TOHATSU MD 70-90C2 Service Manual

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B No.003-21052-2

11-01 NB

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Troubleshooting

Summary of Contents for TOHATSU MD 70-90C2

Page 1 B No.003-21052-2 11-01 NB...
Page 3 Introduction Before reading this manual This service manual provides information that is needed for inspection, service and repair of applicable outboard motors. For information about operation of the products that are not described in this document, refer to the owners manual. For our customers' safe and comfortable use of the products for long term, it is essential to maintain the performance and quality of the outboard.
Page 4 About this manual Composition and use of this manual This service manual is designed so that service persons are able to perform repairs correctly. Understand the following matters well for efficient service and repair. 1 Each chapter begins with the introduction of special tools that are used for the work described. 2 Parts that are serviced in each chapter and their details are presented by using a component composition diagram.
Page 5 This manual uses SI unit system (International System of Units) for the pressure, force (load), torque and stress. This manual newly adopts the international unit construction system (SI unit system) followed by the conventional imperial and metric systems enclosed by ( ) and [ ] as described below. Example : <Pressure>...
Page 6 Description of Pictograph The following symbols represent the contents of individual chapters. Service nspections and Service Data Fuel System nformation Adjustments Electrical Power Unit Lower Unit Bracket System Wiring r/min Troubleshooting Rigging Diagrams The following symbols indicate items needed for the service. Tightening Lubrication Special Tool...
Page 7: Table Of Contents
1.Service Information 2) Inspection of Fuel Tank (option) … 3-6 3) Inspection of Low Pressure Fuel Filter … 3-7 1. Identification 4) Inspection of Air Compressor Air Filter … 3-7 (Engine Serial Number) …………… 1-2 5) Inspection of Air Pressure ………… 3-7 2.
Page 8 2) Installation of Fuel Hose Ass’y …… 4-25 15) Removing Cylinder Head / 3) Draining Fuel from FFP Vapor Separator … 4-26 Head Cover …………………………5-29 4) Removing Vapor Separator ……… 4-26 16) Inspection of Cylinder Head ………5-30 5) Disassembly and Inspection of 17) Removing Exhaust Cover …………5-31 Vapor Separator ……………………...
Page 9 20) Inspection of Forward (A) Gear …… 6-23 21) Assembly of PTT Unit ……………… 7-37 21) Assembly of Forward (A) Gear Parts … 6-24 22) Air Bleeding PTT Unit ……………… 7-40 8.Electrical System 22) Removing Drive Shaft Ass’y ……… 6-25 23) Disassembly of Drive Shaft Ass’y …...
Page 10 PTT Unit Electrical Wiring Assembling State 1 PTT unit will not operate. ……… 9-30 Instruction Diagram -2 ………………… 11-8 Outboard Motor Installation Template … 11-9 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…...
Page 11 INDEX Service Information Service Data Maintenance Fuel System (TLDI) Power Unit Lower Unit Cowl, Bracket and PTT Unit Electrical System Troubleshooting Rigging r/min Wiring Diagram TLDI 75/90C2 2010...
Page 12 TLDI 75/90C2 2010...
Page 13: Service Information
Service Information 1. Identification 2) Gear Shift and Throttle …………… 1-9 (Engine Serial Number) …………… 1-2 3) Engine Oil …………………………… 1-9 2. Work Safety …………………………… 1-2 4) Gear Oil ……………………………… 1-9 1) Fire Prevention ……………………… 1-2 5) Check quantity of engine oil. ……… 1-10 2) Ventilation ……………………………...
Page 14: Service Information
Service Information 1. Identification (Engine Serial Number) Engine serial number is stamped on the bottom cowl of outboard motor body. 1 Model Name 2 Model Type Made in Japan 90C2 3 Serial Number SERIAL No. 66.2 kW RATED POWER FULL THROTTLE RANGE 5150 5850 r / min...
Page 15: Tools
5) Tools Use specified special tools to prevent damaging to parts and to perform work safely and surely. Be sure to follow installation procedures described in this manual and use tightening torque specified. 3AC728710 6) Recommendations on Service Remove foreign substances and dirt from outboard motor and individual parts by cleaning.
Page 16: Cautions In Disassembling And Assembling Components
Service Information 7) Cautions in Disassembling and Assembling Components Secure outboard motor to dedicated stand firmly. Take special care not to scratch painted surfaces or mating surfaces of cylinder and crankcase. Replace parts such as packings, gaskets, O rings, oil seals, spring pins or split pins with new ones after they are removed.
Page 17: Tools And Instruments
3. Tools and Instruments 1) Test Propeller P/N. 3T1-64111-0 Outer diameter : 278mm With : 25mm Rotational speed at WOT Model (Wide Open Throttle) (r/min) TLDI75C2 approximately 5,000 - 5,100 TLDI90C2 approximately 5,500 - 5,600 2) Measuring Instruments For the following measuring instruments, use commercially available ones. Circuit tester ( Resistance : 1Ω, 10Ω, 10 kΩ, AC voltage : 30 to 300V, DC voltage : 30V, Internal voltage 3V or less ) Vernier calipers...
Page 18: Special Tools
Service Information 3) Special Tools Clutch Pin Snap Tool Power Head Stand Shift Rod Joint Puller Piston Ring Tool P/N. 345-72229-0 P/N. 353-72247-1 P/N. 353-72248-0 P/N. 353-72249-0 Used for pulling up shift rod in case the components are Removing or attaching piston Holding power head when disassembling or reassembled with the shift rod at "R"...
Page 19 ø49.5 x ø29.5 Oil Seal Attachment Bevel Gear B Nut Wrench Drive Shaft Socket Backlash Measuring Tool A Kit P/N. 3Y9-99820-0 P/N. 3B7-72231-0 P/N. 3B7-72232-0 P/N. 3B7-72234-0 Used in combination with driver rod Removing or attaching pinion Removing or attaching pinion Measuring backlash between forward Attaching propeller shaft housing oil (B) gear nut...
Page 20 Service Information ø 41.5 x ø21.5 3B7-72785-0 3B7-72783-0 3C7-72783-0 940191-0800 3B7-72784-0 Flywheel Puller Kit Oil Seal Attachment Eye Bolt (Powerhead Lift Ring) P/N. 3T1-72211-0 P/N. 3J6-99820-0 P/N. 3T1-72212-0 Attaching pump case (lower) Used to hook power unit when Removing or attaching flywheel oil seal hanging ø31.5 x ø25.0...
Page 21: Pre-Delivery Inspection
4. Pre-delivery Inspection 1) Steering Handle Check installation of drag link. 2) Gear Shift and Throttle Shift into forward (F), back to neutral (N) and then shift into reverse (R) to check that the shift operations are smooth. Then, set the lever to position a to check that the throttle operations are smooth.
Page 22: Check Quantity Of Engine Oil
Service Information 5) Check quantity of engine oil. Set outboard motor to vertical position. Check engine oil level. Oil Tank Capacity : 4.3L (1.14 gal) Engine Oil： Genuine Oil (Oil for two stroke direct injection engine recommended by the outboard manufacturer) CAUTION When quantity of fills below 1.1L (0.29gal), oil warning lamp blinks and the buzzer...
Page 23: Fuel Line
6) Fuel Line Check that fuel tank contains sufficient amount of gasoline, fuel line is connected and does not leak. CAUTION Supply only unleaded regular octane gasoline into fuel tank. Never use fuel mixed with oil. Use of fuel mixed with engine oil will cause engine trouble.
Page 24: Inspection Of Start Switch And Stop Switch
Service Information 9) Inspection of Start Switch and Stop switch å Turn main switch to START 2 to check that engine starts. START START Turn main switch to OFF 3 to check that engine stops. å Switch Panel Model ∫ Remote Control Model ∫...
Page 25: Cooling Water Check Port
10) Cooling Water Check Port Check that cooling water check port 1 discharges water during engine operation. 11) Idling After engine has warmed up, use tachometer to check idle speed is as specified, using key switch depression. Idle Speed : 700 800 900 r/min Tachometer : P/N.
Page 26: Trim Tab
Service Information (3 x 14.0 x 11.0）［3 x 355 x 279］ (3 x 14.0 x 13.0) ［3 x 355 x 330］ (3 x 13.75 x 15.0) ［3 x 349 x 381］ Propeller (No. of Blades x Diameter x Pitch) (3 x 13.25 x 16.0) ［3 x 336 x 406］...
Page 27: Break-In Operation
5. Break-In Operation Break-in operation is needed for the purpose of smoothening sliding surfaces between components such as pistons, piston rings, piston pins, cylinder, and gears. Break-In Operation…10 Hours Time 10 minutes 2 hours 3 hours 10 hours Throttle Opening: 1/2 of Throttle Opening: 3/4 of Throttle Opening: 3/4 of Method of break-...
Page 28 Service Information 1-16 TLDI 75/90C2 2010...
Page 29: Service Data
Service Data 1. Outboard Dimensions ……………… 2-2 4. Maintenance Data ………………… 2-8 1) Body dimensions …………………… 2-2 5. Torque Specifications …………… 2-14 2) Clamp Dimensions ………………… 2-3 6. Sealant And Lubricant …………… 2-16 2. Cooling Water System Diagram … 2-4 7.
Page 30: Outboard Dimensions
Service Data 1. Outboard Dimensions 1) Body dimensions TLDI75/90C2 Item Type Unit mm/in 25.59 Transom (L) mm/in 35.04 Transom (UL) mm/in 1017 40.04 Transom (L) mm/in 20.35 Transom (UL) mm/in 25.35 mm/in 31.89 mm/in 24.53 mm/in 21.42 mm/in 31∼70 1.22∼2.76 mm/in 23.54 Transom (L) mm/in...
Page 31: Clamp Dimensions
2) Clamp Dimensions CENTER LINE 180 mm 180 mm (7.09 in) (7.09 in) 163.5 mm 163.5 mm (6.44 in) (6.44 in) TOP OF BOAT TRANSOM 121 mm 121 mm (4.76 in) (4.76 in) M12P1.25 13.5 mm (0.53 in) 125.5 mm 125.5 mm Allowable Transom (4.94 in)
Page 32: Cooling Water System Diagram
Service Data 2. Cooling Water System Diagram TLDI 75/90C2 2010...
Page 33 ylinder Head Head over Air Rail Thermostat Exhaust System Air ompressor ylinder over ooling Water heck ylinder Lower Section Port ylinder Lower Section (Water Discharging Passage (Water Feed Passage in Drive Shaft Housing) in Engine Base) ooling Water Pipe Interior of Drive Shaft Housing ooling Water Pump Discharging...
Page 34: Specifications
Service Data 3. Specifications Model Item Unit TL I75C2 EPT0 TL I90C2 EPT0 imensions (Approximate) verall Length mm (in) 810 (31.89) verall Width mm (in) 508 (20.00) verall Height mm (in) 1,540 (60.63) mm (in) 1,667 (65.63) Transom Height mm (in) 517 (20.35) mm (in) 644 (25.35)
Page 35 Model Item Unit TLDI75C2 EPT0 TLDI90C2 EPT0 uel and Oil Type of Fuel Unleaded Gasoline (Reserch Octane Number 90 or over, Pump posted Octane Number 87 or over) Type Genuine Oil (Oil for two stroke direct injection engine recommended by the outboard manufacturer) Quantity L(gal) 4.3L (1.14 us gal)
Page 36: Maintenance Data
Service Data 4. Maintenance Data escription Item Standard Values uild up of carbon in combustion chamber 0.03 mm (0.0012in) or less for scratches Distortion or damage on mating surface Cylinder Head 0.03 mm (0.0012in) or less for distortion Corrosion Cooling water passage clogged 0.03 mm (0.0012in) or less for scratches Mating surface scratches and wear 0.03 mm (0.0012in) or less for distortion...
Page 37 unctional Limit Action To Be Taken lean and remove build up. Repair by polishing the surface plate, starting with #240 to #400 grit sandpaper and finishing with #600 grit sandpaper. Scratches or deflection of 0.03mm (0.0012 in) Replace if over specified limit. Repair or replace depending on the extent of damage.
Page 38 Service Data escription Item Standard Values Air Rail Wear and damage on O-rings Air Regulator Air pressure 0.65 MPa (94.3 psi) [6.5 kgf/cm ] ±10% Fuel Regulator uel pressure Measured air pressure + 0.07 MPa (10.1 psi ) [0.71kgf/cm ] ±10% Seal ring wear and damage Vapor Separator loat...
Page 39 unctional Limit Action To Be Taken Replace with new part. hen parts are worn or damaged Replace with new part. hen parts no longer conform to standard values Replace with new part. hen parts no longer conform to standard values hen parts are worn or damaged Replace with new part.
Page 40 Service Data Description Item Standard Values Tilted up : 8.8 Ñ 11.8 MPa (1,281 Ñ 1,707 psi) [90 Ñ 120 kgf/cm elief valve opening pressure Tilted down : 3.9 Ñ 7.4 MPa (569 Ñ 1,067 psi) [40 Ñ 75 kgf/cm ump Assembly Upper chest : 0.24 MPa (34.1 psi) [2.4 kgf/cm Spool check valve opening pressure...
Page 41 unctional Limit Action To Be Taken Replace with new part hen the valve opens even slightly at ambient temperature Replace with new part. Check valve opening temperature by immersing the thermostat in water and gradually increasing water temperature Replace with new assembly. hen the tips or upper and lower surface lip areas show wear, cracks or damage Replace when wear is excessive.
Page 42: Torque Specifications
Service Data 5. Torque Specifications Temporary Driving Torque Driving Torque Screw B x Type of Wrench Remarks Tightening Location Pitch Fastner ¥ m lb ¥ ft kgf ¥ m ¥ m lb ¥ ft kgf ¥ m ylinder Head over M6 x 1.0 Bolt Driving sequence...
Page 43 Temporary Driving Torque Driving Torque Screw B x Type of Wrench Remarks Tightening Location itch Fastner N ¥ m lb ¥ ft kgf ¥ m N ¥ m lb ¥ ft kgf ¥ m il Reserve Tank Installation Bolt 1/4-20UNC Bolt Ñ...
Page 44: Sealant And Lubricant
Service Data 6. Sealant And Lubricant Remarks octite Konishi Three Shinetsu ThreeBond CHUO YUKA SUMICO Bond Silicones Applied to Centax 1342 1373B 1741 FM-531 M-902 KS-64 (*1) Ring grooves and outer circumference Piston ○ (Piston pin outer circumference) Piston Pin Piston pin holes ○...
Page 45 Remarks Loctite Konishi Three Shinetsu ThreeBond CHUO YUK Silicones SUMICO Bond pplied to 1741 Centax 1342 1373B FM-531 LM-902 KS-64 (*1) pply to two O Rings. ir Injector O Ring ○ Terminal section ir Injector Terminal ○ pply to two O Rings. Fuel Injector O Ring ○...
Page 46 Service Data Remarks Loctite Konishi Three hinetsu ThreeBond CHUO YUKA ilicones UMICO Bond Applied to 1741 Centax 1342 1373B FM-531 LM-902 K -64 (*1) hift Lever haft Holder Mounting Bolt crew section ○ hift Lever haft Holder liding section and interior (small amount) ○...
Page 47 Remarks Loctite Konishi Three Shinetsu Three ond CHUO YUKA Silicones SUMICO Applied to 1741 Centax 1342 1373 FM-531 LM-902 KS-64 (*1) racket olt Fill with grease ○ racket olt Cap Inner surface ○ Stern racket Washer oth faces ○ Swivel racket Fill interior with grease ○...
Page 48: Warning Indication List
Service Data 7. Warning Indication List • • • Display for abnormalities during operation arning Indicators Speed Control Buzzer Sounding （※ ） Indicator A Indicator B Indicator C Continuous High speed ESG ntermittent Flashing (3 beeps for every 2 minutes) Continuous Flashing Low speed ESG...
Page 49 ault Description Remedy Reference ngine over-rev. Readjust propeller, outboard engine mounting height and/or trim. Approx. 6,000 r/min Low oil level Approx. 1.1L Lor less Replenish engine oil in tank. Cooling water temp. high 85¡C (185¡F) ngine cooling water temp. abnormally high 90¡C (194¡F) Air compressor cooling water temp.
Page 50 Service Data 2-22 TLDI 75/90C2 2010...
Page 51: Maintenance
Maintenance 1. Special Tools ………………………… 3-2 6. Operating System …………………… 3-13 2. Inspection Schedule ……………… 3-3 1) Adjustment of Throttle Cable ……… 3-13 3. Inspection Items …………………… 3-4 2) Adjustment of Shift Cable ………… 3-14 1) Inspection of Top Cowl …………… 3-4 3) Inspection of Idle Engine Speed …...
Page 52: Special Tools
Maintenance 1. Special Tools Spring Pin Tool A (ø3.5) Spring Pin Tool B (ø3.5) Compression Gauge Pressure Gauge Ass'y P/N. 3AC-99030-0 P/N. 3T5-72880-0 P/N. 369-72217-0 P/N. 369-72218-0 Measuring compression Measuring air rail fuel pressure Removing spring pin Installing spring pin pressure and air pressure Tachometer...
