TOHATSU TLDI 50 Manuals

TOHATSU TLDI 50 Manuals

Manuals and User Guides for TOHATSU TLDI 50. We have 4 TOHATSU TLDI 50 manuals available for free PDF download: Service Manual, Owner's Manual

TOHATSU TLDI 50 Service Manual

TOHATSU TLDI 50 Service Manual (329 pages)

2 Stroke

Brand: TOHATSU | Category: Outboard Motor | Size: 67.68 MB

Table of Contents

Section 1 Service Safety

3
- Table of Contents
  3
- Introduction
  4
- Safety Statements
  4
- Safety Precautions
  5
- Workmanship Standards
  7
- Test Tank Guidlines
  9
Section 2 General Service Information

10
- General Precautions
  11
- Abbreviations and Symbols
  12
- Unit Conversions
  13
- Service Specifications
  14
- Engine Specifications
  17
- Lubrication Chart
  20
- Periodic Inspections
  23
- Break-In Procedure
  27
- Tune-Up Procedure
  29
- Emergency Stop Switch and Lanyard
  30
- Operator Alert Systems
  31
- Synchronization and Linkage Adjustments
  34
- Anodes - Inspection and Testing
  48
Section 3 Fuel System

49
- General Precautions
  50
- Service Specifications
  51
- Fuel System Requirements
  52
- Troubleshooting
  54
- Description of Operation
  56
- Fuel Tank
  59
- Fuel Line and Primer
  60
- Fuel and Oil Filters
  61
- Fuel Pump
  62
- Automixing System
  65
- Carburetor
  68
- Intake Manifold
  72
Section 4 Powerhead

75
- General Precautions
  76
- Service Specifications
  77
- Troubleshooting
  81
- Description of Operation
  82
- Cylinder Compression Test
  83
- RPM Performance Test
  84
- Overheat Sensor
  85
- Water Pressure Sensor
  86
- Thermostat
  88
- Recoil Starter
  89
- Powerhead
  91
Section 5 Midsection

115
- General Precautions
  116
- Service Specifications
  117
- Tiller Steering Handle
  119
- Lower Engine Cover
  123
- Driveshaft Housing
  124
- Stern and Swivel Brackets
  130
Section 6 Gearcase

138
- General Precautions
  139
- Service Specifications
  140
- Water Pump
  141
- Gearcase
  142
- Backlash - Shim Adjustment Table
  164
- Gearcase Repair Procedures
  167
Section 7 Electrical System

180
- General Precautions
  181
- Service Specifications
  182
- Electrical Servicing Standards
  186
- Troubleshooting
  190
- Description of Operation
  192
- Battery Care and Maintenance
  196
- Ignition System
  201
- RPM Limitation Test
  226
- Ignition System Repair Procedures
  238
- Starting System
  253
- Charging System
  285
- General Precautions
  301
- Air Bleeding Procedure
  305
- Trim Sender/Trim Meter Test
  306
- Power Trim/Tilt
  308
- Troubleshooting
  318

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TOHATSU TLDI 50 Service Manual

TOHATSU TLDI 50 Service Manual (186 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 3.78 MB

Table of Contents

Specifications
2
Specifications Table
4
Outline Dimensions
5
External Dimensions
6
Air-Assisted Low-Pressure Direct Injection
7
Background on TLDI
7
Two-Stroke Low-Pressure Direct Injection (TLDI)
7
ECU Control
8
Crank-Position Sensor (CPS)
9
Long-Duration CDI (L-CDI)
9
Throttle-Position Sensor (TPS)
9
Water-Temperature Sensor (WTS)
9
Fuel Supply System
10
Air Supply System Diagram
11
Oil Supply System Diagram
12
Table of Contents
14
Servicing Information
14
Chapter 2 Servicing Information

16
Chapter 3 Inspection and Maintenance

39
- Periodic Inspections
  39
- Inspecting Engine Oil Systems
  40
- Inspecting Compression System
  41
  - Cleaning Fuel Tank
    41
  - Cleaning Fuel Tank Filter
    41
  - Inspecting Gear Case Area
    42
    
    Replacing Gear Oil
    42
    
    Replacing Propeller
    42
  - Inspecting Cooling System
    43
    
    Replacing Pump Impeller
    43
    
    Thermostat Test
    43
  - Washing Procedure
    43
    
    Overview of Cooling System
    44
    
    Tubing
    44
  - Inspecting Air Rail Pressure
    45
  - Inspecting Power Trim and Tilt System
    45
- Disassembling, Inspecting and Reassembling Power Unit
  46
Chapter 4 Disassembling

47
- Power Unit
  47
- Removing Power Unit
  48
  - Reassembling Power Unit
    50
  - Electrical System
    51
  - Peripheral Parts
    51
    
