TOHATSU BFT 80A Owner's Manual
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TOHATSU BFT 80A Owner's Manual

TOHATSU BFT 80A Owner's Manual

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OWNER'S
OW NER'S MAN UAL
MANUAL
Original instructions
BFT 75A
BFT 80A
BFT 90A
BFT 100A

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Summary of Contents for TOHATSU BFT 80A

  • Page 1 OWNER’S OW NER’S MAN UAL MANUAL Original instructions BFT 75A BFT 80A BFT 90A BFT 100A...
  • Page 2 © 2017 Honda Motor Co., Ltd. PGM-FI is a trademark of Honda Motor Co., Ltd. registered in Japan and other countries.
  • Page 3 Here’s Outboard Motor, consult an This manual covers operation and what they mean: authorized TOHATSU Outboard maintenance of the TOHATSU Motor dealer. BFT75A/80A/90A/100A Outboard Motor. Indicates serious injury or death All information in this publication is...
  • Page 4 Model BFT75A BFT80A Type LRTD LRTU XRTU LRTU XRTU • • • 537 mm (21.1 in) Transom Height • • (Shaft Length) 664 mm (26.1 in) ∗ ∗ ∗ ∗ ∗ Tiller Handle (H1 type) ∗ ∗ ∗ ∗ ∗ Tiller Handle (H2 type) ∗...
  • Page 5 Model BFT90A BFT100A Type LRTD LRTU LRTU XRTU • • • 537 mm (21.1 in) Transom Height • (Shaft Length) 664 mm (26.1 in) ∗ ∗ ∗ ∗ Tiller Handle (H1 type) ∗ ∗ ∗ ∗ Tiller Handle (H2 type) ∗...
  • Page 6 This Owner’s Manual is using the FRAME SERIAL NUMBER ENGINE SERIAL NUMBER following type names when it describes the operations special to a type. Remote control (optional equipment) type: R type Tiller handle (optional equipment) type: H type Power trim/tilt type: T type The tiller handle type is classified into the following two categories.

  • Page 7: Table Of Contents

    CONTENTS 1. SAFETY ...................8 ACG Indicator/Buzzer ............44 SAFETY INFORMATION ............8 PGM-FI Indicator/Buzzer ............45 2. SAFETY LABEL LOCATIONS ............11 Water Separator Buzzer ............45 3. COMPONENT IDENTIFICATION ..........14 Trim Tab ................46 4. CONTROLS AND FEATURES ............24 Anode ..................46 H type Cooling Water Check Hole ............
  • Page 8 CONTENTS Tiller Handle Height/Angle Adjustment (H type) ......68 Moorage (T type) ..............113 Steering Handle Friction (H type) ..........70 Power Tilt Switch (T type) ............114 Remote Control Lever Friction (R type) ........70 Manual Relief Valve (T type) ........... 115 Water Separator ................71 Trim Tab Adjustment ...............
  • Page 9 CONTENTS 12. MAINTENANCE ...............131 Tool Kit and Emergency Parts ..........132 MAINTENANCE SCHEDULE ..........133 Engine Oil .................135 Spark Plugs ................137 Battery ..................141 Lubrication ................143 Water Separator .................145 Fuel Filter ..................148 Fuel Tank and Tank Filter (equipped type) .......150 EMISSION CONTROL SYSTEM ...........151 Fuse ...................152 ACG Fuse ..................153 Propeller ..................154...

  • Page 10: Safety

    If any fuel is spilled make sure that the area is dry before starting the engine. • TOHATSU outboard motor is designed to give safe and • Gasoline is harmful or fatal if dependable service if swallowed.
  • Page 11 SAFETY • Know how to stop the engine • Stop the engine immediately if quickly in case of emergency. anyone falls overboard. Understand the use of all controls. • Do not run the engine while the • Do not exceed the boat boat is near anyone in the water.
  • Page 12 SAFETY Fire and Burn Hazards The engine and exhaust system Carbon Monoxide Poisoning Gasoline is extremely flammable, and become very hot during operation and Hazard gasoline vapor can explode. Use remain hot for a while after Exhaust contains poisonous carbon extreme care when handling gasoline.

  • Page 13: Safety Label Locations

    They warn you of potential hazards that can cause serious injury. Read the labels and safety notes and precautions described in this manual carefully. If a label comes off or becomes hard to read, contact your TOHATSU outboard motor dealer for a replacement. READ OWNER'S MANUAL...
  • Page 14 SAFETY LABEL LOCATIONS FUEL TANK (equipped type) FUEL CAUTION FUEL CAUTION...
  • Page 15 SAFETY LABEL LOCATIONS CE mark location [U type only] CE MARK (1) Model name (2) Engine family name (10) (3) Year code (4) Rated power (5) Dry mass (weight) (with propeller, without battery cable) (6) Country of manufacture (7) Frame number (8) Manufacturer and address (9) Name and address of authorized representative...

  • Page 16: Component Identification

    3. COMPONENT IDENTIFICATION [R (Remote Control) type] OIL FILLER CAP ENGINE COVER ENGINE COVER OIL LEVEL DIPSTICK FIXING LEVER (front) NMEA INTERFACE ENGINE COVER COUPLER FIXING LEVER (rear) POWER TILT SWITCH TILT LOCK LEVER IDLE PORT FLUSH PORT COOLING STERN CONNECTOR WATER FRAME SERIAL...
  • Page 17 COMPONENT IDENTIFICATION REMOTE CONTROL BOX (equipped type or optional equipment) SIDE-MOUNTTYPE (R1 type) PANEL-MOUNTTYPE (R2 type) REMOTE CONTROL LEVER REMOTE CONTROL LEVER POWER TRIM/TILT SWITCH NEUTRAL RELEASE LEVER TRL (Trolling) CONTROL SWITCH* NEUTRAL RELEASE INDICATORS LEVER BUZZER (Oil pressure, Overheat, (inside) ACG, PGM-FI) FAST IDLE LEVER...
  • Page 18 COMPONENT IDENTIFICATION TOP-MOUNT TYPE (R3 type) (SINGLE OUTBOARD MOTOR TYPE) (DUAL OUTBOARD MOTOR TYPE) REMOTE CONTROL LEVER REMOTE CONTROL LEVERS POWER TRIM/TILT SWITCH (RIGHT) R3 type: POWER TRIM/TILT POWER TRIM/ SWITCH (LEFT) SPARE EMERGENCY TILT SWITCH STOP SWITCH CLIP Store the spare emergency stop switch clip in the tool bag.
  • Page 19 COMPONENT IDENTIFICATION SWITCH PANEL without indicators type (optional equipment) (PANEL-MOUNT, TOP-MOUNT SINGLE) (for THREE OUTBOARD MOTORS type) BUZZER ENGINE SWITCH KEY (IGNITION SWITCH KEY) ENGINE SWITCH (IGNITION SWITCH) EMERGENCY STOP SWITCH EMERGENCY STOP EMERGENCY STOP SWITCH LANYARD SWITCH CLIP (for TWO OUTBOARD MOTORS type) For the switch panel without indicators type, use it along with the NMEA2000-compatible device.
  • Page 20 COMPONENT IDENTIFICATION [H (Tiller Handle) type] OIL FILLER CAP ENGINE COVER ENGINE COVER OIL LEVEL DIPSTICK FIXING LEVER NMEA (front) INTERFACE COUPLER ENGINE COVER FIXING LEVER (rear) POWER TILT SWITCH (T type) TILT LOCK TILLER HANDLE IDLE PORT LEVER (H1 type) (optional equipment) COOLING FLUSH PORT...
  • Page 21 COMPONENT IDENTIFICATION TILLER HANDLE (H1 type) (optional equipment) INDICATORS (Oil pressure, Overheat, ACG, PGM-FI) SHIFT LEVER EMERGENCY STOP SWITCH EMERGENCY STOP THROTTLE FRICTION SWITCH CLIP ADJUSTER EMERGENCY STOP SWITCH LANYARD POWER TRIM/TILT SWITCH (T type) THROTTLE GRIP STEERING FRICTION ADJUSTING KNOB ENGINE SWITCH KEY SPARE EMERGENCY STOP SWITCH CLIP (IGNITION SWITCH KEY)
  • Page 22 COMPONENT IDENTIFICATION TILLER HANDLE (H2 type) (optional equipment) SHIFT LEVER THROTTLE FRICTION INDICATORS ADJUSTER TRL (Trolling) (Oil pressure, Overheat, ACG, PGM-FI) CONTROL SWITCH THROTTLE GRIP EMERGENCY STOP EMERGENCY SWITCH CLIP STOP SWITCH EMERGENCY STOP SWITCH ENGINE SWITCH LANYARD POWER TRIM/TILT SWITCH (IGNITION SWITCH) ENGINE SWITCH KEY (IGNITION SWITCH KEY)
  • Page 23 COMPONENT IDENTIFICATION [Common] FUEL GAUGE FUEL TANK (equipped type) FUEL FILLER CAP FUEL TANK FUEL FILLER CAP TUBE ASSEMBLY VENT KNOB (equipped type) FUEL LINE JOINT (outboard motor side) PRIMING BULB...
  • Page 24 COMPONENT IDENTIFICATION FUEL TUBE ASSEMBLY FUEL LINE JOINT (equipped type) (fuel tank side) PRIMING BULB FUEL LINE JOINT (outboard motor side)
  • Page 25 COMPONENT IDENTIFICATION TRL (Trolling) CONTROL SWITCH PANEL TACHOMETER (Optional equipment) TRIM METER (Optional equipment) (Optional equipment: R type) TRL (Trolling) CONTROL SWITCH...

