Tohatsu BFT 90A Owner Manual

OWNER’S

MANUAL

BFT 75A

90A

Original instructions

© 2017 Honda Motor Co , Ltd

PGM-FI is a trademark of Honda Motor Co , Ltd registered in Japan and other countries

Thank you for purchasing a

TOHATSU Outboard Motor.

This manual covers operation and maintenance of the TOHATSU

BFT75A/90A Outboard Motor.

All information in this publication is based on the latest product information available at the time of approval for printing.

Tohatsu Corporation reserves the right to make changes at any time without notice and without incurring any obligation.

No part of this publication may be reproduced without written permission.

This manual should be considered a permanent part of the Outboard

Motor and should remain with it if it is resold.

Throughout this manual, you will see safety messages proceeded by the following words and symbols. Here’s what they mean:

If a problem should arise, or if you have any questions about the

Outboard Motor, consult an authorized TOHATSU Outboard

Motor dealer.

Indicates serious injury or death

WILL result if instructions are not followed.

Indicates a strong possibility that serious personal injury or death may result if instructions are not followed.

Indicates a possibility that personal injury or equipment damage could result if instructions are not followed.

Indicates that equipment or property damage could result if instructions are not followed.

Gives helpful information.

TOHATSU Outboard Motors are designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the Outboard

Motor. Failure to do so could result in personal injury or equipment damage.

• Have your dealer install the tiller handle.

• The illustration may vary according to the type.

1

Model

Type

Transom Height

(Shaft Length)

Tiller Handle (H1 type)

Tiller Handle (H2 type)

Remote Control

Power Trim/Tilt

Trim Meter

Tachometer

TRL (Trolling) Control Switch

537 mm (21.1 in)

664 mm (26.1 in)

LRTD

•

∗

∗

∗

∗

•

∗

∗

BFT75A

LRTU

•

∗

∗

∗

∗

•

∗

∗

XRTU

∗

∗

•

∗

∗

∗

•

∗

LRTD

•

∗

∗

∗

∗

•

∗

∗

BFT90A

LRTU

•

∗

∗

∗

∗

•

∗

∗

XRTU

∗

∗

•

∗

∗

∗

•

∗

Note that the types of the outboard motor differ according to the countries where they are sold.

BFT75A/90A is provided with the following types according to the shaft length, control system, and tilt system.

TYPE CODE Example

L R T D

Destination

U: Europe, D: General Export

*: Optional Equipment

Tilt system

T: Power Trim/Tilt (with hydraulic assisted function)

Control system

R: Remote Control

Shaft Length

L: 537 mm (21.1 in) (Long Shaft)

X: 664 mm (26.1 in) (Extra Long Shaft)

2

This Owner’s Manual is using the following type names when it describes the operations special to a type.

Remote control

(optional equipment) type: R type

Tiller handle

(optional equipment) type: H type

Power trim/tilt type: T type

The tiller handle type is classified into the following two categories.

Tiller handle

(optional equipment) type: H1 type

Multi-Function Tiller handle

(optional equipment) type: H2 type

The remote control type is classified into the following three categories according to the control box position.

Side-mount type: R1 type

Panel-mount type: R2 type

Top-mount type: R3 type

Check the type of your outboard motor and read this Owner’s Manual thoroughly before operation.

FRAME SERIAL NUMBER

STERN BRACKET

Texts with no type indication are the information and/or procedures common to all types.

Record the frame and engine serial numbers for your reference. Refer to the serial numbers when ordering parts, and when making technical or warranty inquiries.

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

Frame serial number:

ENGINE SERIAL NUMBER

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

Engine serial number:

3

CONTENTS

1. SAFETY ...........................................................................................7

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

2. SAFETY LABEL LOCATIONS ....................................................10

3. COMPONENT IDENTIFICATION ..............................................13

4. CONTROLS AND FEATURES .................................................... 22

H type

Engine Switch (Ignition Switch) ............................................22

Shift Lever ..............................................................................23

Throttle Grip ...........................................................................24

Throttle Friction Adjuster ......................................................25

Emergency Stop Switch .........................................................25

Emergency Stop Switch Lanyard/Clip ...................................26

Steering Friction Adjusting Knob ..........................................27

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

R type

Remote Control Lever ............................................................29

Neutral Release Lever ............................................................32

Engine Switch (Ignition Switch) ............................................32

Fast Idle Lever (R1 type)/Fast Idle Button (R2, R3 types) ....33

Emergency Stop Switch .........................................................34

Emergency Stop Switch Lanyard/ Clip ..................................34

Spare Emergency Stop Switch Clip (optional equipment) ....35

TRL (Trolling) Control Switch ..............................................36

T type

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

Trim Meter (equipped type or optional equipment) ...............38

Power Tilt Switch (outboard motor pan) ...............................39

Manual Relief Valve ..............................................................39

Common

Tilt Lock Lever ......................................................................40

Oil Pressure Indicator/Buzzer ................................................40

Overheat Indicator/Buzzer .....................................................41

4

ACG Indicator/Buzzer ........................................................... 42

PGM-FI Indicator/Buzzer ...................................................... 43

Water Separator Buzzer ......................................................... 43

Trim Tab ................................................................................ 44

Anode ..................................................................................... 44

Cooling Water Check Hole .................................................... 45

Cooling Water Intake Port ..................................................... 45

Engine Cover Fixing Lever ................................................... 46

Tachometer (equipped type or optional equipment) .............. 46

Fuel Filler Cap (equipped type) ............................................. 46

Fuel Gauge ............................................................................. 47

Fuel Line Connector And Joint (equipped type) ................... 47

NMEA Interface Coupler ...................................................... 48

Operating Hour Notification System ..................................... 48

5. INSTALLATION ........................................................................... 51

Transom Height .......................................................................... 51

Location ...................................................................................... 52

Installation Height ...................................................................... 52

Outboard Motor Installation ....................................................... 53

Outboard Motor Angle Inspection (Cruising) ............................ 54

Battery Connections .................................................................... 55

Remote Control Installation (equipped type or optional equipment) .............................................................................. 57

<Remote Control Box Location> .......................................... 58

<Remote Control Cable Length> .......................................... 58

Propeller Selection ...................................................................... 59

6. PRE-OPERATION CHECKS ........................................................ 60

Engine Cover Removal/Installation ............................................ 60

Engine Oil ................................................................................... 60

Fuel ............................................................................................. 63

GASOLINE CONTAINING ALCOHOL .................................. 64

Propeller and Cotter Pin Inspection ............................................ 65

Tiller Handle Height/Angle Adjustment (H type) ......................66

Steering Handle Friction (H type) ...............................................68

Remote Control Lever Friction (R type) .....................................68

Water Separator ...........................................................................69

Battery .........................................................................................69

Other Checks ...............................................................................71

7. STARTING THE ENGINE ............................................................72

Fuel Line Connection ..................................................................72

Fuel Priming ................................................................................74

Starting the Engine ......................................................................75

H type ......................................................................................75

R type ......................................................................................79

R1 type ................................................................................79

R2, R3 types ........................................................................83

Emergency Starting .....................................................................87

8. OPERATION ..................................................................................93

Break-in Procedure ......................................................................93

Gear Shifting ...............................................................................94

H type ......................................................................................94

R1 type ....................................................................................96

R2 type ....................................................................................97

R3 type ....................................................................................98

Steering

H type ......................................................................................99

R type ......................................................................................99

Cruising

H type ....................................................................................100

R type ....................................................................................103

TRL (Trolling) Control Switch .................................................105

Trimming the Outboard Motor ..................................................106

Trim Meter (equipped type or optional equipment) ..................109

Tilting the Outboard Motor (T type) ....................................110

CONTENTS

Moorage (T type) ................................................................. 111

Power Tilt Switch (T type) ....................................................... 112

Manual Relief Valve (T type) ................................................... 113

Trim Tab Adjustment ............................................................... 114

Engine Protection System

<Engine Oil Pressure, Overheat, Water Contamination,

PGM-FI and ACG Warning Systems> ............................... 115

<Over-rev Limiter> .......................................................... 119

<Anode> .......................................................................... 119

Shallow Water Operation ......................................................... 119

Multiple Outboard Motors ........................................................ 120

9. STOPPING THE ENGINE .......................................................... 121

Emergency Engine Stop ........................................................... 121

Normal Engine Stop ................................................................. 122

H type ................................................................................... 122

R type.................................................................................... 124

10. TRANSPORTING ..................................................................... 125

Fuel Line Disconnection ........................................................... 125

Transporting .............................................................................. 125

Trailering .................................................................................. 126

11. CLEANING AND FLUSHING ................................................. 128

5

CONTENTS

12. MAINTENANCE .......................................................................129

Tool Kit and Emergency Parts ..................................................130

MAINTENANCE SCHEDULE ................................................131

Engine Oil .................................................................................133

Spark Plugs ................................................................................135

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

Lubrication ................................................................................141

Water Separator .........................................................................143

Fuel Filter ..................................................................................146

Fuel Tank and Tank Filter (equipped type) ...............................148

EMISSION CONTROL SYSTEM ...........................................149

Fuse ...........................................................................................150

ACG Fuse ..................................................................................151

Propeller ....................................................................................152

Inspect After Operating .............................................................153

Submerged Outboard Motor .....................................................153

13. STORAGE ..................................................................................154

Fuel ............................................................................................154

Vapor Separator Draining .........................................................155

Battery Storage ..........................................................................156

Outboard Motor Position ...........................................................157

14. DISPOSAL .................................................................................158

15. TROUBLESHOOTING .............................................................159

16. SPECIFICATIONS .....................................................................161

17. ‘‘EC DECLARATION OF CONFORMITY’’

CONTENT OUTLINE.............................................................. 164

18. INDEX ........................................................................................169

6

SAFETY INFORMATION

For your safety and the safety of others, pay special attention to these precautions.

Operator Responsibility

• TOHATSU outboard motor is designed to give safe and dependable service if operated according to instructions.

Read and understand the

Owner’s Manual before operating the outboard motor.

Failure to do so could result in personal injury or equipment damage.

• Gasoline is harmful or fatal if swallowed. Keep the fuel tank out of reach of children.

• Gasoline is extremely flammable and is explosive under certain conditions.

Refuel in a well-ventilated area with the engine stopped.

• Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stored.

1. SAFETY

• Do not overfill the fuel tank.

After refueling make sure that the fuel tank cap is closed properly and securely.

• Be careful not to spill any fuel while refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled make sure that the area is dry before starting the engine.

7

SAFETY

• Shift to the neutral position and then shift to the reverse position at low engine speed.

Do not shift to the reverse position suddenly at high engine speed.

• Moving parts can injure you. Install the engine cover after emergency starting the engine. Do not operate the outboard motor without the engine cover.

• Know how to stop the engine quickly in case of emergency.

Understand the use of all controls.

• Do not exceed the boat manufacturer’s power recommendation, and be sure that the outboard motor is properly mounted.

• Never permit anyone to operate the outboard motor without proper instruction.

• Before operating the outboard motor, familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.

• Do not attempt to modify the outboard motor.

• Always wear a life-jacket when on board.

• Do not operate the outboard motor without the engine cover. Exposed moving parts can cause injury.

• Do not remove any guards, labels, shields, covers or safety devices; they are installed for your safety.

• Stop the engine immediately if anyone falls overboard.

• Do not run the engine while the boat is near anyone in the water.

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

8

Fire and Burn Hazards

Gasoline is extremely flammable, and gasoline vapor can explode. Use extreme care when handling gasoline.

KEEP OUT OF REACH OF

CHILDREN.

• Remove the fuel tank from the boat for refueling.

• Refuel in a well-ventilated area with the engine stopped. Keep flames and sparks away, and do not smoke in the area.

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

(there should be no fuel in the filler neck). After refueling, tighten the fuel filler cap securely. If any fuel is spilled, make sure the area is dry before starting the engine.

SAFETY

The engine and exhaust system become very hot during operation and remain hot for a while after stopping. Contact with hot engine components can cause burns and may ignite some materials.

• Avoid touching a hot engine or exhaust system.

• Allow the engine to cool before performing maintenance or transporting.

Carbon Monoxide Poisoning

Hazard

Exhaust contains poisonous carbon monoxide, a colorless and odorless gas. Breathing exhaust can cause loss of consciousness and may lead to death.

• If you run the engine in an area that is confined, or even partially enclosed, the air can become contaminated with a dangerous amount of exhaust gas. To keep exhaust gas from building up, provide adequate ventilation.

9

2. SAFETY LABEL LOCATIONS

[Equipped type]

These labels are in the locations shown.

They warn you of potential hazards that can cause serious injury.

Read the labels and safety notes and precautions described in this manual carefully.

If a label comes off or becomes hard to read, contact your TOHATSU outboard motor dealer for a replacement.

READ OWNER'S MANUAL

GEAR SHIFTING

Multi-Function TILLER HANDLE

(H2 type)

(optional equipment)

READ OWNER'S

MANUAL

READ OWNER'S MANUAL

EMERGENCY ENGINE STARTING

10

FUEL TANK

(equipped type)

FUEL CAUTION

SAFETY LABEL LOCATIONS

FUEL CAUTION

11

SAFETY LABEL LOCATIONS

CE mark location [U type only]

CE MARK

(10)

(4)

(5)

(7)

(8)

(9)

(1)

(2)

(3)

(6)

(1) Model name

(2) Engine family name

(3) Year code

(4) Rated power

(5) Dry mass (weight) (with propeller, without battery cable)

(6) Country of manufacture

(7) Frame number

(8) Manufacturer and address

(9) Name and address of authorized representative

(10)The identification number of the notified body

Year code D E F G H J

Year of manufacture 2013 2014 2015 2016 2017 2018

Name and address of manufacturer and authorized representative are written in the

“EC Declaration of Conformity” CONTENT OUTLINE in this Owner’s Manual.

