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TOHATSU MFS 2, Service Manual

The TOHATSU MFS 2 is a high-performance outboard motor designed for ultimate efficiency and reliability. With its compact design and advanced technology, this motor delivers optimum power for smooth and effortless boating experiences. Enhance your ownership experience by downloading the free Owner's Manual from manualshive.com, providing detailed instructions for maximized performance and maintenance.

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5

5-17

4st  2/2.5/3.5  2007

9) Removal of Rocker Arm

1. 

Remove bolts and then cylinder head cover.

2. 

Remove lock nut 

1

, and then pivot 

2

, rocker arm 

3

and

push rod 

4

.

3. 

Remove pivot bolt 

5

, and then push rod plate 

6

.

2

1

2

6

3

1

5

4

MFS2̲sec05̲070524.qxd    07.5.24  3:18  PM    ページ 17

Summary of Contents for MFS 2

Page 1: ...OB No 003 21058 0 07 04 NB 2600 Printed in Japan OB No 003 21058 0 07 04 NB 2600 MFS2A cover E 070524 qxd 07 5 24 5 06 PM ページ 1 ...

Page 2: ...manual is utilized so that our customers can always use their outboard motor with full satisfaction Information for securing of safety Safety Statements The following safety statements are found throughout this manual and indicate information which if ignored could result in fatal safety hazards or property damages Provides an important one point advice WARNING Indicates the presence of a hazard o...

Page 3: ... Unit Electrical System Power Unit Troubleshooting Tightening Torque Accessories Wiring Diagrams Bracket The following symbols represent the contents of individual chapters The following symbols indicate items needed for the service The following symbols indicate a point to which lubrication oil sealing agent or screw locking agent is to be applied Screw Lock Agent Three Bond 1373B Waterproof Grea...

Page 4: ...2 Inspection of Compression Pressure 3 13 13 Inspection and Adjustment of Valve Clearances 3 14 14 Adjustment of Throttle Cable 3 16 15 Inspection of Gear Shift Operation 3 17 16 Flushing with Water 3 18 17 Inspection of Idle Engine Speed 3 18 18 Inspection of Ignition Timing 3 19 19 Inspection of Anode 3 19 20 Replacement of Anode 3 19 21 Inspection of Propeller 3 19 22 Inspection of Thermostat 3...

Page 5: ...aft Housing 6 12 13 Removing Pump Case Lower 6 12 14 Disassembly of Pump Case Lower 6 13 15 Assembly of Pump Case Lower 6 13 16 Removing Clutch Cam and Cam Rod 6 13 17 Disassembly of Clutch Cam and Cam Rod 6 13 18 Inspection of Clutch Cam and Cam Rod 6 13 19 Assembly of Clutch Cam and Cam Rod 6 13 20 Removing Drive Shaft 6 14 21 Disassembly of Drive Shaft 6 14 22 Inspection of Drive Shaft 6 14 23 ...

Page 6: ... 3 5 2007 1 Service Information 2 Service Data 3 Maintenance 4 Fuel System Carburetor 5 Power Unit 6 Lower Unit 7 Bracket 8 Electrical System 9 Troubleshooting INDEX OK MFS2 sec00 070524 qxd 07 5 24 3 04 PM ページ 5 ...

Page 7: ...Propeller 1 5 2 Instruments 1 5 3 List of Special Tool 1 6 4 Predelivery Inspection 1 7 1 Steering Handle 1 7 2 Gear Shift 1 7 3 Engine Oil 1 7 4 Gear Oil 1 7 5 Fuel Tank and Fuel Line 1 8 6 Rigging 1 8 7 Inspection of Tilt Stopper 1 8 8 Inspection of Stop Switch 1 9 9 Cooling Water Check Port 1 9 10 Idle Operation 1 9 11 Propeller Selection 1 10 12 Inspection of Forward and Reverse Shifts 1 10 5 ...

Page 8: ... when working indoors 3 Protection Wear a pair of goggles working gloves and safety shoes to protect your body from chemicals and oils and eyes from particles generated by grinding or polishing Avoid contact with oil grease or sealing agent to the skin In case of exposure to such matters wash away with soap and warm water immediately 4 Genuine Parts Use parts and or chemicals that are genuine item...

Page 9: ...n this manual and use tightening torque specified 6 Recommendations on Service Remove foreign substances and dirt from outboard motor and individual parts by cleaning Apply recommended oil or grease to rotating areas and sliding surfaces Always perform verifications such as ensuring smooth movement and sealing 1 3 3R0728150 3AC728710 MFS2 sec01 070524 qxd 07 5 24 3 05 PM ページ 3 ...

Page 10: ...g parts take sufficient care also for details such as fit repair limits air tightness cleanliness of oil holes for lubrication and greasing packings wirings and piping For components using many bolts and nuts for assembling such as cylinder head and crankcase tighten all the fasteners evenly to their specified torque clockwise in two or three stages inner ones first and then outer ones Reverse the...

Page 11: ...ion of 0 01 mm Thickness gauge JIS B 7524 0 03 0 3 mm V block JIS B 7540 Surface plate JIS B 7513 500 mm x 500 mm Dial gauge magnet base or dial gauge stand Model Speed at WOT Wide Open Throttle r min F2A F2 5 A 4 500 5 500 F3 5 A 5 000 6 000 3 Tools and Instruments 1 Test Propeller P N 3AB 64111 0 Outer diameter 120mm Width 16mm Reference value This test propeller has been designed for break in o...

Page 12: ... Measuring gaps Removing spring pin Spring Pin Tool A P N 345 72227 0 1 6 Service Information 4st 2 2 5 3 5 2007 3 List of Special Tool 3B7 72783 0 3B7 72784 0 Driver Rod 3 P N 3AB 99702 0 Used in combination with center plate and bearing attachment Used in combination with driver rod and bearing attachment to locate lower gear case bearing Center Plate 3 P N 3AB 99701 0 Installing drive shaft bea...

Page 13: ...ing 3 Engine Oil 1 Set outboard motor straight ahead and vertical 2 Fill with Engine Oil 4 Stroke Engine Oil 300cm3 10 fl oz OIL F N 1 CAUTION Engine oil is removed before shipment to prevent leakage during transportation 3 Use oil level gauge to check oil quantity Straight ahead and vertical 1 2 O I L GEAR GEAR GEAR 4 Gear Oil 1 Check quantity of gear oil Gear Oil 180cm3 6 fl oz OIL Spilling of o...

Page 14: ...ted and is free of leaks CAUTION Since this is a 4 stroke engine model do not use fuel mixed with engine oil Use of fuel mixed with engine oil will cause engine trouble 7 Inspection of Tilt Stopper 1 Fully tilt up the outboard motor 1 lock with the tilt stopper 2 and then check that the holding mechanism functions normally 2 1 Test run to determine the best installation height a 30 50 mm 1 2 2 0 i...

Page 15: ...use tachometer to check idle engine speed is as specified 1 Idle Engine Speed 1 250 1 350 r min RPM 9 Cooling Water Check Port 1 Check that cooling water check port 1 discharges water during engine runs 1 Tachometer P N 3AC 99010 0 1 High Tension Cord Use tachometer to measure after warm up operation Set the measurement mode to 4 stroke 2 cylinder 2 stroke 1 cylinder MFS2 sec01 070524 qxd 07 5 24 ...

Page 16: ...low speed and do not increase the engine speed unnecessarily 1 Forward Return handle grip 2 to idle speed a and then move shift lever 1 toward the operator F quickly 2 Reverse In the same way as forward shift inspection set the engine to idle speed shift into 1 to neutral N put up handle 3 turn outboard motor 180 degrees and then shift into forward F quickly 3 Shallow water run In shallow water ru...

Page 17: ...ak in Operation Break in operation is needed to smooth sliding surfaces between components such as pistons and cylinder piston rings piston pins crank shaft connecting rods and intake and exhaust valves Operation Dead Slow or Idling 1 2 of WOT or less at approximately 3 000 r min 3 4 of WOT or less at approximately 4 000 r min WOT run for approximately 1 minute can be included every 10 minutes of ...

Page 18: ...s present in gear oil 3 Check that no fuel leakage exists in the cowl 4 Check that no oil and water leak in the cowl and no water is present in engine oil 5 If using in salt water after test run use flushing attachment 1 optional and fresh water to wash cooling water path by idling engine 1 1 1 Flushing Attachment optional MFS2 sec01 070524 qxd 07 5 24 3 05 PM ページ 12 ...

Page 19: ...e Dimensions 2 2 2 Clamp Dimensions 2 3 2 Cooling Water System Diagram 2 4 3 Wiring Diagram 2 5 4 Specifications 2 6 5 Maintenance Data 2 8 6 Tightening Torque Data 2 12 7 Sealant Application Locations 2 14 MFS2 sec02 070524 qxd 07 5 24 3 12 PM ページ 1 ...

Page 20: ...776 30 55 S mm in 435 17 13 C L mm in 562 22 13 D mm in 446 17 56 E mm in 108 4 25 F mm in 354 13 94 G mm in 336 13 23 H mm in 303 11 93 I mm in 58 2 28 J mm in 208 8 19 K mm in 628 24 72 L mm in 363 14 29 M mm in 340 13 39 N mm in 276 10 87 O mm in 453 17 83 P deg 65 1 Outline Dimensons 1 Engine Dimensions MFS2 sec02 070524 qxd 07 5 24 3 12 PM ページ 2 ...

