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

TOHATSU MFS 40A Owner's Manual

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O W N E R' S
M A N U A L
AAAA
Original instructions
MFS 40A
MFS 50A
MFS 60A
OB No.003-11106-HBC1
EN

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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 Original instructions MFS 40A MFS 50A MFS 60A OB No.003-11106-HBC1...
  • Page 2 MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE. Copyright © 2023 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 In case you encounter any problems, please contact an authorized TOHATSU service shop or dealer for assistance. Tohatsu Corporation reserves the right to change, modify, add, or remove a part or whole of the owner’s manual without prior notice and incurring any obligations.
  • Page 4 BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS PROCEDURE IS NOT FOL- LOWED. ENOM00003-1 PRE-DELIVERY INSPECTION Make sure Pre-delivery inspection has been properly done by authorized TOHATSU dealer before operating your outboard motor. ENOM00005-1 Serial Number Your outboard motor has a unique serial number. The serial number is identification of outboard motor and is located on the outboard motor as shown in the figures below.
  • Page 5 ENOM00007-0 NOTICE: DANGER/WARNING/CAUTION/Note Before installing, operating or otherwise handling your outboard motor, be sure to thor- oughly read and understand this Owner's Manual and carefully follow all of the instruc- tions. Of particular importance is information preceded by the words “DANGER,” “WARNING,”...

  • Page 7: Table Of Contents

    3. Propeller installation ......... . 24 4. TOCS (Tohatsu Onboard Communication System) installation..26 6.
  • Page 8 7. Striking underwater object ........89 8.
  • 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 TABLE...

  • Page 10: General Safety Information

    GENERAL SAFETY INFORMATION ENOM00009-1 SAFE OPERATION OF BOAT As the operator/driver of a 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 Be sure to use genuine parts, genuine lubricants, or recom- mended lubricants. Be aware that the installation and use of parts not approved by Tohatsu Corporation will void warranty and may lead to unsafe operating conditions. ENOM00011-1...

  • Page 12: Specifications

    SPECIFICATIONS ENOM00810-A MODEL FEATURE Model F40A F50A F60A Type Transom heights Tiller Handle Remote Control Power Trim & Tilt Gas-assisted 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 (ICOMIA 39/94 Rev.1) dB (A) Hand Vibration Level 40/50A: 2.9 60A: 3.5 (ICOMIA 38/94 Rev.1) m/s Remark: Specifications subject to change without notice. *1: With properller *2: Transom angle is at -12° Tohatsu outbard is power rated in accordance with ISO8665 (propeller shaft output).
  • Page 14 SPECIFICATIONS Service data Model MFS 40/50/60A Multi-function Multi-function Remote Item Control tiller handle tiller handle Unleaded Regular Gasoline : R+M/2: 87 or higher Fuel Grade RON: 91 or higher Fuel Tank Capacity L (US gal) 25 (6.60) Grade API: SH, SJ, SL SAE: 10W-30, 10W-40 Engine Oil 2.2 (2.3/1.9) without oil filter replacement L (US/Imp.

  • Page 15: Parts Name

    PARTS NAME ENOM00820-0 ET, EG (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 ENOF00127-7 Control Lever PTT switch Fuel connector (Fuel tank Neutral lock arm Neutral throttle button side) PTT switch Main switch Free throttle lever Stop switch Main switch Stop switch lock Stop switch Stop switch lanyard Stop switch lock Fuel gauge...

  • Page 17: Label Locations

    LABEL LOCATIONS ENOM00019-A Warning label locations ENOF00127-D3...
  • Page 18 LABEL LOCATIONS Read owner's manual. For tiller handle model Warning lamp (See page 32). ENOF00120-0 2-1. Warning regarding starting 3GF-72198-1 For tiller handle model engine (See page 38). 4. Stop switch (See page 39 and page 51) 2-2. HOT SURFACE Can cause burns.
  • Page 19 LABEL LOCATIONS Warning regarding gasoline (See page 27). ENOF00005-L Warning regarding gasoline (See page 27). ENOF00005-M Warning regarding gasoline (See page 27). ENOF00005-F...
  • Page 20 LABEL LOCATIONS ENOM00019-B CE label locations 1521 CAN ICES-2 / NMB-2 ENOF00894-1 1. Model code (Model name) 2. Serial No. 3. Rated power 4. Dry mass weight (Without propeller, with battery cable) 5. Manufacturer name 6. Manufacturer address 7. Authorised representative 8.

