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

M 9.9D2
M 15D2
M 18E2
OB No.003-11049-HBA1
 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 © 2021 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 service
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

ENOM00003-0
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before
you take delivery.
4

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).

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.

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

Serial Number:

ENOF01700-1

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 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2. Battery installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
4. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . . . . . . 48
1. Removing the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3. Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9. ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3. Remote control lever friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10. INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6. Cold weather precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8. Auxiliary outboard motor operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12. TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
 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

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 out-
board 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.

ENOM00247-0
STOP SWITCH LANYARD
The engine can be stopped with pulling out the stop switch lock from the stop switch.
The stop switch lanyard is the coiled red cord with the stop switch lock on one end and
a metal clip on the other end. With attaching the stop switch lanyard to the operator's
body part or operator’s personal flotation device (PFD), the engine will stop when the
stop switch lanyard is being stretched and pulled out the lock from the switch when the
operator falls accidentally overboard or leaves from operator’s position. This function
can be prevent losing control of and minimize or prevent risk of collision with boats,
people and other objects. It is operator’s responsibility to use the stop switch lanyard.
ENOW00004-1

WARNING
Accidental activation of the 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 Stop Switch, the 500 mm (20 inch.) stop switch lan-
yard is coiled and can extended to a full 1300 mm (51 inch.).

ENOM00800-A
PERSONAL FLOTATION 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 53). It is the
operator's responsibility to perform all safety checks and to ensure that all lubrication
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 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 M9.9D2 M15D2 M18E2

2 Type MF MF MF EF EP

S z z z z z

Transom heights L z z z z z

UL

Tiller Handle z z z z

Remote Control z

Power Tilt

Gas-assisted tilt

Manual tilt z z z z z

*1: Option

ENOM00811-B
MODEL NAME EXAMPLE
M18E2MFL

M 18 E 2 M F L

Model Horse Product Minor Starter Steering Shaft

description power generation change system system length

P=Remote control
(Pleasure)
F=Tiller handle S= Short 15 in
E= Electrical (Fisher) L= Long 20 in
M(X)=Two stroke - A and up 2 and up start
UL= Ultra long
M= Manual start *Multi-function tiller 25 in
handle is available as
an optional part
 SPECIFICATIONS 13

ENOM01100-0

9.9D2/15D2 MF

9.9D2/15D2
Item MODEL
MF 2
Overall Length mm (in) 869 (34.2)
Overall Width mm (in) 345 (13.6)
S mm (in) 1067 (42.0)
Overall Height L mm (in) 1194 (47.0)
UL mm (in) -
S mm (in) 435 (17.1)
Transom Height L mm (in) 562 (22.1)
UL mm (in) -
S kg (lb) 41 (90)
Weight L kg (lb) 42 (93)
UL kg (lb) -
Output kW (ps) 7.3 (9.9)/11.0 (15)
Max. Operating Range min-1 (rpm) 9.9D2 (4500-5300), 15D2 (5200-5800)
Trolling Speed in Forward Gear min-1 (rpm) 800
Idle Speed in Neutral Gear min-1 (rpm) 950
Engine Type 2-Stroke
Number of Cylinders 2
Bore x Stroke mm (in) 55 x 52 (2.17 x 2.05)
Piston Displacement cm3 (Cu in) 247 (15.07)
Exhaust System Through hub exhaust
Cooling System Forced water cooling
Lubrication System Engine Oil Mixed Gasoline
Starting System Manual
Ignition System Flywheel Magneto C.D. Ignition
Spark Plugs B7HS-10 or BR7HS-10
Trim Position 6
Fuel Unleaded Regular Gasoline : R+M/2: 87 or higher RON: 91 or higher
Fuel Tank Capacity L (US gal) 25 (6.6)
Fuel : Engine Oil Mixing Ratio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1
Gear Oil mL (fl. oz) Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 370 (12.5)
Gear Shift Dog Clutch (F-N-R)
Gear Reduction Ratio 1.85 (13 : 24)
Operator Sound Pressure
85.9
(ICOMIA 39/94) dB (A)
Hand Vibration Level
4.9
(ICOMIA 38/94) m/s2

Remark: Specifications subject to change without notice.

Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
 14 SPECIFICATIONS

ENOM01101-0

18E2 MF, 18E2 EF, 18E2 EP

18E2
2 Item MODEL
MF EF EP
Overall Length mm (in) 869 (34.2) 565 (2.22)
Overall Width mm (in) 345 (13.6) 290 (11.4)
S mm (in) 1067 (42.0)
Overall Height L mm (in) 1194 (47.0)
UL mm (in) -
S mm (in) 435 (17.1)
Transom Height L mm (in) 562 (22.1)
UL mm (in) -
S kg (lb) 41 (90) 44 (97)
Weight L kg (lb) 42 (93) 45 (99)
UL kg (lb) -
Output kW (ps) 13.2 (18)
Max. Operating Range min-1 (rpm) 5200-5800
Trolling Speed in Forward Gear min-1 (rpm) 800
Idle Speed in Neutral Gear min-1 (rpm) 950
Engine Type 2-Stroke
Number of Cylinders 2
Bore x Stroke mm (in) 60 x 52 (2.36 x 2.05)
Piston Displacement cm3 (Cu in) 294 (17.94)
Exhaust System Through hub exhaust
Cooling System Forced water cooling
Lubrication System Engine Oil Mixed Gasoline
Starting System Manual Electric starter motor *1
Ignition System Flywheel Magneto C.D. Ignition
Spark Plugs B7HS-10 or BR7HS-10
Trim Position 6
Fuel Unleaded Regular Gasoline : R+M/2: 87 or higher RON: 91 or higher
Fuel Tank Capacity L (US gal) 25 (6.6)
Fuel : Engine Oil Mixing Ratio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1
Gear Oil mL (fl. oz) Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 370 (12.5)
Gear Shift Dog Clutch (F-N-R)
Gear Reduction Ratio 1.85 (13 : 24)
Operator Sound Pressure
85.9
(ICOMIA 39/94) dB (A)
Hand Vibration Level
4.9 –
(ICOMIA 38/94) m/s2

Remark: Specifications subject to change without notice.

*1 With manual starter.
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
 15
PARTS NAME
ENOM00820-0

MF

1 11 19 20
2 12 21
13
3 3
4 14

5 15

16

17
6

7 18

8
9

10

22
23

26
25
24
ENOF01750-0

1 Tilt Handle 11 Starter Handle 21 Fuel Connector (Male)

2 Top Cowl 12 Shift Lever 22 Oil Plug (Upper)
3 Bottom Cowl 13 Throttle Grip 23 Water Plug
4 Cowl Hook Lever 14 Throttle Friction Screw 24 Oil Plug (Lower)
5 Cooling Water Check Port 15 Clamp Screw 25 Spark Plug
6 Drive Shaft Housing 16 Clamp Bracket 26 Fuel Filter
7 Anti-Ventilation Plate 17 Thrust Rod
8 Anode / Trim Tab 18 Water Inlet
9 Sub-Water Inlet 19 Stop Switch
10 Propeller 20 Choke Knob
 16 PARTS NAME

ENOM01102-0

EF

1 11 19 22
2 12 20 23
13
3 3
21

4 14

5 15

16

17
6

7 18

8
9

10

24
25

28
27
26
ENOF01751-0

1 Tilt Handle 11 Starter Handle 21 Battery Cord

2 Top Cowl 12 Shift Lever 22 Choke Knob
3 Bottom Cowl 13 Throttle Grip 23 Fuel Connector (Male)
4 Cowl Hook Lever 14 Throttle Friction Screw 24 Oil Plug (Upper)
5 Cooling Water Check Port 15 Clamp Screw 25 Water Plug
6 Drive Shaft Housing 16 Clamp Bracket 26 Oil Plug (Lower)
7 Anti-Ventilation Plate 17 Thrust Rod 27 Spark Plug
8 Anode / Trim Tab 18 Water Inlet 28 Fuel Filter
9 Sub-Water Inlet 19 Starter Switch
10 Propeller 20 Stop Switch
 PARTS NAME 17

ENOM01103-0

EP

1 11 17 19
2 12 20

3
18 3
4

5 13

14

15
6

7 16

8
9

10

21
22

25
24
23
ENOF01752-0

1 Tilt Handle 11 Starter Handle 21 Oil Plug (Upper)

2 Top Cowl 12 Shift Lever 22 Water Plug
3 Bottom Cowl 13 Clamp Screw 23 Oil Plug (Lower)
4 Cowl Hook Lever 14 Clamp Bracket 24 Spark Plug
5 Cooling Water Check Port 15 Thrust Rod 25 Fuel Filter
6 Drive Shaft Housing 16 Water Inlet
7 Anti-Ventilation Plate 17 Stop Switch
8 Anode / Trim Tab 18 Battery Cord
9 Sub-Water Inlet 19 Choke Knob
10 Propeller 20 Fuel Connector (Male)
 18 PARTS NAME

