TOHATSU TLDI 40 Service Manual
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TOHATSU TLDI 40 Service Manual

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WASH
OIL LEVEL
OIL
SERVICE MANUAL

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Summary of Contents for TOHATSU TLDI 40

  • Page 1 WASH OIL LEVEL SERVICE MANUAL...
  • Page 2 Chapter 1 Specifications 1. Specifications Table ..............1-3 2. Outline Dimensions ...............1-4 3. Background on TLDI..............1-6...

  • Page 4: Specifications Table

    1. Specifications Table MODEL Item EPTO EFTO Overall length (approx.) 630 mm (24.8 in) 1120 mm (44.1 in) Overall width (approx.) 345 mm (13.6 in) 384 mm (15.1 in) Transom (S) 1227 mm (48.3 in) Overall height Transom (L) 1354 mm (53.3 in) (approx.) Transom (UL) 1481 mm (58.3 in)

  • Page 5: Outline Dimensions

    2. Outline Dimensions...
  • Page 6 External Dimensions Item Remarks 499 mm (19.6 in) Transom (S) 728 mm (28.7 in) Transom (L) 855 mm (33.7 in) Transom (UL) 982 mm (38.7 in) Transom (S) 403 mm (15.9 in) Transom (L) 530 mm (20.9 in) Transom (UL) 657 mm (25.9 in) 568 mm (22.4 in) Models EFTO, EFO...

  • Page 7: Background On Tldi

    Tohatsu applies to direct fuel-injection system engines. 1. Two-Stroke Low-Pressure Direct Injection (TLDI) TLDI is the name Tohatsu uses for two-stroke engines that utilize the air-assisted, low-pressure direct injection system. The air-assisted, low-pressure direct injection system has been combined with the L-CDI or (Long-arc duration CDI ignition system and Engine Control Unit (ECU), which performs precision control of fuel mixture, injection timing and ignition timing to maximize combustion efficiency in the TLDI-50 engine.
  • Page 8 3. ECU Control With TLDI, a network of connected sensors enables the Engine Control Unit (ECU) to precisely regulates fuel mixture injection rate and ignition timing. The ECU also uses a stratified fuel feed process to provide lean combustion in the low-speed range, while utilizing more homogenized change to ensure the fuel mixture is distributed uniformly throughout the combustion chamber when operating in the high- speed range to ensure maximum combustion efficiency.
  • Page 9 Long-duration CDI (L-CDI) The L-CDI or Long-arc duration CDI ignition system is used as the TLDI ignition system to maximize combustion efficiency, fuel economy and minimize exhaust emissions. The L-CDI system offers a longer plug sparking interval, via spark plug, than used with conventional two-stroke engines. This is designed to ensure more complete combustion of the mixture in the chamber.
  • Page 11 1-10...
  • Page 12 1-11...
  • Page 13 1-12...
  • Page 14 Chapter 2 Servicing Information 1. General Precautions for Servicing ..........2-3 2. Specifications and Standards Used in Servicing .......2-4 3. Lists of Points for Applying Sealant, Adhesive and Lubrication ..2-10 4. Torque Table .................2-16 5. Special Tools ................2-17...

  • Page 16: General Precautions For Servicing

    (3) Always replace packing, gaskets, O-rings and split pins with new ones when reassembling engine parts. Make a point of replacing snap rings as well. (4) When replacing, be sure to use genuine Tohatsu brand parts and lubricants or products recommended by Tohatsu.

  • Page 17: Specifications And Standards Used In Servicing

    2. Specifications and Standards Used in Servicing Name of Part Item to check Standard values • Outer diameter • 67.96 mm (2.676 in) Measure at a point 12 mm (0.47 in) Piston above the lower edge of the piston skirt. •...
  • Page 18 Service limit Servicing procedure • 0.8 mm (0.031 in) or more • Replace with new piston ring if cylinder liner wear has not yet exceeded the repair limit. • 0.9 mm (0.035 in) or more • 0.05 mm (0.002 in) or more •...
  • Page 19 Name of Part Item to check Standard values • 10 mm (0.39 in) or more at • Sparking performance 350 rpm Measured using spark tester • #1 ⇒ #2 ⇒ #3 • Sparking order • 280 W • Alternator (max.) •...
  • Page 20 Service limit Servicing procedure 1) 1.2 mm (0.047 in) or more 1) Repair so that plugs conform to standard values. 2) When electrodes show excessive wear 2) Replace with new spark plug. • When sensor no longer conforms to standard •...
  • Page 21 Name of Part Item to check Standard values • Tilted up: 13.7 to 16.7 MPa Pump assembly: (140 to 170 kg/cm ) (1987 to 2421 psi) • Relief valve opening pressure • Tilted down: 2.0 to 3.3 MPa (2.0 to 34 kg/cm ) (290 to 479 psi) •...
  • Page 22 Service limit Servicing procedure • When parts no longer conform to standard values • Replace with new parts. • When parts show excessive wear or damage • When parts show excessive wear or damage • When parts showed deterioration or contamination •...

  • Page 23: Lists Of Points For Applying Sealant, Adhesive And Lubrication

    3. Lists of Points for Applying Sealant, Adhesive and Lubrication 1342 1373B Adhesive 648 1741 Primer 7471 Engine block Piston Piston pin Piston ring Cylinder liner Drive pulley Pulley nut Small-end bearing Big-end bearing Main bearing Big-end bearing washer Main bearing, upper Main bearing, upper oil seal Crankcase head O-ring Crankshaft oil seal, lower...
  • Page 24 Remarks LT-2 LOR#101 KS-64 Ring groove, piston pin hole and skirt Skirt Inwall Apply Loctite 648 to the punched side after applying primer to the shaft and punched surface Sliding surface Sliding surface Sliding surface Sliding surface Sliding surface Lip area Lip area (on oil seal in crankcase head) Lip area (on oil seal in crankcase head) Confirm thickness of coating...
  • Page 25 1342 1373B Adhesive 648 1741 Primer 7471 Air rail Air injector O-ring Fuel injector O-ring Fuel regulator O-ring Air regulator O-ring Compressions seal Spark plug O-ring Air hose L nipple O-ring Fuel hose L nipple O-ring Valve assembly Air compressor Air compressor piston Air compressor cylinder Air compressor piston pin...
  • Page 26 Remarks LT-2 LOR#101 KS-64 O-rings at 2 locations O-rings at 2 locations O-rings at 2 locations O-rings at 2 locations Air rail, 6 locations Air rail, 3 locations O-rings at 2 locations O-rings at 2 locations Taper screw Entire outer surface Entire outer surface Apply when inserting pin Entire outer surface...
  • Page 27 1342 1373B Adhesive 648 1741 Primer 7471 Gear case Cam rod bushing Cam rod bushing O-ring, 2.4 to 5.9 Cam rod bushing O-ring, 3.5 to 21.7 Cam rod bushing stopper bolt Gear case lubricating oil Gear case bolt Extension housing bolt Propeller shaft housing bolt Stern bracket Bracket bolt...
  • Page 28 Remarks LT-2 LOR#101 KS-64 Entire surface Under-neck surface Oil capacity 500 ml Under-neck surface Under-neck surface Under-neck surface Fill with grease, apply grease to tapped hole Inner surface Both surfaces Fill interior with grease Sliding surface Sliding surface Sliding surface Thread Spline surface Sliding surface...

