Page 1 MD 30B2 40/50B2...
Page 3 Introduction Before reading this manual This service manual provides information that is needed for inspection, service and repair of applicable outboard motors. For information about operation of the products that are not described in this document, refer to the owners manual. For our customers' safe and comfortable use of the products for long term, it is essential to maintain the performance and quality of the outboard.
Page 4 About this manual Composition and use of this manual This service manual is designed so that service persons are able to perform repairs correctly. Understand the following matters well for efficient service and repair. 1 Each chapter begins with the introduction of special tools that are used for the work described. 2 Parts that are serviced in each chapter and their details are presented by using a component composition diagram.
Page 5 This manual uses SI unit system (International System of Units) for the pressure, force (load), torque and stress. This manual newly adopts the international unit construction system (SI unit system) followed by the conventional imperial and metric systems enclosed by ( ) and [ ] as described below. Example : <Pressure>...
Page 6 Description of Pictograph r/min GEAR GEAR 7471 1741 1741 1373B 1373B 1342 1342 TLD D30/40/50B2 2013...
Page 7: Table Of Contents
1) Inspection of Fuel Pipes and Joints … 3-5 1.Service Information 2) Inspect on of Fue Tank …………… 3-5 1. Identification 3) Inspection of Fuel Filter …………… 3-6 (Engine Serial Number) ………… 1-2 4) Inspection of Air Compressor Air Filter … 3-6 2.
Page 8 1) Removing High Pressure Fuel Hose Ass’y 4-24 13) Remov ng A r Chamber …………… 5-27 14) Remov ng Dr ve Pu ey Nut ……… 5-29 2) Insta at on of Fue Hose Ass’y …… 4-25 15) Remov ng Thermostat …………… 5-29 3) Draining Fuel from FFP Vapor Separator …...
Page 9 Hous ng Ass’y ……………………… 6-20 Hous ng Parts ……………………… 7-28 14) Inspection of Propeller Shaft Housing … 6-22 9) Assemb ng Rubber Mount ng ……… 7-31 15) Assembly of Propeller Shaft Housing … 6-22 10) Assemb ng Extens on Hous ng … 7-32 16) Disassembly of Propeller Shaft Ass’y …...
Page 10 19) Inspect on of O Leve Sensor …… 8-12 7) F ng O Tank …………………… 10-7 20) Inspection of Fuel Feed Pump (FFP). … 8-12 8) Pr m ng O Pump ………………… 10-8 21) Inspect on of PTT So eno d ……… 8-13 4.
Page 11 INDEX Service Information Service Data Maintenance Fuel System (TLDI) Power Unit Lower Unit Cowl, Bracket and PTT Unit Electrical System Troubleshooting Rigging r/min Wiring Diagram TLD D30/40/50B2 2013...
Page 12 TLD D30/40/50B2 2013...
Page 13 Service Information 3) Eng ne O ………………………… 1-10 1. Identification 4) Gear O …………………………… 1-10 (Engine Serial Number) ………… 1-2 5) Check quant ty of eng ne o . …… 1-11 2. Work Safety ………………………… 1-2 1) F re Prevent on …………………… 1-2 6) Fue L ne ……………………………...
Page 14: Identification (Engine Serial Number)
Service Information 1. Identification (Engine Serial Number) Engine serial number is stamped on the bottom cowl of outboard motor body. 1 Model Name Outboard Motor 3T5 ( D50B2) 2 Model Type Rated Power: 36.8kW-5500r/min 3 Serial Number Mass: 80 -108 kg Serial No.
Page 15: Recommendat Ons On Serv Ce
5) Tools Use specified special tools to prevent damaging to parts and to perform work safely and surely. Be sure to follow installation procedures described in this manual and use tightening torque specified. 3 C72 710 6) Recommendations on Service Remove foreign substances and dirt from outboard motor and individual parts by cleaning.
Page 16: Assemb Ng Components
Service Information 7) Cautions in Disassembling and Assembling Components Secure outboard motor to dedicated stand firmly. Take special care not to scratch painted surfaces or mating surfaces of cylinder and crankcase. Replace parts such as packings, gaskets, O rings, oil seals, spring pins or split pins with new ones after they are removed.
Page 17: Tools And Instruments
3. Tools and Instruments 1) Test Propeller P/N. 3C8-64110-0 Outer diameter : 198mm With : 20mm Rotational speed at WOT (Wide Open Throttle) (r/min) approximately 5,150 – 5,800 2) Measuring Instruments For the following measuring instruments, use commercially available ones. Circuit tester ( Resistance : 1Ω, 10Ω, 10 kΩ, AC voltage : 30 to 300V, DC voltage : 30V, Internal voltage 3V or less ) Vernier calipers...
Page 18 Service Information 3) Special Tools Piston Ring Tool Thickness Gauge Tachometer Vacuum/Pressure Gauge P/N. 353-72249-0 P/N. 353-72251-0 P/N. 3AC-99010-0 P/N. 3AC-99020-0 Removing or attaching piston Measuring engine revolution Measuring gaps Inspecting pressure rings speed Compression Gauge Slide Hammer Kit Shimming Gauge Backlash Measuring Tool Kit D40/50 P/N 3C8 72250 0 P/N.
Page 19 Spring Pin Tool A Spring Pin Tool B P/N. 345-72227-0 (ø3.0) P/N. 345-72228-0 (ø3.0) Propeller Shaft Housing Puller Ass'y Driver Rod P/N. 369-72217-0 (ø3.5) P/N. 369-72218-0 (ø3.5) P/N. 3A3-72259-0 P/N. 3AC-99702-0 Removing propeller shaft Used in combination with center Removing spring pin Installing spring pin housing place and various attachments...
Page 20 Service Information Pressure Gauge Ass'y Drive Pulley Puller Ass'y Eye Bolt (Powerhead Lift Ring) P/N. 3T5-72880-0 P/N. 3T5-72890-0 P/N. 3T9-72212-0 Measuring air rail fuel pressure Used to hook power unit when Removing of drive pulley and air pressure hanging ø51.5 x ø39.5 3B7-72785-0 3B7-72783-0 3C7-72783-0...
Page 21: Pre-Delivery Inspection
4. Pre-delivery Inspection 1) Steering Handle Check installation of drag link. 2) Gear Shift and Throttle Remote Control Model Shift into forward (F), back to neutral (N) and then shift into reverse (R) to check that the shift operations are smooth. Then, set the lever to position a to check that the throttle operations are smooth.
Page 22 Service Information 3) Engine Oil Supply engine oil. Engine Oil : Genuine Oil (Oil for two stroke direct injection engine recommended by the outboard manufacturer) 2st OIL CAUTION Engine oil is removed before shipment to prevent leakage during transportation. 4) Gear Oil Full tilt down outboard motor to make it vertical, and then check gear oil quantity.
Page 23 5) Check quantity of engine oil. Set outboard motor to vertical position. Check engine oil level. Oil Tank Capacity : 2.0L (0.53 gal) Engine Oil : Genuine Oil (Oil for two stroke direct injection engine recommended by the outboard manufacturer) CAUTION When quantity of fills below 1.1L (0.29gal), oil warning lamp blinks and the buzzer...
Page 24: Inspect On Of Ptt Un T
Service Information 6) Fuel Line Check that fuel tank contains sufficient amount of gasoline, fuel line is connected and does not leak. CAUTION Supply only unleaded regular octane gasoline (Pump posted 87 Octane / Research octane rating of 91 or higher) into fuel tank. Never use fuel mixed with oil.
Page 25 9) Inspection of Gas Shock Absorber Check that outboard motor tilts up/down smoothly. Tilt up outboard motor and lock it with tilt lock lever 1 to check that gas assisted holding mechanism functions normally. 10) Inspection of Start Switch and Stop switch å...
Page 26: Coo Ng Water Check Port
Service Information Press stop switch 4 hard or pull out lock plate 5 from å stop switch 4 to check that engine stops. Switch Panel Model å Remote Control Model ∫ Tiller Handle Model ç ∫ ç 11) Cooling Water Check Port Check that cooling water check port 1 discharges water during engine operation.
Page 27 12) Idling After engine has warmed up, use tachometer to check idle speed is as specified, using key switch depression. Idle Speed : 700 800 900 r/min Tachometer : P/N. 3AC-99010-0 1 High tension cord 13) Propeller Selection Select a propeller that is best-suited to type of boat and application.
Page 28: Break-In Operation
Service Information 14) Trim Tab Adjustment of trim tab angle After installing outboard motor on the boat, use trim tab to achieve balance between port and starboard steering loads. Loosen trim tab nut 2, adjust angle of trim tab 1 as described below, and then tighten the nut to specified torque.
Page 29: Test Run
6. Test Run Start engine and check if gear shift can be made smoothly. After warming up the engine, read tachometer to check idling engine speeds specified below. Idling Engine Speeds : 700 · 800 · 900 r/min Tachometer : P/N.
Page 30 Service Information 1-18 TLD D30/40/50B2 2013...
Page 31: Service Data
Service Data 1. Outboard Dimensions …………… 2-2 4. Maintenance Data ………………… 2-14 1) Body d mens ons ………………… 2-2 5. Torque Specifications …………… 2-20 2) C amp D mens ons ………………… 2-4 6. Sealant And Lubricant …………… 2-22 2. Cooling Water System Diagram … 2-6 7.
Page 32: Outboard Dimensions
Service Data 1. Outboard Dimensions 1) Body dimensions TLD D30/40/50B2 2013...
Page 33 EFTO Item Type Unit mm/in 19.65 19.65 mm/in 28.66 28.66 mm/in 33.66 33.66 mm/in 38.66 38.66 mm/in 15.87 15.87 mm/in 20.87 20.87 mm/in 25.87 25.87 mm/in 21.65 21.65 mm/in 26.77 26.77 mm/in 3.07 3.35 mm/in 23.62 23.62 mm/in 20.47 20.47 mm/in 16.89 17.32...
Page 34 Service Data 2) Clamp Dimensions Template on page 11-13 Manual Tilt Model CENTER LINE 234 mm (9.21 in) 117 mm 117 mm (4.61 in) (4.61 in) TOP OF BOAT TRANSOM ø13 mm 204 mm (8.04 in) 102 mm 102 mm (4.02 in) (4.02 in) ø13 mm...
Page 35 TLD D30/40/50B2 2013...
Page 36: Cooling Water System Diagram
Service Data 2. Cooling Water System Diagram TLD D30/40/50B2 2013...
Page 37 TLD D30/40/50B2 2013...
Page 38: Specifications
Service Data 3. Specifications Model Item Unit D40B2 D50B2 EPTO EFTO Dimensions (Approximate) Overall length mm (in) 630 (24.80) 1,120 (44.09) Overall width mm (in) 345 (13.58) 384 (15.12) Overall height mm (in) 1,227 (48.31) mm (in) 1,354 (53.31) mm (in) 1,481 (58.31) Transom length mm (in)
Page 39 Model Item Unit D40B2 D50B2 EPTO EFTO Fuel and Oil Type of Fuel Unleaded Gasoline(Reserch Octane Number 90 or over, Pump posted Octane Number 87 or over) Type Genuine Oil (Oil for two stroke direct injection engine recommended by the outboard manufacturer) Quantity L (gal) 2.0L (0.53 us gal)
Page 40 Service Data Model Item Unit D40B2Z WD50B2 EPTO EFTO EPTO EFTO Dimensions (Approximate) Overall length mm (in) 630 (24.80) 1,120 (44.09) 630 (24.80) 1,120 (44.09) Overall width mm (in) 345 (13.58) 384 (15.12) 345 (13.58) 384 (15.12) Overall height mm (in) 1,227 (48.31) –...
Page 41 Model Item Unit D40B2Z WD50B2 EPTO EFTO EPTO EFTO Fuel and Oil Type of Fuel Unleaded Gasoline(Reserch Octane Number 90 or over, Pump posted Octane Number 87 or over) Type Genuine Oil (Oil for two stroke direct injection engine recommended by the outboard manufacturer) Quantity L (gal) 2.0L (0.53 us gal)
Page 42 Service Data Model Item Unit D50B2 D30B2 EPOL EPTO EFTO Dimensions (Approximate) Overall length mm (in) 630 (24.80) 1,120 (44.09) Overall width mm (in) 345 (13.58) 384 (15.12) Overall height mm (in) 1,354 (53.31) Transom length mm (in) 530 (20.87) Weight (Approximate) kg (lb) 86.5 (191)
Page 43 Model Item Unit D50B2 D30B2 EPOL EPTO EFTO Fuel and Oil Type of Fuel Unleaded Gasoline(Reserch Octane Number 90 or over, Pump posted Octane Number 87 or over) Type Genuine Oil (Oil for two stroke direct injection engine recommended by the outboard manufacturer) Quantity L (gal) 2.0L (0.53 us gal)
Page 44: Maintenance Data
Service Data 4. Maintenance Data 2-14 TLD D30/40/50B2 2013...
Page 45 2-15 TLD D30/40/50B2 2013...
Page 46 Service Data 2-16 TLD D30/40/50B2 2013...
Page 47 2-17 TLD D30/40/50B2 2013...
Page 48 Service Data 2-18 TLD D30/40/50B2 2013...
Page 49 2-19 TLD D30/40/50B2 2013...
Page 50: Torque Specifications
Service Data 5. Torque Specifications 1→2→3→4 2-20 TLD D30/40/50B2 2013...
Page 51 2-21 TLD D30/40/50B2 2013...
