TOHATSU MD 30B2 User manual

MD 30B2
40/50B2

TLD D30/40/50B2 2013 i
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. To
ensure this, the maintenance and service have to be done properly by service technicians with
fundamental knowledge and skills. This manual is utilized so that our customers can always use their
outboard motor with full satisfaction.
Safety Information
Safety Statements
The following safety statements are found throughout this manual and indicate
information which, if ignored, could result in fatal safety hazards or property damages:
WARNING
Indicates the presence of a hazard or an
unsafe activity which, if ignored, could
result in severe injury or death.
DANGER
Indicates the presence of a hazard which,
if ignored, will result in severe injury or
death.
CAUTION
Indicates the presence of a hazard or an
unsafe activity which, if ignored, could
result in minor personal injury or damage to
the products or facilities.
Attention.

TLD D30/40/50B2 2013
ii
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.
3 Fastening torques are described in the component composition diagram. In the body text are critical
points of the applicable work.
4 Pictograms indicate that there is an important work instruction for the relevant parts. It also shows the type
of lubricant and its application point(s).
5 The component composition diagrams describe the names of the parts, the number of pieces of the parts
used, size of fasteners and special notes.
6 Specific works are described in detail by using illustrations and adding advice on the work.
6 20
Lower Unit
TLDI 30 40/50B2 2013
3 Check o l seal 4 for wear and crack
Replace f necessa y
13) Disassembly of Propeller Shaft
Housing Ass’y
1 Pull out prope ler shaft ass’y 1
2 Remove everse (C) gear 2 by using bladed screw d ivers
3
4 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
CAUTION
Be careful not to burn
Hea ing of propeller shaft housing can also be
made by using a heat gun or heat lamp 5 Bear ng Do no reu e
4
1
2
3
5
6 4
Lower Unit
TLDI 30 40/5 B2 2013
Ref
No De cr p i n Rema ks
Q y
TEF
TEF
G ARG AR
GEAR
G17
G17
G17
342
342
1342
OBMOBM
OBM
2. Parts Layout
Gear Case (Drive Shaft, MD30/40 50)
1-1 Gear Case Ass'y 1 for Transom "S" "L"
1-2 Gear Case Ass'y 1 for Transom "UL" wi h
Sub Water Pipe
2 Ro ler Bearing 22-30-30 1
3
Tape ed Ro l r Bea ing 32007 1
4 Plug 2
5 Plug 1
6 Gasket 10 1-15 1 1
7 Gasket 8 1-15-1 2
8 Trim Tab 1
9 Bolt 1 M6 L 20mm
10 Pre-Coa ed Bolt 6-25 2
11 Washer 2 M6
12 Bevel Gear Ass'y A) 1
13 Bevel Gear B 1
Do no reu e
Do no reu e
Do no reu e
Do no reu e
14 Nut 1
15 Bevel Gear C 1
16 Washer 22 1-28-3 1
17 1 Shim 41-51 5 0 1 A
17 2 Shim 41-51 5 0 15 A
17 3 Shim 41-51 5 0 3 A
17 4 Shim 41-51 5 0 5 A
18 1 Shim 36-44-0 3 A
18 2 Shim 36-44-0 15 A
18 3 Shim 36-44-0 1 A
19 Prope ler Shaft 1
20 Pin 1
21 Clutch 1
22 Sp ing Re ainer 1
23 Sp ing 1
Ref
No De cr p i n Rema ks
Q y
Se ec i n f ne ess ry
OBM
OBM
OBM
ARAR
G AR
O MO M
OBM
OBMOBM
OBM
O M
O M
OBM
O MO M
OBM
O MO M
OBM
OBM
OBM
OBM
BMBM
OBM
BM
BM
OBM
BM
BM
OBM
OBM
OBM
OBM
OBMOBM
OBM
G RG R
GEAR
G ARG AR
GEAR
G17G17
G17
3 2
1342
1 2
1342
3 2
1342
OBM
OBM
OBM
OBMOBM
OBM
EF
TEF
6 2
Lower Unit
TLDI 0/40 50B2 2013
1. Special tools
Ro ler Bearing Press Kit
P/N 3LC 72900 0
Removing or at aching gear case
needle bearing
Ro ler Bearing At achment
MD30 40/50 P/N 3MC 99710 0
MWD50 P N 3LC 99710 0
U ed n omb n t on w th r v r r d nd c nt r p a e
A ac i g r pe l r s af ho s ng ne d e ea ng
ø31 5 x ø25 x H32
At aching fo ward (A) gear
bearing outer ace
Bearing Outer Press Kit
P/N 3B7 72739 1
3B7-72733 0
3B -7 731 0
3B7- 2732 0
Removing sp ing pin
Spring Pin Tool A
P/N 345 72227 0 (ø3 0)
P/N 369 72217 0 (ø3 5)
Instal ing spring pin
Spring Pin Tool B
P/N 345 72228 0 (ø3 0)
P/N 369 72218 0 (ø3 5)
Removing or at aching pinion
(B) gear nut
Bevel Gear B Nut Wrench
MD30/40/50 P/N 346 72231 0
2
Removing or at aching pinion
(B) gear nut
Bevel Gear Nut Socket
P/N 346 72232 0
Bevel Gear Bearing Ins a l Tool
P/N 3C8 72719 0
Insta ling forward A) gear
bearing
Driver Rod
P/N 3AC 99702 0
Used in combina ion wi h center
place and various a tachmen s
Removing reverse (C) gear
bearing
Universal Pu ler Pla e
P/N 3AC 99750 0
Removing prope ler shaft
housing
P opeller Shaft Housing Puller Ass'y
P/N 3A3 72259 0
S ide Hammer Ass'y
P/N 3AC 99080 0
Removing forwa d (A) gear
bearing outer ace
ø100 x ø79 5 x ø51 5 x ø61 5
Cen er Plate
P/N 3AC 99701 0
Removing or instal ing p ope ler
shaft housing bearing
Bevel Gear Bea ing Puller Ass'y
MD30 40 50 P N 3A3 72755 0
MWD50 P N 3B7 72755 0
Removing fo wa d (A) gear bea ing
ou er race
Removing or a taching pinion
(B) gear nut
Bevel Gear B Nut Wrench
MWD50 P N 353 72231 0
28
Removing or a tac ing gear case and
p opeller shaf housing needle bea ing
Ro ler Bearing Pu ler Kit
MD30 40 50 P N 3C8 72700 0
MWD50 P N 3B7 72700 0
⑥
⑤
②
①
④
③

