Tohatsu BFT 115A Owner Manual

OWNER ’S MANUAL

BFT 115A

BFT 150A

TOHATSU CORPORATION

5-4, Azusawa 3-Chome, Itabashi-Ku

Tokyo 174-0051, Japan

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

OM_BFT115-150A_US_Cover.indd 1

31ZX1T14

00X31-ZX1-T140

XXX.XXXX.XX

PRINTED IN JAPAN

OWNER’S MANUAL

BFT 115A

BFT 150A

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 signal words, DANGER, WARNING, or CAUTION.

These signal words mean: and one of three

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 ................................... 10

CONTROL AND FEATURE IDENTIFICATION

CODES ................................................................ 10

HOW TO DETERMINE WHICH DIRECTION

THE PROPELLER SHAFT ROTATES ............. 10

COMPONENT AND CONTROL LOCATIONS ... 11

CONTROLS ............................................................ 15

Side-Mount Type

Ignition Switch .................................................... 15

Emergency Stop Switch Clip and Emergency

Stop Switch ..................................................... 15

Gearshift/Throttle Control Lever ........................ 16

Fast Idle Lever ..................................................... 17

Panel-Mount Type

Ignition Switch .................................................... 18


Stop Switch ..................................................... 19

Gearshift/Throttle Control Lever ........................ 20

Fast Idle Button ................................................... 21

CONTENTS

Top-Mount Type

Ignition Switch ....................................................22


Stop Switch ......................................................22

Gearshift/Throttle Control Lever .........................23

Fast Idle Button ...................................................25

Common Controls

Power Trim/Tilt Switch .......................................26

Power Tilt Switch ................................................27

Manual Relief Valve ............................................27

Tilt Lock Lever ....................................................27

TRL (Trolling) Control Switch.............................28

Engine Cover Latch .............................................28

Trim Tab ..............................................................29

INSTRUMENTS .....................................................29

Trim Meter (optional equipment) ........................29

Tachometer (optional equipment) .......................29

NMEA Interface Coupler ....................................30

Operating Hour Notification System ...................30

3

CONTENTS

INDICATORS ......................................................... 33

Alternator (ACG) Indicator ................................. 33

Malfunction Indicator .......................................... 33

Oil Pressure Indicator .......................................... 34

Overheat Indicator ............................................... 34

Cooling System Indicator .................................... 35

OTHER FEATURES .............................................. 35

Water Separator Buzzer ...................................... 35

Rev Limiter ......................................................... 36

Anodes ................................................................. 36

Fuel Priming Bulb ............................................... 36

BEFORE OPERATION ................................................ 37

ARE YOU READY TO GET UNDERWAY? ....... 37

IS YOUR OUTBOARD MOTOR

READY TO GO? ................................................ 37

OPERATION .................................................................39

SAFE OPERATING PRECAUTIONS ...................39

BREAK-IN PROCEDURE .....................................39

FUEL PRIMING .....................................................40

INFREQUENT OR OCCASIONAL USE ..............41

STARTING THE ENGINE .....................................41

Side-Mount Type .................................................41

Panel-Mount Type ...............................................44

Top-Mount Type ..................................................47

STOPPING THE ENGINE ......................................49

Emergency Engine Stopping ...............................49

Normal Engine Stopping .....................................50

GEARSHIFT AND

THROTTLE OPERATION .................................51

STEERING ..............................................................52

CRUISING ..............................................................53

Trolling Speed Control ........................................55

TRIM TAB ..............................................................56

SHALLOW WATER OPERATION .......................56

MOORING, BEACHING, LAUNCHING ..............57

MULTIPLE OUTBOARD MOTORS .....................58

4

SERVICING YOUR OUTBOARD MOTOR ............... 59

THE IMPORTANCE OF MAINTENANCE .......... 59

MAINTENANCE SAFETY ................................... 60

TOOL KIT and OWNER’S MANUAL .................. 61

SPARE EMERGENCY STOP SWITCH CLIP ...... 61

MAINTENANCE SCHEDULE .............................. 62

TRIM TAB ADJUSTMENT ................................... 64

MANUAL RELIEF VALVE .................................. 65

ENGINE COVER REMOVAL AND

INSTALLATION ................................................ 65

Engine Oil Level Check ...................................... 66

Engine Oil Change .............................................. 67

Oil Filter Change ................................................. 69

Engine Oil Recommendations ............................. 70

Lubrication Points ............................................... 71

Spark Plug Service .............................................. 73

CONTENTS

REFUELING ...........................................................77

FUEL RECOMMENDATIONS ..............................77

Fuel Filter Inspection and Replacement ..............78

Water Separator Inspection and Service ..............81

Anode Replacement .............................................83

Propeller Replacement .........................................83

CLEANING AND FLUSHING .....................................85

Cleaning and Flushing .........................................85

STORAGE .....................................................................87

Fuel ......................................................................87

Engine Oil ............................................................89

HOISTING THE OUTBOARD MOTOR ...............90

STORAGE PRECAUTIONS ..................................90

REMOVAL FROM STORAGE ..............................91

5

CONTENTS

TRANSPORTING ......................................................... 92

WITH OUTBOARD MOTOR

INSTALLED ON BOAT .................................... 92

WITH OUTBOARD MOTOR

REMOVED FROM BOAT ................................. 92

TAKING CARE OF UNEXPECTED PROBLEMS ..... 93

ELECTRIC STARTER WILL NOT OPERATE .... 93

ENGINE WILL NOT START ................................ 94

HARD STARTING OR STALLS AFTER

STARTING ......................................................... 96

ENGINE OVERHEATS ......................................... 97

FUSES ..................................................................... 98

Electric Starter Will Not Operate ........................ 98

Battery Will Not Charge ..................................... 98

Fuse Replacement ............................................... 98

OIL PRESSURE INDICATOR TURNS OFF AND

ENGINE SPEED IS LIMITED ......................... 100

OVERHEAT INDICATOR COMES ON AND

ENGINE SPEED IS LIMITED ......................... 101

WATER SEPARATOR BUZZER SOUNDS ....... 103

SUBMERGED OUTBOARD MOTOR ................ 103

TECHNICAL INFORMATION ..................................105

Serial Number Locations ...................................105

Battery ...............................................................106

Emission Control System Information ..............106

Star Label ...........................................................109

Specifications .....................................................111

CONSUMER INFORMATION ..................................113

Emission Control System Warranty ..................113

INDEX .........................................................................118

6

IMPORTANT SAFETY

INFORMATION

TOHATSU BFT115A and BFT150A 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 well-ventilated 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.

