TOHATSU MFS2.5C Portable Outborads Motor Instruction Manual
- June 13, 2024
- TOHATSU
Table of Contents
MFS2.5C Portable Outborads Motor
Product Information:
The product is a Tohatsu Outboard Motor, available in two
models: MFS 2.5C and MFS 3.5C. It is important to read the owner’s
manual before using the outboard motor to ensure safety and prevent
any potential risks. Tohatsu Corporation reserves the right to
modify the owner’s manual without prior notice. The product
complies with certain European Parliament directives and UK
regulations.
Product Usage Instructions:
-
Owner Registration and Identification: Upon purchasing
the product, fill out the WARRANTY CARD completely and mail it to
the provided address. This will serve as your warranty registration
and identify you as the legal owner of the product. -
Pre-Delivery Inspection: Before operating the outboard
motor, ensure that a pre-delivery inspection has been properly done
by an authorized TOHATSU dealer. -
Serial Number: The outboard motor has a unique serial
number. It is located on the motor and is required for warranty
registration, warranty claims, technical inquiries, and other
occasions. Write down the serial number and date of purchase in the
provided space. -
Notice – Danger/Warning/Caution/Note: Thoroughly read
and understand the Owner’s Manual before installing, operating, or
handling the outboard motor. Pay special attention to information
preceded by the words DANGER, WARNING, CAUTION, and Note to ensure
safe operation at all times.
Note: The provided information is for reference purposes
only. For detailed instructions and safety precautions, please
refer to the complete owner’s manual.
O W N E R’ S MANUAL
Original instructions
EN
MFS 2.5C MFS 3.5C
OB No.003-11151- BC1
ENOM00001-0
READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE
INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.
Copyright © 2023 Tohatsu Corporation. All 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.
3
YOUR TOHATSU OUTBOARD MOTOR
ENOM00006-2
To You, Our Customer
Congratulations on your purchase of the TOHATSU outboard motor. You are now
the proud owner of an excellent outboard motor that will serve you for many
years to come. This owner’s manual contains important safety, operational and
maintenance information. The efficiency and longevity of your outboard motor
will depend heavily on your operating methods and periodic maintenance.
Failure to operate and maintain your outboard motor according to the
instruction in this owner’s manual may void the limited warranty, as well as
reduce the efficiency and reliability of the outboard motor.
Any person operating TOHATSU outboard motor must carefully read and fully
understand the entire contents of this manual prior to operation. For safety,
follow all safety warnings contained within the owner’s manual and the labels
applied to your outboard motor. You should keep this owner’s manual where
accessible while operating your outboard motor. If the outboard motor is
resold, make sure the manual is passed on to the next owner. In case you
encounter any problems, please contact an authorized TOHATSU service shop or
dealer for assistance.
Tohatsu Corporation reserves the right to change, modify, add, or remove a
part or whole of the owner’s manual without prior notice and incurring any
obligations.
We are excited to take a part in your boating adventures and wish for your
great and safe boating experience.
TOHATSU CORPORATION
ENOM00113-1
DECLARATION OF CONFORMITY (DoC)
This product conforms to certain portion of the European Parliament directive
and UK Regulations. DoC contains the following information; z Name and Address
of the manufacturer, EU – notified body, EU – authorized repre-
sentative, and UK – approved body. z Applied community directives and
regulations z Reference standard z Description of the product. (model name and
serial number) z Signature of the responsible person (name / title / date and
place of issue).
4
ENOM00002-0
OWNER REGISTRATION AND IDENTIFICATION
Upon purchasing this product, be sure that the WARRANTY CARD is correctly and
completely filled out and mailed to the addressee noted there on. 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 APPLICABLE LIMITED WARRANTY, IF THIS
PROCEDURE IS NOT FOLLOWED.
ENOM00003-1
PRE-DELIVERY INSPECTION
Make sure Pre-delivery inspection has been properly done by authorized TOHATSU
dealer before operating your outboard motor.
ENOM00005-1
Serial Number
Your outboard motor has a unique serial number. The serial number is
identification of outboard motor and is located on the outboard motor as shown
in the figures below. The serial number is required for warranty registration,
filing a warranty claim as well as making technical inquiries and may be
required for other occasions.Therefore, please write down the serial number
and date of purchase in the space below.
Serial Number:
Serial Number:
ENOF01600-1
Date of purchase:
ENOF01601-1
5
ENOM00007-0
NOTICE: DANGER/WARNING/CAUTION/Note
Before installing, operating or otherwise handling your outboard motor, be
sure to thoroughly read and understand this Owner’s Manual and carefully
follow all of the instructions. Of particular importance is information
preceded by the words “DANGER,” “WARNING,” “CAUTION,” and “Note.” Always pay
special attention to such information to ensure safe operation of the outboard
motor at all times.
ENOW00001-0
DANGER
Failure to observe will result in severe personal injury or death, and
possibly property damage.
ENOW00002-0
WARNING
Failure to observe could result in severe personal injury or death, or property damage.
ENOW00003-0
CAUTION
Failure to observe could result in personal injury or property damage.
ENON00001-0
Note
This instruction provides special information to facilitate the use or
maintenance of the outboard motor or to clarify important points.
CONTENTS
1. GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . .10 2. SPECIFICATIONS . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3. PARTS
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 15 4. LABEL LOCATIONS . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 5.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 19
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 19 6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 21
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 21 2. Fuel filling . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 3. Engine oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 23 4. Break-In . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 26 Before starting . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.
Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 26 2. Starting the engine . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 3. Warming
up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 30 4. Forward, reverse, and acceleration . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 31 5. Stopping the engine . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 34 7. Trim angle . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 8.
Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 36 8. REMOVING AND CARRYING THE OUTBOARD MOTOR. .
. . . . . . . . . . . . . . . . . 38 1. Removing the outboard motor . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2. Carrying the
outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 3. Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 39 9. ADJUSTMENT. . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 41 1. Steering friction . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 41 2. Throttle grip friction .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 10. INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 42 1. Daily Inspection . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 2.
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 47 3. Off-season storage . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 4. Pre-season
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 58 5. Submerged outboard motor . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 59 6. Cold weather precautions. . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 7.
Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 59 8. Auxiliary outboard motor operation . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 60 11. TROUBLESHOOTING . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 61 12. ACCESSORIES KIT . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 63 13. PROPELLER TABLE . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INDEX
9
1. GENERAL SAFETY INFORMATION
1
2. SPECIFICATIONS
2
3. PARTS NAME
3
4. LABEL LOCATIONS
4
5. INSTALLATION
5
6. PRE-OPERATING PREPARATIONS
6
7. ENGINE OPERATION
7
8. REMOVING AND CARRYING THE OUTBOARD MOTOR
8
9. ADJUSTMENT
9
10. INSPECTION AND MAINTENANCE
10
11. TROUBLESHOOTING
11
12. ACCESSORIES KIT
12
13. PROPELLER TABLE
13
1
1
10
GENERAL SAFETY INFORMATION
ENOM00009-1
1 SAFE OPERATION OF BOAT As the operator/driver of a boat, you are responsible
for the safety of those aboard and those in other boat around yours, and for
following local boating regulations. You should be thoroughly knowledgeable on
how to correctly operate the boat, outboard motor, and accessories. To learn
about the correct operation and maintenance of the outboard motor, please read
through this manual carefully. It is very difficult for a person in the water
to take evasive action should he or she see a power boat heading in his/her
direction, even at a slow speed. Therefore, when your boat is in the immediate
vicinity of people in the water, the outboard motor must be shifted to neutral
and shut off.
ENOW00005-0
WARNING
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOVING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TO A BOAT OR GEAR HOUSING.
ENOM00247-1
STOP SWITCH LANYARD
The engine can be stopped by pulling out the stop switch lock from the 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 if the operator accidentally
falls overboard or leaves from operator’s position. This function may prevent
losing control of the boat and minimize or prevent risk of collision with
other boats, people and other objects. It is operator’s responsibility to use
the stop switch lanyard.
ENOW00004-1
WARNING
Accidental activation of the Stop Switch (such as the tether being pulled out
in heavy seas) could cause passengers to lose their balance and even fall
overboard, or it could result in loss of power in heavy seas, strong currents,
or high winds. Loss of control while mooring is another potential hazard. To
minimize accidental activation of the Stop Switch, the 500 mm (20 inch.) stop
switch lanyard is coiled and can extended to a full 1300 mm (51 inch.).
ENOM00800-A
PERSONAL FLOTATION DEVICE
As the operator/driver and passenger of a boat, you are responsible to wear a
PFD (Per-
sonal Flotation Device) while on the boat.
