TOHATSU BFT 75A Series Owner's Manual
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TOHATSU BFT 75A Series Owner's Manual

TOHATSU BFT 75A Series Owner's Manual

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OWNER' S MAN UAL
BFT 75A
BFT 90A

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Summary of Contents for TOHATSU BFT 75A Series

  • Page 1 OWNER’ S MAN UAL BFT 75A BFT 90A...
  • Page 2 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Keep this Owner’s Manual handy, so you can refer to it at any time. This Owner’s Manual is considered a permanent part of the outboard motor and should remain with the outboard motor if resold.
  • Page 3 INTRODUCTION Congratulations on your selection of We suggest you read the warranty a TOHATSU outboard motor. We are policy to fully understand its certain you will be pleased with your coverage and your responsibilities of purchase of one of the finest ownership.
  • Page 4 INTRODUCTION A FEW WORDS ABOUT You will find important safety information in a variety of forms, including: SAFETY • Safety Labels — on the outboard motor. Your safety and the safety of others are very important. And using this • Safety Messages — preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.

  • Page 5: Table Of Contents

    CONTENTS OUTBOARD MOTOR SAFETY ........7 Fast Idle Button ..........30 Tiller-Handle (optional equipment):.......31 IMPORTANT SAFETY INFORMATION....7 SAFETY LABEL LOCATION........9 Ignition Switch ..........31 Emergency Stop Switch Clip and Emergency Stop Switch...........31 CONTROLS AND FEATURES ........11 Throttle Grip............32 CONTROL AND FEATURE IDENTIFICATION Throttle Friction Adjuster........33 CODES..............
  • Page 6 CONTENTS INDICATORS............41 BREAK-IN PROCEDURE........55 Alternator (ACG) Indicator........41 PORTABLE FUEL TANK (optional equipment) ..56 FUEL HOSE CONNECTIONS.........57 Malfunction Indicator........... 42 FUEL PRIMING............58 Oil Pressure Indicator........... 42 INFREQUENT OR OCCASIONAL USE ....59 Overheat Indicator..........43 STARTING THE ENGINE ........59 Cooling System Indicator........44 Remote Control Box:..........59 OTHER FEATURES ..........
  • Page 7 CONTENTS EMERGENCY STARTER ROPE ......90 STORAGE ..............120 MAINTENANCE SCHEDULE........ 91 Fuel ..............120 TRIM TAB ADJUSTMENT........93 Engine Oil............122 MANUAL RELIEF VALVE ........94 HOISTING THE OUTBOARD MOTOR ....122 ENGINE COVER REMOVAL AND STORAGE PRECAUTIONS ........122 INSTALLATION........... 94 REMOVAL FROM STORAGE......123 Engine Oil Level Check ........
  • Page 8 CONTENTS WATER SEPARATOR BUZZER SOUNDS..136 SUBMERGED OUTBOARD MOTOR....136 TECHNICAL INFORMATION ........138 Serial Number Locations......... 138 Battery ..............139 Emission Control System Information ....139 Star Label ..............142 Specifications ............144 CONSUMER INFORMATION........147 Emission Control System Warranty ......147 INDEX................

  • Page 9: Outboard Motor Safety

    • Attach the emergency stop switch INFORMATION lanyard securely to the operator. • It is the operator’s responsibility to The TOHATSU BFT75A and provide the necessary safeguards to • Always wear a PFD (Personal BFT90A outboard motors are protect people and property. Know...
  • Page 10 OUTBOARD MOTOR SAFETY Refuel With Care Carbon Monoxide Hazard • Gasoline is extremely flammable, Exhaust contains poisonous carbon Running the engine of your and gasoline vapor can explode. monoxide, a colorless, odorless gas. outboard while in an Refuel outdoors, in a well- Breathing carbon monoxide can enclosed or partially ventilated area, with the engine...

  • Page 11: Safety Label Location

    The labels shown here contain important safety information. Please read them carefully. These labels are considered permanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized TOHATSU dealer for a replacement.
  • Page 12 OUTBOARD MOTOR SAFETY PORTABLE FUEL TANK (optional equipment) FUEL CAUTION...

  • Page 13: Controls And Features

    CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES Model BFT75A BFT90A Type LRT□ LRT□ XRT□ • • Transom Height 21.1 in (537 mm) (Shaft Length) • 26.1 in (664 mm) Tiller Handle/Multi-Function Tiller Handle Remote Control • • • Power Trim/Tilt Tachometer Trim Meter TRL (Trolling) Control Switch...

  • Page 14: Component And Control Locations

    CONTROLS AND FEATURES COMPONENT AND CONTROL LOCATIONS OIL LEVEL DIPSTICK ENGINE COVER OIL FILLER CAP ENGINE COVER LATCH (rear) ENGINE COVER NMEA INTERFACE SPARK PLUG LATCH (front) COUPLER (under ignition coil) POWER TILT SWITCH IDLE PORT TILT LOCK LEVER STERN COOLING SYSTEM BRACKET INDICATOR...
  • Page 15 CONTROLS AND FEATURES Remote Controls (optional equipment) (SIDE-MOUNT REMOTE CONTROL) GEARSHIFT/THROTTLE CONTROL LEVER NEUTRAL RELEASE LEVER POWER TRIM/TILT SWITCH TRL (Trolling) CONTROL SWITCH* INDICATORS (Oil pressure, Overheat, Alternator, Malfunction) BUZZER (inside) FAST IDLE LEVER IGNITION SWITCH IGNITION SWITCH EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH LANYARD CONTROL LEVER...
  • Page 16 CONTROLS AND FEATURES (PANEL-MOUNT REMOTE CONTROL) (SINGLE TOP-MOUNT REMOTE CONTROL) GEARSHIFT/THROTTLE CONTROL LEVER NEUTRAL RELEASE LEVER GEARSHIFT/THROTTLE CONTROL LEVER POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH FAST IDLE BUTTON FAST IDLE BUTTON (DUAL TOP-MOUNT REMOTE CONTROL) GEARSHIFT/THROTTLE CONTROL LEVERS POWER TRIM/TILT SWITCH (RIGHT) POWER TRIM/TILT SWITCH (LEFT)
  • Page 17 CONTROLS AND FEATURES CONTROL PANEL CONTROL PANEL without indicators type (for PANEL-MOUNT/TOP-MOUNT SINGLE type) (for PANEL-MOUNT/TOP-MOUNT SINGLE type) INDICATORS BUZZER (Oil pressure, Overheat, IGNITION Alternator, Malfunction) BUZZER SWITCH KEY IGNITION IGNITION EMERGENCY IGNITION SWITCH KEY SWITCH STOP SWITCH SWITCH EMERGENCY EMERGENCY STOP STOP SWITCH EMERGENCY STOP...
  • Page 18 CONTROLS AND FEATURES TILLER HANDLE (optional equipment) INDICATORS (Oil pressure, Overheat, Alternator, Malfunction) GEARSHIFT LEVER EMERGENCY STOP SWITCH EMERGENCY STOP THROTTLE FRICTION SWITCH CLIP ADJUSTER EMERGENCY STOP SWITCH LANYARD POWER TRIM/TILT SWITCH THROTTLE GRIP IGNITION SWITCH KEY SPARE EMERGENCY STOP SWITCH CLIP STEERING FRICTION IGNITION SWITCH ADJUSTING KNOB...
  • Page 19 CONTROLS AND FEATURES Multi-Function Tiller Handle (optional equipment) GEARSHIFT LEVER THROTTLE FRICTION INDICATORS TRL (Trolling) CONTROL ADJUSTER (Oil pressure, Overheat, Alternator, Malfunction) SWITCH THROTTLE GRIP EMERGENCY EMERGENCY STOP STOP SWITCH SWITCH CLIP EMERGENCY STOP SWITCH LANYARD POWER TRIM/TILT SWITCH IGNITION SWITCH SPARE EMERGENCY STOP SWITCH CLIP IGNITION SWITCH KEY STEERING FRICTION...
  • Page 20 CONTROLS AND FEATURES Portable Fuel Tank (optional equipment) Fuel Tank Hose Assembly (standard equipment) FUEL GAUGE FUEL HOSE CONNECTOR FUEL TANK FUEL FILLER CAP VENT KNOB FUEL TANK HOSE ASSEMBLY FUEL HOSE JOINT (outboard motor side) FUEL PRIMING BULB...
  • Page 21 CONTROLS AND FEATURES Trim Meter Tachometer TRL (Trolling) Control Switch (optional equipment) (optional equipment) Panel (optional equipment) TRL (Trolling) CONTROL SWITCH...

