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TOHATSU 2 Stroke 3.5B, Owner'S Manual

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TOHATSU 2 Stroke 3.5B Owner'S Manual Download Page 6

11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12. TOOL KIT AND SPARE PARTS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
13. OPTIONAL ACCESSORIES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
14. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

MFS2.5-3.5B_EN.book  Page 6  Wednesday, December 5, 2012  10:36 AM

Summary of Contents for 2 Stroke 3.5B

Page 1: ...MANUAL 2 5B 3 5B MFS OWNER S OB No 003 11085 7 MFS2 5 3 5B_EN book Page 1 Wednesday December 5 2012 10 36 AM...

Page 2: ...SERIOUS INJURY OR DEATH KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE Copyright 2009 2012 Tohatsu Corporation All rights reserved No part of this manual may be reproduced or transmitted in...

Page 3: ...D BY APPLICABLE LAW YOUR OUTBOARD MOTOR WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY IF THIS PROCEDURE IS NOT FOLLOWED ENOM00003 0 PRE DELIVERY CHECK Be sure that the product has been checke...

Page 4: ...excellent outboard motor that will service you for many years to come This manual should be read in its entirety and the inspection and maintenance procedures described later in this manual should be...

Page 5: ...22 Before starting 22 1 Filling the fuel 22 2 Feeding the fuel 24 3 Starting 24 4 Warming up the engine 27 5 Forward and reverse 28 6 Stopping 30 7 Trim angle 31 8 Tilt up tilt down 32 9 Outboard moto...

Page 6: ...11 TROUBLESHOOTING 49 12 TOOL KIT AND SPARE PARTS 51 13 OPTIONAL ACCESSORIES 52 14 PROPELLER TABLE 53 MFS2 5 3 5B_EN book Page 6 Wednesday December 5 2012 10 36 AM...

Page 7: ...N 5 PRE OPERATING PREPARATIONS 6 ENGINE OPERATION 7 REMOVING AND CARRYING THE OUTBOARD MOTOR 8 TRAILERING 9 ADJUSTMENT 10 INSPECTION AND MAINTENANCE 11 TROUBLESHOOTING 12 TOOL KIT AND SPARE PARTS 13 O...

Page 8: ...facilitate the use or maintenance of the outboard motor or to clarify important points ENOM0008 0 EMERGENCY STOP SWITCH The Emergency Stop Switch will stall the outboard motor when the stop switch te...

Page 9: ...ICE RIGIDLY ATTACHED TO A BOAT OR GEAR HOUSING ENOM00010 0 SERVICING REPLACEMENT PARTS LUBRICANTS We recommend that only an authorized service shop perform service or maintenance on this outboard moto...

Page 10: ...2 Piston Displacement mL Cu in 85 5 5 2 Exhaust System Above propeller exhaust Cooling System Water cooling Engine Lubrication Splashing system Starting System Manual starter Ignition System Ignitor S...

Page 11: ...ate 8 Anode 9 Propeller 10 Oil Plug Lower Fill 11 Water Inlet 12 Oil Plug Upper Level 13 Drive Shaft Housing 14 Thrust Rod 15 Clamp Bracket 16 Clamp Screw 17 Throttle Grip 18 Shift Lever 19 Starter Ha...

Page 12: ...ine oil level and unleaded gasoline 2 Warning label on position of outboard motor when setting down 3 Only for USA and CANADA models Warning regarding fuel tank cap See pages 22 24 Locations of warnin...

Page 13: ...elow Warning Caution Read manual thoroughly Check oil level Use unleaded gasoline only Lay as indicated Warning rotating object Warning high voltage Warning high temperature ENOF00012 0 ENOF00254 0 EN...

Page 14: ...hat the anti ventilation plate of the outboard motor is below the water sur face If the above condition cannot be met due to the shape of the bottom of your boat please consult your authorized dealer...

Page 15: ...out following this manual can lead to unsafe conditions such as poor maneuverabil ity lack of control or fire Loose clamp screws and or mounting bolts can lead to the release or displace ment of the o...