12

[R (Remote Control) type]

ENGINE COVER

FIXING LEVER

(front)

STERN

BRACKET

MANUAL

RELIEF VALVE

ANODE

3. COMPONENT IDENTIFICATION

OIL FILLER CAP

ENGINE COVER

OIL LEVEL DIPSTICK

ENGINE COVER

FIXING LEVER

(rear)

POWER TILT

SWITCH

IDLE PORT

COOLING

WATER

CHECK HOLE

ANODE

(each side)

FLUSH PORT

CONNECTOR

ENGINE OIL

DRAIN BOLT

NMEA

INTERFACE

COUPLER

TILT LOCK

LEVER

FRAME SERIAL

NUMBER

TRIM TAB

EXHAUST PORT/

WATER OUTLET PORT

PROPELLER


GEAR OIL LEVEL

PLUG

COOLING WATER

INTAKE PORT

(each side)

ANTICAVITATION PLATE

GEAR OIL DRAIN BOLT

13

COMPONENT IDENTIFICATION

REMOTE CONTROL BOX

(equipped type or optional equipment)

SIDE-MOUNTTYPE (R1 type)

REMOTE CONTROL LEVER

POWER TRIM/TILT SWITCH

BUZZER

(inside)

PANEL-MOUNTTYPE (R2 type)


NEUTRAL RELEASE

LEVER

TRL (Trolling) CONTROL SWITCH

INDICATORS

(Oil pressure, Overheat,

ACG, PGM-FI)

FAST IDLE LEVER

NEUTRAL RELEASE

LEVER

ENGINE

SWITCH

POWER TRIM/TILT

SWITCH

FAST IDLE BUTTON

CONTROL

LEVER

FRICTION

ADJUSTER

EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH CLIP

R1, R2 types:

SPARE EMERGENCY STOP SWITCH CLIP

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

14


TOP-MOUNT TYPE (R3 type)

(SINGLE OUTBOARD MOTOR TYPE)


(DUAL OUTBOARD MOTOR TYPE)

REMOTE CONTROL LEVERS

POWER TRIM/TILT

SWITCH (RIGHT)

R3 type:

POWER TRIM/

TILT SWITCH

POWER TRIM/TILT

SWITCH (LEFT) SPARE EMERGENCY

STOP SWITCH CLIP



SWITCH PANEL (optional equipment)

(PANEL-MOUNT, TOP-MOUNT)

BUZZER

INDICATORS

(Oil pressure,

Overheat, ACG,

PGM-FI)


(for TOP-MOUNT DUAL type)

ENGINE

SWITCH

EMERGENCY

STOP SWITCH

EMERGENCY STOP SWITCH CLIP

EMERGENCY STOP SWITCH LANYARD

15


[H (Tiller Handle) type]

ENGINE COVER

FIXING LEVER

(front)

TILLER HANDLE

(H1 type)


STERN BRACKET

MANUAL RELIEF

VALVE (T type)

ANODE

ENGINE COVER


OIL FILLER CAP

NMEA

INTERFACE

COUPLER

ENGINE COVER

FIXING LEVER

(rear)

POWER TILT

SWITCH

(T type)

IDLE PORT

COOLING

WATER

CHECK HOLE

ANODE

(each side)

FLUSH PORT

CONNECTOR

ENGINE OIL

DRAIN BOLT

TILT LOCK

LEVER

FRAME SERIAL

NUMBER

TRIM TAB

EXHAUST PORT/

WATER OUTLET PORT

PROPELLER


GEAR OIL LEVEL

PLUG

COOLING WATER

INTAKE PORT

(each side)

ANTICAVITATION PLATE

GEAR OIL DRAIN BOLT

16

TILLER HANDLE (H1 type) (optional equipment)

INDICATORS

(Oil pressure, Overheat,

ACG, PGM-FI)

EMERGENCY STOP SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD


SHIFT LEVER

THROTTLE FRICTION

ADJUSTER

ENGINE SWITCH

STEERING FRICTION

ADJUSTING KNOB


(T type)

THROTTLE GRIP



17


TILLER HANDLE (H2 type) (optional equipment)

INDICATORS

(Oil pressure, Overheat, ACG, PGM-FI) TRL (Trolling)

CONTROL SWITCH

SHIFT LEVER


ADJUSTER

THROTTLE GRIP

18

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

ENGINE SWITCH

ENGINE SWITCH KEY


ADJUSTING KNOB


LANYARD




[Common]

FUEL GAUGE


FUEL TANK

(equipped type)

FUEL FILLER CAP

FUEL FILLER CAP

VENT KNOB

FUEL LINE JOINT

(outboard motor side)

PRIMING BULB

FUEL TANK

TUBE ASSEMBLY

(equipped type)

19


FUEL TUBE ASSEMBLY

(equipped type)

FUEL LINE JOINT

(fuel tank side)

PRIMING BULB

FUEL LINE JOINT


20

TACHOMETER (Optional equipment)


TRIM METER (Optional equipment) TRL (Trolling) CONTROL SWITCH PANEL

(Optional equipment: R type)


21

4. CONTROLS AND FEATURES (H type)

Engine Switch (Ignition Switch)

(H1 type)

ON

START

NEUTRAL

SHIFT LEVER

OFF

ENGINE SWITCH

(IGNITION SWITCH)

START

(H2 type)

ON

ON

OFF

START

OFF

SHIFT LEVER

ENGINE SWITCH

(IGNITION SWITCH)

NEUTRAL

NEUTRAL

This tiller handle is equipped with an automotive type ignition switch.

Key positions:

START:

ON:

OFF: to start the engine.

to run the engine after starting.

to stop the engine

(IGNITION OFF).

Do not leave the engine switch

(ignition switch) ON (key in ON position) when the engine is not running as the battery will discharge.

The starter motor will not work unless the shift lever is in the

NEUTRAL position.

22

OFF ON START

NEUTRAL

Shift Lever

(H1 type)

FORWARD

NEUTRAL

REVERSE

SHIFT

LEVER

CONTROLS AND FEATURES (H type)

(H2 type)

REVERSE

NEUTRAL

FORWARD

SLOW

SHIFT

LEVER

SLOW

THROTTLE GRIP

FORWARD REVERSE

NEUTRAL

Use the shift lever to run the boat in forward or reverse gear, or to cut off the engine power from the propeller.

There are three positions for the shift lever.

FORWARD: The boat moves ahead.

NEUTRAL: The engine power is cut off from the propeller. The boat does not move.

REVERSE: The boat reverses.

REVERSE FORWARD

NEUTRAL

Use the shift lever to run the boat in forward or reverse gear, or to cut off the engine power from the propeller.

There are three positions for the shift lever.

FORWARD: The boat moves ahead.

NEUTRAL: The engine power is cut off from the propeller. The boat does not move.

REVERSE: The boat reverses.

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

SHIFT LEVER

You can chose which side to have the shift lever installed. Consult your authorized TOHATSU outboard motor dealer.

23


Throttle Grip

(H1 type)

(H1 type)

THROTTLE

INDICATOR

THROTTLE GRIP

(H2 type)

(H2 type)

FAST SLOW

START

FAST START

SLOW

THROTTLE GRIP

Turn the grip clockwise or counterclockwise to adjust the engine speed. Turning the grip in the direction shown by arrow increases the engine speed.

24

THROTTLE

INDICATOR

The curve on the grip indicates the engine speed.

Throttle Friction Adjuster

(H1 type)

THROTTLE FRICTION ADJUSTER

RELEASE


(H2 type)


ADJUSTER

FIX

Emergency Stop Switch

(H1 type)


FIX

THROTTLE GRIP

RELEASE STOP

THROTTLE GRIP

The throttle friction adjuster adjusts resistance to throttle grip rotation.

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

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

(H2 type)


STOP

Press the emergency stop switch to stop the engine.

25


Emergency Stop Switch Lanyard/Clip (H1 type)

EMERGENCY STOP

SWITCH

EMERGENCY STOP

SWITCH CLIP

(H2 type)


STOP STOP

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

The emergency stop switch lanyard is provided to stop the engine immediately when the operator falls overboard or away from the outboard motor.

The engine stops when the clip at the end of the emergency stop switch lanyard is pulled out of the emergency stop switch.

When operating the outboard motor, be sure to attach one end of the emergency stop switch lanyard securely to the operator.

If the emergency stop switch lanyard is not set, the boat might run out of control when the operator, for example, falls overboard and is not able to operate the outboard motor.

For the sake of the operator’s and the passengers’ safety, be sure to set the emergency stop switch clip located at one end of the emergency stop switch lanyard with the emergency stop switch. Attach the other end of the emergency stop switch lanyard securely to the operator.

26

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

SPARE EMERGENCY



(H2 type) Steering Friction Adjusting Knob

(H1 type)


ADJUSTING KNOB

To increase friction


To decrease friction


ADJUSTING KNOB


The engine does not start unless the emergency stop switch clip is set on the emergency stop switch.

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

Use the spare emergency stop switch clip to make the disabled engine start when the emergency stop switch lanyard is not available as, for example, when the operator falls overboard.

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

27


TRL (Trolling) Control Switch

(H2 type)

DOWN

UP

TRL (Trolling)

CONTROL SWITCH

The engine speed can be adjusted with the trolling control switch when in trolling mode.

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

28

CONTROLS AND FEATURES (R type)

Remote Control Lever

(R1 type)


NEUTRAL RELEASE LEVER

FORWARD

NEUTRAL

REVERSE

FORWARD

32°

NEUTRAL

32°

SHIFT

MINIMUM

REVERSE

SHIFT

MINIMUM

THROTTLE OPENING


MAXIMUM

MAXIMUM


Shifting gear into forward, reverse, or neutral and the engine speed adjustment can be performed with the remote control lever.

It is necessary to pull up the neutral release lever to operate the remote control lever.

FORWARD:

Moving the lever to the FORWARD position (i.e. approximately 32° from the NEUTRAL position) engages the gear into forward. Moving the lever further from the FORWARD position will increase the throttle opening and the boat forward speed.

NEUTRAL:

Engine power is cut off from the propeller.

REVERSE:

Moving the lever to the REVERSE position (i.e. approximately 32° from the NEUTRAL position) engages the gear into reverse. Moving the lever further from the REVERSE position will increase the throttle opening and the boat reverse speed.

29


(R2 type)


NEUTRAL RELEASE LEVER

FORWARD

NEUTRAL

FORWARD

35°

NEUTRAL

35°

SHIFT

MINIMUM

REVERSE

SHIFT

MINIMUM



MAXIMUM

MAXIMUM


It is necessary to pull up the neutral release lever to operate the remote control lever.

REVERSE

FORWARD:


NEUTRAL:



REVERSE:


30


(R3 type)

(SINGLE TYPE)


FORWARD

NEUTRAL

(DUAL TYPE)

FORWARD

REVERSE

REVERSE



FORWARD:


NEUTRAL:


NEUTRAL

35°

NEUTRAL

35°

FORWARD REVERSE

SHIFT SHIFT

THROTTLE

OPENING

MINIMUM

THROTTLE

OPENING

MINIMUM

MAXIMUM

MAXIMUM


REVERSE:


31


Neutral Release Lever

(R1 type)


Engine Switch (Ignition Switch)

(R1 type)

ON

START

OFF

(R2, R3 types)

ENGINE

SWITCH

OFF

ON

NEUTRAL

RELEASE LEVER

(R2 type)


NEUTRAL

RELEASE

LEVER

The neutral release lever is set on the remote control lever to prevent an accidental operation of the remote control lever.

The remote control lever does not operate unless it is moved while pulling the neutral release lever up.

32

ON

START

OFF START

ENGINE SWITCH

This remote control is equipped with an automotive type ignition switch.

On the side-mount type (R1 type), the engine switch locates on your side near the remote control box.

On the panel-mount type (R2 type) and the top-mount type (R3 type), the engine switch locates at the center of the control panel.

Key positions:

START: to start the engine.

ON: to run the engine after starting.

OFF: to stop the engine

(IGNITION OFF).

Do not leave the engine switch

(ignition switch) ON (key in ON position) when the engine is not running as the battery will discharge.

The starter motor will not work unless the remote control lever is in the NEUTRAL position, and the clip is in the emergency stop switch.

Fast Idle Lever (R1 type)/Fast Idle

Button (R2, R3 types)

The fast idle lever/fast idle button is only needed for starting carbureted outboard models. The BFT75A and

BFT90A models use programmed fuel injection so, this lever will not be needed for starting.

After the engine starts and if the outside temperature is below 5°C

(41°F), the fast idle lever/fast idle button can be used to accelerate engine warm up.


< Fast Idle Lever>

(R1 type)


NEUTRAL

MAXIMUM

FAST IDLE

<Fast Idle Button>

(R2 type)

NEUTRAL

FORWARD

REVERSE

LOWEST

POSITION

FAST IDLE LEVER

The fast idle lever will not move unless the remote control lever is in the NEUTRAL position. Conversely, the remote control lever will not move unless the fast idle lever is in the lowest position.

Lower the fast idle lever to the lowest position to decrease the fast idle.

REMOTE

CONTROL

LEVER

Push

Pull up NEUTRAL

RELEASE

LEVER


Pushing the fast idle button, turn the remote control lever forward. Keep turning the lever forward. The throttle opens and the engine speed increases after the lever passed the shift point.

Note that the gearshift mechanism does not function when the fast idle button is pushed once and then released after the remote control lever is moved.

The control lever does not operate unless the neutral release lever is pulled.

33


<Fast Idle Button>

(R3 type)

NEUTRAL

FORWARD

REVERSE

Emergency Stop Switch

(R1 type)

Emergency Stop Switch Lanyard/

Clip

EMERGENCY STOP

SWITCH LANYARD

STOP

Push


REMOTE

CONTROL

LEVER

Use the fast idle button and the remote control lever to adjust the engine speed without gearshift when warming up the engine.

Pushing the fast idle button, turn the remote control lever forward. Keep turning the lever forward. The throttle opens and the engine speed increases after the lever passed the shift point.

Note that the gearshift mechanism does not function when the fast idle button is pushed once and then released after the remote control lever is moved.


(R2, R3 types)

EMERGENCY STOP

SWITCH

STOP

Press the emergency stop switch to stop the engine.

34


The emergency stop switch lanyard is provided to stop the engine immediately in the event the operator should fall overboard or away from the controls.

The emergency stop switch clip must be engaged with the emergency stop switch or the engine will not start.

When the emergency stop switch clip becomes disengaged with the emergency stop switch the engine will stop immediately.

(R1 type)

EMERGENCY

STOP SWITCH


Spare Emergency Stop Switch Clip


If the emergency stop switch lanyard is not set, the boat might run out of control when the operator, for example, falls overboard and is not able to operate the outboard motor.

For the sake of the operator’s and the passenger’s safety, be sure to set the emergency stop switch clip located at one end of the emergency stop switch lanyard with the emergency stop switch. Attach the other end of the emergency stop switch lanyard securely to the operator.

STOP

EMERGENCY STOP

SWITCH LANYARD


(R2, R3 types)

EMERGENCY

STOP SWITCH


STOP

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

35



TRL (Trolling)

CONTROL SWITCH

Remote Control Box

(Side-mount type)


TRL (Trolling) Control Switch

Panel

(optional equipment)

The engine speed can be adjusted with the trolling control switch when in trolling mode.

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

36

Power Trim/Tilt Switch

Power Trim

Press the power trim/tilt switch on the tiller handle or on the remote control lever to adjust the outboard motor trim angle of – 4° to 16° to maintain proper boat trim. The power trim/tilt switch can be operated while the boat is under way or while stopped.

By using the power trim/tilt switch the operator can change the trim angle of the outboard motor to achieve maximum boat acceleration, speed, stability and maintain optimum fuel consumption.

(H1 type)

POWER TRIM/

TILT SWITCH

(H2 type)

POWER TRIM/

TILT SWITCH

The outboard motor trim angle of

– 4° to 16° is the angle when the outboard motor is installed on the boat at 12°.

(R1 type)

CONTROLS AND FEATURES (T type)

(R2 type)



(R3 type)

(SINGLE TYPE)

POWER TRIM/

TILT SWITCH

REMOTE

CONTROL

LEVER

(R3 type)

(DUAL TYPE)


(LEFT) (RIGHT)

POWER TRIM/

TILT SWITCH

REMOTE

CONTROL

LEVER

REMOTE

CONTROL

LEVERS

37


Excessive trim/tilt angle during operation can cause the propeller to raise out of the water and cause propeller ventilation and engine over-revving. Excessive trim/tilt angle can also damage the water pump.

Trim Meter


68°

12°

TILT

ANGLE

0°

16°

TRIM ANGLE

0°

- 4°

(VERTICAL LINE)

(when transom angle is 12°)

Power Tilt

Press the power trim/tilt switch to adjust the outboard motor tilt angle of 16° to 68°.

By using the power trim/tilt switch the operator can change the tilt angle of the outboard motor for shallow water operation, beaching, launching from a trailer, or mooring.

Please tilt up simultaneously, when you mount the dual type outboard motor.

TRIM METER

The trim meter has a range of – 4° to

16° and indicates the trim angle of the outboard motor. Refer to the trim meter when using the power trim/tilt switch to achieve proper boat performance.

The outboard motor trim angle of – 4° to 16° is the angle when the outboard motor is installed on the boat at 12°.

38

Power Tilt Switch

(outboard motor pan)

POWER TILT SWITCH

The power tilt switch located on the outboard motor pan is a convenience switch for tilting the outboard motor for trailering, or performing outboard maintenance. This power tilt switch should only be operated with the boat being stopped and engine off.


Manual Relief Valve

POWER

(To fix)

MANUAL

(To release)

MANUAL RELIEF VALVE

After tilting the outboard motor, turn the manual relief valve clockwise securely.

Check that no person is under the outboard motor before carrying out this operation because if the manual relief valve is loosened (turned counterclockwise) when the outboard motor is tilted up, the outboard motor will suddenly tilt down.

The manual relief valve must be tightened securely before operating the outboard motor or the outboard motor could tilt up when operating in reverse.