ENOM00822-0

Remote control box & Fuel tank

9
3 1 8

2 10

6
5
7
12
13
11

ENOF00127-F2A

1 Control Lever 8 Fuel Gauge

2 Neutral Lock Arm 9 Air Vent Screw
3 Free Throttle Lever 10 Fuel Tank Cap
4 Main Switch 11 Fuel Connector (Engine
5 Stop Switch side)
6 Stop Switch Lock 12 Primer Bulb
7 Stop Switch Lanyard 13 Fuel Connect
 19
LABEL LOCATIONS
ENOM00019-A

Warning label locations

3, 4

4
2
1

6
5 8

ENOF01703-3
 20 LABEL LOCATIONS

1, 3. Read owner's manual. For RC model

5. Be sure to fasten one end of the stop
switch lanyard to your body during
operation.

3F0X72185-0

2. Engine stop switch (See page 41). ENOF00008-1

6. Warning regarding gasoline.

4
ENOF00131-B

4. HOT SURFACE
Can cause burns.
Do not touch when operating or ENOF00005-E
immediately after stop the engine. 7. Warning regarding gasoline (See
page 26).
ELECTRICAL SHOCK HAZARD
High voltage can cause severe electri-
cal shock.
Do not touch electrical components
such as ignition coil or spark plug cord
wh en st ar ting or op e r a ting th e ENOF00005-L

engine. 8. Warning regarding gasoline (See

page 26).
HAZARD CAUSED BY ROTATING PARTS
Rotating parts can cause severe
injury.
Keep hands, feet, hair, and clothing
away from all moving parts to prevent
injury.

ENOF00005-M
9. Warning regarding gasoline (See
page 26).

314X72185-0

ENOF00005-F
 LABEL LOCATIONS 21

ENOM01001-0

Serial number label locations

1)
2)
3)
4)
5)
6) 4
7)
8)

ENOF01704-2

1. Model code (Model name)

2. Serial No.
3. Rated power
4. Dry mass weight
5. Manufacture name
6. Manufacture address
7. Authorised representative
8. Authorised representative address

Description of serial number year code

Last two digits of alphabet represent production year as below.

Year Code BA BB BC BD BE
Year of
2021 2022 2023 2024 2025
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.
 22
INSTALLATION
ENOM00024-B
Keep the outboard motor in a vertical
1. Mounting the outboard position when mounting.
motor on 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.
ENOF01705-0

ENOW00009-$

WARNING
ENOM00025-B
z Mounting the outboard motor without Position ... Above keel line
following this manual can lead to unsafe
Place the outboard motor in the center
conditions such as poor maneuverability,
lack of control or fire. of the boat's transom.
z Loose clamp screws and/or mounting
bolts can lead to the release or displace-
1
ment of the outboard motor, possibly
resulting in lost of control and/or serious
personal injury. Be sure that fasteners are
tightened to the specified torque (30 Nm
(3.0 kgf) 13 ft-lb). Check the fasteners for
tightness from time to time.
z Be sure to use outboard mounting fasten- 2
ers included in the outboard motor pack-
age or their equivalents in terms of size,
material, quality and strength.
ENOF01141-0

1. Center of boat
2. Boat transom
 INSTALLATION 23

ENOM00026-0 ENOM00832-E
Transom matching Mounting the outboard motor
Be sure that the anti ventilation plate of
1. Set the outboard motor to appropri-
the outboard motor is 30–50 mm (1.2–2
ate position.
in) below the bottom of hull.
2. Tighten the clamp screws by turning
If the above condition cannot be met due
their handles.
to the shape of the bottom of your boat,
3. Secure the clamp brackets to the
please consult your authorized dealer.
transom board using bolts, flat wash-
ers and nylon locking nuts.
4. Secure the outboard motor to the
boat with a rope to prevent acciden-
tal loss of the outboard motor over-
1
board.
30−50 mm
(1.2−2 in) ENON00930-1
5
2 Note
ENOF01706-0 z Do not use tools to tighten clamp
screws. Over tightening could result in
damage to the clamp screws and clamp
1. Bottom of hull
2. Anti ventilation plate brackets.
ENOW00007-0 z Do not reuse Nylon locking nut.

CAUTION ENON00002-1
Note
z Before beginning the running test, check
Mounting hardware and rope are not
that the boat with maximum capacity
included in the standard accessories.
loading floats on the water in a proper
attitude. Check the position of water sur-
face on the driveshaft housing. If the
water surface is near the bottom cowling,
in high waves, water may enter the engine 3
cylinders.
z Incorrect outboard motor mounting
h e i g h t or 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, 4
bottom surface conditions or underwater
5
accessories, can cause water spray possi- 2, 3
bly reaching the engine through an open- 1
ing of the bottom cowling during cruising. ENOF01707-0
Exposing the engine to such conditions for
extended periods can lead to severe 1. Bolt (8 × 85)
engine damage. 2. Nylon locking nut
3. Washer
4. Clamp screw
5. Rope
 24 INSTALLATION

ENON00003-B z Do not smoke near the battery when the

Note battery is charging.
Apply sealing agent, such as silicone sealed z Do not charge the battery when the elec-
between the bolts and the transom board trolyte level is low. Otherwise, the bat-
holes before tightening the bolts. ter y will be damage d and may cause
malfunction.

ENOW00014-0
ENOM00029-A

2. Battery installation CAUTION

z Make sure that the battery leads do not
ENOW00012-0 get stuck between the outboard motor
and boat when turning, etc.
WARNING z The starter motor may fail to operate if
Battery electrolyte contains sulfuric acid the leads are incorrectly connected.
5 and thus is hazardous, causing a burn if it z Be sure to correctly connect the (+) and
comes in contact with your skin, or poison- (—) leads. If not, the charging system will
ous if swallowed. be damaged.
Keep batter y and electroly te away from z Do not disconnect the battery leads from
reach of children battery while the engine is operating, the
When handling the battery, be sure to: electrical parts could be damaged.
z Read all warnings shown on the battery z Always use a fully charged battery.
case
ENOW00015-0
z Prevent electrolyte from coming in con-
tact with any part of your body. Contact CAUTION
can cause serious burn or, if it comes in
contact with your eye, loss of sight. Use Do not use a batter y that is not recom-
safety glasses and rubber gloves. mended. Use of a battery not recommended
In case battery electrolyte comes in contact can lead to poor performance of, and/or
with: damage to, the electrical system.
z Skin, flush thoroughly with water.
z Eye, flush thoroughly with water, and then ENON00006-D

seek immediate medical treatment. Note

In case battery electrolyte is swallowed: Minimum battery requirements: 12v 36Ah/
z Seek immediate medical treatment. 5HR, 12v 40Ah/20HR, 330 Cold Cranking
Amps (CCA).
ENOW00013-A
Larger capacity battery is required when it
is using freezing condition.
WARNING Recommend connecting only the engine
Battery generates explosive hydrogen gas. ba t te r y c able s to th e st ar tin g ba t -
Be sure to: tery.Specifications and features of batter-
z Charge the battery in a well-ventilated ies vary among the manufacturers. Consult
the manufacturer for details.
place.
* The battery should be purchased sepa-
z Place the battery away from any source of
rately and is not supplied with the out-
fire, sparks and open flames such as
board motor.
burners or welding equipment.
 INSTALLATION 25

1. Place the battery box in a convenient

position away from possible water
spray. Securely fasten both the box
and the battery so they do not shake
loose.
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.

2
1 ENOF00022-1

1. Battery cord (red)

2. Battery cord (black)
 26
PRE-OPERATING PREPARATIONS
ENOM00030-A
Some of these adverse effe c ts are
1. Fuel handling caused because the ethanol in the gaso-
line can absorb moisture from the air,
ENOW000017-0
resulting in a separation of the water/
CAUTION ethanol from the gasoline 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 mis- z Deterioration of rubber or plastic parts
use of the engine, and damage cause d 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 recom-
rily when using a major brand of unleaded
6
mended to add a filter that has water
gasoline meeting the following specifica- separating capability, and check the fuel
tions: system for leaks and mechanical parts for
USA and Canada — having a posted pump corrosion and abnormal wear more fre-
Octane Rating of 87 (R+M)/2 minimum. quently.
Premium gasoline (92 [R+M]/2 Octane) is And, in case any of such abnormality is
also acceptable. Do not use leaded gaso- found, discontinue the use of such gaso-
line. line and contact our dealer immediately.
Outside US A and C ana da — Use If the outboard motor will only be used
unleaded gasoline with declared octane infrequently, please see the remarks on
rating of 91 RON or over. Use of premium fuel deterioration in the STORAGE chap-
gasoline of 98 RON is also allowed. ter (P 53) for additional information.
ENOW00020-0
ENOM00032-A
GASOLINES CONTAINING CAUTION
ALCOHOL
When operating a TOHATSU engine on gaso-
The fuel system components on your
line containing alcohol, storage of gasoline in
TOHATSU engine will withstand up to 10% the fuel tank for long periods should be
ethyl alcohol (hereinafter referred to as avoided. Long periods of storage, common
the "ethanol"), content in the gasoline. to boats, create unique problems. In cars,
But if the gasoline in your area contains alcohol blend fuels normally are consumed
before they can absorb enough moisture to
ethanol, you should be aware of certain
cause trouble, but boats often sit idle long
adverse effects that can occur. Increas- enough for phase separation to take place.
ing the percentage of ethanol in the fuel In addition, internal corrosion may take
can also worsen these adverse effects. place during storage if alcohol has washed
 PRE-OPERATING PREPARATIONS 27

