TOHATSU MFS-5D-LPG Outboard Motor Owner’s Manual

TOHATSU MFS-5D-LPG Outboard Motor

Specifications

• Model: MFS 5D LPG
• OB No.: 003-11158-4BD1
• Warnings: Contains chemicals including gasoline or LPG exhaust emissions, and carbon monoxide

Product Usage Instructions

Owner Registration and Identification:

Upon purchasing the product, fill out and mail the WARRANTY CARD to the provided address. This card serves as your warranty registration and identifies you as the legal owner. Failure to follow this procedure may void the limited warranty.

Pre-Delivery Check:

Ensure that a pre-delivery inspection has been completed by an authorized TOHATSU dealer before operating the outboard motor.

Serial Number:

Locate the unique serial number on your outboard motor for warranty registration, filing claims, technical inquiries, and other occasions. Write down the serial number and date of purchase for reference.

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 DANGER, WARNING, CAUTION, and Note for safe operation.

FAQs

• Q: What should I do if I encounter a warning or notice while using the outboard motor?
  • A: If you encounter any warning or notice, stop the operation immediately and refer to the Owner’s Manual for guidance. Ignoring warnings may result in personal injury or property damage.

“`

O W N E R’ S MANUAL
AAAA
MFS 5D LPG
OB No.003-11158-4BD1

WARNING:
This product can expose you to chemicals including gasoline or LPG exhaust emissions, which are known to the State of California to cause cancer, and carbon monoxide, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www.p65warnings.ca.gov
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 © 2024 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

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

ENOF01500-1

Date of purchase:

ENOF01501-1

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.
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DANGER
Failure to observe will result in severe personal injury or death, and possibly property damage.

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WARNING

Failure to observe could result in severe personal injury or death, or property damage.

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CAUTION

Failure to observe could result in personal injury or property damage.

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Note
This instruction provides special information to facilitate the use or maintenance of the outboard motor or to clarify important points.

GENERAL SAFETY INFORMATION

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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.
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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.
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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.).
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PERSONAL FLOTATION DEVICE
As the operator/driver and passenger a boat, you are responsible to wear a PFD (Personal Flotation Device) while on the boat.

GENERAL SAFETY INFORMATION 11
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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 46). 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.ss
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.
Propane Propane (Liquefied petroleum gas / LPG) is extremely flammable and can be explosive. Use extreme care when handling propane. You should be thoroughly knowledgeable on how to correctly handle propane by reading this manual.

12

SPECIFICATIONS

ENOM00810-D
MODEL FEATURE

2 Type

F5D LPG Model

F5D LPG MF

S

z

Transom heights

L

UL

Tiller Handle

z

Remote Control *1

(z)

Manual tilt

z

1: Option 2: SP model equip with charging coil as a standard.

ENOM00811-D
MODEL NAME EXAMPLE
F 5 DLPGL

F Model description
F= Four stroke

5

D

LPG

Horse power

Product generation

Fuel

–

A and up

LPG=Propane

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

F5D LPG SP*2 MF
z z z (z) z

SPECIFICATIONS 13

ENOM00401-0
MF

Item

Model

MFS 5DS

MFS 5DS SP

2

Separate Tank

Overall Length

mm (in)

823 (32.4)

Overall Width

mm (in)

345 (13.6)

Overall Height

mm (in)

S : 1030 (40.6) L : 1157 (45.6) UL : 1284 (50.6)

Transom Height

mm (in)

S : 436 (17.2) L : 563 (22.2) UL : 690 (27.2)

S kg (lb)

27.0 (60.0)

Weight*1

L kg (lb)

27.5 (61.1)

UL kg (lb)

–

28.0 (62.2)

Engine Type

4 stroke

Number of Cylinder Piston Displacement

cm3 (cu.in.)

1 123 (7.5)

Bore x Stroke

mm (in)

59 x 45 (2.30 x 1.75)

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)

3.7 (5) 5000 – 6000
1100 1300

Exhaust System

Through-hub exhaust

Lubrication System

Wet sump (Trochoid pump)

Cooling System

Water cooling (with thermostat)

Starting System

Manual starter

Ignition System

Flywheel Magneto CD Ignition

Alternator

12V – 5A*2

Steering Angle

Degree

150

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

2.15 (28:13)

Emisson Controul System

EM (Engine modification)

Operator Sound Pressure (ICOMIA 39/94 Rev.1) dB (A)

81.0

Hand Vibration Level (ICOMIA 38/94 Rev.1) m/s2

5.9

Remark: Specifications subject to change without notice. 1: With propeller, with battery cable. 2: Equippted only for SP model, the other models OPTION. *3: 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 Connector
Engine Oil
Gear Oil
Battery (minimum requirements) Spark Plug Spark Plug Gap Intake Valve Clearance Exhaust Valve Clearance

Model
Grade mL
(US/Imp.oz) Grade mL
(US/Imp.oz)
mm (in) mm (in) mm (in)

Tightening torque
Engine Oil Drain Bolt Gear Oil Plug Propeller Nut Spark Plug

MFS 5DS

MFS 5DS SP

Separate Tank

Propane

CGA 600

API: SH, SJ, SL SAE: 10W-30, 10W-40

450 (15/16)

API:GL-5, SAE:80-90

195 (6.6/6.9)

–

40Ah/20HR, 330CCA

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) 12N · m (9 ft · lb, 1.2 kgf · m) 18N · m (13 ft · lb, 1.8 kgf · m)

15
PARTS NAME
ENOM00402-A
5D

1

18

2

17 16

19

20

21

3

3 45 6
7 8
9 28

15
14 13

12 11 10

26 27

1 Tilt Handle 2 Top Cowl 3 Bottom Cowl 4 Cooling Water Check Port 5 Tilt Lever 6 Steering Adjustment Screw 7 Anode 8 Anti Ventilation Plate 9 Propeller 10 Oil Plug (Lower) (Fill) 11 Water Inlet 12 Oil Plug (Upper) (Level)

