Tohatsu BFT 90AK1 Owner Manual

OWNER’S MANUAL

BFT 75A

BFT 90A

5 4 , A z u s a w a 3 C h o m

Tokyo 174-0051, Japan e , tI a b a s h -i K u

Tel: +813 - 3966-3117 Fax:+81-3-3966-0090 www.tohatsu.com

OM_BFT75-100A_US_Cover.indd 1

31ZZ0T03

00X31-ZZ0-T030

XXX.XXXX.XX

PRINTED IN JAPAN

OWNER’S MANUAL

BFT 75A

BFT 90A

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Keep this Owner’s Manual handy, so you can refer to it at any time. This Owner’s

Manual is considered a permanent part of the outboard motor and should remain with the outboard motor if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.

Congratulations on your selection of a TOHATSU outboard motor. We are certain you will be pleased with your purchase of one of the finest outboard motors on the market.

We want to help you get the best results from your new outboard motor and to operate it safely. This manual contains information on how to do that; please read it carefully.

As you read this manual you will find information preceded by a symbol. That information is intended to help you avoid damage to your outboard motor, other property, or the environment.

We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership.

When your outboard motor needs scheduled maintenance, keep in mind that your TOHATSU dealer is specially trained in servicing

TOHATSU outboard motors. Your

TOHATSU dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.

Best Wishes,

Tohatsu Corporation

INTRODUCTION

1

INTRODUCTION

A FEW WORDS ABOUT

SAFETY

Your safety and the safety of others are very important. And using this outboard motor safely is an important responsibility.

To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

Of course, it is not practical or possible to warn you about all the hazards associated with operating or maintaining an outboard motor. You must use your own good judgment.

You will find important safety information in a variety of forms, including:

• Safety Labels — on the outboard motor.

• Safety Messages — preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Safety Headings — such as IMPORTANT SAFETY INFORMATION .

• Safety Section — such as OUTBOARD MOTOR SAFETY .

• Instructions — how to use this outboard motor correctly and safely.

This entire book is filled with important safety information — please read it carefully.

2

OUTBOARD MOTOR SAFETY .................................... 7

IMPORTANT SAFETY INFORMATION................. 7

SAFETY LABEL LOCATION................................... 9

CONTROLS AND FEATURES .................................... 11

CONTROL AND FEATURE IDENTIFICATION

CODES................................................................... 11

COMPONENT AND CONTROL LOCATIONS..... 12

CONTROLS.............................................................. 20

Remote Control Box: ............................................. 20

Side-Mount Type ................................................. 20

Ignition Switch................................................ 20

Emergency Stop Switch Clip and Emergency

Stop Switch .................................................. 20

Gearshift/Throttle Control Lever .................... 21

Fast Idle Lever ................................................ 22

Panel-Mount Type................................................ 23

Ignition Switch................................................ 23


Stop Switch .................................................. 24


Fast Idle Button............................................... 26

Top-Mount Type .................................................. 27

Ignition Switch................................................ 27


Stop Switch .................................................. 27


CONTENTS

Fast Idle Button ...............................................30

Tiller-Handle (optional equipment):.......................31

Ignition Switch ................................................31


Stop Switch...................................................31

Throttle Grip....................................................32

Throttle Friction Adjuster................................33

Gearshift Lever................................................34

Steering Friction Adjusting Knob ...................35

TRL (Trolling) Control Switch

(optional equipment) .........................................36

Power Trim/Tilt Switch ........................................37

Power Tilt Switch .................................................38

Manual Relief Valve.............................................38

Tilt Lock Lever.....................................................39

Engine Cover Latch (front/rear) ...........................39

Trim Tab ...............................................................39

INSTRUMENTS .......................................................40

Trim Meter (optional equipment) .........................40

Tachometer (optional equipment) ........................40

Fuel Gauge (optional equipment) .........................40

3

CONTENTS

INDICATORS........................................................... 41

Alternator (ACG) Indicator.................................. 41

Malfunction Indicator........................................... 42

Oil Pressure Indicator........................................... 42

Overheat Indicator................................................ 43

Cooling System Indicator..................................... 44

OTHER FEATURES ................................................ 44

Water Separator Buzzer ....................................... 44

Overrev Limiter.................................................... 45

Portable Fuel Tank (optional equipment) ............ 45

Fuel Filler Cap Vent Knob................................... 45

Fuel Priming Bulb ................................................ 46

Anodes.................................................................. 46

NMEA Interface Coupler..................................... 47

Operating Hour Notification System ................... 47

BEFORE OPERATION ................................................. 51

ARE YOU READY TO GET UNDERWAY? ......... 51

IS YOUR OUTBOARD MOTOR

READY TO GO? ................................................... 51

Tiller Handle Height/Angle Adjustment

(optional equipment) ......................................... 53

OPERATION ................................................................. 55

SAFE OPERATING PRECAUTIONS ..................... 55

4

BREAK-IN PROCEDURE........................................55

PORTABLE FUEL TANK (optional equipment).....56

FUEL HOSE CONNECTIONS.................................57

FUEL PRIMING........................................................58

INFREQUENT OR OCCASIONAL USE ................59

STARTING THE ENGINE .......................................59

Remote Control Box:............................................59

Side-Mount Type...............................................59

Panel-Mount Type .............................................62

Top-Mount Type ...............................................65

Tiller-Handle: .......................................................67

EMERGENCY STARTING......................................70

STOPPING THE ENGINE........................................72

Emergency Engine Stopping ................................72

Normal Engine Stopping ......................................73

GEARSHIFT AND THROTTLE OPERATION ......77

STEERING ................................................................80

CRUISING.................................................................81

SHALLOW WATER OPERATION .........................84

MOORING, BEACHING, LAUNCHING................85

MULTIPLE OUTBOARD MOTORS.......................87

SERVICING YOUR OUTBOARD MOTOR ................88

THE IMPORTANCE OF MAINTENANCE ............88

MAINTENANCE SAFETY ......................................89

TOOL KIT and OWNER’S MANUAL.....................90

EMERGENCY STARTER ROPE ............................ 90

MAINTENANCE SCHEDULE................................ 91

TRIM TAB ADJUSTMENT..................................... 93

MANUAL RELIEF VALVE .................................... 94

ENGINE COVER REMOVAL AND

INSTALLATION................................................... 94

Engine Oil Level Check ....................................... 95

Engine Oil Change ............................................... 97

Oil Filter Change.................................................. 98

Engine Oil Recommendations.............................. 99

Spark Plug Service ............................................. 100

Lubrication Points .............................................. 103

REFUELING........................................................... 105

FUEL RECOMMENDATIONS ............................. 107

Water Separator Inspection and Service ............ 108

Fuel Filter Inspection and Replacement............. 111

Portable Fuel Tank and Tank Filter Cleaning

(optional equipment) ....................................... 114

Anode Replacement ........................................... 115

Propeller Replacement ....................................... 115

Inspect After Operating...................................... 117

CLEANING AND FLUSHING ................................... 118

Cleaning and Flushing............................................. 118

CONTENTS

STORAGE ....................................................................120

Fuel .....................................................................120

Engine Oil...........................................................122

HOISTING THE OUTBOARD MOTOR ...............122

STORAGE PRECAUTIONS ..................................122

REMOVAL FROM STORAGE..............................123

TRANSPORTING ........................................................124

WITH OUTBOARD MOTOR

INSTALLED ON BOAT......................................124

WITH OUTBOARD MOTOR

REMOVED FROM BOAT ..................................125

TAKING CARE OF UNEXPECTED PROBLEMS ....126

ENGINE WILL NOT START.................................126

HARD STARTING OR STALLS

AFTER STARTING.............................................129

ENGINE OVERHEATS..........................................130

FUSES .....................................................................131

Electric Starter Will Not Operate .......................131

Battery Will Not Charge.....................................131

Fuse Replacement...............................................131

OIL PRESSURE INDICATOR TURNS OFF AND

ENGINE SPEED IS LIMITED ............................133

OVERHEAT INDICATOR COMES ON AND

ENGINE SPEED IS LIMITED ............................134

5

CONTENTS

WATER SEPARATOR BUZZER SOUNDS......... 136

SUBMERGED OUTBOARD MOTOR.................. 136

TECHNICAL INFORMATION .................................. 138

Serial Number Locations......................................... 138

Battery ..................................................................... 139

Emission Control System Information .................... 139

Star Label ................................................................ 142

Specifications .......................................................... 144

CONSUMER INFORMATION................................... 147

Emission Control System Warranty ........................ 147

INDEX.......................................................................... 152

6

IMPORTANT SAFETY

INFORMATION

The TOHATSU BFT75A and

BFT90A outboard motors are designed for use with boats that have a suitable manufacturer’s power recommendation. Other uses can result in injury to the operator or damage to the outboard motor and other property.

Most injuries or property damage can be prevented if you follow all instructions in this manual and on the outboard motor. The most common hazards are discussed in this chapter, along with the best way to protect yourself and others.

Operator Responsibility

• It is the operator’s responsibility to provide the necessary safeguards to protect people and property. Know how to stop the engine quickly in case of emergency. Understand the use of all controls.

• Stop the engine immediately if anyone falls overboard, and do not run the engine while the boat is near anyone in the water.

• Always stop the engine if you must leave the controls for any reason.

OUTBOARD MOTOR SAFETY

• Attach the emergency stop switch lanyard securely to the operator.

• Always wear a PFD (Personal

Flotation Device) while on the boat.

• Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.

• Be sure that anyone who operates the outboard motor receives proper instruction.

• Be sure the outboard motor is properly mounted on the boat.

• Do not remove the engine cover while the engine is running.

7


Refuel With Care

• Gasoline is extremely flammable, and gasoline vapor can explode.

Refuel outdoors, in a wellventilated area, with the engine stopped. Never smoke near gasoline, and keep other flames and sparks away.

• Refuel carefully to avoid spilling fuel. Avoid overfilling the fuel tank.

• After refueling, tighten the filler cap securely. If any fuel is spilled, make sure the area is dry before starting the engine.

Carbon Monoxide Hazard

Exhaust contains poisonous carbon monoxide, a colorless, odorless gas.

Breathing carbon monoxide can cause loss of consciousness and may lead to death.

If you run the engine in an area that is confined, or even partly enclosed, the air you breathe could contain a dangerous amount of exhaust gas.

Never run your outboard inside a garage or other enclosure.

Running the engine of your outboard while in an enclosed or partially enclosed area can cause a rapid build-up of toxic carbon monoxide gas.

Breathing this colorless, odorless gas can quickly cause unconsciousness and lead to death.

Only run your outboard engine when it is located in a well ventilated area outdoors.

8

SAFETY LABEL LOCATION

TILLER-HANDLE

(optional equipment)


The labels shown here contain important safety information. Please read them carefully. These labels are considered permanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized TOHATSU dealer for a replacement.

9


PORTABLE FUEL TANK


10

FUEL CAUTION

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

Model BFT75A BFT90A

Type

Transom Height

(Shaft Length)

21.1 in (537 mm)

26.1 in (664 mm)

Tiller Handle/Multi-Function Tiller Handle

LRT □

•

*

LRT □

•

*

XRT □

•

*

Remote Control

Power Trim/Tilt

*

•

*

*

•

*

*

•

* Tachometer

Trim Meter * * *

TRL (Trolling) Control Switch * * *

* Optional equipment

Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.

TYPE CODE (example)

L R T □

Destination

Tilt System: T= Power Trim/Tilt

Control System: R= Remote Control

Transom Height (Shaft Length): L= 21.1 in (537 mm), X= 26.1 in (664 mm)

11


COMPONENT AND CONTROL LOCATIONS

ENGINE COVER

ENGINE COVER

LATCH (rear)

OIL LEVEL DIPSTICK

ENGINE COVER

LATCH (front)

SPARK PLUG

(under ignition coil)

POWER TILT

SWITCH

IDLE PORT

STERN

BRACKET

MANUAL

RELIEF VALVE

COOLING SYSTEM

INDICATOR

FLUSH PORT

CONNECTOR

ANODE

(each side) ENGINE OIL

DRAIN BOLT

TRIM TAB

ANODE

EXHAUST PORT/WATER

OUTLET PORT

PROPELLER


ANTIVENTILATION

PLATE

12

OIL FILLER CAP

NMEA INTERFACE

COUPLER

TILT LOCK

LEVER

FRAME SERIAL

NUMBER

GEAR OIL

LEVEL SCREW

COOLING WATER

INTAKE PORT

(each side)

GEAR OIL DRAIN SCREW


Remote Controls (optional equipment)

(SIDE-MOUNT REMOTE CONTROL)

POWER TRIM/TILT

SWITCH

BUZZER

(inside)

GEARSHIFT/THROTTLE CONTROL LEVER

NEUTRAL RELEASE LEVER

TRL (Trolling) CONTROL SWITCH*

INDICATORS

(Oil pressure, Overheat,

Alternator, Malfunction)

FAST IDLE LEVER

IGNITION SWITCH

IGNITION SWITCH

KEY

EMERGENCY STOP SWITCH

CONTROL LEVER

FRICTION

ADJUSTER

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

* For TRL (Trolling) control switch equipped type.

13


(PANEL-MOUNT REMOTE CONTROL)

GEARSHIFT/THROTTLE

CONTROL LEVER

NEUTRAL RELEASE

LEVER

(SINGLE TOP-MOUNT REMOTE CONTROL)


CONTROL LEVER

POWER

TRIM/TILT

SWITCH

POWER TRIM/TILT

SWITCH

FAST IDLE

BUTTON

FAST IDLE BUTTON

(DUAL TOP-MOUNT REMOTE CONTROL)

GEARSHIFT/THROTTLE CONTROL LEVERS

POWER TRIM/TILT

SWITCH (RIGHT)

POWER TRIM/TILT

SWITCH (LEFT)

FAST IDLE

BUTTON

14


CONTROL PANEL

(for PANEL-MOUNT/TOP-MOUNT SINGLE type)

BUZZER

INDICATORS



CONTROL PANEL without indicators type

(for PANEL-MOUNT/TOP-MOUNT SINGLE type)

BUZZER

IGNITION

SWITCH KEY

IGNITION

SWITCH

EMERGENCY STOP

SWITCH CLIP

IGNITION

SWITCH KEY

EMERGENCY

STOP SWITCH

IGNITION

SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH LANYARD

(for TWO OUTBOARD

MOTORS type)

(for THREE OUTBOARD

MOTORS type)

(for TWO OUTBOARD MOTORS type)

For the control panel without indicators type, use it along with the NMEA2000-compatible device.

15


TILLER HANDLE (optional equipment)

INDICATORS




EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

IGNITION

SWITCH KEY

IGNITION SWITCH STEERING FRICTION

ADJUSTING KNOB

16

GEARSHIFT LEVER

THROTTLE FRICTION

ADJUSTER

POWER TRIM/TILT SWITCH

THROTTLE GRIP

SPARE EMERGENCY STOP SWITCH CLIP

Store the spare emergency stop switch clip in the tool bag.


Multi-Function Tiller Handle (optional equipment)

INDICATORS

(Oil pressure, Overheat, Alternator, Malfunction)

TRL (Trolling) CONTROL

SWITCH

GEARSHIFT LEVER


ADJUSTER

THROTTLE

GRIP

IGNITION SWITCH

IGNITION SWITCH KEY

STEERING FRICTION

ADJUSTING KNOB

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH LANYARD


SPARE EMERGENCY STOP SWITCH CLIP

Store the spare emergency stop switch clip in the tool bag.

17


Portable Fuel Tank (optional equipment)

Fuel Tank Hose Assembly (standard equipment)

FUEL HOSE CONNECTOR FUEL GAUGE

FUEL TANK

18

FUEL FILLER CAP VENT KNOB

FUEL HOSE JOINT

(outboard motor side)

FUEL PRIMING BULB

FUEL TANK HOSE

ASSEMBLY

Trim Meter


Tachometer



TRL (Trolling) Control Switch

Panel


TRL (Trolling) CONTROL SWITCH

19


CONTROLS

Remote Control Box:

Side-Mount Type

Ignition Switch

OFF

ON START

Turning the ignition switch key to the

START position operates the starter motor. The key automatically returns to the ON position when released from the START position.

