TOHATSU TLDI MD 115A SERIES User manual

OB No.003-21060-0
07-05 NB-2600
OB No.003-21060-0
07-05 NB-2600
Printed in Japan
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i
TLDI 115A 2007
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.
Information for securing of safety
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:
Provides an important one-point advice.
WARNING
Indicates the presence of a hazard or an
unsafe activity which, if ignored, could
result in severe injury or death.
WARNING
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.
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ii TLDI 115A 2007
About this manual
Composition and use of this manual
This service manual is designed so that service persons are able to perform their work correctly.
Understand the following matters well for efficient works.
1Each chapter begins with the introduction of special tools that are used for the work described in the
chapter so that the service persons are able to figure out the tools needed.
2Parts that are serviced in each chapter and their details are presented by using a component composition
diagram.
3Driving torques are described in the component composition diagram and in the body text are critical
points of the applicable work.
4Pictograms indicate that there is an important work instruction for the relevant parts. It also shows the type
of lubricant and its application point(s).
5The component composition diagrams describe the names of the parts, the number of pieces of the parts
used, size of fasteners and special notes.
6Specific works are described in detail by using illustrations and adding advice on the work.
6-14
Lower Unit
TLDI 115A 2007
9) Disassembly of Propeller Shaft
Housing Ass'y
1. Pull out propeller shaft ass'y 1.
2. Remove reverse (C) gear by using screw drivers 3.
−
CAUTION
Heat propeller shaft housing by putting it in
the hot water of approximately 60 to 70˚C,
and remove bearing 4.
CAUTION
Be careful not to burn.
1
2
3
4
Heating of compressor housing can also be
made by using a heat gun or heat lamp.
4. Use a press to remove oil seal 5and needle bearing 6at
the same time.
Before removing, check bearing for play or
deflection. Replace if necessary.
Direct the side of attachment without O-ring to
needle bearing.
Needle Bearing Attachment 7:
P/N. 3T1-99710-0
Driver Rod 8:
P/N. 3AC-99702-0
Center Plate 9:
P/N. 3AC-99701-0
Needle Bearing Puller Kit 7:
P/N. 3B7-72700-0
5. When removing only oil seal, use bladed screw driver to
pry apart.
This work can be done also by using the following tool kit.
8
9
7
6
5
5Oil Seal
6Needle Bearing
Do not reuse.
Do not reuse.
3. Remove bearing 4.
4Bearing Do not reuse.
5-8
Power Unit
TLDI 115A 2007
1-4
1-2
1-3
1-1
2
3
26
24
21
23
25
22
45
6
8
7
1
13
14
11
12
10
15
10
18
19
17 9
9
16
20
20
Air Chamber
Starter
Solenoid
13 N·m (9 lb·ft) [1.3 kgf·m]
GREASE
OBMOBMOBM
OBM
6 N·m (4 lb·ft) [0.6 kgf·m]
G17G17G17
BOND
G17
SOC
OIL-COMP.
GMGM
SOCSOCSOC
Electric Parts (Starter Motor)
1 Starter Motor 1
1-1 Positive Brush (+) 2
1-2 Negative Brush (-) 2
1-3 Brush Spring 4
1-4 Pinion 1
2 Bolt 2 M8 L=40mm
3 Spring Washer 2 M8
4 Washer, 8.5-24-1.5 2
5 Spacer, 8.4-12-21.5 2
6 Starter Motor Mount "A" 2
7 Starter Motor Mount "B" 1
8 Starter Motor Bracket 1
9 Bolt 3 M8 L=45mm
10 Spring Washer 3 M8
11 Starter Motor Damper 2
Ref.
No. Description Remarks
Q'ty
GREASE
OBMOBM
OBM
G17G17
BOND
G17
12 Starter Motor Band 1
13 Bolt 1 M8 L=40mm W/PW
14 Bolt 1 M8 L=20mm
15 Washer 1 M8
16 Starter Cable 1 L=500mm
17 Starter Cable 1 L=300mm
18 Bolt 1 M6 L=12mm W/PW
19 Bolt 1 M8 L=16mm W/PW
20 Terminal Cap 2
21 Ring Gear Cover 1
22 Grommet, 16-2.5 4
23 Caution Decal "B" 1
24 Fuse Decal 1
25 Spark Plug Decal 1
26 Ring Gear Cover Hook 4
Ref.
