Tohatsu — M2-5-M3-5 / 2016

Exploded diagrams and part specifications.

1CYLINDER · CRANK CASE 2PISTON · CRANK SHAFT 3CARBURETOR 4RECOIL STARTER 5MAGNETO 6DRIVE SHAFT HOUSING · TILLER HANDLE (M3.5B2)7GEAR CASE (M3.5B2)8DRIVE SHAFT HOUSING · GEAR CASE (M2.5/3.5A2)9CLAMP BRACKET · SWIVEL BRACKET 10TOP COWL 11FUEL TANK 12OPTIONAL PARTS (ACCESSORIES)13ASSEMBLY · KIT PARTS

Fig. 1CYLINDER · CRANK CASE

REF	Part No.	Name	Qty
1	309B01100-3	CYL BLOCK & CRANKCASE ASSY	1
1	3F0B01100-1	CYL BLOCK & CRANKCASE ASSY	1
2	393-01131-0	* NIPPLE 5.5-5	1
3	345-01111-0	* DOWEL PIN 6-12	2
4	916124-0665	* BOLT	4
5	910124-0630	* BOLT	2
6	309B01001-2	CYLINDER HEAD	1
7	309-01005-2	CYLINDER HEAD GASKET	1
8	9161F4-0630	BOLT	4
9	940121-0600	WASHER	4
10	309-02111-0	REED VALVE	1
11	309-02113-0	REED VALVE STOPPER	1
12	921521-7412	SCREW	2
13	9701-1-1013	SPARK PLUG (BPR6HS10)	1
14	98AB-30-150	HOSE	1
15	3F0-01214-0	CRANKCASE HEAD GASKET	1
16	3F0-01210-1	CRANKCASE HEAD	1
17	3F0-01215-0	OIL SEAL 10.1-20-7	2
18	309-01210-1	CRANKCASE HEAD	1
19	910103-5618	BOLT	2
20	309-06972-0	CLAMP 6.5-47.5P	1

Fig. 2PISTON · CRANK SHAFT

REF	Part No.	Name	Qty
1	309-00106-0	THRUST PLATE	1
2	309-00107-0	THRUST PLATE	1
2	3F0-00107-0	THRUST PLATE	1
3	309-00121-0	OIL SEAL 20-42-8	1
4	309-00122-0	OIL SEAL 15-35-15	1
5	3F0-00122-0	OIL SEAL 17-40-8	1
6	309-00069-0	CRANKSHAFT SUB-ASSY	1
7	3F0-00069-0	CRANKSHAFT SUB-ASSY	1
8	309-00040-0	* CONNECTING ROD	1
9	309-00043-0	* ROLLER BEARING 16-22-12	1
10	309-00031-0	* CRANKSHAFT A	1
11	309-00034-0	* CRANKSHAFT D	1
12	3F0-00034-0	* CRANKSHAFT D	1
13	309-00061-1	* CRANK PIN	1
14	3F0-00113-0	MAIN BEARING 6004	1
15	9643-3-6202	BALL BEARING 6202	1
15	9643-3-6203	BALL BEARING 6203	1
16	309-00042-0	ROLLER BEARING 10.5-14-15	1
17	302-00011-0	PISTON RING	1
17	302-00014-0	PISTON RING (0.5 O/S)	1
18	309-87130-0	PISTON REPAIR KIT	1
18	309-87131-0	PISTON REPAIR KIT (0.5 O/S)	1
19	309-00001-1	* PISTON	1
19	309-00004-1	* PISTON (0.5 O/S)	1
20	309-00021-1	* PISTON PIN	1
21	309-00024-1	* PISTON PIN CLIP	2