Page 52: Sealant And Lubricant
Service Data 6. Sealant And Lubricant Remarks Three Shinetsu Three Bond Locktite Locktite Konishi Chuo Yuka Center Bond Silicones Research Application Points Cen ax KS 6 Piston Ring grooves, outer circumference and piston pin holes ○ Piston Pin Piston pin outer circumference ○...
Page 53 Remarks Three Shinetsu Three Bond Locktite Locktite Konishi Chuo Yuka Center Bond Silicones Research Application Points Cen ax KS 6 Sliding faces Bushing (Throttle Shaft) ○ Bushing A Sliding faces ○ Bushing B Sliding faces ○ Washer Sliding faces ○ Wave Washer Sliding faces ○...
Page 54 Service Data Remarks Three Shinetsu Three Bond Locktite Locktite Konishi Chuo Yuka Cen er Bond Si icones Research Application Points Centax KS 6 Gear B Nut After degreasing screw section completely ○ Propeller Shaft Housing nside ○ Propeller Shaft Housing O Ring ○...
Page 55 Remarks Three Shinetsu Three Bond Locktite Locktite Konishi Chuo Yuka Center Bond Silicones Research Application Points Cen ax KS 6 Stern Bracket Washer Both faces ○ Stern Bracket Fill with grease ○ Steering Shaft Sliding face ○ Steering Shaft Bushing Sliding face ○...
Page 56: Warning Indication List
Service Data 7. Warning Indication List • • • Display for abnormalities during operation （※ ） 2-26 TLD D30/40/50B2 2013...
Page 57 ・・・ 2-27 TLD D30/40/50B2 2013...
Page 58 Service Data 2-28 TLD D30/40/50B2 2013...
Page 59: Maintenance
Maintenance 1. Special Tools ………………………… 3-2 6. Operating System ………………… 3-12 2. Inspection Schedule ……………… 3-3 1) Adjustment of Thrott e Cab e 3. Top Cowl ……………………………… 3-4 (for T er hand e mode ) ………… 3-12 1) Inspect on of Top Cow …………… 3-4 2) Adjusting of Remote Control Cable …...
Page 60: Special Tools
Maintenance 1. Special Tools Compression Gauge Pressure Gauge Ass'y Spring Pin Tool A (ø3.0) Spring Pin Tool B (ø3.0) P/N. 3AC-99030-0 P/N. 3T5-72880-0 P/N. 345-72227-0 P/N. 345-72228-0 Measuring compression Measuring air rail fuel pressure Removing spring pin Installing spring pin pressure and air pressure Tachometer...
Page 61: Inspection Schedule
2. Inspection Schedule Inspection intervals Description Inspection procedure Remarks First 20 Every 50 Every 100 Every 200 hours of hours of hours of hours of 1 month 3 months 6 months 1 year Check and clean or Replace if ○ Fuel ﬁlter ○...
Page 62: Top Cowl
Maintenance 3. Top Cowl 1) Inspection of Top Cowl Push top cowl using both hands to check for looseness and state of closing. Replace top cowl if cracked or damaged. 2) Oil Filter and Oil Tank Only clean if debris, water, or contamination is present. If cleaned then you must bleed the oil system.
Page 63: Fuel System
4. Fuel System 1) Inspection of Fuel Pipes and Joints Check the fuel system piping for fuel leak, dirt, deterioration and damage, and replace or clean parts if necessary. 2) Inspection of Fuel Tank Turn fuel pick up elbow 2 of fuel tank 1 counterclockwise to remove the part, and clean the filter 3.
Page 64: Inspection Of Fuel Filter
Maintenance 3) Inspection of Fuel Filter CAUTION · If red float 1 is floating in the filter, water is in the cup. · Remove the cup and drain the water. Check fuel filter 2 for contamination, and fuel filter cup 3 for invasion of foreign matter and cracks.
Page 65 Set the lever of pressure gauge ass’y to position b to relief pressure, after engine stopping. Remove pressure gauge ass’y and attach cap. 6) Inspection of Fuel Pressure CAUTION When attaching pressure gauge ass’y, cover the joint of inspection valve and gauge with rag to prevent spread of fuel that leaks.
Page 66 Maintenance 7) Inspection of Drive Belt Remove ring gear cover. DANGER Make sure to check engine stopped. Remove air compressor to check drive belt for wear and damage on the inner and outer faces while turning flywheel clockwise. Check if oil or dirt is adhered to the belt.
Page 67: Power Unit
5. Power Unit 1) Inspection of Spark Plugs Remove plug caps and then spark plugs. Clean spark plug electrodes 1 by using spark plug cleaner. Replace if necessary. Check electrodes 1 for corrosion or excessive build up of carbon, and washer 2 for damage. Replace if necessary. Check spark plug gap a.
Page 68: Inspection Of Compression Pressure
Maintenance 2) Inspection of Compression Pressure CAUTION · To prevent accidental start of the engine, remove lock plate (of stop switch lanyard) from stop switch before measuring compression pressure. · Clean areas around spark plugs on the cylinder before removing spark plugs to prevent dirt from entering cylinder.
Page 69 3) Inspection of Thermostat Loosen cover installation bolts 1, remove them, and then remove cover 2 and thermostat 3. Hang thermostat 3 in the water contained in vessel. Put thermometer in the water, and warm up water to measure valve opening temperature. Put a piece of thread in the closed valve gap and hang it in the water.
Page 70: Inspection Of Cooling Water Passage
Maintenance 4) Inspection of Cooling Water Passage Check cooling water intake for clog. Clean if necessary. Set lower unit in the water and start engine. Check that cooling water check port 2 ejects water. 6. Operating System 1) Adjustment of Throttle Cable (for Tiller handle model) Remove throttle cable 1 from throttle cable bracket 2.
Page 71: Adjusting Of Remote Control Cable
Adjust right cable length so that the advancer arm 3 is touched to full close stopper 5 when throttle full close position, then temporary tighten the lock nut. Tighten left and right lock nut 6 to tend the throttle cable. ·...
Page 72: Ptt System
Maintenance 7. PTT System 1) Inspection of PTT Unit Operation Tilt up and down outboard motor several times to check that unit operates smoothly in full range. Check PTT fluid quantity if necessary. Refer to “Inspection of PTT Fluid Quantity”. Check that PTT motor produces noise of normal revolution.
Page 73: Lower Unit
Replenish to the specified quantity if the fluid lacks. PTT Fluid: ATF DEXRON III PTT Fluid Quantity: 325 cm (10.98 fl.oz) Attach the cap. Reservoir Cap: 1.8 N · m (0.9 lb · ft) [0.12 kgf · m] 8. Lower Unit 1) Inspection of Gear Oil Quantity Tilt down outboard motor to make it vertical.
Page 74 Maintenance 2) Replacement of Gear Oil Tilt outboard motor a little as shown. Place drain oil pan below oil plug 1, remove lower oil plug 1 and then upper oil plug 2 to drain oil. Remove lower oil plug first when draining. Check gear oil for presence of metal particles, change of color (abnormal if clouded), and viscosity.
Page 75: Inspection Of Gear Case (For Leakage)
3) Inspection of Gear Case (for leakage) Drain gear oil. Remove upper oil plug 1 and connect a commercially available leakage tester to this hole. Apply specified pressure to gear case, and check if the pressure is maintained without further compression for 10 seconds.
Page 76: Others
Maintenance Check following parts. 7 Bolts : M8 4 pcs. 8 Washers 4 pcs. 9 Pump Case (Upper) 0 Pump Case Liner q Pump Impeller → Replace with new one. w Key e Seal → Replace with new one. r Guide Plate t Gasket →...
Page 77 Check anode 1 a and trim tab 2 for deterioration. Replace anode (or trim tab) if volume is reduced to 2/3 of new part. 2) Inspection of Propeller Check propeller blades and hub for cracks, damages, wear and corrosion. Check spline for twist, and replace propeller if necessary.
Page 78 Maintenance 3) Inspection of Battery Inspect battery liquid level. If lower than “LOWER” mark a , add distilled water until the level goes in between “UPPER” and “LOWER” marks. Measure specific gravity of battery liquid. Charge battery if specific gravity is less than specified value. WARNING Electrolyte contains sulfuric acid that is poisonous and highly corrosive, which is dangerous.
Page 79 4) Flushing with Water WARNING Exhaust gas contains carbon monoxide which can cause intoxication if inhaled. Do not operated engine in a closed space such as interior of boat house. WARNING Be careful not to touch rotating propeller. Be sure to remove propeller before running engine on the land.
Page 80 Maintenance 3-22 TLD D30/40/50B2 2013...
Page 81: Fuel System (Tldi)
Fuel System (TLDI) Vapor Separator …………………… 4-26 1. Special Tools ………………………… 4-2 6) Assemb y of Vapor Separator …… 4-26 2. Parts Layout ………………………… 4-3 7) Installation of Vapor Separator Ass’y 4-27 Vapor Separator & Fue L ne ………… 4-3 FFP Ass y ………………………………...
Page 82: Special Tools
Fuel System (TLDI) 1. Special Tools Vacuum/Pressure Gauge Driver Rod Piston Slider Oil Seal Attachment P/N. 3T1-72871-0 P/N. 3AC-99020-0 P/N. 3AC-99702-0 P/N. 3T1-99820-0 Used in combination with center Assembling piston for air Used to press-fit crank case Inspecting pressure place and various attachments compressor head oil seal ø51.5 x ø39.5...
Page 83: Parts Layout
2. Parts Layout Vapor Separator & Fuel Line Description Remarks Description Remarks Q'ty Q'ty 1 Vapor Separator Ass y 25 Pump D aphragm 2 Screw 3 M4 L=14mm 26 D aphragm Gasket B Do not reuse. 3 Screw 1 M4 L=30mm 27 Check Va ve 4 F oat Vapor Separator 28 Screw...
Page 84: Ffp Ass Y
Fuel System (TLDI) FFP Ass'y 1342 1342 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 1342 1342 1342 TLD D30/40/50B2 2013...
Page 85 Ref. Description Q'ty Remarks Fue Feed Pump Ass y Fue Feed Pump Case Ass y FFP Upper Case Ass y FFP Adapter Washer Meta 10.2-17-2 Do not reuse. Gasket FFP Do not reuse. Grommet FFP Upper Grommet FFP Lower Lower Cab e Term na Ass y (+) Cab e Term na Ass y (–) Grommet Cab e Term na...
Page 86 Fuel System (TLDI) Air Rail 2st OIL S.O.C 1342 1342 1342 S.O.C 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 1342 1342 2st OIL 2st OIL 2st OIL S.O.C TLD D30/40/50B2 2013...
Page 87 Ref. Description Q'ty Remarks A r Injector Comp ete O-R ng 5-52 Do not reuse. O-R ng 2.4-9.5 Do not reuse. Fue F ter Band A r Ra Ass y L-N pp e Va ve Ass y (Pressure Check) P ug 10.5 O-R ng 6.8-1.9 Do not reuse.
Page 88 Fuel System (TLDI) Air Compressor 2st OIL 1342 1342 1342 7471 7471 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 1342 1342 TLD D30/40/50B2 2013...
Page 89 Ref. Description Q'ty Remarks Dr ve Pu ey Nut Pu ey Key Dr ve Pu ey Be t Gu de A r Compressor Ass y Compressor Head Ass y N pp e Adapter Meta Washer 10.2-17-2 Do not reuse. Bo t M6 L=30mm Gasket Compressor Head Do not reuse.
Page 90 Fuel System (TLDI) Oil Pump 2st OIL 2st OIL 4-10 TLD D30/40/50B2 2013...
Page 91 Ref. Description Q'ty Remarks O Pump Ass y O-R ng 1.6-19.2 Do not reuse. A r Vent Bo t Washer O Pump Bo t Spr ng Washer O Pump Dr ven Gear Bush ng 9-20-20.8 O Pump Rod Ba Jo nt Connector Check Va ve Comp ete P pe L=570mm...
Page 92: What Is Tldi
Fuel System (TLDI) 3. What is TLDI? Direct Fuel Injection System TLDI (Two-stroke Low-pressure Direct injection) TLDI is a kind of two stroke engine system that adopts air-assisted low pressure direct fuel injection. The adoptions of the air-assisted low pressure direct fuel injection system and digital inductive ignition system and control of factors by means of ECU (Engine Control Unit) such as fuel injection amount, fuel injection timing and ignition timing provide fuel combustion at higher efficiency, lower fuel consumption and lower emission, as well as powerful performance that is one of outstanding features of two stroke engines.
Page 93 Inductive Ignition TLDI adopts an inductive ignition system that provides the fuel combustion at higher efficiency, lower fuel consumption and lower emission. The inductive ignition of TLDI has spark plug ignition duration that is longer than that of conventional two stroke carbureted engines for surer combustion of the air-fuel mixture in the combustion chamber, ensuring more stabilized engine operation under varied operating environment.
Page 94 Fuel System (TLDI) Air Injector The air injector injects fuel and compressed air into the combustion chamber of each cylinder. The component is controlled by ECU to inject the amount of fuel mixture at the timing that is best suited to the current engine operation conditions based on the information from sensors.
Page 95: Ecu
TLDI uses ECU to control factors such as fuel injection amount, injection timing and ignition timing to the best suited conditions based on the information from the sensors.Moreover, the TLDI achieves lean combustion through stratified charge in the low engine speed range, and highly efficient combustion through electronic control of premixed charge that provides homogeneous fuel distribution in the combustion chamber in the high speed range.