8

SAFETY LABEL LOCATION


The label shown here contains important safety information. Please read it carefully. This label is considered a permanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized TOHATSU dealer for a replacement.

9

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

Model

Type

Transom Height

(Shaft Length)

20.0 in

(508 mm)

25.0 in

(635 mm)

Standard Rotating Propeller Shaft

Counterrotating Propeller Shaft

Power Trim/Tilt

L □

●

●

●

BFT115A

X □

●

●

●

XC □

●

●

●

L □

●

●

●

BFT150A

X □

●

●

●

XC □

●

●

●

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

TYPE CODE (example)

X C □

HOW TO DETERMINE

WHICH DIRECTION THE

PROPELLER SHAFT

ROTATES

The direction the propeller shaft rotates can be determined based on whether or not the shaft has a groove.

With groove: Counterrotating

Without groove: Standard rotating

WITHOUT

GROOVE

WITH

GROOVE

GROOVE

Destination

A: American

Rotating direction of propeller shaft

C: Counterrotating propeller shaft

None: Standard rotating propeller shaft

Transom Height

L: 20.0 in (508 mm), X: 25.0 in (635 mm)

10


COMPONENT AND CONTROL LOCATIONS

ENGINE COVER

SPARK PLUG

(under coil)

JUNCTION BOX

(FUSES)

OIL FILLER CAP

NMEA INTERFACE

COUPLER

ENGINE COVER

LATCH

POWER TILT

SWITCH

STERN

BRACKET

MANUAL

RELIEF VALVE

ANODE

[Example: BFT115A]

OIL LEVEL DIPSTICK

FLUSH PORT

CONNECTOR

ANODE

COOLING SYSTEM

INDICATOR

ENGINE OIL

DRAIN BOLT

(inside cover)

ANODE

ANTIVENTILATION

PLATE

EXHAUST PORT/WATER

OUTLET PORT

PROPELLER

(optional equipment)

TRIM TAB

TILT LOCK

LEVER

PRODUCT

IDENTIFICATION

NUMBER

GEAR OIL LEVEL

CHECK SCREW

COOLING WATER

INTAKE PORT

GEAR OIL DRAIN/FILL

SCREW

11


Remote Controls (optional equipment)

Side-Mount Control Type

GEARSHIFT/THROTTLE

CONTROL LEVER

POWER TRIM/TILT

SWITCH

BUZZER

(inside)

NEUTRAL RELEASE

LEVER

TRL (Trolling) CONTROL

SWITCH


CONTROL LEVER

INDICATORS

(Oil pressure, Overheat,

Alternator, Malfunction)

FAST IDLE LEVER

Panel-Mount Control Type

POWER TRIM/TILT

SWITCH

NEUTRAL RELEASE

LEVER

CONTROL

LEVER

FRICTION

ADJUSTER

IGNITION

SWITCH

IGNITION

SWITCH KEY

FAST IDLE BUTTON

Control Panel

(for Panel-Mount Type)

BUZZER

INDICATORS



EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH CLIP

IGNITION

SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY

STOP SWITCH

12

Top-Mount Type

(Single Outboard Motor Type)


CONTROL LEVER


(Dual Outboard Motor Type)

POWER TRIM/TILT

SWITCH (RIGHT)


CONTROL LEVERS

POWER TRIM/TILT

SWITCH POWER TRIM/TILT

SWITCH (LEFT)


Control Panel

(Top-Mount Single Type)

BUZZER

INDICATORS



IGNITION

SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH LANYARD


(for Top-Mount Dual Type)

13


Instruments


Tachometer Trolling Control Switch Panel

Trim Meter

TRL (Trolling)

CONTROL SWITCH

14

CONTROLS

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 engine will not start unless the gearshift/throttle control lever is in the N (neutral) position (p. 41) 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

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

15


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).

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.

SPARE SWITCH CLIP


Gearshift/Throttle Control Lever


CONTROL LEVER

NEUTRAL RELEASE

LEVER

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

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

16

F (FORWARD)

N (NEUTRAL)

32° 32°

SHIFT

MINIMUM

R (REVERSE)

SHIFT

MINIMUM

THROTTLE OPENING

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. Refer to p. 52.

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 43 for engine warm-up instructions.

17


N (neutral)

MAXIMUM FAST IDLE

LOWEST

POSITION

Panel-Mount Type


ON

START

OFF

FAST IDLE LEVER

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.

IGNITION

SWITCH







18



EMERGENCY

STOP SWITCH








EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

19




CONTROL LEVER

F (FORWARD)

N (NEUTRAL)

35° 35°

SHIFT SHIFT

R (REVERSE)

MINIMUM


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. 52.


20

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)

CONTROL

LEVER

Push

N (neutral)

R (reverse)

Pull up

NEUTRAL

RELEASE

LEVER


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.


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

21


Top-Mount Type


OFF

ON

START








EMERGENCY

STOP SWITCH

IGNITION SWITCH

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP


EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

22







The gearshift/throttle control lever(s)

SINGLE TYPE controls engine speed and selects F


DUAL TYPE


CONTROL LEVER


(optional equipment) GEARSHIFT/THROTTLE

CONTROL LEVERS

23




A friction adjuster inside the control box adjusts the operating resistance of the control lever(s). Refer to p. 52.


F (FORWARD)


N (NEUTRAL)

35°

SHIFT

35°

SHIFT

MINIMUM

MINIMUM

R (REVERSE)


MAXIMUM

MAXIMUM

GEARSHIFT/THROTTLE CONTROL LEVER

24

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 forward or reverse after pushing in the fast idle button to increase the idle speed.

25


Common Controls

Power Trim/Tilt Switch

(Side-Mount Type) (Top-Mount Type)

SINGLE TYPE

POWER TRIM/TILT SWITCH

CONTROL

LEVER

POWER TRIM/TILT

SWITCH

CONTROL

LEVER

(Panel-Mount Type)


CONTROL LEVER

DUAL TYPE


(LEFT)

(RIGHT)

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

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. 53).

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

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

CONTROL

LEVERS

26

Power Tilt Switch Manual Relief Valve

MANUAL RELIEF VALVE


Tilt Lock Lever

FREE

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.

LOCK

POWER

(To fix)

MANUAL

(To release)

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

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.

