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TOHATSU BFT 75A, Owner'S Manual

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TOHATSU BFT 75A Owner'S Manual Download Page 110

108

SERVICING YOUR OUTBOARD MOTOR

Engine damage or performance 
problems that result from using a fuel 
with percentages of ethanol or 
methanol greater than shown above 
are not covered under warranty.

If your outboard motor will be used 
on an infrequent or intermittent basis, 
please refer to the fuel section of the 

STORAGE

 chapter (p.120) for 

additional information regarding fuel 
deterioration.

Water Separator Inspection and 

Service

Water separator is located near the 
engine cover latch on the boat side. 
Water accumulation in the water 
separator can cause loss of power or 
hard starting. Check the water 
separator periodically. Clean it or 
consult with an authorized 
TOHATSU outboard motor dealer for 
cleaning.

1. Remove the engine cover (p.94).

2. Remove the separator assembly. If 

it is difficult to remove the 

separator assembly by yourself, 

consult an authorized TOHATSU 

dealer.

WATER SEPARATOR

Gasoline is highly 
flammable and explosive.

You can be burned or 
seriously injured when 
handling fuel.

• Stop the engine and let it 

cool before handling fuel.

• Keep heat, sparks, and 

flame away.

• Handle fuel only outdoors.
• Keep away from your 

vehicle.

• Wipe up spills immediately.

Summary of Contents for BFT 75A

Page 1: ...US_Cover indd 1 u K i h s a b a t I e m o h C 3 a w a s u z A 4 5 Tokyo 174 0051 Japan Tel 81 3 3966 3117 Fax 81 3 3966 0090 www tohatsu com PRINTED IN JAPAN XXX XXXX XX 31ZZ0T03 00X31 ZZ0 T030 OWNER...

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 an...

Page 5: ...trol Lever 25 Fast Idle Button 26 Top Mount Type 27 Ignition Switch 27 Emergency Stop Switch Clip and Emergency Stop Switch 27 Gearshift Throttle Control Lever 28 Fast Idle Button 30 Tiller Handle opt...

Page 6: ...le Adjustment optional equipment 53 OPERATION 55 SAFE OPERATING PRECAUTIONS 55 BREAK IN PROCEDURE 55 PORTABLE FUEL TANK optional equipment 56 FUEL HOSE CONNECTIONS 57 FUEL PRIMING 58 INFREQUENT OR OCC...

Page 7: ...Replacement 115 Propeller Replacement 115 Inspect After Operating 117 CLEANING AND FLUSHING 118 Cleaning and Flushing 118 STORAGE 120 Fuel 120 Engine Oil 122 HOISTING THE OUTBOARD MOTOR 122 STORAGE PR...

Page 8: ...6 SUBMERGED OUTBOARD MOTOR 136 TECHNICAL INFORMATION 138 Serial Number Locations 138 Battery 139 Emission Control System Information 139 Star Label 142 Specifications 144 CONSUMER INFORMATION 147 Emis...

Page 9: ...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 anyone fal...

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 contain important safety information Please read them carefully These labels are considered permanent parts of your outboard motor If a label comes off or becomes hard to read contact an authorized...

Page 12: ...10 OUTBOARD MOTOR SAFETY PORTABLE FUEL TANK optional equipment FUEL CAUTION...

Page 13: ...applications Model BFT75A BFT90A Type LRT LRT XRT Transom Height Shaft Length 21 1 in 537 mm 26 1 in 664 mm Tiller Handle Multi Function Tiller Handle Remote Control Power Trim Tilt Tachometer Trim M...

Page 14: ...ANTIVENTILATION PLATE GEAR OIL DRAIN SCREW GEAR OIL LEVEL SCREW FRAME SERIAL NUMBER TILT LOCK LEVER COOLING WATER INTAKE PORT each side NMEA INTERFACE COUPLER ENGINE COVER LATCH front STERN BRACKET M...

Page 15: ...SWITCH TRL Trolling CONTROL SWITCH CONTROL LEVER FRICTION ADJUSTER EMERGENCY STOP SWITCH LANYARD EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH IGNITION SWITCH KEY IGNITION SWITCH BUZZER inside FAST...

