TOHATSU MFS 40A Owner's Manual
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TOHATSU MFS 40A Owner's Manual

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O W N E R' S
M A N U A L
AAAA
MFS 40A
MFS 50A
MFS 60A
OB No.003-11105-CBA1

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Summary of Contents for TOHATSU MFS 40A

  • Page 1 O W N E R’ S M A N U A L AAAA MFS 40A MFS 50A MFS 60A OB No.003-11105-CBA1...
  • Page 2 MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE. Copyright © 2021 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 ENOM00006-1 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 ENOM00005-A Serial Number In the space below, please record the outboard motor's serial number (indicated both on the swivel bracket and on the cylinder block). The serial number will be needed when ordering parts, and when making technical or warranty inquiries. Serial Number: ENOF00800-1 Serial Number:...
  • Page 5 ENOM00007-0 NOTICE: DANGER/WARNING/CAUTION/Note Before installing, operating or otherwise handling your outboard motor, be sure to thoroughly read and understand this Owner's Manual and carefully follow all of the instructions. Of particular importance is information preceded by the words “DAN- GER,” “WARNING,” “CAUTION,” and “Note.” Always pay special attention to such information to ensure safe operation of the outboard motor at all times.

  • Page 7: Table Of Contents

    3. Propeller installation ......... . 24 4. TOCS (Tohatsu Onboard Communication System) installation..26 6.
  • Page 8 8. Operation with multiple outboard motors ......86 11. TROUBLESHOOTING ..........87 12.
  • Page 9 INDEX 1. GENERAL SAFETY INFORMATION 2. SPECIFICATIONS 3. PARTS NAME 4. LABEL LOCATIONS 5. INSTALLATION 6. PRE-OPERATING PREPARATIONS 7. ENGINE OPERATION 8. REMOVING AND CARRYING THE OUTBOARD MOTOR 9. ADJUSTMENT 10. INSPECTION AND MAINTENANCE 11. TROUBLESHOOTING 12. TOOL KIT AND SPARE PARTS 13.

  • Page 10: General Safety Information

    GENERAL SAFETY INFORMATION ENOM00009-0 SAFE OPERATION OF BOAT As the operator/driver of the boat, you are responsible for the safety of those aboard and those in other boat around yours, and for following local boating regulations. You should be thoroughly knowledgeable on how to correctly operate the boat, outboard motor, and accessories.
  • Page 11 GENERAL SAFETY INFORMATION ENOM00010-0 SERVICING, REPLACEMENT PARTS & LUBRICANTS We recommend that only an authorized service shop perform service or maintenance on this outboard motor. Be sure to use genuine parts, genuine lubricants, or 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 64).

  • Page 12: Specifications

    SPECIFICATIONS ENOM00810-A MODEL FEATURE Model F40A F50A F60A Type Transom heights Tiller Handle Remote Control Power Trim & Tilt These models can be purchased with remote rigging kit or multi-function tiller han- dle. ENOM00811-A MODEL NAME EXAMPLE F 50A ETL Model Product gen- Starter...
  • Page 13 SPECIFICATIONS ENOM00013-0 F40A/50A/60A Item MODEL ET (with multi-function (with RC) tiller handle) type I: 1382 (54.4), Overall Length mm (in) 783 (30.8) type II 1434 (56.5)*1 Overall Width mm (in) 404 (15.9) Overall Height S·L·UL mm (in) 1257 (49.5) 1390 (54.7) 1504 (59.2) Transom Height S·L·UL mm (in) 405 (15.9) 538 (21.2) 652 (25.7)
  • Page 14 Remark: Specifications subject to change without notice. *1 Type I is conventional multi function tiller handle. Type II is equipped with a PTT switch on the end of throttle grip. *2 With propeller Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).

