TOHATSU MFS 25d Service Manual

4st 25/30 2022
vi
(6) Warning Buzzer and Lamp (LED),
and Control of Engine Revolution
Speed …………………………………… 4-24
1) Location of Warning Buzzer and
Lamp (LED) ……………………………… 4-24
2) Waring Notification, Abnormality and
Action to be taken ……………………… 4-24
5. Ignition System ………………………… 4-25
(1)
Configuration of Ignition System … 4-25
(2) Ignition Control ……………………… 4-26
1) Ignition Timing Control ………………… 4-26
2) Ignition and Combustion Order ………… 4-26
3) Ignition Timing …………………………… 4-26
4) Operations ………………………………… 4-26
(3) Fuel Feed System …………………… 4-27
6. Components of Fuel Feed System … 4-28
1) Fuel Pump
[Low Pressure Mechanical Pump] ……… 4-28
2) Vapor Separator ………………………… 4-28
3) Fuel Regulator …………………………… 4-29
4) Fuel Cooler ……………………………… 4-29
7. Outline of Fuel Injection System … 4-30
1) Air Intake System ………………………… 4-30
8. Inspection Items ………………………… 4-31
1) Inspection of Fuel Supply System ……… 4-31
2) Inspection of Filter ……………………… 4-31
3) Inspection of Fuel Pump ………………… 4-33
4) Inspection of Fuel Connector …………… 4-33
5) Measurement of Fuel Pressure ………… 4-34
6) Draining Fuel …………………………… 4-35
7) Disassembly of Vapor Separator ……… 4-36
8) Inspection of Vapor Separator ………… 4-37
9) Reassembly of Vapor Separator ……… 4-37
10) Inspection of ISC (Idle Speed Control) … 4-38
11) Inspection of Idle Speed ………………… 4-38
5. Power Unit
1. Special Tools ……………………………… 5-2
2. Parts Layout ……………………………… 5-3
Engine ………………………………………… 5-3
Magneto ……………………………………… 5-4
Intake Manifold ……………………………… 5-6
Fuel System ………………………………… 5-8
Electrical Parts ……………………………… 5-12
Pulley & Timing Belt ………………………… 5-16
Cylinder Head & Oil Pump ………………… 5-18
Cylinder & Crankcase ……………………… 5-22
Piston & Crankshaft ………………………… 5-24
Top Cowl ……………………………………… 5-26
Recoil Starter ………………………………… 5-28
3. Inspection Items ………………………… 5-30
1) Inspection of Compression Pressure … 5-30
2) Inspection of Oil Pressure ……………… 5-30
3) Inspection of Valve Clearance ………… 5-31
4) Removal of Power Unit ………………… 5-31
5) Removal of Oil Strainer ………………… 5-34
6) Inspection of Oil Strainer ……………… 5-34
7) Removal of Flywheel …………………… 5-35
8) Installation of Flywheel ………………… 5-37
9) Removal of Timing Belt and Pulley …… 5-39
10) Inspection of Timing Belt ………………… 5-40
11)
Installation of Pulley and Timing Belt …… 5- 41
12) Removal of Air Intake System &
Fuel System ……………………………… 5-43
13) Removal of Electrical System Parts …… 5-46
14) Removal of Cylinder Head Assy ……… 5-49
15) Disassembly of Cylinder Head Assy …… 5-50
16) Inspection of Valve Spring ……………… 5-51
17) Inspection of Valve ……………………… 5-52
18) Inspection of Valve Guide ……………… 5-52
19) Inspection of Valve Seat ………………… 5-53
20) Correction of Valve Seat ………………… 5-54
21) Inspection of Rocker Arm and
Rocker Arm Shaft ………………………… 5-56
22) Inspection of Camshaft ………………… 5-57
23) Inspection of Cylinder Head …………… 5-58
24) Inspection of Oil Pump ………………… 5-59
25) Installation of Valve ……………………… 5-60
26) Installation of Camshaft ………………… 5-61
27) Installation of Rocker Arm Shaft ……… 5-61
28) Installation of Oil Pump ………………… 5-62
29) Installation of Cylinder Head Assy ……… 5-63
30) Disassembly of Cylinder Block ………… 5-65
31) Inspection of Cylinder Block …………… 5-66
32) Inspection of Piston Outer Diameter …… 5-67
33)
Inspection of Cylinder Inner Diameter …… 5- 67
34) Inspection of Piston Clearance ………… 5-68
35) Inspection of Piston Ring Side Clearance … 5-68
36) Inspection of Piston Rings ……………… 5-68
37) Inspection of Piston Pins ……………… 5-69
38) Inspection of Connecting Rod Small End
Inner Diameter …………………………… 5-69
39) Inspection of Connecting Rod Big End
Side Clearance …………………………… 5- 69
40) Inspection of Crankshaft ………………… 5-70
41) Inspection of Crank Pin Oil Clearance …… 5- 71
42) Inspection of Crankshaft Main Journal
Oil Clearance …………………………… 5-72
43) Inner Diameter of Cylinder/Crankcase
Bearing Holder (Inner Diameter Codes) … 5-73
44) Thickness of Metal Bearing
(Color of Inner Diameter Code) ………… 5-73
45) Installation of Piston and Connecting Rod … 5-74
46) Assembly of Cylinder Block …………… 5-76
47) Installation of Electrical System Parts ……… 5- 78
48) Installation of Air Intake System &
Fuel System ……………………………… 5-81
49) Installation of Oil Strainer ……………… 5-84
50) Installing the Power Unit ………………… 5-84
51) Removal of Recoil Starter ……………… 5-88
52) Disassembly of Recoil Starter ………… 5-88
53) Inspection of Recoil Starter …………… 5-89
54) Installation of Recoil Starter …………… 5-90
6. Lower Unit
1. Special Tools ……………………………… 6-2
2. Parts Layout ……………………………… 6-4
Gear Case (Drive Shaft) …………………… 6-4
Gear Case (Propeller Shaft) ………………… 6-8
3. Inspection Items ………………………… 6-10
1) Draining Gear Oil ………………………… 6-10
2) Removal of Propeller …………………… 6-10
3) Removal of Lower Unit ………………… 6-11
4)
Removal of Water Pump and Cam Rod … 6-12
5) Inspection of Water Pump ……………… 6-13

TOHATSU MFS 25d Specifications

General

Brand	TOHATSU
Model	MFS 25d
Category	Outboard Motor
Language	English