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TOHATSU MFS 9.9 User Manual

TOHATSU MFS 9.9
266 pages
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OB No.003-21062-0
08-12 NB-2600
Printed in Japan
OB No.003-21062-0
08-12 NB-2600
E_MFS20C_00_cover_081216.qxd 09.1.20 5:36 PM ページ 1

Table of Contents

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TOHATSU MFS 9.9 Specifications

General IconGeneral
BrandTOHATSU
ModelMFS 9.9
CategoryOutboard Motor
LanguageEnglish

Summary

Introduction

Safety Information

Explains safety statements for hazards and unsafe activities.

Service Information

Inspection of Starting Switch and Stop Switch

Checks operation of start and stop switches.

Work Safety

Covers fire prevention, ventilation, protection, and genuine parts.

Break-in Operation

Explains the purpose and procedure for break-in operation.

Checks After Test Run

Checks for water in gear oil, fuel leaks, and oil/water leaks.

Cautions in Disassembling and Assembling Components

General precautions for disassembly and assembly procedures.

Pre-delivery Inspection

Engine Oil

Procedure for filling engine oil and checking the level.

Gear Oil

Checks the quantity of gear oil in the gear case.

Service Data

Electrical parts

Ignition coil, plug cap, spark plug, rectifier, and starter motor details.

Tightening Torque Specifications

Lists torque values for various fasteners.

Specifications

Performance

Details maximum output, fuel consumption, and operating RPM.

Tightening Torque Specifications

Maintenance

Inspection Items

Inspection of Compression Pressure

Procedure for measuring engine compression pressure.

Inspection of Oil Pressure

Measures oil pressure at various RPMs.

Removing Timing Belt and Pulley

Aligns timing marks, removes timing pulley nut and engine hanger.

Inspection of Valve

Checks valve for dents, wear, and stem diameter.

Removing Lower Unit

Procedures for removing the lower unit.

Inspection of Valve Guide

Measures valve guide inner diameter and clearance.

Replacement of Engine Oil

Replacement of Oil Filter

Inspection of Water Pump

Inspection of Water Pump

Checks pump case, impeller, liner, key, and guide plate for wear.

Replacement of Gear Oil

Inspection of Gear Case (for leakage)

Replacement of Timing Belt

Installatin of Timing Belt

Inspection of Spark Plugs

Inspection of Compression Pressure

Inspection and Adjustment of Valve Clearance

Inspection of Gear Shift Operation

Fuel System

Inspection of Fuel Pump

Adjusting Float Height

Power Unit

Inspection of Valve Clearance

Removing Power Unit

Installation of Pulley and Timing Belt

Installation of Pulley and Timing Belt

Turns timing pulley to align marks and checks alignment.

Removing Cylinder Head

Inspection of Valve Spring

Inspection of Valve Seat

Correction of Valve Seat

Inspection of Locker Arm and Locker Arm Shaft

Inspection of Cam Shaft

Inspection of Cylinder Head

Inspection of Oil Pump

Installation of Valves

Installation of Cam Shaft

Installation of Rocker Arm Shaft

Installation of Oil Pump

Installation of Cylinder Head

Disassembly of Cylinder Block

Inspection of Piston Outer Diameter

Inspection of Cylinder Inner Diameter

Inspection of Piston Clearance

Inspection of Piston Ring Side Clearance

Inspection of Piston Rings

Inspection of Piston Pins

Inspection of Connecting Rod Small End Inner Diameter

Inspection of Connecting Rod Big End Side Clearance

Inspection of Crank Shaft

Inspection of Crank Pin Oil Clearance

Crankshaft Main Journal Oil Inspection of clearance

Assembling Piston and Connecting Rod

Assembling Piston and Connecting Rod

Installs exhaust cover, thermostat, oil filter, and cylinder head.

Installation of Timing Belt

Installation of Timing Belt

Attaches ground wire, ignition coil, and sensor wires.

Installation of Starter Motor

Installation of Starter Motor

Installs starter solenoid, connects wires, fuse cord, and cable terminals.

Installing Intake Manifold

Installing Intake Manifold

Prepares, installs, and connects rectifier, wires, and fuel hose.

Installing Flywheel

Installation of Power Unit

Installation of Power Unit

Hoists and installs the power unit onto the engine base.

Disassembly of Recoil Starter

Inspection of Recoil Starter

Installation of Recoil Starter

Installation of Recoil Starter

Reverses disassembly to assemble the recoil starter.

