TOHATSU MX40-50D3 Mid Range Instruction Manual

June 13, 2024
TOHATSU

MX40-50D3 Mid Range

Product Information

Product Model:

MX 40D3 MX 50D3

Manufacturer:

Tohatsu Corporation

Serial Number:

Your outboard motor has a unique serial number. The serial
number is identification of the outboard motor and is required for
warranty registration, filing a warranty claim, making technical
inquiries, and other occasions.

Important Safety Information:

Before installing, operating, or otherwise handling your
outboard motor, it is crucial to thoroughly read and understand the
Owner’s Manual and carefully follow all instructions. Pay special
attention to information preceded by the words DANGER, WARNING,
CAUTION, and Note to ensure safe operation at all times.

Product Usage Instructions

  1. Pre-Delivery Inspection: Before operating your
    outboard motor, make sure that the pre-delivery inspection has been
    properly done by an authorized TOHATSU dealer.

  2. Serial Number: Locate the serial number on the
    outboard motor and write it down along with the date of purchase
    for warranty registration, warranty claims, technical inquiries,
    and other occasions.

  3. Installation: Follow the instructions provided
    in the manual for proper installation of the outboard motor.

  4. Pre-Operating Preparations: Perform the
    necessary pre-operating preparations as described in the manual
    before starting the engine.

  5. Engine Operation: Follow the instructions for
    operating the outboard motor, ensuring safe and proper usage.

  6. Removing and Carrying the Outboard Motor:
    Learn the correct procedure for removing and carrying the outboard
    motor to prevent damage and ensure safety.

  7. Adjustment: If required, refer to the manual
    for adjustment procedures to optimize the performance of the
    outboard motor.

  8. Inspection and Maintenance: Regularly inspect
    and maintain the outboard motor according to the guidelines
    provided in the manual.

  9. Troubleshooting: In case of any issues or
    malfunctions, refer to the troubleshooting section of the manual
    for guidance.

  10. Tool Kit and Spare Parts: Familiarize yourself
    with the tool kit and spare parts that come with the outboard motor
    for emergency situations or routine maintenance.

  11. Propeller Table: Consult the propeller table
    section of the manual for information on propeller selection based
    on your requirements.

O W N E R’ S MANUAL

Original instructions
EN
MX 40D3 MX 50D3
OB No.003-1109 -ABC1

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
ENOM00003-1
PRE-DELIVERY INSPECTION
Make sure Pre-delivery inspection has been properly done by authorized TOHATSU dealer before operating your outboard motor.

4
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:

ENOF01300-1
Date of purchase:

ENOF01901-1

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2. Battery installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5. Warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 5. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 7. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 9. Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . . . . . . 44 1. Removing the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 3. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 9. ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10. INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 6. Cold weather precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 7. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 8. Operation with multiple outboard motors . . . . . . . . . . . . . . . . . . . . . . . . .67

11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 12. TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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. TOOL KIT AND SPARE PARTS

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 49). 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-B
MODEL FEATURE

2 Type

Model

S Transom heights
L

Tiller Handle

Remote Control

Manual tilt
*1: Option

ENOM00811-B
MODEL NAME EXAMPLE
MX50D3MFL

MX40D3

MF

EF

z

z

z

z

z

( z )*1 z

( z )*1 z

MX50D3

MF

EF

z

z

z

z

z

( z )*1 z

( z )*1 z

MX Model description
M(X)= Two stroke

50
Horse power

D
Product generation

A and up

3 Minor change
2 and up

M
Starter system
E= Electrical start
M= Manual start

F Steering system
F=Tiller handle

L
Shaft length
S= Short 15 in L= Long 20 in UL= Ultra long
25 in

SPECIFICATIONS 13

ENOM01600-0
MX40D3/50D3 MF, EF

Item

Model

MX40/50D3

2

MF

EF

Overall Length

mm (in)

1143 (45.0)

Overall Width

mm (in)

384 (15.1)

Overall Height

S mm (in) L mm (in)

1225 (48.2)

1352 (53.2)

Transom Height

S mm (in) L mm (in)

403 (15.9)

530 (20.9)

Weight*1

S kg (lb) L kg (lb)

72 (159) 73.5 (162)

— 89 (196)

Engine Type

2 stroke

Number of Cylinder Piston Displacement

cm3 (cu.in.)

3 697 (42.53)

Bore x Stroke

mm (in)

68 x 64 (2.68 x 2.52)

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)

29.4 (40) 37.0 (50) 5000 – 5800 750 900

Exhaust System

Through-hub exhaust

Lubrication System

Gasoline oil mixed type

Cooling System

Water cooling (with thermostat)

Starting System

Manual starter

Electric starter motor*2

Ignition System

Flywheel Magneto CD Ignition

Alternator

12V – 11A

Steering Angle

Degree

80

Trim Angle*3

Degree

-8 – 12

Trim Position

6

Tilt Up Angle*3

Degree

63

Gear Shift

Dog clutch (F-N-R)

Gear Reduction Ratio

1.85 (24:13)

Remark: Specifications subject to change without notice. 1 With propeller. 2 With manual starter. *3 Transom angle is at -12° Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).

14 SPECIFICATIONS

Service data

Model

MX40/50D3

Item

MF

EF

2

Fuel

Fuel Tank Capacity

Unleaded Regular Gasoline : R+M/2: 87 or higher RON: 91 or higher

L (US gal)

25 (6.6) Separate

Engine Oil

Grade Genuine two stroke engine oil or NMMA certified TC-W3 outboard oil

Engine Oil Mixing Ratio

Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1

Gear Oil

Grade mL (US/Imp.oz)

API:GL-5, SAE:80-90 500 (16.9/17.6)

Battery (minimum requirements)

64Ah/5HR, 70Ah/20HR, 512CCA

Spark Plug

NGK B8HS-10 or BR8HS-10

Spark Plug Gap

mm (in)

0.9-1.0 (0.035-0.039)

Tightening torque
Gear Oil Plug Propeller Nut Spark Plug

4N · m (3 ft · lb, 0.4 kgf · m) 35N · m (25 ft · lb, 3.25 kgf · m) 27N · m (20 ft · lb, 2.7 kgf · m)

PARTS NAME
ENOM01653-0
MX40D3MF/50D3MF, EF

1 19 18
2

3

4

15

5 14
13

22

6

12

7

8

11

9

10

20 16 21
17 5

24

15
3
23
25

1 Tilt Handle 2 Top Cowl 3 Hook Lever 4 Water Check Port 5 Reverse Lock Lever 6 Water Plug 7 Anti-ventilation Plate 8 Trim Tab 9 Propeller 10 Oil Plug (lower) 11 Water Strainer

12 Oil Plug (upper) 13 Clamp Bracket 14 Thrust Rod 15 Clamp Screw 16 Throttle Grip 17 Throttle Friction Screw 18 Shift Lever 19 Starter Handle 20 Stop Switch 21 Choke Knob 22 Anode

23 Main switch 24 Fuel Filter 25 Spark Plug

ENOF1902-D1

16 PARTS NAME
ENOM00822-0
Fuel tank

2

3

1

3

6
1 Fuel Gauge 2 Air Vent Screw 3 Fuel Tank Cap 4 Fuel Connector (Engine
side) 5 Primer Bulb 6 Fuel Connector (Fuel tank
side)

5 4
ENOF00127-G1

17
LABEL LOCATIONS
ENOM01659-0
Warning label locations

1, 2

3, 4

4

6 5
7
8

ENOF01955-5A

18 LABEL LOCATIONS
1, 3. Read owner’s manual.

3F0X72185-0
2. Engine stop switch. (See page 38).
4

314X72185-0
5. Warning regarding gasoline (See page 25).

