TOHATSU BFT 150A Owner's Manual
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TOHATSU BFT 150A Owner's Manual

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OWNER'S MANUAL
BFT 115A
150A

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  • Page 1 OWNER’S MANUAL BFT 115A 150A...
  • 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 outboard 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 outboard motor safely is an important signal words, DANGER, WARNING, or CAUTION.

  • Page 5: Table Of Contents

    CONTENTS OUTBOARD MOTOR SAFETY ........7 Top-Mount Type IMPORTANT SAFETY INFORMATION ....7 Ignition Switch ............22 Emergency Stop Switch Clip and Emergency  SAFETY LABEL LOCATION ........ 9 Stop Switch ............22 CONTROLS AND FEATURES ........10 Gearshift/Throttle Control Lever ......23 CONTROL AND FEATURE IDENTIFICATION Fast Idle Button ...........25 CODES ..............
  • Page 6 CONTENTS INDICATORS ............30 OPERATION ..............36 Alternator (ACG) Indicator ......... 30 SAFE OPERATING PRECAUTIONS ....36 Malfunction Indicator .......... 30 BREAK-IN PROCEDURE ........36 Oil Pressure Indicator .......... 31 FUEL PRIMING .............37 Overheat Indicator ..........31 INFREQUENT OR OCCASIONAL USE ....37 Cooling System Indicator ........32 STARTING THE ENGINE ........38 OTHER FEATURES ..........
  • Page 7 CONTENTS SERVICING YOUR OUTBOARD MOTOR ....56 REFUELING ............74 THE IMPORTANCE OF MAINTENANCE ..56 FUEL RECOMMENDATIONS ......74 MAINTENANCE SAFETY ........57 Fuel Filter Inspection and Replacement ....75 TOOL KIT and OWNER’S MANUAL ....58 Water Separator Inspection and Service ....78 SPARE EMERGENCY STOP SWITCH CLIP ...
  • Page 8 CONTENTS TRANSPORTING ............89 TECHNICAL INFORMATION ........102 WITH OUTBOARD MOTOR  Serial Number Locations ........102 INSTALLED ON BOAT ........89 Battery ...............103 WITH OUTBOARD MOTOR  Emission Control System Information ....103 REMOVED FROM BOAT ......... 89 Star Label ............106 Specifications .............108 TAKING CARE OF UNEXPECTED PROBLEMS ..

  • Page 9: Outboard Motor Safety

    INFORMATION • It is the operator’s responsibility to provide the necessary safeguards to • Always wear a PFD (Personal TOHATSU BFT115A and BFT150A protect people and property.  Flotation Device) while on the outboard motors are designed for use Know how to stop the engine boat.
  • Page 10 OUTBOARD MOTOR SAFETY Refuel With Care Carbon Monoxide Hazard • Gasoline is extremely flammable, Exhaust contains poisonous carbon and gasoline vapor can explode. monoxide, a colorless, odorless gas. Refuel outdoors, in a  Breathing carbon monoxide can well-ventilated area, with the cause loss of consciousness and may engine stopped.

  • Page 11: Safety Label Location

    The label shown here contains important safety information. Please read it carefully. This label is considered a permanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized TOHATSU dealer for a replacement.

  • Page 12: Controls And Features

    CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES Model BFT115A BFT150A Type 20.0 in  Transom Height ● ● (508 mm) (Shaft Length) 25.0 in  ● ● ● ● (635 mm) Standard Rotating Propeller Shaft ● ● ● ● Counterrotating Propeller Shaft ●...

  • Page 13: Component And Control Locations

    CONTROLS AND FEATURES COMPONENT AND CONTROL LOCATIONS JUNCTION BOX OIL FILLER CAP (FUSES) SPARK PLUG ENGINE COVER (under coil) NMEA INTERFACE COUPLER ENGINE COVER LATCH POWER TILT OIL LEVEL DIPSTICK SWITCH FLUSH PORT CONNECTOR TILT LOCK LEVER COOLING SYSTEM STERN INDICATOR BRACKET ENGINE OIL...
  • Page 14 CONTROLS AND FEATURES Remote Controls (optional equipment) Side-Mount Control Type Panel-Mount Control Type GEARSHIFT/THROTTLE GEARSHIFT/THROTTLE CONTROL LEVER CONTROL LEVER NEUTRAL RELEASE LEVER NEUTRAL RELEASE LEVER POWER TRIM/TILT INDICATORS SWITCH (Oil pressure, Overheat, Alternator, Malfunction) SPARE EMERGENCY POWER TRIM/TILT FAST IDLE STOP SWITCH CLIP SWITCH LEVER...
  • Page 15 CONTROLS AND FEATURES Top-Mount Type (Dual Outboard Motor Type) (Single Outboard Motor Type) GEARSHIFT/THROTTLE GEARSHIFT/THROTTLE CONTROL LEVERS CONTROL LEVER POWER TRIM/TILT SWITCH (RIGHT) POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH (LEFT) FAST IDLE BUTTON FAST IDLE BUTTON Control Panel (for Top-Mount Dual Type) (Top-Mount Single Type) BUZZER INDICATORS...
  • Page 16 CONTROLS AND FEATURES Instruments (optional equipment) Trolling Control Switch Panel Tachometer TRL (Trolling) CONTROL SWITCH Trim Meter...

