Ñïèñîê ðàçäåëîâ Service Information Tohatsu1.Service Information1. 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 |
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