M 2.5A2 M З.5A2 M З.5В2
 ")
#,
"-
+.
2$
用䗴手䢚
,/
OWNER’S
MANUAL
M 2.5A2
M 3.5A2
M 3.5B2
OB No.003-11045-7AF1
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 © 2016 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
ENOM00003-0
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before you
take delivery.
4
ENOM00005-B
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:
ENOF02001-0
ENOF02000-0
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.
11.
12.
13.
GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PARTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . 36
1. Removing the outboard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8. Auxiliary outboard motor operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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. TOOL KIT AND SPARE PARTS
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 inch.) stop
switch lanyard is coiled and can extended to a full 1300 mm (51 inch.).
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 40). 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-B
MODEL FEATURE
2
Model
M2.5A2
M3.5A2
M3.5B2
MF
MF
MF
S
z
z
z
L
z
z
z
z
z
z
z
z
z
Type
Transom heights
UL
Tiller Handle
Remote Control
Separate fuel tank
Integral fuel tank
z
Shifting
z
Manual tilt
z
z
*1: Option
ENOM00811-B
MODEL NAME EXAMPLE
M3.5B2S
M
3.5
B
2
S
Model description
Horse power
Product generation
Minor change
Shaft length
M (X)= Two stroke
F= Four stroke
D= Two stroke DI
-
A and up
2 and up
S= Short 15 in
L= Long 20 in
UL= Ultra long 25 in
SPECIFICATIONS
13
ENOM01300-0
2.5A2, 3.5A2, 3.5B2
Item
Overall Length
Overall Width
Overall Height
Transom Height
Weight
Output
MODEL
2.5A2
3.5A2
mm (in)
550 (21.7)
mm (in)
345 (13.6)
220 (8.7)
S mm (in)
958 (37.7)
L mm (in)
1085 (42.7)
S mm (in)
435 (17.1)
L mm (in)
562 (22.1)
S kg (lb)
12.5 (28)
13.0 (29)
L kg (lb)
13.0 (29)
13.5 (30)
kW (ps)
Max. Operating Range
rpm
Trolling Speed in Forward Gear
rpm
Idle Speed in Neutral Gear
rpm
1.8 (2.5)
2.6 (3.5)
3,800-5,200
4,200-5,300
1,100
-
1,300
Engine Type
2-Stroke
Number of Cylinders
Bore x Stroke
Piston Displacement
3.5B2
1
mm (in)
47 x 43 (1.85 x 1.69)
mL (Cu in)
Exhaust System
74.6 (4.55)
Underwater exhaust
Cooling System
Forced water cooling
Lubrication System
Engine Oil Mixed Gasoline
Starting System
Manual starter
Ignition System
Flywheel Magneto C.D. Ignition
Spark Plugs
NGK BP6HS-10/BPR6HS-10
Trim Position
4
Unleaded regular gasoline : Pump posted 87 Octane
(research octane rating of 91)
Fuel
Fuel Tank Capacity
Engine Oil
Fuel : Engine Oil Mixing Retio
Gear Oil
Gear Shift
Gear Reduction Ratio
L (US gal)
Approx. 1.4 (0.37) integral tank
Genuine motor oil or recommended one (TCW-III)
Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1
Genuine Gear Oil or API GL5, SAE #80 to #90,
approx. 3.5B2:180mL (6.1 fl.oz), 3.5A2 & 2.5A2:90mL (3.0 fl.oz),
Foward
F-N
1.85 (13 : 24)
2.15 (13 : 28)
Remark: Specifications subject to change without notice.
Tohatsu outboard is power rated in accordance with ISO8655 (propeller shaft output).
2
14
PARTS NAME
ENOM01301-0
2.5A2, 3.5A2, 3.5B2
1
11
2
3
24
12
3
25
22
26
4
5
13
6
14
7
23
15
16
8
27
17
18
9
19
20
21
30
10
28
29
ENOF02002-0
1
2
3
4
5
6
7
8
9
10
11
12
Air Vent Screw
Fuel Tank Cap
Top Cowl
Plug Cap Cover
Fuel Cock
Cooling Warter Check Port
Clamp Bracket
Drive Shaft housing
Propeller
Water Inlet (2.5/3.5A2)
Starter Handle
Shift Lever(3.5B2 only)
13
14
15
16
17
18
19
20
21
22
Handle Grip
Carring Handle
Clamp Screw
Thrust Rod
Oil Plug (Upper)
Anti-Ventilation Plate
Water Inlet (3.5B2 only)
Gear Case
Oil Plug (Lower)
Throttle Lever
23 Tilt Stopper
24 Stop Switch
25 Carburetor Cover
26 Chork Lever
27 Drive Shaft Housing
Grommet (3.5B2 only)
28 Steering Adjustment Screw
29 Spark Plug
30 Fuel Filter
15
LABEL LOCATIONS
ENOM00019-A
Warning label locations
2
1
3
4
4
ENOF02003-0
1. Warning label regarding owner’s manual, top cowl, engine stop switch.
3C7-72180-3
2. Warning regarding fuel tank cap. (See
page19, 24)
3. Warning label regarding Emergency
manual starting procedure (3.5B2 only)
(See page 27)
ENOF00005-Z
4. Warning regarding high voltage.
3C8-72181-0B
ENOF02050-0
16
LABEL LOCATIONS
ENOM01001-0
Serial number label locations
O utboard Motor
R a te d Power:
Ma ss:
Serial No.
