TOHATSU MD 40B2 Owner's Manual
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TOHATSU MD 40B2 Owner's Manual

TOHATSU MD 40B2 Owner's Manual

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OWNER'S
MANUAL
MD 40B2
MD 50B2
MD 75C2
MD 90C2
MD 115A2
OB No.003-11120-2AG2

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Summary of Contents for TOHATSU MD 40B2

  • Page 1 OWNER’S MANUAL MD 40B2 MD 50B2 MD 75C2 MD 90C2 MD 115A2 OB No.003-11120-2AG2...
  • Page 2 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.
  • Page 3 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 4: 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: 40, 50 ENOF01301-0...
  • Page 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,”...

  • Page 7: Table Of Contents

    4. Propeller installation......... . 34 5. TOCS (Tohatsu Onboard Communication System) installation..36 6.
  • Page 8 5. Submerged outboard motor ........94 6.
  • Page 9 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 10: 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 11 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 72).

  • Page 12: Specifications

    SPECIFICATIONS ENOM00810-A MODEL FEATURE Model D40B2 D50B2 Type Transom heights Electrical start Multi-function tiller handle Remote Control Power Trim & Tilt Mnual tilt ( ) These models can be purchased with remote rigging kit or multi-function tiller handle Model D75C2 D90C2 Type EPTO...
  • Page 13 Remark: Specifications subject to change without notice. *1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 54) Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).

  • Page 14: Emission Control System

    Remark: Specifications subject to change without notice. *1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 54) Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
  • Page 15 Remark: Specifications subject to change without notice. *1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 54) Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
  • Page 16 Remark: Specifications subject to change without notice. *1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 54) Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
  • Page 17 Remark: Specifications subject to change without notice. *1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 54) Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).

  • Page 18: Parts Name

    PARTS NAME ENOM00607-0 ETO (with multi-function tiller handle)/40B2, 50B2 ENOF01307-0 Tilt Handle Clamp Bracket Spark Plug Top Cowl Thrust Rod Fuel Filter Hook Lever Throttle Grip Water Check Port Shift Lever Tilt Stopper Stop Switch Water Plug Pilot Lamp Anti-ventilation Plate Main Switch Trim Tab Battery Cords...
  • Page 19 PARTS NAME ENOM00608-0 ETO (with RC)/40B2, 50B2 ENOF01308-0 Tilt Handle Clamp Bracket Top Cowl Thrust Rod Hook Lever Power Trim & Tilt Switch Water Check Port Fuel Connector Tilt Stopper Battery Cords Water Plug Power Trim & Tilt Anti-ventilation Plate Anode Trim Tab Oil Tank...
  • Page 20 PARTS NAME ENOM00609-0 EPTO/75C2, 90C2 5, 9 ENOF01309-0 Tilt Handle Thrust Rod Top Cowl Fuel Nipple Hook Lever Power Trim & Tilt Switch Water Check Port Battery Cords Water Plug Power Trim & Tilt Anti-ventilation Plate Anode Trim Tab Flushing Connector Cap Propeller Oil Tank Oil Plug (upper)
  • Page 21 PARTS NAME ENOM00610-0 EPTO/115A2 5, 9 ENOF01310-0 Tilt Handle Power Trim & Tilt Switch Top Cowl Battery Cords Hook Lever Power Trim & Tilt Water Check Port Anode Water Plug Flushing Connector Cap Anti-ventilation Plate Oil Tank Trim Tab Spark Plug Propeller Fuel Filter Oil Plug (upper)
  • Page 22 PARTS NAME ENOM00822-0 Remote control box & Fuel tank ENOF00127-B Control Lever Fuel Gauge Neutral lock arm Air Vent Screw PTT switch Fuel Tank Cap Free throttle lever Tab Lock Main switch Fuel Connector (Engine side) Stop switch Primer Bulb Stop switch lock Fuel Connector (Fuel tank side) Stop switch lanyard...

