Tohatsu MFS 8 S [9/84] Chapter 2 service data and tools

Содержание

• Top page 1
• Chapter 1 specifications 2
• Chapter 2 service data and tools 2
• Chapter 3 inspection and maintenance 2
• Chapter 4 power unit 2
• Contents 2
• Chapter 5 lower unit 3
• Chapter 6 recoil starter 3
• Chapter 7 carburetor and fuel pump 3
• Chapter 8 oil pump 3
• Chapter 9 electrical system 3
• Chapter 9 test run and inspection 3
• Contents 3
• Chapter 1 specifications 4
• Dimensions 4
• Engine 4
• Item model or 4
• Performance 4
• Specifications 4
• Type 8a 9 a 4
• Chapter 1 specifications 5
• Item model or 5
• Lower unit 5
• Specifications 5
• Type 8a 9 a 5
• Warning systems 5
• Chapter 1 specifications 6
• Dimensions 6
• Chapter 2 service data and tools 7
• Service data and maintenance standards 7
• Chapter 2 service data and tools 8
• Chapter 2 service data and tools 9
• Chapter 2 service data and tools 10
• Chapter 2 service data and tools 11
• Chapter 2 service data and tools 12
• Chapter 2 service data and tools 13
• Chapter 2 service data and tools 14
• Chapter 2 service data and tools 15
• Table of points to apply sealants adhesives and lubricants 15
• Chapter 2 service data and tools 16
• Chapter 2 service data and tools 17
• Chapter 2 service data and tools 18
• Description bolt or nut thread 18
• Engine 18
• Lower unit 18
• N m kg m lb ft 18
• Standard torque 18
• Table of tightening torque 18
• Tightening torque 18
• 1 general tools 19
• Chapter 2 service data and tools 19
• Disassembly and repair 19
• Tools and instruments required for 19
• Tools and instruments required for disassembly and repair 19
• Chapter 2 service data and tools 20
• Chapter 2 service data and tools 21
• How to use special tools 21
• Chapter 2 service data and tools 22
• Chapter 2 service data and tools 23
• Drive shaft bearing tool 3b2 72256 0 23
• Backlash measuring tool 24
• Chapter 2 service data and tools 24
• Chapter 3 inspection and maintenance 25
• O o o o 25
• Periodical inspections 25
• Troubleshooting 26
• Change of engine oil 27
• Chapter 3 inspection and maintenance 27
• Method to change engine oil 27
• Chapter 3 inspection and maintenance 28
• Inspection of fuel system 28
• A caution 29
• Chapter 3 inspection and maintenance 29
• Compression test 29
• Chapter 3 inspection and maintenance 30
• Chapter 3 inspection and maintenance 31
• Inspection of timing belt 31
• Change of gear oil 32
• Chapter 3 inspection and maintenance 32
• A caution 33
• Chapter 3 inspection and maintenance 33
• Flushing cleaning 33
• Chapter 3 inspection and maintenance 34
• Inspection of cooling system 34
• Chapter 4 power unit 35
• General notes on service 35
• Chapter 4 power unit 36
• Removing parts 36
• Removing power unit 36
• Removing power unit removing parts 36
• Chapter 4 power unit 37
• Chapter 4 power unit 38
• Disassembling engine 38
• Chapter 4 power unit 39
• Chapter 4 power unit 40
• Chapter 4 power unit 41
• Chapter 4 power unit 42
• Engine parts 42
• Inspection and measurement of 42
• Inspection and measurement of engine parts 42
• Chapter 4 power unit 43
• Chapter 4 power unit 44
• Chapter 4 power unit 45
• Chapter 4 power unit 46
• Chapter 4 power unit 47
• Chapter 4 power unit 48
• Chapter 4 power unit 49
• Chapter 4 power unit 50
• Repair and replacement of engine 50
• Repair and replacement of engine parts 50
• Chapter 4 power unit 51
• Reassembling engine 51
• Chapter 4 power unit 52
• Chapter 4 power unit 53
• Chapter 4 power unit 54
• Chapter 4 power unit 55
• Chapter 4 power unit 57
• Chapter 4 power unit 58
• Chapter 4 power unit 59
• Chapter 4 power unit 60
• Chapter 5 lower unit 61
• Disassembly of gear case 61
• Chapters lower unit 63
• Disassembly of propeller shaft and clutch 63
• Disassembly of water pump case 63
• Chapter 5 lower unit 64
• Removal of cam rod drive shaft and bevel gear 64
• Chapters lower unit 65
• Chapters lower unit 66
• Gear case assembly 66
• Installation of bevel gear and driveshaft 66
• Installation of clutch cam and cam rod 66
• Assembly of water pump case 67
• Chapters lower unit 67
• Assembly of propeller shaft and clutch 68
• Chapters lower unit 68
• Chapter 5 lower unit 69
• Installation of gear case 69
• Standards for oil seals and o rings for gear case 69
• Chapter 6 recoil starter 71
• Chapters recoil starter 71
• Recoil starter starter lock 71
• Chapters recoil starter 72
• Disassembling 72
• Reassembling 72
• Chapters recoil starter 73
• Inspection 73
• A caution 74
• Carburetor 74
• Chapter 7 carburetor and fuel pump 74
• A caution 75
• Chapter 7 carburetor and fuel pump 75
• Fuel pump 75
• Chapter 8 oil pump 76
• Component parts 76
• Br w brown with white tracer 77
• Chapter 9 electrical system 77
• Ef type 77
• Lg b r r w w r 77
• Lg____lg 77
• Mf type 77
• Note including optional parts in the diagram 77
• Or orange 77
• Rec reg 77
• Red with white tracer white with red tracer 77
• Tracer 77
• W r v r 77
• W r w r 77
• White yellow light green black with red 77
• White yellow light green black with red tracer red with white tracer white with red tracer 77
• Wire caldr 77
• Wiring diagram 77
• В black l blue bt brown g green grange 77
• В black lue rown reen 77
• Chapter 9 electrical system 78
• Ep type 78
• Inspection 78
• After the tester pointer shakes once 79
• Before measuring the item marked with con make a shortcircuit between the ignition terminal and earth terminal 79
• Chapter 9 electrical system 79
• Condition of the above measurement hioki 3030 tester was used with the measurement range of 1 kq 79
• Oo marked with con indicates a minute value because the tester pointer shakes a little for this item 79
• Since the value marked with con is the capacitor characteristic the tester reads a stable value shown in parentheses 79
• Tester s negative terminals 79
• Tester s positive terminals 79
• The values shown in the above table are just standards and it is impossible to check each value accurately 79
• Tolerance of resistance 20 79
• Chapter 9 electrical system 80
• Chapter 9 electrical system 81
• Ep type cable harness wiring diagram 81
• Ф c d unit 2 rectifier fuse cord chock solenoid starter solenoid stop switch 81
• Chapter 10 test run and inspection 82
• Inspection 82
• Test tank and test propeller 82
• Additional tightening after test run 83
• Break in 83
• Break in period 10 hours 83
• Chapter 10 test run and inspection 83
• Check the tightening condition of respective bolts and nuts after test run and additionally tighten them with the 83
• Cooling water and or oil leak from parts joined spots of the engine 83
• Cooling water discharge condition cooling water must vigorously be discharged from the water inspection 83
• Engine speed at acceleration and deceleration 83
• Extraordinary noise 83
• Fuel leak from parts joined spots of the engine 83
• Idle speed and stable idling 83
• Inlet exhaust valve etc is replaced perform a break in of the engine for fitting the sliding surfaces 83
• Items to be checked during test run 83
• Note perform a break in of the engine according to the following standards 83
• Off the lamp goes out as the engine starts 83
• On off operation of the engine oil warning lamp 83
• On the lamp goes on when the lead wire of the oil pressure switch is grounded to the body 83
• Operation of the clutch 83
• Operation of the stop switch 83
• Specified tightening torque 83
• When any of the piston piston ring piston pin crank shaft connecting rod cylinder cam shaft rocker arm 83
• While idling the engine check the following items 83
• Back cover 84
• Tomatsu corporation 84