13 Thrust Rod 14 Clamp Bracket 15 Clamp Screw 16 Throttle Grip 17 Shift Lever 18 Starter Handle 19 Choke Knob 20 Stop Switch 21 Fuel Connector 22 Warning Lamp 23 Engine Oil Filler Cap 24 Spark Plug

22
23 24
25
ENOF01502-B1
25 Engine Oil Drain Screw 26 Shut Off Valve 27 Regulator 28 Mixer

16
LABEL LOCATIONS
ENOM00019-A
Warning label locations

4 65 4

1 2, 3
ENOF01503-B2

LABEL LOCATIONS

1, 6-4. Read owner’s manual.
3YG-72180-0
2. Oil pressure lamp (See page 27).

6-2. Hazard caused by rotating parts. 6-3. Electrical shock hazard.

3

2

ENOF00131-0
3. Engine stop switch (See page 36). 4

4, 6-1. Hot surface.

ENOF00131-B

4
1
3NV-72181-1

3GR-76191-0
5. Warning regarding emergency starting (See page 32).

3UR-72187-1

18 LABEL LOCATIONS

ENOM00019-A
ECI (Emission Control Information) label locations

1 2
3

54

76

8

9

4

q0 w

1EMISSION CONTROL SYSTEM INFORMATION 2THIS ENGINE MEETS U.S. EPA EXH/EVAP AND CALIFORNIA SIME
EXH/SIMW EVAP REGS FOR (MODEL YEAR).
3REFER TO THE OWNER’S MANUAL FOR MAINTENANCE
SPECIFICATIONS AND ADJUSTMENTS.
4EVAP FAMILY 5EVAP ECS 6PART No. 7MODEL YEAR AND MONTH 8FAMILY NAME 9DISPLACEMENT 0OUTPUT qMAXIMUM POWER wTRADEMARK & NAME OF MANUFACTURER

ENOFA0009-1

EPA Emissions Regulations Outboards sold by Tohatsu America Corporation in the United States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard engines. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, wherever practicable, returned to the original intent of the design. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual.

The Emission Control Information label was affixed to engines as permanent evidence of EPA certification.
Emissions Warranty Coverage WARRANTY INFORMATION Four Stroke Outboard Limited Warranty Canadian and California residents who have purchased an outboard motor from a Canadian and California dealer receive additional warranty coverage for specific emissions related components. To fully understand your warranty coverage please read our standard warranty statement and the Emission Warranty Statement provided by your dealer.

INSTALLATION

ENOM00024-B
1. Mounting the outboard motor on boat

Keep the outboard motor in a vertical position when mounting.

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.

5
ENOF01505-1
ENOM00025-0
Mounting position
Place the outboard motor in the center of the boat’s transom.
1

1. Center of boat 2. Chine

2
ENOF02406-0

ENOM00026-0
Transom matching
Be sure that the anti ventilation plate of the outboard motor is 5­25 mm (0.2­1 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

ENOM00831-0
Mounting the outboard motor

1. Set the outboard motor to appropri-

ate position.

1

2. Tighten the clamp screws by turning

1. Bottom of hull 2. Anti ventilation plate

5-25 mm (0.2-1 in)
2
ENOF01506-0

their handles. 3. Secure the outboard motor to the
boat with a rope to prevent accidental loss of the outboard motor overboard.

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 water from entering the engine. z Make sure to mount the engine in correct position. If outboard motor is mounted

ENON00930-0
Note
Do not use tools to tighten clamp screws. Over tightening could result in damage to the clamp screws and clamp brackets.
ENON00002-0
Note
A rope is not included in the standard accessories.

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. z Tighten the clamp screws sufficiency, otherwise falling down of outboard could be happened.

ENOF01507-A

INSTALLATION 21

ENOM00029-A
2. Battery installation (For SP model)

ENOW00012-1

WARNING

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 contact 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-B

WARNING

Battery generates explosive hydrogen gas. Be sure to: z Charge the battery in a well-ventilated
place. z Place the battery away from any source of
fire, sparks and open flames such as burners or welding equipment. z Do not charge the battery when the electrolyte level is low. Otherwise, the battery will be damaged and may cause malfunction.

ENOW00014-0

CAUTION

z Make sure that the battery leads do not get stuck between the outboard motor and boat when turning, etc.
z The starter motor may fail to operate if the leads are incorrectly connected.
z Be sure to correctly connect the (+) and (–) 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.
5
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.

ENON00006-1C
Note
Minimum battery requirements: 12V 40Ah/20HR, 330 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. * The battery should be purchased separately and is not supplied with the outboard motor.
1. Connect the battery cable to the leads that come from the bottom cowl.

22 INSTALLATION

2. Place the battery box in a convenient

position and away from possible water

spray. Securely fasten both the box

and the battery so they do not shake

loose.

3. Connect the positive lead (+) to the

positive terminal (+) of the battery,

and then connect the negative lead

(–). When disconnecting the battery,

always remove the negative lead (–)

first. After connecting the positive

terminal (+), securely place a cap on it

5

to prevent short circuits.

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

ENOF01508-0

ENOM00726-B
3. Altitude adjustment kit Installation

High altitude:
When engine operates at high altitude (over 1000m/3280ft) engine may need to have a high altitude kit installed. Otherwise, operating the engine at high altitude may increase its emissions and decrease fuel efficiency and performance. Contact authorized Tohatsu dealer for more detail.

