Contents - TOHATSU MFS 9.9 Owner's Manual

1.Service Information
1. Identification (Engine Serial Number)
2. Work Safety
1) Fire Prevention ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-2
2) Ventilation ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-2
3) Protection ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-2
4) Genuine Parts ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-2
5) Tools ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯1-3
6) Recommendations on Service ⋯⋯⋯⋯⋯⋯⋯⋯ 1-3
7) Cautions in Disassembling and
Assembling Components ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-4
3. Tools and Instruments
1) Test Propeller ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-5
2) Measuring Instruments ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-5
3) Special Tools⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-6
4. Pre-delivery Inspection
1) Steering Handle ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9
2) Gear Shift ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9
3) Engine Oil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9
4) Gear Oil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9
5) Fuel Line ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-10
6) Rigging ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-10
7) Manual Tilt ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-10
8) Inspection of Starting Switch and Stop Switch ⋯ 1-11
9) Cooling Water Check Port ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-12
10)Idling ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-12
11) Propeller Selection ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-12
12) Trim Tab ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-13
5. Break-in Operation
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-14
6. Test Run
7. Check After Test Run
1. Outline Dimensons
1) Engine outer dimensions⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-2
2) Transom Bolts ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-3
2. Fuel Feed System
1) Fuel Feed Route ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-4
3. Engine Lubrication System Diagram
4. Cooling Water System Diagram
5. Specifications
6. Maintenance Data
7. Tightening Torque Specifications
2.Service Data
1. Outline Dimensons
1) Engine outer dimensions⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-2
2) Transom Bolts ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-3
2. Fuel Feed System
1) Fuel Feed Route ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-4
3. Engine Lubrication System Diagram
4. Cooling Water System Diagram
5. Specifications
6. Maintenance Data
7. Tightening Torque Specifications
8. Sealant and Lubricant
3.Maintenance
1. Special Tools
2. Inspection Schedule
3. Inspection Items
1) Inspection of Top Cowl ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-4
2) Fuel System ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-4
3) Inspection of Fuel Tank ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-5
4) Inspection of Fuel Filter ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-5
5) Replacement of Engine Oil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-6
6) Replacement of Oil Filter⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-7
7) Inspection of Gear Oil Quantity ⋯⋯⋯⋯⋯⋯⋯⋯ 3-8
8) Inspection of Water Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-8
9) Replacement of Gear Oil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-10
10) Inspection of Gear Case (for leakage) ⋯⋯⋯⋯ 3-11
11) Inspection of Timing Belt ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-12
12) Replacement of Timing Belt ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-13
13) Installatin of Timing Belt ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-15
14) Inspection of Spark Plugs ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-17
15) Inspection of Compression Pressure ⋯⋯⋯⋯⋯ 3-18
16) Inspection and Adjustment of Valve Clearance⋯ 3-19
17) Throttle Cable For F type ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-20
4st 9.9/15/20 2008
⋯⋯ 1-2
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-2
⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-5
⋯⋯⋯⋯⋯⋯⋯⋯ 1-9
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-13
⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-14
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-2
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-4
⋯⋯⋯2-5
⋯⋯⋯⋯ 2-6
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-7
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-10
⋯⋯⋯⋯ 2-18
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-2
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-4
⋯⋯⋯2-5
⋯⋯⋯⋯ 2-6
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-7
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-10
⋯⋯⋯⋯ 2-18
⋯⋯⋯⋯⋯⋯⋯⋯ 2-19
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-2
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-3
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-4
18) Throttle Cable Adjustment of Throttle Link
19) Inspection of Gear Shift Operation ⋯⋯⋯⋯⋯⋯ 3-27
20) Inspection of Idle Engine Speed ⋯⋯⋯⋯⋯⋯⋯ 3-29
21) Inspection of Ignition Timing⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-29
22) Inspection of Anode ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-30
23) Replacement of Anode ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-30
24) Inspection of Propeller ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-31
25) Inspection of Thermostat ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-31
26) Inspection of Cooling Water Passage⋯⋯⋯⋯⋯ 3-32
27) Flushing with Water ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-33
28) Inspection of Battery ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-34
29) Greasing Points ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯3-35
4.Fuel System
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-2
1. Special Tools
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-3
2. Parts Layout
Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-3
Intake Manifold & Fuel Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-5
3. Carburetor Inner Passages
1) Idling Passage ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-6
2) Off-Idle Passage ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-7
3) High Speed Passage ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-8
4) Acceleration Passage ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-9
5) Choking Passage ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-10
4. Inspection Items
1) Removing Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-11
Remote Control Model ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-11
Tiller Handle Model ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-12
2) Disassembling Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-14
3) Cleaning and Inspection ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-16
4) Inspection of Fuel Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-17
5) Inspection of Fuel Connector ⋯⋯⋯⋯⋯⋯⋯⋯ 4-18
6) Assembling Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-18
7) Adjusting Float Height ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-20
8) Installing Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-20
5.Power Unit
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-2
1. Special tools
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-3
2. Parts Layout
Engine ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-3
Magneto⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-4
Electric Parts⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-5
Intake Manifold & Fuel Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-6
Camshaft & Oil Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-7
Cylinder Head ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-8
Intake Valve & Exhaust Valve ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-9
Cylinder ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-10
Piston & Crankshaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-11
Recoil Starter ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-12
Top Cowl ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-13
3. Inspection Items
1) Inspection of Comperession Pressure ⋯⋯⋯⋯ 5-14
2) Inspection of Oil Pressure⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-15
3) Inspection of Valve Clearance ⋯⋯⋯⋯⋯⋯⋯⋯ 5-16
4) Removing Power Unit ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-18
5) Removing Plunger and Oil Starter ⋯⋯⋯⋯⋯⋯ 5-20
6) Inspection of Oil Strainer ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-20
7) Flywheel and Electrical Components ⋯⋯⋯⋯⋯ 5-20
8) Removing Timing Belt and Pulley ⋯⋯⋯⋯⋯⋯ 5-22
9) Inspection of Timing Belt ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-23
10) Installation of Pulley and Timing Belt ⋯⋯⋯⋯⋯ 5-24
11) Removing Cylinder Head ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-27
12) Inspection of Valve Spring ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-29
13) Inspection of Valve⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-30
14) Inspection of Valve Guide ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-30
15) Inspection of Valve Seat ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-31
16) Correction of Valve Seat ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-32
17) Inspection of Locker Arm and Rocker Arm Shaft 5-34
18) Inspection of Cam Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-35
19) Inspection of Cylinder Head ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-36
20) Inspection of Oil Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-37
21) Installation of Valves ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-38
22) Installation of Cam Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-39
23) Installation of Rocker Arm Shaft ⋯⋯⋯⋯⋯⋯⋯ 5-39
24) Installation of Oil Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-40
25) Installation of Cylinder Head⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-41
26) Disassembly of Cylinder Block⋯⋯⋯⋯⋯⋯⋯⋯ 5-42
27) Inspection of Piston Outer Diameter ⋯⋯⋯⋯⋯ 5-43
⋯⋯ 3-22
⋯⋯⋯⋯⋯⋯ 4-6
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-11
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-14
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