  • Page 15: Parts Name

    PARTS NAME ENOM00820-0 ET (with multi-function tiller handle) Tilt Handle Tiller Handle Top Cowl Throttle Grip Bottom Cowl PTT Switch Cooling Water Warning Lamp Check Port Stop Switch Drive Shaft Stop Switch Housing Lanyard Anode Oil Filler Cap Trim Tab Spark Plug Propeller Oil Level Gauge...
  • Page 16 PARTS NAME ENOM00822-0 Remote control box & Fuel tank (Optional part) ENOF00127-H Control Lever PTT switch Fuel connector (Engine side) Neutral lock arm Neutral throttle button Primer bulb PTT switch Main switch Fuel connector (Fuel tank Free throttle lever Stop switch side) Main switch Stop switch lock...

  • Page 17: Label Locations

    LABEL LOCATIONS ENOM00019-A Warning label locations ENOF00943-0...
  • Page 18 LABEL LOCATIONS 1, 2-4. Read owner's manual. For RC model Engine stop switch warning. 3WL-72180-0 2-1. Hot surface. ENOF00008-1 For Top mount RC 2-2. Hazard caused by rotating parts. Read owner's manual. 2-3. Electrical shock hazard. 2-5. Fuel filter maintenance. ENOF00120-0 Warning regarding gasoline.
  • Page 19 LABEL LOCATIONS Warning tag regarding combination of Read owner's manual (See page 37). the fuel tank and primer bulb ass’y (See page 37). ENOF00005-J ENOF00010-0 Warning tag regarding instructions of the fuel tank cap (See page 28). ENOF00011-0 Warning regarding fuel tank cap (See page 28) ENOF00012-0...
  • Page 20 MODEL YEAR AND PRODUCTION MONTH ENOF00894-A EPA Emissions Regulations The Emission Control Information label Outboards sold by Tohatsu America Cor- was affixed to engines as permanent evi- poration in the United States are certi- dence of EPA certification. fied to the United States Environmental...

  • Page 21: Installation

    INSTALLATION ENOM00024-A ENOW00006-0 1. Mounting the outboard WARNING motor on boat Most boats are rated and certified in terms of their maximum allowable horsepower, as ENOW00006-C shown on the boat’s certification plate. Do WARNING not equip your boat with an outboard motor that exceeds this limit.
  • Page 22 INSTALLATION attitude. Check the position of water sur- ENOM00025-0 Position ... Above keel line face on the driveshaft housing. If the Place the outboard motor in the center water surface is near the bottom cowling, in high waves, water may enter the engine of the boat's transom.

  • Page 23: Battery Installation

    INSTALLATION ENOM00029-A 351 (13.82) 2. Battery installation 327 (12.87) 163.5 163.5 ENOW00012-0 WARNING Battery electrolyte contains sulfuric acid and thus is hazardous, causing a burn if it Ø12.5 comes in contact with your skin, or poison- ous if swallowed. Ø12.5 Keep batter y and electroly te away from reach of children When handling the battery, be sure to:...

  • Page 24: Propeller Installation

    INSTALLATION 2. Connect the positive lead (+) to the ENOW00014-0 positive terminal (+) of the battery, CAUTION and then connect the negative lead Make sure that the battery leads do not (—). When disconnecting the battery get stuck between the outboard motor always remove the negative lead (—) and boat when turning, etc.
  • Page 25 INSTALLATION blade and anti-ventilation plate to hold pro- peller. ENOF00084-A 1. Propeller 2. Thrust holder ENOF00084-B 3. Stopper 4. Washer ENOW00086-0 5. Nut CAUTION 6. Split pin 4. Tighten the propeller nut to specified Do not install propeller without thrust torque with holding the propeller by holder, or propeller boss could be dam- wood block.

  • Page 26: Tocs (Tohatsu Onboard Communication System) Installation

    INSTALLATION ENOM00971-0 4. TOCS (Tohatsu Onboard Communication System) installation TOCS (Tohatsu Onboard Communication System) interface coupler can provide information regarding engine speed, fuel consumption, and various malfunction via an optional interface cable. Contact authorized Tohatsu dealer for more detail. ENOF00933-0...

