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TOHATSU M4C Owner's Manual

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  • Page 3 OWNER’S MANUAL M 4C M 5B OB No.003-11068-6AF1...
  • 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 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: ENOF02101-0 ENOF02100-0...
  • 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 44).

  • Page 14: Specifications

    SPECIFICATIONS ENOM00810-A MODEL FEATURE Model M5B-D Type Transom heights Tiller Handle Remote Control ( )*1 ( )*1 Separate fuel tank Integral fuel tank Manual tilt *1: Option ENOM00811-A MODEL NAME EXAMPLE M 5 BDL Model descrip- Horse Product Fuel tank Shaft length tion power...
  • Page 15 Gear Reduction Ratio 2.15 (13 : 28) *:In case of dual fuel tank system, use it together with 12 L separate tank. Remark: Specifications subject to change without notice. Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).

  • Page 16: Parts Name

    PARTS NAME ENOM01401-0 4C, 5B-D 5B-D Dual Fuel Tank ENOF02102-0 Air Vent Screw Starter Handle Choke Knob Fuel Tank Cap Shift Lever Stop Switch Tilt Handle Throttle Glip Fuel Cock Knob Top Cowl Clamp Screw Fuel Connector Bottom Cowl Clamp Bracket Fuel Cock Cooling Water Check Port Thrust Rod...
  • Page 17 PARTS NAME ENOM00822-0 Fuel tank ENOF02103-0 Fuel gauge Air vent screw Fuel tank cap Fuel connector (Engine side) Primer bulb Fuel connector (Fuel tank side)

  • Page 18: Label Locations

    LABEL LOCATIONS ENOM01402-0 Warning label locations ENOF02104-0...
  • Page 19 LABEL LOCATIONS Warning label regarding owner’s man- Warning regarding gasoline (See ual, top cowl and engine stop switch. page 24). ENOF00005-S Warning regarding gasoline (See ENOF00005-W page 24). 2-1. Warning regarding high temperature. 2-2. Warning regarding rotating object. 2-3. Warning regarding high voltage ENOF00005-L ENOF00129-A Warning label regarding high voltage.
  • Page 20 LABEL LOCATIONS ENOM01001-0 Serial number label locations r o t l a i ENOF02105-0 1. Model code(Model name) 2. Rated power 3. Dry mass weight 4. Serial No. 5. Manufacture name 6. Manufacture adress...

  • Page 21: Installation

    INSTALLATION Keep the outboard motor in a vertical posi- ENOM00024-B 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 22 INSTALLATION ENOM00830-A Mounting bolts Manual tilt type 1. To attach the outboard motor to the boat, tighten the clamp screws by turning their handles. 30−50 mm (1.2−2 in) Also, use the bolts to secure the out- board motor brackets on transom ENOF01506-A board.

  • Page 23: Remote Control Device Installation (Option)

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

  • Page 24: 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- age, common to boats, create unique prob- ethyl alcohol (hererinafter referred to as the lems.

  • Page 25: Engine Oil Recommendation

    PRE-OPERATING PREPARATIONS age if alcohol has washed protective oil films from internal components. Fuel by Oil Mixing (25:1, 50:1) ENOW00018-0 1.0L (25:1) 25: 1 WARNING 0.48L Fuel leakage can cause fire or explosion, (25:0.5) (12:0.48) 50: 1 potentially leading to severe injury or loss 0.24L (12:0.24) of life.

  • Page 26: Fuel Filling

    PRE-OPERATING PREPARATIONS Leaking gasoline is a dangerous fire haz- ard. ENOW00028-A WARNING Consult an authorized dealer for details on handling gasoline, if necessary. Gasoline and its vapors are very flammable and can be explosive. When carrying a fuel tank containing gaso- line: Close the fuel tank cap and air vent screw of fuel tank cap, or gasoline vapor...
  • Page 27 PRE-OPERATING PREPARATIONS Dispose aged or contaminated gasoline 2. Open the fuel tank cap slowly. in accordance with local regulations. 3. When using integral tank Remove top cowl and fill the fuel not to ENOW00029-A over the full mark. WARNING When using separate tank Fill the fuel carefully not to over flow.

  • Page 28: 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 29: Engine Operation

    ENGINE OPERATION ENOM00042-0 ENOW00403-0 Before starting CAUTION When separate tank is used for dual tank ENOW00022-B model, be sure to open air vent of integral CAUTION tank as well as air vent of separate tank. If air vent of integral tank that contains fuel is Be sure to fill the engine before starting closed, swelling of air in the tank by heat engine.
  • Page 30 ENGINE OPERATION ENOW00404-0 CAUTION When using integral tank, disconnect fuel connector. 4. If you use a separate tank, connect the fuel connector to the engine and fuel tank. ENOF02112-0 1. Fuel cock knob 2. Close 3. Open M5B-D ENOF02114-0 If you use a separate tank, set the fuel 1.