Page 21: ...sions 70 5mm 63 5mm 150mm 63 5mm 36mm 1 42in 45 5mm 43mm 45 5mm 2 77in 30 58mm 1 18 2 28 in Thickness Allowable Transom 2 50in 5 91in 1 69in 2 50in 1 79in DIAMETER TOP OF BOAT TRANSOM CENTER LINE MFS2 sec02 070524 qxd 07 5 24 3 12 PM ページ 3 ...

Page 22: ...ing 8Drive Shaft Housing 9Water Pipe 0Water Pump qExhaust Gas and Discharged Water wCooling Water Intake Thermostat1 Cylinder with cylinder head 2 Water Pump0 Water Pipe9 Cooling Water Intakew Exhaust Gas and Discharged Waterq Drive Shaft Housing8 6 Water Feed Passage in Drive Shaft Housing 7 Water Discharging Passage in Drive Shaft Housing Cooling Water Check Port5 2 Cooling Water System Diagram ...

Page 23: ...2 5 2 4st 2 2 5 3 5 2007 1 2 3 6 4 5 B Br Br B 1Flywheel B Black 2Igniter Br Brown 3Stop Switch 4Ground 5Spark Plug 6Stop Switch Lanyard 3 Wiring Diagram MFS2 sec02 070524 qxd 07 5 24 3 12 PM ページ 5 ...

Page 24: ...r Unit Engine Type No of Cylinders Total Displacement Starting System Shift Operation System Bore x Stroke Max Output Full Throttle Revolution Speed Range Weight approximate Performance Overall Width Transom Length Digital CDI 85 5 5 2 OHV Cross Flow 55 x 36 2 17 x 1 42 9 1 250 1 350 1 150 1 250 Overall Height BTDC 7ﾟ BTDC 25ﾟ Electronic Control DCPR6E NGK Carburetor Horizontal Butterfly Valve Sys...

Page 25: ...l Gear Clutch Dog Clutch Propeller Shaft Driving Shear Pin Propeller Rotation Direction Clockwise at forward F shift as viewed from rear Propeller Standard I7 3 x 7 x 7 3 x 188 x 178 Plastic Bracket No of Trim Steps 4 Trim Angle Transom 12 7ﾟ 8ﾟ Max Tilt Angle 65 1 Requirements of both API and SAE shall be met 2 Angle of propeller shaft relative to horizon when transom angle is 12 degrees 3 Range ...

Page 26: ...Clearance Big End Oil Clearance Top Ring 0 15 0 30mm 0 0059 0 0118in Measure piston pin hole diameter Crank pin outer diameter Crankshaft roundness Use V blocks to support crankshaft at bearings of both ends Outer Diameter Measure outer diameter at 7mm 0 28in above lower end of piston skirt at right angle to piston pin Piston Clearance Out of roundness Carbon build up on piston crown and in ring g...

Page 27: ...place if over specified limit Adjust into specified range 5 45mm 0 2146in 5 44mm 0 2142in Replace if under specified limit 5 55mm 0 2185in 5 57mm 0 2193in Replace if over specified limit 0 070mm 0 00276in 0 080mm 0 00315in Replace if over specified limit 2 0mm 0 08in 2 0mm 0 08in Repair or replace if over specified limit 33 2mm 1 31in Replace if under specified limit 23 78mm 0 9362in Replace if un...

Page 28: ...onic Control 2 0 3 0kΩ 5 5 9 5kΩ Measurement value with HIOKI Analog 3030 100Ω range Non conductive Resistance Infinite Measurement value with HIOKI Analog 3030 100Ω range Conductive 5 to 9kΩ 25 0mm 0 984in Gap between the bushing and drive shaft Wear Bend Crack Break Backlash between forward gear and pinion A and B gears Spline Upper Base Tangent Length 2 Gears Bearing Wear and Damage Propeller S...

Page 29: ...e at around 65ﾟC 150ﾟF for approximately 5 minutes 3 0mm 0 12in Replace if under specified limit The impeller is worn cracked or damaged on the tips or upper and lower surface lips Replace pump case liner and guide plate as a set Replace if severely worn Replace if severely worn Replace if severely worn 23 5mm 0 925in Replace if under specified limit Replace if necessary 0 4mm 0 016in Replace if o...

Page 30: ...k Plug 16 M12 x 1 25 18 13 1 8 Igniter 10 M6 x 1 0 Bolt 6 4 0 6 Thermostat Cap 10 M6 x 1 0 Bolt 6 4 0 6 Cylinder Head Cover 10 M6 x 1 0 Bolt 6 4 0 6 Fuel Tank 10 M6 x 1 0 Bolt 6 4 0 6 Power Unit Installation 10 M6 x 1 0 Bolt 6 4 0 6 Bolt M6 x 1 0 M6 x 1 0 M6 x 1 0 Bolt Bolt First Tightening Torque First Tightening Torque First Tightening Torque Second Tightening Torque Second Tightening Torque Sec...

Page 31: ...l Tilt Handle 10 M6 x 1 0 Nut 2 1 5 0 2 Tiller Handle Steering Bracket 13 M8 x 1 25 Bolt 13 9 1 3 M5 Bolts and Nuts 8 M5 x 0 8 Bolts and Nuts 4 3 0 4 M6 Bolts and Nuts 10 M6 x 1 0 Bolts and Nuts 6 4 0 6 M8 Bolts and Nuts 13 M8 x 1 25 Bolts and Nuts 13 9 1 3 M10 Bolts and Nuts 17 M10 x 1 25 Bolts and Nuts 27 20 2 7 Value enclosed by is hex hole size Wrench A Screw B x Pitch Type of Fastener Tighten...

Page 32: ...ings Whole area of the part Piston Pins Outer circumference Connecting Rod Inner surface of big and small ends Connecting Rod Cap Inner surface Crankshaft Sliding area and areas of bearings and gears Oil Seal Crankshaft Lip area Thrust Plate Crankshaft Whole area of the part Crank Case Cylinder Mating Face Oil Level Gauge Outer circumference Outer circumference Lip area Oil Seals 2 pcs In the cran...

Page 33: ...ea O Ring Whole area of the part Lip area Outer circumference at press fit Propeller Shaft Propeller contact area Clamp Screw Threaded area Tilt Stopper Entire circumference of shaft area Thrust Supporter Sliding area Steering Bushing Sliding area Thrust Bushing Sliding area Steering Stopper Inner area of split pin insertion hole Bolt Steering Stopper Threaded area Stopper Spring Coil area both en...

Page 34: ... Whole area of the part Throttle Wire Wire area Bolts Cowl Latch Threaded area Bolts Bottom Cowl Threaded area Bolts Tiller Handle Threaded area Bolts Tank Installation Threaded area Grease Nipples Press fit area Engine Oil Copacity 300J 10fl oz Gear Oil Copacity 180J 6 fl oz Applied to Remarks Chuo Yuka Cowl Fuel Tank Tiller Handle Lower Unit Gear Oil 4 stroke Engine Oil Silicon Grease Teflon Gre...

Page 35: ...ection of Gear Case for leakage 3 11 11 Inspection of Spark Plug 3 12 12 Inspection of Compression Pressure 3 13 13 Inspection and Adjustment of Valve Clearances 3 14 14 Adjustment of Throttle Cable 3 16 15 Inspection of Gear Shift Operation 3 17 16 Flushing with Water 3 18 17 Inspection of Idle Engine Speed 3 18 18 Inspection of Ignition Timing 3 19 19 Inspection of Anode 3 19 20 Replacement of A...

Page 36: ...enance 4st 2 2 5 3 5 2007 1 Special Tool Measuring compression pressure Measuring engine revolution speed Compression Gauge P N 3AC 99030 0 Tachometer P N 3AC 99010 0 MFS2 sec03 070524 qxd 07 5 24 3 16 PM ページ 2 ...

Page 37: ...o o o Wear Engine Oil o o o 300cm3 10fl oz Replace Replace Replace Valve Clearance o o Inspection and adjustment Compression Pressure o Inspection Thermostat o Rust closing damage Propeller o o o o Bending damage and wear of blades Gear Oil o o o o Oil replacement or replenishment GL5 SAE90 Replace Replace Replace Check for water leak 180cm3 6fl oz Anode o o o Corrosion and wear Water Strainer o o...

Page 38: ...ection for fuel leak dirt deterioration and damages Clean or replace parts if necessary 3 Inspection Items 1 Inspection of Top Cowl 1 Push top cowl to check for looseness and state of closing 3 Inspection of Fuel Tank 1 Remove dirt and water from fuel tank 1 if any 1 MFS2 sec03 070524 qxd 07 5 24 3 16 PM ページ 4 ...

Page 39: ...4 Inspection of Fuel Cock Fuel Filter 1 Check fuel cock 1 fuel filter a for dirt and clogging and clean if necessary 1 5 Inspection of Fuel Cock 1 Check that fuel cock 1 can be opened and closed normally MFS2 sec03 070524 qxd 07 5 24 3 16 PM ページ 5 ...

Page 40: ...lt 2 to drain oil 5 Tighten drain bolt 2 to specified torque 6 Replacement of Engine Oil 1 Oil Level 300cm3 250cm3 2 Oil Specification 20 10 0 10 20 30 40 10W 40 10W 30 Engine Oil Ambient air temperature C Upper Limit Center Lower Limit Engine Oil 4 Stroke Engine Oil API SF SG SH SAE 10W 30 10W 40 NMMA FC W Certified 10W 30 Quantity of Engine Oil 300cm3 10 fl oz OIL Use oil with viscosity that is ...

