MFS15 Tohatsu Owners Manual

OWNER’S
MANUAL
MFS 9.9D
MFS 15D
MFS 20D
Original instructions
OB No.003-11115-3AG1
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 © 2017 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-A
To You, Our Customer
Thank you for selecting a TOHATSU outboard motor. You are now the proud owner of an
excellent outboard motor that will service you for many years to come.
This manual should be read in its entirety and the inspection and maintenance procedures
described later in this manual should be followed carefully. Should a problem arise with the
outboard motor, please follow the troubleshooting procedures listed at the end of this
manual. If the problem persists, contact an authorized TOHATSU service shop or dealer.
Please always keep this manual together with the outboard motor as a reference to every-
one who uses the outboard motor. If the outboard motor is resold, make sure the manual
is passed on to the next owner.
We hope you will enjoy your outboard motor and wish you good luck in your boating
adventures.
TOHATSU CORPORATION
ENOM00113-0
EC DECLARATION OF CONFORMITY (DoC)
This product conforms to certain portion of the European Parliament directive. DoC con-
tains the following information;
z Name and Address of the manufacturer.
z Applied community directives
z Reference standard
z Description of the product. (Model name and serial number)
z Signature of the responsible person (Name / Title / Date and place of issue).
ENOM00002-0
OWNER REGISTRATION AND IDENTIFICATION
Upon purchasing this product, be sure that the WARRANTY CARD is correctly and com-
pletely filled out and mailed to the addressee noted there on. This WARRANTY CARD
identifies you as the legal owner of the product and serves as your warranty registration.
TO THE EXTENT PERMITTED BY APPLICABLE LAW, YOUR OUTBOARD MOTOR WILL
NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS PROCEDURE IS
NOT FOLLOWED.
ENOM00003-0
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before you
take delivery.
4
ENOM00005-A
Serial Number
In the space below, please record the outboard motor's serial number (indicated both on
the swivel bracket and on the cylinder block). The serial number will be needed when
ordering parts, and when making technical or warranty inquiries.
Serial Number:
ENOF01201-0
ENOF01200-1
Serial Number: Date of purchase:

5
ENOM00007-0
NOTICE: DANGER/WARNING/CAUTION/Note
Before installing, operating or otherwise handling your outboard motor, be sure to thor-
oughly read and understand this Owner's Manual and carefully follow all of the instruc-
tions. 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 dam-
age.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2. Remote control device installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3. Battery installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5. Warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8. Tilt up and tilt down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9. Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . 51
1. Removing the outboard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3. Remote control lever friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10. INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8. Auxiliary outboard motor operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12. ACCESSORIES KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9
INDEX
1 GENERAL SAFETY INFORMATION 1
2. SPECIFICATIONS 2
3. PARTS NAME 3
4. LABEL LOCATIONS 4
5. INSTALLATION 5
6. PRE-OPERATING PREPARATIONS 6
7. ENGINE OPERATION 7
8. REMOVING AND CARRYING THE
OUTBOARD MOTOR 8
9. ADJUSTMENT 9
10. INSPECTION AND MAINTENANCE 10
11. TROUBLESHOOTING 11
12. ACCESSORIES KIT 12
13. PROPELLER TABLE 13
14
14
10
GENERAL SAFETY INFORMATION
ENOM00009-0
SAFE OPERATION OF BOAT
1 As the operator/driver of the 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 standing or floating 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
should be shifted to neutral and shut off.
ENOW00005-0
WARNING
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOV-
ING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TO
A BOAT OR GEAR HOUSING.
ENOM0008-A
EMERGENCY STOP SWITCH
The Emergency Stop Switch will stall the outboard motor when the stop switch lanyard is
pulled off. This stop switch lanyard has to be attached to the operator of the outboard
motor to minimize or prevent injuries from the propeller in case the operator falls over-
board.
It is operator’s responsibility to use the Emergency Stop Switch Lanyard.
ENOW00004-A
WARNING
Accidental activation of the Emergency 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 Emergency Stop Switch, the 500 mm (20 in.) stop
switch lanyard is coiled and can extended to a full 1300 mm (51 in.).
ENOM00800-A
PERSONAL FLOATATION DEVICE
As the operator/driver and passenger of the boat, you are responsible to wear a PFD (Per-
sonal Floatation Device) while on the boat.
GENERAL SAFETY INFORMATION 11
ENOM00010-0
SERVICING, REPLACEMENT PARTS & LUBRICANTS
We recommend that only an authorized service shop perform service or maintenance on 1
this outboard motor. Be sure to use genuine parts, genuine lubricants, or recommended
lubricants.
ENOM00011-A
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct maintenance
procedures following maintenance section of this manual (See page 61). It is the opera-
tor's responsibility to perform all safety checks and to ensure that all lubrication and main-
tenance instructions are complied with for safe operation. Please comply with all
instructions concerning lubrication and maintenance. You should take the engine to an
authorized dealer or service shop for periodic inspection at the prescribed intervals.
Correct periodic maintenance and proper care of this outboard motor will reduce the
chance of problems and limit overall operating expenses.
Carbon Monoxide Poisoning Hazard

Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal if
inhaled for any length of time.
Never start or operate the engine indoors or in any space which is not well ventilated.
Gasoline
Gasoline and its vapors are very flammable and can be explosive. Use extreme care when
handling gasoline. You should be thoroughly knowledgeable on how to correctly handle
gasoline by reading this manual.
12
SPECIFICATIONS
ENOM00810-A
MODEL FEATURE
Model F9.9D F15D F20D
2 Type MF EP MF EF EFT EP EPT MF EF EFT EP EPT
S z z z z z z z z z z z z
Transom heights L z z z z z z z z z z z z
UL z z z z z z z z
Tiller Handle z z z z z z z
Remote Control z z z z z
Power Tilt z z z z
Mnual tilt z z z z z z z z
ENOM00811-A
MODEL NAME EXAMPLE
F 20D EPTL
F 20 D E P T L
Model descrip- Horse Product Starter Steering

Tilt system Shaft length
tion power generation system system
P= Remote
T= Power S= Short 15 in
E= Electrical Control (Plea-
F= Four stroke trim&tilt L= Long 20 in
D= Two stroke DI - A and up start sure)
Blank= Manual UL= Ultra long
M= Manual start F= Tiller handle
(Fisher) tilt 25 in
SPECIFICATIONS 13
ENOM00301-0
MF, EF, EFT
9.9D/15D/20D
Item MODEL
MF EF EFT
2
Overall Length mm (in) 1055 (41.5)
Overall Width mm (in) 365 (14.4)
Overall Height S·L·UL mm (in) 1085 (42.7) 1235 (48.6) 1362 (53.6)
Transom Height S·L·UL mm (in) 413 (16.3) 562 (22.1) 689 (27.1)
S kg (lb) 52 (115) 55.5 (122) 62.5 (138)
Weight*1 L kg (lb) 53.5 (118) 57.0 (126) 64.0 (141)
UL kg (lb) 55 (121) 58.5 (129) 65.5 (144)
Output kW (ps) 9.9D : 7.3 (9.9) 15D : 11.0 (15) 20D : 14.7 (20)
9.9D/15D: 5000-6000
Max. Operating Range min-1 (rpm)
20D: 5400-6100
Idle Speed in Forward Gear min-1 (rpm) 900
Idle Speed in Neutral Gear min-1 (rpm) 950
Engine Type 4-Stroke
Number of Cylinder 2
Bore × Stroke mm (in) 61 × 60 (2.40 × 2.36)
Piston Displacement cm3 (Cu in) 351 (21.42)
Exhaust System Through hub exhaust
Cooling System Water cooling
Engine Lubrication Trochoid pump
Starting System Manual Electric starter motor*
Ignition System Flywheel Magneto C.D. ignition
Spark Plug NGK DCPR6E
Trim Position 6
Engine Oil mL (fl.oz.) API, SH, SJ or SL 10W-30, Approx. 1000 (33.8)
Gear Oil mL (fl.oz.) Genuine Gear Oil or API GL5, SAE #80-90, Approx. 370 (12.5)
Unleaded regular gasoline : Pump posted
Fuel
87 Octane (research octane rating of 91)
Fuel Tank Capacity L (US gal) 12 (3.17)
Gear Reduction Ratio 2.15 (13 : 28)
Emission Control System EM (Engine modification)
Operator Sound Pressure
83.9
(ICOMIA 39/94) dB (A)
Hand Vibration Level
2.5
(ICOMIA 38/94) m/s2
Remark: Specifications subject to change without notice.
*1 With propeller, with battery cable.
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
14 SPECIFICATIONS
ENOM00302-0
EP, EPT
9.9D/15D/20D
2 Item MODEL
EP EPT
Overall Length mm (in) 640 (25.2)
Overall Width mm (in) 350 (13.8)
Overall Height S·L·UL mm (in) 1085 (42.7) 1235 (48.6) 1362 (53.6)
Transom Height S·L·UL mm (in) 413 (16.3) 562 (22.1) 689 (27.1)
S kg (lb) 54.5 (120) 61.5 (136)
Weight L kg (lb) 56 (123) 63 (139)
UL kg (lb) 57.5 (127) —
Output kW (ps) 9.9D : 7.3(9.9) 15D: 11.0 (15) 20D: 14.7 (20)
9.9D/15D: 5000-6000
Max. Operating Range min-1 (rpm)
20D: 5400-6100
Idle Speed in Forward Gear min-1 (rpm) 900
Idle Speed in Neutral Gear min-1 (rpm) 950
Engine Type 4-Stroke
Number of Cylinder 2
Bore × Stroke mm (in) 61 × 60 (2.40 × 2.36)
Piston Displacement cm3 (Cu in) 351 (21.42)
Exhaust System Through hub exhaust
Cooling System Water cooling
Engine Lubrication Trochoid pump
Startring System Electric starter motor with manual*
Ignition System Flywheel Magneto C.D. ignition
Spark Plug NGK DCPR6E
Trim Position 6 5
Engine Oil mL (fl.oz.) API, SH, SJ or SL 10W-30/40, Approx. 1000 (33.8)
Gear Oil mL (fl.oz.) Genuine Gear Oil or API GL5, SAE #80-90, Approx. 370 (12.5)
Unleaded regular gasoline: Pump posted
Fuel
87 Octane (research octane rating of 91)
Fuel Tank Capacity L (US gal) 12 (3.17)
Gear Reduction Ratio 2.15 (13 : 28)
Emission Control System EM (Engine modification)
Operator Sound Pressure
83.9
(ICOMIA 39/94) dB (A)
Hand Vibration Level
—
(ICOMIA 38/94) m/s2
Remark: Specifications subject to change without notice.
*1 With propeller, with battery cable.
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
15
PARTS NAME
ENOM00303-0
MF, EF, EP, EFT, EPT
1 18 19
20
17 21
3
2
3
16
15 22
4 23
14
5
13
6
12
7
8 24
9 25
10
11
26
29
28
27 ENOF01202-0
1 Tilt Handle 12 Drive Shaft Housing 24 Water Plug

2 Top Cowl 13 Thrust Rod 25 Oil Plug (Upper) (Level)
3 Bottom Cowl 14 Clamp Bracket 26 Oil Plug (Lower) (Fill)
4 Cooling Water Check Port 15 Clamp Screw 27 Oil Filter
5 Power Tilt Switch *1 16 Throttle Grip*2 28 Spark Pulg
(EPT and EFT type only) 17 Shift Lever*2 29 Oil Filler Cap
6 Oil Drain Bolt 18 Starter Handle *1: Power tilt type only.
7 Anti Ventilation Plate 19 Stop Switch *2: Tiller handle type only.
*3: Electrical starter type only.
8 Anode/Trim Tab 20 Warning Lamp
9 Sub Water Inlet 21 Fuel Connector
10 Water Inlet 22 Starter Switch*3
11 Propeller 23 Choke Knob*2
16 PARTS NAME
MF, EF, EP, EFT, EPT
36
3 32
31
37
34
33 Power Tilt Type
35
30
*5 *4
38
39
40 44
41
43 42
ENOF01203-0
30 Primer Bulb 42 Cord Assembly *5

