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TOHATSU
Outboard Motor
MFS 9.9
TOHATSU MFS 9.9 User Manual
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9-4
T
roubleshooting
O
K
4st 9.9/15/20 2008
Replace neutral switch.
Repair or replace wir
e
harness.
Check start switch or main
switch.
Check electrical conductivity
of neutral switch.
Conductive?
Replace start switch or
main switch.
Check electrical conductivity of
wire harness.
Normal?
Conductive?
Disassemble starter
motor and check.
NO
NO
NO
YES
YES
YES
（
State 1
:
Engine will not start.
）
E_MFS20C_ch09_090126.qxd
09.1.26
2:37
PM
ページ
4
246
248
Table of Contents
Default Chapter
2
Introduction
2
Safety Information
2
Safety Statements
2
What Is the si Unit System?
4
Description of Pictograph
5
Contents
6
Table of Contents
7
Index
8
Service Information
10
Fire Prevention
11
Identification
11
Ventilation
11
Work Safety
11
Recommendations on Service
12
Tools
12
Measuring Instruments
14
Test Propeller
14
Tools and Instruments
14
Special Tools
15
Engine Oil
18
Gear Shift
18
Pre-Delivery Inspection
18
Steering Handle
18
Fuel Line
19
Manual Tilt
19
Rigging
19
Inspection of Starting Switch and Stop Switch
20
Cooling Water Check Port
21
Idling
21
Propeller Selection
21
Range of Operating Engine Speed at WOT
21
Break-In Operation
22
Example of Trim Tab Angle Adjustment
22
Trim Tab
22
Checks after Test Run
23
Idling Revolution Speed
23
Tachometer
23
Test Run
23
Service Data
26
Engine Outer Dimensions
27
Outline Dimensions
27
Mechanical Tilt Model
28
Transom Bolts
28
Fuel Feed Route
29
Fuel Feed System
29
Engine Lubrication System Diagram
30
Cooling Water System Diagram
31
Dimensions
32
Performance
32
Specifications
32
Weight
32
Fuel and Oil
33
Lower Unit
33
Power Unit
33
Bracket
34
Optional Parts
34
Warning System
34
Maintenance Data
35
Tightening Torque Specifications
43
Sealant and Lubricant
44
Maintenance
48
Inspection Schedule
50
Check Piping
51
Fuel System
51
Inspection of Top Cowl
51
Inspection of Fuel Filter
52
Inspection of Fuel Tank
52
Oil Level
53
Oil Specification
53
Quantity of Engine Oil
53
Replacement of Engine Oil
53
Replacement of Oil Filter
54
Inspection of Gear Oil Quantity
55
Inspection of Water Pump
55
Replacement of Gear Oil
57
Inspection of Gear Case (for Leakage)
58
Specified Gear Case Maintained Pressure
58
Inspection of Timing Belt
59
Replacement of Timing Belt
60
Installatin of Timing Belt
62
Inspection of Spark Plugs
64
Inspection of Compression Pressure
65
Inspection and Adjustment of Valve Clearance
66
For F Type
67
Throttle Cable
67
Adjustment of Throttle Link
69
Inspection of Gear Shift Operation
74
Inspection of Idle Engine Speed
76
Inspection of Ignition Timing
76
Inspection of Anode
77
Replacement of Anode
77
Inspection of Propeller
78
Inspection of Thermostat
78
Inspection of Cooling Water Passage
79
Flushing with Water
80
Flushing with Water Using Drive Cleaner 3
80
Battery
81
Charging Requirements
81
Inspection of Battery
81
Specific Gravity of Electrolyte
81
Greasing Points
82
Special Tools
85
Carburetor
86
Parts Layout
86
Intake Manifold & Fuel Pump
88
Carburetor Inner Passages 1) Idling Passage
89
Off-Idle Passage
90
High Speed Passage
91
Acceleration Passage
92
Choking Passage
93
Inspection Items
94
Remote Control Model
94
Removing Carburetor
94
Tiller Handle Model
95
Disassembling Carburetor
97
Cleaning and Inspection
99
Inspection of Fuel Pump
100
Assembling Carburetor
101
Inspection of Fuel Connector
101
Adjusting Float Height
103
Float Height a
103
Installing Carburetor
103
Inspection of Connecting Rod Small End Inner Diameter ⋯
104
Magneto
107
Electric Parts
108
Camshaft & Oil Pump
110
Cylinder Head
111
Intake Valve & Exhaust Valve
112
Cylinder
113
Piston & Crankshaft
114
Recoil Starter
115
Top Cowl
116
Inspection of Oil Pressure
118
Inspection of Valve Clearance
119
Rocker Arm Lock Nut 5
120
Valve Clearance (When Engine Is Cold)
120
Removing Power Unit
121
Inspection of Oil Strainer
123
Removing Plunger and Oil Strainer
123
Removing Timing Belt and Pulley
125
Installation of Pulley and Timing Belt
127
Removing Cylinder Head
130
Inspection of Valve Spring
132
Inspection of Valve
133
Inspection of Valve Guide
133
Inspection of Valve Seat
134
Correction of Valve Seat
135
Inspection of Cam Shaft
138
Inspection of Cylinder Head
139
Functional Limit
140
Inspection of Oil Pump
140
Installation of Valves
141
Installation of Cam Shaft
142
Installation of Rocker Arm Shaft
142
Installation of Oil Pump
143
Cylinder Head Bolts (M6)
144
Cylinder Head Bolts (M8)
144
Installation of Cylinder Head
144
Disassembly of Cylinder Block
145
Inspection of Cylinder Inner Diameter
146
Inspection of Piston Outer Diameter
146
Inspection of Piston Clearance
147
Inspection of Piston Ring Side Clearance
147
Inspection of Piston Rings
147
Inspection of Connecting Rod
148
Inspection of Connecting Rod Big End Side Clearance
148
Inspection of Piston Pins
148
