TOHATSU BFT 200D Owner'S Manual Download Page 104

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102

SERVICING YOUR OUTBOARD MOTOR

If water is present in the fuel filter

with water separator, refer to fuel

filter with water separator

replacement procedure to remove the

strainer cup and empty the water from

the inside of the cup.

<Replacement>

1. Remove the engine cover (p. 88).

2. Disconnect the 2 pin coupler

(blue).

3. Remove the suspension strap from

the fuel filter with water separator

bracket, and then remove the

suspension strap from the fuel filter

with water separator.

4. Bind the two fuel hoses with hose

clips to prevent fuel leakage, and

disconnect the fuel hoses.

2 PIN COUPLER

(BLUE)

FUEL HOSES

WATER

SEPARATOR

BRACKET

SUSPENSION

STRAP

WATER

SEPARATOR

HOSE CLIPS

Summary of Contents for BFT 200D

Page 1: ...250D BFT 200D BFT 225D BFT 250D 31ZVLT03 00X31 ZVL T030 OWNER S MANUAL OWNER S MANUAL 5 4 Azusawa 3 Chome Itabashi Ku Tokyo 174 0051 Japan Tel 81 3 3966 3117 Fax 81 3 3966 2951 www tohatsu com PRINTED...

Page 2: ...ication were in effect at the time of approval for printing Honda Motor Co Ltd reserves the right however to discontinue or change specifications or design at any time without notice and without incur...

Page 3: ...manual you will find information preceded by a symbol That information is intended to help you avoid damage to your outboard motor other property or the environment We suggest you read the warranty po...

Page 4: ...You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels on the outboard motor Safety Messages preceded by a safety alert symbol and...

Page 5: ...Lever Top Mount type DBW type 26 Function Switches Flush Mount type 27 Function Switches Single Top Mount type DBW type 28 Side Mount Type 30 Ignition Switch 30 Emergency Stop Switch Clip and Emergenc...

Page 6: ...ERATION 54 SAFE OPERATING PRECAUTIONS 54 BREAK IN PROCEDURE 54 FUEL PRIMING 55 INFREQUENT OR OCCASIONAL USE 55 STARTING THE ENGINE 56 Flush Mount Type Top Mount Type DBW type 56 Side Mount Type 59 Flu...

Page 7: ...r Change 92 Engine Oil Recommendations 93 Lubrication Points 94 Spark Plug Service 95 REFUELING 99 FUEL RECOMMENDATIONS 100 Fuel Filter with Water Separator Inspection and Replacement 100 Anode Replac...

Page 8: ...L PRESSURE INDICATOR TURNS OFF AND ENGINE SPEED IS LIMITED 123 OVERHEAT INDICATOR COMES ON AND ENGINE SPEED IS LIMITED 124 WATER SEPARATOR BUZZER SOUNDS 125 SUBMERGED OUTBOARD MOTOR 126 Emergency Gear...

Page 9: ...lity to provide the necessary safeguards to protect people and property Know how to stop the engine quickly in case of emergency Understand the use of all controls Stop the engine immediately if anyon...

Page 10: ...st contains poisonous carbon monoxide a colorless odorless gas Breathing carbon monoxide can cause loss of consciousness and may lead to death If you run the engine in an area that is confined or even...

Page 11: ...e label shown here contains important safety information Please read it carefully This label is considered a permanent part of your outboard motor If the label comes off or becomes hard to read contac...

Page 12: ...D XCR XCD UCR UCD Transom Height 20 0 in 508 mm 25 0 in 635 mm 30 0 in 762 mm Standard Rotating Propeller Shaft Counterrotating Propeller Shaft Power Trim Tilt Mechanical wire Drive by Wire DBW TYPE C...

Page 13: ...ICH DIRECTION THE PROPELLER SHAFT ROTATES The direction the propeller shaft rotates can be determined based on whether or not the shaft has a groove With groove Counterrotating Without groove Standard...

