TOHATSU MFS 6C Page 168 Service Manual Download

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Bracket

7-2

4st 4/5/6 2011

1. Parts Layout

Bracket & Reverse Lock

P/L Fig. 9

OBM

RUB

OBM

GREASE

RUB

GREASE

OBM

MFS4-5-6̲E̲ch07̲110422.qxd 11.4.22 5:55 PM ページ 2

Summary of Contents for MFS 6C

Page 1: ...MFS 4 5 6B C Models OB No 003 21034 2 11 04 NB 4 5 6B C MFS 4 5 6B C Models OB No 003 21034 2 11 04 NB Printed in Japan MFS4 5 6 E cover 110420 qxd 11 4 21 9 15 AM 1...

Page 2: ...MFS4 5 6 E cover 110420 qxd 11 4 21 9 15 AM 2...

Page 3: ...tboard motor with full satisfaction This service manual it is produced B models to a base and the service information for the C models is addition on the end of the manual as supplementary information...

Page 4: ...For Transom UL 66 Grommet Water Pipe Upper 1 Ref No Description Remarks Q ty Do not reuse Do not reuse Do not reuse Do not reuse Do not reuse Do not reuse Do not reuse When reusing bearing without re...

Page 5: ...tly with metric system in the world the metric system includes different kinds of unit systems Though the metric system was established expecting that a single unit system would be used in the world v...

Page 6: ...G17 G17 BO N D G103 G103 BO N D 1342 342 1342 O IL CO M P SOC SOC SOC LT 518 518 O I L GEAR GEAR G REASE OBM OBM OBM 4st O I L LIT G REASE G REASE MOL MOL MOL TEF G REASE G REASE RUB LOR Liquid O Ring...

Page 7: ...lacement of Anode 3 18 18 Inspection of Propeller 3 19 19 Inspection of Thermostat 3 19 20 Inspection of Cooling Water Passage 3 20 21 Flushing with Water 3 21 22 Greasing Points 3 22 4 Fuel System 1...

Page 8: ...of Pump Case Lower 6 16 20 Assembly of Pump Case Lower 6 16 21 Inspection of Drive Shaft 6 17 22 Inspection of Pinion B Gear and Forward A Gea 6 17 23 Disassembly of Gear Case 6 18 24 Inspection of G...

Page 9: ...0 11 Service Information Service Data Inspections and Adjustments Fuel System Power Unit Lower Unit Bracket Electrical System Troubleshooting Wiring Diagram C Model Service Information INDEX OK MFS4 5...

Page 10: ...4st 4 5 6 2011 viii MFS4 5 6 E ch00 110422 qxd 11 4 22 6 14 PM 8...

Page 11: ...Propeller 1 5 2 Instruments 1 5 3 Special Tools 1 6 4 Pre delivery Inspection 1 8 1 Steering Handle 1 8 2 Gear Shift 1 8 3 Engine Oil 1 8 4 Gear Oil 1 8 5 Fuel Tank Line 1 9 6 Rigging 1 9 7 Inspection...

Page 12: ...n working indoors 3 Protection Wear a pair of goggles working gloves and safety shoes to protect skin from chemicals and oils and eyes from particles generated by grinding or polishing Avoid contact o...

Page 13: ...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...

Page 14: ...s for oil feeding or greasing packings wirings pipings and other detailed parts For the components that use many bolts and nuts such as cylinder head or crank case tighten the fasteners in the order s...

Page 15: ...0 01 Thickness gauge 0 03 to 0 3 mm V block Surface plate 500 mm x 500 mm Dial gauge magnet base or dial gauge stand 3 Tools and Instruments 1 Test Propeller P N 3B2 64110 1 Outer diameter 164mm Widt...

Page 16: ...Measuring compression pressure Compression Gauge P N 3AC 99030 0 Removing installing flywheel Flywheel Puller Kit P N 369 72211 0 Removing or installing valve springs Valve Spring Compressor Attachme...

Page 17: ...dle Bearing Press Kit P N 369 72900 0 Measuring gap between forward and pinion gears A and B gears Backlash Measuring Tool Kit P N 369 72740 0 369 72727 0 Measuring backlash Clamp A P N 3B7 72720 0 Fl...

Page 18: ...F N R F 1 2 1 4 Gear Oil 1 Check quantity of gear oil Gear Oil 195 cm3 6 6 fl oz OIL 1 Oil Level Gauge 1 Oil Plug 2 Gasket Do not reuse 1 Steering Adjust Screw c Lighter d Heavier 3 Engine Oil 1 Set...

Page 19: ...ng mechanism functions normally 1 Test run to determine the best installation height a 30 50 mm 1 2 2 0 in Dual Tank model Separate Tank model 5 Fuel Tank Line 1 Check that fuel tank contains sufficie...

Page 20: ...1 2 1 2 10 Idle Operation 1 After engine has warmed up in neutral use tachometer to check idle engine speed is as specified 1 Idle Engine Speed 1 300 r min RPM 9 Cooling Water Check Port 1 Check that...

Page 21: ...n of propeller can cause adverse effects on engine life fuel consumption etc as well as on performance 1 Forward Return handle grip 2 to idle speed a and then move shift lever 1 toward the operator F...

Page 22: ...5 Check that shifting into reverse R will not tilt up outboard motor and allow water to run into boat 3 3 Shift gear into forward F and run dead slow for approximately 10 minutes 1 1 High Tension Cor...

Page 23: ...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...

Page 24: ...1 14 Service Information 4st 4 5 6 2011 MFS4 5 6 E ch01 110422 qxd 11 4 22 5 41 PM 14...

Page 25: ...2 2 2 Clamp Dimensions 2 4 2 Engine Lubrication System Diagram 2 5 3 Cooling Water System Diagram 2 6 4 Specifications 2 8 5 Maintenance Data 2 10 6 Tightening Torque Specifications 2 14 7 Sealant an...

Page 26: ...mm in 400 15 75 E mm in 510 20 08 F mm in 110 4 33 G mm in 330 12 99 H mm in 350 13 78 I mm in 335 13 19 J mm in 30 60 1 18 2 36 K mm in 275 10 83 S mm in 658 25 91 L L mm in 758 29 84 UL mm in 858 3...

Page 27: ...689 27 13 D mm in 400 15 75 E mm in 510 20 08 F mm in 110 4 33 G mm in 330 12 99 H mm in 350 13 78 I mm in 335 13 18 J mm in 30 60 1 18 2 36 K mm in 275 10 83 S mm in 658 25 91 L L mm in 758 29 84 UL...

Page 28: ...2 4 Service Data 4st 4 5 6 2011 2 Clamp Dimensions MFS4 5 6E ch02 110422 qxd 11 4 22 6 58 PM 4...

Page 29: ...2 5 2 4st 4 5 6 2011 2 Engine Lubrication System Diagram MFS4 5 6E ch02 110422 qxd 11 4 22 6 58 PM 5...

Page 30: ...2 6 Service Data 4st 4 5 6 2011 1 2 3 4 5 6 7 8 9 0 q w 1 2 3 4 5 7 6 9 0 q 8 w 1 2 3 4 5 7 8 9 0 3 Cooling Water System Diagram MFS4 5 6E ch02 110422 qxd 11 4 22 6 58 PM 6...

Page 31: ...2 7 2 4st 4 5 6 2011 MFS4 5 6E ch02 110422 qxd 11 4 22 6 58 PM 7...

Page 32: ...8 Service Data 4st 4 5 6 2011 4 Specifications 0 1 2 3 3 3 3 4 5 5 6 6 7 8 5 1 28 2 2 2 9 8 09 1 1 8 2 2 8 2 8 7 8 8 4 8 6 8 4 3 5 A 7 B 9 9 6 1 8 9 2 1 8 8 MFS4 5 6E ch02 110427 qxd 11 4 27 8 51 AM...

Page 33: ...9 0 6 7 0 7 5 7 9 6 0 0 A A A B C 3 B 3 Bracket 1 3 7 D E D 0 35 5 5 0 E 55 3 6 E 3 A A0 A A0 2 7 0 F G Warning system Optional parts H7 8 8 H 9 E 7 7 0 5 0 6 6 0 0 0 B 3 7 0 7 Sepalate Tank Model Mod...