4
1)
2)
3)
4) 5)
6)
7)
Made in Japan
ENOF02048-0
1.
2.
3.
4.
5.
6.
Model code(Model name)
Rated power
Dry mass weight
Serial No.
Manufacture name
Manufacture address
17
INSTALLATION
ENOM00024-B
1. Mounting the outboard motor on
boat
Keep the outboard motor in a vertical position when mounting.
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.
Do not operate the outboard motor until it
has been securely mounted on the boat in
accordance with the instructions below.
ENOF02004-0
ENOW00009-0
WARNING
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
Nm (3.0 kgf) 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 Nm (3.0 kgf) 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.
2
1
ENOF02005-0
1. Clamp Screw
2. Tighten
ENOM00025-0
Position ... Above keel line
Set engine at center of boat.
1
2
ENOF01141-0
1. Center of boat
5
18
INSTALLATION
2. Boat transom
ENOM00830-A
Mounting bolts
ENOM00026-0
Transom matching
Be sure that the anti ventilation plate of the
outboard motor is 30–50 mm (1.2–2 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.
Manual tilt type
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
5
Note
1
30−50 mm
(1.2−2 in)
A rope is not included in the standard
accessories.
2
ENOF01608-0
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
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.
ENOF02006-0
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 (hererinafter referred to as the
"ethanol"), content in the gasoline. But if
the gasoline in your area contains ethanol,
you should be aware of certain adverse
effects that can occur. Increasing the percentage of ethanol in the fuel can also
worsen these adverse effects. Some of
19
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 51) for additional information.
ENOW00020-0
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, common to boats, 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 stor-
6
20
PRE-OPERATING PREPARATIONS
age if alcohol has washed protective oil
films from internal components.
Fuel by Oil Mixing (25:1, 50:1)
Oil
ENOW00018-0
1.0L
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.
0.5L
0.4L
(10 : 0.4)
0.2L
0
6
ENOW0002A-A
CAUTION
Use of engine oils that do not meet these
requirements will result in reduced engine
life, and other engine problems.
Use a genuine engine oil or recommended
one (TCW3). Refer to your Distributor.
Will not recommend use of other two
stroke engine oil.
Add engine oil into fuel oil tank. The mixing
ratio with gasoline is 50 : 1 (50 parts gasoline and one part oil). Mix well by hand. The
mixing ratio during break-in running is 25 :
1.
Mixing Ratio
Gasoline : Engine Oil
During break-in
25 : 1
After break-in
50 : 1
(25:0.5)
50 : 1
(10 : 0.2)
2L
10L
Gasoline
25L
30L
ENOF01708-0
ENOM01003-A
Engine oil – gasoline mixing
procedure
ENOW00937-0
CAUTION
ENOM01002-0
2. Engine oil recommendation
(25:1)
25 : 1
WARNING
z Do not use other than two stroke engine
oil with specified grade, or the engine
may be damaged.
z Do not use fuel prepared in other than
specified mixing ratio.
- Lack of engine oil can cause severe
engine trouble such as piston seizure.
- Excess of engine oil can shorten spark
plug life, and/or cause increase of noxious exhaust.
For quantities of engine oil and gasoline to
be pre-mixed, refer to table in previous
page.
„ When fuel tank built in the outboard
motors is used for operation:
1 Prepare separate fuel container for premixing.
2 Pour engine oil into fuel container, and
then, gasoline.
3 Put cap on the container, and close
tightly.
4 Shake the container to mix engine oil
and gasoline well and even.
5 Pour the mixture into fuel tank.
PRE-OPERATING PREPARATIONS
21
Leaking gasoline is a dangerous fire hazard.
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.
ENOF01709-B
ENON00922-0
Notes
z It is recommended to pre-mix by using
separate fuel container. Attempting to
pre-mix in the integral fuel tank can
make the mixture uneven.
z If integral fuel tank is used for mixing,
pour engine oil into the tank little by little
while putting gasoline into the tank.
ENOM00043-D
3. Fuel filling
ENOW00019-0
WARNING
Do not fill the fuel tank over capacity. The
rise of gasoline temperature may cause
gasoline to expand which, if overfilled, may
leak through air vent screw when it is open.
When or before refueling:
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.
