TOHATSU 18 - Disassembly of Gear Case; Removal of Gear Case; Disassembly of Water Pump Case

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Contents2
Specifications3
Precautions During Work8
Service Data9
Service Data and Maintenance Standards Chart10
Thermostat Switching Test14
Periodic Inspection Chart16
Table of Sealants, Adhesives, Lubricating Oils and Usage Locations17
Table of Tightening Torques20
Tools and Instruments Required for Disassembly, Maintenance and Repair21
How to Use Special Tools22
Flywheel Magneto Tool22
Piston Pin Tool22
Spring Pin Tool23
Needle Roller Bearing Tool23
Needle Roller Bearing in Propeller Shaft Housing24
Needle Roller Bearing of Gear Case25
Socket and Wrench for Bevel Gear B Nut26
Clutch Pin Snap Tool26
Backlash Measuring Tool27
Bevel Gear a Bearing Puller28
Power Unit29
Removal of Power Unit30
Removal of Accessories/Starter Motor32
Removal of Recoil Starter33
Removal of Flywheel Magneto34
Removal of Carburetor/CD Unit and Ignition Coil/Thermostat35
Cylinder and Crank Case Assembly36
Piston and Crank Shaft37
Engine Disassembly38
Removal of Cylinder Head/Exhaust Cover and Engine Anode38
Removial of Inlet Manifold and Reed Valve39
Removal of Crank Case and Crankshaft39
Removal of Piston40
Engine Assembly42
Installing the Piston42
Installing the Crank Shaft and Crank Case42
Engine Assembly Procedure43
Installation of Reed Valve and Inlet Manifold44
Installation of Exhaust Cover and Engine Anode44
Installation of Cylinder Head44
Throttle Mechanism and Bar Handle Exploded View45
Installation and Adjustment of Accessories46
Installation of Flywheel Magneto/Fuel Lines46
Adjustment of Throttle Mechanism47
Procedure for Adjusting Ignition Timing When Opening the Throttle Fully47
Procedure for Adjusting Ignition Timing When the Throttle Is Fully Closed48
Adjusting Sliding Motion of the Advancer Arm48
Adjusting Opening of Throttle Toward the Reverse Side48
Inspecting Starter Locking Cam49
Standards for Engine Oil and O-Ring49
Installation of Starter Motor49
Recoil Starter and Starter Lock Exploded View50
Recoil Starter Disassembly51
Recoil Starter Assembly52
Applying Initial Load on the Starter Spring53
Checking the Force Acting on the Ratchet53
Lower Unit54
Drive Shaft Housing and Gear Case Exploded View55
Disassembly of Gear Case56
Removal of Gear Case56
Disassembly of Water Pump Case56
Removal of Propeller57
Disassembly of Propeller Shaft and Clutch57
Removal of Clutch Cam and Cam Rod58
Removal of Bevel Gear and Drive Shaft58
Gear Case Assembly60
Installation of Bevel Gear and Drive Shaft60
Installation of Clutch Cam and Cam Rod60
Backlash Adjustment between Bevel Gears a and B61
Assembly of Water Pump Case62
Assembly of Propeller Shaft and Clutch63
Propeller Installation64
Installation of Gear Case64
Standards for Oil Seals and O Rings for Gear Case64
Disassembly of Lower Motor Cover and Drive Shaft Housing65
Removal of Lower Motor Cover65
Removal of Exhaust Pipe and Water Pipe65
Bracket and Reverse Lock (Type I) Exploded View66
Bracket and Reverse Lock (Type II) Exploded View67
Disassembly of Stern Bracket/Swiveling Bracket68
Disassembly of Drive Shaft Housing69
Drive Shaft Housing and Mounting Bracket70
Assembly of Lower Motor Cover and Drive Shaft Housing70
Assembly of Drive Shaft Housing70
Installation of Exhaust Pipe and Water Pipe71
Installation of Lower Motor Cover/Choke Lever72
Assembly of Gear Shift Lever72
Shift Lever Adjustments73
Installation of Motor Cover74
Disassembly of Steeging System, Hanle and Bracket74
Removal of Steering Shaft Assembly74
Disassembly of Steering System74
Removal of Steering Handle75
Assembly of Steering System, Handle and Bracket76
Assembly of Stern Bracket76
Adjustment of Reverse Lock76
Installation of Steering Handle77
Assembling the Steering System77
Carburetor78
Carburetor - Exploded View/Outline of Operation79
Pilot System: Flow of Fuel Mixture During Start and Idling/Slow Operation79
Main System: Flow of Fuel Mixture for Operations above Medium Speed79
Float System80
Carburetor - Inspections80
Inlet (Carburetor with Reed Valve/Fuel Pump) Exploded View81
Electrical System82
Flywheel Magneto and CD Unit Exploded View83
CD Magneto Construction and Maintenance83
Flywheel Inspection and Maintenance83
Coil Plate and Coils83
CD Unit - Inspection and Maintenance84
To Test CD Unit/Test Check Table85
Ignition Coils Inspection and Judgement86
Stop Switch Inspection and Maintenance86
Inspection of Connecting Wires and Contacts86
Precautions in Handling the CD Magneto86
Electrical Starter Exploded View87
Precautions During Electrical System Tests and Trials88
Electric Cicruit (EP Type) Diagram88
Electric Cicruit (EF Type) Diagram89
Inspection of Parts Related to Electric Starter90
Inspection after Mounting or Repair of Starter Motor Accessories90
Starter Motor Periodic Inspection Chart90
Starter Motor Inspection and Maintenance91
Checking the Starter Solenoid91
Complete Check of Rectifier92
Main Switch (EP, Ef)/Neutral Switch Checks93
Remote Control94
Engine Side Mounting Kit for Remote Control Exploded View95
Installation of Remote Control Cables96
Control Box Installation (Driver's Side)97
Installation of Remote Control Cables at Engine97
Remote Control Installed Illustration98
Inspections, Adjustments and Trials99
Testing Tank and Dynamometer100
Conditions and Precautions for Testing Tank100
Adjustments and Operational Checks of Outboard Motor100
Inspections and Adjustments after Final Assembly101
Troubleshooting102

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