Tohatsu MD40B2 manual

MANUAL 30B2 4 0B2 5 0B2 75C2 90C2 1 1 5A2 M D OWNER’S OB No.003-11075-D OWNER’S MANUAL 30B2 4 0B2 5 0B2 75C2 90C2 1 1 5A2 M D TOHATSU CORPORATION 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 003-11075-D   1109NB Printed in Japan OM_E_MD30B2-11[...]

RE AD THIS MANU AL BE FO RE US IN G T HE O UT BO AR D M OTO R. FAIL UR E TO FO LL OW TH E IN S T R UC T I O NS AN D S A F E TY P R EC A U T IO N S I N T H IS MA N U A L C A N R E SU LT IN SE R I OU S INJUR Y OR DEA TH. KEEP THIS MANUAL IN A SAFE LOCA TION FOR FUTURE REFERENCE. ! Copyright © 2009-2012 T ohatsu Corporation. All rights reserved. No p[...]

YOUR T OHA TSU OUTBOARD MOT OR OWNER REGISTRA TION AND IDENTIFICA TION Upon purchasing this product, be sure that the W ARRANTY CARD is correctly and completely filled out and mailed to the addressee noted there on. This WARRANTY CARD identifies you as the legal owner of the product and serves as your warranty registration. TO TH E EXTE NT PERMIT[...]

Serial Number In the space below , please record the out board motor's serial number (indicated both on the lower motor cover and on the cylinder block). The serial number will be needed in the event of theft or to quickly identifying the outboard motor type. Serial Number : T o Y ou, Our Customer Thank you for selecting a TOHA TSU outboard mo[...]

CONTENTS 1 2 3 4 5 6 7 8 9 10 GENERAL SAFETY INFORMA TION                                      8 SPECIFICA TIONS                                ?[...]

11 12 13 14 4. Pre-season check                                                 81 5. Checking after striking underwater object                    ?[...]

INDEX 14 12 11 10 9 8 7 6 5 4 3 2 1 7 1. SPECIFICA TIONS 2. NAMES OF P ARTS 3. LOCA TIONS OF W ARNING LABELS 4. INST ALLA TION 5. PRE-OPERA TING PREP ARA TIONS 6. ENGINE OPERA TION 7. REMOVING AND CARR YING THE OUTBOARD MOTOR 8. TRAILERING 9. ADJUSTMENT 10. INSPECTION AND MAINTENANCE 1 1. TROUBLESHOOTING 12. TOOL KIT AND SP ARE P ARTS 13. OPTIONAL [...]

8 GENERAL SAFETY INFORMA TION GENERAL SAFETY INFORMA TION NOTICE : DANGER/W ARNING/CAUTION/Note Be fore in sta ll in g, o pe ra ti ng o r ot he rw is e ha nd li ng y ou r ou tb oard mo tor , b e su re to thoroughly r ead and understand this Owner's Manual and carefully follow all of the i ns tru ct ion s. O f pa r tic ul ar im po r tan ce i s [...]

9 GENERAL SAFETY INFORMA TION SAFE OPERA TION OF BOA T As t h e op e r at o r /d r i ve r o f th e b oa t , y ou a re re s po n s ib l e f or t h e sa f e ty o f t ho s e a bo a rd a n d t h o se i n o t h e r b oa t a ro u n d y o u rs , a n d f o r f ol l o w i n g l oc a l b o a t in g regulations. Y ou should be thor oughly knowledgeable on how[...]

10 1 SPECIFICA TIONS SPECIFICA TIONS MODEL 30B2 40B2 Item EPTO EFTO EFO Overall Length mm (in) 630 (24.8) 1,120 (44.1) Overall Width mm (in) 345 (13.6) 384 (15.1) Overall Height S·L·UL mm (in) 1,227 (48.3) · 1,354 (53.3) · 1,481 (58.3) T ransom Height S·L·UL mm (in) 403 (15.9) · 530 (20.9) · 657 (25.9) Weight S kg (lb) - - - L kg (lb) 94.5 [...]

11 1 SPECIFICA TIONS MODEL 50B2 Item EPTO EFTO EFO Overall Length mm (in) 630 (24.8) 1,120 (44.1) Overall Width mm (in) 345 (13.6) 384 (15.1) Overall Height S·L·UL mm (in) 1,227 (48.3) · 1,354 (53.3) · 1,481 (58.3) T ransom Height S·L·UL mm (in) 403 (15.9) · 530 (20.9) · 657 (25.9) Weight S kg (lb) 93.5 (206) 96.5 (213) 88.5 (195) L kg (lb)[...]

12 1 SPECIFICA TIONS MODEL W50B2 Item EPTO EFTO Overall Length mm (in) 630 (24.8) 1,120 (44.1) Overall Width mm (in) 345 (13.6) 384 (15.1) Overall Height L·UL mm (in) 1,415 (55.7) · 1,542 (60.7) T ransom Height L·UL mm (in) 550 (21.7) · 677 (26.7) Weight L kg (lb) 100.5 (222) 103.5 (228) UL kg (lb) 101.5 (224) 104.5 (230) Output kW (Hp) 36.8 (5[...]

