TOHATSU MFS 25d Service Manual

4st 25/30 2022
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1. Service Information
1. Identification (Engine Serial Number) … 1-2
2. Securing of Work Safety ……………… 1-2
1) Fire Prevention …………………………… 1-2
2) Ventilation ………………………………… 1-2
3) Protection ………………………………… 1-2
4) Genuine Parts …………………………… 1-3
5) Tools ……………………………………… 1-3
6) Recommendations on Service ………… 1-3
7) Cautions in Disassembling and
Assembling Components ……………… 1-4
3. Tools and Instruments ………………… 1-5
1) Test Propeller …………………………… 1-5
2) Measuring Instruments ………………… 1-5
3) Special Tools ……………………………… 1-6
4. Pre-delivery Inspection………………… 1-9
1) Steering Handle ………………………… 1-9
2) Gear Shift ………………………………… 1-9
3) Engine Oil ………………………………… 1-10
4) Gear Oil …………………………………… 1-10
5) Fuel Line ………………………………… 1-10
6) Rigging …………………………………… 1-10
7) Inspection of
PTT Unit (EFT, EHT, EPT) … 1-11
8) Inspection of Gas Shock Absorber (EFG) … 1-11
9) Inspection of Manual Tilt (MF, EF) ……… 1-11
10) Inspection of Starting Stop Switch and
Stop Switch ……………………………… 1-12
11) Cooling Water Check Port ……………… 1-14
12) Idling ……………………………………… 1-14
13) Propeller Selection ……………………… 1-14
14) Trim Tab …………………………………… 1-15
5. Break-in Operation ……………………… 1-16
6. Test Run …………………………………… 1-16
7. Checks After Test Run ………………… 1-17
2. Service Data
1. Outline Dimensions …………………… 2-2
1) Engine Dimensions ……………………… 2-2
2) Transom Bolts …………………………… 2-8
2. Fuel Injection System ………………… 2-9
1) ECU Fuel Feed System ………………… 2-9
3. Engine Lubrication System Diagram … 2-10
4. Cooling Water System Diagram …… 2-11
5. Specifications …………………………… 2-12
6. Maintenance Data ……………………… 2-16
7. Tightening Torque Data ……………… 2-24
8. Sealant Application Locations ……… 2-26
3. Maintenance
1. Special Tools ……………………………… 3-2
2. Inspection Schedule …………………… 3-3
3. Inspection Items ………………………… 3-4
1) Inspection of Top Cowl ………………… 3-4
2) Fuel System
Inspection of Fuel Hose ………………… 3-4
3) Inspection of Fuel Tank ………………… 3-5
4) Inspection of Fuel Filter ………………… 3-5
5) Replacement of Engine Oil ……………… 3-6
6) Replacement of Oil Filter ……………… 3-7
7) Inspection of Gear Oil Quantity ………… 3-9
8) Inspection of Water Pump ……………… 3-9
9) Replacement of Gear Oil ……………… 3-11
10) Inspection of Gear Case (for leakage)
… 3- 12
11) Inspection of Timing Belt ………………… 3-12
12) Replacement of Timing Belt …………… 3-13
13) Inspection of Spark Plugs ……………… 3-18
14) Inspection of Compression Pressure … 3-19
15) Inspection and Adjustment of
Valve Clearance ………………………… 3-20
16) Adjustment of Throttle Cable
(Basic Tiller Handle Model) …………… 3-21
17) Adjustment of Shift • Throttle Cable
(Multi-Function Tiller Handle Model) …… 3-22
18) Adjustment of Shift • Throttle Cable
(Remote Control Model) ………………… 3-25
19) Inspection of Shift Lever Gear Operations … 3-28
20) Inspection of PT Unit Operation………… 3-29
21) Inspection of Gas Shock Absorber Operation … 3-29
22) Inspection of Manual Tilt Operations … 3- 30
23) Inspection of PT Fluid Quantity ………… 3-30
24) Inspection of Idle Speed ………………… 3-31
25) Inspection of Ignition Timing …………… 3-31
26) Inspection of Anodes …………………… 3-32
27) Replacement of Anodes ………………… 3-33
28) Replacement of Cooling Water
Passage Anode (Cylindrical Shape) …… 3-33
29) Inspection of Propeller ………………… 3-34
30) Inspection of Thermostat ……………… 3-34
31) Inspection of Cooling Water Passage … 3- 35
32) Inspection of Cooling Water Pressure …… 3- 35
33) Flushing with Water ……………………… 3-36
34) Inspection of Battery …………………… 3-37
35) Grease points …………………………… 3-38
4. Fuel System
(Fuel Injection)
1. Special Tools ……………………………… 4-2
2. Piping Arrangement Diagram ……… 4-3
Fuel Hose, Vent Hose, Breather Hose,
Cooling Water Hose ………………………… 4-3
3. Parts Layout ……………………………… 4-4
Intake Manifold ……………………………… 4-4
Fuel System ………………………………… 4-6
Magneto ……………………………………… 4-10
Electrical Parts ……………………………… 4-12
Fuel Tank ……………………………………… 4-16
4. ECU System ……………………………… 4-18
(1) Configuration of ECU System …… 4-18
1) Sensors …………………………………… 4-19
2) Actuators ………………………………… 4-20
3) Control System (ECU) …………………… 4-21
(2) Control System ……………………… 4-21
(3) Fuel Injection Control ……………… 4-22
1) Fuel Injection Timing …………………… 4-22
2) Start Up Fuel Mapping ………………… 4-23
3) Acceleration Fuel Mapping ……………… 4-23
4) Deceleration Fuel Mapping …………… 4-23
5) Correction Based On Intake
Air Temperature ………………………… 4-23
6) Engine Temperature Correction ………… 4-23
(4) Control of Fuel Feed Pump (FFP) … 4-23
(5) Control of Tachometer …………… 4-23

TOHATSU MFS 25d Specifications

General

Brand	TOHATSU
Model	MFS 25d
Category	Outboard Motor
Language	English