  • Page 29: Torque Table

    4. Torque Table Item Part to tighten Initial torque (N-m) Full torque (N-m) Ib-ft q2.0 to 2.9 Cylinder head cover to r4.6 to 6.3 (0.5 to 0.6 kg-m) Bolt (M6) 3.6 to 4.4 cylinder head (0.2 to 0.3 kg-m) Cylinder head cover w12 to 15 e29 to 34 (3.0 to 3.4 kg-m) cylinder head to...

  • Page 30: Special Tools

    5. Special Tools 1. List of Special Tool FUEL 5.5MPa 0.62MPa 3T5728680 3T5728800 Pressure gauge assembly Crimping pliers Drive pulley press Piston slider 3T5-72880-0 3T5-72864-0 3T5-72868-0 3T5-72871-0 For measuring air rail fuel and For crimping OETIKER make For press fitting in the drive For installing the piston in the air pressure.
  • Page 31 Drive pulley puller assembly Flywheel puller kit 3C7-72211-1 3T5-72890 For removing drive pulley. For removing and installing flywheel. Spring pin tool A Spring pin tool B Needle bearing puller kit 345-72227-0 345-72228-0 3C8-72700-0 For removing and installing gear case needle bearing and For removing and installing spring pins.
  • Page 32 2. Using the Special Tool q Pressure Gage Assembly Measuring Fuel and Air Pressure 1. Mover the lever for cock (3T5-72883-0) to position A shown in the figure below. 2. Screw adapter B (3T5-72884-0) into either the air or fuel pressure measuring valves located on the air rail.
  • Page 33 w Crankshaft Holder (3T5-72815-0) Removing Pulley Nut 1. Disassemble the flywheel. (Refer to section q of this chapter.) 2. Install the magneto key and crankshaft holder for this engine. 3. Use the magneto nut to secure the crankshaft holder in place. (The magneto nut is threaded clockwise.) 4.
  • Page 34 4. Insert the three collars (3T5-72895-0) between plate C (3T5-72893-0) and the already joined plates A and B. 5. Using a 19 mm socket wrench, turn the bolt (3T5-72894-0) until the drive pulley comes away. Note: Apply Tohatsu grease to the sections in the diagram marked by the asterisk (*). Bolt 8-125 3T5-72896-0...
  • Page 35 r Drive Pulley Press (3T5-72868-0) Inserting Drive Pulley 1. Remove any oil or grease from crankshaft and drive pulley hole. Apply Loctite Primer 7471; wait 5 minutes; then apply Loctite 648 to the hole. 2. Insert the half moon key in the crankshaft and install the drive pulley. 3.
  • Page 36 3T5-72863-0 Fuel injector O-ring 2.8 - 20.2 Apply Tohatsu engine oil here. u Crimping Pliers (3T5-72864-0) This tool is used to install the specified clamps on the fuel and air system hoses. It is intended for use with the following parts.
  • Page 37 2-24...

  • Page 38: Table Of Contents

    Chapter 3 Inspection and Maintenance 1. Periodic Inspections..............3-2 2. Inspecting Engine Oil Systems ............3-3 3. Inspecting Fuel Systems...............3-3 4. Inspecting Compression System ..........3-4 5. Inspecting Gear Case Area ............3-5 6. Washing Procedure ...............3-6 7. Inspecting Cooling System............3-6 8. Inspecting Power Trim and Tilt System ........3-8 9.
  • Page 39 1. Periodic Inspections Inspection intervals Inspection 10 hrs. 30 hrs 50 hrs. 100 hrs. 200 hrs. Inspection procedure Remarks points Yearly 1.5 years bimonthly monthly 3 months 6 months 2 years High press. Replace Entire cartridge Fuel filter Wear on pipes & Piping Replace leaking connectors...

  • Page 40: Inspecting Engine Oil Systems

    2. Inspecting Engine Oil System Bleeding Air From Oil Pump Conduct a visual check of the clear vinyl pipes connecting the oil pump to the oil tank to inspect for the presence of air. Bleed hoses if necessary. Do this by loosening the oil drain screw q on the From oil filter air pump and bleed until all air has been removed from the piping.

  • Page 41: Inspecting Compression System

    Cleaning Fuel Tank Filter q Fuel pickup elbow w Filter Turn q to the left to remove and clean w. Cleaning Fuel Tank Clean the fuel tank whenever there is a buildup of water or foreign matter. 4. Inspecting Compression System Measuring Procedures Use the following procedures to measure the compression of the individual cylinders.

  • Page 42: Inspecting Gear Case Area

    5. Inspecting Gear Case Area Replacing Propeller Worn or bent propeller blades will not only affect performance and can also lead to engine damage. • Move the shift lever to the neutral position; stop the engine, then replace the propeller. •...

  • Page 43: Washing Procedure

    6. Washing Procedure Flushing attachment Take care not to come into contact with the propeller while it is in motion. Be sure to remove the propeller when operating the engine on land. q WASH Be sure not to operate the engine in confined areas, such as a boat house, as the exhaust fumes contain toxic carbon monoxide gas.
  • Page 44 • t Bolt: type H835 at 4 locations Inspect the following components. • y Upper pump case • u Pump case liner • i Pump impeller Replace with new one. • o Key for water pump impeller • !0 Gasket for pump case Replace with new one.