31 Fuel Tank Cap 43 Engine Stop Switch Cord *5
32 Air Vent Screw 44 Power Tilt Switch
33 Fuel Connector *4: Power tilt, tiller handle type only.
34 Fuel Pick up Elbow *5: Remote control type only.
35 Fuel Tank
36 Clamp Screw *4
37 Power Tilt *1
38 Power Tilt Switch *5
39 Remote Control Box *5
40 Main Switch *5
41 Stop Switch *5
17
LABEL LOCATIONS
ENOM00019-A
Warning label locations
2
1
4
3, 4
6 7
ENOF01204-1
18 LABEL LOCATIONS
1. Warning label urge to read the owner’s 5. Warning label regarding position of
manual . outboard motor when setting down.
ENOF00120-0 ENOF00006-0
2-1. Warning regarding emergency start- For RC model
ing (See page 36). 6. Warning label regarding stop switch
2-2. Warning regarding high temperature. lanyard.
4 2-3. Warning regarding rotating object.
2-4. Warning regarding high voltage
4
2 3 ENOF00005-D
7. Warning regarding gasoline (See

page 26).
1
3PA-72181-100
3. Warning label regarding stop switch

(See page 34, 35, 43, 43)
ENOF00005-S
8. Warning regarding gasoline (See

ENOF00131-B
page 26).
4. Warning label regarding oil pressure
(See page 29).
ENOF00005-L
ENOF00131-0
LABEL LOCATIONS 19
ENOM00019-B
CE label locations
O utboard Motor
1)
0123 R a te d Power: 2)
Ma ss: 3)
Serial No. 4)
5) 4
6)
Made in Japan CAN ICES-2/NMB-2
ENOF01237-2
1. Model code(Model name)

2. Rated power
3. Dry mass weight( Without propeller, with battery
cable)
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 AG AH AK BX BA
Year of
2017 2018 2019 2020 2021
manufacture
20
INSTALLATION
ENOM00024-A Do not operate the outboard motor until it
1. Mounting the outboard motor on has been securely mounted on the boat in
accordance with the instructions below.
boat
ENOW00009-0
ENOW00006-B
WARNING
WARNING
z Mounting the outboard motor without
Before installing the outboard motor on the following this manual can lead to unsafe
boat, hang the outboard motor with the conditions such as poor maneuverabil-
hoist or equivalent device by attaching the ity, lack of control or fire.
engine hanger to the outboard. Use the z Loose clamp screws and/or mounting
hoist with allowable load is 150 kg (330 lbs) bolts can lead to the release or displace-
or above. ment of the outboard motor, possibly
resulting in lost of control and/or serious
5 personal injury. Be sure that fasteners
are tightened to the specified torque (30
N·m (3.0 kgf·m) 13 ft·lb). Check the fas-
teners for tightness from time to time.
z Be sure to use outboard mounting fas-
teners included in the outboard motor
package or their equivalents in terms of
size, material, quality and strength.
Tighten fasteners to the specified torque
(30 N·m (3.0 kgf·m) 13 ft·lb). Test cruise
to check if fasteners are tightened
securely.
z Outboard motor mounting must be per-
formed by trained service person(s)
using lift or hoist with sufficient capacity.
Outboard motor mounting must be per-

formed by trained service person(s) using
lift or hoist with sufficient capacity.
ENOF01206-0
ENOW00006-0
WARNING
Most boats are rated and certified in terms
of 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.
INSTALLATION 21
ENOM00025-0 z Incorrect outboard motor mounting

Position ... Above keel line height or existence of underwater
Set engine at center of boat. object(s), such as hull bottom design,
bottom surface conditions or underwa-
1 ter accessories, can cause water spray
possibly reaching the engine through an
opening of the bottom cowling during
cruising. Exposing the engine to such
conditions for extended periods can
lead to severe engine damage.
2
ENOM00830-A
Mounting bolts
Manual tilt type
5
ENOF01141-0
1. To attach the outboard motor to the
1. Center of boat boat, tighten the clamp screws by
2. Boat transom
turning their handles.
ENOM00026-0 Also, use the bolts to secure the out-
Transom matching board motor brackets on transom
Be sure that the anti ventilation plate of the board.
outboard motor is 5–25 mm (0.2–1 in) Secure the outboard motor with a rope
below the bottom of hull. to prevent loss overboard.
If the above condition cannot be met due ENON00002-0
to the shape of the bottom of your boat, Note

please consult your authorized dealer. A rope is not included in the standard
accessories.
2
1
5−25 mm
1
(0.2−1 in) 3
2 4
ENOF01208-0
ENOF00016-0
1. Bottom of hull
1. Bolt (8 × 85)
2. Anti ventilation plate
2. Nut
ENOW00007-0
3. Washer
4. Clamp screw
CAUTION ENOW00945-0
z Before beginning the running test, check

that the boat with maximum capacity
CAUTION
loading floats on the water in a proper z Please inspect whether there is a loos-
attitude. Check the position of water ening of the clamp screw or mounting
surface on the driveshaft housing. If the bolts before departure.
water surface is near the bottom cowl- z Loosening may cause a dangerous situ-
ing, in high waves, water may enter the ation, such as loss of control.
engine cylinders.
22 INSTALLATION
PTT type transom. Mounting bolts installed with

1. To attach the outboard motor to the the threaded end at the inside surface of
boat, use the bolts to secure the out- the transom can cause personal injury.
z Tighten the bolts sufficiency, otherwise
board motor brackets on transom falling down of outboard could be hap-
board. pened.
ENON00003-0
Notes
1 1. Apply sealing agent, such as silicone
sealed between the bolts and the tran-
som board holes before tightening the
A
bolts.
2. Be sure to tighten the mounting bolt
nuts to the specified torque.
4
5 (30 N·m (3.0 kgf·m) 13 ft·lb)
ENOM00840-0
2 2. Remote control device

5
installation
3 ENOF00308-0
1. Bolt (12 × 105) ENOW00100-A
2. Washer (small diameter)
3.
4.
Nut
Washer (large diameter)
CAUTION
Be careful not to loop the remote control
194
152 cables to a diameter of 406 mm (16 in) or
less. Otherwise, it affects the service life of
the cable.
1818 51
64
ENOW00850-0
Remote control box location
188
275
10
-∅
12
18 18
11 3
∅
36
1, 2
187
193
ENOF00305-0
View A
ENOW00008-A
ENOF00841-0
CAUTION 1. Shift cable
2. Throttle cable
z Mounting bolts should be installed with 3. Cable harness B
the bolt head at inside surface of the
INSTALLATION 23
Install the remote control box in a position comes in contact with your skin, or poison-
where it is easy to reach and operate the ous if swallowed.
Keep battery and electrolyte away from
controls.
reach of children
Make sure there are no obstacles that can When handling the battery, be sure to:
interfere with the operation of the remote z Read all warnings shown on the battery
control cable. case
z Prevent electrolyte from coming in con-
ENOW00850-0
tact with any part of your body. Contact
Remote control cable length can cause serious burn or, if it comes in
contact with your eye, loss of sight. Use
safety glasses and rubber gloves.
In case battery electrolyte comes in con-
tact with:
z Skin, flush thoroughly with water.
z Eye, flush thoroughly with water, and
then seek immediate medical treatment.
5
In case battery electrolyte is swallowed:
ENOF00842-0
z Seek immediate medical treatment.
ENOW00013-A
Measure the distance from the remote

WARNING
control box to the outboard motor where
the remote control cable should be routed. Battery generates explosive hydrogen gas.
Be sure to:
Prepare a cable that is 300-450mm (11.8-
z Charge the battery in a well-ventilated
17.7in) longer than the measured distance. place.
Temporarily pull the cable along the z Place the battery away from any source
intended cable route to check its length is of fire, sparks and open flames such as
sufficient. burners or welding equipment.
z Do not smoke near the battery when the
Connect the remote control cable to the
battery is charging.
engine, then run the cable to the remote z Do not charge the battery when the
control box, making sure it is not sharply electrolyte level is low. Otherwise, the
bent, too taut and free from obstructions battery will be damaged and may cause
that could interfere with steering. malfunction.
ENOW00014-0
ENOM00029-A
3. Battery installation
CAUTION
z Make sure that the battery leads do not
ENOW00012-0 get stuck between the outboard motor
and boat when turning, etc.
WARNING z The starter motor may fail to operate if
the leads are incorrectly connected.
Battery electrolyte contains sulfuric acid
and thus is hazardous, causing a burn if it
24 INSTALLATION
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 operat-
ing, the electrical parts could be dam-
aged.
z Always use a fully charged battery.
ENOW00015-0
2
1 ENOF00022-0
CAUTION 1. Battery cord (red)
Do not use a battery that is not recom- 2. Battery cord (black)
mended. Use of a battery not recom-
mended can lead to poor performance of,
5 and/or damage to, the electrical system.
ENON00006-A
Note
Recommended battery: 12V 70Ah/5HR,
650 (Cold Cranking Amps (CCA), In case of
cold whether: 12V100Ah/5HR (850CCA))
Specifications and features of batteries vary
among the manufacturers. Consult the
manufacturer for details.
* The battery should be purchased sepa-
rately and is not supplied with the outboard
motor.
1. Place the battery box in a convenient

position away from possible water
spray. Securely fasten both the box
and the battery so they do not shake
loose.
2. 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 ter-
minal (+), securely place a cap on it to
prevent short circuits.
25
PRE-OPERATING PREPARATIONS
ENOM00030-A
adverse effects. Some of these adverse
1. Fuel handling effects are caused because the ethanol in
the gasoline can absorb moisture from the
ENOW000017-0
air, resulting in a separation of the water/
CAUTION ethanol from the gasoline in the fuel tank.
These may cause increased:
Use of improper gasoline can damage your
z Corrosion of metal parts
engine. Engine damage resulting from the
use of improper gasoline is considered z Deterioration of rubber or plastic parts
misuse of the engine, and damage caused z Fuel permeation through rubber fuel
thereby will not be covered under the lim- lines
ited warranty. z Starting and operating difficulties
ENOM00031-A If the use of gasoline containing alcohol is