Page 16: ...TILT SWITCH NEUTRAL RELEASE LEVER FAST IDLE BUTTON SINGLE TOP MOUNT REMOTE CONTROL GEARSHIFT THROTTLE CONTROL LEVER POWER TRIM TILT SWITCH FAST IDLE BUTTON DUAL TOP MOUNT REMOTE CONTROL FAST IDLE BUT...

Page 17: ...ERGENCY STOP SWITCH LANYARD EMERGENCY STOP SWITCH CONTROL PANEL without indicators type for PANEL MOUNT TOP MOUNT SINGLE type BUZZER IGNITION SWITCH EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LA...

Page 18: ...RGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD GEARSHIFT LEVER THROTTLE FRICTION ADJUSTER POWER TRIM TILT SWITCH THROTTLE GRIP SPARE EMERGENCY STOP SWITCH CLIP Store the s...

Page 19: ...FRICTION ADJUSTING KNOB IGNITION SWITCH KEY IGNITION SWITCH SPARE EMERGENCY STOP SWITCH CLIP Store the spare emergency stop switch clip in the tool bag EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH...

Page 20: ...Portable Fuel Tank optional equipment Fuel Tank Hose Assembly standard equipment FUEL TANK FUEL GAUGE FUEL HOSE CONNECTOR FUEL FILLER CAP VENT KNOB FUEL HOSE JOINT outboard motor side FUEL PRIMING BUL...

Page 21: ...19 CONTROLS AND FEATURES Trim Meter optional equipment Tachometer optional equipment TRL Trolling Control Switch Panel optional equipment TRL Trolling CONTROL SWITCH...

Page 22: ...eased from the START position The ignition switch can be used to start the engine only when the control lever is in the N neutral position p 59 and the emergency stop switch clip is in the emergency s...

Page 23: ...rely When used as described the emergency 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...

Page 24: ...adjusts the operating resistance of the control lever s Refer to p 78 Less friction allows easier control lever movement More friction helps to hold a steady throttle setting while cruising Fast Idle...

Page 25: ...on system and the starter motor Turning the ignition switch key to the START position operates the starter motor The key automatically returns to the ON position when released from the START position...

Page 26: ...y stop switch lanyard must be attached securely to the operator or to the operator s PFD Personal Flotation Device When used as described the emergency stop switch clip and emergency stop switch lanya...

Page 27: ...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 28: ...dle speed without engaging the drive gears Move the control lever toward the F forward or R reverse position after pushing in the fast idle button to increase the idle speed It is necessary to positio...

Page 29: ...START position The ignition switch can be used to start the engine only when the control lever is in the N neutral position p 65 and the emergency stop switch clip is in the emergency stop switch Tur...

Page 30: ...perator 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 from the controls Gea...

Page 31: ...e the control box adjusts the operating resistance of the control lever s Refer to p 78 Less friction allows easier control lever movement More friction helps to hold a steady throttle setting while c...

Page 32: ...increase the idle speed without engaging the drive gears Move the control lever toward the F forward or R reverse position after pushing in the fast idle button to increase the idle speed It is neces...

Page 33: ...position when released from the START position The engine will not start unless the gearshift lever is in the N neutral position p 68 and the emergency stop switch clip is in the emergency stop switch...

Page 34: ...s PFD Personal Flotation Device When used as described the emergency stop switch and emergency stop switch lanyard system stops the engine if the operator falls away from the controls A spare switch...

Page 35: ...Handle Multi Function Tiller Handle The throttle friction adjuster adjusts resistance to throttle grip rotation Turn the adjuster clockwise to increase friction for holding a throttle setting while cr...

Page 36: ...he engine can be started with the gearshift lever in the N neutral position only Tiller Handle Multi Function Tiller Handle The shift lever will not move unless the throttle grip is in the fully close...

Page 37: ...Friction Adjusting Knob Tiller Handle Multi Function Tiller Handle Use the steering friction adjusting knob to adjust the tiller handle friction Turning it clockwise increases friction and turning it...

Page 38: ...ling Control Switch Panel The Trolling Control Switch is a rocker switch with UP and DN down positions to adjust the trolling speed up or down in 50 rpm increments within the range of 650 to 1 000 rpm...

