HOME | TOHATSU GLOBAL...4 ENOM00005-A Serial Number In the space below, please record the outboard...

MANUAL

MFS 9.9DMFS 15DMFS 20D

OWNER’S

OB No.003-11115-3AG1

Original instructions

ENOM00001-0

READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THEINSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUSINJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.

Copyright © 2017 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced ortransmitted in any from or by any means without the express written permission of Tohatsu Corporation.

3

YOUR TOHATSU OUTBOARD MOTORENOM00006-A

To You, Our CustomerThank you for selecting a TOHATSU outboard motor. You are now the proud owner of anexcellent outboard motor that will service you for many years to come.This manual should be read in its entirety and the inspection and maintenance proceduresdescribed later in this manual should be followed carefully. Should a problem arise with theoutboard motor, please follow the troubleshooting procedures listed at the end of thismanual. 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 every-one who uses the outboard motor. If the outboard motor is resold, make sure the manualis passed on to the next owner.

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

TOHATSU CORPORATION

ENOM00113-0

EC DECLARATION OF CONFORMITY (DoC)This product conforms to certain portion of the European Parliament directive. DoC con-tains the following information;

Name and Address of the manufacturer.Applied community directivesReference standardDescription of the product. (Model name and serial number)Signature of the responsible person (Name / Title / Date and place of issue).

ENOM00002-0

OWNER REGISTRATION AND IDENTIFICATIONUpon purchasing this product, be sure that the WARRANTY CARD is correctly and com-pletely filled out and mailed to the addressee noted there on. This WARRANTY CARDidentifies you as the legal owner of the product and serves as your warranty registration.TO THE EXTENT PERMITTED BY APPLICABLE LAW, YOUR OUTBOARD MOTOR WILLNOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS PROCEDURE ISNOT FOLLOWED.

ENOM00003-0

PRE-DELIVERY CHECKBe sure that the product has been checked by an authorized TOHATSU dealer before youtake delivery.

4

ENOM00005-A

Serial NumberIn the space below, please record the outboard motor's serial number (indicated both onthe swivel bracket and on the cylinder block). The serial number will be needed whenordering parts, and when making technical or warranty inquiries.

Serial Number:

Serial Number: Date of purchase:

ENOF01200-1ENOF01201-0

5

ENOM00007-0

NOTICE: DANGER/WARNING/CAUTION/NoteBefore installing, operating or otherwise handling your outboard motor, be sure to thor-oughly read and understand this Owner's Manual and carefully follow all of the instruc-tions. Of particular importance is information preceded by the words “DANGER,”“WARNING,” “CAUTION,” and “Note.” Always pay special attention to such information toensure safe operation of the outboard motor at all times.ENOW00001-0

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

ENOW00002-0

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

ENOW00003-0

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 outboardmotor or to clarify important points.

DANGER

WARNING

CAUTION

1. GENERAL SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123. PARTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154. LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . 202. Remote control device installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223. Battery installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285. Warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448. Tilt up and tilt down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469. Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . 511. Removing the outboard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

9. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543. Remote control lever friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

10. INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788. Auxiliary outboard motor operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

CONTENTS

11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7912. ACCESSORIES KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8113. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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.ACCESSORIES KIT

13.PROPELLER TABLE

INDEX

2

14

3

4

5

6

7

8

9

10

11

12

13

14

1

10

1

GENERAL SAFETY INFORMATIONENOM00009-0

SAFE OPERATION OF BOATAs the operator/driver of the boat, you are responsible for the safety of those aboard andthose in other boat around yours, and for following local boating regulations. You shouldbe thoroughly knowledgeable on how to correctly operate the boat, outboard motor, andaccessories. 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 shouldhe 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 motorshould be shifted to neutral and shut off.ENOW00005-0

SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOV-ING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TOA BOAT OR GEAR HOUSING.

ENOM0008-A

EMERGENCY STOP SWITCHThe Emergency Stop Switch will stall the outboard motor when the stop switch lanyard ispulled off. This stop switch lanyard has to be attached to the operator of the outboardmotor to minimize or prevent injuries from the propeller in case the operator falls over-board.It is operator’s responsibility to use the Emergency Stop Switch Lanyard.ENOW00004-A

Accidental activation of the Emergency Stop Switch (such as the tether being pulled out inheavy seas) could cause passengers to lose their balance and even fall overboard, or itcould result in loss of power in heavy seas, strong currents, or high winds. Loss of controlwhile mooring is another potential hazard.To minimize accidental activation of the Emergency Stop Switch, the 500 mm (20 in.) stopswitch lanyard is coiled and can extended to a full 1300 mm (51 in.).

ENOM00800-A

PERSONAL FLOATATION DEVICEAs the operator/driver and passenger of the boat, you are responsible to wear a PFD (Per-sonal Floatation Device) while on the boat.

WARNING

WARNING

GENERAL SAFETY INFORMATION 11

1ENOM00010-0

SERVICING, REPLACEMENT PARTS & LUBRICANTSWe recommend that only an authorized service shop perform service or maintenance onthis outboard motor. Be sure to use genuine parts, genuine lubricants, or recommendedlubricants.

ENOM00011-A

MAINTENANCEAs the owner of this outboard motor, you should be acquainted with correct maintenanceprocedures following maintenance section of this manual (See page 61). It is the opera-tor's responsibility to perform all safety checks and to ensure that all lubrication and main-tenance instructions are complied with for safe operation. Please comply with allinstructions concerning lubrication and maintenance. You should take the engine to anauthorized dealer or service shop for periodic inspection at the prescribed intervals.Correct periodic maintenance and proper care of this outboard motor will reduce thechance of problems and limit overall operating expenses.

Carbon Monoxide Poisoning HazardExhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal ifinhaled 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 whenhandling gasoline. You should be thoroughly knowledgeable on how to correctly handlegasoline by reading this manual.

12

2

SPECIFICATIONSENOM00810-A

MODEL FEATURE

ENOM00811-A

MODEL NAME EXAMPLEF 20D EPTL

Model F9.9D F15D F20D

Type MF EP MF EF EFT EP EPT MF EF EFT EP EPT

Transom heights

S

L

UL

Tiller Handle

Remote Control

Power Tilt

Mnual tilt

F 20 D E P T L

Model descrip-tion

Horse power

Product generation

Starter system

Steering system Tilt system Shaft length

F= Four strokeD= Two stroke DI - A and up

E= Electrical start

M= Manual start

P= Remote Control (Plea-

sure)F= Tiller handle

(Fisher)

T= Power trim&tilt

Blank= Manual tilt

S= Short 15 inL= Long 20 inUL= Ultra long

25 in

SPECIFICATIONS 13

2

ENOM00301-0

Remark: Specifications subject to change without notice.*1 With propeller, with battery cable.Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).

MF, EF, EFT

Item MODEL9.9D/15D/20D

MF EF EFTOverall Length mm (in) 1055 (41.5)

Overall Width mm (in) 365 (14.4)

Overall Height S·L·UL mm (in) 1085 (42.7) 1235 (48.6) 1362 (53.6)

Transom Height S·L·UL mm (in) 413 (16.3) 562 (22.1) 689 (27.1)

Weight*1

S kg (lb) 52 (115) 55.5 (122) 62.5 (138)

L kg (lb) 53.5 (118) 57.0 (126) 64.0 (141)

UL kg (lb) 55 (121) 58.5 (129) 65.5 (144)

Output kW (ps) 9.9D : 7.3 (9.9) 15D : 11.0 (15) 20D : 14.7 (20)

Max. Operating Range min-1 (rpm)9.9D/15D: 5000-6000

20D: 5400-6100

Idle Speed in Forward Gear min-1 (rpm) 900

Idle Speed in Neutral Gear min-1 (rpm) 950

Engine Type 4-Stroke

Number of Cylinder 2

Bore × Stroke mm (in) 61 × 60 (2.40 × 2.36)

Piston Displacement cm3 (Cu in) 351 (21.42)

Exhaust System Through hub exhaust

Cooling System Water cooling

Engine Lubrication Trochoid pump

Starting System Manual Electric starter motor*

Ignition System Flywheel Magneto C.D. ignition

Spark Plug NGK DCPR6E

Trim Position 6

Engine Oil mL (fl.oz.) API, SH, SJ or SL 10W-30, Approx. 1000 (33.8)

Gear Oil mL (fl.oz.) Genuine Gear Oil or API GL5, SAE #80-90, Approx. 370 (12.5)

FuelUnleaded regular gasoline : Pump posted 87 Octane (research octane rating of 91)

Fuel Tank Capacity L (US gal) 12 (3.17)

Gear Reduction Ratio 2.15 (13 : 28)

Emission Control System EM (Engine modification)

Operator Sound Pressure (ICOMIA 39/94) dB (A)

83.9

Hand Vibration Level (ICOMIA 38/94) m/s2

2.5

SPECIFICATIONS14

2

ENOM00302-0

Remark: Specifications subject to change without notice.*1 With propeller, with battery cable.Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).