  • Page 21: Installation

    INSTALLATION ENOM00024-A ENOW00006-1 1. Mounting the outboard WARNING motor on boat Most boats are rated and certified for their maximum allowable horsepower, as shown ENOW00006-1C on the boat’s certification plate. Do not WARNING equip your boat with an outboard motor that exceeds this limit.
  • Page 22 INSTALLATION ENOM00025-0 ENOW00007-1 Position ... Above keel line CAUTION Place the outboard motor in the center of the boat's transom. Before running test, check the boat with maximum loading capacity. Overloading or incorre c t weight distribution of the weight may result in boat to lose control, even swamping or capsizing.

  • Page 23: Battery Installation

    INSTALLATION Keep batter y and electroly te away from 351 (13.82) reach of children. 327 (12.87) When handling the battery, be sure to: Read all warnings shown on the battery 163.5 163.5 case. Prevent electrolyte from coming in con- tact with any part of your body. Contact can cause serious burn or, if come in con- tact with your eye, loss of sight.

  • Page 24: Propeller Installation

    INSTALLATION ENOW00015-1 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 damage to the electrical system. ENON00006-1E Note ENOF00022-1 Minimum batter y re quirements: 12v 1.
  • Page 25 INSTALLATION ENOF00084-A ENOF00084-B 1. Propeller ENOW00086-0 2. Thrust holder 3. Stopper CAUTION 4. Washer 5. Nut Do not install propeller without thrust 6. Split pin holder, or propeller boss could be dam- 4. Tighten the propeller nut to specified aged. torque with holding the propeller by Do not reuse split pin.

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

    INSTALLATION ENOM00971-A 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. Contact authorized Tohatsu dealer for more details. ENOF00933-0...

  • Page 27: Pre-Operating Preparations

    When operating an outboard motor with The fuel system components on your gasoline containing ethanol, storing gasoline TOHATSU outboard motor will withstand in the fuel tank for long periods should be up to 10% ethyl alcohol (hereinafter avoided. Storing gasoline for long periods referred to as the "ethanol") content in...

  • Page 28: Fuel Filling

    PRE-OPERATING PREPARATIONS The static electricity may ignite the gaso- ENOW00018-1 line vapor during refueling. WARNING Stop the engine, and do not start the engine during refueling. Fuel leakage can cause fire or explosion, Do not smoke. potentially leading to severe injury or loss of Be careful not to overfill fuel tank.

  • Page 29: Engine Oil Filling

    PRE-OPERATING PREPARATIONS 1. Fully open the air vent screw on the ENOW00092-1 fuel tank cap and release internal CAUTION pressure. Do not overfill engine oil, or engine oil could leak and/or engine could be dam- aged. If engine oil level is over upper limit marks of oil level gauge, drain oil to level lower than upper limit.
  • Page 30 PRE-OPERATING PREPARATIONS ENOW0002A-A CAUTION Use of engine oils that do not meet these requirements will result in reduced engine life, and other engine problems. ENOF00081-0 1. Upper limit 2. Lower limit Engine oil recommendation Use only high quality 4-stroke outboard motor oil to insure performance and pro- longed engine life.

  • Page 31: Break-In

    PRE-OPERATING PREPARATIONS ENOM00033-A 4. Break-In Your new outboard motor and lower unit ENOW00023-1 require break-in for the moving compo- CAUTION nents a ccording to the conditions Operating the outboard motor without described in the following time table. break-in can shorten life. Please refer to ENGINE OPERATION sec- If any abnormality is experienced during the tion (See page 37) to learn how to cor-...