  • Page 23: Label Locations

    LABEL LOCATIONS ENOM00019-A Warning label locations 1, 2 40/50 1, 2 (115) 75/90/115 ENOF01311-A...
  • Page 24 LABEL LOCATIONS Warning label regarding owner’s man- Indicator label regarding engine failure/ ual, top cowl, engine stop switch, malfunction (See page 43).) ENOF00005-C Warning regarding high voltage, rotat- ing parts, high temperature, fuel filter and fuel line. ENOF00005-W Warning regarding engine oil replenish- ment.
  • Page 25 LABEL LOCATIONS Warning label on engine stop switch. Warning regarding gasoline (See page 38). ENOF00008-0 Warning regarding gasoline. ENOF00005-F Warning regarding fuel tank cap (See page 39). ENOF00005-E Warning regarding gasoline (See page 38). ENOF00012-0 Warning tag regarding combination of fuel tank and primer bulb ass'y.
  • Page 26 LABEL LOCATIONS Warning tag regarding instructions of the fuel tank cap (See page 39). ENOF00011-0...
  • Page 27 LABEL LOCATIONS ENOM00019-A ECI (Emission Control Information) decal locations 40, 50 75, 90 1 EMISSION CONTROL INFORMATION 2 THIS ENGINE CONFORMS TO (MODEL YEAR) CALIFORNIA AND U.S. EPA EMISSION REGULATION FOR SPARK IGNITION MARINE ENGINES. 3 THIS EQUIPMENT MEETS U.S. EPA EVAP STANDARD. 4 REFER TO THE OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.
  • Page 28 LABEL LOCATIONS EPA Emissions Regulations Emissions Warranty Coverage Outboards sold by Tohatsu America Cor- WARRANTY INFORMATION poration in the United States are certified Four Stroke Outboard Limited War- to the United States Environmental Protec- ranty tion Agency as conforming to the require-...

  • Page 29: Installation

    INSTALLATION Do not operate the outboard motor until it ENOM00024-A has been securely mounted on the boat in 1. Mounting the outboard motor on accordance with the instructions below. boat ENOW00009-0 ENOW00006-B WARNING WARNING 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-...
  • Page 30 INSTALLATION water surface is near the bottom cowl- ENOM00025-0 Position ... Above keel line ing, in high waves, water may enter the Set engine at center of boat. engine cylinders. Incorrect outboard motor mounting height or existence of underwater object(s), such as hull bottom design, bottom surface conditions or underwa- ter accessories, can cause water spray possibly reaching the engine through an...
  • Page 31 INSTALLATION 40, 50 ENOF00610-0 ENOF00612-1 1. Clamp Screw 1. Washer (small diameter) 2. Washer (small diameter) 2. Washer (large diameter) 3. Washer (large diameter) 3. Bolt (12 mm x length 105 mm) 4. Bolt (12 mm x length 105 mm) 4.

  • Page 32: Remote Control Device Installation

    INSTALLATION 75, 90, 115 ENON00003-0 Notes 1. Apply sealing agent, such as silicone sealed between the bolts and the tran- som board holes before tightening the bolts. 2. Be sure to tighten the mounting bolt nuts to the specified torque. (30 Nm (3.0 kgf) 13 ft-lb) ENOM00840-0 2.

  • Page 33: Battery Installation

    INSTALLATION Keep battery and electrolyte away from ENOW00850-0 Remote control cable length reach of children ENOW00100-A When handling the battery, be sure to: Read all warnings shown on the battery CAUTION case Be careful not to loop the remote control Prevent electrolyte from coming in con- cables to a diameter of 406 mm (16 inches) tact with any part of your body.

