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TOHATSU MFS2.5B Owner's Manual

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OWNER'S
MANUAL
MFS
2.5B
3.5B
OB No.003-11085-7

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  • Page 1 OWNER’S MANUAL 2.5B 3.5B OB No.003-11085-7...
  • Page 2 INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE. Copyright © 2009-2012 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 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. ENOM00004-0 Limited Warranty Please refer to the TOHATSU outboard motor Limited warranty provided to you with this product, the terms and conditions of which, as amended from time to time, are incorpo- rated by reference into the manual.

  • Page 4: Serial Number

    ENOM00006-0 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 5: Table Of Contents

    CONTENTS GENERAL SAFETY INFORMATION ....... . 8 1. SPECIFICATIONS ..........10 2.
  • Page 6 11. TROUBLESHOOTING ......... . 49 12.
  • Page 7 INDEX GENERAL SAFETY INFORMATION 1. SPECIFICATIONS 2. NAMES OF PARTS 3. LOCATIONS OF WARNING LABELS 4. INSTALLATION 5. PRE-OPERATING PREPARATIONS 6. ENGINE OPERATION 7. REMOVING AND CARRYING THE OUTBOARD MOTOR 8. TRAILERING 9. ADJUSTMENT 10. INSPECTION AND MAINTENANCE 11. TROUBLESHOOTING 12.

  • Page 8: General Safety Information

    GENERAL SAFETY INFORMATION 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 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 10: Specifications

    SPECIFICATIONS EENOM00201-0 2.5B, 3.5B Item MODEL 2.5B 3.5B Overall Length mm (in) 690 (27.2) Overall Width mm (in) 363 (14.3) Except for USA and Canada model 1026 (40.4) 1153 (45.4) Overall Height S·L mm (in) For USA and Canada model 1040 (40.9) 1167 (45.9) Transom Height S·L mm (in)

  • Page 11: Names Of Parts

    NAMES OF PARTS ENOM00202-0 2.5B, 3.5B ENOF00201-0 Fuel Tank Cap Drive Shaft Housing Engine Oil Drain Screw Tilt Handle Thrust Rod Engine Oil Level Gauge Top Cowl Clamp Bracket Air Vent Screw Cowl Latch Clamp Screw Fuel Cock Cooling Water Check Port Throttle Grip : Integral Fuel Tank Steering Adjustment Screw...

  • Page 12: Locations Of Warning Labels

    LOCATIONS OF WARNING LABELS ENOM00203-0 Locations of warning labels ENOF00202-0 Warning label regarding owner’s man- Warning label on position of outboard ual, top cowl, engine stop switch, motor when setting down. engine oil level and unleaded gasoline. ENOF00253-0 Only for USA and CANADA models Warning regarding fuel tank cap (See pages 22–24).
  • Page 13 LOCATIONS OF WARNING LABELS Check oil level ENOF00116-0 Use unleaded gasoline only ENOF00012-0 Rotating part, high voltage, high tem- perature warning label. ENOF00117-0 Lay as indicated ENOF00203-0 Warning, rotating object ENOF00254-0 ENOM00204-0 Symbols I n d i v i d u a l s y m b o l m a r k s m e a n s a s ENOF00249-0 described below.

  • Page 14: Installation

    INSTALLATION ENOM00024-0 1. Mounting the outboard motor on boat ENOW00006-0 30–50 mm WARNING (1.2–2 in) Most boats are rated and certified in terms of their maximum allowable horsepower, as shown on the boat’s certification plate. ENOF00206-0 Do not equip your boat with an outboard 1.
  • Page 15 INSTALLATION ENOW00007-0 personal injury. Be sure that fasteners are tightened to the specified torque (30 CAUTION Nm (3.0 kgf) 13 ft-lb). Check the fasten- ers for tightness from time to time.  Before beginning the running test, check  Be sure to use outboard mounting fas- that the boat with maximum capacity teners included in the outboard motor loading floats on the water in a proper...

