TOHATSU TLDI MD 115A SERIES Service Manual
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TOHATSU TLDI MD 115A SERIES Service Manual

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B No.003-21060-0
07-05 NB-2600

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Summary of Contents for TOHATSU TLDI MD 115A SERIES

  • Page 1 B No.003-21060-0 07-05 NB-2600...
  • Page 2 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 3 About this manual Composition and use of this manual This service manual is designed so that service persons are able to perform their work correctly. Understand the following matters well for efficient works. 1 Each chapter begins with the introduction of special tools that are used for the work described in the chapter so that the service persons are able to figure out the tools needed.
  • Page 4 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 5: Service Information

    Description of Pictograph The following symbols represent the contents of individual chapters. Service Inspections and Service Data Fuel System Information Adjustments Electrical Power Unit Lower Unit Bracket System Wiring r/min Troubleshooting Rigging Diagrams The following symbols indicate items needed for the service. Lubrication Tightening Special Tool...

  • Page 6: Table Of Contents

    1.Service Information 5. Cooling System ……………………… 3-9 1) Inspection of Cooling Water Passage … 3-9 1. Identification (Engine Serial Number) … 1-2 2) Flushing with Water ………………… 3-10 2. Securing of work safety ………… 1-2 3) Inspection of Compression Pressure … 3-13 1) Fire Prevention ………………………...
  • Page 7 Structure of Air Compressor ....4-35 25) Assembling Coil Bracket Parts …… 5-50 7. Removing Air Compressor ..... 4-36 26) Assembling Crank Case Head Parts … 5-50 1) Removing Drive Belt ......4-36 27) Installing Air Chamber ……………… 5-51 2) Removing Air Compressor ....4-36 28) Attaching Coil Bracket ………………...
  • Page 8 1. Special tools ………………………… 7-2 17) Inspection of MAT 2. Parts Layout ………………………… 7-3 (Manifold Temperature) Sensor…… 8-12 Cowl ……………………………………… 7-3 18) Inspection of MAP Sensor Bottom Cowl ……………………………… 7-4 (Manifold Air Pressure Sensor) …… 8-12 Shift ……………………………………… 7-6 19) Inspection of Starter Solenoid …… 8-12 Drive Shaft Housing………………………...
  • Page 9 2) Oil …………………………………… 10-6 3) Electric Fuel Pump ………………… 10-6 4) Installation of Fuel Filter …………… 10-6 5) Connection of Fuel Hose ………… 10-7 6) Filling Fuel System ………………… 10-7 7) Filling Oil Tank ……………………… 10-7 8) Priming Oil Pump …………………… 10-8 4.
  • Page 10 INDEX Service Information Service Data Inspections and Adjustments Fuel System (TLDI) Power Unit Lower Unit Cowl, Bracket and PTT Electrical System Troubleshooting Rigging r/min Wiring Diagram TLDI 115A 2007...
  • Page 11 Service Information 1. Identification (Engine Serial Number) … 1-2 2) Gear Shift and Throttle …………… 1-10 2. Securing of work safety ………… 1-2 3) Engine Oil …………………………… 1-10 1) Fire Prevention ……………………… 1-2 4) Gear Oil ……………………………… 1-10 2) Ventilation …………………………… 1-2 5) Check quantity of engine oil ………...

  • Page 12: Identification (Engine Serial Number)

    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 Tokyo, Made in Japan 3 Serial Number 2006 Model 115A SERIAL No. XXXXXXXX 84.6 kW RATED POWER FULL THROTTLE RANGE 5150...

  • Page 13: 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 14: 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 15: 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) 115A approximately 5,500 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 ) Vernier calipers...

  • Page 16: List Of Special Tool

    Service Information 3) List of Special Tool 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 17 ø51.5 x ø24.5 Bearing Attachment Bevel Gear B Nut Wrench Drive Shaft Socket Backlash Measuring Tool A Kit P/N. 3AC-99905-0 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 reverse (C) gear bearing (B) gear nut...
  • Page 18 Service Information 3T1-72781-0 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 P/N. 3J6-99820-0 P/N. 3T1-72211-0 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 19 ø49.5 x ø29.5 Oil Seal Attachment P/N. 3Y9-99820-0 Used in combination with driver rod Attaching propeller shaft housing oil seal TLDI 115A 2007...

  • Page 20: Pre-Delivery Inspection

    Service Information 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 21: Check Quantity Of Engine Oil

    5) Check quantity of engine oil. Set outboard motor to vertical position. Check engine oil level. Oil Tank Capacity： 6.7r （1.77 gal） Engine Oil： Genuine MD Platinum Oil (Oil for two stroke direct injection engine recommended by the outboard manufacturer) CAUTION When quantity of faills below 1.4L (0.37gal), oil warning lamp blinks and the buzzer...

  • Page 22: Fuel Line

    Service Information 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 23: Inspection Of Start Switch And Stop Switch

    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 24: Propeller Selection

    Service Information 10) Propeller Selection Select a propeller that is best-suited to type of boat and application. Range of operating engine revolution at WOT： 5,150∼5,850 r/min å CAUTION Wrong-selection of propeller can cause adverse effects on engine life, fuel consumption, etc. as well as on performance. å...

  • Page 25: Trim Tab

    12) Trim Tab Adjustment of trim tab angle After installing outboard motor on the boat, use trim tab to achieve balance between port and starboard steering loads. Loosen trim tab nut 2, adjust angle of trim tab 1 as described below, and then tighten the nut to specified torque.

  • Page 26: Test Run

    Service Information 6. Test Run Start engine and check if gear shift can be made smoothly. After warming up the engine, read tachometer to check idling engine speeds specified below. Idling Engine Speeds : 700 · 800 · 900 r/min Tachometer : P/N.

  • Page 27: Service Data

    Service Data 1. Outboard Dimensions ……………… 2-2 4. Warning Indication List • • • 1) Body dimensions ……………………… 2-2 Display for abnormalities during operation … 2-8 2)Clamp Dimensions …………………… 2-3 5. Torque Specifications …………… 2-10 2. Cooling Water System Diagram … 2-4 6.

  • Page 28: Outboard Dimensions

    Service Data 1. Outboard Dimensions 1) Body dimensions 115A Item Type Unit mm/in 29.53 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 33.62 mm/in 24.33 mm/in 24.96 mm/in 31～70 1.22～2.76 mm/in 23.54 Transom (L)

  • Page 29: 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 30: Cooling Water System Diagram

    Service Data 2. Cooling Water System Diagram TLDI 115A 2007...
  • Page 31 Cylinder Head Head Cover Air Compressor Thermostat Exhaust System Air Rail Cylinder Cover Cooling Water Check Cylinder Lower Section Port Cylinder Lower Section (Water Discharging Passage (Water Feed Passage in Drive Shaft Housing) in Engine Base) Cooling Water Pipe Interior of Drive Shaft Housing Cooling Water Pump Discharging...

  • Page 32: Specifications

    Service Data 3. Specifications Model Item Unit EPT0 Dimensions (Approximate) Overall Length mm（in） 800（31.50） Overall Width mm（in） 495（19.49） mm（in） 1,640（64.57） Overall Height mm（in） 1,767（69.57） mm（in） 517（20.35） Transom Height mm（in） 644（25.35） Weight (Approximate) kg（lb） 178（392） kg（lb） 181（399） Performance Max. Output kW (ps) 84.6（115）...
  • Page 33 Model Item Unit EPT0 Fuel and Oil Unleaded Gasoline Type of Fuel (Reserch Octane Number 90 or over, Pump posted Octane Number 87 or over) Genuine MD Oil Type (Oil for two stroke direct injection engine recommended by the outboard manufacturer) Quantity 6.7 L (1.77 gal) Type...

  • Page 34: Warning Indication List

    Service Data 4. Warning Indication List • • • Display for abnormalities during operation Warning Indicators Speed Control (*1) Buzzer Sounding Indicator A Indicator B Indicator C Continuous High speed ESG Intermittent Flashing (3 beeps for every 2 minutes) Continuous Flashing Low speed ESG Continuous...
  • Page 35 Fault Description Reference Remedy Engine over-rev. Approx. 6,000 r/min Readjust propeller, outboard engine mounting height and/or trim. Approx. 1.4 L Low oil level Replenish engine oil in tank. (0.37 gal) or less Cooling water temp. high 85℃ (185ﾟF) Engine cooling water temp. 90℃...

  • Page 36: Torque Specifications

    Service Data 5. Torque Specifications Temporary Driving Torque Wrench Screw B x Type of Driving Torque Tightening Location Remarks Pitch Fastner N･m lb･ft kg･m N･m lb･ft kg･m Cylinder Head Cover M6 x 1.0 Bolt ①2.0 ④6.0 Driving sequence ①→②→③→④ Cylinder Head Cover & M8 x 1.25 Bolt ②12...
  • Page 37 Temporary Driving Torque Wrench Screw B x Type of Driving Torque Tightening Location Remarks Pitch Fastner N･m lb･ft kg･m N･m lb･ft kg･m Oil Reserve Tank Installation Bolt Oil Reserve Cap Manual Valve Tilt Motor Ass'y Bolt Gear Pump Bolt Trim Rod Guide Tilt Rod Guide 13.0 0.15...

  • Page 38: Maintenance Data

    Service Data 6. Maintenance Data Description Item Standard Values Build up of carbon in combustion chamber 0.03 mm (0.0012in) or less for scratches Distortion or damage on mating surface 0.03 mm (0.0012in) or less for distortion Cylinder Head 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 39 Functional Limit Action To Be Taken Clean and remove build up. Repair by polishing the surface plate, starting with #240 to #400 grit Scratches or deflection of 0.10 mm (0.004 in) sandpaper and finishing with #600 grit sandpaper. Replace if over specified limit. Repair or replace depending on the extent of damage.
  • Page 40 Service Data Description Item Standard Values Air Rail Wear and damage on O-rings 0.55 Mpa (79.6 psi) [5.6 kg/㎠] ±7% Air Regulator Air pressure Measured air pressure + 0.07 Mpa (10.1 psi) [0.71kg/㎠] ±10% Fuel Regulator Fuel pressure Seal ring wear and damage Vapor Separator Float Cylinder bore...
  • Page 41 Functional Limit Action To Be Taken When parts are worn or damaged Replace with new part. When parts no longer conform to standard values Replace with new part. When parts no longer conform to standard values Replace with new part. When parts are worn or damaged Replace with new part.
  • Page 42 Service Data Description Item Standard Values Tilted up : 8.8 - 11.8 MPa (1,281 - 1,707 psi) 　 　　　　　　 [90 - 120 kg/㎠] Relief valve opening pressure Tilted down : 3.9 - 7.4 MPa (569 - 1,067 psi) 　 　　　　　　 [40 - 75kg/㎠] Upper chest: 0.24 MPa (34.1 psi) [2.4 kg/㎠] Pump Assembly...
  • Page 43 Functional Limit Action To Be Taken Replace with new part. When the valve opens even slightly at ambient temperature Check valve opening temperature by immersing the thermostat in Replace with new part. water and gradually increasing water temperature When the tips or upper and lower surface lip areas show wear, Replace with new assembly.