Page 41: ... oil level gauge 4 7 Attach oil filler cap 1 start engine and idle for 5 minutes to warm up 8 Stop engine and check oil level and for oil leaks after 5 minutes 1 3 4 4st OIL 4st O I L 300cm3 250cm3 Upper Limit Center Lower Limit Quantity of Engine Oil 300cm3 10 fl oz OIL MFS2 sec03 070524 qxd 07 5 24 3 16 PM ページ 7 ...

Page 42: ...er oil plug 1 and check level of gear oil in the gear case Gear Oil Hypoid Gear Oil API GL 5 SAE 90 OIL 1 2 3 O I L GEAR GEAR GEAR If the oil is low add through lower oil plug hole 2Gasket Do not reuse 1 Remove grommet 1 and loosen bolt 2 Inspection of water pump does not require removal of power unit from outboard motor body Tilt up and lock with tilt stopper Over flow of some oil from plug hole ...

Page 43: ...ks and wear Replace if necessary 7 Check key 4 and drive shaft groove d for wear Replace if necessary 8 Reinstall the components removed For details refer to Chapter 6 Check drive shaft spline a for adhesion of oil rust and wear When removing or attaching water pump and pump case lower be careful that the drive shaft is not pushed up Pushing up the drive shaft causes pinion B gear to drop into the...

Page 44: ...l Hypoid Gear Oil API GL 5 SAE 90 Quantity of Gear Oil 180 cm3 6 fl oz OIL 2 3 3 1 3 3 2 a 1 O I L GEAR GEAR GEAR 2 a 1 3 3 O I L GEAR GEAR GEAR 3 Check gear oil for presence of metal particles change of color abnormal if clouded and viscosity Check lower unit internal components if necessary Remove lower oil plug 1 first when draining Use lower plug hole 1 when filling with gear oil Upper hole 2 ...

Page 45: ...amage to oil seal Specified Gear Case Maintained Pressure 0 049 MPa 7 psi 0 5 kgf cm2 10 Inspection of Gear Case for leakage 1 Drain gear oil Refer to 9 Replacement of Gear Oil in Chapter 3 2 Remove upper oil plug 1 and connect a commercially available leakage tester to this hole Rotating propeller shaft while maintaining pressure and testing with gear oil drained make it easy to find leakage due ...

Page 46: ... Remove plug cap and then spark plug Spark Plug Gap a Standard 0 8 0 9 mm 0 031 0 035 in Spark Plug 18 N m 13 lb ft 1 8 kgf m 2 a 1 2 2 Use spark plug cleaner or wire brush to clean spark plug electrode 1 Replace if necessary 3 Check electrode 1 for corrosion or excessive build up of carbon and washer 2 for damage Replace if necessary c b SOC O IL CO M P GM SOC SOC Specified Spark Plug DCPR6E NGK ...

Page 47: ...sion Gauge P N 3AC 99030 0 Compression Pressure Reference 1 13 MPa 164 psi 11 5 kgf cm2 If compression pressure increases after the above measure check pistons and piston rings for wear Replace if necessary If compression pressure does not increase after the above measure check valve clearances valves valve seats and cylinder sleeve Adjust or replace if necessary a CAUTION To prevent accidental st...

Page 48: ...lve d and exhaust valve e Adjust gap if it is out of specified range 4 c Valve Clearance when engine is cold IN Intake side d 0 06 0 14 mm 0 0024 0 0055 in EX Exhaust side e 0 11 0 19 mm 0 0043 0 0075 in When removing or installing cylinder head cover without removing power unit use 10 mm box wrench with large offset angle 2 Pull recoil starter 3 to turn flywheel clockwise until flywheel T mark a ...

Page 49: ...ning pivot 6 clockwise makes valve clearance smaller Turning pivot 6 counterclockwise makes valve clearance larger Perform inspection and adjustment of valve clearances when engine is cold After the adjustment turn flywheel twice top dead center in compression stroke to check the clearance again Torque Wrench 7 Use commercially available item Thickness Gauge 8 Use commercially available item 7 8 W...

Page 50: ... 1 mm 0 04 in at the center 8 Turn throttle grip 1 from full close position a to full open position b and check that the throttle lever of carburetor 6 touches the full open stopper j Then return the throttle grip 1 from full open position b to full close position a and check that the throttle lever of carburetor touches the full close stopper k throttle stop screw L 5 Attach high speed side f cab...

Page 51: ... 2 and joint 3 if necessary 1 Shift lever 1 into neutral N 2 Remove grommet 4 and loosen bolt 5 3 Check positions of cam rod 2 and joint 3 and adjust if necessary F N 1 4 5 3 5 2 4st OIL 4st O I L 4 Attach grommet 4 Joint Bolt 6 N m 4 lb ft 0 6 kgf m Check that propeller shaft rotates smoothly at neutral N position when turned by hand Bolt 5 should be loosened not be removed from joint 3 MFS2 sec0...

Page 52: ...t engine 5 Check that cooling water check port discharges water and run engine for 3 to 5 minutes at low speed 6 Stop engine and stop water supply remove flushing attachment 1 attach and tighten water plug 2 and then reinstall propeller 1 2 1 3 CAUTION Touching rotating propeller could lead to injury Be sure to remove propeller before running engine on the land WARNING Exhaust gas contains carbon ...

Page 53: ...dherence of grease and oil Clean or replace if necessary CAUTION Do not coat anode with oil grease or paint or the anti corrosion function does not work normally 1 When it is necessary to disassemble outboard motor for inspection of anode refer to disassembly described in this manual 21 Inspection of Propeller 1 Check propeller blades and shear pin for cracks damages wear and corrosion Replace if ...

Page 54: ...el 3 Put thermometer in the water and warm up water to measure valve opening temperature 2 a Thermostat Cap Bolt 6 N m 4 lb ft 0 6 kgf m Put a piece of thread in the closed valve gap and hang it in the water Valve opening moment can be known when thermostat 2 is released to drop due to opening with rise of temperature Since thermostat starts to open a few minutes after the opening temperature is r...

Page 55: ... strainer 1 for clogging Clean if necessary 2 Set outboard motor in the water and start engine 3 Check that cooling water is discharged from cooling water check port 2 If not check water pump and cooling water passage in the engine 1 2 MFS2 sec03 070524 qxd 07 5 24 3 16 PM ページ 21 ...

Page 56: ...supporter 3 3 Apply grease to propeller shaft a G REASE OBM OBM OBM 3 2 G REASE OBM OBM OBM G REASE OBM OBM OBM 24 Greasing Points 1 Apply grease to throttle cable and sliding areas G REASE OBM OBM OBM G REASE OBM OBM OBM aDo not lubricate here MFS2 sec03 070524 qxd 07 5 24 3 16 PM ページ 22 ...

Page 57: ...g Fuel 4 6 3 Inspection of Fuel Tank and Fuel Tank Cap 4 7 4 Inspection of Fuel Cock 4 7 5 Inspection of Fuel Filter 4 7 6 Inspection of Carburetor 4 8 7 Assembling of Carburetor 4 9 8 Assembling Carburetor 4 10 9 Adjustment of Throttle Cable 4 11 10 Inspection of Idle Engine Speed 4 12 11 Adjustment of Idle Engine Speed 4 12 MFS2 sec04 070524 qxd 07 5 24 4 44 PM ページ 1 ...

Page 58: ...Fuel System Carburetor 4 2 4st 2 2 5 3 5 2007 1 Special Tool Measuring engine revolution speed Tachometer P N 3AC 99010 0 MFS2 sec04 070524 qxd 07 5 24 3 17 PM ページ 2 ...

Page 59: ...Cover 1 3 Collar 6 2 9 10 7 3 4 Washer 6 16 1 5 3 5 Bolt 3 M6 L 25mm 6 Fuel Cock 1 7 Fuel Cock Rod 1 8 Seal Ring 1 9 Fuel Cock Knob 1 10 Fuel Cock Rod Hose 1 11 Fuel Hose 1 12 Clip ø9 5 2 13 Fuel Hose 1 14 Clip ø15 2 15 Fuel Tank Cap 1 15 1 Tank Cap Gasket 1 15 2 Tank Cap Hook 1 16 Fuel Tank Seal 1 17 Caution Decal B 1 18 Fuel Hose Protector 1 Ref No Description Remarks Q ty MFS2 sec04 070524 qxd ...

Page 60: ... O Ring 1 1 13 Stop Screw 1 1 14 Stop Screw Spring 1 1 15A Pilot Screw Set 1 1 15B Pilot Screw Set for EU 1 for EUROPE 2 Carburetor Gasket 2 3 Insulator 1 4 Intake Manifold 1 5 Intake Manifold Gasket 1 6 Bolt 2 M6 L 30mm 7 Intake Silencer 1 8 Flame Arrester 1 Ref No Description Remarks Q ty 9 Collar 6 2 9 7 5 2 10 Collar 6 2 9 7 1 11 Bolt 2 M6 L 85mm 12 Washer 2 13 Cable Holder 1 14 Bolt 1 M6 L 16...

Page 61: ... 3 Inspection Items 1 Inspection of Fuel Feed System Piping 1 Remove top cowl and check each section for fuel leak dirt deterioration and damages Clean or replace parts if necessary MFS2 sec04 070524 qxd 07 5 24 3 17 PM ページ 5 ...