protective oil films from internal compo- z Be sure to remove the static electricity
nents. charged in your body before refueling.
z The sparks due to static electricity may
ENOW00018-0 cause explosion of flammable gasoline.
z Stop the engine, and do not start the
WARNING engine during refueling.
Fuel leakage can cause fire or explosion, z Do not smoke.
potentially leading to severe injury or loss of z Be careful not to overfill fuel tank. Wipe
life. Ever y fuel system par t should b e up any spilled gasoline immediately.
checked periodically, and especially after
long term storage, for fuel leak, change of When or before cleaning the gasoline tank:
hardness of rubber, expansion and/or corro- z Dismount fuel tank from the boat.
sion of metals. In case any indication of fuel z Place the fuel tank away from every
leakage or degradation of fuel part is found, source of ignition, such as sparks or open
replace relevant part immediately before flames.
continuing operation. z Do the work outdoors or in a well venti-
lated area.
ENOM00043-B z Wipe off gasoline well immediately if

6
spilled.
2. Fuel filling
After cleaning gasoline tank:
ENOW00019-0
z Wipe off gasoline well immediately if
spilled.
WARNING z If the fuel tank is disassembled for clean-
Do not fill the fuel tank over capacity. The ing, reassemble carefully. Imper fec t
rise of gasoline temperature may cause gas- assembly may cause a fuel leak, possibly
oline to expand which, if overfilled, may leak leading to fire or explosion.
through air vent screw when it is open. Leak- z Dispose aged or contaminated gasoline in
ing gasoline is a dangerous fire hazard. accordance with local regulations.

ENOW00028-A ENOW00029-A

WARNING WARNING
Consult an authorized dealer for details on When opening fuel tank cap, be sure to fol-
handling gasoline, if necessary. low the procedure described below. Fuel
could blast out through the fuel tank cap in
Gasoline and its vapors are very flammable case the cap is loosened by using another
and can be explosive. procedure when internal pressure of fuel
tank is raised by heat from sources such as
When carrying a fuel tank containing gaso- sun light.
line:
z Close the fuel tank cap and air vent screw 1. Full open the air vent screw on the
of fuel tank cap, or gasoline vapor will be fuel tank cap and release internal
emitted through the air vent screw, cre-
pressure.
ating a fire hazard.
z Do not smoke.

When or before refueling:

 28 PRE-OPERATING PREPARATIONS

Use a genuine engine oil or recom-

1 mended one (TCW3). Refer to your Dis-
tributor.
2 Will not recommend use of other two
stroke engine oil.

Add engine oil into fuel oil tank. The mix-

ing ratio with gasoline is 50 : 1 (50 parts
gasoline and one part oil). Mix well by
ENOF00027-B
hand. The mixing ratio during break-in
1. Air vent screw running is 25 : 1.
2. Fuel tank cap
Mixing Ratio
2. Open the fuel tank cap slowly. Gasoline : Engine Oil
3. Fill the fuel carefully not to over flow. During break-in 25 : 1
After break-in 50 : 1
6
Fuel by Oil Mixing (25:1, 50:1)
Oil
1.0L
(25:1)
25 : 1

0.5L
0.4L (10 : 0.4) (25:0.5)
50 : 1
SAFE FILL 0.2L
(10 : 0.2)
LEVEL
25 L 0 2L 10L 25L 30L
NIVEAU Gasoline ENOF01708-0
MAXIMUM
ENOF00030-A

4. After filling the tank, close the fuel ENOM01003-0

tank cap. Engine oil – gasoline mixing
ENOM01002-0 procedure
3. Engine oil recommendation ENOW00937-0

ENOW0002A-A
CAUTION
z Do not use other than two stroke engine
CAUTION oil with specified grade, or the engine
Use of engine oils that do not meet these may be damaged.
requirements will result in reduced engine z Do not use fuel prepared in other than
life, and other engine problems. specified mixing ratio.
- Lack of engine oil can cause severe engine
trouble such as piston seizure.
 PRE-OPERATING PREPARATIONS 29

- Excess of engine oil can shorten spark

plug life, and/or cause increase of noxious
exhaust.

For quantities of engine oil and gasoline

to be pre-mixed, refer to table in previ-
ous page.
„ When portable fuel tank is used for
operation of outboard motor(s):
1 Pour engine oil into fuel tank, and
then, gasoline.
2 Put cap on the tank, and close tightly.
3 Close air vent plug tightly.
ENOW00938-0

WARNING
Loose cap or air vent plug can cause leak of
fuel during shaking the tank.
6
4 Shake the tank to mix engine oil and ENOF01709-0
gasoline well and even.
2 Pour engine oil into fuel container, and
then, gasoline.
„ When fuel tank built in the boat is
used for operation of outboard 3 Put cap on the container, and close
motor(s): tightly.
1 Prepare separate fuel container for 4 Shake the container to mix engine oil
pre-mixing. and gasoline well and even.
5 Pour the mixture into fuel tank.
ENON00922-0-0
Notes
z It is recommended to pre-mix by using
separate fuel container. Attempting to
pre-mix in the fuel tank built-in the
boat can make the mixture uneven.
z If built-in fuel tank is used for mixing,
pour engine oil into the tank little by lit-
tle while putting gasoline into the tank.
 30 PRE-OPERATING PREPARATIONS

ENOM00033-B

4. Break-In

Your new outboard motor and lower unit ENOW00023-1

require break-in for the moving compo- CAUTION

nents a ccording to the conditions
Operating the outboard motor without
described in the following time table.
break-in can shorten life of the product.
ENOW00024-A
If any abnormality is experienced during the
break-in:
WARNING z Discontinue the operation immediately.
Do not operate the outboard motor in z Have the dealer check the product and
closed area or area with no forced ventila- take proper action(s) if necessary.
tion.
Exhaust gas emitted by this outboard motor
ENOM01004-1
contains carbon monoxide that will cause
death if inhaled continuously. Inhaling the
Fuel mix ratio for break-in
Gasoline 25: Genuine Engine Oil 1
6
gas initially causes symptoms such as feeling
of sickness, drowsiness and headache. 25:1 when using genuine engine oil or the
During operation of the outboard motor: recommended one (TCW3).
z Keep peripheral area well ventilated. ENON00008-1
z Always attempt to stay on the windward Note
side of emission.
z Run at varied speed less than specified
engine speed during the break-in peri-
ods.
z Break-in must be conduct under load
in the water with propeller installed
and in-gear.

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
 31
ENGINE OPERATION
ENOM00042-0

Before starting 1

ENOW00022-B 2

CAUTION
Be sure to fill the engine before star ting
engine. (To properly fill the engine with oil
follow the instructions. See page 28)
ENOF00027-B

1. Air vent screw

2. Fuel tank cap

2. Open the fuel tank cap slowly and

release internal pressure completely.
After that, close the fuel tank.
3. Connect the fuel connector to the
engine and fuel tank.

ENOF01710-0

7
3
ENOM00044-E
2
1. Fuel feeding
ENOW00029-A

WARNING 1
When opening fuel tank cap, be sure to fol- ENOF01711-0
low the procedure described below. Fuel 1. Fuel connector
could blast out through the fuel tank cap in 2. Pull
case the cap is loosened by using another 3. Insert
procedure when internal pressure of fuel
tank is raised by heat from sources such as 2
sun light. 1

1. Full open the air vent screw on the

fuel tank cap.

ENOF00861-A

1. Pull
2. Insert
 32 ENGINE OPERATION

4. Squeeze primer bulb until it becomes And be sure to remove the propeller, when
stiff to feed fuel to carburetor. Direct starting the engine in the test tank. (See
page 61)
arrow mark upward when priming.
1
3

2
ENOF00862-0

1. Engine side 2
2. Fuel tank side
ENOF00863-0

1. Test tank
Do not squeeze primer bulb with engine 2. Water
running or when the outboard motor is 3. Over 10 cm (4 in.)

tilted up. Otherwise, fuel could overflow.