Page 53: Inspection Schedule
2. Inspection Schedule Inspection Period Initial 20 Inspection Item Inspection Part Remarks 50 hours 100 hours 200 hours hours or Every 2 or Every or Every or Every initial 1 years 3 months 6 months year month Fuel Filter ○ ○...
Page 54: Inspection Items
Maintenance 3. Inspection Items 1) Inspection of Top Cowl Push top cowl using both hands to check for looseness and state of closing. Loosen cover stay securing nuts 1, adjust fit of cowl, and then, tighten the nuts. Turn toward a to loosen cowl. Turn toward b to tighten cowl.
Page 55 Set key switch 1 a to “ON”. START Pull off lock plate 3 within one second from the moment warning buzzer 2 stops. Pull stop switch 4 twice within two seconds. When the above operation is completed, the buzzer sounds three times and oil pump starts to run.
Page 56: Fuel System
Maintenance 4. Fuel System 1) Inspection of Fuel Pipes and Joints Check the fuel system piping for fuel leak, dirt, deterioration and damage, and replace or clean parts if necessary. 2) Inspection of Fuel Tank (option) Turn fuel pick up elbow 2 of fuel tank 1 counterclockwise to remove the part, and clean the filter 3.
Page 57: Inspection Of Low Pressure Fuel Filter
3) Inspection of Low Pressure Fuel Filter CAUTION · If red float 1 is floating in the filter, water is in the cup. · Remove the cup and drain the water. Check fuel filter 2 for contamination, and fuel filter cup 3 for invasion of foreign matter and cracks.
Page 58: Inspection Of Fuel Pressure
Maintenance Set the lever of pressure gauge ass’y to position b to relief pressure, after engine stopping. Remove pressure gauge ass’y and attach cap. 6) Inspection of Fuel Pressure CAUTION When attaching pressure gauge ass’y, cover the joint of inspection valve and gauge with rag to prevent spread of fuel that leaks.
Page 59: Inspection Of Drive Belt
7) Inspection of Drive Belt Remove ring gear cover. DANGER Make sure to check engine stopped. Check drive belt for wear and damage on the inner and outer faces while turning flywheel clockwise. Check if oil or dirt is adhered to the belt. Replace with new one if any of the problems exists.
Page 60: Power Unit
Maintenance 5. Power Unit 1) Inspection of Spark Plugs Remove plug caps and then spark plugs. Clean spark plug electrodes 1 by using spark plug cleaner. Replace if necessary. Check electrodes 1 for corrosion or excessive build up of carbon, and washer 2 for damage. Replace if necessary. Check spark plug gap a.
Page 61: Inspection Of Compression Pressure
2) Inspection of Compression Pressure CAUTION · To prevent accidental start of the engine, remove lock plate (of stop switch lanyard) from stop switch before measuring compression pressure. · Clean areas around spark plugs on the cylinder before removing spark plugs to prevent dirt from entering cylinder.
Page 62: Inspection Of Thermostat
Maintenance 3) Inspection of Thermostat Remove air rail. Loosen cover installation bolts 1, remove them, and then remove cover 2 and thermostat 3. Hang thermostat 3 in the water contained in vessel. Put thermometer in the water, and warm up water to measure valve opening temperature.
Page 63: Inspection Of Cooling Water Passage
4) Inspection of Cooling Water Passage Check cooling water intake for clog. Clean if necessary. Set lower unit in the water and start engine. Check that cooling water check port 2 ejects water. 6. Operating System 1) Adjustment of Throttle Cable Loosen lock nut 1.
Page 64: Adjustment Of Shift Cable
Maintenance Attach cable joint, washer and “R” shaped pin to advancer arm. Check if throttle control can be made smoothly. If necessary, readjust by following the steps 1 to 7. Make sure the cable pushes the throttle arm against the stop at WOT in forward against.
Page 65: Inspection Of Idle Engine Speed
3) Inspection of Idle Engine Speed Start engine and run for 5 minutes to warm up. Attach tachometer to high tension cord 1 to check idle speed. · More accurate and stable reading can be obtained when tachometer lead is connected with high tension cords of individual cylinders linked with each other.
Page 66: Lower Unit
Maintenance Remove cap 2 and check PTT fluid quantity. CAUTION Be sure to remove the cap when outboard motor is in full tilt up position. Removal of the cap in other than full tilt up position may cause the fluid to blast out. Quantity of PTT fluid is normal when some fluid spills out of cap hole when cap is removed.
Page 67: Replacement Of Gear Oil
Use lower plug hole when filling with gear oil. Upper hole cannot be used because doing so will not allow air to escape from gear case. Gear Oil: Tohatsu genuine Gear Oil or Hypoid Gear Oil API：GL-5 SAE：#80∼90 Gear Oil Quantity: 900 cm （30.4 fl.oz）...
Page 68: Inspection Of Gear Case (For Leakage)
Maintenance 3) Inspection of Gear Case (for leakage) Drain gear oil. Remove upper oil plug 1 and connect a commercially available leakage tester to this hole. Apply specified pressure to gear case, and check if the pressure is maintained without further compression for 10 seconds.
Page 69: Others
Check following parts. 7 Bolts : M8 4 pcs. 8 Washers 4 pcs. 9 Pump Case (Upper) 0 Pump Case Liner q Pump Impeller ➝ Replace with new one. w Key ➝ Replace with new one. e Seal r Guide Plate ➝...
Page 70: Inspection Of Propeller
Maintenance Check anode 1 a and trim tab 2 for deterioration. Replace anode (or trim tab) if volume is reduced to 2/3 of new part. 2) Inspection of Propeller Check propeller blades and hub for cracks, damages, wear and corrosion. Check spline for twist, and replace propeller if necessary.
Page 71: Inspection Of Battery
3) Inspection of Battery Inspect battery liquid level. If lower than “LOWER” mark a , add distilled water until the level goes in between “UPPER” and “LOWER” marks. Measure specific gravity of battery liquid. Charge battery if specific gravity is less than specified value. WARNING Electrolyte contains sulfuric acid that is poisonous and highly corrosive, which is dangerous.
Page 72: Flushing With Water
Maintenance 4) Flushing with Water WARNING Exhaust gas contains carbon monoxide which can cause intoxication if inhaled. Do WASH not operated engine in a closed space such as interior of boat house. WARNING Be careful not to touch rotating propeller. Be sure to remove propeller before running engine on the land.
Page 73 Flushing using flushing device Set outboard motor to vertical position. Take out flushing connector cap 1 and attach flushing attachment 2 to it. Put water hose on the flushing attachment and run water for 3 to 5 minutes. CAUTION The flushing can be made without running the engine.
Page 74: Greasing
Maintenance 5) Greasing Inject grease through grease nipple 1 until excessive grease appears from a. Apply grease to propeller shaft spline. Only under pinion on splines outside will wear on pinion and flywheel. Apply grease to throttle cam sliding areas. 3-24 TLDI 75/90C2 2010...
Page 75: Fuel System (Tldi)
Fuel System (TLDI) 1. Special Tools ………………………… 4-2 4) Removing Vapor Separator ……… 4-26 2. Parts Layout ………………………… 4-3 5) Disassembly and Inspection of Vapor Separator & Fuel Line …………… 4-3 Vapor Separator …………………… 4-27 FFP Ass'y ………………………………… 4-4 6) Assembly of Vapor Separator …… 4-27 Air Rail ……………………………………...
Page 76 Fuel System (TLDI) 1. Special Tools Piston Slider Vacuum/Pressure Gauge Driver Rod Oil Seal Attachment P/N. 3T1-72871-0 P/N. 3AC-99020-0 P/N. 3AC-99702-0 P/N. 3T1-99820-0 Used in combination with center Assembling piston for air Used to press-fit crank case Inspecting pressure place and various attachments compressor head oil seal ø51.5 x ø39.5...
Page 77: Parts Layout
P/L Fig. 8 2. Parts Layout Vapor Separator & Fuel Line .6 Nám ( . lbáft) [0. 6 kgfám] Fig.7 2st OIL THROTTLE BODY ASSÕY 2st OIL 2st OIL 6 Nám (4 lbáft) [0.6 kgfám] 2st OIL .6 Nám ( . lbáft) [0. 6 kgfám] 2st OIL Ref.
Page 78: Ffp Ass'y
Fuel System (TLDI) FFP Ass'y P/L Fig. 6 HIGH PRESSURE 3. Nám ( .3 lbáft) [0.3 kgfám] FUEL FILTER 1342 1342 15 Nám (11 lbáft) [1.5 kgfám] 2st OIL 2st OIL 2st OIL 2st OIL CYLINDER VAPOR SEPARATOR 3. Nám ( .3 lbáft) [0.3 kgfám] Yellow Blue 2st OIL...
Page 79 Ref. Description Q'ty Remarks Fuel Feed Pump Ass'y Fuel Feed Pump Case Ass'y Upper Case FFP Adapter Hose Joint Do not reuse. Metal Washer 10.2-17-2 Do not reuse. Seal FFP Grommet Upper FFP Grommet Lower FFP Cable Terminal Ass'y (+) Cable Terminal Ass'y (-) Grommet Cable Terminal Grommet Upper Cable Terminal...
Page 80: Air Rail
Fuel System (TLDI) P/L Fig. 4 Air Rail 2st OIL S.O.C 15 Nám (11 lbáft) [1.5 kgfám] 1342 * Do not overtighten, or the part may be 1342 1342 damaged 20 Nám (14 lbáft) [2.0 kgfám] 2st OIL S.O.C Fig.6 2st OIL 1342 1342...
Page 81 Ref. Description Q'ty Remarks Air Rail Ass'y L-Nipple Valve Ass'y Plug 10.5 O-Ring 6.8-1.9 Do not reuse. Stopper Plug Bolt M6 L=12mm Hose Clamp 29-64 Do not reuse. Bolt M8 L=65mm Washer Air Injector Complete Orange O-Ring 5-52 Do not reuse. O-Ring 2.4-9.5 Brown Do not reuse.
Page 82: Air Compressor
Fuel System (TLDI) P/L Fig. 5 Air Compressor 60 Nám (190 lbáft) [ 6 kgfám] 2st OIL 50 Nám (36 lbáft) [5 kgfám] Fig. 1342 1342 1342 2st OIL 6 Nám (4 lbáft) [0.6 kgfám] 2st OIL 2st OIL 9 Nám (7 lbáft) [0.9 kgfám] 1342 1342 2st OIL...
Page 83 Ref. Description Q'ty Remarks Air Compressor Ass'y Compressor Head Ass'y Adapter Hose Joint Metal Washer 10.2-17-2 Do not reuse. Bolt M6 L=35mm Gasket Compressor Head Do not reuse. Reed Valve Ass'y Valve Seat Gasket Do not reuse. Air Compressor Piston Connecting Rod Piston Ring (Compressor) Do not reuse.
Page 84: Oil Pump
Fuel System (TLDI) P/L Fig. 13 Oil Pump 0 Nám (7 lbáft) [ .0 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] 0 Nám (7 lbáft) [ .0 kgfám] (#3 AIR BOX) (# Cylinder) 32 3 (#2 Cylinder) (#2 AIR BOX) (#3 Cylinder) (# AIR BOX) Fig.5...
Page 85 Ref. Description Q'ty Remarks Oil Pump Ass'y Mount Rubber 12-18-2.5 Spacer 8.4-12-17 Bolt M8 L=35mm Washer 8.5-24-1.5 Bracket Oil Pump Stay Lead Wire Band 170 Pipe L=200mm Clip ø Pipe Oil Pump to # 1 Air Box L=560mm Pipe Oil Pump to # 2 # 3 Air Box L=380mm Pipe Oil Pump to # 1 Cylinder...
Page 86: What Is Tldi
Fuel System (TLDI) 3. What is TLDI? Direct Fuel Injection System TLDI (Two-stroke Low-pressure Direct injection) TLDI is a kind of two stroke engine system that adopts air-assisted low pressure direct fuel injection. The adoptions of the air-assisted low pressure direct fuel injection system and digital inductive ignition system and control of factors by means of ECU (Engine Control Unit) such as fuel injection amount, fuel injection timing and ignition timing provide fuel combustion at higher efficiency, lower fuel consumption and lower emission, as well as powerful performance that is one of outstanding features of two stroke engines.
Page 87: Inductive Ignition
Inductive Ignition TLDI adopts an inductive ignition system that provides the fuel combustion at higher efficiency, lower fuel consumption and lower emission. The inductive ignition of TLDI has spark plug ignition duration that is longer than that of conventional two stroke carbureted engines for surer combustion of the air-fuel mixture in the combustion chamber, ensuring more stabilized engine operation under varied operating environment.
Page 88 Fuel System (TLDI) Air Injector The air injector injects fuel and compressed air into the combustion chamber of each cylinder. The component is controlled by ECU to inject the amount of fuel mixture at the timing that is best suited to the current engine operation conditions based on the information from sensors.
Page 89: Ecu
TLDI uses ECU to control factors such as fuel injection amount, injection timing and ignition timing to the best suited conditions based on the information from the sensors.Moreover, the TLDI achieves lean combustion through stratified charge in the low engine speed range, and highly efficient combustion through electronic control of premixed charge that provides homogeneous fuel distribution in the combustion chamber in the high speed range.
Page 90 Fuel System (TLDI) 4-16 TLDI 75/90C2 2010...
Page 91 TLDI 75/90C2 2010 4-17...
Page 92 Fuel System (TLDI) 4-18 TLDI 75/90C2 2010...
Page 93: Removing Air Rail
4. Removing Air Rail WARNING · Be sure to decompress fuel and air before disassembling fuel system components. · Disassembling fuel system components can cause spurting of compressed fuel. 1) Decompression of Fuel Line and Air Line Push in the air valve 2 attached to air rail 1 to decompress the air line.
Page 94 Fuel System (TLDI) Loosen two bolts 9 that secure air rail, and remove air rail ass’y 0 carefully. When removing the air rail, leave the air injectors on the cylinder side. Be careful not to drop O ring located on the air injectors.
Page 95: Inspection Of Injectors
3）Inspection of Injectors Check air injectors and fuel injectors for cracks and damages. Replace if necessary. Check disc springs of air injectors for dirt, correct position settling and damages Clean, or replace if necessary. (Refer to "Injector Assembling Diagram" in page 4-23.) 5.
Page 96: Fuel System
Fuel System (TLDI) Attach O rings 5 and 6 and compression seal r to air injector 4. Attach O rings 9 and 0 to air regulator 7 and fuel regulator 8. Attach compression seal w to fuel injector insert q, and then, attach the assembly to the air rail.
Page 97 Insert Injector Assembling Diagram ompression Seal Fuel Injector Adapter Air Passage ompression Seal Fuel Injector Fuel Passage ooling Water Passage Air Injector isk Spring (Be careful of the orientation.) Attaching Hose Clamps Attach the following parts. Install fuel regulator 1 and air regulator 3, secure them using collars 4, plate 5 and bolt 6, and attach clamp 7.
Page 98 Fuel System (TLDI) Attaching hose clamp. Lightly Lubricate inside of clamp to prevent hose damage. Crush hose clamp 2 as shown to tighten the hose securely. WARNING Do not reuse hose clamp. Be sure to use new one. Do not crush hose clamp too much, or the ②...
Page 99: Removing High Pressure Fuel Hose Ass'y
Arrange the pipes as shown. Attach air hose ass’y 1 to air compressor hose joint adapter with fasteners tightened to specified torque. Air Hose Ass’y 1 : 15 N·m (11 lb·ft) [1.5 kgf·m] Do not tighten with excessive torque. The part may be damaged.
Page 100: Draining Fuel From Ffp Vapor Separator
Fuel System (TLDI) 3) Draining Fuel from FFP Vapor Separator Decompress fuel and air pressures. WARNING Compressed fuel and/or air may spurt if it is not decompressed. Loosen air vent screw 1, and then, drain screw 2 to drain fuel from vapor separator and collect it in a container.
Page 101: Disassembly And Inspection Of Vapor Separator
5) Disassembly and Inspection of Vapor Separator Remove float chamber of vapor separator, and then, remove float valve 1 and float 2. Inspection of Vapor Separator 1. Check needle valve 1 for deformation and wear. 2. Check float 2 for deformation, crack and other defects.
Page 102: Assembly Of Vapor Separator Ass'y
Fuel System (TLDI) 7) Assembly of Vapor Separator Ass’y Reverse the removing steps. 1 Vapor Separator Ass’y 2 Tighten bolts. Bolts 2 : 6 N·m (4 lb·ft) [0.6 kgf·m] 8) Removing FFP* Ass’y * FFP : Fuel Feed Pump Remove parts in the order described below. Disconnect FFP connector 1, loosen hose joint 2, and then remove fuel hose ass’y.