13 1 SPECIFICA TIONS 75C2 , 90C2 MODEL 75C2 90C2 Item EPTO Overall Length mm (in) 810 (31.9) Overall Width mm (in) 508 (20.0) Overall Height L·UL mm (in) 1,540 (60.6) · 1,667 (65.6) T ransom Height L·UL mm (in) 517 (20.4) · 644 (25.4) Weight L·UL kg (lb) 152 (335) · 155 (342) Output kW (Hp) 55.2 (75) 66.2 (90) Max. Operating Range rpm 5,150 -[...]

14 1 SPECIFICA TIONS 1 15A2 MODEL 1 15A2 Item EPTO Overall Length mm (in) 800 (31.5) Overall Width mm (in) 495 (19.5) Overall Height L·UL mm (in) 1,640 (64.6) · 1,767 (69.6) T ransom Height L·UL mm (in) 517 (20.4) · 644 (25.4) Weight L·UL kg (lb) 178 (392) · 181 (399) Output kW (Hp) 84.6 (115) Max. Operating Range rpm 5,150 - 5,850 Engine T y[...]

15 2 NAMES OF P ARTS NAMES OF P ARTS EFO / 40B2 , 50B2 ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ Tilt Handle T op Cowl Hook Lever W ater Check Port Reverse Lock Lever W ater Plug Anti-ventilation Plate T rim T ab ⑨ ⑩ ○ 1 1 ○ 1 2 ○ 1 3 ○ 1 4 ○ 1 5 ○ 1 6 Propeller Oil Plug (lower) W ater Inlet Oil Plug(upper) Clamp Bracket Thrust Rod Clamp Scre[...]

16 2 NAMES OF P ARTS EFTO / 30B2 , 40B2 , 50B2 , W50B2 ○ 1 ○ 2 ○ 3 ○ 8 ○ 9 ○ 1 0 ○ 1 0 ○ 1 1 ○ 1 3 ○ 1 4 ○ 1 5 ○ 1 6 ○ 1 7 ○ 1 8 ○ 24 ○ 22 ○ 1 9 ○ 2 0 ○ 2 3 ○ 2 1 ○ 1 2 ○ 4 ○ 5 ○ 6 ○ 6 ○ 1 2 ○ 7 [W50] [W50] ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ Tilt Handle T op Cowl Hook Lever W ater Check Port Tilt S[...]

17 2 NAMES OF P ARTS EPTO / 30B2 , 40B2 , 50B2 , W50B2 ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ Tilt Handle T op Cowl Hook Lever W ater Check Port Tilt Stopper W ater Plug Anti-ventilation Plate T rim T ab ⑨ ⑩ ○ 1 1 ○ 1 2 ○ 1 3 ○ 1 4 ○ 1 5 ○ 1 6 Propeller Oil Plug (lower) W ater Inlet Oil Plug(upper) Clamp Bracket Thrust Rod Power T rim &[...]

18 2 NAMES OF P ARTS ○ 1 ○ 2 ○ 3 ○ 3 ○ 8 ○ 9 ○ 1 0 ○ 1 1 ○ 1 3 ○ 1 4 ○ 1 5 ○ 1 6 ○ 1 7 ○ 1 8 ○ 1 9 ○ 1 2 ○ 4 ○ 5 ○ 6 ○ 7 EFTO / 75C2 , 90C2 ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ Tilt Handle T op Cowl Hook Lever W ater Check Port W ater Plug Anti-ventilation Plate T rim T ab Propeller ⑨ ⑩ ○ 1 1 ○ 1 2 ○ 1 3[...]

19 2 NAMES OF P ARTS EPTO / 1 15A2 ○ 1 ○ 2 ○ 3 ○ 3 ○ 8 ○ 9 ○ 1 0 ○ 1 1 ○ 1 3 ○ 1 4 ○ 1 5 ○ 1 6 ○ 1 7 ○ 1 8 ○ 1 2 ○ 4 ○ 5 ○ 6 ○ 7 Note These parts for model 115A2 are not enclosed in the engine package. ○ 2 6 ○ 2 9 ○ 2 8 ○ 2 7 ○ 3 0 ○ 3 1 ○ 2 0 ○ 2 1 ○ 2 2 ○ 1 9 ○ 2 3 ○ 2 5 ○ 2 4 ① ?[...]

20 LOCA TIONS OF W ARNING LABELS 3 LOCA TIONS OF W ARNING LABELS Warni ng lab el reg arding o wn er's m anu al, top c owl, e ngi ne sto p switc h, engi ne oi l level a nd unl ead ed gas olin e Warni ng lab el o n engi ne sto p swi tch Onl y for U SA a nd CA N ADA m ode ls Wh en op eni ng or cl osi ng fu el ta nk ca p, be sure to o bse rve wa r[...]

21 INST ALLA TION 4 Installation ■ Single-engine Installation P os i t i o n t he o u t b o ar d e n gi n e a t t h e exact center of the ster n, and mount it using a cushioning pad or plate. ■ T win-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 eng in es, b e su re to k eep a n in ter va l o f 4 7 0 ~ 6 6 0 m m ( f o r [...]