  • Page 16: Pre-Operating Preparations

    The fuel system components on your  Dispose aged or contaminated gasoline TOHATSU engine will withstand up to 10% in accordance with local regulations. alcohol content in the gasoline. But if the gasoline in your area contains either meth-...

  • Page 17: Low Permeation Fuel Hose Requirement

    United leaks and mechanical parts for corrosion States.  TOHATSU engine has used fuel hoses and abnormal wear more frequently. And, in case any of such abnormality is for The Environmental Protection...

  • Page 18: Epa Pressurized Fuel Tank Requirements

    PRE-OPERATING PREPARATIONS ENOM00206-0 ENOM00207-0 3. EPA pressurized fuel tank 4. Recommended engine oil requirements Use only high quality 4-stroke engine oil to EQUIPPED FOR UNITED STATES AND insure performance and prolonged engine CANADA MODEL life. The Environmental Protect ion Agency Use NMMA FC-W certified 4-stroke engine (EPA) required integral fuel systems that oil below.

  • Page 19: Altitude Adjustment Kit Requirement

    PRE-OPERATING PREPARATIONS ENOM00246-0 5. Altitude adjustment kit requirement For U.S.A. market only High altitude: When engine operates at high altitude engine may need to have a high altitude kit installed. Otherwise, operating the engine at high altitude may increase its emissions and decrease fuel efficiency and perfor- mance.

  • Page 20: Break-In

    PRE-OPERATING PREPARATIONS ENOM00038-0 6. 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 21: Esg (A Device Preventing Over Revolution)

    PRE-OPERATING PREPARATIONS ENOM00208-0 7. ESG (A device preventing over revolution) ESG is a device to prevent over revolution of the engine (more than approximately 6300 rpm). If you sense that the ESG is activated return to shore at a reduced speed (rpm). Possible causes of ESG activation are: Worn, broken, bent propeller and shear pin.

  • Page 22: Engine Operation

    ENGINE OPERATION ENOM00042-0 ENOM00043-0 Before starting 1. Filling the fuel ENOW00022-0 ENOW00028-0 CAUTION DANGER The engine oil is drained for shipping from Consult an authorized dealer for details on the factory. Be sure to fill the engine to the handling gasoline, if necessary. proper level before starting engine.
  • Page 23 ENGINE OPERATION ENOW00029-0 1. Full line WARNING 4. After filling the tank, close the tank cap. When opening fuel tank cap, be sure to fol- low the procedure described below. Fuel ENOM00210-0 For USA and Canada model could blast out through the fuel tank cap in case the cap is loosened by using another 1.

  • Page 24: Feeding The Fuel

    ENGINE OPERATION ENOM00211-0 ENOM00212-0 2. Feeding the fuel 3. Starting Except for USA and Canada 1. Place the shift lever in the neutral posi- tion. model 1. Loosen the air vent screw on the tank cap by two turns. 2. Open the fuel cock. ENOF00215-0 1.
  • Page 25 ENGINE OPERATION ENOW00201-0 WARNING Accidental activation of the Emergency Stop Switch (such as the tether being pulled out in heavy seas) could cause pas- sengers to lose their balance and even fall overboard, or it could result in loss of power in heavy seas, strong currents, or high winds.
  • Page 26 ENGINE OPERATION ENOF00220-0 3. Remove the recoil starter. ENOF00217-0 1. Cowl latch Removing the recoil starter ENOF00221-0 4. Tighten the three bolts (A, B, C) fas- tening the tank and one bolt (D) fasten- ing the recoil starter.  Confirm that the shift lever is at Neutral ENOF00218-0 (N) position.

  • Page 27: Warming Up The Engine

    ENGINE OPERATION or while engine is in operation. Touching any of these parts can cause electrical shock. ENOM00043-0 4. Warming up the engine Warm the engine at low engine speeds for about three minutes. This allows the lubri- cating oil to circulate to all parts of the engine.

