Table Of Contents - TOHATSU MFS 9.9 Owner's Manual

Table of Contents

Introduction2
Safety Information2
Safety Statements2
What Is The Si Unit System?4
Description Of Pictograph5
Contents6
Table Of Contents7
Index8
Service Information10
Identification11
Work Safety11
Fire Prevention11
Ventilation11
Tools12
Recommendations On Service12
Tools And Instruments14
Test Propeller14
Measuring Instruments14
Special Tools15
Pre-Delivery Inspection18
Steering Handle18
Gear Shift18
Engine Oil18
Fuel Line19
Rigging19
Manual Tilt19
Inspection Of Starting Switch And Stop Switch20
Cooling Water Check Port21
Idling21
Propeller Selection21
Range Of Operating Engine Speed At Wot21
Trim Tab22
Example Of Trim Tab Angle Adjustment22
Break-In Operation22
Test Run23
Checks After Test Run23
Idling Revolution Speed23
Tachometer23
Service Data26
Outline Dimensions27
Engine Outer Dimensions27
Transom Bolts28
Mechanical Tilt Model28
Fuel Feed System29
Fuel Feed Route29
Engine Lubrication System Diagram30
Cooling Water System Diagram31
Specifications32
Dimensions32
Weight32
Performance32
Power Unit33
Fuel And Oil33
Lower Unit33
Bracket34
Warning System34
Optional Parts34
Maintenance Data35
Tightening Torque Specifications43
Sealant And Lubricant44
Maintenance48
Inspection Schedule50
Inspection Of Top Cowl51
Fuel System51
Check Piping51
Inspection Of Fuel Tank52
Inspection Of Fuel Filter52
Replacement Of Engine Oil53
Oil Level53
Oil Specification53
Quantity Of Engine Oil53
Replacement Of Oil Filter54
Inspection Of Gear Oil Quantity55
Inspection Of Water Pump55
Replacement Of Gear Oil57
Inspection Of Gear Case (For Leakage)58
Specified Gear Case Maintained Pressure58
Inspection Of Timing Belt59
Replacement Of Timing Belt60
Installatin Of Timing Belt62
Inspection Of Spark Plugs64
Inspection Of Compression Pressure65
Inspection And Adjustment Of Valve Clearance66
Throttle Cable67
For F Type67
Adjustment Of Throttle Link69
Inspection Of Gear Shift Operation74
Inspection Of Idle Engine Speed76
Inspection Of Ignition Timing76
Inspection Of Anode77
Replacement Of Anode77
Inspection Of Propeller78
Inspection Of Thermostat78
Inspection Of Cooling Water Passage79
Flushing With Water80
Flushing With Water Using Drive Cleaner 380
Inspection Of Battery81
Battery81
Specific Gravity Of Electrolyte81
Charging Requirements81
Greasing Points82
Parts Layout86
Carburetor86
Intake Manifold & Fuel Pump88
Carburetor Inner Passages 1) Idling Passage89
Off-Idle Passage90
High Speed Passage91
Acceleration Passage92
Choking Passage93
Inspection Items94
Removing Carburetor94
Remote Control Model94
Tiller Handle Model95
Disassembling Carburetor97
Cleaning And Inspection99
Inspection Of Fuel Pump100
Inspection Of Fuel Connector101
Assembling Carburetor101
Adjusting Float Height103
Float Height A103
Installing Carburetor103
Inspection Of Connecting Rod Small End Inner Diameter ⋯104
Magneto107
Electric Parts108
Camshaft & Oil Pump110
Cylinder Head111
Intake Valve & Exhaust Valve112
Cylinder113
Piston & Crankshaft114
Recoil Starter115
Top Cowl116
Inspection Of Oil Pressure118
Inspection Of Valve Clearance119
Rocker Arm Lock Nut 5120
Valve Clearance (When Engine Is Cold)120
Removing Power Unit121
Removing Plunger And Oil Strainer123
Inspection Of Oil Strainer123
Removing Timing Belt And Pulley125
Installation Of Pulley And Timing Belt127
Removing Cylinder Head130
Inspection Of Valve Spring132
Inspection Of Valve133
Inspection Of Valve Guide133
Inspection Of Valve Seat134
Correction Of Valve Seat135
Inspection Of Cam Shaft138
Inspection Of Cylinder Head139
Inspection Of Oil Pump140
Functional Limit140
Installation Of Valves141
Installation Of Cam Shaft142
Installation Of Rocker Arm Shaft142
Installation Of Oil Pump143
Installation Of Cylinder Head144
Cylinder Head Bolts (M8)144
Cylinder Head Bolts (M6)144
Disassembly Of Cylinder Block145
Inspection Of Piston Outer Diameter146
Inspection Of Cylinder Inner Diameter146
Inspection Of Piston Clearance147
Inspection Of Piston Ring Side Clearance147
Inspection Of Piston Rings147
Inspection Of Piston Pins148
Inspection Of Connecting Rod148
Small End Inner Diameter148
Inspection Of Connecting Rod Big End Side Clearance148
Inspection Of Crank Shaft149