If the power trim/tilt switch will not tilt the outboard motor, the outboard motor can be manually tilted up or down by opening the manual relief valve. To tilt the outboard motor manually, turn the manual relief valve under the left stern bracket no more than 1 or 2 turns counterclockwise using a screwdriver.

39

CONTROLS AND FEATURES (Common)

Tilt Lock Lever

FREE

Oil Pressure Indicator/Buzzer

The oil pressure indicator turns off and the buzzer sounds when the oil level is low and/or the engine lubrication system is faulty.

The engine speed slows down gradually this time.

(H type)

(GREEN)

LOCK

TILT LOCK LEVER

Use the tilt lock lever to raise the outboard motor and lock it in the position when the boat is moored or anchored for a long time.

Tilt the outboard motor as far as it goes and move the lock lever in the locking direction.

OIL PRESSURE

INDICATOR

(internal buzzer)

(R1 type)

(R2, R3 types)

OIL PRESSURE

INDICATOR

(GREEN)

BUZZER

OIL PRESSURE

INDICATOR

(GREEN)

BUZZER

40

Overheat Indicator/Buzzer

The overheat indicator turns on and the buzzer sounds when the engine cooling circuit is faulty. The engine speed slows down this time.

(H type)

(RED)

(R1 type)


OVERHEAT

INDICATOR

(RED)

BUZZER

OVERHEAT

INDICATOR


(R2, R3 types)

OVERHEAT

INDICATOR

(RED)

BUZZER

41


(R1 type) ACG Indicator/Buzzer

The ACG indicator turns on and the buzzer sounds when the charging system is faulty.

ACG

INDICATOR

(H type)

(RED)

(RED)

BUZZER

ACG INDICATOR

(R2, R3 types)

ACG

INDICATOR


(RED)

BUZZER

42

PGM-FI Indicator/Buzzer

The PGM-FI indicator turns on and the buzzer sounds when the engine control system is faulty.

(H type)

(RED)

(R1 type)


PGM-FI

INDICATOR

Water Separator Buzzer

The water separator buzzer sounds when water has accumulated in the water separator.

(RED)

BUZZER

PGM-FI INDICATOR

(R2, R3 types)

PGM-FI

INDICATOR


(RED)

BUZZER

WATER SEPARATOR

43


Trim Tab

GEAR CASE GROMMET

Anode

TRIM TAB TIGHTENING BOLT

If the steering wheel/handle is pulled to the side while running at full speed, adjust the trim tab so that the boat runs straight ahead.

Remove the gear case grommet.

Loosen the tightening bolt and turn the trim tab right or left to adjust (see

page 114).

ANODE

(each side)

The anode metal is a sacrificed metal which protects the outboard motor from corrosion.

Do not paint the anode. It deteriorates the function of the anode metal, which can lead to rust and corrosion damage to the outboard motor.

44

ANODE

(stern bracket)

Cooling Water Intake Port

COOLING WATER INTAKE PORT

(each side)

The engine cooling water is drawn into the engine through this port.


Cooling Water Check Hole

COOLING WATER CHECK HOLE

The cooling water is checked here to see whether it is circulating inside the engine properly.

After starting the engine, check at the cooling water check hole whether the cooling water is circulating through the engine.

45


Engine Cover Fixing Lever

(Front/Rear)

Tachometer


ENGINE COVER

FIXING LEVER

(front/rear)

Fuel Filler Cap (equipped type)

(with vent knob)

FUEL FILLER CAP VENT KNOB

OPEN

FUEL

FILLER CAP

CLOSE

UNLOCK

LOCK

Latch/unlatch the engine cover fixing lever to install or remove the engine cover.

TACHOMETER

The tachometer shows the engine speed in revolutions per minute.

The fuel filler cap vent knob controls air entering and leaving the fuel tank.

When refilling the fuel tank, turn the vent knob counterclockwise to open and remove the fuel filler cap.

Turn the vent knob clockwise and close it securely before transporting or storing the fuel tank.

46

Fuel Gauge

FUEL GAUGE


Fuel Line Connector And Joint

(equipped type)

FUEL LINE CONNECTOR

The fuel line connector and joint are used to connect the fuel line between the fuel tank and the separate outboard motor.


HOSE PLUG

The fuel gauge indicates the fuel level in the tank.

FUEL HOSE FUEL LINE

JOINT

HOSE CLAMP


47


NMEA Interface Coupler

NMEA INTERFACE

COUPLER

The NMEA2000 interface coupler can provide information regarding engine speed, fuel consumption, and various warnings to an existing

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

Operating Hour Notification

System

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

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 131).

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

48

<Operating hour notification timing>

20 hours

80 hours after reset

Start of operation

Notify Notify

Every 100 hours

100 hours after reset

Notify


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.

<Display>

Steps

Outboard motor

Display

Maintenance indication on display

1

—

Switch ON

Not shown

Main en nce indica ion

2

Ignition switch

ON

—

Shown

Maintenance indication

3

Start engine

—

Shown

Maintenance indication

4

Gear at F or R

—

Not shown

Main en nce indica ion

49


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.

How to reset the Hour Counter

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

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

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

4. Press the emergency stop switch

5 times within 20 seconds. The buzzer will sound once indicating the hour counter is reset.

50

5. INSTALLATION

Transom Height

Improperly installed outboard motor can result in the outboard motor dropped into the water, boat not able to cruise straight ahead, engine speed not increase, and much fuel consumption.

We recommend that the outboard motor be installed by an authorized

TOHATSU outboard motor dealer.

Consult the authorized TOHATSU dealer in your area for the Y-OP (User

Optional Parts)/equipments installation and operation.

Applicable Boat

Select the boat suitable for the engine power.

Engine power:

BFT75A : 55.2 kW (75 PS)

BFT90A : 66.2 kW (90 PS)

Power recommendation is indicated on most of the boats.

Do not exceed the boat manufacturer’s power recommendation. Damage and injury may result.

T

Type:

L:

X:

T (Outboard Motor

Transom Height)

<when transom angle is 12°>

537 mm (21.1 in)

664 mm (26.1 in)

Select the outboard motor which is correct for the boat transom height of your boat.

51

INSTALLATION

Location

CENTER LINE

Install the outboard motor at the stern, at the center line of the boat.

Installation Height

BOAT TRANSOM

HEIGHT

IDLE PORT

150 mm

(5.9 in) or more

0 to 25 mm

(0 to 1 in)

WATER LEVEL

FULLY

TRIM/TILT

DOWN

TRANSOM

HEIGHT

ANTICAVITATION

PLATE

The anticavitation plate of the outboard motor should be 0 to 25 mm

(0 to 1 in) below the bottom of the boat.

The correct dimensions differ according to the type of the boats and the configuration of the bottom of the boats. Follow the manufacture’s recommended installation height.

• The water level must be at least

100 mm (4 in) above the anticavitation plate, otherwise the water pump may not receive sufficient cooling water, and the engine will overheat.

• Adverse effect to the engine can occur if the installation position of the outboard motor is too low.

Trim/tilt down the outboard motor with the boat fully loaded and stop the engine. Check that the idle port is 150 mm (5.9 in) or more above the water level.

52

INSTALLATION

Outboard Motor Installation

BOLT (12 × 119 mm) (4)

STERN BRACKET

WASHER (8)

NUT (8)

Standard torque:

55 N·m (5.6 kgf·m, 41 lbf·ft)

The standard torque is given just as a guideline. Torque of the nut can be different according to the material of the boat. Consult with an authorized


ENGINE

HANGERS

WASHER (4)

1. Apply the silicone sealant

(Three Bond 1216 or equivalent) to the outboard motor mounting holes.

2. Set the outboard motor on the boat and secure with the bolts, washers, and nuts.

Install the outboard motor securely.

Loosely mounted outboard motor can result in accidental loss of the outboard motor and damage and injury to the equipment and personnel.

Before installing the outboard motor on the boat, hang the outboard motor with the hoist or equivalent devise by attaching the two engine hangers to the outboard.

Use the hoist which allowable load is

250 kg (551 lbs) or above.

53

INSTALLATION

Outboard Motor Angle Inspection

(Cruising)

INCORRECT

CAUSES BOAT TO ‘‘SQUAT’’

INCORRECT

CAUSES BOAT TO ‘‘PLOW’’

Install the outboard motor at the best trim angle for stable cruising and maximum power.

Trim angle too large: Incorrect causes boat to ‘‘squat.’’

Trim angle too small: Incorrect causes boat to ‘‘plow.’’

CORRECT

GIVES MAXIMUM PERFORMANCE

The trim angle differs according to the combination of the boat, outboard motor, and propeller, and the operating conditions.

Adjust the outboard motor so that it is perpendicular to the water surface

(i.e. axis of the propeller is parallel with the water surface).

54

Battery Connections

Use a battery which has CCA

(COLD CRANKING AMPERES)

582A at – 18°C (0°F) and a reserve capacity 229 minutes (12V 55Ah/

5HR or 12V 65Ah/20HR) or more specifications.

The battery is an optional part (i.e. part to be purchased separately from the outboard motor).

Batteries produce explosive gases:

If ignited, an explosion can cause serious injury or blindness. Provide adequate ventilation when charging.

• CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid.

Contact with eyes or skin, even through clothing, may cause severe burns. Wear a faceshield and protective clothing.

• Keep flames and sparks away, and do not smoke in the area.

ANTIDOTE: If electrolyte gets into your eyes, flush thoroughly with warm water for at least 15 minutes and call a physician immediately.

INSTALLATION

• POISON: Electrolyte is poison.

ANTIDOTE:

─ External: Flush thoroughly with water.

─ Internal: Drink large quantities of water or milk.

Follow with milk of magnesia or vegetable oil, and call a physician immediately.

• KEEP OUT OF REACH OF

CHILDREN.

To protect the battery from mechanical damage and to prevent the battery from falling or tipping over, the battery must be:

• Installed in the correct size corrosion-resistant battery box.

• Properly secured in the boat.

• Secured in a location free from direct sunlight and water spray.

• Secured away from the fuel tank to avoid potential sparks near the fuel tank.

55

INSTALLATION

(–) TERMINAL

BLACK

(+) TERMINAL

RED

Connect the battery cables:

1. Connect the cable with the red terminal cover to the positive ( + ) terminal of the battery.

2. Connect the cable with the black terminal cover to the negative ( – ) terminal of the battery.

When more than one outboard motor is mounted on a boat, connect a battery to each respective outboard motors.

• Be sure to connect the ( + ) side battery cable first. When disconnecting the cables, disconnect the ( – ) side first then the ( + ) side.

• Unless the cables are properly connected to the terminals, the starter motor may fail to operate normally.

• 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.

• Do not place the fuel tank near the battery.

• 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 outboard from starting. If the outboard starts and the buzzer sounds momentarily, there may be barely sufficient voltage reaching the engine.

56

INSTALLATION

Remote Control Installation


Improperly installed steering system, remote control box, and remote control cable, or installing those of the different types could cause unpredictable accident.

Consult an authorized TOHATSU outboard motor dealer for proper installation.

The control box is available in three types as shown.

Select the most suitable control box for your outboard motor considering the installation position, operationability, etc. of the control box.

See your outboard motor dealer for further information.

SIDE-MOUNT TYPE CONTROL BOX

TOP-MOUNT TYPE CONTROL BOX

AND SWITCH PANEL

(FOR SINGLE OUTBOARD MOTOR

TYPE)

PANEL-MOUNT TYPE CONTROL

BOX AND SWITCH PANEL

TOP-MOUNT TYPE CONTROL BOX

AND SWITCH PANEL

(FOR DUAL OUTBOARD MOTOR

TYPE)

57

INSTALLATION

<Remote Control Box Location>


REMOTE

CONTROL BOX

REMOTE

CONTROL

CABLES

<Remote Control Cable Length>

Do not bend the remote control cable as sharp as its route diameter is 300 mm (11.8 in) or less, or it affects the service life of the cable and the remote control lever operation.

Install the remote control box in the position where is easy to operate the remote control lever and switches.

Be sure that there are no obstacles on the route of the control cable.

The control box position of the R2 type and the R3 type should be determined in the same manner.

Measure the distance from the control box to the outboard motor along the cable routing.

Recommended cable length is 300 –

450 mm (11.8 – 17.7 in) longer than the measured distance.

Set the cable along the predetermined route and be sure that it is long enough to the route.

Connect the cable to the engine and be sure it is not kinked, bent sharp, pulled taut, or interfered while steering.

58

Propeller Selection

Select the adequate propeller so that the engine speed at full throttle is as follows when the boat is loaded.

Model

BFT75A

Engine speed (min

-1

(rpm))

5,000 to 6,000

BFT90A 5,300 to 6,300

Engine speed varies according to the propeller size and the boat condition.

Use of the outboard motor outside the full throttle speed range will adversely affect the engine and cause serious problem. Use of the correct propeller assures powerful acceleration, top speed, excellency in terms of economy and cruising comfort, and it assures longer engine life as well.

Consult with your authorized

TOHATSU outboard motor dealer for proper propeller selection.

INSTALLATION

59

6. PRE-OPERATION CHECKS

BFT75A/90A is 4-stroke, water cooled outboard motor which uses unleaded gasoline for fuel (see page

63). It also requires the engine oil.

Check the following before operating the outboard motor.

Perform the following

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

pre-operation checks with the engine stopped.

Engine Cover Removal/Installation Engine Oil

LATCH

(front/rear)

ENGINE COVER

FIXING LEVER

(front/rear)

• To remove, raise the front and rear engine cover fixing levers and remove the engine cover.

• To install, set the engine cover, hook the front and rear latches, and push down the front and rear engine cover fixing levers.

• Engine oil is a major factor affecting engine performance and service life. Nondetergent and low quality oils are not recommended, because they have inadequate lubricating properties.

• Running the engine with insufficient oil can cause serious engine damage.

<Recommended 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.

Do not operate the outboard motor without the engine cover. Exposed moving parts can cause injury.

60

SAE 10W-30 is recommended for general use.

AMBIENT TEMPERATURE

<Inspection and Refilling>

UPPER

LEVEL

MARK

LOWER

LEVEL

MARK

PRE-OPERATION CHECKS

1. Position the outboard motor vertically, and remove the engine cover.

2. Remove the oil level dipstick and wipe with a clean rag.

3. Reinsert the dipstick all the way in, then pull it out and read the level. If near or below the lower level mark, remove the oil filler cap and fill to the upper level mark with the recommended oil. Tighten the oil filler cap and install the dipstick securely. Do not overtighten.

When the engine oil is contaminated or discolored, replace with the fresh

engine oil (see page 133 for

replacement interval and procedure).


61


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.

Oil filler cap removal (Unlock):

OIL FILLER CAP

Rib of the ACG cover

Operating Method

Running the engine below

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

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

Result

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

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

Effect

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

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

2)Pull the cap to remove it.

62

Oil filler cap installation (Lock):

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

2)Turn the oil filler cap 90° clockwise so the lug of the cap is in line with the rib of the ACG cover.

(It should click.)

4. Install the engine cover and lock it securely.

Do not overfill the engine oil.

Check the engine oil after refilling.

Excessive engine oil as well as the insufficient oil could cause damage to the engine.

Fuel

(Fuel Tank equipped type)

UPPER LEVEL


FUEL GAUGE

Check the fuel gauge and refill the tank to the upper level mark if necessary. Do not fill the fuel tank above the UPPER level mark.

Fuel tank capacity (separate tank):

25 L (6.6 US gal, 5.5 Imp gal)

(Using the fuel tank mounted on the boat)

Check the fuel level and refill if necessary. Do not fill the fuel tank above the UPPER LIMIT.

Refer to the boat manufacturer’s instructions.

Use unleaded gasoline with a

Research Octane Number of 91 or higher (a Pump Octane Number of 86 or higher). Use of leaded gasoline may cause damage to the engine.

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

Avoid getting dirt, dust or water in the fuel tank.

Open the vent knob before removing the fuel filler cap. When the vent knob is firmly closed, the cap will be difficult to remove.

