OWNER’S
MANUAL
MD 30B2
MD 40B2
MD 50B2
MD 75C2
MD 90C2
MD 115A2
Original instructions
OB No.003-11119-3AG1
ENOM00001-0
READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE
INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.
Copyright © 2017 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced or
transmitted in any from or by any means without the express written permission of Tohatsu Corporation.
3
YOUR TOHATSU OUTBOARD MOTOR
ENOM00006-A
To You, Our Customer
Thank you for selecting a TOHATSU outboard motor. You are now the proud owner of an
excellent outboard motor that will service you for many years to come.
This manual should be read in its entirety and the inspection and maintenance procedures
described later in this manual should be followed carefully. Should a problem arise with the
outboard motor, please follow the troubleshooting procedures listed at the end of this
manual. If the problem persists, contact an authorized TOHATSU service shop or dealer.
Please always keep this manual together with the outboard motor as a reference to everyone who uses the outboard motor. If the outboard motor is resold, make sure the manual
is passed on to the next owner.
We hope you will enjoy your outboard motor and wish you good luck in your boating
adventures.
TOHATSU CORPORATION
ENOM00113-0
EC DECLARATION OF CONFORMITY (DoC)
This product conforms to certain portion of the European Parliament directive. DoC contains the following information;
z Name and Address of the manufacturer.
z Applied community directives
z Reference standard
z Description of the product. (Model name and serial number)
z Signature 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.
ENOM00003-0
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before you
take delivery.
4
ENOM00005-A
Serial Number
In the space below, please record the outboard motor's serial number (indicated both on
the swivel bracket and on the cylinder block). The serial number will be needed when
ordering parts, and when making technical or warranty inquiries.
Serial Number:
30, 40 50
ENOF01301-0
ENOF01300-1
75, 90
ENOF01303-0
ENOF01302-1
115
ENOF01305-0
ENOF01302-1
Serial Number:
Date of purchase:
5
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 “DANGER,”
“WARNING,” “CAUTION,” and “Note.” Always pay special attention to such information to
ensure safe operation of the outboard motor at all times.
ENOW00001-0
DANGER
Failure to observe will result in severe personal injury or death, and possibly property damage.
ENOW00002-0
WARNING
Failure to observe could result in severe personal injury or death, or property damage.
ENOW00003-0
CAUTION
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 outboard
motor or to clarify important points.
CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PARTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2. Remote control device installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3. Battery installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4. Propeller installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5. TOCS (Tohatsu Onboard Communication System) installation. . . . . . . . . 34
PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5. Warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1. Engine oil feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . 63
1. Removing the outboard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3. Remote control lever friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8. Operation with multiple outboard motors . . . . . . . . . . . . . . . . . . . . . . . . . 91
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
12. ACCESSORIES KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9
INDEX
1 GENERAL SAFETY INFORMATION
1
2. SPECIFICATIONS
2
3. PARTS NAME
3
4. LABEL LOCATIONS
4
5. INSTALLATION
5
6. PRE-OPERATING PREPARATIONS
6
7. ENGINE OPERATION
7
8. REMOVING AND CARRYING THE
OUTBOARD MOTOR
8
9. ADJUSTMENT
9
10. INSPECTION AND MAINTENANCE
10
11. TROUBLESHOOTING
11
12. ACCESSORIES KIT
12
13. PROPELLER TABLE
13
14
14
10
GENERAL SAFETY INFORMATION
ENOM00009-0
1
SAFE OPERATION OF BOAT
As the operator/driver of the 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 outboard motor,
please read through this manual carefully.
It is very difficult for a person standing or floating 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 outboard motor
should be shifted to neutral and shut off.
ENOW00005-0
WARNING
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.
ENOM0008-A
EMERGENCY STOP SWITCH
The Emergency Stop Switch will stall the outboard motor when the stop switch lanyard is
pulled off. This stop switch lanyard has to be attached to the operator of the outboard
motor to minimize or prevent injuries from the propeller in case the operator falls overboard.
It is operator’s responsibility to use the Emergency Stop Switch Lanyard.
ENOW00004-A
WARNING
Accidental activation of the Emergency 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 Emergency Stop Switch, the 500 mm (20 in.) stop
switch lanyard is coiled and can extended to a full 1300 mm (51 in.).
ENOM00800-A
PERSONAL FLOATATION DEVICE
As the operator/driver and passenger of the boat, you are responsible to wear a PFD (Personal Floatation Device) while on the boat.
GENERAL SAFETY INFORMATION
11
ENOM00010-0
SERVICING, REPLACEMENT PARTS & LUBRICANTS
We recommend that only an authorized service shop perform service or maintenance on
this outboard motor. Be sure to use genuine parts, genuine lubricants, or recommended
lubricants.
ENOM00011-A
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct maintenance
procedures following maintenance section of this manual (See page 61). It is the operator's responsibility to perform all safety checks and to ensure that all lubrication and maintenance instructions are complied with for safe operation. Please comply with all
instructions concerning lubrication and maintenance. 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 this outboard motor will reduce the
chance of problems and limit overall operating expenses.
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.
1
12
SPECIFICATIONS
ENOM00810-A
MODEL FEATURE
Model
D40B2
Type
2
D50B2
ETO
EO
ETO
S
z
z
z
L
z
z
z
Electrical start
z
z
Multi-function tiller handle
(z)
Transom heights
Remote Control
z
Power Trim & Tilt
z
z
(z)
z
z
Mnual tilt
(z) These models can be purchased with remote rigging kit or multi-function tiller handle
Model
D75C2
D90C2
EPTO
EPTO
L
z
z
UL
z
z
Electrical start
z
z
Remote Control
z
z
Power Trim & Tilt
z
z
Oil auto-mixing
z
z
Type
Transom heights
Model
D115A2
Type
EPTO
Transom heights
L
z
UL
z
Electrical start
z
Remote Control
z
Power Trim & Tilt
z
Oil auto-mixing
z
(z) These models can be purchased with remote rigging kit or multi function tiller handle.
ENOM00811-A
MODEL NAME EXAMPLE
D115A2 EPTOL
D
115
A2
E
P
T
O
L
Model description
Horse
power
Product
generation
Starter
system
Steering
system
Tilt
system
Lubrication
system
Shaft
length
A and up
E= Electrical
start
M= Manual
start
P=Remote
controlࠉ
(Pleasure)
F=Tiller handle
(Fisher)
O=
Oil automxing
Blank=
Oil Pre-mixing
S= Short
15 in
L= Long
20 in
UL=
Ultra long 25
in
F= Four stroke
D= Two stroke DI
-
T= Power
trim&tilt
G=
Gas assist
Blank=
Manual tilt
SPECIFICATIONS
13
ENOM00601-A
40B2
Item
MODEL
40B2
ETO (with RC)
Overall Length
mm (in)
Overall Width
mm (in)
Overall Height S·L
mm (in)
1227 (48.3)
1354 (53.3)
Transom Height S·L
mm (in)
403 (15.9)
530 (20.9)
Weight
Output
630 (24.8)
355 (14.0)
S kg (lb)
93.5 (206)
L kg (lb)
94.5 (208)
kW (ps)
29.4 (40)
Max. Operating Range
rpm
5150–5850
Idle Speed
rpm
700/800/900 *1
Engine Type
Direct fuel injection
Number of Cylinder
Bore × Stroke
Piston Displacement
3
mm (in)
mL (Cu in)
68 × 64 (2.68 × 2.52)
697 (42.5)
Exhaust System
Through hub exhaust
Cooling System
Water cooling
Engine Lubrication
Oil injection
Starting System
Electric starter motor
Ignition System
Inductive Ignition
Spark Plug
NGK IZFR6Q
Alternator
12 V, 280 W (Max.)
Trim Position
4
Engine Oil
Genuine Motor Oil or recommended one
Gear Oil
Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 500 mL
Fuel Tank Capacity
L (US gal)
25 (6.6)
Engine Oil Capacity
L (US gal)
Approx. 2.0 (0.53)
Gear Reduction Ratio
Fuel
1.85 (13 : 24)
Unleaded regular gasoline : Pump posted 87 Octane
(research octane rating of 91)
Emission Control System
DFI (Direct Fuel Injection)
Operator Sound Pressure
(ICOMIA 39/94) dB (A)
84.0
Hand Vibration Level
(ICOMIA 38/94) m/sec2
—
Remark: Specifications subject to change without notice.
*1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 54)
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
2
14
SPECIFICATIONS
ENOM00601-1
40B2
2
Item
MODEL
ETO
40B2
EO
(with multi-function
tiller handle)
(with multi-function
tiller handle)
EO
(with RC)
Overall Length
mm (in)
Overall Width
mm (in)
Overall Height S·L
mm (in)
1227 (48.3)
1354 (53.3)
Transom Height S·L
mm (in)
403 (15.9)
530 (20.9)
Weight
Output
775 (30.5)
630 (24.8)
355 (14.0)
345 (13.6)
S kg (lb)
97.5 (215)
89.5 (197)
85.5 (188)
L kg (lb)
98.5 (217)
90.5 (200)
86.5 (191)
kW (ps)
29.4 (40)
Max. Operating Range
rpm
5150–5850
Idle Speed
rpm
700/800/900 *1
Engine Type
Direct fuel injection
Number of Cylinder
Bore × Stroke
Piston Displacement
3
mm (in)
68 × 64 (2.68 × 2.52)
mL (Cu in)
697 (42.5)
Exhaust System
Through hub exhaust
Cooling System
Water cooling
Engine Lubrication
Oil injection
Starting System
Electric starter motor
Ignition System
Inductive Ignition
Spark Plug
NGK IZFR6Q
Alternator
12 V, 280 W (Max.)
Trim Position
4
Engine Oil
6
Genuine Motor Oil or recommended one
Gear Oil
Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 500 mL
Fuel Tank Capacity
L (US gal)
25 (6.6)
Engine Oil Capacity
L (US gal)
Approx. 2.0 (0.53)
Gear Reduction Ratio
Fuel
1.85 (13 : 24)
Unleaded regular gasoline : Pump posted 87 Octane
(research octane rating of 91)
Emission Control System
DFI (Direct Fuel Injection)
Operator Sound Pressure
(ICOMIA 39/94) dB (A)
84.0
Hand Vibration Level
(ICOMIA 38/94) m/sec2
3.8
Remark: Specifications subject to change without notice.
*1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 54)
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
—
SPECIFICATIONS
15
ENOM00602-0
50B2
50B2
Item
MODEL
ETO
(with multi-function
tiller handle)
ETO
(with RC)
Overall Length
mm (in)
Overall Width
mm (in)
Overall Height S·L
mm (in)
1227 (48.3)
1354 (53.3)
Transom Height S·L
mm (in)
403 (15.9)
530 (20.9)
Weight
Output
630 (24.8)
S kg (lb)
93.5 (206)
97.5 (215)
L kg (lb)
94.5 (208)
98.5 (217)
kW (ps)
Max. Operating Range
rpm
Idle Speed
rpm
37 (50)
5150–5850
700/800/900 *1
Engine Type
Direct fuel injection
Number of Cylinder
Bore × Stroke
Piston Displacement
775 (30.5)
355 (14.0)
3
mm (in)
68 × 64 (2.68 × 2.52)
mL (Cu in)
697 (42.5)
Exhaust System
Through hub exhaust
Cooling System
Water cooling
Engine Lubrication
Oil injection
Starting System
Electric starter motor
Ignition System
Inductive Ignition
Spark Plug
NGK IZFR6Q
Alternator
12 V, 280 W (Max.)
Trim Position
4
Engine Oil
Genuine Motor Oil or recommended one
Gear Oil
Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 500 mL
Fuel Tank Capacity
L (US gal)
25 (6.6)
Engine Oil Capacity
L (US gal)
Approx. 2.0 (0.53)
Gear Reduction Ratio
Fuel
1.85 (13 : 24)
Unleaded regular gasoline : Pump posted 87 Octane
(research octane rating of 91)
Emission Control System
DFI (Direct Fuel Injection)
Operator Sound Pressure
(ICOMIA 39/94) dB (A)
84.0
Hand Vibration Level
(ICOMIA 38/94) m/sec2
—
Remark: Specifications subject to change without notice.
