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TOHATSU 2 Stroke 9.9D2, Owner'S Manual

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TOHATSU 2 Stroke 9.9D2 Owner'S Manual Download Page 6

4

ENOM00005-A

Serial Number

In the space below, please record the outboard motor's serial number (indicated both on
the bottom cowl and on the cylinder block). The serial number will be needed when order-
ing parts, and when making technical or warranty inquiries.

Serial Number:

Serial Number:                                                     Date of purchase:

ENOF01700-0

ENOF01701-0

Summary of Contents for 2 Stroke 9.9D2

Page 1: ...2...

Page 2: ......

Page 3: ...MANUAL OWNER S OB No 003 11049 BAF1 M9 9D2 M15D2 M18E2...

Page 4: ...ONS IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE Copyright 2016 Tohatsu Corporation All rights reserved No part of this manual may be r...

Page 5: ...otor please follow the troubleshooting procedures listed at the end of this manual If the problem persists contact an authorized TOHATSU service shop or dealer Please always keep this manual together...

Page 6: ...e outboard motor s serial number indicated both on the bottom cowl and on the cylinder block The serial number will be needed when order ing parts and when making technical or warranty inquiries Seria...

Page 7: ...ion to such information to ensure 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 ENOW0000...

Page 8: ......

Page 9: ...he engine 39 6 Steering 41 7 Trim angle 41 8 Tilt up and down 43 8 REMOVING AND CARRYING THE OUTBOARD MOTOR 46 1 Removing the outboard motor 46 2 Carrying the outboard motor 46 3 Traillering 47 9 ADJU...

Page 10: ......

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

Page 12: ...NY SOLID DEVICE RIGIDLY ATTACHED TO A BOAT OR GEAR HOUSING ENOM0008 A EMERGENCY STOP SWITCH The Emergency Stop Switch will stall the outboard motor when the stop switch lanyard is pulled off This stop...

Page 13: ...e operation Please comply with all instructions concerning lubrication and maintenance You should take the engine to an authorized dealer or service shop for periodic inspection at the prescribed inte...

Page 14: ...er Tilt Gas assisted tilt Manual tilt z z z z z M 18 E 2 M F L Model descrip tion Horse power Product generation Minor change Starter system Steering system Shaft length M X Two stroke F Four stroke D...

Page 15: ...rd Gear rpm 800 Idle Speed in Neutral Gear rpm 950 Engine Type 2 Stroke Number of Cylinders 2 Bore x Stroke mm in 55 x 52 2 17 x 2 05 Piston Displacement mL Cu in 247 15 07 Exhaust System Through hub...

Page 16: ...rd Gear rpm 800 Idle Speed in Neutral Gear rpm 950 Engine Type 2 Stroke Number of Cylinders 2 Bore x Stroke mm in 60 x 52 2 36 x 2 05 Piston Displacement mL Cu in 294 17 94 Exhaust System Through hub...

Page 17: ...oling Water Check Port 6 Drive Shaft Housing 7 Anti Ventilation Plate 8 Anode Trim Tab 9 Sub Water Inlet 10 Propeller 11 Starter Handle 12 Shift Lever 13 Throttle Grip 14 Adjust Nut 15 Clamp Screw 16...

Page 18: ...eck Port 6 Drive Shaft Housing 7 Anti Ventilation Plate 8 Anode Trim Tab 9 Sub Water Inlet 10 Propeller 11 Starter Handle 12 Shift Lever 13 Throttle Grip 14 Adjust Nut 15 Clamp Screw 16 Clamp Bracket...

Page 19: ...r 5 Cooling Water Check Port 6 Drive Shaft Housing 7 Anti Ventilation Plate 8 Anode Trim Tab 9 Sub Water Inlet 10 Propeller 11 Starter Handle 12 Shift Lever 13 Clamp Screw 14 Clamp Bracket 15 Thrust R...

