Tohatsu MX 50D3 Owner Manual

O W N E R’ S

M A N U A L

トーハツ船外機オーナーズマニュアル

Original instructions

MX 40D

3

MX 50D

3

OB No.003-11098-8BA1

ENOM00001-0

READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE INSTRUCTIONS

AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. KEEP THIS

MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.

Copyright © 20 1 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced or transmitted in any from or by any means without the express written permission of Tohatsu Corporation.

YOUR TOHATSU OUTBOARD MOTOR

ENOM00006-A

To You, Our Customer

Thank you for selecting a TOHATSU outboard motor. You are now the proud owner of an excellent outboard motor that will service you for many years to come.

This manual should be read in its entirety and the inspection and maintenance procedures described later in this manual should be followed carefully. Should a problem arise with the outboard motor, please follow the troubleshooting procedures listed at the end of this manual. If the problem persists, contact an authorized TOHATSU service shop or dealer.

Please always keep this manual together with the outboard motor as a reference to everyone who uses the outboard motor. If the outboard motor is resold, make sure the manual is passed on to the next owner.

We hope you will enjoy your outboard motor and wish you good luck in your boating adventures.

TOHATSU CORPORATION

ENOM00003-0

PRE-DELIVERY CHECK

Be sure that the product has been checked by an authorized TOHATSU dealer before you take delivery.

3

4

ENOM00005-A

Serial Number

In the space below, please record the outboard motor's serial number. The serial number will be needed when ordering parts, and when making technical or warranty inquiries.

Serial Number:

ENOF01300-1

Serial Number: Date of purchase:

ENOM00007-0

NOTICE: DANGER/WARNING/CAUTION/Note

Before installing, operating or otherwise handling your outboard motor, be sure to thoroughly read and understand this Owner's Manual and carefully follow all of the instructions. Of particular importance is information preceded by the words “DANGER,”

“WARNING,” “CAUTION,” and “Note.” Always pay special attention to such information to ensure safe operation of the outboard motor at all times.

ENOW00001-0

DANGER

Failure to observe will result in severe personal injury or death, and possibly property damage.

ENOW00002-0

WARNING

Failure to observe could result in severe personal injury or death, or property damage.

ENOW00003-0

CAUTION

Failure to observe could result in personal injury or property damage.

ENON00001-0

Note

This instruction provides special information to facilitate the use or maintenance of the outboard motor or to clarify important points.

5

CONTENTS

1. GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3. PARTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4. LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. Battery installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5. Warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

6. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9. Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . . . . . . 43

1. Removing the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

9. ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

10. INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6. Cold weather precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

7. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

8. Operation with multiple outboard motors . . . . . . . . . . . . . . . . . . . . . . . . 65

11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

12. TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

INDEX

9

1. GENERAL SAFETY INFORMATION

2. SPECIFICATIONS

3. PARTS NAME

4. LABEL LOCATIONS

5. INSTALLATION

6. PRE-OPERATING PREPARATIONS

7. ENGINE OPERATION

8. REMOVING AND CARRYING THE OUTBOARD

MOTOR

9. ADJUSTMENT

10. INSPECTION AND MAINTENANCE

11. TROUBLESHOOTING

12. TOOL KIT AND SPARE PARTS

13. PROPELLER TABLE

13

1

1

10

11

8

9

12

4

5

6

7

1

2

3

1

10

GENERAL SAFETY INFORMATION

ENOM00009-0

SAFE OPERATION OF BOAT

As the operator/driver of the boat, you are responsible for the safety of those aboard and those in other boat around yours, and for following local boating regulations. You should be thoroughly knowledgeable on how to correctly operate the boat, outboard motor, and accessories. To learn about the correct operation and maintenance of the outboard motor, please read through this manual carefully.

It is very difficult for a person standing or floating in the water to take evasive action should he or she see a power boat heading in his/her direction, even at a slow speed.

Therefore, when your boat is in the immediate vicinity of people in the water, the outboard motor should be shifted to neutral and shut off.

ENOW00005-0

WARNING

SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOVING BOAT,

GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TO A BOAT OR GEAR

HOUSING.

ENOM00247-0

STOP SWITCH LANYARD

The engine can be stopped with pulling out the stop switch lock from the stop switch.

The stop switch lanyard is the coiled red cord with the stop switch lock on one end and a metal clip on the other end. With attaching the stop switch lanyard to the operator's body part or operator’s personal flotation device (PFD), the engine will stop when the stop switch lanyard is being stretched and pulled out the lock from the switch when the operator falls accidentally overboard or leaves from operator’s position. This function can be prevent losing control of and minimize or prevent risk of collision with boats, people and other objects. It is operator’s responsibility to use the stop switch lanyard.

ENOW00004-1

WARNING

Accidental activation of the Stop Switch (such as the tether being pulled out in heavy seas) could cause passengers to lose their balance and even fall overboard, or it could result in loss of power in heavy seas, strong currents, or high winds. Loss of control while mooring is another potential hazard.

To minimize accidental activation of the Stop Switch, the 500 mm (20 inch.) stop switch lanyard is coiled and can extended to a full 1300 mm (51 inch.).

ENOM00800-A

PERSONAL FLOTATION DEVICE

As the operator/driver and passenger of the boat, you are responsible to wear a PFD

(Personal Flotation Device) while on the boat.

GENERAL SAFETY INFORMATION

11

ENOM00010-0

SERVICING, REPLACEMENT PARTS & LUBRICANTS

We recommend that only an authorized service shop perform service or maintenance on this outboard motor. Be sure to use genuine parts, genuine lubricants, or recommended lubricants.

1

ENOM00011-A

MAINTENANCE

As the owner of this outboard motor, you should be acquainted with correct maintenance procedures following maintenance section of this manual (See page 48). It is the operator's responsibility to perform all safety checks and to ensure that all lubrication and maintenance instructions are complied with for safe operation. Please comply with all instructions concerning lubrication and maintenance. You should take the engine to an authorized dealer or service shop for periodic inspection at the prescribed intervals.

Correct periodic maintenance and proper care of this outboard motor will reduce the chance of problems and limit overall operating expenses.

Carbon Monoxide Poisoning Hazard

Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal if inhaled for any length of time.

Never start or operate the engine indoors or in any space which is not well ventilated.

Gasoline

Gasoline and its vapors are very flammable and can be explosive. Use extreme care when handling gasoline. You should be thoroughly knowledgeable on how to correctly handle gasoline by reading this manual.

12

SPECIFICATIONS

ENOM00810-B

MODEL FEATURE

2

Model

Type

Transom heights

Tiller Handle

Remote Control

Multi-function tiller handle

Power Tilt

Gas-assisted tilt

Manual tilt

*1: Option

S

L

ENOM00811-B

MODEL NAME EXAMPLE

MX50D3MFL

MF z z z

( z )*1

MX40D3

EF z z

( z )*1 z z

MF z z z

( z )*1

MX50D3

EF z z

( z )*1 z z

MX

Model description

M(X)= Two stroke

50

Horse power

D

Product generation

A and up

3

Minor change

2 and up

M

Starter system

E= Electrical start

M= Manual start

F

Steering system

F=Tiller handle

(Fisher)

L

Shaft length

S= Short 15 in

L= Long 20 in

UL= Ultra long

25 in

SPECIFICATIONS

13

ENOM01600-0

X40D3/50D3 MF, EF

Item

Overall Length

Overall Width

Overall Height

Transom Height

Weight

Output

Max. Operating Range

Idle Speed in Neutral Gear

Idle Speed in Forward Gear

Engine Type

Number of Cylinder

Bore x Stroke

Piston Displacement

Exhaust System

Cooling System

Lubrication System

Starting System

Ignition System

Spark Plugs

Alternator

Trim Position

Fuel

Fuel Tank Capacity

Engine Oil

Fuel: Engine Oil mixing ratio

Gear Oil*

Gear Shift

Gear Reduction Ratio mm (in) cm

3

(Cu in)

L (US gal) mL (fl.oz.)

MODEL mm (in) mm (in)

S mm (in)

L mm (in)

S mm (in)

L mm (in)

S kg (lb)

L kg (lb) kW (ps) min

-1

(rpm) min

-1

(rpm) min

-1

(rpm)

X40D3/X50D3 MF X40D3/X50D3 EF

1143 (45.0)

384 (15.1)

1225 (48.2) -

1352 (53.2)

403 (15.9) -

530 (20.9)

72 (159) -

73.5 (162) 78.5 (173.1)

MX40D3: 29.4 (40) MX50D3: 37 (50)

5000-5800

900

750

2-Stroke

3

68 x 64 (2.68 x 2.52)

697 (42.53)

Through hub exhaust

Forced water cooling

Engine oil mixed gasoline

Manual Manual & Electric

Flywheel Magneto C.D. Ignition

NGK B8HS-10

12V-130W

6

Unleaded regular gasoline pump posted 87 Octane (research octane rating of 91)

25 (6.6)

Genuine motor oil or recommended one (TCW-III)

Fuel:Oil Mixing Ratio 50 : 1

Genuine Gear Oil or API GL5,SAE #80 - #90, Approx 500 (16.9)

Dog clutch (F-N-R)

2.08 (27 : 13)

Remark: Specifications subject to change without notice.