22 INST ALLA TION 4 ■ T ransom Height In s t a ll t he e ng i n e w i th t he A n ti - v en t i la t i on Plate at a level 10~30m m(0.4~1. 2in.) be lo w t he b ot t om o f t he b oa t. ■ T ransom Matching Be s ure t ha t an t i v e nt i la t io n pl a te o f the o ut boa rd is b elo w th e wa ter s ur- f a c e w h e n r u n n in g w i t h w i d[...]

23 INST ALLA TION 4 Clamp Bracket Dimensional Drawing ■ manual tilting type EFO 40, 50 ■ with the Power T rim and T ilt type EFTO, EPT O 30, 40, 50 Note It is recom mend ed to install uppe r mou nting bolts w ith bol t head at inside sur face of trans om. B olts wit h threaded end at insid e sur face of transo m can caus e perso nal injur y . N[...]

24 INST ALLA TION 4 ■ Power T rim and T ilt type EPTO 75, 90, 1 15 A p ropeller mu st b e s elect ed so t hat t h e e n g in e r p m m e a s u re d a t w i d e op en t hro tt l e w hi l e c ru i si ng is w it hi n the max. operating range; 5,150 to 5,850 rpm F o r g e n u i n e p r o p e l l e r s , r e f e r t o Propeller T able of this manual. [...]

25 INST ALLA TION 4 30, 40, 50 I t i s r ec omm en d ed th at y ou con s u lt w it h your aut horized dealer fo r inst allatio n ad j u st me n t o f t he r e mot e co n tr o l de v ic e . ■ Inst all atio n o f the Re mote Co ntro l Cables (Box side) : F o l l o w t h e i n s t r u c t i o n m a n u a l provided with the r emote control box. ■ [...]

26 INST ALLA TION 4 ◎ Screw the tip of the remote contr ol c a b l e i n t o t h e c a b l e j o i n t u p t o a p p r o x . 1 0 m m ( 0 . 3 9 i n c h ) , t h e n l oc k t h e m w it h a l o c k n u t. A p p l y g r e as e t o t h e h o l e o f t h e c a b l e joint. ④ M o ve t h e R e m o t e C o n t r o l l e v e r Forward, to Neutral and to [...]

27 INST ALLA TION 4 ⑥ Adjust the cable joint (shift side) so th a t t he h ol e m e et s wi t h t he s hi f t ar m p in , an d l o ck t he ca b le j oi nt w i t h t h e n u t , a n d i n s e r t t h e s h i f t a r m p i n a n d t h e n s e c u re w i t h a w a sh e r a n d R - s h a p e d p i n . A l s o , a d j u s t t h e c a b l e j o i n t ([...]

28 INST ALLA TION 4 Free Accel lever Fully opened Fully closed Approx. 32° M o v e t h e s h i f t a r m F o r w a r d , t o Neutral and to Reverse to co nfirm th e s h if t i s w or k in g, an d t h en se t the shift arm to Neutral. ◎ Scr ew the tip of t he r emo te co ntr ol c a b l e i n t o t h e c a b l e j o i n t u p t o approx.10mm(0.39[...]

29 INST ALLA TION 4 ⑥ Install th e hose cl amp to t he cord grommet. Install the cord clamp. ⑦ Adjust the cable joint (shift side) so th a t t he h ol e m e et s wi t h t he s hi f t ar m p in , an d l o ck t he ca b le j oi nt w i t h t h e n u t , a n d i n s e r t t h e s h i f t a r m p i n a n d t h e n s e c u re w i t h a w a sh e r a n [...]

30 INST ALLA TION 4 I n s t a l l t h e m e t e r s s e c u r e l y i n t h e d a s h b o a r d w h e r e t h e y c a n b e e a s i l y r e a d a n d a r e n o t e x p o s e d t o w a t e r s p l a s h e s . T h e rec o mm e nd e d d as h bo a rd t h ic kn e ss i s 2 ~ 1 1 m m ( 0 . 0 8 ~ 0 . 4 i n . ) . F o r d a s h b o a r d s t h i c k e r t h [...]

31 INST ALLA TION 4 Ta ch om et er L B B B B B B L L L L L R R R P B P B Y W Y W Lg R Y R / G R / Lg R Y R / G R / Lg B R W Lg B R W Tr im g au ge Tr i m se n de r Tr i m se n de r Ca b le h a rn e ss B Me t er l e ad wi re (3 T5 -7 25 37 - 1) 75 ・ 90 ・ 115 30 ・ 40 ・ 50 ■ Color Code B : black L : blue Lg : light green P : pink R : red W :[...]

32 INST ALLA TION 4 Incorrect or unstable installation of the Drag Link Assembly can r esult in accidents while riding the boat or breakage of the hull. Installation of the Drag Link Assembly by your dealer is highly recommended. ① Connect the Drag Link Rod to the tip of the steering cable. Tighten the rod using self-locking nut, making sur e the[...]

