TOHATSU MFS 9.9CY Manuals

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

TOHATSU MFS 9.9CY Service Manual (364 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 73 MB

Before Reading this Manual
3
Safety Information
3
About this Manual
4
Table of Contents
7
Service Information
14
Identification (Engine Serial Number)
14
Ensuring Work Safety
14
Fire Prevention
14
Ventilation
14
Protection
15
Genuine Parts
15
Tools
15
Recommendations on Service
15
Cautions in Disassembling and Assembling Components
16
Tools and Instruments
17
Test Propeller
17
Measuring Instruments
17
Special Tools
18
Pre-Delivery Inspection
20
Steering Handle
20
Gear Shift
20
Engine Oil
21
Gear Oil
21
Fuel Line
21
Rigging
21
Inspection of Manual Tilt (MF, EF, EP)
22
Inspection of PT Unit (EFT, EPT)
22
Inspection of Starting Switch and Stop Switch
22
Cooling Water Check Port
24
Idling
24
Propeller Selection
24
Trim Tab
25
Break-In Operation
26
Test Run
26
Checks after Test Run
27
Service Data
29
Outline Dimensions
30
Engine Dimensions
30
Transom Bolts
32
Fuel Injection System
34
ECU Fuel Feed System
34
Engine Lubrication System Diagram
35
Cooling Water System Diagram
36
Specifications
37
Maintenance Data
40
Correction Method
41
Standard Value
46
Tightening Torque Data
48
Sealant Application Locations
50
Maintenance
59
Special Tools
60
Inspection Schedule
61
Inspection Items
62
Inspection of Top Cowl
62
Inspection of Fuel System Piping
62
Inspection of Fuel Tank
63
Inspection of Fuel Filter
63
Replacement of Engine Oil
64
Inspection of Gear Oil Quantity
66
Inspection of Water Pump
66
Replacement of Gear Oil
68
Inspection of Gear Case (for Leakage)
69
Inspection of Timing Belt
70
Replacement of Timing Belt
71
Inspection of Spark Plugs
76
Inspection of Compression Pressure
77
Inspection and Adjustment of Valve Clearance
78
Adjustment of Throttle Cable (Tiller Handle Model)
80
Adjustment of Shift/Throttle Cable (Remote Control Model)
82
Inspection of Shift Lever Gear Operations
86
Inspection of Idle Speed
87
Inspection of Ignition Timing
88
Inspection of Anodes
89
Replacement of Anodes
90
Replacement of Cooling Water Passage Anode (Cylindrical Shape)
90
Inspection of Propeller
91
Inspection of Thermostat
91
Inspection of Cooling Water Passage
92
Flushing with Water
93
Inspection of Battery
94
Grease Points
95
Fuel System (Fuel Injection)
97
Special Tools
98
Piping Arrangement Diagram
99
Fuel Hose, Vent Hose, Breather Hose
99
Port Side
99
Cooling Water Hose
99
Parts Layout
100
Intake Manifold & Fuel Pump
100
Magneto & Electric Parts
106
Fuel Tank
110
ECU System
111
Configuration of ECU System
111
Sensors
112
Actuators
114
Control System (ECU)
115
Control System
115
Fuel Injection Control
116
Start up Fuel Mapping
116
Acceleration Fuel Mapping
116
Deceleration Fuel Mapping
116
Engine Temperature Correction
116
Control of Fuel Feed Pump (FFP)
117
Control of Tachometer
117
Warning Buzzer and Lamp (LED), and Control of Engine Revolution Speed
118
Location of Warning Buzzer and Lamp (LED)
118
Waring Notification, Abnormality and Action to be Taken
118
Ignition System
119
Configuration of Ignition System
119
Ignition Control
120
Ignition Timing Control
120
Ignition and Combustion Order
120
Ignition Timing
120
Operations
120
Fuel Feed System
121
Components of Fuel Feed System
122
Fuel Pump [Low Pressure Mechanical Pump]
122
Vapor Separator
122
Fuel Regulator
123
Fuel Cooler
123
Outline of Fuel Injection System
124
Air Intake System
124
Inspection Items
125
Inspection of Fuel Supply System
125
Inspection of Filter
125
Inspection of Fuel Pump
127
Inspection of Fuel Connector
127
Measurement of Fuel Pressure
128
Draining Fuel
129
Disassembly of Vapor Separator
129
Inspection of Vapor Separator
130
Reassembly of Vapor Separator
131
Inspection of ISC (Idle Speed Control)
131
Inspection of Idle Speed
131
Power Unit
134
Special Tools
134
Measuring Compression Pressure
134
Parts Layout
135
Engine
135
Magneto & Electric Parts
136
Intake Manifold & Fuel Pump
140
Pulley & Timing Belt
146
Cylinder Head & Oil Pump
148
Cylinder & Crankcase
150
Piston & Crankshaft
152
Top Cowl
154
Recoil Starter
156
Inspection Items
158
Inspection of Compression Pressure
158
Inspection of Oil Pressure
158
Inspection of Valve Clearance
158
Removal of Power Unit
158
Removing Oil Strainer
161
Inspection of Oil Strainer
161
Removing Timing Belt and Pulley
161
Inspection of Timing Belt
164
Installation of Pulley and Timing Belt
165
Removal of Cylinder Head
168
Inspection of Valve Spring
174
Inspection of Valve
174
Inspection of Valve Guide
175
Inspection of Valve Seat
176
Correction of Valve Seat
177
Inspection of Rocker Arm and Rocker Arm Shaft
179
Inspection of Camshaft
180
Inspection of Cylinder Head
181
Inspection of Oil Pump
182
Installation of Valves
183
Installation of Camshaft
184
Installation of Rocker Arm Shaft
184
Installation of Oil Pump
185
Installation of Cylinder Head
186
Disassembly of Cylinder Block
188
Inspection of Piston Outer Diameter
189
Inspection of Cylinder Inner Diameter
189