Page 103: Assembly Of Ffp Ass'y
10) Assembly of FFP Ass’y Assemble following parts. Attach hose joint adapter 1 and metal washer 2 to upper 1342 1342 1342 case 3. Hose Joint Adapter 1 : 14 - 16 N·m (10 - 12 lb·ft) [1.4 - 1.6 kgf·m] Degrease edge and then apply adhesive : ThreeBond 1342 1342...
Page 104: Inspection Of Fuel Pump
Fuel System (TLDI) Attach upper grommet 8 and cable terminal grommets 9. Terminal area of parts 8, 9, 0 and q : Genuine Engine Oil Attach black wire 0 ( - ) and red wire q ( + ) of cable 2st OIL terminal to FFP case.
Page 105: Installation Of Ffp Ass'y To Cylinder
Apply specified vacuum pressure to check that no air leaks through check valve located in the fuel pump. Specified Vacuum Pressure : -0.03MPa (-4 psi) [-0.3 kgf/cm Connect vacuum / pressure gauge to outlet of fuel pump. Apply specified pressure to check that no air leaks through check valve located in the fuel pump.
Page 106: Removing And Installation Of Air Compressor
Fuel System (TLDI) 7. Removing and Installation of Air Compressor 1) Removing Drive Belt Mark drive belt with an arrow as shown to indicate orientation. CAUTION When reusing the drive belt, install it in its original orientation indicated by the arrow. Loosen compressor mounting bolts and slide the compressor to crank case side.
Page 107: Removing Driven Pulley
Check drive belt for missing tooth (teeth) and adherence of oil. Replace the belt with new one if any of the above problems exists. Crack or chip of the belt, if any, can be found easily when it is turned over. 4) Removing Driven Pulley Remove compressor cylinder 1 from air compressor ass’y by referring to exploded diagram.
Page 108: Disassembly Of Compressor Housing
Fuel System (TLDI) Fix crank shaft at its lower end by using a vice, loosen driven pulley securing nut, and then remove driven pulley. CAUTION Be careful not to damage the crank pin 1 area when fixing crank shaft using a vice. 1 Crank Pin 5) Disassembly of Compressor Housing Remove oil seal 1 and bearing 2.
Page 109: Inspection Of Reed Valve
6) Inspection of Reed Valve Check if reed valve is bent, damaged or worn. Replace reed valve ass’y if the reed valve gap is over the specified limit. Gap of Reed Valve at the Tip a : 0.2 mm (0.008 in)or less 7) Inspection of Cylinder and Piston Clean compressor cylinder, compressor head and compressor housing, check the parts for cracks damages.
Page 110: Installation Of Crank Shaft
Fuel System (TLDI) Apply two stroke engine oil to periphery of oil seal 5, lithium grease to the lip area, and install it into compressor housing by using a press. Driver Rod 1 : P/N. 3AC-99702-0 Oil Seal Attachment 4 : 2st OIL P/N.
Page 111: Installation Of Piston
10) Installation of Piston Attach piston rings 2 to piston 1. CAUTION Bring piston ring gaps away from each other. CAUTION Be careful not to scratch piston when attaching the rings. Apply two stroke engine oil to cylinder inner wall 3, piston periphery, and piston rings, and install piston ass’y to the cylinder so that “UP”...
Page 112: Installation Of Compressor Housing Ass'y
Fuel System (TLDI) 11) Installation of Compressor Housing Ass’y Attach dowel pins 2 to compressor cylinder 1. Install compressor housing ass’y 3 and gasket by using bolt 4. Put crank pin into connecting rod big end and install the assembly while shaking crank shaft a little.
Page 113: Measurement Of Fuel Pressure And Air Pressure
12) Measurement of Fuel Pressure and Air Pressure Use pressure gauge ass’y to measure fuel pressure and air pressure in the air rail. Pressure Gauge Ass’y : P/N. 3T5-72880-0 Perform the measurements by using the method described below. Fuel Pressure Air Pressure TLDI 75/90C2 2010 4-39...
Page 114 Fuel System (TLDI) How to Use Pressure Gauge Pressure Gauge Ass’y Measurement of Fuel Pressure and Air Pressure 1. Set the lever (3T5-72883-0) to position “A” shown below. 2. Screw adapter B (3T5-72884-0) into a valve of air rail for measuring air pressure or fuel pressure. WARNING Be careful of fuel that spurts when screwing the adapter into the fuel...
Page 115: Inspection Of Oil Filter
13) Inspection of Oil Filter Check if oil filter is cracked, damaged or leaks, or if dirt or water is in it. Clean or replace if necessary. 14) Inspection of Oil Tank Check if oil tank is cracked, damaged or leaks, or if dirt or water is in it.
Page 116: Air Bleeding
Fuel System (TLDI) 15) Air Bleeding Visually check if any air is found in the oil line from oil tank to cylinder block, and if any air is found, bleed the air by using the following procedure. Fill oil tank. Disconnect oil filter inlet hose, and then reconnect the hose when oil containing no air bubble flows out.
Page 117: Power Unit
Power Unit 1. Special tools ………………………… 5-2 17) Removing Exhaust Cover …………5-31 2. Parts Layout ………………………… 5-3 18) Inspection of Exhaust Cover ………5-32 Engine …………………………………… 5-3 19) Removing Crank Case ……………5-32 Magneto…………………………………… 5-4 20) Removing Pistons …………………5-34 Electric Parts (ECU•Diagram) ………… 5-6 21) Disassembly of Crank Shaft ………5-35 Electric Parts (Starter Motor) ……………...
Page 118 Power Unit 1. Special tools x ø19 ø34.5 Piston Ring Tool Driver Rod Universal Puller Plate Oil Seal Attachment P/N. 353-72249-0 P/N. 3AC-99702-0 P/N. 3AC-99750-0 P/N. 3C7-99820-0 Used in combination with center Removing reverse (C) gear Used to press-fit crank case ピストンリングの取外し、...
Page 119: Parts Layout
2. Parts Layout Engine 5 Nám (18 lbáft) [ .5 kgfám] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Power Unit Apron Ring Gear Cover Ass'y Screw 4 M6 L=12mm W/PW Gasket Battery Cord Dowel Pin Screw 2 M6 L=16mm W/PW Bolt 8 L=107mm x 6, L=120mm x 2 TLDI 75/90C2 2010...
Page 120: Magneto
Power Unit Magneto P/L Fig. 9 60 Nám (190 lbáft) [ 6 kgfám] Fig.5 6 Nám (4 lbáft) [0.6 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] Fig. Fig.1 TLDI 75/90C2 2010...
Page 121 Ref. Description Q'ty Remarks Flywheel (W/Gear) Alternator Ass'y Bolt M6 L=30mm Coil Bracket Dowel Pin 6-12 Crank Position Sensor Bolt M5 L=12mm Key (Magneto) TLDI 75/90C2 2010...
Page 122: Electric Parts (Ecu•Diagram)
Power Unit Electric Parts (ECU•Diagram) P/L Fig. 10 Starter Motor (+) Fig.11 1741 1741 1741 1741 1741 1741 Fig.13 1741 1741 1741 Solenoid Switch Remote Control Box Water Temperature (Cylinder) il Tank Fig.3 22 Nám (16 lbáft) [2.2 kgfám] Fig.13 Fig.4 Fig.1 6 Nám (4 lbáft) [0.6 kgfám]...
Page 123 Ref. Description Q'ty Remarks ECU Ass'y 90ps 3FW10AA ECU Ass'y 75ps 3FY10AA Bolt M6 L=30mm Washer 6.5-21-1 Mount Rubber 8.5-14-2.5 Mount Rubber 8.5-14-2.5 Spacer 6.2-9-16.6 Ignition Coil Plug Cap (Resistance) Bolt M6 L=30mm Rectifier Complete Bolt M6 L=25mm Bolt M6 L=12mm Cable Terminal Holder Bolt M6 L=20mm...
Page 124: Electric Parts (Starter Motor)
Power Unit Electric Parts (Starter Motor) P/L Fig. 11 25 Nám (1 lbáft) [2.5 kgfám] 25 Nám (1 lbáft) [2.5 kgfám] 25 Nám (1 lbáft) [2.5 kgfám] 25 Nám (1 lbáft) [2.5 kgfám] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Ring Gear Cover 12 Starter Motor Mount...
Page 125: Air Chamber (Air Box)
Air Chamber (Air Box) P/L Fig. 3 Fig.1 9 Nám (7 lbáft) [0.9 kgfám] 1342 1342 6 Nám ( lbáft) [0.6 kgfám] 1342 1342 1342 Ref. Description Remarks Q'ty Air Chamber Ass'y Sealing Cap Gasket Air Box Do not reuse. Gasket Inlet Manifold Do not reuse.
Page 126: Throttle
Power Unit Throttle P/L Fig. 7 6 Nám (4 lbáft) [0.6 kgfám] 1342 1342 APOR SEPARATOR 1342 1342 1342 Fig. 4-34 1342 1342 (When reusing the part) Fig.3 9 Nám (7 lbáft) [0.9 kgfám] 1342 1342 1342 5-10 TLDI 75/90C2 2010...
Page 127 Ref. Description Q'ty Remarks Advancer Arm Rod Snap 5-3 Throttle Link Rod Link Rod Ass'y (TPS) Bolt M8 L=35mm Washer 8.5-24-1.5 Bushing 12-14-15.5 Washer 12.5-24-1 Collar 8.4-12-17 Cable Joint Washer 8.5-18-1.6 R-Pin d=8 13-1 Throttle Body Ass'y 90ps Mark 3T9 13-2 Throttle Body Ass'y 75ps Mark 3FY...
Page 128: Cylinder Crank Case
Power Unit Cylinder Crank Case P/L Fig. 1 2st OIL M8 12 Nám ( 9 lbáft) [1.2 kgfám] M6 2 Nám (1.4 lbáft) [0.2 kgfám] M8 32 Nám ( 23 lbáft) [3.2 kgfám] M6 6 Nám ( 4 lbáft) [0.6 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] 25 Nám (18 lbáft) [2.5 kgfám] ig.13...
Page 129 Ref. Description Q'ty Remarks CYL Block · Crankcase Ass'y Dowel Pin 6-12 Knock Main Bearing Stud Bolt M10-P1.25 Bolt for Advancer arm stopper M6 L=18mm Collar 6.2-9-9.3 for Advancer arm stopper Nut M10-P1.25 Bolt M10 L=65mm Washer 10.5-20-3.2 Bolt L=50 M8 L=50mm Bolt L=65 M8 L=65mm...
Page 130: Piston & Crank Shaft
Power Unit Piston & Crank Shaft P/L Fig. 2 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL Bearing 2st OIL 2st OIL Molybdenum Piston Pin Hole Inner Face 2st OIL 2st OIL Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Crankshaft Ass'y...
Page 131: Inspection Items
3. Inspection Items 1) Inspection of Compression Pressure CAUTION • To prevent accidental start of the engine, remove lock plate (of stop switch lanyard) from stop switch before measuring compression pressure. • Clean areas around spark plugs on the cylinder before removing spark plugs to prevent dirt from entering cylinder.
Page 132: Removing Power Unit
Power Unit 2) Removing Power Unit Remove ring gear cover. Disconnect battery cables from battery terminal. +1 from starter motor, and Disconnect battery cables then - 2. Remove PTT cable 3 from solenoid switch. Disconnect connector 4 of PTT switch. 5-16 TLDI 75/90C2 2010...
Page 133 Disconnect ground wire 5 from bottom cowl. Disconnect remote control harness connectors 6. Remove "R" shaped pins and then throttle cable 7 and shift cable 8. Remove shift assist ass’y 9 from shift arm. Be careful not to lose washers that are removed together with cables.
Page 134 Power Unit Disconnect hose q for flushing device located on the port side of bottom cowl. Disconnect fuel hose w from fuel filter. WARNING Disconnect hose while holding with waste cloth to soak fuel that spills. Remove apron e. Loosen outside engine mount bolts first and then remove all of them.
Page 135: Removing Air Compressor
Hoist power unit by using eye bolt e. Hoist power unit taking care not to catch wires and hoses. Eye Bolt r : P/N. 3T1-72212-0 Remove 2-crank case bolts. Remove crank case head t. Put the tip of bladed screw driver in the mating face of crank case head as shown to separate from the engine body evenly.
Page 136: Removing Flywheel
Power Unit 4) Removing Flywheel Attach flywheel puller kit to flywheel. Flywheel Puller Lit: P/N. 3T1-72211-0 Fix flywheel puller, and loosen drive pulley (Magneto nut) and remove it. Drive pulley (Magneto nut) is threaded right- hand. Remove magneto by using flywheel puller kit and flywheel center plate.
Page 137: Removing Starter Motor
Disconnect alternator connectors. Loosen alternator securing bolts (M6, 3 pieces) and remove alternator. Loosen coil bracket securing bolts (M6, 4 pieces) and remove bracket. 6) Removing Starter Motor Remove starter motor securing band and securing bolts (M8, 2 pcs.) on the upper surface, and then, starter motor from bracket.
Page 138: Removing Cord Ass'y
Power Unit 7) Removing Cord Ass'y Removing ECU Disconnect ECU connectors while pushing hook of ECU connector and pull apart. After removing top two ECU mount rubber bolts, remove ECU by pulling it upward. Disconnect air compressor water temperature sensor connector while pushing hook of the connector.
Page 139 Disconnect FFP connector while pushing hook of the connector. Disconnect oil pump connector while pulling hook of the connector. Disconnect TPS connectors while pushing hook of the connector. • Connector on the outer → Blue (T2) • Connector in the inner → Gray (T1) Disconnect MAP and MAT sensor connector while pushing hook of the connector.(option) Disconnect rectifier connector while pushing lock of the...
Page 140 Power Unit Disconnect overheat sensor connector located on the cylinder block while pushing lock of the connector. Disconnect ignition coil connector while pulling lock of the connector. Repeat this step for four cylinders. Disconnect cord ass’y from terminal. Remove ignition coil #1 lower side installation bolt, and then, disconnect grounding wire.
Page 141: Removing Oil Pump
Removing Rectifier Loosen two rectifier mounting bolts and remove the unit. Remove ignition coil #3 lower side installation bolt, and then, grounding wire. Remove terminal. 8) Removing Oil Pump Remove oil pump securing bolts (M6, 2 pcs.), and then, remove pump together with pump bracket. •...
Page 142: Inspection Of Throttle Body
Power Unit Loosen advancer arm mounting bolt and remove the arm. Check ball joint cap for wear and damage link rod for bend. Remove throttle position sensor’s lower mounting screw. That is rubber mounted. Do not remove or loosen screws a. 4 Mount Bolt 5 Washer ( 8.5-24-1.5) 6 Washer (12.5-24-1)
Page 143: Removing Air Chamber
11) Removing Air Chamber Loosen air chamber cover mounting bolts in the order shown, remove them, and remove air chamber cover. • Disconnect recirculation hose. Refer to “Recirculation System” in Chapter 4. • When air chamber cover is removed, the oil collected in the cover may flow out.
Page 144: Removing Thermostat
Power Unit Remove air chamber and remove reed valve ass’y 1. Inspection of Reed Valve Ass’y Check reed valve and valve seat surface for bend, wear and damage. Replace if the bend is out of the specified range. Reed Valve Stopper Height b : 9.2 - 9.4 mm (0.362 - 0.370 in) Reed Valve Bend a : Replace reed valve with new one if its bend is...
Page 145: Inspection Of Thermostat
13) Inspection of Thermostat Put thermostat in the vessel containing water, heat it, and measure the temperature at which the thermostat starts to open. Replace thermostat if the valve is open even a little at ambient temperature. Valve Opening Temperature : 60˚C (140˚F) Valve Full Open Temperature : 75˚C (167˚F)
Page 146: Inspection Of Cylinder Head
Power Unit Loosen cylinder head / head cover mounting bolts in the order shown, remove them, and remove cylinder head / head cover. • When loosening M8 bolts, loosen in descending order of the numbers shown embossed on the head cover. •...
Page 147: Removing Exhaust Cover
If the distortion is over the limit, lap the component by using a sheet of sand paper #240 - #400 placed on a surface plate or thick plate glass and moving it on the paper drawing the letter “8" on it. Finish by using sand paper #600.
Page 148: Inspection Of Exhaust Cover
Power Unit • Pry the gap of the cover at five grooves one by one by using a bladed screw driver. • The cover can be removed easier if parts cleaning agent is applied in the gap one by one from the top one. •...
Page 149 • When removing crank case, pry the gap at the groove of crank case by using a bladed screw driver. • Note that there are two knock pins on the mating surface of crank case. Remove crank shaft ass'y. Put a pipe of ø19mm (0.748 in) in the drive shaft side of crank shaft ass'y, hold the crank shaft ass'y using both hands, lift it in parallel with the cylinder block to remove taking care not to damage the piston rings.
Page 150: Removing Pistons
Power Unit 20) Removing Pistons Remove piston pin clip by using a pair of pointed nose pliers. When removing piston pin clip, be careful not to damage the piston pin hole. Remove piston pin 1, washer and needle bearing. Use piston pin tool 2 if necessary. Put the piston pin tool on the piston pin and tap it lightly taking care not to apply excessive force to the connecting rod.