63


Gasoline is extremely flammable and is explosive under certain conditions.

• Refuel in a well-ventilated area with the engine stopped.

• Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored.

• Do not overfill the fuel tank

(there should be no fuel in the filler neck). After refueling, make sure the tank cap is closed properly and securely.

• Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

• Avoid repeated or prolonged contact with skin or breathing of vapor.

KEEP OUT OF REACH OF

CHILDREN.

GASOLINE CONTAINING

ALCOHOL

If you decide to use a gasoline containing alcohol (gasohol), be sure its octane rating is at least as high as that recommended by TOHATSU.

There are two types of “gasohol”: one containing ethanol, and the other containing methanol.

Do not use gasohol that contains more than 10% ethanol.

Do not use gasoline containing more than 5% methanol (methyl or wood alcohol) and that does not also contain co-solvents and corrosion inhibitors for methanol.

• Fuel system damage or engine performance problems resulting from the use of gasoline that contains more alcohol than recommended is not covered under the warranty.

• Before buying gasoline from an unfamiliar station, first determine if the gasoline contains alcohol, if it does, find out the type and percentage of alcohol used.

If you notice any undesirable operating symptoms while using a particular gasoline. Switch to a gasoline that you know contains less than the recommended amount of alcohol.

64


Propeller and Cotter Pin

Inspection

COTTER PIN

The propeller blades are thin and sharp. Careless handling of the propeller can result in injury.

When checking the propeller:

• Remove the emergency stop switch clip to prevent an accidental start of the engine.

• Wear heavy gloves.

Propeller rotates rapidly while cruising. Before starting the engine, check the propeller blades for damage and deformation and replace if necessary.

Obtain a spare propeller for the event of an unpredictable accident while cruising. If no spare propeller is available, return to the pier at low

speed and replace (see page 152).

Consult an authorized TOHATSU outboard motor dealer for propeller selection.

Keep the spare washer, castle nut and cotter pin with you on your boat.

CASTLE NUT

PROPELLER

Engine speed varies according to the propeller size and the boat condition.

Use of the outboard motor outside the full throttle speed range will adversely affect the engine and cause a serious problem. Use of the correct propeller assures powerful acceleration, top speed, excellency in terms of economy and cruising comfort, and it assures longer engine life as well.

Consult with your authorized

TOHATSU outboard motor dealer for proper propeller selection.

1. Check the propeller for damage, wear, or deformation.

Replace whenever the propeller is faulty.

2. Check whether the propeller is installed properly.

3. Check the cotter pin for damage.

65


Tiller Handle Height/Angle

Adjustment (H type)

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

<Height/Angle Adjustment

Procedure>

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

2. Pull down the tiller handle.

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

(H1 type)

HANDLE ANGLE: 13°


HANDLE

ANGLE: 21°

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


298 mm

(11.7 in)


361 mm

(14.2 in)


438 mm

(17.2 in)

HEIGHT

Reference point

HEIGHT

ADJUSTMENT

BLOCK

8 × 28 mm

FLANGE BOLT

66

(H2 type)


HANDLE ANGLE:

21°


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

317 mm

(12.5 in)



8 × 28 mm

FLANGE BOLT

HEIGHT ADJUSTMENT

BLOCK

378 mm

(14.9 in)


HEIGHT

Reference point

456 mm

(18.0 in)


67


Steering Handle Friction (H type)

(H1 type)


ADJUSTING KNOB



(H2 type)

Remote Control Lever Friction

(R type)

(R1 type)

CONTROL LEVER

FRICTION ADJUSTER


ADJUSTING KNOB





Check whether the remote control lever moves smoothly.

Friction of the control lever can be adjusted by turning the control lever friction adjuster right or left.

Check whether the handle moves smoothly.

For smooth steering, adjust the steering friction adjusting knob so that a slight drag is felt when turning.

68


Battery (R2 type) Water Separator



CONTROL LEVER


(R3 type)



CONTROL LEVER


WATER SEPARATOR

Water separator is located near by the engine cover fixing lever of the boat side. Check the water separator for water accumulation. Clean it or consult with an authorized

TOHATSU outboard motor dealer for

cleaning (see page 143).

Battery handling differs according to the type of the battery and the instructions described below might not be applicable to the battery of your outboard. Refer to the battery manufacturer’s instructions.

Battery Inspection

Check whether the battery fluid is between the upper and lower levels, and check the vent hole in the battery caps for clogging.

If the battery fluid is near or below the lower level, add the distilled water to the upper level (see page

139).

Check that the battery cables are connected securely.

If the battery terminals are contaminated or corroded, remove the battery and clean the terminals

(see page 140).

69


POSITIVE ( + )

TERMINAL

UPPER

LEVEL

LOWER

LEVEL




Contact with eyes or skin, even through clothing, may cause severe burns.

Wear a faceshield and protective clothing.




ANTIDOTE:





CHILDREN.

70


(5) TOOL KIT (see page 130)

Other Checks

(2)

(1)

Check the following items:

(1) The fuel hose for kinking, collapsing or a loose connection.

(2) The tiller handle for loose installation, wobble or smooth operation (H type).

The remote control lever for smooth operation (R type).

(3) The switch for correct operation.

(4) The stern bracket for damage.

(5) The tool kit for missing spare

parts and tools (see page 130).

(6) The anode metal for damage, looseness or excessive corrosion.

(2)

(3)

(4)

(3)

(6)

The anode (sacrificed metal) helps to protect the outboard motor from corrosion damage; it must be exposed directly to the water whenever the outboard motor is in use. Replace the anodes when they have been reduced to about two-thirds of their original size, or if they are crumbling.

Parts/materials which should be installed on board:

• Owner’s Manual

• Tool kit

• Spare parts: spark plugs, engine oil, spare propeller, castle nut, washer and cotter pin.

• Spare emergency stop switch clip

• Other parts/materials required by laws/regulations.

The possibility of corrosion damage is increased if the anode is painted over or allowed to deteriorate.

71

7. STARTING THE ENGINE

Fuel Line Connection • Be sure that the fuel line is not kinked.

(Fuel Tank equipped type)

FUEL HOSE HOSE PLUG

Gasoline is extremely flammable, and gasoline vapor can explode, causing serious injury or death.

• Be careful not to spill fuel.

Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting, storing or transporting the engine.

• Do not smoke or allow flames or sparks where fuel is refueled or stored.

HOSE

CLAMP

FUEL

LINE

JOINT

FUEL TUBE

ASSEMBLY

• Set the fuel tank securely so that it does not move or fall down while cruising.

• Position the fuel tank so the tank fuel line connector is no more than

1 m (3.3 feet) below the outboard motor fuel line connector.

• Do not place the fuel tank more than 2 m (6.6 feet) away from the outboard motor.

72

FUEL HOSE

(outboard motor side) BARB

HOSE CLAMP

(stainless steel)

ARROW

PRIMING BULB


1. Remove the hose plug from the engine side fuel hose. Insert the fuel line joint in the engine side fuel hose and secure it with the hose clamp. Make sure the arrow mark on the priming bulb points toward the engine side.

• Store the hose plug in a secure place.

FUEL LINE CONNECTOR

(to fuel tank)

FUEL FILLER CAP

VENT KNOB

OPEN

STARTING THE ENGINE

(Using the fuel tank mounted on the boat)

FUEL TUBE ASSEMBLY

(equipped type) (outboard motor side)

FUEL HOSE

(tank side)

2. Connect the fuel line to the tank.

Be sure the connector is securely latched.

Always disconnect the fuel line when storing or transporting the outboard motor.

3. Turn the fuel filler cap vent knob counterclockwise all the way to open the vent.

BARB

HOSE CLAMP

(stainless steel)


1. Remove the hose plug from the engine side fuel hose. Insert the fuel line joint into the engine side fuel hose and secure it with the hose clamp. (The procedure is the same as in the case of using a fuel tank equipped type. Refer to the previous page.)

2. Insert another fuel line joint up to the barb of the joint in the fuel tank side and secure it with the hose clamp (stainless steel type).

Refer to the owner’s manual for the boat.

73


Fuel Priming

ARROW

OUTLET END


Be careful not to spill any fuel.

Spilled fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

PRIMING BULB

INLET END

(tank side)

Hold the priming bulb so that the outlet end is higher than the inlet (so that the arrow on the priming bulb points up), and squeeze it until it feels firm, indicating that fuel has reached the outboard motor. Check for leaks.

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

74


Starting the Engine (H type)

(H1 type)

STOP

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

(H2 type)


STOP

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

To prevent damage to the outboard from overheating, never run the engine with the propeller out of water.

1. Insert the emergency stop switch clip at one end of the emergency stop switch lanyard into the emergency stop switch. Attach the other end of the lanyard securely to the operator.

The exhaust contains poisonous carbon monoxide.

Do not start the engine in a poor ventilation area such as in a boat house.

If the operator does not attach the emergency stop switch lanyard, and is thrown from his seat or out of the boat, the out-of-control boat can seriously injure the operator, passengers, or bystanders. Always properly attach the lanyard before starting the engine.

The engine will not start unless the emergency stop switch clip is engaged with the emergency stop switch.

75


(H1 type)

NEUTRAL

SPARE EMERGENCY



Use the spare emergency stop switch clip to make the disabled engine start when the emergency stop switch lanyard is not available as, for example, when the operator falls overboard.

SHIFT

LEVER

NEUTRAL

(H2 type)

NEUTRAL

SHIFT

LEVER

NEUTRAL

2. Move the shift lever to the

NEUTRAL position. The engine does not start unless the shift lever is set in the NEUTRAL position.

76

(H1 type)

THROTTLE

GRIP

“ ” MARK

(H2 type)

START

START

(H1 type)


ON

START


(H2 type)


ON

START

OFF

OFF

START ON

‘‘ ’’ MARK

THROTTLE GRIP

3. Align the ‘‘ ’’ mark on the throttle grip with the projected end of the ‘‘ ’’ mark on the handle.

OFF ON START

4. Turn the engine switch key to the

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.

77


(H1, H2 types)

• The starter motor consumes a large amount of current. Do not therefore run it continuously for more than 5 seconds at a time. If the engine does not start within 5 seconds, wait at least 10 seconds before running the starter motor again.

• Do not turn the engine switch key to the START position while the engine is running.

COOLING WATER

CHECK HOLE

The “Neutral Starting System” prevents the engine from being started unless the control lever is set in the N (neutral) position even though the engine is cranked by the starting engine.

5. After starting, check whether the cooling water is flowing out of the cooling water check hole. Amount of water flowing out of the check hole might vary due to the thermostat operation, but this is normal.

COOLING WATER

INTAKE PORT (each side) cooling water intake port is obstructed and remove foreign materials if necessary. Check the cooling water check hole for clogging. If water still does not flow out, have your outboard motor checked by your outboard motor dealer. Do not operate the engine until the problem has been corrected.

If water does not flow out, or if steam comes out, stop the engine.

Check to see if the screen in the

78

(H1, H2 types)

NORMAL: ON

ABNORMAL: OFF


7. Warm up the engine as follows:

Above 5°C (41°F) – run the engine for at least 3 minutes.

Below 5°C (41°F) – run the engine for at least 5 minutes at approx.

2,000 min

-1

(rpm).

Failure to completely warm up the engine will result in poor engine performance.

Starting the Engine (R type)

(R1 type)

EMERGENCY STOP

SWITCH

STOP ENGINE OIL

PRESSURE

INDICATOR

LIGHT

6. Check to see if the oil pressure indicator turns ON.

If it does not turn on, stop the engine and perform the following inspections.

1)Check the oil level (see page 60).

2)If the oil level is normal and the oil pressure indicator does not turn ON, consult with an authorized TOHATSU outboard motor dealer.

• If the engine is not properly warmed-up before raising the engine speed, the warning 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 0°C (32°F) or below.

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

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD



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


79


1. Insert the emergency stop switch clip at one end of the emergency stop switch lanyard into the emergency stop switch. Attach the other end of the emergency stop switch lanyard securely to the operator.

SPARE EMERGENCY




The engine will not start unless the emergency stop switch clip is engaged with the emergency stop switch.


NEUTRAL

NEUTRAL

FAST IDLE LEVER

2. Set the control lever in the

NEUTRAL position.

The engine does not start unless the control lever is set in the

NEUTRAL position.

3. Leave the fast idle lever in the

START (fully lowered) position.

80


OFF

ON START







The “Neutral Starting System” prevents the engine from being started unless the control lever is set in the N (neutral) position even though the engine is cranked by the starting engine.

COOLING WATER

CHECK HOLE


(each side)


81



Check to see if the screen in the cooling water intake port is obstructed and remove foreign materials if necessary. Check the cooling water check hole for clogging. If water still does not flow out, have your outboard motor checked by your outboard motor dealer. Do not operate the engine until the problem has been corrected.


If it does not turn on, stop the engine and perform the following inspections.


2)If the oil level is normal and the oil pressure indicator does not turn

ON, consult with an authorized


OIL PRESSURE

INDICATOR

NORMAL: ON

ABNORMAL: OFF




2,000 min

-1

(rpm).


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


82


Starting the Engine

(R2, R3 types)

EMERGENCY

STOP SWITCH

CONTROL PANEL

STOP

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

When the boat is mounted with two outboard motors, perform the following on the right and left engines respectively.

1. Insert the clip at one end of the emergency stop switch lanyard into the emergency stop switch.

Attach the other end of the emergency stop switch lanyard securely to the operator.

Be sure to install the emergency stop switch clip to the emergency stop switch on the remote control box as well as on the control panel.

The engine does not start unless the clip is set on the emergency stop switch.

SPARE EMERGENCY







83


NEUTRAL NEUTRAL

NEUTRAL

REMOTE

CONTROL

LEVER REMOTE

CONTROL

LEVER

(R3 type) (R2 type)

2. Set the control lever in the

NEUTRAL position.

The engine does not start unless the control lever is set in the

NEUTRAL position.

NEUTRAL

ENGINE

SWITCH KEY

ON

START

ON

START




84




• The “Neutral Starting System” prevents the engine from being started unless the control lever is set in the N (neutral) position even though the engine is cranked by the starting engine.

• When the boat is mounted with two outboard motors, perform the above procedure on the right and left outboard motors respectively.

COOLING WATER

CHECK HOLE


(each side)



Check to see if the screen in the cooling water intake port is obstructed and remove foreign materials if necessary. Check the cooling water check hole for clogging. If water still does not flow out, have your outboard motor checked by your outboard motor dealer. Do not operate the engine until the problem has been corrected.

85


OIL PRESSURE

INDICATOR

NORMAL: ON

ABNORMAL: OFF


If it does not turn ON, stop the engine and perform the following inspections.


2)If the oil level is normal and the oil pressure indicator does not turn

ON, consult with an authorized





2,000 min

-1

(rpm).


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


86

Emergency Starting

ENGINE COVER FIXING LEVER

(front/rear)

6 mm WASHER

CLAMP

HOOKS


6 × 25 mm

FLANGE BOLT

ACG COVER

CLAMPS

CLAMP

(on the silencer case)

BREATHER TUBE

If the starting system does not operate properly for some reasons, the engine can be started using the emergency starter rope in the tool kit.


OFF position.

2. Raise the front and rear fixing levers, and remove the engine cover.

3. Release the breather tube from the four clamps.

4. Remove 6 × 25 mm flange bolt and washer, then remove the ACG cover.

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

Take care not to lose the bolt and washer.

87


(H1 type) NEUTRAL (R1 type)

NEUTRAL

SHIFT

LEVER

(H2 type)

NEUTRAL

NEUTRAL

REMOTE

CONTROL

LEVER

(R2 type)

NEUTRAL

6. Set the shift lever or remote control lever is in the NEUTRAL position.

NEUTRAL

NEUTRAL

The ‘‘Neutral Starting System’’ will not work in emergency starting.

Be sure to set the shift lever/control lever into the NEUTRAL position to prevent start-in-gear when starting the engine in emergency. Sudden unexpected acceleration could result in serious injury or death.