Page 16: ...aged or contaminated gasoline in accordance with local regulations ENOM00030 0 ENOW000017 0 Use of improper gasoline can damage your engine Engine damage resulting from the use of improper gasoline is...

Page 17: ...parts for corrosion and abnormal wear more frequently And in case any of such abnormality is found discontinue the use of such gaso line and contact our dealer immediately Damages resulting from the...

Page 18: ...will expand and contract as the fuel expands and contracts during heating and cooling cycles of the outside air This is normal Please refer to pages 22 24 when using this fuel tank ENOM00207 0 Use onl...

Page 19: ...ay need to have a high altitude kit installed Otherwise operating the engine at high altitude may increase its emissions and decrease fuel efficiency and perfor mance Please see LIMITED WARRANTY INFOR...

Page 20: ...utboard motor in closed area or area with no forced ventila tion Exhaust gas emitted by this outboard motor contains carbon monoxide that will cause death if inhaled continuously Inhal ing the gas ini...

Page 21: ...at a reduced speed rpm Possible causes of ESG activation are Worn broken bent propeller and shear pin Slipping propeller rubber Making sharp turns at high speeds Trim angle ENON00202 0 Note If the eng...

Page 22: ...k cap or gasoline vapor will be emitted through the air vent screw creating a fire hazard Do not smoke When or before refueling Stop the engine and do not start the engine during refueling Do not smok...

Page 23: ...ease air pressure in the fuel tank 1 Two turns the air vent screw 2 Open the fuel tank cap slowly 3 Fill the fuel not to over the shown level 1 Full line 4 After filling the tank close the tank cap EN...

Page 24: ...k ENOM00212 0 1 Place the shift lever in the neutral posi tion 1 Shift lever 2 Neutral N 3 Forward F 2 Attach the stop switch tether to a secure place on your arm or clothing And then install the lock...

Page 25: ...y when the engine is warm If the engine is warm open the throttle grip until the RESTART mark 5 Gently pull the starter handle until you feel slight resistance engagement and then quickly and strongly...

Page 26: ...Tighten the three bolts A B C fas tening the tank and one bolt D fasten ing the recoil starter Confirm that the shift lever is at Neutral N position Wrap a rope around the starter pulley then pull qui...

Page 27: ...or objects on the boat to be thrown for ward due to inertial force Do not touch electrical components such as ignition coils spark plug cables or spark plug caps when starting engine or while engine...

Page 28: ...ed Be careful not to pull the tether acciden tally during cruising Unintentional stop of engine can cause loss of control of outboard motor Rapid loss of engine power can lead to falling down or caus...

Page 29: ...ng cruise Operating cold engine may cause damage to your motor ENOW00051 0 During shallow water operation be careful not to place your hand between the swivel bracket and the stern bracket Be sure to...

Page 30: ...can accelerate wear or degradation of parts In such case replace gear oil earlier than the period spec ified ENOM00220 0 1 Turn the throttle grip to the low speed position 2 Set the shift lever to th...

Page 31: ...gle The position of the thrust rod is correct if the hull is horizontal during operation 1 Perpendicular to the water surface ENOM00053 0 Improper trim angle bow rises too high Set the thrust rod lowe...

Page 32: ...to place your hand between the swivel bracket and the stern bracket Be sure to tilt the outboard motor down slowly ENON00209 0 Note Be sure to stop the motor during tilt up or tilt down operation ENOM...

Page 33: ...handle side must look downward 1 Tilt handle 2 Starter handle 3 Correct 1 Wrong ENOW00205 0 The outboard motor is set in the correct tilt up position in the usual condition how ever the outboard moto...

Page 34: ...eak potentially catching fire Do not give a shock to an outboard motor during transportation It becames a cause of breakage ENOM00072 0 Outboard motor should be stored in a ver tical position ENON0021...

Page 35: ...nded to support the outboard motor while the boat is docked beached etc ENOW00072 0 When trailering the outboard motor should be in a vertical normal running position fully down Trailering in the tilt...

