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TOHATSU MD 30B2, Owner'S Manual

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MANUAL 

30B2 

40B2 

50B2 

75C2 

90C2 

115A2 

MD 

OWNER’S 

OB No.003-11075-D

OWNER’S MANUAL 

30B2 

40B2 

50B2 

75C2 

90C2 

115A2 

MD 

TOHATSU CORPORATION

Address : 5-4, 3-chome, Azusawa, Itabashi-ku,
                TOKYO, 174-0051 JAPAN
Phone :    TOKYO (03)3966-3117
FAX :       TOKYO (03)3966-2951
URL :       www.tohatsu.co.jp

003-11075-D

 

1109NB

Printed in Japan

OM_E_MD30B2-115A2_cover_111018.indd   1

11/10/31   10:54

Summary of Contents for MD 30B2

Page 1: ...UAL 30B2 40B2 50B2 75C2 90C2 115A2 MD TOHATSU CORPORATION Address 5 4 3 chome Azusawa Itabashi ku TOKYO 174 0051 JAPAN Phone TOKYO 03 3966 3117 FAX TOKYO 03 3966 2951 URL www tohatsu co jp 003 11075 D...

Page 2: ...RIOUS 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 an...

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

Page 4: ...t 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 followed...

Page 5: ...Recommended engine oil 38 5 Break in 40 6 Warning system 41 ENGINE OPERATION 44 1 Starting 44 2 Warming up the engine 50 3 Forward and reverse 51 4 Shallow water running 53 5 Stopping the engine 55 6...

Page 6: ...striking underwater object 82 6 If the engine becomes submerged in water 82 7 Precautions in cold weather 82 TROUBLESHOOTING 83 TOOL KIT AND SPARE PARTS 85 OPTIONAL ACCESSORIES 87 PROPELLER TABLE 89 O...

Page 7: ...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 OPTI...

Page 8: ...use of the Emergency Stop Switch tether Failure to observe will result in severe personal injury or death and possibly property damage DANGER Note This instruction provides special information to faci...

Page 9: ...ntenance on this outboard motor Be sure to use genuine parts genuine lubricants or recommended lubricants MAINTENANCE As the owner of this outboard motor you should be acquainted with correct maintena...

Page 10: ...g System Water cooling Engine Lubrication Oil injection Starting System Electric starter motor Ignition System Inductive Ignition Spark Plug NGK IZFR6Q Alternator 12V 280W Max Trim Position 4 6 Engine...

Page 11: ...ls EC Electronic Control Cooling System Water cooling Engine Lubrication Oil injection Starting System Electric starter motor Ignition System Inductive Ignition Spark Plug NGK IZFR6Q Alternator 12V 28...

Page 12: ...m Water cooling Engine Lubrication Oil injection Starting System Electric starter motor Ignition System Inductive Ignition Spark Plug NGK IZFR6Q Alternator 12V 280W Max Trim Position 4 Engine Oil Genu...

Page 13: ...ater cooling Engine Lubrication Oil injection Starting System Electric starter motor Ignition System Inductive ignition Spark Plug NGK IZFR6Q Alternator 12V 490W Max Trim Position 2 Engine Oil Genuine...

Page 14: ...ng Engine Lubrication Oil injection Starting System Electric starter motor Ignition System Inductive ignition Spark Plug NGK IZFR5J Alternator 12V 490W Max Trim Position 2 Engine Oil Genuine Motor Oil...

Page 15: ...lation Plate Trim Tab 11 12 13 14 15 16 Propeller Oil Plug lower Water Inlet Oil Plug upper Clamp Bracket Thrust Rod Clamp Screw Throttle Grip 17 18 19 20 21 22 Stop Switch Shift Lever Anode Pilot Lam...

Page 16: ...k Port Tilt Stopper Water Plug Anti ventilation Plate Trim Tab 11 12 13 14 15 16 Propeller Oil Plug lower Water Inlet Oil Plug upper Clamp Bracket Thrust Rod Clamp Screw Throttle Grip 17 18 19 20 21 2...

