Tohatsu BFT 225A Owner Manual

36ZY3T120_EN.book Page 1 Tuesday, November 28, 2017 5:12 PM

OWNER’S

MANUAL

Original instructions

BFT 200A

BFT 225A


© 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

BFT200A/225A 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:

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.

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

Outboard Motor, consult your outboard motor dealer.

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.

1


Control and Feature Identification Codes

Model

Type

Transom Height

(Shaft Length)

508 mm (20.0 in)

LU

•

BFT200A

XU XD

635 mm (25.0 in)

Standard Rotating Propeller Shaft

•

•

•

•

•

Counterrotating Propeller Shaft

Power Trim/Tilt

• • •

XCU

•

•

•

XU

BFT225A

XD XCU

•

•

•

•

•

•

BFT200A/225A is provided with the following types according to the shaft length and the rotating direction of the propeller shaft.

TYPE CODE

Example

X C D

•

•

•

Destination

D: General Export , U: Europe

Rotating direction of propeller shaft

C: Counterrotating propeller shaft is equipped.

None: Standard rotating propeller shaft is equipped.

Transom Height

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

How To Determine Which

Direction The Propeller Shaft

Rotates

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

With grooves: Counterrotating

Without grooves: Standard rotating

WITHOUT

GROOVES

WITH

GROOVES

GROOVES

2


Remote Control Types

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:

Top-mount type:

R2 type

R3 type

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

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

Serial Number Locations

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

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 a plate attached on the left side of the stern bracket.

Frame serial number:

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

Engine serial number:

3


CONTENTS

1. SAFETY ...........................................................................................6

SAFETY INFORMATION ...........................................................6

2. SAFETY LABEL LOCATIONS ......................................................8

3. COMPONENT IDENTIFICATION ..............................................10

4. CONTROLS AND FEATURES ....................................................15

Remote Control Lever .................................................................15

R1 type ...................................................................................15

R2 type ...................................................................................16

R3 type ...................................................................................17

Neutral Release Lever .................................................................18

Engine Switch .............................................................................18

Fast Idle Lever/Fast Idle Button ..................................................19

PGM-FI Indicator/Buzzer ...........................................................20

ACG Indicator/Buzzer ................................................................20

Oil Pressure Indicator/Buzzer .....................................................21

Overheat Indicator/Buzzer ..........................................................21

Water Separator Buzzer ..............................................................21

Power Trim/Tilt Switch ...............................................................22

Trim Meter (optional equipment) ................................................23

Power Tilt Switch (outboard motor pan) ....................................23

Manual Relief Valve ...................................................................24

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

Emergency Stop Switch Lanyard/Clip ........................................25

Spare Emergency Stop Switch Clip (optional equipment) .........26

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

Trim Tab ......................................................................................27

Anode ..........................................................................................27

Cooling Water Check Hole .........................................................28

Cooling Water Intake Port ..........................................................28

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

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

NMEA Interface Coupler ............................................................29

4

Operating Hour Notification System .......................................... 29

5. INSTALLATION ........................................................................... 32

Transom Height .......................................................................... 32

Location ...................................................................................... 33

Installation Height ...................................................................... 33

Outboard Motor Installation ....................................................... 34

Outboard Motor Angle Inspection (Cruising) ............................ 35

Battery Connections .................................................................... 36

Remote Control Box Location ............................................... 36

Remote Control Cable Length ............................................... 36

Remote Control Installation (optional equipment) ..................... 38

Propeller Selection ...................................................................... 40

Fuel Line Connection ................................................................. 40

6. PRE-OPERATION CHECKS ........................................................ 41

Engine Cover Removal/Installation ............................................ 41

Engine Oil ................................................................................... 42

Fuel ............................................................................................. 44

GASOLINE CONTAINING ALCOHOL .................................. 45

Propeller and Cotter Pin Inspection ............................................ 46

Remote Control Lever Friction ................................................... 47

Fuel Filter .................................................................................... 47

Battery ......................................................................................... 48

Other Checks .............................................................................. 49

7. STARTING THE ENGINE ........................................................... 50

Fuel Priming ............................................................................... 50

Starting the Engine ..................................................................... 50

R1 type ................................................................................... 50

R2, R3 types .......................................................................... 54


8. OPERATION ..................................................................................58

Break-in Procedure ......................................................................58

Gear Shifting ...............................................................................59

R1 type ...................................................................................59

R2 type ...................................................................................60

R3 type ...................................................................................61

Cruising .......................................................................................62

Trimming the Outboard Motor ....................................................64

Trim Meter ..................................................................................66

Tilting the Outboard Motor .........................................................67

Moorage ......................................................................................68

Power Tilt Switch ........................................................................69

Manual Relief Valve ...................................................................69

Trim Tab Adjustment ..................................................................70

Engine Protection System ...........................................................71

<Engine Oil Pressure, Overheat, Water Separator,

PGM-FI and ACG Warning Systems> ...............................71

<Over-rev Limiter> ................................................................75

<Anode> .................................................................................75

Shallow Water Operation ............................................................75

Multiple Outboard Motors ..........................................................76

9. STOPPING THE ENGINE .............................................................77

Emergency Engine Stop ..............................................................77

Normal Engine Stop ....................................................................77

10. TRANSPORTING ........................................................................79

Fuel Line Disconnection .............................................................79

Transporting ................................................................................79

Trailering .....................................................................................80

11. CLEANING AND FLUSHING ...................................................81

12. MAINTENANCE .........................................................................82

Tool Kit and Spare Parts .............................................................83

MAINTENANCE SCHEDULE ..................................................84

CONTENTS

Engine Oil ................................................................................... 86

Spark Plugs ................................................................................. 88

Lubrication .................................................................................. 91

Fuel Filter .................................................................................... 92

Water Separator .......................................................................... 95

EMISSION CONTROL SYSTEM ............................................. 97

Battery ......................................................................................... 98

Fuse ........................................................................................... 100

ACG Fuse ................................................................................. 101

Propeller .................................................................................... 102

Inspect After Operating ............................................................ 103

Submerged Outboard Motor ..................................................... 103

13. STORAGE ................................................................................. 105

Fuel ........................................................................................... 105

Vapor Separator Draining ......................................................... 106

Battery Storage ......................................................................... 107

Outboard Motor Position .......................................................... 108

14. DISPOSAL ................................................................................. 109

15. TROUBLESHOOTING ............................................................. 110

16. SPECIFICATIONS .................................................................... 112

17. ‘‘EC DECLARATION OF CONFORMITY’’

CONTENT OUTLINE ............................................................ 115

18. INDEX ....................................................................................... 120

5


1. SAFETY

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.

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.

• 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.

• 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.

• 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.

6


• 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.

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.

SAFETY

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.

7


2. SAFETY LABEL LOCATIONS

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 outboard motor dealer for a replacement.