ENOF00131-B
4. HOT SURFACE Can cause burns. Do not touch when operating or immediately after the engine has stopped.

6. Warning regarding page 25).

ENOF00005-E
gasoline (See

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.

ENOF00005-L

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.

7. Warning regarding gasoline (See page 25).
ENOF00005-M
8. Warning regarding gasoline (See page 25).
ENOF00005-F

LABEL LOCATIONS 19
4

20 LABEL LOCATIONS
ENOM01001-0
Serial number label locations

Outboard Motor 1)

Rated Power:

M a s s :

4

Serial No.

Made in Japan

1. Model code (Model name) 2. Rated power 3. Dry mass weight 4. Serial No. 5. Manufacture name 6. Manufacture 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

ENOF01904-A

BF 2026

BG 2027

21
INSTALLATION

ENOM00024-A
1. Mounting the outboard motor on boat

ENOW00006-1B

WARNING

To avoid personal injury or damage of equipment, make sure the allowable lifting capacity of the hoist is at least twice the weight of the outboard motor. Do not allow the lift hook or chain from the hoist to come in contact with any part of the outbord motor during lifting.

ENOW00009-2A
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 and/or mounting hardware can lead to the release or displacement of the outboard motor, possibly resulting in loss of control and/or serious personal injury. Be sure that fasteners are tightened to the specified torque. Check the fasteners for tightness before operating your outboard.
5 z Be sure to use outboard mounting hard-
ware included in the outboard motor package or their equivalents in terms of size, material, quality and strength.
Outboard motor mounting must be performed by trained service person(s) using lift or hoist with sufficient capacity.

ENOM00025-C
Position … Above keel line
Single-engine Installation Place the outboard motor in the center of the boat’s transom.
1

ENOW00006-1

ENOF01313-0
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.

1. Center of boat 2. Boat transom

2
ENOF01141-0

22 INSTALLATION

ENOM01201-0
Twin-engine Installation When installing two outboard engines, be sure to keep an interval of approximately 470-660 mm (18.5-26 in) between the two.
1

even swamping or capsizing. Make sure that there is enough distance between bottom cowl and water surface to prevent water from entering the engine. z Make sure to mount the engine in correct position. If outboard motor is mounted incorrectly, water may intrude the engine from openings of the bottom cowl while cruising. Exposing the engine to such condition may result in severe damage to the engine.

ENOM00832-0
Mounting the outboard motor

5
1. Approx 580 mm (22.8 in)

ENOF01823-0

1. Set the outboard motor to appropriate position.
2. Tighten the clamp screws by turning

ENOM00026-0
Transom matching
Be sure that the anti ventilation plate of the outboard motor is 10-30mm (0.41.2in.) 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.

their handles. 3. Secure the clamp brackets to the
transom board using bolts, flat washers and nylon locking nuts. 4. Secure the outboard motor to the boat with a rope to prevent accidental loss of the outboard motor overboard.

ENON00930-1
Note

1
10-30 mm (0.4-1.2 in)
2

z Do not use tools to tighten clamp screws. Over tightening could result in damage to the clamp screws and clamp brackets.
z Do not reuse nylon locking nut.

ENOF01344-0
1. Bottom of hull 2. Anti ventilation plate
ENOW00007-1
CAUTION

ENON00002-0
Note
A rope is not included in the standard accessories.

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,

INSTALLATION 23

ENON00948-0
Notes

z Apply sealing agent, such as silicone

sealant between the bolts and the

transom board holes before tightening

1

the bolts.

z Do not reuse nylon locking nut.

2
4
1. Clamp Screw 2. Washer (small diameter) 3. Washer (large diameter) 4. Bolt (12 mm × length 105 mm) 5. Nylon locking nut

3
5
ENOF00610-0

234 (9.21″) 117 (4.61″) 117 (4.61″)
25 (0.98″) 25 (0.98″) ø13 204 (8.03″) 102 (4.02″) 102 (4.02″) ø13
1. Top of transom

1
39 (1.54″) 64 (2.52″) 89 (3.50″)
222 (8.74″) 26 (1.02″) 248 (9.76″)
ENOF00611-0

ENOW00008-2

CAUTION

z Install upper mounting bolts from the boat side. Exposing threaded side of bolts on the boat side can casue personal injury.
z Tighten the bolts securely, otherwise the outboard motor could fall down.

ENOM00029-A
2. Battery installation

ENOW00012-1

WARNING

5

Battery electrolyte contains sulfuric acid

and is hazardous, causes a burn if come in

contact with your skin, and poisonous 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

can cause serious burn or, if come in con-

tact with your eye, loss of sight. Use

safety glasses and rubber gloves.

In case you came in contact with battery

electrolyte: z For skin, flush thoroughly with water. z For eye, flush thoroughly with water, and

then seek immediate medical treatment.

In case battery electrolyte is swallowed: z Seek immediate medical treatment.

ENOW00013-A

WARNING

Battery generates explosive hydrogen gas. Be sure to: z Charge the battery in a well-ventilated
place.

24 INSTALLATION

z Place the battery away from any source of fire, sparks and open flames such as burners or welding equipment.
z Do not smoke near the battery when the battery is charging.
z Do not charge the battery when the electrolyte level is low. Otherwise, the battery will be damaged and may cause malfunction.

  • The battery should be purchased separately and is not supplied with the outboard motor.
    1. Place the battery box in a convenient position away from possible water and moisture. Securely fasten both the box and the battery so they do not shake loose.

ENOW00014-0

2. Connect the positive lead (+) to the

CAUTION

positive terminal (+) of the battery, and then connect the negative lead

z Make sure that the battery leads do not

(–). When disconnecting the battery

get stuck between the outboard motor

5

and boat when turning, etc.

z The starter motor may fail to operate if

the leads are incorrectly connected.

always remove the negative lead (–) first. After connecting the positive terminal (+), securely place a cap on it

z Be sure to correctly connect the (+) and

to prevent short circuits.