Page 96 Fuel System (TLDI) 4-16 TLD D30/40/50B2 2013...
Page 97 4-17 TLD D30/40/50B2 2013...
Page 98: Removing Air Rail
Fuel System (TLDI) 4. Removing Air Rail WARNING · Be sure to decompress fuel and air before disassembling fuel system components. · Disassembling fuel system components can cause spurting of compressed fuel. 1) Decompression of Fuel Line and Air Line Push in the air valve 2 attached to air rail 1 to decompress the air line.
Page 99 Loosen two bolts 9 that secure air rail, and remove air rail ass’y 0 carefully. When removing the air rail, leave the air injectors on the cylinder side. Be careful not to drop O ring located on the air injectors. Pull the air rail straight without applying force to the air injectors.
Page 100: Assembly Of Air Rail
Fuel System (TLDI) 3) Inspection of Injectors Check air injectors and fuel injectors for cracks and damages. Replace if necessary. Check disc springs of air injectors for dirt, correct position settling and damages Clean, or replace if necessary. (Refer to "Injector Assembling Diagram" in page 4-22.) 5.
Page 101 Attach O rings 9 and 0 to air regulator 7 and fuel regulator 8. Attach compression seal w to fuel injector insert q, and then, attach the assembly to the air rail. • Attach the insert q in a correct orientation shown by arrow A.
Page 102 Fuel System (TLDI) Injector Assembling Diagram Attaching Hose Clamps Attach the following parts. Install fuel regulator 8 and air regulator 7, secure them using collars t, plate y and bolt u. Be sure to install collar t below plate y. Attach hose to fuel regulator by using hose clamp Do not reuse hose clamp.
Page 103 Attaching hose clamp. Lightly Lubricate inside of clamp to prevent hose damage. Crush hose clamp i as shown to tighten the hose securely. WARNING Do not reuse hose clamp. Be sure to use new one. Clamp Pliers : Do not reuse P/N.
Page 104: Removing And Installation Of Fuel System
Fuel System (TLDI) Install air rail ass’y to cylinder head, and secure with bolts. CAUTION When installing air rail ass’y, be careful of orientation of disc spring 5. Installing the part in wrong orientation can cause squirt of fuel. Refer to “Injector Assembling Diagram”...
Page 105 2) Installation of Fuel Hose Ass’y Reverse the removing steps. Fuel Filter Band Securing Bolt 4 Fuel Filter Band Bolt 4 : 12 N·m (9 lb·ft) [1.2 kgf·m] Nut for attaching to FFP Fuel Hose Ass’y Nut 7 : 15 N·m (11 lb·ft) [1.5 kgf·m] Do not tighten with excessive torque.
Page 106 Fuel System (TLDI) 5) Disassembly and Inspection of Vapor Separator Remove float chamber of vapor separator, and then, remove float valve 1 and float 2. Inspection of Vapor Separator 1. Check needle valve 1 for deformation and wear. 2. Check float 2 for deformation, crack and other defects.
Page 107 7) Installation of Vapor Separator Ass’y Reverse the removing steps. 1 Vapor Separator Ass’y 2 Tighten bolts. Bolts 2 : 6 N·m (4 lb·ft) [0.6 kgf·m] 8) Removing FFP* Ass’y * FFP : Fuel Feed Pump Remove parts in the order described below. Disconnect FFP connector 1, loosen hose joint 2, and then remove fuel hose ass’y.
Page 108 Fuel System (TLDI) 10) Assembly of FFP Ass’y Assemble following parts. 1342 1342 Attach hose joint adapter 1 and metal washer 2 to upper 1342 case 3. Hose Joint Adapter 1 : 1.5 N·m (11 lb·ft) [1.5 kgf·m] Degrease edge and then apply adhesive : ThreeBond 1342 1342 1342...
Page 109 Attach upper grommet 8 and cable terminal grommets 9. Grommets 8, 9 : Genuine Engine Oil Attach black wire 0 ( − ) and red wire q ( + ) of cable terminal to FFP case. Be sure to connect the wires to their corresponding 2st OIL flat terminals ( −...
Page 110 Fuel System (TLDI) 11) Inspection of Fuel Pump Remove fuel hoses (2) from fuel pump. CAUTION Catch fuel that spills when the hoses are removed. Connect vacuum/pressure gauge to inlet of fuel pump. Fill fuel pump with 20:1 gasoline-oil mixture. Close fuel pump outlet with a finger and apply specified pressure.
Page 111 12) Installation of FFP Ass’y to Cylinder Put fuel hose 3, fuel return hose 4 and vapor return hose 5 and secure them by using hose clips. Attach FFP Ass’y 1 by using bolt 2. Bolt 2 : 6 N·m (4 lb·ft) [0.6 kgf·m] Attach high pressure fuel hose 6 to FFP 1.
Page 112 Fuel System (TLDI) 7. Removing and Installation of Air Compressor 1) Removing Air Compressor Remove compressor by using the following steps. Remove water temperature sensor coupler 1 of compressor. Loose the clamps of oil pipe 2, Recirculation pipe 3 and cooling water pipe 4 at compressor side and pull hoses out.
Page 113 3) Removing Driven Pulley Remove compressor cylinder 1 from air compressor ass’y by referring to exploded diagram. Fix crank shaft at its lower end by using a vice, loosen driven pulley securing nut, and then remove driven pulley. CAUTION Be careful not to damage the crank pin 2 area when fixing crank shaft using a vice.
Page 114 Fuel System (TLDI) 4) Disassembly of Compressor Housing Remove oil seal 1 and bearing 2. Heat compressor housing to 60 to 70 degrees Centigrade (140 to 158 degrees Fahrenheit) by using hot water before removing bearing 2. CAUTION Do not reuse removed bearing. Heating of compressor housing can also be made by using a heat gun or heat lamp.
Page 115 7) Assembly of Compressor Housing Apply two stroke engine oil to periphery of bearing 3, and install it into compressor housing by using a press. Driver Rod 1 : P/N. 3AC-99702-0 2st OIL Bearing Attachment 2 : P/N. 3T1-99905-0 3 Bearing Do not reuse •...
Page 116 Fuel System (TLDI) 8) Installation of Crank Shaft Install crank shaft 1 to the housing 2, and fix the crank shaft at its lower end by using a vice. Attach collar 3, O ring 4, and driven pulley 5, and tighten nut 6 to the specified torque.
Page 117 Apply two stroke engine oil to cylinder inner wall 3, piston periphery, and piston rings, and install piston ass’y to the cylinder so that “UP” mark of the piston head is at the 2st OIL pulley side. Piston Slider 4 : P/N.
Page 118 Fuel System (TLDI) 11) Installing Air Compressor Install compressor by using the following steps. Install compressor slide up into belt and on dowel pins, and then tighten the bolts to specified torque. Air Compressor Mounting Bolt 8 : 13N·m (9 lb·ft) [1.3 kgf·m] Check the knock pin 1, installed to crank case.
Page 119 12) Measurement of Fuel Pressure and Air Pressure Use pressure gauge ass’y to measure fuel pressure and air pressure in the air rail. Pressure Gauge Ass’y : P/N. 3T5-72880-0 Perform the measurements by using the method described below. Fuel Pressure Air Pressure 4-39 TLD D30/40/50B2 2013...
Page 120 Fuel System (TLDI) How to Use Pressure Gauge Pressure Gauge Ass’y Measurement of Fuel Pressure and Air Pressure 1. Set the lever (3T5-72883-0) to position “A” shown below. 2. Screw adapter B (3T5-72884-0) into a valve of air rail for measuring air pressure or fuel pressure. WARNING Be careful of fuel that spur ts when screwing the adapter into the fuel pressure...
Page 121 8. Inspection of Lubrication System 1) Inspection of oil Pump Check if O-ring is cracked, damaged or leakes. Replace if necessary. 2) Inspection of Oil Filter Check if oil filter is cracked, damaged or leaks, or if dirt or water is in it. Clean or replace if necessary.
Page 122 Fuel System (TLDI) 4) Air Bleeding CAUTION Be sure to clean up any oil spills by waste textile. Visually check if any air is found in the oil line from oil tank to cylinder block, and if any air is found, bleed the air by using the following procedure.
Page 123 Power Unit 1. Special tools ………………………… 5-2 22) Removing of Recirculation Hoses … 5-33 2. Parts Layout ………………………… 5-3 23) Remov ng Crank Case …………… 5-33 Eng ne …………………………………… 5-3 24) Remov ng P stons ………………… 5-35 Magneto ………………………………… 5-4 25) D sassemb y of Crank Shaft ………...
Page 124 Power Unit 1. Special tools 3B7-72785-0 3B7-72783-0 3C7-72783-0 940191-0800 3B7-72784-0 Piston Ring Tool Universal Puller Plate Flywheel Puller Kit P/N. 353-72249-0 P/N. 3AC-99750-0 P/N. 3T1-72211-0 Removing and installing the Removing reverse (C) gear Removing or attaching flywheel piston rings bearing Drive Pulley Puller Ass'y Eye Bolt (Powerhead Lift Ring) Piston Pin Tool...
Page 125 2. Parts Layout Engine Description Remarks Description Remarks Q'ty Q'ty 1 Power Un t 7 Apron 2 R ng Gear Cover Ass y 8 Screw 1 M5 L=40mm W/PW 9 Ny on Nut 1 M5 3 Gasket 4 Dowe P n 10 Sea Rubber 11 Battery Cord 5 Bo t...
Page 126 Power Unit Magneto 1342 1342 1342 1342 1342 1342 TLD D30/40/50B2 2013...
Page 127 Ref. Description Q'ty Remarks F ywhee (W/R ng Gear) A ternator Ass y Screw M6 L=35mm Spr ng Washer Key (Magneto) Nut 18P1.5 Washer 19-34-3 P ck-Up Co Crank Pos t on Sensor Bo t M5 L=12mm Co Bracket Bo t M6 L=25mm Clamp 6.5-47.5P...
Page 128 Power Unit Electric Parts (ECU • Diagram) TLD D30/40/50B2 2013...
Page 129 Ref. Description Q'ty Remarks ECU Ass y 50ps 40ps (Ita y) Labe 3GF09AA Bo t M6 L=30mm Washer 6.5-21-1 Mount Moter Cover Lower Rubber Mount 8.5-14-2.5 Spacer 6.2-9-16.6 C amp 6.5-47.5P Ign t on Co (W/Res stance Cap) #1 P ug Cap (W/Res stance) Band Lead W re 158 Ign t on Co (W/Res stance Cap) #2, 3 #2, #3...
Page 130 Power Unit Electric Parts (Starter Motor) Description Remarks Description Remarks Q'ty Q'ty 1 R ng Gear Cover 17 Washer 1 M6 18 Spr ng Washer 2 M6 2 Co ar 3 Rubber Mount 9-16-4.3 19 Nut 2 M6 4 Caut on Deca (B) 20 Bo t 5 Fuse Deca 21 Spr ng Washer...
Page 131 Air Chamber (Air Box) 1342 1342 1342 1342 1342 1342 1342 1342 1342 1342 1342 1342 1342 1342 1342 Description Remarks Q'ty 1 A r Chamber Ass y 2 Reed Va ve Ass y 3 Intake Man fo d Gasket Do not reuse.
Page 132 Power Unit Throttle 1342 1342 1342 1342 1342 1342 1342 1342 1342 5-10 TLD D30/40/50B2 2013...
Page 133 Ref. Description Q'ty Remarks Advancer Arm Rod Snap 5-3 L nk Rod Ass y (Thrott e) L nk Rod Ass y (TPS) Bo t M6 L=35mm Washer 6.5-21-1 Co ar 6.2-12-17 Cab e Jo nt for “P” Type Washer 8.5-18-1.6 for “P”...
Page 134 Power Unit Cylinder Crank Case 2st OIL 2st OIL 2st OIL 5-12 TLD D30/40/50B2 2013...
Page 135 Ref. Description Q'ty Remarks Cy B ock • Crankcase Ass’y Dowe P n 6-12 Bo t M6 L=18mm Co ar 6.2-9-9.3 Bo t M8 L=45mm Washer Cy nder Head Cover Cy nder Head Cover Gasket Do not reuse. Dowe P n 4-10 Bo t M6 L=20mm Thermostat...
Page 136 Power Unit Piston & Crank Shaft 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL 2st OIL Description Remarks Description Remarks Q'ty Q'ty 7 P ston P n 1 Crankshaft Ass y (W/Gear) 2 Ma n Bear ng 6305 8 P ston P n C p Do not reuse.
Page 137 3. Inspection Items 1) Inspection of Compression Pressure CAUTION • To prevent accidental start of the engine, remove lock plate (of stop switch lanyard) from stop switch before measuring compression pressure. • Clean areas around spark plugs on the cylinder before removing spark plugs to prevent dirt from entering cylinder.
Page 138 Power Unit 2) Removing Power Unit Remove ring gear cover. Disconnect battery cables from battery terminal. Disconnect battery cables + 1 from starter solenoid. Remove oil tank bolt and oil tank temporarily, then disconnect battery cables - 2 . After disconnect battery cables, temporarily tighten oil tank bolt.
Page 139 Disconnect neutral switch connector. (F type) Loosen lock nut, then remove throttle cable 5 from throttle holder 4. (F type) Remove throttle cable form advancer arm 6. (F type) Remove throttle limiter rod 8 from throttle stopper arm 7. Remove shift lever rod 9 from shift arm (F type). Remove "R"...