Page 34: ...4 01 0 1 6 5 3 11 0 4 3 1 6 3 5 4 3 0 4 0 04 0 7 7 8 9 7 8 1 3 05 5 3 9 00 3 0 5 3 4 7 8 54 0 5 9 55 05 7 8 01 9 01 8 3 55 4 3 04 9 5 3 4 044 3 8 0 9 0 0 8 0 00 54 0 5 2 5 5 0 A 0 4 0 A 1 0 4 B 3 4 3...

Page 35: ...0 0 0 0 0 5 0 4 0 4 1 4 0 4 4 41 01 5 1 05 0 4 41 0 04 5 051 50 0 5 0 0 4 0 4 41 0 5 0 4 0 4 0 0 4 0 0 0 0 5 0 D E 5 5 D E1 2 8 5 1 D E 5 5 D E1 2 2 D 8 5 1 2 2 2 2 2 2 2 2 2 2 2 C 2 2 2 2 2 2 2 MFS4...

Page 36: ...22 Sail Pro EPA Sail Pro EU 6B 5B 4B 5 924 29424 2915 A 2952 2922 A 2922 4 3944 295 38 2925 A 292 292228 A 292258 B322 C DB52 E FG G A G G A 53 12 29 293 29252 15 72 29 7 A 2978H 8 I DB52 E D H E 7JD...

Page 37: ...9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 5 91 2953 2922 A 2922 4 3947 295 7 2912 2922 4 9 73 132 L 3 9 92 2915 2923 292252 29 292118 2948 292 87 291 2922 4 291 2922 4 9 2 291 3 295 29228 293 29252 C 293 29252...

Page 38: ...1 25 Bolt 12 9 1 2 25 18 2 Oil pan 13 M8x1 25 Bolt 12 9 1 2 25 18 2 5 10 M6x1 0 Bolt 5 4 0 5 9 7 0 9 Oil drain bolt 10 M10x1 25 Bolt 18 13 1 8 Pivot bolt 13 M8x1 25 Bolt 25 18 2 5 Pivot adjust nut 10...

Page 39: ...r wall Ring grooves and periphery Whole area Periphery Big and small end bores Inside Sliding surface Bearing and Gear Sliding surface Outer surface Inside and outside Lip Outer surface at press fitti...

Page 40: ...using Cowl Sliding surface Thread Crankshaft spline at press fitting at press fitting Thread Lip Outer surface at press fitting Impeller sliding surface Thread Thread at press fitting at press fitting...

Page 41: ...ection of Gear Case for leakage 3 10 10 Inspection of Spark Plugs 3 11 11 Inspection of Compression Pressure 3 12 12 Inspection and Adjustment of Valve Clearance 3 13 13 Throttle Cable 3 15 14 Inspect...

Page 42: ...enance 4st 4 5 6 2011 1 Special Tools Measuring compression pressure Measuring engine revolution speed Compression Gauge P N 3AC 99030 0 Tachometer P N 3AC 99010 0 MFS4 5 6 E ch03 110422 qxd 11 4 22 5...

Page 43: ...o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o 0 1 2 3 4 5 3 6 7 0 1 0 89 0 2 4 4 5 6 8 Fuel System Starting...

Page 44: ...and check each section for fuel leak dirt deterioration and damages Clean or replace parts if necessary 3 Inspection Items 1 Inspection of Top Cowl Push top cowl using both hands to check for loosenes...

Page 45: ...filter 4 Remove dirt and water from fuel tank 2 if any 2 3 4 4 Inspection of Fuel Filter Check fuel filter for dirt build up of fuel residue and fuel filter for invasion of foreign matter and cracks...

Page 46: ...engine oil can be drained from drain bolt 1 easily 2 Remove oil level gauge 2 3 Place drain oil pan below drain bolt 1 4 Remove drain bolt 1 to drain oil 1 1 Engine Oil 4 Stroke Engine Oil API SE SF S...

Page 47: ...lt and separate shift rod pieces Disconnect shift rod at lower side of shift rod joint 1 Be careful not to drop shift rod joint and bolt when they are removed 1 5 Tighten drain bolt 1 6 Pour new oil i...

Page 48: ...pump case Upper 3 4 Remove impeller 4 and check it 5 Check upper pump case for deformation Replace if necessary 6 Check impeller 4 and pump case liner 5 for cracks and wear Replace if necessary 7 Chec...

Page 49: ...immediately Gear Oil Hypoid Gear Oil API GL 5 SAE 80W 90 90 Quantity of Gear Oil 195 cm3 6 6fl oz OIL 3 3 1 1 3 3 2 2 2 3 a O IL GEAR GEAR GEAR 4 4 a O IL GEAR GEAR GEAR 3 3 2 3 3 Check gear oil for p...

Page 50: ...Pressure 0 049 MPa 7 psi 0 5 kgf cm2 9 Inspection of Gear Case for leakage 1 Drain gear oil 2 Remove upper oil plug 1 and connect a commercially available leakage tester to this hole Rotating propelle...

Page 51: ...Remove plug caps and then spark plugs Spark Plug Gap a Standard value 0 8 0 9mm 0 031 0 035in Spark Plugs 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...

Page 52: ...lves valve seats and cylinder head Adjust or replace if necessary 4 Remove all plug caps and then all spark plugs 5 Install compression gauge 2 to plug hole 1 1 11 Inspection of Compression Pressure 1...

Page 53: ...2 1 1 1 1 a 2 Align locating marks 1 of flywheel and crankcase with each other 3 When fuel pump is removed cam shaft can be seen If projection 2 of cam shaft can be seen it can be known that the pisto...

Page 54: ...0 06 0 14mm 0 0025 0 0055in EX exhaust side 0 11 0 19mm 0 0045 0 0075in 7 Rotate pivot to adjust valve clearance and then tighten lock nut 6 Put thickness gauge 3 in the gap between rocker arm and val...

Page 55: ...x low speed side wire The wire is in proper state if pushing inner wire at the center makes deflection of about 1mm 4 Repeat above steps for high speed side wire and fix it 5 Return choke knob to home...

Page 56: ...p to full open position and check if throttle lever of carburetor makes contact with stopper 7 Set throttle grip to full close position and check if throttle lever of carburetor makes contact with sto...

Page 57: ...w a 14 Inspection of Idle Engine Speed 1 Start engine and run for 5 minutes to warm up 2 Attach tachometer to spark plug high tension cord 1 to check idle speed 1 Idle Speed 1300 r min RPM Tachometer...

Page 58: ...ded excessively Replace anode if volume is reduced to 2 3 of new part 1 1 Do not coat anode with oil or paint Since periphery of anode installation bolt is corroded more than other areas be sure to re...

Page 59: ...iner 3 Put thermometer in the water warm up water and measure water temperature when valve opens 1 1 2 a Thermostat Cover Bolt 6 N m 4 lb ft 0 6 kgf m 18 Inspection of Propeller 1 Check propeller blad...

Page 60: ...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 cooli...

Page 61: ...ck port 2 discharges water and run engine for 3 to 5 minutes at low speed 7 Stop engine and stop water supply remove flushing attachment 1 remove tape and then reinstall propeller 1 2 CAUTION Touching...

Page 62: ...and sliding areas G REASE G REASE OBM OBM OBM OBM OBM OBM G REASE OBM OBM OBM OBM 1 a a RVB VB RUB G REASE RUB 2 Apply grease through grease nipples 1 until excessive grease appears from bushing a Ap...

Page 63: ...and bushing 4 of hook lever 4 G REASE G REASE OBM OBM OBM OBM OBM OBM G REASE OBM OBM OBM OBM 6 Apply grease to propeller shaft spline 5 5 G REASE G REASE OBM OBM OBM OBM OBM OBM G REASE OBM OBM OBM...

Page 64: ...3 24 Maintenance 4st 4 5 6 2011 MFS4 5 6 E ch03 110422 qxd 11 4 22 5 45 PM 24...

Page 65: ...Fuel 4 12 3 Inspection of Fuel Tank and Fuel Tank Cap 4 13 4 Inspection of Fuel Cock 4 13 5 Inspection of Fuel Filter 4 13 6 Removing Carburetor 4 14 7 Disassembling Carburetor 4 16 8 Inspection and c...