Page 39: ...T SWITCH CONTROL LEVER POWER TRIM TILT SWITCH CONTROL LEVER POWER TRIM TILT SWITCHES LEFT RIGHT CONTROL LEVERS Tiller Handle Tiller Handle Multi Function Tiller Handle The power trim tilt switch is lo...

Page 40: ...ine pan It is a rocker switch 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 w...

Page 41: ...the stern bracket Engine Cover Latch front rear 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 outb...

Page 42: ...tilt switch to achieve the best performance from the boat Tachometer optional equipment The tachometer shows engine speed in revolutions per minute Refer to the tachometer when using the throttle and...

Page 43: ...rs light 2 The buzzer will beep twice 3 The Malfunction Oil Pressure and Overheat indicators will go out after the second beep 4 The ACG indicator will go out after the engine starts 5 The Oil Pressur...

Page 44: ...control system malfunction the malfunction indicator turns on and the buzzer sounds at one second intervals Oil Pressure Indicator Remote Control Box ACG INDICATOR RED internal buzzer side mount type...

Page 45: ...l models are equipped with a buzzer that sounds continuously when the oil pressure indicator turns off Low oil pressure indicates that the engine oil level is low or that there is a problem with the e...

Page 46: ...et p 47 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 running This shows that water is...

Page 47: ...s activated check the trim angle of the outboard motor Check to see if the correct propeller is installed Portable Fuel Tank optional equipment The portable fuel tank has a capacity of 6 6 US gal 25 L...

Page 48: ...priming bulb until it feels firm This will ensure that fuel is supplied to the engine p 58 The anodes are made of a sacrificial material that helps to protect the outboard motor from corrosion There...

Page 49: ...ance is due the engine notifies the NMEA2000 network and a maintenance indication is displayed on an NMEA2000 compatible device After periodic maintenance is performed reset the hour counter by 1 Stop...

Page 50: ...the number of months since the last maintenance before the alert based on engine operating hours displays see MAINTENANCE SCHEDULE on page 91 Reset the hour counter whenever maintenance is performed w...

Page 51: ...without delay after returning to port 2 Reset the hour counter If not reset the maintenance indication will remain in the display and the hour count until the next maintenance will be in error Steps...

Page 52: ...ard 2 Put the shift lever in F Forward or R Reverse 3 Turn the ignition switch ON Do not start the engine The buzzer will sound once 4 Press the emergency stop switch 5 times within 20 seconds When us...

Page 53: ...securely to the operator or to the operator s PFD Personal Flotation Device IS YOUR OUTBOARD MOTOR READY TO GO For your safety and to maximize the service life of your equipment it is very important...

Page 54: ...ops by pulling the emergency stop switch clip from the emergency stop switch p 72 Maintenance Inspection Check the engine oil level p 95 Running the engine with a low oil level can cause engine damage...

Page 55: ...ve the 8 28 mm flange bolt and the height adjustment block 2 Pull down the tiller handle Determine the height adjustment block installation direction and secure the block with the 8 28 mm flange bolt...

Page 56: ...HANDLE ANGLE 13 Install the height adjustment block so that the selected angle of the tiller handle is in this position HEIGHT ADJUSTMENT BLOCK 8 28 mm FLANGE BOLT Reference point HEIGHT HANDLE ANGLE...

Page 57: ...ss and may lead to death BREAK IN PROCEDURE Break in period 10 hours Proper break in operation allows the moving parts to wear in smoothly for best performance and long service life Avoid continuous o...

Page 58: ...nt Place the portable fuel tank in a well ventilated location away from direct sunlight to reduce the possibility of a gasoline vapor explosion To ensure that the outboard motor will be able to draw f...

Page 59: ...the priming bulb points toward the outboard motor side Store the hose plug in a secure place 2 Connect the fuel hose to the tank and the outboard motor as shown Be sure both connectors snap securely...

Page 60: ...rrow then squeeze the priming bulb several times until it feels firm indicating that fuel has reached the engine Check to be sure there are no fuel leaks before starting the engine Do not touch the pr...

Page 61: ...cy stop switch clip in the emergency stop switch and securely to the operator or to the operator s PFD Personal Flotation Device The engine will not start or run unless the emergency stop switch clip...

Page 62: ...tral position The control lever cannot be moved away from the N neutral position unless the fast idle lever is lowered 4 Turn the ignition switch key to the ON position the buzzer will sound twice 5 T...