Page 14: ...H STERN BRACKET MANUAL RELIEF VALVE ANODE PROPELLER ANTICAVITATION PLATE ANODE IDLE PORT FLUSH PLUG CONNECTOR COOLING SYSTEM INDICATOR TRIM TAB ENGINE COVER LATCH each side ENGINE OIL DRAIN BOLT EXHAU...

Page 15: ...13 CONTROLS AND FEATURES SPARK PLUGS under coil OIL LEVEL DIPSTICK FUEL FILTER with WATER SEPARATOR Mechanical wire type THROTTLE ARM SHIFT ARM SHAFT...

Page 16: ...14 CONTROLS AND FEATURES NMEA INTERFACE COUPLER JUNCTION BOX FUSES OIL FILLER CAP SPARK PLUGS under coil Mechanical wire type THROTTLE REEL...

Page 17: ...quipment GEARSHIFT THROTTLE CONTROL LEVER NEUTRALRELEASE LEVER POWER TRIM TILT SWITCH POWER TRIM TILT SWITCH FUNCTION SWITCHES DUAL TOP MOUNT REMOTE CONTROL POWER TRIM TILT SWITCH FUNCTION SWITCHES GE...

Page 18: ...STOP switch type Horizontal type EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD EMERGENCY STOP SWITCH IGNITION SWITCH START STOP SWITCH SINGLE TYPE ALL ENGINE START FOR MULTIPLE OUTBOARD MOT...

Page 19: ...52 752 752 67 752 17 50 7 3257 67 17 5 EMERGENCY STOP STOP POWER TRIM TILT SWITCH FUNCTION SWITCHES DUAL TYPE Emergency Stop Switch Panel optional equipment TRIPLE TYPE EMERGENCY STOP SWITCH EMERGENCY...

Page 20: ...MERGENCY STOP SWITCH IGNITION SWITCH FAST IDLE LEVER NEUTRAL RELEASE LEVER INDICATORS Oil pressure Overheat Alternator Malfunction FLUSH MOUNT REMOTE CONTROL GEARSHIFT THROTTLE CONTROL LEVER POWER TRI...

Page 21: ...LE type BUZZER IGNITION SWITCH POWER TRIM TILT SWITCH LEFT GEARSHIFT THROTTLE CONTROL LEVERS POWER TRIM TILT SWITCH RIGHT DUAL TOP MOUNT REMOTE CONTROL EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH...

Page 22: ...CH KEY BUZZER IGNITION SWITCH EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD for DUAL OUTBOARD MOTORS type for TRIPLE OUTBOARD MOTORS type For the switch panel without...

Page 23: ...switch key to the START position starts the engine The key automatically returns to the ON position when released from the START position The engine will not start unless the gearshift throttle contr...

Page 24: ...switch This switch locates on the key switch panel Key positions ON to run the engine after starting OFF to stop the engine IGNITION OFF Do not leave the power switch ON when the engine is not running...

Page 25: ...pe switch At this time the indicator of the corresponding switch comes on The starter motor will not work unless the gearshift throttle control lever is in the NEUTRAL position and the clip is in the...

Page 26: ...e operator or to the operator s PFD Personal Flotation Device When used as described the emergency stop switch clip and emergency stop switch lanyard system stops the engine if the operator falls away...

Page 27: ...move the lever out of the N neutral position you must squeeze the neutral release lever on the underside of the lever handle A friction adjuster near the base of the control lever adjusts the operati...

Page 28: ...s engine speed A friction adjuster inside the control box adjusts the operating resistance of the control lever s Refer to p 73 Less friction allows easier control lever movement More friction helps t...

Page 29: ...e switch and the gearshift throttle control lever to adjust the engine speed without gearshift when warming up the engine Keeping the switch pressed when the gearshift throttle control lever is in the...

Page 30: ...s are used for operations in the fast idle mode trolling mode one lever mode and station select mode NT WARM Lights The shift is in neutral Blinks It is in the fast idle mode ACT Lights The shift and...

Page 31: ...en in trolling mode If you press and hold the switch while cruising with the throttle closed the mode changes to trolling mode One Lever Mode For multiple outboard motors type Shifting gear and the en...