  • Page 45: Inspecting Power Trim And Tilt System

    8. Inspecting Power Trim and Tilt System Checking Oil Level Note that the oil level is checked by first tilting up the outboard engine (see figure), so that the reserve tank is in a perpendicular position. To check level, turn the oil plug counterclockwise to remove it;...

  • Page 46: Table Of Contents

    Chapter 4 Disassembling, Inspecting and Reassembling Power Unit 1. Power Unit ..................4-2 1) Removing Power Unit ..............4-3 2) Installing Power Unit ..............4-5 2. Peripheral Parts ................4-6 1) Electrical System ...............4-6 2) Air Supply System ..............4-10 3) Fuel System................4-20 4) Oil Pump ..................4-29 5) Throttle Mechanism ..............4-31 3.

  • Page 47: Power Unit

    1. Power Unit...

  • Page 48: Removing Power Unit

    1) Removing Power Unit Disassemble the following components. Fuel connector Battery Ring gear cover r Battery cable Disassemble the following components. Begin by disassembling the oil tank; then remove the 3 connectors from the power trim and tilt (PT&T) switch. t Oil tank mounting bolts y PT&T switch cable connectors Fuel hose (remove from strainer inlet)
  • Page 49 Disassemble splash pan. Remove engine mounting bolts. q Bolt: type H880 at 6 locations Secure eyebolts q to the flywheel; then use a suffi- ciently strong hoist to suspend the power unit while keeping it in the horizontal position. Suspend slowly, taking care not to catch the power unit on any of the wiring or hoses.
  • Page 50 2) Reassembling Power Unit Install the following components. Replace with new gasket. • Install the engine base gasket. • Knock pin Secure eyebolts to the flywheel; then use a sufficiently strong hoist to suspend the power unit while keeping it in the horizontal position.

  • Page 51: Peripheral Parts

    2. Peripheral Parts 1) Electrical System Removing CPS *, Flywheel and Alternator Remove the following component. q CPS * CPS: abbreviation for crank position sensor. Remove the following component. w Flywheel nut Special tool Plate Socket wrench: 27 mm Bolt: type M820 Remove the following component.
  • Page 52 Remove the following components. u Coil bracket i Cable clamp Remove the following components. o Solenoid switch bracket !0 Bolt: type H625 at 3 locations Removing ECU * * ECU: abbreviation for the engine control unit. Remove the following components. q ECU connector While pressing down on hook, remove by prying gently with a flathead screwdriver.
  • Page 53 Removing Harness Assembly Remove the following components. Remove harnesses in order starting from remote control side. r Water temperature connector • Remove by pressing down on hook and pulling out connector. t Fuel injector connector • Remove by pressing down on wire hook and pulling out connector.
  • Page 54 Removing Ignition Coil and Rectifier Regulator Remove the following components. !0 Ignition coil #1 !1 Ignition coil #2 !2 Ignition coil #3 !3 Rectifier regulator...

  • Page 55: Air Supply System

    2) Air Supply System Prior to Removing Peripheral Components (1) Press on the core of the air valve w located on the air rail q to release pressure from the air lines. (2) Press on the core of the fuel valve e located on the air rail q to release pressure from the fuel lines.
  • Page 56 Removing Air Compressor Remove the following components. q Detach the oil pipe on the compressor side. w Detach recirculation pipe on the compressor side. e Detach cooling water pipe on compressor side. r Remove air hose on compressor side. t Compressor bolts: at 3 locations Remove the following components.
  • Page 57 Air Compressor Configuration AIR COMPRESSOR 10,11 4-12...
  • Page 58 Inspecting Air Compressor Component Points to check O-ring • Scratches and wear Collar • Wear and damage Oil seal • Wear and damage • Replace with new one if defects are found Bearing • Rotate by hand and check for play and catching •...
  • Page 59 Assembling Piston Assemble the following components. Piston rings • Instaing order of rings: Expander side rails Top. • Install so that the side rail gap of the oil ring is positioned at a 90° angle to the expander gap. • Install the top and secondary rings so that their gaps are positioned at 120°...
  • Page 60 Assemble the following components. Bolt: type H630 at 4 locations Cylinder head 2 Upper gasket Replace with new one. Reed valve assembly 2 Lower gasket Replace with new one. Cylinder • Take care not to mistake the top and bottom and front and back sections of the reed valve assembly when installing.
  • Page 61 Disassembling Air Rail Remove the following components. q Fuel hose assembly and nipples Disassemble and pull out the stopper plate. w Air hose assembly Disconnect the hose joint on the compressor side. e Cooling water outlet hose r Fuel return hose t Air discharge hose y Cooling water inlet hose Remove the following components.
  • Page 62 Air Rail Assembly Configuration 4-17...
  • Page 63 Inspecting Air Rail Components Points to check Air injector • Wear, deterioration and damage on O-rings and seal rings. Replace with new ones if problems are detected. • Remove any carbon buildup on tip using wire brush. • Refer to chapter 6 for electrical system inspection. Set piece for air injector •...
  • Page 64 Assembling Air Rail • Apply genunie engine oil to the O-rings. Assemble the following components. q Insert w Seal ring • Take care to install with insert q facing in the proper direction as shown in View A to the right. e Adapter r Fuel injector A View...