The ignition switch can be used to start the engine only when the control lever is in the N (neutral) position

(p.59) and the emergency stop switch clip is in the emergency stop switch.

Turning the ignition switch to the

OFF position stops the engine.

Emergency Stop Switch Clip and

Emergency Stop Switch


EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

IGNITION

SWITCH

The ignition switch controls the ignition system and the starter motor.

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

20

The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The emergency stop switch lanyard must be attached to the operator’s PFD (Personal Flotation

Device) or to the operator securely.

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.

A spare switch clip (optional equipment) can be stored in the tool bag.


Gearshift/Throttle Control Lever


CONTROL LEVER

SPARE SWITCH CLIP


NEUTRAL RELEASE

LEVER

The gearshift/throttle control lever controls engine speed and selects F

(forward), N (neutral), or R (reverse) gears.

21


F (FORWARD)

N (NEUTRAL)

32° 32°

SHIFT

MINIMUM

R (REVERSE)

SHIFT

MINIMUM

THROTTLE OPENING


MAXIMUM

Fast Idle Lever

FAST IDLE LEVER

MAXIMUM


CONTROL LEVER

Moving the control lever 32° from N

(neutral) selects the gear, and further movement increases engine speed.

The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle.

A friction adjuster adjusts the operating resistance of the control lever(s). Refer to p.78.

Less friction allows easier control lever movement. More friction helps to hold a steady throttle setting while cruising.

Use the fast idle lever to accelerate engine warm-up after starting the engine. Do not use the fast idle lever when starting the engine.

See page 61 for engine warm-up instructions.

22

N (neutral)

MAXIMUM FAST IDLE

FAST IDLE LEVER

LOWEST

POSITION

The fast idle lever allows you to increase the idle speed only when the control lever is in the N (neutral) position. Place the fast idle lever in its lowest position to cancel the fast idle and return the control lever to normal operation.

Panel-Mount Type


OFF

IGNITION

SWITCH

ON

START









23





The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The emergency stop switch lanyard must be attached securely to the operator or to the operator’s PFD

(Personal Flotation Device).


EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

24


Gearshift/Throttle Control Lever


CONTROL LEVER F (FORWARD)


N (NEUTRAL)

35° 35°

SHIFT

MINIMUM

R (REVERSE)

SHIFT

MINIMUM


MAXIMUM

NEUTRAL

RELEASE

LEVER

The gearshift/throttle control lever controls engine speed and selects F


MAXIMUM



The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle.


CONTROL LEVER

A friction adjuster near the base of the control lever adjusts the operating resistance of the control lever. Refer to p.78.


25


Fast Idle Button


Use the fast idle button to accelerate engine warm-up after starting the engine. Do not use the fast idle button when starting the engine.


F (forward)

N (neutral)

R (reverse)

It is necessary to position the control lever in the N (neutral) position to push in the fast idle button.

Return the control lever to N (neutral) position to cancel the fast idle operation.

CONTROL

LEVER

Push

Pull up

NEUTRAL

RELEASE

LEVER


The fast idle button allows you to increase the idle speed without engaging the drive gears. Move the control lever toward the F (forward) or R (reverse) position after pushing in the fast idle button to increase the idle speed.

26

Top-Mount Type


ON

START

OFF

IGNITION

SWITCH












EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

27





Gearshift/Throttle Control Lever The gearshift/throttle control lever(s) controls engine speed and selects F

SINGLE TYPE


DUAL TYPE

GEARSHIFT/

THROTTLE

CONTROL

LEVER


CONTROL LEVERS

28




A friction adjuster inside the control box adjusts the operating resistance of the control lever(s). Refer to p.78.


F (FORWARD)

35°

SHIFT

N (NEUTRAL)

SHIFT

35°

R (REVERSE)

MINIMUM


MINIMUM


MAXIMUM

MAXIMUM

GEARSHIFT/THROTTLE CONTROL LEVER

29


Fast Idle Button

F (forward)

N (neutral)

R (reverse)

It is necessary to position the control lever in the N (neutral) position to push in the fast idle button.

Return the control lever to N (neutral) position to cancel the fast idle operation.

CONTROL

LEVER


Use the fast idle button to accelerate engine warm-up after starting the engine. Do not use the fast idle button when starting the engine.


Push


The fast idle button allows you to increase the idle speed without engaging the drive gears. Move the control lever toward the F (forward) or R (reverse) position after pushing in the fast idle button to increase the idle speed.

30

Tiller-Handle (optional equipment):


(Tiller Handle)

ON

START

OFF

IGNITION SWITCH

IGNITION

SWITCH

KEY

(Multi-Function Tiller Handle)

ON

START

CONTROLS AND FEATURES stop switch clip is in the emergency stop switch.



OFF



(Tiller Handle)

IGNITION SWITCH

IGNITION

SWITCH

KEY




The engine will not start unless the gearshift lever is in the N (neutral) position (p. 68) and the emergency


EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY STOP

SWITCH CLIP

31




EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP SWITCH CLIP



When used as described, the emergency stop switch and emergency stop switch lanyard system stops the engine if the operator falls away from the controls.

A spare switch clip is supplied with the outboard motor.

Throttle Grip

(Tiller Handle)

THROTTLE GRIP

INCREASE

THROTTLE INDEX MARK

EMERGENCY STOP

SWITCH LANYARD

SPARE SWITCH CLIP

32


INCREASE

THROTTLE INDEX MARK

POINTER

THROTTLE

GRIP

The throttle grip controls engine speed.

An index mark on the tiller arm shows throttle position and is helpful for setting the throttle correctly when starting (p. 79).




ADJUSTER

HOLD

Throttle Friction Adjuster

(Tiller Handle)


ADJUSTER

RELEASE

THROTTLE GRIP

HOLD

RELEASE

THROTTLE GRIP

The throttle friction adjuster adjusts resistance to throttle grip rotation.

Turn the adjuster clockwise to increase friction for holding a throttle setting while cruising.

Turn the adjuster counterclockwise to decrease friction for easy throttle grip rotation.

33


Gearshift Lever

(Tiller Handle)

F

(forward)

N (neutral)

R (reverse)

The gearshift lever is used to select F


The engine can be started with the gearshift lever in the N (neutral) position only.

(Tiller Handle)


SLOWEST

SLOWEST

SLOWEST

GEARSHIFT LEVER


R (reverse)

N (neutral)

F (forward)

SLOWEST

THROTTLE GRIP

THROTTLE GRIP

The shift lever will not move unless the throttle grip is in the fully closed position.

GEARSHIFT

LEVER

34


GEARSHIFT LEVER

You can chose which side of the tiller handle to have the gearshift lever installed. Consult your authorized

TOHATSU outboard motor dealer.

Steering Friction Adjusting Knob

(Tiller Handle)


ADJUSTING KNOB

To increase friction




To decrease friction STEERING

FRICTION

ADJUSTING KNOB

To decrease friction

Use the steering friction adjusting knob to adjust the tiller handle friction. Turning it clockwise increases friction and turning it counterclockwise decreases friction.

35


TRL (Trolling) Control Switch


Remote Control Box

(Side-mount type)

For TRL (Trolling) control switch equipped type.

Tiller-Handle


TRL (Trolling) Control Switch

Panel

TROLLING

CONTROL SWITCH

TRL (Trolling)

CONTROL SWITCH


The Trolling Control Switch is a rocker switch with UP and DN

(down) positions to adjust the trolling speed up or down in 50 rpm increments within the range of 650 to

1,000 rpm.

If you press and hold the TRL control switch while cruising with the throttle closed, the mode changes to trolling mode (p.83).

36

Power Trim/Tilt Switch


(side-mount type)


Tiller-Handle

(Tiller Handle)

(top-mount single type)


POWER

TRIM/TILT

SWITCH

CONTROL

LEVER

(panel-mount type)


CONTROL LEVER

CONTROL

LEVER

POWER TRIM/

TILT SWITCH


POWER TRIM/

TILT SWITCH

(top-mount dual type)

POWER TRIM/TILT SWITCHES

(LEFT) (RIGHT)

CONTROL

LEVERS

The power trim/tilt switch is located on the tiller handle or on the control lever. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.

37


You can use the power trim/tilt switch anytime whether the boat is underway, stopped, or the ignition switch is in the OFF position. It is necessary for the ignition switch to be in the ON position for the trim meter to indicate the outboard motor angle.

Trim the outboard motor to obtain the best performance and stability (p.81).

Tilt the outboard motor for shallow water operation, beaching, launching, or mooring.

For dual mount outboard motors, tilt them up at the same time.

Power Tilt Switch

(engine pan side)

POWER TILT SWITCH

The power tilt switch is located on the engine pan. It is a rocker switch with

UP and DN (down) positions for changing the angle of the outboard motor.

The power tilt switch will operate without turning the ignition switch

ON.

This switch is used with the engine stopped to raise the outboard motor for mooring, trailering, or maintenance.

38

Manual Relief Valve

POWER

(To hold)

MANUAL

(To release)

MANUAL RELIEF VALVE

The outboard motor can be tilted manually after opening the manual relief valve. This allows the outboard motor to be tilted up or down when no battery is connected.

Check that nobody is under the outboard motor before opening the manual relief valve. If the manual relief valve is loosened (turned counterclockwise) when the outboard motor is tilted up, the outboard motor will suddenly tilt down.

Tilt Lock Lever

FREE

Engine Cover Latch

(front/rear)

ENGINE

COVER

LATCHES

(front/rear)


Trim Tab

GEAR CASE

GROMMET

UNLATCH

LOCK

STERN BRACKET

TILT LOCK LEVER

The tilt lock lever is used to support the outboard motor in the fully-raised position.

When the boat is to be moored for a long time, tilt the outboard motor up as far as it will go. Then move the tilt lock lever to the LOCK position, and gently lower the outboard motor until the lever contacts the stern bracket.

LOCK

The engine cover latch fastens the engine cover to the outboard motor.

TRIM TAB

TRIM TAB BOLT

The trim tab compensates for “torque steer,” which is a reaction of the outboard motor to propeller rotation.

If uncompensated, torque steer would make the outboard motor tend to turn to one side.

When the trim tab is correctly adjusted (p.93), steering effort is equal in either direction.

39


INSTRUMENTS

Trim Meter


Tachometer


Fuel Gauge


FUEL GAUGE

The trim meter indicates the relative trim angle of the outboard motor.

Refer to the trim meter when using the power trim/tilt switch to achieve the best performance from the boat.

The tachometer shows engine speed in revolutions per minute.

Refer to the tachometer when using the throttle and power trim/tilt controls to achieve the best performance from the boat.

A fuel gauge is built into the fuel tank connector of the portable fuel tank.

40

INDICATORS

The indicator lights come on and the buzzer sounds when you turn the ignition switch ON, allowing you to see that they are working. If an indicator does not light during this test, it cannot alert you if that system develops a problem. Have your

TOHATSU dealer check for burnedout bulbs or other problems.

Under normal conditions, the following occur when the ignition switch is turned ON:

1. The ACG, Malfunction, Oil

Pressure, and Overheat indicators light.

2. The buzzer will beep twice.

3. The Malfunction, Oil Pressure, and

Overheat indicators will go out after the second beep.

4. The ACG indicator will go out after the engine starts.

5. The Oil Pressure indicator will light again after the engine starts and will stay lit to indicate the oil pressure is normal.


If using a panel-mount or top-mount control panel without indicators, check the indicators displayed on an

NMEA2000-compatible device.

For information about NMEA2000compatible device displays, refer to the display device's manual.

Alternator (ACG) Indicator



ACG INDICATOR

(RED)

BUZZER

(panel-mount/top-mount types)

ACG INDICATOR

(RED)

BUZZER

41


Tiller-Handle

(RED)


MALFUNCTION

INDICATOR

ACG INDICATOR

(RED)

(internal buzzer)

The ACG indicator turns on and the buzzer sounds in one-second intervals when the charging system is faulty.

BUZZER

Tiller-Handle

(RED)

Malfunction Indicator



MALFUNCTION

INDICATOR

(RED)

BUZZER

MALFUNCTION

INDICATOR


When the engine control system detects an engine control system malfunction, the malfunction indicator turns on and the buzzer sounds at one-second intervals.

42

Oil Pressure Indicator



OIL PRESSURE

INDICATOR


OIL PRESSURE

INDICATOR

(GREEN)

BUZZER

(GREEN)

BUZZER

Tiller-Handle

OIL PRESSURE

INDICATOR

(GREEN)


When the oil pressure indicator is lit, oil pressure is OK.

If oil pressure becomes low, the indicator will turn off, and the engine protection system will limit engine speed. Refer to TAKING CARE OF

UNEXPECTED PROBLEMS , on p.133.

All models are equipped with a buzzer that sounds continuously

CONTROLS AND FEATURES when the oil pressure indicator turns off.

Low oil pressure indicates that the engine oil level is low or that there is a problem with the engine lubrication system.


OVERHEAT

INDICATOR

(RED)

Overheat Indicator



OVERHEAT

INDICATOR

BUZZER

Tiller-Handle

(RED)

(RED)

BUZZER

OVERHEAT

INDICATOR


43


When the alert triggers, the overheat indicator comes on and the buzzer sounds a steady tone as the engine speed is reduced to 1,800 rpm. If the condition persists for another 20 seconds, the engine shuts off. Refer to

TAKING CARE OF UNEXPECTED

PROBLEMS , on p.134.

All models are equipped with a buzzer that sounds continuously when the red overheat indicator light comes on.

The buzzer will also sound when the hour counter is reset (p.47).

Engine overheating may be the result of clogged water intakes.

Cooling System Indicator

COOLING SYSTEM INDICATOR

Water should flow from the cooling system indicator while the engine is running. This shows that water is circulating through the cooling system.

If water stops flowing while the engine is running, it indicates a cooling system problem, such as clogged water intakes, which will cause engine overheating.

The cooling system indicator discharge port can also become plugged.

44

OTHER FEATURES

Water Separator Buzzer

The water separator buzzer sounds a rapid, repeating signal when water has accumulated in the water separator.

WATER SEPARATOR

Overrev Limiter

The engine is equipped with an overrev limiter to prevent the possibility of mechanical damage from excessive engine speed.

The overrev limiter may be activated during operation, limiting engine speed, if the outboard motor is trimmed or tilted up excessively, or when propeller ventilation occurs during a sharp turn.

If the overrev limiter is activated, check the trim angle of the outboard motor.

Check to see if the correct propeller is installed.

Portable Fuel Tank



FUEL HOSE

(standard equipment)

The portable fuel tank has a capacity of 6.6 US gal (25 L) and has a fuel gauge built into the fuel tank connector.


Fuel Filler Cap Vent Knob

VENT KNOB

OPEN

CLOSE

FUEL FILLER CAP

The fuel filler cap is provided with a vent knob to seal the portable fuel tank for carrying it to and from the boat. Open the vent by turning the vent knob counterclockwise all the way before starting the engine.

45


Fuel Priming Bulb Anodes

UP

OUTLET END


PRIMING BULB

INLET END

(fuel tank side)

A priming bulb is built into the fuel hose that connects the fuel tank to the outboard motor.

Before starting the engine, hold the priming bulb up in the direction of the arrow; then squeeze the priming bulb until it feels firm. This will ensure that fuel is supplied to the engine

(p.58).

ANODE

(each side)

The anodes are made of a sacrificial material that helps to protect the outboard motor from corrosion.

There are two anodes on the gear case, one on the stern bracket and two small anodes in the water passages of the engine block.

