TOHATSU BFT200A Owner's Manual
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TOHATSU BFT200A Owner's Manual

Tohatsu outboard motor owner's manual
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OWNER'S MANUAL
BFT 200A
225A

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  • Page 1 OWNER’S MANUAL BFT 200A 225A...
  • 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 ............23 Emergency Stop Switch Clip and Emergency  SAFETY LABEL LOCATION ........ 9 Stop Switch ............23 CONTROLS AND FEATURES ........10 Gearshift/Throttle Control Lever ......24 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 ....55 Spark Plug Service ..........68 THE IMPORTANCE OF MAINTENANCE ..55 REFUELING ............71 MAINTENANCE SAFETY ........56 FUEL RECOMMENDATIONS ......72 TOOL KIT and OWNER’S MANUAL ....57 Fuel Filter Inspection and Replacement ....72 SPARE EMERGENCY STOP SWITCH CLIP..57 Water Separator Inspection and Service ....76 MAINTENANCE SCHEDULE ......
  • Page 8 CONTENTS TRANSPORTING ............89 TECHNICAL INFORMATION ........103 WITH OUTBOARD MOTOR  Serial Number Locations ........103 INSTALLED ON BOAT ........89 Battery ...............104 WITH OUTBOARD MOTOR  Emission Control System Information ....105 REMOVED FROM BOAT ......... 89 Star Label ............108 Specifications .............110 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 The TOHATSU BFT200A/225A protect people and property. Know Flotation Device) while on the outboard motor is designed for use how to stop the engine quickly in boat.

  • Page 10: Carbon Monoxide Hazard

    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 BFT200A BFT225A Type Transom Height 20.0 in (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 ENGINE COVER POWER TILT SWITCH TILT LOCK LEVER ENGINE COVER COOLING LATCH SYSTEM INDICATOR PRODUCT ENGINE OIL IDENTIFICATION DRAIN BOLT NUMBER STERN (inside cover) IDLE PORT BRACKET MANUAL ANODE RELIEF VALVE ANODE FLUSH PORT ANODE CONNECTOR ANTIVENTILATION...
  • Page 14 CONTROLS AND FEATURES OIL FILLER CAP SPARK PLUGS (under ignition coil) JUNCTION BOX (FUSES) SPARK PLUGS (under ignition coil) NMEA INTERFACE COUPLER WATER SEPARATOR OIL LEVEL DIPSTICK FUEL FILTER (inside strainer cup)
  • Page 15 CONTROLS AND FEATURES Remote Controls (optional equipment) (SIDE-MOUNT REMOTE CONTROL) (PANEL-MOUNT REMOTE CONTROL) GEARSHIFT/THROTTLE GEARSHIFT/THROTTLE CONTROL LEVER NEUTRAL RELEASE CONTROL LEVER LEVER NEUTRAL RELEASE LEVER POWER TRIM/TILT SWITCH INDICATORS (Oil pressure, Overheat, POWER TRIM/TILT Alternator, Malfunction) SWITCH SPARE SWITCH CLIP FAST IDLE LEVER FAST IDLE BUTTON...
  • Page 16 CONTROLS AND FEATURES (SINGLE TOP-MOUNT REMOTE CONTROL) (DUAL TOP-MOUNT REMOTE CONTROL) GEARSHIFT/THROTTLE GEARSHIFT/THROTTLE CONTROL LEVER CONTROL LEVERS 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) (for TOP-MOUNT SINGLE type) INDICATORS BUZZER...
  • Page 17 CONTROLS AND FEATURES Tachometer  (optional equipment) Trim Meter  (optional equipment)

  • Page 18: Controls

    CONTROLS AND FEATURES CONTROLS Turning the ignition switch key to the The engine will not start unless the START position starts the engine. gearshift/throttle control lever is in Side-Mount Type The key automatically returns to the the N (neutral) position (p. 38) and ON position when released from the the emergency stop switch clip is in Ignition Switch...