  • Page 17: 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 motor. The key automatically returns Side-Mount Type EMERGENCY STOP SWITCH to the ON position when released from the START position.

  • Page 18: Gearshift/Throttle Control Lever

    CONTROLS AND FEATURES The emergency stop switch clip must A spare switch clip is stored in a slot Gearshift/Throttle Control Lever be inserted in the emergency stop in the control housing. GEARSHIFT/THROTTLE switch in order for the engine to start CONTROL LEVER and run.

  • Page 19: Fast Idle Lever

    CONTROLS AND FEATURES Fast Idle Lever N (NEUTRAL) 30° 30° F (FORWARD) R (REVERSE) FAST IDLE LEVER SHIFT SHIFT MINIMUM MINIMUM THROTTLE OPENING THROTTLE OPENING MAXIMUM MAXIMUM GEARSHIFT/THROTTLE CONTROL LEVER Use the fast idle lever to accelerate Moving the control lever 30° from N A friction adjuster near the base of engine warm-up after starting the (neutral) selects the gear, and further...

  • Page 20: Ignition Switch

    CONTROLS AND FEATURES Panel-Mount Type Turning the ignition switch key to the N (neutral) START position operates the starter MAXIMUM FAST IDLE motor. The key automatically returns Ignition Switch to the ON position when released START from the START position. LOWEST The engine will not start unless the POSITION...

  • Page 21: Emergency Stop Switch Clip And Emergency

    CONTROLS AND FEATURES Emergency Stop Switch Clip and The emergency stop switch clip must A spare switch clip (optional be inserted in the emergency stop equipment) can be stored in the tool Emergency Stop Switch switch in order for the engine to start bag.

  • Page 22: Gearshift/Throttle Control Lever

    CONTROLS AND FEATURES Gearshift/Throttle Control Lever N (NEUTRAL) 35° 35° F (FORWARD) GEARSHIFT/THROTTLE R (REVERSE) CONTROL LEVER SHIFT SHIFT MINIMUM MINIMUM THROTTLE OPENING THROTTLE OPENING MAXIMUM 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 (neutral) selects the gear, and further the control lever adjusts the operating...

  • Page 23: Fast Idle Button

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

  • Page 24: Top-Mount Type Ignition Switch

    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 motor. The key automatically returns Ignition Switch to the ON position when released EMERGENCY from the START position. STOP SWITCH START The engine will not start unless the...

  • Page 25: 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 26 CONTROLS AND FEATURES Moving the control lever 35° from N N (NEUTRAL) (neutral) selects the gear, and further movement increases engine speed. 35° 35° F (FORWARD) R (REVERSE) A friction adjuster inside the control SHIFT SHIFT box adjusts the operating resistance of the control lever(s).

  • Page 27: 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 28: Common Controls

    CONTROLS AND FEATURES Common Controls The power trim/tilt switch is located on the control lever. It is a rocker switch with UP and DN (down) Power Trim/Tilt Switch positions for changing the angle of (Side-Mount Type) (Top-Mount Type) the outboard motor. SINGLE TYPE You can use the power trim/tilt switch POWER TRIM/TILT SWITCH...

  • Page 29: Power Tilt Switch

    CONTROLS AND FEATURES Power Tilt Switch Manual Relief Valve Tilt Lock Lever MANUAL RELIEF VALVE FREE LOCK POWER MANUAL (To fix) (To release) POWER TILT SWITCH TILT LOCK LEVER The power tilt switch is located on the The tilt lock lever is used to support The outboard motor can be tilted engine pan.