6
22
PRE-OPERATING PREPARATIONS
z Dispose aged or contaminated gasoline
in accordance with local regulations.
ENOW00029-A
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.
]ENOM00033-AB
4. Break-In
Your new outboard motor and lower unit
require break-in for the moving compon e n t s a c c o rd i n g t o t h e c o n d i t i o n s
described in the following time table.
Please refer to ENGINE OPERATION section (See page 24) to learn how to correctly start and operate the outboard
motor.
ENOW00024-A
1. Before opening fuel tank cap, turn air
vent screw two turns counterclockwise
to release air pressure in the fuel tank.
6
&/0'è
1. Two turns the air vent screw
2. Fuel tank cap
WARNING
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.
z Always attempt to stay on the windward
side of emission.
2. Open the fuel tank cap slowly.
3. Fill the fuel not to over the shown level.
1
Throttle
Position
Speed
ENOF02008-0
1. Full line
4. After filling the tank, close the tank cap.
1–10
min
10 min –
3 hrs
3–5 hrs
After
5 hrs
Idle
Less
than 1/2
throttle
Less
than 3/4
throttle
Full
throttle
available
1
2
Crusing Approx.
at
500minimu
3,500
m speed rpm max
3
Approx.
4,000
rpm
4
Abailabl
e to
operate
at wide
open
throttle
PRE-OPERATING PREPARATIONS
23
ENON00008-0
Note
Proper break-in allows outboard motor to
deliver it full performance for longer service
life.
&/0'è
ENOW00023-0
CAUTION
Operating the outboard motor without
break-in can shorten service life of the
product.
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.
ENOM01004-0
Fuel mix ratio for break-in
Gasoline 25: Genuine Engine Oil 1
25:1 when using genuine engine oil or the
recommended one (TCW3).
ENOW00940-0
CAUTION
z During the break-in period, never run the
engine continuously at high speed.
z After running-in is completed, select the
correct propeller so that the engine
speed is the recommended range at the
wide-opon throttle.
z After completing 5 hours of breakin,
replace the gear oil with new oil. Refer to
“Changing the gear oil” in subsection (2),
Periodic Inspection.
6
24
ENGINE OPERATION
tank is raised by heat from sources such as
sun light.
ENOM00042-0
Before starting
ENOW00022-B
CAUTION
1. Before opening fuel tank cap, turn air
vent screw two turns counterclockwise
to release air pressure in the fuel tank.
Be sure to fill the engine before starting
engine. (To properly fill the engine with oil
follow the instructions. See page 20)
&/0'è
1. Two turns the air vent screw
2. Fuel tank cap
2. Open the fuel cock.
ENOF01710-B
7
ENOW00027-C
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
spread the engine oil.
1
ENOF02028-0
1. Fuel cock
ENOW00937-0
ENOM00044-F
CAUTION
1. Fuel feeding
ENOW00029-A
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
Be sure to close the fuel cock when the
outboard motor is tilted up Otherwise, fuel
could overflow.
ENON00923-0
Note
If fuel is not supplied immediately to the carburetor (new engine or after cleaning), wait
for about 15 seconds for the proper quantity
ENGINE OPERATION
of fuel to flow into the carburetor after opening the fuel cock.
25
ENOW00032-B
CAUTION
Do not try to crank after engine has
started.
ENOM00045-D
2. Starting the engine
ENOW00941-0
ENOW00036-A
CAUTION
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.
Run the engine only at idling.
And be sure to remove the propeller, when
starting the engine in the test tank. (See
page 47)
When the shift lever is at the “NEUTRAL”
position, never move the throttle lever to
medium or high speeds. This may cause
serious damage to the engine by rotating it
at excessively high speed. (3.5B2)
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.)
3
1
1
2
ENOF00863-0
1. Test tank
2. Water
3. Over 10 cm (4 in.)
ENOF02014-0
1. Stop switch lock
ENOW00036-0
ENON00924-0
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.
Note
The engine will not start if the lock is in
released condition.
7
26
ENGINE OPERATION
2. Set the shift lever in the Neutral position. (3.5B2 only)
ENON00502-0
Note
If engine does not start with 4 or 5 times
starting operation, push the knob back and
restart.
1
ENOF02015-0
5. Pull the starter handle slowly until you
feel engagement, keep pulling till you
feel less resistance. Then pull it quickly.
repeat if necessary until started.
1. Shift lever
1
3. Set the throttle lever to the Start position.
2
1
7
ENOF02018-0
ENOF02016-0
1. Slowly
2. Quickly
1. Throttle lever
4. Set the choke lever to the Close position.
ENON00926-0
Note
Return the recoil starter grip slowly when
the engine has started. Releasing the starter
grip at the extended position may cause a
trouble in the starting system.
ENON00927-0
Note
1
2
ENOF02017-0
1. Close
2. Open
ENON00501-A
Note
Choke is not necessary when the engine is
warm.
