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WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS PROCEDURE IS NOT FOLLOWED. PRE-DELIVERY CHECK Be sure that the product has been checked by an authorized TOHATSU dealer before you take delivery. Limited Warranty Please refer to the TOHATSU outboard motor Limited warranty provided to you with this product, the terms and conditions of which, as amended from time to time, are incorporated by reference into the manual.
Serial Number : To You, Our Customer Thank you for selecting a TOHATSU outboard motor. You are now the proud owner of an excellent outboard motor that will service you for many years to come. This manual should be read in its entirety and the inspection and maintenance procedures described later in this manual should be followed carefully.
INDEX GENERAL SAFETY INFORMATION 1. SPECIFICATIONS 2. NAMES OF PARTS 3. INSTALLATION 4.PRE-OPERATING PREPARATIONS 5.ENGINE OPERATION 6.REMOVING AND CARRYING THE OUTBOARD MOTOR 7.TRAILERING 8.WARNING SYSTEM 9.ADJUSTMENT 10.INSPECTION AND MAINTENANCE 11.TROUBLESHOOTING 12.TOOL KIT AND SPARE PARTS 13.OPTIONAL ACCESSORIES 14.PROPELLER TABLE...
GENERAL SAFETY INFORMATION NOTICE : DANGER/WARNING/CAUTION/Note Before installing, operating or otherwise handling your outboard motor, be sure to thoroughly read and understand this Owner's Manual and carefully follow all of the instructions. Of particular importance is information preceded by the words "DANGER,"...
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SAFE OPERATION OF BOAT As the operator/driver of the boat, you are responsible for the safety of those aboard and those in other boat around yours, and for following local boating regulations. You should be thoroughly knowledgeable on how to correctly operate the boat, outboard motor, and accessories.
NAMES OF PARTS NAMES OF PARTS 60C EFO, 70C EFO (MFG) Tilt Handle Clamp Bracket Battery Cords Top Cowl Thrust Rod Starter handle Hook Lever Clamp Screw Gas Assistant Water Check Port Throttle Grip Reverse Lock Lever Shift Lever Anti-ventilation Plate Stop Switch Trim Tab Main Switch...
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NAMES OF PARTS 60C EFTO, 70C EFTO Tilt Handle Clamp Bracket Cord Ass'y C Top Cowl Thrust Rod Battery Cords Hook Lever Power Trim & Tilt Fillter Lid Water Check Port Anode Power Trim & Tilt Switch A Reverse Lock Lever Throttle Grip Power Trim &...
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NAMES OF PARTS 60C EPO, 70C EPO Tilt Handle Clamp Bracket Top Cowl Thrust Rod Hook Lever Clamp Screw Water Check Port Fuel Connector Reverse Lock Lever Battery Cords Anti-ventilation Plate Fillter Lid Trim Tab Propeller Water Inlet...
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NAMES OF PARTS 60C EPTO, 70C EPTO for P Type for P Type for T Type Tilt Handle Thrust Rod Neutral Warm-up Lever Top Cowl Power Trim & Tilt Main Switch Hook Lever Anode Harness B Water Check Port Fuel Connector Stop Switch Reverse Lock Lever Battery Cords...
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NAMES OF PARTS 90A2, 120A2 (115A2), 140A2 EPTO Top Cowl Remote Control Box Filler Lid Hook Lever Remote Control Lever Multi-purpose Meter Water Check Port Power Trim & Tilt Switch (120A2, 140A2) Tilt Stopper Neutral Warm-up Lever ● Tachometer Gear Case Main Switch ●...
INSTALLATION 1. Mounting the outboard motor on boat ■ Twin-engine Installation W h e n i n s t a l l i n g t w o o u t b o a r d engines, be sure to keep an interval �������...
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INSTALLATION ■ Transom Height ■ Attaching the Clamp Bracket Install the engine with the Anti- After positioning the Clamp Bracket, ventilation Plate at a level 10~30mm fix it with clamp screw fitted on the (0.4~1.2in.) below the bottom of the type “without Shock Absorber”...