PRE-OPERATING PREPARATIONS

ENOM00030-A
1. Fuel handling

ENOW00948-0

WARNING

z Only LP gas can be used to fuel the outboard motor. Do not use any fuel other than LP gas. Failure to observe this may result in the outbreak of fire or damage to the engine.
z Leaking LP gas may cause a fire or explosion if ignited causing serious bodily injury or death.
z Turn off the engine when handling LP gas and when connecting or splitting hoses, and perform these tasks in a well-ventilated area.
z Do not smoke or allow flames, sparks, etc., in the vicinity of the gas when handling LP gas and when connecting or splitting hoses. Also, make sure that static electricity that has built up within the body is discharged prior to performing these tasks.
z Check to make sure that the gas is not leaking when starting up the engine.
z Turn off the engine immediately if LP gas leaks are detected (smell of gas or other indications of a leak), and then perform the following measures:
z Close the valve when not used. z Remove the gas hose from the outboard
motor during except for operation. z Contact your LP gas dealer. z LP gas is heavier than air and may settle in
low places while dissipating. z Contact with the liquid contents of the
cylinder will cause freeze burns to the skin. z Do not allow children to tamper or play with LPG tank.

ENOW000017-0

CAUTION

Use of improper fuel can damage your engine. Engine damage resulting from the use of improper fuel is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty.

ENOM00031-1B
FUEL RATING
Use only major brand propane gas.
Propane fuel only.

ENON00396-0
Note

The fuel that highly containing butane may

cause hard starting of the engine.

6

ENOM00125-1
FUEL TANK
The fuel tank without regulator is recom-
mended. If it’s avoidable to use a tank
with regulator,
pressure must exceed 100 kPa (14.5 psi) [1kgf/cm2] at least.

ENOM00043-B
2. Fuel filling

ENOW00949-0

WARNING

z Be certain LPG tank is purged of trapped air prior to first filling.
z Before filling any LPG tank there must be a visual inspection of the tank. Check for any damages such as deep dents or areas of heavy rust if the tank is metal.
z Never fill an LPG tank beyond 80% full: a fire causing death or serious injury may occur.
z Do not use a LPG tank expired life span. Re qualification will be required after

24 PRE-OPERATING PREPARATIONS

specific years from the date of manufacture. Please follow to the LPG tank manufactures’ instruction. z When filling fuel, keep LPG tank in an upright position. z When transporting, keep LPG secured in an upright position with the tank valve turned off. z Do not use, store or transport tank where it would be exposed to high temperatures.
ENOM00037-C
3. Engine oil filling

3. Fill the engine through filler port with recommended oil to the middle of dipstick mark.
4. Tighten the oil filler cap (dipstick).
1

ENOW00022-2

CAUTION

1. Oil filler cap (Dipstick)

6 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.

ENOF00446-1

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.
1. Place the engine in a vertical position.
2. Remove the top cowl and the oil filler cap (dipstick).

1

2

ENOF01531-0

1. Upper limit 2. Lower limit

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 or SJ

Engine oil viscosity must be selected from the following chart according to the average temperatures in your area.

PRE-OPERATING PREPARATIONS 25

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 450 mL (0.48 US qt.)

ENOW0002A-A

CAUTION

Use of engine oils that do not meet these

requirements will result in reduced engine

6

life, and other engine problems.

26 PRE-OPERATING PREPARATIONS

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 timetable. Please refer to ENGINE OPERATION section (See page 29) to learn how to correctly start and operate the outboard motor.
ENOW00024-A

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.

DANGER

Do not operate the outboard motor in

6

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.

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

ENOM00039-A
5. Warning system
If outboard motor encounters an abnormal condition of fault, the warning lamp (LED) will be ON.
See next page for conditions which will lead to an abnormal condition or fault.
ENOM00040-D
Location of warning lamp
Warning lamp (LED) Tiller handle models: Located on the bottom cowl.

PRE-OPERATING PREPARATIONS 27
6

1
1. Warning lamp

ENOF00415-1

28 PRE-OPERATING PREPARATIONS

ENOM00041-E
Warning indicators, faults and remedy

Warning indicators

Lamp (LED)

ESG

On for several sec.

–

ON

ON

–

Remarks *1: In this case, oil pressure switch is “ON”.

Description of faults
Normal system test when start up Engine speed exceeds maximum allowable RPM
Low oil pressure*1

Remedy
1 2

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 6300min-1 (rpm).

6

ENOM00126-A
Remedy

ENOW00025-B

1. Reduce the speed to less than half

CAUTION

open throttle, and move to safe place quickly, and stop the engine. Check the propeller for bent or dam-

High speed ESG ON: Engine speed will be limited to 6300 min-1 (rpm) and engine will
run rough until throttle is reduced.

age 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 stop

the engine until it cools down.

Check the engine oil level, and add

engine oil if necessary.

Consult your dealer if the engine oil

level is too low or too high.

29
ENGINE OPERATION

ENOM00042-0
Before starting
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 48)
1

1. Oil filler cap (Dipstick)

ENOF00446-1

1

2

ENOF01531-0

1. Upper limit 2. Lower limit
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.

ENOW00950-0
WARNING
Before starting engine, secure the tank in an upright position.
ENOM00044-E
1. Fuel feeding
ENOW00951-0
WARNING
z Check the special gas hose connector and connection points on the engine to make sure that they are not contaminated with dirt, mud, moisture or any other foreign matter, or otherwise damaged, and then make sure that the connection is firm.
z Failure to achieve a firm connection may
7 result in gas leaks, which could lead to
explosions or the outbreak of fire. z If dirt, mud, sand, moisture or any other
foreign matter is discovered, clean it off in a well-ventilated area. z Do not use the engine if damage is discovered on the special gas hose connector or connection points on the engine. z Do not use a tool to tighten connector. Over tighten may cause breakage of the connector.
1. Make sure the valve of the LPG tank is closed.