  • Page 22: Controls

    CONTROLS AND FEATURES CONTROLS Turning the ignition switch key to the Emergency Stop Switch Clip and START position operates the starter Emergency Stop Switch Remote Control Box: motor. The key automatically returns EMERGENCY STOP SWITCH to the ON position when released Side-Mount Type from the START position.

  • Page 23: Gearshift/Throttle Control Lever

    CONTROLS AND FEATURES The emergency stop switch clip must A spare switch clip (optional Gearshift/Throttle Control Lever equipment) can be stored in the tool be inserted in the emergency stop bag. GEARSHIFT/THROTTLE switch in order for the engine to start CONTROL LEVER and run.

  • Page 24: Fast Idle Lever

    CONTROLS AND FEATURES Fast Idle Lever N (NEUTRAL) 32° 32° FAST IDLE LEVER F (FORWARD) R (REVERSE) SHIFT SHIFT MINIMUM MINIMUM THROTTLE OPENING THROTTLE OPENING MAXIMUM MAXIMUM GEARSHIFT/THROTTLE CONTROL LEVER Use the fast idle lever to accelerate engine warm-up after starting the Moving the control lever 32°...

  • Page 25: Panel-Mount Type

    CONTROLS AND FEATURES Panel-Mount Type Turning the ignition switch key to the N (neutral) START position operates the starter Ignition Switch motor. The key automatically returns MAXIMUM FAST IDLE to the ON position when released START from the START position. LOWEST POSITION The ignition switch can be used to...

  • Page 26: Emergency Stop Switch Clip And Emergency Stop Switch

    CONTROLS AND FEATURES Emergency Stop Switch Clip and The emergency stop switch clip must be inserted in the emergency stop Emergency Stop Switch switch in order for the engine to start EMERGENCY STOP SWITCH and run. The emergency stop switch lanyard must be attached securely to the operator or to the operator’s PFD (Personal Flotation Device).

  • Page 27: Gearshift/Throttle Control Lever

    CONTROLS AND FEATURES Gearshift/Throttle Control Lever N (NEUTRAL) GEARSHIFT/THROTTLE 35° 35° F (FORWARD) CONTROL LEVER R (REVERSE) SHIFT SHIFT MINIMUM MINIMUM THROTTLE OPENING MAXIMUM THROTTLE OPENING NEUTRAL RELEASE LEVER MAXIMUM GEARSHIFT/THROTTLE CONTROL LEVER The gearshift/throttle control lever Moving the control lever 35° from N A friction adjuster near the base of controls engine speed and selects F (neutral) selects the gear, and further...

  • Page 28: Fast Idle Button

    CONTROLS AND FEATURES Fast Idle Button It is necessary to position the control N (neutral) lever in the N (neutral) position to F (forward) R (reverse) push in the fast idle button. Return the control lever to N (neutral) position to cancel the fast idle operation.

  • Page 29: Top-Mount Type

    CONTROLS AND FEATURES Top-Mount Type Turning the ignition switch key to the Emergency Stop Switch Clip and START position operates the starter Emergency Stop Switch Ignition Switch motor. The key automatically returns EMERGENCY STOP SWITCH to the ON position when released START from the START position.

  • Page 30: Gearshift/Throttle Control Lever

    CONTROLS AND FEATURES The emergency stop switch clip must Gearshift/Throttle Control Lever The gearshift/throttle control lever(s) be inserted in the emergency stop controls engine speed and selects F SINGLE TYPE switch in order for the engine to start (forward), N (neutral), or R (reverse) and run.
  • Page 31 CONTROLS AND FEATURES Moving the control lever 35° from N N (NEUTRAL) (neutral) selects the gear, and further movement increases engine speed. 35° 35° R (REVERSE) F (FORWARD) SHIFT SHIFT A friction adjuster inside the control box adjusts the operating resistance of the control lever(s).

  • Page 32: Fast Idle Button

    CONTROLS AND FEATURES Fast Idle Button It is necessary to position the control N (neutral) lever in the N (neutral) position to F (forward) push in the fast idle button. R (reverse) Return the control lever to N (neutral) position to cancel the fast idle operation.

  • Page 33: Tiller-Handle (Optional Equipment)

    CONTROLS AND FEATURES Tiller-Handle (optional (Multi-Function Tiller Handle) stop switch clip is in the emergency equipment): stop switch. START Turning the ignition switch to the Ignition Switch OFF position stops the engine. (Tiller Handle) Emergency Stop Switch Clip and START Emergency Stop Switch (Tiller Handle) IGNITION...

  • Page 34: Throttle Grip

    CONTROLS AND FEATURES (Multi-Function Tiller Handle) The emergency stop switch clip must Throttle Grip be inserted in the emergency stop (Tiller Handle) EMERGENCY STOP SWITCH switch in order for the engine to start and run. The emergency stop switch lanyard must be attached securely to the operator or to the operator’s PFD (Personal Flotation Device).

  • Page 35: Throttle Friction Adjuster

    CONTROLS AND FEATURES (Multi-Function Tiller Handle) The throttle grip controls engine (Multi-Function Tiller Handle) speed. THROTTLE FRICTION An index mark on the tiller arm ADJUSTER THROTTLE shows throttle position and is helpful GRIP for setting the throttle correctly when starting (p. 79). HOLD Throttle Friction Adjuster RELEASE...

