Power Unit - TOHATSU TLDI MD 115A SERIES Service Manual

1. Special tools .............................. 5-2
2. Parts Layout .............................. 5-3
Engine .......................................... 5-3
Magneto.......................................... 5-4
Electric Parts.................................... 5-6
Electric Parts (Starter Motor) ............... 5-8
Air Chamber .................................... 5-9
Throttle .......................................... 5-10
Cylinder Crank Case ........................ 5-12
Piston & Crank Shaft ........................ 5-14
3. Inspection Items ........................ 5-15
1) Removing Power Unit .................. 5-15
2) Removing Flywheel ..................... 5-19
3) Removing Stator Coil .................. 5-20
4) Removing Cord Ass'y .................. 5-21
5) Removing Throttle Link ............... 5-24
6) Removing Air Chamber ............... 5-25
7) Inspection of Throttle Body............ 5-26
Exploded Diagram of Short Block ... 5-28
Exploded Diagram of Piston-Crank
Shaft Assembly ........................ 5-29
8) Removing Thermostat .................. 5-30
9) Removing Cylinder Head / Head Cover ... 5-31
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Power Unit

10) Inspection of Cylinder Head ......... 5-32
11) Removing Exhaust Cover ............ 5-33
12) Inspection of Exhaust Cover ......... 5-33
13) Removing Crank Case ............... 5-34
14) Removing Pistons ..................... 5-35
15) Disassembly of Crank Shaft ......... 5-36
16) Inspection of Crank Shaft ............ 5-36
17) Inspection of Engine Parts ............ 5-38
18) Inspection of Pistons .................. 5-39
19) Assembling Crank Shaft ............... 5-42
20) Installing Pistons ........................ 5-43
21) Assembling Power Unit Parts ...... 5-44
22) Assembling Crank Case Halves ... 5-46
23) Assembling Exhaust Cover Parts ... 5-47
24) Assembling Cylinder Head Parts ... 5-49
25) Assembling Coil Bracket Parts ...... 5-50
26) Assembling Crank Case Head Parts ... 5-50
27) Installing Air Chamber .................. 5-51
28) Attaching Coil Bracket .................. 5-53
29) Attaching Recirculation Hoses ...... 5-54
30) Installing Alternator ..................... 5-55
31) Installing Flywheel ..................... 5-55
32) Installing Power Unit .................. 5-56
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