Inspection of Piston Clearance
190
Inspection of Piston Ring Side Clearance
190
Inspection of Piston Ring
190
Inspection of Piston Pin
191
Inspection of Connecting Rod Small End Inner Diameter
191
Inspection of Connecting Rod Big End Side Clearance
191
Inspection of Crankshaft
192
Inspection of Crank Pin Oil Clearance
193
Inspection of Crankshaft Main Journal Oil Clearance
194
Inner Diameter of Cylinder/Crankcase Bearing Holder (Inner Diameter Codes)
195
Thickness of Metal Bearing (Color of Inner Diameter Code)
195
Installation of Piston and Connecting Rod
196
Assembling Electrical System and Fuel System Parts
200
Installation of Oil Strainer
205
Installation of Power Unit
205
Adjustment of Starter Lock Cable
208
Disassembly of Recoil Starter
208
Inspection of Recoil Starter
209
Installation of Recoil Starter
209
Lower Unit
212
Special Tools
212
Parts Layout
214
Drive Shaft Housing
214
Gear Case
216
Inspection Items
220
Draining Gear Oil
220
Removal of Propeller
220
Removal of Lower Unit
221
Disassembly of Water Pump
221
Inspection of Water Pump
222
Removal of Clutch Cam and Cam Rod
222
Disassembly of Clutch Cam and Cam Rod
223
Inspection of Cam Rod and Clutch Cam
223
Assembly of Clutch Cam and Cam Rod
223
Removal of Pump Case (Lower)
223
Disassembly of Pump Case (Lower)
223
Assembly of Pump Case (Lower)
224
Disassembly of Propeller Shaft Assy
224
Inspection of Propeller Shaft
225
Assembly of Propeller Shaft Assy
225
Disassembly of Propeller Shaft Housing
225
Inspection of Propeller Shaft Housing
226
Assembly of Propeller Shaft Housing
226
Removal of Drive Shaft
227
Inspection, Disassembly, and Assembly of Drive Shaft
227
Removal of Bevel Gear Assy a and Bearing
229
Inspection of Bevel Gear Assy a and Bevel Gear B
229
Disassembly of Gear Case
230
Inspection of Gear Case
230
Assembly of Gear Case
231
Installation of Bevel Gear Assy a
233
Installation of Bevel Gear B
233
Installation of Propeller Shaft Housing
236
Installation of Water Pump
237
Installation of Lower Unit
239
Parts Layout
242
Bottom Cowl & Shift
256
Inspection Items
261
Inspection of Throttle Cable
261
Installation of Tiller Handle
261
Adjustment of Co-Pilot Plate
263
Disassembly of Drive Shaft Housing
265
Installation of Drive Shaft Housing Assy
268
Removal of Steering Shaft
269
Installation of Steering Shaft
270
Disassembly of Clamp Bracket (MF & EF Models)
273
Installation of Clamp Bracket
274
(MF & EF Models)
274
Inspection of Reverse Lock
275
(MF & EF & EP Models)
275
Parts Layout (PT Model)
278
Bracket (EFT & EPT Models)
278
Power Tilt Assy
282
Power Tilt Functions
283
Operations of Hydraulic Circuit
283
Manual Tilt Operation
283
Tilt up Operation
284
Tilt down Operation
285
Shock Absorber Valve
286
Thermal Valve
287
Removal of PT Unit
288
Removal and Inspection of Manual Valve
290
Motor
291
Removal, Inspection, and Repair of PT Motor
291
Continuity Test
292
Inspection of Motor
292
Replacement of Motor
292
Assembly of PT Motor
293
Pump
294
Disassembly of PT Pump
294
Assembly of PT Pump
296
Air-Purging PT Unit (Separated from Outboard Motor)
298
Installation of PT Assy
299
Inspection of PT Solenoid
301
Inspection of PT Switch
302
Electrical System
304
Special Tools
304
Bow Side View
306
Starboard Side View
307
Housing Cover (Front)
308
Parts Layout
310
Magneto & Electric Parts
310
Intake Manifold & Fuel Pump
314
The Ignition System and the Ignition Control System
320
Inspection of the Ignition Spark
320
Inspection of the Plug Cap
320
Inspection of the Ignition Coil
321
Inspection of the ECU Coil (Exciter Coil)
321
Inspection of the Pulser Coil
322
Adjustment of the Pulser Coil Air Gap
322
Inspection of the Oil Pressure Switch
323
Inspection of the Engine Temperature Sensor
324
Inspection of the Neutral Switch (Except for MF)
324
Inspection of the Main Switch Assy (EF, EFT)
325
Inspection of the Main Switch Assy (Key)
325
Inspection of the Stop Switch Assy
326
The Fuel Control System
327
Inspection of the Injector
327
Inspection of the ISC Valve
327
Inspection of the T-MAP Sensor
328
Inspection of the Fuel Feed Pump (FFP)
328
Inspection of the Throttle Position Sensor (TPS)
329
The Starting System (Except for MF)
329
Inspection of the Fuse
329
Inspection of the Starter Solenoid Switch
329
Disassembly of the Starter Motor Assy
330
Inspection of the Pinion Assy
330
Inspection of the Armature
330
Inspection of the Brush
331
Operation Test of Starter Motor Assy
332
The Charging System (Except for MF)
332
Inspection of the Charge Coil
332
Inspection of the Rectifier
332
ECU Coupler
333
Troubleshooting List
336
Power Unit
337
Starting System
337
Ignition System
339
Fuel System
341
(Defective Acceleration or Deceleration)
343
Ignition System
344
Fuel System
345
Lubrication System
346
Cooling System
347
State 3 Engine Rotation Is Unstable or Hunting Occurs in Low Speed Range
348
Ignition System
349
Fuel System
350
Unit
351
State 1 PT Unit will Not Operate
351
State 2 PT Unit Is Not Capable of Sustaining the Outboard Motor
352
Diagnosis
353
Wiring Diagram
355
Wiring Chart
356