No. Description Remarks
Q'ty
OIL-COMP.
GMGM
SOCSOCSOC
SOC
P/L Fig. 10
4
6-2
Lower Unit
TLDI 115A 2007
1. Special tools
Measuring backlash between forward
(A) gear and pinion (B) gear
Backlash Measuring Tool A Kit
P/N. 3B7-72234-0
Removing spring pin
Spring Pin Tool A
P/N. 369-72217-0
Installing spring pin
Spring Pin Tool B
P/N. 369-72218-0
Removing or attaching pinion
(B) gear nut
Bevel Gear B Nut Wrench
P/N. 3B7-72231-0
Removing or attaching pinion
(B) gear nut
Drive Shaft Socket
P/N. 3B7-72232-0
Measuring gaps
Thickness Gauge
P/N. 353-72251-0
Bevel Gear Bearing Puller Ass'y
P/N. 3B7-72755-0
Removing forward (A) gear bearing
outer race
Adjusting pinion (B) gear
height
Shimming Gauge
P/N. 3B7-72250-0
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
Used in combination with driver rod
Attaching reverse (C) gear bearing
Bearing Attachment
P/N. 3AC-99905-0
ø51.5 x ø24.5
Removing propeller shaft
housing
Propeller Shaft Housing Puller Ass'y
P/N. 353-72252-0
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
Measuring backlash between pinion
(B) gear and reverse (C) gear
Backlash Measuring Tool B Kit
P/N. 3B7-72255-0
Removing or attaching gear case and
propeller shaft housing needle bearing
Needle Bearing Puller Kit
P/N. 3B7-72700-0
2
3
5
1
6
4
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iii
TLDI 115A 2007
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/cm
2
]
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 cm
3
（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.
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TLDI 115A 2007
iv
Description of Pictograph
OIL RPM
O K
The following symbols represent the contents of individual chapters.
The following symbols indicate items needed for the service.
The following symbols indicate a point to which lubrication oil, sealing agent or screw-locking agent is to be applied.
r/min
GREASE
OBM
OBM
Waterproof
Grease
ATFATF
OIL
ATF DEXRON III
ADH
17411741
OIL
GEARGEAR
Gear Oil
TB
1373B1373B1373B
LIT
GREASE
Low
Temperature
Resistant
Lithium
Grease G17G17
BOND
[Konishi Bond]
• G17
2st
OIL
TB
13421342
LT
518518
Oil Compound
[Shinetsu Silicon]
S.O.C
OIL-COMP.
SOC
SOC
Molybdenum
Grease
• Moly Paste 500
GREASE
MOL
MOL
Inspections and
Adjustments
Service
Information Service Data
Fuel System
Lower Unit Electrical
System
Power Unit
Troubleshooting Rigging Wiring
Diagrams
Bracket
Specified
Electrical
Value
Lubrication
Oil
Special Tool
Specified
Measurement
Value
Tightening
Torque
Specified Part
Test Run
Adjustment
Engine RPM
Use Limit
2 stroke
Engine Oil
Screw Lock
Agent
[Three Bond®]
• 1373B
Screw Lock
Agent
[Three Bond®]
• 1342
Instant
Adhesive
[Three Bond®]
• 1741
Gasket Seal
Agent
[Loctite®]
• 518
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TLDI 115A 2007 v
1.Service Information
1. Identification (Engine Serial Number) …1-2
2. Securing of work safety ………… 1-2
1) Fire Prevention ……………………… 1-2
2) Ventilation …………………………… 1-2
3) Protection …………………………… 1-2
4) Genuine Parts ……………………… 1-2
5) Tools ………………………………… 1-3
6) Recommendations on service …… 1-3
7) Cautions in disassembling and assembling components …1-4
3. Tools and Instruments …………… 1-5
1) Test Propeller ……………………… 1-5
2) Measuring instruments …………… 1-5
3) List of Special Tool ………………… 1-6
4. Pre-delivery Inspection …………… 1-10
1) Steering Handle …………………… 1-10
2) Gear Shift and Throttle …………… 1-10
3) Engine Oil …………………………… 1-10
4) Gear Oil ……………………………… 1-10
5) Check quantity of engine oil ……… 1-11
6) Fuel Line …………………………… 1-12
7) Installation of Outboard Motor (Rigging) …1-12
8) Inspection of PTT Unit……………… 1-12