  • Page 44: Sealant And Lubricant

    Service Data 7. Sealant And Lubricant Remarks Konish Three Shinetsu ThreeBond Loctite Chuo Yuka Bond Silicones Applied to Centax 1342 1373B 1741 FM-531 KS-64 (*1) Ring grooves and outer circumference ○ Piston (Piston pin outer circumference) ○ Piston Pin Piston pin holes ○...
  • Page 45 Remarks Konish Three Shinetsu ThreeBond Loctite Chuo Yuka Bond Silicones Applied to Centax 1342 1373B 1741 FM-531 KS-64 (*1) ○ Air Injector O Ring Apply to two O Rings. ○ Air Injector Terminal Terminal section ○ Fuel Injector O Ring Apply to two O Rings.
  • Page 46 Service Data Remarks Konish Three Shinetsu ThreeBond Loctite Chuo Yuka Bond Silicones Applied to Centax 1342 1373B 1741 FM-531 KS-64 (*1) ○ Pinion Gear (B Gear) Nut After degreasing screw section completely ○ Propeller Shaft Housing Inside Propeller Shaft Housing ○...
  • Page 47 Remarks Konish Three Shinetsu ThreeBond Loctite Chuo Yuka Bond Silicones Applied to Centax 1342 1373B 1741 FM-531 KS-64 (*1) Bracket Bolt Fill with grease (○) ○ Stern Bracket Washer Both faces ○ Swivel Bracket Fill interior with grease ○ Steering Shaft Sliding section ○...

  • Page 48: Inspections And Adjustments

    Inspections and Adjustments 1. Special Tool …………………………… 3-2 2) Adjustment of Drive Belt Tension …… 3-15 2. Inspection Schedule ……………… 3-3 3) Inspection of Spark Plugs …………… 3-16 3. Top Cowl ……………………………… 3-4 4) Inspection of Thermostat …………… 3-17 1) Adjustment of Cover Hook…………… 3-4 7.

  • Page 49: Special Tool

    Inspections and Adjustments 1. Special Tool Spring Pin Tool A Spring Pin Tool B 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 TLDI 115A 2007...

  • Page 50: Inspection Schedule

    2. Inspection Schedule Initial 20 50 hours hours or hours or hours or Every 2 Section Inspection Part or Every Inspection Item Remarks initial 1 Every 6 Every years 3 months month months year ○ ○ ○ ○ ○ Fuel Filter Inspection and filter cleaning High Pressure ○...

  • Page 51: Top Cowl

    Inspections and Adjustments 3. Top Cowl 1) Adjustment of Cover Hook Push cover to check for play, and adjust if necessary. Remove cover stay 1 . Add or remove washer(s) 2 for adjustment. CAUTION Remove washer(s) if too much play. Add washer(s) if too much tightening is needed.

  • Page 52: Air Bleeding

    3) 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 bubbles flows out.

  • Page 53: Fuel System

    Inspections and Adjustments 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. TLDI 115A 2007...

  • Page 54: Inspection Of Fuel Filter

    2) Inspection of Fuel Filter Check fuel filter 4 for contamination, and fuel filter cup 5 for invasion of foreign matter and cracks. Clean fuel filter cup with gasoline, and replace fuel filter 4 if necessary. Do not spill fuel when removing fuel filter cup. CAUTION If red float 7 is floating in the filter, water is in the cup.

  • Page 55: Inspection Of Fuel Pressure

    Inspections and Adjustments Set the lever of pressure gauge ass'y to position a. Measure air pressure while idling the engine or cranking for 15 seconds. Air Pressure : Specified Value 0.52 - 0.58 MPa (75.25 - 83.95 psi) [5.2 - 5.8 kgf/cm CAUTION The air pressure reduces gradually after stopping the engine or cranking.

  • Page 56: Cooling System

    Set the lever of pressure gauge ass'y to postion b to relief pressure. CAUTION When depressuring, collect fuel that spills from the tip of the gauge. Remove gauge. CAUTION Be careful not to let the fuel in the gauge leak when removing the gauge. Attach the cap.

  • Page 57: Flushing With Water

    Inspections and Adjustments 2) Flushing with Water WARNING Be careful not to touch rotating propeller. Be sure to remove propeller before running WASH engine on the land. WARNING Exhaust gas contains carbon monoxide which can cause intoxication if inhaled. Do not operated engine in a closed space such as interior of boat house.
  • Page 58 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 59 Inspections and Adjustments Inspection of Water Pump Remove the following part. Drive out spring pin 1 by using spring pin tool 2. Spring Pin Tool A 2: P/N. 369-72217-0 ● Remove gear case ass'y from drive shaft housing. Do not reuse. Remove the following parts.

  • Page 60: Inspection Of Compression Pressure

    3) Inspection of Compression Pressure Start and idle engine for 5 minutes to warm up, and then stop. Shift gear into neutral (N). Remove lock plate (of stop switch lanyard) from stop switch. CAUTION To prevent accidental start of the engine, remove lock plate (of stop switch lanyard) from stop switch before measuring compression pressure.

  • Page 61: Power Unit

    Inspections and Adjustments 6. Power Unit 1) Inspection of Drive Belt Remove ring gear cover. 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 62: Adjustment Of Drive Belt Tension

    2) Adjustment of Drive Belt Tension Loosen compressor securing bolts. While pushing compressor toward cylinder head ( a ), tighten the securing bolts to fix the compressor. Deflection of Belt: 4 - 6 mm (0.16 - 0.24 in) when pushing the belt with 20 N (2.0 kg) .

  • Page 63: Inspection Of Spark Plugs

    Inspections and Adjustments 3) 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 64: Inspection Of Thermostat

    4) Inspection of Thermostat Remove air rail. Loosen cover installation bolts 2, remove them, and then remove cover 1 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 65: Operating System

    Inspections and Adjustments 7. Operating System 1) Adjustment of Throttle Cable Loosen lock nut 1. Remove "R" shaped pin 2 and washer 3. Remove cable joint 4 from advancer arm 5. Bring advancer arm 5 to full close stopper 6. Set remove control lever to throttle full close position 7.

  • Page 66: Adjustment Of Shift Cable

    2) Adjustment of Shift Cable Loosen lock nut 1. Remove "R" shaped pin 2 and washer 3. Remove cable joint 4 from shift lever 5. Set shift lever to neutral position (N). Set remote control lever to neutral position (N). Adjust cable joint screw-in length so that the pin of shift lever is aligned with the hole of cable joint.

  • Page 67: Ptt System

    Inspections and Adjustments 8. PTT System 1) Inspection of PTT Unit Operation Tilt up and down outboard motor several times to check that unit operates smoothly in full range. Check PTT fluid quantity if necessary. Refer to "Inspection of PTT Fluid Quantity".

  • Page 68: Lower Unit

    Replenish to the specified quantity if the fluid lacks. PTT Fluid: ATF DEXRON III PTT Fluid Quantity: 682 cm (23.1 fl.oz) Attach the cap. Reservoir Cap: 7 N · m (5 lb · ft) [0.7 kgf · m] 9. Lower Unit 1) Inspection of Gear Oil Quantity Tilt down outboard motor to make it vertical.

  • Page 69: Replacement Of Gear Oil

    Inspections and Adjustments 2) Replacement of Gear Oil Tilt outboard motor a little as shown. Place drain oil pan below oil plug 1, remove lower oil plug 1 and then upper oil plug 2 to drain oil. Remove lower oil plug first when draining. Check gear oil for presence of metal particles, change of color (abnormal if clouded), and viscosity.

  • Page 70: Inspection Of Gear Case (For Leakage)

    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 71: Others

    Inspections and Adjustments 10. Others 1) Replacement of Anode Dirt on Anode and Trim Tab Check if grease or oil is adhered to the components. Clean if necessary. CAUTION Anode protects outboard motor from galvanic corrosion. Do not paint or apply grease or oil to anode.

  • Page 72: Inspection Of Battery

    2) 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 73: Greasing

    Inspections and Adjustments 3) 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. 3-26 TLDI 115A 2007...

  • Page 74: Fuel System (Tldi

    Fuel System (TLDI) 1. Special Tools ........4-2 7) Assembly of Vapor Separator Ass'y ... 4-29 2. Parts Layout ........4-3 8) Removing FFP Ass'y ......4-29 Vapor Separator & Fuel Line ....4-3 9) Disassembly and Inspection of FFP ... 4-29 FFP Ass'y ..........

  • Page 75: Fuel System (Tldi)

    Fuel System (TLDI) 1. Special Tools Piston Slider Vacuum/Pressure Gauge Driver Rod Oil Seal Attachment P/N. 3AC-99020-0 P/N. 3AC-99702-0 P/N. 3T1-72871-0 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 76: Parts Layout

    P/L Fig. 6 2. Parts Layout Vapor Separator & Fuel Line 1-10 2st OIL 14-3 14-2 14-4 14-5 1-10 14-1 FFP(Lower) FFP(Upper) Cylinder 2st OIL 見出 見出 部 品 名 備 考 部 品 名 備 考 個数 個数 番号 番号 Vapor Separator 14-2 Filter 1-1 Screw 3 M4 L=14mm W/SW 14-3 O-Ring B Do not reuse...

  • Page 77: Ffp Ass'y

    Fuel System (TLDI) FFP Ass'y P/L Fig. 5 15 N·m (11 lb·ft) [1.5 kgf·m] 1-18 1342 1342 3.2 N·m (2.3 lb·ft) [0.32 kgf·m] 2st OIL 1-12 Black 1-17 1-10 1-11 1-11 2st OIL 2st OIL 1-15 1-16 1-14 1-19 1-13 2st OIL Yellow Blue...
  • Page 78 見出 部 品 名 個数 備 考 番号 FFP (Fuel Feed Pump) Ass'y Hose Joint Adapter Metal Washer, 10.2-17-2 Do not reuse Fuel Feed Pump FFP Case FFP Case (Upper) O-Ring, Do not reuse FFP Grommet (Upper) FFP Grommet (Lower) Cable Terminal (Positive) 1-10 Cable Terminal (Negative) 1-11...