Page 20: ...2 0 Remote control box Fuel tank 1 Control Lever 2 Neutral Lock Arm 3 Free Throttle Lever 4 Main Switch 5 Stop Switch 6 Stop Switch Lock 7 Stop Switch Lanyard 8 Fuel Gauge 9 Air Vent Screw 10 Fuel Tan...

Page 21: ...19 4 LABEL LOCATIONS ENOM00019 A Warning label locations 1 2 6 7 5 4 3 ENOF01703 0...

Page 22: ...ject 2 3 Warning regarding high voltage For RC model 3 Warning label regarding stop switch lanyard 4 Warning regarding gasoline 5 Warning regarding gasoline See page 25 6 Warning regarding gasoline Se...

Page 23: ...e Model name 2 Rated power 3 Dry mass weight 4 Serial No 5 Manufacture name 6 Manufacture address Serial number label locations r e w o P d e t a R r o t o M d r a o b t u O o N l a i r e S s s a M n...

Page 24: ...d torque 30 Nm 3 0 kgf 13 ft lb Check the fasten ers for tightness from time to time z Be sure to use outboard mounting fas teners included in the outboard motor package or their equivalents in terms...

Page 25: ...om cowling during cruising Exposing the engine to such conditions for extended periods can lead to severe engine damage ENOM00830 A Mounting bolts Manual tilt type 1 To attach the outboard motor to th...

Page 26: ...mm 16 inches or less Otherwise it affects the service life of the cable Measure the distance from the remote control box to the outboard motor where the remote control cable should be routed Prepare a...

Page 27: ...the ethanol in the gasoline can absorb moisture from the air resulting in a separa tion of the water ethanol from the gasoline in the fuel tank These may cause increased z Corrosion of metal parts z D...

Page 28: ...When or before refueling z Be sure to remove the static electricity charged in your body before refueling z The sparks due to static electricity may cause explosion of flammable gasoline z Stop the e...

Page 29: ...il Mix well by hand The mixing ratio during break in running is 25 1 Mixing Ratio ENOM01003 0 Engine oil gasoline mixing procedure ENOW00937 0 z Do not use other than two stroke engine oil with specif...

Page 30: ...nd even When fuel tank built in the boat is used for operation of outboard motor s 1 Prepare separate fuel container for pre mixing 2 Pour engine oil into fuel container and then gasoline 3 Put cap on...

Page 31: ...z Always attempt to stay on the windward side of emission ENOW00023 0 Operating the outboard motor without break in can shorten service life of the product If any abnormality is experienced during th...

Page 32: ...p be sure to fol low the procedure described below Fuel could blast out through the fuel tank cap in case the cap is loosened by using another procedure when internal pressure of fuel tank is raised b...

Page 33: ...hen starting the engine in the test tank See page 59 1 Test tank 2 Water 3 Over 10 cm 4 in ENOW00036 0 Be sure to stop engine immediately if cool ing water check port is not discharging water and chec...

Page 34: ...or or to the operator s PFD Personal Flo tation Device 1 Stop switch lock 2 Stop switch 2 Set the control lever in the Neutral position 1 Shift lever 2 Neutral 3 Set the throttle grip to START positio...

Page 35: ...ossible and or damaging the starter If cranking over 5 seconds fails to start engine return main switch to ON and crank engine again after 10 seconds or more 5 Return the choke knob fully after engine...

Page 36: ...ns the Free accel lever to close position 8 Check the cooling water from cooling water check port 1 Cooling water check port 2 Idle port ENOM00042 C Emergency starting ENOW00099 A When the emergency s...

Page 37: ...wind the rope around the flywheel sev eral turns clockwise 5 Tie a loop in the another end of the emergency starter rope and attach socket wrench that is included in the tool kit ENOW00860 0 Be sure t...

Page 38: ...ed 5 Return the choke knob 1 Choke knob ENOM00043 A ENOW00932 0 Be sure to check that cooling water is coming out of the cooling water check port during warm up Warm the engine at low engine speeds fo...

