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1991-2000 Tohatsu 2 hp-140 hp outboard motor service manual Preview image 1

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1991-2000 Tohatsu 2 hp-140 hp outboard motor service manual Preview image 4

1991-2000 Tohatsu 2 hp-140 hp outboard motor service manual

Models covered in this manual:

2 hp - 140 hp / Tohatsu

2 hp, 2.5 hp, 3.5 hp, 4 hp, 5 hp, 6 hp, 8 hp, 9.8 hp, 15 hp, 18 hp, 20 hp, 25 hp, 30 hp, 40 hp, 50 hp, 60 hp, 70 hp, 90 hp, 115 hp, 120 hp, and 140 hp.

Production/model years: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000

File specifications

File size: 47.84 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 0.98 Minutes

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Product Information

General Information

Introduction
- Manual organization
- Tools and techniques
- Troubleshooting and testing

Tools and Techniques

Basic tools
- Hand tools
- Special tools
Advanced techniques
- Measuring techniques
- Diagnostic tools

Troubleshooting and Testing

General troubleshooting
- Diagnostic procedures
- Common issues
Testing systems
- Ignition system testing
- Fuel system testing
- Electrical system testing
- Cooling system testing
- Charging system testing

Lubrication, Maintenance and Tune-Up

Regular maintenance
- Lubrication points
- Maintenance schedule
Tune-up procedures
- Spark plug maintenance
- Carburetor adjustments

Synchronization and Adjustment

Synchronization procedures
- Throttle linkage adjustment
- Carburetor synchronization
Adjustment procedures
- Idle speed adjustment
- Timing adjustments

Fuel System

Fuel tank
- Inspection
- Repair and maintenance
Fuel lines
- Inspection
- Replacement
Carburetor
- Disassembly and cleaning
- Reassembly and adjustment

Electrical and Ignition Systems

Ignition system
- Spark plug inspection
- Ignition coil testing
Electrical components
- Battery maintenance
- Wiring inspection and repair

Power Head

Power head disassembly
- Component identification
- Removal procedures
Power head reassembly
- Cleaning and inspection
- Installation procedures

Gearcase and Midsection

Gearcase disassembly
- Component identification
- Removal procedures
Gearcase reassembly
- Cleaning and inspection
- Installation procedures

Manual Rewind Starter

Rewind starter inspection
- Component identification
- Testing procedures
Rewind starter repair
- Disassembly
- Reassembly

Power Trim and Tilt Repair

Trim and tilt system
- Inspection
- Repair procedures
Hydraulic system
- Inspection
- Repair procedures

Index

Alphabetical index
- Component references

Wiring Diagrams

Electrical schematics
- Wiring layouts
- Component connections

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