Inspection Of Crank Pin Oil Clearance150
Crankshaft Main Journal Oil Inspection Of Clearance151
Be Sure That Individual Bearings Are Installed151
To Their Original Locations151
Inner Diameter Of Cylinder152
Thickness Of Metal Bearing152
Color Of Inner Diameter Code152
Assembling Piston And Connecting Rod153
Cylinder Block Groove154
Install Bearings With Their Projection Fit Into155
Crank Case Groove155
First Tightening Torque : 10 N · M (7 Lb · Ft) [1.0 Kgf · M]155
Second Tightening Torque : 23.5 N · M (17 Lb · Ft) [2.4 Kgf · M]155
First Tightening Torque : 6 N · M (4 Lb · Ft) [0.6 Kgf · M]155
Second Tightening Torque : 11.5 N · M (8.5 Lb · Ft) [1.2 Kgf · M]155
Installation Of Timing Belt157
Installation Of Power Unit166
Removing Recoil Starter166
Adjustment Of Starter Lock Cable166
Disassembly Of Recoil Starter167
Inspection Of Recoil Starter168
Installation Of Recoil Starter169
Gear Case173
Drive Shaft Housing174
Drive System & Water Pump175
Draining Gear Oil177
Removing Propeller177
Removing Lower Unit178
Disassembly Of Water Pump178
Removing Propeller Shaft Housing Ass'y179
Disassembly Of Propeller Shaft Ass'y180
Inspection Of Propeller Shaft180
Assembly Of Propeller Shaft Ass'y180
Disassembly Of Propeller Shaft Housing181
Inspection Of Propeller Shaft Housing182
Assembly Of Propeller Shaft Housing183
Disassembly Of Pump Case (Lower)184
Assembly Of Pump Case (Lower)184
Removing Clutch Cam And Cam Rod184
Inspection Of Cam Rod And Clutch Cam185
Assembly Of Cam Rod And Clutch Cam185
Removing Drive Shaft185
Disassembly Of Drive Shaft185
Inspection Of Drive Shaft186
Removing Forward (A) Gear186
Inspection Of Pinion Gear187
Assembly Of Forward (A) Gear187
Assembly Of Drive Shaft187
Disassembly Of Gear Case188
Needle Bearing188
Inspection Of Gear Case189
Assembly Of Lower Unit189
Assembly Of Gear Case189
Cam Rod Bushing Bolt189
Backlash Measuring Tool Kit190
Installation Of Pinion (B) Gear192
Determination Of Forward Gear Backlash193
Reassembly Of Pinion (B) Gear Nut195
Reassembly Of Pump Case (Lower)196
Assembly Of Water Pump196
Installation Of Lower Unit198
Swivel Bracket202
Clamp Bracket & Reverse Lock203
Tiller Handle204
Bottom Cowl205
Shift & Stop Switch206
Shift (For Ep)207
Inspection Of Throttle Cable209
Installation Of Tiller Handle209
Adjustment Of Co-Pilot Plate210
Removing Drive Shaft Housing210
Assembly Of Drive Shaft Housing214
Installation Of Drive Shaft Housing Ass'y215
Disassembling Clamp Bracket219
Assembly Of Clamp Bracket220
Electrical System222
Electrical Component Layout224
Port Side View224
Bow Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯225
Starboard Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯226
Top View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯227
Back View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯228
Parts Laout229
Starter Motor231
Ignition System And Ignition Control System233
Inspection Of Plug Cap ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯234
Inspection Of Pulser Coil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯235
Inspection Of Oil Pressure Switch236
Inspection Of Exciter Coil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯236
Inspection Of Neutral Switch (Tiller Handle Model)237
Inspection Of Start Switch (Tiller Handle Model)237
Starting System238
Inspection Of Fuse238
Inspection Of Starter Solenoid238
Inspection Of Stop Switch ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯238
Inspection Of Starter Motor Pinion239
Inspection Of Armature239
Disassembly Of Starter Motor ⋯⋯⋯⋯⋯⋯⋯⋯239
Inspection Of Brushes ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯240
Inspection Of Starter Motor Operation241
Battery Charging System241
Inspection Of Rectifier241
Rectifier Tester Check Chart241
Cd Unit Coupler242
Troubleshooting244
Troubleshooting Chart245
Engine Will Not Start246
Ignition System248
Compression Pressure ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯251
Engine Starts But Stalls Soon252
Compression Pressure254
Idle Engine Speed Will Not Stabilize255
Rapid Opening Of Throttle Fails Acceleration. ⋯⋯⋯⋯256
Gear Shifting Cannot Be Made Normally257
Warning Indication258
Display For Abnormalities During Operation258
Wiring Diagram260