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TOHATSU 9.9 Service Manual

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Owner's manual (64 pages)

Table of Contents

Contents
Specifications
Precautions During Work
Service Data
Service Data and Maintenance Standards Chart
Thermostat Switching Test
Periodic Inspection Chart
Table of Sealants, Adhesives, Lubricating Oils and Usage Locations
Table of Tightening Torques
Tools and Instruments Required for Disassembly, Maintenance and Repair
How to Use Special Tools
Flywheel Magneto Tool
Piston Pin Tool
Spring Pin Tool
Needle Roller Bearing Tool
Needle Roller Bearing in Propeller Shaft Housing
Needle Roller Bearing of Gear Case
Socket and Wrench for Bevel Gear B Nut
Clutch Pin Snap Tool
Backlash Measuring Tool
Bevel Gear a Bearing Puller
Power Unit
Removal of Power Unit
Removal of Accessories/Starter Motor
Removal of Recoil Starter
Removal of Flywheel Magneto
Removal of Carburetor/CD Unit and Ignition Coil/Thermostat
Cylinder and Crank Case Assembly
Piston and Crank Shaft
Engine Disassembly
Removal of Cylinder Head/Exhaust Cover and Engine Anode
Removial of Inlet Manifold and Reed Valve
Removal of Crank Case and Crankshaft
Removal of Piston
Engine Assembly
Installing the Piston
Installing the Crank Shaft and Crank Case
Engine Assembly Procedure
Installation of Reed Valve and Inlet Manifold
Installation of Exhaust Cover and Engine Anode
Installation of Cylinder Head
Throttle Mechanism and Bar Handle Exploded View
Installation and Adjustment of Accessories
Installation of Flywheel Magneto/Fuel Lines
Adjustment of Throttle Mechanism
Procedure for Adjusting Ignition Timing When Opening the Throttle Fully
Procedure for Adjusting Ignition Timing When the Throttle Is Fully Closed
Adjusting Sliding Motion of the Advancer Arm
Adjusting Opening of Throttle Toward the Reverse Side
Inspecting Starter Locking Cam
Standards for Engine Oil and O-Ring
Installation of Starter Motor
Recoil Starter and Starter Lock Exploded View
Recoil Starter Disassembly
Recoil Starter Assembly
Applying Initial Load on the Starter Spring
Checking the Force Acting on the Ratchet
Lower Unit
Drive Shaft Housing and Gear Case Exploded View
Disassembly of Gear Case
Removal of Gear Case
Disassembly of Water Pump Case
Removal of Propeller
Disassembly of Propeller Shaft and Clutch
Removal of Clutch Cam and Cam Rod
Removal of Bevel Gear and Drive Shaft
Gear Case Assembly
Installation of Bevel Gear and Drive Shaft
Installation of Clutch Cam and Cam Rod
Backlash Adjustment between Bevel Gears a and B
Assembly of Water Pump Case
Assembly of Propeller Shaft and Clutch
Propeller Installation
Installation of Gear Case
Standards for Oil Seals and O Rings for Gear Case
Disassembly of Lower Motor Cover and Drive Shaft Housing
Removal of Lower Motor Cover
Removal of Exhaust Pipe and Water Pipe
Bracket and Reverse Lock (Type I) Exploded View
Bracket and Reverse Lock (Type II) Exploded View
Disassembly of Stern Bracket/Swiveling Bracket
Disassembly of Drive Shaft Housing
Drive Shaft Housing and Mounting Bracket
Assembly of Lower Motor Cover and Drive Shaft Housing
Assembly of Drive Shaft Housing
Installation of Exhaust Pipe and Water Pipe
Installation of Lower Motor Cover/Choke Lever
Assembly of Gear Shift Lever
Shift Lever Adjustments
Installation of Motor Cover
Disassembly of Steeging System, Hanle and Bracket
Removal of Steering Shaft Assembly
Disassembly of Steering System
Removal of Steering Handle
Assembly of Steering System, Handle and Bracket
Assembly of Stern Bracket
Adjustment of Reverse Lock
Installation of Steering Handle
Assembling the Steering System
Carburetor
Carburetor - Exploded View/Outline of Operation
Pilot System: Flow of Fuel Mixture During Start and Idling/Slow Operation
Main System: Flow of Fuel Mixture for Operations above Medium Speed
Float System
Carburetor - Inspections
Inlet (Carburetor with Reed Valve/Fuel Pump) Exploded View
Electrical System
Flywheel Magneto and CD Unit Exploded View
CD Magneto Construction and Maintenance
Flywheel Inspection and Maintenance
Coil Plate and Coils
CD Unit - Inspection and Maintenance
To Test CD Unit/Test Check Table
Ignition Coils Inspection and Judgement
Stop Switch Inspection and Maintenance
Inspection of Connecting Wires and Contacts
Precautions in Handling the CD Magneto
Electrical Starter Exploded View
Precautions During Electrical System Tests and Trials
Electric Cicruit (EP Type) Diagram
Electric Cicruit (EF Type) Diagram
Inspection of Parts Related to Electric Starter
Inspection after Mounting or Repair of Starter Motor Accessories
Starter Motor Periodic Inspection Chart
Starter Motor Inspection and Maintenance
Checking the Starter Solenoid
Complete Check of Rectifier
Main Switch (EP, Ef)/Neutral Switch Checks
Remote Control
Engine Side Mounting Kit for Remote Control Exploded View
Installation of Remote Control Cables
Control Box Installation (Driver's Side)
Installation of Remote Control Cables at Engine
Remote Control Installed Illustration
Inspections, Adjustments and Trials
Testing Tank and Dynamometer
Conditions and Precautions for Testing Tank
Adjustments and Operational Checks of Outboard Motor
Inspections and Adjustments after Final Assembly
Troubleshooting

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Page 103 Copyright © 2007 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Tohatsu Corporation.

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