  • Page 36: Gearshift Lever

    CONTROLS AND FEATURES Gearshift Lever The gearshift lever is used to select F (Multi-Function Tiller Handle) (forward), N (neutral), or R (reverse) (Tiller Handle) gears. N (neutral) (forward) SLOWEST R (reverse) The engine can be started with the gearshift lever in the N (neutral) position only.

  • Page 37: Steering Friction Adjusting Knob

    You can chose which side of the tiller friction. Turning it clockwise handle to have the gearshift lever increases friction and turning it installed. Consult your authorized counterclockwise decreases friction. TOHATSU outboard motor dealer.

  • Page 38: Trl (Trolling) Control Switch (Optional Equipment)

    CONTROLS AND FEATURES TRL (Trolling) Control Switch Tiller-Handle TRL (Trolling) Control Switch (optional equipment) Panel (Multi-Function Tiller Handle) Remote Control Box (Side-mount type) For TRL (Trolling) control switch equipped type. TROLLING CONTROL SWITCH TRL (Trolling) CONTROL SWITCH The Trolling Control Switch is a rocker switch with UP and DN (down) positions to adjust the trolling speed up or down in 50 rpm...

  • Page 39: Power Trim/Tilt Switch

    CONTROLS AND FEATURES Power Trim/Tilt Switch Tiller-Handle (Tiller Handle) Remote Control Box (side-mount type) (top-mount single type) POWER TRIM/TILT SWITCH POWER TRIM/ TILT SWITCH CONTROL CONTROL LEVER POWER LEVER (Multi-Function Tiller Handle) TRIM/TILT SWITCH POWER TRIM/ TILT SWITCH (panel-mount type) (top-mount dual type) POWER TRIM/TILT SWITCHES POWER TRIM/TILT SWITCH...

  • Page 40: Power Tilt Switch

    CONTROLS AND FEATURES You can use the power trim/tilt switch Power Tilt Switch Manual Relief Valve (engine pan side) anytime whether the boat is POWER MANUAL (To hold) (To release) underway, stopped, or the ignition switch is in the OFF position. It is necessary for the ignition switch to be in the ON position for the trim meter to indicate the outboard motor angle.

  • Page 41: Tilt Lock Lever

    CONTROLS AND FEATURES Tilt Lock Lever Engine Cover Latch Trim Tab (front/rear) GEAR CASE GROMMET ENGINE COVER LATCHES FREE (front/rear) UNLATCH LOCK LOCK TRIM TAB BOLT TRIM TAB STERN BRACKET The engine cover latch fastens the TILT LOCK LEVER The trim tab compensates for “torque engine cover to the outboard motor.

  • Page 42: Instruments

    CONTROLS AND FEATURES INSTRUMENTS Tachometer Fuel Gauge (optional equipment) (optional equipment) Trim Meter FUEL GAUGE (optional equipment) The tachometer shows engine speed in revolutions per minute. The trim meter indicates the relative trim angle of the outboard motor. Refer to the tachometer when using the throttle and power trim/tilt Refer to the trim meter when using controls to achieve the best...

  • Page 43: Indicators

    Have your (RED) TOHATSU dealer check for burned- BUZZER out bulbs or other problems. Under normal conditions, the following occur when the ignition...

  • Page 44: Malfunction Indicator

    CONTROLS AND FEATURES Tiller-Handle Oil Pressure Indicator (panel-mount/top-mount types) MALFUNCTION (RED) Remote Control Box INDICATOR (side-mount type) ACG INDICATOR OIL PRESSURE (RED) INDICATOR BUZZER (internal buzzer) (GREEN) The ACG indicator turns on and the Tiller-Handle BUZZER buzzer sounds in one-second intervals (RED) when the charging system is faulty.

  • Page 45: Overheat Indicator

    CONTROLS AND FEATURES Tiller-Handle when the oil pressure indicator turns (panel-mount/top-mount types) off. (GREEN) OVERHEAT INDICATOR Low oil pressure indicates that the engine oil level is low or that there is a problem with the engine lubrication OIL PRESSURE INDICATOR system.

  • Page 46: Cooling System Indicator

    CONTROLS AND FEATURES When the alert triggers, the overheat Cooling System Indicator OTHER FEATURES indicator comes on and the buzzer COOLING SYSTEM INDICATOR Water Separator Buzzer sounds a steady tone as the engine speed is reduced to 1,800 rpm. If the The water separator buzzer sounds a condition persists for another 20 rapid, repeating signal when water...

  • Page 47: Overrev Limiter

    CONTROLS AND FEATURES Overrev Limiter Portable Fuel Tank Fuel Filler Cap Vent Knob (optional equipment) The engine is equipped with an VENT KNOB PORTABLE FUEL TANK overrev limiter to prevent the OPEN possibility of mechanical damage from excessive engine speed. The overrev limiter may be activated CLOSE during operation, limiting engine...

  • Page 48: Fuel Priming Bulb

    CONTROLS AND FEATURES Anodes Fuel Priming Bulb OUTLET END (outboard motor side) PRIMING BULB ANODE ANODE INLET END (stern bracket) (each side) (fuel tank side) A priming bulb is built into the fuel The anodes are made of a sacrificial hose that connects the fuel tank to the material that helps to protect the outboard motor.

  • Page 49: Nmea Interface Coupler

    CONTROLS AND FEATURES NMEA Interface Coupler Operating Hour Notification System NMEA INTERFACE COUPLER This outboard motor engine counts the number of operating hours since the last periodic maintenance. When the next periodic maintenance is due, the engine notifies the NMEA2000 network, and a maintenance indication is displayed on an NMEA2000-compatible device.
  • Page 50 CONTROLS AND FEATURES Periodic maintenance is required <Operating hour notification timing> when either the operating hours or the time since last maintenance reaches the prescribed limit. Therefore, periodic maintenance may be Every 100 hours required based on the number of months since the last maintenance before the alert based on engine 80 hours...
  • Page 51 CONTROLS AND FEATURES <Display> When the periodic maintenance is conducted before “Periodic Steps Maintenance” is indicated, reset the hour counter. Outboard Ignition switch — Start engine Gear at F or R If not reset, the hour count until the motor next maintenance will be in error.
  • Page 52 CONTROLS AND FEATURES How to reset the Hour Counter 1. Be sure to turn OFF the engine before beginning the reset proce- dure. Pull the emergency stop switch clip out of the emergency stop switch by pulling the emer- gency stop switch lanyard. 2.

  • Page 53: Before Operation

    Familiarize yourself with all laws and you find, or have your authorized checks, be sure the ignition switch is regulations relating to boating and the TOHATSU dealer correct it, before in the OFF position. use of outboard motors. you operate the outboard motor.
  • Page 54 BEFORE OPERATION Safety Inspection • Check that all fasteners are in place • Check that the anodes are securely and securely tightened. attached to the stern bracket and • Before each use, look around and the gear case (p.115) and are not •...