Page 63: ...gine to warm up sufficiently to ensure good performance Above 41 F 5 C warm up the engine for at least 3 minutes Below 41 F 5 C warm up the engine for at least 5 minutes at 2 000 rpm Raise the fast id...

Page 64: ...tral position Panel Mount Type 1 Put the emergency stop switch clip in the emergency stop switch and attach the emergency stop switch lanyard securely to the operator or to the operator s PFD Personal...

Page 65: ...tarts When the engine starts release the key allowing it to return to the ON position If the engine fails to start within 5 seconds release the key and wait at least 10 seconds before operating the st...

Page 66: ...eeze 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 indicator p...

Page 67: ...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 68: ...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 5...

Page 69: ...using the control panel without indicators type check the oil pressure indicator and overheat indicator displayed on an NMEA2000 compatible device If the indicators show any abnormal condition immedia...

Page 70: ...s attach the emergency stop switch lanyard securely to the operator or to the operator s PFD before starting the engine Tiller Handle Multi Function Tiller Handle 2 Check the position of the gearshift...

Page 71: ...up the throttle grip can be turned to the SLOW position without stalling 6 Before getting underway allow the engine to warm up sufficiently to ensure good performance Above 41 F 5 C warm up the engin...

Page 72: ...he engine manually using the emergency starter rope supplied with the outboard motor 1 Turn the ignition switch key to the OFF position p 74 2 Unlatch the engine cover latches and remove the engine co...

Page 73: ...ut in the alternator pulley and wind the starter rope one and a half turns clockwise along the groove in the alternator pulley 8 Pull the emergency starter rope slowly until resistance is felt then pu...

Page 74: ...perform the emergency starting procedure be sure the lanyard is attached securely to operator before operating the outboard motor 12 Have your closest authorized TOHATSU dealer check your electrical...

Page 75: ...is way occasionally to verify that the emergency stop switch is operating properly Turn the ignition switch key to the OFF position after verifying the emergency stop switch operation Normal Engine St...

Page 76: ...the N neutral position After cruising at full throttle cool down the engine by idling for a few minutes before stopping the engine Remote Control Box Side Mount Type Panel Mount Top Mount Types IGNITI...

Page 77: ...p switch by pulling the emergency stop switch lanyard p 72 3 When the boat is not in use remove and store the ignition switch key and the emergency stop switch clip and lanyard If you are using a port...

Page 78: ...osition to stop the engine In the event that the engine 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...

Page 79: ...gear The control lever cannot be moved from the N neutral position unless the neutral release lever is squeezed side mount panel mount types Moving the control lever beyond the gear selection range i...

Page 80: ...nt throttle setting while cruising Tiller Handle Tiller Handle CONTROL LEVER FRICTION ADJUSTER TO DECREASE FRICTION TOINCREASE FRICTION CONTROL LEVER FRICTION ADJUSTER TO INCREASE FRICTION TO DECREASE...

Page 81: ...e gearshift lever is in the F forward position Tiller Handle Tiller Handle Multi Function Tiller Handle Use the throttle friction adjuster to help hold a constant throttle setting while cruising Turn...

Page 82: ...e steering friction adjusting knob to help hold a steady course while cruising Turn the knob clockwise to increase steering friction for holding a steady course Turn the knob counterclockwise to decre...

Page 83: ...and check the trim angle of the outboard motor Trim Use the power 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...

Page 84: ...Multi Function Tiller Handle POWER TRIM TILT SWITCH CONTROL LEVER CONTROL LEVER POWER TRIM TILT SWITCH POWER TRIM TILT SWITCH CONTROL LEVER POWER TRIM TILT SWITCH LEFT RIGHT CONTROL LEVERS POWER TRIM...

Page 85: ...ard motor in gear with the throttle control in the fully closed idle position Press and hold the UP or DN side of the TRL control switch to activate the Trolling Speed Control OUTBOARD MOTOR TRIMMED T...

Page 86: ...o the Trolling Speed Control setting Trim Tab If steering effort is not equal in both directions adjust the trim tab to compensate for torque steer which is the reaction of the outboard motor to prope...

Page 87: ...maximum clearance when beaching or launching use the power 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 gent...