Page 32: ...ition starts the engine The key automatically returns to the ON position when released from the START position The engine will not start unless the gearshift throttle control lever is in the N neutral...

Page 33: ...stop switch clip and emergency stop switch lanyard system stops the engine if the operator falls away from the controls A spare switch clip optional equipment can be stored in the tool bag Gearshift T...

Page 34: ...ition you must squeeze the neutral release lever on the underside of the lever handle A friction adjuster adjusts the operating resistance of the control lever s Refer to p 74 Less friction allows eas...

Page 35: ...ows you to increase the idle speed only when the control lever is in the N neutral position Place the fast idle lever in its lowest position to cancel the fast idle and return the control lever to nor...

Page 36: ...cy Stop Switch The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run The emergency stop switch lanyard must be attached securely to the...

Page 37: ...er out of the N neutral position you must squeeze the neutral release lever on the underside of the lever handle A friction adjuster near the base of the control lever adjusts the operating resistance...

Page 38: ...crease the idle speed without engaging the drive gears Move the control lever forward or reverse after pushing in the fast idle button to increase the idle speed It is necessary to position the contro...

Page 39: ...e engine Emergency Stop Switch Clip and Emergency Stop Switch The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run The emergency stop s...

Page 40: ...ed A friction adjuster inside the control box adjusts the operating resistance of the control lever s Refer to p 74 Less friction allows easier control lever movement More friction helps to hold a ste...

Page 41: ...llows you to increase the idle speed without engaging the drive gears Move the control lever forward or reverse after pushing in the fast idle button to increase the idle speed It is necessary to posi...

Page 42: ...LEVER POWER TRIM TILT SWITCH top mount type drive by wire type SINGLE TYPE POWER TRIM TILT SWITCH CONTROL LEVER DUAL TYPE POWER TRIM TILT SWITCH CONTROL LEVERS POWER TRIM TILT SWITCH CONTROL LEVER fl...

Page 43: ...e OFF position It is necessary for the ignition switch to be in the ON position for the trim meter to indicate the outboard motor angle Trim the outboard motor to obtain the best performance and stabi...

Page 44: ...with UP and DN down positions for changing the angle of the outboard motor The power tilt switch will operate without turning the ignition switch ON This switch is used with the engine stopped to rais...

Page 45: ...ever contacts the stern bracket Engine Cover Latch The engine cover latch fastens the engine cover to the outboard motor Trim Tab The trim tab compensates for torque steer which is a reaction of the o...

Page 46: ...t The tachometer shows engine speed in revolutions per minute Refer to the tachometer when using the throttle and power trim tilt controls to achieve the best performance from the boat NMEA Interface...

Page 47: ...h The buzzer will sound twice 5 Insert and remove the emergency stop switch clip five times within 20 seconds When reset the buzzer will sound once Mechanical wire type 1 Stop the engine 2 Set the gea...

Page 48: ...ours after reset 20 hours Start of operation Notify Notify Notify Maintenance indication Maintenance indication Maintenance indication Maintenance indication NMEA2000 compatible display Follow instruc...

Page 49: ...light during this test it cannot alert you if that system develops a problem Have your TOHATSU dealer check for burned out bulbs or other problems Under normal conditions the following occur when the...

Page 50: ...m will limit engine speed Refer to TAKING CARE OF UNEXPECTED PROBLEMS on p 123 All models are equipped with a buzzer that sounds continuously when the oil pressure indicator turns off Low oil pressure...

Page 51: ...red overheat indicator light comes on Engine overheating may be the result of clogged water intakes Cooling System Indicator Water should flow from the cooling system indicator while the engine is ru...

Page 52: ...limiting engine speed if the outboard motor is trimmed or tilted up excessively or when propeller ventilation occurs during a sharp turn If the rev limiter is activated check the trim angle of the ou...

Page 53: ...cts the fuel tank to the outboard motor Before starting the engine hold the priming bulb up in the direction of the arrow then squeeze the priming bulb until it feels firm This will ensure that fuel i...

Page 54: ...R OUTBOARD MOTOR READY TO GO For your safety and to maximize the service life of your equipment it is very important to take a few moments before you operate the outboard motor to check its condition...