Page 17: ...ventilation Plate Trim Tab 11 12 13 14 15 16 Propeller Oil Plug lower Water Inlet Oil Plug upper Clamp Bracket Thrust Rod Power Trim Tilt Switch Fuel Connector 17 18 19 Battery Cords Power Trim Tilt...

Page 18: ...Water Check Port Water Plug Anti ventilation Plate Trim Tab Propeller 11 12 13 14 15 16 Oil Plug upper Water Inlet Oil Plug lower Clamp Bracket Thrust Rod Fuel Nose Nipple Power Trim Tilt switch Batt...

Page 19: ...Plate Trim Tab Propeller Oil Plug upper Water Inlet Oil Plug lower 12 13 14 15 16 17 18 19 20 21 22 Clamp Bracket Thrust Rod Fuel Nose Nipple Power Trim Tilt switch Battery Cords Power Trim Tilt Anode...

Page 20: ...e California Air Resources Board Regulation governing Portable Outboard Marine Tanks this portable marine tank and cap assembly has been manufac tured to meet the January 2011 regulations contained wi...

Page 21: ...ounting the outboard motor on boat Before beginning the running test check that the boat with maximum capacity loading floats on the water in a proper attitude Check the position of water surface on t...

Page 22: ...e drilled be forehand by referring to the dimensional drawing Anti ventilation Plate 10 30mm 0 4 1 2 in Overheating may occur if the Anti ven tilation Plate is at a level higher than the bottom of the...

Page 23: ...surface of transom can cause personal injury Nut Bolt 12mm length 105mm Washer large diameter Washer small diameter 13 13 234 9 21 39 1 54 222 8 74 248 9 76 26 1 02 204 8 03 25 0 98 25 0 98 64 2 52 89...

Page 24: ...h as silicon sealer between bolts and transom board holes before tightening bolts 2 Be sure to tighten mounting bolt nuts to specified torque Nut Washer small diameter Washer large diameter Bolt 12mm...

Page 25: ...the Remote Control Cables to the bracket tie them to the bottom cowl Detach the throttle and shift cable joints by removing the R shaped pins 3 Installing the remote control devices Bracket Screw Thro...

Page 26: ...d first when the lever is turned is a shift cable Check that the shift lever is in Neutral and the Free Accel lever is fully closed when the remote control cables have been connected Set the shift arm...

Page 27: ...gine 75 90 115 Turn the three hook levers fastening the bottom cowl and then remove the top cowl Remove the hose clamp fastening the cord grommet Remove the bolts fastening the cord clamp and then rem...

Page 28: ...Lever Forward until the first engaging point approx 32 The cable which is moved first when the lever is turned is a shift cable Check that the shift lever is in Neutral and the Free Accel lever is ful...

Page 29: ...and R shaped pin Connecting Cords and cable 30 40 50 Connect cable harness B and meter lead wire to cable harness A Place and fix Cable harness B to P T switch bracket as shown Connect the trim sende...

Page 30: ...n the fitting plate should be cut accordingly Be sure to tighten the fitting nuts on the fitting plate evenly The dashboard inclination should be 50 80 Set the tachometer selector knob to 4p Cut holes...

Page 31: ...g R Y R G R Lg B R W Lg B R W Trim gauge Trim sender Trim sender Cable harness B Meter lead wire 3T5 72537 1 75 90 115 30 40 50 Color Code B black L blue Lg light green P pink R red W white Y yellow Y...

Page 32: ...a split pin to the bolt 5 Installing the drag link assembly Note Depending on the steering cable manufacturer spacers optional may by required Note Apply grease in required places Refer to the illustr...

Page 33: ...120AH 1000 Cold Cranking Amps CCA Specifications and features of batteries vary among the manufacturers Consult the manufacturer for details Make sure that the battery cords do not get stuck between...