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INSTALLATION ■ Manual titlting type ■ Power trim and tilt type, gas assistant type ������ ������ ������ ������ ������ ������ ������ ������ ��������� ��������� ��������� ��������� �������������� ��� ��� �������������� �������������� �������������� ������� ����������� ������� ������ ������� �� ������� �� �����������...
INSTALLATION A f t e r i n s t a l l i n g t h e o u t b o a r d , 2. Propeller selection make sure that its steering and tilt movements are not obstructed A propeller must be selected so that by any part of the boat.
Cable (engine side) and the Cord Assembly (Wiring Harness) : ������� 60C/70C When using other than Tohatsu’s 1 Detach the bracket and set cord genuine remote control box, DO NOT assembly B and the remote control select the one without neutral safety switch that prevents in-gear start.
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INSTALLATION 2 Detach the throttle and shit cable to the first point at which it engages joints by removing the R-pins. (approx. 32). The cable which moves first when the lever is turned should be the shift cable. Check that the shift lever is in “NEUTRAL”...
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INSTALLATION 90A2 5 Adjust the cable joints until the hole of each is aligned with the advancer 1 Detach the upper engine cover. arm pin. After adjustment, lock each cable joint with the nut and secure it with the R-pin. 2 Detach the upper grommet cord clamp bolt.
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INSTALLATION 120A2, 140A2 4 Move the remote control lever to the “FORWARD” “NEUTRAL” and 1 Detach the upper engine cover. “REVERSE” positions to confirm that the shift is working properly, then set the lever to “NEUTRAL”. 2 Detach the upper grommet cord clamp bolt.
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INSTALLATION ������� Be careful not to loop the remote control cables to a diameter of 406 mm (16 inches) or less. 5 Double-check that the remote control cables (i.e., the throttle cable and shift cable) have been connected correctly. Move the remote control lever forward to the first point at which it engages (approx.
INSTALLATION 3 Set the tachometer selector knob to 4. Installing the meters “6P”. Selector 60C/70C/90A2 1 Install the meters securely in the da shboard where they can be easily read and are not exposed to water splashes. The recommended dashboard thickness is 2 – 11 mm (0.08 –...
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INSTALLATION Connection of Leads Tachometer: EPO EPTO Trim meter: EPTO Trim sender: EPTO Tachometer Lower Trim meter oil level caution lamp Meter lamp switch (optional) Meter wire Cord ass’y B Color Codes B: Black R: red L: Blue Sb: sky blue Lg: Light green W: white O: Orange...
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INSTALLATION 120A2, 140A2 3 Set the selector knob at the back of the meter to “12P”. 1 Install the multi-purpose meter securely in the dashboard where the instrument can be easily read and is not exposed to water splashes. The recommended dashboard thickness Selector is 2 –...
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INSTALLATION Meter harness Meter lead wire B Meter lamp switch (optional) Cable harness B Color Codes B: Black P: Pink G: Green R: Red L: Blue Sb: Sky blue Lg: Light green W: White O: Orange Y: Yellow Notes 1. Oblique lines (Z) depict cords with a color stripe.
INSTALLATION 1 Connect the Drag Link rod to the tip 5. Installing the drag link assembly of the steering cable. Tighten the rod using the nut with (Standard accessories for EPTO and nylon-stopper, making sure the rod EPO types) can swing freely. Incorrect or unstable installation of 2 Connect the other tip of the rod to the Drag Link assembly can result...
INSTALLATION 6. Installing the battery ������� Battery generates explosive Note hydrogen gas. Be sure to: • Charge the battery in a well- Minimum recommended battery : ventilated place. 12V, 70AH (800 Marine Cranking • Place the battery away from any Amps (MCA) or 650 Cold Cranking source of fire, sparks and open Amps (CCA)) Specifications and...