  • Page 27: 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 28: Fuel Filling

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

  • Page 29: Engine Oil Filling

    PRE-OPERATING PREPARATIONS ENOM00037-A 3. Engine oil filling ENOW00022-1 CAUTION The engine oil is drained for shipping from the factory. Be sure to fill the engine to the proper level before starting engine. ENOF00029-0 ENOW00092-A 1. Air vent screw CAUTION 2. Fuel tank cap Do not overfill engine oil, or engine oil 2.
  • Page 30 PRE-OPERATING PREPARATIONS 10W−40 10W−30 ˚C ˚F ENOF00208-0 Engine oil volume Approximately 2400 mL (2.5 US.qt.) ENOF00924-0 1. Filler cap 2. Dipstick ENOW0002A-A 3. Filler port CAUTION Use of engine oils that do not meet these requirements will result in reduced engine life, and other engine problems.

  • Page 31: 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 32: 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 intermit- tent short beeps and the warning lamp (LED) will synchronize with the buzzer and engine speed will be limited (engine will ENOF00852-1 not be stopped).
  • Page 33 PRE-OPERATING PREPARATIONS ENOM00041-A Warning indicators, faults and remedy For RC model Warning indicators Description of faults Rem- Remark or notice Sound A lamp Normal system test 1 second Continu- when key on High Engine speed exceeds Approx. Continu- speed maximum 6,200 min-1 (rpm) allowable RPM Continu-...
  • Page 34 PRE-OPERATING PREPARATIONS For Tiller handle model Warning indicators Description of faults Rem- Remark or notice Sound lamp lamp lamp Continu- Normal system test 1 second when key on High Engine speed exceeds Approx. Continu- speed maximum 6,200 min-1 (rpm) allowable RPM Continu- speed Low oil pressure...
  • Page 35 PRE-OPERATING PREPARATIONS Remedy ENOM00870-0 Engine oil replacement indicator Reduce the throttle to less than half function reset method opening, and move to safe place As for "Engine oil replacement indicator quickly, and stop the engine. function", informing the appropriate Check the propeller for bent or dam- timing of engine oil replacement by blink- aged blades.
  • Page 36 PRE-OPERATING PREPARATIONS 3. Wait 5-10 seconds and pull the red knob out and release. ENOF00854-0 4. Within 5-10 seconds you will here 3 beeps to inform you that you have successfully reset the system. ENOF00856-0 5. Turn the ley to the 'off' position and replace the safety lanyard lock.

  • Page 37: Engine Operation

    ENGINE OPERATION approximately 10 times in order to prime the ENOM00042-0 oil pump. Before starting ENOM00246-0 Oil Level checking ENOM00044-B 1. Fuel feeding Check the engine oil level before each use. If the oil level is low or too high, the life of the engine will be shortened signif- ENOW00029-A icantly.(To properly check the engine oil...
  • Page 38 ENGINE OPERATION otherwise fuel spillage may occur when the connector is connected to the engine. ENOF00036-0 Do not connect fuel connector except when operating engine. Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. ENOF00860-B 1.

  • Page 39: Starting The Engine

    ENGINE OPERATION Do not squeeze primer bulb with engine 1. Test tank 2. Water running or when the outboard motor is 3. Over 10 cm (4 in.) tilted up. Otherwise, fuel could overflow. ENOM00045-A ENOW00036-0 2. Starting the engine CAUTION Be sure to stop engine immediately if cooling ENOW00958-0 water check port is not discharging water,...
  • Page 40 ENGINE OPERATION 4. Set the throttle grip to START posi- tion. ENOF00864-1 1. Stop switch lock 2. Main switch key 2. Insert the main switch key. ENOF00866-2 1. Throttle grip 3. Set the control lever in the Neutral position. 5. Turn the main switch key to ON posi- tion and confirm three warning lamps light up with buzzer sound and then go off.
  • Page 41 ENGINE OPERATION 3. Set the control lever in the Neutral ENOW00032-1 position. Do not raise the free throt- CAUTION tle lever when starting the engine. Do not hold turning starter motor more than 5 seconds, or the battery may be consumed, potentially making the engine star ting impossible and/or damaging the starter.
  • Page 42 ENGINE OPERATION ENOF00871-1 1. ON ENOF00936-1 2. START 3. OFF ENON00035-A Note The free throttle lever can not be raised when the control lever shift is in Forward or Reverse. 6. Check the cooling water from cooling ENOF02409-0 water check port. 1.
  • Page 43 ENGINE OPERATION 4. Turn the main switch key to ON posi- ENON00939-0 Note tion and confirm warning lamp light The neutral throttle button can not be up with buzzer sound and then go off. push-in when the control lever shift is in Forward or Reverse.
  • Page 44 ENGINE OPERATION 4. Tie a loop in the another end of the emergency starter rope and attach socket wrench that is included in the tool kit. ENOF00872-0 2. Remove the flywheel cover. ENOF00874-0 ENOW00860-0 CAUTION Be sure to keep the harness away from the rotation parts.

