Tohatsu MFS90A Manual

Tohatsu Påhængsmotor MFS90A

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O W N E R’S

M A N U A L

AAAA

Original instructions

MFS 100A

MFS 90A

MFS 75A

MFS 115A

OB No.003-11159-3BB1

MFS 140A

ENOM00001-0

READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE INSTRUCT IONS

AND SAFET Y PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. KEEP T HIS

MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.

transmitted in any from or by any means without the express written permission of Tohatsu Corporation.

YOUR TOHATSU OUTBOARD MOTOR

ENOM00006-2

To You, Our Customer

Congratulations on your purchase of the TOHATSU outboard motor. You are now the

proud owner of an excellent outboard motor that will serve you for many years to come.

This owner's manual contains important safety, operational and maintenance informa-

tion.

The efficiency and longevity of your outboard motor will depend heavily on your oper-

ating methods and periodic maintenance. Failure to operate and maintain your out-

board motor according to the instruction in this owner's manual may void the limited

warranty, as well as reduce the efficiency and reliability of the outboard motor.

Any person operating TOHATSU outboard motor must carefully read and fully under-

stand the entire contents of this manual prior to operation. For safety, follow all safety

warnings contained within the owner's manual and the labels applied to your outboard

motor. You should keep this owner's manual where accessible while operating your out-

board motor. If the outboard motor is resold, make sure the manual is passed on to the

next owner. In case you encounter any problems, please contact an authorized

TOHATSU service shop or dealer for assistance.

Tohatsu Corporation reserves the right to change, modify, add, or remove a part or

whole of the owner’s manual without prior notice and incurring any obligations.

We are excited to take a part in your boating adventures and wish for your great and

safe boating experience.

TOHATSU CORPORATION

ENOM00113-1

DECLARATION OF CONFORMITY (DoC)

This product conforms to certain portion of the European Parliament directive and UK

Regulations. DoC contains the following information;

zName and Address of the manufacturer, EU - notified body, EU - authorized repre-

sentative, and UK - approved body.

zApplied community directives and regulations

zReference standard

zDescription of the product. (model name and serial number)

zSignature of the responsible person (name / title / date and place of issue).

ENOM00002-0

OWNER REGISTRATION AND IDENTIFICATION

Upon purchasing this product, be sure that the WARRANTY CARD is correctly and

completely filled out and mailed to the addressee noted there on. This WARRANTY

CARD identifies you as the legal owner of the product and serves as your warranty

registration.

TO THE EXTENT PERMITTED BY APPLICABLE LAW, YOUR OUTBOARD MOTOR WILL NOT

BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS PROCEDURE IS NOT

FOLLOWED.

ENOM00003-1

PRE-DELIVERY INSPECTION

Make sure Pre-delivery inspection has been properly done by authorized TOHATSU

dealer before operating your outboard motor.

ENOM00005-1

Serial Number

Your outboard motor has a unique serial number. The serial number is identification of

outboard motor and is located on the outboard motor as shown in the figures below.

The serial number is required for warranty registration, filing a warranty claim as well as

making technical inquiries and may be required for other occasions.Therefore, please

write down the serial number and date of purchase in the space below.

Serial Number:

Serial Number: Date of purchase:

ENOF02400-0

ENOF02401-1

ENOM00007-0

NOTICE: DANGER/WARNING/CAUTION/Note

Before installing, operating or otherwise handling your outboard motor, be sure to

thoroughly read and understand this Owner's Manual and carefully follow all of the

instructions. Of particular importance is information preceded by the words “DAN-

GER,” “WARNING,” “CAUTION,” and “Note.” Always pay special attention to such

information to ensure safe operation of the outboard motor at all times.

ENOW00001-0

Failure to observe will result in severe personal injury or death, and possibly property damage.

ENOW00002-0

Failure to observe could result in severe personal injury or death, or property damage.

ENOW00003-0

Failure to observe could result in personal injury or property damage.

ENON00001-0

Note

This instruction provides special information to facilitate the use or maintenance of the out-

board motor or to clarify important points.

DANGER

WARNING

CAUTION

1. GENERAL SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3. PARTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4. LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Battery installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Propeller installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4. TOCS (Tohatsu Onboard Communication System) installation. . . . . . . . . 25

6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

3. Engine oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5. Warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

1. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

9. Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . . . . . . .57

1. Removing the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

3. Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

9. ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3. Remote control lever friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

10. INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

6. Cold weather precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

CONTENTS

8. Operation with multiple outboard motors . . . . . . . . . . . . . . . . . . . . . . . . 85

11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

12. ACCESSORIES KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1. GENERAL SAFETY INFORMATION

2. SPECIFICATIONS

3. PARTS NAME

4. LABEL LOCATIONS

5. INSTALLATION

6. PRE-OPERATING PREPARATIONS

7. ENGINE OPERATION

8. REMOVING AND CARRYING THE OUTBOARD

MOTOR

9. ADJUSTMENT

10. INSPECTION AND MAINTENANCE

11. TROUBLESHOOTING

12. ACCESSORIES KIT

13. PROPELLER TABLE

INDEX

GENERAL SAFETY INFORMATION

ENOM00009-1

SAFE OPERATION OF BOAT

As the operator/driver of a boat, you are responsible for the safety of those aboard and

those in other boat around yours, and for following local boating regulations. You should

be thoroughly knowledgeable on how to correctly operate the boat, outboard motor,

and accessories. To learn about the correct operation and maintenance of the out-

board motor, please read through this manual carefully.

It is very difficult for a person in the water to take evasive action should he or she see a

power boat heading in his/her direction, even at a slow speed.

Therefore, when your boat is in the immediate vicinity of people in the water, the out-

board motor must be shifted to neutral and shut off.

ENOW00005-0

SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOVING BOAT,

GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TO A BOAT OR GEAR

HOUSING.

ENOM00247-1

STOP SWITCH LANYARD

The engine can be stopped by pulling out the stop switch lock from the stop switch. The

stop switch lanyard is the coiled red cord with the stop switch lock on one end and a

metal clip on the other end. With attaching the stop switch lanyard to the operator's

body part or operator’s personal flotation device (PFD), the engine will stop when the

stop switch lanyard is being stretched and pulled out the lock from the switch if the

operator accidentally falls overboard or leaves from operator’s position. This function

may prevent losing control of the boat and minimize or prevent risk of collision with

other boats, people and other objects. It is operator’s responsibility to use the stop

switch lanyard.

ENOW00004-1

Accidental activation of the Stop Switch (such as the tether being pulled out in heavy seas)

could cause passengers to lose their balance and even fall overboard, or it could result in loss

of power in heavy seas, strong currents, or high winds. Loss of control while mooring is

another potential hazard.

To minimize accidental activation of the Stop Switch, the 500 mm (20 inch.) stop switch lan-

yard is coiled and can extended to a full 1300 mm (51 inch.).

ENOM00800-A

PERSONAL FLOTATION DEVICE

As the operator/driver and passenger of a boat, you are responsible to wear a PFD (Per-

sonal Flotation Device) while on the boat.

WARNING

GENERAL SAFETY INFORMATION 11

ENOM00010-1

SERVICING, REPLACEMENT PARTS & LUBRICANTS

We recommend that only an authorized service shop perform service or maintenance

on your outboard motor. Be sure to use genuine parts, genuine lubricants, or recom-

mended lubricants. Be aware that the installation and use of parts not approved by

Tohatsu Corporation will void warranty and may lead to unsafe operating conditions.

ENOM00011-1

MAINTENANCE

As the owner of the outboard motor, you should be acquainted with correct mainte-

nance procedures following by maintenance section of this manual (See page 62). It is

the operator's responsibility to perform all safety inspections, proper lubrication and to

follow all maintenance instructions for safe operation. You should take the engine to an

authorized dealer or service shop for periodic inspection at the prescribed intervals.

Correct periodic maintenance and proper care of outboard motor will reduce the

chance of problems, limit overall operating expenses and contribute to longevity of your

outboard motor.

Carbon Monoxide Poisoning Hazard

Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal

if inhaled for any length of time.

Never start or operate the engine indoors or in any space which is not well ventilated.

Gasoline

Gasoline and its vapors are very flammable and can be explosive. Use extreme care

when handling gasoline. You should be thoroughly knowledgeable on how to correctly

handle gasoline by reading this manual.

SPECIFICATIONS

ENOM00810-A

MODEL FEATURE

( )z These models can be purchased with remote rigging kit or multi-function tiller han-

dle.

ENOM00811-A

MODEL NAME EXAMPLE

F 140A ETL

Model F75A F90A F100A F115A F140A

Type ET ET ET ET ET

Transom heights

Lzzzzz

UL z z z z

Multi-function tiller

handle ( ) ( ) ( ) ( ) ( )zzzzz

Remote Control ( ) ( ) ( ) ( ) ( )zzzzz

Power Trim & Tilt zzzzz

F A E T L140

Model descrip-

tion Horse power Product genera-

tion

Starter

system Tilt system Shaft length

F= Four stroke - A and up E= Electrical start T= Power trim&tilt L= Long 20 in

UL= Ultra long 25 in

SPECIFICATIONS 13

ENOM00013-0

Remark: Specifications are subject to change without notice.

Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).

*With propeller

Item Model

F75/90/100/115/140A

Remote Control

Multi-function tiller handle

Overall Length mm (in) 826 (32.5) 1541 (60.7)

Overall Width mm (in) 540 (21.3)

Overall Height mm (in) L : 1652 (65.1) UL : 1779 (70.1)

Transom Height mm (in) L : 517 (20.4) UL : 644 (25.4)

Weight* L kg (lb) 178.0 (392) 182.5 (402)

UL kg (lb) 182.5 (402) 187.0 (412)

Engine Type 4 stroke

Number of Cylinder 4

Piston Displacement

3 (

cu.in.)

1995 (121.6)

Bore x Stroke mm (in) 84 x 90 (3.30 x 3.55)

Max. Output kW (PS) 55.2 (75) 66.2 (90) 73.6 (100) 84.6 (115) 103.0 (140)

Max. Operating Range

min

-1

(rpm)

5150 - 5850

Idle Speed

min

-1

(rpm)

700

Exhaust System Through hub exhaust

Lubrication System Wet sump (Trochoid pump)

Cooling System Water cooling (with thermostat)

Starting System Electric starter motor

Ignition System Battery ignition

Alternator 12V - 41A

Steering Angle Degree 70

Trim Angle Degree 8 -22

Trim Position 2

Trim Up Angle Degree 75

Gear Shift Dog clutch (F-N-R)

Gear Reduction Ratio 2.08 (25:12)

Operator Sound Pressure

(ICOMIA 39/94 Rev.1) dB (A) 90.4

Hand Vibration Level

(ICOMIA 38/94 Rev.1) m/s2- 3.6

PARTS NAME16

818

11 9

ENOF02403-0

ENOM00822-0

Remote control box & Fuel tank

Control Lever

Neutral lock arm

PTT switch

Free throttle lever

Main switch

Stop switch

Stop switch lock

Stop switch lanyard

Control lever

Neutral lock arm

PTT switch

Neutral throttle button

Main switch

Stop switch

Stop switch lock

Stop switch lanyard

Fuel gauge

Air vent screw

Fuel tank cap

Primer bulb

Fuel connector (Fuel tank

side)

LABEL LOCATIONS

ENOM00019-A

Warning label locations

ENOF02404-0

LABEL LOCATIONS18

Read owner's manual.

2-1. Warning regarding starting the

engine (See page 38).

2-2. HOT SURFACE

Can cause burns.

Do not touch when operating or

immediately after the engine has

stopped.