READ OWNER’S MANUAL GEAR SHIFTING

8


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 H J K L M N

Year of manufacture 2017 2018 2019 2020 2021 2022

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

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

9


3. COMPONENT IDENTIFICATION

ENGINE COVER

LATCH

FRAME SERIAL

NUMBER

MANUAL RELIEF

VALVE

ANODE

ENGINE COVER

POWER TILT

SWITCH

TILT LOCK

LEVER

COOLING WATER

CHECK HOLE

IDLE PORT

ENGINE OIL

DRAIN BOLT

(inside cover)

STERN

BRACKET

ANODE ANODE

FLUSH PLUG

CONNECTOR

ANTICAVITATION

PLATE

EXHAUST PORT/

WATER OUTLET PORT

PROPELLER

GEAR OIL LEVEL

PLUG

TRIM TAB

GEAR OIL DRAIN

PLUG

COOLING WATER INTAKE PORT

(each side)

10


COMPONENT IDENTIFICATION

OIL FILLER CAP

SPARK

PLUGS

(under ignition coil)

SPARK

PLUGS

(under ignition coil)

OIL LEVEL DIPSTICK

FUEL FILTER

(inside strainer cup)

JUNCTION BOX

(FUSES)

INTERFACE COUPLER

WATER SEPARATOR

11



REMOTE CONTROL BOX

(optional equipment)

SIDE-MOUNT TYPE (R1 type) PANEL-MOUNT TYPE (R2 type)

POWER TRIM/TILT

SWITCH

BUZZER

(inside)

REMOTE CONTROL

LEVER

NEUTRAL RELEASE

LEVER

INDICATORS

(Oil pressure, Overheat,

ACG, PGM-FI)

FAST IDLE LEVER

REMOTE CONTROL

LEVER

NEUTRAL RELEASE

LEVER

ENGINE SWITCH

POWER TRIM/TILT

SWITCH

12

CONTROL

LEVER

FRICTION

ADJUSTER

EMERGENCY STOP

SWITCH

EMERGENCY STOP

SWITCH LANYARD EMERGENCY STOP

SWITCH CLIP

FAST IDLE BUTTON



TOP-MOUNT TYPE (R3 type)

(SINGLE OUTBOARD MOTOR TYPE) (DUAL OUTBOARD MOTOR TYPE)

REMOTE CONTROL LEVER REMOTE CONTROL LEVERS

POWER TRIM/TILT

SWITCH (RIGHT)

POWER TRIM/TILT

SWITCH

POWER TRIM/TILT

SWITCH (LEFT)



SWITCH PANEL (optional equipment)

(PANEL-MOUNT, TOP-MOUNT)

BUZZER

INDICATORS

(Oil pressure, Overheat,

ACG, PGM-FI)

ENGINE SWITCH

(for TOP-MOUNT DUAL type)

EMERGENCY STOP SWITCH

EMERGENCY STOP SWITCH CLIP

EMERGENCY STOP SWITCH LANYARD

13



(Common)

TACHOMETER (Optional equipment) TRIMMETER (Optional equipment)

14


4. CONTROLS AND FEATURES

R1 type Remote Control Lever (R1 type)

REMOTE CONTROL LEVER

FORWARD

NEUTRAL

REVERSE

NEUTRAL

RELEASE LEVER

FORWARD

THROTTLE OPENING

32°

NEUTRAL

32°

SHIFT

MINIMUM

REVERSE

SHIFT

MINIMUM


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.

MAXIMUM

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.

15


CONTROLS AND FEATURES



NEUTRAL

RELEASE

LEVER

FORWARD

FORWARD

MINIMUM


35°

NEUTRAL

SHIFT

35°

REVERSE

SHIFT

MINIMUM

THROTTLE

OPENING

NEUTRAL

MAXIMUM


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

REVERSE

MAXIMUM

FORWARD:


NEUTRAL:


REMOTE

CONTROL LEVER

REVERSE:


16




SINGLE TYPE

REMOTE CONTROL

LEVER

FORWARD

NEUTRAL

REVERSE

DUAL TYPE

FORWARD

REVERSE

NEUTRAL

FORWARD

NEUTRAL

35° 35°

SHIFT SHIFT

THROTTLE

OPENING

MINIMUM

REVERSE

THROTTLE

OPENING

MINIMUM

MAXIMUM

MAXIMUM

REMOTE CONTROL LEVERS REMOTE CONTROL LEVER


FORWARD:


REVERSE:


NEUTRAL:


17



Neutral Release Lever

(R1 type)


Engine Switch

(R1 type)

(R2, R3 type)

ON

START

OFF

ON START

ENGINE

SWITCH

KEY

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.

18

OFF START

ENGINE SWITCH KEY

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:

OFF: 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 remote control lever is in the NEUTRAL position, and the clip is in the emergency stop switch.


Fast Idle Lever/Fast Idle Button

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 BFT200A and

BFT225A 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

REMOTE CONTROL

LEVER

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

FAST IDLE

BUTTON

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.

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

19



<Fast Idle Button>

(R3 type)

FORWARD

NEUTRAL

REVERSE

PGM-FI Indicator/Buzzer

(R1 type)

PGM-FI

INDICATOR

ACG Indicator/Buzzer

(R1 type)

ACG

INDICATOR

REMOTE

CONTROL

LEVER

Push


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.

20

(R2, R3 type)

PGM-FI

INDICATOR

(RED)

BUZZER

(RED)

BUZZER

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

(R2, R3 type)

ACG

INDICATOR

(RED)

(RED)

BUZZER

BUZZER

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


Oil Pressure Indicator/Buzzer

(R1 type)

OIL PRESSURE

INDICATOR

Overheat Indicator/Buzzer

(R1 type) OVERHEAT

INDICATOR


Water Separator Buzzer

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

(GREEN)

(RED)

BUZZER

BUZZER

(R2, R3 type)

OIL PRESSURE

INDICATOR

(R2, R3 type)

OVERHEAT

INDICATOR

(GREEN)

(RED)

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.

BUZZER

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

21



Power Trim/Tilt Switch

Power Trim

Press the power trim/tilt switch 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.

(R1 type) (R3 type)

SINGLE TYPE

POWER TRIM/TILT

SWITCH

POWER

TRIM/TILT

SWITCH

(R2 type)

REMOTE CONTROL

LEVER

POWER TRIM/TILT SWITCH


DUAL TYPE

REMOTE

CONTROL

LEVER


(LEFT) (RIGHT)

REMOTE

CONTROL

LEVERS

The outboard motor trim angle of

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

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.

22


Trim Meter



Power Tilt Switch

(outboard motor pan)

POWER TILT SWITCH

68°

0°

12°

TILT ANGLE

16° – 4°

TRIM ANGLE 0°

(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 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.

The outboard motor trim angle of

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

23



Manual Relief Valve

MANUAL RELIEF VALVE

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

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

POWER

(To fix)

MANUAL

(To release)

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.

24


Emergency Stop Switch

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.

