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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O W N E R' S
M A N U A L
トーハツ船外機 オーナーズマニュアル
Original instructions
MD 30B
MD 40B
MD 50B
MD 75C
MD 90C
MD 115A
OB No.003-11119-5AH1
2
2
2
2
2
2

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Summary of Contents for TOHATSU MD 40B2

  • Page 1 O W N E R’ S M A N U A L トーハツ船外機 オーナーズマニュアル Original instructions MD 30B MD 40B MD 50B MD 75C MD 90C MD 115A OB No.003-11119-5AH1...
  • Page 2 MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE. Copyright © 2018 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 proce- dures described later in this manual should be followed carefully.
  • Page 4 TO THE EXTENT PERMITTED BY APPLICABLE LAW, YOUR OUTBOARD MOTOR WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS PROCEDURE IS NOT FOLLOWED. ENOM00003-0 PRE-DELIVERY CHECK Be sure that the product has been checked by an authorized TOHATSU dealer before you take delivery.
  • Page 5 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 ordering parts, and when making technical or warranty inquiries. Serial Number: 30, 40 50 ENOF01301-0...
  • Page 6 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 ......... . 32 5. TOCS (Tohatsu Onboard Communication System) installation..34 6.
  • Page 8 6. Cold weather precautions........95 7.
  • 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. ACCESSORIES KIT 13. PROPELLER TABL...

  • 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 recom- mended lubricants. ENOM00011-A MAINTENANCE As the owner of this outboard motor, you should be acquainted with correct mainte- nance procedures following maintenance section of this manual (See page 68).

  • Page 12: Specifications

    SPECIFICATIONS ENOM00810-A MODEL FEATURE Model D30B2 D40B2 D50B2 Type Transom heights Electrical start Multi-function tiller handle Remote Control Power Trim & Tilt Manual tilt *1 Option. Model D75C2 D90C2 Type EPTO EPTO Transom heights Electrical start Remote Control Power Trim & Tilt Oil auto-mixing Model D115A2...
  • 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 53) Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
  • Page 14 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 53) 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 53) 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 53) 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 53) 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)/30B2, 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-H1 Control Lever Main switch Neutral lock arm Stop switch PTT switch Stop switch lock Free throttle lever Stop switch lanyard Main switch Fuel gauge Stop switch Air vent screw Stop switch lock Fuel tank cap Stop switch lanyard Fuel connector (Engine side)

  • Page 23: Label Locations

    LABEL LOCATIONS ENOM00019-A Warning label locations 1, 2 30/40/50 2 (115), 3 75/90/115 ENOF01311-2...
  • Page 24 LABEL LOCATIONS Warning label regarding owner’s man- Warning label regarding stop switch ual, top cowl, engine stop switch, (See page 57). ENOF00005-P Indicator label regarding engine fail- ure/malfunction (See page 40).) ENOF00005-W Warning regarding engine oil replen- ishment. (See page 37, 40) ENOF00005-C 7-1.
  • Page 25 LABEL LOCATIONS Indicator label regarding engine fail- Warning regarding gasoline (See ure/malfunction (See page 40). page 35). stick this label at pace near the driver's seat where is easy to see. ENOF00005-L Warning regarding gasoline (See page 35). 3T5-72050-0 For RC model ENOF00005-M Warning label on engine stop switch.
  • Page 26 LABEL LOCATIONS ENOM00019-B CE label locations r o t 0123 l a i CAN ICES-2/NMB-2 ENOF01312-1 1. Model code(Model name) 2. Rated power 3. Dry mass weight( Without propeller, with battery cable) 4. Serial No. 5. Manufacturer name 6. Manufacturer address Description of serial number year code Last two digits of alphabet represent production year as below.

  • Page 27: Installation

    INSTALLATION ENOM00024-A ENOW00009-0 1. Mounting the outboard WARNING motor on boat Mounting the outboard motor without following this manual can lead to unsafe ENOW00006-B conditions such as poor maneuverability, WARNING lack of control or fire. Loose clamp screws and/or mounting Before installing the outboard motor on the bolts can lead to the release or displace- boat, hang the outboard motor with the...
  • Page 28 INSTALLATION attitude. Check the position of water sur- ENOM00025-0 Position ... Above keel line face on the driveshaft housing. If the Set engine at center of boat. water surface is near the bottom cowling, in high waves, water may enter the engine cylinders.
  • Page 29 INSTALLATION Power trim and tilt type 1. To attach the outboard motor to the boat, use the bolts to secure the outboard motor brackets on transom board. 30, 40, 50 ENOF00610-0 1. Clamp Screw 2. Washer (small diameter) 3. Washer (large diameter) 4.

