Tohatsu 3 & 4 Cylinder Outboard Motor Service Workshop Manual

Workshop Service and Repair Manual for the Tohatsu 3 & 4 cylinder 2 stroke outboard engines. This full workshop manual set covers every component, service and repair procedure in full Tohatsu factory specification with clear concise step by step photographs and technical drawings for both the 3 & 4 cylinder motors with torque setting values throughout for fasteners and reassembly, below is an exhaustive list of the items covered within this set.

This is the most comprehensive service manual set available as used by marine engineers and boatyards the world over.

TOHATSU 3&4 CYLINDER OUTBOARD MOTOR SERVICE MANUAL

SECTION 1 SERVICE SAFETY
Introduction
Safety Statements
Safety Precautions
Workmanship Standards
Test Tank Guidelines

SECTION 2 GENERAL SERVICE INFORMATION
General Precautions
Abbreviations and Symbols
Unit Conversions
Service Specifications
Engine Specifications
Lubrication Chart
Periodic Inspections
Break-ln Procedure
Tune-Up Procedure
Emergency Stop Switch and Lanyard
Synchronization and Linkage Adjustments
Carburettor Adjustment
Anodes – Inspection and Testing

SECTION 3 FUEL SYSTEM
General Precautions
Service Specifications
Fuel System Requirements
Troubleshooting
Description of Operation
Fuel Tank
Fuel Line and Primer
Fuel and Oil Filters
Fuel Pump
Automixing System
Carburettor
Intake Manifold

SECTION 4 POWERHEAD
General Precautions
Service Specifications
Troubleshooting
Description of Operation
Cylinder Compression Test
Thermostat
RPM Performance Test
Recoil Starter
Flywheel
Powerhead

SECTION 5 MIDSECTION
General Precautions
Service Specifications
Tiller Steering Handle
Lower Engine Cover
Driveshaft Housing
Stern and Swivel Brackets

SECTION 6 GEARCASE
General Precautions
Service Specifications
Water Pump
Gearcase
Backlash – Shim AdjustmentTable
Gearcase Repair Procedures

SECTION 7 ELECTRICAL SYSTEM
General Precautions
Service Specifications
Electrical Servicing Standards
Troubleshooting
Description of Operation
Battery Care and Maintenance
Ignition System
Ignition System Repair Procedures
RPM Limitation Test
Starting System
Charging System

SECTION 8 POWER TRIM/TILT

General Precautions
Service Specifications
Air Bleeding Procedure
Trim Sender/Trim Meter Test
Power Trim/Tilt
Troubleshooting