TOHATSU MD 70-90C2 Service Manual page 8

2) Installation of Fuel Hose Ass'y ...... 4-25
3) Draining Fuel from FFP Vapor Separator ... 4-26
4) Removing Vapor Separator ......... 4-26
5) Disassembly and Inspection of
Vapor Separator ........................ 4-27
6) Assembly of Vapor Separator ...... 4-27
7) Assembly of Vapor Separator Ass'y... 4-28
8) Removing FFP* Ass'y .................. 4-28
9) Disassembly and Inspection of FFP... 4-28
10) Assembly of FFP Ass'y ............... 4-29
11) Inspection of Fuel Pump ............... 4-30
12) Installation of FFP Ass'y to Cylinder ... 4-31
7. Removing and Installation of
Air Compressor ........................... 4-32
1) Removing Drive Belt .................. 4-32
2) Removing Air Compressor ............ 4-32
3) Inspection of Drive Belt ............... 4-32
4) Removing Driven Pulley ............... 4-33
5) Disassembly of Compressor Housing ... 4-34
6) Inspection of Reed Valve ............ 4-35
7) Inspection of Cylinder and Piston ... 4-35
8) Assembly of Compressor Housing ... 4-35
9) Installation of Crank Shaft ............ 4-36
10) Installation of Piston .................. 4-37
11) Installation of Compressor Housing Ass'y ... 4-38
12) Measurement of Fuel Pressure and
Air Pressure .............................. 4-39
13) Inspection of Oil Filter .................. 4-41
14) Inspection of Oil Tank .................. 4-41
15) Air Bleeding .............................. 4-42
5.Power Unit
1. Special tools .............................. 5-2
2. Parts Layout .............................. 5-3
Engine .......................................... 5-3
Magneto.......................................... 5-4
Electric Parts (ECU•Diagram) ............ 5-6
Electric Parts (Starter Motor) ............... 5-8
Air Chamber (Air Box) ........................ 5-9
Throttle .......................................... 5-10
Cylinder Crank Case ........................ 5-12
Piston & Crank Shaft ........................ 5-14
3. Inspection Items ........................ 5-15
1) Inspection of
Compression Pressure ...............5-15
2) Removing Power Unit ..................5-16
3) Removing Air Compressor .........5-19
4) Removing Flywheel .....................5-20
5) Removing Alternator ..................5-20
6) Removing Starter Motor ...............5-21
7) Removing Cord Ass'y ..................5-22
8) Removing Oil Pump.....................5-25
9) Removing Throttle Link ...............5-25
10) Inspection of Throttle Body............5-26
11) Removing Air Chamber ...............5-27
12) Removing Thermostat ..................5-28
13) Inspection of Thermostat ............5-29
14) Removing Fuel System ...............5-29
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15) Removing Cylinder Head /
Head Cover ..............................5-29
16) Inspection of Cylinder Head .........5-30
17) Removing Exhaust Cover ............5-31
18) Inspection of Exhaust Cover .........5-32
19) Removing Crank Case ...............5-32
20) Removing Pistons .....................5-34
21) Disassembly of Crank Shaft .........5-35
22) Inspection of Crank Shaft ............5-35
23) Inspection of Cylinder ..................5-36
24) Inspection of Pistons ..................5-37
25) Assembly of Crank Shaft ............5-40
26) Installation of Pistons ..................5-41
27) Inspection of Crankcase ...............5-41
28) Assembly of Power Unit Parts ......5-42
29) Assembly of Crank Case Halves ...5-43
23) Installation of Exhaust Cover .........5-45
31) Installation of Cylinder Head .........5-46
32) Assembly of Crank Case Head ......5-47
33) Installation of Air Chamber ............5-48
34) Installation of Recirculation Hoses 5-50
35) Installation of Throttle Link ............5-50
36) Installation of Oil Pump ...............5-50
37) Installation of Fuel System ............5-51
38) Installation of Cord Ass'y and
Electrical Parts ...........................5-51
39) Installation of Starter Motor .........5-51
40) Installation of Alternator ...............5-51
41) Installation of Drive Pulley and
Flywheel....................................5-52
42) Installation of Air Compressor ......55-2
43) Installation of Power Unit ............5-52
6.Lower Unit
1. Special Tools .............................. 6-2
2. Parts Layout .............................. 6-4
Gear Case (Drive Shaft) ..................... 6-4
Gear Case (Propeller Shaft) ............... 6-6
3. Inspection Items ........................ 6-8
1) Draining Gear Oil ........................ 6-8
2) Removing Propeller ..................... 6-8
3) Removing Lower Unit .................. 6-9
4) Disassembly of Cam Rod ............ 6-9
5) Inspection of Clutch Cam ............ 6-10
6) Assembly of Clutch Cam Parts ...... 6-10
7) Removing Water Pump ............... 6-11
8) Inspection of Water Pump ............ 6-12
9) Disassembly of Water Pump Case (Lower) ... 6-13
10) Assembly of Water Pump Case (Lower) ... 6-14
11) Removing Propeller Shaft Housing Ass'y ... 6-15
12) Disassembly of Propeller Shaft Housing Ass'y ... 6-16
13) Inspection of Propeller Shaft Housing ... 6-17
14) Assembly of Propeller Shaft Housing ... 6-18
15) Disassembly of Propeller Shaft Ass'y ... 6-20
16) Inspection of Propeller Shaft Ass'y ... 6-21
17) Assembly of Propeller Shaft Ass'y ... 6-21
18) Removing Forward (A) Gear Ass'y ... 6-22
19) Disassembly of Forward Gear (A) Gear ... 6-23
TLDI 75/90C2 2010