46

ANODE

(stern bracket)

NMEA Interface Coupler

NMEA INTERFACE COUPLER

The NMEA2000

®

interface coupler can provide information regarding engine speed, fuel consumption, and various warnings to an existing

NMEA2000 network via an optional interface cable. Contact your dealer for more information.


Operating Hour Notification

System

This outboard motor engine counts the number of operating hours since the last periodic maintenance. When the next periodic maintenance is due, the engine notifies the NMEA2000 network, and a maintenance indication is displayed on an


After periodic maintenance is performed, reset the hour counter by:

1. Stopping the engine.

2. Setting the gearshift at F or R.

3. Turning the ignition switch ON.

The buzzer will sound once.

4. Pressing the emergency stop switch

5 times within 20 seconds.

When using the control panel without indicators type, within 20 seconds, pull and insert the emergency stop switch clip, or remove the clip and pull the emergency stop switch 5 times.

The buzzer will sound once when the hour counter is reset.

47


Periodic maintenance is required when either the operating hours or the time since last maintenance reaches the prescribed limit. Therefore, periodic maintenance may be required based on the number of months since the last maintenance before the alert based on engine operating hours displays (see

MAINTENANCE SCHEDULE on page 91).

Reset the hour counter whenever maintenance is performed, whether based on the time interval or the number of operating hours.

<Operating hour notification timing>

20 hours

80 hours after reset

Start of operation

Notify Notify

Every 100 hours

100 hours after reset

Notify

48

<Display>

Steps

Outboard motor

Display

Maintenance indication on display

1

—

Switch ON

Not shown

Maintenance indication

2

Ignition switch

ON

—

Shown


3

Start engine

—

Shown


4

Gear at F or R

—

Not shown



When the periodic maintenance is conducted before “Periodic

Maintenance” is indicated, reset the hour counter.

If not reset, the hour count until the next maintenance will be in error.

NMEA2000-compatible display:

• Follow instructions for the display.

• If the display allows selection of notification to be preset, select “Notify” (or equivalent).

• Turn on the power supply to the display before turning on the ignition switch of the outboard motor.

• The indication may differ, depending on the type of display.

When “Periodic Maintenance” is indicated:

1. Have the periodic maintenance performed without delay after returning to port.

2. Reset the hour counter.

If not reset, the maintenance indication will remain in the display, and the hour count until the next maintenance will be in error.

49


How to reset the Hour Counter

1. Be sure to turn OFF the engine before beginning the reset procedure. Pull the emergency stop switch clip out of the emergency stop switch by pulling the emergency stop switch lanyard.

2. Put the shift lever in “F” (Forward) or “R” (Reverse).

3. Turn the ignition switch ON. Do not start the engine. The buzzer will sound once.

4. Press the emergency stop switch

5 times within 20 seconds.

When using the control panel without indicators type, within 20 seconds, pull and insert the emergency stop switch clip, or remove the clip and pull the emergency stop switch 5 times.

The buzzer will sound once indicating the hour counter is reset.

50

ARE YOU READY TO GET

UNDERWAY?

Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury.

Knowledge

Read and understand this manual.

Know what the controls do and how to operate them.

Familiarize yourself with the outboard motor and its operation before you get underway. Know what to do in case of an emergency.

Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.

BEFORE OPERATION

Safety

Always wear a PFD (Personal

Flotation Device) while on the boat.

Attach the emergency stop switch clip securely to the operator or to the operator’s PFD (Personal Flotation

Device).

IS YOUR OUTBOARD

MOTOR READY TO GO?

For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the outboard motor to check its condition.

Be sure to take care of any problem you find, or have your authorized

TOHATSU dealer correct it, before you operate the outboard motor.

Failure to properly maintain this outboard motor, or failing to correct a problem before operation, could result in a significant malfunction.

Some malfunctions can cause serious injuries or death.

Always perform a pre-operation inspection before each operation and correct any problems.

Before beginning your pre-operation checks, be sure the ignition switch is in the OFF position.

51


Safety Inspection

• Before each use, look around and underneath the engine for signs of oil or gasoline leaks.

• If you are using the portable fuel tank (optional equipment), make sure it is in good condition and properly secured in the boat (p.56).

• Check that the fuel hose is undamaged and properly connected.

• Wipe up any spills before starting the engine.

• Check the stern bracket to be sure the outboard motor is securely installed.

• Check that all controls are operating properly.

• Replace any damaged parts.

• Check that all fasteners are in place and securely tightened.

• Check the emergency stop switch for proper operation. Start the engine (p.20, 24, 27 or 31). Make sure the engine stops by pulling the emergency stop switch clip from the emergency stop switch (p.72).

Maintenance Inspection

• Check the engine oil level (p.95).

Running the engine with a low oil level can cause engine damage.

Overfilling the engine can cause the engine to smoke or have oil leaks which can cause engine damage.

• Check to be sure the propeller is undamaged and the castle nut is secured with the cotter pin (p.116).

• Check that the anodes are securely attached to the stern bracket and the gear case (p.115) and are not excessively worn. The anodes help protect the outboard motor from corrosion.

• Make sure a tool kit and the emergency starter rope are onboard

(p.90). Replace any missing items.

• Check the fuel level in the fuel tank

(p.105).

• Check that the battery fluid is between the upper and lower levels, and the battery leads are connected securely.

• Check the water separator for water contamination (p.108).

52


Tiller Handle Height/Angle

Adjustment (optional equipment)

The tiller handle height and angle can be adjusted to three positions by changing the installation direction of the height adjustment block. Select a suitable height and angle for the operator and secure the block.

1. Raise the tiller handle and remove the 8 × 28 mm flange bolt and the height adjustment block.

2. Pull down the tiller handle.

Determine the height adjustment block installation direction and secure the block with the 8 × 28 mm flange bolt.

(Tiller Handle)

HANDLE ANGLE: 13°


HANDLE

ANGLE: 21°

Install the height adjustment block so that the selected angle of the tiller handle is in this position.


11.7 in

(298 mm)


14.2 in

(361 mm)


17.2 in

(438 mm)

HEIGHT

Reference point

HEIGHT

ADJUSTMENT

BLOCK

8 × 28 mm

FLANGE BOLT

53




HANDLE ANGLE:

21°

Install the height adjustment block so that the selected angle of the tiller handle is in this position.


HEIGHT ADJUSTMENT

BLOCK

8 × 28 mm

FLANGE BOLT

HEIGHT

Reference point


12.5 in

(317 mm)


14.9 in

(378 mm)


18.0 in

(456 mm)

54

SAFE OPERATING

PRECAUTIONS

To safely realize the full potential of this outboard motor, you need a complete understanding of its operation and a certain amount of practice with its controls.

Before operating the outboard motor for the first time, please review the

IMPORTANT SAFETY

INFORMATION on page 7 and the chapter titled BEFORE OPERATION .

For your safety, do not start or run the engine in a confined or partly enclosed area. Your engine’s exhaust contains poisonous carbon monoxide, a colorless, odorless gas that can collect rapidly. Breathing carbon monoxide can cause loss of consciousness and may lead to death.

Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas.

Breathing carbon monoxide can cause unconsciousness or death.

Never run this product's engine in a closed, or even partially closed area.

OPERATION

BREAK-IN PROCEDURE

Break-in period: 10 hours

Proper break-in operation allows the moving parts to wear in smoothly for best performance and long service life. Avoid continuous operation at a steady speed.

First 15 minutes:

Run the engine at trolling speed. Use the minimum throttle opening necessary to operate the boat at a safe trolling speed.

Next 45 minutes:

Run the engine up to a maximum of

2,000 to 3,000 rpm, which is about

10% to 30% of maximum throttle opening. Operating at maximum

2,000 ~ 3,000 rpm should be limited to 50% of the 45 minutes.

55

OPERATION

Next 60 minutes:

Run the engine up to a maximum of

4,000 to 5,000 rpm, which is about

50% to 80% of maximum throttle opening. Operating at maximum

4,000 ~ 5,000 rpm should be limited to 50% of the 60 minutes.

30-second full-throttle bursts are OK, but do not operate the engine continuously at full throttle.

For boats that plane easily, bring the boat up on plane, and then reduce the throttle opening to the recommended rpm range.

Next 8 hours:

Do not run the engine at full throttle for more than 5 minutes at a time.




Secure the portable fuel tank in the boat so that it won't move around and become damaged.

FUEL HOSE


Place the portable fuel tank in a wellventilated location, away from direct sunlight, to reduce the possibility of a gasoline vapor explosion.

To ensure that the outboard motor will be able to draw fuel from the tank, place the tank within 6 feet

(2 m) of the outboard motor and not more than 3 feet (1 m) below the fuel connector on the outboard motor.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Stop the engine and let it cool before handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.

• Keep away from your vehicle.

• Wipe up spills immediately.

56

FUEL HOSE CONNECTIONS

Turn the portable fuel tank vent knob counterclockwise to the open position.

HOSE PLUG

FUEL HOSE


BARB

OPERATION

FUEL HOSE CONNECTOR

FUEL

HOSE

HOSE

CLAMP

FUEL HOSE

ASSEMBLY

FUEL HOSE

JOINT

HOSE CLAMP

(stainless steel)

ARROW

PRIMING

BULB

(toward outboard motor side)

1. Remove the hose plug from the outboard motor side fuel hose.

Insert the fuel hose joint into the outboard motor side fuel hose and secure it with the hose clamp.

Make sure the arrow mark on the priming bulb points toward the outboard motor side.

• Store the hose plug in a secure place.


2. Connect the fuel hose to the tank and the outboard motor, as shown.

Be sure both connectors snap securely into place. Always disconnect the fuel hose when storing or transporting the outboard motor.

57

OPERATION

(Using the fuel tank mounted on the boat)

FUEL HOSE ASSEMBLY



FUEL HOSE


BARB

FUEL PRIMING

If you are using a portable fuel tank, turn the portable fuel tank vent knob counterclockwise to the open position.

UP

OUTLET END


HOSE CLAMP

(stainless steel)


PRIMING BULB

1. Remove the hose plug from the outboard motor side fuel hose.

Insert the fuel hose joint into the outboard motor side fuel hose and secure it with the hose clamp

(p.56).

2. Insert another fuel hose joint up to the barb of the joint in the fuel tank side and secure it with the hose clamp (stainless steel type). Refer to the owner’s manual for the boat.

INLET END


Hold the priming bulb up in the direction of the arrow; then squeeze the priming bulb several times until it feels firm, indicating that fuel has reached the engine.

Check to be sure there are no fuel leaks before starting the engine.

58

Do not touch the priming bulb with the engine running or when tilting up the outboard motor. The vapor separator could overflow.








INFREQUENT OR

OCCASIONAL USE

If your outboard motor will be used on an infrequent or intermittent basis, please refer to the fuel section of the

STORAGE chapter (p.120) for additional information regarding fuel deterioration.

STARTING THE ENGINE

Control

Remote Control Box:

Page

Side-Mount Type....................... 59

Panel-Mount Type ..................... 62

Top-Mount Type........................ 65

Tiller-Handle:................................ 67

Remote Control Box:

Side-Mount Type


OPERATION

1. Put the emergency stop switch clip in the emergency stop switch, and securely to the operator or to the operator’s PFD (Personal Flotation

Device).

The engine will not start or run unless the emergency stop switch clip is in the emergency stop switch.

The emergency stop switch clip and emergency stop switch lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat.

Always attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD before starting the engine.

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

59

OPERATION

N (neutral)

FAST IDLE

RANGE

LOWEST

POSITION

OFF

ON START

CONTROL

LEVER

2. Set the control lever in the N

(neutral) position.

The engine will not start if the F

(forward) or R (reverse) gears are engaged.


FAST IDLE LEVER

3. Leave the fast idle lever in the OFF

(fully lowered) position.

The fast idle lever cannot be raised unless the control lever is in the N

(neutral) position.

The control lever cannot be moved away from the N (neutral) position unless the fast idle lever is lowered.

4. Turn the ignition switch key to the

ON position; the buzzer will sound twice.


START position and hold it there until the engine starts.

When the engine starts, release the key, allowing it to return to the ON position.

60

OPERATION

If the engine fails to start within 5 seconds, release the key and wait at least 10 seconds before operating the starter again.

MAXIMUM FAST IDLE

FAST IDLE

RANGE

• Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.

• Turning the ignition switch key to the START position while the engine is running can damage the starter motor and flywheel.

6. Before getting underway, allow the engine to warm-up sufficiently to ensure good performance.

Above 41°F (5°C), warm-up the engine for at least 3 minutes.

Below 41°F (5°C), warm-up the engine for at least 5 minutes at

2,000 rpm. Raise the fast idle lever to achieve approximately 2,000 rpm.

• If the engine is not properly warmed up before raising the engine speed, the buzzer and overheat indicator may activate and the engine speed will be automatically reduced.

• The cooling system may freeze in areas where the temperature reaches 32°F (0°C) or below.

Cruising at high speed without warming the engine up may cause engine damage.

61

OPERATION

During the warm-up period, check the oil pressure indicator (p.42), overheat indicator (p.43), and cooling system indicator (p.44).

If the indicators show any abnormal condition, immediately stop the engine and determine the cause of the problem. Refer to

TAKING CARE OF

UNEXPECTED PROBLEMS on p.133-136.

7. If the fast idle lever was used to warm-up the engine, gradually lower the lever as the engine warms up.

When the fast idle lever is fully lowered, the control lever can be moved away from the N (neutral) position.



EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

1. Put the emergency stop switch clip in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD (Personal

Flotation Device).




62

N (neutral)

ON

START

OFF

CONTROL

LEVER


(neutral) position.



IGNITION

SWITCH

KEY






OPERATION




63

OPERATION

N (neutral)

CONTROL

LEVER





2,000 rpm. Push the fast idle button, and then move the control lever forward or reverse to open the throttle and achieve approximately

2,000 rpm.

64





If using the control panel without indicators type, check the oil pressure indicator and overheat indicator displayed on an



TAKING CARE OF


6. If the fast idle button was used to warm up the engine, gradually return the control lever to the N

(neutral) position as the engine warms up.

Top-Mount Type


EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD


Flotation Device).

OPERATION




CONTROL

LEVER

N (neutral)


(neutral) position.



65

OPERATION

OFF

ON

START

IGNITION

SWITCH

KEY







N (neutral)



CONTROL

LEVER





2,000 rpm. Push the fast idle button, and then move the control lever forward or reverse to open the throttle and achieve approximately

2,000 rpm.

66





If using the control panel without indicators type, check the oil pressure indicator and overheat indicator displayed on an



TAKING CARE OF


6. If the fast idle button was used to warm up the engine, gradually return the control lever to the N

(neutral) position as the engine warms up.

Tiller-Handle:

(Tiller Handle)

OPERATION


EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY STOP

SWITCH CLIP



EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY

STOP SWITCH

CLIP

67

OPERATION


Flotation Device).




(Tiller Handle)

GEARSHIFT

LEVER

N (neutral)


N (neutral)

GEARSHIFT

LEVER

2. Check the position of the gearshift lever. It must be in the N (neutral) position for starting.

The engine will not start if the gearshift lever is in the F (forward) or R (reverse) position.

(Tiller Handle)

START

POSITION

POINTER

THROTTLE GRIP


START

POSITION

POINTER

THROTTLE GRIP

3. Align the engine start symbol

‘‘ ’’ on the tiller handle with the pointer ‘‘ ’’ on the throttle grip.



68

(Tiller Handle)

ON

OFF

OFF


START



ON

START

OPERATION







Below 41°F (5°C), warm-up the engine for at least 5 minutes at 2,000 rpm.



Also, as the engine warms up, the throttle grip can be turned to the

SLOW position without stalling.





69

OPERATION


TAKING CARE OF


EMERGENCY STARTING

If the battery is discharged or the starter motor is inoperative, you can start the engine manually using the emergency starter rope supplied with the outboard motor.

6 × 25 mm

FLANGE BOLT

6 mm WASHER

CLAMP

HOOKS

ALTERNATOR

COVER

CLAMPS

UNLATCH

ENGINE COVER

LATCHES

(front/rear)


OFF position (p.74).