  • Page 26: Controls And Features

    4. CONTROLS AND FEATURES (H type) This tiller handle is equipped with an Engine Switch (Ignition Switch) NEUTRAL automotive type ignition switch. (H1 type) START Key positions: SHIFT LEVER START: to start the engine. to run the engine after starting. ENGINE SWITCH KEY OFF: to stop the engine...

  • Page 27: Shift Lever

    You can chose which side to have the propeller. The boat propeller. The boat shift lever installed. Consult your does not move. does not move. authorized TOHATSU outboard REVERSE: The boat reverses. REVERSE: The boat reverses. motor dealer.

  • Page 28: Throttle Grip

    CONTROLS AND FEATURES (H type) Throttle Grip (H1 type) (H1 type) THROTTLE INDICATOR THROTTLE GRIP FAST SLOW (H2 type) START (H2 type) FAST START SLOW THROTTLE GRIP Turn the grip clockwise or THROTTLE counterclockwise to adjust the engine INDICATOR speed. Turning the grip in the The curve on the grip indicates the direction shown by arrow increases engine speed.

  • Page 29: Throttle Friction Adjuster

    CONTROLS AND FEATURES (H type) Throttle Friction Adjuster Emergency Stop Switch (H1 type) (H2 type) (H1 type) THROTTLE FRICTION EMERGENCY STOP SWITCH THROTTLE FRICTION ADJUSTER ADJUSTER HOLD RELEASE RELEASE STOP (H2 type) HOLD THROTTLE GRIP EMERGENCY STOP SWITCH The throttle friction adjuster adjusts resistance to throttle grip rotation.

  • Page 30: Emergency Stop Switch Lanyard/Clip

    CONTROLS AND FEATURES (H type) Emergency Stop Switch Lanyard/Clip (H1 type) (H2 type) EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP STOP STOP EMERGENCY STOP EMERGENCY STOP EMERGENCY EMERGENCY STOP EMERGENCY SWITCH CLIP SWITCH LANYARD STOP SWITCH SWITCH CLIP STOP SWITCH LANYARD LANYARD...

  • Page 31: Steering Friction Adjusting Knob

    CONTROLS AND FEATURES (H type) Steering Friction Adjusting Knob (H2 type) (H1 type) STEERING FRICTION ADJUSTING KNOB To increase friction To increase friction To decrease SPARE EMERGENCY friction STOP SWITCH CLIP To decrease friction STEERING FRICTION ADJUSTING KNOB The engine does not start unless the emergency stop switch clip is set on the emergency stop switch.

  • Page 32: Trl (Trolling) Control Switch

    CONTROLS AND FEATURES (H type) TRL (Trolling) Control Switch (H2 type) DOWN TRL (Trolling) CONTROL SWITCH The engine speed can be adjusted with the trolling control switch when in trolling mode. If you press and hold the TRL control switch while cruising with the throttle closed, the mode changes to trolling mode.

  • Page 33: Remote Control Lever

    CONTROLS AND FEATURES (R type) Remote Control Lever NEUTRAL (R1 type) 32° 32° FORWARD REVERSE REMOTE CONTROL LEVER SHIFT SHIFT NEUTRAL RELEASE LEVER MINIMUM MINIMUM THROTTLE OPENING FORWARD THROTTLE OPENING NEUTRAL REVERSE MAXIMUM MAXIMUM REMOTE CONTROL LEVER Shifting gear into forward, reverse, or FORWARD: REVERSE: neutral and the engine speed...
  • Page 34 CONTROLS AND FEATURES (R type) (R2 type) NEUTRAL 35° 35° REMOTE CONTROL LEVER REVERSE FORWARD NEUTRAL RELEASE LEVER SHIFT SHIFT FORWARD MINIMUM THROTTLE OPENING MINIMUM THROTTLE OPENING NEUTRAL MAXIMUM MAXIMUM REVERSE REMOTE CONTROL LEVER Shifting gear into forward, reverse, or FORWARD: REVERSE: Moving the lever to the FORWARD...
  • Page 35 CONTROLS AND FEATURES (R type) (R3 type) (SINGLE TYPE) (DUAL TYPE) FORWARD NEUTRAL REMOTE CONTROL LEVER NEUTRAL 35° 35° FORWARD REVERSE FORWARD SHIFT SHIFT THROTTLE THROTTLE OPENING OPENING NEUTRAL MINIMUM MINIMUM MAXIMUM REVERSE MAXIMUM REVERSE REMOTE CONTROL LEVERS REMOTE CONTROL LEVER Shifting gear into forward, reverse, or FORWARD: REVERSE:...

  • Page 36: Neutral Release Lever

    CONTROLS AND FEATURES (R type) Neutral Release Lever Engine Switch (Ignition Switch) START (R2, R3 types) (R1 type) (R1 type) REMOTE CONTROL LEVER START ENGINE SWITCH KEY (IGNITION SWITCH KEY) NEUTRAL START RELEASE LEVER (R2 type) ENGINE SWITCH KEY (IGNITION SWITCH KEY) REMOTE CONTROL LEVER This remote control is equipped with an automotive type ignition switch.

  • Page 37: Fast Idle Lever (R1 Type)/Fast Idle Button (R2, R3 Types)

    CONTROLS AND FEATURES (R type) Fast Idle Lever (R1 type)/Fast Idle < Fast Idle Lever> <Fast Idle Button> Button (R2, R3 types) (R1 type) (R2 type) NEUTRAL The fast idle lever/fast idle button is FORWARD REMOTE CONTROL LEVER only needed for starting carbureted REVERSE MAXIMUM NEUTRAL...