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

2

3

14

PARTS NAME

ENOM01653-0

X40D3MF/X50D3MF, EF

1

2

3

4

5

6

7

8

9

19

18

12

15

14

13

22

11

10

16

20

21

17

5

24 25

23

1 Tilt Handle

2 Top Cowl

3 Hook Lever

4 Water Check Port

5 Reverse Lock Lever

6 Water Plug

7 Anti-ventilation Plate

8 Trim Tab

9 Propeller

10 Oil Plug (lower)

11 Water Strainer

12 Oil Plug (upper)

13 Clamp Bracket

14 Thrust Rod

15 Clamp Screw

16 Throttle Grip

17 Throttle Friction Screw

18 Shift Lever

19 Starter Handle

20 Stop Switch

21 Choke Knob

22 Anode

23 Main switch

24 Fuel Filter

25 Spark Plug

ENOF1902-D1

ENOM00822-0

Fuel tank

1

2

3

1 Fuel Gauge

2 Air Vent Screw

3 Fuel Tank Cap

4 Fuel Connector (Engine side)

5 Primer Bulb

6 Fuel Connector (Fuel tank side)

6

5

4

ENOF00127-G1

PARTS NAME

15

3

4

16

LABEL LOCATIONS

ENOM01659-0

Warning label locations

1, 2

3, 4

5

6

7

8

ENOF01955-5A

1, 3. Read owner's manual.

LABEL LOCATIONS

17

5.

Warning regarding gasoline (See page 24).

3F0X72185-0

2.

Engine stop switch. (See page 37).

ENOF00131-B

4.

HOT SURFACE

Can cause burns.

Do not touch when operating or immediately after stop the engine.

ELECTRICAL SHOCK HAZARD

High voltage can cause severe electrical shock.

Do not touch electrical components such as ignition coil or spark plug cord wh e n st ar ting or o p e r a ting th e engine.

HAZARD CAUSED BY ROTATING PARTS

Rotating parts can cause severe injury.

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury.

ENOF00005-E

6.


4

ENOF00005-L

314X72185-0

18

LABEL LOCATIONS

7.


4

ENOF00005-M

8.


ENOF00005-F

LABEL LOCATIONS

19

ENOM01001-0

Serial number label locations

O u t b o a r d M o t o r

R a t e d P o w e r :

M a s s :

S e r i a l N o .

M a d e i n J a p a n

1)

2)

3)

4)

5)

6)

1. Model code (Model name)

2. Rated power

3. Dry mass weight

4. Serial No.

5. Manufacture name

6. Manufacture address

Description of serial number year code

Last two digits of alphabet represent production year as below.

Year Code

Year of manufacture

BA

2021

BB

2022

BC

2023

BD

2024

ENOF01904-A

BE

2025

4

5

20

INSTALLATION

ENOM00024-A

1. Mounting the outboard motor on boat

ENOW00006-B

WARNING

Before installing the outboard motor on the boat, hang the outboard motor with the hoist or equivalent device by attaching the engine hanger to the outboard. Use the hoist with allowable load is 250 kg (550 lbs) or above.

ENOW00009$

WARNING z Mounting the outboard motor without following this manual can lead to unsafe conditions such as poor maneuverability, lack of control or fire.

z Loose clamp screws and/or mounting bolts can lead to the release or displacement of the outboard motor, possibly resulting in lost of control and/or serious personal injury. Be sure that fasteners are tightened to the specified torque (30 Nm

(3.0 kgf) 13 ft-lb). Check the fasteners for tightness from time to time.

z Be sure to use outboard mounting fasteners included in the outboard motor package or their equivalents in terms of size, material, quality and strength

Outboard motor mounting must be performed by trained service person(s) using lift or hoist with sufficient capacity.

ENOM00025-C

Position ... Above keel line

 Single-engine Installation

Place the outboard motor in the center of the boat's transom.

1

ENOF01313-0

ENOW00006-0

WARNING

Most boats are rated and certified in terms of their maximum allowable horsepower, as shown on the boat’s certification plate. Do not equip your boat with an outboard motor that exceeds this limit. If in doubt, contact your dealer.

Do not operate the outboard motor until it has been securely mounted on the boat in accordance with the instructions below.

1. Center of boat

2. Boat transom

2

ENOF01141-0

INSTALLATION

21

ENOM01201-0

 Twin-engine Installation

When installing two outboard engines, be sure to keep an interval of approximately

470-660 mm (18.5-26 in) between the two.

1

ENOF01823-0

1. Approx 580 mm (22.8 in)

ENOM00026-0

Transom matching

Be sure that the anti ventilation plate of the outboard motor is 10-30mm (0.4-

1.2in.) below the bottom of hull.

If the above condition cannot be met due to the shape of the bottom of your boat, please consult your authorized dealer.

1

10−30 mm

(0.4−1.2 in)

2

ENOF01344-0

1. Bottom of hull

2. Anti ventilation plate

ENOW00007-0

CAUTION z Before beginning the running test, check that the boat with maximum capacity loading floats on the water in a proper attitude. Check the position of water surface on the driveshaft housing. If the water surface is near the bottom cowling, in high waves, water may enter the engine cylinders.

z Incorrect outboard motor mounting h e i g h t o r e x i s t e n c e o f un d e r wa t e r object(s), such as hull bottom design, bottom surface conditions or underwater accessories, can cause water spray possibly reaching the engine through an opening of the bottom cowling during cruising.

Exposing the engine to such conditions for extended periods can lead to severe engine damage.

ENOM00832-0

Mounting the outboard motor

1. Set the outboard motor to appropriate position.

2. Tighten the clamp screws by turning their handles.

3. Secure the clamp brackets to the transom board using bolts, flat washers and nylon locking nuts.

4. Secure the outboard motor to the boat with a rope to prevent accidental loss of the outboard motor overboard.

ENON00930-1

Note z Do not use tools to tighten clamp screws. Over tightening could result in damage to the clamp screws and clamp brackets.

z Do not reuse nylon locking nut.

ENON00002-0

Note

A rope is not included in the standard accessories.

5

22

INSTALLATION

5

ENON00003-B

Notes

Apply sealing agent, such as silicone sealed between the bolts and the transom board holes before tightening the bolts.

1

2

4

1. Clamp Screw

2. Washer (small diameter)

3. Washer (large diameter)

4. Bolt (12 mm × length 105 mm)

5. Nylon locking nut

3

5

ENOF00610-0

234 (9.21”)

117 (4.61”) 117 (4.61”)

1

25 (0.98”)

25 (0.98”)

39 (1.54”)

64 (2.52”)

89 (3.50”)

ø13

204 (8.03”)

102 (4.02”) 102 (4.02”)

ø13

222 (8.74”)

26 (1.02”) 248 (9.76”)

ENOF00611-0

1. Top of transom

ENOW00008-A

CAUTION z Upper mounting bolts should be installed with the bolt head at inside surface of the transom. Mounting bolts installed with the threaded end at the inside surface of the transom can cause personal injury.

z Tighten the bolts sufficiency, otherwise falling down of outboard could be happened.

ENOM00029-A

2. Battery installation

ENOW00012-0

WARNING

Battery electrolyte contains sulfuric acid and thus is hazardous, causing a burn if it comes in contact with your skin, or poisonous if swallowed.

Keep batter y and electroly te away from reach of children

When handling the battery, be sure to: z Read all warnings shown on the battery case z Prevent electrolyte from coming in contact with any part of your body. Contact can cause serious burn or, if it comes in contact with your eye, loss of sight. Use safety glasses and rubber gloves.

In case battery electrolyte comes in contact with: z Skin, flush thoroughly with water.

z Eye, flush thoroughly with water, and then seek immediate medical treatment.

In case battery electrolyte is swallowed: z Seek immediate medical treatment.

ENOW00013-A

WARNING

Battery generates explosive hydrogen gas.

Be sure to: z Charge the battery in a well-ventilated place.

z Place the battery away from any source of fire, sparks and open flames such as burners or welding equipment.

INSTALLATION

23 z Do not smoke near the battery when the battery is charging.

z Do not charge the battery when the electrolyte level is low. Otherwise, the batter y will be damage d and may cause malfunction.

ENOW00014-0

CAUTION z Make sure that the battery leads do not get stuck between the outboard motor and boat when turning, etc.

z The starter motor may fail to operate if the leads are incorrectly connected.

z Be sure to correctly connect the (+) and

(—) leads. If not, the charging system will be damaged.

z Do not disconnect the battery leads from battery while the engine is operating, the electrical parts could be damaged.

z Always use a fully charged battery.

ENOW00015-0

CAUTION

Do not use a batter y that is not recommended. Use of a battery not recommended can lead to poor performance of, and/or damage to, the electrical system.

ENON00006-D

Note

Minimum battery requirements: 12v 64Ah/

5HR, 12v 70Ah/20HR, 512 Cold Cranking

Amps (CCA).

Larger capacity battery is required when it is using freezing condition.

Recommend connecting only the engine batter y cables to the star ting batter y.

Specifications and features of batteries vary among the manufacturers. Consult the manufacturer for details.

* The battery should be purchased separately and is not supplied with the outboard motor.

1. Place the battery box in a convenient position away from possible water spray. Securely fasten both the box and the battery so they do not shake loose.

2. Connect the positive lead (+) to the positive terminal (+) of the battery, and then connect the negative lead

(—). When disconnecting the battery always remove the negative lead (—) first. After connecting the positive terminal (+), securely place a cap on it to prevent short circuits.

1. Battery cord (red)

2. Battery cord (black)

1

2

ENOF00022-1

5

6

24

PRE-OPERATING PREPARATIONS

ENOM00030-A

1. Fuel handling

ENOW000017-0

CAUTION

Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage cause d thereby will not be covered under the limited warranty.

Some of these a dverse effe c ts are caused because the ethanol in the gasoline can absorb moisture from the air, resulting in a separation of the water/ ethanol from the gasoline in the fuel tank.

These may cause increased: z Corrosion of metal parts z Deterioration of rubber or plastic parts z Fuel permeation through rubber fuel lines z Starting and operating difficulties

ENOM00031-A

FUEL RATING

TOHATSU engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications:

USA and Canada — having a posted pump

Octane Rating of 87 (R+M)/2 minimum.

Premium gasoline (92 [R+M]/2 Octane) is also acceptable. Do not use leaded gasoline.