30 ENGINE OPERATION
1

4. Fully open the valve of the LPG tank slowly.
1

ENOF001522106-0

1. Close
2. Connect the hose to the LPG tank by turning connector counter-clockwise.
1

EENNOOFF0001522109-0
1. Open
ENOM00045-C
2. Starting the engine

ENOW00958-1

WARNING
7 z Do not remove or install the top cowl

after the engine has started.

z The exposed rotating engine parts cause

EENNOOFF0001522107-0

serious injury.

1. Connect
3. Connect the hose connector to the engine side by turning connector clockwise.

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.

1. Connect

1
ENOF001522108-0

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 56)

ENGINE OPERATION 31

Tiller handle type

3

1. Be sure to install the stop switch lock

to the stop switch, and attach the

stop switch lanyard securely to the

1

operator or to the operator’s PFD

(Personal Flotation Device.)

2 1
ENOF00863-0
1. Test tank 2. Water 3. Over 10 cm (4 in.)

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.

This model is provided with start in gear protection.
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.

1. Stop switch lock

EENNOOFF000042310-0A

2. Set the shift lever in the Neutral posi-

tion. N

7
R

N

(R)

(F)

F
1
ENOF00438-1

1. Shift lever
3. Set the throttle grip to CLOSED position.

1
1. Throttle grip

ENOF01107-0

ENGINE OPERATION

4. Pull the choke knob fully.
ENON00501-0
Note
Choke is not necessary when the engine is warm. Set the throttle grip to CLOSED position.

7. Cooling water from cooling water check port.

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.
21

1

1. Cooling water check port

ENOF00437-2

ENOM00042-F
Emergency starting
ENOW00099-1
WARNING

7

When the emergency starter rope is used for starting engine;

z Start in gear protection does not work.

1. Slowly 2. Quickly

ENOF00432-1

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.

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

6. Check the after engine starting, return the choke knob while check the engine speeds. if the engine

around. z Attach engine stop switch lanyard to
clothing or any part of body such as wrist, arm before starting engine the outboard

speeds unstable, pull the choke knob

motor.

to operated.

1. Remove the top cowl.

ENGINE OPERATION 33
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.

1

ENOF01521-1
1. Cowl latch
2. Disconnect the rink of the starter lock rod.
ENOF00433-0
3. Remove the bolts (3 pcs) and remove the recoil starter.

ENOF00435-0

5. 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.

7

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.

ENOF00434-0

34 ENGINE OPERATION
8. Pull the starter handle slowly until you feel engagement, keep pulling till you feel less resistance. Then pull it quickly.

1

1. Cooling water check port

ENOF00437-A1

ENOF00436-0
9. Once the outboard motor is started, do not reinstall the recoil starter and top cowl.

ENOM00044-A
Engine speeds
Idling speed after warming up.

Clutch in (In gear) 1150 min-1 (rpm)

Clutch off (Out of gear) 1300 min-1 (rpm)

ENOM00043-A
7 3. Warming up the engine

ENOW00932-1

CAUTION

ENOM00046-A
4. Forward, reverse, and acceleration

Be sure to check that cooling water is discharged from the cooling water check port during warm up.

ENOW00037-1

WARNING

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.

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.
ENOW00967-0
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.

ENGINE OPERATION 35

z Arrange the lanyard 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.

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.

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
7 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.

N

(R)

(F)

1
1. Shift lever

R N F
ENOF00438-1

36 ENGINE OPERATION

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.
2. When the engine reaches trolling (or idling) speed, quickly pull the shift lever to the Reverse position.
Acceleration Open throttle grip gradually.

1
1. Throttle grip

ENOF01107-0

2. Put the shift lever in the Neutral posi-

tion.

Run the engine for 2-3 minutes at

idling speed for cooling down if it has

been running at full speed.

3. Push the stop switch.

7

1
1. Throttle grip
ENOM00049-A
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.

EENNOOFF000423190–B01
4. Close the valve of the LPG tank. 1

1. Close

ENOF00152310-0

ENGINE OPERATION 37

ENOW00984-0
WARNING
After stopping the engine: z After close the valve of the fuel tank, con-
sume remained fuel by running the engine if the motor will be stored. 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.

2

1
1. Hock 2. Stop switch lock 3. Stop switch

3
ENOF00241309–01

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.

ENOF00891-0

ENOM00920-A
6. Steering

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

7

Move the tiller handle to the right.

ENOF00892-0

ENOM00050-0
7. Trim angle

ENOW00043-1

WARNING

z Adjust the trim angle when the engine is stopped.

38 ENGINE OPERATION

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.

ENOM00052-0
Proper trim angle The position of the thrust rod is correct if the hull is horizontal during operation.
1

ENOW00044-1A

WARNING

Excessive trim up or down may cause unsta-

ENOF00051-1

ble 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.

1. Perpendicular to the water surface
ENOM00053-A
Improper trim angle (bow rises too high) Set the thrust rod (or preset knob) lower

if the bow of the boat rises above horiThe trim angle of the outboard motor can zontal.
7 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.

ENOF00052-0
ENOM00054-0
Improper trim angle (bow dips into the water) Set the thrust rod (or preset knob) higher if the bow of the boat is below horizontal.

ENOF00053-0

ENGINE OPERATION 39

ENOM00060-A
8. Tilt up and down

1
2
4 3
ENOF00440-0
1. Trim angle adjustment hole 2. Thrust rod 3. Higher 4. Lower
Trim angle adjustment 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.

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.

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

7

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.

ENOW00071-0

CAUTION

Do not use tilt stopper or lever when trailering the boat. Use only for holding the outboard motor in the fully tilted up while the boat is stored.

40 ENGINE OPERATION

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

Then lower the motor slowly.

ENOM00423-0
Tilt up With the shift lever in Forward, fully tilt the motor up toward you by holding the tilt handle provided at the rear of the top cowl. Then slightly lower the motor for locking in the up position.