Page 151: Disassembly Of Crank Shaft
21) Disassembly of Crank Shaft Remove main bearing (Lower). Remove "C" ring 1 and pull out spacer 2. Remove main bearing (lower) 3 by using universal puller plate and universal puller. Universal Puller Plate 4 : 3AC-99750-0 Puller 5 : Commercially Available Item Protecting Plate 6 : 22) Inspection of Crank Shaft Visually check crank shaft ass’y upper and lower end...
Page 152: Inspection Of Cylinder
Power Unit Replace crank shaft ass’y if the deflection is over the standard value. Connecting Rod Deflection Limit : 2.0 mm (0.0800 in) Check small end side gap. Replace washer or piston, crank if the gap is over the standard value. Small End Side Gap a : Standard Value 0.20 - 0.55 mm (0.0079 - 0.0217 in) 23) Inspection of Cylinder...
Page 153: Inspection Of Pistons
2) Calculate taper of inner diameter of the cylinder. Replace the cylinder or use oversized piston if the taper is equal to or over the specified value. Calculation of taper : (Measurement Point) a (Measurement Point) c Functional Limit of taper : 0.08 mm (0.0032 in) 3) Calculate out-of-roundness of inner diameter of the cylinder.
Page 154 Power Unit Inspection of Piston Rings 1) Push a piston ring into the cylinder by using top surface of a piston. 2) Use thickness gauge to measure piston ring gap. Replace piston ring if the gap is over specified value. Thickness Gauge : Commercially Available Item Piston Ring End Gap : Standard Value...
Page 155 Inspection of Piston Pin Hole Measure piston pin hole inner diameter, and replace piston if the inner diameter is over the limit. Piston Pin Hole : Standard Value 23.00 mm (0.9056 in) Functional Limit : 23.03 mm (0.9067 in) Inspection of Piston Pins Measure piston pin outer diameter, and replace piston pin if the outer diameter is over the limit.
Page 156: Assembly Of Crank Shaft
Power Unit 25) Assembly of Crank Shaft Press-fitting Bearing 1) Insert a holding bar a in between crank webs and press-fit bearing. Attach spacer 40-52-7 1 and washer 66-85-2 2 and then press-fit bearing 6208 3. Bearing Press-Fitting Tool 7 : 2st OIL Inner Diameter: ø45 mm (1.575 in) Do not reuse removed bearing.
Page 157: Installation Of Pistons
26) Installation of Pistons Installation of Piston Rings Complete 3rd ring first. • When attaching a piston ring, face the side of the ring marked with "T" upward 1. • Bring piston ring gap to knock pin 2. Installation of Piston Pin Attach piston to washer, needle bearing and connecting rod by using piston pin.
Page 158: Assembly Of Power Unit Parts
Power Unit 28) Assembly of Power Unit Parts Install main bearing (upper) 1 to crank shaft ass’y. • Face the marking on the bearing to flywheel side. • Apply LIT grease to the oil seal lip. 2st OIL 2st OIL Install crank shaft ass'y to cylinder.
Page 159: Assembly Of Crank Case Halves
Positioning Upper Bearing and Main Bearing • Bring knock hole of each bearing to dowel pin of cylinder’s journal areas. • Attempt to move each bearing lightly to check if dowel pin is in the hole snugly. • Each bearing is provided with a bearing lubrication hole 3 on the opposite side of knock hole to check the location.
Page 160 Power Unit Install crank case to cylinder. Before securing with bolts, fit crank case snugly to the cylinder by tapping with a plastic hammer to make the gap between surfaces surfaces even. Tighten crank case securing bolts and nuts (M10) in the order of the numbers shown.
Page 161: Installation Of Exhaust Cover
23) Installation of Exhaust Cover Assemble exhaust cover, gasket, anode and anode cap. Attach exhaust cover securing bolts (M6) and tighten them in the order of their numbers shown to specified torque. Exhaust cover Bolts : 6 N · m (4 lb · ft) [0.6 kgf · m] Tighten the bolts in the order of the numbers marked on the exhaust cover.
Page 162: Installation Of Cylinder Head
Power Unit 31) Installation of Cylinder Head Attach anode 1 to cylinder. Attach dowel pins to cylinder head, and then attach gaskets and cylinder head cover. Temporary tighten cylinder cover securing bolts (M6) in the order of the numbers shown. Temporary Tightening : 2 N ·...
Page 163: Assembly Of Crank Case Head
Install thermostat, thermo-cap and gasket. Thermostat Cap Bolts 6 N · m (4 lb · ft) [0.6 kgf · m] 32) Assembly of Crank Case Head Circumference Apply grease and oil to oil seal 19.6-35-10 and press-fit it 2st OIL to crank case head.
Page 164: Installation Of Air Chamber
Power Unit 33) Installation of Air Chamber Attach reed valve, air chamber and gaskets to crank case. Attach and tighten securing bolts (M6) (M6) to specified torque in the order of the numbers shown. 1342 1342 1342 • Use new gaskets. •...
Page 165 • Apply LIT grease to sliding faces of throttle cam and roller. • Apply ThreeBond 1342 to throttle body securing bolts. 1342 1342 1342 1342 1342 Attach air chamber cover and gasket. Attach and tighten air chamber securing bolts (M6) to specified torque in the order of the numbers shown.
Page 166: Installation Of Recirculation Hoses
Power Unit 34) Installation of Recirculation Hoses ine Check Valve #2 Crank Case Air Chamber 240 mm (9.5 in) ine Check Valve #1 Cylinder iner #2 Cylinder Scavenging Passage 185 mm (7.3 in) ine Check Valve #1 Cylinder Scavenging Passage #3 Cylinder iner 185 mm (7.3 in)
Page 167: Installation Of Fuel System
37) Installation of Fuel System Refer to “Removing and Installation of Fuel System” in Chapter 4. 38) Installation of Cord Ass’y and Electrical Parts Reverse cord ass’y removing procedure described in “Removing Cord Ass’y” in Chapter 5. 39) Installation of Starter Motor Secure starter motor mounting band by using bolts (M10, 2 pcs.) on the upper surface of the motor, and then, install starter motor to bracket.
Page 168: Installation Of Drive Pulley And Flywheel
Power Unit 41) Installation of Drive Pulley and Flywheel Attach key, flywheel and drive pulley to crank shaft, and tighten the nut to specified torque. Flywheel Puller Kit : P/N. 3T1-72211-0 Drive Pulley : 260 N · m (190 lb · ft) [26 kgf · m] Degrease tapered areas of crank shaft and flywheel before installing them.
Page 169 Clean mating faces of engine base and cylinder ass’y, and then, attach dowel pins 4 gasket. Use new engine base gasket. Install power unit securely, and tighten engine mount bolts 2 specified torque. Engine Mount Bolts 2 : 25 N · m (18 lb · ft) [2.5 kgf · m] Be careful not to catch wires and hoses and other parts between engine base mating surfaces.
Page 170 Power Unit 5-54 TLDI 75/90C2 2010...
Page 171: Lower Unit
Lower Unit 1. Special Tools ………………………… 6-2 20) Inspection of Forward (A) Gear …… 6-23 2. Parts Layout ………………………… 6-4 21) Assembly of Forward (A) Gear Parts … 6-24 Gear Case (Drive Shaft) ………………… 6-4 22) Removing Drive Shaft Ass’y ……… 6-25 Gear Case (Propeller Shaft) ……………...
Page 172 Lower Unit 1. Special Tools Thickness Gauge Propeller Shaft Housing Puller Ass'y Spring Pin Tool A (ø3.5) Spring Pin Tool B (ø3.5) P/N. 353-72251-0 P/N. 353-72252-0 P/N. 369-72217-0 P/N. 369-72218-0 Removing propeller shaft Measuring gaps Removing spring pin Installing spring pin housing ø100 x ø79.5 x ø51.5 x ø61.5 Bevel Gear Bearing Puller Ass'y...
Page 173 3B7-72731-0 3B7-72732-0 3B7-72733-0 Backlash Measuring Tool Clamp Dial Gauge Plate Bearing Outer Press Kit Needle Bearing Press Kit P/N. 3C7-72900-1 P/N. 3B7-72720-0 P/N. 3B7-72729-0 P/N. 3B7-72739-0 Used to attach dial gauge Attaching forward (A) gear Removing or attaching gear case Measuring backlash when measuring backlash bearing outer race...
Page 174: Lower Unit
Lower Unit P/L Fig. 15 2. Parts Layout Gear Case (Drive Shaft) Inner Face Apply thinly on GEAR GEAR GEAR GEAR GEAR the interior face. GEAR Outer Face Fig.20 GEAR GEAR GEAR GEAR GEAR GEAR Circumference GEAR GEAR GEAR Fig.1 1342 1342 0 Nám (29 lbáft) [ .0 kgfám]...
Page 175 Ref. Description Q'ty Remarks Gear Case Ass'y Needle Bearing 28.6-38.1-3 Do not reuse. Oil Plug Water Plug M8P1.25 Gasket 8.1-15-1 Do not reuse. Plate Gear Case Screw M6 L=14mm Hole Plug Gear Case Water Plug M10P1.25 Gasket 10.1-15-1 Do not reuse. Nipple 6-1/8 Bevel Gear B 12-1...
Page 176: Gear Case (Propeller Shaft)
Lower Unit P/L Fig. 16 Gear Case (Propeller Shaft) Fig.15 Screw section 17 15 25 Nám (18 lbáft) [2.5 kgfám] When reusing the part 1342 1342 12 10 GEAR GEAR GEAR Circumference GEAR GEAR GEAR GEAR GEAR 12 Nám (9 lbáft) [1.2 kgfám] GEAR 1342 1342...
Page 177 Ref. Description Q'ty Remarks Tapered Roller Bearing 30209 Do not reuse. Trim Tab Packing Trim Tab Do not reuse. Stud Bolt M8 L=25mm Nylon Nut Propeller Shaft Housing Ass'y Propeller Shaft Housing O-Ring 3.1-94.4 Do not reuse. Needle Bearing 30-40-30 Do not reuse.
Page 178: Inspection Items
Lower Unit 3. Inspection Items 1) Draining Gear Oil Drain gear oil. Refer to “Replacement of Gear Oil” in Chapter 3. ・Drain all gear oil, and check if any metal particle is found in the drained oil. ・Check gear oil color. White or cream color possibly indicates that water is contained in the gear oil.
Page 179: Removing Lower Unit
3) Removing Lower Unit WARNING When working with outboard motor in tilt up position, be sure to lock with tilt stopper. ・Removal of lower unit does not require removal of power unit from outboard motor body. ・When removing lower unit from outboard motor, 3 Spring Pin Do not reuse.
Page 180: Inspection Of Clutch Cam
Lower Unit Remove shift rod joint 1 and clutch cam 2. Spring Pin Tool A 3 (ø3.5): P/N. 369-72217-0 Remove O ring 5 from cam rod bushing 4. 5 O Ring Do not reuse. 5) Inspection of Clutch Cam Check the part for wear and damage. Replace if necessary.
Page 181: Removing Water Pump
Attach cam rod bushing 1, shift rod joint 5 and clutch cam 6 to cam rod 4. 7 Spring Pin Do not reuse. Drive spring pin 7. CAUTION Drive spring pin 7 so that it is flush with clutch cam surface as shown. Spring Pin Tool B 8 (ø3.5) : P/N.
Page 182: Inspection Of Water Pump
Lower Unit Remove water pump impeller key 5. Remove guide plate 6 and pump case (lower) 7. When removing pump case (lower), insert bladed screw driver into the groove of the case, and pry slowly to separate the part. 8) Inspection of Water Pump Check pump case liner and guide plate for deformation and wear.
Page 183: Disassembly Of Water Pump Case (Lower)
Check impeller key 1 and key groove for wear. Replace if necessary. Check oil seal for wear and crack on the lip area. Replace if necessary. 9) Disassembly of Water Pump Case (Lower) Use bladed screw driver or seal remover to remove oil seal 1.
Page 184: Assembly Of Water Pump Case (Lower)
Lower Unit 10) Assembly of Water Pump Case (Lower) Install oil seal 1 and shim 2 by using oil seal attachment 3 and driver rod 4 and then press-fit. ・Apply gear oil to oil seal circumference before installing oil seal. ・Apply OBM grease to oil seal lip.
Page 185: Removing Propeller Shaft Housing Ass'y
11) Removing Propeller Shaft Housing Ass’y Loosen and remove bolts 1. Use propeller shaft housing puller to pull out propeller shaft housing to the position where O ring of the housing can be removed. Propeller Shaft Housing Puller Ass’y 2 : P/N.
Page 186: Disassembly Of Propeller Shaft Housing Ass'y
Lower Unit 12) Disassembly of Propeller Shaft Housing Ass’y Pull out propeller shaft ass’y 1. Remove reverse (C) gear by using bladed screw drivers Check oil seal 4 for wear and crack. Replace if necessary. Remove bearing 5. CAUTION Heat propeller shaft housing by putting it in the hot water of approximately 60 - 70˚C (140 - 158˚F), and remove bearing 4.
Page 187: Inspection Of Propeller Shaft Housing
Use a press to remove oil seal 4 and needle bearing 6 at the same time. ・Before removing, check bearing for play or deflection. Replace if necessary. ・Direct the side of attachment without O-ring to needle bearing. Needle Bearing Attachment 7 : P/N.
Page 188: Assembly Of Propeller Shaft Housing
Lower Unit 14) Assembly of Propeller Shaft Housing CAUTION When gear case, propeller shaft, bearing, housing or reverse (C) gear is replaced, measure the backlash and perform shim adjustment. Use a press to push new needle bearing 4 into propeller shaft bearing to specified depth.
Page 189 Install bearing 7. Use a press to install new bearing to propeller shaft housing. Clean bearing installation face and apply gear oil before installation. Bearing Attachment 8 : P/N. 3U1-99905-0 Driver Rod 1 : P/N. 3AC-99702-0 GEAR GEAR GEAR GEAR 7 Bearing Do not reuse.
Page 190: Disassembly Of Propeller Shaft Ass'y
Lower Unit 15) Disassembly of Propeller Shaft Ass’y Remove push rod 1 and steel balls 2 (3 pcs.). 3 Clutch Pin Snap Do not reuse. Put a bladed screw driver into one of clutch pin snap 3 end, and take the snap out from the clutch groove while winding it.
Page 191: Inspection Of Propeller Shaft Ass'y
16) Inspection of Propeller Shaft Ass’y Check propeller shaft for bend, wear and damage. Replace if necessary. Measure propeller shaft runout. Runout Limit : 0.05 mm (0.0020 in) a Supporting Points Check clutch dog b and push rod c for crack and wear. Replace if necessary.
Page 192: Removing Forward (A) Gear Ass'y
Lower Unit Attach new clutch pin snap 3 by using a bladed screw driver to turn the snap. CAUTION Do not reuse removed clutch pin snap. When attaching clutch pin snap, do not apply excessive force to the part, or the snap may expand during operation of the engine, resulting in damaging gear and/or other parts severely.
Page 193: Disassembly Of Forward Gear (A) Gear
19) Disassembly of Forward Gear (A) Gear Remove taper roller bearing 1. Use two bladed screw drivers to remove taper roller bearing from forward gear (A) gear. Put the drivers into grooves of forward (A) gear, and pry out taking care not to damage the shim. CAUTION Be careful not to damage shim 3.
Page 194: Assembly Of Forward (A) Gear Parts
Lower Unit 21) Assembly of Forward (A) Gear Parts CAUTION When gear case, forward (A) gear or bearing is replaced, measure backlash and attach a proper shim. Refer to “Chapter 6 Shim Adjustment”. GEAR GEAR GEAR Install needle bearing 1. Apply gear oil to press-fit face when press-fitting needle bearing.
Page 195: Removing Drive Shaft Ass'y
22) Removing Drive Shaft Ass’y Remove pinion (B) gear nut 4, and then, remove pinion (B) gear 3 and drive shaft. · Degrease pinion (B) gear nut completely so that the nut wrench does not slip on the nut. · Loosen and remove the nut by using a drive shaft socket and a wrench and turning the wrench counterclockwise.
Page 196: Disassembly Of Drive Shaft Ass'y
Lower Unit 23) Disassembly of Drive Shaft Ass’y Remove outer race 1 and shim 2. Remove drive shaft spring 3. Remove taper roller bearings 4 and 5 by using press and universal puller 6. CAUTION Do not reuse removed bearing. Be sure to replace with new one.
Page 197: Inspection Of Forward (A) Gear And Pinion (B) Gear
25) Inspection of Forward (A) Gear and Pinion (B) Gear Check gear teeth and dog for crack, wear and damage. Replace if necessary. 26) Assembly of Drive Shaft Parts Attach pinion (B) gear nut 1 to drive shaft temporarily. Install bearing 1 by using press. Before installing bearing, be sure to clean drive shaft installation face and apply gear oil.