2-3. HAZARD CAUSED BY ROTATING

PARTS

Rotating parts can cause severe

injury.

Keep hands, feet, hair, and clothing

away from all rotating parts to pre-

vent injury.

2-4. ELECTRICAL SHOCK HAZARD

High voltage can cause severe elec-

trical shock.

Do not touch electrical components

such as ignition coil or spark plug

cord when starting

or while the engine is in operation.

2-5. Fuel filter maintenance. (See page

63, 68, 69)

For tiller handle model

Warning lamp (See page 31).

For tiller handle model

4. Stop switch (See page 39 and

page 50)

For RC model

Warning regarding stop switch lan-

yard.

For Top mount RC

Read owner's manual.

Warning regarding gasoline.

Warning regarding gasoline (See

page 26).

ENOF00120-0

EL F ILTE

GAS

LOAT

WATER

123

3UG-72181-0

3GF-72198-1

3GF-72200-1

ENOF00008-1

ENOF00120-0

ENOF00005-E

ENOF00005-L

LABEL LOCATIONS 19

Warning regarding gasoline (See

page 26).

10.

Warning regarding gasoline (See

page 26).

11.

Caution tag regarding for replenish

the engine oil. (See page 28).

ENOF00005-M

ENOF00005-F

3VJ-72044-000

LABEL LOCATIONS20

ENOM00019-B

1. Model code (Model name)

2. Serial No.

3. Rated power

4. Dry mass weight (Without propeller, with battery

cable)

5. Manufacturer name

6. Manufacturer address

7. Authorised representative

8. Authorised representative address

CE label locations

1521

CAN ICES-2 / NMB-2

0026

ENOF02405-2

Description of serial number year code

Last two digits of alphabet represent production year as below.

Year Code BB BC BD BE BF

Year of

manufacture 2022 2023 2024 2025 2026

INSTALLATION

ENOM01800-0

ENOW00961-0

Do not over-power the boat and take care

not to over-load the engine. Boat manufac-

turers specify the maximum allowable engine

power and complement of their boat in

accordance with certain standards and show

the data on the plate attached to the boat.

For unknown matters, if any, inquire to the

manufacturer of the boat.

ENOW00962-0

Never use boat equipped with an outboard

motor that outputs power exceeding the

maximum allowable limit specified by the

manufacturer of the boat, or the following

problems can occur:

zThe boat can go out of control.

zThe buoyancy property of the boat varies

from the designed value if the boat is

overloaded especially at the transom.

zThe boat may crack or be damaged

around the transom.

Over-powering boats can cause serious

injury, fatal accident and/or serious damages

to the hull.

Mounting outboard motor must be per-

formed by trained service person(s) in

well-equipped place where lift or hoist

can be used.

ENOM00025-0

Position ... Above keel line

Place the outboard motor in the center

of the boat's transom.

1. Center of boat

2. Chine

ENOM01801-0

Transom matching

Be sure that the anti ventilation plate of

the outboard motor should align with the

bottom of the hull or should not exceed

more than 30mm (1.2in) below the bot-

tom of the hull.

If the above condition cannot be met due

to the shape of the bottom of your boat,

please consult your authorized dealer.

1. Bottom of hull

2. Anti ventilation plate

ENOW00007-1

zBefore running test, check the boat with

maximum loading capacity. Overloading or

inc orr ect weigh t dis tr ib ution of th e

weight may result in boat to lose control,

even swamping or capsizing. Make sure

1. Mounting the outboard

motor on boat

WARNING

CAUTION

ENOF02406-0

0−30 mm

(0−1.2 in)

ENOF00015-C

INSTALLATION22

that there is enough distance between

bottom cowl and water surface to prevent

water from entering the engine.

zMake sure to mount the engine in correct

position. If outboard motor is mounted

incorrectly, water may intrude the engine

from openings of the bottom cowl while

cruising. Exposing the engine to such con-

dition may result in severe damage to the

engine.

ENOM01802-1

Mounting the outboard motor

The outboard motor is secured to the

boat transom through the 4 bolts with

flat washers and nylon locking nuts.

ENOW00965-0

The outboard motor may displace or come

off from the boat, if the mounting bolts

loose, possibly resulting in lost of control

and /or serious personal injury. Check the

mounting bolt tightness on a regular basis.

1. Bolt (12 mm × lenght 105 mm)

2. Washer (large diameter

3. Nylon locking nut

4. Washer (small diameter)

ENON00946-0

Note

Do not reuse nylon locking nut.

ENOM001816-0

ENOW00012-1

Batter y electrolyte contains sulfuric acid

and is hazardous, causes a burn if come in

contact with your skin, and poisonous if

swallowed.

Keep battery and electrolyte away from

reach of children.

When handling the battery, be sure to:

zRead all warnings shown on the battery

case.

zPrevent electrolyte from coming in con-

tact with any part of your body. Contact

can cause serious burn or, if come in con-

tact wi th your eye, loss of si ght. Use

safety glasses and rubber gloves.

In case you came in contact with battery

electrolyte:

zFor skin, flush thoroughly with water.

zFor eye, flush thoroughly with water, and

then seek immediate medical treatment.

In case battery electrolyte is swallowed:

zSeek immediate medical treatment.

ENOW00013-B

Battery generates explosive hydrogen gas.

Be sure to:

zCharge the battery in a well-ventilated

place.

zPlace the battery away from any source of

fir e, spar ks and open flames such as

burners or welding equipment.

zDo not smoke near the battery when the

battery is charging.

WARNING

4ENOF00614-0

2. Battery installation

WARNING

INSTALLATION 23

ENOW00014-0

zMake sure that the battery leads do not

get stuck between the outboard motor

and boat when turning, etc.

zThe starter motor may fail to operate if

the leads are incorrectly connected.

zBe sure to correctly connect the (+) and

(—) leads. Do not reverse the batter y

leads. Otherwise, the electrical system

will be damaged.

zDo not disconnect the battery leads from

battery while the engine is operating, the

electrical parts could be damaged.

zAlways use a fully charged battery.

ENOW00015-1

Do not use a batter y that is not recom-

mended. Use of a battery not recommended

can lead to poor performance of, and/or

damage to the electrical system.

ENON00006-1E

Note

Minimum batter y requirements: 12v

70Ah/20HR, 512 Cold Cranking Amps

(CCA).

Larger capacity battery is required when it

is used under a freezing condition.

Recommend connecting only the engine

battery cables to the starting battery.

Specifications and features of battery vary

by manufacturers.

Consult the manufacturer for details.

* The battery should be purchased sepa-

rately and is not supplied with the out-

board motor.

1. Place the battery box in a convenient

position and away from possible water

spray. Securely fasten both the box

and the battery so they do not shake

loose.

2. Connect the positive leads (+) to the

positive terminal (+) of the battery,

and then connect the negative lead

(—). When disconnecting the battery,

always remove the negative lead (—)

first. After connecting the positive

terminal (+), securely place a cap on it

to prevent short circuits.

1. Starter cable (red)

2. Battery cable (red)

3. Battery cable (black)

ENON00944-0

Note

zDo not use wing nuts to fasten battery

cables.

zWing nuts tend to loosen and cause

electrical system damage.

CAUTION

ENOF02444-0

ENOF02445-0

INSTALLATION24

ENOM00123-0

ENOW00084-0

zDo not begin propeller removal and instal-

lation procedure with spark plug caps

attached, shift in forward or reverse,

main switch at other than “OFF”, engine

stop switch lock attached to the switch,

and starter key attached, or engine could

accidentally start leading to serious per-

sonal injury. Disconnect battery cable if

possible.

zThe propeller edge is thin and sharp. Wear

the groves during replacement to protect

your hands.

ENOW00085-0

Do not hold propeller with hand(s) when

loosening or tightening propeller nut. Put a

piece of wood block between propeller

blade and anti-ventilation plate to hold pro-

peller.

ENOW00086-0

zDo not install propeller without thrust

holder, or propeller boss could be dam-

aged.

zDo not reuse split pin.

zAfter installing split pin, spread the pin

apart to prevent it from falling out which

could lead to the propeller coming off

during operation.

Propeller must be selected that will allow

the engine to reach recommended maxi-

mum operating range during cruising.

Genuine propellers are listed on PROPEL-

LER TABLE of this manual (See page 90).

1. Remove the split pin, propeller nut

and washer.

2. Apply water proof grease to the pro-

peller shaft before installing a new

propeller.

3. Install the thrust holder, propeller

stopper, washer and propeller nut

onto the shaft.

1. Propeller

2. Thrust holder

3. Bush

4. Stopper

5. Washer

6. Nut

7. Split pin

4. Tighten the propeller nut to specified

torque with holding the propeller by

wood block. And align one of grooves

to propeller shaft hole.

3. Propeller installation

WARNING

CAUTION

ENOF00084-B

Wide-open throttle rpm range

5150 – 5850 min-1 (rpm)

ENOF01336-0

INSTALLATION 25

Propeller nut torque:

35 N·m (25 ft·lb, 3.5kgf·m)

5. Install a new split pin into the nut hole

and bend it.

ENOM01821-1

TOCS (Tohatsu Onboard Communication

System) interface coupler can provide

information regarding engine speed, fuel

consumption, and various possible mal-

functions. Contact authorized Tohatsu

dealer for more details.

4. TOCS (Tohatsu Onboard

Communication System)

installation

ENOF02441-0

PRE-OPERATING PREPARATIONS

ENOM00030-A

ENOW000017-0

Use of improper gasoline can damage your

engine. Engine damage resulting from the

use of improper gasoline is considered mis-

use of the engine, and damage caused

thereby will not be covered under the lim-

ited warranty.

ENOM00031-1

FUEL RATING

Use only major brand unleaded fuel

meeting the following specifications:

USA and Canada — having a posted pump

Octane Rating of 87 (R+M)/2 minimum.

Premium gasoline (92 [R+M]/2 Octane) is

also acceptable. Do not use leaded gaso-

line.

O u t s i d e U S A an d C an a da — U s e

unleaded gasoline with declared octane

rating of 91 RON or over. Use of premium

gasoline of 98 RON is also allowed.

ENOM00032-1

GASOLINES CONTAINING

ETHANOL

The fuel system components on your

TOHATSU outboard motor will withstand

up to 10% ethyl alcohol (hereinafter

referred to as the "ethanol") content in

the gasoline. If the gasoline in your area

contains ethanol, be aware of certain

adverse effects that can occur. Increas-

ing the percentage of ethanol in the fuel

can also worsen these adverse effects.

Some of these adverse effec ts are

caused by ethanol absorbing moisture in

the air, which leads to separation of the

water/ethanol from the gasoline in the

fuel tank.

Use of gasoline containing ethanol may

accelerate:

zCorrosion of metal parts

zDeterioration of rubber or plastic parts

zFuel permeation through rubber fuel

lines

zStarting and operating difficulties

If the use of gasoline containing ethanol

cannot be avoided or presence of etha-

nol is suspected in the gasoline, it is rec-

ommended to use a filter to separate

water, and frequently check the fuel sys-

tem for leaks, mechanical parts for cor-

rosion and abnormal wear.

In case any of such abnormality is found,

discontinue the use of such gasoline and

contact our dealer immediately.

If the outboard motor will only be used

infrequently, please see the remarks on

fuel deterioration in the STORAGE chap-

ter (P 82) for additional information.

ENOW00975-0

When operating an outboard motor with

gasoline containing ethanol, storing gasoline

in the fuel tank for long periods should be

avoided. Storing gasoline for long periods

creates unique problems. In cars, ethanol

blended fuels are normally consumed before

they can absorb enough moisture to cause

problems, but boats often sit idle long

enough for separation phase to take place.

