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TOHATSU TLDI 40 User Manual

TOHATSU TLDI 40
185 pages
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SERVICE MANUAL
OIL
WASH
OILLEVEL
B

Table of Contents

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TOHATSU TLDI 40 Specifications

General IconGeneral
Horsepower40 HP
Starting SystemElectric
Cooling SystemWater-Cooled
Full Throttle RPM Range5000-6000 RPM
Gear Ratio2.08:1
LubricationOil Injection
SteeringRemote Control
Shaft Length20 in
Fuel TypeUnleaded gasoline (min 87 octane)
Ignition SystemCDI
ExhaustThrough Propeller

Summary

Chapter 1 Specifications

1. Specifications Table

Lists technical specifications for the outboard motor models.

2. Outline Dimensions

Provides diagrams and measurements for physical dimensions.

3. Background on TLDI

Explains the TLDI (Two-stroke Low-pressure Direct Injection) technology.

Chapter 2 Servicing Information

1. General Precautions for Servicing

Outlines essential safety and general procedures for disassembly/assembly.

2. Specifications and Standards Used in Servicing

Details technical specifications and acceptable wear limits for parts.

3. Lists of Points for Applying Sealant, Adhesive and Lubrication

Table indicating where to apply sealants, adhesives, and lubricants.

4. Torque Table

Lists torque specifications for various bolts and components.

5. Special Tools

Lists and illustrates specialized tools required for servicing.

Chapter 3 Inspection and Maintenance

1. Periodic Inspections

Schedule and procedures for regular maintenance checks.

2. Inspecting Engine Oil Systems

Procedures for checking and maintaining the engine oil system.

3. Inspecting Fuel Systems

Procedures for checking and maintaining the fuel system.

4. Inspecting Compression System

Method for measuring engine cylinder compression.

5. Inspecting Gear Case Area

Procedures for inspecting the gear case, including oil replacement.

6. Washing Procedure

Instructions for flushing the engine cooling system.

7. Inspecting Cooling System

Procedures for checking the engine's cooling system components.

8. Inspecting Power Trim and Tilt System

Procedures for inspecting the power trim and tilt system.

9. Inspecting Air Rail Pressure

Procedure for checking air pressure in the air rail system.

Chapter 4 Disassembling, Inspecting and Reassembling Power Unit

1. Power Unit

Overview of the power unit assembly.

2. Peripheral Parts

Covers various external components attached to the power unit.

3. Engine Block

Details on disassembling, inspecting, and reassembling the engine block.

Chapter 5 Installing and Inspecting Electrical Components

1. Wire Routing

Illustrates the correct routing of electrical wiring harnesses.

2. Wiring Diagram

Provides schematics for the engine's electrical system.

3. Assembly

Step-by-step instructions for assembling electrical components.

4. Inspection

Procedures for inspecting electrical components like magnetos and regulators.

Chapter 6 Disassembly, Inspection and Reassembly Lower Unit

1. Configuration

Exploded views of the lower unit's drive shaft and propeller shaft assemblies.

2. Disassembly

Detailed steps for disassembling the lower unit components.

3. Inspection

Procedures for inspecting lower unit components for wear and damage.

4. Reassembly

Step-by-step instructions for reassembling the lower unit.

Chapter 7 Power Trim and Tilt

1. Configuration

Schematic diagram of the power trim and tilt system.

2. Names of Parts

Identifies and labels the components of the power trim and tilt system.

3. Troubleshooting

Provides a guide to diagnosing and resolving power trim and tilt system issues.

4. Disassembly and Assembly

Detailed procedures for disassembling and reassembling the power trim and tilt system.

Chapter 8 Tiller Handle Type

1. Installing Gearshift Lever Assembly

Instructions for installing the gearshift lever mechanism.

2. Installing Switchbox Assembly

Procedures for installing the electrical switchbox.

3. Installing Handle Assembly

Steps for installing the tiller handle assembly.

4. Installing Handle To Engine

Instructions for connecting the tiller handle assembly to the engine.

Chapter 9 Troubleshooting

1. Troubleshooting Tables

Tables listing symptoms, causes, and remedies for engine malfunctions.

2. TLDI Self-Diagnosing Functions

Explanation of the engine's self-diagnosis system and modes.

Chapter 10 Test Run and Inspection After Servicing

1. Test Run Tank and Test Propeller

Requirements and precautions for engine test runs.

2. Inspection

Checks to perform before, during, and after a test run, including engine break-in.

Chapter 11 Installation on Boat and Test Run

1. Precautions for Using This Engine

General safety precautions for operating the engine.

2. Remote Control System—Installing Cable (Engine side) for EP Series

Steps for connecting the remote control cables to the engine.

3. Gauges and Battery

Instructions for installing boat gauges and connecting the battery.

4. Operating the Engine

Procedures for starting, force-feeding fuel/oil, and initial engine operation.

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