Page 198: Disassembly Of Gear Case
Lower Unit Attach drive shaft spring 3. CAUTION When attaching the spring, face the side b toward pinion (B) gear side. Attach spring as illustrated. 27) Disassembly of Gear Case Remove needle bearing 1 by using the following tools. Needle Bearing Press Kit : P/N.
Page 199: Inspection Of Gear Case
olt, Needle Roller earing Press Plate C, Flywheel Puller "F"Mark Collar, Needle Roller earing Press Stopper Guide earing "F"Mark Outer Press Rod, Needle Roller earing Press Needle Roller Marking Face Press , Needle Roller earing O Ring Washer Remove taper roller bearing outer race w. Put the slide hammer in the gear case, hook claw of slide hammer on the outer race to fix it, and slide the hammer to pull out the outer race.
Page 200: Assembly Of Gear Case Parts
Lower Unit 29) Assembly of Gear Case Parts CAUTION When gear case, forward (A) gear or bearing is replaced, measure backlash and attach a proper shim. Refer to “Chapter 6 Shim Adjustment”. Use the following tools to install taper roller bearing 1 outer race.
Page 201 Install needle bearing by using the following tools. Needle Bearing Press Kit : P/N. 3C7-72900-1 Bearing Outer Press Guide 2 : P/N. 3Y9-72905-0 Needle Bearing Press Rod 3 Needle Bearing Press 4 : P/N. 3Y9-72770-0 O Ring 5 Bolt M8-80 6 Washer M8 7 Needle Bearing Press Collar 8 Needle Bearing Press Bolt 9...
Page 202: Measurement Of Pinion (B) Gear Height And Shim Selection
Lower Unit 30) Measurement of Pinion (B) Gear Height and Shim Selection CAUTION When gear case, drive shaft or pump case (lower) is replaced, measure pinion (B) bear height and back lash between gears, and perform shim adjustment. Before measuring back lash of each gear, measure drive shaft pinion (B) gear height and adjust the height to proper value if necessary.
Page 203 Add shim 6 to bottom of b pump case (lower) to adjust the gap a to specified value. Pinion (B) Gear Height a : 0.45 - 0.49 mm (0.0177 - 0.0193 in) Type of Shims 4 Applicable : 0.1 mm (0.0039 in) P/N. 353-64016-0 0.15 mm (0.0059 in) P/N.
Page 204: Measurement Of Back Lash Between Forward (A) And Pinion (B) Gears And Shim Selection
Lower Unit 31) Measurement of Back Lash between Forward (A) and Pinion (B) Gears and Shim Selection CAUTION Before measuring backlash between forward (A) and pinion (B) gears, measure pinion (B gear height. Refer to “Measurement of Pinion (B) Gear Height and Shim Selection”...
Page 205 Tighten shaft 2 until drive shaft 9 starts to move (rotate). When drive shaft starts to move, additionally tighten shaft 2 1/2 of a turn (180˚). · As an alternative to the above measuring tool, a tool used for pulling out the following propeller shaft housing can be used to secure forward gear (A) gear.
Page 206 Lower Unit Select proper thickness of shim based on the backlash Shim Thickness : mm (in ) Dial Gauge Reading : mm (in) + means addition of shim/- measured with dial gauge and on the table shown. means removal of shim ·...
Page 207: Measurement Of Back Lash Between Pinion (B) And Reverse (C) Gears And Shim Selection
32) Measurement of Back Lash between Pinion (B) and Reverse (C) Gears and Shim Selection CAUTION Before measuring backlash between pinion (B) and reverse (C) gears, establish pinion (B) gear height. Refer to “Measurement of Pinion (B) Gear Height and Shim Selection” in Chapter 6. In accordance with procedure described in “Assembling Lower Unit”...
Page 208 Lower Unit Attach backlash measuring tool clamp w to drive shaft. Turn drive shaft q clockwise / counterclockwise slowly while pulling it up, and read change of dial gauge indication. 0¡ When measuring, contact dial gauge tip to inside of V groove located in the clamp ass’y. Backlash Measuring Tool Clamp w : P/N.
Page 209: Assembly Of Lower Unit Parts
33) Assembly of Lower Unit Parts Install forward (A) gear 1. Install drive shaft spring guide 2, wave washer 3 and drive shaft 4. CAUTION Align protrusion a of spring guide 2 with nner face gear case groove b. GEAR GEAR GEAR GEAR...
Page 210 Lower Unit Install pinion (B) gear 5 and tighten pinion (B) gear nut 6 to specified torque. · Tighten the nut by using a drive shaft socket 8 and a wrench and turning the wrench clockwise. Cover the wrench 7 with rag to prevent it from hitting the case directly.
Page 211: Attaching Clutch Cam Ass'y
Attach water pump liner i to pump case (upper) o. CAUTION Align pump liner i protrusion a with pump case (upper) o concave b. Apply OBM grease to inside of water pump liner. nner Face Put pump case (upper) o and pump case seal p on the drive shaft, and install them on the pump case (lower) q.
Page 212: Measurement Of Propeller Shaft Play And Selection Of Washer Thickness
Lower Unit Attach O ring 2 to propeller shaft housing 1. Apply OBM grease to O ring. Attach steel balls (3pcs.) 4, clutch push rod 5 and washer 6 that was removed when disassembling to propeller shaft 3. CAUTION When gear case, propeller shaft or propeller When bolts are reused shaft housing is replaced, measure 1342...
Page 213: Installation Of Lower Unit
Select washer 1 thickness so that the play is within the specified range. Specified Value of Play : 0.2 - 0.4 mm (0.0078 - 0.0157 in) Type of Washers : 2.8 mm (0.110 in) P/N. 3B7-64035-0 3.0 mm (0.118 in) P/N. 3B7-64034-0 3.2 mm (0.126 in) P/N.
Page 214 Lower Unit Put lower unit ass’y into drive shaft housing. Connect speedometer pick up tube 2, and align positions of water pipe and water pipe seal 3. Reconnect speedometer tube, and secure the tube using tie band. Tighten lower unit ass’y installation bolts and nut to specified torque.
Page 215 Attach propeller and tighten propeller nut 0 to specified torque. CAUTION · Before removing or installing propeller, be sure to disconnect battery cables from battery and remove stop switch lock plate. · When removing or installing propeller, do not handle propeller with bare hands. 2 Nám (9 lbáft) [ .2 kgfám] ·...
Page 216 Lower Unit 6-46 TLDI 75/90C2 2010...
Page 217: Cowl, Bracket And Ptt Unit
Cowl, Bracket and PTT Unit 1. Special Tools ………………………… 7-2 9) Removing Steering Shaft Arm …… 7-24 2. Parts Layout ………………………… 7-3 10) Removing PTT Unit ………………… 7-25 Top Cowl (Motor Cover Upper) ………… 7-3 11) Removing Clamp Bracket ………… 7-27 Bottom Cowl (Motor Cover Lower) ……...
Page 218: Special Tools
Cowl, Bracket and PTT Unit 1. Special Tools 1：Trim Rod Guide Wrench P/N. 3B7-72792-0 2：Trim Rod Guide Wrench P/N. 3C8-72791-1 Removing or attaching PTT piston rod ass'y TLDI 75/90C2 2010...
Page 219: Top Cowl (Motor Cover Upper)
P/L Fig. 21 2. Parts Layout Top Cowl (Motor Cover Upper) 1741 1741 1741 1741 & & " & & & " 1741 1741 1741 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Top Cowl Ass'y (Service) Motor Cover (Upper) Nylon Nut 6P1.0 10 M6 Sound Isolation (Left)
Page 220: Bottom Cowl (Motor Cover Lower)
Cowl, Bracket and PTT Unit Bottom Cowl (Motor Cover Lower) P/L Fig. 19 1342 1342 Fig.4 AIR RAIL Fig.14 1342 1342 1342 TLDI 75/90C2 2010...
Page 221 Ref. Description Q'ty Remarks Bottom Cowl Motor Cover (Lower) Mount Rubber Motor Cover Lower 12-18-2.5 Spacer 8.4-12-17 Bolt M8 L=35mm Washer 8.5-24-1.5 Clamp Bolt M6 L=25mm Grommet 17-2.7 Grommet A Lower Cover Grommet Power Trim Tilt Cord Ass'y · Grommet 17-3 Cord Grommet Grommet Clamp L=60...
Page 222: Shift
Cowl, Bracket and PTT Unit P/L Fig. 20 Shift Fig.7- 0 Remote Control Cable 7 Nám (5 lbáft) [0.7 kgfám] Fig. 9 Fig. 5 TLDI 75/90C2 2010...
Page 223 Ref. Description Q'ty Remarks Shift Rod Lever Nylon Nut Shift Lever Shaft Holder Shift Lever Shaft Bolt M8 L=25mm Washer 10.5-18-1.5 Cable Pin Shift Arm Bolt M8 L=35mm Bushing 12-14-15.5 Collar 8.4-12-17 Washer 8.5-24-1.5 Washer 12.5-24-1 Shift Rod Snap Pin d=6 Washer 7-18-1.6 Shift Assist Ass'y R-Pin d=8...
Page 224: Drive Shaft Housing
Cowl, Bracket and PTT Unit P/L Fig. 14 Drive Shaft Housing 3 Nám (9 lbáft) [ .3 kgfám] 1741 1741 6 Nám (4 lbáft) [0.6 kgfám] 1741 6 Nám (4 lbáft) [0.6 kgfám] Nám (8 lbáft) [ . kgfám] 40 Nám (29 lbáft) [4.0 kgfám] 1342 1342 1342...
Page 225 Ref. Description Q'ty Remarks Engine Basement Drain Plug Engine Base Exhaust Plug Seal Rubber Lower Cover L=690 Engine Basement Gasket Do not reuse. Dowel Pin 6-12 Bolt M6 L=35mm Exhaust Pipe Bolt M6-35 Pre-coated M6 L=35mm Gasket Exhaust Pipe Do not reuse. Exhaust Housing Grommet Grommet Idle Port...
Page 226: Bracket
Cowl, Bracket and PTT Unit P/L Fig. 17 Bracket 25 Nám (18 lbáft) [2.5 kgfám] 5 Nám (33 lbáft) [ .5 kgfám] 1342 1342 1342 1342 1342 1342 Fig.1 30 1 13 22 20 32 Nám (23 lbáft) [3.2 kgfám] 1373B 1373B 1373B...
Page 227 Ref. Description Q'ty Remarks Swivel Bracket Ass'y Grease Fitting Bolt M6 L=10mm Bolt 12-20 M12 L=20mm Clamp Bracket (Right) Stern Bracket (Right) Starboard Clamp Bracket (Left) Stern Bracket (Left) Port Bolt M10 L=20mm Washer Trim Sender Bolt M6 L=20mm Washer 6-16-1.5 Extension Cord Trim Sensor L=6000 Clamp 6.5-47.5P Bolt...
Page 228: Power Trim & Tilt
Cowl, Bracket and PTT Unit Power Trim & Tilt P/L Fig. 18 30Nám (94 lbáft) [ 3 kgfám] 4 Nám (3 lbáft) [0.4 kgfám] 7 Nám (5 lbáft) [0.7 kgfám] 80 Nám (58 lbáft) [8 kgfám] 9 Nám (7 lbáft) [0.9 kgfám] 38 42 5 Nám (4 lbáft) [0.5 kgfám] 3 Nám (2 lbáft) [0.3 kgfám]...
Page 229 Ref. Description Q'ty Remarks Motor Ass'y Yoke Ass'y Armature Ass'y O-Ring Do not reuse. Bracket Ass'y Brush Ass'y Breaker Spring Bolt Pump Filter B Coupling Pump O-Ring Do not reuse. Manual Valve O-Ring Do not reuse. Packing Do not reuse. Back Up Ring C-Ring Piston Rod Ass'y...
Page 230: Inspection Items
Cowl, Bracket and PTT Unit 3. Inspection Items 1) Removing Top Cowl 1 and turn Pull outward upper motor cover hook levers down lever 2 and remove upper motor cover. 2) Adjustment of Cover Hook Push cover to check for play, and adjust if necessary. Loosen cover stay securing nuts 1, adjust fit of cowl, and then, tighten the nuts.
Page 231: Removing Drive Shaft Housing
Remove pin and washer, then shift rod lever from shift rod. Loosen and remove four bolts that secure bottom cowl to engine base. Remove bottom cowl. 4) Removing Drive Shaft Housing Use the following steps to remove drive shaft housing. Loosen and remove lower rubber mount cap installation bolts to remove mount cap 1.
Page 232 Cowl, Bracket and PTT Unit Loosen and remove upper rubber mount cap installation bolts to remove mount cap 2. CAUTION Drive shaft housing drops if mount bolt is removed in this step. Loosen and remove upper rubber mount installation bolts to remove rubber mount 3.
Page 233: Disassembly Of Drive Shaft Housing
5) Disassembly of Drive Shaft Housing 1 Drive Shaft Housing 2 Engine Base 3 Idle Exhaust Passage 4 Water Pipe 5 Reverse Gas Passage Remove bolts that secure engine base to drive shaft housing. Remove M6 installation bolt located in the area shown by the arrow.
Page 234 Cowl, Bracket and PTT Unit Loosen and remove bolts 8 that secure exhaust housing to engine base and remove exhaust housing 7. Loosen and remove bolts 0 that secure exhaust pipe 9 to engine base and remove exhaust pipe. 7-18 TLDI 75/90C2 2010...
Page 235: Inspection Of Drive Shaft Housing
6) Inspection of Drive Shaft Housing Check mount rubber and dumper rubber for crack and deterioration. Replace if necessary. Check water pipe 1 and reverse gas passage 2 for corrosion and deformation. Replace if necessary. Check engine base 2, exhaust housing 4 and drive shaft housing 5 for corrosion, and idle exhaust passage 6 for damage.
Page 236: Assembly Of Drive Shaft Housing
Cowl, Bracket and PTT Unit 7) Assembly of Drive Shaft Housing Install exhaust pipe 1 and gasket 2 to engine base 3 and tighten bolts 4 to specified torque. Exhaust Pipe Bolts 4 : 11 N · m (8 lb · ft) [1.1 kgf · m] Install exhaust housing grommet 5 to exhaust housing 1741 1741...
Page 237 Install water pipe auxiliary mount 9 to drive shaft housing. Install water pipe to drive shaft housing, and attach gasket after confirming that dowel pins 0 are on the drive shaft housing. TLDI 75/90C2 2010 7-21...
Page 238 Cowl, Bracket and PTT Unit Attach reverse gas passage in the drive shaft housing facing “UP” mark of reverse gas passage q upward and “F” mark forward. Install idle exhaust port grommet w to exhaust housing. Check that drive shaft housing dowel pin is placed and secured to engine base properly.
Page 239: Installing Drive Shaft Housing
8) Installing Drive Shaft Housing Drive shaft housing can be supported easily if it is attached at upper mount side first. Install upper mount 1 and tighten bolts 2 to specified torque. CAUTION Install the mount with the side of smaller size a facing forward.
Page 240: Removing Steering Shaft Arm
Cowl, Bracket and PTT Unit Install idle exhaust passage. Idle exhaust passage is designed to reduce engine idling noise. After installing the idle exhaust passage, check that no exhaust gas and cooling water leak through the installation face. Idle Exhaust Installation Bolts q : 6 N ·...
Page 241: Removing Ptt Unit
Pull up steering shaft arm 3 to remove. 10) Removing PTT Unit Fully tilt up outboard motor and lock with tilt stopper 1. WARNING · Be sure to lock outboard motor with tilt stopper after tilting up. Leaving outboard motor up without locking may lead to accidental descent due to reduction of PTT hydraulic pressure.
Page 242 Cowl, Bracket and PTT Unit Remove tie wrap 3 and clamp 4 and draw PTT wires 5 to the direction shown. Remove upper cylinder piston stopper washer and bolt, and remove cylinder pin 6. Cylinder pin can be pulled out easier while adjusting trim rod length.
Page 243: Removing Clamp Bracket
11) Removing Clamp Bracket Remove anode 1. Remove ground wire 2 and grease nipple 3. Remove thrust rod q. Loosen nylon nut 4, and separate clamp brackets 5 and 6 and swivel bracket 7 from each other. Remove trim sensor 8. Remove tilt stopper 9.
Page 244: Assembly Of Clamp Bracket
Cowl, Bracket and PTT Unit 12) Assembly of Clamp Bracket Install trim sensor 1 to clamp bracket. Install tilt stopper 2 and tilt stopper spring 9 to swivel bracket 8. Run swivel shaft 3 through clamp brackets, swivel bracket, bushing and washer, and tighten nylon nut 4 to specified torque.
Page 245 Attach bushings to PTT (upper) and swivel bracket. Extend tilt rod until PTT tilt rod hole aligns with swivel bracket hole. Blue Green WARNING Connecting electrical wires to battery terminals may cause sparks to occur. Do not perform this work when flammable matter is near the working area.
Page 246: Assembly Of Steering Arm
Cowl, Bracket and PTT Unit 14) Assembly of Steering Arm Put thrust plate 1, seal ring 2 and bushing 3 on the steering shaft 4, and install the steering shaft from above. Put bushing 6, O ring 7 and thrust plate 8 on the shaft. Be sure to put bushing 6 fully to the end on the steering shaft.
Page 247: Removing Ptt Motor
15) Removing PTT Motor WARNING · Connecting electrical wires to battery terminals may cause sparks to occur. Do not perform this work when flammable matter is near the working area. · Before removing PTT motor, fully extend trim rods and tilt arm to prevent the fluid from spurting due to internal pressure.
Page 248: Inspection Of Ptt Motor
Cowl, Bracket and PTT Unit Disconnect PTT motor lead wire 4. Hold the plug with a bladed screw driver and pull out PTT motor lead. Remove screw, disconnect PTT motor lead 5, and then, remove brushes 6. CAUTION Do not touch bi-metal a. Doing so affects operation of circuit breaker.