FUEL RATING inevitable, or presence of alcohol is sus-
TOHATSU engines will operate satisfacto- pected in the gasoline, it is recommended
rily when using a major brand of unleaded
6
to add a filter that has water separating
gasoline meeting the following specifica- capability, and check the fuel system for
tions: leaks and mechanical parts for corrosion
USA and Canada — having a posted and abnormal wear more frequently.
pump Octane Rating of 87 (R+M)/2 mini- And, in case any of such abnormality is
mum. Premium gasoline (92 [R+M]/2 found, discontinue the use of such gaso-
Octane) is also acceptable. Do not use line and contact our dealer immediately.
leaded gasoline. If the outboard motor will only be used
Outside USA and Canada — Use infrequently, please see the remarks on
unleaded gasoline with declared octane fuel deterioration in the STORAGE chapter
rating of 91 RON or over. Use of premium (P 78) for additional information.
gasoline of 98 RON is also allowed. ENOW00020-1
ENOM00032-A CAUTION
GASOLINES CONTAINING
When operating a TOHATSU engine on
ALCOHOL gasoline containing alcohol, storage of
The fuel system components on your gasoline in the fuel tank for long periods
TOHATSU engine will withstand up to 10% should be avoided. Long periods of stor-
ethyl alcohol (hereinafter referred to as the age, create unique problems. In cars, alco-
"ethanol"), content in the gasoline. But hol blend fuels normally are consumed
before they can absorb enough moisture to
even if the gasoline in your area contains
cause trouble, but boats often sit idle long
ethanol less than 10%, you should be enough for phase separation to take place.
aware of certain adverse effects that can In addition, internal corrosion may take
occur. Increasing the percentage of etha- place during storage if alcohol has washed
nol in the fuel can also worsen these
26 PRE-OPERATING PREPARATIONS
protective oil films from internal compo- z Be sure to remove the static electricity
nents. charged in your body before refueling.
z The sparks due to static electricity may
ENOW00018-0 cause explosion of flammable gasoline.
z Stop the engine, and do not start the
WARNING engine during refueling.
Fuel leakage can cause fire or explosion, z Do not smoke.
potentially leading to severe injury or loss z Be careful not to overfill fuel tank. Wipe
of life. Every fuel system part should be up any spilled gasoline immediately.
checked periodically, and especially after
long term storage, for fuel leak, change of When or before cleaning the gasoline tank:
hardness of rubber, expansion and/or cor- z Dismount fuel tank from the boat.
rosion of metals. In case any indication of z Place the fuel tank away from every
fuel leakage or degradation of fuel part is source of ignition, such as sparks or
found, replace relevant part immediately open flames.
before continuing operation. z Do the work outdoors or in a well venti-
lated area.
ENOW00019-1 z Wipe off gasoline well immediately if
6
spilled.
WARNING z
After cleaning gasoline tank:
Do not fill the fuel tank over capacity. The
z Wipe off gasoline well immediately if
rise of gasoline temperature may cause
spilled.
gasoline to expand which, may leak
z If the fuel tank is disassembled for
through air vent screw when it is open.
cleaning, reassemble carefully. Imper-
Leaking gasoline is a dangerous fire haz-
fect assembly may cause a fuel leak,
ard.
possibly leading to fire or explosion.
ENOM00043-B
z Dispose aged or contaminated gasoline
in accordance with local regulations.
2. Fuel filling
EENOW00029-A
ENOW00028-A
WARNING
WARNING When opening fuel tank cap, be sure to fol-
Consult an authorized dealer for details on low the procedure described below. Fuel
handling gasoline, if necessary. could blast out through the fuel tank cap in
case the cap is loosened by using another
Gasoline and its vapors are very flammable procedure when internal pressure of fuel
and can be explosive. tank is raised by heat from sources such as
sun light.
When carrying a fuel tank containing gaso-
line: ENOW00946-0
z Close the fuel tank cap and air vent

screw of fuel tank cap, or gasoline vapor CAUTION
will be emitted through the air vent Separate tank must be fixed at appropriate
screw, creating a fire hazard. position so that well ventilated and tank
z Do not smoke. does not move or fall down while operat-
ing.
When or before refueling:
PRE-OPERATING PREPARATIONS 27
1. Full open the air vent screw on the tank

cap and release internal pressure.
1
2
ENOF01209-0
ENOF00417-0
1. Air vent screw
2. Tank cap
Use only high quality 4-stroke engine oil to
insure performance and prolonged engine
2. Open the fuel tank cap slowly.
3. Fill the fuel carefully not to over flow.
life.
The SAE oil viscosity 10W-30 or 10W-40
6
FC-W outboard motor engine oil is recom-
mended.
You can also use oils that carry the API
rating of SH, SJ, or SL. Select the appro-
priate viscosity, based on atmospheric
SAFE FILL temperature, from the chart below.
LEVEL
12 L
NIVEAU
MAXIMUM
ENOF00419-A
10W−40
4. After filling the tank, close the fule tank 10W−30
cap. -30 -20 -10 0 10 20 30 40 ˚C

ENOM00037-A -22 -4 14 32 50 68 86 96 ˚F
ENOF00208-0
3. Engine oil recommendation
ENOW0002A-A
ENOW00022-A
CAUTION
CAUTION
Use of engine oils that do not meet these
The engine oil is drained for shipping from requirements will result in reduced engine
the factory. Be sure to fill the engine to the life, and other engine problems.
proper level before starting engine. (To
properly fill the engine with oil follow the
instructions, See page 63)
]ENOM00033-A
4. Break-In
Your new outboard motor and lower unit z Keep peripheral area well ventilated.
require break-in for the moving compo- z Always attempt to stay on the windward
side of emission.
nents according to the conditions
described in the following time table.
Please refer to ENGINE OPERATION sec- ENOW00023-1
tion (See page 36) to learn how to cor-

rectly start and operate the outboard CAUTION
motor. Operating the outboard motor without
ENOW00024-A
break-in can shorten service life.
If any abnormality is experienced during
DANGER the break-in:
z Discontinue the operation immediately.
Do not operate the outboard motor in z Have the dealer check the product and
6
closed area or area with no forced ventila- take proper action(s) if necessary.
tion.
Exhaust gas emitted by this outboard ENON00008-0
motor contains carbon monoxide that will Note
cause death if inhaled continuously. Inhal-
Proper break-in allows outboard motor to
ing the gas initially causes symptoms such
deliver it full performance for longer service
as feeling of sickness, drowsiness and life.
headache.
During operation of the outboard motor:
1–10 min 10 min – 2 hrs 2–3 hrs 3–10 hrs After 10 hrs
Less than 1/2 Less than 3/4 Full throttle
Throttle Position Idle 3/4 throttle
throttle throttle available
Approx. 4000
Full throttle run min-1 (rpm). Full
Approx. 3000
Speed allowed for 1 throttle run
min-1 (rpm) max
min every 10 min allowed for 2
min every 10 min
ENOM00039-C
5. Warning system
If outboard motor encounters an abnormal

condition of fault, the warning horn will
emit a continuous beep or intermittent
short beeps and the warning lamp (LED)
will synchronize with the horn and engine
speed will be limited (engine will not be 1
stopped). ENOF00314-A1
*No horn is located for tiler handle type 1. Warning lamp

and EP type.
See next page for conditions which will
lead to an abnormal condition or fault.
6
ENOM00040-C
Location of warning horn and
lamp
Warning horn
RC model: Located inside the remote con-
trol.
Tiller handle model: No warning horn.
Warning lamp (LED)
RC model: Located in the tachometer &
bottom cowl.
Tiller handle models:Located on the bot-
tom cowl
ENON00009-A
Note
Warning lamp for optional tachometer will
synchronize with the waring lamp for engine
side.
ENOF00851-A
1. Warning lamp
ENOM00041-D
Warning indicators, faults and remedy
Warning indicators
Description of faults Remedy
Sound Lamp (LED) ESG
On for several
- - Normal system test when start up
sec.
Engine speed exceeds maximum
- - High speed ESG
allowable RPM
1
Continuous *2
ON *2
Low speed ESG Low oil pressure *1
2
Remarks
*1: In this case, oil pressure switch is “ON”.
*2: It is necessary to stop the engine, if you want to stop the working indicators and re-set the warning system.
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, and the ESG is activated not to ignite the spark
plug, therefore, the engine speed varies and be controlled under 6300min-1 (rpm).
6 Low speed ESG

Low speed ESG is a device to prevent the engine from getting damage. If the engine has problems regarding oil
pressure the low speed ESG is activated not to ignite the spark plug, the engine speed varies and be controlled
under 2800min-1 (rpm).
Remedy
1. Reduce the throttle to less than half
opening, and move to safe place
quickly, and stop the engine.
Check the propeller for bent or dam-
aged blades.
Consult an authorized dealer if engine
shows the same result even after
replacing propeller with new one.
2. Move to safe place quickly, and stop
the engine.
Check the engine oil level, and add
engine oil if necessary.
Consult your dealer if the engine oil
level is too low or too high.
ENOW00025-A 6
CAUTION
z Low speed ESG ON: Engine speed will
be limited to 2800 min-1 (rpm), however
you should not continue to run engine.
z High speed ESG ON: Engine speed will
be limited to 6300 min - 1 (rpm) and
engine will run rough until throttle is
reduced.
32
ENGINE OPERATION
ENOM00042-0 procedure when internal pressure of fuel
Before starting tank is raised by heat from sources such as
sun light.
ENOW00022-A
ENOW00947-0
CAUTION
CAUTION
The engine oil is drained for shipping from
the factory. Be sure to fill the engine to the When using a separate tank, be sure that
proper level before starting engine. (To the fuel line is not kinked and is connected
properly fill the engine with oil follow the securely.
instructions. See page 63)
1. Full open the air vent screw on the tank
cap.
1
2
7
ENOF01209-0 ENOF00417-0
1. Air vent screw
2. Fuel tank cap
ENOW00027-A
2. Open the fuel tank cap slowly and

CAUTION release internal pressure completely.
Before starting engine for the first time After that, close the fuel tank cap.
after reassembling engine or off-season 3. Connect the fuel connector to the
storage, disconnect stop switch lock and
crank approximately 10 times in order to
engine and fuel tank.
prime the oil pump.
1
ENOM00044-C
1. Fuel feeding
ENOW00029-A
2
3
WARNING
When opening fuel tank cap, be sure to fol- ENOF00310-0
low the procedure described below. Fuel
could blast out through the fuel tank cap in 1. Fuel connector
2. Push
case the cap is loosened by using another 3. Insert
ENGINE OPERATION 33
2
1 3
2
ENOF00861-A
ENOF00863-0
1. Pull
2. Insert 1. Test tank
4. Squeeze primer bulb until it becomes 2. Water
3. Over 10 cm (4 in.)
stiff to feed fuel to carburetor. Direct
arrow mark upward when priming.
ENOW00036-0
1
CAUTION
Be sure to stop engine immediately if cool-
ing water check port is not discharging
water, and check if cooling water intake is
blocked. Operating engine could lead to
7
2 overheating potentially leading to engine
ENOF00862-0 damage. Consult an authorized dealer if
1. Engine side the cause cannot be found.
2. Fuel tank side
ENOW00032-A
Do not squeeze primer bulb with engine
running or when the outboard motor is CAUTION
tilted up. Otherwise, fuel could overflow. Do not hold turning starter motor more
ENOM00045-B than 5 seconds, or the battery may be con-
sumed, potentially making the engine start-
2. Starting the engine ing impossible and/or damaging the
starter.
ENOW00036-A If cranking over 5 seconds fails to start
engine, return main switch to “ON”, and
CAUTION crank engine again after 10 seconds or
When the engine is started in the test tank, more.
to avoid over heating and water pump Do not try to crank after engine has
damage, be sure the water level is at least started.
10 cm (4 in.) above the anti ventilation
plate. This model is provided with start in gear
And be sure to remove the propeller, when protection.
starting the engine in the test tank. (See
page 68)
Run the engine only at idling.
34 ENGINE OPERATION
ENON00010-0 1. Shift lever

Note
Start-in-gear protection prevents engine
from starting at other than neutral shift. In- 3. Set the throttle grip to START position.
gear starting of engine will move the boat
immediately, potentially leading to falling
down or causing passenger(s) to be thrown
overboard.
Tiller handle type

1. Be sure to install the stop switch lock
to the stop switch, and attach the stop 1
ENOF01107-0
switch lanyard securely to the operator
or to the operator's PFD (Personal Flo- 1. Throttle grip
tation Device.)
4. Pull the choke knob fully.
1
ENOF00310-A
1 ENOF00314-0
1. Stop switch lock 1. Choke knob
ENON00501-0
2. Set the control lever in the Neutral
Note
position.
Choke is not necessary when the engine is
warm. Set the throttle grip to “RE-START”
R position.
N ENON00502-0
1 Note
F
If engine does not start with 4 or 5 times
starting operation, push the knob back and
restart.
(For manual starter type)

This engine is equipped with a compres-
ENOF01210-0 sion release mechanism.
ENGINE OPERATION 35
5. Pull the starter handle slowly until you

feel engagement, keep pulling till you
feel less resistance. Then pull it quickly.
repeat if necessary until started.
1 2
3
ENOF01212-0
Side mount RC type

to the stop switch, and attach the stop
ENOF01211-0
switch lanyard securely to the operator
or to the operator's PFD (Personal Flo-
1. Slowly
2. Quickly tation Device.)
3. Starter handle
(For electrical starter type)

4. Push the starter switch button and
release the button when the engine 7
has started.
1
ENOF00869-0
1. Stop switch lock
2. Insert the main switch key.