  • Page 19: Emergency Stop Switch Clip And Emergency Stop Switch

    CONTROLS AND FEATURES  Emergency Stop Switch Clip and The emergency stop switch clip must Gearshift/Throttle Control be inserted in the emergency stop Emergency Stop Switch Lever switch in order for the engine to start GEARSHIFT/THROTTLE EMERGENCY and run. The emergency stop switch CONTROL LEVER STOP SWITCH lanyard must be attached securely to...
  • Page 20 CONTROLS AND FEATURES Moving the control lever 30° from N (neutral) selects the gear, and further movement increases engine speed. The control lever automatically locks itself in the N (neutral) position. To N (NEUTRAL) move the lever out of the N (neutral) 30°...

  • Page 21: Fast Idle Lever

    CONTROLS AND FEATURES Fast Idle Lever Panel-Mount Type N (NEUTRAL) MAXIMUM Ignition Switch FAST IDLE FAST IDLE LEVER START LOWEST POSITION IGNITION SWITCH FAST IDLE LEVER The fast idle lever allows you to Use the fast idle lever to accelerate The ignition switch controls the increase the idle speed only when the engine warm-up after starting the...

  • Page 22: Emergency Stop Switch Clip And Emergency Stop Switch

    CONTROLS AND FEATURES Turning the ignition switch key to the Emergency Stop Switch Clip and The emergency stop switch clip must START position starts the engine. be inserted in the emergency stop Emergency Stop Switch The key automatically returns to the switch in order for the engine to start EMERGENCY ON position when released from the...

  • Page 23: Gearshift/Throttle Control Lever

    CONTROLS AND FEATURES  Gearshift/Throttle Control N (NEUTRAL) Lever 35° 35° R (REVERSE) F (FORWARD) GEARSHIFT/THROTTLE CONTROL LEVER SHIFT SHIFT MINIMUM MINIMUM THROTTLE OPENING THROTTLE OPENING MAXIMUM NEUTRAL RELEASE LEVER MAXIMUM The gearshift/throttle control lever controls engine speed and selects F GEARSHIFT/THROTTLE (forward), N (neutral), or R (reverse) CONTROL LEVER...

  • Page 24: 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 25: Top-Mount Type

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

  • Page 26: Gearshift/Throttle Control Lever

    CONTROLS AND FEATURES  Gearshift/Throttle Control N (NEUTRAL) Lever 35° 35° SINGLE TYPE R (REVERSE) F (FORWARD) SHIFT SHIFT GEARSHIFT/ THROTTLE CONTROL THROTTLE OPENING LEVER MINIMUM MINIMUM THROTTLE OPENING MAXIMUM DUAL TYPE MAXIMUM GEARSHIFT/THROTTLE CONTROL LEVER Moving the control lever 35° from N Less friction allows easier control GEARSHIFT/THROTTLE (neutral) selects the gear, and further...

  • 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) R (REVERSE) push in the fast idle button. 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 Power Trim/Tilt Switch switch with UP and DN (down) positions for changing the angle of (top-mount type) (side-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 TILT LOCK LEVER POWER TILT SWITCH FREE LOCK POWER MANUAL (To fix) (To release) 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: Engine Cover Latch

    CONTROLS AND FEATURES Engine Cover Latch Trim Tab INSTRUMENTS TIGHTENING Trim Meter  BOLT (optional equipment) UNLOCK ENGINE COVER LATCH TRIM TAB The engine cover latch fastens the The trim tab compensates for ‘‘torque TRIM METER engine cover to the outboard motor. steer,’’...

  • Page 31: Tachometer (Optional Equipment)

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

  • Page 32: Indicators

    (RED) test, it cannot alert you if that system (RED) develops a problem. Have your TOHATSU dealer check for burned- out bulbs or other problems. Under BUZZER BUZZER normal conditions, the following occur when the ignition switch is...

  • 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 If oil pressure becomes low, the INDICATOR INDICATOR 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 Water Separator Buzzer sounds a steady tone as the engine speed is reduced to 1,800 rpm. If the The water separator buzzer sounds a condition persists for another 20 rapid, repeating signal when water...

  • Page 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. ANODE (each side) The rev limiter may be activated during operation, limiting engine speed, if the outboard motor is trimmed or tilted up excessively, or...

  • Page 36: Before Operation

    Be sure to take care of any problem you find, or have your authorized Familiarize yourself with all laws and TOHATSU dealer correct it, before regulations relating to boating and the you operate the outboard motor. use of outboard motors.

