TOHATSU MD 70-90C2 Service Manual page 9

20) Inspection of Forward (A) Gear ...... 6-23
21) Assembly of Forward (A) Gear Parts ... 6-24
22) Removing Drive Shaft Ass'y ......... 6-25
23) Disassembly of Drive Shaft Ass'y ... 6-26
24) Inspection of Drive Shaft............... 6-26
25) Inspection of Forward (A)
Gear and Pinion (B) Gear ............ 6-27
26) Assembly of Drive Shaft Parts ...... 6-27
27) Disassembly of Gear Case............ 6-28
28) Inspection of Gear Case ............... 6-29
29) Assembly of Gear Case Parts ...... 6-30
30) Measurement of Pinion (B) Gear
Height and Shim Selection ............ 6-32
31) Measurement of Back Lash between
Forward (A) and Pinion (B) Gears and
Shim Selection ........................... 6-34
32) Measurement of Back Lash between
Pinion (B) and Reverse (C) Gears and
Shim Selection ........................... 6-37
33) Assembly of Lower Unit Parts ...... 6-39
34) Attaching Clutch Cam Ass'y ......... 6-41
35) Measurement of Propeller Shaft Play and
Selection of Washer Thickness ............ 6-42
36) Installation of Lower Unit ............ 6-43
7.Cowl, Bracket and
PTT Unit
1. Special Tools .............................. 7-2
2. Parts Layout .............................. 7-3
Top Cowl (Motor Cover Upper) ............ 7-3
Bottom Cowl (Motor Cover Lower) ...... 7-4
Shift ............................................. 7-6
Drive Shaft Housing........................... 7-8
Bracket .......................................... 7-10
Power Trim & Tilt .............................. 7-12
3. Inspection Items ........................ 7-14
1) Removing Top Cowl .................. 7-14
2) Adjustment of Cover Hook ............ 7-14
3) Removing Bottom Cowl ............... 7-14
4) Removing Drive Shaft Housing ...... 7-15
5) Disassembly of Drive Shaft Housing ... 7-17
6) Inspection of Drive Shaft Housing ... 7-19
7) Assembly of Drive Shaft Housing ... 7-20
8) Installing Drive Shaft Housing ...... 7-23
9) Removing Steering Shaft Arm ...... 7-24
10) Removing PTT Unit ..................... 7-25
11) Removing Clamp Bracket ............ 7-27
12) Assembly of Clamp Bracket ......... 7-28
13) Installation of PTT Unit ............... 7-28
14) Assembly of Steering Arm ............ 7-30
15) Removing PTT Motor .................. 7-31
16) Inspection of PTT Motor ............... 7-32
17) Assembly of PTT Motor ............... 7-33
18) Removing Reservoir .................. 7-34
19) Disassembly and Assembly of
Gear Pump .............................. 7-35
20) Disassembly of Tilt Cylinder and
Trim Cylinder.............................. 7-36
TLDI 75/90C2 2010
21) Assembly of PTT Unit .................. 7-37
22) Air Bleeding PTT Unit .................. 7-40
8.Electrical System
1. Special Tools .............................. 8-2
2. Parts Layout .............................. 8-3
Starter Motor.................................... 8-3
3. Inspection Items ........................... 8-4
1) Disassembly of Starter Motor......... 8-4
2) Inspection of Armature ............... 8-7
3) Inspection of Brushes .................. 8-8
4) Inspection of Starter Motor Pinion ... 8-8
5) Inspection of Magneto Switch ...... 8-8
6) Assembly of Starter Motor ............ 8-9
7) Inspection of Ignition and spark ...... 8-11
8) Inspection of Plug Cap ............... 8-11
9) Inspection of Ignition Coils ............ 8-12
10) Inspection of Pick Up Coil
(Crank Position Sensor) ............... 8-12
11) Inspection of Pick Up Coil Air Gap ... 8-12
12) Inspection of Alternator ............... 8-13
13) Inspection of Rectifier Complete ... 8-14
14) Inspection of Throttle Position Sensor ... 8-15
15) Inspection of Water Temperature Sensor ... 8-15
16) Inspection of Power Relay ............ 8-15
17) Inspection of Air Injectors ............ 8-16
18) Inspection of Fuel Injectors ......... 8-16
19) Inspection of MAT sensor (Manifold
Temperature Sensor) (Option) ......... 8-16
20) Inspection of MAP Sensor (Manifold
Absolute Air Pressure Sensor) (Option)...... 8-16
21) Inspection of Starter Solenoid ...... 8-17
22) Inspection of Oil Level Sensor ...... 8-17
23) Inspection of Oil Pump ............... 8-17
24) Inspection of Fuel Feed Pump (FFP). ... 8-18
25) Inspection of PTT Solenoid ......... 8-18
26) Inspection of PTT Switch ............ 8-19
9.Troubleshooting
1. Troubleshooting........................... 9-2
Power Unit ................................. 9-14
State 1 Engine will not start or is
hard to start. ........................ 9-14
Ignition System................................. 9-16
Fuel System .................................... 9-18
Air System....................................... 9-20
State 2 Full throttle engine revolution
speed is low, engine revolution
speed falls off, or engine stalls.
.......................................... 9-22
Ignition System................................. 9-23
Fuel System .................................... 9-24
Lubrication system ........................... 9-25
Cooling System .............................. 9-26
State 3 Engine rotation is unstable or
surging occurs in low speed
range. ................................. 9-27
Ignition System................................. 9-28
Fuel System .................................... 9-29
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