In cold weather, pull the starter handle 2 or
3 times while moving up the choke lever to
choke the engine.
ENGINE OPERATION
6. When the engine has started, immediately return the choke lever to the
Open position then move the throttle
lever downward to slow speed.
27
z Attach engine stop switch lanyard to
clothing or any part of body like arm
before starting engine.
1. Remove the top cowl fixing bolts, to
remove the top cowl.
1
2
ENOF02017-0
1. Close
2. Open
ENON00928-0
Note
ENOF02019-0
If the engine stops soon after having been
started with the choke lever at the Close
position, set the choke lever to the Open
position and perform the starting procedure
again.
2. Remove the three bolts fastening the
recoil starter.
3. Remove the recoil starter.
ENOM00042-D
Emergency starting
ENOW00099-A
WARNING
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.
ENOF02020-0
4. Insert the knotted end of the starter
rope into the notch in the flywheel and
wind the rope around the flywheel several turns clockwise.
5. Tie a loop in the another end of the
emergency starter rope and attach
socket wrench that is included in the
tool kit.
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.
7
28
ENGINE OPERATION
ENOM00044-B
Engine speeds
Idling speed after warming up.
ENOF02021-0
8. After engine starts, do not reinstall flywheel cover and top cowl.
ENOM00043-C
Model
Trolling speed
(in Forward)
Idling speed
(in Nutral)
2.5A2
1,100 rpm
-
3.5A2
1,100 rpm
-
3.5B2
1,100 rpm
1,300 rpm
ENOM00046-A
4. Forward, reverse, and
acceleration
3. Warming up the engine
ENOW00932-0
ENOW00037-0
CAUTION
WARNING
Be sure to check that cooling water is
coming out of the cooling water check port
during warm up.
7
Warm the engine at low engine speeds for
about
3 minutes : above 41°F (5 Υ )
5 minutes at 2000 rpm : above 41°F (5 Υ )
This allows the lubricating oil to circulate to
all parts of the engine. Operating the
engine without warm up shortens the
engine's life.
1
ENOF02022-0
1. Cooling water check port
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
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
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.
ENGINE OPERATION
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.
ENOW00861-0
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
29
ENOM00890-B
Tiller handle type
ENOW00867-0
WARNING
Sudden acceleration and deceleration may
cause passenger(s) to be thrown overboard or falling down.
ENOW00865-A
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.
CAUTION
ENOW01303-0
Gear and clutch damage may occur if shifting at high engine speed.
Engine must be in the slow idle position
before shifting is attempted.
Forward (3.5B2 only)
7
ENOW00863-0
CAUTION
2
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.
1
3
ENOF02023-0
1. Shift lever
2. Neutral (N)
3. Forward (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.
ENOW00864-0
CAUTION
Do not increase engine speed unnecessarily when the shift is in neutral and reverse,
or engine damage may occur.
Forward
1. Lower the throttle lever in order to
reduce engine speed.
2. When the engine reaches trolling (or
idling) speed, quickly pull the shift lever
to the Forward position.
Reverse
1. Lower the throttle lever in order to
reduce engine speed.
2. When the engine reaches trolling (or
idling) speed, quickly pull the shift lever
to the Neutral position.
30
ENGINE OPERATION
3. The handle upright, turn the outboard
motor at an angle of 180° and quickly
turn the shift lever to the Forward (F)
side. (3.5B2 only needs to operate shift
lever)
ENOM00049-C
5. Stopping the engine
ENOW00868-0
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.
ENOF02024-0
Acceleration
ENOW00867-0
Tiller handle type
1. Lower the throttle lever in order to the
slow position.
WARNING
7
Sudden acceleration and deceleration may
cause passenger(s) to be thrown overboard or falling down.
The speed is controlled by operating the
throttle lever. Moving the throttle lever
graduaally upward increases the speed,
and moving it downward decreases the
speed.
3
1
2
ENOF02025-0
1. Throttle lever
2. Fully closed
3. Fully opened
1
2
ENOF02026-0
1. Throttle lever
2. Fully closed
2. Put the shift lever in the Neutral position. (3.5B2 only)
Run the engine for 2-3 minutes at
idling speed for cooling down if it has
been running at full speed.
ENGINE OPERATION
31
3. Push the stop switch.
1
2
1
2
ENOF02029-0
ENOF02027-0
1. Stop switch
2. Stop switch lock
1. Stop switch
2. Stop switch lock
ENOM00920-0
6. Steering
4. Close the air vent screw and fuel cock.
ENOW00870-0
2
WARNING
Sudden steering may cause passenger(s)
to be thrown overboard or falling down.
Tiller handle type
Right turn
Move the tiller handle to the left
Left turn
Move the tiller handle to the right.
1
ENOF02030-A
1. Fuel cock
2. Air vent screw
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.