Page 39: ...ged z Do not shift into Reverse during cruis ing or control may be lost falling down or causing passenger s to be thrown overboard Leading to serious personal injury and steering system and or shift i...

Page 40: ...ft lever to the Forward position Reverse 1 Turn the throttle grip to reduce engine speed 2 When the engine reaches trolling or idling speed quickly pull the shift lever to the Reverse position Acceler...

Page 41: ...Reverse R position at 32 where the gear is connected while lifting up on the lock button located under the con trol lever grip 2 Further rearward motion will open the throttle Acceleration ENOW00867 A...

Page 42: ...RC type 1 Put the control lever in the Neutral position and run the engine for 2 3 minutes at idling speed for cooling down if it has been running at full speed 2 Turn the main switch key to the OFF p...

Page 43: ...Left turn Move the tiller handle to the right Remote control type Right turn Turn the steering wheel to the right Left turn Turn the steering wheel to the left ENOM00050 0 ENOW00043 A z Adjust the tri...

Page 44: ...ntrol of boat may be lost The trim angle of the outboard motor can be adjusted to suit the transom angle of the hull and load conditions Choose an appropriate trim angle that will allow the anti venti...

Page 45: ...etween the swivel bracket and the stern bracket Be sure to tilt the outboard motor down slowly ENOW00056 A When tilting up outboard motor with fuel joint for over a few minutes be sure to dis connect...

Page 46: ...your hand between the swivel bracket and the clamp bracket Be sure to tilt the outboard motor down slowly ENOW00053 0 While in shallow water drive position do not operate the outboard motor in Revers...

Page 47: ...he outboard motor in the shal low water running position 1 Reverse lock lever 2 Tilt up position 3 Tilt down position 2 Return to normal running position Put the reverse lock lever in the tilt down po...

Page 48: ...n hazard which can cause serious injury or death ENOW00065 0 Close air vent screw of fuel tank before carrying or storing outboard motor and fuel tank or fuel may leak potentially catching fire ENOW00...

Page 49: ...w of fuel tank and fuel cock before carrying or storing outboard motor and fuel tank or fuel may leak potentially catching fire ENOW00071 0 The tilt support device supplied on your outboard motor is n...

Page 50: ...d clearance should be provided sufficiently 2 Transom saver bar ENOW00067 0 Do not go under outboard motor tilted up even if it is supported by support bar or accidental fall of outboard motor could l...

Page 51: ...throttle grip can be made with the throttle adjustment screw 1 Heavier 2 Lighter 3 Throttle friction adjustment screw ENOM00076 0 ENOW00076 0 z Be sure that outboard motor is secured to transom or se...

Page 52: ...direct the trim tab towards A left from rear of boat z If the boat veers toward the right direct the trim tab towards B right from rear of boat 1 Trim tab ENON00022 A Notes z After adjustment securely...

Page 53: ...and mainte nance procedures described in this sec tion z The maintenance intervals shown in the checklist apply to an outboard motor in normal use If you use your outboard motor under severe condition...

Page 54: ...and magneto work normally when turning the throttle grip and check links for looseness Replace 1 Correct 1 Recoil Starter Check ropes for wear and chafing Check the ratchet for engagement Replace 1 C...

Page 55: ...and cool ing water passage after every cruising or before storing outboard motor for long time Before flushing remove the propeller and the forward thrust holder ENOM00085 D Flushing attachment ENOW0...

Page 56: ...e anti ventilation plate And be sure to remove the propeller when starting the engine in the test tank See page 59 1 Test tank 2 Water 3 Over 10 cm 4 in ENOM00950 0 Fuse replacement For electrical sta...

Page 57: ...and disconnect the battery cable from the battery negative terminal 2 Remove the engine cover 3 Remove the fuse box lid 4 Remove the fuse and check it If the fuse is blown replace it with a fuse of th...