Page 249: Assembly Of Ptt Motor
Measure diameter of commutator. Replace if the following specification is not met. Lower Limit of Commutator Diameter c : 21.0 mm (0.83 in.) Check electrical conductivity of armature. Replace if any of the following conditions is not met. Armature Conductivity Commutator Conductive Commutator d -...
Page 250: Removing Reservoir
Cowl, Bracket and PTT Unit Install stator to base. ・Cover armature shaft end with clean cloth, hold the shaft using a pair of pliers, and install armature to stator carefully. ・Assemble lead holder and spacer, pull lead wires carefully, move protection tube back to original position, and then, tie lead wires by using tape.
Page 251: Disassembly And Assembly Of Gear Pump
19) Disassembly and Assembly of Gear Pump Remove gear pump 1. CAUTION Confirm the order of assembling of valve seat ass’y, valve pin and O ring when disassembling. Before removing, loosen manual valve to release hydraulic pressure. Remove O ring 2, down relief valve 3 and filter 4 from gear pump.
Page 252: Disassembly Of Tilt Cylinder And Trim Cylinder
Cowl, Bracket and PTT Unit 20) Disassembly of Tilt Cylinder and Trim Cylinder CAUTION When removing tilt cylinder rod guide, fully extend trim rods and tilt arm. Loosen and remove tilt cylinder rod guide 2 by using trim rod guide wrench 1 and remove tilt piston ass’y. Trim Rod Guide Wrench 1 : P/N.
Page 253: Assembly Of Ptt Unit
21) Assembly of PTT Unit Put recommended PTT fluid into the unit through hole a. Recommended PTT Fluid: ATF DEXRON 682 cm (23.0 floz.) Push free piston 1 into tilt cylinder unit fully to the bottom. Fill with PTT fluid from b, c, and d to a proper level. Install trim piston ass’y to trim cylinder, and tighten trim rod guide 2 to specified torque.
Page 254 Cowl, Bracket and PTT Unit Attach new O ring 4, valve pin 5 and valve seat ass’y 6 to tilt cylinder. Install gear pump 7. Gear Pump Installation Bolts : 9 N · m (7 lb · ft) [0.9 kgf · m] Put O ring on the reservoir cap.
Page 255 Attach joint q and gear pump filter w to gear pump. Fill gear pump with PTT oil to a proper level. Remove air bubbles by using a means such as a syringe. Install O ring e and PTT motor ass’y r, and tighten bolts t to specified torque.
Page 256: Air Bleeding Ptt Unit
Cowl, Bracket and PTT Unit 22) Air Bleeding PTT Unit Turn manual valve 1 clockwise to tighten. Set PTT unit upright. Remove reservoir cap and check PTT fluid level. CAUTION If the fluid level is correct, the fluid should overflow out of the filter hole when the reservoir cap is removed.
Page 257: Electrical System
Electrical System 1. Special Tools ………………………… 8-2 13) Inspection of Rectifier Complete … 8-14 2. Parts Layout ………………………… 8-3 14) Inspection of Throttle Position Sensor … 8-15 Starter Motor……………………………… 8-3 15) Inspection of Water Temperature Sensor … 8-15 3. Inspection Items ……………………… 8-4 16) Inspection of Power Relay …………...
Page 258: Special Tools
Electrical System 1. Special Tools Spark Tester P/N. 3F3-72540-0 Checking sparks TLDI 75/90C2 2010...
Page 259: Parts Layout
2. Parts Layout P/L Fig. 12 Starter Motor 6 Nám (4 lbáft) [0.6 kgfám] Molybdenum Molybdenum Molybdenum 6 Nám (4 lbáft) [0.6 kgfám] Ref. Description Remarks Q'ty Brush Holder Internal Gear Pinion Ass'y Planet Gear Shift Lever Set Magnetic Switch Dust Cover Set TLDI 75/90C2 2010...
Page 260: Inspection Items
Electrical System 3. Inspection Items 1) Disassembly of Starter Motor Remove starter motor from power unit. Refer to “Removing Starter Motor” in chapter 5. Loosen M8 nut 1 of magneto switch terminal, and then, remove motor lead. Loosen bolts 3 (M5, 2 pcs.) of starter motor rear cover 2, and then, remove the cover.
Page 261 Loosen bolts 8 (M6, 72 pcs.) on the upper part of magneto switch 7, and then, remove magneto switch ass’y. Remove yoke 0 and center bracket A q from gear case 9. After removing dust rubber w from gear case 9, remove shift lever r together with center bracket ass’y e.
Page 262 Electrical System Remove clip u from pinion shaft, and then, remove pinion clutch. CAUTION When removing clip, be careful not to give damage to surface of pinion shaft. ・Move pinion stopper i fully to clutch side. ・Use bladed screw driver to remove clip from groove of shaft.
Page 263: Inspection Of Armature
2) Inspection of Armature Check commutator 1 for dirt. If necessary, clean by using sand paper of No. 600 or by air-blowing. Measure commutator 1 outer diameter. Replace starter motor ass’y if outer diameter is less than specified value. Commutator Outer Diameter : Standard Value 29.0 mm (1.14 in) Wear Limit : 28.0 mm (1.10 in)
Page 264: Inspection Of Brushes
Electrical System 3) Inspection of Brushes Measure brush length a, and replace brush if the length is less than specified value. Brush Length a : Standard Value 16 mm (0.63 in) Wear Limit : 12 mm (0.47 in) Check conductivity between brush and starter terminal. Replace brush ass’y if any of the following conditions are not met.
Page 265 6）Assembly of Starter Motor Attach washer 2, pinion shaft 3 and washer 4 to center bracket 1 in this order. Apply TEF grease or molybdenum grease to pinion shaft. Attach E clip 5 to groove of pinion shaft. Attach pinion clutch 6 to pinion shaft, and secure with clip ・Use new clip.
Page 266: Assembly Of Starter Motor
Electrical System Attach shift lever q and pinion shaft ass’y w to center bracket ass’y e, and then, put outer gear r and planetary gear t. ・Align center bracket ass’y and outer gear with bolt through holes, and attach to location shown.
Page 267: Inspection Of Ignition And Spark
7) Inspection of Ignition and spark WARNING · When testing, put electrode cap assuredly to prevent direct contact with spark tester wiring and leak of electrical current, and perform test carefully. · Keep flammable gas, fuel, oil away from tester to prevent them from catching sparks.
Page 268: Inspection Of Ignition Coils
Electrical System 9) Inspection of Ignition Coils a b c This test can be made without removing parts. Remove ignition coil coupler. Measure ignition coil resistance. Replace if other than specified value. Ignition Coil Resistance : Between a and b 0.4 - 0.6 Ω Primary Side : Secondary Side : Between c and d 10.8 - 16.2 kΩ...
Page 269: Inspection Of Alternator
12) Inspection of Alternator Disconnect alternator connector and measure resistance between terminals. Replace alternator if the resistance is out of specified range. Resistance between Terminals of Connectors a, b and c : @20˚C (68 ˚F) 0.12 - 0.19 Ω TLDI 75/90C2 2010 8-13...
Page 270: Inspection Of Rectifier Complete
Electrical System 13) Inspection of Rectifier Complete Measure resistance between terminals. This test can be made without removing parts. Rectifier Tester Check Table “ON” means conductive and “OFF” means no conductivity. Positive Tester Lead (Red) Black Black Yellow Yellow Yellow (0Ω) (0Ω) Black...
Page 271: Inspection Of Throttle Position Sensor
14) Inspection of Throttle Position Sensor This test can be made without removing parts. Measure resistance between terminals. Replace throttle position sensor if the resistance is out of specified range. When lever is at position A (wide open throttle) : Between a - c : 4 - 6 kΩ...
Page 272: Inspection Of Air Injectors
Electrical System 17) Inspection of Air Injectors This test can be made without removing parts. Measure resistance between terminals. Replace air injector if the resistance is out of specified range. Resistance between terminals : @20˚C (68 ˚F) 1.2 - 1.4 Ω Apply 12V to the terminals to check if the part “clicks”.
Page 273: Inspection Of Starter Solenoid
21) Inspection of Starter Solenoid This test can be made without removing parts. Connect tester lead wires to both terminal of starter solenoid. （B）（G） Connector green (G) lead wire to battery positive terminal. Connector black (B) lead wire to battery negative terminal. Check electrical conductivity between terminals of starter solenoid.
Page 274: Inspection Of Fuel Feed Pump (Ffp)
Electrical System 24）Inspection of Fuel Feed Pump (FFP). ・This test can be performed without removing parts. ・Fuel feed pump (FFP) operates approximately 2 seconds when main switch is set to “ON”. Check that fuel feed pump (FFP) operation noise is heard. If no noise is heard, check fuel system.
Page 275: Inspection Of Ptt Switch
26) Inspection of PTT Switch Check electrical conductivity of PTT switch. Replace if other than specified value. Lead Wires Switch Position Sky Blue (Sb) Red (R) Pink (P) Up (Ascend) Free Down (Descend) TLDI 75/90C2 2010 8-19...
Page 276 Electrical System 8-20 TLDI 75/90C2 2010...
Page 277: Troubleshooting O K
Troubleshooting 1. Troubleshooting……………………… 9-2 Ignition System…………………………… 9-28 Power Unit …………………………… 9-14 Fuel System ……………………………… 9-29 State 1 Engine will not start or is PTT Unit hard to start. …………………… 9-14 State 1 PTT unit will not operate. ……… 9-30 Ignition System…………………………… 9-16 State 2 PTT is not capable of sustaining Fuel System ………………………………...
Page 278: Troubleshooting
Troubleshooting 1. Troubleshooting Note: This information is applicable also to 40B/50B and 70B/90B. This troubleshooting information covers malfunctions and abnormalities of electrical parts which are warned of by the buzzer and warning lamp. For the operations of the buzzer and warning lamp, refer to “Warning Indication List”. Warning Warning Warning...
Page 279 Action to be taken Cause (Refer to reference value or service data.) 1-1-1. hift is in "F" or "R" position. hift into neutral position. Battery is low, or battery cable or circuit connection is Replace battery or charge. 1-2-1. loose or corroded. Check terminals and cables.
Page 280 Troubleshooting Warning Warning Warning indicator A lamp lamp C Self- (Oil level) (Water temp.) ( attery volt.) Symptom Item diagnosable ○ Fuel pressure is low. Normal value range: 0.67 - 0.78MPa (97.17 - 113.13psi) [6.7 - 7.8kg/cm ] Air rail internal fuel pressure is Fuel System high.
Page 281 Action to be taken Cause (Refer to reference value or service data.) Fuel regulator leaks. Replace. - -1 . Fuel leak - -13. Check hose damage and joints. Return circuit from fuel regulator outlet to vapor Check, and repair if necessary. - -14.
Page 282 Troubleshooting Warning Warning Warning indicator A lamp lamp C Self- (Oil level) (Water temp.) ( attery volt.) Symptom Item diagnosable ○ Spark Plug Cap Crank Position Sensor Engine can be Electrical cranked but will Self-diag. reports that battery Flashing not start. System ○...
Page 283 Action to be taken Cause (Refer to reference value or service data.) -4-6. Cap is loose. Check. -4-7. Cap is faulty. Replace. -4-8. CPS Gap. Check, and adjust if necessary. -4-9. ECU malfunction. Replace ECU. Replace battery or charge. Battery power is low. Battery voltage becomes less than -4-10.
Page 284 Troubleshooting Warning Warning Warning indicator A lamp lamp C Self- (Oil level) (Water temp.) ( attery volt.) Symptom Item diagnosable ○ Fuel pressure is low. Normal value range: 0.67 - 0.78MPa (97.17 - 11 .1 psi) [6.7 - 7.8kg/cm Fuel System Fuel pressure is high.
Page 285 Action to be taken Cause (Refer to reference value or service data.) -2-8. Fuel regulator leaks. Refer to 2-2-12. Fuel leaks. Refer to 2-2-1 . -2-9. -2-10. Air rail internal air pressure is low. Refer to 2- . -2-11. Fuel regulator is faulty. Replace.
Page 286 Troubleshooting Warning Warning Warning indicator A lamp lamp C Self- (Oil level) (Water temp.) ( attery volt.) Symptom Item diagnosable ○ Compression insufficient Power Head Air rail internal air pressure is low. Air System Air rail internal air pressure is high. Fuel Tank Fuel Hose Fuel Filter...
Page 287 Action to be taken Cause (Refer to reference value or service data.) -1- . Crankcase head oil seal is faulty. Check, and repair if necessary. -2-1. Refer to 2-3. Refer to 2-3. -3-1. Fuel tank is empty or fuel level is low. Refer to 2-2-1.
Page 288 Troubleshooting Warning Warning Warning indicator A lamp B lamp C Self- (Oil level) (Water temp.) (Battery volt.) Symptom Item diagnosable Beep ( ○ ) Continuous ○ Flashing sounding Cooling water temp. is high. (Water temp. lamp is flashing.) Continuous ○ Flashing sounding ○...
Page 289 Action to be taken Cause (Refer to reference value or service data.) 9-1-1. Cooling water inlet is blocked. Check. 9-1-2. Water pump is faulty. Check, and repair if necessary. Replace. 9-1-3. Battery is faulty, or two batteries are connected in series. Check.
Page 290: Power Unit
Troubleshooting Before working on the engine, check that hull, rigging and engine installation are normal, and then battery is fully charged.For mechanical troubleshooting, refer to relevant troubleshooting section in this chapter. For checking and servicing outboard motor, refer to service procedures described in this manual to perform the work safely.
Page 291 Check electrical conductivity of neutral switch. Conductive? Replace neutral switch. Check start switch or main switch. Replace start switch or Normal? main switch. Check electrical conductivity of wire harness. Repair or replace wire Conductive? harness. Disassemble starter motor and check. TLDI 75/90C2 2010 9-15...
Page 292: Ignition System
Troubleshooting Ignition System Check spark plugs. Clean and adjust Normal? spark plug, or replace. WARNING · When testing, put electrode cap assuredly to prevent Use spark tester to check direct contact with spark tester wiring and leak of ignition sparks. electrical current.
Page 293 Normal? Replace ignition coil. Check ECU. TLDI 75/90C2 2010 9-17...
Page 294: Fuel System
Troubleshooting Fuel System Check operation of fuel feed pump (FFP). Check electrical conductivity Operating of wire harness and fuse. noise heard? Repair or replace Conductive? defective parts. Check if proper voltage is supplied to fuel feed pump (FFP). Check or replace Battery voltage battery.
Page 295 Replace air rail. Normal? Check fuel filter for clogging and dirt, and hoses for leak. Repair and clean or Normal? replace defective parts. Check fuel pump. Replace fuel pump. Normal? Check vapor separator needle valve for bend and wear. Replace needle valve. Normal? Check ignition system and compression...
Page 296: Air System
Troubleshooting Air System Check operation of air rail air injector. Measure resistance Normal? Replace air injector. between terminals. Apply 12V between terminals to check if Replace air injector. injector "clicks". Check fuel system and compression pressure. Nut of air hose joining Any air leak from Tighten nut and air compressor tightened?
Page 297 Check air compressor. Disassemble compressor Rotate pulley to check if Normal? and check reed valve and discharge pressure exists. piston rings. Replace air filter. Check air filter for clogging. TLDI 75/90C2 2010 9-21...
Page 298: State 2 Full Throttle Engine Revolution
Troubleshooting State 2 Full throttle engine revolution speed is low, engine revolution speed falls off, or engine stalls. Check battery cables for defective contact, and ground lead wire securing bolt for looseness or Repair or replace Normal? defective parts. Check throttle position sensor and crank position sensor connectors for connections.
Page 299: Ignition System