Page 62: ...uel WARNING Remove fuel tank fuel hose and carburetor after fully drain the fuel from these parts 1 2 Set fuel cock knob 2 to full open position b 2 b 3 Place a piece of rag below the carburetor and loosen c drain screw 3 to drain all fuel 4 Retighten drain screw 3 c c d 3 MFS2 sec04 070524 qxd 07 5 24 3 17 PM ページ 6 ...

Page 63: ... and fuel tank cap for crack leakage and damage Replace if necessary 5 Inspection of Fuel Filter 1 Check fuel filter fuel cock for dirt and clogging and clean if necessary Carburetor Tank 4 Inspection of Fuel Cock 1 Check fuel cock for leakage MFS2 sec04 070524 qxd 07 5 24 3 17 PM ページ 7 ...

Page 64: ...r downward taking care that detergent and dust do not enter the eyes and do not damage small parts of the carburetor Do not use wire to clean the jet Doing so may enlarge the jet hole resulting in significantly reducing the performance 3 Check main jet 1 main nozzle 2 and slow jet 3 for dirt Clean or replace if necessary 4 Check float valve for bend and wear Replace if necessary 5 Check float for ...

Page 65: ... line that is located opposite to pivot c side 7 Assembling of Carburetor 1 Attach main nozzle 1 and main jet 2 to carburetor body as shown 1 2 2 Attach float valve float 4 and float arm pin 3 as shown and check if float 4 moves smoothly 3 Attach slow jet and float chamber 4 5 3 5 When attaching float to carburetor body put float valve 5 in the valve seat Put float arm pin in the horizontal hole o...

Page 66: ...arburetor gaskets 1 and 3 and insulator 2 together with their projections a at the same side and install carburetor 2 Attach choke wire 4 to choke lever 5 of carburetor 4 5 6 a Projections 1 and 3 a Projections 1 and 3 Carburetor Bolt 6N m 4 lb ft 0 6kgf m 6 10 mm Wrench Do not reuse Do not reuse MFS2 sec04 070524 qxd 07 5 24 3 17 PM ページ 10 ...

Page 67: ...ttle lever of carburetor 6 touches the full open stopper j Then return the throttle grip 1 from full open position b to full close position a and check that the throttle lever of carburetor touches the full close stopper k throttle stop screw L 5 Attach high speed side f cable and low speed side e cable by using the same way 6 Push back choke rod 2 fully c wide open choke 7 Turn throttle grip 1 to...

Page 68: ...peed Idle Engine Speed 1 250 1 350r min RPM Idle Engine Speed 1 250 1 350r min RPM 3 After adjusting idle engine speed open throttle several times and then continue idle operation for more than 15 seconds to check that engine idles consistantly 10 Inspection of Idle Engine Speed 1 Start engine and run for 5 minutes to warm up 2 Check idle engine speed 1 Use tachometer to measure after warm up oper...

Page 69: ...ter 5 22 19 Inspection of Piston Clearance 5 22 20 Inspection of Piston Ring Side Clearance 5 23 21 Inspection of Piston Rings 5 23 22 Inspection of Piston Pin 5 24 23 Inspection Connecting Rod Small End Inner Diameter 5 24 24 Inspection of Connecting Rod Big End Inner Diameter 5 24 25 Inspection of Connecting Rod Big End Side Clearance 5 25 26 Inspection of Crank Shaft 5 25 27 Disassembly and Ass...

Page 70: ...ving flywheel Removing or installing valve springs Compression Gauge P N 3AC 99030 0 Flywheel Holder P N 3AC 99200 0 Flywheel Puller Kit P N 3C7 72211 1 Valve Spring Compressor Attachment P N 3AB 99076 0 3B7 72783 0 3B7 72784 0 Thickness Gauge P N 353 72251 0 Measuring gaps MFS2 sec05 070524 qxd 07 5 24 3 18 PM ページ 2 ...

Page 71: ...Q ty 5 5 3 4st 2 2 5 3 5 2007 4 1 5 6 6 2 3 3 TB 1342 1107 1107 6 N m 4 lb ft 0 6 kgf m TB 1342 1342 1342 6 N m 4 lb ft 0 6 kgf m TB 1342 1342 1342 6 N m 4 lb ft 0 6 kgf m TEF TEF G REASE 2 Parts Layout Engine Do not reuse TEF G REASE TEF TB 1107 1107 1107 TB 1342 1342 1342 MFS2 sec05 070524 qxd 07 5 24 3 18 PM ページ 3 ...

Page 72: ...N m 4 lb ft 0 5 kgf m LIT G REASE LIT LIT G REASE LIT G17 G17 BO N D G17 Ref No Part Name Remarks Q ty P L Fig 8 LIT G REASE LIT G17 G17 BO N D G17 Do not reuse 1 Recoil Starter 1 1 1 Starter Spring 1 1 2 Reel 1 1 3 Starter Rope 1 ø3 5 L 1200 1 4 Ratchet 2 1 5 Return Spring 2 1 6 Friction Plate 1 1 7 Starter Shaft Screw 1 1 8 Friction Spring 1 1 9 Starter Handle 1 1 10 Rope Anchor 1 1 11 Rope Anch...

Page 73: ... Case Head 1 10 Oil Seal 10 1 20 7 2 11 O Ring 2 4 35 2 1 5 5 5 4st 2 2 5 3 5 2007 2 6 11 19 10 10 9 12 5 13 15 14 14 1 16 8 7 2 3 4 1 1 6 6 17 18 18 6 6 6 N m 4 lb ft 0 6 kgf m 18 N m 13 lb ft 1 8 kgf m 1 6 N m 4 lb ft 0 6 kgf m 2 8 8 N m 6 5 lb ft 0 9 kgf m 1 6 N m 4 lb ft 0 6 kgf m 2 8 8 N m 6 5 lb ft 0 9 kgf m 6 N m 4 lb ft 0 6 kgf m LIT G REASE LIT LIT G REASE LIT LIT G REASE LIT 4st OIL 4st ...

Page 74: ... 4 M6 L 16mm 5 Washer 6 16 1 5 4 6 Thermostat 1 52 C Mark 5B or 52B 7 Thermostat Cap 1 8 Thermostat Cap Gasket 1 5 6 Power Unit 4st 2 2 5 3 5 2007 17 6 8 7 9 10 10 1 14 4 4 3 2 20 19 20 18 12 11 13 15 16 16 Fig 3 7 1 1 1 2 1 2 1 2 1 2 1 1 1 1 1 3 1 4 1 4 1 3 1 2 5 5 5 4 6 N m 4 lb ft 0 6 kgf m 6 N m 4 lb ft 0 6 kgf m 6 N m 4 lb ft 0 6 kgf m 18 N m 13 lb ft 1 8 kgf m 6 N m 4 lb ft 0 6 kgf m 1 6 N m...

Page 75: ...ng 2 L 35 7 Retainer 2 8 Cotter 4 9 Valve Spring Seat 2 10 Lifter 2 11 Push Rod 2 12 Push Rod Plate 1 10 4 A mark A view 9 6 7 8 14 15 16 5 9 6 7 8 1 2 3 11 10 11 12 13 10 N m 7 lb ft 1 0 kgf m 25 N m 18 lb ft 2 5 kgf m 4st OIL 4st O I L 4st OIL 4st O I L 4st OIL 4st O I L 4st OIL 4st OIL 4st O I L 4st OIL 4st OIL 4st O I L 4st OIL 4st O I L 4st OIL 4st O I L 5 5 7 4st 2 2 5 3 5 2007 Cam Shaft Val...

Page 76: ...ank Shaft P L Fig 2 LIT G REASE LIT 4st O I L 4st OIL Ref No Part Name Remarks Q ty Do not reuse Do not reuse Do not reuse 1 Crankshaft Ass y 1 with Gear 1 1 Ball Bearing 6204 1 2 Thrust Plate 20 2 32 1 1 3 Piston 1 4 Piston Ring Top 1 5 Piston Ring 2nd 1 6 Piston Ring Oil 1 7 Piton Pin 1 8 Piton Pin Clip 2 9 Connecting Rod Ass y 1 9 1 Connecting Rod Bolt 2 10 Oil Seal 20 35 7 1 11 Magneto Key 1 M...

Page 77: ...er Compression Gauge P N 3AC 99030 0 Compression Pressure Reference 1 13 MPa 164 psi 11 5 kgf cm2 If compression pressure increases after the above measure check pistons and piston rings for wear Replace if necessary If compression pressure does not increase after the above measure check valve clearances valves valve seats and cylinder sleeves Adjust or replace if necessary CAUTION To prevent acci...

Page 78: ... Remove oil filler cap and check that ø5 mm 0 2 in hole c of cam shaft gear 4 can be seen 2 Pull recoil starter 3 to turn flywheel clockwise until flywheel T mark a is brought to flywheel cover mark b 3 Check clearances of intake valve d and exhaust valve e Adjust gap if it is out of specified range Valve Clearance when engine is cold IN Intake Side d 0 06 0 14 mm 0 0024 0 0055 in EX Exhaust Side ...

Page 79: ...Turning pivot 6 clockwise makes valve clearance smaller Turning pivot 6 counterclockwise makes valve clearance larger Perform inspection and adjustment of valve clearances when engine is cold After the adjustment turn flywheel twice top dead center in compression stroke to check the clearance again Torque Wrench 7 Use commercially available item Thickness Gauge 8 Use commercially available item Wh...