*1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 54)
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
3.8
2
16
SPECIFICATIONS
ENOM00604-0
75C2, 90C2
2
Item
MODEL
75C2
90C2
EPTO
Overall Length
mm (in)
Overall Width
mm (in)
Overall Height L·UL
mm (in)
1540 (60.6)
1667 (65.6)
Transom Height L·UL
mm (in)
517 (20.4)
644 (25.4)
150 (331)
153 (337)
Weight
L·UL kg (lb)
Output
kW (ps)
Max. Operating Range
rpm
Idle Speed
rpm
Engine Type
Piston Displacement
508 (20.0)
55 (75)
66 (90)
5150–5850
700/800/900 *1
Direct fuel injection
Number of Cylinder
Bore × Stroke
810 (31.9)
3
mm (in)
mL (Cu in)
86 × 72.7 (3.39 × 2.86)
1267
Exhaust System
Through hub exhaust
Cooling System
Water cooling
Engine Lubrication
Oil injection
Starting System
Electric starter motor
Ignition System
Inductive Ignition
Spark Plug
NGK IZFR6Q
Alternator
12 V, 490 W (Max.)
Trim Position
2
Engine Oil
Genuine Motor Oil or recommended one
Gear Oil
Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 900 mL
Fuel Tank Capacity
L (US gal)
—
Engine Oil Capacity
L (US gal)
Approx. 4 (1.06)
Gear Reduction Ratio
Fuel
2.33 (12:28)
Unleaded regular gasoline : Pump posted 87 Octane
(research octane rating of 91)
Emission Control System
DFI (Direct Fuel Injection)
Operator Sound Pressure
(ICOMIA 39/94) dB (A)
81.7
Hand Vibration Level
(ICOMIA 38/94) m/sec2
—
Remark: Specifications subject to change without notice.
*1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 54)
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
SPECIFICATIONS
17
ENOM00605-0
115A2
Item
MODEL
115A2
EPTO
Overall Length
mm (in)
Overall Width
mm (in)
800 (31.5)
Overall Height L·UL
mm (in)
1640 (64.6)
1767 (69.6)
Transom Height L·UL
mm (in)
517 (20.4)
644 (25.4)
Weight
L·UL kg (lb)
178 (392)
181 (399)
Output
kW (ps)
495 (19.5)
85 (115)
Max. Operating Range
rpm
5150–5850
Idle Speed
rpm
700/800/900 *1
Engine Type
Direct fuel injection
Number of Cylinder
Bore × Stroke
Piston Displacement
4
mm (in)
mL (Cu in)
88 × 72.7 (3.46 × 2.86)
1768 (107.9)
Exhaust System
Through hub exhaust
Cooling System
Water cooling
Engine Lubrication
Oil injection
Starting System
Electric starter motor
Ignition System
Inductive Ignition
Spark Plug
NGK IZFR5J
Alternator
12 V, 490 W (Max.)
Trim Position
2
Engine Oil
Genuine Motor Oil or recommended one
Gear Oil
Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 900 mL
Fuel Tank Capacity
L (US gal)
—
Engine Oil Capacity
L (US gal)
Approx. 6.7 (1.77)
Gear Reduction Ratio
Fuel
2.0 (13:26)
Unleaded regular gasoline : Pump posted 87 Octane
(research octane rating of 91)
Emission Control System
DFI (Direct Fuel Injection)
Operator Sound Pressure
(ICOMIA 39/94) dB (A)
83.3
Hand Vibration Level
(ICOMIA 38/94) m/sec2
—
Remark: Specifications subject to change without notice.
*1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 54)
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
2
18
PARTS NAME
ENOM00607-0
ETO (with multi-function tiller handle)/40B2, 50B2
19
1
3
16
15
2
23
18
3
4
5
17
14
13
6
7
12
8
11
21
20
22
9
10
24
25
26
1
2
3
4
5
6
7
8
9
10
11
12
Tilt Handle
Top Cowl
Hook Lever
Water Check Port
Tilt Stopper
Water Plug
Anti-ventilation Plate
Trim Tab
Propeller
Oil Plug (lower)
Water Inlet
Oil Plug (upper)
13
14
15
16
17
18
19
20
21
22
23
24
Clamp Bracket
Thrust Rod
Throttle Grip
Shift Lever
Stop Switch
Pilot Lamp
Main Switch
Battery Cords
Power Trim & Tilt
Anode
Power Trim & Tilt Switch
Oil Tank
25 Spark Plug
26 Fuel Filter
ENOF01307-0
PARTS NAME
19
ENOM00608-0
ETO (with RC)/30B2, 40B2, 50B2
1
3
2
15
16
14
18
3
4
5
13
6
17
19
12
7
11
8
9
10
20
21
22
1
2
3
4
5
6
7
8
9
10
11
12
Tilt Handle
Top Cowl
Hook Lever
Water Check Port
Tilt Stopper
Water Plug
Anti-ventilation Plate
Trim Tab
Propeller
Oil Plug (lower)
Water Inlet
Oil Plug (upper)
13
14
15
16
17
18
19
20
21
22
Clamp Bracket
Thrust Rod
Power Trim & Tilt Switch
Fuel Connector
Battery Cords
Power Trim & Tilt
Anode
Oil Tank
Spark Plug
Fuel Filter
ENOF01308-0
20
PARTS NAME
ENOM00609-0
EPTO/75C2, 90C2
1
3
2
3
15
14
19
3
4
16
12
13
17
18
6
5, 9
7
8
11
10
20
21
22
1
2
3
4
5
6
7
8
9
10
11
12
Tilt Handle
Top Cowl
Hook Lever
Water Check Port
Water Plug
Anti-ventilation Plate
Trim Tab
Propeller
Oil Plug (upper)
Water Inlet
Oil Plug (lower)
Clamp Bracket
13
14
15
16
17
18
19
20
21
22
Thrust Rod
Fuel Nipple
Power Trim & Tilt Switch
Battery Cords
Power Trim & Tilt
Anode
Flushing Connector Cap
Oil Tank
Spark Plug
Fuel Filter
ENOF01309-0
PARTS NAME
21
ENOM00610-0
EPTO/115A2
1
2
15
3
14
19
3
16
4
12
6
13
17
18
5, 9
7
10
8
11
21
20
22
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Tilt Handle
Top Cowl
Hook Lever
Water Check Port
Water Plug
Anti-ventilation Plate
Trim Tab
Propeller
Oil Plug (upper)
Water Inlet
Oil Plug (lower)
Clamp Bracket
Thrust Rod
Fuel Nipple
15
16
17
18
19
20
21
22
Power Trim & Tilt Switch
Battery Cords
Power Trim & Tilt
Anode
Flushing Connector Cap
Oil Tank
Spark Plug
Fuel Filter
ENOF01310-0
3
22
PARTS NAME
ENOM00822-0
Remote control box & Fuel tank
3
10
9
1
3
11
2
4
5
7
8
6
14
13
12
ENOF00127-E
1
2
3
4
5
6
7
8
Control Lever
Neutral lock arm
PTT switch
Free throttle lever
Main switch
Stop switch
Stop switch lock
Stop switch lanyard
9
10
11
12
13
14
Fuel gauge
Air vent screw
Fuel tank cap
Fuel connector (Engine side)
Primer bulb
Fuel connector (Fuel tank side)
23
LABEL LOCATIONS
ENOM00019-A
Warning label locations
1, 2
30/40/50
7
4
6
5
2 (115), 3
4
75/90/115
7
8
11
10
12
9
13
ENOF01311-0
24
LABEL LOCATIONS
1. Warning label regarding owner’s manual, top cowl, engine stop switch,
5. Warning label regarding stop switch
(See page 54).
ENOF00005-P
6. Indicator label regarding engine failure/
malfunction (See page 40).)
4
ENOF00005-W
2. Warning regarding engine oil replenishment. (See page 37, 40)
ENOF00005-C
7-1. Warning regarding emergency starting (See 49).
7-2. Warning regarding high temperature.
7-3. Warning regarding rotating object.
7-4. Warning regarding high voltage.
7-5. Caution regarding fuel filter. (See
page 58, 63, 67)
3T1-72043-0
3. Warning label regarding installation of
remote control system (See page 30).
5
ENOF00120-0
1
4
4. Warning regarding engine oil replenishment (See page 37, 40).
Affix this label near the outboard motor
where it can be easily read.
3B7-72043-0
2
3
3KZX72181-1
LABEL LOCATIONS
8. Indicator label regarding engine failure/
malfunction (See page 40).
stick this label at pace near the driver's
seat where is easy to see.
12. Warning
regarding
gasoline
regarding
gasoline
(See
page 35).
ENOF00005-M
13. Warning
(See
page 35).
3T5-72050-0
9. Warning label on engine stop switch.
ENOF00005-F
ENOF00008-0
10. Warning regarding gasoline.
ENOF00005-E
11. Warning
regarding
gasoline
page 35).
ENOF00005-L
(See
25
4
26
LABEL LOCATIONS
ENOM00019-B
CE label locations
O utboard Motor
0123
4
1)
2)
3)
4)
5)
6)
R a te d Power:
Ma ss:
Serial No.
Made in Japan
CAN ICES-2/NMB-2
ENOF01312-1
1. Model code(Model name)
2. Rated power
3. Dry mass weight( Without propeller, with battery
cable)
4. Serial No.
5. Manufacture name
6. Manufacture address
Description of serial number year code
Last two digits of alphabet represent production year as below.
Year Code
AG
AH
AK
BX
BA
Year of
manufacture
2017
2018
2019
2020
2021
27
INSTALLATION
ENOM00024-A
1. Mounting the outboard motor on
boat
Do not operate the outboard motor until it
has been securely mounted on the boat in
accordance with the instructions below.
ENOW00009-0
ENOW00006-B
WARNING
WARNING
Before installing the outboard motor on the
boat, hang the outboard motor with the
hoist or equivalent device by attaching the
engine hanger to the outboard. Use the
hoist with allowable load is 250 kg (550 lbs)
or above.
z Mounting the outboard motor without
following this manual can lead to unsafe
conditions such as poor maneuverability, lack of control or fire.
z Loose clamp screws and/or mounting
bolts can lead to the release or displacement of the outboard motor, possibly
resulting in lost of control and/or serious
personal injury. Be sure that fasteners
are tightened to the specified torque (30
N·m (3.0 kgf·m) 13 ft·lb). Check the fasteners for tightness from time to time.
z Be sure to use outboard mounting fasteners included in the outboard motor
package or their equivalents in terms of
size, material, quality and strength.
Tighten fasteners to the specified torque
(30 N·m (3.0 kgf·m) 13 ft·lb). Test cruise
to check if fasteners are tightened
securely.
z Outboard motor mounting must be performed by trained service person(s)
using lift or hoist with sufficient capacity.
Outboard motor mounting must be performed by trained service person(s) using
lift or hoist with sufficient capacity.
ENOF01313-0
ENOW00006-0
WARNING
Most boats are rated and certified in terms
of their maximum allowable horsepower,
as shown on the boat’s certification plate.
Do not equip your boat with an outboard
motor that exceeds this limit. If in doubt,
contact your dealer.
5
28
INSTALLATION
ENOM00025-0
Position ... Above keel line
Set engine at center of boat.
1
2
5
ENOF01141-0
1. Center of boat
2. Boat transom
ENOM00026-0
Transom matching
Be sure that the anti ventilation plate of the
outboard motor is 10–30 mm (0.4–1.2 in)
below the bottom of hull.
If the above condition cannot be met due
to the shape of the bottom of your boat,
please consult your authorized dealer.
water surface is near the bottom cowling, in high waves, water may enter the
engine cylinders.
z Incorrect outboard motor mounting
height or existence of underwater
object(s), such as hull bottom design,
bottom surface conditions or underwater accessories, can cause water spray
possibly reaching the engine through an
opening of the bottom cowling during
cruising. Exposing the engine to such
conditions for extended periods can
lead to severe engine damage.
ENOM00830-B
Mounting bolts
Manual tilt type
40, 50
1. To attach the outboard motor to the
boat, tighten the clamp screws by
turning their handles.
Also, use the bolts to secure the outboard motor brackets on transom
board.
Secure the outboard motor with a rope
to prevent loss overboard.
ENON00002-0
Note
1
10−30 mm
(0.4−1.2 in)
2
ENOF01344-0
1. Bottom of hull
2. Anti ventilation plate
ENOW00007-0
CAUTION
z Before beginning the running test, check
that the boat with maximum capacity
loading floats on the water in a proper
attitude. Check the position of water
surface on the driveshaft housing. If the
A rope is not included in the standard
accessories.
INSTALLATION
1
29
Power trim and tilt type type
1. To attach the outboard motor to the
boat, use the bolts to secure the outboard motor brackets on transom
board.
30, 40, 50
3
2
5
4
5
ENOF00610-0
1.
2.
3.
4.
5.
Clamp Screw
Washer (small diameter)
Washer (large diameter)
Bolt (12 mm × length 105 mm)
Nut
2
1
3
234 (9.21”)
1
117 (4.61”) 117 (4.61”)
39 (1.54”)
25 (0.98”)
64 (2.52”)
25 (0.98”)
89 (3.50”)
4
1.
2.
3.
4.
ENOF00612-1
Washer (small diameter)
Washer (large diameter)
Bolt (12 mm × length 105 mm)
Nut
327
ø13
(12.9”)
204 (8.03”)
51
(2.0”)
102 (4.02”) 102 (4.02”)
253.5
ø12.5
(10.0”)
ENOF00611-0
1. Top of transom
56
26 (1.02”) 248 (9.76”)
(2.2”)
18 18 18
222 (8.74”)
ø13
ENOW00945-0
CAUTION
z Please inspect whether there is a loosening of the clamp screw or mounting
bolts before departure.
z Loosening may cause a dangerous situation, such as loss of control.