O u t s i d e U S A a n d C a n a d a — U s e unleaded gasoline with declared octane rating of 91 RON or over. Use of premium gasoline of 98 RON is also allowed.

ENOM00032-A

GASOLINES CONTAINING

ALCOHOL

The fuel system components on your

TOHATSU engine will withstand up to 10% ethyl alcohol (hererinafter referred to as the "ethanol"), content in the gasoline.

But if the gasoline in your area contains ethanol, you should be aware of certain adverse effects that can occur. Increasing the percentage of ethanol in the fuel can also worsen these adverse effects.

If the use of gasoline containing alcohol is inevitable, or presence of alcohol is suspected in the gasoline, it is recommended to add a filter that has water separating capability, and check the fuel system for leaks and mechanical parts for corrosion and abnormal wear more frequently.

And, in case any of such abnormality is found, discontinue the use of such gasoline and contact our dealer immediately.

If the outboard motor will only be used infrequently, please see the remarks on fuel deterioration in the STORAGE chapter (P 61) for additional information.

ENOW00020-0

CAUTION

When operating a TOHATSU engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars, alcohol blend fuels normally are consumed before they can absorb enough moisture to cause trouble, but boats often sit idle long enough for phase separation to take place.

In addition, internal corrosion may take place during storage if alcohol has washed

PRE-OPERATING PREPARATIONS

25 protective oil films from internal components.

ENOW00018-0

WARNING

Fuel leakage can cause fire or explosion, potentially leading to severe injury or loss of li fe. Eve r y fue l syste m p ar t sh oul d b e checked periodically, and especially after long term storage, for fuel leak, change of hardness of rubber, expansion and/or corrosion of metals. In case any indication of fuel leakage or degradation of fuel part is found, replace relevant part immediately before continuing operation.

ENOM00043-B

2. Fuel filling

ENOW00019-0

WARNING

Do not fill the fuel tank over capacity. The rise of gasoline temperature may cause gasoline to expand which, if overfilled, may leak through air vent screw when it is open. Leaking gasoline is a dangerous fire hazard.

ENOW00028-A

WARNING

Consult an authorized dealer for details on handling gasoline, if necessary.

Gasoline and its vapors are very flammable and can be explosive.

When carrying a fuel tank containing gasoline: z Close the fuel tank cap and air vent screw of fuel tank cap, or gasoline vapor will be emitted through the air vent screw, creating a fire hazard.

z Do not smoke.

When or before refueling: z Be sure to remove the static electricity charged in your body before refueling.

z The sparks due to static electricity may cause explosion of flammable gasoline.

z Stop the engine, and do not start the engine during refueling.

z Do not smoke.

z Be careful not to overfill fuel tank. Wipe up any spilled gasoline immediately.

When or before cleaning the gasoline tank: z Dismount fuel tank from the boat.

z Place the fuel tank away from every source of ignition, such as sparks or open flames.

z Do the work outdoors or in a well ventilated area.

z Wipe off gasoline well immediately if spilled.

After cleaning gasoline tank: z Wipe off gasoline well immediately if spilled.

z If the fuel tank is disassembled for cleaning, reassemble carefully. Imper fe c t assembly may cause a fuel leak, possibly leading to fire or explosion.

z Dispose aged or contaminated gasoline in accordance with local regulations.

ENOW00029-A

WARNING

When opening fuel tank cap, be sure to follow the procedure described below. Fuel could blast out through the fuel tank cap in case the cap is loosened by using another procedure when internal pressure of fuel tank is raised by heat from sources such as sun light.

6

26


6

1. Full open the air vent screw on the fuel tank cap and release internal pressure.

1

2

ENOF00027-B

1. Air vent screw

2. Fuel tank cap

2. Open the fuel tank cap slowly.

3. Fill the fuel carefully not to over flow.

SAFE FILL

LEVEL

25 L

NIVEAU

MAXIMUM

ENOF00030-A

4. After filling the tank, close the fuel tank cap.

ENOM01660-0

3. Engine oil recommendation

ENOW0002A-A

CAUTION

Use of engine oils that do not meet these requirements will result in reduced engine life, and other engine problems.

ENOW00603-0

CAUTION

Do not mix different brands of oil. Mixing different brands of oil, or different types of oil even if the brand is the same, may cause gelling, resulting in possible filter screen blockage. This could result in serious engine damage because of impaired lubrication performance.

Use a genuine engine oil or recommended one (TCW3). Refer to your Distributor.

Will not recommend use of other two stroke engine oil.

Pre-mixing type

Add engine oil into fuel oil tank. The mixing ratio with gasoline is 50 : 1 (50 parts gasoline and one part oil). Mix well by hand. The mixing ratio during break-in running is 25 : 1.

Mixing Ratio

During break-in

After break-in

Engine Oil : Gasoline

25 : 1

50 : 1

Oil

1.0L

Fuel by Oil Mixing (25:1, 50:1)

25 : 1

(25:1)

0.5L

0.4L

0.2L

0

2L

(10 : 0.4)

(10 : 0.2)

10L

Gasoline

50 : 1

(25:0.5)

25L 30L

ENOF01708-0


27

ENOM01003-0

Engine oil – gasoline mixing procedure

ENOW00937-0

CAUTION z Do not use other than two stroke engine oil with specified grade, or the engine may be damaged.

z Do not use fuel prepared in other than specified mixing ratio.

- Lack of engine oil can cause severe engine trouble such as piston seizure.

- Excess of engine oil can shorten spark plug life, and/or cause increase of noxious exhaust.

For quantities of engine oil and gasoline to be pre-mixed, refer to table in previous page.

 When portable fuel tank is used for operation of outboard motor(s):

1 Pour engine oil into fuel tank, and then, gasoline.

2 Put cap on the tank, and close tightly.

3 Close air vent plug tightly.

ENOW00938-0

WARNING

Loose cap or air vent plug can cause leak of fuel during shaking the tank.

4 Shake the tank to mix engine oil and gasoline well and even.

 When fuel tank built in the boat is used for operation of outboard motor(s):

1 Prepare separate fuel container for pre-mixing.

ENOF01709-0

2 Pour engine oil into fuel container, and then, gasoline.

3 Put cap on the container, and close tightly.

4 Shake the container to mix engine oil and gasoline well and even.

5 Pour the mixture into fuel tank.

ENON00922-0-0

Notes z It is recommended to pre-mix by using separate fuel container. Attempting to pre-mix in the fuel tank built-in the boat can make the mixture uneven.

z If built-in fuel tank is used for mixing, pour engine oil into the tank little by little while putting gasoline into the tank.

6

28


6

]ENOM00033%

4. Break-In

Your new outboard motor and lower unit require break-in for the moving compon e nts a c c ording to the c on ditions described in the following time table.

ENOW00024-A

WARNING

Do not operate the outboard motor in closed area or area with no forced ventilation.

Exhaust gas emitted by this outboard motor contains carbon monoxide that will cause death if inhaled continuously. Inhaling the gas initially causes symptoms such as feeling of sickness, drowsiness and headache.

During operation of the outboard motor: z Keep peripheral area well ventilated.

z Always attempt to stay on the windward side of emission.

ENOW00023-1

CAUTION

Operating the outboard motor without break-in can shorten life of the product.

If any abnormality is experienced during the break-in: z Discontinue the operation immediately.

z Have the dealer check the product and take proper action(s) if necessary.

ENOM01004-0

Fuel mixing ratio for break-in

Gasoline 25: Genuine Engine Oil 1

25:1 when using genuine engine oil or the recommended one (TCW3).

ENON00008-1

Note z Run at varied speed less than specified engine speed during the break-in periods.

z Break-in must be conduct under load in the water with propeller installed and in-gear.

Throttle Position

Speed

1–10 min

Idle

10 min – 2 hrs

Less than 1/2 throttle

Approx. 3000 min

-1

(rpm) max

2–3 hrs

Less than 3/4 throttle

3–10 hrs

3/4 throttle

Full throttle run allowed for 1 min every 10 min

Approx. 4000 min

-1

(rpm). Full throttle run allowed for 2 min every 10 min

After 10 hrs

Full throttle available


29

ENOM00039%

5. Warning system

If outboard motor encounters an abnormal condition of fault engine speed will be limited (engine will not be stopped).

ENOM00041)

Warning indicators, faults and remedy

Warning indicators

Low speed

ESG

High speed

ESG

Description of faults

-

ON

ON

-

Engine speed exceeds maximum allowable min

-1

(rpm)

Over heating

Remedy

1

High speed ESG (Electronic Safety Governor)

High speed ESG is a device to prevent over revolution of the engine. If the load to the engine becomes light for some reason, it runs at a higher speed than the usual. In such the case, the buzzer sounds and the ESG is activated not to ignite the spark plug, therefore, the engine speed varies and be controlled under 6300 min

-1

(rpm).

Low speed ESG

Low speed ESG is a device to prevent the engine from getting damage. If the engine has problems regarding engine temperature, the low speed ESG is activated not to ignite the spark plug. Therefore, the engine speed varies and be controlled under 3500 min

-1

(rpm).

Remedy

1.

Reduce the throttle to less than half opening, and move to safe place quickly, and stop the engine.

Check the propeller for bent or damaged blades.

Consult an authorized dealer if engine shows the same result even after replacing propeller with new one.

2.

Move to safe place quickly, and check the discharge of cooling water from the water check port at idle speed and stop engine.

Remove any foreign matter on the gear case and propeller if necessary.

Consult an authorized dealer if no discharge of cooling water.

6

30

ENGINE OPERATION

ENOM00042-0

Before starting

ENOW00022-B

CAUTION

Be sure to mix the engine oil with gasoline

(Follow the instruction. See page 27)

1. Full open the air vent screw on the fuel tank cap.

1

2

7

ENOF01710-0

ENOW00027-C

CAUTION

Before starting engine for the first time after reassembling engine or off-season storage, disconne c t stop switch lock and crank approximately 10 times in order to circulate the engine oil.