  • Page 30: Trl (Trolling) Control Switch (Optional Equipment)

    CONTROLS AND FEATURES TRL (Trolling) Control Switch Engine Cover Latch Trim Tab (optional equipment) TRIM TAB SWITCH BOLT PANEL UNLOCK ENGINE COVER LATCH TRIM TAB TRL (Trolling) CONTROL SWITCH The engine cover latch fastens the The trim tab compensates for ‘‘torque The TRL (Trolling) control switch is a rocker switch with UP and DN engine cover to the outboard motor.

  • Page 31: Instruments

    CONTROLS AND FEATURES INSTRUMENTS Tachometer NMEA Interface Coupler (optional equipment) ® The NMEA2000 interface coupler Trim Meter can provide information regarding (optional equipment) engine speed, fuel consumption, and various warnings to an existing NMEA2000 network via an optional interface cable. Contact your dealer for more information.

  • Page 32: Indicators

    (RED) (RED) test, it cannot alert you if that system develops a problem. Have your TOHATSU dealer check for burned- out bulbs or other problems. Under BUZZER BUZZER normal conditions, the following (panel-mount/top-mount types)

  • Page 33: Oil Pressure Indicator

    CONTROLS AND FEATURES Oil Pressure Indicator When the oil pressure indicator is lit, Overheat Indicator oil pressure is OK. (side-mount type) (side-mount type) OIL PRESSURE OVERHEAT INDICATOR INDICATOR If oil pressure becomes low, the indicator will turn off, and the engine protection system will limit engine speed.

  • Page 34: 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 sounds a steady tone as the engine Water Separator Buzzer speed is reduced to 1,800 rpm. If the condition persists for another 20 The water separator buzzer sounds a seconds, the engine shuts off.

  • Page 35: Rev Limiter

    CONTROLS AND FEATURES Rev Limiter Anodes Fuel Priming Bulb The engine is equipped with a rev limiter to prevent the possibility of OUTLET END mechanical damage from excessive (outboard motor side) engine speed. The rev limiter may be activated during operation, limiting engine speed, if the outboard motor is PRIMING BULB trimmed or tilted up excessively, or...

  • Page 36: Before Operation

    Be sure to do in case of an emergency. to take care of any problem you find, or have your authorized TOHATSU Familiarize yourself with all laws and dealer correct it, before you operate regulations relating to boating and the the outboard motor.
  • Page 37 BEFORE OPERATION Safety Inspection the engine stops by pulling the • Check that the battery fluid is emergency stop switch clip from between the upper and lower • Before each use, look around and the emergency stop switch. levels, and the battery leads are underneath the engine for signs of connected securely.

  • Page 38: Operation

    OPERATION SAFE OPERATING BREAK-IN PROCEDURE Next 60 minutes: Run the engine up to a maximum of PRECAUTIONS 4,000 to 5,000 rpm, which is about Break-in period: 10 hours To safely realize the full potential of 50% to 80% of maximum throttle this outboard motor, you need a opening.

  • Page 39: Fuel Priming

    OPERATION FUEL PRIMING INFREQUENT OR OCCASIONAL USE Gasoline is highly flammable and explosive. If your outboard motor will be used OUTLET END on an infrequent or intermittent basis, (outboard motor side) You can be burned or seriously please refer to the fuel section of the injured when handling fuel.

  • Page 40: Starting The Engine

    OPERATION STARTING THE ENGINE to the operator’s PFD (Personal N (neutral) Flotation Device). Control The engine will not start or run, Side-Mount Type ...... p. 38 unless the emergency stop switch Panel-Mount Type ....p. 41 clip is in the emergency stop Top-Mount Type .......
  • Page 41 OPERATION If the engine fails to start within 5 START seconds, release the key and wait at least 10 seconds before operating the starter again. LOWEST POSITION • Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.
  • Page 42 OPERATION During the warm-up period, check the oil pressure indicator (p. 31), • If the engine is not properly MAXIMUM FAST IDLE overheat indicator (p. 31), and warmed up before raising the FAST IDLE cooling system indicator (p. 32). engine speed, the buzzer and RANGE overheat indicator may activate If the indicators show any...

  • Page 43: Panel-Mount Type

    OPERATION Panel-Mount Type The engine will not start or run, unless the emergency stop switch N (neutral) EMERGENCY STOP clip is in the emergency stop SWITCH 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 CONTROL from the controls while operating...
  • Page 44 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 will overheat the starter motor and can CONTROL damage it.