TLD D30/40/50B2 2013 iii
Example : <Pressure>
Conventional system (kilo-gram meter unit)
Conventional system (US pound inch unit)
SI unit (1 kgf/cm2 = 0.0980665 MPa)
* Measurements are shown using SI unit followed by conventional units (US unit) and [Japanese domestic unit].
0.90 MPa(128 psi)[9.0 kgf/cm2]
Example : <Driving torque>
*
* The conventional unit for measurement of force uses "kgf (kilogram force)" to discriminate it from
"kg (mass kilogram)" of SI unit system.
18 N·m（13lb·ft）[1.8 kgf·m]
Example : <Volume>
900 cm3（30.4 fl.oz）
Example : <Length>
10 mm（0.39 in）
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.
<Reference>
What is the SI unit system?
Although the measurement unit is standardized mostly with metric system in the world, the metric system
includes different kinds of unit systems.
Though the metric system was established expecting that a single unit system is used in the world, various
physical units were established later, resulting in branching the metric system in different unit systems.
The new unit system is called "International System of Units" because it was established for the purpose of
unifying the different unit systems.
Since the metric system was initially established in France, and International Bureau of Weights and
Measures (IBWM) is located in Paris, General Conference of Weights and Measures (GCWM) passes a
resolution of the international unit system as "Systéme International d'Unités (French)" that is abbreviated as
"SI unit".
For example, conventional metric system uses the unit of mass (kg) and unit of force (kg or kgf) without
discriminating them, but the SI unit system uses, for example, "kg" as the unit of mass, and "N" as the unit of
force, aiming to apply a kind of unit for a kind of physical quantity.

TLD D30/40/50B2 2013
iv
Description of Pictograph
ADH
17411741
TB
1373B1373B
G17G17
BOND
TB
13421342
LT
518518
OIL-COMP.
SOC
LOR
Liquid O-Ring
8648
LT
7471
LT
OIL RPM
O
Kr/min
GREASE
OBM
ATFATF
OIL
OIL
GEARGEAR
LIT
GREASE
2st
OIL
III