1

2

1. Tilt lever 2. Tilt stopper

ENOF00443-0

ENOM00068-A

9. Shallow water operation

ENOW00051-0

7

WARNING

ENOF00441-1

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

1

While in shallow water drive position, do not

operate the outboard motor in Reverse.

3

2

Operate the outboard motor at slow speed

and keep the cooling water intake sub-

merged.

1. Tilt up position 2. Tilt stopper 3. Shallow water running position

ENOF00442-0

ENOM00424-0
Tilt down Slightly tilt the motor up, and pull the tilt lever toward you to release the tilt-lock.

ENOW00054-1A

CAUTION

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

1

1. Water inlet

ENOF01144-A

Shallow water running position: 1. With the shift lever in Forward, tilt the
motor up slowly by about 40° and then lower the tilt lever for setting at the shallow water running position.
Return to normal running position: 2. Tilt the motor up fully and then return
the motor down slowly to the normal running position.

1. Tilt lever 2. Tilt stopper

1
2
ENOF00443-0

ENGINE OPERATION 41
7

42
REMOVING AND CARRYING THE OUTBOARD MOTOR

ENOM00070-D
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.

ENOF01505-1 ENOM00071-A
2. Carrying the outboard motor

ENOW00933-0

WARNING
1
Be sure to disconnect fuel connector except

ENOF00437-2

when operating engine.

1. Cooling water check port

Fuel leakage is a fire or explosion hazard,

8 1. Before stopping the engine, close the which can cause serious injury or death.

valve of the propane tank to consume remained fuel in the fuel line. And wait until engine is stopped.

ENOW00952-0

WARNING

2. Disconnect the fuel connector, the remote control cables and the battery cords from the outboard motor.
3. Remove the outboard motor from boat and completely drain the water from the gear case in a vertical position.

z When transporting, keep tank secured in an upright position with the tank valve turned off.
z Do not use, store or transport tank where it would be exposed to high temperatures.

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 43

through the exhaust port and cause engine problems.

ion or any softer surface shown below.

ENOF01510-1

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.

ENOF01532-0

ENON00941-0
Note

ENOF01533-0
8

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 45).

ENOF01511-1
ENOM00442-0
If the outboard motor must be laid down, be sure to close the valve of the LPG tank and disconnect fuel line, and then turn the engine until engine stop so that consume the remaining fuel in the fuel system completely. When laying down the outboard motor, place front-side, starboard-side, or port-side down on a cush-

ENOM00072-1A
3. Trailering

ENOW00072-0

CAUTION

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

44 REMOVING AND CARRYING THE OUTBOARD MOTOR

ENOW00073-A

WARNING

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

(like a transom saver bar) in the tilted position.
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.

ENOF00075-A

ENOW00952-0

WARNING

z When transporting, keep tank secured in an upright position with the tank valve turned off.
z Do not use, store or transport tank where it would be exposed to high temperatures.

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 45).

8

ENOW00071-0

CAUTION
Do not use tilt stopper or lever when traile-

2

1

ring the boat. Use only for holding the outboard motor in the fully tilted up while the boat is stored.

ENOF00074-B
1. Ground clearance should be provided sufficiently.
2. Transom saver bar

ENOW00072-A

CAUTION

ENOW00067-0

WARNING

When trailering the outboard motor should be in a vertical (normal running) position, fully down. Trailering in the tilted position may cause damage to the outboard motor, boat, etc. 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

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.

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.
ENON0506-0
Note
The steering friction adjustment screw is used to adjust the friction load of the steering, but not to fix the steering. Excess tightening of the adjustment screw may cause damage to the swivel bracket.
ENOM00544-0
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. Heavier 2. Lighter 3. Throttle friction adjustment screw
9

1

2

3

ENOF00444-0

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

46
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

ENOM00428-0
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 Fuel System
Fuel Tank
Engine Oil
Electrical Equipment
Throttle System Recoil Starter
Clutch and Propeller
System
Installation of Motor
Cooling Water
Tools and Spares Steering Devices
Other parts

Points to Check

Remedy

· Check the amount of fuel in the tank.

Replenish

· Check the rubber hoses for fuel leakage.

Replace if necessary

· Check for crack, leakage, damage in the fuel tank.

Replace

· Check for leakage at full close.

Replace

· Check the oil level.

Fill to the upper level mark on dipstick

· Check that the battery electrolyte level and specific gravity are normal.

Replenish or recharge

· Check for loose connections on the battery terminal.

Retighten

· Check that the stop switch functions normally and make sure Remedy or replace the lock plate is secured.

· Check cords for loose connections and damage.

Correct or replace

· Check the spark plug(s) for dirt, wear and carbon build-up. Clean or replace

· Check mixer linkage is working normally when turning the throttle grip.

Correct

· Check the rope for wear and chafing.

Replace

· Check the ratchet engagement.

Correct or replace

· Check that clutch engages correctly when operating the shift Adjust

lever.

· Visually Check propeller for bent or damaged blades.

Replace

· Check the propeller nut is tightened and the split pin is in cor-

rect position.

· Check all the bolts attaching the motor to the boat.

Tighten

· Check the thrust rod installation.

· After starting the outboard motor, make sure that water is being discharged from the cooling water check port.

Repair

· Check that there are tools and spare parts for replacing spark

plug(s), the propeller, etc.

· Check that you have the spare rope.

· Make sure that steering handle and remote control is function- Repair

ing normally.

· Check if the anode is securely installed.

Repair if necessary

· Check the anode for corrosion and deformation.

