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Ñïèñîê ðàçäåëîâ Service Information Tohatsu

1.Service Information
1. Identification (Engine Serial Number)    1-2
2. Securing of 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) List of Special Tool                1-6
4. Pre-delivery Inspection            1-10
1) Steering Handle                  1-10
2) Gear Shift and Throttle            1-10
3) Engine Oil                        1-10
4) Gear Oil                          1-10
5) Check quantity of engine oil        1-11
6) Fuel Line                        1-12
7) Installation of Outboard Motor (Rigging)   1-12
8) Inspection of PTT Unit             1-12
9) Inspection of Start Switch and Stop switch   1-13
10) Propeller Selection                1-14
11) Cooling Water Check Port          1-14
12) Trim Tab                        1-15
5. Break-In Operation                1-15
6. Test Run                           1-16
7. Checks After Test Run            1-16
2.Service Data
1. Outboard Dimensions              2-2
1) Body dimensions                   2-2
2)Clamp Dimensions                  2-3
2. Cooling Water System Diagram    2-4
3. Specifications                     2-6
4. Warning Indication List • • •
Display for abnormalities during operation    2-8
5. Torque Specifications            2-10
6. Maintenance Data                2-12
7. Sealant And Lubricant            2-18
3.Inspections and
Adjustments
1. Special Tool                       3-2
2. Inspection Schedule              3-3
3. Top Cowl                          3-4
1) Adjustment of Cover Hook           3-4
2) Oil Filter and Oil Tank               3-4
3) Air Bleeding                        3-5
4. Fuel System                        3-6
1) Inspection of Fuel Pipes and Joints    3-6
2) Inspection of Fuel Filter              3-7
3) Inspection of Air Compressor Air Filter    3-7
4) Inspection of Air Pressure            3-7
5) Inspection of Fuel Pressure          3-8
5. Cooling System                    3-9
1) Inspection of Cooling Water Passage   3-9
2) Flushing with Water                3-10
3) Inspection of Compression Pressure    3-13
6. Power Unit                        3-14
1) Inspection of Drive Belt              3-14
2) Adjustment of Drive Belt Tension      3-15
3) Inspection of Spark Plugs            3-16
4) Inspection of Thermostat            3-17
7. Operating System                 3-18
1) Adjustment of Throttle Cable         3-18
2) Adjustment of Shift Cable            3-19
8. PTT System                        3-20
1) Inspection of PTT Unit Operation      3-20
2) Inspection of PTT Fluid Quantity      3-21
9. Lower Unit                        3-21
1) Inspection of Gear Oil Quantity       3-22
2) Replacement of Gear Oil            3-23
3) Inspection of Gear Case (for leakage)    3-23
10. Others                             3-24
1) Replacement of Anode              3-24
2) Inspection of Battery                3-25
3) Greasing                          3-26
4.Fuel System (TLDI)
1. Special Tools ..................................... 4-2
2. Parts Layout....................................... 4-3
Vapor Separator & Fuel Line .................. 4-3
FFP Ass'y................................................ 4-4
High Pressure Fuel Filter & Air Rail ........ 4-6
Air Compressor....................................... 4-8
Oil Pump ................................................. 4-10
3. What is TLDI?..................................... 4-12
Direct Fuel Injection System ................... 4-12
Inductive Ignition ..................................... 4-13
ECU ........................................................ 4-15
Fuel / Air Feed System ........................... 4-16
Oil System............................................... 4-17
Recirculation System .............................. 4-18
4. Removing Air Rail............................. 4-19
1) Decompression of Fuel Line and Air Line .... 4-19
2) Removing Air Rail Ass'y ..................... 4-19