(–) leads. If not, the charging system will

be damaged.

z Do not disconnect the battery leads from

battery while the engine is operating, the

electrical parts could be damaged.

z Always use a fully charged battery.

ENOW00015-1

CAUTION

Do not use a battery that is not recommended. Use of a battery not recommended can lead to poor performance of, and/or damage to the electrical system.

1
1. Battery cord (red) 2. Battery cord (black)

2
ENOF00022-1

ENON00006-1E
Note
Minimum battery requirements: 12v 64Ah/5HR, 12v 70Ah/20HR, 512 Cold Cranking Amps (CCA). Larger capacity battery is required when it is used under a freezing condition. Recommend connecting only the engine battery cables to the starting battery. Specifications and features of battery vary by manufacturers. Consult the manufacturer for details.

25
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 63) 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.

26 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-B
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 27

1. Fully open the air vent screw on the fuel tank cap and release internal pressure. 1 2
ENOF00027-B
1. Air vent screw 2. Fuel tank cap
2. Open the fuel tank cap slowly. 3. Fill the fuel carefully not to overflow.

ENOW00603-0

CAUTION

Do not mix different brands of oil. Mixing different brands of oil, or different types of oil even if the brand is the same, may cause gelling, resulting in possible filter screen blockage. This could result in serious engine damage because of impaired lubrication performance.

Use a genuine two stroke engine oil or ones recommended (TC-W3). Refer to your Distributor. Use of other two stroke engine oil is not recommended.

Pre-mixing type

6

Add engine oil into fuel tank. The mixing

ratio of gasoline and oil is 50:1. Make sure

that gasoline and oil are mixed well. The

mixing ratio during break in is 25:1.

SAFE FILL LEVEL 25 L
NIVEAU MAXIMUM

ENOF00030-A

4. After filling the tank, close the fuel tank cap.
ENOM01660-0
3. Engine oil recommendation

ENOW0002A-A

CAUTION

Use of engine oils that do not meet these requirements will result in reduced engine life, and other engine problems.

Mixing Ratio

During break-in After break-in

Engine Oil : Gasoline 25 : 1 50 : 1

Fuel by Oil Mixing (25:1, 50:1)
Oil

1.0L

25 : 1

(25:1)

0.5L 0.4L 0.2L
0 2L

(10 : 0.4) (10 :0.2)

50 : 1

10L Gasoline

(25:0.5)
25L 30L
ENOF01708-0

28 PRE-OPERATING PREPARATIONS

ENOM01003-0
Engine oil ­ gasoline mixing procedure
ENOW00937-1
CAUTION
z Do not use other than two stroke engine oil with specified grade, or the engine may be damaged.
z Do not use fuel prepared in other than specified mixing ratio.
– Lack of engine oil can cause severe engine problems such as piston seizure.
– Excess of engine oil can shorten spark plug life, and/or cause increase of noxious exhaust.
For engine oil and gasoline mixing ratio,
6 refer to table in previous page.
When portable fuel tank is used for operation of outboard motor(s): 1 Pour engine oil into fuel tank, and then, gasoline. 2 Put cap on the tank, and close tightly. 3 Close air vent plug tightly.
ENOW00938-0
WARNING
Loose cap or air vent plug can cause leak of fuel.
4 Shake the tank to mix engine oil and gasoline well.
For boat with built in fuel tank: 1 Prepare separate fuel container for pre- mixing.

ENOF01709-0
2 Pour engine oil into fuel container, and then, gasoline.
3 Put cap on the container, and close tightly.
4 Shake the container to mix engine oil and gasoline well.
5 Pour the fuel into fuel tank.
ENON00922-1
Notes
z It is recommended to pre-mix by using separate fuel container. Avoid mixing the oil and gasoline in the built in fuel tank on the boat.
z If mixing in built-in fuel tank on the boat, allow it to mix well by pouring engine oil into the tank little by little while pouring gasoline into the tank.

PRE-OPERATING PREPARATIONS 29

]ENOM00033-%
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 timetable.
ENOW00024-A
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 of the product. 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.

ENOM01004-0
Fuel mixing ratio for break-in Gasoline 25: Genuine Engine Oil 1
6
ENON00008-2
Note
z During Break-in, run the outboard motor at varied RPM less than specified engine speed. Not following the procedure 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

30 PRE-OPERATING PREPARATIONS

ENOM00039-%
5. Warning system

If outboard motor encounters an abnormal condition of fault engine speed will be limited (engine will not be stopped).

ENOM00041-)
Warning indicators, faults and remedy

Warning indicators

Low speed ESG

High speed ESG

ON

ON

Description of faults
Engine speed exceeds maximum allowable min-1 (rpm)
Over heating

Remedy
1

6

High speed ESG (Electronic Safety Governor)

High speed ESG is a device to prevent over revolution of the engine. If the load to the engine becomes light for

some reason, it runs at a higher speed than the usual. In such the case, the buzzer sounds and the ESG is activated not to ignite the spark plug. Therefore, the engine speed varies and is controlled under 6300 min-1

(rpm).

Low speed ESG

Low speed ESG is a device to prevent the engine from getting damage. If the engine has problems regarding

engine temperature, the low speed ESG is activated not to ignite the spark plug. Therefore, the engine speed varies and is controlled under 3500 min-1 (rpm).

Remedy 1. Reduce the speed to less than half open throttle, and move to safe place quickly,
and stop the engine. Check the propeller for bent or damage on blades. Consult an authorized dealer if engine shows the same result even after replacing propeller with a new one. 2. Move to safe place quickly, and check if cooling water is discharged from the water check port at idle speed and stop the engine. Remove any foreign matter on the gear case and propeller if necessary. Consult an authorized dealer if no discharge of cooling water.

31
ENGINE OPERATION

ENOM00042-0
Before starting

ENOW00022-B

CAUTION

Be sure to mix the engine oil with gasoline (Follow the instruction. See page 28)

1. Fully open the air vent screw on the fuel tank cap. 1
2

ENOF01710-0

ENOW00027-C

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 the engine oil.

ENOM00044-E
1. Fuel feeding
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. Air vent screw 2. Fuel tank cap

ENOF00027-B

2. Open the fuel tank cap slowly and release internal pressure completely.

After that, close the fuel tank.

3. Connect the fuel connector to the

engine and fuel tank.