In addition, internal corrosion may take

place during storage if ethanol washes away

the oil films protecting internal components.

1. Fuel handling

CAUTION

PRE-OPERATING PREPARATIONS 27

ENOW00018-1

Fuel leakage can cause fire or explosion,

potentially leading to severe injury or loss of

life. Every par t of fuel system should be

inspected periodically. Inspect for fuel leak,

hardness or any alteration of rubber, expan-

sion and/or corrosion of metals especially

after long term storage. In case any indica-

tion of fuel leakage or degradation in fuel

system is found, replace the part immedi-

ately before using the outboard motor.

ENOM00043-B

ENOW00976-0

Do not fill the fuel tank over capacity. Under

high temperature conditions, excessive gas-

oline may evaporate/leak through air vent

screw when it is loose or open. Leaking of

gasoline is a may lead to a dangerous fire

hazard.

ENOW00028-1

Consult an authorized dealer for details on

handling gasoline, if necessary.

Gasoline and its vapor are very flammable

and can be explosive.

When carrying a fuel tank containing gaso-

line:

zClose the fuel tank cap and air vent screw

of fuel tank cap, or gasoline may evapo-

rate through the air vent screw and may

lead to a fire hazard.

zDo not smoke.

When or before refueling:

zBe sure to remove the static electricity

charged in your body before refueling.

zThe static electricity may ignite the gaso-

line vapor during refueling.

zStop the engine, and do not start the

engine during refueling.

zDo not smoke.

zBe careful not to overfill fuel tank. Wipe

up any spilled gasoline immediately.

When or before cleaning the gasoline tank:

zDismount fuel tank from the boat.

zPlace the fuel tank away from every

source of ignition, such as sparks or open

flames.

zDo the work outdoors or in a well venti-

lated area.

zWipe up gasoline well immediately if

spilled.

After cleaning gasoline tank:

zWipe up gasoline well immediately if

spilled.

zIf the fuel tank is disassembled for clean-

ing, r eassemble carefully. Incorrect

assembly may cause a fuel leak, possibly

leading to fire or explosion.

zDispose aged or contaminated gasoline in

accordance with local regulations.

ENOW00029-1

When opening fuel tank cap, be sure to fol-

low the procedure described below. Fuel

could blast out if the fuel tank cap is opened

by using another procedure when internal

pressure of fuel tank is raised by heat from

sources such as sun light.

ENOW00946-0

Separate tank must be fixed at appropriate

position so that well ventilated and tank

does not move or fall down while operating.

WARNING

2. Fuel filling

WARNING

CAUTION

PRE-OPERATING PREPARATIONS28

1. Fully open the air vent screw on the

fuel tank cap and release internal

pressure.

1. Air vent screw

2. Fuel tank cap

2. Open the fuel tank cap slowly.

3. Fill the fuel carefully not to over flow.

4. After filling the tank, close the fuel

tank cap.

ENOM00037-A

ENOW00022-2

The engine oil is drained for shipping at the

factory. Be sure to fill the engine oil to the

proper level before starting the engine.

ENOW00092- 1

zDo not overfill engine oil, or engine oil

could leak and/or engine could be dam-

aged. If engine oil level is over upper limit

marks of dip stick, drain oil to level lower

than upper limit.

zBe sure that outboard motor is upright

when checking or changing oil.

zStop the engine immediately if low oil

pressure warning lamp or oil leak is found,

or engine could be severely damaged.

Consult your dealer.

zWipe off engine oil well immediately if

spilled and dispose of it in accordance

with local fire prevention and environ-

ment protection regulations.

ENOM01812-B

1. Place the outboard motor in a vertical

position.

2. Turn the top cowl hook levers to

unlock, lift and remove the top cowl.

1. Cowl hook lever

3. Engine oil filling

CAUTION

ENOF00027-B

SAFE FILL

LEVEL

25 L

NIVEAU

MAXIMUM

ENOF00030-A

CAUTION

ENOF02435-0

ENOF02436-0

PRE-OPERATING PREPARATIONS 29

3. Remove the oil filler cap.

4. Fill the engine through the filler port

with the oil to between the upper and

lower limit mark on the dipstick.

5. Tighten the oil filler cap.

1. Filler cap

2. Dipstick

3. Filler port

1. Upper limit 4200 mL (4.4/3.7 US/Imp qt.)

2. Lower limit 2200 mL (2.3/1.9 US/Imp. qt.)

6. Start the engine and idling for 5 min-

utes, then check for no oil leaks and

no warning indicate.

7. Stop the engine and leave it for 5

minutes and check oil level on the

dipstick. Add oil if necessary.

8. Make sure that the top cowl is cor-

rectly seated on the bottom cowl seal

rubber.

9. Turn the top cowl hook levers to

securely lock.

1. Cowl hook lever

Engine oil recommendation

Use only high quality 4-stroke outboard

motor oil to insure performance and pro-

longed engine life.

SAE: 10W-30 or 10W-40

API: SH, SJ or SL

Engine oil viscosity must be selected

from the following chart according to the

average temperatures in your area.

ENOW0002A-A

Use of engine oils that do not meet these

requirements will result in reduced engine

life, and other engine problems.

ENOF02407-0

ENOF02432-0

Engine oil volume

Approximately 4,000 mL (4.2/3.5 US/Imp.qt.)

CAUTION

ENOF02439-0

ENOF02440-0

10W−40

10W−30

˚C

˚F

-10

-20

-4

-30

-22

ENOF00208-0

PRE-OPERATING PREPARATIONS30

ENOM00033-A

Your new outboard motor and lower unit

require break-in for the moving compo-

nents accor di ng to t he condi ti o ns

described in the following time table.

Please refer to ENGINE OPERATION sec-

tion (See page 37) to learn how to cor-

rectly start and operate the outboard

motor.

ENOW00024-1

Do not operate the outboard m otor in

closed area or area with not enough ventila-

tion.

Exhaust gas emitted by the outboard motor

contains carbon monoxide that may cause

dizziness, nausea, other health problem or

even death if inhaled continuously.

During operation of the outboard motor:

zKeep peripheral area well ventilated.

zAlways stay on the windward side of emis-

sion.

ENOW00023-1

Operating the outboard motor without

break-in can shorten life.

If any abnormality is experienced during the

break-in:

zDiscontinue the operation immediately.

zHave the dealer check the product and

take proper action(s) if necessary.

ENON00008-2

Note

zDuring Break-in, run the outboard

motor at varied RPM less than specified

engine speed. Not following the proce-

dure may result in problems and may

shorten the product life.

zBreak-in must be conducted under

load in the water in-gear with propeller

installed.

4. Break-In

DANGER

CAUTION

1–10 min 10 min – 2 hrs 2–3 hrs 3–10 hrs After 10 hrs

Throttle Position Idle Less than 1/2

throttle

Less than 3/4

throttle 3/4 throttle Full throttle

available

Speed Approx. 3000

min -1

(rpm) max

Full throttle run

allowed for 1

min every 10

min

Approx. 4000

min-1 (rpm). Full

throttle run

allowed for 2

min every 10

min

PRE-OPERATING PREPARATIONS32

ENOM01822-0

Warning indicators, faults and remedy

For RC model

*1: In this case, oil pressure switch is “ON”.

*2: It is necessary to stop the engine, if you want to stop the working indicators and re-set the warning system.

*3: Engine speed controlled to 1800 min-1(rpm).

*4: Flashing pattern, 1 sec ON and 9 secs OFF.

High speed ESG (Electronic Safety Governor)

High speed ESG is a device to prevent over revolution of the engine. If the load to the engine becomes light for

some reason, it runs at a higher speed than the usual. In such the case, the buzzer sounds and the ESG is

activated to restrict amount of fuel injection. Therefore, the engine speed varies and be controlled under 6000

min-1 (rpm).

Low speed ESG

Low speed ESG is a device to prevent the engine from getting damage. If the engine has problems regarding

cooling water, oil pressure, and sensors, the low speed ESG is activated to restrict amount of fuel injection.

Therefore, the engine speed varies and be controlled under 1800 min

-1 (rpm) or 2800 min-1 (rpm).

Warning indicators

ESG Description of faults

or notice

Rem-

edy

Sound

A lamp

Continuous ON - Normal system test

when key on

Continuous - High speed ESG Engine speed exceeds

maximum

allowable RPM

Continuous (*2) ON

(*2) Low speed ESG (*2) Low oil pressure (*1) 2

Continuous - Low speed ESG Engine temperature is high 3

Continuous Flashing Low speed ESG (*3) Engine temperature is abnormally high 3

- Flashing Low speed ESG Engine temperature sensor or MAP

sensor mulfanction,

or battery overcharge.

- Flashing -

Mulfanction of sensors or electrical

parts other than

the above sensors.

- Flashing (*4) - Oil change reminder (every 100 hrs.) 5

One beep - - Lowest RPM of variable idling system

Two beep - - Highest RPM of variable idling system

PRE-OPERATING PREPARATIONS 33

ENOM00126-0

Remedy

Reduce the speed to less than half

open throttle, and move to safe place

quickly, and stop the engine.

Check the propeller for bent or dam-

age on blades.

Consult an authorized dealer if engine

shows the same result even after

replacing propeller with a new one.

Move to safe place quickly, and stop

the engine until it cools down.

Check the engine oil level, and add

engine oil if necessary.

Consult your dealer if the engine oil

level is too low or too high.

Move to safe place quickly, and check

if cooling water is discharged from

the water check port at idle speed

and stop the engine.

Remove any foreign matter on the

gear case and propeller if necessary.

Consult an authorized dealer if no

discharge of cooling water.

Consult an authorized dealer.

Replace the engine oil (See page 69)

and reset the indicator (See page 35).

PRE-OPERATING PREPARATIONS34

ENOM00041-A

Warning indicators, faults and remedy

*1: In this case, oil pressure switch is “ON”.

*2: It is necessary to stop the engine, if you want to stop the working indicators and re-set the warning system.

*3: Engine speed controlled to 1800 min-1(rpm).

*4: Flashing pattern, 1 sec ON and 9 secs OFF.

High speed ESG (Electronic Safety Governor)

High speed ESG is a device to prevent over revolution of the engine. If the load to the engine becomes light for

some reason, it runs at a higher speed than the usual. In such the case, the buzzer sounds and the ESG is

activated to restrict amount of fuel injection. Therefore, the engine speed varies and be controlled under 6000

min-1 (rpm).

Low speed ESG

Low speed ESG is a device to prevent the engine from getting damage. If the engine has problems regarding

cooling water, oil pressure, and sensors, the low speed ESG is activated to restrict amount of fuel injection.

Therefore, the engine speed varies and be controlled under 1800 min

-1 (rpm) or 2800 min-1 (rpm).

Warning indicators

ESG Description of faults

or notice

Rem-

edy

Sound

A lamp B lamp C lamp

Continuous ON ON ON - Normal system test

when key on

Continuous ---High speed

ESG

Engine speed exceeds

maximum

allowable RPM

Continuous (*2) ON

(*2) - - Low speed

ESG (*2) Low oil pressure (*1) 2

Continuous -Flashing -Low speed

ESG Engine temperature is high 3

Continuous Flashing Flashing Flashing Low speed

ESG (*3)

Engine temperature is

abnormally high 3

-- - Flashing - Low battery voltage 4

- Flashing Flashing Flashing Low speed

ESG

Engine temperature sensor

or MAP sensor mulfanction,

or battery overcharge.

- Flashing Flashing Flashing -Mulfanction of sensors or

electrical parts other than

the above sensors.