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INSTALLATION 1 Keep the battery in the designated battery space of the boat. Secure it tightly and make sure it cannot be reached by water. 2 Co nnect the po sitiv e (+) co rd connector (with red tube) to the positive (+) terminal first.
INSTALLATION 7. Installing the Steering Handle and Main Switch Box 3 Install the main switch box at a place where the driver is able to operate MFG/EFO/EFTO types the switches easily. And confirm no 1 Connect the throttle cable coming obstacles at the cord passage before from the motor to the handle, then fix installing the main switch box.
PRE-OPERATING PREPARATIONS ������ 1. Recommended gasoline types Consult an authorized dealer for details ������� on handling of gasoline, if necessary. Gasoline and its vapors are very Use of low-quality gasoline results in flammable and can be explosive. a short engine life as well as starting difficulties and other engine problems.
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������� TOHATSU recommend the use of Do not fill the fuel tank over capacity. The gasoline if its ethanol content is less rise of gasoline temperature may cause than 10% or methanol content is less gasoline to expand which, if overfilled, may...
PRE-OPERATING PREPARATIONS 2. Recommended engine oil Note U s e a g e n u i n e e n g i n e o i l o r Use of engine oils that do not meet recommended one. Refer to your these requirements will result in reduced engine life, and other engine problems.
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PRE-OPERATING PREPARATIONS Engine oil – gasoline mixing procedure For quantities of engine oil and gasoline to be pre-mixed, refer to table in previous page. ������� ● Do not use other than two stroke engine oil with specified grade, or the engine may be damaged. ●...
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PRE-OPERATING PREPARATIONS ������� Auto-mixing Model (EFO, EFTO, EPO, EPTO) 1. In the unlikely event that gasoline by mistake is filled into the oil ������� tank, drain the oil tank completely, and consult an authorized service During break-in of the engine, engine shop for advice.
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PRE-OPERATING PREPARATIONS ■ 90A/120A2/140A2 Air vent screw To check valve From Vinyl pipe oil filter Vinyl pipe Note Wipe off any spilled oil with a rag, and dispose of it in an appropriate manner.
PRE-OPERATING PREPARATIONS 3. Break-in Your new outboard motor and lower ������� unit require break-in for the moving c o m p o n e n t s a c c o r d i n g t o t h e Operating the outboard motor without conditions described in the following break-in can shorten service life of the...
ENGINE OPERATION ENGINE OPERATION 1 Loosen the air vent screw on the Before starting tank cap. Before starting engine for the first time Air Vent Screw after reassembling engine or off-season storage, disconnect stop switch lock and pull the starter handle completely out approximately 10 times in order to prime the oil pump.
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ENGINE OPERATION P Type: 4 Install the lock in the stop switch. Set the Remote Conr tol lever to Neutral (N), and move the free accel lever to Open. Stop switch Neutral (N) Lock Hook Fully open Control lever Fully closed Free accel lever Main switch Stop switch...
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ENGINE OPERATION E Type: E Type: Turn the main switch key to ON, and While keeping the key pressed, turn it push on it for choke operation. (The to START. key need not be pushed if the engine START is warm) START ON START START...
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ENGINE OPERATION Manual Rope Start 9 When the engine starts, release the key and allow it to return to ON. Then ■ In case of trouble with the Recoil return the throttle grip to the “SLOW” Starter or the Electric Starter position.
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ENGINE OPERATION Note The battery cables must be connected to the battery also when starting the OPEN CLOSE engine manually. ������� • DO NOT re-install the ring gear cover, after the engine has been started using the emergency start procedure. 60C/70C •...
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ENGINE OPERATION ■ In case of trouble with the Recoil ������� Starter: Be careful that your clothes or 1 Set the shift lever to Neutral (N). other items do not get caught in the rotating engine parts. 2 Remove the top cowl. To prevent accident and injury, do 3 Take of f the recoil star ter by not re-attach the recoil starter after...
