TOHATSU MFS 15C User manual

MFS15/20C
Disassembling & Reassembling procedure
TOHATSU Corporation Japan
Service Div.

MFS20C Open Packing ~ PDI
<Open Packing of carton box ~ PDI>
Open the packing
Check the carton box for breakage or damage of the packing before opening.
Check the contents
Open the carton box and check the contents.
Main part : Out board motor, with Propeller
Enclosed parts : Fuel tank, Fuel hose, Tools, Owner’s manual, Spark plugs (2pcs), Emergency
starter rope
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PDI (abbreviation of Pre-Delivery Inspection)
Check and confirm about following items, using Pre-Delivery Inspection Check Sheet.
CHECK BEFORE OPERATION
CHECK DURING OPERATION
CUSTOMER DELIVERY CHECK LIST
[The procedure before PDI work]
Place outboard motor on the motor stand using a hoist.
(It is careful when carrying out hooking of the outboard motor.)

Check for external scratches and cracks, according to the PDI sheet.
Visual Inspection Throttle Linkage Operation Engine Oil Level
Propeller Selection Electric Starter Operation Shift Lever Operation
Throttle Handle Operation Indicator Lamp and Buzzer Stop Switch Operation

[Pre-delivery running and adjustment]
Install test propeller (confirm to no free gap on the test propeller on the drive shaft.)
Prepare unleaded gasoline.
When install an outboard motor on a test tank, securely tighten bolts and fix to transom.
PDI is an important procedure to ensure Long engine life.
Please be sure to perform first time operation according to the owner’s manual.
Test Run and check all operations before Customer delivery.
Refer to the PDI sheet for each part check points.
*Necessity of the PDI
Tohatsu outboard motors are produced in a factory and each adjustment is tested by running before
shipment. However, dealers and distributors need to adjust for their area.
Temperature or humidity is different globally. And the test run before delivering an outboard motor is
necessary for these different places.
Customer must sentence should be here.