Ignition System Check spark plugs. Clean and adjust spark Normal? plugs, or replace. WARNING · When testing, put electrode cap assuredly to prevent Use spark tester to check direct contact with spark tester wiring and leak of ignition sparks. electrical current. ·...
Page 300: Fuel System
Troubleshooting Fuel System Check fuel filter for clogging and dirt, and hoses for leak. Repair or replace Normal? defective parts. Measure fuel pressure. Out of specified Check fuel injector clogging range? and resistance. Replace fuel injector. Normal? Check ignition system, lubrication system and/or cooling system.
Page 301 Check needle valve of vapor separator. Normal? Replace needle valve. Check ignition system, lubrication system and/or cooling system. Lubrication system Check oil level in the oil tank. Within specified Add engine oil to range? specified level. Check oil level sensor. Replace oil level Normal? switch.
Page 302: Cooling System
Troubleshooting Cooling System Check cooling water passage for clogging or leak. Clean or replace Normal? cooling water passage. Check thermostat. Replace thermostat. Normal? Measure water temperature sensor resistance. Replace water Normal? temperature sensor. Check water pump. Replace water pump. Normal? Check ignition system, fuel system and/or lubrication system.
Page 303: State 3 Engine Rotation Is Unstable Or
State 3 Engine rotation is unstable or surging occurs in low speed range. Check throttle position sensor and crank position sensor connectors for connections and resistance. Repair or replace Normal? defective parts. Check throttle link and throttle cam for play and wear. Adjust throttle link or Normal? replace throttle cam...
Page 304: Ignition System
Troubleshooting Ignition System Check spark plugs. Clean and adjust spark Normal? plugs, or replace. WARNING Use spark tester to check · When testing, put electrode cap assuredly to prevent ignition sparks. direct contact with spark tester wiring and leak of electrical current.
Page 305: Fuel System
Fuel System Check fuel pump. Replace fuel pump. Normal? Check vapor separator needle valve for bend and wear. Normal? Replace needle valve. Check injector for clogging and resistance. Normal? Replace injector. Check ignition system. TLDI 75/90C2 2010 9-29...
Page 306 Troubleshooting PTT Unit State 1 PTT unit will not operate. Check operation of PTT motor. Operating Check battery and fuse. noise heard? Repair or replace Normal? defective parts. Check electrical conductivity of PTT switch. Conductive? Replace PTT switch. Check electrical conductivity of PTT solenoid.
Page 307: Range
Check PTT fluid level. Add PTT fluid to Within specified specified level. range? Disassemble PTT unit to check. State 2 PTT is not capable of sustaining outboard motor. Check if manual valve is closed. Closed? Close manual valve. Check PTT fluid level. Add PTT fluid to Within specified specified level.
Page 308: Self-Diagnosis Function Of Tldi
Troubleshooting 2. Self-Diagnosis Function of TLDI The self-diagnosis function detects a trouble(s) of electrical system of TLDI engine and displays the part by using ECU installed in the engine. TLDI engine requires no instruments and special equipment such as personal computer when executing the self-diagnosis function that uses key switch operation, tachometer’s RPM indication and a combination of three warning lamps to show information necessary for troubleshooting through the following four modes.
Page 309: Operation Procedure Of Self-Diagnosis Function
2) Operation Procedure of Self-Diagnosis Function * The self-diagnosis function is enabled only when the engine is stopped state. * The self-diagnosis function is stopped at any moment during the following procedure when the key switch is set to “OFF”. After attaching stop switch lock, set key switch to "ON".
Page 310 Troubleshooting Go into process of the self-diagnosis operation from here. seconds Set the key to "ON", and push it in (for approximately 5 seconds) until the buzzer sounds. Beep!! Beep!! Beep!! Self-Diagnisos Mode 1[Tachometer Operation Test] After the pointer returns to "zero", the process goes to mode 2 automatically.
Page 311 Self-Diagnisos Mode 4 [Deletion of fault history] In any of the states in the self-diagnosis mode 3, the fault history is deleted by removing stop switch lock plate and pushing in key for approximately 3 seconds. At this moment, the buzzer "Beeps" three times.
Page 312: Operation
Troubleshooting 3) Warning Indication List • • • Display for abnormalities during operation Warning Indicators Speed Control Buzzer Sounding (*1) Indicator A Indicator B Indicator C Continuous High speed ESG × × × Intermittent (3 beeps for every 2 minutes) lashing ×...
Page 313 ault Description Reference Remedy Engine over-rev. Approx. 6,000 r/min Readjust propeller, outboard engine mounting height and/or trim. Low oil level Approx. 1.4L (3.7 gal) or less Replenish engine oil. Cooling water temp. high Approx. 85ûC 185û （） *Varies depending on engine speed. Engine cooling water temp.
Page 314: Operating Hour Indication List (Self Diagnosis • Mode 2)
Troubleshooting 4) Operating Hour Indication List (Self Diagnosis • Mode 2) Lamp Indication Tacho meter Engine Operating Hours (hours) Tach. Indication (r/min) Lamp A Lamp B Lamp C 0 - 1 1,000 — — — 1 - 2 2,000 — —...
Page 315 TLDI 75/90C2 2010 9-39...
Page 316: Trouble Indication List (Self Diagnosis • Mode 3)
Troubleshooting 5) Trouble Indication List (Self Diagnosis • Mode 3) Fault Log Malfunction / Failure Indication Fault Fault Log (Yes) Description of Problem Tacho meter Tachometer Indication Indicator A Indicator B Indicator C (r/min) No malfunction of failure Lighting of the lamp means that Lighting of the lamp means that Battery voltage high the wiring is broken or a...
Page 317 emedial Measures and Added Notes efer to troubleshooting. eplace the component, or check wiring and connections for abnormality, and repair if necessary. When an injector of ignition coil malfunctions, the lamp B does not go on in the self-diagnosing mode where engine is not operating to check that the components are under control of ECU.
Page 318 Troubleshooting Fault Log Malfunction / Failure Indication Fault Fault Log (Yes) Description of Problem Tacho meter Tachometer Indication Indicator A Indicator B Indicator C (r/min) 6,500 Engine cooling water temp high Engine cooling water temp. 6,500 Flashing abnormally high Lighting of the lamp means that Lighting of the lamp means that Air compressor cooling water the cooling water temperature...
Page 319 Remedial Measures and Added Notes Refer to troubleshooting. Refer to troubleshooting. Refer to troubleshooting. TLDI 75/90C2 2010 9-43...
Page 320: Resetting Tps Initial Values
Troubleshooting 6) Resetting TPS Initial Values Use the following proseedures to reset the ECU and TPS idling position in case where self-diagnosing indicates idling position errors for TPS1 and TPS2. 1 When either the TPS or ECU is replaced or control cables replaced : 2 When the self-diagnosing function indicates“TPS Idling Position Error : 3 When links and rod snap rings are replaced due to warping or wear in the linkage : 4 When the TPS idling Position Error indication appears after performing engine disassembly and assembly...
Page 321 Wait another 5 to 10 seconds, again pull the red knob on the stop switch for about 0.5 seconds, then release the switch. Seconds 0 . 5 S e c o n d s Resetting of TPS and ECU is completed when the buzzer “Beeps” three Seconds times approximately 5 seconds after the knob of stop switch is returned to Beep ！...
Page 322 Troubleshooting 9-46 TLDI 75/90C2 2010...
Page 323 Rigging r/min r/min 1. Service Information ………………… 10-2 4. Connections to Outboard Motor … 10-8 2. Service Data ………………………… 10-2 1) Steering Cable ……………………… 10-8 1) Load Limit of Boat ………………… 10-2 2) Drag Link …………………………… 10-9 2) Installation Dimensions …………… 10-2 3) Installation of Remote Control Cable 3) Clamp Dimensions …………………...
Page 324: Service Information
Rigging r/min 1. Service Information The persons who perform the rigging should take sufficient care for prevention of damages to himself or herself and the products, prevention of fire, and ventilation of the shop. The persons who operate the boat equipped with this product for test run should read the operating instructions of the outboard, and be familiar with the operating procedure.
Page 325: Clamp Dimensions
3) Clamp Dimensions CENTER LINE 180 mm 180 mm (7.09 in) (7.09 in) 163.5 mm 163.5 mm (6.44 in) (6.44 in) TOP OF BOAT TRANSOM 121 mm 121 mm (4.76 in) (4.76 in) M12P1.25 13.5 mm (0.53 in) 125.5 mm 125.5 mm Allowable Transom (4.94 in)
Page 326 Rigging r/min Transom Dimensions and Drilling Template (An example) * Full scale transom dimensions and drilling template is shown at the end of this manual. 10-4 TLDI 75/90C2 2010...
Page 327: Hanging Outboard Motor
Installation of an outboard motor at higher position can cause the matters described below. 1) Lower steering torque 2) Higher top speed 3) More stable boat attitude 4) Propeller can easily run above water surface (over-revs) during planning or when the boat is heavily loaded.
Page 328: Fuel System
Rigging r/min Install outboard motor(s). Secure the outboard motor by using fasteners contained in the package of the product. 1 : 12.7mm (1/2in.) Bolts (4 pcs.) 2 : Flat Washers (4 pcs.) 3 : Lock Nuts (4 pcs.) 4 : Flat Washers (4 pcs.) 4 : Marine Sealant : Apply to the bolts’...
Page 329: Connection Of Fuel Hose
5) Connection of Fuel Hose Secure remote fuel hose to the fitting by using hose tie. : Remove cap 2 from tip of hose nipple 1 of fuel hose. : Use hose tie to secure remote fuel hose. For fuel hose, use independent fuel line / fuel tank pick up for individual engines, and use fuel hose of minimum inner diameter of 8mm (0.315 in, 5/16 in).
Page 330: Priming Oil Pump
Rigging r/min 8) Priming Oil Pump After installing outboard motor, prime oil pump before initially starting the engine. The priming removes all air bubbles contained in the pump, oil feed hose and internal oil passage. Refer to “Air Purging” in Chapter 4. WARNING To prevent damaging to fuel pump, fill engine’s fuel system with fuel.
Page 331: Drag Link
2) Drag Link Attach drag link as shown. When installing steering rod that connects engine and steering cable, be sure to use special bolt ( 1 : 3E0-84917-0) and nylon lock nuts ( 2 : 353-84918-0 and 3 : 353-84916-0). Do not use regular non-lock type nuts in place of these lock nuts, or the nuts may be loosened due to mechanical vibration resulting in...
Page 332: Installation Of Remote Control Cable (Engine Side)
Rigging r/min 3) Installation of Remote Control Cable (Engine Side) Turn upper motor cover hook levers 1 and 2 and remove upper motor cover. Remove cord clamp installation bolts and remove cord clamp and grommet. Remove “R” shaped pin 3 and washer 4 of throttle side and shift side, and set shift arm 5 to F, N, R positions and then to N.
Page 333 Screw cable joint 1 on the tip of remote control cable by approximately 10mm. Open the cut of grommet and run meter cord ass’y and cord ass’y B attached to remote control box from front of lower motor cover. Then, run two remote control cables.
Page 334 Rigging r/min Adjust screw in length of cable joint so that cable joint hole aligns with shift arm and advancer arm pins, lock the joint with nut, and then, set it on the arm pin and secure with “R” pin and washer. Put the cable in cable clip groove, and then secure it by using cord clamp.
Page 335: Lower Unit
5. Lower Unit 1) Installation of Propeller WARNING · Before removing or installing propeller, be sure to disconnect battery cables from battery and remove stop switch lock plate. · When removing or installing propeller, do not handle propeller with bare hands. ·...
Page 336: Electric System
Rigging r/min 6. Electric System 1) Battery Capacity 12V100 AH or more 12V120 AH or more (in cold regions) CCA：850 CCA：1000 MCA：500 MCA：850 2) Connection of Battery Cables Single Outboard Installation 1 : Red Sleeve (Positive Side) 2 : Black Sleeve (Negative Side) 3 : Starting Battery Twin Outboard Installation Be sure to connect negative terminals of the starting...
Page 337: Accessories And Meters
7. Accessories and Meters 1) Accessories. Start In-Gear Protection (Neutral Safe Starting Switch) The remote control box connected to the outboard motor is equipped with start in-gear protection (neutral safe starting switch) This function disables the engine starting when shift gear is engaged. WARNING If engine starts with the shift gear engaged, the boat may start to move unexpectedly, possibly leading to serious injury or fatal accident.
Page 338: Meter Leads
Rigging r/min <Tachometer> Set selector 3 to “4P” on the back of the meter. Connect cord ass’y B and meter lead wire to cord ass’y A. Connect trim sensor 1 with trim sensor extension cord 2. 10-16 TLDI 75/90C2 2010...
Page 339: Wiring Diagram
Wiring Diagram TLDI Wire Harness Terminals and Instruction Diagram -1 ………………… 11-7 Connections ……………………………… 11-2 Electrical Wiring Assembling Main Harness Diagram ………………… 11-3 Instruction Diagram -2 ………………… 11-8 75/90C2 EPTO Electrical Circuit…… 11-5 Outboard Motor Installation Template … 11-9 Electrical Wiring Assembling...
Page 340 Wiring Diagram TLDI Wire Harness Terminals and Connections 25 26 27 28 11 12 15 16 17 18 19 20 NO Component Lead Wire Color TPS1 (Throttle Position Sensor 1) Blue/Red Key Switch (PUSH) Blue CPS (Crank Position Sensor) Blue/Black Warning Lamp (Oil) Light green Warning Lamp (Temp.)
Page 341 Main Harness Diagram FUEL INJECTOR #1 COMPRESSOR WATER TEMP SENSOR FUEL INJECTOR #2 FUEL INJECTOR #3 RECTIFIER IG COIL #1 AIR INJECTOR #1 (GND) Lg/R Lg/R AIR RAIL (GND) IG COIL #1 AIR INJECTOR #2 Br/Y Lg/W Lg/W Br/Y IG COIL #2 POWER Br/Y RELAY...
Page 342 TLDI 75/90C2 2010 11-4...
Page 343 Wiring Diagram TLDI 75/90C2 EPTO Electrical Circuit Name of Component Name of Component Alternator Ass'y Cord Ass'y B Rectifier Complete Neutral Switch Battery (Local) Buzzer PTT switch Main Switch Oil Level Sensor Lanyard Stop Switch Throttle Position Sensor PTT Switch Water Temp.
Page 344 TLDI 75/90C2 EPTO Electrical Circuit FUSE HOLDER MAGNETO Br/Y AIR CHAMBER km/h Warnig Warnig Warnig Lamp 1 Lamp 2 Lamp 3 AIR RAIL Lg/R B Br R R G L Lg/W START O-O-O Main Switch Circuit Lg/B CYLINDER PUSH VARIABLE IDLE O-O-----O HEAD #1 6...
Page 345 Electrical Wiring Assembling Instruction Diagram -1 ix 2 oil hoses and cord assÕy to crank case by using ix cord ass'y to crankcase by stay and band. Be careful that oil hose is not squeezed. using stay and band. Water temp. sensor Water temp.
Page 346 Electrical Wiring Assembling Instruction Diagram -2 PTT solenoid switch A PTT solenoid switch B Pass PTT wires through gap between main harness Fuse box and air chamber. PTT solenoid switch A Fuel injector Water temp.sensor Flywheel magneto PTT solenoid switch B Alternator Bind PTT relay cords and connectors for optional...
Page 347 Upper edge of transom WARNING Do not drill upper mounding holes on the area of the transom below 25.4 mm (1 in) or lower from the top edge of the transom. Ø13.0 mm hole (0.51 in) 163.5 mm 163.5 mm (6.44 in) (6.44 in) WARNING...
Page 348 © 2010 Tohatsu orporation. 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 orporation.
Page 349 OB No.003-21052-2 11-01 NB Printed in Japan...