33 INST ALLA TION 4 T h i s e n g i n e w i l l n o t s t a r t w i t h o u t battery . 6. Installing the battery ! WARNING Bat te r y ele c tro ly te c on tai ns sul fur ic ac id an d thu s is ha za rd ous, c au sin g a bur n if it c om es in c on tac t w ith yo ur sk in, or p ois on ous i f swal lowe d. KEEP B A T TERY AND ELEC TROL Y TE A WA Y F[...]

34 INST ALLA TION 4 ① Keep the batter y in the designated batte ry spac e of the boat , Se cure it t ig h tl y an d m ak e s ure i t c an no t be reached by water . ② C o n n e c t t h e p o s i t i v e ( + ) c o r d c o n n e c t o r ( w i t h r e d t ub e ) t o t h e p o s i t i v e ( + ) t e r m i n a l f i r s t . T h e n c o n n e c t t h [...]

35 PRE-OPERA TING PREP ARA TIONS 5 PRE-OPERA TING PREP ARA TIONS 1. Recommended gasoline types Us e of im p ro p e r g a s ol in e c an d am ag e yo u r e n g i ne . E n gi n e d am a g e re s u l ti n g f r o m t he u s e o f i m pr o p e r g a s o li ne i s c o n si d e r e d m i s u s e of t h e e n g i ne , a n d d a m a g e c a u s e d t h e r[...]

36 PRE-OPERA TING PREP ARA TIONS 5 structure f acilitati ng interior cleaning. ! WARNING Do no t fil l the fu el tan k ov er cap acity . Th e rise of g asoli ne t empe rature may cause ga soline t o exp an d whic h, if ov er f illed, ma y l eak t hro ug h ai r v ent screw whe n it is open . Leaki n g gaso l i n e is a dang e rou s fi re h azard .[...]

37 PRE-OPERA TING PREP ARA TIONS 5 REM OVIN G THE FUE L C AP Fuel c ap Man ual vent s crew T ab loc k IMP OR T ANT : Contents may be under pressur e. Rotate t he fuel cap 1 /4 turn to r elieve pr essure bef ore opening. ① Open the manual vent s crew on t op of the fuel cap co mpletely . ② T ur n t h e f u el c a p u nt il i t c o nt a ct s the [...]

38 PRE-OPERA TING PREP ARA TIONS 5 4. Recommended engine oil Use a gen uin e e ngin e o il or reco mmen ded one . Refer to your Distributor . Will no t recommend use of other two stroke engine oil. D o n o t m i x d i f f e r e n t b r a n d s o f o i l . M i x i n g d i f f e r e n t b r a n d s o f o i l , o r dif fe ren t ty pe s of oil e ven if[...]

39 PRE-OPERA TING PREP ARA TIONS 5 ■ Oil pump air vent V i s u a l l y c h e c k w h e t h e r t h e r e i s a i r i n t h e o il t h r o u g h t h e v in y l p i pe c o n n e c ti n g t h e o i l t a n k w i t h t h e o i l p u m p . I f p re s en t, P u rg e t he a i r a s follows: 30, 40, 50 Lo os en th e ai r v en t s cre w o n th e o il pump[...]

40 PRE-OPERA TING PREP ARA TIONS 5 Y o ur ne w o u tb o ard mo t or an d l o we r un i t re q u i re b re a k- i n f o r t h e m o v in g c o m p o n e n t s a c c o r d i n g t o t h e cond ition s de scri bed in the foll owing time table. 1-10min 10min-2hrs 2-3hrs 3-10hrs After 10hrs Throttle Position Idle Less than 1/2 throttle Less than 3/4 thr[...]

41 PRE-OPERA TING PREP ARA TIONS 5 W h e n t h e re i s s o me t h i n g a b n o r ma l w i t h t h e e n g i n e , t h e w a r n i n g l a mp flashes and/or the buzzer sounds. I f a t r o u b l e o c c u r s , d e al w i t h i t a s mentioned below . ■ ESG (A de vi ce pr eve nt ing o ver r evo lut io n) E S G i s a d e v i c e t o p r e v e n t[...]

42 PRE-OPERA TING PREP ARA TIONS 5 After replenishment of oil is complete, st ar t th e e ng in e a nd ma k e su re t ha t th e wa r n i ng l a mp i n t h e t a ch o m et e r i s t u r n e d o f f w i t h o u t s o u n d i n g o f t h e b uz z e r o r t h e w ar n i n g l a m p i n t he s w i t c h b o x i s t u r n e d o ff w i t h ou t sounding o[...]

43 PRE-OPERA TING PREP ARA TIONS 5 ■ Battery voltage too low If the battery voltage dr ops to 10 V or lower , the war ning lamp flashes. And also if the voltage is too high, all of the three warning lamps flash. I f t h e b a t t e r y i s d e f e c t i v e o r t h e battery cable is poorly connected, the warning lamp flashes a nd the engine s[...]