7

1

3

2
1. Fuel connector 2. Pull 3. Insert

ENOF01905-0

2 1

1. Pull 2. Insert

ENOF00861-A

32 ENGINE OPERATION

4. Squeeze primer bulb until it becomes stiff to feed fuel to carburetor. Point the arrow mark upward when priming.
1

2. Run at idling only 3. Remove the propeller
(See page 58)
3

1

2

1. Engine side

ENOF00862-0

2

2. Fuel tank side

ENOF00863-0

Do not squeeze primer bulb with engine running or when the outboard motor is

1. Test tank 2. Water 3. Over 10 cm (4 in.)

tilted up to avoid fuel from overflowing.

ENOM00045-A
2. Starting the engine

ENOW00036-1

CAUTION

7

Operating outboard motor without cooling

ENOW00958-1

water will lead to overheating and damage on

WARNING

the outboard motor severely. In case the cooling water check port is not discharging

z Do not remove or install the top cowl after the engine has started.
z The exposed rotating engine parts cause serious injury.

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.

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.

ENOW00032-A

CAUTION

Do not keep turning starter motor for over 5 seconds, or the battery may be consumed, potentially making the engine starting impossible and/or damaging the starter. If cranking over 5 seconds fails to start engine, return main switch to “ON”, and crank engine again after 10 seconds or more. Do not try to crank after engine has started.

This model is provided with start in gear protection.

ENGINE OPERATION 33

ENON00010-1
Note
Start-in-gear protection prevents the engine from starting at other than neutral shift. In-gear starting of engine will move the boat immediately, potentially leading to fall down or causing passenger(s) to be thrown overboard.
ENOM01662-A
Tiller handle type
1. Be sure to install the stop switch lock to the stop switch, and attach the stop switch lanyard securely to the operator or to the operator’s PFD (Personal Flotation Device.) 1
2

3. Set the throttle grip to START position. 3

4

2

1
1. Throttle grip 2. START position 3. Full closed 4. Full opened

ENOF01908-1

4. Pull the choke knob fully.

7

ENOF01906-0
1. Stop switch lock 2. Stop switch
2. Set the shift lever in the Neutral position.

1
1. Choke knob

ENOF01909-0

2 1

1. Shift lever 2. Neutral

ENOF01907-0

ENON00501-0
Note
Choke is not necessary when the engine is warm. Set the throttle grip to “START” position.
ENON00502-0
Note
If engine does not start with 4 or 5 times starting operation, push the knob back and restart.

34 ENGINE OPERATION

(For manual starter type)
4. 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.

6. Make sure that water is being discharged from cooling water check port.

1

2

2 3

1
ENOF01911-0

1. Slowly 2. Quickly 3. Starter handle

ENOF00519-0

1. Cooling water check port 2. Idle port
ENOM00042-F
Emergency starting

7 (For electrical starter type)

ENOW00099-1

4. Push the starter switch button and release the button when the engine has started.

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

ENOF01910-1

and the top cowl after the engine has been started.

5. Return the choke knob fully after engine has 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,

arm before starting engine the outboard

motor.

1. Remove the top cowl.

ENGINE OPERATION 35

ENOF01345-0
2. Remove starter lock cable from recoil starter by loosing starter cable lock screw.

ENOF01961-0
5. Tie a loop to other end of the emergency starter rope and attach socket wrench that is included in the tool kit.

7

ENOF01959-0
3. Remove the bolts (3pcs) and remove the recoil starter.
ENOF01960-0
4. Insert the knotted end of the starter rope into the notch in the flywheel and wind the rope clockwise around the flywheel several turns.

ENOF01915-0

ENOW00860-0

CAUTION

Be sure to keep the harness away from the rotation parts.

6. Be sure to install the stop switch lock to the stop switch, and attach the stop switch lanyard securely to the operator or to the operator’s PFD (Personal Flotation Device.)
7. Set the shift lever in the Neutral position.
8. Pull the starter handle slowly until you feel engagement, keep pulling till you feel less resistance, then pull it quickly.

36 ENGINE OPERATION

9. Once the outboard motor stated, do not reinstall recoil starter and top cowl.
ENOM0004B-0
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.

ENOM00046-A
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.

Warm the engine at low engine speeds for about

ENOW00967-0

WARNING

3 minutes : above 5°C (41°F)

z Attach the other end of emergency stop

5 minutes at 2000 min-1 (rpm) :

switch lanyard to the operator’s PFD (Per-

above 5°C (41°F)

sonal Flotation device) or arm and keep it

7

This allows the lubricating oil to circulate to all parts of the engine. Operating the

attached during cruising. z Do not attach the lanyard to a part of
clothing that can be torn easily when

engine without warm up shortens the

pulled.

engine’s life.

z Arrange the lanyard so that will not be

caught by any object 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 fall down or causing passen-

ger(s) to be thrown overboard.

2
1. Cooling water check port 2. Idle port

1
ENOF01911-0

ENOM00044-A
Engine speeds
Idling speed after warming up.

Clutch in (In gear) 750 min-1 (rpm)

Clutch off (Out of gear) 900 min-1 (rpm)

ENOW00042-1
WARNING
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 be damaged.
z Do not shift into Reverse during cruising, or control may be lost, fall down or causing passenger(s) to be thrown overboard. Leading to serious personal injury, and steering system and/or shifting mechanism may be damaged.

ENGINE OPERATION 37

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 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 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.

ENOM00890-A
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.

Forward

1. Turn the throttle grip to reduce

engine speed.

7

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.

2. When the engine reaches trolling (or

idling) speed, quickly pull the shift

lever to the Reverse position.

38 ENGINE OPERATION
Acceleration Open throttle grip gradually.

3

2

1

boat to be thrown forward due to inertial force.
Tiller handle type
1. Turn the throttle grip to the slow position.
3

1. Shift lever 2. Forward 3. Reverse
3
7

ENOF01916-0

4
1
1. Throttle grip 2. START position 3. Full closed 4. Full opened

2
ENOF01908-1

4

2

1
1. Throttle grip 2. START position 3. Full closed 4. Full opened
ENOM00049-A
5. Stopping the engine

ENOF01908-1

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 for a few seconds to stop the engine.
1

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

1. Stop switch

ENOF01918-0

ENGINE OPERATION 39

ENOW00869-1
WARNING
After stopping the engine: z Close the air vent screw on the fuel tank
cap. z Disconnect the fuel connector from the
engine and the fuel tank. z Disconnect the battery cable, after each
use.
Emergency engine stopping Remove stop switch lock to stop the engine.
1 2

ENOM00920-0
6. Steering

ENOF00891-0

ENOW00870-1

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.
7

1. Stop switch 2. Stop switch lock

ENOF01919-0

ENOM00910-1
Spare emergency stop switch lock 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

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.

40 ENGINE OPERATION

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.

ENOW00044-1A

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.

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.

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

7

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.

