TOHATSU MFS 9.9E User manual
トーハツ船外機サービスマニュアル
22
トーハツ船外機サービスマニュアル
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Copyright © 2017 Tohatsu Corporation. All rights reserved. No part of this manual
may be reproduced or transmitted in any form or by any means without the express
written permission of Tohatsu Corporation.
MFS1520E_EN_Cover_171225N.indd 3-4 17.12.25 4:41:59 PM
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This service manual provides information that is needed for inspection, service and repair of
applicable outboard motors. For information about operation of the products that are not described
in this document, refer to the owners manual. For our customers' safe and dependable use of the
product for long term, it is essential to maintain the performance and quality of the outboard. To
ensure this, the maintenance and service have to be done properly by service technicians with
fundamental knowledge and skills. This manual is utilized so that our customers can always use their
outboard motor with full satisfaction.
Safety Information
Safety Statements
The following safety statements are found throughout this manual and indicate
information which, if ignored, could result in fatal safety hazards or property damage:
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This service manual is designed so that service persons are able to perform repairs correctly.
Understand the following matters well for efficient service and repair.
Each chapter begins with the introduction of special tools that are used for the work described.
Parts that are serviced in each chapter and their details are presented by using a component composition
diagram.
Fastening torques are described in the component composition diagram. In the body text are critical
points of the applicable work.
Pictograms indicate that there is an important work instruction for the relevant parts. It also shows the type
of lubricant and its application point(s).
The component composition diagrams describe the names of the parts, the number of pieces of the parts
used, size of fasteners and special notes.
Specific works are described in detail by using illustrations and adding advice on the work.
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This manual uses SI unit system (International System of Units) for pressure, force (load), torque and
stress. This manual newly adopts the international unit construction system (SI unit system) followed by the
conventional imperial and metric systems enclosed by ( ) and [ ] as described below.
<Reference>
What is the SI unit system?
Although the measurement unit is standardized mostly with metric system in the world, the metric system
includes different kinds of unit systems.
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systems.
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unifying the different unit systems.
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Measures (IBWM) is located in Paris, General Conference of Weights and Measures (GCWM) passed a
resolution of the international unit system as "Systéme International d'Unités (French)" that is abbreviated as
"SI unit".
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discriminating them, but the SI unit system uses, for example, "kg" as the unit of mass, and "N" as the unit of
force, aiming to apply a kind of unit for a kind of physical quantity.
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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
ΰÊ/ÃÊ>`ÊÃÌÀÕiÌÃÊ oooo 1-5
1) Test Propeller ………………………… 1-5
2) Measuring Instruments ……………… 1-5
3) Special Tools ………………………… 1-6
{°Ê*Ài`iÛiÀÞÊëiVÌÊoooo 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) Inspection of PT unit (EFT, EPT) …… 1-10
