TOHATSU TLDI MD 115A SERIES Service Manual page 39

Functional Limit
Scratches or deflection of 0.10 mm (0.004 in)
Scratches or deflection of 0.10 mm (0.004 in)
φ88.08 mm (3.4677 in)
When the cylinder liner cannot be repaired using #400 to #600 grit
sandpaper due to deep scratching or scuffing to the sliding surface
in contact with the piston or when the difference between the
minimum and maximum points of wear in the liner bore is 0.06 mm
(0.0024 in) or more.
φ87.78 mm (φ3.4559 in)
0.30 mm (0.0118 in)
0.10 mm (0.0039 in)
φ23.03 mm (0.9067 in)
0.040 mm (0.0016 in)
0.80 mm (0.0315 in)
0.80 mm (0.0315 in)
0.80 mm (0.0315 in)
φ22.97 mm (0.9045 in)
0.05 mm (0.0020 in)
Abnormally wear or damage
2 mm (0.08 in)
When the difference in standard value
When the end reed valve fails to close
Excessive wear on valve seat
Valve is damaged
When the difference in compression between cylinders exceeds
0.1 MPa (14.9 psi) [1.05 kg/㎠]
When abnormally higher than standard value
TLDI 115A 2007
Action To Be Taken
Clean and remove build up.
Repair by polishing the surface plate, starting with #240 to #400 grit
sandpaper and finishing with #600 grit sandpaper.
Replace if over specified limit.
Repair or replace depending on the extent of damage.
Clean and remove obstruction.
Repair by polishing the surface plate, starting with #240 to #400 grit
sandpaper and finishing with #600 grit sandpaper.
Replace if over specified limit.
Bore and hone to 0.5 oversize piston diameter. Check ports and grind if
necessary. (Use 0.5 oversize pistons and piston rings.)
Replace if over specified limit.
Clean and remove build up.
Replace if excessively worn.
Replace if less than specified limit.
Replace if over specified limit.
Clean and remove build up.
Repair or replace depending on the extent of damage.
(Repair using #400 to #600 grit sandpaper.)
Replace if over specified limit.
Replace if over specified limit.
Replace if less than specified limit.
Replace with new crankshaft assembly.
Replace if over specified limit.
Replace with new part.
Replace if over specified limit.
Replace with new part.
Replace entire valve assembly.
Remove carbon from piston crown and cylinder head.
Bore and hone to 0.5 mm (0.020 in) oversize piston dameter.
Check ports and grind if necessary.
(Use 0.5 oversize pistons and piston rings.)
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