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OWNER’S
MANUAL

M 2.5A2
M 3.5A2
M 3.5B2
Original instructions
OB No.003110458AG1
 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 © 2017 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 procedures
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 service shop or dealer.
Please always keep this manual together with the outboard motor as a reference to every-
one 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

ENOM00003-0
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before you
take delivery.

ENOM00113-0
EC DECLARATION OF CONFORMITY (DoC)
This product conforms to certain portion of the European Parliament directive. DoC con-
tains 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).

ENON00937-0
Note
For CE marked model
The Outboard engine is intended to install on non-recreational craft within the European Union
because it has not been confirmed compliance with requirement of Directive 2013/53/EU.
4

ENOM00005-A
Serial Number
In the space below, please record the outboard motor's serial number. The serial number
will be needed when ordering parts, and when making technical or warranty inquiries.

Serial Number:

ENOF02000-0 ENOF02001-0

Serial Number: Date of purchase:

 5

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 dam-
age.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4. LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . 37
1. Removing the outboard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10. INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8. Auxiliary outboard motor operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
12. TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
 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. TOOL KIT AND SPARE PARTS 12

13. PROPELLER TABLE 13

14

14
 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 MOV-
ING 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 lanyard 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 operator falls over-
board.
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 (Per-
sonal Floatation 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 on 1
this outboard motor. Be sure to use genuine parts, genuine lubricants, or recommended
lubricants.

ENOM00011-A
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct maintenance
procedures following maintenance section of this manual (See page 41). It is the opera-
tor's responsibility to perform all safety checks and to ensure that all lubrication and main-
tenance 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 prescribed 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-B
MODEL FEATURE

Model M2.5A2 M3.5A2 M3.5B2

2 Type MF MF MF

S z z z

Transom heights L z z z

UL

Tiller Handle z z z

Remote Control

Separate fuel tank

Integral fuel tank z z z

Shifting z

Manual tilt z z z

*1: Option

ENOM00811-B
MODEL NAME EXAMPLE
M3.5B2S

M 3.5 B 2 S

Product genera-
Model description Horse power Minor change Shaft length
tion

M (X)= Two stroke S= Short 15 in

F= Four stroke - A and up 2 and up L= Long 20 in
D= Two stroke DI UL= Ultra long 25 in
 SPECIFICATIONS 13

ENOM01300-0

2.5A2, 3.5A2, 3.5B2

Item MODEL 2.5A2 3.5A2 3.5B2

Overall Length mm (in) 550 (21.7) 2
Overall Width mm (in) 345 (13.6) 220 (8.7)
S mm (in) 958 (37.7)
Overall Height
L mm (in) 1085 (42.7)
S mm (in) 435 (17.1)
Transom Height
L mm (in) 562 (22.1)
S kg (lb) 12.5 (28) 13.0 (29)
Weight
L kg (lb) 13.0 (29) 13.5 (30)
Output kW (ps) 1.8 (2.5) 2.6 (3.5)
Max. Operating Range rpm 3,800-5,200 4,200-5,300
Trolling Speed in Forward Gear rpm 1,100
Idle Speed in Neutral Gear rpm - 1,300
Engine Type 2-Stroke
Number of Cylinders 1
Bore x Stroke mm (in) 47 x 43 (1.85 x 1.69)
Piston Displacement mL (Cu in) 74.6 (4.55)
Exhaust System Underwater exhaust
Cooling System Forced water cooling
Lubrication System Engine Oil Mixed Gasoline
Starting System Manual starter
Ignition System Flywheel Magneto C.D. Ignition
Spark Plugs NGK BP6HS-10/BPR6HS-10
Trim Position 4
Unleaded regular gasoline : Pump posted 87 Octane
Fuel
(research octane rating of 91)
Fuel Tank Capacity L (US gal) Approx. 1.4 (0.37) integral tank
Engine Oil Genuine motor oil or recommended one (TCW-III)
Fuel : Engine Oil Mixing Retio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1
Genuine Gear Oil or API GL5, SAE #80 to #90,
Gear Oil
approx. 3.5B2:180mL (6.1 fl.oz), 3.5A2 & 2.5A2:90mL (3.0 fl.oz),
Gear Shift Foward F-N
Gear Reduction Ratio 1.85 (13 : 24) 2.15 (13 : 28)
Operator Sound Pressure
(ICOMIA 39/94) dB (A)
81.8

Hand Vibration Level

(ICOMIA 38/94) m/s2
5.1

Remark: Specifications subject to change without notice.

Tohatsu outboard is power rated in accordance with ISO8655 (propeller shaft output).
 14
PARTS NAME
ENOM01301-0

2.5A2, 3.5A2, 3.5B2

1 11
2
24

3 3 12 25
22
4 26

5 13
6 14 23

7
15

16
8
17 27
18

9 19
20
21
10 30

28
29

ENOF02002-0
1 Air Vent Screw 13 Handle Grip 25 Carburetor Cover
2 Fuel Tank Cap 14 Carring Handle 26 Chork Lever
3 Top Cowl 15 Clamp Screw 27 Drive Shaft Housing
4 Plug Cap Cover 16 Thrust Rod Grommet (3.5B2 only)
5 Fuel Cock 17 Oil Plug (Upper) 28 Steering Adjustment Screw
6 Cooling Warter Check Port 18 Anti-Ventilation Plate 29 Spark Plug
7 Clamp Bracket 19 Water Inlet (3.5B2 only) 30 Fuel Filter
8 Drive Shaft housing 20 Gear Case
9 Propeller 21 Oil Plug (Lower)
10 Water Inlet (2.5/3.5A2) 22 Throttle Lever
11 Starter Handle 23 Tilt Stopper
12 Shift Lever(3.5B2 only) 24 Stop Switch
 15
LABEL LOCATIONS
ENOM00019-A

Warning label locations

2 1
4, 5

4
3

ENOF02003-1

1-1. Warning label urge to read the 2. Warning regarding fuel tank cap. (See
owner’s manual. page20, 25)
1-2. Warning regarding stop switch (See
page 31).
1
2

ENOF02050-0

3. Warning regarding high temperature.

314X67531-3

3GR-76191-0
 16 LABEL LOCATIONS

4. Warning label urge to read the owner's

manual.

3F0X72185-0

5. Warning regarding high temperature,

high voltage, rotating object.
4

314X72185-0
 LABEL LOCATIONS 17

ENOM01001-0

Serial number label locations

O utboard Motor
1)
R a te d Power: 2)
Ma ss: 3)
Serial No. 4) 4
5)
6)
Made in Japan CAN ICES2/NMB2

ENOF020481

1. Model code(Model name)

2. Rated power
3. Dry mass weight
4. Serial No.
5. Manufacture name
6. Manufacture 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
ENON00937-0
Note
For CE marked model
The Outboard engine is intended to install on non-recreational craft within the European Union
because it has not been confirmed compliance with requirement of Directive 2013/53/EU.
 18
INSTALLATION
ENOM00024-B
Keep the outboard motor in a vertical posi-
1. Mounting the outboard motor on tion when mounting.
boat
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
5 has been securely mounted on the boat in
accordance with the instructions below.
ENOF02004-0

