1991-2000 Tohatsu Marine Engine 2hp to 140hp Service Manual

Complete troubleshooting, repair, and maintenance guide for Tohatsu marine engines 2hp to 140hp, covering 1991-2000 models. Includes detailed procedures and diagrams. Part No. 123-456789

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Document Details

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Document Number / Seller:
29292 / Paul Peterson
File Size:
47.84 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Mar 28, 2025

Models Covered & Key Technical Specifications

Tohatsu Marine Engine 2hp to 140hp Service Manual | Troubleshooting & Repair. System Storage Capacity: 47.84 MB Sequences. Core Tank Capacity: 47.84 MB Baseline. Specific Consumption Data: 1991-2000 Requirements. Critical Heat Dissipation: 1991-2000 Threshold. Universal Footprint Data: 1991-2000 Mapping. Calibrated Tank Capacity: 1991-2000 Configuration.

Professional Workshop Service Manual & Technical Specifications

Tohatsu Marine Engine 2hp to 140hp Service Manual: Troubleshooting, Repair and Maintenance Guide, covers 1991-2000 Maintenance-Registry

Component-Focus: Engine Performance // Model-Designation: 2hp-140hp // Component-Focus: Maintenance Schedule Metric Rating Calibration-Data
Engine Speed 1500 RPM Idle Speed: 900 RPM
Ignition Timing 20° BTDC Wide Open Throttle: 25° BTDC
Exciter Coil Resistance 168-252 Ohms Pulser Coil Resistance: 30-46 Ohms
Spark Plug Gap 0.9-1.0 mm Primary Ignition Coil Resistance: 0.2-0.3 Ohms
CDI Output Cranking Speed 198-220 Peak Volts Alternator Coil Resistance: 0.24-0.36 Ohms
Maintenance Interval 50 Hours 100 Hours

Factory procedures are documented for engine tune-ups, diagnostics, and repair of all major systems. This manual includes detailed explanations of engine operation and component functions.

General Information

Provides an overview of the engine's basic functions, including intake, compression, power, and exhaust phases. It also covers fastener types and thread specifications.

Tools and Techniques

Details essential tools and techniques for performing maintenance, troubleshooting, and repairs on the engine.

Troubleshooting and Testing

Covers common engine problems, diagnostic procedures, and testing equipment such as multimeters and compression gauges.

Lubrication, Maintenance, and Tune-Up

Offers guidance on routine maintenance, lubrication schedules, and tune-up procedures to ensure optimal engine performance and longevity.

Synchronization and Adjustment

Explains procedures for synchronizing carburetors, adjusting ignition timing, and setting idle speeds for various engine models. ...documents torque specifications for engine components to ensure proper assembly and function.

FAQ

Specify the **applicable** lubrication requirements? keyboard_arrow_down

90 mL (3.0 oz.) is the specified capacity for the 2.5-3.5 HP models' gearcase lubrication.

What is the **exact** testing parameters? keyboard_arrow_down

A spark plug gap of 0.9-1.0 mm (0.035-0.039 in.) is the specified parameter for the 2.5-3.5 HP models.

Calculate the **specific** diagnostic procedures? keyboard_arrow_down

20° BTDC is the specified ignition timing for idle speed on the 2.5 HP models.

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This manual is incredibly detailed and easy to follow. The troubleshooting section helped me fix an issue I had been struggling with for weeks!