  • Page 34: Propeller Installation

    INSTALLATION Always use a fully charged battery. ENOW00015-0 CAUTION Do not use a battery that is not recom- mended. Use of a battery not recom- mended can lead to poor performance of, and/or damage to, the electrical system. ENOF00022-0 ENON00006-A Note 1.
  • Page 35 INSTALLATION 1. Remove the split pin, propeller nut and ENOW00085-0 washer. WARNING 2. Remove the propeller and thrust Do not hold propeller with hand(s) when holder. loosening or tightening propeller nut. Put a 3. Apply water proof grease to the pro- piece of wood block between propeller blade and anti-ventilation plate to hold pro- peller shaft before installing a new pro-...

  • Page 36: Tocs (Tohatsu Onboard Communication System) Installation

    TOCS (Tohatsu Onboard Communication System) interface coupler can provide information regarding engine speed, fuel consumption, and various malfunction via an optional interface cable. Contact autho- rized Tohatsu dealer for more detail. ENOF01336-0 1. Propeller 40, 50 2. Thrust holder 3. Bush 4.

  • Page 37: Altitude Adjustment Kit Requirement

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

  • Page 38: 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, create unique problems. In cars, alco-...

  • Page 39: Fuel Filling

    PRE-OPERATING PREPARATIONS protective oil films from internal compo- When or before refueling: nents. 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 40: Engine Oil Recommendation

    PRE-OPERATING PREPARATIONS properly fill the engine with oil follow the instructions, See page 74) ENOF00029-0 1. Air vent screw 2. Fuel tank cap 2. Loosen the tank cap until it contacts ENOF00641-0 the tab lock and release internal pres- 1. Genuine of recommended engine oil sure completely.
  • Page 41 PRE-OPERATING PREPARATIONS ENOW00022-0 ENOM00645-0 Oil pump air vent CAUTION Visually check whether there is air in the oil through the vinyl pipe connecting the oil The engine oil is drained for shipping from the factory. Be sure to fill the engine to the tank with the oil pump.

  • Page 42: Break-In

    PRE-OPERATING PREPARATIONS ENOM00033-A 4. Break-In Your new outboard motor and lower unit Always attempt to stay on the windward side of emission. require break-in for the moving compo- 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 described in the following time table.

  • Page 43: Warning System

    PRE-OPERATING PREPARATIONS ENOM00039-0 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 ENOF00852-0 stopped).
  • Page 44 PRE-OPERATING PREPARATIONS ENOM00041-C Warning indicators, faults and remedy Warning indicators Description of faults Rem- or notice Remark Sound lamp lamp lamp Continu- Normal system test 1 second when key on High Engine speed exceeds Approx. Continu- speed maximum 6,000 r/min allowable RPM Intermit- tent (3...
  • Page 45 PRE-OPERATING PREPARATIONS Remedy 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.

  • Page 46: Engine Operation

    ENGINE OPERATION execute the following operation for forc- ENOM00042-0 Before starting edly feeding the engine oil to the oil line before starting the engine. ENOW00022-A ENOM00657-0 CAUTION 40, 50 type a. Disconnect the link rod by turning the The engine oil is drained for shipping from the factory.
  • Page 47 ENGINE OPERATION c. Within 2 seconds after removing the stop switch lock, quickly repeat pulling and pushing back the stop switch knob 2 times. d. The buzzer sounds 3 times and the oil pump is actuated for about 1 minute for pressure feed or oil.

  • Page 48: Fuel Feeding

    ENGINE OPERATION Do not connect fuel connector except ENOM00044-B when operating engine. Fuel leakage is a 2. Fuel feeding fire or explosion hazard, which can cause serious injury or death. ENOW00029-A WARNING 1. Full open the air vent screw on the fuel tank cap.

  • Page 49: Starting The Engine

    ENGINE OPERATION And be sure to remove the propeller, when starting the engine in the test tank. (See page 80) ENOF00861-A 1. Pull 2. Insert 4. Squeeze primer bulb until it becomes ENOF00863-0 stiff to feed fuel to vapor separator. 1.
  • Page 50 ENGINE OPERATION 4. Set the throttle grip to START position. ENON00010-0 Note Start-in-gear protection prevents engine from starting at other than neutral shift. In- gear starting of engine will move the boat immediately, potentially leading to falling down or causing passenger(s) to be thrown overboard.
  • Page 51 ENGINE OPERATION ENOF00665-0 1. Idle port 2. Cooling water check port 75, 90, 115 Side mount RC type START PUSH TO IDLE CHANGE 1. Be sure to install the stop switch lock to the stop switch, and attach the stop ENOF00867-0 switch lanyard securely to the operator 1.