Page 66: ...Fuel System 4 2 4st 4 5 6 2011 1 Special Tools Inspecting pressure Vacuum Pressure Gauge P N 3AC 99020 0 MFS4 5 6 E ch04 110422 qxd 11 4 22 5 48 PM 2...

Page 67: ...4 4 3 4st 4 5 6 2011 MFS4 5 6 E ch04 110422 qxd 11 4 22 5 48 PM 3...

Page 68: ...44 15 16 14 12 13 11 5 6 19 4 31 33 32 36 34 35 37 Fig 1 50 Fig 1 51 Fig 1 9 Fig 10 51 Fig 10 25 44 44 44 45 46 10 9 8 A 4st OIL 4st O I L Fuel System 4 4 4st 4 5 6 2011 2 Parts Layout Carburetor Fuel...

Page 69: ...Float Arm Pin 1 12 Float Chamber 1 13 Float Chamber O Ring 1 14 Screw 2 M4 L 12mm 15 Drain Screw 1 16 O Ring Drain Screw 1 17 Stop Screw 1 18 Spring Stop Screw 1 19 1 Pilot Screw 1 19 2 Pilot Screw E...

Page 70: ...Fuel System 4 6 4st 4 5 6 2011 Integral Fuel Tank P L Fig 13 MFS4 5 6 E ch04 110422 qxd 11 4 22 5 48 PM 6...

Page 71: ...M6 L 25mm 13 Nut 1 M6 14 Bolt 1 M6 L 20mm 15 Bracket Rear 1 16 Fuel Tank Cap Ass y 1 17 Tank Filler Cap Gasket 1 18 Fuel Tank Seal 1 19 Clamp 6 5 47 5P 2 20 Screw 1 M5 L 10mm 21 Washer 1 22 Clamp 6 5...

Page 72: ...n the air enters carburetor through air intake port runs through throat venturi and throttle valve and then is sucked into the combustion chamber area in the cylinder that is in air intake stroke The...

Page 73: ...e The low pressure causes the fuel to be ejected from bypass port and idle port c k b j l l l m f g e a d h h i a Air intake b Air vent inlet c Main air jet d Pilot air jet e Bypass port f Pilot outle...

Page 74: ...es through main nozzle and ejects from venturi The fuel that runs through main nozzle is mixed with air that comes from air bleed hole made on the side of main nozzle to make the fuel air atomized Whe...

Page 75: ...um area is formed in the venturi on the back of choke valve Then the fuel goes through main nozzle bypass port and pilot outlet and sucked into carburetor bore where it is mixed with air that runs in...

Page 76: ...if necessary 2 Draining Fuel 1 Remove fuel tank cap 1 and use fuel pump to remove fuel 1 a 2 a a a 3 2 Set fuel cock knob 2 to full open position a 3 Place a piece of rag below the carburetor and loos...

Page 77: ...fuel tank and fuel tank cap for crack leakage and damage Replace if necessary 5 Inspection of Fuel Filter 1 Check fuel filter for dirt and clogging and clean if necessary 4 Inspection of Fuel Cock 1...

Page 78: ...reful not to bend wire tip 3 when disconnecting For easiness of explanation the picture shows the scene with recoil starter removed WARNING Before working on fuel system make sure to disconnect batter...

Page 79: ...n removing throttle rod and carburetor perform the work as shown taking care not to give damage to the parts 7 7 Before disconnecting fuel hose place a piece of cloth below fuel pump to blot leaking f...

Page 80: ...rburetor 1 Remove drain screw 1 to drain fuel 1 2 2 Remove float bowl 2 3 Remove float ass y 3 3 CAUTION Use rag to absorb fuel flowing out from hose CAUTION When removing any jets be careful not to d...

Page 81: ...3 Check main jet 1 and main nozzle 2 for dirt Clean or replace if necessary 4 Check float valve for bend and wear Replace if necessary 5 Check float for deformation Replace if necessary CAUTION Point...

Page 82: ...thly 4 3 Attach float ass y firmly to float arm pin 4 9 Inspection of Fuel Connector 1 Check fuel connector for crack and damage 2 Connect vacuum pressure gauge to outlet of fuel connector 3 Apply spe...

Page 83: ...loat bowl 3 a a 1 b 2 11 Adjustment of Float Height 1 Measure height a of float 1 Adjust height a of float 1 by bending tab b if the height is out of specified range Float Height a 9 0 10 0 mm 0 354 0...

Page 84: ...d Inspection of Fuel Pump 1 Remove screws 4 to disassemble fuel pump body CAUTION To prevent fuel from dripping on the floor use a cloth to catch the fuel 2 Remove diaphragm from fuel pump body by unl...

Page 85: ...ck diaphragm 1 for break crack and damage and replace if necessary 4 Check check valve 2 for damage and deterioration and replace if necessary 5 fuel pump body for crack and damage and replace if nece...

Page 86: ...Fuel System 4 22 4st 4 5 6 2011 MFS4 5 6 E ch04 110422 qxd 11 4 22 5 48 PM 22...

Page 87: ...8 17 Inspection of Lifter 5 28 18 Inspection of Cam Shaft 5 29 19 Inspection of Piston Outer Diameter 5 30 20 Inspection of Cylinder Inner Diameter 5 30 21 Inspection of Piston Clearance 5 30 22 Inspe...

Page 88: ...eel Compression Gauge P N 3AC 99030 0 Flywheel Puller Kit P N 369 72211 0 Piston Slider P N 3H6 72871 0 Installing piston Removing or installing valve springs Valve Spring Compressor Attachment P N 3A...

Page 89: ...1 Recoil Starter 1 2 Fuel Tank 1 3 Oil Level Gauge 1 4 Dowel Pin 2 5 Bolt 6 M6 L 30mm 6 Gasket Ref No Description Remarks Q ty 2 Parts Layout Engine Do not reuse Do not reuse MFS4 5 6 E ch05 110425 q...

Page 90: ...b ft 5 0 kgf m SOC O IL CO M P GM SOC SOC G17 G17 BO N D G17 1 8 7 9 10 12 23 24 11 20 13 22 21 17 15 18 16 2 3 4 6 5 3 4 2 25 19 14 Magneto P L Fig 6 O IL CO M P GM SOC SOC SOC G17 G17 BO N D G17 MFS...

Page 91: ...lamp 6 5 67P 2 12 2 Clamp 6 5 47 5P 1 13 Screw 1 M6 L 12mm 14 Rectifier Complete 1 15 Fuse 10A 1 16 Clamp 7 80P 1 17 Battery Cable 1 18 Cable Terminal Plug 1 19 Grommet 17 3 1 20 Pilot Lamp Ass y 1 21...

Page 92: ...REASE TEF 4st OIL 4st O I L 4st OIL 4st O I L LIT G REASE LIT 1 2 1 2 SOC O IL CO M P GM SOC SOC TB 1342 1342 1342 4st OIL 4st O I L TB 1342 1342 1342 G103 G103 BO N D G103 TB 1342 1342 1342 G103 G103...

Page 93: ...er Body 1 28 Strainer Cap 1 29 Mesh Strainer 1 30 Pipe Strainer 1 31 Seal Rubber Strainer 2 32 Strainer Stopper 1 33 Screw 1 M5 L 12mm 34 Bolt 5 1 2 35 Washer 2 36 Oil pan Gasket 1 37 Exhaust Cover Ga...

Page 94: ...4st O I L 4st OIL 4st O I L 4st OIL 4st O I L 4st OIL 4st O I L 4st OIL 4st O I L LOR Liq uid O Rin g LOR Cylinder Head Valve Cam Shaft P L Fig 3 O IL CO M P GM SOC SOC SOC 4st O I L 4st OIL LOR Liq...

Page 95: ...M6 L 16mm 16 Washer 6 16 1 5 4 17 Thermostat 1 18 Thermostat Cap 1 19 Thermostat Cap Gasket 1 20 Camshaft Ass y F6A 1 21 Lifter 2 22 Push Rod 2 23 Plate Push Rod 1 24 Pivot Bolt 2 25 Rocker Arm 2 26...