Small End Inner Diameter
148
Inspection of Crank Shaft
149
Inspection of Crank Pin Oil Clearance
150
Be Sure that Individual Bearings Are Installed
151
Crankshaft Main Journal Oil Inspection of Clearance
151
To Their Original Locations
151
Color of Inner Diameter Code
152
Inner Diameter of Cylinder
152
Thickness of Metal Bearing
152
Assembling Piston and Connecting Rod
153
Cylinder Block Groove
154
Crank Case Groove
155
First Tightening Torque : 10 N · M (7 Lb · Ft) [1.0 Kgf · M]
155
First Tightening Torque : 6 N · M (4 Lb · Ft) [0.6 Kgf · M]
155
Install Bearings with Their Projection Fit into
155
Second Tightening Torque : 11.5 N · M (8.5 Lb · Ft) [1.2 Kgf · M]
155
Second Tightening Torque : 23.5 N · M (17 Lb · Ft) [2.4 Kgf · M]
155
Installation of Timing Belt
157
Adjustment of Starter Lock Cable
166
Installation of Power Unit
166
Removing Recoil Starter
166
Disassembly of Recoil Starter
167
Inspection of Recoil Starter
168
Installation of Recoil Starter
169
Gear Case
173
Parts Layout
173
Drive Shaft Housing
174
Drive System & Water Pump
175
Draining Gear Oil
177
Inspection Items
177
Removing Propeller
177
Disassembly of Water Pump
178
Removing Lower Unit
178
Inspection of Water Pump
179
Removing Propeller Shaft Housing Ass'y
179
Assembly of Propeller Shaft Ass'y
180
Disassembly of Propeller Shaft Ass'y
180
Inspection of Propeller Shaft
180
Disassembly of Propeller Shaft Housing
181
Inspection of Propeller Shaft Housing
182
Assembly of Propeller Shaft Housing
183
Assembly of Pump Case (Lower)
184
Disassembly of Pump Case (Lower)
184
Removing Clutch Cam and Cam Rod
184
Assembly of Cam Rod and Clutch Cam
185
Disassembly of Drive Shaft
185
Inspection of Cam Rod and Clutch Cam
185
Removing Drive Shaft
185
Inspection of Drive Shaft
186
Removing Forward (A) Gear
186
Assembly of Drive Shaft
187
Assembly of Forward (A) Gear
187
Inspection of Pinion Gear
187
Disassembly of Gear Case
188
Needle Bearing
188
Assembly of Gear Case
189
Assembly of Lower Unit
189
Cam Rod Bushing Bolt
189
Inspection of Gear Case
189
Backlash Measuring Tool Kit
190
Installation of Pinion (B) Gear
192
Determination of Forward Gear Backlash
193
Assembly of Propeller Shaft Housing
195
Reassembly of Pinion (B) Gear Nut
195
Assembly of Water Pump
196
Reassembly of Pump Case (Lower)
196
Installation of Lower Unit
198
Swivel Bracket
202
Clamp Bracket & Reverse Lock
203
Tiller Handle
204
Bottom Cowl
205
Shift & Stop Switch
206
Shift (for EP)
207
Inspection of Throttle Cable
209
Installation of Tiller Handle
209
Adjustment of Co-Pilot Plate
210
Removing Drive Shaft Housing
210
Assembly of Drive Shaft Housing
214
Installation of Drive Shaft Housing Ass'y
215
Disassembling Clamp Bracket
219
Assembly of Clamp Bracket
220
Electrical System
222
Special Tools
223
Electrical Component Layout
224
Port Side View
224
Bow Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
225
Starboard Side View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
226
Top View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
227
Back View ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
228
Magneto
229
Parts Laout
229
Electric Parts
230
Starter Motor
231
Shift & Stop Switch
232
Ignition System and Ignition Control System
233
Inspection of Plug Cap ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
234
Inspection of Pulser Coil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
235
Inspection of Exciter Coil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
236
Inspection of Oil Pressure Switch
236
Inspection of Neutral Switch (Tiller Handle Model)
237
Inspection of Start Switch (Tiller Handle Model)
237
Inspection of Fuse
238
Inspection of Starter Solenoid
238
Inspection of Stop Switch ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
238
Starting System
238
Disassembly of Starter Motor ⋯⋯⋯⋯⋯⋯⋯⋯
239
Inspection of Armature
239
Inspection of Starter Motor Pinion
239
Inspection of Brushes ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
240
Battery Charging System
241
Inspection of Rectifier
241
Inspection of Starter Motor Operation
241
Rectifier Tester Check Chart
241
CD Unit Coupler
242
Troubleshooting
244
Troubleshooting Chart
245
Engine will Not Start
246
Power Unit
246
Engine will Not Start
247
Ignition System
248
Fuel System
250
Compression Pressure ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯
251
Engine Starts but Stalls Soon
252
Ignition System
253
Compression Pressure
254
Idle Engine Speed will Not Stabilize
255
Rapid Opening of Throttle Fails Acceleration. ⋯⋯⋯⋯
256
Gear Shifting Cannot be Made Normally
257
Warning Indication
258
Display for Abnormalities During Operation
258
Wiring Diagram
260
Other manuals for TOHATSU MFS 9.9
Service Manual
29 pages
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TOHATSU MFS 9.9 Specifications
General
Brand
TOHATSU
Model
MFS 9.9
Category
Outboard Motor
Language
English
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