  • Page 30: Remote Control Device Installation

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

  • Page 31: Battery Installation

    INSTALLATION comes in contact with your skin, or poison- ENOW00850-0 Remote control cable length ous if swallowed. ENOW00100-A Keep batter y and electroly te away from reach of children CAUTION When handling the battery, be sure to: Be careful not to loop the remote control Read all warnings shown on the battery cables to a diameter of 406 mm (16 in) or case...

  • Page 32: Propeller Installation

    INSTALLATION Do not disconnect the battery leads from battery while the engine is operating, the electrical parts could be damaged. Always use a fully charged battery. ENOW00015-0 CAUTION Do not use a batter y that is not recom- mended. Use of a battery not recommended can lead to poor performance of, and/or ENOF00022-0 damage to, the electrical system.
  • Page 33 INSTALLATION 1. Remove the split pin, propeller nut ENOW00085-0 and 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...

  • Page 34: Tocs (Tohatsu Onboard Communication System) Installation

    TOCS (Tohatsu Onboard Communication System) interface coupler can provide information regarding engine speed, fuel consumption, and various malfunc- tion via an optional interface cable. ENOF01336-0 Contact authorized Tohatsu dealer for 1. Propeller 2. Thrust holder more detail. 3. Bush 4. Stopper 5.

  • Page 35: Pre-Operating Preparations

    TOHATSU engine will withstand up to CAUTION 10% ethyl alcohol (hereinafter referred When operating a TOHATSU engine on gaso- to as the "ethanol"), content in the gaso- line containing alcohol, storage of gasoline line. But even if the gasoline in your area...

  • Page 36: Fuel Filling

    PRE-OPERATING PREPARATIONS phase separation to take place. In addition, Be sure to remove the static electricity internal corrosion may take place during charged in your body before refueling. storage if alcohol has washed protective oil The sparks due to static electricity may films from internal components.

  • Page 37: Engine Oil Recommendation

    PRE-OPERATING PREPARATIONS 1. Full open the air vent screw on the properly fill the engine with oil follow the instructions, See page 74) fuel tank cap and release internal pressure. ENOF00027-B ENOF00641-0 1. Air vent screw 2. Fuel tank cap 1.
  • Page 38 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 The engine oil is drained for shipping from the factory. Be sure to fill the engine to the oil tank with the oil pump.

  • Page 39: 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- nents a ccording to the conditions described in the following time table. ENOW00023-1 Please refer to ENGINE OPERATION sec- CAUTION...

  • Page 40: Warning System

    PRE-OPERATING PREPARATIONS ENOM00039-0 5. Warning system If outboard motor encounters an abnor- mal condition of fault, the warning buzzer will emit a continuous beep or intermittent short beeps and the warn- ing lamp (LED) will synchronize with the buzzer and engine speed will be limited ENOF00852-0 (engine will not be stopped).
  • Page 41 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 42 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 authorize d de aler if engine shows the same result even after replacing propeller with new one.

  • Page 43: Engine Operation

    ENGINE OPERATION sure to execute the following operation ENOM00042-0 Before starting for forcedly feeding the engine oil to the oil line before starting the engine. ENOW00022-A ENOM00657-0 CAUTION 30, 40, 50 type a. Disconnect the link rod by turning the The engine oil is drained for shipping from the factory.
  • Page 44 ENGINE OPERATION b. Within 1 second after the buzzer stops sounding, remove the stop switch lock. c. Within 2 seconds after removing the stop switch lock, quickly repeat pull- ing 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 45: Fuel Feeding

    ENGINE OPERATION 3, 4 ENOF00027-B ENOF00654-0 1. Oil tank-Filter 1. Air vent screw 2. Filter-Oil Pump 2. Fuel tank cap 3. 75,90:Oil Pump-Cylinder Block (seven lines) 4. 115:Oil Pump-Cylinder Block (nine lines) 2. Connect the fuel connector to the engine and fuel tank. ENOM00044-B 2.