EP, EPT

Item MODEL9.9D/15D/20D

EP EPTOverall Length mm (in) 640 (25.2)

Overall Width mm (in) 350 (13.8)

Overall Height S·L·UL mm (in) 1085 (42.7) 1235 (48.6) 1362 (53.6)

Transom Height S·L·UL mm (in) 413 (16.3) 562 (22.1) 689 (27.1)

Weight

S kg (lb) 54.5 (120) 61.5 (136)

L kg (lb) 56 (123) 63 (139)

UL kg (lb) 57.5 (127) —

Output kW (ps) 9.9D : 7.3(9.9) 15D: 11.0 (15) 20D: 14.7 (20)

Max. Operating Range min-1 (rpm)9.9D/15D: 5000-6000

20D: 5400-6100

Idle Speed in Forward Gear min-1 (rpm) 900

Idle Speed in Neutral Gear min-1 (rpm) 950

Engine Type 4-Stroke

Number of Cylinder 2

Bore × Stroke mm (in) 61 × 60 (2.40 × 2.36)

Piston Displacement cm3 (Cu in) 351 (21.42)

Exhaust System Through hub exhaust

Cooling System Water cooling

Engine Lubrication Trochoid pump

Startring System Electric starter motor with manual*

Ignition System Flywheel Magneto C.D. ignition

Spark Plug NGK DCPR6E

Trim Position 6 5

Engine Oil mL (fl.oz.) API, SH, SJ or SL 10W-30/40, Approx. 1000 (33.8)

Gear Oil mL (fl.oz.) Genuine Gear Oil or API GL5, SAE #80-90, Approx. 370 (12.5)

FuelUnleaded regular gasoline: Pump posted 87 Octane (research octane rating of 91)

Fuel Tank Capacity L (US gal) 12 (3.17)

Gear Reduction Ratio 2.15 (13 : 28)

Emission Control System EM (Engine modification)

Operator Sound Pressure (ICOMIA 39/94) dB (A)

83.9

Hand Vibration Level (ICOMIA 38/94) m/s2

—

15

3

PARTS NAMEENOM00303-0

MF, EF, EP, EFT, EPT

1

2

3

8

9

11

10

13

14

15

16

17

18

23

2019

21

22

12

4

5

6

7

27

28

29

26

25

24

ENOF01202-0

1 Tilt Handle2 Top Cowl3 Bottom Cowl4 Cooling Water Check Port5 Power Tilt Switch *1

(EPT and EFT type only)6 Oil Drain Bolt7 Anti Ventilation Plate8 Anode/Trim Tab9 Sub Water Inlet10 Water Inlet11 Propeller

12 Drive Shaft Housing13 Thrust Rod14 Clamp Bracket15 Clamp Screw16 Throttle Grip*217 Shift Lever*218 Starter Handle19 Stop Switch20 Warning Lamp21 Fuel Connector22 Starter Switch*323 Choke Knob*2

24 Water Plug25 Oil Plug (Upper) (Level)26 Oil Plug (Lower) (Fill)27 Oil Filter28 Spark Pulg29 Oil Filler Cap*1: Power tilt type only.*2: Tiller handle type only.*3: Electrical starter type only.

PARTS NAME16

3

MF, EF, EP, EFT, EPT

37

36

40

4142

44

39

*538

43

*4

30

31

33

32

34

35

ENOF01203-0

Power Tilt Type

30 Primer Bulb31 Fuel Tank Cap32 Air Vent Screw33 Fuel Connector34 Fuel Pick up Elbow35 Fuel Tank36 Clamp Screw *437 Power Tilt *138 Power Tilt Switch *539 Remote Control Box *540 Main Switch *541 Stop Switch *5

42 Cord Assembly *543 Engine Stop Switch Cord *544 Power Tilt Switch*4: Power tilt, tiller handle type only.*5: Remote control type only.

17

4

LABEL LOCATIONSENOM00019-A

Warning label locations

12

8

7

5

6

3, 4

ENOF01204-1

LABEL LOCATIONS18

4

1. Warning label urge to read the owner’smanual .

2-1. Warning regarding emergency start-ing (See page 36).

2-2. Warning regarding high temperature.2-3. Warning regarding rotating object.2-4. Warning regarding high voltage

3. Warning label regarding stop switch(See page 34, 35, 43, 43)

4. Warning label regarding oil pressure(See page 29).

5. Warning label regarding position ofoutboard motor when setting down.

For RC model6. Warning label regarding stop switch

lanyard.

7. Warning regarding gasoline (Seepage 26).

8. Warning regarding gasoline (Seepage 26).

ENOF00120-0

3PA-72181-1001

2 34

ENOF00131-B

ENOF00131-0

ENOF00006-0

ENOF00005-D

ENOF00005-S

ENOF00005-L

LABEL LOCATIONS 19

4

ENOM00019-B

1. Model code(Model name)2. Rated power3. Dry mass weight( Without propeller, with battery

cable)4. Serial No.5. Manufacture name6. Manufacture address

CE label locations

:rewoP detaR

rotoM draobtuO

.oN laireS:ssaM

napaJ ni edaM

0123

CAN ICES-2/NMB-2

ENOF01237-2

2)3)4)5)6)

1)

Description of serial number year code

Last two digits of alphabet represent production year as below.

Year Code AG AH AK BX BA

Year of manufacture

2017 2018 2019 2020 2021

20

5

INSTALLATIONENOM00024-A

ENOW00006-B

Before installing the outboard motor on theboat, hang the outboard motor with thehoist or equivalent device by attaching theengine hanger to the outboard. Use thehoist with allowable load is 150 kg (330 lbs)or above.

ENOW00006-0

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

Do not operate the outboard motor until ithas been securely mounted on the boat inaccordance with the instructions below.

ENOW00009-0

Mounting the outboard motor withoutfollowing this manual can lead to unsafeconditions such as poor maneuverabil-ity, lack of control or fire.Loose clamp screws and/or mountingbolts can lead to the release or displace-ment of the outboard motor, possiblyresulting in lost of control and/or seriouspersonal injury. Be sure that fastenersare tightened to the specified torque (30N·m (3.0 kgf·m) 13 ft·lb). Check the fas-teners for tightness from time to time.Be sure to use outboard mounting fas-teners included in the outboard motorpackage or their equivalents in terms ofsize, material, quality and strength.Tighten fasteners to the specified torque(30 N·m (3.0 kgf·m) 13 ft·lb). Test cruiseto check if fasteners are tightenedsecurely.Outboard motor mounting must be per-formed by trained service person(s)using lift or hoist with sufficient capacity.

Outboard motor mounting must be per-formed by trained service person(s) usinglift or hoist with sufficient capacity.

1. Mounting the outboard motor on boat

WARNING

WARNING

ENOF01206-0

WARNING

INSTALLATION 21

5

ENOM00025-0

Position ... Above keel lineSet engine at center of boat.

1. Center of boat2. Boat transom

ENOM00026-0

Transom matchingBe sure that the anti ventilation plate of theoutboard motor is 5–25 mm (0.2–1 in)below the bottom of hull.If the above condition cannot be met dueto the shape of the bottom of your boat,please consult your authorized dealer.

1. Bottom of hull2. Anti ventilation plateENOW00007-0

Before beginning the running test, checkthat the boat with maximum capacityloading floats on the water in a properattitude. Check the position of watersurface on the driveshaft housing. If thewater surface is near the bottom cowl-ing, in high waves, water may enter theengine cylinders.

Incorrect outboard motor mountingheight or existence of underwaterobject(s), such as hull bottom design,bottom surface conditions or underwa-ter accessories, can cause water spraypossibly reaching the engine through anopening of the bottom cowling duringcruising. Exposing the engine to suchconditions for extended periods canlead to severe engine damage.

ENOM00830-A

Mounting bolts

Manual tilt type1. To attach the outboard motor to the

boat, tighten the clamp screws byturning their handles.Also, use the bolts to secure the out-board motor brackets on transomboard.Secure the outboard motor with a ropeto prevent loss overboard.

ENON00002-0

Note

A rope is not included in the standardaccessories.

1. Bolt (8 × 85)2. Nut3. Washer4. Clamp screwENOW00945-0

Please inspect whether there is a loos-ening of the clamp screw or mountingbolts before departure.Loosening may cause a dangerous situ-ation, such as loss of control.

CAUTION

2

1

ENOF01141-0

1

2

5−25 mm(0.2−1 in)

ENOF01208-0

CAUTION

1

4

2

3

ENOF00016-0

INSTALLATION22

5

PTT type1. To attach the outboard motor to the

boat, use the bolts to secure the out-board motor brackets on transomboard.

1. Bolt (12 × 105)2. Washer (small diameter)3. Nut4. Washer (large diameter)

View AENOW00008-A

Mounting bolts should be installed withthe bolt head at inside surface of the

transom. Mounting bolts installed withthe threaded end at the inside surface ofthe transom can cause personal injury.Tighten the bolts sufficiency, otherwisefalling down of outboard could be hap-pened.

ENON00003-0

Notes

1. Apply sealing agent, such as siliconesealed between the bolts and the tran-som board holes before tightening thebolts.