ENGINE OPERATION Engine speed 2. Warming up the engine Proper idle speed after warm-up operation. Before driving the boat, let the engine run at low speed for approximately Note three minutes to let it warm and allow the oil to circulate through the In case of cold engine starting, idling machine.
ENGINE OPERATION 3. Forward and reverse F type Turn the throttle grip toward “SLOW” ������� and move the Shift Lever quickly to Forward or Reverse when the engine Before shifting into forward or reverse, speed has reached the lowest rpm. make sure that boat is properly moored and outboard motor can be steered fully to the right and left.
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ENGINE OPERATION P type ������� While pressing the lock button on • Before moving the Shift Lever to the Remote Control lever upward, Reverse, make sure the Reverse swiftly move the Lever to Forward (F) Lock is engaged (in up position). or Reverse (R) to the engaging point (approx.32°...
ENGINE OPERATION ������� 4. Shallow water running ● Before moving the Shift Lever to ������� Reverse, make sure the Reverse Lock is engaged (in up position). During shallow water operation, be careful not to place your hand between Reverse lock lever Lock the swivel bracket and the stern bracket.
ENGINE OPERATION F Type 5. Stopping the engine 1 Return the throttle grip to the “Slow” speed position, then shift the shift ������� lever to Neutral (N) position. ● Do not shift into Reverse during Throttle grip Slow planning, or control will be lost leading to serious personal injury, boat may swamp, and/or hull may be damaged.
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ENGINE OPERATION P Type Notes 1 Move the Remote Control lever to ● After stopping the engine, close the Neutral (N) and let the engine idle air vent screw on the tank cap. for 2-3 minutes to allow it to cool ●...
ENGINE OPERATION 6. Trim angle Notes ● After stopping the engine, close the The following instructions explain how air vent screw on the tank cap. to set the best trim angle of the boat. ● Disconnect the fuel connector of the engine or the fuel tank.
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ENGINE OPERATION ������� ● Do not put hand or finger in between outboard motor body and clamp bracket when adjusting trim angle to prevent injury in case the outboard motor body falls. ● Unsuitable trim position can cause Thrust rod loss of control of boat.
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ENGINE OPERATION ������� The Power Trim & Tilt can be set to any trim angle, however, avoid cruising with the outboard motor tilted in the tilt range. Operating the boat in this manner, the outboard motor may ingest In this case, decrease the trim air into the water cooling system, angle by pressing the switch on the resulting in engine overheating.
ENGINE OPERATION ■ Proper Trim Angle 7. Mooring with the engine tilted up The trim angle is optimum when the boat is parallel to the water surface When the engine has been stopped while running. and it will not be used for a long time or �������...
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ENGINE OPERATION EFTO, EPTO Type 4 Operate the Power Trim & Tilt switch to DN to retract the trim ■ Tilt up rods. 1 Disconnect that fuel connector from the engine. If the trim rods are not retreacted shells and other foreign matter 2 Operate the Power Trim &...
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ENGINE OPERATION Manual Tilt Type: ■ Tilt down 1 Operate the Power Trim & Tilt ■ Tilt up switch to UP. 1 Disconnect the fuel connector. 2 Unlock the tilt stopper. 2 Set the reverse lock lever on 3 Operate the Power Trim & Tilt the port side to “RELEASE”...
ENGINE OPERATION Gas Assistant Type: 8. Caution while in boating ■ Tilt up Move (UP) lock lever to “Free” While in boating, observe the weather position. Fully tilt up the outboard and surrounding conditions at all time motor. for safe. Stop the engine and check when you face the following situations: While keeping the outboard motor in full tilt up position, move, (DOWN)
REMOVING AND CARRYING THE OUTBOARD MOTOR ������� 1. Removing the outboard motor Close air vent screw of fuel tank and 1 Stop the engine. fuel cock before carrying or storing 2 Disconnect the fuel connector, the outboard motor and fuel tank, or fuel remote control cables, the battery may leak, potentially catching fire.
