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MFS 5
TOHATSU MFS 5 Service Manual
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4st 4/5/6 2011
vii
1
2
3
4
5
6
7
8
9
10
11
Ser
vice Information
Ser
vice Data
Inspections and
Adjustments
Fuel System
Power Unit
Lower Unit
Bracket
Electrical System
Tr
oubleshooting
Wiring Diagram
C Model Ser
vice Information
INDEX
O
K
MFS4-5-6Ech00110422.qxd
11.4.22
6:14
PM
ページ7
8
10
Table of Contents
1.Service Information
7
Service Information
3
Service Data
6
Table of Contents
7
Identification (Engine Serial Number)
12
Work Safety
12
Fire Prevention
12
Genuine Parts
12
Protection
12
Ventilation
12
Recommendations on Service
13
Tools
13
Cautions in Disassembling and Assembling Components
14
Tools and Instruments
15
Instruments
15
Test Propeller
15
Special Tools
16
Pre-Delivery Inspection
18
Engine Oil
18
Gear Oil
18
Gear Shift
18
Steering Handle
18
Fuel Tank Line
19
Inspection of Tilt Stoppe
19
Rigging
19
Cooling Water Check Port
20
Idle Operation
20
Inspection of Stop Switch
20
Inspection of Forward and Reverse Shifts
21
Propeller Selection
21
Break-In Operation
22
Test Run
22
Check after Test Run
23
Service Information
6
Service Data
25
Clamp Dimensions
28
Engine Lubrication System Diagram
29
Cooling Water System Diagram
30
Specifications
32
Maintenance Data
34
Tightening Torque Specifications
38
Sealant and Lubricant
39
Maintenance
41
Special Tools
42
Inspection Schedule
43
Inspection Items
44
Fuel System
44
Inspection of Top Cowl
44
Inspection of Fuel Filter
45
Inspection of Fuel Tank
45
Replacement of Engine Oil
46
Inspection of Gear Oil Quantity
47
Inspection of Water Pump
47
Replacement of Gear Oil
49
Inspection of Gear Case (for Leakage)
50
Inspection of Spark Plugs
51
Inspection of Compression Pressure
52
Inspection and Adjustment of Valve Clearance
53
Throttle Cable
55
Inspection of Idle Engine Speed
57
Inspection of Ignition Timing
57
Inspection of Anode
58
Replacement of Anode
58
Inspection of Propeller
59
Inspection of Thermostat
59
Inspection of Cooling Water Passage
60
Flushing with Water
61
Greasing Points
62
Fuel System
65
Special Tools
66
Fuel System
66
Parts Layout
68
Carburetor & Fuel Pump
68
Integral Fuel Tank
70
Carburetor Inner Passages
72
Idling Passage
72
Off-Idle Passage
73
High Speed Passage
74
Choking Passage
75
Inspection Items
76
Draining Fuel
76
Inspection of Fuel Feed System Piping
76
Inspection of Fuel Cock
77
Inspection of Fuel Filter
77
Inspection of Fuel Tank and Fuel Tank Cap
77
Removing Carburetor
78
Disassembling Carburetor
80
Inspection and Clean of Carburetor
81
Assembling of Carburetor
82
Inspection of Fuel Connector
82
Adjustment of Float Height
83
Installing Carburetor
83
Disassembly and Inspection of Fuel Pump
84
Removing Fuel Pump
84
Assembly of Fuel Pump
85
Power Unit
87
Power Unit
88
Special Tools
88
Parts Layout
89
Engine
89
Magneto
90
Cylinder & Oil Pan
92
Cylinder Head & Valve & Cam Shaft
94
Piston & Crank Shaft
96
Recoil Starter
97
Top Cowl
98
Inspection Items
99
Inspection of Compression Pressure
99
Inspection of Valve Clearance
100
Removing Power Unit
102
Removal and Disassembly of Crank Case Head
103
Assembly of Crank Case Head
104
Inspection of Crank Case Head
104
Installation of Crank Case Head
104
Disassembly of Power Unit
105
Removal of Rocker Arm
108
Disassembly and Inspection of Oil Feed Pump
109
Inspection of Push Rod
109
Inspection of Push Rod Plate
109
Inspection of Rocker Arm and Pivot
109
Removing Cylinder Head
109
Disassembly of Cylinder and Oil Pan
112
Disassembly and Inspection of Breather Chamber
114
Inspection of Lifter
114
Inspection of Cam Shaft
115
Inspection of Piston Outer Diameter
116
Inspection of Cylinder Inner Diameter
116
Inspection of Piston Clearance
116
Inspection of Piston Ring Side Clearance
117
Inspection of Piston Rings
117
Inspection of Piston Pin
118
Inspection Connecting Rod Small End Inner Diameter
118
Inspection of Connecting Rod Big End Inner Diameter
118