ENOW00009-0

WARNING
z Mounting the outboard motor without
following this manual can lead to unsafe
conditions such as poor maneuverabil-
ity, lack of control or fire. 2
z Loose clamp screws and/or mounting
1 ENOF02005-0
bolts can lead to the release or displace-
ment of the outboard motor, possibly
1. Clamp Screw
resulting in lost of control and/or serious 2. Tighten
personal injury. Be sure that fasteners
are tightened to the specified torque (30 ENOM00025-0
Nm (3.0 kgf) 13 ft-lb). Check the fasten- Position ... Above keel line
ers for tightness from time to time.
Set engine at center of boat.
z Be sure to use outboard mounting fas-
teners included in the outboard motor
package or their equivalents in terms of
1
size, material, quality and strength.
Tighten fasteners to the specified torque
(30 Nm (3.0 kgf) 13 ft-lb). Test cruise to
check if fasteners are tightened
securely.
z Outboard motor mounting must be per- 2
formed by trained service person(s)
using lift or hoist with sufficient capac-
ity.
ENOF01141-0
1. Center of boat
 INSTALLATION 19

2. Boat transom ENOM00830-A

Mounting bolts
ENOM00026-0
Transom matching Manual tilt type
1. To attach the outboard motor to the
Be sure that the anti ventilation plate of the
outboard motor is 30–50 mm (1.2–2 in) boat, tighten the clamp screws by
below the bottom of hull. turning their handles.
Also, use the bolts to secure the out-
If the above condition cannot be met due
to the shape of the bottom of your boat, board motor brackets on transom
please consult your authorized dealer. board.
Secure the outboard motor with a rope
to prevent loss overboard.
ENON00002-0
Note
1
30−50 mm A rope is not included in the standard 5
(1.2−2 in) accessories.
2
ENOF01608-0

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
attitude. Check the position of water ENOF02006-0
surface on the driveshaft housing. If the
water surface is near the bottom cowl-
ing, in high waves, water may enter the
engine cylinders.
z Incorrect outboard motor mounting
height or existence of underwater
object(s), such as hull bottom design,
bottom surface conditions or underwa-
ter accessories, can cause water spray
possibly reaching the engine through an
opening of the bottom cowling during
cruising. Exposing the engine to such
conditions for extended periods can
lead to severe engine damage.
 20
PRE-OPERATING PREPARATIONS
ENOM00030-A
these adverse effects are caused because
1. Fuel handling the ethanol in the gasoline can absorb
moisture from the air, resulting in a separa-
ENOW000017-0
tion of the water/ethanol from the gasoline
CAUTION in the fuel tank.
These may cause increased:
Use of improper gasoline can damage your
z Corrosion of metal parts
engine. Engine damage resulting from the
use of improper gasoline is considered z Deterioration of rubber or plastic parts
misuse of the engine, and damage caused z Fuel permeation through rubber fuel
thereby will not be covered under the lim- lines
ited warranty. z Starting and operating difficulties

ENOM00031-A If the use of gasoline containing alcohol is

FUEL RATING inevitable, or presence of alcohol is sus-
TOHATSU engines will operate satisfacto- pected in the gasoline, it is recommended
rily when using a major brand of unleaded
6
to add a filter that has water separating
gasoline meeting the following specifica- capability, and check the fuel system for
tions: leaks and mechanical parts for corrosion
USA and Canada — having a posted and abnormal wear more frequently.
pump Octane Rating of 87 (R+M)/2 mini- And, in case any of such abnormality is
mum. Premium gasoline (92 [R+M]/2 found, discontinue the use of such gaso-
Octane) is also acceptable. Do not use line and contact our dealer immediately.
leaded gasoline. If the outboard motor will only be used
Outside USA and Canada — Use infrequently, please see the remarks on
unleaded gasoline with declared octane fuel deterioration in the STORAGE chapter
rating of 91 RON or over. Use of premium (P 52) for additional information.
gasoline of 98 RON is also allowed. ENOW00020-0

ENOM00032-A CAUTION
GASOLINES CONTAINING
When operating a TOHATSU engine on
ALCOHOL gasoline containing alcohol, storage of
The fuel system components on your gasoline in the fuel tank for long periods
TOHATSU engine will withstand up to 10% should be avoided. Long periods of stor-
ethyl alcohol (hererinafter referred to as the age, common to boats, create unique prob-
"ethanol"), content in the gasoline. But if lems. In cars, alcohol blend fuels normally
are consumed before they can absorb
the gasoline in your area contains ethanol,
enough moisture to cause trouble, but
you should be aware of certain adverse boats often sit idle long enough for phase
effects that can occur. Increasing the per- separation to take place. In addition, inter-
centage of ethanol in the fuel can also nal corrosion may take place during stor-
worsen these adverse effects. Some of
 PRE-OPERATING PREPARATIONS 21

age if alcohol has washed protective oil

films from internal components. Fuel by Oil Mixing (25:1, 50:1)
Oil
ENOW00018-0
1.0L
(25:1)
25 : 1
WARNING
0.5L
0.4L (25:0.5)
Fuel leakage can cause fire or explosion, (10 : 0.4)
50 : 1
0.2L
potentially leading to severe injury or loss (10 : 0.2)
0 2L 10L 25L 30L
of life. Every fuel system part should be
checked periodically, and especially after Gasoline ENOF01708-0

long term storage, for fuel leak, change of

hardness of rubber, expansion and/or cor-
rosion of metals. In case any indication of ENOM01003-A
fuel leakage or degradation of fuel part is Engine oil – gasoline mixing
found, replace relevant part immediately procedure
before continuing operation.
ENOW00937-0

ENOM01002-0
CAUTION
2. Engine oil recommendation
z Do not use other than two stroke engine 6
oil with specified grade, or the engine
ENOW0002A-A
may be damaged.
CAUTION z Do not use fuel prepared in other than
specified mixing ratio.
Use of engine oils that do not meet these - Lack of engine oil can cause severe
requirements will result in reduced engine engine trouble such as piston seizure.
life, and other engine problems. - Excess of engine oil can shorten spark
plug life, and/or cause increase of nox-
Use a genuine engine oil or recommended ious exhaust.
one (TCW3). Refer to your Distributor.
For quantities of engine oil and gasoline to
Will not recommend use of other two
be pre-mixed, refer to table in previous
stroke engine oil.
page.

Add engine oil into fuel oil tank. The mixing „ When fuel tank built in the outboard
ratio with gasoline is 50 : 1 (50 parts gaso- motors is used for operation:
line and one part oil). Mix well by hand. The 1 Prepare separate fuel container for pre-
mixing ratio during break-in running is 25 : mixing.
1. 2 Pour engine oil into fuel container, and
then, gasoline.
Mixing Ratio
3 Put cap on the container, and close
Gasoline : Engine Oil tightly.
During break-in 25 : 1
4 Shake the container to mix engine oil
After break-in 50 : 1 and gasoline well and even.
5 Pour the mixture into fuel tank.
 22 PRE-OPERATING PREPARATIONS

Leaking gasoline is a dangerous fire haz-

ard.

ENOW00028-A

WARNING
Consult an authorized dealer for details on
handling gasoline, if necessary.

Gasoline and its vapors are very flammable

and can be explosive.

When carrying a fuel tank containing gaso-

line:
z Close the fuel tank cap and air vent
screw of fuel tank cap, or gasoline vapor
will be emitted through the air vent
screw, creating a fire hazard.
6 z Do not smoke.