Page 96: ...1 Piston 1 3 2 Piston 0 5 O S 1 4 1 Piston Ring STD 1st 1 4 2 Piston Ring 0 5O S 1st 1 5 1 Piston Ring STD 2nd 1 5 2 Piston Ring 0 5O S 2nd 1 Ref No Description Remarks Q ty 6 1 Piston Ring Oil STD 1...

Page 97: ...Rope 1 12 Starter Handle 1 13 Rope Anchor 1 14 Sealing Plate Starter 1 15 Starter Lock 1 Ref No Description Remarks Q ty 16 Collar 4 6 21 1 17 Starter Lock Spring 1 18 Starter Lock Cam 1 19 Washer 1...

Page 98: ...del 2 Top Cowl Integral Tank 1 For Integral Tank Model 3 Top Cowl Seal 1 4 Starter Seal 1 5 1 Decal Set F4B 1 4ps 5 2 Decal Set F5B 1 5ps 5 3 Decal Set F6B 1 6ps Ref No Description Remarks Q ty 6 Sail...

Page 99: ...stop switch before measuring compression pressure This will prevent engine from accidental starting CAUTION Clean areas around spark plugs on the cylinder before removing spark plugs to prevent dirt f...

Page 100: ...d range This step brings piston to top dead center of compression stroke The compression stroke can be known visually when fuel pump is removed Projection mark 4 on the cam shaft is seen in this strok...

Page 101: ...N Intake Side c 0 06 0 14 mm 0 0024 0 0055 in EX Exhaust Side d 0 11 0 19mm 0 0043 0 0075 in Pivot Lock Nut 7 10 N m 7 lb ft 1 0 kgf m Perform inspection and adjustment of valve clearances when engine...

Page 102: ...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 1 2 1 2 5 5 3 Disconnect rubber hose 5 from fuel pump 4 Disconnect wiring connectors and earth w...

Page 103: ...ls 3 3 6 Remove bolts 8 6 pcs and then lift power unit to remove 8 8 7 6 5 Turn throttle grip to full close position and disconnect throttle cables 7 2 pcs from throttle drum 6 Do not reuse Do not reu...

Page 104: ...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 Gasket 1 1 2 Install...

Page 105: ...tools toward directions as shown and perform work taking care not to allow flywheel holder to slip Flywheel Holder 4 Commercially use Flywheel Puller Kit 6 P N 369 72211 0 M6 L 60mm Bolts 3 pcs or re...

Page 106: ...2011 5 Remove fuel hose 7 from carburetor 6 Loosen carburetor mounting bolts 8 and remove carburetor 7 7 8 8 7 Loosen intake manifold mounting bolts and then remove manifold 9 9 9 MFS4 5 6 E ch05 1104...

Page 107: ...er mounting bolts and then remove igniter w e e 10 Loosen fuel pump mounting screws and then remove fuel pump e 0 0 q q 8 Loosen thermostat cap mounting bolts remove cap 0 and then thermostat q MFS4 5...

Page 108: ...top dead center 2 Remove bolts and then cylinder head cover T T 3 Remove adjust nut 1 and then pivot 2 and rocker arm 3 1 1 3 3 2 2 4 4 5 5 6 6 Store IN side and EX side rocker arms and push rods sep...

Page 109: ...r crack wear and damage Replace if necessary 2 1 12 Inspection of Push Rod Plate 1 Check push rod plate for crack and damage Replace if necessary 13 Inspection of Push Rod 1 Check push rod for bend we...

Page 110: ...cified value a a b b 5 Measure oil pump outer rotor height Replace outer rotor if the height is less than specified value Standard Value 0 15 mm 0 0059 in Functional Limit 0 2 mm 0 0078 in Standard Va...

Page 111: ...re side clearance between pump rotor and body by using depth gauge or vernier caliper Replace if over specified limit Standard Value 6 00mm 0 2362 in Functional Limit 6 06 mm 0 2386 in Standard Value...

Page 112: ...pan 1 9 8 7 9 6 4 2 5 3 1 Wipe off spilt oil completely When tightening bolts follow the numbers shown 2 Remove crankshaft washer 1 and then cam shaft 2 1 1 2 2 3 Remove lifter 3 3 3 4 Loosen cylinder...

Page 113: ...0 from crankcase 0 0 9 Remove bearing from crankcase by using a commercially available bearing puller 5 Turn crankshaft to a position where connecting rod bolts 4 and connecting rod cap 5 can be remov...

Page 114: ...ove two breather collars 1 and two wave washers 2 check the parts and replace if necessary 1 1 2 2 2 17 Inspection of Lifter 1 Check lifter for bend and wear Replace if necessary 34 34 a a a a 3 Attac...

Page 115: ...ut Replace if it is over specified value Cam Shaft Runout Limit 0 03 mm 0 0012 in Cam Height a both intake and exhaust Standard value 28 33 mm 1 1154 in Functional Limit 28 07 mm 1 1051 in Cam Shaft J...

Page 116: ...he inner diameters are over specified value 2 Obtain taper through calculation described below Replace cylinder block if taper is over specified value 3 Obtain out of roundness through calculation des...

Page 117: ...e oil ring together with top ring or second ring when the ring is replaced 23 Inspection of Piston Rings 1 Push piston ring 1 into ring gauge 55 000mm 2 16535in parallel to top edge If the gauge is no...

Page 118: ...on 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 Clearance between Piston Pin and Pin Hole 0 002 0...

Page 119: ...er specified value Connecting Rod Big End Side Clearance a 0 20 0 40 mm 0 0079 0 0157 in Functional Limit 0 70 mm 0 0276 in 28 Inspection of Crank Shaft 1 Check crank shaft gear 1 and bearing 2 for da...

Page 120: ...nd then remove cover 2 1 1 3 Check oil strainer cover screen mesh 3 for dirt and clogging Clean or replace if necessary 3 3 2 2 4 4 4 Disassemble oil pressure control Loosen plunger cover mounting bol...

Page 121: ...n the work bench Push in valve spring retainer 1 by using valve spring compressor attachment 2 remove cotter pin 3 and then remove spring 4 and valve 5 Valve Spring Compressor Attachment 2 P N 3AB 990...

Page 122: ...Diameter a Standard value Intake and Exhaust Sides 5 51 mm 0 2169 in Functional Limit Intake Side IT 5 54 mm 0 2181 in Exhaust Side E 5 57 mm 0 2193 in 2 Obtain clearance between valve guide and valv...

Page 123: ...ilt up on the valve 2 Apply thin coat of red lead on the valve seat 3 Use valve lapper 1 commercially available item as shown to push valve 2 onto valve seat lightly 4 Measure width of area where valv...

Page 124: ...correct valve seat 2 Turn 45 degree cutter clockwise to cut valve seat surface to make it smooth 3 Use 30 degree cutter to adjust contact position of valve seat upper end Be careful not to over cut v...

Page 125: ...pecified value 5 Use 45 degree cutter to adjust contact width of valve seat c to specified value 6 Valve seat contact area is located on the center which should be adjusted to specified value by cutti...

Page 126: ...ound completely from cylinder head and valve 11 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 Se...

Page 127: ...ompressor Attachment 1 P N 3AB 99076 0 3 With valve spring 5 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 v...

Page 128: ...into the groove so that the gap is away from gap 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 si...

Page 129: ...ue Before installing apply engine oil to mating surface between bearing and crankshaft 1 1 3 3 Before assembling apply engine oil to piston pin piston rings outer surface of piston and inner surface o...

Page 130: ...c b b 5 7 Bring crank shaft mark d to cam shaft w mark e 4st O I L 4st OIL 4st O I L 4st OIL 5 Attach connecting rod cap 4 to connecting rod and tightening connecting rod bolts 5 in two steps to spec...

Page 131: ...Cylinder head ass y installation bolts 1st tightening torque 12 N m 9 lb ft 1 2 kgf m 2nd tightening torque 25 N m 18lb ft 2 5 kgf m M8 1st Tightening Torque 12 N m 9 lb ft 1 2 kgf m 2nd Tightening T...

Page 132: ...rs Perform tappet adjustment Refer to 5 17 4 2 3 1 8 Attach cylinder head cover and tighten bolts to specified torque in the order shown Cylinder Head Cover Bolts 6 N m 4 lb ft 0 6 kgf m 7 Attach cyli...