(R1 type)

STOP


Emergency Stop Switch Lanyard/

Clip

EMERGENCY STOP

SWITCH LANYARD


(R2, R3 type)


EMERGENCY STOP SWITCH CLIP

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.

STOP

25



(R1 type)


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.

STOP

EMERGENCY STOP

SWITCH CLIP

(R2, R3 type)

EMERGENCY

STOP SWITCH

LANYARD


Spare Emergency Stop Switch Clip


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

A spare emergency stop switch clip can be stored in the tool bag (see page

83).

STOP

EMERGENCY STOP

SWITCH CLIP EMERGENCY STOP

SWITCH LANYARD

26


Tilt Lock Lever

TILT LOCK LEVER

Trim Tab

FREE

TIGHTENING

BOLT


Anode

LOCK

ANODE

(each side)

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.

TRIM TAB

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

ANODE

(stern bracket)

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.

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

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

27



Cooling Water Check Hole

COOLING WATER CHECK HOLE

Cooling Water Intake Port


(each side)

Engine Cover Latch

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.

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

ENGINE COVER LATCH

Pull the engine cover latch to remove the engine cover.

28


Tachometer


TACHOMETER

The tachometer shows the engine speed in revolutions per minute.

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.

29



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 84)

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

<Operating hour notification timing>

20 hours

80 hours after reset

Start of operation

Notify Notify

Every 100 hours

100 hours after reset

Notify

<Display>

Steps

Outboard motor

Display

Maintenance indication on display

1

—

Switch ON

Not shown

Maintenance indication

2

Ignition switch

ON

—

Shown


3

Start engine

—

Shown


4

Gear at F or R

—

Not shown


30


NMEA2000-compatible display:

• Follow instructions for the display.

• If the display allows selection of notification to be preset, select

“Notify” (or equivalent).

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

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


When “Periodic Maintenance” is indicated:

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

2. Reset the hour counter.

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

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.

31


5. INSTALLATION

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 your outboard motor dealer.

Consult your 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:

BFT200A: 147.1 kW (200 PS)

BFT225A: 165.5 kW (225 PS)

Power recommendation is indicated on most of the boats.

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

32

Transom Height

Type:

L:

X:

T (Transom Height)

(when transom angle is 12°)

508 mm (20.0 in)

635 mm (25.0 in)

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


Location Installation Height

TRANSOM HEIGHT

INSTALLATION

IDLE PORT

CENTER LINE

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

150 mm (5.9 in) or more

WATER LEVEL 0 – 25 mm

(0 – 1.0 in)

FULLY TRIM/TILT DOWN

BOAT TRANSOM HEIGHT

Make sure that the boat transom height is correct for the outboard motor. Incorrect installation height will reduce performance.

The outboard motor should be installed so that the anticavitation plate is 0 – 25 mm (0 – 1.0 in) upper the bottom of the boat. The correct dimensions differ according to the type of the boats and the figuration 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.

33


INSTALLATION

Outboard Motor Installation

STERN BRACKET

WASHER (6)

BOLT (6) WASHER (12)

NUT (12)

LIFTING EYES

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 lock nuts.

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 your outboard motor dealer.

34

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 three lifting eyes to the outboard.

Use the hoist which allowable load is

300 kg (661 lbs) or above.


Outboard Motor Angle Inspection

(Cruising)

INSTALLATION

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).

35


INSTALLATION

Remote Control Box Location Battery Connections

Use a battery which has CCA (COLD

CRANKING AMPERES) 799 A at

– 18°C (0°F) and a reserve capacity

229 minutes (12V-110Ah/20HR) or more specifications.

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

Remote Control Cable Length

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.

• 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.

36


(–) TERMINAL

(+) TERMINAL

RED

BLACK

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.

INSTALLATION

• 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.

37


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 your 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

(FOR SINGLE OUTBOARD MOTOR TYPE)

AND SWITCH PANEL

PANEL-MOUNT TYPE CONTROL

BOX AND SWITCH PANEL

TOP-MOUNT TYPE CONTROL BOX AND

SWITCH PANEL

(FOR DUAL OUTBOARD MOTOR TYPE)

38


INSTALLATION

<Remote Control Box Location>

REMOTE

CONTROL BOX

REMOTE

CONTROL

LEVER

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.

39


INSTALLATION

Propeller Selection

Select the adequate propeller so that the engine speed at full throttle is

5,000 min -1 (rpm) to 6,000 min -1

(rpm) when the boat is loaded.

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 outboard motor dealer for proper propeller selection.

Fuel Line Connection

Connect the fuel line to the tank and the outboard motor. Follow the boat manufacturer’s instructions.

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 storing or transporting the outboard motor.

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

40


BFT200A/BFT225A is 4-stroke, water cooled outboard motor which uses unleaded regular gasoline for fuel. It also requires the engine oil.

Check the following before operating the outboard motor.

6. PRE-OPERATION CHECKS

Engine Cover Removal/Installation

<Removal>

<Installation>

COVER SIDE COVER LOCKS

Perform the following pre-operation checks with the engine stopped.

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

ENGINE COVER LATCH

1. Pull the engine cover latch.

2. Remove the engine cover by taking it up.

MAIN BODY SIDE

1. Place the engine cover on the main body.

2. Slide the engine cover so that the cover lock on the cover is mated with the lock in the main body.

41


PRE-OPERATION CHECKS

Engine Oil

HANDLE

3. While pulling the handle on the engine cover toward you, push the front end of the engine cover until you hear click.

4. Also, push the rear end until you hear click.

Do not operate the outboard motor without the engine cover.

Exposed moving parts can cause injury.

• 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 outboard motor oil certified to meet or exceed U.S. automobile manufacturer’s requirements for

Service category SG, SH or SJ.

Outboard motor oils category SG, SH or SJ will show this designation on the container.

SAE 10W-30 is recommended for general use.

AMBIENT TEMPERATURE

42



<Inspection and Refilling>


UPPER

LEVEL

MARK

LOWER

LEVEL

MARK

OIL FILLER CAP

1. Position the outboard motor vertically, and remove the engine cover (see page 41).

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 securely. Do not overtighten.

When the engine oil is contaminated or discolored, replace with the fresh engine oil (see page 86 for replacement interval and procedure).

4. Install the engine cover and lock it securely (see page 41).

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.

43



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

Operating Method

Running the engine below

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

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

Result Effect

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

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

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

Fuel

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 an oil/gasoline mixture or dirty gasoline. Avoid getting dirt, dust or water in the fuel tank.

44


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.

45



Propeller and Cotter Pin

Inspection

COTTER PIN

CASTLE NUT 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.

Consult your outboard motor dealer for propeller selection.

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

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 outboard motor dealer for proper propeller selection.

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

2. Check whether the propeller is installed properly.

3. Check the cotter pin for damage.

Replace whenever the propeller is faulty.