2. Be sure to tighten the mounting boltnuts to the specified torque.(30 N·m (3.0 kgf·m) 13 ft·lb)

ENOM00840-0

ENOW00100-A

Be careful not to loop the remote controlcables to a diameter of 406 mm (16 in) orless. Otherwise, it affects the service life ofthe cable.

ENOW00850-0

Remote control box location

1. Shift cable2. Throttle cable3. Cable harness B

CAUTION

4

1

A

2 5

3 ENOF00308-0

193187

275

188

64

36

1818

1818

51

194152

∅11

12-∅

10

ENOF00305-0

2. Remote control device installation

CAUTION

3

1, 2

ENOF00841-0

INSTALLATION 23

5

Install the remote control box in a positionwhere it is easy to reach and operate thecontrols. Make sure there are no obstacles that caninterfere with the operation of the remotecontrol cable.

ENOW00850-0

Remote control cable length

Measure the distance from the remotecontrol box to the outboard motor wherethe remote control cable should be routed. Prepare a cable that is 300-450mm (11.8-17.7in) longer than the measured distance. Temporari ly pul l the cable along theintended cable route to check its length issufficient. Connect the remote control cable to theengine, then run the cable to the remotecontrol box, making sure it is not sharplybent, too taut and free from obstructionsthat could interfere with steering.

ENOM00029-A

ENOW00012-0

Battery electrolyte contains sulfuric acidand thus is hazardous, causing a burn if it

comes in contact with your skin, or poison-ous if swallowed.Keep battery and electrolyte away fromreach of childrenWhen handling the battery, be sure to:

Read all warnings shown on the batterycasePrevent electrolyte from coming in con-tact with any part of your body. Contactcan cause serious burn or, if it comes incontact with your eye, loss of sight. Usesafety glasses and rubber gloves.

In case battery electrolyte comes in con-tact with:

Skin, flush thoroughly with water.Eye, flush thoroughly with water, andthen seek immediate medical treatment.

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

ENOW00013-A

Battery generates explosive hydrogen gas.Be sure to:

Charge the battery in a well-ventilatedplace.Place the battery away from any sourceof fire, sparks and open flames such asburners or welding equipment.Do not smoke near the battery when thebattery is charging.Do not charge the battery when theelectrolyte level is low. Otherwise, thebattery will be damaged and may causemalfunction.

ENOW00014-0

Make sure that the battery leads do notget stuck between the outboard motorand boat when turning, etc.The starter motor may fail to operate ifthe leads are incorrectly connected.

3. Battery installation

WARNING

ENOF00842-0

WARNING

CAUTION

INSTALLATION24

5

Be sure to correctly connect the (+) and(—) leads. If not, the charging systemwill be damaged.Do not disconnect the battery leadsfrom battery while the engine is operat-ing, the electrical parts could be dam-aged.Always use a fully charged battery.

ENOW00015-0

Do not use a battery that is not recom-mended. Use of a battery not recom-mended can lead to poor performance of,and/or damage to, the electrical system.

ENON00006-A

Note

Recommended battery: 12V 70Ah/5HR,650 (Cold Cranking Amps (CCA), In case ofcold whether: 12V100Ah/5HR (850CCA))Specifications and features of batteries varyamong the manufacturers. Consult themanufacturer for details.* The battery should be purchased sepa-rately and is not supplied with the outboardmotor.

1. Place the battery box in a convenientposition away from possible waterspray. Securely fasten both the boxand the battery so they do not shakeloose.

2. Connect the positive lead (+) to thepositive terminal (+) of the battery, andthen connect the negative lead (—).When disconnect ing the batteryalways remove the negative lead (—)first. After connecting the positive ter-minal (+), securely place a cap on it toprevent short circuits.

1. Battery cord (red)2. Battery cord (black)

CAUTION

2

1 ENOF00022-0

25

6

PRE-OPERATING PREPARATIONSENOM00030-A

ENOW000017-0

Use of improper gasoline can damage yourengine. Engine damage resulting from theuse of improper gasoline is consideredmisuse of the engine, and damage causedthereby will not be covered under the lim-ited warranty.

ENOM00031-A

FUEL RATINGTOHATSU engines will operate satisfacto-rily when using a major brand of unleadedgasoline meeting the following specifica-tions:USA and Canada — having a postedpump Octane Rating of 87 (R+M)/2 mini-mum. Premium gasoline (92 [R+M]/2Octane) is also acceptable. Do not useleaded gasoline.Outside USA and Canada — Useunleaded gasoline with declared octanerating of 91 RON or over. Use of premiumgasoline of 98 RON is also allowed.

ENOM00032-A

GASOLINES CONTAINING ALCOHOLThe fuel system components on yourTOHATSU engine will withstand up to 10%ethyl alcohol (hereinafter referred to as the"ethanol"), content in the gasoline. Buteven if the gasoline in your area containsethanol less than 10%, you should beaware of certain adverse effects that canoccur. Increasing the percentage of etha-nol in the fuel can also worsen these

adverse effects. Some of these adverseeffects are caused because the ethanol inthe gasoline can absorb moisture from theair, resulting in a separation of the water/ethanol from the gasoline in the fuel tank.These may cause increased:

Corrosion of metal partsDeterioration of rubber or plastic partsFuel permeation through rubber fuellinesStarting and operating difficulties

If the use of gasoline containing alcohol isinevitable, or presence of alcohol is sus-pected in the gasoline, it is recommendedto add a filter that has water separatingcapability, and check the fuel system forleaks and mechanical parts for corrosionand abnormal wear more frequently.And, in case any of such abnormality isfound, discontinue the use of such gaso-line and contact our dealer immediately.If the outboard motor will only be usedinfrequently, please see the remarks onfuel deterioration in the STORAGE chapter(P 78) for additional information.

ENOW00020-1

When operating a TOHATSU engine ongasoline containing alcohol, storage ofgasoline in the fuel tank for long periodsshould be avoided. Long periods of stor-age, create unique problems. In cars, alco-hol blend fuels normally are consumedbefore they can absorb enough moisture tocause trouble, but boats often sit idle longenough for phase separation to take place.In addition, internal corrosion may takeplace during storage if alcohol has washed

1. Fuel handling

CAUTION

CAUTION

PRE-OPERATING PREPARATIONS26

6

protective oil films from internal compo-nents.

ENOW00018-0

Fuel leakage can cause fire or explosion,potentially leading to severe injury or lossof life. Every fuel system part should bechecked periodically, and especially afterlong term storage, for fuel leak, change ofhardness of rubber, expansion and/or cor-rosion of metals. In case any indication offuel leakage or degradation of fuel part isfound, replace relevant part immediatelybefore continuing operation.

ENOW00019-1

Do not fill the fuel tank over capacity. Therise of gasoline temperature may causegasol ine to expand which, may leakthrough air vent screw when it is open.Leaking gasoline is a dangerous fire haz-ard.

ENOM00043-B

ENOW00028-A

Consult an authorized dealer for details onhandling gasoline, if necessary.

Gasoline and its vapors are very flammableand can be explosive.

When carrying a fuel tank containing gaso-line:

Close the fuel tank cap and air ventscrew of fuel tank cap, or gasoline vaporwill be emitted through the air ventscrew, creating a fire hazard.Do not smoke.

When or before refueling:

Be sure to remove the static electricitycharged in your body before refueling.The sparks due to static electricity maycause explosion of flammable gasoline.Stop the engine, and do not start theengine during refueling.Do not smoke.Be careful not to overfill fuel tank. Wipeup any spilled gasoline immediately.

When or before cleaning the gasoline tank:Dismount fuel tank from the boat.Place the fuel tank away from everysource of ignition, such as sparks oropen flames.Do the work outdoors or in a well venti-lated area.Wipe off gasoline well immediately ifspilled.

After cleaning gasoline tank:Wipe off gasoline well immediately ifspilled.If the fuel tank is disassembled forcleaning, reassemble carefully. Imper-fect assembly may cause a fuel leak,possibly leading to fire or explosion.Dispose aged or contaminated gasolinein accordance with local regulations.

EENOW00029-A

When opening fuel tank cap, be sure to fol-low the procedure described below. Fuelcould blast out through the fuel tank cap incase the cap is loosened by using anotherprocedure when internal pressure of fueltank is raised by heat from sources such assun light.

ENOW00946-0

Separate tank must be fixed at appropriateposition so that well ventilated and tankdoes not move or fall down while operat-ing.

WARNING

WARNING

2. Fuel filling

WARNING WARNING

CAUTION

PRE-OPERATING PREPARATIONS 27

6

1. Full open the air vent screw on the tankcap and release internal pressure.

1. Air vent screw2. Tank cap

2. Open the fuel tank cap slowly.3. Fill the fuel carefully not to over flow.

4. After filling the tank, close the fule tankcap.

ENOM00037-A

ENOW00022-A

The engine oil is drained for shipping fromthe factory. Be sure to fill the engine to theproper level before starting engine. (Toproperly fill the engine with oil follow theinstructions, See page 63)

Use only high quality 4-stroke engine oil toinsure performance and prolonged enginelife.The SAE oil viscosity 10W-30 or 10W-40FC-W outboard motor engine oil is recom-mended.You can also use oils that carry the APIrating of SH, SJ, or SL. Select the appro-priate viscosity, based on atmospherictemperature, from the chart below.