When or before refueling:

z Be sure to remove the static electricity
charged in your body before refueling.
ENOF01709-B z The sparks due to static electricity may
cause explosion of flammable gasoline.
z Stop the engine, and do not start the
ENON00922-0
Notes engine during refueling.
z Do not smoke.
z It is recommended to pre-mix by using z Be careful not to overfill fuel tank. Wipe
separate fuel container. Attempting to up any spilled gasoline immediately.
pre-mix in the integral fuel tank can
make the mixture uneven. When or before cleaning the gasoline tank:
z If integral fuel tank is used for mixing, z Dismount fuel tank from the boat.
pour engine oil into the tank little by little z Place the fuel tank away from every
while putting gasoline into the tank. source of ignition, such as sparks or
open flames.
z Do the work outdoors or in a well venti-
ENOM00043-D lated area.
z Wipe off gasoline well immediately if
3. Fuel filling spilled.
z
ENOW00019-0
After cleaning gasoline tank:
WARNING z Wipe off gasoline well immediately if
spilled.
Do not fill the fuel tank over capacity. The z If the fuel tank is disassembled for
rise of gasoline temperature may cause cleaning, reassemble carefully. Imper-
gasoline to expand which, if overfilled, may fect assembly may cause a fuel leak,
leak through air vent screw when it is open. possibly leading to fire or explosion.
 PRE-OPERATING PREPARATIONS 23

z Dispose aged or contaminated gasoline ]ENOM00033-AB

in accordance with local regulations.

4. Break-In
ENOW00029-A
Your new outboard motor and lower unit
WARNING require break-in for the moving compo-
When opening fuel tank cap, be sure to fol- n e n t s a c c o rd i n g t o t h e c o n d i t i o n s
low the procedure described below. Fuel described in the following time table.
could blast out through the fuel tank cap in Please refer to ENGINE OPERATION sec-
case the cap is loosened by using another tion (See page 25) to learn how to cor-
procedure when internal pressure of fuel
rectly start and operate the outboard
tank is raised by heat from sources such as
sun light. motor.
ENOW00024-A

1. Before opening fuel tank cap, turn air

vent screw two turns counterclockwise
WARNING
to release air pressure in the fuel tank. Do not operate the outboard motor in
closed area or area with no forced ventila-
tion. 6
Exhaust gas emitted by this outboard
motor contains carbon monoxide that will
 cause death if inhaled continuously. Inhal-
 ing the gas initially causes symptoms such
as feeling of sickness, drowsiness and
headache.
During operation of the outboard motor:
&/0'è z Keep peripheral area well ventilated.
1. Two turns the air vent screw
z Always attempt to stay on the windward
2. Fuel tank cap side of emission.
2. Open the fuel tank cap slowly.
3. Fill the fuel not to over the shown level. 1–10 10 min – After
3–5 hrs
min 3 hrs 5 hrs
Less Less Full
Throttle
Idle than 1/2 than 3/4 throttle
1 Position
throttle throttle available
4
1 2 Abailabl
3
Crusing Approx. e to
Approx.
Speed at 500- operate
4,000
minimu 3,500 at wide
rpm
m speed rpm max open
throttle

ENOF02008-0

1. Full line

4. After filling the tank, close the tank cap.

 24 PRE-OPERATING PREPARATIONS

ENON00008-0
Note
Proper break-in allows outboard motor to
deliver it full performance for longer service
life.





&/0'è

ENOW00023-0

CAUTION
6 Operating the outboard motor without
break-in can shorten service life of the
product.
If any abnormality is experienced during
the break-in:
z Discontinue the operation immediately.
z Have the dealer check the product and
take proper action(s) if necessary.

ENOM01004-0
Fuel mix ratio for break-in
Gasoline 25: Genuine Engine Oil 1
25:1 when using genuine engine oil or the
recommended one (TCW3).
ENOW00940-0

CAUTION
z During the break-in period, never run the
engine continuously at high speed.
z After running-in is completed, select the
correct propeller so that the engine
speed is the recommended range at the
wide-opon throttle.
z After completing 5 hours of breakin,
replace the gear oil with new oil. Refer to
“Changing the gear oil” in subsection (2),
Periodic Inspection.
 25
ENGINE OPERATION
ENOM00042-0
1. Before opening fuel tank cap, turn air
Before starting vent screw two turns counterclockwise
to release air pressure in the fuel tank.
ENOW00022-B

CAUTION
Be sure to fill the engine before starting

engine. (To properly fill the engine with oil

follow the instructions. See page 21)

&/0'è

1. Two turns the air vent screw

2. Fuel tank cap
2. Open the fuel cock.

ENOF01710-B

7
ENOW00027-C

CAUTION
1
Before starting engine for the first time
after reassembling engine or off-season ENOF02028-0
storage, disconnect stop switch lock and 1. Fuel cock
crank approximately 10 times in order to ENOW00937-0
spread the engine oil.
CAUTION
Be sure to close the fuel cock when the
ENOM00044-F
outboard motor is tilted up Otherwise, fuel
1. Fuel feeding could overflow.

ENOW00029-A
ENON00923-0
Note
WARNING
If fuel is not supplied immediately to the car-
When opening fuel tank cap, be sure to fol- buretor (new engine or after cleaning), wait
low the procedure described below. Fuel for about 15 seconds for the proper quantity
could blast out through the fuel tank cap in of fuel to flow into the carburetor after open-
case the cap is loosened by using another ing the fuel cock.
procedure when internal pressure of fuel
tank is raised by heat from sources such as
sun light.
 26 ENGINE OPERATION

ENOM00045-D ENOW00941-0

2. Starting the engine CAUTION

ENOW00036-A When the shift lever is at the “NEUTRAL”
position, never move the throttle lever to
CAUTION medium or high speeds. This may cause
serious damage to the engine by rotating it
When the engine is started in the test tank,
at excessively high speed. (3.5B2)
to avoid over heating and water pump
damage, be sure the water level is at least 1. Be sure to install the stop switch lock
10 cm (4 in.) above the anti ventilation
to the stop switch, and attach the stop
plate.
Run the engine only at idling. switch lanyard securely to the operator
or to the operator's PFD (Personal Flo-
And be sure to remove the propeller, when tation Device.)
starting the engine in the test tank. (See
page 48)

3
1

7 1

2
ENOF00863-0 ENOF02014-0

1. Test tank 1. Stop switch lock

2. Water
ENON00924-0
3. Over 10 cm (4 in.)
Note
The engine will not start if the lock is in
ENOW00036-0
released condition.
CAUTION 2. Set the shift lever in the Neutral posi-
Be sure to stop engine immediately if cool- tion. (3.5B2 only)
ing water check port is not discharging
water, and check if cooling water intake is
blocked. Operating engine could lead to 1
overheating potentially leading to engine
damage. Consult an authorized dealer if
the cause cannot be found.

ENOW00032-B

CAUTION ENOF02015-0

D o n o t t r y t o cr an k a f te r e n g i n e h a s 1. Shift lever
started.
 ENGINE OPERATION 27

3. Set the throttle lever to the Start posi- 5. Pull the starter handle slowly until you
tion. feel engagement, keep pulling till you
feel less resistance. Then pull it quickly.
repeat if necessary until started.

1 1 2

ENOF02016-0

1. Throttle lever
4. Set the choke lever to the Close posi-
tion.
ENOF02018-0

1. Slowly
2. Quickly
ENON00926-0

Note
1 Return the recoil starter grip slowly when
the engine has started. Releasing the starter 7
grip at the extended position may cause a
2 trouble in the starting system.
ENOF02017-0

1. Close ENON00927-0
2. Open Note
ENON00501-A
In cold weather, pull the starter handle 2 or
Note
3 times while moving up the choke lever to
Choke is not necessary when the engine is choke the engine.
warm.
6. When the engine has started, immedi-
ENON00502-0
ately return the choke lever to the
Note
Open position then move the throttle
If engine does not start with 4 or 5 times lever downward to slow speed.
starting operation, push the knob back and
restart.