  • Page 38: Emergency Stop Switch

    CONTROLS AND FEATURES (R type) <Fast Idle Button> Emergency Stop Switch When using the switch panel without (R3 type) (R1 type) indicators type, pull the emergency stop switch clip out of the emergency NEUTRAL FORWARD stop switch (see page 123). REVERSE Emergency Stop Switch Lanyard/ Clip...

  • Page 39: Spare Emergency Stop Switch Clip (Optional Equipment)

    CONTROLS AND FEATURES (R type) The emergency stop switch clip must (R1 type) Spare Emergency Stop Switch Clip be engaged with the emergency stop (optional equipment) EMERGENCY STOP SWITCH switch or the engine will not start. When the emergency stop switch clip becomes disengaged with the emergency stop switch the engine will stop immediately.

  • Page 40: Trl (Trolling) Control Switch

    CONTROLS AND FEATURES (R type) TRL (Trolling) Control Switch TRL (Trolling) CONTROL SWITCH TRL (Trolling) CONTROL SWITCH TRL (Trolling) Control Switch Panel Remote Control Box (optional equipment) (Side-mount type) The engine speed can be adjusted with the trolling control switch when For TRL (Trolling) control switch in trolling mode.

  • Page 41: Power Trim/Tilt Switch

    CONTROLS AND FEATURES (T type) Power Trim/Tilt Switch (R2 type) (H1 type) POWER TRIM/TILT SWITCH Power Trim REMOTE CONTROL LEVER Press the power trim/tilt switch on the tiller handle or on the remote control lever to adjust the outboard motor trim angle of –...

  • Page 42: Trim Meter (Equipped Type Or Optional Equipment)

    CONTROLS AND FEATURES (T type) Trim Meter (equipped type or optional Excessive trim/tilt angle during equipment) operation can cause the propeller to raise out of the water and cause propeller ventilation and engine over-revving. Excessive trim/tilt angle can also damage the water 68°...

  • Page 43: Power Tilt Switch (Outboard Motor Pan)

    CONTROLS AND FEATURES (T type) Power Tilt Switch Manual Relief Valve After tilting the outboard motor, turn (outboard motor pan) the manual relief valve clockwise POWER MANUAL securely. (To hold) (To release) Check that no person is under the outboard motor before carrying out this operation because if the manual relief valve is loosened (turned counterclockwise) when the...

  • Page 44: Tilt Lock Lever

    CONTROLS AND FEATURES (Common) Tilt Lock Lever Oil Pressure Indicator/Buzzer (R1 type) OIL PRESSURE The oil pressure indicator turns off INDICATOR and the buzzer sounds when the oil level is low and/or the engine lubrication system is faulty. The engine speed slows down gradually this time.

  • Page 45: Overheat Indicator/Buzzer

    CONTROLS AND FEATURES (Common) Overheat Indicator/Buzzer (H type) (R2, R3 types) OVERHEAT (RED) The overheat indicator turns on and INDICATOR the buzzer sounds when the engine cooling circuit is faulty. The engine speed slows down this time. (RED) OVERHEAT If using a panel-mount or top-mount INDICATOR switch panel without indicators, check the indicators displayed on an...

  • Page 46: Acg Indicator/Buzzer

    CONTROLS AND FEATURES (Common) ACG Indicator/Buzzer (R1 type) The ACG indicator turns on and the INDICATOR buzzer sounds when the charging system is faulty. If using a panel-mount or top-mount (RED) switch panel without indicators, BUZZER check the indicators displayed on an NMEA2000-compatible device.

  • Page 47: Pgm-Fi Indicator/Buzzer

    CONTROLS AND FEATURES (Common) PGM-FI Indicator/Buzzer (R1 type) Water Separator Buzzer PGM-FI The PGM-FI indicator turns on and The water separator buzzer sounds INDICATOR the buzzer sounds when the engine when water has accumulated in the control system is faulty. water separator.

  • Page 48: Trim Tab

    CONTROLS AND FEATURES (Common) Trim Tab Anode GEAR CASE GROMMET ANODE ANODE (each side) (stern bracket) TRIM TAB TIGHTENING BOLT The anode metal is a sacrificed metal If the steering wheel/handle is pulled which protects the outboard motor to the side while running at full from corrosion.

  • Page 49: Cooling Water Check Hole

    CONTROLS AND FEATURES (Common) Cooling Water Intake Port Cooling Water Check Hole COOLING WATER CHECK HOLE COOLING WATER INTAKE PORT (each side) The cooling water is checked here to see whether it is circulating inside the engine properly. After starting the engine, check at the The engine cooling water is drawn cooling water check hole whether the into the engine through this port.

  • Page 50: Engine Cover Fixing Lever

    CONTROLS AND FEATURES (Common) Engine Cover Fixing Lever Tachometer Fuel Filler Cap (equipped type) (Front/Rear) (equipped type or optional (with vent knob) equipment) FUEL FILLER CAP VENT KNOB ENGINE COVER FIXING LEVER OPEN (front/rear) FUEL CLOSE FILLER CAP UNLOCK TACHOMETER The tachometer shows the engine speed in revolutions per minute.

  • Page 51: Fuel Gauge

    CONTROLS AND FEATURES (Common) Fuel Gauge Fuel Line Connector And Joint The fuel line connector and joint are (equipped type) used to connect the fuel line between the fuel tank and the separate FUEL LINE CONNECTOR FUEL GAUGE outboard motor. (fuel tank side) HOSE PLUG The fuel gauge indicates the fuel level...

  • Page 52: Nmea Interface Coupler

    CONTROLS AND FEATURES (Common) NMEA Interface Coupler Operating Hour Notification Periodic maintenance is required System when either the operating hours or the NMEA INTERFACE time since last maintenance reaches COUPLER This outboard motor engine counts the prescribed limit. Therefore, the number of operating hours since periodic maintenance may be the last periodic maintenance.
  • Page 53 CONTROLS AND FEATURES (Common) <Operating hour notification timing> NMEA2000-compatible display: • Follow instructions for the display. • If the display allows selection of notification to be preset, select “Notify” (or equivalent). Every 100 hours • Turn on the power supply to the display before turning on the 80 hours 100 hours...
  • Page 54 CONTROLS AND FEATURES (Common) How to reset the Hour Counter When “Periodic Maintenance” is indicated: 1. Be sure to turn OFF the engine 1. Have the periodic maintenance before beginning the reset performed without delay after procedure. Pull the emergency stop returning to port.

  • Page 55: Installation

    We recommend that the outboard motor be installed by an authorized TOHATSU outboard motor dealer. Consult the authorized TOHATSU dealer in your area for the Y-OP (User Type: T (Outboard Motor...

  • Page 56: Location

    INSTALLATION Location Installation Height IDLE PORT BOAT TRANSOM HEIGHT 150 mm (5.9 in) or more 0 to 25 mm (0 to 1 in) WATER LEVEL FULLY CENTER LINE TRIM/TILT DOWN TRANSOM HEIGHT ANTICAVITATION • The water level must be at least PLATE 100 mm (4 in) above the Install the outboard motor at the...

  • Page 57: Outboard Motor Installation

    ENGINE guideline. Torque of the nut can be HANGERS different according to the material of the boat. Consult with an authorized TOHATSU outboard motor dealer. WASHER (8) NUT (8) WASHER (4) Install the outboard motor securely. Loosely mounted outboard motor...

  • Page 58: Outboard Motor Angle Inspection (Cruising)

    INSTALLATION Outboard Motor Angle Inspection (Cruising) INCORRECT INCORRECT CORRECT CAUSES BOAT TO ‘‘SQUAT’’ CAUSES BOAT TO ‘‘PLOW’’ GIVES MAXIMUM PERFORMANCE Trim angle too small: Incorrect Install the outboard motor at the best The trim angle differs according to causes boat to ‘‘plow.’’ trim angle for stable cruising and the combination of the boat, outboard maximum power.

