TLDI 75/90C2 2010
vi
2) Installation of Fuel Hose Ass’y …… 4-25
3)
Draining Fuel from FFP Vapor Separator
…4-26
4) Removing Vapor Separator ……… 4-26
5) Disassembly and Inspection of
Vapor Separator …………………… 4-27
6) Assembly of Vapor Separator …… 4-27
7)
Assembly of Vapor Separator Ass’y
…4-28
8) Removing FFP* Ass’y ……………… 4-28
9)
Disassembly and Inspection of FFP
…4-28
10) Assembly of FFP Ass’y …………… 4-29
11) Inspection of Fuel Pump …………… 4-30
12)
Installation of FFP Ass’y to Cylinder
…4-31
7. Removing and Installation of
Air Compressor ……………………… 4-32
1) Removing Drive Belt ……………… 4-32
2) Removing Air Compressor ………… 4-32
3) Inspection of Drive Belt …………… 4-32
4) Removing Driven Pulley …………… 4-33
5)
Disassembly of Compressor Housing
…4-34
6) Inspection of Reed Valve ………… 4-35
7) Inspection of Cylinder and Piston …4-35
8)
Assembly of Compressor Housing
…4-35
9) Installation of Crank Shaft ………… 4-36
10) Installation of Piston ……………… 4-37
11)
Installation of Compressor Housing Ass’y
…4-38
12) Measurement of Fuel Pressure and
Air Pressure ………………………… 4-39
13) Inspection of Oil Filter ……………… 4-41
14) Inspection of Oil Tank ……………… 4-41
15) Air Bleeding ………………………… 4-42
5.Power Unit
1. Special tools ………………………… 5-2
2. Parts Layout ………………………… 5-3
Engine …………………………………… 5-3
Magneto…………………………………… 5-4
Electric Parts (ECU•Diagram) ………… 5-6
Electric Parts (Starter Motor) …………… 5-8
Air Chamber (Air Box)…………………… 5-9
Throttle …………………………………… 5-10
Cylinder Crank Case …………………… 5-12
Piston & Crank Shaft …………………… 5-14
3. Inspection Items …………………… 5-15
1) Inspection of
Compression Pressure ……………5-15
2) Removing Power Unit ………………5-16
3) Removing Air Compressor ………5-19
4) Removing Flywheel …………………5-20
5) Removing Alternator ………………5-20
6) Removing Starter Motor ……………5-21
7) Removing Cord Ass'y ………………5-22
8) Removing Oil Pump…………………5-25
9) Removing Throttle Link ……………5-25
10) Inspection of Throttle Body…………5-26
11) Removing Air Chamber ……………5-27
12) Removing Thermostat………………5-28
13) Inspection of Thermostat …………5-29
14) Removing Fuel System ……………5-29
15) Removing Cylinder Head /
Head Cover …………………………5-29
16) Inspection of Cylinder Head ………5-30
17) Removing Exhaust Cover …………5-31
18) Inspection of Exhaust Cover ………5-32
19) Removing Crank Case ……………5-32
20) Removing Pistons …………………5-34
21) Disassembly of Crank Shaft ………5-35
22) Inspection of Crank Shaft …………5-35
23) Inspection of Cylinder ………………5-36
24) Inspection of Pistons ………………5-37
25) Assembly of Crank Shaft …………5-40
26) Installation of Pistons ………………5-41
27) Inspection of Crankcase ……………5-41
28) Assembly of Power Unit Parts ……5-42
29) Assembly of Crank Case Halves …5-43
23) Installation of Exhaust Cover ………5-45
31) Installation of Cylinder Head ………5-46
32) Assembly of Crank Case Head ……5-47
33) Installation of Air Chamber …………5-48
34) Installation of Recirculation Hoses 5-50
35) Installation of Throttle Link …………5-50
36) Installation of Oil Pump ……………5-50
37) Installation of Fuel System …………5-51
38) Installation of Cord Ass’y and
Electrical Parts ………………………5-51
39) Installation of Starter Motor ………5-51
40) Installation of Alternator ……………5-51
41) Installation of Drive Pulley and
Flywheel………………………………5-52
42) Installation of Air Compressor ……55-2
43) Installation of Power Unit …………5-52
6.Lower Unit
1. Special Tools ………………………… 6-2
2. Parts Layout ………………………… 6-4
Gear Case (Drive Shaft) ………………… 6-4
Gear Case (Propeller Shaft) …………… 6-6
3. Inspection Items …………………… 6-8
1) Draining Gear Oil …………………… 6-8
2) Removing Propeller ………………… 6-8
3) Removing Lower Unit ……………… 6-9
4) Disassembly of Cam Rod ………… 6-9
5) Inspection of Clutch Cam ………… 6-10
6) Assembly of Clutch Cam Parts …… 6-10
7) Removing Water Pump …………… 6-11
8) Inspection of Water Pump ………… 6-12
9)
Disassembly of Water Pump Case (Lower)
…6-13
10)
Assembly of Water Pump Case (Lower)
…6-14
11)
Removing Propeller Shaft Housing Ass’y
…6-15
12)
Disassembly of Propeller Shaft Housing Ass’y
…6-16
13)
Inspection of Propeller Shaft Housing
…6-17
14)
Assembly of Propeller Shaft Housing
…6-18
15)
Disassembly of Propeller Shaft Ass’y
…6-20
16)
Inspection of Propeller Shaft Ass’y
…6-21
17)
Assembly of Propeller Shaft Ass’y
…6-21
18)
Removing Forward (A) Gear Ass’y
…6-22
19)
Disassembly of Forward Gear (A) Gear
…6-23
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