TOHATSU 40 Service Manual page 73

6. Remove the reed valve assemblies from the manifold or lift them
from the crankcase as applicable. DO NOT disassemble the reed
valve assemblies.
7. Inspect the manifold and reed valve assemblies, this section.
Inspection
1. Inspect the reed valve assemblies:
All gasket surfaces must be flat, within ± 0.003 in [0.08 mm].
1
Inspect reeds (1) for cracks or chips. Reeds must be seated
2
flat without any preload.
Inspect valve seat surfaces (2) for rise, wear, or damage.
Check tightness of reed valve stoppers. If loose, tighten screws
usingLoctite 242.
Lift height of each reed valve stopper must be within
3
specification.
Model
40
50
60 / 70 / 80 / 90
115 / 120 / 140
Inspect entire valve assembly for corrosion.
If any part of the reed valve assembly is worn, damaged, or
corroded, entire valve assembly must be replaced.
Used reeds must never be turned over and reused.
Reed could break when returned to service,
causing serious powerhead damage.
2. Inspect the intake manifold. All gasket surfaces must be
4
smooth and free of nicks. Check manifold surface for flatness
in all directions. Mounting surface must be flat, within ± 0.004 in
[0.10 mm].
All intake manifold components must be perfectly
clean before assembly. Use isopropyl alcohol. DO
NOT use a carburetor cleaner or hot soaking tank.
3-/ 4-Cylinder
Lift Height Limit
in [mm]
0.25 - 0.26 [6.5 - 6.7]
0.36 - 0.37 [9.3 - 9.5]
0.39 - 0.40 [10.0 - 10.2]
0.36 - 0.37 [9.3 - 9.5]
CAUTION
NOTE
FUEL SYSTEM
T1038
T1039
T1040
T1041
3-25