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Related Manuals for TOHATSU MFS 6A3Z 8A3 9.8A3
Summary of Contents for TOHATSU MFS 6A3Z 8A3 9.8A3
- Page 1 OWNER’S MANUAL 6A3Z 9.8A3 OB No.003-11082-7...
- Page 2 INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE. Copyright © 2009-2011 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced or transmitted in any from or by any means without the express...
- Page 3 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.
- Page 4 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.
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Page 5: Table Of Contents
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GENERAL SAFETY INFORMATION . - Page 7 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.ADJUSTMENT 9.INSPECTION AND MAINTENANCE 10.TROUBLESHOOTING 11.TOOL KIT AND SPARE PARTS 12.OPTIONAL ACCESSORIES 13.PROPELLER TABLE...
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Page 8: General Safety Information
8 GENERAL SAFETY INFORMATION 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,"... - Page 9 GENERAL SAFETY INFORMATION 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.
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Page 10: Specifications
SPECIFICATIONS SPECIFICATIONS 6A3Z (Available in specific region) MODEL Item 975 (38.4) 590 (23.2) Overall Length mm (in) 354 (13.9) 320 (12.6) Overall Width mm (in) 1,035 (40.7) · 1,162 (45.7) · 1,289 (50.7) Overall Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1) Transom Height S·L·UL mm (in) S Kg (lb) - Page 11 SPECIFICATIONS 8A3, 9.8A3 9.8A3 MODEL Item 975 (38.4) 590 (23.2) Overall Length mm (in) 354 (13.9) 320 (12.6) Overall Width mm (in) 1,035 (40.7) · 1,162 (45.7) · 1,289 (50.7) Overall Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1) Transom Height S·L·UL mm (in) S Kg (lb)
- Page 12 NAMES OF PARTS 8A3, 9.8A3 9.8A3 MODEL Item 975 (38.4) 590 (23.2) Overall Length mm (in) 354 (13.9) 320 (12.6) Overall Width mm (in) 1,035 (40.7) · 1,162 (45.7) · 1,289 (50.7) Overall Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1) Transom Height S·L·UL mm (in) S Kg (lb)
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Page 13: Names Of Parts
NAMES OF PARTS NAMES OF PARTS MF , EF , EP EP type only ＊：MF and EF type only. ☆：EF type only. ① ○ ○ Tilt Handle Drive Shaft Housing Primer Bulb ② ○ ○ Top Cowl Thrust Rod Fuel Tank Cap ③... - Page 14 NAMES OF PARTS EFT , EPT EPT type only ＊：EFT type only. ☆：EPT type only. ① ○ ○ Tilt Handle Drive Shaft Housing Primer Bulb ② ○ ○ Top Cowl Clamp Bracket Fuel Tank Cap ③ ○ ○ Cowl Latch Clamp Screw Air Vent Screw ④...
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Page 15: Installation
INSTALLATION INSTALLATION CAUTION 1. Mounting the outboard motor on boat ● Before beginning the running test, WARNING check that the boat with maximum capacity loading floats on the water in a proper attitude. Check the position Most boats are rated and certified of water surface on the driveshaft in terms of their maximum allowable housing. - Page 16 16 INSTALLATION MF, EF, EP type Note ① To attach the outboard motor to the boat, tighten the clamp screws by It is recommended to install upper mounting bolts with bolt head at turning their handles. inside surface of transom. Bolts with Also, tighten the bolts.
- Page 17 INSTALLATION EFT, EPT type (Power tilt model) Note It is recommended to install upper mounting bolts with bolt head at inside surface of transom. Bolts with threaded end at inside surface of transom can cause personal injury. Notes 1. Apply sealing agent such as silicone sealed between the bolts and transom board holes before tightening the bolts.
