TOHATSU TLDI 40 Service Manual page 18

Service limit
• 0.8 mm (0.031 in) or more
• 0.9 mm (0.035 in) or more
• 0.05 mm (0.002 in) or more
• 2 mm (0.08 in) or more
• Scratch depth or distortion is 0.03 mm
(0.0012 in) or more
• Scratch depth or distortion is 0.03 mm
(0.0012 in) or more
• When the cylinder liner cannot be repaired using
#400 to #600 sandpaper due to excessive
scratching or scoring or when the difference
between the maximum and minimum points of
wear in liner bore is 0.06 mm (0.0024 in) or more
1) When difference in compression between
cylinders exceeds 0.1 MPa
(1.05 kg/cm , 14.5 psi)
2
2) When abnormally higher than standard value
• No longer conforms to standard value
• Valve reed fails to close
• Excessive wear on valve seat
• Valve is damaged
Servicing procedure
• Replace with new piston ring if cylinder liner
wear has not yet exceeded the repair limit.
• Replace with new crankshaft.
• Replace with new crankshaft assembly.
• Repair by polishing the surface plate, starting
with #240 to #400 grit sandpaper and finishing
with #600 grit sandpaper.
• Repair by polishing the surface plate, starting
with #240 to #400 grit sandpaper and finishing
with #600 grit sandpaper.
• Bore and hone to ø68.55 (2.699 in) + 0 to 0.02
mm (0 to 0.0008 in). Check ports and grind if
necessary.
Use oversize pistons and piston rings.
1) Bore and hone to ø68.55 (2.699 in) + 0 to 0.02
mm (0 to 0.0008 in). Check ports and grind if
necessary.
Use oversize pistons and piston rings.
2) Remove carbon from piston crown and cylinder
head surfaces and clean exhaust gas bypass
valve.
• Replace with new part.
• Replace entire valve assembly.
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