9) Inspection of Start Switch and Stop switch …1-13
10) Propeller Selection ………………… 1-14
11) Cooling Water Check Port ………… 1-14
12) Trim Tab …………………………… 1-15
5. Break-In Operation ………………… 1-15
6. Test Run………………………………… 1-16
7. Checks After Test Run …………… 1-16
2.Service Data
1. Outboard Dimensions ……………… 2-2
1) Body dimensions……………………… 2-2
2)Clamp Dimensions …………………… 2-3
2. Cooling Water System Diagram …2-4
3. Specifications………………………… 2-6
4. Warning Indication List • • •
Display for abnormalities during operation …2-8
5. Torque Specifications …………… 2-10
6. Maintenance Data ………………… 2-12
7. Sealant And Lubricant …………… 2-18
3.Inspections and
Adjustments
1. Special Tool…………………………… 3-2
2. Inspection Schedule ……………… 3-3
3. Top Cowl ……………………………… 3-4
1) Adjustment of Cover Hook…………… 3-4
2) Oil Filter and Oil Tank………………… 3-4
3) Air Bleeding …………………………… 3-5
4. Fuel System …………………………… 3-6
1) Inspection of Fuel Pipes and Joints …3-6
2) Inspection of Fuel Filter ……………… 3-7
3) Inspection of Air Compressor Air Filter …3-7
4) Inspection of Air Pressure …………… 3-7
5) Inspection of Fuel Pressure ………… 3-8
5. Cooling System ……………………… 3-9
1)
Inspection of Cooling Water Passage …3-9
2) Flushing with Water ………………… 3-10
3) Inspection of Compression Pressure …3-13
6. Power Unit …………………………… 3-14
1) Inspection of Drive Belt ……………… 3-14
2) Adjustment of Drive Belt Tension …… 3-15
3) Inspection of Spark Plugs …………… 3-16
4) Inspection of Thermostat …………… 3-17
7. Operating System…………………… 3-18
1) Adjustment of Throttle Cable………… 3-18
2) Adjustment of Shift Cable …………… 3-19
8. PTT System …………………………… 3-20
1) Inspection of PTT Unit Operation …… 3-20
2) Inspection of PTT Fluid Quantity …… 3-21
9. Lower Unit …………………………… 3-21
1) Inspection of Gear Oil Quantity……… 3-22
2) Replacement of Gear Oil …………… 3-23
3) Inspection of Gear Case (for leakage) … 3-23
10. Others…………………………………… 3-24
1) Replacement of Anode ……………… 3-24
2) Inspection of Battery ………………… 3-25
3) Greasing ……………………………… 3-26
4.Fuel System (TLDI)
1. Special Tools ..................................... 4-2
2. Parts Layout....................................... 4-3
Vapor Separator & Fuel Line .................. 4-3
FFP Ass'y................................................ 4-4
High Pressure Fuel Filter & Air Rail ........ 4-6
Air Compressor....................................... 4-8
Oil Pump ................................................. 4-10
3. What is TLDI?..................................... 4-12
Direct Fuel Injection System ................... 4-12
Inductive Ignition..................................... 4-13
ECU ........................................................ 4-15
Fuel / Air Feed System ........................... 4-16
Oil System............................................... 4-17
Recirculation System .............................. 4-18
4. Removing Air Rail............................. 4-19
1) Decompression of Fuel Line and Air Line
.... 4-19
2) Removing Air Rail Ass'y ..................... 4-19
5. Assembling Air Rail.......................... 4-21
1) Installing Injectors and Regulators...... 4-21
6. Removing Fuel System ................... 4-25
1) Removing Fuel Hose Ass'y................. 4-25
2) Attaching 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............. 4-28
7) Assembly of Vapor Separator Ass'y ... 4-29
8) Removing FFP Ass'y .......................... 4-29
9) Disassembly and Inspection of FFP ... 4-29
10) Assembly of FFP Ass'y..................... 4-30
11) Attaching FFP Ass'y to Cylinder ....... 4-32
12) Inspection of Fuel Pump................... 4-33
Air Piping of Air Compressor............... 4-34