TOHATSU MFS 9.9CY Owner's Manual (90 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 2 MB

Table of Contents
7
General Safety Information
10
Specifications
12
Parts Name
17
Label Locations
20
Installation
23
- Mounting the Outboard Motor on Boat
  23
- Battery Installation
  25
Pre-Operating Preparations
27
- Fuel Handling
  27
- Fuel Filling
  28
- Engine Oil Filling
  29
- Break-In
  31
- Warning System
  32
Engine Operation
34
- Before Starting
  34
- Fuel Feeding
  34
- Starting the Engine
  35
- Warming up the Engine
  41
- Forward, Reverse, and Acceleration
  42
- Stopping the Engine
  44
- Steering
  46
- Trim Angle
  46
- Tilt up and down
  49
- Shallow Water Operation
  52
Removing and Carrying the Outboard Motor
54
- Removing the Outboard Motor
  54
- Carrying the Outboard Motor
  54
- Trailering
  55
Adjustment
57
- Steering Friction
  57
- Throttle Grip Friction
  57
- Remote Control Lever Friction
  58
- Trim Tab Adjustment
  58
Inspection and Maintenance
60
- Daily Inspection
  61
- Periodic Inspection
  66
- Off-Season Storage
  79
- Pre-Season Check
  82
- Submerged Outboard Motor
  82
- Cold Weather Precautions
  83
- Striking Underwater Object
  83
- Auxiliary Outboard Motor Operation
  83
Troubleshooting
84

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