Tune-Up Procedure - TOHATSU 40 Service Manual

SECTION 2

TUNE-UP PROCEDURE

Deteriorated or damaged parts identified during
engine tune-up must be replaced in order to
maintain safe engine operation.
1. Inspect engine for leaks, missing, loose or damaged parts, or
other visible defects.
2. Remove each spark plug and check for fouling, cracks in
ceramic, and incorrect gap. Replace plugs if needed.
3. Check engine compression. Refer to Cylinder Compression Test
in Section 4.
4. Check all wiring, connectors, and clamps for damage. Replace
parts as needed.
5. Replace fuel and oil filters and inspect each carburetor. Check all
fuel hoses for deterioration and replace as needed.
6. Check for proper clutch engagement and make shift cable
adjustments as needed.
Model
40 /50 Shift lever stopper : Position onto Shift arm
60 / 70 F-type Shift lever stopper : Position onto Shift lever stopper plate
60 / 70 P-type Cable rod/joints : Length
80 / 90 F-type Shift lever stopper : Position onto Shift lever stoppeer plate
80 / 90 P-type Cable rod/joints : Length
115 / 120 / 140 Cable rod/joints : Length
7. Check for proper operation of the reverse lock mechanism.
8. Adjust the engine ignition timing and carburetors. See
Synchronization and Linkage Adjustments, this section.
9. Remove propeller and inspect propeller shaft oil seal for leakage.
Inspect propeller, thrust washer, and other propeller shaft hardware
for damage. Replace as needed.
10. Drain and refill the gearcase with specified gear oil. See Engine
Specifications in this section.
11. Lubricate all engine components as specified in the Lubrication
Chart, this section.
12. Retorque all bolts and screws to specification.
2-20
WARNING
Adjustment Part
3-/ 4-Cylinder