  • Page 45: Top-Mount Type

    OPERATION During the warm-up period, check Top-Mount Type the oil pressure indicator (p. 31), • If the engine is not properly EMERGENCY STOP overheat indicator (p. 31), and SWITCH warmed up before raising the cooling system indicator (p. 32). engine speed, the buzzer and overheat indicator may activate If the indicators show any and the engine speed will be...
  • Page 46 OPERATION The engine will not start or run, N (neutral) unless the emergency stop switch clip START is in 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 the controls while operating the boat.
  • Page 47 OPERATION If the engine fails to start within 5 N (neutral) seconds, release the key and wait at • If the engine is not properly least 10 seconds before operating warmed up before raising the the starter again. engine speed, the buzzer and overheat indicator may activate CONTROL and the engine speed will be...

  • Page 48: Stopping The Engine

    OPERATION During the warm-up period, check STOPPING THE ENGINE To stop the engine in an emergency, the oil pressure indicator (p. 31), pull the emergency stop switch clip overheat indicator (p. 31), and out of the emergency stop switch by Emergency Engine Stopping cooling system indicator (p.

  • Page 49: Normal Engine Stopping

    OPERATION Normal Engine Stopping Top-Mount Type Panel-Mount/Top-Mount Types Side-Mount Type N (neutral) N (neutral) IGNITION CONTROL CONTROL SWITCH KEY LEVER LEVER 1. Move the control lever(s) to the N 2. Turn the ignition switch key to the (neutral) position. OFF position to stop the engine. In Panel-Mount Type the event that the engine does not After cruising at full throttle, cool...

  • Page 50: Gearshift And Throttle Operation

    OPERATION GEARSHIFT AND To shift gears, move the control lever Panel-Mount Type to select the F (forward), N (neutral), THROTTLE OPERATION N (neutral) or R (reverse) gear. F (forward) Side-Mount Type R (reverse) The control lever cannot be moved CONTROL LEVER from the N (neutral) position unless the neutral release lever is squeezed (side-mount/panel-mount types).

  • Page 51: Steering

    OPERATION STEERING Side-Mount Type Top-Mount Type Steer the boat in the same manner as an automobile. TO INCREASE FRICTION TO INCREASE FRICTION TO DECREASE FRICTION CONTROL LEVER TO DECREASE FRICTION ADJUSTER FRICTION Panel-Mount Type CONTROL LEVER FRICTION ADJUSTER CONTROL LEVER FRICTION ADJUSTER Adjust the control lever friction adjuster so the control lever will hold...

  • Page 52: Cruising

    OPERATION CRUISING Trim Under normal conditions, the boat will perform best when the Use the power trim/tilt switch to trim antiventilation plate is level with the Engine Speed the outboard motor for the best water surface. performance and stability. For best fuel economy, limit the When cruising into a high wind, trim throttle opening to 80%.
  • Page 53 OPERATION Side-Mount Type Top-Mount Type OUTBOARD OUTBOARD MOTOR TRIMMED MOTOR TRIMMED (single type) TOO LOW TOO HIGH POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH OUTBOARD MOTOR TRIMMED CORRECTLY BOW TOO LOW DUE TO 1. LOAD IN THE FRONT 2. OUTBOARD MOTOR TRIMMED TOO LOW Panel-Mount Type (dual type)

  • Page 54: Trolling Speed Control (Optional Equipment)

    OPERATION Trolling Speed Control DN: Reduce engine speed The throttle control will operate when UP: Increase engine speed in the Trolling Speed Control mode, (optional equipment) but once the speed reaches 3,000 rpm, The engine must be fully warmed up the Trolling Speed Control is SWITCH PANEL before you can activate the Trolling...

  • Page 55: Trim Tab

    OPERATION TRIM TAB SHALLOW WATER OPERATION If steering effort is not equal in both directions, adjust the trim tab to When operating in shallow water, use compensate for ‘‘torque steer,’’ which the power trim/tilt switch (p. 51) to is the reaction of the outboard motor tilt the outboard motor so that the to propeller rotation.

  • Page 56: Mooring, Beaching, Launching

    OPERATION MOORING, BEACHING, TRIM RODS POWER TILT SWITCH LAUNCHING Before tilting up, leave the outboard motor in the running position for one minute after stopping the engine to drain the water from inside the engine. To lower the outboard motor, tilt up Stop the engine and disconnect the using the power tilt switch, then fuel hose from the outboard motor...

  • Page 57: Multiple Outboard Motors

    OPERATION Be sure the valve is closed before MULTIPLE OUTBOARD MANUAL RELIEF VALVE operating the outboard motor. If the MOTORS valve is not closed, the outboard motor will tilt up when operated in On boats equipped with more than reverse. one outboard motor, all motors normally operate at the same time.