  • Page 59: Battery Connections

    INSTALLATION Battery Connections • POISON: Electrolyte is poison. Use a battery which has CCA ANTIDOTE: Batteries produce explosive gases: (COLD CRANKING AMPERES) ─ External: Flush thoroughly If ignited, an explosion can cause 582A at – 18°C (0°F) and a reserve with water.
  • Page 60 INSTALLATION • Battery cable extension: (+) TERMINAL Extending the original battery • Be sure to connect the ( + ) side (–) TERMINAL cable will cause the battery battery cable first. When voltage to drop due to the disconnecting the cables, increased length of the cable and disconnect the ( –...

  • Page 61: Remote Control Installation (Equipped Type Or Optional Equipment)

    TOP-MOUNT TYPE CONTROL BOX cause unpredictable accident. AND SWITCH PANEL Consult an authorized TOHATSU (FOR SINGLE OUTBOARD MOTOR outboard motor dealer for proper TYPE) installation. SIDE-MOUNT TYPE CONTROL BOX The control box is available in three types as shown.

  • Page 62: Remote Control Box Location

    INSTALLATION <Remote Control Box Location> <Remote Control Cable Length> Do not bend the remote control REMOTE CONTROL LEVER cable as sharp as its route diameter REMOTE REMOTE is 300 mm (11.8 in) or less, or it CONTROL CONTROL BOX CABLES affects the service life of the cable and the remote control lever operation.

  • Page 63: Propeller Selection

    Use of the correct propeller assures powerful acceleration, top speed, excellency in terms of economy and cruising comfort, and it assures longer engine life as well. Consult with your authorized TOHATSU outboard motor dealer for proper propeller selection.

  • Page 64: Pre-Operation Checks

    6. PRE-OPERATION CHECKS BFT75A/80A/90A/100A is 4-stroke, Engine Cover Removal/Installation Engine Oil water cooled outboard motor which uses unleaded gasoline for fuel (see • Engine oil is a major factor page 65). It also requires the engine affecting engine performance oil. Check the following before and service life.
  • Page 65 PRE-OPERATION CHECKS SAE 10W-30 is recommended for <Inspection and Refilling> 1. Position the outboard motor general use. vertically, and remove the engine UPPER cover. LEVEL MARK 2. Remove the oil level dipstick and wipe with a clean rag. LOWER 3. Reinsert the dipstick all the way in, LEVEL MARK then pull it out and read the level.
  • Page 66 PRE-OPERATION CHECKS When you check the oil level with the dipstick, you might notice the engine oil Oil filler cap removal (Unlock): appears milky or the oil level has increased. If you notice either condition, change the engine oil. See the following table for an explanation of these conditions.

  • Page 67: Fuel

    PRE-OPERATION CHECKS Oil filler cap installation (Lock): Fuel Fuel tank capacity (separate tank): 25 L (6.6 US gal, 5.5 Imp gal) 1)Insert the oil filler cap into the oil (Fuel Tank equipped type) filler port with the lug being set (Using the fuel tank mounted on horizontally.

  • Page 68: Gasoline Containing Alcohol

    • Refuel in a well-ventilated area its octane rating is at least as high as recommended is not covered under with the engine stopped. that recommended by TOHATSU. the warranty. • Do not smoke or allow flames or There are two types of “gasohol”: one •...

  • Page 69: Propeller And Cotter Pin Inspection

    Consult an authorized TOHATSU life as well. outboard motor dealer for propeller Consult with your authorized selection. TOHATSU outboard motor dealer for Keep the spare washer, castle nut and proper propeller selection. cotter pin with you on your boat.

  • Page 70: Tiller Handle Height/Angle Adjustment (H Type)

    PRE-OPERATION CHECKS Tiller Handle Height/Angle (H1 type) Adjustment (H type) HANDLE ANGLE: 13° 298 mm HANDLE ANGLE: 7° The tiller handle height and angle can (11.7 in) be adjusted to three positions by HANDLE ANGLE: 21° HANDLE ANGLE: 7° changing the installation direction of the height adjustment block.
  • Page 71 PRE-OPERATION CHECKS (H2 type) Install the height adjustment block so that the selected angle of the HANDLE ANGLE: 7° tiller handle is in this position. HANDLE ANGLE: 317 mm 21° (12.5 in) HANDLE ANGLE: 7° HANDLE ANGLE: 13° 378 mm (14.9 in) 8 ×...

  • Page 72: Steering Handle Friction (H Type)

    PRE-OPERATION CHECKS Steering Handle Friction (H type) Remote Control Lever Friction (H1 type) (H2 type) (R type) STEERING FRICTION (R1 type) ADJUSTING KNOB To increase CONTROL LEVER friction FRICTION ADJUSTER To increase friction To decrease friction To decrease friction To decrease friction To increase STEERING FRICTION...

  • Page 73: Water Separator

    Clean it or water to the upper level (see page consult with an authorized 141). TOHATSU outboard motor dealer for To increase cleaning (see page 145). Check that the battery cables are friction connected securely.
  • Page 74 PRE-OPERATION CHECKS • Keep flames and sparks away, POSITIVE ( + ) and do not smoke in the area. TERMINAL ANTIDOTE: If electrolyte gets into your eyes, flush thoroughly with warm water for at least 15 minutes and call a physician immediately.

  • Page 75: Other Checks

    PRE-OPERATION CHECKS Other Checks (5) TOOL KIT (see page 132) Check the following items: The anode (sacrificed metal) helps to Parts/materials which should be (1) The fuel hose for kinking, protect the outboard motor from installed on board: collapsing or a loose connection. corrosion damage;...

  • Page 76: Starting The Engine

    7. STARTING THE ENGINE Fuel Line Connection • Be sure that the fuel line is not FUEL HOSE kinked. (outboard BARB motor side) (Fuel Tank equipped type) Gasoline is extremely flammable, FUEL HOSE HOSE PLUG and gasoline vapor can explode, causing serious injury or death.
  • Page 77 STARTING THE ENGINE (Using the fuel tank mounted on FUEL FILLER CAP FUEL LINE CONNECTOR the boat) VENT KNOB (to fuel tank) FUEL TUBE ASSEMBLY OPEN (equipped type) (outboard motor side) FUEL HOSE (tank side) BARB HOSE CLAMP (stainless steel) (fuel tank side) 1.

  • Page 78: Fuel Priming

    STARTING THE ENGINE Fuel Priming Be careful not to spill any fuel. ARROW Spilled fuel vapor may ignite. If any fuel is spilled, make sure the OUTLET END area is dry before starting the (outboard engine. motor side) PRIMING BULB Do not touch the priming bulb with the engine running or when tilting up the outboard motor.

  • Page 79: Starting The Engine

    STARTING THE ENGINE Starting the Engine (H type) (H2 type) (H1 type) To prevent damage to the outboard EMERGENCY STOP SWITCH from overheating, never run the EMERGENCY engine with the propeller out of STOP SWITCH water. 1. Insert the emergency stop switch clip at one end of the emergency STOP stop switch lanyard into the...
  • Page 80 STARTING THE ENGINE (H1 type) (H2 type) NEUTRAL NEUTRAL SPARE EMERGENCY STOP SWITCH CLIP SHIFT LEVER Store the spare emergency stop SHIFT switch clip in the tool bag. LEVER Use the spare emergency stop switch clip to make the disabled engine start when the emergency stop switch lanyard is not available as, for example, when the operator falls...
  • Page 81 STARTING THE ENGINE (H1 type) (H1 type) (H2 type) THROTTLE GRIP ENGINE SWITCH KEY ENGINE SWITCH KEY START START “ ” MARK START (H2 type) START START START ‘‘ ’’ MARK 4. Turn the engine switch key to the START position and hold it there until the engine starts.
  • Page 82 STARTING THE ENGINE (H1, H2 types) • The starter motor consumes a COOLING WATER large amount of current. Do not CHECK HOLE therefore run it continuously for more than 5 seconds at a time. If the engine does not start within 5 seconds, wait at least 10 seconds before running the starter motor again.