Page 88: ...ioning the engine Be sure the valve is closed before operating the outboard motor If the valve is not closed the outboard motor will tilt up when operated in reverse Check that nobody is under the out...

Page 89: ...in N neutral and tilt it up so its propeller is above the water s surface If the propeller of the stopped motor is left in the water it may turn as the boat moves through the water causing a reverse f...

Page 90: ...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 91: ...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 92: ...re clip may either be stored in the tool bag or in an easily accessible location on the boat If your tool kit needs replacement it is not available as a kit and each item must be ordered individually...

Page 93: ...if they are crumbling REGULAR SERVICE PERIOD 3 Perform at every indicated month or operating hour interval whichever comes first ITEM Each use After use First month or 20 hrs Every 6 months or 100 hrs...

Page 94: ...ce the fuel line if there are signs of leaks cracks or damage REGULAR SERVICE PERIOD 3 Perform at every indicated month or operating hour interval whichever comes first ITEM Each use After use First m...

Page 95: ...emove the gear case grommet and loosen the trim tab bolt then adjust the angle of the trim tab Retighten the trim tab bolt and reinstall the gear case grommet securely If less effort is required to ma...

Page 96: ...to turn the valve counterclockwise 1 or 2 turns Close the valve firmly after positioning the outboard motor Be sure the valve is closed before operating the outboard motor If the valve is not closed...

Page 97: ...he oil level with the dipstick you might notice the engine oil appears milky or the oil level has increased If you notice either condition change the engine oil See the following table for an explanat...

Page 98: ...erfilling the engine will cause it to smoke or have oil leaks 5 Install the oil filler cap and tighten it securely Do not overtighten Oil filler cap installation Lock 1 Insert the oil filler cap into...

Page 99: ...p 96 and the drain bolt 3 Allow the used oil to drain completely Use a new sealing washer and then reinstall the engine oil drain bolt and washer Tighten the drain bolt securely DRAIN BOLT TIGHTENING...

Page 100: ...4 L 5 Install the oil filler cap and tighten it securely p 96 6 Install and lock the engine cover Oil Filter Change 1 Drain the engine oil and reinstall the drain bolt see Engine Oil Change on p 97 2...

Page 101: ...he engine and check for leaks be sure the water level is at least 2 inches 5 cm above the antiventilation plate If you are changing the oil filter while the outboard motor is out of the water use comm...

Page 102: ...idium spark plugs optional parts 1 Disconnect the battery negative terminal 2 Unlock and remove the engine cover p 94 3 Remove the 6 20 mm flange SH bolt and remove the plug maintenance cover 4 Remove...

Page 103: ...the electrodes are 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 ele...

Page 104: ...is procedure for the other three spark plugs 13 Reinstall the covers Optional Parts Iridium Spark Plug RECOMMENDED SPARK PLUG IZFR6K 11E NGK Incorrect spark plugs can cause engine damage Installation...

Page 105: ...6 months refer to the MAINTENANCE SCHEDULE on page 91 Apply anticorrosion oil to pivot surfaces where grease cannot penetrate THROTTLE ARM LINK PIVOT PLATE THROTTLE ROD LINK TILT BRACKET TILT SHAFT T...

Page 106: ...MOTOR SHIFT LINK BRACKET SHIFT PIVOT SHIFT ARM LINK PIN PIVOT PLATE SLIDE PIVOT CLICK SPRING ROLLER TILT LOCK LEVER each side MOUNT FRAME TILT SHAFT THREAD UPPER CYLINDER PIN BUSHING LOWER CYLINDER B...

Page 107: ...eck the fuel gauge and refill the tank when necessary Remove the fuel tank from the boat for refueling 1 Turn the vent knob counterclockwise all the way to open the vent 2 Turn the fuel filler cap cou...

Page 108: ...After refueling install the cap and tighten it until you hear it click Close the vent by turning the vent knob clockwise all the way and return the fuel tank to the boat Using the fuel tank mounted i...

Page 109: ...st system life Never use gasoline that is stale contaminated or mixed with oil Avoid getting dirt or water in the fuel tank You may use unleaded gasoline containing no more than 10 ethanol E10 or 5 me...