Page 80: ...tle cables 6 2 pcs from throttle drum 5 3 4 3 Removing Power Unit 1 Turn fuel cock 1 to OFF and remove fuel tank ass y 2 and fuel cock ass y 1 2 1 4 Remove bolt 7 and disconnect leads black 8 of igniter and stop switch 5 Disconnect lead 9 brown of igniter When lifting power unit perform the work carefully while checking if cables and hoses are caught by other parts MFS2 sec05 070524 qxd 07 5 24 3 ...

Page 81: ...2 2 5 3 5 2007 4 Removal and Disassembly of Crank Case Head 1 Remove bolts and remove crank case head ass y 2 Remove O ring 3 Remove oil seal Do not reuse Do not reuse MFS2 sec05 070524 qxd 07 5 24 3 18 PM ページ 13 ...

Page 82: ...ew oil seal 1 to crank case head by using a commercially available mandrel Apply lithium grease to the lip of oil seal LIT G REASE LIT 1 7 Installation of Crank Case Head 1 Attach a new O ring 4st OIL 4st O I L 2 Install crank case head ass y to cylinder block ass y Crank Case Head Bolt 6 N m 4 lb ft 0 6 kgf m 1 Do not reuse Do not reuse MFS2 sec05 070524 qxd 07 5 24 3 18 PM ページ 14 ...

Page 83: ...set bolts evenly and keep flywheel puller parallel to flywheel while working CAUTION Apply forces to tools toward directions as shown and perform work taking care not to allow flywheel holder to slip Screw puller onto crank shaft end until flywheel is disengaged from tapered section of crank shaft If bolts with specified size are not available use recoil starter bolts or if they are deformed use n...

Page 84: ...nit 4st 2 2 5 3 5 2007 5 Remove bolts and then igniter 7 7 6 Remove breather pipe 8 7 Remove intake manifold 9 and carburetor 0 8 Remove throttle cable bracket q 8 0 9 q MFS2 sec05 070524 qxd 07 5 24 3 18 PM ページ 16 ...

Page 85: ...al of Rocker Arm 1 Remove bolts and then cylinder head cover 2 Remove lock nut 1 and then pivot 2 rocker arm 3 and push rod 4 3 Remove pivot bolt 5 and then push rod plate 6 2 1 2 6 3 1 5 4 MFS2 sec05 070524 qxd 07 5 24 3 18 PM ページ 17 ...

Page 86: ... and pivot 2 for crack wear and damage Replace if necessary 2 1 11 Inspection of Push Rod Plate 1 Check push rod plate for crack and damage Replace if necessary 12 Inspection of Push Rod 1 Check push rod for bend wear and damage Replace if necessary MFS2 sec05 070524 qxd 07 5 24 3 18 PM ページ 18 ...

Page 87: ...emove crank case 8 1 5 Remove cam shaft 1 and lifter 2 6 Remove connecting rod bolts 3 and connecting rod cap 4 and then crank shaft 5 and oil seal 6 7 Remove oil slinger 7 8 Remove connecting rod 8 and piston ass y from cylinder block 9 Remove piston pin clip 9 and piston pin from piston and connecting rod ass y and then remove piston q Wipe off spilled oil completely Removed bearings should be a...

Page 88: ... is simple in structure Slinger is driven by the gear of crank shaft and splashes oil collected in oil pan over the crank case parts 1 Check slinger for crack damage and wear Replace if necessary 15 Inspection of Lifter 1 Check lifter for bend and wear Replace if necessary MFS2 sec05 070524 qxd 07 5 24 3 18 PM ページ 20 ...

Page 89: ...ut Limit 0 03 mm 0 0012 in Cam Height a both intake and exhaust Standard value 24 04 mm 0 9464 in Functional Limit 23 78 mm 0 9362 in Cam Shaft Journal Outer Diameter b Standard value 11 97 mm 0 4713 in Cam Shaft Journal Outer Diameter c Standard value 12 97 mm 0 5106 in Functional Limit b 11 95 mm 0 4705 in Functional Limit c 12 95 mm 0 5098 in 4 Measure cam shaft journal outer diameters b and c ...

Page 90: ... described below Replace cylinder block if taper is over specified value 3 Obtain out of roundness through calculation described below Replace cylinder block if out of roundness is over specified value Piston Clearance 0 020 0 060 mm 0 00079 0 00236 in Functional Limit 0 150 mm 0 00591 in 19 Inspection of Piston Clearance 1 If piston clearance is over specified limit replace cylinder block piston ...

Page 91: ...g or second ring when the ring is replaced 21 Inspection of Piston Rings 1 Push piston ring 1 into ring gauge 55 000mm 2 16535in parallel to top edge If the gauge is not available measure at the top or bottom of cylinder bore with no wear 2 When ring gauge is not available use piston crown to push piston ring 1 into to cylinder parallel to top edge 3 Measure piston ring closed gap a Replace if it ...

Page 92: ... Diameter b Standard value 20 010 mm 0 78780 in Functional Limit 20 015 mm 0 78799 in a 2 Measure piston pin boss inner diameter a 3 Obtain clearance between piston pin and pin boss Replace piston pin or piston if the clearance is over specified value 22 Inspection of Piston Pin 1 Measure piston pin outer diameter Replace if it is less than specified value Clearance between Piston Pin and Pin Hole...

Page 93: ...nk shaft gear 1 and bearing 2 for damage and wear Replace crank shaft ass y or bearing if necessary 2 Measure crank pin outer diameter Replace crank shaft if outer diameter is less than specified value 1 2 a Crank Pin Outer Diameter Standard value 19 98mm 0 7866 in Functional Limit 19 95mm 0 7854 in 3 Measure crank shaft runout Replace crank shaft or bearing if outer diameter is less than specifie...

Page 94: ...nk shaft by using a commercially available bearing puller 2 Install new bearing 1 to crank shaft CAUTION Do not reuse removed bearing Replace with new one Pipe 2 ø22mm Flat Bar 3 1 2 1 3 Only flywheel side bearing 1 can be replaced 1 Do not reuse 1 Do not reuse MFS2 sec05 070524 qxd 07 5 24 3 18 PM ページ 26 ...

Page 95: ... parallel to crank shaft 1 5 Install connecting rod 2 and cap 3 to crank pin 6 4 2 3 7 1 5 6 Do not move connecting rod and crankshaft until oil clearance measurement is completed Be sure to install the cap 3 in original position direction Be sure that connecting rod mark a points crank shaft flywheel side 5 6 7 Remove connecting rod cap 3 and measure width of crushed plasti gauge 5 on the crank p...

Page 96: ...ap of expander 5 4 to the right by 90 degrees 5 Install second ring 2 taper and top ring 1 to piston Install top Ring 1 and Second Ring 2 so that their side with manufacturer s identification d T faces upward valve side 6 Bring their gaps are away from each other as shown 5 5 4 4 3 2 UP b c 1 a 4st OIL 4st O I L Point 3AB UP mark a of connecting rod and UP mark b of piston to the same direction Be...

Page 97: ...Free Length a Standard value 35 0 mm 1 38 in Functional Limit 33 2 mm 1 31 in 4 5 3 6 2 1 30 Removal of Valves and Springs 1 Place cylinder block on the work bench 1 Push in valve spring retainer 2 by using valve spring compressor attachment 3 remove cotter pin 4 and then remove spring 5 and valve 6 Valve Spring Compressor Attachment 3 P N 3AB 99076 0 Valves springs and other related parts should ...

Page 98: ...045 mm 0 00071 0 00177 in Exhaust Side E 0 025 0 052 mm 0 00098 0 00205 in Functional Limit Intake Side IT 0 070 mm 0 00276 in Exhaust Side E 0 080 mm 0 00315 in a Before inspecting valve guide check that valve stem outer diameter is within specified range 3 Measure valve stem runout Replace if it is over specified value Valve Stem Runout Limit Intake Side IT 0 05 mm 0 0020 in Exhaust Side E 0 03 ...

Page 99: ...lightly 4 Measure width of area where valve face contacted with valve seat a that can be identified with red lead adhered to valve face Correct valve seat if contact area is above or below the center or contact area of valve seat is over specified limit Valve Seat Contact Width a Standard value Intake and Exhaust Sides 1 0 mm 0 04 in Functional Limit Intake and Exhaust Sides 2 0 mm 0 08 in MFS2 se...

Page 100: ... it smooth 30û 45û 60û 1 45 a 30 b a Carbon build up or uneven surface 3 Use 30 degree cutter to adjust contact position of valve seat upper end b Width before correction Be careful not to over cut valve seat Turn valve seat cutter while pushing down evenly 4 Use 60 degree cutter to adjust contact position of valve seat lower end 60 b b Width before correction MFS2 sec05 070524 qxd 07 5 24 3 18 PM...

Page 101: ...b 30 b Width before correction c Specified width 6 Valve seat contact area is located on the center which should be adjusted to specified value by cutting upper and lower ends by using 30 degree and 60 degree seat cutters respectively if the area is too wide 7 If valve seat contact area is narrow and is located nearer to valve face upper end use 30 degree seat cutter to cut upper end If necessary ...

Page 102: ... Check valve seat contact width c CAUTION Perform the work by taking care not to allow abrasive compound to adhere to valve stem and valve guide Valve Seat Contact Width c Standard value 1 0 mm 0 04 in Use finer abrasive compound to finish When changing abrasive compound to finer one remove present one completely After completion of lapping wipe off the compound and then clean 45 b c b Width befor...

