TOHATSU MFS 9.9 Manuals

Manuals and User Guides for TOHATSU MFS 9.9. We have 2 TOHATSU MFS 9.9 manuals available for free PDF download: Owner's Manual, Service Manual

TOHATSU MFS 9.9 Owner's Manual (267 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 11 MB

Introduction
2
Safety Information
2
Safety Statements
2
What Is the si Unit System?
4
Description of Pictograph
5
Contents
6
Table of Contents
7
Index
8
Service Information
10
Fire Prevention
11
Identification
11
Ventilation
11
Work Safety
11
Recommendations on Service
12
Tools
12
Measuring Instruments
14
Test Propeller
14
Tools and Instruments
14
Special Tools
15
Engine Oil
18
Gear Shift
18
Pre-Delivery Inspection
18
Steering Handle
18
Fuel Line
19
Manual Tilt
19
Rigging
19
Inspection of Starting Switch and Stop Switch
20
Cooling Water Check Port
21
Idling
21
Propeller Selection
21
Range of Operating Engine Speed at WOT
21
Break-In Operation
22
Example of Trim Tab Angle Adjustment
22
Trim Tab
22
Checks after Test Run
23
Idling Revolution Speed
23
Tachometer
23
Test Run
23
Service Data
26
Engine Outer Dimensions
27
Outline Dimensions
27
Mechanical Tilt Model
28
Transom Bolts
28
Fuel Feed Route
29
Fuel Feed System
29
Engine Lubrication System Diagram
30
Cooling Water System Diagram
31
Dimensions
32
Performance
32
Specifications
32
Weight
32
Fuel and Oil
33
Lower Unit
33
Power Unit
33
Bracket
34
Optional Parts
34
Warning System
34
Maintenance Data
35
Tightening Torque Specifications
43
Sealant and Lubricant
44
Maintenance
48
Inspection Schedule
50
Check Piping
51
Fuel System
51
Inspection of Top Cowl
51
Inspection of Fuel Filter
52
Inspection of Fuel Tank
52
Oil Level
53
Oil Specification
53
Quantity of Engine Oil
53
Replacement of Engine Oil
53
Replacement of Oil Filter
54
Inspection of Gear Oil Quantity
55
Inspection of Water Pump
55
Replacement of Gear Oil
57
Inspection of Gear Case (for Leakage)
58
Specified Gear Case Maintained Pressure
58
Inspection of Timing Belt
59
Replacement of Timing Belt
60
Installatin of Timing Belt
62
Inspection of Spark Plugs
64
Inspection of Compression Pressure
65
Inspection and Adjustment of Valve Clearance
66
For F Type
67
Throttle Cable
67
Adjustment of Throttle Link
69
Inspection of Gear Shift Operation
74
Inspection of Idle Engine Speed
76
Inspection of Ignition Timing
76
Inspection of Anode
77
Replacement of Anode
77
Inspection of Propeller
78
Inspection of Thermostat
78
Inspection of Cooling Water Passage
79
Flushing with Water
80
Flushing with Water Using Drive Cleaner 3
80
Battery
81
Charging Requirements
81
Inspection of Battery
81
Specific Gravity of Electrolyte
81
Greasing Points
82
Special Tools
85
Carburetor
86
Parts Layout
86
- Intake Manifold & Fuel Pump
  88
- Carburetor Inner Passages 1) Idling Passage
  89
- Off-Idle Passage
  90
- High Speed Passage
  91
- Acceleration Passage
  92
- Choking Passage
  93
  - Inspection Items
    94
  - Remote Control Model
    94
  - Removing Carburetor
    94
- Tiller Handle Model
  95
- Disassembling Carburetor
  97
- Cleaning and Inspection
  99
- Inspection of Fuel Pump
  100
- Assembling Carburetor
  101
- Inspection of Fuel Connector
  101
- Adjusting Float Height
  103
- Float Height a
  103
- Installing Carburetor
  103
  - Inspection of Connecting Rod Small End Inner Diameter ⋯
    104
  - Magneto
    107
  - Electric Parts
    108
  - Camshaft & Oil Pump
    110
  - Cylinder Head
    111
  - Intake Valve & Exhaust Valve
    112
  - Cylinder
    113
  - Piston & Crankshaft
    114
  - Recoil Starter
    115
  - Top Cowl
    116
  - Inspection of Oil Pressure
    118
  - Inspection of Valve Clearance
    119
  - Rocker Arm Lock Nut 5
    120
  - Valve Clearance (When Engine Is Cold)
    120
  - Removing Power Unit
    121
  - Inspection of Oil Strainer
    123
  - Removing Plunger and Oil Strainer
    123
  - Removing Timing Belt and Pulley
    125
  - Installation of Pulley and Timing Belt
    127
  - Removing Cylinder Head
    130
  - Inspection of Valve Spring
    132
  - Inspection of Valve
    133
  - Inspection of Valve Guide
    133
  - Inspection of Valve Seat
    134
  - Correction of Valve Seat
    135
  - Inspection of Cam Shaft
    138
  - Inspection of Cylinder Head
    139
  - Functional Limit
    140
  - Inspection of Oil Pump
    140
  - Installation of Valves
    141
  - Installation of Cam Shaft
    142
  - Installation of Rocker Arm Shaft
    142
  - Installation of Oil Pump
    143
  - Cylinder Head Bolts (M6)
    144
  - Cylinder Head Bolts (M8)
    144
  - Installation of Cylinder Head
    144