  • Page 37: Maintenance Inspection

    BEFORE OPERATION Safety Inspection • Check the emergency stop switch • Check the fuel level in the fuel tank for proper operation. Start the (p. 72). • Before each use, look around and engine (p. 17, 20 or 23). Make sure underneath the engine for signs of •...

  • Page 38: Operation

    OPERATION SAFE OPERATING BREAK-IN PROCEDURE Next 60 minutes: Run the engine up to a maximum of PRECAUTIONS Break-in period: 10 hours 4,000 to 5,000 rpm, which is about To safely realize the full potential of 50% to 80% of maximum throttle Proper break-in operation allows the 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 on an infrequent or intermittent basis, OUTLET END (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 Flotation Device). N (NEUTRAL) The engine will not start or run Control unless the emergency stop switch Side-Mount Type ....... P. 38 clip is in the emergency stop Panel-Mount Type ..... P. 41 switch. Top-Mount Type ......P. 43 CONTROL The emergency stop switch clip Side-Mount Type...
  • Page 41 OPERATION If the engine fails to start within 5 seconds, release the key and wait at START 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 overheat indicator (p. 31), and MAXIMUM FAST IDLE warmed up before raising the cooling system indicator (p. 32). FAST IDLE 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) clip is in the emergency stop EMERGENCY switch. 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 CONTROL from the controls while operating...
  • Page 44 OPERATION If the engine fails to start within 5 N (NEUTRAL) START seconds, release the key and wait at least 10 seconds before operating the starter again. • Using the electric starter for more than 5 seconds at a time will CONTROL overheat the starter motor and can LEVER...

  • 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 warmed up before raising the SWITCH 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 unless N (NEUTRAL) the emergency stop switch clip is in START 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 Emergency Engine Stopping overheat indicator (p. 31), and out of the emergency stop switch by cooling system indicator (p.

  • Page 49: Normal Engine Stopping

    OPERATION Normal Engine Stopping Top-Mount Type Side-Mount Type Side-Mount Type N (NEUTRAL) N (NEUTRAL) CONTROL LEVER CONTROL LEVER IGNITION SWITCH KEY 1. Move the control lever(s) to the N Panel-Mount/Top-Mount Types Panel-Mount Type (neutral) position. N (NEUTRAL) After cruising at full throttle, cool down the engine by idling for a few minutes before stopping the engine.

  • Page 50: Gearshift And  Throttle Operation

    OPERATION GEARSHIFT AND  2. Turn the ignition switch key to the Panel-Mount Type OFF position to stop the engine.  THROTTLE OPERATION N (NEUTRAL) In the event that the engine does F (FORWARD) R (REVERSE) not stop when the ignition switch Side-Mount Type key is turned to the OFF position, CONTROL LEVER...

  • Page 51: Cruising

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

  • Page 52: Steering

    OPERATION STEERING CRUISING Trim Use the power trim/tilt switch to trim Steer the boat in the same manner as Engine Speed the outboard motor for the best an automobile. For best fuel economy, limit the performance and stability. throttle opening to 80%. Use the You can use the power trim/tilt switch throttle friction control (p.
  • Page 53 OPERATION Under normal conditions, the boat Side-Mount Type Top-Mount Type will perform best when the (single type) antiventilation plate is level with the POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH water surface. When cruising into a high wind, trim the outboard motor down slightly to level the boat and improve stability.

  • Page 54: Shallow Water Operation

    OPERATION SHALLOW WATER  If steering effort is not equal in both OUTBOARD OUTBOARD directions, adjust the trim tab to MOTOR OPERATION MOTOR TRIMMED TOO TRIMMED TOO compensate for ‘‘torque steer,’’ which HIGH is the reaction of the outboard motor When operating in shallow water, use to propeller rotation.

  • Page 55: Mooring, Beaching, Launching

    OPERATION MOORING, BEACHING, TRIM RODS 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. Stop the engine and disconnect the POWER TILT fuel hose from the outboard motor SWITCH before tilting the outboard motor.

  • Page 56: Multiple Outboard Motors

    OPERATION For manual tilting, use a screwdriver MULTIPLE OUTBOARD to turn the valve counterclockwise 1 MOTORS Do not attempt to use the power tilt or 2 turns. Close the valve firmly switch to tilt the outboard motor after positioning the engine. On boats equipped with more than down while the tilt lock lever is in the one outboard motor, all motors...