TLD D30/40/50B2 2013 v
1.Service Information
1. Identification
(Engine Serial Number) ………… 1-2
2. Work Safety ………………………… 1-2
1) F re Prevent on …………………… 1-2
2) Vent at on ………………………… 1-2
3) Protect on ………………………… 1-2
4) Genu ne Parts ……………………… 1-2
5) Too s ………………………………… 1-3
6) Recommendat ons on Serv ce …… 1-3
7) Caut ons n D sassemb ng and
Assemb ng Components ………… 1-4
3. Tools and Instruments …………… 1-5
1) Test Prope er ……………………… 1-5
2) Measur ng Instruments …………… 1-5
3) Spec a Too s ……………………… 1-6
4. Pre-delivery Inspection ………… 1-9
1) Steer ng Hand e …………………… 1-9
2) Gear Sh ft and Thrott e …………… 1-9
3) Eng ne O ………………………… 1-10
4) Gear O …………………………… 1-10
5) Check quant ty of eng ne o ……… 1-11
6) Fue L ne …………………………… 1-12
7) Insta at on of Outboard Motor
(R gg ng) …………………………… 1-12
8) Inspect on of PTT Un t …………… 1-12
9) Inspect on of Gas Shock Absorber 1-13
10) Inspect on of Start Sw tch and
Stop sw tch ………………………… 1-13
11) Coo ng Water Check Port ……… 1-14
12) Id ng ………………………………… 1-15
13) Prope er Se ect on ………………… 1-15
14) Tr m Tab …………………………… 1-16
5. Break-In Operation ………………… 1-16
6. Test Run ……………………………… 1-17
7. Checks After Test Run …………… 1-17
2.Service Data
1. Outboard Dimensions …………… 2-2
1) Body d mens ons ………………… 2-2
2) C amp D mens ons ………………… 2-4
2. Cooling Water System Diagram … 2-6
3. Specifications ……………………… 2-8
4. Maintenance Data ………………… 2-14
5. Torque Specifications …………… 2-20
6. Sealant And Lubricant …………… 2-22
7. Warning Indication List • • •
Display for abnormalities during operation … 2-26
3.Maintenance
1. Special Tools ………………………… 3-2
2. Inspection Schedule ……………… 3-3
3. Top Cowl ……………………………… 3-4
1) Inspect on of Top Cow …………… 3-4
2) O F ter and O Tank …………… 3-4
3) A r B eed ng ………………………… 3-4
4. Fuel System ………………………… 3-5
1)
Inspection of Fuel Pipes and Joints … 3-5
2) Inspect on of Fue Tank …………… 3-5
3) Inspection of Fuel Filter …………… 3- 6
4) Inspection of Air Compressor Air Filter … 3- 6
5) Inspect on of A r Pressure ……… 3-6
6) Inspect on of Fue Pressure ……… 3-7
7) Inspect on of Dr ve Be t …………… 3-8
5. Power Unit …………………………… 3-9
1) Inspect on of Spark P ugs ………… 3-9
2) Inspection of Compression Pressure … 3-10
3) Inspect on of Thermostat ………… 3-11
4) Inspection of Cooling Water Passage … 3-12
6. Operating System ………………… 3-12
1) Adjustment of Thrott e Cab e
(for T er hand e mode ) ………… 3-12
2) Adjusting of Remote Control Cable … 3-13
3) Inspect on of Id e Eng ne Speed … 3-13
7. PTT System ………………………… 3-14
1) Inspection of PTT Unit Operation … 3-14
2) Inspect on of PTT F u d Quant ty … 3-14
8. Lower Unit …………………………… 3-15
1) Inspect on of Gear O Quant ty … 3-15
2) Rep acement of Gear O ………… 3-16
3) Inspection of Gear Case (for leakage) … 3-17
4) Inspect on of Water Pump ……… 3-17
9. Others ………………………………… 3-18
1) Rep acement of Anode …………… 3-18
2) Inspect on of Prope er …………… 3-19
3) Inspect on of Battery ……………… 3-20
4) F ush ng w th Water ……………… 3-21
5) Greas ng …………………………… 3-21
4. Fuel System (TLDI)
1. Special Tools ………………………… 4-2
2. Parts Layout ………………………… 4-3
Vapor Separator & Fue L ne ………… 4-3
FFP Ass y ……………………………… 4-4
A r Ra …………………………………… 4-6
A r Compressor ………………………… 4-8
O Pump ………………………………… 4-10
3. What is TLDI? ……………………… 4-12
D rect Fue Inject on System ………… 4-12
ENGINE WITH CARBURETOR ……… 4-12
TLDI ……………………………………… 4-12
Induct ve Ign t on ……………………… 4-13
ECU ……………………………………… 4-15
Fue / A r Feed System ………………… 4-16
O System / Rec rcu at on System …… 4-17
4. Removing Air Rail ………………… 4-18
1) Decompression of Fuel Line and Air Line 4-18
2) Remov ng A r Ra Ass’y ………… 4-18
3) Inspect on of Injectors …………… 4-20
5. Assembly of Air Rail ……………… 4-20
1) Installing of Injectors and Regulators 4-20
2) Insta at on of A r Injector and
A r Ra ……………………………… 4-23
6. Removing and installation of
Fuel System ………………………… 4-24