  • 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 ENOF00851-A not be stopped).
  • Page 33 PRE-OPERATING PREPARATIONS ENOM00041-A Warning indicators, faults and remedy For one warning lamp Warning indicators Description of faults Rem- Remark or notice Sound A lamp Continu- Normal system test 1 second when key on High Engine speed exceeds Approx. Continu- speed maximum 6,200 min (rpm)
  • Page 34 PRE-OPERATING PREPARATIONS For three warning lamps 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 (rpm) allowable RPM Continu- speed Low oil pressure...
  • Page 35 PRE-OPERATING PREPARATIONS ENOM00126-A1 ENOM00870-0 Remedy Engine oil replacement indicator function reset method Reduce the speed to less than half As for "Engine oil replacement indicator open throttle, and move to safe place function", informing the appropriate tim- quickly, and stop the engine. ing of engine oil replacement by blinking Check the propeller for bent or dam- of the lamp, when beyond 100 hours...
  • 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 disconne ct stop switch lock and crank ENOM00042-0 approximately 10 times in order to prime the Before starting oil pump. ENOM00246-0 Oil Level checking ENOM01804-0 Check the engine oil level before each 1. Fuel feeding use. If the oil level is low or too high, the life of the engine will be shortened sig- ENOW00029-A nificantly.

  • Page 38: Starting The Engine

    ENGINE OPERATION 3. Remove the cap from the fuel joint. tilted up to avoid fuel from overflowing. Connect the fuel hose of the primer ENOM00045-K bulb and secure with a hose band. 2. Starting the engine ENOW00958-1 WARNING Do not remove or install the top cowl after the engine has started.
  • Page 39 ENGINE OPERATION Tiller handle type ENOW00036-1 CAUTION 1. Be sure to install the stop switch lock to the stop switch, and attach the Operating outboard motor without cooling stop switch lanyard securely to the water will lead to overheating and damage on operator or to the operator's PFD the outboard motor severely.
  • Page 40 ENGINE OPERATION 4. Set the throttle grip to START posi- ENOW00032-1 tion. CAUTION Do not hold turning starter motor more than 5 seconds, or the battery may be consumed, potentially making the eng ine star ting impossible and/or damaging the starter. If cranking over 5 seconds fails to star t engine, return main switch to “ON”, and crank engine again after 10 seconds or more.
  • Page 41 ENGINE OPERATION Side 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 beep sound and then to the stop switch, and attach the lights out.
  • Page 42 ENGINE OPERATION 6. Make sure that water is being dis- 3. Set the control lever in the Neutral charged from the cooling water check position. Do not use the Neutral port. throttle button to open the throttle when starting the engine. ENOF00868-0 ENOF00937-0 ENOM00974-A...
  • Page 43 ENGINE OPERATION ENOM00042-A Emergency starting ENOW00099-1 WARNING When the emergency starter rope is used for starting engine; Start in gear protection does not work. Make sure that shift is in neutral position. If the gear is in Forward or Reverse, the ENOF00938-1 boat can start moving immediately and may lead to accident and personal injury.

  • Page 44: Warming Up The Engine

    ENGINE OPERATION 2. Remove the flywheel cover. ENOW00860-0 CAUTION Be sure to keep the harness away from the rotation parts. ENOF00873-0 1. Bolt 2. Rubber grommet 3. Insert the knotted end of the starter rope into the notch in the flywheel ENOF00875-0 and wind the rope clockwise around 1.
  • Page 45 ENGINE OPERATION Warm the engine at low engine speeds The free throttle lever is for warm-up for about operation.(Not required for engine start- 3 minutes : above 5°C (41°F) ing) With the control lever in neutral, 5 minutes at 2000 min (rpm) : blow 5°C move the free throttle lever upward to (41°F)

  • Page 46: Forward, Reverse, And Acceleration

    ENGINE OPERATION indicating the maximum trolling speed is set. Trolling speed control function will reset and trolling speed is set to 850 min ( r p m ) w h e n t h e e n g in e s p e e d is increased above 3,000 min (rpm) or after the engine restarted.
  • Page 47 ENGINE OPERATION ENOW00042-1 ENON00014-0 Note WARNING Frequent shifting to forward or reverse can Do not shift into Reverse during planing, accelerate wear or degradation of parts. In or control will be lost leading to serious such case, replace gear oil earlier than the period specified.
  • Page 48 ENGINE OPERATION 2. When the engine reaches trolling (or 4. Fully opened (Forward) 5. Fully opened (Reverse) idling) speed, quickly pull the shift 6. Free throttle lever lever to the Forward position. 7. Control lever 8. Neutral lock arm Reverse Forward 1.

