TOHATSU MFS 25d Service Manual

4st 25/30 2022
vii
6) Inspection of Water Pipe ………………… 6-13
7)
Disassembly of Water Pump Case (Lower) … 6-14
8) Assembly of Water Pump Case (Lower) … 6-14
9) Disassembly of Cam Rod ……………… 6-14
10) Inspection of Clutch Cam ……………… 6-15
11) Assembly of Clutch Cam ……………… 6-15
12) Removal of Propeller Shaft Housing Assy … 6-16
13) Disassembly of Propeller Shaft
Housing Assy …………………………… 6-16
14) Inspection of Propeller Shaft Housing … 6-18
15) Assembly of Propeller Shaft Housing … 6-18
16) Disassembly of Propeller Shaft Assy … 6-21
17) Inspection of Propeller Shaft Assy …… 6-22
18) Assembly of Propeller Shaft Assy ……… 6-23
19) Removal of Bevel Gear Assy A ………… 6-24
20) Disassembly of Bevel Gear Assy A …… 6-24
21) Inspection of Bevel Gear Assy A ……… 6-25
22) Assembly of Bevel Gear Assy A ……… 6-25
23) Removal of Drive Shaft ………………… 6-26
24) Disassembly of Drive Shaft …………… 6-27
25) Inspection of Drive Shaft ………………… 6-27
26) Inspection of Bevel Gear B ……………… 6-28
27) Assembly of Drive Shaft ………………… 6-28
28) Disassembly of Gear Case ……………… 6-29
29) Inspection of Gear Case ………………… 6-30
30) Assembly of Gear Case ………………… 6-30
31) Assembly of Bevel Gear B ……………… 6-32
32) Bevel Gear B Height Measurement and
Shim Selection …………………………… 6-33
33) Backlash Measurement Between Bevel
Gear Assy A and Bevel Gear B and Shim
Selection ………………………………… 6-35
34) Installation of Pump Case ……………… 6-37
35) Installation of Propeller Shaft Housing Assy … 6-38
36) Inspection of Gear Case (for Leakage) … 6-39
37) Installation of Lower Unit ……………… 6-40
7. Bracket
1. PT Wiring Diagram and Layout ……… 7-2
2. Parts Layout ……………………………… 7-4
Drive Shaft Housing ………………………… 7-4
Bracket (Manual Tilt) ………………………… 7-6
Bracket (PT · Gas Assist) …………………… 7-10
Power Tilt ……………………………………… 7-12
Tiller Handle ………………………………… 7-14
Multi-Function Tiller Handle ………………… 7-18
Bottom Cowl ………………………………… 7-22
Shift …………………………………………… 7-24
Remote Control ……………………………… 7-26
3. Inspection Items ………………………… 7-28
1)
Inspection of Throttle Cable and Shift Cable … 7-28
2) Installation of Tiller Handle ……………… 7-28
3) Adjustment of Friction Lever …………… 7-29
4) Removal of Drive Shaft Housing ……… 7-30
5) Disassembly of Drive Shaft Housing … 7-31
6) Assembly of Drive Shaft Housing ……… 7-32
7) Installation of Drive Shaft Housing Assy … 7- 33
8) Removal of Steering Shaft ……………… 7-34
9) Installation of Steering Shaft …………… 7-35
10) Disassembly of Clamp Bracket
(Power Tilt Model, Gas Assist Model) … 7-36
11) Installation of Clamp Bracket
(Power Tilt Model, Gas Assist Model) … 7-38
12) Disassembly of Clamp Bracket
(Manual Tilt Model) ……………………… 7-38
13) Installation of Clamp Bracket
(Manual Tilt Model) ……………………… 7-39
14)
Removal of PT Unit / Gas Shock Absorber … 7- 40
15) Removal of PT Motor …………………… 7-41
16) Inspection of PT Motor ………………… 7-42
17) Assembly of PT Motor …………………… 7-43
18) Removal of PT Pump and Valve ……… 7-44
19) Inspection of PT Pump and Valve ……… 7-44
20) Removal of Tilt Cylinder ………………… 7-45
21) Inspection of Tilt Cylinder ……………… 7-45
22) Inspection of Valve ……………………… 7-46
23) Installation of PT Pump and Motor …… 7-46
24) Assembly of Tilt Cylinder ……………… 7-47
25) Installation of PT Unit / Gas Shock Absorber … 7-49
26) Air-Purging of PT Unit
(With Outboard Motor Installed) ……… 7-50
27) Inspection of PT Solenoid ……………… 7-51
28) Inspection of PT Switch ………………… 7-51
8. Electrical System
1. Special Tools ……………………………… 8-2
2. Electrical Component Layout ……… 8-3
Port Side View ……………………………… 8-3
Bow Side View ……………………………… 8-4
Starboard Side View ………………………… 8-5
Housing Cover (Front) ……………………… 8-6
3. Parts Layout ……………………………… 8-8
Magneto ……………………………………… 8-8
Electrical Parts ……………………………… 8-10
Intake Manifold ……………………………… 8-14
Fuel System ………………………………… 8-16
4. The Ignition System and the
Ignition Control System ……………… 8-20
1) Inspection of the Ignition Spark ………… 8-20
2) Inspection of the Plug Cap ……………… 8-20
3) Inspection of the Ignition Coil …………… 8-21
4) Inspection of the Exciter Coil and ECU
Charge Coil ……………………………… 8-21
5) Inspection of the Pulser Coils ………… 8-22
6) Adjustment of the Pulser Coil Air Gap … 8-22
7) Inspection of the Oil Pressure Switch … 8-23
8)
Inspection of the Engine Temperature Sensor 8-24
9) Inspection of the Neutral Switch
(Except for MF) …………………………… 8-24
10) Inspection of the Start Switch (EF, EFT) … 8-25
11) Inspection of the Main (Key) Switch …… 8-25
12) Inspection of the Stop Switch
(Except for MF) …………………………… 8-26
5. The Fuel Control System ……………… 8-27
1) Inspection of the Injector ………………… 8-27
2) Inspection of the ISC Valve …………… 8-27
3) Inspection of the T-MAP Sensor ……… 8-28
4)
Inspection of the Fuel Feed Pump (FFP) … 8-28
5) Inspection of the Throttle Position
Sensor (TPS) …………………………… 8-29
6.
The Starting System (Except for MF) … 8-29
1) Inspection of the Fuse …………………… 8-29
2) Inspection of the Starter Solenoid ……… 8-29
3) Disassembly of the Starter Motor ……… 8-30
4) Inspection of the Starter Motor Pinion … 8-30
5) Inspection of the Armature ……………… 8-30

TOHATSU MFS 25d Specifications

General

Brand	TOHATSU
Model	MFS 25d
Category	Outboard Motor
Language	English