  • Page 55: Tiller Handle Height/Angle Adjustment (Optional Equipment)

    BEFORE OPERATION Tiller Handle Height/Angle (Tiller Handle) Adjustment (optional equipment) HANDLE ANGLE: 13° 11.7 in HANDLE ANGLE: 7° The tiller handle height and angle can (298 mm) be adjusted to three positions by HANDLE ANGLE: 21° HANDLE ANGLE: 7° changing the installation direction of the height adjustment block.
  • Page 56 BEFORE OPERATION (Multi-Function Tiller Handle) Install the height adjustment block so that the selected angle of the tiller handle is in this position. HANDLE ANGLE: 7° HANDLE ANGLE: 12.5 in 21° (317 mm) HANDLE ANGLE: 7° HANDLE ANGLE: 13° 14.9 in (378 mm) 8 ×...

  • Page 57: Operation

    OPERATION SAFE OPERATING BREAK-IN PROCEDURE PRECAUTIONS Break-in period: 10 hours To safely realize the full potential of Exhaust contains poisonous carbon monoxide gas that this outboard motor, you need a Proper break-in operation allows the can build up to dangerous complete understanding of its moving parts to wear in smoothly for levels in closed areas.

  • Page 58: Portable Fuel Tank (Optional Equipment)

    OPERATION Next 60 minutes: PORTABLE FUEL TANK Secure the portable fuel tank in the (optional equipment) Run the engine up to a maximum of boat so that it won't move around and 4,000 to 5,000 rpm, which is about PORTABLE FUEL TANK become damaged.

  • Page 59: Fuel Hose Connections

    OPERATION FUEL HOSE CONNECTIONS FUEL HOSE CONNECTOR FUEL HOSE BARB (outboard Turn the portable fuel tank vent knob motor side) counterclockwise to the open position. HOSE PLUG HOSE CLAMP (stainless steel) PRIMING ARROW BULB (toward outboard motor side) 1. Remove the hose plug from the HOSE FUEL HOSE FUEL...

  • Page 60: Fuel Priming

    OPERATION (Using the fuel tank mounted on FUEL PRIMING Do not touch the priming bulb with the boat) the engine running or when tilting up If you are using a portable fuel tank, the outboard motor. The vapor turn the portable fuel tank vent knob FUEL HOSE ASSEMBLY separator could overflow.

  • Page 61: Infrequent Or Occasional Use

    OPERATION INFREQUENT OR STARTING THE ENGINE 1. Put the emergency stop switch clip OCCASIONAL USE in the emergency stop switch, and Control Page securely to the operator or to the If your outboard motor will be used Remote Control Box: operator’s PFD (Personal Flotation Device).
  • Page 62 OPERATION N (neutral) ON START FAST IDLE RANGE LOWEST POSITION CONTROL LEVER IGNITION SWITCH KEY FAST IDLE LEVER 3. Leave the fast idle lever in the OFF 4. Turn the ignition switch key to the (fully lowered) position. 2. Set the control lever in the N ON position;...
  • Page 63 OPERATION If the engine fails to start within 5 seconds, release the key and wait at • If the engine is not properly least 10 seconds before operating MAXIMUM FAST IDLE warmed up before raising the the starter again. engine speed, the buzzer and FAST IDLE overheat indicator may activate RANGE...

  • Page 64: Panel-Mount Type

    OPERATION During the warm-up period, check Panel-Mount Type The engine will not start or run the oil pressure indicator (p.42), unless the emergency stop switch EMERGENCY STOP SWITCH overheat indicator (p.43), and clip is in the emergency stop cooling system indicator (p.44). switch.
  • Page 65 OPERATION If the engine fails to start within 5 START N (neutral) seconds, release the key and wait at least 10 seconds before operating the starter again. • Using the electric starter for more than 5 seconds at a time CONTROL will overheat the starter motor LEVER...
  • Page 66 OPERATION During the warm-up period, check N (neutral) the oil pressure indicator (p.42), • If the engine is not properly overheat indicator (p.43), and warmed up before raising the cooling system indicator (p.44). engine speed, the buzzer and overheat indicator may activate If using the control panel without and the engine speed will be indicators type, check the oil...

  • Page 67: Top-Mount Type

    OPERATION Top-Mount Type The engine will not start or run unless N (neutral) the emergency stop switch clip is in EMERGENCY STOP SWITCH the emergency stop switch. The emergency stop switch clip and emergency stop switch lanyard system is a safety device that will stop the engine if you fall away from CONTROL the controls while operating the boat.
  • Page 68 OPERATION If the engine fails to start within 5 N (neutral) START seconds, release the key and wait at least 10 seconds before operating the starter again. CONTROL • Using the electric starter for LEVER more than 5 seconds at a time will overheat the starter motor and can damage it.

  • Page 69: Tiller-Handle

    OPERATION During the warm-up period, check Tiller-Handle: the oil pressure indicator (p.42), (Tiller Handle) • If the engine is not properly overheat indicator (p.43), and EMERGENCY STOP SWITCH warmed up before raising the cooling system indicator (p.44). engine speed, the buzzer and overheat indicator may activate If using the control panel without and the engine speed will be...
  • Page 70 OPERATION 1. Put the emergency stop switch clip (Tiller Handle) (Tiller Handle) in the emergency stop switch, and N (neutral) START attach the emergency stop switch POSITION lanyard securely to the operator or POINTER to the operator’s PFD (Personal GEARSHIFT Flotation Device).
  • Page 71 OPERATION (Tiller Handle) 5. Turn the ignition switch key to the 6. Before getting underway, allow the START position and hold it there engine to warm-up sufficiently to until the engine starts. ensure good performance. START When the engine starts, release the Above 41°F (5°C), warm-up the key, allowing it to return to the ON engine for at least 3 minutes.

  • Page 72: Emergency Starting

    OPERATION If the indicators show any EMERGENCY STARTING 6 × 25 mm abnormal condition, immediately FLANGE BOLT If the battery is discharged or the ALTERNATOR stop the engine and determine the COVER starter motor is inoperative, you can cause of the problem. Refer to 6 mm WASHER start the engine manually using the TAKING CARE OF...
  • Page 73 OPERATION 5. Secure the breather tube to the 8. Pull the emergency starter rope EMERGENCY clamp of the silencer case. slowly until resistance is felt, then STARTER pull briskly. Direction ROPE Take care not to lose the bolt and to pull washer.

  • Page 74: Stopping The Engine

    EMERGENCY STOP SWITCH CLIP securely to operator before PULL operating the outboard motor. 12. Have your closest authorized TOHATSU dealer check your electrical system and correct the problem so that you can use the EMERGENCY STOP electric starter. SWITCH CLIP...