TLD D30/40/50B2 2013
vi
1) Removing High Pressure Fuel Hose Ass’y 4-24
2) Insta at on of Fue Hose Ass’y …… 4-25
3) Draining Fuel from FFP Vapor Separator … 4-25
4) Remov ng Vapor Separator ……… 4-25
5) D sassemb y and Inspect on of
Vapor Separator …………………… 4-26
6) Assemb y of Vapor Separator …… 4-26
7) Installation of Vapor Separator Ass’y 4-27
8) Remov ng FFP Ass’y ……………… 4-27
9) Disassembly and Inspection of FFP 4-27
10) Assemb y of FFP Ass’y …………… 4-28
11) Inspect on of Fue Pump ………… 4-29
12) Installation of FFP Ass’y to Cylinder … 4-31
7. Removing and Installation of
Air Compressor …………………… 4-32
1) Remov ng A r Compressor ……… 4-32
2) Inspect on of Dr ve Be t …………… 4-32
3) Remov ng Dr ven Pu ey ………… 4-33
4) Disassembly of Compressor Housing 4-34
5) Inspect on of Reed Va ve ………… 4-35
6) Inspect on of Cy nder and P ston 4-35
7) Assembly of Compressor Housing … 4-35
8) Insta at on of Crank Shaft ……… 4-36
9) Insta at on of P ston ……………… 4-37
10) Insta at on of Compressor
Hous ng Ass’y ……………………… 4-38
11) Insta ng A r Compressor ………… 4-38
12) Measurement of Fue Pressure and
A r Pressure ……………………… 4-39
8. Inspection of
Lubrication System ……………… 4-41
1) Inspect on of O Pump …………… 4-41
2) Inspect on of O F ter …………… 4-41
3) Inspect on of O Tank …………… 4-41
4) A r B eed ng ………………………… 4-42
5.Power Unit
1. Special tools ………………………… 5-2
2. Parts Layout ………………………… 5-3
Eng ne …………………………………… 5-3
Magneto ………………………………… 5-4
E ectr c Parts (ECU • D agram) ……… 5-6
E ectr c Parts (Starter Motor) ………… 5-8
A r Chamber (A r Box) ………………… 5-9
Thrott e ………………………………… 5-10
Cy nder Crank Case …………………… 5-12
P ston & Crank Shaft …………………… 5-14
3. Inspection Items …………………… 5-15
1) Inspection of Compression Pressure … 5-15
2) Remov ng Power Un t …………… 5-16
3) Assemb y of Crank Case Head … 5-20
4) Remov ng A r Compressor ……… 5-20
5) Remov ng F ywhee ……………… 5-20
6) Remov ng O Tank ………………… 5-21
7) Remov ng A ternator ……………… 5-21
8) Remov ng Starter Motor ………… 5-22
9) Remov ng Cord Ass y and ECU … 5-22
10) Remov ng O Pump ……………… 5-25
11) Remov ng Thrott e L nk …………… 5-26
12) Inspect on of Thrott e Body ……… 5-27
13) Remov ng A r Chamber …………… 5-27
14) Remov ng Dr ve Pu ey Nut ……… 5-29
15) Remov ng Thermostat …………… 5-29
16) Inspect on of Thermostat ………… 5-30
17) Remov ng Fue System …………… 5-30
18) Removing Cylinder Head / Head Cover … 5-30
19) Inspect on of Cy nder Head ……… 5-31
20) Remov ng Exhaust Cover ………… 5-32
21) Inspect on of Exhaust Cover …… 5-32
22) Removing of Recirculation Hoses … 5-33
23) Remov ng Crank Case …………… 5-33
24) Remov ng P stons ………………… 5-35
25) D sassemb y of Crank Shaft ……… 5-36
26) Remov ng of Dr ve Pu ey ………… 5-36
27) Inspect on of Crank Shaft ………… 5-37
28) Inspect on of Cy nder …………… 5-38
29) Inspect on of P stons ……………… 5-39
30) Assemb y of Crank Shaft ………… 5-42
31) Insta at on of P stons …………… 5-43
32) Inspect on of Crankcase ………… 5-43
33) Assemb y of Power Un t Parts …… 5-44
34) Assemb y of Crank Case Ha ves … 5-45
35) Insta at on of Exhaust Cover …… 5-47
36) Insta at on of Cy nder Head …… 5-48
37) Insta at on of Dr ve Pu ey ……… 5-49
38) Installation of Recirculation Hoses … 5-50
39) Insta at on of A r Chamber ……… 5-51
40) Insta at on of O Pump …………… 5-51
41) Insta at on of Thrott e Body ……… 5-52
42) Insta at on of Thrott e L nk ……… 5-53
43) Insta at on of Fue System ……… 5-53
44) Insta at on of A r Compressor …… 5-53
45) Insta ng So eno d Bracket ……… 5-54
46) Insta at on of Cord Ass’y and
E ectr ca Parts …………………… 5-55
47) Insta at on of Starter Motor ……… 5-55
48) Insta at on of A ternator ………… 5-55
49) Insta ng O Tank ………………… 5-55
50) Insta at on of F ywhee …………… 5-56
51) Insta at on of Power Un t ………… 5-56
6.Lower Unit
1. Special tools ………………………… 6-2
2. Parts Layout ………………………… 6-4
Gear Case (Drive Shaft, D30/40/50) … 6-4
Gear Case (Dr ve Shaft, WD50) ……… 6-8
Gear Case (Propeller Shaft, WD50) … 6-10
3. Inspection Items …………………… 6-12
1) Dra n ng Gear O ………………… 6-12
2) Remov ng Prope er ……………… 6-12
3) Remov ng Lower Un t …………… 6-13
4) D sassemb y of Cam Rod ………… 6-14
5) Inspect on of C utch Cam ………… 6-14
6) Assemb y of C utch Cam Parts … 6-15
7) Remov ng Water Pump …………… 6-16
8) Inspect on of Water Pump ……… 6-17
9) Inspect on of Water P pe ………… 6-17
10) Disassembly of Water Pump Case (Lower) … 6-18
11) Assembly of Water Pump Case (Lower) … 6-18
12) Removing Propeller Shaft Housing Ass’y … 6-19
13) D sassemb y of Prope er Shaft