  • Page 46: Starting The Engine

    ENGINE OPERATION 3. Squeeze primer bulb until 2. Water 3. Over 10 cm (4 in.) becomes stiff to feed fuel to vapor separator. Direct arrow mark upward when priming. ENOW00036-0 CAUTION Be sure to stop engine immediately if cooling water check port is not discharging water, and check if cooling water intake is blocked.
  • Page 47 ENGINE OPERATION Tiller handle type 4. Set the throttle grip to START posi- tion. 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 Flotation Device.) ENOF00866-0 1.
  • Page 48 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 ENOF00867-0 to the stop switch, and attach the 1.
  • Page 49 ENGINE OPERATION ENOF00871-1 ENOF00870-1 1. ON 1. Neutral (N) 2. START 2. Control lever 3. OFF 3. Fully opened (Forward) ENON00035-A 4. Fully opened (Reverse) Note 5. Free throttle lever 6. Main switch key The free throttle lever can not be raised 7.
  • Page 50 ENGINE OPERATION Top mount RC type 4. Turn the main switch key to ON posi- tion and confirm three warning lamps 1. Be sure to install the stop switch lock light up with buzzer sound and then to the stop switch, and attach the go off.
  • Page 51 ENGINE OPERATION To prevent accident and injury by rotating ENON00939-0 Note parts, do not re-attach flywheel cover and the top cowl after the engine has The neutral throttle button can not be been started. push-in when the control lever shift is in Do not pull starter rope if any bystander is Forward or Reverse.

  • Page 52: Warming Up The Engine

    ENGINE OPERATION 4. Tie a loop in the another end of the ENOM00043-A 4. Warming up the engine emergency starter rope and attach socket wrench that is included in the tool kit. ENOW00932-0 CAUTION Be sure to check that cooling water is com- ing out of the cooling water check port dur- ing warm up.
  • Page 53 ENGINE OPERATION ENOM00044-0 ENOM00973-0 Neutral throttle button (Top Engine speeds mount RC type) Idling speed after warming up. Remark: In case of cold engine starting, ENOW00957-0 idling speed is increased about 400 min CAUTION (rpm) for several minutes. The control lever does not operate unless Clutch in (In gear) Clutch off (Out of gear) the neutral lock arm is pulled.

  • Page 54: Forward, Reverse, And Acceleration

    ENGINE OPERATION E a c h tim e t h e m ain s wi t c h ke y is ENOW00042-0 pressed in the above manner, engine WARNING speed changes as follows. Do not shift into Reverse during planing, or control will be lost leading to serious Starting personal injury, boat may swamp, and/or...
  • Page 55 ENGINE OPERATION Acceleration ENOW00864-0 ENOW00867-0 CAUTION WARNING Do not increase engine speed unnecessarily Sudden acceleration and deceleration may when the shift is in neutral and reverse, or cause passenger(s) to be thrown overboard engine damage may occur. or falling down. Open throttle grip gradually.
  • Page 56 ENGINE OPERATION Open throttle grip or control lever grad- ually. ENOF00877-1 ENOF00879-2 1. Forward (F) 2. Neutral (N) 1. Control lever 3. Reverse (R) 4. Fully opened (Forward) 5. Fully opened (Reverse) NOM00975-0 Top mount RC type 6. Free throttle lever 7.

  • Page 57: Stopping The Engine

    ENGINE OPERATION Forward Tiller handle type 1. Turn the throttle grip to the slow 1. Quickly push the control lever to the position. Forward (F) position 35°, where the gear is connected, while lifting up on the neutral lock arm located under the control lever grip.
  • Page 58 ENGINE OPERATION Side mount RC type ENOM00975-0 Top mount RC type 1. Put the control lever in the Neutral 1. Put the control lever in the Neutral position and run the engine for 2-3 position and run the engine for 2-3 minutes at idling speed for cooling minutes at idling speed for cooling down if it has been running at full...
  • Page 59 ENGINE OPERATION Emergency engine stopping Press the emergency stop switch or remove stop switch lock to stop the engine. ENOF00938-B 1. Stop switch 2. Stop switch lock ENOM00910-0 Spare emergency stop switch lock A spare emergency stop switch lock is provided in the tool bag.