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Page 18: Installing The Remote Control Devices
Lock nut 2. Installing the remote control devices Cable joint Remoto control cable WARNING When using other than Tohatsu's genuine remote control box, DO NOT select the Approx. 10mm one without neutral safety switch that (0.39 inch) prevents in-gear start. -
Page 19: Connecting The Cord Assembly
INSTALLATION ③ Connecting the Cord assembly WARNING (Wiring Harness) Do not disconnect cord ass'y when Pass the Cord assembly from the engine is in operation, or engine will go out of control. Remote control box through the hole in the Lower motor cover and cover the wire ends with the Sleeve (provided in a tool bag) and then c o n n e c t t h e e l e c t r i c t e r m i n a l s... -
Page 20: Ept Model
20 INSTALLATION EPT model Green Blue Blue Green Brown Blue Black Brown Yellow Brown Black Pink Sky blue Black Brown ② Connect the positive cord (+) to the CAUTION positive terminal (+) of the battery, ● Make sure that the battery cords do and then connect the negative not get stuck between the outboard cord (−). -
Page 21: Installing The Battery
INSTALLATION WARNING 3. Installing the battery Battery electrolyte contains sulfuric acid ① Place the battery box in a con- and thus is hazardous, causing a burn venient position away from water if it comes in contact with your skin, or spray. -
Page 22: Pre-Operating Preparations
● Wipe off gasoline well immediately if spilt. GASOLINES CONTAINING ALCOHOL The fuel system components on your After cleaning gasoline tank: TOHATSU engine will withstand up to ● Wipe off gasoline well immediately if 10% alcohol content in the gasoline. spilt. ● If the fuel tank is disassembled But if the gasoline in your area contains for cleaning, reassemble carefully. -
Page 23: Low Permeation Fuel Hose Requirement
S tarting and operating difficulties ● CAUTION WARNING When operating a TOHATSU engine on Fuel leakage can cause fire or explosion, gasoline containing alcohol, storage of potentially leading to severe injury or gasoline in the fuel tank for long periods loss of life. -
Page 24: Epa Pressurized Portable Fuel Tank Requirements
24 PRE-OPERATING PREPARATIONS REMOVING THE FUEL CAP 3. EPA pressurized portable fuel tank requirements Manual vent screw Fuel cap EQUIPPED FOR UNITED STATES AND CANADA MODEL T h e E n v i r o n m e n t a l P r o t e c t i o n Agency (EPA) will require portable fuel syste m s that are pro duced after January 1, 2011 for use with... -
Page 25: Recommended Engine Oil
PRE-OPERATING PREPARATIONS Fuel demand valve - installed in the 5. Recommended engine oil fuel hose between the fuel tank and primer bulb. U s e o n l y h i g h q u a l i t y 4 - s t ro k e engine oil to insure performance and CAUTION prolonged engine life. -
Page 26: Break-In
26 PRE-OPERATING PREPARATIONS 6. Break-in Your new outboard motor and lower CAUTION 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... -
Page 27: Engine Oil Warning Lamp
PRE-OPERATING PREPARATIONS 7. Engine oil warning lamp 8. ESG (A device preventing over revolution) Oil pressure is required to lubricate ESG is a device to prevent over revo- internal engine parts. lution of the engine (more than ap- proximately 6,250 rpm). When the warning lamp (Red) is off, it indicates that oil pressure is present. -
Page 28: Engine Operation
28 ENGINE OPERATION ENGINE OPERATION For USA and Canada model Before starting (EPA approved tank) ① Full open the air vent screw on the Before starting engine for the first time tank cap and turn the tank cap after reassembling engine or off-season until it contacts the tab lock. - Page 29 ENGINE OPERATION ⑥ Set the throttle grip to "START" po- sition. Stop Switch Lock Stop Switch Lock MF, EF and EFT type ⑤ Place the shift lever in the Neutral position. ⑦ Pull the choke knob fully. Be sure that the shift is in Neutral when starting the engine.
- Page 30 30 ENGINE OPERATION MF type EP and EPT type ⑧ Pull the starter handle slowly until ⑤ Insert the main switch key. ⑥ Set the control lever in the Neutral you feel engagement, keep pulling till you feel less resistance. Then position.
