TOHATSU MFS 100A Owner'S Manual Download Page 76

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INSPECTION AND MAINTENANCE

ENOF02434-0

Summary of Contents for MFS 100A

Page 1: ...O W N E R S M A N U A L AAAA Original instructions MFS 100A MFS 90A MFS 75A OB No 003 11159 0BX1 MFS 115A...

Page 2: ...ONS IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE Copyright 2020 Tohatsu Corporation All rights reserved No part of this manual may be r...

Page 3: ...the time of approval for printing Tohatsu Corporation reserves the right to make changes at any time without notice and without incurring any obligation Please always keep this manual together with t...

Page 4: ...n This WARRANTY CARD identifies you as the legal owner of the product and serves as your warranty registration TO THE EXTENT PERMITTED BY APPLICABLE LAW YOUR OUTBOARD MOTOR WILL NOT BE COVERED BY THE...

Page 5: ...outboard motor s serial number indicated both on the swivel bracket and on the cylinder block The serial number will be needed when ordering parts and when making technical or warranty inquiries Seri...

Page 6: ...on 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 damage ENOW00002...

Page 7: ...engine 41 3 Warming up the engine 42 4 Forward reverse and acceleration 42 5 Stopping the engine 45 6 Steering 48 7 Trim angle 49 8 Tilt up and down 51 9 Shallow water operation 53 8 REMOVING AND CARR...

Page 8: ...8 Operation with multiple outboard motors 83 11 TROUBLESHOOTING 84 12 ACCESSORIES KIT 87 13 PROPELLER TABLE 88...

Page 9: ...LABEL 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 ACCESSORIES...

Page 10: ...stop switch The stop switch lanyard is the coiled red cord with the stop switch lock on one end and a metal clip on the other end With attaching the stop switch lanyard to the operator s body part or...

Page 11: ...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 12: ...15A ETL Model F75A F90A F100A F115A Type ET ET ET ET Transom heights L z z z z UL z z z Multi function tiller handle z z z z Remote Control z z z z Power Trim Tilt z z z z F 115 A E T L Model descrip...

Page 13: ...n Displacement cm3 Cu in 1995 121 6 Exhaust System Through hub exhaust Cooling System Water cooling with thermostat Lubrication System Wet sump Trochoid pump Starting System Electric starter motor Ign...

Page 14: ...With propeller Tohatsu outboard is power rated in accordance with ISO8665 propeller shaft output Operator Sound Pressure ICOMIA 39 94 Rev 1 dB A 90 4 Hand Vibration Level ICOMIA 38 94 Rev 1 m s2 3 6...

Page 15: ...lug Lower 10 Cooling Water Inlet 11 Oil Plug Upper 12 Anti ventilation Plate 13 Splash Plate 14 Anode 15 Thrust Rod 16 Clamp Bracket 17 Steering Friction Lever 18 Main Switch Key 19 Shift Lever 20 Til...

Page 16: ...lock arm 3 PTT switch 4 Free throttle lever 5 Main switch 6 Stop switch 7 Stop switch lock 8 Stop switch lanyard 9 Control lever 10 Neutral lock arm 11 PTT switch 12 Neutral throttle button 13 Main s...

Page 17: ...17 4 LABEL LOCATIONS ENOM00019 A Warning label locations ENOF02404 0 1 4 2 9 10 8 7 11 3 5 6...

Page 18: ...66 67 For tiller handle model 3 Indicator regarding engine failure malfunction See page 31 For tiller handle model 4 Warning regarding stop switch See page 37 and page 47 For RC model 5 Warning regard...

Page 19: ...L LOCATIONS 19 4 9 Warning regarding gasoline See page 26 10 Warning regarding gasoline See page 26 11 Caution tag regarding for replenish the engine oil See page 28 ENOF00005 M ENOF00005 F 3VJ 72044...

Page 20: ...me 6 Manufacturer address CE 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 a p a J n i e d a M 0026 CAN ICES 2 NMB 2 1 2 3 4 5 6 ENOF02405 0 Description of se...

Page 21: ...ts can cause serious injury fatal accident and or serious damages to the hull Outboard motor mounting must be per formed by trained service person s using proper tools ENOM00025 0 Position Above keel...

Page 22: ...diameter ENOM001816 0 ENOW00012 0 Battery electrolyte contains sulfuric acid and thus is hazardous causing a burn if it comes in contact with your skin or poison ous if swallowed Keep battery and elec...