Trained personnel should check that the unit has been pre-delivered in accordance with the relevant Tohatsu Outboard
Manual. The following points must be confirmed at pre-delivery and during the water test.
RefNo:
MODEL PRIMARY ID (Port) PRIMARY ID (Starboard) HULL ID NUMBER (HIN)
BOAT MAKER/MODEL IGNITION KEY NUMBER (Port) IGNITION KEY NUMBER (Starboard) TRAILER NUMBER
CHECKBEFOREOPERATION CHECKDURINGOPERATION
All Standard Items Supplied (Defect, Breakage, Missing parts)
Engine Mounting (Height, Width, Proper hardware, Secured)
Harness and hoses installation (Secured and Properly Dressed)
Main Wire Harness installation Extended ft Not Extended
Multifunction Gage Dip Switch Setting forApplication
Instrument Operation/Connections
Tiller Handle Installation/Secure
RemoteControlOperation/Adjustments Type:
CableStrokeandRouting Length: m Min.radius: cm
Shift Throttle Operation
CableStrokeandRouting Length: m Min.radius: cm
MechanicalSteeringOperation/Installation Maker:
HydraulicSteeringOperation/Bleed Maker:
Primer Pump Installed Properly (Arrow pointing up)
Fuel Line/Tank Installation/Connections Routing Sealed/Secured
InnerDiameter: m Length: m Height: m
BoatFuelFilter Type
FuelVacuumTestResult: kPa@WOT rpm(over 50ps)
BatteryMeets/ExceedsEngineSpecifications Type:
Battery Charged/Secured/Connections Tight
Battery Cable Installation and Routing
BatteryCableType: CableLength:
Battery S/W installation (Secured, Properly Connections)
Manual Tilt Operation
Power Trim/Tilt Operation
Lower Unit Oil Level
Overheat Warning System (Ground sensor lead on applicable models)
Visual Inspection of Engine
<2-Stroke Fuel and Oil Setup>
Break-InPremixRatio(ExceptTLDImodels) 25 : 1
Oil in Remote andMarine Engine Tank
Tohatsu TCW3 EquivalentQualityOilBrand:
Breed Oil Injection Pump / No air in oil Injection Lines
Electric Oil Pump Function
<4-Stroke Oil Setup>
Check Engine Oil Level (Ensure unit is not overfilled)
Engine Oil Classification: Brand:
<Carburetion: 2 and 4-Stroke models>
Manual/Electric Choke Operation
Electric Starter Operation (Start in gear protection functions)
Manual/Electric Choke Operation
Neutral Switch function
Stop Switch/Emergency Switch Operation
Steering Operation
Throttle Operation/FrictionAdjustment Neutral/Cruising
Proper Shift CableAdjustment/Operation (F-N-R)
Cooling System Water Flow
Fuel/Oil/Water/Exhaust leaks
Oil Warning system Check (Equipped models)
Indicator Lamp and Buzzer
Oil and TemperatureWarning functions (Equipped models)
Engine reaches operating temperature
Power Trim/Tilt Operation
Instrument Operation
Trim Tab Adjustment (retorque after operation)
Propeller Selection: Brand: Tohatsu Other:
Material: SUS AL Plastic
Model: Dia: Pitch:
IdleRPM Single/P: rpm S: rpm
IngearidleRPM Single/P: rpm S: rpm
Factory-recommendedW.O.T.RPMRange: rpm
W.O.T.RPM Single/P: rpm S: rpm
No Cavitations/Ventilation
Remarks:
Inspector’s signature Date
Dealer name Phone number
Dealership address
CUSTOMER DELIVERY CHECKLIST
Operation of Equipment/BoatAccessories Explained
(Proper Trim and Tilt operation demonstrated)
Operation/Orientation Ride with Dealership Personnel
Warranty/Owner’s Manual and Keys Given to Customer by Dealer.
Customer Introduced to Service Manager/Writer
Return-to-Port Operations (Oil System, RPM Reduction)
Gauge Operation/Warning Symbols Explained
2-Stroke: Use of Tohatsu 2 stroke/TC-W3 or Equivalent Rated Oil
4-Stroke: Use of Tohatsu 4 stroke or Equivalent Rated Oil
4-Stroke: Show Customer Proper Checking Procedures and Proper Level of
Engine Oil
Engine Break-in Procedure Explained
Maintenance/Care Schedule Explained
Advised of First Scheduled Maintenance
Warranty Coverage Explained to Customer’s Satisfaction,
Including Customer Responsibilities
Customer questions answered by Dealership Personnel
Break-in Time Placedon Engine by Dealership Personnel
hours: Minutes:
Customer name Phone number
Customer address
Customer signature Date
Date of Issue : / /2008 ORIGINALTO BE HELD BY DEALER/COPY TO CUSTOMER
TOHATSU OUTBOARD MOTOR
Pre-Delivery Inspection Check List 2 and 4-Stroke Models
The above materia
l
has been explained and/or provided to me by dealership personne
l
.
My questions were answered and explained to my satisfaction.

6
□MFS20C Maintenance section
Power head
<Disassembly>
Remove each terminal of harness to remove the power head
*Battery cable (○
+, ○ -)
*Remote control harness coupler and connectors (Remote control model)
*Warning lamp, starter switch and stop switch
*PTT switch coupler, each ground wire (PTT model)
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*Shift link rod connection (*Remote control cable connection)
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*Fuel hose connection (fuel filter’s inlet side)
*Cooling water hose connection
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After removing each connection, remove the apron and power head mounting bolts.
(It is possible to detach it smoothly by removing the water pipe lock plate)
Remove the power head.

8
(Oil strainer and Plunger are detached up and down and inversely.)
Remove the recoil starter.

9
·Loose the flywheel nut using the special tool (Flywheel Puller kit 3B7-72211-0).
·Remove the flywheel from crankshaft using a flywheel Puller.
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Remove the all electric system and sensor connections, and remove the main harness.