- Page 31 ENGINE OPERATION ② Loosen the screw for starter lock CAUTION wire. Do not keep turning starter motor for over 5 seconds, or the battery may be consumed, potentially making the engine starting impossible and/or damaging the starter. If cranking over 5 seconds fails to start engine, return main switch to "ON", and crank engine again after 10 seconds or more.
- Page 32 32 ENGINE OPERATION ◎ Confirm that the shift lever is at If the choke solenoid fails to neutral position. operate (EP and EPT type only) ◎ Wrap a rope around the starter pul- ① Remove the top cowl. ley then pull quickly to start. ◎...
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Page 33: Warming Up The Engine
ENGINE OPERATION Engine speeds 2. Warming up the engine Idling speed after warming up. Remark: In case of cold engine War m the engine at low engine starting, idling speed is increased speeds for about three minutes. This about 300 rpm for several minutes. allows the lubricating oil to circulate to all parts of the engine. -
Page 34: Forward And Reverse
34 ENGINE OPERATION MF, EF and EFT type 3. Forward and reverse WARNING Before shifting into forward or reverse, make sure that boat is properly moored and outboard motor can be steered fully to the right and left. Make sure that no swimmer(s) is ahead or astern of the boat. - Page 35 ENGINE OPERATION ■ Forward CAUTION Quickly push the control lever to the Forward (F) position 32˚, where the Be sure to warm up engine well before starting cruise. Operating cold engine gear is connected, while lifting up on may cause damage to your motor. the lock button located at the bottom of the control lever grip.
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Page 36: Stopping
36 ENGINE OPERATION EP and EPT type 4. Stopping MF, EF and EFT type START Stop switch Stop Switch Lock Stop switch lock ① Turn the throttle grip to the slow position. ② Put the shift lever in the Neutral po- sition. -
Page 37: Trim Angle
ENGINE OPERATION WARNING 5. Trim angle ● Do not put hand or finger in between The trim angle of the outboard motor outboard motor body and clamp can be adjusted to suit the transom bracket when adjusting trim angle to angle of the hull, and load conditions. - Page 38 38 ENGINE OPERATION EFT and EPT type ■ Improper Trim Angle (bow rise too high) If the trim angle is excessive, the bow will rise out of the water and the speed will decrease. EFT model Furthermore, the bow may sway or the bottom may slam the water while cruising.
- Page 39 ENGINE OPERATION MF, EF type ① Stop the engine. ② Shift the outboard into neutral. ③ Raise the engine to the tilt up posi- tion. ④ Change the thrust rod position. ⑤ Gentry lower the outboard. Thrust Rod Higher Transom angle settings Lower Tilt release position WARNING...
- Page 40 40 ENGINE OPERATION ② L ock the tilt with the Tilt stopper EPT type ① O perate the Power Tilt switch and after the outboard motor has been tilt the outboard motor up. (The tilted up. Main Switch must be "ON".) Tilt Stopper ③...
- Page 41 ENGINE OPERATION EFT/EPT type CAUTION The provided Power tilt makes tilt- up/down electrically. It may be used The power Tilt can be set to any trim as a power trim and tilt when the angle, however, avoid cruising with the outboard motor tilted in the tilt range.
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Page 42: Tilt Up, Tilt Down And Shallow Water Operation
42 ENGINE OPERATION ■ Tilt down 6. Tilt up, tilt down and shallow water operation Slightly tilt the motor up, and pull the tilt lever toward you to release the tilt- WARNING lock. Then lower the motor slowly. When tilting up or down, be careful not to place your hand between the swivel bracket and the stern bracket. - Page 43 ENGINE OPERATION ■ Tilt down ① Move the tilt lock knob to the un- lock position. ② Raise the outboard to the tilt re- lease position. ③ Gently lower the outboard. Tilt lock knob in lock position Tilt lock knob in unlock position Tilt up position Tilt...