8) Inspection of Manual Tilt
(Except for EFT, EPT)………………… 1-10
9) Inspection of Starting Switch and
Stop Switch …………………………… 1-11
10) Cooling Water Check Port …………… 1-12
11) Idling …………………………………… 1-12
12) Propeller Selection …………………… 1-12
x°ÊÊÀi>Ê"«iÀ>ÌÊoooooo 1-13
È°ÊÊ/iÃÌÊ,ÕÊ ooooooooooo 1-14
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1) Engine Dimensions …………………… 2-2
2) Transom Bolts ………………………… 2-4
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1) ECU Fuel Feed System ……………… 2-5
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Ó°Ê Ã«iVÌÊ-Vi`ÕiÊooooo 3-3
Î°Ê Ã«iVÌÊÌiÃÊooooooo 3-4
1) Inspection of Top Cowl ……………… 3-4
2) Inspection of Fuel Hoses …………… 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 …………… 3-9
9) Replacement of Gear Oil …………… 3-11
10) Inspection of Gear Case (for leakage)
………………………………………… 3-12
11) Inspection of Timing Belt …………… 3-13
12) Replacement of Timing Belt ………… 3-13
13) Inspection of Spark Plugs …………… 3-17
14) Inspection of Compression Pressure 3-18
15) Inspection and Adjustment of
Valve Clearance ……………………… 3-19
16) Adjustment of Throttle Cable
(Tiller handle model) ………………… 3-20
17) Adjustment of Shift • Throttle Cable
(Remote control model) ……………… 3-21
18) Inspection of Shift Lever Gear Operations
………………………………………… 3-23
19) Inspection of PT Unit Operation …… 3-24
20) Inspection of Manual Tilt Operations 3-24
21) Inspection of PT Fluid Quantity ……… 3-25
22) Inspection of Idle Speed……………… 3-25
23) Inspection of Ignition Timing ………… 3-26
24) Inspection of Anodes ………………… 3-27
25) Replacement of Anodes ……………… 3-28
26) Inspection of Propeller ……………… 3-28
27) Inspection of Thermostat …………… 3-29
28) Inspection of Cooling Water Passage 3-29
29) Inspection of Cooling Water Pressure 3-29
30) Flushing with Water…………………… 3-30
31) Inspection of Battery ………………… 3-31
32) Greasing points ……………………… 3-32
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Fuel Hose, Vent Hose, Breather Hose,
Cooling Water Hose ……………………… 4-3
ΰÊÊ*>ÀÌÃÊ>ÞÕÌÊ ooooooooo 4-4
Intake Manifold …………………………… 4-4
Electric Parts ……………………………… 4-8
Separate Fuel Tank ……………………… 4-12
{°Ê 1Ê-ÞÃÌiÊ ooooooooo 4-13
Ê £®v}ÕÀ>ÌÊvÊ1Ê-ÞÃÌi
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1) Sensors ………………………………… 4-14
2) Actuators ……………………………… 4-16
3) Control System (ECU) ……………… 4-17
Ê Ó®ÌÀÊ-ÞÃÌiÊ ooooooo 4-17
Ê Î®ÕiÊiVÌÊÌÀÊoooo 4-18
1) Fuel Injection Timing ………………… 4-18
2) Start Up Fuel Mapping ……………… 4-19
3) Acceleration Fuel Mapping ………… 4-19
4) Deceleration Fuel Mapping ………… 4-19
5) Correction Based On
Intake Air Temperature ……………… 4-19
6) Correction Based On
Cylinder Cooling Water Temperature
………………………………………… 4-19
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1) Location of Warning Buzzer
and Lamp (LED) ……………………… 4-20
2) Warning Notification, Abnormality and
Action to be taken …………………… 4-20
x°ÊÊ}ÌÊ-ÞÃÌiÊ ooooooo 4-21
1) Ignition Timing Controls ……………… 4-22
2) Ignition and Combustion Orders …… 4-22
3) Ignition Timing ………………………… 4-22
4) Operations …………………………… 4-22
È°ÊÊ
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1) Fuel Pump (Low Pressure
Mechanical Pump) …………………… 4-24
2) Vapor Separator ……………………… 4-24
3) Fuel Regulator ………………………… 4-25
4) Fuel Cooler …………………………… 4-25
Ç°Ê
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1) Air Intake System …………………… 4-26
n°ÊëiVÌÊÌiÃÊ ooooooo 4-27
1) Inspection of Fuel Supply System Piping
………………………………………… 4-27
2) Inspection of Filter …………………… 4-27
3) Inspection of Fuel Pump……………… 4-29
4) Inspection of Fuel Connector………… 4-29
5) Measuring Fuel Pressure …………… 4-30
6) Draining Fuel ………………………… 4-31
7) Disassembly of Vapor Separator …… 4-31
8) Inspection of Vapor Separator ……… 4-32
9) Reassembly of Vapor Separator …… 4-33