  • Page 58: Servicing Your Outboard Motor

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

  • Page 59: Maintenance Safety

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

  • Page 60: Tool Kit And Owner's Manual

    SERVICING YOUR OUTBOARD MOTOR TOOL KIT and OWNER’S MANUAL SPARE EMERGENCY STOP (Tool kit does not come with Counter Rotation Types) SWITCH CLIP PHILLIPS/FLAT SPARK PLUG SCREWDRIVER WRENCH 6 mm HEX. GRIP WRENCH TOOL BAG 19 mm EYE WRENCH OWNER’S MANUAL Always carry a spare emergency stop The tool kit can be used for simple maintenance procedures and emergency switch clip onboard.

  • Page 61: Maintenance Schedule

    (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 62 (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 63: Trim Tab Adjustment

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

  • Page 64: Manual Relief Valve

    If the or difficult to secure, an adjustment valve is not closed, the outboard may be necessary. Please see the motor will tilt up when operated in service manual or your TOHATSU reverse. dealer for adjustment.

  • Page 65: Engine Oil Level Check

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Level Check OIL FILLER CAP Check the engine oil level with the engine stopped and the outboard motor in the vertical position. 1. Unlock and remove the engine cover (p. 62). 2. Remove the dipstick and wipe it clean.

  • Page 66: Engine Oil Change

    SERVICING YOUR OUTBOARD MOTOR When you check the oil level with the dipstick, you might notice the engine oil Engine Oil Change appears milky or the oil level has increased. If you notice either condition, An engine oil evacuation device may change the engine oil.
  • Page 67 SERVICING YOUR OUTBOARD MOTOR SEALING WASHER DRAIN BOLT COVER Improper disposal of engine oil can DRAIN GUIDE BOLT be harmful to the environment. If you change your own oil, please dispose of the used oil properly. Put it in a DRAIN sealed container, and take it to a BOLT...

  • Page 68: Oil Filter Change

    SERVICING YOUR OUTBOARD MOTOR 6. Install the oil drain bolt cover. Push Oil Filter Change FILTER WRENCH, 65 mm the lever of the oil drain bolt cover OIL FILTER 1. Drain the engine oil, and then in the direction pointed by the reinstall the drain bolt and sealing arrow mark of ‘‘LOCK’’, and washer.

  • Page 69: Engine Oil Recommendations

    Use  antiventilation plate). 4-stroke detergent oil. If you are changing the oil filter Use only a TOHATSU Genuine oil while the outboard motor is out of filter or a filter of equivalent Use 4-stroke high detergent, premium the water, use commercially quality specified for your model.

  • Page 70: Lubrication Points

    SERVICING YOUR OUTBOARD MOTOR Lubrication Points THROTTLE LINK/ Apply TOHATSU Marine grease to the PIVOT/PLATE THROTTLE ROD/LINK TILT BRACKET parts shown below: Apply anticorrosion oil to pivot surfaces where grease cannot penetrate. ENGINE COVER BRACKET TILT SHAFT PTT THRUST RECEIVER...
  • Page 71 SERVICING YOUR OUTBOARD MOTOR THROTTLE ARM/ SHIFT ARM/PIVOT ENGINE COVER PLATE/NEUTRAL LOCK CABLE SWITCH/CLICK ENGINE COVER ENGINE COVER LOCK COVER LOCK BOLTS (LEFT SIDE) ARM ROLLER CABLE (FRONT) LEVER/OPEN SHAFT TILT LOCK LEVER ENGINE COVER LOCK CABLE (RIGHT SIDE) SWIVEL SHAFT TILT SHAFT THREAD LOWER CYLINDER UPPER CYLINDER PIN/...

  • Page 72: Spark Plug Service

    SERVICING YOUR OUTBOARD MOTOR Spark Plug Service 3. Remove the two clips from the upper part of the under cover <Standard Spark Plug> grommet. UNDER COVER RECOMMENDED SPARK PLUGS: To remove the clips, raise the inner GROMMET CLIP ZFR6K-11 (NGK) part of each clip with a screwdriver, KJ20DR-M11 (DENSO) then pull out the clips.
  • Page 73 SERVICING YOUR OUTBOARD MOTOR 6. Use a 6 mm hex. wrench to remove SPARK PLUG COVER the bolt holding the ignition coil. Move the ignition coil to a position that allows removal of the wire connector easily. 7. Disconnect the wire connector from the ignition coil by pushing on the lock tab and pulling on the connector.
  • Page 74 SERVICING YOUR OUTBOARD MOTOR 13. After each spark plug seats, 15. Install the ignition coil. Reinstall SIDE ELECTRODE tighten with the spark plug the bolt. wrench supplied in the tool kit to 0.039 – 0.043 in 16. Repeat this procedure for the compress the sealing washer.
  • Page 75 SERVICING YOUR OUTBOARD MOTOR <Optional Parts: Iridium Spark electrode, never use a ‘‘leaf-type Plug> feeler gauge.’’ The gap should be 0.039 – 0.051 RECOMMENDED SPARK PLUGS: inches (1.0 – 1.3 mm). IZFR6K11 (NGK) • Do not adjust the spark plug gap. If SKJ20DR-M11 (DENSO) the gap is out of specification, replace the spark plug with a new...