Replace

10

48 INSPECTION AND MAINTENANCE

ENOM00081-B
Oil level checking
1. Place the engine in a vertical position.
2. Remove the top cowl and the oil filler cap (dipstick).
3. Wipe oil off the dipstick with a cleancloth and screw the dipstic back completely.
4. Remove the dipstick again . Check the oil level on the dipstick. Oil level must be between the upper limit and lower limit shown on the dipstick.
5. Return the dipstick.
1

1. Oil filler cap (Dipstick)
10

ENOF00446-1

ENON00025-0
Note
Consult with an authorized dealer if the engine oil is milky color, or appears contaminated.

ENOM00082-A
Engine oil replenishing

ENOW00983-1

CAUTION

z Do not add engine oil of brand and gradeother than existing one. In case engine oilof other brand or grade is added, drain all oil 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 middle dipstick mark.

1 2
1. Upper limit 2. Lower limit
ENON00024-0
Note

ENOF01531-0

The oil level should be checked when the engine is cooled.

ENOF00448-1

INSPECTION AND MAINTENANCE 49

ENOM00083-B
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. Before flushing, remove the propeller and the forward thrust holder.

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 2

1. Flushing plug (option) 2. Hose (commercially available)

ENOF00449-A

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.

50 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 56)
3
1

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

ENOF00863-0

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 negative (-) terminal.
2. Remove the engine cover. 3. Remove the fuse box lid. 4. Remove the fuse and check it. If the
fuse is blown, replace it with a fuse of the same specified rating. The outboard motor is supplied with spare fuses in the spare fuse holder.

10

ENOM00950-1
Fuse replacement (for SP 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.

If the fuse is blown, try to determine the

1
1. Blown fuse

ENOF01524-0

INSPECTION AND MAINTENANCE 51

ENOM00431-1
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

Hose Mixer Regulator Shut off valve

Inspection intervals

First 20 hours or 1 month

Every 50
hours or 3 months

Every 100 hours or 6 months

Every 200 hours or 1 year

z/ z/

Every 400 hours or 2 year

Inspection procedure

Check /Replace if necessary

Check /Replace if necessary

Check /Replace if necessary

Check /Replace if necessary

Ignition System
Starting System

Spark plug

z

Spark plug cap/ High tension cord

Starter rope

z/ z/

Check and clean Check /Replace if necessary Check /Replace if necessary

Engine oil

z Replace

z Replace

Replace

Engine

Valve clearance

Check and adjustment

Lower Unit
Shift/ Throttle

Idling speed Compression pressure Combustion chamber Thermostat Propeller Split pin
Gear oil
Water strainer Water pump impeller Water pump housing Throttle cable Shift link

z/ z/

Check /Adjust

Check

Clean

z

z

z

z

z Replace

z

z Replace

z

z

z/

Replace

Check Check and replace if necessary Check and replace if necessary Check and replace Check Check/Replace if necessary

Check and replace if necessary

Check and replace if necessary Check and adjustment

Remarks

Gap 0.8­0.9 mm (0.031­0.035 in)

Approx.450 mL (15.2 fl.oz) Refer to P50
IN: 0.06­0.14 mm (0.0024­0.0055 in) EX: 0.11­0.19 mm (0.0043­0.0075 in)

10

Refer to P56
Refer to P56
195 mL (6.6 fl.oz) Refer to P55

52 INSPECTION AND MAINTENANCE

Inspection intervals

Description

First 20 hours or 1 month

Every 50
hours or 3 months

Every 100 hours or 6 months

Every 200 hours or 1 year

Every 400 hours or 2 year

Inspection procedure

Warning system

Check

Stop switch

z

z

Check

Bolt, nut

Retighten

Sliding part / rotating part

z

z

z

z

Apply grease

Grease nipples

z

z

Pump in grease

Outer equipment

z

z

z

z

Check

Anode

z/

Check /Replace if necessary

Top cowl / Latch

z/

Check /Adjustment

”z” This procedure can be performed by end user (or dealer) ”” This procedure shall be carried out by the dealer.

Remarks
Refer to P36 Refer to P60 Refer to P60 Refer to P59

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 and start operation z Frequent shifting operation z Frequent operation in acidic, polluted, muddy, sandy, or shallow water

10

Appropriate maintenance can prolong your engine life. Consult your Tohatsu authorized dealer for suitable maintenance interval depending on operating and environmental conditions.

INSPECTION AND MAINTENANCE 53

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.

ENOM00443-0
To change engine oil: Be sure to use recommended engine oil.
1. Stop the engine and leave it in a verti-
cal position over 5 minutes.

2. Turn the steering on the outboard motor left.
3. Put an oil drain pan under the oil drain bolt.
4. Remove the oil drain bolt and completely drain oil from the engine.
1

ENOF01513-0
1. Drain hole
5. 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) 6. Pull the bottom of cowl latch to
unlock, lift and remove the top cowl. 7. Fill the engine through the filler port
with the recommended oil to between the upper and lower limit mark on the dipstick. 8. Tighten the oil filler cap (dipstick). 9. Leave the outboard motor for 5 minutes and check oil level on the dipstick. Add oil if necessary. 10. Insert the dipstick to the hole completely and install the top cowl.

10

54 INSPECTION AND MAINTENANCE

11. Start the engine and idling for 5 minuets, then check for no oil leaks and no warning indicate.
1

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.

1. Oil filler cap (Dipstick)

ENOF00446-1

1 2
1. Upper limit 2. Lower limit
ENON00920-0
Note

ENOF01531-0

Use only recommended engine oil (See page 24)

10

Oil volume needed for complete oil replacement Approximately 450 mL (0.48 US qt.)

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.

ENOM00122-0
LPG tank, gas hose and connector inspection
ENOW00953-0
WARNING
Be sure to select LPG tank, gas hose and connector in accordance with recommended specification.

ENOW00954-1

WARNING

z Do not use a LPG tank expired life span. Re qualification will be required after specific years from the date of manufacture. Please follow to the fuel tank manufacture’s instruction.
z Be sure to follow your fuel tank, hose and connector manufacture’s inspection instruction.