1 ENOF00315-0
position.
4. Raise the free accel lever a little (both
1. Starter Button
of cold engine and warm engine).
ENON00504-0
5. Check the cooling water from cooling Note
water check port.
The free accel lever can not be raised when
the control lever shift is in Forward or
Reverse.
36 ENGINE OPERATION
7. Returns the Free accel lever to close

position.
1 2 8. Confirm warning lamp light up and
N
R
then go off after engine has started.
F
5
4 1
3 6
7
ENOF00870-0
1. Neutral (N)
2. Control lever
3. Fully open (Forward)
4. Fully open (Reverse) ENOF00851-A
5. Free throttle lever 1. Warning lamp
6. Main switch key 9. Check the cooling water from cooling
7. Stop switch
water check port.
5. Turns the main switch key to START
position. Then, continuously push the
key to operate the choke.
7 ENON00503-0
Note
Choke operation is not necessary if the
engine is warm.
ENOF01212-0
1
2
3 ENOM00042-B
Emergency starting
4
ENOW00099-A
WARNING
ENOF00871-A
When the emergency starter rope is used
1. ON for starting engine;
2. START z Start in gear protection does not work.
3. OFF Be sure to shift is at neutral position.
4. Push operate choke Otherwise the engine will move the boat
immediately and cause personal injury.
6. Stop pushing the key when the engine z Be careful that your clothes or other
has started. items do not get caught in the rotating
The key returns to the original position, engine parts.
z To prevent accident and injury by rotat-
automatically.
ing parts, do not re-attach flywheel
ENGINE OPERATION 37
cover and the top cowl after the engine 3. Remove the bolts (5pcs) and remove
has been started. the recoil starter.
z Do not pull starter rope if any bystander
is behind. The action can injure the
bystander.
z Attach engine stop switch lanyard to
clothing or any part of body like arm
before starting engine.
1. Remove the top cowl.
ENOF00125-0
4. Insert the knotted end of the starter

rope into the notch in the flywheel and
wind the rope around the flywheel sev-
eral turns clockwise.
ENOF01213-0
2. Remove starter lock cable from recoil 7

starter by pulling the starter lock cable.
ENOF00126-0
5. Tie a loop in the another end of the

emergency starter rope and attach
ENOF00124-0
socket wrench that is included in the
tool kit.
38 ENGINE OPERATION
5. Stop pushing the key when the engine

has started.
6. Return the choke plate to open posi-
tion.
ENOF01214-0
ENOW00860-0
CAUTION
Be sure to keep the harness away from the
rotation parts.
ENOF00320-0

to the stop switch, and attach the stop
7 switch lanyard securely to the operator
or to the operator's PFD (Personal Flo-
tation Device.)
position.
8. Pull the starter handle slowly until you
feel engagement, keep pulling till you
feel less resistance. Then pull it quickly.
9. After engine starts, do not reinstall fly-
ENOF00321-0
wheel cover and top cowl.
ENOM00043-B
ENOM00518-0
If the choke solenoid fails to 3. Warming up the engine

operate (EP and EPT type only)
ENOW00932-0
1. Remove the top cowl. CAUTION

2. Close the choke plate by finger.
Be sure to check that cooling water is
3. Raise the Free accel lever a little. coming out of the cooling water check port
4. Turn the main switch key to start posi- during warm up.
tion.
Warm the engine at low engine speeds for
about
ENGINE OPERATION 39
3 minutes : above 5°C (41°F) ENOW00038-A
5 minutes at 2000 min-1 (rpm) : below 5°C WARNING

(41°F)
z Attach other end of emergency stop
This allows the lubricating oil to circulate to
switch lanyard to the operator's PFD
all parts of the engine. Operating the (Personal Flotation device) or arm and
engine without warm up shortens the keep it attached during cruising.
engine's life. z Do not attach the tether to a part of
clothing that can be torn easily when
pulled.
z Arrange the tether so that will not be
caught by any object when pulled.
z Be careful not to pull the tether acciden-
tally during cruising. Unintentional stop
of engine can cause loss of control of
outboard motor. Rapid loss of engine
power can lead to falling down or caus-
ing passenger(s) to be thrown over-
ENOF01212-0 board.
ENOW00042-0
ENOM00044-0
Engine speeds
Idling speed after warming up.
WARNING 7
z Do not shift into Reverse during planing,
Remark: In case of cold engine starting, or control will be lost leading to serious
idling speed is increased about 400 min-1 personal injury, boat may swamp, and/
(rpm) for several minutes. or hull may be damaged.
z Do not shift into Reverse during cruis-
Clutch in (In gear) Clutch off (Out of gear)
ing, or control may be lost, falling down
900 min-1 (rpm) 950 min-1 (rpm) or causing passenger(s) to be thrown
overboard. Leading to serious personal
ENOM00046-A injury, and steering system and/or shift-
ing mechanism may be damaged.
4. Forward, reverse, and
acceleration ENOW00861-0
ENOW00037-0
WARNING
Do not shift at high boat speed, or control
WARNING may be lost, falling down or causing pas-
Before shifting into forward or reverse, senger(s) to be thrown overboard. Leading
make sure that boat is properly moored to serious personal injury.
and outboard motor can be steered fully to
ENOW00862-0
the right and left. Make sure that no swim-
mer(s) is ahead or astern of the boat.
CAUTION
Gear and clutch damage may occur if shift-
ing at high engine speed.
40 ENGINE OPERATION
Engine must be in the slow idle position

before shifting is attempted.
R
ENOW00863-0
N
CAUTION 1
F
Idle speed may be higher during warming
up of engine. If shifted to Forward or
Reverse during warming up, it may be diffi-
cult to shift back to neutral. In such case,
stop engine, shift to neutral, and restart
engine to warm up.
ENON00014-0
ENOF01210-0
Note 1. Shift lever
Frequent shifting to forward or reverse can Forward
accelerate wear or degradation of parts. In
1. Turn the throttle grip to reduce engine
such case, replace gear oil earlier than the
period specified. speed.
2. When the engine reaches trolling (or
ENOW00864-0 idling) speed, quickly pull the shift lever
7 CAUTION to the Forward position.
Reverse
Do not increase engine speed unnecessar- 1. Turn the throttle grip to reduce engine
ily when the shift is in neutral and reverse,
or engine damage may occur.
speed.
2. When the engine reaches trolling (or
idling) speed, quickly pull the shift lever
ENOM00890-A
to the Reverse position.
Tiller handle type
Acceleration
ENOW00865-A
ENOW00867-0
CAUTION WARNING
Do not force to shift when the throttle grip Sudden acceleration and deceleration may
is not in the fully closed position, other- cause passenger(s) to be thrown over-
wise, steering system and/or shifting board or falling down.
mechanism may be damaged.
ENOW00867-0
WARNING
Sudden acceleration and deceleration may
cause passenger(s) to be thrown over-
board or falling down.
ENGINE OPERATION 41
Open throttle grip gradually. Forward

1. Quickly push the control lever to the
Forward (F) position 32°, where the
gear is connected, while lifting up on
the lock button located under the con-
trol lever grip.
2. Further forward motion will open the
throttle.
Reverse
1
ENOF01119-0 1. Quickly pull the control lever to the
1. Throttle grip Reverse (R) position at 32°, where the
gear is connected, while lifting up on
ENOM0900-0
the lock button located under the con-
Side mount RC type
trol lever grip.
ENOW00867-0
2. Further rearward motion will open the
WARNING throttle.
Sudden acceleration and deceleration may Acceleration
cause passenger(s) to be thrown over- ENOW00867-A
board or falling down.

CAUTION 7
Sudden acceleration and deceleration may
cause passenger(s) to be thrown over-
7 board or falling down.
8
Open control lever gradually.
2 N
1 F 3R
6 N
F R
7 5 1
4
ENOF00877-0
1. Forward (F) ENOF00879-A
2. Neutral (N)
3. Reverse (R) 1. Control lever
4. Fully open (Forward)
5. Fully open (Reverse)
6. Free throttle lever
7. Control lever
8. Lock button
42 ENGINE OPERATION
ENOM00049-A
5. Stopping the engine

ENOW00868-0
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.
It can also cause loss of boat speed, possi- ENOF00314-B
bly leading the crew(s) and or objects on

the boat to be thrown forward due to iner- Side mount RC type
tial force.
1. Put the control lever in the Neutral
Tiller handle type position and run the engine for 2-3
1. Turn the throttle grip to the slow posi- minutes at idling speed for cooling
tion. down if it has been running at full
speed.
7
N
F R
1
1
ENOF01107-0
2
1. Throttle grip
2. Put the shift lever in the Neutral posi- ENOF00881-0
tion.
2. Turn the main switch key to the OFF
Run the engine for 2-3 minutes at
position or push the stop switch. ( Do
idling speed for cooling down if it has
not forget to turn the key off).
been running at full speed.
3. Turn the main switch key to the OFF
ON
position or push the stop switch. ( Do
not forget to turn the key off). OFF
START
ENOF00882-0
1. Control lever
ENGINE OPERATION 43
2. Main switch key When used as described, the emergency

ENOW00869-0
stop switch clip and emergency stop
switch lanyard system stops the engine if
WARNING the operator falls away from the controls.
After stopping the engine: When an operator falls into water, be sure
z Close the air vent screw on the tank cap. to use emergency stop switch lock of the
z Disconnect the fuel connector of the spare.
engine and the fuel tank. Be sure to confirm the spare stop switch
z Disconnect the battery cord, after each
use.
lock is in the tool bag before begin to oper-
ate.
Emergency engine stopping
Remove stop switch lock to stop the
engine.
ENOF00891-0
ENOM00920-0
6. Steering 7
ENOW00870-0
2
WARNING
1 ENOF00314-C
Sudden steering may cause passenger(s)
1. Stop switch
to be thrown overboard or falling down.
2. Stop switch lock
Tiller handle type

Right turn
Move the tiller handle to the left
Left turn
Move the tiller handle to the right.
1
2
ENOF00884-0
1. Stop switch
2. Stop switch lock
ENOM00910-0
Spare emergency stop switch lock
A spare emergency stop switch lock is
provided in the tool bag.
44 ENGINE OPERATION
injury in case the outboard motor body

falls.
z Unsuitable trim position can cause loss
of control of boat. When testing a trim
position, run boat slow initially to see if it
can be controlled safely.
ENOW00044-0
WARNING
Excessive trim up or down may lead to
unstable boat operation, potentially caus-
ing the steering difficulty that leads to acci-
ENOF00892-0
dent during cruising.
z Do not cruise at high speed if improper
Remote control type trim position is suspected. Stop the boat
Right turn and readjust trim angle before continu-
Turn the steering wheel to the right. ing cruise.
z For outboard motor model with PTT
Left turn
switch on the bottom cowl, do not oper-
Turn the steering wheel to the left. ate the switch during cruising, or control
of boat may be lost.
7
The trim angle of the outboard motor can
be adjusted to suit the transom angle of
the hull, and load conditions. Choose an
appropriate trim angle that will allow the
anti-ventilation plate to run parallel to the
water surface during operation.
ENOM00052-0
Proper trim angle
The position of the thrust rod is correct if
ENOF00893-0
the hull is horizontal during operation.
ENOM00050-0
7. Trim angle
1
ENOW00043-A
WARNING
z Adjust the trim angle when the engine is
stopped. ENOF00051-1
z Do not put hand or finger in between
outboard motor body and clamp bracket 1. Perpendicular to the water surface
when adjusting trim angle to prevent
ENGINE OPERATION 45
ENOM00053-0
Power Tilt type
Improper trim angle (bow rises too
high)
Set the thrust rod lower if the bow of the
boat rises above horizontal.
1
2
ENOF00674-B
ENOF00052-0 1. Thrust rod