  • Page 49: Stopping The Engine

    ENGINE OPERATION ENOM00975-0 ENOM00049-A Top mount RC type 5. Stopping the engine ENOW00868-1 WARNING Be careful not to remove engine stop switch lanyard from engine accidentally while boat is running. Sudden stop of engine can cause loss of steering control, speed, possibly leading the crew(s) and or objects on the boat to be thrown forward due to inertial ENOF00937-0...
  • Page 50 ENGINE OPERATION 1. Turn the throttle grip to the slow ENOW00869-2 position. WARNING 2. Put the shift lever in the Neutral posi- After stopping the engine: tion. Close the air vent screw on the fuel tank Run the engine for 2-3 minutes at cap.
  • Page 51 ENGINE OPERATION Emergency engine stopping Press the emergency stop switch or remove stop switch lock to stop the engine. ENOF00938-A1 ENOF02411-0 2. Main switch key ENOF00883-2 3. ON 4. START 1. Stop switch 5. OFF 2. Stop switch lock ENOW00869-2 WARNING After stopping the engine: Close the air vent screw on the fuel tank...

  • Page 52: Steering

    ENGINE OPERATION ENOM00920-0 6. Steering ENOW00870-1 WARNING Sudden steering may cause passenger(s) to be thrown overboard or fall. ENOF00938-B1 Tiller handle type Right turn Move the tiller handle to the left Left turn Move the tiller handle to the right. ENOF02412-0 1.

  • Page 53: Trim Angle

    ENGINE OPERATION ENOM00050-0 ENOM00052-0 Proper trim angle 7. Trim angle The position of the thrust rod is correct if the hull is horizontal during operation. ENOW00043-1 WARNING Adjust the trim angle when the engine is stopped. Do not put hand or finger in between out- board motor body and clamp bracket when adjusting trim angle to prevent pos- sible injury.

  • Page 54: Tilt Up And Down

    ENGINE OPERATION ENOM00060-A 8. Tilt up and down ENOW00055-1 WARNING Do not tilt the outboard motor up or down when swimmer(s) and/or passenger(s) are near to prevent them from being caught between outboard motor body and clamp bracket. ENOF00888-0 1. Thrust rod 2.
  • Page 55 ENGINE OPERATION 4. Move (DOWN) lock lever to “Lock” ENOM00065-A Gas assist type position after the outboard motor is ENOW00871-0 completely tilted down. WARNING When taking outboard motor from package or removing outboard motor from the boat, never release the lock lever. If the lock lever is released, it will very easy for the clamp bracket to spring up to the tilting direction because it is not fixed.
  • Page 56 ENGINE OPERATION 2. Operate the Power Trim & Tilt switch and tilt the outboard motor down until the motor touches to the thrust rod. ENOF00891-B ENOF00067-2 It is possible to tilt up or down whether or not the main switch is "ON" or "OFF". ENOM00940-1 Manual relief valve If the battery is dead, and/or the power...

  • Page 57: Shallow Water Operation

    ENGINE OPERATION ENOW00054-1A CAUTION Do not over tilt the outboard motor when driving in shallow water, or air may be sucked through water inlet, potentially leading to engine overheating. ENOF0089A-0 1. Power 2. Manual ENOF01144-A Manual relief valve specified torque: 1.
  • Page 58 ENGINE OPERATION 2. Return to normal running position Move (UP) lock lever to “Free” posi- tion. Outboard motor moves down to thrust rod. Move (DOWN) lock lever to “Lock” position. ENOM00069-A Power Trim & Tilt type 1. Operate the Power Trim & Tilt switch and tilt the outboard motor up into desired shallow water running posi- tion.

  • Page 59: Removing And Carrying The Outboard Motor

    REMOVING AND CARRYING THE OUTBOARD MOTOR ENOM00070-L 1. Removing the outboard motor ENOW00006-1B WARNING To avoid personal injury or damage of equip- ment , make sure the allowable lifting capac- ity of the hoist is at least twice the weight of the outboard motor.

  • Page 60: Trailering

    REMOVING AND CARRYING THE OUTBOARD MOTOR Otherwise, engine's exterior may be dam- a g e d or wa ter m ay enter th e cylinder through the exhaust port and cause engine problems. ENOF00072-B ENOM00072-1A 3. Trailering ENOW00072-0 CAUTION ENOF00072-A Trailering in the tilted position may cause damage to the outboard motor, boat, etc.
  • Page 61 REMOVING AND CARRYING THE OUTBOARD MOTOR intended to support the outboard motor while the boat is docked, beached, etc. When transporting a boat on a trailer with the outboard motor attached, dis- connect the fuel line from the outboard motor beforehand and keep the out- board motor in the vertical or on a tran- som saver bar.