Emergency engine stopping
Remove stop switch lock to stop the
engine.
ENOF00892-0
7
32
ENGINE OPERATION
ENOM00050-0
7. Trim angle
1
ENOW00043-A
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.
ENOF00051-1
1. Perpendicular to the water surface
ENOM00053-0
Improper trim angle (bow rises too
high)
Set the thrust rod lower if the bow of the
boat rises above horizontal.
ENOW00044-0
WARNING
7
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 operate 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.
ENOM00052-0
Proper trim angle
The position of the thrust rod is correct if
the hull is horizontal during operation.
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.
ENOF00053-0
ENGINE OPERATION
„ Manual Tilt type
33
6. Gentry lower the outboard.
ENOM00060-A
8. Tilt up and down
ENOW00055-0
WARNING
2
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.
1
3
ENOF00229-0
1. Thrust rod
2. Higher
3. Lower
ENOW00048-0
WARNING
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.
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.
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
2
1
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
ENOF01612-0
1. Push in
2. Pull out
5. Reinstall the thurst rod securely.
Note
Before tilting the outboard motor up, after
stopping the motor leave it in the running
7
34
ENGINE OPERATION
position for about a minute to allow water to
drain from inside the engine.
ENOM01304-0
Outboard motor position in tilt up
ENOW00053-0
CAUTION
ENOM00222-0
Tilt up
1. Close the fuel cock and tighten the air
vent screw of the tank cap.
2. Tilt up the outboard motor fully to your
side and press the tilt stopper knob
inside to set it up.
However, the outboard motor may be set in
the wrong tilt-up position if the motor
direction is sharpy changed in course of
tilting up.
If the outboard motor is set in a wrong
position, try to tilt it up once more to set it
in the correct position.
2
When the outboard motor is in the tiltup
position, the tilt handle side must be in the
upward direction.
1
7
1
ENOF02030-A
1. Fuel cock
2. Air vent screw
2
3
ENOF02032-0
1
1. Tilt handle
2. Starter handle
3. Correct
ENOF02031-0
1. Tilt stopper
1
ENOF02033-0
1. Wrong
ENGINE OPERATION
35
ENOM00223-0
Tilt down
Pull the outboard motor to your side and
draw the tilt stopper knob out for tilting
down.
1
ENOF02034-0
1. Tilt stopper
7
36
REMOVING AND CARRYING THE OUTBOARD MOTOR
ENOM00070-B
ENOW00065-0
1. Removing the outboard motor
ENOW00064-B
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. Be sure to close the air vent and the
fuel cock.
3. Remove the outboard motor from boat
and completely drain the water from
the gear case.
WARNING
Close air vent screw of fuel tank before
carrying or storing outboard motor and fuel
tank, or fuel may leak, potentially catching
fire.
ENOW00066-0
CAUTION
z Do not give a shock to an outboard
motor during transportation. It becames
a cause of breakage.
z Do not carry or store outboard motor in
any of positions described below.
Otherwise, engine damage or property
damage could result from leaking oil.
8
ENOF02035-0
ENOF02004-0
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.
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.
REMOVING AND CARRYING THE OUTBOARD MOTOR
37
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.
ENOW00072-A
ENOF02036-0
CAUTION
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.
1
ENOF02037-0
1. Handle
ENOM00072-A
3. Traillering
ENOW00072-0
When trailering the outboard motor should
be in a vertical (normal running) position,
fully down. Trailering in the tilted position
may cause damage to the outboard motor,
boat, etc.
If trailering with outboard motor fully down
is not available (the gear case skeg is too
close to the road in a vertical position), fix
the outboard motor securely using a device
(like a transom saver bar) in the tilted position.
When transporting a boat on a trailer with
the outboard motor still attached, disconnect the fuel line from the outboard motor
beforehand and keep the outboard motor
in the normal running position or on a transom saver bar.
Tiller handle type
CAUTION
Trailering in the tilted position may cause
damage to the outboard motor, boat, etc.
ENOW00068-0
WARNING
Close air vent screw of fuel tank and fuel
cock before carrying or storing outboard
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 39).
8
38
REMOVING AND CARRYING THE OUTBOARD MOTOR
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
ADJUSTMENT
39
ENOM00073-A
1. Steering friction
ENOW00074-A
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.
ENON0925-0
Note
The steering adjust screw is used to adjust
the friction load of the steering, but not to fix
the steering. Excess tightening of the
adjustment screw may cause damage to
the swivel bracket.
Adjust this lever to achieve the desired
steering friction (drag) on the tiller handle.
Move lever towards (2) to tighten friction
and move lever towards (3) to loosen friction.
1
9
2
3
2
3
ENOF02038-0
1. Steering friction bolt
2. Heavier
3. Lighter
40
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
41
ENOM01305-0
1. Daily Inspection
Perform the following checks before and
after use.