44 ENGINE OPERA TION 6 Preparations Except for USA and Canada model (regular tank) ① Full open the air vent screw on the tank cap. Air vent Screw For USA and Canada model (EP A approved tank) ① Full open the air vent screw on the t a n k c a p a nd t u r n t h e t a nk c a p until it contacts the tab lock. Close th e ta nk c ap a f te r co mp l[...]

45 ENGINE OPERA TION 6 a. Repeat to squeeze the primer bulb until it becomes firm. b . S e t t h e m a i n s w i t c h t o " O N " po si ti on a nd h ol d i t tu r ne d o n fo r 3 s ec o nd s. − T o ac tu a te th e F F P (Fuel Feed Pump). c . Tu r n o f f t h e m a i n s w i t c h a n d a g a i n s q u e e z e t h e p r i m e r b u l b[...]

46 ENGINE OPERA TION 6 ■ 75 ・ 90 ・ 1 15 type (Electric Oil Pump) C he c k t o s e e b y e y e s i f t h e o i l l i n e from the oil tank to the cylinder block ( ① to ⑪ in the 75 , 9 0, 115 mo del ) g et s a i r i n s i d e o r n o t. I f t h e re i s a ir inside the oil line, r emove it as follows. ◎ Oil tank-Filter ( ① ) a. Fill the[...]

47 ENGINE OPERA TION 6 OFF ON START Main switch key Starting ■ EFO, EFTO type ① Set the shift lever to Neutral ② T u r n t h e t h r o t t le g r i p s o t h a t t h e i n d i c a t o r l i n e m e e t s t h e " S T A RT " mark (completely closed). ③ T ur n t he m ain swit ch key to "ON" , an d wa i t a f ew s e co n ds [...]

48 ENGINE OPERA TION 6 ④ R e l e a s e t he m ai n s w i t c h k e y a s s o o n a s t h e e n g i n e s t a r t s . T h e key will retur n to the "ON" position automatically . ■ EPTO type ① I n s e r t t h e k e y i n t o t h e r e m o t e control box. ② S e t t h e R e m o t e C o n t r o l l e v e r t o Neutral (N). Do no t kee[...]

49 ENGINE OPERA TION 6 ③ T ur n t he m ain swit ch key to "ON" , an d wa i t a f ew s e co n ds u nt i l t h e sound of the warning buz zer sto ps. ④ Continue tur ning the key clockwise to start the engine. W h e n t h e e n g i n e s t a r t s , r e l e a s e t h e k e y a n d a l l ow i t t o r e t u r n t o "ON". Do no t [...]

50 ENGINE OPERA TION 6 Before driving the boat, let the engine ru n a t lo w s pe e d t o l e t it w a r m a nd al lo w t he oi l t o c irc ul at e t hro ug h t he en g in e . I f t h e e ng i ne i s n ot w ar m e d u p b e fo re h an d, t h e e n g in e l i fe w i l l shorten greatly . T h i s o u t b o a rd e n g i n e a u t o m a t i c a l l y c[...]

51 ENGINE OPERA TION 6 ■ EFO, EFTO type T ur n t he th rot tl e g ri p to wa rd " SL OW " an d mo v e th e Sh i ft L e ve r qu i ck l y to Forward or Reverse when t he engi ne speed has reached the lowest rpm. Note Do no t increase engin e speed unne cessa rily in reverse. 3. Forward and reverse ! WARNING Befo re shi f tin g int o for w[...]

52 ENGINE OPERA TION 6 ■ EPTO type W h i l e p re s s i n g t h e l o c k b u t t o n o n t h e R e m o t e C o n t r o l l e v e r u p w a r d , swiftly move t he Lever to Forward (F) or R everse (R) to t he en gaging poin t (approx.32 ° forward or backw ard fr om Neutral ). If the lever is mov ed fur ther for ward or ba ckw ard, the t hrott le[...]

53 ENGINE OPERA TION 6 Be sur e to war m up en gin e well b efo re st ar ti ng c rui se. O pe rat ing c ol d eng ine ca n give d ama ge to i t. ! CAUTION Note Idle spee d may be higher durin g warming up of e ngine. If shif ted to For ward or reverse during war ming up, it may be dif ficult to shif t back to neutral. In su ch case, stop engin e, s[...]

54 ENGINE OPERA TION 6 ■ EFO type ① S e t t h e R e v e r s e L o c k L e v e r provide d on th e st arbo ard si de t o "Release" by turning it downward. ② Tilt the engine up approx. 4 5 ° a nd l o w er i t. T h e e n g i ne w il l n o w b e s et t o t h e s h a l lo w w a t er setting. ③ Releasing the shallow water setting a . T[...]

55 ENGINE OPERA TION 6 ■ EFO, EFTO type ① Reduce the engine speed to idling rpm. ② T ur n the Main Switch to "OFF". The engine will then stop. ■ EPTO type ① Mo ve the Re mot e C ontrol l ever to Neutral (N) and let the engine idle fo r 2- 3 m in ut es t o a ll ow i t to co ol down. ② T ur n the mai n sw itch key co unter- cloc[...]

