TOHATSU 120A2EPTO Owner'S Manual Download Page 29

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Summary of Contents for 120A2EPTO

Page 1: ...TOHATSU OUTBOARDS No 003 11039 4...

Page 2: ...Copyright 2007 Tohatsu Corporation All rights reserved No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Tohatsu Corporation...

Page 3: ......

Page 4: ...1 Use or operation NOT conforming to the instructions described in this owner s manual 2 Participation in or preparation for racing or other competitive activities 3 Water entering the engine or the e...

Page 5: ...Should difficulty arise with the engine please follow the troubleshooting procedures listed at the end of this manual If the problem persists contact an authorized TOHATSU service shop or your dealer...

Page 6: ...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 hazards To prevent such hazardous si...

Page 7: ...S LUBRICANTS Only let an authorized TOHATSU service shop perform serving or maintenance on this product Be sure to use genuine parts and genuine lubricants or recommended lubricants MAINTENANCE As the...

Page 8: ...CES l6 JCJ JL NG HEMETERS 24 4 INS ALL NG HE BATTERY 28 5 INSTALLINGTHEDRAGLINKASSEMBLY 2 9 6 lNSTALLINGTHESTEERlNCHANDLEAND N SWITCH BOX q PROPELLER SELECTION 3 F ELANO ENG NE O L 32 ENG NE OPE AT ON...

Page 9: ..._ _ _ _ _ _ _ _ _ qI INSPECTION AND MAINTENANCE 66 DAILY NSpECT ON 67 2 PER JD C NSPE y ON _ 69 3 OFF SEASONSTORAGE 77 4 PRE SEASON CHECK 9 5 MOTORSUBMERGED1NWATER 80 6 COLDWEATHERPRECAUTIONS 81 7 CHE...

Page 10: ...System Starting System Ignition Spark Plugs Alternator No of Trim Adjustments Engine Oil Gear Oil Fuel Tank Capacity litter US gal Engine Oil Capacity litter US gal Gear Reduction Ratio Fuel 1 93R Thr...

Page 11: ...ixing Fuel Mixing Ratio 12O l 5O l Cooling System Forced water cooling Starting System Electric starter motor Ignition Flywheel Magneto CD Ignition Spark Plugs NGK BRHS lO BRBHS 10 or Champion L 78ClR...

Page 12: ...ank Capacity litter US gal Engine Oil Capacity litter US gal Gear Reduction Ratio Fuel 90A EFO Aourox 690 r Approx 360 L 1435 UL 1562 L 516 UL 643 L 135 I L 130 UL 137 5 1 UL 132 5 67 0 5 000 5 500 3...

Page 13: ...Fuel Mixing Ratio 12O l 5O l Cooling System Forced water cooling Starting System Electric starter motor Ignition Flywheel Magneto CD Ignition Spark Plugs NGK B8HS lO BRRHS 10 or Champion L 78C RL 78C...

Page 14: ...or Cover Hook Lever I Water Check Pori Tilt Slopper Lever 8 Anti ventilallon Plate I Trim Tab Anode I Propeller Water stmner Slern backeel 0 Thrusl Rod aamp screw 03 ThroNe Grip 03 Shift Lever Stop Sw...

Page 15: ...ook Lever Water Check Port Q Till Slopper Lever Anli venlilalion Plale Trim Tab Anode Q Propeller I Water Slminer Stern Erackel Thrust Rod Clamp screw Thronle Grip I Shift Lever J Stop Switch 0 Main S...

Page 16: ...er Lever Q Am ventilalfon Plate 0 Trim Tab Anode Q Propeller Waler Slrainer I stern Bracket l must Rod CC Filler Lid I Power Tram 8 Till PTQ Power Trim B Till Swilch A 0 Anode Power Trim 8 Till Swilch...

Page 17: ...Model 60C EPO Model 7OC EPO 0 Till Handle Upper Molar Cover 0 Hook Lever Water Check Port 0 Till Stopper Lever 8 Anti ventilation Plate 0 Trim Tab Anode Propeller 8 Waler Slrainer Stern Bracket 8...