GENERAL SAFETY INFORMATION 11
ENOM00010-1
1 SERVICING, REPLACEMENT PARTS & LUBRICANTS
We recommend that only an authorized service shop perform service or
maintenance on your outboard motor. Be sure to use genuine parts, genuine
lubricants, or recommended lubricants. Be aware that the installation and use
of parts not approved by Tohatsu Corporation will void warranty and may lead
to unsafe operating conditions.
ENOM00011-1
MAINTENANCE
As the owner of the outboard motor, you should be acquainted with correct
maintenance procedures following by maintenance section of this manual (See
page 42). It is the operator’s responsibility to perform all safety
inspections, proper lubrication and to follow all maintenance instructions for
safe operation. 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 outboard motor will reduce the chance of
problems, limit overall operating expenses and contribute to longevity of your
outboard motor.
Carbon Monoxide Poisoning Hazard Exhaust gas contains carbon monoxide, a
colorless and odorless gas which can be fatal if inhaled for any length of
time. Never start or operate the engine indoors or in any space which is not
well ventilated.
Gasoline Gasoline and its vapors are very flammable and can be explosive. Use
extreme care when handling gasoline. You should be thoroughly knowledgeable on
how to correctly handle gasoline by reading this manual.
12
SPECIFICATIONS
ENOM00810-A
MODEL FEATURE
2 Type
Model
S Transom heights
L
Tiller Handle
Remote Control
Separate fuel tank
Integral fuel tank
Manual tilt
*1: Option
ENOM00811-A
MODEL NAME EXAMPLE
F 3.5 CL
F Model description
F= Four stroke
3.5 Horse power
–
F2.5C MF z z z
z z
F3.5C MF z z z
z z
C Product genera-
tion
A and up
L
Shaft length
S= Short 15 in L= Long 20 in UL= Ultra long 25 in
SPECIFICATIONS 13
ENOM00201-0
2.5C, 3.5C
Item
Model
MFS 2.5C
MFS 3.5C
2
Overall Length
mm (in)
715 (28.2)
Overall Width
mm (in)
363 (14.3)
Overall Height
mm (in)
S : 1032 (40.6) L : 1159 (45.6)
Transom Height
mm (in)
S : 427 (16.8) L : 554 (21.8)
Weight*1
S kg (lb) L kg (lb)
18.5 (41) 19.5 (43)
Engine Type
4 stroke
Number of Cylinder Piston Displacement
cm3 (cu.in.)
1 86 (5.2)
Bore x Stroke
mm (in)
55 x 36 (2.15 x 1.40)
Max. Output Max. Operating Range Idle Speed in Forward Gear Idle Speed in Neutral Gear
kW (PS) min-1 (rpm) min-1 (rpm) min-1 (rpm)
1.8 (2.5) 4500 – 5500
1200 1300
2.6 (3.5) 5000 – 6000
Exhaust System
Above propeller exhaust
Lubrication System
Wet sump
Cooling System Starting System Ignition System Steering Angle Trim Angle2 Trim Position Tilt Up Angle2 Gear Shift Gear Reduction Ratio Emisson Controul System Operator Sound Pressure (ICOMIA 39/94 Rev.1) dB (A)
Degree Degree
Degree
Water cooling (with thermostat) Manual starter
Flywheel Magneto CD ignition 360 -7 – 8 4 65
Dog clutch (F-N) 2.15 (28:13)
EM (Engine modification)
79.1
Hand Vibration Level (ICOMIA 38/94 Rev.1) m/s2
5.7
Remark: Specifications subject to change without notice. 1: With propeller. 2: Transom angle is at -12° Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
14 SPECIFICATIONS
Service data
Item
2
Fuel
Fuel Tank Capacity
Engine Oil
Gear Oil
Spark Plug Spark Plug Gap Intake Valve Clearance Exhaust Valve Clearance
Tightening torque
Engine Oil Drain Bolt Gear Oil Plug Spark Plug
Model
L (US gal) Grade mL
(US/Imp.oz) Grade mL
(US/Imp.oz)
mm (in) mm (in) mm (in)
MFS 2.5C
MFS 3.5C
Unleaded Regular Gasoline : R+M/2: 87 or higher RON: 91 or higher
1.0 (0.26)
API: SH, SJ, SL SAE: 10W-30, 10W-40
300 (10/11)
API:GL-5, SAE:80-90
180 (6.1/6.3)
NGK DCPR6E 0.8-0.9 (0.031-0.035) 0.06-0.14 (0.0024-0.0055) 0.11-0.19 (0.0043-0.0075)
18N · m (13 ft · lb, 1.8 kgf · m) 4N · m (3 ft · lb, 0.4 kgf · m) 18N · m (13 ft · lb, 1.8 kgf · m)
PARTS NAME
ENOM00202-0
2.5C, 3.5C
1 2 3 4 5 6
7
8
9
20
24
25
20 19 18 21
17 23
16
15 14 13
12 11 10
15
22
3
26
27
1 Fuel Tank Cap 2 Tilt Handle 3 Top Cowl 4 Cowl Latch 5 Cooling Water Check
Port 6 Steering Adjustment Screw 7 Anti Ventilation Plate 8 Anode 9 Propeller
10 Oil Plug (Lower) (Fill) 11 Water Inlet 12 Oil Plug (Upper) (Level)
28
13 Drive Shaft Housing 14 Thrust Rod 15 Clamp Bracket 16 Clamp Screw 17
Throttle Grip 18 Shift Lever 19 Starter Handle 20 Air Vent Screw 21 Choke Knob
22 Stop Switch 23 Tilt Stopper 24 Fuel Tank
ENOF00201-A
25 Engine Oil Filler Cap 26 Engine Oil Drain Bolt 27 Engine Oil Level Gauge 28
Fuel Cock
16
LABEL LOCATIONS
ENOM00203-0
Warning label locations
5
4
3
1 2
4
1. Read owner’s manual.
ENOF00120-0
2. Engine stop switch (See page 27, 33).
ENOF01605-C
3, 4-2. HOT SURFACE Can cause burns. Do not touch when operating or
immediately after the engine has stopped.
ENOF00131-B
3GR-76191-0
4-1.Warning regarding starting the engine (See page 27).
4-3. HAZARD CAUSED BY ROTATING PARTS Rotating parts can cause severe injury.
Keep hands, feet, hair, and clothing away from all rotating parts to prevent
injury.
4-4. ELECTRICAL SHOCK HAZARD High voltage can cause severe electrical shock.
Do not touch electrical components such as ignition coil or spark plug cord
when starting or while the engine is in operation.
4
2
3
1
3PA-72181-100
5. Warning regarding fuel tank cap (See page 21, 24).
ENOF02050-0
LABEL LOCATIONS 17
4
18 LABEL LOCATIONS
ENOM00019-B
CE label locations
1521
CAN ICES-2 / NMB-2
2)
4
1. Model code(Model name) 2. Serial No. 3. Rated power 4. Dry mass weight(
Without propeller, with battery
cable) 5. Manufacturer name 6. Manufacturer address 7. Authorised
representative 8. Authorised representative address
Description of serial number year code
Last two digits of alphabet represent production year as below.
Year Code
Year of manufacture
BC 2023
BD 2024
BE 2025
ENOF01606-4
BF 2026
BG 2027
19
INSTALLATION
ENOM00024-B
1. Mounting the outboard motor on boat
ENOW00006-1
WARNING
Most boats are rated and certified for their maximum allowable horsepower, as shown on the boat’s certification plate. Do not equip your boat with an outboard motor that exceeds this limit. If in doubt, contact your dealer. Do not operate the outboard motor until it has been securely mounted on the boat in accordance with the instructions below.
ENOW00009-2C
WARNING
z Mounting the outboard motor without following this manual can lead to unsafe
conditions such as poor maneuverability, lack of control or fire.
z Loose clamp screws can lead to the release or displacement of the outboard
motor, possibly resulting in loss of control and/or serious personal injury.
Check the clamp screws for tightness before operating your outboard.
Keep the outboard motor in a vertical position when mounting.
ENOF01607-1
5
ENOM00025-0
Position … Above keel line
Place the outboard motor in the center of the boat’s transom.
1
2
1. Center of boat 2. Boat transom
ENOF01141-0
ENOM00026-0
Transom matching
Be sure that the anti ventilation plate of the outboard motor is 3050 mm
(1.22 in) below the bottom of hull. If the above condition cannot be met due
to the shape of the bottom of your boat, please consult your authorized
dealer.
20 INSTALLATION
ENON00930-0
Note
1
30-50 mm (1.2-2 in)
2
Do not use tools to tighten clamp screws. Over tightening could result in
damage to the clamp screws and clamp brackets.
ENON00002-0
Note
ENOF01608-0
A rope is not included in the standard accessories.