REMOVING AND CARRYING THE MOTOR EFO type 3. Storing the outboard motor Lay the engine with the shift lever up. Keep the motor in a vertical position Note when you store it. If you can not carry the engine in an Note upright position, loosen the drain screw on the carburetors to drain fuel...
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REMOVING AND CARRYING THE MOTOR * Tie the clamp bracket to the outboard with a rope. * Pay attention to the tilting direction so as not to be injured by the springing clamp bracket. Reverse lock LOCK Tilting direction Rope Stern bracket �������...
TRAILERING TRAILERING ������� When trailering the outboard motor should be in a vertical (normal running) position, fully down. Trailering in the tilted position may cause damage to the outboard motor, boat, etc. If trailering with outboard motor fully down is not available (the gear case skeg is too close to the road in a vertical position), fix the outboard motor securely using a device (like...
WARNING SYSTEM WARNING SYSTEM 1. Outline 3 Oil level sensor that informs oil level This outboard warns of engine trouble in the tank at 3 liters and 1.5 liters. using the following three ways. (120A2/140A2) / at O.7 liters (90A2) 1 Warning buzzer / at O.5 liters (60C/70C).
WARNING SYSTEM 3. Corrective actions at warning Notes This function may be turned on in case Take one of the following actions as a propeller has run out of the water. applicable, in case a warning condition In such a case, the function will be has occurred.
ADJUSTMENT ADJUSTMENT 1. Remote control lever load Notes ● The trim tab also acts as an anode EPO, EPTO to prevent electrolytic corrosion. (Throttle friction adjustment screw) Therefore do not paint or grease this part. To adjust the load of the remote ●...
ADJUSTMENT 3. Steering load adjustment 4. Throttle grip turning load adjustment EFO/EPO EF/EFO/EFTO/MFG Steering load can be adjusted by Turn the friction adjustment screw on turning the steering adjust bolt on the the steering handle to adjust the turning Swivel Bracket. load of the throttle grip.
INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE Care of your outboard motor To keep your outboard motor in the best operating condition, it is very important that you perform daily and periodic maintenance as suggested in the maintenance schedules that follow. �������...
INSPECTION AND MAINTENANCE 1. Daily inspection Perform the following checks before ������� and after use. Do not use outboard motor if any abnormality is found during pre- operation check or it could result in severe damage to the motor or severe personal injury.
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INSPECTION AND MAINTENANCE Washing with fresh water Note When the engine has been used in salt water or polluted water, wash the It is recommended to check chemical properties of water on which your exterior and flush the cooling passage outboard motor is regularly used.
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INSPECTION AND MAINTENANCE Replacing the propeller 3 A p p l y g e n u i n e g r e a s e t o t h e A worn-out or bent propeller will lower propeller shaft before mounting the the motor's performance, and cause new propeller.
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INSPECTION AND MAINTENANCE Replacing the spark plugs Notes ������� ● Spark plug torque : 27.0Nm (20ft-lb) (2.7kgf-m) ● Do not reuse spark plug with damaged If a torque-wrench is not available insulation, or sparks can leak through when you are fitting a spark plug, a crack, potentially leading to electric good estimate of the correct torque is shock, explosion and/or fire.
INSPECTION AND MAINTENANCE 2. Periodic inspection It is important to inspect and maintain your outboard motor regularly. At each interval on the chart below, be sure to perform the indicated servicing. Maintenance intervals should be determined according to the number of hours or number of months, whichever comes first. For periodic inspection and maintenance, consult your servicing dealer.
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INSPECTION AND MAINTENANCE ■ Fuel filter (for fuel tank) Note Loosen a Fuel Pick-up Elbow and remove it. Then clean the Fuel Filter. Your outboard motor should receive careful, and complete inspection at 300 hours. This is the best time for ■...
