TOHATSU M 9.9 D2 Owner's Manual
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TOHATSU M 9.9 D2 Owner's Manual

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  • Page 3 OWNER’S MANUAL M 9.9D M 15D M 18E OB No.003-11049-BAF1...
  • Page 4 INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE. Copyright © 2016 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.
  • Page 5 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.

  • Page 6: Serial Number

    ENOM00005-A Serial Number In the space below, please record the outboard motor's serial number (indicated both on the bottom cowl and on the cylinder block). The serial number will be needed when order- ing parts, and when making technical or warranty inquiries. Serial Number: ENOF01701-0 ENOF01700-0...
  • Page 7 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,”...

  • Page 9: Table Of Contents

    CONTENTS 1. GENERAL SAFETY INFORMATION ....... 10 2. SPECIFICATIONS ..........12 3.
  • Page 11 INDEX 1 GENERAL SAFETY INFORMATION 2. SPECIFICATIONS 3. PARTS NAME 4. LABEL LOCATIONS 5. INSTALLATION 6. PRE-OPERATING PREPARATIONS 7. ENGINE OPERATION 8. REMOVING AND CARRYING THE OUTBOARD MOTOR 9. ADJUSTMENT 10. INSPECTION AND MAINTENANCE 11. TROUBLESHOOTING 12. TOOL KIT AND SPARE PARTS 13.

  • Page 12: General Safety Information

    GENERAL SAFETY INFORMATION ENOM00009-0 SAFE OPERATION OF BOAT 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.
  • Page 13 GENERAL SAFETY INFORMATION ENOM00010-0 SERVICING, REPLACEMENT PARTS & LUBRICANTS We recommend that only an authorized service shop perform service or maintenance on 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 51).

  • Page 14: Specifications

    SPECIFICATIONS ENOM00810-B MODEL FEATURE Model M9.9D2 M15D2 M18E2 Type Transom heights Tiller Handle Remote Control Power Tilt Gas-assisted tilt Manual tilt *1: Option ENOM00811-B MODEL NAME EXAMPLE M18E2MFL Model descrip- Horse Product Minor Starter Steering Shaft length tion power generation change system system...
  • Page 15 Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 370ml (12.5 fl. oz) Gear Shift Dog Clutch (F-N-R) Gear Reduction Ratio 1.85 (13 : 24) Remark: Specifications subject to change without notice. Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
  • Page 16 Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 370ml (12.5 fl. oz) Gear Shift Dog Clutch (F-N-R) Gear Reduction Ratio 1.85 (13 : 24) Remark: Specifications subject to change without notice. *1 With manual Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).

  • Page 17: Parts Name

    PARTS NAME ENOM00820-0 ENOF01750-0 1 Tilt Handle 11 Starter Handle 21 Fuel Connector (Male) 2 Top Cowl 12 Shift Lever 22 Oil Plug (Upper) 3 Bottom Cowl 13 Throttle Grip 23 Water Plug 4 Cowl Hook Lever 14 Adjust Nut 24 Oil Plug (Lower) 5 Cooling Water Check Port 15 Clamp Screw...
  • Page 18 PARTS NAME ENOM01102-0 ENOF01751-0 1 Tilt Handle 11 Starter Handle 21 Battery Cord 2 Top Cowl 12 Shift Lever 22 Choke Knob 3 Bottom Cowl 13 Throttle Grip 23 Fuel Connector (Male) 4 Cowl Hook Lever 14 Adjust Nut 24 Oil Plug (Upper) 5 Cooling Water Check Port 15 Clamp Screw 25 Water Plug...
  • Page 19 PARTS NAME ENOM01103-0 ENOF01752-0 1 Tilt Handle 11 Starter Handle 21 Oil Plug (Upper) 2 Top Cowl 12 Shift Lever 22 Water Plug 3 Bottom Cowl 13 Clamp Screw 23 Oil Plug (Lower) 4 Cowl Hook Lever 14 Clamp Bracket 24 Spark Plug 5 Cooling Water Check Port 15 Thrust Rod...
  • Page 20 PARTS NAME ENOM00822-0 Remote control box & Fuel tank ENOF00127-F Control Lever Fuel Gauge Neutral Lock Arm Air Vent Screw Free Throttle Lever Fuel Tank Cap Main Switch Fuel Connector (Engine side) Stop Switch Primer Bulb Stop Switch Lock Fuel Connect Stop Switch Lanyard...