1. Bottom of hull 2. Anti ventilation plate
ENOW00007-1A
CAUTION
5 z Before running test, check the boat with
maximum loading capacity. Overloading or
incorrect weight distribution of the
weight may result in boat to lose control,
even swamping or capsizing. Make sure
that there is enough distance between bottom cowl and water surface to prevent
1 ENOF01626-0
water from entering the engine. z Make sure to mount the engine in correct
1. Clamp screw
position. If outboard motor is mounted incorrectly, water may intrude the engine from openings of the bottom cowl while
ENOW00945-0
CAUTION
cruising. Exposing the engine to such condition may result in severe damage to the engine. z Tighten the clamp screws sufficiency, otherwise falling down of outboard could be happened.
z Please inspect whether there is a loosening of the clamp screw or mounting
bolts before departure.
z Loosening may cause a dangerous situation, such as loss of control.
ENOM00830-1
Mounting the outboard motor
1. Set the outboard motor to appropriate position.
2. Tighten the clamp screws by turning their handles.
3. Secure the outboard motor to the boat with a rope to prevent accidental
loss of the outboard motor overboard.
21
PRE-OPERATING PREPARATIONS
ENOM00030-A
1. Fuel handling
ENOW000017-0
CAUTION
Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty.
ENOM00031-1
FUEL RATING
Use only major brand unleaded fuel meeting the following specifications: USA
and Canada — having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium
gasoline (92 [R+M]/2 Octane) is also acceptable. Do not use leaded gasoline.
Outside USA and Canada — Use unleaded gasoline with declared octane rating of
91 RON or over. Use of premium gasoline of 98 RON is also allowed.
ENOM00032-1
GASOLINES CONTAINING ETHANOL
The fuel system components on your TOHATSU outboard motor will withstand up to
10% ethyl alcohol (hereinafter referred to as the “ethanol”) content in the
gasoline. If the gasoline in your area contains ethanol, be aware of certain
adverse effects that can occur. Increasing the percentage of ethanol in the
fuel can also worsen these adverse effects. Some of these adverse effects are
caused by ethanol absorbing moisture in
the air, which leads to separation of the water/ethanol from the gasoline in
the fuel tank. Use of gasoline containing ethanol may accelerate: 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 gasoline containing ethanol cannot be avoided or presence of
ethanol is suspected in the gasoline, it is recommended to use a filter to
separate
6 water, and frequently check the fuel sys-
tem for leaks, mechanical parts for corrosion and abnormal wear. In case any
of such abnormality is found, discontinue the use of such gasoline and contact
our dealer immediately. If the outboard motor will only be used infrequently,
please see the remarks on fuel deterioration in the STORAGE chapter (P 56) for
additional information.
ENOW00975-0
CAUTION
When operating an outboard motor with gasoline containing ethanol, storing gasoline in the fuel tank for long periods should be avoided. Storing gasoline for long periods creates unique problems. In cars, ethanol blended fuels are normally consumed before they can absorb enough moisture to cause problems, but boats often sit idle long enough for separation phase to take place. In addition, internal corrosion may take place during storage if ethanol washes away the oil films protecting internal components.
22 PRE-OPERATING PREPARATIONS
ENOW00018-1
WARNING
Fuel leakage can cause fire or explosion, potentially leading to severe injury or loss of life. Every part of fuel system should be inspected periodically. Inspect for fuel leak, hardness or any alteration of rubber, expansion and/or corrosion of metals especially after long term storage. In case any indication of fuel leakage or degradation in fuel system is found, replace the part immediately before using the outboard motor.
ENOM00043-C
2. Fuel filling
z The static electricity may ignite the gasoline vapor during refueling.
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 Dismount fuel tank from the boat.
z Place the fuel tank away from every
source of ignition, such as sparks or open flames. z Do the work outdoors or
in a well ventilated area. z Wipe up gasoline well immediately if spilled.
ENOW00976-0
6
WARNING
After cleaning gasoline tank: z Wipe up gasoline well immediately if
spilled.
Do not fill the fuel tank over capacity. Under z If the fuel tank is disassembled for clean-
high temperature conditions, excessive gas-
ing, reassemble carefully. Incorre c t
oline may evaporate/leak through air vent
assembly may cause a fuel leak, possibly
screw when it is loose or open. Leaking of
leading to fire or explosion.
gasoline is a may lead to a dangerous fire z Dispose aged or contaminated gasoline in
hazard.
accordance with local regulations.
ENOW00028-1
WARNING
Consult an authorized dealer for details on handling gasoline, if necessary.
Gasoline and its vapor are very flammable and can be explosive.
When carrying a fuel tank containing gasoline: z Close the fuel tank cap and
air vent screw
of fuel tank cap, or gasoline may evaporate through the air vent screw and may
lead to a fire hazard. z Do not smoke.
ENOW00029-1
WARNING
When opening fuel tank cap, be sure to follow the procedure described below. Fuel could blast out if the fuel tank cap is opened by using another procedure when internal pressure of fuel tank is raised by heat from sources such as sun light.
When or before refueling: z Be sure to remove the static electricity
charged in your body before refueling.
PRE-OPERATING PREPARATIONS 23
1. Before opening fuel tank cap, turn air vent screw two times
counterclockwise to release air pressure in the fuel tank.
1 2
ENOM00037-1
3. Engine oil filling
ENOW00022-2
CAUTION
The engine oil is drained for shipping at the factory. Be sure to fill the engine oil to the proper level before starting the engine.
ENOF00209-B
1. Air vent screw 2. Fuel tank cap
2. Open the fuel tank cap slowly. 3. Fill the fuel not to over the shown
level.
1. Full line
1
ENOF00210-0
4. After filling the tank, close the tank cap.
ENOW00982-0
CAUTION
z Do not overfill engine oil, or engine oil
could leak and/or engine could be dam-
aged. If engine oil level is over upper limit
marks of oil level gauge, drain oil to level
lower than upper limit.
6
z Be sure that outboard motor is upright
when checking or changing oil.
z Wipe off engine oil well immediately if
spilled and dispose of it in accordance
with local fire prevention and environ-
ment protection regulations.
1. Place the engine in a vertical position. 2. Remove the top cowl and the
oil filler
cap. 3. Fill the engine through filler port with
recommended oil to the FULL mark. 4. Tighten the oil filler cap.
24 PRE-OPERATING PREPARATIONS
ENOW0002A-A
CAUTION
1
Use of engine oils that do not meet these requirements will result in reduced
engine life, and other engine problems.
2 3
FULL LOW
4
1. Oil filler cap
2. Oil level gauge
6
3. Upper level 4. Lower level
ENOF00239-B
Engine oil recommendation Use only high quality 4-stroke outboard motor oil to insure performance and prolonged engine life.
SAE: 10W-30 or 10W-40 API: SF,SG,SH,SJ, or SL
Engine oil viscosity must be selected from the following chart according to the average temperatures in your area.
10W-40
10W-30
-30 -20 -10 0 10 20 30 40 °C -22 -4 14 32 50 68 86 96 °F
ENOF00208-0
Engine oil volume Approximately 300 mL (10 fl.oz.)
PRE-OPERATING PREPARATIONS 25
ENOM00033-A
4. Break-In
Your new outboard motor and lower unit require break-in for the moving
components according to the conditions described in the following time table.
Please refer to ENGINE OPERATION section (See page 26) to learn how to
correctly start and operate the outboard motor.
ENOW00024-1
DANGER
Do not operate the outboard motor in closed area or area with not enough
ventilation. Exhaust gas emitted by the outboard motor contains carbon
monoxide that may cause dizziness, nausea, other health problem or even death
if inhaled continuously. During operation of the outboard motor: z Keep
peripheral area well ventilated. z Always stay on the windward side of emis-
sion.
ENOW00023-1
CAUTION
Operating the outboard motor without break-in can shorten 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.
ENON00008-2
Note
z During Break-in, run the outboard
motor at varied RPM less than specified
6
engine speed. Not following the proce-
dure may result in problems and may
shorten the product life.
z Break-in must be conducted under
load in the water in-gear with propeller
installed.
Throttle Position Speed
110 min Idle
10 min 2 hrs Less than 1/2
throttle
Approx. 3000 min-1 (rpm) max
23 hrs Less than 3/4
throttle
Full throttle run allowed for 1 min every 10 min
310 hrs
3/4 throttle
Approx. 4000 min-1 (rpm). Full
throttle run allowed for 2 min every 10
min
After 10 hrs
Full throttle available
26
ENGINE OPERATION
ENOM00042-F
Before starting
ENOM00044-D
1. Fuel feeding
ENOM00246-0
Oil Level checking
Check the engine oil level before each use. If the oil level is low or too
high, the life of the engine will be shortened significantly.(To properly
check the engine oil level follow the instructions, see page 44)
ENOW00029-1
WARNING
When opening fuel tank cap, be sure to follow the procedure described below.
Fuel could blast out if the fuel tank cap is opened by using another procedure
when internal pressure of fuel tank is raised by heat from sources such as sun
light.