  • Page 65: Fuel System

    Assemble~components q Air hose assembly w Collar e Stopper plate r Bolt Installing Hoses (See figure) q From air compressor (air) w To air compressor (cooling water) e To FFP (fuel) r To cylinder (air) t From exhaust cover (cooling water) 3) Fuel System Disassembling Fuel Hose Assembly Remove the following components.
  • Page 66 Disassembling Vapor Separator Drain the fuel from the vapor separator using the following procedures. q Loosen the air vent screw. w Loosen the drain screw. Hold a cloth in place to absorb spilling fuel when loosening w. Detach the following hoses. e Vapor discharge hose r Vapor return hose t Fuel inlet hose...
  • Page 67 Vapor Separator Configuration Inspecting Vapor Separator Components Points to check O-rings • Wear, deterioration and damage. Float valve • Wear, deterioration and damage. Float • Presence of cracks. • Contamination by fuel. 4-22...
  • Page 68 Assembling Vapor Separator Assemble in the reverse order of disassembly. q Air vent screw Torque: 0.98 N-m: 0.1 kg-m: 0.7 Ib-ft w Drain screw Torque: 1.4 N-m: 0.14 kg-m: 1.0 Ib-ft Assembling Vapor Separator assembly Assemble in the reverse order of disassembly. q Vapor separator assembly w Bolt: type H630 at 2 locations Washers: at 4 locations...
  • Page 69 FFP Configuration – – – Yellow Blue 4-24...
  • Page 70 Inspecting FFP Components Points to check Pipe grommet Upper cable terminal grommet • Wear, deterioration and damage. Cable terminal grommet Replace if defects are detected. O-rings FFP Case • Clogging by foreign matter and water. FFP assembly • Dirt and foreign matter on lower intake port. •...
  • Page 71 Assembling FFP Assemble the following components. i Hose joint adapter Torque: 14 to 16 N-m: 1.4 to 1.6 kg-m: 10 to 12 Ib-ft Adhesive to apply after degreasing thread area: Three Bond 1342 o Metal washers Always replace after disassembly. !0 Upper case Assemble the following components.
  • Page 72 Assemble the following components. !3 Upper grommet e Cable terminal grommet e and !3 Grease to apply Genuine engine oil u Cable terminal (-): black cable u Cable terminal (+): Red cable terminals u Grease to apply Genuine engineoil Connect to the flat connector cable terminal by lin- ing up with the ±...
  • Page 73 Assemble the following components. w Cable terminal upper grommet r Seal ring (O-ring) w and r Grease to apply: Genuine engine oil !0 Upper case !8 Bolt: type H518 at 4 locations Torque: 2.6 to 3.5 N-m: 0.27 to 0.36 kg-m:2.0 to 2.6 Ib-ft Installing FFP Assembly on Cylinder Install the following components.

  • Page 74: Oil Pump

    4) Oil Pump Disassembling Oil Pump and Oil Tank Disassemble the following components. q Oil filter w Oil pump bolt e Oil pump r Oil pipe :4 Remove by pulling the pipes (4) out from oil pump. Remove the following components. q Oil level sensor cable w Bolt: type H630 e Oil tank...
  • Page 75 Inspect the following components. q Bushing w Oil pump driven gear Check for wear and damage. Assembling Oil Pump Assemble the following components q Bushing w Oil pump driven gear q and w Oil to apply Genuine engine oil • Make sure that q faces right side up. •...
  • Page 76 5) Throttle Machanism Disassembling Advancer Arm Disassemble the following components. q Throttle link rod w TPS* link rod e Oil pump link rod * TPS: abbreviation for throttle position sensor Prior to removing q, w and e it will be necessary to disconnect the rod snaps from the advancer arm.
  • Page 77 Assembling Advancer Arm Assemble the following components. Advancer arm Throttle link rod TPS link rod Oil pump link rod Bolt: type H635 Washers Collar Install the following components. Throttle link ball joint cap TPS link ball joint cap Oil pump ball joint cap Install ball joint and cap by hand using a pinching motion.
  • Page 78 Assembling TPS Assemble in the reverse order of disassembly. Disassembling Air Box and Throttle Body Disassemble the following components. Bolt: type H625 at 8 locations Clamp q Air box cover Remove the following components. w Bolt: type H625 at 2 locations q Throttle body assembly r Bolt: type H625 at 12 locations e Air box...
  • Page 79 Inspect the following component. q Reed valve assembly Valve stopper height: 9.3 to 9.5 mm: 0.366 to 0.374 in Check whether valve closes properly, is worn or damaged. Inspect the following component. q Throttle body Check throttle cam w for wear. Check cam roller e for wear.

  • Page 80: Engine Block

    3. Disassembling Engine Block Cylinder and Crankcase Assembly (To Air Rail) (Air Compressor) Line check valve 4-35...
  • Page 81 Piston and Crankshaft 4-36...
  • Page 82 Removing Thermostat Remove the following components. q Bolt: type H625 at 2 locations w Thermostat cap e Thermostat Inspect the following components. • Check to see whether foreign matter has entered valve. • Confirm valve operates within designated temperature range. •...
  • Page 83 Inspecting Cylinder Head Inspect the following components. q Cylinder head Inspecting: Check for carbon deposit in combustion chamber. Check for sediment in water jacket. Inspecting: • Use components w and e to measure distortion. • w Straight gauge • e Thickness gauge •...
  • Page 84 Disassembling Exhaust Cover Remove the following components. q Bolt: type H630 at 2 locations w Bolt: type H630 at 12 locations Remove in order starting from the highest embossed number. e Outer exhaust cover r Inner exhaust cover Remove by prying gently with a flathead screwdriver alternately along the 4 grooves on the sides of the cover.
  • Page 85 Remove the following component. Crankshaft assembly Disassembling Drive Pulley Remove the following components. q Pulley nut (36 mm) Special tool Crankshaft holder (36mm) 3T5-72815-0 e Magneto key r Magneto nut • Install the magneto key on the crankshaft holder w and secure using the magneto nut. •...
  • Page 86 Removing Piston Remove the following components. • Piston pin clip at 2 locations Remove both and take care not to scratch the pin hole. Remove the following component. w Piston pin w Piston pin tool Special tool 345-72215-0 • Position w against piston pin; then holding the opposite side by hand tap lightly on w with a hammer to remove pin.
  • Page 87 Inspecting Engine Components Inspecting Cylinders CYLINDER HEAD SIDE • Cylinder bore (using cylinder gauge) Standard value Service limit 68.05 mm Replace when 68.11 mm (2.679 in) (2.682 in) or more • Measure the area showing the greatest wear. • Also replace when difference between minimum and maximum cylinder bore is 0.06 mm (0.002 in) or more.
  • Page 88 Inspecting Piston Rings q Piston ring w Ring gauge e Thickness gauge • Piston ring end gap Ring Standard value Service limit 0.22 to 0.37 mm Replace when 0.8 mm (0.009 to 0.015 in) (0.032 in) or more 0.33 to 0.48 mm Replace when 0.9 mm 2nd, 3rd (0.013 to 0.019 in) (0.035 in) or more...
  • Page 89 Assembling Piston Assemble the following components. q Top ring (Keystone ring: 1T) Keystone w 2nd and 3rd rings (plain rings: stamped 2T) Plain Plain Special tool Piston ring tool 353-72249-0 • Install starting from the 3rd ring. • Install with the stamped mark facing upwards. •...
  • Page 90 Assembling Short Block Assemble in reverse order of disassembly. Apply genuine engine oil to the following parts. Big end of connecting rod Small end of connecting rod and pin boss oil hole Main bearing Piston ring and entire circumference of piston Entire surface of cylinder bore Upper bearing O-ring Line up piston ring end gap with knock pin.
  • Page 91 Assembling Crankcase Degrease the mating surface of the crankcase. Caution: Insufficient degreasing will render sealant less effective, resulting in oil leakage. Apply sealant evenly over the mating surface on the cylinder. Sealant: Loctite #518 Apply evenly inside the bolt holes so that there are no bare patches.
  • Page 92 Install the following components. Thermostat Replace with new one. Thermostat cap gasket Thermostat cap Bolt: at 2 locations Bolt: at 4 locations Torque : 4.6 to 6.3 N-m: 0.47 to 0.64 kg-m : 3.4 to 4.6 Ib-ft Caution: Be sure to tighten M6 bolts only after tightening the M8 bolts on the head cover.
  • Page 93 4-48...
  • Page 94 Chapter 5 Installing and Inspecting Electrical Components 1. Wire Routing...................5-2 2. Wiring Diagram ................5-8 3. Assembly ..................5-17 4. Inspection ..................5-22...
  • Page 95 1. Wire Routing...
  • Page 97 MAGNETO...
  • Page 98 ELECTRIC PARTS EFO TYPE Battery (+) Starter motor...
  • Page 99 SWITCH BOX (F Type) Cable color abbreviations : Black Br : Brown G : Green : Blue Lg : Light green : Pink R : Red Sb : Sky blue W : White : Yellow...