  • Page 62: Adjustment

    ADJUSTMENT Friction adjustment of the throttle grip ENOM00073-0 1. Steering friction can be made with the throttle adjust- ment screw. Tiller handle type ENOW00074-1 WARNING Do not over tighten the steering friction lever, it could result in difficult handling of the outboard motor, resulting in the loss of control causing an accident and could lead to severe injury.

  • Page 63: Trim Tab Adjustment

    ADJUSTMENT Side mount type ENOW00075-1 WARNING Inappropriate adjustment of trim tab could cause steering difficulty. After installing or readjusting trim tab, check if steering load is even. If straight-line cruising can not be achieved, adjust the trim tab located ENOF00078-2 under the anti-ventilation plate.

  • Page 64: Multi-Function Tiller Handle Angle Adjustment

    ADJUSTMENT Angle of Multi-Function Tiller Handle NOM01903-0 5. Multi-function tiller handle according to the number of spacers. angle adjustment Spacer [1] Spacer [2] Angle (approx) (Qty) (Qty) ENOW00985-0 WARNING Do not install or remove spacers on the 20.5 bracket with engine running. 23.5 Do not install more than 6 spacers [ 1 ].

  • Page 65: Inspection And Maintenance

    INSPECTION AND MAINTENANCE ENOM00077-1 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 mainte- nance schedules as follows. ENOW00077-1 CAUTION Your personal safety and that of your pas- sengers depends on how well you main-...

  • Page 66: 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 67 INSPECTION AND MAINTENANCE Item Points to Check Remedy • Make sure that steering handle and remote control is Repair Steering Devices functioning normally. • 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 68 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 use or before with local fire prevention and environ- storing outboard motor for long time. ment protection regulations.
  • Page 69 INSPECTION AND MAINTENANCE ENOF00863-0 ENOF00921-0 1. Test tank 2. Water 1. Hose joint 3. Over 10 cm (4 in.) ENOM00085-A Flushing by test tank ENOM01903-A ENOW00081-1 Gear case flushing device WARNING ENOW00082-0 WARNING Do not start engine without removing pro- peller, turning propeller out in the open may Never start or operate the engine indoors or lead to personal injury.
  • Page 70 1. Gear case flushing device to the cause or the fuse continues to 5. Place the shift lever in the neutral blow, request an authorized Tohatsu dealer for inspection. position and start the engine and run at idle speed for 3-5 minutes.
  • Page 71 INSPECTION AND MAINTENANCE 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. 1 2 3 ENOF00922-1 1.

