User Manuals: TOHATSU TLDI 40 Outboard Motor

User Manuals: TOHATSU TLDI 40 Outboard Motor

Manuals and User Guides for TOHATSU TLDI 40 Outboard Motor. We have 1 TOHATSU TLDI 40 Outboard Motor manual available for free PDF download: Service Manual

TOHATSU TLDI 40 Service Manual

TOHATSU TLDI 40 Service Manual (186 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 3 MB

Table of Contents

Specifications
2
Specifications Table
4
Outline Dimensions
5
External Dimensions
6
Air-Assisted Low-Pressure Direct Injection
7
Background on TLDI
7
Two-Stroke Low-Pressure Direct Injection (TLDI)
7
ECU Control
8
Crank-Position Sensor (CPS)
9
Long-Duration CDI (L-CDI)
9
Throttle-Position Sensor (TPS)
9
Water-Temperature Sensor (WTS)
9
Fuel Supply System
10
Air Supply System Diagram
11
Oil Supply System Diagram
12
Table of Contents
14
Servicing Information
14
Chapter 2 Servicing Information

16
Chapter 3 Inspection and Maintenance

39
- Periodic Inspections
  39
- Inspecting Engine Oil Systems
  40
- Inspecting Compression System
  41
  - Cleaning Fuel Tank
    41
  - Cleaning Fuel Tank Filter
    41
  - Inspecting Gear Case Area
    42
    
    Replacing Gear Oil
    42
    
    Replacing Propeller
    42
  - Inspecting Cooling System
    43
    
    Replacing Pump Impeller
    43
    
    Thermostat Test
    43
  - Washing Procedure
    43
    
    Overview of Cooling System
    44
    
    Tubing
    44
  - Inspecting Air Rail Pressure
    45
  - Inspecting Power Trim and Tilt System
    45
- Disassembling, Inspecting and Reassembling Power Unit
  46
Chapter 4 Disassembling

47
- Power Unit
  47
- Removing Power Unit
  48
  - Reassembling Power Unit
    50
  - Electrical System
    51
  - Peripheral Parts
    51
    