2. Higher
3. Lower
ENOM00054-0
Improper trim angle (bow dips into the
water) Trim angle adjustment (Manual tilt
Set the thrust rod higher if the bow of the type)
boat is below horizontal. The transom angle adjustment
1. Stop the engine.
2. Shift into neutral.
3. Raise the outboard motor to the tilt up
7
position.
4. Change the thrust rod position as fol-
lowing picture.
ENOF00053-0
Manual Tilt type
3
2
ENOF01238-1
1 1. Push in
2. Rise the stopper
2 3. Pull out
5. Reinstall the thurst rod securely.
3 ENOF00674-A
6. Gentry lower the outboard.
1. Thrust rod
2. Higher
3. Lower
46 ENGINE OPERATION
Trim angle adjustment (Power tilt type) ENOW00048-0
The transom angle adjustment WARNING

1. Stop the engine
When tilting up or down, be careful not to
2. Operate the Power Tilt switch and
place your hand between the swivel
raise the outboard motor to the tilt up bracket and the stern bracket.
position. Be sure to tilt the outboard motor down
3. Lock the tilt with the Tilt stopper. slowly.
4. Change the trim lock pin position as ENOW00056-A
following picture.
WARNING
When tilting up outboard motor with fuel
joint for over a few minutes, be sure to dis-
2 connect fuel hose, or fuel may leak, poten-
tially catching fire.
1 3 ENOW00057-0
CAUTION
Do not tilt up outboard motor while engine
7 operates, or no cooling water may be fed,
leading to engine seizure due to overheat-
ENOF01426-0
ing.
1. Tilt lock pin
2. Higher ENON00921-0
3. Lower Note
5. Reinstall the tilt lock pin securely. Before tilting the outboard motor up, after
6. Operate the Power Tilt switch and stopping the motor leave it in the running
lower the outboard. position for about a minute to allow water to
drain from inside the engine.
ENOM00060-B
ENOM00062-0
8. Tilt up and down Manual Tilt type
Tilt up
ENOW00055-0
Push the reverse lock lever down until it
WARNING stops. (This is the tilt up position.) Now, tilt
Do not tilt up or down outboard motor
the outboard motor all the way up until it is
when swimmer(s) or passenger is near to locked in place.
prevent them from being caught between
outboard motor body and clamp bracket in
case the outboard motor body falls.
ENGINE OPERATION 47
1 1
2 2
3 3
ENOF00059-0 ENOF00059-0
1. Reverse lock lever 1. Reverse lock lever

2. Tilt up position 2. Tilt up position
3. Tilt down position 3. Tilt down position
ENOF01216-0
ENOM00063-0
Tilt down
Pull the reverse lock lever upward until it
stops. (This is the tilt down position.) Now,
lift up the outboard motor slightly, and then
allow gravity to lower it for you.
48 ENGINE OPERATION
ENOM00069-A
The outboard motor can also be tilted up
Power Tilt type and down using the switch provided under
Tilt up
the bottom cowl.
1. Operate the Power Tilt switch and tilt
the outboard motor up.
2. Lock the tilt with the Tilt stopper after
the outboard motor has been tilted up
Tilt down
1. Release the tilt stopper from the set-up
position while slightly tilting up out-
board motor.
the outboard motor down until the ENOF01217-0
motor touches to the thrust rod. It is possible to tilt up or down in spite of

main switch “ON” or “OFF”.
UP
ENOM00940-0
Manual relief valve
DN If the battery is dead, and the power tilt
7
switch thus inoperative, open the manual
valve completely in the Manual direction.
This will allow manual tilting of the out-
board motor.
DN UP
ENOW00872-0
WARNING
ENOF00067-A
Make sure the manual relief valve is closed
before operating the outboard motor. If the
manual relief valve is not closed, the out-
board motor will tilt up when operated in
1 reverse.
ENOW00873-0
WARNING
Before opening the manual relief valve,
make sure nobody is under the outboard
motor. If the outboard motor is in the tilted
ENOF00069-A
up position, it will tilt down suddenly if the
1. Tilt stopper manual relief valve is loosened in the "Man-
ual" direction.
ENGINE OPERATION 49
through water inlet and sub-water inlet,

potentially leading to engine overheating.
1 1
ENOF01144-0
1. Water inlet
2. Sub-water inlet
2 ENOF00326-0
Manual tilt type
1. Power 1. Shallow water running position:
2. Manual
Put the reverse lock lever in the tilt up
position, and tilt up the outboard motor
7
ENOM00068-A
9. Shallow water operation to put the outboard motor in the shal-

low water running position.
ENOW00051-0
WARNING 1
During shallow water operation, be careful 2
not to place your hand between the swivel
bracket and the clamp bracket. Be sure to
tilt the outboard motor down slowly.
ENOW00053-0
3
CAUTION
ENOF00059-0
While in shallow water drive position, do
not operate the outboard motor in Reverse. 1. Reverse lock lever
Operate the outboard motor at slow speed 2. Tilt up position
and keep the cooling water intake sub- 3. Tilt down position
merged.
2. Return to normal running position:
ENOW00054-0 Put the reverse lock lever in the tilt
CAUTION down position, slightly lift up the out-
board motor, and then put it down.
Do not overtilt outboard motor when driv-
ing shallow water, or air may be sucked
50 ENGINE OPERATION
ENOF00059-0
1. Reverse lock lever

2. Tilt up position
3. Tilt down position
ENOM00069-A
Power Tilt type
the outboard motor up into desired
shallow water running position.
7
DN UP
ENOF00343-A
UP
DN
ENOF00067-0
51
REMOVING AND CARRYING THE OUTBOARD MOTOR
ENOM00070-A
1. Removing the outboard motor

ENOW00890-0
WARNING
Before installing the outboard motor on the
boat, hang the outboard motor with the
hoist or equivalent device by attaching the
engine hanger to the outboard.
Use the hoist with allowable load is 150 kg
(330 lbs) or above.
ENOW00064-0
CAUTION
Engine may be hot immediately after oper-
ating and could cause burns if touched.
Allow engine to cool down before attempt-
ENOF01206-0
ing to carry the outboard.
ENOM00071-A
1. Stop the engine.
2. Carrying the outboard motor
3. Disconnect the fuel connector, the
8
ENOW00933-0
remote control cables and the battery
cords from the outboard motor. WARNING
4. Attach the hoist hooks to the engine Be sure to disconnect fuel connector
hanger. except when operating engine.
Fuel leakage is a fire or explosion hazard,
5. Remove the outboard motor from boat
which can cause serious injury or death.
and completely drain the water from
the gear case. ENOW00065-0
WARNING
Close air vent screw of fuel tank before
carrying or storing outboard motor and fuel
tank, or fuel may leak, potentially catching
fire.
ENOW00066-0
CAUTION
z Do not give a shock to an outboard
motor during transportation. It becames
a cause of breakage.
52 REMOVING AND CARRYING THE OUTBOARD MOTOR
z Do not carry or store outboard motor in then the port side faces down as shown
any of positions described below. in the drawing above.
Otherwise, engine damage or property z Elevate power unit 2 inches to 4 inches if
damage could result from leaking oil. traveling to avoid oil spillage.
ENOF01221-0
ENOM00072-A
ENOF01219-0
3. Trailering
Keep the outboard motor in a vertical posi- ENOW00072-0
tion when carrying.

The optional outboard motor stand is rec-
CAUTION
ommended for keeping the outboard Trailering in the tilted position may cause
motor vertical both during transport and damage to the outboard motor, boat, etc.
storage. ENOW00073-A
8 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.
ENOF00075-1
ENOW00068-0
WARNING
ENOF01220-0 Close air vent screw of fuel tank and fuel
ENON00021-A
cock before carrying or storing outboard
Note motor and fuel tank, or fuel may leak,
potentially catching fire.
z If the outboard motor must be laid down
be sure drain the fuel and engine oil,
REMOVING AND CARRYING THE OUTBOARD MOTOR 53
ENOW00071-0
CAUTION
The tilt support device supplied on your
outboard motor is not intended for towing.
It is intended to support the outboard
motor while the boat is docked, beached,
etc.
When transporting a boat on a trailer with

the outboard motor still attached, discon-
nect the fuel line from the outboard motor
beforehand and keep the outboard motor
in the normal running position or on a tran-
som saver bar.
Tiller handle type

To prevent the outboard motor from mov-
ing when it is attached on a boat during
transport on a trailer, properly tighten the
steering friction lever (page 75).
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.
54
ADJUSTMENT
ENOM00073-0
Friction adjustment of the throttle grip can
1. Steering friction be made with the throttle adjustment
screw.
Tiller handle type
ENOW00074-A
2 3
WARNING
Do not overtighten the steering friction
lever it could result in difficulty of move-
ment resulting in the loss of control caus-
ing an accident and could lead to severe 1
ENOF00330-1
injury.
1. Steering friction lever
Adjust this lever to achieve the desired 2. Decrease
3. Increase
steering friction (drag) on the tiller handle.
Move lever towards (2) to decrease friction ENOM00075-0
and move lever towards (3) to increase
3. Remote control lever friction
friction.
ENOW00074-C
1
WARNING
Do not overtighten the remote control
throttle friction adjustment screw or it
could result in difficulty of movement
resulting in the loss of control causing an
accident and could lead to severe injury.
9 To adjust the friction of the remote control
3 2 ENOF00329-0 lever, turn the throttle friction adjustment
1. Steering friction lever screw on the front of the remote control.
2. Decrease
3. Increase Turn clockwise to increase the friction and
ENOM00074-A counter-clockwise to decrease it.
2. Throttle grip friction
ENOW00074-B
WARNING
Do not overtighten the throttle adjustment
screw or it could result in difficulty of
movement resulting in the loss of control
causing an accident and could lead to
severe injury.
ADJUSTMENT 55
Side mount type 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
2 3 boat).
1 ENOF00078-1
1. Throttle friction adjustment screw

2. Decrease
3. Increase
ENOM00076-0
4. Trim tab adjustment

ENOW00076-1
WARNING
z Be sure that outboard motor is secured 1 1
ENOF00912-A
to transom or service stand, or acciden-
tal drop or fall of outboard motor could 1. Trim tab
lead to severe personal injury. ENON00022-A
z Be sure to lock outboard motor when it Notes

9
is tilted up, otherwise accidental fall of z After adjustment securely tighten the
outboard motor could lead to severe trim tab fixing bolt.
personal injury. z Check for looseness of the bolt and the
z Do not go under outboard motor tilted trim tab at regular intervals.
up and locked, or accidental fall of out-
board motor could lead to severe per-
sonal injury.
ENOW00075-1
WARNING
Inappropriate adjustment of trim tab could
cause steering difficulty. After installing or
readjusting trim tab, check if steering load
is even.
If straight-line cruising can not be

achieved, adjust the trim tab located under
56
INSPECTION AND MAINTENANCE
ENOM00077-0
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 main-
tenance as suggested in the maintenance
schedules that follow.
ENOW00077-0
CAUTION
z Your personal safety and that of your
passengers depends on how well you
maintain your outboard motor. Carefully
observe all of the inspection and mainte-
nance procedures described in this sec-
tion.
z The maintenance intervals shown in the
checklist apply to an outboard motor in
normal use. If you use your outboard
motor under severe conditions such as
frequent full-throttle operation, frequent
operation in brackish water, or for com-
mercial use, maintenance should be per-
formed 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 out-
board motor arising from the use of
other than genuine parts is not covered
under the warranty.
10
INSPECTION AND MAINTENANCE 57
ENOM00322-1
1. Daily Inspection
Perform the following checks before and ENOW00078-1
after use. WARNING

Do not use outboard motor if any abnor-
mality is found during pre-operation check
otherwise it could result in severe damage
to the motor or severe personal injury.
Item Points to Check Remedy