  • Page 75: Normal Engine Stopping

    OPERATION (Multi-Function Tiller Handle) Normal Engine Stopping Panel-Mount Type EMERGENCY STOP SWITCH N (neutral) Remote Control Box: Side-Mount Type N (neutral) CONTROL LEVER PULL CONTROL EMERGENCY LEVER STOP SWITCH EMERGENCY LANYARD STOP SWITCH CLIP Top-Mount Type To stop the engine in an emergency, N (neutral) pull the emergency stop switch clip out of the emergency stop switch by...
  • Page 76 OPERATION 1. Move the control lever to the N Remote Control Box: Panel-Mount/Top-Mount Types (neutral) position. Side-Mount Type After cruising at full throttle, cool down the engine by idling for a few minutes before stopping the engine. IGNITION SWITCH KEY IGNITION SWITCH KEY...
  • Page 77 OPERATION 2. Turn the ignition switch key to the Tiller-Handle: (Multi-Function Tiller Handle) OFF position to stop the engine. (Tiller Handle) In the event that the engine does not stop when the ignition switch key is turned to the OFF position, pull the emergency stop switch clip out of the emergency stop SLOW...
  • Page 78 OPERATION 1. Move the throttle grip to the Tiller-Handle: 2. Turn the ignition switch key to the slowest speed and the gearshift OFF position to stop the engine. (Tiller Handle) lever or control lever to the N In the event that the engine does (neutral) position.

  • Page 79: Gearshift And Throttle Operation

    OPERATION GEARSHIFT AND Panel-Mount Type To shift gears, move the control lever THROTTLE OPERATION to select the F (forward), N (neutral), N (neutral) or R (reverse) gear. F (forward) Remote Control Box: R (reverse) The control lever cannot be moved Side-Mount Type from the N (neutral) position unless CONTROL LEVER...
  • Page 80 OPERATION Remote Control Box: Top-Mount Type Tiller-Handle: (Tiller Handle) Side-Mount Type POINTER THROTTLE CONTROL LEVER GRIP FRICTION ADJUSTER TO INCREASE SLOW FRICTION TO DECREASE FRICTION TO DECREASE FAST FRICTION TO INCREASE FRICTION CONTROL LEVER (neutral) FRICTION ADJUSTER Panel-Mount Type (forward) CONTROL LEVER (reverse) Adjust the control lever friction...
  • Page 81 OPERATION (Multi-Function Tiller Handle) To shift gears, turn the throttle grip to (Multi-Function Tiller Handle) the SLOW position; then move the THROTTLE FRICTION ADJUSTER gearshift lever to select the F (forward), N (neutral), or R (reverse) gears. THROTTLE GRIP The engine can be started with the gearshift lever in the N (neutral) HOLD SLOW...

  • Page 82: Steering

    OPERATION STEERING Steering Friction Adjusting Knob (Multi-Function Tiller Handle) (Tiller Handle) Remote Control Box: STEERING FRICTION ADJUSTING KNOB Steer the boat in the same manner as To increase friction an automobile. To increase friction Tiller-Handle: STEERING To decrease To decrease friction FRICTION RIGHT TURN LEFT TURN...

  • Page 83: Cruising

    OPERATION CRUISING If engine speed becomes unstable at It is necessary to trim the angle of the high speed due to activation of the outboard motor to compensate for Engine Speed overrev limiter, reduce speed and changes in boat load, weight check the trim angle of the outboard distribution, water conditions, or For best fuel economy, limit the...
  • Page 84 OPERATION Remote Control Box: Top-Mount Type Tiller-Handle: (single type) (Tiller Handle) POWER TRIM/TILT Side-Mount Type SWITCH CONTROL Press UP to trim or LEVER tilt the outboard motor up. (dual type) Press DN to trim or tilt the outboard POWER TRIM/TILT SWITCH motor down.
  • Page 85 OPERATION Trolling Speed Control TRL (Trolling) Control Switch OUTBOARD OUTBOARD Panel (optional equipment) MOTOR MOTOR Remote Control Box TRIMMED TOO TRIMMED TOO (Side-mount type) HIGH OUTBOARD MOTOR TRIMMED CORRECTLY TRL (Trolling) CONTROL SWITCH For TRL (Trolling) control switch BOW TOO LOW DUE TO 1.

  • Page 86: Shallow Water Operation

    OPERATION The buzzer will make one long sound Trim Tab When the trim tab is correctly indicating activation. adjusted, steering effort will be equal If steering effort is not equal in both The initial trolling speed is set at 650 in both directions.

  • Page 87: Mooring, Beaching, Launching

    OPERATION MOORING, BEACHING, To lower the outboard motor, tilt up LAUNCHING using the power tilt switch, then move the tilt lock lever to the FREE Before tilting up, leave the outboard position, and then lower the outboard motor in the running position for one motor to the desired position.
  • Page 88 OPERATION Be sure the valve is closed before (lock position) POWER MANUAL operating the outboard motor. If the (To hold) (To release) valve is not closed, the outboard motor will tilt up when operated in reverse. FREE Check that nobody is under the outboard motor before opening the manual relief valve.

  • Page 89: Multiple Outboard Motors

    OPERATION MULTIPLE OUTBOARD MOTORS On boats equipped with more than one outboard motor, all motors normally operate at the same time. If one or more motor(s) is stopped while the other(s) is running, put the stopped motor in “N” (neutral) and tilt it up so its propeller is above the water's surface.

  • Page 90: Servicing Your Outboard Motor

    It will also help reduce air To ensure the best quality and basic hand tools. Other service tasks pollution. reliability, use only new, TOHATSU that are more difficult or require Genuine parts or their equivalents for special tools are best handled by repair and replacement.

  • Page 91: Maintenance Safety

    SERVICING YOUR OUTBOARD MOTOR MAINTENANCE SAFETY Safety Precautions • Read the instructions before you begin, and make sure you have the Some of the most important safety • Make sure the engine is off before tools and skills required. precautions follow. However, we you begin any maintenance or repairs.

  • Page 92: Tool Kit And Owner's Manual

    SERVICING YOUR OUTBOARD MOTOR TOOL KIT and OWNER’S MANUAL EMERGENCY STARTER ROPE 8 × 10 mm SPARK PLUG WRENCH WRENCH PHILLIPS 18 × 19 mm BOX SCREWDRIVER WRENCH EMERGENCY STARTER ROPE FUSE PULLER TOOL BAG OWNER’S MANUAL GRIP An emergency starter rope is supplied.

  • Page 93: Maintenance Schedule

    108-111 (1) Lubricate more frequently when used in salt water. (2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the TOHATSU service manual for service procedures. (3) For professional commercial use, log hours of operation to determine proper maintenance intervals.
  • Page 94 Shift cable Check-adjust (2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the TOHATSU service manual for service procedures. (3) For professional commercial use, log hours of operation to determine proper maintenance intervals.

  • Page 95: Trim Tab Adjustment

    SERVICING YOUR OUTBOARD MOTOR TRIM TAB ADJUSTMENT RIGHT The trim tab compensates for “torque steer,” which is a reaction of the LEFT outboard motor to propeller rotation. GEAR CASE GEAR CASE TRIM TAB TRIM TAB GROMMET GROMMET If uncompensated, torque steer would BOLT BOLT make the outboard motor tend to turn...