  • Page 21: Label Locations

    LABEL LOCATIONS ENOM00019-A Warning label locations ENOF01703-0...
  • Page 22 LABEL LOCATIONS Warning label urge to read the owner’s Warning regarding gasoline. manual . ENOF00005-E Warning regarding gasoline (See page 25). ENOF00005-W 2-1. Warning regarding high temperature. 2-2. Warning regarding rotating object. 2-3. Warning regarding high voltage ENOF00005-L Warning regarding gasoline (See page 25).
  • Page 23 LABEL LOCATIONS ENOM01001-0 Serial number label locations r o t l a i ENOF01704-0 1. Model code(Model name) 2. Rated power 3. Dry mass weight 4. Serial No. 5. Manufacture name 6. Manufacture address...

  • Page 24: Installation

    INSTALLATION ENOM00024-B Keep the outboard motor in a vertical posi- 1. Mounting the outboard motor on tion when mounting. boat 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.
  • Page 25 INSTALLATION ENON00002-0 Note A rope is not included in the standard accessories. 30−50 mm (1.2−2 in) ENOF01706-0 1. Bottom of hull 2. Anti ventilation plate ENOW00007-0 CAUTION 2, 3 Before beginning the running test, check ENOF01707-0 that the boat with maximum capacity 1.

  • Page 26: Remote Control Device Installation

    INSTALLATION ENOM00840-0 2. Remote control device installation ENOW00850-0 Remote control box location ENOF00842-0 Measure the distance from the remote control box to the outboard motor where 1, 2 the remote control cable should be routed. Prepare a cable that is 300-450mm (11.8- 17.7in) longer than the measured distance.

  • Page 27: Pre-Operating Preparations

    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 (hererinafter referred to as the age, common to boats, create unique prob- lems.

  • Page 28: Fuel Filling

    PRE-OPERATING PREPARATIONS age if alcohol has washed protective oil When or before refueling: films from internal components. Be sure to remove the static electricity charged in your body before refueling. The sparks due to static electricity may ENOW00018-0 cause explosion of flammable gasoline. WARNING Stop the engine, and do not start the engine during refueling.

  • Page 29: Engine Oil Recommendation

    PRE-OPERATING PREPARATIONS Use a genuine engine oil or recommended one (TCW3). Refer to your Distributor. Will not recommend use of other two stroke engine oil. Add engine oil into fuel oil tank. The mixing ratio with gasoline is 50 : 1 (50 parts gaso- line and one part oil).
  • Page 30 PRE-OPERATING PREPARATIONS For quantities of engine oil and gasoline to Pour engine oil into fuel container, and then, gasoline. be pre-mixed, refer to table in previous page. Put cap on the container, and close tightly. When portable fuel tank is used for Shake the container to mix engine oil operation of outboard motor(s): and gasoline well and even.

  • Page 31: Break-In

    PRE-OPERATING PREPARATIONS ]ENOM00033-A 4. Break-In Your new outboard motor and lower unit ENOW00023-0 require break-in for the moving compo- CAUTION n e n t s a c c o r d i n g t o t h e c o n d i t i o n s Operating the outboard motor without described in the following time table.

  • Page 32: Engine Operation

    ENGINE OPERATION ENOM00042-0 tank is raised by heat from sources such as sun light. Before starting 1. Full open the air vent screw on the fuel ENOW00022-B tank cap. CAUTION Be sure to fill the engine before starting engine. (To properly fill the engine with oil follow the instructions.