Lower Unit

Disassembly of Propeller Shaft Ass'y

Inspection of Propeller Shaft

Assembly of Propeller Shaft Ass'y

Disassembly of Propeller Shaft Housing

Inspection of Propeller Shaft Housing

Assembly of Propeller Shaft Housing

Assembly of Propeller Shaft Housing

Installs needle bearing, oil seal, ball bearing, and reverse gear assembly.

Removing Drive Shaft

Inspection of Drive Shaft

Inspection of Pinion (B) Gear and Forward (A) Gear

Assembly of Forward (A) Gear

Assembly of Drive Shaft

Disassembly of Gear Case

Assembly of Lower Unit

Assembly of Gear Case

Assembly of Gear Case

Installs needle bearing using specialized tools.

Installation of Pinion (B) Gear

Determination of Forward (A) Gear Backlash

Determination of Forward (A) Gear Backlash

Performs shim adjustment based on gauge readings and checks smooth turning.

Reassembly of Pinion (B) Gear Nut

Assembly of Water Pump

Assembly of Water Pump

Installs upper pump case, tightens bolts, feeds gear oil.

Installation of Lower Unit

Installation of Lower Unit

Applies grease, attaches thrust holder, propeller, and nut.

Adjustment of Co-pilot Plate

Removing Drive Shaft Housing

Disassembly of Drive Shaft Housing

Disassembly of Drive Shaft Housing

Removes upper rubber mount and checks rubber mount for abnormality.

Assembly of Drive Shaft Housing

Assembly of Drive Shaft Housing

Installs water pipe, exhaust cover, and upper mount.

Assembly of Drive Shaft Housing Ass'y

Assembly of Drive Shaft Housing Ass'y

Installs drive shaft housing ass'y, rubber mount, and brackets.

Removing Steering Shaft

Removing Steering Shaft

Removes drive shaft housing and attaches earth wire.

Installing Steering Shaft

Installing Steering Shaft

Puts bushing and O ring into swivel bracket, applies grease.

Disassembling Clamp Bracket (Manual Tilt Model)

Disassembling Clamp Bracket (Manual Tilt Model)

Removes thrust rod, nuts, and swivel bracket shaft.

Assembly of Clamp Bracket

Assembly of Clamp Bracket

Inserts distance piece, installs clamp bracket and shaft, tightens nuts.

Electrical System

Ignition System and Ignition Control System

Covers inspection of ignition sparks, coils, and related components.

Starting System

Details inspection and disassembly of the starter motor and related parts.

Ignition System and Ignition Control System

Inspection of Ignition Sparks

Checks spark plugs and uses a spark tester.

Inspection of Oil Pressure Switch

Checks oil pressure switch conductivity and pressure.

Starting System

Inspection of Starter Solenoid

Checks starter solenoid conductivity.

Disassembly of Starter Motor

Inspection of Starter Motor Pinion

Inspection of Brushes

Inspection of Starter Motor Operation

Battery Charging System

Inspection of Rectifier

Checks wire harness and conductivity of rectifier.

Troubleshooting

Troubleshooting Chart

A table listing symptoms, estimated causes, and page references.

Power Unit

Troubleshooting steps for engine not starting or stalling.

Warning Indication ... Display for Abnormalities During Operation

Lists warning indications, their causes, and actions.

Troubleshooting Chart

Fuel and Lubrication Systems

Lists common issues and potential causes related to fuel and lubrication.

Compression

Lists common issues and potential causes related to compression.

Electrical System

Lists common issues and potential causes related to the electrical system.

Power Unit

State 1 Engine will not start.

Continues troubleshooting for engine not starting, checking switches and wire harness.

Ignition System

Ignition System

Checks spark plugs, tester, connections, and ignition coil resistance.

Fuel System

Fuel System

Checks air vent, fuel filter, fuel hose, and carburetor for stalls soon issues.

Compression Pressure

Compression Pressure

Checks compression pressure and for intake air leaks.

Idle engine speed will not stabilize.

Idle engine speed will not stabilize.

Adjusts throttle cable, checks ignition timing, pulser coil, and CD timing.

Rapid opening of throttle fails acceleration.

Rapid opening of throttle fails acceleration.

Checks throttle cable, carburetor, ignition system, and compression pressure.

Gear shifting cannot be made normally.

Gear shifting cannot be made normally.

Checks shift lever, rod joint, cable, and lower unit clutch.

Warning Indication ... Display for Abnormalities During Operation

Warning Indication

Lists warning indications, their causes, and actions.

Wiring Diagram

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