ø12.5
251
(9.9”)
ENOF00613-0
30
INSTALLATION
75, 90, 115
ENON00003-0
Notes
1. Apply sealing agent, such as silicone
sealed between the bolts and the transom board holes before tightening the
bolts.
2. Be sure to tighten the mounting bolt
nuts to the specified torque.
(30 N·m (3.0 kgf·m) 13 ft·lb)
2
ENOM00840-0
3
1
4
1.
2.
3.
4.
ENOF00614-0
ENOW00850-0
Remote control box location
Bolt (12 mm × length 105 mm)
Washer (large diameter)
Nut
Washer (small diameter)
327
(12.9”)
3
1
1, 2
ø13
(0.5”)
254 (10”)
51 (2”)
17.5 (0.7”)
17.5 (0.7”)
17.5 (0.7”)
ENOF00841-0
56
(2.2”)
5
2. Remote control device
installation
251
(9.9”)
ENOF00615-0
1. Top of transom
ENOW00008-A
CAUTION
z Mounting bolts should be installed with
the bolt head at inside surface of the
transom. Mounting bolts installed with
the threaded end at the inside surface of
the transom can cause personal injury.
z Tighten the bolts sufficiency, otherwise
falling down of outboard could be happened.
1. Shift cable
2. Throttle cable
3. Cable harness B
Install the remote control box in a position
where it is easy to reach and operate the
controls.
Make sure there are no obstacles that can
interfere with the operation of the remote
control cable.
INSTALLATION
ENOW00850-0
Remote control cable length
ENOW00100-A
CAUTION
Be careful not to loop the remote control
cables to a diameter of 406 mm (16 in) or
less. Otherwise, it affects the service life of
the cable.
Keep battery and electrolyte away from
reach of children
When handling the battery, be sure to:
z Read all warnings shown on the battery
case
z Prevent electrolyte from coming in contact with any part of your body. Contact
can cause serious burn or, if it comes in
contact with your eye, loss of sight. Use
safety glasses and rubber gloves.
In case battery electrolyte comes in contact with:
z Skin, flush thoroughly with water.
z Eye, flush thoroughly with water, and
then seek immediate medical treatment.
In case battery electrolyte is swallowed:
z Seek immediate medical treatment.
ENOW00013-A
ENOF00842-0
Measure the distance from the remote
control box to the outboard motor where
the remote control cable should be routed.
Prepare a cable that is 300-450mm (11.817.7in) longer than the measured distance.
Temporarily pull the cable along the
intended cable route to check its length is
sufficient.
Connect the remote control cable to the
engine, then run the cable to the remote
control box, making sure it is not sharply
bent, too taut and free from obstructions
that could interfere with steering.
ENOM00029-A
3. Battery installation
ENOW00012-0
WARNING
Battery electrolyte contains sulfuric acid
and thus is hazardous, causing a burn if it
comes in contact with your skin, or poisonous if swallowed.
WARNING
Battery generates explosive hydrogen gas.
Be sure to:
z Charge the battery in a well-ventilated
place.
z Place the battery away from any source
of fire, sparks and open flames such as
burners or welding equipment.
z Do not smoke near the battery when the
battery is charging.
z Do not charge the battery when the
electrolyte level is low. Otherwise, the
battery will be damaged and may cause
malfunction.
ENOW00014-0
CAUTION
z Make sure that the battery leads do not
get stuck between the outboard motor
and boat when turning, etc.
z The starter motor may fail to operate if
the leads are incorrectly connected.
z Be sure to correctly connect the (+) and
(—) leads. If not, the charging system
will be damaged.
z Do not disconnect the battery leads
from battery while the engine is operating, the electrical parts could be damaged.
31
5
32
INSTALLATION
z Always use a fully charged battery.
ENOW00015-0
CAUTION
Do not use a battery that is not recommended. Use of a battery not recommended can lead to poor performance of,
and/or damage to, the electrical system.
2
1
ENON00006-A
Note
5
Recommended battery: 12V 100Ah/5HR,
850 (Cold Cranking Amps (CCA), In case of
cold whether: 12V120Ah/5HR (1000CCA))
Specifications and features of batteries vary
among the manufacturers. Consult the
manufacturer for details.
* The battery should be purchased separately and is not supplied with the outboard
motor.
1. Place the battery box in a convenient
position away from possible water
spray. Securely fasten both the box
and the battery so they do not shake
loose.
2. Connect the positive lead (+) 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.
ENOF00022-0
1. Battery cord (red)
2. Battery cord (black)
ENOM00123-0
4. Propeller installation
ENOW00085-A
WARNING
Do not begin propeller removal and installation 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 personal
injury.
Disconnect battery cable if possible.
INSTALLATION
ENOW00085-0
WARNING
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 propeller.
1. Remove the split pin, propeller nut and
washer.
2. Remove the propeller and thrust
holder.
3. Apply water proof grease to the propeller shaft before installing a new propeller.
4. Install the thrust holder, propeller,
stopper, washer and propeller nut onto
the shaft.
30, 40, 50
3
6
5
5
4
ENOF00084-B
ENOW00086-0
1
2
CAUTION
z Do not install propeller without thrust
holder, or propeller boss could be damaged.
z Do not reuse split pin.
z After installing split pin, spread the pin
apart to prevent it from falling out which
could lead to the propeller coming off
during operation.
ENOF01315-0
1.
2.
3.
4.
5.
6.
Propeller
Thrust holder
Stopper
Washer
Propeller nut
Split pin
75, 90
7
Propeller must be selected that will allow
the engine to reach recommended maximum operating range during cruising.
6
5
4
Wide-open throttle rpm range
30/40 : 4750 – 5750 min-1 (rpm)
2
50 : 5150 – 5850 min-1 (rpm)
3
1
75/90 : :5150 – 5850 min-1 (rpm)
ENOF01335-0
115 : 5150 – 5850 min-1 (rpm)
Genuine propellers are listed on PROPELLER TABLE of this manual (See page 85).
33
1.
2.
3.
4.
5.
6.
Propeller
Thrust holder
Bush
Adaptor
Washer
Propeller nut
34
INSTALLATION
7. Split pin
ENOM00971-0
5. TOCS (Tohatsu Onboard
Communication System)
installation
115
4 7
6
5
2
3
1
ENOF01336-0
5
1.
2.
3.
4.
5.
6.
7.
Propeller
Thrust holder
Bush
Stopper
Washer
Propeller nut
Split pin
TOCS (Tohatsu Onboard Communication
System) interface coupler can provide
information regarding engine speed, fuel
consumption, and various malfunction via
an optional interface cable. Contact authorized Tohatsu dealer for more detail.
30, 40, 50
5. Tighten the propeller nut to specifie
torque with holding the propeller by
wood block. And align one of grooves
to propeller shaft hole.
Propeller nut torque:
35 N·m (25 ft·lb, 3.5kgf·m)
ENOF00084-B
6. Install a new split pin into the nut hole
and bend it.
ENOF013380
75, 90, 115
ENOF013140
PRE-OPERATING PREPARATIONS
ENOM00030-A
1. Fuel handling
ENOW000017-0
CAUTION
Use of improper gasoline can damage your
engine. Engine damage resulting from the
use of improper gasoline is considered
misuse of the engine, and damage caused
thereby will not be covered under the limited warranty.
ENOM00031-A
FUEL RATING
TOHATSU engines will operate satisfactorily when using a major brand of unleaded
gasoline 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 gasoline.
Outside USA and Canada — Use
unleaded gasoline with declared octane
rating of 91 RON or over. Use of premium
gasoline of 98 RON is also allowed.
ENOM00032-A
GASOLINES CONTAINING
ALCOHOL
The fuel system components on your
TOHATSU engine will withstand up to 10%
ethyl alcohol (hereinafter referred to as the
"ethanol"), content in the gasoline. But
even if the gasoline in your area contains
ethanol less than 10%, you should be
aware of certain adverse effects that can
occur. Increasing the percentage of ethanol in the fuel can also worsen these
35
adverse effects. Some of these adverse
effects are caused because the ethanol in
the gasoline can absorb moisture from the
air, resulting in a separation of the water/
ethanol from the gasoline in the fuel tank.
These may cause increased:
z Corrosion of metal parts
z Deterioration of rubber or plastic parts
z Fuel permeation through rubber fuel
lines
z Starting and operating difficulties
If the use of gasoline containing alcohol is
inevitable, or presence of alcohol is suspected in the gasoline, it is recommended
to add a filter that has water separating
capability, and check the fuel system for
leaks and mechanical parts for corrosion
and abnormal wear more frequently.
And, 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 chapter
(P 87) for additional information.
ENOW00020-1
CAUTION
When operating a TOHATSU engine on
gasoline containing alcohol, storage of
gasoline in the fuel tank for long periods
should be avoided. Long periods of storage, create unique problems. In cars, alcohol blend fuels normally are consumed
before they can absorb enough moisture to
cause trouble, but boats often sit idle long
enough for phase separation to take place.
In addition, internal corrosion may take
place during storage if alcohol has washed
6
36
PRE-OPERATING PREPARATIONS
protective oil films from internal components.
ENOW00018-0
WARNING
Fuel leakage can cause fire or explosion,
potentially leading to severe injury or loss
of life. Every fuel system part should be
checked periodically, and especially after
long term storage, for fuel leak, change of
hardness of rubber, expansion and/or corrosion of metals. In case any indication of
fuel leakage or degradation of fuel part is
found, replace relevant part immediately
before continuing operation.
ENOM00043-B
6
2. Fuel filling
ENOW00019-1
WARNING
Do not fill the fuel tank over capacity. The
rise of gasoline temperature may cause
gasoline to expand which, may leak
through air vent screw when it is open.
Leaking gasoline is a dangerous fire hazard.
z Be sure to remove the static electricity
charged in your body before refueling.
z The sparks due to static electricity may
cause explosion of flammable gasoline.
z Stop the engine, and do not start the
engine during refueling.
z Do not smoke.
z Be careful not to overfill fuel tank. Wipe
up any spilled gasoline immediately.
When or before cleaning the gasoline tank:
z Dismount fuel tank from the boat.
z Place the fuel tank away from every
source of ignition, such as sparks or
open flames.
z Do the work outdoors or in a well ventilated area.
z Wipe off gasoline well immediately if
spilled.
z
After cleaning gasoline tank:
z Wipe off gasoline well immediately if
spilled.
z If the fuel tank is disassembled for
cleaning, reassemble carefully. Imperfect assembly may cause a fuel leak,
possibly leading to fire or explosion.
z Dispose aged or contaminated gasoline
in accordance with local regulations.
ENOW00029-A
ENOW00028-A
WARNING
Consult an authorized dealer for details on
handling gasoline, if necessary.
Gasoline and its vapors are very flammable
and can be explosive.
When carrying a fuel tank containing gasoline:
z Close the fuel tank cap and air vent
screw of fuel tank cap, or gasoline vapor
will be emitted through the air vent
screw, creating a fire hazard.
z Do not smoke.
When or before refueling:
WARNING
When opening fuel tank cap, be sure to follow 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.
ENOW00946-0
CAUTION
Separate tank must be fixed at appropriate
position so that well ventilated and tank
does not move or fall down while operating.
PRE-OPERATING PREPARATIONS
1. Full open the air vent screw on the fuel
tank cap and release internal pressure.
1
37
2
1
2
ENOF00027-A
1. Air vent screw
2. Fuel tank cap
3
ENOF00641-0
1. Genuine of recommended engine oil
2. Filler lid
3. Oil tank cap
2. Open the fuel tank cap slowly.
3. Fill the fuel carefully not to over flow.
Use a genuine engine oil or recommended
one. Refer to your Distributor.
Will not recommended use of other two
stroke engine oil.
ENOW0002A-A
CAUTION
Use of engine oils that do not meet these
requirements will result in reduced engine
life, and other engine problems.
SAFE FILL
LEVEL
25 L
NIVEAU
MAXIMUM
ENOW00603-0
ENOF00030-B
4. After filling the tank, close the fuel tank
cap.
ENOM00037-B
3. Engine oil recommendation
ENOW00022-A
CAUTION
The engine oil is drained for shipping from
the factory. Be sure to fill the engine to the
proper level before starting engine. (To
properly fill the engine with oil follow the
instructions, See page 70)
CAUTION
Do not mix different brands of oil. Mixing
different brands of oil, or different types of
oil even if the brand is the same, may cause
gelling, resulting in possible filter screen
blockage. This could result in serious
engine damage because of impaired lubrication performance.
6
38
PRE-OPERATING PREPARATIONS
ENOW00022-0
ENOM00645-0
CAUTION
The engine oil is drained for shipping from
the factory. Be sure to fill the engine to the
proper level before starting engine. (To
properly fill the engine with oil follow the
instructions in section 10 of this manual)
ENON00007-0
Note
Use of engine oils that do not meet these
requirements will result in reduced engine
life, and other engine problems.