56 ENGINE OPERA TION 6 ■ EFO, EFTO, EPT O type ③ Disconnect the fuel connector from the engine. ④ Close the air vent screw on the fuel tank cap. Notes ● Af ter stopping the e ngine, close the air vent screw on th e tank ca p. ● Disco nnect t he fuel c onne ctor of the engin e or the f uel tan k. ● Dis conn ec t the c abl es fr om t he b[...]

57 ENGINE OPERA TION 6 ■ Improper Trim Angle (bow dips into the water) If the trim angle is too small, the bow w i l l d i p i n t o w a t e r , t h e s p e e d w i l l d ec r e a s e, a nd w a te r m a y e n t e r t h e boat. In this case, the trim angle should be increased by setting the th rust rod in a higher hole. The following instructions [...]

58 ENGINE OPERA TION 6 EFTO, EPT O type The Provided Power T rim & Tilt can be adjusted to set the desired trim angle o f t h e o u t b o a rd m o t o r i n r e l at i o n t o th e t r an s o m s h a pe , p l an i n g s p e ed s and load. It is imperative that the trim ang le is ad just ed co rrect ly . Inc orrec t a d j u s t m e n t w i l l c[...]

59 ENGINE OPERA TION 6 ■ Improper T rim Angle (bow rises too high) I f t h e t r i m a n g l e i s e x c e s s i v e , t h e bow will rise out of the water and the speed will decrease. F u r t h er mo r e , t h e b o w m a y s w a y o r the bottom may slam the water whil e cruising. In t his c ase, decrease the trim angle by pressing the switch o[...]

60 ENGINE OPERA TION 6 Wh en t h e en gi ne ha s b ee n s to pp ed and it will not be used for a long time or when mooring in sha llow wat er , tilt the e ngi ne u p to pre ven t dam age t o the propeller and gear case. EFO type ① Disconnect the fuel connector from the engine. ② Set the Reverse Lock Lever on the s t a r b o a rd s i d e t o &qu[...]

61 ENGINE OPERA TION 6 ② O p e r a t e t h e P o w e r Tr i m & T i l t switch and tilt and engine up. The engine can also be tilted up using the swit ch p rovided und er the Lowe r Engine Cover . ③ Lo c k th e t il t w it h th e T il t s to p p er after the engine has been ti lted up. ④ T o t i l t t h e e n g in e d ow n , T u r n t he [...]

62 ENGINE OPERA TION 6 POWER MANUAL 30 ・ 40 ・ 50 ④ Manual tilting I f t h e b a t t e r y i s d e a d , a n d t h e P o w e r Tr i m & T i l t S w i t c h t h u s inopera tive, t urn the manual valve a few turns in the Manual dir ection. This will allow manual tilting of the engine. ! WARNING Do no t til t up or d own o ut bo ard m oto r [...]

63 REMOVING AND CARR YING THE OUTBOARD MOTOR 7 1. Removing the outboard motor ① Stop the engine. ② Disconnect the fuel connector , the remote c ontrol c ables, the batte ry c o rd s , b r a c k e t f i x i n g b o l t s a n d nuts etc. ③ R em ov e t he ou tb oa rd m ot or f rom th e hu ll an d co mp le te ly d ra in th e water from the gear c[...]

64 REMOVING AND CARR YING THE OUTBOARD MOTOR 7 Kee p t he mo tor in a ve r tica l pos itio n when you store it. ■ EFO type ＊ T i e t h e c l a m p b r a c k e t t o t h e outboard with a r ope. ＊ Pay attention to the tilting direction s o a s n o t t o b e i n j u r e d b y t h e springing clamp bracket. Note If you store the mo tor in a hori[...]

65 TRAILERING 8 TRAILERING When trailering the outboard motor should be in a v er tical (normal running) position, fully down. T railering in the tilted position may cause damage to the outboar d motor , boat, etc. If tra ile rin g wi th ou tb oa rd mo tor fu lly dow n is n ot avai lab le (t he gea r c as e ske g is to o cl ose t o the r oad in a v[...]

66 ADJUSTMENT 9 ADJUSTMENT ■ EPTO type only 　 (Throttle friction adjustment scr ew) T o a d j u s t t h e l o a d o f t h e r e m o t e co ntro l l eve r , t ur n t he t hro tt le f ri ct io n ad jus tm en t sc rew on t he f ron t of t he re m o t e c o n t r o l B o x . T u r n c l o c k w i s e t o i n c r e a s e t h e l o a d a n d c o u n [...]

67 ADJUSTMENT 9 ■ 30, 40, 50 type S t e e r i n g l o a d c a n b e a d j u s t e d b y turning the steering adjust bolt on the Swivel Bracket. T ur n clockwise to increase load T u r n c o u nt e r-c l oc k w i se t o d ec r ea s e the load EFO EFTO, EPT O ■ EFO, EFTO type T u r n t h e f r i c t i o n a d j u s t m e n t s c re w on th e s te[...]