ENOM00044-E

1. Fuel feeding

ENOW00029-A

WARNING

When opening fuel tank cap, be sure to follow the procedure described below. Fuel could blast out through the fuel tank cap in case the cap is loosened by using another procedure when internal pressure of fuel tank is raised by heat from sources such as sun light.

ENOF00027-B

1. Air vent screw

2. Fuel tank cap

2. Open the fuel tank cap slowly and release internal pressure completely.

After that, close the fuel tank.

3. Connect the fuel connector to the engine and fuel tank.

1

1. Fuel connector

2. Pull

3. Insert

1. Pull

2. Insert

1

2

2

3

ENOF01905-0

ENOF00861-A

ENGINE OPERATION

31

4. Squeeze primer bulb until it becomes stiff to feed fuel to carburetor. Direct arrow mark upward when priming.

1

And be sure to remove the propeller, when star ting the engine in the test tank. (See page 56)

3

1

2

ENOF00862-0

1. Engine side

2. Fuel tank side

Do not squeeze primer bulb with engine running or when the outboard motor is tilted up. Otherwise, fuel could overflow.

ENOM00045-A

2. Starting the engine

ENOW00958-0

WARNING z Do not remove or install the top cowl after the engine has been started. z The exposed rotating engine parts or moving parts cause serious injury.

ENOW00959-0

CAUTION

The top cowl must be installed while the engine running except in an emergency. If the top cowl is not installed correctly, water splash can damage the engine.

ENOW00036-A

CAUTION

When the engine is started in the test tank, to avoid over heating and water pump damage, be sure the water level is at least 10 cm

(4 in.) above the anti ventilation plate.

Run the engine only at idling.

2

ENOF00863-0

1. Test tank

2. Water

3. Over 10 cm (4 in.)

ENOW00036-0

CAUTION

Be sure to stop engine immediately if cooling water check port is not discharging water, and check if cooling water intake is blocked.

Operating engine could lead to overheating potentially leading to engine damage. Consult an authorized dealer if the cause cannot be found.

ENOW00032-A

CAUTION

Do not keep turning starter motor for over 5 seconds, or the battery may be consumed, potenti ally making the engine st ar ting impossible and/or damaging the starter.

If cranking over 5 seconds fails to star t engine, return main switch to “ON”, and crank engine again after 10 seconds or more.

Do not try to crank after engine has started.

This model is provided with start in gear protection.

7

32


ENON00010-0

Note

Start-in-gear protection prevents engine from starting at other than neutral shift.

In-gear starting of engine will move the boat immediately, potentially leading to falling down or causing passenger(s) to be thrown overboard.

ENOM01662-0

Tiller handle type

1. Be sure to install the stop switch lock to the stop switch, and attach the stop switch lanyard securely to the operator or to the operator's PFD

(Personal Flotation Device.)

1

3. Set the throttle grip to START position.

3

4

2

1

1. Throttle grip

2. START position

3. Full closed

4. Full opened

4. Pull the choke knob fully.

ENOF01908-1

7

2

ENOF01906-0

1. Stop switch lock

2. Stop switch

2. Set the control lever in the Neutral position.

1

1. Choke knob

1

2

ENOF01907-0

ENOF01909-0

ENON00501-0

Note

Choke is not necessary when the engine is warm. Set the throttle grip to “START” position.

ENON00502-0

Note

If engine does not start with 4 or 5 times starting operation, push the knob back and restart.

1. Shift lever

2. Neutral


33

(For manual starter type)

4. Pull the starter handle slowly until you feel engagement, keep pulling till you feel less resistance. Then pull it quickly. repeat if necessar y until started.

1 2

6. Check the cooling water from coolingwater check port.

3

ENOF00519-0

1. Slowly

2. Quickly

3. Starter handle

(For electrical starter type)

4. Push the starter switch button and release the button when the engine has started.

ENOF01910-0

5. Return the choke knob fully after engine has started.

2

1

ENOF01911-0

1. Cooling water check port

2. Idle port

ENOM00042-A

Emergency starting

ENOW00099-A

WARNING

When the emergency starter rope is used for starting engine; z Start in gear protection does not work. Be sure to shift is at neutral position. Otherwise the engine will move the boat immediately and cause personal injury. z Be careful that your clothes or other items do not get caught in the rotating engine parts.

z To prevent accident and injury by rotating parts, do not re-attach flywheel cover and the top cowl after the engine has been started.

z Do not pull starter rope if any bystander is b e h i n d . T h e a c t i o n c a n i n j u r e t h e bystander.

z Attach engine stop switch lanyard to clothing or any par t of body like arm before starting engine.

1. Remove the top cowl.

7

34


ENOF01345-0

2. Remove starter lock cable from recoil starter by loosing starter cable lock screw.

ENOF01961-0

5. Tie a loop in the another end of the emergency starter rope and attach socket wrench that is included in the tool kit.

7

ENOF01959-0

3. Remove the bolts (3pcs) and remove the recoil starter.

ENOF01960-0

4. Insert the knotted end of the starter rope into the notch in the flywheel and wind the rope around the flywheel several turns clockwise.

ENOF01915-0

ENOW00860-0

CAUTION

Be sure to keep the harness away from the rotation parts.

6. Be sure to install the stop switch lock to the stop switch, and attach the stop switch lanyard securely to the operator or to the operator's PFD

(Personal Flotation Device.)

7. Set the control lever in the Neutral position.

8. Pull the starter handle slowly until you feel engagement, keep pulling till you feel less resistance. Then pull it quickly.


35

9. After engine starts, do not reinstall recoil starter and top cowl.

ENOM0004B-0

3. Warming up the engine

ENOW00932-0

CAUTION

Be sure to check that cooling water is coming out of the cooling water check por t during warm up.

Warm the engine at low engine speeds for about

3 minutes : above 5°C (41°F)

5 minutes at 2000 min

-1

(rpm) :

above 5°C (41°F)

This allows the lubricating oil to circulate to all parts of the engine. Operating the engine without warm up shortens the engine's life.

2

1

ENOF01911-0

1. Cooling water check port

2. Idle port

ENOM00044-A

Engine speeds

Idling speed after warming up.

Clutch in (In gear)

750 min

-1

(rpm)

Clutch off (Out of gear)

900 min

-1

(rpm)

ENOM00046-A

4. Forward, reverse, and acceleration

ENOW00037-0

WARNING

Before shifting into forward or reverse, make sure that boat is properly moored and outboard motor can be steered fully to the right and left. Make sure that no swimmer(s) is ahead or astern of the boat.

ENOW00038-A

WARNING z Attach other end of emergency stop switch lanyard to the operator's PFD (Personal Flotation device) or arm and keep it attached during cruising.

z Do not attach the tether to a part of clothing that can be torn easily when pulled. z Arrange the tether so that will not be caught by any object when pulled.

z Be careful not to pull the tether accidentally during cruising. Unintentional stop of engine can cause loss of control of outboard motor. Rapid loss of engine power can lead to falling down or causing passenger(s) to be thrown overboard.

ENOW00042-0

WARNING z Do not shift into Reverse during planing, or control will be lost leading to serious personal injury, boat may swamp, and/or hull may be damaged.

z Do not shift into Reverse during cruising, or control may be lost, falling down or causing passenger(s) to be thrown overboard. Leading to serious personal injury, and ste er ing system and /or shif ting mechanism may be damaged.

7

36


7

ENOW00861-0

WARNING

Do not shift at high boat speed, or control may be lost, falling down or causing passenger(s) to be thrown overboard. Leading to serious personal injury.

ENOW00862-0

CAUTION

Gear and clutch damage may occur if shifting at high engine speed.

Engine must be in the slow idle position before shifting is attempted.

ENOW00863-0

CAUTION

Idle speed may be higher during warming up of engine. If shifted to Forward or Reverse during warming up, it may be difficult to shift back to neutral. In such case, stop engine, shift to neutral, and restart engine to warm up.

ENON00014-0

Note

Frequent shifting to forward or reverse can accelerate wear or degradation of parts. In such case, replace gear oil earlier than the period specified.

ENOW00864-0

CAUTION

Do not increase engine speed unnecessarily when the shift is in neutral and reverse, or engine damage may occur.

ENOM00890-A


ENOW00865-A

CAUTION

Do not force to shift when the throttle grip is not in the fully closed position, otherwise, steering system and/or shifting mechanism may be damaged.

ENOW00867-0

WARNING

Sudden acceleration and deceleration may cause passenger(s) to be thrown overboard or falling down.

Forward

1. Turn the throttle grip to reduce engine speed.

2. When the engine reaches trolling (or idling) speed, quickly pull the shift lever to the Forward position.

Reverse

1. Turn the throttle grip to reduce engine speed.

2. When the engine reaches trolling (or idling) speed, quickly pull the shift lever to the Reverse position.

Acceleration

ENOW00867-0

WARNING

Sudden acceleration and deceleration may cause passenger(s) to be thrown overboard or falling down.

Open throttle grip gradually.

1

3 2


37 crew(s) and or objects on the boat to be thrown forward due to inertial force.


1. Turn the throttle grip to the slow position.

3

2

4

ENOF01916-0

1. Shift lever

2. Forward

3. Reverse

3

1

1. Throttle grip

2. START position

3. Full closed

4. Full opened

ENOF01908-1

4

2

1

1. Throttle grip

2. START position

3. Full closed

4. Full opened

ENOM00049-A

5. Stopping the engine

ENOF01908-1

ENOW00868-0

WARNING

Be careful not to remove engine stop switch lanyard from engine accidentally while boat is running. Sudden stop of engine can cause loss of steering control. It can also cause loss of boat speed, possibly leading the

2. Put the shift lever in the Neutral position.

Run the engine for 2-3 minutes at idling speed for cooling down if it has been running at full speed.

