Owner'S Manual: MD 40B MD 50B MD 75C MD 90C MD 115A MD 30B

O W N E R’ S
MANUAL
トーハツ船外機オーナーズマニュアル
Original instructions
MD 30B2
MD 40B2
MD 50B2
MD 75C2
MD 90C2
MD 115A 2
OB No.003-11119-5AH1
ENOM00001-0
READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE INSTRUCTIONS
AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. KEEP THIS
MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.
Copyright © 2018 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 written permission of Tohatsu Corporation.
3
YOUR TOHATSU OUTBOARD MOTOR

ENOM00006-A
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 proce-
dures described later in this manual should be followed carefully. Should a problem
arise with the outboard motor, please follow the troubleshooting procedures listed at
the end of this manual. If the problem persists, contact an authorized TOHATSU ser-
vice shop or dealer.
All information in this manual is based on the latest product information available at
the time of approval for printing.
Tohatsu Corporation reserves the right to make changes at any time without notice and
without incurring any obligation.
Please always keep this manual together with the outboard motor as a reference to
everyone who uses the outboard motor. If the outboard motor is resold, make sure
the manual is passed on to the next owner.
We hope you will enjoy your outboard motor and wish you good luck in your boating
adventures.
TOHATSU CORPORATION
ENOM00113-0
EC DECLARATION OF CONFORMITY (DoC)
This product conforms to certain portion of the European Parliament directive. DoC
contains the following information;
z Name and Address of the manufacturer.
z Applied community directives
z Reference standard
z Description of the product. (Model name and serial number)
z Signature of the responsible person (Name / Title / Date and place of issue).
4
ENOM00002-0
OWNER REGISTRATION AND IDENTIFICATION
Upon purchasing this product, be sure that the WARRANTY 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 THE EXTENT PERMITTED BY APPLICABLE LAW, YOUR OUTBOARD MOTOR WILL NOT
BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS PROCEDURE IS NOT
FOLLOWED.
ENOM00003-0
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before
you take delivery.
5
ENOM00005-A
Serial Number
In the space below, please record the outboard motor's serial number (indicated both
on the bottom cowl and on the cylinder block). The serial number will be needed when
ordering parts, and when making technical or warranty inquiries.
Serial Number:
30, 40 50
ENOF01300-1 ENOF01301-0
75, 90
ENOF01302-1 ENOF01303-0
115
ENOF01305-0
ENOF01302-1
Serial Number: Date of purchase:

6
ENOM00007-0
NOTICE: DANGER/WARNING/CAUTION/Note
Before installing, operating or otherwise handling your outboard motor, be sure to thor-
oughly read and understand this Owner's Manual and carefully follow all of the instruc-
tions. Of particular importance is information preceded by the words “DANGER,”
“WARNING,” “CAUTION,” and “Note.” Always pay special attention to such information
to ensure safe operation of the outboard motor at all times.
ENOW00001-0
DANGER
Failure to observe will result in severe personal injury or death, and possibly property damage.
ENOW00002-0
WARNING
Failure to observe could result in severe personal injury or death, or property damage.
ENOW00003-0
CAUTION
Failure to observe could result in personal injury or property damage.
ENON00001-0
Note
This instruction provides special information to facilitate the use or maintenance of the outboard
motor or to clarify important points.
CONTENTS
1. GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. PARTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4. LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2. Remote control device installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3. Battery installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4. Propeller installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5. TOCS (Tohatsu Onboard Communication System) installation. . . . . . . . . 34
6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5. Warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1. Engine oil feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
7. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . . . . . . .67
1. Removing the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
3. Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9. ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3. Remote control lever friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
10. INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6. Cold weather precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8. Operation with multiple outboard motors . . . . . . . . . . . . . . . . . . . . . . . . 95
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
12. ACCESSORIES KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
9
INDEX
1. GENERAL SAFETY INFORMATION 1
2. SPECIFICATIONS 2
3. PARTS NAME 3
4. LABEL LOCATIONS 4
5. INSTALLATION 5
6. PRE-OPERATING PREPARATIONS 6
7. ENGINE OPERATION 7
8. REMOVING AND CARRYING THE OUTBOARD
MOTOR 8
9. ADJUSTMENT 9
10. INSPECTION AND MAINTENANCE 10
11. TROUBLESHOOTING 11
12. ACCESSORIES KIT 12
13. PROPELLER TABL 13
1
10
GENERAL SAFETY INFORMATION
ENOM00009-0
SAFE OPERATION OF BOAT
1 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. To learn about the correct operation and maintenance of the
outboard motor, please read through this manual carefully.
It is very difficult for a person standing or floating in the water to take evasive action
should he or she see a power boat heading in his/her direction, even at a slow speed.
Therefore, when your boat is in the immediate vicinity of people in the water, the
outboard motor should be shifted to neutral and shut off.
ENOW00005-0
WARNING
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOVING
BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TO A BOAT OR
GEAR HOUSING.
ENOM0008-A
EMERGENCY STOP SWITCH
The Emergency Stop Switch will stall the outboard motor when the stop switch lan-
yard is pulled off. This stop switch lanyard has to be attached to the operator of the
outboard motor to minimize or prevent injuries from the propeller in case the opera-
tor falls overboard.
It is operator’s responsibility to use the Emergency Stop Switch Lanyard.
ENOW00004-A
WARNING
Accidental activation of the Emergency Stop Switch (such as the tether being pulled out in
heavy seas) could cause passengers to lose their balance and even fall overboard, or it could
result in loss of power in heavy seas, strong currents, or high winds. Loss of control while
mooring is another potential hazard.
To minimize accidental activation of the Emergency Stop Switch, the 500 mm (20 inch.) stop
switch lanyard is coiled and can extended to a full 1300 mm (51 inch.).
ENOM00800-A
PERSONAL FLOATATION DEVICE
As the operator/driver and passenger of the boat, you are responsible to wear a PFD
(Personal Flotation Device) while on the boat.
GENERAL SAFETY INFORMATION 11
ENOM00010-0
SERVICING, REPLACEMENT PARTS & LUBRICANTS
We recommend that only an authorized service shop perform service or maintenance 1
on this outboard motor. Be sure to use genuine parts, genuine lubricants, or recom-
mended lubricants.
ENOM00011-A
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct mainte-
nance procedures following maintenance section of this manual (See page 68). It is
the operator's responsibility to perform all safety checks and to ensure that all lubri-
cation and maintenance instructions are complied with for safe operation. Please
comply with all instructions concerning lubrication and maintenance. You should take
the engine to an authorized dealer or service shop for periodic inspection at the pre-
scribed intervals.
Correct periodic maintenance and proper care of this outboard motor will reduce
the chance of problems and limit overall operating expenses.
Carbon Monoxide Poisoning Hazard

Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be
fatal if inhaled for any length of time.
Never start or operate the engine indoors or in any space which is not well ventilated.
Gasoline
Gasoline and its vapors are very flammable and can be explosive. Use extreme care
when handling gasoline. You should be thoroughly knowledgeable on how to correctly
handle gasoline by reading this manual.
12
SPECIFICATIONS
ENOM00810-A
MODEL FEATURE
Model D30B2 D40B2 D50B2
Type ETO ETO EO ETO EO
2 Transom heights
S
L
z
z
z
z
z
z
z
z
z
z
Electrical start z z z z z
Multi-function tiller handle *1 *1 *1 *1 *1
Remote Control z z z z z
Power Trim & Tilt z z z
Manual tilt z z
*1 Option.
Model D75C2 D90C2
Type EPTO EPTO
L z z
Transom heights
UL z z
Electrical start z z
Remote Control z z
Power Trim & Tilt z z
Oil auto-mixing z z
Model D115A2
Type EPTO
L z
Transom heights
UL z
Electrical start z
Remote Control z
Power Trim & Tilt z
Oil auto-mixing z
(z) These models can be purchased with remote rigging kit or multi function -A
MODEL NAME EXAMPLE
D115A2 EPTOL
D 115 A2 E P T O L
Model Horse Product Starter Steering Tilt Lubrica- Shaft
genera- tion
description power tion system system system system length
P=Remote
controlࠉ
(Pleasure)
T= Power
F=Tiller han- S= Short
dle trim&tilt O=
15 in
E= Electrical (Fisher) Oil auto-
L= Long
F= Four stroke start G= mxing
D= Two stroke DI - A and up M= Manual Gas assist Blank=
20 in
*Multi- UL=
start function Oil Pre-mix-
Ultra long 25
tiller handle is Blank= ing
Manual tilt in
available as
an optional
part
SPECIFICATIONS 13
ENOM00601-0
30B2 (Available in specific region), 40B2
30B2 40B2
Item MODEL
EPTO 2
Overall Length mm (in) 630 (24.8)
Overall Width mm (in) 355 (14.0)
Overall Height S·L mm (in) 1227 (48.3) 1354 (53.3)
Transom Height S·L mm (in) 403 (15.9) 530 (20.9)
S kg (lb) 93.5 (206)
Weight
L kg (lb) 94.5 (208)
Output kW (ps) 22.1 (30) 29.4 (40)
Max. Operating Range min-1 (rpm) 4750–5750 5150–5850
Idle Speed min-1 (rpm) 700/800/900 *1
Engine Type Direct fuel injection
Number of Cylinder 3
Bore × Stroke mm (in) 68 × 64 (2.68 × 2.52)
Piston Displacement cm3 (Cu in) 697 (42.5)
Exhaust System Through hub exhaust
Cooling System Water cooling
Engine Lubrication Oil injection
Starting System Electric starter motor
Ignition System Inductive Ignition
Spark Plug NGK IZFR6Q
Alternator 12 V, 280 W (Max.)
Trim Position 4
Engine Oil Genuine Motor Oil or recommended one
Gear Oil Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 500 mL
Fuel Tank Capacity L (US gal) 25 (6.6)
Engine Oil Capacity L (US gal) Approx. 2.0 (0.53)
Gear Reduction Ratio 1.85 (13 : 24)
Fuel Unleaded Regular Gasoline : R+M/2: 87 or higher RON: 91 or higher
Emission Control System DFI (Direct Fuel Injection)
Operator Sound Pressure
84.0
(ICOMIA 39/94) dB (A)
Hand Vibration Level
—
(ICOMIA 38/94) m/s2
Remark: Specifications subject to change without notice.
*1: The idling speed can be set to any of the three rpm ranges, 700, 800 or 900. (See page 53)
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
14 SPECIFICATIONS
ENOM00601-1
40B2
40B2
2 EPTO EPO
Item MODEL (with multi-func- (with multi-func-
EPO
tion tiller handle tion tiller handle
*option) *option)
Overall Length mm (in) 775 (30.5) 630 (24.8)
Overall Width mm (in) 355 (14.0) 345 (13.6)
S kg (lb) 97.5 (215) 89.5 (197) 85.5 (188)
Weight
L kg (lb) 98.5 (217) 90.5 (200) 86.5 (191)
Output kW (ps) 29.4 (40)
Max. Operating Range min-1 (rpm) 5150–5850
Bore × Stroke mm (in) 68 × 64 (2.68 × 2.52)
Trim Position 4 6
84.0
3.8 —
(ICOMIA 38/94) m/s2
SPECIFICATIONS 15
ENOM00602-0
50B2
50B2
EPTO 2
Item MODEL
EPTO (with multi-function
tiller handle *option)
Overall Length mm (in) 630 (24.8) 775 (30.5)
S kg (lb) 93.5 (206) 97.5 (215)
Weight
L kg (lb) 94.5 (208) 98.5 (217)
Bore × Stroke mm (in) 68 × 64 (2.68 × 2.52)
Trim Position 4
84.0
— 3.8
(ICOMIA 38/94) m/s2
16 SPECIFICATIONS
ENOM00604-0
75C2, 90C2
75C2 90C2
2 Item MODEL
EPTO
Overall Height L·UL mm (in) 1540 (60.6) 1667 (65.6)
Transom Height L·UL mm (in) 517 (20.4) 644 (25.4)
Weight L·UL kg (lb) 150 (331) 153 (337)
Output kW (ps) 55.2 (75) 66.2 (90)
Bore × Stroke mm (in) 86 × 72.7 (3.39 × 2.86)
Piston Displacement cm3 (Cu in) 1267
Trim Position 2
Fuel Tank Capacity L (US gal) —
Engine Oil Capacity L (US gal) Approx. 4 (1.06)
Gear Reduction Ratio 2.33 (12:28)
81.7
—
(ICOMIA 38/94) m/s2
SPECIFICATIONS 17
ENOM00605-0
115A2
115A2
Item MODEL
EPTO 2
Overall Height L·UL mm (in) 1640 (64.6) 1767 (69.6)
Transom Height L·UL mm (in) 517 (20.4) 644 (25.4)
Weight L·UL kg (lb) 178 (392) 181 (399)
Bore × Stroke mm (in) 88 × 72.7 (3.46 × 2.86)
Spark Plug NGK IZFR5J
Trim Position 2
Fuel Tank Capacity L (US gal) —
Gear Reduction Ratio 2.0 (13:26)
83.3
—
(ICOMIA 38/94) m/s2
18
PARTS NAME
ENOM00607-0
ETO (with multi-function tiller handle)/40B2, 50B2
19
1
3 16
15
2
23
3 18
4 17
5
14 21
13
6 20
7 12 22
8 11
9
10
24 25
26 ENOF01307-0
1 Tilt Handle 13 Clamp Bracket 25 Spark Plug

2 Top Cowl 14 Thrust Rod 26 Fuel Filter
3 Hook Lever 15 Throttle Grip
4 Water Check Port 16 Shift Lever
5 Tilt Stopper 17 Stop Switch
6 Water Plug 18 Pilot Lamp
7 Anti-ventilation Plate 19 Main Switch
8 Trim Tab 20 Battery Cords
9 Propeller 21 Power Trim & Tilt
10 Oil Plug (lower) 22 Anode
11 Water Inlet 23 Power Trim & Tilt Switch
12 Oil Plug (upper) 24 Oil Tank
PARTS NAME 19
ENOM00608-0
ETO (with RC)/30B2, 40B2, 50B2
3
2
15 16
3
4
5
14 18
13
6 17
12 19
7
11
8
9
10
20 21
22 ENOF01308-0
1 Tilt Handle 13 Clamp Bracket