Page 18: ...Motor Cover 0 Hook Lever Water Check PO Q Till Slopper Lever Anli venlilatlon Plate 0 Trim Tab Anode Propeller 8 Water sm ner 0 G Stern Bracket I Thrust Rod Power Trim Tilt Pm Anode Fuel Conneclor Ba...

Page 19: ...e for T Type Q Remote Control Box CD Primer Bulb Q Remote Contml Lever Tachometer Q Power Trim lX Swilch Trim Meter Neuld Warm up Lever Q Main Swilch Q Harness B 0 Stop Swllch Q Fuel Tank Q Air Vent S...

Page 20: ...90A EFO...

Page 21: ...and Tilt I aanew Cables cQ Remote Control Box Remote Control Lever 03 Power Trim B Tilt Switch 03 Neutral Warm up Lever I Main Switch Harness B Stop Switch Fuel Tank ZAir Vent Screw Fuel Connector Pr...

Page 22: ...mounted on the boat in accordance with the instructions below Note Consult your authorized dealer to receive the proper instructions or ask your dealer to mount the motor as necessary Single outboard...

Page 23: ...lation plate is at a level higher than the bottom of the boat If the height difference exceeds IO 30 mm the engine power is likely to be reduced as a result of increased water resistance against the g...

Page 24: ...l2 X 105 mm and nuts provided Be sure to use the washers The small diameter washers go with the bolts and the larger diameter washers go with the nuts The mounting holes may be drilled beforehand by r...

Page 25: ...he battery cables is fitted make sore that it does not interfere with the movement of the outboard From time to time check the bolts and clamp screws fortighteness 2 Installing the Remote Control Devi...

Page 26: ...resecure the bracket to the moror cover lower Flemo etonlrol s enmn Cord ThW k cable b Detach the throttle and shift cable joints by removing the R pins Pass at least 10 mm of the remote control cabl...

Page 27: ...cable which moves first when the lever is turned should be the shift cable Check that the shift lever is in NEUTRAL position and that the neutral warn up lever is fully closed when the remote control...

Page 28: ...e joint with the nut and secure it with the R pin f Connect cord ass y B to cord ass y A Connect the pink and light blue leads from cord ass y A and B together A CAUTION Do not disconnect the electric...

Page 29: ...etach the upper engine ccwer b Detach the upper grommet cord clamp bolts c Detach the throttle and shift cable joints by removing the R shaped pins d Move the Remote Control lever Forward to Neutral a...

Page 30: ...140A2 a Detach the upper engine cover b Detach the upper grommet cord clamp bolt c Detach the throttle and shift cable joints by removing the R shaped pins d Move the Remote Control lever Forward to...

Page 31: ...The cable which moves first when the lever is turned should be the shift cable Check that the shift lever is in NEUTRAL position and that the neutral warn up lever is fully closed when the remote cont...

Page 32: ...in a g Connect the pink and light blue leads from cable harness A and B to each other h Using the washers and R shaped pins to adjust the thread length connect the throttle and shift cables to the pi...

Page 33: ...ness is 2 I I mm 0 08 0 43 in For dashboards thicker than I I mm 0 43 in the fitting plate should be cut accordingly Be sure to tighten the fitting nuts on the fitting plate evenly The dashboard incli...

Page 34: ...ads Tachometer EPO EF TO Trim meter EPTO Trim sender EPTO Color Codes B black L blue Lg light green 0 orange P pink R red Sb sky blue W whire Y yellow Note The parts marked with mark are to be wired w...

Page 35: ...2 l lmm 0 08 0 4in For dashboads thicker than 1lmm 0 4in the fitting plate should be cut accordingly Be sure to tighten the fitting nuts on the fitting plate evenly n The dashboard inclination should...

Page 36: ...i purpose Meter Connect rhe lead wires of Ihe meter referring to the writing diagram below Notes 0 Oblique lines Z depict cords with a color stripe 0 Only connect leads market with when a meter lamp s...

Page 37: ...and consult a doctor Always use safety glasses and rubber gloves when handling the battery Remark Further to notice on the label of your battery Notes 1 Make sure that the battery leads do not get st...

Page 38: ...ssembly by your dealer is highly recommended Note Depending on the steering cable manufacture spacers optical may be required Connect the Drag Link rod to the tip of the steering cable Tighten the rod...