  • Page 79: High Pressure Fuel Filter & Air Rail

    Fuel System (TLDI) P/L Fig. 4 High Pressure Fuel Filter & Air Rail 15 N·m (11 lb·ft) [1.5 kgf·m] 2st OIL * Do not overtighten, 24-4 or the part may be S.O.C damaged 24-3 24-2 1342 1342 1342 24-5 24-1 2st OIL S.O.C 18-2...
  • Page 80 見出 部 品 名 個数 備 考 番号 Air Rail L-Nipple Valve Valve Cap ø Plug, 10.5 O-Ring, 1.9-6.8 Do not reuse Plug Stopper Bolt M6 L=12mm W/SW Air Hose I/D=ø4 Liter=115 Fuel regulator - Air rail Clamp, 29/64 Do not reuse Bolt M8 L=65mm Washer Air Injector...

  • Page 81: Air Compressor

    Fuel System (TLDI) P/L Fig. 11 Air Compressor 260 N·m (190 lb·ft) [26 kgf·m] 50 N·m (36 lb·ft) [5 kgf·m] 2st OIL 1-19 1-20 1342 1-18 1342 1342 1-16 1-11 2st OIL 1-10 1-15 6 N·m (4 lb·ft) [0.6 kgf·m] 1-16 2st OIL 1-13...
  • Page 82 見出 部 品 名 個数 備 考 番号 Air Compressor Compressor Head (with Nipple) 1-1-1 Hose Joint Adapter 1-1-2 Metal Washer, 10.2-17-2 Do not reuse Bolt M6 L=35mm W/PW Compressor Head Gasket Do not reuse Reed Valve Ass'y Valve Seat Gasket Do not reuse Piston &...

  • Page 83: Oil Pump

    Fuel System (TLDI) P/L Fig. 12 Oil Pump 10 N·m (7 lb·ft) [1.0 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 10 N·m (7 lb·ft) [1.0 kgf·m] 11 18 (#1 Cylinder) (#4 Air Chamber) (#2 Cylinder) (#3 Air Chamber) (#3 Cylinder) (#2 Air Chamber) (#4 Cylinder) (#1 Air Chamber)
  • Page 84 見出 部 品 名 個数 備 考 番号 Electric Oil Pump Rubber Mount, 12-18-2.5 Spacer, 8.4-12-17 Bolt M8 L=35mm Washer, 8.4-24-1.5 Oil Pomp Bracket Bolt M6 L=30mm W/SW&PW Oil Pipe A Oil tank - Oil filter Oil Pipe B Oil filter - Oil pump Clip, ø9.5 Oil Pipe Oil pump - #1 Air chamber...

  • Page 85: 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 86: 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 87 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 88: 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 89 Fuel System (TLDI) 4-16 TLDI 115A 2007...
  • Page 90 TLDI 115A 2007 4-17...
  • Page 91 Fuel System (TLDI) 4-18 TLDI 115A 2007...

  • Page 92: Removing Air Rail

    4. Removing Air Rail 1) Decompression of Fuel Line and Air Line Decompress fuel line and air line before removing the air rail. Push in the air valve 2 attached to air rail 1 to decompress the air line. Push in the fuel valve 3 attached to air rail 1 to decompress the fuel line.
  • Page 93 Fuel System (TLDI) Loosen three bolts 8 that secure air rail, and remove air rail ass'y 9 carefully. Disconnect fuel injector cord wires before removing the air rail. Refer to "Chapter 5 Removing Cord Ass'y. When removing the air rail, leave the air injectors on the cylinder side.

  • Page 94: Assembling Air Rail

    5. Assembling Air Rail 1) Installing Injectors and Regulators Use O ring set tool to attach O rings 2 and 3 to fuel injector 1. O Ring Set Tool : P/N. 3T5-72863-0 CAUTION 2st OIL To avoid incorrect installation of the fuel injectors, check the marking "37001 (37003)"...
  • Page 95 Fuel System (TLDI) Attach compression seal w to fuel injector insert q, and then, attach the assembly to the air rail. Attach the insert q in a correct orientation shown by arrow A. Attach fuel injector adapter e and fuel injector 1 to the air View from Arrow A rail.
  • Page 96 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. Be sure to install collar 4 below plate 5. Attach hose to fuel regulator by using hose clamp Do not reuse hose clamp.
  • Page 97 Fuel System (TLDI) Attach the following parts. Attach air hose ass'y using collar 2, nipple plate 3 and bolt 4 in this order. Arrange the pipes as shown. Attach air hose ass'y 1 to air compressor hose joint adapter with fasteners tightened to specified torque.

  • Page 98: Removing Fuel System

    6. Removing Fuel System 1) Removing Fuel Hose Ass'y Remove following parts. Remove fuel hose ass'y 1 after loosening joint between FFP 5 and air rail 6. Remove high pressure fuel filter 3 from mounting bolt 4 and exhaust cover. Use rag to catch fuel that spills from the parts 5 and 6 when they are removed.

  • Page 99: 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 100: 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 101: Assembly Of Vapor Separator

    Fuel System (TLDI) 6) Assembly of Vapor Separator Assemble following parts. 1 Float Valve 2 Float 3 Float Arm Pin 4 Tighten screw. Screw 4 : 1.6 N·m (1.1 lb·ft) [0.16 kgf·m] 5 Drain Screws : Tighten two screws. 6 O Rings : 2 pcs.

  • Page 102: Assembly Of Vapor Separator Ass'y

    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

    Fuel System (TLDI) 10) Assembly of FFP Ass'y Assemble following parts. Attach hose joint adapter 8 and metal washer 9 to upper 1342 1342 1342 case 0. Hose Joint Adapter 8 : 14 - 16 N·m (10 - 12 lb·ft) [1.4 - 1.6 kgf·m] Degrease edge and then apply adhesive 8 : ThreeBond 1342 1342...
  • Page 104 Attach upper grommet e and cable terminal grommets 3. Terminal area of parts 3, 7 and e : Genuine Engine Oil Attach black wire 7 ( - ) and red wire 7 ( + ) of cable 2st OIL terminal to FFP case. Be sure to connect the wires to their 2st OIL corresponding flat terminals ( - and + ).

  • Page 105: Attaching Ffp Ass'y To Cylinder

    Fuel System (TLDI) 11) Attaching FFP Ass'y to Cylinder Attach FFP Ass'y 1 by using bolt 2. Bolt 2 : 6 N·m (4 lb·ft) [0.6 kgf·m] Put fuel hose 3, fuel return hose 4 and vapor return hose 5 and secure them by using hose clips. Attach high pressure fuel hose 6 to FFP 1.

  • Page 106: Inspection Of Fuel Pump

    12) Inspection of Fuel Pump Remove fuel hoses (2) from fuel pump. CAUTION Catch fuel that spills when the hoses are removed. Connect vacuum/pressure gauge to inlet of fuel pump. Close fuel pump outlet with a finger and apply specified pressure.
  • Page 107 Fuel System (TLDI) 4-34 TLDI 115A 2007...

  • Page 108: Structure Of Air Compressor

    Structure of Air Compressor TLDI 115A 2007 4-35...

  • Page 109: Removing Air Compressor

    Fuel System (TLDI) 7. Removing 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 110: Inspection Of Drive Belt

    3) Inspection of Drive Belt Check drive belt for crack, damage and wear on both faces. 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.

  • Page 111: Removing Driven Pulley

    Fuel System (TLDI) 4) Removing Driven Pulley Remove compressor cylinder. 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.

  • Page 112: Disassembly Of Compressor Housing

    5) Disassembly of Compressor Housing Remove oil seal 1 and bearing 2. Heat compressor housing to 60 to 70 degrees Centigrade (140 to 158 degrees Fahrenheit) by using hot water before removing bearing 2. CAUTION Do not reuse removed bearing. Heating of compressor housing can also be made by using a heat gun or heat lamp.

  • Page 113: Assembly Of Compressor Housing

    Fuel System (TLDI) 8) Assembly of Compressor Housing Apply two stroke engine oil to periphery of bearing 3, and install it into compressor housing by using a press. Driver Rod 1 : P/N. 3AC-99702-0 Bearing Attachment 2 : 2st OIL P/N.

  • Page 114: Installation Of Crank Shaft

    9) Installation of Crank Shaft Install crank shaft 1 to the housing, and fix the crank shaft at its lower end by using a vice. Attach collar 3, O ring 4, and driven pulley 5, and tighten nut 6 to the specified torque. 2st OIL Driven Pulley Nut 6 50N·m (36 lb·ft) [5.0kgf·m]...

  • Page 115: Installation Of Piston

    Fuel System (TLDI) 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 116: Installation Of Compressor Housing Ass'y

    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 117: Measurement Of Fuel Pressure And Air Pressure

    Fuel System (TLDI) 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 4-44...
  • Page 118 How to Use Pressure Gauge Pressure Gauge Ass'y Measurement of Fuel Pressure and Air Pressure 1. Set the lever of cock (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 119: Inspection Of Oil Filter

    Fuel System (TLDI) 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 120: Air Bleeding

    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 121 Fuel System (TLDI) 4-48 TLDI 115A 2007...
  • Page 122 TLDI 115A 2007 4-49...

  • Page 123: Power Unit

    Power Unit 1. Special tools ………………………… 5-2 10) Inspection of Cylinder Head ……… 5-32 2. Parts Layout ………………………… 5-3 11) Removing Exhaust Cover ………… 5-33 Engine …………………………………… 5-3 12) Inspection of Exhaust Cover ……… 5-33 Magneto…………………………………… 5-4 13) Removing Crank Case …………… 5-34 Electric Parts………………………………...

  • Page 124: Special Tools

    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 Removing or attaching piston Used in combination with center Removing reverse (C) gear Used to press-fit crank case rings place and various attachments...

  • Page 125: Parts Layout

    2. Parts Layout Engine 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 115A 2007...

  • Page 126: Magneto

    Power Unit Magneto P/L Fig. 8 260 N·m (190 lb·ft) [26 kgf·m] Fig.11-4 6 N·m (4 lb·ft) [0.6 kgf·m] Air Compressor Circumference 2st OIL 2st OIL 2st OIL TLDI 115A 2007...
  • Page 127 Ref. Description Q'ty Remarks Flywheel Alternator Bolt M6 L=35mm W/PW Pick-UP Coil Crank position sensor Bolt M5 L=12mm W/SW Coil Bracket Ass'y with Oil seal Oil Seal, 35-58-9 Do not reuse. O-Ring, 2.4-59.6 Do not reuse. Bolt M6 L=20mm W/PW Oil Pipe Compressor - Coil bracket Clip, ø6.9...