- Flashing (*4) - - - Oil change reminder (every

100 hrs.) 5

One beep - - - - Lowest RPM of variable

idling system

Two beep - - - - Highest RPM of variable

idling system

PRE-OPERATING PREPARATIONS 35

ENOM00126-0

Remedy

Reduce the speed to less than half

open throttle, and move to safe place

quickly, and stop the engine.

Check the propeller for bent or dam-

age on blades.

Consult an authorized dealer if engine

shows the same result even after

replacing propeller with a new one.

Move to safe place quickly, and stop

the engine until it cools down.

Check the engine oil level, and add

engine oil if necessary.

Consult your dealer if the engine oil

level is too low or too high.

Move to safe place quickly, and check

if cooling water is discharged from

the water check port at idle speed

and stop the engine.

Remove any foreign matter on the

gear case and propeller if necessary.

Consult an authorized dealer if no

discharge of cooling water.

Consult an authorized dealer.

Replace the engine oil (See page 69)

and reset the indicator (See page 35).

ENOM00870-0

Engine oil replacement indicator

function reset method

As for "Engine oil replacement indicator

function", informing the appropriate

timing of engine oil re placement by

blinking of the lamp, when beyond 100

hours operating.

1. Be certain the safety lanyard is

installed. Turn the key to the 'on'

position and after the 'beep' pull the

safety lanyard off.

2. Within 5-10 seconds, pull the red

knob on the safety switch out and

release.

3. Wait 5-10 seconds and pull the red

knob out and release.

1 Second

ENOF00853-0

ENOF00854-0

PRE-OPERATING PREPARATIONS36

4. Within 5-10 seconds you will here 3

beeps to inform you that you have

successfully reset the system.

5. Turn the ley to the 'off' position and

replace the safety lanyard lock.

The engine oil replacement indicators

function operates again after 100 hours

operation from reset this function.

ENOF00856-0

ENGINE OPERATION

ENOM00042-0

ENOM00246-0

Oil Level checking

Check the engine oil level before each

use. If the oil level is low or too high, the

life of the engine will be shortened sig-

nificantly. (To properly check the engine

oil level, follow the instructions, see

page 64)

1. Oil filler cap

2. Dipstick

3. Filler port

1. Upper limit 4200 mL (4.4/3.7 US/Imp qt.)

2. Lower limit 2200 mL (2.3/1.9 US/Imp. qt.)

ENOM01804-0

ENOW00029-A

When opening fuel tank cap, be sure to fol-

low the procedure described below. Fuel

could blast out through the fuel tank cap in

case the cap is loosened by using another

procedure when internal pressure of fuel

tank is raised by heat from sources such as

sun light.

ENOW00947-0

When using a separate tank, be sure that the

fu el lin e is not kinked and is connected

securely.

1. Fully open the air vent screw on the

fuel tank cap.

1. Air vent screw

2. Fuel tank cap

2. Open the fuel tank cap slowly and

release internal pressure completely.

After that, close the fuel tank.

3. Remove the cap from the fuel joint.

Connect the fuel hose of the primer

bulb and secure with a hose band.

Before starting

ENOF02407-0

ENOF02432-0

1. Fuel feeding

WARNING

CAUTION

ENOF00027-B

ENGINE OPERATION40

4. Set the throttle grip to START posi-

tion.

1. Throttle grip

5. Turn the main switch key to ON posi-

tion and confirm three warning lamps

light up with beep sound and then

lights out.

6. Turn the main switch key to the START

position and release it to start the

engine. The engine will crank continu-

ously until the engine starts.

ENON00942-0

Note

zIt takes maximum 4 seconds of the

continuous crank before the engine

starts.

zIf fail to start the engine, crank again

after 10 seconds or more.

1. Main switch key

2. Warning lamp

7. Make sure that water is being dis-

charged from the cooling water check

port.

ENOM01807-0

Side mount RC type

1. Be sure to install the stop switch lock

to the stop switch, and attach the

stop switch lanyard securely to the

operator or to the operator's PFD

(Personal Flotation Device.)

ENOF00866-2

ENOF00867-3A

ENOF02408-0

ENGINE OPERATION 41

1. Stop switch lock

2. Insert the main switch key.

3. Set the control lever in the Neutral

position. Do not raise the free throt-

tle lever when starting the engine.

1. Neutral (N)

2. Control lever

3. Fully opened (Forward)

4. Fully opened (Reverse)

5. Free throttle lever

6. Main switch key

7. Stop switch

4. Turn the main switch key to ON posi-

tion and confirm three warning lamps

light up with beep sound and then

lights out.

1. Warning lamp

5. Turn the main switch key to the START

position and release it to start the

engine. The engine will crank continu-

ously until the engine starts.

ENON00942-0

Note

zIt takes maximum 4 seconds of the

continuous crank before the engine

starts.

zIf fail to start the engine, crank again

after 10 seconds or more.

1. ON

2. START

3. OFF

ENON00035-1

Note

The free throttle lever cannot be raised

when the control lever is in Forward or

Reverse.

6. Check the cooling water from cooling

water check port.

ENOF00869-1

ENOF00870-1

ENOF00851-A

ENOF00871-1

ENGINE OPERATION42

ENOM00974-B

Top mount RC type

1. Be sure to install the stop switch lock

to the stop switch, and attach the

stop switch lanyard securely to the

operator or to the operator's PFD

(Personal Flotation Device.)

1. Stop switch lock

2. Insert the main switch key.

3. Set the control lever in the Neutral

position. Do not use the Neutral

throttle button to open the throttle

when starting the engine.

1. Forward (F)

2. Neutral (N)

3. Reverse (R)

4. Fully opened (Forward)

5. Fully opened (Reverse)

6. Neutral throttle button

7. Control lever

8. Neutral lock arm

4. Turn the main switch key to ON posi-

tion and confirm three warning lamps

light up with buzzer sound and then

go off.

1. Warning lamp

5. Turn the main switch key to the START

position and release it to start the

engine. The engine will crank continu-

ously until the engine starts.

ENOF02408-0

ENOF00936-1

ENOF02409-0

ENOF00937-0

ENOF00851-A

ENGINE OPERATION 43

ENON00942-0

Note

zIt takes maximum 4 seconds of the

continuous crank before the engine

starts.

zIf fail to start the engine, crank again

after 10 seconds or more.

1. ON

2. START

3. OFF

ENON00939-0

Note

The neutral throttle button can not be

push-in when the control lever shift is in

Forward or Reverse.

6. Check the cooling water from cooling

water check port.

ENOM00043-A

ENOW00932-1

Be sure to check that cooling water is dis-

charged from the cooling water check port

during warm up.

Warm the engine at low engine speeds

for about

3 minutes : above 5°C (41°F)

5 minutes at 2000 min-1 (rpm) : blow 5°C

(41°F)

This allows the lubricating oil to circulate

to all parts of the engine. Operating the

engine without warm up shortens the

engine's life.

ENOM01826-0

Engine speeds

Idling speed after warming up.

Remark: The idling speed automatically

increases depending on the engine tem-

perature. When the engine reaches nor-

mal operating temperature, it will return

to the specified idling speed.

ENOF00938-1

ENOF02410-0

3. Warming up the engine

CAUTION

Clutch in (In gear) Clutch off (Out of gear)

700 min-1 (rpm) 700 min-1 (rpm)

ENOF02408-0

ENGINE OPERATION44

ENOM00972-0

Free throttle lever (Side mount RC

type)

ENOW00956-0

zKeep the free throttle lever fully closed-

position when start the engine.

zThe free throttle lever is inoperative

unless the



control lever is in neutral.

zAlso, the control lever is inoperative

unless the free throttle lever is returned

to the fully-closed position.

The free throttle lever is for warm-up

operation. (Not required for engine start-

ing) With the control lever in neutral,

move the free throttle lever upward to

open the throttle.

1. Fully-open

2. Fully-closed

ENOM00973-0

Neutral throttle button (Top

mount RC type)

ENOW00957-0

The control lever does not operate unless

the neutral lock arm is pulled.

The neutral throttle button is for warm-

up operation. (Not required for engine

starting) When the control lever is in

neutral, push and hold the neutral throt-

tle button. While holding the button,

move the lever forward to throttle up the

engine.

When the control lever is returned to the

neutral position, the button will reset

automatically.

1. Neutral throttle button

2. Forward

ENOM00880-A

Trolling speed control

(except for normal tiller handle

type)

If the main switch key is pressed for 1

(one) second during idling or trolling

operation, engine speed changes.

each time the main switch key is pressed.

Engine speed changes as follows.

Starting

700 min

-1

(rpm)

ЍЍ

650 min

-1

(rpm)

ЍЍ

700 min

-1

(rpm)

Ќࠉ

ࠉ

ࠉࠉ Ў

750 min

-1

(rpm) 750 min

-1

(rpm)

Ќࠉ

ࠉ

ࠉࠉ Ў

800 min

-1

(rpm)



ЋЋ



850 min

-1

(rpm)

ЋЋ



800 min

-1

(rpm)

CAUTION

ENOF00934-0

ENOF00935-0

1second

ENOF00876-0

ENGINE OPERATION46

ENOW00863-0

Idle speed may be higher during warming up

of engine. If shifted to Forward or Reverse

during warming up, it may be difficult to shift

back to neutral. In such case, stop engine,

shift to neutral, and restart engine to warm

up.

ENON00014-0

Note

Frequent shifting to forward or reverse can

accelerate wear or degradation of parts. In

such case, replace gear oil earlier than the

period specified.

ENOW00864-0

Do not increase engine speed unnecessarily

when the shift is in neutral and reverse, or

engine damage may occur.

ENOM00890-B

Tiller handle type

ENOW00865-0

Do not force to shift when the throttle grip is

not in the fully closed position, otherwise,

steering system and/or shifting mechanism

may be damaged. The control lever is inop-

erative unless the throttle grip is in the fully

closed position. (Multi-function tiller type)

1. Shift lever

Forward

1. Turn the throttle grip to reduce

engine speed.

2. When the engine reaches trolling (or

idling) speed, quickly pull the shift

lever to the Forward position.

Reverse

1. Turn the throttle grip to reduce

engine speed.

2. When the engine reaches trolling (or

idling) speed, quickly pull the shift

lever to the Reverse position.

Acceleration

After shifting, twist the throttle grip grad-

ually to accelerate.

1. Throttle grip

CAUTION

ENOF00865-2

ENOF00878-2

ENGINE OPERATION 47

ENOM00900-0

Side mount RC type

1. Forward (F)

2. Neutral (N)

3. Reverse (R)

4. Fully opened (Forward)

5. Fully opened (Reverse)

6. Free throttle lever

7. Control lever

8. Neutral lock arm

Forward

1. Quickly push the control lever to the

Forward (F) position 32°, where the

gear is connected, while lifting up on

the neutral lock arm located under

the control lever grip.

2. Further forward motion will open the

throttle.

Reverse

1. Quickly pull the control lever to the

Reverse (R) position at 32°, where the

gear will be connected, while lifting up

on the neutral lock arm located under

the control lever grip.

2. Further rearward motion will open

the throttle.

Acceleration

After shifting, advance the control lever

gradually to accelerate.

1. Control lever

ENOM00975-A

Top mount RC type

1. Forward (F)

2. Neutral (N)

3. Reverse (R)

4. Fully opened (Forward)

5. Fully opened (Reverse)

6. Neutral throttle button

7. Control lever

8. Neutral lock arm

Forward

1. Quickly push the control lever to the

Forward (F) position 35°, where the

gear is connected, while lifting up on

the neutral lock arm located under

the control lever grip.

2. Further forward motion will open the

throttle.