ENOF00053-0

1 1 2

ENOF00051-1
1. Perpendicular to the water surface
ENOM00053-0
Improper trim angle (bow rises too high) Set the thrust rod lower if the bow of the boat rises above horizontal.

1. Thrust rod 2. Higher 3. Lower

3

ENOF00674-A

ENGINE OPERATION 41

Trim angle adjustment (Manual tilt type) The transom angle adjustment 1. Stop the engine. 2. Shift into neutral position. 3. Tilt up the outboard motor. 4. Remove the thrust rod as shown pic-
ture.

1

2

3

ENOF01238-1

1. Push in 2. Rise the stopper 3. Pull out
5. Reinstall the thrust rod in the desired position securely.
6. Gentry tilt down the outboard motor.

ENOM00060-A
8. Tilt up and down

ENOW00048-1

WARNING

When tilting up or down, be careful not to place your hand between the swivel bracket and the clamp bracket.

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

CAUTION

Do not tilt up the outboard motor while

engine is operating, or no cooling water may

be discharged, leading to engine seizure due

to overheating.

7

ENON00921-1
Note
After use, leave the outboard motor upright for a minute to drain the water from inside the engine.

ENOW00055-1

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 between outboard motor body and clamp bracket.

ENOM00062-1B
Tilt up Push the reverse lock lever down until it
stops. (This is the tilt up position.) Then,
tilt the outboard motor all the way up
until it is locked in place.

42 ENGINE OPERATION

1 2

2. Tilt down position 3. Tilt up position
ENOM00068-A
9. Shallow water operation

3
1. Reverse lock lever 2. Tilt down position 3. Tilt up position
7

ENOF00059-0

ENOW00051-0

WARNING

During shallow water operation, be careful not to place your hand between the swivel bracket and the clamp bracket. Be sure to tilt the outboard motor down slowly.

ENOW00053-0

CAUTION

While in shallow water drive position, do not operate the outboard motor in Reverse. Operate the outboard motor at slow speed and keep the cooling water intake submerged.

ENOF01317-0
ENOM00063-1
Tilt down Pull the reverse lock lever upward until it comes to a stop (This is the tilt down position), lift up the outboard motor to free it from the reverse lock, then release to lower the outboard motor.
1

ENOW00054-1

CAUTION

Do not over tilt the outboard motor when driving in shallow water, or air may be sucked through water inlet and sub-water inlet, potentially leading to engine overheating.

2

2 3

1
1. Water inlet 2. Sub-water inlet

ENOF01144-0

1. Reverse lock lever

ENOF00059-0

1. Shallow water running position: Put the reverse lock lever in the tilt up position, and tilt up the outboard motor to put the outboard motor in the shallow water running position.
1
2

3
ENOF00059-0
1. Reverse lock lever 2. Tilt down position 3. Tilt up position
2. Return to normal running position: Put the reverse lock lever in the tilt down position, slightly lift up the outboard motor, and then put it down.
1
2

3
1. Reverse lock lever 2. Tilt down position 3. Tilt up position

ENOF00059-0

ENGINE OPERATION 43
7

44
REMOVING AND CARRYING THE OUTBOARD MOTOR

ENOM00070-A
1. Removing the outboard motor

ENOW00006-1B

WARNING

To avoid personal injury or damage of equipment , make sure the allowable lifting capacity of the hoist is at least twice the weight of the outboard motor. Do not allow the lift hook or chain from the hoist to come in contact with any part of the outbord motor during lifting.

ENOW00064-1

CAUTION

ENOM00071-A

ENOF01313-0

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.

2. Carrying the outboard motor

ENOW00933-0

WARNING

1. Stop the engine.
8 2. Remove the top cowl.

Be sure to disconnect fuel connector except when operating engine.

3. Disconnect the fuel connector, the Fuel leakage is a fire or explosion hazard,

remote control cables and the bat- which can cause serious injury or death.

tery cords from the outboard motor. 4. Attach the hoist hooks to the engine
hanger.

ENOW00065-1

WARNING

5. Remove the outboard motor from boat and completely drain the water from the gear case.

Close air vent screw on fuel tank before carrying or storing outboard motor and fuel tank, or fuel may leak, potentially catching fire.

ENOW00066-1

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

REMOVING AND CARRYING THE OUTBOARD MOTOR 45
through the exhaust port and cause engine problems.

ENOF01727-0
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.

ENOM00072-C
3. Traillering

ENOF00680-0

ENOW00072-0

CAUTION

Trailering in the tilted position may cause damage to the outboard motor, boat, etc.

ENOW00073-A

WARNING

Be sure to disconnect fuel connector except when operating engine.
8 Fuel leakage is a fire or explosion hazard,
which can cause serious injury or death.

ENOF01921-0
ENON00021-3
Note
If the outboard motor must be laid down, be sure that fuel is completely drained, then lay the outboard motor with port side down on the cushion as shown in the drawing.

ENOF00075-1

ENOW00068-0

WARNING

Close air vent screw of fuel tank and fuel cock before carrying or storing outboard motor and fuel tank, or fuel may leak, potentially catching fire.

ENOW00071-0

CAUTION

The tilt support device supplied on your outboard motor is not intended for towing. It is

46 REMOVING AND CARRYING THE OUTBOARD MOTOR
intended to support the outboard motor while the boat is docked, beached, etc.
When transporting a boat on a trailer with the outboard motor attached, disconnect the fuel line from the outboard motor beforehand and keep the outboard motor in the vertical 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 47).

8

2

1

ENOF00073-A
1. Ground clearance should be provided sufficiently.
2. Transom saver bar
ENOW00067-0
WARNING
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.

47
ADJUSTMENT

ENOM00073-C
1. Steering friction

ENOM00074-A
2. Throttle grip friction

Tiller handle type
ENOW00074-2
WARNING
Steering may be difficult when steering friction adjustment bolt is over tightened, it may also result in loss of control causing an accident and could lead to severe injury.
ENON00506-1
Note
The steering friction adjustment bolt is used to adjust the friction load of the steering. Excessive tightening of the adjustment bolt may cause damage to the swivel bracket.
Steering friction can be adjusted in accordance with your preference by turning the steering friction adjustment bolt.

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.

3 1

3

2

9

1 2

1. Steering friction adjustment bolt 2. Lighter 3. Heavier

ENOF01922-0

ENOF01923-0
1. Heavier 2. Lighter 3. Throttle friction adjustment screw

ENOM00076-0
3. Trim tab adjustment

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.

48 ADJUSTMENT

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.

ENOW00075-0

WARNING

Inappropriate adjustment of trim tab could cause steering difficulty. After installing or readjusting trim tab, check if steering fiction is even.