Oil pump air vent
Visually check whether there is air in the oil
through the vinyl pipe connecting the oil
tank with the oil pump. If present, Purge
the air as follows:
30, 40, 50
Loosen the air vent screw on the oil pump
to purge the air, and tighten it when all air,
as seen through the vinyl pipe on the oil
pump side, has been purged.
30, 40, 50
ENOW00604-0
CAUTION
6
1
z In the unlikely event that gasoline by
mistake is filled into the oil tank, drain
the oil tank completely, and consult an
authorized service shop for advice.
z Check the amount of oil in the oil tank
visually before starting the engine. Running out of oil at sea is a cause for
potential disaster.
The required amount of engine oil is automatically supplied from the oil tank,
through the oil pump, according to the
engine running conditions. Gasoline is fed
over a separate feeding line.
ENOM00644-1
Replenishing oil in the engine oil tank.
1. Open the filler lid from the top cowl.
2. Open the oil tank cap.
3. Fill the oil tank with the genuine engine
oil.
4. After replenishment of the oil tank, be
sure to close the oil tank cap tightly.
2
3
ENOF00642-0
1. Air vent screw
2. From oil filter
3. Vinyl pipe
75, 90, 115
See page 44 for air removal from the oil
lines.
ENON00608-0
Note
Wipe off any spilled oil with a rag, and dispose of it.
PRE-OPERATING PREPARATIONS
39
ENOM00033-A
4. Break-In
Your new outboard motor and lower unit
require break-in for the moving components according to the conditions
described in the following time table.
Please refer to ENGINE OPERATION section (See page 43) to learn how to correctly start and operate the outboard
motor.
ENOW00024-A
DANGER
Do not operate the outboard motor in
closed area or area with no forced ventilation.
Exhaust gas emitted by this outboard
motor contains carbon monoxide that will
cause death if inhaled continuously. Inhaling the gas initially causes symptoms such
as feeling of sickness, drowsiness and
headache.
During operation of the outboard motor:
z Keep peripheral area well ventilated.
Throttle Position
Speed
z Always attempt to stay on the windward
side of emission.
ENOW00023-1
CAUTION
Operating the outboard motor without
break-in can shorten service life.
If any abnormality is experienced during
the break-in:
z Discontinue the operation immediately.
z Have the dealer check the product and
take proper action(s) if necessary.
6
ENON00008-0
Note
Proper break-in allows outboard motor to
deliver it full performance for longer service
life.
1–10 min
10 min – 2 hrs
2–3 hrs
3–10 hrs
After 10 hrs
Idle
Less than 1/2
throttle
Less than 3/4
throttle
3/4 throttle
Full throttle
available
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
40
PRE-OPERATING PREPARATIONS
ENOM00039-0
1
5. Warning system
If outboard motor encounters an abnormal
condition of fault, the warning horn will
emit a continuous beep or intermittent
short beeps and the warning lamp (LED)
will synchronize with the horn and engine
speed will be limited (engine will not be
stopped).
See next page for conditions which will
lead to an abnormal condition or fault.
ENOM00040-B
6
Location of warning horn and
lamp
„ Warning horn
RC model: Located inside the remote control.
Multi-Function tiller handle model: Located
in the tiller handle. *Only for 30, 40, 50
„ Warning lamp (LED)
RC model: Located in the tachometer.
Multi-Function tiller handle model: Located
in the tiller handle. *Only for 30, 40, 50
1
ENOF00851-0
1. Warning lamp
ENOF00852-0
1. Warning lamp
PRE-OPERATING PREPARATIONS
41
ENOM00041-C
Warning indicators, faults and remedy
Warning indicators
ESG
Description of faults
or notice
Remark
Remedy
Sound
A
lamp
B
lamp
C
lamp
Continuous
ON
ON
ON
-
Normal system test
when key on
1 second
Continuous
-
-
-
High
speed
ESG
Engine speed exceeds
maximum
allowable RPM
Approx.
6,000 r/min
Intermittent (3
beeps for
every 2
minutes)
Flashing
-
-
Low
speed
ESG
Low oil level
2
Continuous
-
Flashing
-
Low
speed
ESG
Cooling water temp. is high
3
Continuous
-
Flashing
-
Forced
idling
Cooling water temp is
abnormally high
3
-
-
-
Flashing
-
Battery voltage is low
Engine is stopped
under 9V
4
-
-
Flashing
-
Low
speed
ESG
Battery voltage is low
Approx. 10V or less
4
-
Flashing
Flashing
Flashing
Low
speed
ESG
Malfunction of sensor
5
-
Flashing
Flashing
Flashing
Forced
idling
Malfunction of sensor
5
-
Flashing
Flashing
Flashing
-
Malfunction of electrical
part or sensor
5
1
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 not to
ignite the spark plug, therefore, the engine speed varies and be controlled under 6000min-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 not to ignite the spark plug, and disable
fueling therefore, the engine speed varies and be controlled under 3000min-1 (rpm).
6
42
6
PRE-OPERATING PREPARATIONS
Remedy
1. Reduce the throttle to less than half
opening, and move to safe place
quickly, and stop the engine.
Check the propeller for bent or damaged blades.
Consult an authorized dealer if engine
shows the same result even after
replacing propeller with new one.
2. Move to safe place quickly, and stop
the engine.
Check the engine oil level, and add
engine oil if necessary.
3. Move to safe place quickly, and check
the discharge of cooling water from the
water check port at idle speed and
stop engine.
Remove any foreign matter on the gear
case and propeller if necessary. Consult an authorized dealer if no discharge of cooling water.
4. Charge or replace the battery.
5. Consult an authorized dealer.
ENOW00025-A
CAUTION
z Low speed ESG ON: Engine speed will
be limited to 3000 min-1 (rpm), however
you should not continue to run engine.
z High speed ESG ON: Engine speed will
be limited to 6000 min - 1 (rpm) and
engine will run rough until throttle is
reduced.
43
ENGINE OPERATION
execute the following operation for forcedly feeding the engine oil to the oil line
before starting the engine.
ENOM00042-0
Before starting
ENOW00022-A
ENOM00657-0
CAUTION
The engine oil is drained for shipping from
the factory. Be sure to fill the engine to the
proper level before starting engine. (To
properly fill the engine with oil follow the
instructions. See page 70)
1
2
30, 40, 50 type
a. Disconnect the link rod by turning the
rod snap interlocking with the oil pump
as shown in the figure.
b. Make sure that the oil pump control
lever is set at open side position.
c. Idle the engine for more than 30 minutes.
d. Reset the link rod to the advancer arm.
30, 40, 50
1
2
4
3
3
ENOF00641-0
5
1. Genuine of recommended engine oil
2. Filler lid
3. Oil tank cap
ENOW00027-A
CAUTION
Before starting engine for the first time
after reassembling engine or off-season
storage, disconnect stop switch lock and
crank approximately 10 times in order to
prime the oil pump.
ENOM00656-A
1. Engine oil feeding
When the engine is new or have been left
without operation for a long time, or just
after the engine is overhauled, be sure to
6
1.
2.
3.
4.
5.
6.
7.
Rod snap
Link rod
Advancer arm
Cable joint
Throttle cable
R shaped pin
Nut
7
ENOF00651-0
7
44
ENGINE OPERATION
c. Within 2 seconds after removing the
stop switch lock, quickly repeat pulling
and pushing back the stop switch knob
2 times.
d. The buzzer sounds 3 times and the oil
pump is actuated for about 1 minute for
pressure feed or oil.
e. When air is completely removed from
the oil line, turn off the key switch.
1
2
3
4
5
6
ENOF00652-0
1.
2.
3.
4.
5.
6.
75, 90, 115
Air vent screw
Link rod
From oil filter
Vinyl pipe
Open side
Control lever
OFF
ON
START
ENOM00658-0
7
75, 90, 115 type (Electric oil pump)
Check to see by eyes if the oil line from the
oil tank to the cylinder block ((1) to (4) in
the 75, 90, 115 model) gets air inside or
not. If there is air inside the oil line, remove
it as follows.
z Oil tank-Filter (1)
a. Fill the oil tank up with the specified oil.
b. Remove the pipe of the filter inlet side at
the part (A).
c. Since the oil drains out with air, wait
until air is completely discharged from
the pipe. After checking for no air in the
oil line, reconnect the pipe as it was and
attach the clip to secure pipe connection.
z Filter-Oil Pump-Cylinder Block
[75, 90, 115: (2)–(4)]
a. Turn on the key switch.
b. Within 1 second after the buzzer stops
sounding, remove the stop switch lock.
2
1
3
ENOF00653-0
1. Look
2. Key switch
3. Stop switch knob
A
3, 4
1
2
ENOF00654-0
1.
2.
3.
4.
Oil tank-Filter
Filter-Oil Pump
75,90:Oil Pump-Cylinder Block (seven lines)
115:Oil Pump-Cylinder Block (nine lines)
ENGINE OPERATION
45
ENOM00044-B
2. Fuel feeding
3
2
ENOW00029-A
WARNING
1
When opening fuel tank cap, be sure to follow 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.
ENOF01316-0
1. Fuel connector
2. Pull
3. Insert
ENOW00947-0
2
CAUTION
1
When using a separate tank, be sure that
the fuel line is not kinked and is connected
securely.
7
1. Full open the air vent screw on the fuel
tank cap.
ENOF00861-A
1. Pull
2. Insert
1
2
3. Squeeze primer bulb until it becomes
stiff to feed fuel to vapor separator.
Direct arrow mark upward when priming.
1
ENOF00027-A
1. Air vent screw
2. Fuel tank cap
2. Connect the fuel connector to the
engine and fuel tank.
2
ENOF00862-0
1. Engine side
2. Fuel tank side
Do not squeeze primer bulb with engine
running or when the outboard motor is
tilted up. Otherwise, fuel could overflow.
46
ENGINE OPERATION
ENOM00045-A
ENOW00032-A
3. Starting the engine
CAUTION
ENOW00036-A
CAUTION
When the engine is started in the test tank,
to avoid over heating and water pump
damage, be sure the water level is at least
10 cm (4 in.) above the anti ventilation
plate.
And be sure to remove the propeller, when
starting the engine in the test tank. (See
page 79)
Run the engine only at idling.
Do not hold turning starter motor for more
than 5 seconds, or the battery may be consumed, potentially making the engine starting impossible and/or damaging the
starter.
If cranking over 5 seconds fails to start
engine, return main switch to “ON”, and
crank engine again after 10 seconds or
more.
Do not try to crank after engine has
started.
This model is provided with start in gear
protection.
ENON00010-0
Note
3
7
1
Start-in-gear protection prevents engine
from starting at other than neutral shift. Ingear starting of engine will move the boat
immediately, potentially leading to falling
down or causing passenger(s) to be thrown
overboard.
2
ENOF00863-0
1. Test tank
2. Water
3. Over 10 cm (4 in.)
ENOW00036-0
Tiller handle 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.)
CAUTION
Be sure to stop engine immediately if cooling water check port is not discharging
water, and check if cooling water intake is
blocked. Operating engine could lead to
overheating potentially leading to engine
damage. Consult an authorized dealer if
the cause cannot be found.
1
ENOF00864-0
1. Stop switch lock
ENGINE OPERATION
2. Insert the main switch key.
3. Set the control lever in the Neutral
position.
1
N
F
R
next operation after returning the main
switch key to “OFF”.
5. Turn the main switch key to ON position and confirm three warning lamps
light up with buzzer sound and then go
off.
6. Turn the main switch key to START
position and release the key when the
engine has started. The key returns to
the original position, automatically.
N
ENOF00865-0
F
R
1. Shift lever
4. Set the throttle grip to START position.
1
2
OFF
ON
START
PUSH TO IDLE CHANGE
ENOF00867-0
1
1. Main switch key
2. Warning lamp
ENOF00866-0
1. Throttle grip
ENON00613-A
Note
Turn the throttle grip to the “START” (fully
closed), before turning the main switch key
to “ON”.
The wrong operation i.e. turn the main
switch key to “ON” on the condition that the
handle grip or accel lever is opened will be
memorized by ECU (engine control unit).
If this wrong operation has done repeatedly,
it will have a possibility that the three warning lamps flash. In this case, turn the throttle
grip to “START” (fully closed) and start the
47
ENOW00032-1
CAUTION
Do not hold turning starter motor more
than 5 seconds, or the battery may be consumed, potentially making the engine starting impossible and/or damaging the
starter.
If cranking over 5 seconds fails to start
engine, return main switch to “ON”, and
crank engine again after 10 seconds or
more.
7. Check the cooling water from cooling
water check port.
7
48
ENGINE OPERATION
3. Set the control lever in the Neutral
position. Do not raise the free throttle
lever when starting the engine.