Fig. 3CARBURETOR

REF	Part No.	Name	Qty
1	3D5-03100-5	CARBURETOR ASSY	1
1	3F0-03100-4	CARBURETOR ASSY	1
2	309-03170-0	* THROTTLE WIRE ASSY	1
3	309-03178-0	* SCREW	1
4	309-03173-0	* THROTTLE LEVER HOLDER	1
5	309-03101-0	* CARBURETOR BODY CAP	1
6	309-03107-0	* THROTTLE VALVE SPRING	1
7	309-03108-0	* SPRING RECEIVER	1
8	309-03154-0	* JET NEEDLE CLIP	1
9	3F0-03153-3	* JET NEEDLE (#256)	1
10	309-03106-1	* THROTTLE VALVE	1
10	3D5-03106-0	* THROTTLE VALVE	1
11	309-03155-2	* NEEDLE JET	1
12	309-03121-0	* FLOAT CHAMBER GASKET	1
13	309-03125-0	* FLOAT	1
14	309-03120-0	* FLOAT CHAMBER	1
15	309-03192-0	* DRAIN SCREW	1
16	309-03193-0	* GASKET	1
17	309-03151-3	* MAIN JET (#86)	1
18	309-03126-0	* FLOAT ARM PIN	1
19	309-03127-1	* FLOAT HINGE	1
20	309-03147-1	* FLOAT VALVE	1
21	309-03148-1	* NEEDLE VALVE SEAT	1
22	309-03156-0	* ADJUST SCREW	1
23	309-03157-0	* SPRING	1
24	309-03161-0	* CHOKE PLATE	1
25	332-03104-0	* CHOKE PLATE NUT	1
26	941303-0600	SPRING WASHER	1
27	309-03163-0	* SHUTTER BOLT	1
28	309-03164-0	* SHUTTER LEVER	1
29	309-03113-0	* CARBURETOR BODY BAND	1
30	309-03114-0	* CARBURETOR BODY BAND BOLT	1
31	921532-6410	* SCREW	2
32	921532-0510	* SCREW	1
33	309-03177-0	* THROTTLE LEVER WASHER	1
34	309-03175-0	* THROTTLE LEVER GASKET	2
35	309-03176-1	* THROTTLE LEVER END	1
36	309-03174-1	* THROTTLE LEVER COLLAR	1
37	309-03172-1	* THROTTLE LEVER	1
38	309-03116-2	* O-RING 2.4-15.7	1
39	309-03401-0	KNOB	2
40	921603-0305	SCREW	2
41	314B02496-2	CARBURETOR COVER W/DECAL	1
41	3F0B02496-1	CARBURETOR COVER W/DECAL	1
42	921603-0435	SCREW	2

Fig. 4RECOIL STARTER

REF	Part No.	Name	Qty
1	312-05000-0	RECOIL STARTER ASSY	1
2	312-05001-0	* STARTER CASE	1
3	307-05004-0	* STARTER SPRING	1
4	307-05104-0	* REEL	1
5	307-05003-0	* RATCHET	1
6	307-05007-0	* FRICTION SPRING	1
7	307-05021-0	* SPRING COVER	1
8	307-05012-0	* RETURN SPRING	1
9	307-05006-0	* FRICTION PLATE	1
10	307-05027-0	* THRUST WASHER	1
11	307-05011-0	* E-RING	1
12	307-05013-0	* STARTER ROPE φ4-1250	1
13	307-05019-0	* STARTER HANDLE	1
14	309-05028-0	* PAD	1
15	910421-0612	BOLT	3
16	910121-0612	BOLT	3
17	309-05901-1	STARTER PULLEY	1
18	3C7-72182-2	CAUTION DECAL (C)	1