  • Page 128: Electric Parts (Starter Motor)

    Power Unit Electric Parts P/L Fig. 9 6 N·m (4 lb·ft) [0.6 kgf·m] 22 N·m (16 lb·ft) [2.2 kgf·m] Compressor 10-1 Air Rail Starter Solenoid Switch Rectifier Solenoid Switch IG#1 FI#1 FI#2 IG#1 AI#1 10-1 IG#2 FI#3 AI#2 Cylinder IG#3 AI#3 FI#4 Chamber...
  • Page 129 Ref. Description Q'ty Remarks Bolt M6 L=30mm W/SW Washer, 6.5-21-1 Rubber Mount, 8.5-14-2.5 Rubber Mount, 8.5-14-2.5 Spacer, 6.2-9-16.6 Ignition Coil, # 1 Plug Cap (with Resistance) Ignition Coil, # 2 & # 3 & # 4 Bolt M6 L=35mm W/SW&PW Water Temperature Sensor 10-1 O-Ring, 2-10...
  • Page 130 Power Unit Electric Parts (Starter Motor) P/L Fig. 10 6 N·m (4 lb·ft) [0.6 kgf·m] Air Chamber Starter Solenoid 13 N·m (9 lb·ft) [1.3 kgf·m] Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Starter Motor 12 Starter Motor Band 1-1 Positive Brush (+) 13 Bolt M8 L=40mm W/PW 1-2 Negative Brush (-)
  • Page 131 Air Chamber P/L Fig. 3 Fig.1-1 9 N·m (7 lb·ft) [0.9 kgf·m] 1342 1342 1342 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 Ref. Description Remarks Q'ty Air Chamber Intake Manifold Gasket Do not reuse. Bolt, 6-35 Pre-coated 16 M6 L=35mm Air Chamber Cover Air Chamber Cover Gasket Do not reuse.

  • Page 132: Throttle

    Power Unit Throttle P/L Fig. 7 15 N·m (11 lb·ft) [1.5 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 Vapor Separator Motor Bracket 23-1 15 N·m (11 lb·ft) [1.5 kgf·m] 1342 1342 1342 (When reusing the part) 1342 1342 5-10 TLDI 115A 2007...
  • Page 133 Ref. Description Q'ty Remarks Advancer Arm Bolt M8 L=35mm W/SW Washer, 8.5-24-1.5 Bushing, 12-14-15.5 Washer, 12.5-24-1 Collar, 8.4-12-17 Bolt M6 L=12mm Collar, 6.2-9-3 Rod Snap, 5-3 Throttle Link Rod Old Part No. 3T9-63716-0 TPS Link Rod Cable Joint Washer, 8.5-18-1.6 or 353-83719-0 Snap Pin, d=8 Throttle Body...

  • Page 134: Cylinder Crank Case

    Power Unit Cylinder Crank Case P/L Fig. 1 1 M6 2.0 N·m (1.4 lb·ft) [2.0 kgf·m] 2st OIL 2 M8 12 N·m ( 9 lb·ft) [1.2 kgf·m] 3 M8 32 N·m ( 23 lb·ft) [3.2 kgf·m] 4 M6 6 N·m ( 4 lb·ft) [0.6 kgf·m] Fig.12 Oil Pump Fig.3...
  • Page 135 Ref. Description Q'ty Remarks Cylinder-Crank Case Stud Bolt M10 L=65mm Nut, 10-P1.25 M10 P=1.25mm Bolt M10 L=65mm Washer, 10.5-20-3.2 Bolt M8 L=50mm Bolt M8 L=65mm Bolt M8 L=40mm Washer, 8.5-19.5-3.2 Dowel Pin, 6-12 1-10 Main Bearing Dowel Pin 1-11 Main Bearing Dowel Pin 1-12 Stud Bolt M10 L=55mm...

  • Page 136: Piston & Crank Shaft

    Power Unit Piston & Crank Shaft P/L Fig. 2 2st OIL Piston Pin Hole Inner Face 2st OIL Molybdenum Bearing 2st OIL 2st OIL 2st OIL Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Crank Shaft Ass'y Piston (STD) 1-1 Spacer, 40-52-7 Piston (0.5mm O/S) Option 1-2 Washer, 66-85-2...

  • Page 137: Inspection Items

    3. Inspection Items 1) Removing Power Unit Remove ring gear cover. Disconnect battery cables from battery terminal. Remove clamps that secure shift cable and remote control cable from bottom cowl. Remove bracket cover, and then, remove battery cables 1 and PTT cable 2 from solenoid switch and other parts. Disconnect connector 3 of PTT switch.
  • Page 138 Power Unit Disconnect earth wire 4 located below electric oil pump. Disconnect remote control harness connectors 5. Remove "R" shaped pins and then throttle cable 6 and shift cable 7. Remove shift assist ass’y 8 from shift arm. Be careful not to lose washers that are removed together with cables.
  • Page 139 Disconnect hose 0 for flushing device located on the port side of bottom cowl. Disconnect fuel hose q from fuel filter. Remove apron w. Loosen engine mount bolts and then remove them. TLDI 115A 2007 5-17...
  • Page 140 Power Unit Hoist power unit by using eye bolt e. Eye Bolt e : P/N. 3T1-72212-0 Hoist power unit taking care not to catch wires and hoses. Remove 2-carank case bolts. Remove crank case head 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 141: Removing Flywheel

    2) Removing Flywheel Attach flywheel puller kit to flywheel. Fix flywheel puller, and loosen drive pulley (Magneto nut) and remove it. Drive pulley (Magneto nut) is threaded right- hand. Remove magneto by using pressing bolt. Turn center bolt clockwise to remove flywheel. TLDI 115A 2007 5-19...

  • Page 142: Removing Stator Coil

    Power Unit 3) Removing Stator Coil Remove oil tank installation bolt (upper one) and move oil tank a little. Disconnect CPS connector that is located in the back of oil tank. Disconnect alternator connectors. Loosen alternator securing bolts and remove alternator. Loosen coil bracket securing bolts and remove bracket.

  • Page 143: Removing Cord Ass'y

    4) 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. Disconnect fuel injector connector while pushing hook of the connector.
  • Page 144 Power Unit Disconnect FFP connector while pushing hook of the connector. Disconnect TPS connectors while pushing hook of the connector. Connector on the front → Blue Connector in the back → Gray Disconnect MAP and MAT sensor connector while pushing hook of the connector. Disconnect rectifier connector while pushing lock of the connector.
  • Page 145 Disconnect ignition coil connector while pulling lock of the connector. Repeat this step for four cylinders. Removing Ignition Coils Loosen mounting bolt of ignition coils #1, #2, #3 and #4, and remove the coils. Earth wire of cord ass’y and other wires are secured together by #1 coil upper bolts.

  • Page 146: Removing Throttle Link

    Power Unit 5) Removing Throttle Link Remove throttle link rod 1 and TPS link rod 2. Remove each link rod at the advancer arm side 3 first. When removing each link rod at the ball joint side, be careful not to apply force to the arm. Remove throttle position sensor’s lower mounting screw.

  • Page 147: Removing Air Chamber

    6) Removing Air Chamber Loosen air chamber cover mounting bolts in the order shown, remove them, and remove air chamber cover. When air chamber cover is removed, the oil collected in the cover may flow out. Use rag to catch the oil. Loosen throttle body mounting bolt and remove the throttle body.

  • Page 148: Inspection Of Throttle Body

    Power Unit 7) Inspection of Throttle Body Check throttle body for wear of throttle cam and cam roller, and check if throttle cam and roller move smoothly. Do not move adjust screw located on the upper part of throttle body. Loosen air chamber mounting bolts in the order shown, remove them, and remove air chamber.
  • Page 149 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 9.2 - 9.4 mm (0.362 - 0.370 in) Reed Valve Bend a : 0.2 mm (0.008 in)

  • Page 150: Exploded Diagram Of Short Block

    Power Unit Exploded Diagram of Short Block 5-28 TLDI 115A 2007...

  • Page 151: Exploded Diagram Of Piston-Crank Shaft Assembly

    Exploded Diagram of Piston-Crank Shaft Assembly TLDI 115A 2007 5-29...

  • Page 152: Removing Thermostat

    Power Unit 8) Removing Thermostat Loosen thermostat cap mounting bolts 2, remove them, remove cap 1 , and take out thermostat 3. If thermostat cap is seized, tap lightly using a plastic hammer and then remove. Inspection of Thermostat 1) Put thermostat in the vessel containing water, heat it, and measure the temperature at which the thermostat starts to open.

  • Page 153: Removing Cylinder Head / Head Cover

    9) Removing Cylinder Head / Head Cover 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 154: Inspection Of Cylinder Head

    Power Unit 10) Inspection of Cylinder Head Remove carbon deposit in the combustion chamber of cylinder head, and check the interior for degradation, damage and other defects. Check water jacket interior for deposits. When cleaning mating surfaces of cylinder head by using a means such as a scraper or wire brush, be careful not to scratch the surfaces.

  • Page 155: Removing Exhaust Cover

    11) Removing Exhaust Cover Loosen exhaust cover mounting bolts in the order shown, remove them, and remove exhaust cover. Loosen the bolts in descending order of the numbers embossed on the exhaust cover. Pry the gap of the cover at five grooves one by one by using a bladed screw driver.

  • Page 156: Removing Crank Case

    Power Unit 13) Removing Crank Case Loosen crank case mounting bolts in the order shown, remove them, and remove crank case. 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.

  • Page 157: Removing Pistons

    14) Removing Pistons Remove piston pin clip by using a pair of pointed nose pliers. Remove another piston pin clip. Be careful not to damage the piston pin hole. Remove piston pin 1. Use piston pin tool if the pin cannot be removed with the pliers.

  • Page 158: Disassembly Of Crank Shaft

    Power Unit 15) Disassembly of Crank Shaft 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 : 16) Inspection of Crank Shaft Visually check crank shaft ass’y upper and lower end...
  • Page 159 · Check if that main bearing rotates smoothly. Replace crank shaft ass’y if necessary. · Measure crank shaft deflection. Replace crank shaft if the deflection is over the specified value. Dial Gauge 1 : Commercially Available Item V Block 2 : Commercially Available Item Crank Shaft Deflection Limit : 0.05 mm (0.0020 in) Replace crank shaft ass’y if the deflection is over the...