  • Page 96: Manual Relief Valve

    SERVICING YOUR OUTBOARD MOTOR MANUAL RELIEF VALVE Check that nobody is under the ENGINE COVER REMOVAL AND INSTALLATION outboard motor before opening the POWER MANUAL manual relief valve. If the manual (To hold) (To release) relief valve is loosened (turned counterclockwise) when the outboard ENGINE COVER...

  • Page 97: Engine Oil Level Check

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Level Check 3. Insert the dipstick all the way in, and then remove it and check the Check the engine oil level with the oil level shown on the dipstick. engine stopped and the outboard 4.
  • Page 98 SERVICING YOUR OUTBOARD MOTOR Oil filler cap removal (Unlock): • Running the engine with a low OIL FILLER CAP Rib of the alternator oil level can cause engine cover damage. • Do not overfill. Overfilling the engine will cause it to smoke or have oil leaks.

  • Page 99: Engine Oil Change

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Change DRAIN BOLT TIGHTENING DRAIN BOLT TORQUE: An engine oil evacuation device may 17 lbf·ft (23 N·m, 2.3 kgf·m) SEALING WASHER be used to remove the engine oil. (Replace) Drain the used oil while the engine is Improper disposal of engine oil can warm.

  • Page 100: Oil Filter Change

    SERVICING YOUR OUTBOARD MOTOR 4. With the outboard motor in a Oil Filter Change 64 mm FILTER WRENCH vertical position, fill to the upper 1. Drain the engine oil, and reinstall limit mark on the oil level dipstick the drain bolt (see Engine Oil (p.95) with the recommended oil.

  • Page 101: Engine Oil Recommendations

    4-stroke detergent oil. have oil leaks. Use 4-stroke high detergent, premium Use only a TOHATSU Genuine oil 7. Start the engine and check for leaks quality motor oil certified to meet or filter or a filter of equivalent quality (be sure the water level is at least 2 exceed U.S.

  • Page 102: Spark Plug Service

    SERVICING YOUR OUTBOARD MOTOR Spark Plug Service 6 × 20 mm CONNECTOR FLANGE SH BOLT <Standard spark plug> LOCK TAB RECOMMENDED SPARK PLUG: IGNITION ZFR6K-9E (NGK) COIL Incorrect spark plugs can cause engine damage. See page 102 for instructions of handing the iridium spark plugs PLUG MAINTENANCE COVER (optional parts).
  • Page 103 SERVICING YOUR OUTBOARD MOTOR SIDE ELECTRODE BOX WRENCH New plug Plug needing replacement 0.031 – 0.035 in (0.8 – 0.9 mm) SEALING WASHER INSULATOR 6. Inspect the spark plugs. Replace them if the electrodes are worn, or if the insulators are cracked or chipped.
  • Page 104 SERVICING YOUR OUTBOARD MOTOR 8. Install the spark plugs carefully, by 10. Install the ignition coil. Reinstall These spark plugs have an iridium the 6 × 25 mm flange bolt. hand, to avoid cross-threading. coated center electrode. Be sure to observe the following 9.

  • Page 105: Lubrication Points

    SERVICING YOUR OUTBOARD MOTOR Lubrication Points TILLER HANDLE THROTTLE ARM/ (optional equipment) THROTTLE ROD/LINK Apply TOHATSU Marine grease to LINK/PIVOT/PLATE the parts shown below: Lubrication interval: After the first 20 hours or 1 month, then every 100 hours or 6 months...
  • Page 106 SERVICING YOUR OUTBOARD MOTOR SHIFT LINK BRACKET/ SHIFT PIVOT/SHIFT ARM/ LINK PIN/PIVOT PLATE/ TILT LOCK LEVER SLIDE PIVOT/ (each side) TILT SHAFT THREAD CLICK SPRING ROLLER UPPER CYLINDER PIN/BUSHING MOUNT FRAME LOWER CYLINDER BUSHING/COLLAR SWIVEL SHAFT...

  • Page 107: Refueling

    SERVICING YOUR OUTBOARD MOTOR REFUELING VENT KNOB FUEL GAUGE Portable Fuel Tank OPEN (optional equipment) FUEL TANK CAPACITY: 6.6 US gal (25 L) Check the fuel gauge and refill the 2. Turn the fuel filler cap counterclockwise so that it touches tank when necessary.
  • Page 108 SERVICING YOUR OUTBOARD MOTOR 3. Press down the pressure relief tab, Using the fuel tank mounted in SAFE FILL LEVEL and then turn the fuel filler cap 1/4 the boat. turn counterclockwise. Release the pressure relief tab. Wait to relieve Check the fuel level and refill if pressure.

  • Page 109: Fuel Recommendations

    SERVICING YOUR OUTBOARD MOTOR FUEL RECOMMENDATIONS You may use unleaded gasoline containing no more than 10% ethanol Gasoline is highly Use unleaded gasoline with a pump (E10) or 5% methanol by volume. In flammable and explosive. octane rating of 86 or higher. addition, methanol must contain cosolvents and corrosion inhibitors.

  • Page 110: Water Separator Inspection And Service

    1. Remove the engine cover (p.94). separator periodically. Clean it or consult with an authorized 2. Remove the separator assembly. If it is difficult to remove the TOHATSU outboard motor dealer for separator assembly by yourself, cleaning. consult an authorized TOHATSU dealer.
  • Page 111 SERVICING YOUR OUTBOARD MOTOR HOSE CLIPS HARNESS WATER LEVEL SENSOR WATER CLIP 2 PIN CONNECTOR (commercially available) SEPARATOR WATER BRACKET SEPARATOR CLIP C WATER SEPARATOR SUSPENSION STRAP HARNESS FUEL HOSES 4. Remove the suspension strap from 5. Open the harness clip and remove the water separator bracket;...
  • Page 112 SERVICING YOUR OUTBOARD MOTOR • Assemble so the flat part on the WATER LEVEL POSITIONING back of the suspension is parallel to BAFFLE SENSOR 2 PIN BAND PLATE the water separator joint as shown CONNECTOR HARNESS below. O-RING CLIP (Replace) BODY Assemble so the flat part of the suspension and the water separator joint...

  • Page 113: Fuel Filter Inspection And Replacement

    SERVICING YOUR OUTBOARD MOTOR 12. Prime the engine using the Fuel Filter Inspection and Replacement priming bulb (p.58). Check for fuel leaks. The fuel filter (inside the strainer cup) Gasoline is highly Repair any fuel leaks if necessary. flammable and explosive. is located between the fuel pump and If the buzzer sounds or excessive the water separator.
  • Page 114 2. Looking through the translucent authorized TOHATSU dealer. strainer cup, check the fuel filter for water accumulation and 5. Disconnect the fuel hoses from the clogging.
  • Page 115 SERVICING YOUR OUTBOARD MOTOR 10. Prime the engine using the FUEL FILTER priming bulb (p.58). Check for (inside strainer cup) fuel leaks. Repair any fuel leaks if FUEL INTAKE necessary. SIDE JOINT 11. Install the engine cover. If loss of power or hard starting are EDGE AT found to be caused by excessive THE BASE...

