TOHATSU 2.5, 3.5 Owner's Manual

TOHATSU

OUTBOARDS

I 5
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No.00311045-3

Copyright © 2007 Tohatsu Corporation. All rights reserved. No part
of this manual may be reproduced or transmitted in any form or by
any means without the express written permission of Tohatsu
Corporation.

,:. 7,

:., ,,’

YOUR TOHATSU OUTBOARD MOTOR

OWNER REGISTRATION AND IDENTIFICATION

Upon purchasing this product, be sure your dealer* fills out the WARRANTY

CARD correctly and completely and mails it to the distributor. This card
identifies you as the legal cwner of the product and serves as your warranty
registmtion.
If this procedure is not followed, your outboard motor will not be covered by

warrantly~

* : In this manual. “dealer” always means an authorized TOHATSU dealer.

PRE-DELIVERY CHECK

Be sure that the product has been checked by the dealer before the delivery

Limited Warranty

This TOHATSU product is fully guaranteed against defective materials and

workmanship for the period from the date of purchase, provided that the
purchase has been registed in accordance with the above.

The limited warranty will not apply to the normal wear and tear of parts.

adjustments. tune-ups, or to any damage caused by:

I)Use or operation NOT conforming to the instmctions described in this

owner’s manual,

2) Participation in or preparation for racing or other competltwe activities,

3) Water entering the engine or the engine room,

4) Damage of an accidents. collisions, contact with foreign materials, or
submenion.

5) Growth of marine orgamsms on motor surfaces~

6) Any other careless use or operation.

7) Normal deterioration.

The limited warranty does not cover maintenance items. The following items

are some examples not to be covered by the limited warranty.

spark plugs, anode. trim-tub. propeller, fuel filter. oil filter. carbon brush.
starter rope, shear-pin, split-pin, b&nut-washer. wire cable, rubber goods:
pump impeller, oil seal, “0”.ring, fuel pipe, primer bulb, etc., viny tube.

The limited warranty will become void if the product has been altered.

modified, or repaired by anyone other than a company or service firm
authorized by TOHATSU.

The limited warranty will cover only your TOHATSU product and will not

cover the boat the product is mounted on. the trailer, equipment. or accessories
associated with the product.

Serial Number

In the space below. please record the engine’s serial number (indicated both on
the lower motor cover and on the cylinder block). This number will come in
handy in the event of theft or to help in quickly identifying the product type.

Serial Number :

To You, Our Customer:

Thank you for selecting a TOHATSU product. You are now the proud owner of
an erellent outboard engine that will service you for many years to come.

We would like to point out that carefree usage can only be assured on condition

that this manual is read through in its entirety and the maintenance routines
described later in this manual are followed carefully. Should difficulty arise
with the engine. please follow the troubleshooting procedures listed at the end

of this manual. If the problem persists, contact an authorized TOHATSU
Service shop or your dealer.

We hope you will get much enjoyment from this product and wish you good

luck in your boating adventures.

TOHATSU CORPORATION

NOTICE: DANGER/WARNING/CAUTION/Note

Before operating your outboard motor, be sure to thoroughly read and
understand this Owner’s Manual and follow all of the instructions shown. Of
particular importance is information preceded by the words “DANGER.”
“WARNING.” ” CAUTION,” and “Note.” Always pay special attention to such
information to ensure safer and trouble-free operation at all times.

Failure to observe will result in severe personal injury or death.

Failure to observe could result in severe personal injury or death.

I

A

CAUTION

Failure to observe could result in minor personal injury or product or
property damage.

Note:

This instruction provides special information to facilitate the use or

maintenance of the outboard or to clarify important points.

EMERGENCY STOP SWITCH

The stop switch will cut off the engine when the stop switch line is pulled out.
This line can be attached to the body of the operator. effectively preventing

injuries from the propeller in case he/she falls overboard.