  • Page 160: Inspection Of Engine Parts

    Power Unit 17) Inspection of Engine Parts Inspection of Cylinder ) at a, b and c. 1) Measure cylinder inner diameters (D If any of the diameter is over the limit, replace the cylinder or bore the liner to make it compatible with an oversize piston. Cylinder Inner Diameters (D ) : Standard Value 88.02 mm (3.4654 in)

  • Page 161: Inspection Of Pistons

    18) Inspection of Pistons Inspection of Piston Outer Diameter Measure piston outer diameter, and replace the piston if the outer diameter is less than the functional Limit. Measurement Point b : 11.5 mm (0.45 in) above bottom end of piston skirt. approximately 90 degrees from pin hole.
  • Page 162 Power Unit Inspection of Piston Ring Side Clearance 1) Attach a piston ring to piston, and measure piston ring side clearance. Replace piston ring if the clearance is over specified value. Piston Ring Tool : P/N. 353-72249-0 Piston Ring Side Clearance : Standard Value : Top Ring 0.04 - 0.08 mm...
  • Page 163 Inspection of Piston Pins Measure piston pin outer diameter, and replace piston pin if the outer diameter is over the limit. Piston Pin Outer Diameter : Standard Value 23.00 mm (0.9056 in) Functional Limit : 22.97 mm (0.9045 in) Measuring Locations : and D 10 mm (0.394 in) from top end and bottom end respectively...

  • Page 164: Assembling Crank Shaft

    Power Unit 19) Assembling 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 : Inner Diameter: ø45 mm (1.575 in) Do not reuse removed bearing.

  • Page 165: Installing Pistons

    20) Installing Pistons Installation of Piston Rings Complete 3rd piston 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 connecting rod by using piston pin. "UP"...

  • Page 166: Assembling Power Unit Parts

    Power Unit 21) Assembling Power Unit Parts Install main bearing (upper) 1 to crank shaft ass’y. Face the marking on the bearing to flywheel side. Install crank shaft ass'y to cylinder. Apply genuine engine oil to the following parts before assembling them.
  • Page 167 Repositioning Crank Shaft Ass’y Reposition crank shaft ass’y attached to cylinder by bringing main bearing holes 1 to cylinder dowel pins 2. Attempt to move main bearing and upper bearing lightly to check that dowel pins are in the bearing holes snugly. Positioning Upper Bearing and Main Bearing Bring knock hole of each bearing to dowel pin of cylinder’s journal areas.

  • Page 168: Assembling Crank Case Halves

    Power Unit 22) Assembling Crank Case Halves Degrease crank case and cylinder mating faces. Apply sealing agent to crank case’s mating surface. Crank Case Mating Surface : Loctite #518 Be careful not to allow sealing agent to squeeze out. Apply sealing agent on the area inside of the bolt holes continuously in width of approximately 1 mm as shown.

  • Page 169: Assembling Exhaust Cover Parts

    23) Assembling Exhaust Cover Parts Assemble exhaust cover (inner), exhaust cover (outer) 1-10 and gaskets. 1-11 1-12 1-11 1-12 1-12 1-11 Attach exhaust cover securing bolts and tighten them in the order of their numbers shown to specified torque in two steps. Temporary Tightening : 12 N ·...
  • Page 170 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 171: Assembling Cylinder Head Parts

    24) Assembling Cylinder Head Parts Attach anode 1 to cylinder. Attach dowel pins to cylinder head, and then attach gaskets and cylinder head cover. Tighten cylinder cover securing bolts (M6) the order of the numbers shown. Temporary Tightening : 1-10 2.0 N ·...

  • Page 172: Assembling Coil Bracket Parts

    Power Unit Install thermostat, thermo-cap and gasket. Final Tightening : 6 N · m (4 lb · ft) [0.6 kgf · m] Tighten head cover bolts M6 after tightening bolts M8. Never tighten bolts M6 before tightening bolts M8. 25) Assembling Coil Bracket Parts Apply grease and oil to oil seal and press-fit it to coil bracket.

  • Page 173: Installing Air Chamber

    27) Installing Air Chamber Attach reed valve, air chamber and gaskets to crank case. Attach and tighten securing bolts (M6) to specified torque in the order of the numbers shown. 1342 1342 Bolts (M6) 1342 9 N · m (7 lb · ft) [0.9 kgf · m] Use new gaskets.
  • Page 174 Power Unit · Apply LIT grease to sliding faces of throttle cam and roller. · Apply ThreeBond 1342 to throttle body securing bolts. 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 175: Attaching Coil Bracket

    28) Attaching Coil Bracket Attach O ring and coil bracket to cylinder ass’y and secure them with bolts. Coil Bracket Bolt 1 : 6 N · m (4 lb · ft) [0.6 kgf · m] Be sure to check that O ring is set properly. 2st OIL TLDI 115A 2007 5-53...

  • Page 176: Attaching Recirculation Hoses

    Power Unit 29) Attaching Recirculation Hoses Pipe, 4-8 Line Check Valve #2 Crank Case (Upper) Air Chamber 280 mm (11 in) Line Check Valve #3 Crank Case (Lower) Lower Bearing 300 mm (11.8 in) Line Check Valve #1 Cylinder Liner #4 Cylinder Exhaust Passage 480 mm...

  • Page 177: Installing Alternator

    30) Installing Alternator Tighten alternator securing bolts to specified torque. Alternator Securing Bolts : 6 N · m (4 lb · ft) [0.6 kgf · m] 31) Installing Flywheel Attach key, flywheel and drive pulley to crank shaft, and tighten the nut to specified torque. Flywheel Puller Kit : P/N.

  • Page 178: Installing Power Unit

    Power Unit 32) Installing Power Unit Attach O ring coated with two stroke engine oil to crank case head. Attach crank case head to cylinder ass’y taking care of the orientation. ''F'' Install crank case head so that the mark "F" is at front side (crank case side) of engine.

  • Page 179: Lower Unit

    Lower Unit 1. Special tools ………………………… 6-2 19) Disassembly of Forward Gear (A) Gear … 6-24 2. Parts Layout ………………………… 6-4 20) Inspection of Forward (A) Gear …… 6-24 Gear Case (Drive Shaft) ………………… 6-4 21) Assembly of Forward (A) Gear Parts … 6-25 Gear Case (Propeller Shaft) ……………...
  • Page 180 Lower Unit 1. Special tools Thickness Gauge Propeller Shaft Housing Puller Ass'y Spring Pin Tool A Spring Pin Tool B 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 Slide Hammer Kit...
  • Page 181 3B7-72731-0 3B7-72732-0 3B7-72733-0 Bevel Gear Bearing Install Tool Backlash Measuring Tool Clamp Dial Gauge Plate Bearing Outer Press Kit P/N. 3B7-72719-0 P/N. 3B7-72720-0 P/N. 3B7-72729-0 P/N. 3B7-72739-0 Installing forward (A) gear Used to attach dial gauge Attaching forward (A) gear Measuring backlash bearing when measuring backlash...

  • Page 182: Lower Unit

    Lower Unit P/L Fig. 14 2. Parts Layout Gear Case (Drive Shaft) Inner Face Apply thinly on GEAR GEAR GEAR the interior face. GEAR GEAR GEAR Circumference Circumference Fig.16-1 GEAR GEAR GEAR Circumference GEAR GEAR GEAR 40 N·m (29 lb·ft) [4.0 kgf·m] 11-2 1342 1342...
  • Page 183 Ref. Description Q'ty Remarks Gear Case Needle Bearing, 28.6-38.1-31.8 Do not reuse. Bolt M8 L=35mm Washer Bolt, 10-40 M10 L=40mm Washer M10 L=40mm Oil Plug Gasket, 8.1-15-1 Do not reuse. Gear Case Plate Gear Case Plate Plug Screw M6 L=14mm Water Strainer Set 11-1 Screw...

  • Page 184: Gear Case (Propeller Shaft)

    Lower Unit P/L Fig. 15 Gear Case (Propeller Shaft) Screw section Fig.14-1 25 N·m (18 lb·ft) [2.5 kgf·m] When reusing the part 1342 1342 GEAR GEAR GEAR 22-1-1 22-1 Circumference GEAR GEAR GEAR 12 N·m (9 lb·ft) [1.2 kgf·m] 1342 1342 1342 GEAR...
  • Page 185 Ref. Description Q'ty Remarks Forward Gear (A gear) Needle Bearing, 25-32-26 Do not reuse. Bearing, 30209 Do not reuse. Shim, 47-57-0.15 Selection if necessary Shim, 47-57-0.1 Propeller Shaft Clutch Clutch Pin Clutch Pin Snap Do not reuse. Clutch Push Rod Steel Ball, 9/16 Clutch Spring Retainer Clutch Spring...

  • Page 186: 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 187: Removing Lower Unit

    3) Removing Lower Unit Shift the gear into forward (F) to set shift rod to upper position. Remove spring pin and disconnect shift rod. · Disconnect shift rod at upper side of shift rod joint 1. · Use spring pin tool A 2 to remove spring pin. ·...

  • Page 188: Removing Water Pump

    Lower Unit 4) Removing Water Pump Loosen and remove pump case (upper) bolts, and remove pump case (upper) parts 1, 2, 3 and 4 in this order. 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.

  • Page 189: Inspection Of Water Pump

    5) Inspection of Water Pump Check pump case liner and guide plate for deformation and wear. Replace if necessary. Check pump impeller for crack, damage and wear. Replace if necessary. · The impeller may show gloss or have melted area if it is rotated with insufficient water. ·...

  • Page 190: Disassembly Of Water Pump Case (Lower)

    Lower Unit 6) Disassembly of Water Pump Case (Lower) Use bladed screw driver or seal remover to remove oil seal 1. Two oil seals are used. Note that there is a shim in between oil seals. 7) 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.

  • Page 191: Removing Propeller Shaft Housing Ass'y

    8) 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 Housing Puller Ass'y 2 : P/N.

  • Page 192: Disassembly Of Propeller Shaft Housing Ass'y

    Lower Unit 9) Disassembly of Propeller Shaft Housing Ass'y Pull out propeller shaft ass'y 1. − screw drivers 3. Remove reverse (C) gear by using Remove bearing 4. 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 193: Inspection Of Propeller Shaft Housing

    10) Inspection of Propeller Shaft Housing Clean the part by using a solvent and then check. Replace if necessary. Check reverse (C) gear for crack or abnormal wear of the teeth and dog. Replace if necessary. Check bearing for abnormality. Replace if necessary.

  • Page 194: Assembly Of Propeller Shaft Housing

    Lower Unit 11) Assembly of Propeller Shaft Housing Use a press to push new needle bearing 4 into propeller shaft bearing to specified depth. · Install needle bearing with the manufacturer's a facing the tool side. mark · Screw in needle bearing attachment 2 lightly by a hand so that no gap is made at driver rod ·...
  • Page 195 Install oil seal 5. Use a press to install new oil seal to propeller shaft housing. · Install oil seal with the marking facing tool side. · Clean oil seal installation face and apply gear oil before installation. · Apply grease to lip of oil seal after installing it. Driver Rod 1 : P/N.
  • Page 196 Lower Unit 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 7 Bearing Do not reuse.