  • Page 45: Warming Up The Engine

    ENGINE OPERATION 7. Pull the starter handle slowly until (rpm) for several minutes. you feel engagement, keep pulling till Clutch in (In gear) Clutch off (Out of gear) you feel less resistance. Then pull it 850 min (rpm) 850 min (rpm) quickly.
  • Page 46 ENGINE OPERATION ENOM00973-0 Neutral throttle button (Top mount RC type) ENOW00957-0 second CAUTION ENOF00876-0 The control lever does not operate unless Each time the main switch key is pressed the neutral lock arm is pulled. in the above manner, engine speed The neutral throttle button is for warm- changes as follows.

  • Page 47: Forward, Reverse, And Acceleration

    ENGINE OPERATION ENOM00046-A ENOW00861-0 4. Forward, reverse, and WARNING acceleration Do not shift at high boat speed, or control may be lost, falling down or causing passen- ENOW00037-0 ger(s) to be thrown overboard. Leading to serious personal injury. WARNING Before shifting into forward or reverse, make ENOW00862-0 sure that boat is properly moored and out- CAUTION...
  • Page 48 ENGINE OPERATION Acceleration ENOM00890-A Tiller handle type ENOW00867-0 ENOW00865-0 WARNING CAUTION Sudden acceleration and deceleration may Do not force to shift when the throttle grip is cause passenger(s) to be thrown overboard not in the fully closed position, otherwise, or falling down. steering system and/or shifting mechanism Open throttle grip gradually.
  • Page 49 ENGINE OPERATION 1. Forward (F) 2. Neutral (N) 3. Reverse (R) 4. Fully opened (Forward) 5. Fully opened (Reverse) 6. Free throttle lever 7. Control lever 8. Neutral lock arm Forward 1. Quickly push the control lever to the Forward (F) position 32°, where the gear is connected, while lifting up on the neutral lock arm located under ENOF00879-2...

  • Page 50: 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 51 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 52 ENGINE OPERATION ENOW00869-0 WARNING After stopping the engine: Close the air vent screw on the fuel tank cap. Disconnect the fuel connector of the engine and the fuel tank. Disconnect the battery cord, after each use. ENOF00938-B1 Emergency engine stopping Press the emergency stop switch or remove stop switch lock to stop the engine.

  • Page 53: Steering

    ENGINE OPERATION ENOM00920-0 ENOM00050-0 6. Steering 7. Trim angle ENOW00870-0 ENOW00043-0 WARNING WARNING Sudden steering may cause passenger(s) to Do not put hand or finger in between out- be thrown overboard or falling down. board motor body and clamp bracket when adjusting trim angle to prevent Tiller handle type injury in case the outboard motor body...
  • Page 54 ENGINE OPERATION ENOF00051-1 1. Perpendicular to the water surface ENOF00888-0 ENOM00053-0 1. Thrust rod Improper trim angle (bow rises too 2. Higher high) 3. Lower Set the thrust rod lower if the bow of the Trim angle adjustment boat rises above horizontal. The transom angle adjustment 1.