Page 39: ...late in the outer groove and fix it with screws Handle B Install the steering handle to the motor with two bolts Handle Install the main switch box at a place where the driver is able to operate the s...

Page 40: ...Use of an inappropriate propeller for your particular needs can cause serious damage to your outboard motor Please check the Propeller selection table at the end of this manual and consult your deale...

Page 41: ...el Tank Will not recommend use of other hvo stroke engine oil When using a fixed fuel tank in place of genuine fuel tank it is recommended to select a one with a structure facilitating interior cleani...

Page 42: ...EPO EPTO Type The required amount of engineoil is automatically supplied from the oil tank through the oil pump according to the engine running condmons Gasolineis fed wer aseparatefeeding line I A CA...

Page 43: ...nuine Engine Oil or recommended oil A CAUTION 1 In the unlikely event that gasoline by mistake is filled into the oil tank drain the oil tank completely and consult an authorized service shop for advi...

Page 44: ...e oil pump If present purge the air as follows n Loosen the air vent screw on the oil pump to purge the air and tighten it when all air as seen through the vinyl pipe on the oil pump side has been pur...

Page 45: ...e Follow the procedures shown below carefully Time Break in melhord 0 min Trolling or idling speed Running Conditions Cruising at minimum speed 10 min Thm le opemng I 2 about3 000 rpm I 1 hr Throttle...

Page 46: ...stall the lock in hestop switch I A CAUTION Be sure to connect the emergency stop line to your wrist The engine is shut down if the stop line switch is disconnected This is a safety measure designed t...

Page 47: ...ontact your authorized dealer Insert the key into the main switch P Type Set the Remote Conrtol lever to Neutral N and move the neutral warm up lever to Open F Type Place the shift lever in Neutral Tu...

Page 48: ...n switch key to ON and push on it for choke operation The key need not be pushed if rhe engine is warm Note for P Type The neutral warm up lever is inoperative unless the Remote Control lever is set t...

Page 49: ...up lever to theclosed position FType return thethrottle grip to the SLOW position I A CAUTION 1 Extended operation of the starter motor will run the battery down Operate the starter motor for maximum...

Page 50: ...set the shift lever to Neutral N Remove the upper engine cover Take off the ring gear cover by removing the fixing bolts sot 7oc 90A 120A2 140A2 Move the manual choke lever to the Closed position Whe...

Page 51: ...n Note The battery cables must be connected to the battery also when starting the engine manually A WARNING 1 DO NOT reinstall the ring gear cover after the engine has been started using the emergency...

Page 52: ...p beforehand the engine life will shorten greatly During the warm up operation confirm that cooling water is discharged from the check port and Idle port ii CAUTION If cooling water is not discharged...

Page 53: ...ing at high RPM Be sure to slow down to trolling or idling rpm before shifting I 0 Remote control type P type While pressing the lock button on the remote control lever upward swiftly move the lever t...

Page 54: ...rn to idling speed 2 Before moving the shitt lever to REVERSE position make sure the reverse lock is engaged in UP position EPO I 3 Do not increase the engine speed excessively while reversing 0 Tille...

Page 55: ...ition EF EFO types 2 Do not increase the engine speed excessively while reversing A maximum limit of half throttle is recommended when running in REVERSE for safe running LOCK Note The shift lever can...

Page 56: ...CAUTION The following precautions should be applied if you are boating in shallow water with the motor trimmed beyond the trim limit cut out point 1 Keep the engine speed at IDLING RPM only This is be...

Page 57: ...the bou may sway or the bottom may slam the water while cruising In this case decrease the trim angle by flicking the switch on the Remote Control lever to DN 60C 70C 90A 0 Improper Trim Angle bow di...

Page 58: ...tained when the boat is parallel to the water surface while in running 0 Improper trim angle bow rises too high If the trim angle is excessive the bow will rise out of the water and the speed will dec...

Page 59: ...the same manner with the trim angle adjustment A CAUTION 0 When in shallow water running take care that the water strainer is submerged at all times and that water is continuously running out of the...

Page 60: ...ow it to cool down 2 Never disconnect the electrical harness for stopping the engine when motor running Notes 1 When another electrical equipment or accessory is fitted the electricity will be used fo...