  • Page 197: Disassembly Of Propeller Shaft Ass'y

    12) Disassembly of Propeller Shaft Ass'y Remove push rod 1 and steel ball 2. 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 198: Inspection Of Propeller Shaft Ass'y

    Lower Unit 13) 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 199: Disassembly Of Cam Rod

    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 200: Inspection Of Clutch Cam

    Lower Unit 16) Inspection of Clutch Cam Check the part for wear and damage. Replace if necessary. Check especially for wear on the face a that scrapes against push rod and flaws on the circumference b. 17) Assembly of Clutch Cam Parts Attach O rings 1.9-6.8 2 and O ring 3.5-27.7 3 to cam rod bushing 1.

  • Page 201: Removing Forward (A) Gear Ass'y

    18) Removing Forward (A) Gear Ass'y Take out bearing 1 and forward (A) gear 2 by using a hand put in the gear case. · Put mid finger into forward (A) gear hole and take it between the finger and the first finger (thumb), and lift the thumb side of the gear to remove it.

  • Page 202: Disassembly Of Forward Gear (A) Gear

    Lower Unit 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.

  • Page 203: Assembly Of Forward (A) Gear Parts

    21) Assembly of Forward (A) Gear Parts Install needle bearing 1. Apply gear oil to press-fit face when press-fitting needle bearing. Needle Bearing Attachment 2 : P/N. 3T1-99710-0 GEAR GEAR GEAR Driver Rod 3 : P/N. 3AC-99702-0 CAUTION When press-fitting needle bearing, face the marking side to tool side.

  • Page 204: Removing Drive Shaft Ass'y

    Lower Unit 22) Removing Drive Shaft Ass'y Remove pinion (B) gear nut 4, and then, remove pinion (B) gear 3 and drive shaft. Drive Shaft Socket 1 : P/N. 3B7-72232-0 Bevel Gear B Nut Wrench 2 : P/N. 3B7-72231-0 · Degrease pinion (B) gear nut completely so that the nut wrench does not slip on the nut.

  • Page 205: Disassembly Of Drive Shaft Ass'y

    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. · Check bearing for play or deflection before removing, and replace if necessary.

  • Page 206: Inspection Of Drive Shaft

    Lower Unit 24) Inspection of Drive Shaft Check drive shaft for bend and wear. Replace if necessary. Measure drive shaft runout. Runout Limit : 0.3 mm (0.012 in) a Supporting Points 25) Assembly of Drive Shaft Parts Attach pinion (B) gear nut 1 to drive shaft temporarily. Install bearing 1 by using press.
  • Page 207 Attach drive shaft spring 3. CAUTION When attaching the spring, face the side b toward pinion (B) gear side. Refer to "Chapter 6 Shim Adjustment". TLDI 115A 2007 6-29...

  • Page 208: Disassembly Of Gear Case

    Lower Unit 26) Disassembly of Gear Case Remove needle bearing 1 by using the following tools. Needle Bearing Press Kit : P/N. 3C7-72900-1 Bearing Outer Press Guide 2 : P/N. 3C7-72765-0 Needle Bearing Press Rod 3 : P/N. 3C7-72767-0 Needle Bearing Press 4 : P/N.

  • Page 209: Inspection Of Forward (A) Gear And Pinion (B) Gear

    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. Slide Hammer Kit : P/N.

  • Page 210: Assembly Of Gear Case Parts

    Lower Unit 29) Assembly of Gear Case Parts Use the following tools to install taper roller bearing 1 outer race. Bearing Outer Press Kit : P/N. 3B7-72739-0 Bearing Outer Press Plate 2 : P/N. 3B7-72732-0 Bearing Outer Press Guide 3 : P/N.
  • Page 211 Install needle bearing by using the following tools. Needle Bearing Press Kit : P/N. 3C7-72900-1 Bearing Outer Press Guide 2 : P/N. 3C7-72765-0 Needle Bearing Press Rod 3 : P/N. 3C7-72767-0 Needle Bearing Press 4 : P/N. 3C7-72770-0 O Ring 5 : P/N.

  • Page 212: Assembly Of Lower Unit Parts

    Lower Unit 30) 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 gear case groove b. Inner face 1342 1342...
  • Page 213 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 214 Lower Unit Attach O ring w to pump case (lower) q and install pump case (lower) to gear case. Apply OBM grease to O ring. Put dowel pin e on the pump case (lower) q, and attach pump case guide plate gasket r and pump case guide plate t.

  • Page 215: Attaching Clutch Cam Ass'y

    31) Attaching Clutch Cam Ass'y Install clutch cam ass'y 1. Apply OBM grease to O ring of clutch cam ass'y, and install the assembly by pushing cam rod bushing into gear case. Be careful of direction of clutch cam. Attach stopper 2 and bolt 3. Forward Direction Attach O ring 2 to propeller shaft housing 1.

  • Page 216: Installation Of Lower Unit

    Lower Unit 32) Installation of Lower Unit Set shift rod 1 to up position. · Apply thin coat of OBM grease to spline of drive shaft before assembling. · Apply thin coat of OBM grease to water pipe seal rubber. ·...
  • Page 217 Connect shift rod joint 1 and shift rod 2, and drive in spring pin 3. Spring Pin Tool B 4 : P/N. 369-72218-0 Do not reuse spring pin. Replace with new one when removed. 3 Spring Pin Do not reuse. Attach propeller and tighten propeller nut 2 to specified torque.

  • Page 218: Measurement Of Pinion (B) Gear Height And Shim Selection

    Lower Unit 33) Measurement of Pinion (B) Gear Height and Shim Selection Before measuring back lash of each gear, measure drive shaft pinion (B) gear height and adjust the height to proper value if necessary. In accordance with procedure described in "Assembly of Lower Unit"...
  • Page 219 This work can be made easier when the opening of gear case of propeller shaft side is faced upward and fixed horizontally with a holder. Put a shimming gauge 1 into gear case, and measure gap a between shimming gauge 1 and pinion (B) gear 2. Thickness gauge measures the gap between shimming gauge 1 and pinion (B) gear end.

  • Page 220: Pinion (B) Gears And Shim Selection

    Lower Unit 34) 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 221 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˚). Tighten the nut to secure the plate so that the shaft 2 will not move even if drive shaft is turned. ·...
  • Page 222 Lower Unit Attach backlash measuring tool clamp w to drive shaft. Turn drive shaft 9 clockwise / counterclockwise slowly while pulling it up, and read change of dial gauge e indication. 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 223: Reverse (C) Gears And Shim Selection

    35) 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 224 Lower Unit Fix shaft 6 at the tip by using a tool, finger-tighten nut 3, and then additionally tighten 1/4 of a turn (90˚) by using a tool. 90° 6-46 TLDI 115A 2007...
  • Page 225 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. 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 226: Measurement Of Propeller Shaft Play And Selection Of Washer Thickness

    Lower Unit 36) Measurement of Propeller Shaft Play and Selection of Washer Thickness CAUTION Before measuring propeller shaft play, adjust backlash between forward (A) and pinion (B) gears and reverse (C) and pinion (B) gears. Refer to "Measurement of Backlash between Forward (A) and Pinion (B) Gears and Shim Selection"...

  • Page 227: Cowl, Bracket And Ptt

    Cowl, Bracket and PTT 1. Special tools ………………………… 7-2 10) Removing Steering Shaft Arm …… 7-24 2. Parts Layout ………………………… 7-3 11) Removing PTT Unit ………………… 7-25 Cowl ……………………………………… 7-3 12) Removing Clamp Bracket ………… 7-27 Bottom Cowl ……………………………… 7-4 13) Assembling Clamp Bracket Parts……...

  • Page 228: Special Tools

    Cowl, Bracket and PTT 1. Special tools 1：Trim Rod Guide Wrench P/N. 3B7-72792 2：Trim Rod Guide Wrench P/N. 3C8-72791 Removing or attaching PTT piston rod ass'y TLDI 115A 2007...

  • Page 229: Parts Layout

    P/L Fig. 20 2. Parts Layout Cowl 1-10 1-11 1-12 1-16 1-18 1-11 1-12 1-13 1-15 1-14 1-17 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Top Cowl UNIQUE 1-10 Tilt Handle 1-1 Top Cowl Seal 1-11 Washer, 6-16-1.5 1-2 Cover Stay Ass'y 1-12 Nylon Nut 1-3 Roller, 6.1-14.7-14 1-13 Grommet...

  • Page 230: Bottom Cowl

    Cowl, Bracket and PTT Bottom Cowl P/L Fig. 19 1342 1342 1342 1342 Oil Pump Bracket 1342 1342 1342 TLDI 115A 2007...
  • Page 231 Ref. Description Q'ty Remarks Bottom Cowl Rubber Mount, 12-18-2.5 Spacer, 8.4-12-17 Bolt M8 L=35mm Washer, 8.5-24-1.5 Cord Clamp Bolt M6 L=25mm W/SW · 9 PW Grommet, 17-2.7 Bottom Cowl Grommet "A" "PTT" Cord Grommet Grommet, 17-3 Cord Grommet Clamp, 60 Grommet Cramp, 6.5-67P Bolt...

  • Page 232: Shift

    Cowl, Bracket and PTT P/L Fig. 16 Shift Remote Control Cable 7 N·m (5 lb·ft) [0.7 kgf·m] 1342 1342 Fig.19-1 Fig.14-51 1342 1342 1342 TLDI 115A 2007...
  • Page 233 Ref. Description Q'ty Remarks Shift Rod Shift Rod Lever Nylon Nut, 10-P1.5 Shift Lever Shaft Shift Lever Shaft Holder Bolt M8 L=25mm W/PW Washer, 10.5-18-1.5 Cable Pin Spring Washer Shift Assist Ass'y Shift Arm Washer, 8.5-24-1.5 Bushing, 12-14-15.5 Collar, 8.4-12-17 Washer, 12.5-24-1 Bolt M8 L=35mm W/SW...

  • Page 234: Drive Shaft Housing

    Cowl, Bracket and PTT P/L Fig. 13 Drive Shaft Housing 6 N·m (4 lb·ft) [0.6 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 1741 1741 1741 27-1 6 N·m (4 lb·ft) [0.6 kgf·m] 20 N·m (14 lb·ft) [2.0 kgf·m] 40 N·m (29 lb·ft) [4.0 kgf·m] 1342 1342 1342...
  • Page 235 Ref. Description Q'ty Remarks Drive Shaft Housing "L" Bolt, 10-107 M10 L=107mm Bolt, 10-120 M10 L=120mm Washer Drive Shaft Housing Gasket Apron Ass'y Apron Seal Apron Grommet Bolt M6 L=12mm Apron Bolt, 6-16 M6 L=16mm Washer Extension Housing "UL" for Transom "UL" Bolt for Transom "UL"...