Fig. 5MAGNETO

REF	Part No.	Name	Qty
1	3F0-06101-0	FLYWHEEL ASSY	1
2	3F0-06120-0	EXCITER COIL	1
3	3F0-06915-0	CLAMP	1
4	309-00132-0	NUT 10-P1.25	1
5	921521-6520	SCREW	2
6	921521-0510	SCREW	1
7	3F0-06049-1	IGNITION COIL ASSY W/LABEL	1
8	3C8-72181-0	* CAUTION DECAL (B)	1
9	3F0-06157-0	* PROTECTOR	1
10	3M2-06926-0	* PLUG CAP TERMINAL	1
11	3M2-06921-0	* PLUG CAP	1
12	910103-0620	BOLT	1
13	3F0-06060-0	CD UNIT	1
14	910103-0616	** BOLT	1
15	3C8-66308-0	** WASHER 6-16-1.5	2
16	309-00131-0	KEY 10-3.7-3	1
17	3D5-06870-0	STOP SWITCH ASSY	1
18	353-06821-0	* STOP SWITCH LANYARD ASSY	1
19	3C7-06921-0	PLUG CAP W/RESISTANCE	1

Fig. 6DRIVE SHAFT HOUSING · TILLER HANDLE (M3.5B2)

图 06驱动轴外壳·舵柄手柄 (M3.5B2) DRIVE SHAFT HOUSING · TILLER HANDLE (M3.5B2) Fig.

REF	Part No.	Name	Qty
1	9101E3-7635	BOLT	2
2	3F0Q61020-2	DRIVE SHAFT HOUSING (S)	1
3	345-01111-0	* DOWEL PIN 6-12	2
4	9101E3-5625	BOLT	6
5	309-61012-3	DRIVE SHAFT HOUSING GASKET	1
6	9106E3-0808	BOLT	1
7	332-60006-0	GASKET 8.1-15-1	1
8	369-61016-0	GROMMET 29-3	1
9	3F0Q61102-2	EXTENSION HOUSING ASSY (L)	1
10	369-60003-0	* DRIVE SHAFT BUSHING	1
11	3F0-61101-1	STUD 6-171	1
13	3F0-66214-0	SHIFT ROD (S)	1
14	951503-0212	SPLIT PIN 2-12	1
15	940103-0500	WASHER	1
16	369-66241-0	SHIFT ROD JOINT ASSY	1
17	910103-5616	BOLT	1
18	3F0-66110-0	SHIFT LEVER	1
19	3G9-66136-0	O-RING 2-10	2
20	369-66116-0	CERAMIC BALL 7.7	1
21	369-66112-1	SPRING	1
22	3F0-66225-0	SHIFT ROD LEVER	1
23	3F0-66227-0	TAPPING SCREW 4-20	1
24	940103-0400	WASHER	1
25	3F0Q66228-0	COVER	1
26	9101E3-0616	BOLT	2
28	3F0-66229-1	GASKET	1
29	309Q63010-0	TILLER HANDLE ASSY	1
30	309Q63011-0	* TILLER HANDLE	1
31	309-63012-0	* GRIP	1
32	910103-0830	BOLT	1
33	309-63024-0	TILLER HANDLE DAMPER	2
34	309-63025-0	SPACER 8.4-12-14.2	1
35	345-67115-0	WASHER 6.5-21-1	2
36	3F0Q67521-0	CARRYING HANDLE	1
37	9101E3-0625	BOLT	2
38	9301E3-0600	NUT	2

Fig. 7GEAR CASE (M3.5B2)