2 ENOF02017-0

1. Close
2. Open
 28 ENGINE OPERATION

ENON00928-0
2. Remove the three bolts fastening the
Note recoil starter.
If the engine stops soon after having been 3. Remove the recoil starter.
started with the choke lever at the Close
position, set the choke lever to the Open
position and perform the starting procedure
again.

ENOM00042-D
Emergency starting
ENOW00099-A

WARNING
ENOF02020-0
When the emergency starter rope is used 4. Insert the knotted end of the starter
for starting engine;
z Start in gear protection does not work.
rope into the notch in the flywheel and
Be sure to shift is at neutral position. wind the rope around the flywheel sev-
Otherwise the engine will move the boat eral turns clockwise.
immediately and cause personal injury. 5. Tie a loop in the another end of the
z Be careful that your clothes or other emergency starter rope and attach
items do not get caught in the rotating
7 engine parts.
socket wrench that is included in the
tool kit.
z To prevent accident and injury by rotat-
ing parts, do not re-attach flywheel 6. Set the control lever in the Neutral
cover and the top cowl after the engine position.
has been started.
z Do not pull starter rope if any bystander
7. Pull the starter handle slowly until you
is behind. The action can injure the feel engagement, keep pulling till you
bystander. feel less resistance. Then pull it quickly.
z Attach engine stop switch lanyard to
clothing or any part of body like arm
before starting engine.

1. Remove the top cowl fixing bolts, to

remove the top cowl.
ENOF02021-0

8. After engine starts, do not reinstall fly-

wheel cover and top cowl.

ENOF02019-0
 ENGINE OPERATION 29

ENOM00043-C ENOM00046-A

3. Warming up the engine 4. Forward, reverse, and

acceleration
ENOW00932-0

CAUTION ENOW00037-0

Be sure to check that cooling water is WARNING

coming out of the cooling water check port
Before shifting into forward or reverse,
during warm up.
make sure that boat is properly moored
and outboard motor can be steered fully to
Warm the engine at low engine speeds for the right and left. Make sure that no swim-
about mer(s) is ahead or astern of the boat.
3 minutes : above 41°F (5 Υ )
ENOW00038-A
5 minutes at 2000 rpm : above 41°F (5 Υ )
This allows the lubricating oil to circulate to WARNING
all parts of the engine. Operating the z Attach other end of emergency stop
engine without warm up shortens the switch lanyard to the operator's PFD
engine's life. (Personal Flotation device) or arm and
keep it attached during cruising.
z Do not attach the tether to a part of
clothing that can be torn easily when 7
pulled.
z Arrange the tether so that will not be
caught by any object when pulled.
z Be careful not to pull the tether acciden-
tally during cruising. Unintentional stop
1 of engine can cause loss of control of
outboard motor. Rapid loss of engine
ENOF02022-0
power can lead to falling down or caus-
1. Cooling water check port ing passenger(s) to be thrown over-
board.
ENOM00044-B
Engine speeds ENOW00042-0

Idling speed after warming up.

Trolling speed Idling speed
WARNING
Model
(in Forward) (in Nutral) z Do not shift into Reverse during planing,
2.5A2 1,100 rpm - or control will be lost leading to serious
3.5A2 1,100 rpm - personal injury, boat may swamp, and/
3.5B2 1,100 rpm 1,300 rpm or hull may be damaged.
z Do not shift into Reverse during cruis-
ing, or control may be lost, falling down
or causing passenger(s) to be thrown
overboard. Leading to serious personal
injury, and steering system and/or shift-
ing mechanism may be damaged.
 30 ENGINE OPERATION

ENOW00861-0 ENOM00890-B
Tiller handle type
WARNING ENOW00867-0

Do not shift at high boat speed, or control

may be lost, falling down or causing pas-
WARNING
senger(s) to be thrown overboard. Leading Sudden acceleration and deceleration may
to serious personal injury. cause passenger(s) to be thrown over-
board or falling down.
ENOW00862-0

ENOW00865-A
CAUTION
Gear and clutch damage may occur if shift- CAUTION
ing at high engine speed. Do not force to shift when the throttle grip
Engine must be in the slow idle position is not in the fully closed position, other-
before shifting is attempted. wise, steering system and/or shifting
mechanism may be damaged.
ENOW00863-0

CAUTION ENOW01303-0
Forward (3.5B2 only)
Idle speed may be higher during warming
up of engine. If shifted to Forward or
7 Reverse during warming up, it may be diffi-
cult to shift back to neutral. In such case,
stop engine, shift to neutral, and restart
engine to warm up.
2 3
ENON00014-0
Note
Frequent shifting to forward or reverse can
accelerate wear or degradation of parts. In
such case, replace gear oil earlier than the
1 ENOF02023-0
period specified.
1. Shift lever
2. Neutral (N)
ENOW00864-0 3. Forward (F)

CAUTION Forward
Do not increase engine speed unnecessar- 1. Lower the throttle lever in order to
ily when the shift is in neutral and reverse, reduce engine speed.
or engine damage may occur.
2. When the engine reaches trolling (or
idling) speed, quickly pull the shift lever
to the Forward position.
Reverse
1. Lower the throttle lever in order to
reduce engine speed.
2. When the engine reaches trolling (or
idling) speed, quickly pull the shift lever
to the Neutral position.
 ENGINE OPERATION 31

3. The handle upright, turn the outboard ENOM00049-C

motor at an angle of 180° and quickly 5. Stopping the engine

turn the shift lever to the Forward (F)
side. (3.5B2 only needs to operate shift ENOW00868-0

lever) WARNING
Be careful not to remove engine stop
switch lanyard from engine accidentally
while boat is running. Sudden stop of
engine can cause loss of steering control.
It can also cause loss of boat speed, possi-
bly leading the crew(s) and or objects on
the boat to be thrown forward due to iner-
tial force.

ENOF02024-0
Tiller handle type
1. Lower the throttle lever in order to the
Acceleration
ENOW00867-0
slow position.

WARNING
1
Sudden acceleration and deceleration may
cause passenger(s) to be thrown over-
2 7
board or falling down.

The speed is controlled by operating the

ENOF02026-0
throttle lever. Moving the throttle lever
1. Throttle lever
graduaally upward increases the speed, 2. Fully closed
and moving it downward decreases the
speed. 2. Put the shift lever in the Neutral posi-
tion. (3.5B2 only)
Run the engine for 2-3 minutes at
3
idling speed for cooling down if it has
1 been running at full speed.
2
3. Push the stop switch.

1
ENOF02025-0
2
1. Throttle lever
2. Fully closed
3. Fully opened

ENOF02027-0

1. Stop switch
2. Stop switch lock
 32 ENGINE OPERATION

4. Close the air vent screw and fuel cock. When used as described, the emergency
stop switch clip and emergency stop
2 switch lanyard system stops the engine if
the operator falls away from the controls.
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 oper-
ate.
1

ENOF02030-A

1. Fuel cock
2. Air vent screw

ENOF00891-0
ENOW00869-0

ENOM00920-0
WARNING
6. Steering
After stopping the engine:
7 z Close the air vent screw on the fuel tank ENOW00870-0
cap.
z Disconnect the fuel connector of the WARNING
engine and the fuel tank.
z Disconnect the battery cord, after each Sudden steering may cause passenger(s)
use. to be thrown overboard or falling down.

Tiller handle type

Emergency engine stopping
Right turn
Remove stop switch lock to stop the
Move the tiller handle to the left
engine.
Left turn
Move the tiller handle to the right.

