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TOHATSU MFS 115A, Owner'S Manual

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TOHATSU MFS 115A Owner'S Manual Download Page 38

ENGINE OPERATION

38

7

Do NOT use a primer bulb/hose assembly
that does not contain a Fuel Demand Valve or
a sealing mechanism as shown below: other-
wise fuel spillage may occur when the con-
nector is connected to the engine.

Do not connect fuel connector except when
operating engine. Fuel leakage is a fire or
explosion hazard, which can cause serious
injury or death.

1. Full open the air vent screw on the

fuel tank cap.

1. 

Air vent screw

2. 

Fuel tank cap

2. Open  the  fuel  tank  cap  slowly  and

release internal pressure completely.

After that, close the fuel tank.

3. Remove the cap from the fuel joint.

Connect the fuel hose of the primer
bulb and secure with a hose band.

1. 

Joint

2. 

Cap

4. Connect the primer bulb to the fuel

tank.

1. 

Pull

2. 

Insert

5. Squeeze primer bulb until it becomes

stiff to feed fuel to vapor separator.
Direc t arrow mark upward when
priming.

1. 

Engine side

2. 

Fuel tank side

Do not squeeze primer bulb with engine
running or when the outboard motor is
tilted up. Otherwise, fuel could overflow.

ENOM01805-0

ENOW00958-0

z

Do not remove or install the top cowl
after the engine has been started. 

z

The exposed rotating engine parts or
moving parts cause serious injury. 

ENOF00036-0

1

2

ENOF00029-0

1

2

ENOF02442-0

2. Starting the engine

  

WARNING

1

2

ENOF00861-A

1

2

ENOF00862-0

Summary of Contents for MFS 115A

Page 1: ...O W N E R S M A N U A L AAAA MFS 90A MFS 75A OB No 003 11160 0BX1 MFS 115A ...

Page 2: ...ll rights reserved No part of this manual may be reproduced or transmitted in any from or by any means without the express written permission of Tohatsu Corporation This product can expose you to chemicals including gasoline engine exhaust which is known to the State of California to cause cancer and carbon monoxide which is known to the State of California to cause birth defects or other reproduc...

Page 3: ...me without notice and without incurring any obligation Please always keep this manual together with the outboard motor as a reference to everyone who uses the outboard motor If the outboard motor is resold make sure the manual is passed on to the next owner We hope you will enjoy your outboard motor and wish you good luck in your boating adventures TOHATSU CORPORATION ENOM00002 0 OWNER REGISTRATIO...

Page 4: ...e 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 Serial Number Serial Number Date of purchase ENOF02400 0 ENOF02401 0 ...

Page 5: ...ion to such information to ensure safe operation of the outboard motor at all times ENOW00001 0 Failure to observe will result in severe personal injury or death and possibly property damage ENOW00002 0 Failure to observe could result in severe personal injury or death or property damage ENOW00003 0 Failure to observe could result in personal injury or property damage ENON00001 0 Note This instruc...

Page 6: ......

Page 7: ... engine 38 3 Warming up the engine 43 4 Forward reverse and acceleration 45 5 Stopping the engine 48 6 Steering 51 7 Trim angle 51 8 Tilt up and down 54 9 Shallow water operation 56 8 REMOVING AND CARRYING THE OUTBOARD MOTOR 57 1 Removing the outboard motor 57 2 Carrying the outboard motor 57 3 Trailering 58 9 ADJUSTMENT 60 1 Steering friction 60 2 Throttle grip friction 60 3 Remote control lever ...

Page 8: ...8 Operation with multiple outboard motors 85 11 TROUBLESHOOTING 96 12 ACCESSORIES KIT 89 13 PROPELLER TABLE 90 14 EMISSION CONTROL SYSTEM INFORMATION 101 ...

Page 9: ... 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 KIT 13 PROPELLER TABLE 14 EMISSION CONTROL SYSTEM INFORMATION INDEX 2 3 4 5 6 7 8 9 10 11 12 13 14 1 ...

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 operator s personal flotation device PFD the engine will stop when the stop switch lanyard is being stretched and pulled out the lock from the switch when the operator falls accidentally overboard or...

Page 11: ...fe 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 intervals Correct periodic maintenance and proper care of this outboard motor will reduce the chance of problems and limit overall operating expenses Carbon Monoxide Poisoning Hazard Exhaust gas contains...