If straight-line cruising can not 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 toward the right direct the trim tab towards B (right from rear of boat).
9

ENON00022-A
Notes
z After adjustment securely tighten the trim tab fixing bolt.
z Check for looseness of the bolt and the trim tab at regular intervals.

1. Trim tab

1
ENOF02449-0

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.

49
10

50 INSPECTION AND MAINTENANCE

ENOM01607-0
1. Daily Inspection

Perform the following checks before and after use.

ENOW00078-0

WARNING

Do not use outboard motor if any abnormality is found during pre-operation check or it could result in severe damage to the motor or severe personal injury.

10

Item Fuel System Lubrication
System
Electrical Equipment
Throttle System Recoil Starter
Clutch and Propeller System
Installation of Motor
Cooling Water Tools and Spares
Other Parts

Points to Check
· Check the amount of fuel in the tank. · Check for dust or water in the fuel filter. · Check rubber pipes for fuel leakage.
· Check the amount of engine oil in the oil tank. · Check for dust or water in the oil filters.
· Check the spark plugs for dirt, wear and carbon built-up. Spark plugs : NGK B-8HS-10/NGK BR-8HS-10
· Check if the main switch functions normally. · Check if the battery electrolyte level and specific gravity are
nomal. · Check for loose connections on battery terminal. · Check that the stop switch functions normally and make sure
the lock plate is secured. · Check cords for loose connections and damage.
· Check if the carburetor and magneto are working normally by turning the throttle grip, and check for any looseness between the links.
· Check ropes for wear and damage. · Check the ratchet for engagement.
· Check the propeler for bent or damaged blades. · Check the propeller nut is tightened and the split pin is in correct
position
· Check all the motor installation bolts with the boat. · Check the thrust rod installation.
· After starting the outboard motor, make sure that water is being discharged from the cooling water check port.
· To be ready tools and spare parts for replacing spark plugs, propeller, etc.
· Check if the spare rope is provided.
· Check if the anode and trim tab are securely installed. · Check the anode and trim tab for corrosion and deformation.

Action Replenish Clean Replace 1 Replenish Clean Clean or replace
Remedy or replace
1 Replenish or recharge
Retighten Remedy or replace 1
Correct or replace
1 Replace 1 Correct 1
Replace 1 Correct or replace 1 Replace
Tighten Tighten
Repair if necessary Replace

*1 Have this handled by your dealer.

INSPECTION AND MAINTENANCE 51

ENOM00083-0
Washing outboard motor
ENOW00081-1
WARNING
Do not start engine without removing propeller, 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.

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 from exterior and cooling water passage after every use or before storing outboard motor for long time. Before flushing, remove the propeller and the forward thrust holder.

ENOM00085-F
Flushing attachment 1. Tilt down the outboard motor. 2. Remove the water plug from the gear
case, and screw in the flushing attachment.
3. Connect a water hose. Turn on the water and adjust the flow (Be sure to seal the water inlet and sub water inlet, located in the gear case with tape)
4. Put the shift lever in the neutral position and start the engine. Continue flushing the outboard motor for 3 to 5 minutes at idling.
5. Stop the engine and water supply. Remove the flushing attachment and tape. After the flushing, be sure to reattach the water plug.

1

2
1. Flushing attachment (option) 2. Tape

10
ENOF01324-0

52 INSPECTION AND MAINTENANCE

. 1 1

2
1. Flushing attachment (option) 2. Water inlet

ENOF01420-0

ENOM00085-A
Flushing by test tank
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 58)

ENOM01903-0
Gear case flushing device
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.

ENOW00986-0

CAUTION

Never leave the outboard motor unattended while running on the flushing devise. When the flushing devise slip off from the gear case, the engine will overheat and may cause serious damage.

1. Fully tilt down the outboard motor. 2. With the propeller removed, seal the
sub-water inlet with a tape to prevent air from being sucked into the water pump.

10 3
2
1. Test tank 2. Water 3. Over 10 cm (4 in.)

1
ENOF00863-0

1

2

ENOF02559-0

1. Sub-water inlet 2. Tape

3. Install the gear case flushing device on

gear case so that the rubber cups

cover the cooling water inlets tightly.

INSPECTION AND MAINTENANCE 53

4. Connect a water hose to the flushing devise and turn on the water and adjust the flow so that excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water.
1

ENOM00950-B
Fuse replacement (For electrical starter type)
ENOW00923-1
CAUTION
Before replacing a fuse, disconnect the battery cable from the battery negative (-) terminal first. Failure to properly remove battery cables may cause a short-circuit.

ENOW00924-0

CAUTION

Never use a fuse with a rating that exceeds the specified rating as this could cause serious damage to the electrical system.

ENOF01420-C
1. Gear case flushing device
5. Place the shift lever in the neutral position and start the engine and run at idle speed for 3-5 minutes.
6. Check if a steady stream of water flows from the cooling water check port.
7. Stop the engine and turn off the water. Remove the flushing devise and tape. Install the propeller.
8. Leave the outboard motor in vertical position to completely drain the cooling water from the outboard motor.

If the fuse is blown, try to determine the

cause and respond to the problem as

simply replacing the fuse will likely be

blown again. If you are unable to respond

to the cause or the fuse continues to

blow, request an authorized Tohatsu

dealer for inspection.

1. Stop the engine and disconnect the

battery cable from the battery nega-

tive (-) terminal.

2. Remove the top cowl.

10

3. Remove the cover and detach the

fuse holder.

54 INSPECTION AND MAINTENANCE
4. Remove the fuse for inspection. If the fuse is blown, replace it with a new fuse having same specified rating.

1
1. Brown fuse

ENOF01962-0

10

INSPECTION AND MAINTENANCE 55

ENOM01006-1
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.

Item

Fuel System

Carburetor *1
Fuel filter Piping Fuel tank

Ignition
Starting System

Spark plugs
Ignition timing 1 Starter motor 1
Battery

Starter rope

Propeller

Lower Unit

Gear oil

Water pump *1
Bolt and Nuts
Sliding and Rotating Parts Grease Nipples
Outer Equipment

Anode

Servicing Interval

10 hours or 50 hours or

1 month

3 months

Every 100 hours or 6
months

z

z

z

z

z

z

z

z

z

z

z

z

Action
Strip, clean and adjust. Adjust idling. Check and clean. Check and clean. Clean Check gaps. Remove carbon deposits.

Remarks
0.9-1.0 mm (0.035-0.039 in)

z

z

Adjust timing.

Check for salt deposits

z

and battery cable

condition.

z

z

z

Installation, fluid quantity, gravity

z

z

z

Check for wear or damage.

z

z

z

Check for bend blades, damage, wear.

Change or replenish-oil

z

z

z

and check for water

leakes.

z

z

Check for wear or damage.