Page 110: ...er latch on the boat side Water accumulation in the water separator can cause loss of power or hard starting Check the water separator periodically Clean it or consult with an authorized TOHATSU outbo...

Page 111: ...eparator assembly take care not to damage the wire harness with the separator bracket 5 Open the harness clip and remove the harness from clip C then disconnect the water level sensor 2 pin connector...

Page 112: ...0 Connect the water level sensor 2 pin connector Install the harness to clip C and the harness clip Align the positioning bands on the harness with the end of clip C and the harness clip as shown abov...

Page 113: ...h gasoline Fuel Filter Inspection and Replacement The fuel filter inside the strainer cup is located between the fuel pump and the water separator Water or sediment accumulation in the filter can caus...

Page 114: ...place fuel hose clips on the fuel hoses on each side of the fuel filter 4 Remove the fuel filter assembly from the strainer bracket If it is difficult to remove the fuel filter assembly by yourself c...

Page 115: ...rime the engine using the priming bulb p 58 Check for fuel leaks Repair any fuel leaks if necessary 11 Install the engine cover If loss of power or hard starting are found to be caused by excessive wa...

Page 116: ...r from the tank 2 Clean the filter in nonflammable solvent Inspect the fuel tank filter and the connector gasket Replace them if damaged 3 Reinstall the filter and hose connector in the fuel tank Tigh...

Page 117: ...tect the outboard motor Propeller Replacement Before replacing the propeller remove the emergency stop switch clip from the emergency stop switch to prevent any possibility of the engine being started...

Page 118: ...nut aligns with the cotter pin hole Do not tighten past the first alignment of the castle nut groove and the cotter pin hole TIGHTENING TORQUE LIMIT 33 lbf ft 44 1 N m 4 5 kgf m Do not tighten the ca...

Page 119: ...117 SERVICING YOUR OUTBOARD MOTOR Inspect After Operating 1 Stop the engine and remove the engine cover p 94 2 Confirm the cooling water leakage from the engine...

Page 120: ...may be damaged Before applying a corrosion inhibitor cover the HO2 sensor with a protective material to prevent damage Cleaning Wash the outside of the outboard motor with clean fresh water and flush...

Page 121: ...ply and flush the outboard motor for at least 10 minutes 7 After flushing disconnect the garden hose and reconnect the flush port connector 8 Tilt up the outboard motor and move the tilt lock lever to...

Page 122: ...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 123: ...wing 5 After thoroughly draining tighten the drain screw securely and return the outboard motor to the vertical position 6 Secure the drain hose to the projection of the intake manifold 7 Drain the fu...

Page 124: ...2 Attach the hoist hooks to the engine hangers 3 Disconnect the outboard motor from the boat hoist the outboard motor and move it to the storage area 4 After the outboard motor is placed in storage a...

Page 125: ...m 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 trap moisture promoti...

Page 126: ...ulti Function Tiller Handle Tighten the steering friction adjusting knob securely The preferred method is to leave the engine in the normal running position but if there is insufficient road clearance...

Page 127: ...125 TRANSPORTING WITH OUTBOARD MOTOR REMOVED FROM BOAT Secure the outboard motor in either the vertical or horizontal position shown on p 122 and 123...

Page 128: ...rgency stop switch Insert clip in emergency stop switch Gearshift lever or control lever not in neutral position Shift to neutral Throttle grip not in START position tiller handle optional equipment T...

Page 129: ...fuel Refuel p 105 Fuel hose not primed Squeeze priming bulb p 58 Fuel filter or fuel tank filter clogged Replace fuel filters p 111 Bad fuel outboard motor stored without draining gasoline or refueled...

Page 130: ...perly gapped Replace spark plugs p 100 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 mal...

Page 131: ...F p 60 Throttle grip not in START position tiller handle optional equipment Turn throttle grip to START position p 68 Fuel hose not primed Squeeze priming bulb p 58 Fuel filter or fuel tank clogged Re...

Page 132: ...place spark plugs p 100 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 Correction...

Page 133: ...not activate the trim tilt mechanism Battery Will Not Charge A 70 A ACG fuse protects the alternator circuit If the ACG fuse blows the engine will not charge the battery Refer to p 132 Fuse Replaceme...

Page 134: ...er than specified Serious damage to the electrical system could result If a blown fuse is found try to determine and correct the electrical problem that caused the blown fuse An uncorrected electrical...