10) Inspection of ISC (Idle Speed Control)
………………………………………… 4-33
11) Inspection of Idle Speed……………… 4-33
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Ó°Ê *>ÀÌÃÊ>ÞÕÌÊoooooooooo 5-3
Engine……………………………………… 5-3
Magneto & Electric Parts ………………… 5-4
Fuel Pump ………………………………… 5-8
Pulley & Timing Belt ……………………… 5-12
Cylinder Head & Oil Pump ……………… 5-14
Cylinder & Crankcase …………………… 5-16
Piston & Crankshaft ……………………… 5-18
Top cowl …………………………………… 5-19
Recoil Starter ……………………………… 5-20
ΰÊÊëiVÌÊÌiÃÊ ooooooo 5-21
1) Inspection of Compression Pressure
………………………………………… 5-21
2) Inspection of Oil Pressure …………… 5-21
3) Inspection of Valve Clearance ……… 5-21
4) Removing Power Unit………………… 5-21
5) Removing Oil Strainer………………… 5-27
6) Inspection of Oil Strainer …………… 5-27
7) Removing Timing Belt and Pulley…… 5-27
8) Inspection of Timing Belt …………… 5-29
9) Installation of Pulley and Timing Belt
………………………………………… 5-29
10) Removing Cylinder Head …………… 5-32
11) Inspection of Valve Spring …………… 5-35
12) Inspection of Valve …………………… 5-35
13) Inspection of Valve Guide …………… 5-35
14) Inspection of Valve Seat……………… 5-36
15) Correction of Valve Seat……………… 5-37
16) Inspection of Locker Arm and
Locker Arm Shaft ……………………… 5-39
17) Inspection of Cam Shaft……………… 5-40
18) Inspection of Cylinder Head ………… 5-41
19) Inspection of Oil Pump ……………… 5-42
20) Installation of Valves ………………… 5-43
21) Installation of Cam Shaft …………… 5-44
22) Installation of Rocker Arm Shaft …… 5-44
23) Installation of Oil Pump ……………… 5-45
24) Installation of Cylinder Head ………… 5-46
25) Disassembly of Cylinder Block ……… 5-47
26) Inspection of Piston Outer Diameter
………………………………………… 5-48
27) Inspection of Cylinder Inner Diameter
………………………………………… 5-48
28) Inspection of Piston Clearance ……… 5-48
29) Inspection of Piston Ring Side
Clearance ……………………………… 5-49
30) Inspection of Piston Rings …………… 5-49
31) Inspection of Piston Pins …………… 5-50
32) Inspection of Connecting Rod Small End
Inner Diameter ………………………… 5-50
33) Inspection of Connecting Rod Big End
Side Clearance………………………… 5-50
34) Inspection of Crankshaft……………… 5-51
35) Inspection of Crank Pin (rod journal)
Oil Clearance ………………………… 5-52
36) Inspection of Crank Shaft Main Journal
Oil Clearance ………………………… 5-53
37) Inner Diameter of Cylinder/Crank Case
Bearing Holder (Inner Diameter Code)
………………………………………… 5-54
38) Thickness of Metal Bearing (Color of
Inner Diameter Code) ………………… 5-54
39) Assembling Piston and
Connecting Rod ……………………… 5-55
40) Assembling Fuel system Parts ……… 5-59
41) Installation of Oil Strainer …………… 5-60
42) Installation of Electrical Parts ……… 5-60
43) Installation of Flywheel ……………… 5-62
44) Installation of Power Unit …………… 5-63
45) Removing Recoil Starter …………… 5-67
46) Disassembly of Recoil Starter ……… 5-68
47) Inspection of Recoil Starter ………… 5-69
48) Installation of Recoil Starter ………… 5-69
È°ÜiÀÊ1Ì
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Ó°ÊÊ*>ÀÌÃÊ>ÞÕÌÊ ooooooooo 6-4
Gear Case ………………………………… 6-4
ΰÊÊëiVÌÊÌiÃÊooooooo 6-8
1) Draining Gear Oil……………………… 6-8
2) Removing Propeller…………………… 6-8
3) Removing Lower Unit ………………… 6-9
4) Removing of Water Pump and
Cam Rod ……………………………… 6-10
4st 9.9/15/20 2017
5) Inspection of Water Pump …………… 6-11
6) Inspection of Water Pipe …………… 6-11
7) Disassembly of Water Pump Case
(Lower) ………………………………… 6-12
8) Assembly of Water Pump Case (Lower)
………………………………………… 6-12
9) Disassembly of Cam Rod …………… 6-13
10) Inspection of Clutch Cam …………… 6-13
11) Assembly of Clutch Cam Parts ……… 6-13
12) Removing Propeller Shaft Housing Ass'y
………………………………………… 6-14
13) Disassembly of Propeller Shaft Housing
………………………………………… 6-14
14) Inspection of Propeller Shaft Housing
………………………………………… 6-16
15) Assembly of Propeller Shaft Housing