Page 34: ...with red tube to the positive terminal first Then connect the negative cord connector to the negative terminal When disconnecting the battery always disconnect the negative cord first Recommended bat...

Page 35: ...ects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused...

Page 36: ...separation of the water alcohol from the gasoline in the fuel tank These may cause increased Corrosion of metal parts Deterioration of rubber or plastic parts Fuel permeation through rubber fuel line...

Page 37: ...Pa 5 0 psi These tanks may contain the following An air inlet that opens to allow air to enter as the fuel is drawn out of the tank An air outlet that opens vents to the atmosphere if pressure exceeds...

Page 38: ...ot meet these requirements will result in reduced engine life and other engine problems In the unlikely event that gasoline by mistake is filled into the oil tank drain the oil tank completely and con...

Page 39: ...ollows 30 40 50 Loosen the air vent screw on the oil pump to purge the air and tighten it when all air as seen through the vinyl pipe on the oil pump side has been purged 75 90 115 See page 41 for air...

Page 40: ...longer service life Do not operate the outboard motor in closed area or area with no forced ventilation Exhaust gas emitted by this outboard motor contains carbon monoxide that will cause death if inh...

Page 41: ...activated with flashing of the warning lamp and the buzzer that sounds continuative alarms three times at intervals of 2 minutes Remarks The warning system against low oil level is activated regardles...

Page 42: ...stop the engine after making sure that cooling water is drained out of the cooling water check port If dust vinyl etc are adhering to the gear case remove them This controlled engine speed will not b...

Page 43: ...here is a poor connection reconnect it tightly Charge the battery Replace the battery with a new one Engine trouble In case of an engine trouble all the three warning lamps flashes at the same time Re...

Page 44: ...nk After connection be sure to fasten the hose tightly with a hose band or the like 75 90 115 Cap Fuel hose nipple Fuel hose in fuel tank side ENGINE OPERATION 1 Starting Note The engine will not star...

Page 45: ...he engine 30 40 50 type a Disconnect the link rod by turning the rod snap interlocking with the oil pump as shown in the figure b Make sure that the oil pump control lever is set at open side position...

Page 46: ...pe connection Filter Oil Pump Cylinder Block 75 90 115 a Turn on the key switch b Within 1 second after the buzzer stops sounding remove the stop switch lock c Within 2 seconds after removing the stop...

Page 47: ...o be thrown overboard due to inertial force R N F Note Turn the handle grip to the START fully closed before turning the main switch key to ON The wrong operation i e turn the main switch key to ON on...

Page 48: ...ter Severe personal injury or engine damage will result Neutral N Control lever Fully opened Fully closed Free Accel lever Ignition key Stop switch Note Turn the free accel lever to the fully closed p...

Page 49: ...g over 5 seconds fails to start engine return main switch to ON and crank engine again after 10 seconds or more CAUTION WARNING Do not operate the engine with gear case out of water Severe personal in...

Page 50: ...not exceed the full throttle engine speed 2 Warming up the engine Be sure to stop engine immediately if cooling water check port is not discharging water and check if cooling water intake is blocked O...

Page 51: ...not attach the tether to a part of clothing that can be torn easily when pulled Arrange the tether so that will not be caught by any object when pulled Be careful not to pull the tether accidentally d...

Page 52: ...Free Accel Lever Fully open Fully open Control Lever Lock Button Lock Reverse lock lever Before moving the Shift Lever to Reverse make sure the Reverse Lock is engaged in up position EFO model only E...

Page 53: ...osition do not operate the outboard in reverse Operate the outboard at slow speed and keep the cooling water intake submerged CAUTION Note Slow down to trolling speed and shift into neutral before set...

Page 54: ...shallow water setting a Turn the Reverse Lock Lever upward to set them in LOCK position b Tilt up the engine slightly and then let it go down The shallow water setting is then released c The engine i...