1
2

ENOF02029-0

1. Stop switch
2. Stop switch lock

ENOM00910-0
Spare emergency stop switch lock ENOF00892-0
(For CE marking model)
A spare emergency stop switch lock is
provided in the tool bag.
 ENGINE OPERATION 33

ENOM00050-0

7. Trim angle
1
ENOW00043-A

WARNING
z Adjust the trim angle when the engine is
stopped. ENOF00051-1
z Do not put hand or finger in between
outboard motor body and clamp bracket 1. Perpendicular to the water surface
when adjusting trim angle to prevent
injury in case the outboard motor body ENOM00053-0

falls. Improper trim angle (bow rises too

high)
z Unsuitable trim position can cause loss
of control of boat. When testing a trim Set the thrust rod lower if the bow of the
position, run boat slow initially to see if it boat rises above horizontal.
can be controlled safely.

ENOW00044-0

WARNING
Excessive trim up or down may lead to 7
unstable boat operation, potentially caus-
ing the steering difficulty that leads to acci-
dent during cruising. ENOF00052-0

z Do not cruise at high speed if improper

trim position is suspected. Stop the boat ENOM00054-0
and readjust trim angle before continu- Improper trim angle (bow dips into the
ing cruise. water)
z For outboard motor model with PTT Set the thrust rod higher if the bow of the
switch on the bottom cowl, do not oper- boat is below horizontal.
ate the switch during cruising, or control
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
ENOF00053-0
water surface during operation.

ENOM00052-0
Proper trim angle
The position of the thrust rod is correct if
the hull is horizontal during operation.
 34 ENGINE OPERATION

„ Manual Tilt type 6. Gentry lower the outboard.

ENOM00060-A

8. Tilt up and down

ENOW00055-0

WARNING
Do not tilt up or down outboard motor
when swimmer(s) or passenger is near to
prevent them from being caught between
outboard motor body and clamp bracket in
1 case the outboard motor body falls.
2
3
ENOW00048-0
ENOF00229-0

1. Thrust rod WARNING

2. Higher
3. Lower When tilting up or down, be careful not to
place your hand between the swivel
bracket and the stern bracket.
Trim angle adjustment (Manual tilt
Be sure to tilt the outboard motor down
type)
7 The transom angle adjustment
slowly.

1. Stop the engine. ENOW00056-A

2. Shift into neutral.

WARNING
3. Raise the outboard motor to the tilt up
position. When tilting up outboard motor with fuel
joint for over a few minutes, be sure to dis-
4. Change the thrust rod position as fol- connect fuel hose, or fuel may leak, poten-
lowing picture. 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 overheat-
2 ing.

ENON00921-0
Note
1 Before tilting the outboard motor up, after
ENOF01612-0
1. Push in
stopping the motor leave it in the running
2. Pull out position for about a minute to allow water to
drain from inside the engine.
5. Reinstall the thurst rod securely.
 ENGINE OPERATION 35

ENOM00222-0 If the outboard motor is set in a wrong

Tilt up position, try to tilt it up once more to set it
1. Close the fuel cock and tighten the air in the correct position.
vent screw of the tank cap.
2. Tilt up the outboard motor fully to your When the outboard motor is in the tiltup
side and press the tilt stopper knob position, the tilt handle side must be in the
inside to set it up. upward direction.

2 1

1 3
ENOF02032-0

ENOF02030-A 1. Tilt handle

1. Fuel cock 2. Starter handle
2. Air vent screw 3. Correct
7

1
ENOF02033-0
ENOF02031-0
1. Wrong
1. Tilt stopper

ENOM01304-0
Outboard motor position in tilt up
ENOW00053-0

CAUTION
However, the outboard motor may be set in
the wrong tilt-up position if the motor
direction is sharpy changed in course of
tilting up.
 36 ENGINE OPERATION

ENOM00223-0
Tilt down
Pull the outboard motor to your side and
draw the tilt stopper knob out for tilting
down.

ENOF02034-0

1. Tilt stopper

7
 37
REMOVING AND CARRYING THE OUTBOARD MOTOR
ENOM00070-B ENOW00065-0

1. Removing the outboard motor WARNING

ENOW00064-B Close air vent screw of fuel tank before
carrying or storing outboard motor and fuel
CAUTION tank, or fuel may leak, potentially catching
fire.
Engine may be hot immediately after oper-
ating and could cause burns if touched. ENOW00066-0
Allow engine to cool down before attempt-
ing to carry the outboard. CAUTION
1. Stop the engine. z Do not give a shock to an outboard
motor during transportation. It becames
2. Be sure to close the air vent and the
a cause of breakage.
fuel cock. z Do not carry or store outboard motor in
3. Remove the outboard motor from boat any of positions described below.
and completely drain the water from Otherwise, engine damage or property
the gear case. damage could result from leaking oil.

8
ENOF02035-0

Keep the outboard motor in a vertical posi-

ENOF02004-0
tion when carrying.
ENOM00071-A
The optional outboard motor stand is rec-
2. Carrying the outboard motor ommended for keeping the outboard
motor vertical both during transport and
ENOW00933-0
storage.
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.
 38 REMOVING AND CARRYING THE OUTBOARD MOTOR

motor and fuel tank, or fuel may leak,

potentially catching fire.

ENOW00071-0

CAUTION
The tilt support device supplied on your
outboard motor is not intended for towing.
It is intended to support the outboard
motor while the boat is docked, beached,
etc.

ENOW00072-A
ENOF02036-0
ENON00021-A CAUTION
Note
When trailering the outboard motor should
z If the outboard motor must be laid down be in a vertical (normal running) position,
be sure drain the fuel and engine oil, fully down. Trailering in the tilted position
then the port side faces down as shown may cause damage to the outboard motor,
in the drawing above. boat, etc.
z Elevate power unit 2 inches to 4 inches if If trailering with outboard motor fully down
traveling to avoid oil spillage. is not available (the gear case skeg is too
close to the road in a vertical position), fix
the outboard motor securely using a device
(like a transom saver bar) in the tilted posi-
8 tion.

When transporting a boat on a trailer with

1 the outboard motor still attached, discon-
ENOF02037-0
nect the fuel line from the outboard motor
1. Handle beforehand and keep the outboard motor
ENOM00072-A
in the normal running position or on a tran-
3. Traillering som saver bar.

ENOW00072-0
Tiller handle type
CAUTION To prevent the outboard motor from mov-
ing when it is attached on a boat during
Trailering in the tilted position may cause
damage to the outboard motor, boat, etc. transport on a trailer, properly tighten the
steering friction lever (page 40).
ENOW00068-0

WARNING
Close air vent screw of fuel tank and fuel
cock before carrying or storing outboard
 REMOVING AND CARRYING THE OUTBOARD MOTOR 39

2 1

ENOF00073-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
accidental fall of outboard motor could
lead to severe personal injury.

8
 40
ADJUSTMENT
ENOM00073-A

1. Steering friction
ENOW00074-A

WARNING
Do not overtighten the steering friction
lever it could result in difficulty of move-
ment resulting in the loss of control caus-
ing an accident and could lead to severe
injury.

ENON0925-0
Note
The steering adjust screw is used to adjust
the friction load of the steering, but not to fix
the steering. Excess tightening of the
adjustment screw may cause damage to
the swivel bracket.

Adjust this lever to achieve the desired

steering friction (drag) on the tiller handle.
Move lever towards (2) to tighten friction
and move lever towards (3) to loosen fric-
tion.