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CHAPTER 2 SERVICE DATA AND TOOLS Description Connecting rod Check Item Standard value 1 Inner diameter of the small end 14 01 mm 0 5516 in 2 Oil clearance of the big end 0 015 0 041 mm 0 0006 0 0016 in 3 Side clearance of the big end 0 1 0 25 mm 0 0039 0 0098 in IN 0 13 0 17 mm 0 0051 0 0067 in 1 Valve clearance EX 0 18 0 22 mm 0 0071 0 0087 in 2 Outer diameter of valve stem Engine related Items Intake valve Exhaust valve 3 Inner diameter of valve guide 4 Clearance to valve stem IN 5 48 mm 0 2157 in EX 5 46 mm 0 2150 in IN 5 51 mm 0 2169 in EX 5 51 mm 0 2169 in IN 0 008 0 04 mm 0 0003 0 0016 in EX 0 025 0 057mm 0 0010 0 0022 in 5 Contact width of valve seat Valve spring Cam shaft EX 1 0 mm 0 0394 in 1 Free length 35 mm 1 378 in 1 Height of cam both IN and EX 23 63 mm 0 93 in 2 Outer diameter of bearing Pulley side 17 98 mm 0 7079 in Oil pump side 15 97 mm 0 6287 in 3 Clearance to holder bearing Rocker arm Shaft IN 1 0 mm 0 0394 in 1 Inner diameter 0 02 0 05 mm 0 0008 0 002 in 13 01 mm 0 5122 in 2 Outer diameter 12 99 mm 0 5114 in 3 Shaft clearance 0 006 0 035mm 0 00024 0 0014 in Timing belt 1 Tension Appearance Engine block 1 Compression pressure at 500 rpm 0 88 MPa 9 0 kg cm2 500 rpm Fuel related Items 8 Carburetor Setting mark 3V1A 3V2A Venturi 12 mm 0 47 in 17 mm 0 67 in Throttle bore 23 mm 0 91 in 23 mm 0 91 in Main jet MJ 76 92 Main air jet MAJ 150 135 Inner diameter of main nozzle 2 3 mm 0 09 in 2 6 mm 0 10 in Slow jet SJ 39 39 Slow air jet SAJ 90 70 Opening angle of throttle at W O T 75 Blind 75 Blind 9 0 mm 0 35 in 9 0 mm 0 35 in 900 rpm 900 rpm Pilot screw PS Fuel level from flange surface to float bottom Idle speed Clutch in 1 Inner diameter of pump body 2 Clearance between outer rotor and body 3 Height of outer rotor Oil pump 9 8 4 Clearance between rotor and body side 5 Clearance between outer rotor and inner rotor 6