ENOF00877-1

ENOF00879-2

ENOF00937-0

ENGINE OPERATION48

Reverse

1. Quickly pull the control lever to the

Reverse (R) position at 35°, where the

gear is connected, while lifting up on

the neutral lock arm located under

the control lever grip.

2. Further rearward motion will open

the throttle.

Acceleration

After shifting, advance the control lever

gradually to accelerate.

ENOM00049-A

ENOW00868-1

Be careful not to remove engine stop switch

lanyard from engine accidentally while boat

is running. Sudden stop of engine can cause

loss of steering control, speed, possibly

leading the crew(s) and or objects on the

boat to be thrown forward due to inertial

force.

Tiller handle type

1. Turn the throttle grip to the slow

position.

2. Put the shift lever in the Neutral posi-

tion.

Run the engine for 2-3 minutes at

idling speed for cooling down if it has

been running at full speed.

1. Throttle grip

2. Shift lever

3. Main switch key

3. Turn the main switch key to the OFF

position.

Side mount RC type

1. Put the control lever in the Neutral

position and run the engine for 2-3

minutes at idling speed for cooling

down if it has been running at full

speed.

1. Control lever

2. Main switch key

5. Stopping the engine

WARNING

ENOF00866-2

ENOF00880-C

ENOF00881-1

ENGINE OPERATION 49

2. Turn the main switch key to the OFF

position.

1. ON

2. START

3. OFF

ENOW00869-1

After stopping the engine:

zClose the air vent screw on the fuel tank

cap.

zDisconnect the fuel connector from the

engine and the fuel tank.

zDisconnect the battery cable, after each

use.

ENOM00975-0

Top mount RC type

1. Put the control lever in the Neutral

position and run the engine for 2-3

minutes at idling speed for cooling

down if it has been running at full

speed.

1. Control lever

2. Turn the main switch key to the OFF

position.

2. Main switch key

3. ON

4. START

5. OFF

ENOW00869-1

After stopping the engine:

zClose the air vent screw on the fuel tank

cap.

zDisconnect the fuel connector from the

engine and the fuel tank.

zDisconnect the battery cable, after each

use.

Emergency engine stopping

Press the emergency stop switch or

remove stop switch lock to stop the

engine.

WARNING

ENOF00871-1

ENOF00939-0

WARNING

ENOF00938-A1

ENOF02411-0

ENGINE OPERATION50

1. Stop switch

2. Stop switch lock

1. Stop switch

2. Stop switch lock

1. Stop switch

2. Stop switch lock

ENOM00910-1

Spare emergency stop switch lock

(For CE marking model)

A spare emergency stop switch lock is

provided in the accessories bag.

Make sure that spare stop switch lock is

available before operating outboard

motor.

When used as described, the emergency

stop switch clip and emergency stop

switch lanyard system stops the engine if

the operator is thrown overboard. When

an operator falls into water, be sure to

use spare emergency stop switch lock.

ENOF00883-2

ENOF00869-A

ENOF00938-B1

ENOF02412-0

ENOF00891-0

ENGINE OPERATION 51

ENOM00920-0

ENOW00870-1

Sudden steering may cause passenger(s) to

be thrown overboard or fall.

Tiller handle type

Right turn

Move the tiller handle to the left

Left turn

Move the tiller handle to the right.

Remote control type

Right turn

Turn the steering wheel to the right.

Left turn

Turn the steering wheel to the left.

ENOM01815-0

ENOW00043-1

zAdjust the trim angle when the engine is

stopped.

zDo not put hand or finger in between out-

board motor body and clamp bracket

when adjusting trim angle to prevent pos-

sible injury.

zUnsuitable trim position can cause loss of

control of boat. When testing a trim posi-

tion, run the boat slowly initially to see if

it can be controlled safely.

ENOW00044-1

Excessive trim up or down may cause unsta-

ble boat operation, loss of control that may

leads to accident during cruising.

zFor manual tilt model, If you feel the trim

is improperly positioned, stop the boat

and readjust trim angle before continuing

to cruise.

zFor outboard motor model with PT or PTT

switch on the bottom cowl, do not oper-

ate the switch during while cruising, or

control of boat may be lost.

The trim angle of the outboard motor can

be adjusted to suit the transom angle of

the hull, and load conditions. Choose an

appropriate trim angle that will allow the

anti-ventilation plate to run parallel to

the water surface during operation.

ENOM01817-0

Power Trim & Tilt type

The provided power trim & tilt can be

adjusted to set the desired trim angle of

the outboard motor according to the

transom shape, planing speeds and load.

6. Steering

WARNING

ENOF00892-0

ENOF00893-0

7. Trim angle

WARNING

ENGINE OPERATION52

It is imperative that the trim angle is

adjusted correctly. Incorrect adjustment

will cause the boat to sway, deteriorate

engine performance and may cause

unsafe steering conditions.

ENOW00970-0

The power trim & tilt can be set to any trim

angle. However, do not use the tilt angle

range when cruising except shallow water

operation.It may ingest air into the water

cooling system, resulting in engine overheat-

ing.

1. Max.tilt angle : 63° from the vertical

2. Trim angle : -4 to 10°

3. Boat transom angle : -12°

ENOM01808-0

Proper trim angle

The trim angle is optimum when the boat

is parallel to the water surface while run-

ning.

1. Perpendicular to the water surface

ENOM01809-0

Improper trim angle (bow rises too

high)

When the trim angle is excessive, the bow

will rise out of the water and the speed

will be decrease. Furthermore, the bow

may sway or the bottom may slam the

water while running.

Decrease the trim angle by pressing

"DN"(Down) of power trim & tilt switch.

CAUTION

0°

ENOF02446-0

ENOF00051-1

ENOF00052-0

ENOF02437-0

DN UP

ENOF00067-2

ENGINE OPERATION 53

ENOM01818-0

Improper trim angle (bow dips into the

water)

When the trim angle is too small, the bow

will dip into the water, the speed will

decrease, and water may enter the boat.

Increase the trim angle by pressing "UP"

of power trim & tilt switch.

ENOM01819-0

Trim meter

When the trim angle is set as desired,

take a reading off the trim meter, and

record it for future reference.

ENOM01820-0

Trust rod adjustment

The trim angle at full tilt down is adjust-

able by selected the thrust rod position.

1. Thrust rod

2. Higher

3. Lower

1. Stop the engine.

2. Shift into neutral position.

3. Tilt up the outboard motor.

4. Lock the tilt stopper.

5. Remove the Snap pin and thrust rod

as shown in the picture.

1. Snap pin

2. Thrust rod

6. Reinstall the thrust rod in the desired

position securely.

7. Put the Snap pin back and unlock the

tilt stopper.

8. Gently tilt down the outboard motor.

ENOF00941-0

ENOF00053-0

JNOF00807-1

ENOF02413-0

ENOF02414-0

ENGINE OPERATION54

ENOM00060-A

ENOW00055-1

Do not tilt the outboard motor up or down

when swimmer(s) and/or passenger(s) are

near to prevent them from being caught

between outboard motor body and clamp

bracket.

ENOW00048-1

When tilting up or down, be careful not to

place your hand between the swivel bracket

and the stern bracket.

ENOW00056-A

When tilting up outboard motor with fuel

joint for over a few minutes, be sure to dis-

connect fuel hose, or fuel may leak, poten-

tially catching fire.

ENOW00057-1

Do not tilt up the outboard motor while

engine is operating, or no cooling water may

be discharged, leading to engine seizure due

to overheating.

ENON00921-1

Note

After use, leave the outboard motor

upright for a minute to drain the water

from inside the engine.

ENOM01810-0

Power Trim & Tilt type

Tilt up

1. Press the power trim and tilt switch

"UP" until the motor has been tilted

up completely.

2. Pull the tilt stopper down as shown

below drawing.

1. Tilt stopper

3. Press the power trim and tilt switch

"DN" (Down) until the trim rods has

been retracted completely.

8. Tilt up and down

WARNING

CAUTION

ENOF02437-0

DN UP

ENOF00067-2

ENOF00941-0

ENOF013190

ENGINE OPERATION 55

1. Trim rod

Tilt down

1. Release the tilt stopper from the set-

up position while slightly tilting up

outboard motor.

2. Operate the Power Trim & Tilt switch

and tilt the outboard motor down

until the motor touches to the thrust

rod.

The outboard motor can also be tilted up

and down using the switch provided on

the bottom cowl.

It is possible to tilt up or down whether or

not the main switch is "ON" or "OFF".

ENOM00940-1

Manual relief valve

If the battery is dead, and/or the power

tilt switch is inoperative open the manual

valve completely in the Manual direction.

This allows the outboard motor to be

tilted manually.

ENOW00872-1

Make sure the manual relief valve is closed

before operating the outboard motor. If the

manual relief valve is not closed, the out-

board motor will be tilted up when shifting in

reverse.

ENOW00873-1

Before opening the manual relief valve, make

sure nobody is under the outboard motor. If

the outboard motor is in the tilted upposi-

tion with the manual relief valve loosend, the

outboard motor will be tilted down suddenly.

1. Power

2. Manual

Manual relief valve specified torque:

3 N- - -m (2.2 ft lb, 0.3 kgf m)

ENOF02416-0

ENOF02417-0

WARNING

ENOF00679-0

ENGINE OPERATION56

ENOM00068-A

ENOW00051-0

During shallow water operation, be careful

not to place your hand between the swivel

bracket and the clamp bracket. Be sure to

tilt the outboard motor down slowly.

ENOW00053-0

While in shallow water drive position, do not

operate the outboard motor in Reverse.

Operate the outboard motor at slow speed

and keep the cooling water intake sub-

merged.

ENOW00054-1A

Do not over tilt the outboard motor when

driving in shallow water, or air may be sucked

through water inlet, potentially leading to

engine overheating.

1. Water inlet

ENOM00069-A

Power Trim & Tilt type

1. Operate the Power Trim & Tilt switch

and tilt the outboard motor up into

desired shallow water running posi-

tion.

9. Shallow water operation

WARNING

CAUTION

ENOF01144-A

ENOF02437-0

DN UP

ENOF00067-2

ENOF00941-0

REMOVING AND CARRYING THE OUTBOARD MOTOR

ENOM00070-A

ENOW00006-1B

To avoid personal injury or damage of equip-

ment , make sure the allowable lifting capac-

ity of the hoist is at least twice the weight of

the outboard motor.

Do not allow the lift hook or chain from the

hoist to come in contact with any part of the

outbord motor during lifting.

ENOW00064-1

Engine may be hot immediately after opera-

tion and could cause burns if came in con-

tact. Allow engine to cool down before

attempting to carry the outboard.

1. Stop the engine.

2. Remove the top cowl.

3. Disconnect the fuel connector, the

remote control cables and the bat-

tery cords from the outboard motor.

4. Attach the hoist hooks to the engine

hanger.

5. Remove the outboard motor from

boat and completely drain the water

from the gear case.

ENOM00071-A

ENOW00933-0

Be sure to disconnect fuel connector except

when operating engine.

Fuel leakage is a fire or explosion hazard,

which can cause serious injury or death.

ENOW00065-1

Close air vent screw on fuel tank before car-

rying or storing outboard motor and fuel

tank, or fuel may leak, potentially catching

fire.

ENOW00968-1

Do not give a shock to an outboard motor

during transportation.

1. Removing the outboard

motor

WARNING

CAUTION

2. Carrying the outboard motor

WARNING

CAUTION

ENOF02419-1

REMOVING AND CARRYING THE OUTBOARD MOTOR58

Keep the outboard motor in a vertical

position when carrying.

The optional outboard motor stand is

recommended for keeping the outboard

motor vertical both during transport and

storage.

ENOM00072-1A

ENOW00072-0

Trailering in the tilted position may cause

damage to the outboard motor, boat, etc.