• Check the amount of fuel in the tank. Replenish
• Check for debris or water in the fuel filters. Clean or replace if
Fuel System
necessary
• Check the rubber hoses for fuel leakage. Replace if necessary
• Check for crack, leakage, damage in the fuel tank cap. Replace if necessary
• Check for crack, damage in the gasket. Replace if necessary
Fuel Tank Cap
• Check for leakage at full close. Replace if necessary
• Check for ratchet performance. Replace if necessary
Engine Oil • Check the oil level. Fill oil
• Check that the main switch functions normally. Replace if necessary
• Check that the battery electrolyte level and specific gravity are Replenish or recharge
normal.
• Check for loose connections on the battery terminal. Retighten
• Check that the stop switch functions normally and make sure Remedy or replace if
Electrical the stop switch lock is there. necessary
Equipment • Check cords for loose connections and damage. Correct or replace if
necessary
• Check the spark plugs for dirt, wear and carbon build-up. Clean or replace if
necessary
• Check the warning LED lamp (ON for 5 to 7 secs.) when start Repair
up. 10
• Check the rope for wear and chafing. Replace if necessary
Recoil starter
• Check the ratchet engagement. Replace if necessary
• Check that clutch engages correctly when operating the shift Adjust
Clutch and lever.
Propeller Sys-
tem • Visually Check propeller for bent or damaged blades. Replace if necessary
• Check the propeller nut is tightened and the split pin is present. Tighten or replace
Installation of • Check all the bolts attaching the motor to the boat. Tighten
Motor • Check the thrust rod installation. Replace if necessary
Power Tilt • Check working of the tilt up and down of the motor. Repair
• Check that cooling water is discharged from the cooling water Repair
Cooling Water
check port after the engine has started.
• Check that there are tools and spare parts for replacing spark Order
Tools and
plugs, the propeller, etc.
Spares
• Check that you have the spare rope and stop switch lock. Order
58 INSPECTION AND MAINTENANCE
Item Points to Check Remedy

Steering • Check the operation of the steering handle. Repair
Devices
• Check if the anode is securely installed. Repair if necessary
Other parts
• Check the anode for corrosion and deformation. Replace
ENOM00081-A
Oil level checking
If the oil level is low, or too high, the life of
the engine will be shortened significantly.
1. Stop the engine and set it in a vertical
position.
3. Remove the dipstick after 5 minutes 1
engine has stopped.
2 ENOF00081-0
4. Wipe oil off the oil dipstick with a clean
1. Upper level 1000 mL
rag. 2. Lower level 750 mL
5. Put in the dipstick. ENON00024-0
6. Take out the dipstick and check the oil Note

level. The oil level should be checked when the
7. Return the dipstick. engine is cold.
ENON00025-0
Note
Consult with an authorized dealer if the
engine oil is milky color, or appears contam-
inated.
1
ENOM00082-A
Engine oil replenishing
10 2 ENOW00079-A
CAUTION
ENOF01222-0 z Do not add engine oil of brand and grade
other than existing one. In case engine
1. Filler cap
2. Dipstick oil of other brand or grade is added,
drain all oil and ask dealer for treatment.
z In case other than engine oil such as
gasoline is put in the oil chamber, empty
the chamber and ask dealer for treat-
ment.
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 ENOW00920-0
spilled and dispose of it in accordance

with local fire prevention and environ-
CAUTION
ment protection regulations. When washing the outboard motor, be
z Do not replenish engine oil over upper careful not to spray the water inside of the
limit. If overfilled, remove oil to upper top cowl, especially electrical components.
limit. If engine oil is over the upper limit,
it can leak potentially leading to engine ENON00026-0
damage. Note
If the oil level is low, or at lowest mark, add It is recommended to check chemical prop-
erties of water on which your outboard
recommended oil to the middle dipstick motor is regularly used.
mark.
If outboard motor is used in salt water,
brackish water or water with a high acidic
level, use fresh water to remove salt,
chemicals or mud. And flush cooling water
passage after every cruising or before stor-
ing outboard motor for long time. Before
flushing, remove the propeller and the for-
ward thrust holder.
ENOM00085-B
ENOF01209-0 Flushing attachment

ENOW00922-0
ENOM00083-B
CAUTION
Washing outboard motor
ENOW00081-0
To prevent the engine from starting when
you are near the propeller, remove the stop
WARNING switch lock.
Do not start engine without removing pro- 10

peller, or accidentally turning propeller 1. Tilt down the outboard motor.
could cause personal injury.
2. Remove the water plug from the gear
ENOW00082-0 case, and screw in the flushing attach-
ment.
WARNING
3. Connect a water hose. Turn on the
Never start or operate the engine indoors water and adjust the flow.
or in any space which is not well ventilated.
Exhaust gas contains carbon monoxide, a 4. Put the shift lever in the neutral position
colorless and odorless gas which can be and start the engine.
fatal if inhaled for any length of time. Continue flushing the outboard motor
for 3 to 5 minutes at idling.
5. Stop the engine and water supply. 10 cm (4 in.) above the anti ventilation
Remove the flushing attachment and plate.
And be sure to remove the propeller, when
tape.
starting the engine in the test tank. (See
6. After the flushing, be sure to reattach page 68)
the water plug. Run the engine only at idling.
.
3
1
1
2
ENOF00863-0
ENOF01223-0
1. Test tank
1. Flushing attachment (Option) 2. Water
3. Over 10 cm (4 in.)
ENOM00085-A
Flushing by test tank
ENOW00081-0 ENOM00950-0
Fuse replacement
WARNING ENOW00923-0
Do not start engine without removing pro-

peller, or accidentally turning propeller
CAUTION
could cause personal injury. Before replacing a fuse, disconnect the
battery cable from the battery negative (-)
ENOW00082-0
terminal. Failure to do so may cause a
10 WARNING short-circuit.
Never start or operate the engine indoors ENOW00924-0
or in any space which is not well ventilated.

Exhaust gas contains carbon monoxide, a
CAUTION
colorless and odorless gas which can be Never use a fuse with a rating that exceeds
fatal if inhaled for any length of time. the specified rating as this could cause
serious damage to the electrical system.
ENOW00036-A
CAUTION If a blown fuse is detected, try to deter-

When the engine is started in the test tank, mine the cause for this and correct it. If the
to avoid over heating and water pump cause for the problem is not corrected, the
damage, be sure the water level is at least
fuse will likely blow again.
If the fuse continues to blow, request an
authorized Tohatsu dealer to inspect the

outboard motor.
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
2
the same specified rating. The out- ENOF01234-0
board motor is supplied with spare 1. Fuse for charging system

fuses in the spare fuse holder. 2. Fuse for main circuit
3. Blown fuse
3 10
ENOF01224-0
ENOM00090-B
2. Periodic Inspection
It is important to inspect and maintain your outboard motor regularly. At each interval on
the chart below, be sure to perform the indicated servicing.
Maintenance intervals should be determined according to the number of hours or number
of months, whichever comes first.
Inspection intervals
Description First 20 Every 50 Every 100 Every 200 Inspection procedure Remarks
hours or 1 hours or 3 hours or 6 hours or 1
month months months year
Carburetorr*1 z Check and clean, if necessary.

Check and clean or Replace if
Fuel filter z z
necessary. (See page 66)
Piping/Hoses z z
necessary.
Fuel System
Fuel tank z z Clean (See page 69)
Fuel tank cap z z
necessary.
Fuel pump*1 z z
necessary.
Check gaps. Remove carbon deposits 0.8-0.9 mm
Ignition Spark plug z z
or Replace if necessary. (See page 69) (0.031-0.035 in)
Starter rope z z Check for wear or chafing
Starting *1 Check for salt deposits and the battery
Starter motor z
System cable condition.
Battery z z Check installation, fluid quantity, gravity.
Replace Replace 1000 ml
Engine oil z z
Replace. (See page 58)
(33.8 fl.oz.)
Replace every 200 hrs or 2 years (See
Oil filter*1 Entire cartridge
page 65)
IN:
0.13-0.17 mm
10 Valve Clearance*1 z z Check & adjust
(0.0051-0.0067 in)
EX:
Engine 0.18-0.22 mm
(0.0071-0.0087 in)
Timing belt*1 z Check and Replace if necessary.
Compression
z Check and repair if necessary.
pressure*1
Combusion
Clean every 200 hrs or 2 years
chamber*1
*1 z
Thermostat Check and Replace if necessary.
Inspection intervals
Description First 20 Every 50 Every 100 Every 200 Inspection procedure Remarks
hours or 1 hours or 3 hours or 6 hours or 1
month months months year
Check for bent blades, damage, wear.

Propeller z z
Replace if necessary. (Seepage 68)
Replace Replace Change or replenish-oil and check for 370 mL
Gear oil z
z z water leaks. (See page 74) (12.5 fl.oz.)
Lower Unit
Cooling water
z z Check clogging
inlet
Replace Check for wear or damage and replace Replace impeller
Water pump*1 z
z if necessary every 12 months.
Power tilt *1 z z Check & replenish oil, manually operate
Warning system*1 z Check function
Bolts and Nuts z z Retighten
Check for wear or damage and replace
Throttle wire z
if necessary
Remote control cable z Check and adjust if necessary
Sliding and Rotating Parts. Apply and pump in grease. (See
z z
Grease Nipples page 73)
Outer Equipment z z Check for corrosion.
Replace if
Anode z Check for corrosion and deformation.
necessary.
*1: Have this handled by your dealer.
ENON00030-0
Note
Your outboard motor should receive careful, and complete inspection at 300 hours. This is the best
time for major maintenance procedures to be carried out.
ENOM00091-A z Be sure that outboard motor is in upright

Engine oil replacement and level position when checking or
Engine oil mixed with dust or water will changing oil.
dramatically shorten the life of the engine. z Stop engine immediately if low oil pres- 10
ENOW00091-0
sure warning lamp is lit or oil leak is
found, or engine could be severely dam-
CAUTION aged. Consult dealer.
z Wipe off engine oil well immediately if
You may be injured due to high engine tem- spilled and dispose of it in accordance
peratures if you fill engine oil just after with local fire prevention and environ-
stopping. Changing engine oil should be ment protection regulations.
done after the engine has been cooled.
ENOW00092-0 ENOW00090-0
CAUTION CAUTION
z Do not overfill engine oil, or engine oil Use of engine oils that do not meet these
could leak and/or engine could be dam- requirements will result in reduced engine
aged. If engine oil level is over upper life, and other engine problems.
limit marks of oil gauge, drain oil to level
lower than upper limit.
ENOW00933-0 rect torque as soon as possible with a

torque-wrench.
CAUTION
Engine oil mixed with dust or water will
7. Reset the engine in a vertical position.
dramatically shorten the life of the engine. 8. Repeat 3 to 7 procedures two or three
times to drain the oil completely.
To change engine oil:
9. Remove the top cowl and the oil filler
Be sure to use recommended engine oil
cap.
(see page 13).
10. Fill the engine through filler port with
1. Stop the engine and allow it to cool.
recommended oil (see chart below) to
2. Tilt up the outboard motor and lock the
the middle of dipstick mark.
tilt with the tilt stopper.
11. Tighten the oil filler cap.
3. Turn the steering on the outboard
motor so that the drain hole is facing
downward.
4. Put a oil drain pan under the oil drain
screw. 3
5. Remove the oil drain screw and com-
pletely drain oil from the engine.
1
2
1
ENOF01222-A
1. Filler cap
2. Dipstick
3. Filler port
10 ENOF01225-0
1. Drain hole
6. Tighten the oil drain screw with apply-
ing oil on the sealing surface of screw.
(Use new oil drain washer)
Oil drain screw specified torque
1
24N·m (17 ft·lb, 2.4 kgf·m)
ENOF00113-0
ENON00028-A
2
Note 1. Upper limit (Max.)
2. Lower limit (Min.)
If a torque-wrench is not available when you
are fitting a oil filter, a good estimate of the
correct torque is 3/4 to 1 a turn past finger-
tight. Have the oil filter adjusted to the cor-
ENON00920-0 ENOM00092-A
Note Oil filter replacement
ENOW00091-0
Use only recommended engine oil (See
page 13)
CAUTION
You may be injured due to high engine tem-
peratures if you fill engine oil just after
stopping. Changing engine oil should be
10W−40
done after the engine has been cooled.
10W−30 ENOW00926-0
-30 -20 -10