ENOW0002A-A

Use of engine oils that do not meet theserequirements will result in reduced enginelife, and other engine problems.

3. Engine oil recommendation

CAUTION

12

ENOF00417-0

SAFE FILLLEVEL12 L

NIVEAUMAXIMUM

ENOF00419-A

CAUTION

ENOF01209-0

10W−40

10W−30

˚C˚F

4096

3086

2068

1050

032

-1014

-20-4

-30-22

ENOF00208-0


6

]ENOM00033-A

Your new outboard motor and lower unitrequire break-in for the moving compo-nents accord ing to the cond i t ionsdescribed in the following time table.Please refer to ENGINE OPERATION sec-tion (See page 36) to learn how to cor-rectly start and operate the outboardmotor.ENOW00024-A

Do not operate the outboard motor inclosed area or area with no forced ventila-tion.Exhaust gas emitted by this outboardmotor contains carbon monoxide that willcause death if inhaled continuously. Inhal-ing the gas initially causes symptoms suchas feeling of sickness, drowsiness andheadache.During operation of the outboard motor:

Keep peripheral area well ventilated.Always attempt to stay on the windwardside of emission.

ENOW00023-1

Operating the outboard motor withoutbreak-in can shorten service life.If any abnormality is experienced duringthe break-in:

Discontinue the operation immediately.Have the dealer check the product andtake proper action(s) if necessary.

ENON00008-0

Note

Proper break-in allows outboard motor todeliver it full performance for longer servicelife.

4. Break-In

DANGER

CAUTION

1–10 min 10 min – 2 hrs 2–3 hrs 3–10 hrs After 10 hrs

Throttle Position IdleLess than 1/2

throttleLess than 3/4

throttle3/4 throttle

Full throttle available

SpeedApprox. 3000

min-1 (rpm) max

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


6

ENOM00039-C

If outboard motor encounters an abnormalcondition of fault, the warning horn willemit a continuous beep or intermittentshort beeps and the warning lamp (LED)will synchronize with the horn and enginespeed will be limited (engine will not bestopped).*No horn is located for tiler handle typeand EP type.See next page for conditions which willlead to an abnormal condition or fault.

ENOM00040-C

Location of warning horn and lamp

Warning hornRC model: Located inside the remote con-trol.Tiller handle model: No warning horn.

Warning lamp (LED)RC model: Located in the tachometer &bottom cowl.Tiller handle models:Located on the bot-tom cowl

ENON00009-A

Note

Warning lamp for optional tachometer willsynchronize with the waring lamp for engineside.

1. Warning lamp

1. Warning lamp

5. Warning system

1

ENOF00851-A

ENOF00314-A1

1


6

ENOM00041-D

Warning indicators, faults and remedy

Remarks*1: In this case, oil pressure switch is “ON”.*2: It is necessary to stop the engine, if you want to stop the working indicators and re-set the warning system.

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, and the ESG is activated not to ignite the spark plug, therefore, the engine speed varies and be controlled under 6300min-1 (rpm).

Low speed ESGLow speed ESG is a device to prevent the engine from getting damage. If the engine has problems regarding oil pressure the low speed ESG is activated not to ignite the spark plug, the engine speed varies and be controlled under 2800min-1 (rpm).

Warning indicatorsDescription of faults Remedy

Sound Lamp (LED) ESG

-On for several

sec.- Normal system test when start up

- - High speed ESGEngine speed exceeds maximum

allowable RPM 1

Continuous*2 ON*2 Low speed ESG Low oil pressure*1 2


6

Remedy1. Reduce the throttle to less than half

opening, and move to safe placequickly, and stop the engine.Check the propeller for bent or dam-aged blades.Consult an authorized dealer if engineshows the same result even afterreplacing propeller with new one.

2. Move to safe place quickly, and stopthe engine.Check the engine oil level, and addengine oil if necessary.Consult your dealer if the engine oillevel is too low or too high.

ENOW00025-A

Low speed ESG ON: Engine speed willbe limited to 2800 min-1 (rpm), howeveryou should not continue to run engine.High speed ESG ON: Engine speed willbe l imited to 6300 min-1 (rpm) andengine will run rough until throttle isreduced.

CAUTION

32

7

ENGINE OPERATIONENOM00042-0

ENOW00022-A

The engine oil is drained for shipping fromthe factory. Be sure to fill the engine to theproper level before starting engine. (Toproperly fill the engine with oil follow theinstructions. See page 63)

ENOW00027-A

Before starting engine for the first timeafter reassembling engine or off-seasonstorage, disconnect stop switch lock andcrank approximately 10 times in order toprime the oil pump.

ENOM00044-C

ENOW00029-A

When opening fuel tank cap, be sure to fol-low the procedure described below. Fuelcould blast out through the fuel tank cap incase the cap is loosened by using another

procedure when internal pressure of fueltank is raised by heat from sources such assun light.

ENOW00947-0

When using a separate tank, be sure thatthe fuel line is not kinked and is connectedsecurely.

1. Full open the air vent screw on the tankcap.

1. Air vent screw2. Fuel tank cap

2. Open the fuel tank cap slowly andrelease internal pressure completely.After that, close the fuel tank cap.

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

1. Fuel connector2. Push3. Insert

Before starting

CAUTION

CAUTION

1. Fuel feeding

WARNING

ENOF01209-0

CAUTION

12

ENOF00417-0

1

2233

ENOF00310-0

ENGINE OPERATION 33

7

1. Pull2. Insert4. Squeeze primer bulb until it becomes

stiff to feed fuel to carburetor. Directarrow mark upward when priming.

1. Engine side2. Fuel tank side

Do not squeeze primer bulb with enginerunning or when the outboard motor istilted up. Otherwise, fuel could overflow.ENOM00045-B

ENOW00036-A

When the engine is started in the test tank,to avoid over heating and water pumpdamage, be sure the water level is at least10 cm (4 in.) above the anti ventilationplate.And be sure to remove the propeller, whenstarting the engine in the test tank. (Seepage 68)Run the engine only at idling.

1. Test tank2. Water3. Over 10 cm (4 in.)

ENOW00036-0

Be sure to stop engine immediately if cool-ing water check port is not dischargingwater, and check if cooling water intake isblocked. Operating engine could lead tooverheating potentially leading to enginedamage. Consult an authorized dealer ifthe cause cannot be found.

ENOW00032-A

Do not hold turning starter motor morethan 5 seconds, or the battery may be con-sumed, potentially making the engine start-ing impossible and/or damaging thestarter. If cranking over 5 seconds fails to startengine, return main switch to “ON”, andcrank engine again after 10 seconds ormore.Do not try to crank after engine hasstarted.

This model is provided with start in gearprotection.

2. Starting the engine

CAUTION

12

ENOF00861-A

1

2ENOF00862-0

CAUTION

CAUTION

1

3

2

ENOF00863-0

ENGINE OPERATION34

7

ENON00010-0

Note

Start-in-gear protection prevents enginefrom starting at other than neutral shift. In-gear starting of engine will move the boatimmediately, potentially leading to fallingdown or causing passenger(s) to be thrownoverboard.

Tiller handle type1. Be sure to install the stop switch lock

to the stop switch, and attach the stopswitch lanyard securely to the operatoror to the operator's PFD (Personal Flo-tation Device.)

1. Stop switch lock

2. Set the control lever in the Neutralposition.

1. Shift lever

3. Set the throttle grip to START position.

1. Throttle grip

4. Pull the choke knob fully.

1. Choke knobENON00501-0

Note

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

ENON00502-0

Note

If engine does not start with 4 or 5 timesstarting operation, push the knob back andrestart.

(For manual starter type)This engine is equipped with a compres-sion release mechanism.

1

ENOF00310-A

ENOF01210-0

R

N

F1

1ENOF01107-0

1 ENOF00314-0

ENGINE OPERATION 35

7

5. Pull the starter handle slowly until youfeel engagement, keep pulling till youfeel less resistance. Then pull it quickly.repeat if necessary until started.

1. Slowly2. Quickly3. Starter handle

(For electrical starter type)4. Push the starter switch button and

release the button when the enginehas started.

1. Starter Button

5. Check the cooling water from coolingwater check port.

Side mount RC type1. Be sure to install the stop switch lock

to the stop switch, and attach the stopswitch lanyard securely to the operatoror to the operator's PFD (Personal Flo-tation Device.)

1. Stop switch lock

2. Insert the main switch key.3. Set the control lever in the Neutral

position. 4. Raise the free accel lever a little (both

of cold engine and warm engine). ENON00504-0

Note

The free accel lever can not be raised whenthe control lever shift is in Forward orReverse.

ENOF01211-0

1 2

3

1 ENOF00315-0

ENOF01212-0

1ENOF00869-0

ENGINE OPERATION36

7

1. Neutral (N)2. Control lever3. Fully open (Forward)4. Fully open (Reverse)5. Free throttle lever6. Main switch key7. Stop switch

5. Turns the main switch key to STARTposition. Then, continuously push thekey to operate the choke.

ENON00503-0

Note

Choke operation is not necessary if theengine is warm.

