TOHATSU MFS 9.8B Service Manual

4st 8/9.8 2016
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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
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1) Test Propeller ……………………………………… 1-5
2) Measuring Instruments …………………………… 1-5
3) Special Tools ……………………………………… 1-6
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1) Steering & Throttle ………………………………… 1-8
2) Gear Shift ………………………………………… 1-8
3) Engine Oil ………………………………………… 1-8
4) Gear Oil …………………………………………… 1-9
5) Fuel Line …………………………………………… 1-9
6) Rigging ……………………………………………… 1-9
7) Manual Tilt ………………………………………… 1-9
8) Inspection of PT unit ……………………………… 1-9
9) Inspection of Starting Switch and
Stop Switch ………………………………………… 1-10
10) Cooling Water Check Port ……………………… 1-11
11) Idling ………………………………………………… 1-11
12) Propeller Selection ………………………………… 1-11
13) Trim Tab …………………………………………… 1-12
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1) Engine Outer Dimensions ………………………… 2-2
2) Transom Bolts ……………………………………… 2-4
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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) Inspection of Gear Oil Quantity ………………… 3-7
7) Inspection of Water Pump ……………………… 3-7
8) Replacement of Gear Oil ………………………… 3-9
9)
Inspection of Gear Case (for leakage) …………… 3-10
10) Inspection of Timing Belt ………………………… 3-11
11) Replacement of Timing Belt ……………………… 3-11
12) Inspection of Spark Plugs ………………………… 3-16
13) Inspection of Compression Pressure …………… 3-17
14) Inspection and Adjustment of Valve
Clearance ………………………………………… 3-18
15) Throttle Cable For F type ………………………… 3-20
For P type ………………………… 3-22
16) Inspection of Gear Shift Operation ……………… 3-26
17) Inspection of Idle Engine Speed ………………… 3-27
18) Inspection of Ignition Timing ……………………… 3-28
19) Inspection of Anode ……………………………… 3-28
20) Replacement of Anode …………………………… 3-28
21) Inspection of Propeller …………………………… 3-29
22) Inspection of Thermostat ………………………… 3-29
23) Inspection of Cooling Water Passage …………… 3-30
24) Flushing with Water ……………………………… 3-30
25) Inspection of Battery ……………………………… 3-31
26) Greasing Points …………………………………… 3-32
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Intake Manifold & Fuel Pump …………………… 4-3
Carburetor ………………………………………… 4-4
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1) Idling Passage …………………………………… 4-6
2) Off-Idle Passage …………………………………… 4-7
3) High Speed Passage ……………………………… 4-8
4) Choking Passage ………………………………… 4-9
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1) Inspection of Choke Solenoid
(some models only) ……………………………… 4-10
2) Removing Carburetor ……………………………Ê4-10
Remote Control Model …………………………… 4-10
Tiller Handle Model ………………………………Ê4-11
3) Disassembling Carburetor ………………………Ê4-13
4) Cleaning and Inspection ………………………… 4-14
5)
Disassembly and Inspection of Fuel Pump …………… 4-15
6) Assembly of Fuel Pump ………………………… 4-16
7) Inspection of Fuel Connector ……………………Ê4-17
8) Inspection of Fuel Filter …………………………Ê4-17
9) Assembling Carburetor …………………………Ê4-18
10) Adjusting Float Height ……………………………Ê4-19
11) Installing Carburetor ………………………………Ê4-19
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Engine …………………………………………………… 5-3
Magneto • Electric Parts ……………………………… 5-5
Intake Manifold & Fuel Pump ………………………… 5-6
Pully & Timing Belt ……………………………………… 5-7
Cylinder Head &Oil Pump …………………………… 5-8
Cylinder & Crank Case ………………………………… 5-10
Piston & Crankshaft …………………………………… 5-11
Recoil Starter …………………………………………… 5-12
Top Cowl ………………………………………………… 5-13
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1) Inspection of Compression Pressure …………… 5-14
2) Inspection of Oil Pressure ………………………… 5-15
3) Inspection of Valve Clearance …………………… 5-15
4) Removing Power Unit …………………………… 5-17
5) Removing Plunger and Oil Strainer ……………… 5-19

TOHATSU MFS 9.8B Specifications

General

Brand	TOHATSU
Model	MFS 9.8B
Category	Outboard Motor
Language	English