  • Page 101: Wiring Diagram

    2. Wiring Diagram EPTO DOWN Lg/R Lg/W T.P.S 2 Lg/B T.P.S 1...
  • Page 102 Optional 1 2 3 4 5 km/h B Br R R G L G(NO) G(COM) START PUSH VARIABLE IDLE...
  • Page 103 EFTO DOWN Lg/R Lg/W T.P.S 2 Lg/B T.P.S 1 5-10...
  • Page 104 B Br R R G L START PUSH VARIABLE IDLE Sp P Sp P Switch Box 5-11...
  • Page 105 Lg/R Lg/W T.P.S 2 Lg/R T.P.S 1 5-12...
  • Page 106 B Br R R G L START PUSH VARIABLE IDLE Switch Box 5-13...
  • Page 107 EPTO Component Component Alternator assembly 23 Ground cable Rectifier complete 24 Cable assembly A Battery (obtain locally) 25 Ground cable PT&T switch B 26 Lower motor cover Oil level sensor 27 Cable assembly B Throttle position sensor 28 Neutral switch Water temperature sensor 29 Beeper (Buzzer) Crank position sensor...
  • Page 108 EFTO Component Component Alternator assembly 18 FFP Rectifier complete 19 FFP cable Battery (obtain locally) 20 Battery cable Oil level sensor 21 Starter cable Throttle position sensor 22 Ground cable Water temperature sensor 23 Cable assembly A Crank position sensor 24 Neutral switch 25 Ground cable Fuse holder assembly...
  • Page 109 Component Component Alternator assembly 16 FFP cable Rectifier complete 17 Battery cable Battery (obtain locally) 18 Starter cable Oil level sensor 19 Cable assembly A Throttle position sensor 20 Neutral switch Water temperature sensor 21 Ground cable Crank position sensor 22 Cable assembly C 23 Tachometer Fuse holder assembly...
  • Page 110 3. Assembly Solenoid Bracket q Pre-Assembly step 1 Attach the cable clamp, fuse holder plate and rubber mount to the bracket. Rubber mount (up, down) Fuse holder plate Collar Cable clamp w Pre-Assembly Step 2 Attach the fuse holder red lead (+) a to the PT&T solenoids and put on the cable caps. Attach the ground cable b to the PT&T solenoids.
  • Page 111 r Pre-Assembly Step 4 Past the fuse holder red lead (+),PT&T solenoid ground cable and starter solenoid green lead through the hole in the center of the solenoid bracket; then install the starter solenoid, power trim and tilt solenoid and fuse holder. Rectifier regulator Partially tighten the connector on the fuse holder red lead.
  • Page 112 y Assembly Step 1 Install bracket on air box. When installing bracket be sure to install starter solenoid and PT&T solenoid ground cables on A A and the cable clamp on bolt B B . bolt rectifier regulator Air box Magneto coil Cable clamp u Assembly Step 2...
  • Page 113 i Assembly Step 3 q Install the battery cables (+,–). w Install the PT&T cables using the blue and green leads. Battery cable (–) Starter motor q Battery Rectifier regulator Ground cable (–) Battery cable (+) Oil level sensor Cable cap Also pass fuse holder red lead through the cable cap.
  • Page 114 o Assembly Completed Rectifier regulator Oil level sensor Light coil Note: The sections of clamp shaded in diagonal lines indicate how the lines coming from above are to be gathered together in a downward direction. Cables are to be positioned below the clamp anchors.
  • Page 115 4. Inspection Flywheel Magneto The flywheel magneto itself does not require inspection, however, the following precautions are necessary when operating in the flywheel area during servicing operations. The magnets is attached to the flywheel using adhesive glue, so it will be necessary to observe the following precautions. Precautions •...
  • Page 116 Starter Motor Length when new Brushes and Springs 12.5 mm 0.49 in q Check the brushes for wear. Wear limit 9.5 mm 0.37 in When brush length is 9.5 mm (0.37 in) or less Replace with new one. w Inspect insulation between brush holders. If conductive, determine cause or replace insulation.
  • Page 117 5-24...
  • Page 118 Chapter 6 Disassembly, Inspection and Reassembly Lower Unit 1. Configuration..................6-2 2. Disassembly ..................6-4 3. Inspection ..................6-7 4. Reassembly ..................6-9...
  • Page 119 1. Configuration GEAR CASE (DRIVE SHAFT)
  • Page 120 GEAR CASE (PROPELLER SHAFT)
  • Page 121 2. Disassembly Caution: • Begin the procedure by first removing the spark plug caps and then removing the spark plugs. • When working with the outboard engine tilted full up, make sure to secure the engine firmly in place using a tilt up stopper.
  • Page 122 Disassembling Water Pump Case q Remove the lower section of the water pump case. Remove by inserting a flathead screwdriver along the case removal groove. Disassembling Propeller Shaft and Clutch Remove the various components using the following procedures. o Bolt: type H625 at 2 locations i Propeller shaft housing (with q to u) t Clutch pin snap ring Replace with new pin...
  • Page 123 Removing Bevel Gear and Drive Shaft Remove the following components. Bevel gear B nut Bevel gear B Drive shaft Bevel gear A Bevel gear A bearing Bevel gear C Removal Procedure 1. Insert r onto spline q. 2. Attach t to w. t Bevel gear B nut wrench: Special tool 346-72231-0...
  • Page 124 3. Inspection Inspect the following components. Component Inspection points Remarks • Wear and damage on pawls of bevel gears A and C. Replace. Bevel gears A, B, C • Wear and damage on clutch pawl. Replace. and clutch • Meshing of bevel gears A, B and C and backlash*. Replace as necessary.
  • Page 125 Inspecting Bevel Gear Backlash Backlash Measuring Tool Install the clamp assembly w on the drive shaft q. Line up the tip of the dial gauge with center of the V groove e on the clamp assembly. q Drive shaft w Clamp assembly : 3B7-72720-0 Special tool r Plate : 3A3-72713-0...
  • Page 126 4. Reassembly Assembling Gear Case Observe the precautionary notes provided at various steps while assembling in the reverse order of disassembly. Installing Bevel Gear on Drive Shaft Install the following components. • Bevel gear A bearing Use the outer race to press fit the bearing in place. q Drive shaft w Bevel gear B e Bevel gear B nut...
  • Page 127 Assembling Clutch Cam, Cam Rod and Clutch Cam Rod Bushing Install the following components. q Clutch cam w Clutch cam rod e Cam rod bushing r Clutch cam spring pin: 3-12 t O-ring: 2.4 to 5.8 y O-ring: 3.5 to 21.7 Special tool Spring pin tool B 345-72228-0...
  • Page 128 Assembling Water Pump Install the following components. Refer to section 7 (Inspecting Cooling System) of Chapter 3 (Inspection and Maintenance) for detailed descriptions of components. • Confirm oil seals r are facing right side up. protrusion • Be sure to insert shim t between the oil seals •...
  • Page 129 Adding Gear oil Refer to section 5 (Inspecting Gear Case Area) of Chapter 3 (Inspection and Maintenance) for detailed description of gear oil replacement procedure. Assembling Gear Case Assembly • Apply a thin coating of the specified grease to the spline area on the engine side of the drive shaft.
  • Page 130 Chapter 7 Power Trim and Tilt 1. Configuration .................7-2 2. Names of Parts................7-3 3. Troubleshooting................7-4 4. Disassembly and Assembly............7-12...
  • Page 131 1. Configuration Battery 100AH Solenoid switch Switch (UP) Solenoid switch Symbol Definitions (DN) : Red : Black Sb : Sky blue : Pink : Blue : Green Breaker Motor Inlet valve Inlet valve Relief valve (DN) Oil Pump 20 to 34 kg /cm Valve seat assembly A 285 to 484 psi Valve seat assembly B...