NEUTRAL

SHIFT

LEVER

REMOTE

CONTRO

L LEVER

(R3 type)

NEUTRAL

NEUTRAL

REMOTE

CONTROL

LEVER

88

(H1 type)

“ ” MARK

THROTTLE

GRIP

(R1 type)

START


EMERGENCY

STARTER ROPE

(H2 type)

THROTTLE GRIP

START

START

FAST IDLE LEVER

7. H type:

Align the “ ” (start mark) on the throttle grip with the projected end of the “ ” mark on the tiller handle.

‘‘ ’’ MARK

R1 type:

Leave the fast idle lever in the

START (fully lowered) position.

KNOT AC GENERATOR ROTOR

8. Set the AC generator rotor so the cutouts are on the right and left sides of the AC generator rotor as shown. Hook the knot at the end of the starter rope (accessory) against a cutout in the AC generator rotor and wind the starter rope one and half turns clockwise along the groove in the AC generator rotor.

89


(H1 type)

EMERGENCY

STOP SWITCH

(R1 type)

EMERGENCY STOP

SWITCH

9. Insert the clip at the end of the emergency stop switch lanyard into the emergency stop switch.

Attach the other end of the emergency stop switch lanyard securely to the operator.

STOP

STOP

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

(H2 type)


EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

(R2, R3 types)

EMERGENCY

STOP SWITCH

The engine does not start unless the clip is set on the emergency stop switch.

STOP

STOP

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

90

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

(H1 type)

ON


(H2 type)

ON

ENGINE

SWITCH

KEY

ON

(R1 type)

ENGINE

SWITCH KEY

(R2, R3 types)

ON



ON position.

ON

The propeller must be lowered into the water, running the outboard motor out of the water will damage the water pump and overheat the engine.

11. Pull the emergency starter rope lightly until resistance is felt, then pull briskly.

If the engine fails to start refer to

Troubleshooting page 149.

ENGINE

SWITCH KEY

Exposed moving parts can cause injury. Use extreme care when installing the engine cover. Do not operate the outboard motor without the engine cover.

91


12. Leave the AC generator cover off and install the engine cover. Lock the engine cover fixing levers.

13. Attach the emergency stop switch lanyard securely to the operator and return to the closest boat landing.

14. After returning to the closest boat landing, contact your closest outboard motor dealer and perform the following.

• Have the electrical system checked.

• Have your dealer reassemble the parts removed in the emergency starting procedure.

92

Break-in Procedure

Break-in period: 10 hours

Break-in operation allows the mating surfaces of the moving parts to wear evenly and thus ensures proper performance and longer outboard motor life.

Break-in your new outboard motor as follows.

First 15 minutes:

Run the outboard motor at trolling speed. Use the minimum amount of throttle opening necessary to operate the boat at a safe trolling speed.

Next 45 minutes:

Run the outboard motor up to a maximum of 2,000 to 3,000 min

-1

(rpm) or 10% to 30% throttle opening.

Next 60 minutes:

Run the outboard motor up to maximum of 4,000 to 5,000 min

-1

(rpm) or 50% to 80% throttle opening. Short bursts of full throttle are acceptable but do not operate the outboard motor continuously at full throttle.

Next 8 hours:

Avoid continuous full throttle operation (100% throttle opening).

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

For boats that plane easily, bring the boat up on plane then reduce the throttle opening to the specified break-in settings called out above.

8. OPERATION

93

OPERATION

Gear Shifting (H type)

(H1 type)

F (FORWARD) R (REVERSE)

SHIFT LEVER

N (NEUTRAL)

NEUTRAL

REVERSE

FORWARD

(H2 type)

FORWARD

REVERSE

NEUTRAL

N (NEUTRAL)

SHIFT LEVER

FORWARD

REVERSE

94

The shift lever has 3 positions:

FORWARD, NEUTRAL, and

REVERSE.

An indicator at the base of the shift lever aligns with the icon attached at the tiller handle.

Be sure to perform the gearshift operation at a low engine speed.

Shifting the gear at a high engine speed will damage the drive system.

Be sure that the gear was shifted securely, then operate the throttle grip to raise the engine speed.

(H1 type)

THROTTLE

GRIP

(H2 type)

SLOW

SLOW

SLOW

OPERATION

1. Align the pointer on the tiller handle with the SLOW position on the throttle grip to decrease engine speed.

2. Move the shift lever to engage the desired gear.

The throttle mechanism is designed to limit throttle opening in REVERSE and NEUTRAL. Do not turn the throttle grip with force in the FAST direction. The throttle can be opened to FAST only in FORWARD gear.

THROTTLE GRIP

SLOW

95

OPERATION

Gear Shifting

(R1 type)


FORWARD

NEUTRAL

FORWARD

NEUTRAL

NEUTRAL

REVERSE

MAXIMUM

OPENING

REVERSE

Pull up

NEUTRAL RELEASE

LEVER

Moving the control lever further from approximately 32° will increase throttle opening and boat speed.

Avoid sharp and abrupt operation of the control lever.

Operate it moderately. Operate the control lever and raise the engine speed after making sure that the gear was shifted securely.

MAXIMUM

OPENING

The control lever will not move unless the neutral release lever is pulled up.

While pulling the neutral release lever, move the control lever approximately 32° toward the

FORWARD or REVERSE position to engage the desired gear.

96

OPERATION

Gear Shifting

(R2 type)


NEUTRAL

REVERSE

FORWARD

Pull up

NEUTRAL RELEASE

LEVER

FORWARD

REMOTE CONTROL

LEVER

NEUTRAL

REVERSE

Avoid sharp and abrupt operation of the control lever. Operate it moderately. Operate the control lever and raise the engine speed after making sure that the gear was shifted securely.

While pulling the neutral release lever, move the control lever approximately 35° toward the


Moving the control lever further from approximately 35° will increase throttle opening and boat speed.

The control lever will not move unless the neutral release lever is pulled up.

97

OPERATION

Gear Shifting

(R3 type)

(SINGLE TYPE)

FORWARD

NEUTRAL

(DUAL TYPE)

FORWARD

REVERSE

REMOTE CONTROL

LEVER

REMOTE

CONTROL

LEVER


NEUTRAL

REVERSE

Avoid sharp and abrupt operation of the control lever. Operate it moderately. Operate the control lever and raise the engine speed after making sure that the gear was shifted securely.

Move the control lever(s) approximately 35° toward the


When the boat is mounted with the two outboard motors, hold the control lever in the center as shown, and operate the right and left levers simultaneously.

Moving the control lever(s) further from approximately 35° will increase throttle opening and boat speed.

98

OPERATION

Steering (H type)

RIGHT TURN LEFT TURN

(H1 type)


ADJUSTING KNOB


(H2 type)



Move the tiller handle to the left.

Move the tiller handle to the right.


ADJUSTING KNOB


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

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

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

Turn the knob counterclockwise to decrease friction for easy turning.

Steering (R type)

Steer the boat in the same manner as an automobile.

99

OPERATION

Cruising (H type)

(H1 type)

POWER TRIM/

TILT SWITCH

(H1, H2 types)

(H2 type)

DN

(down)

POWER TRIM/

TILT SWITCH

LOWERMOST

POSITION

Press the DN (down) of the power trim/tilt switch and tilt the outboard motor to the lowermost position.

(T type)

100

(H1 type)

FORWARD

SHIFT

LEVER

FORWARD

1. With the shift lever in the

FORWARD position.

(H2 type) FORWARD

SHIFT

LEVER

FORWARD

OPERATION

101

OPERATION

(H1 type)


ADJUSTER

FAST

(H2 type)


ADJUSTER

FAST

FIX

RELEASE

THROTTLE

GRIP

• When cruising at full throttle, note that the engine speed must be in the range.

• If you feel that the engine speed jumped up when the hull jumped or at ventilation, cruise the boat by returning the throttle to the slow speed side.

• See “Propeller Selection” (see page

59) for a relation between the

propeller and the engine speed.

THROTTLE GRIP

FAST

2. Turn the throttle grip in the FAST direction to increase the speed.

For the sake of fuel economy, open the throttle about 80%.

To hold the throttle at a steady setting, turn the throttle friction adjuster clockwise. To free the throttle grip for manual speed control, turn the friction adjuster counterclockwise.

102

FAST Do not operate without the engine cover. Exposed moving parts could cause injury; water may damage the engine.

For best performance, passengers and equipment should be distributed evenly to balance the boat.

Cruising (R type)

(R1 type)

POWER TRIM/

TILT SWITCH

(R2 type)

POWER TRIM/

TILT SWITCH

OPERATION

(R3 type)

(single type)

POWER TRIM/

TILT SWITCH

(dual type)


(LEFT) (RIGHT)

1. Press the DN (down) of the power trim/tilt switch and trim the outboard motor at the lowermost position.

LOWERMOST

POSITION

R3 type:

When the two outboard motors are mounted:

1)Press the DN (down) of the power trim/tilt switch on the control lever and trim the outboard motors at the lowermost position.

2)With the outboard motors trimmed at the lowermost position, adjust the trim angle of the right and left outboard motors using the switch on the control lever simultaneously.

103

OPERATION

(R1 type) (R2 type)

NEUTRAL

FORWARD

REVERSE

NEUTRAL

REVERSE

(R3 type)

FORWARD

NEUTRAL

REVERSE

FORWARD

REMOTE

CONTROL

LEVER

REMOTE

CONTROL

LEVER

FORWARD

• When cruising at full throttle, note that the engine speed must be in the range.

• If you feel that the engine speed jumped up when the hull jumped or at ventilation, cruise the boat by returning the throttle to the slow speed side.

• See “Propeller Selection” (see page

55) for a relation between the propeller and the engine speed.

FORWARD

FORWARD

2. Move the control lever from

NEUTRAL toward FORWARD position.

R1 type:

Moving about 32° engages the gear. Moving the control lever further opens the throttle and increases the engine speed.

R2, R3 types:

Moving about 35° engages the gear. Moving the control lever further opens the throttle and increase the engine speed.

Do not operate without the engine cover. Exposed moving parts could cause injury; water may damage the engine.

For the sake of fuel economy, open the throttle about 80%.

For best performance, passengers and equipment should be distributed evenly to balance the boat.

104


UP

DOWN

TRL (Trolling)

CONTROL SWITCH

Remote Control Box

(Side-mount type)

DOWN

UP


Tiller Handle (H2 type)

UP

DOWN


TRL (Trolling) Control Switch

Panel

(optional equipment: R type)

DN: Reduce engine speed

UP: Increase engine speed

After the engine has warmed up, keeping the UP or DN button pushed when cruising with the throttle fully closed, changes the mode to trolling mode.

OPERATION

A long buzz sounds once.

When the mode is changed to trolling mode, the engine speed is 650 min

-1

(rpm).

You can adjust the engine speed by

50 min

-1

(rpm) every time you press the switch once. You will hear a short buzz.

The engine speed can be adjusted within the range of 650 – 1,000 min

-1

(rpm).

Continuing to press the switch will not decrease or increase the engine speed beyond the lower (650 min -1

(rpm)) or higher (1,000 min

-1

(rpm)) limit.

If you try to do this, a short buzz sounds twice.

The throttle may be operated while in trolling mode. The trolling mode is cancelled when you reach 3,000 min

-1

(rpm).

105

OPERATION

Trimming the Outboard Motor

(H1 type)


(H2 type)

Press DN to lower bow.

Press UP to raise bow.

68°

12°

TILT

ANGLE

0°

- 4°

16°

0°

TRIM ANGLE (VERTICAL LINE)

(when transom angle is 12°)




The BFT75A/90A T types are equipped with the power trim/tilt system which can adjust the outboard motor angle (trim/tilt angle) while cruising and mooring. The outboard motor angle can also be adjusted while cruising and accelerating to obtain the maximum speed and optimum driveability and fuel economy.

106

Press either UP or DN (down) of the power trim/tilt switch and tilt the outboard motor to the best position in compliance with the cruising conditions.

The power trim/tilt system operates when the switch is pressed, and it stops when the switch is released.

To trim up slightly, press on UP momentarily but securely.

To trim down slightly, press on DN

(down) in the same manner.

OPERATION

(R1 type)




REMOTE

CONTROL

LEVER

(R2 type)



REMOTE

CONTROL

LEVER


(R3 type)


(Single Type)





(LEFT) (RIGHT)

(Dual Type)

REMOTE

CONTROL

LEVERS

• Improper trim angle results in unstable steering condition.

• Do not trim excessively while cruising through rough waves, or it may cause an accident.

• Excessive trim angle can result in cavitation and racing of the propeller, and trimming up the outboard motor excessively can cause damage to the impeller pump.

• Decrease the trim angle on high speed turns to reduce the possibility of propeller ventilation.

• Improper outboard motor trim angle can result in an unstable steering condition.

107

OPERATION

OUTBOARD MOTOR

TRIMMED TOO LOW

OUTBOARD MOTOR

TRIMMED CORRECTLY

OUTBOARD MOTOR

TRIMMED TOO HIGH

When cruising:

(A) Into a high wind, trim the outboard motor down slightly to lower the bow and improve boat stability.

(B) With a tail wind, trim the outboard motor up slightly to raise the bow and improve boat stability.

(C) Through rough waves, do not trim the outboard motor too low or too high to avoid an unstable steering condition.

108

Trim Meter


The trim meter indicates the trim angle of the outboard motor. Refer to the trim meter, and press the UP or

DN (down) portion of the power trim/ tilt switch to adjust the outboard motor trim angle to achieve boat performance and stability.

The illustration represents R1 type.

Perform the same procedure for the other types.

BOW TOO LOW DUE TO

1. LOAD IN THE FRONT

2. OUTBOARD MOTOR TRIMMED

TOO LOW

OPERATION

BOW TOO HIGH DUE TO

1. LOAD IN THE REAR

2. OUTBOARD MOTOR TRIMMED

TOO HIGH

With the outboard motor trimmed low the trim meter will read as shown. To raise the bow increase the outboard motor trim angle by pressing the UP portion of the power trim/tilt switch.

With the outboard motor trimmed high the trim meter will read as shown. To lower the bow decrease the outboard motor trim angle by pressing the DN (down) portion of the power trim/tilt switch.

109

OPERATION

Tilting the Outboard Motor

(T type)

Tilt the outboard motor to prevent the propeller and gear case from hitting the bottom when the boat is beached or stopped in shallow water.

Please tilt up simultaneously, when you mount the dual type outboard motor.

1. Move the shift lever or the remote control lever to the NEUTRAL position and stop the engine.

2. Press the UP of the power trim/tilt switch and tilt the outboard motor to the best position in compliance.

(H1 type)


(H2 type)

(R1 type)

POWER TRIM/

TILT SWITCH

(R2 type)

POWER TRIM/

TILT SWITCH

(R3 type)

(single type)

POWER TRIM/

TILT SWITCH

(R3 type)

(dual type)

POWER TRIM/

TILT SWITCH

(LEFT) (RIGHT)

POWER TRIM/TILT

SWITCH

110

Moorage (T type)

FREE

LOCK

TILT LOCK LEVER

Tilt up the outboard motor using the tilt lock lever when mooring the boat.

Move the shift lever or the remote control lever to the NEUTRAL position and stop the engine before tilting up the outboard motor.

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.

TILT LOCK LEVER

1. Raise the outboard motor as full as it goes using the power trim/tilt switch.

2. Move the tilt lock lever to the

LOCK position and lower the outboard motor until the lock lever contacts the stern bracket.

3. Press the DN (down) of the power trim/tilt switch and fully shorten the trim rods.

4. To tilt down, raise the outboard motor as far as it goes using the power trim/tilt switch, move the tilt lock lever to the FREE position.

OPERATION

TRIM RODS

111

OPERATION

(R3 type) (DUAL TYPE)


(LEFT) (RIGHT)

Power Tilt Switch (T type)

POWER TILT SWITCH

After tilting down the outboard motors, adjust the trim angle of the right and left outboard motors.

