TOHATSU MD 70-90C2 Manuals

TOHATSU MD 70-90C2 Manuals

Manuals and User Guides for TOHATSU MD 70-90C2. We have 1 TOHATSU MD 70-90C2 manual available for free PDF download: Service Manual

TOHATSU MD 70-90C2 Service Manual

TOHATSU MD 70-90C2 Service Manual (349 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 14.36 MB

Table of Contents

1.Service Information

7
- Table of Contents
  7
- Service Information
  13
- Service Information
  
  14
- Identification (Engine Serial Number)
  
  14
- Work Safety
  
  14
  - Fire Prevention
    14
  - Ventilation
    14
  - Protection
    14
  - Genuine Parts
    14
  - Tools
    15
  - Recommendations on Service
    15
  - Cautions in Disassembling and Assembling Components
    16
- Tools and Instruments
  
  17
  - Test Propeller
    17
  - Measuring Instruments
    17
  - Special Tools
    18
- Pre-Delivery Inspection
  
  21
  - Steering Handle
    21
  - Gear Shift and Throttle
    21
  - Engine Oil
    21
  - Gear Oil
    21
  - Check Quantity of Engine Oil
    22
  - Fuel Line
    23
  - Installation of Outboard Motor (Rigging)
    23
  - Inspection of PTT Unit
    23
  - Inspection of Start Switch and Stop Switch
    24
  - Cooling Water Check Port
    25
  - Idling
    25
  - Propeller Selection
    25
  - Trim Tab
    26
- Break-In Operation
  
  27
- Test Run
  
  27
- Checks after Test Run
  
  27
- Service Data
  
  29
  - Clamp Dimensions
    29
- Outboard Dimensions
  
  30
  - Body Dimensions
    30
  - Clamp Dimensions
    31
- Cooling Water System Diagram
  
  32
- Specifications
  
  34
- Maintenance Data
  
  36
- Torque Specifications
  
  42
- Sealant and Lubricant
  
  44
- Warning Indication List
  
  48
- Maintenance
  
  51
- Special Tools
  
  52
- Inspection Schedule
  
  53
- Inspection Items
  
  54
  - Inspection of Top Cowl
    54
  - Oil Filter and Oil Tank
    54
  - Air Bleeding
    54
- Fuel System
  
  56
- Power Unit
  
  60
- Operating System
  
  63
- PTT System
  
  65
  - Inspection of PTT Unit Operation
    65
  - Inspection of PTT Fluid Quantity
    65
- Lower Unit
  
  66
- Others
  
  69
  - Replacement of Anode
    69
  - Inspection of Propeller
    70
  - Inspection of Battery
    71
  - Flushing with Water
    72
  - Greasing
    74
- Fuel System (TLDI)
  
  75
- Parts Layout
  
  77
  - Vapor Separator & Fuel Line
    77
  - FFP Ass'y
    78
  - Air Rail
    80
  - Air Compressor
    82
  - Oil Pump
    84
- What Is TLDI
  
  86
  - Direct Fuel Injection System
    86
  - Engine with Carburetor
    86
  - Tldi
    86
  - Inductive Ignition
    87
  - Ecu
    89
- Removing Air Rail
  
  93
- Assembly of Air Rail
  
  95
  - Installing of Injectors and Regulators
    95
  - Fuel System
    96
    
    Removing High Pressure Fuel Hose Ass'y
    99
    
    Installation of Fuel Hose Ass'y
    99
    
    Draining Fuel from FFP Vapor Separator
    100
    
    Removing Vapor Separator
    100
    
    Disassembly and Inspection of Vapor Separator
    101
    
    Assembly of Vapor Separator
    101
    
    Assembly of Vapor Separator Ass'y
    102
    
    Removing FFP* Ass'y
    102
    
    Disassembly and Inspection of FFP
    102
  - Assembly of FFP Ass'y
    103
  - Inspection of Fuel Pump
    104
  - Installation of FFP Ass'y to Cylinder
    105
- Removing and Installation of Air Compressor
  