We highly recommend use of the stop switch line because it can save the life of

the operator if somethings bad happens. However, we would also like to point

out the drawbacks of the switch. Accidental activation of the swtch (such as the

line 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 prevent such hazardous situations. the 500 mm line is coiled and can
extended to a full 1,300 mm

WARNINGS

As the operation/driver of the boat, you are responsible for the safety of those
aboard and those in other crafts around yours, and for following local boating
regulations. Therefore you should possess thorough knowledge of correct
operation of the boat, its accessories, and the engine. To learn about the correct
operation and maintenance of the engine. 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 engine should be shifted to neutral and shut off.

SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES
CONTACT WlTH A MOVING BOAT, GEAR HOUSING, PROPELLER, OR
ANY SOLID DEVICE RIGIDLY ATTACHED TO A BOAT OR GEAR
HOUSING.
It is the operator’s responsibility to perform all safety checks and to enwre that
all lubrication and maintenance instructions are complied with for safe
operation. It is also the operator’s responsibility to return the unit to the local
dealer for periodic inspection.
Correct periodic maintenance and good care of this outboard engine will lessen
the chance of problems and keep overall operating expenses at a minimum.

SERVICING, REPLACEMENT PARTS & LUBRICANTS

Only let an authorized TOHATSU service shop perform sewing or maintenance
on this product. Be sure to use genuine parts and genuine lubricants or
recommended lubricants.

MAINTENANCE

As the owner of this outboard engine. you should be acquainted with its correct
maintenance. Please comply with all instructions on lubrication and

maintenance. and return the engine to the dealer or service shop for periodic
inspection at the prescribed intervals.

Troublefree operation cannot be expended unless the engine receives adequate

periodic maintenance. If maintenance is performed periodically. it is not likely
that a costly overhaul will ever be required.

USE OF SERVICE SHOP

When subjecting your TOHATSU product to a check or repair, please be sure

to use a TOHATSU dealer authorized by TOHATSU or a TOHATSU agent.

CONTENTS

, SpEClFlCATlONS

.

.......................................

Page

.I

2. NAMES OF PARTS ......................................

3. INSTALLING THE OUTBOARD

(1) Position ............................................

(2) Transom Height ...................................... .4

(3) Tmnsom
(4) Securing the Outboard

Matching

................................... -4

.................................

......................... -4

.3

,4

-5

(5)AdjustmentofOutboardAngle ~~~~~~~~~~~~~~~~~~~~~~~~~~~5

t,. ,=,,,=L AND ENGINE OIL ................................ -7

5. OPERATION. ............................................

-9

(,)Break.Tn.. ........................................... 9

(2) staning ................. ......................... ..~O

(3) Starting if Recoil Starter is Out of Order.

................. ‘14

(4)Warm.“p..........................................., 6

(s)ShiftingtoFoward

................................... 16

(6) Reversing. .......................................... ,7

(,)Spee,, Co&,,,

(8)R”nninginShallowWater

(9) Stopping

(IO) Mooring rhe Boat. ...

.......................................

............................. 18

........................................... 18

..............................

..2 0

(11) Removing and Carrying the Outboard .................. ‘21

(12) Precautions during Operation

..........................