REF	Part No.	Name	Qty
1	3ARQ60000-1	GEAR CASE ASSY	1
3	338-60218-2	* ANODE	1
4	910103-0616	** BOLT	1
5	9601-0-6004	BALL BEARING 6004	1
6	332-60005-2	PLUG 8-8	2
7	332-60006-0	GASKET 8.1-15-1	2
8	3F0-64321-0	SPACER 10.1-15-72	1
9	3F0Q87323-1	PROPELLER SHAFT HOUSING ASSY	1
10	3F0Q60101-1	* PROPELLER SHAFT HOUSING	1
11	9601-0-6001	* BALL BEARING 6001	1
12	309-60111-0	* OIL SEAL 12-24-8	1
13	345-65015-0	* O-RING 3.2-47	1
14	369-64010-2	BEVEL GEAR ASSY (A)	1
15	369-64014-0	SHIM 21-28-0.1	1
15	369-64015-0	SHIM 21-28-0.15	1
16	369-64020-2	BEVEL GEAR B	1
17	3F0-64301-0	DRIVE SHAFT ASSY (S)	1
17	3F0-64302-0	DRIVE SHAFT ASSY (L)	1
18	9601-0-6000	* BALL BEARING 6000	1
19	369-65021-1	WATER PUMP IMPELLER	1
20	369-65022-0	KEY φ2-11	1
21	3F0-65016-0	PUMP CASE (UPPER)	1
22	3F0-65011-0	PUMP CASE LINER	1
23	3F0-65032-0	GROMMET	1
24	3F0-65018-0	PUMP CASE GASKET	1
25	3F0-65025-0	WATER PUMP GUIDE PLATE	1
26	3F0-65029-0	GUIDE PLATE GASKET	1
27	9161E3-0645	BOLT	4
28	940103-0600	WASHER	4
29	941303-0600	SPRING WASHER	4
30	3H2-65040-1	PUMP CASE ASSY (LOWER)	1
31	3F0-60223-0	* OIL SEAL 10-22-8	1
32	3F0-65020-0	PUMP CASE GASKET (LOWER)	1
33	301-66023-0	O-RING 2.4-9.5	1
34	3B2-65022-0	KEY φ3-11	2
35	3F0-66031-0	CAM ROD BUSHING	1
36	3F0-64215-0	CLUTCH	1
37	3F0-64221-0	SPRING	1
38	3F0-64223-0	PUSH ROD	1
39	3F0-64211-0	PROPELLER SHAFT	1
40	3F0-66011-0	CLUTCH CAM	1
41	3F0-66012-0	CAM ROD (S)	1
41	3F0-66013-0	CAM ROD (L)	1
42	951407-0308	SPRING PIN 3-8	2
43	369-66021-1	O-RING 2.5-4.9	1
44	9101E3-7635	BOLT	2
45	9101E3-5620	BOLT	2
46	951503-0435	SPLIT PIN 4-35	1
47	309-64126-1	SHEAR PIN 4-24	1
48	3F0-65100-0	WATER PIPE ASSY (S)	1
48	3F0-65110-0	WATER PIPE ASSY (L)	1
49	309-65031-1	* GROMMET 10.6-10.4-4	1
50	309-64106-0	PROPELLER ASSY (6")	1
50	314-64103-0	PROPELLER ASSY (4.5")	1
50	3F0-64101-0	PROPELLER ASSY (7")	1
50	3F0B64512-0	PROPELLER ASSY (6")	1

Fig. 8DRIVE SHAFT HOUSING · GEAR CASE (M2.5/3.5A2)

图 08驱动轴外壳·齿轮箱 (M2.5/3.5A2) DRIVE SHAFT HOUSING · GEAR CASE (M2.5/3.5A2) Fig.

REF	Part No.	Name	Qty
1	309Q60000-2	GEAR CASE ASSY	1
2	309-64321-1	* SPACER	1
4	945002-2800	* C-RING d=28	1
5	309-64311-1	DRIVE SHAFT (LOWER)	1
6	9601-0-6300	BALL BEARING 6300	1
7	309-64014-0	SHIM 17.5-10.2-0.2	1
7	309-64015-0	SHIM 17.5-10.2-0.1	1
7	309-64017-0	SHIM 17.5-10.2-0.05	1
8	309-64020-0	BEVEL GEAR B	1
9	945307-0700	E-RING d=7	1
10	309-65021-1	WATER PUMP IMPELLER	1
11	309-65022-0	KEY φ4-15	1
12	309Q65010-1	WATER PUMP CASE	1
13	9601-0-6001	* BALL BEARING 6001	1
14	309-60111-0	* OIL SEAL 12-24-8	1
15	309-65015-0	O-RING 1.5-47.75	1
16	309-65032-0	GROMMET 10.2-8	1
17	309-64210-0	PROPELLER SHAFT ASSY	1
18	9101E3-7630	BOLT	2
19	309-60223-0	OIL SEAL 13-28.1-18	1
20	309Q60101-1	WATER PUMP CASE COVER	1
21	309Q61020-2	DRIVE SHAFT HOUSING (S)	1
21	309Q61030-2	DRIVE SHAFT HOUSING (L)	1
22	309-64312-1	DRIVE SHAFT (UPPER S)	1
22	309-64313-1	DRIVE SHAFT (UPPER L)	1
23	309-64322-0	GIRD PIPE	1
23	309-64323-0	GIRD PIPE	1
24	309-65100-0	WATER PIPE ASSY (S)	1
24	309-65110-0	WATER PIPE ASSY (L)	1
25	309Q67521-0	CARRYING HANDLE	1

