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TOHATSU TLDI 50 Service Manual

TOHATSU TLDI 50
185 pages
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SERVICE MANUAL
OIL
WASH
OILLEVEL
B

Table of Contents

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TOHATSU TLDI 50 Specifications

General IconGeneral
Horsepower50 HP
Cooling SystemWater-Cooled
Starting SystemElectric Start
Gear Ratio2.08:1
Full Throttle RPM Range5000-6000 RPM
LubricationOil Injection
ExhaustThrough Propeller
Fuel SystemDirect Fuel Injection
Ignition SystemCDI
Shaft Length20 in
SteeringRemote

Summary

Chapter 1 Specifications

Specifications Table

Detailed specifications for engine models 40A and 50A, covering dimensions, weight, performance, and electrical components.

Outline Dimensions

Diagrams and measurements of external dimensions of the outboard motor, labeled with letters A through Y for reference.

Chapter 2 Servicing Information

General Precautions for Servicing

Essential safety and handling precautions for conducting disassembly and assembly work on the outboard motor.

Specifications and Standards Used in Servicing

Technical specifications and standard values for various engine parts, critical for accurate inspection and maintenance.

Torque Table

A table listing torque specifications for various bolts and nuts used in engine assembly and disassembly procedures.

Special Tools

A catalog of specialized tools required for specific maintenance and repair procedures on the outboard motor.

Using the Special Tool

Guidance on the proper usage of specialized tools for various servicing tasks.

Pressure Gage Assembly

Instructions for using the pressure gauge assembly to measure fuel and air pressure in the engine.

Chapter 3 Inspection and Maintenance

Periodic Inspections

A schedule outlining regular inspection points and intervals for various engine systems and components.

Inspecting Compression System

Detailed procedures for measuring engine cylinder compression, including results and corrective actions.

Chapter 4 Disassembling, Inspecting and Reassembling Power Unit

Electrical System

Details removal, inspection, and assembly of electrical components such as CPS, flywheel, alternator, ECU, and wiring.

Chapter 5 Installing and Inspecting Electrical Components

Wiring Diagram

Provides detailed wiring diagrams for EPTO and EFTO series, including component identification and color coding.

Solenoid Bracket Assembly

Detailed instructions for the pre-assembly and final assembly of the solenoid bracket.

Chapter 6 Disassembly, Inspection and Reassembly Lower Unit

Disassembly

Detailed steps for disassembling the gear case, including propeller, gear case, and oil draining.

Reassembly

Instructions for reassembling the gear case, propeller shaft, clutch, and water pump.

Assembling Gear Case

General guidelines and specific steps for reassembling the gear case assembly.

Chapter 7 Power Trim and Tilt

Troubleshooting

Comprehensive guide for motor operation, tilt/trim movement, oil issues, and electrical faults.

Symptoms and Points to Check

Lists common symptoms and points to check for diagnosing power trim and tilt system issues.

Checking Procedure

Step-by-step diagnostic procedures for checking switches, wiring, battery, and motor operation.

Disassembly and Assembly

Detailed procedures and precautions for disassembling and assembling the power trim and tilt system.

Chapter 9 Troubleshooting

Troubleshooting Tables

Tables detailing engine symptoms, items to check, causes, and remedies for various malfunctions.

TLDI Self-Diagnosing Functions

Explains the TLDI self-diagnosing function, modes, terminology, procedures, and warning indicator definitions.

Self-Diagnosing Function Procedures

Step-by-step guide for using the self-diagnosing function, including modes and operational procedures.

Warning Indicator Definition Table

Table correlating warning indicators, beeps, and faults with engine conditions.

Chapter 10 Test Run and Inspection After Servicing

Inspection

Checklists for items to inspect before, during, and after a test run, including engine break-in procedures.

Chapter 11 Installation on Boat and Test Run

Operating the Engine

Procedures for starting the engine, including bleeding air, force-feeding fuel and oil, and operating modes.

Starting Procedure

Step-by-step instructions for starting the engine, including air bleeding and throttle control.

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