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INSPECTION AND MAINTENANCE Cleaning Engine Oil Line Replacing gear oil Oil filter and oil tank. Check the oil tank ������� and/or filter for entrapped water and • Be sure that outboard motor is dust. secured to transom or service 1 Disconnect all pipes between the oil stand, or accidental drop or fall tank and oil pump.
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INSPECTION AND MAINTENANCE Checking and Refilling Oil in the 3 Install the upper oil plug, and then Power Trim & Tilt Unit. remove oil tube nozzle and install the lower oil plug. ■ Oil level Check the oil level of the reservoir tank as shown below while the tank is kept in a vertical position.
INSPECTION AND MAINTENANCE ■ Recommend oil 3. Off-season storage Use an automatic transmission fluid approved by GM. ������� Recommended oils are as shown below. ● When the motor is out of the water, ● M O B I L : M O B I L D T E # 2 2 , being transported, or in storage, MOBIL ATF 220 always remove the negative (-)
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INSPECTION AND MAINTENANCE Keep in mind that if gasoline is kept ■ Battery in the carburetor for a long time, 1 Disconnect the battery cords. gum and varnish will be generated, 2 Clean the exterior of the battery with causing the float valve to stick. fresh water or compressed air.
INSPECTION AND MAINTENANCE ������� 4. Pre-season check The following steps must be taken Have your dealer check the engine when first using the engine after pre- before the season starts, or if your season storage. prefer, be sure to check the following ●...
INSPECTION AND MAINTENANCE 5. Checking after striking underwater object 6. If the engine becomes submerged in water Striking sea bottom or underwater After pick up, immediately bring the object may severely damage the outboard to your dealer. outboard motor. Following are the emergency measures Immediately bring the outboard motor t o b e t a k e n o n t h e s u b m e r g e d to your dealer and ask for the following...
INSPECTION AND MAINTENANCE 7. Precautions in cold weather When morning in cold weather at sub- zero temperatures the water in the cooling water pump may freeze and severely damage the pump, impeller, and associated parts. To avoid this, submerge the lower half of the engine into the water, or tilt the engine and operate the electric starter motor for 5 seconds with the stop switch lock plate...
TROUBLESHOOTING TROUBLESHOOTING If you encounter problem with the engine, check the list below and locate the problem you are experiencing. Then follow the suggested remedies. Do not hesitate to contact your dealer, as professionals advice and assistance is the best way to keep the engine in optimum condition. Difficult Engine Poor...
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TROUBLESHOOTING Difficult Engine Poor Unstable Abnor- Abnor- Cannot Overheat- Power to start starts. idling engine mally mally low obtain ing of Trim & engine but stops running high engine high engine Tilt inop- soon speed or engine speeds engine erative engine speed speeds...
TOOL KIT AND SPARE PARTS TOOL KIT AND SPARE PARTS The following a list of the tools and spare parts provided with the motor. Items Quantity Remark Tool Bag Pliers Socket Wrench 10 X 13mm Service Tools Socket Wrench 21mm Socket Wrench Handle Screwdriver (Phillips-type and flat head) Adapter-type...
OPTIONAL ACCESSORIES OPTIONAL ACCESSORIES Water Pressure Meter Speedometer (50MPH) Water Temperature Meter Speedometer (75MPH) Flushing attachment Voltmeter Flushing attachment Hour Meter (engine operation hour counter) Tachometer...
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OPTIONAL ACCESSORIES Twin-control Box Kit Propeller (for twin-engine operation) Tie Bar Kit B Genuine grease (250g) (for twin-engine operation) Genuine gear oil (500mL) Remote control cable (7 – 30 feet, 19 kind length) Touch-up Paint Extension cord (2 m) for trim meter 10P extension cord (2 m) for RC box Genuine Engine Oil (0.4L, 1L, 4L, 20L)
PROPELLER TABLE PROPELLER TABLE To ensure optimum performance, the propeller should match the boat type and its load. Use a genuine propeller. A propeller must be selected so that the engine rpm measured at wide open throttle, while cruising, is within the recommended range. 120A2, 140A2 .