  • Page 60: Steering

    ENGINE OPERATION ENOM00920-0 ENOM00050-0 7. Steering 8. Trim angle ENOW00870-0 ENOW00043-A WARNING WARNING Sudden steering may cause passenger(s) to Adjust the trim angle when the engine is be thrown overboard or falling down. stopped. Do not put hand or finger in between out- Tiller handle type board motor body and clamp bracket when adjusting trim angle to prevent...
  • Page 61 ENGINE OPERATION Manual Tilt type ENOF00051-1 1. Perpendicular to the water surface ENOF00674-A ENOM00053-0 Improper trim angle (bow rises too 1. Thrust rod high) 2. Higher Set the thrust rod lower if the bow of 3. Lower the boat rises above horizontal. Power Tilt type ENOF00052-0 ENOM00054-0...

  • Page 62: Tilt Up And Down

    ENGINE OPERATION 4. Change the thrust rod position as 6. Operate the Power Tilt switch and following picture. lower the outboard. ENOM00060-A 9. Tilt up and down ENOW00055-0 WARNING Do not tilt up or down outboard motor when swimmer(s) or passenger is near to prevent them from being caught between outboard motor body and clamp bracket in case the ENOF01238-1...
  • Page 63 ENGINE OPERATION allow water to drain from inside the engine. ENOM00062-A Manual Tilt type (*30, 40, 50 only) Tilt up Push the reverse lock lever down until it stops. (This is the tilt up position.) Now, tilt the outboard motor all the way up ENOF00059-0 until it is locked in place.
  • Page 64 ENGINE OPERATION of main switch “ON” or “OFF”. ENOM00940-0 Manual relief valve If the battery is dead, and the power tilt switch thus inoperative, open the man- ENOF00941-0 ual valve completely in the Manual direc- tion. This will allow manual tilting of the 30, 40, 50 outboard motor.

  • Page 65: Shallow Water Operation

    ENGINE OPERATION 75, 90, 115 ENOF01144-A 1. Water inlet ENOF00679-0 1. POWER 2. MANUAL Manual tilt type (*30, 40, 50 only) 1. Shallow water running position: ENOM00068-A Put the reverse lock lever in the tilt 10.Shallow water operation up position, and tilt up the outboard motor to put the outboard motor in ENOW00051-0 the shallow water running position.
  • Page 66 ENGINE OPERATION ENOF00067-B ENOF00067-2 ENOF00668-0 ENOF00941-0 2. Return to normal running position: Put the reverse lock lever in the tilt down position, slightly lift up the outboard motor, and then put it down. ENOF00059-0 1. Reverse lock lever 2. Tilt up position 3.

  • 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: Trailering

    REMOVING AND CARRYING THE OUTBOARD MOTOR Keep the outboard motor in a vertical ENOM00072-A 3. Trailering position when carrying. The optional outboard motor stand is recommended for keeping the outboard ENOW00072-0 motor vertical both during transport and CAUTION storage. Trailering in the tilted position may cause damage to the outboard motor, boat, etc.
  • Page 69 REMOVING AND CARRYING THE OUTBOARD MOTOR Tiller handle type To prevent the outboard motor from moving when it is attached on a boat during transport on a trailer, properly tig hten the ste ering fric tion le v er (page 70). ENOF00074-A 1.

  • Page 70: Adjustment

    ADJUSTMENT ment resulting in the loss of control causing ENOM00073-A an accident and could lead to severe injury. 1. Steering friction Friction adjustment of the throttle grip Tiller handle type can be made with the throttle adjust- (*30, 40, 50 only) ment screw.

  • Page 71: Trim Tab Adjustment

    ADJUSTMENT Side mount type motor could lead to severe personal injury. ENOW00075-1 WARNING Inappropriate adjustment of trim tab could cause steering difficulty. After installing or readjusting trim tab, check if steering load is even. ENOF00078-2 If straight-line cruising can not be 1.

  • 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 maintenance as suggested in the main- tenance schedules that follow. ENOW00077-0 CAUTION Your personal safety and that of your pas- sengers depends on how well you main-...