. 7

22

6. ADJUSTING THE STEERING RESISTANCE .

..--....23

7. INSPECTION AND MAINTENANCE.-.-...---..-----..24
(1) Daily Inspection

(2) Periodic Inspection . . . . .29

(3) Preparing the Outboard for Long-Term Storage. . . .32

(4) Inspection After Long-Term Storage ‘. . . . .33

(5)IftheEngineisSubmergedinWater ,...-..----..........33

6. TRO,,BLES,,OOTlNG . . . .34

. . . .25

9. TOOL KIT AND SPARE PARTS

,~.ACCESSORl,=S . . . . ..-.................................37

1,. WIRING DIAGRAM.. . . . . . . . . . . . _.. . . . . . .___. ..~,g

..-.-..--...---...--...36

1. SPECIFICATIONS

Model
Overall Length, mm

Overall Width, mm
Overall Height, mm

Transom Height, mm
Weight, kg S * L

Output, kW

Max. Operation Range, ‘pm
Idle Speed in Forward Gear, ‘pm

Idle Speed in Neutral Gear, ‘pm
Number of Cylinders

Piston Displacement, mL
Bore & Stroke, mm
Exhaust System
Lubrication System

Fuel

Engine Oil

Engine Oil Mixing Ratio

Cooling System
Starting System
Ignition

Spark Plugs

3.5B2 3.5A2

I I

550 550
220 220 1 195 1 195
s: 955 s: 955 L: 1,082 L: 1,082
s: 435 s: 435 L: 562 L: 562

2.5A2

E
1,100

1,300

1

14.6
41 x 43
Underwater exhaust
Fuel mixture

Unleaded regular gasoline pump
posted 81 Octane (research octane
rating of 91)

Genuine or recommended Z-stroke

eneine oil
Fuel 50 : Engine Oil 1

Forced water cooling

Recoil starter & pull rope
Flywheel Magneto CD. Ignition

NGK BP6HS-lO/BPR6HS-10 or
Champion L87YCfRL87YC
(l.Omm gap)

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Trim Stages

Gear Oil, (II-IL)

Genuine Gear Oil or API GL5, SAE

#80 to #90,

3.5B2: 180, 3.5A2 & 2.5A2: 90

Model 3SB2 3.542

Fuel Tank Capacity, L Approx. 1.4 (Integral tank)

2.5A2

Fuel Consumption
(at full throttle) L/H

Gear Reduction Ratio
Gear Shift

Propeller
(Blade X Diameter X Pitch)

1.7

13 : 28 13 : 24
F-N Forward
“, - 7” “F - 6”

(3 x 188 x 145)

1.4

2

2. NAMES OF PARTS

3. INSTALLING THE OUTBOARD

: : : : :

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. . . . . . . . . . . .,.,.,.,..... 1~:~: .,.,.: .,.,. :.::~::.:.:.:.:.:.:.:.:.:.~:..

Be sure that the maximum engine horsepower rating does not exceed

that recommended for your boat. It is very DANGEROUS to operate a

boat with an overpowered engine.

Do not operate the engine until it has been securely mounted on the
boat in accordance with the instruction below.

(1) Position

Position the outboard at the exact center of the transom board.

..~

Transom height of boa1

(2) Transom Height

Install the outboard so that the anticavitation plate is at a level of 30 - 50
mm (1.18 -1.97in.) below the bottom line of the boat.

(3) Transom Matching

Be sure that the anti-cavitation plate of the outboard is below the water
surface when running with wide open throttle.
In case the above condition cannot be met due to a bottom shape of your
boat, please consult your dealers

4

(4) Securing the Outboard

Tighten the clamp screws by hand to secure the outboard to the boat

A

CAUTION

During boating, retighten the
acrews from time to time to
ensure safety.
In addition, attach a safety
rope or chain to the outboard

to prevent possible loss

overboard.

Adjustment of Outboard Angle

(5)

The angle of the outboard can be
adjusted by changing the position
of the thrust rod in the holes

provided in the stem brackets,
according to the angle of the
transom board of the boat, the

weight of the load, etc. The angle

should be adjusted so that the
anticavitation plate is parallel to
the water surface when the boat is
running.

5

* Correct angle of trim

The optimum angle of trim is obtained when the boat is parallel to the water

surface while running.

* Incorrect angle of trim (bow rises too high)

If the angle of trim is excessive. the bow will rise out of the water and the

speed will decrease. In this case, decrease the angle by setting the thrust rod

in a lower hole.

* Incorrect angle of trim (bow dips into the water)

If the trim angle is too small, the bow will dip into water, the speed will

decrease, and water may enter the boat.
In this case, increase the angle by setting the thrust rod in a higher hole.