Tohatsu Outboard Service and Repair Manual

This Clymer outboard shop manual covers Tohatsu 2.5-140 horsepower two-stroke engines for the years 1992-2000.

Models Included are:

TOHATSU 115 HP
TOHATSU 120 HP
TOHATSU 140 HP
TOHATSU 15 HP
TOHATSU 18 HP
TOHATSU 2.5 HP
TOHATSU 25 HP
TOHATSU 3.5 HP
TOHATSU 30 HP
TOHATSU 40 HP
TOHATSU 5 HP
TOHATSU 50 HP
TOHATSU 60 HP
TOHATSU 70 HP
TOHATSU 8 HP
TOHATSU 80 HP
TOHATSU 9.8 HP
TOHATSU 9.9 HP
TOHATSU 90 HP

The Tohatsu outboard manual by Clymer is a great  reference for repair and service information. This service manual is written for the do-it-yourselfer as well as the experienced mechanic.  The repair manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the engine. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail.  The shop manual will guide mechanics and owners through each service, troubleshooting and repair procedure possible.

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The Tohatsu outboard manual includes the following chapter information:

CHAPTER ONE | GENERAL INFORMATION
Manual organization | Notes, cautions and warnings | Torque specifications | Engine operation | Fasteners | Lubricants | Gasket sealant | Galvanic corrosion | Protection from galvanic corrosion | Propellers

CHAPTER TWO | TOOLS AND TECHNIQUES
Safety first | Basic hand tools | Test equipment | Service hints | Special tips | Mechanic's techniques

CHAPTER THREE | TROUBLESHOOTING AND TESTING
Test equipment | Troubleshooting preparation | Operating requirements | Starting difficulty | Ignition system testing | Warning system | Starting system | Charging system | Fuses and wire harness | Engine speed limiting system | Trim system | Electrical testing | Engine noises | Cooling system | Gearcase

CHAPTER FOUR | LUBRICATION, MAINTENANCE AND TUNE-UP
Tune-up | Submersion | Storage

CHAPTER FIVE | SYNCHRONIZATION AND ADJUSTMENT
Fuel system | Ignition timing | Throttle linkage adjustment (all models)

CHAPTER SIX | FUEL SYSTEM
Fuel tank | Fuel filter replacement | Primer bulb | Fuel pumps | Carburetor

CHAPTER SEVEN | ELECTRICAL AND IGNITION SYSTEMS
Battery | Electric starting system | Starter motor | Charging system | Ignition system | Warning system

CHAPTER EIGHT | POWER HEAD
Flywheel | Power head | Inspection

CHAPTER NINE | GEARCASE AND MIDSECTION
Gearcase operation | Propeller removal and installation | Gearcase removal and installation | Water pump | Gearcase | Inspection

CHAPTER TEN | MANUAL REWIND STARTER
Removal, repair and installation

CHAPTER ELEVEN | POWER TRIM AND TILT REPAIR
Fluid filling | Air bleeding

INDEX

WIRING DIAGRAMS

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Publisher: Clymer Manuals
Binding: Paperback — 8¼ x 10¾ inches
Pages: 322 — Hundreds of b&w photos and illustrations
ISBN: 0892877928

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The Tohatsu outboard service and repair manual applies to the following years:
1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000

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