  • Page 83: R Type

    ON, consult with an To prevent damage to the outboard authorized TOHATSU outboard Before leaving the dock, check the from overheating, never run the motor dealer. operation of the emergency stop engine with the propeller out of switch.
  • Page 84 STARTING THE ENGINE 1. Insert the emergency stop switch REMOTE CONTROL LEVER clip at one end of the emergency stop switch lanyard into the SPARE EMERGENCY NEUTRAL emergency stop switch. Attach the STOP SWITCH CLIP other end of the emergency stop switch lanyard securely to the NEUTRAL operator.
  • Page 85 STARTING THE ENGINE COOLING WATER • The starter motor consumes a CHECK HOLE large amount of current. Do not therefore run it continuously for ON START more than 5 seconds at a time. If the engine does not start within 5 seconds, wait at least 10 seconds before running the starter motor again.
  • Page 86 1)Check the oil level (see page 63). 2)If the oil level is normal and the oil pressure indicator does not turn ON, consult with an authorized TOHATSU outboard motor dealer.

  • Page 87: R2, R3 Types

    STARTING THE ENGINE Starting the Engine (R2, R3 types) When the boat is mounted with two The engine does not start unless the outboard motors, perform the clip is set on the emergency stop SWITCH PANEL EMERGENCY following on the right and left switch.
  • Page 88 STARTING THE ENGINE NEUTRAL NEUTRAL START NEUTRAL ENGINE SWITCH KEY NEUTRAL REMOTE CONTROL REMOTE LEVER CONTROL LEVER (R2 type) (R3 type) START 3. Turn the engine switch key to the 2. Set the control lever in the START position and hold it there NEUTRAL position.
  • Page 89 STARTING THE ENGINE COOLING WATER CHECK HOLE • The starter motor consumes a If water does not flow out, or if large amount of current. Do not steam comes out, stop the engine. therefore run it continuously for Check to see if the screen in the more than 5 seconds at a time.
  • Page 90 2)If the oil level is normal and the oil pressure indicator does not turn ON, consult with an authorized Before leaving the dock, check the TOHATSU outboard motor dealer. operation of the emergency stop switch. NORMAL: ON If using a panel-mount or top-mount...

  • Page 91: Emergency Starting

    STARTING THE ENGINE Emergency Starting 6 × 25 mm 6 mm WASHER FLANGE BOLT ENGINE COVER FIXING LEVER CLAMP (front/rear) ACG COVER HOOKS CLAMPS CLAMP (on the silencer case) BREATHER TUBE If the starting system does not operate 3. Release the breather tube from the properly for some reasons, the engine Take care not to lose the bolt and four clamps.
  • Page 92 STARTING THE ENGINE 6. Set the shift lever or remote control (H1 type) (R1 type) NEUTRAL lever is in the NEUTRAL position. NEUTRAL NEUTRAL The ‘‘Neutral Starting System’’ will SHIFT not work in emergency starting. LEVER REMOTE Be sure to set the shift lever/control CONTROL lever into the NEUTRAL LEVER...
  • Page 93 STARTING THE ENGINE (H1 type) (R1 type) EMERGENCY “ ” MARK STARTER ROPE THROTTLE GRIP START AC GENERATOR ROTOR FAST IDLE LEVER KNOT START CUTOUT 7. H type: (H2 type) Align the “ ” (start mark) on the 8. Set the AC generator rotor so the START throttle grip with the projected end cutouts are on the right and left...
  • Page 94 STARTING THE ENGINE 9. Insert the clip at the end of the (R1 type) (H1 type) EMERGENCY emergency stop switch lanyard into STOP SWITCH EMERGENCY STOP the emergency stop switch. SWITCH Attach the other end of the emergency stop switch lanyard securely to the operator.
  • Page 95 STARTING THE ENGINE 10. Turn the engine switch key to the (H1 type) (R1 type) ON position. ENGINE SWITCH KEY The propeller must be lowered into the water, running the outboard motor out of the water will damage the water pump and overheat the engine.
  • Page 96 STARTING THE ENGINE 12. Leave the AC generator cover off and install the engine cover. Lock the engine cover fixing levers. 13. Attach the emergency stop switch lanyard securely to the operator and return to the closest boat landing. 14. After returning to the closest boat landing, contact your closest outboard motor dealer and perform the following.

  • Page 97: Operation

    8. OPERATION Break-in Procedure Next 60 minutes: Break-in period: 10 hours Run the outboard motor up to maximum of 4,000 to 5,000 min Break-in operation allows the mating (rpm) or 50% to 80% throttle surfaces of the moving parts to wear opening.

  • Page 98: Gear Shifting

    OPERATION The shift lever has 3 positions: Gear Shifting (H type) FORWARD, NEUTRAL, and (H1 type) F (FORWARD) R (REVERSE) REVERSE. An indicator at the base of the shift lever aligns with the icon attached at the tiller handle. NEUTRAL N (NEUTRAL) Be sure to perform the gearshift operation at a low engine speed.
  • Page 99 OPERATION 1. Align the pointer on the tiller 2. Move the shift lever to engage the (H1 type) handle with the SLOW position on desired gear. the throttle grip to decrease engine THROTTLE speed. GRIP The throttle mechanism is designed to limit throttle opening in REVERSE and NEUTRAL.

  • Page 100: R1 Type

    OPERATION Gear Shifting (R1 type) REMOTE CONTROL LEVER FORWARD NEUTRAL NEUTRAL NEUTRAL FORWARD REVERSE MAXIMUM MAXIMUM OPENING OPENING REVERSE Pull up NEUTRAL RELEASE LEVER Moving the control lever further from The control lever will not move approximately 32° will increase unless the neutral release lever is Avoid sharp and abrupt operation throttle opening and boat speed.

  • Page 101: R2 Type

    OPERATION Gear Shifting REVERSE (R2 type) NEUTRAL FORWARD REMOTE CONTROL LEVER FORWARD NEUTRAL NEUTRAL RELEASE LEVER Pull up REMOTE CONTROL LEVER REVERSE Moving the control lever further from The control lever will not move approximately 35° will increase unless the neutral release lever is Avoid sharp and abrupt operation throttle opening and boat speed.

  • Page 102: R3 Type

    OPERATION Gear Shifting NEUTRAL (R3 type) FORWARD (SINGLE TYPE) (DUAL TYPE) FORWARD REVERSE NEUTRAL REMOTE CONTROL LEVER REMOTE CONTROL LEVER REVERSE REMOTE CONTROL LEVERS When the boat is mounted with the Moving the control lever(s) further two outboard motors, hold the control from approximately 35°...

  • Page 103: Steering H Type

    OPERATION Steering (H type) (H1 type) (H2 type) STEERING FRICTION ADJUSTING KNOB RIGHT TURN LEFT TURN To increase friction To increase friction To decrease friction To decrease Move the tiller Move the tiller friction STEERING FRICTION handle to the left. handle to the right.