27


TRL (Trolling) Control Switch

(optional equipment; based on control box)

Remote Control Box

(Side-Mount Type)

Trolling Control Switch Panel

(optional equipment)

Engine Cover Latch

TRL (Trolling)

CONTROL SWITCH

UNLOCK

TRL (Trolling) CONTROL SWITCH

The TRL (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

900 rpm.

If you press and hold the TRL control switch while cruising with the throttle closed, the mode changes to trolling mode (p. 55).

ENGINE COVER LATCH

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

28

Trim Tab

TRIM TAB

BOLT

INSTRUMENTS

Trim Meter



Tachometer


TRIM TAB

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. 64), steering effort is equal in both directions.

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.

29


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.

NMEA INTERFACE COUPLER

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

NMEA2000-compatible device.

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.

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

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 62).

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

30

<Operating hour notification timing>

20 hours

80 hours after reset

Start of operation

Notify Notify

Every 100 hours

100 hours after reset

Notify

<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



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.

31


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.

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.

32

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.

Alternator (ACG) Indicator

(side-mount type)

ACG INDICATOR

(RED)

(RED)

(panel-mount/top-mount types)

ACG INDICATOR

BUZZER


Malfunction Indicator


MALFUNCTION

INDICATOR


MALFUNCTION

INDICATOR

(RED)

(RED)

BUZZER

BUZZER

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

BUZZER

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

33


Oil Pressure Indicator


OIL PRESSURE

INDICATOR


OIL PRESSURE

INDICATOR

(GREEN)

(GREEN)

BUZZER

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. 100.

All models are equipped with a buzzer that sounds continuously 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


OVERHEAT

INDICATOR


OVERHEAT

INDICATOR

(RED)

(RED)

BUZZER

BUZZER BUZZER

34

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. 101.

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

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.


OTHER FEATURES

Water Separator Buzzer

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

WATER SEPARATOR

35


Rev Limiter

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

The rev 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 rev limiter is activated, check the trim angle of the outboard motor.

Check to see if the correct propeller is installed.

Anodes

ANODE

(each side)

ANODE

(stern bracket)

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.

Fuel Priming Bulb

UP

OUTLET END

(outboard motor side)

PRIMING BULB

INLET END (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. 40).

36

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 lanyard securely to the operator or to the operator’s PFD.

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.

37

BEFORE OPERATION

Safety Inspection

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

• 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. 41, 44 or 47). Make sure

38

the engine stops by pulling the emergency stop switch clip from the emergency stop switch.

Maintenance Inspection

• Check the engine oil level (p. 66).

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. 84).

• Check that the anodes are securely attached to the stern bracket and the gear case (p. 83) and are not excessively worn. The anodes help protect the outboard motor from corrosion.

• Make sure the tool kit is onboard

(p. 61). Replace any missing items.

• Check the fuel level in the fuel tank

(p. 77).

• 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. 81).

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.

39

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.

FUEL PRIMING

UP

OUTLET END

(outboard motor side)

PRIMING BULB

INLET END

(tank side)

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.

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

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.

40

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. 87) for additional information regarding fuel deterioration.

STARTING THE ENGINE

Control

Side-Mount Type ...................... p. 41

Panel-Mount Type..................... p. 44

Top-Mount Type ....................... p. 47

Side-Mount Type

EMERGENCY STOP SWITCH

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

1. Put the emergency stop switch clip in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or

OPERATION 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.

Before leaving the dock, check the operation of the emergency stop switch.

41

OPERATION

N (neutral)

OFF

ON START

LOWEST

POSITION

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.

IGNITION SWITCH KEY

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.

42

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.

FAST IDLE LEVER

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.

43

OPERATION

During the warm-up period, check the oil pressure indicator (p. 34), overheat indicator (p. 34), and cooling system indicator (p. 35).

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. 100 – 103.

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.

Panel-Mount Type

EMERGENCY STOP

SWITCH

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).





44

CONTROL

LEVER

N (neutral)


(neutral) position.



ON

START

OPERATION


OFF

IGNITION

SWITCH KEY








45

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.

46






TAKING CARE OF


6. If the fast idle control 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

EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY STOP

SWITCH CLIP

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).

OPERATION





CONTROL

LEVER

N (neutral)


(neutral) position.



47

OPERATION

OFF

ON

IGNITION

SWITCH KEY

START







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.

48






TAKING CARE OF


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

(neutral) position as the engine warms up.

OPERATION

STOPPING THE ENGINE

Emergency Engine Stopping

Side-Mount Type

EMERGENCY STOP

SWITCH

EMERGENCY

STOP SWITCH

LANYARD

PULL

EMERGENCY STOP

SWITCH CLIP

Panel-Mount/Top-Mount Types

EMERGENCY

STOP SWITCH

CONTROL PANEL

EMERGENCY

STOP SWITCH

LANYARD

PULL

EMERGENCY STOP SWITCH CLIP

49

OPERATION

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.

Normal Engine Stopping


N (neutral)

CONTROL

LEVER

Panel-Mount Type

N (neutral)

CONTROL

LEVER

50

Top-Mount Type

N (neutral)

CONTROL

LEVER

1. Move the control lever(s) to the N

(neutral) position.

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


OFF

IGNITION

SWITCH KEY


GEARSHIFT AND

THROTTLE OPERATION


CONTROL LEVER

OFF

OPERATION


N (neutral)

F (forward)

R (reverse)

IGNITION

SWITCH KEY


OFF position to stop the engine. In the event that the engine does not stop when the ignition switch key is turned to OFF, press the emergency stop switch until the engine stops.

3. When the boat is not in use, remove and store the ignition switch key and the emergency stop switch clip and lanyard.

F (forward)

N (neutral)

NEUTRAL

RELEASE

LEVER

R (reverse)

CONTROL

LEVER

NEUTRAL

RELEASE

LEVER


N (neutral)

F (forward)

R (reverse)

CONTROL

LEVER

51

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.


CONTROL LEVER

FRICTION

ADJUSTER

TO DECREASE

FRICTION

TO INCREASE

FRICTION


CONTROL LEVER

FRICTION ADJUSTER

TO INCREASE

FRICTION

TO DECREASE

FRICTION


TO INCREASE

FRICTION

TO DECREASE

FRICTION

CONTROL LEVER

FRICTION ADJUSTER

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

STEERING

Steer the boat in the same manner as an automobile.

52

CRUISING

Engine Speed

For best fuel economy, limit the throttle opening to 80%. Use the throttle friction control (p. 52) 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 a rev 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 rev limiter.