-22 -4 14
0
32
10
50
20
68
30
86
40
96
˚C
˚F
CAUTION
ENOF00208-0 Wipe off engine oil well immediately if
spilled and dispose of it in accordance with
Oil volume needed for complete oil replace-
ment local fire prevention and environment pro-
tection regulations.
With oil filter replace- Without oil filter
ment replacement
1. Drain oil from the engine.
1200 mL 1000 mL
(40.6 fl.oz.) (33.8 fl.oz.) 2. Place a rag or towel below the oil filter
ENOW00925-0 to absorb any spilled oil.
3. Unscrew old filter by turning the filter to
CAUTION
counter clockwise.
Wipe off engine oil well immediately if 4. Clean the mounting base. Apply film of
spilled and dispose of it in accordance with
local fire prevention and environment pro-
clean oil to O-ring.
tection regulations. Do not use grease.
Install oil filter and tighten it to specified
torque by using oil filter wrench.
ENON00031-0
Oil filter torque:
Note
z If any amount of water is found in engine
18 N·m (13 ft·lb, 1.8 kgf·m)
ENON00028-A
10
oil, making it milky white, consult dealer. Note
z If engine oil is contaminated with fuel,
emitting strong fuel smell, consult dealer. If a torque-wrench is not available when you
z Some oil dilution is normal if engine is are fitting a oil filter, a good estimate of the
idled or trolled for long periods, espe- correct torque is 3/4 to 1 a turn past finger-
cially in cooler water temperatures. tight. Have the oil filter adjusted to the cor-
rect torque as soon as possible with a
torque-wrench.
z Contact authorized dealer for fuel sys-

tem services. Services by unqualified
person could lead to engine damage.
Fuel filters are provided inside the fuel tank

and engine.
1
ENOF00094-0 ENOM00094-0
Fuel filter (for engine)
1. Oil filter wrench
P/N 3AC-99090-0
1. Replace the fuel filter provided inside of
P/N 3AC99090M engine cover if there is water or dirt
(US. CANADA Only)
inside.
1 1 ENOF00338-0
ENOF00337-0
1. Fuel filter
1. Oil filter
ENOM00093-A ENOM00096-A
Fuel filters and fuel tank cleaning Fuel filter (for fuel tank)
ENOW00093-0 Water or dirt in the fuel tank will cause
engine performance problems.
WARNING
10 Gasoline and its vapors are very flammable
Check and clean the tank at specified
times or after the outboard motor has
and can be explosive. been stored for a long period of time (over
z Do not start this procedure while engine
three months).
is operating or hot even after stopping it.
z Place fuel filter away from every source 1. Remove the fuel pickup elbow of the
of ignition such as sparks or open fuel tank by turning it counterclockwise
flames. 2. Clean the fuel filter and check the O-
z Wipe off gasoline well immediately if ring. Replace it if necessary.
spilled and dispose of it in accordance
with local fire prevention and environ- 3. Reassemble all parts.
ment protection 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.
ENOF01227-0
3. Insert the oil tube nozzle into the lower

oil plug hole, and fill with gear oil by
ENOF01226-0
squeezing the oil tube until oil flows out
of the upper plug hole and bubbles is
1. Fuel pick up disappeared to remove the air.
2. Filter
ENON00033-0
ENOM00098-A
Note
Gear oil replacement Use genuine gear oil or the recommended
ENOW00094-0 one (API GL-5: SAE #80 to #90).
Required volume: approx. 370 mL (12.5
WARNING fl.oz.).
z Be sure that outboard motor is secured
to transom or service stand, or acciden-
tal drop or fall of outboard motor could
z Be sure to lock outboard motor if it is
tilted up, or accidental fall of outboard 10
motor could lead to severe personal
injury.
z Do not go under outboard motor tilted
sonal injury.
1. Tilt down the outboard motor.

2. Remove the oil plugs (lower and ENOF01228-0
upper), and completely drain the gear

4. Install the upper oil plug, and then
oil into a pan.
remove oil tube nozzle and install the
lower oil plug.
ENOW00095-0 ENOM00086-A
Propeller replacement
CAUTION ENOW00084-0
Do not reuse oil plug gasket. Always use

new gasket and tighten oil plug properly to
WARNING
prevent entry of water into lower unit. z Do not begin propeller removal and
installation procedure with spark plug
c a p s a t t a c h e d , s h i f t i n f o r w a rd o r
reverse, main switch at other than
“OFF”, engine stop switch lock attached
to the switch, and starter key attached,
or engine could accidentally start lead-
ing to serious personal injury. Discon-
nect battery cable if possible.
z The propeller edge is thin and sharp.
Wear the groves during replacement to
protect your hands.
ENOW00086-0
ENOF01229-0 CAUTION
ENOW00928-0 z Do not install propeller without thrust
holder, or propeller boss could be dam-
CAUTION aged.
z Do not reuse split pin.
Wipe off gear oil well immediately if spilled z After installing split pin, spread the pin
and dispose of it in accordance with local apart to prevent it from falling out which
fire prevention and environment protection could lead to the propeller coming off
regulations. during operation.
ENON00032-0
A worn-out or bent propeller will lower the
Note
motor's performance, and cause engine
10 If water in the oil, giving it a milky colored trouble.
appearance. Contact your dealer.
1. Put a piece of wood block between
ENON00033-0 propeller blade and anti-ventilation
Note plate to hold propeller.
Use genuine gear oil or the recommended
one (API GL-5: SAE #80 to #90).
Required volume: approx. 370 mL (12.5
fl.oz.).
ENOF00084-B
ENOW00086-0
2. Remove the split pin, propeller nut and
washer. CAUTION
3. Remove the propeller and thrust z Do not install propeller without thrust
holder. holder, or propeller boss could be dam-
4. Apply water proof grease to the pro- aged.
z Do not reuse split pin.
peller shaft before installing a new pro-
z After installing split pin, spread the pin
peller. apart to prevent it from falling out which
5. Install the thrust holder, propeller, could lead to the propeller coming off
stopper, washer and propeller nut onto during operation.
the shaft.
ENOM00087-A
1 Spark plugs replacement

ENOW00087-0
2 34
WARNING
z Do not reuse spark plug with damaged
5 insulation, or sparks can leak through
crack, potentially leading to electric
shock, explosion and/or fire.
z Do not touch spark plugs immediately
ENOF00084-C
after stopping engine as they will be hot
1. Propeller and could cause severe bur ns if
2. Thrust holder touched. Allow motor to cool down first.
3. Washer
4. Propeller nut
5. Split pin
ENOW00929-0
6. Tighten the propeller nut to specified
torque, and align one of grooves to CAUTION
propeller shaft hole.
Use only the recommended spark plugs.
Propeller nut torque: Spark plugs which have an different heat 10
12 N·m (9 ft·lb, 1.2kgf·m) range may cause engine damage.
7. Install a new split pin into the nut hole
If the spark plug(s) is fouled, has carbon
and bend it.
build up, or is worn, it should be replaced.
When reusing spark plugs, remove dirt
from the electrodes and adjust spark gap
to specification.
1. Stop the engine.

ENOF00084-D
3. Remove the spark plug caps.
4. Remove the spark plugs by turning it the correct torque as soon as possible with
counter-clockwise, using a 5/8" (16 a torque-wrench.
mm) socket wrench and handle that is

provided in tool bag.
5. Inspect the spark plug. Replace the
spark plug if the electrodes are worn or
i f t h e i n s u l a t o r s a re c r a c k e d o r
chipped.
6. Measure the spark plug electrode gap
with a wire type feeler gauge. The gap
should be 0.8-0.9 mm (0.031-0.035
inches). If the gap is different, replace
the spark plug with a new one ENOF01230-0
Use spark plug NGK DCPR-6E.
1
2 ENOF00085-0
1. Electrode
2. Spark gap (0.8–0.9 mm, 0.031–0.035 in)
7. Install the spark plug by hand and turn

it carefully to avoid cross-threading.
8. Tighten the spark plug to the specified
torque.
10 ENON00028-0
Note
z Spark plug torque:
18.0 N·m (13.3 ft·lb) [1.84 kgf·m]
If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of
the correct torque is 1/4 to 1/2 a turn past
finger-tight. Have the spark plug adjusted to
ENOM00088-A
Anode replacement
A sacrificial anode protects the outboard motor from electrolytic corrosion. Anode is
located on the gear case, cylinder etc.. When the anode is eroded more than 1/3 of origi-
nal size, replace it.
ENON00029-0
Notes
z Never grease or paint the anode.
z At each inspection re-tighten the anode attaching bolt. As it is likely to be subjected to electrolytic
corrosion.
*3
10
*1
*2
ENOF01231-0
*1 : PTT model
*2 : Manual tilt model
*3 : Remove CD unit to access the anode.
ENOM00089-B 1. Oil cap

Power Tilt oil checking 2. Oil level
ENOW00088-0
Recommended oil
Use an automatic transmission fluid or
WARNING equivalent.
z Be sure that outboard motor is secured Recommended oils are as shown below.
to transom or service stand, or acciden- ATF Dexron III
tal drop or fall of outboard motor could
Air purging from the Power Trim and
z Be sure to lock outboard motor if it is
tilted up, or accidental fall of outboard Tilt unit.
motor could lead to severe personal Entrapped air in the Power Tilt unit will
injury. cause poor tilting movement and
z Do not go under outboard motor tilted increased noise.
1. With the outboard motor mounted on
sonal injury. the boat, set the manual release valve
to the Manual side, and tilt the out-
ENOW00089-A
board motor manually up/down 5-6
CAUTION times while checking the oil level.
2. When done, close the valve by turning
Do not unscrew the oil cap with the out-
board motor tilted down. Pressurized oil in
it clockwise towards the Power side.
the oil tank may spurt out.
Check the oil level in the reservoir tank

while the tank is kept in a vertical position.
1. Tilt the outboard motor up and lock the
tilt with the tilt stopper.
2. Remove the oil cap by turning counter
clockwise, then check if the oil level
10 reaches the bottom line of the plug
hole. 1
1
2 ENOF00326-0
2
1. POWER
2. MANUAL
ENOF00558-0
ENOM00960-0
Grease point
Apply water proof grease to the parts shown below.
*1
10
ENOF01232-0
*1 : Need disassembling the hook lever to apply grease.

ENOM00100-A
3. Drain all fuel from the fuel hoses, fuel
3. Off-season storage pump and carburetor (See page 75),
and clean these parts.
ENOW00934-0
Keep in mind that if gasoline is kept in
WARNING the carburetor for a long time, gum and
varnish will develop, causing the float
z Be sure to disconnect fuel connector
valve to stick, restricting the fuel flow.
except when operating engine.
z Fuel leakage is a fire or explosion haz- 4. Remove the spark plugs and put a tea-
ard, which can cause serious injury or spoon of engine oil or spray storage oil
death. into the combustion chamber through
the spark plug holes.
ENOW00097-0
5. Turn the starter motor several turns to
WARNING lubricate inside the cylinder.
Be sure to use cloth to remove fuel remain- ENOW00930-0
ing in the cowl and dispose of it in accor-

d a n c e w i t h l o c a l f i re p re v e n t i o n a n d WARNING
environment protection regulations. z Be sure to remove stop switch lock to
prevent ignited the spark plugs.
ENOW00096-0
z Put a cloth to spark plug hole and wipe
CAUTION up any spilled engine oil, when cranking
the outboard motor.
Before servicing the motor for storage:
z Remove the battery cables. 6. Change the engine oil (See page 63).
z Remove the spark plug caps from the 7. Change the gear oil in the gear case
spark plugs. (See page 67).
z Do not run the motor out of the water.
8. Apply grease to grease point (See
Before you put your outboard motor in page 73.
storage, it is a good opportunity to have it 9. Stand the outboard motor up vertically
10 serviced and prepared by your dealer. in a dry place.
Be sure to use fuel stabilizer while running
the motor before storage. (See page 75)
ENOM00101-B
Engine
1. Wash the engine exterior and flush the
cooling water system thoroughly with
fresh water. Drain the water com-
pletely.
Wipe off any surface water with an oily
rag.
2. Remove the fuel hose from the out- ENOF01113-0
board motor.
ENOW00066-0
1. Before adding fuel stabilizer additive,
CAUTION drain the carburetor (See page 79).
2. Follow the instructions on the label
Do not carry or store outboard motor in any
of positions described below.
when adding the fuel stabilizer additive.
Otherwise, engine damage or property 3. After adding the additive, let the out-
damage could result from leaking oil. board motor run in the water for 10
minutes to make sure any old fuel in
the fuel system has been completely
replaced by the fuel with additive.
4. Turn the engine OFF
ENON00891-0
Note
If your motor is used occasionally, it is rec-
ommended to use a good fuel stabilizer in
ENOF01219-0
every tank of fuel and keep the container full
to reduce condensation and evaporation.
ENON00021-A
Note
z If the outboard motor must be laid down
ENOM00970-A
be sure drain the fuel and engine oil, Fuel system draining
then the outboard motor on a cushion
ENOW00936-0
as shown in the drawing below (See
page 75 and 52). WARNING
z Elevate power unit 2 inches to 4 inches if
traveling to avoid oil spillage. 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
10
sources of ignition, e.g. sparks or open
ENOF01221-0
flames
z Perform all work outdoors or in a well
ventilated place.
ENOM00950-0
Adding a fuel stabilizer ENOW00097-0
When adding a fuel stabilizer additive
(commercially available), first fill the fuel WARNING
tank with fresh fuel. If the fuel tank is only Be sure to use cloth to remove fuel remain-
partially filled, air in the tank can cause the ing in the cowl and dispose of it in accor-
fuel to deteriorate during storage. dance with local fire prevention and
environment protection regulations.
ENOM00102-0
1. Disconnect the fuel hose from the out-