  • Page 33: Starting The Engine

    ENGINE OPERATION ENOF00861-A ENOF00863-0 1. Pull 2. Insert 1. Test tank 2. Water 4. Squeeze primer bulb until it becomes 3. Over 10 cm (4 in.) stiff to feed fuel to carburetor. Direct arrow mark upward when priming. ENOW00036-0 CAUTION Be sure to stop engine immediately if cool- ing water check port is not discharging water, and check if cooling water intake is...
  • Page 34 ENGINE OPERATION ENOM01005-A 3. Set the throttle grip to START position. Tiller handle type 1. Be sure to install the stop switch lock to the stop switch, and attach the stop switch lanyard securely to the operator or to the operator's PFD (Personal Flo- tation Device.) ENOF01714-0 1.
  • Page 35 ENGINE OPERATION (For manual starter type) crank engine again after 10 seconds or more. 4. Pull the starter handle slowly until you feel engagement, keep pulling till you 5. Return the choke knob fully after feel less resistance. Then pull it quickly. engine has started.

  • Page 36: Emergency Starting

    ENGINE OPERATION 6. Stop pushing the key when the engine has started. The key returns to the original position, automatically. 7. Returns the Free accel lever to close position. 8. Check the cooling water from cooling water check port. ENOF00870-0 1.
  • Page 37 ENGINE OPERATION Attach engine stop switch lanyard to 4. Insert the knotted end of the starter clothing or any part of body like arm rope into the notch in the flywheel and before starting engine. wind the rope around the flywheel sev- eral turns clockwise.

  • Page 38: Warming Up The Engine

    ENGINE OPERATION 8. Pull the starter handle slowly until you ENOM00043-A 3. Warming up the engine feel engagement, keep pulling till you feel less resistance. Then pull it quickly. ENOW00932-0 CAUTION Be sure to check that cooling water is coming out of the cooling water check port during warm up.

  • Page 39: Forward, Reverse, And Acceleration

    ENGINE OPERATION ENOM00046-A injury, and steering system and/or shift- ing mechanism may be damaged. 4. Forward, reverse, and acceleration ENOW00861-0 WARNING ENOW00037-0 WARNING Do not shift at high boat speed, or control may be lost, falling down or causing pas- Before shifting into forward or reverse, senger(s) to be thrown overboard.
  • Page 40 ENGINE OPERATION ENOM00890-A Tiller handle type ENOW00865-A CAUTION Do not force to shift when the throttle grip is not in the fully closed position, other- wise, steering system and/or shifting mechanism may be damaged. ENOW00867-0 WARNING ENOF01721-0 Sudden acceleration and deceleration may 1.

  • Page 41: Stopping The Engine

    ENGINE OPERATION ENOW00865-A 2. Further rearward motion will open the throttle. CAUTION Acceleration Do not force to shift when the throttle grip ENOW00867-A is not in the fully closed position, other- CAUTION wise, steering system and/or shifting mechanism may be damaged. Sudden acceleration and deceleration may cause passenger(s) to be thrown over- board or falling down.
  • Page 42 ENGINE OPERATION Tiller handle type Side mount RC type 1. Turn the throttle grip to the slow posi- 1. Put the control lever in the Neutral tion. position and run the engine for 2-3 minutes at idling speed for cooling down if it has been running at full speed.

  • Page 43: Steering

    ENGINE OPERATION Emergency engine stopping Remove stop switch lock to stop the engine. ENOF00892-0 Remote control type Right turn ENOF01723-0 Turn the steering wheel to the right. Left turn Turn the steering wheel to the left. ENOF00884-0 1. Stop switch 2.
  • Page 44 ENGINE OPERATION Unsuitable trim position can cause loss ENOM00053-0 Improper trim angle (bow rises too of control of boat. When testing a trim high) position, run boat slow initially to see if it Set the thrust rod lower if the bow of the can be controlled safely.

  • Page 45: Tilt Up And Down

    ENGINE OPERATION Trim angle adjustment (Manual tilt ENOW00048-0 type) WARNING The transom angle adjustment 1. Stop the engine. When tilting up or down, be careful not to p l a c e y o u r h a n d b e t w e e n t h e s w i v e l 2.