Page 12: ...XAMPLE F 115A ETL Model F75A F90A F115A Type ET ET ET Transom heights L z z z UL z z Multi function tiller handle z z z Remote Control z z z Power Trim Tilt z z z F 115 A E T L Model descrip tion Horse power Product genera tion Starter system Tilt system Shaft length F Four stroke A and up E Electrical start T Power trim tilt L Long 20 in UL Ultra long 25 in ...

Page 13: ...ent 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 Ignition System Battery ignition Spark Plug NGK LKR6E Alternator 12V 41A Trim position 2 Trim angle Degree 8 24 Tilt up angle Degree 75 Steering angle Degree 70 Engine Oil Grade API Standards SH SJ SL SAE 10W 30 40...

Page 14: ...ice 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 Item MODEL F75 90 115A ET with RC ET with multi function tiller handle ...

Page 15: ...Plug 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 Tiller Handle 21 Throttle Grip 22 PTT Switch 23 Warning Lamp 24 Stop Switch 25 Stop Switch Lanyard 26 Oil Filler Cap 27 Spark Plug 28 Oil Level Gauge 29 Cowl Hook Lever 30 Idle Port 31 Manual Valve 32 O...

Page 16: ...k 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 switch 14 Stop switch 15 Stop switch lock 16 Stop switch lanyard 17 Fuel gauge 18 Air vent screw 19 Fuel tank cap 20 Tab lock 21 Primer bulb 22 Fuel connector Fuel tank side ...

Page 17: ...17 4 LABEL LOCATIONS ENOM00019 A Warning label locations ENOF02404 A 1 4 2 10 8 7 13 3 5 6 11 12 9 ...

Page 18: ...ngine failure malfunction See page 31 For tiller handle model 4 Warning regarding stop switch See page 39 and page 50 For RC model 5 Warning regarding stop switch lan yard For Top mount RC 6 Warning regarding urge to read the owner s manual 7 Warning regarding gasoline 8 Warning regarding gasoline See page 26 3WL 72180 000 3SS 72181 000 ENOF00005 C ENOF00005 P ENOF00005 D ENOF00120 0 ENOF00005 E E...

Page 19: ...ank and primer bulb ass y See page 37 10 Warning tag regarding instructions of the fuel tank cap See page 27 11 Warning regarding fuel tank cap See page 27 12 Caution tag regarding for replenish the engine oil See page 28 ENOF00010 0 ENOF00011 0 ENOF00012 0 3VJ 72044 000 ...

Page 20: ...nent evi dence of EPA certification Emissions Warranty Coverage WARRANTY INFORMATION Four Stroke Outboard Limited Warranty Canadian and California residents who have purchased an outboard motor from a Canadian and California dealer receive additional warranty coverage for specific emissions related components To fully understand your warranty coverage please read our standard warranty state ment a...

Page 21: ...ats 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 line Place the outboard motor in the center of the boat s transom 1 Center of boat 2 Chine ENOM01801 0 Transom matching Be sure that the anti ventilation plate of the outboard motor should align with...

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 electrolyte away from reach of children When handling the battery be sure to z Read all warnings shown on the battery case z Prevent electrolyte from coming in con tact with any part of your body Contact...

Page 23: ...is 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 the manufacturer for details The battery should be purchased sepa rately and is not supplied with the out board motor 1 Place the battery box in a convenient position away from possible water spray ...

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 selected that will allow the engine to reach recommended maxi mum operating range during cruising Genuine propellers are listed on PROPEL LER TABLE of this manual See page 90 1 Remove the split pin pro...

Page 25: ...ENOM01821 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 cable Contact authorized Tohatsu dealer for more detail 4 TOCS Tohatsu Onboard Communication System installation ENOF02441 0 ...

Page 26: ...erse 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 tank These may cause increased z Corrosion of metal parts z Deterioration of rubber or plastic parts z Fuel permeation through rubber fuel lines z Starting and operating difficulties If the use of gas...

Page 27: ...moke When or before refueling z Be sure to remove the static electricity charged in your body before refueling z The sparks due to static electricity may cause explosion of flammable gasoline z Stop the engine and do not start the engine during refueling z Do not smoke z Be careful not to overfill fuel tank Wipe up any spilled gasoline immediately When or before cleaning the gasoline tank z Dismou...

Page 28: ...s 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 low oil pres sure warning lamp is lit or oil leak is found or engine could be severely damaged Consult dealer z Wipe off engine oil well immediately if spilled and dispose of it in accordance with l...