2. Unlatch the engine cover latches and remove the engine cover.

BREATHER

TUBE

CLAMP

(on the silencer case)

3. Release the breather tube from the four clamps.

4. Remove 6 × 25 mm flange bolt and

6 mm washer, and then remove the alternator cover.

70

5. Secure the breather tube to the clamp of the silencer case.

Take care not to lose the bolt and washer.

6. Set the controls the same as for normal starting (p. 59, 62, 64, 67).

Use the fast idle control if needed.

Turn the ignition switch key to the

ON position.

Direction to pull

EMERGENCY

STARTER

ROPE

OPERATION

8. Pull the emergency starter rope slowly until resistance is felt, then pull briskly.

Keep away from moving parts while pulling the rope.

If necessary, rewind the rope and pull again. If the engine does not start after several attempts, refer to

TAKING CARE OF


KNOT CUTOUT ALTERNATOR

PULLEY

7. Set the alternator pulley so the cutouts are on the right and left sides of the alternator pulley as shown. Hook the knot at the end of the starter rope against a cutout in the alternator pulley, and wind the starter rope one and a half turns clockwise along the groove in the alternator pulley.

Exposed moving parts can cause injury.

• Do not operate the outboard motor without the engine cover.

• Use extreme care when installing the engine cover.

71

OPERATION

9. If the fast idle control(s) was used to start the engine, return the control(s) to the normal operating position as the engine warms up.


10. Leave the alternator cover off, but install the engine cover (p.94) and lock it in place by latching the engine cover latches.

11. If it was necessary to remove the emergency stop switch lanyard from you to perform the emergency starting procedure, be sure the lanyard is attached securely to operator before operating the outboard motor.

12. Have your closest authorized

TOHATSU dealer check your electrical system and correct the problem so that you can use the electric starter.

STOPPING THE ENGINE

Emergency Engine Stopping


Side-Mount Type


EMERGENCY

STOP SWITCH

LANYARD

PULL

Panel-Mount/Top-Mount Types

EMERGENCY

STOP SWITCH

CONTROL PANEL

EMERGENCY

STOP SWITCH

LANYARD

PULL



(Tiller Handle)



PULL

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

72



Normal Engine Stopping


Side-Mount Type

N (neutral)

PULL

EMERGENCY

STOP SWITCH

CLIP

EMERGENCY

STOP SWITCH

LANYARD

To stop the engine in an emergency, pull the emergency stop switch clip out of the emergency stop switch by pulling the emergency stop switch lanyard.

We suggest that you stop the engine this way occasionally to verify that the emergency stop switch is operating properly.

Turn the ignition switch key to the

OFF position after verifying the emergency stop switch operation.

CONTROL

LEVER

OPERATION


N (neutral)

CONTROL

LEVER

Top-Mount Type

N (neutral)

CONTROL

LEVER

73

OPERATION

1. Move the control lever to the N

(neutral) position.

After cruising at full throttle, cool down the engine by idling for a few minutes before stopping the engine.


Side-Mount Type

OFF

IGNITION

SWITCH KEY


OFF

IGNITION

SWITCH KEY

74


OFF position to stop the engine.

In the event that the engine does not stop when the ignition switch key is turned to the OFF position, pull the emergency stop switch clip out of the emergency stop switch by pulling the emergency stop switch lanyard (p.72).

3. When the boat is not in use, remove and store the ignition switch key and the emergency stop switch clip and lanyard. If you are using a portable fuel tank, disconnect the fuel hose if you will be storing or transporting the outboard motor.


(Tiller Handle)

THROTTLE GRIP

SLOW

N (neutral)

OPERATION


THROTTLE GRIP

N (neutral)

SLOW

GEARSHIFT

LEVER

GEARSHIFT

LEVER

75

OPERATION

1. Move the throttle grip to the slowest speed and the gearshift lever or control lever to the N

(neutral) position.

After cruising at full throttle, cool down the engine by idling for a few minutes before stopping the engine.


(Tiller Handle)

OFF




OFF position to stop the engine.

In the event that the engine does not stop when the ignition switch key is turned to the OFF position, pull the emergency stop switch clip out of the emergency stop switch by pulling the emergency stop switch lanyard (p.72).

3. When the boat is not in use, remove and store the ignition switch key and the emergency stop switch clip and lanyard. If you are using a portable fuel tank, disconnect the fuel hose if you will be storing or transporting the outboard motor.

OFF


76

GEARSHIFT AND

THROTTLE OPERATION


Side-Mount Type

CONTROL LEVER

N (neutral)

NEUTRAL

RELEASE

LEVER


N (neutral)

F (forward)

CONTROL

LEVER

R (reverse)

NEUTRAL

RELEASE

LEVER

OPERATION

To shift gears, move the control lever to select the F (forward), N (neutral), or R (reverse) gear.

The control lever cannot be moved from the N (neutral) position unless the neutral release lever is squeezed

(side-mount/panel-mount types).

Moving the control lever beyond the gear selection range increases engine speed.

Top-Mount Type

N (neutral)

F (forward)

R (reverse)

F (forward)

R (reverse) CONTROL

LEVER

77

OPERATION


Side-Mount Type

CONTROL LEVER

FRICTION ADJUSTER

Top-Mount Type


(Tiller Handle)

POINTER

THROTTLE

GRIP

SLOW TO INCREASE

FRICTION

TO DECREASE

FRICTION


CONTROL LEVER


TO INCREASE

FRICTION

TO INCREASE

FRICTION

TO DECREASE

FRICTION

FAST

CONTROL LEVER


Adjust the control lever friction adjuster so the control lever will hold a constant throttle setting while cruising.

F

(forward)

N

(neutral)

R

(reverse)

GEARSHIFT

LEVER

78

TO DECREASE

FRICTION


POINTER

SLOW

THROTTLE

GRIP

R (reverse)

N (neutral)

F (forward)

To shift gears, turn the throttle grip to the SLOW position; then move the gearshift lever to select the F


The engine can be started with the gearshift lever in the N (neutral) position only.

The throttle grip can be turned to the

FAST position only when the gearshift lever is in the F (forward) position.


(Tiller Handle)

THROTTLE FRICTION ADJUSTER

THROTTLE GRIP

HOLD

RELEASE

OPERATION


THROTTLE FRICTION ADJUSTER

RELEASE

THROTTLE

GRIP

HOLD

Use the throttle friction adjuster to help hold a constant throttle setting while cruising.

Turn the adjuster clockwise to increase throttle grip friction for holding a constant speed.

Turn the adjuster counterclockwise to decrease friction for easy grip rotation.

79

OPERATION

STEERING


Steer the boat in the same manner as an automobile.


RIGHT TURN LEFT TURN

Steering Friction Adjusting Knob

(Tiller Handle)


ADJUSTING KNOB





Move the tiller handle to the left.

Move the tiller handle to the right.

Steer by moving the tiller handle opposite the direction you want the boat to turn.

STEERING

FRICTION

ADJUSTING KNOB


Use the steering friction adjusting knob to help hold a steady course while cruising.

Turn the knob clockwise to increase steering friction for holding a steady course.

Turn the knob counterclockwise to decrease friction for easy turning.

80

CRUISING

Engine Speed

For best fuel economy, limit the throttle opening to 80%. Use the throttle friction control (p.78, 79) to help you hold a steady speed.

For rough water conditions or large waves, slow down to prevent the propeller from rising out of the water.

The engine is equipped with an overrev limiter to prevent the possibility of mechanical damage from excessive engine speed.

If, for example, the outboard motor is tilted excessively or propeller ventilation occurs during a sharp turn, the engine may overrev, activating the overrev limiter.

OPERATION

If engine speed becomes unstable at high speed due to activation of the overrev limiter, reduce speed and check the trim angle of the outboard motor.

Trim

Use the power trim/tilt switch to trim the outboard motor for the best performance and stability.

You can use the power trim/tilt switch at any time, whether the boat is underway or stopped.

Press the UP or DN (down) side of the switch to adjust the angle of the outboard motor.

Refer to the trim meter (p.40) for an indication of whether the outboard motor is trimmed high or low.

It is necessary to trim the angle of the outboard motor to compensate for changes in boat load, weight distribution, water conditions, or propeller selection.

Under normal conditions, the boat will perform best when the antiventilation plate is level with the water surface.

When cruising into a high wind, trim the outboard motor down slightly to level the boat and improve stability.

With a tail wind, trim the outboard motor up slightly.

81

OPERATION


Side-Mount Type

POWER

TRIM/TILT

SWITCH

CONTROL

LEVER



CONTROL LEVER

Top-Mount Type

(single type)

POWER TRIM/TILT

SWITCH


(Tiller Handle)

(dual type)


(LEFT) (RIGHT)

CONTROL

LEVER

CONTROL

LEVERS

Press UP to trim or tilt the outboard motor up.

Press DN to trim or tilt the outboard motor down.



POWER TRIM/

TILT SWITCH

82

OUTBOARD

MOTOR

TRIMMED TOO

LOW

OUTBOARD

MOTOR

TRIMMED TOO

HIGH

Trolling Speed Control


(Side-mount type)

OPERATION

TRL (Trolling) Control Switch

Panel (optional equipment)

OUTBOARD MOTOR

TRIMMED CORRECTLY

BOW TOO LOW DUE TO

1. LOAD IN THE FRONT

2. OUTBOARD MOTOR TRIMMED

TOO LOW

TRL (Trolling) CONTROL

SWITCH

For TRL (Trolling) control switch equipped type.

Tiller-Handle

(optional equipment)


BOW TOO HIGH DUE TO

1. LOAD IN THE REAR

2. OUTBOARD MOTOR TRIMMED

TOO HIGH

TROLLING

CONTROL SWITCH


DN: Reduce engine speed

UP: Increase engine speed

Place the outboard motor in-gear with the throttle control in the fully closed

(idle) position. Press and hold the UP or DN side of the TRL control switch to activate the Trolling Speed

Control.

83

OPERATION

The buzzer will make one long sound indicating activation.

The initial trolling speed is set at 650 rpm.

The engine speed can be adjusted in

50 rpm increments by pressing the

UP or DN side of the TRL control switch. A short sound of the buzzer occurs each time the engine speed is adjusted.

In Trolling Speed Control mode, the engine speed can be adjusted between

650 and 1,000 rpm.

Continuing to press the switch when at either of these limits will result in two short sounds from the buzzer.

The throttle control will operate when in the Trolling Speed Control mode, but once the speed reaches 3,000 rpm, the Trolling Speed Control is deactivated. If 3,000 rpm is not reached and the throttle is closed, the engine speed will decrease to the

Trolling Speed Control setting.

Trim Tab

If steering effort is not equal in both directions, adjust the trim tab to compensate for “torque steer,” which is the reaction of the outboard motor to propeller rotation.

GEAR CASE

GROMMET

TRIM TAB BOLT

TRIM TAB

Adjust the trim tab with the engine stopped. Remove the gear case grommet. Loosen the trim tab bolt above the trim tab, turn the trim tab, and then tighten the bolt and install the gear case grommet securely.

When the trim tab is correctly adjusted, steering effort will be equal in both directions.

Refer to TRIM TAB ADJUSTMENT on p.93.

SHALLOW WATER

OPERATION

When operating in shallow water, use the power trim/tilt switch (p.82) to tilt the outboard motor so that the propeller and gear case won’t hit the bottom.

Proceed at low speed, and monitor water flow from the cooling system indicator (p.44) to be sure the outboard motor is not tilted so high that the water intakes are out of the water.

84

68°

12°

TILT

ANGLE

0°

16°

TRIM ANGLE

-4°

0°

(VERTICAL LINE)

(when transom angle at 12°)

MOORING, BEACHING,

LAUNCHING

Before tilting up, leave the outboard motor in the running position for one minute after stopping the engine to drain the water from inside the engine.

Stop the engine and disconnect the fuel hose from the outboard motor before tilting the outboard motor.

To raise the outboard motor out of the water while the engine is stopped and the boat is moored, or for maximum clearance when beaching or launching, use the power tilt switch on the engine pan to tilt the outboard motor up as far as it will go. Move the tilt lock lever to the LOCK position, and then gently lower the outboard motor until the lever contacts the stern bracket. Use the power tilt switch to fully shorten the trim rods.

OPERATION

To lower the outboard motor, tilt up using the power tilt switch, then move the tilt lock lever to the FREE position, and then lower the outboard motor to the desired position.

POWER TILT SWITCH

85

OPERATION

(lock position)

FREE

POWER

(To hold)

MANUAL

(To release)

LOCK

TILT LOCK LEVER

STERN BRACKET

TRIM RODS


The outboard motor can also be tilted manually after opening the manual relief valve. This feature enables the outboard motor to be tilted up or down when no battery is connected.

For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns. Close the valve firmly after positioning the engine.

86

Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.


MULTIPLE OUTBOARD

MOTORS

On boats equipped with more than one outboard motor, all motors normally operate at the same time.

If one or more motor(s) is stopped while the other(s) is running, put the stopped motor in “N” (neutral) and tilt it up so its propeller is above the water's surface.

If the propeller of the stopped motor is left in the water, it may turn as the boat moves through the water, causing a reverse flow of water from the exhaust side. This reverse flow will happen if the stopped engine's propeller is in the water, its gearshift is in “R” (reverse), and the boat is moving forward. Reverse flow can cause an engine malfunction.

OPERATION

87

SERVICING YOUR OUTBOARD MOTOR

THE IMPORTANCE OF

MAINTENANCE

Proper maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution.

Failure to properly maintain this outboard motor, or failing to correct a problem before operation, could result in a significant malfunction.

Some malfunctions can cause serious injuries or death.

Always follow the inspection and maintenance recommendations and schedules in this owner's manual.

To help you properly care for your outboard motor, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a TOHATSU technician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions. If you operate your outboard motor under unusual conditions, consult an authorized TOHATSU dealer for recommendations applicable to your individual needs and use.

Remember that your authorized

TOHATSU dealer knows your outboard motor best and is fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new, TOHATSU

Genuine parts or their equivalents for repair and replacement.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual, using parts that are “certified” to

EPA standards.

88

MAINTENANCE SAFETY

Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

Improper maintenance can cause an unsafe condition.

Failure to properly follow maintenance instructions and precautions can cause serious injuries or death.

Always follow the procedures and precautions in this owner’s manual.


Safety Precautions

• Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:

- Carbon monoxide poisoning from engine exhaust.

Do not start or run the engine in a confined or partly enclosed area.

- Burns from hot parts.

Let the engine and exhaust system cool before touching.

- Injury from moving parts.

Do not run the engine unless instructed to do so.

• Read the instructions before you begin, and make sure you have the tools and skills required.

• To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts.

• Wear gloves when handling the propeller to protect your hands from sharp edges.

89


TOOL KIT and OWNER’S MANUAL EMERGENCY STARTER

ROPE

8 × 10 mm

WRENCH

SPARK PLUG

WRENCH

PHILLIPS

SCREWDRIVER

18 × 19 mm BOX

WRENCH

EMERGENCY STARTER ROPE

GRIP FUSE PULLER TOOL BAG OWNER’S MANUAL

The tool kit can be used for simple maintenance procedures and emergency repairs. Keep these items on the boat so that they will always be available if you need them.

Always carry a spare emergency stop switch clip onboard. The spare clip may either be stored in the tool bag or in an easily accessible location on the boat.

If your tool kit needs replacement, it is not available as a kit and each item must be ordered individually.

An emergency starter rope is supplied. Keep the emergency starter rope on the boat, so it will always be available if you need it.

90


MAINTENANCE SCHEDULE

Follow the MAINTENANCE SCHEDULE table and service your outboard motor accordingly.

REGULAR SERVICE PERIOD (3)

Perform at every indicated month or operating hour interval, whichever comes first.

Each use After use

First month or

20 hrs.

