    21
  - Break-In Operation
    22
  - Test Run
    22
  - Check after Test Run
    23
- Service Information
  6
- Service Data
  25
  - Clamp Dimensions
    28
  - Engine Lubrication System Diagram
    29
  - Cooling Water System Diagram
    30
  - Specifications
    32
  - Maintenance Data
    34
  - Tightening Torque Specifications
    38
  - Sealant and Lubricant
    39
- Maintenance
  41
  - Special Tools
    42
  - Inspection Schedule
    43
  - Inspection Items
    44
    
    Fuel System
    44
    
    Inspection of Top Cowl
    44
    
    Inspection of Fuel Filter
    45
    
    Inspection of Fuel Tank
    45
    
    Replacement of Engine Oil
    46
    
    Inspection of Gear Oil Quantity
    47
    
    Inspection of Water Pump
    47
    
    Replacement of Gear Oil
    49
    
    Inspection of Gear Case (for Leakage)
    50
    
    Inspection of Spark Plugs
    51
    
    Inspection of Compression Pressure
    52
    
    Inspection and Adjustment of Valve Clearance
    53
    
    Throttle Cable
    55
    
    Inspection of Idle Engine Speed
    57
    
    Inspection of Ignition Timing
    57
    
    Inspection of Anode
    58
    
    Replacement of Anode
    58
    
    Inspection of Propeller
    59
    
    Inspection of Thermostat
    59
    
    Inspection of Cooling Water Passage
    60
    
    Flushing with Water
    61
    
    Greasing Points
    62
- Fuel System
  65
  - Special Tools
    66
    
    Fuel System
    66
  - Parts Layout
    68
    
    Carburetor & Fuel Pump
    68
    
    Integral Fuel Tank
    70
  - Carburetor Inner Passages
    72
    
    Idling Passage
    72
    
    Off-Idle Passage
    73
    
    High Speed Passage
    74
    
    Choking Passage
    75
  - Inspection Items
    76
    
    Draining Fuel
    76
    
    Inspection of Fuel Feed System Piping
    76
    
    Inspection of Fuel Cock
    77
    
    Inspection of Fuel Filter
    77
    
    Inspection of Fuel Tank and Fuel Tank Cap
    77
    
    Removing Carburetor
    78
    
    Disassembling Carburetor
    80
    
    Inspection and Clean of Carburetor
    81
    
    Assembling of Carburetor
    82
    
    Inspection of Fuel Connector
    82
    
    Adjustment of Float Height
    83
    
    Installing Carburetor
    83
    
    Disassembly and Inspection of Fuel Pump
    84
    
    Removing Fuel Pump
    84
    
    Assembly of Fuel Pump
    85
    
    Power Unit
    87
- Power Unit
  88
  - Special Tools
    88
  - Parts Layout
    89
    