ENOW00971-0

On applicable models remove the fuel con-

nector and fuel line except when operating

engine.

Fuel leakage is a fire or explosion hazard,

which can cause serious injury or death.

ENOW00068-0

Close air vent screw of fuel tank and fuel

cock before carrying or storing outboard

motor and fuel tank, or fuel may leak, poten-

tially catching fire.

ENOW00071- 0

The tilt support device supplied on your out-

board motor is not intended for towing. It is

intended to suppor t the outboard motor

while the boat is docked, beached, etc.

When transporting a boat on a trailer

with the outboard motor still attached,

disconnect the fuel line from the

outboard motor beforehand and keep

the outboard motor in the normal

running position or on a transom saver

bar.

Tiller handle type

While transporting outboard motor

attached to the boat on a trailer, properly

tighten the steering friction bolt to pre-

vent the outboard motor from moving

(page 60).

3. Trailering

CAUTION

WARNING

ENOF02421-0

WARNING

CAUTION

ENOF00075-1

REMOVING AND CARRYING THE OUTBOARD MOTOR 59

1. Ground clearance should be provided

sufficiently.

2. Transom saver bar

ENOW00067-0

Do not go under outboard motor tilted up

even if it is supported by suppor t bar, or

accidental fall of outboard motor could lead

to severe personal injury.

WARNING

ENOF00074-A

ADJUSTMENT 61

Side mount type

1. Throttle friction adjustment screw

2. Decrease

3. Increase

Top mount type

1. Throttle friction adjustment screw

2. Lighter

3. Heavier

ENOM00076-0

ENOW00076-1

zBe sure that the outboard motor is

secured to transom or service stand, or

accidental drop or fall of outboard motor

could lead to severe personal injury.

zBe sure to lock the outboard motor in the

tilt up position, or accidental fall of out-

board motor could lead to severe per-

sonal injury.

zDo not go under outboard motor in the tilt

up position and locked, or accidental fall

of outboard motor could lead to severe

personal injury.

ENOW00075-1

Inappropriate adjustment of trim tab could

cause steering difficulty. After installing or

readjusting trim tab, check if steering load is

even.

If straigh t- line cr uising cannot be

achieved, adjust the trim tab located

under the anti-ventilation plate.

zIf the boat veers toward the left, direct

the trim tab towards A (left from rear

of boat).

zIf the boat veers toward the right,

direct the trim tab towards B (right

from rear of boat).

1. Trim tab

ENON00022-A

Notes

zAfter adjustment securely tighten the

trim tab fixing bolt.

zCheck for looseness of the bolt and the

trim tab at regular intervals.

4. Trim tab adjustment

WARNING

ENOF00078-2

ENOF00942-0

WARNING

ENOF02449-0

INSPECTION AND MAINTENANCE

ENOM00077-1

Care of your outboard motor

To keep your outboard motor in the best

operating condition, it is very important

that you perform daily and periodic

maintenance as suggested in the mainte-

nance schedules as follows.

ENOW00077-1

zYour personal safety and that of your pas-

sengers depends on how well you main-

tain your outboard motor. Carefully read

all of the inspection and maintenance

procedures described in this section.

zThe maintenance intervals shown in the

checklist apply to an outboard motor in

nor mal use. If you use your outboar d

motor under severe conditions such as

frequent full-throttle operation, frequent

operation in brackish water, or for com-

mercial use, maintenance should be per-

formed at shorter intervals. If in doubt,

consult your dealer for advice.

zWe strongly recommend that you use only

genuine replacement parts on your out-

board motor. Damage to your outboard

motor arising from the use of other than

genuine parts is not covered under the

warranty.

CAUTION

INSPECTION AND MAINTENANCE 63

ENOM00079-0

Perform the following checks before and

after use.

ENOW00078-1

Do not use outboard motor if any abnormal-

ity is found during pre-operation check oth-

erwise it could result in severe damage to

the motor or severe personal injury.

1. Daily Inspection

WARNING

Item Points to Check Remedy

Fuel System

• Check the amount of fuel in the tank. Replenish

• Check for debris or water in the fuel filters. Clean or replace if

necessary

• Check the rubber hoses for fuel leakage. Replace if necessary

Fuel Tank Cap • Check for crack, leakage, damage in the fuel tank cap. Replace if necessary

• Check for leakage at full close. Replace if necessary

Engine Oil • Check the oil level. Fill oil

Electrical

Equipment

• Check that the main switch functions normally. Replace if necessary

• Check that the battery electrolyte level and specific gravity

are normal. Replenish or recharge

• Check for loose connections on the battery terminal. Retighten

• Check that the stop switch functions normally and make sure

the stop switch lock is secured.

Remedy or replace if

necessary

• Check cords for loose connections and damage. Correct or replace if

necessary

• Check the spark plugs for dirt, wear and carbon build-up. Clean or replace if

necessary

• Check the warning buzzer (one beep) and warning LED lamp

(ON for 1 secs.) when key is ON. Repair

Clutch and

Propeller Sys-

tem

• Check that clutch engages correctly when operating the shift

lever. Adjust

• Visually check propeller for bent or damaged blades. Replace if necessary

• Check the propeller nut is tightened and the split pin is in

correct position. Tighten or replace

Installation of

Motor

• Check all the bolts attaching the motor to the boat. Tighten

• Check the thrust rod installation. Replace if necessary

Power Trim &

Tilt • Check working of the tilt up and down of the motor. Repair

Cooling Water • After starting the outboard motor, make sure that water is

being discharged from the cooling water check port. Repair

Tools and

Spares

• Check that there are tools and spare parts for replacing spark

plugs, the propeller, etc.

• Check that you have the spare stop switch lock.

Order

Steering

Devices • Check the operation of the steering handle. Repair

INSPECTION AND MAINTENANCE64

ENOM01823-0

Oil level checking

If the oil level is low, or too high, the life

of the engine will be shortened signifi-

cantly.

1. Stop the engine and place the out-

board motor in a vertical position.

2. Turn the top cowl hook levers to

unlock, lift and remove the top cowl.

3. After the engine has been shut off 5

minutes, remove the dipstick and

wipe oil off with a clean cloth.

4. Insert the dipstick to the hole com-

pletely.

5. Remove the dipstick. Oil level must be

between the upper limit and lower

limit shown on the dipstick.

6. If the oil level is below the lower limit,

add the oil to between the upper and

lower limit mark on the dipstick.

1. Filler cap

2. Dipstick

3. Filler port

1. Upper limit 4200 mL (4.4/3.7 US/Imp qt.)

2. Lower limit 2200 mL (2.3/1.9 US/Imp. qt.)

ENON00024-0

Note

The oil level should be checked when the

engine is cooled.

ENON00025-0

Note

Consult with an authorized dealer if the

engine oil is milky color, or appears con-

taminated.

ENOM00082-A

Engine oil replenishing

ENOW00972-0

zDo not add or mix different brands of

engine oil or grade with existing oil. In

case engine oil of other brand or grade is

added, drain all oil and ask dealer for

treatment.

zIn case other than engine oil such as gaso-

line is put in the oil chamber, empty the

chamber and ask dealer for treatment.

zWhen replenishing engine oil, be careful

not to allow entry of foreign matters such

as dust and water into oil chamber.

Other parts

• Make sure that steering handle and remote control is

functioning normally. Repair if necessary

• Check the anode for corrosion and deformation. Replace

Item Points to Check Remedy

ENOF02407-0

CAUTION

ENOF02432-0

INSPECTION AND MAINTENANCE 65

zWipe off engine oil well immediately if

spilled and dispose of it in accordance

with local fire prevention and environ-

ment protection regulations.

zDo not replenish engine oil over upper

limit. If overfilled, remove oil to upper

limit. If engine oil is over the upper limit, it

can leak potentially leading to engine

damage.

If the oil level is low, or at lowest mark,

add recommended oil to the middle dip-

stick mark.

ENOM00083-1

Washing outboard motor

ENOW00920-0

When washing the outboard motor, be care-

ful not to spray the water inside of the top

cowl, especially electrical components.

ENON00026-0

Note

It is recommended to check chemical

properties of water on which your out-

board motor is regularly used.

If outboard motor is used in salt water,

brackish water or water with a high acidic

level, use fresh water to remove salt,

chemicals or mud. And flush cooling

water passage af ter every cruising or

before storing outboard motor for long

time. Before flushing, remove the propel-

ler and the forward thrust holder.

ENOM00085-E

Flushing hose joint

ENOW00921-0

Do not operate the engine when flushing the

outboard motor with a hose joint as this can

cause damage to the outboard motor.

ENOW00922-0

To prevent the engine from starting when

you are near the propeller, remove the stop

switch lock.

1. Tilt down the outboard motor.

2. Remove the flushing connector cap

from the outboard motor, and screw

in the hose joint.

3. Connect a water hose. Turn on the

water and adjust the flow.

Continue flushing the outboard motor

for 3 to 5 minutes

4. After the flushing, be sure to reattach

the flushing connector cap.

5. Tilt up the outboard motor.

CAUTION

ENOF02420-0

CAUTION

INSPECTION AND MAINTENANCE66

1. Hose joint

ENOM00085-A

Flushing by test tank

ENOW00081-1

Do not start engine without removing pro-

peller, turning propeller out in the open may

lead to personal injury.

ENOW00082-0

Never start or operate the engine indoors or

in any space which is not well ventilated.

Exhaust gas contains carbon monoxide, a

colorless and odorless gas which can be fatal

if inhaled for any length of time.

ENOW00036-1A

When starting the outboard motor in the

test tank, make sure that:

1. Water level is at least 10 cm (4 in.) above

the anti-ventilation plate to avoid over-

heating of the engine.

2. Run at idling only

3. Remove the propeller

(See page 74)

1. Test tank

2. Water

3. Over 10 cm (4 in.)

ENOM00950-1

Fuse replacement

ENOW00923-1

Before replacing a fuse, disconnect the bat-

tery cable from the battery negative (-) ter-

min al first. Failur e to pro perly remove

battery cables may cause a short-circuit.

ENOW00924-0

Never use a fuse with a rating that exceeds

the specified rating as this could cause seri-

ous damage to the electrical system.

If the fuse is blown, try to determine the

cause and respond to the problem as

simply replacing the fuse will likely be

blown again. If you are unable to respond

to the cause or the fuse continues to

blow, request an authorized Tohatsu

dealer for inspection.

WARNING

CAUTION

ENOF02425-0

CAUTION

ENOF00863-0

INSPECTION AND MAINTENANCE 67

ENOM01816-0

1. Stop the engine and disconnect the

baterry cable from the battery (-)

negative.

2. Turn the top cowl hook levers to

unlock, lift and remove the top cowl.

3. Remove the grommet from the elec-

tric bracket cover.

4. Remove the fuse cover.

5. Remove the fuse and check it. If the

fuse is blown, replace to the supplied

spare fuses in the spare fuse holder.

1. Grommet

2. 20A

3. 20A

4. 30A

5. Blown fuse

2 3 42 3 4

ENOF02426-0

INSPECTION AND MAINTENANCE68

ENOM01106-1

It is important to inspect and maintain your outboard motor regularly. Make sure to per-

form each service at interval specified in the chart below. Maintenance intervals are

determined by the number of hours outboard motor has been used or number of

months, whichever comes first.