Every

6 months or

100 hrs.

Every year or

200 hrs.

Every 2 years or

400 hrs.

Refer to page

ITEM

Engine oil Check level o

95

Gear case oil

Change

Change o o

(2) o o

(2)

97

-

Engine oil filter Replace o

(2) 98

Throttle linkage

Idle speed

Check-adjust

Check-adjust o

(2) o

(2) o

(2) o

(2) -

-

Valve clearance Check-adjust o

(2) -

Spark plug (Standard plug) Check-adjust/Replace o

100-102

Spark plug

(Optional iridium plug)

Check

Replace o o

102

Propeller and cotter pin

Anode metal (Outside engine)

Check

Check o o

116

115

Anode metal (Inside engine) Check o

(2) (6) -

Lubrication Grease o

(1) o

(1) 103, 104

Water separator Check o

108-111

(1) Lubricate more frequently when used in salt water.

(2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the TOHATSU service manual for service procedures.

(3) For professional commercial use, log hours of operation to determine proper maintenance intervals.

(6) Replace the anodes when they have been reduced to about two-thirds their original size, or if they are crumbling.

91


Fuel filter

(High pressure side)

Fuel tank and tank filter

Fuel line

Thermostat

Battery and cable connection

Bolts and nuts

Breather tube

Cooling water passages

Coolant leak

Water pump

Emergency stop switch

Engine oil leak

Each operation part

Engine condition (5)

Power trim/tilt

Shift cable

REGULAR SERVICE PERIOD (3)

Perform at every indicated month or operating hour interval, whichever comes first.

ITEM

Fuel filter

(Low pressure side)

Check

Replace

Check

Replace

Clean

Check

Replace

Check

Check level-tightness

Check-tightness

Check

Clean

Check

Check

Check

Check

Check

Check

Check

Check-adjust

Each use o o o o o o

(7)

After use o o

(4)

First month or

20 hrs.

o

(2)

Every

6 months or

100 hrs.

o o o o

(2)

Every 2 years (If necessary) (2) (8)

(2)

(4) o

(2) o

(2)

Every year or

200 hrs.

o o o o

(2)

(2)

(2) procedures.

(3) For professional commercial use, log hours of operation to determine proper maintenance intervals.

(4) When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

(5) Upon starting, check for unusual engine sounds and cooling water flowing freely from the check hole.

(7) Check the fuel line for leaks, cracks or damage. If it is leaking, cracked or damaged, take it to your servicing dealer for replacement before using your outboard.

(8) Replace the fuel line if there are signs of leaks, cracks or damage.

92

Every 2 years or

400 hrs.

o o

(2)

Refer to page

111-113

-

-

-

-

117

-

-

-

114

-

-

-

-

-

52

52

-

-


TRIM TAB ADJUSTMENT

The trim tab compensates for “torque steer,” which is a reaction of the outboard motor to propeller rotation.

If uncompensated, torque steer would make the outboard motor tend to turn to one side.

When the trim tab is correctly adjusted, steering effort is equal in either direction.

If steering effort is unequal, remove the gear case grommet and loosen the trim tab bolt then adjust the angle of the trim tab. Retighten the trim tab bolt and reinstall the gear case grommet securely.

TRIM TAB

BOLT

LEFT

LEFT

GEAR CASE

GROMMET

TRIM TAB

If less effort is required to make left turns, move the back of the trim tab left.

TRIM TAB

BOLT

RIGHT

RIGHT

GEAR CASE

GROMMET

TRIM TAB

If less effort is required to make right turns, move the back of the trim tab right.

Adjust the trim tab in small increments, and retest steering effort with the boat evenly loaded and running at cruising speed.

93



POWER

(To hold)

MANUAL

(To release)


The outboard motor can be tilted manually after opening the manual relief valve. This feature enables the outboard motor to be tilted up or down when no battery is connected.


For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns. Close the valve firmly after positioning the outboard motor.

Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.

ENGINE COVER REMOVAL

AND INSTALLATION

ENGINE

COVER

LATCHES

(front/rear)

UNLATCH

LOCK

The engine cover latches fasten the engine cover to the outboard motor.

To remove the engine cover, unlatch both front and rear latches, then lift the engine cover off the outboard motor.

To install the engine cover, place the cover on the outboard motor, then latch both front and rear latches securely.

94

Engine Oil Level Check

Check the engine oil level with the engine stopped and the outboard motor in the vertical position.

1. Unlock and remove the engine cover (p.94).

2. Remove the dipstick and wipe it clean.

UPPER LIMIT

LOWER LIMIT

OIL LEVEL DIPSTICK


3. Insert the dipstick all the way in, and then remove it and check the oil level shown on the dipstick.

4. If the oil level is low, remove the oil filler cap (p.96), and add oil to reach the upper limit mark shown on the dipstick. Use the oil recommended on p.99.

When you check the oil level with the dipstick, you might notice the engine oil appears milky or the oil level has increased. If you notice either condition, change the engine oil. See the following table for an explanation of these conditions.

Operating Method

Running the engine below

3,000 rpm for more than 30% of the time so the engine does not warm up.

Frequent starting and stopping without allowing the engine to warm up.

Result

• Water condenses in the engine and mixes with the oil, resulting in a milky appearance.

• Unburned fuel mixes with the oil, increasing the volume of oil.

Effect

The engine oil deteriorates, becomes less efficient as a lubricant, and causes an engine malfunction.

95


Oil filler cap removal (Unlock):

OIL FILLER CAP

Rib of the alternator cover

1)Turn the oil filler cap 90° counterclockwise so the lug of the cap sets horizontally.

2)Pull the cap to remove it.

• Running the engine with a low oil level can cause engine damage.

• Do not overfill. Overfilling the engine will cause it to smoke or have oil leaks.

5. Install the oil filler cap and tighten it securely. Do not overtighten.

Oil filler cap installation (Lock):

1)Insert the oil filler cap into the oil filler port with the lug being set horizontally.

2)Turn the oil filler cap 90° clockwise so the lug of the cap is in line with the rib of the alternator cover. (It should click.)

6. Install and lock the engine cover.

96

Engine Oil Change

An engine oil evacuation device may be used to remove the engine oil.

Drain the used oil while the engine is warm. Warm oil drains quickly and completely.



DRAIN BOLT

SEALING WASHER

(Replace)

DRAIN BOLT TIGHTENING

TORQUE:

17 lbf·ft (23 N·m, 2.3 kgf·m)

OIL DRAIN GUIDE

2. Place a suitable container below the oil drain guide to catch the used oil, and then remove the oil filler cap

(p.96) and the drain bolt.

3. Allow the used oil to drain completely. Use a new sealing washer, and then reinstall the engine oil drain bolt and washer.

Tighten the drain bolt securely.

Improper disposal of engine oil can be harmful to the environment. If you change your own oil, please dispose of the used oil properly. Put it in a sealed container, and take it to a recycling center. Do not throw it in the trash, pour it on the ground, or pour it down a drain.

97


4. With the outboard motor in a vertical position, fill to the upper limit mark on the oil level dipstick

(p.95) with the recommended oil.

Engine oil refill capacity:

Without oil filter change:

4.4 US qt (4.2 L)

With oil filter change:

4.6 US qt (4.4 L)

5. Install the oil filler cap and tighten it securely (p.96).

6. Install and lock the engine cover.

Oil Filter Change

1. Drain the engine oil, and reinstall the drain bolt (see Engine Oil

Change on p.97).

2. Tilt the outboard motor, and place a suitable container below the oil drain guide to catch the used oil.

3. Use a suitable tool to remove the oil filter, and thoroughly drain the filter into the used oil container.

OIL FILTER

64 mm FILTER WRENCH

OIL DRAIN GUIDE

RUBBER SEAL

98

4. Clean the oil filter mounting base, and coat the rubber seal of the new oil filter with clean engine oil.

Use only a TOHATSU Genuine oil filter or a filter of equivalent quality specified for your model.

Using the wrong filter, or a non-

TOHATSU filter which is not of equivalent quality, may cause engine damage.

5. Screw on the new filter by hand until it contacts the engine, then use a suitable tool to tighten the filter an additional 7/8 turn.

OIL FILTER TIGHTENING

TORQUE:

9 lbf·ft (12 N·m, 1.2 kgf·m)

6. Return the outboard motor to the vertical position, and fill the crankcase with the specified amount of the recommended oil.


Do not overfill. Overfilling the engine will cause it to smoke or have oil leaks.

7. Start the engine and check for leaks

(be sure the water level is at least 2 inches (5 cm) above the antiventilation plate).

If you are changing the oil filter while the outboard motor is out of the water, use commercially available ear muffs and water hose to supply water.

Engine Oil Recommendations

Oil is a major factor affecting performance and service life. Use

4-stroke detergent oil.

Use 4-stroke high detergent, premium quality motor oil certified to meet or exceed U.S. automobile manufacturer’s requirements for API

Service category SG, SH, SJ or SL.

Motor oils classified SG, SH, SJ or

SL will show this designation on the container.

SAE 10W-30 is recommended for general use.

Running the outboard motor without sufficient cooling water will damage the water pump and overheat the engine.

8. Stop the engine, and check the oil level as described on page 95. If necessary, add oil to bring the oil level to the upper limit mark on the dipstick.

AMBIENT TEMPERATURE

99


Spark Plug Service

<Standard spark plug>

RECOMMENDED SPARK PLUG:

ZFR6K-9E (NGK)

6 × 20 mm

FLANGE SH BOLT

CONNECTOR

LOCK TAB

IGNITION

COIL

Incorrect spark plugs can cause engine damage.

See page 102 for instructions of handing the iridium spark plugs

(optional parts).

1. Disconnect the battery negative

(-) terminal.


PLUG MAINTENANCE COVER

3. Remove the 6 × 20 mm flange

SH bolt and remove the plug maintenance cover.

6 × 25 mm

FLANGE BOLT

4. Remove the 6 × 25 mm flange bolt.

Disconnect the connector by pushing the lock tab and remove the ignition coil.

100

BOX WRENCH

New plug


SIDE ELECTRODE

Plug needing replacement

0.031 – 0.035 in

(0.8 – 0.9 mm)

SEALING WASHER

INSULATOR

SPARK PLUG WRENCH

5. Remove the spark plug using the spark plug wrench, box wrench and the Phillips



(accessories).

screwdriver

6. Inspect the spark plugs. Replace them if the electrodes are worn, or if the insulators are cracked or chipped.

7. Measure the spark plug electrode gap with a wire-type feeler gauge.

Correct the gap, if necessary, by carefully bending the side electrode.

The gap should be:

0.031 – 0.035 in (0.8 – 0.9 mm)

101


8. Install the spark plugs carefully, by hand, to avoid cross-threading.

9. After each spark plug seats, tighten with the spark plug wrench to compress the sealing washer.

If reinstalling used spark plugs, tighten 1/8 - 1/4 turn after the spark plugs seat.

If installing new spark plugs, tighten 1/2 turn after the spark plugs seat.

SPARK PLUG TORQUE:

13 lbf·ft (18 N·m, 1.8 kgf·m)

Loose spark plugs can overheat and damage the engine.

Overtightening the spark plugs can damage the threads in the cylinder head.

10. Install the ignition coil. Reinstall the 6 × 25 mm flange bolt.

11. Push the connector onto the ignition coil. Make sure it locks in place.

12.Repeat this procedure for the other three spark plugs.

13. Reinstall the covers.

<Optional Parts: Iridium Spark

Plug>

RECOMMENDED SPARK PLUG:

IZFR6K-11E (NGK)

Incorrect spark plugs can cause engine damage.

Installation and removal procedure of the iridium spark plugs are the same as the standard spark plugs.

These spark plugs have an iridium coated center electrode.

Be sure to observe the following when servicing iridium spark plugs.

• Do not clean the spark plugs. If an electrode is contaminated with accumulated objects or dirt, replace the spark plug with a new one.

• Use only a ‘‘wire-type feeler gauge’’ to check the spark plug gap if necessary. To prevent damaging the iridium coating of the center electrode, never use a ‘‘leaf-type feeler gauge.’’

The gap should be 0.039 – 0.051 inches (1.0 – 1.3 mm).

• Do not adjust the spark plug gap. If the gap is out of specification, replace the spark plug with a new one.

102

Lubrication Points

Apply TOHATSU Marine grease to the parts shown below:

Lubrication interval:

After the first 20 hours or 1 month, then every 100 hours or 6 months

(refer to the MAINTENANCE

SCHEDULE on page 91).

Apply anticorrosion oil to pivot surfaces where grease cannot penetrate.


THROTTLE ARM/

LINK/PIVOT/PLATE THROTTLE ROD/LINK

TILLER HANDLE


TILT BRACKET

TILT SHAFT

PROPELLER SHAFT SWIVEL CASE THRUST RECEIVER

Apply corrosion inhibitor to all areas under the engine cover and any exposed metal surfaces except the belts.

103


SHIFT LINK BRACKET/

SHIFT PIVOT/SHIFT ARM/

LINK PIN/PIVOT PLATE/

SLIDE PIVOT/

CLICK SPRING ROLLER

TILT LOCK LEVER

(each side) TILT SHAFT THREAD

UPPER CYLINDER

PIN/BUSHING

MOUNT FRAME

SWIVEL SHAFT

LOWER CYLINDER

BUSHING/COLLAR

104

REFUELING

Portable Fuel Tank


FUEL TANK CAPACITY:

6.6 US gal (25 L)


FUEL GAUGE VENT KNOB

OPEN

Check the fuel gauge and refill the tank when necessary.

Remove the fuel tank from the boat for refueling.

1. Turn the vent knob counterclockwise all the way to open the vent.

2. Turn the fuel filler cap counterclockwise so that it touches the pressure relief tab.

FUEL FILLER CAP

PRESSURE RELIEF TAB

105


3. Press down the pressure relief tab, and then turn the fuel filler cap 1/4 turn counterclockwise. Release the pressure relief tab. Wait to relieve pressure.

FUEL FILLER CAP

SAFE FILL LEVEL

Using the fuel tank mounted in the boat.

Check the fuel level and refill if necessary. Do not fill the fuel tank above the UPPER LIMIT. Refer to the boat manufacturer’s instructions.

PRESS

PRESSURE RELIEF TAB

4. The fuel filler cap will lock again.

Press down the pressure relief tab, and turn counterclockwise to remove the fuel filler cap.

Refuel in a well-ventilated area. Fill the tank to the SAFE FILL LEVEL line.

After refueling, install the cap and tighten it until you hear it click. Close the vent by turning the vent knob clockwise all the way, and return the fuel tank to the boat.

FUEL FILLER CAP VENT KNOB

Fuel can damage paint and plastic.

Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under warranty.

CLOSE

106








Never refill the fuel tank inside a building where gasoline fumes may reach flames or sparks. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc.

Spilled fuel is not only a fire hazard, it causes environmental damage.

Wipe up spills immediately.


FUEL RECOMMENDATIONS

Use unleaded gasoline with a pump octane rating of 86 or higher.

Your outboard motor is certified to operate on unleaded gasoline.

Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life.

Never use gasoline that is stale, contaminated, or mixed with oil.

Avoid getting dirt or water in the fuel tank.

You may use unleaded gasoline containing no more than 10% ethanol

(E10) or 5% methanol by volume. In addition, methanol must contain cosolvents and corrosion inhibitors.

Use of fuels with content of ethanol or methanol greater than shown above may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system.

107


Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty.

If your outboard motor will be used on an infrequent or intermittent basis, please refer to the fuel section of the

STORAGE chapter (p.120) for additional information regarding fuel deterioration.

Water Separator Inspection and

Service

WATER SEPARATOR








Water separator is located near the engine cover latch on the boat side.

Water accumulation in the water separator can cause loss of power or hard starting. Check the water separator periodically. Clean it or consult with an authorized

TOHATSU outboard motor dealer for cleaning.