  • Page 132: Names Of Parts

    2. Names of Parts 1. Oil valve 2. Relief valve (UP) 3. Relief valve (DN) 4. Spool 5. Check valve (upper chamber) (Valve seat assembly A) 6. Check valve (lower chamber) (Valve seat assembly B) 7. Manual valve 8. Seal washer 9.

  • Page 133: Troubleshooting

    3. Troubleshooting (1) Symptoms and Points to Check (1) Motor operation abnormal, lacks power or won't turn over. Is the main switch On? Are any engine cables disconnected? CH w Is the circuit breaker in the Off position due to having been tripped? CH e Is the fuse burned out? CH r...
  • Page 134 CH !5 Are there any internal malfunctions in the PT&T? Is there rust on the stern bracket, or on the stern bracket assembly bolts? CH !4 Is the piston bent, warped or not operating properly? CH !3 Has air entered the hydraulic system? CH !2 Is the proper oil being used? CH !1...
  • Page 135 (1) Checking Procedure Are any engine cables disconnected? • Confirm that battery cables are connected to battery. • Confirm that cable connectors are firmly secured in place. Is the circuit breaker in the Off position due to having been tripped? •...
  • Page 136 Solenoid switch Conductivity Blue to black DN Solenoid Switch Blue to red Green to black UP solenoid switch Green to red Does the motor turn over when the battery is directly connected? • Disconnect the blue lead and green lead of the PT&T and touch the plugs against the red and black lead terminals, respectively.
  • Page 137 • When unable to tilt up due to lack of oil: When the oil reservoir is empty and powered tilting up is not possible, turn the manual valve a few turns counter- clockwise; then tilt the engine up manually and set the tile stopper. When replenishing oil, fill until oil is even with the bottom of the oil plug hole.
  • Page 138 Has air entered the hydraulic system? • The presence of the air in the lines is relatively easy to detect, as the PT&T unit will occasionally generate sluggish sounds. • Air Bleeding Procedure(oil plug must be closed during air removal procedure): With the manual valve opened, repeat a full stroke manual tilt up and down operation five or more times.
  • Page 139 Replace the PT&T assembly. CH @2 Inspect the shock absorber valve on the tilt cylinder. CH @1 Inspect the free piston on the tilt cylinder. CH @1 Inspect the piston on the tilt cylinder. Replace the oil pump. CH @0 Inspect the spool on the spool valve.
  • Page 140 Disassemble and inspect the manual valve. • Check the tip of the valve for damage. • Check the O-rings for damage. • Check the seal washers for damage, especially the rubber seals. • Check for wear and damage deep within the valve mounting holes. Note: Watch for collapsed seal washers when reassembling.