Page 23: ...s required when it is using freezing condition Recommend connecting only the engine battery cables to the starting battery Specifications and features of batteries vary among the manufacturers Consult...

Page 24: ...be dam aged z Do not reuse split pin z After installing split pin spread the pin apart to prevent it from falling out which could lead to the propeller coming off during operation Propeller must be se...

Page 25: ...NOM01821 0 TOCS Tohatsu Onboard Communication System interface coupler can provide information regarding engine speed fuel consumption and various possible mal functions via an optional interface cabl...

Page 26: ...rse effects Some of these adverse effects are caused because the ethanol in the gasoline can absorb moisture from the air resulting in a separation of the water ethanol from the gasoline in the fuel t...

Page 27: ...oke 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 th...

Page 28: ...over upper limit marks of oil gauge drain oil to level lower than upper limit z Be sure that outboard motor is in upright and level position when checking or changing oil z Stop engine immediately if...

Page 29: ...top cowl is cor rectly seated on the bottom cowl seal rubber 9 Turn the top cowl hook levers to securely lock 1 Cowl hook lever Engine oil recommendation Use only high quality 4 stroke outboard motor...

Page 30: ...ral area well ventilated z Always attempt to stay on the windward side of emission ENOW00023 1 Operating the outboard motor without break in can shorten service life If any abnormality is experienced...

Page 31: ...d will be limited engine will not be stopped See next page for conditions which will lead to an abnormal condition or fault ENOM00040 A Location of warning buzzer and lamp Warning buzzer RC model Loca...

Page 32: ...ng cooling water oil pressure and sensors the low speed ESG is activated to restrict amount of fuel injection therefore the engine speed varies and be controlled under 1800 min 1 rpm or 2800 min 1 rpm...

Page 33: ...engine Remove any foreign matter on the gear case and propeller if necessary Consult an authorized dealer if no discharge of cooling water 4 Charge or replace the battery 5 Consult an authorized deale...

Page 34: ...re 3 beeps to inform you that you have successfully reset the system 5 Turn the ley to the off position and replace the safety lanyard lock The engine oil replacement indicators function operates agai...

Page 35: ...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 by heat from sources such as sun light ENOW009...

Page 36: ...ts or moving parts cause serious injury ENOW00959 0 The top cowl must be installed while the engine running except in an emergency If the top cowl is not installed correctly water splash can damage th...

Page 37: ...ill move the boat immediately potentially leading to falling down or causing passenger s to be thrown overboard ENOM01806 0 Tiller handle type 1 Be sure to install the stop switch lock to the stop swi...

Page 38: ...k port ENOM01807 0 Side mount RC type 1 Be sure to install the stop switch lock to the stop switch and attach the stop switch lanyard securely to the operator or to the operator s PFD Personal Flotati...

Page 39: ...fore the engine starts z If fail to start the engine crank again after 10 seconds or more 1 ON 2 START 3 OFF ENON00035 A Note The free throttle lever can not be raised when the control lever shift is...

Page 40: ...amps light up with buzzer sound and then go off 1 Warning lamp 5 Turn the main switch key to the START position and release it to start the engine The engine will crank continu ously until the engine...

Page 41: ...6 0 z Keep the free throttle lever fully closed position when start the engine z The free throttle lever is inoperative unless the control lever is in neutral z Also the control lever is inoperative u...

Page 42: ...wice when set to 850 min 1 rpm engine speed and tells the highest engine speed was set Reset the engine speed when after engine restarted and or engine speed is above 3 000 min 1 rpm and then trolling...

Page 43: ...to be thrown overboard or falling down ENOW00862 0 Gear and clutch damage may occur if shifting at high engine speed Engine must be in the slow idle position before shifting is attempted ENOW00863 0...

Page 44: ...erse R 4 Fully opened Forward 5 Fully opened Reverse 6 Free throttle lever 7 Control lever 8 Neutral lock arm Forward 1 Quickly push the control lever to the Forward F position 32 where the gear is co...

Page 45: ...the gear is connected while lifting up on the neutral lock arm located under the control lever grip 2 Further rearward motion will open the throttle Acceleration After shifting advance the control le...

Page 46: ...speed 1 Control lever 2 Main switch key 2 Turn the main switch key to the OFF position 1 ON 2 START 3 OFF ENOW00869 0 After stopping the engine z Close the air vent screw on the fuel tank cap z Disco...