TLD D30/40/50B2 2013 vii
Hous ng Ass’y ……………………… 6-20
14) Inspection of Propeller Shaft Housing … 6-22
15) Assembly of Propeller Shaft Housing … 6-22
16) Disassembly of Propeller Shaft Ass’y … 6-24
17) Inspection of Propeller Shaft Ass’y … 6-25
18) Assembly of Propeller Shaft Ass’y … 6-26
19) Remov ng Dr ve Shaft Ass’y ……… 6-27
20) Disassembly of Drive Shaft Ass’y … 6-28
21) Inspect on of Dr ve Shaft ………… 6-28
22) Inspect on of P n on (B) Gear …… 6-28
23) Assemb y of Dr ve Shaft Parts …… 6-29
24) Removing Forward (A) Gear Ass’y … 6-31
25) Disassembly of Forward Gear (A) Gear … 6-31
26) Inspect on of Forward (A) Gear … 6-32
27) Assembly of Forward (A) Gear Parts … 6-32
28) D sassemb y of Gear Case ……… 6-34
29) Inspect on of Gear Case ………… 6-35
30) Assemb y of Gear Case Parts …… 6-36
31) Measurement of P n on (B) Gear
He ght and Sh m Se ect on ……… 6-38
32) Measurement of Back Lash between
Forward (A) and P n on (B)
Gears and Sh m Se ect on ……… 6-40
33) Measurement of Back Lash between
P n on (B) and Reverse (C)
Gears and Sh m Se ect on ……… 6-44
34) Assemb y of Lower Un t Parts …… 6-46
35) Assemb y of Pump Case ………… 6-47
36) Attach ng C utch Cam Ass’y ……… 6-48
37) Installing Propeller Shaft Housing Ass'y … 6-49
38) Measurement of Prope er
Shaft P ay and Se ect on of
Washer Th ckness ………………… 6-49
39) Insta at on of Lower Un t ………… 6-50
7.Cowl, Bracket and
PTT Unit
1. Parts Layout ………………………… 7-2
Dr ve Shaft Hous ng …………………… 7-2
Bracket Power Tr m and T t …………… 7-4
Power Tr m And T t …………………… 7-6
Bracket Manua T t …………………… 7-8
Manua T t ……………………………… 7-10
T er Hand e (F Type) ………………… 7-12
Bottom Cow (Motor Cover Lower) …… 7-14
Sh ft ……………………………………… 7-16
Sw tch Box (F type) …………………… 7-18
Top Cow (Motor Cover Upper) ……… 7-19
2. Inspection Items …………………… 7-20
1) Inspect on of Thrott e Cab e ……… 7-20
2) Remov ng of T er Hand e ………… 7-20
3) Insta at on of T er Hand e ………… 7-22
4) Remov ng Bottom Cow …………… 7-24
5) Remov ng Dr ve Shaft Hous ng …… 7-25
6) D sassemb y of
Dr ve Shaft Hous ng ………………… 7-26
7) Inspect on of Dr ve Shaft Hous ng … 7-27
8) Assemb y of Dr ve Shaft
Hous ng Parts ……………………… 7-28
9) Assemb ng Rubber Mount ng ……… 7-31
10) Assemb ng Extens on Hous ng … 7-32
11) Remov ng Steer ng Shaft Arm …… 7-33
12) Insta ng Steer ng Shaft …………… 7-34
13) Remov ng PTT Un t/
Gas Shock Absorber ……………… 7-35
14) D sassemb ng C amp Bracket …… 7-36
15) Assemb ng C amp Bracket ……… 7-37
16) D sassemb ng t t mechan sm …… 7-38
17) Assemb ng t t mechan sm ……… 7-39
18) Remov ng PTT Motor ……………… 7-40
19) D sassemb ng PTT Motor ………… 7-41
20) Inspect on of PTT Motor ………… 7-42
21) Assemb ng PTT Motor Parts …… 7-43
22) Remov ng PTT Pump
and Va ves ………………………… 7-43
23) Inspect on of PTT Pump
and Va ves ………………………… 7-44
24) Remov ng Reserver Tank ………… 7-44
25) Inspect on of T t Cy nder and
Reserve Tank ……………………… 7-45
26) Insta at on of T er Hand e ……… 7-45
27) Insta at on of PTT Pump
and Motor …………………………… 7-46
28) A r-Purg ng PTT Un t
(separated from outboard motor) … 7-47
29) Insta at on of PTT Un t/
Gas Shock Absorber ……………… 7-49
30) A r-Purg ng PTT Un t
( nsta ed on the outboard motor) … 7-50
8.Electrical System
1. Special Tools ………………………… 8-2
2. Parts Layout ………………………… 8-3
E ectr c Parts (Starter Motor) ………… 8-3
3. Inspection Items …………………… 8-4
1) D sassemb y of Starter Motor …… 8-4
2) Inspect on of Armature …………… 8-4
3) Inspect on of Brushes …………… 8-5
4) Inspect on of P n on ……………… 8-5
5) Inspect on of Ign t on and spark … 8-6
6) Inspect on of P ug Cap …………… 8-6
7) Inspect on of Ign t on Co s ……… 8-7
8) Inspect on of P ck Up Co
(Crank Pos t on Sensor) ………… 8-7
9) Inspect on of P ck Up Co A r Gap 8-7
10) Inspect on of A ternator …………… 8-8
11) Inspect on of Rect f er Comp ete … 8-9
12) Inspection of Throttle Position Sensor … 8- 10
13) Inspection of Water Temperature Sensor 8- 10
14) Inspect on of A r Injectors ………… 8-10
15) Inspect on of Fue Injectors ……… 8-11
16) Inspect on of MAT sensor (Man fo d
Temperature Sensor) (Opt on) …… 8-11
17) Inspection of MAP Sensor (Manifold
Absolute Air Pressure Sensor) (Option) … 8- 11
18) Inspect on of Starter So eno d …… 8-12