5. Assembling Air Rail.......................... 4-21
1) Installing Injectors and Regulators...... 4-21
6. Removing Fuel System ................... 4-25
1) Removing Fuel Hose Ass'y................. 4-25
2) Attaching Fuel Hose Ass'y.................. 4-25
3) Draining Fuel from FFP Vapor Separator..... 4-26
4) Removing Vapor Separator ................ 4-26
5) Disassembly and Inspection of Vapor Separator... 4-27
6) Assembly of Vapor Separator............. 4-28
7) Assembly of Vapor Separator Ass'y ... 4-29
8) Removing FFP Ass'y .......................... 4-29
9) Disassembly and Inspection of FFP ... 4-29
10) Assembly of FFP Ass'y..................... 4-30
11) Attaching FFP Ass'y to Cylinder ....... 4-32
12) Inspection of Fuel Pump................... 4-33
Air Piping of Air Compressor............... 4-34
vi TLDI 115A 2007
Structure of Air Compressor ............... 4-35
7. Removing Air Compressor............. 4-36
1) Removing Drive Belt........................... 4-36
2) Removing Air Compressor.................. 4-36
3) Inspection of Drive Belt....................... 4-37
4) Removing Driven Pulley ..................... 4-38
5) Disassembly of Compressor Housing ...... 4-39
6) Inspection of Reed Valve.................... 4-39
7) Inspection of Cylinder and Piston ....... 4-39
8) Assembly of Compressor Housing ..... 4-40
9) Installation of Crank Shaft................... 4-41
10) Installation of Piston.......................... 4-42
11) Installation of Compressor Housing Ass'y......... 4-43
12) Measurement of Fuel Pressure and Air Pressure.... 4-44
13) Inspection of Oil Filter ....................... 4-46
14) Inspection of Oil Tank ....................... 4-46
15) Air Bleeding ...................................... 4-47
Arrangement of Oil Feed Lines........... 4-48
Arrangement of Recirculation hoses ...... 4-49
5.Power Unit
1. Special tools                      5-2
2. Parts Layout                      5-3
Engine                              5-3
Magneto                             5-4
Electric Parts                         5-6
Electric Parts (Starter Motor)            5-8
Air Chamber                          5-9
Throttle                              5-10
Cylinder Crank Case                  5-12
Piston & Crank Shaft                  5-14
3. Inspection Items                  5-15
1) Removing Power Unit              5-15
2) Removing Flywheel                5-19
3) Removing Stator Coil              5-20
4) Removing Cord Ass'y              5-21
5) Removing Throttle Link            5-24
6) Removing Air Chamber            5-25
7) Inspection of Throttle Body         5-26
Exploded Diagram of Short Block    5-28
Exploded Diagram of Piston-Crank Shaft Assembly    5-29
8) Removing Thermostat             5-30
9) Removing Cylinder Head / Head Cover    5-31
10) Inspection of Cylinder Head        5-32
11) Removing Exhaust Cover          5-33
12) Inspection of Exhaust Cover        5-33
13) Removing Crank Case            5-34
14) Removing Pistons                5-35
15) Disassembly of Crank Shaft        5-36
16) Inspection of Crank Shaft          5-36
17) Inspection of Engine Parts          5-38
18) Inspection of Pistons              5-39
19) Assembling Crank Shaft            5-42
20) Installing Pistons                  5-43
21) Assembling Power Unit Parts      5-44
22) Assembling Crank Case Halves    5-46
23) Assembling Exhaust Cover Parts    5-47
24) Assembling Cylinder Head Parts    5-49
25) Assembling Coil Bracket Parts      5-50
26) Assembling Crank Case Head Parts    5-50
27) Installing Air Chamber             5-51
28) Attaching Coil Bracket             5-53
29) Attaching Recirculation Hoses      5-54
30) Installing Alternator                5-55
31) Installing Flywheel                5-55
32) Installing Power Unit              5-56
6.Lower Unit
1. Special tools                      6-2
2. Parts Layout                      6-4
Gear Case (Drive Shaft)                6-4
Gear Case (Propeller Shaft)            6-6