3. Push the stop switch for a few seconds to stop the engine.

1

ENOF01918-0

1. Stop switch

7

38


7

ENOW00869-0

WARNING

After stopping the engine: z Close the air vent screw on the fuel tank cap.

z Disconnect the fuel connector of the engine and the fuel tank.

z Disconnect the battery cord, after each use.

Emergency engine stopping

Remove stop switch lock to stop the engine.

2

1

ENOF00891-0

ENOM00920-0

6. Steering

ENOW00870-0

WARNING

Sudden steering may cause passenger(s) to be thrown overboard or falling down.


Right turn

Move the tiller handle to the left

Left turn

Move the tiller handle to the right.

ENOF01919-0

1. Stop switch

2. Stop switch lock

ENOM00910-0

Spare emergency stop switch lock

A spare emergency stop switch lock is provided in the tool bag.

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

When an operator falls into water, be sure to use emergency stop switch lock of the spare.

Be sure to confirm the spare stop switch lock is in the tool bag before begin to operate.

ENOF00892-0

ENOM00050-0

7. Trim angle

ENOW00043-A

WARNING z Adjust the trim angle when the engine is stopped.

z Do not put hand or finger in between outboard motor body and clamp bracket when adjusting trim angle to prevent


39 injury in case the outboard motor body falls.

z Unsuitable trim position can cause loss of control of boat. When testing a trim position, run boat slow initially to see if it can be controlled safely.

ENOW00044-0

WARNING

Excessive trim up or down may lead to unstable boat operation, potentially causing the steering difficulty that leads to accident during cruising.

z Do not cruise at high speed if improper trim position is suspected. Stop the boat and readjust trim angle before continuing cruise.

z For outboard motor model with PTT switch on the bottom cowl, do not operate the switch during cruising, or control of boat may be lost.

The trim angle of the outboard motor can be adjusted to suit the transom angle of the hull, and load conditions. Choose an appropriate trim angle that will allow the anti-ventilation plate to run parallel to the water surface during operation.

ENOM00052-0

Proper trim angle

The position of the thrust rod is correct if the hull is horizontal during operation.

ENOM00053-0

Improper trim angle (bow rises too high)

Set the thrust rod lower if the bow of the boat rises above horizontal.

ENOF00052-0

ENOM00054-0

Improper trim angle (bow dips into the water)

Set the thrust rod higher if the bow of the boat is below horizontal.

ENOF00053-0

7

1

1

2

3

ENOF00674-A

1. Perpendicular to the water surface

ENOF00051-1

1. Thrust rod

2. Higher

3. Lower

40


7

Trim angle adjustment (Manual tilt type)

The transom angle adjustment

1. Stop the engine.

2. Shift into neutral position.

3. Tilt up the outboard motor.

4. Remove the thrust rod as shown picture.

1

3

2

ENOF01238-1

1. Push in

2. Rise the stopper

3. Pull out

5. Reinstall the thrust rod in the desired position securely.

6. Gentry tilt down the outboard motor.

ENOM00060-A

8. Tilt up and down

ENOW00055-0

WARNING

Do not tilt up or down outboard motor when swimmer(s) or passenger is near to prevent them from being caught between outboard motor body and clamp bracket in case the outboard motor body falls.

Be sure to tilt the outboard motor down slowly.

ENOW00056-A

WARNING

When tilting up outboard motor with fuel joint for over a few minutes, be sure to disconnect fuel hose, or fuel may leak, potentially catching fire.

ENOW00057-0

CAUTION

Do not tilt up outboard motor while engine operates, or no cooling water may be fed, leading to engine seizure due to overheating.

ENON00921-0

Note

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

ENOM00062-0

Tilt up

Push the reverse lock lever down until it stops. (This is the tilt up position.) Now, tilt the outboard motor all the way up until it is locked in place.

1

2

ENOW00048-0

WARNING

When tilting up or down, be careful not to place your hand between the swivel bracket and the stern bracket.

3

1. Reverse lock lever

2. Tilt down position

3. Tilt up position

ENOF00059-0


41

ENOF01317-0

ENOM00063-0

Tilt down

Pull the reverse lock lever upward until it stops. (This is the tilt down position.)

Now, lift up the outboard motor slightly, and then allow gravity to lower it for you.

1

2

ENOW00053-0

CAUTION

While in shallow water drive position, do not operate the outboard motor in Reverse.

Operate the outboard motor at slow speed and keep the cooling water intake submerged.

ENOW00054-0

CAUTION

Do not overtilt outboard motor when driving shallow water, or air may be sucked through water inlet and sub-water inlet, potentially leading to engine overheating.

2

1

ENOF01144-0

3 1. Water inlet

2. Sub-water inlet

ENOF00059-0



3. Tilt up position

ENOM00068-A

9. Shallow water operation

ENOW00051-0

WARNING

During shallow water operation, be careful not to place your hand between the swivel bracket and the clamp bracket. Be sure to tilt the outboard motor down slowly.

1. Shallow water running position:

Put the reverse lock lever in the tilt up position, and tilt up the outboard motor to put the outboard motor in the shallow water running position.

7

42


2

1

3

7

ENOF00059-0



3. Tilt up position

2. Return to normal running position:

Put the reverse lock lever in the tilt down position, slightly lift up the outboard motor, and then put it down.

1

2

3

ENOF00059-0



3. Tilt up position

43

REMOVING AND CARRYING THE OUTBOARD MOTOR

ENOM00070-A

1. Removing the outboard motor

ENOW00890-A

WARNING

Before removing the outboard motor on the boat, hang the outboard motor with the hoist or equivalent device by attaching the engine hanger to the outboard.

Use the hoist with allowable load is 250 kg

(550 lbs) or above.

ENOW00064-0

CAUTION

Engine may be hot immediately after operating and could cause burns if touched. Allow engine to cool down before attempting to carry the outboard.

1. Stop the engine.


3. Disconnect the fuel connector, the remote control cables and the battery cords from the outboard motor.

4. Attach the hoist hooks to the engine hanger.

5. Remove the outboard motor from boat and completely drain the water from the gear case.

ENOF01313-0

ENOM00071-A

2. Carrying the outboard motor

ENOW00933-0

WARNING

Be sure to disconnect fuel connector except when operating engine.

Fuel leakage is a fire or explosion hazard, which can cause serious injury or death.

ENOW00065-0

WARNING

Close air vent screw of fuel tank before carrying or storing outboard motor and fuel tank, or fuel may leak, potentially catching fire.

ENOW00066-1

CAUTION z Do not give a shock to an outboard motor during transportation. It becames a cause of breakage.

z Do not carry or store outboard motor in any of positions described below.

Otherwise, engine's exterior parts may be damaged or water may enter the cylinder

8

44

REMOVING AND CARRYING THE OUTBOARD MOTOR through the exhaust por t and c ause engine problems.

8

ENOF01727-0

Keep the outboard motor in a vertical position when carrying.

The optional outboard motor stand is recommended for keeping the outboard motor vertical both during transport and storage.

ENOF00680-0

ENOM00072-C

3. Traillering

ENOW00072-0

CAUTION

Trailering in the tilted position may cause damage to the outboard motor, boat, etc.

ENOW00073-A

WARNING

Be sure to disconnect fuel connector except when operating engine.

Fuel leakage is a fire or explosion hazard, which can cause serious injury or death.

ENOF01921-0

ENON00021-C

Note

If the outboard motor must be laid down, be sure drain the fuel from the fuel line and carburetor in advance, then the port side face down on the cushion as shown in the drawing.

ENOF00075-1

ENOW00068-0

WARNING

Close air vent screw of fuel tank and fuel cock before carrying or storing outboard motor and fuel tank, or fuel may leak, potentially catching fire.

ENOW00071-0

CAUTION

The tilt support device supplied on your outboard motor is not intended for towing. It is

REMOVING AND CARRYING THE OUTBOARD MOTOR

45 intended to support the outboard motor while the boat is docked, beached, etc.

When transporting a boat on a trailer with the outboard motor still attached, disconnect the fuel line from the outboard motor beforehand and keep the outboard motor in the normal running position or on a transom saver bar.


To prevent the outboard motor from moving when it is attached on a boat during transport on a trailer, properly tighten the steering friction adjustment bolt (page 46).

8

2

1

ENOF00073-A

1. Ground clearance should be provided sufficiently.

2. Transom saver bar

ENOW00067-0

WARNING

Do not go under outboard motor tilted up even if it is supported by support bar, or accidental fall of outboard motor could lead to severe personal injury.

9

46

ADJUSTMENT

ENOM00073-C

1. Steering friction


ENOW00074-D

WARNING

Do not over tighten the steering friction adjustment bolt it could result in difficulty of movement resulting in the loss of control causing an accident and could lead to severe injury.

ENON00506-A

Note

The steering friction adjustment bolt is used to adjust the friction load of the steering, but not to fix the steering. Excess tightening of the adjustment bolt may cause damage to the swivel bracket.

Steering friction can be adjusted in accordance with your preference by turning the steering friction adjustment bolt.

ENOM00074-A

2. Throttle grip friction

ENOW00074-B

WARNING

Do not overtighten the throttle adjustment screw or it could result in difficulty of movement resulting in the loss of control causing an accident and could lead to severe injury.

Friction adjustment of the throttle grip can be made with the throttle adjustment screw.

1

2

3

3

2

1

1. Steering friction adjustment bolt

2. Lighter

3. Heavier

ENOF01922-0

1. Heavier

2. Lighter

3. Throttle friction adjustment screw

ENOF01923-0

ENOM00076-0

3. Trim tab adjustment

ENOW00076-0

WARNING z Be sure that outboard motor is secured to transom or service stand, or accidental drop or fall of outboard motor could lead to severe personal injury.

z Be sure to lock outboard motor if it is tilted up, or accidental fall of outboard motor could lead to severe personal injury.

z Do not go under outboard motor tilted up and locked, or accidental fall of outboard motor could lead to severe personal injury.