TLD D30/40/50B2 2013
viii
19) Inspect on of O Leve Sensor …… 8-12
20) Inspection of Fuel Feed Pump (FFP). … 8- 12
21) Inspect on of PTT So eno d ……… 8-13
22) Inspect on of PTT Sw tch ………… 8-14
9.Troubleshooting
1. Troubleshooting …………………… 9-2
Power Unit …………………………… 9-14
State 1 Engine will not start or is
hard to start. …………………………… 9-14
Ign t on System ………………………… 9-16
Fue System …………………………… 9-18
A r System ……………………………… 9-20
State 2 Full throttle engine revolution
speed is low, engine revolution
speed falls off, or engine stalls.
………………………………… 9-22
Ign t on System ………………………… 9-23
Fue System …………………………… 9-24
Lubr cat on system ……………………… 9-25
Coo ng System ………………………… 9-26
State 3 Engine rotation is unstable or
surging occurs in low speed
range. ………………………… 9-27
Ign t on System ………………………… 9-28
Fue System …………………………… 9-29
PTT Unit
State 1 PTT unit will not operate. … 9-30
State 2 PTT is not capable of sustaining
outboard motor. ……………… 9-31
2. Self-Diagnosis Function of TLD I 9-32
1) Terms related to self-diagnosis function 9-32
2) Operat on Procedure of Se f-D agnos s
Funct on ……………………………… 9-33
3) Warn ng Ind cat on L st • • •
D sp ay for abnorma t es dur ng
operat on ……………………………… 9-36
4) Operat ng Hour Ind cat on L st
(Se f D agnos s • Mode 2) ………… 9-38
5) Troub e Ind cat on L st
(Se f D agnos s • Mode 3) ………… 9-40
6) Resett ng TPS In t a Va ues ……… 9-44
10.Rigging
1. Service Information ……………… 10-2
2. Service Data ………………………… 10-2
1) Load L m t of Boat ………………… 10-2
2) Insta at on D mens ons …………… 10-2
3) C amp D mens ons ………………… 10-3
4) Hang ng Outboard Motor ………… 10-5
5) Insta at on of Outboard Motor …… 10-5
3. Fuel System ………………………… 10-6
1) Fue ………………………………… 10-6
2) O …………………………………… 10-6
3) E ectr c Fue Pump ………………… 10-6
4) Insta at on of Fue F ter ………… 10-6
5) Connect on of Fue Hose ………… 10-7
6) F ng Fue System ……………… 10-7
7) F ng O Tank …………………… 10-7
8) Pr m ng O Pump ………………… 10-8
4. Connections to
Outboard Motor ……………………… 10-8
1) Steer ng Cab e …………………… 10-8
2) Drag L nk …………………………… 10-9
3) Insta at on of Remote Contro Cab e
(Eng ne S de) ……………………… 10-10
5. Lower Unit …………………………… 10-13
1) Insta at on of Prope er …………… 10-13
6. Electric System …………………… 10-14
1) Battery Capac ty …………………… 10-14
2) Connect on of Battery Cab es …… 10-14
3) Insta at on of Battery ( es) ……… 10-14
7. Accessories and Meters ………… 10-15
1) Accessor es. ……………………… 10-15
2) Insta at on of Meters ……………… 10-15
11.Wiring Diagram
TLDI Wire Harness Terminals
and Connections ……………………… 11-2
Main Harness Diagram ……………… 11-3
D40/50B2 EPTO, EPO, D30B2 EPTO
Electrical Circuit …………………………… 11-5
D40/50B2 EFTO, EFO, D30B2 EFTO
Electrical Circuit …………………………… 11-8
Electrical Wiring Assembling
Instruction Diagram -1 ……………… 11-10
Electrical Wiring Assembling
Instruction Diagram -2 ……………… 11-11
Completed Pre-Assembly …………… 11-12
Assembly Step -1 ……………………… 11-12
Assembly Step -2 ……………………… 11-12
Assembly Step -2 ……………………… 11-12
Outboard Motor Installation Template …… 11-13
INDEX ………………………… end of a vo ume

TLD D30/40/50B2 2013 ix
1
2
3
4
5
6
7
8
9
10
11
Service Information
Service Data
Maintenance
Fuel System (TLDI)
Power Unit
Lower Unit
Cowl, Bracket and
PTT Unit
Electrical System
Troubleshooting
Rigging
Wiring Diagram
INDEX
O
K
r/min