  • Page 57: 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 58: 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 59: Tool Kit And Owner's Manual

    SERVICING YOUR OUTBOARD MOTOR TOOL KIT and OWNER’S MANUAL SPARE EMERGENCY STOP SWITCH CLIP (Tool kit does not come with Counter Rotation Types) 10 mm BOX WRENCH 6 mm HEX. WRENCH FLAT SCREWDRIVER 19 mm EYE WRENCH Always carry a spare emergency stop switch clip onboard.

  • Page 60: Maintenance Schedule

    (1) (1) Lubricate more frequently when used in salt water. (2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the TOHATSU Service Manual for service procedures.
  • Page 61 Check-adjust o (2) (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: Trim Tab Adjustment

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

  • Page 63: Manual Relief Valve

    SERVICING YOUR OUTBOARD MOTOR MANUAL RELIEF VALVE ENGINE COVER REMOVAL Installation AND INSTALLATION MANUAL RELIEF VALVE COVER LOCKS COVER SIDE Removal POWER MANUAL (To fix) (To release) The outboard motor can be tilted manually after opening the manual ENGINE COVER LATCH relief valve.

  • Page 64: Engine Oil Level Check

    Do not overtighten. then remove it and check the oil may be necessary. Please see the 6. Install and lock the engine cover  level shown on the dipstick. service manual or your TOHATSU (p. 61). dealer for adjustment.
  • Page 65 SERVICING YOUR OUTBOARD MOTOR When you check the oil level with the dipstick, you might notice the engine oil 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 66: Engine Oil Change

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Change SEALING WASHER Improper disposal of engine oil can An engine oil evacuation/filling  be harmful to the environment. device may be used to remove/add If you change your own oil, please the engine oil. ...

  • Page 67: Oil Filter Change

    OIL FILTER Oil Filter Change  Use only a TOHATSU Genuine oil 1. Drain the engine oil, and reinstall  filter or a filter of equivalent the drain bolt, washer, and drain quality specified for your model.

  • Page 68: Engine Oil Recommendations

    SERVICING YOUR OUTBOARD MOTOR 7. Start the engine and check for Engine Oil Recommendations leaks. Oil is a major factor affecting performance and service life. Use  Running the engine without water 4-stroke detergent oil. can cause serious engine damage. Use 4-stroke high detergent, premium If you are changing the oil filter quality motor oil certified to meet or...

  • Page 69: Lubrication Points

    SERVICING YOUR OUTBOARD MOTOR Lubrication Points Apply TOHATSU Marine grease to the parts shown below: Lubrication interval: ENGINE After the first 20 hours or 1 month, then every 100 COVER THROTTLE THROTTLE ARM/ LATCH/LOCK hours or 6 months (refer to the MAINTENANCE...

  • Page 70: Spark Plug Service

    SERVICING YOUR OUTBOARD MOTOR • Do not adjust the spark plug gap.  Spark Plug Service 3. Remove the 6 × 22 mm flange bolt If the gap is out of specification, and remove the plug maintenance RECOMMENDED SPARK PLUG: replace the spark plug with a new cover.
  • Page 71 SERVICING YOUR OUTBOARD MOTOR LOCK TAB 0.039 – 0.051 in SPARK PLUG (1.0 – 1.3 mm) WRENCH IGNITION COIL SEALING WASHER INSULATOR 19 mm EYE BOLT WRENCH WIRE CONNECTOR 4. Disconnect the wire connector 6. Remove the spark plugs with a 7.
  • Page 72 SERVICING YOUR OUTBOARD MOTOR 9. Install the spark plugs carefully, by 11. Install the ignition coil. Reinstall hand, to avoid cross-threading. the bolt. 10. After each spark plug seats, 12. Push the wire connector onto the tighten with the spark plug ignition coil.

  • Page 73: Refueling

    SERVICING YOUR OUTBOARD MOTOR REFUELING Never refill the fuel tank inside a building where gasoline fumes may Check the fuel level and refill if reach flames or sparks. Keep gasoline necessary. Do not fill the fuel tank away from appliance pilot lights, above the UPPER LIMIT.