………………………………………… 6-16
16) Disassembly of Propeller Shaft Ass'y
………………………………………… 6-17
17) Inspection of Propeller Shaft Ass'y … 6-18
18) Assembly of Propeller Shaft Ass'y … 6-19
19) Removing Drive Shaft Ass'y ………… 6-20
20) Disassembly of Drive Shaft Ass'y …… 6-21
21) Inspection of Drive Shaft …………… 6-21
22) Inspection of Pinion (B) Gear ……… 6-22
23) Assembly of Drive Shaft Parts ……… 6-22
24) Removing Forward (A) Gear ………… 6-22
25) Disassembly of Forward (A) Gear … 6-23
26) Inspection of Forward (A) Gear……… 6-23
27) Disassembly of Gear Case ………… 6-24
28) Inspection of Gear Case……………… 6-24
29) Inspection of Gear Case (for leakage)
………………………………………… 6-25
30) Assembly of Gear Case Parts ……… 6-26
31) Installation of Pinion (B) Gear ……… 6-28
32) Measurement of Back Lash
between Forward (A) and Pinion (B)
Gears and Shim Selection …………… 6-29
33) Reassembly of Pinion (B) Gear Nut … 6-31
34) Assembly of Pump Case …………… 6-32
35) Installing Propeller Shaft Housing Ass'y
………………………………………… 6-33
36) Installation of Lower Unit …………… 6-34
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Manual Tilt Operation …………………… 7-3
Tilt Up Operation ………………………… 7-4
Tilt Down Operation ……………………… 7-5
Shock Absorber Valve …………………… 7-6
Thermal Valve …………………………… 7-7
{°Ê*>ÀÌÃÊ>ÞÕÌÊ oooooooooo 7-8
Drive Shaft Housing ……………………… 7-8
Tiller Handle & Shift ……………………… 7-10
Front Panel &
Drive Shaft Housing Cover ……………… 7-14
Remote Control Parts …………………… 7-16
Bracket (Manual) ………………………… 7-18
Bracket (PT) ……………………………… 7-22
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1) Inspection of Throttle Cable ………… 7-26
2) Installation of Tiller Handle…………… 7-26
3) Adjustment of Friction Lever ………… 7-28
4) Removing Drive Shaft Housing ……… 7-29
5) Disassembly of Drive Shaft Housing
………………………………………… 7-30
6) Assembly of Drive Shaft Housing …… 7-32
7) Installation of Drive Shaft Housing Ass'y
………………………………………… 7-33
8) Removing Steering Shaft …………… 7-34
9) Installing Steering Shaft ……………… 7-35
10) Disassembling Clamp Bracket
(EFT, EPT models) …………………… 7-36
11) Assembling Clamp Bracket
(EFT, EPT models) …………………… 7-37
12) Disassembling Clamp Bracket
(MF, EF models) ……………………… 7-38
13) Assembling Clamp Bracket
(MF, EF models) ……………………… 7-39
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n°Ê*/ÊÌÀÊ ooooooooooo 7-44
1) Removal, Check and Repair of
PT Motor ……………………………… 7-44
2) Continuity Test ………………………… 7-45
3) Inspection of Motor …………………… 7-45
4) Replacement of Motor ……………… 7-45
5) Assembling PT Motor………………… 7-46
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1) Disassembly of PT Pump …………… 7-47
2) Assembling PT Pump ………………… 7-49
3) Air-Purging PT Unit (Separated from
Outboard Motor) ……………………… 7-51
4) Installation of PT Ass'y ……………… 7-52
5) Inspection of PT Relay ……………… 7-54
6) Inspection of PT Switch ……………… 7-55
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Ó°Ê iVÌÀV>Ê«iÌÊ>ÞÕÌÊ 8-3
Port Side View …………………………… 8-3
Bow Side View …………………………… 8-4
Starboard Side View……………………… 8-5
Top View …………………………………… 8-6
Housing Cover (Front) …………………… 8-7
ΰÊÊ *>ÀÌÃÊ>ÞÕÌÊ ooooooooo 8-8
Magneto & Electric Parts ………………… 8-8
Fuel Pump ………………………………… 8-12
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1) Inspection of Ignition Firing ………… 8-16
2) Inspection of Plug Cap ……………… 8-16
3) Inspection of Ignition Coils…………… 8-17
4) Inspection of Exciter Coil …………… 8-17
5) Inspection of Pulser Coil……………… 8-18
6) Adjustment of Pulser Coil Air Gap … 8-18
7) Inspection of Oil Pressure Switch…… 8-19
4st 9.9/15/20 2017
8) Inspection of Engine Temperature Sensor
………………………………………… 8-20
9) Inspection of Neutral Switch (Except MF)
………………………………………… 8-20
10) Inspection of Start Switch (EF, EFT)
………………………………………… 8-21
11) Inspection of Stop Switch …………… 8-21