2 Top Cowl 14 Thrust Rod
3 Hook Lever 15 Power Trim & Tilt Switch
4 Water Check Port 16 Fuel Connector
5 Tilt Stopper 17 Battery Cords
6 Water Plug 18 Power Trim & Tilt
7 Anti-ventilation Plate 19 Anode
8 Trim Tab 20 Oil Tank
9 Propeller 21 Spark Plug
10 Oil Plug (lower) 22 Fuel Filter
11 Water Inlet
12 Oil Plug (upper)
20 PARTS NAME
ENOM00609-0
EPTO/75C2, 90C2
1
3 2 15
3
14
19
3
4 16
12 17
13
18
6
5, 9
7
11
8 10
20 21
22 ENOF01309-0
1 Tilt Handle 13 Thrust Rod

2 Top Cowl 14 Fuel Nipple
3 Hook Lever 15 Power Trim & Tilt Switch
4 Water Check Port 16 Battery Cords
5 Water Plug 17 Power Trim & Tilt
6 Anti-ventilation Plate 18 Anode
7 Trim Tab 19 Flushing Connector Cap
8 Propeller 20 Oil Tank
9 Oil Plug (upper) 21 Spark Plug
10 Water Inlet 22 Fuel Filter
11 Oil Plug (lower)
12 Clamp Bracket
PARTS NAME 21
ENOM00610-0
EPTO/115A2
2 15 3
3
14
19
3 16
4 12
17
6 13
18
5, 9
7
8 10 11
20 21
22 ENOF01310-0
1 Tilt Handle 15 Power Trim & Tilt Switch

2 Top Cowl 16 Battery Cords
3 Hook Lever 17 Power Trim & Tilt
4 Water Check Port 18 Anode
5 Water Plug 19 Flushing Connector Cap
6 Anti-ventilation Plate 20 Oil Tank
7 Trim Tab 21 Spark Plug
8 Propeller 22 Fuel Filter
9 Oil Plug (upper)
10 Water Inlet
11 Oil Plug (lower)
12 Clamp Bracket
13 Thrust Rod
14 Fuel Nipple
22 PARTS NAME
ENOM00822-0
Remote control box & Fuel tank
9
1 11
10
3 3
2
13
15 14
4
5 12
16
7 6
8 17 18
19
22
21
20 ENOF00127-H1
1 Control Lever 13 Main switch

2 Neutral lock arm 14 Stop switch
3 PTT switch 15 Stop switch lock
4 Free throttle lever 16 Stop switch lanyard
5 Main switch 17 Fuel gauge
6 Stop switch 18 Air vent screw
7 Stop switch lock 19 Fuel tank cap
8 Stop switch lanyard 20 Fuel connector (Engine side)
9 Control lever 21 Primer bulb
10 Neutral lock arm 22 Fuel connector (Fuel tank
11 PTT switch side)
12 Neutral throttle button
23
LABEL LOCATIONS
ENOM00019-A
Warning label locations
1, 2 30/40/50
7
6
5
2 (115), 3
4
75/90/115 7
12
9
11
13
10
14
ENOF01311-2
24 LABEL LOCATIONS
1. Warning label regarding owner’s man- 5. Warning label regarding stop switch
ual, top cowl, engine stop switch, (See page 57).
ENOF00005-P
6. Indicator label regarding engine fail-

ure/malfunction (See page 40).)
4
ENOF00005-W
2. Warning regarding engine oil replen-

ishment. (See page 37, 40) ENOF00005-C
7-1. Warning regarding emergency start-

ing (See 49).
7-2. Warning regarding high temperature.
7-3. Warning regarding rotating object.
7-4. Warning regarding high voltage.
7-5. Caution regarding fuel filter. (See
page 58, 63, 67)
3T1-72043-0
3. Warning label regarding installation of

remote control system (See page 30).
ENOF00120-0 1 4
4. Warning regarding engine oil replen- 3
ishment (See page 37, 40). 2 3KZX72181-1
Affix this label near the outboard

motor where it can be easily read.
3B7-72043-0
LABEL LOCATIONS 25
8. Indicator label regarding engine fail- 12. Warning regarding gasoline (See
ure/malfunction (See page 40). page 35).
stick this label at pace near the
driver's seat where is easy to see.
ENOF00005-L
13. Warning regarding gasoline (See
page 35).
4
3T5-72050-0
For RC model
ENOF00005-M
9. Warning label on engine stop switch.
14. Warning regarding gasoline (See
page 35).
ENOF00008-0
For Top mount RC

10. Warning label urge to read the
owner's manual.
ENOF00005-F
ENOF00120-0
11. Warning regarding gasoline.
ENOF00005-E
26 LABEL LOCATIONS
ENOM00019-B
CE label locations
O utboard Motor
1)
0123 R a te d Power: 2)
Ma ss: 3)
4)
4
Serial No.
5)
6)
Made in Japan CAN ICES-2/NMB-2
ENOF01312-1
1. Model code(Model name)

2. Rated power
3. Dry mass weight( Without propeller, with battery
cable)
4. Serial No.
5. Manufacturer name
6. Manufacturer address
Description of serial number year code

Last two digits of alphabet represent production year as below.
Year Code AG AH AK BX BA
Year of
2017 2018 2019 2020 2021
manufacture
27
INSTALLATION
ENOM00024-A ENOW00009-0
1. Mounting the outboard WARNING

motor on boat
z Mounting the outboard motor without
following this manual can lead to unsafe
ENOW00006-B
conditions such as poor maneuverability,
WARNING lack of control or fire.
z Loose clamp screws and/or mounting
Before installing the outboard motor on the bolts can lead to the release or displace-
boat, hang the outboard motor with the ment of the outboard motor, possibly
hoist or equivalent device by attaching the resulting in lost of control and/or serious
engine hanger to the outboard. Use the hoist personal injury. Be sure that fasteners are
with allowable load is 250 kg (550 lbs) or tightened to the specified torque (30 N·m
above. (3.0 kgf·m) 13 ft·lb). Check the fasteners
for tightness from time to time.
z Be sure to use outboard mounting fasten-
ers included in the outboard motor pack-
5
age or their equivalents in terms of size,
material, quality and strength. Tighten
fasteners to the specified torque (30 N·m
(3.0 kgf·m) 13 ft·lb). Test cruise to check
if fasteners are tightened securely.
z Outboard motor mounting must be per-
formed by trained service person(s) using
lift or hoist with sufficient capacity.
Outboard motor mounting must be per-

formed by trained service person(s)
using lift or hoist with sufficient capac-
ity.
ENOF01313-0
ENOW00006-0
WARNING
Most boats are rated and certified in terms
of their maximum allowable horsepower, as
shown on the boat’s certification plate. Do
not equip your boat with an outboard motor
that exceeds this limit. If in doubt, contact
your dealer.
Do not operate the outboard motor until it
has been securely mounted on the boat in
accordance with the instructions below.
28 INSTALLATION
ENOM00025-0 attitude. Check the position of water sur-

Position ... Above keel line face on the driveshaft housing. If the
Set engine at center of boat. water surface is near the bottom cowling,
in high waves, water may enter the engine
1 cylinders.
z Incorrect outboard motor mounting
h e i g h t o r e x i s t e n c e o f un d e r wa t e r
object(s), such as hull bottom design,
bottom surface conditions or underwa-
ter accessories, can cause water spray
possibly reaching the engine through an
2 opening of the bottom cowling during
cruising. Exposing the engine to such
conditions for extended periods can lead
to severe engine damage.
5 1. Center of boat
ENOF01141-0
2. Boat transom ENOM00830-B

Mounting bolts
ENOM00026-0
Transom matching Manual tilt type
Be sure that the anti ventilation plate of 40, 50
the outboard motor is 10–30 mm (0.4– 1. To attach the outboard motor to the
1.2 in) below the bottom of hull. boat, tighten the clamp screws by
If the above condition cannot be met turning their handles.
due to the shape of the bottom of your Also, use the bolts to secure the out-
boat, please consult your authorized board motor brackets on transom
dealer. board.
Secure the outboard motor with a
rope to prevent loss overboard.
ENON00002-0
Note
1 A rope is not included in the standard
10−30 mm accessories.
(0.4−1.2 in)
2
ENOF01344-0
1. Bottom of hull
2. Anti ventilation plate
ENOW00007-0
CAUTION
z Before beginning the running test, check
that the boat with maximum capacity
loading floats on the water in a proper
INSTALLATION 29
Power trim and tilt type

1. To attach the outboard motor to the
boat, use the bolts to secure the
outboard motor brackets on transom
1 board.
30, 40, 50
3
2
4 5
1. Clamp Screw
ENOF00610-0
5
2. Washer (small diameter) 2
3. Washer (large diameter)
4. Bolt (12 mm × length 105 mm)
5. Nut 1 4
234 (9.21”)
3 ENOF00612-1
1 1. Washer (small diameter)
117 (4.61”) 117 (4.61”)
39 (1.54”) 3. Bolt (12 mm × length 105 mm)
25 (0.98”) 64 (2.52”) 4. Nut
25 (0.98”) 89 (3.50”)
327
ø13 (12.9”)
204 (8.03”)
102 (4.02”) 102 (4.02”)

(2.0”)
51
222 (8.74”)
18 18 18
ø13 26 (1.02”) 248 (9.76”)
ENOF00611-0 ø12.5
(10.0”)
253.5
1. Top of transom
ENOW00945-0
CAUTION
(2.2”)
56
ø12.5
z Please inspect whether there is a loosen- 251
ing of the clamp screw or mounting bolts (9.9”)
ENOF00613-0
before departure.
z Loosening may cause a dangerous situa-
tion, such as loss of control.
30 INSTALLATION
75, 90, 115 ENON00003-0

Notes
1. Apply sealing agent, such as silicone
sealed between the bolts and the
transom board holes before tighten-
ing the bolts.
2. Be sure to tighten the mounting bolt
nuts to the specified torque.
(30 N·m (3.0 kgf·m) 13 ft·lb)
2
ENOM00840-0
2. Remote control device

3 installation
1
5
ENOW00850-0
4 ENOF00614-0
Remote control box location
1. Bolt (12 mm × length 105 mm)
3. Nut
4. Washer (small diameter)
327
(12.9”)
1 3
51 (2”)
17.5 (0.7”) 1, 2
17.5 (0.7”)
ø13 17.5 (0.7”)
254 (10”)
(0.5”)
ENOF00841-1
(2.2”)
56
1. Shift cable
251 2. Throttle cable
(9.9”)
ENOF00615-0 3. Cable harness B
1. Top of transom
Install the remote control box in a posi-
ENOW00008-A tion where it is easy to reach and oper-
CAUTION ate the controls.
Make sure there are no obstacles that
z Mounting bolts should be installed with can interfere with the operation of the
the bolt head at inside sur face of the
transom. Mounting bolts installed with
remote control cable.
the threaded end at the inside surface of
the transom can cause personal injury.
z Tighten the bolts sufficiency, otherwise
falling down of outboard could be hap-
pened.
INSTALLATION 31
ENOW00850-0 comes in contact with your skin, or poison-

Remote control cable length ous if swallowed.
ENOW00100-A
Keep batter y and electroly te away from
CAUTION reach of children
When handling the battery, be sure to:
Be careful not to loop the remote control z Read all warnings shown on the battery
cables to a diameter of 406 mm (16 in) or case
less. Otherwise, it affects the service life of z Prevent electrolyte from coming in con-
the cable. tact with any part of your body. Contact
can cause serious burn or, if it comes in
contact with your eye, loss of sight. Use
safety glasses and rubber gloves.
In case battery electrolyte comes in contact
with:
z Skin, flush thoroughly with water.
z Eye, flush thoroughly with water, and
then seek immediate medical treatment.
5
In case battery electrolyte is swallowed:
ENOF00842-0 z Seek immediate medical treatment.
ENOW00013-A
Measure the distance from the remote
control box to the outboard motor WARNING
where the remote control cable should Battery generates explosive hydrogen gas.
be routed. Be sure to:
Prepare a cable that is 300-450mm z Charge the battery in a well-ventilated
place.
(11.8-17.7in) longer than the measured
z Place the battery away from any source of
distance. fire, sparks and open flames such as
Temporarily pull the cable along the burners or welding equipment.
intended cable route to check its length z Do not smoke near the battery when the
is sufficient. battery is charging.
z Do not charge the battery when the elec-
Connect the remote control cable to the
trolyte level is low. Otherwise, the battery
engine, then run the cable to the remote will be damaged and may cause malfunc-
control box, making sure it is not sharply tion.
bent, too taut and free from obstruc-
ENOW00014-0
tions that could interfere with steering.
CAUTION
ENOM00029-A
z Make sure that the battery leads do not
3. Battery installation get stuck between the outboard motor
and boat when turning, etc.
ENOW00012-0 z The starter motor may fail to operate if
the leads are incorrectly connected.
WARNING z Be sure to correctly connect the (+) and
(—) leads. If not, the charging system will
Battery electrolyte contains sulfuric acid
be damaged.
and thus is hazardous, causing a burn if it
32 INSTALLATION
z Do not disconnect the battery leads from

battery while the engine is operating, the
electrical parts could be damaged.
z Always use a fully charged battery.
ENOW00015-0
CAUTION
Do not use a batter y that is not recom- 2
mended. Use of a battery not recommended
can lead to poor performance of, and/or 1 ENOF00022-0
damage to, the electrical system. 1. Battery cord (red)