Page 140 Power Unit Remove ground cable w from bottom cowl. Disconnect cooling water check port hose e under the air compressor. Disconnect fuel hose r from fuel filter. WARNING Disconnect hose while holding with waste cloth to soak fuel that spills. Remove apron t.
Page 141 Loosen outside engine mount bolts first and then remove all of them. Hoist power unit by using eye bolt y. • Set eye bolt installation hole a illustration shown and Install eye bolt to cylinder head side. • Hoist power unit taking care not to catch wires and hoses.
Page 142 Power Unit 3) Assembly of Crank Case Head Apply grease and oil to oil seal 19.6-35-10 1 and press-fit 2st OIL it to crank case head. Apply grease and oil to oil seal 35-589 2 and press-fit it to crank case head. 2st OIL 2st OIL 4) Removing Air Compressor...
Page 143 6) Removing Oil Tank Remove oil tank installation bolt (upper one) and move oil tank a little. • Before removing oil tank, disconnect oil level gage connector, and oil hose at oil filter side. • Bend oil hose at the tip to prevent oil from spilling. 7) Removing Alternator Disconnect alternator connectors.
Page 144 Power Unit 8) Removing Starter Motor Remove starter motor securing band and securing bolts (M8, 4 pcs.) on the upper surface, and then, starter motor from bracket. • Disconnect grounding wire from air chamber. • Loosen FFP bolts. 9) Removing Cord Ass'y and ECU Disconnect overheat sensor connector located on the cylinder block and the air compressor.
Page 145 Disconnect air injector connector while opening locks located on both sides of the connector by using a bladed screw driver. Repeat this step for three cylinders. Disconnect FFP connector while pushing hook of the connector. Disconnect TPS connectors while pushing hook of the connector.
Page 146 Power Unit Remove solenoid bracket and electric sub ass'y from power unit. Note that grounding wire of cord ass’y is secured together. Disconnect ECU connectors while pushing hook of ECU connector and pull apart. After removing top two ECU mount rubber bolts, remove ECU by pulling it upward.
Page 147 Removing Ignition Coils Loosen mounting bolt of ignition coils #1, #2 and #3, and remove the coils. Removing Rectifier Loosen two rectifier mounting bolts and remove the unit. Removing Crank Position Sensor Loosen two mounting bolts and remove the crank position sensor.
Page 148 Power Unit 11) Removing Throttle Link Remove throttle link rod 1 and TPS link rod 2. • Remove each link rod at the advancer arm side 3 first. • When removing each link rod at the ball joint side, be careful not to apply force to the arm. Loosen advancer arm mounting bolt and remove the arm.
Page 149 12) Inspection of Throttle Body Check throttle body for wear of throttle cam and cam roller, and check if throttle cam and roller move smoothly. Do not move adjust screw located on the upper part of throttle body. 13) Removing Air Chamber Loosen air chamber cover mounting bolts in the order shown, remove them, and remove air chamber cover.
Page 150 Power Unit Loosen air chamber mounting bolts in the order shown, remove them, and remove air chamber. Remove air chamber and remove reed valve ass’y 1. Inspection of Reed Valve Ass’y Check reed valve and valve seat surface for bend, wear and damage.
Page 151 14) Removing Drive Pulley Nut Remove drive pulley nut 1 and belt guide 2. Crankshaft Holder 3 P/N. 3T5-72815-0 Hold drive pulley nut by crankshaft holder 3, and then loosen nut using spanner and wrench (36 mm). 15) Removing Thermostat Loosen thermostat cap mounting bolts 2, remove them, remove cap 1 , and take out thermostat 3.
Page 152 Power Unit 16) Inspection of Thermostat Put thermostat in the vessel containing water, heat it, and measure the temperature at which the thermostat starts to open. Replace thermostat if the valve is open even a little at ambient temperature. Valve Opening Temperature : 52˚C (125.6˚F) Valve Full Open Temperature : 65˚C (149˚F)
Page 153 Remove engine anode 1 and check it. Replace it if it is reduced to 2/3 of the original size. 19) Inspection of Cylinder Head Remove carbon deposit in the combustion chamber of cylinder head, and check the interior for degradation, damage and other defects.
Page 154 Power Unit 20) Removing Exhaust Cover Loosen exhaust cover mounting bolts in the order shown, remove them, and remove exhaust cover. Loosen the bolts in descending order of the numbers embossed on the exhaust cover. • Pry the gap of the cover at five grooves one by one by using a bladed screw driver.
Page 155 22) Removing of Recirculation Hoses Remove recirculation hoses. 23) Removing Crank Case Remove starter motor bracket. 5-33 TLD D30/40/50B2 2013...
Page 156 Power Unit Loosen crank case mounting bolts in the order shown, remove them, and remove crank case. • When removing crank case, pry the gap at the groove of crank case by using a bladed screw driver. • Note that there are two knock pins on the mating surface of crank case.
Page 157 24) Removing Pistons Remove piston pin clip by using a pair of pointed nose pliers. When removing piston pin clip, be careful not to damage the piston pin hole. Remove piston pin 1, washer and needle bearing. Use piston pin tool 2 if necessary. Put the piston pin tool on the piston pin and tap it lightly taking care not to apply excessive force to the connecting rod.
Page 158 Power Unit 25) Disassembly of Crank Shaft Remove main bearing (Lower). Remove "C" ring 1 and pull out spacer 2. Remove main bearing (lower) 3 by using universal puller plate and universal puller. Universal Puller Plate 4 : 3AC-99750-0 Puller 5 : Commercially Available Item Protecting Plate 6 •...
Page 159 Slowly removing drive pulley, while tightening center bolt (19 mm) 4 step by step. 27) Inspection of Crank Shaft Visually check crank shaft ass’y upper and lower end bearings for flaws, wear and other damages. Replace crank shaft ass’y if necessary. Specified Value a : #1, Top ø36.0 mm (1.4173 in) #3, Under ø25.0 mm (0.9843 in)
Page 160 Power Unit Replace crank shaft ass’y if the deflection is over the standard value. Connecting Rod Deflection Limit : 2.0 mm (0.08 in) 28) Inspection of Cylinder Measure cylinder inner diameters (D ) at a, b and c. If any of the diameter is over the limit, replace the cylinder or bore the liner to make it compatible with an oversize piston.
Page 161 29) Inspection of Pistons Inspection of Piston Outer Diameter Measure piston outer diameter, and replace the piston if the outer diameter is less than the functional Limit. Measurement Point b : 12 mm (0.47 in) above bottom end of piston skirt. approximately 90 degrees from pin hole.
Page 162 Power Unit Inspection of Piston Ring Side Clearance 1) Attach a piston ring to piston, and measure piston ring side clearance. Replace piston ring if the clearance is over specified value. Piston Ring Tool : P/N. 353-72249-0 Piston Ring Side Clearance : Standard Value : Top Ring Second Ring...
Page 163 Inspection of Piston Pins Measure piston pin outer diameter, and replace piston pin if the outer diameter is over the limit. Piston Pin Outer Diameter : Standard Value 17.00 mm (0.6693 in) Measuring Locations : and D 10 mm (0.394 in) from top end and bottom end respectively 27.5 mm (1.083 in) from the end Inspection of Piston Pin Clearance...
Page 164 Power Unit 30) Assembly of Crank Shaft Press-fitting Bearing 1) Insert a holding bar a in between crank webs and press-fit bearing 1. Bearing Press-Fitting Tool 2 : Inner Diameter: ø30 mm (1.181 in) Do not reuse removed bearing. 2st OIL 2st OIL Press-fit spacer 35-48.6-16 3 and attach "C"...
Page 165 31) Installation of Pistons Installation of Piston Rings Complete 3rd ring first. • When attaching a piston ring, face the side of the ring marked with "T" upward 1. • Bring piston ring gap to knock pin 2. Installation of Piston Pin Attach piston to washer, needle bearing and connecting rod by using piston pin.
Page 166 Power Unit 33) Assembly of Power Unit Parts Install main bearing (upper) 1 to crank shaft ass’y, if remove drive pulley. • Face the marking on the bearing to flywheel side. • Apply LIT grease to the oil seal lip. 2st OIL 2st OIL Install crank shaft ass'y to cylinder.
Page 167 Positioning Upper Bearing and Main Bearing • Attempt to move each bearing lightly to check if dowel pin is in the hole snugly. • Each bearing is provided with a bearing lubrication hole 2 on the opposite side of knock hole to check the location.
Page 168 Power Unit Install crank case to cylinder. Before securing with bolts, fit crank case snugly to the cylinder by tapping with a plastic hammer to make the gap between surfaces surfaces even. Tighten crank case securing bolts and nuts (M8) in the order of the numbers shown.
Page 169 35) Installation of Exhaust Cover Assemble exhaust cover, gasket, anode and anode cap. Attach exhaust cover securing bolts (M6) and tighten them in the order of their numbers shown to specified torque. Exhaust cover Bolts : 12 N · m (9 lb · ft) [1.2 kgf · m] Tighten the bolts in the order of the numbers marked on the exhaust cover.
Page 170 Power Unit 36) Installation of Cylinder Head Attach anode 1 to cylinder. Attach dowel pins to cylinder head, and then attach gaskets and cylinder head cover. Temporary tighten cylinder cover securing bolts (M6) in the order of the numbers shown. Temporary Tightening : 2.5 N ·...
Page 171 37) Installation of Drive Pulley Clean and remove grease at installation surface (inside) of crankshaft and drive pulley. • Apply Loctite 7471 (primer) to crankshaft after cleaning, and dry approximate 5 minutes. • Apply Loctite 648 to installation surface (inside) of drive pulley.
Page 172 Power Unit 38) Installation of Recirculation Hoses ① ② ③ 5-50 TLD D30/40/50B2 2013...
Page 173 39) Installation of Air Chamber Attach reed valve, air chamber and gaskets to crank case. Attach and tighten securing bolts (M6) (M6) to specified torque in the order of the numbers shown. 1342 1342 1342 • Use new gaskets. • When reusing bolts, apply screw lock #1342. Air Chamber Bolts (M6) –...
Page 174 Power Unit Install new O-ring to oil pump ass'y, then cylinder ass'y. • Align slot of oil pump drive gear and drive shaft. • Reconnect oil hose to crankcase. “Refer to Oil System diagram” in Chapter 4. • Use waste cloth to let it soak with oil if spilled from hose.
Page 175 • Apply LIT grease to sliding faces of throttle cam and roller. • Apply ThreeBond 1342 to throttle body securing bolts. 1342 1342 1342 1342 1342 Attach air chamber cover and gasket. Attach and tighten air chamber securing bolts (M6) to specified torque in the order of the numbers shown.
Page 176 Power Unit 45) Installing Solenoid Bracket Install fuse holder plate, cord clamp and rubber mount. Rubber mount (up down) Set cord clamp angle to 15 degree. Fuse holder late Collar Cable clamp Install starter solenoid, PTT solenoid and fuse holder to solenoid bracket.
Page 177 46) Installation of Cord Ass’y and Electrical Parts Reverse cord ass’y removing procedure described in “Removing Cord Ass’y” in Chapter 5. 47) Installation of Starter Motor Secure starter motor mounting band by using bolts (M8, 4 pcs.) on the upper surface of the motor, and then, install starter motor to bracket.
Page 178 Power Unit 50) Installation of Flywheel Attach key, flywheel and drive pulley to crank shaft, and tighten the nut to specified torque. Flywheel Puller Kit : P/N. 3T1-72211-0 Drive Pulley : 150 N · m (118 lb · ft) [15 kgf · m] Degrease tapered areas of crank shaft and flywheel before installing them.
Page 179 Lower Unit 1. Special tools ………………………… 6-2 21) Inspect on of Dr ve Shaft ………… 6-28 2. Parts Layout ………………………… 6-4 22) Inspect on of P n on (B) Gear …… 6-28 Gear Case (Drive Shaft, D30/40/50) … 6-4 23) Assemb y of Dr ve Shaft Parts …… 6-29 Gear Case (Dr ve Shaft, WD50) ………...
Page 180 Lower Unit 1. Special tools Spring Pin Tool A Spring Pin Tool B P/N. 345-72227-0 (ø3.0) P/N. 345-72228-0 (ø3.0) Propeller Shaft Housing Puller Ass'y Driver Rod P/N. 369-72217-0 (ø3.5) P/N. 369-72218-0 (ø3.5) P/N. 3A3-72259-0 P/N. 3AC-99702-0 Removing propeller shaft Used in combination with center Removing spring pin Installing spring pin housing...
Page 181 Shimming Gauge D30/40/50:P/N. 3C8-72250-0 Thickness Gauge Backlash Measuring Tool Kit Backlash Measuring Tool Kit WD50:P/N. 353-72250-0 P/N. 353-72251-0 D30/40/50:P/N. 3C8-72234-1 WD50:P/N. 3B7-72234-0 Adjusting pinion (B) gear Used to attach dial gauge Measuring backlash between forward Measuring gaps height when measuring backlash (A) gear and pinion (B) gear Dial Gauge Plate Backlash Measuring Tool Clamp...
Page 182 Lower Unit 2. Parts Layout Gear Case (Drive Shaft, D30/40/50) GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR 1342 1342 1342 GEAR GEAR GEAR 1342 1342 1342 1342 1342 1342 Description Remarks Description Remarks Q'ty Q'ty 1-1 Gear Case Ass'y 1 for Transom "S", "L"...