  • Page 73: Daily Inspection

    INSPECTION AND MAINTENANCE ENOM00703-0 1. Daily inspection Pe r form th e following ch e c ks an d ENOW00078-1 inspection before and after use. WARNING Do not use outboard motor if any abnormal- ity is found during pre-operation check oth- erwise it could result in severe damage to the motor or severe personal injury.
  • Page 74 INSPECTION AND MAINTENANCE Item Points to Check Remedy Steering • Check working of steering handle and remote control. Devices • 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...
  • Page 75 INSPECTION AND MAINTENANCE 4. Put the shift lever in the neutral ENOW00920-0 position and start the engine. Con- CAUTION tinue flushing the outboard motor When washing the outboard motor, be care- for 3 to 5 minutes at idling. ful not to spray the water inside of the top 5.
  • Page 76 INSPECTION AND MAINTENANCE ENOM00085-C ENOM00085-A Flushing hose joint (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 the could cause personal injury.
  • Page 77 75, 90 rected, the 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 nega- tive (-) terminal.
  • Page 78 INSPECTION AND MAINTENANCE ENOF01330-0 1. Blown fuse...

  • Page 79: Periodic Inspection

    INSPECTION AND MAINTENANCE ENOM00708-0 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 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 Warning system Check function Bolts and Nuts Retighten Sliding and Rotating Parts.
  • Page 81 INSPECTION AND MAINTENANCE 4. Check the wear and clogging for each 1. Disconnect all pipes between the oil parts, and replace if necessary. tank and oil pump. 5. Remove fuel and any water or debris 2. Clean out foreign matter. from the cup, filter and hoses.
  • 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 accidental 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 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 engine stop switch lock attached to the 4. Apply water proof grease to the pro- switch, and star ter key attached, or peller shaft before installing a new engine could accidentally start leading to propeller. serious personal injury. Disconnect bat- 5.
  • Page 85 INSPECTION AND MAINTENANCE 6. Tighten the propeller nut to speci- fied torque, and align one of grooves 1. Stop the engine. to propeller shaft hole. 2. Remove the top cowl. Propeller nut torque: 3. Remove the spark plug caps. 35 N·m (25 ft·lb, 3.5kgf·m) 4.
  • Page 86 INSPECTION AND MAINTENANCE 8. Tighten the spark plug to the speci- fied torque. ENON00028-0 Note Spark plug torque: 18.0 N·m (13.3 ft·lb) [1.84 kgf·m] If a torque-wrench is not available when you are fitting a spark plug, a good esti- mate of the correct torque is 1/4 to 1/2 a turn past finger-tight.
  • Page 87 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 original 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 accidental 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 outboard 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. 30, 40, 50 ENOF01341-0...

  • Page 91: Off-Season Storage

    INSPECTION AND MAINTENANCE 3. Drain all fuel from the fuel hoses, ENOM00100-A 3. Off-season storage fuel pump, fuel filter (See page 80) and vapor separator (See page 92), ENOW00934-0 and clean these parts. Keep in mind that if gasoline is kept WARNING in the vapor separator for a long Be sure to disconnect fuel connector...
  • Page 92 INSPECTION AND MAINTENANCE 8. Stand the outboard motor up verti- 1. Before adding fuel stabilizer additive, cally in a dry place. dr ain th e vap or se par a tor ( S e e page 92). 2. Follow the instructions on the label when adding the fuel stabilizer addi- tive.
  • Page 93 INSPECTION AND MAINTENANCE 1. Disconnect the fuel hose from the 75, 90, 115 outboard 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 The following steps must be taken when out to assure optimum performance. first using the engine after off-season storage.

  • 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 sev- e r a l tim e s t o cir c ul a t e t h e oil throughout the outboard motor.

  • 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. Possible cause Empty fuel tank Incorrect connection of fuel system...
  • 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: Accessories Kit

    ACCESSORIES KIT ENOM00721-0 30, 40, 50 The following a list of the tools and spare parts provided with the motor. Name Quantity Remark Tool bag Socket wrench 10 × 13 mm Socket wrench 16 mm Service tools Socket wrench handle Pliers Screwdriver Cross-and straight-point...
  • Page 99 ACCESSORIES KIT 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 Screwdriver (Phillips-...

  • Page 100: Propeller Table

    PROPELLER TABL 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 min (rpm) 30, 40, 50...
  • Page 101 O W N E R’ S M A N U A L MD 30B MD 40B MD 50B MD 75C MD 90C MD 115A 5-4, Azusawa 3-Chome, Itabashi-Ku Tokyo 174-0051, Japan Tel: +81-3-3966-3117 Fax: +81-3-3966-0090 www.tohatsu.com...

This manual is also suitable for:

Md 90c2Md 115a2Md 30b2Md 75c2Md 50b2

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