ENOW00078-0
WARNING
Do not use outboard motor if any abnormality is found during pre-operation check
or it could result in severe damage to the
motor or severe personal injury.
Item
Fuel System
Fuel Tank Cap
Electrical
Equipment
Throttle System
Recoil Starter
Clutch and
Propeller System
Installation of
Motor
Cooling Water
Tools and
Spares
Other parts
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Points to Check
Check the amount of fuel in the tank.
Check for debris in the fuel filters.
Check the rubber hoses for fuel leakage.
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 that the stop switch functions normally and make sure
the lock plate is in right location.
Check cords for loose connections and damage.
Check the spark plug for dirt, wear and carbon build-up.
Check that the carburetor choke valve functions normally.
Check carburetor linkage is working normally when moving the
throttle lever.
Check the rope for wear and chafing.
Check the ratchet engagement.
Check that the clutch engages correctly when operation the shift
lever. (3.5B only)
Visually check the propeller and shear pin for bent or damaged
blades.
Check that the split pin is on the propeller.
Check the clamp screws attaching the motor to the boat for
tightness.
Check the thrust rod installation.
Check that cooling water is discharged from the cooling water
check port after the engine has started.
Check that there are tools and spare parts for replacing spark
plugs, the propeller, etc.
Check that you have the spare rope.
Check if the anode is securely installed.
Check the anode for corrosion and deformation.
*1 Have this handled by your dealer.
Remedy
Replenish
Clean or Replace
Replace *1
Replace
Replace
Replace
Remedy or replace *1
Correct or replace *1
Clean or replace *1
Replace *1
Correct *1
Replace *1
Correct or replace *1
Adjust *1
Replace
Tighten
Tighten
Repair *1
Repair if necessary
Replace
10
42
INSPECTION AND MAINTENANCE
ENOM00083-0
ENOM00085-B
Washing outboard motor
Flushing attachment (3.5B2 only)
ENOW00922-0
ENOW00081-0
CAUTION
WARNING
Do not start engine without removing propeller, or accidentally turning propeller
could cause personal injury.
To prevent the engine from starting when
you are near the propeller, remove the stop
switch lock.
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.
ENOW00920-0
CAUTION
When washing the outboard motor, be
careful not to spray the water inside of the
top cowl, especially electrical components.
1. Tilt down the outboard motor.
2. Remove the water plug from the drive
shaft housing, 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 water plug.
5. Tilt up the outboard motor.
.
ENON00026-0
Note
It is recommended to check chemical properties of water on which your outboard
motor is regularly used.
10
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 from exterior and 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
1
ENOF02040-0
1. Flushing attachment (option)
INSPECTION AND MAINTENANCE
43
ENOM00085-A
Flushing by test tank
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.
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 47)
3
10
1
2
ENOF00863-0
1. Test tank
2. Water
3. Over 10 cm (4 in.)
44
INSPECTION AND MAINTENANCE
ENOM01306-0
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.
Servicing Interval
Item
10 hours
or
1 month
Action
50 hours Every 100
or
hours or
3 months 6 months
z
Carburetor *1
Clean, and adjust.
z
z
Fuel tank
z
z
z
z
z
Ignition
Spark plugs
z
z
z
Check gaps. Remove carbon deposits or 0.9–1.0 mm
Replace.
(0.035–0.039 in)
Starting
System
Starter rope
z
z
z
Check for wear or chafting.
Propeller
z
z
z
Check for bent blades, damage, wear.
Shear pin &
Split pin
z
z
z
Check and Replace.
Gear oil
z
z
z
Replace or Fill gear oil and check for
water leaks.
z
z
z
z
z
z
z
z
z
Fuel System
Fuel filter
Piping/Hose
Check and clean or Replace.
Check and Replace.
Clean.
Lower Unit
Water pump *1
Bolt and Nuts
10
Remarks
z
Sliding and Rotating Parts.
Grease Nipples
Outer Equipment
z
Anode
180 mL (6.1 fl.oz.)
: 3.5B2
90ml (3.0 fl.oz.) :
2.5A2/3.5A2
Check for wear or damage.
Retighten.
Apply and pump in grease.
Check for corrosion.
Check for corrosion and deformation.
*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.
INSPECTION AND MAINTENANCE
45
ENOM00093-A
Fuel filters and fuel tank cleaning
ENOW00093-B
WARNING
Gasoline and its vapors are very flammable
and can be explosive.
Keep out of reach of children.
z Avoid repeated or prolonged contact
with skin or breathing of vapor.
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.
ENOM01405-0
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).
„ integral tank type
1. Drain all fuel from the fuel tank.
2. Remove the fuel cock from the fuel
tank and clean the fuel filter. Replace it
if necessary.
1
2
3
ENOF02047-0
1. Fuel tank
2. Fuel filter
3. Fuel cock
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.