  • Page 52: Emergency Starting

    ENGINE OPERATION 1. Neutral (N) 6. Check the cooling water from cooling 2. Control lever water check port. 3. Fully opened (Forward) 4. Fully opened (Reverse) 5. Free throttle lever 6. Main switch key 7. Stop switch 4. Turn the main switch key to ON posi- tion and confirm three warning lamps light up with buzzer sound and then go off.
  • Page 53 ENGINE OPERATION Do not pull starter rope if any bystander 4. Tie a loop in the another end of the is behind. The action can injure the emergency starter rope and attach bystander. socket wrench that is included in the Attach engine stop switch lanyard to tool kit.

  • Page 54: Warming Up The Engine

    ENGINE OPERATION ENOM00043-A ENOM00044-0 Engine speeds 4. Warming up the engine Idling speed after warming up. Remark: In case of cold engine starting, ENOW00932-0 idling speed is increased about 400 rpm CAUTION for several minutes. Be sure to check that cooling water is Clutch in (In gear) Clutch off (Out of gear) coming out of the cooling water check port...
  • Page 55 ENGINE OPERATION the right and left. Make sure that no swim- ENOW00862-0 mer(s) is ahead or astern of the boat. CAUTION ENOW00038-A Gear and clutch damage may occur if shift- ing at high engine speed. WARNING Engine must be in the slow idle position before shifting is attempted.
  • Page 56 ENGINE OPERATION Acceleration ENOM00890-A Tiller handle type ENOW00867-0 ENOW00865-0 WARNING CAUTION Sudden acceleration and deceleration may Do not force to shift when the throttle grip cause passenger(s) to be thrown over- is not in the fully closed position, other- board or falling down. wise, steering system and/or shifting Open throttle grip gradually.

  • Page 57: Stopping The Engine

    ENGINE OPERATION Acceleration ENOW00867-A CAUTION Sudden acceleration and deceleration may cause passenger(s) to be thrown over- board or falling down. Open control lever gradually. ENOF00877-0 1. Forward (F) 2. Neutral (N) 3. Reverse (R) 4. Fully opened (Forward) 5. Fully opened (Reverse) 6.
  • Page 58 ENGINE OPERATION Side mount RC type 1. Put the control lever in the Neutral position and run the engine for 2-3 minutes at idling speed for cooling down if it has been running at full speed. ENOF00866-0 1. Throttle grip 2.

  • Page 59: Steering

    ENGINE OPERATION Emergency engine stopping Be sure to confirm the spare stop switch Remove stop switch lock to stop the lock is in the tool bag before begin to oper- engine. ate. ENOF00891-0 ENOM00920-0 7. Steering ENOW00870-0 ENOF00883-0 WARNING 1. Stop switch 2.

  • Page 60: Trim Angle

    ENGINE OPERATION Left turn For outboard motor model with PTT 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. The trim angle of the outboard motor can be adjusted to suit the transom angle of the hull, and load conditions.
  • Page 61 ENGINE OPERATION Trim angle adjustment (Manual tilt ENOM00054-0 Improper trim angle (bow dips into the type) water) The transom angle adjustment Set the thrust rod higher if the bow of the 1. Stop the engine. boat is below horizontal. 2. Shift into neutral. 3.