  • Page 116: Portable Fuel Tank And Tank Filter Cleaning (Optional Equipment)

    SERVICING YOUR OUTBOARD MOTOR Portable Fuel Tank and Tank Fuel Tank Fuel Tank Filter Filter Cleaning CONNECTOR 5 mm SCREW (4) (optional equipment) GASKET Gasoline is highly flammable and explosive. You can be burned or seriously injured when FUEL TANK handling fuel.

  • Page 117: Anode Replacement

    SERVICING YOUR OUTBOARD MOTOR Anode Replacement Propeller Replacement Painting or coating the anodes will Before replacing the propeller, defeat their purpose and will lead to remove the emergency stop switch rust and corrosion damage to the clip from the emergency stop switch outboard motor.
  • Page 118 8. Be sure to replace the cotter pin with a new one. TIGHTENING TORQUE LIMIT: 1. Apply marine grade grease to the • Use a TOHATSU Genuine 33 lbf·ft (44.1 N·m, 4.5 kgf·m) propeller shaft. stainless steel cotter pin or...

  • Page 119: Inspect After Operating

    SERVICING YOUR OUTBOARD MOTOR Inspect After Operating 1. Stop the engine and remove the engine cover (p.94). 2. Confirm the cooling water leakage from the engine.

  • Page 120: Cleaning And Flushing

    CLEANING AND FLUSHING Cleaning and Flushing Cleaning Flushing With a Garden Hose (commercially available) After each use in salt water or dirty Wash the outside of the outboard water, thoroughly clean and rinse the motor with clean, fresh water, and outboard motor with fresh water.
  • Page 121 CLEANING AND FLUSHING FLUSH PORT GARDEN HOSE FLUSH PORT CONNECTOR CONNECTOR FLUSH PORT GARDEN HOSE JOINT CONNECTOR (commercially available) EXHAUST PORT 5. Screw the flush port connector onto the garden hose. 6. Turn on the fresh water supply and flush the outboard motor for at least 10 minutes.

  • Page 122: Storage

    STORAGE Fuel as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled. Depending on the region where you The air in a partially filled fuel tank operate your outboard, fuel promotes fuel deterioration. Very formulations may deteriorate and warm storage temperatures accelerate oxidize rapidly.
  • Page 123 STORAGE Draining the Fuel System 2. Release the drain hose from the 4. Tilt the outboard motor up all the projection of the intake manifold and way. Leave the outboard motor You can avoid fuel deterioration set the end of the hose toward the tilted up until the gasoline stops problems by draining the fuel tank outside of the engine undercase.

  • Page 124: Engine Oil

    STORAGE Engine Oil HOISTING THE OUTBOARD 4. After the outboard motor is placed MOTOR in storage and disconnected from 1. Change the engine oil and the oil the hoist, install the engine cover. filter (p.97-99). HOIST HOOKS STORAGE PRECAUTIONS 2. Remove the spark plugs (p.100), and remove the emergency stop Select a well-ventilated storage area.

  • Page 125: Removal From Storage

    STORAGE REMOVAL FROM STORAGE CUSHION (protective material) Check your outboard motor as described in the BEFORE OPERATION chapter of this manual. If the cylinders were coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal.

  • Page 126: Transporting

    TRANSPORTING WITH OUTBOARD MOTOR Tiller-Handle Tighten the steering friction adjusting INSTALLED ON BOAT knob securely. (Tiller Handle) STEERING FRICTION When trailering a boat with the The preferred method is to leave the ADJUSTING KNOB outboard motor attached, always To increase engine in the normal running position, friction disconnect the fuel line from the...

  • Page 127: With Outboard Motor Removed From Boat

    TRANSPORTING WITH OUTBOARD MOTOR REMOVED FROM BOAT Secure the outboard motor in either the vertical or horizontal position shown on p.122 and 123.

  • Page 128: Taking Care Of Unexpected Problems

    TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction Clip not inserted in emergency stop switch. Insert clip in emergency stop switch. Gearshift lever or control lever not in neutral position. Shift to neutral. Throttle grip not in START position (tiller handle – Turn throttle grip to START position (p.68).
  • Page 129 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction Out of fuel. Refuel (p.105). Fuel hose not primed. Squeeze priming bulb (p.58). Fuel filter or fuel tank filter clogged. Replace fuel filters (p.111). Bad fuel; outboard motor stored without draining Drain fuel tank and vapor separator (p.121).
  • Page 130 Use starting procedure (p.59, 62, 64, 67); if engine still malfunction, stuck valves, starter malfunction, switch will not start, then take outboard motor to an authorized malfunction, or electrical problem in the starting circuit, TOHATSU dealer, or refer to the service manual. etc.

  • Page 131: Hard Starting Or Stalls After Starting

    TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS AFTER STARTING Possible Cause Correction Fast idle lever raised (remote control/side-mount type). Leave fast idle lever OFF (p.60). Throttle grip not in START position (tiller handle – Turn throttle grip to START position (p.68). optional equipment).

  • Page 132: Engine Overheats

    Possible Cause Correction Spark plugs faulty, fouled, or improperly gapped. Replace spark plugs (p.100). Fuel system malfunction, fuel pump failure, ignition Take outboard motor to an authorized TOHATSU dealer, malfunction, etc. or refer to the service manual. ENGINE OVERHEATS Possible Cause Correction Water intake screens clogged.

  • Page 133: Fuses

    TAKING CARE OF UNEXPECTED PROBLEMS FUSES Fuse Replacement FUSE CASE LID SPARE FUSES (10 A, 15 A, 30 A) Electric Starter Will Not Operate Disconnect the battery cable at the battery negative (-) terminal before The 10 A, 15 A, and 30 A main fuses replacing the fuse.
  • Page 134 If a fuse is outboard motor to an authorized blown, install a replacement fuse of the same specified rating. The TOHATSU dealer for inspection and outboard motor is supplied with service, or refer to the service spare fuses in the fuse holder.

  • Page 135: Oil Pressure Indicator Turns Off And Engine Speed Is Limited

    TAKING CARE OF UNEXPECTED PROBLEMS 4. Remove the old fuse by removing OIL PRESSURE INDICATOR Panel-Mount/Top-Mount Types TURNS OFF AND ENGINE two 5 mm screws. OIL PRESSURE SPEED IS LIMITED INDICATOR 5. Install a new fuse with the “70 A” mark downward.

  • Page 136: Overheat Indicator Comes On And Engine Speed Is Limited

    If the engine protection system a low engine oil level, or there may remains activated after 30 seconds, be a problem with the engine return to the nearest boat landing, and lubrication system. have the outboard motor inspected by an authorized TOHATSU dealer.
  • Page 137 TAKING CARE OF UNEXPECTED PROBLEMS Panel-Mount/Top-Mount Types If using a panel-mount or top-mount If the engine is stopped after running control panel without indicators, at full throttle, and then restarted soon OVERHEAT check the indicators displayed on an afterward, that could activate the INDICATOR NMEA2000-compatible device.