46



Fuel Filter

Remote Control Lever Friction

(R1 type)

CONTROL LEVER FRICTION

ADJUSTER

(R2 type)

To increase friction

To decrease friction To decrease friction


(R3 type)

Check whether the remote control lever moves smoothly.

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


CONTROL

LEVER

FRICTION

ADJUSTER

To decrease friction

CONTROL LEVER FRICTION ADJUSTER

FUEL FILTER (inside strainer cup)

Fuel filter is located beside the oil level dipstick. Check the fuel filter for water accumulation. If water is accumulated, drain them (see page

93).

47



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.

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 98).

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 99).

UPPER

LEVEL

LOWER

LEVEL

Batteries produce explosive gases: If ignited, an explosion can cause serious injury or blindness.

Provide adequate ventilation when charging.



48




ANTIDOTE:





CHILDREN.


Other Checks


(5) TOOL KIT (see page 83)

(2)

(4)

(3)

(1)

Check the following items:

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

(2) The control lever for smooth operation.

(3) The switch for correct operation.

(4) The stern bracket for damage.

(5) The tool kit for missing spare parts and tools (see page 83).

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

(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.

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

Parts/materials which should be installed on board:

• Owner’s Manual

• Tool kit

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

• Spare emergency stop switch clip.

• Other parts/materials required by laws/regulations.

49


7. STARTING THE ENGINE

Fuel Priming

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

R1 type

Starting the Engine

(R1 type)


STOP

PRIMING BULB

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.

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.

50

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

The exhaust contains poisonous carbon monoxide.

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

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


STARTING THE ENGINE

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

SPARE EMERGENCY

STOP SWITCH CLIP


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.

NEUTRAL


NEUTRAL

A spare emergency stop switch clip

(optional equipment) can be stored in the tool bag.

2. Set the control lever in the

NEUTRAL position.

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

NEUTRAL position.

51




OFF

ON START

ENGINE SWITCH KEY

3. 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.

• 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.


(each side)

4. 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.

52


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

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.

5. 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 43).

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

ON, consult with your outboard motor dealer.

OIL PRESSURE

INDICATOR LIGHT

NORMAL: ON

ABNORMAL: OFF

6. Warm up the engine as follows:

Above 5°C (41°F) – run the engine for 2 or 3 minutes.

Below 5°C (41°F) – run the engine for at least 5 minutes at 2,000 min -1

(rpm).

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


53



R2, R3 types Starting the Engine

(R2, R3 types)


STOP

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

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.

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

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.

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

54

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

SPARE EMERGENCY

STOP SWITCH CLIP


A spare emergency stop switch clip

(optional equipment) can be stored in the tool bag.


NEUTRAL

NEUTRAL

NEUTRAL

REMOTE

CONTROL

LEVER REMOTE

CONTROL

LEVER

(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.

(R3 type)


ENGINE

SWITCH KEY

ON

START

NEUTRAL

ON

START


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.

• 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.

55



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



(each side)

4. 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.

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

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.

56


ENGINE OIL PRESSURE

INDICATOR

NORMAL: ON

ABNORMAL: OFF


5. 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 43).

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

ON, consult with your outboard motor dealer.

6. Warm up the engine as follows:

Above 5°C (41°F) – run the engine for 2 or 3 minutes.

Below 5°C (41°F) – run the engine for at least 5 minutes at 2,000 min -1

(rpm).

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

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.

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

57


8. OPERATION

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.

58


Gear Shifting

(R1 type)

NEUTRAL RELEASE LEVER

REMOTE CONTROL

LEVER

FORWARD

NEUTRAL

32°

MAXIMUM

OPENING

Pull up

OPERATION

FORWARD

NEUTRAL

NEUTRAL

REVERSE

32°

MAXIMUM

OPENING

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 32° toward the

FORWARD or REVERSE position to engage the desired gear.

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

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

59


OPERATION

R2 type

Gear Shifting

(R2 type)


FORWARD

NEUTRAL

REVERSE

FORWARD

NEUTRAL

NEUTRAL RELEASE

LEVER

REMOTE

CONTROL

LEVER

REVERSE

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.


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


60


OPERATION

R3 type

Gear Shifting

(R3 type)

SINGLE TYPE

FORWARD

NEUTRAL

REVERSE

DUAL TYPE

FORWARD

REMOTE

CONTROL

LEVER

REMOTE

CONTROL

LEVER

NEUTRAL

REVERSE


REMOTE CONTROL LEVERS

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.

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


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

61


OPERATION

Cruising

(R1 type)

POWER TRIM/TILT

SWITCH

(R2 type)

POWER TRIM/TILT

SWITCH

(R3 type)

(single type)

POWER TRIM/

TILT SWITCH

(dual type)


(LEFT) (RIGHT)

1. Press on 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 on the DN (down) of the power trim/tilt switch on the remote 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 remote control lever simultaneously.

62


OPERATION

(R1 type) (R2 type)

NEUTRAL

FORWARD

FORWARD

REVERSE

NEUTRAL

(R3 type)

REVERSE

FORWARD

NEUTRAL

REVERSE

REMOTE

CONTROL

LEVER

REMOTE

CONTROL

LEVER

FORWARD

• When cruising at full throttle, note that the engine speed must be in the range between 5,000 min -1 (rpm) and 6,000 min -1 (rpm).

• 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

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

FORWARD

FORWARD

2. Move the control lever from

NEUTRAL toward FORWARD position.

R2, R3 type:

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

R1 type:

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

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

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.

63


OPERATION

Trimming the Outboard Motor POWER TRIM/TILT SWITCH

Press UP to raise bow.

Press DN to lower bow.

(R1 type)

REMOTE

CONTROL

LEVER

POWER TRIM/TILT SWITCH (R3 type)

Single Type


REMOTE

CONTROL

LEVER


68°

12°

TILT ANGLE

0°

16°

TRIM ANGLE

– 4°

0°

(VERTICAL LINE)

(when transom angle is 12°)

The BFT200A/BFT225A is 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.


(R2 type)


(LEFT) (RIGHT)

Dual Type



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.

REMOTE

CONTROL

LEVER

REMOTE

CONTROL

LEVERS

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.

64


OPERATION

• 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.

OUTBOARD MOTOR

TRIMMED TOO LOW

OUTBOARD MOTOR

TRIMMED TOO HIGH

OUTBOARD MOTOR TRIMMED

CORRECTLY

• 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.

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.

65


OPERATION

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

BOW TOO HIGH DUE TO

1. LOAD IN THE REAR

2. OUTBOARD MOTOR TRIMMED

TOO HIGH

When the boat is mounted with the two outboard motors, adjust with the switch on the control lever side.

Adjustment with the switch on the console side will impair the balance between the right and left outboard motors, which adversely affects operationability and stability of the outboard motors.

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.

66


Tilting the Outboard Motor

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 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.

OPERATION

(R1 type)


(R3 type)

(single type)


(R2 type)


(dual type)


(LEFT) (RIGHT)

67


OPERATION

Moorage

FREE

LOCK

TILT LOCK LEVER

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


(LEFT) (RIGHT)

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

Shift the control lever into 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.