Inspection of Connecting Rod Big End Side Clearance
119
Inspection of Crank Shaft
119
Disassembly and Inspection of Oil Pan
120
Removal of Valves and Springs
121
Inspection of Valve Springs
121
Inspection of Valve
122
Inspection of Valve Guide
122
Inspection of Valve Seat
123
Correction of Valve Seat
124
Installation of Valves
127
Installation of Piston and Connecting Rod
128
Assembly of Cylinder Oil Pan
129
Installation of Cylinder Head
131
Installing Flywheel
133
Installation of Power Unit
136
Lower Unit
139
Special Tools
140
Parts Layout
142
Drive Shaft Housing
142
Inspection Items
146
Draining Gear Oil
146
Removing Propeller
146
Removing Lower Unit
147
Disassembly of Water Pump
147
Inspection of Water Pump
148
Removing Propeller Shaft Housing Ass'y
149
Disassembly of Propeller Shaft Housing
150
Inspection of Propeller Shaft Housing
150
Assembly of Propeller Shaft Housing
151
Removing Drive Shaft
151
Disassembly of Propeller Shaft Ass'y
152
Inspection of Propeller Shaft
152
Assembly of Propeller Shaft Ass'y
152
Removing Clutch Cam and Cam Rod
153
Disassembly of Clutch Cam and Cam Rod
153
Inspection of Clutch Cam and Cam Rod
153
Assembly of Clutch Cam and Cam Rod
154
Removing Pump Case (Lower)
154
Disassembly of Pump Case (Lower)
154
Assembly of Pump Case (Lower)
154
Inspection of Drive Shaft
155
Inspection of Pinion (B) Gear and Forward (A) Gea
155
Disassembly of Gear Case
156
Inspection of Gear Case
157
Assembly of Gear Case
157
Installation of Forward Gear and Pinion Gear (a and B Gears)
158
Reassembly of Pump Case (Lower)
158
Installation of Clutch Cam and Cam Rod
158
Determination of Forward (A) Gear Backlash
159
Installation of Water Pump
161
Installation of Propeller Shaft Housing
162
Filling with Gear Oil
163
Installation of Lower Unit
163
Bracket
167
Parts Layout
168
Bracket & Reverse Lock
168
Drive Shaft Housing & Shift
170
Bottom Cowl & Tiller Handle
172
Cowl
174
Disassembling and Assembling Procedure
175
Removal and Inspection of Drive Shaft Housing
175
Removal and Inspection of Clamp Bracket
177
Iinstallation of Clamp Bracket and Drive Shaft
178
Removal, Inspection and Installation of Water Pipe
180
Remove, Inspection and Installation of Tiller Handle
181
Adjustment of Throttle Cable
184
Special Tools
188
Magneto
189
Ignition System and Ignition Control System
190
Control System
190
Inspection of Ignition Spark
190
Inspection of Plug Cap
191
Inspection of Igniter
192
Inspection of Oil Pressure Switch
193
Inspection of Stop Switch
193
Inspection of Lighting Coil
194
Inspection of Rectifier
194
Troubleshooting O K
195
Troubleshooting
196
Troubleshooting List
196
Power Unit
197
Engine will Not Start or Is a Little Hard to Start
197
Troubleshooting
198
Engine Starts but Stalls Soon
199
Fuel System
199
Ignition System
200
Intake • Compression Pressure
201
Idle Engine Speed will Not Stabilize
202
Rough Acceleration
203
Gear Shifting Cannot be Made Normally
204
Wiring Diagram
205
C Model Service Information
209
Introduction
211
Default Chapter
212
Specification • Service Data
212
Parts Layout
222
Chapter 1 Predelivery Inspection
240
Difference Item
240
Fuel Tank and Fuel Line (P1-9)
240
Gear Shift (P1-8)
240
Inspection of Forward and Reverse Shifts (P1-11)
240
Chapter 3 Inspection Items
241
Fuel System (P3-4)
241
Check Piping
241
Inspection of Fuel Tank (P3-5)
241
Chapter 4 Inspection Items
242
Inspection of Fuel Feed System Piping (P4-12)
242
Draining Fuel (P4-12)
242
Inspection of Fuel Tank and Fuel Tank Cap (P4-13)
242
Inspection of Fuel Cock (P4-13)
242
Removing Carburetor (P4-14)
243
Chapter 5 Inspection Items
245
Removing Power Unit (P5-16)
245
Chapter 8 Inspection Item
247
Inspection of Igniter (P8-6)
247
Inspection of Rectifier (P8-8)
248
Chapter 10 Wiring Diagram
250
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TOHATSU MFS 5 Specifications
General
Brand
TOHATSU
Model
MFS 5
Category
Outboard Motor
Language
English
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