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

OPERATION

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. 29) 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.

Excessive trim/tilt angle during operation can cause propeller ventilation, overheating, and water pump damage.

53

OPERATION






(single type)


OUTBOARD

MOTOR TRIMMED

TOO LOW

OUTBOARD

MOTOR TRIMMED

TOO HIGH

OUTBOARD MOTOR TRIMMED

CORRECTLY

BOW TOO LOW DUE TO

1. LOAD IN THE FRONT

2. OUTBOARD MOTOR TRIMMED

TOO LOW

(dual type)


(LEFT) (RIGHT)

BOW TOO HIGH DUE TO

1. LOAD IN THE REAR

2. OUTBOARD MOTOR TRIMMED

TOO HIGH

54

Trolling Speed Control

Remote Control Box

(Side-Mount Type)

TRL (Trolling) CONTROL

SWITCH

OPERATION

Trolling Control Switch Panel

(optional equipment)

TRL (Trolling) CONTROL SWITCH

DN: Reduce engine speed

UP: Increase engine speed

The engine must be fully warmed up before you can activate the Trolling

Speed Control.

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. 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 900 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.

55

OPERATION

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.

TRIM TAB

BOLT

SHALLOW WATER

OPERATION

When operating in shallow water, use the power trim/tilt switch (p. 54) 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. 35) to be sure the outboard motor is not tilted so high that the water intakes are out of the water.

TRIM TAB

Adjust the trim tab with the engine stopped. Loosen the bolt above the trim tab, turn the trim tab, and then tighten the bolt securely.

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

Refer to TRIM TAB ADJUSTMENT on p. 64.

56

72°

12°

TILT

ANGLE

0°

16°

0°

– 4°

(VERTICAL LINE)

TRIM ANGLE

(when transom angle is 12°)

OPERATION

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.

TRIM RODS

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.

Do not attempt to use the power tilt switch to tilt the outboard motor down while the tilt lock lever is in the

LOCK position. Damage to the power tilt system may occur.

POWER TILT SWITCH

LOCK

TILT LOCK LEVER

(Lock position)

FREE

STERN BRACKET

57

OPERATION


POWER

(To fix)

MANUAL

(To release)

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.

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.

58

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.

SERVICING YOUR OUTBOARD MOTOR

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.

59


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.

60

TOOL KIT and OWNER’S MANUAL

(Tool kit does not come with Counter Rotation Types)


SPARE EMERGENCY STOP

SWITCH CLIP

PHILLIPS/FLAT

SCREWDRIVER

SPARK PLUG

WRENCH

GRIP 6 mm HEX.

WRENCH

TOOL BAG

OWNER’S MANUAL 19 mm EYE WRENCH

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.

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

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.

61


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.

ITEM

Engine oil

Engine oil filter

Gear case oil

ACG belt

Throttle linkage

Idle speed

Valve clearance

Spark plug

Check level

Change

Replace

Change

Check-adjust

Check-adjust

Check-adjust

Check-adjust

Check-adjust/Replace

(Standard plug)

Propeller and cotter pin

Anode metal

Anode metal

Lubrication

Water separator

Fuel filter

(Low pressure side)

Check

Check Outside engine

Check Inside engine

Grease

Check

Check

Replace

Each use o o o o

After use

First month or

20 hrs.

o o (2) o (2) o (2) o (1)

Every

6 months or

100 hrs.

o o (2) o (2) o (2) o o (1) o

Every year or

200 hrs.

o (2) o (2) o (2)

Every

2 years or

400 hrs.

o (2) (6)

Refer to page o

(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 one third their original size, or if they are crumbling.

66

69

–

–

–

–

–

73 – 75

84

83

–

71 – 72

81 – 82

78 – 80

62


REGULAR SERVICE PERIOD (3)

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

ITEM

Fuel filter Replace

(High pressure side)

Thermostat

Fuel line

Check

Check

Replace

Battery and cable connection Check level-tightness

Bolts and nuts

Crankcase breather tube

Cooling water passages

Water pump

Check-tightness

Check

Clean

Check

Emergency stop switch

Engine oil leak

Each operation part

Engine condition (5)

Power Trim/Tilt

Spark plug

(Optional iridium plug)

Shift Cable

Check

Check

Check

Check

Check

Check

Replace

Check-adjust

Each use o (7) o o o o o

After use o (4)

First month or

20 hrs.

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

Every

6 months or

100 hrs.

o (2) o (2)

Every year or

200 hrs.

o (2) o (2) o (2) o

Every

2 years or

400 hrs.

o (2) o

Refer to page

– o (2)

(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.

(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.

–

76

76

38

–

–

–

–

–

–

–

–

38

–

38

–

63


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, loosen the trim tab bolt and adjust the angle of the trim tab. Retighten the trim tab bolt securely.

LEFT

LEFT

TRIM TAB BOLT

TRIM TAB

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

RIGHT

RIGHT

TRIM TAB BOLT

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.

64



POWER

(To fix)

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

UNLOCK


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

To remove the engine cover, pull the engine cover latch to the unlocked position, then lift the engine cover straight up from the outboard motor.

To install the engine cover, place the cover on the outboard motor, and push down evenly.

The cover should be tight at the mid-case point. If the cover is loose or difficult to secure, an adjustment may be necessary. Please see the service manual or your TOHATSU dealer for adjustment.

65


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. 65).

2. Remove the dipstick and wipe it clean.

OIL LEVEL DIPSTICK

OIL FILLER CAP

UPPER

LIMIT

4. If the oil level is low, remove the oil filler cap, and add oil to reach the upper limit mark shown on the dipstick. Use the oil recommended on p. 70.

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

6. Install and lock the engine cover.

LOWER

LIMIT

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

• 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.

66


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 Effect

• 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.

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

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 COVER

LEVER

2. Push the drain bolt cover lever and remove the cover while pulling the cover backward at an angle.

67


DRAIN BOLT COVER SEALING WASHER

(Replace)

GUIDE

DRAIN

BOLT

DRAIN

BOLT

COVER

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 down a drain.


GUIDE


GUIDE

3. Set the drain bolt cover under the guide.

4. Place a suitable container below the oil drain guide to catch the used oil, and then remove the oil filler cap, drain bolt, and sealing washer.

5. 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.