  • Page 138: Water Separator Buzzer Sounds

    If there is a TOHATSU dealership If there is no water flowing from the nearby, take the outboard motor to the cooling system indicator, stop the dealer immediately.
  • Page 139 7. As soon as possible, take the spark plug hole to lubricate the the water pump and overheat the outboard motor to an authorized inside of the cylinders. Reinstall TOHATSU dealer for inspection engine. the spark plugs. and service. If the engine was running when it...

  • Page 140: Technical Information

    TECHNICAL INFORMATION Serial Number Locations FRAME SERIAL NUMBER ENGINE SERIAL NUMBER Record the frame serial number, the engine serial number, and the date of purchase in the space provided on this page. You will need these numbers when ordering parts and when making technical or warranty inquiries.

  • Page 141: Battery

    This voltage toxic. drop may cause the buzzer to sound KEEP CHILDREN AWAY TOHATSU utilizes appropriate air/ momentarily when engaging the FROM THE BATTERY. starter motor and may prevent the fuel ratios and other emissions engine from starting.
  • Page 142 Among those acts that constitute procedures must be followed in order conditions. tampering are: to keep the emissions from your TOHATSU engine within the • Removal or alteration of any part emission standards. of the intake, fuel, or exhaust systems.
  • Page 143 TOHATSU • Hard starting or stalling after solely for the use of non-TOHATSU recommends that you retain all starting replacement parts or service receipts covering maintenance on performed at a location other than an •...

  • Page 144: Star Label

    TECHNICAL INFORMATION Star Label The Star Label means Cleaner Marine Engine US, Puerto Rico, and US Virgin Islands This engine has been certified as a: A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board.
  • Page 145 TECHNICAL INFORMATION The one-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2001 exhaust emission One Star standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to Emission the U.S.

  • Page 146: Specifications

    68° (when Transom angle at 12°) Ignition system Full transistor battery Transom angle 8°, 12°, 16°, 20°, 24° Lubrication Trochoid pump pressure lubrication system * With propeller These TOHATSU outboard motors are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.
  • Page 147 Electric starter Transom angle 8°, 12°, 16°, 20°, 24° Ignition system Full transistor battery Lubrication Trochoid pump pressure lubrication system * With propeller These TOHATSU outboard motors are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.
  • Page 148 TECHNICAL INFORMATION BFT75A/BFT90A Tune up Spark plug gap 0.031-0.035 in (0.8-0.9 mm) See page 101 ± Idle speed See service manual 50 rpm ± Valve clearance (cold) Intake: 0.17 0.02 mm See service manual ± Exhaust: 0.28 0.02 mm Other specifications No other adjustment is needed...

  • Page 149: Consumer Information

    CONSUMER INFORMATION Emission Control System Warranty CALIFORNIA EMISSIONS CONTROL SYSTEM WARRANTY STATEMENT YOUR Your new Tohatsu outboard engine complies with both the WARRANTY RIGHTS AND OBLIGATIONS U.S. EPA and State of California emission regulations. Tohatsu Corporation provides the same emission warranty The California Air Resources Board (CARB) and Tohatsu coverage for outboard engines sold in all 50 states.
  • Page 150 You are responsible for presenting your outboard engine warranty, the part will be repaired or replaced by Tohatsu to a Tohatsu authorized dealer as soon as a problem exists. Corporation. See the Emission Control System Warranty The warranty repairs will be completed in a reasonable Parts table on page 151 for parts description.
  • Page 151 CONSUMER INFORMATION WARRANTY COVERAGE: durability) could result in denial of coverage. If a non-Tohatsu replacement part is used in the repair or See Manufacturer’s Warranty Coverage above for maintenance of your engine, and an authorized Tohatsu warranty coverage terms. This warranty is transferred to...
  • Page 152 Failures other than those resulting from defects in material or workmanship are not covered by this warranty. This Tohatsu Corporation disclaims any responsibility for warranty does not extend to emission control systems or incidental or consequential damages such as loss of time...
  • Page 153 Portable fuel tank, Outboard internal fuel tank, Fuel cap, Fuel Two years, no limit on hours of hoses, Primer bulb, Fuel hose joint, Vapor separator, and Carbon canister, use; or the length of the Tohatsu Evaporative All other parts not listed that may affect the evaporative...

  • Page 154: Index

    INDEX Alternator (ACG) Indicator ........... 41 Emergency Stop Switch Clip and Emergency Stop Anodes................46 Switch Replacement............115 Panel-Mount Type........... 24 ARE YOU READY TO GET UNDERWAY? ..... 51 Side-Mount Type............. 20 Tiller-Handle ............31 Top-Mount Type ............. 27 Battery ................. 139 Emission Control System Information......
  • Page 155 INDEX Fast Idle Button Ignition Switch Panel-Mount Type ..........26 Panel-Mount Type........... 23 Top-Mount Type............. 30 Side-Mount Type............. 20 Fast Idle Lever............... 22 Tiller-Handle ............31 Fuel Top-Mount Type ............. 27 Filler Cap Vent Knob..........45 IMPORTANT SAFETY INFORMATION ..... 7 Filter Inspection and Replacement......
  • Page 156 INDEX Oil Pressure Indicator ............ 42 SHALLOW WATER OPERATION ......84 OIL PRESSURE INDICATOR TURNS OFF AND Spark Plug Service............100 ENGINE SPEED IS LIMITED......133 Specifications............... 144 Operating Hour Notification System......47 Star Label ..............142 OPERATION ..............55 STARTING THE ENGINE ...........
  • Page 157 INDEX Tachometer (optional equipment) ......... 40 TAKING CARE OF UNEXPECTED PROBLEMS... 126 TECHNICAL INFORMATION ......... 138 THE IMPORTANCE OF MAINTENANCE....88 Throttle Friction Adjuster ............. 33 Grip ................. 32 Tiller Handle Height/Angle Adjustment ...... 53 Tilt Lock Lever.............. 39 TOOL KIT and OWNER’S MANUAL ......90 TRANSPORTING............
  • Page 158 MEMO...
  • Page 159 © 2020 Honda Motor Co., Ltd. − All Rights Reserved PGM-FI is a trademark of Honda Motor Co., Ltd. registered in Japan and other countries.
  • Page 160 OWN ER’ S MA N UAL BFT 75A BF T 90A 31ZZ0T03 00X31-ZZ0-T030 XXX.XXXX.XX Tokyo 174-0051 , Japan Tel: +81- 3 - 3966-3117 Fax:+81-3-3966-0090 PRINTED IN JAPAN www.tohatsu.com...

This manual is also suitable for:

Bft75a lrt seriesBft90a lrt seriesBft90a xrt seriesBft75a k1Bft90a k1Bft 90a

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