1. ON2. START3. OFF4. Push operate choke

6. Stop pushing the key when the enginehas started.

The key returns to the original position,automatically.

7. Returns the Free accel lever to closeposition.

8. Confirm warning lamp light up andthen go off after engine has started.

1. Warning lamp9. Check the cooling water from cooling

water check port.

ENOM00042-B

Emergency startingENOW00099-A

When the emergency starter rope is usedfor starting engine;

Start in gear protection does not work.Be sure to shift is at neutral position.Otherwise the engine will move the boatimmediately and cause personal injury. Be careful that your clothes or otheritems do not get caught in the rotatingengine parts.To prevent accident and injury by rotat-ing parts, do not re-attach flywheel

NRF

1 2

3

4

5

67

ENOF00870-0

1

23

4

ENOF00871-A

WARNING

1

ENOF00851-A

ENOF01212-0

ENGINE OPERATION 37

7

cover and the top cowl after the enginehas been started.Do not pull starter rope if any bystanderis behind. The action can injure thebystander.Attach engine stop switch lanyard toclothing or any part of body like armbefore starting engine.

1. Remove the top cowl.

2. Remove starter lock cable from recoilstarter by pulling the starter lock cable.

3. Remove the bolts (5pcs) and removethe recoil starter.

4. Insert the knotted end of the starterrope into the notch in the flywheel andwind the rope around the flywheel sev-eral turns clockwise.

5. Tie a loop in the another end of theemergency starter rope and attachsocket wrench that is included in thetool kit.

ENOF01213-0

ENOF00124-0

ENOF00125-0

ENOF00126-0

ENGINE OPERATION38

7

ENOW00860-0

Be sure to keep the harness away from therotation parts.

6. Be sure to install the stop switch lockto the stop switch, and attach the stopswitch lanyard securely to the operatoror to the operator's PFD (Personal Flo-tation Device.)

7. Set the control lever in the Neutralposition.

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

9. After engine starts, do not reinstall fly-wheel cover and top cowl.

ENOM00518-0

If the choke solenoid fails to operate (EP and EPT type only)

1. Remove the top cowl.2. Close the choke plate by finger.3. Raise the Free accel lever a little.4. Turn the main switch key to start posi-

tion.

5. Stop pushing the key when the enginehas started.

6. Return the choke plate to open posi-tion.

ENOM00043-B

ENOW00932-0

Be sure to check that cooling water iscoming out of the cooling water check portduring warm up.

Warm the engine at low engine speeds forabout

CAUTION

ENOF01214-0

3. Warming up the engine

CAUTION

ENOF00320-0

ENOF00321-0

ENGINE OPERATION 39

7

3 minutes : above 5°C (41°F) 5 minutes at 2000 min-1 (rpm) : below 5°C(41°F)This allows the lubricating oil to circulate toall parts of the engine. Operating theengine without warm up shortens theengine's life.

ENOM00044-0

Engine speedsIdling speed after warming up.Remark: In case of cold engine starting,idling speed is increased about 400 min-1

(rpm) for several minutes.

ENOM00046-A

ENOW00037-0

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

ENOW00038-A

Attach other end of emergency stopswitch lanyard to the operator's PFD(Personal Flotation device) or arm andkeep it attached during cruising.Do not attach the tether to a part ofclothing that can be torn easily whenpulled. Arrange the tether so that will not becaught by any object when pulled.Be careful not to pull the tether acciden-tally during cruising. Unintentional stopof engine can cause loss of control ofoutboard motor. Rapid loss of enginepower can lead to falling down or caus-ing passenger(s) to be thrown over-board.

ENOW00042-0

Do not shift into Reverse during planing,or control will be lost leading to seriouspersonal injury, boat may swamp, and/or hull may be damaged.Do not shift into Reverse during cruis-ing, or control may be lost, falling downor causing passenger(s) to be thrownoverboard. Leading to serious personalinjury, and steering system and/or shift-ing mechanism may be damaged.

ENOW00861-0

Do not shift at high boat speed, or controlmay be lost, falling down or causing pas-senger(s) to be thrown overboard. Leadingto serious personal injury.

ENOW00862-0

Gear and clutch damage may occur if shift-ing at high engine speed.

Clutch in (In gear) Clutch off (Out of gear)

900 min-1 (rpm) 950 min-1 (rpm)

4. Forward, reverse, and acceleration

WARNING

ENOF01212-0

WARNING

WARNING

WARNING

CAUTION

ENGINE OPERATION40

7

Engine must be in the slow idle positionbefore shifting is attempted.

ENOW00863-0

Idle speed may be higher during warmingup of engine. If shifted to Forward orReverse during warming up, it may be diffi-cult to shift back to neutral. In such case,stop engine, shift to neutral, and restartengine to warm up.

ENON00014-0

Note

Frequent shifting to forward or reverse canaccelerate wear or degradation of parts. Insuch case, replace gear oil earlier than theperiod specified.

ENOW00864-0

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

ENOM00890-A

Tiller handle typeENOW00865-A

Do not force to shift when the throttle gripis not in the fully closed position, other-wise, steering system and/or shiftingmechanism may be damaged.

ENOW00867-0

Sudden acceleration and deceleration maycause passenger(s) to be thrown over-board or falling down.

1. Shift lever

Forward1. Turn the throttle grip to reduce engine

speed. 2. When the engine reaches trolling (or

idling) speed, quickly pull the shift leverto the Forward position.

Reverse1. Turn the throttle grip to reduce engine

speed. 2. When the engine reaches trolling (or

idling) speed, quickly pull the shift leverto the Reverse position.

AccelerationENOW00867-0


CAUTION

CAUTION

CAUTION

WARNING

WARNING

ENOF01210-0

R

N

F1

ENGINE OPERATION 41

7

Open throttle grip gradually.

1. Throttle grip

ENOM0900-0

Side mount RC typeENOW00867-0


1. Forward (F)2. Neutral (N)3. Reverse (R)4. Fully open (Forward)5. Fully open (Reverse)6. Free throttle lever7. Control lever8. Lock button

Forward1. Quickly push the control lever to the

Forward (F) position 32°, where thegear is connected, while lifting up onthe lock button located under the con-trol lever grip.

2. Further forward motion will open thethrottle.

Reverse1. Quickly pull the control lever to the

Reverse (R) position at 32°, where thegear is connected, while lifting up onthe lock button located under the con-trol lever grip.

2. Further rearward motion will open thethrottle.

AccelerationENOW00867-A


Open control lever gradually.

1. Control lever

WARNING

ENOF01119-01

NRF

78

12 3

4

57

6

ENOF00877-0

CAUTION

NRF

1

ENOF00879-A

ENGINE OPERATION42

7

ENOM00049-A

ENOW00868-0

Be careful not to remove engine stopswitch lanyard from engine accidentallywhile boat is running. Sudden stop ofengine can cause loss of steering control.It can also cause loss of boat speed, possi-bly leading the crew(s) and or objects onthe boat to be thrown forward due to iner-tial force.

Tiller handle type1. Turn the throttle grip to the slow posi-

tion.

1. Throttle grip2. Put the shift lever in the Neutral posi-

tion.Run the engine for 2-3 minutes atidling speed for cooling down if it hasbeen running at full speed.

3. Turn the main switch key to the OFFposition or push the stop switch. ( Donot forget to turn the key off).

Side mount RC type1. Put the control lever in the Neutral

position and run the engine for 2-3minutes at idling speed for coolingdown if it has been running at fullspeed.

2. Turn the main switch key to the OFFposition or push the stop switch. ( Donot forget to turn the key off).

1. Control lever

5. Stopping the engine

WARNING

1ENOF01107-0

ENOF00314-B

NRF

2

1

ENOF00881-0

ON

OFFSTART

2

ENOF00882-0

ENGINE OPERATION 43

7

2. Main switch key

ENOW00869-0

After stopping the engine:Close the air vent screw on the tank cap.Disconnect the fuel connector of theengine and the fuel tank.Disconnect the battery cord, after eachuse.

Emergency engine stoppingRemove stop switch lock to stop theengine.

1. Stop switch2. Stop switch lock

1. Stop switch2. Stop switch lock

ENOM00910-0

Spare emergency stop switch lockA spare emergency stop switch lock isprovided in the tool bag.

When used as described, the emergencystop switch clip and emergency stopswitch lanyard system stops the engine ifthe operator falls away from the controls.When an operator falls into water, be sureto use emergency stop switch lock of thespare.Be sure to confirm the spare stop switchlock is in the tool bag before begin to oper-ate.

ENOM00920-0

ENOW00870-0

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

Tiller handle typeRight turnMove the tiller handle to the leftLeft turnMove the tiller handle to the right.

WARNING

1

2

ENOF00314-C

1

2ENOF00884-0

6. Steering

WARNING

ENOF00891-0

ENGINE OPERATION44

7

Remote control typeRight turnTurn the steering wheel to the right.Left turnTurn the steering wheel to the left.