  • Page 76: Refueling

    SERVICING YOUR OUTBOARD MOTOR REFUELING Never refill the fuel tank inside a FUEL RECOMMENDATIONS building where gasoline fumes may Check the fuel level and refill if Use unleaded gasoline with a pump reach flames or sparks. Keep gasoline necessary. Do not fill the fuel tank octane rating of 86 or higher.

  • Page 77: Fuel Filter Inspection And Replacement

    SERVICING YOUR OUTBOARD MOTOR Engine damage or performance Fuel Filter Inspection and problems that result from using a fuel Replacement with percentages of ethanol or Gasoline is highly flammable and methanol greater than shown above The fuel filter (inside the strainer cup) explosive.
  • Page 78 TOHATSU dealer. Remove the suspension strap from the fuel filter bracket, and then remove the strap from the fuel filter assembly.
  • Page 79 SERVICING YOUR OUTBOARD MOTOR 10.Prime the engine using the FUEL STRAINER ASSEMBLY STRAINER BODY priming bulb (p. 37). Check for fuel leaks. STRAINER BRACKET Repair any fuel leaks if necessary. If loss of power or hard starting are found to be caused by excessive O-RING water or sediment accumulation in (Replace)

  • Page 80: Water Separator Inspection And Service

    Check the water separator the wire harness with the separator periodically. Clean it or consult with bracket. an authorized TOHATSU dealer for cleaning. 3. Pinch the fuel tubes with tube clamps to prevent fuel leakage.
  • Page 81 SERVICING YOUR OUTBOARD MOTOR 9. Squeeze and release the priming WATER SEPARATOR BRACKET bulb to fill the vapor separator, and check for fuel leaks. Repair any WATER SEPARATOR fuel leaks if necessary. If the buzzer sounds or water or sediment accumulation are found to be caused by excessive water or O-RING sediment accumulation in the fuel...

  • Page 82: 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 83 8. Be sure to replace the cotter pin cotter pin hole. with a new one. 1. Apply marine grade grease to the • Use a TOHATSU Genuine propeller shaft. stainless steel cotter pin or TIGHTENING TORQUE LIMIT: equivalent cotter pin and bend 2.

  • Page 84: Cleaning And Flushing

    CLEANING AND FLUSHING Cleaning and Flushing Cleaning For safety, remove the emergency stop switch clip so the engine cannot After each use in salt water or dirty Wash the outside of the outboard be started while you are standing near water, thoroughly clean and flush the motor with clean, fresh water, and the propeller.
  • Page 85 CLEANING AND FLUSHING GARDEN HOSE FLUSH PORT CONNECTOR GARDEN HOSE JOINT (Commercially available) EXHAUST PORT 5. Screw the flush port connector onto 6. Turn on the fresh water supply and the garden hose. flush the outboard motor for at least 10 minutes. 7.

  • Page 86: Storage

    STORAGE Fuel as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled. The air in a partially filled fuel tank Depending on the region where you operate your outboard, fuel promotes fuel deterioration. Very formulations may deteriorate and warm storage temperatures accelerate fuel deterioration.
  • Page 87 STORAGE Draining the Fuel System 1. Unhook the drain hose from the front bracket clamp. You can avoid fuel deterioration problems by draining the fuel tank Gasoline is highly flammable and 2. Set the end of the hose toward the and vapor separator.

  • Page 88: Engine Oil

    STORAGE 4. Tilt the outboard motor up all the Engine Oil way. Leave the outboard motor 1. Change the engine oil and the oil tilted up until the gasoline stops filter (p. 63 – 67). flowing. 2. Remove the spark plugs (p. 70), 5.

  • Page 89: Hoisting The Outboard Motor

    STORAGE HOISTING THE OUTBOARD STORAGE PRECAUTIONS MOTOR HOIST Select a well-ventilated storage area. HOOKS If possible, avoid storage areas with LIFTING ENGINE COVER high humidity. EYES If storing a container of gasoline, store it away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer.