Page 36: ...e adjustment screw may cause damage to the swivel bracket ENOM00074 0 Friction adjustment of the throttle grip can be made with the throttle adjustment screw 1 Lighter 2 Heavier ENOW00074 0 Do not ove...

Page 37: ...er intervals If in doubt consult your dealer for advice We strongly recommend that you use only genuine replacement parts on your outboard motor Damage to your out board motor arising from the use of...

Page 38: ...ace Check the spark plug for dirt wear and carbon build up Clean or replace Throttle Sys tem Check that the carburetor choke valve functions normally Replace Check carburetor linkage is working normal...

Page 39: ...ade is added drain all oil and ask dealer for treatment In case other than engine oil such as gasoline is put in the oil chamber empty the chamber and ask dealer for treat ment When replenishing engin...

Page 40: ...tachment Connect a hose to the flushing attach ment With the shift lever in Neutral N run the engine at a idle speed while flushing the cooling system to ensure all sea water and mud are removed 1 Flu...

Page 41: ...burns if touched Allow motor to cool down first If the spark plug is fouled has carbon build up or is worn it should be replaced When reusing spark plugs remove dirt from the electrodes and adjust spa...

Page 42: ...ing bolt As it is likely to be sub jected to electrolytic corrosion 1 Anode ENOW00209 0 Be sure that outboard motor is secured to transom or service stand or acciden tal drop or fall of outboard motor...

Page 43: ...p 2 Check and clean or Replace if necessary Fuel pump 3 Check and clean or Replace if necessary Disassemble and check each 300 hours Ignition Spark plug Check gaps Remove carbon deposits or Replace if...

Page 44: ...e the oil drain screw and com pletely drain oil from the engine 5 Tighten the oil drain screw 6 Fill the engine through filler port with recommended oil see chart below to the upper level mark 7 Tight...

Page 45: ...g or changing oil ENON00031 0 Notes If any amount of water is found in engine oil making it milky white consult dealer If engine oil is contaminated with fuel emitting strong fuel smell consult dealer...

Page 46: ...tor out of the water 1 Wash the engine exterior and flush the cooling water system thoroughly with fresh water Drain the water com pletely See page 39 Wipe off any surface water with an oily rag 2 Use...

Page 47: ...r right away 1 Wash the outboard motor with fresh water to remove salt or dirt 2 Remove the engine oil drain screw and completely drain water and oil from the engine 3 Remove the spark plugs and com p...

Page 48: ...sion case bolts propeller shaft housing bolts propeller or propeller shaft upper and lower mount rubber bolts and or mount bracket bolts Ask an authorized dealer to tighten any loose bolts and nuts a...

Page 49: ...Overheating of engine Possible cause FUEL SYSTEM Empty fuel tank Deformed or damaged fuel hose Closed air vent on fuel tank Clogged fuel filter fuel pump or carburetor Use of improper engine oil Use o...

Page 50: ...ust rod position Unbalanced load on boat Transom too high or too low Low compression Carbon deposits in the combustion chamber Engine makes noise Too much the valve clearance Engine failing to start E...

Page 51: ...emark Service tools Tool bag 1 Pliers 1 Socket wrench 1 10 13 mm Socket wrench 1 16 mm Socket wrench handle 1 Screwdrivers 1 Cross and straight point Screwdriver handle 1 Spare parts Emergency starter...

Page 52: ...0248 0 Propeller Flushing attachment Genuine gear oil 500 mL Touch up paint 300 mL Genuine engine oil 1 L ENOF00248 0 ENOF00102 0 ENOF00104 0 ENOF00105 0 ENOF00106 0 MFS2 5 3 5B_EN book Page 52 Wednes...

Page 53: ...pm 3 5 5000 6000 rpm ENON00245 0 Note Each size shows number of propeller blades diameters pitch Propeller Mark Propeller Size Diameter pitch Material Remarks Light boats 7 3 188 178 mm 3 7 4 7 0 in P...

Page 54: ...2 5B 3 5B MFS OWNER S MANUAL 003 11085 7 1211NB Printed in Japan MFS2 5 3 5B_EN book Page 54 Wednesday December 5 2012 10 36 AM...

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