1
7
2
1. Loosen the air vent screw on the tank cap by two turns.
2. Open the fuel cock.
1
FULL LOW
3
1. Oil level gauge 2. Upper level 3. Lower level
ENOF00239-A
ENOW00027-D
CAUTION
Before starting engine for the first time after reassembling engine or off- season storage, disconnect stop switch lock and crank approximately 10 times in order to circulate oil through the engine.
2
1. Air vent screw 2. Fuel cock
ENOF00213-1
ENOW00937-0
CAUTION
Be sure to close the fuel cock when the outboard motor is tilted up Otherwise, fuel could overflow.
ENGINE OPERATION 27
ENOM00045-H
2. Starting the engine
ENOW00958-1
WARNING
z Do not remove or install the top cowl after the engine has started.
z The exposed rotating engine parts cause serious injury.
ENOW00959-0
CAUTION
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 the engine.
ENOW00036-1A
CAUTION
When starting the outboard motor in the test tank, make sure that: 1. Water
level is at least 10 cm (4 in.) above
the anti-ventilation plate to avoid overheating of the engine. 2. Run at
idling only 3. Remove the propeller (See page 51)
ENOW00036-1
CAUTION
Operating outboard motor without cooling water will lead to overheating and damage on the outboard motor severely. In case the cooling water check port is not discharging water, stop the outboard motor immediately, check for any object, debris which may be blocking the cooling water check port. If you are unable to locate the cause, consult an authorized dealer immediately.
ENOW00032-B
CAUTION
Do not try to crank after engine has started.
1. Be sure to install the stop switch lock to the stop switch, and attach the
7 stop switch lanyard securely to the
operator or to the operator’s PFD (Personal Flotation Device.)
1
3
1
1. Stop switch lock
ENOF01609-1
2
1. Test tank 2. Water 3. Over 10 cm (4 in.)
ENOF00863-0
28 ENGINE OPERATION
2. Set the shift lever in the Neutral position.
N
N 2 F
F
1
3
ENOF00215-B
1. Shift lever 2. Neutral (N) 3. Forward (F)
3. Set the throttle grip to START position.
ENON00501-0
Note
Choke is not necessary when the engine is warm. Set the throttle grip to “RE-
START” position.
ENON00502-0
Note
If engine does not start with 4 or 5 times starting operation, push the knob
back and restart.
5. Pull the starter handle slowly until you feel engagement, keep pulling till you feel less resistance. Then pull it quickly. Repeat the procedure until the outboard motor is started.
1
2
7
1
1. Throttle grip
4. Pull the choke knob fully.
ENOF01107-0
1. Slowly 2. Quickly
ENOF01624-A
6. After engine starting, return the choke knob while check the engine
speeds. if the engine speeds unstable, pull the choke knob to operated.
7. Be sure to check that cooling water is coming out of the cooling water
check port.
1
1. Choke knob
ENOF00216-1
ENGINE OPERATION 29
ENOW00064-0
CAUTION
Engine may be hot immediately after operating and could cause burns if touched. Allow engine to cool down before attempting to carry the outboard.
arm before starting engine the outboard motor.
1. Remove the top cowl.
1
1. Cooling water check port
1
ENOF00223-2
ENOM00042-G
Emergency starting
ENOW00099-1
WARNING
When the emergency starter rope is used for starting engine; z Start in gear
protection does not work.
Make sure that shift is in neutral position. If the gear is in Forward or
Reverse, the boat can start moving immediately and may lead to accident and
personal injury. z Be careful that of your clothes or other items do not to
get caught in the rotating parts. z To prevent accident and injury by rotating
parts, do not re-attach flywheel cover or recoil starter and the top cowl
after the engine has been started. z Do not pull starter rope if any bystander
is around. z Attach engine stop switch lanyard to clothing or any part of body
such as wrist,
ENOF00217-1
1. Cowl latch
2. Loosen the three bolts (A, B, C) fas-
7 tening the tank. (Don’t remove the
tank fastening bolts.) A B
C
ENOF00218-0
3. Remove the three bolts (D, E, F) fastening the recoil starter. E
D F
ENOF00219-0
30 ENGINE OPERATION
4. Remove the recoil starter.
8. Set the shift lever in the Neutral position.
9. Pull the starter handle slowly until you feel engagement, keep pulling
till you feel less resistance. Then pull it quickly.
ENOF00220-0
5. Tighten the three bolts (A, B, C) fastening the tank and one bolt (D)
fastening the recoil starter.
A
ENOF00222-1
7
10. Once the outboard motor is started, do not reinstall the recoil starter and
D
C
B
top cowl.
ENOF00221-0
6. Insert the knotted end of the starter rope into the notch in the flywheel and wind the rope clockwise around the flywheel several turns.
ENOM00043-B
3. Warming up the engine
ENOW00932-1
CAUTION
Be sure to check that cooling water is discharged from the cooling water check port during warm up.
ENOF01610-0
7. Tie a loop in the another end of the emergency starter rope and attach
socket wrench, Both the loop and the wrench are provided in outboard motor
box.
Warm the engine at low engine speeds for about 3 minutes : above 5°C (41°F) 5 minutes at 2000 min-1 (rpm) : below 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.
ENGINE OPERATION 31
1
1. Cooling water check port
ENOF00223-2A
ENOM00044-A
Engine speeds
Idling speed after warming up.
Clutch in (In gear) 1200 min-1 (rpm)
Clutch off (Out of gear) 1300 min-1 (rpm)
ENOM00046-B
4. Forward, reverse, and acceleration
ENOW00037-1
WARNING
Before shifting into forward or reverse, make sure that boat is properly moored and outboard motor can be steered fully to the right and left. Make sure that no swimmer(s) is around of the boat.
ENOW00038-1
WARNING
z Attach the other end of emergency stop switch lanyard to the operator’s PFD
(Personal Flotation device) or arm and keep it attached during cruising.
z Do not attach the lanyard to a part of clothing that can be torn easily when
pulled.
z Arrange the tether so that will not be caught by any object when pulled.
z Be careful not to pull the lanyard accidentally during cruising.
Unintentional stop of engine can cause loss of control of outboard motor.
Rapid loss of engine power can lead to fall down or causing passenger(s) to be
thrown overboard.
ENOW00861-1
WARNING
Do not shift at high boat speed, or control may be lost, fall down or causing
passenger(s) to be thrown overboard. Leading to serious personal injury.
ENOW00867-1
WARNING
Sudden acceleration and deceleration may
7 cause passenger(s) to be thrown overboard
or fall down.
ENOW00862-1
CAUTION
Gear and clutch damage may occur if shifting at high engine speed. Engine must be in the slow idle position before shifting.
ENOW00863-0
CAUTION
Idle speed may be higher during warming up of engine. If shifted to Forward or Reverse during warming up, it may be difficult to shift back to neutral. In such case, stop engine, shift to neutral, and restart engine to warm up.
ENON00014-0
Note
Frequent shifting to forward or reverse can accelerate wear or degradation of
parts. In
32 ENGINE OPERATION
such case, replace gear oil earlier than the period specified.
ENOW00864-0
CAUTION
Do not increase engine speed unnecessarily when the shift is in neutral and reverse, or engine damage may occur.
2. When the engine reaches trolling (or idling) speed, quickly pull the shift
lever to the Neutral position.
3. The handle upright, turn the outboard motor at an angle of 180° and
quickly turn the shift lever to the Forward (F) side.
ENOM00890-B
Tiller handle type
ENOW00865-A
CAUTION
Do not force to shift when the throttle grip is
not in the fully closed position, otherwise,
steering system and/or shifting mechanism may be damaged.
ENOF00225-A
Acceleration
7
Open throttle grip gradually.
N
N 2 F
1
1. Shift lever 2. Neutral (N) 3. Forward (F)
F 3
ENOF00215-B
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 Forward position.
Reverse 1. Turn the throttle grip to reduce
engine speed.
1
1. Throttle grip
ENOM00049-B
5. Stopping the engine
ENOF01119-0
ENOW00868-1
WARNING
Be careful not to remove engine stop switch lanyard from engine accidentally while boat is running. Sudden stop of engine can cause loss of steering control, 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.
ENGINE OPERATION 33
2
1
ENOF01107-0
1. Throttle grip
2. Put the shift lever in the Neutral position. Run the engine for 2-3
minutes at idling speed for cooling down if it has been running at full speed.
3. Push the stop switch.
2
3
1
1. Fuel cock 2. Air vent screw
ENOF00227-1
ENOW00869-1
WARNING
After stopping the engine:
z Close the fuel cock and the air vent screw
on the fuel tank cap .
7
Emergency engine stopping Remove stop switch lock to stop the engine.