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1) Inspection of Injectors………………… 8-22
2) Inspection of ISC Valve ……………… 8-22
3) Inspection of T-MAT Sensor ………… 8-23
4) Inspection of Fuel Feed Pump
(EP, EPT) ……………………………… 8-23
5) Inspection of Throttle Position
Sensor (TPS) ………………………… 8-24
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ÊÊÊÊ……………………………………… 8-24
1) Inspection of Fuse …………………… 8-24
2) Inspection of Starter Solenoid ……… 8-24
3) Disassembly of Starter Motor ……… 8-25
4) Inspection of Starter Motor Pinion … 8-25
5) Inspection of Armature ……………… 8-25
6) Inspection of Brushes ………………… 8-26
7) Inspection of Starter Motor
Operation ……………………………… 8-27
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1) Inspection of Charge Coil …………… 8-27
2) Inspection of Rectifier ………………… 8-27
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Ó°Ê*ÜiÀÊ1ÌÊ oooooooooo 9-3
ÊÊÊState 1 : Engine will not start or
is hard to start. …………………………… 9-3
Starting System …………………………… 9-3
Ignition System …………………………… 9-5
Fuel System ……………………………… 9-7
State 2 : Full throttle engine
revolution speed is low.
Engine revolution speed fall off.
Engine stalls ……………………………………
9-9
Ignition System …………………………… 9-10
Fuel System ……………………………… 9-11
Lubrication System ……………………… 9-12
Cooling System …………………………… 9-13
State 3 : Engine rotation is unstable or
hunting occurs in low speed range.
………………………………………… 9-14
Ignition System …………………………… 9-15
Fuel System ……………………………… 9-16
ΰÊ*/Ê1ÌÊ oooooooooooo 9-17
State 1 : PT will not operate. …………………
9-17
State 2 : PT is not capable of sustaining
outboard motor. ………………… 9-18
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Ê Ê£°Ê-iÌÊ1«Ê ooooooooooo 9-19
1) Diagnosis Software Install …………… 9-20
2) Installing USB to serial converter driver
(If there is no RS232 port) …………… 9-21
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Ê ÊÊ ÊiVÌÊ oooooooo 9-22
1) Preparation …………………………… 9-22
Ê Î°ÊÊ"«iÀ>Ì}Ê*ÀVi`ÕÀiÊ ooo 9-23
1) Start Up ………………………………… 9-23
2) Models and Menu Selection ………… 9-23
3) Preface and Introduction …………… 9-23
4) Setting Communication (COM) Port… 9-24
5) Engine Monitor………………………… 9-26
6) Diagnostic History …………………… 9-27
7) At Engine Shut-down Test …………… 9-28
8) At Engine Running Test ……………… 9-29
9) Air Purging for High Pressure fuel circuit
………………………………………… 9-30
10) Explanation of Error code …………… 9-31
11) Exit Diagnostic ………………………… 9-31
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1) Installation of Remote Control Cable
(Engine Side) Remote Control Model
………………………………………… 10-2
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1) Installation of Meters ………………… 10-6
2) Installation of Battery ………………… 10-6
3) Wiring Diagram of Remote and
Control Meters ………………………… 10-7
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1) Warning Indication …………………… 10-8
££°7À}Ê>}À>
7À}Ê>ÀÌ……………………………… 11-2
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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
ΰÊ/ÃÊ>`ÊÃÌÀÕiÌÃÊ oooo 1-5
1)Test Propeller …………………………… 1-5
2)Measuring Instruments ………………… 1-5
3)Special Tools …………………………… 1-6
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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)Inspection of PT unit (EFT, EPT)……… 1-10
8)Inspection of Manual Tilt
(Except for EFT, EPT) ………………… 1-10
9)Inspection of Starting Switch and
Stop Switch …………………………… 1-11
10)Cooling Water Check Port …………… 1-12
11)Idling …………………………………… 1-12
12)Propeller Selection …………………… 1-12
x°Ê ÊÀi>Ê"«iÀ>ÌÊ ooooo Ê1-13
È°Ê Ê/iÃÌÊ,ÕÊooooooooooo 1-13
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4st 9.9/15/20 2017
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Engine serial number is stamped on the Swivel bracket of
outboard motor body.