2. Battery cord (black)
ENON00006-A
Note
5 Recommended battery: 12V 100Ah/5HR,
ENOM00123-0
850 (Cold Cranking Amps (CCA), In case of 4. Propeller installation

cold whether: 12V120Ah/5HR (1000CCA))
Specifications and features of batteries ENOW00085-A
vary among the manufacturers. Consult
the manufacturer for details. WARNING
* The battery should be purchased sepa-
rately and is not supplied with the out- Do not begin propeller removal and installa-
board motor. t i o n p r o c e dur e w i t h s p a r k p lu g c a p s
attached, shift in forward or reverse, main
1. Place the battery box in a convenient switch at other than “OFF”, engine stop
position away from possible water switch lock attached to the switch, and
spray. Securely fasten both the box starter key attached, or engine could acci-
dentally start leading to serious personal
and the battery so they do not shake
injury.
loose. Disconnect battery cable if possible.
2. Connect the positive lead (+) to the
positive terminal (+) of the battery,
and then connect the negative lead
(—). When disconnecting the battery
always remove the negative lead (—)
first. After connecting the positive
terminal (+), securely place a cap on
it to prevent short circuits.
INSTALLATION 33
ENOW00085-0
1. Remove the split pin, propeller nut
WARNING and washer.
2. Remove the propeller and thrust
Do not hold propeller with hand(s) when
loosening or tightening propeller nut. Put a
holder.
piece of wood block between propeller 3. Apply water proof grease to the pro-
blade and anti-ventilation plate to hold propeller shaft before installing a new
peller. propeller.
4. Install the thrust holder, propeller,
stopper, washer and propeller nut
onto the shaft.
30, 40, 50
6
3 5
5
4
ENOF00084-B
ENOW00086-0
2 1
CAUTION
z Do not install propeller without thrust ENOF01315-0
holder, or propeller boss could be dam- 1. Propeller
aged. 2. Thrust holder
z Do not reuse split pin. 3. Stopper
z After installing split pin, spread the pin 4. Washer
5. Propeller nut
apart to prevent it from falling out which 6. Split pin
could lead to the propeller coming off
during operation. 75, 90
7
Propeller must be selected that will
allow the engine to reach recommended 6
5
maximum operating range during cruis-
4
ing.
Wide-open throttle rpm range 3 1
2
30/40 : 4750 – 5750 min-1 (rpm)
50 : 5150 – 5850 min-1 (rpm)
ENOF01335-0
75/90 : :5150 – 5850 min-1 (rpm)
1. Propeller
115 : 5150 – 5850 min-1 (rpm) 2. Thrust holder
Genuine propellers are listed on PROPEL- 3. Bush
4. Adaptor
LER TABLE of this manual (See page 100). 5. Washer
6. Propeller nut
7. Split pin
34 INSTALLATION
115 ENOM00971-0
5. TOCS (Tohatsu Onboard

4 7 Communication System)
6 installation
5
TOCS (Tohatsu Onboard Communication
System) interface coupler can provide
3 1
2 information regarding engine speed,
fuel consumption, and various malfunc-
ENOF01336-0 tion via an optional interface cable.
1. Propeller Contact authorized Tohatsu dealer for
2. Thrust holder more detail.
3. Bush
5 4.
5.
Stopper
Washer 30, 40, 50
6. Propeller nut
7. Split pin
5. Tighten the propeller nut to speci-

fied torque with holding the propel-
ler by wood block. And align one of
grooves to propeller shaft hole.
Propeller nut torque:
35 N·m (25 ft·lb, 3.5kgf·m)
ENOF01338-0
75, 90, 115
ENOF00084-B
6. Install a new split pin into the nut

hole and bend it.
ENOF01314-0
35
PRE-OPERATING PREPARATIONS
ENOM00030-A
also worsen these adverse effects. Some
1. Fuel handling of these adverse effects are caused
because the ethanol in the gasoline can
ENOW000017-0
absorb moisture from the air, resulting
CAUTION in a separation of the water/ethanol
from the gasoline in the fuel tank.
Use of improper gasoline can damage your
These may cause increased:
engine. Engine damage resulting from the
use of improper gasoline is considered mis- z Corrosion of metal parts
use of the engine, and damage cause d z Deterioration of rubber or plastic
thereby will not be covered under the lim- parts
ited warranty. z Fuel permeation through rubber fuel
lines
ENOM00031-A z Starting and operating difficulties
FUEL RATING
TOHATSU engines will operate satisfac- If the use of gasoline containing alcohol
torily when using a major brand of
6
is inevitable, or presence of alcohol is
unleaded gasoline meeting the following suspected in the gasoline, it is recom-
specifications: mended to add a filter that has water
USA and C anada — having a posted separating capability, and check the fuel
pump Octane Rating of 87 (R+M)/2 mini- system for leaks and mechanical parts
mum. Premium gasoline (92 [R+M]/2 for corrosion and abnormal wear more
Octane) is also acceptable. Do not use frequently.
leaded gasoline. And, in case any of such abnormality is
Outside US A and C ana da — Use found, discontinue the use of such gas-
unleaded gasoline with declared octane oline and contact our dealer immedi-
rating of 91 RON or over. Use of pre- ately.
mium gasoline of 98 RON is also allowed. If the outboard motor will only be used
infrequently, please see the remarks on
ENOM00032-A
fuel deterioration in the STORAGE chap-
GASOLINES CONTAINING
ter (P 87) for additional information.
ALCOHOL
The fuel system components on your ENOW00020-1
TOHATSU engine will withstand up to CAUTION

10% ethyl alcohol (hereinafter referred
When operating a TOHATSU engine on gaso-
to as the "ethanol"), content in the gaso-
line containing alcohol, storage of gasoline
line. But even if the gasoline in your area in the fuel tank for long periods should be
contains ethanol less than 10%, you avoided. Long periods of storage, create
should be aware of cer tain adverse unique problems. In cars, alcohol blend
effects that can occur. Increasing the fuels normally are consumed before they
can absorb enough moisture to cause trou-
percentage of ethanol in the fuel can
ble, but boats often sit idle long enough for
36 PRE-OPERATING PREPARATIONS
phase separation to take place. In addition, z Be sure to remove the static electricity
internal corrosion may take place during charged in your body before refueling.
storage if alcohol has washed protective oil z The sparks due to static electricity may
films from internal components. cause explosion of flammable gasoline.
z Stop the engine, and do not start the
ENOW00018-0 engine during refueling.
z Do not smoke.
WARNING z Be careful not to overfill fuel tank. Wipe
Fuel leakage can cause fire or explosion, up any spilled gasoline immediately.
potentially leading to severe injury or loss of
life. Ever y fuel system par t should b e When or before cleaning the gasoline tank:
checked periodically, and especially after z Dismount fuel tank from the boat.
long term storage, for fuel leak, change of z Place the fuel tank away from every
hardness of rubber, expansion and/or cor- source of ignition, such as sparks or open
rosion of metals. In case any indication of flames.
fuel leakage or degradation of fuel part is z Do the work outdoors or in a well venti-
found, replace relevant part immediately lated area.
before continuing operation. z Wipe off gasoline well immediately if
6
spilled.
ENOM00043-B
After cleaning gasoline tank:
2. Fuel filling z Wipe off gasoline well immediately if
spilled.
ENOW00019-1
z If the fuel tank is disassembled for clean-
ing, reassemble carefully. Imper fec t
WARNING assembly may cause a fuel leak, possibly
Do not fill the fuel tank over capacity. The leading to fire or explosion.
rise of gasoline temperature may cause gas- z Dispose aged or contaminated gasoline in
oline to expand which, may leak through air accordance with local regulations.
vent screw when it is open. Leaking gasoline
is a dangerous fire hazard. ENOW00029-A
ENOW00028-A
WARNING
When opening fuel tank cap, be sure to fol-
WARNING low the procedure described below. Fuel
Consult an authorized dealer for details on could blast out through the fuel tank cap in
handling gasoline, if necessary. case the cap is loosened by using another
procedure when internal pressure of fuel
Gasoline and its vapors are very flammable tank is raised by heat from sources such as
and can be explosive. sun light.
When carrying a fuel tank containing gaso- ENOW00946-0
line:
z Close the fuel tank cap and air vent screw
CAUTION
of fuel tank cap, or gasoline vapor will be Separate tank must be fixed at appropriate
emitted through the air vent screw, cre- position so that well ventilated and tank
ating a fire hazard. does not move or fall down while operating.
z Do not smoke.
When or before refueling:

PRE-OPERATING PREPARATIONS 37
1. Full open the air vent screw on the properly fill the engine with oil follow the
fuel tank cap and release internal instructions, See page 74)
pressure.
1 2
1
ENOF00027-B
3 ENOF00641-0
1. Air vent screw
2. Fuel tank cap 1. Genuine of recommended engine oil
2. Filler lid
2. Open the fuel tank cap slowly. 3. Oil tank cap
6
3. Fill the fuel carefully not to over flow.
Use a genuine engine oil or recom-
mended one. Refer to your Distributor.
Will not recommended use of other two
stroke engine oil.
ENOW0002A-A
CAUTION
SAFE FILL Use of engine oils that do not meet these
LEVEL requirements will result in reduced engine
25 L
NIVEAU
life, and other engine problems.
MAXIMUM
ENOF00030-A
ENOW00603-0
4. After filling the tank, close the fuel CAUTION

tank cap.
Do not mix different brands of oil. Mixing
ENOM00037-B
different brands of oil, or different types of
3. Engine oil recommendation oil even if the brand is the same, may cause
gelling, resulting in possible filter screen
ENOW00022-A
blockage. This could result in serious engine
damage because of impaired lubrication
CAUTION performance.
The engine oil is drained for shipping from

the factory. Be sure to fill the engine to the
proper level before star ting engine. ( To
ENOW00022-0 ENOM00645-0
Oil pump air vent
CAUTION Visually check whether there is air in the
The engine oil is drained for shipping from oil through the vinyl pipe connecting the
the factory. Be sure to fill the engine to the oil tank with the oil pump. If present,
proper level before star ting engine. ( To Purge the air as follows:
properly fill the engine with oil follow the
instructions in section 10 of this manual)
30, 40, 50
ENON00007-0 Loosen the air vent screw on the oil
Note pump to purge the air, and tighten it
Use of engine oils that do not meet these when all air, as seen through the vinyl
re quirements will result in re duce d pipe on the oil pump side, has been
engine life, and other engine problems. purged.
ENOW00604-0
30, 40, 50
CAUTION
6 z In the unlikely event that gasoline by mis-
take is filled into the oil tank, drain the oil
1
tank completely, and consult an autho-
rized service shop for advice.
z Check the amount of oil in the oil tank
visually before starting the engine. Run-
ning out of oil at sea is a cause for poten-
tial disaster.
The required amount of engine oil is

automatically supplied from the oil tank, 2
through the oil pump, according to the
engine running conditions. Gasoline is
fed over a separate feeding line.
3
ENOF00642-0
ENOM00644-1
Replenishing oil in the engine oil tank. 1. Air vent screw
2. From oil filter
1. Open the filler lid from the top cowl. 3. Vinyl pipe
2. Open the oil tank cap.
3. Fill the oil tank with the genuine 75, 90, 115
engine oil. See page 44 for air removal from the oil
lines.
4. After replenishment of the oil tank,
ENON00608-0
be sure to close the oil tank cap
Note
tightly.
Wipe off any spilled oil with a rag, and dis-
pose of it.
ENOM00033-A
4. Break-In
Your new outboard motor and lower unit z Always attempt to stay on the windward
require break-in for the moving compo- side of emission.
nents a ccording to the conditions
described in the following time table. ENOW00023-1
Please refer to ENGINE OPERATION sec-
tion (See page 43) to learn how to cor- CAUTION
rectly start and operate the outboard Operating the outboard motor without
motor. break-in can shorten service life.
ENOW00024-A
If any abnormality is experienced during the
break-in:
DANGER z Discontinue the operation immediately.
z Have the dealer check the product and
Do not operate the outboard motor in take proper action(s) if necessary.
6
closed area or area with no forced ventila-
tion. ENON00008-0
Exhaust gas emitted by this outboard motor Note
contains carbon monoxide that will cause
Proper break-in allows outboard motor to
death if inhaled continuously. Inhaling the
deliver it full performance for longer ser-
gas initially causes symptoms such as feeling vice life.
of sickness, drowsiness and headache.
During operation of the outboard motor:
z Keep peripheral area well ventilated.
1–10 min 10 min – 2 hrs 2–3 hrs 3–10 hrs After 10 hrs
Less than 1/2 Less than 3/4 Full throttle
Throttle Position Idle 3/4 throttle
throttle throttle available
Approx. 4000
Full throttle run min-1 (rpm). Full
Approx. 3000 allowed for 1 throttle run
Speed
min-1 (rpm) max min every 10 allowed for 2
min min every 10
min
ENOM00039-0
5. Warning system 1
If outboard motor encounters an abnor-

mal condition of fault, the warning
buzzer will emit a continuous beep or
intermittent short beeps and the warn-
ing lamp (LED) will synchronize with the
buzzer and engine speed will be limited ENOF00852-0
(engine will not be stopped). 1. Warning lamp
See next page for conditions which will

lead to an abnormal condition or fault.
ENOM00040-B
Location of warning buzzer and
6 lamp
Warning buzzer
RC model: Located inside the remote
control.
Multi-Func tion tiller handle model:
Located in the tiller handle. *Only for
30, 40, 50
Warning lamp (LED)
RC model: Located in the tachometer.
Multi-Func tion tiller handle model:
Located in the tiller handle. *Only for
30, 40, 50
ENOF00851-0
1. Warning lamp
ENOM00041-C
Warning indicators, faults and remedy
Warning indicators
Description of faults Rem-

ESG or notice Remark edy
Sound
A B C
lamp lamp lamp
Continu- ON ON ON - Normal system test 1 second

ous when key on
High Engine speed exceeds

Continu- Approx.
- - - speed maximum 1
ous 6,000 r/min
ESG allowable RPM
Intermit-
tent (3 Low
Flash-
beeps for ing - - speed Low oil level 2
every 2 ESG
minutes)
6
Low Cooling water temp. is
Continu- Flash-
- - speed 3
ous ing high
ESG
Continu- Flash- Forced Cooling water temp is

- - 3
ous ing idling abnormally high
- - - Flash- - Battery voltage is low Engine is stopped 4

ing under 9V
Low
Flash-
- - ing - speed Battery voltage is low Approx. 10V or less 4
ESG
Low
Flash- Flash- Flash-
-
ing ing ing speed Malfunction of sensor 5
ESG
Flash- Flash- Flash- Forced

- Malfunction of sensor 5
ing ing ing idling
- Flash- Flash- Flash- - Malfunction of electrical 5

ing ing ing part or sensor
High speed ESG (Electronic Safety Governor)

High speed ESG is a device to prevent over revolution of the engine. If the load to the engine becomes light for
some reason, it runs at a higher speed than the usual. In such the case, the buzzer sounds and the ESG is
activated not to ignite the spark plug, therefore, the engine speed varies and be controlled under 6000min-1
(rpm).
Low speed ESG