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

68

STERN BRACKET

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 slightly, move the tilt lock lever to the FREE position.

TRIM RODS


Power Tilt Switch

POWER TILT SWITCH

Manual Relief Valve

MANUAL RELIEF VALVE

POWER

(To fix)

MANUAL

(To release)

OPERATION

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.

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

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

The switch operation is the same as that of the switch on the control lever side.

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

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.

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

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

69


OPERATION

Trim Tab Adjustment

TIGHTENING BOLT

RIGHT

LEFT

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.

70 turns:

TRIM TAB

If less effort is required to make left

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

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.

TIGHTENING BOLT

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

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


Engine Protection System

<Engine Oil Pressure, Overheat,

Water Separator, PGM-FI and

ACG Warning Systems>

OIL PRESSURE

INDICATOR

(GREEN)

ACG

INDICATOR

(RED)

OIL PRESSURE

INDICATOR

(GREEN)

BUZZER

ACG

INDICATOR

(RED)

OPERATION

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 separator is activated as described in the following table.

OVERHEAT

INDICATOR

(RED)

BUZZER

(R1 type)

PGM-FI

INDICATOR

(RED)

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 green oil pressure indicator will turn OFF and the red overheat indicator will turn

ON. A continuous buzzer will sound

OVERHEAT

INDICATOR

(RED)

(R2, R3 type)

PGM-FI

INDICATOR

(RED) 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.

71


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

Overheat

(Red)

ACG

(Red)

ON (2 sec) ON

OFF

OFF

ON

OFF

OFF

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.

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

72


OPERATION

When the oil pressure warning system is activated:

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

43).

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.


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 outboard motor dealer.

When the overheat warning system is activated:

1. Return the gearshift lever or 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.

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.

73


OPERATION


(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 outboard motor dealer.

When the PGM-FI activated:

1. Consult with your outboard motor dealer.

When the ACG warning system is activated.

1. Check the battery (see page 98). If the battery is OK, consult with your outboard motor dealer.

WATER SEPARATOR

When the water separator buzzer sounds:

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

93).

74


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 outboard motor dealer.

<Anode>

ANODE

(stern bracket)

ANODE

(each side)

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 4 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 (see page 67). 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.

75


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.

76


9. STOPPING THE ENGINE

Emergency Engine Stop

(R1 type)

EMERGENCY STOP

SWITCH LANYARD

Normal Engine Stop

NEUTRAL

NEUTRAL

STOP NEUTRAL

EMERGENCY

STOP SWITCH

CLIP

(R2, R3 type)


LANYARD

Pull the curl cord of the emergency stop switch and remove the lock plate from the switch; this will stop the engine.

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.

REMOTE

CONTROL

LEVER

(R1 type)

1. Move the shift lever to NEUTRAL position.

REMOTE

CONTROL

LEVER

(R2 type)

NEUTRAL

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)

NEUTRAL

NEUTRAL

77


STOPPING THE ENGINE

OFF

ENGINE

SWITCH KEY

OFF

ENGINE

SWITCH

(R1 type)


OFF position to stop the engine.

OFF

ENGINE

SWITCH KEY

(R2, R3 type)

In the event that the engine does not stop when the engine switch is turned to OFF, disconnect the fuel line connector from the outboard motor.

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.

78


10. TRANSPORTING

Fuel Line Disconnection

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

Transporting

LIFTING EYES

HOIST HOOKS

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




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

1. Remove the engine cover (see page

41).

2. Set the hoist hooks against the lifting eyes and hang the outboard motor to remove it from the boat.

79


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 (see page

41).

Trailering

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.

80


11. CLEANING AND FLUSHING

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

FLUSH PLUG CONNECTOR

Do not apply water or corrosion inhibitor directly to the electrical components under the engine cover, such as the AC generator, O2 sensor, or the AC generator belt, timing belt. If water or corrosion inhibitor penetrates these components, they may be damaged.

Before applying a corrosion inhibitor, cover the AC generator, belts and 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. Wash the outside of the outboard motor with clean, fresh water.

4. Remove the flush plug connector from the outboard motor.

5. Install the water hose joint

(commercially available).

WATER HOSE

FLUSH PLUG

CONNECTOR

WATER HOSE JOINT

(commercially available)

6. Connect a fresh water hose to the water hose joint.

7. Turn on the fresh water supply to the hose and flush the engine for at least 10 minutes.

8. After flushing, remove the water hose and water hose joint and reinstall the flush plug connector.

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

LOCK position.

81


12. MAINTENANCE

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 it securely by pulling up the lock lever.

• 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.

82


MAINTENANCE

Tool Kit and Spare Parts

(Tool Kit does not come with

Counter Rotation Types)

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.

OWNER’S MANUAL

TOOL BAG

10 mm BOX WRENCH

FLAT SCREWDRIVER

GRIP

6 mm HEX.

WRENCH

19 mm EYE WRENCH

SPARK PLUG

WRENCH

83


MAINTENANCE

MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD (3)

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

ITEM

Engine oil

Engine oil filter

Gear case oil

Timing belt

ACG belt

Throttle linkage

Valve clearance

Spark plug

Check level

Change

Replace

Change

Check-adjust

Check-adjust

Check-adjust

Check-adjust

Check

Clean

Replace

Check Propeller and cotter pin

Anode metal (Outside engine) Check

Anode metal (Inside engine)

(6)

Sleeve Check

Exhaust manifold Check

V bank bottom Replace

Idling speed

Lubrication

Water separator

Fuel filter

Check-adjust

Grease

Check

Check

Replace

Each use o o o o

After use

First month or

20 hrs.

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

Every

6 months or

100 hrs.

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

Every year or

200 hrs.

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

Every

2 years or

400 hrs.

Every

6 years or

1,200 hrs.

Refer to page o o (2) o (2) o o (2)

49

—

—

—

88

—

88

46

—

91

95

92

94

—

—

—

—

43

86

—

—

(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.

84


MAINTENANCE

ITEM

Fuel filter

(High pressure type)

Thermostat and thermostat cover

Fuel line

Battery and cable connection

Bolts and nuts

Crankcase breather tube

Cooling water passages

Coolant leak

Water pump

Housing, Impeller

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.

Each use

After use

Check

Replace

Check

Check

Replace

Check level-tightness

Check-tightness

Check

Clean

Check

Check

Check

Check

Check

Check

Check

Check

Check-adjust o (8) o o o o o o (4) o

First month or

20 hrs.

o (2)

Every

6 months or

100 hrs.

o (2) o (2) o (4) o (2) o (2) (7)

Every year or

200 hrs.

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

Every

2 years or

400 hrs.

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

Every

6 years or

1,200 hrs.

Refer to page

(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.