  • Page 72: Periodic Inspection

    INSPECTION AND MAINTENANCE ENOM01106-1 2. Periodic Inspection It is important to inspect and maintain your outboard motor regularly. Make sure to per- form each service at interval specified in the chart below. Maintenance intervals are determined by the number of hours outboard motor has been used or number of months, whichever comes first.
  • Page 73 Frequent sudden acceleration and sudden deceleration Frequent stop start operation Frequent shifting operation Frequent operation in acidic, polluted, muddy, sandy, or shallow water Appropriate maintenance can prolong your engine life. Consult your Tohatsu authorized dealer for suitable maintenance interval depending on operating and environmental conditions.
  • Page 74 INSPECTION AND MAINTENANCE 2. Tilt up the outboard motor and lock ENOM00091-C Engine oil replacement the tilt with the tilt stopper. ENOW00091-1 3. Turn the steering on the outboard CAUTION motor so that the oil drain bolt is fac- ing downward. You may be injured due to high engine tem- 4.
  • Page 75 INSPECTION AND MAINTENANCE 9. Pull the bottom of cowl latch to ENON00920-0 Note unlock, lift and remove the top cowl. Use only recommended engine oil (See 10. Fill the engine through the filler port page 30). wi t h t h e r e c o mm e n d e d oil t o between the upper and lower limit mark on the dipstick.
  • Page 76 INSPECTION AND MAINTENANCE fire prevention and environment protection regulations. 1. Drain oil from the engine. 2. Place a rag or towel below the oil fil- ter to absorb any spilled oil. 3. Unscrew old filter by turning the filter to counter-clockwise. 4.
  • Page 77 INSPECTION AND MAINTENANCE (over three months). ENOM00094-0 Fuel filter (for engine) 1. Remove four screws to remove the 1. Check the cup for water and debris. Fuel Pick-Up. 2. Clean the fuel filter and replace the gasket. 3. Reassemble all parts. ENOF01243-0 1.
  • Page 78 INSPECTION AND MAINTENANCE 1. Tilt down the outboard motor. 4. Install the upper oil plug, and then remove oil tube nozzle and install the 2. Remove the oil plugs (lower and lower oil plug. upper), and completely drain the gear oil into a pan.
  • Page 79 INSPECTION AND MAINTENANCE 2. Remove the split pin, propeller nut ENOM00086-A Propeller replacement and washer. ENOW00084-1 3. Remove the propeller and thrust WARNING holder. 4. Apply waterproof grease to the pro- Do not install or remove propeller on the peller shaft before installing a new outboard motor with spark plug caps attached, shift in forward or reverse, propeller.
  • Page 80 INSPECTION AND MAINTENANCE ENOM00087-C 6. Measure the spark plug gap with a Spark plugs replacement wire t ype feeler g auge. The g ap ENOW00087-1 should be 0.7-0.8 mm (0.028-0.031 WARNING in). If the gap is out of specification, replace the spark plug with a new one Do not reuse spark plug, if the insulation is damaged or sparks can leak through Use spark plug ;...
  • Page 81 INSPECTION AND MAINTENANCE ENOM00088-1A Anode replacement A sacrificial anode protects the outboard motor from galvanic corrosion. Anode is located on the gear case, cylinder etc.. When the anode is eroded more than 1/3 of original size, replace it. ENON00029-1 Notes Never grease or paint the anode.
  • Page 82 INSPECTION AND MAINTENANCE ENOM01827-0 ENOW00089-0 Ground wire checking CAUTION The ground wires described below are making electrically connect between Do not unscrew the oil plug with the out- board motor tilted down. Pressurized oil in moving parts and sacrificial anodes to the oil tank may spurt out.
  • Page 83 INSPECTION AND MAINTENANCE 1. With the outboard motor installed on the boat, set the manual release valve to the Manual side, and tilt the out- board motor up/down manually 5-6 times. 2. When done, close the valve by turning it clockwise. ENOF0089A-0 1.
  • Page 84 INSPECTION AND MAINTENANCE ENOM00960-0 Grease point Apply waterproof grease to the parts shown below. ENOF00931-0...

  • Page 85: 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. ENOW00934-1 3. Drain all fuel from the fuel hoses, fuel WARNING pump, fuel filter (See page 77) and vapor separator (See page 87), and Be sure to disconnect the fuel hose from a clean these parts.
  • Page 86 INSPECTION AND MAINTENANCE 9. Place the outboard motor in the ver- then lay the outboard motor with port side down on the cushion as shown in the tical position under a dry condition. drawing. ENOF00072-B ENOM00950-0 Adding a fuel stabilizer When adding a fuel stabilizer additive (commercially available), first fill the fuel tank with fresh fuel.
  • Page 87 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, refill the vapor WARNING separator with fuel, and then drain the fuel again. Repeat this procedure For details on handling fuel, contact an until no water or other contaminants authorized dealer.

  • Page 88: 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 89: Cold Weather Precautions

    INSPECTION AND MAINTENANCE 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- out the outboard motor.

  • Page 90: Troubleshooting

    TROUBLESHOOTING ENOM00109-0 If you encounter a problem, check the 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 Closed air vent on fuel tank...
  • Page 91 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 92: Accessories Kit

    ACCESSORIES KIT ENOM00109-1 The followings are a list of the tools and spare parts provided with the motor. Items Quantity Remark Tool bag Pliers Socket wrench 10 × 13 mm Service tools Socket wrench 16 mm (spark plug) Socket wrench handle Screwdrivers Cross-and straight-point Screwdriver handle...

  • Page 93: 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 Size (Number of Blades x Pitch x Diameter) Propeller Mark Light boats...
  • Page 94 INSPECTION & MAINTENANCE LOG Date Engine Hour Inspection/Maintenance Performed Performed by...
  • Page 96 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: +81-3-3966-2951 www.tohatsu.com...

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