  • Page 141: Disassembly And Assembly

    4. Disassembly and Assembly Precautions For Disassembling and Assembling Power Trim and Tilt (PT&T) System (1) Make sure to disassemble with the engine tilted up and piston fully extended. Open the manual valve slightly and leave to set for a while. Make sure that internal pressure has been reduced to zero before commencing operations.
  • Page 142 Chapter 8 Tiller Handle Type 1. Installing Gearshift Lever Assembly..........8-2 2. Installing Switchbox Assembly ............8-3 3. Installing Handle Assembly ............8-4 4. Installing Handle To Engine ............8-4...
  • Page 143 1. Installing Gearshift Lever Assembly (1) Following the procedures illustrated in the figure below, apply grease to the designated locations and install the gearshift lever on the lower cover. Gearshift lever Gearshift lever (3T5-66110-0) install position Gearshift leverB (3T5-66129-0) Lower cover Washer, 14-22-1 Seal ring,13.8-22-5 TLDI...
  • Page 144 2. Installing Switchbox Assembly (1) Screw in the lanyard stop switch to the switch box; then tighten the switch from the inside of the box with a pliers. (2) Insert the stay into the overheat warning beeper (buzzer) and secure using the bolt (910103-6612) from the inside of the switchbox.
  • Page 145 3. Installing Handle Assembly (1) Install the switch box on the handle using the bolt (910103-6625). (2) Position the cable holder so that one end is approximately 200 mm from the cable outlet of the cable assembly C switch box; then press into place and secure to the steering bracket using the screws (921903-0625).
  • Page 146 Chapter 9 Troubleshooting 1. Troubleshooting Tables..............9-2 2. TLDI Self-Diagnosing Functions ..........9-14...
  • Page 147 1. Troubleshooting Tables This section on troubleshooting covers the various malfunctions and failures that can occur in the engine’s electrical components. Notification of malfunctions and failures is provided using a system of warning beep (buzzer) and indicator lights. This system of beeps and indicators is described in a separate section. Self- Warning Warning...
  • Page 148 Cause Remedy (see chapter on Servicing Information for specs.) 1-1-1. Gearshift in forward or reverse position. Shift to neutral position. Battery low; or battery cables or circuit line Recharge or replace battery. 1-2-1. connections may be loose or corroded. Check battery terminal and cable condition. Check the 3 fuses.
  • Page 149 Self- Warning Warning Warning diagnosable Symptom indicator indicator B indicator Item Beeps points A (oil) (water temp) C (battery) Low fuel pressure in air rail [normal: 0.6 to 0.64 MPa] 2-2. High fuel pressure in air rail Fuel system [normal: 0.6 to 0.64 MPa] 87 to 93 psi Low air pressure in air rail [normal: 0.53 to 0.57 MPa]...
  • Page 150 Cause Remedy (see chapter on Servicing Information for specs.) 2-2-12. Replace. Fuel regulator leakage. 2-2-13. Inspect piping and connectors for damage. Fuel leakage. Inspect and repair. Return circuit from fuel regulator outlet to 2-2-14. vapor separator is clogged. Replace. 2-2-15. Faulty fuel regulator.
  • Page 151 Self- Warning Warning Warning diagnosable Symptom Item indicator indicator B indicator Beeps points A (oil) (water temp) C (battery) Sparkplug cap. Crank position sensor. Engine 2-4. Self-diagnosing function turns over Flashing Electrical indicates low (abnormal) but does not system battery voltage. start Self-diagnosing function indicates faulty components.
  • Page 152 Cause Remedy (see chapter on Servicing Information for specs.) Loose cap. Inspect. 2-4-6. Replace. 2-4-7. Faulty cap. Inspect and adjust. 2-4-8. Incorrect gap with encoder (flywheel). Replace ECU. 2-4-9. ECU not functioning. Recharge or replace battery. Battery low or less than 10V during turnover 2-4-10.
  • Page 153 Self- Warning Warning Warning diagnosable Symptom Item Beeps indicator indicator B indicator points A (oil) (water temp) C (battery) Low fuel pressure in air rail. [normal: 0.6 to 0.64 MPa] 3-2. 87 to 93 psi Fuel system High fuel pressure in air rail. [normal: 0.6 to 0.64 MPa] Low air pressure in air rail.
  • Page 154 Cause Remedy (see chapter on Servicing Information for specs.) Refer to steps 2-2-12. 3-2-8. Fuel regulator leakage. Refer to step 2-2-13. 3-2-9. Fuel leakage. Refer to step 2-3. 3-2-10. Low compression in air rail. Replace. 3-2-11. Faulty fuel regulator. Return circuit from fuel regulator outlet to Inspect and repair.
  • Page 155 Self- Warning Warning Warning diagnosable Symptom Item indicator indicator B indicator Beeps points A (oil) (water temp) C (battery) 6-1. Faulty compression Power head 6-2. Low air pressure in air rail Air system High air pressure in air rail Fuel tank Fuel Hose Fuel filter 6-3.
  • Page 156 Cause Remedy (see chapter on Servicing Information for specs.) 6-1-6. Inspect and repair as necessary. Faulty oil seal on crankcase. 6-2-1. Refer to step 2-3. Refer to step 2-2-1. 6-3-1. Fuel is low or empty in tank. 6-3-2. Air vent is clogged. Refer to step 2-2-2.
  • Page 157 Self- Warning Warning Warning diagnosable Symptom Item Beeps indicator indicator B indicator points A (oil) (water temp) C (battery) Cooling water Flashing Continuous temperature too high (temp. indicator flashes) Flashing Continuous Poor 9-1. Battery voltage Flashing acceleration Electrical abnormally high (battery at full throttle control indicator flashes)
  • Page 158 Cause Remedy (see chapter on Servicing Information for specs.) Inspect. Cooling water inlet is clogged. 9-1-1. Inspect, repair and replace as necessary. Faulty water pump. 9-1-2. Faulty battery or 2 batteries connected in Inspect. 9-1-3. series. Inspect and replace as necessary. 9-1-4.
  • Page 159 2. TLDI Self-Diagnosing Functions The TLDI engine self-diagnosing function is used to display detailed information on the locations of faults in the electrical system that have been detected by the engine control unit (ECU). Special devices, such as monitoring equipment and personal computers, are not required for the self-diagnosis function. It utilizes a system of key switch operation, tachometer readings and three types of warning indicator lights to provide the information required for the four operating modes listed below.
  • Page 160 Beeper: On the EP models, the beeper is located on the remote control box. On the EF models, it is located on the swithch box. The beeper emits the following four sound patterns. Long beep: 2 seconds Short beep: 0.3 seconds Intermittent short beep: 3 short beeps at 2 minute intervals Continuous uninterrupted beep Fault log:...
  • Page 161 Using the Self-Diagnosing Function With the switch in the ON position, press the key for a period of approximately 5 seconds until a beep sounds. [Tachometer Operation Test] Self-diagnosing Mode 1: Mode 1 starts with two long beeps as the tachometer needle points to 5,000 rpm.
  • Page 162 [Fault Log Delete] Self-diagnosing Mode 4: Even when in Mode 3 can be enabled by releasing the stop switch lock and pressing the key for approximately 3 seconds until 3 short beeps are emitted. This deletes the fault log. Note: This will not delete records of engine operating hours. Turn the key switch to the OFF position to terminate the self-diagnosing function.
  • Page 163 9-18...
  • Page 164 Engine Operating Hours Table (Self-Diagnosing Mode 2) Warning indicators Engine operating hours (h) Tachometer reading (rpm) Indicator A Indicator B Indicator C 1,000 — — — 0 – 1 1 – 2 2,000 — — — 2 – 3 3,000 —...
  • Page 165 Fault Indication Table (Self-Diagnosing Mode 3) Fault log Malfunction & failure indication Fault Fault log (yes) Description Tachometer (rpm) Indicator B Indicator C Indicator A No malfunction or failure ON indicates ON indicates Battery voltage high severed line or severed line or Flashing Battery voltage abnormally high component fault.
  • Page 166 Remedial Measures and Added Notes Refer to troubleshooting tables. Replenish engine oil. * Indicator B staying on after engine oil is replenished indicates severed or shorted line or faulty component. Refer to troubleshooting tables. Check wiring and connections and repair or replace components as necessary. * 1: With regard to injector and ignition coil faults, indicator B does not go on when self-diagnosing modes are enabled while the engine is off in order to determine operation under proper ECU control.
  • Page 167 (3) Resetting TPS Initial Values Use the following procedures to reset of the ECU and TPS in cases where self-diagnosing indicates idling position errors for TPS1 and TPS2. q When either the TPS or ECU is replaced: w When the self-diagnosing function indicates [TPS idling position error]: e When links and rod snap rings are replaced due to warpage and wear in the linkage: r When the [TPS idling position error] indication appears after performing engine disassembly and assembly operations:...
  • Page 168 Chapter 10 Test Run and Inspection After Servicing 1. Test Run Tank and Test Propeller..........10-2 2. Inspection ..................10-3...
  • Page 169 1. Test Run Tank and Test Propeller Test Run Tank Requirements and Precautions For Use q Partition (required when testing two engines 20 cm or more in one tank) 10 cm 26 cm w Ventilation duct e Water level r Transom board 75°...
  • Page 170 2. Inspection Items to Check Prior to Test Run • Fuel line condition • Gearshift lever operation • Electrical wiring, connections and clamps • Operation, including catch, of reverse lock • Integrity of self-diagnosing function • Oil line condition Items to Check During the Test Run Check the following items while the engine is in an idling state.
  • Page 171 10-4...