  • Page 62: Tilt Up And Tilt Down

    ENGINE OPERATION 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- connect fuel hose, or fuel may leak, poten- tially catching fire. ENOW00057-0 CAUTION Do not tilt up outboard motor while engine...
  • Page 63 ENGINE OPERATION 2. Operate the Power Trim & Tilt switch and tilt the outboard motor down until the motor touches to the thrust rod. ENOF00067-A ENOF01317-0 ENOM00063-0 Tilt down Pull the reverse lock lever upward until it ENOF00067-0 40, 50 stops.
  • Page 64 ENGINE OPERATION 40, 50 ENOF01320-0 It is possible to tilt up or down in spite of main switch “ON” or “OFF”. ENOM00940-0 Manual relief valve ENOF00070-1 If the battery is dead, and the power tilt 1. POWER switch thus inoperative, open the manual 2.

  • Page 65: Shallow Water Operation

    ENGINE OPERATION Manual tilt type (*40, 50 only) ENOM00068-A 10.Shallow water operation 1. Shallow water running position: Put the reverse lock lever in the tilt up position, and tilt up the outboard motor ENOW00051-0 to put the outboard motor in the shal- WARNING low water running position.
  • Page 66 ENGINE OPERATION 2. Return to normal running position: Put the reverse lock lever in the tilt down position, slightly lift up the out- board motor, and then put it down. ENOF00059-0 1. Reverse lock lever 2. Tilt up position 3. Tilt down position ENOM00069-A Power Tilt type 1.

  • Page 67: Removing And Carrying The Outboard Motor

    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 250 kg (550 lbs) or above.

  • Page 68: Traillering

    REMOVING AND CARRYING THE OUTBOARD MOTOR ENOW00066-A ENOM00072-A CAUTION 3. Traillering Do not give a shock to an outboard motor during transportation. It becames a cause ENOW00072-0 of breakage. CAUTION Trailering in the tilted position may cause Keep the outboard motor in a vertical posi- damage to the outboard motor, boat, etc.
  • Page 69 REMOVING AND CARRYING 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 70).

  • Page 70: Adjustment

    ADJUSTMENT causing an accident and could lead to ENOM00073-A severe injury. 1. Steering friction Friction adjustment of the throttle grip can Tiller handle type be made with the throttle adjustment (*40, 50 only) screw. 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...

  • Page 71: Trim Tab Adjustment

    ADJUSTMENT Side mount type 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 72: 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 73: Daily Inspection

    INSPECTION AND MAINTENANCE ENOM00703-0 1. Daily inspection Perform the following checks and inspec- ENOW00078-1 tion before and 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.
  • Page 74 INSPECTION AND MAINTENANCE Item Points to Check Remedy • Check if the anode and trim tab are securely installed. Repair if necessary Other parts • Check the anode and trim tab for corrosion and deformation. Replace ENOM00082-A Engine oil replenishing ENOW00079-A CAUTION Do not add engine oil of brand and grade...
  • Page 75 INSPECTION AND MAINTENANCE 4. Put the shift lever in the neutral position ENOW00920-0 and start the engine. Continue flushing CAUTION the outboard motor for 3 to 5 minutes When washing the outboard motor, be at idling. careful not to spray the water inside of the 5.
  • Page 76 INSPECTION AND MAINTENANCE ENOM00085-C ENOM00085-A Flushing attachment (bottom cowl) Flushing by test tank *75, 90, 115 ENOW00081-0 ENOW00921-0 WARNING CAUTION Do not start engine without removing pro- peller, or accidentally turning propeller Do not operate the engine when flushing could cause personal injury. the outboard motor with a flushing attach- ment as this can cause damage to the out- board motor.

  • Page 77: Fuse Replacement

    75, 90 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.
  • Page 78 INSPECTION AND MAINTENANCE ENOF01330-0 1. Blown fuse...