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TLDI 115A 2007
vi
Structure of Air Compressor ............... 4-35
7. Removing Air Compressor............. 4-36
1) Removing Drive Belt........................... 4-36
2) Removing Air Compressor.................. 4-36
3) Inspection of Drive Belt....................... 4-37
4) Removing Driven Pulley ..................... 4-38
5) Disassembly of Compressor Housing
...... 4-39
6) Inspection of Reed Valve.................... 4-39
7) Inspection of Cylinder and Piston ....... 4-39
8) Assembly of Compressor Housing ..... 4-40
9) Installation of Crank Shaft................... 4-41
10) Installation of Piston.......................... 4-42
11) Installation of Compressor Housing Ass'y
......... 4-43
12) Measurement of Fuel Pressure and Air Pressure
.... 4-44
13) Inspection of Oil Filter....................... 4-46
14) Inspection of Oil Tank....................... 4-46
15) Air Bleeding ...................................... 4-47
Arrangement of Oil Feed Lines........... 4-48
Arrangement of Recirculation hoses
...... 4-49
5.Power Unit
1. Special tools ………………………… 5-2
2. Parts Layout ………………………… 5-3
Engine …………………………………… 5-3
Magneto…………………………………… 5-4
Electric Parts……………………………… 5-6
Electric Parts (Starter Motor) …………… 5-8
Air Chamber ……………………………… 5-9
Throttle …………………………………… 5-10
Cylinder Crank Case …………………… 5-12
Piston & Crank Shaft …………………… 5-14
3. Inspection Items …………………… 5-15
1) Removing Power Unit ……………… 5-15
2) Removing Flywheel ………………… 5-19
3) Removing Stator Coil ……………… 5-20
4) Removing Cord Ass'y ……………… 5-21
5) Removing Throttle Link …………… 5-24
6) Removing Air Chamber …………… 5-25
7) Inspection of Throttle Body………… 5-26
Exploded Diagram of Short Block …5-28
Exploded Diagram of Piston-Crank Shaft Assembly …5-29
8) Removing Thermostat……………… 5-30
9) Removing Cylinder Head / Head Cover …5-31
10) Inspection of Cylinder Head ……… 5-32
11) Removing Exhaust Cover ………… 5-33
12) Inspection of Exhaust Cover ……… 5-33
13) Removing Crank Case …………… 5-34
14) Removing Pistons ………………… 5-35
15) Disassembly of Crank Shaft ……… 5-36
16) Inspection of Crank Shaft ………… 5-36
17) Inspection of Engine Parts ………… 5-38
18) Inspection of Pistons ……………… 5-39
19) Assembling Crank Shaft …………… 5-42
20) Installing Pistons …………………… 5-43
21) Assembling Power Unit Parts …… 5-44
22) Assembling Crank Case Halves …5-46
23) Assembling Exhaust Cover Parts …5-47
24) Assembling Cylinder Head Parts …5-49
25) Assembling Coil Bracket Parts …… 5-50
26) Assembling Crank Case Head Parts …5-50
27) Installing Air Chamber……………… 5-51
28) Attaching Coil Bracket……………… 5-53
29) Attaching Recirculation Hoses …… 5-54
30) Installing Alternator ………………… 5-55
31) Installing Flywheel ………………… 5-55
32) Installing Power Unit ……………… 5-56
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) Removing Water Pump …………… 6-10
5) Inspection of Water Pump ………… 6-11
6) Disassembly of Water Pump Case (Lower) …6-12
7) Assembly of Water Pump Case (Lower) …6-12
8)
Removing Propeller Shaft Housing Ass'y
…6-13
9)
Disassembly of Propeller Shaft Housing Ass'y
…6-14
10)
Inspection of Propeller Shaft Housing
…6-15
11)
Assembly of Propeller Shaft Housing
…6-16
12)
Disassembly of Propeller Shaft Ass'y
…6-19
13)
Inspection of Propeller Shaft Ass'y
…6-20
14)
Assembly of Propeller Shaft Ass'y
…6-20
15) Disassembly of Cam Rod ………… 6-21
16) Inspection of Clutch Cam ………… 6-22
17) Assembly of Clutch Cam Parts …… 6-22
18) Removing Forward (A) Gear Ass'y …6-23
19) Disassembly of Forward Gear (A) Gear …6-24
20) Inspection of Forward (A) Gear …… 6-24
21) Assembly of Forward (A) Gear Parts …6-25