When you are away from the power trim/tilt switch on the control lever side or the tiller handle side, you can operate the power tilt switch on the outboard motor side.

The switch operation is the same as that of the power trim/tilt switch.

Do not operate this power tilt switch on the outboard motor while sailing.

112

Manual Relief Valve (T type)

POWER

(To fix)

MANUAL

(To release)

Check that no person is under the outboard motor before carrying out this operation because if the manual relief valve is loosened (turned counterclockwise) when the outboard motor is tilted up, the outboard motor will suddenly tilt down.

To tilt the outboard motor manually, turn the manual relief valve under the stern bracket 1 or 2 turns counterclockwise using a screwdriver.

After tilting up/down manually, close the manual relief valve to lock the outboard motor in the position.

MANUAL RELIEF VALVE

When power trim/tilt system does not operate because of dead battery or faulty power trim/tilt motor, the outboard motor can be manually tilted up or down by operating the manual relief valve.

The manual relief valve must be tightened securely before operating the outboard motor or the outboard motor could tilt when operating in reverse.

OPERATION

113

OPERATION

Trim Tab Adjustment

GEAR CASE

GROMMET

RIGHT

GEAR CASE

GROMMET

LEFT

TIGHTENING BOLT

TRIM TAB

The trim tab is provided to adjust for

“torque steer” which is a reaction of the propeller rotation or propeller torque. If during a high speed turn an unequal amount of effort is required to turn the boat right or left, adjust the trim tab so that an equal amount of effort is required.

Distribute the load evenly in the boat and run the boat in a straight course at full throttle. Slightly turn the steering wheel for both right and left turns to determine the amount of effort required.

114

Remove the gear case grommet and loosen the tightening bolt to adjust the trim tab. After adjustment, reinstall the grommet securely.

If less effort is required to make left turns:

Loosen the trim tab tightening bolt and turn the rear end of the trim tab toward the left. Tighten the bolt securely.

TIGHTENING BOLT

TRIM TAB

If less effort is required to make right turns:

Loosen the trim tab tightening bolt and turn the rear end of the trim tab toward the right. Tighten the bolt securely.

Make small adjustments at a time and retest. Incorrect trim tab adjustment can cause adverse steering.

Engine Protection System

<Engine Oil Pressure, Overheat,

Water Contamination, PGM-FI and ACG Warning Systems>

OIL PRESSURE

INDICATOR

(GREEN)

ACG

INDICATOR

(RED)

OVERHEAT

INDICATOR

(RED)


(H type)

PGM-FI

INDICATOR

(RED)

OIL PRESSURE

INDICATOR

(GREEN)

ACG

INDICATOR

(RED)

OVERHEAT

INDICATOR

(RED)

BUZZER

(R1 type)

OIL PRESSURE

INDICATOR

(GREEN)

PGM-FI

INDICATOR

(RED)

ACG

INDICATOR

(RED)

OVERHEAT

INDICATOR

(RED)

(R2, R3 types)

PGM-FI

INDICATOR

(RED)

OPERATION

If the engine oil pressure drops and/ or the engine overheats, either or both warning systems could be activated.

When activated the engine speed will decrease gradually and the oil pressure indicator will turn OFF and the overheat indicator will turn ON.

A continuous buzzer will sound on all type.

The engine speed can not be increased with a larger throttle opening until the malfunction is corrected.

When the malfunction is corrected the engine speed will increase gradually.

If the engine overheats, the engine will stop in 20 seconds after the engine protection system will limit engine speed.

Each warning system of PGM-FI,

ACG, oil pressure, overheat, and water contamination is activated as described in the following table.

115

OPERATION

Symptom

At starting

During operation

Low oil pressure

Overheat

ACG warning

PGM-FI warning

Water contamination

System

Oil pressure

(Green)

ON (2 sec)

ON

OFF

ON

ON

ON*

ON

INDICATOR LIGHTS

Overheat

(Red)

ACG

(Red)

ON (2 sec) ON

OFF

OFF

OFF

OFF

ON

OFF

OFF

ON

OFF*

OFF

OFF

OFF

PGM-FI

(Red)

ON (2 sec)

OFF

OFF

OFF

OFF

ON

OFF

BUZZER

CORRESPONDING

SYSTEM

With the engine switch key turned on: ON (2 times)

OFF

ON (continuously)

ON (continuously) alternating ON and OFF

(at long intervals) alternating ON and OFF

(at long intervals) alternating ON and OFF

(at short intervals)

• Some indicator and/or buzzer will be activated at the same time due to the occurrence of a malfunction.

• The buzzer will also sound when the hour counter is reset (see page 50).

*: Occasionally may blink due to the occurrence of a malfunction.

116

When the oil pressure warning system is activated:

1. Stop the engine immediately and check the engine oil level (see page

60).

2. If the oil is up to the recommended level, restart the engine. If the oil pressure warning system stops after

30 seconds, the system is normal.

OPERATION

When the overheat warning system is activated:

COOLING WATER CHECK HOLE

If the engine is turned off after running at full throttle, the engine temperature may rise above normal.

If the engine is restarted, shortly after being turned off, the overheat warning system could be activated momentarily.

If the throttle was closed suddenly after cruising at full throttle, the engine speed may drop below the specified idle speed. This could cause the oil pressure warning system to activate momentarily.

3. If the oil pressure warning system stays activated after 30 seconds, return to the closest boat landing and contact your closest authorized


1. Return the shift lever or remote control lever to the N (neutral) position immediately. Check to see if water is flowing out of the cooling water check hole.

2. If water is flowing out of the cooling water check hole, continue idling for 30 seconds. If the overheat warning system stops after 30 seconds the system is normal.

117

OPERATION

When the water separator buzzer sounds:


(each side)

3. If the overheat warning system stays activated, stop the engine. Tilt up the outboard motor and check the water intakes for obstructions. If there are no obstructions at the water intakes, return to the closest boat landing and contact your closest outboard motor dealer.

When the PGM-FI activated:

1. Consult with an authorized


WATER SEPARATOR

When the ACG warning system is activated:

1. Check the battery (see page 139).

If the battery is OK, consult with an authorized TOHATSU outboard motor dealer.

1. Check the water separator for water contamination. If water is accumulated, clean them (see page

143).

118

OPERATION

Shallow Water Operation <Over-rev Limiter>

This outboard motor is equipped with an engine over-rev limiter which activates when the engine speed increases excessively. The over-rev limiter can be activated while cruising, tilting up the outboard motor, or when ventilation occurs during a sharp turn.

When the over-rev limiter is activated:

1. Reduce the throttle opening immediately and check the trim angle.

2. If the trim angle is correct but the over-rev limiter stays activated, stop the engine, check the condition of the outboard motor, check to see if the correct propeller is installed and check it for damage.

Correct or service as necessary, by contacting your authorized


<Anode>

ANODE (each side)

ANODE

(stern bracket)

The anode is a sacrificial material which helps to protect the outboard motor from corrosion.

Painting or coating the anode will lead to rust and corrosion damage to the outboard motor.

There are also 2 small sacrificial anodes in the water passages of the engine block.

Excessive trim/tilt angle during operation can cause the propeller to raise out of the water and cause propeller ventilation and engine over-revving. Excessive trim/tilt angle can also damage the water pump and overheat the engine.

When operating in shallow water, tilt the outboard motor up to prevent the propeller and gear case from hitting

the bottom (refer to page 110). With

the outboard motor tilted up, operate the outboard motor at low speed.

Monitor the cooling water check hole for water discharge. Be sure that the outboard motor is not tilted so high that the water intakes are out of the water.

119

OPERATION

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.

120

Emergency Engine Stop

(H1 type)

EMERGENCY

STOP SWITCH

(R1 type)

9. STOPPING THE ENGINE

EMERGENCY

STOP SWITCH

Pull the lanyard of the emergency stop switch and remove the emergency stop switch clip from the switch; this will stop the engine.

STOP

STOP

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

(H2 type)


EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

(R2, R3 types)

EMERGENCY

STOP SWITCH

It is a good idea to stop the engine with the emergency stop switch lanyard from time to time to be sure that the emergency stop switch is operating properly.

STOP

STOP

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

121

STOPPING THE ENGINE

Normal Engine Stop

(H1 type)

(H type)

THROTTLE

GRIP

SHIFT

LEVER

SLOW

SLOW

(H2 type)

SLOW

NEUTRAL

NEUTRAL

NEUTRAL

SHIFT

LEVER

SLOW

122

THROTTLE GRIP

NEUTRAL

1. Turn the throttle grip to SLOW position and move the shift lever to

NEUTRAL.

After sailing with the throttle fully open, cool down the engine by running it at the idle speed for a few minutes.

(H1 type)



OFF position to stop the engine.


OFF

OFF

(H2 type)


In the event that the engine does not stop when the engine switch is turned to OFF, push the emergency stop switch to stop the engine.

3. Remove the engine switch key and store it.

If you are using a portable fuel tank, disconnect the fuel line if you will be storing or transporting the outboard motor.

OFF

OFF

123


(R type)

1. Move the control lever to the

NEUTRAL position.

After sailing with the throttle fully open, cool down the engine by running it at the idle speed for a few minutes.

REMOTE

CONTROL

LEVER

(R3 type)

124

NEUTRAL

NEUTRAL


(R1 type)

NEUTRAL

REMOTE

CONTROL

LEVER

(R2 type)

NEUTRAL

ENGINE SWITCH

KEY

OFF

OFF

(R1 type)

EMERGENCY

STOP SWITCH

NEUTRAL

NEUTRAL

ENGINE

SWITCH KEY

(R2, R3 types)


OFF position to stop the engine.

In the event that the engine does not stop when the engine switch is turned to OFF, push the emergency stop switch to stop the engine.

3. Remove the engine switch key and store it.

If you are using a portable fuel tank, disconnect the fuel line if you will be storing or transporting the outboard motor.

Fuel Line Disconnection

Before transporting the outboard motor, disconnect and remove the fuel line.

Transporting

ENGINE HANGERS

Gasoline is extremely flammable, and gasoline vapor can explode, causing serious injury or death.


Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before storing or transporting the outboard motor.

• Do not smoke or allow flames or sparks where fuel is drained or stored.

When transporting the outboard motor on a vehicle, perform the following.

1. Remove the engine cover.

10. TRANSPORTING

ENGINE

HANGERS

HOIST

HOOKS

2. Set the hoist hooks against the two engine hangers and hang the outboard motor to remove it from the boat.

125

TRANSPORTING

OUTBOARD MOTOR STAND

3. Secure the outboard motor on an outboard motor stand with the mounting bolts and nuts.

4. Remove the hoist hook and reinstall the engine cover.

Trailering

(H1 type)


ADJUSTING KNOB

(H2 type)




ADJUSTING KNOB

When trailering or transporting the boat with the outboard motor attached always disconnect the fuel line from the portable fuel tank and tighten the steering friction adjusting knob

securely (see page 68).

126

(R type)

When trailering or transporting the boat with the outboard motor attached, it is recommended that the outboard motor remain in normal running position.

Do not trailer or transport the boat with the outboard motor in the tilted position. The boat or outboard motor could be severely damaged if the outboard motor drops.

The outboard motor should be trailered in the normal running position. If there is insufficient road clearance in this position, then trailer the outboard motor in the tilted position using an outboard motor support device such as a transom saver bar, or remove the outboard motor from the boat.

TRANSPORTING

127

11. CLEANING AND FLUSHING

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

FLUSH PORT

CONNECTOR

Do not apply water or corrosion inhibitor directly to the electrical components under the engine cover, such as the O2 sensor. If water or corrosion inhibitor penetrates this component, it may be damaged. Before applying a corrosion inhibitor, cover the O2 sensor with a protective material to prevent damage.

Shut off the engine before performing the cleaning and flushing.

1. Disconnect the fuel line 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.

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

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

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

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

LOCK position.

• When using the water hose joint:

WATER HOSE JOINT

(commercially available)

FLUSH PORT

CONNECTOR

WATER HOSE

128

Periodic maintenance and adjustment are important to keep the outboard motor in the best operating condition.

Service and inspect according to the

MAINTENANCE SCHEDULE.

Shut off the engine before performing any maintenance. If the engine must be run, make sure the area is well ventilated. Never run the engine in an enclosed or confined area. Exhaust contains poisonous carbon monoxide gas; exposure can cause loss of consciousness and may lead to death.

Be sure to reinstall the engine cover, if it was removed, before starting the engine. Lock the engine cover fixing lever securely

(see page 60).

• If the engine must be run, make sure there is water at least 100 mm (4 in) above the anticavitation plate, otherwise the water pump may not receive sufficient cooling water, and the engine will overheat.

• Use only TOHATSU Genuine parts or their equivalents for maintenance or repair. The use of replacement parts which are not of equivalent quality may damage the outboard motor.

12. MAINTENANCE

129

MAINTENANCE

Tool Kit and Emergency Parts

The following tools and owner’s manual are supplied with the outboard motor for maintenance, adjustment, and emergency repairs.

<Spare Emergency Stop Switch

Clip>

A spare emergency stop switch clip is available from your outboard motor dealer.

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.

8 × 10 mm WRENCH SPARK PLUG WRENCH

PHILLIPS

SCREWDRIVER

GRIP

18 × 19 mm WRENCH

FUSE PULLER

EMERGENCY STARTER ROPE

TOOL BAG

130

MAINTENANCE

MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD (3)

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

Each use After use

ITEM

Engine oil o

Engine oil filter

Gear case oil

Throttle linkage

Valve clearance

Spark plug (Standard plug)

Spark plug

(Optional iridium plug)

Propeller and cotter pin

Anode (Outside engine)

Anode (Inside engine)

Idling speed

Lubrication

Water separator

Check level

Change

Replace

Change

Check-adjust

Check-adjust

Check-adjust/Replace

Check

Clean

Replace

Check

Check

Check

Check-adjust

Grease

Check o o o

First month or

20 hrs.

o o (2) o (2)

Every

6 months or

100 hrs.

o

Every year or

200 hrs.

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

Every

2 years or

400 hrs.

o o (2) (6)

Refer to page

60

133

—

—

—

—

135—137

137—138

—

137—138

65

71

—

—

141—142

143

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

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

TOHATSU Service Manual for service procedures.

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

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

131

MAINTENANCE

ITEM

Fuel filter

(Low pressure side)

Fuel filter

(High pressure side)

Fuel tank and tank filter

Fuel line

Thermostat

Battery and cable connection

Bolts and Nuts

Breather tube

Cooling water passages

Coolant leak

Water pump

Emergency stop switch

Engine oil leak

Each operation part

Engine condition (5)

Power Trim/Tilt

Shift Cable

REGULAR SERVICE PERIOD (3)

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

Check

Replace

Check

Replace

Clean

Check

Replace

Check

Check level-tightness

Check-tightness

Check

Clean

Check

Check

Check

Check

Check

Check

Check

Check-adjust

Each use After use o (8) o o o o o

First month or

20 hrs.

Every

6 months or

100 hrs.

o o (2) o (2) o (2) (7)

Every year or

200 hrs.

o (4) o o

Every 2 years (if necessary) (2) (9) o (2) o (2) o (2) o (4) o (2) o (2)

Every

2 years or

400 hrs.

o o (2)

Refer to page

146, 147

147, 148

—

—

148, 149

71

—

—

69, 139

—

—

—

153

—

—

—

—

—

—

—

(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) The user who performs shift operation frequently will recommend you exchange of a shift cable around three years.

(8) 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.

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

132

MAINTENANCE

Engine Oil

Insufficient or contaminated engine oil adversely affects the service life of the sliding and moving parts.

Oil change interval:

20 operating hours after the date of purchase or first month for initial replacement, then every 100 operating hours or 6 months.

Oil capacity:

4.2 L (4.4 US qt, 3.7 Imp qt)

…when oil filter is not replaced

4.4 L (4.6 US qt, 3.9 Imp qt)

…when oil filter is replaced

Recommended Oil:

SAE 10W-30 engine oil or equivalent, API Service category SG,

SH or SJ.