  • Page 55: Tilt Up And Down

    ENGINE OPERATION ENOM00060-A ENOM00065-A Gas assist type 8. Tilt up and down ENOW00871-0 WARNING ENOW00055-0 WARNING When taking outboard motor from package or removing outboard motor from the boat, Do not tilt up or down outboard motor when never release the lock lever. If the lock lever swimmer(s) or passenger is near to prevent is released, it will very easy for the clamp them from being caught between outboard...
  • Page 56 ENGINE OPERATION 4. Move (DOWN) lock lever to “Lock” 2. Operate the Power Trim & Tilt switch position after the outboard motor is and tilt the outboard motor down completely tilted down. until the motor touches to the thrust rod. ENOF00067-2 ENOF00064-A 1.

  • Page 57: Shallow Water Operation

    ENGINE OPERATION ENOF00891-B It is possible to tilt up or down in spite of main switch “ON” or “OFF”. ENOF0089A-0 ENOM00940-0 Manual relief valve 1. Power If the battery is dead, and the power trim 2. Manual Manual relief valve specified torque: &...
  • Page 58 ENGINE OPERATION water inlet, potentially leading to engine ENOM00069-A Power Trim & Tilt type overheating. 1. Operate the Power Trim & Tilt switch and tilt the outboard motor up into desired shallow water running posi- tion. ENOF01144-A ENOF00067-2 1. Water inlet ENOM00880-A Gas assist type ENOF00941-0...

  • Page 59: 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 60: Trailering

    REMOVING AND CARRYING THE OUTBOARD MOTOR Do not carry or store outboard motor in ENON00021-B Note any of positions described below. Otherwise, engine oil or cooling water If the outboard motor must be laid may enter the cylinder cause engine prob- down, be sure to drain the remaining lems.
  • Page 61 REMOVING AND CARRYING THE OUTBOARD MOTOR ENOW00068-0 ENOW00067-0 WARNING WARNING Close air vent screw of fuel tank and fuel Do not go under outboard motor tilted up cock before carrying or storing outboard even if it is supported by support bar, or motor and fuel tank, or fuel may leak, poten- accidental fall of outboard motor could lead tially catching fire.

  • Page 62: Adjustment

    ADJUSTMENT ment screw. ENOM00073-0 1. Steering friction Tiller handle type ENOW00074-A WARNING Do not overtighten the steering friction lever it could result in difficulty of movement resulting in the loss of control causing an ENOF00911-1 accident and could lead to severe injury. 1.

  • Page 63: 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 64: 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 65: Daily Inspection

    INSPECTION AND MAINTENANCE ENOM00079-0 1. Daily Inspection Perform the following checks before and ENOW00078-1 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 66 INSPECTION AND MAINTENANCE Item Points to Check Remedy Steering • Check the operation of the steering handle. Repair Devices • Check if the anode is securely installed. Repair if necessary Other parts • Check the anode for corrosion and deformation. Replace ENOM00081-D Oil level checking...
  • Page 67 INSPECTION AND MAINTENANCE Wipe off engine oil well immediately if chemicals or mud. And flush cooling spilled and dispose of it in accordance water passage after every cruising or with local fire prevention and environ- before storing outboard motor for long ment protection regulations.
  • Page 68 (4 in.) above the anti ventilation plate. If the fuse continues to blow, request an And be sure to remove the propeller, when authorized Tohatsu dealer to inspect the starting the engine in the test tank. (See page 76) outboard motor.
  • Page 69 INSPECTION AND MAINTENANCE 2. Remove the engine cover. 3. Remove the fuse box lid. 4. Remove the fuse and check it. If the fuse is blown, replace it with a fuse of the same specified rating. The out- board motor is supplied with spare fuses in the spare fuse holder.