Page 183 GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR 1342 1342 1342 GEAR GEAR GEAR 1342 1342 1342 1342 1342 1342 Description Remarks Description Remarks Q'ty Q'ty 24 Snap 37 Water Pump Impeller 25 Propeller Shaft Housing Ass'y 1 D30/40/50B2 38 Key 26 Propeller Shaft Housing 39 Pump Case (Upper)
Page 184 Lower Unit GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR 1342 1342 1342 GEAR GEAR GEAR 1342 1342 1342 1342 1342 1342 Description Remarks Description Remarks Q'ty Q'ty 52 Bolt 1 M6 L=16mm 65 Bolt 6 M8 L=35mm 53 Push Rod 66-1 Water Pipe (S) 1 D30/40/50B2 for Transom "S", 54 Ball 3/8...
Page 185 GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR 1342 1342 1342 GEAR GEAR GEAR 1342 1342 1342 1342 1342 1342 Description Remarks Q'ty 71 Thrust Holder 72 Stopper 73 Propeller Nut 74 Washer 17-32-3 75 Split Pin 3-25 TLD D30/40/50B2 2013...
Page 186 Lower Unit Gear Case (Drive Shaft, WD50) GEAR GEAR GEAR 1342 GEAR GEAR GEAR 1342 1342 GEAR GEAR GEAR GEAR GEAR GEAR 1342 1342 1342 1342 1342 1342 Description Remarks Description Remarks Q'ty Q'ty 1 Gear Case Ass'y 1 with Sub Water Pipe 14 Water Pipe Seal (Lower) 2 Roller Bearing 25-33-30 15 Pump Case (Lower)
Page 187 GEAR GEAR GEAR 1342 GEAR GEAR GEAR 1342 1342 GEAR GEAR GEAR GEAR GEAR GEAR 1342 1342 1342 1342 1342 1342 Description Remarks Q'ty 29 Spring Pin 3.5-14 Do not reuse. 30 Spring Pin 3.5-10 Do not reuse. 31 Cam Rod Bushing 32 O-Ring 1.9-6.8 Do not reuse.
Page 188 Lower Unit Gear Case (Propeller Shaft, WD50) 1342 1342 1342 1342 1342 Description Remarks Description Remarks Q'ty Q'ty 14 Spring Retainer 1 Tapered Roller Bearing 32007JR Do not reuse. 15 Spring 2 Trim Tab 16 Snap 3 Trim Tab Gasket Do not reuse.
Page 189 1342 1342 1342 1342 1342 Description Remarks Q'ty 22-8 Propeller Ass'y 16.5" 1 3 X 273 X 417 22-9 Propeller Ass'y 17.5" 1 3 X 276 X 447 23 Thrust Holder 24 Stopper 6-11 TLD D30/40/50B2 2013...
Page 190 Lower Unit 3. Inspection Items 1) Draining Gear Oil Drain gear oil. Refer to “Replacement of Gear Oil” in Chapter 3. · Drain all gear oil, and check if any metal particle is found in the drained oil. · Check gear oil color. White or cream color possibly indicates that water is contained in the gear oil.
Page 191 3) Removing Lower Unit WARNING When working with outboard motor in tilt up position, be sure to lock with tilt stopper. · Removal of lower unit does not require removal of power unit from outboard motor body. · When removing lower unit from outboard motor, tilting the outboard motor makes the work easier.
Page 192 Lower Unit 4) Disassembly of Cam Rod Remove stopper, pull out cam rod bushing, and take out cam rod from gear case. When removing cam rod bushing, put a bladed screw driver into groove of the bushing and pull out while lifting it. Remove shift rod joint 1 and clutch cam 2.
Page 193 6) Assembly of Clutch Cam Parts Attach O rings 1.9-6.8 2 and O ring 3.5-27.7 3 to cam rod bushing 1. GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR 23 O Rings Do not reuse. Attach cam rod bushing 1, shift rod joint 5 and clutch cam 6 to cam rod 4.
Page 194 Lower Unit 7) Removing Water Pump Loosen and remove pump case (upper) bolts, and remove pump case (upper) parts 1, 2, 3 and 4 in this order. Remove water pump impeller key 5. Remove guide plate 6, gasket 7 and pump case (lower) When removing pump case (lower), insert bladed screw driver into the groove of the case, and pry slowly to separate the part.
Page 195 8) Inspection of Water Pump Check pump case liner 1 and guide plate 2 for deformation and wear. Replace if necessary. Check pump impeller 3 for crack, damage and wear. Replace if necessary. · The impeller may show gloss or have melted area if it is rotated with insufﬁcient water.
Page 196 Lower Unit 10) Disassembly of Water Pump Case (Lower) Use bladed screw driver or seal remover to remove oil seal 1. · Two oil seals are used. Note that there is a shim in between oil seals. · Be careful not to give ﬂaw to oil seal press ﬁt face.
Page 197 12) Removing Propeller Shaft Housing Ass’y Loosen and remove bolts 1. Use propeller shaft housing puller to pull out propeller shaft housing to the position where O ring of the housing can be removed. Propeller Shaft Housing Puller Ass’y 2 : P/N.
Page 198 Lower Unit 13) Disassembly of Propeller Shaft Housing Ass’y Pull out propeller shaft ass’y 1. Remove reverse (C) gear 2 by using bladed screw drivers Check oil seal 4 for wear and crack. Replace if necessary. Remove bearing 5. CAUTION Heat propeller shaft housing by putting it in the hot water of approximately 60 - 70˚C (140 - 158˚F), and remove bearing 4.
Page 199 Use a press to remove oil seal 4 and roller bearing 6 at the same time. · Before removing, check bearing for play or deﬂection. Replace if necessary. · Direct the side of attachment without O-ring to roller bearing. 5 Oil Seal Do not reuse.
Page 200 Lower Unit 14) Inspection of Propeller Shaft Housing Clean the part by using a solvent and then check. Replace if necessary. Check reverse (C) gear for crack or abnormal wear of the teeth and dog. Replace if necessary. Check bearing for abnormality. Replace if necessary.
Page 201 Install oil seal 5. Use a suitable press 6 to install new oil seal to propeller shaft housing. · Install oil seal with the marking facing tool side. · Clean oil seal installation face and apply gear oil before installation. ·...
Page 202 Lower Unit Attach shim 0 used on the reverse (C) gear 9 to the gear. GEAR GEAR Use a suitable press to install reverse (C) gear 9. GEAR Clean reverse (C) gear bearing installation face and apply gear oil before installation. Bevel Gear Bearing Install Tool q : P/N.
Page 203 Pull out clutch pin 4, and remove clutch spring retainer 5, clutch spring 6, and clutch by referring to the figure. WARNING · W h e n r e m o v i n g c l u t c h p i n , w e a r protective glasses, and do not point opening of propeller shaft to your face or body while holding the propeller shaft.
Page 204 Lower Unit 18) Assembly of Propeller Shaft Ass’y Attach spring 6, spring retainer 5, steel ball 2, push rod 1, clutch 7 and clutch pin 4 to propeller shaft. · When attaching clutch, face the narrower claw a to push rod side. ·...
Page 205 19) Removing Drive Shaft Ass’y Remove pinion (B) gear nut 4, and then, remove pinion (B) gear 3 and drive shaft. · Degrease pinion (B) gear nut completely so that the nut wrench does not slip on the nut. · Loosen and remove the nut by using a drive shaft socket and a wrench and turning the wrench counterclockwise.
Page 206 Lower Unit 20) Disassembly of Drive Shaft Ass’y Remove outer shim 1. Remove drive shaft spring 2. Remove taper ball bearings 3 by using press and universal puller 4. CAUTION Do not reuse removed bearing. Be sure to replace with new one. ·...
Page 207 23) Assembly of Drive Shaft Parts Attach pinion (B) gear nut 1 to drive shaft temporarily. Install bearing 2 by using press and a suitable pipe 3. Before installing bearing, be sure to clean drive shaft installation face and apply gear oil. CAUTION Do not press drive shaft thread a directly.
Page 208 Lower Unit Install another bearing 4 as same. GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR 4 Bearing 4 Bearing Do not reuse. Do not reuse. Attach drive shaft spring 5. CAUTION When attaching the spring, face the side b toward pinion (B) gear side.
Page 209 24) Removing Forward (A) Gear Ass’y Take out bearing 1 and forward (A) gear 2 by using a hand put in the gear case. · Put mid ﬁnger into forward (A) gear hole and take it between the ﬁnger and the ﬁrst ﬁnger (thumb), and lift the thumb side of the gear to remove it.
Page 210 Lower Unit WD50 only Remove roller bearing 3. Drive out roller bearing from the gear by using a bladed screw driver or a punch and a hammer at teeth side of the gear. CAUTION · When removing roller bearing, take care not to scratch forward (A) gear bearing face.
Page 211 Attach shim 4 used before disassembly to taper roller bearing 5, and press-fit the part. Apply gear oil to press-ﬁt face when press-ﬁtting taper roller bearing. Bevel Gear Bearing Install Tool 3 : P/N. 3C8-72719-0 GEAR GEAR GEAR GEAR GEAR GEAR 6-33 TLD D30/40/50B2 2013...
Page 212 Lower Unit 28) Disassembly of Gear Case Remove roller bearing 1 by using the following tools. Align the mark (C or D) of press guide 2 with right side installation hole on the pump case. WD50 D30/40/50 1 Roller Bearing 1 Roller Bearing Do not reuse.
Page 213 This work can be done also by using the following tool kit. D30/40/50 WD50 Roller Bearing Puller Kit : Roller Bearing Puller Kit : P/N. 3C8-72700-0 P/N. 3B7-72700-0 Remove taper roller bearing outer race w. Put the slide hammer in the gear case, hook claw of slide hammer on the outer race to fix it, and slide the hammer to pull out the outer race.
Page 214 Lower Unit 30) Assembly of Gear Case Parts CAUTION When gear case, forward (A) gear or bearing is replaced, measure backlash and attach a proper shim. Refer to “Chapter 6 Shim Adjustment”. Use the following tools to install taper roller bearing 1 outer race.
Page 215 Install roller bearing 7 by using the following tools. CAUTION Install bearing so that marked side faces upward. · Align following marks of the press guide 8 and installation hole of the pump case front-right side, then attach press guide. ·...
Page 216 Lower Unit 31) Measurement of Pinion (B) Gear Height and Shim Selection CAUTION When gear case, drive shaft or pump case (lower) is replaced, measure pinion (B) bear height and back lash between gears, and perform shim adjustment. Before measuring back lash of each gear, measure drive shaft pinion (B) gear height and adjust the height to proper value if necessary.
Page 217 D30/40/50 WD50 Shimming Gauge 3 : Shimming Gauge 3 : P/N. 3C8-72250-0 P/N. 353-72250-0 Thickness Gauge : Thickness Gauge : P/N. 353-72251-0 P/N. 353-72251-0 Add shim 6 to bottom of b pump case (lower) to adjust the gap a to specified value. D30/40/50 WD50 Pinion (B) Gear Height a :...
Page 218 Lower Unit 32) Measurement of Back Lash between Forward (A) and Pinion (B) Gears and Shim Selection CAUTION Before measuring backlash between forward (A) and pinion (B) gears, measure pinion (B) gear height. Refer to “Measurement of Pinion (B) Gear Height and Shim Selection”...
Page 219 Install backlash measuring tool parts 2 to 7 and secure them with installation bolts (M8 L=30mm) 8. D30/40/50 WD50 Dial Gauge Plate 1 : Dial Gauge Plate 1 : P/N. 3B7-72729-0 P/N. 3B7-72729-0 Backlash Measuring Tool Kit : Backlash Measuring Tool Kit : P/N.
Page 220 Lower Unit Attach backlash measuring tool clamp w to drive shaft. Turn drive shaft 9 clockwise / counterclockwise slowly while pulling it up, and read change of dial gauge e indication. · When measuring, contact dial gauge tip to inside of V groove located in the clamp ass’y.
Page 221 D30/40/50 WD50 Shim Thickness : mm (in ) Shim Thickness : mm (in ) Dial Gauge Reading : mm (in) Dial Gauge Reading : mm (in) +means addition of shim/- +means addition of shim/- means removal of shim means removal of shim 0 00 ~ 0 16 (0 00 ~ 0 0063) −0 10...
Page 222 Lower Unit WD50 only 33) Measurement of Back Lash between Pinion (B) and Reverse (C) Gears and Shim Selection CAUTION Before measuring backlash between pinion (B) and reverse (C) gears, establish pinion (B) gear height. Refer to “Measurement of Pinion (B) Gear Height and Shim Selection”...
Page 223 Attach backlash measuring tool clamp w to drive shaft. Turn drive shaft t clockwise / counterclockwise slowly while pulling it up, and read change of dial gauge e indication. When measuring, contact dial gauge tip to inside of V groove located in the clamp ass’y. Backlash Measuring Tool Clamp w : P/N.
Page 224 Lower Unit 34) Assembly of Lower Unit Parts After installing forward (A)gear with taper roller bearing 1, install drive shaft ass'y 2, pinion (B) gear 3 and pinion (B) gear nut 4, and tighten the nut to specified torque. 1342 1342 1342 1342...
Page 225 D30/40/50 WD50 Bevel Gear B Nut Wrench 6 : Bevel Gear B Nut Wrench 6 : P/N. 353-72231-0 P/N. 346-72231-0 Bevel Gear Nut Socket 5 : Bevel Gear Nut Socket 5 : P/N. 346-72232-0 P/N. 346-72232-0 Pinion (B) Gear Nut 4 : 53 N ·...