22) Removing Drive Shaft Ass'y ……… 6-26
23) Disassembly of Drive Shaft Ass'y …6-27
24) Inspection of Drive Shaft…………… 6-28
25) Assembly of Drive Shaft Parts …… 6-28
26) Disassembly of Gear Case………… 6-30
27) Inspection of Forward (A) Gear and
Pinion (B) Gear……………………… 6-31
28) Inspection of Gear Case …………… 6-31
29) Assembly of Gear Case Parts …… 6-32
30) Assembly of Lower Unit Parts …… 6-34
31) Attaching Clutch Cam Ass'y ……… 6-37
32) Installation of Lower Unit ………… 6-38
33) Measurement of Pinion (B) Gear Height
and Shim Selection ………………… 6-40
34) Measurement of Back Lash between Forward (A) and
Pinion (B) Gears and Shim Selection ……… 6-42
35) Measurement of Back Lash between Pinion (B) and
Reverse (C) Gears and Shim Selection …… 6-45
36) Measurement of Propeller Shaft Play and
Selection of Washer Thickness ……… 6-48
7.Cowl, Bracket and PTT
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TLDI 115A 2007 vii
1. Special tools ………………………… 7-2
2. Parts Layout ………………………… 7-3
Cowl ……………………………………… 7-3
Bottom Cowl ……………………………… 7-4
Shift ……………………………………… 7-6
Drive Shaft Housing……………………… 7-8
Bracket …………………………………… 7-10
Power Trim & Tilt ………………………… 7-12
3. Inspection Items …………………… 7-14
1) Inner Cowl …………………………… 7-14
2) Removing Top Cowl ……………… 7-14
3) Adjustment of Cover Hook ………… 7-14
4) Removing Bottom Cowl …………… 7-15
5) Removing Drive Shaft Housing …… 7-16
6) Disassembly of Drive Shaft Housing …7-17
7) Inspection of Drive Shaft Housing…7-19
8) Assembly of Drive Shaft Housing Parts …7-20
9) Assembling Drive Shaft Housing Parts …7-23
10) Removing Steering Shaft Arm …… 7-24
11) Removing PTT Unit ………………… 7-25
12) Removing Clamp Bracket ………… 7-27
13) Assembling Clamp Bracket Parts …… 7-28
14) Installation of PTT Unit ……………… 7-28
15) Assembling Steering Arm Parts…… 7-30
16) Removing Motor …………………… 7-31
17)
Inspection of Power Trim and Tilt Motor
…7-32
18)
Assembling Power Trim and Tilt Motor Parts
…7-34
19) Removing Reservoir ……………… 7-35
20) Disassembly of Gear Pump ……… 7-35
21) Disassembling Bracket Unit and
Assembling the Parts ……………… 7-36
22) Disassembly of Tilt Cylinder and
Trim Cylinder, and Assembly of the Parts …7-36
23) Assembling PTT Unit Parts ……… 7-37
24) Air-Purging PTT Unit ……………… 7-41
8.Electrical System
1. Special Tools ………………………… 8-2
2. Parts Layout ………………………… 8-3
Starter Motor……………………………… 8-3
3. Inspection Items …………………… 8-4
1) Disassembly of Starter Motor……… 8-4
2) Inspection of Armature …………… 8-4
3) Inspection of Brushes ……………… 8-5
4) Inspection of Pinion ………………… 8-5
5) Inspection of Ignition and sparks …8-6
6) Inspection of Plug Cap ……………… 8-6
7) Inspection of Ignition Coils ………… 8-7
8) Inspection of Pick Up Coil
(Crank Position Sensor) ……………8-7
9) Inspection of Pick Up Coil Air Gap …8-7
10) Inspection of Alternator …………… 8-8
11) Inspection of Rectifier Complete …8-9
12) Inspection of Throttle Position Sensor …8-10
13) Inspection of Water Temperature Sensor …8-10
14) Inspection of Power Relay ………… 8-11
15) Inspection of Air Injectors ………… 8-11
16) Inspection of Fuel Injectors ……… 8-11
17) Inspection of MAT
(Manifold Temperature) Sensor…… 8-12
18) Inspection of MAP Sensor
(Manifold Air Pressure Sensor) …… 8-12
19) Inspection of Starter Solenoid …… 8-12
20) Inspection of Oil Level Sensor …… 8-13
21) Inspection of Oil Pump …………… 8-13
22) Inspection of PTT Solenoid ……… 8-14
23) Inspection of PTT Switch ………… 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
Ignition System…………………………… 9-16
Fuel System ……………………………… 9-18
Air System………………………………… 9-20
State 2 Full throttle engine revolution
speed is low, engine revolution
speed falls off, or engine stalls.
