Tohatsu MFS 9.8 A3 [50/84] Repair and replacement of engine parts

Содержание

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

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CHAPTER 4 POWER UNIT 6 Repair and Replacement of Engine Parts Repair of valve seat 1 Plane the valve seat face with the 45 valve seat cutter 2 Depending on the situation the contact position of the seat is too high or too low use the 30 cutter or 60 cutter and then repair the surface area with the 45 cutter 3 Apply Prussian Blue compound or equivalent evenly on the seat face While turning the valve with the valve lapper check face width between the valve and valve seat If necessary repair the face width with the valve seat cutter Standard value Standard value IN 1 0 mm 0 0394 in 2 0 mm or more 0 0787 in EX 1 0 mm 0 0394 in 2 0 mm or more 0 0787 in 4 After repair of the valve seat lap the valve for good fitting Apply lapping compound thinly on the seat and lap the valve while turning and tapping it with the valve lapper Remarks Since the lapping supplied in coarse medium a set of and compound three fine is grades lap the valve with all of them in order from coarse medium and fine Notes When using lapping compound of a different grade completely wipe out the previously used compound beforehand After lapping is complete wash the valve and valve seat after completely wiping the compound out of them 47