  • Page 236: Bracket

    Cowl, Bracket and PTT P/L Fig. 17 Bracket 45 N·m (33 lb·ft) [4.5 kgf·m] 35-3 1342 1342 35-4 1342 35-1 35-4 35-5 35-2 35-4 35-3 45 43 Fig.13-27 1342 1342 1342 Apply after rigging 14-3 14-2 14-1 25 N·m (18 lb·ft) [2.5 kgf·m] 32 31 6 11 22 23...
  • Page 237 Ref. Description Q'ty Remarks Clamp Bracket (Right) Starboard Clamp Bracket (Left) Port Bolt M10 L=20mm Washer Swivel Bracket Shaft Bracket Bolt Washer, 25.7-50-1 Nylon Nut, 7/8 7/8-14UNF Thrust Rod Thrust Rod Pin Swivel Bracket with Pin (3E0-62475-0) Bushing, 25.6-28.6-40 Grease Fitting Washer Tilt Stopper 14-1...

  • Page 238: Power Trim & Tilt

    Cowl, Bracket and PTT Power Trim & Tilt P/L Fig. 18 4 N·m (3 lb·ft) [0.4 kgf·m] 130N·m (94 lb·ft) [13 kgf·m] 80 N·m (58 lb·ft) [8 kgf·m] 7 N·m (5 lb·ft) [0.7 kgf·m] 5 N·m (4 lb·ft) [0.5 kgf·m] 9 N·m (7 lb·ft) [0.9 kgf·m] 3 N·m (2 lb·ft) [0.3 kgf·m] 7-12...
  • Page 239 Ref. Description Q'ty Remarks Motor Cable L=1,250mm Yoke Ass'y Motor O-Ring Do not reuse. Bracket Bolt Piston Rod Ass'y (Tilt) O-Ring Do not reuse. O-Ring Do not reuse. Free Piston O-Ring Do not reuse. Back-UP Ring Trim Piston O-Ring Do not reuse. Back-UP Ring Rod Guide Sub Ass'y (Trim) O-Ring...

  • Page 240: Inspection Items

    Cowl, Bracket and PTT 3. Inspection Items 1) Inner Cowl Inner cowl structure is adopted to reduce acoustic noise and protection of engine from invasion of water. 2) Removing Top Cowl Turn upper motor cover hook levers 1 and 2 and remove upper motor cover.

  • Page 241: Removing Bottom Cowl

    4) Removing Bottom Cowl Remove power trim pump electrical cables from bottom cowl. There is a clamp on the back of bottom cowl to secure cables. Loosen bolts that secures shift lever shaft holder. Remove shift rod lever from shift rod. Loosen and remove four bolts that secure bottom cowl to engine base.

  • Page 242: Removing Drive Shaft Housing

    Cowl, Bracket and PTT 5) Removing Drive Shaft Housing Use the following steps to remove drive shaft housing. Loosen and remove upper rubber mount cap installation bolts to remove mount cap 1. Loosen and remove upper rubber mount installation bolts to remove rubber mount 2.

  • Page 243: Disassembly Of Drive Shaft Housing

    6) Disassembly of Drive Shaft Housing Remove bolts that secure engine base to drive shaft housing. Remove M6 installation bolt located in the area shown by the arrow. Tap lightly with a plastic hammer to separate engine base from the housing if it is seized. If necessary, use a bladed screw driver to pry the engine base taking care not to scratch mating surface.
  • Page 244 Cowl, Bracket and PTT Loosen and remove bolts 7 that secure exhaust housing 5 to engine base and remove exhaust housing. Loosen and remove bolts 8 that secure exhaust pipe 6 to engine base and remove exhaust pipe. 7-18 TLDI 115A 2007...

  • Page 245: Inspection Of Drive Shaft Housing

    7) Inspection of Drive Shaft Housing Check mount rubber and dumper rubber for crack and deterioration. Replace if necessary. Check water pipe 3 and reverse gas passage 4 for corrosion and deformation. Replace if necessary. Check engine base 1, exhaust housing 5 and drive shaft housing 6 for corrosion, and idle exhaust passage 2 for damage.

  • Page 246: Assembly Of Drive Shaft Housing Parts

    Cowl, Bracket and PTT Check that drive shaft housing is provided with two holes on the area opposite to reverse gas pipe installation face. 60 mm 60 mm (2.362 in) (2.362 in) ø10 mm The drive shaft housing of model 115 is provided (0.394 in) with two holes.
  • Page 247 Install water pipe auxiliary mount 7 to drive shaft housing. Install water pipe to drive shaft housing, and attach gasket after confirming that dowel pins r are on the drive shaft housing. TLDI 115A 2007 7-21...
  • Page 248 Cowl, Bracket and PTT 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 249: Assembling Drive Shaft Housing Parts

    9) Assembling Drive Shaft Housing Parts When assembling drive shaft housing parts, reverse the disassembling procedure. Install upper mount 1 and tighten bolts 2 to specified torque. Upper Rubber Mount Bolts 2 : 45 N · m (33 lb · ft) [4.5 kgf · m] CAUTION Install the mount with the side of smaller a facing forward.

  • Page 250: Removing Steering Shaft Arm

    Cowl, Bracket and PTT 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 251: Removing Ptt Unit

    Pull up steering shaft arm 3 to remove. 11) Removing PTT Unit Fully tilt up outboard motor and lock with tilt stopper 1. WARNING Be sure to lock the outboard motor with tilt stopper after tilting it up. Outboard motor may tilt down accidentally if hydraulic pressure in the PTT unit drops for some reason.
  • Page 252 Cowl, Bracket and PTT 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 253: Removing Clamp Bracket

    12) 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 254: Assembling Clamp Bracket Parts

    Cowl, Bracket and PTT 13) Assembling Clamp Bracket Parts 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 255 Attach bushings to PTT (upper) and swivel bracket. Extend tilt rod until PTT tilt rod hole aligns with swivel bracket hole. Blue Green Install cylinder pin upper 4 and secure with bolt 5. Run PTT and trim sensor leads through clamp bracket hole and collect them using wire clamp and tile wrap.

  • Page 256: Assembling Steering Arm Parts

    Cowl, Bracket and PTT 15) Assembling Steering Arm Parts Put thrust plate 1, O 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. Install mount bracket 9.

  • Page 257: Removing Motor

    16) Removing Motor Fully extend tilt rod and trim rods. CAUTION Check that tilt rod and trim rods are fully Blue Green extended. Disassembling the unit with the rods retracted causes the hydraulic fluid to spurt. CAUTION When working on the PTT unit, tilt down the outboard motor to vertical position.

  • Page 258: Inspection Of Power Trim And Tilt Motor

    Cowl, Bracket and PTT 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 disconnect PTT motor lead from stator.
  • Page 259 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 260: Assembling Power Trim And Tilt Motor Parts

    Cowl, Bracket and PTT 18) Assembling Power Trim and Tilt Motor Parts Connect PTT motor leads and secure them with screws 2. Put brushes 3 into brush holders, and attach armature 4. 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.

  • Page 261: Removing Reservoir

    19) Removing Reservoir Put an aluminum plate on each side of a vise as shown, and hold power trim and tilt unit with the vise. CAUTION Do not use rag or paper to clean the hydraulic system. Using rag or paper causes the fiber to remain on the unit, causing malfunction.

  • Page 262: Disassembling Bracket Unit And Assembling The Parts

    Cowl, Bracket and PTT 21) Disassembling Bracket Unit and Assembling the Parts Remove manual valve 1. Attach a new O ring to down relief valve. Attach filter 2 to down relief valve 3, and put the filter assembly in the gear pump. Attach new O ring 4 to manual valve.

  • Page 263: Assembling Ptt Unit Parts

    Cover tilt cylinder opening with clean cloth 1 and apply compressed air from hole a to remove free piston 2. WARNING Do not look into tilt cylinder opening because free piston or power trim fluid may fly out of the opening due to the internal pressure.
  • Page 264 Cowl, Bracket and PTT 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. CAUTION When installing, check that trim rods are fully extended.
  • Page 265 Put PTT fluid in the tilt cylinder through hole a to a proper level. Install tilt piston to cylinder, and tighten tilt rod guide 5 to specified torque. CAUTION When installing, check that tilt rod is fully extended. After installing tilt piston, do not push tilt rod.
  • Page 266 Cowl, Bracket and PTT Remove air bubbles by using a means such as a syringe. Install O ring 4 and power trim and tilt motor ass'y 5, and tighten bolts 6 to specified torque. CAUTION Engage armature shaft joint groove with the shaft of pump.

  • Page 267: Air-Purging Ptt Unit

    24) Air-Purging 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 268: Electrical System

    Electrical System 1. Special Tools ………………………… 8-2 11) Inspection of Rectifier Complete … 8-9 2. Parts Layout ………………………… 8-3 12) Inspection of Throttle Position Sensor … 8-10 Starter Motor……………………………… 8-3 13) Inspection of Water Temperature Sensor … 8-10 3. Inspection Items …………………… 8-4 14) Inspection of Power Relay …………...

  • Page 269: Electrical System

    Electrical System 1. Special Tools Spark Tester P/N. 3F3-72540-0 Checking sparks TLDI 115A 2007...

  • Page 270: Parts Layout

    2. Parts Layout Starter Motor Ref. Description Remarks Q'ty Starter Motor 1-1 Carbon Brush (+) 1-2 Carbon Brush (-) 1-3 Brush Spring 1-4 Pinion 1 Do not reuse clip. TLDI 115A 2007...

  • Page 271: Inspection Items

    Electrical System 3. Inspection Items 1) Disassembly of Starter Motor Push down pinion stopper 1, remove pinion stopper clip 2, and then, remove pinion return spring and pinion. Remove bolt and screw, and disassemble starter motor. 2) Inspection of Armature Check armature commutator a for deposit of carbon and other dirt.

  • Page 272: Inspection Of Brushes

    3) Inspection of Brushes Measure brush length a, and replace brush if the length is less than specified value. Brush Length a : Standard Value 14 - 15 mm (0.55 - 0.59 in) Wear Limit : 12 mm (0.47 in) Check conductivity between brush and starter terminal.

  • Page 273: Inspection Of Ignition And Sparks

    Electrical System 5) Inspection of Ignition and spark Disconnect plug cap 1 from spark plugs. Connect plug cap 1 to spark tester. Connect spark tester clip to spark plug tip electrode. Spark Tester : P/N. 3F3-72540-0 Spark Performance : 10 mm (0.4 in) or over Start engine and check spark.

  • Page 274: Inspection Of Ignition Coils

    7) Inspection of Ignition Coils a b c Remove ignition coil coupler. Measure ignition coil resistance. Replace if other than specified value. This test can be made without removing parts. 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 275: Inspection Of Alternator

    Electrical System 10) 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 115A 2007...