INSPECTION AND MAINTENANCE 55

ENOM00098-A
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.

Required volume: approx. 195 mL (6.6 fl.Oz).
ENOF01515-0
4. Install the upper oil plug, and then remove oil tube nozzle and install the lower oil plug.
Oil plug specified tightening torque 4Nm (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.
10

ENOF01514-0
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).

ENOF01516-0

56 INSPECTION AND MAINTENANCE

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.

1. Put a piece of wood block between propeller blade and anti-ventilation plate to hold propeller.

ENOM00086-A
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 equipped).
z The propeller edge is thin and sharp. Wear the gloves while installing or removing to protect your hands.

10

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.

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.

1. Thrust rod 2. Propeller 3. Washer 4. Propeller nut 5. Split pin

1 2
3 4
5
ENOF00450-A

INSPECTION AND MAINTENANCE 57

6. Tighten the propeller nut to specified torque and align one of the grooves with propeller shaft hole.
Propeller nut torque: 12 Nm (9 ft-lb, 1.2 kgf-m) 7. Install a new split pin into the nut hole
and bend both ends of pin apart to lock propeller in place.

ENOF00084-E

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 plug(s) 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 plug, 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 cap. 4. Remove the spark plug 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 if 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.

1 2

ENOF00085-0

1. Electrode 2. Spark gap (0.8­0.9 mm, 0.031­0.035 in)

10

7. Install the spark plug by hand and turn it carefully to avoid cross- threading.

58 INSPECTION AND MAINTENANCE
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

ENOF01517-0

INSPECTION AND MAINTENANCE 59
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
ENOF01518-1

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

10

ENOF01519-1

INSPECTION AND MAINTENANCE 61

ENOM00100-A
3. Off-season storage

ENOW00955-0
WARNING
z Close the valve of the LPG tank. z After close the valve of the tank, consume
remained fuel by running the engine if the motor is stored.

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.

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 68)

5. Pull the recoil starter several turns to lubricate inside the cylinder.

ENOW00930-1

WARNING

z Be sure to remove stop switch lock to prevent the spark plug(s) 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 53). 7. Change the gear oil in the gear case
(See page 55). 8. Apply grease to grease point (See
page 60). 9. Place the outboard motor in the ver-
tical position under a dry condition.

ENOM00101-E
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. Consume remained fuel by turning the engine if the motor is stored.
4. Remove the spark plug and put a teaspoon of engine oil or spray storage oil into the combustion chamber through the spark plug holes.

ENOW00066-1

ENOF01511-1

10

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.

62 INSPECTION AND MAINTENANCE

ENON00941-0
Note
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 45).

ENOF01510-1
ENOM00442-0
If the outboard motor must be laid down, be sure to close the valve of the LPG tank and disconnect fuel line, and then turn the engine until engine stop so that consume the remaining fuel in the fuel system completely. When laying down the outboard motor, place front-side, starboard-side, or port-side down on a cushion or any softer surface shown below.

10

ENOF01532-0

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 fuel.

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. 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.

ENOF01533-0

INSPECTION AND MAINTENANCE 63

ENOM00104-A
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. Check the electrolyte level, and measure the voltage and specific gravity of the battery.

Specific Gravity at 20° 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 installed.
4. Change the engine oil (See page 53). 5. Before starting the engine, discon-
nect stop switch lock and crank approximately 10 times in order to prime the oil pump. 6. Fill fuel tank completely. 7. Start the engine and warm up the engine 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 used for storage inside the engine will be circulated out to assure optimum performance.

ENOM00105-C
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.
3. Remove the spark plug, and completely drain the water from the engine by pulling recoil starter several times. Replace oil to the correct level. The oil and filter 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.

10

64 INSPECTION AND MAINTENANCE

ENOM00106-1A
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. Antifreeze Measures 1. Make sure the LPG tank and pipes are
protected against freezing if there is a risk of the outdoor temperature falling to -5 degrees Centigrade or lower. 2. The amount of gas ejected from LPG tank differs in accordance with the outdoor temperature, so consult with your LPG dealer with regard to methods of increasing tank capacity and other measures if necessary.
ENOM00107-A
7. Striking underwater object

ENOF01145-0
ENOM00120-2
8. Auxiliary outboard motor operation
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.

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. 3. Return to the nearest harbor slowly
and carefully. 4. Consult a dealer check the outboard
motor before operation again.5

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 Warning lamp ON

FUEL SYSTEM

Possible cause

zz zzzz zzzz zzzz zzzz z zzzz
zz zzzz
zz
zzzz
zzzz
z
zzzz zzzz zzzz z zzzz z z

zzz zzz zzz zzz

zzz

zzz

zz

zz

z

z

zzz

z

z

zzz

zzz zz zz
zz

Empty fuel tank Incorrect connection of fuel system Air entering fuel line Deformed or damaged fuel hose Leaking of fuel system Closed LPG tank valve Clogged regulator or mixer Use of improper engine oil Use of improper LPG High oil level Low oil level Poor mixer adjustment Faulty oil pump Faulty regulator Clogged or damaged negative pressure hose for shut off valve Spark plug other than specified Dirt, soot, etc. on spark plug No Spark or weak spark Short circuit of engine stop switch Ignition timing incorrect (Ignitor, valve timing) Lock plate not fitted Disconnection of wire or loose ground connection