ENOM00045-A ENOW00036-0

2. Starting the engine CAUTION

7 ENOW00958-0
Be sure to stop engine immediately if cooling
water check port is not discharging water,
WARNING and check if cooling water intake is blocked.
Operating engine could lead to overheating
z Do not remove or install the top cowl potentially leading to engine damage. Con-
after the engine has been started. sult an authorized dealer if the cause cannot
z The exposed rotating engine parts or be found.
moving parts cause serious injury.
This model is provided with start in gear
ENOW00959-0
protection.
CAUTION ENON00010-0
Note
The top cowl must be installed while the
engine running except in an emergency. If Start-in-gear protection prevents engine
the top cowl is not installed correctly, water from starting at other than neutral shift.
splash can damage the engine. In-gear starting of engine will move the
boat immediately, potentially leading to
ENOW00036-A
falling down or causing passenger(s) to be
thrown overboard.
CAUTION
When the engine is started in the test tank,
to avoid over heating and water pump dam-
age, be sure the water level is at least 10 cm
(4 in.) above the anti ventilation plate.
Run the engine only at idling.
 ENGINE OPERATION 33

ENOM01005-A
3. Set the throttle grip to START posi-
Tiller handle type tion.
1. Be sure to install the stop switch lock
to the stop switch, and attach the 3
stop switch lanyard securely to the 2
operator or to the operator's PFD
(Personal Flotation Device.) 1
4
1
2

ENOF01714-1

1. Throttle grip
2. START position
3. Fully closed
ENOF01712-0 4. Fully opened

1. Stop switch lock

4. Pull the choke knob fully.
2. Stop switch

2. Set the control lever in the Neutral 7

position.

1
1
ENOF01740-0

1. Choke knob

ENOF01713-0

1. Shift lever
2. Neutral
 34 ENGINE OPERATION

(For manual starter type) If cranking over 5 seconds fails to star t

4. Pull the starter handle slowly until you engine, return main switch to “ON”, and
crank engine again after 10 seconds or more.
feel engagement, keep pulling till you
feel less resistance. Then pull it
quickly. repeat if necessar y until 5. Return the choke knob fully after
started. engine has started.
6. Check the cooling water from cooling
1 2 water check port.

ENOF00519-0

1. Slowly 2
2. Quickly
3. Starter handle
1
7
ENOF01715-0
(For electrical starter type)
1. Cooling water check port
4. Push the starter switch button and 2. Idle port
release the button when the engine
has started. Side mount RC type
1. Be sure to install the stop switch, and
a t t a ch th e sto p switch lanyar d
1 securely to the operator or to the
operator's PFD (Personal Flotation
Device.)

ENOF01753-0

1. Starter switch button

ENOW00032-0

CAUTION 1
Do not keep turning starter motor for over 5
seconds, or the battery may be consumed,
potentially making the engine star ting ENOF00869-1
impossible and/or damaging the starter. 1. Stop switch lock

2. Insert the main switch key.

 ENGINE OPERATION 35

3. Set the control lever in the Neutral 3. OFF

4. Push to operate choke knob.
position.
4. Raise the free accel lever a little (both 6. Stop pushing the key when the engine
of cold engine and warm engine). has started.
The key returns to the original posi-
1 2 tion, automatically.
N
7. Returns the Free accel lever to close
F R
5 position.
8. Check the cooling water from cooling
4 water check port.

3 6
7
ENOF00870-1
1. Neutral (N)
2. Control lever
3. Fully opened (Forward)
4. Fully opened (Reverse)
5. Free throttle lever
6. Main switch key
7. Stop switch
ENON00035-A
Note
2
7
The free throttle lever can not be raised 1 ENOF01715-0
when the control lever shift is in Forward 1. Cooling water check port
or Reverse. 2. Idle port

ENOM00042-C

5. Turn the main switch key to START Emergency starting

position. Then, continuously push the ENOW00099-A

key to operate the choke.

WARNING
ENON00503-0

Note When the emergency starter rope is used for

starting engine;
Choke operation is not necessary if the z Start in gear protection does not work. Be
engine is warm. sure to shift is at neutral position. Other-
wise the engine will move the boat imme-
3 1 diately and cause personal injury.
z Be careful that your clothes or other
2
items do not get caught in the rotating
engine parts.
z To prevent accident and injury by rotating
4 parts, do not re-attach flywheel cover
and the top cowl after the engine has
been started.
z Do not pull starter rope if any bystander is
ENOF00871-A1
b ehind. Th e a c ti on c an injure th e
1. ON bystander.
2. START
 36 ENGINE OPERATION

z Attach engine stop switch lanyard to 4. Insert the knotted end of the starter
clothing or any par t of body like arm rope into the notch in the flywheel
before starting engine.
and wind the rope around the fly-
1. Remove the top cowl. wheel several turns clockwise.

ENOF01719-0
ENOF01716-0

2. Disconnect the rink of the starter 5. Tie a loop in the another end of the
lock rod. emergency starter rope and attach
socket wrench that is included in the
tool kit.
7 ENOW00860-0

CAUTION
Be sure to keep the harness away from the
rotation parts.

6. Be sure to install the stop switch lock

ENOF01717-0
to the stop switch, and attach the
3. Remove the bolts (3pcs) and remove stop switch lanyard securely to the
the recoil starter. operator or to the operator's PFD
(Personal Flotation Device.)
7. Set the control lever in the Neutral
position.
8. Pull the starter handle slowly until you
feel engagement, keep pulling till you
feel less resistance. Then pull it
quickly.
ENOF01817-0
 ENGINE OPERATION 37

ENOM00043-A

3. Warming up the engine

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

ENOF01720-0
for about
3 minutes : above 5°C (41°F)
9. After engine starts, do not reinstall
5 minutes at 2000 min-1 (rpm) :
recoil starter and top cowl.
above 5°C (41°F)
ENOM00518-0 This allows the lubricating oil to circulate
If the choke solenoid fails to to all parts of the engine. Operating the
operate (EP type only) engine without warm up shortens the
engine's life.
1. Pull the choke knob fully. 7
2. Raise the Free accel lever a little.
3. Turn the main switch key to start
position.
4. Stop pushing the key when the engine
has started.
5. Return the choke knob.
2

1 ENOF01715-0
1. Cooling water check port
2. Idle port

ENOM00044-A
Engine speeds
Idling speed after warming up.
1 Trolling speed Idling speed
ENOF01740-0 (In Forward) (in Neutral)
1. Choke knob 800 min-1 (rpm) 950 min-1 (rpm)
 38 ENGINE OPERATION

ENOM00972-0 and left. Make sure that no swimmer(s) is

Free throttle lever (Side mount RC ahead or astern of the boat.
type)
ENOW00038-A
ENOW00956-0

CAUTION WARNING
z Keep the free throttle lever fully closed z Attach other end of emergency stop
position when start the engine. switch lanyard to the operator's PFD (Per-
z The free throttle lever is inoperative sonal Flotation device) or arm and keep it
unless the control lever is in neutral. attached during cruising.
z Also, the control lever is inoperative z Do not attach the tether to a part of
unless the free throttle lever is returned clothing that can be torn easily when
to the fully-closed position. pulled.
z Arrange the tether so that will not be
The free throttle lever is for warm-up caught by any object when pulled.
operation.(Not required for engine start- z Be careful not to pull the tether acciden-
tally during cruising. Unintentional stop of
ing) With the control lever in neutral, engine can cause loss of control of out-
move the free throttle lever upward to board motor. Rapid loss of engine power
open the throttle. can lead to falling down or causing pas-
senger(s) to be thrown overboard.

7 1 ENOW00042-0

WARNING
2
z Do not shift into Reverse during planing,
or control will be lost leading to serious
personal injury, boat may swamp, and/or
hull may be damaged.
z Do not shift into Reverse during cruising,
ENOF00934-0 or control may be lost, falling down or
1. Fully-open causing passenger(s) to be thrown over-
2. Fully-closed board. Leading to serious personal injury,
and ste er ing system and /or shif ting
ENOM00046-A mechanism may be damaged.
4. 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, make serious personal injury.
sure that boat is properly moored and out-
board motor can be steered fully to the right
 ENGINE OPERATION 39

ENOW00862-0 ENOW00867-0

CAUTION WARNING
Gear and clutch damage may occur if shifting Sudden acceleration and deceleration may
at high engine speed. cause passenger(s) to be thrown overboard
Engine must be in the slow idle position or falling down.
before shifting is attempted.

ENOW00863-0 Forward
1. Turn the throttle grip to reduce
CAUTION engine speed.
Idle speed may be higher during warming up 2. When the engine reaches trolling (or
of engine. If shifted to Forward or Reverse
idling) speed, quickly pull the shift
during warming up, it may be difficult to shift
back to neutral. In such case, stop engine, lever to the Forward position.
shift to neutral, and restart engine to warm Reverse
up. 1. Turn the throttle grip to reduce
engine speed.
ENON00014-0
Note 2. When the engine reaches trolling (or
idling) speed, quickly pull the shift
Frequent shifting to forward or reverse can
lever to the Reverse position.
accelerate wear or degradation of parts. In
such case, replace gear oil earlier than the Acceleration
7
period specified. ENOW00867-0

ENOW00864-0 WARNING
Sudden acceleration and deceleration may
CAUTION cause passenger(s) to be thrown overboard
Do not increase engine speed unnecessarily or falling down.
when the shift is in neutral and reverse, or
engine damage may occur. Open throttle grip gradually.