Page 61: ...low it tO cool down NEUTRAL N p Q Disconnect the fuel COtlneCtOr from the engine Turn the main switch key coun ter clockwise or pull out the stop switch The engine stops The engine can also be stopped...

Page 62: ...en shift the shift lever to Neutral N posltion 7 Turn the main switch key to OFF position or take off the stop switch lock plate from the switch ON ON Disconnect the fuel connector from the engine Clo...

Page 63: ...ct that fuel connector from the engine Turn the ignition key to ONE Operate the Power Trim Tilt switch and I Lock the tilt stopper If the outboards is leaving in the tilt up condition without locking...

Page 64: ...This will allow manual tilting of the engine Always lock the engine in the upper position with the tilt stopper ril i WAR N 1N a j iilil iililiiiI ll ll j li When tilting up or down be sure that no f...

Page 65: ...t the outboard up entirely The outboard will be locked automatically in the raised positions Fig 2 Tilt down To tilt the engine down turn the tilt stopper lever downward toward RELEASE Tilt the engine...

Page 66: ...ght on the material propeller AWhen the cooling water does Check cooling water intake port for not discharge or decrease dust vinyl sheet ect When abnormal vibration and Check mounting bolts of the no...

Page 67: ...gear case 2 Carrying the motor Be sure to keep the engine vertical posture whenever you carry the motor NOTE 0 If do not carry the engine at upright position loosen the drain screw on the carburetors...

Page 68: ...posture lay the motor same as above figure EFIEFOIEPO Type When taking out the motor from package or storing the motor taking out from the boat never release the reverse lock lever Otherwise it is da...

Page 69: ...tilting down Trailering at tilted up condition of the motor may cause of damage to the motor boat etc by unexpected tilt lock release getting a shock when trailering If trailering the motor at tilt do...

Page 70: ...il level sensor that informs oil level in the tank at 3 liters and I 5 liters 120A2 140A2 at 0 7 Q 90A iat 0 5 Q 60C 70C 4 Warning buzzer that is built m the remote control box The buzzer can be activ...

Page 71: ...on None 3 500 rpm Engine overheats GotoO On Oil level indicator None Remaining oil less llluminales lhan 0 7 lilers Gob 0 6OC 70C Buzzer RPM limitation PPw Trouble Aclion 0 NOW 3 500 rpm Cooling wate...

Page 72: ...er revolution protection function is turned on Note This function may be turned on in case a propeller has run out of the water In such a case the function will be turned off automarlcally after the p...

Page 73: ...t of the remote control box Turn the screw clockwise for heavier movement and counterclockwise for lighter movement 2 Trim Tab Adjustment If straight line cruising cannot be achieved adjust the trim t...

Page 74: ...o corrosion the trim tab will wear down over time 3 Steering Movement Adjustment EF EFO EPO The steering movement can be adjusted by turning the steering adjustment bolt on the swivel bracket Turn the...

Page 75: ...hould be performed at shorter intervals If in doubt consult your dealer for advice 0 We strongly recommend that you use only genuine replacement parts on your outboard motor Damage to your outboard ar...

Page 76: ...C RL 78C 1 Omm gap Actlon Replenish Clean Replace Replenish Clean Clean or replace l Check if the main switch functions normally Remedy or replace l Check that the battery electrolyte level and specif...

Page 77: ...replaCe 0 Check all the motor installation bolts with the boat Tighten 0 Check the thrust rod installation 0 Check working of the tilt up and down of the motor l Check that cooling water is discharge...

Page 78: ...uld be determined according to the number of hours or number of months whichever comes frst Your outboard motor should receive careful and complete inspection at 300 hours This IS the best time for ma...

Page 79: ...nonths Action Remarks 0 Bend of blades damage wear Change of oil or 0 replenishment and water leak 0 Check for Wear or damage Apply and pump in oil level and refill Check function of manual release Ch...

Page 80: ...propeller by pulling it toward you Apply genuine grease to the proprller shaft and thrust holder Mount the new propeller Fit the stopper and washer securely tighten the nut and insert the new split pi...

Page 81: ...HS lO BR8HS IO or recommended ones CHAMPION L 78C RL78C with gap 1 0 A CAUTION Do not touch the high tension cords running from the ignition coil to the spark plugs while the engine is running or it i...