3. Inspection Items                  6-8
1) Draining Gear Oil                  6-8
2) Removing Propeller                6-8
3) Removing Lower Unit              6-9
4) Removing Water Pump            6-10
5) Inspection of Water Pump          6-11
6) Disassembly of Water Pump Case (Lower)    6-12
7) Assembly of Water Pump Case (Lower)    6-12
8) Removing Propeller Shaft Housing Ass'y    6-13
9) Disassembly of Propeller Shaft Housing Ass'y    6-14
10) Inspection of Propeller Shaft Housing   6-15
11) Assembly of Propeller Shaft Housing    6-16
12) Disassembly of Propeller Shaft Ass'y    6-19
13) Inspection of Propeller Shaft Ass'y    6-20
14) Assembly of Propeller Shaft Ass'y    6-20
15) Disassembly of Cam Rod          6-21
16) Inspection of Clutch Cam          6-22
17) Assembly of Clutch Cam Parts      6-22
18) Removing Forward (A) Gear Ass'y    6-23
19) Disassembly of Forward Gear (A) Gear    6-24
20) Inspection of Forward (A) Gear      6-24
21) Assembly of Forward (A) Gear Parts    6-25
22) Removing Drive Shaft Ass'y        6-26
23) Disassembly of Drive Shaft Ass'y    6-27
24) Inspection of Drive Shaft           6-28
25) Assembly of Drive Shaft Parts      6-28
26) Disassembly of Gear Case         6-30
27) Inspection of Forward (A) Gear and
Pinion (B) Gear                   6-31
28) Inspection of Gear Case            6-31
29) Assembly of Gear Case Parts      6-32
30) Assembly of Lower Unit Parts      6-34
31) Attaching Clutch Cam Ass'y        6-37
32) Installation of Lower Unit          6-38
33) Measurement of Pinion (B) Gear Height
and Shim Selection                6-40
34) Measurement of Back Lash between Forward (A) and
Pinion (B) Gears and Shim Selection        6-42
35) Measurement of Back Lash between Pinion (B) and
Reverse (C) Gears and Shim Selection      6-45
36) Measurement of Propeller Shaft Play and
Selection of Washer Thickness        6-48
7.Cowl, Bracket and PTT
TLDI 115A 2007 vii
1. Special tools                      7-2
2. Parts Layout                      7-3
Cowl                                7-3
Bottom Cowl                          7-4
Shift                                7-6
Drive Shaft Housing                   7-8
Bracket                              7-10
Power Trim & Tilt                      7-12
3. Inspection Items                  7-14
1) Inner Cowl                        7-14
2) Removing Top Cowl              7-14
3) Adjustment of Cover Hook          7-14
4) Removing Bottom Cowl            7-15
5) Removing Drive Shaft Housing      7-16
6) Disassembly of Drive Shaft Housing    7-17
7) Inspection of Drive Shaft Housing   7-19
8) Assembly of Drive Shaft Housing Parts    7-20
9) Assembling Drive Shaft Housing Parts    7-23
10) Removing Steering Shaft Arm      7-24
11) Removing PTT Unit                7-25
12) Removing Clamp Bracket          7-27
13) Assembling Clamp Bracket Parts     7-28
14) Installation of PTT Unit              7-28
15) Assembling Steering Arm Parts     7-30
16) Removing Motor                  7-31
17) Inspection of Power Trim and Tilt Motor   7-32
18) Assembling Power Trim and Tilt Motor Parts    7-34
19) Removing Reservoir              7-35
20) Disassembly of Gear Pump        7-35
21) Disassembling Bracket Unit and
Assembling the Parts              7-36
22) Disassembly of Tilt Cylinder and
Trim Cylinder, and Assembly of the Parts    7-36
23) Assembling PTT Unit Parts        7-37
24) Air-Purging PTT Unit              7-41
8.Electrical System
1. Special Tools                      8-2
2. Parts Layout                      8-3
Starter Motor                         8-3
3. Inspection Items                  8-4
1) Disassembly of Starter Motor       8-4
2) Inspection of Armature            8-4
3) Inspection of Brushes              8-5
4) Inspection of Pinion                8-5
5) Inspection of Ignition and sparks    8-6
6) Inspection of Plug Cap              8-6
7) Inspection of Ignition Coils          8-7
8) Inspection of Pick Up Coil