ENOM00890-A
Tiller handle type
ENOW00865-A
3 2
CAUTION 1
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.

ENOF01721-0
1. Shift lever
2. Forward
3. Reverse
 40 ENGINE OPERATION

3
2 7 8

2 7
1 3
1 N
F R
4 6

4
ENOF01714-A1
ENOF00877-1
1. Throttle grip
1. Forward (F)
2. START position 2. Neutral (N)
3. Fully close 3. Reverse (R)
4. Fully opens 4. Fully open (Forward)
5. Fully open (Reverse)
ENOM0900-0 6. Free throttle lever
Side mount RC type 7. Control lever
8. Lock button
ENOW00867-0 Forward
7 WARNING 1. Quickly push the control lever to the
Forward (F) position 32°, where the
Sudden acceleration and deceleration may gear is connected, while lifting up on
cause passenger(s) to be thrown overboard
the lock button located under the
or falling down.
control lever grip.
ENOW00865-A 2. Further forward motion will open the
throttle.
CAUTION
Reverse
Do not force to shift when the throttle grip is 1. Quickly pull the control lever to the
not in the fully closed position, otherwise,
steering system and/or shifting mechanism
Reverse (R) position at 32°, where the
may be damaged. gear is connected, while lifting up on
the lock button located under the
control lever grip.
2. Further rearward motion will open
the throttle.
 ENGINE OPERATION 41

Acceleration Tiller handle type

ENOW00867-A 1. Turn the throttle grip to the slow
position.
CAUTION
3
Sudden acceleration and deceleration may
cause passenger(s) to be thrown overboard 2
or falling down.

Open throttle grip or control lever gradu- 1

ally. 4

N
F R
ENOF01714-1

1. Throttle grip
1 2. START position
3. Fully closed
4. Fully opened

1. Control lever
ENOF00879-2 2. Put the shift lever in the Neutral posi-
tion.
7
ENOM00049-A
Run the engine for 2-3 minutes at
idling speed for cooling down if it has
5. Stopping the engine been running at full speed.
ENOW00868-0
3. Push the stop switch for a few sec-
onds to stop the engine.
WARNING
Be careful not to remove engine stop switch
lanyard from engine accidentally while boat
is running. Sudden stop of engine can cause 1
loss of steering control. It can also cause
loss of boat speed, possibly leading the
crew(s) and or objects on the boat to be
thrown forward due to inertial force.

ENOF01722-0
1. Stop switch
 42 ENGINE OPERATION

Side mount RC type z Disconnect the battery cord, after each

1. Put the control lever in the Neutral use.
position and run the engine for 2-3
Emergency engine stopping
minutes at idling speed for cooling
Remove stop switch lock to stop the
down if it has been running at full
engine.
speed.

2
1
N
F R

2
ENOF00881-1
ENOF01723-0
1. Control lever
2. Main switch key

7 2. Turn the main switch key to the OFF

position or push the stop switch. ( Do
not forget to turn the key off).
3 1
1
2
2

ENOF00869-A

1. Stop switch
ENOF00871-1
2. Stop switch lock
1. ON
2. START ENOM00910-0

3. OFF Spare emergency stop switch lock (For

CE marking model)
ENOW00869-0
A spare emergency stop switch lock is
provided in the tool bag.
WARNING When used as described, the emergency
After stopping the engine: stop switch clip and emergency stop
z Close the air vent screw on the fuel tank switch lanyard system stops the engine if
cap. the operator falls away from the controls.
z Disconnect the fuel connector of the
When an operator falls into water, be
engine and the fuel tank.
 ENGINE OPERATION 43

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
operate.

ENOF00891-0
ENOF00893-0
ENOM00920-0 ENOM00050-0

6. Steering 7. 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.

Tiller handle type

z Do not put hand or finger in between out- 7
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.
Move the tiller handle to the right. z Unsuitable trim position can cause loss of
control of boat. When testing a trim posi-
tion, run boat slow initially to see if it can
be controlled safely.

ENOW00044-0

WARNING
Excessive trim up or down may lead to unsta-
ble 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
Remote control type and readjust trim angle before continuing
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.
 44 ENGINE OPERATION

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.
ENOF00053-0
ENOM00052-0
Proper trim angle
The position of the thrust rod is correct if
the hull is horizontal during operation.

1
1

ENOF00051-1 2
3
7 1. Perpendicular to the water surface
ENOF01724-0

1. Thrust rod
ENOM00053-0 2. Higher
Improper trim angle (bow rises too 3. Lower
high)
Set the thrust rod lower if the bow of the
Trim angle adjustment
boat rises above horizontal. The transom angle adjustment
1. Stop the engine.
2. Shift into neutral position.
3. Tilt up the outboard motor.

ENOF00052-0

ENOM00054-0
Improper trim angle (bow dips into the
water)
Set the thrust rod higher if the bow of
the boat is below horizontal.
 ENGINE OPERATION 45

4. Remove the thrust rod as shown pic- ENOW00056-A

ture. WARNING
When tilting up outboard motor with fuel
joint for over a few minutes, be sure to dis-
connect fuel hose, or fuel may leak, poten-
tially catching fire.

ENOW00057-0
1
CAUTION
3 Do not tilt up outboard motor while engine
2 operates, or no cooling water may be fed,
ENOF01238-1
leading to engine seizure due to overheating.
1. Push in
2. Rise the stopper ENON00921-0
3. Pull out Note
5. Reinstall the thrust rod in the desired
Before tilting the outboard motor up, after
position securely. stopping the motor leave it in the running
6. Gentry tilt down the outboard motor. position for about a minute to allow water
to drain from inside the engine.

ENOM00060-A 7
ENOM00062-B
8. Tilt up and down Tilt up
Push the reverse lock lever down until it
ENOW00055-0 stops. (This is the tilt up position.) Now,
WARNING tilt the outboard motor all the way up
until it is locked in place.
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 case the
outboard motor body falls. 3
1

ENOW00048-0

WARNING
When tilting up or down, be careful not to
place your hand between the swivel bracket
and the stern bracket.
2 ENOF01725-0
1. Reverse lock lever
Be sure to tilt the outboard motor down 2. Tilt up position
slowly. 3. Tilt down position
 46 ENGINE OPERATION

ENOW00053-0

CAUTION
While in shallow water drive position, do not
operate the outboard motor in Reverse.
Operate the outboard motor at slow speed
and keep the cooling water intake sub-
merged.

ENOW00054-0

ENOF01726-0 CAUTION
Do not overtilt outboard motor when driving
ENOM00063-0
shallow water, or air may be sucked through
Tilt down
water inlet and sub-water inlet, potentially
Pull the reverse lock lever upward until it leading to engine overheating.
stops. (This is the tilt down position.)
Now, lift up the outboard motor slightly,
and then allow gravity to lower it for you.
2

7 3
1
1
ENOF01144-0

1. Water inlet
2. Sub-water inlet

2 ENOF01725-0 1. Shallow water running position:

1. Reverse lock lever Put the reverse lock lever in the tilt up
2. Tilt up position
3. Tilt down position position, and tilt up the outboard
motor to put the outboard motor in
ENOM00068-A
the shallow water running position.
9. Shallow water operation

ENOW00051-0

WARNING
During shallow water operation, be careful
not to place your hand between the swivel
bracket and the clamp bracket. Be sure to
tilt the outboard motor down slowly.
 ENGINE OPERATION 47

3
1

2 ENOF01725-0

1. Reverse lock lever

2. Tilt up position
3. Tilt down position

2. Return to normal running position:

Put the reverse lock lever in the tilt
down position, slightly lift up the out-
board motor, and then put it down.

7
3
1

2 ENOF01725-0

1. Reverse lock lever

2. Tilt up position
3. Tilt down position
 48
REMOVING AND CARRYING THE OUTBOARD MOTOR
ENOM00070-B ENOW00065-0

1. Removing the outboard WARNING

motor
Close air vent screw of fuel tank before car-
rying or storing outboard motor and fuel
ENOW00064-0
tank, or fuel may leak, potentially catching
CAUTION fire.

Engine may be hot immediately after operat- ENOW00066-A

ing and could cause burns if touched. Allow
engine to cool down before attempting to CAUTION
carry the outboard.
z Do not give a shock to an outboard motor
1. Stop the engine. during transportation. It becames a cause
of breakage.
2. Disconnect the fuel connector, the z Do not carry or store outboard motor in
remote control cables and the bat- any of positions described below.
tery cords from the outboard motor. Otherwise, engine's exterior parts may be
3. Remove the outboard motor from damaged or water may enter the cylinder
through the exhaust por t and cause
boat and completely drain the water engine problems.
from the gear case.

