9161F4-0830 Tohatsu BOLT

Recommended Repairs
Batteries and/or Battery Cables
Inspect the main power switch, battery posts, and battery cables for loose connections and corrosion. If the battery cables are corroded, remove the battery cables and clean the battery cables. Tighten any loose connections.
Inspect the batteries.
Charge the batteries. Refer to Special Instruction, SEHS7633, "Battery Test Procedure".
Load test the batteries. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries". Starting Circuit
Check the starting circuit. Refer to the schematic diagram in Troubleshooting, "Starting - Test".Starting Motor or Flywheel Ring Gear
If the pinion engages the flywheel but the flywheel does not turn, there may be a problem with the starting motor. If the starting motor turns but the flywheel does not turn, inspect the gear teeth, the clutch jaws, or other parts.Inspect the pinion and the flywheel ring gear for damage. If the teeth of the pinion and/or of the flywheel ring gear are worn or broken, replace the parts.If the pinion does not engage correctly with the flywheel, the pinion shaft may be stuck. Remove the pinion. Grease the splines of the drive shaft and the pinion.If the pinion does not engage the flywheel, the clutch jaws may be broken.Before you remove the starting motor, turn the crankshaft by hand. Ensure that a mechanical failure inside the engine is not preventing the crankshaft from turning. If the crankshaft will turn by hand, try the starting motor again. If the starting motor does not turn the crankshaft, remove the starting motor. Repair the starting motor or replace the starting motor.Low Air Pressure
Determine the cause of the low air pressure. Inspect the air lines for leaks. Repair any leaks in the air lines.Static Load
Make sure that the driven equipment is not preventing the crankshaft from turning. Try to turn the crankshaft by hand. If necessary, disengage the driven equipment and test the engine.Internal Mechanical Problem
If the crankshaft will not turn and the driven equipment is disengaged, remove the spark plugs. Check for fluid in the cylinders. If this is not the problem, the engine must be disassembled in order to investigate internal mechanical problems. Possible internal problems include the following conditions:
Bearing seizure
Piston seizure
Valve and piston contactCheck the Harness Codes
The harness inside the terminal box has jumper wires (harness codes) for the slave Electronic Control Module (ECM) and the optional Auxiliary Sensing Module (ASM).The ECM that is connected to the harness reads the harness code. This provides the ECM with a unique identifier on the Cat Data Link.The jumper wires must be connected in order for the Caterpillar Electronic Technician (ET) to communicate with the modules. The jumper wires must be connected in order for the engine to crank. The jumper wires must remain connected in order for the engine to run.The jumper wire for the slave ECM connects terminals P3-60 and P3-29.The jumper wire for ASM connects terminals P5-60 and P5-68.Check the continuity between the terminals. Verify that the jumper wires are in good condition. Make repairs, as needed.