  • Page 104: Cruising H Type

    OPERATION Cruising (H type) (H1 type) (H1, H2 types) POWER TRIM/ TILT SWITCH LOWERMOST POSITION Press the DN (down) of the power (H2 type) POWER TRIM/ trim/tilt switch and tilt the outboard TILT SWITCH motor to the lowermost position. (T type) (down)
  • Page 105 OPERATION (H1 type) (H2 type) FORWARD FORWARD SHIFT LEVER SHIFT LEVER FORWARD FORWARD 1. With the shift lever in the FORWARD position.
  • Page 106 OPERATION (H2 type) (H1 type) • When cruising at full throttle, note THROTTLE FRICTION that the engine speed must be in the THROTTLE FRICTION ADJUSTER ADJUSTER range. FAST • If you feel that the engine speed RELEASE HOLD jumped up when the hull jumped or at ventilation, cruise the boat by FAST returning the throttle to the slow...

  • Page 107: R Type

    OPERATION Cruising (R type) (R3 type) (R1 type) (R2 type) (single type) (dual type) POWER TRIM/ POWER TRIM/ TILT SWITCH TILT SWITCH POWER TRIM/ POWER TRIM/TILT SWITCH (LEFT) (RIGHT) TILT SWITCH LOWERMOST POSITION 1. Press the DN (down) of the power R3 type: 2)With the outboard motors trimmed trim/tilt switch and trim the...
  • Page 108 OPERATION (R1 type) (R2 type) (R3 type) • When cruising at full throttle, note NEUTRAL that the engine speed must be in the REVERSE NEUTRAL NEUTRAL range. REVERSE FORWARD REVERSE • If you feel that the engine speed FORWARD jumped up when the hull jumped or REMOTE at ventilation, cruise the boat by FORWARD...

  • Page 109: Trl (Trolling) Control Switch

    OPERATION TRL (Trolling) Control Switch A long buzz sounds once. When the mode is changed to trolling mode, the engine speed is 650 min (rpm). You can adjust the engine speed by DOWN 50 min (rpm) every time you press the switch once.

  • Page 110: Trimming The Outboard Motor

    OPERATION Trimming the Outboard Motor (H1 type) (H2 type) POWER TRIM/TILT SWITCH Press DN to lower bow. Press UP to raise bow. Press UP to raise bow. 68° 12° Press DN to lower bow. TILT POWER TRIM/TILT SWITCH ANGLE 0° - 4°...
  • Page 111 OPERATION (R1 type) (R3 type) POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH • Improper trim angle results in unstable steering condition. (Single Type) Press UP to • Do not trim excessively while Press UP to raise bow. raise bow. cruising through rough waves, or Press DN to it may cause an accident.
  • Page 112 OPERATION OUTBOARD MOTOR OUTBOARD MOTOR TRIMMED TOO LOW TRIMMED TOO HIGH OUTBOARD MOTOR TRIMMED CORRECTLY When cruising: (A) Into a high wind, trim the outboard motor down slightly to lower the bow and improve boat stability. (B) With a tail wind, trim the outboard motor up slightly to raise the bow and improve boat stability.

  • Page 113: Trim Meter (Equipped Type Or Optional Equipment)

    OPERATION Trim Meter BOW TOO LOW DUE TO BOW TOO HIGH DUE TO 1. LOAD IN THE FRONT 1. LOAD IN THE REAR (equipped type or optional 2. OUTBOARD MOTOR TRIMMED 2. OUTBOARD MOTOR TRIMMED equipment) TOO LOW TOO HIGH The trim meter indicates the trim angle of the outboard motor.

  • Page 114: Tilting The Outboard Motor (T Type)

    OPERATION Tilting the Outboard Motor (R1 type) (R3 type) (H1 type) (T type) (single type) POWER TRIM/ Tilt the outboard motor to prevent the TILT SWITCH POWER TRIM/ propeller and gear case from hitting TILT SWITCH the bottom when the boat is beached or stopped in shallow water.

  • Page 115: Moorage (T Type)

    OPERATION Moorage (T type) TRIM RODS FREE LOCK TILT LOCK LEVER TILT LOCK LEVER Tilt up the outboard motor using the 1. Raise the outboard motor as full as it goes using the power trim/tilt tilt lock lever when mooring the boat. switch.

  • Page 116: Power Tilt Switch (T Type)

    OPERATION Power Tilt Switch (T type) (R3 type) (DUAL TYPE) POWER TRIM/TILT SWITCH POWER TILT SWITCH (LEFT) (RIGHT) When you are away from the power After tilting down the outboard trim/tilt switch on the control lever motors, adjust the trim angle of the side or the tiller handle side, you can right and left outboard motors.

  • Page 117: Manual Relief Valve (T Type)

    OPERATION Manual Relief Valve (T type) Check that no person is under the outboard motor before carrying out POWER MANUAL this operation because if the manual (To hold) (To release) relief valve is loosened (turned counterclockwise) when the outboard motor is tilted up, the outboard motor will suddenly tilt down.

  • Page 118: Trim Tab Adjustment

    OPERATION Trim Tab Adjustment GEAR CASE GEAR CASE GROMMET GROMMET RIGHT LEFT TIGHTENING BOLT TIGHTENING BOLT TRIM TAB TRIM TAB The trim tab is provided to adjust for Remove the gear case grommet and If less effort is required to make right “torque steer”...

  • Page 119: Engine Protection System

    OPERATION Engine Protection System Each warning system of PGM-FI, OIL PRESSURE <Engine Oil Pressure, Overheat, ACG, oil pressure, overheat, and INDICATOR INDICATOR (GREEN) (RED) Water Contamination, PGM-FI water contamination is activated as and ACG Warning Systems> described in the following table. If using a panel-mount or top-mount If the engine oil pressure drops and/ switch panel without indicators,...
  • Page 120 OPERATION System INDICATOR LIGHTS BUZZER Oil pressure Overheat PGM-FI CORRESPONDING Symptom (Green) (Red) (Red) (Red) SYSTEM With the engine switch key At starting ON (2 sec) ON (2 sec) ON (2 sec) turned on: ON (2 times) During operation Low oil pressure ON (continuously) Overheat ON (continuously)
  • Page 121 30 seconds, idling for 30 seconds. If the return to the closest boat landing overheat warning system stops and contact your closest authorized after 30 seconds the system is TOHATSU outboard motor dealer. normal.
  • Page 122 WATER SEPARATOR stays activated, stop the engine. Tilt 1. Consult with an authorized up the outboard motor and check TOHATSU outboard motor dealer. the water intakes for 1. Check the water separator for obstructions. If there are no water contamination. If water is...

  • Page 123: Over-Rev Limiter

    There are also 2 small sacrificial damage. water. anodes in the water passages of the Correct or service as necessary, by engine block. contacting your authorized TOHATSU outboard motor dealer.

  • Page 124: Multiple Outboard Motors

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

  • Page 125: Stopping The Engine

    9. STOPPING THE ENGINE Emergency Engine Stop Pull the lanyard of the emergency stop switch and remove the (H1 type) (R1 type) EMERGENCY emergency stop switch clip from the EMERGENCY STOP SWITCH switch; this will stop the engine. STOP SWITCH It is a good idea to stop the engine with the emergency stop switch STOP...

  • Page 126: Normal Engine Stop

    STOPPING THE ENGINE 1. Turn the throttle grip to SLOW Normal Engine Stop (H type) NEUTRAL position and move the shift lever to (H1 type) NEUTRAL. THROTTLE GRIP After sailing with the throttle fully open, cool down the engine by SHIFT LEVER running it at the idle speed for a few...
  • Page 127 STOPPING THE ENGINE 2. Turn the engine switch key to the (H1 type) ENGINE SWITCH KEY OFF position to stop the engine. In the event that the engine does not stop when the engine switch is turned to OFF, push the emergency stop switch to stop the engine.