DRAIN BOLT TIGHTENING

TORQUE:

17 lbf·ft (23 N·m, 2.3 kgf·m)

UNDER COVER PUSH

LOCKING LUG

LEVER

PROJECTION

68

6. Install the oil drain bolt cover. Push the lever of the oil drain bolt cover in the direction pointed by the arrow mark of ‘‘LOCK’’, and install the oil drain bolt cover so that the locking lug securely sets on the projection of the under cover.

7. With the outboard motor in a vertical position, fill to the upper limit mark on the dipstick (p. 66) with the recommended oil.

Engine oil refill capacity:

Without oil filter change:

6.9 US qt (6.5 L)

With oil filter change:

7.1 US qt (6.7 L)

8. Install the oil filler cap and tighten it securely.

9. Install and lock the engine cover.


Oil Filter Change

1. Drain the engine oil, and then reinstall the drain bolt and sealing washer. Reinstall the drain bolt cover (see Engine Oil Change on p. 67).

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.

FILTER WRENCH, 65 mm

OIL FILTER

OIL DRAIN GUIDE

RUBBER SEAL

69


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 3/4 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.

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 66. If necessary, add oil to bring the oil level to the upper limit mark on the dipstick.

70

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 or SJ.

Motor oils classified SG, SH or SJ will show this designation on the container.

SAE 10W-30 is recommended for general use.

AMBIENT TEMPERATURE

Lubrication Points

Apply TOHATSU Marine grease to the parts shown below:

THROTTLE LINK/

PIVOT/PLATE


THROTTLE ROD/LINK TILT BRACKET

Apply anticorrosion oil to pivot surfaces where grease cannot penetrate.

ENGINE COVER BRACKET TILT SHAFT

PTT THRUST RECEIVER

PROPELLER SHAFT


SWIVEL CASE

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

71


ENGINE COVER

LOCK CABLE

(LEFT SIDE)

THROTTLE ARM/

SHIFT ARM/PIVOT

PLATE/NEUTRAL

SWITCH/CLICK

ARM ROLLER

ENGINE COVER

CABLE (FRONT)

ENGINE COVER LOCK

LEVER/OPEN SHAFT

COVER LOCK BOLTS

TILT LOCK LEVER

ENGINE COVER

LOCK CABLE

(RIGHT SIDE)

72

SWIVEL SHAFT TILT SHAFT THREAD

LOWER CYLINDER

BUSH/COLLAR


UPPER CYLINDER PIN/

BUSH

Spark Plug Service

<Standard Spark Plug>

RECOMMENDED SPARK PLUGS:

ZFR6K-11 (NGK)

KJ20DR-M11 (DENSO)

Incorrect spark plugs can cause engine damage.

See page 76 for instructions of handling the Iridium spark plugs

(optional parts).

1. Disconnect the battery negative (–) terminal.


UNDER COVER

GROMMET


CLIP

3. Remove the two clips from the upper part of the under cover grommet.

To remove the clips, raise the inner part of each clip with a screwdriver, then pull out the clips.

UNDER

COVER

CLIP (2)

Do not try to remove the clip with force without raising the inner part of the clip. Otherwise, it can damage the clip and/or under cover.

4. Fold down the upper part of the under cover grommet without removing it from the idle port.

IDLE PORT

UNDER COVER GROMMET

CLIP

73


SPARK PLUG COVER

BOLTS

5. Remove the two bolts with the 6 mm hex. wrench, and remove the spark plug cover.

IGNITION COIL

BOLT

6. Use a 6 mm hex. wrench to remove the bolt holding the ignition coil.

Move the ignition coil to a position that allows removal of the wire connector easily.

7. Disconnect the wire connector from the ignition coil by pushing on the lock tab and pulling on the connector. Pull on the plastic connector, not the wires.

8. Remove the ignition coil by pulling it up slightly.

Do not strike or drop the ignition coil, or it may be damaged and require replacement.

SPARK PLUG

WRENCH

19 mm EYE

WRENCH

9. Remove the spark plugs with a spark plug wrench and 19 mm eye wrench.

New plug Plug needing replacement

LOCK TAB

74

WIRE CONNECTOR

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

SIDE ELECTRODE

0.039 – 0.043 in

(1.0 – 1.1 mm)

SEALING

WASHER

INSULATOR

11. 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:

0.039 – 0.043 in (1.0 – 1.1 mm)

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


13. After each spark plug seats, tighten with the spark plug wrench supplied in the tool kit 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)

15. Install the ignition coil. Reinstall the bolt.

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

17. Reinstall the covers. When reinstalling the covers, make sure not to jam the wire harnesses between the covers and engine case.

CLIP

UNDER

COVER

GROMMET

UNDER

COVER

Loose spark plugs can overheat and damage the engine.

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

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

Clip installation:

• Press the under cover grommet and under cover and be sure that they adhere closely to each other.

• Insert the clips with the inner part raised off, then push in the inner part securely until they click.

75


<Optional Parts: Iridium Spark

Plug>

RECOMMENDED SPARK PLUGS:

IZFR6K11 (NGK)

SKJ20DR-M11 (DENSO) 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.

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

76

REFUELING

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.









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 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.

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.

77


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. 87) for additional information regarding fuel deterioration.

Fuel Filter Inspection and

Replacement

The fuel filter (inside the strainer cup) is located below the intake manifold.

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.








78

ENGINE COVER


STRAINER

ASSEMBLY

FUEL HOSES

UNLOCK


1. Remove the engine cover (p. 65).

FUEL FILTER

(inside strainer cup)

2. Looking through the translucent strainer cup, check the fuel filter for water accumulation or sediment.

SUSPENSION STRAP

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

Remove the suspension strap from the fuel filter bracket, and then remove the strap from the fuel filter assembly.

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

79


STRAINER BODY

O-RING

(Replace)

FUEL STRAINER ASSEMBLY

STRAINER

BRACKET

10.Prime the engine using the priming bulb (p. 40). Check for fuel leaks.

Repair any fuel leaks if necessary.

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.

FUEL FILTER

STRAINER CUP

SCREW (3)

5. Remove the three screws and separate the fuel strainer cup from the strainer body.

6. Thoroughly clean the strainer cup, and replace the fuel filter.

7. Reassemble the strainer body and the cup using a new O-ring.

STRAINER TIGHTENING

TORQUE:

2.5 lbf·ft (3.4 N·m, 0.35 kgf·m)

80

SUSPENSION

STRAP

ALIGNMENT

POSITION

STRAINER CUP

8. Align the center of suspension strap with the screw position and install the fuel strainer assembly.

9. Reinstall the strainer assembly in the original position.


Water Separator Inspection and

Service

INTAKE MANIFOLD

WATER SEPARATOR

The water separator is located below the intake manifold. 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 dealer for cleaning.