Page 29: ... 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 oil to insure performance and pro longed engine life NMMA FC W rated oil SAE 10W 30 or 10W 40 API SH SJ or SL Engine oil viscosity must be selected from the following chart according to the average temperatur...

Page 30: ...eral 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 during the break in z Discontinue the operation immediately z Have the dealer check the product and take proper action s if necessary ENON00008 A Note z Proper break in allows outboard motor to deliv...

Page 31: ...ed 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 Located inside the remote control Tiller handle model Located in the tiller handle Warning lamp LED RC model Located in the tachometer Tiller handle model Located on the tiller handle 1 Warning lamp 1 Wa...

Page 32: ...the engine from getting damage If the engine has problems regarding 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 Warning indicators ESG Description of faults or notice Rem edy Sound A lamp Continuous ON Normal system test when key on Continuous Hi...

Page 33: ...safe place quickly and stop the engine Check the engine oil level and add engine oil if necessary Consult your dealer if the engine oil level is too low or too high 3 Move to safe place quickly and check the discharge of cooling water from the water check port at idle speed and stop engine Remove any foreign matter on the gear case and propeller if necessary Consult an authorized dealer if no disc...

Page 34: ...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 Warning indicators ESG Description of faults or notice Rem edy Sound A lamp B lamp C lamp Continuous ON ON ON Normal system test when key on Continuous High speed ESG Engine speed exceeds maximum allowable RPM ...

Page 35: ... 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 dealer 6 Replace the engine oil and reset the indicator ENOM00870 0 Engine oil replacement indicator function reset method As for Engine oil replacement indicator function informing the appropriate timing...

Page 36: ...ere 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 again after 100 hours operation from reset this function ENOF00856 0 ...

Page 37: ...uel 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 ENOW00030 B When using EPA approval fuel tank only use a primer bulb hose assembly that has a Fuel Demand Valve FDV installed in the fuel hose or a sealing mechanism in the fuel connector as shown below FDV and fue...

Page 38: ...lose the fuel tank 3 Remove the cap from the fuel joint Connect the fuel hose of the primer bulb and secure with a hose band 1 Joint 2 Cap 4 Connect the primer bulb to the fuel tank 1 Pull 2 Insert 5 Squeeze primer bulb until it becomes stiff to feed fuel to vapor separator Direct arrow mark upward when priming 1 Engine side 2 Fuel tank side Do not squeeze primer bulb with engine running or when t...

Page 39: ...ater intake is blocked Operating engine could lead to overheating potentially leading to engine damage Con sult an authorized dealer if the cause cannot be found ENOW00974 0 Starter motor will not operate if the stop switch lock is not properly installed This model is provided with start in gear protection ENON00010 0 Note Start in gear protection prevents engine from starting at other than neutra...

Page 40: ...sound and then go off 6 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 starts ENON00942 0 Note z It takes maximum 4 seconds of the continuous crank before the engine starts z If fail to start the engine crank again after 10 seconds or more 1 Main switch key 2 Warning lamp 7 Check the cooling water from cooling ...

Page 41: ... 6 Main switch key 7 Stop switch 4 Turn the main switch key to ON posi tion and confirm three warning lamps 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 starts ENON00942 0 Note z It takes maximum 4 seconds of the continuous crank before the engine st...

Page 42: ...the Neutral throttle button to open the throttle when starting the engine 1 Forward F 2 Neutral N 3 Reverse R 4 Fully opened Forward 5 Fully opened Reverse 6 Neutral throttle button 7 Control lever 8 Neutral lock arm 4 Turn the main switch key to ON posi tion and confirm three warning lamps light up with buzzer sound and then go off 1 Warning lamp 5 Turn the main switch key to the START position a...

Page 43: ...g water is com ing out of the cooling water check port dur ing warm up Warm the engine at low engine speeds for about 3 minutes above 5 C 41 F 5 minutes at 2000 min 1 rpm blow 5 C 41 F This allows the lubricating oil to circulate to all parts of the engine Operating the engine without warm up shortens the engine s life ENOM00044 0 Engine speeds Idling speed after warming up Remark In case of cold ...

Page 44: ...e neutral lock arm is pulled The neutral throttle button is for warm up operation Not required for engine starting When the control lever is in neutral push and hold the neutral throt tle button While holding the button move the lever forward to throttle up the engine When the control lever is returned to the neutral position the button will reset automatically 1 Neutral throttle button 2 Forward ...