Fig. 9CLAMP BRACKET · SWIVEL BRACKET

图 09夹紧支架·旋转支架 CLAMP BRACKET · SWIVEL BRACKET Fig.

REF	Part No.	Name	Qty
1	309Q62111-4	CLAMP BRACKET	2
2	309-62115-2	BOLT 8-122	1
3	930403-0800	NYLON NUT 8-P1.25	1
4	307-62116-1	WASHER 8.5-28-1	2
5	309-62117-1	DISTANCE PIECE	1
6	930103-0600	NUT	2
8	309-62212-2	THRUST SUPPORTER	1
9	3F0-62160-0	THRUST ROD ASSY	1
10	309-62463-0	KNOB	1
11	309-62464-2	TILT STOPPER	1
12	309Q62391-1	SWIVEL BRACKET	1
13	309Q62392-1	SWIVEL BRACKET	1
14	9101E3-0630	BOLT	4
15	309-62321-1	BUSHING	2
16	309Q62442-2	FRICTION KNOB	1
17	309-62441-2	FRICTION PIECE	1
18	309-62446-1	SPRING	1
19	9401E3-0600	WASHER	1
20	3GTQ62105-1	CLAMP SCREW KIT	2
21	3GTQ62108-1	* CLAMP SCREW ASSY	1
22	369-62106-1	** CLAMP SCREW	1
23	3ABQ62102-0	** CLAMP SCREW HANDLE	1
24	3C8-62104-2	** RIVET 3-22	1
25	332-62101-1	* CLAMP SCREW PAD	1
26	3C8-62107-0	* SHOULDER BOLT	1

Fig. 10TOP COWL

REF	Part No.	Name	Qty
1	309-87801-8	DECAL SET	1
1	314-87801-8	DECAL SET	1
1	3F0-87801-8	DECAL SET	1
2	9215E3-0612	SCREW	6
3	309-67006-0	TOP COWL JOINT PLATE	4
4	309-67007-0	NUT	8
5	921603-0510	SCREW	8
6	309Q06927-1	COVER	1
7	307-67005-0	GROMMET 16-5-2.5	2
8	3C7-72180-3	* CAUTION DECAL (A)	1
9	309Q67001-8	TOP COWL SUB-ASSY (R)	1
9	3F0Q67001-8	TOP COWL SUB-ASSY (R)	1
10	309Q67002-8	TOP COWL SUB-ASSY (L)	1

Fig. 11FUEL TANK

REF	Part No.	Name	Qty
1	3GP-70020-0	FUEL TANK CAP ASSY	1
2	3GR-70021-0	* TANK FILLER CAP GASKET	1
3	940103-0400	WASHER	1
4	3H9-70095-0	* HOOK	1
5	951503-1610	* SPLIT PIN 1.6-10	1
6	309-70010-3	FUEL TANK	1
7	309-70015-0	SPACER 7.2-10-6	2
8	309-70016-0	WASHER 6.5-16-2	2
9	910421-0620	BOLT	2
10	941322-0600	SPRING WASHER	2
11	309-70011-0	FUEL COCK ASSY	1
12	98AB-50-250	HOSE	1
13	338-02215-0	CLIP φ10	2
14	309-70036-0	FUEL TANK SEAL	1

Fig. 12OPTIONAL PARTS (ACCESSORIES)

图 12选装件(附件) OPTIONAL PARTS (ACCESSORIES) Fig.