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Gasoline is hazardous material and very flammable. Do not
handle gasoline near ignition source such as spark or static
electricity.
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Exhaust gas or gasoline vapor is hazardous for human
health. Be sure to ventilate well when working indoors.
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Wear a pair of goggles, working gloves and safety shoes to
protect human body from chemicals and oils and eyes from
particles generated by grinding or polishing works. Avoid
adhesion of matters such as oil, grease or sealing agent to
the skin. In case of exposure to such matters, wash away
with soap or warm water immediately.
{®ÊiÕiÊ*>ÀÌÃ
Use parts and/or chemicals that are genuine items or
recommended.
Model Name
Model Type
Serial Number
1-3
4st 9.9/15/20 2017
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Use specified special tools to prevent damaging to parts
and to perform work safely and surely. Be sure to follow
installation procedures described in this manual and use
tightening torque specified.
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Remove foreign substances and dirt from outboard motor
body and individual parts by cleaning. Apply recommended
oil or grease to rotating areas and sliding surfaces. After
individual works, always perform verifications such as
ensuring smooth movement and sealing.
2
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1-4
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4st 9.9/15/20 2017
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(1) Secure outboard motor to dedicated stand firmly.
(2) Take special care not to scratch painted surface or mating
surfaces of cylinder and crankcase.
(3) Replace unreusable parts such as packings, gaskets, O
rings, oil seals, spring pins or split pins with new ones after
they were removed . Replace deformed snap rings with new
ones.
(4) When replacing parts, be sure to use genuine parts. For
fluids such as gear oil, use genuine product.
(5) Be sure to use special tools that are specified, and perform
the works properly.
(6) When reassembling parts, use their mating marks. For parts
without mating marks, simple marking makes reassembling
easier. Use applicable parts list for reference.
(7) Clean individual parts that have been removed, and check
their conditions.
(8) When reassembling parts, take sufficient care also for
details such as fits, repair limits, air tight, clogging of oil
holes for lubrication and greasing, packings, wirings and
piping. For components using many bolts and nuts for
assembling, such as cylinder head and crankcase, tighten
all the fasteners evenly to their specified torques clockwise
in two or three stages, inner ones first and then outer ones.
(Reverse the order when disassembling.)
(9) When installing bearings, face the flat (numbered) side to
the special assembling tool.
(10) When installing oil seals, be careful not to scratch the
surface of the lip that contacts with the shaft, and install
them in correct orientation. Apply recommended grease to
the lip before installation.
(11) When applying liquid packing, take sufficient care for the
thickness and quantity. Excessive application may be oozed
out, adversely affecting interior of the crankcase. Use
adhesive after thoroughly reading the instructions.
1
1
7
3
2
5
4
4
10
31
31
31
31
31
32
42
42
36
35
40
41
33
33
34
38
39
37
23
25 24
26
30
37
1-5
4st 9.9/15/20 2017
Ó®Êi>ÃÕÀ}ÊÃÌÀÕiÌÃ
For the following measuring instruments, use commercially available ones.