Page 133: ...iter clearance 0 5mm 0 020 in 3 Attach thermostat 1 gasket 2 and thermostat cap 3 and tighten bolts to specified torque Thermostat cap mounting bolts 6 N m 4 lb ft 0 6 kgf m Old 1 2 3 3 Thickness Gaug...

Page 134: ...o cylinder and tighten bolts to specified torque Ensure that O ring is attached properly Intake manifold installation bolt 6 N m 4 lb ft 0 6 kgf m 5 Install carburetor 6 Install fuel pump and connect...

Page 135: ...hree Bond 1342 and then attach oil pressure switch 5 Apply SOC grease to terminal and then attach pressure switch code 10 Attach crankcase head 6 6 6 Oil Pressure Switch 5 9 N m 7 lb ft 0 5 kgf m TB 1...

Page 136: ...power unit 2 and tighten bolts 3 in two or three steps to specified torque 4 Connect lead wires 4 of igniter and stop switch 4 4 5 Connect throttle wire 5 Refer to 3 15 5 5 Power Unit Installation Bo...

Page 137: ...5 5 51 4st 4 5 6 2011 6 Connect rod 6 and choke wire 7 6 7 6 7 7 Install fuel tank 8 and connect pipe 8 8 MFS4 5 6 E ch05 110425 qxd 11 4 25 11 39 AM 51...

Page 138: ...5 52 Power Unit 4st 4 5 6 2011 MFS4 5 6 E ch05 110425 qxd 11 4 25 11 39 AM 52...

Page 139: ...Disassembly of Clutch Cam and Cam Rod 6 15 16 Inspection of Clutch Cam and Cam Rod 6 15 17 Assembly of Clutch Cam and Cam Rod 6 16 18 Removing Pump Case Lower 6 16 19 Disassembly of Pump Case Lower 6...

Page 140: ...r gear case bearing Bearing Press Collar P N 3H6 72768 0 Used in combination with driver rod and center plate to locate lower gear case bearing Bearing Press P N 3H6 72769 0 Installing bearings Bearin...

Page 141: ...6 6 3 4st 4 5 6 2011 MFS4 5 6 E ch06 110422 qxd 11 4 22 5 50 PM 3...

Page 142: ...4st 4 5 6 2011 P L Fig 7 G REASE OBM OBM OBM OBM TB 1342 342 1342 1342 TB 1342 342 1342 1342 2 Parts Layout Drive Shaft Housing TB 1342 1342 1342 G REASE OBM OBM OBM OBM MFS4 5 6 E ch06 110422 qxd 11...

Page 143: ...Grommet Cam Rod 1 11 Dowel Pin 6 12 2 12 Bolt 1 M8 L 8mm 13 Gasket 8 1 15 1 1 14 Grommet 29 3 1 15 Bolt 6 M6 L 30mm 16 Drive Shaft Housing Gasket 1 17 Extension Housing 1 18 Bolt 1 M6 L 25mm 19 Washer...

Page 144: ...OBM OBM O I L GEAR GEAR GEAR GEAR TEF G REASE TEF O I L GEAR GEAR GEAR GEAR G REASE OBM OBM OBM OBM LIT G REASE LIT TB 1342 342 1342 1342 TB 1342 342 1342 1342 Gear Case Drive Shaft Gear Case Propell...

Page 145: ...40 Pump Case Gasket Lower 1 41 Bolt 1 M6 L 25mm 42 Water Pipe Seal Lower 1 43 1 Drive Shaft Ass y S 1 For Transom S 43 2 Drive Shaft Ass y L 1 For Transom L 43 3 Drive Shaft Ass y UL 1 For Transom UL...

Page 146: ...nut 2 and then propeller 4 1 Split Pin 2 Propeller Nut 3 Washer 4 Propeller 5 Thrust Holder 6 Propeller Shaft 7 Propeller Shaft Housing 7 6 5 4 3 2 1 4 2 Remove lower oil plug 1 first WARNING Before r...

Page 147: ...unit does not require removal of power unit from outboard motor body Tilt up and lock with tilt stopper Shift in reverse Check drive shaft spline a for adhesion of oil rust and wear Bolt 2 should be...

Page 148: ...Check pump case upper 1 for deformation Replace if necessary 3 3 2 2 2 Check impeller 2 and pump case liner 3 for crack and wear Replace if necessary a a 4 4 3 Check key 4 and drive shaft installatio...

Page 149: ...peller Shaft Housing Ass y 1 Remove bolts 1 and pull out propeller shaft housing ass y 2 3 3 2 2 1 2 2 Remove propeller shaft ass y When the ass y is pulled out a little put bladed screw driver 3 in t...

Page 150: ...ing brush to clean propeller shaft housing and check it for crack or damage Replace if necessary 2 Check reverse C gear teeth and clutch for crack or damage Replace if necessary 2 Oil Seal Do not reus...

Page 151: ...not reuse 1 Do not reuse 10 Removing Drive Shaft 1 Pull up pump case lower and drive shaft ass y 1 remove pinion B gear 2 and then pull out forward A gear 3 1 3 2 O I L GEAR GEAR GEAR GEAR O I L GEAR...

Page 152: ...nspection of Propeller Shaft 1 Check propeller shaft for bend and wear Replace if necessary 2 Measure propeller shaft runout a Support point 2 Do not reuse 2 Do not reuse Spring Pin Tool A P N 345 722...

Page 153: ...rten spring 1 by referring to illustration insert spring pin tool A 4 into hole of clutch 2 to secure spring Slowly press fit new spring pin 3 from the other side putting it on the spring pin tool A a...

Page 154: ...case lower 3 with numbered side down by using a commercially available mandrel 2 2 Apply OBM grease to lip of oil seal 1 1 Do not reuse 18 Removing Pump Case Lower 1 Remove pump case lower 1 and driv...

Page 155: ...s Replace if necessary 2 Measure drive shaft runout Runout Limit Max 0 2 mm 0 008 in a Supporting Points 22 Inspection of Pinion B Gear and Forward A Gear 1 Check pinion B gear forward A gear reverse...

Page 156: ...of Gear Case 1 Check bearings 1 for cracks and generation of abnormal noise Replace if necessary 1 Do not reuse 2 Remove bearing 1 by using commercially available bearing puller Do not remove bearing...

Page 157: ...pth a 100 mm 0 15 mm 3 9370 in 0 0059 in Do not reuse removed bearing 1 Install bearing 1 with numbered side up to gear case 2 to specified depth 1 Do not reuse Bearing Attachment 4 7 P N 3BV 99905 0...

Page 158: ...ckness if any deformation or damage is found on removed shim 3 1 2 LIT G REASE LIT 27 Reassembly of Pump Case Lower 1 Apply grease to lip of oil seal 1 after installing it 2 Attach new O ring 2 and pu...

Page 159: ...orward A gear and pinion B gear with propeller shaft housing propeller shaft and reverse C gear removed from gear case 1 Fix gear case with vice Clean drive shaft with new rag before assembling the to...

Page 160: ...ve shaft by using hand Fix shaft B with bladed screw driver and tighten nut while pushing the shaft At this time be careful not to overtighten the nut or shaft B is locked Tighten nut fully by using f...

Page 161: ...nstallation of Water Pump 1 Attach new gaskets 1 and 2 water pump guide plate 3 and dowel pin 2 Attach key 4 to drive shaft 3 Bring impeller 5 groove a to key 4 and install impeller to drive shaft Whe...

Page 162: ...ing ass y 1 3 Apply grease to new O ring 3 and install it 4 Apply grease to clutch push rod 4 and install it to propeller shaft ass y 2 5 Attach propeller shaft housing ass y 1 to gear case and tighte...

Page 163: ...GEAR GEAR GEAR 32 Filling with Gear Oil 1 Feed gear oil to specified quantity a Refer to Chapter 3 1 1 a O IL GEAR GEAR GEAR Perform Inspection of Gear Case Leakage in Chapter 3 if necessary 1 Gasket...

Page 164: ...unit installation bolts 2 nut 3 to specified torque 3 Install cam rod 1 to joint 4 and tighten bolt 5 to specified torque Joint Bolt 5 6 N m 4 lb ft 0 6 kgf m 6 4 5 4 Attach grommet 6 to drive shaft...

