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TOHATSU
Outboard Motor
MFS 25d
TOHATSU MFS 25d Service Manual
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9-4
T
r
oubleshooting
O
K
4st 25/30 2022
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Check start switch or main switch.
Check electrical conductivity
of neutral switch.
Conductive?
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Check electrical conductivity
of wire harness.
Normal?
Conductive?
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361
363
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
Inspection Schedule
67
Fuel System Inspection of Fuel Hose
68
Inspection Items
68
Inspection of Top Cowl
68
Inspection of Fuel Filter
69
Inspection of Fuel Tank
69
Replacement of Engine Oil
70
Replacement of Oil Filter
71
Inspection of Gear Oil Quantity
73
Inspection of Water Pump
73
Replacement of Gear Oil
75
Inspection of Gear Case (for Leakage)
76
Inspection of Timing Belt
76
Replacement of Timing Belt
77
Inspection of Spark Plugs
82
Inspection of Compression Pressure
83
Inspection and Adjustment of Valve Clearance
84
Adjustment of Throttle Cable (Basic Tiller Handle Model)
85
Adjustment of Shift • Throttle Cable (Multi-Function Tiller Handle Model)
86
Adjustment of Shift • Throttle Cable (Remote Control Model)
89
Inspection of Shift Lever Gear Operations
92
Inspection of Gas Shock Absorber Operation
93
Inspection of PT Unit Operation
93
Inspection of Manual Tilt Operations
94
Inspection of PT Fluid Quantity
94
Inspection of Idle Speed
95
Inspection of Ignition Timing
95
Inspection of Anodes
96
Replacement of Anodes
97
Replacement of Cooling Water Passage Anode (Cylindrical Shape)
97
Inspection of Propeller
98
Inspection of Thermostat
98
Inspection of Cooling Water Pressure
99
Flushing with Water
100
Inspection of Battery
101
Grease Points
102
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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Owner's Manual
102 pages
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TOHATSU MFS 25d Specifications
General
Brand
TOHATSU
Model
MFS 25d
Category
Outboard Motor
Language
English
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