General Precautions For Servicing - TOHATSU TLDI 40 Service Manual

1. General Precautions for Servicing

Users of this manual should observe the following general precautions when
conducting disassembly and assembly work.
(1) Make sure that the outboard motor is securely mounted on a work stand before starting work.
(2) Take care not to scratch or damage painted surfaces and the mating surfaces where cylinders, the
cylinder head, the crankcase and other parts are joined.
(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.
(5) Always use the recommended special tools to ensure work is done properly.
(6) When disassembling and assembling components, make note of position marks, adding your own
marks if none are provided, as a way to ensure the various parts and components are properly mated
when being reassembled.
(7) To prevent smaller parts, such as bolts, nuts and washers from getting lost or damaged, where possible,
lightly insert or tighten them back in their original locations.
(8) As normal practice, check disassembled parts for any wear or damage by first wiping them clean; then
washing them in solvent.
(9) With reassembly operations it is essential to observe precise detail in centering, vacuum sealing,
lubricating (with oil or grease), packing parts and components, and connecting wiring and piping. Also
ensure there are no blockages in fluid lines.
1) When reassembling parts requiring numerous nuts and bolts (cylinder, crankcase etc.), begin by
alternately tightening diagonally opposed inner bolts, moving in a concentric circle; then tightening
the outer bolts. This will ensure that engine parts are assembled evenly and securely. (Use the
same procedure in the reverse order when disassembling.)
2) When installing oil seals, be careful not to scratch or reverse the sides that mate with the shaft and
always apply grease to the lip surfaces.
3) Confirm the correct quantity and thickness when applying sealant. Applying excessively will result in
the excess portion being excreted into or outside of the case, potentially causing damage. Adhere
strictly to the written instructions when applying adhesives.
4) Apply penetrating oil spray to nuts or bolts that are difficult to remove due to rust and wait 5 minutes
before removing.
5) For the various inspection specifications, torque values, special tools, and the points where sealant,
adhesive and grease are to be applied, refer to the relevant tables.
6) The various nuts, bolts and washers referred to in this manual are listed below.
Name
H820
N8
W8
SW8
Screw 620
(10) Observe all necessary safety procedures to prevent accidents and injury during work operations.
Type
Hexagon bolt
Hexagon Nut
L8 Hexagon Nut
Plain washer
Spring washer
Pan head screw
Diameter Length
8 mm 20 mm
8 mm
8 mm
8 mm
8 mm
6 mm 20 mm
2-3