Page 135: ...l the engine cover 9 Reconnect the battery A spare fuse is located in the reverse side of the fuse case lid and tightened with two 3 mm screws When the new fuse is set as a spare fuse on the reverse s...

Page 136: ...the engine lubrication system If the throttle is closed suddenly after full throttle operation engine speed may drop below the specified idle rpm and that could activate the engine protection system...

Page 137: ...speed If you are at cruising speed engine speed will decrease automatically All types are equipped with a buzzer that sounds when the overheat indicator comes on Engine overheating may be the result...

Page 138: ...ns activated after 30 seconds return to the nearest boat landing and have the outboard motor inspected by an authorized TOHATSU dealer WATER SEPARATOR BUZZER SOUNDS When the water separator buzzer sou...

Page 139: ...run the engine until it has been repaired 6 Attempt to start the engine Be sure the water level is at least 2 inches 5 cm above the antiventilation plate If you are attempting to start the engine whil...

Page 140: ...ill 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 right side of the stern bracket Frame Serial Nu...

Page 141: ...ching the engine WARNING Battery posts terminals and related accessories contain lead and lead compounds Wash your hands after handling Emission Control System Information Source of Emissions The comb...

Page 142: ...o furnish written instructions describing the operation and maintenance of emission control systems The following instructions and procedures must be followed in order to keep the emissions from your...

Page 143: ...ble EPA certified parts and have service performed at non TOHATSU locations However the use of replacement parts that are not of the original design and quality may impair the effectiveness of your em...

Page 144: ...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 145: ...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 146: ...andle Starter system Electric starter Ignition system Full transistor battery Lubrication system Trochoid pump pressure lubrication Specified oil Engine API standard SG SH SJ SL SAE 10W 30 Gear case A...

Page 147: ...d remote control tiller handle Starter system Electric starter Ignition system Full transistor battery Lubrication system Trochoid pump pressure lubrication Specified oil Engine API standard SG SH SJ...

Page 148: ...0A Tune up Spark plug gap 0 031 0 035 in 0 8 0 9 mm See page 101 Idle speed 750 50 rpm See service manual Valve clearance cold Intake 0 17 0 02 mm Exhaust 0 28 0 02 mm See service manual Other specifi...

Page 149: ...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 150: ...151 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 yo...

Page 151: ...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 152: ...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 153: ...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 154: ...S 20 CONTROLS AND FEATURES 11 Cooling System Indicator 44 CRUISING 81 E Electric Starter Will Not Operate 131 EMERGENCY STARTER ROPE 90 STARTING 70 Emergency Stop Switch Clip and Emergency Stop Switch...

Page 155: ...pe 25 Side Mount Type 21 Top Mount Type 28 H HARD STARTING OR STALLS AFTER STARTING 129 HOISTING THE OUTBOARD MOTOR 122 I Ignition Switch Panel Mount Type 23 Side Mount Type 20 Tiller Handle 31 Top Mo...

Page 156: ...rim Tilt Switch 37 Propeller Replacement 115 R REFUELING 105 REMOVAL FROM STORAGE 123 S SAFE OPERATING PRECAUTIONS 55 SAFETY LABEL LOCATION 9 Serial Number Locations 138 SERVICING YOUR OUTBOARD MOTOR...

Page 157: ...gle Adjustment 53 Tilt Lock Lever 39 TOOL KIT and OWNER S MANUAL 90 TRANSPORTING 124 WITH OUTBOARD MOTOR INSTALLED ON BOAT 124 WITH OUTBOARD MOTOR REMOVED FROM BOAT 125 Trim Meter optional equipment 4...

Page 158: ...156 MEMO...

Page 159: ...2020 Honda Motor Co Ltd All Rights Reserved PGM FI is a trademark of Honda Motor Co Ltd registered in Japan and other countries...

Page 160: ...US_Cover indd 1 u K i h s a b a t I e m o h C 3 a w a s u z A 4 5 Tokyo 174 0051 Japan Tel 81 3 3966 3117 Fax 81 3 3966 0090 www tohatsu com PRINTED IN JAPAN XXX XXXX XX 31ZZ0T03 00X31 ZZ0 T030 OWNER...

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