Page 165: ...g direction to align one of grooves to propeller shaft hole and attach split pin w Perform Inspection of Lower Unit Air Leakage in Chapter 3 if necessary If propeller nut groove cannot be aligned with...

Page 166: ...6 28 Lower Unit 4st 4 5 6 2011 MFS4 5 6 E ch06 110422 qxd 11 4 22 5 50 PM 28...

Page 167: ...edure 7 9 1 Removal and inspection of drive shaft housing 7 9 2 Removal and inspection of clamp bracket 7 11 3 IInstallation of clamp bracket and drive shaft 7 12 4 Removal inspection and installation...

Page 168: ...rts Layout Bracket Reverse Lock P L Fig 9 G REASE OBM OBM OBM OBM G REASE RUB RUB G REASE RUB RUB G REASE OBM OBM OBM OBM G REASE OBM OBM OBM OBM G REASE RUB RUB G REASE OBM OBM OBM OBM MFS4 5 6 E ch0...

Page 169: ...w 2 M6 L 12mm 16 Stern Bracket Spring 1 17 Screw 1 M4 L 6mm 18 Washer 4 3 16 1 5 1 19 Thrust Rod 1 20 Thrust Rod Spring 1 21 Bolt 4 M6 L 40mm 22 Thrust Bushing 1 23 Bushing Upper Steering 1 24 Bushing...

Page 170: ...4 4st 4 5 6 2011 Drive Shaft Housing Shift P L Fig 7 G REASE OBM OBM OBM OBM TB 1342 342 1342 1342 TB 1342 342 1342 1342 TB 1342 1342 1342 G REASE OBM OBM OBM OBM MFS4 5 6 E ch07 110422 qxd 11 4 22 5...

Page 171: ...Grommet Cam Rod 1 11 Dowel Pin 6 12 2 12 Bolt 1 M8 L 8mm 13 Gasket 8 1 15 1 1 14 Grommet 29 3 1 15 Bolt 6 M6 L 30mm 16 Drive Shaft Housing Gasket 1 17 Extension Housing 1 18 Bolt 1 M6 L 25mm 19 Washe...

Page 172: ...ASE OBM OBM OBM OBM G REASE RUB RUB G REASE OBM OBM OBM OBM G REASE OBM OBM OBM OBM G REASE OBM OBM OBM OBM G REASE OBM OBM OBM OBM Bottom Cowl Tiller Handle G REASE OBM OBM OBM OBM G REASE RUB RUB MF...

Page 173: ...1 26 Adjusting Screw 1 27 Washer 1 28 Nut 1 M6 29 Throttle Shaft 1 30 Throttle Decal 1 31 Plastic Rivet 6 5 1 32 Spacer Handle 1 33 Washer 30 45 1 1 34 Spring Washer 2 35 Throttle Wire 2 36 Protector...

Page 174: ...Separate Tank Model 2 Top Cowl Integral Tank 1 For Integral Tank Model 3 Top Cowl Seal 1 4 Starter Seal 1 5 1 Decal Set F4B 1 4ps 5 2 Decal Set F5B 1 5ps 5 3 Decal Set F6B 1 6ps Ref No Description Re...

Page 175: ...ion of drive shaft housing 1 Tilt up drive shaft housing 3 Remove thrust rod 2 1 1 2 2 3 3 4 4 2 Remove reverse lock arm 1 4 Remove wing nut 3 for co pilot Loosed four swivel bracket B bolts 4 Hold dr...

Page 176: ...acket 7 10 4st 4 5 6 2011 5 Remove drive shaft housing 5 5 5 6 7 6 Check steering bushing 6 and thrust place 7 for wear and damage and replace if necessary MFS4 5 6 E ch07 110422 qxd 11 4 22 5 55 PM 1...

Page 177: ...t 1 and remove bolt 3 Remove tilt stopper 5 mounting bolt 6 from swivel bracket 4 and then remove tilt stopper 5 1 1 3 2 3 2 4 5 6 4 5 6 2 Remove bracket distance place 2 mounting screws 3 4 Check til...

Page 178: ...ASE OBM OBM OBM OBM OBM OBM G REASE OBM OBM OBM OBM 3 3 4 5 6 7 8 9 2 Install clamp bracket to swivel bracket A Apply grease to both sides of washer 2 4 Install thrust bushing 5 thrust place 6 steerin...

Page 179: ...grease through swivel shaft grease nipple w Keep putting grease until excessive grease appears from thrust bushing 0 0 Attach wing nut 0 and check operation of steering friction 5 Install drive shaft...

Page 180: ...aft housing 2 2 Check water pipe for crack and damage 3 Install water pipe 1 into drive shaft housing 2 1 1 1 1 3 2 G REASE OBM OBM OBM OBM Apply grease to water pipe grommet 3 before installation Att...

Page 181: ...l 3 Loosen throttle grip screw 4 and remove the grip 5 Remove throttle shaft supporter 6 screw Check bushing 7 and throttle shaft dumper 8 for damage 4 Check throttle wire 9 for break bend and crack a...

Page 182: ...OBM t y t y G REASE OBM OBM OBM OBM 6 Attach throttle shaft 0 with throttle wire 9 to tiller handle q and tighten adjusting screw w securely Tighten throttle supporter 8 Install tiller handle bushing...

Page 183: ...ghten nut 1 to specified torque 1 b a 9 10 Check operations of tiller handle and throttle grip Tiller handle securing nut 1 6 N m 4 lb ft 0 6 kgf m Arrange throttle cable 9 as shown a High speed side...

Page 184: ...ow speed side wire The wire is in proper state if pushing inner wire at the center makes deflection of about 1 mm 4 Repeat above steps for high speed side wire and fix it 5 Return choke knob to home p...

Page 185: ...full open position and check if throttle lever of carburetor makes contact with stopper 7 Set throttle grip to full close position and check if throttle lever of carburetor makes contact with stopper...

Page 186: ...Bracket 7 20 4st 4 5 6 2011 MFS4 5 6 E ch07 110422 qxd 11 4 22 5 55 PM 20...

Page 187: ...trol 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 5 Inspection of Oil Pressure Switch 8 7 6 Inspection of Rect...

Page 188: ...t 4 5 6 2011 1 Special Tools Inspecting spark Inspecting pressure Spark Tester P N 3F3 72540 0 Vacuum Pressure Gauge P N 3AC 99020 0 Thickness Gauge P N 353 72251 0 Measuring gaps MFS4 5 6 E ch08 1104...

Page 189: ...Nut 12 P1 25 1 9 Igniter W R Cap 1 10 Plug Cap W Resistance 1 11 Bolt 2 M6 L 30mm 12 1 Clamp 6 5 67P 2 12 2 Clamp 6 5 47 5P 1 Ref No Description Remarks Q ty 13 Screw 1 M6 L 12mm 14 Rectifier Complet...

Page 190: ...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 to spark plug tip electrode 0 5 1 0 5 10 WAR...

Page 191: ...3 0 7 0 k 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...

Page 192: ...the measurement range of the circuit tester or voltage due to diode used in the unit This check provide only a reference and it is impossible to perform perfect check 3 Install plug cap onto high ten...

Page 193: ...Oil Pressure Switch Remove the part and test it as a separate unit Vacuum Pressure Gauge P N 3AC 99020 0 Oil Pressure Switch 8 N m 6 lb ft 0 8 kgf m 3 Apply pressure slowly with vacuum pressure gauge...

Page 194: ...between rectifier terminals Replace if out of specification 1 2 a b a b Rectifier Tester Check Chart a b a b 7 Inspection of Lighting Coil 1 Measure resistance between lighting coil terminals a and b...

Page 195: ...rd to start Recoil starter operates normally 9 3 2 Engine starts but stalls soon 9 5 Fuel System 9 5 Ignition System 9 6 Intake Compression Pressure 9 7 3 Idle engine speed will not stabilize 9 8 4 Ro...

Page 196: ...on timing is not properly adjusted Ignighteor valve timing Stop switch lock is not in place Disconnection of lead wires or loose earth wire Valve clearance is wrong Cylinderhead sealing is defective V...

Page 197: ...el 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 i...

