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2006 tohatsu 90hp 2 stroke air compressor seized

A

akjackh

New member
Hello, the air compressor on my motor recently seized up and gouged the side of the cylinder and possibly bent the connecting rod. I tried honing the cylinder but spinning it though by hand it still binds up on the gouge. Any tips for repairing it or would I be better off buying a new one? I’ve also been unable to find much for parts online so if anyone knows a good place to look that would be great!
Thanks, Jack
 
The compressor is NLA, but one for a 50 hp version will work perfectly. verify your pressure regulators and oiling, or your new one may puke too. If fuel gets into the air line, you are done.
 
Full info is in the Factory service manual. You will need a special high pressure gauge set to do it by the factory method.
 
Do you know if there’s a good online factory service manual or would that be something I’d have to get a hard copy of? I removed the regulators to check their seals (all looked good) and I noticed there was fuel present at the air regulator as well as the fuel regulator, just thought I’d ask to see if thats normal? Pretty new to outboard maintenance so definitely still trying to learn things. Thanks!
 
The manual is copyrighted to no pdf versions. No, you should not see gas in the air rail. Ever.
 
Replaced the regulator and everything seems to be running okay except now it dies when I put it into gear (unless I give it full throttle then slam it into gear.) It’s also now giving error codes for a faulty TPS. I tested it and it’s only getting resistance once it’s about half way turned then the numbers drop gradually (with no dead spots) as it goes to full throttle. I’ve tried resetting the TPS several times and it wasn’t an issue before my air compressor failed. Thought I’d ask if it sounds like a bad TPS to you? Thanks for all your help so far!
 
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