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TOHATSU TLDI MD 115A SERIES User Manual

TOHATSU TLDI MD 115A SERIES
353 pages
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OB No.003-21060-0
07-05 NB-2600
OB No.003-21060-0
07-05 NB-2600
Printed in Japan
MD115AcoverE.qxd07.6.82:32PMページ1

Table of Contents

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TOHATSU TLDI MD 115A SERIES Specifications

General IconGeneral
Power Output115 HP
Starting SystemElectric
LubricationOil Injection
CoolingWater-cooled
SteeringRemote
Trim SystemPower Trim and Tilt
Shaft Length20" (508 mm)
Engine Type2-Stroke
Ignition SystemCDI
Fuel SystemDirect Fuel Injection
ExhaustThrough Propeller

Summary

Service Information

Identification (Engine Serial Number)

Locating and understanding the engine serial number stamped on the outboard motor body.

Securing of Work Safety

Essential safety precautions including fire prevention, ventilation, and personal protection during service.

Pre-delivery Inspection

Step-by-step checks and inspections to be performed before delivering the outboard motor.

Service Data

Specifications

Comprehensive list of technical specifications for the outboard motor, including dimensions, weight, and performance.

Warning Indication List

Details on warning indicators, buzzer sounds, and their corresponding meanings for abnormalities during operation.

Inspections and Adjustments

Inspection Schedule

Maintenance schedule outlining inspection and replacement intervals for key components.

Cooling System

Procedures for inspecting cooling water passages, flushing the system, and checking compression pressure.

PTT System

Inspection procedures for the Power Trim and Tilt (PTT) unit operation and fluid quantity.

Lower Unit

Inspection procedures for gear oil quantity, gear case, and propeller.

Fuel System (TLDI)

Removing Air Rail

Step-by-step instructions for safely removing the air rail assembly.

Assembling Air Rail

Procedures for correctly installing injectors and regulators onto the air rail.

Removing Fuel System

Detailed steps for removing fuel hoses, fuel filter, and related components.

Removing Air Compressor

Instructions for removing the drive belt and the air compressor unit.

Power Unit

Lower Unit

Draining Gear Oil

Procedure for draining the gear oil from the lower unit.

Removing Propeller

Steps for safely removing the propeller, including necessary precautions.

Removing Lower Unit

Detailed instructions for removing the entire lower unit assembly from the outboard motor.

Removing Water Pump

Step-by-step guide for removing the water pump assembly.

Inspection of Water Pump

Procedures for inspecting the water pump components for wear and damage.

Disassembly of Water Pump Case (Lower)

Instructions for disassembling the lower water pump case.

Assembly of Water Pump Case (Lower)

Procedures for assembling the lower water pump case with new seals and parts.

Removing Propeller Shaft Housing Ass'y

Steps for removing the propeller shaft housing assembly.

Disassembly of Propeller Shaft Housing Ass'y

Detailed procedure for disassembling the propeller shaft housing assembly.

Inspection of Propeller Shaft Housing

Inspection of the propeller shaft housing for wear, cracks, and other defects.

Assembly of Propeller Shaft Housing

Step-by-step instructions for assembling the propeller shaft housing.

Disassembly of Propeller Shaft Ass'y

Procedure for disassembling the propeller shaft assembly, including clutch components.

Inspection of Propeller Shaft Ass'y

Inspection of the propeller shaft assembly for bend, wear, and damage.

Assembly of Propeller Shaft Ass'y

Steps for assembling the propeller shaft assembly with new parts.

Removing Forward (A) Gear Ass'y

Steps for removing the forward gear assembly.

Disassembly of Forward Gear (A) Gear

Procedure for disassembling the forward gear.

Inspection of Forward (A) Gear

Inspection of the forward gear teeth and clutch claws for damage.

Assembly of Forward (A) Gear Parts

Instructions for assembling the forward gear parts.

Removing Drive Shaft Ass'y

Steps for removing the drive shaft assembly.

Disassembly of Drive Shaft Ass'y

Procedure for disassembling the drive shaft assembly.

Inspection of Drive Shaft

Inspection of the drive shaft for bend and wear.

Assembly of Drive Shaft Parts

Instructions for assembling the drive shaft parts.

Measurement of Back Lash between Forward (A) and Pinion (B) Gears and Shim Selection

Procedure for measuring backlash and selecting shims for forward and pinion gears.

Measurement of Back Lash between Pinion (B) and Reverse (C) Gears and Shim Selection

Procedure for measuring backlash and selecting shims for pinion and reverse gears.

Measurement of Propeller Shaft Play and Selection of Washer Thickness

Procedure for measuring propeller shaft play and selecting the correct washer thickness.

Cowl, Bracket and PTT

Power Trim & Tilt

Parts layout and specifications for the power trim and tilt system.

Removing Top Cowl

Steps for removing the upper motor cover.

Removing Bottom Cowl

Detailed instructions for removing the bottom cowl.

Removing Drive Shaft Housing

Steps for removing the drive shaft housing.

Disassembly of Drive Shaft Housing

Procedure for disassembling the drive shaft housing.

Inspection of Drive Shaft Housing

Inspection of the drive shaft housing for distortion, corrosion, and damage.

Assembly of Drive Shaft Housing Parts

Instructions for assembling the drive shaft housing parts.

Removing Steering Shaft Arm

Steps for removing the steering shaft arm.

Electrical System

Inspection Items

Overview of inspection procedures for starter motor components.

Troubleshooting

Power Unit

Troubleshooting guide for power unit issues, focusing on starting system problems.

Rigging

Fuel System

Recommendations for fuel system setup, including fuel/water separators and fuel filter.

Wiring Diagram

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