TOHATSU MFS 5D Manuals

Manuals and User Guides for TOHATSU MFS 5D. We have 2 TOHATSU MFS 5D manuals available for free PDF download: Service Manual, Owner's Manual

TOHATSU MFS 5D Service Manual

TOHATSU MFS 5D Service Manual (218 pages)

4 Stroke

Brand: TOHATSU | Category: Outboard Motor | Size: 28.14 MB

Table of Contents

Service Information
6
Table of Contents
7
Identification (Engine Serial Number)
12
Work Safety
12
Fire Prevention
12
Ventilation
12
Protection
12
Genuine Parts
12
Tools
13
Recommendations on Service
13
Cautions in Disassembling and Assembling Components
14
Tools and Instruments
15
Test Propeller
15
Instruments
15
Special Tools
16
Pre-Delivery Inspection
18
Steering Handle
18
Gear Shift
18
Engine Oil
18
Gear Oil
18
Fuel Tank Line
19
Rigging
19
Inspection of Tilt Stopper
19
Inspection of Stop Switch
20
Cooling Water Check Port
20
Idle Operation
20
Propeller Selection
21
Inspection of Forward and Reverse Shifts
21
Break-In Operation
22
Test Run
22
Checks after Test Run
23
Service Data
25
Outline Dimensions
26
Engine Dimensions
26
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
Inspection of Top Cowl
44
Fuel System
44
Inspection of Fuel Tank
45
Inspection of Fuel Filter
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 Plug
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
Parts Layout
67
Fuel Tank
67
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
Inspection of Fuel Feed System Piping
76
Draining Fuel
76
Inspection of Fuel Tank and Fuel Tank Cap
77
Inspection of Fuel Cock
77
Inspection of Fuel Filter
77
Removing Carburetor
78
Disassembling Carburetor
80
Inspection and Clean of Carburetor
81
Inspection of Fuel Connector
82
Assembling of Carburetor
82
Adjustment of Float Height
83
Installing Carburetor
83
Removing Fuel Pump
84
Disassembly and Inspection of Fuel Pump
84
Assembly of Fuel Pump
85
Power Unit
88
Special Tools
88
Parts Layout
89
Engine
89
Magneto
90
Cylinder & Oil Pan
92
Cylinder Head & Valve & Camshaft
96
Piston & Crankshaft
98
Recoil Starter
99
Top Cowl
100
Inspection Items
101
Inspection of Compression Pressure
101
Inspection of Valve Clearance
102
Removing Power Unit
104
Removal and Disassembly of Crank Case Head
105
Inspection of Crank Case Head
106
Assembly of Crank Case Head
106
Installation of Crank Case Head
107
Disassembly of Power Unit
107
Removal of Rocker Arm
110
Removing Cylinder Head
111
Inspection of Rocker Arm and Pivot
111
Inspection of Push Rod Plate
112
Inspection of Push Rod
112
Disassembly and Inspection of Oil Pump
112
Disassembly of Cylinder and Oil Pan
114
Disassembly and Inspection of Breather Chamber
116
Inspection of Lifter
116
Inspection of Camshaft
117
Inspection of Piston Outer Diameter
118
Inspection of Cylinder Inner Diameter
118
Inspection of Piston Clearance
118
Inspection of Piston Ring Side Clearance
119
Inspection of Piston Rings
119
Inspection of Piston Pin
120
Nspection Connecting Rod Small End Inner Diameter
120
Inspection of Connecting Rod Big End Inner Diameter
120
Inspection of Connecting Rod Big End Side Clearance
121
Inspection of Crankshaft
121
Disassembly and Inspection of Oil Pan
122
Removal of Valves and Springs
123
Inspection of Valve Springs
123
Inspection of Valve
124
Inspection of Valve Guide
124
Inspection of Valve Seat
125
Correction of Valve Seat
126
Installation of Valves
129
Installation of Piston and Connecting Rod
130
Assembly of Cylinder Oil Pan
131
Installation of Cylinder Head
133
Installing Flywheel
135
Installation of Power Unit
138
Lower Unit
141
Drive Shaft Housing
144
Gear Case (Drive Shaft) • Gear Case (Propeller Shaft)
146
Inspection Item
150
Draining Gear Oil
150
Removing Propeller
150
Removing Lower Unit
151
Disassembly of Water Pump
151
Inspection of Water Pump
152
Removing Propeller Shaft Housing Ass'y
153
Disassembly of Propeller Shaft Housing
154
Inspection of Propeller Shaft Housing
154
Assembly of Propeller Shaft Housing
155
Disassembly of Propeller Shaft Ass'y
156
Inspection of Propeller Shaft
156
Assembly of Propeller Shaft Ass'y
156
Removing Clutch Cam and Cam Rod
157
Assembly of Clutch Cam and Cam Rod
158
Removing Pump Case (Lower)
158
Disassembly of Pump Case (Lower)
158
Assembly of Pump Case (Lower)
159
Inspection of Drive Shaft
159
Inspection of Pinion (B) Gear and Forward (A) Gear
159
Disassembly of Gear Case
160
Inspection of Gear Case
161
Assembly of Gear Case
161
Installation of Forward Gear and Pinion Gear (a and B Gears)
162
Reassembly of Pump Case (Lower)
162
Installation of Clutch Cam and Cam Rod
162
Determination of Forward (A) Gear Backlash
163
Installation of Water Pump
165
Installation of Propeller Shaft Housing
166
Filling with Gear Oil
167
Installation of Lower Unit
167
Bracket
171
Parts Layout
172
Bracket • Reverse Lock
172
Drive Shaft Housing • Shift
174
Bottom Cowl • Tiller Handle
176
Top Cowl
180
Disassembling and Assembling Procedure
181
Removal and Inspection of Drive Shaft Housing
181
Removal and Inspection of Clamp Bracket
183
Installation of Clamp Bracket and Drive Shaft Housing
184
Removal, Inspection and Installation of Water Pipe
186
Remove, Inspection and Installation of Tiller Handle
187
Adjustment of Throttle Cable
190
Special Tools
194
Parts Layout
196
Magneto
196
Ignition System and Ignition Control System
198
Inspection of Ignition Spark
198
Inspection of Plug Cap
199
Inspection of Stop Switch
201
Inspection of Oil Pressure Switch
201
Inspection of Rectifier
202
Inspection of Lighting Coil
202
Troubleshooting
204
Troubleshooting List
204
Power Unit
205
Engine will Not Start or Is a Little Hard to Start
205
Engine Starts but Stalls Soon
207
Fuel System
207
Ignition System
208
Intake • Compression Pressure
209
Idle Engine Speed will Not Stabilize
210
Gear Shifting Cannot be Made Normally
212
Wiring Diagram
213

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TOHATSU MFS 5D Owner's Manual

TOHATSU MFS 5D Owner's Manual (74 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 1.62 MB

Table of Contents

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