1
2
N
2
1
F
ENOF00664-0
R
5
4
1. Idle port
2. Cooling water check port 30, 40, 50
3
6
7
ENOF00870-0
2
1
7
ENOF00665-0
1. Idle port
2. Cooling water check port 75, 90, 115
Side mount RC type
1.
2.
3.
4.
5.
6.
7.
Neutral (N)
Control lever
Fully opened (Forward)
Fully opened (Reverse)
Free throttle lever
Main switch key
Stop switch
4. Turn the main switch key to ON position and confirm three warning lamps
light up with buzzer sound and then go
off.
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
ENOF00851-0
1. Warning lamp
1
ENOF00869-0
1. Stop switch lock
2. Insert the main switch key.
5. Turn the main switch key to START
position and release the key when the
engine has started. The key returns to
the original position, automatically.
ENGINE OPERATION
49
ENOM00042-A
Emergency starting
1
3
*Only for 30, 40, 50
2
ENOW00099-A
WARNING
ENOF00871-0
1. ON
2. START
3. OFF
ENON00035-A
Note
The free throttle lever can not be raised
when the control lever shift is in Forward or
Reverse.
6. Check the cooling water from cooling
water check port.
When the emergency starter rope is used
for starting engine;
z Start in gear protection does not work.
Be sure to shift is at neutral position.
Otherwise the engine will move the boat
immediately and cause personal injury.
z Be careful that your clothes or other
items do not get caught in the rotating
engine parts.
z To prevent accident and injury by rotating parts, do not re-attach flywheel
cover and the top cowl after the engine
has been started.
z Do not pull starter rope if any bystander
is behind. The action can injure the
bystander.
z Attach engine stop switch lanyard to
clothing or any part of body like arm
before starting engine.
1. Remove the top cowl.
2
1
ENOF00664-0
1. Idle port
2. Cooling water check port 30, 40, 50
ENOF01345-0
2
1
ENOF00665-0
1. Idle port
2. Cooling water check port 75, 90, 115
2. Remove the flywheel cover.
7
50
ENGINE OPERATION
6. Set the control lever in the Neutral
position.
7. Pull the starter handle slowly until you
feel engagement, keep pulling till you
feel less resistance. Then pull it quickly.
8. After engine starts, do not reinstall flywheel cover and top cowl.
ENOM00043-A
ENOF00661-0
3. Insert the knotted end of the starter
rope into the notch in the flywheel and
wind the rope around the flywheel several turns clockwise.
7
4. Tie a loop in the another end of the
emergency starter rope and attach
socket wrench that is included in the
tool kit.
4. Warming up the engine
ENOW00932-0
CAUTION
Be sure to check that cooling water is
coming out of 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) :
below 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.
ENOF00663-0
ENOW00860-0
CAUTION
Be sure to keep the harness away from the
rotation parts.
5. 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
2
ENOF00664-0
1. Idle port
2. Cooling water check port 30, 40, 50
ENGINE OPERATION
51
ENOM00046-A
5. Forward, reverse, and
acceleration
2
ENOW00037-0
WARNING
1
ENOF00665-0
1. Idle port
2. Cooling water check port 75, 90, 115
ENOM00044-0
Before shifting into forward or reverse,
make sure that boat is properly moored
and outboard motor can be steered fully to
the right and left. Make sure that no swimmer(s) is ahead or astern of the boat.
ENOW00038-A
Engine speeds
Idling speed after warming up.
Remark: In case of cold engine starting,
idling speed is increased about 400 min-1
(rpm) for several minutes.
Clutch in (In gear)
Clutch off (Out of gear)
800 min-1 (rpm)
800 min-1 (rpm)
ENOM00-0
Trolling engine speed control
function
If the main switch key is pressed for 1 (one)
second during idling or trolling operation,
engine revolution change.
ON
WARNING
z Attach other end of emergency stop
switch lanyard to the operator's PFD
(Personal Flotation device) or arm and
keep it attached during cruising.
z Do not attach the tether to a part of
clothing that can be torn easily when
pulled.
z Arrange the tether so that will not be
caught by any object when pulled.
z Be careful not to pull the tether accidentally during cruising. Unintentional stop
of engine can cause loss of control of
outboard motor. Rapid loss of engine
power can lead to falling down or causing passenger(s) to be thrown overboard.
ENOW00042-0
1seconds
ENOF00876-0
Each time the main switch key is pressed
in the above manner, engine speed
changes as follows.
Starting
700min-1 (rpm) Ѝ 800min-1 (rpm)
ЌࠉࠉࠉࠉࠉЎ
800min-1 (rpm) Ћ 900min-1 (rpm)
WARNING
z Do not shift into Reverse during planing,
or control will be lost leading to serious
personal injury, boat may swamp, and/or
hull may be damaged.
z Do not shift into Reverse during cruising, or control may be lost, falling down
or causing passenger(s) to be thrown
overboard. Leading to serious personal
injury, and steering system and/or shifting mechanism may be damaged.
7
52
ENGINE OPERATION
ENOW00861-0
ENOM00890-A
WARNING
Do not shift at high boat speed, or control
may be lost, falling down or causing passenger(s) to be thrown overboard. Leading
to serious personal injury.
ENOW00862-0
CAUTION
Gear and clutch damage may occur if shifting at high engine speed.
Engine must be in the slow idle position
before shifting is attempted.
ENOW00863-0
CAUTION
7
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.
Tiller handle type
ENOW00865-0
CAUTION
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 inoperative unless the throttle grip
is in the fully closed position. (Multi-function tiller type)
ENOW00867-0
WARNING
Sudden acceleration and deceleration may
cause passenger(s) to be thrown overboard or falling down.
1
R
N
F
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.
ENOF00865-A
1. Shift lever
ENOW00864-0
CAUTION
Do not increase engine speed unnecessarily when the shift is in neutral and reverse,
or engine damage may occur.
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.
ENGINE OPERATION
53
Acceleration
ENOW00867-0
7
WARNING
8
Sudden acceleration and deceleration may
cause passenger(s) to be thrown overboard or falling down.
Open throttle grip gradually.
1
2
N
F
7
3R
6
5
4
ENOF00877-0
1.
2.
3.
4.
5.
6.
7.
8.
1
ENOF00878-0
1. Throttle grip
1
ENOF01119-0
1. Throttle grip
ENOM0900-0
Side mount RC type
ENOW00867-0
WARNING
Sudden acceleration and deceleration may
cause passenger(s) to be thrown overboard or falling down.
Forward (F)
Neutral (N)
Reverse (R)
Fully opened (Forward)
Fully opened (Reverse)
Free throttle lever
Control lever
Lock button
Forward
1. Quickly push the control lever to the
Forward (F) position 32°, where the
gear is connected, while lifting up on
the lock button 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 is connected, while lifting up on
the lock button located under the control lever grip.
2. Further rearward motion will open the
throttle.
7
54
ENGINE OPERATION
Acceleration
ENOW00867-A
CAUTION
Sudden acceleration and deceleration may
cause passenger(s) to be thrown overboard or falling down.
Open control lever gradually.
1
ENOF00866-0
N
1. Throttle grip
R
F
1
2
ENOF00881-0
7
1. Control lever
2. Main switch key
ENOM00049-A
6. Stopping the engine
2. Put the shift lever in the Neutral position.
Run the engine for 2-3 minutes at
idling speed for cooling down if it has
been running at full speed.
3. Turn the main switch key to the OFF
position or push the stop switch. ( Do
not forget to turn the key off).
N
2
ENOW00868-0
R
WARNING
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.
It can also cause loss of boat 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.
F
3
OFF
ON
START
PUSH TO IDLE CHANGE
1. Throttle grip
2. Shift lever
3. Main switch key
ENOF00880-0
ENGINE OPERATION
Side mount RC type
1. Put the
position
minutes
down if
speed.
control lever in the Neutral
and run the engine for 2-3
at idling speed for cooling
it has been running at full
55
Emergency engine stopping
Remove stop switch lock to stop the
engine.
N
F
R
1
N
R
F
1
2
2
ENOF00881-0
ENOF00883-0
2. Turn the main switch key to the OFF
position or push the stop switch. ( Do
not forget to turn the key off).
1. Stop switch
2. Stop switch lock
7
ON
OFF
START
1
2
2
ENOF00884-0
ENOF00882-0
1. Control lever
2. Main switch key
ENOW00869-0
WARNING
After stopping the engine:
z Close the air vent screw on the fuel tank
cap.
z Disconnect the fuel connector of the
engine and the fuel tank.
z Disconnect the battery cord, after each
use.
1. Stop switch
2. Stop switch lock
ENOM00910-0
Spare emergency stop switch lock
A spare emergency stop switch lock is
provided in the tool bag.
When used as described, the emergency
stop switch clip and emergency stop
switch lanyard system stops the engine if
the operator falls away from the controls.
When an operator falls into water, be sure
to use emergency stop switch lock of the
spare.
Be sure to confirm the spare stop switch
56
ENGINE OPERATION
lock is in the tool bag before begin to operate.
ENOF00891-0
ENOM00920-0
ENOF00893-0
7. Steering
ENOM00050-0
8. Trim angle
ENOW00870-0
WARNING
ENOW00043-A
Sudden steering may cause passenger(s)
to be thrown overboard or falling down.
7
Tiller handle type
Right turn
Move the tiller handle to the left
Left turn
Move the tiller handle to the right.
WARNING
z Adjust the trim angle when the engine is
stopped.
z Do not put hand or finger in between
outboard motor body and clamp bracket
when adjusting trim angle to prevent
injury in case the outboard motor body
falls.
z Unsuitable trim position can cause loss
of control of boat. When testing a trim
position, run boat slow initially to see if it
can be controlled safely.
ENOW00044-0
WARNING
ENOF00892-0
Remote control type
Right turn
Turn the steering wheel to the right.
Left turn
Turn the steering wheel to the left.
Excessive trim up or down may lead to
unstable boat operation, potentially causing the steering difficulty that leads to accident during cruising.
z Do not cruise at high speed if improper
trim position is suspected. Stop the boat
and readjust trim angle before continuing cruise.
z For outboard motor model with PTT
switch on the bottom cowl, do not oper-
ENGINE OPERATION
57
ate the switch during 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.
ENOF00053-0
„ Manual Tilt type
ENOM00052-0
Proper trim angle
The position of the thrust rod is correct if
the hull is horizontal during operation.
1
1
2
ENOF00051-1
1. Perpendicular to the water surface
ENOF00674-A
1. Thrust rod
2. Higher
3. Lower
„ Power Tilt type
ENOM00053-0
Improper trim angle (bow rises too
high)
Set the thrust rod lower if the bow of the
boat rises above horizontal.
2
3
1
ENOF00888-0
ENOF00052-0
ENOM00054-0
Improper trim angle (bow dips into the
water)
Set the thrust rod higher if the bow of the
boat is below horizontal.
1. Thrust rod
2. Higher
3. Lower
7
58
ENGINE OPERATION
Trim angle adjustment (Manual tilt
type)
The transom angle adjustment
1. Stop the engine.
2. Shift into neutral.
3. Raise the outboard motor to the tilt up
position.
4. Change the thrust rod position as following picture.
4. Change the trim lock pin position as
following picture.
2
1
ENOF01147-0
1. Snap pin
2. Thrust rod
1
2
7
3
ENOF01238-1
1. Push in
2. Rise the stopper
3. Pull out
5. Reinstall the thurst rod securely.
6. Operate the Power Tilt switch and
lower the outboard.
ENOM00060-A
9. Tilt up and down
ENOW00055-0
5. Reinstall the thurst rod securely.
6. Gentry lower the outboard.
Trim angle adjustment (Power tilt type)
The transom angle adjustment
1. Stop the engine
2. Operate the Power Tilt switch and
raise the outboard motor to the tilt up
position.
3. Lock the tilt with the Tilt stopper.
WARNING
Do not tilt up or down outboard motor
when swimmer(s) or passenger is near to
prevent them from being caught between
outboard motor body and clamp bracket in
case the outboard motor body falls.
ENOW00048-0
WARNING
When tilting up or down, be careful not to
place your hand between the swivel
bracket and the stern bracket.
Be sure to tilt the outboard motor down
slowly.
ENGINE OPERATION
59
ENOW00056-A
WARNING
When tilting up outboard motor with fuel
joint for over a few minutes, be sure to disconnect fuel hose, or fuel may leak, potentially catching fire.
ENOW00057-0
CAUTION
ENOF01317-0
Do not tilt up outboard motor while engine
operates, or no cooling water may be fed,
leading to engine seizure due to overheating.
ENON00921-0
Note
Before tilting the outboard motor up, after
stopping the motor leave it in the running
position for about a minute to allow water to
drain from inside the engine.
ENOM00063-0
Tilt down
Pull the reverse lock lever upward until it
stops. (This is the tilt down position.) Now,
lift up the outboard motor slightly, and then
allow gravity to lower it for you.
1
7
2
ENOM00062-A
Manual Tilt type (*30, 40, 50 only)
Tilt up
Push the reverse lock lever down until it
stops. (This is the tilt up position.) Now, tilt
the outboard motor all the way up until it is
locked in place.