ENOW00075-0

WARNING

Inappropriate adjustment of trim tab could cause steering difficulty. After installing or readjusting trim tab, check if steering fiction is even.

If straight-line cr uising can not be achieved, adjust the trim tab located under the anti-ventilation plate.

z If the boat veers toward the left direct the trim tab towards A (left from rear of boat).

z If the boat veers toward the right direct the trim tab towards B (right from rear of boat).

ADJUSTMENT

47

ENON00022-A

Notes z After adjustment securely tighten the trim tab fixing bolt.

z Check for looseness of the bolt and the trim tab at regular intervals.

9

1

1. Trim tab

1

ENOF00912-A

48

INSPECTION AND MAINTENANCE

10

ENOM00077-0

Care of your outboard motor

To keep your outboard motor in the best operating condition, it is very important that you perform daily and periodic maintenance as suggested in the maintenance schedules that follow.

ENOW00077-0

CAUTION z Your personal safety and that of your passengers depends on how well you maintain your outb oard motor. C arefully observe all of the inspection and maintenance procedures described in this section.

z The maintenance intervals shown in the checklist apply to an outboard motor in normal use. If you use your outboard motor under severe conditions such as frequent full-throttle operation, frequent operation in brackish water, or for commercial use, maintenance should be performed at shorter intervals. If in doubt, consult your dealer for advice.

z We strongly recommend that you use only genuine replacement parts on your outboard motor. Damage to your outboard motor arising from the use of other than genuine parts is not covered under the warranty.

INSPECTION AND MAINTENANCE

49

ENOM01607-0

1. Daily Inspection

Perform the following checks before and after use.

ENOW00078-0

WARNING

Do not use outboard motor if any abnormality is found during pre-operation check or it could result in severe damage to the motor or severe personal injury.

Item

Fuel System

Lubrication

System

Electrical

Equipment

Throttle System

Points to Check

• Check the amount of fuel in the tank.

• Check for dust or water in the fuel filter.

• Check rubber pipes for fuel leakage.

• Check the amount of engine oil in the oil tank.

• Check for dust or water in the oil filters.

• Check the spark plugs for dirt, wear and carbon built-up.

Spark plugs : NGK B-8HS-10/NGK BR-8HS-10

• Check if the main switch functions normally.

• Check if the battery electrolyte level and specific gravity are nomal.

• Check for loose connections on battery terminal.

• Check if the emergency stop switch functions normally and make sure the lock plate is present.

• Check cords for loose connections and damage.

• Check if the choke solenoid and valve for the carburetor works normally.

• Check if the carburetor and magneto work normally when turning the throttle grip, and also check links for looseness.

Recoil Starter

Clutch and

Propeller System

Installation of

Motor

Cooling Water

Tools and Spares

• Check ropes for wear and damage.

• Check the ratchet for engagement.

• Check the propeler for bent or damaged blades.

• Check if the propeller nut is tightened and the split pin is present.

• Check all the motor installation bolts with the boat.

• Check the thrust rod installation.

• Check that cooling water is discharged from the cooling water check port after the engine has started.

• To be ready tools and spare parts for replacing spark plugs, propeller, etc.

• Check if the spare rope is provided.

Steering Devices • Check working of steering handle and remote control.

Other Parts

• Check if the anode and trim tab are securely installed.

• Check the anode and trim tab for corrosion and deformation.

Action

Replenish

Clean

Replace *1

Replenish

Clean

Clean or replace

Remedy or replace *1

Replenish or recharge

Retighten

Remedy or replace *1

Correct or replace *1

Replace *1

Correct *1

Replace *1

Correct or replace *1

Replace

Tighten

Tighten

Repair if necessary

Replace

*1 Have this handled by your dealer.

10

50


ENOM00083-0

Washing outboard motor

ENOW00081-0

WARNING

Do not start engine without removing propeller, or accidentally turning propeller could cause personal injury.

ENOW00082-0

WARNING

Never start or operate the engine indoors or in any space which is not well ventilated.

Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal if inhaled for any length of time.

ENOW00920-0

CAUTION

When washing the outboard motor, be careful not to spray the water inside of the top cowl, especially electrical components.

10

ENON00026-0

Note

It is recommended to check chemical properties of water on which your outboard motor is regularly used.

If outboard motor is used in salt water, brackish water or water with a high acidic level, use fresh water to remove salt, chemicals or mud from exterior and cooling water passage after every cruising or before storing outboard motor for long time. Before flushing, remove the propeller and the forward thrust holder.

ENOM00085-F

Flushing attachment

ENOW00922-0

CAUTION

To prevent the engine from starting when you are near the propeller, remove the stop switch lock.

1. Tilt down the outboard motor.

2. Remove the water plug from the gear case, and scre w in th e flushing attachment.

3. Attach the flushing attachment and connect a water hose. Turn on the water and adjust the flow (Be sure to seal the water inlet and sub water inlet, located in the gear case with tape)

4. Put the shift lever in the neutral position and start the engine.

Continue flushing the outboard motor for 3 to 5 minutes at idling.

5. Stop the engine and water supply.

Remove the flushing attachment and tape. After the flushing, be sure to reattach the water plug.

2

1

1. Flushing attachment (option)

2. Tape

ENOF01324-0


51

.

1

3

1

1

2

2

ENOF01420-0

1. Flushing attachment (option)

2. Water inlet

ENOM00085-A

Flushing by test tank

ENOW00081-0

WARNING

Do not start engine without removing propeller, or accidentally turning propeller could cause personal injury.

ENOW00082-0

WARNING

Never start or operate the engine indoors or in any space which is not well ventilated.

Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal if inhaled for any length of time.

ENOW00036-A

CAUTION

When the engine is started in the test tank, to avoid over heating and water pump damage, be sure the water level is at least 10 cm

(4 in.) above the anti ventilation plate.

And be sure to remove the propeller, when star ting the engine in the test tank. (See page 56)

1. Test tank

2. Water

3. Over 10 cm (4 in.)

ENOF00863-0

ENOM00950-0

Fuse replacement (For electrical starter type)

ENOW00923-0

CAUTION

Before replacing a fuse, disconnect the battery cable from the battery negative (-) terminal. Failure to do so may cause a shortcircuit.

ENOW00924-0

CAUTION

Never use a fuse with a rating that exceeds the specified rating as this could cause serious damage to the electrical system.

10

If a blown fuse is detected, try to determine the cause for this and correct it. If the cause for the problem is not corrected, the fuse will likely blow again.

If the fuse continues to blow, request an authorized Tohatsu dealer to inspect the outboard motor.

52


1. Stop the engine and disconnect the battery cable from the battery negative (-) terminal.

2. Remove the engine cover.

3. Remove the fuse box lid.

4. Remove the fuse and check it. If the fuse is blown, replace it with a fuse of the same specified rating. The outboard motor is supplied with spare fuses in the spare fuse holder.

1

10

1. Brown fuse

ENOF01962-0


53

ENOM01006-0

2. Periodic Inspection

It is important to inspect and maintain your outboard motor regularly. At each interval on the chart below, be sure to perform the indicated servicing.

Maintenance intervals should be determined according to the number of hours or number of months, whichever comes first.

Fuel

System

Ignition

Starting

System

Carburetor *1

Fuel filter

Piping

Fuel tank

Lower

Unit

Gear oil

Water pump *1

Bolt and Nuts

Sliding and Rotating Parts

Grease Nipples

Engine

Oil

System *1

Oil Tank

Oil Pipe

Outer Equipment

Oil Filter

Anode

Item

Spark plugs

Ignition timing *1

Starter motor *1

Battery

Starter rope

Propeller

Power Trim & Tilt *1

Servicing Interval

10 hours or

1 month

50 hours or

3 months

Every 100 hours or 6 months z z z z z z z z z z z z

Action Remarks

Strip, clean and adjust.

Adjust idling.

Check and clean.

Check and clean.

Clean

Check gaps.

Remove carbon deposits.

0.9-1.0 mm

(0.035-0.039 in) z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z

Adjust timing.

Check for salt deposits and battery cable condition.

Installation, fluid quantity, gravity

Check for wear or damage.

Check for bend blades, damage, wear.

Change or replenish-oil and check for water leakes.

Check for wear or damage.

Retighten.

Apply and pump in grease.

Check power unit oil level and refill.

Check function of manual release valve.

Check for leakage, damage, position of clips and filter conditions

Check for corrosion.

Check for corrosion and deformation.

Replace impeller every 12 months.

Repair or consult your deler

Replace.

*1 Have this handled by your dealer.

10

54


ENON00030-0

Note

Your outboard motor should receive careful, and complete inspection at 300 hours. This is the best time for major maintenance procedures to be carried out.

10

ENOM00093-A

Fuel filters and fuel tank cleaning

ENOW00093-A

WARNING

Gasoline and its vapors are very flammable and can be explosive.

Keep out of reach of children.

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

z Do not start this procedure while engine is operating or hot even after stopping it.

z Place fuel filter away from every source of ignition such as sparks or open flames.

z Wipe off gasoline well immediately if spilled and dispose of it in accordance with local fire prevention and environment protection regulations.

z Install fuel filter with all related parts in place, or fuel leak could occur, leading to catching fire or explosion.

z Check fuel system regularly for leakage.

z Contact authorized dealer for fuel system services. Services by unqualified person could lead to engine damage.

Water or dirt in the fuel tank will cause engine performance problems.

Check and clean the tank at specified times or after the outboard motor has been stored for a long period of time

(over three months).

Fuel filters are provided inside the fuel tank and engine.