Page 55: ...s personal injury boat may swamp and or hull may be damaged Do not shift into Reverse during cruising or control may be lost falling down or causing passenger s to be thrown overboard Leading to serio...

Page 56: ...nector of the engine or the fuel tank Disconnect the cables from the battery if the engine will not be used for an extended period of time 30 40 50 air vent screw Never fill up portable fuel tanks on...

Page 57: ...thrust rod in the correct thrust rod hole Proper trim angle The trim angle is optimum when the boat is parallel to the water surface while running Improper trim angle bow rises too high If the trim a...

Page 58: ...e water cooling system resulting in engine overheating CAUTION WARNING Do not put hand or finger in between outboard motor body and clamp bracket when adjusting trim angle to prevent injury in case th...

Page 59: ...el to the water surface while running UP Down DN WARNING Do not put hand or finger in between outboard motor body and clamp bracket when adjusting trim angle to prevent the body parts from being caugh...

Page 60: ...7 Mooring with the engine tilted up WARNING Do not put hand or finger in between outboard motor body and clamp bracket when adjusting trim angle to prevent the body parts from being caught in case the...

Page 61: ...ine down Turn the Reverse Lock Lever upward toward LOCK Tilt the engine up slightly and then let it go down The Reverse Lock will be set automatically EFTO EPTO type Disconnect the fuel connector from...

Page 62: ...rd motor with fuel joint for over a few minutes be sure to disconnect fuel hose or close fuel cock or fuel may leak potentially catching fire Do not tilt up outboard motor while engine operates or no...

Page 63: ...vent screw of fuel tank be fore carrying or storing outboard mo tor and fuel tank or fuel may leak potentially catching fire Do not give a shock to an outboard motor during transportation It be comes...

Page 64: ...e boat never release the lock lever If the lock lever is released it will be very easy the clamp bracket to spring up to the tilting direction because it is not fixed WARNING Do not go under outboard...

Page 65: ...otor fully down is not available the gear case skeg is too close to the road in a vertical position fix the outboard motor securely using a device like a transom saver bar in the tilted position CAUTI...

Page 66: ...t Check for looseness of the bolt and the trim tab at regular intervals Due to corrosion the trim tab will wear down over time 1 Remote control lever load 2 Trim tab adjustment Heavier Lighter Throttl...

Page 67: ...ion adjustment screw on the steering handle to adjust the turning load of the throttle grip 3 Steering load adjustment 4 Throttle grip turning load adjustment WARNING Do not increase throttle friction...

Page 68: ...vices and systems may be performed by any marine SI Spark Ignition engine repair establishment or individual INSPECTION AND MAINTENANCE Your personal safety and that of your passengers depends on how...

Page 69: ...battery terminal Check if the stop switch functions normally and make sure the lock plate is present Check cords for loose connections and damage Clean or replace Remedy or replace Replenish or rechar...

Page 70: ...ove salt mud and other foreign particles WARNING Never start or operate the engine indoors or in any space which is not well ventilated Exhaust gas contains carbon monoxide a colorless and odorless ga...

Page 71: ...s h i n g connector and then connect a rubber hose to the flushing attachment Connect the other end of the rubber hose to a faucet water tap and turn on the faucet to wash the engine It is not requir...

Page 72: ...re fitting a spark plug a good estimate of the correct torque is 1 4 to 1 2 a turn past finger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench WARNING...

Page 73: ...months Every 100 hours or 6 months Every 200 hours or 1 years Fuel System Compression System Fuel filter Replace Check and clean or Replace if necessary Entire cartridge High pressure fuel filter 1 R...

Page 74: ...for bent blades damage wear Gear oil Replace Replace Replace Change or replenish oil and check for water leaks Water pump 1 Check for wear or damage Replace impeller every 12 months Thermostat 1 Check...

