TOHATSU TLDI MD 115A SERIES Service Manual 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.
2 Parts that are serviced in each chapter and their details are presented by using a component composition
diagram.
3 Driving torques are described in the component composition diagram and in the body text are critical
points of the applicable work.
4 Pictograms indicate that there is an important work instruction for the relevant parts. It also shows the type
of lubricant and its application point(s).
5 The component composition diagrams describe the names of the parts, the number of pieces of the parts
used, size of fasteners and special notes.
6 Specific works are described in detail by using illustrations and adding advice on the work.
Lower Unit
1. Special tools
Thickness Gauge Propeller Shaft Housing Puller Ass'y Spring Pin Tool A
P/N. 353-72251-0 P/N. 353-72252-0 P/N. 369-72217-0
Removing propeller shaft
Measuring gaps Removing spring pin
housing
ø100 x ø79.5 x ø51.5 x ø61.5
Bevel Gear Bearing Puller Ass'y Slide Hammer Kit
P/N. 3B7-72755-0 P/N. 3AC-99080-0 P/N. 3AC-99701-0
Removing forward (A) gear bearing Removing forward (A) gear Removing or installing propeller
outer race bearing outer race shaft housing bearing
ø51.5 x ø24.5
Universal Puller Plate Bearing Attachment Bevel Gear B Nut Wrench
P/N. 3AC-99750-0 P/N. 3AC-99905-0 P/N. 3B7-72231-0
Removing reverse (C) gear Used in combination with driver rod Removing or attaching pinion
bearing Attaching reverse (C) gear bearing
Backlash Measuring Tool A Kit Shimming Gauge Backlash Measuring Tool B Kit
P/N. 3B7-72234-0 P/N. 3B7-72250-0 P/N. 3B7-72255-0
Measuring backlash between forward Adjusting pinion (B) gear Measuring backlash between pinion
(A) gear and pinion (B) gear height (B) gear and reverse (C) gear
6-2
ii
1
Spring Pin Tool B
P/N. 369-72218-0
Installing spring pin
Power Unit
Electric Parts (Starter Motor)
Center Plate Driver Rod
P/N. 3AC-99702-0
Used in combination with center
place and various attachments
3
Drive Shaft Socket
P/N. 3B7-72232-0
Removing or attaching pinion
(B) gear nut (B) gear nut
Needle Bearing Puller Kit
P/N. 3B7-72700-0
Removing or attaching gear case and
propeller shaft housing needle bearing
20
TLDI 115A 2007
16
Ref.
Description
No.
1 Starter Motor
1-1 Positive Brush (+)
1-2 Negative Brush (-)
1-3 Brush Spring
1-4 Pinion
2 Bolt
3 Spring Washer
4 Washer, 8.5-24-1.5
5 Spacer, 8.4-12-21.5
6 Starter Motor Mount "A"
5
7 Starter Motor Mount "B"
8 Starter Motor Bracket
9 Bolt
10 Spring Washer
11 Starter Motor Damper
5-8
2
23
25
24
21
22
26
2
6 N·m (4 lb·ft) [0.6 kgf·m]
3
4
5 1-4
18
6
10
9
8
Air Chamber
10
17
9
7
OBM OBM OBM
OBM 1-2
1-1
1
SOC SOC SOC GM GM
1-3
SOC
Starter
Solenoid
19
13
12
G17 G17 G17
G17 14
11 15
20
13 N·m (9 lb·ft) [1.3 kgf·m]
Ref.
Remarks Description
Q'ty No. Q'ty
1 12 Starter Motor Band 1
2 13 Bolt 1 M8 L=40mm W/PW
2 14 Bolt 1 M8 L=20mm
4 15 Washer 1 M8
1 16 Starter Cable 1 L=500mm
2 M8 L=40mm 17 Starter Cable 1 L=300mm
2 M8 18 Bolt 1 M6 L=12mm W/PW
2 19 Bolt 1 M8 L=16mm W/PW
2 20 Terminal Cap 2
2 21 Ring Gear Cover 1
1 22 Grommet, 16-2.5 4
1 23 Caution Decal "B" 1
3 M8 L=45mm 24 Fuse Decal 1
3 M8 25 Spark Plug Decal 1
2 26 Ring Gear Cover Hook 4
P/L Fig. 10
Lower Unit
9) Disassembly of Propeller Shaft
Housing Ass'y
Pull out propeller shaft ass'y 1.
1.
4 4
2. Remove reverse (C) gear by using − screw drivers 3.
3. Remove bearing 4.
OBM
CAUTION
OBM OBM
SOC Heat propeller shaft housing by putting it in
the hot water of approximately 60 to 70˚C,
SOC SOC SOC GM GM
and remove bearing 4.
G17
G17 G17
CAUTION
Be careful not to burn.
Remarks
Heating of compressor housing can also be
made by using a heat gun or heat lamp.
4. Use a press to remove oil seal 5 and needle bearing 6 at
the same time.
Before removing, check bearing for play or
deflection. Replace if necessary.
Direct the side of attachment without O-ring to
needle bearing.
TLDI 115A 2007
Needle Bearing Attachment 7 :
P/N. 3T1-99710-0
Driver Rod 8 :
P/N. 3AC-99702-0
Center Plate 9 :
P/N. 3AC-99701-0
This work can be done also by using the following tool kit.
Needle Bearing Puller Kit 7 :
P/N. 3B7-72700-0
5. When removing only oil seal, use bladed screw driver to
pry apart.
6-14
6
1
3
2
4
4 Bearing
Do not reuse.
8
9
6
7
5
5 Oil Seal Do not reuse.
6 Needle Bearing
Do not reuse.
TLDI 115A 2007
TLDI 115A 2007