ENOF01727-0

ENOF01705-0
ENOM00071-A
Keep the outboard motor in a vertical
2. Carrying the outboard motor position when carrying.
The optional outboard motor stand is
ENOW00933-0
recommended for keeping the outboard
WARNING motor vertical both during transport and
storage.
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.
 REMOVING AND CARRYING THE OUTBOARD MOTOR 49

Fuel leakage is a fire or explosion hazard,

which can cause serious injury or death.

ENOF00075-1

ENOW00068-0

WARNING
Close air vent screw of fuel tank and fuel
ENOF01738-0 cock before carrying or storing outboard
ENON00021-C motor and fuel tank, or fuel may leak, poten-
Note tially catching fire.

If the outboard motor must be laid down, ENOW00071-0

be sure drain the fuel from the fuel line
and carburetor in advance, then the port CAUTION
side face down on the cushion as shown in
the drawing. The tilt support device supplied on your out-
board motor is not intended for towing. It is
intended to support the outboard motor
while the boat is docked, beached, etc.

When transporting a boat on a trailer 8

with the outboard motor still attached,
disconnect the fuel line from the out-
1 board motor beforehand and keep the
ENOF01728-0 outboard motor in the normal running
1. Handle position or on a transom saver bar.
ENOM00072-A

3. Trailering Tiller handle type

To prevent the outboard motor from
ENOW00072-0
moving when it is attached on a boat
CAUTION during transport on a trailer, properly
tig h t e n t h e s t e e rin g fri c ti o n b ol t
Trailering in the tilted position may cause
(page 51).
damage to the outboard motor, boat, etc.

ENOW00073-A

WARNING
Be sure to disconnect fuel connector except
when operating engine.
 50 REMOVING AND CARRYING THE OUTBOARD MOTOR

2 1
ENOF00074-B

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
 51
ADJUSTMENT
ENOM00073-C ENOM00074-A

1. Steering friction 2. Throttle grip friction

Tiller handle type ENOW00074-B

ENOW00074-D WARNING
WARNING Do not overtighten the throttle adjustment
screw or it could result in difficulty of move-
Do not over tighten the steering friction
ment resulting in the loss of control causing
adjustment bolt it could result in difficulty of
an accident and could lead to severe injury.
movement resulting in the loss of control
causing an accident and could lead to severe Friction adjustment of the throttle grip
injury.
can be made with the throttle adjustment
ENON00506-B screw.
Note
The steering friction adjustment bolt is
used to adjust the friction load of the
steering, but not to fix the steering. Excess
tightening of the adjustment bolt may
cause damage to the swivel bracket.
2
Steering friction can be adjusted in 1
accordance with your preference by 3
ENOF00445-0
turning the steering friction adjustment
bolt. 1. Heavier
2. Lighter
3. Throttle friction adjustment screw

3 ENOM00075-0
9
3. Remote control lever
1
friction
2 ENOW00074-C

WARNING
Do not over tighten the remote control
ENOF01729-0 throttle friction adjustment screw or it
1. Steering friction adjustment bolt could result in difficult y of movement
2. Lighter resulting in the loss of control causing an
3. Heavier
accident and could lead to severe injury.

To adjust the friction of the remote con-

trol lever, turn the throttle friction
adjustment screw on the front of the
remote control . Turn c lock wise to
 52 ADJUSTMENT

increase the friction and counter-clock- achieved, adjust the trim tab located
wise to decrease it. 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
2 from rear of boat).
3
1

ENOF00078-2

1. Throttle friction adjustment screw

2. Lighter
3. Heavier

ENOM00076-0

4. Trim tab adjustment

ENOW00076-0

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
Notes
9 z Be sure to lock outboard motor if it is
tilted up, or accidental fall of outboard
z After adjustment securely tighten the
motor could lead to severe personal
trim tab fixing bolt.
injury.
z Check for looseness of the bolt and the
z Do not go under outboard motor tilted up
trim tab at regular intervals.
and locked, or accidental fall of outboard
motor could lead to severe personal
injury.

ENOW00075-0

WARNING
Inappropriate adjustment of trim tab could
cause steering difficulty. After installing or
readjusting trim tab, check if steering fiction
is even.

If straight-line cruising can not be

 53
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 mainte-
nance 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, 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 out-
board motor. Damage to your outboard
motor arising from the use of other than
genuine parts is not covered under the
warranty.
10
 54 INSPECTION AND MAINTENANCE

ENOM01005-0

1. Daily Inspection

Perform the following checks before and ENOW00078-0

after use. WARNING

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

Item Points to Check Action

• Check the amount of fuel in the tank. Replenish
Fuel System • Check for dust or water in the fuel filter. Clean or replace
• Check rubber pipes for fuel leakage. Replace *1
• Check that the stop switch functions normally and make sure Remedy or replace *1
Electrical the lock plate is there.
Equipment • Check cords for loose connections and damage. Correct or replace *1
• Check the spark plugs for dirt, wear and carbon build-up. Clean or replace
• Check that the choke solenoid and valve for the carburetor Replace *1
function normally.
Throttle System
• Check if the carburetor and magneto work normally when Correct *1
turning the throttle grip, and check links for looseness.
• Check ropes for wear and chafing. Replace *1
Recoil Starter
• Check the ratchet for engagement. Correct or replace *1
• Check that clutch engages correctly when operating the shift Adjust *1
Clutch and lever and remote control.
Propeller System • Visually check propeller for bent or damaged blades. Replace.
• Check the propeller nut is tightened and the split pin is present.
Installation of • Check all the bolts attaching the motor to the boat. Tighten
10 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.
Steering • Check the operation of the steering handle and remote Repair *1
Devices control.

• 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
*1 Have this handled by your dealer.
 INSPECTION AND MAINTENANCE 55

ENOM00083-0 ENOM00085-D
Washing outboard motor Flushing attachment
ENOW00921-0
ENOW00081-0

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
CAUTION
Never start or operate the engine indoors or
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.

ENOW00920-0 1. Tilt down the outboard motor.

2. Remove the water plug from the gear
CAUTION case, and scre w in the flushing
When washing the outboard motor, be care- attachment.
ful not to spray the water inside of the top
3. Connect a water hose. Turn on the
cowl, especially electrical components.
water and adjust the flow (Be sure to
ENON00026-0 seal the water inlet and sub-water
Note inlet, located in the gear case with
It is recommended to check chemical tape).
properties of water on which your out- 4. Put the shift lever in the neutral posi-
board motor is regularly used.
tion and start the engine.
If outboard motor is used in salt water,
brackish water or water with a high acidic
Continue flushing the outboard motor
for 3 to 5 minutes at idling.
10
level, use fresh water to remove salt, 5. Stop the engine and water supply.
chemicals or mud from exterior and Remove the flushing attachment and
cooling water passage after every cruising tape. After the flushing, be sure to
or before storing outboard motor for reattach the water plug.
long time. Before flushing, remove the
propeller and the forward thrust holder.
 56 INSPECTION AND MAINTENANCE

. And be sure to remove the propeller, when

starting the engine in the test tank. (See
page 61)
1

3
1

3
2
2
ENOF01420-B
ENOF00863-0
1. Flushing attachment (option)
2. Water inlet 1. Test tank
3. Sub-water inlet 2. Water
3. Over 10 cm (4 in.)
ENOM00085-A
Flushing by test tank
ENOW00081-0 ENOM00950-0
Fuse replacement (For electrical
WARNING starter type)
Do not start engine without removing pro- ENOW00923-0

peller, or accidentally turning propeller

could cause personal injury. CAUTION
Before replacing a fuse, disconnect the bat-
ENOW00082-0
tery cable from the battery negative (-) ter-
WARNING minal. Failure to do so may cause a short-
circuit.
Never start or operate the engine indoors or
in any space which is not well ventilated. ENOW00924-0

10 Exhaust gas contains carbon monoxide, a

colorless and odorless gas which can be fatal CAUTION
if inhaled for any length of time. Never use a fuse with a rating that exceeds
the specified rating as this could cause seri-
ENOW00036-A
ous damage to the electrical system.
CAUTION
When the engine is started in the test tank, If a blown fuse is detected, try to deter-
to avoid over heating and water pump dam- mine the cause for this and correct it. If
age, be sure the water level is at least 10 cm
the cause for the problem is not cor-
(4 in.) above the anti ventilation plate.
rected, the fuse will likely blow again.
If the fuse continues to blow, request an
authorized Tohatsu dealer to inspect the
outboard motor.
 INSPECTION AND MAINTENANCE 57

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
fuse is blown, replace it with a fuse of
the same specified rating.

ENOF01755-0

1. Blown fuse

10
 58 INSPECTION AND MAINTENANCE

ENOM01106-0

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 num-
ber of months, whichever comes first.

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

Strip, clean and adjust.

Carburetor *1 z Adjust idling.

Check and clean or

Fuel System
Fuel filter z z z Replace.

Piping/Hose z z z Check and Replace.

Fuel tank z z Clean.

Check gaps. Remove

Spark plugs z z carbon deposits or
Ignition Replace.