TLD D30/40/50B2 2013
x

1
Service Information
1
1. Identification
(Engine Serial Number) ………… 1-2
2. Work Safety ………………………… 1-2
1) F re Prevent on …………………… 1-2
2) Vent at on ………………………… 1-2
3) Protect on ………………………… 1-2
4) Genu ne Parts ……………………… 1-2
5) Too s ………………………………… 1-3
6) Recommendat ons on Serv ce …… 1-3
7) Caut ons n D sassemb ng and
Assemb ng Components ………… 1-4
3. Tools and Instruments …………… 1-5
1) Test Prope er ……………………… 1-5
2) Measur ng Instruments …………… 1-5
3) Spec a Too s ……………………… 1-6
4. Pre-delivery Inspection ………… 1-9
1) Steer ng Hand e …………………… 1-9
2) Gear Sh ft and Thrott e …………… 1-9
3) Eng ne O ………………………… 1-10
4) Gear O …………………………… 1-10
5) Check quant ty of eng ne o . …… 1-11
6) Fue L ne …………………………… 1-12
7) Insta at on of Outboard Motor
(R gg ng) …………………………… 1-12
8) Inspect on of PTT Un t …………… 1-12
9) Inspection of Gas Shock Absorber … 1-13
10) Inspect on of Start Sw tch and
Stop sw tch ……………………………… 1- 13
11) Coo ng Water Check Port ……… 1-14
12) Id ng ………………………………… 1-15
13) Prope er Se ect on ………………… 1-15
14) Tr m Tab …………………………… 1-16
5. Break-In Operation ………………… 1-16
6. Test Run ……………………………… 1-17
7. Checks After Test Run …………… 1-17

1-2
Service Information
TLD D30/40/50B2 2013
1. Identification (Engine Serial Number)
Engine serial number is stamped on the bottom cowl of
outboard motor body.
2. Work Safety
1) Fire Prevention
Gasoline is hazardous material and very flammable. Do
not handle gasoline near ignition source such as spark or
static electricity.
2) Ventilation
Exhaust gas or gasoline vapor is hazardous. Be sure to
ventilate well when working indoors.
3) Protection
Wear a pair of goggles, working gloves and safety shoes
to protect skin from chemicals and oils and eyes from
particles generated by grinding or polishing. Avoid contact
of oil, grease or sealing agent to the skin. In case of
exposure to such matters, wash away with soap or warm
water immediately.
4) Genuine Parts
Use parts and/or chemicals that are genuine items or
recommended.
1 Model Name
2 Model Type
3 Serial Number
Outboard Motor
Made in Japan
3T5 ( D50B2)
Rated Power: 36.8kW-5500r/min
Mass: 80 -108 kg
Serial No.
12
3

1-3
1
TLD D30/40/50B2 2013
3R 728 50
3 C72 710
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.
6) Recommendations on Service
Remove foreign substances and dirt from outboard motor
and individual parts by cleaning. Apply recommended
oil or grease to rotating areas and sliding surfaces. After
individual assembly, always perform verifications such as
ensuring smooth movement and sealing.

1-4
Service Information
TLD D30/40/50B2 2013
LIT
GREASE
LIT
350 100
300
40mm to thick or more , wooded
Power Unit Work Board
ø45mm to 50mm hole
ø45mm to 50mm hole
7) Cautions in Disassembling and
Assembling Components
(1) Secure outboard motor to dedicated stand firmly.
(2) Take special care not to scratch painted surfaces or mating
surfaces of cylinder and crankcase.
(3) Replace parts such as packings, gaskets, O rings, oil
seals, spring pins or split pins with new ones after they are
removed. Replace deformed snap rings with new ones.
(4) When replacing parts, be sure to use genuine parts. For
fluids such as gear oil, use genuine product.
(5) Be sure to use special tools that are specified, and perform
the work properly.
(6) When reassembling parts, use their mating marks. For
parts without mating marks, simple marking makes
reassembling easier. Use applicable parts list for
reference.
(7) Clean individual parts that have been removed, and check
their condition.
(8) When assembling, be careful of the fit, repair limits, air-
tightness, clogging of oil holes for oil feeding or greasing,
packings, wirings, pipings and other detailed parts. For the
components that use many bolts and nuts such as cylinder
head or crank case, tighten the fasteners in the order
shown by the numbers to prevent uneven tightening. If the
numbers are not shown, tighten the fastners in diagonal
or clockwise order from inner ones to outer ones evenly to
specified torque. In either case, tighten the fastners to the
specified torque in two or three steps. (Reverse the order
when disassembling.)
(9) When installing bearings, face the flat (numbered) side to
the special assembling tool.
(10) When installing oil seals, be careful not to scratch the
surface of the lip that contacts with the shaft, and install
them in correct orientation. Apply recommended grease to
the lip before installation.
(11) When applying liquid sealant, take care to use sparingly.
Excessive application may be oozed out, adversely
affecting interior of the crankcase. Use adhesive after
thoroughly reading the instructions.
(12) When servicing power unit, use of wooden work board
makes the work easier.

1-5
1
TLD D30/40/50B2 2013
3. Tools and Instruments
1) Test Propeller
P/N. 3C8-64110-0
Outer diameter : 198mm
With : 20mm
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 ( M1 type, 300 mm )
Micrometer ( minimum graduation of 0.01, outer, 0 to 25 mm, 25 to 50 mm, 50 to 75 mm )
Cylinder gauge ( 4 to 6 mm, 10 to 25 mm, 25 to 30 mm, 50 to 75 mm )
Ring gauge ( ø5.5, ø16, ø25, ø30, ø61)
Dial gauge ( minimum graduation of 0.01 )
Thickness gauge ( 0.03 to 0.3 mm )
V block
Surface plate ( 500 mm x 500 mm )
Dial gauge magnet base or dial gauge stand
Rotational speed at WOT
(Wide Open Throttle) (r/min)
approximately 5,150 – 5,800