<Engine Oil Replacement>

OIL FILLER CAP

Drain the oil while the engine is still warm to assure rapid and complete draining.

1. Position the outboard motor vertically, and remove the engine cover. Remove the oil filler cap

(see page 62).

SEALING WASHER

(Replace)

GUIDE

DRAIN BOLT

2. Place a suitable container under the guide.

3. Remove the engine oil drain bolt and sealing washer using the wrench and drain the engine oil.

Install a new sealing washer and drain bolt, and tighten bolt securely.

DRAIN BOLT TIGHTENING

TORQUE:

23 N·m (2.3 kgf·m , 17 lbf·ft)

133

MAINTENANCE

UPPER

LEVEL

MARK

LOWER

LEVEL

MARK


4. Refill to the upper level mark on the oil level dipstick with the recommended oil.

5. Install the dipstick securely.

6. Reinstall the oil filler cap securely.

Do not overtighten (see page 63).

7. Install and lock the engine cover securely.

Please dispose of used outboard motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station for reclamation. Do not throw it in the trash or pour it on the ground.

Wash your hands with soap and water after handling used oil.

134

MAINTENANCE

Spark Plugs

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

<Standard Spark Plug>

Recommended spark plug:

ZFR6K-9E (NGK)

6 × 20 mm FLANGE SH BOLT

The spark plug becomes very hot during operation and will remain hot for a while after stopping the engine. Allow the engine to cool before servicing the spark plug.

See page 137 for instructions of

handling the iridium spark plugs

(optional parts).

Use only the recommended spark plugs or equivalent. Spark plugs which have an improper heat range may cause engine damage.

<Inspection and Replacement>

1. Disconnect the battery negative (–) terminal.

2. Unlock and remove the engine

cover (see page 60).

PLUG MAINTENANCE COVER

3. Remove the 6 × 20 mm flange SH bolt and remove the plug maintenance cover.

135

MAINTENANCE

CONNECTOR

LOCK TAB

IGNITION

COIL

BOX WRENCH New plug Plug needing replacement

6 × 25 mm

FLANGE BOLT

4. Remove the 6 × 25 mm flange bolt.

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

PLUG WRENCH

5. Remove the spark plug using the plug wrench, box wrench and the screwdriver (accessories).

6. Inspect the spark plugs.

(1) If the electrodes are heavily

corroded or carbon-soiled,

clean with a wire brush.

(2) Replace a spark plug if the

central electrode is worn.

The spark plug can wear out in

different ways.

If the sealing washer shows signs of wear, or if the insulators are cracked or chipped, replace the spark plugs.

136

SIDE ELECTRODE

0.8 – 0.9 mm

(0.031 – 0.035 in)

SEALING

WASHER

INSULATOR

7. Measure the plug gaps with a wire-type feeler gauge.

The gaps should be 0.8 – 0.9 mm

(0.031 – 0.035 in). Correct as necessary by carefully bending the side electrode.

8. Thread the plugs in by hand to prevent cross threading.

9. After the spark plugs are seated, tighten with a spark plug wrench to compress the washers.

SPARK PLUG TORQUE:

18 N·m (1.8 kgf·m , 13 lbf·ft)

MAINTENANCE

If installing new spark plugs, tighten

1/2 turn after the spark plugs seat to compress the washers.

If reinstalling used spark plugs, tighten 1/8 – 1/4 turn after the spark plugs seat to compress the washers.

<Optional Parts: Iridium Spark

Plug>

Recommended spark plug:

IZFR6K-11E (NGK)

The spark plugs must be securely tightened. An improperly tightened plug can become very hot and may cause engine damage.

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

11. Install the ignition coil. Reinstall the bolt.

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

13. Reinstall the plug maintenance cover and engine cover. When reinstalling the covers, make sure not to jam the wire harnesses in between the covers and engine case.

Use only the recommended spark plugs or equivalent. Spark plugs which have an improper heat range may cause engine damage.

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

137

MAINTENANCE

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.

The cleaning of the iridium spark plugs consult with an authorized

TOHATSU outboard motor dealer, unless the owner has the proper tools and is mechanically proficient.

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

The gaps should be 1.0 – 1.3 mm

(0.039 – 0.051 in).

• Do not adjust the spark plug gap.

If the gap is out of specification, replace the spark plug with a new one.

138

MAINTENANCE

Battery

Battery handling differs according to the type of the battery and the instructions described below might not be applicable to the battery of your outboard. Refer to the battery manufacturer’s instructions.








ANTIDOTE:





CHILDREN.

UPPER LEVEL

BATTERY CAP

LOWER LEVEL

<Battery Fluid Level>

Check whether the battery fluid is between the upper and lower levels, and check the vent hole in the battery caps for clogging.

If the battery fluid is near or below the lower level, add the distilled water to the upper level.

139

MAINTENANCE

<Battery Cleaning>

1. Disconnect the battery cable at the battery negative (–) terminal, then at the battery positive (+) terminal.

2. Remove the battery and clean the battery terminals and battery cable terminals with a wire brush or sand paper.

Clean the battery with a solution of baking soda and warm water, taking care not to get the solution or water in the battery cells. Dry the battery thoroughly.

NEGATIVE (–)

TERMINAL

BLACK

POSITIVE (+)

TERMINAL

RED

3. Connect the battery positive (+) cable to the battery positive (+) terminal, then the battery negative

(–) cable to the battery negative (–) terminal. Tighten the bolts and nuts securely. Coat the battery terminals with grease.

When disconnecting the battery cable, be sure to disconnect at the battery negative (–) terminal first.

To connect, connect at the positive

(+) terminal first, then at the negative (–) terminal. Never dis/ connect the battery cable in the reverse order, or it causes a short circuit when a tool contacts the terminals.

140

Lubrication

Wipe the outside of the engine with a cloth dipped in clean oil. Apply marine anticorrosion grease to the following parts:

Lubrication interval:

20 hours or a month after the date of purchase for initial lubrication, then every 100 hours or 6 months.

THROTTLE ARM/

LINK/PIVOT/PLATE

• Apply anticorrosion oil to pivot surfaces where grease cannot penetrate.

• Lubricate more frequently when used in salt water.

MAINTENANCE

TILLER HANDLE

(H type)

THROTTLE ROD/LINK

TILT BRACKET

TILT SHAFT

PROPELLER SHAFT SWIVEL CASE THRUST RECEIVER

141

MAINTENANCE

SHIFT LINK BRACKET/

SHIFT PIVOT/SHIFT ARM/

LINK PIN/PIVOT PLATE/

SLIDE PIVOT/

CLICK SPRING ROLLER

TILT LOCK LEVER

(each side) TILT SHAFT THREAD

UPPER CYLINDER PIN/

BUSHING

MOUNT FRAME

SWIVEL SHAFT

LOWER CYLINDER BUSHING/

COLLAR

142

Water Separator

WATER SEPARATOR

Water separator is located near by the engine cover fixing lever of the boat side. Water accumulation in the water separator can cause loss of power or hard starting. Check the water separator periodically. Clean it or consult with an authorized

TOHATSU outboard motor dealer for cleaning.

MAINTENANCE

<Cleaning>

FUEL TUBES SCREWS Gasoline is extremely flammable, and gasoline vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area.


CHILDREN.

• Always work in a well-ventilated area.

• Be sure that any fuel drained from the outboard motor is stored in a safe container.

• Be careful not to spill fuel when cleaning the water separator.

Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

SUSPENSION

STRAP

WATER

SEPARATOR

WATER SEPARATOR BRACKET

1. Remove the engine cover (see page

60).

2. Remove the suspension strap from the water separator bracket, then remove the strap from the separator assembly.

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

143

MAINTENANCE

HARNESS

CLIP

WATER LEVEL SENSOR

2 PIN CONNECTOR

CLIP C

CUP

O-RING

(Replace) SCREW (3)

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

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

HARNESS

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

4. Pinch the fuel tubes with tube clips to prevent fuel leakage.

5. Disconnect the fuel tubes from the water separator.

WATER

SEPARATOR

CUP

SUSPENSION

STRAP

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

7. Thoroughly clean the water separator cup.

8. Reassemble the water separator body and the cup using a new

O-ring.

TIGHTENING TORQUE:

4.2 N·m (0.43 kgf·m, 3.1 lbf·ft)

WATER

SEPARATOR

FLAT PART ON BACK

OF SUSPENSION

JOINT

144

POSITIONING

BAND

HARNESS CLIP

WATER LEVEL

SENSOR 2 PIN

CONNECTOR

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

11. Prime the engine using the

priming bulb (see page 74). Check

for fuel leaks.

Repair any fuel leaks if necessary.

CLIP C

HARNESS

POSITIONING

BAND

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

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

If the buzzer sounds, water or sediment accumulation is found to be caused by excessive water or sediment accumulated in the water separator cup, inspect the fuel tank.

Clean the fuel tank if necessary.

MAINTENANCE

145

MAINTENANCE

Fuel Filter

FUEL FILTER

(inside strainer cup)

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

Water or sediment accumulated in the fuel filter can cause loss of power or hard starting. Check and replace the fuel filter periodically.

Inspection interval:

Every 100 operating hours or 6 months.

Replacement interval:

Every 400 operating hours or 2 years.

Gasoline is extremely flammable, and gasoline vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area.


CHILDREN.


• Be sure that any fuel drained from the outboard motor is stored in a safe container.

• Be careful not to spill fuel when replacing the filter. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

146

<Inspection> <Replacement>

FUEL TUBES

MAINTENANCE

FUEL FILTER


FUEL INTAKE

SIDE JOINT

EDGE AT

THE BASE

OF JOINT

FUEL FILTER


1. Remove the engine cover (see page

60).

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

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

FUEL FILTER BRACKET

SUSPENSION STRAP

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

Before removing the filter, pinch the fuel tubes on each side of filter using tube clips to prevent fuel leakage.

2. Disconnect the fuel tubes from the fuel filter.

ALIGNMENT

MARK ON THE

SUSPENSION

SUSPENSION STRAP

3. Install a new fuel filter in the reverse order of removal.

Assemble the fuel filter with the strainer cup by aligning the edge at the base of the fuel intake side joint of the fuel filter with the alignment mark on the suspension as shown above.

147

MAINTENANCE

4. Prime the engine using the priming

bulb (see page 74). Check for fuel

leaks. Repair any fuel leaks if necessary.

If loss of power or hard starting is found caused by excessive water or sediment accumulated in the fuel filter, inspect the fuel tank. Clean the fuel tank if necessary.

Fuel Tank and Tank Filter

(equipped type)

<Fuel Tank Cleaning>

FUEL LINE

Cleaning interval:

Every year or after every 200 hours of outboard motor operation.



CHILDREN.


• Be sure that any fuel drained from the fuel tank is stored in a safe container.

• Be careful not to spill fuel when cleaning the tank and filter.

Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

148

1. Disconnect the fuel line from fuel tank.

2. Empty the tank, pour in a small quantity of gasoline, and clean the tank thoroughly by shaking it.

Drain and dispose of the gasoline properly.

MAINTENANCE

<Tank Filter Cleaning>

5 mm SCREWS CONNECTOR

GASKET

FUEL TANK

FILTER JOINT

(Fuel Hose Connector)

FUEL TANK

FILTER

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

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

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

EMISSION CONTROL SYSTEM

The combustion process produces carbon monoxide and hydrocarbons.

Control of hydrocarbons is very important because under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide dose not react in the same way, but it is toxic.

Problems that May Affect Outboard

Motor Emissions

If you are aware of any of the following symptoms, have the outboard motor inspected and repaired by your authorized

TOHATSU dealer:

1. Hard starting or stalling after starting

2. Rough idle

3. Misfiring or backfiring during acceleration

4. Poor performance (driveability) and poor fuel economy

149

MAINTENANCE

Fuse

FUSE PULLER

(supplied in the tool bag)

FUSE CASE LID

SPARE FUSES

(10 A, 15 A, 30 A)

BLOWN FUSE

If the fuse blows, running the engine will not charge the battery. Before replacing the fuse, check the current ratings of the electrical accessories and ensure that there are no abnormalities.

• Never use a fuse with a different rating from that specified.

Serious damage to the electrical system or a fire may result.

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

Failure to do so may cause a short circuit.

150

FUSES

(10 A, 15 A, 30 A)

If the fuse is blown, check the cause, then replace the fuse with a spare fuse of the same rated capacity. Unless the cause is found, the fuse may blow again.

<Replacement>

1. Stop the engine.


3. Remove the fuse case lid and pull the old fuse out of the clip with the fuse puller supplied in the tool bag.

4. Push a new fuse into the clips.

DESIGNATED FUSE:

10 A, 15 A, 30 A

ACG Fuse

“70 A” MARK SPARE FUSE (70 A)

FUSE

CASE

LID

ACG FUSE (70 A)

Disconnect the battery cable at the battery terminal before checking or replacing the ACG fuse.

MAINTENANCE

<Replacement>

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

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

1. Stop the engine.


3. Remove the fuse case lid.

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

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

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

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

DESIGNATED FUSE:

70 A

151

MAINTENANCE

Propeller

PROPELLER (optional equipment)

COTTER PIN

CASTLE NUT

3. Tighten the castle nut with your hand first until the propeller has no play. Then, tighten the castle nut again with a tool until the groove in the castle nut aligns with the cotter pin hole. (Note that this tool is not included in the tools that come together with the outboard motor.)

THRUST WASHER

If the propeller is damaged by striking a rock, or other obstacle, replace the propeller as follows.

18.5 mm

WASHER

COTTER PIN

(Replace)

Replacement

1. Remove the cotter pin then remove the 18 mm castle nut, washer, propeller and thrust washer.

2. Install the new propeller in the reverse sequence to removal.

• When replacing, remove the emergency stop switch clip to prevent an accidental startup of the engine.

• The propeller is thin and sharp.

To protect your hands, wear the heavy gloves during replacement.

CASTLE NUT TIGHTENING

TORQUE:

1 N·m (0.1 kgf·m, 0.7 lbf·ft)

UPPER LIMIT OF TORQUE:

44.1 N·m (4.5 kgf·m, 33 lbf·ft)

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

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

• Use a genuine TOHATSU cotter pin and bend the pin ends as shown.

152

Inspect After Operating

1. Stop the engine and remove the

engine cover (see page 60).

2. Confirm the cooling water leakage from the engine.

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

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

If the outboard motor 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 outboard motor until it has been repaired.

2. Drain the vapor separator as

described on page 155.

3. Change the engine oil (see page

133).

4. Remove the spark plugs (see pages

135–138). Operate the starter to

expel water from the engine’s cylinder.

5. Pour a teaspoon of engine oil into each spark plug hole, then pull the emergency starter rope several times to lubricate the inside of the cylinders.

Reinstall the spark plugs.

6. Install the engine cover and lock the fixing lever securely (see page

60).

MAINTENANCE

7. Attempt to start the engine.

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

• If there was water in the engine crankcase, or the used engine oil showed signs of water contamination, then a second engine oil change should be performed after running the engine for 1/2 hour.

• If the engine starts, and no mechanical damage is evident, continue to run the engine for 1/2 hour or longer (be sure the water level is at least 100 mm (4 in) above the anticavitation plate).

8. As soon as possible, take the outboard motor to your outboard motor dealer for inspection and service.

153

13. STORAGE

For longer service life of the outboard motor, have your outboard motor serviced by your outboard motor dealer before storage. However, the following procedures can be performed by you, the owner, with a minimum of tools.

Fuel

Gasoline spoils very quickly depending on factors such as light exposure, temperature and time.

In worst cases, gasoline can be contaminated within 30 days.

Using contaminated gasoline can seriously damage the engine (fuel system clogged, valve stuck).

Such damage due to spoiled fuel is disallowed from coverage by the warranty.

To avoid this please strictly follow these recommendations:

• Only use specified gasoline (see

page 63).