2 3
1
1. Shift lever 2. Stop switch 3. Stop switch lock 4. Hook
4
ENOF01611-1
4. Close the air vent screw and fuel cock.
1
1. Shift lever 2. Stop switch 3. Stop switch lock 4. Hook
4
ENOF00226-1
34 ENGINE OPERATION
ENOM00910-1
Spare emergency stop switch lock (For CE marking model) A spare emergency stop
switch lock is provided in the accessories bag. Make sure that spare stop
switch lock is available before operating outboard motor. When used as
described, the emergency stop switch clip and emergency stop switch lanyard
system stops the engine if the operator is thrown overboard. When an operator
falls into water, be sure to use spare emergency stop switch lock.
ENOM00050-0
7. Trim angle
ENOF00892-0
ENOW00043-1
WARNING
7
ENOM00920-A
6. Steering
ENOW00870-1
ENOF00891-0
z Adjust the trim angle when the engine is stopped.
z Do not put hand or finger in between outboard motor body and clamp bracket
when adjusting trim angle to prevent possible injury.
z Unsuitable trim position can cause loss of control of boat. When testing a
trim position, run the boat slowly initially to see if it can be controlled
safely.
WARNING
Sudden steering may cause passenger(s) to be thrown overboard or fall.
Tiller handle type
Right turn Move the tiller handle to the left Left turn Move the tiller handle
to the right.
ENOW00044-1
WARNING
Excessive trim up or down may cause unstable boat operation, loss of control
that may leads to accident during cruising. z For manual tilt model, If you
feel the trim
is improperly positioned, stop the boat and readjust trim angle before
continuing to cruise. z For outboard motor model with PTT switch on the bottom
cowl, do not operate the switch during while cruising, or control of boat may
be lost.
The trim angle of the outboard 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
operation.
ENOM00052-0
Proper trim angle The position of the thrust rod is correct if the hull is
horizontal during operation.
1
ENGINE OPERATION 35
ENOF00053-0
ENOF00051-1
1. Perpendicular to the water surface
2
1
7
3
ENOM00053-0
Improper trim angle (bow rises too
ENOF00229-0
high)
1. Thrust rod
Set the thrust rod lower if the bow of the
2. UP (Higher) 3. DOWN (Lower)
boat rises above horizontal.
Trim angle adjustment The transom angle adjustment 1. Stop the engine.
2. Shift into neutral position.
3. Tilt up the outboard motor.
ENOF00052-0
ENOM00054-0
Improper trim angle (bow dips into the water) Set the thrust rod higher if the
bow of the boat is below horizontal.
36 ENGINE OPERATION
4. Remove the thrust rod by pressing clip as shown picture.
ENOW00056-A
WARNING
When tilting up outboard motor with fuel joint for over a few minutes, be sure to disconnect fuel hose, or fuel may leak, potentially catching fire.
ENOW00057-1
2
CAUTION
Do not tilt up the outboard motor while
1
engine is operating, or no cooling water may be discharged, leading to engine seizure due
ENOF01612-0
to overheating.
1. Push 2. Pull
5. Reinstall the thrust rod in the desired
ENON00921-1
Note
position securely. 6. Gentry tilt down the outboard motor.
7
ENOM00060-A
8. Tilt up and down
After use, leave the outboard motor upright for a minute to drain the water
from inside the engine.
ENOM00222-0
Tilt up
ENOW00055-1
1. Close the fuel cock and tighten the air
WARNING
Do not tilt the outboard motor up or down when swimmer(s) and/or passenger(s)
are near to prevent them from being caught
vent screw of the tank cap. 2. Tilt up the outboard motor fully to
your side and press the tilt stopper knob inside to set it up.
between outboard motor body and clamp
bracket.
2
ENOW00048-1
WARNING
When tilting up or down, be careful not to place your hand between the swivel bracket and the stern bracket.
1
1. Fuel cock 2. Air vent screw
ENOF00227-1
ENGINE OPERATION 37
1
1. Tilt stopper
ENOF00231-0
ENOM00223-0
Tilt down
Pull the outboard motor to your side and
draw the tilt stopper knob out for tilting
down.
7
1
1. Tilt stopper
ENOF00231-A
38
REMOVING AND CARRYING THE OUTBOARD MOTOR
ENOM00070-H
1. Removing the outboard motor
ENOW00064-1
CAUTION
Engine may be hot immediately after operation and could cause burns if came in contact. Allow engine to cool down before attempting to carry the outboard.
ENOF01607-1 ENOM00071-A
2. Carrying the outboard motor
ENOW00068-1
WARNING
8
1. Cooling water check port
1
ENOF00223-2
Close air vent screw on fuel tank and fuel cock before carrying or storing
outboard motor and/or fuel tank, or fuel may leak, potentially catching fire.
ENOW00066-1
1. Stop the engine. 2. Close the fuel cock and tighten the air
vent screw of the tank cap. 3. Loosen clamp screws by hand. 4. Remove the
outboard motor from the
boat and completely drain the water from the gear case in a vertical position.
CAUTION
z Do not give a shock to an outboard motor during transportation.
z Do not carry or store outboard motor in any of positions described below.
Otherwise, engine’s exterior may be damaged or water may enter the cylinder
through the exhaust port and cause engine problems.
REMOVING AND CARRYING THE OUTBOARD MOTOR 39
ENOF01613-1
Keep the outboard motor in a vertical position when carrying. The optional outboard motor stand is recommended for keeping the outboard motor vertical both during transport and storage.
ENOF01627-0
ENOF01628-0
ENON00941-0
Note
When laying the outboard front-side
8
down, turn the clamp bracket 90° clock-
wise or anti-clockwise so that it does not
interfere with the ground. Then tighten up
the steering adjustment screw to maintain
its position (see page 41).
ENOF01614-1
ENOM00441-0
If the outboard motor must be laid down, be sure to drain the remaining fuel
in the fuel line and carburetor (see page 58). When laying down the outboard
motor, place front-side, starboard-side, or portside down on a cushion or any
softer surface shown below.
ENOM00072-1A
3. Trailering
ENOW00072-0
CAUTION
Trailering in the tilted position may cause damage to the outboard motor, boat, etc.
40 REMOVING AND CARRYING THE OUTBOARD MOTOR
ENOW00068-1
WARNING
Close air vent screw on fuel tank and fuel cock before carrying or storing outboard motor and/or fuel tank, or fuel may leak, potentially catching fire.
ENOW00071-0
CAUTION
2
1
The tilt support device supplied on your outboard motor is not intended for towing. It is intended to support the outboard motor while the boat is docked, beached, etc.
ENOF00074-B
1. Ground clearance should be provided sufficiently.
2. Transom saver bar
ENOW00067-0
ENOW00072-A
WARNING
CAUTION
Do not go under outboard motor tilted up even if it is supported by support bar, or
When trailering the outboard motor should accidental fall of outboard motor could lead
be in a vertical (normal running) position, to severe personal injury.
fully down. Trailering in the tilted position
may cause damage to the outboard motor,
boat, etc.
8
If trailering with outboard motor 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 posi-
tion.
When transporting a boat on a trailer with the outboard motor still attached, disconnect the fuel line from the outboard motor beforehand and keep the outboard motor in the normal running position or on a transom saver bar.
Tiller handle type
While transporting outboard motor attached to the boat on a trailer, properly
tighten the steering friction bolt to prevent the outboard motor from moving.
(page 41).
41
ADJUSTMENT
ENOM00073-0
1. Steering friction
EENOM00074-A
2. Throttle grip friction
Tiller handle type
ENOW00074-1E
WARNING
Do not overtighten the steering friction adjustment screw or it could result
in difficult handling of the outboard motor, resulting in the loss of control
causing an accident and could lead to severe injury.
ENON00949-0
Note
The steering friction adjustment screw is used to adjust the friction load of
the steering. Excessive tightening of the adjustment screw lt may cause damage
to the swivel bracket.
Steering friction can be adjusted in accordance with your preference by
turning the steering friction adjustment screw.
ENOW00074-1B
WARNING
Do not overtighten the throttle adjustment screw or it could result in difficult handling of the outboard motor, resulting in the loss of control causing an accident and could lead to severe injury.
Friction adjustment of the throttle grip can be made with the throttle adjustment screw.
2 1
3
ENOF00445-A
1. Increase 2. Decrease 3. Throttle friction adjustment screw
9
2
3
1
2
3
ENOF00237-0
1. Steering friction adjustment screw 2. Decrease 3. Increase
42
INSPECTION AND MAINTENANCE
ENOM00077-1
Care of your outboard motor
To keep your outboard motor in the best operating condition, it is very
important that you perform daily and periodic maintenance as suggested in the
maintenance schedules as follows.
ENOW00077-1
CAUTION
z Your personal safety and that of your passengers depends on how well you
maintain your outboard motor. Carefully read all of the inspection and
maintenance procedures described in this section.