Page 82: ...se Connect a water hose to the flushing plug and flush out with water Be sure to secure the water stra ner and sub water strainer on the gear case beforhand Run the engine at low speed in Neurral to f...

Page 83: ...l or if not available an API American Petroleum Institute oil grade of GL5 SAE SO to SO Required volume approx 900 mL Install the upper oil plug Then remove the oil tube nozzle and install the lower o...

Page 84: ...hree months W Cleaning Engine Oil Line Oil filter and oil tank Check the oil tank and or filter for entrapped water and dust Disconnect all pipes behveen the oil tank and oil pump of the outboard engi...

Page 85: ...TRON II SHELL TELLUS OIL 22 K22 ESSO FSSO AUTOMATIC TRANSMISSION FLUID As shipped from the factory NISSEKI ATF DEXTRON oil has been used To prevent oil geling do not mix with another brand Drain the o...

Page 86: ...ing water system thoroughly with fresh water Let the water drain completely Wipe off any surface water with an oily rag Drain all fuel from the fuel pipes fuel pump and carburetor and clean these part...

Page 87: ...ur outboard for the winter open up all the water drain holes in the gear case to permit any remaining water to drain out If a speedometer is installed disconnect the pickup tube and allow it to drain...

Page 88: ...d 1 250 12 0 314 charged 1 280 13 2 Fully charged Check the electrolyte level and measure the voltage and specific gravity of the battery I Check that the battery is secure and the battery cables inst...

Page 89: ...to make sure the oil is evenly distributed After the above steps it might be possible to start the engine However the electrical components and carburetor will soon deteriorate and become inoperative...

Page 90: ...4 Run the engine for 5 minutes at the slowest speed 5 Run the engine for 10 minutes at half speed In steps 2 and 3 above the oil used for winter storage inside the engine will be cleaned out and optim...

Page 91: ...or damage of power unit installation bolts gear case and extension case bolts propeller shaft housing bolis upper and lower mount rubber bolts and nuts power trim and tilt bolts and mount rubber cap...

Page 92: ...h 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 professional advice and assistance is the bes...

Page 93: ...84...

Page 94: ...uts Washers A B Fuel Tank wlh primer bulb Flushing Plug Remote Control Box Drag Link Multi purpose Meter Meter Harness Lead Wire Ior Meter Remok Conlrol BOX Drag L nk Tachometer Trim Meter 3 Lead Wire...

Page 95: ...q ACCESSORIES Consult with your dealer for details of the optional accessories Voltmeter Hour Meter engine operation hourcounler Meter Lamp Switch Drive cleaner 86...

Page 96: ...Propeller Remok Conlrol cable 7 30 lee 19 k nd lengths Ior twin engine operation Gre Se Gear Oil 509 2509 260 mL 500 mL Touch up Spray 87 Engine Oil 0 4L 1 L 4L ZOL...

Page 97: ...its load Heavier Load boat Lighter Load boat PROPELLER Use a genuine propellers A propeller must be selected so that the engine rpm measured at wide open throttle while cruising is within the rcommend...

Page 98: ...rket 23 Mm switch 24 Stop swilch 25 Power trim lill switch Colourof Cord B Slack Br Brown G Green L Blue Lg Light green Or orange P Pink R Red Sb Sky Blue W While Y Yellow Nole I means stripe cord col...

Page 99: ...rket 23 Main switch 24 Stop switch 25 Power lrim till swilch Colour of Cord B Black Br Brown G Green L Blue Lg Light green or orange P Pink R Red Sb Sky Blue W White Y Yellow Note I means stripe cord...

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Page 101: ...6OC 70C EFOIEFTO 91...

Page 102: ...YP 96...

Page 103: ...60C 70C EPO EPTO 60C 70C EPO EPTO I I I I I I...

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Page 105: ...90A EF T 0 ii...

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Page 107: ...90A EPTO...

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Page 109: ...120Az 14OAz EPTO...

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Page 111: ...tr TOHATSU CORPORATION Address 4 8 3 chome Azusawa kabashiku TOKYO 174 Japan Cable TaHArSU TOKYO Telex 272 2051 THTJ FecalmIle TOKYO 03 3888 7885 GM GIII Phone TOKYO 03 3888 3117...

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