Low speed ESG is a device to prevent the engine from getting damage. If the engine has problems regarding
cooling water, oil pressure, and sensors, the low speed ESG is activated not to ignite the spark plug, and
disable fueling therefore, the engine speed varies and be controlled under 3000min-1 (rpm).
Remedy
1. Reduce the throttle to less than half
opening, and move to safe place
quickly, and stop the engine.
Check the propeller for bent or dam-
aged blades.
Consult an authorize d de aler if
engine shows the same result even
after replacing propeller with new
one.
2. Move to safe place quickly, and stop
the engine.
Check the engine oil level, and add
engine oil if necessary.
3. Move to safe place quickly, and check
6 the discharge of cooling water from the
water check port at idle speed and
stop engine.
Remove any foreign matter on the gear
case and propeller if necessary. Con-
sult an authorized dealer if no dis-
charge of cooling water.
4. Charge or replace the battery.
5. Consult an authorized dealer.
ENOW00025-A
CAUTION
z Low speed ESG ON: Engine speed will be
limited to 3000 min-1 (rpm), however you
should not continue to run engine.
z High speed ESG ON: Engine speed will be
limited to 6000 min -1 (rpm) and engine
will run rough until throttle is reduced.
43
ENGINE OPERATION
ENOM00042-0
sure to execute the following operation
Before starting for forcedly feeding the engine oil to the
oil line before starting the engine.
ENOW00022-A
ENOM00657-0
CAUTION 30, 40, 50 type
The engine oil is drained for shipping from a. Disconnect the link rod by turning the
the factory. Be sure to fill the engine to the rod snap interlocking with the oil
proper level before star ting engine. ( To pump as shown in the figure.
properly fill the engine with oil follow the
instructions. See page 74)
b. Make sure that the oil pump control
lever is set at open side position.
c. Idle the engine for more than 30 min-
1 2 utes.
d. Reset the link rod to the advancer
arm.
30, 40, 50
1
2 7
4
3 ENOF00641-0
3
1. Genuine of recommended engine oil
2. Filler lid
3. Oil tank cap 5
ENOW00027-A
CAUTION 6 7 ENOF00651-0
Before starting engine for the first time after 1. Rod snap
reassembling engine or off-season storage, 2. Link rod
disconne ct stop switch lock and crank 3. Advancer arm
4. Cable joint
approximately 10 times in order to prime the
5. Throttle cable
oil pump. 6. R shaped pin
7. Nut
ENOM00656-A
1. Engine oil feeding
When the engine is new or have been

left without operation for a long time, or
just after the engine is overhauled, be
44 ENGINE OPERATION
b. Within 1 second after the buzzer stops

1 sounding, remove the stop switch
lock.
c. Within 2 seconds after removing the
2 stop switch lock, quickly repeat pull-
ing and pushing back the stop switch
3 knob 2 times.
d. The buzzer sounds 3 times and the oil
4 pump is actuated for about 1 minute
for pressure feed or oil.
5 6
e. When air is completely removed from
ENOF00652-0
the oil line, turn off the key switch.
1. Air vent screw
2. Link rod
3. From oil filter 75, 90, 115
4. Vinyl pipe
5. Open side Side mount RC type
6. Control lever
OFF
ON
ENOM00658-0
START
75, 90, 115 type (Electric oil pump)
7 Check to see by eyes if the oil line from
2
the oil tank to the cylinder block ((1) to
1 3
(4) in the 75, 90, 115 model) gets air
inside or not. If there is air inside the oil
line, remove it as follows.
ENOF00653-1
1. Look
z Oil tank-Filter (1) 2. Key switch
a. Fill the oil tank up with the specified 3. Stop switch knob
oil. Top mount RC type

b. Remove the pipe of the filter inlet
side at the part (A). ON
OFF START
c. Since the oil drains out with air, wait
until air is completely discharged
2
from the pipe. After checking for no
air in the oil line, reconnect the pipe
as it was and attach the clip to secure
pipe connection. 1
3
z Filter-Oil Pump-Cylinder Block
ENOF00938-C
[75, 90, 115: (2)–(4)] 1. Look
a. Turn on the key switch. 2. Key switch
3. Stop switch knob
ENGINE OPERATION 45
A 1
2
3, 4 1 ENOF00027-B
ENOF00654-0
1. Oil tank-Filter 1. Air vent screw

2. Filter-Oil Pump 2. Fuel tank cap
3. 75,90:Oil Pump-Cylinder Block (seven lines)
4. 115:Oil Pump-Cylinder Block (nine lines)
2. Connect the fuel connector to the
ENOM00044-B engine and fuel tank.
2. Fuel feeding
3
ENOW00029-A 2
WARNING 7
When opening fuel tank cap, be sure to fol- 1
low the procedure described below. Fuel
could blast out through the fuel tank cap in
case the cap is loosened by using another
procedure when internal pressure of fuel ENOF01316-0
tank is raised by heat from sources such as
1. Fuel connector
sun light. 2. Pull
3. Insert
ENOW00947-0
2
CAUTION
1
When using a separate tank, be sure that the
fuel line is not kinked and is connected
securely.
1. Full open the air vent screw on the

fuel tank cap.
ENOF00861-A
1. Pull
2. Insert
46 ENGINE OPERATION
3. Squeeze primer bulb until it 2. Water

3. Over 10 cm (4 in.)
becomes stiff to feed fuel to vapor
separator. Direct arrow mark upward
when priming. ENOW00036-0
1 CAUTION
Be sure to stop engine immediately if cooling
water check port is not discharging water,
and check if cooling water intake is blocked.
Operating engine could lead to overheating
potentially leading to engine damage. Con-
sult an authorized dealer if the cause cannot
2
ENOF00862-0 be found.
1. Engine side
2. Fuel tank side ENOW00032-A
Do not squeeze primer bulb with engine CAUTION

running or when the outboard motor is Do not hold turning starter motor for more
tilted up. Otherwise, fuel could over- than 5 seconds, or the battery may be con-
flow. sumed, potentially making the engine start-
ing impossible and/or damaging the starter.
7 ENOM00045-A
If cranking over 5 seconds fails to star t
3. Starting the engine engine, return main switch to “ON”, and
crank engine again after 10 seconds or more.
ENOW00036-A Do not try to crank after engine has started.
CAUTION This model is provided with start in gear

protection.
When the engine is started in the test tank,
ENON00010-0
to avoid over heating and water pump dam-
age, be sure the water level is at least 10 cm
Note
(4 in.) above the anti ventilation plate. Start-in-gear protection prevents engine
from starting at other than neutral shift.
And be sure to remove the propeller, when In-gear starting of engine will move the
starting the engine in the test tank. (See boat immediately, potentially leading to
page 83) falling down or causing passenger(s) to be
Run the engine only at idling. thrown overboard.
2
ENOF00863-0
1. Test tank
ENGINE OPERATION 47
Tiller handle type 4. Set the throttle grip to START posi-

1. Be sure to install the stop switch lock tion.
to the stop switch, and attach the
stop switch lanyard securely to the
operator or to the operator's PFD
(Personal Flotation Device.)
2 1
1
ENOF00866-0
1. Throttle grip
ENON00613-A
ENOF00864-0
Note
1. Stop switch lock
Turn the throttle grip to the “START” (fully
2. Insert the main switch key. closed), before turning the main switch
key to “ON”.
3. Set the control lever in the Neutral The wrong operation i.e. turn the main 7
position. switch key to “ON” on the condition that
the handle grip or accel lever is opened
will be memorized by ECU (engine control
1 N unit).
F If this wrong operation has done repeat-
R
edly, it will have a possibility that the
three warning lamps flash. In this case,
turn the throttle grip to “START” (fully
closed) and start the next operation after
returning the main switch key to “OFF”.
5. Turn the main switch key to ON posi-

ENOF00865-0 tion and c onfirm thre e warning
1. Shift lever lamps light up with buzzer sound and
then go off.
6. Turn the main switch key to START
position and release the key when
the engine has star ted. The key
returns to the original position,
automatically.
48 ENGINE OPERATION
N
F
R
1
2
1
2
ENOF00665-0
OFF
ON
1. Idle port
2. Cooling water check port 75, 90, 115
START
PUSH TO IDLE CHANGE Side mount RC type
ENOF00867-0
1. Be sure to install the stop switch lock
1. Main switch key
2. Warning lamp stop switch lanyard securely to the
ENOW00032-1 operator or to the operator's PFD
CAUTION (Personal Flotation Device.)
Do not hold turning starter motor more than

7 5 seconds, or the battery may be consumed,
potentially making the engine star ting
impossible and/or damaging the starter.
If cranking over 5 seconds fails to star t
engine, return main switch to “ON”, and
crank engine again after 10 seconds or more.
1
7. Check the cooling water from cool-
ing water check port.
ENOF008691
1. Stop switch lock
2. Insert the main switch key.

3. Set the control lever in the Neutral
position. Do not raise the free throt-
tle lever when starting the engine.
2
1
ENOF00664-0
1. Idle port
ENGINE OPERATION 49
1 3 1
2
2
N
F R
5
3 6
7 ENOF00871-1
ENOF00870-1
1. ON
1. Neutral (N) 2. START
2. Control lever 3. OFF
3. Fully opened (Forward) ENON00035-A
4. Fully opened (Reverse)
5. Free throttle lever
Note
6. Main switch key The free throttle lever can not be raised
7. Stop switch
when the control lever shift is in Forward
or Reverse.
4. Turn the main switch key to ON posi-
tion and c onfirm thre e warning 6. Check the cooling water from cool-
lamps light up with buzzer sound and ing water check port.
7
then go off.
2
1
ENOF00664-0
ENOF00851-0 1. Idle port
1. Warning lamp 2. Cooling water check port 30, 40, 50

position and release the key when
the engine has star te d. The key
returns to the original position,
automatically.
2
1
ENOF00665-0
1. Idle port
50 ENGINE OPERATION
Top mount RC type 4. Turn the main switch key to ON posi-

1. Be sure to install the stop switch lock tion and confirm three warning lamps
to the stop switch, and attach the light up with buzzer sound and then
stop switch lanyard securely to the go off.
(Personal Flotation Device.)
11
1
ENOF00851-0
ENOF00851-0
1. Warning lamp
ENOF00936-0 position and release the key when the
1. Stop switch lock engine has started. The key returns to
the original position, automatically.
2. Insert the main switch key.
7 3. Set the control lever in the Neutral

position. Do not use the Neutral
1
throttle button to open the throttle 2

when starting the engine. 3
7 8
2
F
1 N 3
F R
7 ENOF00938-0
N 1. ON
5 2. START
3. OFF
4
R
6
ENOF00937-0
1
1. Forward (F)
2. Neutral (N)
3. Reverse (R)
4. Fully opened (Forward)
5. Fully opened (Reverse)
6. Neutral throttle button
7. Control lever
8. Neutral lock arm ENOF00851-0
1. Warning lamp
ENGINE OPERATION 51
ENON00939-0 z To prevent accident and injury by rotating

Note parts, do not re-attach flywheel cover
The neutral throttle button can not be and the top cowl after the engine has
push-in when the control lever shift is in been started.
Forward or Reverse. z Do not pull starter rope if any bystander is
b ehind. Th e a c ti on c an injure th e
6. Check the cooling water from cooling bystander.
water check port. z Attach engine stop switch lanyard to
clothing or any par t of body like arm
before starting engine.
1. Remove the top cowl.
2
1
ENOF00664-0
1. Idle port
2. Cooling water check port 40, 50
7
ENOF01345-0
2. Remove the flywheel cover.

2
1
ENOF00665-0
1. Idle port
ENOM00042-A
Emergency starting
ENOF00661-0
*Only for 30, 40, 50
ENOW00099-A
3. Insert the knotted end of the starter
WARNING rope into the notch in the flywheel
When the emergency starter rope is used for and wind the rope around the fly-
starting engine; wheel several turns clockwise.
z Start in gear protection does not work. Be
sure to shift is at neutral position. Other-
wise the engine will move the boat imme-
diately and cause personal injury.
z Be careful that your clothes or other
items do not get caught in the rotating
engine parts.
52 ENGINE OPERATION
4. Tie a loop in the another end of the ENOM00043-A
emergency starter rope and attach 4. Warming up the engine

socket wrench that is included in the
tool kit. ENOW00932-0
CAUTION
Be sure to check that cooling water is com-
ing out of the cooling water check port dur-
ing warm up.
Warm the engine at low engine speeds

for about
3 minutes : above 5°C (41°F )
5 minutes at 2000 min-1 (rpm) :
ENOF00663-0
below 5°C (41°F )
This allows the lubricating oil to circu-
ENOW00860-0
late to all parts of the engine. Operating
CAUTION the engine without warm up shortens
the engine's life.
Be sure to keep the harness away from the
7 rotation parts.
5. Be sure to install the stop switch lock

stop switch lanyard securely to the
(Personal Flotation Device.) 2
1
6. Set the control lever in the Neutral
ENOF00664-0
position. 1. Idle port
7. Pull the starter handle slowly until 2. Cooling water check port 30, 40, 50
you feel engagement, keep pulling till
you feel less resistance. Then pull it
quickly.
8. After engine starts, do not reinstall
flywheel cover and top cowl.
2
1
ENOF00665-0
1. Idle port
ENGINE OPERATION 53
ENOM00044-0 ENOM00973-0
Engine speeds Neutral throttle button (Top

Idling speed after warming up. mount RC type)
Remark: In case of cold engine starting, ENOW00957-0
idling speed is increased about 400 min-

1 (rpm) for several minutes. CAUTION
The control lever does not operate unless
Clutch in (In gear) Clutch off (Out of gear)
the neutral lock arm is pulled.
800 min-1 (rpm) 800 min-1 (rpm)
The neutral throttle button is for warm-
ENOM00972-0
up operation. (Not required for engine
Free throttle lever (Side mount starting) When the control lever is in
RC type) neutral, push and hold the neutral throt-
ENOW00956-0
tle button. While holding the button,
CAUTION move the lever forward to throttle up
the engine.
z Keep the free throttle lever fully closed-
position when start the engine. When the control lever is returned to
z The free throttle lever is inoperative the neutral position, the button will
unless thecontrol lever is in neutral. reset automatically.
z Also, the control lever is inoperative
unless the free throttle lever is returned 7
to the fully-closed position.
2
The free throttle lever is for warm-up
operation.(Not required for engine
starting) With the control lever in neu-
1
tral, move the free throttle lever upward
to open the throttle.
ENOF00935-0
1 1. Neutral throttle button