SEPARATOR

ASSEMBLY

FUEL TUBES









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

SUSPENSION STRAP

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.

3. Pinch the fuel tubes with tube clamps to prevent fuel leakage.

81


CUP

O-RING

(Replace)

BOWL SUSPENSION STRAP

4. Remove the three screws and separate the bowl from the body.

5. Thoroughly clean the bowl.

6. Reassemble the water separator bowl and cup. Use a new O-ring.

TIGHTENING TORQUE:

2.5 lbf·ft (3.4 N·m, 0.35 kgf·m)

WATER SEPARATOR BRACKET

WATER SEPARATOR

SUSPENSION

STRAP

ALIGNMENT

POSITION

BOWL

7. Align the center of suspension strap with the screw position and install the water separator assembly.

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

9. Prime the engine using the priming bulb (p. 40). Check for fuel leaks.

Repair any fuel leaks if necessary.

If the buzzer sounds or water or sediment accumulation 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.

82

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 one third 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 washer, and then remove the propeller and thrust washer.

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

83


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 washer with as shown.

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.

TIGHTENING TORQUE LIMIT:

33 lbf·ft (44 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.

MARINE GREASE

THRUST WASHER

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

WASHER

COTTER PIN

(stainless)

CASTLE NUT

84

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.

Do not apply water or corrosion inhibitor directly to the electrical components under the engine cover, such as the AC generator, HO2S sensor, or the AC generator belt. If water or corrosion inhibitor penetrates these components, they may be damaged. Before applying a corrosion inhibitor, cover the AC generator, belt and HO2S sensor with a protective material to prevent damage.

CLEANING AND FLUSHING

Cleaning

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

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.

FLUSH PORT

CONNECTOR

4. Disconnect the flush port connector.

85

CLEANING AND FLUSHING

FLUSH PORT

CONNECTOR

GARDEN HOSE

GARDEN HOSE JOINT

(Commercially available)

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

EXHAUST PORT

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.

86

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.

STORAGE

87

STORAGE

Draining the Fuel System

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

FRONT BRACKET CLAMP

1. Unhook the drain hose from the front bracket clamp.

2. 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.








DRAIN SCREW

DRAIN HOSE

VAPOR SEPARATOR

(Draining the fuel becomes easier when the front end of the drain hose is as low as possible)

88

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. Clamp the drain hose on the front bracket clamp.

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

Engine Oil

1. Change the engine oil and the oil filter (p. 66 – 70).

2. Remove the spark plugs (p. 73), and remove the emergency stop switch clip from the emergency stop switch.

3. Pour 1 – 2 teaspoons (5 – 10 cm 3 )

(p. 104) 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. 75).

STORAGE

89

STORAGE

HOISTING THE OUTBOARD

MOTOR

ENGINE COVER LIFTING

EYES

HOIST

HOOKS

UNLOCK



2. Attach the hoist hooks to the lifting eyes.

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.

90

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.

PROTECTOR

If it is necessary to store the outboard motor horizontally as shown, drain the vapor separator (p. 88), and drain the engine oil (p. 67), 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.

STORAGE

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.

91

TRANSPORTING

WITH OUTBOARD MOTOR

INSTALLED ON BOAT

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

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

(commercially available)

WITH OUTBOARD MOTOR

REMOVED FROM BOAT

Secure the outboard motor in either the vertical or horizontal position shown on p. 91.

92

TAKING CARE OF UNEXPECTED PROBLEMS

ELECTRIC STARTER WILL NOT OPERATE

Possible Cause

Battery connections loose or corroded.

Battery discharged.

Fuse(s) blown.

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. 98).

Use starting procedure (p. 41, 44, 47); if engine still will not start, then take outboard motor to an authorized

TOHATSU dealer, or refer to the service manual.

93


ENGINE WILL NOT START

Possible Cause

Clip not inserted in emergency stop switch.

Control lever not in neutral position.

Fast idle lever raised (side-mount type).

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

Insert clip in emergency stop switch.

Shift to neutral.

Leave fast idle lever OFF (p. 42).

Refuel (p. 77).

Squeeze priming bulb (p. 40).

Replace fuel filters (p. 78).

Drain fuel tank and vapor separator (p. 88). Refill with fresh gasoline (p. 77).

94

ENGINE WILL NOT START

Possible Cause

Water separator full of water accumulation.

Spark plugs faulty, fouled, or improperly gapped.

Spark plugs wet with fuel (flooded engine).


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

Correction

Clean water separator (p. 81).

Gap (non-iridium type) or replace spark plugs (p. 73).

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

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

95


HARD STARTING OR STALLS AFTER STARTING

Possible Cause

Fast idle lever raised (side-mount type).

Fuel hose not primed.

Fuel filter or fuel tank filter clogged.

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

Water separator full of water accumulation.

Correction

Leave fast idle lever OFF (p. 42).

Squeeze priming bulb (p. 40).

Replace fuel filters (p. 78).

Drain fuel tank and vapor separator (p. 88). Refill with fresh gasoline (p. 77).

Clean water separator (p. 81).

96


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

Gap (non-iridium type) or replace spark plugs (p. 73).


ENGINE OVERHEATS

Possible Cause

Water intake screens clogged.

Faulty thermostat or water pump.

Correction

Clean water intake screens.


97


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. 5) 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.

Battery Will Not Charge

A 100 A ACG fuse protects the alternator circuit. If the ACG fuse blows, the engine will not charge the battery. Refer to p. 100.

Fuse Replacement

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.

(2)

SPARE FUSES

(10 A, 15 A, 30 A)

3. Remove the junction box lid.

FUSE PULLER

RELAYS

(Do not remove the relays)

FUSE

HOLDER

FUSES (10 A, 15 A, 30 A)

10 A (No. 5) MAIN FUSE

45°

(1) JUNCTION

BOX LID

98

FUSE PULLER

BLOWN FUSE


4. Use the fuse puller from the fuse holder 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 junction box lid.

MAIN FUSE RATINGS:

10 A, 15 A, 30 A

5. Reinstall the junction box lid, and the engine cover.

6. Reconnect the battery.

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.

99


ACG Fuse

5. Install a new fuse with the

‘‘100 A.’’

ACG FUSE: 100 A

6. Reinstall the junction box lid, and the engine cover.

7. Reconnect the battery.

A spare fuse is located on the fuse holder.