  • Page 31: Starting The Engine

    ENGINE OPERATION 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 blocked. Operating engine could lead to overheating potentially leading to engine damage. Consult an authorized dealer if ENOF00862-0 the cause cannot be found.
  • Page 32 ENGINE OPERATION 2. Set the control lever in the Neutral ENON00501-A Note position. Choke is not necessary when the engine is warm. ENON00502-0 Note If engine does not start with 4 or 5 times starting operation, push the knob back and restart.

  • Page 33: Emergency Starting

    ENGINE OPERATION 2. Disconnect the rink of the starter lock ENOM00042-A Emergency starting rod. ENOW00099-A WARNING When the emergency starter rope is used for starting engine; Start in gear protection does not work. Be sure to shift is at neutral position. Otherwise the engine will move the boat immediately and cause personal injury.

  • Page 34: Warming Up The Engine

    ENGINE OPERATION all parts of the engine. Operating the ENOW00860-0 engine without warm up shortens the CAUTION engine's life. Be sure to keep the harness away from the rotation parts. 6. Be sure to install the stop switch lock to the stop switch, and attach the stop switch lanyard securely to the operator or to the operator's PFD (Personal Flo- tation Device.)
  • Page 35 ENGINE OPERATION Do not attach the tether to a part of ENOW00863-0 clothing that can be torn easily when CAUTION pulled. Arrange the tether so that will not be Idle speed may be higher during warming caught by any object when pulled. up of engine.

  • Page 36: Stopping The Engine

    ENGINE OPERATION 2. START position 3. Fully closed 4. Fully opened ENOM00049-A 5. Stopping the engine ENOW00868-0 WARNING ENOF02116-A 1. Shift lever 2. Forward Be careful not to remove engine stop 3. Reverse switch lanyard from engine accidentally Forward while boat is running. Sudden stop of 1.

  • Page 37: Steering

    ENGINE OPERATION 3. Push the stop switch. ENOM00920-A 6. Steering ENOW00870-0 WARNING Sudden steering may cause passenger(s) to be thrown overboard or falling down. Tiller handle type Right turn Move the tiller handle to the left ENOF00210-0 ENOF02126-0 Left turn 1.
  • Page 38 ENGINE OPERATION ENOW00044-0 WARNING Excessive trim up or down may lead to unstable boat operation, potentially caus- ing the steering difficulty that leads to acci- dent during cruising. Do not cruise at high speed if improper trim position is suspected. Stop the boat ENOF00052-0 and readjust trim angle before continu- ing cruise.

  • Page 39: Tilt Up And Down

    ENGINE OPERATION 3. Raise the outboard motor to the tilt up ENOW00056-A position. WARNING 4. Change the thrust rod position as fol- When tilting up outboard motor with fuel lowing picture. joint for over a few minutes, be sure to dis- connect fuel hose, or fuel may leak, poten- tially catching fire.

  • Page 40: Shallow Water Operation

    ENGINE OPERATION ENOM00068-A 9. Shallow water operation ENOW00051-0 WARNING During shallow water operation, be careful not to place your hand between the swivel bracket and the clamp bracket. Be sure to tilt the outboard motor down slowly. ENOW00053-0 CAUTION ENOF00442-0 1.
  • Page 41 ENGINE OPERATION Manual tilt type Shallow water running position: 1. With the shift lever in Neutral or For- ward, tilt the motor up slowly by about 40° and then lower the tilt lever for set- ting at the shallow water running posi- tion.

  • Page 42: Removing And Carrying The Outboard Motor

    REMOVING AND CARRYING THE OUTBOARD MOTOR Fuel leakage is a fire or explosion hazard, ENOM00070-C which can cause serious injury or death. 1. Removing the outboard motor ENOW00065-0 ENOW00064-A WARNING CAUTION Close air vent screw of fuel tank before Engine may be hot immediately after oper- carrying or storing outboard motor and fuel ating and could cause burns if touched.

  • Page 43: Traillering

    REMOVING AND CARRYING THE OUTBOARD MOTOR Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. ENOF00075-1 ENOW00068-0 WARNING Close air vent screw of fuel tank and fuel cock before carrying or storing outboard ENOF02131-0 motor and fuel tank, or fuel may leak, ENON00021-A Note...
  • Page 44 REMOVING AND CARRYING THE OUTBOARD MOTOR 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.