Page 55: ...the emergency stop switch Maintenance Inspection Check the engine oil level p 89 Running the engine with a low oil level can cause engine damage Overfilling the engine can cause the engine to smoke o...

Page 56: ...engine at trolling speed Use the minimum throttle opening necessary to operate the boat at a safe trolling speed Next 45 minutes Run the engine up to a maximum of 2 000 to 3 000 rpm which is about 10...

Page 57: ...ould overflow INFREQUENT OR OCCASIONAL USE If your outboard motor will be used on an infrequent or intermittent basis please refer to the fuel section of the STORAGE chapter p 109 for additional infor...

Page 58: ...op switch clip is in the emergency stop switch The emergency stop switch clip and emergency stop switch lanyard system is a safety device that will stop the engine if you fall away from the controls w...

Page 59: ...engine is running With START STOP Switch Type 3 Insert the key to the power switch and turn it to the ON position 4 Push the start stop switch 5 Before getting underway allow the engine to warm up suf...

Page 60: ...peed without warming the engine up may cause engine damage During the warm up period check the oil pressure indicator p 48 overheat indicator p 49 and cooling system indicator p 49 If the indicators s...

Page 61: ...mergency stop switch clip and emergency stop switch lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat Always attach the emergency...

Page 62: ...key to the START position and hold it there until the engine starts When the engine starts release the key allowing it to return to the ON position If the engine fails to start within 5 seconds relea...

Page 63: ...m may freeze in areas where the temperature reaches 32 F 0 C or below Cruising at high speed without warming the engine up may cause engine damage During the warm up period check the oil pressure indi...

Page 64: ...witch The emergency stop switch clip and emergency stop switch lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat Always attach the...

Page 65: ...e than 5 seconds at a time will overheat the starter motor and can damage it Turning the ignition switch key to the START position while the engine is running can damage the starter motor and flywheel...

Page 66: ...cooling system indicator p 49 If the indicators show any abnormal condition immediately stop the engine and determine the cause of the problem Refer to TAKING CARE OF UNEXPECTED PROBLEMS on p 115 6 If...

Page 67: ...switch lanyard securely to the operator or to the operator s PFD before starting the engine 2 Set the control lever in the N neutral position The engine will not start if the F forward or R reverse ge...

Page 68: ...good performance Above 41 F 5 C warm up the engine for 2 or 3 minutes Below 41 F 5 C warm up the engine for at least 10 minutes at 2 000 rpm Push the fast idle button and then move the control lever...

Page 69: ...l lever to the N neutral position as the engine warms up Station Select Mode For multiple station type use the switch to change the operating station If you press and hold the switch of the inactive s...

Page 70: ...gine and emergency stop switch are operating properly Normal Engine Stopping Flush Mount Type Top Mount Type DBW type Flush Mount Type Top Mount Type DBW type EMERGENCY STOP SWITCH EMERGENCY STOP SWIT...

Page 71: ...without START STOP switch 2 Turn the ignition switch key to the OFF position to stop the engine In the event that the engine does not stop when the ignition switch key is turned to the OFF position p...

Page 72: ...ntrol lever s to the N neutral position After cruising at full throttle cool down the engine by idling for a few minutes before stopping the engine Side Mount Type N NEUTRAL CONTROL LEVER Flush Mount...

Page 73: ...does not stop when the ignition switch key is turned to the OFF position pull the emergency stop switch clip out of the emergency stop switch by pulling the emergency stop switch lanyard p 68 3 When...

Page 74: ...NEUTRAL F FORWARD R REVERSE NEUTRAL RELEASE LEVER CONTROL LEVER Top Mount Type DBW type N NEUTRAL F FORWARD R REVERSE CONTROL LEVER CONTROL LEVER NEUTRAL RELEASE LEVER N NEUTRAL F FORWARD R REVERSE N...

Page 75: ...BW type To increase friction Front side COVER Rear side To decrease friction CONTROL LEVER FRICTION ADJUSTER BOLT NUT To increase friction Front side COVER Rear side To decrease friction CONTROL LEVER...