1. Remove the engine cover (p.94).

2. Remove the separator assembly. If it is difficult to remove the separator assembly by yourself, consult an authorized TOHATSU dealer.

108

HOSE CLIPS

(commercially available)

WATER

SEPARATOR

WATER

SEPARATOR

BRACKET


WATER

SEPARATOR

HARNESS

CLIP

WATER LEVEL SENSOR

2 PIN CONNECTOR

CLIP C

SUSPENSION STRAP

HARNESS

FUEL HOSES

3. Pinch the fuel hoses with hose clips to prevent fuel leakage.

4. Remove the suspension strap from the water separator bracket; then remove the strap from the separator assembly.

During removal of the separator assembly, take care not to damage the wire harness with the separator bracket.

5. Open the harness clip and remove the harness from clip C; then disconnect the water level sensor 2 pin connector.

6. Disconnect the fuel hoses from the water separator.

109


BODY

BAFFLE

PLATE

O-RING

(Replace)

• Assemble so the flat part on the back of the suspension is parallel to the water separator joint as shown below.

Assemble so the flat part of the suspension and the water separator joint are parallel to each other.

POSITIONING

BAND

HARNESS

CLIP

WATER LEVEL

SENSOR 2 PIN

CONNECTOR

SCREW (3)

WATER

SEPARATOR CUP

SUSPENSION

STRAP

7. Remove the three screws and separate the water separator cup from the body.

8. Thoroughly clean the water separator cup.

9. Reassemble the water separator in the reverse order of removal. Use a new O-ring.

TIGHTENING TORQUE:

3.1 lbf·ft (4.2 N·m, 0.43 kgf·m)

110

WATER

SEPARATOR

FLAT PART ON BACK

OF SUSPENSION

JOINT

HARNESS

CLIP C POSITIONING

BAND

10. Connect the water level sensor 2 pin connector. Install the harness to clip C and the harness clip.

Align the positioning bands on the harness with the end of clip C and the harness clip as shown above.

11. Reinstall the water separator in the reverse order of removal.

12. Prime the engine using the priming bulb (p.58). Check for fuel leaks.

Repair any fuel leaks if necessary.

If the buzzer sounds or excessive water or sediment accumulation are found in the fuel filter, inspect the fuel tank.

Clean the fuel tank and tank filter if necessary. It may be necessary to drain the fuel tank completely and refill with fresh gasoline.


Fuel Filter Inspection and

Replacement

The fuel filter (inside the strainer cup) is located between the fuel pump and the water separator.

Water or sediment accumulation in the filter can cause loss of power or hard starting. To prevent engine malfunction, inspect the filter and replace when necessary.








111


HOSE CLIPS


FUEL FILTER STRAINER

BRACKET

FUEL FILTER

(inside strainer cup)

1. Remove the engine cover (p. 94).

2. Looking through the translucent strainer cup, check the fuel filter for water accumulation and clogging.

If necessary, replace the fuel filter with a new one.

FUEL

HOSE

FUEL FILTER

FUEL HOSE

3. Before removing the fuel filter, to prevent fuel leakage, place fuel hose clips on the fuel hoses on each side of the fuel filter.


4. Remove the fuel filter assembly from the strainer bracket. If it is difficult to remove the fuel filter assembly by yourself, consult an authorized TOHATSU dealer.

5. Disconnect the fuel hoses from the fuel filter.

6. Remove the fuel filter from the suspension strap.

112

FUEL INTAKE

SIDE JOINT

EDGE AT

THE BASE

OF JOINT

FUEL FILTER

(inside strainer cup)

ALIGNMENT

MARK ON THE

SUSPENSION


7. Install a new fuel filter. Assemble the fuel filter by aligning the edge at the base of the fuel intake side joint of the fuel filter with the alignment mark on the suspension as shown above.

8. Install the fuel filter assembly into the strainer bracket.

9. Connect the fuel hoses to the fuel filter.


10. Prime the engine using the priming bulb (p.58). Check for fuel leaks. Repair any fuel leaks if necessary.

11. Install the engine cover.

If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fuel tank.

Clean the fuel tank and tank filter if necessary. It may be necessary to drain the fuel tank completely and refill with fresh gasoline.

113


Portable Fuel Tank and Tank

Filter Cleaning


Fuel Tank Fuel Tank Filter

5 mm SCREW (4) CONNECTOR

GASKET








FUEL HOSE


Empty the portable fuel tank into an approved gasoline container. Use a funnel to avoid spilling fuel. Rinse the fuel tank with nonflammable solvent to remove any accumulated sediment.

FUEL TANK

FILTER

FUEL TANK FILTER JOINT

(Fuel Hose Connector)

1. Remove the four 5 mm screws using a flat screwdriver, and then remove the fuel hose connector and fuel tank filter from the tank.

2. Clean the filter in nonflammable solvent. Inspect the fuel tank filter and the connector gasket. Replace them if damaged.

3. Reinstall the filter and hose connector in the fuel tank. Tighten the four 5 mm screws securely.

114

Anode Replacement

ANODE

(each side)

ANODE

(stern bracket)

The anodes are located on each side of the gear case and on the stern bracket. They are made of a sacrificial material that helps to protect the outboard motor from corrosion.

Replace the anodes when they have been reduced to about half their original size, or if they are crumbling.


Painting or coating the anodes will defeat their purpose and will lead to rust and corrosion damage to the outboard motor. The anodes must be exposed to the water in order to protect the outboard motor.

Propeller Replacement

Before replacing the propeller, remove the emergency stop switch clip from the emergency stop switch to prevent any possibility of the engine being started while you are working with the propeller.

The propeller blades may have sharp edges, so wear heavy gloves to protect your hands.

Operating the outboard motor at higher altitudes will reduce available power. This may require decreasing the propeller pitch to maintain correct engine RPM.

Removal

1. Remove the cotter pin, unscrew the castle nut, remove the 18.5 mm washer, and then remove the propeller and thrust washer.

2. Inspect the propeller shaft for any fishing line or debris.

115


Installation

1. Apply marine grade grease to the propeller shaft.

2. Install the thrust washer with the grooved side toward the gear case.

3. Install the propeller.

4. Install the 18.5 mm washer.

5. Lightly tighten the castle nut by hand or wrench until the propeller has no free play.

6. Tighten the castle nut using a torque wrench.

CASTLE NUT TIGHTENING

TORQUE:

0.7 lbf·ft (1 N·m, 0.1 kgf·m)

7. Then, using a torque wrench, tighten the castle nut until the first available groove in the castle nut aligns with the cotter pin hole. Do not tighten past the first alignment of the castle nut groove and the cotter pin hole.

116

TIGHTENING TORQUE LIMIT:

33 lbf·ft (44.1 N·m, 4.5 kgf·m)

Do not tighten the castle nut above the TIGHTENING TORQUE LIMIT, or the propeller and shaft may be damaged.

8. Be sure to replace the cotter pin with a new one.

• Use a TOHATSU Genuine stainless steel cotter pin or equivalent cotter pin and bend the pin ends as shown.

Note that these wrenches are not included with the tool set that comes with the outboard motor. Contact your authorized TOHATSU dealer for additional tool information.

PROPELLER (optional equipment)

MARINE GREASE

THRUST WASHER

18.5 mm

WASHER

COTTER PIN

CASTLE NUT

COTTER PIN

Inspect After Operating

1. Stop the engine and remove the engine cover (p.94).

2. Confirm the cooling water leakage from the engine.


117

CLEANING AND FLUSHING

Cleaning and Flushing

After each use in salt water or dirty water, thoroughly clean and rinse the outboard motor with fresh water.

Touch up any damaged paint, and coat areas that may rust with corrosion inhibitor. Lubricate controls with a silicone spray lubricant.

Cleaning

Wash the outside of the outboard motor with clean, fresh water, and flush the cooling system as follows.

HO2 SENSOR

Do not apply water or corrosion inhibitor directly to the electrical components under the engine cover, such as the HO2 sensor. If water or corrosion inhibitor penetrates these components, they may be damaged.

Before applying a corrosion inhibitor, cover the HO2 sensor with a protective material to prevent damage.

Flushing With a Garden Hose

(commercially available)

Do not run the engine when flushing the outboard motor with a garden hose or the outboard motor may be damaged.

For safety, remove the emergency stop switch clip so the engine cannot be started while you are standing near the propeller.

1. Disconnect the fuel hose from the outboard motor.

2. Tilt down the outboard motor.

3. Clean and wash the outside of the outboard motor with fresh water.

118

FLUSH PORT

CONNECTOR

FLUSH PORT

CONNECTOR

GARDEN HOSE

CLEANING AND FLUSHING

FLUSH PORT

CONNECTOR

4. Disconnect the flush port connector.

GARDEN HOSE JOINT


EXHAUST PORT

5. Screw the flush port connector onto the garden hose.

6. Turn on the fresh water supply and flush the outboard motor for at least 10 minutes.

7. After flushing, disconnect the garden hose and reconnect the flush port connector.

8. Tilt up the outboard motor and move the tilt lock lever to the

LOCK position.

119

STORAGE

Fuel

Depending on the region where you operate your outboard, fuel formulations may deteriorate and oxidize rapidly. Fuel deterioration and oxidation can occur in as little as

15 days and may cause damage to the fuel system. Please check with your servicing dealer for local storage recommendations.

Gasoline will oxidize and deteriorate in storage. Old gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your fuel tank and vapor separator deteriorates during storage, you may need to have the vapor separator and other fuel system components serviced or replaced.

The length of time that gasoline can be left in your fuel tank and vapor separator without causing functional problems will vary with such factors as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled.

The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel deterioration problems may occur in less than 15 days, if the gasoline was not fresh when you filled the fuel tank.

You can avoid fuel deterioration problems by draining all the fuel from the fuel tank and vapor separator.

120

Draining the Fuel System

You can avoid fuel deterioration problems by draining the fuel tank and vapor separator.

1. Remove the engine cover (p.94).

INTAKE MANIFOLD DRAIN HOSE

VAPOR SEPARATOR

VAPOR SEPARATOR

DRAIN SCREW

STORAGE

2. Release the drain hose from the projection of the intake manifold and set the end of the hose toward the outside of the engine undercase.

Place an approved gasoline container below the fuel drain outlet, and use a funnel to avoid spilling fuel.

3. Loosen the vapor separator drain screw.








4. Tilt the outboard motor up all the way. Leave the outboard motor tilted up until the gasoline stops flowing.

5. After thoroughly draining, tighten the drain screw securely and return the outboard motor to the vertical position.

6. Secure the drain hose to the projection of the intake manifold.

7. Drain the fuel tank into an approved gasoline container.

Close the fuel cap vent.

If using the portable fuel tank, close the fuel filler cap vent knob.

Store the portable fuel tank in a cool dry place out of direct sunlight.

121

STORAGE

Engine Oil

1. Change the engine oil and the oil filter (p.97-99).

2. Remove the spark plugs (p.100), and remove the emergency stop switch clip from the emergency stop switch.

3. Pour 1-2 teaspoons (5-10 cm

3

) of clean engine oil into each cylinder.

4. Rotate the engine a few revolutions to distribute the oil in the cylinders.

5. Reinstall the spark plugs (p.102).

HOISTING THE OUTBOARD

MOTOR

HOIST

HOOKS

ENGINE

HANGERS


2. Attach the hoist hooks to the engine hangers.

3. Disconnect the outboard motor from the boat, hoist the outboard motor, and move it to the storage area.

4. After the outboard motor is placed in storage and disconnected from the hoist, install the engine cover.

STORAGE PRECAUTIONS

Select a well-ventilated storage area.

If possible, avoid storage areas with high humidity.

If storing a container of gasoline, store it away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a spark producing electric motor, or where power tools are operated.

122

OUTBOARD MOTOR STAND

If the outboard motor will be removed from the boat for storage, we recommend storing it vertically by mounting it on a commercially available stand.

STORAGE

CUSHION

(protective material)

(Port side turned down as shown.)

If it is necessary to store the outboard motor horizontally as shown, drain the vapor separator (p.121) and drain the engine oil (p.97) before removing the outboard motor from the boat.

Rest the outboard motor on a cushion of protective material.

Cover the outboard motor to keep out dust. Do not use a plastic sheet as a dust cover. A nonporous cover will trap moisture, promoting rust and corrosion.

REMOVAL FROM STORAGE

Check your outboard motor as described in the BEFORE

OPERATION chapter of this manual.

If the cylinders were coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal.

123

TRANSPORTING

WITH OUTBOARD MOTOR

INSTALLED ON BOAT

When trailering a boat with the outboard motor attached, always disconnect the fuel line from the portable fuel tank.


Use an outboard motor support bar to prevent the outboard motor from moving while trailering the boat.

Refer to the manufacturer’s instructions for using an outboard motor support bar.

Tiller-Handle

(Tiller Handle)


ADJUSTING KNOB




Tighten the steering friction adjusting knob securely.

The preferred method is to leave the engine in the normal running position, but if there is insufficient road clearance, you can tilt the outboard motor using a commercially available outboard motor support bar available through your dealer. Refer to the manufacturer’s instructions for using an outboard motor support bar.


OUTBOARD MOTOR SUPPORT BAR


STEERING

FRICTION

ADJUSTING KNOB


124

WITH OUTBOARD MOTOR

REMOVED FROM BOAT

Secure the outboard motor in either the vertical or horizontal position shown on p.122 and 123.

TRANSPORTING

125

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START

Possible Cause

Clip not inserted in emergency stop switch.

Gearshift lever or control lever not in neutral position.

Throttle grip not in START position (tiller handle – optional equipment).

Fast idle lever raised (side-mount type).

Correction

Insert clip in emergency stop switch.

Shift to neutral.

Turn throttle grip to START position (p.68).

Leave fast idle lever OFF (p.60).

126


Possible Cause

Out of fuel.

Fuel hose not primed.

Fuel filter or fuel tank filter clogged.

Bad fuel; outboard motor stored without draining gasoline, or refueled with bad gasoline.


Correction

Refuel (p.105).

Squeeze priming bulb (p.58).

Replace fuel filters (p.111).

Drain fuel tank and vapor separator (p.121). Refill with fresh gasoline (p.105).

127



Possible Cause

Battery connections loose or corroded.

Battery discharged.

Fuse(s) blown.

Spark plugs faulty, fouled, or improperly gapped.

Spark plugs wet with fuel (flooded engine).

Fuel system malfunction, fuel pump failure, ignition malfunction, stuck valves, starter malfunction, switch malfunction, or electrical problem in the starting circuit, etc.

Correction

Clean and tighten battery connections.

Recharge battery.

Replace fuse(s) (p.131).

Replace spark plugs (p.100).

Dry and reinstall spark plugs. Start engine with the throttle open.

Use starting procedure (p.59, 62, 64, 67); if engine still will not start, then take outboard motor to an authorized

TOHATSU dealer, or refer to the service manual.

128


HARD STARTING OR STALLS AFTER STARTING

Possible Cause Correction

Fast idle lever raised (remote control/side-mount type).

Leave fast idle lever OFF (p.60).

Turn throttle grip to START position (p.68).

Throttle grip not in START position (tiller handle – optional equipment).

Fuel hose not primed.

Fuel filter or fuel tank clogged.

Bad fuel; outboard motor stored without draining gasoline, or refueled with bad fuel.

Squeeze priming bulb (p.58).

Replace fuel filters (p.111).

Drain fuel tank and vapor separator (p.121). Refill with fresh gasoline (p.105).

129


HARD STARTING OR STALLS AFTER STARTING

Possible Cause

Spark plugs faulty, fouled, or improperly gapped.

Fuel system malfunction, fuel pump failure, ignition malfunction, etc.

Correction

Replace spark plugs (p.100).

Take outboard motor to an authorized TOHATSU dealer, or refer to the service manual.

ENGINE OVERHEATS

Possible Cause

Water intake screens clogged.

Faulty thermostat or water pump.

Correction

Clean water intake screens.