ENON00934-0
Note
Please dispose of used oil in a manner that
is compatible with the environment.
We suggest you take it in a sealed container
to your local service station for reclamation.
Do not throw it in the trash, pour it on the
ground or down a drain.
1. Tilt down the outboard motor.
10
46
INSPECTION AND MAINTENANCE
2. Remove the oil plugs (lower and
upper), and completely drain the gear
oil into a pan.
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.
ENOF01617-0
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.
ENON00033-0
ENOF01618-0
Note
ENOW00928-0
Use genuine gear oil or the recommended
one (API GL-5: SAE #80 to #90).
Required volume:
approx. 180 mL (6.1 fl.oz) 3.5B2
approx. 90 ml (3.0 fi.oz.) 2.5A2/3.5A2
10
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.
ENON00033-0
Note
Use genuine gear oil or the recommended
one (API GL-5: SAE #80 to #90).
Required volume:
approx. 180 mL (6.1 fl.oz) 3.5B2
approx. 90 ml (3.0 fi.oz.) 2.5A2/3.5A2
ENOF01618-0
INSPECTION AND MAINTENANCE
47
ENOM00232-A
Propeller replacement
ENOW00084-0
1
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
“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.
2
3
ENOF00242-0
1. Shear pin
2. Propeller
3. Split pin
2. Remove the shear pin from the shaft.
3. Install a new shear pin.
ENOW00208-0
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. Pull out the split pin from the propeller
boss and remove the propeller from
the shaft.
ENOM00087-C
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.
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.
10
48
INSPECTION AND MAINTENANCE
1. Stop the engine.
2. Remove the plug cap cover.
3. Remove the spark plug caps.
ENON00028-0
Note
z Spark plug torque:
27.0 Nm (20.0 ft-lb) [2.7 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.
1
ENOF02042-0
1. Socket wrench
10
4. Remove the spark plugs by turning it
counter-clockwise, using a 13/16" (21
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 0.9-1.0 mm (0.035-0.039
inches). If the gap is different, replace
the spark plug with a new one
Use spark plug (NGK BP6HS-10 or
BPR6HS-10) or recommended ones.
1
2
ENOF00085-0
1. Electrode
2. Spark gap (0.9–1.0 mm, 0.035–0.039 in)
7. Install the spark plug by hand and turn
it carefully to avoid cross-threading.
8. Tighten the spark plug to the specified
torque.
INSPECTION AND MAINTENANCE
49
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.
10
ENOF02043-0
50
INSPECTION AND MAINTENANCE
ENOM00960-0
Grease point
Apply water proof grease to the parts shown below.
10
ENOF02044-0
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.
ENOW00096-A
CAUTION
Before servicing the motor for storage:
z Remove the spark plug caps from the
spark plugs.
z Do not run the motor out of the water.
Before you put your outboard motor in
storage, it is a good opportunity to have it
serviced and prepared by your dealer.
Be sure to use fuel stabilizer while running
the motor before storage. (See page 52)
51
3. Drain all fuel from the fuel hoses and
carburetor (See page 52), and clean
these parts.
Keep in mind that if gasoline is kept in
the carburetor 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. Pull the ricoil starter several times to
lubricate inside the cylinder.
ENOW00930-0
WARNING
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.
6. Change the gear oil in the gear case
(See page 45).
7. Apply grease to grease point (See
page 50).
8. Stand the outboard motor up vertically
in a dry place.
ENOM00101-D
Engine
1. Wash the engine exterior and flush the
cooling water system thoroughly with
fresh water. Drain the water completely.
Wipe off any surface water with an oily
rag.
2. Remove the fuel hose from the outboard motor.
ENOF02036-0
10
52
INSPECTION AND MAINTENANCE
ENOW00066-0
CAUTION
Do not carry or store outboard motor in any
of positions described below.
Otherwise, engine damage or property
damage could result from leaking oil.
1. Before adding fuel stabilizer additive,
drain the carburetor (See page 52).
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
ENOF02035-0
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 79 and 68).
z Elevate power unit 2 inches to 4 inches if
traveling to avoid oil spillage.
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-C
Fuel system draining
ENOW00028-A
WARNING
For details on handling fuel, contact an
authorized dealer.
10
1
ENOF02037-0
1. Handle
ENOM00950-A
Adding a fuel stabilizer
When adding a fuel stabilizer additive
(commercially available), first fill the fuel
tank with fresh oil and fuel. If the fuel tank
is only partially filled, air in the tank can
cause the fuel to deteriorate during storage.
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.
INSPECTION AND MAINTENANCE
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.
1. Close the fuel cock.
53
7. Check the drained fuel for the presence of water or other contaminants. If
either is present, reassemble the outboard motor, refill the carburetor with
fuel, and then drain the fuel again.