  • Page 74: Fuel Recommendations

    SERVICING YOUR OUTBOARD MOTOR FUEL RECOMMENDATIONS Engine damage or performance Fuel Filter Inspection and problems that result from using a fuel Replacement Use unleaded gasoline with a pump with percentages of ethanol or octane rating of 86 or higher. methanol greater than shown above The fuel filter (inside the strainer cup) are not covered under warranty.
  • Page 75 SERVICING YOUR OUTBOARD MOTOR <Inspection> If the fuel filter is clogged, refer to fuel filter replacement procedure  ENGINE COVER LATCH (p. 74) to remove the filter and clean Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
  • Page 76 1. Remove the strainer assembly. If it is difficult to remove the strainer DRAIN SCREW assembly by yourself, consult an authorized TOHATSU dealer. 1. Remove the drain hose from the Remove the suspension strap from clamp on the cylinder head cover...
  • Page 77 SERVICING YOUR OUTBOARD MOTOR 5. Thoroughly clean the strainer cup, 10. Reinstall the fuel filter assembly STRAINER BODY and install a new fuel filter. to the fuel filter bracket. O-RINGS FUEL HOSES 6. Reassemble the strainer body and 11. Prime the engine using the  (Replace) the cup using new O-rings....

  • Page 78: Water Separator Inspection And Service

    3. Remove the cover under the idle starting. Check the water separator port. periodically. Clean it or consult with 4. Remove the left under cover by an authorized TOHATSU dealer for removing the 6 × 17 mm special cleaning. bolts.
  • Page 79 SERVICING YOUR OUTBOARD MOTOR 2 PIN COUPLER (BLUE) STAY WATER SEPARATOR CUP O-RING (Replace) LOCK TAB SCREWS LOCK TAB 2 PIN HOSE CLIPS COUPLER (BLUE) FUEL HOSES DRAIN HOSE HOSE CLIP DRAIN VALVE SUSPENSION SUSPENSION STRAP STRAP WATER SEPARATOR BRACKET WATER SEPARATOR STAY 11.
  • Page 80 SERVICING YOUR OUTBOARD MOTOR If the buzzer sounds or water or PROTRUDED PORTION WATER SEPARATOR sediment accumulation is found in the SUSPENSION STRAP fuel filter, inspect the fuel tank. Clean the fuel tank and tank filter if necessary. It may be necessary to drain the fuel tank completely and refill with fresh gasoline.

  • Page 81: Anode Replacement

    SERVICING YOUR OUTBOARD MOTOR Anode Replacement Painting or coating the anodes will def eat their purpose and will lead to rust and corrosion damage to the outboard motor. The anodes must be exposed to the water in order to protect the outboard motor. ANODE ...

  • Page 82: Propeller Replacement

    RPM. with a new one. 5. Lightly tighten the castle nut by Removal • Use a TOHATSU Genuine hand or wrench until the propeller stainless steel cotter pin or has no free play. 1. Remove the cotter pin, unscrew the...

  • Page 83: Inspect After Operating

    SERVICING YOUR OUTBOARD MOTOR Note that the castle nut wrench is not included with the tool set that comes with Inspect After Operating the outboard motor. Contact your authorized TOHATSU dealer for additional 1. Stop the engine and remove the tool information.

  • Page 84: Cleaning And Flushing

    CLEANING AND FLUSHING Cleaning and Flushing Cleaning 1. Disconnect the fuel hose connector from the outboard motor. After each use in salt water or dirty Wash the outside of the outboard 2. Tilt down the outboard motor. water, thoroughly clean and flush the motor with clean, fresh water, and outboard motor with fresh water.
  • Page 85 CLEANING AND FLUSHING FLUSH PORT CONNECTOR GARDEN HOSE EXHAUST PORT 4. Screw the flush port connector onto 5. Turn on the fresh water supply and the garden hose. flush the outboard motor for at least 10 minutes. 6. After flushing, disconnect the  garden hose and reconnect the flush port connector.