  • Page 45: Adjustment

    ADJUSTMENT causing an accident and could lead to ENOM00073-0 severe injury. 1. Steering friction Friction adjustment of the throttle grip can Tiller handle type be made with the throttle adjustment ENOW00074-A screw. 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 46: 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 47: Daily Inspection

    INSPECTION AND MAINTENANCE ENOM01403-0 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 48 INSPECTION AND MAINTENANCE ENOM00083-0 ENOM00085-E Washing outboard motor Flushing attachment ENOW00922-0 ENOW00081-0 CAUTION WARNING To prevent the engine from starting when Do not start engine without removing pro- you are near the propeller, remove the stop peller, or accidentally turning propeller switch lock.
  • Page 49 INSPECTION AND MAINTENANCE ENOM00085-A Flushing by test tank ENOW00081-0 WARNING Do not start engine without removing pro- peller, or accidentally turning propeller could cause personal injury. ENOW00082-0 WARNING Never start or operate the engine indoors or in any space which is not well ventilated. Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal if inhaled for any length of time.

  • Page 50: Periodic Inspection

    INSPECTION AND MAINTENANCE ENOM01404-0 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 51 INSPECTION AND MAINTENANCE ENOM00093-A ENOM00094-0 Fuel filters and fuel tank cleaning Fuel filter (for engine) 1. Replace the fuel filter provided inside of ENOW00093-B engine cover if there is water or dirt WARNING inside. Gasoline and its vapors are very flammable and can be explosive.
  • Page 52 INSPECTION AND MAINTENANCE Separate tank type board motor could lead to severe per- sonal injury. 1. Remove the fuel pickup elbow of the fuel tank by turning it counterclockwise ENON00934-0 Note 2. Clean the fuel filter and check the O- ring.

  • Page 53: Propeller Replacement

    INSPECTION AND MAINTENANCE 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 Use genuine gear oil or the recommended one (API GL-5: SAE #80 to #90). Required volume: approx.
  • Page 54 INSPECTION AND MAINTENANCE trouble. 6. Tighten the propeller nut to specified 1. Put a piece of wood block between torque, and align one of grooves to propeller blade and anti-ventilation propeller shaft hole. plate to hold propeller. Propeller nut torque: 12 Nm (9 ft lb, 1.2 kgf 7.
  • Page 55 INSPECTION AND MAINTENANCE 2. Remove the top cowl. 3. Remove the spark plug caps. 4. Remove the spark plugs by turning it counter-clockwise, using a 13/16" (21 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.

  • Page 56: 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 57 INSPECTION AND MAINTENANCE ENOM00960-0 Grease point Apply water proof grease to the parts shown below. ENOF02139-0...

  • Page 58: Off-Season Storage

    INSPECTION AND MAINTENANCE 4. Remove the spark plugs and put a tea- ENOM00100-A 3. Off-season storage spoon of engine oil or spray storage oil into the combustion chamber through ENOW00934-0 the spark plug holes. WARNING 5. Pull the recoil starter several turns to lubricate inside the cylinder.

  • Page 59: Adding A Fuel Stabilizer

    INSPECTION AND MAINTENANCE 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 every tank of fuel and keep the container full to reduce condensation and evaporation. ENOF02130-0 ENOM00970-C Fuel system draining...

  • Page 60: Pre-Season Check

    INSPECTION AND MAINTENANCE 7. When thoroughly drained, retighten the 5. Start the engine and warm up the drain screw securely. engine for 3 minutes in the “NEUTRAL” position. 8. Check the drained fuel for the pres- ence of water or other contaminants. If 6.

  • Page 61: Cold Weather Precautions

    INSPECTION AND MAINTENANCE 4. Inject a sufficient amount of engine oil through the spark plug holes. Pull the recoil starter rope several times to circulate the oil throughout the out- board motor. ENOM00106-A 6. Cold weather precautions If you moor your boat in cold weather at ENOF01145-0 temperatures below 0°C (32°F), there is the danger of remained water freezing in...

  • Page 62: Troubleshooting

    TROUBLESHOOTING ENOM01406-0 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 hose...
  • Page 63 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 or bent propeller Improper thrust rod position Unbalanced load on boat Transom too high or too low...

  • Page 64: Tool Kit And Spare Parts

    TOOL KIT AND SPARE PARTS ENOM01407-0 Name Quantity Remark Tool bag Pliers Socket wrench 10 × 13 mm Service tools Socket wrench 21 mm Socket wrench handle Screwdriver (Phillips-type Adapter-type and flat head) Emergency starter rope 1000 mm Spare parts Spark plug NGK: BPR 7HS-10 Split pin...

  • Page 65: Propeller Table

    PROPELLER TABLE ENOM01408-0 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. 4: 4500–5500 rpm 5: 4500–5500 rpm Propeller Size (Diameter × pitch) Propeller Mark inch...
  • Page 66 OWNER’S MANUAL M 4C M 5B 003-11068-6AF1 1512NB Printed in Japan...

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