…………………………………… 9-22
Ignition System…………………………… 9-23
Fuel System ……………………………… 9-24
Lubrication system ……………………… 9-25
Cooling System ………………………… 9-26
State 3 Engine rotation is unstable or
surging occurs in low speed
range. …………………………… 9-27
Ignition System…………………………… 9-28
Fuel 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) Operation Procedure of Self-Diagnosis
Function ……………………………… 9-33
3) Warning Indication List • • •
Display for abnormalities during
operation ……………………………… 9-36
4) Operating Hour Indication List
(Self Diagnosis • Mode 2) …………… 9-38
5) Trouble Indication List
(Self Diagnosis • Mode 3) …………… 9-40
6)Resetting TPS Initial Values ………… 9-44
10.Rigging
1. Service Information………………… 10-2
2. Service Data ………………………… 10-2
1) Load Limit of Boat ………………… 10-2
2) Installation Dimensions …………… 10-2
3) Clamp Dimensions ………………… 10-3
4) Hanging Outboard Motor ………… 10-5
5) Installation of Outboard Motor …… 10-5
3. Fuel System …………………………… 10-6
1) Fuel…………………………………… 10-6
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TLDI 115A 2007
viii
2) Oil …………………………………… 10-6
3) Electric Fuel Pump ………………… 10-6
4) Installation of Fuel Filter …………… 10-6
5) Connection of Fuel Hose ………… 10-7
6) Filling Fuel System ………………… 10-7
7) Filling Oil Tank ……………………… 10-7
8) Priming Oil Pump …………………… 10-8
4. Connections to Outboard Motor …10-8
1) Steering Cable ……………………… 10-8
2) Drag Link …………………………… 10-9
3) Installation of Remote Control Cable
(Engine Side) ……………………… 10-10
5. Lower Unit ……………………………… 10-13
1) Installation of Propeller …………… 10-13
6. Electric System ……………………… 10-14
1) Battery Capacity …………………… 10-14
2) Connection of Battery Cables …… 10-14
3) Installation of Battery (ies) ………… 10-14
7. Accessories and Meters ………… 10-15
1) Accessories. ………………………… 10-15
2) Installation of Meters ……………… 10-15
3) Wiring Remote Control and
Meter Leads ………………………… 10-17
11.Wiring Diagram
TLDI Wire Harness Terminals and
Connections ……………………………… 11-2
Main Harness Diagram ………………… 11-3
115A EPTO Electrical Circuit ……… 11-5
Electrical Wiring Assembling
Instruction Diagram -1 ………………… 11-7
Electrical Wiring Assembling
Instruction Diagram -2 ………………… 11-8
Electrical Wiring Assembling
Instruction Diagram -3 ………………… 11-9
Outboard Motor Installation Template …11-11
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TLDI 115A 2007 ix
1
2
3
4
5
6
7
8
9
10
11
Service Information
Service Data
Inspections and
Adjustments
Fuel System (TLDI)
Power Unit
Lower Unit
Cowl, Bracket and PTT
Electrical System
Troubleshooting
Rigging
Wiring Diagram
INDEX
O K
r/min
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1
Service Information
1
1. Identification (Engine Serial Number) …1-2
2. Securing of work safety ………… 1-2
1) Fire Prevention ……………………… 1-2
2) Ventilation …………………………… 1-2
3) Protection …………………………… 1-2
4) Genuine Parts ……………………… 1-2
5) Tools ………………………………… 1-3
6) Recommendations on service …… 1-3
7)
Cautions in disassembling and assembling components
…1-4
3. Tools and Instruments …………… 1-5
1) Test Propeller ……………………… 1-5
2) Measuring instruments …………… 1-5
3) List of Special Tool ………………… 1-6
4. Pre-delivery Inspection …………… 1-10
1) Steering Handle …………………… 1-10
2) Gear Shift and Throttle …………… 1-10
3) Engine Oil …………………………… 1-10
4) Gear Oil ……………………………… 1-10
5) Check quantity of engine oil ……… 1-11
6) Fuel Line …………………………… 1-12
7)
Installation of Outboard Motor (Rigging)
…1-12
8) Inspection of PTT Unit……………… 1-12
9)
Inspection of Start Switch and Stop switch
…1-13
10) Propeller Selection ………………… 1-14
11) Cooling Water Check Port ………… 1-14
12) Trim Tab …………………………… 1-15
5. Break-In Operation ………………… 1-15
6. Test Run………………………………… 1-16
7. Checks After Test Run …………… 1-16
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1-2
Service Information
TLDI 115A 2007
1. Identification (Engine Serial Number)
Engine serial number is stamped on the bottom cowl of
outboard motor body.