3
ENOF00059-0
1. Reverse lock lever
2. Tilt up position
3. Tilt down position
1
ENOM00069-A
Power Trim & Tilt type
2
3
ENOF00059-0
1. Reverse lock lever
2. Tilt up position
3. Tilt down position
Tilt up
1. Operate the Power Trim & Tilt switch
and tilt the outboard motor up.
2. Lock the tilt with the Tilt stopper after
the outboard motor has been tilted up
Tilt down
1. Release the tilt stopper from the set-up
position while slightly tilting up outboard motor.
60
ENGINE OPERATION
2. Operate the Power Trim & Tilt switch
and tilt the outboard motor down until
the motor touches to the thrust rod.
UP
DN
ENOF00067-A
UP
ENOF01320-0
DN
ENOF00067-0
It is possible to tilt up or down in spite of
main switch “ON” or “OFF”.
30, 40, 50
ENOM00940-0
Manual relief valve
If the battery is dead, and the power tilt
switch thus inoperative, open the manual
valve completely in the Manual direction.
This will allow manual tilting of the outboard motor.
1
7
ENOW00872-0
WARNING
ENOF01318-0
Make sure the manual relief valve is closed
before operating the outboard motor. If the
manual relief valve is not closed, the outboard motor will tilt up when operated in
reverse.
1. Tilt stopper
75, 90, 115
1
ENOW00873-0
WARNING
ENOF01319-0
1. Tilt stopper
The outboard motor can also be tilted up
and down using the switch provided under
the bottom cowl.
Before opening the manual relief valve,
make sure nobody is under the outboard
motor. If the outboard motor is in the tilted
up position, it will tilt down suddenly if the
manual relief valve is loosened in the "Manual" direction.
ENGINE OPERATION
30, 40, 50
61
bracket and the clamp bracket. Be sure to
tilt the outboard motor down slowly.
ENOW00053-0
CAUTION
1
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 submerged.
ENOW00054-0
CAUTION
2
ENOF00070-1
Do not overtilt outboard motor when driving shallow water, or air may be sucked
through water inlet, potentially leading to
engine overheating.
1. POWER
2. MANUAL
7
75, 90, 115
1
1
ENOF01144-A
1. Water inlet
2
ENOF00679-0
1. POWER
2. MANUAL
ENOM00068-A
10.Shallow water operation
ENOW00051-0
WARNING
During shallow water operation, be careful
not to place your hand between the swivel
62
ENGINE OPERATION
Manual tilt type (*30, 40, 50 only)
1
1. Shallow water running position:
Put the reverse lock lever in the tilt up
position, and tilt up the outboard motor
to put the outboard motor in the shallow water running position.
2
3
1
2
ENOF00059-0
1. Reverse lock lever
2. Tilt up position
3. Tilt down position
3
ENOM00069-A
Power Tilt type
ENOF00059-0
7
1. Reverse lock lever
2. Tilt up position
3. Tilt down position
1. Operate the Power Tilt switch and tilt
the outboard motor up into desired
shallow water running position.
UP
DN
ENOF00067-A
UP
DN
ENOF00067-0
ENOF00668-0
2. Return to normal running position:
Put the reverse lock lever in the tilt
down position, slightly lift up the outboard motor, and then put it down.
REMOVING AND CARRYING THE OUTBOARD MOTOR
63
ENOM00070-A
1. Removing the outboard motor
ENOW00890-0
WARNING
Before installing the outboard motor on the
boat, hang the outboard motor with the
hoist or equivalent device by attaching the
engine hanger to the outboard.
Use the hoist with allowable load is 250 kg
(550 lbs) or above.
ENOW00064-0
CAUTION
Engine may be hot immediately after operating and could cause burns if touched.
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 battery
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.
ENOF01313-0
ENOM00071-A
2. Carrying the outboard motor
ENOW00933-0
WARNING
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.
ENOW00065-0
WARNING
Close air vent screw of fuel tank before
carrying or storing outboard motor and fuel
tank, or fuel may leak, potentially catching
fire.
8
64
REMOVING AND CARRYING THE OUTBOARD MOTOR
ENOW00066-A
ENOM00072-A
CAUTION
3. Traillering
Do not give a shock to an outboard motor
during transportation. It becames a cause
of breakage.
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.
ENOW00072-0
CAUTION
Trailering in the tilted position may cause
damage to the outboard motor, boat, etc.
ENOW00073-A
WARNING
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.
ENOF00075-1
8
ENOW00068-0
WARNING
ENOF01321-0
ENON00021-A
Note
z If the outboard motor must be laid down
be sure drain the fuel and engine oil,
then the port side faces down as shown
in the drawing above.
z Elevate power unit 2 inches to 4 inches if
traveling to avoid oil spillage.
Close air vent screw of fuel tank and fuel
cock before carrying or storing outboard
motor and fuel tank, or fuel may leak,
potentially catching fire.
ENOW00071-0
CAUTION
The tilt support device supplied on your
outboard motor is not intended for towing.
It is intended to support 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
ENOF00680-0
REMOVING AND CARRYING THE OUTBOARD MOTOR
65
in the normal running position or on a transom saver bar.
Tiller handle type
To prevent the outboard motor from moving when it is attached on a boat during
transport on a trailer, properly tighten the
steering friction lever (page 66).
2
1
ENOF00073-A
1. Ground clearance should be provided sufficiently.
2. Transom saver bar
ENOW00067-0
WARNING
Do not go under outboard motor tilted up
even if it is supported by support bar, or
accidental fall of outboard motor could
lead to severe personal injury.
8
66
ADJUSTMENT
causing an accident and could lead to
severe injury.
ENOM00073-A
1. Steering friction
Friction adjustment of the throttle grip can
be made with the throttle adjustment
screw.
Tiller handle type
(*30, 40, 50 only)
ENOW00074-B
WARNING
Do not overtighten the steering friction
lever it could result in difficulty of movement resulting in the loss of control causing an accident and could lead to severe
injury.
Adjust this lever to achieve the desired
steering friction (drag) on the tiller handle.
Move lever towards (2) to decrease friction
and move lever towards (3) to increase
friction.
3
2
1
ENOF00911-0
1. Throttle friction adjustment screw
2. Decrease
3. Increase
ENOM00075-0
3. Remote control lever friction
1
ENOW00074-C
WARNING
2
3
Do not overtighten the remote control
throttle friction adjustment screw or it
could result in difficulty of movement
resulting in the loss of control causing an
accident and could lead to severe injury.
9
ENOF00910-0
1. Steering friction lever
2. Decrease
3. Increase
ENOM00074-A
2. Throttle grip friction
*30, 40, 50 only
ENOW00074-B
WARNING
Do not overtighten the throttle adjustment
screw or it could result in difficulty of
movement resulting in the loss of control
To adjust the friction of the remote control
lever, turn the throttle friction adjustment
screw on the front of the remote control.
Turn clockwise to increase the friction and
counter-clockwise to decrease it.
ADJUSTMENT
Side mount type
2
the anti-ventilation plate.
z If the boat veers toward the left direct
the trim tab towards A (left from rear of
boat).
z If the boat veers toward the right direct
the trim tab towards B (right from rear of
boat).
3
1
67
ENOF00078-0
1. Throttle friction adjustment screw
2. Decrease
3. Increase
ENOM00076-0
4. Trim tab adjustment
ENOW00076-1
WARNING
z Be 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.
z Be sure to lock outboard motor when it
is tilted up, otherwise accidental fall of
outboard motor could lead to severe
personal injury.
z Do not go under outboard motor tilted
up and locked, or accidental fall of outboard motor could lead to severe personal injury.
ENOW00075-1
WARNING
Inappropriate adjustment of trim tab could
cause steering difficulty. After installing or
readjusting trim tab, check if steering load
is even.
If straight-line cruising can not be
achieved, adjust the trim tab located under
1
1
ENOF00912-A
1. Trim tab
ENON00022-A
Notes
z After adjustment securely tighten the
trim tab fixing bolt.
z Check for looseness of the bolt and the
trim tab at regular intervals.
9
68
INSPECTION AND MAINTENANCE
ENOM00077-0
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 maintenance
schedules that follow.
ENOW00077-0
CAUTION
10
z Your personal safety and that of your
passengers depends on how well you
maintain your outboard motor. Carefully
observe all of the inspection and maintenance procedures described in this section.
z The maintenance intervals shown in the
checklist apply to an outboard motor in
normal use. If you use your outboard
motor under severe conditions such as
frequent full-throttle operation, frequent
operation in brackish water, or for commercial use, maintenance should be performed at shorter intervals. If in doubt,
consult your dealer for advice.
z We strongly recommend that you use
only genuine replacement parts on your
outboard motor. Damage to your outboard motor arising from the use of
other than genuine parts is not covered
under the warranty.
INSPECTION AND MAINTENANCE
69
ENOM00703-0
1. Daily inspection
Perform the following checks and inspection before and after use.
ENOW00078-1
WARNING
Do not use outboard motor if any abnormality is found during pre-operation check
otherwise it could result in severe damage
to the motor or severe personal injury.
Item
Fuel System
Fuel Tank Cap
Lubrication
System
Electrical
Equipment
Throttle System
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Clutch and
Propeller System
Installation of
Motor
Power Trim &
Tilt
Cooling Water
Tools and
Spares
Steering
Devices
•
•
•
•
•
Points to Check
Check the amount of fuel in the tank.
Check for dust or water in the fuel filter.
Check rubber pipes for oil leakage.
Fuel
Check for crack, leakage, damage in the fuel tank cap.
Check for crack, damage in the gasket and tether.
Check for leakage at full close.
Check for ratchet performance.
Check the amount of engine oil in the oil tank.
Check for dust or water in the oil filters.
Check the spark plugs for dirt, wear and carbon built-up.
Spark plugs (30·40·50·75·90) NGK IZFR6Q (0.8 mm gap) (0.0315 in)
Spark plugs (115) NGK IZFR5J (0.8 mm gap) (0.0315 in)
Check if the main switch functions normality.
Check if the battery electrolyte level and specific gravity are normal
Check for loose connections on battery terminal.
Check if the stop switch functions normally and make sure the lock
plate is present.
Check cords for loose connections and damage.
Check if the magneto works normally when turning the throttle grip,
and also check links for looseness.
Check if the clutch engages correctly when operating the Remote
Control. (or Shift lever)
Check the propeller for bent or damaged blades.
Check if the propeller nut is tightened and the split pin is present.
Check all the motor installation bolts with the boat.
Check the thrust rod installation.
Check working of the tilt up and down of the motor.
• Check that cooling water is discharged from the cooling water check
port after the engine has started.
• To be prepare tools and spare parts for replacing spark plugs, propeller, etc.
• Check if the spare rope is provided.
• Check working of steering handle and remote control.
Remedy
Replenish
Clean
Replace
Replace
Replace
Replace
Replace
Replenish
Clean
Clean or replace
Remedy or replace
Replenish or recharge
Retighten
Remedy or replace
Correct or replace
Correct
Adjust
Replace
Tighten
Tighten
10
70
INSPECTION AND MAINTENANCE
Item
Other parts
Points to Check
• Check if the anode and trim tab are securely installed.
• Check the anode and trim tab for corrosion and deformation.
Remedy
Repair if necessary
Replace
ENOM00082-A
Engine oil replenishing
1
ENOW00079-A
2
CAUTION
z Do not add engine oil of brand and grade
other than existing one. In case engine
oil of other brand or grade is added,
drain all oil and ask dealer for treatment.
z In case other than engine oil such as
gasoline is put in the oil chamber, empty
the chamber and ask dealer for treatment.
z When replenishing engine oil, be careful
not to allow entry of foreign matters
such as dust or water into oil chamber.
z Wipe off engine oil well immediately if
spilled and dispose of it in accordance
with local fire prevention and environment protection regulations.
z Do 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 and potentially lead to engine
damage.
10
If the oil level is low, or at lowest mark, add
recommended oil to the oil tank.
1. Open the filler lid from the top cowl.
2. Open the oil tank cap
3. Fill the oil tank with the genuine engine
oil.
4. After replenishing of the oil tank, be
sure to close the oil tank cap tightly.
3
ENOF00641-0
1. Genuine of recommended engine oil
2. Filler lid
3. Oil tank cap
ENOM00083-A
Washing outboard motor
ENOW00081-0
WARNING
Do not start engine without removing propeller, or accidentally turning propeller
could cause personal injury.
ENOW00082-0
WARNING
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.
INSPECTION AND MAINTENANCE
ENOW00920-0
CAUTION
When washing the outboard motor, be
careful not to spray the water inside of the
top cowl, especially electrical components.
ENON00026-0
Note
71
4. Put the shift lever in the neutral position
and start the engine. Continue flushing
the outboard motor for 3 to 5 minutes
at idling.
5. Stop the engine and water supply.
Remove the flushing attachment and
tape.