10
Remove the bolts, and remove the fuel pump.
Remove the bolts, and remove the intake manifold with carburetor.

11
Remove the bolts, and remove the starter motor.
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Loose the drive pulley nut ○
cusing crank holder (○
ｂ○ 13 ).
To prevent the piston and the valve being interfered
Crank holder
Remove the timing belt, drive pulley, and cam pulley.

12
Remove the bolts, and remove the cylinder head cover.
Remove the bolts, and remove the cylinder head.
Remove the bolts, and Remove the oil pump assembly.

13
Loose the rocker arm lock nut, and loosen adjusting screw as much as possible.
Remove the rocker arm, spring, washer and rocker arm shaft.
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Remove the cam shaft.
Compress the valve spring by using compressor. Then, remove cotter, spring and valve.

14
Remove the oil seal and install new oil seal.
Inspect in of valve spring and valve.
(1) Valve spring free length (2) Valve spring inclination limit
length: 35.0mm ~ 33.5mm Inclination limit: 1.5mm
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(3) Valve stem Outside diameter (4) Valve stem deflection limit
Intake side: 5.46mm ~ 5.48mm Intake side: 0.05mm
Exhaust side: 5.44mm ~ 5.46mm Exhaust side: 0.03mm

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<Inspect in of rocker arm and rocker arm shaft>
Measure rocker arm inner diameter and Rocker
shaft Outer diameter.
(1)Rocker arm
Inner diameter: 13.01mm~13.05mm
(2)Rocker shaft
Outer diameter: 12.94mm~12.99mm
(3)Shaft clearance
0.006mm~0.060mm
<Inspect in of cam shaft>
Measure deflection camshaft.
deflection limit: 0.05mm
Cylinder Head
<Assembly>
Assembling cylinder head reverse of their disassemble steps.
Tightening torque as follows:
Size x Q'ty 1st 2nd
M6x3 0.6kg.m 1.0kg.m
Cylinder head M8x6 1.0kg.m 3.0kg.m
Cylinder head cover M6x4 0.6kg.m 0.9kg.m
Oil pump M6x3 0.25kgm 0.9kgm
Cam shaft pulley M6x1 1.1kgm
Tappet adjusting lock nut M6x4 0.7kgm

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(1)Installation of valves
Attach the new valve stem seal.
Attach the parts to the valve in order of the retainer in the valve, valve spring seat,
and the valve spring
Apply Oil to valve guide.
Stem seal Intake: Black
Exhaust: Green
Attach the cotter with compressing the valve spring. Strike the top of valve stem lightly with a
plastic hammer. Then cotter is stabilized.
(2) Attaching of camshaft
Apply enough oil to the new oil seal outer, and attach it.
(Spread the lithium grease enough on the lip.)

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(3) Attaching of locker arm shaft
Apply enough oil to the camshaft and rocker arm shaft.
(4) Attaching of oil pump
Align cuts of oil pump drive shaft and camshaft pin with each other to install oil pump.
Refuel engine oil to the oil passage in 2ml.
(Apply engine oil to oil pump o-ring and camshaft lower side journal.)
(5) Attaching of cylinder head
Be sure to align mark of cam shaft pulley○
aand mark of cylinder head ○ b, then tighten the
nut.
Camshaft’s pin

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Be sure to align mark of the belt guide ○
cand mark of the cylinder block ○ d.
Certainly
·Use a new cylinder head gasket.
·Do not turn cam shaft pulley with the timing belt removed.
(Doing so can make pistons and valves interfere with each other, resulting in damages to
these parts)
Disassembly of Cylinder Block
Remove installation bolts, and remove crank case.

19
Remove installation bolts, and connecting rod cap.
Remove crank shaft from cylinder block.
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Check the balance of crank shaft. Crank shaft Deflection Limit: 0.05mm
(The crank shafts are exchanged when the amplitude is more than the limit value.)

20
Remove connecting rods with piston assemblies from cylinder block.
(Be careful not to damage the piston and piston ring.)
Remove the piston pin clip then the piston from the connecting rod.
Inspection of power head cooling water passage
Remove the thermostat cap and thermostat.
Check whether thermostat valve is open by catching debris.
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