TOHATSU MFS 9.8B Service Manual

4st 8/9.8 2016
vi
6) Inspection of Plunger and Oil Strainer ………… 5-19
7) Flywheel and Electrical Components …………… 5-19
8) Removing Timing Belt and Pulley ……………… 5-21
9) Inspection of Timing Belt ………………………… 5-22
10) Installation of Pulley and Timing Belt …………… 5-22
11) Removing Cylinder Head ………………………… 5-25
12) Inspection of Valve Spring ……………………… 5-27
13) Inspection of Valve ………………………………… 5-27
14) Inspection of Valve Guide ………………………… 5-27
15) Inspection of Valve Seat ………………………… 5-28
16) Correction of Valve Seat ………………………… 5-29
17) Inspection of Rocker Arm and Rocker
Arm Shaft ………………………………………… 5-31
18) Inspection of Cam Shaft ………………………… 5-32
19) Inspection of Cylinder Head ……………………… 5-33
20) Inspection of Oil Pump …………………………… 5-33
21) Installation of Valves ……………………………… 5-34
22) Installation of Cam Shaft ………………………… 5-35
23) Installation of Rocker Arm Shaft ………………… 5-36
24) Installation of Oil Pump …………………………… 5-36
25) Installation of Cylinder Head …………………… 5-37
26) Disassembly of Cylinder Block …………………… 5-38
27) Inspection of Piston Outer Diameter …………… 5-39
28) Inspection of Cylinder Inner Diameter ………… 5-40
29) Inspection of Piston Clearance ………………… 5-40
30)
Inspection of Piston Ring Side Clearance …………… 5-40
31) Inspection of Piston Rings ……………………… 5-41
32) Inspection of Piston Pins ………………………… 5-41
33) Inspection of Connecting Rod Small
End Inner Diameter ……………………………… 5-42
34) Inspection of Connecting Rod Big End
Side Clearance …………………………………… 5-42
35) Inspection of Crank Shaft ………………………… 5-42
36) Inspection of Crank Pin Oil Clearance ………… 5-44
37) Inspection of Crankshaft Main Journal
Oil Clearance ……………………………………… 5-45
38)
Inner Diameter of Cylinder/Crank Case
Bearing Holder (Inner Diameter Code)
…………… 5-46
39) Thickness of Metal Bearing
(Color of Inner Diameter Code) ………………… 5-46
40)
Assembling Piston and Connecting Rod …………… 5-47
41) Assembling Cylinder Block ……………………… 5-48
42) Assembling of Power Unit ………………………… 5-50
43) Installation of Electrical Components …………… 5-51
44) Installation of Starter Motor
(Electric Start Model) ……………………………… 5-53
45) Installation of Flywheel …………………………… 5-55
46) Installation of Recoil Starter ……………………… 5-55
47) Installation of Intake Manifold …………………… 5-56
48) Installation of Plunger and Oil Strainer ………… 5-58
49) Installation of Power Unit ………………………… 5-58
50) Removing Recoil Starter ………………………… 5-59
51) Disassembly of Recoil Starter ………………… 5-59
52) Inspection of Recoil Starter ……………………… 5-60
53) Assembling of Recoil Starter …………………… 5-60
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Drive Shaft Housing …………………………………… 6-3
Gear Case ……………………………………………… 6-4
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1) Draining Gear Oil ………………………………… 6-8
2) Removing Propeller ……………………………… 6-8
3) Removing Lower Unit …………………………… 6-9
4) Disassembly of Water Pump …………………… 6-9
5) Inspection of Water Pump ……………………… 6-10
6)
Removing Clutch Cam and Cam Rod ……………… 6-10
7)
Disassembly of Clutch Cam and Cam Rod …………… 6-11
8)
Inspection of Cam Rod and Clutch Cam …………… 6-11
9)
Assembly of Cam Rod and Clutch Cam …………… 6-11
10)
Removing Pump Case (Lower) …………………… 6-11
11) Disassembly of Pump Case (Lower) …………… 6-11
12) Assembly of Pump Case (Lower) ……………… 6-12
13)
Removing Propeller Shaft Housing Ass'y …………… 6-12
14)
Disassembly of Propeller Shaft Ass'y …………… 6-12
15) Inspection of Propeller Shaft …………………… 6-13
16) Assembly of Propeller Shaft Ass'y ……………… 6-13
17)
Disassembly of Propeller Shaft Housing ……………… 6-13
18)
Inspection of Propeller Shaft Housing ……………… 6-14
19)
Assembly of Propeller Shaft Housing ……………… 6-14
20) Removing Drive Shaft …………………………… 6-15
21) Inspection of Drive Shaft ………………………… 6-15
22)
Removing forward (A) gear and bearing …………… 6-16
23) Inspection of Pinion (B) Gear and
Forward (A) Gear ………………………………… 6-16
24) Disassembly of Gear Case ……………………… 6-17
25) Inspection of Gear Case ………………………… 6-17
26) Assembly of Gear Case ………………………… 6-18
27) Installation of Forward (A) Gear ………………… 6-20
28) Installation of Pinion (B) Gear …………………… 6-20
29) Measurement of pinion (B) gear
backlash and selection of shims ………………… 6-21
30) Assembly of Propeller Shaft Housing …………… 6-23
31) Reassembly of Pump Case (Lower) …………… 6-24
32) Assembly of Water Pump ………………………… 6-24
33) Installation of Lower Unit ………………………… 6-26
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Drive Shaft Housing …………………………………… 7-2
Clamp Bracket (For MF & EF Models) ………………… 7-3
Clamp Bracket (For EP Model) ………………………… 7-5
Tiller Handle …………………………………………… 7-8
Bottom Cowl …………………………………………… 7-9
Shift ……………………………………………………… 7-10
Remote Control Parts ………………………………… 7-11
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1) Inspection of Throttle Cable ……………………… 7-12
2) Installation of Tiller Handle ……………………… 7-12
3) Adjustment of Co-pilot Plate …………………… 7-13
4) Removing Drive Shaft Housing ………………… 7-14
5) Disassembly of Drive Shaft Housing …………… 7-15
6) Assembly of Drive Shaft Housing ……………… 7-17
7)
Installation of Drive Shaft Housing Ass'y ………… 7-18
8) Removing Steering Shaft ………………………… 7-19
9) Installing Steering Shaft ………………………… 7-20
10) Disassembling Clamp Bracket
(EP Model) ………………………………………… 7-21
11) Assembling of Clamp Bracket
(EP Model) ………………………………………… 7-22
12) Disassembling Clamp Bracket
(MF & EF Models) ………………………………… 7-23
13) Assembling of Clamp Bracket
(MF & EF Models) ………………………………… 7-24

TOHATSU MFS 9.8B Specifications

General

Brand	TOHATSU
Model	MFS 9.8B
Category	Outboard Motor
Language	English