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MFS 2
TOHATSU MFS 2 Service Manual
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4
4-5
4st 2/2.5/3.5 2007
3. Inspection Items
1)
Inspection of Fuel Feed System Piping
1.
Remove top cowl and check each section for fuel
leak, dirt, deterioration and damages. Clean or
replace parts if necessary.
MFS2sec04070524.qxd
07.5.24
3:17
PM
ページ5
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62
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
Inspection of Compression Pressure
77
Inspection of Valve Clearance
78
Removing Power Unit
80
Removal and Disassembly of Crank Case Head
81
Inspection of Crank Case Head
82
Assembly of Crank Case Head
82
Installation of Crank Case Head
82
Disassembly of Power Unit
83
Removal of Rocker Arm
85
Inspection of Rocker Arm and Pivot
86
Inspection of Push Rod Plate
86
Inspection of Push Rod
86
Disassembly of Cylinder Block
87
Inspection of Slinger (Splash Lubrication)
88
Inspection of Lifter
88
Inspection of Cam Shaft
89
Inspection of Piston Outer Diameter
90
Inspection of Cylinder Inner Diameter
90
Inspection of Piston Clearance
90
Inspection of Piston Ring Side Clearance
91
Inspection of Piston Rings
91
Inspection of Piston Pin
92
Inspection Connecting Rod Small End Inner Diameter
92
Inspection of Connecting Rod Big End Inner Diameter
92
Inspection of Connecting Rod Big End Side Clearance
93
Inspection of Crank Shaft
93
Disassembly and Assembly of Crank Shaft
94
Inspection of Crank Pin Oil Clearance
95
Installation of Piston and Connecting Rod
96
Removal of Valves and Springs
97
Inspection of Valve Springs
97
Inspection of Valve
98
Inspection of Valve Guide
98
Inspection of Valve Seat
99
Correction of Valve Seat
100
Installation of Valves
103
Assembly of Cylinder and Crank Case
104
Assembly to Power Unit
106
Assembly of Rocker Arm
108
Assembly of Power Unit
109
Disassembly of Recoil Starter
110
Inspection of Recoil Starter
110
Assembly of Recoil Starter
111
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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TOHATSU MFS 2 Specifications
General
Brand
TOHATSU
Model
MFS 2
Category
Engine
Language
English
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