Page 58: ...System Carburetor 1 z Strip clean and adjust Adjust idling Fuel filter z z z Check and clean or Replace Piping Hose z z z Check and Replace Fuel tank z z Clean Ignition Spark plugs z z Check gaps Rem...

Page 59: ...fuel sys tem services Services by unqualified person could lead to engine damage Water or dirt in the fuel filter and tank will cause engine performance problems Check and clean the fuel filter and ta...

Page 60: ...tilted up and locked or accidental fall of out board motor could lead to severe per sonal injury ENON00934 0 Note Please dispose of used oil in a manner that is compatible with the environment We sug...

Page 61: ...ar oil or the recommended one API GL 5 SAE 80 to 90 Required volume approx 360 mL 11 8 fl Oz ENOM00086 A Propeller replacement ENOW00084 0 z Do not begin propeller removal and installation procedure w...

Page 62: ...n 6 Tighten the propeller nut to specified torque and align one of grooves to propeller shaft hole Propeller nut torque 25 Nm 18 ft lb 2 5kgf m 7 Install a new split pin into the nut hole and bend it...

Page 63: ...hould be 0 9 1 0 mm 0 035 0 039 inches If the gap is different replace the spark plug with a new one Use spark plug NGK B7HS 10 or BR7HS 10 1 Electrode 2 Spark gap 0 9 1 0 mm 0 035 0 039 in 7 Install...

Page 64: ...lytic corrosion Anode is located on the gear case cylinder etc When the anode is eroded more than 1 3 of origi nal size replace it ENON00029 0 Notes z Never grease or paint the anode z At each inspect...

Page 65: ...INSPECTION AND MAINTENANCE 63 10 ENOM00960 0 Grease point Apply water proof grease to the parts shown below ENOF01737 0...

Page 66: ...flush the cooling water system thoroughly with fresh water Drain the water com pletely Wipe off any surface water with an oily rag 2 Remove the fuel hose from the out board motor 3 Drain all fuel from...

Page 67: ...dditive commercially available first fill the fuel tank with fresh oil and fuel If the fuel tank is only partially filled air in the tank can cause the fuel to deteriorate during stor age 1 Before add...

Page 68: ...ave the outboard motor until all fuel has been drained 6 When thoroughly drained retighten the drain screw securely 7 Check the drained fuel for the pres ence of contaminants If it is present check th...

Page 69: ...nside the engine will be circulated out to assure optimum performance ENOM00105 D ENOW00098 0 Do not attempt to start submerged out board motor immediately after it is recov ered or engine could be se...

Page 70: ...top the engine immediately 2 Check the control system gear case boat transom etc 3 Return to the nearest habor slowly and carefully 4 Consult a dealer check the outboard motor before operation again E...

Page 71: ...vent on fuel tank z z z z z z z Clogged fuel filter fuel pump or carburetor z z z z z Use of improper engine oil z z z z z Use of improper gasoline z z z z z z Excessive oil in mixture z Shortage of...

Page 72: ...z z z z Incorrect propeller selection z z z z z z Damaged and bent propeller z z z z Improper thrust rod position z z z z z Unbalanced load on boat z z z z z Transom too high or too low Engine failing...

Page 73: ...s Name Quantity Remark Servicing Tools Tool Bag Pliers Socket Wrench Socket Wrench Socket Wrench Handle Screwdriver Phillips type and flat head 1 1 1 1 1 1 10 x 13 mm 21 mm Adapter type Spare Parts Ro...

Page 74: ...ust be selected so that the engine rpm measured at wide open throttle while cruising is within the recommended range 9 9D2 4 500 to 5 300 rpm 15D2 18E2 5 200 to 5 800 rpm Mark Propeller Size Diameter...

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Page 76: ...OWNER S MANUAL M9 9D2 M15D2 M18E2 003 11049 BAF1 1512NB Printed in Japan...

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