Page 76: ...hrottle setting while cruising STEERING Steer the boat in the same manner as an automobile TO INCREASE FRICTION TO DECREASE FRICTION CONTROL LEVER FRICTION ADJUSTER CONTROL LEVER FRICTION ADJUSTER TO...

Page 77: ...wer trim tilt switch to trim the outboard motor for the best performance and stability You can use the power trim tilt switch at any time whether the boat is underway or stopped Press the UP or DN dow...

Page 78: ...Mount Type Single Top Mount Type Mechanical wire type POWER TRIM TILT SWITCH POWER TRIM TILT SWITCH POWER TRIM TILT SWITCH POWER TRIM TILT SWITCH POWER TRIM TILT SWITCH Flush mount type Mechanical wir...

Page 79: ...im tab with the engine stopped Loosen the bolt above the trim tab turn the trim tab and then tighten the bolt securely When the trim tab is correctly adjusted steering effort will be equal in both dir...

Page 80: ...min 1 rpm every time you press the switch once You will hear a short buzz The engine speed can be adjusted within the range of 650 1 000 min 1 rpm Continuing to press the switch will not decrease or i...

Page 81: ...TRAL position the mode changes to one lever mode A long buzz sounds once and SYNC indicator comes on SHALLOW WATER OPERATION When operating in shallow water use the power trim tilt switch p 75 76 to t...

Page 82: ...wer tilt switch on the engine pan to tilt the outboard motor up as far as it will go Move the tilt lock lever to the LOCK position and then gently lower the outboard motor until the lever contacts the...

Page 83: ...utboard motor before opening the manual relief valve If the manual relief valve is loosened turned counterclockwise when the outboard motor is tilted up the outboard motor will suddenly tilt down MULT...

Page 84: ...usual conditions consult an authorized TOHATSU dealer for recommendations applicable to your individual needs and use Remember that your authorized TOHATSU dealer knows your outboard motor best and is...

Page 85: ...s Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the too...

Page 86: ...s be available if you need them If your tool kit needs replacement it is not available as a kit and each item must be ordered individually 10 mm BOX WRENCH PHILLIPS SCREWDRIVER 19 mm EYE WRENCH GRIP S...

Page 87: ...use First month or 20 hrs Every 6 months or 100 hrs Every year or 200 hrs Every 2 years or 400 hrs Every 3 years or 600 hrs Every 6 years or 1 200 hrs Engine oil Check level o Change o o Engine oil fi...

Page 88: ...mage 9 Mechanical Remote Control type only Each use After use First month or 20 hrs Every 6 months or 100 hrs Every year or 200 hrs Every 2 years or 400 hrs Every 3 years or 600 hrs Every 6 years or 1...

Page 89: ...equal in either direction If steering effort is unequal loosen the trim tab bolt and adjust the angle of the trim tab Retighten the trim tab bolt securely If less effort is required to make left turn...

Page 90: ...operating the outboard motor If the valve is not closed the outboard motor will tilt up when operated in reverse ENGINE COVER REMOVAL AND INSTALLATION Removal 1 Pull all the engine cover latches 2 Re...

Page 91: ...vel Check Check the engine oil level with the engine stopped and the outboard motor in the vertical position 1 Unlock and remove the engine cover p 88 2 Remove the dipstick and wipe it clean 3 Insert...

Page 92: ...gine oil See the following table for an explanation of these conditions Operating Method Result Effect Running the engine below 3 000 rpm for more than 30 of the time so the engine does not warm up Wa...

Page 93: ...ten the drain bolt securely TIGHTENING TORQUE 17 lbf ft 23 N m 2 3 kgf m Improper disposal of engine oil can be harmful to the environment If you change your own oil please dispose of the used oil pro...

Page 94: ...filter into the used oil container 4 Clean the oil filter mounting base and coat the rubber seal of the new oil filter with clean engine oil Use only a TOHATSU Genuine oil filter or a filter of equiva...

Page 95: ...commercially available earmuffs and a hose to supply water 8 Stop the engine and check the oil level as described on page 89 If necessary add oil to bring the oil level to the upper limit mark on the...