2. Forward
2 ENOM00-0
Trolling engine speed control

function
If the main switch key is pressed for 1
(one) second during idling or trolling
ENOF00934-0
operation, engine revolution change.
1. Fully-open
2. Fully-closed
ON
1second
ENOF00876-0
54 ENGINE OPERATION
E a c h tim e t h e m ain s wi t c h ke y is ENOW00042-0
pressed in the above manner, engine WARNING

speed changes as follows.
z Do not shift into Reverse during planing,
or control will be lost leading to serious
Starting personal injury, boat may swamp, and/or
700 min-1 (rpm) Ѝ 800 min-1 (rpm) hull may be damaged.
ЌࠉࠉࠉࠉࠉЎ z Do not shift into Reverse during cruising,
800 min-1 (rpm) Ћ 900 min-1 (rpm) or control may be lost, falling down or
causing passenger(s) to be thrown over-
board. Leading to serious personal injury,
ENOM00046-A
and ste er ing system and /or shif ting
mechanism may be damaged.
5. Forward, reverse, and
ENOW00861-0
acceleration
WARNING
ENOW00037-0
Do not shift at high boat speed, or control
WARNING may be lost, falling down or causing passen-
ger(s) to be thrown overboard. Leading to
Before shifting into forward or reverse, serious personal injury.
make sure that boat is properly moored and
7 outboard motor can be steered fully to the ENOW00862-0
right and left. Make sure that no swimmer(s)
is ahead or astern of the boat. CAUTION
ENOW00038-A
Gear and clutch damage may occur if shift-
ing at high engine speed.
WARNING Engine must be in the slow idle position
before shifting is attempted.
z Attach other end of emergency stop
switch lanyard to the operator's PFD ENOW00863-0
(Personal Flotation device) or arm and
keep it attached during cruising. CAUTION
z Do not attach the tether to a part of
Idle speed may be higher during warming up
clothing that can be torn easily when
of engine. If shifted to Forward or Reverse
pulled.
during warming up, it may be difficult to
z Arrange the tether so that will not be
shift back to neutral. In such case, stop
caught by any object when pulled.
engine, shift to neutral, and restart engine
z Be careful not to pull the tether acciden-
to warm up.
tally during cruising. Unintentional stop of
engine can cause loss of control of out- ENON00014-0
board motor. Rapid loss of engine power Note
can lead to falling down or causing pas-
senger(s) to be thrown overboard. Frequent shifting to forward or reverse
can accelerate wear or degradation of
parts. In such case, replace gear oil earlier
than the period specified.
ENGINE OPERATION 55
ENOW00864-0 Acceleration
ENOW00867-0
CAUTION
WARNING
Do not increase engine speed unnecessarily
when the shift is in neutral and reverse, or Sudden acceleration and deceleration may
engine damage may occur. cause passenger(s) to be thrown overboard
or falling down.
ENOM00890-A Open throttle grip gradually.

Tiller handle type
ENOW00865-0
CAUTION
Do not force to shift when the throttle grip
is not in the fully closed position, otherwise,
steering system and/or shifting mechanism
may be damaged. The control lever is inop-
erative unless the throttle grip is in the fully
closed position. (Multi-function tiller type)
N
ENOF00878-0 7
1 1. Throttle grip
F
R
ENOF00865-A
1. Shift lever
1
Forward ENOF01119-0
1. Throttle grip
1. Turn the throttle grip to reduce
engine speed.
ENOM0900-0
2. When the engine reaches trolling (or Side mount RC type
idling) speed, quickly pull the shift ENOW00867-0
lever to the Forward position.

Reverse
WARNING
1. Turn the throttle grip to reduce Sudden acceleration and deceleration may
engine speed. cause passenger(s) to be thrown overboard
or falling down.
2. When the engine reaches trolling (or
idling) speed, quickly pull the shift
lever to the Reverse position.
56 ENGINE OPERATION
Open throttle grip or control lever grad-

ually.
7 8
2 7
1 3
N N
F R R
6 F
5 1
ENOF00877-1
ENOF00879-2
1. Forward (F)
2. Neutral (N) 1. Control lever
3. Reverse (R)
4. Fully opened (Forward)
5. Fully opened (Reverse) NOM00975-0
6. Free throttle lever Top mount RC type
7. Control lever
ENOW00867-0
8. Neutral lock arm
Forward WARNING
7 1. Quickly push the control lever to the
Sudden acceleration and deceleration may
Forward (F) position 32°, where the cause passenger(s) to be thrown overboard
gear is connected, while lifting up on or falling down.
the lock button located under the
control lever grip.
7 8
2. Further forward motion will open the 2
F
throttle. 1 N 3
Reverse 7 F R
1. Quickly pull the control lever to the

N
Reverse (R) position at 32°, where 5
the gear is connected, while lifting
up on the lock button located under 4
R
the control lever grip. 6
ENOF00937-0
2. Further rearward motion will open 1. Forward (F)
the throttle. 2. Neutral (N)
3. Reverse (R)
Acceleration 4. Fully opened (Forward)
ENOW00867-0 5. Fully opened (Reverse)
6. Neutral throttle button
WARNING 7.
8.
Control lever
Neutral lock arm
Sudden acceleration and deceleration may
cause passenger(s) to be thrown overboard
or falling down.
ENGINE OPERATION 57
Forward Tiller handle type

1. Quickly push the control lever to the 1. Turn the throttle grip to the slow
Forward (F) position 35°, where the position.
gear is connected, while lifting up on
the neutral lock arm located under
the control lever grip.
2. Further forward motion will open the
throttle.
Reverse
1. Quickly pull the control lever to the
Reverse (R) position at 35°, where
the gear is connected, while lifting
up on the neutral lock arm located 1
under the control lever grip. ENOF00866-0
2. Further rearward motion will open 1. Throttle grip
the throttle.
Acceleration 2. Put the shift lever in the Neutral
ENOW00867-0 position.
WARNING Run the engine for 2-3 minutes at
idling speed for cooling down if it
7
Sudden acceleration and deceleration may has been running at full speed.
cause passenger(s) to be thrown overboard
3. Turn the main switch key to the OFF
or falling down.
position or push the stop switch. (
Open throttle grip or control lever grad- Do not forget to turn the key off).
ually.
N
ENOM00049-A
2
F
6. Stopping the engine R
3
ENOW00868-0
WARNING
Be careful not to remove engine stop switch
lanyard from engine accidentally while boat
is running. Sudden stop of engine can cause
OFF
loss of steering control. It can also cause ON
loss of boat speed, possibly leading the

crew(s) and or objects on the boat to be START
PUSH TO IDLE CHANGE ENOF00880-0
thrown forward due to inertial force.
1. Throttle grip
2. Shift lever
3. Main switch key
58 ENGINE OPERATION
Side mount RC type ENOM00975-0

Top mount RC type
1. Put the control lever in the Neutral
1. Put the control lever in the Neutral
position and run the engine for 2-3
position and run the engine for 2-3
minutes at idling speed for cooling
minutes at idling speed for cooling
down if it has been running at full
down if it has been running at full
speed.
speed.
F
N
N
F R F R
1
N
1
2 R
ENOF00881-1
ENOF00939-0
1. Control lever
2. Main switch key 1. Control lever
2. Turn the main switch key to the OFF 2. Turn the main switch key to the OFF
7 position. position.
3 1 3
2
4
5 2
ENOF00871-1
1. ON ENOF00938-A
2. START
3. OFF 2. Main switch key
ENOW00869-0
3. ON
4. START
5. OFF
WARNING ENOW00869-0
After stopping the engine:

z Close the air vent screw on the fuel tank WARNING
cap. After stopping the engine:
z Disconnect the fuel connector of the z Close the air vent screw on the fuel tank
engine and the fuel tank. cap.
z Disconnect the battery cord, after each z Disconnect the fuel connector of the
use. engine and the fuel tank.
z Disconnect the battery cord, after each
use.
ENGINE OPERATION 59
Emergency engine stopping

Press the emergency stop switch or
remove stop switch lock to stop the
engine.
1
N 2
F
R
ENOF00938-B
1
1. Stop switch
2. Stop switch lock
ENOM00910-0
Spare emergency stop switch lock
2 A spare emergency stop switch lock is
provided in the tool bag.
When used as described, the emergency
stop switch clip and emergency stop
ENOF00883-0 switch lanyard system stops the engine
1. Stop switch
2. Stop switch lock
if the operator falls away from the con- 7
trols.
When an operator falls into water, be
sure to use emergency stop switch lock
of the spare.
Be sure to confirm the spare stop switch
lock is in the tool bag before begin to
1 operate.
ENOF00869-A
1. Stop switch
2. Stop switch lock
ENOF00891-0
60 ENGINE OPERATION
ENOM00920-0 ENOM00050-0
7. Steering 8. Trim angle

ENOW00870-0 ENOW00043-A
WARNING WARNING
Sudden steering may cause passenger(s) to z Adjust the trim angle when the engine is
be thrown overboard or falling down. stopped.
z Do not put hand or finger in between out-
Tiller handle type board motor body and clamp bracket
Right turn when adjusting trim angle to prevent
Move the tiller handle to the left injury in case the outboard motor body
Left turn falls.
z Unsuitable trim position can cause loss of
Move the tiller handle to the right.
control of boat. When testing a trim posi-
tion, run boat slow initially to see if it can
be controlled safely.
ENOW00044-0
WARNING
7 Excessive tr im up or down may lead to
unstable boat operation, potentially causing
the steering difficulty that leads to accident
during cruising.
z Do not cruise at high speed if improper
ENOF00892-0
trim position is suspected. Stop the boat
and readjust trim angle before continuing
Remote control type
cruise.
Right turn z For outboard motor model with PTT
Turn the steering wheel to the right. switch on the bottom cowl, do not oper-
Left turn ate the switch during cruising, or control
Turn the steering wheel to the left. of boat may be lost.
The trim angle of the outboard motor

can be adjusted to suit the transom
angle of the hull, and load conditions.
Choose an appropriate trim angle that
will allow the anti-ventilation plate to
run parallel to the water surface during
operation.
ENOM00052-0
Proper trim angle
ENOF00893-0
The position of the thrust rod is correct
if the hull is horizontal during operation.
ENGINE OPERATION 61
Manual Tilt type
ENOF00051-1
1
1. Perpendicular to the water surface
ENOM00053-0
2 ENOF00674-A
Improper trim angle (bow rises too

1. Thrust rod
high) 2. Higher
Set the thrust rod lower if the bow of 3. Lower
the boat rises above horizontal. Power Tilt type
7
3
ENOF00052-0
1
ENOM00054-0
Improper trim angle (bow dips into the
water)
Set the thrust rod higher if the bow of ENOF00888-0
the boat is below horizontal. 1. Thrust rod

2. Higher
3. Lower
Trim angle adjustment (Manual tilt type)

The transom angle adjustment
1. Stop the engine.
2. Shift into neutral.
3. Raise the outboard motor to the tilt
ENOF00053-0
up position.
62 ENGINE OPERATION
4. Change the thrust rod position as 6. Operate the Power Tilt switch and
following picture. lower the outboard.
ENOM00060-A
9. Tilt up and down

ENOW00055-0
1 WARNING
Do not tilt up or down outboard motor when
swimmer(s) or passenger is near to prevent
3 them from being caught between outboard
2
ENOF01238-1 motor body and clamp bracket in case the
outboard motor body falls.
1. Push in
2. Rise the stopper
3. Pull out
ENOW00048-0
5. Reinstall the thrust rod securely.
6. Gentry lower the outboard. WARNING
When tilting up or down, be careful not to
Trim angle adjustment (Power tilt type) place your hand between the swivel bracket
7 The transom angle adjustment and the stern bracket.
1. Stop the engine Be sure to tilt the outboard motor down
slowly.
2. Operate the Power Tilt switch and
raise the outboard motor to the tilt ENOW00056-A
up position.
3. Lock the tilt with the Tilt stopper.
WARNING
4. Change the trim lock pin position as When tilting up outboard motor with fuel
following picture. joint for over a few minutes, be sure to dis-
connect fuel hose, or fuel may leak, poten-
2 tially catching fire.
ENOW00057-0
CAUTION
Do not tilt up outboard motor while engine
operates, or no cooling water may be fed,
leading to engine seizure due to overheating.
ENON00921-0
1
Note
ENOF01147-0
Before tilting the outboard motor up,
1. Snap pin
2. Thrust rod
after stopping the motor leave it in the
running position for about a minute to
5. Reinstall the thrust rod securely.
ENGINE OPERATION 63
allow water to drain from inside the

engine. 1
2
ENOM00062-A
Manual Tilt type (*30, 40, 50 only)

Tilt up
Push the reverse lock lever down until it
3
stops. (This is the tilt up position.) Now,
tilt the outboard motor all the way up
ENOF00059-0
until it is locked in place.
1. Reverse lock lever
2. Tilt up position
1 3. Tilt down position
2 ENOM00069-A
Power Trim & Tilt type

Tilt up
1. Operate the Power Trim & Tilt switch
and tilt the outboard motor up.
3
2. Lock the tilt with the Tilt stopper
ENOF00059-0
after the outboard motor has been 7
tilted up
2. Tilt up position Tilt down
3. Tilt down position 1. Release the tilt stopper from the
set-up position while slightly tilting
up outboard motor.
2. Operate the Power Trim & Tilt switch
and tilt the outboard motor down
until the motor touches to the thrust
rod.
ENOF01317-0
UP
DN
ENOM00063-0 ENOF00067-A
Tilt down
Pull the reverse lock lever upward until it UP
stops. (This is the tilt down position.)
Now, lift up the outboard motor slightly, DN
and then allow gravity to lower it for you.
ENOF00067-2
64 ENGINE OPERATION
of main switch “ON” or “OFF”.