  • Page 86: Storage

    STORAGE Fuel 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 promotes fuel deterioration. Very  operate your outboard, fuel warm storage temperatures accelerate formulations may deteriorate and fuel deterioration.
  • Page 87 STORAGE Draining the Fuel System 3. Loosen the vapor separator drain VAPOR DRAIN CLIP screw by using a commercially You can avoid fuel deterioration SEPARATOR HOSE available flat tip screwdriver. problems by draining the fuel tank and vapor separator. Drain the fuel into an approved fuel Gasoline is highly flammable and container.

  • Page 88: Engine Oil

    STORAGE 4. With the outboard motor turned to Engine Oil the starboard side, tilt the outboard 1. Change the engine oil and the oil motor up. Keep the end of the drain filter (p. 64 – 66). hose below the level of the vapor separator drain screw, and watch 2.

  • Page 89: Hoisting The Outboard Motor

    STORAGE HOISTING THE OUTBOARD STORAGE PRECAUTIONS MOTOR HOIST HOOKS Select a well-ventilated storage area. If possible, avoid storage areas with ENGINE COVER high humidity. LATCH 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 PROTECTOR MOTOR STAND 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

    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 93 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction Out of fuel. Refuel (p. 71). Fuel hose not primed. Squeeze priming bulb (p. 37). Fuel filter or fuel tank filter clogged. Replace fuel filters (p. 72). Drain fuel tank and vapor separator (p. 85 – 86).  Bad fuel;...
  • Page 94 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 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 clogged. Replace fuel filters (p.

  • Page 96: Engine Overheats

    Correction Spark plugs faulty, fouled, or improperly gapped. Replace spark plugs (p. 68). Fuel system malfunction, fuel pump failure, ignition Take outboard motor to an authorized TOHATSU dealer, malfunction, etc. or refer to the service manual. ENGINE OVERHEATS Possible Cause Correction Water intake screens clogged.

  • Page 97: Fuses

    TAKING CARE OF UNEXPECTED PROBLEMS FUSES Fuse Replacement SPARE FUSES MAIN FUSES (10 A, 15 A, 30 A) (10 A, 15 A, 30 A) Electric Starter Will Not  Operate Disconnect the battery cable at the JUNCTION battery negative (–) terminal before COVER The 10 A, 15 A, and 30 A main fuses replacing the f use.
  • Page 98 TAKING CARE OF UNEXPECTED PROBLEMS 5. Pull the old fuse out of the clip with the fuse puller supplied in the  Fuse No. Amps. Component (s) or Circuit (s) Protected junction box. 150 A ACG, Battery 30 A No. 9, 10, 11 Fuse 6.
  • Page 99 ACG FUSE: 150 A If fuses continue to blow, take the outboard motor to an authorized 7. After finishing replacement, close TOHATSU dealer for inspection and the junction box cover. PAWLS service, or refer to the service SPARE FUSE (150 A) manual.

  • Page 100: Oil Pressure Indicator Turns Off And Engine Speed Is Limited

    TAKING CARE OF UNEXPECTED PROBLEMS A spare fuse is located in the junction OIL PRESSURE INDICATOR If oil pressure becomes low, the oil box. pressure indicator will turn off, and TURNS OFF AND ENGINE Push two pawls, then pull out the the engine protection system limits SPEED IS LIMITED spare fuse.

  • Page 101: Overheat Indicator Comes On And Engine Speed Is Limited

    OVERHEAT engine will respond normally to INDICATOR throttle control lever operation. If the engine protection system remains activated after 30 seconds, (RED) return to the nearest boat landing, and have the outboard motor inspected by an authorized TOHATSU dealer. BUZZER...

  • Page 102: Water Separator Buzzer Sounds

    (a rapid, repeating signal): indicator. authorized TOHATSU dealer. Check the water separator for water If water is flowing from the cooling contamination. If water is present, system indicator, continue idling for stop the engine, and clean the water 30 seconds.

  • Page 103: Submerged Outboard Motor

    If there is a TOHATSU dealership nearby, take the outboard motor to the 4. Remove the spark plugs (p. 68). dealer immediately. If you are far...
  • Page 104 2 inches (5 cm) engine. above the antiventilation plate to avoid overheating and water pump damage. 7. As soon as possible, take the  outboard motor to an authorized TOHATSU dealer for inspection and service.

