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TOHATSU MFS25 Service Manual

TOHATSU MFS25
319 pages
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OB No.003-21054-1
06-02 NB-2600
Printed in Japan
4 Stroke
OB No.003-21054-1
06-02 NB-2600
MFS2530cover.qxd06.3.94:24PM ページ1

Table of Contents

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TOHATSU MFS25 Specifications

General IconGeneral
Horsepower25 hp
Cylinders2
Fuel SystemCarburetor
Cooling SystemWater-Cooled
Gear Ratio2.08:1
Starting SystemManual
Shaft Length20 in
Fuel TypeGasoline
Fuel Tank Capacity12 L
SteeringTiller

Summary

1 Service Information

1 Identification (Engine Serial Number)

Details on locating and identifying the engine serial number stamped on the outboard motor body.

2 Securing of Work Safety

Essential safety precautions including fire prevention, ventilation, protection, and genuine parts.

3 Tools and Instruments

Lists and descriptions of tools and instruments required for service procedures.

4 Pre-delivery Inspection

Procedures for inspecting the outboard motor before delivery to the customer.

5 Break-in Operation

Guidelines for the initial break-in period to ensure proper component seating.

6 Test Run

Steps for conducting a test run after service or assembly.

7 Checks After Test Run

Post-test checks to ensure proper operation and identify any issues.

2 Service Data

1 Outline Dimensions

Provides detailed dimensional specifications for the outboard motor and its components.

2 Fuel Injection System

Details regarding the fuel injection system, including ECU fuel feed.

3 Engine Lubrication System Diagram

A diagram illustrating the engine's lubrication system flow.

4 Cooling Water System Diagram

A diagram showing the components and flow of the cooling water system.

5 Specifications

Comprehensive technical specifications for various models and performance parameters.

6 Maintenance Data

Specific maintenance data and tolerances for engine parts.

7 Tightening Torque Data

Crucial torque specifications for fasteners during assembly and service.

8 Sealant Application Locations

Guidance on where and which sealants to apply during assembly.

3 Maintenance

1 Special Tool

Lists and illustrates special tools required for maintenance tasks.

2 Inspection Schedule

Outlines the recommended inspection intervals and items.

3 Inspection Items

Detailed procedures for inspecting various components like fuel system, engine oil, gear oil, water pump, timing belt, and spark plugs.

4 Fuel System (Fuel Injection)

1 Special Tools

Lists specialized tools required for fuel system diagnostics and service.

2 Piping Arrangement Diagram

Illustrates the routing of fuel, vent, breather, and cooling water hoses.

3 Parts Layout

Exploded views and part identification for the fuel system components.

4 ECU System

Details the Electronic Control Unit's role, configuration, and control functions.

5 Ignition System

Explains the ignition system's configuration and operation.

6 Components of Fuel Feed System

Identifies and describes the key components of the fuel feed system.

7 Outline of Fuel Injection System

An overview of the air intake system and its related components.

8 Inspection Items

Procedures for inspecting various parts of the fuel supply system, filters, pumps, and connectors.

5 Power Unit

1 Special Tools

Lists specialized tools needed for power unit maintenance and inspection.

2 Parts Layout

Provides detailed exploded views of engine components and their identification.

3 Inspection Items

Comprehensive list of inspection and maintenance procedures for engine components.

6 Lower Unit

1 Special Tools

Lists specialized tools required for lower unit service and disassembly.

2 Parts Layout

Exploded views and identification of parts within the gear case, drive system, and water pump.

3 Inspection Items

Detailed procedures for inspecting and servicing lower unit components like gears, water pump, and propeller shaft.

7 Bracket

1 Special Tools

Lists specialized tools required for bracket and PTT system service.

2 PTT Wiring and Layout Diagram

Wiring diagram and layout for the Power Trim and Tilt (PTT) system.

3 Parts Layout

Exploded views of drive shaft housing, swivel bracket, and PTT components.

4 Inspection Items

Procedures for inspecting throttle, steering, PTT unit, and related bracket components.

8 Electrical System

1 Special Tools

Lists specialized tools for electrical system testing and diagnostics.

2 Electrical Component Layout

Visual identification of electrical components from different views.

3 Parts Layout

Exploded views of magneto, ECU, starter motor, and fuel system electrical parts.

4 Ignition System, Ignition Control System

Detailed explanation of the ignition system and ECU's control functions.

5 Fuel Control System

Information on injectors, ISC valve, and fuel sensors within the fuel control system.

6 Starting System

Procedures for inspecting and troubleshooting the starting system components.

7 Battery Charging System

Inspection procedures for the alternator and rectifier.

8 ECU Coupler

Details on the ECU coupler and terminal identification for wiring.

9 Troubleshooting

1 Troubleshooting List

A comprehensive list of common engine problems, their probable causes, and initial checks.

2 Power Unit

Troubleshooting flowcharts for starting system, ignition, fuel, lubrication, and cooling systems.

3 PTT Unit

Troubleshooting steps for PTT unit operation and capability issues.

4 3AC Diagnosis

Setup, hardware connection, and operating procedures for the 3AC diagnostic system for ECU analysis.

10 Accessories

1 Remote Control Components

Instructions for installing remote control cables and components for the outboard motor.

2 Installation of Meters and Battery

Guidelines for selecting and installing marine meters and batteries.

3 Operation

Information on warning indications and basic operational procedures.

11 Wiring Diagrams

1 Wiring Chart

A chart detailing wire colors and terminal connections for various electrical components.

2 MF/MFG Model

Wiring diagram specific to MF and MFG models, showing component connections.

3 EF/EFG/EFT Model

Wiring diagram specific to EF, EFG, and EFT models, detailing electrical connections.

4 EP/EPG/EPT Model

Wiring diagram specific to EP, EPG, and EPT models, illustrating system wiring.

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