Ignition timing *1 z z Adjust timing.

Check for salt deposits and

Starter motor *1 z battery cable condition.

Starting System Battery Check Installation, fluid

z z z quantity, gravity.

Starter rope z z z Check for wear or damage.

Check for bend blades,

Propeller z z z damage, wear.

Change or replenish-oil and

Lower Unit Gear oil z z z
10
check for water leaks.

Check for wear or damage. Replace impeller

Water pump *1 z z every 12 months.

Bolt and Nuts z z z Retighten.

Sliding and Rotating Parts. Apply and pump in grease.

Grease Nipples
z z

Outer Equipment z z z Check for corrosion.

Check for corrosion and Replace.

Anode z z 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.
 INSPECTION AND MAINTENANCE 59

ENOM00093-C ENOM00094-0
Fuel filters and fuel tank cleaning Fuel filter (for engine)
ENOW00093-A 1. Check in the cup for water and
WARNING debris.

Gasoline and its vapors are very flammable

and can be explosive.
z Do not start this procedure while engine
is operating or hot even after stopping it.
z Place fuel filter away from every source of
ignition such as sparks or open flames.
z Wipe off gasoline well immediately if
spilled and dispose of it in accordance
with local fire prevention and environ-
ment protection regulations.
z Install fuel filter with all related parts in
place, or fuel leak could occur, leading to
catching fire or explosion.
ENOF01756-0
z Check fuel system regularly for leakage.
z Contact authorized dealer for fuel system
services. Services by unqualified person
could lead to engine damage. 1 6
Water or dirt in the fuel filter and tank will
2
cause engine performance problems.
Check and clean the fuel filter and tank 3
at specified times or after the outboard 4
motor has been stored for a long period
of time (over three months). 5
Fuel filters are provided inside the fuel
ENOF00096-B
tank and engine.
1.
2.
Body
O-ring 10
3. Filter
4. O-ring
5. Cup
6. Indication of Fuel Flow

2. If present, disconnect hoses from 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
parts, and replace if necessary.
 60 INSPECTION AND MAINTENANCE

5. Remove fuel and any water or debris motor could lead to severe personal
from the cup, filter and hoses. injury.
z Do not go under outboard motor tilted up
6. Reassemble all parts. and locked, or accidental fall of outboard
motor could lead to severe personal
ENOM00096-A injury.
Fuel filter (for fuel tank)
1. Remove four screws to remove the ENON00934-0
Note
Fuel Pick-Up.
2. Clean the fuel filter and replace the Please dispose of used oil in a manner that
is compatible with the environment.
gasket. We suggest you take it in a sealed con-
3. Reassemble all parts. tainer to your local service station for rec-
lamation. Do not throw it in the trash, pour
it on the ground or down a drain.

1. Tilt down the outboard motor.

2. Remove the oil plugs (lower and
1 upper), and completely drain the gear
oil into a pan.
2

ENOF00926-1

10 1. Fuel pick-up
2. Filter ENOF01732-0

ENOM00098-A 3. Insert the oil tube nozzle into the

Gear oil replacement lower oil plug hole, and fill with gear
ENOW00094-0
oil by squeezing the oil tube until oil
WARNING flows out of the upper plug hole and
bubbles is disappeared to remove the
z Be sure that outboard motor is secured to
transom or service stand, or accidental air.
drop or fall of outboard motor could lead ENON00033-0

to severe personal injury. Note

z Be sure to lock outboard motor if it is Use genuine gear oil or the recommended
tilted up, or accidental fall of outboard one (API GL-5: SAE #80 to #90).
 INSPECTION AND MAINTENANCE 61

Required volume: approx. 360 mL (11.8 ENOW00928-0

fl.Oz).
CAUTION
Wipe off gear oil well immediately if spilled
and dispose of it in accordance with local
fire prevention and environment protection
regulations.

ENON00032-0
Note
If water in the oil, giving it a milky colored
appearance. Contact your dealer.

ENOM00086-A
Propeller replacement
ENOW00084-0

ENOF01733-0
WARNING
4. Install the upper oil plug, and then z Do not begin propeller removal and instal-
remove oil tube nozzle and install the lation procedure with spark plug caps
lower oil plug. attached, shift in forward or reverse,
main switch at other than “OFF”, engine
Oil plug specified tightening torque
stop switch lock attached to the switch,
4N·m (3 ft·lb, 0.4 kgf·m) and starter key attached, or engine could
ENOW00095-0 accidentally start leading to serious per-
sonal injury. Disconnect battery cable if
CAUTION possible.
Do not reuse oil plug gasket. Always use new z The propeller edge is thin and sharp. Wear
gasket and tighten oil plug properly to pre- the groves during replacement to protect
vent entry of water into lower unit. your hands.

ENOW00086-0
10
CAUTION
z Do not install propeller without thrust
holder, or propeller boss could be dam-
aged.
z Do not reuse split pin.
z After installing split pin, spread the pin
apart to prevent it from falling out which
could lead to the propeller coming off
during operation.

A worn-out or bent propeller will lower

the motor's performance, and cause
ENOF01734-0 engine trouble.
 62 INSPECTION AND MAINTENANCE

1. Put a piece of wood block between 25 Nm(18 ft-lb, 2.5kgf-m)

propeller blade and anti-ventilation 7. Install a new split pin into the nut hole
plate to hold propeller. and bend it.

ENOF00084-E

ENOF00084-B
ENOM00087-B
Spark plugs replacement
2. Remove the split pin, propeller nut
ENOW00087-0
and washer.
3. Remove the propeller and thrust WARNING
holder. z Do not reuse spark plug with damaged
4. Apply water proof grease to the pro- insulation, or sparks can leak through
peller shaft before installing a new crack, potentially leading to electric
shock, explosion and/or fire.
propeller.
z Do not touch spark plugs immediately
5. Install the thrust holder, propeller, after stopping engine as they will be hot
stopper, washer and propeller nut and could cause severe burns if touched.
onto the shaft. Allow motor to cool down first.

1 ENOW00929-0
2 3 4
CAUTION
10 Use only the recommended spark plugs.
Spark plugs which have an different heat
5 range may cause engine damage.

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

ENOF00084-C buil d up , or is w orn , i t sh o ul d b e
1. Propeller replaced.
2. Thrust holder When reusing spark plugs, remove dirt
3. Washer
4. Propeller nut from the electrodes and adjust spark gap
5. Split pin to specification.
6. Tighten the propeller nut to specified
torque, and align one of grooves to
1. Stop the engine.
propeller shaft hole.
2. Remove the top cowl.
Propeller nut torque:
 INSPECTION AND MAINTENANCE 63

3. Remove the spark plug caps.

4. Remove the spark plugs by turning it
counter-clockwise, using a 21 mm (13/
16 in) 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.
6. Measure the spark plug electrode gap
with a wire type feeler gauge. The gap ENOF01735-0

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 B7HS-10 or
BR7HS-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 speci- 10
fied torque.
ENON00028-0
Note
z Spark plug torque:
25.0 Nm (18 ft-lb) [2.5 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.
 64 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
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 electrolytic
corrosion.

10

*1

ENOF01736-A

*1 : Both side
 INSPECTION AND MAINTENANCE 65

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

10

ENOF01737-0
 66 INSPECTION AND MAINTENANCE

ENOM00100-A
2. Remove the fuel hose from the out-
3. Off-season storage board motor.
3. Drain all fuel from the fuel hoses, fuel
ENOW00934-0
pump, fuel filter (See page 59) and
WARNING carburetor (See page 68), and clean
these parts.
z Be sure to disconnect fuel connector
except when operating engine.
Keep in mind that if gasoline is kept in
z Fuel leakage is a fire or explosion hazard, the carburetor for a long time, gum
which can cause serious injury or death. and varnish will develop, causing the
float valve to stick, restricting the fuel
ENOW00097-0
flow.
WARNING 4. Remove the spark plugs and put a
Be sure to use cloth to remove fuel remain- teaspoon of engine oil or spray stor-
ing in the cowl and dispose of it in accor- age oil into the combustion chamber
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 through the spark plug holes.
environment protection regulations. 5. Pull the recoil starter several times to
ENOW00096-0
lubricate inside the cylinder.
ENOW00930-0
CAUTION
WARNING
Before servicing the motor for storage:
z Remove the battery cables. z Be sure to remove stop switch lock to
z Remove the spark plug caps from the prevent ignited the spark plugs.
spark plugs. z Put a cloth to spark plug hole and wipe up
z Do not run the motor out of the water. any spilled engine oil, when cranking the
outboard motor.
Before you put your outboard motor in
storage, it is a good opportunity to have 6. Change the gear oil in the gear case
it serviced and prepared by your dealer. (See page 60).
10 Be sure to use fuel stabilizer while run- 7. Apply grease to grease point (See
ning the motor before storage. (See page 65).
page 67) 8. Stand the outboard motor up verti-
cally in a dry place.
ENOM00101-C
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.
 INSPECTION AND MAINTENANCE 67