UP ENOM00940-0
Manual relief valve
DN If the battery is dead, and the power tilt
switch thus inoperative, open the man-
ENOF00941-0
ual valve completely in the Manual direc-
30, 40, 50 tion. This will allow manual tilting of the
outboard motor.
1 ENOW00872-0
WARNING
Make sure the manual relief valve is closed
before operating the outboard motor. If the
manual relief valve is not closed, the out-
board motor will tilt up when operated in
reverse.
ENOF01318-0
ENOW00873-0
1. Tilt stopper
WARNING
7 75, 90, 115
Before opening the manual relief valve,
make sure nobody is under the outboard
1 motor. If the outboard motor is in the tilted
up position, it will tilt down suddenly if the
manual relief valve is loosened in the "Man-
ual" direction.
30, 40, 50
ENOF01319-0
1. Tilt stopper
The outboard motor can also be tilted

up and down using the switch provided
under the bottom cowl.
2
ENOF00070-1
ENOF01320-0
1. POWER
It is possible to tilt up or down in spite 2. MANUAL
ENGINE OPERATION 65
75, 90, 115
1
ENOF01144-A
2
ENOF00679-0 1. Water inlet
1. POWER
2. MANUAL
Manual tilt type (*30, 40, 50 only)
ENOM00068-A 1. Shallow water running position:
10.Shallow water operation Put the reverse lock lever in the tilt
up position, and tilt up the outboard
ENOW00051-0
motor to put the outboard motor in
the shallow water running position.
WARNING 7
During shallow water operation, be careful 1
not to place your hand between the swivel
bracket and the clamp bracket. Be sure to 2
tilt the outboard motor down slowly.
ENOW00053-0
CAUTION 3
While in shallow water drive position, do not
operate the outboard motor in Reverse. ENOF00059-0
Operate the outboard motor at slow speed
and keep the cooling water intake sub- 2. Tilt up position
merged. 3. Tilt down position
ENOW00054-0
CAUTION
Do not overtilt outboard motor when driving
shallow water, or air may be sucked through
water inlet, potentially leading to engine
overheating.
66 ENGINE OPERATION
UP
DN
ENOF00067-B
UP
DN
ENOF00067-2
UP
DN
ENOF00668-0 ENOF00941-0
2. Return to normal running position:

Put the reverse lock lever in the tilt
7 down position, slightly lift up the
outboard motor, and then put it
down.
ENOF00059-0

2. Tilt up position
3. Tilt down position
ENOM00069-A
Power Tilt type

1. Operate the Power Tilt switch and tilt
the outboard motor up into desired
shallow water running position.
67
REMOVING AND CARRYING THE OUTBOARD MOTOR
ENOM00070-A
1. Removing the outboard

motor
ENOW00890-0
WARNING
Before installing the outboard motor on the
boat, hang the outboard motor with the
hoist or equivalent device by attaching the
engine hanger to the outboard.
Use the hoist with allowable load is 250 kg
(550 lbs) or above.
ENOW00064-0
CAUTION
Engine may be hot immediately after operat-
ing and could cause burns if touched. Allow ENOF01313-0
engine to cool down before attempting to ENOM00071-A
carry the outboard.

2. Carrying the outboard motor
1. Stop the engine.
ENOW00933-0
3. Disconnect the fuel connector, the WARNING 8
remote control cables and the bat- Be sure to disconnect fuel connector except
tery cords from the outboard motor. when operating engine.
4. Attach the hoist hooks to the engine Fuel leakage is a fire or explosion hazard,
which can cause serious injury or death.
hanger.
5. Remove the outboard motor from ENOW00065-0
boat and completely drain the water

from the gear case.
WARNING
Close air vent screw of fuel tank before car-
rying or storing outboard motor and fuel
tank, or fuel may leak, potentially catching
fire.
ENOW00066-A
CAUTION
Do not give a shock to an outboard motor
during transportation. It becames a cause of
breakage.
68 REMOVING AND CARRYING THE OUTBOARD MOTOR
Keep the outboard motor in a vertical ENOM00072-A
position when carrying. 3. Trailering

The optional outboard motor stand is
recommended for keeping the outboard ENOW00072-0
motor vertical both during transport and CAUTION

storage.
Trailering in the tilted position may cause
damage to the outboard motor, boat, etc.
ENOW00073-A
WARNING
Be sure to disconnect fuel connector except
when operating engine.
Fuel leakage is a fire or explosion hazard,
which can cause serious injury or death.
ENOF01321-0
ENOF00075-1
ENON00021-A
Note ENOW00068-0
8 z If the outboard motor must be laid

WARNING
down be sure drain the fuel and
engine oil, then the port side faces Close air vent screw of fuel tank and fuel
down as shown in the following drawing. cock before carrying or storing outboard
z Elevate power unit 2 inches to 4 motor and fuel tank, or fuel may leak,
inches if traveling to avoid oil spillage. potentially catching fire.
ENOW00071-0
CAUTION
The tilt support device supplied on your out-
board motor is not intended for towing. It is
intended to support the outboard motor
ENOF00680-0
while the boat is docked, beached, etc.
When transporting a boat on a trailer

with the outboard motor still attached,
disconnect the fuel line from the out-
board motor beforehand and keep the
outboard motor in the normal running
position or on a transom saver bar.
REMOVING AND CARRYING THE OUTBOARD MOTOR 69
Tiller handle type

To prevent the outboard motor from
moving when it is attached on a boat
during transport on a trailer, properly
tig hten the ste ering fric tion le v er
(page 70).
2 1
ENOF00074-A
1. Ground clearance should be provided
sufficiently.
2. Transom saver bar
ENOW00067-0
WARNING
Do not go under outboard motor tilted up
even if it is supported by support bar, or 8
accidental fall of outboard motor could lead
to severe personal injury.
70
ADJUSTMENT
ENOM00073-A ment resulting in the loss of control causing
1. Steering friction an accident and could lead to severe injury.
Friction adjustment of the throttle grip

Tiller handle type can be made with the throttle adjust-
(*30, 40, 50 only) ment screw.
ENOW00074-B
WARNING
Do not overtighten the steering friction lever
3
it could result in difficulty of movement
resulting in the loss of control causing an 2
accident and could lead to severe injury.
1
Adjust this lever to achieve the desired
steering friction (drag) on the tiller han-
dle. Move lever towards (2) to decrease ENOF00911-0
friction and move lever towards (3) to 1. Throttle friction adjustment screw
2. Decrease
increase friction. 3. Increase
ENOM00075-0
3. Remote control lever friction

1
ENOW00074-C
3 2 WARNING
Do not over tighten the remote control
9 throttle friction adjustment screw or it
could result in difficult y of movement
resulting in the loss of control causing an
ENOF00910-0 accident and could lead to severe injury.
1. Steering friction lever
2. Decrease To adjust the friction of the remote con-
3. Increase trol lever, turn the throttle friction
ENOM00074-A
adjustment screw on the front of the
2. Throttle grip friction remote control . Turn c lock wise to
increase the friction and counter-clock-
*30, 40, 50 only wise to decrease it.
ENOW00074-B
WARNING
Do not overtighten the throttle adjustment
screw or it could result in difficulty of move-
ADJUSTMENT 71
Side mount type motor could lead to severe personal

injury.
ENOW00075-1
WARNING
Inappropriate adjustment of trim tab could
2 cause steering difficulty. After installing or
3 readjusting trim tab, check if steering load is
1 even.
ENOF00078-2
1. Throttle friction adjustment screw If straight-line cruising can not be

2. Decrease achieved, adjust the trim tab located
3. Increase
Top mount type under the anti-ventilation plate.
z If the boat veers toward the left direct
the trim tab towards A (left from rear of
boat).
z If the boat veers toward the right direct
the trim tab towards B (right from rear of
boat).
2 1
3
ENOF00942-0
1. Throttle friction adjustment screw

2. Lighter
3. Heavier 9
ENOM00076-0
4. Trim tab adjustment

ENOW00076-1
WARNING
z Be sure that outboard motor is secured to 1 1
ENOF00912-A
transom or service stand, or accidental
drop or fall of outboard motor could lead 1. Trim tab
to severe personal injury. ENON00022-A
z Be sure to lock outboard motor when it is Notes

tilted up, otherwise accidental fall of out- z After adjustment securely tighten the
board motor could lead to severe per- trim tab fixing bolt.
sonal injury. z Check for looseness of the bolt and
z Do not go under outboard motor tilted up the trim tab at regular intervals.
and locked, or accidental fall of outboard
72
INSPECTION AND MAINTENANCE
ENOM00077-0
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 main-
tenance schedules that follow.
ENOW00077-0
CAUTION
z Your personal safety and that of your pas-
sengers depends on how well you main-
tain your outboard motor. C arefully
observe all of the inspection and mainte-
nance procedures described in this sec-
tion.
z The maintenance intervals shown in the
checklist apply to an outboard motor in
normal use. If you use your outboard
motor under severe conditions such as
frequent full-throttle operation, fre-
quent operation in brackish water, or for
commercial use, maintenance should be
per forme d at shor ter inter vals. If in
doubt, consult your dealer for advice.
z We strongly recommend that you use only
genuine replacement parts on your out-
board motor. Damage to your outboard
motor arising from the use of other than
genuine parts is not covered under the
warranty.
10
INSPECTION AND MAINTENANCE 73
ENOM00703-0
1. Daily inspection
Pe r form th e following ch e c ks an d ENOW00078-1
inspection before and after use. WARNING

Do not use outboard motor if any abnormal-
ity is found during pre-operation check oth-
erwise it could result in severe damage to
the motor or severe personal injury.
Item Points to Check Remedy

• Check the amount of fuel in the tank. Replenish
• Check for dust or water in the fuel filter. Clean
Fuel System
• Check rubber pipes for oil leakage. Replace
• Fuel
• Check for crack, leakage, damage in the fuel tank cap. Replace
Fuel Tank Cap • Check for crack, damage in the gasket. Replace
• Check for leakage at full close. Replace
Lubrication • Check the amount of engine oil in the oil tank. Replenish
System • Check for dust or water in the oil filters. Clean
• Check the spark plugs for dirt, wear and carbon built-up. Clean or replace
Spark plugs (30·40·50·75·90) NGK IZFR6Q (0.8 mm gap) (0.0315
in) Spark plugs (115) NGK IZFR5J (0.8 mm gap) (0.0315 in)
• Check if the main switch functions normality. Remedy or replace
Electrical • Check if the battery electrolyte level and specific gravity are nor- Replenish or
Equipment mal recharge
• Check for loose connections on battery terminal. Retighten
• Check if the stop switch functions normally and make sure the Remedy or replace
lock plate is present.
• Check cords for loose connections and damage. Correct or replace
10
Throttle Sys- • Check if the magneto works normally when turning the throttle Correct
tem grip, and also check links for looseness.
• Check if the clutch engages correctly when operating the Adjust
Clutch and Remote Control. (or Shift lever)
Propeller Sys- • Check the propeller for bent or damaged blades. Replace
tem • Check if the propeller nut is tightened and the split pin is
present.
Installation of • Check all the motor installation bolts with the boat. Tighten
Motor • Check the thrust rod installation. Tighten
Power Trim & • Check working of the tilt up and down of the motor.
Tilt
• Check that cooling water is discharged from the cooling water
Cooling Water
check port after the engine has started.
• To be prepare tools and spare parts for replacing spark plugs,
Tools and propeller, etc.
Spares
• Check if the spare rope is provided.
74 INSPECTION AND MAINTENANCE
Item Points to Check Remedy

Steering • Check working of steering handle and remote control.
Devices
• Check if the anode and trim tab are securely installed. Repair if necessary
Other parts
• Check the anode and trim tab for corrosion and deformation. Replace
ENOM00082-A
Engine oil replenishing
1 2
ENOW00079-A
CAUTION
z Do not add engine oil of brand and grade
other than existing one. In case engine oil
of other brand or grade is added, drain all
oil and ask dealer for treatment.
z In case other than engine oil such as gas-
oline is put in the oil chamber, empty the
chamber and ask dealer for treatment.
z When replenishing engine oil, be careful
not to allow entry of foreign matters such 3 ENOF00641-0
as dust or water into oil chamber. 1. Genuine of recommended engine oil

z Wipe off engine oil well immediately if 2. Filler lid
spilled and dispose of it in accordance 3. Oil tank cap
with local fire prevention and environ-
ENOM00083-A
ment protection regulations.
z Do not replenish engine oil over upper Washing outboard motor
limit. If overfilled, remove oil to upper ENOW00081-0
limit. If engine oil is over the upper limit,

it can leak and potentially lead to engine WARNING
damage. Do not start engine without removing pro-
peller, or accidentally turning propeller
If the oil level is low, or at lowest mark, could cause personal injury.
10 add recommended oil to the oil tank.
1. Open the filler lid from the top cowl. ENOW00082-0
2. Open the oil tank cap WARNING

3. Fill the oil tank with the genuine
Never start or operate the engine indoors or
engine oil.
in any space which is not well ventilated.
4. After replenishing of the oil tank, be Exhaust gas contains carbon monoxide, a
sure to close the oil tank cap tightly. colorless and odorless gas which can be fatal
if inhaled for any length of time.
ENOW00920-0
4. Put the shift lever in the neutral
CAUTION position and start the engine. Con-
tinue flushing the outboard motor
When washing the outboard motor, be care-
for 3 to 5 minutes at idling.
ful not to spray the water inside of the top
cowl, especially electrical components. 5. Stop the engine and water supply.
Remove the flushing attachment and
ENON00026-0
tape.
Note
30, 40, 50
It is recommended to check chemical
properties of water on which your out-
board motor is regularly used.
1
If outboard motor is used in salt water,
brackish water or water with a high
acidic level, use fresh water to remove
salt, chemicals or mud. And flush cooling
water passage after every cruising or
before storing outboard motor for long
time. Before flushing, remove the pro-
ENOF01324-0
peller and the forward thrust holder.
1. Flushing attachment
ENOM00085-B 75, 90, 115.
Flushing attachment (gear case)
30, 40, 50
ENOW00922-0
1
CAUTION
To prevent the engine from starting when
you are near the propeller, remove the stop
switch lock.
10
1. Tilt down the outboard motor.
2. Remove the water plug from the gear ENOF01325-0
case, and scre w in the flushing 1. Flushing attachment

attachment.
3. Attach the flushing attachment and
connect a water hose. Turn on the
water and adjust the flow (Be sure to
seal the water inlet and sub water
inlet, located in the gear case with
tape)
ENOM00085-C ENOM00085-A
Flushing hose joint (bottom cowl) Flushing by test tank
*75, 90, 115 ENOW00081-0
ENOW00921-0
WARNING
CAUTION Do not start engine without removing pro-
Do not operate the engine when flushing the peller, or accidentally turning propeller
outboard motor with a flushing attachment could cause personal injury.
as this can cause damage to the outboard
motor. ENOW00082-0
ENOW00922-0
WARNING
Never start or operate the engine indoors or
CAUTION in any space which is not well ventilated.
To prevent the engine from starting when Exhaust gas contains carbon monoxide, a
you are near the propeller, remove the stop colorless and odorless gas which can be fatal
switch lock. if inhaled for any length of time.
ENOW00036-A