Page 226 Lower Unit Attach water pump liner 0 to pump case (upper) q. CAUTION Align pump liner 0 protrusion a with pump case (upper) q concave b. Apply OBM grease to inside of water pump liner. Put pump case (upper) q and gasket (2 pcs.) on the drive shaft, and install them on the pump case (lower) 3.
Page 227 37) Installing Propeller Shaft Housing Ass'y Attach O ring 2 to propeller shaft housing 1. Apply OBM grease to O ring. Attach steel ball 4, clutch push rod 5 and washer 6 that was removed when disassembling to propeller shaft 3. Install propeller shaft 3 to propeller shaft housing 1, and install the assembly to gear case.
Page 228 Lower Unit Select washer 1 thickness so that the play is within the specified range. Specified Value of Play : 0.2 - 0.4 mm (0.0078 - 0.0157 in) Type of Washers : 3.0 mm (0.118 in) P/N. 353-64032-0 2.75 mm (0.1083 in) P/N. 353-64034-0 2.5 mm (0.0984 in) P/N.
Page 229 Put lower unit ass’y into drive shaft housing. Connect and align positions of water pipe and water pipe seal 2. Move flywheel clockwise if necessary to align crank splines. Tighten lower unit ass’y installation bolts and nut to specified torque. CAUTION To make centering of lower unit ass’y to drive shaft housing, attach bolts to two...
Page 230 Lower Unit Connect shift rod joint 3 and shift rod 4, and drive in spring pin 5. · Do not reuse spring pin. · Replace with new one when removed. Spring Pin Tool B 6 : (ø3.0) P/N. 345-72228-0 5 Spring Pin Do not reuse.
Page 231 Cowl, Bracket and PTT Unit 1. Parts Layout ………………………… 7-2 13) Remov ng PTT Un t/ Dr ve Shaft Hous ng …………………… 7-2 Gas Shock Absorber ……………… 7-35 Bracket Power Tr m and T t …………… 7-4 14) D sassemb ng C amp Bracket …… 7-36 15) Assemb ng C amp Bracket ………...
Page 232 Cowl, Bracket and PTT Unit 1. Parts Layout Drive Shaft Housing 1342 1 342 1342 1741 1741 1741 1741 1741 1741 1741 1741 1741 1342 1342 1342 1342 1342 1342 1741 1741 1741 TLD D30/40/50B2 2013...
Page 233 Ref. Description Q'ty Remarks Eng ne Basement Exhaust P ug Eng ne Basement Gasket Do not reuse. Eng ne Basement Sea Do not reuse. Bo t M6 L=25mm Dowe P n 6-12 Exhaust P pe Bo t Exhaust P pe Gasket 10-1 Dr ve Shaft Hous ng (S) for Transom “S”...
Page 234 Cowl, Bracket and PTT Unit Bracket Power Trim and Tilt 1342 1342 1342 1342 1 342 1342 TLD D30/40/50B2 2013...
Page 235 Ref. Description Q'ty Remarks C amp Bracket (PTT-R) Stern Bracket (R) Starboard C amp Screw K t C amp Screw (PTT) C amp Screw Pad Shou der Bo t C amp Bracket (PTT-L) Stern Bracket (L) Port Anode Stern Bracket Bo t M6 L=30mm Sw ve Bracket Shaft Ass y...
Page 236 Cowl, Bracket and PTT Unit Power Trim And Tilt 1342 1342 1342 1342 1342 1342 TLD D30/40/50B2 2013...
Page 237 Ref. Description Q'ty Remarks Motor Ass y Armature Ass y Motor Bracket Ass y Breaker O-R ng 2-55.5 Do not reuse. Screw M5 L=20mm Coup ng Pump O-R ng 1.8-69.6 Do not reuse. Screw Va ve Ass y Re ef Va ve Ass y Pump Bo t Bo t...
Page 238 Cowl, Bracket and PTT Unit Bracket Manual Tilt 1342 1342 1342 1342 1342 TLD D30/40/50B2 2013...
Page 239 Ref. Description Q'ty Remarks C amp Bracket (R) Stern Bracket (R ght) Starboard C amp Screw K t C amp Screw C amp Screw Hand e R vet 3-22 C amp Screw Pad Shou der Bo t C amp Bracket (L) Stern Bracket (Left) Port Sw ve Bracket Shaft Ass y Bracket Bo t...
Page 240 Cowl, Bracket and PTT Unit Manual Tilt 7-10 TLD D30/40/50B2 2013...
Page 241 Ref. Description Q'ty Remarks T t Stopper Ass’y Bush ng 10.2-12-29.5 Sett ng P ate Bo t M8 L=20mm Fr ct on Spr ng Sett ng P ece T t Stopper T t Ass stant Spr ng (R) T t Ass stant Spr ng (L) T t Ass stant Shaft Reverse Lock (L) Reverse Lock (R)
Page 242 Cowl, Bracket and PTT Unit Tiller Handle (F Type) 7-12 TLD D30/40/50B2 2013...
Page 243 Ref. Description Q'ty Remarks T er Hand e Ass y Steer ng Hand e A ssy T er Hand e Thrott e Shaft Thrott e Shaft Damper A Spacer Thrott e Shaft A Spr ng P n Bush ng 8.4-10-11 Screw M5 L=25mm Thrott e Shaft Support...
Page 244 Cowl, Bracket and PTT Unit Bottom Cowl (Motor Cover Lower) 7-14 TLD D30/40/50B2 2013...
Page 245 Ref. Description Q'ty Remarks Bottom Cow Grommet Power Tr m • T t Sw tch Mount Moter Cover Lower Spacer 6.2-9-15.7 Bo t M6 L=30mm Washer 6.5-21-1 P ug Choke Knob Hook Lever Washer 14-22-1 Sea R ng Hook Lever Hook Lever Bush ng Wave Washer Cover Hook...
Page 246 Cowl, Bracket and PTT Unit Shift 7-16 TLD D30/40/50B2 2013...
Page 247 Ref. Description Q'ty Remarks Sh ft Arm Bush ng Sh ft Lever Shaft Wave Washer d=12 DWG Sh ft Rod Lever Sh ft Rod Lever Sh ft Lever Stopper for “P” Type Sh ft Lever Stopper for “F” Type Sh ft Lever Stopper for “P”...
Page 248 Cowl, Bracket and PTT Unit Switch Box (F type) Cord Colors コード色 Black ：黒 Brown ：茶 Green ：緑 Blue ：青 Light green ：ライトグリーン Pink ：ピンク：赤 Skya blue ：空 White ：白：...
Page 249 Top Cowl (Motor Cover Upper) Description Remarks Description Remarks Q'ty Q'ty 1 Top Cow Ass y 10 Ny on Nut 6P1.0 4 for T t Hand e M6 2 Top Cow Sea 11 Washer 6-16-1.5 4 M6 3 F er L d 12 Sea Rubber F er L d 4 F er L d H nge 13-1 Deca Set (D50B2)
Page 250 Cowl, Bracket and PTT Unit 2. Inspection Items 1) Inspection of Throttle Cable Check operation of throttle cable. Check throttle cable inner wire and outer wire for bend and damage. Replace if necessary. 2) Removing of Tiller Handle Remove advancer arm 1 and remove throttle wire from adovancer arm.
Page 251 Remove tiller handle holder installation nut 7. Remove tiller handle and throttle shaft 8. 7-21 TLD D30/40/50B2 2013...
Page 252 Cowl, Bracket and PTT Unit 3) Installation of Tiller Handle Install bushing 1, wave washer 2 and washer 3 on the steering bracket 4. Install throttle cable as shown. 7-22 TLD D30/40/50B2 2013...
Page 253 Install throttle shaft 5 with wire to Tiller handle. Be careful of location of throttle friction 6, throttle shaft spacer 7, throttle shaft damper 8 and bushing 9. Attach Tiller handle ass'y to steering bracket 4, and tighten nut 0 to specified torque. Tiller Handle Nut 9 : 27 N ·...
Page 254 Cowl, Bracket and PTT Unit 4) Removing Bottom Cowl Remove power unit. Refer to “Removing Power Unit” in chapter 5. Remove snap retainer 1. And then, remove shift rod lever Remove shift rod 3. Loosen and remove four bolts that secure bottom cowl to engine base.
Page 255 5) Removing Drive Shaft Housing Use the following steps to remove drive shaft housing. Loosen and remove lower rubber mount cap installation bolts to remove mount cap 1. Loosen and remove lower rubber mount installation nuts to remove rubber mount 2. Remove only the nut and do not remove mount bolt.
Page 256 Cowl, Bracket and PTT Unit 6) Disassembly of Drive Shaft Housing Loosen upper mount lubber cap mounting bolts 1, and remove it. Remove engine base bolts 2. Tap lightly with a plastic hammer to separate engine base from the housing if it is seized. If necessary, use a bladed screw driver to pry the engine base taking care not to scratch mating surface.
Page 257 Loosen and remove bolts 7 that secure exhaust pipe 6 to engine base and remove exhaust pipe. 7) Inspection of Drive Shaft Housing Check mount rubber 1 and dumper rubber 2 for crack and deterioration. Replace if necessary. Check water pipe 3 for corrosion and deformation. Replace if necessary.
Page 258 Cowl, Bracket and PTT Unit Check if drive shaft housing is distorted. Place the housing on the surface plate and use dial gauge to measure distortion on the upper face of the housing. Replace if the difference is over 0.228mm (0.0090in) on each measuring point.
Page 259 Install exhaust housing grommet 5 to exhaust housing When installing the grommet by using adhesive, clean adhering area to remove dirt and oil and dry the area before applying adhesive. 1741 1741 1741 Install exhaust housing 6 and gasket 7 to engine base 3 and tighten bolts to specified torque.
Page 260 Cowl, Bracket and PTT Unit Install water pipe to drive shaft housing, and attach gasket after confirming that dowel pins 9 are on the drive shaft housing. Check that drive shaft housing dowel pin is placed and secured to engine base properly. Check that water pipe is at joint of engine base.
Page 261 9) Assembling Rubber Mounting Install upper mount 1 and bolts 2 install by upper mount holding plate 3. 1342 1342 CAUTION Install the mount with the side of longer size a facing forward. Attach lower mount 6 and bolt 7 to drive shaft housing. CAUTION Install the mount with the side of longer size b facing forward.
Page 262 Cowl, Bracket and PTT Unit WD50 Only 10) Assembling Extension Housing Align notches a inside the tube joint 1 with hole b of the extension pipe 2, then insert. Passage c for adjusting water flow. Check the passage for clogged by salt, clean if necessary. Insert tube joint 1 and extension pipe 2 to extension housing 3, as shown.
Page 263 11) Removing Steering Shaft Arm Remove "C" ring 1 that supports mount bracket 2. Remove mount bracket 2. When mount bracket cannot be removed, tap the bracket at both ends alternately by using a plastic hammer. Pull up steering shaft arm 3 to remove. Do not lose bushing 4 and O-ring 5.
Page 264 Cowl, Bracket and PTT Unit 12) Installing Steering Shaft Attach thrust plate 1 and bushing 2 friction piece 3 to steering shaft. Stand swivel bracket ass'y vertically, and insert steering shaft into swivel bracket ass'y. Attach bushing 4, new O ring 5, and thrust plate 6 to swivel bracket.
Page 265 13) Removing PTT Unit/Gas Shock Absorber Fully tilt up outboard motor and lock with tilt stopper 1. WARNING Be sure to lock outboard motor with tilt stopper after tilting up. Leaving outboard m o t o r w i t h o u t l o c k i n g m a y l e a d t o accidental descent due to reduction of PTT hydraulic pressure.
Page 266 Cowl, Bracket and PTT Unit 14) Disassembling Clamp Bracket WARNING · When disassembling clamp bracket, be sure to fully tilt up outboard motor. If outboard motor is fully tilt down it can pop out spring suddenly and result in severe injury. ·...
Page 267 15) Assembling Clamp Bracket å Apply grease to swivel bracket, swivel bracket shaft, bushing. å : PTT/ Gas assist model ∫ : Manual tilt model ∫ Manual Tilt Model Only Put bushing to swivel bracket, and then, insert swivel bracket shaft 1 into clamp bracket 2 and tilt assistant spring 3.
Page 268 Cowl, Bracket and PTT Unit 16) Disassembling tilt mechanism Set tilt stopper lever to "release" side, and then, remove tilt stopper setting plate 1. Remove tilt stopper 2, bushing 3, set piece 4 and spring 5. 7-38 TLD D30/40/50B2 2013...
Page 269 Remove springs 6. Remove E-rings, and then, remove reverse lock shaft 7 by using screw driver. 17) Assembling tilt mechanism Install reverse lock link 1 and arm 2 as shown and then, install reverse lock shaft. 7-39 TLD D30/40/50B2 2013...
Page 270 Cowl, Bracket and PTT Unit Install reverse lock spring 3 and spring 4 springs in reverse procedures of disassembling. Install tilt stopper 5, bushing 6, set piece 7 and spring 18) Removing PTT Motor Remove PTT motor 2, O-rings 3, 4 and coupling 5 from PTT unit 1.