  • Page 46: Shallow Water Operation

    ENGINE OPERATION 2. Tilt up position 3. Tilt down position ENOM00068-A 9. Shallow water operation ENOW00051-0 WARNING During shallow water operation, be careful not to place your hand between the swivel ENOF01725-0 bracket and the clamp bracket. Be sure to 1.
  • Page 47 ENGINE OPERATION Manual tilt type 1. Shallow water running position: Put the reverse lock lever in the tilt up position, and tilt up the outboard motor to put the outboard motor in the shal- low water running position. ENOF01725-0 1. Reverse lock lever 2.

  • Page 48: Removing And Carrying The Outboard Motor

    REMOVING AND CARRYING THE OUTBOARD MOTOR ENOM00070-B ENOW00065-0 1. Removing the outboard motor WARNING Close air vent screw of fuel tank before ENOW00064-0 carrying or storing outboard motor and fuel CAUTION tank, or fuel may leak, potentially catching fire. Engine may be hot immediately after oper- ating and could cause burns if touched.

  • Page 49: Traillering

    REMOVING AND CARRYING THE OUTBOARD MOTOR ENOW00073-A WARNING Be sure to disconnect fuel connector except when operating engine. Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. ENOF00075-1 ENOF01738-0 ENOW00068-0 ENON00021-A Note WARNING If the outboard motor must be laid down Close air vent screw of fuel tank and fuel be sure drain the fuel and engine oil, cock before carrying or storing outboard...
  • Page 50 REMOVING AND CARRYING THE OUTBOARD MOTOR 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.

  • Page 51: Adjustment

    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 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 injury.
  • Page 52 ADJUSTMENT achieved, adjust the trim tab located under the anti-ventilation plate. If the boat veers toward the left direct the trim tab towards A (left from rear of boat). If the boat veers toward the right direct the trim tab towards B (right from rear of boat).

  • Page 53: Inspection And Maintenance

    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 Your personal safety and that of your passengers depends on how well you...

  • Page 54: Daily Inspection

    INSPECTION AND MAINTENANCE ENOM01005-0 1. Daily Inspection Perform the following checks before and ENOW00078-0 after use. WARNING Do not use outboard motor if any abnor- mality is found during pre-operation check or it could result in severe damage to the motor or severe personal injury.
  • Page 55 INSPECTION AND MAINTENANCE ENOM00083-0 ENOM00085-D Washing outboard motor Flushing attachment ENOW00921-0 ENOW00081-0 CAUTION WARNING Do not operate the engine when flushing Do not start engine without removing pro- the outboard motor with a flushing attach- peller, or accidentally turning propeller ment as this can cause damage to the out- could cause personal injury.
  • Page 56 10 cm (4 in.) above the anti ventilation fuse will likely blow again. plate. If the fuse continues to blow, request an authorized Tohatsu dealer to inspect the outboard motor.
  • Page 57 INSPECTION AND MAINTENANCE 1. Stop the engine and disconnect the battery cable from the battery negative (-) terminal. 2. Remove the engine cover. 3. Remove the fuse box lid. 4. Remove the fuse and check it. If the fuse is blown, replace it with a fuse of the same specified rating.

  • Page 58: Periodic Inspection

    INSPECTION AND MAINTENANCE ENOM01106-0 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.
  • Page 59 INSPECTION AND MAINTENANCE ENOM00093-C ENOM00094-0 Fuel filters and fuel tank cleaning Fuel filter (for engine) 1. Check in the cup for water and debris. ENOW00093-A WARNING Gasoline and its vapors are very flammable and can be explosive. Do not start this procedure while engine is operating or hot even after stopping it.
  • Page 60 INSPECTION AND MAINTENANCE ENOM00096-C ENON00934-0 Fuel filter (for fuel tank) Note 1. Remove the fuel pickup elbow of the Please dispose of used oil in a manner that fuel tank by turning it counterclockwise is compatible with the environment. We suggest you take it in a sealed container 2.