Page 45: ...t when pulled z Be careful not to pull the lanyard acciden tally during cruising Unintentional stop of engine can cause loss of control of out board motor Rapid loss of engine power can lead to falling down or causing pas senger s to be thrown overboard ENOW00042 0 z Do not shift into Reverse during planing or control will be lost leading to serious personal injury boat may swamp and or hull may b...

Page 46: ... the throttle grip is not in the fully closed position otherwise steering system and or shifting mechanism may be damaged The control lever is inop erative unless the throttle grip is in the fully closed position Multi function tiller type 1 Shift lever Forward 1 Turn the throttle grip to reduce engine speed 2 When the engine reaches trolling or idling speed quickly pull the shift lever to the For...

Page 47: ...d 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 lever gradually to accelerate 1 Control lever ENOM00975 A Top mount RC type 1 Forward F 2 Neutral N 3 Reverse R 4 Fully opened Forward 5 Fully opened Reverse 6 Neutral throttle button 7 Control lever 8 Neutral lock arm Forw...

Page 48: ... speed possibly leading the crew s and or objects on the boat to be thrown forward due to inertial force Tiller handle type 1 Turn the throttle grip to the slow position 2 Put the shift lever in the Neutral posi tion Run the engine for 2 3 minutes at idling speed for cooling down if it has been running at full speed 1 Throttle grip 2 Shift lever 3 Main switch key 3 Turn the main switch key to the ...

Page 49: ...r 2 3 minutes at idling speed for cooling down if it has been running at full speed 1 Control lever 2 Turn the main switch key to the OFF position 2 Main switch key 3 ON 4 START 5 OFF ENOW00869 0 After stopping the engine z Close the air vent screw on the fuel tank cap z Disconnect the fuel connector of the engine and the fuel tank z Disconnect the battery cord after each use Emergency engine stop...

Page 50: ...ol bag 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 When an operator falls into 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 R N F 1 2 ENOF00883 1 2 1 ENOF00869 A 1 2 ENOF00938 B1 1 2...

Page 51: ...ive trim up or down may lead to unsta ble boat operation potentially causing the steering difficulty that leads to accident during cruising z Do not cruise at high speed if improper trim position is suspected Stop the boat and readjust trim angle before continuing cruise z For outboard motor model with PTT switch on the bottom cowl do not oper ate the switch during cruising or control of boat may ...

Page 52: ...ng in engine over heating 1 Tilt angle 0 75 2 Trim angle 8 24 ENOM01808 0 Proper trim angle The trim angle is optimum when the boat is parallel to the water surface while run ning 1 Perpendicular to the water surface ENOM01809 0 Improper trim angle bow rises too high When the trim angle is excessive the bow will rise out of the water and the speed will be decrease Furthermore the bow may sway or t...

Page 53: ...for future reference ENOM01820 0 Trust rod adjustment The trim angle at full tilt down is adjust able by selected the thrust rod position 1 Thrust rod 2 Higher 3 Lower 1 Stop the engine 2 Shift into neutral position 3 Tilt up the outboard motor 4 Lock the tilt stopper 5 Remove the Snap pin and thrust rod as shown picture 1 Snap pin 2 Thrust rod 6 Reinstall the thrust rod in the desired position se...

Page 54: ...lly catching fire ENOW00057 0 Do not tilt up outboard motor while engine operates or no cooling water may be fed leading to engine seizure due to overheating ENON00921 0 Note Before tilting the outboard motor up after stopping the motor leave it in the running position for about a minute to allow water to drain from inside the engine ENOM01810 0 Power Trim Tilt type Tilt up 1 Press the power trim ...

Page 55: ...tch thus inoperative open the manual valve completely in the Manual direction This will allow manual tilting of the outboard motor ENOW00872 0 Make sure the manual relief valve is closed before operating the outboard motor If the manual relief valve is not closed the out board motor will tilt up when operated in reverse ENOW00873 0 Before opening the manual relief valve make sure nobody is under t...

Page 56: ...e the outboard motor at slow speed and keep the cooling water intake sub merged ENOW00054 0 Do not overtilt outboard motor when driving shallow water or air may be sucked through water inlet potentially leading to engine overheating 1 Water inlet 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 9 Shall...

Page 57: ...ontrol 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 ENOM00071 A ENOW00933 0 Be sure to disconnect fuel connector except when operating engine Fuel leakage is a fire or explosion hazard which can cause serious injury or death ENOW00065 0 Close air vent screw...