85

—

25

—

—

—

—

103

—

—

—

—

49

—

48, 98

—

—

—

—


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:

7.6 L (8.0 US qt, 6.7 Imp qt)

…when oil filter is not replaced

7.8 L (8.2 US qt, 6.9 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 (see page 41). Remove the oil filler cap.

DRAIN PLUG COVER

DRAIN PLUG COVER SCREW

2. Loosen the drain plug cover screw using a flat screwdriver and remove the drain plug cover.

86


SEALING WASHER

DRAIN BOLT TIGHTENING

TORQUE:

23 N·m (2.3 kgf·m , 17 lbf·ft)


GUIDE

UPPER

LEVEL

MARK

DRAIN PLUG COVER

DRAIN BOLT

3. Set the drain plug cover under the guide.

4. Place a suitable container under the guide.

5. Remove the engine oil drain bolt and sealing washer using the 12 mm wrench and drain the engine oil.

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

LOWER

LEVEL

MARK

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

MAINTENANCE

OIL FILLER CAP

7. Reinstall the oil filler cap securely.

Do not overtighten.

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.

87


MAINTENANCE

Spark Plugs

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

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.

Check interval:

Every 200 operating hours or every year.

Replace interval:

Every 400 hours or 2 years

Recommended spark plug:

IZFR6K-11E (NGK)

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

This outboard motor uses spark plugs that have an iridium coated center electrode. Be sure to observe the following when servicing the 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 your serving 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.’’

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

88


1. Disconnect the battery negative (–) terminal.

2. Unlock and remove the engine cover (see page 41).

LOCK TAB IGNITION COIL

MAINTENANCE

SPARK PLUG

WRENCH

6 × 22 mm

FLANGE BOLT

PLUG MAINTENANCE COVER

3. Remove the 6 × 22 mm flange bolt and remove the plug maintenance cover.

BOLT

WIRE CONNECTOR

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

5. Use a 10 mm wrench to remove the bolt holding the ignition coil.

Remove the ignition coil by pulling it up slightly. Take care not give an impact or drop the ignition coil.

Replace the ignition coil if drop it.

19 mm EYE

WRENCH

6. Use the spark plug wrench and 19 mm eye wrench to remove the spark plugs.

7. Visually inspect the spark plugs.

Discard the spark plugs if there is apparent wear, or if the insulators are cracked or chipped.

89


MAINTENANCE

1.0 – 1.3 mm

(0.039 – 0.051 in)

WASHER

INSULATOR

SPARK PLUG TORQUE:

18 N·m (1.8 kgf·m , 13 lbf·ft)

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.

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

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

The gaps should be 1.0 – 1.3 mm

(0.039 – 0.051 in). If the gap is out of the specification, replace the plug with a new one. Never try to readjust the gap.

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

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

90

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

11.Install the ignition coil. Reinstall the bolt.

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

13.Repeat this procedure for the other five spark plugs.


MAINTENANCE

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.

ENGINE

COVER

LATCH/

LOCK

(each side)

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

• Lubricate more frequently when used in salt water.

PTT THRUST RECEIVER

(each side)

THROTTLE

REEL

THROTTLE ARM/

SHIFT ARM SHAFT

SHIFT ARM/

CLICK

ROLLER/

NEUTRAL

SWITCH

TILT SHAFT

SWIVEL PROPELLER

SHAFT

TILT LOCK LEVER/SHAFT CAM

91


MAINTENANCE

Fuel Filter

FUEL FILTER


The fuel filter (inside the strainer cup) is located beside the oil level dipstick.

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.

• 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 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.

92


<Inspection>

FUEL FILTER



41).

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

If the fuel filter is clogged, refer to page 94 to remove the filter and clean it.

If a water is remained in the fuel filter, refer to page 94 to remove the strainer cup and empty the water from the inside of the cup. Then drain the water by following procedure.

CLAMP DRAIN TUBE

DRAIN SCREW UNDER COVER

MAINTENANCE

2. Loosen the drain screw with the flat tip screwdriver provided in the tool kit.

3. Send the fuel by using the primer bulb (see page 50).

4. Once the water has drained out of the drain tube and gasoline starts to flow out of the drain tube, stop pushing the primer bulb. (Five times may be required to drain the water.)

Store the gasoline in a suitable container.

5. When the gasoline flowing is stopped, tighten the drain screw, and hold the drain tube by the clamp on the cylinder head cover.

6. Check for fuel leaks while squeezing the priming bulb.

1. Remove the drain tube held by the clamp on the left cylinder head cover, and move the tip of the drain tube which is inside of the under cover to the outside.

93


MAINTENANCE

<Replacement>

O-RINGS

(Replace)

FUEL TUBES

STRAINER

CUP

TUBE

CLIPS

FUEL

FILTER

FLOAT

STRAINER

BRACKET SUSPENSION STRAP

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

3. Unscrew the strainer cup.

4. Thoroughly clean the strainer cup, and replace with a new fuel filter.

5. Reassemble the fuel filter, float, and strainer cup. Use new O-rings.

6. Install the suspension strap to the strainer assembly.

7. Align the center of the two fuel tubes and arrow of the suspension strap rib.

FUEL TUBES

ARROW

8. Connect the fuel tubes to the strainer assembly securely with the tube clamps.

Remove the tube clips used to close the fuel tubes.

9. Reinstall the strainer assembly in the reverse order of removal.

10. Prime the engine using the priming bulb (see page 50). Check for fuel leaks. Repair any fuel leaks if necessary.

SUSPENSION

STRAP

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.

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 strainer assembly.

94


Water Separator

No.6 CYLINDER IGNITION COIL

WATER SEPARATOR

Water separator is located under No.6 cylinder ignition coil. Water accumulation in the water separator can cause loss of power or hard starting. Check the water separator periodically. Clean it or consult with your outboard motor dealer for cleaning.



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 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.

MAINTENANCE

<Cleaning>

6 × 17 mm SPECIAL BOLTS

LEFT

UNDER

COVER

IDLE

PORT

6 × 17 mm

SPECIAL BOLTS COVER


41).

2. Remove the spark plug maintenance cover (see page 89).

3. Remove the cover under the idle port.

4. Remove the left under cover by removing the 6 × 17 mm special bolts.

95


MAINTENANCE

LOCK TAB

2 PIN

COUPLER

(BLUE)

STAY 2 PIN COUPLER (BLUE)

LOCK TAB

TUBE CLIPS

FUEL TUBES

WATER SEPARATOR CUP

O-RING

(Replace)

SCREWS

DRAIN TUBE

TUBE CLIP

DRAIN VALVE

SUSPENSION

STRAP

WATER SEPARATOR BRACKET

5. Disconnect the 2 pin coupler (blue) pushing up the lock tab.

6. Remove the 2 pin coupler (blue) from the stay pushing up the lock tab.

7. Remove the suspension strap from the water separator bracket.

SUSPENSION

STRAP

WATER SEPARATOR STAY

8. Bind the two fuel tubes with the tube clips to prevent the fuel leakage, disconnect the fuel tubes.

9. Bind the drain tube with the tube clip, disconnect the tube from the drain valve.

10.Remove the suspension strap from the water separator.