Battery
ENOW00931-A
board motor.
2. Remove the top cowl. WARNING
3. Place an approved fuel container z Place the battery away from any source
under the drain screw and use a funnel of fire, sparks and open flames such as
to avoid spilling fuel. burners or welding equipment.
z Place the battery away from fuel tank.
4. Loosen the carburetor drain screw.
Accidental sparks of battery may cause
5. Tilt up the outboard motor until fuel explosion of gasoline.
flows out of the drain hole.
6. Leave the outboard motor in this posi- 1. Disconnect the battery cables and be
tion until all fuel has been drained. sure to remove the negative terminal
first.
7. When thoroughly drained, retighten the
drain screw securely. 2. Wipe off any chemical deposits, dirt, or
grease.
8. Check the drained fuel for the pres-
ence of water or other contaminants. If 3. Apply grease to the battery terminals.
either is present, reassemble the out- 4. Charge the battery completely before
board motor, refill the carburetor with storing it for the winter.
fuel, and then drain the fuel again. 5. Recharge the battery once a month to
Repeat this procedure until no water or prevent it from discharging and the
other contaminants are present in the electrolyte from deteriorating.
drained fuel. 6. Store the battery in a dry place.
ENOM00104-A
4. Pre-season check
The following steps must be taken when

10 first using the engine after off-season stor-
age.
1. Check that the shift and throttle func-
tion properly. (Be sure to turn the pro-
peller shaft when checking the shift
1
function or else the shift linkage may
ENOF01233-0 be damaged.)
1. Carburetor drain screw
2. Check the electrolyte level, and mea-
sure the voltage and specific gravity of
the battery.
Specific Gravity Terminal Voltage

After taking your outboard motor out of the
Charge Condition
at 20°C (V) water, immediately take it to your dealer.
1.120 10.5 Fully discharged The following are the emergency measures
1.160 11.1 1/4 charged to be taken for a submerged outboard
1.210 11.7 1/2 charged motor, if you can not take it your dealer
1.250 12 3/4 charged right away.
1.280 13.2 Fully charged 1. Wash the outboard motor with fresh
water to remove salt or dirt.
3. Check that the battery is secure and 2. Remove the engine oil drain screw and
t h e b a t t e r y c a b l e s a r e p ro p e r l y completely drain water and oil from the
installed. engine.
4. Change the engine oil (See page 63). 3. Remove the spark plugs, and com-
5. Before starting the engine, disconnect pletely drain the water from the engine
stop switch lock and crank approxi- by pulling ricoil starter several times.
mately 10 pulling the recoil starter Replace oil filter and oil to the correct
(Manual start model) or 3times of 3sec. level.
turning the starter motor (Electric start The oil and filter may need to be
model) in order to prime the oil pump. changed again after running a short
6. Fill fuel tank completely. period to get all moisture completely
7. Start the engine and warm up the out of the crankcase.
engine for 3 minutes in the “NEUTRAL” 4. Inject a sufficient amount of engine oil
position. through the spark plug holes.
8. Run the engine for 5 minutes at the Pull the recoil starter several times to
slowest speed. circulate the oil throughout the out-
9. Run the engine for 10 minutes at half board motor.
ENOM00106-A
throttle. The oil used for storage inside
6. Cold weather precautions
the engine will be circulated out to
assure optimum performance.
10
ENOM00105-A If you moor your boat in cold weather at
5. Submerged outboard motor temperatures below 0°C (32°F), there is
the danger of remained water freezing in
ENOW00098-0 the cooling water pump, which may dam-
age the pump, impeller, etc. To avoid this
CAUTION problem, submerge the lower half of the
Do not attempt to start submerged out- outboard motor into the water.
board motor immediately after it is recov-
ered, or engine could be severely
damaged.
ENOM00107-A
7. Striking underwater object

ENOW00935-0
CAUTION
Striking the sea bottom or an underwater
object may severely damage the outboard
motor.
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
10 ENOM00120-1
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
could damage the gear.
79
TROUBLESHOOTING
ENOM00326-0
If you encounter a problem, consult the check 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 starting but stopping soon
Engine speed abnormally high
Engine speed abnormally low
Overheating of engine
Engine falling to start
Power tilt inoperative

Possible cause
Poor acceleration
Poor idling
z z Empty fuel tank

z z z z z z Incorrect connection of fuel system
z z z z z z Air entering fuel line
FUEL SYSTEM
z z z z z z Deformed or damaged fuel hose

z z z z z z Closed air vent on fuel tank
z z z z z z Clogged fuel filter, fuel pump, or carburetor
z z z z Use of improper engine oil
z z z z z Use of improper gasoline
z z Excessive supply of fuel
z z z z z z Poor carburetor adjustment
z z z z z z Spark plug other than specified
z z z z z Dirt, soot, etc. on spark plug
z z z z z No Spark or weak spark
z Short circuit of engine stop switch
ELECTRICAL SYSTEM
z z z z Ignition timing incorrect

z Lock plate not fitted
z z Disconnection of wire or loose ground connection 11
z z Blown 20 Amp fuse in the starting circuit
z Not shifted into neutral position
z z Weak battery or battery connections are loose or corroded
z z Ignition key switch failure
z Wiring or electrical connection faulty
z Starter motor or starter solenoid failure
z Power tilt switch defective, Solenoid is defective
80 TROUBLESHOOTING
Engine starting but stopping soon
Engine speed abnormally high
Engine speed abnormally low
Overheating of engine
Engine falling to start
Power tilt inoperative

Possible cause
Poor acceleration
Poor idling
z z z z z Low compression
COMPRESSION &
OIL SYSTEM
z Carbon deposits in the combustion chamber

z z Incorrect valve clearance
z Low oil pressure/level
z z z z Incorrect adjustment of throttle link

z Insufficient cooling water flow, clogged or defective pump
z z Faulty thermostat
z z z Cavitation or ventilation
OTHERS
z z z z Incorrect propeller selection

z z z z z Damaged or bent propeller
z z z Improper thrust rod position
z z z z Unbalanced load on boat
z z z z Transom too high or too low
z A great deal of air is contained inside pump
11
81
ACCESSORIES KIT
ENOM00327-0
The following a list of the tools and spare parts provided with the motor.
Items Quantity Remark
Tool bag 1
Pliers 1
Socket wrench 1 10 × 13 mm
Service tools Socket wrench 1 16 mm
Socket wrench handle 1
Screwdrivers 1 Cross-and straight-point
Screwdriver handle 1
Emergency starter rope 1
Spark plug 1 NGK DCPR6E
Spare parts
Split pin 1
Stop switch lock 1
Fuel tank 1 12 L
Primer bulb 1 set
Remote control box 1 set for EP and EPT
Remote control attachment 1 set for EP and EPT
Parts Packaged
Drag link 1 for EP and EPT
with Engine
Bracket fixing
Bolt 4 8 mm
Nut 4 8 mm EPT/EFT only
Washer 8 8 mm
12
82
PROPELLER TABLE
ENOM00329-0
Use a genuine propeller.
A propeller must be selected so that the engine rpm measured at wide open throttle while
cruising is within the recommended range.
9.9/15: 5000–6000 min-1 (rpm)

20: 5400–6100 min-1 (rpm)
Propeller Propeller Size (Blades × diameter × pitch)

Mark in. mm
Light boats 11.5 3 × 9.25 × 11.5 3 × 235 × 292
10 3 × 9.25 × 10 3 × 235 × 254
9 3 × 9.25 × 9 3 × 235 × 229
8 3 × 9.25 × 8 3 × 235 × 203
7 3 × 9.2 × 6.9 3 × 234 × 174
6 3 × 9.2 × 6.1 3 × 234 × 155
Heavy boats 7 4 × 10 × 4 4 × 254 × 178
13
OWNER’S MANUAL
MFS 9.9D
MFS 15D
MFS 20D 003-11115-3AG1 1701NB
Printed in Japan

MFS15 Tohatsu Owners Manual

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OWNER’S

YOUR TOHATSU OUTBOARD MOTOR

Serial Number: Date of purchase:

1 GENERAL SAFETY INFORMATION 1

10. INSPECTION AND MAINTENANCE 10

12. ACCESSORIES KIT 12

13. PROPELLER TABLE 13

Carbon Monoxide Poisoning Hazard

Model F9.9D F15D F20D

2 Type MF EP MF EF EFT EP EPT MF EF EFT EP EPT

Model descrip- Horse Product Starter Steering

MF, EF, EFT

MF, EF, EP, EFT, EPT

1 Tilt Handle 12 Drive Shaft Housing 24 Water Plug

MF, EF, EP, EFT, EPT

30 Primer Bulb 42 Cord Assembly *5

Warning label locations

7. Warning regarding gasoline (See

3. Warning label regarding stop switch

8. Warning regarding gasoline (See

1. Model code(Model name)

Description of serial number year code

Outboard motor mounting must be per-

ENOM00025-0 z Incorrect outboard motor mounting

to the shape of the bottom of your boat, Note

z Before beginning the running test, check

PTT type transom. Mounting bolts installed with

2 2. Remote control device

Measure the distance from the remote

z Be sure to correctly connect the (+) and

1. Place the battery box in a convenient

ENOM00031-A If the use of gasoline containing alcohol is

z Close the fuel tank cap and air vent

1. Full open the air vent screw on the tank

4. After filling the tank, close the fule tank 10W−30

cap. -30 -20 -10 0 10 20 30 40 ˚C

tion (See page 36) to learn how to cor-

If outboard motor encounters an abnormal

*No horn is located for tiler handle type 1. Warning lamp

High speed ESG (Electronic Safety Governor)

6 Low speed ESG

2. Open the fuel tank cap slowly and

ENON00010-0 1. Shift lever

Tiller handle type

(For manual starter type)

5. Pull the starter handle slowly until you

Side mount RC type

(For electrical starter type)

1. Stop switch lock

2. Insert the main switch key.

7. Returns the Free accel lever to close

1. Remove the top cowl.

4. Insert the knotted end of the starter

2. Remove starter lock cable from recoil 7

5. Tie a loop in the another end of the

5. Stop pushing the key when the engine

6. Be sure to install the stop switch lock

If the choke solenoid fails to 3. Warming up the engine

1. Remove the top cowl. CAUTION

3 minutes : above 5°C (41°F) ENOW00038-A

Manual Tilt type