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, frequent operation in brackish water, or for
commercial use, maintenance should be performed at shorter intervals. If in
doubt, consult your dealer for advice.
z We strongly recommend that you use only genuine replacement parts on your
outboard motor. Damage to your outboard motor arising from the use of other
than genuine parts is not covered under the warranty.
10
INSPECTION AND MAINTENANCE 43
ENOM00228-0
1. Daily Inspection
Perform the following checks before and after use.
ENOW00078-1
WARNING
Do not use outboard motor if any abnormality is found during pre-operation check otherwise it could result in severe damage to the motor or severe personal injury.
Item
Points to Check
Remedy
· Check the amount of fuel in the tank.
Fill fuel
Fuel System · Check for debris in the fuel filters.
Clean or Replace
· Check the rubber hoses for fuel leakage.
Replace
· Check for crack, leakage, damage in the fuel tank cap.
Replace
· Check for crack, damage in the gasket and tether. Fuel Tank Cap
· Check for leakage at full close.
Replace Replace
· Check for ratchet performance.
Replace
Engine Oil · Check the oil level, dirt and entering water.
Fill fuel or Replace
Electrical Equipment
· Check that the stop switch functions normally and make sure Remedy or replace
the lock plate is in right location.
· Check cords for loose connections and damage.
Correct or replace
· Check the spark plug for dirt, wear and carbon build-up.
Clean or replace
· Check that the carburetor choke valve functions normally.
Replace
Throttle System · Check carburetor linkage is working normally when turning the Correct
throttle grip.
· Check the rope for wear and chafing. Recoil Starter
· Check the ratchet engagement.
Replace Correct or replace
Clutch and Propeller Sys-
tem
· Check that the clutch engages correctly when operation the Adjust shift
lever.
· Visually check the propeller and shear pin for bent or damaged Replace
blades.
· Check that the split pin is on the propeller.
Installation of Motor
· Check the clamp screws attaching the motor to the boat for Tighten
tightness.
· Check the thrust rod installation.
Cooling Water
· After starting the outboard motor, make sure that water is being discharged from the cooling water check port.
Tools and Spares
· Check that there are tools and spare parts for replacing spark plugs, the
propeller, etc.
· Check that you have the spare rope.
· Check if the anode is securely installed. Other parts
· Check the anode for corrosion and deformation.
Repair if necessary Replace
10
44 INSPECTION AND MAINTENANCE
ENOM00229-2
Oil level checking
Check the engine oil level before each use. If the oil level is low, or too
high, the life of the engine will be shortened significantly. 1. Place the
engine in a vertical position. 2. Check the oil level by the oil level
gauge.
1
2 3
10
FULL LOW
4 ENOF00239-B
1. Oil filler cap 2. Oil level gauge 3. Upper limit 4. Lower limit
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
contaminated.
ENOM00082-B
Engine oil replenishing
ENOW00079-A
CAUTION
z Do not add engine oil of brand and grade other than existing one. In case
engine oil of other brand or grade is added, drain all oil and ask dealer for
treatment.
z In case other than engine oil such as gasoline is put in the oil chamber,
empty the chamber and ask dealer for treatment.
z When replenishing engine oil, be careful not to allow entry of foreign
matters such as dust and water into oil chamber.
z Wipe off engine oil well immediately if spilled and dispose of it in
accordance with local fire prevention and environment protection regulations.
z Do not replenish engine oil over upper limit. If overfilled, remove oil to
upper limit. If engine oil is over the upper limit, it can leak potentially
leading to engine damage.
If the oil level is low, or at lowest mark, add recommended oil to the FULL mark.
ENOF00240-A
INSPECTION AND MAINTENANCE 45
ENOM00083-C
Washing outboard motor
ENOW00920-0
CAUTION
When washing the outboard motor, be careful not to spray the water inside of
the top cowl, especially electrical components.
ENON00026-0
Note
It is recommended to check chemical properties of water on which your outboard
motor is regularly used.
If outboard motor is used in salt water, brackish water or water with high
acidic level, use fresh water to remove salt, chemicals or mud. And flush
cooling water passage after every use or before storing outboard motor for
long time.
ENOM00085-A
Flushing attachment
ENOW00921-0
CAUTION
Do not operate the engine when flushing the outboard motor with a hose joint
as this can cause damage to the outboard motor.
ENOW00922-0
CAUTION
To prevent the engine from starting when you are near the propeller, remove the stop switch lock.
1. Tilt down the outboard motor. 2. Remove the water plug from the bot-
tom cowl, and screw in the flushing plug as below picture. 3. Connect a water
hose. Turn on the water and adjust the flow.
Continue flushing the outboard motor for 3 to 5 minutes. 4. After the flushing, be sure to reattach the water plug. 5. Tilt up the outboard motor.
1
1. Flushing attachment (option)
ENOF00241-1
ENOM00085-A
Flushing by test tank
ENOW00081-1
WARNING
Do not start engine without removing pro-
10 peller, turning propeller out in the open may
lead to personal injury.
ENOW00082-0
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 gas which can be fatal if inhaled for any length of time.
46 INSPECTION AND MAINTENANCE
ENOW00036-1A
CAUTION
When starting the outboard motor in the test tank, make sure that: 1. Water
level is at least 10 cm (4 in.) above
the anti-ventilation plate to avoid overheating of the engine. 2. Run at
idling only 3. Remove the propeller (See page 51)
3
1
2
1. Test tank 2. Water 3. Over 10 cm (4 in.)
ENOF00863-0
10
INSPECTION AND MAINTENANCE 47
ENOM01106-1
2. Periodic Inspection
It is important to inspect and maintain your outboard motor regularly. Make sure to perform each service at interval specified in the chart below. Maintenance intervals are determined by the number of hours outboard motor has been used or number of months, whichever comes first. Recode inspection performed in the INSPECTION & MAINTENANCE LOG at the back of this manual.
Description
Fuel System
Carburetor*1 Fuel filter
Piping /Hoses Fuel tank Fuel tank cap
Ignition
Starting System
Spark plug
Ignition timing1 Starter rope1
Engine oil
Engine
Valve Clearance*1
Thermostat1 Propeller Shear pin and split pin Lower Unit Gear oil
Water pump1
Bolts and Nuts
Inspection intervals
First 20 Every 50 Every 100 Every 200 hours or 1 hours or 3 hours or 6 hours
or 1
month months months year
Inspection procedure
z
z Strip clean, and adjust.
Check and clean or Replace if
z
z
z
z
necessary.
Check and clean or Replace if
z
z
z
z
necessary.
z
z
z
z Clean.
Check and clean or Replace if
z
z
z
z
necessary.
Check gaps.
z
z
z Remove carbon deposits or
Replace if necessary.
z
z
z Check timing.
z
z
z
z Check for wear or chafing.
Replace z
Replace z
Replace z
Replace.
z
z
z Check & adjust.
z
z Check and Replace if necessary.
Check for bent blades, damage,
z
z
z
z
wear.
z
z
z
z Check or Replace if necessary.
Replace z
Replace Replace Change or replenish-oil and
z
z check for water leaks.
z
z
z Check for wear or damage.
z
z
z Retighten.
Remarks
0.80.9 mm (0.0310.035 in)
(See page 44) IN: 0.060.14 mm (0.00240.0055 in) EX: 0.110.19 mm
(0.00430.0075 in)
180 mL (6.1 fl.oz.) Replace impeller every 12 months.
10
48 INSPECTION AND MAINTENANCE
Inspection intervals
Description
First 20 Every 50 Every 100 Every 200 hours or 1 hours or 3 hours or 6 hours
or 1
month months months year
Inspection procedure
Sliding and Rotating Parts Grease Nipples
z
z
z
z Apply and pump in grease.
Outer Equipment
z
z
z
z Check for corrosion.
Anode
Check for corrosion and defor-
z
z
z
mation.
*1: Have this handled by your dealer.
Remarks
Replace if necessary.
Outboards used in rental, commercial, or other under severe condition as described below in detail require more frequent inspections and maintenance than shown in this manual.
z Continuous operation at maximum engine speed z Continuous operation at idling or trolling speed z Operation without appropriate warm up z Stopping without sufficient time for the engine to cool down z Frequent sudden acceleration and sudden deceleration z Frequent stop start operation z Frequent shifting operation z Frequent operation in acidic, polluted, muddy, sandy, or shallow water
Appropriate maintenance can prolong your engine life. Consult your Tohatsu authorized dealer for suitable maintenance interval depending on operating and environmental conditions.
10
INSPECTION AND MAINTENANCE 49
ENOM00091-B
Engine oil replacement
ENOW00091-1
CAUTION
You may be injured due to high engine temperatures if you fill engine oil just
after operation. Engine oil should be changed after the engine has been
cooled.