Page 75: ...50 approx 700mL 23 65 U S fluid oz 75 90 115 approx 900mL 30 40 U S fluid oz WARNING Be sure that outboard motor is secured to transom or service stand or accidental drop or fall of outboard motor cou...

Page 76: ...nect all pipes between the oil tank and oil pump Clean out foreign matter Refit the pipes to the oil tank and pumps and then fill up with new engine oil For air purging refer to Item No 5 Fuel and Eng...

Page 77: ...outboard motor could lead to severe personal injury 30 40 50 Oil cap Oil level 75 90 115 Oil cap Oil level You may be injured due to high engine temperatures if you fill engine oil just after stopping...

Page 78: ...anually up down 5 6 times while checking the oil level When done close the valve by turning it clockwise towards the Power side Recommended oil Use an automatic transmission fluid or equivalent Recomm...

Page 79: ...ler shaft Change the gear oil in the gear case Apply grease to all sliding parts joints nuts and bolts Use a dry cloth to completely wipe off water and salt from the electrical components Stand the ou...

Page 80: ...ot allow the battery to discharge since it can be damaged by freezing When storing your outboard for the winter open up all the water drain holes in the gear case to permit any remaining water to drai...

Page 81: ...e sure to turn the propeller shaft when checking the shift function or else the shift linkage may be damaged If the engine has been kept without running for a long time the following operation is requ...

Page 82: ...ck plate taken away to allow the water to drain completely Striking sea bottom or underwater object may severely damage the outboard motor Immediately bring the outboard motor to your dealer and ask f...

Page 83: ...old charge Starter motor will not crank Power Trim Tilt Inoperative Possible causes Empty fuel tank Incorrect connection of fuel system Air enters fuel line Deformed or damaged fuel pipe Closed air ve...

Page 84: ...stained or damaged Insufficient throttle aperture Battery is charged insufficiently Battery is nearly dead Poor connection of battery terminal Low level of electrolyte Power trim tilt switch is defec...

Page 85: ...type and flat head 1 1 1 1 1 1 Adapter type Spare Parts Rope 1 600mm Spark Plug Split Pin 1 3 1 NGK IZFR6Q Diameter Length 3 25mm Parts Packaged with Engine Bracket Fixing Bolts Bracket Fixing Nuts W...

Page 86: ...1 1 1 1 1 Adapter type Spare Parts Spark Plug 75 90 Spark Plug 115 Split Pin 3 4 1 NGK IZFR6Q NGK IZFR5J Diameter Length 3 25mm Parts Packaged with Engine Bracket Fixing Bolts Bracket Fixing Nuts Was...

Page 87: ...AL ACCESSORIES Flushing attachiment Speedometer 50MPH Speedometer 75MPH Water Pressure Meter Voltmeter Hour Meter engine operation hour counter Fuel Meter Tachometer Drive cleaner OM_E_MD30B2 115A2_bo...

Page 88: ...SORIES 13 Tie Bar Kit B for twin engine operation Genuine gear oil 500ml Twin control Box Kit for twin engine operation Propeller Touch up Spray Paint Engine oil 4l OM_E_MD30B2 115A2_body_111213 indd...

Page 89: ...hter Load Heavier Load shows propeller with four blades 30 40 50 17 5 16 5 15 14 13 12 11 10 9 Mark Lighter Load Heavier Load W50 M 21 M 19 M 17 M 16 M 15 M 13 M 11 Mark Lighter Load Heavier Load 115...

Page 90: ...M E M O M E M O OM_E_MD30B2 115A2_body_111213 indd 90 11 12 13 13 07...

Page 91: ...RIOUS 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 an...

Page 92: ...UAL 30B2 40B2 50B2 75C2 90C2 115A2 MD TOHATSU CORPORATION Address 5 4 3 chome Azusawa Itabashi ku TOKYO 174 0051 JAPAN Phone TOKYO 03 3966 3117 FAX TOKYO 03 3966 2951 URL www tohatsu co jp 003 11075 D...

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