ENOM00050-0

ENOW00043-A

Adjust the trim angle when the engine isstopped.Do not put hand or finger in betweenoutboard motor body and clamp bracketwhen adjusting trim angle to prevent

injury in case the outboard motor bodyfalls.Unsuitable trim position can cause lossof control of boat. When testing a trimposition, run boat slow initially to see if itcan be controlled safely.

ENOW00044-0

Excessive trim up or down may lead tounstable boat operation, potentially caus-ing the steering difficulty that leads to acci-dent during cruising.

Do not cruise at high speed if impropertrim position is suspected. Stop the boatand readjust trim angle before continu-ing cruise.For outboard motor model with PTTswitch on the bottom cowl, do not oper-ate the switch during cruising, or controlof boat may be lost.

The trim angle of the outboard motor canbe adjusted to suit the transom angle ofthe hull, and load conditions. Choose anappropriate trim angle that will allow theanti-ventilation plate to run parallel to thewater surface during operation.

ENOM00052-0

Proper trim angleThe position of the thrust rod is correct ifthe hull is horizontal during operation.

1. Perpendicular to the water surface

7. Trim angle

WARNING

ENOF00892-0

ENOF00893-0

WARNING

1

ENOF00051-1

ENGINE OPERATION 45

7

ENOM00053-0

Improper trim angle (bow rises too high)Set the thrust rod lower if the bow of theboat rises above horizontal.

ENOM00054-0

Improper trim angle (bow dips into the water)Set the thrust rod higher if the bow of theboat is below horizontal.

Manual Tilt type

1. Thrust rod2. Higher3. Lower

Power Tilt type

1. Thrust rod2. Higher3. Lower

Trim angle adjustment (Manual tilt type)The transom angle adjustment 1. Stop the engine.2. Shift into neutral.3. Raise the outboard motor to the tilt up

position.4. Change the thrust rod position as fol-

lowing picture.

1. Push in2. Rise the stopper3. Pull out

5. Reinstall the thurst rod securely.6. Gentry lower the outboard.

ENOF00052-0

ENOF00053-0

1

3

2

ENOF00674-A

3

222

ENOF00674-B

1

32

1

ENOF01238-1

ENGINE OPERATION46

7

Trim angle adjustment (Power tilt type)The transom angle adjustment 1. Stop the engine2. Operate the Power Tilt switch and

raise the outboard motor to the tilt upposition.

3. Lock the tilt with the Tilt stopper.4. Change the trim lock pin position as

following picture.

1. Tilt lock pin2. Higher3. Lower

5. Reinstall the tilt lock pin securely.6. Operate the Power Tilt switch and

lower the outboard.

ENOM00060-B

ENOW00055-0

Do not tilt up or down outboard motorwhen swimmer(s) or passenger is near toprevent them from being caught betweenoutboard motor body and clamp bracket incase the outboard motor body falls.

ENOW00048-0

When tilting up or down, be careful not toplace your hand between the swivelbracket and the stern bracket.Be sure to tilt the outboard motor downslowly.

ENOW00056-A

When tilting up outboard motor with fueljoint for over a few minutes, be sure to dis-connect fuel hose, or fuel may leak, poten-tially catching fire.

ENOW00057-0

Do not tilt up outboard motor while engineoperates, or no cooling water may be fed,leading to engine seizure due to overheat-ing.

ENON00921-0

Note

Before tilting the outboard motor up, afterstopping the motor leave it in the runningposition for about a minute to allow water todrain from inside the engine.

ENOM00062-0

Manual Tilt typeTilt upPush the reverse lock lever down until itstops. (This is the tilt up position.) Now, tiltthe outboard motor all the way up until it islocked in place.

8. Tilt up and down

WARNING

31

22

ENOF01426-0

WARNING

WARNING

CAUTION

ENGINE OPERATION 47

7

1. Reverse lock lever2. Tilt up position3. Tilt down position

ENOM00063-0

Tilt downPull the reverse lock lever upward until itstops. (This is the tilt down position.) Now,lift up the outboard motor slightly, and thenallow gravity to lower it for you.


1

2

3

ENOF00059-0

ENOF01216-0

1

2

3

ENOF00059-0

ENGINE OPERATION48

7

ENOM00069-A

Power Tilt typeTilt up1. Operate the Power Tilt switch and tilt

the outboard motor up.2. Lock the tilt with the Tilt stopper after

the outboard motor has been tilted upTilt down1. Release the tilt stopper from the set-up

position while slightly tilting up out-board motor.

2. Operate the Power Tilt switch and tiltthe outboard motor down until themotor touches to the thrust rod.

1. Tilt stopper

The outboard motor can also be tilted upand down using the switch provided underthe bottom cowl.

It is possible to tilt up or down in spite ofmain switch “ON” or “OFF”.

ENOM00940-0

Manual relief valveIf the battery is dead, and the power tiltswitch thus inoperative, open the manualvalve completely in the Manual direction.This will allow manual tilting of the out-board motor.ENOW00872-0

Make sure the manual relief valve is closedbefore operating the outboard motor. If themanual relief valve is not closed, the out-board motor will tilt up when operated inreverse.

ENOW00873-0

Before opening the manual relief valve,make sure nobody is under the outboardmotor. If the outboard motor is in the tiltedup position, it will tilt down suddenly if themanual relief valve is loosened in the "Man-ual" direction.

UP

UPDN

DN

ENOF00067-A

1

ENOF00069-A

WARNING

WARNING

ENOF01217-0

ENGINE OPERATION 49

7

1. Power2. Manual

ENOM00068-A

ENOW00051-0

During shallow water operation, be carefulnot to place your hand between the swivelbracket and the clamp bracket. Be sure totilt the outboard motor down slowly.

ENOW00053-0

While in shallow water drive position, donot operate the outboard motor in Reverse.Operate the outboard motor at slow speedand keep the cooling water intake sub-merged.

ENOW00054-0

Do not overtilt outboard motor when driv-ing shallow water, or air may be sucked

through water inlet and sub-water inlet,potentially leading to engine overheating.

1. Water inlet2. Sub-water inlet

Manual tilt type1. Shallow water running position:

Put the reverse lock lever in the tilt upposition, and tilt up the outboard motorto put the outboard motor in the shal-low water running position.


2. Return to normal running position:Put the reverse lock lever in the tiltdown position, slightly lift up the out-board motor, and then put it down.

9. Shallow water operation

WARNING

CAUTION

CAUTION

1

2 ENOF00326-0

1

2

ENOF01144-0

1

2

3

ENOF00059-0

ENGINE OPERATION50

7


ENOM00069-A

Power Tilt type1. Operate the Power Tilt switch and tilt

the outboard motor up into desiredshallow water running position.

1

2

3

ENOF00059-0

UPDN

ENOF00343-A

UP

DN

ENOF00067-0

51

8

REMOVING AND CARRYING THE OUTBOARD MOTORENOM00070-A

ENOW00890-0

Before installing the outboard motor on theboat, hang the outboard motor with thehoist or equivalent device by attaching theengine hanger to the outboard.Use the hoist with allowable load is 150 kg(330 lbs) or above.

ENOW00064-0

Engine may be hot immediately after oper-ating and could cause burns if touched.Allow engine to cool down before attempt-ing to carry the outboard.

1. Stop the engine.2. Remove the top cowl.3. Disconnect the fuel connector, the

remote control cables and the batterycords from the outboard motor.

4. Attach the hoist hooks to the enginehanger.

5. Remove the outboard motor from boatand completely drain the water fromthe gear case.

ENOM00071-A

ENOW00933-0

Be sure to disconnect fuel connectorexcept when operating engine.Fuel leakage is a fire or explosion hazard,which can cause serious injury or death.

ENOW00065-0

Close air vent screw of fuel tank beforecarrying or storing outboard motor and fueltank, or fuel may leak, potentially catchingfire.

ENOW00066-0

Do not give a shock to an outboardmotor during transportation. It becamesa cause of breakage.

1. Removing the outboard motor

WARNING

CAUTION

2. Carrying the outboard motor

WARNING

WARNING

CAUTION

ENOF01206-0

REMOVING AND CARRYING THE OUTBOARD MOTOR52

8

Do not carry or store outboard motor inany of positions described below.Otherwise, engine damage or propertydamage could result from leaking oil.

Keep the outboard motor in a vertical posi-tion when carrying.The optional outboard motor stand is rec-ommended for keeping the outboardmotor vertical both during transport andstorage.

ENON00021-A

Note

If the outboard motor must be laid downbe sure drain the fuel and engine oil,

then the port side faces down as shownin the drawing above.Elevate power unit 2 inches to 4 inches iftraveling to avoid oil spillage.

ENOM00072-A

ENOW00072-0

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

ENOW00073-A

Be sure to disconnect fuel connectorexcept when operating engine.Fuel leakage is a fire or explosion hazard,which can cause serious injury or death.

ENOW00068-0

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

ENOF01219-0

ENOF01220-0

3. Trailering

CAUTION

WARNING

WARNING

ENOF01221-0

ENOF00075-1

REMOVING AND CARRYING THE OUTBOARD MOTOR 53

8

ENOW00071-0

The tilt support device supplied on youroutboard motor is not intended for towing.It is intended to support the outboardmotor while the boat is docked, beached,etc.