  106
  - Removing Drive Belt
    106
  - Removing Air Compressor
    106
  - Inspection of Drive Belt
    106
  - Removing Driven Pulley
    107
  - Disassembly of Compressor Housing
    108
  - Inspection of Reed Valve
    109
  - Inspection of Cylinder and Piston
    109
  - Assembly of Compressor Housing
    109
  - Installation of Crank Shaft
    110
  - Installation of Piston
    111
  - Installation of Compressor Housing Ass'y
    112
  - Measurement of Fuel Pressure and Air Pressure
    113
  - Inspection of Oil Filter
    115
  - Inspection of Oil Tank
    115
  - Air Bleeding
    116
- Power Unit
  
  117
- Parts Layout
  
  119
  - Engine
    119
  - Magneto
    120
  - Electric Parts (Ecu•Diagram)
    122
  - Electric Parts (Starter Motor)
    124
  - Air Chamber (Air Box)
    125
  - Throttle
    126
  - Cylinder Crank Case
    128
  - Piston & Crank Shaft
    130
- Inspection Items
  
  131
  - Inspection of Compression Pressure
    131
  - Removing Power Unit
    132
  - Removing Air Compressor
    135
  - Removing Flywheel
    136
  - Removing Alternator
    136
  - Removing Starter Motor
    137
  - Removing Cord Ass'y
    138
  - Removing Oil Pump
    141
  - Removing Throttle Link
    141
  - Inspection of Throttle Body
    142
  - Removing Air Chamber
    143
  - Removing Thermostat
    144
  - Inspection of Thermostat
    145
  - Removing Fuel System
    145
  - Removing Cylinder Head / Head Cover
    145
  - Inspection of Cylinder Head
    146
  - Removing Exhaust Cover
    147
  - Inspection of Exhaust Cover
    148
  - Removing Crank Case
    148
  - Removing Pistons
    150
  - Disassembly of Crank Shaft
    151
  - Inspection of Crank Shaft
    151
  - Inspection of Cylinder
    152
  - Inspection of Pistons
    153
  - Assembly of Crank Shaft
    156
  - Installation of Pistons
    157
  - Inspection of Crankcase
    157
  - Assembly of Power Unit Parts
    158
  - Assembly of Crank Case Halves
    159
  - Installation of Exhaust Cover
    161
  - Installation of Cylinder Head
    162
  - Assembly of Crank Case Head
    163
  - Installation of Air Chamber
    164
  - Installation of Recirculation Hoses
    166
  - Installation of Throttle Link
    166
  - Installation of Oil Pump
    166
  - Installation of Fuel System
    167
  - Installation of Cord Ass'y and Electrical Parts
    167
  - Installation of Starter Motor
    167
  - Installation of Alternator
    167
  - Installation of Drive Pulley and Flywheel
    168
  - Installation of Air Compressor
    168
  - Installation of Power Unit
    168
  - Lower Unit
    171
- Lower Unit
  
  174
- Parts Layout
  
  174
  - Gear Case (Drive Shaft)
    174
  - Gear Case (Propeller Shaft)
    176
- Inspection Items
  
  178
- Cowl, Bracket and PTT Unit
  
  217
- Special Tools
  
  218
  - Top Cowl (Motor Cover Upper)
    219
  - Bottom Cowl (Motor Cover Lower)
    220
  - Shift
    222
  - Drive Shaft Housing
    224
  - Bracket
    226
  - Power Trim & Tilt
    228
- Inspection Items
  
