Name: TOHATSU M40D
Brand: TOHATSU
Rating: 4 (1 reviews)

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Contents2
Specifications4
Outline Dimensions6
Service Data and Maintenance Standards7
Table of Points to Apply Sealants, Adhesives and Lubricants13
Table of Tightening Torque16
Tools and Instruments Required for Disassembly and Repair17
How to Use Special Tools19
Flywheel Cup Puller19
Piston Pin Tool19
Piston Slider19
Drive Shaft Bearing Tool20
Backlash Measuring Tool21
Spring Pin Tool21
Inspection and Maintenance22
Periodical Inspections22
Troubleshooting23
Points to Apply Oil or Grease24
Change of Engine Oil25
Change of Gear Oil25
Inspection of Ignition System26
Inspection of Fuel System27
Inspection of Compressor System28
Inspection of Gear Shift and Propeller System29
Inspection of Cooling System30
Power Unit31
Removing Power Unit32
Removing Parts32
Disassembling Engine34
Cylinder Head, Valves and Relating Parts35
Oil Pan (Exhaust Manifold), Oil Pump and Relating Parts36
Crank Shaft, Cam Shaft, Piston, Cylinder and Related Parts37
Inspection and Measurement of Engine Parts38
Measurement with Vernier Calipers38
Measurement with Depth Gauge or Calipers38
Measurement with Micrometer39
Measurement with Cylinder Gauge41
Measurement with Thickness Gauge42
Measurement with Plastigage43
Measurement with Pressure Gauge44
Other Inspections44
Repair and Replacement of Engine Parts45
Repair of Valve Seat45
Reassembling Engine46
Piston Ring46
Lower Unit47
Disassembling Gear Case47
Removing Propeller47
Disassembling Propeller Shaft and Clutch48
Disassembling Water Pump Case48
Removing Cam Rod, Drive Shaft and Bevel Gear49
Inspection of Parts Related to Gear Case50
Reassembling Gear Case51
Clutch and Related Parts51
Bevel Gears and Related Parts51
Propeller Shaft Housing51
Water Pump and Related Parts52
Volume of Gear Oil Required to Pour in52
Sectional View of Gear Case Assembly53
Gear Shift54
Gear Case, Shaft, Water Pump55
Disassembling Lower Motor Cover and Drive Shaft Housing56
Reassembling Lower Motor Cover and Drive Shaft Housing58
Drive Shaft Housing, Gear Case, Motor Cover59
Bracket, Reverse Lock Arm60
Handle, Throttle61
Recoil Starter Disassembling62
Recoil Starter Reassembling62
Recoil Starter, Starter Lock63
Carburetor64
Fuel Pump65
Electrical System66
Electric Circuit Diagram66
Flywheel Inspection66
Exciter Coil, Pulsator Coil, Ignition Coil Inspection66
C.D. Unit Inspection67
Manner to Check Ignition Timing67
Magneto68
Test Run and Inspection after Complete Assembly69
Test Run Tank and Test Propeller69
Items to be Checked During Test Run70
Additional Tightening after Test Run70
Break-In70
Optional Parts71
Remote Control System71
Location of Remote Control Box71
Installing Remote Control Cable (Control Box Side)71
Installing the Remote Control Cable (Engine Side)72
Optional Parts (Remote Control)73
Lighting Coil and Rectifier Kit74
Installing Rectifier Kit75
Inspection of Rectifier and Fuse76
Vertical Starter Kit77

Brand	TOHATSU
Model	M40D
Category	Outboard Motor
Language	English

TOHATSU M40D Service Manual

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