ENOM00094-0

Fuel filter (for engine)

1. Check in the cup for water and debris.

ENOF01925-0

2

3

4

1

6

5

ENOF00096-B

1. Body

2. O-ring

3. Filter

4. O-ring

5. Cup

6. Arrow to indicate fuel flow direction

2. If present, disconnect hoses from the fuel connector (male) and the fuel pump.


55

3. Remove the cup, filter and O-rings from the fuel filter body.

4. Check the wear and clogging for each parts, and replace if necessary.

5. Remove fuel and any water or debris from the cup, filter and hoses.

6. Reassemble all parts.

ENOM00096-A

Fuel filter (for fuel tank)

1. Remove four screws to remove the

Fuel Pick-Up.

2. Clean the fuel filter and replace the gasket.

3. Reassemble all parts.

drop or fall of outboard motor could lead to severe personal injury.

z Be sure to lock outboard motor if it is tilted up, or accidental fall of outboard motor could lead to severe personal injury.

z Do not go under outboard motor tilted up and locked, or accidental fall of outboard motor could lead to severe personal injury.

ENON00934-0

Note

Please dispose of used oil in a manner that is compatible with the environment.

We suggest you take it in a sealed container to your local service station for reclamation. Do not throw it in the trash, pour it on the ground or down a drain.

1

2

1. Tilt down the outboard motor.

2. Remove the oil plugs (lower and upper), and completely drain the gear oil into a pan.

ENOF00926-1

1. Fuel pick-up

2. Filter

ENOM00098-B

Gear oil replacement

ENOW00094-0

WARNING z Be sure that outboard motor is secured to transom or service stand, or accidental

ENOF01331-0

3. Insert the oil tube nozzle into the lower oil plug hole, and fill with gear oil by squeezing the oil tube until oil flows out of the upper plug hole and bubbles is disappeared to remove the air.

10

56


ENON00033-0

Note

Use genuine gear oil or the recommended one (API GL-5: SAE #80 to #90).

Required volume: approx. :500mL (16.9

fl.oz)

ENOW00928-0

CAUTION

Wipe off gear oil well immediately if spilled and dispose of it in accordance with local fire prevention and environment protection regulations.

ENON00032-0

Note

If water in the oil, giving it a milky colored appearance. Contact your dealer.

10

ENOF01333-0

4. Install the upper oil plug, and then remove oil tube nozzle and install the lower oil plug.

Oil plug specified tightening torque

4N·m (3 ft · lb, 0.4 kgf · m)

ENOW00095-0

CAUTION

Do not reuse oil plug gasket. Always use new gasket and tighten oil plug properly to prevent entry of water into lower unit.

ENOM00086-A

Propeller replacement

ENOW00084-0

WARNING z Do not begin propeller removal and installation procedure with spark plug caps attached, shift in forward or reverse, main switch at other than “OFF”, engine stop switch lock attached to the switch, and starter key attached, or engine could accidentally start leading to serious personal injury. Disconnect battery cable if possible.

z The propeller edge is thin and sharp. Wear the groves during replacement to protect your hands.

ENOW00086-0

CAUTION z Do not install propeller without thrust holder, or propeller boss could be damaged.

z Do not reuse split pin.

z After installing split pin, spread the pin apart to prevent it from falling out which could lead to the propeller coming off during operation.

A worn-out or bent propeller will lower the motor's performance, and cause engine trouble.

ENOF01331-0


57

1. Put a piece of wood block between propeller blade and anti-ventilation plate to hold propeller.

6. Tighten the propeller nut to specified torque, and align one of grooves to propeller shaft hole.

Propeller nut torque:

35 Nm (25 ft-lb, 3.25kgf-m)

7. Install a new split pin into the nut hole and bend it.

ENOF00084-B

2. Remove the split pin, propeller nut and washer.

3. Remove the propeller and thrust holder.

4. Apply water proof grease to the propeller shaft before installing a new propeller.

5. Install the thrust holder, propeller, stopper, washer and propeller nut onto the shaft.

3

6

4

5

1. Propeller

2. Thrust holder

3. Stopper

4. Washer

5. Propeller nut

6. Split pin

2 1

ENOF01315-0

ENOF00084-E

ENOM00087-B

Spark plugs replacement

ENOW00087-0

WARNING z Do not reuse spark plug with damaged insulation, or sparks can leak through crack, potentially leading to electric shock, explosion and/or fire.

z Do not touch spark plugs immediately after stopping engine as they will be hot and could cause severe burns if touched.

Allow motor to cool down first.

10

ENOW00929-0

CAUTION

Use only the recommended spark plugs.

Spark plugs which have an different heat range may cause engine damage.

If the spark plug(s) is fouled, has carbon b uil d up , or is w orn , i t sh o ul d b e replaced.

When reusing spark plugs, remove dirt from the electrodes and adjust spark gap to specification.

58


1. Stop the engine.


3. Remove the spark plug caps.

4. Remove the spark plugs by turning it counter-clockwise, using a 21 mm (13/

16 in) socket wrench and handle that is provided in tool bag.

5. Inspect the spark plug. Replace the spark plug if the electrodes are worn or if the insulators are cracked or chipped.

6. Measure the spark plug electrode gap with a wire type feeler gauge. The gap should be 0.9-1.0 mm (0.035-0.039

inches). If the gap is different, replace the spark plug with a new one

Use spark plug :

NGK B8HS-10

1

2

ENOF00085-0

1. Electrode

2. Spark gap (0.9–1.0 mm, 0.035–0.039 in)

10

7. Install the spark plug by hand and turn it carefully to avoid cross-threading.

8. Tighten the spark plug to the specified torque.

ENON00028-0

Note z Spark plug torque:

27.0 Nm (20 ft-lb) [2.7 kgf-m]

If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.

ENOF01926-0


59

ENOM00088-A

Anode replacement

A sacrificial anode protects the outboard motor from electrolytic corrosion. Anode is located on the gear case, cylinder etc.. When the anode is eroded more than 1/3 of original size, replace it.

ENON00029-0

Notes z Never grease or paint the anode.

z At each inspection re-tighten the anode attaching bolt. As it is likely to be subjected to electrolytic corrosion.

*1 : Both side

*1

ENOF01927-0

10

10

60


ENOM00960-0

Grease point

Apply water proof grease to the parts shown below.

ENOF01928-0


61

ENOM00100-A

3. Off-season storage

ENOW00934-0

WARNING z Be sure to disconnect fuel connector except when operating engine.

z Fuel leakage is a fire or explosion hazard, which can cause serious injury or death.

ENOW00097-0

WARNING

Be sure to use cloth to remove fuel remaining in the cowl and dispose of it in accord an c e w i t h l o c a l f i r e p r e v e n t i o n an d environment protection regulations.

ENOW00096-0

CAUTION

Before servicing the motor for storage: z Remove the battery cables.

z Remove the spark plug caps from the spark plugs.

z Do not run the motor out of the water.

Before you put your outboard motor in storage, it is a good opportunity to have it serviced and prepared by your dealer.

Be sure to use fuel stabilizer while running the motor before storage. (See page 62)

ENOM00101-D

Engine

1. Wash the engine exterior and flush the cooling water system thoroughly with fresh water. Drain the water completely.

Wipe off any surface water with an oily rag.

2. Remove the fuel hose from the outboard motor.

3. Drain all fuel from the fuel hoses, fuel pump, fuel filter (See page 54) and carburetor (See page 63), and clean these parts.

Keep in mind that if gasoline is kept in the carburetor for a long time, gum and varnish will develop, causing the float valve to stick, restricting the fuel flow.

4. Remove the spark plugs and put a teaspoon of engine oil or spray storage oil into the combustion chamber through the spark plug holes.

5. Pull the recoil starter several times or turn the starter motor to lubricate inside the cylinder.

ENOW00930-0

WARNING z Be sure to remove stop switch lock to prevent ignited the spark plugs.

z Put a cloth to spark plug hole and wipe up any spilled engine oil, when cranking the outboard motor.

6. Change the gear oil in the gear case

(See page 55).

7. Apply grease to grease point (See page 60).

8. Stand the outboard motor up vertically in a dry place.

10

62


10

ENOF01921-0

ENOW00066-1

CAUTION

Do not carry or store outboard motor in any of positions described below.

Otherwise, engine's exterior parts may be damaged or water may enter the cylinder through the exhaust port and cause engine problems.

ENOF01727-0

ENON00021-D

Note

If the outboard motor must be laid down, be sure drain the fuel ࠉ completely in advance, then the port side face down on the cushion as shown in the drawing.

ENOF00680-0

ENOM00950-A

Adding a fuel stabilizer

When adding a fuel stabilizer additive

(commercially available), first fill the fuel tank with fresh oil and fuel. If the fuel tank is only partially filled, air in the tank can cause the fuel to deteriorate during storage.

1. Before adding fuel stabilizer additive, drain the carburetor (See page 63).

2. Follow the instructions on the label when adding the fuel stabilizer additive.

3. After adding the additive, let the outboard motor run in the water for 10 minutes to make sure any old fuel in the fuel system has been completely replaced by the fuel with additive.

4. Turn the engine OFF

ENON00891-0

Note

If your motor is used occasionally, it is recommended to use a good fuel stabilizer in every tank of fuel and keep the container full to reduce condensation and evaporation.


63

ENOM00970-A

Fuel system draining

ENOW00028-A

WARNING

For details on handling fuel, contact an authorized dealer.

Fuel and fuel vapors are extremely flammable and can be explosive.

z If fuel is spilled, wipe it up immediately.

z Keep the fuel tank well away from sources of ignition, e.g. sparks or open flames z Perform all work outdoors or in a well ventilated place.

ENOW00097-0

WARNING

Be sure to use cloth to remove fuel remaining in the cowl and dispose of it in accord an c e w i t h l o c a l f i r e p r e v e n t i o n an d environment protection regulations.