Page 96: ...T ARM SHAFT flush mount type top mount type mechanical wire type THROTTLE REEL flush mount type top mount type mechanical wire type ENGINE COVER LATCH LOCK each side SHIFT LINK PIVOT SHIFT LINK GUIDE...

Page 97: ...onnect the battery negative terminal 2 Unlock and remove the engine cover p 88 3 Disconnect the wire connector from the ignition coil by pushing on the lock tab and pulling on the connector Pull on th...

Page 98: ...worn or if the insulators are cracked or chipped 7 Measure the spark plug electrode gap with a wire type feeler gauge Correct the gap if necessary by carefully bending the side electrode The gap shoul...

Page 99: ...r the spark plugs seat If installing new spark plugs tighten 1 2 turn after the spark plugs seat TIGHTENING TORQUE 13 lbf ft 18 N m 1 8 kgf m Loose spark plugs can overheat and damage the engine Overt...

Page 100: ...to observe the following when servicing iridium spark plugs Do not clean the spark plugs If an electrode is contaminated with accumulated objects or dirt replace the spark plug with a new one Use onl...

Page 101: ...r sparks Keep gasoline away from appliance pilot lights barbecues electric appliances power tools etc Spilled fuel is not only a fire hazard it causes environmental damage Wipe up spills immediately G...

Page 102: ...arting and or performance problems It may also damage metal rubber and plastic parts of the fuel system Engine damage or performance problems that result from using a fuel with percentages of ethanol...

Page 103: ...to fuel filter with water separator replacement procedure p 102 to remove the filter and clean it Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel...

Page 104: ...Replacement 1 Remove the engine cover p 88 2 Disconnect the 2 pin coupler blue 3 Remove the suspension strap from the fuel filter with water separator bracket and then remove the suspension strap from...

Page 105: ...e fuel filter with water separator in the reverse order of removal Use a new O ring TIGHTENING TORQUE 2 5 lbf ft 3 4 N m 0 35 kgf m 8 Position the aligning mark as shown in the figure when installing...

Page 106: ...ement The anodes are located on each side of the gear case They are made of a sacrificial material that helps to protect the outboard motor from corrosion Replace the anodes when they have been reduce...

Page 107: ...manufacturer s instructions for proper installation 1 Apply marine grade grease to the propeller shaft 2 Install the thrust washer with the grooved side toward the gear case 3 Install the propeller 4...

Page 108: ...omes with the outboard motor Contact your authorized TOHATSU dealer for additional tool information MARINE GREASE THRUST WASHER CASTLE NUT WASHER PROPELLER COTTER PIN Inspect After Operating 1 Stop th...

Page 109: ...bitor penetrates these components they may be damaged Before applying a corrosion inhibitor cover the AC generator and belt with a protective material to prevent damage Cleaning Wash the outside of th...

Page 110: ...on the fresh water supply and flush the outboard motor for at least 10 minutes 6 After flushing disconnect the garden hose and reconnect the flush port connector 7 Tilt up the outboard motor and move...

Page 111: ...during storage you may need to have the vapor separator and other fuel system components serviced or replaced The length of time that gasoline can be left in your fuel tank and vapor separator without...

Page 112: ...de of the engine undercase and below the level of the vapor separator drain screw 3 Loosen the vapor separator drain screw by using a commercially available flat tip screwdriver VAPOR SEPARATOR DRAIN...

Page 113: ...r separator to finish draining 6 After draining thoroughly tighten the drain screw securely 7 Clip the drain hose on the head cover 8 Drain the fuel tank into an approved gasoline container Engine Oil...

Page 114: ...e and disconnected from the hoist install the engine cover p 88 STORAGE PRECAUTIONS Select a well ventilated storage area If possible avoid storage areas with high humidity If storing a container of g...

Page 115: ...the outboard motor from the boat Rest the outboard motor on a cushion of protective material Cover the outboard motor to keep out dust Do not use a plastic sheet as a dust cover A nonporous cover will...