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Page 44: Shallow Water Operation
44 ENGINE OPERATION MF, EF type 7. Shallow water operation ■ Shallow water running position WARNING With the shift lever in Neutral or Forward, tilt the motor up slowly by During shallow water operation, be about 40˚ and then lower the tilt le- careful not to place your hand between ver for setting at the shallow water the swivel bracket and the stern bracket. - Page 45 ENGINE OPERATION EP type ■ Setting shallow water drive ■ Releasing shallow water drive ① Stop the engine. ① Stop the engine. ② Shift the outboard into forward. ② Tilt the outboard up to the tilt re- ③ Tilt the outboard up to one of the lease position.
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Page 46: Removing And Carrying The Outboard Motor
46 REMOVING AND CARRYING THE OUTBOARD MOTOR REMOVING AND CARRYING THE OUTBOARD MOTOR 1. Removing the outboard motor 3. Storing the outboard motor ① Stop the engine. Outboard motor should be stored in a ② Disconnect the fuel connector, vertical position. the remote control cables and the battery cords from the outboard Note... -
Page 47: Trailering
TRAILERING TRAILERING WARNING Do not go under outboard motor tilted up even if it is supported by support bar, or accidental fall of outboard motor could lead to severe personal injury. WARNING Close air vent screw of fuel tank and fuel cock before carrying or storing outboard motor and fuel tank, or fuel may leak, potentially catching fire. -
Page 48: Adjustment
48 ADJUSTMENT ADJUSTMENT 1. Steering friction 2. Throttle grip MF, EF type MF, EF and EFT type The steering friction can be adjusted The turning force of the throttle grip in accordance with your preference can be adjusted with a throttle adjust by turning the steering adjust bolt. -
Page 49: Remote Control Lever Load
ADJUSTMENT 3. Remote Control Lever Load Notes EP and EPT type ● The trim tab also acts as an anode (Throttle friction adjustment screw) to prevent electrolytic corrosion. Therefore do not paint or grease To adjust the load of the remote this part. -
Page 50: Inspection And Maintenance
50 INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE Care of your outboard motor EPA Emissions Regulations To keep your outboard motor in the EPA (United States Environmental best operating condition, it is very Protection Agency) has emission important that you perform daily and regulations regulating air pollution periodic maintenance as suggested from new outboard motors. -
Page 51: Daily Inspection
INSPECTION AND MAINTENANCE 1. Daily inspection WARNING 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. Item Points to Check Remedy... - Page 52 52 INSPECTION AND MAINTENANCE Maintaining engine oil Notes If the engine oil is low, the life of the engine will be shortened significantly. Consult with an authorized dealer if the engine oil is milky color, or appears contaminated. ■ Checking oil level ①...
- Page 53 INSPECTION AND MAINTENANCE ■ Use flushing attachment. Washing outboard motor ① Remove propeller (refer to Propeller If outboard motor is used in salt water, brackish water or water with a Replacement). Remove the water high acidic level, use fresh water to plug from the motor, and screw in remove salt, chemicals or mud from the flushing attachment.
- Page 54 54 INSPECTION AND MAINTENANCE Replacing the propeller WARNING A worn-out or bent propeller will lower the motor's performance, and cause Do not hold propeller with hand(s) engine trouble. when loosening or tightening propeller nut. Put a piece of wood block between Before removing the propeller, remove propeller blade and anti-ventilation the spark plug caps from the spark...
- Page 55 INSPECTION AND MAINTENANCE ⑤ Attach spark plug and tighten to Replacing the spark plugs specified torque. WARNING Notes ● Do not reuse spark plug with damaged insulation, or sparks ◎ Spark plug torque : can leak through crack, potentially 18.0Nm(13.3ft-lb)(1.84kgf-m) leading to electric shock, explosion If a torque-wrench is not available and/or fire.
- Page 56 56 INSPECTION AND MAINTENANCE ② Recommended oil Checking and Refilling Oil in the Use an automatic transmission Power Tilt. ① Check the oil level of the reservoir fluid or equivalent. tank as shown on the right while the Recommended oils are as shown tank is kept in a vertical position.