Take outboard motor to an authorized TOHATSU dealer, or refer to the service manual.

130

FUSES

Electric Starter Will Not

Operate

The 10 A, 15 A, and 30 A main fuses protect the electric starter relay and related circuits.

The 10 A (No. 2) main fuse protects the ignition switch and related circuits.

If this fuse blows, the engine will not start or run, and the power trim/tilt switch will not activate the trim/tilt mechanism.


Fuse Replacement

FUSE CASE LID SPARE FUSES

(10 A, 15 A, 30 A)

Disconnect the battery cable at the battery negative (-) terminal before replacing the fuse.

Failure to do so may cause a short circuit.

Main Fuse

1. Stop the engine and disconnect the battery cable.

2. Remove the engine cover.

3. Remove the fuse case lid.

FUSES

(10 A,

15 A,

30 A)

Battery Will Not Charge

A 70 A ACG fuse protects the alternator circuit. If the ACG fuse blows, the engine will not charge the battery. Refer to p.132.

10 A (No.2) MAIN FUSE

131


FUSE PULLER

4. Use the fuse puller from the tool kit to remove the fuses. If a fuse is blown, install a replacement fuse of the same specified rating. The outboard motor is supplied with spare fuses in the fuse holder.

MAIN FUSE RATINGS:

10 A, 15 A, 30 A

5. Reinstall the fuse case lid and the engine cover.

6. Reconnect the battery.

ACG Fuse

‘‘70 A’’ MARK SPARE FUSE (70 A)

Never use a fuse with a rating greater than specified. Serious damage to the electrical system could result.

If a blown fuse is found, try to determine and correct the electrical problem that caused the blown fuse.

An uncorrected electrical problem may cause the fuse to blow again.

If fuses continue to blow, take the outboard motor to an authorized

TOHATSU dealer for inspection and service, or refer to the service manual.

3 mm SCREWS

5 mm SCREWS

ACG FUSE (70 A)

FUSE CASE LID

1. Stop the engine and disconnect the battery cable.

2. Remove the engine cover.

3. Remove the fuse case lid.

132

4. Remove the old fuse by removing two 5 mm screws.

5. Install a new fuse with the “70 A” mark downward.

ACG FUSE RATING: 70 A

6. After finishing replacement, install the fuse case lid with its hook toward the engine side.

7. Be sure the fuse case lid is securely locked.

8. Reinstall the engine cover.

9. Reconnect the battery.

A spare fuse is located in the reverse side of the fuse case lid and tightened with two 3 mm screws.

When the new fuse is set as a spare fuse on the reverse side of the fuse case lid, set the fuse so that you can see the “70 A” mark on it.


OIL PRESSURE INDICATOR

TURNS OFF AND ENGINE

SPEED IS LIMITED


Side-Mount Type

OIL PRESSURE

INDICATOR


OIL PRESSURE

INDICATOR

(GREEN)

(GREEN)

BUZZER

BUZZER


(GREEN)


133





If oil pressure becomes low, the oil pressure indicator will turn off, and the engine protection system limits engine speed. If you are at cruising speed, engine speed will decrease automatically.

The oil pressure indicator is also equipped with a buzzer that sounds when the oil pressure indicator turns off.

Low oil pressure may be the result of a low engine oil level, or there may be a problem with the engine lubrication system.

If the throttle is closed suddenly after full throttle operation, engine speed may drop below the specified idle rpm, and that could activate the engine protection system momentarily.

If low oil pressure activates the engine protection system, stop the engine, check the engine oil level

(p.95), and add oil if needed.

With the engine oil at the recommended level, restart the engine. If the lubrication system is

OK, the oil pressure indicator should come on within 30 seconds, and the engine will respond normally to throttle control lever operation.

If the engine protection system remains activated after 30 seconds, return to the nearest boat landing, and have the outboard motor inspected by an authorized TOHATSU dealer.

OVERHEAT INDICATOR

COMES ON AND ENGINE

SPEED IS LIMITED


Side-Mount Type

OVERHEAT

INDICATOR

(RED)

BUZZER

134


OVERHEAT

INDICATOR

(RED)

BUZZER


(RED)






If the engine overheats, the overheat indicator will come on, and the engine will stop in 20 seconds after the engine protection system limits engine speed. If you are at cruising speed, engine speed will decrease automatically.

All types are equipped with a buzzer that sounds when the overheat indicator comes on.

Engine overheating may be the result of restricted water intake screens, or there may be a problem with the cooling system thermostat or water pump.

If the engine is stopped after running at full throttle, and then restarted soon afterward, that could activate the engine protection system momentarily.

COOLING SYSTEM INDICATOR

If overheating activates the engine protection system, idle the engine in neutral, and check the cooling system indicator.

135


If water is flowing from the cooling system indicator, continue idling for

30 seconds. If the cooling system is

OK, the overheat indicator should go off within 30 seconds, and the engine will respond normally to throttle control lever operation.

If there is no water flowing from the cooling system indicator, stop the engine, and tilt the outboard motor to inspect the water intake screens. If restricted, clean the water intake screens, return the outboard motor to the running position, restart the engine, and check the cooling system indicator again.

If there is still no water flowing from the cooling system indicator, or if the engine protection system remains activated after 30 seconds, return to the nearest boat landing, and have the outboard motor inspected by an authorized TOHATSU dealer.

136

WATER SEPARATOR

BUZZER SOUNDS

WATER SEPARATOR

When the water separator buzzer sounds (a rapid, repeating signal):

Check the water separator for water contamination. If water is accumulated, stop the engine, and clean the water separator following the instructions on page 108, or consult with an authorized

TOHATSU dealer.

SUBMERGED OUTBOARD

MOTOR

A submerged outboard motor must be serviced immediately after it is recovered from the water in order to minimize corrosion.

If there is a TOHATSU dealership nearby, take the outboard motor to the dealer immediately. If you are far from a dealer, proceed as follows:

1. Remove the engine cover, and rinse the outboard motor with fresh water to remove salt water, sand, mud, etc.

2. Drain the vapor separator as described on p.121.

3. Change the engine oil and oil filter as described on p.97-99. If there was water in the engine crankcase, or if the used engine oil showed signs of water contamination, then a second engine oil change should be performed after running the engine for half an hour.

4. Remove the spark plugs (p.100).

Operate the starter to expel water from the engine’s cylinders.

5. Pour 1-2 teaspoons (5-10 cm

3

)

(p.122) of engine oil into each spark plug hole to lubricate the inside of the cylinders. Reinstall the spark plugs.

If the engine was running when it submerged, there may be mechanical damage, such as bent connecting rods. If the engine binds when cranked, do not attempt to run the engine until it has been repaired.


6. Attempt to start the engine. Be sure the water level is at least 2 inches

(5 cm) above the antiventilation plate.

If you are attempting to start the engine while the outboard motor is out of the water, use commercially available ear muffs and water hose to supply water.

Running the outboard motor without sufficient cooling water will damage the water pump and overheat the engine.

If the engine fails to start, remove the spark plugs and dry them, then reinstall the spark plugs and attempt to start the engine again.

If the engine starts and no mechanical damage is evident, continue to run the engine for a half hour or longer. Be sure the water level is at least 2 inches

(5 cm) above the antiventilation plate to avoid overheating and water pump damage.

7. As soon as possible, take the outboard motor to an authorized

TOHATSU dealer for inspection and service.

137

TECHNICAL INFORMATION

Serial Number Locations

Record the frame serial number, the engine serial number, and the date of purchase in the space provided on this page. You will need these numbers when ordering parts and when making technical or warranty inquiries.

FRAME SERIAL NUMBER ENGINE SERIAL NUMBER

STERN BRACKET

The frame serial number is stamped on a plate attached on the right side of the stern bracket.

Frame Serial Number:

The engine serial number is stamped on the upper right side of the engine.

Engine serial number:

Date of purchase:

138

Battery

The battery contains sulfuric acid (electrolyte), which is highly corrosive and poisonous.

Getting electrolyte in your eyes or on your skin can cause serious burns.

Wear protective clothing and eye protection when working near the battery.

KEEP CHILDREN AWAY

FROM THE BATTERY.

For complete information, refer to the battery manufacturer’s instructions.

Minimum Requirements

12V-55Ah/5HR

(65Ah/20HR)

(CCA582A)

• Be careful to avoid connecting the battery in reverse polarity, as this will damage the battery-charging system in the outboard motor.

• Do not disconnect the battery cables while the engine is running.

Disconnecting the cables while the engine is running will damage the outboard motor’s electrical system.

• Battery cable extension: Extending the original battery cable will cause the battery voltage to drop due to the increased length of the cable and number of connections. This voltage drop may cause the buzzer to sound momentarily when engaging the starter motor and may prevent the engine from starting. If the engine starts and the buzzer sounds momentarily, there may be barely sufficient voltage reaching the engine.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds. Wash your hands after handling.


Emission Control System

Information

Source of Emissions

The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

TOHATSU utilizes appropriate air/ fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.

Ignition Timing Control System

The system constantly adjusts the ignition timing, reducing the amount of HC, CO, and NOx produced.

139


PGM-FI System

The PGM-FI system uses sequential multiport fuel injection. It has two subsystems: Engine Control and Fuel

Control. The Engine Control Module

(ECM) uses various sensors to determine how much air is going into the engine. It then controls how much fuel to inject under all operating conditions.

The U.S. and California Clean Air

Acts

EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems.

The following instructions and procedures must be followed in order to keep the emissions from your

TOHATSU engine within the emission standards.

Tampering and Altering

Tampering is a violation of Federal and California law.

Tampering with or altering the emission control system may increase emissions beyond the legal limit.

Among those acts that constitute tampering are:

• Removal or alteration of any part of the intake, fuel, or exhaust systems.

• Alterations that would cause the engine to operate outside its design parameters.

140

Problems That May Affect

Emissions

If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer.

• Hard starting or stalling after starting

• Rough idle

• Misfiring or backfiring under load

• Afterburning (backfiring)

• Black exhaust smoke or high fuel consumption

Replacement Parts

The emission control systems on your

TOHATSU engine were designed, built, and certified to conform with

EPA and California emission regulations. We recommend the use

TECHNICAL INFORMATION of TOHATSU Genuine parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. TOHATSU cannot deny coverage under the emission warranty solely for the use of non-TOHATSU replacement parts or service performed at a location other than an authorized TOHATSU dealership; you may use comparable EPA certified parts, and have service performed at non-TOHATSU locations. However, the use of replacement parts that are not of the original design and quality may impair the effectiveness of your emissions control system.

A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.

Maintenance

As the outboard engine owner, you are responsible for completing all required maintenance listed in your owner's manual. TOHATSU recommends that you retain all receipts covering maintenance on your outboard engine, but TOHATSU cannot deny warranty coverage solely for the lack of receipts or for your failure to ensure that all scheduled maintenance has been completed.

Follow the MAINTENANCE

SCHEDULE on p.91. Remember that this schedule is based on the assumption that your machine will be used for its designed purpose.

Sustained high-load operation, or use in unusual conditions, will require more frequent service.

141


Star Label

US, Puerto Rico, and US Virgin

Islands

A Star label was applied to this outboard motor in accordance with the requirements of the California Air

Resources Board.

The Star Label means Cleaner Marine Engine

This engine has been certified as a:

The Symbol for Cleaner Marine Engines:

Cleaner Air and Water - for healthier lifestyle and environment.

Better Fuel Economy - burns up to 30 - 40 percent less gas and oil than conventional carbureted two-stroke engines, saving money and resources.

Longer Emission Warranty - protects consumer for worry-free operation.

142

One Star

Low

Emission

Two Stars

Very Low

Emission

Three Stars

Ultra Low

Emission

Four Stars

Super Ultra

Low Emission


The one-star label identifies engines that meet the Air Resources Board’s

Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.

The two-star label identifies engines that meet the Air Resources Board’s

Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than

One Star-Low Emission engines.

The three-star label identifies engines that meet the Air Resources Board’s

Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003-2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low Emission engines.

The four-star label identifies engines that meet the Air Resources Board’s

Sterndrive and Inboard marine engine 2009 exhaust emission standards.

Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than

One Star-Low Emission engines.

Cleaner Watercraft - Get the Facts

1-800-END-SMOG www.arb.ca.gov

143


Specifications

MODEL

Description code

Type

Overall length

Overall width

Overall height

Transom height

(when transom angle at 12°)

Dry mass

[weight]*

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Steering control system

Starter system

Ignition system

Lubrication system

* With propeller

BFT75A K1

BBAJ

LRT

29.2 in (742 mm)

18.1 in (459 mm)

62.0 in (1,576 mm)

21.1 in (537 mm)

364 lbs (165 kg)

55.9 kW (75 HP)

5,000-6,000 rpm

4 stroke OHC in-line 4-cylinder

91.3 cu-in (1,497 cm

3

)

0.031-0.035 in (0.8-0.9 mm)

Outboard motor-mounted, remote control, tiller handle

Electric starter

Full transistor battery

Trochoid pump pressure lubrication

Specified oil

Engine oil capacity

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plug

Fuel pump

Fuel

Gear change

Steering angle

Trim angle

Tilt up angle

Transom angle

Engine: API standard (SG, SH, SJ, SL)

SAE 10W-30

Gear case: API standard (GL-4) SAE 90

Hypoid gear oil

Engine: 4.4 US qt (4.2 L) without oil filter change

4.6 US qt (4.4 L) with oil filter change

Gear case: 1.00 US qt (0.95 L)

ULTRA · LOW EMISSION

12 V-35 A

Water cooling with thermostat

Water exhaust

ZFR6K-9E (NGK)

Low pressure side: mechanical type

High pressure side: electrical type

Unleaded gasoline

(86 pump octane or higher)

Forward-Neutral-Reverse (dog type)

30° right and left

-4° to 16° (when Transom angle at 12°)

68° (when Transom angle at 12°)

8°, 12°, 16°, 20°, 24°

These TOHATSU outboard motors are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.

144


Specifications

MODEL

Description code

Type

Overall length

Overall width

Overall height

Transom height

(when transom angle at 12°)

Dry mass

[weight]*

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Steering control system

Starter system

Ignition system

Lubrication system

BFT90A K1

BBCJ

LRT XRT

29.2 in (742 mm)

18.1 in (459 mm)

62.0 in (1,576 mm) 67.0 in (1,703 mm)

21.1 in (537 mm)

366 lbs (166 kg)

26.1 in (664 mm)

379 lbs (172 kg)

67.1 kW (90 HP)

5,300-6,300 rpm

4 stroke OHC in-line 4-cylinder

91.3 cu-in (1,497 cm

3

)

0.031-0.035 in (0.8-0.9 mm)

Outboard motor-mounted, remote control, tiller handle

Electric starter

Full transistor battery

Trochoid pump pressure lubrication

* With propeller

Specified oil

Engine oil capacity

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plug

Fuel pump

Fuel

Gear change

Steering angle

Trim angle

Tilt up angle

Transom angle

Engine: API standard (SG, SH, SJ, SL)

SAE 10W-30

Gear case: API standard (GL-4) SAE 90

Hypoid gear oil

Engine: 4.4 US qt (4.2 L) without oil filter change

4.6 US qt (4.4 L) with oil filter change

Gear case: 1.00 US qt (0.95 L)

ULTRA · LOW EMISSION

12 V-35 A

Water cooling with thermostat

Water exhaust

ZFR6K-9E (NGK)

Low pressure side: mechanical type

High pressure side: electrical type

Unleaded gasoline

(86 pump octane or higher)

Forward-Neutral-Reverse (dog type)

30° right and left

-4° to 16° (when Transom angle at 12°)

68° (when Transom angle at 12°)

8°, 12°, 16°, 20°, 24°

These TOHATSU outboard motors are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.