Page 103: ...ly by using valve spring compressor attachment 6 Valve Spring Compressor Attachment 6 P N 3AB 99076 0 3 With valve spring 4 being pushed in use small screw driver with small amount of grease at the tip to put cotter 7 4 Remove cylinder block from work bench Tap valve 2 with plastic hammer to fix cotter 7 securely Intake Side Black Exhaust Side Green Do not reuse the seal Use new one Valve spring c...

Page 104: ... assembling apply engine oil to piston peripheral surfaces piston rings and cylinder liner Apply grease to lip of oil seal before installing it 7 Attach connecting rod cap 8 to connecting rod 0 and tightening connecting rod bolts 9 in two steps to specified torque Connecting Rod Bolts 9 1st tightening torque 5 N m 4 lb ft 0 5 kgf m 2nd tightening torque 10 N m 7 lb ft 1 0 kgf m 8 9 c 0 4st OIL 4st...

Page 105: ...Bolts 1 8 1st tightening torque 6 N m 4 lb ft 0 6 kgf m 2nd tightening torque 8 8 N m 6 5 lb ft 0 9 kgf m 11 Apply Loctite 518 to crank case e mating face one side with width of 1 0 mm 0 04 in 518 L T 518 518 L T 518 f e 1 0mm 1 0mm Degrease mating surfaces of cylinder and crank case Be careful not to allow sealing agent to adhere to journal area f Apply Loctite 518 to mating surface of one of cra...

Page 106: ...pecified torque 16 Reconnect rubber hose t 1 2 3 4 5 6 7 8 TEF G REASE TEF r Do not reuse removed gasket Replace with new one Apply Teflon grease to crank shaft spline Oil Pan Bolts 1 8 1st tightening torque 6 N m 4 lb ft 0 6 kgf m 2nd tightening torque 8 8 N m 6 5 lb ft 0 9 kgf m t MFS2 sec05 070524 qxd 07 5 24 3 18 PM ページ 38 ...

Page 107: ...nd perform work taking care not to allow flywheel holder to come off Flywheel Holder 9 P N 3AC 99200 0 Flywheel Nut 43 N m 31 lb ft 4 3 kgf m 7 Attach igniter 0 Igniter Clearance 0 2 0 4mm 0 008 0 016in 8 Install flywheel cover w and recoil starter e e w Thermostat Cap Bolts Breather Cover Bolts Throttle Cable Bracket Bolts 6 N m 4 lb ft 0 6 kgf m Intake Manifold Bolts 10 N m 7 lb ft 1 0 kgf m Thi...

Page 108: ...erfere with each other resulting in damages to these parts Perform adjustment of valve clearances when engine is cold Set piston to top dead center of compression stroke Remove oil filler cap and check that ø5mm 0 2 in hole a of cam shaft gear 2 can be seen 39 Assembly of Rocker Arm 1 Direct magneto key groove 1 to piston top dead center 6 Install cylinder head cover 9 and tighten to specified tor...

Page 109: ...h as rods and cables 7 Install fuel tank 7 and fuel cock ass y 8 and tighten the bolts to specified torque 3 Connect igniter leads and stop switch leads two leads respectively 4 Connect choke wire 5 8 Fill with specified amount of engine oil 3 1 4 2 2 TB 1107 1107 1107 7 8 TB 1342 1342 1342 6 G REASE OBM OBM OBM Engine Oil 4 Stroke Engine Oil API SF SG SH SAE 10W 30 10W 40 NMMA FC W Certified 10W ...

Page 110: ... and recoil starter and flywheel cover ass y 5 Remove starter spring 5 LIT G REASE LIT 5 42 Inspection of Recoil Starter 1 Check ratchet and all springs Replace if any deformation wear or damage is found 2 Check reel and starter case Replace if any crack or damage is found 3 Check starter rope Replace if any wear unraveling or damage is found It is not necessary to remove starter spring from reel ...

Page 111: ...ction of starter case in the internal hook of starter spring 4 Apply low temperature resistant lithium grease Starter Spring Friction Plate 5 Put starter shaft screw and tighten to specified torque LIT G REASE LIT 2 1 1 a Starter Shaft Screw 5 N m 4 lb ft 0 5 kgf m 6 When applying tension to starter spring hook starter rope into reel groove a and turn reel 4 to 5 times to direction to which the re...

Page 112: ...of Pump Case Lower 6 12 15 Assembly of Pump Case Lower 6 13 16 Removing Clutch Cam and Cam Rod 6 13 17 Disassembly of Clutch Cam and Cam Rod 6 13 18 Inspection of Clutch Cam and Cam Rod 6 13 19 Assembly of Clutch Cam and Cam Rod 6 13 20 Removing Drive Shaft 6 14 21 Disassembly of Drive Shaft 6 14 22 Inspection of Drive Shaft 6 14 23 Inspection of Forward Gear and Pinion Gear A and B Gears 6 15 24 ...

Page 113: ...ter Plate 3 P N 3AB 99701 0 Installing drive shaft bearing Bearing Install Tool 2 P N 3AB 99900 0 Universal Puller Plate P N 3AC 99750 0 Installing spring pin Spring Pin Tool B P N 345 72228 0 Removing bearings Bearing Attachment 3 P N 3AB 99905 0 Used in combination with driver rod and center plate to locate lower gear case bearing Bearing Attachment 2 P N 3BR 99905 0 Installing bearings Bearing ...

Page 114: ...1 1 1 Exhaust Plug 1 PT 1 8 2 Dowel Pin 6 12 2 3 Bolt 7 M6 L 30mm 4 Drive Shaft Housing Gasket 1 5 Water Plug 1 M8 P1 25 6 Gasket 8 1 15 1 1 7 Grommet 29 3 1 8 Extension Housing L 1 for L 9 Drive Shaft Bushing 1 10 Drive Shaft Bushing Stopper 1 11 Grommet 13 2 1 12 Bolt 2 M6 L 12mm 13 Stud Bolt 6 171 1 M6 L 171mm 14 Nut 1 M6 15 Bolt 6 30 Pre coated 1 M6 L 30mm 16 Gear Case 1 16 1 Ball Bearing 6000...

Page 115: ... 7 Pump Case Gasket Upper 1 8 Water Pump Guide Plate 1 9 Pump Guide Plate Gasket 1 10 Bolt 4 M6 L 45mm 11 Washer 4 12 Spring Washer 4 13 Dowel Pin 2 11 2 14 Pump Case Lower 1 with Bushing O ring 15 Oil Seal 10 22 8 1 16 Pump Case Gasket Lower 1 17 Water Pipe S 1 for S Water Pipe L 1 for L 17 1 Water Pipe Grommet Upper 1 18 Water Pipe Grommet Lower 1 19 Spacer 10 1 15 72 1 Ref No Description Remark...

Page 116: ...tch Push Rod 1 8 Propeller Shaft Housing 1 9 Oil Seal 12 24 8 1 10 O Ring 3 2 47 1 11 Ball Bearing 6001 1 12 Bolt 2 M6 L 20mm 13 Propeller 7 Plastic 3 x 7 4 x 7 1 Standard Propeller 6 Aluminum 3 x 7 4 x 6 1 Option Propeller 6 Plastic 3 x 7 4 x 6 1 Option Propeller 4 5 Plastic 3 x 7 4 x 4 5 1 Option 14 Shear Pin 4 24 1 15 Split Pin 4 35 1 Ref No Description Remarks Q ty P L Fig 11 Do not reuse Do n...

Page 117: ...6 Split Pin 2 12 1 17 Shift Rod Joint 1set 18 Bolt 1 M6 L 16mm Ref No Description Remarks Q ty 6 6 Lower Unit 4st 2 2 5 3 5 2007 12 2 2 6 7 16 15 5 4 3 1 13 9 10 10 17 17 18 14 8 11 G REASE OBM OBM OBM G REASE OBM OBM OBM G REASE OBM OBM OBM O I L GEAR GEAR GEAR 6 N m 4 lb ft 0 6 kgf m 4 N m 3 lb ft 0 4 kgf m TB 1342 1342 1342 Shift P L Fig 12 Do not reuse Do not reuse Do not reuse Do not reuse Do...

Page 118: ...then 1 to drain gear oil Refer to Replacement of Gear Oil in Chapter 3 2 Removing Propeller 1 Shift gear into neutral N 2 Remove lock plate of stop switch lanyard from stop switch 3 Straighten and pull out split pin 1 and then remove shear pin 3 and propeller 2 1 Split Pin 2 Propeller 3 Shear Pin 4 Propeller Shaft 5 Propeller Shaft Housing 3 Gasket 1 2 3 4 5 Remove lower oil plug 1 first Do not re...

Page 119: ...grommet 1 and loosen bolt 2 Removal of lower unit does not require removal of power unit from outboard motor body Tilt up and lock with tilt stopper 4 5 a Check drive shaft spline a for adhesion of oil rust and wear a b 1 3 2 5 4 Bolt 2 should be loosened not removed from joint 3 When removing or attaching water pump and pump case lower be careful that the drive shaft is not pushed up Pushing up t...

Page 120: ...lace if necessary 3 2 2 Check impeller 2 and pump case liner 3 for cracks and wear Replace if necessary 4 a 3 Check key 4 and drive shaft installation face a for wear Replace if necessary 5 4 Check water pump guide plate 5 for cracks and wear Replace if necessary MFS2 sec06 070524 qxd 07 5 24 3 20 PM ページ 9 ...