(Crank Position Sensor)           8-7
9) Inspection of Pick Up Coil Air Gap    8-7
10) Inspection of Alternator            8-8
11) Inspection of Rectifier Complete    8-9
12) Inspection of Throttle Position Sensor    8-10
13) Inspection of Water Temperature Sensor    8-10
14) Inspection of Power Relay          8-11
15) Inspection of Air Injectors          8-11
16) Inspection of Fuel Injectors        8-11
17) Inspection of MAT
(Manifold Temperature) Sensor     8-12
18) Inspection of MAP Sensor
(Manifold Air Pressure Sensor)      8-12
19) Inspection of Starter Solenoid      8-12
20) Inspection of Oil Level Sensor      8-13
21) Inspection of Oil Pump            8-13
22) Inspection of PTT Solenoid        8-14
23) Inspection of PTT Switch          8-14
9.Troubleshooting
1. Troubleshooting                   9-2
Power Unit                        9-14
State 1 Engine will not start or is
hard to start.                9-14
Ignition System                       9-16
Fuel System                          9-18
Air System                           9-20
State 2 Full throttle engine revolution
speed is low, engine revolution
speed falls off, or engine stalls.
                             9-22
Ignition System                       9-23
Fuel System                          9-24
Lubrication system                    9-25
Cooling System                      9-26
State 3 Engine rotation is unstable or
surging occurs in low speed
range.                        9-27
Ignition System                       9-28
Fuel System                          9-29
PTT Unit
State 1 PTT unit will not operate.      9-30
State 2 PTT is not capable of sustaining
outboard motor.              9-31
2. Self-Diagnosis Function of TLDI    9-32
1) Terms related to self-diagnosis function   9-32
2) Operation Procedure of Self-Diagnosis
Function                          9-33
3) Warning Indication List • • •
Display for abnormalities during
operation                          9-36
4) Operating Hour Indication List
(Self Diagnosis • Mode 2)            9-38
5) Trouble Indication List
(Self Diagnosis • Mode 3)            9-40
6 � �Resetting TPS Initial Values          9-44
10.Rigging
1. Service Information               10-2
2. Service Data                      10-2
1) Load Limit of Boat                10-2
2) Installation Dimensions            10-2
3) Clamp Dimensions                10-3
4) Hanging Outboard Motor          10-5
5) Installation of Outboard Motor      10-5
3. Fuel System                        10-6
1) Fuel                             10-6
viii TLDI 115A 2007
2) Oil                              10-6
3) Electric Fuel Pump                10-6
4) Installation of Fuel Filter            10-6
5) Connection of Fuel Hose          10-7
6) Filling Fuel System                10-7
7) Filling Oil Tank                    10-7
8) Priming Oil Pump                  10-8
4. Connections to Outboard Motor    10-8
1) Steering Cable                    10-8
2) Drag Link                        10-9
3) Installation of Remote Control Cable
(Engine Side)                    10-10
5. Lower Unit                          10-13
1) Installation of Propeller            10-13
6. Electric System                    10-14
1) Battery Capacity                  10-14
2) Connection of Battery Cables      10-14
3) Installation of Battery (ies)          10-14
7. Accessories and Meters          10-15
1) Accessories.                      10-15
2) Installation of Meters              10-15
3) Wiring Remote Control and
Meter Leads                      10-17
11.Wiring Diagram
TLDI Wire Harness Terminals and
Connections                          11-2
Main Harness Diagram                11-3
115A EPTO Electrical Circuit        11-5
Electrical Wiring Assembling
Instruction Diagram -1                11-7
Electrical Wiring Assembling
Instruction Diagram -2                11-8
Electrical Wiring Assembling
Instruction Diagram -3                11-9
Outboard Motor Installation Template   11-11