30, 40, 50
It is recommended to check chemical properties of water on which your outboard
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 after every cruising or before storing outboard motor for long time. Before
flushing, remove the propeller and the forward thrust holder.
1
ENOF01324-0
1. Flushing attachment
ENOM00085-B
Flushing attachment (gear case)
30, 40, 50
75, 90, 115.
ENOW00922-0
1
CAUTION
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 water plug from the gear
case, and screw in the flushing attachment.
3. Attach the flushing attachment and
connect a water hose. Turn on the
water and adjust the flow (Be sure to
seal the water inlet and sub water inlet,
located in the gear case with tape)
10
ENOF01325-0
1. Flushing attachment
72
INSPECTION AND MAINTENANCE
ENOM00085-C
ENOM00085-A
Flushing attachment (bottom cowl)
*75, 90, 115
Flushing by test tank
ENOW00081-0
ENOW00921-0
WARNING
CAUTION
Do not operate the engine when flushing
the outboard motor with a flushing attachment as this can cause damage to the outboard motor.
Do not start engine without removing propeller, or accidentally turning propeller
could cause personal injury.
ENOW00082-0
WARNING
ENOW00922-0
CAUTION
To prevent the engine from starting when
you are near the propeller, remove the stop
switch lock.
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-A
10
1. Tilt down the outboard motor.
2. Remove the flushing connector cap
from the outboard motor, and screw in
the flushing attachment.
3. Attach the flushing attachment and
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.
75, 90, 115
CAUTION
When the engine is started in the test tank,
to avoid over heating and water pump
damage, be sure the water level is at least
10 cm (4 in.) above the anti ventilation
plate.
And be sure to remove the propeller, when
starting the engine in the test tank. (See
page 79)
Run the engine only at idling.
3
1
2
ENOF00863-0
1. Test tank
2. Water
3. Over 10 cm (4 in.)
1
ENOF01326-0
1. Flushing attachment
INSPECTION AND MAINTENANCE
ENOM00950-0
Fuse replacement
73
30, 40, 50.
ENOW00923-0
CAUTION
Before replacing a fuse, disconnect the
battery cable from the battery negative (-)
terminal. Failure to do so may cause a
short-circuit.
ENOW00924-0
CAUTION
1
Never use a fuse with a rating that exceeds
the specified rating as this could cause
serious damage to the electrical system.
ENOF01327-0
If a blown fuse is detected, try to determine the cause for this and correct it. If the
cause for the problem is not corrected, the
fuse will likely blow again.
If the fuse continues to blow, request an
authorized Tohatsu dealer to inspect the
outboard motor.
1. Stop the engine and disconnect the
battery cable from the battery negative
(-) terminal.
2. Remove the engine cover.
3. Remove the fuse box lid.
4. Remove the fuse and check it. If the
fuse is blown, replace it with a fuse of
the same specified rating. The outboard motor is supplied with spare
fuses in the spare fuse holder.
1. Blown fuse
75, 90
10
1
ENOF01329-0
1. Blown fuse
74
INSPECTION AND MAINTENANCE
115
1
ENOF01330-0
1. Blown fuse
10
INSPECTION AND MAINTENANCE
75
ENOM00708-0
2. Periodic inspection
It is important to inspect and maintain your outboard motor regularly. At each interval on
the chart below, be sure to perform the indicated servicing. Maintenance intervals should
be determined according to the number of hours or number of months, whichever comes
first.
For periodic inspection and maintenance, consult your servicing dealer.
Inspection intervals
First 20
Every 50 Every 100 Every 200
hours of 1 hours of 3 hours of 6 hours of 1
month
months
months
year
Description
z
Fuel filter
z
High pressure fuel
filter*1
Fuel System/
Compression System
Engine oil
system
Lower Unit
Replace
z
Replace every 200 hrs or 2 years
Check and clean or Replace if necessary
z
z
Replace
z
Fuel tank
z
z
z
z
Clean
z
z
z
z
Check and clean or Replace if necessary.
z
z
z
z
Check and clean or Replace if necessary.
Air filter*1
z
z
Check and clean or Replace if necessary.
Drive belt*1
z
z
Check and Replace if necessary.
z
z
Check and replace defective parts if
necessary.
z
z
Check and replace defective parts if
necessary.
z
z
Remove carbon deposits or Replace if
necessary.
z
z
Check for salt deposits and the battery
cable condition.
z
z
Check installation, fluid quantity, gravity.
Check and clean or Replace if necessary.
Fuel tank cap
Fuel pump
*1
Pressure*1
Spark plug
z
Starter motor*1
Battery
z
Oil tank
z
z
z
Oil pipe
z
z
z
Oil filter
z
z
z
Check and clean or Replace if necessary.
Propeller
z
Gear oil
Replace
z
Water pump*1
z
z
z
z
Check for bent blades, damage, wear.
Replace
z
Replace
z
Change or replenish-oil and check for
water leaks.
z
z
Check for wear or damage.
z
z
Check and Replace if necessary.
z
z
Check & replenish oil, manually operate
z
z
z
Check function
z
z
z
Retighten
z
Thermostat*1
Power trim & tilt *1
z
Warning system*1
Bolts and Nuts
Check and clean or Replace if necessary.
z
Air Pressure*1
Starting System
Replace
z
Piping/Hoses
Fuel
Ignition
Inspection procedure
z
Remarks
Entire cartridge
Including filter
0.8–0.9 mm
(0.031–0.035 in)
10
Replace impeller
every 12 months.
76
INSPECTION AND MAINTENANCE
Inspection intervals
Description
First 20
Every 50 Every 100 Every 200
hours of 1 hours of 3 hours of 6 hours of 1
month
months
months
year
Inspection procedure
Sliding and Rotating Parts.
Grease Nipples
z
z
z
z
Apply and pump in grease.
Outer Equipment
z
z
z
z
Check for corrosion.
z
z
z
Check for corrosion and deformation.
Anode
Remarks
Replace if necessary.
*1: Have this handled by your dealer
ENON00030-0
Note
Your outboard motor should receive careful, and complete inspection at 300 hours. This is the best
time for major maintenance procedures to be carried out.
ENOM00093-A
Fuel filters and fuel tank cleaning
ENOW00093-A
1
WARNING
10
Gasoline and its vapors are very flammable
and can be explosive.
z Do not start this procedure while engine
is operating or hot even after stopping it.
z Place fuel filter away from every source
of ignition such as sparks or open
flames.
z Wipe off gasoline well immediately if
spilled and dispose of it in accordance
with local fire prevention and environment protection regulations.
z Install fuel filter with all related parts in
place, or fuel leak could occur, leading
to catching fire or explosion.
z Check fuel system regularly for leakage.
z Contact 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.
6
2
3
4
5
ENOF00096-B
1.
2.
3.
4.
5.
6.
Body
O-ring
Filter
O-ring
Cup
Arrow to indicate fuel flow direction
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.
INSPECTION AND MAINTENANCE
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 the fuel pickup elbow of the
fuel tank by turning it counterclockwise
2. Clean the fuel filter and check the Oring. Replace it if necessary.
3. Reassemble all parts.
77
3. Refit the pipes to the oil tank and
pumps, and then fill up with new
engine oil.
4. For air purging, refer to ‘’Engine oil
feeding’’ (See page 38)
30, 40, 50
1
1
ENOF01346-0
1. Oil filter
2
75, 90, 115
10
ENOF00926-0
1. Fuel pick up
2. Filter
ENOM00725-0
Oil filter
Oil filter and oil tank. Check the oil tank
and/or filter for entrapped water and dust.
1. Disconnect all pipes between the oil
tank and oil pump.
2. Clean out foreign matter.
1
1. Oil filter
ENOF01347-0
78
INSPECTION AND MAINTENANCE
75, 90, 115
ENOM00098-A
Gear oil replacement
ENOW00094-0
WARNING
z Be 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.
z Be sure to lock outboard motor if it is
tilted up, or accidental fall of outboard
motor could lead to severe personal
injury.
z Do not go under outboard motor tilted
up 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.
30, 40, 50
ENOF01332-0
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.
30, 40, 50
10
ENOF01333-0
ENOF01331-0
INSPECTION AND MAINTENANCE
75, 90, 115
79
75, 90, 115
ENOF01332-0
ENOF01334-0
4. Install the upper oil plug, and then
remove oil tube nozzle and install the
lower oil plug.
ENOW00095-0
CAUTION
Do not reuse oil plug gasket. Always use
new gasket and tighten oil plug properly to
prevent entry of water into lower unit.
ENOW00928-0
CAUTION
Wipe off gear oil well immediately if spilled
and dispose of it in accordance with local
fire prevention and environment protection
regulations.
ENON00032-0
Note
If water in the oil, giving it a milky colored
appearance. Contact your dealer.
30, 40, 50
ENON00033-0
Note
Use genuine gear oil or the recommended
one (API GL-5: SAE #80 to #90).
Required volume 30, 40, 50: approx. 500
mL (16.9 fl.oz), 75, 90, 115 approx. 900 ml
(30.4 fl.oz).
ENOM00086-A
Propeller replacement
ENOW00084-0
ENOF01331-0
WARNING
z Do not begin propeller removal and
installation procedure with spark plug
c a p s a t t a c h e d , s h i f t i n f o r w a rd o r
reverse, main switch at other than
10
80
INSPECTION AND MAINTENANCE
“OFF”, engine stop switch lock attached
to the switch, and starter key attached,
or engine could accidentally start leading to serious personal injury. Disconnect battery cable if possible.
z The propeller edge is thin and sharp.
Wear the groves during replacement to
protect your hands.
4. Apply water proof grease to the propeller shaft before installing a new propeller.
5. Install the thrust holder, propeller,
stopper, washer and propeller nut onto
the shaft.
30, 40, 50
ENOW00086-0
3
CAUTION
z Do not install propeller without thrust
holder, or propeller boss could be damaged.
z Do not reuse split pin.
z After installing split pin, spread the pin
apart to prevent it from falling out which
could lead to the propeller coming off
during operation.
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.
6
5
4
1
2
ENOF01315-0
1.
2.
3.
4.
5.
6.
Propeller
Thrust holder
Stopper
Washer
Propeller nut
Split pin
75, 90, 115
4 7
6
5
10
2
3
1
ENOF01336-0
ENOF00084-B
2. Remove the split pin, propeller nut and
washer.
3. Remove the propeller and thrust
holder.
1.
2.
3.
4.
5.
6.
7.
Propeller
Thrust holder
Bush
Stopper
Washer
Propeller nut
Split pin
INSPECTION AND MAINTENANCE
6. Tighten the propeller nut to specified
torque, and align one of grooves to
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 it.
ENOF00084-D
ENOM00087-A
Spark plugs replacement
ENOW00087-0
WARNING
z Do not reuse spark plug with damaged
insulation, or sparks can leak through
crack, potentially leading to electric
shock, explosion and/or fire.
z Do not touch spark plugs immediately
after stopping engine as they will be hot
and could cause severe bur ns if
touched. Allow motor to cool down first.
81
1.
2.
3.
4.
Stop the engine.
Remove the top cowl.
Remove the spark plug caps.
Remove the spark plugs by turning it
counter-clockwise, using a 5/8" (16
mm) socket wrench and handle that is
provided in tool bag.
5. Inspect the spark plug. Replace the
spark plug if the electrodes are worn or
i f t h e i n s u l a t o r s a re c r a c k e d o r
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
inches). If the gap is different, replace
the spark plug with a new one
Use spark plug with referring specification (See page 13)
1
2
ENOF00085-0
1. Electrode
2. Spark gap (0.8–0.9 mm, 0.031–0.035 in)
ENOW00929-0
CAUTION
Use only the recommended spark plugs.
Spark plugs which have an different heat
range may cause engine damage.
If the spark plug(s) is fouled, has carbon
build up, or is worn, it should be replaced.
When reusing spark plugs, remove dirt
from the electrodes and adjust spark gap
to specification.
7. Install the spark plug by hand and turn
it carefully to avoid cross-threading.
10
82
INSPECTION AND MAINTENANCE
8. Tighten the spark plug to the specified
torque.
ENON00028-0
Note
z Spark plug torque:
18.0 N·m (13.3 ft·lb) [1.84 kgf·m]
If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of
the correct torque is 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.
ENOF01337-0
10
INSPECTION AND MAINTENANCE
83
ENOM00088-A
Anode replacement
A sacrificial anode protects the outboard motor from electrolytic corrosion. Anode is
located on the gear case, cylinder etc.. When the anode is eroded more than 1/3 of original size, replace it.
ENON00029-0
Notes
z Never grease or paint the anode.
z At each inspection re-tighten the anode attaching bolt. As it is likely to be subjected to electrolytic
corrosion.