Page 121: ...clutch spring by using bladed screw driver 3 with thin tip 8 Inspection of Propeller Shaft 1 Check propeller shaft for bend and wear Replace if necessary 2 Measure propeller shaft runout a a 2 Check clutch 2 clutch push rod 1 and clutch spring 4 for cracks and wear Replace if necessary 4 2 1 Propeller Shaft Runout Limit 0 05 mm 0 0020 in When the ass y is pulled off a little put bladed screw drive...

Page 122: ...e bearing puller 1 1 CAUTION Do not reuse removed bearing When reusing bearing without removing it check it for play or deflection Replace if necessary 2 Remove oil seal 2 2 11 Inspection of Propeller Shaft Housing 1 Use cleaning oil and cleaning brush to clean propeller shaft housing and check it for cracks or damage Replace if necessary 2 When reusing bearing without removing it check it for pla...

Page 123: ... Do not reuse removed bearing Bearing Attachment 2 5 P N 3BR 99905 0 Driver Rod 3 6 P N 3AB 99702 0 1 G REASE OBM OBM OBM 1 14 Disassembly of Pump Case Lower 1 Use bladed screw driver to remove oil seal 1 13 Removing Pump Case Lower 1 Remove pump case lower and cam rod bushing while pressing down drive shaft 1 Do not reuse When removing or attaching water pump and pump case lower be careful that t...

Page 124: ... to remove 1 18 Inspection of Clutch Cam and Cam Rod 1 Check cam rod 1 and clutch cam 3 for cracks and wear Replace if necessary 19 Assembly of Clutch Cam and Cam Rod 1 Install clutch cam 3 and spring pin 2 to cam rod 1 17 Disassembly of Clutch Cam and Cam Rod 1 Remove spring pin 2 and clutch cam 3 from cam rod 1 Use spring pin tool A to remove spring pin Do not reuse removed spring pin O I L GEAR...

Page 125: ... 2 2 21 Disassembly of Drive Shaft 1 Remove drive shaft bearing 1 Do not reuse bearing Be sure to replace with new one CAUTION Universal Puller Plate 2 P N 3AC 99750 0 Before removing check bearing for play or deflection Replace if necessary Be sure to remove or install from bearing of pinion B gear side 22 Inspection of Drive Shaft 1 Check drive shaft for bend and wear Replace if necessary 2 Meas...

Page 126: ...f Drive Shaft 1 Use a press device to install new drive shaft bearing 1 to drive shaft 2 with the numbered side up Bearing Install Tool 2 3 P N 3AB 99900 0 Do not reuse bearing Be sure to replace with new one CAUTION Installation Depth a 92 00 mm 0 15 mm 3 6220 in 0 0006 in If a special tool is not available and thus the above depth cannot be maintained order shaft ass y and gear case ass y Do not...

Page 127: ...less it is replaced with new one Before removing check bearing for play or deflection Replace if necessary 2 2 3 3 4 3 Remove bearing 4 Bearing Attachment 3 3 P N 3AB 99905 0 Driver Rod 3 4 P N 3AB 99702 0 Do not reuse removed bearing CAUTION 1 Do not reuse 2 Remove bearing 1 by using commercially available bearing puller 2 Do not reuse MFS2 sec06 070524 qxd 07 5 24 3 20 PM ページ 16 ...

Page 128: ... 0 05 mm 3 4685 in 0 0020 in If a special tool is not available and thus the above depth cannot be maintained order shaft ass y and gear case ass y 2 Install new bearing 6 with numbered side up 9 8 7 6 O I L GEAR GEAR GEAR Do not reuse removed bearing 26 Inspection of Gear Case 1 Check skeg area a and torpedo like front area b for cracks and damage Replace if necessary b a 6 Do not reuse 1 Install...

Page 129: ...l removed shims and forward A gear 1 and then drive shaft ass y 2 and pinion B gear 3 2 1 3 Replace shim with new one of the same thickness if any deformation or damage is found on removed shim Be careful of direction of cam rod 1 G REASE OBM OBM OBM 2 30 Installation of Pump Case Lower 1 Apply OBM grease to oil seal 2 Install new gasket 2 and pump case lower 1 2 Do not reuse MFS2 sec06 070524 qxd...

Page 130: ...ove d 1 3 2 4 a G REASE OBM OBM OBM 5 6 b G REASE OBM OBM OBM 31 Installation of Water Pump 1 Attach new gaskets 1 and 2 water pump guide plate 3 and dowel pin 4 2 Attach key 5 to drive shaft 3 Bring impeller 6 groove b to key 5 and install impeller to drive shaft a Projection 1 and 2 Do not reuse Apply grease to the key to prevent it from dropping when attaching MFS2 sec06 070524 qxd 07 5 24 3 20...

Page 131: ... Check that OBM grease is applied to housing ass y 1 oil seal 2 2 Install propeller shaft ass y 3 to propeller shaft housing ass y 1 3 Apply grease to new O ring 4 and install it 4 Apply grease to clutch push rod 5 and install it to propeller shaft ass y 3 5 Attach propeller shaft housing ass y 4 to gear case and tighten bolts 7 to specified torque TB 1342 1342 1342 4 1 3 5 2 7 G REASE OBM OBM OBM...

Page 132: ... 2 3 2 1 O I L GEAR GEAR GEAR 3 33 Filling with Gear Oil 1 Feed gear oil to specified quantity 2 Refer to Chapter 3 2 2 3 1 3 O I L GEAR GEAR GEAR Perform Inspection of Gear Case Leakage in Chapter 3 if necessary 3 Gasket Do not reuse 3 Gasket Do not reuse MFS2 sec06 070524 qxd 07 5 24 3 20 PM ページ 21 ...

Page 133: ...all cam rod 1 to joint 4 and tighten bolt 3 to specified torque Joint Bolt 3 6 N m 4 lb ft 0 6 kgf m 6 3 4 3 1 4st OIL 4st O I L 4 Attach grommet 6 to drive shaft housing 5 Attach shear pin and propeller insert split pin and bend the tip WARNING Before removing or installing propeller be sure to disconnect spark plug cap and remove stop switch lock plate G REASE OBM OBM OBM Connect water pipe secu...

Page 134: ...Handle Throttle 7 5 Cowl 7 6 2 Assembling Procedure 7 7 1 Assembly of Clamp Bracket 7 7 2 Installation of Steering Stopper 7 7 3 Installation of Drive Shaft Housing 7 8 4 Installation of Water Pipe 7 8 5 Installation of Tiller Handle 7 9 6 Adjustment of Throttle Cable 7 10 MFS2 sec07 070524 qxd 07 5 24 3 21 PM ページ 1 ...

Page 135: ...ts Layout Clamp Bracket Swivel Bracket 13 4 8 9 7 2 2 2 2 3 2 1 15 6 6 1 5 3 9 12 14 10 11 18 26 24 23 25 28 16 30 27 29 21 22 20 19 17 1 8 TB 1342 1342 1342 6 N m 4 lb ft 0 6 kgf m G REASE OBM OBM OBM G REASE OBM OBM OBM G REASE OBM OBM OBM G REASE OBM OBM OBM G REASE OBM OBM OBM G REASE OBM OBM OBM G REASE OBM OBM OBM G REASE OBM OBM OBM TB 1342 1342 1342 10 N m 7 lb ft 1 0 kgf m TB 1342 1342 13...

Page 136: ...Water PipeGrommet Upper 1 Ref No Part Name Remarks Q ty 1 1 1 4 6 5 22 23 24 25 25 16 17 20 21 16 1 18 18 17 19 19 12 13 11 10 14 15 9 8 7 3 2 2 4st OIL 4st O I L 4st OIL 4st O I L TB 1342 1342 1342 5 N m 4 lb ft 0 5 kgf m 6 N m 4 lb ft 0 6 kgf m 13 N m 9 lb ft 1 3 kgf m TB 1342 1342 1342 13 N m 9 lb ft 1 3 kgf m TB 1342 1342 1342 6 N m 4 lb ft 0 6 kgf m 6 N m 4 lb ft 0 6 kgf m TB 1342 1342 1342 1...

Page 137: ... 16 Split Pin 2 12 1 17 Shift Rod Joint 1set 18 Bolt 1 M6 L 16mm Ref No Part Name Remarks Q ty Bracket 7 4 4st 2 2 5 3 5 2007 12 2 2 6 7 16 15 5 4 3 1 13 9 10 10 17 17 18 14 8 11 G REASE OBM OBM OBM G REASE OBM OBM OBM G REASE OBM OBM OBM O I L GEAR GEAR GEAR 6 N m 4 lb ft 0 6 kgf m 4 N m 3 lb ft 0 4 kgf m TB 1342 1342 1342 Shift P L Fig 12 Do not reuse Do not reuse Do not reuse Do not reuse Do no...

Page 138: ...1 Tiller Handle 1 2 Tiller Handle Bushing 2 3 Cover 1 4 Bolt 2 M6 L 16mm 5 Grip 1 6 Throttle Shaft Damper 1 7 Bushing 14 15 8 7 1 8 Screw 1 ø5 L 18mm 9 Throttle Shaft Supporter 1 10 Screw 1 ø6 L 21mm 11 Friction Piece 1 12 Adjusting Nut 1 13 Spring 1 14 Bolt 1 M6 L 25mm 15 Throttle Cable 2 16 Throttle Decal 1 17 Throttle Shaft 1 18 Throttle Cable Protector 1 19 Throttle Drum 1 20 Throttle Opener 1...