When transporting a boat on a trailer withthe outboard motor still attached, discon-nect the fuel line from the outboard motorbeforehand and keep the outboard motorin the normal running position or on a tran-som saver bar.

Tiller handle typeTo prevent the outboard motor from mov-ing when it is attached on a boat duringtransport on a trailer, properly tighten thesteering friction lever (page 75).

1. Ground clearance should be provided sufficiently.2. Transom saver bar

ENOW00067-0

Do not go under outboard motor tilted upeven if it is supported by support bar, oraccidental fall of outboard motor couldlead to severe personal injury.

CAUTION

WARNING

2 1

ENOF00073-A

54

9

ADJUSTMENTENOM00073-0

Tiller handle typeENOW00074-A

Do not overtighten the steering frictionlever it could result in difficulty of move-ment resulting in the loss of control caus-ing an accident and could lead to severeinjury.

Adjust this lever to achieve the desiredsteering friction (drag) on the tiller handle.Move lever towards (2) to decrease frictionand move lever towards (3) to increasefriction.

1. Steering friction lever2. Decrease3. IncreaseENOM00074-A

ENOW00074-B

Do not overtighten the throttle adjustmentscrew or it could result in difficulty ofmovement resulting in the loss of controlcausing an accident and could lead tosevere injury.

Friction adjustment of the throttle grip canbe made with the throttle adjustmentscrew.

1. Steering friction lever2. Decrease3. Increase

ENOM00075-0

ENOW00074-C

Do not overtighten the remote controlthrottle friction adjustment screw or itcould result in difficulty of movementresulting in the loss of control causing anaccident and could lead to severe injury.

To adjust the friction of the remote controllever, turn the throttle friction adjustmentscrew on the front of the remote control.Turn clockwise to increase the friction andcounter-clockwise to decrease it.

1. Steering friction

WARNING

2. Throttle grip friction

WARNING

3 2

1

ENOF00329-0

3. Remote control lever friction

WARNING

2 3

1ENOF00330-1

ADJUSTMENT 55

9

Side mount type

1. Throttle friction adjustment screw2. Decrease3. Increase

ENOM00076-0

ENOW00076-1

Be sure that outboard motor is securedto transom or service stand, or acciden-tal drop or fall of outboard motor couldlead to severe personal injury.Be sure to lock outboard motor when itis tilted up, otherwise accidental fall ofoutboard motor could lead to severepersonal injury.Do not go under outboard motor tiltedup and locked, or accidental fall of out-board motor could lead to severe per-sonal injury.

ENOW00075-1

Inappropriate adjustment of trim tab couldcause steering difficulty. After installing orreadjusting trim tab, check if steering loadis even.

I f s t ra ight- l ine cru is ing can not beachieved, adjust the trim tab located under

the anti-ventilation plate.If the boat veers toward the left directthe trim tab towards A (left from rear ofboat).If the boat veers toward the right directthe trim tab towards B (right from rear ofboat).

1. Trim tabENON00022-A

Notes

After adjustment securely tighten thetrim tab fixing bolt.Check for looseness of the bolt and thetrim tab at regular intervals.

4. Trim tab adjustment

WARNING

WARNING

1

2 3

ENOF00078-1

11ENOF00912-A

56

10

INSPECTION AND MAINTENANCEENOM00077-0

Care of your outboard motorTo keep your outboard motor in the bestoperating condition, it is very importantthat you perform daily and periodic main-tenance as suggested in the maintenanceschedules that follow.ENOW00077-0

Your personal safety and that of yourpassengers depends on how well youmaintain your outboard motor. Carefullyobserve all of the inspection and mainte-nance procedures described in this sec-tion.The maintenance intervals shown in thechecklist apply to an outboard motor innormal use. If you use your outboardmotor under severe conditions such asfrequent full-throttle operation, frequentoperation in brackish water, or for com-mercial use, maintenance should be per-formed at shorter intervals. If in doubt,consult your dealer for advice.We strongly recommend that you useonly genuine replacement parts on youroutboard motor. Damage to your out-board motor arising from the use ofother than genuine parts is not coveredunder the warranty.

CAUTION

INSPECTION AND MAINTENANCE 57

10

ENOM00322-1

Perform the following checks before andafter use.

ENOW00078-1

Do not use outboard motor if any abnor-mality is found during pre-operation checkotherwise it could result in severe damageto the motor or severe personal injury.

1. Daily Inspection

WARNING

Item Points to Check Remedy

Fuel System

• Check the amount of fuel in the tank. Replenish• Check for debris or water in the fuel filters. Clean or replace if

necessary• Check the rubber hoses for fuel leakage. Replace if necessary

Fuel Tank Cap

• Check for crack, leakage, damage in the fuel tank cap. Replace if necessary• Check for crack, damage in the gasket. Replace if necessary• Check for leakage at full close. Replace if necessary• Check for ratchet performance. Replace if necessary

Engine Oil • Check the oil level. Fill oil

Electrical Equipment

• Check that the main switch functions normally. Replace if necessary• Check that the battery electrolyte level and specific gravity are

normal.Replenish or recharge

• Check for loose connections on the battery terminal. Retighten• Check that the stop switch functions normally and make sure

the stop switch lock is there.Remedy or replace if necessary

• Check cords for loose connections and damage. Correct or replace if necessary

• Check the spark plugs for dirt, wear and carbon build-up. Clean or replace if necessary

• Check the warning LED lamp (ON for 5 to 7 secs.) when start up.

Repair

Recoil starter• Check the rope for wear and chafing. Replace if necessary• Check the ratchet engagement. Replace if necessary

Clutch and Propeller Sys-

tem

• Check that clutch engages correctly when operating the shift lever.

Adjust

• Visually Check propeller for bent or damaged blades. Replace if necessary• Check the propeller nut is tightened and the split pin is present. Tighten or replace

Installation of Motor

• Check all the bolts attaching the motor to the boat. Tighten• Check the thrust rod installation. Replace if necessary

Power Tilt • Check working of the tilt up and down of the motor. Repair

Cooling Water• Check that cooling water is discharged from the cooling water

check port after the engine has started.Repair

Tools and Spares

• Check that there are tools and spare parts for replacing spark plugs, the propeller, etc.

• Check that you have the spare rope and stop switch lock.

Order

Order

INSPECTION AND MAINTENANCE58

10

ENOM00081-A

Oil level checkingIf the oil level is low, or too high, the life ofthe engine will be shortened significantly.1. Stop the engine and set it in a vertical

position.2. Remove the top cowl.3. Remove the dipstick after 5 minutes

engine has stopped.4. Wipe oil off the oil dipstick with a clean

rag.5. Put in the dipstick.6. Take out the dipstick and check the oil

level.7. Return the dipstick.

1. Filler cap2. Dipstick

1. Upper level 1000 mL2. Lower level 750 mL

ENON00024-0

Note

The oil level should be checked when theengine is cold.

ENON00025-0

Note

Consult with an authorized dealer if theengine oil is milky color, or appears contam-inated.

ENOM00082-A

Engine oil replenishingENOW00079-A

Do not add engine oil of brand and gradeother than existing one. In case engineoil of other brand or grade is added,drain all oil and ask dealer for treatment.In case other than engine oil such asgasoline is put in the oil chamber, emptythe chamber and ask dealer for treat-ment.When replenishing engine oil, be carefulnot to allow entry of foreign matterssuch as dust and water into oil chamber.

Steering Devices

• Check the operation of the steering handle. Repair

Other parts• Check if the anode is securely installed. Repair if necessary• Check the anode for corrosion and deformation. Replace

Item Points to Check Remedy

ENOF01222-0

1

2

CAUTION

2

1

ENOF00081-0


10

Wipe off engine oil well immediately ifspilled and dispose of it in accordancewith local fire prevention and environ-ment protection regulations.Do not replenish engine oil over upperlimit. If overfilled, remove oil to upperlimit. If engine oil is over the upper limit,it can leak potentially leading to enginedamage.

If the oil level is low, or at lowest mark, addrecommended oil to the middle dipstickmark.

ENOM00083-B

Washing outboard motorENOW00081-0

Do not start engine without removing pro-peller, or accidentally turning propellercould cause personal injury.

ENOW00082-0

Never start or operate the engine indoorsor in any space which is not well ventilated.Exhaust gas contains carbon monoxide, acolorless and odorless gas which can befatal if inhaled for any length of time.

ENOW00920-0

When washing the outboard motor, becareful not to spray the water inside of thetop cowl, especially electrical components.

ENON00026-0

Note

It is recommended to check chemical prop-erties of water on which your outboardmotor is regularly used.

If outboard motor is used in salt water,brackish water or water with a high acidiclevel, use fresh water to remove salt,chemicals or mud. And flush cooling waterpassage after every cruising or before stor-ing outboard motor for long time. Beforeflushing, remove the propeller and the for-ward thrust holder.

ENOM00085-B

Flushing attachmentENOW00922-0

To prevent the engine from starting whenyou are near the propeller, remove the stopswitch lock.

1. Tilt down the outboard motor.2. Remove the water plug from the gear

case, and screw in the flushing attach-ment.