1
9

2
3

2 3
ENOF02038-0

1. Steering friction bolt

2. Heavier
3. Lighter
 41
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 main-
tenance as suggested in the maintenance
schedules that follow.
ENOW00077-0

CAUTION
z Your personal safety and that of your
passengers depends on how well you
maintain your outboard motor. Carefully
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, frequent
operation in brackish water, or for com-
mercial use, maintenance should be per-
formed at shorter intervals. If in doubt,
consult your dealer for advice.
z We strongly recommend that you use
only genuine replacement parts on your
outboard motor. Damage to your out-
board motor arising from the use of
other than genuine parts is not covered
under the warranty.
10
 42 INSPECTION AND MAINTENANCE

ENOM01305-0

1. Daily Inspection

Perform the following checks before and ENOW00078-0

after use. WARNING

Do not use outboard motor if any abnor-
mality is found during pre-operation check
or it could result in severe damage to the
motor or severe personal injury.

Item Points to Check Remedy

• Check the amount of fuel in the tank. Replenish
Fuel System • Check for debris in the fuel filters. Clean or Replace
• Check the rubber hoses for fuel leakage. Replace *1
• Check for crack, leakage, damage in the fuel tank cap. Replace
Fuel Tank Cap • Check for crack, damage in the gasket and tether. Replace
• Check for leakage at full close. Replace
• Check that the stop switch functions normally and make sure Remedy or replace *1
Electrical the lock plate is in right location.
Equipment • Check cords for loose connections and damage. Correct or replace *1
• Check the spark plug for dirt, wear and carbon build-up. Clean or replace *1
• Check that the carburetor choke valve functions normally. Replace *1
Throttle Sys-
tem • Check carburetor linkage is working normally when moving the Correct *1
throttle lever.
• Check the rope for wear and chafing. Replace *1
Recoil Starter
• Check the ratchet engagement. Correct or replace *1
• Check that the clutch engages correctly when operation the shift Adjust *1
Clutch and lever. (3.5B only)
Propeller Sys- • Visually check the propeller and shear pin for bent or damaged Replace
tem blades.

10
• Check that the split pin is on the propeller.
• Check the clamp screws attaching the motor to the boat for Tighten
Installation of tightness.
Motor
• Check the thrust rod installation. Tighten
• Check that cooling water is discharged from the cooling water Repair *1
Cooling Water
check port after the engine has started.
• Check that there are tools and spare parts for replacing spark
Tools and plugs, the propeller, etc.
Spares
• Check that you have the spare rope.
• Check if the anode is securely installed. Repair if necessary
Other parts
• Check the anode for corrosion and deformation. Replace
*1 Have this handled by your dealer.
 INSPECTION AND MAINTENANCE 43

ENOM00083-0 ENOM00085-B
Washing outboard motor Flushing attachment (3.5B2 only)
ENOW00922-0
ENOW00081-0

WARNING CAUTION
Do not start engine without removing pro- To prevent the engine from starting when
peller, or accidentally turning propeller you are near the propeller, remove the stop
could cause personal injury. switch lock.

ENOW00082-0
1. Tilt down the outboard motor.
WARNING 2. Remove the water plug from the drive
Never start or operate the engine indoors shaft housing, and screw in the flush-
or in any space which is not well ventilated. ing attachment.
Exhaust gas contains carbon monoxide, a
3. Attach the flushing attachment and
colorless and odorless gas which can be
fatal if inhaled for any length of time. connect a water hose. Turn on the
water and adjust the flow. Continue
ENOW00920-0 flushing the outboard motor for 3 to 5
CAUTION minutes.
4. After the flushing, be sure to reattach
When washing the outboard motor, be
the water plug.
careful not to spray the water inside of the
top cowl, especially electrical components. 5. Tilt up the outboard motor.
.
ENON00026-0
Note
It is recommended to check chemical prop-
erties of water on which your outboard 1
motor is regularly used.

If outboard motor is used in salt water,

brackish water or water with a high acidic
10
level, use fresh water to remove salt,
1
chemicals or mud from exterior and cool-
ing water passage after every cruising or
before storing outboard motor for long
time. Before flushing, remove the propeller
and the forward thrust holder. ENOF02040-0

1. Flushing attachment (option)

 44 INSPECTION AND MAINTENANCE

ENOM00085-A
Flushing by test tank
ENOW00081-0

WARNING
Do not start engine without removing pro-
peller, or accidentally turning propeller
could cause personal injury.

ENOW00082-0

WARNING
Never start or operate the engine indoors
or in any space which is not well ventilated.
Exhaust gas contains carbon monoxide, a
colorless and odorless gas which can be
fatal if inhaled for any length of time.

ENOW00036-A

CAUTION
When the engine is started in the test tank,
to avoid over heating and water pump
damage, be sure the water level is at least
10 cm (4 in.) above the anti ventilation
plate.
And be sure to remove the propeller, when
starting the engine in the test tank. (See
page 48)

3
10
1

2
ENOF00863-0

1. Test tank
2. Water
3. Over 10 cm (4 in.)
 INSPECTION AND MAINTENANCE 45

ENOM01306-0

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.
Servicing Interval
Item 10 hours 50 hours Every 100 Action Remarks
or or hours or
1 month 3 months 6 months

Carburetor *1 z Clean, and adjust.

Fuel filter z z z Check and clean or Replace.

Fuel System
Piping/Hose z Check and Replace.

Fuel tank z z z Clean.

Ignition Spark plugs z z z Check gaps. Remove carbon deposits or 0.9–1.0 mm

Replace. (0.035–0.039 in)

Starting
System
Starter rope z z z Check for wear or chafting.

Propeller z z z Check for bent blades, damage, wear.

Shear pin &

Split pin
z z z Check and Replace.

Lower Unit 180 mL (6.1 fl.oz.)

Gear oil z z z Replace or Fill gear oil and check for
water leaks.
: 3.5B2
90ml (3.0 fl.oz.) :
2.5A2/3.5A2

Water pump *1 z Check for wear or damage.

Bolt and Nuts z z z Retighten.

Sliding and Rotating Parts.

z z
10
Apply and pump in grease.
Grease Nipples
Outer Equipment z z z Check for corrosion.

Anode z z Check for corrosion and deformation.

*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.
 46 INSPECTION AND MAINTENANCE

ENOM00093-A
Fuel filters and fuel tank cleaning
ENOW00093-B

WARNING
Gasoline and its vapors are very flammable
and can be explosive.
Keep out of reach of children.
z Avoid repeated or prolonged contact 1
with skin or breathing of vapor.
2
z Do not start this procedure while engine
is operating or hot even after stopping it. 3
z Place fuel filter away from every source
of ignition such as sparks or open
flames. ENOF02047-0

z Wipe off gasoline well immediately if 1. Fuel tank

spilled and dispose of it in accordance 2. Fuel filter
with local fire prevention and environ- 3. Fuel cock
ment protection regulations.
ENOM00098-A
z Install fuel filter with all related parts in
place, or fuel leak could occur, leading
Gear oil replacement
ENOW00094-0
to catching fire or explosion.
z Check fuel system regularly for leakage.
z Contact authorized dealer for fuel sys-
WARNING
tem services. Services by unqualified z Be sure that outboard motor is secured
person could lead to engine damage. to transom or service stand, or acciden-
tal drop or fall of outboard motor could
Fuel filters are provided inside the fuel tank lead to severe personal injury.
and engine. z Be sure to lock outboard motor if it is
tilted up, or accidental fall of outboard
ENOM01405-0 motor could lead to severe personal
Fuel filter (for fuel tank) injury.
10 Water or dirt in the fuel tank will cause z Do not go under outboard motor tilted
up and locked, or accidental fall of out-
engine performance problems.
board motor could lead to severe per-
Check and clean the tank at specified sonal injury.
times or after the outboard motor has
been stored for a long period of time (over ENON00934-0

three months). Note

Please dispose of used oil in a manner that
„ integral tank type
is compatible with the environment.
1. Drain all fuel from the fuel tank. We suggest you take it in a sealed container
2. Remove the fuel cock from the fuel to your local service station for reclamation.
Do not throw it in the trash, pour it on the
tank and clean the fuel filter. Replace it
ground or down a drain.
if necessary.
1. Tilt down the outboard motor.
 INSPECTION AND MAINTENANCE 47

