TOHATSU 40 Service Manual page 319

SECTION 8
Never connect PT/T motor leads directly to
battery when testing. Use battery jumper cables
to prevent sparking and damage to the motor
lead terminals.
Refer to Outboard Motors Service Data publication
for wiring diagrams when performing electrical
testing.
A fully charged battery rated at 12 V, 500 CCA with
105 minutes [70 AH] reserve capacity must be used
for all testing.
All worn, damaged, or missing parts identified during
troubleshooting must be replaced. Refer to latest
Parts Catalog for serviceable parts information.
Preliminary Service Checks
Before troubleshooting, perform the following Service Checks in
the order indicated. Use these checks to help identify problems of
simple origin and to obtain a complete assessment of the unit so
troubleshooting can begin.
Service Check 1
1. Open the manual valve several turns and manually move the
engine through the complete trim/tilt range. Verify the tilt and trim
rods are straight, undamaged, and slide smoothly. Verify there is no
restriction or binding of the swivel and stern brackets and bracket
bolt (tilt tube).
2. Turn the manual valve fully CLOSED and torque to specification.
Service Check 2
1. Check the condition and quantity of the oil in the reservoir. If oil
appears bad or level is low, completely drain, refill, and bleed the
system. Check the old oil for metal fragments or signs of gelling.
Do not mix different brands or types of oil. Doing
so can cause oil gelling which may damage the
system.
8-20
CAUTION
NOTE
NOTE
NOTE
CAUTION
3-/ 4-Cylinder