Page 58: ...uel 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 intended for towing It is intended to support the outboard motor while the boat is docked beached etc When transporting a boat on a trailer with the outboard motor still attached disconnect the fuel li...

Page 59: ...nd 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 lead to severe personal injury WARNING 2 1 ENOF00074 A ...

Page 60: ...d 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 overtighten the remote control throttle friction adjustment screw or it could result in difficulty of movement resulting in the loss of control causing an accident and could lead to severe injury To...

Page 61: ...ad 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 cruising cannot be achieved adjust the trim tab located under the anti ventilation plate z If the boat veers toward the left direct the trim tab towards A left from rear of boat z If the boat veers tow...

Page 62: ...on 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 conditions such as frequent full throttle operation fre quent operation in brackish water or for commercial use maintenance should be performed at shorter intervals If in doubt consult your dealer for advic...

Page 63: ...h 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 dirt wear and carbon build up Clean or replace if necessary Check the warning buzzer one beep and warning LED lamp ON for 1 secs when key is ON Repair Clutch and Propeller Sys tem Check that clutch eng...

Page 64: ...it 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 engine oil is milky color or appears con taminated ENOM00082 A Engine oil replenishing ENOW00972 0 z Do not add or mix different brands of engine oil or grade with existing oil In case engine oil of...

Page 65: ...rly used If outboard 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 storing outboard motor for long time Before flushing remove the propel ler and the forward thrust holder ENOM00085 G Flushing hose joint ENOW00921 0 Do not operate the engine when flushing th...

Page 66: ...lation plate And be sure to remove the propeller when starting the engine in the test tank See page 74 Run the engine only at idling 1 Test tank 2 Water 3 Over 10 cm 4 in ENOM00950 0 Fuse replacement ENOW00923 0 Before replacing a fuse disconnect the bat tery cable from the battery negative ter minal Failure to do so may cause a short circuit ENOW00924 0 Never use a fuse with a rating that exceeds...

Page 67: ...urn 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 replace to the supplied spare fuses in the spare fuse holder 1 Grommet 2 20A 3 20A 4 30A 5 Blown fuse 2 3 4 2 3 4 5 1 ENOF02426 0 ...

Page 68: ...ry Fuel tank z z Check and clean See page 72 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 Spark plug z Check and clean See page 76 0 8 0 9 mm 0 031 0 035 in Spark plug cap High tension cord Check Replace if necessary Starting System Starter motor Check Battery Cable connection Check Engine ...

Page 69: ...z z Check Replace if necessary Seepage 74 Shear pin Split pin z z Check Replace if necessary Gear oil z Replace z z Replace Change and replace See page 73 Approx 1000 mL 34 fl oz Water strainer z z Check Water pump impeller z Replace Check Replace if necessary Water pump housing 1 Check Replace if necessary Shift Throttle Throttle cable z Check Replace if necessary Throttle link Check and adjust S...

Page 70: ...ical 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 Tighten the bolt with a new gasket Oil drain screw specified torque 24 N m 17 ft lb 2 4 kgf m ENON00028 A Note If a torque wrench is not available when you are fitting a oil filter a good estimate of th...

Page 71: ...on 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 if you fill engine oil just after stop ping Changing engine oil should be done after the engine has been cooled ENOW00926 0 Wipe off engine oil well immediately if spilled and dispose of it in accorda...

Page 72: ...ne 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 such as sparks or open flames z Wipe off gasoline well immediately if spilled and dispose of it in accordance with local fire prevention and environ ment protection regulations z Install fuel filter wi...

Page 73: ...been 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 ENOM00098 A Gear oil replacement ENOW00094 0 z Be sure that outboard motor is secured to transom or service stand or accidental drop or fall of outboard motor could lead to severe personal injury z Be s...

Page 74: ... 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 immediately if spilled and dispose of it in accordance with local fire prevention and environment protection regulations ENON00032 0 Note If water in the oil giving it a milky colored appearance Contact yo...

Page 75: ...orn 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 pin propeller nut and washer 3 Remove the propeller and thrust holder 4 Apply water proof grease to the pro peller shaft before installing a new propeller 5 Install the thrust holder propeller stopp...

Page 76: ...emove 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 Replace the spark plug if the electrodes are worn or if the insulators are cracked or chipped 6 Measure the spark plug electrode gap with a wire type feeler gauge The gap should be 0 8 0 9 mm 0 031 ...