CAUTION
2. Remove the flushing connector cap
from the outboard motor, and screw When the engine is started in the test tank,
to avoid over heating and water pump dam-
in the hose joint. age, be sure the water level is at least 10 cm
3. Attach the flushing attachment and (4 in.) above the anti ventilation plate.
connect a water hose. Turn on the And be sure to remove the propeller, when
water and adjust the flow. starting the engine in the test tank. (See
page 83)
Continue flushing the outboard motor Run the engine only at idling.
for 3 to 5 minutes
4. After the flushing, be sure to reat-
tach the flushing connector cap. 3
10 5. Tilt up the outboard motor.
75, 90, 115 1
2
ENOF00863-0
1. Test tank
2. Water
3. Over 10 cm (4 in.)
1
ENOF01326-0
1. Hose joint
ENOM00950-0
30, 40, 50.
Fuse replacement
ENOW00923-0
CAUTION
Before replacing a fuse, disconnect the bat-
tery cable from the battery negative (-) ter-
minal. Failure to do so may cause a short-
circuit.
ENOW00924-0
CAUTION
Never use a fuse with a rating that exceeds 1
the specified rating as this could cause seri-
ous damage to the electrical system.
ENOF01327-0
If a blown fuse is detected, try to deter- 1. Blown fuse

mine the cause for this and correct it. If
the cause for the problem is not cor-
rected, the fuse will likely blow again. 75, 90
If the fuse continues to blow, request an
authorized Tohatsu dealer to inspect
the outboard motor.
1. Stop the engine and disconnect the
battery cable from the battery nega-
tive (-) terminal.
2. Remove the engine cover.
3. Remove the fuse box lid.
4. Remove the fuse and check it. If the
10
fuse is blown, replace it with a fuse
of the same specified rating. The 1
outboard motor is supplied with
spare fuses in the spare fuse holder.
ENOF01329-0
1. Blown fuse
115
ENOF01330-0
1. Blown fuse
10
ENOM00708-0
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.
Inspection intervals
Description First 20 Every 50 Every 100 Every 200 Inspection procedure Remarks
hours of 1 hours of 3 hours of 6 hours of 1
month months months year
Replace Check and clean or Replace if neces-

Fuel filter z z Entire cartridge
z sary.
High pressure Replace
Replace every 200 hrs or 2 years
fuel filter*1 z
Replace Check and clean or Replace if neces-

Piping/Hoses z z z
z sary
Fuel tank z z z z Clean Including filter
Check and clean or Replace if neces-
Fuel System/ Fuel tank cap z z z z
sary.
Compres-
sion System Fuel pump*1 Check and clean or Replace if neces-
z z z z
sary.
Air filter*1 z z
sary.
Drive belt*1 z z Check and Replace if necessary.
Check and replace defective parts if
Fuel Pressure*1 z z
necessary.
Check and replace defective parts if
Air Pressure*1 z z
necessary.
Remove carbon deposits or Replace if 0.8–0.9 mm
Ignition Spark plug z z z
necessary. (0.031–0.035 in)
Check for salt deposits and the battery
Starting Sys-
tem
Starter motor*1 z z
cable condition.
10
Check installation, fluid quantity, grav-
Battery z z z z
ity.
Oil tank z z z
sary.
Engine oil
Oil pipe z z z
system
Oil filter z z z
sary.
Propeller z z z z Check for bent blades, damage, wear.
Replace Replace Replace Change or replenish-oil and check for
Gear oil z z z
Lower Unit water leaks.
Replace impeller
Water pump*1 z z z Check for wear or damage.
every 12 months.
Thermostat*1 z z Check and Replace if necessary.
*1 Check & replenish oil, manually oper-

Power trim & tilt z z z
ate
Inspection intervals
Description First 20 Every 50 Every 100 Every 200 Inspection procedure Remarks
hours of 1 hours of 3 hours of 6 hours of 1
month months months year
Warning system*1 z z z Check function

Bolts and Nuts z z z z Retighten
Sliding and Rotating Parts.
z z z z Apply and pump in grease.
Grease Nipples
Outer Equipment z z z z Check for corrosion.
Replace if neces-
Anode z z z Check for corrosion and deformation.
sary.
*1: Have this handled by your dealer
ENON00030-0
Note
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.
ENOM00093-A ENOM00094-0
Fuel filters and fuel tank cleaning Fuel filter (for engine)
ENOW00093-A 1. Check in the cup for water and
debris.
WARNING
Gasoline and its vapors are very flammable
and can be explosive.
z Do not start this procedure while engine 1 6
is operating or hot even after stopping it.
z Place fuel filter away from every source of 2
ignition such as sparks or open flames.
3
z Wipe off gasoline well immediately if
spilled and dispose of it in accordance 4
with local fire prevention and environ-
10 ment protection regulations. 5
z Install fuel filter with all related parts in
place, or fuel leak could occur, leading to ENOF00096-B
catching fire or explosion.
1. Body
z Check fuel system regularly for leakage. 2. O-ring
z Contact authorized dealer for fuel system 3. Filter
services. Services by unqualified person 4. O-ring
5. Cup
could lead to engine damage.
6. Arrow to indicate fuel flow direction
Fuel filters are provided inside the fuel

2. If present, disconnect hoses from
tank and engine.
the fuel connector (male) and the
fuel pump.
3. Remove the cup, filter and O-rings
from the fuel filter body.
4. Check the wear and clogging for each 1. Disconnect all pipes between the oil
parts, and replace if necessary. tank and oil pump.
5. Remove fuel and any water or debris 2. Clean out foreign matter.
from the cup, filter and hoses. 3. Refit the pipes to the oil tank and
6. Reassemble all parts. pumps, and then fill up with new
ENOM00096-A engine oil.
Fuel filter (for fuel tank) 4. For air purging, refer to ‘’Engine oil
Water or dirt in the fuel tank will cause feeding’’ (See page 38)
engine performance problems. 30, 40, 50
Check and clean the tank at specified
times or after the outboard motor has
been stored for a long period of time
(over three months).
1. Remove four screws to remove the
Fuel Pick-Up.
2. Clean the fuel filter and replace the
gasket.
3. Reassemble all parts.
1
ENOF01346-0
1. Oil filter
1
75, 90, 115

2
10
ENOF00926-1
1. Fuel pick-up
2. Filter
ENOM00725-0
1 ENOF01347-0
Oil filter
Oil filter and oil tank. Check the oil tank 1. Oil filter
and/or filter for entrapped water and

dust.
ENOM00098-A
75, 90, 115
Gear oil replacement
ENOW00094-0
WARNING
z Be sure that outboard motor is secured to
drop or fall of outboard motor could lead
to severe personal injury.
z Be sure to lock outboard motor if it is
tilted up, or accidental fall of outboard
motor could lead to severe personal
injury.
z Do not go under outboard motor tilted up
and locked, or accidental fall of outboard ENOF01332-0
injury. 3. Insert the oil tube nozzle into the
lower oil plug hole, and fill with gear
oil by squeezing the oil tube until oil
2. Remove the oil plugs (lower and flows out of the upper plug hole and
upper), and completely drain the bubbles is disappeared to remove
gear oil into a pan. the air.
30, 40, 50 30, 40, 50
10
ENOF01331-0
ENOF01333-0
75, 90, 115 75, 90, 115
ENOF01334-0 ENOF01332-0
4. Install the upper oil plug, and then ENOW00928-0
remove oil tube nozzle and install the

CAUTION
lower oil plug.
ENOW00095-0
Wipe off gear oil well immediately if spilled
and dispose of it in accordance with local
CAUTION fire prevention and environment protection
regulations.
Do not reuse oil plug gasket. Always use new
gasket and tighten oil plug properly to pre- ENON00032-0
vent entry of water into lower unit. Note
30, 40, 50 If water in the oil, giving it a milky colored
appearance. Contact your dealer.
ENON00033-0
Note
Use genuine gear oil or the recommended
one (API GL-5: SAE #80 to #90).
10
Required volume 30, 40, 50: approx. 500
mL (16.9 fl.oz), 75, 90, 115 approx. 900 mL
(30.4 fl.oz).
ENOM00086-A
Propeller replacement
ENOW00084-0
ENOF01331-0
WARNING
z Do not begin propeller removal and
installation procedure with spark plug
c a p s a t t a c h e d , s h i f t in fo r wa r d o r
reverse, main switch at other than “OFF”,
engine stop switch lock attached to the 4. Apply water proof grease to the pro-
switch, and star ter key attached, or peller shaft before installing a new
engine could accidentally start leading to
propeller.
serious personal injury. Disconnect bat-
tery cable if possible. 5. Install the thrust holder, propeller,
z The propeller edge is thin and sharp. stopper, washer and propeller nut
Wear the groves during replacement to onto the shaft.
protect your hands.
30, 40, 50
ENOW00086-0
6
3
CAUTION
z Do not install propeller without thrust 5
4
holder, or propeller boss could be dam-
aged.
z Do not reuse split pin.
2 1
z After installing split pin, spread the pin
apart to prevent it from falling out which
could lead to the propeller coming off ENOF01315-0
during operation.
1. Propeller
2. Thrust holder
A worn-out or bent propeller will lower 3. Stopper
the motor's performance, and cause 4. Washer
5. Propeller nut
engine trouble. 6. Split pin
1. Put a piece of wood block between
propeller blade and anti-ventilation 75, 90, 115
plate to hold propeller.
4 7
6
5
10
3 1
2
ENOF01336-0
ENOF00084-B
1. Propeller
2. Thrust holder
3. Bush
2. Remove the split pin, propeller nut 4. Stopper
and washer. 5. Washer
6. Propeller nut
3. Remove the propeller and thrust 7. Split pin
holder.
6. Tighten the propeller nut to speci-

fied torque, and align one of grooves 1. Stop the engine.
to propeller shaft hole. 2. Remove the top cowl.
Propeller nut torque: 3. Remove the spark plug caps.
35 N·m(25 ft·lb, 3.5kgf·m) 4. Remove the spark plugs by turning it
7. Install a new split pin into the nut counter-clockwise, using a 5/8" (16
hole and bend it. mm) socket wrench and handle that
is provided in tool bag.
5. Inspect the spark plug. Replace the
spark plug if the electrodes are worn
or if the insulators are cracked or
chipped.
ENOF00084-D 6. Measure the spark plug electrode
gap with a wire type feeler gauge.
ENOM00087-A T h e g ap sh ould b e 0. 8 - 0.9 mm
Spark plugs replacement
ENOW00087-0
(0.031-0.035 inches). If the gap is
different, replace the spark plug with
WARNING a new one
z Do not reuse spark plug with damaged Use spark plug with referring specifi-
insulation, or sparks can leak through cation (See page 13)
crack, potentially leading to electric
shock, explosion and/or fire.
z Do not touch spark plugs immediately
after stopping engine as they will be hot
and could cause severe burns if touched.
Allow motor to cool down first. 1
2 ENOF00085-0
ENOW00929-0 1. Electrode
2. Spark gap (0.8–0.9 mm, 0.031–0.035 in)
10
CAUTION
Use only the recommended spark plugs. 7. Install the spark plug by hand and
Spark plugs which have an different heat turn it carefully to avoid cross-
range may cause engine damage. threading.
If the spark plug(s) is fouled, has carbon
b uil d up , or is w orn , i t sh o ul d b e
replaced.
When reusing spark plugs, remove dirt
from the electrodes and adjust spark
gap to specification.
8. Tighten the spark plug to the speci-

fied torque.
ENON00028-0
Note
z Spark plug torque:
18.0 N·m (13.3 ft·lb) [1.84 kgf·m]
If a torque-wrench is not available when
you are fitting a spark plug, a good esti-
mate of the correct torque is 1/4 to 1/2 a
turn past finger-tight. Have the spark plug
adjusted to the correct torque as soon as
possible with a torque-wrench.
ENOF01337-0
10
ENOM00088-A
Anode replacement
A sacrificial anode protects the outboard motor from electrolytic corrosion. Anode is
located on the gear case, cylinder etc.. When the anode is eroded more than 1/3 of
original size, replace it.
ENON00029-0
Notes
z Never grease or paint the anode.
z At each inspection re-tighten the anode attaching bolt. As it is likely to be subjected to electro-
lytic corrosion.
75, 90, 115
75, 90
30, 40, 50 *1
10
*2
75, 90, 115
*1 ENOF01339-0
*1 : Both side
*2 : Handle by your dealer
ENOM00089-B
40, 50
Power Tilt oil checking
ENOW00088-0
WARNING 2
z Be sure that outboard motor is secured to

drop or fall of outboard motor could lead
to severe personal injury. 1
z Be sure to lock outboard motor if it is
tilted up, or accidental fall of outboard
injury.
z Do not go under outboard motor tilted up
ENOF00929-0
and locked, or accidental fall of outboard
motor could lead to severe personal 1. Oil cap
2. Oil level
injury.
75, 90, 115
ENOW00089-A
CAUTION
2
Do not unscrew the oil cap with the out-
board motor tilted down. Pressurized oil in
the oil tank may spurt out.
Check the oil level in the reservoir tank

while the tank is kept in a vertical posi-
tion. 1
1. Tilt the outboard motor up and lock
the tilt with the tilt stopper.
ENOF01340-0
2. Remove the oil cap by turning counter
10 clockwise, then check if the oil level
1. Oil cap
2. Oil level
reaches the bottom line of the plug Recommended oil
hole. Use an automatic transmission fluid or
equivalent.
Recommended oils are as shown below.
ATF Dexron III
Air purging from the Power Trim and

Tilt unit.
Entrapped air in the Power Tilt unit will
c a us e p o or til tin g m o v e m e n t a n d
increased noise.
1. With the outboard motor mounted

on the boat, set the manual release
valve to the Manual side, and tilt the
outboard motor manually up/down 5-
6 times while checking the oil level.
2. When done, close the valve by turning
it clockwise towards the Power side.
30, 40, 50
2
ENOF00070-1
1. POWER
2. MANUAL
75, 90, 115