Page 116: ...tboard motor support bar The preferred method is to leave the engine in the normal running position but if there is insufficient road clearance you can tilt the outboard motor using a commercially ava...

Page 117: ...WILL NOT START Possible Cause Correction Clip not inserted in emergency stop switch Insert clip in emergency stop switch Control lever not in neutral position Shift to neutral Fast idle lever raised s...

Page 118: ...uel Refuel p 99 Fuel hose not primed Squeeze priming bulb p 55 Fuel filter or fuel tank filter clogged Replace fuel filters p 100 Bad fuel outboard motor stored without draining gasoline or refueled w...

Page 119: ...ly gapped Gap or replace spark plugs p 95 Spark plugs wet with fuel flooded engine Dry and reinstall spark plugs Start engine with the throttle open Fuel system malfunction fuel pump failure ignition...

Page 120: ...aised side mount type Leave fast idle lever OFF p 60 Fuel hose not primed Squeeze priming bulb p 55 Fuel filter or fuel tank clogged Replace fuel filters p 100 Bad fuel outboard motor stored without d...

Page 121: ...r replace spark plugs p 95 Fuel system malfunction fuel pump failure ignition malfunction etc Take outboard motor to an authorized TOHATSU dealer or refer to the service manual Possible Cause Correcti...

Page 122: ...se blows the engine will not start or run Battery Will Not Charge A 150 A ACG fuse protects the alternator circuit If the ACG fuse blows the engine will not charge the battery Refer to ACG Fuse p 122...

Page 123: ...ide 11 15 A PTC Fuse No Rating Component s or Circuit s Protected 1 150 A ACG Battery 2 20 A GROUND Main 3 20 A GROUND Spare 4 30 A STARTER SOLENOID AND RELAYS IN JUNCTION BOX 5 7 5 A REMOTE CONTROL S...

Page 124: ...fuse to blow again If fuses continue to blow take the outboard motor to an authorized TOHATSU dealer for inspection and service or refer to the service manual ACG Fuse Replacement 1 Stop the engine 2...

Page 125: ...URNS OFF AND ENGINE SPEED IS LIMITED If oil pressure becomes low the oil pressure indicator will turn off and the engine protection system limits engine speed If you are at cruising speed engine speed...

Page 126: ...rotection system remains activated after 30 seconds return to the nearest boat landing and have the outboard motor inspected by an authorized TOHATSU dealer OVERHEAT INDICATOR COMES ON AND ENGINE SPEE...

Page 127: ...d check the discharge port first then tilt the outboard motor to inspect the water intake screens If clogged clean the water intake screens return the outboard motor to the running position restart th...

Page 128: ...p 110 111 3 Change the engine oil and oil filter as described on p 91 93 If there was water in the engine crankcase or if the used engine oil showed signs of water contamination then a second engine o...

Page 129: ...engine fails to start remove the spark plugs and dry them then reinstall the spark plugs and attempt to start the engine again If the engine starts and no mechanical damage is evident continue to run...

Page 130: ...r p 88 4 Shift gear into neutral by inserting the phillips screwdriver with the grip of the tool kit p 84 into the hole of the shift actuator and moving the shaft 5 Start the engine p 56 6 Shift gear...

Page 131: ...e You will need these numbers when ordering parts and when making technical or warranty inquiries The frame serial number is stamped on a plate attached on the left side of the stern bracket Frame ser...

Page 132: ...e the battery voltage to drop due to the increased length of the cable and number of connections This voltage drop may cause the buzzer to sound momentarily when engaging the starter motor and may pre...

Page 133: ...Control System The system constantly adjusts the ignition timing reducing the amount of HC CO and NOx produced PGM FI System The PGM FI system uses sequential multiport fuel injection It has three su...

Page 134: ...kfiring Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your TOHATSU engine were designed built and certified to conform with EPA and California emission...

Page 135: ...the MAINTENANCE SCHEDULE on page 85 86 Remember that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load operation or use in unusual c...

Page 136: ...Board The Star Label means Cleaner Marine Engine The Symbol for Cleaner Marine Engines Cleaner Air and Water for healthier lifestyle and environment Better Fuel Economy burns up to 30 40 percent less...