  • Page 28: Forward And Reverse

    ENGINE OPERATION  Do not attach the tether to a part of damage. Consult an authorized dealer if the cause cannot be found. clothing that can be torn easily when pulled.  Arrange the tether so that will not be ENOM00214-0 caught by any object when pulled.
  • Page 29 ENGINE OPERATION ENOW00040-0 WARNING Before shifting, make sure that no swim- mer(s) or obstacle(s) is ahead or astern of the boat. ENOW00041-0 CAUTION Be sure to warm up engine well before starting cruise. Operating cold engine may ENOF00224-0 cause damage to your motor. 1.

  • Page 30: Stopping

    ENGINE OPERATION ENOW00057-0 ENOW00203-0 CAUTION WARNING Do not tilt up outboard motor while engine Avoid serious injury or death from a gaso- operates, or no cooling water may be fed, line fire or explosion. leading to engine seizure due to overheat- Ensure that is 4 and 5.

  • Page 31: Trim Angle

    ENGINE OPERATION 1. Air vent screw ENON00208-0 Notes  After stopping the engine, close the air vent screw on the tank cap.  Close the fuel cock. (Integral fuel tank) ENOF00052-0 ENOM00050-0 7. Trim angle ENOM00054-0 Improper trim angle (bow dips into the water) The trim angle of the outboard motor can Set the thrust rod higher if the bow of the...

  • Page 32: Tilt Up, Tilt Down

    ENGINE OPERATION when adjusting trim angle to prevent 2. Tilt up the outboard motor fully to your injury in case the outboard motor body side and press the tilt stopper knob falls. inside to set it up.  Unsuitable trim position can cause loss of control of boat.

  • Page 33: Outboard Motor Position In Tilt Up

    ENGINE OPERATION 1. Tilt stopper ENOW00205-0 ENOW00055-0 CAUTION WARNING The outboard motor is set in the correct tilt-up position in the usual condition, how- Do not tilt up or down outboard motor ever, the outboard motor may be set in the when swimmer(s) or passenger is near to wrong tilt-up position if the motor direction prevent them from being caught between...

  • Page 34: Removing And Carrying The Outboard Motor

    REMOVING AND CARRYING THE OUTBOARD MOTOR  Do not give a shock to an outboard ENOM00225-0 motor during transportation. It becames 1. Removing the outboard motor a cause of breakage. 1. Stop the engine. 2. Close the fuel lock. ENOM00072-0 3.

  • Page 35: Trailering

    TRAILERING 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. ENOW00068-0 WARNING Close air vent screw of fuel tank and fuel cock before carrying or storing outboard motor and fuel tank, or fuel may leak, potentially catching fire.

  • Page 36: Adjustment

    ADJUSTMENT ENOM00227-0 1. Steering friction The steering friction can be adjusted in accordance with your preference by turn- ing the adjustment screw. ENOF00238-0 1. Lighter 2. Heavier ENOW00074-0 WARNING Do not overtighten the throttle grip or remote control tensioner or it could result in difficulty of movement resulting in the loss of control causing an accident and could lead to severe injury.

  • Page 37: Inspection And Maintenance

    INSPECTION AND MAINTENANCE ENOM00077-0 ENOM00078-0 Care of your outboard motor EPA Emissions Regulations To keep your outboard motor in the best EPA (United States Environmental Protec- operating condition, it is very important tion Agency) has emission regulations reg- that you perform daily and periodic main- ulating air pollution from new outboard tenance as suggested in the maintenance motors.