10
2
ENOF00679-0
1. POWER
2. MANUAL
ENOM00960-0
Grease point
Apply water proof grease to the parts shown below.
30, 40, 50
10
ENOF01341-0
ENOM00100-A
3. Drain all fuel from the fuel hoses,
3. Off-season storage fuel pump, fuel filter (See page 80)
and vapor separator (See page 92),
ENOW00934-0
and clean these parts.
WARNING Keep in mind that if gasoline is kept
in the vapor separator for a long
z Be sure to disconnect fuel connector
time, gum and varnish will develop,
except when operating engine.
z Fuel leakage is a fire or explosion hazard, causing the float valve to stick,
which can cause serious injury or death. restricting the fuel flow.
4. Remove the spark plugs and put a
ENOW00097-0
teaspoon of engine oil or spray stor-
WARNING age oil into the combustion chamber
through the spark plug holes.
Be sure to use cloth to remove fuel remain-
ing in the cowl and dispose of it in accor- 5. Turn the starter motor several turns
d an c e w i t h l o c a l f ir e pr e ve n t i o n an d to lubricate inside the cylinder.
environment protection regulations. ENOW00930-0
ENOW00096-0 WARNING
CAUTION z Be sure to remove stop switch lock to
prevent ignited the spark plugs.
Before servicing the motor for storage: z Put a cloth to spark plug hole and wipe up
z Remove the battery cables. any spilled engine oil, when cranking the
z Remove the spark plug caps from the outboard motor.
spark plugs.
z Do not run the motor out of the water. 6. Change the gear oil in the gear case
Before you put your outboard motor in (See page 82).
storage, it is a good opportunity to have 7. Apply grease to grease point (See
it serviced and prepared by your dealer. page 90).
Be sure to use fuel stabilizer while run- 10
ning the motor before storage. (See
page 92)
ENOM00101-B
Engine
1. Wash the engine exterior and flush
the cooling water system thoroughly
with fresh water. Drain the water
completely.
Wipe off any surface water with an
oily rag.
2. Remove the fuel hose from the out-
board motor.
8. Stand the outboard motor up verti- 1. Before adding fuel stabilizer additive,
cally in a dry place. dr ain th e vap or se par a tor ( S e e
page 92).
2. Follow the instructions on the label
when adding the fuel stabilizer addi-
tive.
3. After adding the additive, let the
outboard motor run in the water for
10 minutes to make sure any old fuel
in the fuel system has been com-
pletely replaced by the fuel with
additive.
4. Turn the engine OFF
ENON00891-0
ENOF01321-0
Note
ENON00021-A
Note If your motor is used occasionally, it is
recommended to use a good fuel stabi-
z If the outboard motor must be laid down lizer in every tank of fuel and keep the
be sure drain the fuel and engine oil, then container full to reduce condensation
the outboard motor on a cushion as shown and evaporation.
in the following drawing (See page 68 and
92).
ENOM00970-0
z Elevate power unit 2 inches to 4 inches if
Fuel system draining
traveling to avoid air intrusion in the
ENOW00028-A
Power Trim and Tilt pump system.
WARNING
For details on handling fuel, contact an
authorized dealer.
10 Fuel and fuel vapors are extremely flamma-
ble and can be explosive.
z If fuel is spilled, wipe it up immediately.
z Keep the fuel tank well away from sources
ENOF00680-0
of ignition, e.g. sparks or open flames
ENOM00950-0 z Perform all work outdoors or in a well
Adding a fuel stabilizer ventilated place.
When adding a fuel stabilizer additive
ENOW00097-0
(commercially available), first fill the fuel
tank with fresh fuel. If the fuel tank is WARNING
only partially filled, air in the tank can
Be sure to use cloth to remove fuel remain-
cause the fuel to deteriorate during ing in the cowl and dispose of it in accor-
storage. d an c e w i t h l o c a l f ir e p r e v e n t i o n an d
environment protection regulations.
1. Disconnect the fuel hose from the 75, 90, 115

outboard motor.
3. Release the drain tube from the
clamp and pull the tube outside the
bottom cowl. Place an approved fuel
1
container under the drain tube end
and use a funnel to avoid spilling
fuel.
4. Loosen the vapor separator drain
screw. ENOF01343-0
5. Tilt up the outboard motor until fuel 1. Vapor separator drain screw
flows out of the drain tube.
ENOM00102-0
6. Leave the outboard motor in this Battery
position until all fu e l has be en ENOW00931-A
drained.
7. When thoroughly drained, retighten WARNING
the drain screw securely. z Place the battery away from any source of
8. Check the drained fuel for the pres- fire, sparks and open flames such as
burners or welding equipment.
ence of water or other contami-
z Place the battery away from fuel tank.
n a n t s. If e i t h e r is p r e s e n t , Accidental sparks of battery may cause
reassemble the outboard motor, explosion of gasoline.
refill the vapor separator with fuel,
and then drain the fuel again. Repeat 1. Disconnect the battery cables and be
this procedure until no water or sure to remove the negative terminal
other contaminants are present in first.
2. Wipe off any chemical deposits, dirt,
the drained fuel.
30, 40, 50 or grease. 10
3. Apply grease to the battery termi-
nals.
4. Charge the battery completely
before storing it for the winter.
5. Recharge the battery once a month
1 to prevent it from discharging and
the electrolyte from deteriorating.
6. Store the battery in a dry place.
ENOF01342-0
*Remove fuel filter before draining

1. Vapor separator drain screw
ENOM00104-C
9. Run the engine for 10 minutes at half
4. Pre-season check throttle. The oil used for storage
inside the engine will be circulated
The following steps must be taken when out to assure optimum performance.
first using the engine after off-season
storage. ENOM00105-A
1. Check that the shift and throttle 5. Submerged outboard motor

function properly. (Be sure to turn
the propeller shaft when checking ENOW00098-0
the shift function or else the shift

linkage may be damaged.)
CAUTION
2. Check the electrolyte level, and mea- Do not attempt to start submerged outboard
sure the voltage and specific gravity motor immediately after it is recovered, or
engine could be severely damaged.
of the battery.
Specific Grav- Terminal Volt- Charge Condi-
After taking your outboard motor out of
ity at 20°C age (V) tion the water, immediately take it to your
1.120 10.5 Fully discharged dealer.
1.160 11.1 1/4 charged The following are the emergency mea-
1.210 11.7 1/2 charged sures to be taken for a submerged out-
1.250 12 3/4 charged board motor, if you can not take it your
1.280 13.2 Fully charged dealer right away.
1. Wash the outboard motor with fresh
3. Check that the battery is secure and water to remove salt or dirt.
the batter y cables are properly 2. Remove the engine oil drain screw
installed. and completely drain water and oil
4. Change the engine oil (See page 74). from the engine.
5. Before starting the engine, discon- 3. Remove the spark plugs, and com-
10 nect stop switch lock and crank pletely drain the water from the
approximately 3times of 3sec. turn- engine by pulling emergency starter
ing the starter motor in order to rope (See page 51) several times.
prime the oil pump. Replace oil filter and oil to the cor-
6. Fill fuel tank completely. rect level.
7. Start the engine and warm up the The oil and filter may need to be
engine for 3 minutes in the “NEU- changed again after running a short
TRAL” position. period to get all moisture completely
8. Run the engine for 5 minutes at the out of the crankcase.
slowest speed.
4. Inject a sufficient amount of engine

oil through the spark plug holes.
Pull the emergency starter rope sev-
e r a l tim e s t o cir c ul a t e t h e oil
throughout the outboard motor.
ENOM00106-A
6. Cold weather precautions

ENOF01145-0
If you moor your boat in cold weather at
temperatures below 0°C (32°F), there is
the danger of remained water freezing ENOM00121-0
in the cooling water pump, which may 8. Operation with multiple

damage the pump, impeller, etc. To outboard motors
avoid this problem, submerge the lower
half of the outboard motor into the When operating the outboard motors in
water. reverse at more than the lowest speed,
be sure that all engines are running.
ENOM00107-A
If any engine has stopped, be sure to tilt
7. Striking underwater object the outboard motor up and keep its pro-
peller out of the water.
ENOW00935-0
Otherwise, water could enter the engine
CAUTION and cause damage to it.
Striking the sea bottom or an underwater

object may severely damage the outboard
motor.
Follow the procedure below and consult 10

a dealer as soon as possible.
1. Stop the engine immediately.
2. Check the control system, gear case,
boat transom etc.
3. Return to the nearest harbor slowly
and carefully.
4. Consult a dealer check the outboard
motor before operation again.
96
TROUBLESHOOTING
ENOM00720-0
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.
Power Trim & Tilt Inoperative

Starter motor will not crank
Battery will not hold charge
Difficult to start engine
Engine runs erratically
Boat speed loss
Possible cause
z Empty fuel tank

z z Incorrect connection of fuel system
z z Air enters fuel line
z z Deformed or damaged fuel pipe
z Closed air vent on fuel tank cap
z z Fuel filter/fuel pump is clogged with dust.
z Use of improper gasoline
z Incomplete forced fuel feeling by primer bulb
z z Poor connection in compression system
z z Use of non-specified spark plugs
z z Dirt or carbon deposits on spark plugs
No sparking or poor sparking (Failure in component of Ignition
z z
system)
z Insufficient cooling water flow
z z Propeller cavitation
z Incorrect propeller selection
z z Damaged or bent propeller
11 z Unbalanced loading. Overload
z Transom is too high/low.
z Bottom of the boat is stained or damaged.
z z Insufficient throttle aperture.
z z Battery is charged insufficiently.
Battery is nearly dead, Poor connection of battery terminal, Low
z z z z
level of electrolyte
z Power trim & tilt switch is defective.
z z Wrong positioning of shift lever at N (neutral) position.
z z z z Main switch in defective.
TROUBLESHOOTING 97
Power Trim & Tilt Inoperative

Starter motor will not crank
Battery will not hold charge
Difficult to start engine
Engine runs erratically
Boat speed loss
Possible cause
z Lock plate is not inserted or poorly inserted into stop switch.

z z z z Wrong wiring, disconnection, poor connection.
z z Faulty operation of starter motor/starter solenoid
z A great deal of air is contained inside pump.
11
98
ACCESSORIES KIT
ENOM00721-0
30, 40, 50
The following a list of the tools and spare parts provided with the motor.
Name Quantity Remark
Tool bag 1
Socket wrench 1 10 × 13 mm
Socket wrench 1 16 mm
Service tools Socket wrench handle 1
Pliers 1
Screwdriver 1 Cross-and straight-point
Screwdriver handle 1
Emergency starter rope 1
Spark plug 3 NGK IZFR6Q
Spare parts
Split pin 1 Diameter × Length 3 × 25 mm
Stop switch lock 1
Bracket fixing bolts 4 12 mm
Bracket fixing nuts 4 12 mm
Washers A, B 4 each A (large), B (small)
Drag link 1
Parts packaged
Fuel tank (with primer bulb) 1
with engine*
Remote control box 1 Not included as standard accessories in
Tachometer 1 US & Canada markets.
Trim meter 1
Lead wire for meter 1
12
ACCESSORIES KIT 99
ENOM00722-0
75, 90, 115
The following a list of the tools and spare parts provided with the motor.
Quantity
Name Remark
MD 75/90 MD 115
Tool bag 1 1
Socket wrench (16 mm) 1 1
Socket wrench (10 × 13) 1 1
Service tools Socket wrench handle 1 1
Pliers 1 1
Screwdriver (Phillips- 1 1 Adapter-type
type and flat head)
Spark plug (75/90) 3 NGK IZFR6Q
Spare parts Spark plug (115) 4 NGK IZFR5J
Split pin 1 1 Diameter × Length 3 × 25 mm
Bracket fixing bolts 4 4 12 mm
Bracket fixing nuts 4 4 12 mm
Parts packaged Washers A, B 4 each 4 each A (large), B (small)
with engine* Drag link 1 1
Hose joint 1 1 For flushing
Primer bulb ass’y 1 1
* Fuel tank, remote control box, tachometer, trim meter, meter lead wire and propeller are not enclosed in the engine
package.
12
100
PROPELLER TABL
ENOM00724-0
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.
5150–5850 min-1 (rpm)
30, 40, 50 75, 90, 115*2

Pitch Pitch
Lighter load 15 Lighter load 21
14 19
13 17
12 15
11 13
9 11
Heavier load 7*1 Heavier load 9
*1: Shows propeller with four blades. *2: The 75-115 model is supplied with so standard
propeller. It is shipped from the factory without
a propeller.
13
O W N E R’ S
MANUAL
MD 30B2
MD 40B2
MD 50B2
MD 75C2
MD 90C2
MD 115A 2
5-4, Azusawa 3-Chome, Itabashi-Ku

Tokyo 174-0051, Japan
Tel: +81-3-3966-3117 Fax: +81-3-3966-0090
www.tohatsu.com

Owner'S Manual: MD 40B MD 50B MD 75C MD 90C MD 115A MD 30B

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O W N E R’ S

YOUR TOHATSU OUTBOARD MOTOR

Serial Number: Date of purchase:

1. GENERAL SAFETY INFORMATION 1

10. INSPECTION AND MAINTENANCE 10

12. ACCESSORIES KIT 12

13. PROPELLER TABL 13

Carbon Monoxide Poisoning Hazard

30B2 (Available in specific region), 40B2

ETO (with multi-function tiller handle)/40B2, 50B2

1 Tilt Handle 13 Clamp Bracket 25 Spark Plug

ETO (with RC)/30B2, 40B2, 50B2

1 Tilt Handle 13 Clamp Bracket

1 Tilt Handle 13 Thrust Rod

1 Tilt Handle 15 Power Trim & Tilt Switch

Remote control box & Fuel tank

1 Control Lever 13 Main switch

Warning label locations

6. Indicator label regarding engine fail-

2. Warning regarding engine oil replen-

7-1. Warning regarding emergency start-

3. Warning label regarding installation of

Affix this label near the outboard

For Top mount RC

11. Warning regarding gasoline.

1. Model code(Model name)

Description of serial number year code

1. Mounting the outboard WARNING

Outboard motor mounting must be per-

ENOM00025-0 attitude. Check the position of water sur-

2. Boat transom ENOM00830-B

Power trim and tilt type

102 (4.02”) 102 (4.02”)

ø13 26 (1.02”) 248 (9.76”)

75, 90, 115 ENON00003-0

2. Remote control device

ENOW00850-0 comes in contact with your skin, or poison-

z Do not disconnect the battery leads from

damage to, the electrical system. 1. Battery cord (red)

850 (Cold Cranking Amps (CCA), In case of 4. Propeller installation

5. TOCS (Tohatsu Onboard

5. Tighten the propeller nut to speci-

75, 90, 115

6. Install a new split pin into the nut

TOHATSU engine will withstand up to CAUTION

When carrying a fuel tank containing gaso- ENOW00946-0

When or before refueling:

4. After filling the tank, close the fuel CAUTION

The engine oil is drained for shipping from

The required amount of engine oil is

If outboard motor encounters an abnor-

See next page for conditions which will

Description of faults Rem-

Continu- ON ON ON - Normal system test 1 second

High Engine speed exceeds

Continu- Flash- Forced Cooling water temp is

- - - Flash- - Battery voltage is low Engine is stopped 4

Flash- Flash- Flash- Forced

- Flash- Flash- Flash- - Malfunction of electrical 5

Manual Tilt type