Replace impeller every 12 months.

z

z

z

Retighten.

z

z

Apply and pump in grease.

z

z

z

Check for corrosion.

z

z

Check for corrosion and deformation.

Replace.

*1 Have this handled by your dealer.

10

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.

56 INSPECTION AND MAINTENANCE

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

ENOM00093-A
Fuel filters and fuel tank cleaning
ENOW00093-1
WARNING
Gasoline and its vapor is very flammable and can be explosive. z Do not start this procedure while engine
is operating or while engine is hot. z Place fuel filter away from every source of
ignition such as sparks or open flames. z If gasoline is spilled, wipe up immediately
and dispose according to the local regulations. z Install fuel filter with all related parts in place, or fuel leak could occur, leading to catching fire or explosion. z Check fuel system regularly for leakage. z Contact authorized dealer for fuel system services. Services by unqualified person could lead to engine damage.
Water or dirt in the fuel tank will cause engine performance problems. Check and clean the tank at specified intervals or after the outboard motor has been stored over three months. Fuel filters are provided inside the fuel tank and engine.

ENOM00094-0
Fuel filter (for engine)
1. Check the cup for water and debris.

ENOF01925-0

1

6

2 3 4

5
ENOF00096-B
1. Body 2. O-ring 3. Filter 4. O-ring 5. Cup 6. Arrow to indicate fuel flow direction

INSPECTION AND MAINTENANCE 57

2. If present, disconnect hoses from the fuel connector (male) and the fuel pump.
3. Remove the cup, filter and O-rings from the fuel filter body.
4. Check the wear and clogging for each part, and replace if necessary.
5. Remove fuel and any water or debris from the cup, filter and hoses.
6. Reassemble all parts.
ENOM00096-A
Fuel filter (for fuel tank)
1. Remove four screws to detach the Fuel Pick-Up.
2. Clean the fuel filter and replace the gasket.
3. Reassemble all parts.

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.

ENON00934-1
Note
Dispose used oil according to the local regulation. For oil disposal, we suggest take it into local service station in a sealed container. Do not throw the used oil in trash, pour it on the ground or down a drain.

1

1. Tilt down the outboard motor.

2. Remove the oil plugs (lower and

2

upper), and completely drain the gear

oil into a pan.
10

1. Fuel pick-up 2. Filter

ENOF00926-1

ENOF01331-0

58 INSPECTION AND MAINTENANCE

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. Make sure that no bubbles are coming out of the upper plug hole and there is no air inside the gear case.
ENON00033-1
Note
Use genuine gear oil or ones recommended (API GL-5: SAE #80 to #90). Required volume: approx. :500mL(16.9 fl.oz)

ENOF01331-0

ENOW00928-1

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

ENOF01333-0
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)
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.

ENOM00086-1A
Propeller replacement
ENOW00084-1
WARNING
z Do not install or remove propeller on the outboard motor 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. Disconnecting battery cable is recommended (if equiped).
z The propeller edge is thin and sharp. Wear the gloves while installing or removing to protect your hands.

INSPECTION AND MAINTENANCE 59

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 outboard motor’s performance, and cause engine trouble. 1. Put a piece of wood block between
propeller blade and anti-ventilation plate to hold propeller.

36
5 4

2

1

1. Propeller 2. Thrust holder 3. Stopper 4. Washer 5. Propeller nut 6. Split pin

ENOF01315-0

6. Tighten the propeller nut to specified torque and align one of grooves to propeller shaft hole.
Propeller nut torque: 35 Nm (25 ft-lb, 3.25kgf-m) 7. Install a new split pin into the nut hole
and bend both ends of pin apart to lock propeller in place.

ENOF00084-B
2. Remove the split pin, propeller nut and washer.
3. Remove the propeller and thrust holder.
4. Apply waterproof grease to the propeller shaft before installing a new propeller.
5. Install the thrust holder, propeller, stopper, washer and propeller nut onto the shaft.

10
ENOF00084-E

60 INSPECTION AND MAINTENANCE

ENOM00087-B
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 gap to specification.

1. Stop the engine. 2. Remove the top cowl. 3. Remove the spark plug caps.
10 4. Remove the spark plugs by turning it
counter-clockwise, using a 21 mm (13/ 16 in) socket wrench and handle that is provided in 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 gap with a wire type feeler gauge. The gap should be 0.9-1.0 mm (0.035-0.039 inches). If the gap is different, replace the spark plug with a new one

Use spark plug : NGK B8HS-10

1 2

ENOF00085-0

1. Electrode 2. Spark gap (0.9­1.0 mm, 0.035­0.039 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.
ENON00028-2
Note
z Spark plug tightening torque: 27 N·m (20 ft·lb) [2.7 kgf·m] If a torque- wrench is not available when you are installing a new spark plug, tighten it 1/2 to 2/3 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.

ENOF01926-0

INSPECTION AND MAINTENANCE 61
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.

1
1 : Both side

10
ENOF01927-0

62 INSPECTION AND MAINTENANCE
ENOM00960-0
Grease point
Apply waterproof grease to the parts shown below.

10

ENOF01928-0

INSPECTION AND MAINTENANCE 63

ENOM00100-1A
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.

ENOW00096-0

CAUTION

Before servicing the motor for storage: z Remove the battery cables. z Remove the spark plug caps from the
spark plugs. z Do not run the motor out of the water.

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 64)

ENOM00101-D
Engine
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. Remove the fuel hose from the outboard motor.
3. Drain all fuel from the fuel hoses, fuel pump, fuel filter (See page 56) and carburetor (See page 65), and clean these parts. Keep in mind that if residue in the carburetor for a long time, gum and varnish will develop, 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 or turn the starter motor 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.sss
6. Change the gear oil in the gear case (See page 57).
10 7. Apply grease to grease point (See
page 62). 8. Stand the outboard motor up verti-
cally in a dry area.

64 INSPECTION AND MAINTENANCE

ENOF00680-0

ENOF01921-0

ENOW00066-1

CAUTION

Do not carry or store outboard motor in any of positions described below. Otherwise, engine’s exterior parts may be damaged or water may enter the cylinder through the exhaust port and cause engine problems.

10
ENOF01727-0
ENON00021-3
Note
If the outboard motor must be laid down, be sure that fuel is completely drained, then lay the outboard motor with port side down on the cushion as shown in the drawing.

ENOM00950-A
Adding a fuel stabilizer
When adding a fuel stabilizer additive (commercially available), first fill the fuel tank with fresh oil and fuel. If the fuel tank is only partially filled, air in the tank may deteriorate the fuel during storage.
1. Before adding fuel stabilizer additive, drain the carburetor (See page 65).
2. Follow the instructions on the label when adding the fuel stabilizer additive.
3. After adding the additive, let the outboard motor run in 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
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.