Page 198: ...9 4 Troubleshooting OK 4st 4 5 6 2011 YES Adjust valve clearance NO Check valve clearance Normal Check valves cylinder block and or piston ass y MFS4 5 6 E ch09 110422 qxd 11 4 22 7 00 PM 4...

Page 199: ...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 o...

Page 200: ...ug 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 fue...

Page 201: ...on 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 Intake Compression Pressure M...

Page 202: ...e 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 Inspection of Intake Manifold Air Intake System and Igni...

Page 203: ...gging 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 Rapid opening of throttle causes eng...

Page 204: ...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 operati...

Page 205: ...10 10 Wiring Diagram MFS4 5 6E ch10 110422 qxd 11 4 22 6 57 PM 1...

Page 206: ...Black Br Brown R Light Green W White Lg Light Green F 4B 5B 6B STOP SWITCH Y Y MAGNETO Y Y Y Y BATTERY RECTIFIER OPTION ALTERNATOR Y R Y R R B Lg Lg W FUSE LIGHT EXTENSION CORD WARNING LIGHT OIL PRESS...

Page 207: ...10 10 3 4st 4 5 6 2011 Br Br B B STOP SWITCH ASSEMBLY REMOTE CONTROL BOX OPTION B Br Br IGNITER STOP SWITCH MFS4 5 6E ch10 110422 qxd 11 4 22 6 57 PM 3...

Page 208: ...10 4 WIring Diagram 4st 4 5 6 2011 MFS4 5 6E ch10 110422 qxd 11 4 22 6 57 PM 4...

Page 209: ...11 C model Service Information 11 MFS4 5 6 E ch11 110425 qxd 11 4 25 11 21 AM 1...

Page 210: ...MFS4 5 6 E ch11 110425 qxd 11 4 25 11 21 AM 2...

Page 211: ...0 1 Gear Shift P1 8 11 30 2 Fuel Tank and Fuel Line P1 9 11 30 3 Inspection of Forward and Reverse Shifts P1 11 11 30 Chapter 3 Inspection Items 11 31 1 Fuel System P3 4 11 31 Check piping 11 31 2 Ins...

Page 212: ...m in 689 27 13 D mm in 383 15 08 E mm in 497 19 57 F mm in 110 4 33 G mm in 422 16 61 H mm in 361 14 21 I mm in 349 13 74 J mm in 30 60 1 18 2 36 K mm in 275 10 83 S mm in 658 25 91 L L mm in 758 29 8...

Page 213: ...689 27 13 D mm in 383 15 08 E mm in 497 19 57 F mm in 110 4 33 G mm in 422 16 61 H mm in 361 14 21 I mm in 349 13 74 J mm in 30 60 1 18 2 36 K mm in 275 10 83 S mm in 658 25 91 L L mm in 758 29 84 UL...

Page 214: ...ification Service Data 4st 4 5 6 2011 2 Specifications 0 1 2 3 3 3 3 4 5 5 6 6 7 8 5 1 28 2 2 2 9 8 09 1 1 8 2 2 8 2 8 7 8 8 4 8 6 8 4 3 5 A B 7 C 9 9 6 1 8 9 2 1 8 8 MFS4 5 6 E ch11 110427 qxd 11 4 2...

Page 215: ...8 6 9 8 2 6 7 2 7 7 8 6 2 2 A B A 9 Bracket 3 7 C 9 D C 9 2 9 9 2 D 6 D 2 1 2 1 4 7 2 E F 1 0 Warning system Optional parts G7 0 H H G 8 D 7 7 2 2 6 6 2 2 2 A 9 7 2 7 Sepalate Tank Model Model Sail Pr...

Page 216: ...4 3 0 4 01 0 1 6 5 3 11 0 4 3 1 6 3 5 4 3 0 4 0 04 0 7 7 8 9 7 8 1 3 05 5 3 9 00 3 0 5 3 4 7 8 54 0 5 9 55 05 7 8 01 9 01 8 3 55 4 3 04 9 5 3 4 044 3 8 0 9 0 0 8 0 00 54 0 5 2 5 5 0 A 0 4 0 A 1 0 B 4...

Page 217: ...0 0 0 0 0 5 0 4 0 4 1 4 0 4 4 41 01 5 1 05 0 4 41 0 04 5 051 50 0 5 0 0 4 0 4 41 0 5 0 4 0 4 0 0 4 0 0 0 0 5 0 D E 5 5 D E1 2 8 5 1 D E 5 5 D E1 2 2 D 8 5 1 2 2 2 2 2 2 2 2 2 2 2 C 2 2 2 2 2 2 2 MFS4...

Page 218: ...87 87 0191 0 11 Sail Pro 6C 5C 4C 4 913 19313 1904 1941 1911 8 191183 2933 194 27 1914 1918 191117 191147 A211 B CA41 D EF F F F 42 01 19 19 19104 04 61 19 6 1967G 7 H CA41 D C G D 6 C ID 197 193 191...

Page 219: ...9 9 9 9 9 9 9 9 9 9 9 9 9 4 90 1942 1911 8 191183 2936 194 6 1901 1911 3 9 62 021 K 2 9 91 1904 1912 191141 19 191007 1937 191 76 190 1911 3 190 1911 3 981 190 28 194 19117 192 19141 B 192 19141 9 9 9...

Page 220: ...le area Inner wall Ring grooves and periphery Whole area Periphery Big and small end bores Inside Sliding surface Bearing and Gear Sliding surface Outer surface Inside and outside Lip Outer surface at...

Page 221: ...t housing Cowl Sliding surface Thread Crankshaft spline at press fitting at press fitting Thread Lip Outer surface at press fitting Impeller sliding surface Thread Thread at press fitting at press fit...

Page 222: ...M SOC SOC SOC TEF G REASE TEF 4st OIL 4st O I L 4st OIL 4st O I L LIT G REASE LIT 1 2 1 2 SOC O IL CO M P GM GM SOC SOC SOC TB 1342 342 1342 1342 4st OIL 4st O I L TB 1342 342 1342 1342 G103 G103 G103...

Page 223: ...ainer Cap 1 29 Mesh Strainer 1 30 Pipe Strainer 1 31 Seal Rubber Strainer 2 32 Strainer Stopper 1 33 Screw 1 M5 L 12mm 34 Bolt 5 16 Precoated 2 M5 35 Washer 2 36 Oilpan Gasket 1 37 Exhaust Cover Gaske...

Page 224: ...st OIL 4st O I L 4st OIL 4st O I L 4st OIL 4st O I L 4st OIL 4st O I L 4st OIL 4st O I L LOR Liq uid O Rin g LOR Cylinder Head Valve Cam Shaft P L Fig 3 O IL CO M P GM SOC SOC SOC 4st O I L 4st OIL LO...

Page 225: ...r Gasket 1 16 Bolt 4 M6 L 16mm 17 Washer 6 16 1 5 4 18 Thermostat 1 Mark 5B or 52B 19 Thermostat Cap 1 20 Thermostat Cap Gasket 1 21 Camshaft Ass y 1 Mark 6 22 Lifter 2 23 Push Rod 2 24 Plate Push Rod...

Page 226: ...37 36 33 34 44 44 38 45 44 41 42 39 40 44 15 16 14 12 13 11 5 6 19 4 26 28 27 31 29 30 32 Fig 1 51 Fig 1 50 Fig 10 20 Fig 10 2 Fig 13 6 Fig 13 7 Fig 13 14 10 9 8 A 4st OIL 4st O I L Carburetor Fuel P...

Page 227: ...Pilot Screw 1 4ps 19 2 Pilot Screw 1 5 6ps 20 Carburetor Gasket 2 21 Insulator 1 22 Intake Silencer 1 23 Collar 6 2 9 7 4 2 24 Bolt 6 85 2 M6 L 85mm 25 Washer 2 M6 26 Fuel Pump Ass y 1 Mark D 27 Chec...

Page 228: ...Description Remarks Q ty 16 Starter Lock 1 17 Collar 4 6 21 1 18 Starter Lock Spring 1 19 Starter Lock Cam 1 20 Washer 1 M6 21 Screw 1 M6 L 16mm 22 Rod Snap 1 23 Collar 6 1 8 6 5 1 24 Starter Lock Ca...