ENOW00092-1
CAUTION
z Do not overfill engine oil, or engine oil could leak and/or engine could be
damaged. If engine oil level is over upper limit marks of dip stick, drain oil
to level lower than upper limit.
z Be sure that outboard motor is upright when checking or changing oil.
z Stop the engine immediately if low oil pressure warning lamp or oil leak is
found, or engine could be severely damaged. Consult your dealer.
z Wipe off engine oil well immediately if spilled and dispose of it in
accordance with local fire prevention and environment protection regulations.
ENOW00090-0
CAUTION
Use of engine oils that does not meet these requirements will result in reducing engine life, and other engine problems.
ENOW00933-0
CAUTION
Engine oil mixed with dust or water will dramatically shorten the life of the engine.
ENOM00248-0
To change engine oil: Be sure to use recommended engine oil
(see page 13).
1. Stop the engine and leave it in a vertical position over 5 minutes.
2. Put an oil drain pan under the oil drain bolt.
3. Remove the oil drain bolt and completely drain oil from the engine.
1
ENOF01616-1
1. Drain hole
4. Apply oil on the sealing surface of the drain bolt. Tighten the bolt with
a new gasket.
Oil drain bolt specified torque 18N·m (13 ft·lb, 1.8 kgf·m) 5. Pull the bottom
of cowl latch to
unlock, lift and remove the top cowl. 6. Fill the engine through the filler
port
with the recommended oil to between the upper and lower limit mark on the oil
level gauge. 7. Tighten the oil filler cap. 8. Leave the outboard motor for 5
minutes and check oil level gauge. Add oil if necessary. 9. Install the top
cowl. 10. Start the engine and idling for 5 minuets, then check for no oil
leaks.
10
50 INSPECTION AND MAINTENANCE
1
2 3
FULL LOW
4
1. Oil filler cap 2. Oil level gauge 3. Upper level 4. Lower level
ENOF00239-B
10
ENOF00240-A
ENON00920-0
Note
Use only recommended engine oil (See page 24)
Oil volume needed for complete oil replacement Approximately 300 mL (10/11
US/Imp.oz.)
ENOW00925-0
CAUTION
Wipe off engine oil well immediately if spilled and dispose of it in
accordance with local
fire prevention and environment protection regulations.
ENON00031-0
Note
z If any amount of water is found in engine oil, making it milky white,
consult dealer.
z If engine oil is contaminated with fuel, emitting strong fuel smell, consult
dealer.
z Some oil dilution is normal if engine is idled or trolled for long periods,
especially in cooler water temperatures.
ENOM00098-B
Gear oil replacement
ENOW00076-1
WARNING
z Be sure that the 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 sure to lock the outboard motor in the tilt up position, or accidental
fall of outboard motor could lead to severe personal injury.
z Do not go under outboard motor in the tilt up position and locked, or
accidental fall of outboard motor could lead to severe personal injury.
1. Tilt down the outboard motor. 2. Remove the oil plugs (lower and
upper), and completely drain the gear oil into a pan.
INSPECTION AND MAINTENANCE 51
ENOW00095-0
CAUTION
Do not reuse oil plug gasket. Always use new gasket and tighten oil plug properly to prevent entry of water into lower unit.
ENOF01617-0
3. Insert the oil tube nozzle into the lower oil plug hole, and fill with
gear oil by squeezing the oil tube until oil flows out of the upper plug hole
and bubbles is disappeared to remove the air.
ENON00033-1
Note
Use genuine gear oil or the ones recommended (API GL-5: SAE #80 to #90).
Required volume: approx. 180 mL (6.1 fl.oz).
ENOF01618-0
4. Install the upper oil plug, and then remove oil tube nozzle and install
the lower oil plug.
Oil plug specified tightening torque 4N·m (3 ft·lb, 0.4 kgf·m)
ENOW00928-1
ENOF01619-0
CAUTION
If gear oil is spilled, wipe off immediately and dispose according to the local regulations.
ENON00032-1
Note
If the gear oil color appears to be milky color, contact your dealer.
10
ENOM00232-B
Propeller replacement
ENOW00084-0
WARNING
z Do not begin propeller removal and installation procedure with spark plug caps attached, shift in forward or reverse, main switch at other than “OFF”, engine stop switch lock attached to the switch, and starter key attached, or engine could accidentally start leading to serious personal injury. Disconnect battery cable if possible.
52 INSPECTION AND MAINTENANCE
z The propeller edge is thin and sharp. Wear the groves during replacement to protect your hands.
ENOW00086-1
CAUTION
z Do not install propeller without thrust holder, or propeller boss could be
damaged.
z Do not reuse split pin. z After installing split pin, spread bend both
end of the pin apart to lock propeller in place.
A worn-out or bent propeller will lower the motor’s performance, and cause
engine trouble. 1. Pull out the split pin from the propel-
ler boss and remove the propeller from the shaft.
1
2 3
10
ENOF00242-0
1. Shear pin 2. Propeller 3. Split pin
2. Remove the shear pin from the shaft.
3. Apply waterproof grease to the propeller shaft before installing a new
propeller.
4. Install the propeller with a new shear pin.
5. Install a new split pin into the propeller’s hole and bend end of the pin
apart to lock propeller in place.
ENOM00087-A
Spark plugs replacement
ENOW00087-1
WARNING
z Do not reuse spark plug, if the insulation is damaged or sparks can leak
through crack, potentially leading to electric shock, explosion and/or fire.
z Do not touch spark plugs immediately after stopping engine as they will be
hot and could cause severe burns if touched.
ENOW00929-0
CAUTION
Use only the recommended spark plugs. Spark plugs which have an different heat range may cause engine damage.
If the spark plug(s) is fouled, has carbon build up, or is worn, it should be replaced. When reusing spark plugs, remove dirt from the electrodes and check the spark plug gap.
1. Stop the engine. 2. Remove 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 are
provided in the tool bag. 5. Inspect the spark plug. Replace the spark plug
with wear on electrodes and if the insulators are cracked or chipped.
6. Measure the spark plug gap with a wire type feeler gauge. The gap should be 0.8-0.9 mm (0.031-0.035 inches). If the gap is out of specification, replace the spark plug with a new one Use spark plug NGK DCPR-6E.
INSPECTION AND MAINTENANCE 53
1 2
ENOF00085-0
1. Electrode 2. Spark gap (0.80.9 mm, 0.0310.035 in)
7. Install the spark plug by hand and turn it carefully to avoid cross-
threading.
8. Tighten the spark plug to the specified torque.
ENON00028-2A
Note
z Spark plug tightening torque: 18 N·m (13 ft·lb) [1.8 kgf·m] If a torque-
wrench is not available when you are installing a new spark plug, tighten it
1/4 to 1/2 a turn past finger-tight. If reusing a spark plug, tighten 1/12 a
turn past finger tight. Have the spark plug adjustment to the correct torque
as soon as possible with a torque-wrench.
10
ENOF01620-0
54 INSPECTION AND MAINTENANCE
ENOM00088-1A
Anode replacement
A sacrificial anode protects the outboard motor from galvanic corrosion. Anode
is located on the gear case, cylinder etc.. When the anode is eroded more than
1/3 of original size, replace it.
ENON00029-1
Notes
z Never grease or paint the anode. z At each inspection, re-tighten all the
anode attaching bolts. Those bolts may loosen if the
anodes are corroded.
10
ENOF01621-A
INSPECTION AND MAINTENANCE 55
ENOM00960-0
Grease point
Apply water proof grease to the parts shown below.
10
ENOF01622-A
56 INSPECTION AND MAINTENANCE
ENOM00100-A
3. Off-season storage
ENOW00934-0
WARNING
z Be sure to disconnect fuel connector except when operating engine.
z Fuel leakage is a fire or explosion hazard, which can cause serious injury
or death.
ENOW00097-0
WARNING
Be sure to use cloth to remove fuel remaining in the cowl and dispose of it in accordance with local fire prevention and environment protection regulations.
Before you put your outboard motor in storage, it is a good opportunity to have it serviced by your dealer. Be sure to use fuel stabilizer while running the motor before storage. (See page 57)
10
ENOM00101-1C
Engine
1. Wash the engine exterior and flush the cooling water system thoroughly
with fresh water. Drain the water completely.
Wipe off water with a cloth.
2. Remove the fuel hose from the outboard motor or close the fuel cock.
3. Drain all fuel from the fuel hoses, fuel pump, fuel filter (see page 58)
and carburetor (See page 58), and clean these parts.
Keep in mind that if gasoline is kept in the carburetor for a long time, gum and varnish will be developed, causing the float valve to stick, restricting the fuel flow. 4. Remove the spark plugs and put a teaspoon of engine oil or spray storage oil into the combustion chamber through the spark plug holes. 5. Pull the recoil starter several times to lubricate inside the cylinder.
