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TOHATSU
Outboard Motor
90 Series
TOHATSU 90 Series User Manual
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9
11
Table of Contents
Contents
2
Specifications
3
Precautions During Work
8
Service Data
9
Service Data and Maintenance Standards Chart
10
Thermostat Switching Test
14
Periodic Inspection Chart
16
Table of Sealants, Adhesives, Lubricating Oils and Usage Locations
17
Table of Tightening Torques
20
Tools and Instruments Required for Disassembly, Maintenance and Repair
21
How to Use Special Tools
22
Flywheel Magneto Tool
22
Piston Pin Tool
22
Spring Pin Tool
23
Needle Roller Bearing Tool
23
Needle Roller Bearing in Propeller Shaft Housing
24
Needle Roller Bearing of Gear Case
25
Socket and Wrench for Bevel Gear B Nut
26
Clutch Pin Snap Tool
26
Backlash Measuring Tool
27
Bevel Gear a Bearing Puller
28
Power Unit
29
Removal of Power Unit
30
Removal of Accessories/Starter Motor
32
Removal of Recoil Starter
33
Removal of Flywheel Magneto
34
Removal of Carburetor/CD Unit and Ignition Coil/Thermostat
35
Cylinder and Crank Case Assembly
36
Piston and Crank Shaft
37
Engine Disassembly
38
Removal of Cylinder Head/Exhaust Cover and Engine Anode
38
Removial of Inlet Manifold and Reed Valve
39
Removal of Crank Case and Crankshaft
39
Removal of Piston
40
Engine Assembly
42
Installing the Piston
42
Installing the Crank Shaft and Crank Case
42
Engine Assembly Procedure
43
Installation of Reed Valve and Inlet Manifold
44
Installation of Exhaust Cover and Engine Anode
44
Installation of Cylinder Head
44
Throttle Mechanism and Bar Handle Exploded View
45
Installation and Adjustment of Accessories
46
Installation of Flywheel Magneto/Fuel Lines
46
Adjustment of Throttle Mechanism
47
Procedure for Adjusting Ignition Timing When Opening the Throttle Fully
47
Procedure for Adjusting Ignition Timing When the Throttle Is Fully Closed
48
Adjusting Sliding Motion of the Advancer Arm
48
Adjusting Opening of Throttle Toward the Reverse Side
48
Inspecting Starter Locking Cam
49
Standards for Engine Oil and O-Ring
49
Installation of Starter Motor
49
Recoil Starter and Starter Lock Exploded View
50
Recoil Starter Disassembly
51
Recoil Starter Assembly
52
Applying Initial Load on the Starter Spring
53
Checking the Force Acting on the Ratchet
53
Lower Unit
54
Drive Shaft Housing and Gear Case Exploded View
55
Disassembly of Gear Case
56
Removal of Gear Case
56
Disassembly of Water Pump Case
56
Removal of Propeller
57
Disassembly of Propeller Shaft and Clutch
57
Removal of Clutch Cam and Cam Rod
58
Removal of Bevel Gear and Drive Shaft
58
Gear Case Assembly
60
Installation of Bevel Gear and Drive Shaft
60
Installation of Clutch Cam and Cam Rod
60
Backlash Adjustment between Bevel Gears a and B
61
Assembly of Water Pump Case
62
Assembly of Propeller Shaft and Clutch
63
Propeller Installation
64
Installation of Gear Case
64
Standards for Oil Seals and O Rings for Gear Case
64
Disassembly of Lower Motor Cover and Drive Shaft Housing
65
Removal of Lower Motor Cover
65
Removal of Exhaust Pipe and Water Pipe
65
Bracket and Reverse Lock (Type I) Exploded View
66
Bracket and Reverse Lock (Type II) Exploded View
67
Disassembly of Stern Bracket/Swiveling Bracket
68
Disassembly of Drive Shaft Housing
69
Drive Shaft Housing and Mounting Bracket
70
Assembly of Lower Motor Cover and Drive Shaft Housing
70
Assembly of Drive Shaft Housing
70
Installation of Exhaust Pipe and Water Pipe
71
Installation of Lower Motor Cover/Choke Lever
72
Assembly of Gear Shift Lever
72
Shift Lever Adjustments
73
Installation of Motor Cover
74
Disassembly of Steeging System, Hanle and Bracket
74
Removal of Steering Shaft Assembly
74
Disassembly of Steering System
74
Removal of Steering Handle
75
Assembly of Steering System, Handle and Bracket
76
Assembly of Stern Bracket
76
Adjustment of Reverse Lock
76
Installation of Steering Handle
77
Assembling the Steering System
77
Carburetor
78
Carburetor - Exploded View/Outline of Operation
79
Pilot System: Flow of Fuel Mixture During Start and Idling/Slow Operation
79
Main System: Flow of Fuel Mixture for Operations above Medium Speed
79
Float System
80
Carburetor - Inspections
80
Inlet (Carburetor with Reed Valve/Fuel Pump) Exploded View
81
Electrical System
82
Flywheel Magneto and CD Unit Exploded View
83
CD Magneto Construction and Maintenance
83
Flywheel Inspection and Maintenance
83
Coil Plate and Coils
83
CD Unit - Inspection and Maintenance
84
To Test CD Unit/Test Check Table
85
Ignition Coils Inspection and Judgement
86
Stop Switch Inspection and Maintenance
86
Inspection of Connecting Wires and Contacts
86
Precautions in Handling the CD Magneto
86
Electrical Starter Exploded View
87
Precautions During Electrical System Tests and Trials
88
Electric Cicruit (EP Type) Diagram
88
Electric Cicruit (EF Type) Diagram
89
Inspection of Parts Related to Electric Starter
90
Inspection after Mounting or Repair of Starter Motor Accessories
90
Starter Motor Periodic Inspection Chart
90
Starter Motor Inspection and Maintenance
91
Checking the Starter Solenoid
91
Complete Check of Rectifier
92
Main Switch (EP, Ef)/Neutral Switch Checks
93
Remote Control
94
Engine Side Mounting Kit for Remote Control Exploded View
95
Installation of Remote Control Cables
96
Control Box Installation (Driver's Side)
97
Installation of Remote Control Cables at Engine
97
Remote Control Installed Illustration
98
Inspections, Adjustments and Trials
99
Testing Tank and Dynamometer
100
Conditions and Precautions for Testing Tank
100
Adjustments and Operational Checks of Outboard Motor
100
Inspections and Adjustments after Final Assembly
101
Troubleshooting
102
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TOHATSU 90 Series Specifications
General
Cylinders
3
Steering
Remote
Starting
Electric
Horsepower
90 HP
Alternator Output
12V
Shaft Length
20"
Fuel Type
Gasoline
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