11. Remove the three screws holding the water separator, delete the water or deposit from the inside of the cup.

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

TIGHTENING TORQUE:

3.4 N·m (0.34 kgf·m, 2.5 lbf·ft)

96


WATER SEPARATOR

ALIGNING MARK

SUSPENSION

STRAP

13. Align the aligning mark as shown in the figure, when installing the suspension strap on the water separator.

14. The drain joint should be positioned within the protruded portion of the suspension strap as shown in the figure.

PROTRUDED PORTION

SUSPENSION STRAP

DRAIN JOINT

15. Prime the engine using the priming bulb (see page 50). Check for fuel leaks. Repair any fuel leaks if necessary.

If the buzzer sounds, water or sediment accumulation is found to be caused by excessive water or sediment accumulated in the fuel filter, inspect the fuel tank. Clean the fuel tank if necessary.

MAINTENANCE

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 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

97


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.

Batteries produce explosive gases:

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






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.

98


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

– )

POSITIVE (+)

TERMINAL

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.

99


MAINTENANCE

Fuse

Before replacing the fuse, check the current ratings of the electrical accessories and ensure that there are no abnormalities.

<Replacement>

SPARE FUSES

(10 A, 15 A, 30 A)

JUNCTION

BOX COVER

FUSES

(10 A, 15 A, 30 A)

FUSE PULLER

BLOWN FUSE

• 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.

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.

FUSE PULLER

1. Stop the engine.

2. Disconnect the battery (see page

99).


41).

4. Open the junction box cover.

5. Pull the old fuse out of the clip with the fuse puller supplied in the fuse box.

6. Push a new fuse into the clips.

100


ACG Fuse

5 mm SCREWS

JUNCTION

BOX COVER

ACG FUSE

(150 A)

1. Stop the engine.

2. Disconnect the battery (see page

99).


41).

4. Open the junction box cover.

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

6. Install a new fuse by tightening two

5 mm screws.

7. After finishing replacement, close the junction box cover.

PAWLS

SPARE FUSE

(150 A)

<Replacement>

A spare fuse is located in the junction box.

Push two pawls, then pull out the spare fuse.

MAINTENANCE

101


MAINTENANCE

Propeller

COTTER PIN

CASTLE NUT

THRUST WASHER

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

• 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.

102

WASHER

PROPELLER

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.

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.)

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.


Inspect After Operating

1. Stop the engine and remove the engine cover (see page 41).

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


41), and rinse the outboard motor with fresh water to remove salt water, sand, mud, etc.

MAINTENANCE

2. Change the engine oil (see page

86).

3. Remove the spark plugs (see page

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

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.

4. Put a teaspoon of engine oil into each spark plug hole to lubricate the inside of the cylinders.

Reinstall the spark plugs.

5. Install the engine cover and lock the latch securely (see page 41).

103


MAINTENANCE

6. 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).

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

104


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 44).

• Use fresh and clean gasoline.

• 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.

13. STORAGE

105


STORAGE

Vapor Separator Draining

VAPOR SEPARATOR

DRAIN TUBE CLIP



CHILDREN.




DRAIN BOLT

1. Unhook the drain tube from the clip on the lower left of the head cover.

2. Set the end of the tube toward the outside of the engine undercase.

3. Loosen the vapor separator drain bolt by using a commercially available flat tip screwdriver.

4. Tilt up the outboard motor.

5. Tilt down the outboard motor, and drain the vapor separator.

6. After draining thoroughly, tighten the drain bolt securely.

7. Clip the drain tube on the head cover.

106


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.

Batteries produce explosive gases:

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






ANTIDOTE





CHILDREN.

( – ) TERMINAL

(+) TERMINAL

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.

107


STORAGE

UPPER LEVEL Outboard Motor Position

BATTERY

CAP

LOWER LEVEL

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.

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.

108


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.

14. DISPOSAL

109


15. TROUBLESHOOTING

WARNING SYSTEM COMES ON

SYMPTOM POSSIBLE CAUSE REMEDY

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.

• Faulty water pump.

• Thermostat clogged.

• Faulty thermostat.

• Cooling water passage clogged.

• Exhaust gas invades cooling system.

Clean the cooling water intake port.

Spark plugs have improper heat range.

Replace the spark plugs (see page 88).

Consult with your outboard motor dealer.

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.

Shortage of engine oil

Improper engine oil is used.

Add engine oil to the specified level

(see page 43).

Change the engine oil

(see page 86).

110


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.

TROUBLESHOOTING

REMEDY

Drain the water separator

(see page 95).

Check the fuel tank and fuel line for water accumulation. If the buzzer sounds again, consult with your outboard motor dealer.


Check the battery (see page 98).


111


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

LU

1,670 mm

(65.7 in)

508 mm

(20.0 in)

BAEJ

BFT200A

XD

XU

920 mm

(36.2 in)

625 mm

(24.6 in)

1,797 mm

(70.7 in)

265 kg

(584 lbs)

270 kg

(595 lbs)

147.1 kW (200 PS)

5,000 – 6,000 min -1 (rpm)

4 stroke OHC 6-cylinder (V6)

3,471 cm 3 (211.7 cu-in)

1.0 – 1.3 mm (0.039 – 0.051 in)

273 kg

(602 lbs)

Motor-mounted

Electric starter

Full transistor battery

BAFJ

XCU

635 mm (25.0 in)

Lubrication system

Specified oil

Oil capacity

D.C. output

Cooling system

Exhaust system

Spark plug

Fuel pump

Fuel

Gear shift

Steering angle

Trim angle

Tilt up angle

Trochoid pump pressure lubrication

Engine: API standard SG, SH, SJ SAE 10W-30

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

Engine: Without oil filter replacement:

7.6 L (8.0 US qt, 6.7 Imp qt)

With oil filter replacement:

7.8 L (8.2 US qt, 6.9 Imp qt)

Gear case: 1.17 L (1.24 US qt, 1.03 Imp qt)

12 V – 60 A

Water cooling with thermostat

Water exhaust

IZFR6K-11E (NGK)

Low pressure side: mechanical type

High pressure side: electrical type

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°)

* Without battery cable, with propeller

This TOHATSU outboard is power rated in accordance with ISO8665 (propeller shaft output).