Page 47: ...cap z Disconnect the fuel connector of the engine and the fuel tank z Disconnect the battery cord after each use Emergency engine stopping Press the emergency stop switch or remove stop switch lock t...

Page 48: ...water be sure to use emergency stop switch lock of the spare Be sure to confirm the spare stop switch lock is in the tool bag before begin to operate ENOM00920 0 ENOW00870 0 Sudden steering may cause...

Page 49: ...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 ventilation plate to run parallel to the water surface during...

Page 50: ...essing DN Down of power trim tilt switch ENOM01818 0 Improper trim angle bow dips into the water When the trim angle is too small the bow will dip into the water the speed will decrease and water may...

Page 51: ...g caught between outboard motor body and clamp bracket in case the outboard motor body falls ENOW00048 0 When tilting up or down be careful not to place your hand between the swivel bracket and the st...

Page 52: ...ted completely 1 Trim rod Tilt down 1 Release the tilt stopper from the set up position while slightly tilting up outboard motor 2 Operate the Power Trim Tilt switch and tilt the outboard motor down u...

Page 53: ...down suddenly if the manual relief valve is loosened in the Manual direction 1 Power 2 Manual Manual relief valve specified torque 3 N m 2 2 ft lb 0 3 kgf m ENOM00068 A ENOW00051 0 During shallow wat...

Page 54: ...ATION 54 7 ENOM00069 A Power Trim Tilt type 1 Operate the Power Trim Tilt switch and tilt the outboard motor up into desired shallow water running posi tion ENOF02437 0 DN UP UP DN ENOF00067 2 UP DN E...

Page 55: ...ntrol cables and the bat tery cords from the outboard motor 4 Attach the hoist hooks to the engine hanger 5 Remove the outboard motor from boat and completely drain the water from the gear case ENOM00...

Page 56: ...el tank and fuel cock before carrying or storing outboard motor and fuel tank or fuel may leak poten tially catching fire ENOW00071 0 The tilt support device supplied on your out board motor is not in...

Page 57: ...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 58: ...lead to severe injury Friction adjustment of the throttle grip can be made with the throttle adjustment screw 1 Throttle friction adjustment screw 2 Decrease 3 Increase ENOM00075 1 ENOW00074 C Do not...

Page 59: ...d to severe personal injury ENOW00075 1 Inappropriate adjustment of trim tab could cause steering difficulty After installing or readjusting trim tab check if steering load is even If straight line cr...

Page 60: ...n 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 conditi...

Page 61: ...functions normally and make sure the stop switch lock is there Remedy or replace if necessary Check cords for loose connections and damage Correct or replace if necessary Check the spark plugs for di...

Page 62: ...t 4200 mL 4 4 3 7 US Imp qt 2 Lower limit 2200 mL 2 3 1 9 US Imp qt ENON00024 0 Note The oil level should be checked when the engine is cooled ENON00025 0 Note Consult with an authorized dealer if the...

Page 63: ...board motor is used in salt water brackish water or water with a high acidic level use fresh water to remove salt chemicals or mud And flush cooling water passage after every cruising or before storin...

Page 64: ...e And be sure to remove the propeller when starting the engine in the test tank See page 72 Run the engine only at idling 1 Test tank 2 Water 3 Over 10 cm 4 in ENOM00950 0 Fuse replacement ENOW00923 0...

Page 65: ...rn the top cowl hook levers to unlock lift and remove the top cowl 3 Remove the grommet from the elec tric bracket cover 4 Remove the fuse cover 5 Remove the fuse and check it If the fuse is blown rep...

Page 66: ...y Fuel tank z z Check and clean See page 70 Fuel tank cap z z Check Replace if necessary Fuel pump Check Replace if necessary Fuel pressure Check Hose z z Check Replace if necessary Ignition System Sp...

Page 67: ...z Check Replace if necessary Seepage 72 Shear pin Split pin z z Check Replace if necessary Gear oil z Replace z z Replace Change and replace See page 71 Approx 1000 mL 34 fl oz Water strainer z z Che...

Page 68: ...cal position 4 Put an oil drain pan under the oil drain bolt 5 Remove the oil drain bolt and com pletely drain oil from the engine 1 Drain hole 6 Apply oil on the sealing surface of the drain bolt Tig...