  • Page 90: Removal From Storage

    STORAGE REMOVAL FROM STORAGE 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. OUTBOARD MOTOR STAND PROTECTOR If the outboard motor will be If it is necessary to store the outboard...

  • Page 91: Transporting

    TRANSPORTING WITH OUTBOARD MOTOR WITH OUTBOARD MOTOR INSTALLED ON BOAT REMOVED FROM BOAT When trailering a boat with the Secure the outboard motor in either outboard motor attached, always the vertical or horizontal position disconnect the fuel line from the fuel shown on p.

  • Page 92: Taking Care Of Unexpected Problems

    Use starting procedure (p. 38, 41, 43); if engine still will malfunction, stuck valves, starter malfunction, switch 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 93: Engine Will Not Start

    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. Control lever not in neutral position. Shift to neutral. Fast idle lever raised (side-mount type). Leave fast idle lever OFF (p.
  • Page 94 Spark plugs wet with fuel (flooded engine). Dry and reinstall spark plugs. Start engine with the throttle open. Fuel system malfunction, fuel pump failure, ignition Take outboard motor to an authorized TOHATSU dealer, malfunction, etc. or refer to the service manual.

  • Page 95: Hard Starting Or Stalls After Starting

    TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS AFTER STARTING Possible Cause Correction Fast idle lever raised (side-mount type). Leave fast idle lever OFF (p. 39). Fuel hose not primed. Squeeze priming bulb (p. 37). Fuel filter or fuel tank filter clogged. Replace fuel filters (p.

  • Page 96: Engine Overheats

    Spark plugs faulty, fouled, or improperly gapped. Gap (non-iridium type) or replace spark plugs (p. 70). 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...

  • Page 97: Fuses

    TAKING CARE OF UNEXPECTED PROBLEMS FUSES Fuse Replacement 3. Remove the junction box lid. FUSE PULLER Electric Starter Will Not RELAYS Disconnect the battery cable at the Operate (Do not remove the relays) battery negative ( – ) terminal before replacing the fuse.
  • Page 98 An uncorrected electrical problem may cause the fuse to blow again. If fuses continue to blow, take the outboard motor to an authorized TOHATSU dealer for inspection and service, or refer to the service manual.

  • Page 99: Oil Pressure Indicator Turns Off And Engine Speed Is Limited

    TAKING CARE OF UNEXPECTED PROBLEMS ACG Fuse 5. Install a new fuse with the OIL PRESSURE INDICATOR TURNS OFF AND ENGINE ‘‘100 A.’’ SPEED IS LIMITED ACG FUSE: 100 A Side-Mount Type 6. Reinstall the junction box lid, and OIL PRESSURE the engine cover.

  • Page 100: Overheat Indicator Comes On And Engine Speed Is Limited

    Panel-Mount/Top-Mount Types have the outboard motor inspected by If the throttle is closed suddenly after an authorized TOHATSU dealer. OVERHEAT full throttle operation, engine speed INDICATOR may drop below the specified idle...
  • Page 101 If there is still no water flowing from neutral, and check the cooling system the cooling system indicator, or if the indicator. engine protection system remains activated after 30 seconds, return to the nearest boat landing, and have the outboard motor inspected by an authorized TOHATSU dealer.

  • Page 102: Water Separator Buzzer Sounds

    If there is a TOHATSU dealership nearby, take the outboard motor to the 4. Remove the spark plugs (p. 70). dealer immediately. If you are far...
  • Page 103 2 inches 7. As soon as possible, take the above the antiventilation plate). outboard motor to an authorized TOHATSU dealer for inspection If you are changing the oil filter while and service. the outboard motor is out of the water, use commercially available ear muffs and water hose to supply water.

  • Page 104: Technical Information

    TECHNICAL INFORMATION Serial Number Locations Record the product identification PRODUCT IDENTIFICATION number, the engine serial number, 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 105: Battery

    • Do not disconnect the battery cables while the engine is running. TOHATSU utilizes appropriate air/ Disconnecting the cables while the fuel ratios and other emissions engine is running will damage the control systems to reduce the outboard motor’s electrical system.
  • Page 106 • Removal or alteration of any part TOHATSU engine within the Ignition Timing Control System of the intake, fuel, or exhaust emission standards. systems.
  • Page 107 Maintenance Emissions The emission control systems on your Follow the maintenance schedule on TOHATSU engine were designed, (p. 59 and 60). Remember that this If you are aware of any of the built, and certified to conform with schedule is based on the assumption...