2. Securing of 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.
Tokyo, Made inJapan
2006 Model
SERIAL No. XXXXXXXX
RATED POWER
FULL THROTTLE RANGE
MASS
5150
178 181 kg
5850 r / min
84.6 kW
115A
3T1
12
3
1 Model Name
2 Model Type
3 Serial Number
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TLDI 115A 2007
1
1-3
3R0728150
3AC728710
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.
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1-4
Service Information
TLDI 115A 2007
LIT
GREASE
LIT
350 100
300
40mm to thick or more , wooded
Power Unit Work Board
ø45mm to 50mm holeø45mm 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.
Fig.12
Oil Pump
Fig.3
Air Chamber
B
C
D
40
40
1-2
1-6
1-4
1-7
1-8
1-8
40
40
37
38
54
55
51
27
28 11
4
4
52
10 13
4
2
14
29
26
23
25
34 34
30
24
1
1-11
1-10
1-11
1-11
1-12
1-12
1-12
1-9
1-9
1-1
1-1
1-51-8
50
42
41
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1-5
1
TLDI 115A 2007
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 )
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 ( ø23, ø88 )
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
3. Tools and Instruments
1) Test Propeller
P/N. 3T1-64111-0
Outer diameter : 278mm
With : 25mm
Model Rotational speed at WOT
(Wide Open Throttle) (r/min)
115A approximately 5,500
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1-6
Service Information
TLDI 115A 2007
3) List of Special Tool
Clutch Pin Snap Tool
P/N. 345-72229-0
Attaching clutch pin
Holding power head when disassembling or
assembling power head
Power Head Stand
P/N. 353-72247-1
Used for pulling up shift rod in case the components are
reassembled with the shift rod at "R" position in the gear case.
* This tool is not required when the components are assembled
with the shift rod at "F" position in the gear case.
Shift Rod Joint Puller
P/N. 353-72248-0
Removing or attaching piston
rings
Piston Ring Tool
P/N. 353-72249-0
Measuring gaps
Thickness Gauge
P/N. 353-72251-0
Removing propeller shaft
housing
Propeller Shaft Housing Puller Ass'y
P/N. 353-72252-0
Removing spring pin
Spring Pin Tool A
P/N. 369-72217-0
Installing spring pin
Spring Pin Tool B
P/N. 369-72218-0
Bevel Gear Bearing Puller Ass'y
P/N. 3B7-72755-0
Removing forward (A) gear bearing
outer race
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
ø100 x ø79.5 x ø51.5 x ø61.5
Center Plate
P/N. 3AC-99701-0
Removing or installing propeller
shaft housing 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
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1-7
1
TLDI 115A 2007
Used in combination with driver rod
Attaching reverse (C) gear bearing
Bearing Attachment
P/N. 3AC-99905-0
ø51.5 x ø24.5
Removing or attaching pinion
(B) gear nut
Bevel Gear B Nut Wrench
P/N. 3B7-72231-0
Removing or attaching pinion
(B) gear nut
Drive Shaft Socket
P/N. 3B7-72232-0
Removing or attaching gear case and
propeller shaft housing needle bearing
Needle Bearing Puller Kit
P/N. 3B7-72700-0
Adjusting pinion (B) gear
height
Shimming Gauge
P/N. 3B7-72250-0
Measuring backlash between pinion
(B) gear and reverse (C) gear
Backlash Measuring Tool B Kit
P/N. 3B7-72255-0
Bevel Gear Bearing Install Tool
P/N. 3B7-72719-0
Installing forward (A) gear
bearing