  • Page 128: R Type

    STOPPING THE ENGINE (R type) ENGINE SWITCH NEUTRAL NEUTRAL EMERGENCY STOP SWITCH (R1 type) NEUTRAL REMOTE CONTROL LEVER NEUTRAL ENGINE (R2 type) SWITCH KEY REMOTE CONTROL LEVER NEUTRAL (R1 type) (R2, R3 types) 2. Turn the engine switch key to the OFF position to stop the engine.

  • Page 129: Transporting

    10. TRANSPORTING Fuel Line Disconnection Transporting HOIST Before transporting the outboard HOOKS ENGINE HANGERS motor, disconnect and remove the fuel line. ENGINE HANGERS Gasoline is extremely flammable, and gasoline vapor can explode, causing serious injury or death. • Be careful not to spill fuel. Spilled fuel or fuel vapor may ignite.

  • Page 130: Trailering

    TRANSPORTING Trailering (H1 type) (H2 type) STEERING FRICTION ADJUSTING KNOB To increase friction OUTBOARD MOTOR STAND To decrease friction 3. Secure the outboard motor on an STEERING FRICTION outboard motor stand with the ADJUSTING KNOB mounting bolts and nuts. When trailering or transporting the 4.
  • Page 131 TRANSPORTING (R type) When trailering or transporting the boat with the outboard motor attached, it is recommended that the outboard motor remain in normal running position. Do not trailer or transport the boat with the outboard motor in the tilted position. The boat or outboard motor could be severely damaged if the outboard motor drops.

  • Page 132: Cleaning And Flushing

    11. CLEANING AND FLUSHING After each use in salt water or dirty 6. Turn on the fresh water supply and FLUSH PORT water, thoroughly clean and flush the flush the outboard motor for at CONNECTOR outboard motor with fresh water. least 10 minutes.

  • Page 133: Maintenance

    Shut off the engine before engine will overheat. performing any maintenance. If the • Use only TOHATSU Genuine engine must be run, make sure the parts or their equivalents for area is well ventilated. Never run maintenance or repair.

  • Page 134: Tool Kit And Emergency Parts

    MAINTENANCE Tool Kit and Emergency Parts The following tools and owner’s 8 × 10 mm WRENCH SPARK PLUG WRENCH manual are supplied with the outboard motor for maintenance, adjustment, and emergency repairs. PHILLIPS 18 × 19 mm WRENCH SCREWDRIVER <Spare Emergency Stop Switch Clip>...

  • Page 135: 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 136 (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 137: Engine Oil

    MAINTENANCE Engine Oil <Engine Oil Replacement> SEALING WASHER DRAIN BOLT Insufficient or contaminated engine OIL FILLER CAP (Replace) oil adversely affects the service life of the sliding and moving parts. GUIDE Oil change interval: 20 operating hours after the date of purchase or first month for initial replacement, then every 100 operating hours or 6 months.
  • Page 138 MAINTENANCE 6. Reinstall the oil filler cap securely. UPPER Do not overtighten (see page 65). LEVEL 7. Install and lock the engine cover MARK securely. LOWER LEVEL MARK Please dispose of used outboard motor oil in a manner that is compatible with the environment.

  • Page 139: Spark Plugs

    MAINTENANCE Spark Plugs <Standard Spark Plug> 6 × 20 mm FLANGE SH BOLT To ensure proper engine operation, Recommended spark plug: the spark plug must be properly ZFR6K-9E (NGK) gapped and free of deposits. Use only the recommended spark plugs or equivalent. Spark plugs The spark plug becomes very hot which have an improper heat range during operation and will remain...
  • Page 140 MAINTENANCE CONNECTOR BOX WRENCH New plug Plug needing replacement LOCK TAB IGNITION COIL 6. Inspect the spark plugs. (1) If the electrodes are heavily corroded or carbon-soiled, clean with a wire brush. (2) Replace a spark plug if the 6 × 25 mm FLANGE BOLT central electrode is worn.
  • Page 141 MAINTENANCE <Optional Parts: Iridium Spark SIDE ELECTRODE Plug> If installing new spark plugs, tighten 1/2 turn after the spark plugs seat to – 0.9 mm Recommended spark plug: compress the washers. – (0.031 0.035 in) IZFR6K-11E (NGK) If reinstalling used spark plugs, tighten 1/8 –...
  • Page 142 The cleaning of the iridium spark plugs consult with an authorized TOHATSU outboard motor dealer, unless the owner has the proper tools and is mechanically proficient. • Use only a ‘‘wire-type feeler gauge’’...

  • Page 143: Battery

    MAINTENANCE Battery • Keep flames and sparks away, UPPER LEVEL and do not smoke in the area. ANTIDOTE: If electrolyte gets Battery handling differs according into your eyes, flush thoroughly to the type of the battery and the with warm water for at least 15 instructions described below might minutes and call a physician not be applicable to the battery of...
  • Page 144 MAINTENANCE <Battery Cleaning> POSITIVE (+) 1. Disconnect the battery cable at the NEGATIVE (–) TERMINAL When disconnecting the battery battery negative (–) terminal, then TERMINAL cable, be sure to disconnect at the at the battery positive (+) terminal. battery negative (–) terminal first. 2.

  • Page 145: Lubrication

    MAINTENANCE Lubrication TILLER HANDLE (H type) THROTTLE ARM/ Wipe the outside of the engine with a LINK/PIVOT/PLATE THROTTLE ROD/LINK cloth dipped in clean oil. Apply marine anticorrosion grease to the following parts: Lubrication interval: 20 hours or a month after the date of purchase for initial lubrication, then TILT BRACKET every 100 hours or 6 months.
  • Page 146 MAINTENANCE SHIFT LINK BRACKET/ SHIFT PIVOT/SHIFT ARM/ LINK PIN/PIVOT PLATE/ TILT LOCK LEVER SLIDE PIVOT/ CLICK SPRING ROLLER (each side) TILT SHAFT THREAD UPPER CYLINDER PIN/ BUSHING MOUNT FRAME LOWER CYLINDER BUSHING/ COLLAR SWIVEL SHAFT...

  • Page 147: Water Separator

    Clean it or assembly. starting the engine. consult with an authorized TOHATSU outboard motor dealer for cleaning. During removal of the water separator assembly, take care not to damage the wire harness with...
  • Page 148 MAINTENANCE • Assemble so the flat part on the HARNESS WATER LEVEL SENSOR back of the suspension is parallel to CLIP 2 PIN CONNECTOR the water separator joint as shown O-RING CLIP C below. (Replace) SCREW (3) Assemble so the flat part of the suspension and the water separator joint are parallel to each other.
  • Page 149 MAINTENANCE 10. Reinstall the water separator in WATER LEVEL POSITIONING SENSOR 2 PIN the reverse order of removal. BAND CONNECTOR 11. Prime the engine using the HARNESS CLIP priming bulb (see page 76). Check for fuel leaks. Repair any fuel leaks if necessary. If the buzzer sounds, water or sediment accumulation is found to be caused by excessive water or...