Page 229: ...eparate Fuel Tank 3 Tilt Handle 1 4 Tapping Screw 4 5 Washer 4 M6 6 Top Cowl Seal 1 7 Sail Pro Decal F6 1 8 1 Decal Set F4C 1 4ps Ref No Description Remarks Q ty 8 2 Decal Set F5C 1 5ps 8 3 Decal Set...

Page 230: ...0 2 Parts Layout 4st 4 5 6 2011 SOC O IL CO M P GM GM SOC SOC SOC G17 G17 G17 BO N D G17 Magneto P L Fig 6 O IL CO M P GM SOC SOC SOC G17 G17 G17 BO N D G17 MFS4 5 6 E ch11 110425 qxd 11 4 25 11 21 AM...

Page 231: ...m 12 1 Clamp 6 5 67P 2 12 2 Clamp 6 5 47 5P 1 13 Screw 1 M6 L 12mm 14 Rectifier Complete 1 for Sail Pro or OPT 15 Fuse 10A 1 16 Battery Cable L 494 1 with Alternator Sail Pro Only 17 Cable Terminal Pl...

Page 232: ...22 2 Parts Layout 4st 4 5 6 2011 P L Fig 7 G REASE OBM OBM OBM OBM TB 1342 342 1342 1342 Drive Shaft Housing Shift TB 1342 1342 1342 G REASE OBM OBM OBM OBM MFS4 5 6 E ch11 110425 qxd 11 4 25 11 21 AM...

Page 233: ...L 8mm 12 Gasket 8 1 15 1 1 13 Grommet 29 3 1 14 Bolt 6 M6 L 30mm 15 Drive Shaft Housing Gasket 1 16 Extension Housing 1 for Transom UL 17 Bolt 1 for Transom UL M6 L 25mm 18 Washer 1 for Transom UL M6...

Page 234: ...racket Reverse Lock P L Fig 9 G REASE OBM OBM OBM OBM G REASE OBM OBM RUB RUB G REASE OBM OBM RUB RUB G REASE OBM OBM OBM OBM G REASE OBM OBM OBM OBM G REASE RVB RUB G REASE OBM OBM OBM OBM MFS4 5 6 E...

Page 235: ...acket Spring 1 18 Screw 1 M4 L 6mm 19 Washer 4 3 16 1 5 1 20 Thrust Rod 1 21 Thrust Rod Spring 1 22 Bolt 4 M6 L 40mm 23 Thrust Bushing 1 24 Bushing Upper Steering 1 25 Bushing Lower Steering 1 26 Fric...

Page 236: ...24 13 12 53 54 40 39 49 44 41 45 38 52 43 50 42 47 46 48 51 32 18 17 55 57 58 56 59 Fig 3 29 Fig 3 19 55 G REASE OBM OBM OBM OBM G REASE OBM OBM RUB RUB G REASE OBM OBM OBM OBM G REASE OBM OBM OBM OB...

Page 237: ...1 1 26 Bolt 1 27 Washer 6 5 23 1 5 2 28 Cable Terminal Plug 1 29 Storage Decal 1 30 Oil Pressure Decal 1 31 Spark Plug Decal 1 32 Fuel Lever Decal 1 33 Bolt 2 M6 L 12mm 34 Washer 6 5 23 1 5 2 35 Bolt...

Page 238: ...11 28 2 Parts Layout 4st 4 5 6 2011 Integral Fuel Tank P L Fig 13 MFS4 5 6 E ch11 110425 qxd 11 4 25 11 21 AM 28...

Page 239: ...10 Fuel Hose 1 Dual Fuel Tank STD 11 Low Permeation Hose 1 Dual Fuel Tank For USA 12 Fuel Hose 1 Dual Fuel Tank STD 13 Low Permeation Hose 1 Dual Fuel Tank For USA 14 Clip 10 Dual Fuel Tank 15 Bolt 2...

Page 240: ...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 Return handle grip 2 to slow side a and then when the engine rea...

Page 241: ...piping Remove top cowl and check each section for fuel leak dirt deterioration and damages Clean or replace parts if necessary 2 Inspection of Fuel Tank P3 5 For Dual Tank Model Remove dirt and water...

Page 242: ...rts if necessary 2 Draining Fuel P4 12 1 Remove fuel tank cap 1 and remove fuel 3 Inspection of Fuel Tank and Fuel Tank Cap P4 13 1 Check fuel tank and fuel tank cap for crack leakage and damage Repla...

Page 243: ...ump Be careful not to bend wire tip 1 when disconnecting Before disconnecting fuel hose place a piece of cloth below fuel pump to absorb leaking fuel 5 Removing Carburetor P4 14 WARNING Before working...

Page 244: ...e item 11 34 4st 4 5 6 2011 5 5 5 Loosen carburetor mounting bolts and remove carburetor 5 Be careful not to bend throttle rod when removing the rod and carburetor MFS4 5 6 E ch11 110425 qxd 11 4 25 1...

Page 245: ...g fuel hose from fuel cock 1 at fuel tank side 2 Remove fuel tank mounting bolts and then remove fuel tank 2 3 Disconnect choke wire 4 from carburetor 3 4 Remove choke wire fixing bracket 5 from stay...

Page 246: ...w starter lock rod and then remove start lock rod 7 Disconnect wires from igniter 8 Disconnect ground wire from cylinder 8 In the same way as B model Disconnect throttle wire Remove engine mounting bo...

Page 247: ...ainted Spark plug cap 0 1 2 3 0 4 5 6 Chapter 8 Inspection Item 1 Inspection of Igniter P8 6 1 Measure igniter resistance Replace if other than specified value Remove the part and test it as a separat...

Page 248: ...N c 0 1 2 3 0 a 2 Inspection of Rectifier P8 8 1 Check conduction of fuse 10 A contained in the fuse box 1 Replace if non conductive 2 Check conduction between rectifier terminals Replace if out of sp...

Page 249: ...MEMO 11 39 4st 4 5 6 2011 11 MFS4 5 6 E ch11 110425 qxd 11 4 25 11 21 AM 39...

Page 250: ...RECTIFIER OPTION ALTERNATOR FUSE LIGHT EXTENSION CORD STOP SWITCH BATTERY WARNING LIGHT OIL PRESSURE SWITCH IGNITER MAGNETO B Black Br Brown R Light Green W White Lg Light Green FLAT TERMINAL Large F...

Page 251: ...11 41 4st 4 5 6 2011 11 Br Br B B B Br Br STOP SWITCH ASSEMBLY REMOTE CONTROL BOX OPTION IGNITER STOP SWITCH MFS4 5 6 E ch11 110425 qxd 11 4 25 11 21 AM 41...

Page 252: ...MEMO 11 42 4st 4 5 6 2011 MFS4 5 6 E ch11 110425 qxd 11 4 25 11 21 AM 42...

Page 253: ...11 43 4st 4 5 6 2011 11 MEMO MFS4 5 6 E ch11 110427 qxd 11 4 27 3 37 PM 43...

Page 254: ...11 44 4st 4 5 6 2011 MEMO MFS4 5 6 E ch11 110427 qxd 11 4 27 3 37 PM 44...

Page 255: ...11 45 4st 4 5 6 2011 11 MEMO MFS4 5 6 E ch11 110427 qxd 11 4 27 3 37 PM 45...

Page 256: ...11 46 4st 4 5 6 2011 MEMO MFS4 5 6 E ch11 110427 qxd 11 4 27 3 37 PM 46...

Page 257: ...11 47 4st 4 5 6 2011 11 MEMO MFS4 5 6 E ch11 110427 qxd 11 4 27 3 37 PM 47...

Page 258: ...11 48 4st 4 5 6 2011 MEMO MFS4 5 6 E ch11 110427 qxd 11 4 27 3 37 PM 48...

Page 259: ...MFS4 5 6 E cover 110420 qxd 11 4 21 9 15 AM 2...

Page 260: ...MFS 4 5 6B C Models OB No 003 21034 2 11 04 NB 4 5 6B C MFS 4 5 6B C Models OB No 003 21034 2 11 04 NB Printed in Japan MFS4 5 6 E cover 110420 qxd 11 4 21 9 15 AM 1...

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TOHATSU MFS 6C, Service Manual

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