  • Page 79: Periodic Inspection

    INSPECTION AND MAINTENANCE ENOM00708-A 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 80 INSPECTION AND MAINTENANCE Inspection intervals First 20 Every 50 Every 100 Every 200 Description Inspection procedure Remarks hours of 1 hours of 3 hours of 6 hours of 1 month months months year Sliding and Rotating Parts. Apply and pump in grease. Grease Nipples Outer Equipment Check for corrosion.
  • Page 81 INSPECTION AND MAINTENANCE 3. Refit the pipes to the oil tank and ENOM00096-A Fuel filter (for fuel tank) pumps, and then fill up with new Water or dirt in the fuel tank will cause engine oil. engine performance problems. 4. For air purging, refer to ‘’Engine oil Check and clean the tank at specified feeding’’...
  • Page 82 INSPECTION AND MAINTENANCE 75, 90, 115 ENOM00098-A Gear oil replacement ENOW00094-0 WARNING Be sure that outboard motor is secured to transom or service stand, or acciden- tal drop or fall of outboard motor could lead to severe personal injury. Be sure to lock outboard motor if it is tilted up, or accidental fall of outboard motor could lead to severe personal injury.

  • Page 83: Propeller Replacement

    INSPECTION AND MAINTENANCE 75, 90, 115 75, 90, 115 ENOF01332-0 ENOF01334-0 4. Install the upper oil plug, and then ENOW00928-0 remove oil tube nozzle and install the CAUTION lower oil plug. Wipe off gear oil well immediately if spilled ENOW00095-0 and dispose of it in accordance with local CAUTION fire prevention and environment protection...
  • Page 84 INSPECTION AND MAINTENANCE “OFF”, engine stop switch lock attached 4. Apply water proof grease to the pro- to the switch, and starter key attached, peller shaft before installing a new pro- or engine could accidentally start lead- peller. ing to serious personal injury. Discon- 5.
  • Page 85 INSPECTION AND MAINTENANCE 6. Tighten the propeller nut to specified 1. Stop the engine. torque, and align one of grooves to 2. Remove the top cowl. propeller shaft hole. 3. Remove the spark plug caps. Propeller nut torque: 4. Remove the spark plugs by turning it 25 Nm (18 ft lb, 2.5kgf counter-clockwise, using a 5/8"...
  • Page 86 INSPECTION AND MAINTENANCE 8. Tighten the spark plug to the specified torque. ENON00028-0 Note Spark plug torque: 18.0 Nm (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.

  • Page 87: 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 88 INSPECTION AND MAINTENANCE 40, 50 ENOM00089-B Power Tilt oil checking ENOW00088-0 WARNING Be sure that outboard motor is secured to transom or service stand, or acciden- tal drop or fall of outboard motor could lead to severe personal injury. Be sure to lock outboard motor if it is tilted up, or accidental fall of outboard motor could lead to severe personal injury.
  • Page 89 INSPECTION AND MAINTENANCE 1. With the outboard motor mounted on the boat, set the manual release valve to the Manual side, and tilt the out- board motor manually up/down 5-6 times while checking the oil level. 2. When done, close the valve by turning it clockwise towards the Power side.
  • Page 90 INSPECTION AND MAINTENANCE ENOM00960-0 Grease point Apply water proof grease to the parts shown below. 40, 50 ENOF01341-A...

  • Page 91: Off-Season Storage

    INSPECTION AND MAINTENANCE 2. Remove the fuel hose from the out- ENOM00100-A 3. Off-season storage board motor. 3. Drain all fuel from the fuel hoses, fuel ENOW00934-0 pump, fuel filter (See page 80) and WARNING vapor separator (See page 92), and clean these parts.

  • Page 92: Adding A Fuel Stabilizer

    INSPECTION AND MAINTENANCE 8. Stand the outboard motor up vertically 1. Before adding fuel stabilizer additive, in a dry place. d r a i n t h e v a p o r s e p a r a t o r ( S e e page 92).
  • Page 93 INSPECTION AND MAINTENANCE 1. Disconnect the fuel hose from the out- 75, 90, 115 board motor. 2. Remove the top cowl. 3. Release the drain tube from the clamp and pull the tube outside the bottom cowl. Place an approved fuel container under the drain tube end and use a funnel to avoid spilling fuel.