SPARE FUSE (100 A)

FUSE (100 A)

FUSE HOLDER

1. Stop the engine and disconnect the battery cable.

2. Remove the engine cover.

3. Remove the junction box lid

(see page 98).

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

OIL PRESSURE INDICATOR

TURNS OFF AND ENGINE

SPEED IS LIMITED


OIL PRESSURE

INDICATOR

(GREEN)

BUZZER


OIL PRESSURE

INDICATOR

(GREEN)

BUZZER

100

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. 66), 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


OVERHEAT

INDICATOR


OVERHEAT

INDICATOR

(RED)

BUZZER

(RED)

BUZZER

101


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.

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.

102

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 present, stop the engine, and clean the water separator following the instructions on page 81, 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 dealership, 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. 88.

3. Change the engine oil and oil filter as described on p. 66 – 70. 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. 73).

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

103


5. Pour a teaspoon (p. 89) 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 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.

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.

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

104

TECHNICAL INFORMATION

Serial Number Locations

Record the product identification 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.

PRODUCT

IDENTIFICATION

NUMBER

RIGHT STERN BRACKET ENGINE SERIAL NUMBER

The product identification number is stamped on a plate attached on the right side of the stern bracket.

Product identification number:

Date of purchase:

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

Engine serial number:

105


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 – 64Ah/5HR (80Ah/20HR)

(CCA622)

• 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.

106

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.

PGM-FI System

The PGM-FI system uses sequential multiport fuel injection. It has three subsystems: Air Intake, 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.

Ignition Timing Control System

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

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.

107


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 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. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission 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

Follow the maintenance schedule on page 62 and 63. 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.

108

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.

109


One Star

Low

Emission

Two Stars

Very 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.

Three Stars

Ultra Low

Emission

Four Stars

Super Ultra

Low Emission

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

110


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

Starter system

Ignition system

Lubrication system

Specified oil

LA

65.6 in (1,665 mm)

20.0 in (508 mm)

BFT115A

BBHJ

XA

33.3 in (845 mm)

22.8 in (580 mm)

XCA

70.5 in (1,790 mm)

25.0 in (635 mm)

478 lbs

(217 kg)

485 lbs

(220 kg)

85.8 kW (115 HP)

492 lbs

(223 kg)

4,500 – 6,000 rpm

4 stroke DOHC in-line 4-cylinder

143.6 cu-in (2,354 cm 3 )

0.039 – 0.043 in (1.0 – 1.1 mm)

Electric starter

Fully transistorized, battery ignition

Trochoid pump pressure lubrication

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Gear change

Steering angle

Tilt up angle


Trim angle


Tune Up

ULTRA · LOW EMISSION

12 V – 40 A

Water cooling with thermostat

Water exhaust

ZFR6K-11 (NGK)

KJ20DR-M11 (DENSO)

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

Stageless (72°)

– 4° to 16°

Oil capacity

Engine: API standard (SG, SH, SJ)

SAE 10W-30

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

Hypoid gear oil

Engine: 6.9 US qt (6.5 L) without oil filter change

7.1 US qt (6.7 L) with oil filter change

Gear case: 1.04 US qt (0.98 L)

Spark plug gap

Idle speed

Valve clearance

(cold)

Other specifications

0.039 – 0.043 in

(1.0 – 1.1 mm)

See page 75

750 ± 50 rpm

See service manual

Intake: 0.23 ± 0.02 mm

Exhaust: 0.30 ± 0.02 mm

See service manual

No other adjustment is needed

* With propeller

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

111


Specifications

MODEL

Description code

Type

Overall length

Overall width

Overall height

Transom height


Dry mass

[weight]*

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Starter system

Ignition system

Lubrication system

Specified oil

LA

65.6 in

(1,665 mm)

BFT150A

BANJ

XA

33.3 in (845 mm)

22.8 in (580 mm)

70.5 in

(1,790 mm)

BAPJ

XCA

20.0 in

(508 mm)

25.0 in

(635 mm)

478 lbs

(217 kg)

485 lbs

(220 kg)

111.9 kW (150 HP)

5,000 – 6,000 rpm

4 stroke DOHC in-line 4-cylinder

143.6 cu-in (2,354 cm 3 )

492 lbs

(223 kg)

0.039 – 0.043 in (1.0 – 1.1 mm)

Electric starter

Fully transistorized, battery ignition

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Gear change

Steering angle

Tilt up angle


Trim angle


Tune Up

ULTRA · LOW EMISSION

12 V – 40 A

Water cooling with thermostat

Water exhaust

ZFR6K-11 (NGK)

KJ20DR-M11 (DENSO)

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

Stageless (72°)

– 4° to 16°

Oil capacity

Trochoid pump pressure lubrication

Engine: API standard (SG, SH, SJ)

SAE 10W-30

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

Hypoid gear oil

Engine: 6.9 US qt (6.5 L) without oil filter change

7.1 US qt (6.7 L) with oil filter change

Gear case: 1.04 US qt (0.98 L)

Spark plug gap

Idle speed

Valve clearance

(cold)

Other specifications

0.039 – 0.043 in

(1.0 – 1.1 mm)

See page 75

750 ± 50 rpm

See service manual

Intake: 0.23 ± 0.02 mm

Exhaust: 0.30 ± 0.02 mm

See service manual

No other adjustment is needed

* With propeller

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

112

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.

113


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 117 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

114

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 117.

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.

115


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.

116


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 62 and 63.