    Removing CPS, Flywheel and Alternator
    51
    
    Removing ECU
    52
    
    Removing Harness Assembly
    53
    
    Removing Ignition Coil and Rectifier Regulator
    54
    
    Air Supply System - Prior to Removing Peripheral Components
    55
    
    Inspecting Drive Belt
    56
    
    Removing Air Compressor
    56
    
    Air Compressor Configuration
    57
    
    Inspecting Air Compressor
    58
    
    Assembling Compressor
    59
    
    Assembling Piston
    59
    
    Disassembling Air Rail
    61
    
    Air Rail Assembly Configuration
    62
    
    Inspecting Air Rail
    63
    
    Assembling Air Rail
    64
    
    Assembling Fuel and Air Assembly
    65
    
    Disassembling Fuel Hose Assembly
    65
  - Fuel System
    65
    
    Disassembling Vapor Separator
    66
    
    Inspecting Vapor Separator
    67
    
    Vapor Separator Configuration
    67
    
    Assembling Vapor Separator
    68
    
    Assembling Vapor Separator Assembly
    68
    
    Disassembling FFP Assembly
    68
    
    FFP Configuration
    69
    
    Inspecting FFP
    70
    
    Assembling FFP
    71
    
    Installing FFP Assembly on Cylinder
    73
    
    Disassembling Oil Pump and Oil Tank
    74
  - Oil Pump
    74
  - Assembling Oil Pump and Oil Tank
    75
  - Throttle Mechanism
    76
  - Disassembling Advancer Arm
    76
  - Assembling Advancer Arm
    77
  - Disassembling TPS
    77
  - Assembling TPS
    78
  - Disassembling Air Box and Throttle Body
    78
  - Assembling Air Box
    79
  - Assembling Air Box and Throttle Body
    79
  - Disassembling Engine Block
    80
  - Cylinder and Crankcase Assembly Diagram
    80
  - Piston and Crankshaft Diagram
    81
  - Removing Thermostat
    82
  - Disassembling Cylinder Head and Head Cover
    82
  - Inspecting Engine Anode
    82
  - Inspecting Cylinder Head
    83
  - Disassembling Exhaust Cover
    84
  - Inspecting Exhaust Cover
    84
  - Disassembling Crankcase
    84
  - Disassembling Drive Pulley
    85
  - Removing Piston
    86
  - Inspecting Engine Components
    87
  - Inspecting Cylinders
    87
  - Inspecting Piston
    87
  - Inspecting Piston Rings
    88
  - Inspecting Crankshaft
    88
  - Assembling Piston Procedure
    89
  - Assembling Short Block
    90
  - Assembling Crankshaft
    90
  - Assembling Crankcase
    91
  - Assembling Cylinder Head
    91
  - Assembling Exhaust Cover
    92
  - Installing Recirculator Hose
    92
  - Installing and Inspecting Electrical Components
    94
Chapter 5 Installing and

95
- Wire Routing
  95
  - Magneto View
    97
  - Electric Parts View
    98
  - Switch Box (F Type) View
    99
  - Wiring Diagram - EPTO
    101
  - Wiring Diagram - EFTO
    103
  - Wiring Diagram - EFO
    105
  - EPTO Parts List
    107
  - EFTO Parts List
    108
  - EFO Parts List
    109
  - Solenoid Bracket Assembly
    110
  - Flywheel Magneto Inspection
    115
  - Rectifier Regulator Inspection
    115
  - Rectifier Checkpoint Table
    115
  - Starter Motor Inspection
    116
  - Armature Inspection
    116
  - Disassembly, Inspection and Reassembly Lower Unit
    118
  - Gear Case (Drive Shaft) Diagram
    119
Chapter 6 Disassembly, Inspection

119
- Configuration
  119
  - Gear Case (Propeller Shaft) Diagram
    120
  - Lower Unit Disassembly
    121
  - Disassembling Gear Case
    121
  - Removing Propeller
    121
  - Removing Gear Case
    121
  - Disassembling Water Pump Case
    122
  - Disassembling Propeller Shaft and Clutch
    122
  - Removing Bevel Gear and Drive Shaft
    123
  - Lower Unit Inspection
    124
  - Inspecting Bevel Gear Backlash
    125
  - Backlash Reading and Corresponding Adjusting Shim Sizes
    125
  - Lower Unit Reassembly
    126
  - Assembling Gear Case
    126
  - Installing Bevel Gear on Drive Shaft
    126
  - Assembling Propeller Shaft and Clutch
    126
  - Assembling Clutch Cam, Cam Rod and Clutch Cam Rod Bushing
    127
  - Assembling Water Pump
    128
  - Adding Gear Oil
    129
  - Assembling Gear Case Assembly
    129
Chapter 7 Power Trim and Tilt

130
Chapter 8 Tiller Handle Type

143
- Installing Gearshift Lever Assembly
  143
- Installing Switchbox Assembly
  144
- Installing Handle to Engine
  145
Chapter 11 Installation on Boat and

173
- Precautions for Using this Engine
  173
  - Remote Control System - Installing Cable (Engine Side) for EP Series
    173
  - Gauges and Battery
    175
    
    Installing the Various Gauges
    175
    
    Installing Battery
    176
    
    Wiring Diagram for Remote Control Unit and Gauges
    176
  - Operating the Engine
    177
  - Starting Procedure
    177
  - Force-Feeding Fuel
    178
  - Force-Feeding Engine Oil
    178
  - EFO and EFTO Series
    179
  - EPTO Series
    180
  - Warning Process
    181
  - Oil Level Indicator
    181
  - Cooling Water Indicator
    182
  - Battery Level Warning
    182
  - Engine Trouble Warning
    183

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