  • Page 172: Test Run

    Chapter 11 Installation on Boat and Test Run 1. Precautions for Using This Engine ..........11-2 2. Remote Control System ..............11-3 3. Gauges and Battery ..............11-4 4. Operating the Engine..............11-6...
  • Page 173 1. Precautions for Using This Engine The other chapters in this manual provide general information required for using this outboard engine. This chapter is dedicated to only those points on which special user caution is required. 2. Remote Control System—Installing Cable (Engine side) for EP Series q Pull the hook lever on the lower motor cover down to detach the upper motor cover.
  • Page 174 t Confirm that the remote control lever on the remote control box is in Neutral and the neutral warm-up lever is in at the fully closed position. Fully opened Fully closed Neutral warm-up lever y Move the gearshift lever to Forward, Neutral and Gearshift lever Reverse;...
  • Page 175 Remarks: • Confirm that, when pushing the remote control lever fully down in the Forward and Reverse directions (approx. 32°), the outboard engine gears engage at a certain point and that, when pushed completely down, the throttle is at the fully opened position. Return the remote control lever to Neutral position and confirm that this also moves the advancer arm on the outboard engine to the fully closed position.
  • Page 176 2) Installing Battery This outboard engine requires battery power in order to operate. Use a 12V 100AH (or 12V 120AH in colder climates) battery. q The battery should be secured in place in its own box to protect it from water spray and prevent it from tipping over with the movement of the boat.
  • Page 177 4. Operating the Engine 1) Starting Procedure Air vent screw q Bleeding air from oil pump Conduct a visual check of the clear vinyl pipes connecting the oil pump to the oil tank to inspect for the presence of air. Bleed hoses if necessary. •...
  • Page 178 w Force-Feeding Fuel Engine side The following fuel force-feeding procedure must be performed for engines that are new, overhauled, in storage for long periods or that ran out of fuel. a. Begin by squeezing the primer bulb until it becomes firm. b.
  • Page 179 EFO and EFTO Series r Confirm that the gearshift lever is in the Neutral position. Remarks: The engine will not start unless the gearshift lever is in Neutral (N). t Turn the throttle grip to the START (fully closed) position. Remarks: Prior to turning the main switch key to ON, make sure that the throttle grip has been set to...
  • Page 180 EPTO Series r Insert the key in the switch. Neutral (N) Remarks: Fully open The engine will not start unless the remote control Fully closed lever is in the Neutral position. Neutral warm-up lever Main switch t Set the remote control lever to neutral. Stop switch Make sure that the neutral warm-up lever has been set to fully closed position.
  • Page 181 2) Warning Process Whenever engine trouble occurs, the warning indicators begin flashing and the beeper sounds. The remedial actions described in the following sections must be taken whenever engine faults occur. q Engine Speed Control System (ESG) A sudden drop in engine load can cause the engine to race out of control.
  • Page 182 e Cooling Water Indicator Tachometer on EPTO series A water temperature warning is displayed and the engine automatically reduces speed whenever the cooling water rises above the designated level. Sensor setting Regulated rpm Threshold 2,800 to 3,200 rpm Over threshold 700 to 900 rpm Remedial Action: Water warning indicator...
  • Page 183 t Engine Trouble Warning Whenever faults or engine trouble occur the three warning indicators begin flashing simultaneously. Remarks: One of the following three types of warnings is output, depending on the cause (seriousness) of the trouble. 1. Warning indicators only flash. 2.
  • Page 184 Copyright © 2007 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.
  • Page 185 Address: 5-4, 3-chome, Azusawa, Itabashi-ku, TOKYO 174-0051, Japan Facsimile: (03) 3966-2951 Phone: (03) 3966-3117 No. 00321050-1 0209012600 Printed in Japan...

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