1
ENOF01728-0
1. Handle

ENOM00950-A
Adding a fuel stabilizer
When adding a fuel stabilizer additive
ENOF01738-0
(commercially available), first fill the fuel
tank with fresh oil and fuel. If the fuel
ENOW00066-1
tank is only partially filled, air in the tank
CAUTION can cause the fuel to deteriorate during
Do not carry or store outboard motor in any storage.
of positions described below.
Otherwise, engine's exterior parts may be 1. Before adding fuel stabilizer additive,
damaged or water may enter the cylinder drain the carburetor (See page 68).
through the exhaust port and cause engine
problems. 2. Follow the instructions on the label
when adding the fuel stabilizer addi-
tive.
3. After adding the additive, let the out-
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 10
ENOF01727-0 ENON00891-0
Note
ENON00021-D
If your motor is used occasionally, it is rec-
Note ommended to use a good fuel stabilizer in
If the outboard motor must be laid down, every tank of fuel and keep the container
be sure drain the fuel completely in full to reduce condensation and evapora-
advance, then the port side face down on tion.
the cushion as shown in the drawing.
 68 INSPECTION AND MAINTENANCE

ENOM00970-A
Fuel system draining 1
ENOW00028-A

WARNING
For details on handling fuel, contact an
authorized dealer.

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
ENOF01739-0
of ignition, e.g. sparks or open flames
z Perform all work outdoors or in a well 1. Carburetor drain screw
ventilated place.
ENOM00102-0

ENOW00097-0
Battery
ENOW00931-A
WARNING
WARNING
Be sure to use cloth to remove fuel remain-
ing in the cowl and dispose of it in accor- z Place the battery away from any source of
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 fire, sparks and open flames such as
environment protection regulations. burners or welding equipment.
z Place the battery away from fuel tank.
Accidental sparks of battery may cause
1. Disconnect the fuel hose from the explosion of gasoline.
outboard motor.
1. Disconnect the battery cables and be
2. Remove the top cowl. sure to remove the negative terminal
3. Place an appropriate rag under the first.
drain screw. 2. Wipe off any chemical deposits, dirt,
10 4. Loosen the carburetor drain screw.
5. Leave the outboard motor until all
or grease.
3. Apply grease to the battery terminals.
fuel has been drained. 4. Charge the battery completely before
6. When thoroughly drained, retighten storing it for the winter.
the drain screw securely. 5. Recharge the battery once a month
7. Check the drained fuel for the pres- to prevent it from discharging and the
ence of contaminants. If it is present, electrolyte from deteriorating.
check the fuel filter and fuel in the 6. Store the battery in a dry place.
fuel tank.
 INSPECTION AND MAINTENANCE 69

ENOM00104-E
8. Run the engine for 5 minutes at the
4. Pre-season check slowest speed.
9. Run the engine for 10 minutes at half
The following steps must be taken when throttle. The oil used for storage
first using the engine after off season inside the engine will be circulated
storage. out to assure optimum performance.
1. Check that the shift and throttle
function properly. (Be sure to turn the ENOM00105-D
propeller shaft when checking the
5. Submerged outboard motor
shift function or else the shift linkage
may be damaged.) ENOW00098-0

2. Check the electrolyte level, and mea-

sure the voltage and specific gravity
CAUTION
of the battery. Do not attempt to start submerged outboard
motor immediately after it is recovered, or
Specific Terminal Charge engine could be severely damaged.
Gravity at 20°C Voltage (V) Condition
1.120 10.5 Fully discharged After taking your outboard motor out of
1.160 11.1 1/4 charged the water, immediately take it to your
1.210 11.7 1/2 charged dealer.
1.250 12 3/4 charged The following are the emergency mea-
1.280 13.2 Fully charged sures to be taken for a submerged out-
board motor, if you can not take it your
3. Check that the battery is secure and dealer right away.
the batter y cables are properly 1. Wash the outboard motor with fresh
installed. water to remove salt or dirt.
4. Fill the fuel tank with oil and fuel. 2. Remove the spark plugs, and com-
5. Connect the fuel line to the engine, pletely drain the water from the
and squeeze primer bulb. engine by pulling recoil starter several 10
6. Before starting the engine, discon- times.
nect stop switch lock and crank 3. Inject a sufficient amount of engine
approximately 10 pulling the recoil oil through the spark plug holes.
starter (Manual start model) or 3times Pull the recoil starter rope several
of 3sec. turning the starter motor times to circulate the oil throughout
(Electric start model) in order to cir- the outboard motor.
culate the oil.
7. Start the engine and warm up the
engine for 3 minutes in the “NEU-
TRAL” position.
 70 INSPECTION AND MAINTENANCE

ENOM00106-A ENOM00120-0

6. Cold weather precautions 8. Auxiliary outboard motor

operation
If you moor your boat in cold weather at
temperatures below 0°C (32°F), there is When the auxiliary outboard motor will
the danger of remained water freezing in not be used, be sure to remove the stop
the cooling water pump, which may dam- switch lock, shift into forward, and then
age the pump, impeller, etc. To avoid this tilt the outboard motor up. Otherwise,
problem, submerge the lower half of the over-rotation of the propeller due to
outboard motor into the water. water spray and water ingestion that
could cause damage to the outboard
ENOM00107-A motor.
7. Striking underwater object
ENOW00935-0

CAUTION
Striking the sea bottom or an underwater
object may severely damage the outboard
motor.

Follow the procedure below and consult

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.
10 4. Consult a dealer check the outboard
motor before operation again.

ENOF01145-0
 71
TROUBLESHOOTING
ENOM01106-0
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 stoping soon

High engine speeds not possible

Engine speed abnormally high

Engine speed abnormally low

Overheating of engine
Engine failing to start

Poor acceleration

Possible cause
Poor idling

z z Empty fuel tank

z z z z z z z Incorrect connection of fuel system
z z z z z z z Air entering fuel line
z z z z z z z Deformed or damaged fuel pipe
z z z z z z z Closed air vent on fuel tank
FUEL SYSTEMS

z z z z z z z Clogged fuel filter, fuel pump, or carburetor

z z z z z Use of improper engine oil
z z z z z Use of improper gasoline
z z z z z z Excessive oil in mixture
z Shortage of oil in mixture
z z Excessive supply of fuel
z z z z z z z Poor carburetor adjustment
z z z z z z Recirculation pipe broken
z z z z z z z Spark plug other than specified
z z z z z z Dirt, soot, etc. on spark plug
z z z z z z No Spark or weak spark
z Short circuit of engine stop switch 11
ELECTRIC SYSTEMS

z z z z z Incorrect adjustment of ignition timing

z Loose battery terminal connection, corrosion
EP and EF
z Discharged battery
types
z Main switch trouble
z Lock plate not fitted to stop switch
z Disconnection of wire or loose ground connection
Insufficient battery capacity, loose terminal EP and EF
z
connection, corrosion types
 72 TROUBLESHOOTING

Engine starting but stoping soon

High engine speeds not possible

Engine speed abnormally high

Engine speed abnormally low

Overheating of engine
Engine failing to start

Poor acceleration
Possible cause
Poor idling

z z z z z Incorrect adjustment of throttle link

z z Insufficient cooling water flow, clogged or defective pump
z z z Faulty thermostat
z z z z Cavitation or ventilation
OTHERS

z z z z z Incorrect propeller selection

z z z z z z Damaged and bent propeller
z z z z Improper thrust rod position
z z z z z Unbalanced load on boat
z z z z z Transom too high or too low

11
 73
TOOL KIT AND SPARE PARTS
ENOM01107-0
The followings are a list of the tools and spare parts provided with the motor.
Name Quantity Remark
Tool Bag 1
Pliers 1
Socket Wrench 1 10 x 13 mm
Servicing Tools
Socket Wrench 1 21 mm
Socket Wrench Handle 1
Screwdriver (Phillips-type and flat head) 1 Adapter-type
Rope 1
Spare stop switch lock 1
Spare Parts
Spark Plug 1 NGK BR7HS-10
Split Pin 1
Fuel Tank 1
Primer bulb 1 set
Parts
Packaged with Engine Remote control head assy. 1 set EP only
Remote control fitting assy. 1 set EP only
Drag link assy. 1 set EP only

12
 74
PROPELLER TABLE
ENOM01108-0
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.

9.9D2 : 4,500 to 5,300 min-1 (rpm)

15D2/18E2 : 5,200 to 5,800 min-1 (rpm)

Propeller Size
Mark (Diameter x pitch)
inch mm
6 9.2 x 6.1 234 x 155
Heavier Load
8 9.25 x 8 235 x 203
9 9.25 x 9 235 x 229
10 9.25 x 10 235 x 254
Lighter Load
11.5 9.25 x 11.5 235 x 292

13






 O W N E R’ S
MANUAL

M 9.9D 2
M 15D 2
M 18E 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