75, 90, 115
75, 90
30, 40, 50
*1
10
*2
75, 90, 115
*1
*1 : Both side
*2 : Handle by your dealer
ENOF01339-0
84
INSPECTION AND MAINTENANCE
ENOM00089-B
Power Tilt oil checking
40, 50
ENOW00088-0
WARNING
z Be 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.
z Be sure to lock outboard motor if it is
tilted up, or accidental fall of outboard
motor could lead to severe personal
injury.
z Do not go under outboard motor tilted
up and locked, or accidental fall of outboard motor could lead to severe personal injury.
2
1
ENOF00929-0
1. Oil cap
2. Oil level
75, 90, 115
ENOW00089-A
CAUTION
2
Do not unscrew the oil cap with the outboard motor tilted down. Pressurized oil in
the oil tank may spurt out.
10
Check the oil level in the reservoir tank
while the tank is kept in a vertical position.
1. Tilt the outboard motor up and lock the
tilt with the tilt stopper.
2. Remove the oil cap by turning counter
clockwise, then check if the oil level
reaches the bottom line of the plug
hole.
1
ENOF01340-0
1. Oil cap
2. Oil level
Recommended oil
Use an automatic transmission fluid or
equivalent.
Recommended oils are as shown below.
ATF Dexron III
Air purging from the Power Trim and
Tilt unit.
Entrapped air in the Power Tilt unit will
cause poor tilting movement and
increased noise.
INSPECTION AND MAINTENANCE
85
1. With the outboard motor mounted on
the boat, set the manual release valve
to the Manual side, and tilt the outboard motor manually up/down 5-6
times while checking the oil level.
2. When done, close the valve by turning
it clockwise towards the Power side.
30, 40, 50
1
2
ENOF00070-1
1. POWER
2. MANUAL
75, 90, 115
10
1
2
ENOF00679-0
1. POWER
2. MANUAL
86
INSPECTION AND MAINTENANCE
ENOM00960-0
Grease point
Apply water proof grease to the parts shown below.
30, 40, 50
10
ENOF01341-0
INSPECTION AND MAINTENANCE
ENOM00100-A
3. Off-season storage
ENOW00934-0
WARNING
z Be sure to disconnect fuel connector
except when operating engine.
z Fuel leakage is a fire or explosion hazard, which can cause serious injury or
death.
ENOW00097-0
WARNING
Be sure to use cloth to remove fuel remaining in the cowl and dispose of it in accord a n c e w i t h l o c a l f i re p re v e n t i o n a n d
environment protection regulations.
87
2. Remove the fuel hose from the outboard motor.
3. Drain all fuel from the fuel hoses, fuel
pump, fuel filter (See page 76) and
vapor separator (See page 88), 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.
4. Remove the spark plugs and put a teaspoon of engine oil or spray storage oil
into the combustion chamber through
the spark plug holes.
5. Turn the starter motor several turns to
lubricate inside the cylinder.
ENOW00930-0
ENOW00096-0
CAUTION
WARNING
Before servicing the motor for storage:
z Remove the battery cables.
z Remove the spark plug caps from the
spark plugs.
z Do not run the motor out of the water.
z Be sure to remove stop switch lock to
prevent ignited the spark plugs.
z Put a cloth to spark plug hole and wipe
up any spilled engine oil, when cranking
the outboard motor.
Before you put your outboard motor in
storage, it is a good opportunity to have it
serviced and prepared by your dealer.
Be sure to use fuel stabilizer while running
the motor before storage. (See page 88)
6. Change the gear oil in the gear case
(See page 78).
7. Apply grease to grease point (See
page 86).
ENOM00101-B
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.
10
88
INSPECTION AND MAINTENANCE
8. Stand the outboard motor up vertically
in a dry place.
1. Before adding fuel stabilizer additive,
drain the vapor separator (See
page 88).
2. Follow the instructions on the label
when adding the fuel stabilizer additive.
3. After adding the additive, let the outboard 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
ENON00891-0
Note
ENOF01321-0
ENON00021-A
Note
z If the outboard motor must be laid down
be sure drain the fuel and engine oil,
then the outboard motor on a cushion
as shown in the drawing below (See
page 64 and 88).
z Elevate power unit 2 inches to 4 inches if
traveling to avoid air intrusion in the
Power Trim and Tilt pump system.
10
ENOF00680-0
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.
If your motor is used occasionally, it is recommended to use a good fuel stabilizer in
every tank of fuel and keep the container full
to reduce condensation and evaporation.
ENOM00970-0
Fuel system draining
ENOW00028-A
WARNING
For details on handling fuel, contact an
authorized dealer.
Fuel and fuel vapors are extremely flammable and can be explosive.
z If fuel is spilled, wipe it up immediately.
z Keep the fuel tank well away from
sources of ignition, e.g. sparks or open
flames
z Perform all work outdoors or in a well
ventilated place.
ENOW00097-0
WARNING
Be sure to use cloth to remove fuel remaining in the cowl and dispose of it in accordance with local fire prevention and
environment protection regulations.
INSPECTION AND MAINTENANCE
1. Disconnect the fuel hose from the outboard motor.
2. Remove the top cowl.
3. Release the drain tube from the clamp
and pull the tube outside the bottom
cowl. Place an approved fuel container
under the drain tube end and use a
funnel to avoid spilling fuel.
4. Loosen the vapor separator drain
screw.
5. Tilt up the outboard motor until fuel
flows out of the drain tube.
6. Leave the outboard motor in this position until all fuel has been drained.
7. When thoroughly drained, retighten the
drain screw securely.
8. Check the drained fuel for the presence of water or other contaminants. If
either is present, reassemble the outboard motor, refill the vapor separator
with fuel, and then drain the fuel again.
Repeat this procedure until no water or
other contaminants are present in the
drained fuel.
30, 40, 50
1
ENOF01342-0
*Remive fuel filter beforedraining
1. Vapor separator draine screw
89
75, 90, 115
1
ENOF01343-0
1. Vapor separator draine screw
ENOM00102-0
Battery
ENOW00931-A
WARNING
z Place the battery away from any source
of fire, sparks and open flames such as
burners or welding equipment.
z Place the battery away from fuel tank.
Accidental sparks of battery may cause
explosion of gasoline.
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.
10
90
INSPECTION AND MAINTENANCE
ENOM00104-C
4. Pre-season check
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 measure the voltage and specific gravity of
the battery.
10
Specific Gravity
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
3. Check that the battery is secure and
t h e b a t t e r y c a b l e s a r e p ro p e r l y
installed.
4. Change the engine oil (See page 72).
5. Before starting the engine, disconnect
stop switch lock and crank approximately 3times of 3sec. turning the
starter motor in order to prime the oil
pump.
6. Fill fuel tank completely.
7. Start the engine and warm up the
engine for 3 minutes in the “NEUTRAL”
position.
8. Run the engine for 5 minutes at the
slowest speed.
9. 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.
ENOM00105-A
5. Submerged outboard motor
ENOW00098-0
CAUTION
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.
The following are the emergency measures
to be taken for a submerged outboard
motor, if you can not take it your dealer
right away.
1. Wash the outboard motor with fresh
water to remove salt or dirt.
2. Remove the engine oil drain screw and
completely drain water and oil from the
engine.
3. Remove the spark plugs, and completely drain the water from the engine
by pulling emergency starter rope (See
page 40) several times.
Replace oil filter and oil to the correct
level.
The oil and filter may need to be
changed again after running a short
period to get all moisture completely
out of the crankcase.
INSPECTION AND MAINTENANCE
91
4. Inject a sufficient amount of engine oil
through the spark plug holes.
Pull the emergency starter rope several
times to circulate the oil throughout the
outboard motor.
ENOM00106-A
6. Cold weather precautions
ENOF01145-0
If you moor your boat in cold weather at
temperatures below 0°C (32°F), there is
the danger of remained water freezing in
the cooling water pump, which may damage the pump, impeller, etc. To avoid this
problem, submerge the lower half of the
outboard motor into the water.
ENOM00107-A
7. Striking underwater object
ENOW00935-0
CAUTION
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 habor slowly and
carefully.
4. Consult a dealer check the outboard
motor before operation again.
ENOM00121-0
8. Operation with multiple
outboard motors
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 propeller out of the water.
Otherwise, water could enter the engine
and cause damage to it.
10
92
TROUBLESHOOTING
ENOM00720-0
Power Trim & Tilt Inoperative
Starter motor will not crank
Battery will not hold charge
Boat speed loss
Engine runs erratically
Difficult to start engine
If you encounter problem with the engine, check the list below and locate the problem you
are experiencing. Then follow the suggested remedies.
Do not hesitate to contact your dealer, as professionals advice and assistance is the best
way to keep the engine in optimum condition.
z
Empty fuel tank
z
z
z
z
z
z
Incorrect connection of fuel system
Air enters fuel line
Deformed or damaged fuel pipe
z
z
Possible cause
Closed air vent on fuel tank cap
z
Fuel filter/fuel pump is clogged with dust.
z
Use of improper gasoline
z
Incomplete forced fuel feeling by primer bulb
z
z
Poor connection in compression system
z
z
Use of non-specified spark plugs
z
z
Dirt or carbon deposits on spark plugs
z
z
No sparking or poor sparking (Failure in component of Ignition
system)
z
z
z
11
z
z
Insufficient cooling water flow
z
Propeller cavitation
z
Incorrect propeller selection
z
Damaged or bent propeller
z
Unbalanced loading. Overload
z
Transom is too high/low.
z
Bottom of the boat is stained or damaged.
z
Insufficient throttle aperture.
z
z
z
z
z
Battery is charged insufficiently.
z
z
Battery is nearly dead, Poor connection of battery terminal, Low
level of electrolyte
z
Power trim & tilt switch is defective.
z
z
z
Wrong positioning of shift lever at N (neutral) position.
z
Main switch in defective.
Battery will not hold charge
Starter motor will not crank
Power Trim & Tilt Inoperative
Boat speed loss
Engine runs erratically
Difficult to start engine
TROUBLESHOOTING
z
z
z
z
z
z
93
Possible cause
Lock plate is not inserted or poorly inserted into stop switch.
z
Wrong wiring, disconnection, poor connection.
Faulty operation of starter motor/starter solenoid
z
A great deal of air is contained inside pump.
11
94
ACCESSORIES KIT
ENOM00721-0
30, 40, 50
The following a list of the tools and spare parts provided with the motor.
Name
Tool bag
Service tools
Spare parts
1
10 × 13 mm
Socket wrench
1
16 mm
Socket wrench handle
1
Pliers
1
Screwdriver
1
Screwdriver handle
1
Emergency starter rope
1
Spark plug
3
NGK IZFR6Q
Split pin
1
Diameter × Length 3 × 25 mm
Stop switch lock
1
Cross-and straight-point
Bracket fixing bolts
4
12 mm
Bracket fixing nuts
4
12 mm
Drag link
12
Remark
1
Socket wrench
Washers A, B
Parts packaged
with engine*
Quantity
4 each
A (large), B (small)
1
Fuel tank (with primer bulb)
1
Remote control box
1
Tachometer
1
Trim meter
1
Lead wire for meter
1
Not included as standard accessories in
US & Canada markets.
ACCESSORIES KIT
95
ENOM00722-0
75, 90, 115
The following a list of the tools and spare parts provided with the motor.
Name
Service tools
Spare parts
Parts packaged
with engine*
Quantity
MD 75/90
Tool bag
1
1
Socket wrench (16 mm)
1
1
Socket wrench (10 × 13)
1
1
Socket wrench handle
1
1
Pliers
1
1
Screwdriver (Phillips-type
and flat head)
1
1
Spark plug (75/90)
3
Spark plug (115)
Remark
MD 115
Adapter-type
NGK IZFR6Q
4
NGK IZFR5J
Diameter × Length 3 × 25 mm
Split pin
1
1
Bracket fixing bolts
4
4
12 mm
Bracket fixing nuts
4
4
12 mm
Washers A, B
4 each
4 each
Drag link
1
1
Flushing attachment
(Hose joint)
1
1
Primer bulb ass’y
1
1
A (large), B (small)
For washing
* Fuel tank, remote control box, tachometer, trim meter, meter lead wire and propeller are not enclosed in the engine
package.
12
82
PROPELLER TABLE
ENOM00724-0
To ensure optimum performance, the propeller should match the boat type and its load.
Use a genuine propeller.
A propeller must be selected so that the engine rpm measured at wide open throttle, while
cruising, is within the recommended range.
5150–5850 rpm
75, 90, 115*2
30, 40, 50
Pitch
Lighter load
15
Pitch
Lighter load
19
13
17
12
15
11
13
9
Heavier load
*1: Shows propeller with four blades.
13
21
14
7*1
11
Heavier load
9
*2: The 75-115 model is supplied with so standard
propeller. It is shipped from the factory without a
propeller.
OWNER’S MANUAL
MD 30B2
MD 40B2
MD 50B2
MD 75C2
MD 90C2
MD 115A2
003-11119-3AG1 1701NB
Printed in Japan
!!+",,
1.,/#)'"-,#$.
)&0)*(
#)(" ///-)#-,. )%*
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