Page 271 19) Disassembling PTT Motor Remove bolt 1, and then remove stator 2. Cover armature shaft end with clean cloth, hold the shaft using a pair of pliers, and remove armature 3 from stator carefully. Remove armature 3 from PTT motor base. Do not apply grease or oil to commutator.
Page 272 Cowl, Bracket and PTT Unit 20) Inspection of PTT Motor Measure brush length. Replace if it is less than specified value. Brush Wear Limit a : 5.0 mm (0.1969 in.) Check electrical conductivity of brush and circuit breaker. Replace if not conductive. CAUTION ·...
Page 273 21) Assembling PTT Motor Parts Connect PTT motor leads and secure them with screws. Put brushes 1 into brush holders, and attach armature 2. Install stator to base. Cover armature shaft end with clean cloth, hold the shaft using a pair of pliers, and install armature to stator carefully.
Page 274 Cowl, Bracket and PTT Unit 23) Inspection of PTT Pump and Valves Clean piston and ball, and check them for damages and wear. Replace PTT pump if necessary. Check drive gear and driven gear for damages and wear. Replace PTT pump if necessary. Check valve for damage and clogging.
Page 275 25) Inspection of Tilt Cylinder and Reserve Tank Check reservoir 1 and upper oil seal for dameges and wear. Replace reserve tank if necessary. Check tilt rod 2 for bend, any scratched of sliding surface and wear. Replace tilt rod if necessary. Check tilt rod for bend and hard rusting.
Page 276 Cowl, Bracket and PTT Unit 27) Installation of PTT Pump and Motor Use vise to fix PTT unit 1 that is protected at both sides with wood pieces or aluminum plates. Assemble valve ass'y 2, releaf valve ass'y 3 and PTT pump ass'y 4, and tighten bolt 5 to specified torque.
Page 277 28) Air-Purging PTT Unit (separated from outboard motor) Turn manual valve 1 clockwise fully. Manual Valve : 1.8 N·m ( 1.3 lb·ft ) [ 0.18 kgf·m ] Place PTT unit 2 vertically. PTT unit must be in vertical position as shown. Remove cap 3 and check fluid level in the reservoir tank.
Page 278 Cowl, Bracket and PTT Unit Reverse connection of PTT motor lead wires to battery terminals to fully stretch tilt rod. T t Rod PTT Motor Lead Wires Battery Term na s B ue (L) + : Pos t ve Term na Stretch Green (G) –...
Page 279 29) Installation of PTT Unit/Gas Shock Absorber Fully tilt up outboard motor and lock with tilt stopper 1. WARNING Be sure to lock outboard motor with tilt stopper after tilting up. Leaving outboard m o t o r w i t h o u t l o c k i n g m a y l e a d t o accidental descent due to reduction of PTT hydraulic pressure.
Page 280 Cowl, Bracket and PTT Unit 30) Air-Purging PTT Unit (installed on the outboard motor) Install outboard motor on the boat. Fully tilt up outboard motor and lock with tilt stopper. Remove cap 2 and check fluid level in the reservoir tank. Turn manual valve counterclockwise fully.
Page 281 Add recommended PTT fluid to specified level if it is lacking. Recommended PTT Fluid : ATF DEXRON III Reservoir tank cap and tighten to specified torque. Reserve Tank Cap : 1.2 N·m ( 0.9 lb·ft ) [ 0.12 kgf·m ] Repeat steps from 5.
Page 282 Cowl, Bracket and PTT Unit 7-52 TLD D30/40/50B2 2013...
Page 283 Electrical System 1. Special Tools ………………………… 8-2 11) Inspect on of Rect f er Comp ete … 8-9 2. Parts Layout ………………………… 8-3 12) Inspection of Throttle Position Sensor … 8-10 E ectr c Parts (Starter Motor) ………… 8-3 13) Inspection of Water Temperature Sensor 8-10 3.
Page 284 Electrical System 1. Special Tools Spark Tester P/N. 3F3-72540-0 Checking sparks TLD D30/40/50B2 2013...
Page 285 2. Parts Layout Electric Parts (Starter Motor) Description Remarks Description Remarks Q'ty Q'ty 1 R ng Gear Cover 17 Washer 1 M6 18 Spr ng Washer 2 M6 2 Co ar 3 Rubber Mount 9-16-4.3 19 Nut 2 M6 20 Bo t 4 Caut on Deca (B) 5 Fuse Deca 21 Spr ng Washer...
Page 286 Electrical System 3. Inspection Items 1) Disassembly of Starter Motor Push down pinion stopper 1, remove pinion stopper clip 2, and then, remove pinion return spring and pinion. Remove bolt and screw, and disassemble starter motor. 2) Inspection of Armature Check armature commutator a for deposit of carbon and other dirt.
Page 287 3) Inspection of Brushes Measure brush length a, and replace brush if the length is less than specified value. Brush Length a : Standard Value 12.5 mm (0.49 in) Wear Limit : 9.5 mm (0.37 in) Check conductivity of brush holder ass'y. Replace if other than specified value.
Page 288 Electrical System 5) Inspection of Ignition and spark WARNING · When testing, put electrode cap assuredly to prevent direct contact with spark tester wiring and leak of electrical current, and perform test carefully. · Keep flammable gas, fuel, oil away from tester to prevent them from catching sparks.
Page 289 7) Inspection of Ignition Coils a b c This test can be made without removing parts. Remove ignition coil coupler. Measure ignition coil resistance. Replace if other than specified value. Ignition Coil Resistance : Primary Side : Between a and b 0.45 - 0.55 Ω Secondary Side : Between c and d 10.8 - 16.2 kΩ...
Page 290 Electrical System 10) Inspection of Alternator Disconnect alternator connector and measure resistance between terminals. Replace alternator if the resistance is out of specified range. Resistance between Terminals of Connectors a, b and c : @20˚C (68 ˚F) 0.374 - 0.506 Ω TLD D30/40/50B2 2013...
Page 291 11) Inspection of Rectifier Complete Measure resistance between terminals. This test can be made without removing parts. a Yellow b Red c Black Rectifier Tester Check Table “ON” means conductive and “OFF” means no conductivity. Positive Tester Lead (Red) Black Yellow Yellow Yellow...
Page 292 Electrical System 12) Inspection of Throttle Position Sensor This test can be made without removing parts. Measure resistance between terminals. Replace throttle position sensor if the resistance is out of specified range. When lever is at position A (wide open throttle) : Between a - c : 4 - 6 kΩ...
Page 293 15) Inspection of Fuel Injectors This test can be made without removing parts. Measure resistance between the terminals, and replace fuel injector if the resistance is out of specified range. Resistance between terminals : @20˚C (68˚F) 1.7 - 1.9 Ω Apply 12V to the terminals to check if the part “clicks”...
Page 294 Electrical System 18) Inspection of Starter Solenoid This test can be made without removing parts. Connect tester lead wires to both terminal of starter solenoid. （B）（G） Connector green (G) lead wire to battery positive terminal. Connector black (B) lead wire to battery negative terminal. Check electrical conductivity between terminals of starter solenoid.
Page 295 21) Inspection of PTT Solenoid This test can be made without removing parts. Disconnect positive and negative cables from battery. Disconnect PTT leads from terminals 1 and 2. å DOWN Check electrical conductivity of PTT solenoid. Replace if other than specified value. PTT Solenoid Conductivity Sky Blue (Sb) -Black (B) Conductive...
Page 296 Electrical System 22) Inspection of PTT Switch å å Check electrical conductivity of PTT switch. Replace if other than specified value. Lead Wires Switch Position Sky Blue (Sb) Red (R) Pink (P) Up (Ascend) Free Down (Descend) ∫ ∫ å EPT model ∫...
Page 297 Troubleshooting Ign t on System ………………………… 9-28 1. Troubleshooting …………………… 9-2 Fue System …………………………… 9-29 Power Unit …………………………… 9-14 State 1 Engine will not start or is PTT Unit State 1 PTT unit will not operate. … 9-30 hard to start. …………………………… 9-14 State 2 PTT is not capable of sustaining Ign t on System …………………………...
Page 298 Troubleshooting 1. Troubleshooting Note: This information is applicable also to 40B/50B and 70B/90B. This troubleshooting information covers malfunctions and abnormalities of electrical parts which are warned of by the buzzer and warning lamp. For the operations of the buzzer and warning lamp, refer to “Warning Indication List”. ○...
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Page 300 Troubleshooting ○ ...
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Page 302 Troubleshooting ○ ○ ○ ○ ○ ① ② ③ TLD D30/40/50B2 2013...
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Page 304 Troubleshooting ○ ○ ○ ○ ○ ...
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Page 306 Troubleshooting ○ ...
Page 307 9-11 TLD D30/40/50B2 2013...
Page 308 Troubleshooting ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 9-12 TLD D30/40/50B2 2013...
Page 309 9-13 TLD D30/40/50B2 2013...
Page 310 Troubleshooting Before working on the engine, check that hull, rigging and engine installation are normal, and then battery is fully charged.For mechanical troubleshooting, refer to relevant troubleshooting section in this chapter. For checking and servicing outboard motor, refer to service procedures described in this manual to perform the work safely.
Page 311 Check electrical conductivity of neutral switch. Conductive? Replace neutral switch. Check start switch or main switch. Replace start switch or Normal? main switch. Check electrical conductivity of wire harness. Repair or replace wire Conductive? harness. Disassemble starter motor and check. 9-15 TLD D30/40/50B2 2013...
Page 312 Troubleshooting Ignition System Check spark plugs. Clean spark plug, or Normal? replace. WARNING · When testing, put electrode cap assuredly to prevent Use spark tester to check direct contact with spark tester wiring and leak of ignition sparks. electrical current. ·...
Page 313 Normal? Replace ignition coil. Check ECU. 9-17 TLD D30/40/50B2 2013...
Page 314 Troubleshooting Fuel System Check operation of fuel feed pump (FFP). Check electrical conductivity Operating of wire harness and fuse. noise heard? Repair or replace Conductive? defective parts. Check if proper voltage is supplied to fuel feed pump (FFP). Check or replace Battery voltage battery.
Page 315 Normal? Replace air rail. Check fuel filter for clogging and dirt, and hoses for leak. Repair and clean or Normal? replace defective parts. Check fuel pump. Normal? Replace fuel pump. Check vapor separator needle valve for bend and wear. Normal? Replace needle valve.
Page 316 Troubleshooting Air System Check operation of air rail air injector. Measure resistance Normal? Replace air injector. between terminals. Apply 12V between terminals to check if Replace air injector. injector "clicks". Check fuel system and compression pressure. Nut of air hose joining Any air leak from Tighten nut and air compressor tightened?
Page 317 Check air compressor. Disassemble compressor Rotate pulley to check if Normal? and check reed valve and discharge pressure exists. piston rings. Check air filter for clogging. Replace air filter. 9-21 TLD D30/40/50B2 2013...
Page 318 Troubleshooting State 2 Full throttle engine revolution speed is low, engine revolution speed falls off, or engine stalls. Check battery cables for defective contact, and ground lead wire securing bolt for looseness or Repair or replace Normal? defective parts. Check throttle position sensor and crank position sensor connectors for connections.
Page 319 Ignition System Check spark plugs. Clean spark plugs, or Normal? replace. WARNING · When testing, put electrode cap assuredly to prevent Use spark tester to check direct contact with spark tester wiring and leak of ignition sparks. electrical current. · Keep flammable gas, fuel, oil away from tester to prevent them from catching sparks.
Page 320 Troubleshooting Fuel System Check fuel filter for clogging and dirt, and hoses for leak. Repair or replace Normal? defective parts. Measure fuel pressure. Out of specified Check fuel injector clogging range? and resistance. Normal? Replace fuel injector. Check ignition system, lubrication system and/or cooling system.
Page 321 Check needle valve of vapor separator. Normal? Replace needle valve. Check ignition system, lubrication system and/or cooling system. Lubrication system Check oil level in the oil tank. Within specified Add engine oil to range? specified level. Check oil level sensor. Replace oil level Normal? switch.
Page 322 Troubleshooting Cooling System Check cooling water passage for clogging or leak. Clean or replace Normal? cooling water passage. Check thermostat. Normal? Replace thermostat. Measure water temperature sensor resistance. Replace water Normal? temperature sensor. Check water pump. Normal? Replace water pump. Check ignition system, fuel system and/or lubrication system.
Page 323 State 3 Engine rotation is unstable or surging occurs in low speed range. Check throttle position sensor and crank position sensor connectors for connections and resistance. Repair or replace Normal? defective parts. Check throttle link and throttle cam for play and wear. Adjust throttle link or Normal? replace throttle cam...
Page 324 Troubleshooting Ignition System Check spark plugs. Clean spark plugs, or Normal? replace. WARNING Use spark tester to check · When testing, put electrode cap assuredly to prevent ignition sparks. direct contact with spark tester wiring and leak of electrical current. ·...
Page 325 Fuel System Check fuel pump. Normal? Replace fuel pump. Check vapor separator needle valve for bend and wear. Normal? Replace needle valve. Check injector for clogging and resistance. Normal? Replace injector. Check ignition system. 9-29 TLD D30/40/50B2 2013...
Page 326 Troubleshooting PTT Unit State 1 PTT unit will not operate. Check operation of PTT motor. Operating Check battery and fuse. noise heard? Repair or replace Normal? defective parts. Check electrical conductivity of PTT switch. Conductive? Replace PTT switch. Check electrical conductivity of PTT solenoid.
