TOHATSU TLDI MD 115A SERIES Service Manual page 8

1. Special tools .............................. 7-2
2. Parts Layout .............................. 7-3
Cowl ............................................. 7-3
Bottom Cowl .................................... 7-4
Shift ............................................. 7-6
Drive Shaft Housing........................... 7-8
Bracket .......................................... 7-10
Power Trim & Tilt .............................. 7-12
3. Inspection Items ........................ 7-14
1) Inner Cowl ................................. 7-14
2) Removing Top Cowl .................. 7-14
3) Adjustment of Cover Hook ............ 7-14
4) Removing Bottom Cowl ............... 7-15
5) Removing Drive Shaft Housing ...... 7-16
6) Disassembly of Drive Shaft Housing ... 7-17
7) Inspection of Drive Shaft Housing ... 7-19
8) Assembly of Drive Shaft Housing Parts ... 7-20
9) Assembling Drive Shaft Housing Parts ... 7-23
10) Removing Steering Shaft Arm ...... 7-24
11) Removing PTT Unit ..................... 7-25
12) Removing Clamp Bracket ............ 7-27
13) Assembling Clamp Bracket Parts...... 7-28
14) Installation of PTT Unit .................. 7-28
15) Assembling Steering Arm Parts...... 7-30
16) Removing Motor ........................ 7-31
17) Inspection of Power Trim and Tilt Motor ... 7-32
18) Assembling Power Trim and Tilt Motor Parts ... 7-34
19) Removing Reservoir .................. 7-35
20) Disassembly of Gear Pump ......... 7-35
21) Disassembling Bracket Unit and
Assembling the Parts .................. 7-36
22) Disassembly of Tilt Cylinder and
Trim Cylinder, and Assembly of the Parts ... 7-36
23) Assembling PTT Unit Parts ......... 7-37
24) Air-Purging PTT Unit .................. 7-41
8.Electrical System
1. Special Tools .............................. 8-2
2. Parts Layout .............................. 8-3
Starter Motor.................................... 8-3
3. Inspection Items ........................ 8-4
1) Disassembly of Starter Motor......... 8-4
2) Inspection of Armature ............... 8-4
3) Inspection of Brushes .................. 8-5
4) Inspection of Pinion ..................... 8-5
5) Inspection of Ignition and sparks ... 8-6
6) Inspection of Plug Cap .................. 8-6
7) Inspection of Ignition Coils ............ 8-7
8) Inspection of Pick Up Coil
(Crank Position Sensor) ...............8-7
9) Inspection of Pick Up Coil Air Gap ... 8-7
10) Inspection of Alternator ............... 8-8
11) Inspection of Rectifier Complete ... 8-9
12) Inspection of Throttle Position Sensor ... 8-10
13) Inspection of Water Temperature Sensor ... 8-10
14) Inspection of Power Relay ............ 8-11
15) Inspection of Air Injectors ............ 8-11
16) Inspection of Fuel Injectors ......... 8-11
TLDI 115A 2007
17) Inspection of MAT
(Manifold Temperature) Sensor...... 8-12
18) Inspection of MAP Sensor
(Manifold Air Pressure Sensor) ...... 8-12
19) Inspection of Starter Solenoid ...... 8-12
20) Inspection of Oil Level Sensor ...... 8-13
21) Inspection of Oil Pump ............... 8-13
22) Inspection of PTT Solenoid ......... 8-14
23) Inspection of PTT Switch ............ 8-14
9.Troubleshooting
1. Troubleshooting........................... 9-2
Power Unit ................................. 9-14
State 1 Engine will not start or is
hard to start. ..................... 9-14
Ignition System................................. 9-16
Fuel System .................................... 9-18
Air System....................................... 9-20
State 2 Full throttle engine revolution
speed is low, engine revolution
speed falls off, or engine stalls.
.......................................... 9-22
Ignition System................................. 9-23
Fuel System .................................... 9-24
Lubrication system ........................... 9-25
Cooling System .............................. 9-26
State 3 Engine rotation is unstable or
surging occurs in low speed
range. ................................. 9-27
Ignition System................................. 9-28
Fuel System .................................... 9-29
PTT Unit
State 1 PTT unit will not operate. ...... 9-30
State 2 PTT is not capable of sustaining
outboard motor. .................. 9-31
2. Self-Diagnosis Function of TLDI ... 9-32
1) Terms related to self-diagnosis function... 9-32
2) Operation Procedure of Self-Diagnosis
Function .................................... 9-33
3) Warning Indication List • • •
Display for abnormalities during
operation .................................... 9-36
4) Operating Hour Indication List
(Self Diagnosis • Mode 2) ............... 9-38
5) Trouble Indication List
(Self Diagnosis • Mode 3) ............... 9-40
6) Resetting TPS Initial Values ............ 9-44
10.Rigging
1. Service Information ..................... 10-2
2. Service Data .............................. 10-2
1) Load Limit of Boat ..................... 10-2
2) Installation Dimensions ............... 10-2
3) Clamp Dimensions ..................... 10-3
4) Hanging Outboard Motor ............ 10-5
5) Installation of Outboard Motor ...... 10-5
3. Fuel System ................................. 10-6
1) Fuel.......................................... 10-6
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