2. Remove the oil plugs (lower and 4. Install the upper oil plug, and then
upper), and completely drain the gear remove oil tube nozzle and install the
oil into a pan. lower oil plug.
ENOW00095-0

CAUTION
Do not reuse oil plug gasket. Always use
new gasket and tighten oil plug properly to
prevent entry of water into lower unit.

ENOF01617-0

3. Insert the oil tube nozzle into the lower

oil plug hole, and fill with gear oil by
squeezing the oil tube until oil flows out
of the upper plug hole and bubbles is
disappeared to remove the air.
ENON00033-0
ENOF01618-0
Note
ENOW00928-0
Use genuine gear oil or the recommended
one (API GL-5: SAE #80 to #90). CAUTION
Required volume:
approx. 180 mL (6.1 fl.oz) 3.5B2 Wipe off gear oil well immediately if spilled
approx. 90 ml (3.0 fi.oz.) 2.5A2/3.5A2 and dispose of it in accordance with local
fire prevention and environment protection
regulations.
10
ENON00032-0
Note
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).
Required volume:
approx. 180 mL (6.1 fl.oz) 3.5B2
approx. 90 ml (3.0 fi.oz.) 2.5A2/3.5A2
ENOF01618-0
 48 INSPECTION AND MAINTENANCE

ENOM00232-A
Propeller replacement
ENOW00084-0
1
WARNING
z Do not begin propeller removal and
installation procedure with spark plug 2
c a p s a t t a c h e d , s h i f t i n f o r w a rd o r
3
reverse, main switch at other than
“OFF”, engine stop switch lock attached
to the switch, and starter key attached, ENOF00242-0
or engine could accidentally start lead-
ing to serious personal injury. Discon- 1. Shear pin
nect battery cable if possible. 2. Propeller
z The propeller edge is thin and sharp. 3. Split pin
Wear the groves during replacement to 2. Remove the shear pin from the shaft.
protect your hands.
3. Install a new shear pin.
ENOW00208-0
ENOM00087-C

CAUTION Spark plugs replacement

ENOW00087-0
z Do not install propeller without thrust
holder, or propeller boss could be dam- WARNING
aged.
z Do not reuse spark plug with damaged
z Do not reuse split pin.
insulation, or sparks can leak through
z After installing split pin, spread the pin
crack, potentially leading to electric
apart to prevent it from falling out which
shock, explosion and/or fire.
could lead to the propeller coming off
z Do not touch spark plugs immediately
during operation.
after stopping engine as they will be hot
A worn-out or bent propeller will lower the and could cause severe bur ns if
touched. Allow motor to cool down first.
motor's performance, and cause engine
10 trouble.
1. Pull out the split pin from the propeller ENOW00929-0

boss and remove the propeller from

the shaft. CAUTION
Use only the recommended spark plugs.
Spark plugs which have an different heat
range may cause engine damage.

If the spark plug(s) is fouled, has carbon

build up, or is worn, it should be replaced.
When reusing spark plugs, remove dirt
from the electrodes and adjust spark gap
to specification.
 INSPECTION AND MAINTENANCE 49

1. Stop the engine. ENON00028-0

Note
2. Remove the plug cap cover.
z Spark plug torque:
3. Remove the spark plug caps.
27.0 Nm (20.0 ft-lb) [2.7 kgf-m]
If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of
1 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.

ENOF02042-0

1. Socket wrench

4. Remove the spark plugs by turning it

counter-clockwise, using a 13/16" (21
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
i f t h e i n s u l a t o r s a re c r a c k e d o r
chipped.
6. Measure the spark plug electrode gap
with a wire type feeler gauge. The gap
should be 0.9-1.0 mm (0.035-0.039
inches). If the gap is different, replace
the spark plug with a new one
Use spark plug (NGK BP6HS-10 or
BPR6HS-10) or recommended ones. 10

1
2 ENOF00085-0

1. Electrode
2. Spark gap (0.9–1.0 mm, 0.035–0.039 in)

7. Install the spark plug by hand and turn

it carefully to avoid cross-threading.
8. Tighten the spark plug to the specified
torque.
 50 INSPECTION AND MAINTENANCE

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 origi-
nal 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 electrolytic
corrosion.

10

ENOF02043-0
 INSPECTION AND MAINTENANCE 51

ENOM00960-0
Grease point
Apply water proof grease to the parts shown below.

10

ENOF02044-0
 52 INSPECTION AND MAINTENANCE

ENOM00100-A
3. Drain all fuel from the fuel hoses and
3. Off-season storage carburetor (See page 53), and clean
these parts.
ENOW00934-0
Keep in mind that if gasoline is kept in
WARNING the carburetor for a long time, gum
and varnish will develop, causing the
z Be sure to disconnect fuel connector
float valve to stick, restricting the fuel
except when operating engine.
z Fuel leakage is a fire or explosion haz- flow.
ard, which can cause serious injury or 4. Remove the spark plugs and put a tea-
death. spoon of engine oil or spray storage oil
into the combustion chamber through
ENOW00097-0
the spark plug holes.
WARNING 5. Pull the ricoil starter several times to
Be sure to use cloth to remove fuel remain- lubricate inside the cylinder.
ing in the cowl and dispose of it in accor- ENOW00930-0
d a n c e w i t h l o c a l f i re p re v e n t i o n a n d
environment protection regulations. WARNING
z Be sure to remove stop switch lock to
ENOW00096-A
prevent ignited the spark plugs.
CAUTION z Put a cloth to spark plug hole and wipe
up any spilled engine oil, when cranking
Before servicing the motor for storage: the outboard motor.
z Remove the spark plug caps from the
spark plugs. 6. Change the gear oil in the gear case
z Do not run the motor out of the water. (See page 46).
Before you put your outboard motor in 7. Apply grease to grease point (See
storage, it is a good opportunity to have it page 51).
serviced and prepared by your dealer. 8. Stand the outboard motor up vertically
10 Be sure to use fuel stabilizer while running in a dry place.
the motor before storage. (See page 53)

ENOM00101-D
Engine
1. Wash the engine exterior and flush the
cooling water system thoroughly with
fresh water. Drain the water com-
pletely.
Wipe off any surface water with an oily
rag.
2. Remove the fuel hose from the out-
board motor.
ENOF02036-0
 INSPECTION AND MAINTENANCE 53

ENOW00066-0
1. Before adding fuel stabilizer additive,
CAUTION drain the carburetor (See page 53).
2. Follow the instructions on the label
Do not carry or store outboard motor in any
of positions described below.
when adding the fuel stabilizer additive.
Otherwise, engine damage or property 3. After adding the additive, let the out-
damage could result from leaking oil. board motor run in the water for 10
minutes to make sure any old fuel in
the fuel system has been completely
replaced by the fuel with additive.
4. Turn the engine OFF
ENON00891-0
Note
If your motor is used occasionally, it is rec-
ENOF02035-0
ommended to use a good fuel stabilizer in
every tank of fuel and keep the container full
ENON00021-A to reduce condensation and evaporation.
Note
z If the outboard motor must be laid down
be sure drain the fuel and engine oil,
ENOM00970-C
then the outboard motor on a cushion
as shown in the drawing below (See
Fuel system draining
page 79 and 68). ENOW00028-A

z Elevate power unit 2 inches to 4 inches if

traveling to avoid oil spillage.
WARNING
For details on handling fuel, contact an
authorized dealer.