ENOW00930-1
WARNING
z Be sure to remove stop switch lock to prevent the spark plugs from igniting.
z Put a cloth to spark plug hole and wipe up any spilled engine oil, when
cranking the outboard motor.
6. Change the engine oil (See page 49). 7. Change the gear oil in the gear
case
(See page 50). 8. Apply grease to grease point (See
page 55). 9. Place the outboard motor in the ver-
tical position under a dry condition.
ENOF01614-1
INSPECTION AND MAINTENANCE 57
ENOW00066-0
CAUTION
Do not carry or store outboard motor in any of positions described below. Otherwise, engine damage or property damage could result from leaking oil.
ENOF01613-1
ENON00941-0
Note
ENOF01628-0
When laying the outboard front-side down, turn the clamp bracket 90° clockwise or anti-clockwise so that it does not interfere with the ground. Then tighten up the steering adjustment screw to maintain its position (see page 41).
ENOM00441-0
If the outboard motor must be laid down, be sure to drain the remaining fuel
in the fuel line and carburetor (see page 58). When laying down the outboard
motor, place front-side, starboard-side, or portside down on a cushion or any
softer surface shown below.
ENOF01627-0
ENOM00950-0
Adding a fuel stabilizer
When adding a fuel stabilizer additive (commercially available), first fill
the fuel tank with fresh fuel. If the fuel tank is only partially filled, air
in the tank can cause the fuel to deteriorate during storage.
1. Before adding fuel stabilizer additive, drain the carburetor (See page
58).
2. Follow the instructions on the label when adding the fuel stabilizer
additive.
3. After adding the additive, let the outboard 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
10
ENON00891-1
Note
If your motor is used occasionally, it is recommended to use a high quality fuel stabilizer for the fuel and keep the fuel tank full to reduce condensation and evaporation.
58 INSPECTION AND MAINTENANCE
ENOM00970-B
Fuel system draining
ENOW00028-A
WARNING
For details on handling fuel, contact an authorized dealer.
Fuel and fuel vapors are extremely flamma-
ble and can be explosive. z If fuel is spilled, wipe it up immediately. z Keep
the fuel tank well away from sources
of ignition, e.g. sparks or open flames z Perform all work outdoors or in a
well
ventilated place.
ENOW00097-0
WARNING
Be sure to use cloth to remove fuel remaining in the cowl and dispose of it in accordance with local fire prevention and environment protection regulations.
1. Turn off the fuel cock.
10
ENOF01625-1
2. Remove the top cowl. 3. Place an approved rag under the
drain screw.
4. Loosen the carburetor drain screw. 1
1. Carburetor drain screw
ENOF01623-0
5. Leave the outboard motor in this position until all fuel has been drained.
6. When thoroughly drained, retighten the drain screw securely.
7. Check the drained fuel for the presence of water or other contaminants. If
either is present, refill the carburetor with fuel, and then drain the fuel
again. Repeat this procedure until no water or other contaminants are present
in the drained fuel.
ENOM00104-K
4. Pre-season check
The following steps must be taken when first using the engine after off-season
storage. 1. Check that the shift and throttle
function properly. (Be sure to turn the propeller shaft when checking the
shift function or else the shift linkage may be damaged.)
2. Change the engine oil (See page 49).
INSPECTION AND MAINTENANCE 59
3. Before starting the engine, disconnect stop switch lock and crank
approximately 10 times in order to circulate oil through the engine.
4. Fill fuel tank completely. 5. Start the engine and warm up the
engine for 3 minutes in the “NEUTRAL” position. 6. Run the engine for 5
minutes at the slowest speed. 7. Run the engine for 10 minutes at half
throttle. The oil used for storage inside the engine will be circulated out to
assure optimum performance.
3. Remove the spark plugs, and completely drain the water from the engine by
pulling recoil starter several times. Replace oil to the correct level. The
oil may need to be changed again after running a short period to get all
moisture completely out of the crankcase.
4. Inject a sufficient amount of engine oil through the spark plug holes.
Pull the recoil starter rope several times to circulate the oil throughout the
outboard motor.
ENOM00105-B
5. Submerged outboard motor
ENOW00098-0
CAUTION
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. The following are the emergency measures to be taken for a submerged
outboard motor. 1. Wash the outboard motor with fresh
water to remove salt or dirt.
2. Remove the engine oil drain screw and completely drain water and oil from
the engine.
ENOM00106-1
6. Cold weather precautions
If you moor your boat in cold weather at temperatures below 0°C (32°F), water
residue in water pump may freeze and may damage the pump, impeller, etc. To
avoid, submerge the lower half of the outboard motor into the water.
ENOM00107-A
7. Striking underwater object 10
ENOW00935-0
CAUTION
Striking the sea bottom or an underwater object may severely damage the outboard motor.
Follow the procedure below and consult a dealer as soon as possible. 1. Stop
the engine immediately. 2. Check the control system, gear case,
boat transom etc.
60 INSPECTION AND MAINTENANCE
3. Return to the nearest harbor slowly and carefully.
4. Consult a dealer check the outboard motor before operation again.
ENOF01145-0
ENOM00120-2
8. Auxiliary outboard motor operation
10
When the auxiliary outboard motor is not in operation, be sure to remove the stop switch lock, shift into forward, and then tilt the outboard motor up. Otherwise, over-rotation of the propeller due to water spray and water ingestion that could cause damage to the outboard motor.
61
TROUBLESHOOTING
ENOM00109-0
If you encounter a problem, check the list below to determine the cause and to
take the proper action. An authorized dealer will always be happy to provide
any assistance and information.
Engine failing to start Engine starting but stopping soon Poor idling Poor acceleration Engine speed abnormally high Engine speed abnormally low Boat speed low Overheating of engine
FUEL SYSTEM
Possible cause
z
zzzz
zzzz
zzzz
zz
zzzz
z
z
zzzz
zzzz
zzzz
zzzz
z
z
zz
z
z
Empty fuel tank z z z Deformed or damaged fuel hose
zz
Closed air vent on fuel tank
z z z Clogged fuel filter, fuel pump, or carburetor z Use of improper engine oil
z z Use of improper gasoline
Excessive supply of fuel z z z Poor carburetor adjustment
z z z Spark plug other than specified
zz zz
Dirt, soot, etc. on spark plug No spark or weak spark
Short circuit of engine stop switch
zz
Ignition timing incorrect
Lock plate not fitted to stop switch
Disconnection of wire or loose ground connection
11
ELECTRICAL SYSTEM
62 TROUBLESHOOTING
Engine failing to start Engine starting but stopping soon Poor idling Poor acceleration Engine speed abnormally high Engine speed abnormally low Boat speed low Overheating of engine
Possible cause
z
zz
zz
Incorrect adjustment of throttle link
z z Insufficient cooling water flow, clogged or defective pump
z zz
z z Faulty thermostat z z Cavitation or ventilation
z z z z z Incorrect propeller selection
z z z z z z Damaged and bent propeller
zz
z z Improper thrust rod position
z z z z z Unbalanced load on boat
z z z z z Transom too high or too low
zzz
z
Low compression
z
z Carbon deposits in the combustion chamber
Engine makes noise
Too much the valve clearance
OTHERS
11
63
ACCESSORIES KIT
ENOM00242-0
The followings are a list of the tools and spare parts provided with the
motor.
Service tools Spare parts
Items Tool bag Pliers Socket wrench Socket wrench Socket wrench handle Screwdrivers Screwdriver handle Emergency starter rope Spark plug Shear pin Split pin Stop switch lock
Quantity 1 1 1 1 1 1 1 1 1 1 1 1
Remark
10 × 13 mm 16 mm Cross-and straight-point ø41000 mm NGK: DCPR6E
12
64
PROPELLER TABLE
ENOM00245-0
Use a genuine propeller. A propeller must be selected so that the engine RPM
measured at wide open throttle while cruising is within the recommended range.
2.5: 45005500 min-1 (rpm) 3.5: 50006000 min-1 (rpm)
ENON00245-0
Note
Each size shows number of propeller blades × diameters × pitch.
Light boats Heavy boats
Propeller Mark 7 6 4.5
Propeller Size Diameter × pitch
3 × 188 × 178 mm 3 × 7.4 × 7.0 in
3 × 188 × 145 mm 3 × 7.4 × 5.7 in
3 × 188 × 110 mm 3 × 7.4 × 4.3 in
Material
Plastic Plastic Aluminum Plastic
Remarks
Standard Option Option Option
13
INSPECTION & MAINTENANCE LOG
Date
Engine Hour
Inspection/Maintenance Performed
Performed by
O W N E R’ S MANUAL
MFS 2.5C MFS .5C
5-4, Azusawa 3-Chome, Itabashi-Ku Tokyo 174-0051, Japan Tel: +81-3-3966-3117
Fax: +81-3-3966-2951 www.tohatsu.com
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>