Page 139: ...1 2 Cowl Latch 1 3 Collar 6 2 9 7 4 1 4 Bolt 1 M6 L 16mm 5 Choke Rod Bushing 1 6 Collar 6 4 10 4 7 4 7 Bolt 4 M6 L 16mm 8 Washer 6 16 1 5 4 9 Spark Plug Decal with Resistance 1 10 Shift Decal F N 1 11 Fuel Lever Decal 1 12 Storage Decal 1 13 Top Cowl 1 13 1 Top Cowl Seal 1 L 1100 13 2 Tilt Handle 1 13 3 Washer 4 13 4 Spring Washer 4 M6 13 5 Nut 4 13 6 Decal Set 1set 13 7 Caution Decal A 1 14 Rope ...

Page 140: ...st rod 9 and tighten clamp screw 0 2 Installation of Steering Stopper 1 Align holes a of steering stopper 1 and stopper lever 2 and press fit pin 3 2 Put steering stopper ass y 1 into swivel bracket 4 hole b and align it with stopper lever 2 and swivel bracket 4 holes c and insert bolt 5 Hook spring 6 on the part e of stop lever 2 and insert bolt 5 while pushing the spring against swivel bracket 4...

Page 141: ...fied torque 3 3 TB 1342 1342 1342 TB 1342 1342 1342 1 2 Swivel Bracket Bolts 3 10 N m 7 lb ft 1 0 kgf m Bring projection steering bushing to dent of swivel bracket when installing the part 2 1 4st OIL 4st O I L 4 Installation of Water Pipe 1 Install water pipe 1 into drive shaft housing 2 TB 1342 1342 1342 MFS2 sec07 070524 qxd 07 5 24 3 21 PM ページ 8 ...

Page 142: ...ket 8 and tighten bolt 9 to specified torque 2 3 8 6 9 0 TB 1342 1342 1342 a b 3 G REASE OBM OBM OBM 8 Cover Bolt 9 6 N m 4 lb ft 0 6 kgf m Steering Bracket Bolt 13 N m 9 lb ft 1 3 kgf m Arrange throttle cable 2 as shown a High Speed Side b Low Speed Side 6 Install tiller handle 3 and steering bracket 4 ass y to drive shaft housing 0 5 1 3 4 G REASE OBM OBM OBM G REASE OBM OBM OBM G REASE OBM OBM ...

Page 143: ...ottle lever of carburetor 6 touches the full open stopper j Then return the throttle grip 1 from full open position b to full close position a and check that the throttle lever of carburetor touches the full close stopper k throttle stop screw L 5 Attach high speed side f cable and low speed side e cable by using the same way 6 Push back choke rod 2 fully c wide open choke 7 Turn throttle grip 1 t...

Page 144: ...Parts Layout 8 3 Magneto 8 3 3 Ignition System and Ignition Control System 8 4 1 Inspection of Ignition Spark 8 4 2 Inspection of Plug Cap 8 5 3 Inspection of Igniter 8 6 4 Inspection of Stop Switch 8 7 MFS2 sec08 070524 qxd 07 5 24 3 22 PM ページ 1 ...

Page 145: ...8 2 Electrical System 4st 2 2 5 3 5 2007 1 Special Tools Inspecting sparks Spark Tester P N 3F3 72540 0 MFS2 sec08 070524 qxd 07 5 24 3 22 PM ページ 2 ...

Page 146: ...0P 1 25 1 M10 9 Washer 1 Ref No Part Name Remarks Q ty 5 7 2 4 2 1 7 1 3 6 1 8 9 6 N m 4 lb ft 0 6 kgf m 18 N m 13 lb ft 1 8 kgf m 43 N m 31 lb ft 4 3 kgf m 2 3 N m 1 7 lb ft 0 23 kgf m G17 G17 BO N D G17 SOC O IL CO M P GM SOC SOC a b b a Spark Plug b Igniter Clearance 0 2 0 4mm 0 008 0 016in 2 Parts Layout Magneto P L Fig 6 O IL CO M P GM SOC SOC SOC G17 G17 BO N D G17 MFS2 sec08 070524 qxd 07 5...

Page 147: ... leak of electrical current and perform test carefully Keep flammable gas fuel and oil away from tester to prevent them from catching sparks Spark Performance 5mm 0 2in or over This test can be made without removing parts 3 Ignition System and Ignition Control System 1 Inspection of Ignition Spark 1 Disconnect plug cap from spark plug 2 Connect plug cap to spark tester 3 Connect spark tester clip ...

Page 148: ... 20 C 3 0 7 0 kΩ Remove the part and test it as a separate unit 1 Disconnect plug cap from spark plug 2 Remove plug cap from high tension cable 3 Measure plug cap resistance Replace if other than specified value G17 G17 BO N D G17 MFS2 sec08 070524 qxd 07 5 24 3 22 PM ページ 5 ...

Page 149: ...ing from 2 to 6MΩ G17 G17 BO N D G17 Igniter Resistance at 20 C Secondary Coil Between High Tension Cord and Black B 2 0 3 0 kΩ Secondary Coil Between Plug Cap and Black B 5 5 9 5 kΩ Igniter Diode Polarity at 20 C Primary Circuit Between Black B and Brown Br No conduction Primary Circuit Between Brown Br and Black B Conductive 3 Install plug cap onto high tension cord by twisting clockwise 4 Insta...

Page 150: ...eck conduction of stop switch and replace if not conductive Switch Position Lead Wire Color Brown Br Black B Remove lock plate a Attach lock plate b Press switch c a b c This test can be made without removing parts MFS2 sec08 070524 qxd 07 5 24 3 22 PM ページ 7 ...

Page 151: ...tart Recoil starter operates normally 9 3 Trouble 2 Engine starts but stalls soon 9 5 Fuel System 9 5 Ignition System 9 6 Compression Pressure 9 7 Trouble 3 Idle engine speed will not stabilize 9 8 Trouble 4 Rough acceleration 9 9 Trouble 5 Gear shifting cannot be made normally 9 10 MFS2 sec09 070524 qxd 07 5 24 3 23 PM ページ 1 ...

Page 152: ...s defective Piston piston ring and or cylinder is worn excessively Combustion chamber excessive carbon deposits Spark plug is loose Cooling water is lacking Water pump is defective or clogged Thermostat operation is defective Anti cavitation plate is damaged Use of mismatched propeller Propeller is damaged or deformed Thrust rod position is not correct Boat is unbalanced by load position Transom i...

Page 153: ...r fuel level and wire connections For mechanical troubleshooting refer to relevant troubleshooting section in this chapter For checking and servicing outboard motor refer to service procedures described in this manual to perform the work safely 2 Power Unit Trouble 1 Engine will not start or is a little hard to start Recoil starter operates normally When testing put electrode cap assuredly to prev...

Page 154: ...9 4 Troubleshooting OK 4st 2 2 5 3 5 2007 YES Adjust valve clearance NO Check valve clearance Normal Check valves cylinder block and or piston ass y MFS2 sec09 070524 qxd 07 5 24 3 23 PM ページ 4 ...

Page 155: ...ter and fuel filter is clogged Does fuel contains water or is fuel filter clogged Check fuel hose for bend and fuel leak Is fuel hose bent or does fuel leak from the hose Replace defective part with new one Fuel System Trouble 2 Engine starts but stalls soon Inspection of Fuel System Ignition System Compression Pressure MFS2 sec09 070524 qxd 07 5 24 3 23 PM ページ 5 ...

Page 156: ...r plug cap Replace spark plug with new one Ignition System When testing put electrode cap assuredly to prevent direct contact with spark tester wiring and leak of electrical current Keep flammable gas fuel and oil away from tester to prevent them from catching sparks WARNING MFS2 sec09 070524 qxd 07 5 24 3 23 PM ページ 6 ...

Page 157: ...mpression pressure Check if secondary air is sucked through mating surface of carburetor or intake manifold Is secondary air sucked Replace defective part and seal with new ones Compression Pressure MFS2 sec09 070524 qxd 07 5 24 3 23 PM ページ 7 ...

Page 158: ...rance YES YES NO NO Normal Out of specified range Check operations of throttle cable and drum Check gaskets if secondary air is sucked through them Trouble 3 Idle engine speed will not stabilize Inspection of Intake Manifold Air Intake System and Ignition System MFS2 sec09 070524 qxd 07 5 24 3 23 PM ページ 8 ...

Page 159: ... clogging dirt and or damage Check ignition system and compression pressure Clean carburetor and or replace defective part s with new one s Is the throttle valve tuned Trouble 4 Rough acceleration Rapid opening of throttle causes engine to stall Acceleration is not smooth Inspection of Carburetor Ignition System and Compression Pressure MFS2 sec09 070524 qxd 07 5 24 3 23 PM ページ 9 ...

Page 160: ...ck spring and ball Replace shift rod YES YES NO NO Normal Normal Normal Replace defective part with new one Check forward gear and pinion A and B gears and clutch Disassemble lower unit and check operation of clutch Trouble 5 Gear shifting cannot be made normally MFS2 sec09 070524 qxd 07 5 24 3 23 PM ページ 10 ...

Page 161: ...Corporation All rights reserved No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Tohatsu Corporation MFS2A cover E 070524 qxd 07 5 24 5 06 PM ページ 2 ...

Page 162: ...OB No 003 21058 0 07 04 NB 2600 Printed in Japan OB No 003 21058 0 07 04 NB 2600 MFS2A cover E 070524 qxd 07 5 24 5 06 PM ページ 1 ...

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