Page 137: ...ssion standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines The three star label identifies engines that meet the Air Resources Board s Personal Watercra...

Page 138: ...hoid pump pressure lubrication Specified oil Engine API standard SG SH SJ or SL oil SAE FC W 10W 30 Gear case API standard GL 4 SAE 90 Hypoid gear oil Oil capacity Engine 8 0 US qt 7 6 L without oil f...

Page 139: ...em Trochoid pump pressure lubrication Specified oil Engine API standard SG SH SJ or SL oil SAE FC W 10W 30 Gear case API standard GL 4 SAE 90 Hypoid gear oil Oil capacity Engine 8 0 US qt 7 6 L withou...

Page 140: ...ttery Lubrication system Trochoid pump pressure lubrication Specified oil Engine API standard SG SH SJ or SL oil SAE FC W 10W 30 Gear case API standard GL 4 SAE 90 Hypoid gear oil Oil capacity Engine...

Page 141: ...ump pressure lubrication Specified oil Engine API standard SG SH SJ or SL oil SAE FC W 10W 30 Gear case API standard GL 4 SAE 90 Hypoid gear oil Oil capacity Engine 8 0 US qt 7 6 L without oil filter...

Page 142: ...other adjustments needed Spark plug gap 0 039 0 043 in 1 0 1 1 mm See page 96 Idle speed 650 50 rpm See service manual Valve clearance cold Intake 0 22 0 02 mm Exhaust 0 30 0 02 mm See service manual...

Page 143: ...in the emission control system warranty on your 2020 Tohatsu outboard engine In California new outboard engines must be designed built and equipped to meet the state s stringent anti smog standards To...

Page 144: ...5 for parts description California Code of Regulations OWNER S WARRANTY RESPONSIBILITIES As the outboard engine owner you are responsible for the performance of the required maintenance listed in your...

Page 145: ...han an authorized Tohatsu dealership however use of a part that is not functionally identical to the original equipment part in any respect that may in any way affect emissions including durability co...

Page 146: ...nance items made in connection with required maintenance service after the items first scheduled replacement as listed in the maintenance section of the product outboard motor owner s manual such as s...

Page 147: ...alve Intake manifold Intake valves and Oxygen sensor or Air fuel ratio sensor Five years or 250 hours of use whichever first occurs or the length of the Tohatsu Limited Warranty Information whichever...

Page 148: ...ND FEATURES 10 Cooling System Indicator 49 CRUISING 75 E Electric Starter Will Not Operate 120 Emergency Stop Switch Clip and Emergency Stop Switch Flush Mount Type Mechanical wire type 33 Flush Mount...

Page 149: ...re type 38 H HARD STARTING OR STALLS AFTER STARTING 118 HOISTING THE OUTBOARD MOTOR 112 I Ignition Switch Flush Mount Type Mechanical wire type 33 Flush Mount Type Top Mount Type DBW type 21 Side Moun...

Page 150: ...0 S SAFE OPERATING PRECAUTIONS 54 SAFETY LABEL LOCATION 9 Serial Number Locations 129 SERVICING YOUR OUTBOARD MOTOR 82 SHALLOW WATER OPERATION 79 SPARE EMERGENCY STOP SWITCH CLIP 84 Spark Plug Service...

Page 151: ...129 THE IMPORTANCE OF MAINTENANCE 82 Tilt Lock Lever 43 TOOL KIT and OWNER S MANUAL 84 TRANSPORTING 114 WITH OUTBOARD MOTOR INSTALLED ON BOAT 114 WITH OUTBOARD MOTOR REMOVED FROM BOAT 114 Trim Meter o...

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Page 156: ...250D BFT 200D BFT 225D BFT 250D 31ZVLT03 00X31 ZVL T030 OWNER S MANUAL OWNER S MANUAL 5 4 Azusawa 3 Chome Itabashi Ku Tokyo 174 0051 Japan Tel 81 3 3966 3117 Fax 81 3 3966 2951 www tohatsu com PRINTED...

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