68 INSPECTION AND MAINTENANCE 10 Care of your outboard motor T o ke e p y ou r o u t bo a rd m o to r i n t he b e s t o pe ra t in g c o n di t io n , i t i s v er y impo rt ant tha t y ou per for m dai ly a nd pe ri o di c m ai nt e na nc e a s s u gg es te d i n t h e m ai nt en an c e s c he d ul es t h a t follow . EP A Emissions Regulations E[...]

69 INSPECTION AND MAINTENANCE 10 P e r f o r m t h e f o l l o w i n g c h e c k s a n d inspection before and after use. 1. Daily inspection ! WARNING Do no t u se o ut boa rd m ot or on wh ich an y abn or ma lity is fo un d d uri ng pr e-op er ati on che ck, or it cou ld go i nt o t ro ub le dur in g cru is in g po t ent ia ll y l ea di ng t o ac[...]

70 INSPECTION AND MAINTENANCE 10 W ashing with fresh water W he n t h e e n g i n e h a s b e en u s e d i n salt water or polluted water , wash the exterior a nd flush the cooling pas sage w i t h f r e s h w a te r u s i n g t h e f l u sh in g attachment. Sc r e w t he in c lu d ed flu sh i ng attachment into the wash hole on the gear case. Co[...]

71 INSPECTION AND MAINTENANCE 10 Replacing the propeller A wor n-out or bent propeller will lower the m oto r's p er for m anc e, an d cau se engine trouble. Before removing the prop eller , remove th e s pa r k pl u g ca p s fr om t he s p ar k p l u g s t o p r o t e c t a g a i n s t p e r s o n a l injury . ① Pu l l o u t t h e s p li t [...]

72 INSPECTION AND MAINTENANCE 10 W h e n r e u s i n g s p a r k p l u g s , r e m o v e d i r t f ro m t h e e l e c tr o d e s a n d a d ju s t spark gap to specification. ① Remove the top cowl. ② Remove the spark plugs by turning cou nter-cloc kwi se wit h t he so cket wre nc h ( 16 mm : 5 /8 in ) f it t ed w i th the handle. T ap lightly o[...]

73 INSPECTION AND MAINTENANCE 10 It i s im p or ta nt t o in s pe c t an d m ai n t ai n yo u r ou t b oa rd m ot o r re gu l ar l y . A t ea c h interval o n the chart below , be sur e to perform the indi cated servi cing. Mainte nance int er val s sh ou ld be d et er mi ne d acc ordi ng t o th e num be r of h our s or n umb er o f months, whichev[...]

74 INSPECTION AND MAINTENANCE 10 Description Inspection intervals Inspection procedure Remarks First 20 hours or 1 month Every 50 hours or 3 months Every 10 0 hours or 6 months Every 20 0 hours or 1 years Engine oil system Oil tank ○ ○ ○ Check and clean or Replace if necessary . Oil pipe ○ ○ ○ Oil filter ○ ○ ○ Check and clean or [...]

75 INSPECTION AND MAINTENANCE 10 Replacing gear oil ① Rem ove t he o il pl ugs ( upp er a nd lo w e r ) , an d c o m p le t e l y d ra i n t h e gear oil into a pan. ② In ser t t he o il t ub e no zz le i nto t he l o w e r o i l p l u g h o le , a n d f i l l w i t h gear oil by squee zing th e oil tube until oil flows out of the upper plug h[...]

76 INSPECTION AND MAINTENANCE 10 Fuel Pick-up Elbow Filter Cleaning T anks and Filters ◎ Fuel filters are provided inside the fuel tank and on the engine. Loose n a Fuel Pic k-up Elbow and r e m o v e i t . T h e n c l e a n t h e F u e l Filter . ◎ Cleaning Fuel T ank Water or d ir t in t he f ue l t an k ma y cause engine trouble. Cl ea n th[...]

77 INSPECTION AND MAINTENANCE 10 Ch e c ki n g a nd R e fi l l in g O il i n t h e Power T rim & T ilt. ① Check the oil level of the reservoir ta n k as s h ow n o n t h e r i g ht w h il e t h e t a n k i s k e p t i n a v e r t i c a l p o s i t i o n . T i l t t h e e n g i n e u p t o check the oil level in the tank. R e m o v e t h e o i[...]

78 INSPECTION AND MAINTENANCE 10 ③ A i r p u r g i n g f ro m t h e P o w e r T r i m and Tilt unit. E n t r a p p ed a i r i n t he P o w e r T r i m & T i l t u n i t w i l l c a u s e p o or t i l t i n g m o v e m e n t . W i t h t h e e n g i n e m o u n t e d o n t h e b o a t , s e t t h e manual rel ease va lve to the Man ual sid e, a[...]

79 INSPECTION AND MAINTENANCE 10 W h e n y o u r o u t b o a r d m o t o r i s i n storage, this is a good opportuni ty to have it ser viced or over hauled by your dealer . ■ Engine ① W a s h t h e e n g i n e e x t e r i o r a n d f l u s h t h e c o o l i n g w a t e r s y s t e m thoroughly with fresh water . Let the water drain completely .[...]