REF	Part No.	Name	Qty
1	312-72201-0	SAFETY ROPE φ4-1000	1
2	312-72100-0	TOOL KIT	1
3	336-60007-0	FLUSHING PLUG	1

Fig. 13ASSEMBLY · KIT PARTS

REF	Part No.	Name	Qty
1	3ARQ87301-1	LOWER UNIT ASSY (S)	1
1	3ARQ87302-1	LOWER UNIT ASSY (L)	1
2	309Q87301-1	LOWER UNIT ASSY (S)	1
3	309B87090-6	ENGINE SHORT BLOCK KIT	1
3	3F0B87090-4	ENGINE SHORT BLOCK KIT	1
4	309-03116-2	* O-RING 2.4-15.7	1
4	309-03121-0	* FLOAT CHAMBER GASKET	1
4	309-03125-0	* FLOAT	1
4	309-03126-0	* FLOAT ARM PIN	1
4	309-03127-1	* FLOAT HINGE	1
4	309-03147-1	* FLOAT VALVE	1
4	309-03148-1	* NEEDLE VALVE SEAT	1
4	309-03154-0	* JET NEEDLE CLIP	1
4	309-03156-0	* ADJUST SCREW	1
4	309-03193-0	* GASKET	1
4	3F0-03153-3	* JET NEEDLE (#256)	1
4	3F0-87122-2	CARBURETOR REPAIR KIT	1
4	921532-6410	* SCREW	2
5	309-00121-0	OIL SEAL 20-42-8	1
5	309-00122-0	OIL SEAL 15-35-15	1
5	309-01005-2	CYLINDER HEAD GASKET	1
5	309-61012-3	DRIVE SHAFT HOUSING GASKET	1
5	309-87121-3	POWER HEAD GASKET SET	1
5	3F0-00122-0	OIL SEAL 17-40-8	1
5	3F0-01214-0	CRANKCASE HEAD GASKET	1
5	3F0-01215-0	OIL SEAL 10.1-20-7	1
5	3F0-87121-3	POWER HEAD GASKET SET	1
6	3F0-65011-0	PUMP CASE LINER	1
6	3F0-65025-0	WATER PUMP GUIDE PLATE	1
6	3F0-87322-1	WATER PUMP REPAIR KIT	1
6	9161E3-0645	BOLT	4
6	940103-0600	WASHER	4
6	941303-0600	SPRING WASHER	4
7	301-66023-0	O-RING 2.4-9.5	1
7	309-60111-0	* OIL SEAL 12-24-8	1
7	309-65015-0	O-RING 1.5-47.75	1
7	309-87321-0	LOWER UNIT GASKET SET	1
7	332-60006-0	GASKET 8.1-15-1	2
7	345-65015-0	* O-RING 3.2-47	1
7	369-65021-1	WATER PUMP IMPELLER	1
7	369-65022-0	KEY φ2-11	1
7	369-66021-1	O-RING 2.5-4.9	1
7	3F0-60223-0	* OIL SEAL 10-22-8	1
7	3F0-65018-0	PUMP CASE GASKET	1
7	3F0-65020-0	PUMP CASE GASKET (LOWER)	1
7	3F0-65029-0	GUIDE PLATE GASKET	1
7	3F0-87321-0	LOWER UNIT GASKET SET	1
8	3F0-61101-1	STUD 6-171	1
8	3F0-64302-0	DRIVE SHAFT ASSY (L)	1
8	3F0-65110-0	WATER PIPE ASSY (L)	1
8	3F0-66013-0	CAM ROD (L)	1
8	3F0Q61102-2	EXTENSION HOUSING ASSY (L)	1
8	3F0Q87312-1	EXTENSION HOUSING KIT (L)	1
8	9101E3-7635	BOLT	1
8	9301E3-0600	NUT	1
8	951407-0308	SPRING PIN 3-8	2