117

INDEX

Alternator (ACG) Indicator ...........................................33

Anodes ...........................................................................36

Replacement ..............................................................83

ARE YOU READY TO GET UNDERWAY? ...............37

B

Battery .........................................................................106

Will Not Charge .........................................................98

BEFORE OPERATION .................................................37

BREAK-IN PROCEDURE ...........................................39

C

CLEANING AND FLUSHING ....................................85

Common Controls .........................................................26

COMPONENT AND CONTROL LOCATIONS .........11

CONSUMER INFORMATION ..................................113

CONTROL AND FEATURE IDENTIFICATION

CODES ......................................................................10

CONTROLS ..................................................................15

CONTROLS AND FEATURES ....................................10

Cooling System Indicator ..............................................35

CRUISING ....................................................................53

E

Electric Starter Will Not Operate ............................ 93, 98

Emergency Stop Switch Clip and Emergency Stop

Switch

Panel-Mount Type ..................................................... 19

Side-Mount Type ...................................................... 15

Top-Mount Type ....................................................... 22

Emission Control System Information ........................ 106

Emission Control System Warranty ............................ 113

Engine

Cover

Latch ..................................................................... 28

REMOVAL AND INSTALLATION .................... 65

Oil

Change .................................................................. 67

Filter Change ........................................................ 69

Level Check .......................................................... 66

Recommendations ................................................. 70

OVERHEATS ........................................................... 97

WILL NOT START .................................................. 94

F

118

Fast Idle Button

Panel-Mount Type .....................................................21

Top-Mount Type ........................................................25

Fast Idle Lever ...............................................................17

Fuel

PRIMING ..................................................................40

Priming Bulb .............................................................36

Fuel

RECOMMENDATIONS ...........................................77

Filter Inspection and Replacement ............................78

Fuse Replacement ..........................................................98

FUSES ...........................................................................98

G

Gearshift/Throttle Control Lever

Panel-Mount Type .....................................................20

Side-Mount Type .......................................................16

Top-Mount Type ........................................................23

GEARSHIFT AND THROTTLE OPERATION ...........51

H

HARD STARTING OR STALLS AFTER

I

STARTING ................................................................96

HOISTING THE OUTBOARD MOTOR .....................90

INDEX

Ignition Switch

Panel-Mount Type ..................................................... 18

Side-Mount Type ...................................................... 15

Top-Mount Type ....................................................... 22

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

INDICATORS ............................................................... 33

INFREQUENT OR OCCASIONAL USE .................... 41

INSTRUMENTS ........................................................... 29

IS YOUR OUTBOARD MOTOR

READY TO GO? ...................................................... 37

L

Lubrication Points ......................................................... 71

M

MAINTENANCE SAFETY ......................................... 60

MAINTENANCE SCHEDULE ................................... 62

Malfunction Indicator ................................................... 33

MANUAL RELIEF VALVE ................................... 27, 65

MOORING, BEACHING, LAUNCHING .................... 57

MULTIPLE OUTBOARD MOTORS .......................... 58

N

NMEA 2000 ®

O

Interface Coupler .................................. 30

119

INDEX

Oil Pressure Indicator ....................................................34

OIL PRESSURE INDICATOR TURNS OFF AND

ENGINE SPEED IS LIMITED ...............................100

OPERATION .................................................................39

Operating Hour Notification System .............................30

OTHER FEATURES .....................................................35

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

Overheat Indicator .........................................................34

OVERHEAT INDICATOR COMES ON AND

ENGINE SPEED IS LIMITED ...............................101

P

Power Tilt Switch ..........................................................27

Power Trim/Tilt Switch .................................................26

Propeller Replacement ...................................................83

R

REFUELING .................................................................77

REMOVAL FROM STORAGE ....................................91

Rev Limiter ....................................................................36

S

SAFE OPERATING PRECAUTIONS ..........................39

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

Serial Number Locations .............................................105

SERVICING YOUR OUTBOARD MOTOR ...............59

SHALLOW WATER OPERATION ..............................56

SPARE EMERGENCY STOP SWITCH CLIP ............ 61

Spark Plug Service ........................................................ 73

Specifications .............................................................. 111

Star Label .................................................................... 109

STARTING THE ENGINE ........................................... 41

Panel-Mount Type ..................................................... 44

Side-Mount Type ...................................................... 41

Top-Mount Type ....................................................... 47

STEERING ................................................................... 52

STOPPING THE ENGINE ........................................... 49

Emergency Engine Stopping ..................................... 49

Normal Engine Stopping .......................................... 50

STORAGE .................................................................... 87

Engine oil .................................................................. 89

Fuel ........................................................................... 87

STORAGE PRECAUTIONS ........................................ 90

SUBMERGED OUTBOARD MOTOR ..................... 103

T

120

Tachometer (optional equipment) ..................................29

TAKING CARE OF UNEXPECTED PROBLEMS .....93

TECHNICAL INFORMATION ..................................105

THE IMPORTANCE OF MAINTENANCE ................59

Tilt Lock Lever ..............................................................27

TOOL KIT and OWNER’S MANUAL ........................61

TRANSPORTING .........................................................92

WITH OUTBOARD MOTOR INSTALLED

ON BOAT ..............................................................92

WITH OUTBOARD MOTOR REMOVED

FROM BOAT ........................................................92

Trim Meter (optional equipment) ..................................29

Trim Tab ........................................................................29

TRIM TAB ADJUSTMENT .........................................64

TRL (Trolling) Control Switch ......................................28

Trolling Speed Control ..................................................55

W

Water Separator Buzzer .................................................35

WATER SEPARATOR BUZZER SOUNDS ...............103

Water Separator Inspection and Service ........................81

INDEX

121

122

MEMO

MEMO

123

124

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 115A

BFT 150A

TOHATSU CORPORATION

5-4, Azusawa 3-Chome, Itabashi-Ku

Tokyo 174-0051, Japan

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

OM_BFT115-150A_US_Cover.indd 1

31ZX1T14

00X31-ZX1-T140

XXX.XXXX.XX

PRINTED IN JAPAN

OWNER’S MANUAL

BFT 115A

BFT 150A

Tohatsu BFT 115A Owner Manual

Assistant Bot

BFT 115A

BFT 150A

OWNER’S MANUAL

BFT 115A

BFT 150A

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

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

HOW TO DETERMINE

WHICH DIRECTION THE

PROPELLER SHAFT

ROTATES

10

COMPONENT AND CONTROL LOCATIONS

11

Remote Controls (optional equipment)

Side-Mount Control Type

Panel-Mount Control Type

Control Panel

(for Panel-Mount Type)

12

Top-Mount Type

(Single Outboard Motor Type)

(Dual Outboard Motor Type)

Control Panel

(Top-Mount Single Type)

(for Top-Mount Dual Type)

13

14

CONTROLS

Side-Mount Type

Ignition Switch

Emergency Stop Switch Clip and

Emergency Stop Switch

15

Gearshift/Throttle Control Lever

16

Fast Idle Lever

17

Panel-Mount Type

Ignition Switch

18

Emergency Stop Switch Clip and

Emergency Stop Switch

19

Gearshift/Throttle Control Lever

20

Fast Idle Button

21

Top-Mount Type

Ignition Switch

Emergency Stop Switch Clip and

Emergency Stop Switch

22

Gearshift/Throttle Control Lever

23

24

Fast Idle Button

25