2. Periodic Inspection

Description

Inspection intervals

Inspection procedure Remarks

First 20

hours or 1

month

Every 50

hours or 3

months

Every 100

hours or 6

months

Every 200

hours or 1

year

Every 400

hours or 2

year

Fuel System

Fuel filter z {/ Check and clean or Replace if

necessary. (See page 72)

High pressure

fuel filter Replace (Every 200 hours or 2

years)

High pressure

fuel hose z/{ z/{ Check / Replace if necessary

Fuel tank z/{ z/{ Check and clean (See

page 72)

Fuel tank cap z/{ z/{ Check/Replace if necessary.

Fuel pump {Check/Replace if necessary.

Fuel pressure {Check

Hose z/{ z/{ Check/Replace if necessary.

Ignition

System

Spark plug zCheck and clean. (See

page 76)

0.8-0.9 mm

(0.031-0.035 in)

Spark plug cap/High

tension cord { { Check/Replace if necessary.

Starting

System

Starter motor {Check

Battery/Cable

connection { { Check

Engine

Engine oil z

Replace

Replace Replace. (See page 64)

Approx 4200 mL

(4.44 US qt.)

with filter

replacement)

Oil filter {

Replace

{

Replace

Replace every 200 hrs or 1

years (See page 71)

Valve Clearance {Check and adjust

Timing belt {Check/Replace if necessary.

Compression

pressure {Check

Combustion

chamber {Clean

Thermostat {Check / Replace if necessary

*"z" This procedure can be performed by end user.

*"{" This procedure shall be carried out by the dealer.

INSPECTION AND MAINTENANCE 69

*"z" This procedure can be performed by end user.

*"{" This procedure shall be carried out by the dealer.

ENON00030-1

Note

It is highly recommended that your outboard motor to go through complete inspection at 300

hours of use.

ENOM00091-A

Engine oil replacement

ENOW00091-1

You may be injured due to high engine tem-

peratures if you fill engine oil just after oper-

ation. Engine oil should be changed after the

engine has been cooled.

ENOW00092-1

z Do not overfill engine oil, or engine oil

could leak and/or engine could be dam-

aged. If engine oil level is over upper limit

marks of dip stick, drain oil to level lower

than upper limit.

z Be sure that outboard motor is upright

when checking or changing oil.

Lower Unit

Propeller z z Check/Replace if necessary.

(Seepage 74)

Shear pin/Split

pin z z Check/Replace if necessary

Gear oil z

Replace zz

Replace

Change and replace. (See

page 73)

Approx.1000 mL

(34 fl.oz.)

Water strainer z z Check

Water pump impeller z {/ {

Replace Check/Replace if necessary.

Water pump

housing*1 {Check/Replace if necessary.

Shift/

Throttle

Throttle cable zCheck/Replace if necessary.

Throttle link { { Check and adjust.

Shift cable {Check/Replace if necessary.

Shift link { { Check and adjust.

Power trim & tilt z/{ z/{ Check & replenish

Warning system {Check

Stop switch z z Check

Meters { { Check

Bolt, Nut { { Retighten

Sliding Part/Rotation part z z Apply grease. (See page 81)

Grease nipple z z Pump in grease

Outer equipment z z Check

Anode (engine) {Check/Replace if necessary.

Anode (except for engine) z {/ Check/Replace if necessary.

Top cowl/Ratch z {/ Check and adjust.

Description

Inspection intervals

Inspection procedure Remarks

First 20

hours or 1

month

Every 50

hours or 3

months

Every 100

hours or 6

months

Every 200

hours or 1

year

Every 400

hours or 2

year

CAUTION

INSPECTION AND MAINTENANCE 71

12. Start the engine and idling for 5 minu-

ets, then check for no oil leaks and no

warning indicate.

1. Oil filler cap

2. Dipstick

3. Filler port

1. Upper limit 4200 mL (4.4/3.7 US/Imp qt.)

2. Lower limit 2200 mL (2.3/1.9 US/Imp. qt.)

ENON00920-0

Note

Use only recommended engine oil (See

page 29)

ENOW00925-0

Wipe off engine oil well immediately if spilled

and dispose of it in accordance with local

fire prevention and environment protection

regulations.

ENON00031-0

Note

z If any amount of water is found in

engine oil, making it milky white, consult

dealer.

z If engine oil is contaminated with fuel,

emitting strong fuel smell, consult

dealer.

z Some oil dilution is normal if engine is

idled or trolled for long periods, espe-

cially in cooler water temperatures.

ENOM00092-A

Oil filter replacement

ENOW00091-1

You may be injured due to high engine tem-

peratures if you fill engine oil just after oper-

ation. Engine oil should be changed after the

engine has been cooled.

ENOW00926-0

Wipe off engine oil well immediately if spilled

and dispose of it in accordance with local

fire prevention and environment protection

regulations.

1. Drain oil from the engine.

2. Place a rag or towel below the oil fil-

ter to absorb any spilled oil.

3. Unscrew old filter by turning the filter

to counter-clockwise.

Oil volume needed for complete oil replacement

With oil filter

replacement

Without oil filter

replacement

Approximately 4200 mL

(4.4/3.7 US/Imp. qt.)

Approximately 4000 mL

(4.2/3.5 US/Imp. qt.)

ENOF02407-0

ENOF02432-0

CAUTION

INSPECTION AND MAINTENANCE72

4. Clean the mounting base. Apply film

of clean oil to O-ring.

Do not use grease.

Install oil filter and tighten it to specified

torque by using oil filter wrench.

Oil filter torque:

18 N·m (13 ft · ·lb, 1.8 kgf m)

ENON00028-A

Note

If a torque-wrench is not available when

you are fitting a oil filter, a good estimate

of the correct torque is 3/4 to 1 a turn past

finger-tight. Have the oil filter adjusted to

the correct torque as soon as possible with

a torque-wrench.

1. Oil filter wrench

P/N 3AC-99090-0

P/N 3AC99090M

(US. CANADA Only)

1. Oil filter

2. Fuel filter

ENOM00093-A

Fuel filters and fuel tank cleaning

ENOW00093-1

Gasoline and its vapor is very flammable and

can be explosive.

zDo not start this procedure while engine

is operating or while engine is hot.

zPlace fuel filter away from every source of

ignition such as sparks or open flames.

zIf gasoline is spilled, wipe up immediately

and dispose according to the local regula-

tions.

zInstall fuel filter with all related parts in

place, or fuel leak could occur, leading to

catching fire or explosion.

zCheck fuel system regularly for leakage.

zContact authorized dealer for fuel system

services. Services by unqualified person

could lead to engine damage.

Fuel filters are provided inside the fuel

tank and engine.

ENOM00094-0

Fuel filter (for engine)

1. Check in the cup for water and

debris.

1. Body

2. O-ring

ENOF00094-0

2ENOF02428-0

WARNING

ENOF01243-0

INSPECTION AND MAINTENANCE 73

3. O-ring

4. Filter

5. Float

6. Cup

7. Indication of Fuel Flow.

2. If present, disconnect hoses from the

fuel connector (male) and the fuel

pump.

3. Remove the cup, filter and O-rings

from the fuel filter body.

4. Check the wear and clogging for each

parts, and replace if necessary.

5. Remove fuel and any water or debris

from the cup, filter and hoses.

6. Reassemble all parts.

ENOM00096-A

Fuel filter (for fuel tank)

Water or dirt in the fuel tank will cause

engine performance problems.

Check and clean the tank at specified

times or after the outboard motor has

been stored for a long period of time

(over three months).

1. Remove four screws to remove the

Fuel Pick-Up.

2. Clean the fuel filter and replace the

gasket.

3. Reassemble all parts.

1. Fuel pick-up

2. Filter

ENOM00098-A

Gear oil replacement

ENOW00076-1

zBe sure that the outboard motor is

secured to transom or service stand, or

accidental drop or fall of outboard motor

could lead to severe personal injury.

zBe sure to lock the outboard motor in the

tilt up position, or accidental fall of out-

board motor could lead to severe per-

sonal injury.

zDo not go under outboard motor in the tilt

up position and locked, or accidental fall

of outboard motor could lead to severe

personal injury.

1. Tilt down the outboard motor.

2. Remove the oil plugs (lower and

upper), and completely drain the gear

oil into a pan.

WARNING

ENOF00926-1

INSPECTION AND MAINTENANCE74

3. Insert the oil tube nozzle into the

lower oil plug hole, and fill with gear

oil by squeezing the oil tube until oil

flows out of the upper plug hole and

bubbles is disappeared to remove the

air.

ENON00033-1

Note

Use genuine gear oil or the ones recom-

mended (API GL-5: SAE #80 to #90).

Required volume: approx. 1000 mL.

4. Install the upper oil plug, and then

remove oil tube nozzle and install the

lower oil plug.

Oil plug specified tightening torque

4N·m (3 ft· ·lb, 0.4 kgf m)

ENOW00095-0

Do not reuse oil plug gasket. Always use new

gasket and tighten oil plug properly to pre-

vent entry of water into lower unit.

ENOW00928-1

If gear oil is spilled, wipe off immediately and

dispose according to the local regulations.

ENON00032-1

Note

If the gear oil color appears to be milky

color, contact your dealer.

ENOM00086-A

Propeller replacement

ENOW00084-1

zDo not install or remove propeller on the

outboard motor with spark plug caps

attached, shift in forward or reverse,

main switch at other than “OFF”, engine

stop switch lock attached to the switch,

and starter key attached, or engine could

ENOF00927-0

ENOF00100-A

CAUTION

WARNING

ENOF00101-A

INSPECTION AND MAINTENANCE 75

accidentally start leading to serious per-

sonal injury. Disconnecting battery cable

is recommended (if equiped).

zThe propeller edge is thin and sharp. Wear

the gloves while installing or removing to

protect your hands.

ENOW00086-1

zDo not install propeller without thrust

holder, or propeller boss could be dam-

aged.

zDo not reuse split pin.

zAfter installing split pin, spread bend both

end of the pin apart to lock propeller in

place.

A worn-out or bent propeller will lower

the motor's performance, and cause

engine trouble.

1. Put a piece of wood block between

propeller blade and anti-ventilation

plate to hold propeller.

2. Remove the split pin, propeller nut

and washer.

3. Remove the propeller and thrust

holder.

4. Apply waterproof grease to the pro-

peller shaft before installing a new

propeller.

5. Install the thrust holder, propeller,

stopper, washer and propeller nut

onto the shaft.

1. Propeller

2. Thrust holder

3. Bush

4. Stopper

5. Washer

6. Nut

7. Split pin

6. Tighten the propeller nut to specified

torque and align one of the grooves

with propeller shaft hole.

Propeller nut torque:

35 N·m



(25 ft· ·lb, 3.5kgf m)

7. Install a new split pin into the nut hole

and bend both ends of pin apart to

lock propeller in place.

CAUTION

ENOF00084-B

ENOF01336-0

ENOF00084-E

INSPECTION AND MAINTENANCE76

ENOM00087-D

Spark plugs replacement

ENOW00087-1

zDo not reuse spark plug, if the insulation

is damaged or sparks can leak through

crack, potentially leading to electric

shock, explosion and/or fire.

zDo not touch spark plugs immediately

after stopping engine as they will be hot

and could cause severe burns if touched.

ENOW00929-A

zUse only the recommended spark plugs.

Spark plugs which have an different heat

range may cause engine damage.

zDo not clean electrodes of iridium spark

plug. If it is contaminated with carbon

deposit or dirt, replace with a new one.

zDo not adjust the plug gasp, if it is out of

specification, replace with a new one.

If the spark plug(s) is fouled, has carbon

buil d up , or is worn , it sh ould be

replaced.

1. Stop the engine.

2. Remove the top cowl.

3. Remove the spark plug caps.

4. Remove the spark plugs by turning it

counter-clockwise, using a 5/8" (16

mm) socket wrench and handle that

are provided in the tool bag.