Page 327 Check PTT fluid level. Within specified Add PTT fluid to range? specified level. Disassemble PTT unit to check. State 2 PTT is not capable of sustaining outboard motor. Check if manual valve is closed. Closed? Close manual valve. Check PTT fluid level. Within specified Add PTT fluid to range?
Page 328 Troubleshooting 2. Self-Diagnosis Function of TLDI The self-diagnosis function detects a trouble(s) of electrical system of TLDI engine and displays the part by using ECU installed in the engine. TLDI engine requires no instruments and special equipment such as personal computer when executing the self-diagnosis function that uses key switch operation, tachometer’s RPM indication and a combination of three warning lamps to show information necessary for troubleshooting through the following four modes.
Page 329 2) Operation Procedure of Self-Diagnosis Function * The self-diagnosis function is enabled only when the engine is stopped state. * The self-diagnosis function is stopped at any moment during the following procedure when the key switch is set to “OFF”. After attaching stop switch lock, set key switch to "ON".
Page 330 Troubleshooting Go into process of the self-diagnosis operation from here. Set the key to "ON", and push it in (for approximately 5 seconds seconds) until the buzzer sounds. Beep!! Beep!! Beep!! Self-Diagnisos Mode 1[Tachometer Operation Test] After the pointer returns to "zero", the process goes to mode 2 automatically.
Page 331 Self-Diagnisos Mode 4 [Deletion of fault history] In any of the states in the self-diagnosis mode 3, the fault history is deleted by removing stop switch lock plate and pushing in key for approximately 3 seconds. At this moment, the buzzer "Beeps" three times.
Page 332 Troubleshooting 3) Warning Indication List • • • Display for abnormalities during operation × × × × × × × × × × × × × × × × × 9-36 TLD D30/40/50B2 2013...
Page 333 （）（）（）（）・・・ 9-37 TLD D30/40/50B2 2013...
Page 334 Troubleshooting 4) Operating Hour Indication List (Self Diagnosis • Mode 2) Lamp Indication Tacho meter Engine Operating Hours (hours) Tach. Indication (r/min) Lamp A Lamp B Lamp C 0 - 1 1,000 — — — 1 - 2 2,000 — —...
Page 335 9-39 TLD D30/40/50B2 2013...
Page 336 Troubleshooting 5) Trouble Indication List (Self Diagnosis • Mode 3) Tacho meter → ：：： 9-40 TLD D30/40/50B2 2013...
Page 337 → → → 9-41 TLD D30/40/50B2 2013...
Page 338 Troubleshooting Tacho meter （）ＦＦＰ 9-42 TLD D30/40/50B2 2013...
Page 339 9-43 TLD D30/40/50B2 2013...
Page 340 Troubleshooting 6) Resetting TPS Initial Values Use the following proseedures to reset the ECU and TPS idling position in case where self-diagnosing indicates idling position errors for TPS1 and TPS2. 1 When either the TPS or ECU is replaced or control cables replaced : 2 When the self-diagnosing function indicates “TPS Idling Position Error : 3 When links and rod snap rings are replaced due to warping or wear in the linkage : 4 When the TPS idling Position Error indication appears after performing engine disassembly and assembly...
Page 341 Wait another 5 to 10 seconds, again pull the red knob on the stop switch for about 0.5 seconds, then release the switch. Seconds 0 . 5 S e c o n d s Resetting of TPS and ECU is completed when the buzzer “Beeps” three Seconds times approximately 5 seconds after the knob of stop switch is returned to original position.
Page 342 Troubleshooting 9-46 TLD D30/40/50B2 2013...
Page 343 Rigging r/min r/min 1. Service Information ……………… 10-2 4. Connections to 2. Service Data ………………………… 10-2 Outboard Motor ……………………… 10-8 1) Load L m t of Boat ………………… 10-2 1) Steer ng Cab e …………………… 10-8 2) Insta at on D mens ons …………… 10-2 2) Drag L nk ……………………………...
Page 344 Rigging r/min 1. Service Information The persons who perform the rigging should take sufficient care for prevention of damages to himself or herself and the products, prevention of fire, and ventilation of the shop. The persons who operate the boat equipped with this product for test run should read the operating instructions of the outboard, and be familiar with the operating procedure.
Page 345 3) Clamp Dimensions Manual Tilt Model 234 mm (9.21 in) 117 mm 117 mm (4.61 in) (4.61 in) ø13 mm 204 mm (8.04 in) 102 mm 102 mm (4.02 in) (4.02 in) ø13 mm DIAMETER PTT/Gas Assist Model 163.5 mm 163.5 mm (6.45 in) (6.45 in)
Page 346 Rigging r/min Transom Dimensions and Drilling Template (An example) * Full scale transom dimensions and drilling template is shown at the end of this manual. 10-4 TLD D30/40/50B2 2013...
Page 347 Installation of an outboard motor at higher position can cause the matters described below. 1) Suck in air from a cooling water inlet, and overheat can easily. 2) Deterioration of steering feeling. 3) Propeller can easily run above water surface (over-revs) during planning or when the boat is heavily loaded.
Page 348 Rigging r/min Install outboard motor(s). Secure the outboard motor by using fasteners contained in the package of the product. 1 : 12mm diameter, Bolts (4 pcs.) 2 : Flat Washers (4 pcs.) 3 : Lock Nuts (4 pcs.) 4 : Flat Washers (4 pcs.) 4 : Marine Sealant : Apply to the bolts’...
Page 349 5) Filling Fuel System Fill the fuel system as described below before initially starting new engine, after engine exhausted fuel, or after draining fuel from engine. WARNING To prevent damaging to fuel pump, fill engine’s fuel system with fuel. If not, the fuel pump operates without fuel during priming of oil pump.
Page 350 Rigging r/min 8) Priming Oil Pump After installing outboard motor, prime oil pump before initially starting the engine. The priming removes all air bubbles contained in the pump, oil feed hose and internal oil passage. Refer to “Air Purging” in Chapter 4. 4.
Page 351 2) Drag Link Attach drag link as shown. When installing steering rod that connects engine and steering cable, be sure to use special bolt 1,split pin 2 and nylon lock nuts 3. Do not use regular bolts and non-lock type nuts in place of these bolts and lock nuts, or the nuts may be loosened due to mechanical vibration resulting in disconnection of the link rod.
Page 352 Rigging r/min 3) Installation of Remote Control Cable (Engine Side) Turn upper motor cover hook levers 1 and 2 and remove upper motor cover. 1 Thottle cable 2 Shift cable 3 Grommet 5 Cord ass'y (B) (Remote control harness) 6 Battery cables 7 Meter cord Ass'y Install cable clip bracket to the bottom cowl.
Page 353 Screw cable joint 9 on the tip of remote control cable by approximately 10mm. The screw-in distance of cable joint, 10 mm, is equivalent to approximately 9 threads. Shift cable is the one of which tip is moved when remote control lever is set to forward (F) side until it stops once (approx.
Page 354 Rigging r/min Adjust screw in length of cable joint so that cable joint hole aligns with shift arm and advancer arm pins, lock the joint with nut, and then, set it on the arm pin and secure with “R” pin and washer. Put the cable in cable clip groove, and then secure it by using cord clamp.
Page 355 5. Lower Unit 1) Installation of Propeller WARNING · Before removing or installing propeller, be sure to disconnect battery cables from battery and remove stop switch lock plate. · When removing or installing propeller, do not handle propeller with bare hands. ·...
Page 356 Rigging r/min 6. Electric System 1) Battery Capacity 12V100 AH or more 12V120 AH or more (in cold regions) CCA : 850 CCA : 1000 MCA : 1100 MCA : 1500 2) Connection of Battery Cables Single Outboard Installation 1 : Red Sleeve (Positive Side) 2 : Black Sleeve (Negative Side) 3 : Starting Battery Twin Outboard Installation...
Page 357 7. Accessories and Meters 1) Accessories. Start In-Gear Protection (Neutral Safe Starting Switch) The remote control box connected to the outboard motor is equipped with start in-gear protection (neutral safe starting switch) This function disables the engine starting when shift gear is engaged. WARNING If engine starts with the shift gear engaged, the boat may start to move unexpectedly, possibly leading to serious injury or fatal accident.
Page 358 Rigging r/min <Tachometer> Set selector 3 to “4P” on the back of the meter. Connect cord ass’y B and meter lead wire to cord ass’y A. Connect trim sensor 1 with trim sensor extension cord 2. (option) Refer to <Electrical Wiring Assembling Instruction Diagram in the Chapter 11>...
Page 359 Wiring Diagram TLDI Wire Harness Terminals and Electrical Wiring Assembling Connections ……………………………… 11-2 Instruction Diagram -2 ……………… 11-11 Main Harness Diagram ……………… 11-3 Completed Pre-Assembly …………… 11-12 Assembly Step -1 ……………………… 11-12 D40/50B2 EPTO, EPO, D30B2 EPTO Electrical Circuit …………………………… 11-5 Assembly Step -2 ………………………...
Page 360: Tldi Wire Harness Terminals And
Wiring Diagram TLDI Wire Harness Terminals and Connections 25 26 27 28 11 12 15 16 17 18 19 20 NO Component Lead W re Co or TPS1 (Thrott e Pos t on Sensor 1) B ue/Red Key Sw tch (PUSH) B ue CPS (Crank Pos t on Sensor) B ue/B ack...
Page 361: Main Harness Diagram
Main Harness Diagram PTT SOLENOID (DOWN) PTT SOLENOID (UP) STARTER MOTOR SOLENOID CWT (WATER TEMP SENSOR) FUSE MAP SENSOR (OPTION) STARTER MOTOR (GND) #1 FUEL INJECTOR CRANK POSITION SENSOR OIL LEVEL SENSOR #2 FUEL INJECTOR MAT SENSOR (OPTION) PTT SWITCH #3 FUEL INJECTOR ERITHMIN FUEL FEED PUMP (FFP)
Page 362 11-4 TLD D30/40/50B2 2013...
Page 363: Electrical Circuit
Wiring Diagram D40/50B2 EPTO, EPO, D30B2 EPTO Electrical Circuit Name of Component Name of Component A ternator Ass y Cord Ass y B Rect f er Comp ete Neutra Sw tch Battery (Loca ) Buzzer PTT sw tch ※ Ma n Sw tch O Leve Sensor Lanyard Stop Sw tch Thrott e Pos t on Sensor...
Page 364 D40/50B2 EPTO, EPO, D30B2 EPTO Electrical Circuit EPTO MODEL FUSE HOLDER EPTO モデルヒューズホルダ MAGNETO マグネト DOWN km/h Wharnig Wharnig Wharnig Lamp 1 Lamp 2 Lamp 3 Lg/R Lg/W Lg/B メンテナンススイッチ回路 Main Switch Circuite B B R R G L #2 6 G ( NO ) G ( CON ) #1 6...
Page 365 11-7 TLD D30/40/50B2 2013...
Page 366: Electrical Circuit
Wiring Diagram D40/50B2 EFTO, EFO, D30B2 EFTO Electrical Circuit Name of Component Name of Component A ternator Ass y Cord Ass y B Rect f er Comp ete Neutra Sw tch Battery (Loca ) Buzzer PTT sw tch ※ Ma n Sw tch O Leve Sensor Lanyard Stop Sw tch Thrott e Pos t on Sensor...
Page 367 D40/50B2 EFTO, EFO, D30B2 EFTO Electrical Circuit FUSE HOLDER ヒューズホルダ MAGNETO マグネト DOWN Lg/R メンテナンススイッチ回路 EFTO MODEL Lg/W Main Switch Circuite EFTO モデル B Br R R G L Lg/B START O-O-O PUSH VARIABLE IDLE O-O-----O #2 6 #1 6 SWITCH BOX スイッチボックス...
Page 368: Electrical Wiring Assembling Instruction Diagram -1
Electrical Wiring Assembling Instruction Diagram -1 11-10 TLD D30/40/50B2 2013...
Page 369: Electrical Wiring Assembling Instruction Diagram -2
Electrical Wiring Assembling Instruction Diagram -2 VIEW:A VIEW:A TLD D30/40/50B2 2013 11-11...
Page 370 B 11-12 TLD D30/40/50B2 2013...
Page 371 WARNING WARNING...
Page 372 INDEX <A> Crank Shaft Assemb y ……………………………………… 5-42 Accessor es ………………………………………………… 10-15 Crank Shaft D sassemb y ………………………………… 5-36 A r B eed ng ………………………………………………… 3-4 Crank Shaft Inspect on …………………………………… 5-37 A r B eed ng ………………………………………………… 4-42 Crank Shaft Insta at on …………………………………… 5-36 A r Chamber Insta at on ……………………………………...
Page 373 Fue / A r Feed System …………………………………… 4-16 Measur ng Instruments …………………………………… 1-5 Fue Feed Pump (FFP) Inspect on ………………………… 8-12 Meters Insta at on ………………………………………… 10-15 Fue F ter Inspect on ……………………………………… 3-6 <O> Fue F ter Insta at on ……………………………………… 10-6 Fue Hose Ass y Insta at on ………………………………...
Page 374 PTT Sw tch Inspect on ……………………………………… 8-14 TLDI W re Harness Term na s and Connect ons ………… 11-2 PTT Un t A r-Purg ng ( nsta ed on the outboard motor) … 7-50 Top Cow Inspect on ………………………………………… 3-4 PTT Un t A r-Purg ng (separated from outboard motor) …...
Page 377 MD 30B2 40/50B2 OB No.003-21050-3 13-10 NB Printed in Japan...

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