  • Page 105: Technical Information

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

  • Page 106: Battery

    TECHNICAL INFORMATION Battery • Battery cable extension: Extending the original battery cable will For complete information, refer to the cause the battery voltage to drop battery manufacturer’s instructions. due to the increased length of the cable and number of connections. Minimum Requirements This voltage drop may cause the buzzer to sound momentarily when...

  • Page 107: Emission Control System Information

    Control, and Fuel Control. The to keep the emissions from your photochemical smog when subjected Engine Control Module (ECM) uses TOHATSU engine within the to sunlight. Carbon monoxide does various sensors to determine how emission standards. not react in the same way, but it is much air is going into the engine.
  • Page 108 Problems That May Affect Replacement Parts Emissions The emission control systems on your TOHATSU engine were designed, If you are aware of any of the Tampering is a violation of Federal built, and certified to conform with and California law.
  • Page 109 TECHNICAL INFORMATION Maintenance Follow the MAINTENANCE SCHEDULE on p. 58 – 59. Remember that this schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load operation, or use in unusual conditions, will require more frequent service.

  • Page 110: 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 111 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 112: Specifications

    Stageless (68°) transom angle is 12°) Trim angle (when – 4° to 16° transom angle is 12°) * Without battery cable, with propeller This TOHATSU outboard motor is power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.
  • Page 113 Stageless (68°) transom angle is 12°) Trim angle (when – 4° to 16° transom angle is 12°) * Without battery cable, with propeller This TOHATSU outboard motor is power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.
  • Page 114 TECHNICAL INFORMATION BFT200A/BFT225A Tune up Spark plug gap 0.039 – 0.051 in (1.0 – 1.3 mm) See page 69 Idle speed 650 ± 50 rpm See service manual Valve clearance (cold) Intake: 0.22 ± 0.02 mm See service manual Exhaust: 0.30 ± 0.02 mm...

  • Page 115: 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 116 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 117 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 118 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 119 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 120: Index

    INDEX Alternator (ACG) Indicator ..........30 Electric Starter Will Not Operate ........95 Anodes................33 Emergency Stop Switch Clip and Emergency Replacement ...............79 Stop Switch ARE YOU READY TO GET UNDERWAY?....34 Panel-Mount Type............20 Side-Mount Type ............17 Battery ................104 Top-Mount Type ............23 Will Not Charge............95 Emission Control System Information......
  • Page 121 INDEX Fast Idle Button Ignition Switch Panel-Mount Type ............22 Panel-Mount Type............19 Top-Mount Type............25 Side-Mount Type ............16 Fast Idle Lever..............19 Top-Mount Type ............23 Fuel IMPORTANT SAFETY INFORMATION ...... 7 Filter Inspection and Replacement ......72 INDICATORS..............30 PRIMING ..............37 INFREQUENT OR OCCASIONAL USE.....
  • Page 122 INDEX Oil Pressure Indicator .............31 SAFE OPERATING PRECAUTIONS ......36 OIL PRESSURE INDICATOR TURNS OFF AND SAFETY LABEL LOCATION........9 ENGINE SPEED IS LIMITED........98 Serial Number Locations ..........103 OPERATION..............36 SERVICING YOUR OUTBOARD MOTOR....55 OTHER FEATURES ............32 SHALLOW WATER OPERATION ......52 OUTBOARD MOTOR SAFETY ........7 SPARE EMERGENCY STOP SWITCH CLIP.....
  • Page 123 INDEX Tachometer (optional equipment)........29 TAKING CARE OF UNEXPECTED PROBLEMS ..90 TECHNICAL INFORMATION........103 THE IMPORTANCE OF MAINTENANCE ....55 Tilt Lock Lever ...............27 TOOL KIT and OWNER’S MANUAL ......57 TRANSPORTING ............89 WITH OUTBOARD MOTOR INSTALLED ON BOAT...............89 WITH OUTBOARD MOTOR REMOVED FROM BOAT ............89 Trim Meter (optional equipment) ........28 Trim Tab .................28 TRIM TAB ADJUSTMENT ..........60...
  • Page 124 MEMO...
  • Page 125 MEMO...
  • Page 126 MEMO...
  • Page 127 © 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 128 BFT 200A 225A 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 31ZY2T00 Printed in Japan 00X31-ZY2-T000...

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