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 forward
(A) gear and pinion (B) gear
Backlash Measuring Tool A Kit
P/N. 3B7-72234-0
Attaching forward (A) gear
bearing outer race
Bearing Outer Press Kit
P/N. 3B7-72739-0
3B7-72733-0
3B7-72731-0
3B7-72732-0
Removing or attaching PTT
piston rod ass'y
1：Trim Rod Guide Wrench
P/N. 3B7-72792
2：Trim Rod Guide Wrench
P/N. 3C8-72791
Needle Bearing Press Kit
P/N. 3C7-72900-1
Removing or attaching gear case
needle bearing
Used to press-fit crank case
head oil seal
Oil Seal Attachment
P/N. 3C7-99820-0
ø34.5 xø19
Used to press-fit crank case
head oil seal
Oil Seal Attachment
P/N. 3E0-99820-0
ø57.5 xø34.5
Spark Tester
P/N. 3F3-72540-0
Checking sparks
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1-8
Service Information
TLDI 115A 2007
Attaching pump case (lower)
oil seal
Oil Seal Attachment
P/N. 3J6-99820-0
ø 41.5 x ø21.5
Removing or attaching flywheel
Flywheel Puller Kit
P/N. 3T1-72211-0
940191-0800
3B7-72785-0
3B7-72784-03B7-72783-0
3T1-72781-0
3C7-72783-0
Used to hook power unit when
hanging
Eye Bolt
P/N. 3T1-72212-0
Removing or attaching piston
pin
Piston Pin Tool
P/N. 3T1-72215-0
Piston Slider
P/N. 3T1-72871-0
Assembling piston for air
compressor
ø31.5 x ø25.0 ø44.5 x ø24.5
Needle Bearing Attachment
P/N. 3T1-99710-0
Used to press-fit forward (A)
gear needle bearing
Attaching air compressor oil
seal
Oil Seal Attachment
P/N. 3T1-99820-0
ø79.5 x ø39.5
Bearing install Tool
P/N. 3T1-99900-0
Attaching drive shaft bearing Attaching air compressor
bearing
Bearing Attachment
P/N. 3T1-99905-0
ø51.5 x ø39.5
O Ring Set Tool (ø24)
P/N. 3T5-72863-0
Assembling O ring into fuel
injector
Caulking clamps made by
OETIKER
Clamp Pliers
P/N. 3T5-72864-0
Measuring air rail fuel pressure
and air pressure
Pressure Gauge Ass'y
P/N. 3T5-72880-0
Used to press-fit coil bracket
oil seal
Oil Seal Attachment
P/N. 3U1-99820-0
ø51.5 x ø39.5
Attaching propeller shaft
housing bearing
Bearing Attachment
P/N. 3U1-99905-0
ø79.5 x ø39.5
Needle Bearing Attachment
P/N. 3U1-99710-0
Used in combination with driver rod and center plate
Attaching propeller shaft housing needle bearing
ø31.5 x ø25 x H32
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1-9
1
TLDI 115A 2007
Used in combination with driver rod
Attaching propeller shaft housing oil
seal
Oil Seal Attachment
P/N. 3Y9-99820-0
ø49.5 x ø29.5
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1-10
Service Information
TLDI 115A 2007
2st
OIL
2st OIL
OIL
GEARGEARGEAR
GEAR
4. Pre-delivery Inspection
1) Steering Handle
Check installation of drag link.
2) Gear Shift and Throttle
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 ato check that the throttle
operations are smooth.
4) Engine Oil
Supply engine oil.
Engine Oil：
Genuine MD Platinum Oil
(Oil for two stroke direct injection engine
recommended by the outboard manufacturer)
OIL
a
a
N
R
F
CAUTION
Engine oil is removed before shipment to
prevent leakage during transportation.
3) Gear Oil
Check quantity of gear oil.
Gear Oil：
900 cm3（30.4 fl.oz）
OIL
Leaking of some oil from plug hole as plug is
removed indicates that gear case is filled with
specified quantity of gear oil.
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