112


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

BAGJ

XD

XU

BFT225A

920 mm

(36.2 in)

625 mm

(24.6 in)

1,797 mm (70.7 in)

635 mm (25.0 in)

272 kg (600 lbs) 275 kg (606 lbs)

165.5 kW (225 PS)

5,000 – 6,000 min -1 (rpm)

4 stroke OHC 6-cylinder (V6)

3,471 cm 3 (211.7 cu-in)

1.0 – 1.3 mm (0.039 – 0.051 in)

Motor-mounted

Electric starter

Full transistor battery

BAHJ

XCU

Lubrication system

Specified oil

Oil capacity

D.C. output

Cooling system

Exhaust system

Spark plug

Fuel pump

Fuel

Gear shift

Steering angle

Trim angle

Tilt up angle

Trochoid pump pressure lubrication

Engine: API standard SG, SH, SJ SAE 10W-30

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

Engine: Without oil filter replacement:

7.6 L (8.0 US qt, 6.7 Imp qt)

With oil filter replacement:

7.8 L (8.2 US qt, 6.9 Imp qt)

Gear case: 1.17 L (1.24 US qt, 1.03 Imp qt)

12 V – 60 A

Water cooling with thermostat

Water exhaust

IZFR6K-11E (NGK)

Low pressure side: mechanical type

High pressure side: electrical type

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°)

* Without battery cable, with propeller

This TOHATSU outboard is power rated in accordance with ISO8665 (propeller shaft output).

113


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

BFT200A

R (Remote control)

79 dB (A)

1 dB (A)

–

–

Not exceed

2.5 m/s 2

–

BFT225A

R (Remote control)

79 dB (A)

1 dB (A)

–

–

Not exceed

2.5 m/s 2

–

Reference to: ICOMIA Standard: as it specifies the engine operating conditions and measurement conditions.

114


17. ‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE

115


‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE

116



117



118



119


18. INDEX

A

ACG Fuse ....................................101

ACG Indicator/Buzzer...................20

Anodes

Function.....................................27

Operation ...................................75

B

Battery

Cleaning.....................................99

Connections ...............................36

Electrolyte Level Inspection......98

Leads Inspection........................48

Storage.....................................107

Break-in Procedure........................58

C

Cleaning and Flushing...................81

Component Identification..............10

Controls and Features ....................20

Control and Feature Identification

Codes ...........................................2

Cooling Water

Check Hole ................................28

Intake Port .................................28

Cruising .........................................62

D

Disposal ...................................... 109

E

‘‘EC DECLARATION OF

CONFORMITY’’ CONTENT

OUTLINE............................... 115

Emergency Stop

Switch ....................................... 25

Switch Lanyard/Clip................. 25

Spare Switch Clip ..................... 26

Emission Control System.............. 97

Engine

Cover

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

Removal/Installation............. 41

Oil

Change.................................. 86

Level Inspection ................... 43

Refilling................................ 43

Protection System ..................... 71

ACG Warning System.......... 71

Anode ................................... 75

Oil Pressure Warning

System .............................. 71

Overheat Warning

System .............................. 71

Over-rev Limiter................... 75

PGM-FI Warning System ..... 71

Water Separator Warning

System............................... 71

Serial Number ............................. 3

Switch ....................................... 18

F

Frame Serial Number ...................... 3

Fast Idle

Button........................................ 19

Lever ......................................... 19

Fuel

Filter.......................................... 92

Inspection.............................. 93

Replacement.......................... 94

Level ......................................... 44

Line

Connection ............................ 40

Disconnection ....................... 79

Priming...................................... 50

Storage .................................... 105

Fuse Replacement ....................... 100

120


G

Gasoline Containing Alcohol ........45

Gear

Shifting ..........................59, 60, 61

I

Installation

Outboard Motor.........................34

Height ........................................33

Location.....................................33

Inspect After Operating ...............103

L

Lubrication ....................................91

M

Maintenance ..................................82

Maintenance Schedule...................84

Manual Relief Valve

Function.....................................24

Operation ...................................69

Moorage

Power Trim/Tilt Type................68

Multiple Outboard Motors.............76

N

Neutral Release Lever................... 18

NMEA Interface Coupler.............. 29

O

Oil Pressure Indicator/Buzzer....... 21

Operating Hour Notification

System ...................................... 29

Operation

Gear Shifting................. 59, 60, 61

Outboard Motor

Installation ................................ 34

Storage Position...................... 108

Outboard Motor Angle

Inspection.................................. 35

Over-rev Limiter ........................... 75

Overheat Indicator/Buzzer

Function .................................... 21

Operation .................................. 71

P

PGM-FI Indicator/Buzzer ............. 20

Power Tilt Switch

Function .................................... 23

Operation .................................. 69

Power Trim/Tilt Switch

Function .................................... 22

Operation .................................. 62

INDEX

Pre-operation Checks .................... 41

Battery....................................... 48

Engine Oil ................................. 42

Fuel ........................................... 44

Fuel Filter.................................. 47

Other Checks............................. 49

Propeller and Cotter Pin

Inspection.............................. 46

Remote Control Lever

Friction.................................. 47

Propeller

Inspection.................................. 46

Replacement............................ 102

Selection.................................... 40

Propeller Shaft

Rotating Direction....................... 2

R

Remote Control

Box

Identification................... 12, 13

Installation Location ............. 39

Cable Length............................. 39

Installation................................. 38

Lever

Function .................... 15, 16, 17

Friction Adjustment .............. 47

Types........................................... 3

121


INDEX

S

Safety

Carbon Monoxide Poisoning

Hazard .....................................7

Information..................................6

Label Locations ...........................8

Operator Responsibility...............6

Shallow Water Operation ..............75

Spare Clip, Emergency Stop

Switch........................................26

Spark Plugs....................................88

Specifications ......................112–114

Starting the Engine

R1 type ......................................50

R2, R3 types ..............................54

Stopping the Engine

Emergency.................................76

Normal Stop ..............................76

Storage.........................................105

Submerged Outboard Motor

Servicing..................................103

Switch Panel ..................................13

T

Tachometer ................................... 29

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

Tilting the Outboard Motor

Remote Control Type ............... 67

Tool Kit and Spare Parts......... 49, 83

Trailering ...................................... 80

Transom

Height ....................................... 32

Transporting.................................. 79

Trim Meter

Function .................................... 23

Operation .................................. 66

Trim Tab

Operation .................................. 27

Adjustment................................ 70

Trimming the Outboard Motor ..... 64

Troubleshooting

Warning System Comes On.... 110

V

Vapor Separator Draining ........... 106

W

Water Separator Buzzer ................ 21

Water Separator

Cleaning .................................... 95

122


MEMO

123


OWNER ’S MANUAL

BFT 200A

BFT 225A

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

Tokyo 174-0051, Japan

Tel: +813 - 3966-3117 Fax:+81-3-3966-2951 www.tohatsu.com

PRINTED IN JAPAN

Tohatsu BFT 225A Owner Manual

Assistant Bot

OWNER’S

MANUAL

Original instructions

BFT 200A

BFT 225A

BFT 200A

BFT 225A

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Table of contents

Tohatsu BFT 225A Owner Manual

Assistant Bot

OWNER’S

MANUAL

Original instructions

BFT 200A

BFT 225A

BFT 200A

BFT 225A

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TOHATSU

BFW 60A

TOHATSU

BFT225A

TOHATSU

BFT 90A

TOHATSU

BFT 90A

Table of contents