  • Page 61: Propeller Replacement

    INSPECTION AND MAINTENANCE ENOW00928-0 CAUTION Wipe off gear oil well immediately if spilled and dispose of it in accordance with local fire prevention and environment protection regulations. ENON00032-0 Note If water in the oil, giving it a milky colored appearance. Contact your dealer. ENON00033-0 Note ENOF01733-0...
  • Page 62 INSPECTION AND MAINTENANCE After installing split pin, spread the pin 1. Propeller 2. Thrust holder apart to prevent it from falling out which 3. Washer could lead to the propeller coming off 4. Propeller nut during operation. 5. Split pin 6.
  • Page 63 INSPECTION AND MAINTENANCE to specification. the correct torque as soon as possible with a torque-wrench. 1. Stop the engine. 2. Remove the top cowl. 3. Remove the spark plug caps. 4. Remove the spark plugs by turning it counter-clockwise, using a 21 mm (13/ 16 in) socket wrench and handle that is provided in tool bag.

  • Page 64: Anode Replacement

    INSPECTION AND MAINTENANCE 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 Never grease or paint the anode.
  • Page 65 INSPECTION AND MAINTENANCE ENOM00960-0 Grease point Apply water proof grease to the parts shown below. ENOF01737-0...

  • Page 66: Off-Season Storage

    INSPECTION AND MAINTENANCE ENOM00100-A 2. Remove the fuel hose from the out- 3. Off-season storage board motor. 3. Drain all fuel from the fuel hoses, fuel ENOW00934-0 pump, fuel filter (See page 57) and car- WARNING buretor (See page 66), and clean these parts.

  • Page 67: Adding A Fuel Stabilizer

    INSPECTION AND MAINTENANCE 8. Stand the outboard motor up vertically in a dry place. ENOF01728-0 1. Handle ENOM00950-A Adding a fuel stabilizer When adding a fuel stabilizer additive (commercially available), first fill the fuel tank with fresh oil and fuel. If the fuel tank is only partially filled, air in the tank can cause the fuel to deteriorate during stor- ENOF01738-0...
  • Page 68 INSPECTION AND MAINTENANCE ENOM00970-A Fuel system draining ENOW00028-A WARNING For details on handling fuel, contact an authorized dealer. Fuel and fuel vapors are extremely flamma- ble and can be explosive. If fuel is spilled, wipe it up immediately. Keep the fuel tank well away from ENOF01739-0 sources of ignition, e.g.

  • Page 69: Pre-Season Check

    INSPECTION AND MAINTENANCE ENOM00104-E 9. Run the engine for 10 minutes at half 4. Pre-season check throttle. The oil used for storage inside the engine will be circulated out to assure optimum performance. The following steps must be taken when first using the engine after off season stor- age.

  • Page 70: Striking Underwater Object

    INSPECTION AND MAINTENANCE age the pump, impeller, etc. To avoid this switch lock, shift into forward, and then tilt problem, submerge the lower half of the the outboard motor up. Otherwise, over- outboard motor into the water. rotation of the propeller due to water spray could damage the gear.

  • Page 71: Troubleshooting

    TROUBLESHOOTING ENOM01106-0 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. Possible cause Empty fuel tank Incorrect connection of fuel system Air entering fuel line Deformed or damaged fuel pipe...
  • Page 72 TROUBLESHOOTING Possible cause Incorrect adjustment of throttle link Insufficient cooling water flow, clogged or defective pump Faulty thermostat Cavitation or ventilation Incorrect propeller selection Damaged and bent propeller Improper thrust rod position Unbalanced load on boat Transom too high or too low...

  • Page 73: Tool Kit And Spare Parts

    TOOL KIT AND SPARE PARTS ENOM01107-0 The following a list of the tools and spare parts provided with the motor. Name Quantity Remark Tool Bag Pliers Socket Wrench 10 x 13 mm Servicing Tools Socket Wrench 21 mm Socket Wrench Handle Screwdriver (Phillips-type and flat head) Adapter-type Rope...

  • Page 74: Propeller Table

    PROPELLER TABLE ENOM01108-0 To ensure optimum performance, the propeller should match the boat type and its load. 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. 9.9D2 : 4,500 to 5,300 rpm 15D2/18E2 : 5,200 to 5,800 rpm Propeller Size...
  • Page 76 OWNER’S MANUAL M 9.9D M 15D M 18E 003-11049-BAF1 1512NB Printed in Japan...

This manual is also suitable for:

M 15d2M 18e2

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