Table Of Contents - TOHATSU MD 70-90C2 Service Manual

1.Service Information
1. Identification
(Engine Serial Number) ............... 1-2
2. Work Safety ................................. 1-2
1) Fire Prevention ........................... 1-2
2) Ventilation ................................. 1-2
3) Protection ................................. 1-2
4) Genuine Parts ........................... 1-2
5) Tools ....................................... 1-3
6) Recommendations on Service ...... 1-3
7) Cautions in Disassembling and
Assembling Components ............ 1-4
3. Tools and Instruments ............... 1-5
1) Test Propeller ........................... 1-5
2) Measuring Instruments ............... 1-5
3) Special Tools ........................... 1-6
4. Pre-delivery Inspection ............... 1-9
1) Steering Handle ........................ 1-9
2) Gear Shift and Throttle ............... 1-9
3) Engine Oil ................................. 1-9
4) Gear Oil .................................... 1-9
5) Check quantity of engine oil. ......... 1-10
6) Fuel Line ................................. 1-11
7) Installation of Outboard Motor
(Rigging) ................................. 1-11
8) Inspection of PTT Unit.................. 1-11
9) Inspection of Start Switch and
Stop switch ....................................... 1-12
10) Cooling Water Check Port ............ 1-13
11) Idling ....................................... 1-13
12) Propeller Selection ..................... 1-13
13) Trim Tab ................................. 1-14
5. Break-In Operation ..................... 1-15
6. Test Run....................................... 1-15
7. Checks After Test Run ............... 1-15
2.Service Data
1. Outboard Dimensions .................. 2-2
1) Body dimensions ........................ 2-2
2) Clamp Dimensions ..................... 2-3
2. Cooling Water System Diagram ... 2-4
3. Specifications.............................. 2-6
4. Maintenance Data ..................... 2-8
5. Torque Specifications ............... 2-14
6. Sealant And Lubricant ............... 2-16
7. Warning Indication List • • •
Display for abnormalities during operation ... 2-20
3.Maintenance
1. Special Tools .............................. 3-2
2. Inspection Schedule .................. 3-3
3. Inspection Items ........................ 3-4
1) Inspection of Top Cowl ............... 3-4
2) Oil Filter and Oil Tank .................. 3-4
3) Air Bleeding .............................. 3-4
4. Fuel System ................................. 3-6
1) Inspection of Fuel Pipes and Joints ... 3-6
TLDI 75/90C2 2010
2) Inspection of Fuel Tank (option) ... 3-6
3) Inspection of Low Pressure Fuel Filter ... 3-7
4) Inspection of Air Compressor Air Filter ... 3-7
5) Inspection of Air Pressure ............ 3-7
6) Inspection of Fuel Pressure ......... 3-8
7) Inspection of Drive Belt ............... 3-9
8) Adjustment of Drive Belt Tension ... 3-9
5. Power Unit ................................. 3-10
1) Inspection of Spark Plugs ............ 3-10
2) Inspection of Compression Pressure ...... 3-11
3) Inspection of Thermostat ............ 3-12
4) Inspection of Cooling Water Passage ... 3-13
6. Operating System ........................ 3-13
1) Adjustment of Throttle Cable ......... 3-13
2) Adjustment of Shift Cable ............ 3-14
3) Inspection of Idle Engine Speed ... 3-15
7. PTT System ................................. 3-15
1) Inspection of PTT Unit Operation ... 3-15
2) Inspection of PTT Fluid Quantity ... 3-15
8. Lower Unit ................................. 3-16
1) Inspection of Gear Oil Quantity ...... 3-16
2) Replacement of Gear Oil ............ 3-17
3) Inspection of Gear Case (for leakage) ... 3-18
4) Inspection of Water Pump ............ 3-18
9. Others .......................................... 3-19
1) Replacement of Anode ............... 3-19
2) Inspection of Propeller ............... 3-20
3) Inspection of Battery .................. 3-21
4) Flushing with Water ..................... 3-22
5) Greasing ................................. 3-24
4.Fuel System (TLDI)
1. Special Tools .............................. 4-2
2. Parts Layout .............................. 4-3
Vapor Separator & Fuel Line ............... 4-3
FFP Ass'y ....................................... 4-4
Air Rail .......................................... 4-6
Air Compressor .............................. 4-8
Oil Pump ....................................... 4-10
3. What is TLDI? .............................. 4-12
Direct Fuel Injection System ............... 4-12
ENGINE WITH CARBURETOR ......... 4-12
TLDI ............................................. 4-12
Inductive Ignition .............................. 4-13
ECU ............................................. 4-15
Fuel / Air Feed System ..................... 4-16
Oil System....................................... 4-17
Recirculation System ........................ 4-18
4. Removing Air Rail ........................ 4-19
1) Decompression of Fuel Line and Air Line ... 4-19
2) Removing Air Rail Ass'y ............... 4-19
3) Inspection of Injectors .................. 4-21
5. Assembly of Air Rail .................. 4-21
1) Installing of Injectors and Regulators ... 4-21
2) Installation of Air Rail .................. 4-24
6. Removing and installation of
Fuel System ................................. 4-25
1) Removing High Pressure Fuel Hose Ass'y... 4-25
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