TOHATSU MD 70-90C2 Service Manual

1.Service Information

Service Information

Identification (Engine Serial Number)

Work Safety

Tools and Instruments

Pre-Delivery Inspection

Break-In Operation

Test Run

Checks after Test Run

Service Data

Outboard Dimensions

Cooling Water System Diagram

Specifications

Maintenance Data

Torque Specifications

Sealant and Lubricant

Warning Indication List

Maintenance

Special Tools

Inspection Schedule

Inspection Items

Fuel System

Power Unit

Operating System

PTT System

Lower Unit

Others

Fuel System (TLDI)

Parts Layout

What Is TLDI

Removing Air Rail

Assembly of Air Rail

Removing and Installation of Air Compressor

Power Unit

Parts Layout

Inspection Items

Lower Unit

Parts Layout

Inspection Items

Cowl, Bracket and PTT Unit

Special Tools

Inspection Items

Electrical System

Special Tools

Parts Layout

Inspection Items

9 Troubleshooting O

Troubleshooting

Rigging

Range

State 2 PTT Is Not Capable of Sustaining Outboard Motor

Self-Diagnosis Function of TLDI

Quick Links

Chapters

Troubleshooting

Related Manuals for TOHATSU MD 70-90C2

Summary of Contents for TOHATSU MD 70-90C2