Circuit tester (HIOKI 3000 Serise : Resistance : 1Ω, 10Ω, 10 kΩ, AC voltage : 30 to 300V, DC voltage : 30V )
Vernier calipers ( M1 type, 300 mm )
Micrometer ( minimum graduation of 0.01, outer, 0 to 25 mm, 25 to 50 mm, 50 to 75 mm )
Cylinder gauge ( 4 to 6 mm, 10 to 25 mm, 25 to 30 mm, 50 to 75 mm )
Ring gauge ( ø5.5, ø17, ø42, ø70 )
Dial gauge ( minimum graduation of 0.01 )
Thickness gauge ( 0.03 to 0.3 mm )
V block
Surface plate ( 500 mm x 500 mm )
Dial gauge magnet base or dial gauge stand
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P/N. 3RS-64110-0
Outer diameter : 130 mm
With : 20 mm
Outboard motor model Rotational speed at WOT
(Wide Open Throttle) (r/min)
MFS9.9E Approx.4000
MFS15E Approx.5000
MFS20E Approx.5800
MM
MM
1-6
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4st 9.9/15/20 2017
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Measuring compression
pressure
Compression Gauge
P/N. 3AC-99030-0
Adjusting valve clearance
Valve Clearance Driver
P/N. 3AC-99071-0
Torque Wrench
P/N. 3AC-99070-0
Adjusting valve clearance
Removing/installing oil filter
Oil Filter Wrench
P/N. 3AC-99090-0
Measuring engine
revolution speed
Tachometer
P/N. 3AC-99010-0
Removing/installing flywheel
Flywheel Puller Kit
P/N. 369-72211-0
Inspecting pressure
Vacuum/Pressure Gauge
P/N. 3AC-99020-1
Measuring fuel pressure
Pressure Gauge Ass'y
P/N. 3T5-72880-0
Holding crank shaft
Crank Shaft Holder
P/N. 3BJ-72815-0
Measuring gaps
Thickness Gauge
P/N. 353-72251-0
Piston Ring Tool
P/N. 353-72249-0
Removing or attaching
piston rings
Removing spring pin
Spring Pin Tool A
P/N. 345-72227-0 (ø3.0)
Installing piston
Piston Slider
P/N. 3AC-72871-0
Installing spring pin
Spring Pin Tool B
P/N. 345-72228-0 (ø3.0)
Bevel Gear B Nut Wrench
P/N. 346-72231-0
Bevel Gear B Nut Socket
P/N. 346-72232-0
Removing/installing Pinion Nut (B Gear Nut)
1-7
4st 9.9/15/20 2017
Used in combination with
center plate and roller bearing
attachment
Driver Rod
P/N. 3AC-99702-0
Used in combination with a driver rod
attaching oil seal of propeller shaft
housing.
Oil Seal Attachment
P/N. 3AG-99820-0
Universal Puller Plate
P/N. 3AC-99750-0
Removing reverse (C) gear
bearing
Measuring backlash
Backlash Measuring Tool Clamp
P/N. 3B7-72720-0
Used in combination with driver
rod and roller bearing attachment
Positioning of propeller shaft housing roller bearing
Center Plate
P/N. 3AC-99701-0
Used to attach dial gauge
when measuring backlash
Dial Gauge Plate
P/N. 3B7-72729-0
Attaching bevel gear / forward (A)
gear bearing outer race
Bearing Outer Press Kit
P/N. 3B7-72739-1
"*
Combined use with driver rod and center plate.
Propeller shaft housing Roller bearing attaching
and removing
Roller Bearing Attachment
P/N. 3BJ-99710-0
Installing pump case (lower)
oil seal
Oil Seal Attachment
P/N. 3BJ-99820-0
Spark Tester
P/N. 3F3-72540-0
Inspecting Ignition
Installing clutch pin
Clutch Pin Snap Tool
P/N. 3KY-72229-0
ø110 x ø71 ø29.5 x ø16.5
ø25.5 x ø12.5
Used to engine diagnosis
Diagnostic Tool kit
P/N. 3RS-72920-0
1-8
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4st 9.9/15/20 2017
RollerBearingPressBolt
（）
RollerBearingPressRod
（）
RollerBearing
OuterPressGuide
（）
Bolt（）
Wssher（）
RollerBearingPressCollar
（）
RollerBearingPressFlange
（）
RollerBearingPress
（）
RollerBearingPressGuide
（）
Ring（）
MarkingSide
mark
mark
Stopper
Measuring backlash between forward (A) gear
and pinion (B) gear
Backlash Measuring Tool Kit
P/N. 3C8-72234-2
"*
Roller Bearing Press Kit
P/N. 3AC-72900-1
Installing/attaching drive shaft housing roller bearing
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