Fuel and fuel vapors are extremely flamma-

ble and can be explosive.

1
z If fuel is spilled, wipe it up immediately.
z Keep the fuel tank well away from
10
ENOF02037-0 sources of ignition, e.g. sparks or open
1. Handle flames
z Perform all work outdoors or in a well
ENOM00950-A ventilated place.
Adding a fuel stabilizer
When adding a fuel stabilizer additive
(commercially available), first fill the fuel
tank with fresh oil and fuel. If the fuel tank
is only partially filled, air in the tank can
cause the fuel to deteriorate during stor-
age.
 54 INSPECTION AND MAINTENANCE

ENOW00097-0
7. Check the drained fuel for the pres-
WARNING ence of water or other contaminants. If
either is present, reassemble the out-
Be sure to use cloth to remove fuel remain-
board motor, refill the carburetor with
ing in the cowl and dispose of it in accor-
d a n c e w i t h l o c a l f i re p re v e n t i o n a n d fuel, and then drain the fuel again.
environment protection regulations. Repeat this procedure until no water or
other contaminants are present in the
drained fuel.
1. Close the fuel cock.
ENOM00104-F

4. Pre-season check

The following steps must be taken when

first using the engine after off season stor-
age.
1. Check that the shift and throttle func-
tion properly. (Be sure to turn the pro-
1 peller shaft when checking the shift
function or else the shift linkage may
ENOF02045-0
be damaged.)
1. Fuel cock
2. Fill fuel tank with oil and fuel.
2. Turn the outboard motor.
3. Open the fuel cock.
3. Place an approved fuel container
4. Before starting the engine, disconnect
under the drain screw.
stop switch lock and crank approxi-
4. Loosen the carburetor drain screw.
mately 10 times in order to circulate
the oil.
5. Start the engine and warm up the
10 engine for 3 minutes in the “NEUTRAL”
position.
6. Run the engine for 5 minutes at the
slowest speed.
7. Run the engine for 10 minutes at half
throttle. The oil used for storage inside
1 the engine will be circulated out to
ENOF02046-0
assure optimum performance.
1. Carburetor drain screw

5. Leave the outboard motor in this posi-

tion until all fuel has been drained.
6. When thoroughly drained, retighten the
drain screw securely.
 INSPECTION AND MAINTENANCE 55

ENOM00105-D ENOM00107-A

5. Submerged outboard motor 7. Striking underwater object

ENOW00098-0 ENOW00935-0

CAUTION CAUTION
Do not attempt to start submerged out- Striking the sea bottom or an underwater
board motor immediately after it is recov- object may severely damage the outboard
ered, or engine could be severely motor.
damaged.
Follow the procedure below and consult a
After taking your outboard motor out of the dealer as soon as possible.
water, immediately take it to your dealer. 1. Stop the engine immediately.
The following are the emergency measures 2. Check the control system, gear case,
to be taken for a submerged outboard boat transom etc.
motor, if you can not take it your dealer 3. Return to the nearest habor slowly and
right away. carefully.
1. Wash the outboard motor with fresh
4. Consult a dealer check the outboard
water to remove salt or dirt.
motor before operation again.
2. Remove the spark plugs, and com-
pletely drain the water from the engine
by pulling recoil starter several times.
3. Inject a sufficient amount of engine oil
through the spark plug holes.
Pull the recoil starter rope several times
to circulate the oil throughout the out-
board motor.
ENOM00106-A

6. Cold weather precautions ENOF01145-0

10
If you moor your boat in cold weather at
ENOM00120-0
temperatures below 0°C (32°F), there is
the danger of remained water freezing in 8. Auxiliary outboard motor
the cooling water pump, which may dam- operation
age the pump, impeller, etc. To avoid this
problem, submerge the lower half of the When the auxiliary outboard motor will not
outboard motor into the water. be used, be sure to remove the stop
switch lock, shift into forward, and then tilt
the outboard motor up. Otherwise, over-
rotation of the propeller due to water spray
could damage the gear.
 56
TROUBLESHOOTING
ENOM01307-0
If you encounter a problem, consult the check list below to determine the cause and to
take the proper action.
An authorized dealer will always be happy to provide any assistance and information.
Engine starting but stopping soon

High engine speeds not possible

Engine speed abnormally high

Engine speed abnormally low

Overheating of engine
Engine failing to start

Possible cause
Poor idling

z z Empty fuel tank

z z Incorrect connection of fuel system
z z z z z z Air entering fuel line
z z z z z z Deformed or damaged fuel pipe
FUEL SYSTEM

z z z z z z Closed air vent on fuel tank

z z z z z z Clogged fuel filter, fuel pump, or carburetor
z z z z Use of improper engine oil
z z z z z Use of improper gasoline
z z z Excessive oil in mixture
z Shortage of oil in mixture
z Exessive supply of fuel
z z z z z z Poor carburetor adjustment
z z z z z Spark plug other than specified
ELECTRICAL SYSTEM

z z z z z Dirt, soot, etc. on spark plugs

z z z z z No spark or weak spark
z Short circuit of engine stop switch

11 z z z z Ignition timing incorrect

z Lock plate not fitted to stop switch
z Sheard shearpin
z z z Insufficient cooling water flow, clogged or defective pump
z z z Cavitation or ventilation
OTHERS

z z z z Incorrect propeller selection

z z z z z Damaged and bent propeller
z z z Improper thrust rod position
z z z z Unbalanced load on boat
z z z z Transom too high or too low
 57
TOOL KIT AND SPARE PARTS
ENOM01308-0
The following a list of the tools and spare parts provided with the motor.

Name Quantity Remark

Tool bag 1
Pliers 1
Socket wrench 1 10 × 13 mm
Service tools Socket wrench 1 21 mm
Socket wrench handle 1
Screwdriver (Phillips-type 1 Adapter-type
and flat head)
Emergency starter rope 1 ø4–1000 mm
Spare stop switch lock 1
Spare parts Spark plug 1 NGK: BPR6HS-10
Share pin 1
Split pin 1

* Not included as standard accessories in some markets.

12
 58
PROPELLER TABLE
ENOM01309-0
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.

2.5A2: 3800–5200 rpm

3.5A2/3.5B2: 4200–5300 rpm
ENON00245-0

Note
Each size shows number of propeller blades × diameters × pitch.

Propeller Size
Propeller Mark Material
Diameter × pitch
Light boats 3 × 188 × 178 mm
7 Plastics
3 × 7.4 × 7.0 in

3 × 188 × 145 mm Plastics

6
3 × 7.4 × 5.7 in Aluminum
3 × 188 × 110 mm
4.5 Plastics
Heavy boats 3 × 7.4 × 4.3 in

13


OWNER’S MANUAL

M 2.5A2
M 3.5A2
M 3.5B2 003-11045-8AG1 1704NB
Printed in Japan