• Use fresh and clean gasoline.

154

• To slow deterioration, keep gasoline in a certified fuel container.

• If long storage (more than 30 days) is foreseen, drain fuel tank and vapor separator.

Vapor Separator Draining

INTAKE MANIFOLD DRAIN TUBE



CHILDREN.


Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before storing or transporting the outboard motor.

• Do not smoke or allow flames or sparks where fuel is drained or stored.

DRAIN SCREW VAPOR SEPARATOR


2. Release the drain tube from the projection of the intake manifold and bring the end of the drain tube out of the under cover.

3. Loosen the vapor separator drain screw.

4. Tilt up the outboard motor.

STORAGE

5. When the gasoline starts to flow out of the drain tube, tilt up the outboard motor and hold it in the position until the gasoline stops flowing. After draining the gasoline completely, return the outboard motor to the horizontal position.

Catch the draining gasoline in a suitable container.

6. After draining, tighten the drain screw and secure the drain tube to the projection of the intake manifold.

155

STORAGE

Battery Storage

Battery handling differs according to the type of the battery and the instructions described below might not be applicable to the battery of your outboard motor. Refer to the battery manufacturer’s instructions.


If ignited, an explosion can cause serious injury or blindness.

Provide adequate ventilation when charging.






ANTIDOTE





CHILDREN.

(–) TERMINAL

(+) TERMINAL

RED

BLACK

1. Disconnect the battery cable at the battery negative (–) terminal, then at the battery positive (+) terminal.

2. Remove the battery and clean the battery terminals and battery cable terminals with a wire brush or sand paper.

Clean the battery with a solution of baking soda and warm water, taking care not to get the solution of water in the battery cells. Dry the battery thoroughly.

156

STORAGE

Outboard Motor Position

(Port side turned down as shown.)

3. Fill the battery with distilled water to the upper level line. Never overfill the battery.

4. Store the battery on a level surface in a cool, dry, well ventilated place out of direct sunlight.

5. Once a month, check the specific gravity of the electrolyte and recharge as required to prolong battery life.

OUTBOARD MOTOR STAND

Transport and store the outboard motor either vertically, as shown above. Attach the stern bracket to stand and secure the outboard motor with bolts and nuts. Store the outboard motor in a well-ventilated area free from direct sunlight and humidity.

Do not place the outboard motor on its side during a prolonged period of storage. If you are obliged to place the outboard motor on its side, drain the engine oil, protect the outboard motor by wrapping it with the urethane material or the blanket as shown.

157

14. DISPOSAL

To protect the environment, do not dispose of this product, battery, engine oil, etc. carelessly by leaving them in the waste. Observe the local laws and regulations or consult your dealer for disposal.

158

15. TROUBLESHOOTING

WARNING SYSTEM COMES ON

SYMPTOM POSSIBLE CAUSE

Overheat warning system comes on:

• Overheat indicator comes on.

• Overheat warning buzzer sounds.

• Engine speed decreases and stops at last.

• Engine speed cannot be increased by opening the throttle.

• Engine will stop in 20 seconds after engine speed is limited.

Cooling water intake port clogged.

Spark plugs have improper heat range.

• Faulty water pump.

• Thermostat clogged.

• Faulty thermostat.

• Cooling water passage clogged.

• Exhaust gas invades cooling system.

Shortage of engine oil Oil pressure warning system comes on:

• Oil pressure indicator does not come on.

• Oil pressure warning buzzer sounds.

• Engine speed decreases.

• Engine speed cannot be increased by opening the throttle.

Improper engine oil is used.

REMEDY

Clean the cooling water intake port.

Replace the spark plugs

(see pages 135 – 138).

Consult with an authorized


Add engine oil to the specified

level (see page 60).

Change the engine oil

(see page 133).

159

TROUBLESHOOTING

SYMPTOM

Water separator warning system comes on:

• Water separator warning buzzer sounds.

PGM-FI warning system comes on:

• PGM-FI indicator comes on.

• PGM-FI warning buzzer sounds intermittently.

ACG warning system comes on:

• ACG indicator comes on.

• ACG warning buzzer sounds intermittently.

POSSIBLE CAUSE

Water is accumulated in the water separator.

PGM-FI warning system is faulty.

Battery voltage is too high or low.

Faulty ACG.

REMEDY

Clean the water separator (see page

143).

Check the fuel tank and fuel line for water accumulation. If the buzzer sounds again, consult with an authorized TOHATSU outboard motor dealer.



Check the battery (see page 139).



160

16. SPECIFICATIONS

MODEL

Description code

Type

Overall length

Overall width

Overall height

Transom height

(when Transom angle is 12 )

Dry mass

(weight)*

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Remote control steering system

Starter system

Ignition system

Lubrication system

BFT75A

BBAJ

LRT XRT

746 mm

(29.4 in)

449 mm

(17.7 in)

1,566 mm

(61.7 in)

537 mm

(21.1 in)

165 kg

(364 lbs)

1,693 mm

(66.7 in)

664 mm

(26.1 in)

171 kg

(377 lbs)

55.2 kW (75 PS)

5,000 – 6,000 min -1 (rpm)

4 stroke OHC in-line 4-cylinder

1,496 cm

3

(91.3 cu-in)

0.8 – 0.9 mm (0.031 – 0.035 in)

Motor-mounted, remote control

Electric starter

Full transistor battery

Trochoid pump pressure lubrication

Specified oil

Engine oil capacity

D.C. output

Cooling system

Exhaust system

Spark plug

Fuel pump

Fuel

Gear shift

Steering angle

Trim angle

Tilt up angle

Transom angle

Engine: API standard (SG, SH, SJ) SAE 10W-30

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

Engine: Without oil filter replacement:

4.2 L (4.4 US qt, 3.7 Imp qt)

With oil filter replacement:

4.4 L (4.6 US qt, 3.9 Imp qt)

Gear case: 0.95 L (1.00 US qt, 0.84 Imp qt)

12 V – 35 A

Water cooling with thermostat

Water exhaust

ZFR6K-9E (NGK)

Low pressure side:

High pressure side: mechanical type electrical type

Automotive unleaded gasoline

(91 research octane, 86 pump octane, or higher)

Dog type: Forward – Neutral – Reverse

30 right and left

– 4 to 16 (when Transom angle is 12 )

68 (when Transom angle is 12 )

8 , 12 , 16 , 20 , 24

* Without battery cable, with propeller

These TOHATSU outboards are power rated in accordance with ISO8665 (propeller shaft output).

161

MODEL

Description code

Type

Overall length

Overall width

Overall height

Transom height

(when Transom angle is 12 )

Dry mass

(weight)*

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Remote control steering system

Starter system

Ignition system

Lubrication system

SPECIFICATIONS

BFT90A

BBCJ

LRT XRT

746 mm

(29.4 in)

449 mm

(17.7 in)

1,566 mm

(61.7 in)

1,693 mm

(66.7 in)

537 mm

(21.1 in)

664 mm

(26.1 in)

166 kg

(366 lbs)

172 kg

(379 lbs)

66.2 kW (90 PS)

5,300 – 6,300 min -1 (rpm)

4 stroke OHC in-line 4-cylinder

1,496 cm

3

(91.3 cu-in)

0.8– 0.9 mm (0.031 – 0.035 in)

Motor-mounted, remote control

Electric starter

Full transistor battery

Trochoid pump pressure lubrication

Specified oil

Engine oil capacity

D.C. output

Cooling system

Exhaust system

Spark plug

Fuel pump

Fuel

Gear shift

Steering angle

Trim angle

Tilt up angle

Transom angle

Engine: API standard (SG, SH, SJ) SAE 10W-30

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

Engine: Without oil filter replacement:

4.2 L (4.4 US qt, 3.7 Imp qt)

With oil filter replacement:

4.4 L (4.6 US qt, 3.9 Imp qt)

Gear case: 0.95 L (1.00 US qt, 0.84 Imp qt)

12 V – 35 A

Water cooling with thermostat

Water exhaust

ZFR6K-9E (NGK)

Low pressure side:

High pressure side: mechanical type electrical type

Automotive unleaded gasoline

(91 research octane, 86 pump octane, or higher)

Dog type: Forward – Neutral – Reverse

30 right and left

– 4 to 16 (when Transom angle is 12 )

68 (when Transom angle is 12 )

8 , 12 , 16 , 20 , 24

* Without battery cable, with propeller

These TOHATSU outboards are power rated in accordance with ISO8665 (propeller shaft output).

162

SPECIFICATIONS

Noise and Vibration

MODEL

CONTROL SYSTEM

Sound pressure level at operator’s ears

(2006/42/EC, ICOMIA 39-94)

Uncertainty

Measured sound power level

(Reference to EN ISO3744)

Uncertainty

Vibration level at hand arm

(2006/42/EC, ICOMIA 38-94)

Uncertainty

T (Tiller handle)

BFT75A

R (Remote control)

82 dB (A) 76 dB (A)

2 dB (A)

91 dB (A)

2 dB (A)

Not exceed

2.5 m/s

2

—

2 dB (A)

—

—

Not exceed

2.5 m/s

2

—

T (Tiller handle)

BFT90A

R (Remote control)

86 dB (A) 81 dB (A)

2 dB (A)

95 dB (A)

2 dB (A)

Not exceed

2.5 m/s

2

—

2 dB (A)

95 dB (A)

2 dB (A)

Not exceed

2.5 m/s

2

—

Reference to: ICOMIA Standard: as it specifies the engine operating conditions and measurement conditions.

163

17. ‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE

164

‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE

165


166


167


168

A

ACG Fuse Replacement ..............151

ACG Indicator/Buzzer

Function.....................................42

Operation ................................. 115

Anode

Function.....................................44

Operation .................................119

B

Battery

Cleaning...................................140

Connections ...............................55

Fluid Level Inspection.............139

Inspection ..................................69

Storage.....................................156

Break-in Procedure ........................93

C

Cleaning and Flushing .................128

Component Identification ..............13

Controls and Features

Common ....................................40

H type ........................................22

R type ........................................29

T type.........................................37

Cooling Water

Check Hole ................................45

Intake Port................................. 45

Cruising....................................... 100

H type...................................... 100

R type...................................... 103

D

Disposal ...................................... 158

E

‘‘EC DECLARATION OF

CONFORMITY’’

Content Outline................... 164

Emergency Stop

Switch ................................. 25, 34

Switch Lanyard/Clip........... 26, 34

Switch Spare Clip ............... 27, 35

Emission Control System............ 149

Engine

Cover

Fixing Lever .......................... 46

Removal/Installation.............. 60

Oil

Change ................................. 133

Level Inspection .................... 61

Refilling ................................. 61

Protection System ................... 115

ACG Warning System ......... 115

Engine Oil Pressure Warning

18. INDEX

System.............................. 115

Overheat Warning System...... 115

PGM-FI Warning System ....... 115

Water Contamination

Warning System ................. 115

Serial Number ............................. 3

Switch

H type........................................ 22

R type........................................ 22

F

Frame Serial Number ...................... 3

Fast Idle

Button........................................ 33

Lever ......................................... 33

Fuel

Filler Cap .................................. 46

Filter

Inspection............................. 147

Replacement......................... 147

Gauge ........................................ 47

Level ......................................... 63

Line

Connection ............................. 72

Connector and Joint ............... 47

Disconnection ...................... 125

Priming...................................... 74

Storage .................................... 154

169

INDEX

Tank cleaning ..........................148

Tank Filter ...............................149

Fuse Replacement........................150

G

Gasoline Containing Alcohol ........64

Gear

Shifting ....................94, 96, 97, 98

I

Inspect After Operating ...............153

Installation

Outboard Motor .........................53

Height ........................................52

Location.....................................52

L

Lubrication ..................................141

M

Maintenance ................................129

Maintenance Schedule.................131

Manual Relief Valve

Function.....................................39

Operation .................................113

Moorage.......................................111

Multiple Outboard Motors...........120

N

Neutral Release Lever................... 32

NMEA Interface coupler .............. 48

O

Oil Pressure Indicator/Buzzer

Function .................................... 40

Operation ................................ 115

Operation ...................................... 93

Operating Hour Notification

System ..................................... 48

Outboard Motor

Angle Inspection....................... 54

Installation ................................ 53

Storage Position ...................... 157

Over-rev Limiter ......................... 119

Overheat Indicator/Buzzer

Function .................................... 41

Operation ................................ 115

P

PGM-FI Indicator/Buzzer

Function .................................... 43

Operation ................................ 115

Power Tilt Switch

Function .................................... 39

Operation ................................ 112

Power Trim/Tilt Switch

Function .................................... 37

Operation......................... 100, 103

Pre-operation Checks .................... 60

Battery....................................... 69

Engine Oil ................................. 60

Fuel ........................................... 63

Other Checks............................. 71

Propeller and Cotter Pin

Inspection............................... 65

Remote Control Lever

Friction................................... 68

Steering Handle

Friction................................... 68

Water Separator ........................ 69

Propeller

Inspection .................................. 65

Replacement............................ 152

Selection.................................... 59

R

Remote Control

Box

Identification .................... 14, 15

Installation Location .............. 58

Cable Length ............................. 58

Installation................................. 57

Lever

170

Function......................29, 30, 31

Friction Adjustment................68

S

Safety

Carbon Monoxide Poisoning

Hazard ......................................9

Fire and Burn Hazards.................9

Information ..................................7

Label Locations .........................10

Operator Responsibility...............7

Shallow Water Operation ............119

Shift Lever .....................................23

Spark Plugs ..................................135

Specifications ..............................161

Starting the Engine

Emergency Starting ...................87

H type ........................................75

R1 type ......................................79

R2, R3 types ..............................83

Steering Handle Friction................68

Function.....................................27

Operation ...................................99

Stopping the Engine

Emergency Stop ......................121

Normal Stop

H type ...................................122

R type ...................................124

Storage ........................................ 154

Submerged Outboard Motor

Servicing ................................. 153

Switch Panel ................................. 15

T

Tachometer ................................... 46

Throttle Friction Adjuster ............. 25

Throttle Grip ................................. 24

Tiller Handle ........................... 17, 18

Tiller Handle Height/Angle

Adjustment................................ 66

Tilt Lock Lever ............................. 40

Tilting the Outboard Motor......... 110

Tool Kit and Emergency

Parts ........................................ 130

Trailering .................................... 126

Transom Height ............................ 51

Transporting................................ 125

Trim Meter

Function .................................... 38

Operation ................................ 109

Trim Tab

Function .................................... 44

Adjustment.............................. 114

Trimming the Outboard Motor ... 106

INDEX

TRL (Trolling) Control Switch

Operation................................. 105

Panel.......................................... 36

Remote Control Box ................. 36

Tiller Handle ............................. 28

Troubleshooting

Warning System Comes On.... 159

V

Vapor Separator Draining ........... 155

W

Water Separator Buzzer ................ 43

Water Separator..................... 69, 143

Cleaning .................................. 143

171

172

MEMO

MEMO

173

OWNER’S MANUAL

BFT 75A

90A

12

12

Tohatsu BFT 90A Owner Manual

Assistant Bot

OWNER’S

MANUAL

BFT 75A

90A

Original instructions

Remote Control Box

(Side-mount type)

TRL (Trolling) Control Switch

Panel

(optional equipment)

Remote Control Box

(Side-mount type)

Tiller Handle (H2 type)

TRL (Trolling) Control Switch

Panel

(optional equipment: R type)

OWNER’S MANUAL

BFT 75A

90A

Related manuals

Table of contents

Tohatsu BFT 90A Owner Manual

Assistant Bot

OWNER’S

MANUAL

BFT 75A

90A

Original instructions

Remote Control Box

(Side-mount type)

TRL (Trolling) Control Switch

Panel

(optional equipment)

Remote Control Box

(Side-mount type)

Tiller Handle (H2 type)

TRL (Trolling) Control Switch

Panel

(optional equipment: R type)

OWNER’S MANUAL

BFT 75A

90A

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Table of contents