  • Page 150: Fuel Filter

    MAINTENANCE Fuel Filter Inspection interval: Every 100 operating hours or 6 FUEL FILTER Gasoline is extremely flammable, months. (inside strainer cup) and gasoline vapor can explode, Replacement interval: causing serious injury or death. Do Every 400 operating hours or 2 years. not smoke or allow flames or sparks in your working area.
  • Page 151 MAINTENANCE <Inspection> <Replacement> FUEL FILTER (inside strainer cup) FUEL TUBES FUEL INTAKE SIDE JOINT EDGE AT THE BASE OF JOINT ALIGNMENT MARK ON THE FUEL FILTER FUEL FILTER BRACKET SUSPENSION (inside strainer cup) SUSPENSION STRAP SUSPENSION STRAP 1. Remove the engine cover (see page 1.

  • Page 152: Fuel Tank And Tank Filter (Equipped Type)

    MAINTENANCE 4. Prime the engine using the priming Fuel Tank and Tank Filter <Fuel Tank Cleaning> bulb (see page 76). Check for fuel (equipped type) leaks. Repair any fuel leaks if Gasoline is extremely flammable, necessary. and gasoline vapor can explode, causing serious injury or death.

  • Page 153: Emission Control System

    2. Clean the filter in nonflammable TOHATSU dealer: solvent. Inspect the fuel tank filter 1. Hard starting or stalling after and the connector gasket. Replace starting them if damaged.

  • Page 154: Fuse

    MAINTENANCE Fuse SPARE FUSES FUSE CASE LID FUSE PULLER (10 A, 15 A, 30 A) (supplied in the tool bag) BLOWN FUSE If the fuse blows, running the engine will not charge the battery. Before replacing the fuse, check the current ratings of the electrical accessories FUSES and ensure that there are no...

  • Page 155: Acg Fuse

    MAINTENANCE ACG Fuse <Replacement> A spare fuse is located in the reverse If the fuse is blown, check the “70 A” MARK SPARE FUSE (70 A) side of the fuse case lid and tightened cause, then replace the fuse with a with two 3 mm screws.

  • Page 156: Propeller

    • When replacing, remove the grooved side toward the gear case. emergency stop switch clip to • Use a genuine TOHATSU cotter prevent an accidental startup of pin and bend the pin ends as the engine.

  • Page 157: Inspect After Operating

    1/2 hour. 4. Remove the spark plugs (see pages • If the engine starts, and no If there is a TOHATSU outboard 137–140). Operate the starter to mechanical damage is evident, motor dealer nearby, take the expel water from the engine’s...

  • Page 158: Storage

    13. STORAGE For longer service life of the outboard • To slow deterioration, keep motor, have your outboard motor gasoline in a certified fuel serviced by your outboard motor container. dealer before storage. However, the • If long storage (more than 30 days) following procedures can be is foreseen, drain fuel tank and performed by you, the owner, with a...

  • Page 159: Vapor Separator Draining

    STORAGE Vapor Separator Draining 5. When the gasoline starts to flow INTAKE MANIFOLD DRAIN TUBE out of the drain tube, tilt up the outboard motor and hold it in the Gasoline is extremely flammable, position until the gasoline stops and gasoline vapor can explode, flowing.

  • Page 160: Battery Storage

    STORAGE Battery Storage • Keep flames and sparks away, (+) TERMINAL and do not smoke in the area. (–) TERMINAL ANTIDOTE: If electrolyte gets Battery handling differs according into your eyes, flush thoroughly to the type of the battery and the with warm water for at least 15 instructions described below might minutes and call a physician...

  • Page 161: Outboard Motor Position

    STORAGE Outboard Motor Position (Port side turned down as shown.) OUTBOARD MOTOR STAND 3. Fill the battery with distilled water Transport and store the outboard to the upper level line. Never motor either vertically, as shown Do not place the outboard motor on overfill the battery.

  • Page 162: Disposal

    14. DISPOSAL To protect the environment, do not dispose of this product, battery, engine oil, etc. carelessly by leaving them in the waste. Observe the local laws and regulations or consult your dealer for disposal.

  • Page 163: Troubleshooting

    • Engine speed cannot be increased by opening the throttle. • Engine will stop in 20 seconds after engine speed is limited. • Faulty water pump. Consult with an authorized TOHATSU outboard motor dealer. • Thermostat clogged. • Faulty thermostat. • Cooling water passage clogged.
  • Page 164 PGM-FI warning system comes on: PGM-FI warning system is faulty. Consult with an authorized • PGM-FI indicator comes on. TOHATSU outboard motor dealer. • PGM-FI warning buzzer sounds intermittently. ACG warning system comes on: Battery voltage is too high or low.

  • Page 165: Specifications

    Motor-mounted, remote control steering system Starter system Electric starter Ignition system Full transistor battery Lubrication Trochoid pump pressure lubrication system * Without battery cable, with propeller These TOHATSU outboards are power rated in accordance with ISO8665 (propeller shaft output).
  • Page 166 Motor-mounted, steering remote control system Starter system Electric starter Ignition system Full transistor battery Lubrication Trochoid pump pressure lubrication system * Without battery cable, with propeller These TOHATSU outboards are power rated in accordance with ISO8665 (propeller shaft output).
  • Page 167 Motor-mounted, remote control steering system Starter system Electric starter Ignition system Full transistor battery Lubrication Trochoid pump pressure lubrication system * Without battery cable, with propeller These TOHATSU outboards are power rated in accordance with ISO8665 (propeller shaft output).
  • Page 168 Motor-mounted, steering remote control system Starter system Electric starter Ignition system Full transistor battery Lubrication Trochoid pump pressure lubrication system * Without battery cable, with propeller These TOHATSU outboards are power rated in accordance with ISO8665 (propeller shaft output).
  • Page 169 SPECIFICATIONS Noise and Vibration MODEL BFT75A K1 BFT80A K1 CONTROL SYSTEM T (Tiller handle) R (Remote control) T (Tiller handle) R (Remote control) Sound pressure level at operator’s ears 82 dB (A) 76 dB (A) 83 dB (A) 81 dB (A) (2006/42/EC, ICOMIA 39-94) Uncertainty 2 dB (A)

  • Page 170: Ec Declaration Of Conformity'' Content Outline

    17. ‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE...
  • Page 171 ‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE...
  • Page 172 ‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE...
  • Page 173 ‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE...
  • Page 174 ‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE...

  • Page 175: Index

    18. INDEX Intake Port......... 47 Engine Oil Pressure Warning Cruising........102 System......117 ACG Fuse Replacement ....153 H type........102 Overheat Warning System..117 ACG Indicator/Buzzer R type........105 PGM-FI Warning System ..117 Function........44 Water Contamination Operation .........117 Warning System ....117 Anode Disposal ........
  • Page 176 INDEX Storage........156 Power Trim/Tilt Switch Tank cleaning ......150 Function ........39 Neutral Release Lever....34 Tank Filter .......151 Operation......102, 105 NMEA Interface coupler ....50 Fuse Replacement......152 Pre-operation Checks ....62 Battery........71 Engine Oil ......... 62 Oil Pressure Indicator/Buzzer Gasoline Containing Alcohol ..66 Fuel ...........
  • Page 177 INDEX Lever R type........126 TRL (Trolling) Control Switch Function......31, 32, 33 Storage ........156 Operation......... 107 Friction Adjustment....70 Submerged Outboard Motor Panel.......... 38 Servicing ......... 155 Remote Control Box ....38 Switch Panel ......... 16 Tiller Handle ......30 Safety Troubleshooting Carbon Monoxide Poisoning...
  • Page 178 MEMO...
  • Page 179 MEMO...
  • Page 180 OWN ER’ S M AN UAL BFT 75A BFT 80A BFT 90A BFT 100A 5-4, Azusawa 3-Chome, Itabashi- Ku Tokyo 174-0051 , Japan Tel: +81- 3 - 3966-3117 Fax:+81-3-3966-2951 www.tohatsu.com PRINTED IN JAPAN...

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