  • Page 94: Pre-Season Check

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

  • Page 95: Cold Weather Precautions

    INSPECTION AND MAINTENANCE 4. Inject a sufficient amount of engine oil through the spark plug holes. Pull the emergency starter rope several times to circulate the oil throughout the outboard motor. ENOM00106-A 6. Cold weather precautions ENOF01145-0 If you moor your boat in cold weather at temperatures below 0°C (32°F), there is ENOM00121-0 the danger of remained water freezing in...

  • Page 96: Troubleshooting

    TROUBLESHOOTING ENOM00720-0 If you encounter problem with the engine, check the list below and locate the problem you are experiencing. Then follow the suggested remedies. Do not hesitate to contact your dealer, as professionals advice and assistance is the best way to keep the engine in optimum condition.
  • Page 97 TROUBLESHOOTING Possible cause Lock plate is not inserted or poorly inserted into stop switch. Wrong wiring, disconnection, poor connection. Faulty operation of starter motor/starter solenoid A great deal of air is contained inside pump.

  • Page 98: Tool Kit And Spare Parts

    TOOL KIT AND SPARE PARTS ENOM00721-0 40, 50 The following a list of the tools and spare parts provided with the motor. Name Quantity Remark Tool bag Socket wrench (16 mm) Socket wrench (10 × 13) Service tools Socket wrench handle Pliers Screwdriver (Phillips-type and Adapter-type...
  • Page 99 TOOL KIT AND SPARE PARTS ENOM00722-0 75, 90, 115 The following a list of the tools and spare parts provided with the motor. Quantity Name Remark MD 75/90 MD 115 Tool bag Socket wrench (16 mm) Socket wrench (10 × 13) Service tools Socket wrench handle Pliers...

  • Page 100: Propeller Table

    PROPELLER TABLE ENOM00724-0 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. 5150–5850 rpm 30, 40, 50 75, 90, 115...

  • Page 101: Emission Control System Information

    EMISSION CONTROL SYSTEM INFORMATION ENOM01000-0 ENOM01003-0 Emission Sources Clean Air Acts of the United States and California, and Environment Canada Carbon monoxide, oxides of nitrogen and hydrocarbons are produced in the course EPA, California, and Canadian regulations of the combustion process. Controlling require all manufacturers to provide written production of oxides of nitrogen and instructions that describe the operation...
  • Page 102 If you notice any of the following symp- ENOM00033-0 toms, have your outboard motor inspected Low permeation fuel hose and repaired by an authorized Tohatsu ser- requirement vice dealer before further use. EQUIPPED FOR UNITED STATES AND Hard starting or stalling immediately...
  • Page 103 EQUIPPED FOR UNITED STATES AND EQUIPPED FOR UNITED STATES AND CANADA MODEL CANADA MODEL The Environmental Protection Agency TOHATSU adopts Primer bulb/hose (EPA) required portable fuel systems that assembly approved by the Environment are produced after January 1, 2011 for use Protection Agency (EPA).
  • Page 104 EMISSION CONTROL SYSTEM INFORMATION Resources Board’s Personal Watercraft ENOM01007-0 Maintenance a n d O u t b o a rd m a r i n e e n g i n e 2 0 0 1 exhaust emission standards. Follow the maintenance schedule pre- Engines meeting these standards have sented on page 70.
  • Page 105 EMISSION CONTROL SYSTEM INFORMATION Engines meeting these standards have 65% lower emissions than One Star-Low Emission engines. ENOF01004-0 ENOM01012-0 Four Stars-Super Ultra Low Emission The four-star label identifies engines that meet the Air Resources Board’s Sterndrive and Inboard marine engine 2009 exhaust emission standards.
  • Page 106 OWNER’S MANUAL MD 40B2 MD 50B2 MD 75C2 MD 90C2 MD 115A2 003-11120-2AG2 1701NB Printed in Japan...

This manual is also suitable for:

Md 90c2Md 115a2Md 75c2Md 50b2

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