Repeat this procedure until no water or
other contaminants are present in the
drained fuel.
ENOM00104-F
4. Pre-season check
1
ENOF02045-0
1. Fuel cock
2. Turn the outboard motor.
3. Place an approved fuel container
under the drain screw.
4. Loosen the carburetor drain screw.
1
ENOF02046-0
1. Carburetor drain screw
5. Leave the outboard motor in this position until all fuel has been drained.
6. When thoroughly drained, retighten the
drain screw securely.
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. Fill fuel tank with oil and fuel.
3. Open the fuel cock.
4. Before starting the engine, disconnect
stop switch lock and crank approximately 10 times in order to circulate
the oil.
5. Start the engine and warm up the
engine for 3 minutes in the “NEUTRAL”
position.
6. Run the engine for 5 minutes at the
slowest speed.
7. 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.
10
54
INSPECTION AND MAINTENANCE
ENOM00105-D
ENOM00107-A
5. Submerged outboard motor
ENOW00098-0
7. Striking underwater object
ENOW00935-0
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 spark plugs, and completely drain the water from the engine
by pulling recoil starter several times.
3. Inject a sufficient amount of engine oil
through the spark plug holes.
Pull the recoil starter rope several times
to circulate the oil throughout the outboard motor.
10
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.
ENOM00106-A
6. Cold weather precautions
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.
ENOF01145-0
ENOM00120-0
8. Auxiliary outboard motor
operation
When the auxiliary outboard motor will not
be used, be sure to remove the stop
switch lock, shift into forward, and then tilt
the outboard motor up. Otherwise, overrotation of the propeller due to water spray
could damage the gear.
55
TROUBLESHOOTING
ENOM01307-0
z
z
z
z
z
Air entering fuel line
z
z
z
z
z
z
Deformed or damaged fuel pipe
z
z
z
z
z
z
Closed air vent on fuel tank
z
z
z
z
z
z
Clogged fuel filter, fuel pump, or carburetor
z
z
z
z
Use of improper engine oil
z
z
z
z
Use of improper gasoline
z
z
z
z
Overheating of engine
z
High engine speeds not possible
z
Engine speed abnormally low
z
z
Engine speed abnormally high
Engine starting but stopping soon
z
Poor idling
Engine failing to start
FUEL SYSTEM
If you encounter a problem, consult the check list below to determine the cause and to
take the proper action.
An authorized dealer will always be happy to provide any assistance and information.
Empty fuel tank
Incorrect connection of fuel system
Excessive oil in mixture
z
z
ELECTRICAL SYSTEM
z
Shortage of oil in mixture
Exessive supply of fuel
z
z
z
z
z
Poor carburetor adjustment
z
z
z
z
z
Spark plug other than specified
z
z
z
z
z
Dirt, soot, etc. on spark plugs
z
z
z
z
z
No spark or weak spark
z
z
z
z
z
Short circuit of engine stop switch
Ignition timing incorrect
z
Lock plate not fitted to stop switch
z
Sheard shearpin
z
z
OTHERS
Possible cause
z
z
z
Insufficient cooling water flow, clogged or defective pump
z
z
Cavitation or ventilation
z
z
z
z
Incorrect propeller selection
z
z
z
z
Damaged and bent propeller
z
z
Improper thrust rod position
z
z
z
z
z
Unbalanced load on boat
z
z
z
z
Transom too high or too low
11
56
TOOL KIT AND SPARE PARTS
ENOM01308-0
The following a list of the tools and spare parts provided with the motor.
Name
Service tools
Spare parts
Quantity
Tool bag
1
Pliers
1
Socket wrench
1
10 × 13 mm
Socket wrench
1
21 mm
Socket wrench handle
1
Screwdriver (Phillips-type
and flat head)
1
Adapter-type
Emergency starter rope
1
ø4–1000 mm
Spark plug
1
NGK: BPR6HS-10
Share pin
1
Split pin
1
* Not included as standard accessories in some markets.
12
Remark
57
PROPELLER TABLE
ENOM01309-0
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.
2.5A2: 3800–5200 rpm
3.5A2/3.5B2: 4200–5300 rpm
ENON00245-0
Note
Each size shows number of propeller blades × diameters × pitch.
Light boats
Heavy boats
Propeller Mark
Propeller Size
Diameter × pitch
Material
7
3 × 188 × 178 mm
3 × 7.4 × 7.0 in
Plastics
6
3 × 188 × 145 mm
3 × 7.4 × 5.7 in
4.5
3 × 188 × 110 mm
3 × 7.4 × 4.3 in
Plastics
Aluminum
Plastics
13
OWNER’S MANUAL
M 2.5A2
M 3.5A2
M 3.5B2
003-11045-7AF1 1512NB
Printed in Japan
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"-
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2$
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2/-0$*(".-$%'/
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$*)" 000.*$.-/ *&+
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