TOHATSU MFS 9.9 User Manual

4st 9.9/15/20 2008
v
1.Service Information
1. Identification (Engine Serial Number) ⋯⋯ 1-2
2. Work Safety ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-2
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
3. Tools and Instruments ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-5
1) Test Propeller ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-5
2) Measuring Instruments ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-5
3) Special Tools⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-6
4. Pre-delivery Inspection ⋯⋯⋯⋯⋯⋯⋯⋯ 1-9
1) Steering Handle ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9
2) Gear Shift ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9
3) Engine Oil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9
4) Gear Oil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-9
5) Fuel Line ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-10
6) Rigging ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-10
7) Manual Tilt ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-10
8) Inspection of Starting Switch and Stop Switch ⋯ 1-11
9) Cooling Water Check Port ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-12
10)Idling ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-12
11) Propeller Selection ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-12
12) Trim Tab ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-13
5. Break-in Operation⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-13
6. Test Run ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-14
7. Check After Test Run ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1-14
1. Outline Dimensons ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-2
1) Engine outer dimensions⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-2
2) Transom Bolts ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-3
2. Fuel Feed System ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-4
1) Fuel Feed Route ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-4
3. Engine Lubrication System Diagram ⋯⋯⋯2-5
4. Cooling Water System Diagram ⋯⋯⋯⋯ 2-6
5.
Specifications
⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-7
6. Maintenance Data ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-10
7. Tightening Torque Specifications ⋯⋯⋯⋯ 2-18
2.Service Data
1. Outline Dimensons ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-2
1) Engine outer dimensions⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-2
2) Transom Bolts ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-3
2. Fuel Feed System ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-4
1) Fuel Feed Route ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-4
3. Engine Lubrication System Diagram ⋯⋯⋯2-5
4. Cooling Water System Diagram ⋯⋯⋯⋯ 2-6
5. Specifications ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-7
6. Maintenance Data ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2-10
7. Tightening Torque Specifications ⋯⋯⋯⋯ 2-18
8. Sealant and Lubricant ⋯⋯⋯⋯⋯⋯⋯⋯ 2-19
3.Maintenance
1. Special Tools⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-2
2. Inspection Schedule ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-3
3. Inspection Items ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-4
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) Replacement of Oil Filter⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-7
7) Inspection of Gear Oil Quantity ⋯⋯⋯⋯⋯⋯⋯⋯ 3-8
8) Inspection of Water Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-8
9) Replacement of Gear Oil ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-10
10) Inspection of Gear Case (for leakage) ⋯⋯⋯⋯ 3-11
11) Inspection of Timing Belt ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-12
12) Replacement of Timing Belt ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-13
13) Installatin of Timing Belt ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-15
14) Inspection of Spark Plugs ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-17
15) Inspection of Compression Pressure ⋯⋯⋯⋯⋯ 3-18
16) Inspection and Adjustment of Valve Clearance⋯ 3-19
17) Throttle Cable For F type ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-20
18) Throttle Cable Adjustment of Throttle Link ⋯⋯ 3-22
19) Inspection of Gear Shift Operation ⋯⋯⋯⋯⋯⋯ 3-27
20) Inspection of Idle Engine Speed ⋯⋯⋯⋯⋯⋯⋯ 3-29
21) Inspection of Ignition Timing⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-29
22) Inspection of Anode ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-30
23) Replacement of Anode ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-30
24) Inspection of Propeller ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-31
25) Inspection of Thermostat ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-31
26) Inspection of Cooling Water Passage⋯⋯⋯⋯⋯ 3-32
27) Flushing with Water ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-33
28) Inspection of Battery ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3-34
29) Greasing Points ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯3-35
4.Fuel System
1. Special Tools⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-2
2. Parts Layout ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-3
Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-3
Intake Manifold & Fuel Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-5
3. Carburetor Inner Passages ⋯⋯⋯⋯⋯⋯ 4-6
1) Idling Passage ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-6
2) Off-Idle Passage ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-7
3) High Speed Passage ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-8
4) Acceleration Passage ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-9
5) Choking Passage ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-10
4. Inspection Items ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-11
1) Removing Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-11
Remote Control Model ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-11
Tiller Handle Model ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-12
2) Disassembling Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-14
3) Cleaning and Inspection ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-16
4) Inspection of Fuel Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-17
5) Inspection of Fuel Connector ⋯⋯⋯⋯⋯⋯⋯⋯ 4-18
6) Assembling Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-18
7) Adjusting Float Height ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-20
8) Installing Carburetor ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4-20
5.Power Unit
1. Special tools ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-2
2. Parts Layout ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-3
Engine ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-3
Magneto⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-4
Electric Parts⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-5
Intake Manifold & Fuel Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-6
Camshaft & Oil Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-7
Cylinder Head ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-8
Intake Valve & Exhaust Valve ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-9
Cylinder ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-10
Piston & Crankshaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-11
Recoil Starter ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-12
Top Cowl ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-13
3. Inspection Items ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-14
1) Inspection of Comperession Pressure ⋯⋯⋯⋯ 5-14
2) Inspection of Oil Pressure⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-15
3) Inspection of Valve Clearance ⋯⋯⋯⋯⋯⋯⋯⋯ 5-16
4) Removing Power Unit ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-18
5) Removing Plunger and Oil Starter ⋯⋯⋯⋯⋯⋯ 5-20
6) Inspection of Oil Strainer ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-20
7) Flywheel and Electrical Components ⋯⋯⋯⋯⋯ 5-20
8) Removing Timing Belt and Pulley ⋯⋯⋯⋯⋯⋯ 5-22
9) Inspection of Timing Belt ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-23
10) Installation of Pulley and Timing Belt ⋯⋯⋯⋯⋯ 5-24
11) Removing Cylinder Head ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-27
12) Inspection of Valve Spring ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-29
13) Inspection of Valve⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-30
14) Inspection of Valve Guide ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-30
15) Inspection of Valve Seat ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-31
16) Correction of Valve Seat ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-32
17) Inspection of Locker Arm and Rocker Arm Shaft 5-34
18) Inspection of Cam Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-35
19) Inspection of Cylinder Head ⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-36
20) Inspection of Oil Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-37
21) Installation of Valves ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-38
22) Installation of Cam Shaft ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-39
23) Installation of Rocker Arm Shaft ⋯⋯⋯⋯⋯⋯⋯ 5-39
24) Installation of Oil Pump ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-40
25) Installation of Cylinder Head⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5-41
26) Disassembly of Cylinder Block⋯⋯⋯⋯⋯⋯⋯⋯ 5-42
27) Inspection of Piston Outer Diameter ⋯⋯⋯⋯⋯ 5-43
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TOHATSU MFS 9.9 Specifications

General

Brand	TOHATSU
Model	MFS 9.9
Category	Outboard Motor
Language	English