    Removing CPS, Flywheel and Alternator
    51
    
    Removing ECU
    52
    
    Removing Harness Assembly
    53
    
    Removing Ignition Coil and Rectifier Regulator
    54
    
    Air Supply System - Prior to Removing Peripheral Components
    55
    
    Inspecting Drive Belt
    56
    
    Removing Air Compressor
    56
    
    Air Compressor Configuration
    57
    
    Inspecting Air Compressor
    58
    
    Assembling Compressor
    59
    
    Assembling Piston
    59
    
    Disassembling Air Rail
    61
    
    Air Rail Assembly Configuration
    62
    
    Inspecting Air Rail
    63
    
    Assembling Air Rail
    64
    
    Assembling Fuel and Air Assembly
    65
    
    Disassembling Fuel Hose Assembly
    65
  - Fuel System
    65
    
    Disassembling Vapor Separator
    66
    
    Inspecting Vapor Separator
    67
    
    Vapor Separator Configuration
    67
    
    Assembling Vapor Separator
    68
    
    Assembling Vapor Separator Assembly
    68
    
    Disassembling FFP Assembly
    68
    
    FFP Configuration
    69
    
    Inspecting FFP
    70
    
    Assembling FFP
    71
    
    Installing FFP Assembly on Cylinder
    73
    
    Disassembling Oil Pump and Oil Tank
    74
  - Oil Pump
    74
  - Assembling Oil Pump and Oil Tank
    75
  - Throttle Mechanism
    76
  - Disassembling Advancer Arm
    76
  - Assembling Advancer Arm
    77
  - Disassembling TPS
    77
  - Assembling TPS
    78
  - Disassembling Air Box and Throttle Body
    78
  - Assembling Air Box
    79
  - Assembling Air Box and Throttle Body
    79
  - Disassembling Engine Block
    80
  - Cylinder and Crankcase Assembly Diagram
    80
  - Piston and Crankshaft Diagram
    81
  - Removing Thermostat
    82
  - Disassembling Cylinder Head and Head Cover
    82
  - Inspecting Engine Anode
    82
  - Inspecting Cylinder Head
    83
  - Disassembling Exhaust Cover
    84
  - Inspecting Exhaust Cover
    84
  - Disassembling Crankcase
    84
  - Disassembling Drive Pulley
    85
  - Removing Piston
    86
  - Inspecting Engine Components
    87
  - Inspecting Cylinders
    87
  - Inspecting Piston
    87
  - Inspecting Piston Rings
    88
  - Inspecting Crankshaft
    88
  - Assembling Piston Procedure
    89
  - Assembling Short Block
    90
  - Assembling Crankshaft
    90
  - Assembling Crankcase
    91
  - Assembling Cylinder Head
    91
  - Assembling Exhaust Cover
    92
  - Installing Recirculator Hose
    92
  - Installing and Inspecting Electrical Components
    94
Chapter 5 Installing and

95
- Wire Routing
  95
  - Magneto View
    97
  - Electric Parts View
    98
  - Switch Box (F Type) View
    99
  - Wiring Diagram - EPTO
    101
  - Wiring Diagram - EFTO
    103
  - Wiring Diagram - EFO
    105
  - EPTO Parts List
    107
  - EFTO Parts List
    108
  - EFO Parts List
    109
  - Solenoid Bracket Assembly
    110
  - Flywheel Magneto Inspection
    115
  - Rectifier Regulator Inspection
    115
  - Rectifier Checkpoint Table
    115
  - Starter Motor Inspection
    116
  - Armature Inspection
    116
  - Disassembly, Inspection and Reassembly Lower Unit
    118
  - Gear Case (Drive Shaft) Diagram
    119
Chapter 6 Disassembly, Inspection

119
- Configuration
  119
  - Gear Case (Propeller Shaft) Diagram
    120
  - Lower Unit Disassembly
    121
  - Disassembling Gear Case
    121
  - Removing Propeller
    121
  - Removing Gear Case
    121
  - Disassembling Water Pump Case
    122
  - Disassembling Propeller Shaft and Clutch
    122
  - Removing Bevel Gear and Drive Shaft
    123
  - Lower Unit Inspection
    124
  - Inspecting Bevel Gear Backlash
    125
  - Backlash Reading and Corresponding Adjusting Shim Sizes
    125
  - Lower Unit Reassembly
    126
  - Assembling Gear Case
    126
  - Installing Bevel Gear on Drive Shaft
    126
  - Assembling Propeller Shaft and Clutch
    126
  - Assembling Clutch Cam, Cam Rod and Clutch Cam Rod Bushing
    127
  - Assembling Water Pump
    128
  - Adding Gear Oil
    129
  - Assembling Gear Case Assembly
    129
Chapter 7 Power Trim and Tilt

130
Chapter 8 Tiller Handle Type

143
- Installing Gearshift Lever Assembly
  143
- Installing Switchbox Assembly
  144
- Installing Handle to Engine
  145
Chapter 11 Installation on Boat and

173
- Precautions for Using this Engine
  173
  - Remote Control System - Installing Cable (Engine Side) for EP Series
    173
  - Gauges and Battery
    175
    
    Installing the Various Gauges
    175
    
    Installing Battery
    176
    
    Wiring Diagram for Remote Control Unit and Gauges
    176
  - Operating the Engine
    177
  - Starting Procedure
    177
  - Force-Feeding Fuel
    178
  - Force-Feeding Engine Oil
    178
  - EFO and EFTO Series
    179
  - EPTO Series
    180
  - Warning Process
    181
  - Oil Level Indicator
    181
  - Cooling Water Indicator
    182
  - Battery Level Warning
    182
  - Engine Trouble Warning
    183

TOHATSU TLDI 50 Service Manual

TOHATSU TLDI 50 Service Manual (105 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 2.3 MB

Table of Contents

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TOHATSU TLDI 50 Owner's Manual

TOHATSU TLDI 50 Owner's Manual (99 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 2.09 MB

Table of Contents

Table of Contents
7
Engine Installation on Boat
17
I Installation
17
Remote Control Box
21
Installing the Remote Control Box
21
Connecting the Remote Control Cable to the Engine
24
Connecting Cords and Cables
28
S Installing the Meters
28
Installing the Drag Link Assembly
31
Non Auto-Mixing Model M40D . M40DEF
35
M50Def
35
Auto-Mixing Model
35
M40Defo
35
M40Defto
35
M40Depo - M40Depto
36
M50Defo - Msodefto . M50Depo
36
Running
39
Lbreak-In
39
2Starting
40
3Manualstart
48
4Warm.up
51
Overheat Buzzer
52
Operation
53

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