Page 69: ...n is normal if engine is idled or trolled for long periods espe cially in cooler water temperatures ENOM00092 A Oil filter replacement ENOW00091 0 You may be injured due to high engine tem peratures i...

Page 70: ...e and its vapors are very flammable and can be explosive z Do not start this procedure while engine is operating or hot even after stopping it z Place fuel filter away from every source of ignition su...

Page 71: ...een stored for a long period of time over three months 1 Remove four screws to remove the Fuel Pick Up 2 Clean the fuel filter and replace the gasket 3 Reassemble all parts 1 Fuel pick up 2 Filter ENO...

Page 72: ...4N m 3 ft lb 0 4 kgf m ENOW00095 0 Do not reuse oil plug gasket Always use new gasket and tighten oil plug properly to pre vent entry of water into lower unit ENOW00928 0 Wipe off gear oil well immedi...

Page 73: ...rn out or bent propeller will lower the motor s performance and cause engine trouble 1 Put a piece of wood block between propeller blade and anti ventilation plate to hold propeller 2 Remove the split...

Page 74: ...move the top cowl 3 Remove the spark plug caps 4 Remove the spark plugs by turning it counter clockwise using a 5 8 16 mm socket wrench and handle that is provided in tool bag 5 Inspect the spark plug...

Page 75: ...electrolytic corrosion Anode is located on the gear case cylinder etc When the anode is eroded more than 1 3 of original size replace it ENON00029 0 Notes z Never grease or paint the anode z At each i...

Page 76: ...INSPECTION AND MAINTENANCE 76 10 ENOF02434 0...

Page 77: ...ept in a vertical posi tion 1 Tilt the outboard motor up and lock the tilt with the tilt stopper 2 Remove the fluid cap by turning counter clockwise then check if the fluid level reaches the bottom li...

Page 78: ...INSPECTION AND MAINTENANCE 78 10 ENOM00960 0 Grease point Apply water proof grease to the parts shown below ENOF02431 0...

Page 79: ...ine 1 Wash the engine exterior and flush the cooling water system thoroughly with fresh water Drain the water completely Wipe off any surface water with an oily rag 2 Use a dry cloth to completely wip...

Page 80: ...parator See page 81 2 Follow the instructions on the label when adding the fuel stabilizer addi tive 3 After adding the additive let the out board motor run in the water for 10 minutes to make sure an...

Page 81: ...under the drain hose end 5 Remove the hose clip and the drain plug by plier to drain the fuel from the vapor separator 6 When thoroughly drained put back the drain plug and the hose clip securely 7 C...

Page 82: ...minutes at half throttle The oil used for storage inside the engine will be circulated out to assure optimum performance ENOM01811 0 ENOW00098 0 Do not attempt to start submerged outboard motor immedi...

Page 83: ...eturn to the nearest harbor slowly and carefully 4 Consult a dealer check the outboard motor before operation again ENOM00121 0 When operating the outboard motors in reverse at more than the lowest sp...

Page 84: ...l level is low in the tank z z z z z z z Fuel system connection is incomplete z z z z z z z Fuel system sucks air z z z z z z z Fuel pipe is twisted z z z z z z z Cap vent is closed z z z z z z z Fuel...

Page 85: ...stretched or installed incorrectly z z z z z Valve clearance is defective z z z z z Valve seat sealing is defective z z z z z Piston piston ring and or cylinder is worn excessively z z z Combustion ch...

Page 86: ...load position z z z z z z Transom installation height is too high or too low z z z Throttle link adjustment is defective Engine will not start Engine stalls immediately after starting Defective idlin...

Page 87: ...drivers 1 Cross and straight point Screwdriver handle 1 Spare parts Spark plug 1 NGK LKR6E Split pin 1 Stop switch lock 1 Parts packaged with engine Primer bulb without connectors 1 set For internatio...

Page 88: ...range 5000 6000 min 1 rpm Propeller Mark Propeller Size Number of Blades x Diameter x Pitch mm in Light boats 13 2 x 21 3 x 335 x 533 3 x 13 2 x 21 13 2 x 19 3 x 335 x 483 3 x 13 2 x 19 13 25 x 17 3 x...

Page 89: ...O W N E R S M A N U A L 5 4 Azusawa 3 Chome Itabashi Ku Tokyo 174 0051 Japan Tel 81 3 3966 3117 Fax 81 3 3966 0090 www tohatsu com MFS 75A MFS 90A MFS 100A MFS 115A...

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