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Page 57: Periodic Inspection
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. - Page 58 58 INSPECTION AND MAINTENANCE Drain hole Notes Your outboard motor should receive careful, and complete inspection at 300 hours. This is the best time for major maintenance procedures to be carried out. Replacing engine oil Engine oil mixed with dust or water Use only high quality 4-stroke engine will dramatically shorten the life of the oil to insure performance and pro-...
- Page 59 INSPECTION AND MAINTENANCE Cleaning the fuel filters and the CAUTION fuel tank Fuel filters are located inside the fuel You may be injured due to high engine temperatures if you fill engine oil just tank and engine. after stopping. Changing engine oil should be done after the engine has WARNING been cooled.
- Page 60 60 INSPECTION AND MAINTENANCE ■ Fuel filter (for fuel tank) Loosen the fuel pickup elbow shown at left, remove it and clean the fuel filter. Fuel Filter pick up elbow ■ Fuel tank Water or dirt in the fuel tank will cause engine performance problems.
- Page 61 INSPECTION AND MAINTENANCE Replacing gear oil until oil flows out from upper plug hole. Oil plug (Upper) WARNING ● Be sure that outboard motor is secured to transom or service stand, or acciden- tal drop or fall of outboard motor could lead to severe personal injury.
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Page 62: Off-Season Storage
62 INSPECTION AND MAINTENANCE 3. Off-season storage ⑥ Change the gear oil in the gear Before you put your outboard motor case. ⑦ Apply grease to the propeller shaft. in storage, it is a good opportunity to ⑧ Apply grease to all sliding parts, have it serviced and prepared by your dealer. -
Page 63: Pre-Season Check
INSPECTION AND MAINTENANCE 4. Pre-season check 5. Motor submerged in water ① Check that the shift and throttle After taking your outboard motor out function properly. of the water, immediately take it to (Be sure to turn the propeller shaft your dealer. -
Page 64: Cold Weather Precautions
64 INSPECTION AND MAINTENANCE 6. Cold weather precautions 7. Checking after striking underwater object If you moor your boat in cold weather Striking the sea bottom or an under- at temperatures below 0˚C (32˚F), water object may severely damage there is the danger of water freezing the outboard motor. -
Page 65: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING If you encounter a problem, consult the check list below to determine the cause and to take the proper action. An authorized dealer will always be happy to provide any assistance and informa- tion. Possible cause ● ● Empty fuel tank ●... - Page 66 66 TROUBLESHOOTING Possible cause ● ● ● ● ● ● ● Spark plug other than specified ● ● ● ● ● ● Dirt, soot, etc. on spark plug ● ● Faulty oil pressure switch ● ● ● ● ● ● No Spark or weak spark ●...
- Page 67 TROUBLESHOOTING Possible cause ● ● ● ● ● Low compression ● ● Carbon deposits in the combustion chamber ● ● Incorrect valve clearance ● Low oil pressure/level ● ● ● Low oil level ● ● Use of improper oil ● ●...
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Page 68: Tool Kit And Spare Parts
68 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 10 × 13 mm Socket wrench Socket wrench 16 mm (spark plug) Service tools Socket wrench handle Screwdrivers... -
Page 69: Optional Accessories
OPTIONAL ACCESSORIES OPTIONAL ACCESSORIES Selector Tachometer Genuine gear oil (500ml) Tachometer with oil lamp (for EPT) Touch-up paint (300ml) Propeller Genuine engine oil (450ml) Flushing attachment High thrst propeller... -
Page 70: Propeller Table
70 PROPELLER TABLE PROPELLER TABLE Use a genuine propeller. A propeller must be selected so that the engine rpm measured at wide open throt- tle while cruising is within the recommended range. 5,000 to 6,000 rpm Propeller Size (Diameter × pitch) Propeller Mark No. - Page 72 OWNER’S MANUAL 6A3Z TOHATSU CORPORATION 9.8A3 Address : 5-4, 3-chome, Azusawa, Itabashi-ku, TOKYO, 174-0051 JAPAN Phone : TOKYO (03)3966-3117 FAX : TOKYO (03)3966-2951 URL : www.tohatsu.co.jp 003-11082-7 1103NB Printed in Japan...