  • Page 38: Daily Inspection

    INSPECTION AND MAINTENANCE ENOM00228-0 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 39: Filling Engine Oil

    INSPECTION AND MAINTENANCE ENOM00080-0 Maintaining engine oil If the engine oil level is low, the life of the engine will be shortened significantly. ENOM00229-0 Checking oil level 1. Stop the engine and set it in a vertical position. 2. Remove the top cowl. ENOF00240-0 3.
  • Page 40 INSPECTION AND MAINTENANCE ENOW00080-0 CAUTION Keep cooling water passage free of clogs, or lack of cooling water flow could lead to engine overheating, potentially resulting in engine trouble. ENON00026-0 Note It is recommended to check chemical prop- erties of water on which your outboard motor is regularly used.
  • Page 41 INSPECTION AND MAINTENANCE  Do not touch spark plugs immediately 1. Pull out the split pin from the propeller after stopping engine as they will be hot boss and remove the propeller from a n d c o u l d c a u s e s e v e r e b u r n s i f the shaft.
  • Page 42 INSPECTION AND MAINTENANCE the correct torque as soon as possible with a torque-wrench. ENOM00234-0 Replacing the anode A sacrificial anode protects the outboard motor from galvanic corrosion. Anode is located on the gear case. When the anode is eroded more than 2/3, replace it. ENON00029-0 Notes ...

  • Page 43: Periodic Inspection

    INSPECTION AND MAINTENANCE ENOM00235-0 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 44 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 Bolts and Nuts Retighten.    Sliding and Rotating Parts ...
  • Page 45 INSPECTION AND MAINTENANCE Use NMMA FC-W certified 4-stroke out- ENON00031-0 Notes board oil below.  If any amount of water is found in engine 10W-30: is recommended for use in all oil, making it milky white, consult dealer. temperature.  If engine oil is contaminated with fuel, emitting strong fuel smell, consult dealer.

  • Page 46: Off-Season Storage

    INSPECTION AND MAINTENANCE ENOW00095-0 serviced and prepared by your dealer. CAUTION ENOW00211-0 CAUTION Do not reuse oil plug gasket. Always use new gasket and tighten oil plug properly to Before servicing the motor for storage: prevent entry of water into lower unit. ...

  • Page 47: Pre-Season Check

    INSPECTION AND MAINTENANCE ENOW00097-0 1. Wash the outboard motor with fresh water to remove salt or dirt. WARNING 2. Remove the engine oil drain screw and Be sure to use cloth to remove fuel remain- completely drain water and oil from the ing in the cowl and dispose of it in accor- engine.

  • Page 48: Checking After Striking Underwater Object

    INSPECTION AND MAINTENANCE ENOM00107-0 7. Checking after striking underwater object Striking the sea bottom or an underwater object may severely damage the outboard motor. Immediately bring the outboard motor to the dealer and ask for the follow- ing checks. 1. Looseness or damage of power unit installation bolts, gear case and exten- sion case bolts, propeller shaft housing bolts, propeller or propeller shaft upper...

  • Page 49: Troubleshooting

    TROUBLESHOOTING ENOM00241-0 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 ...
  • Page 50 TROUBLESHOOTING Possible cause      Incorrect adjustment of throttle link   Insufficient cooling water flow, clogged or defective pump    Faulty thermostat     Cavitation or ventilation      Incorrect propeller selection ...

  • Page 51: Tool Kit And Spare Parts

    TOOL KIT AND SPARE PARTS ENOM00242-0 The following a list of the tools and spare parts provided with the motor. Items Quantity Remark Tool bag Pliers Socket wrench 10 × 13 mm Service tools Socket wrench 16 mm Socket wrench handle Screwdrivers Cross-and straight-point Screwdriver handle...

  • Page 52: Optional Accessories

    OPTIONAL ACCESSORIES ENOM00248-0 Touch-up paint (300 mL) Propeller ENOF00105-0 Genuine engine oil (1 L) ENOF00248-0 Flushing attachment ENOF00106-0 ENOF00102-0 Genuine gear oil (500 mL) ENOF00104-0...

  • Page 53: Propeller Table

    PROPELLER TABLE ENOM00245-0 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. 2: 4500–5500 rpm 3.5: 5000–6000 rpm ENON00245-0 Note Each size shows number of propeller blades diameters pitch.
  • Page 54 OWNER’S MANUAL 2.5B 3.5B 003-11085-7 1211NB Printed in Japan...

This manual is also suitable for:

2.5b3.5bMfs 3.5b

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