1-6
Service Information
TLD D30/40/50B2 2013
3) Special Tools
Removing or attaching piston
rings
Piston Ring Tool
P/N. 353-72249-0
Measuring gaps
Thickness Gauge
P/N. 353-72251-0
Measuring engine revolution
speed
Tachometer
P/N. 3AC-99010-0
Vacuum/Pressure Gauge
P/N. 3AC-99020-0
Inspecting pressure
Compression Gauge
P/N. 3AC-99030-0
Measuring compression
pressure
Slide Hammer Kit
P/N. 3AC-99080-0
Removing forward (A) gear
bearing outer race
Adjusting pinion (B) gear
height
Shimming Gauge
D40/50 P/N 3C8 72250 0
WD50 P/N 353 72250 0
Measuring backlash between forward
(A) gear and pinion (B) gear
Backlash Measuring Tool Kit
D40/50:P/N. 3C8-72234-1
Measuring backlash
Backlash Measuring Tool Clamp
P/N. 3B7-72720-0
Used to attach dial gauge
when measuring backlash
Dial Gauge Plate
P/N. 3B7-72729-0
Measuring backlash between pinion
(B) gear and reverse (C) gear
Backlash Measuring Tool Kit
WD50:P/N. 3A3-72255-0
Piston Slider
P/N. 3T5-72871-0
Assembling piston for air
compressor
Attaching air compressor oil
seal
Oil Seal Attachment
P/N. 3T1-99820-0
Attaching air compressor
bearing
Bearing Attachment
P/N. 3T1-99905-0
ø51.5 x ø39.5
Caulking clamps made by
OETIKER
Clamp Pliers
P/N. 3T5-72864-0
O Ring Set Tool (ø24)
P/N. 3T5-72863-0
Assembling O ring into fuel
injector

1-7
1
TLD D30/40/50B2 2013
Roller Bearing Press Kit
P/N. 3LC-72900-0
Removing or attaching gear case
roller bearing
Roller Bearing Attachment
D40/50 P/N 3MC 99710 0
WD50 P/N 3LC 99710 0
Used in combination with
driver rod and center plate
Attaching propeller shaft housing
roller bearing
ø31.5 x ø25 x H32
Attaching forward (A) gear
bearing outer race
Bearing Outer Press Kit
P/N. 3B7-72739-1
3B7 72733 0
3B7 72731 0
3B7 72732 0
Removing spring pin
Spring Pin Tool A
P/N. 345-72227-0 (ø3.0)
P/N. 369-72217-0 (ø3.5)
Installing spring pin
Spring Pin Tool B
P/N. 345-72228-0 (ø3.0)
P/N. 369-72218-0 (ø3.5)
Removing or attaching pinion
(B) gear nut
Bevel Gear B Nut Wrench
D40/50:P/N. 346-72231-0
25
Removing or attaching pinion
(B) gear nut
Drive Shaft Socket
P/N. 346-72232-0
Bevel Gear Bearing Install Tool
P/N. 3C8-72719-0
Installing forward (A) gear
bearing
Driver Rod
P/N. 3AC-99702-0
Used in combination with center
place and various attachments
Removing reverse (C) gear
bearing
Universal Puller Plate
P/N. 3AC-99750-0
Removing propeller shaft
housing
Propeller Shaft Housing Puller Ass'y
P/N. 3A3-72259-0
Slide Hammer Kit
P/N. 3AC-99080-0
Removing forward (A) gear
bearing outer race
ø100 x ø79.5 x ø51.5 x ø61.5
Center Plate
P/N. 3AC-99701-0
Removing or installing propeller
shaft housing bearing
Bevel Gear Bearing Puller Ass'y
D40/50 P/N 3A3 72755 0
WD50 P/N 3B7 72755 0
Removing forward (A) gear bearing
outer race
Removing or attaching pinion
(B) gear nut
Bevel Gear B Nut Wrench
WD50:P/N. 353-72231-0
28
Removing or attaching gear case and
propeller shaft housing roller bearing
Roller Bearing Puller Kit
D40/50 P/N 3C8 72700 0
WD50 P/N 3B7 72700 0

1-8
Service Information
TLD D30/40/50B2 2013
Removing of drive pulley
Drive Pulley Puller Ass'y
P/N. 3T5-72890-0
Used to hook power unit when
hanging
Eye Bolt (Powerhead Lift Ring)
P/N. 3T9-72212-0
Removing or attaching piston
pin
Piston Pin Tool
P/N. 345-72215-0
Used to press-fit coil bracket
oil seal
Oil Seal Attachment
P/N. 3U1-99820-0
ø51.5 x ø39.5
Measuring air rail fuel pressure
and air pressure
Pressure Gauge Ass'y
P/N. 3T5-72880-0
Removing or attaching flywheel
Flywheel Puller Kit
P/N. 3T1-72211-0
940191-0800
3B7-72785-0
3B7-72784-0
3B7-72783-0 3C7-72783-0
Using for press fit drive pulley
Drive Pulley Press
P/N. 3T5-72868-0
Using for remove and tighten
the drive pulley nut
Crankshaft Holder
P/N. 3T5-72815-0
Spark Tester
P/N. 3F3-72540-0
Checking sparks
Measuring backlash between forward
(A) gear and pinion (B) gear
Backlash Measuring Tool A Kit
WD50:P/N. 3B7-72234-0