8. Check the drained fuel for the presence of water or other contaminants.

If either is present, reassemble the outboard motor, refill the carburetor with fuel, and then drain the fuel again. Repeat this procedure until no water or other contaminants are present in the drained fuel.

1

1. Disconnect the fuel hose from the outboard motor.


3. Place an approved fuel container under the drain screw and use a funnel to avoid spilling fuel.

4. Loosen the carburetor drain screw.

5. Tilt up the outboard motor until fuel flows out of the drain tube.

6. Leave the outboard motor in this p o sitio n until all fu e l h a s b e e n drained.

7. When thoroughly drained, retighten the drain screw securely.

ENOF02370-0

1. Carburetor drain screw

ENOM00102-0

Battery

ENOW00931-A

WARNING z Place the battery away from any source of fire, sparks and open flames such as burners or welding equipment.

z Place the battery away from fuel tank.

Accidental sparks of battery may cause explosion of gasoline.

1. Disconnect the battery cables and be sure to remove the negative terminal first.

2. Wipe off any chemical deposits, dirt, or grease.

3. Apply grease to the battery terminals.

10

64


4. Charge the battery completely before storing it for the winter.

5. Recharge the battery once a month to prevent it from discharging and the electrolyte from deteriorating.

6. Store the battery in a dry place.

ENOM00104-G

4. Pre-season check

10

The following steps must be taken when first using the engine after off season storage.

1. Check that the shift and throttle function properly. (Be sure to turn the propeller shaft when checking the shift function or else the shift linkage may be damaged.)

2. Check the electrolyte level, and measure the voltage and specific gravity of the battery.

Specific

Gravity at 20°C

1.120

1.160

1.210

1.250

1.280

Terminal

Voltage (V)

10.5

11.1

11.7

12

13.2

Charge

Condition

Fully discharged

1/4 charged

1/2 charged

3/4 charged

Fully charged

3. Check that the battery is secure and the batter y cables are proper ly installed.

4. Fill fuel tank with oil and fuel.

5. Start the engine and warm up the engine for 3 minutes in the “NEU-

TRAL” position.

6. Run the engine for 5 minutes at the slowest speed.

7. Run the engine for 10 minutes at half throttle. The oil used for storage inside the engine will be circulated out to assure optimum performance.

ENOM00105-D

5. Submerged outboard motor

ENOW00098-0

CAUTION

Do not attempt to start submerged outboard motor immediately after it is recovered, or engine could be severely damaged.

After taking your outboard motor out of the water, immediately take it to your dealer.

The following are the emergency measures to be taken for a submerged outboard motor, if you can not take it your dealer right away.

1. Wash the outboard motor with fresh water to remove salt or dirt.

2. Remove the spark plugs, and completely drain the water from the engine by pulling recoil starter several times.

3. Inject a sufficient amount of engine oil through the spark plug holes.

Pull the recoil starter rope several times to circulate the oil throughout the outboard motor.

ENOM00106-A

6. Cold weather precautions

If you moor your boat in cold weather at temperatures below 0°C (32°F), there is the danger of remained water freezing in


65 the cooling water pump, which may damage the pump, impeller, etc. To avoid this problem, submerge the lower half of the outboard motor into the water.

be sure that all engines are running.

If any engine has stopped, be sure to tilt the outboard motor up and keep its propeller out of the water.

Otherwise, water could enter the engine and cause damage to it.

ENOM00107-A

7. Striking underwater object

ENOW00935-0

CAUTION

Striking the sea bottom or an underwater object may severely damage the outboard motor.

Follow the procedure below and consult a dealer as soon as possible.

1. Stop the engine immediately.

2. Check the control system, gear case, boat transom etc.

3. Return to the nearest habor slowly and carefully.

4. Consult a dealer check the outboard motor before operation again.

10

ENOF01145-0

ENOM00121-0

8. Operation with multiple outboard motors

When operating the outboard motors in reverse at more than the lowest speed,

11

66

TROUBLESHOOTING

ENOM01608-0

If you encounter problem with the engine, check the list below and locate the problem you are experiencing. Then follow the suggested remedies.

Do not hesitate to contact your dealer, as professionals advice and assistance is the best way to keep the engine in optimum condition.

Difficult to start engine

Engine starts. but stops soon

Poor idling

Unstable engine running speed or engine stops

Abnormally high engine speed

Abnormally low engine speeds

Cannot obtain high engine speeds

Overheating of engine z z z

Empty fuel tank z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z

Incorrect connection of fuel system z

Air enters fuel line z z z z z z z z

Deformed or damaged fuel pipe

Closed air vent on fuel tank cap

Clogged fuel filter, fuel pump or carburetor

Use of improper engine oil

Use of improper gasoline

Excessive supply of gasoline

Poor carburetor adjustment

Recirculation pipe broken

Use of non-specified spark plugs

Dirt or carbon deposits on spark plugs

TROUBLESHOOTING

67 z z z z

Difficult to start engine

Engine starts. but stops soon

Poor idling z z z

Unstable engine running speed or engine stops

Abnormally high engine speed

Abnormally low engine speeds

Cannot obtain high engine speeds

Overheating of engine z z z

No sparks or weak sparks z z z z

Insufficient cooling water flow z z z z

Faulty thermostat z z z z z z z z z z z z z z z

Propeller cavitation z z z

Incorrect propeller selection

Damaged or bent propeller

Unbalanced load in boat z

Transom too high z z z z z z z z z z z Transom too low z z

Incorrect adjustment of throttle link

Incorrect adjustment of ignition timing

Insufficient battery capacity, loose terminals, corrosion

Safety switch lock plate not fitted

11

12

68

TOOL KIT AND SPARE PARTS

ENOM01609-0

The followings are a list of the tools and spare parts provided with the motor.

Servicing Tools

Spare Parts

Name

Tool Bag

Socket Wrench (21 mm)

Socket Wrench (10 x 13 mm)

Socket Wrench Handle

Pliers

Screwdriver (Phillips-type and flat head)

Anode (for Bracket)

Trim Tab

Water Pump Impeller

Guide Plate Gasket

Pump Case Gasket

Gasket (for Gear Oil Plug)

Grease

Starter Rope

Spark Plug

Split Pin

Mounting

Hardwear

Bolt

Nylonn Locking Nut

Washer A (large)

Washer B (small)

2

1

1

1

1

1

1

1

3

1

4

4

4

4

Quantity

1

1

1

1

1

1

Remark

Adapter-type

NGK B8HS-10

12mm

12mm

Parts Packaged with Engine

Fuel Tank (with primer bulb)

Grease Up Point Chart

Owner's Manual

1

1

1

PROPELLER TABLE

ENOM01610-0

To ensure optimum performance, the propeller should match the boat type and its load.

69

Use a genuine propeller.

A propeller must be selected so that the engine rpm measured at wide open throttle, while cruising, is within the recommended range.

40D3, 50D3 5000 to 5800 min

-1

(rpm)

40 50

Heavier Load

Lighter Load

Mark

13

14

15

16

17

7*

9

11

12

* shows propeller with four blades.

Propeller Size (Diameter Pitch)

Inch mm

11.4 x 7.1

12.1 x 9.0

290 x 180

311 x 229

11.6 x 11.0

11.4 x 12.0

11.1 x 13.0

11.1 x 14.0

290 x 279

283 x 305

277 x 330

279 x 356

11.0 x 15.0

11.0 x 16.0

11.0 x 17.0

279 x 381

279 x 406

280 x 432

13

O W N E R’ S

M A N U A L

MX 40D

3

MX 50D

3

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

Tokyo 174-0051, Japan

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

Tohatsu MX 50D3 Owner Manual

Assistant Bot

Original instructions

MX 40D

MX 50D

YOUR TOHATSU OUTBOARD MOTOR

To You, Our Customer

PRE-DELIVERY CHECK

Serial Number

NOTICE: DANGER/WARNING/CAUTION/Note

DANGER

CONTENTS

INDEX

1. GENERAL SAFETY INFORMATION

2. SPECIFICATIONS

3. PARTS NAME

4. LABEL LOCATIONS

5. INSTALLATION

6. PRE-OPERATING PREPARATIONS

7. ENGINE OPERATION

8. REMOVING AND CARRYING THE OUTBOARD

MOTOR

9. ADJUSTMENT

10. INSPECTION AND MAINTENANCE

11. TROUBLESHOOTING

12. TOOL KIT AND SPARE PARTS

13. PROPELLER TABLE

GENERAL SAFETY INFORMATION

SAFE OPERATION OF BOAT

STOP SWITCH LANYARD

PERSONAL FLOTATION DEVICE

SERVICING, REPLACEMENT PARTS & LUBRICANTS

MAINTENANCE

SPECIFICATIONS

MODEL FEATURE

MODEL NAME EXAMPLE

X40D3/50D3 MF, EF

PARTS NAME

X40D3MF/X50D3MF, EF

Fuel tank

LABEL LOCATIONS

Warning label locations

Serial number label locations

INSTALLATION

1. Mounting the outboard motor on boat

Position ... Above keel line

Transom matching

2. Battery installation

PRE-OPERATING PREPARATIONS

1. Fuel handling

FUEL RATING

GASOLINES CONTAINING

ALCOHOL

2. Fuel filling

3. Engine oil recommendation

4. Break-In

5. Warning system

Warning indicators, faults and remedy

ENGINE OPERATION

Before starting

1. Fuel feeding

2. Starting the engine

Tiller handle type

(For manual starter type)

(For electrical starter type)

Emergency starting

3. Warming up the engine

Engine speeds

4. Forward, reverse, and acceleration

Tiller handle type

Tiller handle type

5. Stopping the engine

6. Steering

Tiller handle type

7. Trim angle

8. Tilt up and down

9. Shallow water operation

REMOVING AND CARRYING THE OUTBOARD MOTOR

1. Removing the outboard motor

2. Carrying the outboard motor