  • Page 70: Periodic Inspection

    INSPECTION AND MAINTENANCE ENOM00090-0 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 71 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. Apply and pump in grease.
  • Page 72 INSPECTION AND MAINTENANCE ENOF00923-0 ENOF00924-0 1. Drain hole 6. Tighten the oil drain screw with apply- 1. Filler cap 2. Dipstick ing oil on the sealing surface of screw. 3. Filler port (Use new oil drain washer) Oil drain screw specified torque 24Nm (17 ft lb, 2.4 kgf ENON00028-A...
  • Page 73 INSPECTION AND MAINTENANCE 4. Clean the mounting base. Apply film ENOW00925-0 of clean oil to O-ring. CAUTION Do not use grease. Wipe off engine oil well immediately if spilled Install oil filter and tighten it to specified and dispose of it in accordance with local torque by using oil filter wrench.
  • Page 74 INSPECTION AND MAINTENANCE 5. Float ENOM00093-A Fuel filters and fuel tank cleaning 6. Cup 7. Indication of Fuel Flow. ENOW00093-A WARNING 2. If present, disconnect hoses from the fuel connector (male) and the fuel Gasoline and its vapors are very flammable pump.
  • Page 75 INSPECTION AND MAINTENANCE ENOF00927-0 3. Insert the oil tube nozzle into the lower oil plug hole, and fill with gear oil by squeezing the oil tube until oil ENOF00926-A flows out of the upper plug hole and 1. Fuel pick-up bubbles is disappeared to remove the 2.
  • Page 76 INSPECTION AND MAINTENANCE Oil plug specified tightening torque ENOM00086-A Propeller replacement 4N·m (3 ft·lb, 0.4 kgf·m) ENOW00084-0 ENOW00095-0 WARNING CAUTION Do not begin propeller removal and instal- Do not reuse oil plug gasket. Always use new lation procedure with spark plug caps gasket and tighten oil plug properly to pre- attached, shift in forward or reverse, vent entry of water into lower unit.
  • Page 77 INSPECTION AND MAINTENANCE 7. Install a new split pin into the nut hole and bend it. ENOF00084-B ENOF00084-E 2. Remove the split pin, propeller nut and washer. ENOM00087-A 3. Remove the propeller and thrust Spark plugs replacement holder. ENOW00087-0 4. Apply water proof grease to the pro- WARNING peller shaft before installing a new Do not reuse spark plug with damaged...
  • Page 78 INSPECTION AND MAINTENANCE 2. Remove the top cowl. ENON00938-0 Note 3. Remove the spark plug caps. Do not clean electrodes of the spark 4. Remove the spark plugs by turning it plug by a brush, or an iridium tip on the counter-clockwise, using a 5/8"...
  • Page 79 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 80 INSPECTION AND MAINTENANCE 1. Oil cap ENOM00089-A Power Trim & Tilt oil checking 2. Oil level Recommended oil ENOW00088-0 Use an automatic transmission fluid or WARNING equivalent. Be sure that outboard motor is secured to Recommended oils are as shown below. transom or service stand, or accidental drop or fall of outboard motor could lead ATF Dexron III...
  • Page 81 INSPECTION AND MAINTENANCE ENOM00960-0 Grease point Apply water proof grease to the parts shown below. ENOF00931-0...

  • Page 82: Off-Season Storage

    INSPECTION AND MAINTENANCE 2. Use a dry cloth to completely wipe off ENOM00100-A 3. Off-season storage water and salt from the electrical components. ENOW00934-0 3. Drain all fuel from the fuel hoses, fuel WARNING pump, fuel filter (See page 74) and vapor separator (See page 84), and Be sure to disconnect fuel connector clean these parts.
  • Page 83 INSPECTION AND MAINTENANCE 9. Stand the outboard motor up verti- a cushion or any softer surface shown below. cally in a dry place. Elevate power unit 2 inches to 4 inches if traveling to avoid oil spillage. ENOF00072-B ENOM00950-0 Adding a fuel stabilizer When adding a fuel stabilizer additive (commercially available), first fill the fuel ENOF0089B-0...
  • Page 84 INSPECTION AND MAINTENANCE 8. Check the drained fuel for the pres- ENOM00970-0 Fuel system draining ence of water or other contaminants. ENOW00028-A If either is present, reassemble the WARNING outboard motor, refill the vapor sepa- rator with fuel, and then drain the For details on handling fuel, contact an fuel again.