145


BFT75A/BFT90A Tune up

Spark plug gap

Idle speed

Valve clearance (cold)

Other specifications

0.031-0.035 in (0.8-0.9 mm)

750

±

50 rpm

Intake: 0.17

±

0.02 mm

Exhaust: 0.28

±

0.02 mm

See page 101

See service manual

See service manual

No other adjustment is needed

146

Emission Control System Warranty

Your new Tohatsu outboard engine complies with both the

U.S. EPA and State of California emission regulations.

Tohatsu Corporation provides the same emission warranty coverage for outboard engines sold in all 50 states. In all areas of the United States your outboard engine must be designed, built, and equipped to meet the U.S. EPA and

California Air Resources Board emissions standard for spark ignited marine engines.

CONSUMER INFORMATION

CALIFORNIA EMISSIONS CONTROL

SYSTEM WARRANTY STATEMENT YOUR

WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and Tohatsu

Corporation are pleased to explain the emission control system warranty on your 2020 Tohatsu outboard engine.

In California, new outboard engines must be designed, built, and equipped to meet the state’s stringent anti-smog standards.

Tohatsu Corporation must warrant the emission control system on your outboard engine for the periods of time listed below provided there has been no abuse, neglect, or improper maintenance of your outboard engine.

Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, catalytic converter, canisters, clamps, filters, fuel caps, fuel lines, fuel tanks, valves, and vapor hoses. Also included may be hoses, belts, connectors, and other emission-related assemblies.

Where a warrantable condition exists, Tohatsu

Corporation will repair your outboard engine at no cost to you including diagnosis, parts, and labor.

147


MANUFACTURER’S WARRANTY

COVERAGE:

Select emission control parts from model year 2010 and later outboard engines are warranted for five years or 250 hours of use, whichever first occurs; or the length of the

Tohatsu Limited Warranty Information, whichever is longer. The evaporative emissions control system from model year 2010 and later outboard engines are warranted for two years with no limit on hours of use, or the length of the Tohatsu Limited Warranty Information, whichever is longer, from the date of delivery to the retail purchaser.

However, warranty coverage based on the hourly period is only permitted for engines equipped with hour meters as defined in § 2441 (a)(13)* or their equivalent. If any emission-related part on your engine is defective under warranty, the part will be repaired or replaced by Tohatsu

Corporation. See the Emission Control System Warranty

Parts table on page 151 for parts description.

* California Code of Regulations

OWNER’S WARRANTY RESPONSIBILITIES:

As the outboard engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual.

Tohatsu Corporation recommends that you retain all receipts covering maintenance on your outboard engine, but Tohatsu Corporation cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

As the outboard engine owner, you should, however, be aware that Tohatsu Corporation may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

You are responsible for presenting your outboard engine to a Tohatsu authorized dealer as soon as a problem exists.

The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact

Tohatsu America Corporation

670 South Freeport Parkway

Suite 120 Coppell, TX 75019

Telephone: (496) 771 3740

148

WARRANTY COVERAGE:

See Manufacturer’s Warranty Coverage above for warranty coverage terms. This warranty is transferred to each subsequent purchaser for the duration of the warranty period. Warranty repairs will be made without charge for diagnosis, parts, and labor. All defective parts replaced under this warranty become the property of Tohatsu

Corporation. A list of warranty parts is on page 151.

Normal maintenance items, such as spark plugs and filters, that are on the warranted parts list are warranted up to their required replacement interval only. Tohatsu

Corporation is also liable for damages to other engine components caused by a failure of any warranted part during the warranty period.

Only Tohatsu Corporation approved replacement parts will be used in the performance of any warranty repairs, and they will be provided without charge to the owner.

You may use any replacement part as defined in § 1900

(b)(20)* in the performance of any maintenance or repairs.

Tohatsu cannot deny coverage under the emission warranty solely for use of non-Tohatsu replacement parts or service performed at a location other than an authorized

Tohatsu dealership; however, use of a part that is not functionally identical to the original equipment part in any respect that may in any way affect emissions (including

CONSUMER INFORMATION durability) could result in denial of coverage.

If a non-Tohatsu replacement part is used in the repair or maintenance of your engine, and an authorized Tohatsu dealer determines it causes the failure of a warranted part, your warranty claim may be denied. If the part in question is not related to the reason that your engine requires repair, your claim will not be denied.

* California Code of Regulations

TO OBTAIN WARRANTY SERVICE:

You must take your Tohatsu outboard engine, along with your warranty registration card or other proof of original purchase date, at your expense, to any Tohatsu dealer that is authorized by Tohatsu Corporation to sell and service that Tohatsu product during its normal business hours.

Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used.

If you are unable to obtain warranty service, or are dissatisfied with the warranty service you received, contact the owner of the dealership involved. Normally this should resolve your problem. However, if you require further assistance, write or call Tohatsu Corporation.

149


EXCLUSIONS:

Failures other than those resulting from defects in material or workmanship are not covered by this warranty. This warranty does not extend to emission control systems or parts which are affected or damaged by owner abuse, neglect, improper maintenance, misuse, misfueling, improper storage, and/or collision, the incorporation of, or use of, unsuitable attachments, or the unauthorized alteration of any part.

This warranty does not cover replacement of expendable maintenance items made in connection with required maintenance service after the items first scheduled replacement as listed in the maintenance section of the product (outboard motor) owner’s manual, such as: spark plugs and filters.

DISCLAIMER OF CONSEQUENTIAL

DAMAGE AND LIMITATION OF IMPLIED

WARRANTIES:

Tohatsu Corporation disclaims any responsibility for incidental or consequential damages such as loss of time or the use of outboard engine, or any commercial loss due to the failure of the equipment; and any implied warranties are limited to the duration of this written warranty. This warranty is applicable only where the California or U.S.

EPA emissions control system warranty regulation is in effect.

150


EMISSION CONTROL SYSTEM WARRANTY PARTS:

SYSTEMS COVERED

BY THIS WARRANTY:

PARTS DESCRIPTION:

Evaporative

Fuel Metering

Portable fuel tank, Outboard internal fuel tank, Fuel cap, Fuel hoses, Primer bulb, Fuel hose joint, Vapor separator, and Carbon canister,

All other parts not listed that may affect the evaporative emissions control system

Carburetor assembly, Throttle body, Fuel injector, Fuel pump,

Fuel pressure regulator, Throttle position sensor, Intake air temperature sensor, Engine temperature sensor, Manifold absolute pressure sensor, Idle air control valve, Barometric pressure sensor, Fuel line solenoid valve,

Intake manifold, Intake valves, and Oxygen sensor or Air fuel ratio sensor

Air intake duct, Intake manifold tuning valve (Intake air bypass control valve) Air Induction

Ignition

Flywheel magneto, Ignition pulse generator, Ignition coil assembly, Ignition control module, Engine control module, Crankshaft position sensor, Spark plug cap, Spark plug*, Knock sensor, and Camshaft position sensor

Oil pump and internal parts Lubrication System

Crankcase Emission Control Crankcase breather tube, Positive crankcase ventilation valve, Oil filler cap

Exhaust Exhaust manifold and Exhaust valves

LENGTH OF WARRANTY:

Two years, no limit on hours of use; or the length of the Tohatsu

Limited Warranty Information, whichever is longer.

Five years or 250 hours of use, whichever first occurs; or the length of the Tohatsu Limited

Warranty Information, whichever is longer.

Valve Control System

Miscellaneous Parts

Rocker arm oil control valve

Tubing, fittings, seals, gaskets, and clamps associated with these listed systems.

* Covered up to the first required replacement only. See the Maintenance Schedule on page 91 and 92.

151

INDEX

Alternator (ACG) Indicator ........................................... 41

Anodes........................................................................... 46

Replacement.......................................................... 115

ARE YOU READY TO GET UNDERWAY? ............. 51

B

Battery ......................................................................... 139

Will Not Charge.................................................... 131

BEFORE OPERATION ................................................ 51

BREAK-IN PROCEDURE ........................................... 55

C

CLEANING AND FLUSHING .................................. 118

COMPONENT AND CONTROL LOCATIONS ......... 12

CONSUMER INFORMATION.................................. 147

CONTROL AND FEATURE IDENTIFICATION

CODES..................................................................... 11

CONTROLS .................................................................. 20

CONTROLS AND FEATURES ................................... 11

Cooling System Indicator .............................................. 44

CRUISING .................................................................... 81

E

Electric Starter Will Not Operate ................................ 131

EMERGENCY

STARTER ROPE.................................................... 90

STARTING............................................................. 70

Emergency Stop Switch Clip and Emergency Stop

Switch

Panel-Mount Type................................................... 24

Side-Mount Type..................................................... 20

Tiller-Handle ........................................................... 31

Top-Mount Type ..................................................... 27

Emission Control System Information......................... 139

Emission Control System Warranty............................. 147

Engine

Cover

Latch (front/rear) ................................................. 39

REMOVAL AND INSTALLATION.................. 94

Oil

Change ................................................................. 97

Filter Change ....................................................... 98

Level Check......................................................... 95

Recommendations ............................................... 99

OVERHEATS ....................................................... 130

WILL NOT START .............................................. 126

F

152

Fast Idle Button

Panel-Mount Type .................................................. 26

Top-Mount Type..................................................... 30

Fast Idle Lever............................................................... 22

Fuel

Filler Cap Vent Knob.............................................. 45

Filter Inspection and Replacement........................ 111

Gauge (optional equipment) ................................... 40

HOSE CONNECTIONS......................................... 57

PRIMING................................................................ 58

Priming Bulb........................................................... 46

RECOMMENDATIONS...................................... 107

Fuse Replacement........................................................ 131

FUSES ......................................................................... 131

G

Gearshift Lever............................................................... 34

GEARSHIFT AND THROTTLE OPERATION .......... 77

Gearshift/Throttle Control Lever

Panel-Mount Type .................................................. 25

Side-Mount Type .................................................... 21

Top-Mount Type..................................................... 28

H

I

HARD STARTING OR STALLS AFTER

STARTING ............................................................ 129

HOISTING THE OUTBOARD MOTOR................... 122

INDEX

Ignition Switch

Panel-Mount Type................................................... 23

Side-Mount Type..................................................... 20

Tiller-Handle ........................................................... 31

Top-Mount Type ..................................................... 27

IMPORTANT SAFETY INFORMATION ..................... 7

INDICATORS ............................................................... 41

INFREQUENT OR OCCASIONAL USE..................... 59

Inspect After Operating................................................ 117

INSTRUMENTS............................................................ 40

IS YOUR OUTBOARD MOTOR

READY TO GO?...................................................... 51

L

Lubrication Points........................................................ 103

M

MAINTENANCE SAFETY .......................................... 89

MAINTENANCE SCHEDULE .................................... 91

Malfunction Indicator .................................................... 42

MANUAL RELIEF VALVE.................................. 38, 94

MOORING, BEACHING, LAUNCHING .................... 85

MULTIPLE OUTBOARD MOTORS........................... 87

N

NMEA Interface Coupler............................................... 47

O

153

INDEX

Oil Pressure Indicator .................................................... 42

OIL PRESSURE INDICATOR TURNS OFF AND

ENGINE SPEED IS LIMITED.............................. 133

Operating Hour Notification System............................. 47

OPERATION ................................................................ 55

OTHER FEATURES..................................................... 44

OUTBOARD MOTOR SAFETY ................................... 7

Overheat Indicator ......................................................... 43

OVERHEAT INDICATOR COMES ON AND

ENGINE SPEED IS LIMITED.............................. 134

Overrev Limiter ............................................................. 45

P

PORTABLE FUEL TANK (optional equipment).. 45, 56

Portable Fuel Tank and Tank Filter Cleaning

(optional equipment) .............................................. 114

Power Tilt Switch .......................................................... 38

Power Trim/Tilt Switch................................................. 37

Propeller Replacement................................................. 115

R

REFUELING............................................................... 105

REMOVAL FROM STORAGE.................................. 123

S

SAFE OPERATING PRECAUTIONS ......................... 55

SAFETY LABEL LOCATION....................................... 9

Serial Number Locations............................................. 138

SERVICING YOUR OUTBOARD MOTOR............... 88

154

SHALLOW WATER OPERATION ............................. 84

Spark Plug Service....................................................... 100

Specifications............................................................... 144

Star Label ..................................................................... 142

STARTING THE ENGINE ........................................... 59

Panel-Mount Type................................................... 62

Side-Mount Type..................................................... 59

Tiller-Handle ........................................................... 67

Top-Mount Type ..................................................... 65

STEERING .................................................................... 80

Steering Friction Adjusting Knob ........................... 80

Steering Friction Adjusting Knob.................................. 35

STOPPING THE ENGINE............................................ 72

Emergency Engine Stopping ................................... 72

Normal Engine Stopping ......................................... 73

STORAGE ................................................................... 120

Engine oil .............................................................. 122

Fuel........................................................................ 120

STORAGE PRECAUTIONS....................................... 122

SUBMERGED OUTBOARD MOTOR ...................... 136

T

Tachometer (optional equipment) ................................. 40

TAKING CARE OF UNEXPECTED PROBLEMS... 126

TECHNICAL INFORMATION ................................. 138

THE IMPORTANCE OF MAINTENANCE................ 88

Throttle

Friction Adjuster ..................................................... 33

Grip ......................................................................... 32

Tiller Handle Height/Angle Adjustment ...................... 53

Tilt Lock Lever.............................................................. 39

TOOL KIT and OWNER’S MANUAL ........................ 90

TRANSPORTING....................................................... 124

WITH OUTBOARD MOTOR INSTALLED

ON BOAT.......................................................... 124

WITH OUTBOARD MOTOR REMOVED

FROM BOAT .................................................... 125

Trim Meter (optional equipment).................................. 40

Trim Tab................................................................. 39, 84

TRIM TAB ADJUSTMENT......................................... 93

TRL (Trolling) Control Switch ..................................... 36

Trolling Speed Control .................................................. 83

W

Water Separator Buzzer................................................. 44

WATER SEPARATOR BUZZER SOUNDS ............. 136

Water Separator Inspection and Service...................... 108

INDEX

155

156

MEMO

© 2020 Honda Motor Co., Ltd. − All Rights Reserved

PGM-FI is a trademark of Honda Motor Co., Ltd.

registered in Japan and other countries.

OWNER’S MANUAL

BFT 75A

BFT 90A

5 4 , A z u s a w a 3 C h o m

Tokyo 174-0051, Japan e , tI a b a s h -i K u

Tel: +813 - 3966-3117 Fax:+81-3-3966-0090 www.tohatsu.com

OM_BFT75-100A_US_Cover.indd 1

31ZZ0T03

00X31-ZZ0-T030

XXX.XXXX.XX

PRINTED IN JAPAN

OWNER’S MANUAL

BFT 75A

BFT 90A

Tohatsu BFT 90AK1 Owner Manual

Assistant Bot

BFT 75A

BFT 90A

OWNER’S MANUAL

BFT 75A

BFT 90A

INTRODUCTION

1

A FEW WORDS ABOUT

SAFETY

2

CONTENTS

3

4

5

6

IMPORTANT SAFETY

INFORMATION

Operator Responsibility

OUTBOARD MOTOR SAFETY

7

Refuel With Care

Carbon Monoxide Hazard

8

SAFETY LABEL LOCATION

9

10

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

11

COMPONENT AND CONTROL LOCATIONS

12

Remote Controls (optional equipment)

13

14

15

16

Multi-Function Tiller Handle (optional equipment)

17

Portable Fuel Tank (optional equipment)

Fuel Tank Hose Assembly (standard equipment)

18

Trim Meter

(optional equipment)

Tachometer

(optional equipment)

TRL (Trolling) Control Switch

Panel

(optional equipment)

19

CONTROLS

Remote Control Box:

Side-Mount Type

20

21

22

Panel-Mount Type

23

24

25

26

Top-Mount Type

27

28

29

30

Tiller-Handle (optional equipment):

31

32

33

34

35

TRL (Trolling) Control Switch

(optional equipment)

36

Power Trim/Tilt Switch

37

Power Tilt Switch

(engine pan side)