    Engine
    89
    
    Magneto
    90
    
    Cylinder & Oil Pan
    92
    
    Cylinder Head & Valve & Cam Shaft
    94
    
    Piston & Crank Shaft
    96
    
    Recoil Starter
    97
    
    Top Cowl
    98
  - Inspection Items
    99
    
    Inspection of Compression Pressure
    99
    
    Inspection of Valve Clearance
    100
    
    Removing Power Unit
    102
    
    Removal and Disassembly of Crank Case Head
    103
    
    Assembly of Crank Case Head
    104
    
    Inspection of Crank Case Head
    104
    
    Installation of Crank Case Head
    104
    
    Disassembly of Power Unit
    105
    
    Removal of Rocker Arm
    108
    
    Disassembly and Inspection of Oil Feed Pump
    109
    
    Inspection of Push Rod
    109
    
    Inspection of Push Rod Plate
    109
    
    Inspection of Rocker Arm and Pivot
    109
    
    Removing Cylinder Head
    109
    
    Disassembly of Cylinder and Oil Pan
    112
    
    Disassembly and Inspection of Breather Chamber
    114
    
    Inspection of Lifter
    114
    
    Inspection of Cam Shaft
    115
  - Inspection of Piston Outer Diameter
    116
  - Inspection of Cylinder Inner Diameter
    116
  - Inspection of Piston Clearance
    116
  - Inspection of Piston Ring Side Clearance
    117
  - Inspection of Piston Rings
    117
  - Inspection of Piston Pin
    118
  - Inspection Connecting Rod Small End Inner Diameter
    118
  - Inspection of Connecting Rod Big End Inner Diameter
    118
  - Inspection of Connecting Rod Big End Side Clearance
    119
  - Inspection of Crank Shaft
    119
  - Disassembly and Inspection of Oil Pan
    120
  - Removal of Valves and Springs
    121
  - Inspection of Valve Springs
    121
  - Inspection of Valve
    122
  - Inspection of Valve Guide
    122
  - Inspection of Valve Seat
    123
  - Correction of Valve Seat
    124
  - Installation of Valves
    127
  - Installation of Piston and Connecting Rod
    128
  - Assembly of Cylinder Oil Pan
    129
  - Installation of Cylinder Head
    131
  - Installing Flywheel
    133
  - Installation of Power Unit
    136
- Lower Unit
  139
  - Special Tools
    140
- Parts Layout
  142
  - Drive Shaft Housing
    142
- Inspection Items
  146
  - Draining Gear Oil
    146
  - Removing Propeller
    146
  - Removing Lower Unit
    147
  - Disassembly of Water Pump
    147
  - Inspection of Water Pump
    148
  - Removing Propeller Shaft Housing Ass'y
    149
  - Disassembly of Propeller Shaft Housing
    150
  - Inspection of Propeller Shaft Housing
    150
  - Assembly of Propeller Shaft Housing
    151
  - Removing Drive Shaft
    151
  - Disassembly of Propeller Shaft Ass'y
    152
  - Inspection of Propeller Shaft
    152
  - Assembly of Propeller Shaft Ass'y
    152
  - Removing Clutch Cam and Cam Rod
    153
  - Disassembly of Clutch Cam and Cam Rod
    153
  - Inspection of Clutch Cam and Cam Rod
    153
  - Assembly of Clutch Cam and Cam Rod
    154
  - Removing Pump Case (Lower)
    154
  - Disassembly of Pump Case (Lower)
    154
  - Assembly of Pump Case (Lower)
    154
  - Inspection of Drive Shaft
    155
  - Inspection of Pinion (B) Gear and Forward (A) Gea
    155
  - Disassembly of Gear Case
    156
  - Inspection of Gear Case
    157
  - Assembly of Gear Case
    157
  - Installation of Forward Gear and Pinion Gear (a and B Gears)
    158
  - Reassembly of Pump Case (Lower)
    158
  - Installation of Clutch Cam and Cam Rod
    158
  - Determination of Forward (A) Gear Backlash
    159
    
    Installation of Water Pump
    161
    
    Installation of Propeller Shaft Housing
    162
    
    Filling with Gear Oil
    163
    
    Installation of Lower Unit
    163
- Bracket
  167
  - Parts Layout
    168
    
    Bracket & Reverse Lock
    168
    
    Drive Shaft Housing & Shift
    170
    
    Bottom Cowl & Tiller Handle
    172
    
    Cowl
    174
  - Disassembling and Assembling Procedure
    175
    
    Removal and Inspection of Drive Shaft Housing
    175
    
    Removal and Inspection of Clamp Bracket
    177
    
    Iinstallation of Clamp Bracket and Drive Shaft
    178
    
    Removal, Inspection and Installation of Water Pipe
    180
    
    Remove, Inspection and Installation of Tiller Handle
    181
    
    Adjustment of Throttle Cable
    184
  - Special Tools
    188
    
    Magneto
    189
  - Ignition System and Ignition Control System
    190
    
    Control System
    190
    
    Inspection of Ignition Spark
    190
    
    Inspection of Plug Cap
    191
    
    Inspection of Igniter
    192
    
    Inspection of Oil Pressure Switch
    193
    
    Inspection of Stop Switch
    193
    
    Inspection of Lighting Coil
    194
    
    Inspection of Rectifier
    194
    
    Troubleshooting O K
    195
    
    Troubleshooting
    196
  - Troubleshooting List
    196
  - Power Unit
    197
    
    Engine will Not Start or Is a Little Hard to Start
    197
- Troubleshooting
  198
  - Engine Starts but Stalls Soon
    199
    
    Fuel System
    199
    
    Ignition System
    200
    
    Intake • Compression Pressure
    201
    
    Idle Engine Speed will Not Stabilize
    202
    
    Rough Acceleration
    203
    
    Gear Shifting Cannot be Made Normally
    204
- Wiring Diagram
  205
- C Model Service Information
  209
Introduction

211
- Specification • Service Data
  212
- Parts Layout
  222
- Chapter 1 Predelivery Inspection
  
  240
  - Difference Item
    240
  - Fuel Tank and Fuel Line (P1-9)
    240
  - Gear Shift (P1-8)
    240
  - Inspection of Forward and Reverse Shifts (P1-11)
    240
- Chapter 3 Inspection Items
  
  241
  - Fuel System (P3-4)
    241
  - Check Piping
    241
  - Inspection of Fuel Tank (P3-5)
    241
- Chapter 4 Inspection Items
  
  242
- Chapter 5 Inspection Items
  
  245
  - Removing Power Unit (P5-16)
    245
- Chapter 8 Inspection Item
  
  247
  - Inspection of Igniter (P8-6)
    247
  - Inspection of Rectifier (P8-8)
    248
- Chapter 10 Wiring Diagram
  
  250

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