  - Disassembly of Cylinder Block
    145
  - Inspection of Cylinder Inner Diameter
    146
  - Inspection of Piston Outer Diameter
    146
  - Inspection of Piston Clearance
    147
  - Inspection of Piston Ring Side Clearance
    147
  - Inspection of Piston Rings
    147
  - Inspection of Connecting Rod
    148
  - Inspection of Connecting Rod Big End Side Clearance
    148
  - Inspection of Piston Pins
    148
  - Small End Inner Diameter
    148
  - Inspection of Crank Shaft
    149
  - Inspection of Crank Pin Oil Clearance
    150
- Be Sure that Individual Bearings Are Installed
  151
- Crankshaft Main Journal Oil Inspection of Clearance
  151
- To Their Original Locations
  151
  - Color of Inner Diameter Code
    152
  - Inner Diameter of Cylinder
    152
  - Thickness of Metal Bearing
    152
  - Assembling Piston and Connecting Rod
    153
- Cylinder Block Groove
  154
- Crank Case Groove
  155
- First Tightening Torque : 10 N · M (7 Lb · Ft) [1.0 Kgf · M]
  155
- First Tightening Torque : 6 N · M (4 Lb · Ft) [0.6 Kgf · M]
  155
- Install Bearings with Their Projection Fit into
  155
- Second Tightening Torque : 11.5 N · M (8.5 Lb · Ft) [1.2 Kgf · M]
  155
- Second Tightening Torque : 23.5 N · M (17 Lb · Ft) [2.4 Kgf · M]
  155
  - Installation of Timing Belt
    157
  - Adjustment of Starter Lock Cable
    166
  - Installation of Power Unit
    166
  - Removing Recoil Starter
    166
  - Disassembly of Recoil Starter
    167
  - Inspection of Recoil Starter
    168
  - Installation of Recoil Starter
    169
- Gear Case
  173
- Parts Layout
  173
- Drive Shaft Housing
  174
- Drive System & Water Pump
  175
- Draining Gear Oil
  177
- Inspection Items
  177
- Removing Propeller
  177
- Disassembly of Water Pump
  178
- Removing Lower Unit
  178
- Inspection of Water Pump
  179
- Removing Propeller Shaft Housing Ass'y
  179
- Assembly of Propeller Shaft Ass'y
  180
- Disassembly of Propeller Shaft Ass'y
  180
- Inspection of Propeller Shaft
  180
- Disassembly of Propeller Shaft Housing
  181
- Inspection of Propeller Shaft Housing
  182
- Assembly of Propeller Shaft Housing
  183
- Assembly of Pump Case (Lower)
  184
- Disassembly of Pump Case (Lower)
  184
- Removing Clutch Cam and Cam Rod
  184
  - Assembly of Cam Rod and Clutch Cam
    185
  - Disassembly of Drive Shaft
    185
  - Inspection of Cam Rod and Clutch Cam
    185
  - Removing Drive Shaft
    185
- Inspection of Drive Shaft
  186
- Removing Forward (A) Gear
  186
- Assembly of Drive Shaft
  187
- Assembly of Forward (A) Gear
  187
  - Inspection of Pinion Gear
    187
  - Disassembly of Gear Case
    188
  - Needle Bearing
    188
- Assembly of Gear Case
  189
- Assembly of Lower Unit
  189
- Cam Rod Bushing Bolt
  189
- Inspection of Gear Case
  189
- Backlash Measuring Tool Kit
  190
- Installation of Pinion (B) Gear
  192
- Determination of Forward Gear Backlash
  193
- Assembly of Propeller Shaft Housing
  195
- Reassembly of Pinion (B) Gear Nut
  195
- Assembly of Water Pump
  196
- Reassembly of Pump Case (Lower)
  196
- Installation of Lower Unit
  198
Swivel Bracket
202
Clamp Bracket & Reverse Lock
203
Tiller Handle
204
- Bottom Cowl
  205
- Shift & Stop Switch
  206
- Shift (for EP)
  207
- Inspection of Throttle Cable
  209
- Installation of Tiller Handle
  209
- Adjustment of Co-Pilot Plate
  210
- Removing Drive Shaft Housing
  210
- Assembly of Drive Shaft Housing
  214
- Installation of Drive Shaft Housing Ass'y
  215
- Disassembling Clamp Bracket
  219
- Assembly of Clamp Bracket
  220
- Electrical System
  222
- Special Tools
  223
- Electrical Component Layout
  224
- Magneto
  229
- Parts Laout
  229
- Electric Parts
  230
- Starter Motor
  231
- Shift & Stop Switch
  232
- Ignition System and Ignition Control System
  233
- Inspection of Neutral Switch (Tiller Handle Model)
  237
- Inspection of Start Switch (Tiller Handle Model)
  237
- Starting System
  238
- Battery Charging System
  241
- Inspection of Rectifier
  241
- Inspection of Starter Motor Operation
  241
- Rectifier Tester Check Chart
  241
- CD Unit Coupler
  242
- Troubleshooting
  244
- Troubleshooting Chart
  245
- Engine will Not Start
  246
- Power Unit
  246
- Engine will Not Start
  247
Ignition System

248
- Fuel System
  250
- Gear Shifting Cannot be Made Normally
  257
  - Warning Indication
    258
- Display for Abnormalities During Operation
  258
Wiring Diagram

260

TOHATSU MFS 9.9 Service Manual (29 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 1 MB

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