INSPECTION AND MAINTENANCE 65

ENOM00970-A
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.

8. Check the drained fuel for the presence of water or other contaminants. If fuel is contaminated, reassemble the outboard motor, 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.
1

1. Disconnect the fuel hose from the outboard motor.
2. Remove the top cowl. 3. Place an approved fuel container
under the drain screw and use a funnel to avoid spilling fuel. 4. Loosen the carburetor drain screw. 5. Tilt up the outboard motor until fuel flows out of the drain tube. 6. Leave the outboard motor in this position until all fuel has been drained. 7. When thoroughly drained, retighten the drain screw securely.

1. Carburetor drain screw

ENOF02370-0

ENOM00102-0
Battery

ENOW00931-A

WARNING

z Place the battery away from any source of fire, sparks and open flames such as burners or welding equipment.
z Place the battery away from fuel tank. Accidental sparks of battery may cause explosion of gasoline.

10

1. Disconnect the battery cables and be sure to remove the negative terminal first.
2. Wipe off any chemical deposits, dirt, or grease.
3. Apply grease to the battery terminals.

66 INSPECTION AND MAINTENANCE

4. Charge the battery completely before storing it for the winter.
5. Recharge the battery once a month to prevent it from discharging and the electrolyte from deteriorating.
6. Store the battery in a dry place.
ENOM0110-0
4. Pre-season check

10

The following steps must be taken when first use of 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 for any damage on the shift linkage.)
2. Check the electrolyte level and measure the voltage and specific gravity of the battery.

Specific Gravity at 20°C
1.120 1.160 1.210 1.250 1.280

Terminal Voltage (V)
10.5 11.1 11.7 12 13.2

Charge Condition Fully discharged 1/4 charged 1/2 charged 3/4 charged Fully charged

3. Check that the battery is secure and the battery cables are properly connected.
4. Fill the fuel tank with oil and fuel. 5. Connect the fuel line to the engine,
and squeeze primer bulb.

6. Before starting the engine, disconnect stop switch lock and pull recoil starter approximately 10 times (Manual start model) or 3times for 3sec. turn the starter motor (Electric start model) in order to circulate the oil.
7. Start the engine to warm up for 3 minutes in the “NEUTRAL” position.
8. Run the engine for 5 minutes at the slowest speed.
9. Run the engine for 10 minutes at half throttle. The oil shall circulate to assure optimum performance.

ENOM00105-D
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 spark plugs, and completely drain the water from the engine by pulling recoil starter several times.

INSPECTION AND MAINTENANCE 67

3. 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.

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

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. 3. Return to the nearest habor slowly
and carefully. 4. Consult a dealer check the outboard
motor before operation again.

ENOF01145-0
ENOM00121-0
8. Operation with multiple outboard motors
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 propeller out of the water. Otherwise, water could enter the engine and cause damage to it.
10

68
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.

Difficult to start engine

Engine starts but
stops immedi-
ately

Poor idling

Poor accelera-
tion

Abnormally high
engine speed

Abnormally low
engine speeds

Unable to reach high speed

Overheating of
engine

z

z

z

Empty fuel tank

z

z

z

z

z

z

z

z

z

z

z

Incorrect connection of fuel system

z

z

z

Air enters fuel line

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

11

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

Deformed or damaged fuel pipe

z

z

z

Closed air vent on fuel tank cap

z

z

z

Clogged fuel filter, fuel pump or carburetor

z

z

z

Use of improper engine oil

z

z

Use of improper gasoline

Excessive supply of gasoline

z

z

z

Poor carburetor adjustment

z

z

Recirculation pipe broken

z

z

z

Use of non-specified spark plugs

z

z

Dirt or carbon deposits on spark plugs

z

z

No sparks or weak sparks

TROUBLESHOOTING 69

Difficult to start engine

Engine starts but
stops immedi-
ately

Poor idling

Poor accelera-
tion

Abnormally high
engine speed

Abnormally low
engine speeds

Unable to reach high speed

Overheating of
engine

z

z

z

z

Insufficient cooling water flow

z

z

z

z

Faulty thermostat

z

z

z

Propeller cavitation

z

z

z

z

Incorrect propeller selection

z

z

z

z

z

Damaged or bent propeller

z

z

z

z

Unbalanced load in boat

z

z

z

Transom too high

z

z

z

Transom too low

z

z

z

z

z

z

z

z

z

z

z

Incorrect adjustment of throttle link

z

z

z

Incorrect adjustment of ignition timing

Insufficient battery capacity, loose terminals, corrosion
Safety switch lock plate not fitted

11

70
TOOL KIT AND SPARE PARTS

ENOM01609-0
The followings are a list of the tools and spare parts provided with the motor.

Servicing Tools Spare Parts Parts Packaged with Engine

Name
Tool Bag Socket Wrench (21 mm) Socket Wrench (10 x 13 mm) Socket Wrench Handle Pliers Screwdriver (Phillips-type and flat head)
Anode (for Bracket) Trim Tab Water Pump Impeller Pump Case Gasket Gasket (for Gear Oil Plug) Grease Starter Rope Spark Plug Split Pin Mounting Hardware
Bolt Nylon Locking Nut Washer A (large) Washer B (small)
Fuel Tank (with primer bulb) Grease Up Point Chart Owner’s Manual

Quantity

Remark

1

1

1

1

1

1

Adapter-type

1

1

1

1

2

1

1

3

NGK B8HS-10

1

4

12mm

4

12mm

4

4

1 1 1

12

71
PROPELLER TABLE
ENOM01108-1-0
To ensure optimum performance, the propeller should match the boat type and its load.
Use a genuine propeller. When selecting propeller, make sure that RPM stays in the maximum operating range of engine at wide open throttle.
MX40D3: 5000 – 5800 min-1 (rpm) MX50D3: 5000 – 5800 min-1 (rpm)

Mark

7*

Heavier Load

9

11

12

13

14

15

Lighter Load

16

17

  • shows propeller with four blades.

Propeller Size (Diameter Pitch)

Inch

mm

11.4 x 7.1

290 x 180

12.1 x 9.0

311 x 229

11.6 x 11.0

290 x 279

11.4 x 12.0

283 x 305

11.1 x 13.0

277 x 330

11.1 x 14.0

279 x 356

11.0 x 15.0

279 x 381

11.0 x 16.0

279 x 406

11.0 x 17.0

280 x 432

13

INSPECTION & MAINTENANCE LOG

Date

Engine Hour

Inspection/Maintenance Performed

Performed by

O W N E R’ S MANUAL
MX 40D3 MX 50D3
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)  >>

Download This Manual (PDF format)

Download this manual  >>

Related Manuals