  • Page 276: Inspection Of Rectifier Complete

    11) Inspection of Rectifier Complete Measure resistance between terminals. This test can be made without removing parts. Yellow Black 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 277: Inspection Of Throttle Position Sensor

    Electrical System 12) Inspection of Throttle Position Sensor Measure resistance between terminals. Replace throttle position sensor if the resistance is out of specified range. This test can be made without removing parts. When lever is at position A (wide open throttle) : Between a - c Ω...

  • Page 278: Inspection Of Power Relay

    14) Inspection of Power Relay Measure resistance between a and b terminals. Replace relay if the resistance is out of specified range. This test can be made without removing parts. Resistance between a and b terminals : @20˚C (68˚F) 90 - 110 Ω Apply 12V between terminals a and b and check conductivity between c and d.

  • Page 279: Inspection Of Mat (Manifold Temperature) Sensor

    Electrical System 17) Inspection of MAT (Manifold Temperature) Sensor Measure MAT sensor resistance. Replace if other than specified value. This test can be made without removing parts. MAT (Manifold Temperature) Sensor Temperature (Reference Value) : 2.35 - 2.55kΩ at 20˚C (68˚F) 0.30 - 0.35kΩ...

  • Page 280: Inspection Of Oil Level Sensor

    20) Inspection of Oil Level Sensor Check electrical conductivity between terminals of oil level sensor. Check oil level sensor if out of specified range. This test can be made without removing parts. To be non conductive if float is at position a. To be conductive if float is at position b.

  • Page 281: Inspection Of Ptt Solenoid

    Electrical System 22) Inspection of PTT Solenoid This test can be made without removing parts. Disconnect positive and negative cables from battery. Disconnect PTT leads from terminals 1 and 2. å DOWN Check electrical conductivity of PTT solenoid. Replace if other than specified value.

  • Page 282: Function

    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 283 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 284 Action to be taken Cause (Refer to reference value or service data.) 1-1-1. Shift is in "F" or "R" position. Shift 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 285 Troubleshooting Warning Warning Warning indicator A lamp B lamp C Self- (Oil level) (Water temp.) (Battery volt.) Symptom Item diagnosable Beep ( ○ ) Fuel pressure is low. Normal value range: 0.6 - 0.64MPa (85.3 - 91.4psi) [6 - 6.4kg/cm 2-2.
  • Page 286 Action to be taken Cause (Refer to reference value or service data.) Fuel regulator leaks. 2-2-12. Replace. Fuel leak 2-2-13. Check hose damage and joints. Return circuit from fuel regulator outlet to vapor Check, and repair if necessary. 2-2-14. separator is obstructed. Fuel regulator is faulty.
  • Page 287 Troubleshooting Warning Warning Warning indicator A lamp B lamp C Self- (Oil level) (Water temp.) (Battery volt.) Symptom Item diagnosable Beep ( ○ ) Spark Plug Cap Crank Position Sensor 2-4. Engine can be Electrical cranked but will Self-diag. reports that battery Flashing not start.
  • Page 288 Action to be taken Cause (Refer to reference value or service data.) 2-4-6. Cap is loose. Check. 2-4-7. Cap is faulty. Replace. 2-4-8. CPS Gap. Check, and adjust if necessary. 2-4-9. ECU malfunction. Replace ECU. Replace battery or charge. Battery power is low. Battery voltage becomes less than 2-4-10.

  • Page 289: Troubleshooting

    Troubleshooting Warning Warning Warning indicator A lamp B lamp C Self- (Oil level) (Water temp.) (Battery volt.) Symptom Item diagnosable Beep ( ○ ) Fuel pressure is low. Normal value range: 0.6 - 0.64MPa (85.3 - 91.4psi) [6 - 6.4kg/cm 3-2.
  • Page 290 Action to be taken Cause (Refer to reference value or service data.) 3-2-8. Fuel regulator leaks. Refer to 2-2-12. 3-2-9. Fuel leaks. Refer to 2-2-13. 3-2-10. Air rail internal air pressure is low. Refer to 2-3. 3-2-11. Fuel regulator is faulty. Replace.
  • Page 291 Troubleshooting Warning Warning Warning indicator A lamp B lamp C Self- (Oil level) (Water temp.) (Battery volt.) Symptom Item diagnosable Beep ( ○ ) 6-1. Compression insufficient Power Head Air rail internal air pressure is low. 6-2. Air System Air rail internal air pressure is high. Fuel Tank Fuel Hose Fuel Filter...
  • Page 292 Action to be taken Cause (Refer to reference value or service data.) 6-1-6. Crankcase head oil seal is faulty. Check, and repair if necessary. 6-2-1. Refer to 2-3. Refer to 2-3. 6-3-1. Fuel tank is empty or fuel level is low. Refer to 2-2-1.
  • Page 293 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 294 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. Check. 9-1-3. Battery is faulty, or two batteries are connected in series. 9-1-4.

  • Page 295: 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 296 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 115A 2007 9-15...

  • Page 297: 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 298 Normal? Replace ignition coil. Check ECU. TLDI 115A 2007 9-17...

  • Page 299: 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 300 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 301: 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 302 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 115A 2007 9-21...
  • Page 303 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 disconnection. Repair or replace Normal? defective parts. Check throttle position sensor and crank position sensor connectors for connections.

  • Page 304: 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 305: 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 306 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. Add engine oil to Within specified specified level. range? Check oil level sensor. Replace oil level Normal? switch.

  • Page 307: 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 308: State 3 Engine Rotation Is Unstable Or Surging Occurs In Low Speed Range

    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 309: 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 310: 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 115A 2007 9-29...

  • Page 311: Ptt Unit

    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 312: State 2 Ptt Is Not Capable Of Sustaining Outboard Motor

    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. Close manual valve. Closed? Check PTT fluid level. Add PTT fluid to Within specified specified level.

  • Page 313: 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 314: 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 315 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 316 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 317 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) Flashing ×...
  • Page 318 Fault 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 85˚C （185˚F） Engine cooling water temp. abnormally high 90˚C （194˚F）...

  • Page 319: 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 320: 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 321 Remedial Measures and Added Notes Refer to troubleshooting. Replace 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 322 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 323 Remedial Measures and Added Notes Refer to troubleshooting. Refer to troubleshooting. Refer to troubleshooting. TLDI 115A 2007 9-43...

  • Page 324: 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 setf-diagnosing indicates idling position errors for TPS1 and TPS2. 1 When either the TPS or ECU is replaced or control cabels 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 ldling Position Error indication appears after performing engine disassembly and assembly...
  • Page 325 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 326 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 327: 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 328: 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 329 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 115A 2007...

  • Page 330: 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 331: 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' surface excluding their threaded area.

  • Page 332: 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 333: 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 334: 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 335: 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 336 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 337 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 338: 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 339: Electric System

    Rigging r/min 6. Electric System 1) Battery Capacity 12V100 - 120AH (800 - 1,000C.C.A) 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 batteries by using common earth lead 4 of which size is equal to that of the main battery cables.

  • Page 340: 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 341 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 115A 2007...

  • Page 342: Wiring Remote Control And Meter Leads

    3) Wiring Remote Control and Meter Leads Color of Cords : Black : Blue : Light Green : Orange : Pink : Red Tachometer : Sky Blue : White : Yellow : Green : Yellow / Red G/R : Green / Red Note : Connect leads marked Trim Meter with * when meter lamp...

  • Page 343: Connections

    Wiring Diagram TLDI Wire Harness Terminals and Electrical Wiring Assembling Connections ……………………………… 11-2 Instruction Diagram -2 ………………… 11-8 Main Harness Diagram ………………… 11-3 Electrical Wiring Assembling 115A EPTO Electrical Circuit ……… 11-5 Instruction Diagram -3 ………………… 11-9 Electrical Wiring Assembling Outboard Motor Installation Template …...

  • Page 344: Tldi Wire Harness Terminals And Connections

    Wiring Diagram TLDI Wire Harness Terminals and Connections 25 26 27 28 11 12 15 16 17 18 19 20 Component Lead Wire Color TPS1 Blue/Red Key Switch (PUSH) Blue CPS (Crank position sensor) Blue/Black Warning Lamp (Oil) Light Green Warning Lamp (Temp.) Yellow/Red Warning Lamp (Battery)

  • Page 345: Main Harness Diagram

    Main Harness Diagram WATER TEMP AIR RAIL SENSOR (GND) FUEL INJECTOR # 1 RECTIFIER B/W G/W COMPRESSOR WATER TEMP SENSOR CYLINDER HEAD (GND) AIR INJEC TOR # 1 Lg/R Lg/R FUEL INJECTOR # 2 IG COIL #1 AIR INJEC TOR # 2 Lg/W Lg/W OIL L EVEL SENSOR...

  • Page 346: Epto Electrical Circuit

    Wiring Diagram 115A 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 Swtich Water Temp. Sensor Tacho Meter Crank Position Sensor Meter Lead Wire...
  • Page 347 115A EPTO Electrical Circuit FUSE HOLDER MAGNETO Br/Y km/h CHAMBER Wharnig Wharnig Wharnig Lamp 1 Lamp 2 Lamp 3 AIR RAIL Lg/R B Br R R G L G ( NO ) G ( CON ) Lg/W O------------O START O-O-O Lg/B PUSH CYLINDER...

  • Page 348: Instruction Diagram -1

    Electrical Wiring Assembling Instruction Diagram -1 Run starter motor cord and oil level sensor cord through the clamp and tie them. Attaching ground lead Use a tie to fix battery cord, PTT cord and oil level sensor cord to cord ass’y. (2 locations) Fix cord ass’y to cylinder TPS 1 by using stay and band.

  • Page 349: Electrical Wiring Assembling Instruction Diagram -2

    Electrical Wiring Assembling Instruction Diagram -2 Ground lead of cord ass’y Ground boss of air chamber Secure the ground wire of cord ass'y Fix alternator cord by using with #1 ignition coil upper securing bolt. Starter Cable the clamp that is tightened (Ground Lead) together to upper side of Attach ground lead.

  • Page 350: Electrical Wiring Assembling Instruction Diagram -3

    Electrical Wiring Assembling Instruction Diagram -3 PTT Solenoid Switch A Locations of starter solenoid ground lead Green Pain and PTT solenoid switch A ground lead Starter Solenoid Switch Blue Paint Fuse Holder PTT Solenoid Switch B Location of PTT solenoid switch B ground lead Install protector at G17.

  • Page 351: Outboard Motor Installation Template

    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 352 Copyright © 2007 Tohatsu Corporation. 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 Corporation.
  • Page 353 OB No.003-21060-0 07-05 NB-2600 Printed in Japan...

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