11

ELECTRICAL SYSTEM

66 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 Warning lamp ON

Possible cause

COMPRESSION &
OIL SYSTEM

zzzz zzz
zzzz zzzz
z zz

zz z
zz zz
z zz

zz

z

zz

zz

zz

zzzzz

zzzzzz

zz

zz

zzzzz

zzzzz

zzzz

zz

Incorrect valve clearance Poor sealing of cylinder head Poor sealing of intake or exhaust valve seat Wear of piston, piston ring and cylinder Carbon deposits in the combustion chamber Poor tightening of spark plug Insufficient cooling water flow, clogged or defective pump Faulty thermostat Damage of anti- ventilation plate Incorrect propeller selection Damaged or bent propeller Improper thrust rod position Unbalanced load on boat Transom too high or too low Transom too high or too low

OTHERS

11

67
TOOL KIT AND SPARE PARTS

ENOM00562-1
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 Split pin Stop switch lock

Quantity 1 1 1 1 1 1 1 1 1 1

Remark
10 × 13 mm 16 mm Double head (Cross/Flat)

12

68
PROPELLER TABLE
ENOM00438-0
z Propeller selection is important to optimize outboard motor performance. The type and size of propellers have a direct impact on acceleration, cruising performance such as fuel efficiency, and engine life.
z A propeller must be selected so that the engine RPM measured at wide open throttle while cruising is within the recommended range.
z In general, a large pitch propeller is suitable for smaller operating load, and small pitch propeller is suitable for larger operating load. If the boat load varies significantly, select a propeller that operates within the proper range for the maximum load. However, please note that it is necessary to have rpm setting within the recommended engine speed range for the lighter boat load.
z Consult your dealer for selecting optional propeller.

Load Light
Heavy S:Short shaft L:Long shaft UL:Extra long shaft *:SP model

Propeller Mark
9 7.8 × 8 7.8 × 7
6 Y6

Propeller Size (Diameter × Pitch)

inch

mm

7.9 × 9.0

200 × 229

7.8 × 8.0

198 × 203

7.8 × 7.0

198 × 178

7.9 × 6.0

200 × 152

8.4 × 6.3

212 × 160

Standard Propeller MFS 5D LPG S, L, UL
SP

*Related to equipped propeller In certain models, the standard propeller is already equipped on your outboard motor. Except for propeller came with outboard motor, propellers listed above are optional. Please consult your dealer to select the best propeller for your boat if the standard propeller does not match.

Full Throttle Operating Range

MFS 5DLPG: 5000 – 6000 min-1 (rpm)

1

Propeller Mark Location

1. Y6

2. Others

2

13

ENOFA0001-1

EMISSION CONTROL SYSTEM INFORMATION

ENOM01000-0
Emission Sources
Carbon monoxide, oxides of nitrogen and hydrocarbons are produced in the course of the combustion process. Controlling production of oxides of nitrogen and hydrocarbons is very important because they react to form a photochemical smog under certain conditions when subjected to sunlight. Carbon monoxide does not react in the same way, but is a toxic byproduct.
ENOM01001-0
Ignition Timing Control System
To reduce the amount of HC, CO and NOx produced, the ignition timing control system continuously adjusts the ignition timing.

ENOM01003-0
Clean Air Acts of the United States and California, and Environment Canada
EPA, California, and Canadian regulations require all manufacturers to provide written instructions that describe the operation and maintenance of commercial emission control systems.
The following instructions and procedures must be followed in order to keep the emissions from your engine within these emission standards.
ENOM01004-0
Tampering and Modifications
Tampering is a violation of the Federal Laws of the United States and California.
Tampering with or altering the emission control system could cause emissions to increase beyond legal limits. The following acts, although not all inclusive, are considered as tampering:

z Removing or modifying any part of the intake, fuel or exhaust system.
z Modifications that cause the engine to operate outside its design parameters.

14

70 EMISSION CONTROL SYSTEM INFORMATION

ENOM01005-0
Problems that can affect emission
If you notice any of the following symptoms, have your outboard motor inspected and repaired by an authorized Tohatsu service dealer before further use.
z Hard starting or stalling immediately after starting
z Rough idling z Misfiring/backfiring under load z Afterburning (backfiring) z Black exhaust smoke or increased fuel
consumption

parts must certify that use of the parts will not result in a failure of the engine to comply with these regulations.
ENOM01007-0
Maintenance
Follow the maintenance schedule presented on page 49. Keep in mind that this schedule is based on the assumption that the outboard motor will only be used for its intended purpose. Operation under sustained high loads or other unusual conditions will require more frequent service.

ENOM01006-0
Replacement Parts

The emission control system in your Tohatsu outboard motor has be en designed, built, and certified to conform with the EPA and California emission regulations. Whenever requesting maintenance, use of Tohatsu Genuine parts is highly recommended. Tohatsu Genuine parts constitute replacement parts manufactured to the same high standards as the original parts, thus guaranteeing uninterrupted high performance of your outboard motor. The use of replacement parts other than Tohatsu Genuine parts could jeopardize the effectiveness of the emission control system.

14

Tohatsu, as a manufacturer of aftermarket parts, assumes the responsibility that replacement parts will not adversely affect emission performance. The manufacturer or rebuilder of the replacements

ENOM01008-0
Star label
This outboard motor is labeled with the California Air Resources Board (CARB) star label. A description of this label is presented below.
ENOF01000-0

EMISSION CONTROL SYSTEM INFORMATION 71

ENOF01001-0

ENOF01003-0

ENOM01009-0
One Star-Low Emission One Star- Low emission The one-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.

ENOM01011-0
Three Stars-Ultra Low Emission The three-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003-2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low Emission engines.

ENOF01002-0

ENOF01004-0

ENOM01010-0
Two Stars-Very Low Emission The two-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star-Low Emission engines.

ENOM01012-0
Four Stars-Super Ultra Low Emission The four-star label identifies engines that meet the Air Resources Board’s Sterndrive and Inboard marine engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than One Star-Low Emission engines.

14

O W N E R’ S MANUAL
MFS D LPG
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

• p65warnings.ca.gov
• HOME | TOHATSU GLOBAL

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