  230
  - Removing Top Cowl
    230
  - Adjustment of Cover Hook
    230
  - Removing Bottom Cowl
    230
  - Removing Drive Shaft Housing
    231
  - Disassembly of Drive Shaft Housing
    233
  - Inspection of Drive Shaft Housing
    235
  - Assembly of Drive Shaft Housing
    236
  - Installing Drive Shaft Housing
    239
  - Removing Steering Shaft Arm
    240
  - Removing PTT Unit
    241
  - Removing Clamp Bracket
    243
  - Assembly of Clamp Bracket
    244
  - Installation of PTT Unit
    244
  - Assembly of Steering Arm
    246
  - Removing PTT Motor
    247
  - Inspection of PTT Motor
    248
  - Assembly of PTT Motor
    249
  - Removing Reservoir
    250
  - Disassembly and Assembly of Gear Pump
    251
  - Disassembly of Tilt Cylinder and Trim Cylinder
    252
  - Assembly of PTT Unit
    253
  - Air Bleeding PTT Unit
    256
- Electrical System
  
  257
- Special Tools
  
  258
- Parts Layout
  
  259
  - Starter Motor
    259
- Inspection Items
  
  260
  - Disassembly of Starter Motor
    260
  - Inspection of Armature
    263
  - Inspection of Brushes
    264
  - Inspection of Starter Motor Pinion
    264
  - Inspection of Magneto Switch
    264
  - Assembly of Starter Motor
    266
  - Inspection of Ignition and Spark
    267
  - Inspection of Plug Cap
    267
  - Inspection of Ignition Coils
    268
  - Inspection of Pick up Coil (Crank Position Sensor)
    268
  - Inspection of Pick up Coil Air Gap
    268
  - Inspection of Alternator
    269
  - Inspection of Rectifier Complete
    270
  - Inspection of Throttle Position Sensor
    271
  - Inspection of Water Temperature Sensor
    271
  - Inspection of Power Relay
    271
  - Inspection of Air Injectors
    272
  - Inspection of Fuel Injectors
    272
  - Inspection of MAT Sensor (Manifold Temperature Sensor) (Option)
    272
  - Inspection of MAP Sensor (Manifold Absolute Air Pressure Sensor) (Option)
    272
  - Inspection of Starter Solenoid
    273
  - Inspection of Oil Level Sensor
    273
  - Inspection of Oil Pump
    273
  - Inspection of Fuel Feed Pump (FFP)
    274
  - Inspection of PTT Solenoid
    274
  - Inspection of PTT Switch
    275
9 Troubleshooting O

277
- Troubleshooting O K
  277
- Troubleshooting
  
  278
  - Power Unit
    290
  - State 1 Engine will Not Start or Is
    290
- Rigging
  
  290
  - Ignition System
    292
  - Fuel System
    294
  - Air System
    296
  - State 2 Full Throttle Engine Revolution
    298
  - Ignition System
    299
  - Fuel System
    300
  - Lubrication System
    300
  - Cooling System
    302
  - State 3 Engine Rotation Is Unstable or
    303
  - Range
    303
  - Ignition System
    304
  - Fuel System
    305
- Range
  
  307
- State 2 PTT Is Not Capable of Sustaining Outboard Motor
  
  307
- Self-Diagnosis Function of TLDI
  
  308
10 Rigging R/Min

323
- Service Information
  
  324
- Service Data
  
  324
  - Load Limit of Boat
    324
  - Installation Dimensions
    324
  - Clamp Dimensions
    325
  - Hanging Outboard Motor
    327
  - Installation of Outboard Motor
    327
- Fuel System
  
  328
  - Fuel
    328
  - Oil
    328
  - Electric Fuel Pump
    328
  - Installation of Fuel Filter
    328
  - Connection of Fuel Hose
    329
  - Filling Fuel System
    329
  - Filling Oil Tank
    329
  - Priming Oil Pump
    330
- Connections to Outboard Motor
  
  330
  - Steering Cable
    330
  - Drag Link
    331
  - Installation of Remote Control Cable (Engine Side)
    332
- Lower Unit
  
  335
  - Installation of Propeller
    335
- Electric System
  
  336
  - Battery Capacity
    336
  - Connection of Battery Cables
    336
  - Installation of Battery (Ies)
    336
- Accessories and Meters
  
  337
  - Accessories
    337
  - Installation of Meters
    337
  - Meter Leads
    338
- Wiring Diagram
  
  339

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