  • Page 108: Star Label

    TECHNICAL INFORMATION Star Label The Star Label means Cleaner Marine Engine US, Puerto Rico, and US Virgin This engine has been certified as a: Islands A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board.
  • Page 109 TECHNICAL INFORMATION The one-star label identifies engines that meet the Air Resources Board’s One Star  Personal Watercraft and Outboard marine engine 2001 exhaust emission Low standards. Engines meeting these standards have 75% lower emissions than Emission conventional carbureted two-stroke engines. These engines are equivalent to the U.S.

  • Page 110: Specifications

    7.1 US qt (6.7 L) with oil filter change Gear case: 1.04 US qt (0.98 L) Other specifications No other adjustment is needed * Without battery cable, with propeller These TOHATSU outboard motors are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.
  • Page 111 7.1 US qt (6.7 L) with oil filter change Other specifications No other adjustment is needed Gear case: 1.04 US qt (0.98 L) * Without battery cable, with propeller These TOHATSU outboard motors are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.

  • Page 112: Consumer Information

    CONSUMER INFORMATION Emission Control System Warranty CALIFORNIA EMISSION CONTROL 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. The California Air Resources Board (CARB) and Tohatsu...
  • Page 113 You are responsible for presenting your outboard engine to a Tohatsu dealer as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.
  • Page 114 Tohatsu purchase date, at your expense, to any Tohatsu dealer that America Corporation. A list of warranty parts is on the is authorized by Tohatsu America Corporation to sell and reverse side of this statement.
  • Page 115 Failures other than those resulting from defects in material WARRANTIES: or workmanship are not covered by this warranty. This Tohatsu America Corporation disclaims any responsibility warranty does not extend to emission control systems or for incidental or consequential damages such as loss of...
  • Page 116 CONSUMER INFORMATION EMISSION CONTROL SYSTEM WARRANTY PARTS: SYSTEMS COVERED PARTS DESCRIPTION: BY THIS WARRANTY: Fuel Metering Carburetor assembly, Throttle body, Fuel injector, Fuel pump, Fuel pressure regulator, Throttle position sensor, Intake air temperature sensor, Engine temperature sensor, Manifold absolute pressure sensor, Idle air control valve, Barometric pressure sensor, Fuel line solenoid valve, Intake manifold, Intake valves, and Oxygen sensor or Air fuel ratio sensor Evaporative...

  • Page 117: Index

    INDEX Alternator (ACG) Indicator .......... 30 Electric Starter Will Not Operate ......90, 95 Emergency Stop Switch Clip and Emergency Stop  Anodes ................33 Replacement ............. 80 Switch ARE YOU READY TO GET UNDERWAY? ....34 Panel-Mount Type ............ 19 Side-Mount Type .............
  • Page 118 INDEX Fast Idle Button Ignition Switch Panel-Mount Type ............ 21 Panel-Mount Type ............ 18 Top-Mount Type ............25 Side-Mount Type ............. 15 Fast Idle Lever .............. 17 Top-Mount Type ............22 Fuel IMPORTANT SAFETY INFORMATION ....7 PRIMING ..............37 INDICATORS ..............
  • Page 119 INDEX Oil Pressure Indicator ........... 31 SPARE EMERGENCY STOP SWITCH CLIP.... 58 OIL PRESSURE INDICATOR TURNS OFF AND Spark Plug Service ............70 ENGINE SPEED IS LIMITED ........ 97 Specifications ............. 108 OPERATION ..............36 Star Label ..............106 OTHER FEATURES ............ 32 STARTING THE ENGINE ..........
  • Page 120 INDEX Tachometer (optional equipment) ......... 29 TAKING CARE OF UNEXPECTED PROBLEMS ..90 TECHNICAL INFORMATION ......... 102 THE IMPORTANCE OF MAINTENANCE ....56 Tilt Lock Lever ............. 27 TOOL KIT and OWNER’S MANUAL ....... 58 TRANSPORTING ............89 WITH OUTBOARD MOTOR INSTALLED  ON BOAT .............
  • Page 121 MEMO...
  • Page 122 MEMO...
  • Page 123 © 2013 Honda Motor Co., Ltd. − All Rights Reserved PGM-FI is a trademark of Honda Motor Co., Ltd. registered in Japan and other countries.
  • Page 124 BFT 115A 150A TOHATSU CORPORATION Address : 5-4,AZUSAWA 3-CHOME ITABASHI-KU, TOKYO 174-0051 Phone : +81-3-3966-3117 : +81-3-3966-2951 : www.tohatsu.co.jp 000 00000 0 31ZX1T00 Printed in Japan 00X31-ZX1-T000...

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