5. Inspect the spark plug. Replace the

spark plug with wear on electrode

and if the insulators are cracked or

chipped.

6. Measure the spark plug electrode gap

with a wire type feeler gauge. The gap

should be 0.8-0.9 mm (0.031-0.035

in). If the gap is out of specification,

replace the spark plug with a new one

Use spark plug ; NGK LKR6E

1. Electrode

2. Spark gap (0.8–0.9 mm, 0.031–0.035 in)

7. Install the spark plug and turn it care-

fully to avoid cross-threading.

8. Tighten the spark plug to the speci-

fied torque.

ENON00028-1

Note

zSpark plug tightening torque:

18.0 N·m (13.3 ft·lb) [1.84 kgf·m]

If a torque-wrench is not available when

you are installing a spark plug, tighten it 1/4

to 1/2 a turn past finger-tight. Have the

spark plug adjusted to the correct torque

as soon as possible with a torque-wrench.

WARNING

CAUTION

ENOF00085-0

INSPECTION AND MAINTENANCE 77

ENOM00088-1A

Anode replacement

A sacrificial anode protects the outboard motor from galvanic corrosion. Anode is

located on the gear case, cylinder etc.. When the anode is eroded more than 1/3 of

original size, replace it.

ENON00029-1

Notes

zNever grease or paint the anode.

zAt each inspection, re-tighten all the anode attaching bolts. Those bolts may loosen if the

anodes are corroded.

ENOF02429-0

INSPECTION AND MAINTENANCE78

ENOF02434-0

INSPECTION AND MAINTENANCE 79

ENOM01827-0

Ground wire checking

The ground wires described below are

making electrically connect between

moving parts and sacrificial anodes to

prevent galvanic corrosion.

Inspect the wires and their terminals

periodically. If there is any damage,

replace the ground wire.

ENOM01824-0

Power Trim & Tilt fluid checking

ENOW00088-0

zBe sure that outboard motor is secured to

transom or service stand, or accidental

drop or fall of outboard motor could lead

to severe personal injury.

zBe sure to lock outboard motor if it is

tilted up, or accidental fall of outboard

motor could lead to severe personal

injury.

zDo not go under outboard motor tilted up

and locked, or accidental fall of outboard

motor could lead to severe personal

injury.

ENOW00973-0

Do not unscrew the filler cap with the out-

board motor tilted down. Pressurized fluid in

the reservoir tank may spurt out.

Check the fluid level in the reservoir tank

while the tank is kept in a vertical posi-

tion.

1. Tilt the outboard motor up and lock

the tilt with the tilt stopper.

2. Remove the fluid cap by turning

counter-clockwise, then check if the

fluid level reaches the bottom line of

the fill hole.

1. Filler cap

2. Fluid level

ENOF02447-0

ENOF02448-0

WARNING

CAUTION

ENOF01340-A

INSPECTION AND MAINTENANCE 81

ENOM00960-0

Grease point

Apply waterproof grease to the parts shown below.

ENOF02431-1

INSPECTION AND MAINTENANCE82

ENOM00100-A

ENOW00934-0

zBe sure to disconnect fuel connector

except when operating engine.

zFuel leakage is a fire or explosion hazard,

which can cause serious injury or death.

ENOW00097-0

Be sure to use cloth to remove fuel remain-

ing in the cowl and dispose of it in accor-

dan ce wi th local fi r e pr even ti on an d

environment protection regulations.

ENOW00096-0

Before servicing the motor for storage:

zRemove the battery cables.

zRemove the spark plug caps from the

spark plugs.

zDo not run the motor out of the water.

Before you put your outboard motor in

storage, it is a good opportunity to have

it serviced by your dealer.

Be sure to use fuel stabilizer while run-

ning the motor be fore storage. (See

page 83)

ENOM00101-A

Engine

1. Wash the engine exterior and flush

the cooling water system thoroughly

with fresh water. Drain the water

completely.

Wipe off any surface water with an

oily rag.

2. Use a dry cloth to completely wipe off

water and salt from the electrical

components.

3. Drain all fuel from the fuel hoses, fuel

pump, fuel filter (See page 72) and

vapor separator (See page 83), and

clean these parts.

Keep in mind that if gasoline is kept in

the vapor separator for a long time,

gum and varnish will develop, causing

the float valve to stick, restricting the

fuel flow.

ENOW00930-1

zBe sure to remove stop switch lock to

prevent the spark plug(s) from igniting.

zPut a cloth to spark plug hole and wipe up

any spilled engine oil, when cranking the

outboard motor.

4. Change the engine oil (See page 69).

5. Change the gear oil in the gear case

(See page 73).

6. Apply grease to grease point (See

page 81).

7. Place the outboard motor in the ver-

tical position under a dry condition.

3. Off-season storage

WARNING

CAUTION

WARNING

INSPECTION AND MAINTENANCE 83

ENOW00969-0

When transporting or storing the outboard

motor, it places only in a vertical position

(normal running position).

ENOM00950-0

Adding a fuel stabilizer

When adding a fuel stabilizer additive

(commercially available), first fill the fuel

tank with fresh fuel. If the fuel tank is only

partially filled, air in the tank can cause

the fuel to deteriorate during storage.

1. Before adding fuel stabilizer additive,

dr ai n the v apor se pa ra t or ( See

page 83).

2. Follow the instructions on the label

when adding the fuel stabilizer addi-

tive.

3. After adding the additive, let the out-

board motor run in the water for 10

minutes to make sure any old fuel in

the fuel system has been completely

replaced by the fuel with additive.

4. Turn the engine OFF

ENON00945-0

Note

Over time, oxidation of gasoline can form

buildup of harmful solids called gums.

Water and impurities in the fuel system

can cause corrosion. To stabilize the fuel

and prevent oxidation, gum buildup, and

corrosion throughout the boating season,

recommended to add a good fuel stabilizer

to the fuel tank after each fill up.

ENOM00970-0

Fuel system draining

ENOW00028-A

For details on handling fuel, contact an

authorized dealer.

Fuel and fuel vapors are extremely flamma-

ble and can be explosive.

z If fuel is spilled, wipe it up immediately.

zKeep the fuel tank well away from sources

of ignition, e.g. sparks or open flames

zPerform all work outdoors or in a well

ventilated place.

ENOW00097-0

Be sure to use cloth to remove fuel remain-

ing in the cowl and dispose of it in accor-

da n c e w it h l oc al f ir e pr ev en ti on an d

environment protection regulations.

ENOM01824-0

1. Disconnect the fuel hose from the

outboard motor.

2. Turn the top cowl hook levers to

unlock, lift and remove the top cowl.

3. Pull out the vapor separator drain

hose to outside the bottom cowl.

4. Place an appropriate fuel container

under the drain hose end.

CAUTION

ENOF02421-0

WARNING

INSPECTION AND MAINTENANCE84

5. Remove the hose clip and the drain

plug by plier to drain the fuel from the

vapor separator.

6. When thoroughly drained, put back

the drain plug and the hose clip

securely.

7. Check the drained fuel for the pres-

ence of water or other contaminants.

Consult your dealer, If either present.

Service is required.

1. Drain hose

ENOM00102-0

Battery

ENOW00931-A

zPlace the battery away from any source of

fir e, sp ar ks and open flames such as

burners or welding equipment.

zPlace the battery away from fuel tank.

Accidental sparks of battery may cause

explosion of fuel.

1. Disconnect the battery cables and be

sure to remove the negative terminal

first.

2. Wipe off any chemical deposits, dirt,

or grease.

3. Apply grease to the battery terminals.

4. Charge the battery completely before

storing it for the winter.

5. Recharge the battery once a month

to prevent it from discharging and the

electrolyte from deteriorating.

6. Store the battery in a dry place.

ENOM01825-0

The following steps must be taken when

first using the engine after off-season

storage.

1. Check that the shift and throttle

function properly. (Be sure to turn the

propeller shaft when checking the

shift function or else the shift linkage

may be damaged.)

2. Check the electrolyte level, and mea-

sure the voltage and specific gravity

of the battery.

3. Check that the battery is secure and

the batte ry cable s ar e pr o perly

installed.

4. Change the engine oil (See page 69).

5. Fill fuel tank completely.

6. Start the engine and warm up the

engine for 3 minutes in the “NEU-

TRAL” position.

7. Run the engine for 5 minutes at the

slowest speed.

WARNING

ENOF02438-0

4. Pre-season check

Specific Grav-

ity at 20°C

Terminal

Voltage (V)

Charge

Condition

1.120 10.5 Fully discharged

1.160 11.1 1/4 charged

1.210 11.7 1/2 charged

1.250 12 3/4 charged

1.280 13.2 Fully charged

INSPECTION AND MAINTENANCE 85

8. Run the engine for 10 minutes at half

throttle. The oil used for storage

inside the engine will be circulated

out to assure optimum performance.

ENOM01811-0

ENOW00098-0

Do not attempt to start submerged outboard

motor immediately after it is recovered, or

engine could be severely damaged.

After taking your outboard motor out of

the water, immediately take it to your

dealer.

ENOM00106-1

If you moor your boat in cold weather at

temperatures below 0°C (32°F), water

residue in water pump may freeze and

may damage the pump, impeller, etc. To

avoid, submerge the lower half of the

outboard motor into the water.

ENOM00107-A

ENOW00935-0

Striking the sea bottom or an underwater

object may severely damage the outboard

motor.

Follow the procedure below and consult

a dealer as soon as possible.

1. Stop the engine immediately.

2. Check the control system, gear case,

boat transom etc.

3. Return to the nearest harbor slowly

and carefully.

4. Consult a dealer check the outboard

motor before operation again.

ENOM00121-0

When operating the outboard motors in

reverse at more than the lowest speed,

be sure that all engines are running.

If any engine has stopped, be sure to tilt

the outboard motor up and keep its pro-

peller out of the water.

Otherwise, water could enter the engine

and cause damage to it.

5. Submerged outboard motor

CAUTION

6. Cold weather precautions

7. Striking underwater object

CAUTION

8. Operation with multiple

outboard motors

ENOF01145-0

TROUBLESHOOTING

ENOM00109-0

If you encounter a problem, check the list below to determine the cause and to take the

proper action.

An authorized dealer will always be happy to provide any assistance and information.

Engine will not start.

Engine stalls immediately after starting

Defective idling

Poor acceleration

Engine speed is very high causing

high speed ESG to operate.

Engine speed is very low, causing

low speed ESG to operate.

Boat cannot run at high speed.

Engine overheats.

Battery is not charged.

Starter motor will not operate.

Power tilt will not operate.

Warning lamp A "ON"/"Flash"

Warning lamp B "Flash"

Warning lamp C “Flash”

Three warning lamps “Flash”

Warning buzzer “ON”

Possible cause

Fuel and Lubrication Systems

z z Fuel level is low in the tank.

z z z z z z z Fuel system connection is

incomplete.

z z z z z z z Fuel system sucks air.

z z z z z z z Fuel pipe is twisted.

z z z z z z z Cap vent is closed.

z z z z z z z Fuel filter, fuel pump or injector is

clogged.

z z z z z z z Performance of fuel pump or vapor

separator is deteriorated.

z z z z z Low quality fuel is used

zPrimer bulb is clogged.

z z z z z z Low quality engine oil is used.

z z Engine oil quantity excessive

(emissions of white smoke).

z*z z*Engine oil is lacking (Oil pressure

switch operates).

z*z z*Oil filter is clogged (Oil pressure

switch operates).

z*z z*Oil pump is defective (Oil pressure

switch operates).

Produkt Specifikationer

Mærke:	Tohatsu
Kategori:	Påhængsmotor
Model:	MFS90A

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