3. Connect a water hose. Turn on thewater and adjust the flow.

4. Put the shift lever in the neutral positionand start the engine.

Continue flushing the outboard motorfor 3 to 5 minutes at idling.

WARNING

WARNING

ENOF01209-0

CAUTION

CAUTION


10

5. Stop the engine and water supply.Remove the flushing attachment andtape.

6. After the flushing, be sure to reattachthe water plug.

.

1. Flushing attachment (Option)

ENOM00085-A

Flushing by test tankENOW00081-0

Do not start engine without removing pro-peller, or accidentally turning propellercould cause personal injury.

ENOW00082-0

Never start or operate the engine indoorsor in any space which is not well ventilated.Exhaust gas contains carbon monoxide, acolorless and odorless gas which can befatal if inhaled for any length of time.

ENOW00036-A

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

10 cm (4 in.) above the anti ventilationplate.And be sure to remove the propeller, whenstarting the engine in the test tank. (Seepage 68)Run the engine only at idling.

1. Test tank2. Water3. Over 10 cm (4 in.)

ENOM00950-0

Fuse replacementENOW00923-0

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

ENOW00924-0

Never use a fuse with a rating that exceedsthe specified rating as this could causeserious damage to the electrical system.

If a blown fuse is detected, try to deter-mine the cause for this and correct it. If thecause for the problem is not corrected, thefuse will likely blow again.If the fuse continues to blow, request an

WARNING

WARNING

CAUTION

ENOF01223-0

1

CAUTION

CAUTION

1

3

2

ENOF00863-0


10

authorized Tohatsu dealer to inspect theoutboard motor.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 ofthe same specified rating. The out-board motor is supplied with sparefuses in the spare fuse holder.

1. Fuse for charging system2. Fuse for main circuit3. Blown fuse

3

1

ENOF01224-0

2ENOF01234-0


10

ENOM00090-B

It is important to inspect and maintain your outboard motor regularly. At each interval onthe chart below, be sure to perform the indicated servicing. Maintenance intervals should be determined according to the number of hours or numberof months, whichever comes first.

2. Periodic Inspection

Description

Inspection intervals

Inspection procedure RemarksFirst 20 hours or 1

month

Every 50 hours or 3

months

Every 100 hours or 6

months


year

Fuel System

Carburetorr*1 Check and clean, if necessary.

Fuel filter Check and clean or Replace if necessary. (See page 66)

Piping/Hoses Check and clean or Replace if necessary.

Fuel tank Clean (See page 69)

Fuel tank cap Check and clean or Replace if necessary.

Fuel pump*1 Check and clean or Replace if necessary.

Ignition Spark plug Check gaps. Remove carbon deposits or Replace if necessary. (See page 69)0.8-0.9 mm (0.031-0.035 in)

Starting System

Starter rope Check for wear or chafing

Starter motor*1 Check for salt deposits and the battery cable condition.

Battery Check installation, fluid quantity, gravity.

Engine

Engine oil Replace Replace Replace. (See page 58) 1000 ml (33.8 fl.oz.)

Oil filter*1 Replace every 200 hrs or 2 years (See page 65) Entire cartridge

Valve Clearance*1 Check & adjust

IN: 0.13-0.17 mm (0.0051-0.0067 in) EX: 0.18-0.22 mm (0.0071-0.0087 in)

Timing belt*1 Check and Replace if necessary.

Compression pressure*1 Check and repair if necessary.

Combusion chamber*1 Clean every 200 hrs or 2 years

Thermostat*1 Check and Replace if necessary.


10

*1: Have this handled by your dealer.

ENON00030-0

Note

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

ENOM00091-A

Engine oil replacementEngine oil mixed with dust or water willdramatically shorten the life of the engine.ENOW00091-0

You may be injured due to high engine tem-peratures if you fill engine oil just afterstopping. Changing engine oil should bedone after the engine has been cooled.

ENOW00092-0

Do not overfill engine oil, or engine oilcould leak and/or engine could be dam-aged. If engine oil level is over upperlimit marks of oil gauge, drain oil to levellower than upper limit.

Be sure that outboard motor is in uprightand level position when checking orchanging oil.Stop engine immediately if low oil pres-sure warning lamp is lit or oil leak isfound, or engine could be severely dam-aged. Consult dealer.Wipe off engine oil well immediately ifspilled and dispose of it in accordancewith local fire prevention and environ-ment protection regulations.

ENOW00090-0

Use of engine oils that do not meet theserequirements will result in reduced enginelife, and other engine problems.

Lower Unit

Propeller Check for bent blades, damage, wear. Replace if necessary. (Seepage 68)

Gear oil Replace Replace Change or replenish-oil and check for water leaks. (See page 74)370 mL (12.5 fl.oz.)

Cooling water inlet Check clogging

Water pump*1 Replace Check for wear or damage and replace if necessaryReplace impeller every 12 months.

Power tilt *1 Check & replenish oil, manually operate

Warning system*1 Check function

Bolts and Nuts Retighten

Throttle wire Check for wear or damage and replace if necessary

Remote control cable Check and adjust if necessary

Sliding and Rotating Parts. Grease Nipples

Apply and pump in grease. (See page 73)

Outer Equipment Check for corrosion.

Anode Check for corrosion and deformation. Replace if necessary.

Description

Inspection intervals

Inspection procedure RemarksFirst 20 hours or 1

month

Every 50 hours or 3

months


months


year

CAUTION

CAUTION CAUTION


10

ENOW00933-0

Engine oil mixed with dust or water willdramatically shorten the life of the engine.

To change engine oil:Be sure to use recommended engine oil(see page 13).1. Stop the engine and allow it to cool.2. Tilt up the outboard motor and lock the

tilt with the tilt stopper. 3. Turn the steering on the outboard

motor so that the drain hole is facingdownward.

4. Put a oil drain pan under the oil drainscrew.

5. Remove the oil drain screw and com-pletely drain oil from the engine.

1. Drain hole

6. Tighten the oil drain screw with apply-ing oil on the sealing surface of screw.(Use new oil drain washer)

Oil drain screw specified torque24N·m (17 ft·lb, 2.4 kgf·m)

ENON00028-A

Note

If a torque-wrench is not available when youare fitting a oil filter, a good estimate of thecorrect torque is 3/4 to 1 a turn past finger-tight. Have the oil filter adjusted to the cor-

rect torque as soon as possible with atorque-wrench.

7. Reset the engine in a vertical position.8. Repeat 3 to 7 procedures two or three

times to drain the oil completely.9. Remove the top cowl and the oil filler

cap.10. Fill the engine through filler port with

recommended oil (see chart below) tothe middle of dipstick mark.

11. Tighten the oil filler cap.

1. Filler cap2. Dipstick3. Filler port

1. Upper limit (Max.)2. Lower limit (Min.)

CAUTION

1

ENOF01225-0

ENOF01222-A

1

2

3

2

1ENOF00113-0


10

ENON00920-0

Note

Use only recommended engine oil (Seepage 13)

ENOW00925-0

Wipe off engine oil well immediately ifspilled and dispose of it in accordance withlocal fire prevention and environment pro-tection regulations.

ENON00031-0

Note

If any amount of water is found in engineoil, making it milky white, consult dealer.If engine oil is contaminated with fuel,emitting strong fuel smell, consult dealer.Some oil dilution is normal if engine isidled or trolled for long periods, espe-cially in cooler water temperatures.

ENOM00092-A

Oil filter replacementENOW00091-0

You may be injured due to high engine tem-peratures if you fill engine oil just afterstopping. Changing engine oil should bedone after the engine has been cooled.

ENOW00926-0

Wipe off engine oil well immediately ifspilled and dispose of it in accordance withlocal fire prevention and environment pro-tection regulations.

1. Drain oil from the engine.2. Place a rag or towel below the oil filter

to absorb any spilled oil.3. Unscrew old filter by turning the filter to

counter clockwise.4. Clean the mounting base. Apply film of

clean oil to O-ring.Do not use grease. Install oil filter and tighten it to specifiedtorque by using oil filter wrench.Oil filter torque:18 N·m (13 ft·lb, 1.8 kgf·m)

ENON00028-A

Note

If a torque-wrench is not available when youare fitting a oil filter, a good estimate of thecorrect torque is 3/4 to 1 a turn past finger-tight. Have the oil filter adjusted to the cor-rect torque as soon as possible with atorque-wrench.

Oil volume needed for complete oil replace-ment

With oil filter replace-ment

Without oil filter replacement

1200 mL(40.6 fl.oz.)

1000 mL (33.8 fl.oz.)

CAUTION

10W−40

10W−30

˚C˚F

4096

3086

2068

1050

032

-1014

-20-4

-30-22

ENOF00208-0

CAUTION

CAUTION


10

1. Oil filter wrenchP/N 3AC-99090-0P/N 3AC99090M(US. CANADA Only)

1. Oil filter

ENOM00093-A

Fuel filters and fuel tank cleaningENOW00093-0

Gasoline and its vapors are very flammableand can be explosive.

Do not start this procedure while engineis operating or hot even after stoppin

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