TOHATSU 40 Service Manual page 99

Removal
Ignition system must be disabled to prevent
accidental engine startup during removal of the
powerhead.
If service work requires flywheel to be removed,
remove flywheel before lifting powerhead from the
rest of the engine. See Flywheel, this section.
Mark the mounting location of all clamps so they can
be returned to their original positions during
assembly of the powerhead.
1. Disconnect the battery and fuel tank.
2. Disable the ignition system and disconnect the battery terminals
on the powerhead.
3. Disconnect all electrical connections as applicable:
• Ground connections between lower engine cover and cylinder
block.
• Power trim and tilt connections.
• Remote control or main key switch wire harness.
• Neutral switch.
4. Disconnect fuel INPUT hose from fuel filter.
5. Disconnect pilot water hose from exhaust cover.
6. Complete the following operations.
Tiller models:
3
• Disconnect shift arm L-link (1).
• Remove throttle cable (2) from throttle cable bracket (3).
• Remove advancer arm (4) and throttle cable.
• Disconnect choke knob link rod.
Remote control models:
4
• Disconnect shift cable from shift arm.
• Remove shift assist case (5).
• Disconnect throttle cable from advancer arm.
7. Remove the splash pan.
5
8. Remove the engine mounting bolts.
6
3-/ 4-Cylinder
WARNING
NOTE
NOTE
POWERHEAD
T1202
T1203
T1204
T1205
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