  • Page 85: Pre-Season Check

    INSPECTION AND MAINTENANCE 5. Recharge the battery once a month 7. Start the engine and warm up the to prevent it from discharging and the engine for 3 minutes in the “NEU- electrolyte from deteriorating. TRAL” position. 6. Store the battery in a dry place. 8.

  • Page 86: Cold Weather Precautions

    INSPECTION AND MAINTENANCE level. The oil and filter may need to be changed again after running a short period to get all moisture completely out of the crankcase. 4. Inject a sufficient amount of engine oil through the spark plug holes. Pull the emergency starter rope sev- eral times to circulate the oil through- ENOF01145-0...

  • Page 87: Troubleshooting

    TROUBLESHOOTING ENOM00108-0 If you encounter a problem, consult the check list below to determine the cause and to take the proper action. An authorized dealer will always be happy to provide any assistance and information. Possible cause Empty fuel tank Incorrect connection of fuel system Air entering fuel line Deformed or damaged fuel hose...
  • Page 88 TROUBLESHOOTING Possible cause Low compression Carbon deposits in the combustion chamber Incorrect valve clearance Low oil pressure/level, oil pump failure, Clogged oil filter (Pressure switch ON) Insufficient cooling water flow, clogged or defective pump Faulty thermostat Cavitations or ventilation Incorrect propeller selection Damaged or bent propeller Improper thrust rod position Unbalanced load on boat...

  • Page 89: Tool Kit And Spare Parts

    TOOL KIT AND SPARE PARTS ENOM00109-0 The followings are a list of the tools and spare parts provided with the motor. Items Quantity Remark Socket wrench 16 Socket wrench 10-13 Tool bag Socket wrench handle Pliers ± Screwdriver Emergency starter rope Spark plug NGK IKR6G8 Propeller nut split pin...

  • Page 90: Propeller Table

    PROPELLER TABLE ENOM00111-0 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. 5000–6000 min (rpm) Propeller Propeller Size (Number of Blades x Pitch x Diameter) Mark Light boats CS17...

  • Page 91: Emission Control System Information

    EMISSION CONTROL SYSTEM INFORMATION ENOM01000-0 ENOM01003-0 Emission Sources Clean Air Acts of the United States and California, and Environment Canada Carbon monoxide, oxides of nitrogen EPA, California, and Canadian regula- and hydrocarbons are produced in the tions require all manufacturers to pro- course of the combustion process.
  • Page 92 ENOM01006-0 Replacement Parts 2011. The emission control system in your Tohatsu out board motor has be en designed, built, and certified to conform with the EPA and California emission reg- ulations. Whenever requesting mainte- nance, use of Tohatsu Genuine parts is highly recommended.
  • Page 93 EQUIPPED FOR UNITED STATES AND EQUIPPED FOR UNITED STATES AND CANADA MODEL CANADA MODEL The Environmental Protection Agency TOHATSU adopts Primer bulb/hose (EPA) required portable fuel systems that assembly approved by the Environment are produced after January 1, 2011 for use Protection Agency (EPA).
  • Page 94 EMISSION CONTROL SYSTEM INFORMATION Resources Board’s Personal Watercraft ENOM01007-0 Maintenance and Out board marine engine 2001 exhaust emission standards. Follow the maintenance schedule pre- Engines meeting these standards have sented on page 70. Keep in mind that this 75% lower emissions than conventional schedule is based on the assumption that carbureted two-stroke engines.
  • Page 95 EMISSION CONTROL SYSTEM INFORMATION 2003-2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low Emission engines. ENOF01004-0 ENOM01012-0 Four Stars-Super Ultra Low Emission The four-star label identifies engines that meet the Air Resources Board’s Stern- drive and Inboard marine engine 2009 exhaust emission standards.
  • Page 98 O W N E R’ S M A N U A L MFS 40A MFS 50A MFS 60A 5-4, Azusawa 3-Chome, Itabashi-Ku Tokyo 174-0051, Japan Tel: +81-3-3966-3117 Fax: +81-3-3966-0090 www.tohatsu.com...

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Mfs 60aMfs 50a

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