Page 77: ... 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 inspection re tighten the anode attaching bolt As it is likely to be subjected to electrolytic corrosion ENOF02429 0 ...

Page 78: ...INSPECTION AND MAINTENANCE 78 10 ENOF02434 0 ...

Page 79: ...kept 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 line of the fill hole 1 Filler cap 2 Fluid level Recommended fluid Use an automatic transmission fluid or equiva lent Recommended power trim tilt fluid ATF Dexron III Air purging from the Power Trim an...

Page 80: ...INSPECTION AND MAINTENANCE 80 10 ENOM00960 0 Grease point Apply water proof grease to the parts shown below ENOF02431 0 ...

Page 81: ...gine 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 wipe off water and salt from the electrical components 3 Drain all fuel from the fuel hoses fuel pump fuel filter See page 72 and vapor separator See page 83 and clean these parts Keep in mind that if g...

Page 82: ...eparator See page 83 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 any old fuel in the fuel system has been completely replaced by the fuel with additive 4 Turn the engine OFF ENON00945 0 Note Over time oxidation of gasoline can form buildup of harmful solids called g...

Page 83: ...r 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 Check the drained fuel for the pres ence of water or other contaminants Consult your dealer If either present Service is required 1 Drain hose ENOM00102 0 Battery ENOW00931 A z Place the battery away ...

Page 84: ... 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 immediately after it is recovered or engine could be severely damaged After taking your outboard motor out of the water immediately take it to your dealer ENOM00106 A If you moor your boat in cold weather ...

Page 85: ...Return 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 speed be sure that all engines are running If any engine has stopped be sure to tilt the outboard motor up and keep its pro peller out of the water Otherwise water could enter the engine and cause dama...

Page 86: ...el 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 filter fuel pump or injector is clogged z z z z z z z Performance of fuel pump or vapor separator is deteriorated z z z z z Low quality fuel is used z Primer bulb is clogged z z z z z z Low quality ...

Page 87: ... 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 chamber carbon deposition is too much Spark plug is loose Engine will not start Engine stalls immediately after starting Defective idling Poor acceleration Engine speed is very high causing high speed ...

Page 88: ...y 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 idling Poor acceleration Engine speed is very high causing high speed ESG to operate Engine speed is very low causing low speed ESG to operate Boat cannot run at high speed Engine overheats Battery is not...

Page 89: ...handle 1 Screwdrivers 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 international models Rigging bolt set Bolt 4 M12P1 25 x 105 mm Washer 4 13 34 3 Washer 4 M12 Nut 4 M12P1 25 Cable joint set Cable joint 2 Washer 2 8 5 18 1 6 Snap pin 2 Cable holder set Cable hold...

Page 90: ... 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 337 x 432 3 x 13 25 x 17 13 5 x 15 3 x 343 x 381 3 x 13 5 x 15 13 75 x 13 3 x 349 x 330 3 x 13 75 x 13 14 x 11 3 x 356 x 279 3 x 14 x 11 Heavy boats 14 x 9 3 x 356 x 229 3 x 14 x 9 ...

Page 91: ...as several sensors to determine how much fuel is needed for injection under all operating conditions ENOM01003 0 Clean Air Acts of the United States and California and Environment Canada EPA California and Canadian regula tions require all manufacturers to pro vide written instructions that describe the operation and maintenance of com mercial emission control systems The following instructions an...

Page 92: ...ine parts constitute replacement parts man ufactured to the same high standards as the original parts thus guaranteeing uninterrupted high performance of your outboard motor The use of replacement parts other than Tohatsu Genuine parts could jeopardize the effectiveness of the emission control system Tohatsu as a manufacturer of aftermar ket parts assumes the responsibility that replacement parts ...

Page 93: ...vice prevents overtightening z The fuel tank has a manual vent screw which should be closed for transporta tion and full open for operation and cap removal Since sealed fuel tanks are not openly vented they will expand and contract as the fuel expands and contracts during heating and cooling cycles of the outside air This is normal ENOM00036 0 EQUIPPED FOR UNITED STATES AND CANADA MODEL TOHATSU ad...

Page 94: ...ercraft and Outboard marine engine 2001 exhaust emission standards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 standards for marine engines ENOM01010 0 Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard ma...

Page 95: ...01012 0 Four Stars Super Ultra Low Emission The four star label identifies engines that meet the Air Resources Board s Stern drive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 lower emissions than One Star Low Emission engines ENOF01004 0 ...

Page 96: ...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 115A ...

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