80 INSPECTION AND MAINTENANCE 10 ■ Battery ① Disconnect the battery cords. ② C le a n t h e e x t e r io r o f t h e b a t t e r y with fresh water or compr essed air . W i p e o ff a n y c h e m i c a l d e p o s i t s , dirt and grease from the battery . ③ A p p l y g r e a s e t o t h e b a t t e r y terminals. ④ C h a r g e t h e b a [...]

81 INSPECTION AND MAINTENANCE 10 Ha v e y o u r d e a l e r ch e c k t h e e n g i n e b e f o re t h e s e a s o n s t a r ts , o r i f y o u r prefer , be sure to check the following items yourself: ① C h e c k t h e e l e c t r o l y t e l e ve l , a nd mea sure th e vol tag e and s pec ifi c gravity of the battery . ② C h ec k t h a t t h e[...]

82 INSPECTION AND MAINTENANCE 10 Af te r p ic k up , i mm ed ia te ly br in g t he outboard to your dealer . F o l l o w i n g a r e t h e e m e r g e n c y m e a s u r e s t o b e t a k e n o n t h e submerged outboard. ① T a k e i t o u t o f w a t e r i m m e d i a t el y a n d w a s h i t w i t h f re s h w a t e r t o remove all traces of sa[...]

83 TROUBLESHOOTING 11 If y ou e nc o un t er pr ob l em w it h t h e e n gi n e, c he c k t h e l is t be l ow a nd l oc a te t he problem you ar e experiencing. Then follow the suggested remedies. Do not hesitate to co ntact you r dealer , as profession als advi ce and assistance is the best way to keep the engine in optimum condition. TROUBLESHOO[...]

84 TROUBLESHOOTING 11 Difficult to start engine Engine runs erratically Boat speed loss Battery will not hold charge Starter motor will not crank Power T rim & Tilt Inoperative Possible causes ● ● Propeller cavitation ● Incorrect propeller selection ● ● Damaged or bent propeller ● Unbalanced loading. Overload ● T ran som is to o [...]

85 TOOL KIT AND SP ARE P ARTS 12 The following a list of the tools and spare parts provided with the motor . T OOL KIT AND SP ARE P ARTS 30 , 40 , 50 Name Quantity Remark Servicing T ools T ool Bag Socket Wr ench (16mm) Socket Wr ench (10 × 13) Socket Wr ench Handle Pliers Screwdriver (Phillips-type and flat head) 1 1 1 1 1 1 Adapter -type Spare [...]

86 TOOL KIT AND SP ARE P ARTS 12 The following a list of the tools and spare parts provided with the motor . 75 , 90 ,1 15 Name Quantity Remark MD 75/90 MD 1 15 Servicing T ools T ool Bag Socket Wr ench (16mm) Socket Wr ench (10 × 13) Socket Wr ench Handle Pliers Screwdriver (Phillips-type and flat head) 1 1 1 1 1 1 1 1 1 1 1 1 Adapter-type Spare[...]

87 OPTIONAL ACCESSORIES 13 OPTIONAL ACCESSORIES Flushing attachimen t Speedometer (50MPH) Speedometer (75MPH) Water Pressure Meter Voltmeter Hour Meter (engine operation hour counter) Fuel Meter Tachometer Drive cleaner OM_E_MD30B2-115A2_body_111213.indd 87 11/12/13 13:07[...]

88 OPTIONAL ACCESSORIES 13 Tie Bar Kit B (for twin-engine operation) Genuine gear oil (500ml) Twin-control Box Kit (for twin-engine operation) Propeller Touch-up Spray Paint Engine oil (4l) OM_E_MD30B2-115A2_body_111213.indd 88 11/12/13 13:07[...]

89 PROPELLER T ABLE 14 T o ensure optimum perfor mance, the propeller should match the boat type and its load. Use a genuine propeller . A pr op e l l er m u s t be s e l ec t e d s o t h a t th e e n gi n e r p m m e a s ur ed a t w i de o p e n throttle, while cruising, is within the r ecommended range. 5,150 to 5,850 rpm PROPELLER T ABLE CS15 CS[...]

M E M O M E M O OM_E_MD30B2-115A2_body_111213.indd 90 11/12/13 13:07[...]

RE AD TH IS MA NU AL BE FO RE US IN G T HE OU TB OA RD M OTO R. FAIL UR E TO FO LL OW TH E IN S T R UC T I O NS AN D S A F E TY P R EC A U T IO N S I N T H IS MA N U A L C A N R E SU LT IN SE R I OU S INJUR Y OR DEA TH. KEEP THIS MANUAL IN A SAFE LOCA TION FOR FUTURE REFERENCE. ! Copyright © 2009-2012 T ohatsu Corporation. All rights reserved. No [...]

MANUAL 30B2 4 0B2 5 0B2 75C2 90C2 1 1 5A2 M D OWNER’S OB No.003-11075-D OWNER’S MANUAL 30B2 4 0B2 5 0B2 75C2 90C2 1 1 5A2 M D TOHATSU CORPORATION 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 003-11075-D   1109NB Printed in Japan OM_E_MD30B2-11[...]